Mazda 626 1981 Workshop Manual Download Page 1

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Summary of Contents for 626 1981

Page 2: ...LOC PART NO DESC QTY ORD 1 ti 1 11 BZDB 6 Y 9i 95 01YB 81 P74 I 5 I o rY b 26 1 I 3 1 8 i SHIP 1 4 114 1 INV LINE INV NO NV DATE DLR CODE ...

Page 3: ...IONS FRONT REAR Note After jacking up adjust and place safety stands to support the vehicle approximately level and lower the vehicle onto stands When placing safety stands take care not to damage the brake fluid and fuel pipes ...

Page 4: ...hicles and engines can be voided by improper service or repairs performed by persons other than an authorized Mazda dealer Strict compliance with the instructions in this manual is necessary to prevent loss of coverage under such warranties GENERA L SERVICE INSTRUCTIONS 1 If a vehicle is to be jacked up only at the front or rear end be sure to block wheels in order to ensure safety 2 After a vehic...

Page 5: ...he time of printing this manual All alterations to this manual occurring as the result of modifications will be notified by the issuance of Service Informations or supplementary volumes It is therefore re quested that the manual be kept up to date by carefully maintaining a follow up of these materials Toyo Kogyo reserves the right to alter the specifications and contents of this manual without ob...

Page 6: ... I C 17 Checking Piston Ring End Gap 1 12 l C 18 Connecting Rod Bearing 1 13 l C 19 Checking Connecting Rod Bearing Clearance l 13 l C 20 Checking Connecting Rod Side Play 1 13 l C 21 Checking Connecting Rod Alignment I 13 l C 22 Checking Main Journal and Crankpin l 14 l C 23 Checking Crankshaft Alignment 1 14 1 C 24 Main Bearing 1 14 l C 25 Checking Main Bearing Clearance l 15 l C 26 Checking Cra...

Page 7: ...aner 9 Air cleaner Note After removing the air cleaner cover the carburetor with a clean shop towel to prevent dust or dirt from entering 10 Wiring for 1 Distributor primary 2 Hightension cord and condenser IG coil to distributor 3 Pickup coil 4 Oil pressure switch 5 Alternator B tenninal 6 Alternator wiring coupler 11 Engine mounting nut right side 12 Wiring for I Water temperature gauge unit 2 F...

Page 8: ...the engine hanger Attach the sling to the hoist or other lifting device and take up all slack Pull the engine forword until it clears the clutch shaft Then lift the engine from the vehicle Before installing the engine to the engine stand remove the following parts from the engine 1 E G R pipe 2 Air injection pipe 3 Reed valve Canada 4 Air injection nozzle U S A 5 Air injection pipe joint Canada 6 ...

Page 9: ...install the chain adjuster guide 49 3953 260 3 Tum the crank shaft clockwise 4 Readjust the chain guide as explained on page 1 21 S If the protrusion amount exceeds 17 mm 0 67 in replace the chain Cylinder head I Rocker arm cover and gasket 2 Oil seals 3 Blind cover Note After removing the blind cover install the chain adjuster guide 49 3953 260 to prevent the slipper head of the chain adjuster fr...

Page 10: ...pivot 49 0221 222A and compress the valve spring 1 Taper sleeves 2 Valve spring upper seats 3 Valve springs outer and inner 4 Valve spring lower seats 5 Valve inlet and exhaust Note Place the taper sleeves upper spring seats valve springs lower spring seats and valves in order in a suitable case for reassembling Crankshaft pulley and clutch assembly Remove the crankshaft pulley and clutch assembly...

Page 11: ...n and sprocket 7 Crankshaft key 8 Vibration damper 9 Chain guide strip 10 Chain adjuster with chain adjuster guide 11 Oil strainer 12 Oil pump assembly Piston and connecting rod l Connecting rod caps and bearings 2 Piston and connecting rod assemblies 3 Piston pin Use the press and piston pin setting tool 49 8134 040 Arrange the installer 49 8134 042 and removing guide 49 8134 045 on the piston an...

Page 12: ...g a straight edge on the cylinder head surface Measure the clearance between the straight edge and the cylinder head surface with a feeler gauge If the distortion exceeds 0 15 mm 0 006 in grind with a surface grinder or replace the head Cylinder head hight Grinding Limit 1 C 2 Checking Manifold 109 0 05 mm 4 291 0 002 in 0 20mm 0 008 in Check the inlet and exhaust manifold for distortion To check ...

Page 13: ...kg 12 1 kg 20 9 lb 17 9 lb 31 4 lb 26 7 lb Filling length 32 0 mm 1 260 in 34 0 mm l 339 in 1 C 4 Checking Valve Remove all carbon from the valves Visually inspect all valves for warpage cracks or excessive burning and replace if any of these conditions are found Replace any worn pitted or corroded valves that can not be cleaned or refaced Measure the diameter of the valve stem at two or three pla...

Page 14: ...itable mounted dial indi cator or feel the clearance by moving the stem back and forth If the clearance is 0 20 mm 0 008 in or more replace the valve guide and valve 1 C 6 Replacing Valve Guide I Press out the old guide with the puller installer 49 0221 251A 2 Press in the new guide squarely with the same tool until the ring on the guide touches the cylinder head Note Inlet and exhaust valve guide...

Page 15: ...an up the valve seat Note a If the valve guides are to be replaced this must be done before refacing the valve seat b The valve seat ring is shrinkage fitted in the cylinder head However the seat ring cannot be replaced in view of maintaining strength 1 C 9 Checking Contact between Valve and Valve Seat After the valve or valve seat is ground check the contact between the valve and valve seat as fo...

Page 16: ...he rocker arm bore and shaft is 0 027 0 081 mm 0 0011 0 0032 in Inspect the clearance and if it is more than 0 10 mm 0 004 in replace the rocker arm or shaft 1 C 12 Checking Cylinder Block Clean the cylinder block with a suitable solvent Spe cial care must be taken when cleaning the oil pas sages coolant passages and cylinder bore to remove all sludge dirt and carbon deposit After cleaning use com...

Page 17: ... 39 The difference between the minimum and maximum values out of the 6 measured values is regarded as the amount of wear If the wear of cylinder bore is 0 15 mm 0 0059 in or more it should be honed or rebored Honing and reboring should be made to correspond to piston and rings oversize and to the recommended piston clearance of 0 036 0 075 mm 0 0014 0 0030 in The following oversize piston and ring...

Page 18: ...in rebore the cylinders and use the oversize pistons and rings referring to Par 1 C 13 A 79 954 0 01 mm 3 1478 0 0004 in B 79 980 mm 3 1489 in C 79 550 mm 3 1319 in 1 C 16 Checking Piston Ring Groove Remove the carbon from the piston ring grooves by using a ring groove cleaner or a broken piece of piston ring With a feeler gauge check the side clearance of the piston rings at several places If 1t ...

Page 19: ... kg 30 33 ft lb 4 Remove the bearing cap and measure the width of the Plastigauge using the scale printed on the envelope The connecting rod bearing clearance is 0 027 0 077 mm 0 0011 0 0030 in Correct if the clearance exceeds 0 10 mm 0 0039 in 1 C 20 Checking Connecting Rod Side Play Check the connecting rod side play with a feeler gauge The side play should be between 0 11 0 21 mm 0 004 0 008 in...

Page 20: ...m 0 0024 m Main journal 63 0 045 2 4804 0 0018 0 060 mm 0 0024 m 1 C 23 Checking Crankshaft Alignment To check alignment mount the crankshaft on the V blocks and apply a dial indicator Slowly rotate the crankshaft and note the reading on the dial indi cator The maximum allowable run out is 0 03 mm 0 0012 in If it is not within specification replace the crankshaft with new one 1 C 24 Main Bearing T...

Page 21: ...ar of the crankshaft Thrust bearings are available in the oversize of 0 25 0 50 and 0 75 mm 0 010 0 020 and 0 030 in 1 C 27 Checking Camshaft Clean the camshaft with a suitable solvent Check to see that the cam faces and journals are smooth and are not scored or worn Measure the cam height with a micrometer and replace the camshaft if it is not within the specification Standard Inlet Exhaust Limit...

Page 22: ...es and should be replaced as a set 1 C 30 Checking Camshaft Bearing Clearance Check the camshaft bearing clearance in the same manner for the connecting rod bearing clearance Note the following differences 1 The standard camshaft bearing clearance are 0 019 0 069 mm 0 0007 0 0027 in for the front and rear and 0 029 0 079 mm 0 0011 0 0031 in for the center Correct if the clearance exceeds 0 15 mm 0...

Page 23: ...heck the slipper head on the chain adjuster for wear or damage and the adjuster spring for loss of tension If they are defective replace with a new adjuster assem bly 1 C 34 Checking Chain Guide Strip and Vibration Damper Check the chain guide strip and chain vibration damper for wear or any damage and replace if they are defective 1 D ENGINE ASSEMBLY Assembling piston and connecting rod I Positio...

Page 24: ...ton ring 1 Fit the spacer in the bottom ring groove and install the guide rails on it 2 Install the second ring and then the top ring with a suitable installer Note a Be sure to install the rings with the inscription mark upward as the faces of the top and second rings are tapered b Do not expand the rings more than necessary to install also be careful not to burr the piston with the end of the ri...

Page 25: ...ip 7 Insert the rod shaped oil seals side seals into the grooves on both sides of the rear main bearing cap Note The side seals should be installed as shown in Fig 1 68 8 Fit the halves of the thrust washers to the rear main bearing cap with oil grooves toward the crankshaft thrust side 9 Install the main bearing caps 10 Tighten the bolts to 8 4 9 0 m kg 61 65 ft lb Note The main bearing caps are ...

Page 26: ...procket with the talley marks and nickel plated links aligned 2 Being careful not to change the relations of timing chain camshaft sprocket and crankshaft sprocket fit the crankshaft sprocket onto the crankshaft so as to flush the sprocket with the end of the crank shaft 3 Install the key on the oil pump shaft Note Install the wire to the chain and camshaft sprocket so as not to change the relatio...

Page 27: ... lb and bend the tab of the lockwasher 7 AJign the keyways of the crankshaft and sprocket and install the key Chain adjuster 1 Install the chain adjuster guide 49 3953 260 to the adjuster 2 Install the adjuster to the cylinder block Do not remove the chain adjuster guide until the chain adjustment is finished Chain guide strip and vibration damper I Install the chain vibration damper to the cylind...

Page 28: ...with 30 minutes Note If cleaning of the mating surfaces is difficult apply the sealer 8527 77 739 on the oil pan gasket and install the oil pan gasket in the block Flywheel and clutch Install the flywheel and clutch as described in Par 6 E Crankshaft pulley l Lock the flywheel with the brake 49 0118 271A 2 Install the crackshaft pulley to the crankshaft so that the key groove of the pulley aligns ...

Page 29: ...ormation shown in Fig 1 82 Care must be taken on the following points I The rocker arm shaft supporters are respectively interchangeable for the inlet and the exhaust 2 The oil pipe is installed with the oil ejection holes facing the camshaft In order to avoid vibration of the pipe after it has been installed the O ring fitted on the pipe is pressed into the hole for the pipe on the center bearing...

Page 30: ...to 8 2 8 8 m kg 59 64 ft lb in the sequence 5 Tighten the bolt attaching the cylinder head to the cylinder block 6 Lock the flywheel with the brake 49 0118 271A and tighten the camshaft sprocket lock nut to 7 0 8 0 m kg 51 58 ft lb with the spanner 49 0164 631 A Bend the tab of the lock washer 7 Aligning the key groove with the pin install the distributor drjve gear to the camshaft Tighten the loc...

Page 31: ...in cover 5 Install the blind cover and gasket for the chain adjuster to the chain cover and tighten the nuts Inlet manifold and carburetor assembly 1 Place the gasket on the cylinder head and install the inlet manifold and carburetor assembly 2 Tighten the attaching nuts 3 Connect the ventilation hose to the ventilation valve at the inlet manifold Thermostat 1 Position the thermostat in the housin...

Page 32: ...ghten 2 Place the drive belt on the alternator pulley and install the alternator strap bolt 3 Adjust the drive belt tension as described in Par 3 E Distri utor I Rotate the crankshaft in the direction of revolution until the No I piston is comming up on compression stroke and the ignition timing mark on the crankshaft pulley is in line with the indicator pin on the timing chain cover 2 Align the t...

Page 33: ...over and tighten the at taching nut to 0 15 0 2 m kg 1 1 1 4 ft lb 1 E ENGINE INSTALLATION Carry out the removing operations in the reverse order 1 F CHECKING COMPRESSION PRESSURE l Be sure the engine oil is at the proper level and the battery is properly charged 2 Warm up the engine to the normal operating tem perature 3 Remove all spark plugs 4 Set the throttle valve to the wide open position S ...

Page 34: ...TROL SYSTEM Valve IA 7 IA F 1 Checking Evaoprative IA A 11 Engine Speed Unit IA 8 Line IA A 12 Water Thermo Switch IA 8 IA F 2 Canister EXHAUST GAS RECIRCULATION IA F 3 Check and Cut Valve E G R SYSTEM IA 9 IA F 4 Purge Control Valve IA B 1 Inspecting E G R Control IA F 5 Water Thermo Valve Valve IA 9 lA F 6 Air Vent Solenoid Valve IA 8 2 Replacing E G R Control IA G HEAT HAZARD WARNING Valve IA 9...

Page 35: ...meter to the engine 7 Run the engine at 1 500 rpm and take a reading of the gauge If the reading is below 0 068 kg cml 1 psi replace the pump assembly b Checking relief valve l Operate the engine at idle speed 2 Disconnect the hose from the air cleaner 3 Check to see that the no air should flow out from the relief valve 4 Increase the engine speed to 4 500 rpm and make sure the air flows out from ...

Page 36: ...14 mm 0 4 0 6 in 3 Tighten the strap bolt and the air pump mounting bolt c Replacing drive belt 1 Loosen the air pump strap bolt and mounting bolt then move the air pump until the drive belt can be removed 2 Install a new belt and adjust the belt tension as instructed in this paragraph 1A A 3 Check Valve Secondary air a Checking check valve 1 Warm up the engine until it reaches normal oper ating t...

Page 37: ...the air injection manifold as described in Par I A A 4 2 Air injection nozzle Note If it is difficult to remove the nozzle remove the ex haust manifold and lightly tap the nozzle out with a lastic hammer Install in the reverse order of removing 1A A 6 Air control valve a Checking air control valve I Warm up the engine until it reaches normal oper ating temperature and stop the engine 2 Disconnect ...

Page 38: ...lve inlet manifold at the air control valve and connect the suitable T joint 8 Connect the suitable tube between the No 1 relief valve and suitable T joint 9 Connect the disconnected tube in Step 6 to the suitable T joint so that the inlet manifold can be led directly to the No 2 relief valve Air should be discharged from the outlet port of the air control valve 10 Disconnect the vacuum sensing tu...

Page 39: ...oses from the air control valve 3 Remove the bolts attaching the air control valve to the bracket and remove the air control valve Install the air control valve by following the removal procedures in the reverse order 1A A 7 Vacuum Delay Valve To check the vacuum delay valve proceed as follows l Disconnect the vacuum sensing tube inlet mani fold thermo sensor at the inlet manifold 2 Disconnect the...

Page 40: ...g tube air control valve vacuum check valve from the vacuum check valve 2 Make sure the air passes through the valve when only blowing If the air passes through the valve when sucking replace the vacuum check valve 1A A 9 Water Thermo Valve a Checking water thermo valve 1 Remove the water thermo valve 2 Immerse the water thermo valve in a container 3 Heat up the water gradually and observe the tem...

Page 41: ...es from the three way solenoid valve 3 Remove the three way solenoid valve attaching bolts and remove the valve 4 Install the valve in the reverse order of removing b Checking three way solenoid valve for No 1 relief valve I Disconnect the vacuum sensing tubes from the three way solenoid valve and vacuum pipe 2 Blow through the solenoid valve from the vacuum sensing tube Make sure the air passes t...

Page 42: ... 11 Engine Speed Unit a Checking engine speed unit 1 Connect the voltmeter to the terminal as shown in figure 2 Slowly increase the engine speed and record the engine speed at which the current flows to circuit The engine speed should be 1 200 l 00 rpm 3 Slowly decrease the engine speed and record the engine speed at which the current does not flow to the circuit The difference between the engine ...

