manualshive.com logo in svg

Datsun C210 series, Manual

The Datsun C210 series user manual is a comprehensive guide that provides essential information for owners of this classic vehicle. Featuring step-by-step instructions, maintenance tips, and troubleshooting advice, this manual is available for free download from our website, your ultimate source for user manuals.

Share
Download
background image

Summary of Contents for C210 series

Page 1: ...f 11 r r 1 rf r 1 i i tlJ v 1 f 1 t t oIIlIIIIl t l r f l If r 1 j iI h1 t It i 1 It f 1 r i J 1r 1 1 i 1 1 I J 1 i f I 1 II j it I A Ir t t t j I tJ r r i t j i 1 J ...

Page 2: ...iF I I I F 1 c ...

Page 3: ...21 O TSUN SERV CE flU Model C210 Series v 1 J M QUICK REFERENCE INDEX N SSAN M0101l to 10 10KYO JAItJ I ...

Page 4: ...nning of each individual section is a table of cOntents which gives the page nUlnber on which each major subject begins i All parts in this manual conform to the PARTS CATALOG Model C210 and only the genuine service arts liSted in this PA TS CATALOG rriust be used for replacements All information illustrations and specifications contained in this manual are based on the product information availab...

Page 5: ...ANUAL TRANSMISSION NUMBER AUTOMATIC TRANSMISSION NUMBER APPROXIMATE REFILL CAPACITIES RECOMMENDED FUEL 1 1 RECOMMENDED LUBRICANTS RECOMMENDED LUBRICANTS RECOMMENDED SAE VISCOSITY NUMBER LIFTING INTS AND TOWING PANTOGRAPH JACK GARAGE JACK AND SAFETY STAND TOWING TI E DOWN SPECIAL TOOL GI 2 GI 2 GI 2 GI 2 GI 2 GI 3 GI 3 GI 3 GI 3 GI 3 GI 4 GI 4 GI 4 GI 5 GI 5 GI 5 GI 6 GI 6 GI 6 I 1 I I 0 J ...

Page 6: ...her information CAR IDENTIFICATION PLATE The car identiftcation plate is located on the center of the cowl top in the engine compartment CHASSIS NUMBER The chassis number is stamped on the cowl top in the engine compart ment and is broken down as shown in the foUowing figure K M G C210 V F M I M L Y IDENTIFICATION NUMBER I l MGC lO OOOOU I I LC014 Fig 01 1 Identification Plate and Cha8i6 Number Lo...

Page 7: ...ransl ission case as sho Yfl in the following figure r AT344 Fig GI 5 Automatic Trammiuion Number Location r APP OXIMATE REFILL CAPACITIES Li er Imp measure Fuel tank C Sedan and lardtop 60 l3X gal Cooling system i t Without heater 8si 7 iqt With heater 9 5 8 qt J Engine oil 1 Without fIlter 5 0 4 qt With fIlter 5 5 4U qt J Transmission l 2 0 5 speed ldanual 3 i pt Automatic 5 5 4U qt I Differenti...

Page 8: ...d Anti freeze Type DEXRON N LG 1 2 OOT 3 FM V S S No 116 Remark Refer to Recommended SAE r Viscosit Chart I I I I Uthium soap base F M Y S S Federal Motor Vehicle Safety Standard Permanent anti freeze Ethylene glycol base RECOMMENDEDSAE VISCOSITY NUMBER I l I I I I 2OW 40 2OW 50 I J I I t 15W 60 I IOW 30 lOW 40 lOW 50 I II I 40 to I 30 1 pow 2OW I I lOW 5W 30 5W 20 Not com ended for II s ed hIgh s...

Page 9: ...age jack under the front suspension member Be sure not to lift up the engine oil pan located just behirid the suspension member 1 I 1 GI388 Fig Gl S Front Jack Up Point 3 Jack up the car gently just high enough to place thehafety Stands uiiderl both the side members Place the Cstandsatthe position indicated in Fig GI 9 JJ ll L Io t 11 GI359 ill lif 1 Front jack up point 2 Front supporting point Fi...

Page 10: ...d When towing en automatictrBns mission model on its rear wheels do not exceed 30 km h 20 MPH Bnd a distance of 10 km 6 miles e Release till parking brake and set the gearshift lever in Neutrar position before starting to tow the car f A towing rope should not be cog nel ted to the tiedown hook or any other positions except those desaibed above g Do not take up slack in the rope too quickly h Alwa...

Page 11: ...ST GAS RECIRCULATION CHANGING ENGINE pOOLANT ET 3 E G R 1 CONTROL SYSTEM ET B CH ECKING COOLlNG SYSTEM HOSES CHECKING VAPOR LINES Hoses AND CONNEc I O S ET 4 connections etc AND FUEL CHECKING ENGINE COMPRESSION ET 4 VAPOR CONTROL VALVE ET 9 IGNITION AND FUEL SYSTEM ET 5 CHECKING FUEL TANK CHECKING BATTERY ET 5 VALVE ET 10 CHECKING AND ADJUSTING IGNITION SERVICE DATA AND TIMING ET 5 SPECIFICATIONS ...

Page 12: ...t locking nut securely after adjustment and recheck clearance 4 Ordcr of valve clearance adjust ments isas follows All valves can be adjusted by rotat ing crankshaft four complete turns Note When turning crankshaft with starter feptove high tension wire from ignition coil then turn it a Adjust valve clearances V and Qj with cam lobe CD set at ex tremeupward potition b Adjust valve clearances and w...

Page 13: ...xtremely low viscosity indicates dilution with gasoline 2 Check oil level If below the specified level raise it up to the Hlevel ET 3 Engine oil capacity including oil filter Maximum H level 5 7 liters 6 US qt 5 Imp qt Minimum Ilevel 47 liters C 5 US qt 4 Imp qt 3 Change engine oil in accordance with the maintenance schedule REPLACING OIL FILTER The oil filter is a cartridge type and can b removed...

Page 14: ...gine sufficiently 2 Disconnect all spark plugs 3 Disconnect anti dieseling solenoid valve connector 4 Properly attach a compression tester to spark plug hole in cylinder being tested Ii n It ET010 Fig ET 6 T ting compreuion preuure ET 4 5 Fully open choke valve 6 Depress accelerator pedal to open throttle valves Note Do not PIlDIP pedal 7 Start engine as quickly as possi b e Compression pressure k...

Page 15: ...nd corrosion of straps c After tightening tenninaIs c t them with petrolatum tine to protect them from cortOllion Caution If the battery cables are dis connected they mould be tightly clamped to the battery terminals to secure a good contact CHECKING AND ADJUSTING IGNITION TIMING I Check spark plugs and di tributor breaker point for condition 2 Thoroughly remove dirt and dust from timing mark on c...

Page 16: ...eter to check resist ance on high tension cables I Disconnect cables from spark plugs and remove distributor together with high tension cables Note Do not remoy cables f Icap 2 Connect the ohmmeter between cable terminal on the spark plug side and the oorresponding electrode inside cap 3 If the resistance is more than 30 000 ohms remove cable Cram cap and check the cable resistance only If resista...

Page 17: ... that the amount of CO contained in exhausi gases meets the established standard 2 Install idle limiter cap in position making sure that the adjusting screw can rotate another 1 8 turn in the CO RICH direction of Iso Idle limiter cap ET031 Fig ET 15 Setting idle limiter cap CHECKING CHOKE MECHANISM Choke plate and linkage I Check choke valve and mecha nism for free operation and clean or eplace if...

Page 18: ... through the valve and a strong vacuum should be felt immediately when a finger is placed over valve inlet 2 Replace P C Vvalve and filter in accordance with the maintenance sch dule Fill ET 19 Checking P C V valv CHECKING VENTILATION HOSES I Check hoses and hose connec lions fur leaks 2 Disconncct all hoses and clean with compressed air If any hose cannot be freed of obstruclions replace Be sure ...

Page 19: ...onnector a manameterand a cock or an equiv alent 3 way change cock to the end of the vent line 4 Supply fresh air into the vapor vent line through the cock little by little until the pressure becomes 3 923 kPa 400 mmH20 15 75 inH20 5 Shut the cock completely and leave it that way 6 After 2 5 minutes measure the height of the liquid in the manometer 7 Variation in height should remain within 0 245 ...

Page 20: ...eck valve A large air flow should be felt when sucked forCedly labove 2 7 kPa 20 mmHg 0 79 inHg and should not when sucked softly 4 Suck air through portion B of check valve A largeair flow should be felt when sucked forcedly above 1 3 kPa 10 rnmHg 039 inHg and should not when sucked softly 5 Suck air through portion B while closing portion Awilh finger A large air flow should be felt when sucked ...

Page 21: ...rk plug gap Spark plug lightening torque 0 percentage at idle specd M T A T mm in mm in mm in un in 0 20 0 008 0 25 0 0I 0 0 25 0 0 I 0 0 30 0 012 mm in mm in N kg Ib 8to 12 0 31 to 0 47 8to 12 0 3lto047 98 10 22 is applied N m kg m fr lb N m kg m ft Ib N i kg m t lb 69 to 83 7 0 to 8 5 51 tu 61 12to 16 12 to 1 6 9to 12 12 to 18 1 2 to 18 9to 13 lilers US qt Imp qt liters US qt Imp qt Iilers US qt...

Page 22: ...ys bright a Check wiring connection between battery and starter motor b Check ignition switch c Check starter motor ENGINE WILL CRANK NORMALLY BUT WILL NOT START In this case the following trouble causes may exist but in many cases ignition system of fuel system is in trouble Ignition S I tem in trouble Fue1IYstem in trouble Value mechani8m doe not work properly Low compreuion Trouble shooting pro...

Page 23: ...asket Sticking or damaged piston ring Worn piston ring or cylinder Trouble sIiootiirg proceduie Add small quantity of engine oil through spark ping hole and then measure cylinder compression Compression increases Compression does not change Ignition system out of order Fuel system out of order Low compression ET 13 Corr ctive action Check for loose terminal or disconnectiori in primary circuit Che...

Page 24: ...c irrect idle adjustment Clcgged ait leaner filter Malfunction of idle inpensator of air cl aner Malfunction ofE G R c introLvalve Loose manifold and cyiihder head bolts SVckill laccelerator linkale Incorrect idIeadjustinent t MaI unctlon ofB cn D system t Malfunction of speed switch and amplifier MID or inhIbitor switch A T and harness ET 14 J L l i it fj lJ x p 1 1 Corrective action Clean or rep...

Page 25: ... oiled fan belt Inoperative thermostat Worn water pump Clogged or lea y radiator Worn radiator filler cap Air in cooling system Improper engine oil grade Incorrect ignition timing Clogged carburetor lean mixture Inoperative thermostat Improper octane fuel Improper tire pressure Dragging brake Clutch slipping ET 15 Corrective action Previously mentioned Adjust Clean adjust or replace plugs Dress or...

Page 26: ...is heard at each highest and lowest dead end of piston To locate the place cause a misfrre on each cylinder Tlus noise may be caused by w9rn or damaged bearings or by the uneven surface ofsliding paris Damaged air pump An improper adjustment of valve clearance Noise of timing chain An excessive end play on crankshaft Noisy E F E valve shaft Wear on clutch pilot bushing Note This noise will be hear...

Page 27: ...mproper tightening of oil filter Loose or damaged oil pressure switch Cylinder and piston wear Improper location of piston ring gap or reversely assembled piston ring Damage piston rings Worn piston ring groove and ring Fatigue ofvalve oil seal lip Worn valve stem Inadequate quality of engine oil Engine overheat ET 17 Corrective action Adjust ignition timing Use specified spark plugs Replace them ...

Page 28: ... pressure decreases Improper quality or contamination of oil Damaged air cleaner Overheat or overcoal Improper fuel naixture Decrease ofoil pressure Insufficient clearances Overheat Improper fuel mixtu e ET 18 Correctiveaction Adjust it to the designated rpm Adjust it Repair or tighten the connection of fuel pipes Adjust Correct Use the designated oil Previously mentioned Disassemble oil pump and ...

Page 29: ... intake manifold for leakage Good No good Others Is dukh slipping AllY oven ooling Any overheating Is running resistance excessive Is tire pressure proper Is proper gasoline used Is CO and He measur d by correct methods Note Each time a problem is located make the necessary repairs or replacement and then check the CO and HC concentration When the concentration is down to the prescribed level and ...

Page 30: ...ction in E G R y tcm J Malfunction in P CV system ET 20 Spark plug leakage Valve clearance Blo n cylinder head gasket Piston ring Cylinder Thermostat Radiator Fan belt Engine oil Radiator hose Thermostat Fan Water pump Cylinder head and ga5ket Drakes Load Idling mixlure Clogged P c V valve Air cleaner Carburetor fuerfilter clogged Intake manifold leakage Check proper function Check bi metal cover ...

Page 31: ... Tune up SPECIAL SERVICE TOOLS Tool number tool name STl 064000 I Pivot adjuster 1 Reference page or Fig No Reference page or Fig No Tool number tool name Fig ET I Oil filter wrench STl9320000 Page ET 3 ET 21 ...

Page 32: ...OCK PISTON PISTON PIN AND PISTON RING CONNECTING Rooi EM 2 EM 4 EM 4 EM 4 EM 6 EM 6 EM 8 EM 8 EM 8 EM l0 EM l0 EM ll EM 12 CRANKSHAFT BEAR ING MISCELLANEOUS COMPONENTS ENGINE ASSEMBLY PRECAUTIONS CYLINDER HEAD PISTON AND CONNECTING ROD ENG INE ASSEMBLY SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQU E TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVI...

Page 33: ...8 u 8 1 8 II IS j I Rocker cover 2 Camshaft 3 Timing gear 4 Front cover 5 Oil pump 6 Piston 7 Connectmg rod 8 Crankshaft 9 Oilpan 10 Flywheel 11 Thermostat 12 Cylinder block 13 Cylinder head 14 Valve mechanism EM704 Fig EM l EngiM Component EM 2 ...

Page 34: ...Engine Mechanical I Manifold gasket 2 Intake manifold 3 Exhaust manifold 4 Manifold stove 5 Stove gasket EM750 3 Fig EM 2 Manifold J EM 3 ...

Page 35: ...acket and starting motor 4 Place engine assembly on the en gine stand 1 Remove engine mounting bracket R H 2 Remove oil filter using Qi ir r Wr hSTli1320000 3 Install engine attachment to cyl inder block using bolt holes securing alternator bracket and engine mount ing 4 Set engine on the stand Engine Mechanical ENGINE DISASSEMBLY Engine Attachment ST05340001 Engine Stand Assembly ST050lS000 EM600...

Page 36: ... gear and crankshaft sprocket from crankshaft 00 I Chain tensioner 2 Slack side chain guide 3 Tension side chain guide 4 Oil thrower 5 Oil pump drive gear 6 Crankshaft sprocket Fig EM 9 Removing Chain Tensioner and Timing Chain EM709 Note If it is hard to extract crank shaft sprocket use a suitable puller Fig EM lO 3 Remove piston and connecting rod assembly El v U j I J T J I OEM2a7 Fig EM II R m...

Page 37: ...Note Keep the disassembled parts in order w t J 6 EM 6 CYLINDER HEAD 1 Remove valve rocker spring 2 Loosen valve rocker pivot lock nut and remove rocker arm by pressing down valve spring I C8 0 EM711 Fig EM l 7 Removing Rocker Arm 3 Remove camshaft EM294 Fig EM I8 Removing CaTTUha t Note At this time take care not to damage camshaft bearings and earn lobes r I Camshaft 2 Valve rocker spring 3 Valv...

Page 38: ...r spring retainer Note Do not remove rocker pivot bushing 5 Remove valves using Valve Lifter STl2070000 J Engine Mechanical Fig EM 20 Removing Valve EM 7 Note Be sure to leave camshaft bear ing intact Because the bearing center is liable to be out of align roent ...

Page 39: ... 2 mm 0 008 in VALVE I Check each of the intake and exhaust valve for worn damaged or deformed valve caps or stems Correct or replace the valve that is faulty For standard size of valve refer to Service Data and Specifications 2 Valve face or valve stem end surface should be refaced by using a valve grinder Note When valve head has been worn down to 0 5 mm 0 020 in in thickness replace the valve G...

Page 40: ...ylinder head valve guide hole using Reamer STl1081000 12 2 mm 0 480 in dia at room tempera ture 3 Press new valve guide into head carefully so rhat it will fit smoothly after heating cylinder head to 150 to 2000C 302 to 3920 F Valve guide of 0 2 mm 0 008 in oversize diameter is available for serv ice Refer to Service Data and Specifi cations Fig EM 28 EM 9 4 Ream the bore with valve guide pressed ...

Page 41: ...cking Cam haft Bend 3 Measure camshafr end playas shown in Fig EM 32 If beyond the specified limit replace locating plate Camsh ft end play 0 08 to 0 38 mm 0 0031 to 0 0150 in EM310 Fig EM 32 Checking Cam haft End Play 4 Measure camshaft cam height If beyond the specified limit replace camshaft Refer to Service Data and Specifica tions VALVE TIMING If any valve is found out of speci fications refe...

Page 42: ...torted from the bor ing operation 4 Do not cut too much out of cylinder bore at a time Cut only 0 05 mm 0 0020 in or so in diameter at a time 5 Measurement of a just machined cylinder bore requires utmost care since it is expanded by cutting heat 6 As a final step cylinders should be honed to size 7 Measure the finished cylinder bore for out of round or tapered part Refer to Service pata and Speci...

Page 43: ... correct biieplace Bend arid torsion per 10Qmm 13 94 in length l e i than 0 05 mm 10 0020 in EM133 Fig EM 42 Checking Rod Alignment Fig EM 43 Checking Big End Play CRAN SHAFT I Repair or replace as required If faults are mirior correct with fine crocus cloth 2 Check witha micrometer journals and crank pins for taper and out of round Measurement should be taken along journals for taRer and around j...

Page 44: ... or wear Replace bearings if any fault is detected 2 Crankshaft journals and bearings should be clean and free from dust and dirt before oil clearance is measured 3 Set main bearing on cap block 4 Cut a plastigage to the width of bearing and place it in parallel with crank journal getting clear of the oil hole Install cap on the assembly and tighten them together to the specified torque l l Tighte...

Page 45: ...cation notch comes off the left end of the oblong groove on camshaft locating plate If the location notch is off the left end of the oblong groove chain stretch is beyond limits EM146 100 Fig EM 53 Camshaft Location Plate EM 14 2 Turn engine until No 1 piston is at T D C on its compression stroke selling camshaft on No 2 location hole in camshaft sprocket This No 2 notch should then be on the righ...

Page 46: ...ling lip or oil leakage If necessary replace with a new seal When installing a new seal pay attention to its mounting direc tion Note It is good practice to renew oil seal whenever engine is overhauled Engine Mechanical Front J Front r ILJ Rear Fig EM 55 Oil Seal of Crankshaft EM150 EM 1S ...

Page 47: ...Apply sealant at these points EM720 Fig EM 57 Applying Sealant Main bearing cap and cylinder block Poinu to apply sealant EM315 Ji1 a o J 0 Fig EM 58 Applying Sealant Cylinder block CYLINDER HEAD 1 To install valve proceed as follows 1 Set valve spring inner and outer seat and valve oil seal 2 1nstall valve spring inner and outer valve spring retainer valve spring collet and valve rocker guide by ...

Page 48: ...pward Note a Top ring is chromium plated on liner contacting face b Oil ring is a combined type Upper rail is the same as lower one Marked ide lg1 n EM722 Fig EM 65 talling futon Ring EM 17 ENGINE ASSEMBLY 1 Install baffle plate including steel net 2 Set main bearings at the proper portion of cylinder block DDDtJDDn U 1uUa a a aa EM739 Fig EM 66 Main Bearing Note a Only center bearing No 4 is a fl...

Page 49: ...e coating of engine oil to mating shaft to prevent scratches and folded lip Also apply coating of oil to periphery f oil seal 8 Install rear end plate 9 Install flywheel securely and tighten bolts to specified torque i l Tightening torque Flywheel fixing bolts 137to 157 N m 114 0 to 16 0 qm 101 to 116 ft b Drive plate fixing bolts 127 to 147 N m 13 0 to 15 0 kgm 94 toJ08ft lbL Fig EM 7I Installing...

Page 50: ...ide EM726 Fig EM 75 Installing Timing Chain Note a Set timing chain by making its mating marks align with those of crankshaft sprocket and camshaft sprocket the right hand side b No I hole is factory adjusted When chain stretches excessively adjust camshaft sprocket at No 2 or No 3 hole For adjustment refer to Inspection and Repair of Chain I Install chain guide of slack side and chain teosioner G...

Page 51: ...ter positioning oil pan gasket in place tighten entire circumference 25 Adjust valve clearance to the E L009 specified dimensions Fig EM SO Setting Distributor Driving Spindle b InstaU oil pump together with drive spindle so that the projection on its top located at the 11 25 a m position At this point the smaUer bow sbape will be facing toward the front specified dimensions Using Pivot Adjuster S...

Page 52: ... so equipped Idler pulley and air conditioning compressor mounting bracket if so equipped Distributor High tension cable Engine mounting bracket LH Clutch assembly using Clutch Aligning Bar KV30I00100 KV30100100 I Fig EM 84 EM729 Installing Clutch Auembly 28 Using an overhead hoist and lifting cable hoist engine away from engine stand and remove engine at tachment 29 Install alternator bracket adj...

Page 53: ... inHg at idle rpm 57 3 430 16 9 Oil pressure kPa kgfem 2 si Wal1llat 2 000 rpm p 343 to 412 3 5 to 4 2 49 8 to 59 7 MfT Manual Transmission AfT Automatic Transmission INSPECTION AND ADJUSTMENT CYLINDER HEAD AND VALVE Cylinder head Head surface flatness mm in Standard Less than 0 05 0 0020 Limit 0 1 0 004 Valve I D I I L I EM109 Valve head diameter H mm in In Ex Valve length L mm in In Ex 38 0 to 3...

Page 54: ... 6 1 378 212 mmOn 2 2 0 087 1 2 0 047 Valve gUide EXHAUST 8 3 to 8 5 0 327 to 0 355 dia 3 Q iJ 10 7 to 11 0 0 421 to 0 433 59 0 2 323 Unit mm in 10410 10410 10 6 Intake 10 6 Exhaust 0 409 to 0 409 to 1 11 1 m if f 1 c I 1 a INTAKE EXHAUST Uoil mm in EM116 INTAKE t I EM730 Unit mm in Standard Service Valve guide Outer diameter D 12 023 to 12 034 0 4733 to 0 4738 12 223 to 12 234 0 4812 to 0 4817 Va...

Page 55: ...st Dl STD 0 50 0 0197 Oversize D2 H Finished size of service valve insert cutter Intake DI D2 D3 D4 41 597 to 41613 16377 to 16383 34 1 34 6 7 to 6 7 0 264 to 0000 0 75 to 1 75 0 0295 to 0 0689 9 0 35 I HI l i I 2 J D EM732 37 080 to 37 096 14598 to 1 4605 37 580 to 37 596 I 4795 to I 4802 29 9 to 30 1 1 177 to 1 185 74 to 7 5 0 291 to 0 295 I II 600 o V Il D I D3 2 DI Unit mm in mrn in EM 24 EM73...

Page 56: ...6 1 4764 to 1 4770 In 0 081 to 0 113 0 0032 to 0 0044 Ex L 0 064 to 0 096 0 0025 to 0 0038 CAMSHAFT AND CAMSHAFT BEARING Standard Camshaftjournal to bearing clearance 0 Q38 to 0 067 0 0015 to 0 0026 Inner diameter of camshaft bearing 48 000 to 48 016 18898 to 18904 Outer diameter of camshaft journal 47 949 to 47 962 1 8878 to 1 8883 Camshaft bend Total indicator reading Less than 0 02 0 0008 Unit ...

Page 57: ...Valve timing CYLINDER BLOCK a 240 Engine Mechanical I 1m I 1 I r I I EM671 rom in O c b c 232 8 44 EM120 d I lf i B 100 3 94 J l Unit mm in EM125 EM 26 39 95 to 40 00 1 5728 to 15748 39 95 to 40 00 15728 to 1 5748 0 15 0 0059 Unit degree e f 10 50 ...

Page 58: ...8 Unit mm in Outer diameter 4 0 0 157 87 00 to 87 05 Undersize 3 4252 to 3 4272 4 5 0 177 87 50 to 87 55 Undersize 34449 to 3 4468 1 5 0 0 197 88 00 to 88 05 J Undersize 3 4646 to 3 4665 Inner diameter 82 50 to 82 60 3 2480 to 3 2520 Piston PISTON PISTON RING AND PISTON PIN Piston skirt diameter A mm in STD 0 50 0 0197 Oversize 100 0 0394 Oversize a dimension mm in EM714 EM 27 Unit mm in Wear limi...

Page 59: ...ne Mechanical Standard 0 040 to 0 073 0 0016 to 0 029 0 030 to 0 063 0 0012 to 0 0025 Standard 0 25 to 0 40 0 0098 to 0 D157 0 15 to 0 30 0 0059 to 0 D118 0 3 to 0 9 0012 to 0 035 Standard Limit 0 1 0 004 Limit 1 0 0 039 20 993 to 20 998 0 8265 to 0 8267 21001 to 21008 9 8268 to 0 8271 0 006 to 0 013 0 0002 to 0 0005 0 D15 to 0 033 0 0006 to 0 0013 Unit nUn in Limit 133 0 5 236 Less than 0 025 000...

Page 60: ...014 to 0 066 0 0006 ro 0 0026 0 12 0 0047 0 12 0 0047 Main bearing clearance 0 020 to 0 072 0 0008 to 0 0028 Main bearing undersize T i 1 EM738 Unit mm in Bearing top thickness T Crank journal diameter STD 1 822 to 1 835 0 0717 to 0 0722 54 942 to 54 955 2 1631 to 2 1636 0 25 0 0098 undersize I 947 to 1 960 0 0767 to 0 0772 54 692 to 54 705 2 1532 to 2 1537 0 50 0 0197 Undersize 2 072 to 2 085 0 0...

Page 61: ... Crank journal diameter 1 493 10 I 06 0 0588 100 0593 149961 ro 49 974 I 9670 to I 9675 1 523 to 1536 0 0600 to 0 0605 149 901 to 49 914 19646 to 19651 1553 ro 1566 0 0611 to 0 0617 49 841 to 49 854 I9622 ro 19628 1 618 to 1631 0 0637 to 0 0642 149 711to 49 724 19571 to 1 9576 I 743 to 1 156 0 0686 to 0 0691 149 461 to 49 474 1 9473 to 1 9478 1 868 to 1 881 0 0735 to 0 0741 149 211 ro 49 224 19374...

Page 62: ...5 33 to 40 137 to 157 14 0 to 16 0 101 to 116 127to 147 13 0 to 15 0 94 to 108 10 to 16 10 to 1 6 7 to 12 4 to 10 0 4 to 1 0 2 9 to 7 2 69 to 83 7 0 to 8 5 51 to 61 7 8 to 13 7 0 8 to I 4 5 8 to 10 1 5 9 to 9 8 0 6 to 10 4 3 to 7 2 78 to 118 8 0 to 12 0 58 to 87 49 to 59 5 0 to 6 0 36 to 43 127to 147 130 to 15 0 94 to 108 5 9to 9 8 0 6 to 1 0 4 3 to 7 2 5 9 to 9 8 0 6 ro 10 4 3 to 7 2 12to 18 l 2t...

Page 63: ...ion adjusting mecha nism Excessive camshaft and bearing clearance Improper valve clearance Worn adjusting screw Worn rocker face Loose valve stem in guide Weakened valve spring Seized valve Improper shaft end play Broken impeller Stuck valve H Other mechaiiiCillhoubles Improper valve clearance Insufficient clearance between valve stem and guide Weakned or broken valve spring Seized or damage ofval...

Page 64: ...assage Bearing worn or eccentric Bearing improperly assembled Loose bearing Incorrect connecting rod alignment Shortage of engine oil Low oil pressure Poor quality engine oil Crankshaft journal worn or out of round Clogged oil passage in crankshaft Bearing worn or eccentric Bearing improperly assembled Eccentric crankshaft or bearing EM 33 Corrective action Adjust Replace Replace valve Reface Repa...

Page 65: ... pulley STl7420001 Chain stopper Reference page or Fig No Fig EM Fig EM 3 Fig EM S Fig EM 8 EM 34 Tool number tool name ST10120000 Cylinder head bolt wrench KVIOI041S0 Crankshaft main bearing cap puller Crankshaft main bearing puller Adapter Adapter CD STl 65 I 1000 00 STl65 12001 IDSTl6701001 ST 1303000 I Piston pin press stand STl2070000 Valve lifter Reference page or Fig No Fig EM 13 Fig EM 16 ...

Page 66: ...480 in dia Reamer 8 0 mm 0 31 in dia Drifr Fig EM 28 STl5310000 Crankshaft rear oil seal drifr Fig EM 70 KV 10 1039S0 iSTlI 081 000 00 STl1032000 EM03470000 Piston ring compressor Fig EM 72 CD 00 STll650001 Valve seat cutter set Fig EM 29 STl 0640001 Pivot adjuster Fig EM 82 STl6610001 Pilot bushing puller Fig EM 47 KV30100100 Clutch aligning bar Fig EM 84 EM 35 ...

Page 67: ...CONTENTS ENGINE LUBRICATION SYSTEM LUBRICATION CIRCUIT 01 L PUMP OIL PRESSURE REGULATOR VALVE OIL FILTER OIL PRESSURE RELIEF VALVE EL 2 EL 2 EL 3 EL 4 EL 4 EL 4 SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOL EL 5 H 6 EL 6 J ...

Page 68: ...I Main pearing Crankshaft Connecting rod bearing I I I r J I Piston pin I I I I I Piston cylinder wall Chain tensioner ELon From Mar 1977 Fig EL j Lubricating Circuit c Oil gallery in cylinder block l l Cylinder head oil gallery 1 Camshaft bracket j I Camshaft bearing I 1 I t Camshaft I Timing chain Rocker arm j EL 2 ...