Page 43: ...stop the engine 2 Disconnect the vacuum sensing tube from the E G R valve and pinch it 3 Disconnect the vacuurnssensing tube thermo senser inlet manifold at the inlet manifold 4 Connect the additional vacuum sensing tube to the inlet manifold and E G R control valve so that the inlet manifold vacuum can be led directly to the E G R control valve S Pinch the vacuum sensing tube connected in Step 4 ...

Page 44: ...A B 3 Vacuum Amplifier a Checking vacuum amplifier 1 Remove the air cleaner 2 Disconnect the vacuum sensing tube vacuum am plifier water thermo valve from the water thermo valve and connect a vacuum gauge to the tube 3 Run the engine at idle Disconnect the vacuum sensing tube carburetor vacuum amplifier from the carburetor and make sure that the vacuum reading shows 60 10 mm Hg 2 0 0 4 in Hg 4 Con...

Page 45: ... thermo valve 5 To install reverse the removal procedure Before installing it apply the sealing tape to the water thermo valve to prevent the coolant leakage b Checking water thermo valve J Disconnect the vacuum sensing tubes water thermo valve vacuum amplifier water thermo valve No 1 purge control valve from the waler thermo valve 2 Start the engine and run it at 1 500 rpm 3 Check to see that no ...

Page 46: ...e from the vacuum sensing tube Make sure the air passes through the valve and comes out from the air filter of the valve 5 If the three way solenoid valve does not operate properly replace with a new one 1A C OXIDIZING CATALYTIC CONVERTER SYSTEM 1A C 1 Catalytic converter Visually inspect the catalytic converter for burned condition cracks and corrosion To replace the catalytic converter proceed a...

Page 47: ...e the air flows out from it 4 Increase the engine speed and quickly release the accelerator The air should stop flowing to the valve outlet for a few seconds after releasing the accelerator If the air stops flowing for more than three seconds or does not flow out at all replace the valve b Replacing air by pass valve I Disconnect the vacuum sensing tubes and the air hoses from the air by pass valv...

Page 48: ... rpm 4 Replace the engine speed unit if necessary b Replacing servo diaphragm Remove the air cleaner and remove the parts in the order numbered left To install reverse the removal procedure After installing check the operation of the servo diaphragm as described in item c c Checking servo diaphragm l Connect a tachometer to the engine 2 Warm up the engine and make sure the engine operate at specif...

Page 49: ...ows l Coupler 2 Vacuum sensing tubes 3 Three way solenoid valve attaching bolt 4 Three way solenoid valve To install reverse the removal procedure f Checking three way solenoid valve 1 Disconnect the vacuum sensing tube from the servo diaphragm 2 Disconnect the vacuum sensing tube from the threee way solenoid valve 3 Disconnect the coupler 4 Blow through the three way solenoid valve from the vacuu...

Page 50: ...EMISSION CONTROL SYSTEM lA F 1 Checking Evaporative Line 1 Disconnect the evaporative hose from the canister 2 Connect the disconnected hose to the U tube pressure gauge as shown in figure 3 Gradually apply the low compressed air into the U tube so that the difference of water level should be 356 12 mm 14 0 5 in 4 Then blind the inlet of the U tube and leave the U tube with inlet blind for five mi...

Page 51: ... passage to the fuel tank and blind the other end by finger 3 Blow through the valve The valve should open with the pressure of more than is 0 055 0 07 kg cm l 0 78 1 00 lb in l 4 Remove the pressure gauge and connect it to the passage to atomosphere 5 Blow through the valve and if the valve opens with the pressure of more than O Ql 0 05 kg cm2 0 14 _ 0 71 lb in2 the valve is normal If the valve d...

Page 52: ... air passes No 2 purge control valve 1 Disconnect the vacuum sensing tube No 2 purge control valve _ No 1 purge control valve at the No 1 purge control valve 2 Disconnect the vacuum sensing tube from the No 2 purge control valve 3 Blow slightly the No 2 purge control valve from the vacuum sensing tube and make sure the air does not come out from the port 4 Start the engine and run it at 2 000 rpm ...

Page 53: ...3 Remove the right scarf plate and floor mat 4 Disconnect the coupler of the heat hazard sensor and connect a jumper wire to both terminals in the coupler The warning lamp comes on 1A G 2 Checking Heat Hazard Sensor 1 Remove the sensor 2 Wrap the sensor and thermometer with aluminum foil to prevent the oil penetration and place it in oil 3 Connect the test lamp and battery to the sensor terminals ...

Page 54: ... lB 3 lB 8 6 Checking Water Thermo Switch 18 4 18 C OXIDIZING CATALYTIC CONVERTER SYSTEM 18 4 lB C 1 Catalytic Converter 18 4 lB D DECELERATION CONTROL SYSTEM 18 4 lB D 1 Anti afterburn Valve 18 4 18 D 2 Throttle Positioner System IB 5 lB E POSITIVE CRANKCASE VENTILATION P C V SYSTEM IB 7 18 E 1 P C V Valve 18 7 lB F EVAPORATIVE EMISSION CONTROL SYSTEM lB 7 18 F 1 Checking Evaporative Line 18 7 lB...

Page 55: ...ne speed to 1 500 rpm and check the exhaust gas leakage at the air inlet fitting on the valve by placing a finger 1B A 2 Air Pipe To replace the air pipe proceed as follows l Remove the reed valve as described in Par lB A 1 2 Loosen the nut attaching the air pipe to the air inlet connector bolt then remove the air pipe To install reverse the removal procedure 18 A 3 Air Inlet Connector Bolt To rep...

Page 56: ... any deposits from the E G R control valve and E G R pipes with a piece of wire or brush if necessary Blow them with compressed air Install them in the exact reverse order of removal 18 8 2 Inspecting E G R Control Valve 1 Warm up the engine to the normal operating temper ature and stop the engine 2 Disconnect the vacuum sensing tube from the E G R valve 1st stage valve and pinch it 3 Disconnect t...

Page 57: ...nt drain 2 Vacuum tubes 3 Water thermo valves To install reverse the removal procedure Apply the sealing tape to the water thermo valve to prevent the coolant leakage 18 8 4 Checking Water Thermo Valve 1 Remove the water thermo valve 2 Immerse the water thermo valve in a container 3 Heat up the water gradually and observe the tem perature 4 Blow the valve and if air flows out at 59 C 138 F or abov...

Page 58: ...the catalytic con verter 2 Remove the nuts at the front and rear flanges of the catalytic converter To install reverse the removal procedure 18 D DECELERATION CONTROL SYSTEM 1B D 1 Anti afterburn Valve a Replacing anti afterburn valve Remove the anti afterburn valve as follows I Air cleaner 2 Vacuum sensing tube 3 Air hoses disconnect 4 Anti afterburn valve To install reverse the removal procedure...

Page 59: ...nt does not flow to the circuit The difference between the engine speed recorded in Step 3 and 4 should be 150 250 rpm 4 Replace the engine speed switch if necessary b Replacing servo diaphragm Remove the air cleaner and remove the parts in the order numbered left To install reverse the removal procedure After installing check the operation of the servo diaphragm as descnoed in item c c Checking s...

Page 60: ... is obtained With cooler When air con switch is ON to an equivalent opening to give 1 200 go rpm at idle with vacuum advance e Replacing three way solenoid valve Remove the three way solenoid valve as follows 1 Couplers 2 Vacuum sensing tubes 3 Three way solenoid valve attaching nuts 4 Three way solenoid valve To install reverse the removal procedure f Checking three way solenoid valve 1 Disconnec...

Page 61: ... P C V valve 1 Warm up the engine until it reaches the normal operating temperature 2 Disconnect the ventilation hose from the cylinder head cover 3 Run the engine at idle 4 Close the ventilation hose opening with finger If the engine speed goes down the ventilation valve is working properly If the engine speed does not drop replace the venti lation valve 18 F EVAPORATIVE EMISSION CONTROL SYSTEM 1...

Page 62: ... stands 1 Check and cut valve attaching bolt 2 Fuel hoses 3 Check and cut valve To install reverse the removal procedure Note Push in the rubber hose end to the fuel pipe until the fuel pipe is inserted as shown in figure b Checking check and cut valve I Remove the check and cut valve 2 Connect a pressure gauge to the passage to the fuel tank and blind the other end by finger 3 Blow through the va...

Page 63: ... to prevent the oil penetration and place it in oil 3 Connect the test lamp and battery to the sensor terminals in the coupler as shown in Fig lB 33 4 Gradually heat up the oil The test lamp should be ON when the temperature in aluminum foil is reached to 150 10 C 302 18 F If the sensor does not operate within the specifica tion replace the sensor Note Do not heat up the oil more than 200 C 392 F ...

Page 64: ...sembling Oil Pump 2 1 2 A 3 Checking Oil Pump 2 2 2 A 4 Assembling Oil Pump 2 3 2 A 5 Installing Oil Pump 2 3 2 B CHECKING OIL PRESSURE 2 3 2 C OIL FILTER 2 3 2 D OIL PAN 2 4 2 D I Removing Oil Pan 2 4 2 D 2 Checking Oil Pan 2 4 2 D 3 Installing Oil Pan 2 4 SPECIAL TOOL 2 4 ...

Page 65: ...he following parts in sequence 1 Lock washer nut sprockets and chain 2 Oil pump attaching bolts and adjusting shims 3 Oil pump assembly 2 A 2 Disassembling Oil Pump Disassemble the oil pump in the numerical order 1 O ring 2 Cover attaching bolts and cover 3 Inner rotor and shaft assembly 4 Outer rotor 5 Split pin 6 Spring seat 7 Spring and plunger ...

Page 66: ...ce between the outer rotor and the pump body If the clearance exceeds limit replace the rotor or body Standard Limit 0 14 0 25 mm 0 006 0 010 in 0 30 mm 0 012 in 3 Check the end float of the rotors Then measure the clearance between the straight edge and the cover as shown in Fig 2 8 If the sum of these values measured exceed limit correct the pump cover or pump body or replace Standard 0 04 0 10 ...

Page 67: ... PRESSURE Warm up the engine to the normal operating tempera ture Remove the oil pressure switch and connect the oil pressure gauge 49 0187 280 instead The normal oil pressure is as follows Oil Pressure 3 5 4 5 kg cm2 50 64 lb in2 at 3 000 rpm of engine 2 C OIL FILTER To replace proceed as follows l Remove the oil filter cartridge with a suitable wrench 2 Apply oil onto the oil seal on a new filte...

Page 68: ...n Check the oil pan for cracks damaged drain plug threads Straighten surface as required 2 0 3 Installing Oil Pan Install the oil pan in the reverse order of removing Note a Apply the sealer 8527 77 739 over the inner border of the mating surfaces of the block and oil pan i e inner periphery up to bolt hole b When installing oil pan install a new gasket instead of the used liquid sealer c Operate ...

Page 69: ... 3 Checking Water Pump 3 2 3 B 4 Assembling Water Pump 3 2 3 B S Installing Water Pump 3 2 3 C THERMOSTAT 3 3 3 C l Removing Thermostat 3 3 3 C 2 Checking Thermostat 3 3 3 C 3 Installing Thermostat 3 3 3 D FAN DRIVE 3 3 3 D l Checking Fan Drive 3 3 3 E COOLING SYSTEM PRESSURE TEST 3 4 3 F V BELT AND TENSION ADJUSTMENT 3 4 3 G ANTIFREEZE SOLUTION 3 4 3 H CLEANING COOLING SYSTEM 3 5 SPECIAL TOOLS 3 ...

Page 70: ...ct the radiator and clean or rep11ir if excessively dirty clogged with dust or damaged 3 A 3 Installing Radiator FolJow the removal procedures in the reverse order Note Fill the cooling system with a mixture of clean soft water demineralized water and anti freeze solution or anti corrosive solution according to the season and maker s instruction 3 B WATER PUMP 3 B 1 Removing Water Pump After drain...

Page 71: ...t block 49 0823 146 3 B 3 Checking Water Pump 1 Check each part for damage rust and wear and replace them if necessary 2 Check the bearing for abnormal noise and sluggish rotation Note If the coolant is leaking replace the seal assembly with a new one 3 8 4 Assembling Water Pump Assemble the water pump in the reverse order of dis assembly taking care the caution in Fig 3 7 3 B 5 Installing Water P...

Page 72: ...ully opened If the reading shows a large difference from the specifications replace with a new thermostat Swt to open Fully opens at Lift 82 C 1 5 C 180 2 7 F 95 C 203 F 8 mm 0 315 in or more 3 C 3 Installing Thermostat Install the thermostat in the reverse order of removal Fill the cooling system Operate the engine and check for leaks Note When installing the thermostat into the housing make sure...

Page 73: ...ternal leaks appear and the pressure continues to drop inspect the engine oil to determine whether or not coolant is leaking into the crankcase due to a cracked cylinder block or damaged head gasket 3 F V BELT AND TENSION ADJUSTMENT 1 1f the belt is broken glazed or worn replace the belt with a new one If the belt is stretched so that it cannot be tightened sufficiently install a new belt 2 If the...

Page 74: ...an water through the cooling system in the direction opposite to the normal coolant flow This action causes the water to get behind the corrosive deposits and force them out 6 Fill the cooling system with a mixture of clean soft water demineralized water and anti freeze solution or anti corrosive solution according to the season and maker s instruction Note During a complete refill of the cooling ...

Page 75: ...B CARBURETOR LINKAGE 4 12 4 B l Checking Carburetor Linkage 4 12 4 B 2 Checking Accelerator Linkage 4 13 4 C FUEL PUMP 4 13 4 C l Testing Fuel Pump 4 13 4 C 2 Replacing Fuel Pump 4 14 4 D FUEL FILTER 4 14 4 D l Replacing Fuel Filter 4 14 4 E FUEL TANK 4 14 4 F FUEL CUT VALVE 4 15 4 G FUEL LINE 4 15 4 H FUEL CHECK VALVE 4 16 4 1 ALTITUDE COMPENSATOR 4 16 4 1 1 Checking Altitude Compensator 4 16 4 1...

Page 76: ...iring coupler and bullet connector disconnect 8 Carburetor Note After removing the carburetor cover the inlet manifold port with a clean shop towel to prevent dust or dirt from entering 4 A 2 Disassembling Carburetor Disassemble the carburetor in the numerical order Air horn and Automatic choke 1 Vacuum tube 2 Accelerating pump connecting rod and lever 3 Connect spring 4 Spread the clip automatic ...

Page 77: ...ews and cover 10 Choke diaphragm rod from choke lever disconnect Note Mark the position of the bi metal cover index mark on the choke housing as shown in the figure 11 Choke heater attaching screws and choke heater 12 Choke diaphragm and bracket assembly a Needle valve and float 1 Float pin and gasket 2 Needle valve assembly 4 2 ...

Page 78: ... Slow fuel cut solenoid valve and gasket 0 7 Throttle link disconnect 8 Vacuum diaphragm connecting rod disconnect 9 Separate the tluottle body from the main body Note One of the bolt is inside of the throttte body 10 Diaphragm assembly attaching screws ana gasket 11 Diaphragm cover attaching screws and cover 12 Spring and diaphragm 13 Throttle lever hanger attaching screws 14 Fuel bowl sight glas...

Page 79: ...r bleed No 2 Note 4 Note the size of all jets and air bleeds so they may be installed in the correct position Throttle body Disassembly the throttle body following the order numbered in figure Note a In removing the mixture adjust screw pull out the whole shell while turning it or as shown in the figure cut out the shell by a saw A new mixture adjust screw a new mixture adjust screw spring and a n...

Page 80: ...Worn throttle shaft allows air to enter into the combustion chamber and mixture at low speed becomes lean 3 Check the float needle and seat for wear or rust 4 Check the float for damage 5 Examine all jets and air bleeds for clog If it exists clean in gasoline and blow with compressed air Never use a wire A wire may enlarge the hole or passage changing the calibration of the carburetor 6 Inspect th...

Page 81: ...ace the choke heater 11 When battery power is applied to the solenoid valve the valve stem should be pulled into the valve body 4 A 4 Assembling Carburetor Assemble the carburetor in the reverse order of dis assembling Note a Discard the old gaskets and use new ones b Make sure that all parts are in good condition and clean c Both the primary and secondary barrels have their respective parts which...

Page 82: ...ws a Float level adjustment Note This adjustment is always made without any gasket on the air horn l Invert the air horn on a stand and allow the float to lower by its own weight 2 Measure the clearance H between the float and the air horn bowl If the clearance is not within the specifications bend the float seat lip a until the proper clearance is obtained Standard 11 5 mm 0 453 in 3 Turn the air...

Page 83: ...om vacuum pump choke diaphragm vacuum tube 2 Push the choke valve lightly by a finger in the direc tion of closing it and concurrently check the clear ance R of the choke valve Clearance RI 1 70 0 25 mm 0 067 0 010 in 3 If it is not within the specifications adjust it by bending the choke lever D After checking install the bi metal cover 4 A 5 Adjusting Carburetor a Adjusting fast idle cam 1 Set t...

Page 84: ... 008 in If necessary idjust the choke valve clearance R by bending the starting arm If large adjustments required the choke rod should be bend c Checking unloader system 1 Open the primary throttle valve fully 2 At the time measure the choke valve clearance R Clearance R 3 05 0 40 mm 0 120 0 016 in 3 If it is not within the specifications adjust it by bending the tab as shown in figure ...

Page 85: ...el level The fuel level should be in the specified mark in the sight glass c Make the idle adjustment as instructed in Par 4 A 8 d After idle adjustment is completed check the fast idle speed as follows I Fully depress the accelerator pedal 2 Warm up the engine to normal operating temperature 3 Stop engine and remove the air cleaner 4 While holding the throttle valve slightly open push the choke v...

Page 86: ...adjustment of engine idle mixture paying attention to the following points 1 Remove the throttle chamber of the carburetor and replace the mixture adjust screw mixture adjust spring and shell 2 After assembling install the carburetor in the reverse order of removing 3 Warm up the engine to normal operating temperature 4 Connect an exhaust gas analyzer to the vehicle 5 Disconnect the air hoses b tw...

Page 87: ...ic transmission I0 Check co concentration If it is less than 1 turn the mixture adjust screw counter clockwise l 4 tum 11 Reconnect the air hoses and check the idle speed to be at following specifications If not set the idle speed lo 650 rpm by using throttle adjust screw 650 rpm in neutral 650 rpm D range with manual transmission with automatic transmission 12 Fit a blind plug to the mixture adju...

Page 88: ...een changed with the recommended maintenance mileage interval When in doubt install a new filter a Pressure test I Remove the air cleaner assembly Disconnect the fuel inlet line at the carburetor Use care to prevent combustion due to fuel spillage 2 Connect a pressure gauge a restrictor and flexible hoses between the fuel line and the carburetor 3 Position the flexible hose and restrictor so that ...

Page 89: ...emove the fuel filter in the numerical order Raise the vehicle and support with stands 1 Fuel pump bracket 2 Fuel inlet and outlet hose 3 Fuel filter Install the fuel filter in the reverse order of removing Note When installing however note the fuel hose connections 4 E FUEL TANK Inspect the fuel tank for cracks and corrosion If any defect is present repair or replace as necessary Note When repair...

Page 90: ...inn that the passage is open To replace the fuel cut valve proceed as follows 1 Raise the vehicle and support with stands 2 Remove the attaching bolts and remove the fuel cut valve and bracket assembly 3 Disconnect the hoses at the fuel cut valve and remove the valve 4 G FUEL LINE Inspect the fuel lines for leaks and tighten the fuel line connections to prevent leakage It is important to keep the ...

Page 91: ...52 Replace if necessary Air passes Air does not passes Note more than 700 m 2295 ft High altitude Less than 300 m 984 ft Low altitude The operation of altitude compensator will be changed by the atmospheric pressure 4 1 2 Replacing Altitude Compensator Remove the altitude compensator in the numerical order 1 Vacuum tubes disconnect 2 Altitude compensator bracket 3 Screws 4 Altitude compensator 4 J...

Page 92: ...onnet 2 Check the valves and linkage for sticking or wear 3 Check the valve at the fresh air side closes when the engine is cold 4 Close the bonnet and warm up the engine suffi ciently 5 Open the bonnet and make sure the valve at the fresh air side is open Thermo sensor Air cleaner Carbtxetor Exhaust manifold Intake manifold SPECIAL TOOLS 49 Oll8 870A Driver power valve ...

Page 93: ...8 4A B CARBURETOR LINKAGE 4A 9 4A B 1 Checking Carburetor Linkage 4A 9 4A B 2 Checking Accelerator Linkage 4A 9 4A C THROTTLE OPENER SYSTEM Air conditioning 4A 10 4A C l Checking Throttle Opener 4A 10 4A D FUEL PUMP 4A 10 4A D l Testing Fuel Pump 4A 10 4A D 2 Replacing Fuel Pump 4A 11 4A E FUEL FILTER 4A 11 4A E l Replacing Fuel Filter 4A 11 4A F FUEL TANK 4A 11 4A G FUEL CUT VALVE 4A 12 4A H FUEL...

Page 94: ...carburetor cover the inlet manifold port with a clean shop towel to prevent dust or dirt from entering 4A A 2 Disassembling Carburetor Disassemble the carburetor in the numerical order Automatic choke and Air hone l Vacuum tube disconnect 2 Return spring 3 Accelerating pump connecting rod and arm 4 Choke rod 5 Air hone automatic choke and gasket 6 Fuel inlet fitting Main body 1 Accelerating pump p...

Page 95: ...ir bleed No I 3 Secondary step air bleed No 2 4 Secondary main air bleed 5 Power valve Use the driver 49 0118 870A 6 Secondary main jet 7 Primary main jet 8 Primary main air bleed 9 Slow jet and plug 10 Primary slow air bleed No I 11 Primary slow air bleed No 2 Note Note the size of all jets and air bleeds so they may be installed in the correct position Throttle body 1 Throttle hanger Note Do not...

Page 96: ...he fuel pauages with compressed air and remov i all dirt Never use a wire for cleaning the jets J Inspect the air horn main body and throttle body for cracks and breakage 2 Check the float needle and seat for wear 3 Check the float for damage 4 Inspect the choke shaft and the throttle shaft for wear Worn throttle shaft allows air to enter into the combustion chamber and mixture at low speed become...

Page 97: ... Inspect the accelerating pump plunger cup Replace the plunger it is worn or damaged 7 Check the diaphragm for damage 8 Inspect the mixture adjust screw for burres or ridges 9 Check the solenoid for operation To check connect the solenoid to the battery positive terminal and ground the body When current is applied to the solenoid the valve stem should be pulled into the valve body If the valve doe...

Page 98: ... adjustment as follows l Invert the air horn on a stand and allow the float to lower by its own weight 2 Measure the clearance H between the float and the air horn bowl If the clearance is not within the specifications bend the float seat lip a until the proper clearance is obtained Standard 11 mm 0 433 in Note This adjustment is always made without any gasket on the air horn 3 Tum the air horn to...

Page 99: ...atic choke heater source wiring is normal and choke valve does not operate after warm up replace bi metal cover b Adjusting automatic choke Fast idle cam l Close the choke valve fully 2 Confirm the position of fast idle cam It should be on the fust position 3 Adjust the throttle valve opening angle or clearance G by turning the adjust screw Turning the screw clockwise the opening angle becomes lar...

Page 100: ...8 0 016 in 3 If it is not within the specifications adjust it by bending the tab in the figure f Setting bi metal 1 Hook the choke arm with bi metal hook and install the thermostat cover 2 Confirm the correct operation of choke valve by turning the thermostat cover 3 Align the index mark of thermostat cover at the center of the choke housing 4 Tighten the attaching screws 4A A 6 Adjusting Secondar...

Page 101: ...he engine speed increses to 3 000 4 000 rpm If the engine speed is not within the specification turn the fast idle adjusting screw 4A A 8 Adjusting Idle Speed and Mixture Precheck Be sure the ignition timing spark plugs carburetor float level and etc are in normal condition Preconditions for idle adjustment 1 Apply the parking brake and block the wheels 2 Turn off all lights and other unnecessary ...

Page 102: ... in Fig 4A 31 CO concentration 2 0 1 0 without air injection 4A B CARBURETOR LINKAGE 4A B 1 Checking Carburetor Linkage Check the throttle linkage accelerator linkage and choke linkage for proper operation Examine the choke control for free operation 4A B 2 Checking Accelerator Linkage Check the accelerator pedal position The accelerator pedal should be lower than brake pedal as follows Accelerato...

Page 103: ...e tests are performed with the pump installed on the car Before the tests make sure the fuel filter has been changed with the recommended maintenance mileage interval When in doubt install a new filter a Pressure test 1 Remove the air cleaner assembly Disconnect the fuel inlet line at the carburetor Use care to prevent combustion due to fuel spillage 2 Connect a pressure gauge a restrictor and fle...

Page 104: ...acing Fuel Filter Remove the fuel filter in the numerical order Raise the vehicle and support with stands 1 Fuel inlet and outlet hose 2 Fuel filter Install the fuel filter in the reverse order of removing Note When installing however note the fuel hose connections 4A F FUEL TANK Inspect the fuel tank for cracks and corrosion If any defect is present repair or replace as necessary Note When repair...

Page 105: ...e outlet port of the valve Then blow in air from the inlet part to confirm that the passage is open To replace the fuel cut valve proceed as follows I Raise the vehicle and support with stands 2 Remove the attaching bolts and remove the fuel cut valve and bracket assembly 3 Disconnect the hoses at the fuel cut valve and remove the valve 4A H FUEL LINE Inspect the fuel lines for leaks and tighten t...

Page 106: ...dures in the reverse order Note When ins talling make sure that the arrow make on the valve is directed as shown in Fig 4A 44 4A J AIR CLEANER Remove and clean the element 4A K INTAKE AIR TEMPERATURE CONTROL SYSTEM The intake of fresh air and hot air is automatically controlled over by means of the bimetal and control valve installed in the air cleaner Move the control valve inside the air cleaner...

Page 107: ...nstalling Alternator 5 5 5 G l Removing Distributor 5 16 5 C STARTING MOTOR 5 5 S G 2 Disassembling Distributor 5 16 5 C l Checking Starting Circuit 5 5 5 C 2 Removing Starting Motor 5 5 5 G 3 Checking Distributor 5 17 5 G 4 Assembling Distributor 5 17 5 C 3 Testing Starting Motor 5 6 5 G 5 Installing Distributor S 18 5 C 4 Disassembling Starting Motor 5 6 5 G 6 Testing Distributor 5 18 5 C 5 Insp...

Page 108: ... Check the electrolyte level and add distilled water if necessary Note If addition of distilled water is neglected the plates and separators will become exposed to air causing a sulphation to occur on the plates Do not add dilute sulphuric acid unless the electrolyte has overflowed or leaked out 3 Connect the battery to the charger ensuring that the polarities are correct 4 To charge apply an elec...

Page 109: ...een the R terminal of the alternator and the ground and take a reading of the R terminal voltage Take a reading of the L terminal voltage similarly If either of lhe aforementioned voltmeter readings is not zero the alternator is defective Note During the measurement the ignition switch should be switched off 2 Switch the ignition switch on and take a reading of the L terminal voltage If the readin...

Page 110: ...h bolts 2 Front housing assembly Separate the front housing assembly by prying apart with a screwdriver at the slots of the front housing 3 Pulley nut and pulley Place the front housing and rotor assembly in a vise Clamp the assembly on the rotor 4 Fan and spacer 5 Rotor and bearing assembly 6 Front housing 7 Stator Unsolder the stator leads from the rectifier assembly Hold the stator lead with a ...

Page 111: ... be replaced Short circuit test Place both prods of an ohmmeter on the slip rings If the reading is 3 to 6 ohms there is no trouble in the rotor c Checking diode rectifier assembly Diodes for use in the alternator are available in two different types the positive diode which allows current to flow from the lead wire to the case but not from the case to the lead wire and the negative diode which ha...

Page 112: ...ion by inserting piece of stiff wire into the hole of the brush through the rear housing 2 The soldering of the rectifier leads should be per formed in less than twenty seconds as the excessive heat may damage the diodes 5 B 7 Installing Alternator Install the alternator in the reverse order of removing Adjust the V belt referring to Par 3 E 5 C STARTING MOTOR 5 C 1 Checking Starting Circuit When ...

Page 113: ...k resistance test 1 Install the starting motor on a test bench 2 Test the lock resistance of the starting motor fol lowing the instructions of the test equipment manufacturer Manual transmission Voltage 5 volts Current 310A or less Torque 0 75 m kg 5 4 ft lb or more Automatic Voltage Current Torque transmission 5 volts 500A or less 1 15 m kg 8 3 ft lb 5 C 4 Disassembling Starting Motor or more Dis...

Page 114: ...ined for each segment If the meter reading is not infinite the armature must be replaced Short circuit test Place the armature against the core of the growler tester and hold a steel strip on the armature Then rotate the armature slowly by hand If the armature coil is shorted the steel strip will become magnetized and vibrate Replace the armature if a short is found b Checking commutator If the co...

Page 115: ...laced Repeat this test for the other insulated brush hoJder Do not use this test on the two grounded brush holders e Checking brushes and brush springs Check the brushes and replace if they are worn down more than one third of their original length Otherwise the brush spring tension will be reduced leading to an increase in the brush commutator contact resistance This will lower the torque and cau...

Page 116: ...ouble with the holding coil c Return test Push in the plunger by hand and apply the specified voltage 12 V between the M terminal and the mag netic switch body If the plunger is not attracted there is no trouble 5 C 7 Assembling Starting Motor Assemble the starting motor in the reverse order of disassembly noting the following points 1 Adjust the armature shaft end play to 0 2 0 5 mm 0 008 0 020 i...

Page 117: ...eposits fouling and cracked porcelain Clean the spark plugs with a spark p ug cleaner or a wire brush if they are fouled Replace the badly burned or eroded spark plugs Measure the electrode gap of each spark plug with a wire gauge If it is improper adjust the gap to the specification by bending the outer electrode Spark plug gap 0 80 0 05 mm 0 031 0 002 in 5 0 3 Installing Spark Plug 1 Apply a sma...

Page 118: ...tion timing mark on the crankshaft pulley is in line with the indi cator pin on the timing chain cover 1 Battery negative cable disconnect 2 Ignitor coupler 3 rlightension cords disconnects 4 Vacuum sensing tube disconnect 5 Condenser 6 Distributor 5 E 2 Disassembling Distributor Disassemble the distributor in the numerical order 1 Distributor cap attaching screws 2 Distributor cap 3 Attaching scr...

Page 119: ...control unit to the housing and remove the vacuum control unit 8 Loosen the screws attaching the signal plate and remove the signal plate 9 Loosen the screws attaching plate and remove the plate 10 Drive the retaining pin out of the driver geat with a drift and remove the gear 11 Remove the drive shaft assembly through the top of the distributor housing 12 Oil seal 5 12 ...

Page 120: ...Standard 1 050 ohms 10 at 20 C 68 F 5 E 4 Assembling Distributor Assemble the distributor in the reverse order of disas sembly noting the following points l When installing the cam first align the tally marks on the distributor housing and driven gear as shown in Fig 5 49 Install the rotor onto the cam temporarily and install the cam and rotor onto the governor pin through the drive shaft so that ...

Page 121: ...or into the cylinder head with the tally marks on the distributor housing and the driven gear aligned Install the distributor retaining nut by hand 3 Install the distributor cap 4 Install the hightension cords and connect the primary wire coupler S Connect the vacuum sensing tube to the vacuum control unit 6 Adjust the ignition timing as discribed in Par S E 7 then tighten the distributor attachin...

Page 122: ...nut and rotate the distributor housing until the timing mark on the crankshaft pulley aligns with the indicator pin on the timing chain cover 7 Tighten the distributor lock nut and recheck the timing Ignition timing 0 1 BTDC at 650 g0 rpm m neutral with manual transmission 5 1 BTDC at 650 5o rpm in D position 100 with automatic transmission 5 F SPARK TIMI NG CONTROL SYSTEM U SA Distributor vacuum ...

Page 123: ...sing tube disconnect 4 Condenser S Distributor 5 G 2 Disassembling Distributor 5 Disassemble the distributor in the numerical order l Distributor cap and rotor 2 Cover 3 Rubber seal and grommet 4 Retaining clips and screws 5 Retaining pin 6 Signal rotor 7 Clip and screws vacuum control unit 8 Vacuum control unit 9 Pick up coil assembly 10 Retaining pin 11 Driven gear 12 Governor and drive shaft as...