Page 69: ...l Pump 4 Tighten bolts securing oil pump to front cover DISASSEMBLY AND ASSEMBLY Remove pump cover attaching bolts pump cover and oil pump gasket and slide out pump rotors 2 Remove regulator cap regulator valve and spring 3 Assemble oil pump in reverse order of disassembly Note The mark dotted on outer and inner rotors should face to oil pump body EL3 I Oil pump body 2 Outer rotor 3 Inner rotor an...

Page 70: ...nlet sioe of the pump Check regulator vaI e spring to n ure hat spring tensioll is correct Engjl e l 1 lbripation Sy tem EL076 Fig EL 7 Regulator Valve OIL FILTER The oil filter is a cartridge type The oil filter element should be re placed periodically with the use of Oil Filter Wrellch S1 19320000 When installing an oil Hlter fasten it to cylinder block by hand Note D9 not overtighten filter or ...

Page 71: ...0 0059 to 0 0083 011 pressure regulator valve Regulator valve spring Free length Installed length load mm in mm N mm kg in lb 52 5 2 067 34 8 77 5 to 85 3 34 8 7 9 to 8 7 1 370 174 to 19 2 Regulator valve opening pressure kPa kgem2 psi rpm 343 to 412 3 5 to 4 2 50 to 60 3 000 Tightening torque Oil pump mounting bolts j Oil pump cover bolts N m kg m ft Ib N m kg m ft Ib lito 15 1 1 to 1 5 8 to 11 6...

Page 72: ...il pan Dirty oil strainer Damaged or worn pump rotors Malfunctioning regulator Use ofpoor quality engine oil Correct Clean or replace Replace Replace Replace Warning light remains on engine running Decreased oil pressure Oil pressure switch unserviceable Elecrrical fault Previously mentioned Replace Check circuit Noise Excessive backlash in pump rotors Replace SPECIAL SERVICE TOOL Tool number tool...

Page 73: ... Series SECTIONCD COOLING SYSTEM CONTENTS COOLING SYSTEM DESCRIPTION WATER PUMP TEM COUPLlNG THERMOSTAT CO 2 RADIATOR CO 2 SERVICE DATA AND C03 SPECIFICATIONS CO 4 TROUBLE DIAGNOSES AND CO 4 CORRECTIONS CO 5 C06 CO 7 a ...

Page 74: ...RNING T o avoid serious peBonal injury never remove radiator cap quickly when engine is hot Sudden release of cooling system pressure is very dangerous If it is necessary to remove radiator cap when radiator is hot turn cap slowly countenlockwise to the fiBt stop After all pressure in the cool ing system is released turn cap passing the stop and remove it CO 2 1 Radiator 2 Thermostat 3 Water pwnp ...

Page 75: ...ing water pump assembly Be sure to tighten bolts tJ Tightening torque Water pump securing bolb 3 9 to 4 9 N m 0 4 to 0 5 kgm 2 9 to 3 6 ft Ibl CQ 3 2 Fill cooling system and check for leaks at pump 3 Install fan pulley and fan blade and tighten fixing bolts securely In stall belt and adjust to specified ten sion 4 Operate the engine at fast idling and recheck for leaks 5 Install fan shrouds if app...

Page 76: ... is opened or closed as required and thus the ON OFF control is performed When the air temperature rises the bimetal is expanded and the valve is opened silicone oil is forwarded to the groove that transmits torque and the system is placed under ON condi tion 9 6 Coupling part labyrinth 7 Driven part 8 Pump unit oil outlet 9 Oil inlet When the valve doses silicone oil is not supplied to the groove...

Page 77: ...r cap is designed to maintain a pre set pressure 88 kPa 0 9 kg cm2 13 psi above atmospheric pressure The relief valve consisting of a blow off valve and a vaCUllm valve helps to prevent the coolant from boiling by giving pressure to it How ever when the pressure is reduced below atmospheric pressure the vacu um valve allows air to re enter the radiator preventing the formation of a vacuum in the c...

Page 78: ...tube 88 09 13 157 16 23 THERMOSTAT Frigid type Temperate type Tropical type Valve opening temperature OC OF 86 5 to 89 5 188 to 193 80 5 to 83 5 177 to 182 75 to 78 167 to 172 Max valve lift mm OC in oF 8 100 0 31 212 8 95 031 203 8 90 0 31 194 Fan Tern coupling Not installed Installed No of blades x outer dia mm in 6 x360 14 17 8 x 410 16 14 CO 6 ...

Page 79: ...ricted radiator Inaccurate temperature gauge Impurity in water Faulty thermostat Inaccurate temperature gauge CO 7 Corrective action Repair Repair Tighten Tighten Replace Check engine oil for contamination and reml as necessary Replace Check engine oil in crankcase for mixing with water by pulling oil level gauge Replace Tighten Check hoses for crimps and clear the system of rust and sludge by flu...

Page 80: ...ES AND REMOVAL EF 3 CORRECTION EF 7 FUEL PUMP EF 4 CARBURETOR EF 8 DESCRIPTION EF 4 DESCRIPTION EF 8 FUEL PUMP TESTING EF 4 STRUCTURE AND OPERATION EF 8 REMOVAL AND DISASSEMBLY EF 5 ADJUSTMENT AND INSPECTION EF 12 INSPECTION EF 5 MAJOR SERVICE OPERATION EF 15 ASSEMBLY EF 5 SERVICE DATA AND ELECTRIC FUEL PUMP EF 6 SPECIFICATIONS EF 19 DESCRIPTION EF 6 TROUBLE DIAGNOSES AND INSPECTION EF 6 CORRECTIO...

Page 81: ...air cleaner cover to air cle3J r body and remove air cleaner cover IDLE COMPENSATOR Ail cleaner I il To intake manifold EFOQ4 Fig EF 2 Comtruction of idle compensator INSPECTION I Warm up engin completely 2 Open engine hood and remove air cleaner cover 3 Direct warm air to idle compensa tor with a heat gun And measure operating temperature of idle compensator EF 2 3 Loosen bolts securing air clean...

Page 82: ...odically Engine Fuel 2 Disconnect hose from idle com pensator 3 Remove two setscrews from back of air cleaner lower cover Idle compensator can then be taken out easily 4 To install reverse the removal procedure FUEL FILTER 2 i I I t I I 1 Body 2 Paper element 3 Cover EF005 Fig EF 5 Sectional u wofcartridg type fuel filter EF 3 r f1 I l f I I EC61 Fig EF 4 Removing idle compenwtor REMOVAL Disconnec...

Page 83: ...ly Body co p lower Fig EF 6 Sectional view of fuel pump neet this connector hose assembly be twecn carburetor and fuel pump Note Locate this T onnector as close to carburetor as pos ible 3 Connect a suit hle pressure gauge to the opening of T connector and EF 4 fasten the hose between carburetor and Tconned or securely with a clip 4 Start and run the engine at varying speeds 5 The pres ure gauge i...

Page 84: ... valve assembly for wear on valve and valve spring Blow valve assembly with breath to examine its function 3 Check diaphragm for small holes cracks or wear 4 Check rocker arm for wear at the portion in contact with camshaft 5 Check rocker arm pin for wear A worn pin may cause oil leakage 6 Check all other components for any abnormalities and replace with new parts if necessary EF 5 Fig EF 8 ASSEMB...

Page 85: ... not work perform the following diagnosis page EF OO Notes 8 Do not connect battery in reverse polarity which if left for long time would damage transitor circuit and diSable pump b Do oat drop pump as it may dam age el c ents c Do not pply overvoltage max 1 8V Overvoltage starting by quick charge or overvoltage running would deteriorate or damage elec tronic components EF 6 tor type fuel pump con...

Page 86: ... retainer in that order e Assemble filter gasket and cover with IDIIllnet f T 8I1ten cover with wrench to the stopper If component parts are dirty after di embly clean as follows Wash filter and strainer with clean gasoline and blow with compressed air When cleaning parts check filter for fault Iffaulty replace Wash plunger plunger cylinder and inlet valve with clean gasoline and blow dust off wit...

Page 87: ...s A summary of features is as fol lows I Secon dary throt tle valve is oper ated by the diaphragm which is actu CARBURETOR ated by the vacuum so that higher power and better acceleration are achieved as compared with the mech anical throttle valve type 2 The power valve mechanism so called vacuum piston type affords high speed performance 3 Accelerating pump gives excellent acceleration 4 B C D D ...

Page 88: ...e and bypass hole Adoption of the submerged type of slow jet eliminates such hesitation as occurs on sudden deceleration of the car Small opening of the throttle valve at idling or partial load creates a large neg alive pressure in the intake manifold By this negative pressure fuel is measured through the slow jet located behind the main jet And air coming from the slow air bleed is mixed with fue...

Page 89: ... As the linkage causes the secondary throttle valve to close until the prima ry throttle valve opening reaches 550 fuel consumption during normal oper ation is not excessive I u u 1 No 3 vacuum port 2 P vacuum port 3 S vacuum port 4 Diaphfagm chamber 5 Diaphragm spring 6 Diaphragm 7 P throltle valve 8 S throttle valve 9 Vacuum piston 10 Power jet Fig EF 13 Full throttle allow peed EF 10 During hig...

Page 90: ... the choke valve to open slowly 1 Alternator 2 Automatic choke relay 3 Autcimatic hoke cover 4 P T C heater Al S Bi metal switch 6 P T C heater B 7 B metal 8 Choke vatve Fig EF I5 Schematic drawing of electric automatic choke heater Engine Fuel When ambient temperature is high electric current flows to both heaters r ID I I t 2 Oi metal in choke cover Electric current flows through the heater as t...

Page 91: ... return plate at A When throttle valve is opened fur ther locking arm is detached from secondary throttle arm permitting se condary system to start operation Linkage between primary and sec ondary throttles will function properl y if distance between throttle avlve and inner wall of throttle chamber is 8 7 mm 0 343 in Adjustment is made by bending connecting link 550 I 3 I 4 6 Secondary Ptimary I ...

Page 92: ...ing thermostat cover 2 Install new cover with three screws In installing cover bi metal must be set 3 Set thermostat cover score mark to the score mark on thermostat housing See Figure EF 20 4 Secure the three screws AUTO CHOKE RELAY AND WIRING In peetlon I Disconnect lead wire for auto choke heater EF 13 2 Turn ignition switch ON and check the voltage of harness side terminal of auto choke heater...

Page 93: ...e speed proceed as follows Warm up engine sufficiently Set fast idling earn at 2nd step and read engine speed Fast idling earn is prop erly set if engine speed is within specifications below Clearance A in second step is re ference value 2 The clearance should be specified value in the following table If not adjust the clearance by turning fast idling screw Fast idling earn step 1st 2nd VACUUM BRE...

Page 94: ...ill be affected REMOVAL AND INSTALLATION Remove carburetor from engine taking sufficient care to the following Precautions a When disconnecting fuel lines do not spill fuel from fuel pipe b When removing carburetor do not drop any nut or bolt into intake manifold c Be careful not to bend or scratch any part Remove air cleaner housing 2 Disconnect fuel lines and vacuum lines 3 Disconnect lead wire ...

Page 95: ...ry slow jet 20 Secondary slow air bleed it 0 0 I J 3 n l 21 Cousting jet 22 Plu 23 D C D D as mbly 24 Secondary main air bleed 25 Emulsion tube 26 Secondary small venturi 27 Power wive 28 Primary main air bleed with emulsion lube 29 Primary slow jet 30 Primary slow air bleed 31 D C D D cut solenoid 32 Choke connecting rod 33 Anti dieselin solenoid valve 34 F list idle Cam 35 Diaphragm chamber part...

Page 96: ...uum hose for vacuum break diaphragm 3 Remove four screws securing choke chamber to center body Choke chamber parts can then be taken out 4 Installation is in the reverse se quence of removal cp l ft l 1 Securing screw 2 Acceleratin pump lever 3 Throttle return spring 4 Accelerating pump rod EF887 Fig EF 32 Choke chamber parts EF 17 ...

Page 97: ...er part Throttle chamber can then be taken out 3 Installation is in the reverse se quence ofremoval Note One of three screws has 8 hole for power vaJve mechanism in itself Take care not to confuse them g ID II i cb Throttle chamber securing scre s 2 Center body 3 Throttle chamber 4 Spring 5 Accelerating pump rod I EF888 Fig EF 33 Throttle chamber parto EF 18 ...

Page 98: ...lve stem and fluat scat mm in H H h Fast idle adju tmcnt Fast idle earn first step Gap between throttle al c and arburetar body mm in VlIcuum break adjustment Gap between chokevalvc and carburetor body mm in Choke unlouder adjustment Gap between choke valve and carburetor body mm in 7 2 0 283 23 0 91 1 3 10 1 7 0 051 to 0 067 141 10 1 55 0 0555 10 0 0610 4 30 to 1693 4 10 10 4 70 0 161410 0 1850 B...

Page 99: ...y Outlet valve seat of accelerator pump im proper Linked opening of secondary throttle valve opens too early Power shortage Main jets clogged Every throttle valve does not open fully Idling adjustment incorrect Fuel strainer clogged Vacuum jet clogged Air cleaner f1Iter clogged Diaphragm damaged Power valve operating improperly Improper idling Slow jet clogged Every throttle valve does not close S...

Page 100: ...e clogged Idling adjustment incorrect Secondary throttle valve operating im properly Fuel overflows No fuel Idling adjustment incorrect Fast idle adjustment incorrect Damaged anti dieseling solenoid EF 21 Corrective action Clean Clean tube Clean Adjust Overhaut and clean See condition overflow Check pump fuel pipe and needle valve Adjust Adju t Replace ...

Page 101: ...SION CONTROL SYSTEM DESCRIPTION INSPECTION REPLACEMENT EXHAUST EMISSION CONTROL SYSTEM EC 4 EXHAUST GAS RECIRCULATION CONTROL E G R I SYSTEM EC 4 BOOST CONTROLLED DECELERATION DEVICE B C D D I EC 7 QUICK HEAT MANIFOLD EC 12 DASH POT EC13 EVAPORATIVE EMISSION CONTROL SYSTEM EC 14 EC 2 EC 3 EC 3 EC 3 EC 4 ...

Page 102: ...mission control sys tern Periodic inspection and required servicing of these systems should be carried out to reduce harmful emis sions to a minimum 6 I Thermal vacuum valve 2 Dash pot 3 B C D D 4 1 low guide alve 5 E G R control valve 6 P cV valve r 1 Thermal vacuum valve 2 Distributor 3 E G R control valve 4 B C D D 5 Carburetor 6 Dash pot Fig EC l Emiuiol1 control syltem EC 2 ...

Page 103: ...flow through the valve and its flow goes through the tube connection in the reverse direc tion On cars with an excessively high blow by some of the flow will go through the tube connection to the carburetor air cleaner under all condi tions 1 Crankcase ventilation control valve 2 Scaled filler cap 3 Flame arrester 4 Steel net EC603 Fig EC 2 CrankcaB emision control t m EC 3 INSPECTION P C V VALVE ...

Page 104: ...SYSTEM EXHAUST GAS RECIRCULATION CONTROL E G R SYSTEM DESCRIPTION The Exhaust Gas Recirculation System has exhaust gases recirculate into the combustion chamber and lowers the combustion temperature so as to reduce NOx produced in combus tion process This system is composed of an E G R passage an E G R control valve a thermal Iacuum valve an E G R tube and hoses The E G R control valve measureS th...

Page 105: ...ted ExhaUlt pi EC236A Fig EC 7 E G R y tem ET344 Fig EC 8 Checking E G R control valve 3 Continue to run at idle speed until it warms up thoroughly Increase engine speed again from idling to 3 000 to 3 500 rpm noting if plate of E G R control valve diaphragm and valve shaft move upwards as speed is increased E G R control system is normal if diaphragm moves upward If not check system as in step 4 ...

Page 106: ... con trol valve is not operating properly due to leakage of vacuum signals To reo medy this condition replafo e vacuum hose 2 Remove E C R control valve from intake manifuld 3 Apply a vacuum of 13 3 to 14 7 kPa 100 to 110 mmHg 3 94 to 4 33 inHg to E G R con trol valve VaC lum application can easily be made by the method illust rated in Figure EC 12 ft is corred if valve moves into full up position...

Page 107: ...plate between E G R control valve and E G R passage Install gaskets on and below orifice plate E G R p ce nd E G R tube I E G R tube can be removed by loosening securing nuts 2 Disconnect blow by gas hose and remove three securing bolts and nuts E G R passage can then be taken out 3 Installation is in the reverse se quence of removal Note New gasket should be used in installing E G R passage EC013...

Page 108: ...ed of below 10 kmfh 6MPH for manual transmissiun models It actu ates the cut solenoid to inactivate the B C D D On automatic transmission models an inhibitor switch monitors the N or P position and inactivate the B CD D p I I L j I I I I J J Note Broken line applie5 only to Automatic Transmiuion INSPECTION AND ADJUSTMENT Generally it is unnclcssary to in spect and adjust B C D D however if it shou...

Page 109: ... H C 0 0 remains inoperative and negative pressure decreases with no sustained plateaus while it is falling B B CD D operates but the operat ing pressure is higher than the specified level such as set pres sure Negative Pressure A Set Pre sure Idling Ne a live Preesure Time Negative Pressure B Sol Pressure Idling Negative Preuure Time E C503 Fig EC 24 Charactrristic curl1r high oprrating pressurr ...

Page 110: ...sling screw slighlly Then race engine and confirm thai operating pressure is at the specified value If it is higher than the set level turn adjusting screw clockwise until correct adjustment is made if it is Replace inhibilor switch or amplifier lower than that turn screw counler clockwise Note a Turning adjusting screw one quarter rotation will cause a change in operation pressure ofabout 2 7 kPa...

Page 111: ...ing screws rescrew other three B C D D assembly screws in order to avoid warpil1l B C D D body TIghtenil1l torque B C D D securing screws assembling screws 2 0 to 3 9 N m 0 2 to 0 4 kg m I 4 to 2 9 ft Ib Cut olenolcl Disconnect lead wire at connee tor 2 Remove cut solenoid by unscrew ingit 3 Install new solenoid in the reverse sequence of removal Amplifier speed wltch M T onl The speed switch is p...

Page 112: ...gas flow from the engine is obstructed by the heat con J fold should be replaced IS an as sembly 1 I EC614 Fig EC 36 Chee ing heat control ualPt mOWm n EC12 trol valve in the exhaust manifold and is changed in direction as shuwn by the solid lin in Figure EC 35 The exhaust gas heat the manifold tove Open close operation uf the heat control valve is controlled by the counterweight and thermostat sp...

Page 113: ...radually closes as air in diaphragm chamber leaks INSPECTION I Warm up engine thoroughly 2 Turn throttle torsion shaft and release it gradually until dash pol touches throttle lever 3 Ensure that engine speed is within specified range Specified engine speed 1 500 to I 700 rpm If it isn t adjust dash pot adjusting screw 4 Race engine and ensure that en gine drops to idling speed Note In air conditi...

Page 114: ...uide valve The flow guide valve prevents blow by gas from nowing into the fuel lank and guides fresh air into it preventing gasoline vapor from escap ing into the carburetor air cleaner While the engine is stopped the evapo rative gas opens the flow guide valve and is led to the crankcase Once the EC 14 engine starts the gas evaporating in the crankcase is sucked into the mani fold for combustion ...

Page 115: ... Flow guide valve 2 Vapor vent line 3 Fuel filler cap 4 Check valve 5 Fuel tank EC051A Fig EC 40 Evaporative emission control system Fig EC 41 EF615 Disconnecting vapor vent line EC 15 3 Connect a 3 way connector a manometer and a clamp or an equiv alent 3 way change cock to end of vent line 4 Supply fresh air into vapor vent line through cock little by little until pressure becomes about 3 923 kP...

Page 116: ...e crankcase side C it shoWd never flow to the other two vent lines 3 While the air is pressed into the flow guide valve from the carburetor air cleaner side A it flows to the fuel tank side F and or crankcase side C 4 This valve opens when the inner prellSUfe is 13 cPa 10 mmHg 039 inHg In case of improper operations or breakage replace it lFrom carburetor air Cleaner A From fuel tank F o crankcase...

Page 117: ...t results is not satisfactory replace check valve Emission Control System REPLACEMENT Flow 8ulde valve The flow guide valve is secured to the bracket in the engine compartment with two screws Remove two securing screw Valve can then be taken out easily Installation is in the reverse se quence of removal EC 17 Fig EC 47 Removing low guide oolve Check valve I Remove rear corner finisher Refer to Cha...

Page 118: ...NTS EE 2 EE 2 EE 2 EE 3 EE 3 EE 4 EE 4 EE 4 EE 4 EE 5 EE 7 EE 7 EE 8 EE 8 EE 9 EE 9 EE 9 EE 9 EE 10 EE12 EE 13 EE 14 EE 14 EE 14 ADJUSTMENT IGNITION CIRCUIT DESCRIPTION DISTRIBUTOR CONSTRUCTION CHECKING AND ADJUSTMENT DISASSEMBLY AND ASSEMBLY IGNITION COIL DESCRIPTION SPARK PLUG INSPECTION CLEANING AND REGAP SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENIN...

Page 119: ...y On the other hand a hydrometer reading of 1 220 at IOoC 140F would be I 199 corrected to 200C 6S0F indi cating a partially charged battery The state of charge of battery can be determined by the following table if the specific gravity of electrolyte is known Before checking be sure that cells are filled to correct level m EE473 is EE 3 Charging Condition i Read top level with scale EEOQl Fig EE ...

Page 120: ...ure that electrolyte level is above top of each plate 2 Keep removed plugs in a safe place 3 Do not allow electrolyte tempera ture to go over 450C 1130F 4 After charging check to be cer tain that specific gravity does not exceed 1 260 or 1 280 NS70 at 200C 680F Correction can be made by adding distilled water into cells as necessary 5 Keep battery away from open EE 3 flame while it is being charge...

Page 121: ...t black wire with yellow tracer from magnetic switch terminal and black battery cable from battery terminal of magnetic switch 2 Remove two bolts securing start ing motor to gear case Pull starter assembly forward and remove starting motor 3 Install starting motor in reverse order of removal DISASSEMBLY I Loosen nut securing CORRecting plate to magnetic switch Mtermi nal Remove three screws securi...

Page 122: ...etic switch assembly and field coils Check them for excessive damage or wear and replace if necessary TERMINAL Check terminal for damage and wear and replace if necessary FIELD COIL Check field coil for insulation If the insulation of coil is damaged or worn it should be replaced Te tln field coli for continuity CORRect the probe of a circuit tester or an ohmmeter to field coil positive terminal a...

Page 123: ...mutator is less than specified value replace armature assembly Commutator diamotllr Refer to Service Data and Specifications 3 Measure armature shaft for bend with a dial gauge Replace armature sh1ft if bend exceeds specified value Armature shaft Less than 0 08 mm 0 0031 in EE019 Fig EE I9 IrupectingArmatureShoft or Bend EE 6 4 IlIpect soldered connection of armature lead and commutator If loose c...

Page 124: ...o load and high current draw may result from the following causes I Tight dirty or worn bearings 2 Bent armature shaft or loosened field probe 3 Shorted armature Check armature further 4 A grounded armature or field a Remove input terminal b Raise two negative side brushes from commuta tor c Using a circuit t ster place one probe onto input terminal and the other onto yoke EE 7 TEST PERFORMANCE TE...

Page 125: ...keep the battery fully charged Engine Electrical System If necessary adjust it by changing or adding adjusting washer s Adjust iog washers are available into two different sizes 0 5 mm 0 020 in and 0 8 mm 0 031 in If the starting motor check is OK check magnetic switch assem bly Connect cables between negative battery terminal and start iog motor M terminal positive battery terminal and starting m...

Page 126: ... from alternator 3 Loosen adjusting bolt 4 Remove alternator drive belt 5 Remove parts associated with alternator from engine 6 Remove alternator from car 7 Install alternator in reverse order of removaL DISASSEMBLY Remove through holts Separate front cover with rotor from rear cover with stator by lightly tapping front brackel wit h a wooden mallet V CJ WJ J EE712 Fig EE 32 Separating Front Couer...

Page 127: ...ode cover o EE039 Fig EE 36 Removing Diode Assembly Note Use care in handling diode sembly to prevent an undue stress on it Engine Electrical System INSPECTION AND REPAIR Remove alternator from car and apply tester between lead wire F white with black tracer and lead wire E black color When the resistance is approximate Iy 5n the condition of brush and field coil is satisfactory When no conduc tio...

Page 128: ...form a continuity test on diodes in both directions using an ohmmeter There are six main diodes and three sub diodes attached to set plate Three main diodes are attached to positive EEl plate and three others to negative 8 plate Three sub diodes are attached to terminals The continuity test should be per formed on each diode between the terminal and plate Conductive direction 1 plate 2 ptate 3 Dio...

Page 129: ...383 N 255 to 345 gr 8 99 to 12 17 oz Moreover when brush is worn pressure decreases approximately 0 196 N 20 gr 0 71 oz per I mm 0 04 in wear Brush spring pressure 2 501 to 3 383 N 255 to 345 gr 8 99 to 12 17 oz 2 mm 0 08 In EE049 Fig EE 59 Measuring Spring Pressure ASSEMBLY Assemble alternator in the reverse order of disassembly noting the following I When soldering each stator coil lead wire to ...

Page 130: ...g circuit on car Make sure that battery is fully charged 2 Connect one test probe from voltmeter positive terminal to RAT terminal Connect the other test probe to ground Make sure that voltmeter registers battery voltage 3 Turn on headlights and switch to High Beam 4 Start engine S Increase engine speed gradually until it is approximately 1 100 fpm and take voltmeter reading Measured value Below 1...

Page 131: ...OF REGULATOR VOLTAGE Regulator voltage is measured with regulator assembled with alternator When measuring voltage with regulator mounted on car it is necessary to rotate engine at high speed Connect DC voltmeter l5 30V DC ammeter IS lOA battery and resistor 0 25fl with cables as shown I Check to be sure that aU electrical loads such as lamps air conditioner radio etc are disconnected 2 Before sta...

Page 132: ...to 15 00 Note a Do not measure voltage immediate ly after driving Do this while regu lator is cold b To measure voltage raise engine speed gradually from idling to rated speed c Voltage may be approximately O 3V higher than the rated for two to three minutes after engine is started or more specifically when regulator becomes self heated Measurements should then be made within one mi ute after star...

Page 133: ...ecuring adjusting screw Turn this screw clockwise to increase or counterclockwise to de crease regulating voltage See Fig EE 68 Engine Electrical System EE119 Fig EE 68 Adjusting Regulating Volage Regulator I CHARGING RELAY Normal relay operating voltage is 8 to JOY as measured at alternator A terminal Relay itself however op erates at 4 to 5Y Use a DC voltmeter and set up a circuit as shown in Fi...

Page 134: ...il distributor wiring spark plugs and battery I Battery I 9 8 Below 5 2 Volts pilot lamp remains lit I Check fan belt tension 2 If correct remove regulator and adjust as necessary Over 5 2 Volts pilot lamp remains lit Pilot lamp relay coil or contact point out oforder Replace regulator Over 5 2 Volts pilot lamp does not light Pilot lamp relay assembly is in good condition IGNITION CIRCUIT The circ...

Page 135: ...R CONSTRUCTION IGr I Grease r 1 A 1 C p 2 Rotor head I 3 Breaker plate 4 Fixing plate 8 S Collar 6 Hof 5in8 1 Shaft 8 Governor weight 9 Condenser 10 Carn cD II Sideplll8 Ql 6 00 12 Center carbon I Greas i EE720 Fig EE 76 Distributor EE 18 ...

Page 136: ...I 2 3 4 5 6 7 8 9 10 II 12 13 14 15 16 17 1 f 4 711 Engine Electrical System D 3 Fig EE 77 Distributor ModeID606 52 EE 19 ...

Page 137: ...nt Condenser capacity 0 2 to 0 24 f J F Condenser insulation resistance More than 5MU ADVANCE MECHANISM Specnlcatlons Refer to Service Data and Specifi cations for Distributor Vacuum advance mechanism mechanical parts If vacuum advance mechanism fails to operate properly check for the following items an i correct the mal function as required I Check vacuum inlet for signs of leakage at its connect...

Page 138: ...Y To assemble reverse the order of disassembly Refer to Fig EE 86 for reassembly of governor spring and earn Carefully observe the following in structions 1 Rotor head positioning tip at earn is set on governor spring circular hook side EE 21 2 Weight pin for governor spring A with circular hook fits in long rectangular hole 3 Check to be sure that weight pin on spring A is in slit in earn plate w...

Page 139: ...nsulating and heat radiating characteristic Engine Electrical System IGNITION COIL CD V v 1 V 1 0 i lUl L 11 I I I t i t liOOJ I I Ij EE 22 1 PrimaIy terminal 2 Secondary terminal 3 Cap 4 Sprinl 5 Sidecore 6 Primary coil 7 Secondary coD B Inslilatoloil 9 Center con 10 Segment 11 Case EE143 Fig EE 87 Ignition Coil ...

Page 140: ... bluish burnt electrodes indicate engine overheating More over the appearance results from incorrect ignition timing loose spark plugs low fuel pump pres sure wrong selection of fuel a hOller range plug etc h is advisable to replace with plugs having colder heat range Engine Electrical System SPARK PLUG Normal Overheating 4 After cleaning dress electrodes with a small fIRe file to flatten tl1e sur...

Page 141: ...4173E HITACHI I 12 12 Less than 60 More than 6 000 ALTERNATOR Model Make LTl50 22B HITACHI Nominal rating V A 1250 Ground polarity Negative Revolution rpm 1 000 to 13 500 Minimum revolution under no load when 14 volt is applied rpm Less than 1 000 Output current A at 2 500 rpm More than 40 DISTRIBUTOR Model Make D609 61 HITACHI Firing order I 5 3 6 2 4 Rotating direction Counterclockwise EE 24 ...

Page 142: ...IGNITION COIL Model Make Primary voltage Spark gap SPARK PLUG t 3 I fJ Engine Electrical System v HP5 13EIO HANSHIN 12 mm in More than 7 0 28 7 BP6ES NGK t4 x 19 0 55 x 0 5 A oI rtt 1 MI i T 1 1 f f 1 i fir Ii i C 1 t f 0 ii j i t f l I A c l jt 0 il p Jt EE 25 ...