Page 124: ... 4 Assembling Distributor Assemble the distributor in the reverse order of disas sembly noting the following points I When installing the cam first align the tally marks on the distributor housing and driven gear as shown in Fig 5 63 InstalJ the rotor onto the cam temporarily and install the cam and rotor onto the governor pin through the drive shaft so that the metal strip end of the rotor positi...

Page 125: ... 2 Slide the distributor into the cylinder head with the tally marks on the distributor housing and the driven gear aligned Install the distributor retaining nut by hand 3 Install the distributor rotor and cap 4 Install the hightension cords and connect the primary wire coupler 5 Connect the vacuum sensing tube to the vacuum control unit 6 Adjust the ignition timing as described in Par 5 G 7 then ...

Page 126: ... crankshaft pulley aligns with the indicator pin on the timing chain cover 7 Tighten the distributor lock nut and recheck the timing 8 Disconnect the bullet connectors from water thenno switch 9 Aim the timing light and make sure that the advance timing aligns specifications Ignition timing 8 1 BTDC at 650 50 rpm in neutral with manual transmission 8 1 BTDC at 650 50 rpm m D position with automati...

Page 127: ...mal operating temperature IQ Primary coil resistance 0 9 ohms I0 5 J HIGHTENSION CORD 5 J 1 Checking Registance Check the resistance of each hightension cord The resistance should not exceed 16 000 ohms 40 per 1 m 39 37 in Note a When checking the resistance of the cords or set ting ignition timing do not puncture the cords with a probe The probe may cause a separation in the con ductor b When rem...

Page 128: ...hecking Pilot Bearing 6 3 6 D CLUTCH INSTALLATION 6 4 6 E CLUTCH MASTER CYLINDER 6 4 6 E I Removing Clutch Master Cylinder 6 4 6 E 2 Disassembling Clutch Master Cylinder 6 4 6 E 3 Checking Clutch Master Cylinder 6 5 6 E 4 Assembling Clutch Master Cylinder 6 5 6 E 5 Installing Clutch Master Cylinder 6 5 6 F CLUTCH RELEASE CYLINDER 6 5 6 F 1 Removing Clutch Release Cylinder 6 5 6 F 2 Disassembling C...

Page 129: ...e order of removing Note Before installing clutch pedal apply grease on the bushings 6 A 4 Adjusting Clutch Pedal To adjust the pedal height loosen the Jock nut 3 and turn the stopper bolt 2 until the proper adjustment is made Tighten the lock nut after adjustment is completed Pedal height 5 2 193 _ 0 mm 7 60 _ 0 m To adjust the pedal free travel between the master cylinder push rod and piston loo...

Page 130: ...hed with gasoline or any other solvent Check the release bearing by pressing and turning the front race slowly by hand Replace if the bearing feels rough or seems noisy when turning Check the clutch fork for crack or bend If necessary replace the clutch fork 6 C 2 Checking Pressure Plate and Cover Assembly Check the contact surfaces of the pressure plate with the clutch facing for wear damage or w...

Page 131: ... a lathe If the damage is deep the flywheel should be replaced Check the ring gear teeth and replace if the ring gear teeth are broken cracked or seriously burred Note On the vehicle equipped with an automatic transmission the ring gear and drive plate should be replaced as an assembly 6 C 5 Replacing Ring Gear I Heat the old ring gear and remove it from the flywheel 2 Heat a new ring gear evenly ...

Page 132: ...ked by a small hole on the clutch cover and install the 2 reamer bolts and 4 standard bolts finger tight Then torque the bolts to specifications 6 E CLUTCH MASTER CYLINDER 6 E 1 Removing Clutch Master Cylinder Remove the following parts in the numerical order 1 Fluid pipe Use the spanner 49 0259 770A 2 Attaching nuts 3 Clutch master cylinder Note Never allow the fluid to drop on any painted surfac...

Page 133: ... E 4 Assembling Clutch Master Cylinder Assemble the clutch master cylinder in the reverse order of disassembly Note a Before assembling dip the piston and cups in clean brake fluid b After assembling fill with brake fluid and operate the piston with a screwdriver until the fluid is ejected at the outlet 6 E 5 Installing Clutch Master Cylinder To install the clutch master cylinder carry out the rem...

Page 134: ... system as described in Par 6 G 6 G AIR BLEEDING To bleed the clutch hydraulic system proceed as follows I Raise the vehicle and support with stands 2 Remove the rubber cap from the bleeder screw and attach a vinyl tube to the bleeder screw 3 Place the end of the tube in the glass jar and submerge in brake fluid 4 Open the bleeder valve Depress the clutch pedal and allow it to return slowly Contin...

Page 135: ... Checking Bearings 7A 5 7A C 3 Checking Gears 7A 5 7A C 4 Checking Main Shaft and Main Drive Shaft 7A 5 7A C 5 Checking Counter Shaft 7A 6 7A C 6 Checking Reverse Idle Gear and Shaft 7A 6 7A C 7 Checking Synchronizer Mechanism 7A 6 7A C 8 Checking Control Lever Shift Forks and Rods 7A 6 7A D TRANSMISSION ASSEMBLY 7A 7 7A E TRANSMISSION INSTALLATION 7A 1J SPECIAL TOOLS 7A 11 7A 11 1 ...

Page 136: ...er shaft refer to Par 8 A 7 Exhaust pipe hanger 8 Clutch release cylinder 9 Starting motot 10 Wire back up light switch 11 Speedometer cable 12 Transmission attaching bolts 13 Transmission Note Before remove the transmission place a jack under the engine protecting the oil pan with a block of wood 7A B TRANSMISSION DISASSEMBLY Disassemble the transmission in the numerical order Transmission case 1...

Page 137: ...id down to the left as far as it will go Extension housing I Control lever end 2 Control lever 3 Speedometer driven gear assembly Intermediate housing 1 Intermediate housing and gear assembly Use the pusher 49 0305 430 2 Snap ring 3 Speedometer drive gear steel ball and snap ring 4 Spring pins and shift rod ends 1st 2nd 3rd 4th and 5th Rev 5 Intermediate housing 7A 2 ...

Page 138: ... interlock pins Fig 7A 9 Bearing and gears 1 Snap ring and adjusting washer 2 Main shaft rear bearing Use the puller set 49 0839 425C Fig 7A 10 3 Snap ring and adjusting washer 4 Counter shaft rear bearing Use the puller set 49 0839 425C Fig 7A 11 5 Snap ring adjusting spacer and lock ball 6 5th gear and synchronizer ring 7 Counter 5th gear 8 Spacer Fig 7A 12 7A 3 ...

Page 139: ... hub assembly 5th Rev 11 Reverse gear needle bearing sleeve and thrust washer 12 Counter reverse gear 13 Snap ring and thrust washer 14 Reverse idle gear and thrust washer 15 Counter and main shaft Note Tap the rear end of the main shaft and counter shaft in turn with a plastic hammer 16 Bearing cover 17 Counter and main shaft center bearing 18 Main drive shaft and needle bearing 19 Synchronizer r...

Page 140: ...ng for roughness 2 Inspect the needle bearing for wear of any damage 7A C 3 Checking Gears Inspect the following parts to see if damaged or worn Replace if necessary l Cone surface 2 Clutch hub sleeve fitting part 3 Gear teeth 4 Gear inner and end surface 7A C 4 Checking Main Shaft and Main Drive Shaft 1 Inspect the main shaft for run out by applying a dial indicator to several places along the sh...

Page 141: ...r worn I Gear teeth on synchronizer ring 2 Synchronizer ring tapered surface 3 Clutch sleeve and hub 4 Key 5 Spring for tension 2 Check the clearance between the side faces of the synchronizer ring and gear Standard Limit 1 5 mm 0 059 in 0 8 mm 0 031 in 3 Check the contact between the ring and cone surface by using a thin coat of Prusian Blue If the contact pattern is poor correct it by applying c...

Page 142: ...rse ord r of dis assembly When assembling note the following instructions Note Apply lubricant on sliding portions gears and bearings before re assembly 1 Clutch Hub Assembly Install the key springs so that the open ends of the springs should be kept 120 degrees apart as shown in figure This will keep the spring tension on each key uniform When assembling each clutch hub assembly note their direct...

Page 143: ...t Lock Nut After installing the clutch hub assembly slide the clutch sleeves into 1st gear and reverse gear to lock the rotation of the main shaft Using the wrench 49 1243 465A tighten a new lock nut to the specified torque Tightening torque 13 21 m kg 94 152 ft lb Note After tightening the main shaft lock nut calk the lock nut securely with a chisel 5 5th Gear End Play Adjust the 5th gear end pla...

Page 144: ...er and the snap ring End play less than 0 1 mm 0 004 in Ad ustin washers 2 1 mm 0 083 in 2 3 mm 0 091 in 2 2 mm 0 087 in 2 4 mm 0 094 in 8 Main Shaft Rear Bearing Install the main shaft rear bearing by using the wrench 49 1243 465A 9 Main Shaft Rear Bearing End Play Adjust the main shaft rear bearing end play Clear ance between the thrust washer and the snap ring End play Less than 0 1 mm 0 004 in...

Page 145: ...t fork rods and interlock pins Tightening torque Spring cap bolts Note 1 0 1 5 m kg 7 11 ft lb When assembling the shift fork and control end a new spring pin should be installed with the pin slit positioned in the direction of the shift rod axis as shown in the figure 11 Main Drive Shaft Bearing Install the main drive shaft bearing by using the installer 49 0500 330 7A 10 ...

Page 146: ...6 in 0 3 mm 0 012 in 7A E TRANSMISSION INSTALLATION Install the transmission in the reverse order of removal Note a Apply a very thin coat of grease onto the splines of the main drive shaft b Use the turning holder 49 0259 440 to align the splines on the main drive shaft with the splines in the clutch disc c Fill the transmission with a correct grade and quantity lubricant SPECIAL TOOLS Puller set...

Page 147: ...hecks 78 14 78 D TRANSMISSION ASSEMBLY 7B 14 78 E TRANSMISSION INSTALLATION 78 16 7B F HYDRAULIC CONTROL INSPECTION 7B 16 7B F 1 Checking Transmission Fluid Level 78 16 78 F 2 Checking Engine Idle Speed 7B 16 78 F 3 Checking Line Pressure 78 17 7B F 4 Checking Governor Pressure 78 17 78 F 5 Stall Test 78 17 78 F 6 Checking Shift Point 7B 18 78 G SHIFT CONTROL LINKAGE 78 18 78 G I Adjusting ManuaJ ...

Page 148: ... shift solenoid wire 8 Oil pipes 9 Clutch under cover and stays 10 Torque converter attaching bolts Place a jack under the engine protecting the engine oil pan with a block of wood 11 Cross member 12 Transmission assembly Note When removing the transmission from the engine be careful not to drop out the torque converter from the transmission 78 8 TRANSMISSION DISASSEM8LY When disassembling the tra...

Page 149: ...y 8 Input shaft 9 Loosen the brake band piston stem lock nut and tighten the piston stem to prevent the front clutch drum from falling when the oil pump is removed JO Oil pump Use the puller 49 0378 390 11 Loosen the piston stem and remove the band strut 7B 2 ...

Page 150: ...ing 14 Rear planet carrier 15 Output shaft snap ring Use the remover 49 8000 015 16 lntemaJ drive flange assembly 17 Tum the connecting drum counterclockwise as far as it will go Then tum the connecting drum clockwise and remove the drum and one way clutch from the case as an assembly 18 Extension housing 19 Parking pawl 20 Retaining plate actuator support balls retainer and spring ...

Page 151: ... shaft 78 C OVERHAUL OF MAIN COMPONENTS 78 C 1 Front Clutch a Disassembly Disassemble the front clutch in the numerical order 1 Snap ring 2 Retaining plate 3 Drive plates 4 Driven plates 5 Dished plate 6 Using the compressor 49 0378 375 compress the coil springs and remove the snap ring with the remover 49 8000 025 7 Coil spring retainer and springs 7B 4 ...

Page 152: ...he front clutch in the reverse order of disassembly Note a Discard the old seals and use new seals b Before assembling dip all parts in clean transmission fluid c With a feeler gauge check the clearance between the retaining plate and snap ring This clearance should be 1 6 1 8 mm 0 063 0 071 in If it is not within the specifications select and install the correct size retaining plate The retaining...

Page 153: ...Assemble the rear clutch in the reverse order of disassembly Note al Discard the old seals and use new seals b Before assembling dip all parts in clean transmission fluid c With a feeler gauge check the clearance between the retaining plate and snap ring This clearance should be 0 8 1 5 mm 0 031 0 059 in di Install the rear clutch assembly to the oil pump Blow compressed air into the oil hole and ...

Page 154: ... inside and outside of the piston for wear and any damages c Assembly Assemble the low and reverse brake in the reverse order of disassembly Note a Discard the old seals and use new seals bl Before assembling dip all parts in clean transmission fluid c Tighten the attaching bolts of one way clutch inner race to 1 3 1 8 m kg 9 13 ft lb using the hex head wrench extension 49 0378 345 and torque wren...

Page 155: ...usting screw threads for damage 3 Check the servo spring for distortion 4 Inspect the band lining for excessive wear and damage 5 Inspect the piston seal ring for damage 6 inspect the retainer seals and gasket sealing surface for damage c Assembly Assemble the servo in the reverse order of disassembly Note a Discard the old seals and use new seals b Before assembling dip all parts in clean transmi...

Page 156: ...y for obstruc tions All fluid passages must be clean 3 Check the spring for proper tension and the retainer plates for warping 4 Check the side clearance between the seal ring and groove as shown in Fig 7B 34 This clearance should be 0 04 0 16 mm 0 002 0 006 in To remove the seal ring squeeze it up so that its joint will rise above the groove and disconnect the joint c Assembling Assemble the gove...

Page 157: ...er gear teeth aQd crescent Standard Limit 0 14 0 21 mm 0 006 0 008 in 0 25 mm 0 010 in 4 Check the clearance between the outer gear and housing Standard Limit 0 05 0 20 mm 0 002 0 008 in 0 25 mm 0 010 in 5 Inspect the large seal ring groove on lhe pump housing for damage 6 Inspect the pump housing and cover for dlmage Minor burrs or scores may be removed with crocus cloth 7 Check the clearance bet...

Page 158: ...07 mm 0 0028 in total indicator reading e Tighten the pump attaching bolts to 0 6 0 8 m kg 4 3 5 8 ft lb 78 C 7 Control Valve Body a Disassembly Disassemble the control valve body in the numerical order I Oil strainer 2 Remove the bolts attaching the upper and lower valve bodies Separate the lower valve body and separator plate from the upper valve body Be careful not to lose the check valve and s...

Page 159: ...loth can be used to polish valves and plugs if care is taken to avoid rounding the sharp edges of the valves and plugs 3 Inspect all springs for distortion Check all valves and plugs for free movement in their respective bores Valves and plugs when dry must fall from their own weight in their respective bores 4 Roll the manual valve on a flat surface to check it for a bent condition c Assembly Ass...

Page 160: ... flange in the numerical order I Snap ring 2 Drive flange 3 Internal gear b Assembly Assemble the internal drive flange in the reverse order of disassembly 78 C 10 Planet Carrier a Checking The planetary carrier cannot be divided into its individual components If any part or component is defective replace the carrier as a unit Check the clearance between the pinion washer and the planetary carrier...

Page 161: ...into the various transmission case passages Fig 7B 53 1 Low reverse 6 Rear clutch pressure brake pressure 7 Front clutch pressure 2 Governor feed pressure 8 Pump in 3 Governor pressure 9 Servo release 4 Pump out IO Servo apply 5 Torque converter pressure 78 0 TRANSMISSION ASSEMBLY Assemble the transmission in the reverse order of dis assembly noting the following points 1 Apply sealant on the conv...

Page 162: ... play Using a dial indicator check the end play by moving behind the connecting shell End play 0 25 0 50 mm 0 010 0 020 in From the table below select the bearing race Fig 78 57 of the thickness that will allow specified end play ...