Page 143: ...ittoed clearance Pinion side mm in Middle mm in I Rear side mm in Brush minimum length mm in Spring tension N kg lb I L dimension between pinion front edge and pinion stopper mm in Commutator minimum diameter mm in Armature shaft bend mm in S1l4 173E 0 325 0 601 0 03 to 0 10 0 0012 to 0 0039 025 to 0 32 0 0098 to 0 0126 0 03 to 0 10 0 0012 to 0 0039 0 2 0 008 045 00177 0 2 0 008 More than 12 0 0 4...

Page 144: ...m in Condenser insulation resistance Mn Condenser capacity JlF Contact arm spring N kg lb Vacuum advance Distributor degrees distributor kPa mmHg inHg Centrifugal advance Distributor degrees distributor rpm Engine Electrical System LTl50 22B 0 09 3 85 More than 7 5 0 295 2 501 to 3 383 0 255 to 0 345 0 562 to 0 761 EE 27 More than 30 1 18 0609 61 35 41 0 45 to 0 55 O oJ8 to 0 022 More than 50 More...

Page 145: ...ease voltage at N terminal fl fl fl fl mm in 1 mm inl v Voltage coil resistance n mm in 1 mm in Core gap Point g p IGNITION COIL Model Primary resistance at 200C 680F Secondary resistance rat 200c 680F Resistor Kfl Engine Electrical System fl fl EE 28 TLlZ 82D 143 to 153 103 10 31 40 0 6 to 1 0 0 024 to 0 039 035 to 0 45 0 014 to O oJ8 4 2 to 5 2 37 8 0 8 to 10 0 031 to 0 039 0 4 to 0 6 0 016 to 0...

Page 146: ... Engine Electrical System Plug gap mm in TIGHTENING TORQUE Alternator pulley nut Spark plug N m kg m ft lb N m kg m ft lb BP6ES 0 8 to 0 9 0 031 to 0 035 EE 29 34 to 39 3 5 to 4 0 25 to 29 15 to 20 1 5 to 2 0 II to 14 ...

Page 147: ...re specific gravity of each cell ofbattery Specific gravity of each cell is less than 1 200 When specific gravity can not be raised above 1 200 by charging the battery is run down Specific gravity of some cells is above 1 200 but others show lower specific gravity Unbalance is within 0 05 Discharged battery Charge it and repeat lighting load test Unbalance is withjn 0 05 I Battery is satisfactory ...

Page 148: ...s of terminal Damaged field coil Damaged brushes Damaged bearing Starting motor inoperative Damaged armature Dirty or worn commutator Armature rubs field coil Damaged solenoid switch Worn pinion Locked pinion guide Worn ring gear Damaged solenoid switch Damaged gear teeth Corrective action Charge or replace battery Repair or replace solenoid switch Clean and tighten terminal Replace yoke Replace b...

Page 149: ...short ground or open in stator winding Partially shorted or grounded rotor winding Open or damaged diode Noisy alternator Loose mounting Loose drive pulley Broken ball bearing Improperly seated brushes EE 32 Corrective action Correct or replace brumes and brum springs Clean Retighten or solder connections Replace leads ifnecessary Repair or replace stator Replace rotor Replace Replace rotor Replac...

Page 150: ...rk that occurs between high tension cable and spark plug terminal After checking this repair as neces sary Probable cause Damaged insula tion ofcondenser Breakage of lead wire on low tension side Door insulation of cap and rotor head Point gap wider than specification Wire breakage or short circuit of coil Wire coming off Faulty insulation Point gap too wide Oil sticking on point Point burnt too m...

Page 151: ... shaky breaker plate Replace assembly Worn out or shaky distributor shaft Replace assembly Ignition coil Layer short circuit or inferior quality coil Rephice with good one High tension cable Deterioration of insulation with consequent Replace leak of electricity Spark plugs Fouled Clean Leak of electricity at upper porcelain insula Repair or replace tor Engine knocks Distributor Improper ignition ...

Page 152: ...NER ENGINE REMOVAL INSTALLATION CONTENTS ENGINE REMOVAL AND INSTAlLATION REMOVAL INSTAllATION ENGINE MOUNTING INSULATOR ER 2 ER 2 ER 4 ER 4 ENGINE MOUNTING REAR MEMBER SERVICE DATA AND SPECIFICATIQNS TIGHTENING TORGUE ER 5 ER 6 ER l ...

Page 153: ...litate proper reinstallation 3 Support hood with hand and remove bolts securing it to hood hinge taking care not to let hood slip when bolts are removed I a fj j t fir L L ER439 Fig ER 2 Removing Hood 4 Remove hood from hood hinge ER 2 1 1 Engine mounting front insulator R n 2 E c mountilll front bracket R H 3 Engine maUDlin front bracket L U 4 Engine mounting front insulator LU S Engine mounting ...

Page 154: ...ion 2 Remove compressor retaining bolts and fasten compressor to hood ledge with suitable wire to facilitate removal of engine 4 I Compressor bracket 2 Compressor retaining bolt 3 Compressor EA443 Fig ER 5 Removing Compre68or Away from Engine 10 On power steering equipped models Note Never drain pow steering oil while workis being performed I Remove oil pump belt To re move loosen idler pulley loc...

Page 155: ... any parts ER 4 Adjust accelerator and choke con trol system Refer to Engine Con trol System Section FE for adjust ment For inst lation of air conditioner compressor and belt adjustment For installation of power steering oil pump and belt adjustment Re fer to power steering Section ST for adjustment 3 When installing exhaust front tube on exhaust manifold be sure to use new gasket 4 When installin...

Page 156: ...t8118tlo 20 1 ber Install r engine mounting and 3 Remove bolts connecting rear en insulator1tl reverse order ofremoval gine mounting insulator to transmis noting the following ER S I Install insulator in place so that direction of mounted insulator is same as that in Fig ER I3 Front n ER415 Fig ER 13 R ar Imulator t u 2 Tighten nuts and bolts correctly and securely As for tightening torque I U j s...

Page 157: ...ear mounting member N m kg m ft Ib Rear mounting member to body N m kg m ft Ib Front tube to exhaust manifold N m Ieg m ft Ib Propeller shaft to companion flange N m kg m ft b Clutch operating cylinder to clutch housing N m kg m ft Ib Propeller shaft to center bearing bracket N m Ieg m ft lb Air conditioner compressor retaining bolt N m leg m ft lb Power steering oil pump retaining bolt N m Ieg m ...

Page 158: ...TING CYLINDER CLUTCH LI NE CLUTCH UNIT CLUTCH DISC AND COVER CLUTCH CONTENTS CL 2 CL 2 CL 2 CL 3 CL 3 CL 4 CL 5 CL 6 CL 7 CL 7 RELEASE BEARING PILOT BUSHING SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS CL 9 CL 9 CL 10 CL10 CL 11 CL 11 CL 12 CL 14 ...

Page 159: ...h service I Remove cap of rese rVC ir and top up with recommended brake fluid 2 Thoroughly clean mud and dust from bleeder screw of operating cyl inder so that outlet hole is free from any foreign material Install bleeder hose vinyl hose on bleeder screw Place the other end of it in a container filled with brake fluid 3 Have a co worker depress clutch pedal two or three times With clutch pedal dep...

Page 160: ...lcrum shaft and remove pedal assembly 1 Snap pin 2 Snap ring 3 Return spring 4 Pedal boss 5 Fulcrum shaft 6 Clevis pin 7 Push rod 8 Pedal CL343 Fig CL 3 Clutch Pedal CL3 8 4 C l320 Fig CL 2 Hydraulic Clutch Control INSPECTION Check clutch pedal parts for the following items correcting as neces sary I Bent pedal 2 Weakened return spring 3 Worn or deformed clevis pin and pedal boss 4 Cracks at welde...

Page 161: ... spring seat and re turn spring can be taken out Note Do not reuse piston cup and dust cover after removal CAUTION Never detach reservoir If it is removed for any reason discard it and install new one INSPECTION CAUTION To clean or wash all parts of m8S18r cylinder clean brake fluid must be used Never use mineral oils such as gasoline and kerosene It will ruin the rubber parts of the hydraulic sys...

Page 162: ...ne It will ruin the rubber plrts of the hydraulic ystem I Check cylinder bore and piston for score or rust and if found replace 2 Check cylinder bore and piston for wear If clearance between cylinder bore and piston is more than the specified value replace piston or oper ating cylinder assembly 3 Check condition of piston cup and dust cover Always renew them after disassembly 4 Check bleeder hole ...

Page 163: ...remove any foreign matter before making connections I I Connect clutch tube to master cylinder with flare nut 2 Fix clutch tube to dash panel with clamp 3 Then tighten flare nut tJl Tiwtening torque Flare nut 15 to 18 N m 11 5 to 1 8 kg m 11 to 13 fHb 2 Install clutch hose on operating cylinder with a gasket in plaoe Note Use new gasket CL 6 tJl Tiwtening torqua 16 to 21 N m 1 6 to 2 1 kg m 12 to ...

Page 164: ...ction and adjustment Flywheel and pressure plste Check friction surface of flywheel 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 CL 7 1 Clutch disc assembly 2 Clutch coyer assembly 3 Release bearing 4 Release sleeve 5 Withdrawal lever 6 Withdrawal lever ball pin CL319 Fig CL...

Page 165: ...apluagm Ad justing Wrench ST20050240 as shown in Fig CL 13 Diaphragm spring height A 33 0 to 5 0 mm 1 299 to 1 378 in If necessary replaoe clutch cover assembly Also unevenness of dia pluagm spring toe height should be within the specified limit Unevenness of diaphragm pring toe height Less than 0 5 mm 0 020 in 50240 r 1 IJ J5J o Cl091 Fig CL 13 Adjusting Spring Height 3 Inspect tluust rings for w...

Page 166: ...ll pin and bearing sleeve 3 Bearing sleeve liding surface of transmission case front cover I eL111 Fig CL 18 Lubricating Points of Withdrawal Lever Beari Sleeve and Front Cover 4 Tran mission main drive gear splines Use grease including molybde num disulphide Note A small amount of grease should be coated to the above points If too much lubricant is applied it will run out on the friction plates w...

Page 167: ...lation 4 Install transmission Refer to In stallation Section MT SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS CLUTCH CONTROL SYSTEM Type of clutch control CLUTCH MASTER CYLINDER Type Inner diameter CLUTCH OPERATING CYLINDER Type Inner diameter CLutCH DISC Type Facing size Outer dia x Inner dia x Thickness Thickness of di c assembly Free Installed CLUTCH COVER Type Number of torsion spring...

Page 168: ...ring toe height mm in Pedal stopper lock nut Master cylinder push rod lock nut Operating cylinder bleeder screw Master cylinder to dash panel securing nut N m kg m ft Ib Master cylinder reservoir band N m kg m ft Ib Master cylinder supply valve stopper N m kg m ft Ib Clutch tube flare nut N m kg m ft lb Operating cylinder to clutch housing securing bolt Clutch hose to operating cylinder Clutch cov...

Page 169: ...able when shifting gears especially into low gear TO TEST FOR DRAGGING CLUTCH proceed a follows I Start engine Disengage clutch Shift into reverse gear and then into Neutral Gradually increase engine speed and again shift into reverse gear If clutch is dragging gear grating is heard when shifting gears from Neutral into Reverse 2 Stop engine and shift gears Conduct this test at each gear position ...

Page 170: ...h is disengaged Insufficient grease on the sliding surface of bearing sleeve Clutch cover and bearing 3re not in stalled correctly Replace Replace Replace Replace Repair or replace Adjust or replace Retighten or replace I Replace Apply grease Adjust A noise is heard when car is suddenly rolled off with clutch partially engaged Damaged pilot bushing I Replace When grabbing of clutch occurs car will...

Page 171: ...KV30100100 Clutch aligning bar Fig CL 9 Fig CL 14 ST20050240 Diaphragm spring adjusting Fig CL 13 wrench ST20050 100 Distance piece Fig CL 12 STl661000J Pilot bushing puUer Fig CL20 ST200500l0 Base plate Fig CL 12 GG943 10000 Flare nut torque wrench Page CL 2 Page CL 5 Page CL 6 8 ST20050051 Set bolts Fig CL 12 W Wy W CL 14 ...

Page 172: ...ND SHAFTS BAULK RINGS SHIFTING INSERT OIL SEAL MT 2 MT 4 MT 5 MT 6 MT 6 MT 6 MT 8 MT 8 MT B MT 9 MT 9 MT 9 MT 9 MT 9 MT 9 REAR ENGINE MOUNTING INSULATOR ASSEMBLY FRONT COVER ASSEMBLY REAR EXTENSION ASSEMBLY ADAPTER PLATE GEAR ASSEMBLY TRANSMISSION ASSEMBLY SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SE...

Page 173: ...34 2 5 to 3 5 18 to 25 t6 to 23 16 to 2 3 12 to t 7 13 to 18 1 3to 18 9to 13 P j 3 V TMl77A Fig MT l FS5W71B TnmsmiMion Case Components 1 Front cover 2 Front cover oil seal 3 FtOnt rover ga ket 4 Transmission case 5 Adapter plate 6 Main5haft bearing 7 Bearing retainer 8 Rear extension 9 Breather 10 Rear extension oil seal 11 Sleeve yoke dust cover 12 Reverse lamp switch 13 Drain plug 14 Filler plu...

Page 174: ...edometer bearing shim h ft front COlnters aft front bearing ft drive gear Countershaft g h ft beano Counters a ear spacer R rse counter g eve ear Rever CQun ter g gear d counter Over nve bearing Countershaft rear Countcl 1haft nul dl shaft Reverse I er h t washer Reverse idler t cus Rever idler gear bearing Reverse idler g ar t washer Reverse idler t TUS TM178A C mponents ion Gear 0 FS5W71B Transm...

Page 175: ...ont exhaust tube S Disconnect wires from reverse back up lamp switch 6 Disconnect speedometer cable from rear extension 7 Disconnect ground cable be tween transmission and side member at side member 8 Remove propeUer shaft Refer to Removal Section PO J re a Tightening torque N m kg m ft Ib 910 12 0 9 10 1 2 6 5 to 8 7 81010 0 8101 0 5 8107 2 191025 1910 2 5 14 to 18 TM119A Fig MT3 FS5W71B Tran mwi...

Page 176: ...of control lever and striking rod 3 Remove filler plug and fill trans mission with recommended gear oil to the level of the plug hole Oil capacity 2 0 liters 3 Ji Imp ptl TCAkUTION d iloI a a care m Ismountmg transmlSslon not to strike any adjacent parts and main drive gear 4 Apply sealant to threads of mler plug and install mler plug to tr n is sian case 14 15 J l i 1 J li 1 l I5 W U C r j fi f j...

Page 177: ...emoving Rear Extemion 10 Remove front cover securing bolts and remove front cover Detach countershaft front bearing shim 11 Remove main drive bearing snap ring with Expander TM340 Fig MT 9 Removing Main Drive Bearing Snap Ring 12 Separate transmission case from adapter plate with a soft hammer TM753 Fig MT IO Removing Transmiuion Case 13 Set up Setting Plate Adapter ST2381000l on adapter plate Wit...

Page 178: ...ont of mainshaft gear assembly by hand CAUTION Be careful not to drop gears Meln heft I Remove thrust washer steel ball Ist gear and needle bearing Be careful not t2 lose steel ball retaining thrust washer 2 Press out I st gear mainshaft bush ling together with 2nd gear and 1st 2rtd synchronizer using Bearing Puller sT36031000 6 Remove reverse counter gear and spacer 7 Remove snap ring from revers...

Page 179: ...rd main gear 7 Needle bearing 8 l lainshaft 9 2nd main gear 10 Bushing 11 1st main gear 12 O rcverse synchmnl1cr hub 13 Reverse gear 14 Circtip 15 Thrust block 16 Braketiand 17 Synchronizer ring 18 Overdrive main gear 19 Overdrive gear bushing 20 Washer 21 Mainshaft nut 22 Overdrive mainshaft bearing 23 Speedometer drive gear TM204A Fig MT 18 Mainshaft Assembly REAR EXTENSION Remove lock pin from ...

Page 180: ...ear 0 t3100 37 mm 10 0051 10 0 0146 in 5th gear 0 10 to 0 17 mm 10 0039 to 0 0067 in Reverse idler gear 0 0510 0 50 mm 0 0020 10 0 0197 in l Thickness gauge Fig MT 22 Measuring End Play 4 Check for stripped or damaged speedometer pinion gear If necessary replace BAULK RINGS I Replace any baulk ring which is deformed or cracked 2 Position baulk ring in place on gear cone and measure the baulk ring ...

Page 181: ...mer until they are properly positioned in place Use a new dowel pin 2 Insert reverse idler shaft in adapt er plate Note Make sure that the cut out por tion of reverse idler shaft is lined up with inner face of adapter plate 3 Install bearing retainer in adapter plate Align bearing retainer with reverse idler shaft at the cut out portion of thisshaft Tightening torque Mainshatt bearing retainer scr...

Page 182: ... 3 4 5 6 TM358 Fig MT29 n talling Thrust Wa her 2 Set Transmission Press Stand KV31100400 and place adapter plate assembly on it Manual Transmission For countershaft and reverse idler shaft For mainshaft and reverse I idlershaft J 7j lJi M a HOl emse idle haft TM213A Fig MT 30 Transmission Press Stand 3 Install mainshaft assembly to adapter plate assembly Be sure to place bearing squarely against ...

Page 183: ...rease to it IS Assemble new mainshaft nut and tighten it temporarily 16 Assemble spacer reverse counter gear overdrive counter gear bearing and new counter gear lock nut Ti teningtorque Counter gear lock nut 98 to 127 N m 10 0 to 13 0 kltm 72 to 94 ft b 17 With gears doubly engaged tighten mainshaft lock nut ST22520000 TM768 Fig MT 38 Tightening MailUihaft Nut MT12 Explal 8tion ofconverted torque ...

Page 184: ...r OD gear be sure to replace as a set of main drive gear and counter drive gear and 8 set of main OD gear and counter OD gear Shift forks and fork rods I Place groove in reverse shift fork or reverse that in reverse gear Slide reverse fork rod through re verse shift fork and adapter plate and secure with a new retaining pin 2 Install check ball and check ball spring Apply locking sealer to check b...

Page 185: ...gainst adapter plate Carefully install main drive bearing and countershaft front bearing Make certain that mainshaft rotates freely 3 Fit main drive bearing snap ring to groove in main drive bearing by using Expander TM340 Fig MT 46 Fitting Main Drive Bearing Snap Ring Rear e tenslon I Clean mating surfaces of adapter plate and rear extension Available shim No A I 2 3 4 5 6 7 8 2 92 to 3 01 3 02 t...

Page 186: ...amp switch Tightening torque Reverse lamp switch 20 to 29 N m 2 0 to 3 0 kg m 14 to 22 ft Ib Note Be sure to apply locking sealer before installation 5 Apply a light coat of multi purpose grease to withdrawal lever release bearing and bearing sleeve in stall them on clutch housing After connecting them with holder spring install dust cover on clutch housing MT15 6 Install control lever temporarily...

Page 187: ...gear Gear backlash Main drive counter drive gear 1st gear 2nd gear 3rd gear 5 th gear Reverse counter to reverse idler Reverse idler to reverse main Main drive gear rotating torque mm in mm in mm in mm in mm in mm in 0 27 to 0 34 0 0106 to 0 0134 0 12 to 0 19 0 0047 to 0 0075 0 13 to 0 37 0 005 I to 0 0146 0 10 to 0 17 0 0039 to 00067 om to 0 21 0 0004 to 0 0083 0 05 to 0 50 0 0020 to 0 0197 mm in...

Page 188: ...plug 16 to 21 1 6 to 2 1 12to IS 9to 12 0 9 to 12 6 5 to 8 7 16 to 23 16 to 2 3 12 to 17 137 to 167 l4 to 17 101 to 123 98 to 127 10 to 13 72 to 94 19to 25 1 9 to 2 5 14to 18 16t021 1 6t02 1 12to IS 16t02i 1 6t02 1 12to IS 4to S 0 4 1 0 0 5 2 9 to 3 6 Crossmember n ounti g o lt c Rear engine mq 1 irig install bolt bolt Propeller shaft t ji1ifferentiaI MT17 ...

Page 189: ...th engine idling and ceases when clutch is disengaged or when noise occurs while shifting gears it is an indication that the noise is from trans mission Transmission may rattle during engine idling Check air fuel mixture and ignition timing After above procedure readjust engine idling Probable cause Worn gears shaft and or bearing Insufficient operati g stroke due o worn or loose sliding parI Worn...

Page 190: ...1320 KV32I01330 Puller set Mainshaft puller Adapter Bearing puller Fig MT 16 KV38104010 Oil seal drift Page MT 8 J ST23800000 Transmission drift Page MT 10 ST3S360000 Oil seal drift Page MT 8 ST23810001 Adapter selling plate Fig MT II KV3IlO0400 Transmission press stand Fig MT 30 Page MT II Fig MT 31 LO Fig MT 32 0 Fig MT 36 I I J 0 LJ KV3IlO0300 Fork rod pin punch Fig MT I2 ST23860000 Counter gea...

Page 191: ...n Tool number tool name Reference page or Fig No Tool number tool name ST22360002 Bearing drift Fig MT 36 Mainshaft bearing drift ST223S0000 ST22520000 Wrench Fig MT 38 Fig MT 39 MT 20 Reference page or Fig No Fig MT 42 ...

Page 192: ...3 AT 5 AT 5 AT 5 AT 5 AT 6 AT 6 AT 6 AT 7 AT 13 AT 14 AT 16 AT18 AT 20 AT 22 AT 24 AT 26 AT28 AT 30 AT 32 AT 33 AT 33 AT 33 AT 33 AT 34 AT 35 AT 35 AT 35 AT 35 AT 35 AT 35 AT 35 AT 35 INSPECTION ASSEMBL Y COMPONENT PARTS FRONT CLUTCH REAR CLUTCH LOW REVERSE BRAKE SERVO PISTON GOVERNOR OIL PUMP PLANETARY CARRIER CONTROL VALVE TROUBLE DIAGNOSIS AND ADJUSTMENT INSPECTION AND ADJUSTMENT BEFORE TROUBLE...

Page 193: ...OOTING CHART INSPECTING ITEMS TROUBLE SHOOTING CHART FOR 3N71B AUTOMATIC TRANSMISSION AT 51 AT 52 AT 52 AT 53 AT 53 AT 53 AT 53 AT 54 AT 2 TROUBLE SHOOTING GUiDE FOR 3N71B AUTOMATIC TRANSMISSION SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS SPECIFICATIONS AND ADJUSTMENT TIGHTENING TORQUE SPECIAL SERVICE TOOLS AT 57 AT 59 AT 59 AT 59 AT 51 AT 52 ...

Page 194: ...ection N Neutral position enables the engine to be started and run without driving the vehicle Automatic Transmission DESCRIPTION lD Drive range is used for all normal driving conditions Drive range has three gear ratios from the starting ratio to direct drive 2 2 range provides performance for driving on slippery surfaces 2 range can also be us d for engine braking 2 range can be selected at any ...

Page 195: ...n 15 Con trol val vc 16 Input shaft 17 Torque converter 18 Converter housing 19 Drive plate Tightening torque of bolts and nuts N m kg m ft lb 39 to 49 4 to 5 29 to 36 137 to 157 14 to t6 tOI to 116 oe44t054 4 5t05 5 33t040 J 5 9 to 7 8 0 6 to 0 8 4 3 to 5 8 4 9 to 6 9 0 5 to 0 7 3 6 to 5 1 20 to 25 2 0 to 2 5 14 to 18 13to18 1 310 18 94toI3 8J 5 4 to 7 4 0 55 to 0 75 4 0 to 5 4 CD 2 5 to 3 4 0 25...

Page 196: ...ve body assembly located in the base of the transmission The valves regula te oil pressure and direct it to appropriate transmission components Torque converter Front cI tsh tf Rear Clu ich Low and revhse brake Band b ra I I I J I J i 3 f 1 Housing 2 Cover 3 Outer gear 4 Inned ear 5 Crescent Fig AT 3 Oil Pump MANUAL LINKAGE The hand lever motion the hand lever is located in the driver s compart me...

Page 197: ...n wi tch Ii Down shift 5ol enoid A T089 Fig A T 6 Downshift Solenoid GOVERNER VALVE The primary and s econdary gaver nor valves are instaHed separately on the back of the oil distributor on the transmission output shaft They op crate at the same speed as that of the output shaft that is they operate at a speed in proportion to the vehicle speed The line pressure is applied to those valves as the i...

Page 198: ... Speed change r I Governor valve I valve t I I L i I Oil from pump i i I I I Throt tle valve I I I I I J 1 Regulator valve Manual valve I I n nn ml I I Auxiliary valve Line pressure Clutch and brake The control valve assembly receives oil from the pump and individual signals from the vacuum diaphragm and transmits the individual line pres sures to the transmission friction ele ment torque converte...

Page 199: ...and the line pressure 7 increases Automatic Transmission A i 1 i ii 14 m 1fl J X r 2 s r i f I d X i 1 n Liz i jE 8 12 1 A TOgS Fig AT 10 Pre ure Regulator Valve When the range is sclected at R Reverse the line pressure 6 is applied to the plug in a manner identi cal to the throttle pressure 16 and is added to the spring force Cunsequent Iy the line pressure 7 further in creases When vehicle speed...

Page 200: ...ressure IS is applied to the right end surface and the SSV is forced toward the left Contrarily the spring force line pressure 3 and throttle pressure 19 force the SSV toward the right When vehicle speed exceeds a eer tain level the governor pressure sur passes the sum of the spring force line pressure and throttle pressure and the valve is forced toward the left The line pressure 3 is then closed...

Page 201: ...3 2nd 3rd Shift Valve When the governor pressure IS which is applied to the right side of the PMV is low the valve is forced toward the right by the throltle pres sure 16 applied to the area differ ence of the value and the spring force and the circuit from circuit 16 to circuit 18 is dosed However when veh ide speed increases and the gover nor pressure 15 exce dsa certain level the governor press...

Page 202: ...tly the valve is forced upward and locked As a result the space from the line pressure 4 to the back up pressure 17 is closed completely and the back up pressure I 7 is drained upward 4 ATlDl Fig AT 16 Throttle Baek Up Valve Solenoid downshift valve SDY This valve is a transfer valve which leads the line pressure 7 to 13 and transmits the same to the FSV and SSV when a kickdown signal is re ceived...

Page 203: ... PMV 6 Vacuum throttle valve VTV 7 Throttle back up wive TOV 8 Solenoid downshift valve SDV 9 Second lock valve SLV 10 2 3 timing valve TMV r UP c Automatic Transmission the upward force exceeds the down ward force the vatve is locked upward and passage from circuit 10 2nd from the Top to circuit II is closed Consequently the line pressure 10 is led to the front clutch circuit 11 through the orifi...

Page 204: ... pressure 1 Front clutch pressure 11 e yJ uctionhole G eG G Fig AT 21 Identification of Oil Channels in Oil Pump Automatic Transmission L Air breather AT106 Fig AT 22 Identification ofOil Channels in CWle Front Face r o o Oil pump discharge hole rovemor pressure 15 11 1 uW Torque converter fo IF il o pressure 14 0 Servo release Rear clutch l press re 10 I Governor feed pressure l pressure 1 Servo ...

Page 205: ...that of the N range The Front Rear brake Operation Release c1ulch oil having the line pressure 7 which Park has been introduced into the manual on valve V reaches the I Sl 2nd shift Ruerse 2 182 on valve through the line pressure circuit 5 As the 1st 2nd shift Neutral valve is forced to the right hand side Dt Low 2 458 by the spring the line pressure 5 and Drive 02 Second 458 I2 the low and on act...

Page 206: ...u Jl i Blrod g Servo c 0 I t I I 0 J I I f Orlflc ChllCk V l Throttle Drain V II5 2 3rd Tlml 0 v ZI Menu VI e J Dr ln u pr Gornor 1 1 PAlllUr G nor lauf Torqul veru rP Throttll pr HI AT 15 Downltliit SOlenoid I 112 Th ottr I i Solln ll e j r lh 1 i 1 1 1 II 2 5 f Mod lft 01 Iris ID V8CU 1 Thro I V I Orlflc k V I I II II h no II 1 1ft 2nd 1 I Il 8econcllry a nor v rlm O no Val Fig AT 25 Oil Pre8lur...

Page 207: ...being introduced into Iine pressur circuit 12 through the s 2nd shift val The pressure in t e circuit op erates the release side of the band servo and the front clutch after being led to line pressu i cuit i ill through the 2nd 3rd shift valve The throttle pressure fl6 and the line pressure 6 which vary with the degree of accelerator pedal depression both act on the pressure regulator valve CD and...

Page 208: ...21 1 6 2nc1 3rd Tlmll lQ v P II 1t L v Ir II Oown hih iol nolcl ID 11 i Ttlronl B k u V I E SOI lei I gI Oow thV l V C Thh 1 V It J II 24 ID Pr Modlt III 15 I Orltlc C kll V I O fle Chkk V lv I I I II 5L 1 B I 23 M oo U lrz v IY p N 0 2 I fl31j I Not M rkld X Or l pr Gov rnor t cl Go nor TOrQu r r tlUr Throttl AT17 15tf SecOnd ry GDY norV lv Prlmll y GowernorV lv Fig AT 28 Oil Pre ure Circuit Diag...

Page 209: ...s oil is distributed to each parh as the front lubricanL The oil whicll has been discharged from the torque con verter is also distributed to each part as the rear lubricant As the oil pump rotates at the same speed as the engine the oil pump discharge increases with engine speed But the surplus oil is returned to the oil pan by the pressure regulato r valve CD Automatic Transmission CUI Clulch Lo...

Page 210: ...t kKl 111111 I 1 1 TOfQUI 12 Q 11 l urnltt ind hiftV Iv od L v 1 IL J I II II I xj 3 I II iJ 2 4 A M uI V I 111 III I j u f Oritic ChKIl v Throttl o in v 22 II II t I Dr in Llnlpr Goy rnor 1 GOV lrnO p pr l r ThroW pr DOWrwnlhift SOllnoid J r Th ottll Soli ld e L DOWlJpllft 11 1 q I T j II 18 O Uk Ch k V I 24 P Mod I 1 I I SKOndl y G ernO Vltvl lrnary Governor V tv AT 19 Fig AT 29 Oil Pre ure Circ...