Page 163: ...er 27 15 mm 1 069 in 31 0 mm J 220 in 78 E TRANSMISSION INSTALLATION Install the transmission in the reverse order of removal noting the following points I Tighten the bolts attaching the converter to the drive plate to 3 5 5 0 m kg 25 36 ft lb To tighten to the specification use the wrench 49 0877 435 and install a torque wrench to the center hole of the wrench Then tighten the bolts until the re...

Page 164: ...marks on the gauge Note Do not overfill the transmission fluid 78 F 2 Checking Engine Idle Speed The engine idle speed should be properly adjusted If necessary adjust the idle speed as described in Par 4 A 9 78 F 3 Checking Line Pressure I Run the engine until the fluid reaches its normal operating temperature 60 I00 C 140 212 F Before testing check the transmission fluid level 2 Connect a pressur...

Page 165: ... where it is visible from the driver s seat 3 Chock the front and rear wheels Then apply both the parking and service brakes while making this test Be sure to depress the brake pedal firmly with the left foot before depressing the accelerator pedal 4 Shift the selector lever to O position 5 Slowly depress the accelerator pedal until the throttle valve is fully opened Quickly read and record the en...

Page 166: ... selector lever at N or O position 2 Loosen the lock nut of the selector lever knob and screw in the selector lever knob until the no play of the push button is obtained 3 Screw in the selector lever knob one turn to the position where the push button is on the driver s side 4 Push the push button and confirm that the selector lever can be shifted to P position If the selector lever cannot be shif...

Page 167: ...nge select lever The proper N position is where the slot of the manual shaft is positioned vertically and detent works to position in the shaft correctly with a click sound 4 Move the inhibitor switch so that the identification marks on the switch body and sliding plate is aligned 5 Tighten the inhibitor switch attaching screws securely 6 Slide the select lever P position and make sure that the en...

Page 168: ...ll the attaching screws Adjust the switch as described in Par 7B G 5 2 Check the operation of the switch in each detent position The engine should start only with the transmission selector lever in N or P position 3 Install the console box 78 G 8 Selector Lever a Removal and Installation Remove the selector lever in the numerical order To install reverse the removal procedure I Lock nut and select...

Page 169: ...PROPELLERSSHAFT REMOVAL 8 1 8 B PROPELLER SHAFT INSPECTION 8 2 8 C UNIVERSAL JOINT DISASSEMBLY 8 3 8 D UNIVERSAL JOINT INSPECTION 8 3 8 E UNIVERSAL JOINT ASSEMBLY 8 4 8 F PROPELLER SHAFT INSTALLATION 8 4 SPECIAL TOOL 8 S 8 ...

Page 170: ...anion flange of the rear axle 2 Remove the center bearing bracket from the under body 3 Install the main shaft holder 49 0259 440 into the extension housing to prevent lubricant from leaking out of the housing 4 Remove the bolts attaching the bracket to the center bearing support and remove the bracket 5 Remove the universal joints as descrived in Par 8 C 6 Remove the nut attaching the yoke and be...

Page 171: ...eller shaft Run out limit 0 4 mm 0 016 in 2 Check the propeller shaft for dynamic unbalance The maximum pennissible unbalance is shown in the left table If the unbalance is not within the specifications correct or replace the propeller shaft assembly Note As the looseness on the front universal joint may cause the increase of the unbalance resulting the seizure of the extension housing bush the fr...

Page 172: ...f the yoke with a hammer 6 Remove the bearing at opposite side by the above procedures 4 and 5 and separate the flange yoke from the propeller shaft 7 Remove the remaining two bearings in the same manner 8 Remove the spider from the flange yoke Note The propeller shaft should be replaced as an assembly only But if the unbalance of the propeller shaft assem bly can be checked and corrected within t...

Page 173: ...the bearing until the spider is at the center of the yoke 7 Remove the pusher and install the snap ring 8 Install the sliding yoke or flange yoke and spider assembly to the propeller shaft in the same manner as instructed above Note a Avoid reusing the old snap rings b Use snap rings of same thickness at both sides of yoke c Select snap rings so as to place the spider at t he center of the yoke an...

Page 174: ...8 SPECIAL TOOL 49 0259 440 Turning holder main shaft 8 5 ...

Page 175: ...9 D REAR AXLE INSPECTION 9 4 9 D 1 Checking Drive Pinion and Ring Gear 9 4 9 D 2 Checking Differential Gears 9 5 9 D 3 Checking Bearings 9 5 9 D 4 Replacing Pinion Bearing Outer Race 9 S 9 D 5 Checking Collapsible Spacer 9 5 9 D 6 Checking Oil Seal 9 5 9 D 7 Checking Companion Flange 9 5 9 E REAR AXLE ASSEMBLY 9 6 9 E l Adjusting Drive Pinion 9 6 9 E 2 Adjusting Pinion Bearing Preload 9 7 9 E 3 As...

Page 176: ...aft and backing plate 6 Oil seal if necessary Extract the axle shaft and backing plate assembly using the puller 49 0223 630A and 49 8501 631 9 A 2 Disassembling Rear Axle Shaft Using the bearing separator 49 8531 746 and attachment 49 0259 747 support the spacer and press the axle shaft out of the collar and bearing Note In case the pressure necessary to press out the axle shaft exceeds 10 tons 2...

Page 177: ...g inner race Note If the bearing retaining collar is press fitted with less than 2 7 tons 5 900 lb replace the collar with a new one 9 A 4 Installing Rear Axle Shaft I Oil seal if necessary 2 Apply greese to the oil seal lip 3 Axle shaft and backing plate 4 Mount a dial indicator and make sure the axle shaft end play is 0 0 1 mm 0 0 004 in 5 Parking brake cable 6 Brake shoe assembly 7 Brake drum 8...

Page 178: ...8 A 3 Rear axle 9 C REAR AXLE DISASSEMBLY 9 C 1 Removing Differential Mount the rear axle on the engine stand 49 0107 680A with attachment 49 0419 561 and 49 0223 561A Apply identification punch marks on the carrier differential bearing caps and adjusters for reassembly purpose Remove the following parts from the carrier 1 Adjuster lock plates and bolts 2 Bearing caps and bolts 3 Adjusters 4 Diffe...

Page 179: ... following parts from the carrier l Companion flange 2 Drive pinion 3 Rear bearing and adjusting washer 4 Collapsible spacer 5 Oil seal and front bearing 9 D REAR AXLE INSPECTION Wash the disassembled parts and inspect them on the following points Replace any part found defective 9 D 1 Checking Drive Pinion and Ring Gear Check the drive pinion for damaged or excessively worn teeth damaged bearing ...

Page 180: ...n Bearing Outer Race 1 Remove the old outer race from the carrier by using a drift in slots Fig 9 17 provided for this purpose 2 Install a new outer race into the carrier 9 0 5 Checking Collapsible Spacer Measure the length of the collapsible spacer with a micrometer The standard length is 57 0 15 mm 2 244 0 006 in 9 0 6 Checking Oil Seal Check the oil seal for wear or damage 9 0 7 Checking Compan...

Page 181: ...Install them in the carrier Note a Never use the collapsible spacer b The head portion of the drive pinion model is screw in type so you make sure that the head has no looseness 5 Install the front bearing Q coller A 49 8531 567 companion flange and washer 6 Tighten the nut Q9 so that the drive pinion model turns smoothly 7 Install a dial indicator to the gauge body 49 0727 570 Place the gauge bod...

Page 182: ...and install the rear pinion bearing 9 E 2 Adjusting Pinion Bearing Preload I Install the collapsible spacer onto the drive pinion and install them in the carrier 2 Place the front pinion bearing in position on the pinion Hold the pinion fully forward and drive the pinion bearing over the pinion until seated 3 Apply gear lubricant to the lip of the pinion oil seal and install the pinion oil seal in...

Page 183: ...se 2 Through the openings of the gear case insert each of two pinion gears exactly 180 degrees opposite each other 3 Rotate the gears 90 degrees so that the pinion shaft holes of the case come into alignment with the holes in the pinion gears 4 Insert the pinion shaft through the case and pinion gears 5 Check the backlash of the side gear and pinion gear Standard Limit 0 0 1 mm 0 0 004 in 0 1 mm 0...

Page 184: ...ve bearings 9 E 4 Installing Differential I Place the differential gear assembly in the carrier making ensure that the marks on the face of the pinion and ring gear tooth are in alignment 2 Note the identification marks on the adjusters and install each adjuster to its respective side 3 Install the differential bearing caps making sure that the identification marks on the caps correspond with thos...

Page 185: ...uarter sect must be less than 0 07 mm 0 0028 in However minimum backlash should be more than 0 05 mm 0 0020 in c Check the preload on the side bearings by mea suring the distance between both pilot sections on bearing cap If the preload is out of specifi cation adjust the preload by turning the opposite side bearing adjuster Distance standard preload 185 428 185 5 mm 7 3004 7 3033 in Note When adj...

Page 186: ...d be obtained as shown in Fig 9 37 9 F REAR AX LE INSTALLATION Install the rear axle in the reverse order of removal Note Fill the axle with the correct grade and quantity of lubricant SPECIA L TOOLS Engine stand Puller rear axle shaft Attachment axle shaft puller Separator axle bearing Attachment bearing separator Attachment bearing separator Wrench drain plug Attachment work stand Attachment eng...

Page 187: ...y Tilt Steering Shaft l 0 8 10 B 4 Installing Tilt Steering Shaft 10 9 10 C STEERING LINKAGE 10 10 1O C 1 Checking Ball Joints 10 10 10 C 2 Replacing Idler Arm 10 10 10 C 3 Replacing Pitman Arm 10 11 1O C 4 Replacing Tie rod 10 11 10 C S Replacing Center Link 10 12 1O C 6 Lubrication of Idler Arm 10 12 1O C 7 Lubrication on Ball Joints 10 12 10 D FRONT WHEEL ALIGNMENT 10 12 10 D 1 Inspection Befor...

Page 188: ...el Note Mark the identification mark on to the steering wheel and steering shaft 4 Column covers 5 Switch panel 6 Coupler for combination switch disconnect 7 Combination switch assembly 8 Fixing bracket Note Wrap the bolt holes of the column jacket with tape to prevent lubricant from leaking out of the jacket 9 Air duct Raise the front end of the vehicle and support with stands 10 Ball joint disco...

Page 189: ...ng to the body 13 Under cover 14 Engine mounting 15 Stabilizer bar 16 Steering gear box assembly With collapsible steering models If the car has been involved in a light collision check the steering wheel for axial play before removing When steering shaft is crushed axial play occurs Replace if necessary Note The collapsible steering column and shaft are serviced as an assembly only 10 2 ...

Page 190: ... end of the vehicle and support with stands 3 Remove the front wheel 4 Remove the cotter pin and castellated nut attaching the center link to the pitman ann 5 Disconnect the center link from the pitman arm with the puller 49 0118 8SOC 6 Remove the nut holding the pitman arm and remove the pitman arm with the puller 49 0223 69SE 7 Remove the bolts and nuts retaining the steering gear housing to the...

Page 191: ...ng Gear Wash the disassembled parts and inspect them on the following points Replace any part found defective I Check the operation of the ball nut assembly on the worm shaft If the bail nut does not travel smoothly and freely on the worm shaft and there is roughness the ball nut and worm shaft assembly should be replaced Note The worm shaft and ball nut are serviced as an assembly only 2 Check th...

Page 192: ...uld be 0 2 0 5 kg 0 44 1 10 lb without sector shaft Read the scale just when the worm shaft starts to turn After adjustment is made tighten the lock nut to 1 6 2 0 m kg 12 14 ft lb 2 Check the end clearance between the sector shaft and the adjusting screw with a feeler gauge If the clearance exceeds the limit replace the steering gear assembly End clearance limit 0 1 mm 0 004 in 3 Turn the worm sh...

Page 193: ...stalling Steering Gear Install the steering gear in the reverse order of removing Note a Place the shim in original poS1t1on between the steering gear housing and the frame to obtain proper shaft alignment b The tightening torque for the bolts and nuts at taching the gear housing to the frame is 4 4 5 5 m kg 32 40 ft lb c The tightening torque for the bolt attaching the flexible coupling to the wo...

Page 194: ...ion mark on to the steering wheel and steering shaft 4 Column cover S Switch panel attaching screw 6 Disconnect the wiring couplers from the switch panel 7 Switch panel assembly 8 Coupler for combination switch disconnect 9 Combination switch assembly 10 Coupler for ignition switch disconnect 11 Remove the set plate attaching nut and slides the set plate toward the steering wheel 12 Loosen the bol...

Page 195: ...ing shaft in the numerical order 10 8 3 Assembling Tilt Steering Shaft Follow the disassembling procedures in the reverse order 1 Tighten the adjust nut at the specified torque Tightening torque 50 cm kg 43 in lb 2 Fit the adjust lever and the washer on the adjust nut and then tighten it temporarily by the adjust lever bolt Bear in mind that the bolt has left hand thread 10 8 ...

Page 196: ... H and then tighten the adjust lever bolt at a torque of 1 7 2 8 m kg 12 20 ft lb 4 After tightening the bolt unlock the adjust lever to move the column jacket and then make sure that the column jacket locks securely when locking it 10 B 4 Installing Tilt Steering Shaft Install the tilt steering shaft in the reverse order of removing ...

Page 197: ...8 850C 3 Idler arm assembly Hold the assembly in a vise 4 Split pin and lock nut 5 Idler arm 6 Bushes Check the bushes and replace if they are worn excessively Install the idle arm in the reverse order of removing Note a Clean the disassembled parts with solvent to remove all old grease b When assembling supply the lithium grease to the idler arm housing and bushes Check the revolving torque of th...

Page 198: ...or shaft aligning the identification marks of the pitman arm and sector shaft Tightening torque Note Pitman arm to sector shaft 8 0 12 0 m kg 58 87 ft lb Pitman arm to center link 3 0 4 5 m kg 22 33 ft lb Install a new split pin 10 C 4 Replacing Tie rod Raise the front end of the vehicle and support with stands Remove the tie rod in the numerical order 1 Front wheel 2 Split pins and nuts 3 Tie rod...

Page 199: ...ly when the idler arm has been disassembled When lubricating the idler arm supply lithium grease to the idler arm housing and bushes UL portion in Fig 10 28 10 C 7 Lubrication on Ball Joints The ball joints for the steering linkage are filled with lithium grease and are completed sealed which require no lubrication service 10 0 FRONT WHEEL ALIGNMENT 10 0 1 Inspection Before Checking Front Wheel Al...

Page 200: ...is greater than that at the front by O 6 mm 0 0 24 in it is correct If it is found to be incorrect adjust the toe in by loosening the lock nuts and turning the tie rods 10 0 3 Camber and Caster To check the camber and caster use a wheel align ing gauge following the manufacturer s instructions Camber 1 15 30 Caster Left side 3 10 45 Right side 3 40 45 If it is found to be incorrect adjust the camb...

Page 201: ... so that the front wheels turn 40 2 inward and 33 50 2 outward 10 E STEERING LOCK 10 E 1 Replacing Steering Lock Remove the steering lock in the numerical order 1 Column cover 2 Coupler for ignition switch disconnect Make a groove on the head of the bolts attaching the steering lock body to the column shaft by using a saw so that the screw driver can be used the loosen the screws 3 Steering lock a...

Page 202: ...1 580 49 8545 585 49 0164 631A 49 0180 510A 49 8038 785 SPECIAL TOOLS Puller ball joint Puller pitman arm Wrench lock nut Wrench lock nut Spanner lock nut Allaclunent steering worm bearing preload measuring Boot installer ball joint dust cover ...

Page 203: ... IOA C STEERING GEAR DISASSEMBLY lOA 5 lOA D OVERHAUL OF MAIN COMPONENTS lOA 6 IOA D 1 Steering Gear Housing IOA 6 lOA D 2 Valve and Piston Assembly JOA 7 lOA D 3 Side Cover and Sector Shaft lOA 7 lOA E STEERING GEAR ASSEMBLY lOA 7 lOA F STEERING GEAR INSTALLATION lOA 9 1OA G POWER STEERING PUMP REMOVAL IOA 11 lOA H POWER STEERING PUMP DISASSEMBLY lOA 11 lOA 1 POWER STEERING PUMP INSPECTION lOA 13...

Page 204: ...il pressure is smaller than 65 kg cm2 924 lb in2 there is something wrong with either the oil pump or the gear and pitman Note Do not leave the steering wheel fully turned for a long time or the oil temperature will rise having adverse effect on the parts in the oil line such as the oil pump piping and gear 3 Nexl keep the engine run at about 1500 rpm and record the oil pressure when closing the s...

Page 205: ... to three times to the stopper clockwise and counter clockwise In this case a noise may sometimes come out of the oil line and this is an indication that the air bleeding has not yet been complete 6 When turning the engine off with the steering wheel placed in the straight forward direction the oil level in the pump should not go up If the level goes up too much the air bleeding performed so far h...

Page 206: ...mp Belt Check I If the belt is broken glazed or worn replace the belt with a new one 2 If the belt is noisy check the tension of the belt Also check for misaligned pulleys 3 When the belt is pressed down with 10 kg 22 lb force the belt should deflect the specified amount For new belt 8 IO mm 0 31 0 39 in For used belt 11 13 mm 0 43 0 51 in 10A B STEERING GEAR REMOVAL Remove the power steering gear...

Page 207: ...g gear Plug the lines and port in the gear to prevent entry of dirt Raise the front end of the vehicle and support with stands 8 Ball joint disconnect Use the puller 49 0118 8SOC 9 Pitman arm Use the puller 49 0223 69SE 10 Remove the bolts and nuts retaining the steering gear housing to the body Slide the gear off the coupling and remove the gear IOA 4 ...

Page 208: ...vent on seals 1 Hold the steering gear upside down over a drain pan and tum the worm shaft from left to right several times to drain the fluid from the gear 2 Secure the gear on the work stand 3 Loosen the sector shaft adjusting screw Jock nut 4 To center the gear tum the worm shaft until the identification mark is positioned as shown in Fig IOA 12 S Remove the side cover attaching bolts 6 Tap the...

Page 209: ... assembly down ward 10A D OVERHAUL OF MAIN COMPONENTS 10A D 1 Steering Gear Housing a Disassembly 1 Remove the lower seal from the lower end of the housing 2 Remove the snap ring spacer washer and upper seal b Checking 1 Clean the housing thoroughly in clean solvent and then blow it dry with moisture free compressed air 2 Inspect the housing for scores in the area where the ball nut and seal moves...

Page 210: ...haft b Checking l Confinn that the side cover bearing is in contact with the sector shaft and check the bearings of the gear case for any wear or exfoliation 10A E STEERING GEAR ASSEMBLY 1 Secure the gear housing on the work stand 2 Apply Vaseline to a new 0 ring and place it on the pressure port of the gear housing 3 Apply Vaseline to the Teflon seal on the piston 4 Slide the piston and valve int...

Page 211: ...in place before pushing the cover down on the housing I I install the side cover attaching bolts and lock washers Torque to 3 8 5 0 m kg 29 36 ft lb 12 Confirm that the stub shaft makes more than 1 turns both clockwise and counterclockwise Ales confinn that the rotation torque of the stub shaft is less than 6 cm kg 5 2 in lb in the entires range 13 In the condition that the sector shaft is in the ...

Page 212: ...arm onto the sector shaft align ing the identification marks of the pitman arm and sector shaft Tighten the nut to 15 18 m kg 108 130 ft lb 10A F STEERING GEAR INSTALLATION Install the steering gear in the reverse order of removing Note a Fill the reservoir and bleed the system as described in Par 10A A b Start the engine and turn the steering wheel from left to right Inspect for fluid leaks ...

Page 213: ... and piston ass y 3 Side cover ass y 4 Pressure pipe 1 0 1 3 m kg 7 2 9 4ft lb S Return pipe 6 Pipe bracket ass y 7 Clip 8 Sector shaft ass y lOA t 8 9 Seal kit 13 Dust cover 10 Bolt with washer 11 Bolt with washer 12 Bolt and washer lOA 10 ...

Page 214: ...n lines from the oil pump Plug the lines and ports in the oil pump to prevent entry of dirt 5 Pump ass y 10A H POWER STEERING PUMP DISASSEMBLY 1 Mount the pump in a vise with soft jaws 2 Remove the pulley from the pump 3 Remove the woodruff key from the shaft 4 Remove the outlet connector and discard the 0 ring 5 Remove the bolts that attach the suction line con nector 6 Remove the bolts attaching...

Page 215: ... the body D Cam ring Rotor and shaft assembly Vanes Spring 9 Remove the following parts from the rotor and shaft assembly in the numerical order Snap ring Rotor Side plate Notlt Fix the shaft on a vice with soft cloth so as not to damage the shaft 10 Remove the flow control valve plug Remove the flow control valve and spring from the pump housing Discard the 0 rings on the plug lOA 12 ...

Page 216: ... shaft Wear and damage of the bush Wear and damage of the bore of the flow control valve Wear and damage of the shaft Clearance between the bush and the shaft Standard 0 03 _ 0 07 mm 0 0012 0 0028 in Limit 0 10 mm 0 004 in Clearance between the flow control valve and the bore of the flow control valve Standard 0 015 0 025 mm 0 0006 0 0010 in Limit 0 04 mm 0 0016 in Note Exchange the whole body ass...

Page 217: ...face of the cover 6 Inspect the flow control valve Wear and damage of the outer circumference of the flow control valve Wear and damage of the plug orifice Close one end of the hole of the flow control valve with a finger When air of approximately 4 S kg cm2 57 71 lb in2 is blown from the other end of the hole the valve is acceptable if there is not any air leakage from the small hole at the rear ...

Page 218: ...m kg 4 3 7 2 ft lb 8 Dowelpin 9 Rotor 10 Vane 11 Cam ring 12 Snap ring 13 End cover 14 Bracket ass y 15 Bolts 16 Plug 17 Spool valve ass y 18 Flow control spring 19 Outlet connector 20 Cap ass y 21 Oil tank ass y 6 1 0m kg 4 3 7 2 ft lb 3 2 4 7m kg 23 34 ft lb 22 Tube suction 23 Clip 24 Plate suction 25 Nut 26 Washer ...

Page 219: ...he shaft hub 3 Place the flow control valve spring in its hole and insert the spool valve with the pin end toward the plug 4 Lubricate the new 0 ring with power steering fluid and install them on the plug 5 Install the control valve plug on the housing and torque it to 7 10 m kg 50 72 ft lb Note a When inserting the plug pay attention not to damage the rod at the tip of the spool valve assembly b ...

Page 220: ...o the dowel pins b Use the rotor and the cam ring bearing the same mark c Since the cam ring has holes be sure to align them to the dowel pins 8 Install the vanes in the rotor slots with the rounded edge of the vanes outward Be sure the vanes slide freely Note In case of exchanging the cam ring rotor and vanes exchange these in a set 9 Lubricate the new 0 rings with power steering fluid and instal...

Page 221: ...que the attaching bolts to 0 6 _ 1 0 m kg 4 3 7 2 ft lb Note Clamp the suction connector without twisting the rubber part 13 Lubricate a new 0 ring with power steering fluid and install it on the pressure connector 14 Install the outlet connector on the housing and torque it to 4 _ 5 m kg 29 _ 36 ft lb 15 Confirm that the shaft rotates smoothly without any catch lOA 18 ...

Page 222: ...g pump in the reverse order of removing I Lightly tap the woodruff key into place on the shaft with a plastic hammer 2 Install the pulley onto the pump shaft and tighten the pulley nut to 4 0 5 0 m kg 29 36 ft lb SPECIAL TOOLS Power steering gauge set Puller pitman arm Puller ball joint Attachment steering worm bearing preload measuring ...

Page 223: ... Checking Brake fluid Level Sensor 11 7 11 E HYDRAULIC LINES INSPECTION 11 7 11 F DIFFERENTIAL PROPORTIONING VALVE 11 8 11 G FRONT BRAKE 11 8 11 G I Replacing Disc Brake Pads 11 8 11 G 2 Removing Caliper 11 9 11 G 3 Disassembling Caliper 11 10 11 G 4 Checking Caliper 11 11 11 G 5 Assembling Caliper 11 11 11 G 6 Installing Caliper 11 11 11 G 7 Checking Brake Disc 11 11 11 G 8 Removing Brake Disc 11...

Page 224: ... the lock nut Free travel 7 9 mm 0 28 0 35 in before the piston in the power brake unit operates 11 B BRAKE MASTER CYLINDER 11 B 1 Removing Brake Master Cylinder Remove the brake master cylinder in the numerical order 1 Air cleaner 2 Disconnect the fluid hoses at the brake master cylinder and plug the end of the hoses to prevent fluid leakage 3 Fluid pipes disconnect Use the spanner 49 0259 770A 4...

Page 225: ...low out with compressed air from the outlet hole 11 B 3 Checking Brake Master Cylinder 1 Wash the parts in clean alcohol or brake fluid Never use gasoline or kerosene Blow the parts dry with compressed air 2 Check the piston cups and replace if they are damaged worn softened or swelled 3 Examine the cylinder bore and pistons for wear roughness or scoring 4 Check the clearance of the cylinder bore ...

Page 226: ...r e Before installing the reservoir or inlet fitting make sure that the piston cups do not cover the com pensating ports 11 B 5 Installing Brake Master Cylinder To install the brake master cylinder carry out the removing operation in the reverse order After installing bleed the brake system as described in Par 11 J and check for proper brake operation 11 C POWER BRAKE UNIT 11 C 1 Removing Power Br...

Page 227: ...ate reassembly Attach the suitable wrench to the studs of the rear shell Rotate the rear shell clockwise to unlocked position Note Loosen the rear shell carefully as it is spring loaded 4 Diaphragm and power piston assembly Note Do not remove the rear seal from the rear shell unless the seal is defective and a new seal is available To remove the rear seal support the rear shell and drive out the r...

Page 228: ...action disc for deterioration of rubber 4 Check the valve rod and plunger for all seats to be smooth and free of nicks and dents Replace with a new one if defective 5 Inspect the front and rear shells for scratches scores pits dents or other damage 6 Check the diaphragm for cuts or other damage 11 C 4 Assembling Power Brake Unit I Apply power brake lubricant to the inner surface of the tube sectio...

Page 229: ...ront shell 11 Install the rear shell assembly onto the front shell by using the wrench to rotate the rear shell counter clockwise until scribe marks align Note Press the rear shell down firmly maintaining a pressure until the shell flanges are fully locked 12 Install the dust boot down against the rear shell 13 Install the fork end and lock nut 11 C 5 Installing Power Brake Unit Install the power ...

Page 230: ...o engine vibrations 11 D BRAKE FLUID LEVEL SENSOR 11 D 1 Checking Fluid Level Sensor 1 Disconnect the coupler of the sensor 2 Connect a circuit tester to the coupler and check the continuity by moving the float up and down as shown in Fig 11 25 When the float is below MIN mark the tester should show a continuity while the tester should not show any continuity when the float is above MIN mark If it...

Page 231: ...e pads in the numerical order 1 Insert the top end of the hub nut wrench between the wheel and wheel cap so as to provide a clearance 2 Insert the top end of the hub nut wrench into the illustrated position and pry it against the tire so that the hub nut wrench fully gets in between the wheel and wheel cap 3 As illustrated fully insert and pry the hub nut wrench against the tire Note a Do not use ...

Page 232: ...container 2 Open the bleeder valve and press the piston into the cylinder with the expand tool 49 0221 600C 3 Tighten the bleeder screw and remove the vinyl tube and expand tool 4 Install new pads and shims Note Apply a thin coat of grease lithium soap based grease N L G I No 2 with more than 5 of molybdenum disulfide to the contacting surface of the caliper 11 G 2 Removing Caliper Raise the front...

Page 233: ...rake hose 2 Dust boot Place a hardwood in the caliper pit in order to avoid damage graduaHy blow compressed air from the fluid pipe hole 3 Piston Note If the piston is seized and cannot be forced from the caliper tap lightly around the piston while applying air pressure 4 Piston seal Use the air out tool 49 0208 701 A 5 Bleeder screw if necessary 11 10 ...

Page 234: ... a Discard the old piston seal and the dust seal and use new ones b Be sure that the piston seal does not become twisted and it is seated fully in the groove cl Apply the grease supplied in the seal it on the dust boot and piston seal according to the instructions 11 G 6 Instatling Caliper To install the caliper carry out the removing operation in the reverse order After installing bleed the brake...

Page 235: ... the brake disc in the numerical order 1 Wheel cap refer to Par 11 G l 2 Front wheel 3 Caliper assembly refer to Par 11 G 2 4 Grease cap Note Never allow the caliper assembly to hang from the brake pipe as damage may occur 5 Sprit pin nut lock and nut 6 Thrust washer and outer bearing 7 Brake disc assembly 11 G 9 Installing Brake Disc To install the brake disc carry out the removing opera tion in ...

Page 236: ...ear Brake a Inspecting brake drum Inspect the brake drum and recondition if it is rough or scored Check the out of roundness with a dial indicator If it exceeds limit reface the drum Limit 0 15 mm 10 006 in When refacing the drum remove only so much materiaJ as is necessary to obtain a smooth surface on the drum Drum inner diameter limit 2 29 6 mm 9 0395 in b Inspecting brake linings J Check the b...

Page 237: ...ear roughness or scoring 2 Inspect the piston cups for wear softening swelling or any damage If any of these conditions exists replace the cups 11 H 3 Installing Rear Brake Shoes Install the rear brake shoes in the reverse order of removing Note Adjust the brake shoe clearance as described in Par 11 1 11 14 ...

Page 238: ...luid Never use gasoline or kerosene 2 Examine the cylinder bore and piston for wear roughness or scoring 3 Check the clearance between the cylinder and the piston If it exceeds the limit replace the cylinder or piston Limit 0 15 mm 0 006 in 4 Inspect the piston cups for wear softening swelling or any damage If any of these conditions exists replace the cups 11 H 6 Assembling and Installing Rear Wh...

Page 239: ...ribed in Par 11 K 9 Install the adjusting hole plugs onto the backing plate 11 J AIR BLEEDING If a pressure bleeding equipment is avaiJable it would be easier to use The front and rear hydraulic brake systems are individual and are bleed separately Note a During bleeding operation the reservoir of the master cylinder must be kept at least 3 4 full of the brake fluid b Do not mix low temperature br...

Page 240: ...s are free to tum Then support with stands 3 Adjust the parking brake lever adjusting screw so that the rear brakes are locked when the parking lever is pulled 5 7 notches with approx 10 kg 22 lb of force 4 After adjustment is completed apply the parking brake several times then release and make sure that the rear wheels rotate freely without dragging 5 Lower the vehicle SPECIAL TOOLS Spanner brak...

Page 241: ... 12 D WHEEL BALANCING 12 2 12 E FRONT WHEEL BEARINGS 12 3 12 E 1 Checking Front Wheel Bearing on Car 12 3 12 E 2 Removing Front Wheel Bearings 12 3 12 E 3 Inspecting Front Wheel Bearings 12 4 12 E 4 Installing Front Wheel Bearings 12 4 12 E 5 Adjusting Front Wheel Bearings 12 4 12 F REAR WHEEL BEARING 12 4 ...

Page 242: ...re loss of vehicle control and possible personal injury Do not exceed 80 km h 50 mph under any circum stances Because the spare tire s diameter is smaller than the regular tire the ground clearance is reduced by appox imately 25 mm I in Avoid driving over obstacles Also do not take the car through an automatic car wash when the temporary spare is installed Avoid road hazards such as chuck holes et...

Page 243: ... 0 m kg 65 80 ft 1 b 12 C WHEEL AND TIRE RUN OUT Wheel and tire should be measured for both radial and lateral run 0ut Limit Radial run out Less than 2 0 mm 0 08 in Lateral run out Less than 2 5 mm 0 10 in 12 0 WHEEL BALANCING The allowable unbalance is 360 cm gr 5 0 in oz which is less than 20 gr 0 7 oz at the rim If unbalance exceeds 360 cm gr 5 0 in oz or when a tire is disassembled for repair ...

Page 244: ...ble play is noticed this indicates that the bearings are rough 12 E 2 Removing Front Wheel Hub and Bearings Raise the front end of the vehicle and support with stands l Wheel cap and wheel 2 Caliper and bracket assembly Attach the caliper and bracket assembly to the coil spring with a piece of wire Note Never allow the caliper assembly hang from the brake pipe as damage may occur 3 Grease cap 4 Sp...