Page 211: ...ure 16 which changes with the degree of accelerator pedal depression presses the pressure regulator valve CD and increases the line pressure 7 When the speed of the vehicle has increased the governor pressure IS introduced from the line pressure circuit I actuates the IS 2nd shift valve 2nd 3rd shift valve and pressure modifier valve ID When the governor pressure is high the pressure modifier valv...

Page 212: ... B aka B 1 ft i J 1 1 Band g I I f Throttl Drain V l Manua V lve 2nc1 3n 1 Tlml l 2 1 i 6 9 SK L kV1 6 J CD II 1111 11 0 Valva Line pr Go rno 1 1 Ofeaur l or ln Go rnor pre na TOrque alalr onl I f 12 r r la u 1 1 U L JJ Throttl Solan Baok up Down 1ft Valva 1 I Oownttlift Solenoid ID VecU Throi Valva I r ZncI 3rd Shift lv 13 II i f 0 1 3 h1 2nd Itt 1 1 JI I x lcond Y Gow rnof aM Imary Oow nor V I F...

Page 213: ...und the sun gear in a clockwise direction The one way clutch will act to allow the clockwise rotation of connecting drum When the car speed increases whQe running at D range 1st gear the lst 2nd shift valve moves allow ing the line pressure I to be intro duced into the line pressure 8 through itself The line pressure 8 is further led to the line pressure 9 through the second lock valve and by lock...

Page 214: ... VKuum Control D hr m J 3t B IIl 8 S8Ao of a Throttl II l18Ck P J v tw 1 Ij IlT IrT I I Orlflc Orlflc Ch c k K V I V l iJ Throttl Dr ln v fb 2nd 3rdShift I V 11 13 22 I H 1itJ r 2nd 3n l Timing x V V I i 9 s cond Lock V PRND21 I II II r4 6U 5 J f 1l Jl LIM r CG nor 1 1 rl NOtl Mlrk X Or ln Torqu s ona y G o V IOI Prlmllry Governor V tw G rnor lAUr rt lr laIr Thronl p r Fig AT 35 Oil Pr u Circuit D...

Page 215: ...is forced to rotate the output shaft at tle same spe d the direction to provide the top gear When the car speed further in creases while running at 02 range 2nd gear and the governor pressure IS exceeds the combined force of the spring of the 2nd 3rd shirt val e and the throttle pressure I 9 the 2nd 3rd shift v lve moves and the line pressure 8 acts to release the rront clutch and band servo throu...

Page 216: ... X orv l secondary GOVlrnor V i r Throttle Dr ln Valvl X Drain M Ir l GO l O Linl prl Goy rnor prl c onv rr rp Torqu Throttle prl Nota I lL I 11 1 I l I l 1 rl r 12 I J Throttle tt Vat f6 Vley r e JI W Thro II v rv I il I Orlflc Check V lva Orific Check V lvI rn 1 Il V I 42nd 3rd Shift Valvl 1 I If If J 1 2 ShlftY IYI 1n 2nd c 22 Mlnull Vllvl Fig AT 38 AT 25 nl7Pam Circuit Dl Oil Pres Un Top gear ...

Page 217: ...he line presswe 13 3 plus the force of the 2nd 3rd shift valve spring oppose the governor pressure IS at the 2nd 3rd shift valve and thus performs 3rd 2nd downshift op eration Moreover the line pressure 13 plus the force of the Ist 2nd shift valve spring oppose the governor pres sure IS at the 1st 2nd shift valve and thus perform 3rd 2nd or 2nd 1st downshift operation Automatic Transmissio l em Cl...

Page 218: ...vl I 1 I Orifice Chick V l a ZZ 2nd 3rc1 TimIng ii VoN t L kV lfi C M nuIl V I Notl M rk Or ln I5 lIIlmI Line prnlU Go rnor fl pre Gov rnor PR Vecuu Control Olaphr lllm Vecu m Thro I VI val ID Sol icl Oowl ftV 1 1 tit Throttle fa I Orltlce Cheek VII a I fOr Ifl V I l I F 2 r d 2ndShlftV I I I aZ3 1111 I 4 U6LJ r 5 Jl t Tn I Im v OOYernorV lvl 5 rw l r Go rnorV I Fig A T39 Oil Prere CircuitDiagram ...

Page 219: ...e second lock valve and is led to the tightening side of the band servo The 2nd gear is therefore fixed regardless of vehicle speed When 3 range 3rd gear is shifted to 2 range the line pressure 4 enters the throttle back up valve D and produces a high pressure in the circuit I 7 increasing the throttle pressure I 6 The line pressure 7 is therefore increased and quickly tightens the band Nolte 0 ra...

Page 220: ...r k 0 R 1e l i e S rvo 1f Throttle Or in V IVI 2nd 3d Tlm ng x 1 11 Notl MI k l X Dr ln I r T rottl pr v eU Thro1 V lvl 8 Sole lei Q Cow lift V J 1 Oritic e K V lvl il I iJl r 12 1 2nd hlf I Mlnu VIIVI I I IJ r j L I PRND2 clD I mwry G norVltve Llnl pr IGo no t p G erno ut Torqul c onvert8 Throttl Jrl s cond 0 0 V tv Fig AT 42 Oil Preaure Circuit Diagram 2 Range 2nd Ilear AT 29 ...

Page 221: ...ar assem bly are rotating in the same direction but the planet carrier is rotating at a speed slower than the ring gear So the gear r tio of this speed range is a combination of the ratios provided by the front and rear planetary gear as semblies When the manual valve is posi tioned at I the line pre sure 7 is applied into the line pre5sure circuits I 4 and 5 The oil pressure in 5 actuates the low...

Page 222: ...1 r J L 1 I f OrificI Chick V l Throttl Dr ln V v Ii 12 J ThrbW BlICk 0 V Orlflc ChlKk V DOWIHlto ft Sol oid SOI d OOWI IHV I AocIlt l tts 2nd 3rtiShift 1I V 6 II t1 2nd 3rd Timing r 1 I M nu v I I O 2 Not M rk j X O ln Line ineIGoY or f Jl J Govwnor pr Torque pr taI Throttle f Second Govltrnor V hl 0 I j t AT 31 Fig AT 45 Oil Prere Circuit Diagram 1 Range Low gear ...

Page 223: ...ion Clutch f J i Il8nd 8 f TI lrottl Dr in v L a A Sr Srlk I J x il J L v nv v Oritlc Kk VI Znd3rdTiming v II I 9 L v I I J If II I Note M k X r Or ln Oown lft SOlenoid l r W So r j gJ Dow ift v I l 1A 2nd It iI M n V tvl LI pr r IQo nor f 1 G nor V a norp TorquI eolW p r Thro1tl pr r x Prlmll l G norV AT 32 Fig AT 46 Oil Preaure Cin uit Diagrom 1 Range 2nd ...

Page 224: ... a transmission jack 12 Detach engine rear plate rubber plug Remove bolts securing torque converter to drive plate AT441 Fig A T 47 Removing Torque Converter Attaching Bolta Note Before removing torque conver ter scribe match marks on two parts so lhatthey may be replaced in their original positions 13 Remove rear engine mount se curing bolts and crossmember mount ing bolts 14 Remove starter motor...

Page 225: ...osition I 0 Check level of oil in transmis sion For detailed procedure see page TRANSMISSION CONTROL LINKAGE c I R N D 2 y I I II 11 ph l j 1 Control lever knob 2 Pusher 3 Control lever assembly 4 Selector range lever 5 Control lever bracket 6 Joint trunnion 7 Selector rod 8 Selector rod lock nut A 9 Selector rod lock nut B AT48 for Checking Oil LeveL II Move sel Clor lever through all X sitions t...

Page 226: ...ift lever to N position 2 Adjust clearance C to zero by applying a force in direction C to control lever Screw up lock nut until it just makes contact with trun nion and then back off I complete turn Tighten lock nut MAJOR REPAIR OPERATION the extent of damage that justifies replacement 7 As a rule packings seals and similar parts once disassembled should be replaced with new ones TORQUE CONVERTER...

Page 227: ...tic Transmission Fig A T 56 Removing Oil Pump 9 Remove band strut This can be done by loosening piston stem further AT123 Fig AT 57 Removing Band Strut 10 Remove brake band front clutch and rear clutch as an assembled unit II Remove connecting shell rear clutch hub and front planetary carrier asa unit AT124 Fig A T 58 Removing Connecting Shell 12 With the aid of Snap Ring Re mover HT69860000 pry s...

Page 228: ...rake lever V and remove the lever Back off manual shaft lock nut and remove manual plate and parking rod CID Fig AT67 Removing Manual Plate 22 Remove inhibitor switch and manual s 1aft by loosening two secur ing bolts AT 37 INSPECTION Torque converter housing transmission case and rear extension I Check for damage or cracking if necessary replace 2 Check for dents or score marks on mating surfaces...

Page 229: ... for Assembly 3 Install one way clutch so that the arrow ark i is toward front of vehicle It should be free to rotate only in clockwise direction AT137 Fig AT 71 One Way Clutch 4 After installing rear extension torque attaching bolts to 20 to 25 N m 2 0 to 2 5 kg m 14 to 18 ft Ib Place manual lever in P range and check to be sure that rear output shaft is securely blocked 5 Tighten servo retainer ...

Page 230: ... Under 25 55 1 0059 25 65 to 26 05 10098 to 10256 26 15 to 26 55 10295 to 1 0453 26 65 to 2705 1 0492 to 1 0650 Over 27 15 10689 COMPONENT PARTS The transmission consists of many small parts that are quitc alike in construction yet machined to very close tolerances When disassembling AT 39 10 Check to be sure that brake servo piston moves freely For detailed procedure refer to page AT42 for Servo ...

Page 231: ...owing Out Pi8ton Inspection I Check for signs of wear or dam age to clutch drive plate facing If found worn or damaged excess vely discard Drive plate thickness Standard 1 50 to 1 65 mm 0 0591 to 0 0650 in Allowable limit 1 4 mm 0 055 in 2 Check for wear on snap ring and for weakened or broken coil spring If necessary replace with new ones Spring retainer should also be in spected for warpage Asse...

Page 232: ...k to be sure that clearance be tween snap ring CD and retaining plate CV is held within specified clearance Specified clearance 0 8 to 1 6 mm 0 031 to 0 063 in AT1S6 Fig A T8S Meaaurin Ri to Plate Clearance 2 Testing rear clutcH Install rearclutc ori oil pump cover Blow compressed air into oil hole t p t tjfpr definite clutchioperation as shown in Fig AT 9 1 41 I lA r157 Fig A T 9 Te8ting R ar Clu...

Page 233: ...sion fluid Reverse disassembly procedure to assemble brake 2 Use extreme care to avoid dam aging rubber ring when installing seal lace 3 Blow compressed air from apply side of piston to test for definite piston operation as shown in Fig AT 93 AT160 Fig A T 93 Te ting Pioton Apply ide 4 With apply side of piston plugged with thumb blow compressed air into cylinder from release side as shown in Fig ...

Page 234: ...or outer gear and pump cover Standard clearance 0 02 to 0 04 mm 0 0008 to 0 0016 in Automatic Transmission Replace if over 0 08 mm 0 031 in AT162 Fig A T 96 Measuring Clearance Clearance between seal ring and ring groove Standard clearance 0 04 to 0 16 mm 10 0016 to 0 0063 in clearance Seal ring t II Assembly I Set up pump housing with inner and outer pump gears on it 2 Using Oil Pump Assembling G...

Page 235: ...ver but it is recommended that Hexagon Wrench HT61000800 and Spinner Handle HT623S0000 be used HT6100800 Fig AT 101 Di8a embling Valve Body 2 Remove attaching bolls With bolls removed lower valve body separate plate and upper valve body are free for removal CAUTION 00 not allow orifice check valva and valve spring in lower valve body to be scattered and lost when removing se parate plate Fig AT 10...

Page 236: ...heck valves for sign of burning and if necessary replace 2 Check to be certain t at oil strainer is in good condition If found damaged in any manner discard 3 Test valve springs for weakened tension if necessary replace 4 Examine for any sign of damage or score marks on separate plate If left unheeded oil will bypass correct oil passages causing many types of abnormalities in the system 5 Check oi...

Page 237: ...866 0 492 0 60 1 32 0 55 5 0 16 0 33 5 210 5 88 Second lock 0 0217 0 197 1319 0 827 0 60 1 32 0 9 5 6 14 0 26 8 19 0 2148 Throttle relief 0 035 0 220 1055 0 748 2 19 4 83 023 477 12 0 15 5 11 5 0 10 Orifice check 0 0091 0 1878 0 610 0453 0 01 0 02 0 45 8 3 5 0 218 7 5 2 109 Primary governor 0 0177 0 327 0 858 0 295 0 215 0 474 0 7 8 5 5 5 25 1 10 5 10 79 Secondary governor 0 028 0 335 0 988 0 4 13...

Page 238: ...ed in valve body See fig AT lOll 4 Install upper and lower valves Tightening torque Upper and lower valves 2 5 to 3 4 N m 0 25 to 0 35 kg m 1 8 to 2 5 ft Ib Reamer bolt 4 9 to 6 9 N m 0 5 to 0 7 kg m 3 6 to 5 1 ft Ib Automatic Transmission 5 Install oil strainer Tightening torque 2 9 to 3 9 N m 10 3 to 0 4 kg m 2 2 to 2 9 ft Ib ST25160000 HT61000800 AT174 Fig AT lOS Installing Valu Body Throttle r...

Page 239: ...idling conditions are stabi lized Then apply the brakes and move the transmission shift lever through aU drive positions and place it in park P position In this inspec tion the car must be placed on a level surface The amount of the oil varies with the temperature As a rule the oil level must be measured after its tempera ture becomes sufficiently high I Fill the oil to the line H The difference o...

Page 240: ...ctor lever toward you and turn it as far as p to I range where clicks will be felt by the hand This is the detent of manual valve in the valve body and indicates the correct position of the lever Inspect whether the pointer of selector dial corresponds to this point and also whether the lever comes in alignment with the stepping of posi tion plate when it is released Adjustment This procedure can ...

Page 241: ...uf ficient cooling time should be given between each test for the four ranges 0 2 1 and R JUDGEMENT High stall revolution more than standard revolution If the engine revolution in stall condition is higher than the standard values it indicates that one or more clutches in the transmission are slipping and therefore no further test is required For the following abnormalities the respective causes a...

Page 242: ...range from 0 range output shaft 2 000 rpm Note Car speed can be calculated by the following formula 2x 7T xrxNpx60 V RF x 1 000 where V Car speed kmfh Np Propeller shaft revolution rpm R Final gear ratio r Tire effective radius m 7T The ratio of circumference of a circle to its diameter 3 14 RF 3 900 r 0 299 I8S 70HRI4 CHECKING SPEED CHANGING CONDITION The driver s feeling during gear changes shou...

Page 243: ...12 Fig AT 112 Shift Schedule AT 52 LINE PRESSURE TEST When any slipping occurs in clutch or brake or the feeling during a speed change is not correct the Hne pressure must be checked Measuring lin e p ssure is d9ne by a pressure gauge attached to pressure measuring holes after removing blind plugs located at transmission case The line pressure measurement is begun at idling and taken step by step ...

Page 244: ...ng to a leak in the vacuum tube or dia phragm or by an increased line TROUBLE SHOOTING CHART INSPECTING ITEMS I Inspection with automatic trans mission on vehicle AT 53 Line pressure kPa kg cm2 psi 1 373 to 1 569 14 0 to 16 0 199to 228 922 to 1 079 9 4to 110 134to 156 981 to 1 177 10 0 to 12 0 142 to 171 922 to 1 079 94 to 110 134 to 156 f lift ii 1 A Oil level T B Range seI tJJnk IM C Inhibttqr i...

Page 245: ... 6 3 7 Clutch slips Very poor acceleration Vehicle will not run in R range but runs in D 2 and I ranges I 2 3 5 6 4 9 8 D Clutch slips Very poor acceleration Vehicle will not run in any range 2 3 5 6 4 D Clutches or brakes slip somewhat in 2 6 3 5 7 4 starting Vehicle runs in N range 3 2 i Maximum speed not attained 2 4 5 7 6 3 8 Acceleration poor Vehicle braked by throwing lever into 3 2 1 i R ra...

Page 246: ... 4 6 5 2 V 3rd to 2nd Failure to change gear from 2nd 3 4 6 5 2 V to 1st or from 3rd to 1st Gear change shock felt during deceleration by releasing 2 3 4 5 6 V accelerator pedal Too high a change point from 3rd to 2nd from 2nd to 2 3 4 5 6 V 1st Kickdown does not operate when depressing pedal in 3rd within 2 I 4 5 3 V kickdown vehicle speed Kickdown operates or engine over runs when depressing ped...

Page 247: ...in I range Vehicle moves when changing into P range or parking gear does not disengage when shifted out of P range Transmission overheats Oil shoots out during operation White smoke emitted from exhaust pipe during operation Offensive smell at oil charging pipe Transmission noise in P and N ranges Transmission noise in D 2 J and R ranges Automatic Transmission A B C DE F G HI J K L MNOP m n q r s ...

Page 248: ...Creep of vehicle StaU t st I Oil pressure before testing Measure line pressures in D 2 I and R range while idling Measure engine rpm and line pressure in D 2 1 and R ranges during fuUthrottle operation 2 StaUtest Note Temperature of torque converter oil used in test should be from 60 to IOOoC 140 to 2I20F i e sufficiently warmed up but not overheated CAUTION To cool oil between each stall test for...

Page 249: ...h the accelerator pedal released and the engine vacuum pressure of 0 kPa 0 mmHg o inHg while driving at about 50 km h 31 MPH in 03 range Check for quick shifting down 03 2 and engine braking after shifting the lever into 2 range while driving at about SO km h 31 MPH in OJ range Further check for locking of the transmission in 2nd gear ratio regardless of vehicle speed Check for failure of the tran...

Page 250: ...DJUSTMENT Automatic transmission assembly Torque converter assembly Stamped mark on the TIC Front clutch Number of drive plates Number of driven plates Clearance Thickness of retaining plate X0703 20 D mm in mm in 3 3 16 to 2 0 0 063 to 0 079 10 6 0 417 10 8 0 425 110 0 433 11 2 0 441 II 4 0449 116 0 457 Rear clutch Number of drive plates Number of driven plates Clearance Thickness of retaining pl...

Page 251: ... Control valve assembly Stamped mark on strainer Governor assembly Stamped mark on governor body Engine stall revolution Automatic Transmission mm in 7 8 0 307 8 0 0 315 8 2 0 323 8 4 0 33I 8 6 0 339 8 8 0 346 mm in mm in 80 3 1 5 50 197 E24 rpm 33 7 1 so to 2 350 AT 110 ...

Page 252: ... 0 25 to 0 35 18 to 2 5 Side plate to cOry Yal e dY j 2 5 to 3 4 0 25 to 0 35 18 0 2 5 Ot t t f l o Nut for control valve reamer Dolt iI 9 to 6 9 0 5 to 0 7r3 6 to 5 1 Oil Q1 b d JiJ tWi 2 9 I 3 0 3 0 2 2 2 9 straIner to lower va ve 0 y o to t to Governor valve oil distdl utor 4 9 to 6 9 0 5 to p 7 3 6 to S qr Oil pump horIsing o oj pump cove 09 t 7 8 0 6 t o Q 8 B to S 8 iiIi Inhibitor switcQ g t...

Page 253: ...0 ST2S490000 Socket extension ST2SS 12001 Reference or Fig No Fig AT 52 Fig AT 56 Fig AT 59 Fig AT 64 Fig AT 69 Tool number tool name GG93010000 Torque wrench ST2S420001 Clutch spring compressor ST2S420000 ST2S320001 Snap ring remover ST2SS80000 Oil pump assembling gauge HT61 000800 Hexagon wrench v AT 62 Reference or Fig No Fig AT 69 Fig AT 79 Fig AT 86 Fig AT 79 Fig AT S6 Fig AT 98 Fig AT IOI Fi...

Page 254: ...0 Spinner handle ST2S I60000 Torque driver Automatic Transmission Reference page or Fig No Fig AT 101 Fig AT 104 Fig AT I07 Fig AT 108 AT 53 Tool number tool name ST2S0SS001 Oil pressure gauge set Reference page or Fig Na Fig AT II3 ...

Page 255: ...F DRIVE PINION PRELOAD ADJUSTMENT OF DRIVE PINION HEIGHT PD 2 PD 2 PD 2 PD 2 PD 3 PD 3 PD 3 PD 3 PD 3 PD 3 PD 5 PD 5 PD 6 PD 6 PD 7 PD 7 PD 7 PD 7 PD B PD 9 ADJUSTMENT OF SIDE RETAINER SHIMS INSTALLATION REPLACEMENT OF OIL SEAL FRONT OIL SEAL SIDE OIL SEAL SERVICE DATA AND SPECIFICATIONS PROPELLER SHAFT AND CENTER BEARING GENERAL SPECIFICATIONS SERVICE DATA TIGHTENING TORQUE DIFFERENTIAL CARRIER G...

Page 256: ...aring is noisy or damaged disassemble GENERAL INSPECTION I Check propeUer shaft tube sur face for dents or cracks If damaged replace with an assembly 2 Check journal for axial play If play exceeds specifications repair jour nal Journal axial play Less than 0 02 mm 00008 in PROPELLER SHAFT VIBRATION To check and correct an unbal anced propeUer shaft proceed as fol lows L Remove undercoating and oth...

Page 257: ...e of yoke with a hammer and withdraw bearing race Note When removing journal from yoke be careful not to damage journal and yoke hole JJ J PODOS Fig PD 3 Removing Bearing Inspection Check journal pin for dents or brinell marks and yoke hole for sign of wearor damage Snap ring bearing and seal ring should also be inspected to see if they are damaged worn or deformed Replace if necessary Assembly To...

Page 258: ...1 530000 to specified torque CAUTION Never reuse the removed lock nut Tightening torque Companion flange fixing nut 196 to 235 N m 20 to 24 kg 145 to 174 ft Ib 4 Using punch collapse the upper part of lock nut into the groove of shaft 5 Join companion flange of front shaft with flange yoke of rear shaft and tighten connecting bolt to speci fied torque Tightening torque Flange yoke rear shaft to co...

Page 259: ... and oil seal when removing 13 Side bearing retainer 14 Side bearing retainer adjusting dum 15 O ring 16 Side bearing 17 Pinion mate shaft 18 Pinion mate 19 Thrust washer 20 Rear cover 21 Lock strap 22 Differential case 23 Ring gear 24 Thrust washer 25 Side gear 26 Lock pin Fig PD 7 Removing Side Yoke Fixing Bolt 5 With differential carrier jacked up remove nuts on both ends of differential mounti...

Page 260: ...e retainers using Diff Side Retainer Allachment ST3371OOO0 and suitable puller Note a Mark right and left side retainers before remowl b Be careful not to COnfU8e right and left hand side retainers and shims for proper reassembly ST33710000 c ra 1 Fig PD IO Removing Side Retainer 2 Extract differential case assembly from gear carrier 3 When replacing side bearing ex tract bearing outer race from s...

Page 261: ...er If pinion mate to side gear backlash or the clearance between side gear and thrust washer exceeds the specified value replace thrust washers Pinion mate to side gear backlash 0 10 to 0 20 mm 0 0039 to 0 0079 in 5 Inspect gear carrier and differen tial case for cracks or distortion If either condition is evident replace faulty parts 6 As a general rule oil seal should be replaced at each disasse...

Page 262: ...is obtaioed with it Standard pinion height adjusting washer thickness 3 09 to 329 mm 0 1217 to 0 1295 in 3 Fit drive pinion bearing spacer washer front bearing cone Drive Pin ion Dummy Collar ST312 I4000 and companion flange in this order on dummy shaft and tighteri drive pinion nut to the specified torque wing Stopper ST318S2000 Tightening torque Drive pinion nut 167 to 196 N m 17 0 to 20 0 kg m ...

Page 263: ...e Figures for H D and S are dimen sional variations in a unit of 1 100 mm against each standard measurement Head number HI Set number P0186 Fig PD 22 Variation Number on Driv pinion Examples of calculation Ex I W 3 09 mm N 0 33 mm H 2 0 1 S O T W N I H O S x 0 01 0 20 3 09 0 33 2 I 0 x 0 01 0 20 3 09 0 33 2 I 0 x 0 01 0 20 3 09 0 33 3 x 0 01 0 20 3 09 0 33 0 03 0 20 3 19 mm The correct washer is 3...

Page 264: ...ing retainer has been replaced with new part adjust the side bearing Prop lIer Shaft Differential Carrier preload with adjusting sbinl The re quired thickness of the right and left retainer shims Lan be obtained from the following formulas T A C G O xO OI 0 76 E T B 0 G x 0 01 0 76 F G PD093 Fig PD 24 Thickne of Right and Left Shim Where T I Required thickness of left side retainer shiIll mm T Req...

Page 265: ...ig PD 29 Note When installing retainers take care that side bearing outer races are not damaged by roJler Fig PD 28 Installing Side Retainer Fig PD 29 Arrow Mark on Retainu 4 Measure ring gear to drive pinion backlash If backlash is too smaJl decrease thickness of left shim and PD ll increase thickness of right shim by the same amount If backlash is too great reverse the above procedure Ring gear ...

Page 266: ...f re moval 1 Position differential carrier onto suspension member and temporarily tighten it with four bolts 2 fit differential mounting member to filling bolts by pushing it forwards and tighten nut to specified torque Tightening torque Differential mounting m mber self locking nuts 78 to 98 N m 8 0 to 10 0 kg m 58 to 72 ft lb 3 Secure differential carrier onto rear suspension member with four bo...

Page 267: ...nut 167 to 196 N m 17 to 20 kg 123 to 145 ft Ib Pinion bearing preload with oil eal 1 08 to 1 37 N m 111 0 to 14 0 kg em 9 5 to 12 2 in Ib Note The preload of old bearing is the same value as that of a new bearing 9 Reinstall propeller shaft by re versing the foregoing removal pro cedure And fill up gear oil PO 13 SIDE OIL SEAL Side oil seal is replaced by using the following procedures I Detach d...

Page 268: ...t to compa nion flange bolts Companion flange fixing nut Flange yoke rear shaft to companion flange front shaft bolts N m kg m ft Ib Center bearing support fixing nuts N m kg m ft Ib Center bearing clamp to body nuts N m kg m ft Ib N m kg m ft Ib N m kg m ft Ib 24 to 32 2 4 to 3 3 17 to 24 196 to 235 20 to 24 145 to 174 24 to 32 2 4 to 3 3 17 to 24 9 to 12 0 9 to 1 2 6 5 to 8 7 25 to 39 2 6 to 4 0...

Page 269: ...3 39 0 1335 342 0 1346 3 45 0 1358 348 0 1370 3 51 0 1382 3 54 0 1394 3 57 0 1406 3 60 0 1417 3 63 0 1429 3 66 0 1441 Thickness of pinion height adjusting washer mm in Thickness of drive pinion bearing adjusting washer mm in 2 30 to 2 32 0 0906 to 0 0913 2 32 to 2 34 0 0913 to 0 0921 2 34 to 2 36 0 0921 to 0 0929 2 36 to 2 38 0 0929 to 0 0937 2 38 to 2 40 0 0937 to 0 0945 2 40 to 2 42 0 0945 to 0 ...

Page 270: ...ing gear to drive pinion backlash 0 10 to 0 20 0 0039 to 0 0079 Thickness of side retainer adjusting shim mm in 0 20 0 0079 0 25 0 0098 0 30 0 0118 0 40 0 01 57 0 50 0 0197 Side bearing Preload N m kg cm in Ib 1 18 to 196 12 0 to 20 0 10to 17 Preload at ring gear bolt N kg Ib 17 7 to 29 4 1 8 to 3 0 4 0 to 6 6 20 00 0 7874 0 75 to 0 80 00295 to 0 0315 0 80 to 085 00315 to 00335 0 85 to 090 00335 t...

Page 271: ...yoke fixing bolts N m kg m ft Ib Differential mounting member self locking nut N m kg m ft lb Differential carrier to suspension member bolts N m kg m ft lb Drive shaft to axle shaft bolts N m kg m ft lb PO 17 167 to 196 17 0 to 20 0 123 to 14S 88 to 98 9 0 to 10 0 65 to 72 24 to 32 2 4 to 3 3 17 to 24 39 to 59 4 0 to 6 0 29 to 43 9 to 12 0 9 to 1 2 6 5 to 8 7 39 to 49 4 0 to 5 0 29 to 36 59 to 88...

Page 272: ...unbalance Balance weights missing Worn or damaged universal joint Worn sleeve yoke and mainshaft spline Loose propeller shaft installation Loose joint installation Damaged center bearing or insulator Loose or missing bolts at center bearing bracket to body Dust cover on sleeve yoke rubbing on transmission rear extension Dust cover on companion flange rubbing on differential carrier Damaged center ...

Page 273: ...ust washer Pinion gears too tight on their shaft Interference between side yoke and differ ential case Excessive backlash Incorrect backlash ring gear to drive pinion backlash or side to pinion gear Worn gears or case Worn side yoke and side gear spline Pinion bearing under preload Loosened drive pinion nut Loosen bolts or nu ts fixing ring gear side retainers bearing cap etc PO 19 places cannot b...

Page 274: ...ompanion nange Worn damaged or improperly driven side oil seal or bruised dented or abnormally worn slide face of side yoke l oose bolt such s de yoke side retainer or gear carrier Faulty gasket or O ring Loose filler or drain plug Cloggeil or damaged breather PD 20 Corrective action Replace faulty parts Adjust backlash and replace as required Replace faulty parts Replace faulty parts Replace faul...

Page 275: ...0 Diff auachment Fig PD 9 KV38101900 Master gauge Fig PD I6 20 0 mm 0 787 in 6 6 8 ST3090S000 Drive pinion rear inner Fig PD I3 ST32S01000 Weight block Fig PD I6 race puller set Fig PD 23 CD ST30031000 Puller CV ST30901000 Base ST33230000 Diff side bearing drift Fig PD 17 ST3306S001 CD ST330SI001 CV ST33061 000 Diff side bearing puller set Puller Adapter Fig PD 14 Fig PD I7 ST3061l000 Drive pinion...

Page 276: ... 0 W ST30621000 Drift Page PD S ST318S2000 Stopper Fig PD 18 Page PD II ST312IIOOO Height gauge Fig PD 20 ST30720000 Oil seal drift Page PD 1O Fig PD 21 Page PD 13 C1 ST31212000 Dummy shaft Page PD S ST3127S000 Preload gauge Fig PD 19 Fig PD 20 CD GG91030000 Torque wrench Fig PD 21 CV HT62940000 Socket adapter ID HT62900Q00 Socket adapter ST31214000 Callar Page PD 8 Fig PD 20 2 oc 0 PD 22 ...

Page 277: ...r attachment 0 ST33290001 Side bearing outer race puller ST306S000l Pilot bearing drift II I Reference page or Fig No Fig PD 1O Fig PD I I Page PD 6 PO 23 Tool number tool name ST33720000 Diff side retainer guide ST33270000 Side oil seal drift Reference page or Fig No Fig PD 28 Page PD 13 ...

Page 278: ...RUT EMBLY TENSION ROD AND Sif IlBILlZER ft FA 2 LOWER ARM AND FA 2 SUSPENSION BALL JOINT ifFA 2 SUSPENSION CROSSMEMBE R IFA 4 SERVICE DATA AND 0 4 SPECIFICATIONS F 5i J UE RA SPECIFII i NS F 5 EhION AND1jii l I IS fMENt 6 i IfI GhlTENING TORQUE t Ii Ij4 E 6 li rROl Ela E DIAGNOSES AND MR 1 9 9R ECTIONS SPECIAL SERVICE TOOLS FA lO FA U I ffl FA 12 J li 12 i fFp J FA lf FA 15 FA 18 1 l 1 ...

Page 279: ...veral times in both directions to seat wheel bearing correctly again tighten wheel bearing nut to the above torque 8 Turn back wheel bearing nut A degrees Return angle A 900 Install adjusting cap and align any of its slots with hole in spindle Ifthe above procedure fails to align hole and slot together then tighten lock nut as much as IS degrees until hole in spindle is aligned with any slot CAUTI...

Page 280: ...d positions 2 Toe in can be adjusted by varying length of steering side rods Note a Loosen lock nuts and turn left and right side rod bars equaUy b Turning side rod bar in forward direction ofcar increases toe in Front Axle Front Suspension Toe in A B Toe in 28 Lines parallel to center line of body 4 FA696 FA697 Fig FA 4 AdjU3ting Toe in L c Ifside rods have been disassembled set the distance betw...

Page 281: ... to 120 9 8 to t2 2 71 to 88 69 to 98 7 0 to 10 0 51 to 72 44 to 54 4 5 to 5 5 33 to 40 44 to 54 4 5 to 5 5 33 to 40 REMOVAL Block rearwheels with chocks 2 Jack up front of car and support it with safety stands 3 Remove wheel and tire assembly 4 Remove brake tube brake caliper assembly referring to Section BR FA 700 Fig FA B Front Axle r Fig FA 9 Removing Brake Caliper FA 4 4 After adjustment lock...

Page 282: ...aring Drift ST35300000 until they seat in hub 2 Pack hub and hub cap with re commended multi purpose grease up to sha s P ck thisrecess Lt 1 FA261 Fig FA 14 Lubricating Points of Wheel Hub 3 Coat each bearing cone with rec ommended multi purpose grease FA 5 I FA262 Fig FA 15 Coating Bear ng Cone with Grease 4 Place inner bearing cone in hub and install a new grease seal coating ealing lips with re...

Page 283: ...ring 21 Bound bumper 22 Front ring upper seat 23 Dust seal 24 Strut mounting bearing 25 Strut mounting insulator 26 Cap FA704 Fig FA 17 Removing Knuckle Arm Bo 4 Detach knuckle arm from bottom of strut This can be done by forcing FA 6 o I l Tightening torque N m kg m ft lb 3t to 42 3 2 to 4 3 23 to 31 59 to 18 6 0 to 8 0 43 to 58 39 to 44 4 0 to 4 5 29 to 33 l 1 8 to t 18 0 8 to 1 2 5 8 to 8 1 22 ...

Page 284: ...rod together with cylinder Note Do not remove pistion rod quickly as this will couse oil to spurt out FA215 Fig FA 22 Remouing futon Rod and Cylinder FA 7 Note Piston rod piston rod guide and cylinder are adjusted to provide precision mating surfaces and should be handled a a matched set 7 Drain fluid thoroughly from inner cylinder and discard 8 Wash all parts in suitable solvent 9 Drain fluid tho...

Page 285: ... Lubricate sealing lips of gland packing shown in Fig FA 24 with lithium base grease containing molyb denum disulphide and install gland packing with Gland Packing Guide ST35520000 I A FA859 Fig FA 24 Gn sing Point of Gnd I bcking FA276 Fig FA 25 Instolling Gnd I bcking 7 Tighten gland packing CD Tightening torque 98 to 127 N m 10 0 to 13 0 kgm 72 to 94 ft Ibl FA 8 Note a When tighteniog gland pac...

Page 286: ...bl Note a Temporarily tighten self locking nut on tip of piston rod After installing piston rod on car tighten self locking nut to specification b Replace self locking nut whenever strut is disassembled IS To prevent entry of water and dust apply a thick coat of recom mended multi purpose grease to points indicated by arrows in Fig FA 29 16 After placing spring in position between upper and lower ...

Page 287: ...6 ft lbl Tension rod to lower arm 44 to 54 N m 4 5 to 5 5 kg m 3Jto 40 ft b Tension rod bracket to body 31 to 42 N m 3 2 to 4 3 kg m 23 to 31 ft bl Stabilizer bar bracket 26 to 36 N m 2 7 to 3 7 kg m 20 to 27 ft Ibl Stabilizer bar connecting rod 16 to 22 N m 1 6 to 2 2 kg m 12 to 16 ft bl LOWER ARM AND SUSPENSION BALL JOINT 1he lower arm is connected to the uspension member through a rubber bushin...

Page 288: ...connects lower ann to suspension w lo J wouber Final tightening should be carried out at curb weight with tires on ground And also at this time front side nut should be tightened before rearside nuts c Make sure mating surface of bush ing is clean and free from oil and grease i l Tightening torque Ball joint socket to lower arm 44 to 54 N m 4 5 to 5 5 kg m 33 to 40 ft Ibl Ball joint to knuckle arm...

Page 289: ... STRUT ASSEMBLY Shock absorber type Piston rod diameter mm in Piston diameter mm in Stroke mm in Oamping force at 0 3 m 1 0 ft fsec Expansion N kg Ib Compression N kg lb STABILIZER BAR Bar diameter mm in INSPECTION AND ADJ USTMENT WHEEL ALIGNMENT Unladen 1 Camber Caster Toe in Kingpin inclination Front wheel turning angle In ide Outside 1 Tankful offuel radiator coolant and engine oil full Spare t...

Page 290: ...lb More than 3 9 40 35 TIGHTENING TORQUE BALL JOINT Socket to transverse link Ball joint to knuckle arm Stud nut N m kg m ft lb 44 to 54 4 5 to 5 5 33 to 40 96 to 120 9 8 to 12 2 71 to 88 STRUT Knuckle arm to strut Strut to hoodledge Piston rod self lock nut Gland packing 69 to 98 7 0 to 10 0 5 to 72 31 to 42 3 2 to 4 3 23 to 31 59 to 78 6 0 to 8 0 43 to 58 98 to 127 10 0 to 13 0 72 to 94 DISC BRA...

Page 291: ...tabilizer bar bracket Connecting rod SUsP NsION CROssMEMHR Crossmember to body frame Engine mounting insulator to crossmember FA 14 26 to 36 2 7 to 3 7 20 to 27 lb to 22 16 to 2 2 12 to 16 66 to 78 6 7 to 8 0 48 to 58 19 to 25 19 to 2 6 14 to 19 ...

Page 292: ... adjusted or worn front wheel bearing Faulty wheel alignment Worn lower arm bushings Insufficiently tightened steering gear hallS iog Wear of steering linkage Worn suspension balt joint Excessive backlash due to improper adjust ment of the steering gear box Damaged idler arm Worn column bearing weakened column bearing spring or loose clamp Malfucntion or shock absorber inside the strut or loose in...

Page 293: ...r Deformed steering linkage Incorrect wheel alignrnent Damaged trot mounting bearing Damaged or stiff piston or shock ab orber piston rod in the strut Interference of steering column with turn signal switch Incorrectly adjusted steering gear housing Worn steering linkage Improperly fitted gear housing Incorrectly adjusted wheel bearing Worn lower arm and tension rod bushings Imp oper tire pressure...

Page 294: ...eel alignment Deformed knuckle spindle and suspension linkage U I t Improper tire pressure Imbalandd wheels Y f Fault shock absorber if r FaultY i ire D f d 1 h I e ormeyw ee nm ti i it If Excessively or p orn t e iP1fI J f f l f J FA 17 Corrective action Retighten Retighten Adjust Adjust Replace Adjust Adjust Replace Replace Replace Adjust Adjust Replace Adjust 1 Rotate tires at re commended inte...

Page 295: ...00001 Gland packing wrench PageF A 8 Fig FA 2l o KV48I 00300 Strut and steering gear Page FA 7 ST35520000 Gland packing guide Fig FA 25 housing attachment Page FA 8 Page FA 9 Fig FA 21 11 11 1111 ST3565S00l Coil pring compressor set Page FA 7 HT7252llOOO Ball joint remover Fig FA 33 CD ST3565100l Coil spring compressor Page FA 9 CV ST35652000 Clamp Fig FA 20 FA IS ...

Page 296: ...COIL SPRING AND SHOCK ABSORBER ASSEMBLY REAR AXLE REAR AXLE SHAFT WHEEL BEARINGS AND SEALS SUSPENSION ARM DRIVE SHAFT RA 5 RA 6 SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT SHOCK ABSORBER REAR AXLE TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS RA ll RA ll RA l1 RA ll RA ll RA 12 RA 2 RA 2 RA 3 RA 3 RA 4 RA 13 RA 14 RA 6 RA 7 RA 8 ...

Page 297: ...ng bu g B 19 Bound bumper cover 20 Bound bumper 21 Dust cover 22 Coil spring 23 Suspension ann bushing 24 Brake hose fitting bracket aligned independently and separately from the suspension and the gear carrier is installed directly on the body with the suspension member and the differential mounting member through rubber insulators The coil spring is mounted on the RA 2 8 l I 8 G7 T t t 1 Tighten...

Page 298: ... remove propeller shaft Remove propeller shaft assembly 6 Disconnect rear brake ho es CID CAUTION a When disconnecting brake tube use suitable tube wrench Never use open end or adjustable wrench b Cover brake hose and pipe open ings to prevent entrance of dirt RA 3 7 Support under center of suspen sion member and differential carrier with a transmission jack 8 Disconnect shock absorbers at lower e...

Page 299: ...Front I 04 Slil 40 16 2 Suspension member 791 6 700 2 31 17 431 57 I6 97 Slit Slit Diff mounting member Tightening torque N m kg m ft lb 781098 8 to to 58 to 72 59 to 78 6 to 8 43 to 58 29 to 39 3 to 4 22 to 29 Unit mm in RA529 Fig RA 6 Rear Susperu on Mounting Insulators RA 4 SUSPENSION MEMBER AND STABILIZER Removal I mock front wheels with chocks 2 Raise the rear of car high enough to permit wor...

Page 300: ...ar of car high enough to permit working underneath and until rear spring does not support car weight and support it on safety stands Place stands solidly under body member on both sides 3 Remove cover for shock absorber mounting bolt access hole in parcel shelf 4 Working through access hole in parcel shelf remove nut securing shock absorber to body with a wrench II H X JI JLJ rl I I Fig RA 9 5 Dis...

Page 301: ... 4 0 kg rn 22 to 29 tt Ibl Shock absorber lower end bolt 59 to 78 N m 6 to B kgm 43 to 58 tt lb Piston rod nut 19 to 25N m 1 9 to 2 6 kg m 14 to 19 tt b Rear Axle Rear Suspension REAR AXLE REAR AXLE SHAFT WHEEL BEARINGS AND SEALS Removal and disassembly 1 Companion flange 2 Grease seal 3 Inner wheel bearing 4 Distance piece 5 Outer wheel beariug 6 Bearing spacer 7 Rear axle shaft assembly OCGi 7 0...

Page 302: ... M 55 95 to 56 05 M 55 92 to 55 98 2 2028 to 2 2067 2 2016 to 2 2039 p 56 05 to 56 I5 p 56 02 to 56 08 2 2067 to 2 2106 2 2055 to 2 2079 5 Fill recommended multi purpose grease to the portion indicated by asterisk in Fig RA 17 i 1 Companion flange 2 Grease seal 3 Wheel bearing RA399 Distance piece Bearing housing Rear axle shaft Fig RA 17 Lubricating Portiom ofRear Axle 6 Install grease seal by Re...

Page 303: ...r bu hings in a neutral position 3 Adjust parking brake cable Refer to Section BR for Hand Brake 4 Bleed air from brake system Refer to Section BR for Bleeding Hydraulic System JJ Tightening torque Brake baek plate to rear suspension arm 26 to 36 N m 2 7 to 3 7 kg m 20 to 27 ft Ib Rear wheel bearing lock nut 245 to 324 N m 25 to 33 kgm 181 to 239 ft lb Brake tube flare nut 15 to 18 N m 1 5 to 1 8 ...

Page 304: ...are damaged worn or deformed Replace as required Note Sleeve yoke balls spacers and drive shaft are not available as senrice parts Therefore ifany wear or damage exists in above parts drive shaft must be replaced as an assembly play exceeds 0 02 mm 0 0008 in adjust or replace as required CID I Side yoke 2 O ring 3 Side yoke bolt 4 Spider journal 5 Dust cover 6 Oil seal 7 Bearing race assembly 8 Be...

Page 305: ... axial play of universal joint to within 0 02 mm 0 0008 in Snap rings of seven different thicknesses are available Note Two opposite snap rings should be equal in thickness Identification color White Yellow Red Green Blue Light brown Black assembly and tighten side yoke fitting bolts to specified torque using torque wrench See Fig RA 27 RA l0 C l Tightening torque 31 to 42 N m 3 2 to 4 3 kg m 23 t...

Page 306: ...il diameter Free le gth a l Shock absorber 12 0 47 100 3 94 346 13 62 Stroke 1 f iit 536 21 l J I 7lHJ OI A INSPECT AND ADJI J iF SHOCK ABSORBER jif 4 i f kf iI 1 1t it jA Damping force at 0 3 m 1 0 ft js Expansion N kg lb Compression N kg lb r 598 to 834 61 to 85 135 to 187 354 to 549 36 to 56 79 to 123 REAR AXLE End play mmOn Less than 0 3 0 012 RA ll ...

Page 307: ...ft Ib 78 to 88 8 0 to 9 0 58 to 65 78 to 98 8 0 to 10 0 58 to 72 Aluminum N m kg m ft Ib Differential to differential mounting member nut N m kg m ft Ib Shock absorber upper end nut or bolt N m kg m ft lb 59 to 88 6 to 9 43 to 65 59 to 8g 6 to 9 43 to 65 29 to 39 3 to 4 22 to 29 Differential carrier fitling nut N m kg m ft Ib Shock absorber lower end bolt N m kg m ft Ib 59 to 78 6 to 8 43 to 58 Re...

Page 308: ... of rear axle shaft Loose journal connections etc Unbalance of wheel and lire Damaged rubber parts such as uspension ann bushing and shock absorber mounting bushing Deformed differential mounting member Faulty universal joints Worn or damaged rear suspension member mounting insulator Worn or seized sliding portion of drive shaft ball spline Breakage of coil pring Loose wheel nuts Worn shock absorb...

Page 309: ...ring compressor set Spring compressor Clamp Reference or Fig No Fig RA 8 Fig RA4 Fig RA 5 Fig RA IO RA 14 Tool number tool name Reference or Fig No KV40101000 Rear axle tand Fig RA 13 Fig RA 14 Fig RA 35 ST37750000 Rear axle shaft bearing drift Fig RA 15 ST36230000 Sliding hammer Fig RA 14 Fig RA 35 ST38280000 Rear suspension arm Fig RA 22 bushing remover ST377 I0000 Rear axle grease seal drift Pa...

Page 310: ...GAUGE BRAKE LI NE NP VALVE FRONT DISC BRAKE N22A type BR 2 BR 2 BR 2 BR 2 BR 2 BR 3 BR 3 BR 3 BR 4 BR 6 BR 6 BR 6 BR 7 FRONT DISC ROTOR REAR DRUM BRAKE BRAKE BOOSTER HAND BRAKE HAND BRAKE SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOL BR l0 BR ll BR 13 BR 15 BR 15 BR 16 BR 16 BR 17 BR 19 BR 2...

Page 311: ...al everal times to insure that it travels over its entire troke smoothly without squeaking noise twisting or interference Pedal depressed height d more than 75 inm 2 95 in FRONT DISC BRAKE Front disc brake does not require adjustment under normal conditions since pad to rotor clearance is auto matically compensated for by elastici ty of piston seal and gripper REAR DRUM BRAKE Adjustment is not nec...

Page 312: ...g 2 Remove clevis pin stopper bolt and remove cotter pin from clevis pin and separate Brake Booster operating rod from pedal 3 Remove nuts securing fulcrum shaft to brake pedal bracket Move clutch and brake pedal assembly ap prox 40 mm I 58 in left Brake pedal can then be removed INSPECTION Check brake pedal for the following items servicing as necessary I Check pedal bushing for wear deformation ...

Page 313: ...eferring to Brake Pedal Adjustment BR730 Fig BR 5 Lubricating Points MASTER CYLINDER TOKICO Make 1 lnitt D t t f iJl t x y er Tightening torque N m kg m ft Ib 78 to 88 8 0 to 9 0 58 to 65 7 109 0 7 to 0 9 5 t to 6 5 I Reservoir cap 2 Filter 3 Stopper ring 4 Stopper screw 5 Stopper 6 Primary piston 7 Primary piston return spring 8 Secondary piston 9 Secondary piston return spring 10 Plug 11 Check v...

Page 314: ...any reason discard them and install new ones b Do not remove or disassemble brake fluid level gauge INSPECTION Thoroughly clean all parts in a suitable solvent and check them for wear or damage Replace any part that is faulty CAUTION Use brake fluid to clean Never use mineral oil BR 5 Jq 1 Reservoir cap 2 Filter 3 Stopper ring 4 Stopper screw 5 Stopper 6 Primary piston 7 Primary pbton return sprin...

Page 315: ... twist brake hose INSPECTION Check brake lines lubes and hoses for evidence of cracks d terioration or other damage Replace any faulty parts If leakage occurs at end around joints re tighten or if necessary re place faulty parts INSTALLATION Pay particular attention to follow ing instructions when installing brake lines 1 Leave a sufficien t space between brake lines and adjacent parts so that bra...

Page 316: ...e suit able tube wrench Never use open end or adjustable wrench 2 Remove NP valve retaining bolt and remove NP valve Note Do not disassemble NP valve 3 Installation is in the reverse order of removal CAUTION When installing brake tube use Flare Nut Torque Wrench GG94310000 lTl Tightening torque flared nut 15 to 18 N m 11 5 to 1 8 kg m 11 to 13 ft Ib Brake System NP valve attaching bolt 4to5N m lOA...

Page 317: ...n has been pushed in too far remoYB caliper assembly and disassemble it Then push piston out in direction shown by arrow Assemble it again referring to fol lowing section iiL i l 1 Pistonscal 2 Pi ton B 3 Normal position Do not push too far BA7BO Fig BR I2 Position o Puton 3 Push piston A inner piston in cylinder by pulling yoke Outer pad can then be installed BR088A Fig BR 13 Pulling in Puton A 4...

Page 318: ...ge is major cylinder assembly must be replaced Yoke Check for wear cracks or other damage Replace if any fault i de tected Piston Check piston for score rust wear damage or presence of foreign sub stances Replace if any fault is de tected CAUTION Piston sliding sUrflce is plated 00 not polish with emery paper even if rust or foreign mltter is sticked on sliding surflce BR 9 Piston seal and dust se...

Page 319: ...x with clip 9 Tighten fIXing bolts lfJ Tightening torque 16 to 21 N m 1 6 to 2 1 kg m 12 to 15 fHbl INSTALLATION 1 Install caliper assembly to knuck Ie spindle ifJ Tightening torque Caliper mounting bolt 72 to 97 N m 7 3 to 9 9 kg m 53 to 72 ft Ibl 2 Install brake tube and bleed brake system CAUTION When installing Flare Nut GG94310000 brake tubes use Torque Wrench ifJ Tightening torque Brake tube...

Page 320: ...o 52 N m 3 9 to 5 3 kg m 28 to 38 ft I b Rear shoe Lining is high 7 Anti rattle pin 8 Spring seat 9 Anti rattle spring 10 Retainer 11 Stopper assembly BA984 Fig BR 25 Rear Drum Brake SR 11 REMOVAL 1 Jack up rear of car and support it with safety stands 2 Remove tire and brake drum I Engage hand brake lever 2 Lightly tap stopper head 3 Remove stopper and fastener as an assembly See Fig BR 26 4 Dise...

Page 321: ...s been completely re conditioned or re placed check dnim and shoes for proper contact pattern Brake assembly 1 Replace any linings which are cracked worn or oil stained 2 If lining is worn to less than the specified value replace Uning wear limit Minimum thicknessl 1 5 mm 10 059 in 3 Replace any shoe retum springs which are broken or fatigued 4 Replace fatigued anti rattle pring damaged pin and or...

Page 322: ...nd brake fully applied ob serve the rate of drop in air pressure registered by vacuum gauge If vacuum Probable cause I Air leakage at check valve 2 Damaged diaphragm 3 Reaction disc dropped off 4 Air leakage at poppet assembly seat and valve body Inspecting check valve Remove clip and disconnect hoses at connections The check valve can now be removed r BR105A Fig BR 30 Location o Check Valve BR 13...

Page 323: ...for evidence of fluid leakage Note Determine whether source of problem is in Brake Booster or check valve Before you reach a final conclusion always inspect check valve fll8l 10 788 110 1 560 9 807 lOO 1 420 I 8 826 90 1 280 I 7 846 80 1 140 1 6 865 70 1000 5 884 60 850 4 904 50 710 3 923 40 570 2 942 30 430 1 961 20 280 h 981 lO 140 7 L o a2 981 100 221 1 961 200 441 Rod operating force N kg lb 0...

Page 324: ...and operational tests as previously described 1 Control1ever 2 Brake warning switch 3 Front cable 4 Return spring 5 Center lever 6 Equalizer 7 Rear cable adjuster turnbuckle 8 Cable lock plate 9 Rear cable J I B RgeO Fig BR 38 Removing Control Lever 4 Disconnect front cable from holder attached to center bearing bracket BR 15 Lubricate with multi purpose grease BA979 Fig BR 37 Hand Brake Lillkage ...

Page 325: ...eck parts at each connection and if found deformed or damaged replace INSTALLATION Install hand brake assembly follow ing the reverse procedure of removal Closely ob erving the following items I When installing apply a coating of grease to sliding contact surfaces See Fig BR 37 2 Upon completion of installation of hand brake assembly adjust the entire system referring to Hand Brake Adjustment 3 Ma...

Page 326: ...ragm diameter NP vaIve Split point Reducing ratio mm in kPa kg em psi Brake System INSPECTION AND ADJ USTMENT BRAKE PEDAL Free height h Free play at pedal pad a Full stroke at pedal pad Depressed height d mm in mm in mm in mm in Ill I BR 17 271 10 67 228 6 9 53 98 2 li 22 22 U 22 22 U Master Vac M75 190 5 7 li 3432 35 498 0 4 159 to 165 6 26 to 6 50 1 to 5 0 04 to 0 20 145 5 71 more than 75 2 95 ...

Page 327: ... stopped kPa mmHg inHg mrn in mm in 3 3 25 0 98 9 75 to 10 00 0 3839 to 0 3937 162 6 38 Push rod length A Operating rod length B rd i I cd F J c I FI J B BA290 BR947 CHECK VALVE Maximum vacuum leakage 15 seconds after 66 7 kPa 500 mmHg 19 69 inHg pressure is applied kPa mmHg inHg 1 3 10 0 39 DISC BRAKE N22A type Pad wear limit Minimum thickness mm in 2 0 08 Rotor repair limit Maximum runout Maximu...

Page 328: ...ake Booster to body Operating rod lock nut Range to shell cover Push rod adjusting nut Brake System mm in 1 5 0 059 mm in mm in mm in 230 0 9 06 less than 0 02 0 0008 less than 0 1 0 004 less than 0 02 0 0008 mm in less than 0 15 0 0059 N m kg m ft lb N m kg rri ft lb N m kg m ft Ib N m kg m ft lb N m kg m ft b 8 to 11 0 8 to 1 1 5 8 to 8 0 8 to II 0 8 to 1 1 5 8 to 8 0 15 to 18 15 to 18 II to 13 ...

Page 329: ... or pads Linings or pads excessively worn Master cylinder or wheel cylinders in poor condition Frozen or seized caliper pistons on disc brakes Binding mechanical linkage at brake pedal and toes BR 20 Corrective action Fill and bleed as necessary Test for source of leakage by examining all lines connee tions and wheel cylinder Overhaul master cylinder Replace check valve and bleed system Bleed syst...

Page 330: ...t is ob structed Seized master cylinder piston Poor shoe condition Poor wheel cylinder condition Deformation of piston cups Poor condition of caliper because of faulty piston seals Excessive ronout of rotor Hand brake will not return Clogged ma ter cylinder return port BR 21 Corrective action Inflate to correct pressure Readju t Clean brake mechani m and check for cause of problem Replace linings ...

Page 331: ...brake lining Out of round or off center drum On disc brakes lateral runout of brake rotor is excessive Excessive variation in thickness of brake rotor surfaces BR 22 Corrective action Check and clean Adjust or repair Adjust Replace Adjust pedal height Grind or replace as required Tighten support plate bolts to pecified torque or replace plate Replace as necessary Replace linings Blowout assembly w...

Page 332: ...Tool number tool name GG943 10000 Brake System SPECIAL SERVICE TOOL Flare nut torque wrench Reference page or Fig No Page BR 6 Page BR IO PageBRI2 BR 23 Tool number tool name Reference page or Fig No ...

Page 333: ...EEL AN D TI RE CONTENTS WT5 GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS WT5 WTS wrs WHEEL AND TIRE MAINTENANCE INSPECTION SERVICE DATA AND SPECIFICATIONS WT 2 WT 2 WT3 wr B ...

Page 334: ... wear WTOO4 Fig WT 2 Abnormal Tire Wear Shoulder wear This wear may be caused by under inflation incorrect wheel camber or continued excessive speed around curves In general the first two causes are the mo t common Under inflation causes wear on both ide of treads while camber causes wear on only one side of tread WT 2 Uneven wear Uneven wear is caused by incorrect camber or caster malfunctioning ...

Page 335: ...e TIRE ROTATION Tires tend to wear unevenly and become unbalanced after a certain running distance Uneven tire wear often results in tire noise which is attributed to rear axle gears bearing etc Front tires also tend to wear unevenly because of improperly align ed front wheels Accordingly to equalize tire wear it is necessary to rotate tires periodi cally as recommended in the Periodic Maintenance...

Page 336: ...rough weld SI Wheel nuts won t stay tight TIRE To check for leaks apply soapy solution or submerge tire and wheel or tube in water after inflating it to specified pressure Special inspection for leaks hould be carried out around valve or wheel rim and along tread Note bead and rim where leakage occurs Wipe water away from any area which leak air bubbles and then mark place with chalk After removin...

Page 337: ... 0 35 Tire balancing weiglit ir oz l 10 to 60 0 35 t6 2 12 Wheel rim lateral a radial runout I l J i 39 iI l iitY Difference betwee Jight and left I c r tt lateral runout mm in Less than 0 5 0 020 Recommended tire Inflation pressure pal kPa kg cm Car speed I Under 60 MPH 100 km h Over 60 MPH 100 km h Tire I Front Rear Front Rear 185 70HR14 I 27 186 1 9 24 167 1 7 31 216 2 2 28 196 2 0 195 70HR14 I...

Page 338: ...ced wheel Improperly adjusted brake Improper wheel alignment Excessively distorted or improptrly installed suspension link High speed on curves Sudden starts and improper speed due to rapid acceleration or improper brake ap plication Improper tire pressure Improper front wheel alignment Distorted knuckle or suspension link WT 6 Corrective action Measure and adjust Repair or replace Balance Tighten...

Page 339: ...CHANISM STEER ING LOCK MANUAL STEERING GEAR VRB56L POWER STEERING GEAR I P S 52B AND OIL PUMP ST 2 ST 2 ST 3 ST 5 ST 6 ST 6 STEERING LINKAGE SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS ST 17 ST 19 ST 19 ST 19 ST 21 ST 10 ST 22 ST24 ...

Page 340: ...embly 5 Tlghlening lorque N m Irg m f1 lb 8 8 to 13 7 0 9 to 1 4 6 510 to t 3 9 to 5 9 0 4100 6 2 9104 3 391049 4 0105 0 29 to 36 Manualsteering 15 to 22 1 5 10 2 2 It to 16 Power steering 52 10 62 5 3106 3 38 to 46 Manual steering 311036 3 2 to 3 7 23 to 27 Power steering ST761 Fig ST l St erin g Column and Gear STEERING WHEEL REMOVAL I Disconnect battery ground cable 2 Remove horn pad 3poke stee...