Page 245: ... Install the front wheel hub and bearings in the reverse order of removal with care taken on the following points 1 Clean the bearings thoroughly and repack them wit I lithium grease Do not overpack 2 Fill the hub cavity with lithium grease 3 Adjust the bearing preload as instructed in the following paragraph 12 E 5 Adjusting Front Wheel Bearings 1 Torque the adjusting nut to 2 0 to 2 5 m kg 14 to...

Page 246: ...od and Stabilizer Bar 13 7 13 C 3 Installing Tension Rod and Stabilizer Bar 13 7 13 D REAR SHOCK ABSORBER 13 8 13 D l Removing Rear Shock Absorber 13 8 13 D 2 Installing Rear Shock Absorber 13 9 13 E REAR SPRING 13 9 13 E 1 Removing Rear Spring 13 9 13 E 2 Inspecting Rear Spring 13 10 13 E 3 Installing Rear Spring 13 10 13 F REAR SUSPENSION UPPER LINK 13 11 13 F 1 Removing Upper Link 13 11 13 F 2 ...

Page 247: ... nuts 2 Brake disc assembly See Par 11 G 8 3 Backing plate 4 Front shock absorber attaching bolts 5 Front shock absorber and coil spring assembly Note Remove the shock absorber and coil spring assembly after marking on the suspension tower for correct relocation Hold the shock absorber and coil spring assembly in a vise Using the coil spring compressor 49 0223 640A and 49 0370 641 compress the coi...

Page 248: ...ped with soft jaws 2 Using a spanner 52 mm 2 05 in or monkey wrench remove the cap nut and seal assembly from the reservoir tube 3 Remove the O ring installed on the piston rod guide with a suitable tool 4 Pull out the piston rod and pressure tube assembly from the reservoir tube Note Does not remove the base valve from the pressure tube and piston from the piston rod 13 A 4 Inspecting Front Shock...

Page 249: ...ll the pilot 49 0259 590 over the threads of the piston rod 3 Apply grease to the lip of the oil seal and insert the cap nut carefully through the pilot and onto the piston rod Note The cap nut and oil seal assembly should be replaced with new ones 4 Tighten the cap nut temporarily ensuring that the piston rod is extended to its maximum length with the spanner or monkey wrench 5 Fully lower the pi...

Page 250: ...tening torque Front suspension arm to frame 2 3 3 0 m kg 17 22 ft lb Piston rod to mounting block 6 5 8 2 m kg 47 59 ft lb Front suspension arm to knuckle arm 6 4 9 5 m kg 46 69 ft lb 13 8 FRONT SUSPENSION ARM 13 8 1 Removing Front Suspension Arm Remove the suspension arm in the numerical order Note After the vehicle is jacked do not fail to support it with stands l Front wheel 2 Split pin and nut...

Page 251: ...ck or any damage 4 Inspect the dust seal of the ball joint and replace it it is defective 5 Inspect the control rod for any crack bend or torsion If necessary repair or replace Note The suspension arm and ball joint cannot be disassem bled from each other If either is defective replace the suspension arm and ball joint as an as sembly 13 B 3 Replacing Ball Joint Dust Boot I Remove the just boot us...

Page 252: ...sorber from the steering knuckle inspect the ball joint as follows 1 Rotate the ball stud for few turns to allow the stud to snug down 2 Hook the spring scale in the hole of the knuckle arm for connecting the tie rod and support the knuckle arm by placing a finger 3 Pull the spring scale and take a reading If the reading is lower than 0 4 kg 14 1 oz replace the ball joint in its assembled form 13 ...

Page 253: ...pect the removed parts for cracks defonnation damage or weakness If defective replace the parts as necessary 13 C 3 Installing Tension Rod and Stabilizer Bar Install the stabilizer bar and tension rod in the reverse order of removal Note When installing the stabilizer rubber bushing with the support plate place the open end of the bushing toward the front ...

Page 254: ...er arm Tightening torque Tension rod to lower arm 6 6 8 0 m kg 48 58 ft lb Note When installing the rubber bushing on the tension rod face the flat surface toward the bracket 13 D REAR SHOCK ABSORBER The gas sealed type shock absorbers should not be disassembled as it contains a highly compressed gas If it is found to be defective replace it as assembly 13 0 1 Removing Rear Shock Absorber I Raise ...

Page 255: ...ring 1 Raise the rear end of the vehicle and support with stands under the bracket front side of the lower arms 2 Remove the rear wheel 3 Place a jack under the rear axle housing to support it 4 Remove the absorber attaching nut from the lower end of the rear shock absorber and disengage the shock absorber from the rear axle housing 5 Remove the lateral rod attaching nut from the rear axle housing...

Page 256: ...3 Installing Rear Spring Install the rear spring in the reverse order of removing Note a Install the coil spring so that the open end of the spring is face to the rear axle housing b When installing the upper link lower arm rear shock absorber lower end and lateral rod tighten the bolts and nuts temporarily and after lowering the vehicle finally tighten the bolts and nuts to the specified torque T...

Page 257: ...air or replace 2 Check the rubber bushes for weakness wear or damage lf necessary replace the upper link in its an assembled form 13 F 3 Installing Upper Link Install the upper link in the reverse order of removing Note When installing the upper link and lateral rod tighten the bolts and nuts temporarily and after lowering the vehicle finally tighten the bolts and nuts to the speci fied torque Tig...

Page 258: ...e the rear end of the vehicle and support with stands under the bracket front side of the lower arms 2 Remove the lateral rod attaching nut from the axle housing 3 Remove the lateral rod attaching nut from the body Then remove the lateral rod 13 H 2 Inspecting Lateral Rod 1 Check the lateral rod for any crack bend or torsion lf necessary repair or replace 2 Check the rubber bushes for weakness wea...

Page 259: ...the rubber bushes for weakness wear or damage If necessary replace with new ones 13 1 3 Installing Stabilizer Bar 1 Install the support plate of the stabilizer bar to the axle housing and tighten the bolts temporarily Note Install the rubber bushes of the stabilizer bar support plate so that the open end of the bush toward the rear side 2 Install the front end of the stabilizer bar to the bracket ...

Page 260: ... 1 Removing Quarter Window 14 Regulator and Glass 14 16 14 1 14 L 2 Quarter Window Adjust 14 l ment 14 16 14 2 14 M COMBINATION METER 14 17 14 2 14 M l Removing Combination 14 2 Meter 14 17 14 3 14 M 2 Installing Combination 14 3 Meter 14 17 14 3 14 N CENTER PANEL 14 18 14 3 14 N l Removing Center Panel 14 18 14 4 14 N 2 Installing Center Panel 14 18 14 4 14 0 SWITCH PANEL 14 18 14 4 14 0 1 Removi...

Page 261: ...de by loosening the bonnet attaching bolts 2 Adjust the bonnet up and lown by loosening the hinge attaching bolts 3 Adjust the bonnet lock mechanism after the bonnet has been aligned The bonnet lock female part can be moved fore and aft and side to side to align it with the bonnet lock male part by loosening the attaching bolts 14 B TRUNK LIO 14 B 1 Replacing Trunk Lid Remove the trunk lid in the ...

Page 262: ... the lid lock alignment loosen the lid lock striker and lid lock attaching bolts and move the striker or lid lock as required then tighten the attaching bolts 14 C FRONT BUMPER 14 C 1 Removing Front Bumper Remove the front bumper in the numerical order Note After the vehicle is jacked up support it with stands l Shock absorber attaching nuts 2 Shock absorber piston rod end attaching nuts 14 2 ...

Page 263: ...per for good fit and appearance Check the slide groove for engagement Confirm visually from below Check the engagement by lifting the bumper Bumper height 1 Place vehicle on a level ground under curb weight conditions Tires must be inflated lo recommended pressure 2 Measure the height of bumper above ground at two mounting locations as shown in figure 14 0 REAR BUMPER Note After the vehicle is jac...

Page 264: ...E 1 Removing Windshield Glass For remove the windshield glass use the tool set 49 0305 870A as shown in Fig 14 16 Remove the windshield glass in the numerical order l Rear view mirror and front pillar trims 2 Wiper arms and wiper blades 3 Cowl grille attaching screws and fasteners 4 Disconnect the washer hoses from the washer nozzle 5 Cowl grille When removing the lower mould remove the cowl grill...

Page 265: ...d a bar Cut through the sealant by moving the wire back and forth Keep the wfre in constant contact with the glass so as not to damage the paint 7 Windshield glass 14 E 2 Installing Windshield Glass 1 Using the cutting knife cut the sealant off smoothly so that 1 2 mm 0 04 0 08 in of the sealant remains along the glass opening flange If the thickness of the sealant left along the glass opening fla...

Page 266: ...ant on the glass opening flange Allow the primer to dry 30 minutes before installation of glass Note a Apply as thin the sealant coating as possible to the glass bl Do not allow any dust water oil etc to get on the coating surface and also do not touch the coating surface with hand 4 Bond each spacer to the glass opening flange with bonding agent Fig 14 23 shows the directions and positions of eac...

Page 267: ...act 8 Firmly press the glass against the sealant with hand pressure Then inspect the appearance of the sealant through the glass A dull sport indicates an area where the sealant does not contact glass surface Additional hand pressure will seal most areas When installing the glass 5 8 mm 0 23 in clearance should exist between the body and the glass Check the clearance at the four positions as shown...

Page 268: ... remove the lower mould remove the lower mould supporting screws 3 In case of a vehicle equipped with a rear window defroster perform the works of disconnection and connection of the relevant wiring 4 The directions and positions each spacer to be bonded are shown in Fig 14 30 and 14 31 5 When installing the glass 7 8 mm 0 31 in clearance should exist between the body and the glass Check the clear...

Page 269: ...spect the seat adjuster for smooth operation by moving If necessary apply grease to the seat adjuster 2 Inspect the seat adjusting levers for wear If defective repair or replace it 14 G 3 Replacing Seat Lifter If equipped Remove the seat lifter in the numerical order Remove the seat assembly as described in Par 14 G l 1 Return spring 2 Seat lift lever 3 Attaching bolts 4 Retaining ring and plain w...

Page 270: ...ove the rear seat in the numerical order 1 Seat cushion attaching bolts 2 Seat cushion 3 Seat back attaching bolts 4 Seat back To install reverse the removal procedure Install the rear seat back so that the seat frame fits into the clip of the body as shown in Fig 14 39 Split Fold down Rear Seat If equipped 1 Seat cushion attaching bolts 2 Seat cushion 3 Side seat back attaching bolts 4 Open the t...

Page 271: ...at back To install reverse the removal procedure 14 1 DOOR 14 1 1 Adjusting Door Adjusting door lock striker The striker can be adjusted laterally and vertically as well as fore and aft The striker should not be adjusted to correct door sag 1 Loosen the striker attaching screws and move the striker as required 2 Tighten the attaching screws and check the door fit ...

Page 272: ...eatherstrip without damaging the rubber if the weatherstrip is to be used again 2 Remove the weatherstrip retaining clips from the door 3 Inspect the weatherstrip for crack deformation and damage If defective replace it 4 Fit the retaining clips to the weatherstrip with a plier 5 Position the weatherstrip to the door and fit the retaining clips into place To install reverse the removal procedure 1...

Page 273: ...Position the weatherstrip to the door and fit the retaining clips into place To install reverse the removal procedure 14 J FRONT DOOR 14 J 1 Front Door Window Regulator and Glass a Replacement Remove the door window regulator and glass in the numerical order With the window glass raised to full down position I Window regulator handle 2 Inner handle attaching screw 3 Ann rest 4 Door trim 5 Door scr...

Page 274: ... of the glass by moving the regulator guide up or down And tighten the regulator guide bolts Make sure that the regulator guide Q is parallel with the standard line Note Make sure that the glass moves smoothly b Vertical adjustment of the window Raise the window to full up position adjust the up stoppers Q CV Note Make sure that the regulator touches both up stoppers The clearance between the top ...

Page 275: ...d Note Make sure that the glass moves smoothly 14 K REAR DOOR 14 K 1 Rear Door Window Regulator and Glass a Replacement Remove the door window regulator and glass in the numerical order 1 Window regulator handle 2 Inner handle 3 Arm rest 4 Door trim 5 Door screen 6 Weatherstrip 7 Division bar The window glass raised to full down position 8 Window regulator assembly 9 Remove the window glass assemb...

Page 276: ...uarter Window Adjustment Remove the weatherstrip Body side a Vertical adjustment of the window Raise the window glass to full up position and adjust the up stoppers D l so that the clearance between the top of the glass and weatherstrip retainer is I0 mm 0 39 in Note Make sure that the regulator holder touches both up stoppers Lower the glass and check to see that glass holder slides smoothly on t...

Page 277: ...ON METER 14 M 1 Removing Combination Meter Remove the combination meter in the numerical order 1 Disconnect the negative cable at the battery 2 Steering wheel 3 Column cover 4 Speedometer cable Reach under the instrument panel and disconnect the speedometer cable from combination meter S Meter hood 6 Combination meter attaching screws 7 Disconnect the wiring couplers from the meter 8 Combination m...

Page 278: ...ect the whole of the electrical leads from the center panel assembly 7 Center panel assembly 14 N 2 Installing Center Panel Follow the removal procedures in the reverse order 14 0 SWITCH PANEL 14 0 1 Removing Switch Panel Remove the switch panel in the numerical order 1 Disconnect the negative cable at the battery 2 Steering wheel 3 Column cover 4 Remote control switch 5 Cruise control switch 6 Sw...

Page 279: ...l procedures in the reverse order Adjust the glove box if necessary 14 0 INSTRUMENT PANEL 14 0 1 Removing Instrument Panel Assembly Remove the instrument panel assembly in the numerical order 1 Disconnect the negative cable at the battery 2 Steering wheel 3 Column cover 4 Combination switch 5 Steering shaft attaching bolts 6 Combination meter 7 Glove box See Par 14 P 1 8 Switch panel See Par 14 0 ...

Page 280: ...cal leads from the instrument panel assembly 16 Instrument panel assembly 14 0 2 Installing Instrument Panel Assembly Follow the removal procedures in the reverse order Note a The all electrical wirings should be connected firmly Make sure the all meters and lights operate normally after installing bl When reinstall the defroster hose make sure that the hose is propery fitted and fix the bottom ho...

Page 281: ...ig 14 84 14 21 14 R TOP CEILING full roof 14 R 1 Removing Top Ceiling Remove the top ceiling in the numerical order l Rear view mirror 2 Sun visors 3 Interior light 4 Assist grips 5 Front pillar trims 6 Side garnishes 7 Rear pillar trims ...

Page 282: ...4 8 Remove the polyethylene plates on both sides of top ceiling 9 Remove the polyethylene plates of the top ceiling from the inserting points of the body 10 Remove the top ceiling by removing the fasteners on the rear both side 14 22 ...

Page 283: ...p ceiling to 300C to SOOC 86 F to 122 F 2 Match the center mark of top ceiling to the center of finishing channel set the rear side as shown in figure 3 Insert both ends of the listing wire to their respective positions in successive order beginning from the rear When doing so be careful that the wires do not swing down ...

Page 284: ...body 5 Attach the polyethylene plates on both sides 6 Installing the fasteners 6 Bond the double sided bonding tape to the body flange 7 Bond the top ceiling to the body flange while pulling on the inner to elirninater wrinkles 8 When the top ceiling is bonded without wrinkles cut off any remaining materi 9 Install the parts concerned in the reverse order of removing 14 24 ...

Page 285: ...ion Section A F E E 8 E E cross section m D D cr oss s Fig 14 96 14 S 1 Replacing Top Ceiling Remove the top ceiling in the numerical order 1 Rear view mirror 2 Sun visors Fully open the sunroof and front doors 3 Overhead console ass y Fig 14 96 4 Interior light 5 Assist grips Fig 14 97 14 25 ...

Page 286: ...pillar trims 8 Side garnishes 9 Front top garnishes 10 Rear top garnishes 11 Steering wheel sedan only 12 Front seats sedan only 14 13 Position the gear shift lever at 5th position sedan only 14 Release the parking brake fully release and block the wheel sedan only 14 26 ...