Page 341: ...ION be Ins 1I steeritIg wheel in the reverse 7 Note After installing steering wheel turn it c1oc wise and counterclock wise cheCking for C1tch or drag Also check horn for operation 1 CR il ifIr i fr r Ii I oi i IW l T 1 Steering t h el fi ing t 2 Spring washer 3 Washer 4 Collar wire 5 Steering wheel colJ i 6 Steering column asseiritHy 7 Adjusting lever bolt 8 Column mounting bracket 9 Jacket tube ...

Page 342: ...pward 3 Tighten column mounting brack et temporarily 4 Tighten worm shaft securing bolts temporarily to upport upper side of steering column assembly 5 After sliding jacket tube bracket to dash panel tighten nut to retain it CAUTION a Make sure that undue stress is not applied to rubber coupling b VRB56L gear type To avoid damaging bolt or serra tions align groove in worm shaft with bolt hole in r...

Page 343: ...length L 424 to 427 mm 16 69 to 16 81 in 2 Column mounting bracket Make sure column mounting brack et touches block Refer to Tilt Mecha nism TILT MECHANISM 1f Section A A L 215 5 mm 8 48 in S 32 5 mm 1280 in 9 350 ST625 Fig ST 12 Tilt Mechani m REMOVAL 1 Adjusting lever bolt 2 Washer 3 Adjusting lever nut 4 Adjusting lever 5 Washer 6 Bolt L H threaded I Remove bolt LR threaded washer and adjusting...

Page 344: ...et tube 1 Self shear type screw 2 Screw Fig ST 15 R mou ngSt ering Lock INSTALLATION I Align teering lock hole in jacket tube with mating portion of steering lock 2 Install self hear type screw and cut off their heads MANUAL STEERING GEAR VRBS6L REMOVAL I Remove bolt securing worm shaft to rubber coupling Refer to Steering Column Col lapsible type 2 Remove nut and lock washer se curing gear arm to...

Page 345: ...g System sector haft serrations and install and tighten lock washer and nut 2 I 3 J ID o ST776 Fig ST 17 Steering Gear CAUTION a When pulling sector shaft out be careful not to damage oil seal or associated parts b Set worm gear in a straight ahead position Co Do not remove sector shaft needle bearings from steering gear housing If necessary replace gear housing assembly ST725 Fig ST 19 Neutral Po...

Page 346: ...ith Preload Gauge ST31 27S000 Initial turning torque Worm bearing 0 4 to 0 8 N m 4 0 to 8 0 kg cm 3 5 to 6 9 in b sn127S000 ST780 Fig ST 22 Measuring Initial Turning Torque Note a Rotate worm shaft 8 few turns in both directions to settle down worm bearing and measure the pre load b When adjusting worm bearing pre load add and then remove ahima until correct adjustment is a chieved Adjustment of a...

Page 347: ... If found to be outside of above turning torque specifications readjust adjusting screw until correct turning torque is obtained 15 Pour recommended gear oil into assembly through filler hole and install filler plug Specified refill capacity Gear case Approximately 0 29 liter Imp ptl INSPECTION Wash clean all the disassembled parts in solvent and check for condi tion Se tor shaft I Check gear toot...

Page 348: ...y Tightening torque kg m ft lb 3 to 5 22 to 36 3t05 22t036 1 6 to 2 2 12 to 16 ST763 Fig ST 26 Power Steering and Oil Pump securely locate hose connecton at 8 position higher than oil pump and cover with rag b Be extremely careful to preYent entry of foreign matter into hoses through connecton ST762 Fig ST 27 Dilconnecting Hale ST 10 4 Remove bolts securing steering gear housing to body side frame...

Page 349: ...mp to bracket 16 to 22 N m 1 6 to 2 2 kg m 12 to 16 ft bl Fluid level I Check oil level in reservoir by checking dip stick on HOT side at checking dip stick Oil level should be maintained within F level Hot and Cold 2 Check fluid level and leakage at the recommended interval Recommended oil is Automatic Transmission Fluid Dexron Type See Section GI Recommended Lubri cant Pump belt adjustment Adjus...

Page 350: ...essure relief valve of oil pump is not functioning properly Re place as an assembly 13 If with shut off valve fully closed pressure drops below lower limit the problem is in pump Replace as an assembly Note After checking hydraulic sys tem add lluid as necessary then completely bleed air out of ystem Bleeding hydraulic system I Raise front end of car until wheels clear ground 2 With engine off pou...

Page 351: ...o right lock several times to drain oil from gear housing completely 2 Attach steering gear assembly to Steering Gear Attachment KV48100300 and then place it in a vise Steering System ST783 Fig ST 37 Mounting Steering Gear Assembly in Vise 3 Remove lock nut with Lock Nut Wrench KV48100S00 remove adjust ing plug with Adjusting Plug Wrench KV48 100600 CAUTION a Hold stub shaft with your hand to prev...

Page 352: ...ub haft and install adjust ing plug assembly on it ST791 Fig ST 47 A emblingAdju ting Plug A embly CAUTION a Be careful not to scratch oil seal with serrations of stub shaft b Grasp stub shaft to prevent it from turning with adjusting plug as sembly and then screw in adjust ing plug as far as possible by hand c Be lUre to align cutout portion of spact r with knock pin ST 14 WARNING Be careful not ...

Page 353: ...rn 2 Tighten adjusting plug with Pre load Gauge sn127S000 and Adjust Ing Plug Wrench KV48100600 so that starting torque of stub shaft is 0 9 to 10 N m 9 to 10 kg cm 7 8 to 8 7 in lb ST793 Fig ST 52 Measuring Stub Shaft Preload CAUTION Always Idjust stub shift prelold by turning adjusting plug in screw in direction 3 Hold adjusting plug with Adjust ing Plug Wrench KV48 100600 and then tighten lock ...

Page 354: ...tion where stub shaft is turned back 1 4 rotation from either lock pO ition 0 6 to 1 0 N m 6 to 10 kg cm 5 2 to 8 7 in Ibl ST 16 5 Make Sure that left and right lock positions are reached when stub shaft is rotated approximately 2 1 8 turns from straight ahead position INSPECTION Wash clean all disassembled parts in suitable cleaning solvent and check their condition Adjusting plug assembly Replac...

Page 355: ...pins and nuts fastening ide rod baIl studs to knuckle arms 6 To detach side rod ball studs from knuckle arms insert Steering BaIl Joint Remover HT72520000 between them and separate them ST595 Fig ST 58 Removing Ball Joint 7 Install steering linkage in the re verse order ofremoval ST 17 JJ 6 ST797 Fig ST 56 Steering Linkage fl Tightening torque Ball stud 54 to 98 N m 5 5 to 10 0 kgm 40 to 72 ft Ib ...

Page 356: ...int ofcross rod Note Make sure sliding resistance of idler arm i less than 5 9 N m 06 kg m 4 3 ft lb Cross rod and side rod I When side rod socket and side rod adjusting tube are separated adjust side rod length correctly Adju tment should be done be tween ball stud centers Standard distance A between inner and outer ball stud centers 355 mm 13 98 in A Fig ST 61 Standard Side Rod Length 2 Tighten ...

Page 357: ...play or breakage When looseness or play is found check for wear on tapered portion of ball stud gear arm or idler arm SERVICE DATA AND SPECIRCATIONS GENERAL SPECIFICATIONS Steering wheel 3 spoke outside diameter Steering column Steering gear type Manual steering VRB56L Power steering I P S 52B Turns of steering wheel Lock to lock VRB56L IP S 52B Steering gear ratio VRB56L IP S 52B mm in INSPECTION...

Page 358: ...E BaU jointinitial turning torque Standard side rod length Steering System N m kg cm in Ib N m kg cm in Ib 0 5 to 1 2 5 0 to 12 5 4 3 to 10 9 1 I to 1 5 II to 15 9 5 to 13 0 0 6 to 10 6 to 10 5 2 to 8 7 mm in mm in 1 5 0 059 0 762 0 0300 0 254 0 0100 O I27 0 0050 0 050 0 0020 mm in om to 0 03 0 0004 to 0 0012 mm in 1 575 to 1 600 0 0620 to 0 0630 1 550 to 1575 0 0610 to 0 0620 1 525 to 1 550 0 060...

Page 359: ...LINKAGE Idler arm to body side frame Ball stud nut Idler arm nut Side rod clamp N m kg m ftIb N m kg m ft Ib N m kg m ftIb 39 to 49 4 0 to 5 0 29 to 36 15 to 22 1 5 to 2 2 II to 16 15 to 22 1 5to 2 2 II to 16 N m kg m ft lb N m kg m ft lb N m kg m ft lb N m kg m ft lb N m kg m ft lb 52 to 62 5 3 to 6 3 38 to 46 78 to 98 8 0 to 10 0 58 to 72 15 to 25 1 5 to 2 5 II to 18 15 to 25 1 5to 2 5 I I to 18...

Page 360: ...steering gear housing Wear of steering linkage Damaged idler arm Worn column bearing weakened column bearing spring or loo e clamp Damaged sector shaft Damaged teering worm assembly Damaged worm bearing Deformed steering linkage and or suspension link Insufficient lubricants or mixing impurities in steering linkage or excessively worn steer ng linkage Worn or damaged steering gear and bearing Inco...

Page 361: ... speed Oil pump malfunctioning or oil leakage in steering gear Oil leakage in steering gear Stuffy oil passage in steering gear Wheel bearing not properly adjusted Stuck or damaged control valve in steering gear Front wheel alignment not properly Excessive steering gear play Play at suspension and linkage ball joint Lack of oil in oil pump Hoses or oil ftlter clogged Loose pulley Belt noisy or sla...

Page 362: ... Page ST 13 00 0 0 I P S 52B ST3127S000 Preload gauge Fig ST 22 ST2709 I000 Pressure gauge Fig ST 35 CD GG91030000 Torque wrench Fig ST 52 Fig ST 36 HT62940000 Socket adapter Fig ST 54 i pump outlet W Page ST 12 HT629oooo0 Socket adapter Page ST g Page ST 15 CD iJ Page ST 16 e Shut rf valve J Ps 52B KV48 1 00600 Adjusting plug wrench Fig ST 38 CD KV48100910 Drift bar Fig ST48 Fig ST 52 KV48100920 ...

Page 363: ...NGINE CONTROL FUEL EXHAUST SYSTEMS CONTENTS ENGINE CONTROL SYSTEM ACCELERATOR CONTROL SYSTEM FUEL SYSTEM REMOVAL INSPECTION FE 2 FE 2 FE 4 FE 5 FE 6 INSTAllATION EXHAUST SYSTEM REMOVAL INSPECTION INSTAllATION FE 6 FE 7 FE 7 FE 7 FE 7 GIll ...

Page 364: ...y loosening lock nut 4 Remove torsion shaft by taking off cotter pin and washer 5 Remove wire end bracket 6 Disconnect wire from clips 7 Compressing lock nails push nylon collar out of place Remove wire from slot in pedal1ever Note Be careful not to damage nylon FE 2 1 14 Wire end bracket 15 Supporting insulator 16 Instlbtor fixture 17 Torsion shaft bushing 18 Torsion shaft retwn spring 19 Torsion...

Page 365: ...retor throttle valve begins to open Then turn back adjusting nut two revolutions and tighten lock nut 3 After completing the adjustment check the following Make sure carburetor throttle valve opens fully when accelerator pedal is depressed all the way Make sure that accelerator system functions smoothly without dis turbing any adjacent parts Check throttle lever to make sure it returns to its orig...

Page 366: ...13 Fuelrcturn holO 4 Fuel fiUer hose t4 Breather hose 3 5 Drain hose 15 Fuel tube 6 Air yen tila tion hose 16 Fuel return tu o 7 Lock plate 17 Breather tube 5 8 Fuel gauge tank unit 18 Fuel fIlter 9 a ring 19 Magnet plunger pump l 10 Breather hose 20 Protector t m il 0 mr CJ CJIm 3 m J CO j CD oJ m Cl c lIl J III CD 3III ...

Page 367: ... Fig FE 7 Detaching Check Valve 8 Disconnect breather hose suction hose and return hose 1 Breather hose 2 Return hose 3 Suction hose FE572 Fig FE 8 Disconnecting Hoses 10 Remove four bolts attaching fuel tank and then take out fuel tank FUEL GAUGE TANK UNIT 1 Detach rear seat cushion seat back both rear corner finishers and rear parcel shelf 2 Disconnect wiring harness con nector from fuel gauge t...

Page 368: ... crack ed rusted collapsed or deformed FUEL FILTER Replace fuel fIlter at recommended maintenance intervals or if it becomes clogged or re tricted Fuel fIlter is of a cartridge type and cannot be cleaned Alway replace with a new one CHECK VALVE Refer to Check Valve Section EC for inspection FE 6 INSTALLATION In tall any parts of the fuel system in the reverse order of removal Ob serve the followin...

Page 369: ...igued or sweated 3 With engine running check all connections for leaks and entire sys tem for unusual noise vibration etc INSTALLATION I Wipe clean all contact portions allow them to dry thoroughly 2 See Fig FE 13 for location of exhaust system parts requiring installa tion FE 7 1 Front tube assembly 2 Mounting insulator 3 Rear tube and muffler assembly 4 Tail finisher FE573 Fig FE 13 Exhaust Syst...

Page 370: ...zzle of injector to sealant inlet and press it there fIrmly Inject sealant slowly until sealant be gins to flow out of slit of tube This indicate that bead requires no further sealant Excessive sealant can cause a clogged tube After injecting wash injector thoroughly in clean water to remove all traces of sealant FE163 Fig FE 17 I liecting Seatant 5 Start engine and l t it idle slowly for ten minu...

Page 371: ... Hardtop WINDSHIELD AND REAR WINDOW GLASS BF 2 BF 3 BF 3 BF 3 BF 4 BF 4 BF 4 BF 4 BF 5 BF 5 BF 6 BF 7 BF 7 BF 10 BF12 BF 15 BF 17 DESCRIPTION REMOVAL AND INSTALLATION REPAIRING LEAKS BODY REAR END TRUNK LID TRUNK LID OPENER INTERIOR INSTRUMENT PANEL CONSOLE BOX ROOF CONSOLE SEAT SEAT BELT TRIM AND MOLDING ROOF TR 1M BODY SIDE TRIM MOLDING SPECIAL SERVICE TOOLS BF 17 BF 17 BF 20 BF 21 BF 21 BF 22 B...

Page 372: ...on C l Section D Section E III Section F Section G Section H BF4068 Fig BF 1 Body Construction Sedan Section I iZt Section B Section C Section A Section D II Section E Section F Section G BF4078 Fig BF 2 Body Comtruetion Hardtop Section I Section H BF 2 ...

Page 373: ...lamp wires at connectors 3 Remove bolls attaching each bumper stay to body side members and remove bumper from car INSTALLATION I Position bumper to car and tem porarily tighten attaching bolls 2 Adjust bumper and lighten at taching bolls securely 3 Connect front combination lamp wires at connectors Note a Use extreme care to avoid damaging painted surfaces of car body b When installing bumper 0 c...

Page 374: ...n remove radiator grille 3 Installation is in the reverse order of removal CAUTION a Radiator grille is made of plastic so do not use excessive force b Take care to keep any oil away from radiator grille FRONT APRON Removal and Installation I Remove screws attaching front apron to front fender 2 Remove screw attaching front apron to both hood lock stay and radiator core support Then remove front a...

Page 375: ...d aft and side to side by loosening hood to hinge attaching bolts It can also be adjusted up and down with hinge shims and bumper rubbers to obtain a flush hood fit with fender I Select adequate shim to deter mine height of rear side of hood Shim A 2 0 mm 0 079 in Shim B 1 0 mm 0 039 in 3 1 Hinge 2 Hood 3 Hinge shim BF4188 Fig BF 10 Hinge Shim 2 Adjust hood fore and aft and in and out by loosening...

Page 376: ...r be desired alignment is obtained tighten hood lock male at taching bolts 4 Loosen lock nut of dove tail bolt and m9ve ove tail bolt up or d9wn by turning it clockwise or counter clockwise to obtain a flush fit between the top of hood and fenders Then BF 6 tighten lock nut ecurely IiJ Tightening torque Dove tail lock nut 19 to 25 N m 1 9 to 2 6 kg m 14 to 19 ft b Dove ta bolt 21 L J l Lock nut Ho...

Page 377: ...ol cable from hood lock female and then remove hood lock control cable 4 Install hood lock mechanism in DOORS AND WINDOWS the reverse order of removal Note a Lubricate following parts Pivot safety catch lever return spring of hood lock male lever of hood lock female b Inspect safety catch lever and re turn spring for deformation wear or rust c Inspect hood lock female lever and return spring for d...

Page 378: ...Installation I Remove regulator handle by prying out set pin Fig BF 21 shows set pin assembled to regulator handle and regulator handle to regulator with door glass raised fully 450 Front l Set pin spring BF507B Fig BF 21 Regutator Handle and Set Pin 2 Remove ann rest door inside handle escutcheon door lock knob door finisher and sealing screen 3 Lower door glass as far as possible with regulator ...

Page 379: ...BF 27 move guide channel B upward move it downward for the picture 2 3 Cycle door glass up and down to assure a good window fit 4 After proper glass alignment is obtained tighten guide channel B at taching bolts r fi 2 i J 4 c T t e I t SI IS 0 I Door sash 2 Doorglass 2 BF479 Fig BF 27 Adjusting Guide Channel FRONT DOOR LOCK AND LOCK CONTROL CD Removel end instelletion I Remove regulator handle by...

Page 380: ...o 0 059 in See Fig BF 32 Note Apply grease to sliding surfaces of lever l and prings AdJuetment Door inside handle i non adjust able I Door inside handle 2 Door lock BF428B Fig BF 30 Removing Lock Assembly 5 Remove door outside handle by removing attaching nuts I Door outside handle 2 Door outside handle rod 3 Adjusting nut Nylon 4 Door lock lever BF292B Fig BF 31 Removing Door Outside Handle REAR...

Page 381: ... and disengage door glass from regulator by disengaging screw heads from guide channel through keyholes Refer to Front Door Glass and Regulator 7 In order to facilitate removal of door glass remove bolts and screws retaining center sash Body Removing Screws Attaching Center Sash 8 Lower door glass completely and remove door glass from groove of center sash then lift up and remove door glass 9 Tilt...

Page 382: ...removal Note Apply grease to sliding surfaces oflevers and springs Adjustment Follow the same procedures as for front door 1 Door glass 2 Door lock knob 3 Door lock knob grommet 4 Outer stabilizer 5 Inner stabilizer 6 Door inside handle 7 Guide channel A 8 Regulator assembly 9 Regulator handle 10 Guide channel B 11 Doorglass guide rail assembly 12 Passenger s handle 13 Door lock assembly 14 Door l...

Page 383: ...r of removal Body Note Apply grease to sliding surfaces of regulator guide channel and door glass guide rail check body side weatherstrip to be sure it is installed properly Improper installation may cause water or dust leaks Proper window glass adjustment can be performed as follows See Fig BF42 Adjustment Before adjusting door window glass 10 ut adjustment at waist area 2 In out adjustfnent uppe...

Page 384: ...at front pillar when glass is raised upwards 2 S Adjustment Groove 1 Body side v eatherstrip 2 Door glass 3 Door glass guide rail 4 Rail bracket Fig BF 47 BF600B GIG Fore and Aft Adju tment 1 Door lock assembly 2 Retaining clip 3 Door lock cylinder 4 DOOI outside handle 5 Passenger s handle 6 Bell crank 7 Door lockknob 8 Door lock knob grommet 9 Door inside handle 10 Door inside handle escutcheon ...

Page 385: ...seat belt in one unit BF 15 Power window regulator 1 Side window glass 2 Regulator handle 3 Side window regulator assembly 4 Guide plate 5 Glass stopper BF440B Fig BF 49 RearSide Window 6 Remove sealing screen 7 Lower the side window gla s com pletely with regulator handle 8 Remove three tapping screws fix ing side window molding 9 Remove window glass stopper 10 In models with manual win dows remo...

Page 386: ...Unit mm in 2 B Installation is in the reverse order of removal Note Apply grease to sliding surfaces of regulator guide channel and guide plate Adjustment Adjust guide plate adjusting bolts and glass stoppers so that glass is properly aligned as indicated in Fig BF 52 I Side window glass 2 Glass stopper 3 Roller 4 Guide plate I ro 4 0 04 to 0 16 E 2 to 6 0 08 to 0 24 10 2 to 14 2 0 40 to 0 56 Bf44...

Page 387: ...ive sealant 2 Glass 3 Cut with knife BF464B Fig BF 55 Cutting off Adhesive Caulking 8 Cut off caulking material around entire perimeter of glass as follows 1 Using a knife cut through part of caulking material 2 Secure one end of steel music wire 0 5 mm 0 020 in in diameter to a piece of wood that can serve as a handle Using long nose pliers insert other end of wire through caulking material SF 17...

Page 388: ...rs A B and C and glass location each other They differ in shape 1 Spacer A 2 Spacer B 3 Body center line Unit mm in BF465B Fig BF 57 Location ofSpace Front IE CD IJ J 2 400 15 75 Unit mm in 1 Spat erC 2 Body center line BF 466B Fig BF 58 Location ofSpacers Rear SPACER A r 11 Iii SPACER C jiJ I 1 Cowltop 2 Windshield glaS 3 Windshield pillar outer panel 4 Windshield pillar inner panel 5 Rear parcel...

Page 389: ...ead on glass 10 mm 10 39 in above glass surfaces r Sealant mm 39 in Section A A Fig BF 64 BF956 Applying Adhesive Caulking Note Cut off nozzle end of cartridge as shown below BF t9 7 0 28 8 0 31 Unit mm in BF957 Fig BF 65 Cutting Nozzle of Cartridge Pierce sealing film with needle install cartridge on hand gun CAUTION Sealant starts to harden 15 minutes after it is applied therefore wind shield gl...

Page 390: ...r should not be driven on rough roads or surfaces until sealant has properly vulcanized Unit days 90 50 25 15 2 5 6 10 34 3 10 5 3 17 T r i 1 Primer E REPAIRING LEAKS leaks can be repaired without re moving and reinstalling glass in the following manner 1 To stop leaks first remove mold ings in area ofleak 2 Mark location of leak Note If water is leaking between caulking material and body or be tw...

Page 391: ... lid striker 3 Bumper rubber 4 Shim 5 Trunk lid hinge 6 Torsion bar clip 7 Torsion bar 8 Trunk lid weatherstrip 9 Lock cylinder 10 Trunk lid lock BF4468 Fig BF 69 Trunk Lid 4 To obtain a snug fit between trunk lid and weatherstrip and to align trunk lid lock with trunk lid striker remove trunk rear finisher and loosen trunk lid lock attaching bolts or trunk lid striker just enough to move trunk li...

Page 392: ...Torsion Bar 4 Installation is in the reverse order of removal TRUNK LID LOCK AND LOCK CYLINDER Removel end InstBl18tIon Open trunk lid 2 Remove trunk rear finisher 3 Remove trunk lid lock attaching bolts and remove trunk lid lock from rear upper panel 4 Disconnect trunk lid opener cable and trunk lid lock rod from trunk lid lock 1 Trunk lid lock 2 Trunk lid opener cable 3 Ttunk lid lock rod 4 Lock...

Page 393: ...trunk rear finisher and kicking plate Turn up floor carpet near trunk lid opener handle 3 Disconnect trunk lid lock rod from trunk lid lock 4 Remove trunk lid lock attaching bolts and remove trunk lid lock from rear upper panel 5 Disconnect trunk lid opener cable from trunk lid lock 6 Remove trunk lid opener handle BF 23 BF456B Fig BF 80 Removing Trunk Lid Opener Handle 7 Remove trunk lid opener c...

Page 394: ...sher bracket 8 Cigarette lighter panel 9 Side ventilator case R H 10 Side ventilator case L U 11 Side ventilator duct R H 12 Side ventilator duct LH BF573B Fig BF 82 Instrument Panel 3 Remove column cover 4 In tilt steering models push lever down and lower steering shaft In non tilt steering models loosen two bolts retaining steering column and lower steering shaft S Remove screws retaining cluste...

Page 395: ...r and pull combination meter out toward you 9 On rear side of combination meter disconnect instrument harness connector and then remove combi nation meter 10 Remove heater control assem bly Refer to Section BE II Holding instrument panei re move bolts retaining instrument panel side BF621B Fig BF 84 Removing Clustu Lid o BF472B Fig BF 86 Removing Imtrument Panel Side Attaching Bolts 12 Remove nuts...

Page 396: ...rom headlining by holding its rear side and disconnect lamp harness connector 3 Pull roof console toward rear and remove it 4 Installation is in the reverse order of removal SEAT REMOVAL AND INSTALLATION Front seet Front seat can be removed easily by removing attaching nuts and bolts Reer seet Remove rear seat cushion by re moving bolts and rhen rear seat back by removing bolts and unhooking wire ...

Page 397: ...rage Points Sedan Front Jl Tightening torque Anchor bolt 20 to 35 N m 2 0 to 3 6 kg m 14 to 26 fHb BF 27 BF47BB Fig BF 92 Seat Belt Anchorage Point Hardtop Front 1 Reinforce 2 Weld nut Child restraint anchorage BF575B Fig BF 93 Seat Belt Anchorage Point Rear ...

Page 398: ... headlining assembly 3 InstaUation is in the reverse order of removal 5 I Sun vi or 2 Front welt retainer 3 Insulator 4 Rear welt retainer 5 Headlining 6 Roof side y arnish 7 Assist grip 8 Clip 9 Inside mirror Note When replacing headlining also replace listing wire if deformed BF4828 Fig BF 94 RoofTrim BODY SIDE TRIM SEDAN ID I Kicking plate Front 2 Dash side finisher 3 Windshield pillar garni5h ...

Page 399: ... 15 Splash guard plate BF4848 Fig BF 96 Body Side Trim r F r I Od l L 0 4D u Surround upper molding nt fender molding Section C kSdJ moldlOg Hood Section B Section A Door outside molding f Rear pillar molding Section F Section D Door outer panel Side roof rail outer panel Section E t ROOf panel R d A ear Wid ow C n P uppe molding Drip channel Rear windo lower moldmg Side roof rail inner panel i Wi...

Page 400: ...on C Section A SPECIAL SERVICE TOOLS Tool number tool name KV99 100800 Door hinge wrench ST08800000 Sucker Reference page or Fig No Tool number tool name Fig BF I8 ST088 I0000 Caulking hand gun Fig BF 66 BF JO Drafter molding Section 0 BF487B Fig BF 98 Molding Reference page or Fig No Fig BF 64 ...

Page 401: ...2 BE 2 BE 3 BE 4 BE 10 BE 11 BE 11 BE 15 BE 17 BE 19 BE 19 BE 20 BE 20 BE 20 BE 20 BE 21 BE 21 BE 21 BE 21 BE 21 BE 22 BE 23 BE 25 BE 25 BE 29 BE 31 BE 31 BE 31 BE 31 BE 32 BE 32 BE 32 BE 32 BRAKE WARNING SYSTEM TROUBLE DIAGNOSES AND CORRECTIONS ELECTRICAL ACCESSORIES CIRCUIT DIAGRAM WINDSHIELD WIPER AND WASHER REAR WINDOW WIPER AND WASHER HORN CIGARETTE LIGHTER CLOCK RADIO STEREO REAR WINDOW DEFO...

Page 402: ...ry tenninab as foDows Disronnect cable at negative terminal and tben disoonnect cable at positive tenninal Before connecting abiesto battery terminal be sure to clean termiDab with a rag Fasten cable at positive tennina I and then ground cable at negative terminal Apply grease to top of these tenninab to prevent rust from developing on them b Neva use 8 screwcfriva or service tool to conduct a con...

Page 403: ... eN BE J I Engine room harnes 2 Engine room harness No 2 3 Power window harneu 4 Dash harness 5 lnstrument harness 6 Room harness 7 Bodyharness 8 Parcel shelf harness 9 Console harness 10 Door switch harness BE698C Fig BE 2 Wiring ...

Page 404: ...Body Electrical System WIRING HARNESS ENGINE ROOM HARNESS 8 BE 4 ...

Page 405: ...ght relay 24 To voltage regulator 25 To intermittent amplifier 26 To side turn signal lamp R H 27 To headlamp Outside 28 To horn R H 29 To headlamp Inside 30 To front combination lamp R H 31 To body 32 To front combination lamp L H 33 To headlamp Inside 34 To headlamp Outside 35 To horn L H 36 To side turn signal lamp L H 37 To thetmal transmitter 38 To distributor 39 To distributor 40 To ignition...

Page 406: ...ing unit oil pressure switch 3 To starter motor 4 To back up switch S Useless 6 Useless AfT equipped model CD YG GL G YL RYG rtP BY BW RL YB CV I 1 To engine foom harness 2 To engine room harness 3 To oil pressure sending unit 4 To starter motor 5 To inhibitor switch 6 Useless 7 To kickdown solenoid YB YL 1fJ BE700C Fig BE4 Engine Room Harn 8 No 2 BE 6 ...

Page 407: ...To voltmeter 10 To combimeter 1 11 To combimeter 2 12 To speaker 13 To rear defogger switch 14 To illumination control 15 To console harness 16 To cigarette lighter 17 To diode box 18 To imtrument body 19 To glove box B Yl R1l B GBRllO R GW I BR RG YB Y BG If A Wl l f WR B R YL WB YG Wl WR l J ILg I B BlGW y t y YR R CD Z IIIt IICi 11 1Zt lOII Z 11 1 IIIIII OJoa m en n n 0 en VI C1l 3 ...

Page 408: ...To engine room harness 8 To body harness 9 Tofuel pump harness 10 To hazard switch II To stop lamp switch 12 To resistor 13 To heater control 14 To cooler IS To blower motor 16 Usele g IIIz BR R II GLJiM 1 v h a RROR w L BG R Y ROGRGR v CD YLRLB VB j B BW m g GW GY Rl GR 09 y OL T RG L9 l l l O0 L iiftfLY L O B il Q m I a CD oo OJ0Q m s o crIII Ul III C1l 3 ...

Page 409: ...eless 6 To console harness 7 To se t belt switch 8 To hand brake switch 9 To rear wiper motor 10 To parcel shelf harneslI 11 To rear combination lamp R H 12 To license lamp 13 To body 14 To rear combination lamp L H 15 To dash harness Fuel pump harness 16 To fuel pump FOI power steering equipped models j IIo 0 IllZIIIIIIIII Xll I Ill f o a tDoCo m CD o 1 i Q CJl CIl CD3 ...

Page 410: ...CAL UNIT View A ViewB 7 11 I 1j r I 1 Relay bracket 2 Horn relay 3 Auto choke relay 4 Condenser 5 Voltage regulator 6 Light relay 7 Ignition and accessory relay 8 Intermittent wiper amplifier 9 Inhibitor relay 10 Relay bracket 11 Turn signal flasher unit 12 Hazard flasher unit 13 Seat belt timer unit 14 Diode box 15 Stop and taillight sensor 16 Circuit breaker For power window system BE704C Fig BE...

Page 411: ...al System LIGHTING SYSTEM fliGHTING RELAY H L ll 1 FUSE BOX LE LINK BATTERY l HEAOLAMP L H I HIGH BEAM PILOT LAMP 8 LIGHTING SWITCH 1 I Off 1ST 210 1 1 H L P H LIP H L P i H ZI 7 r Q r H g Z Fig BE 12 Circuit Diagram for Head amp System BE554C BE l ltJgi t t i l ...

Page 412: ...I I t i i z 1 I ri 0l w J l J j rt HEATER CONTROL ILLUMINATIONLAMP OfflCCI 01 81 ICI n 0 10 I 0 L iBi 0 0 1 I 0 B Q Q Q IGNITION SWITCH oil sJ 1iD MlIPMlPMllP5 I 0 010 0 I I 00 0 0 1 0 I 0 0 0 I o 0 ol i6 J Q I LIGHTING SWITCH STOP TAIL LAMP SENSOR I 5 RADIO ILLUMINATION LAMP It JZ o O l1cis r 3 TAIL LAMP MONITOR I ILLUMINATIONCONTROLIAUSTRALIA MOOELSI J 3 KEV ILLUMINATION v LAMP TAIL LAMP IR H I ...

Page 413: ...EEl I Br FUSIBLELINK SIDE FLAsHER LAMP IL H FUSE BOX rO 00 0HAZARDFLASHER UNIT TURN SIGNAL FLASHER UNIT HAZARD SWITCH OHIOI I Q 2 0 1 II 3 Q TURN triU SIGNALPILOT LAMP IR H l 1ID I OflllCCl O Sf TURN itc to SIGNAL 02 PILOT LAMP 1 o 0 IL H l S I 0 L 2 LQ IGNITION SWITCH REAR TURN SIGNAL TURN SIGNAL SWITCH LAMP IL H l TTiI 10 0 2 0 I HORN SWITCH 3 O L 2lIllZ C I iiz a I a J I ZD i C I 0 IIII too Q m...

Page 414: ...llCC 01 51 rrn 00 II STOP LAMP IL H I BE559C Fig BE l 7 Ci1 cuit DiDgram for Slop Lamp System BACK UP LAMP SYSTEM IGNITION ACCESSORY RELAY 1 f 1 BACK tJP LAMP IR H I G BATTERY G le FUSIBLE LINK I I BACK tJP LAMP SWITCH MIT MODELl 8 FUSE BOX l 0 r o 0 INHIBITOR SWITCH AfT MODELl IGNITION SWITCH OlllCI 01 51 I lCI 0 0 I r u t BACK tJP LAMP L H I BE561C Fig BE 19 Circuit Diagram for Back up Lamp Syst...

Page 415: ...o en en w U o z o Z c I 41 0 I J I o o a z J a I J 00 0 zo J SI I z o w a i b g OJ Y a g3 0 J ZU ot l x l u w t h Q rl 0 en J J J 1 ttl o O t 0 g r o f9 II w o o o 1 0 0 1 0 0 a J J ia o o o 11 J I 00001 g L 0 r c 1 z 1 g 1 UlICD oa z jl BE707C Fig BE 20 Circuit Diagram for Room Rear Room and Trunk Room Lamp Sy tem BE 15 ...

Page 416: ...amp monitor Tail lamp monitor Charge warning lamp Brake warning lamp Parking brake warning lamp R H drive Seat belt warning lamp Door warning lamp Fuel warning lamp Hazard warning lamp Clock illumination lamp Ciglirette lighter illumination lamp Heater control illumination lamp Radio illumination lamp Capacity 12V 37 5W 12V 37 5 S0W l2V 21W 12V 5W I2V 5W 12V 21W 12V 21W 12V 5W 12V 2lW l2V 5W 12V l...

Page 417: ... 22 Replacing Wedge Base Type Bulb e To replace bulb pullout bulb from socket To install new bulb push bulb into socket Body Electrical System lJ tU w tlJ OJ v lJ HEADLAMP Removing bulb Installing bulb Note a Before removing sealed beam type headIamp as an a8sem bly and reo placing sealed beam unit remove headIamp finisher b Make sure that the sign Top of beam lens is on the upper side BE563C Fig ...

Page 418: ...0 Len Back up 11 Lens Turn 12 LelU Stop 13 Len Tail 14 Rim LICENSE PLATE LAMP Note a Bulb with cket can be easily removed by pushing down socket b Lens can be easily replaced by turning counterclockwise Body Electrical System 1 Screw 1 Lens 3 Pa eking 4 Bulb 5 Bulb body BE567C Fig BE 27 Side Turn Signal Lamp BES68C Fig BE 28 Rear Combination Lamp f l itJl o I Bulb 2 Lens BE570C Fig BE 3D Liceme Pl...

Page 419: ...r See Fig BE 37 J 2 5 1 OHIACC 01 m Il fO 0 12 Q I J 901 I 4 001 15 I U I BE744B Ignition switch Steering lock BE141C Fig BE 37 Ignition Switch BE 19 IGNITION AND ACCESSORY RELAY REMOVAL AND INSTALLATION See Fig BE l I 1 Disconnect battery ground cable 2 Remove relay bracket in engine compartment 3 Disconnect harness connector 4 Remove ignition and accessory relay 5 Install relay in the reverse or...

Page 420: ...as follows See Fig BE40 I There should be continuity be tween terminals CD V and but not betwee and 2 There hould be continuity be tween terminals and but not between and V when applying DC 12 volt across terminals CD and JH BE579C Fig BE 40 Lighting Relay STOP LAMP SWITCH Stop lamp switch is integral part of brake pedal BE 20 Whenever stop lamp switch is re moved adjustment is required REMOVAL AN...

Page 421: ...nstall switch in the reverse order of removal b 1 Trunk hood hinge L H 2 Torsion bar 3 Trunk room lamp switch BE585C Fig BE 47 Removing Trunk Room Lamp Switch INSPECTION Test continuity through luggage room lamp switch with a test lamp or ohmmeter When plunger is pressed into switch assembly switch contacts are open Contacts are closed when plunger is projected BE 21 GLOVE BOX LAMP SWITCH REMOVAL ...

Page 422: ...trical System aiming wall screen or headlamp tester For operating instructions of any aimer refer to respective operation manuals supplied with the unit HIGH BEAM With type II unit lamps outer lamps covered turn headlamps to high beam See Fig BE 50 Note a Adjust high beams so that main axis of light is parallel to center line of body b Align main axis of light with P point c Dotted lines in illust...

Page 423: ...tch Faulty hazard warning switch Burnt buib Loose connection BE 23 Corrective action Correct cause and replace fusible link Check wiring and or repair connection Conduct continuity test and replace if nee essary Check lighting relay for proper operation and replace if necessary Clean and tighten ground terminal Conduct continuity test and replace if nee essary Check lighting relay for proper opera...

Page 424: ... inhibi tor switch Arr Faulty ignition and accessory relay Faulty ignition switch Faulty lighting switch Tail lamp Faulty stop tail lamp sensor Burnt bulb Loose bulb Loose connection or open circuit BE 24 Corrective action Replace with one specified Replace Repair Replace Replace Repair Replace with specified one Corrective action Correct cause and replace Check wiring and or repair connection Con...

Page 425: ...oom lamp switch Correct cause and replace Check room lamp switch Burnt fuse Faulty door switch Correct cause and replace Conduct continuity test and replace if nee essary Conduct continuity test and replace if nee essary Replace bulb Check relay for proper operation and replace if necessary Check relay for proper operation and replace if r tecessary Faulty diode Brunt door indicator lamp bulb Faul...

Page 426: ...a w a J w w a u w J a 0 W a 0 a o t WI 1 J 1 1 ow a x 0 w II H u f or I I r i II J ffi I D II Fig BE 52 w I I w a a w 0 w I a w I w w w J w a o wI 1 J 1 J I Ow a 1 11 a w I w I J o I g 1 00001 i c c 01 Q I z Q I N I l wI a z i l II 0 0 I ffi 0 a w N L l J t ll a Z w Ia 1 1 BE58 C Circuit Diagram for Oil Pressure Water Temperature Fuel Level Gauge and Voltmeter and Oil Pressure and Fuel Warning Sys...

Page 427: ...ARNING LAMP SYSTEM 5 S H t L I J 0 J W II II o w U U z il th t 1 x if x o w o Q o z Z II w U J I I 0000 0 0 0 c 0 V I I 1 fEe II rm w o t i z Ii I lL J I w a w I I Q II BE1 1C Fig BE 54 Circuit Diagram for Charge W rni a iP ste BE 27 ...

Page 428: ...E LINK RESISTOR FUSE BOX I I rB BRAKE FLU 10 LEVEL SWITCH nFf ICC 01 51 lee 0 Q IS2 1 t I y 8 t Io IGNITION SWITCH I q BRAKE FLUIO LEVEL 0 WARNING LAMP qPARKING BRAKE 0 WARNING LAMP ARKING BRAKE SWITCH 0 BE593C Fig BE 56 Circuit Diagram for Brake Warning Lamp System o v FUSE BOX BE 2B IGNITION SWITCH Off ace 01151 flit BE712C Fig BE 57 Circuit Diagram for Tachom ter ...

Page 429: ...tachometer voltmeter clock and speedometer de tecting switch amplifier and boost meter hose if so equipped 6 Remove combination meter 7 Install combination meter in the reverse order of removal noting the IBE 29 following How to install speedometer cable I Insert inner cable into core on speedometer side 2 Direct projections on periphery of cap vertically and fit projection at inside of cap into g...

Page 430: ...oost meter 14 Stop lamp monitor 15 Tail lamp monitor 16 High beam pilot lamp 17 Stop lamp monitor lamp 18 High beam pilot lamp 19 Tai11amp monitor lamp 20 Illumination lamp 21 Boost meter hose 22 Turn signal indicator lamp R H BE 30 U 15 13 14 2400015 230 0 220 0 0 16 o 017 21 000 18 J 20 19 CJ a a J Z E a CJ Z 3 Cl c E z J CJ 3 z Z J Ie w Q m 3zlza w m18 14 UwOu a 00 3 o w c co J J l i GffiWuuuuu...

Page 431: ...it board 3 Separate fuel level gauge from printed circuit board 4 Install new gauge in the reverse order of removal Fuel geuge tenk unit Fuel gauge tank unit is located on fuel tank Refer to Fuel Gauge Tank Unit Section FE for removal and installation WATER TEMPERATURE INDICATOR SYSTEM REPLACEMENT Gauge See Fig BE 62 Remove combination meter 2 Remove screws retaining printed circuit board 3 Separa...

Page 432: ...lb in the reverse order of removal CHARGE WARNING SYSTEM Replacement Voltage regulator See Fig BE II FROM BATTERY TO FUSIBLE BATTERY LINK a g z a w J TO BATTERY BE 32 I DiSconnect battery ghitrnd cable 2 Disconnect voltage regulator con nectar 3 Remove retaining screws and de tach voltage regulator 4 Install new voltage regulator in the reverse order of removal Inspection I Charge warning lamp glo...

Page 433: ...sconnecting lead wire terminals Then replace it TROUBLE DIAGNOSES AND CORRECTIONS SPEEDOMETER Condition Speedometer pointer and odometer do not operate Unstable speedometer pointer Unusual sound occurs in response to increase in driving speed Inaccurate speedometer indication Inaccurate odometer operation Probable cause Loose speedomerer cable union nut Broken speedometer cable Damaged speedometer...

Page 434: ...s Faulty water temperature gauge Loose connection or open circuit Faulty thermal transmitter Meter pointer returns to original position when ignition switch is turned off Faulty water temperature gauge Meter pointer indicates maximum temper ature even after ignition switch is turned off Faulty water temperature gauge Loose or poor connection Faulty gauge voltage regulator Faulty fuel gauge tank un...

Page 435: ...ed off Faulty oil pressure gauge Meter pointer indicates maximum pressure even after ignition switch is turned off OIL PRESSURE WARNING LAMP Oil pressure warning lamp glows whenever engine oil pressure falls below 20 to 39 kPa 0 2 to 0 4 kg cm2 2 8 to 5 7 psi Condition Lamp does not light when ignition switch is set to ON Lamp does not go out while engine is being operated Probable cause Faulty oi...

Page 436: ...ion Lamp does not go out when engine is started Faulty charging system Inspect charging system ELECTRICAL ACCESSORIES CIRCUIT DIAGRAM WINDSHIELD WIPER AND WASHER SYSTEM With intermittent wiper emplifier IGNITION ACCESSORY RELAY ll1 1 WIPER AMP L t II BATTERY l IG FUSIBLE LINK FUSE BOX WASHER MOTOR WIPER WASHER SWITCH Ull II IU HI II L gSQ I 0 5 0 I I I Q I 0 0 Q HI 0 IGNITION SWITCH OIlICC 01 51 I...

Page 437: ...I t I T t IGNITION SWITCH I Off lCC 01 SI IICt 0 0 1162 I 0 T o 1 REAR WASHER MOTOR REAR WIPER MOTOR B E605C Fig BE 69 Circuit Diagram for Rear WindoW SY6t m IGNITION ACCESSORY RELAY 1 i f BATTERY R le FUSIBLE LINK BE 37 FUSE BOX l HORN RELAY IGNITION SWITCH OFf ACe 01 I ACG 0 0 162 L 16 0 S 1 I T v 0 01 TURN SIGNAL SWITCH 8ILHl t 0 HORN SWITCH t BE606C Fig BE 70 Circuit Diagram for Horn Sy tem ...

Page 438: ...BE607C Fig BE 71 Circuit Diagram for Cigarette Light r and Clock I Off ICI 01 ST O 1 t III 6 u t RADIO AND STEREO SYSTEM IGNITION AND ACCESSORY RELAY 1 11 FUSE BOX QI I BATTERY 18 R Br FUSIBLE LINK FRONT SPEAKER REAR SPEAKER IR H RADIO J STEREO IGNITION SWITCH fOFfiCI 01 ST lir i S 1 IT O 0 REAR SPEAKER IL H l BE608C Fig BE 72 Circuit Dillgram for Radio and Stereo System BE 38 ...

Page 439: ...ACCESSORY RELAY l r BATTERY 18 4d FUSIBLE LINK FUSE BOX r c f C REAR WINDOW DEFOGGER SWITCH 1 OfF ON I 1 II 13 C IGNITION SWITCH h OIf ICCI 01 SI l fC 0 0 j r I t 8 0 II I REAR EFOGGER BE609C Fig BE 73 Circuit DiJJgram for Rear Window Defogger System BE 39 r i1 ...

Page 440: ...1 aQQ FRONT POWER WINDOW V MOTOR IR H n 1 1Lr J CIRCUIT BREAKER r REAR POWER WINDOW MOTOR IR H REAR IR H I UPI I bDI 010 060 6 CENTER LOCK 1 l FRONT IL H I Ii 113 1 I 2 9 I 6 I I 1 B FRONT POWER WINDOW MOTOR IL H N IDOW 1 23T LPOWER WINDOW REAR SWITCH IR H I POWER WINDOW MAIN SWITCH POWER WINDOW REAR SWITCH IL H I I 3 i5 REAR POWER WINDOW MOTOR L H f IIIa E zI III0III OJoa m iii OIII C CD 3 ...

Page 441: ... raising wiper blade from windshield glass 4 Remove right side cowl top grille and cowl top grille cover 5 Remove motor arm attaching nut securing motor arm to wiper linkage BLOWER MOTOR FUSE BOX f C f C FAN SWITCH r Ofl l ol L I f IGNITION SWITCH 0fF Ice 01 511 i lig BOO Fig BE 76 CircuitDiagram for Heater System RESISTOR 6 Remove wiper motor attaching bolts CAUTION Be cereful not to bend linkell...

Page 442: ...motor arm to wiper linkage S Loosen pivot securing nut and remove link assembly J BE274 Fig BE 79 Removing Link Aaembly 6 Install wiper inkage in the reverse order of remoWI Install wipei blade in correcUnstal Iation angl tl r t i rrect sweeping zones Dimension A o to 3 mm io to 0 12 in Body Electrical System BE078C Fig BE 78 Wiper Motor and Wiper Linkage A l eE613C Fig BE 80 Wiper Arm Installatio...

Page 443: ...e Wiper switch I Disconnect battery ground cable 2 Remove steering column cover 3 Disconnect wiper switch connee tor 4 Remove wiper switch from com bination switch by removing retaining screws S Install wiper switch in the reverse order of removal Body Electrical System SECBDe Fig BE 83 Removing Wiper Switch Intermittent wiper amplifier See Fig BE I I The intermittent wiper amplifier is installed ...

Page 444: ...res may lead to improper te t re ults If results of tests A and Bare satisfactory as indicated below inter mittent amplifier i functioning prop erly Note Be careful not to connect lead wires to incorrect tenninals as this will damage transistors Test A Connect test lead wires BE135C Fig BE 86 Checking Intermittent Amplifier 2 Make sure that test lamp comes on in 0 5 second when negative lead wire ...

Page 445: ...r cover 4 Remove bolts attaching motor stay to parcel shelf panel from inside passenger compartment 5 Disconnect wiper motor connee tor 6 Remove bolts securing motor and then remove motor 7 Install wiper motor in the reverse order of removal Install wiper arm in correct installation angle to obtain correct sweeping zones See Fig BE 93 BE618C Fig BE 91 Wiper Motor Rear window washer 1 Rear window w...

Page 446: ...ow Wiper and Washer Switch Body Electrical System INSPECTION Wipeer motor Inspect wiper motor as follows I There should be continuity be tween terminals CD and 2 Apply positive DC 12 volt to terminal and negative to terminal CD and motor will rotate Check continuity between termi nals and ID and and Continuity should repeat ON and OFF periodically A J D ell W J BE622C Fig BE 95 Rear Wiper Motor Re...

Page 447: ...osening reo taining screws 7 Install clock in the reverse order of removal RADIO REMOVAL AND INSTALLATION Radio receiver Disconnect battery ground cable 2 Disconnect console box harness connectors and antenna feeder cable 3 Remove console box 4 Remove stereo ifso equipped 5 Remove radio by loosening reo taining screws 6 Install radio in the reverse order of removal BE47 Speaker I Disconnect batter...

Page 448: ...e printed inside the rear window glass Therefore the element cannot be removed INSPECTION Defogger switch Test continuity of switch with test lamp or ohmmeter Test must be carried out with switch at both ON and OFF See Fig BE 102 J CD r 1 I SWITCH e i 1J BE628C Fig BE 02 Checkill lDefogger Switch Rear window filaments Rear window defogger filaments can be inspected for circuit breaks by one of thr...

Page 449: ...ing pen Unit rom in BE540 Fig BE I06 PO itioning Ruler 4 Wipe clean silver composition from tip of drawing pen S After repair has been completed check repaired wire for continuity This check should be conducted 10 minutes after silver composition is deposi ted Note Do not touch repaired area while test is being conducted Drawing pen M Rear window I Hcat wire fOii 2 Silver composition L 3 Ruler BE5...

Page 450: ...r or test lamp 8 7 U NOOWNI I 1 UP N OOWNI qHT 10 ra 10 9 8 16 6 6 1 3 IUP N DOWN 1 UP N OOWNI 5 01 b J 9 01 b I o b 17 b b I 6 5 I 6 I I I CD Power window rear switch YL IUP N OOWNI 11 b 0 I i 15 66 1 Front door L U 2 Front door R H 3 Re door L U 4 Rear door R H 5 Center lock Power window otor Circuit breaker Test as follows I Set up a circuit as shown in Fig BE 112 2 Gradually decrease rheostat ...

Page 451: ...Battery I2V OC Rheo tat f f Body Electrical System M Circuit breaker Ammeter DC BE632C Fig BE 112 Circuit Breaker BE 51 ...

Page 452: ... the AIR lever which seleclS the air outlet the TEMP lever which control the temperature and the FAN switch knob which regu late airtlow with the fan Heater ducts for cear seat occupants are standard equipment on European and Australian models Body Electrical System To defroster Outside air To rear heater duct To center venlUator 0 I 2 3 4 Intake door Blower Heater duct Heater core 5 Floor door 6 ...

Page 453: ...ired air now n 0 HEAT position ove the le ZTurn the knob to the the desired temperature desired air flow z rn the knob to the desired air flow DEF position J rr Move the lever to the desired temperature t L Turn the knob to the desired air flow Inside air Outside air To rear heater duct Approx 15 To center ventilator o Outside air To center ventilator Approx 50 o To floor Approx 25 To defroster Ap...

Page 454: ...nit Water cock I Disconnect battery ground cable 2 Drain engine coolant 3 Remove dash face finisher if so equipped and defroster duct on the right side 4 Disconnect outlet and inlet hoses and loosen clamp of hose connecting water cock to heater unit 5 Disconnect temperature control cable and air mix door rod connecting air mix door lever to water cock lever 6 Remove screws attaching bracket to hea...

Page 455: ...126 4 1 2 3 AC909 Fig BE J26 AdjustingAirmix Door Rod Ventilation door rod Press link against stopper A and secure ventilation door rod to ventila tion door lever while pressing door lever in the direction of arrow in Fig BE 127 toward closing side of ventilation door t Ventilation door 3 Stopper A lever 4 Link 2 Rod AC910 Fig BE 127 Adjusting Ventilation Door Rod Floor door rod Press link against...

Page 456: ...exist Fan awltch Test continuity through fan switch with a test Ia1nP or ohmmeter See Fig BE 131 OFF 1ST 2ID 3RO 11 0 14 I 5 0 16 11 I 8 U u U Resistor There should exist continuity be tween terminals of resistors although values of resistors are different STARTING SYSTEM For automatic transmission models REMOVAL AND INSTALLATION Inhibitor switch Disconnect battery ground cable 2 Remove nut retain...

Page 457: ...m I Disconnect battery ground cable 2 Disconnect pair oflead wires 3 Loosen lock nut on switch body 4 Remove kickdown switch by rotating switch body 5 Install in the reverse sequence of removal noting the following After installing adjust kickdown switch Refer to Accelerator System for adjustment Section FE Downshift solenoid I Disconnect battery ground cable 2 Disconnect lead wires 3 Remove solen...

Page 458: ...rm raised excessive current still flows due to rare short circuit of motor armature Windshield wiper stops when lightly held with hand due to worn motor brush With arm raised excessive current still flows 3 to 5A due to seized motor shaft Low source voltage Humming occurs on motor in arm opec ating cycle due to seized arm shaft Improper switch contact BE 58 Corrective action Replace motor Replace ...

Page 459: ...ntact due to foreign matter Improper connection between 1st and 2nd switch steps Incomplete auto stop operation Contact is not interrupted BE 59 Corrective action Raise arm and operate windshield wiper without applying load Clean windshield glass and or replace wiper blade Replace motor Remove auto stop device cover and clean contacts carefuUy so as not to deform relay plate Remove switch and make...

Page 460: ...ttery is faulty Probable cause Line voltage below 10 volts Wiper switch faulty Wifing faulty Intermittent amplifier faulty Line voltage too high Wiper motor auto stop mechanism faulty Intermittent amplifier faulty Line voltage belo 10 volts Wiper switch faulty Wiring faulty Intermittent amplifier faulty Wiper motor faulty Intermittent amplifier faulty Wiper switch faulty Wiring faulty Intermittent...

Page 461: ...and horn relay terminals are connected with a test lead Faulty ignition and accessory relay Faulty horn or loose horn terminal con nection Short circuited horn button and or horn button lead wire When blacldead wire i5 disconnected from hom relay terminalCV horn stops sounding Faulty ho n elay Loose or poortconnectorcontact Fuse relay horn and or horn button F ulty horn iBE 6l Corrective action Re...

Page 462: ...y or primary breaker side This wal result in improper engine operation Charging system Sound of alternating current present Alternator Install a O 5 lf capacitor to charging terminal A Note Do not nse a huger capacitor When accelerator pedal is depressed or released noise occurs Voltage regulator Install a O 5I F capacitor to IGN terminal of voltage regulator POWER WINDOW Condition Probable cause ...

Page 463: ...loor door or faulty seal Defroster nozzle or demister nozzle plugged Leak at defroster duct or demister hose to nozzle connection Fuse melted Motor wire connector disconnected Faulty switch Motor inoperative Inner wire rubbing against outer case end Control cable bent exoessively Malfunctioning doors door levers etc Loose bolt in blower motor BE 63 Corrective action Check thermostat Replace as nec...

Page 464: ...use lamp is turned off When an doors are fully closed with engine running lamp is turned off When ignition switch is in ON position lamp is turned on and when engine is started lamp is turned off When ignition switch is in ON position lamp is turned on and when engine is started lamp is turned off When engine is started lamp is turned off ON ON BE 64 The following table shows the conditions of the...

Page 465: ...L SWITCH WeD DIODE DOOR SWITCH G T ROOM a SEATBELT TIMER DIODE BOX ANI l UNIT I CHARGE WARNING LAMP BRAKE WARNING LAMP I SEAT BELT WARNING LAMP 1 DOOR WARNING LAMP I l cj FUEL WARNING LAMP I PARKING BRAKE WARNING LAMP 0 HAND BRAKE SWITCH IGNITION SWITCH I JBillCCI BII Sf IlCCI 0 01 16 I I 0 ISI I 00 I I 10 1000 OIL PRESSUREWARNING LAMP si lllC 4 ISa C C IlII ril n OJ0 I Co m 0 o r ilL a Ul III III...

Page 466: ...r JI i or or 5 f I a 51 z w jJJ Ir J f t Q 0 t Q Q a a J Jz 0 0 OZ t or Ju Q 0 t x o co w l u A J W a a o w U Ir E z w a U h jl ffi il t 1 0O j l i I 01 co eN z I mo x oo m 6 0 5 Q I g61 00 1 3 ID lIDt I BE720C Fig BE J36 Circuit Diagram or Stop and Toil Lamp Monitor System BE 66 ...

Page 467: ...is unfastened Conversely there should not be continuity when fasten ed SEAT BELT WARNING TIMER UNIT REMOVAL AND INSTALlATION See Fig BE II 1 Disconnect battery ground cable 2 Remove dash face finisher Body Electrical System 3 Remove relay mounting bracket which retains main harness and dash harness connector 4 Disconnect harness connector 5 Remove seat belt timer unit by loosening retaining screws...

Page 468: ... AND INSTALLATION See Fig BE II I Disconnect battery ground cable 2 Remove right side front seat 3 Disconnect harness connector 4 Remove sensor CAUTION Do no1drop sensor 5 Install sensor in the reverse order of removal INSPECTION Test cpntinuity through tail and stop lamp sensor with a test lamp or ohmmeter See Fig BE 141 Tail lamp m nitor To test circuit for tail lamp moni tor connect terminal to...

Page 469: ...robable cause Burnt bulb or loose bulb Faulty timer unit Loose or poor connection Faulty printed circuit board Faulty seat belt switch Loose or poor connection BE 69 WARNING LAMP SYSTEM INSPECTION Check can be made by removing combination meter T st continuity through multi pole coonce1tor and 2 pole connector of combination meter with ohmmeter or test lamp See Fig BE 60 Corrective action R place ...

Page 470: ...j 1ie offuei Probable cause Burnt bulb or loose bulb Faulty voltage regulator When door and fuel warning lamps only do not glow Loose or poor connection Faulty printed circuit board Faulty diode box Faulty voltage regulator or alternator Corrective action Replace bulb or COrrect Replace Correct connector terminal contacts Replace Replace Correct adjust or replace Check charge warning system Oil pr...

Page 471: ...s turned to 1st or 2nd position Monitor lamp does not glow Probable cause Burnt bulb or loose bulb Faulty printed circuit board Faulty stop tail lamp sensor Burnt stop or tail lamp Faulty stop lamp switch Faulty printed circuit board Burnt or loose monitor lamp BE l COnIiective action Replace bulb or correct Replace Replace Replace Replace Replace Replace or correct ...

Page 472: ...AC 20 AC 21 AC 21 AC 22 AC 22 AC 23 AC 24 AC 25 AC 25 AC 25 AC 26 AC 26 AC 27 AC 27 AC 30 AC 31 VACUUM CHECK VALVE AIR INTAKE DOOR ACTUATOR AIR INTAKE DOOR SOLENOlD IJ LVE DELAY RELAY AIR INTAKE DOOR SOLENOID VACUUM SWITCH Magnet valve VACUUM HOSE DIAGRAM WIRING DIAGRAM COMPRESSOR MODEL 132 AXIAL PRELIMINARY CLEANING COMPRESSOR CLUTCH SHAFT SEAL SUCTION AND DISCHARGE CONNECTORS FRONT AND REAR CYLI...

Page 473: ... into a liquid by absorption of its heat by the cold water 1 Imliill IIi8h preSSOIe gas IIi8h pressure liquid Co pressor t The cooler operates on this princi ple The liquid used is the refrigerant R 12 The heat inside the passenger compartment is absorbed by changing the refrigerant from a liquid to a gas and then dissipated to the outside by changing the refrigerant from a gas back to a liquid LW...

Page 474: ... in the high pressure line The plug melts when its temper ature reaches I050C 22IOF and discharges high pressure refrigerant gas into the atmosphere If it melts the entire receiver drier assembly must be replaced From To expansion condenser valve A EXPANSION VALVE D The expansion valve restricts the flow of liquid refrigerant as it passes through it and delivers sprayed refrig erant to the evapora...

Page 475: ...addition it has bi level and ventilation functions Its control system consists of a mechani cal system using cables and engine vacuum and electric system The air conditioning unit is in stalled in the passenger compartments l o c d e so fo ll 3 Ooo s li 0 till e ii Eo E 5 c 0 0 0 0 ti 8 icc o NM lt f QI OOO lO AC030A Fig AC4 Air Conditioning Unit and Air Flar AC 4 ...

Page 476: ...x door Ventilation Compressor lever Air intake door and Water cock door Floor door Blower motor and F I actuator I OFF I OFF COOL A C I Recirc air 100 Open Closed I ON VENT A C I Outside air 1 3 Open Closed I ON Recire air 2 3 BI LEVEL I Out ide air 100 lopen lopen I OFF BI LEVEL I Controlled by I REC ON Recire air 100 temperature lopen lopen ON ON lever HEAT I Outside air 100 Closed Open I OFF HE...

Page 477: ...witch Magnet vein While the vacuum switch coil is energiZed by n lectric current vacuum is imposed on the fast idle actuator side When current to the coil is inter rupted passage on the 4 way con nector side closes leaving the fast idle actuator side open to the atmosphere AC 6 ni Air intake door solenoid Air intake door actuator AC236A Fig AC 6 Vacuum Syttem Fast Idle actuator The device is a vac...

Page 478: ... temperature The rotary switch also regulates the current flow to the air intake door solenoid valve and the air intake door solenoid in order to determine the to position of the air intake door T te RECIRC switch which is 10 cated between the air ilitake door i9Ie n W yaI e a d the rotary switch is ELECTRICAL CIRCUIT lo ieleCtion of the internally circu ted air in the BI LEVEt and the HEATposiiio...

Page 479: ...cl l R S Rtt Rt i oIII fCtl R J f coOL C pO IOl1 0toT f R f 1 5E f l 8I O lI1 11 01 0 11 8 E IE po IOl1 RECljlC yj tC co t u 1 M lU SliIlTCIoI AIlItIMlll 1 tOOOJ l O ENO O vAl liE llt l Io iRe T JlIt 1IlE1 AlRJtt JOO1 WtI USI9NII IATltfl i 01 0 ilitft MOtOR fl5t r l ffoM 5 l ITl l VACUUIol111 1 1 1 IIolll1P4 I I tOooO O tN010I Ilt olS s t J Off SWi l tl l O t Oll c lv 5 1 l It MflEl 1 1 Jl LA I AI...

Page 480: ...OR l 1 11 l I I I i i I i It I L J ROTAR l WHet B L r V RELAY IONI1 ION SWfTtH IG e l l IGNITION r S TCH I I f 1 RECIRC SWITCH 5111 2 r f 1 rR rF ir I L AHEAY I I I 1 v I 1 J j W H t l5WHC ROTA Eh fU5181E LINl FUSIBLELINK 1 T THEIlJolOST ll VACUUMSWITCH 20 BATTERY AlRINTAKESOLENOIDVALVE OEl A RELAY i J Il T1 lER RELAY 41 l n 1e 00 l t E 0 L J 1 g U t BOO 8 T THERMOSTAr RECOIIC s ncH I o liW lR 1 I...

Page 481: ...arried out only by well trained servicemen This chapter de scribes essential points ofservicing If a large amount of dirt and sand enter the system they will be carried with refrigerant and may clog the system or scratch rotating parts This points out the need for care in seivicing the system That is disconnecting joints should be carried out in a clean place Water should not be allowed to get ins...

Page 482: ...losion of the system The above precautions are essen tial in handling of Refrigerant 12 and their strict observation requires sufficient training Therefore it is of first impor tance that any other personnel than a well trained serviceman should not be allowed to handle the refrigerant EVACUATING AND CHARGING SYSTEM During servicing use caution to keep air from getting into refrigerant When air en...

Page 483: ...ly build up at the low pressure side of system and air may be sucked in In addition dirt and dust will easily enter the valve result ing in foreign matter entering the system CAUTION 00 not over tighten valve cap AC 12 2 Oleck valve Will be half opened during connection and disconnection of charging hoses and refrigerant will be forcefully discharged Therefore connect and disconnect charging hoses...

Page 484: ...also connect low pressure suction serv ica valva to that of manifold gauga For locations of high and low pres SIIre discharge and suction service valvas sea Fig AC 35 3 Open both manifold gauge valves slightly and slowly discharge refriger ant from system See Fig AC 15 WARNING Protect fingen with cloth against frostbite by refrigerant whan con necting the charging hose to the service valve or disc...

Page 485: ...re gauge b The rate of 1I of the low pressure gauge should be I than 3 3 kPa 25 mmHg I inHg in five minutes If the pressure rises or the specified negative pressure can not be obtained there is a leak in the system In this case immediately charge system with refrigerant and repair the leak de scribed in the following I Confirm that both valves of manifold gauge are fully closed and then disconnect...

Page 486: ...ifold gauge and charge refrigerant into system See Fig AC 17 Note When refrigerant charging speed is slow immerse refrigerant can in water heated to a temperature of about 4O C I 040 F See Fig AC 18 WARNING a Under any circumstances the reo frigerant can must not be warm ed in water heated to a temper ature of over 520C 1260F b A blow torch or stove must never be used to warm up the can Air Condit...

Page 487: ...le Make a note of the amount charged from can AC252 Fig AC 21 Charging Refrigerant AC 16 Refrigerant capacity Unit kg Ib Minimum Maximum 0 9 2 0 1 2 2 6 Note The presence of bubbles in sight gIass of receiver drier s an unsuitable method of checkfug the amount of refrigerant charged in system The state of the bubbles in sight gIass should ouly be used for checking whether the amount of chuged refr...

Page 488: ...pe ELECTRIC LEAK DETECTOR NO LEAK Greenish blue Pale blue For the operational procedures SMALL LEAK Yellow Bright blue refer to the instructions furnished with LARGE LEAK Purple Vivid green each electric leak detector Discharge refrigefanl in one or two seconds to ascertain that system has a sufficient pressure needed for leak detection Charge with 0 4 kg 0 9 Ib of refrigerant if necessary 2 Ught ...

Page 489: ... A r I I AC257 Both pressureson high and low pressure sides are slightly low Check for gas leakage repair as required re plenish and charge system of about five minutes Judge according to the following table Suitable Too much refrigerant High pressure side is hot and low pressure side is cold High pressure side is abnormaUy hot Almost tran arent Bubbles may appear when engine speed is raised and l...

Page 490: ...rvice valves of the system Refer to Handling Manifold Gauge 5 Set air lever to A C position 6 Set temperature lever to maxi mum cold position 7 Set blower to its highest speed 8 Start the engine and hold engine speed at 1 500 rpm 9 After the air conditioner has been operated for about 10 minutes meas ure system pressures at high pressure discharge side and low pressure suc tion side 10 Measure the...

Page 491: ... engine speed to 800 rpm using following procedures as a guide On cars equipped with automatic transmission make this adjustment with shift control lever in N posi tion Air Conditioning SERVICE PROCEDURES Engine When AC is OFF 124S 650 700 at N range 124S Push down plastic stopper and ad just lever stroke so that engine speed is 800 rpm See Fig AC 2S 2 Depress and release accelerator pedal several...

Page 492: ...pplied midway between idler pulley and compressor pulley COMPRESSOR Compressor pulley AC045A Fig AC 26 Belt Terulion I Loosen idler pulley lock nut and then adjust pulley by turning adjusting bolt 2 After adjustment tighten idler pulley lock nut I Tightening torque 44 to 54 N m 4 5 to 5 5 kg m 33 to 40 t lb AC 21 REMOVAL AND INSTALLATION AC899 Fig AC 27 Idler Pulley and B cket Loosen idler pulley ...

Page 493: ...Upon installation of compressor turn compressor clutch by hand a few turns 5 For tightening torque on refrig erant line fittings refer to Refrigerant Line 6 For compressor drive belt ten sion refer to Idler Pulley and Com pressor Drive Belt 7 Evacuate and recharge system Refer to Evacuating System and Charging Refrigerant in General Serv ice 8 Conduct leak test and make sure that there is no leak ...

Page 494: ...tening torque refer to Re frigerant Line 6 For evacuating and charging CAUTION Plug all openings to prevent entrance of dirt end moisture REFRIGERANT LINES AC 23 system refer to General Service 7 Conduct leak test and make sure that there is no leak from connections INSPECTION Check receiver drier for leaks or damage Ifnecessary replace 1 Condenser 2 Receiver drier 3 Com pressor 4 Cooling unit Tig...

Page 495: ...uD up all OpenillllS to prevent entrance of dirt and moisture Air Conditioning 4 Remove glove box and dash face finisher 5 Remove defroster duct and second connector on passenger s side 6 Disconnect wiring harness con nectors from compressor relay and thermostat 7 Remove upp r mOllnting bolt and lower right and left mounting brackets and then remove cooling unit from dash panel DISASSEMBLY AND ASS...

Page 496: ...evaporator Refer to Cooling Unit 3 Remove heat insulator covering sensing bulb 4 Remove clamp attaching sensing bulb S Loosen flare nuts and remove expansion valve from evaporator and inlet pipe CAUTION Plug all openings to prevent entrance of dirt and moisture 6 Installation is in the reverse order of removal THERMOSTAT REMOVAL AND INSTALLATION I Remove cooling unit Refer to Cooling Unit for remo...

Page 497: ...outlet of heater unit to tile front and bring side ventilator outl iinto co llacl with instrument panel Then remove heater unit by rotating the whole unit in such a manner that air inlet contacts the floor See Fig AC 37 12 Installation is in the reverse order of removal Concerning adjust ment of control cable refer to Adjust ment of Control Cable I Side ventilator outlet 2 Air inlet 3 Defroster no...

Page 498: ...ontinuity of each fuse referring to the following continuity diagram AC068A Fig AC 40 Ruistor AC 27 AIR CONDITIONER CONTROL REMOVAL AND INSTALLATION I Disconnect battery ground cable 2 Remove control box dash face finisher and defroster ducts 3 Pull out control knobs 4 Disconnect radio from center bezel 5 Remove center bezel with clock 6 Disconnect temperature control cable and air control cable f...

Page 499: ...ter Consult the con tinuity diagram described in Fig AC42 through AC44 Rotery switch Align mark compoation o VENT position 7 Bl LEVEL position DE REAT position pOSItion COOL W I um BUT OU o8g g 01 5 b 8 0 600 AC244A Fig AC 42 Rotary Switch Fan switch em 1 OFF LOWIMEDI H II 5 2 3 T AC245A Fig AC 43 Fan Switch AC 28 ...

Page 500: ...ot mark on control switch with COOL A Cposition mark as shown in Fig AC 4S 2 Set air control lever in COOL AjC position Align dot mark on air control lever with dot on control switch then install control switch ADJUSTMENT OF CO TROL CABLES Temperature control cable I Set temperature lever in maxi mum cold position 2 Temporarily tighten control rod mounting screw Yt f t t t ...

Page 501: ...lever 2 Rod 3 Stopper A 4 Link AC910 Fig AC 48 Adjusting Ventilation Door Rod Floor door rod Prelink against stopper B and secure floor door rod to floor door lever while pushing door lever in the direction of arrow in Fig AC 49 to ward closing side of floor door 1 Stopper B 2 Link 3 Floor door lever 4 Saew AC057A Fig AC 49 Adjusting Floor Door Rod Air control cable L Set air control lever in VENT...

Page 502: ...ee Fig AC 53 Air Conditioning S Test lamp should go out auto matically after 9 to IS minutes If not replace timer relay I I AC107A Fig AC 53 Removing Low r Brackett Attaching Bolt 6 Remove upper and lower nuts securing blower assembly ana remo bracket tightening cooler unit assem bly and blower assembly together AC 31 b 8 00 4 5 AC066A Fig AC 51 Timer Relay 1 Vacuum check valve 2 Air intake door a...

Page 503: ...uum hose and lead wires from air intake door solenoid valve at connector 4 Remove screws retaining solenoid valve to blower case and then remove solenoid valve AC064A Fig AC 55 Removing Air Intake Door Solenoid Value S Installation is in the reverse order of removal INSPECTION I Check relay for continuity be tween yellow green and black leads using ohmmeter or test lamp 2 Apply 12V DC voltage betw...

Page 504: ... nut securing vacuum switch Vacuum switch and fast idle actu ator can be removed together as one unit assembly Vacuum switch side Mk M Check valve To boost meter 4 way connector it To intake manifold AC 33 3 I Vacuum switch 2 4 way connector 3 Attaching nut Fig AC 58 AC248A Removing Vacuum Switch 4 Installation is in the reverse order of removal INSPECTION I Test continuity in solenoid valve with ...

Page 505: ... VlI1 1I YELLOVl STRIPE GREEN VlI1 1I VlIII1 E STRIPE VlIII1 E VlI1 1I REO S I IPE w toIo01 OR t Jj f i GN nON J f tj l Lt GB fp N S IITCII l Cl C g S o l oo 0 t o Scl B 1 IIERtoIoOS1 p 1 a C E OOOR p IRISOLENOIO ELp 1 OIOOE c s C O Jp CUUtoIo SWI1 CII p lR IN1 p E DOOR SOLENOID Jp L JE toIop GNET OELp I RELp I CLU1 CII t l il 5 Pn z t J BODY Ep R1 1I ...

Page 506: ... CIRCUIT DIAGRAM OF ILLUMINATION LAMP FUSIBLE LINK o a m FFII t 12nd b I lOA LIGHT SWITCH AC 35 AIC CONTROL ILLUMINATION LAMP AC071A Fig AC 61 Circuit Ditzgram ofl11u ination Lamp J i t r N t Xu f b tXij r a S 4 i J i ...

Page 507: ...d 16 Gasket 17 Fr ont discha r8e vaive plate assembly 18 Suction valve plate 19 Key p C 36 20 Discharge connector n Gylinder shaft assembly 22 Oil drain plug 23 Oil dIe plug 24 Rear discharge plate assembly 25 Oil pump gear 26 Rear cylinder head 27 SUainer 28 Suction connector Tightening torque N m kg m ft lb 13 to 16 1 3 to 16 9 to 12 4 to 6 0 4 to 006 2 9 to 4 3 7 to 10 0 7 to 1 0 5 1 to 7 2 18 ...

Page 508: ...emoving Snap Ring 4 Place Puller Pilot KV99233040 over compressor shaft and pull off pulley assembly using suitable pulley puller See Fig AC 102 CAUTION a 00 not attach puller teeth to pulley except at designated spots as shown in Fig AC l0l or pulley may be deformed b Be sure to use pulley puller with Puller Pilot KV99233040 AC136A Fig AC IOl Removing Pulley Assem bly AC37 n 5 Loosen coil mountin...

Page 509: ...shim and readjust Air Clmditioning ACl38A Fig AC 104 Checking Clearance Note When replacing compressor clutch assembly do not forget break in operation acc omplished by engaging and disengaging the c1utcb some thirty times Break in operation raises the level of trans mitted torque SHAFT SEAL REMOVAL I Remove oil ftIler and drain plugs drain compressor oiL ACl39A Fig AC I05 Draining Oil 2 Remove cl...

Page 510: ...he end of com pressor shaft 3 Coat O ring and carbon seal face of shaft seal with clean compressor oil Note Make sure that shaft seal is free of dirt 4 Engage shaft seal with the tip of Shaft Seal Remover Installer KV9923S 140 With shaft seal and cut out of drive shaft aligned insert shaft seal into bore of neck of compressor body KV99267080 Cutout AC157A Fig AC 115 InsertingShaft Seal 5 Insure th...

Page 511: ...its groove toward comp or See Fig AC H4 t ACl46A Fig AC 116 CheckingGa Leakage SUCTION AND DISCHARGE CONECTORS REMOVAL CAUTION 00 not leave compressor on its side or upside down for more than 10 minutes a compressor oil will enter low pressure chamber I Remove discharge connector by loosening bolts with alien wrench Then remove O ring and strainer AC 40 AC147A Fig AC I7 Removing Di8charge Conn OL ...

Page 512: ...move and discard D rings and gaskets 8 Carefully remove discharge valve plate assembly and suction valve plate If cylinder head discharge valve plate and suction valve plate are re moved as a unit screw a suitable bolt into threaded hole in discharge valve plate assembly to drive out suction valve plate and discharge valve plate u AC152A Fig AC 122 Removing V lve Plate Assembly CAUTION a When remo...

Page 513: ...ad bolts Tighten bolts evenly First give each a short turn then another Finish tightening on third round l l Tightening torque Socket head bolt 20 to 24 N m 2 0 to 2 4 kg m 14 to 17 ft Ibl AC150A Fig AC 126 Sequence ofTight ing AC 42 9c Install shaft seal Refer to Shaft Seal for installation 10 Conduct a leak test Refer to Shaft Seal for gas leak test II Install and adjust compressor clutch Refer ...

Page 514: ... em nd harle the syuem A nl essary replll e UTlc Insufficient coolinB No bubbles in light slau With manifold pUIC check IYStem pressure Melly temperature of discharF Refer Performam Tell Air YSII I may cause bubhb Sigh I gllU System pressure and temperature of disc har e air are abnormal Refer Performance Tell DiI3 05CS for detail I Headprelsure is hlah I Overcharp of refnaczul Disdlarp some of re...

Page 515: ...SION VALVE I Slight cooling Sweating or frosted expan sionvalye inlet ef lil 1 AC21QA AC 44 Expansion valve restricts refrigerant flow Expansion valve is clog ged Expansion valve is in operative Valve siuck closed Thermal bulb has lost charge ga scaJe iDdicat 8 range based on the assumption that the air conditioning system is in good order Corrective action 1 Leak test 2 Repair leak 3 Charge syste...

Page 516: ... Probable cause Expansion valve allows too much refrigerant through evaporator Faulty expansion valve Air mixed with refrigerant in system Drier is saturated with moisture Moisture has fro zen at expansion valve Refrigerant flow is restrict ed COffective action Check valve for operation If suction side does not show a pressure decrease replace valve I Discharge system 2 Replace valve 3 Evacuate an...

Page 517: ...ressure line Internal problem in com pressor or damaged gasket and valve Corrective action Check fan belt and nuidcoupling Check condenser for dirt accumulation Check engine cooling system for overheat Check for refrigerant overch rge Note If pressure remains high in spite of aU above actions taken re move and inspect the condenser for possible oil clogging I Discharge system 2 Remove receiver dri...

Page 518: ...IN I SYSTEM Excessive Insufficient cooling AC218A AC 47 Probable cause Too much oil circulates with refrigerant causing the cooling capacity of the system to be reduced Corrective action Refer to Oil Level Check for correcting oil level I Jr f ...

Page 519: ... motor L LighION I Check lead w1e connection and when no problem is fClUnd replace relay Blower motor inoperative Check fuse AC48 Fuse OK I Ground one of lead wires blue green I speed blue red 2 speed blue white 3 speed leading to blower switch Blower does not run t Ground blue white wire of blower motor Blower does not run I I Connect 12 volt test light to blue wire leading to blower motor Light ...

Page 520: ...I I DischuFlyltemfromservlceYi VII disd1arp IIde E leu te and rechar the system MIen torque Is till peat rcpUr replKe comprtQOr 8eltalippinJ Cbedr belt tenJion andadjusI it If bell II worn out or um pd plaalt II SNuml comprtllOr I lnttmal problem In comprellOr cyl Inder Checkl tem Repair o replace ifnccelllry CompreSlOf oilleakin Alr blow on pot where oil teak CV ldence found Thm check for refnpr ...

Page 521: ...make surt of proper ction Further check lead wire clion nd if problem found replace fan blower switch Connectl2 volt test light lablue yellow wire to compressor day Ground the other end of test light 1 Light ON I Light OFF Ii Check lead wirt conneCtion If problem is folind eplace cumpRssor day Connect 12 voll test li3ht between Iwobtuel yellow wires of thermostat Ii t LighlON Il p I Ugh OFF I of 1...

Page 522: ...r Discharge air Air intake door Air source Compressor and F IC D Air temperature Blower motor Operation Condition Open Outside air 100 OFF OFF Closed Recirc air IOO OFF OFF Side and center ventilators Closed Recirc air 100 ON Cold to Hot ON May be on or off by switching thermostat on Ol off Side and center ventilators Partially open Recirc air 2 3 ootside air 1 3 ON Cold to Hot ON May be on or off...

Page 523: ...d the BI LEVEL position is restored The switch may be turned OFF by setting it manually to FRE position OFF ON 2 Operation lamp ON Discharge air Air intake door Air source Compressor and F LC D Air temperature Blower motor Discharge air Air intake door Air source Compressor and F LCD Air temperature Blower motor Floor front and rear seats and defroster Open Outside 100 OFF Cold to Hot ON Floor fro...

Page 524: ...witch and con nect vacuum tester to the open end of the hose and vacuum switch Light ON Light OFF Connect 12 volt test light to vacuum switch lead wire Check vacuum tube connector four way three way connector and hose If hose or connectors are damaged replace it Light ON Light OFF 1 f Replace vacuum switch Inspect circuit of vacuum switch Refer to Compressor Clutch Diagnoses i j Note Vacuum tester...

Page 525: ... is opened Remove hose from achla Ot and opefllte air con l ditioner No mlu J 1 Connect 11 0 eU light betWeen yeUowl peen and black connectors of air intake dOOl 101enoOO lve j I L Ligh Off L lnlpeCt electrical circuit of air intake door Ole old valve Refer to Wiring D f1gr8 fll J l Light ON J Check lead wire connection if no problem b found replace air intake door IOlenold wl r 810wer f Qtor runs...

Page 526: ...er piping When hose piping is correct connect 12 volt test light between yelloW I green and black of air in take door solenoid valve L r r Check hose connection f it is found normal replace r l actuator k j T 7 j f t li i I tf l t lf 1 ltA t j t 0 t t 1 r Light OFF L Inspect electrical circuit of air intake door solenoid valve Check delay relay air intake door solenoid and rotary switch for operat...

Page 527: ...lators only Ii Floor door is closed Adjust floor door rod and con trol cable Air comes out but outside air does not come in Air intake door actuator is not operatedRefer to Only inside air is being cooled in VENT AjC Position Air comes out but inside air does not come in Air intake door actuator is operatedRefer to Outside air is being cooled in COOL AjC Position l Air does not come out Blower mot...

Page 528: ...0 door operate Air in door ad and con rad and control u e door is in 0 trOl cable cable circulating air posi tion Refer to Only in side air is being cooled in VE f AIC position io4 lI i I Air doeS not corne out of heater outlets at 1oor le el in front and rear atS and defroste I 1 Blo ller motor runs Blo ller motor does 1 not run I floor door is 1 closedMiust floor door Refer to Blo ller ad and co...

Page 529: ...s too is l ot neale d eal aU too Air intaKe dOOI acluatot does not floor doo is o pened to neate enti alion doot is opened 10 out ets side and center ventilatots o perate Adjust float doOt rod and conttol Adjust venti atiOn doot tad and Refet to OnlY insIde alt is beIng cable canuol cable oled in f AIC osition CO I BloWet otot does not run Refet 10 Blowet M otOt DiagnOSlls YJ i os0 os SlP ...

Page 530: ...on Abnormal Cooler does not operate Normal Cooler operates I r Compressor clutch does not operate Refer to Compressor Clutch Diagnoses Air intake door actuator is operated Outside air 100 Refer to Outside air is being cooled in COOL A C Position ACS9 HEAT position f j J 1 t ...

Page 531: ...8 22 72 24 75 26 79 2B B2 20 68 22 72 24 75 26 79 28 82 2 5 to 3 8 36 5 to 38 8 4 4 to 5 7 39 9 to 42 3 6 3 to 7 6 433 to 45 7 8 1 to 9 9 466 to 49 B 10 0 to 11 5 500 to 52 7 3 B to 5 1 38 8 to 41 2 5 7 to 7 1 42 3 to 44 B 7 6 to 8 9 4S 1to 4B 0 9 9 to 109 49 B to 51 6 11 5 to l2 B 52 7 to 55 0 Pressure high Discharge side kPa kg cm2 psi 1 000 to 1 226 10 2 to 12 5 145 to 178 1 128 to 1 383 11 S t...

Page 532: ...8 1 30 x 1 016 Clockwise viewed from drive end SUNISO SGS 250 8 8 REFRIGERANT Type Capacity kg lb R 12 0 9 to 1 2 2 0 to 2 6 INSPECTION AND ADJUSTMENT BELT TENSION Fan belt applied pressure mm in N kg lb AC compressor belt applied pressure 8 to 12 0 31 to 0 47 98 10 22 8to 12 0 31 to 0 47 98 10 22 F I C D ADJUSTMENT Transmission Engine Manual L24S When A C is OFF 650 700 at oN range When F IC D is...

Page 533: ...ge connector bolt Suction valve bolt Suction connector bolt Oil filler plug Drain plug 4 Air Conditioning N m kg m ft Ib 44 to 54 4 5 to 5 5 33 to 40 44 to 54 4 5 to 5 5 33 to 40 29 to 34 3 0 to 3 5 22 to 25 44 to 49 4 5 to 5 0 33 to 36 N m kg m ft Ib 13 to 16 1 3 to 1 6 9 to 12 4 to 6 0 4 to 0 6 2 9 to 4 3 20 to 24 2 0 to 2 4 14 to 17 7 to 10 0 7 to 10 5 1 to 7 2 18 to 22 18 to 2 2 13 to 16 8 to ...

Page 534: ...ference page or Fig No Unit application Fig AC 98 132 AXIAL Fig AC 99 132 AXIAL Fig AC 101 Tool number tool name KV9923S14O Shaft seal remover installer DK970630IO Shaft handle KV99268080 Cylinder holder 132 AXIAL Fig AC 102 KV99267080 132 AXIAL Fig AC 108 132 AXIAL AC 63 Shaft seal guide Reference page 01 Fig No Unit application Fig AC 109 Page AC 39 132 AXIAL Page AC 39 132 AXIAL Fig AC 119 132 ...

Page 535: ...V E TH It U rml1 ft I al o 8 Wi BACK UP LAMP SW fONLY ANTI DIESELING SOLE NOlO IGNITION COIL RG I GLL mr f e I GW R YL r l L t FJ ev W LG 11 fl 1U I L l tt I O T f i l T I L VOLTAGE REGULATOR aRAKE FLUtD I ICKDDWN LEII L sw AITDNLY INTERMITTENT J f WIPER AMPLIFIER e friiWl III J 31II a J J 3 It III IP CI lIItZ lII lP i III eJ J tt ttJ i III F tbor RADIO COND ENSER f FUSE BLOCK USE IDA FUSES ONLY i...

Page 536: ...GR t HA R It FLASHER UNIT di L TURN SIGNAL FLASHER UNIT CJ GY STOP LAMP SW G y SEATBELT 0 SW W FRONT DOOR SW R H Q 8 D BR REAR DOOR SW R H ISEOAN ONL Y B c f JR BR J I I B Et YLl O liIIC LR L 1 1 I l itl j rrr ln m U t l1 l IT m T t M IP m J BW uo I I ol STOP AND TAIL L I Lr 9 fn ri1i j x 0 0 LAMP m rn B ff1 mO BLOWER L y gJI B rn MOTOR REAR WIPER SW SEAT8ELT RECIRe s N TIMER 6 FUEL PUMP 1011 DWEl...

Page 537: ... 0 REAKER l Y J USELESS YL SEDAN ONLY REAR MOTOR R H REAR AUTOMATIC TRANSMISSION 8 MANUAL TRANSMISSION This wiring di rlm hn been prepare the assumption that the ear fully equipped including all f cloryoptiol lll equipment COLOR COOE B BLACK W WHITE R RED G GREEN l BLUE Y YELLOW Lg LIGHT GREEN Br BROWN SWITCH AND RELAY POSITIONS 1 IGNITION SWITCH IN lOCK KEY REMOVED 2 LIGHTING SWITCH WIPER SWITCH ...

Page 538: ...n Co li O IT ffi XQoo L iTIDo lJ i J I 1 r fl f Jr 8 n I C v II r u u I ij II o Ii II 1 I r o o 4 k j o I G o co 0 jJ 0 t r II J 1 II 1 r 0 9 f l ued February 978 010 OO Iblication Io SM8E C210AO ...

Reviews:

No comments

Related manuals for C210 series

KC HiLiTES C Series Wiring Diagram preview
C Series
Brand: KC HiLiTES Pages: 4
Jeep Cherokee 16 1982 Technical & Service Manual preview
Cherokee 16 1982
Brand: Jeep Pages: 1311
Alpine eX-10 Installation Manual preview
eX-10
Brand: Alpine Pages: 8
DEFA 412737 Fitting Instructions Manual preview
412737
Brand: DEFA Pages: 7
Prorack K869 Fitting Instructions Manual preview
K869
Brand: Prorack Pages: 15
FORM FIT 1303 Installation Instructions preview
1303
Brand: FORM FIT Pages: 2
iRacing Porsche 911 GT3 R User Manual preview
Porsche 911 GT3 R
Brand: iRacing Pages: 25
Wagan Wireless Handsfree Car Kit User Manual preview
Wireless Handsfree Car Kit
Brand: Wagan Pages: 20
Unex OBU-352EC Quick Start Manual preview
OBU-352EC
Brand: Unex Pages: 30
true-i HMBS-200 User Manual preview
HMBS-200
Brand: true-i Pages: 11
Menabo YELO 4 NS Fitting Instructions Manual preview
YELO 4 NS
Brand: Menabo Pages: 8
Ford 2003 Mustang Workshop Manual preview
2003 Mustang
Brand: Ford Pages: 4378
Toyota 2013 Prius c Owner'S Manual preview
2013 Prius c
Brand: Toyota Pages: 549
Wald Black Bison Sports Series Installation Manual preview
Black Bison Sports Series
Brand: Wald Pages: 7
Mazda 0000-8E-N31 Installation Instructions Manual preview
0000-8E-N31
Brand: Mazda Pages: 7
APS iArmor IA-S159 Installation Instructions preview
iArmor IA-S159
Brand: APS Pages: 4
Harbor Freight Tools 95058 Installation And Operation Instructions Manual preview
95058
Brand: Harbor Freight Tools Pages: 8
Audiovox CDC-TO3 Installation Manual preview
CDC-TO3
Brand: Audiovox Pages: 2

Brands by name

Popular brands

Load more brands