Page 287: ...ior Light and three fasteners on the rear side Note When removing the fasteners be most careful not to scratch the top ceiling When detatching the top ceiling incline it and take it off from the assistant driver s seat side as shown in the illustration Note When removing and installing the top ceiling take utmost care so that it will not interfere with other parts of the vehicle and be most carefu...

Page 288: ...g sunroof l Outer panel 2 Weatherstrip 3 Lower panel ass y 4 Front guide bracket S Rear guide bracket 14 6 Packing 11 Stopper 7 Inner trim ass y 12 Frame as s y 8 Deflector ass y 13 Tube ass y 9 Rail cover 14 Motor ass y 10 Rail ass y 15 Regulator ass y 14 28 ...

Page 289: ... Fig 14 106 Fig 14 107 Fig 14 108 14 29 Guide bracket ass y rear 14 T 1 Removing Sliding Sunroof 1 Open the outer panel approximately IO cm 2 Remove the inner trim clips and push the trim inward 3 Fully open the outer panel and pull out the inner trim ...

Page 290: ...w deflector Note The deflector is always pushed toward the opening direction by a spring Hold the deflector by hand preventing it from hitting the roof panel and pull out the deflector link connector 8 Remove the stopper 9 Remove the rail cover 10 Close the panel leaving an open space of approxi mately 47 mm 1 85 in between the front end of lower panel and the roofpancl 11 Remove the rear bracket ...

Page 291: ...erformed more efficiently with the manual operation handle 1 Insert the driving cable into the tube ass y Note a Apply an ample amount of grease to the driving cable and insert the cable through the end of the tube ass y b Apply an ample amount of grease on the sliding surfaces of cam and guide shoe 2 Properly adjust the left and right positions of driving cable Note Insert the guide rail into its...

Page 292: ...e a When opening the lower panel the roof panel and lower panel may interfere with each other Make sure that the guide rollers are in the guide rails completely b When opening the lower panel push on the roof panel at a slightly inclined angle but do not to allow the cable to protrude from the rail 7 Remove the rail cover and stopper Note Install the stopper according to the markings shown on the ...

Page 293: ...g the adjust screw Turn clockwise Up Turn counterclockwise Down 3 Tighten mounting screws I and 2 Procedure to adjust C C Cross Section 1 Loosen the mounting screws and the adjusting screw For easy adjustment do not overly loosen mounting screws excessively 2 Adjust by moving the outer panel from inside or outside 3 Tighten the adjusting screw and the mounting screws in that order 11 Open the oute...

Page 294: ...ear portion of panel does not interfere excessively with the roof panel If interfering fully open the outer panel and move the stopper forward Note If the stopper is moved forward too far it may cause a malfunction or leaks Make sure the gap between the outer panel and roof panel is not more than 5 mm 0 20 in Widthwise adjustment of guide front bracket and guide rails Move both of them left and ri...

Page 295: ...st it to 20 25 kg 44 55 lb by turning the torque adjusting nut Note a For the measurement remove the inner trim and use the long hole at the center of lower panel b After the adjustment be sure to lock the nut with a ball washer SPECIAL TOOL 49 0305 870A Tool set window ...

Page 296: ... 8 071 a 164 6 457 f 460 18 1 11 A Stabilizer fixing hole E Lower arm fixing hole l 43 1 693 g 82 3 228 B Rear frame basic hole F Upper link fixing hole c 302 11 890 h 97 3 819 d 255 I0 040 1 100 3 937 C Rear frame basic hole G Lateral rod bracket basic hole ll I e 1o 4 095 I 4 1 5 1 634 Shown mch D Steering gear box fixing hole H Rear shock absorber fixing hole OJ 0 0 n J m n A z Cl 0 3 m z en 0 ...

Page 297: ...Removing Combination Switch 15 7 15 E 2 Checking Combination Switch 15 7 I5 F REAR WINDOW DEFOGGER 15 8 I5 F l Checking Rear Window Defogger 15 8 15 G WINDSHIELD WIPER 15 9 15 G 1 Replacing Wiper Motor 15 9 15 G 2 Checking Wiper Motor 15 10 15 G 3 Adjustment 15 11 15 H HEATER 15 11 15 H l Checking Heater Fan Switch and Blower 15 11 15 1 REMOTE CONTROL MIRROR If equipped 15 I2 15 1 1 Checking Remot...

Page 298: ...5 The left table shows bulb capacity Front tum signal and parking 27 8 Rear combination Tum and tail signal light 27 8 Stop light 27 Back up light 27 License light 6 Glove box light 3 4 Trunk room light 5 Interior light 5 Spot light 6 Indicator Warning light Tum signal 3 4 High beam 3 4 Oil level 3 4 Heat hazard without tachometer 3 4 with tachometer 1 4 Brake 3 4 Seat belt 3 4 Automatic select le...

Page 299: ...n meter See Par 14 M l 2 Meter cover 3 Fuel gauge and water temperature gauge attaching nuts 4 Fuel gauge and water temperature gauge To install reverse the removal procedure Note The all electrical wmngs should be connected firmly Make sure the all meters and lights operate normally after installing 15 C 2 Checking Fuel Gauge a Fuel Gauge 1 Use the checker 49 0839 285 2 Set the checker to the spe...

Page 300: ...alue 671 1 ohms Push the buttons as shown in Fig 15 6 3 Disconnect the coupler under the left side instrument panel 4 Connect the checker to the coupler as shown in Fig 15 8 Terminal connection Fuel gauge U Fuel gauge unit Colored Y 5 Tum the ignition switch on and check the gauge indication 6 Repeat the above inspection on the other points ...

Page 301: ...ct the negative cable at the battery 2 Open the trunk lid 3 Service hole cover attaching screws 4 Service hole cover 5 Wire coupler disconnect 6 Fuel gauge unit Use the hook wrench 49 1345 875B Measure the resistance between the G terminal and e terminal on the fuel gauge unit with an ohmmeter The resistance should charge smoothly when the float arm is moved and be of the values when in the table ...

Page 302: ...ture Gauge Unit Replace the water temperature gauge unit in the numerical order 1 Wiring connector 2 Water temperature gauge unit To Install reverse the removal procedure 15 C 4 Checking Water Temperature Gauge a Water Temperature Gauge Check the resistance on each point in the same manner for the fuel gauge ...

Page 303: ...the negative cable at the battery 2 Column covers 3 Wire couplers disconnect 4 Ignition switch contact housing 15 0 2 Checking Ignition Switch Check the continuity between the switch terminals using the circuit tester Terminal connections Color code Switch Position LOCK ACC ON START Terminal B WR T ACC L IG1 BY x IG2 BW ST BR L RB T E B I Ki RY T T T T Kz G 1 1 1 1 15 6 l ...

Page 304: ... SWITCH 15 E 1 Removing Combination Switch Remove the combination switch from the steering shaft as described in Par 10 A l 15 E 2 Checking Combination Switch Check the continuity between the switch terminals using the circuit tester Turn Signal and Hazard Switch 9 TL c TIG c FB a HBA h FU I TR d b TIG HBA FB Turn signal Hazard Light Dimmer and Passing Switch dHO a HL b HU BA HL HU Light Dimmer Pa...

Page 305: ...LOW Combination switch e SW c INT a E f SWL d AS b SWH SWH T NT SW E Wiper Washer Cruise Control Terminal SE RE co E Switch Position OFF SET RESUME COAST A Cruise con box CD Combination switch SET R B Cruise con box J I Combination switch COAST L C Cruise con box Combination switch RESUME Y D Earth B A SE C RE 8 00 DE 15 F REAR WINDOW DEFROSTER 15 F 1 Checking Rear Window Defroster Switch Check th...

Page 306: ...positive Close to zero side from center According to the left table if any defects are found check the breakage portion as follows I Move the terminal of meter to the side where breakage is known to exist and note the sudden change in voltage at a portion That portion is where the filament is broken 2 Use the coductive silver paint Part No 2835 77 6000 i e Dupont No 481 7 to repair the broken sect...

Page 307: ... the wiper motor verifying the autostop position Tightening torque Wiper arm assembly lock nut 1 0 1 2 kg m 7 2 8 7 ft lb 15 G 2 Checking Wiper Motor 1 Earth the motor earth wire 2 Connect a ohmmeter between the L terminal and battery terminal 3 Earth the LW or LR terminal and check the number of wiping revolutions and note the amperage Wiping revolusion Amperage no load LOW 50 60 rpm 3A or less H...

Page 308: ...rect installation angle to obtain correct sweeping zone as shown in figure b Nozzle direction 15 H HEATER 15 H 1 Checking Heater Fan Switch and Blower a Heater fan switch Check the continuity between the switch terminals using a circuit tester Terminal B L M H Switch Position OFF LOW MIDDLE HIGH b Heater blower Terminal connection a High speed terminal b Low speed terminal c Middle speed terminal ...

Page 309: ...R SWITCH 15 J 1 Checking Inhibitor Switch Check the continuity between the switch terminals using the circuit tester I Terminal B B P N BW IG RW IR RL Switch Position p R N Note Dotted lines show the connection for starting circuit a R Inhibitor switch Rear combination lamp RL b P N Inhibitor switch Starter BW c IG Fuse box Inhibitor switch RW d B Steering lock Inhibitor switch 8 15 12 ...

Page 310: ...ops to 0 and returns to 8 volt when releasing it Approx 8 volt During turning COAST switch to arrow direction the volt age drops to 0 and returns to 8 volt when releasing it Approx 8 volt During turning RESUME switch to arrow direction the voltage drops to 0 and returns to 8 volt when releasing it 12 volt during depressing the brake pedal or clutch pedal 12 volt during depressing tJ1e brake pedal ...

Page 311: ...ator warning light YL a9 Heat hazard warning light Floor sensor YL a10 Fuse box Heat hazard warning light BW al1 Steering lock L Brake system warning light RB a12 Oil pressure switch Oil pressure warning light YR alO bl Combination meter chime oscillator b2 Combination switch TR Turn signal indicator light RH GW b3 Head light High beam indicator light RW b4 Earth B bS Combination switch TL Turn si...

Page 312: ... pressure switch Oil pressure warning light YR b7 b6 IJ8 1 5 b 9 1 4 clO 1 3 bl l l l bl bl Combination meter chime Oscillator b2 Combination switch TR Turn signal indicator light RH GW b3 Head light High beam indicator light RW b4 Earth B bS Combination switch TL Turn signal indicator light LH GB b6 Fuse box Combination chime LB b7 Water thermo unit Water temperature gauge YB b8 Earth B b9 Rear d...

Page 313: ...s SPECIAL TOOLS ...

Page 314: ...or your performing operations satisfac torily easily and efficiently and so it would be advisable for your to provide your service shops with these tools by all means B Selective The degree of necessity of the tools in this list are not so high as that of the tools in A but please provide your service shops with the tools in B if possible in order to easily perform operations ...

Page 315: ...her valve seal A J Remover A i I Installer valve guide 49 8134 040 OBg Tool set piston A pin setting 49 3953 260 Guide chain B adjuster 49 0221 270B 49 0118 271A Puller main bearing B n M cap tt w u Brake ring gear A o rm o 49 4120 110 ry Remover chain B ring 49 0164 631A Spanner lock nut B COOLING GROUP TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49...

Page 316: ...0 Installer main A drive gear bearing m Installer transmis A sion bearing 49 0259 440 49 0862 350 Turning holder A c main shaft Guide shift fork B assy 49 1243 465A 49 0187 451A Wrench main shaft A ID Guide interlock B lock nut pin assy I AUTOMATIC TRANSMISSION GROUP TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49 0378 320A Stand transmission B case 1...

Page 317: ...9 561 Attachment engine stand 49 0259 710A Holder coupling flange PRIORITY ILLUSTRATION A B s TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49 0378 400A u Gauge set oil A pressure 49 0378 480 Confirmation B gauge 49 8000 015 p Remover snap J B ring 49 8000025 fo Remover snap B ring 49 8000 035 Spinner handle B TOOL NUMBER PRIORITY 1LLUSTRATION DESCRIPTION 49 0223 561A Attachment A diff work 49 025...

Page 318: ...ut 49 8501 631 Attachment rear B axle shaft puller I 49 8531 746 Separator bearing B 49 0259 748 Attachment B bearing separator s 4 TOOL NUMBER DESCRIPTION 49 0305 555 Gauge block 49 0727 570 Gauge body pinion height adjust TOOL NUMBER DESCRIPTION 49 0221 600C Expand tool disk brake 49 0223 630A Puller rear axle shaft 49 0259 747 Attachment bearing separator PRIORITY ILLUSTRATION A A PRIORITY ILLU...

Page 319: ...ER GROUP TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49 0187 280 Oil pressure gauge B I s TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49 0180 510A Attachment steer B ing worm bearing preload measuring 49 0118 850C Puller ball joint B 49 8038 785 ID Boot installer ball B joint dust cover 490370 641 f Y f j J Screw coil spring A compressor 49 1205 605 Adapter caster B camber gauge 49 8545 585 Ad...

Page 320: ... nut __ 49 Ol18 870A Driver carburetor B power valve I 49 8531 855 Nut wrench B s 6 TOOL NUMBER PRIORITY DESCRIPTION 49 1345 875A Hook wrench fuel A gauge tank unit 49 0305 870A Tool set window A Bond type 49 0208 701A Air out tool boot B 49 2113 0108 Gauge set air pump A ILLUSTRATION a II I 0 011 I I e L J 000 t ...

Page 321: ...TECHNICAL DATA IOI ...

Page 322: ... mm 0 3142 in O ol8 0 053 mm 0 0007 0 0021 in 0 20 mm 0 008 in 1 Valve Exhaust Overall length Head diameter 1 ace angle Valve margin Wear limit Stem diameter Standard Wear limit Stem to guide clearance Standard Wear limit Valve spring Outer Wire diameter Outer coil diameter Free length Standard Limit foitting length Fitting load Standard Limit Valve spring Inner Wire diameter Outer coil diameter F...

Page 323: ... 0012 In Protrusion of adjuster sliper head limit 13 mm 0 512 in Thickness Valve timing Top 3 6 O l mm Inlet valve opens 10 BTDC 0 1417 0 0039 in Inlet valve closes 57 ABDC Second 3 6 O l mm Exhaust valve opens 54 BBDC 0 1417 0 0039 in Exhaust falve closes 13 ATDC Oil 3 6 0 2 mm Connecting rod 0 1417 0 0079 in Length Center to center 166 0 05 mm Side clearance 6 5355 0 0020 in Top 0 030 0 070 mm P...

Page 324: ...497 g ooo7 in Oil capacity 3 9 liters 4 1 U S quarts I Wear limit of bore 0 15 mm 0 0059 in or more 3 4 Imp quarts Boring size 0 25 mm 0 QIO in I 0 50 mm 0 020 in COOLING SYSTEM Coolin2 capacity LUBRICATING SYSTEM With heater 7 5 liters Oil pump 7 9 U S quarts Type Rotor 6 6 Imp quarts Without heater 6 9 liters Feeding capacity at 13 liters min 7 3 U S quarts 2 000 rpm of engine 13 7 U S quarts 6 ...

Page 325: ...lSS Slip ring diameter Main all bleed Standard 33 0 2 mm Primary SO l 299 0 008 in Secondary SO Limit 32 2 mm 1 268 in Slow jet Pulley ratio 1 1 9 Primary U S A 48 Starting motor Canada 46 Manual transmission Secondary 90 Capacity 0 8kw Slow all bleed Lock test Primary No 1 100 Voltage S Ovolt Primary No 2 170 Current 310 amp or less Secondary No 1 SO Torque 0 75 m kg 5 4 ft lb or more Secondary N...

Page 326: ...ms at 20 C 68 F Above 18 c 0 F A P I Service GL 4 or GL 5 Canada 0 9 ohms at 20 C 68 F I SAE90 Hightension cord 16 ki1 m 40 per m Below 18 C 0 F A P I Service GL 4 or GL 5 SAE 80 CLUTCH Type Single dry plate diaphragm spring Pressure plate Permissible lateral 0 05 mm 0 0020 in run out AUTOMATIC TRANSMISSION Clutch disc Lateral run out of clutch Model JATCO 3N71B disc Gear ratio Limit 1 0 mm 0 039 ...

Page 327: ...gr 0 28 in oz Thickness offriction plate 2 0 mm 0 079 in At center 12 5 cm 0 17 in oz Total clearance measured 0 8 1 05 mm At rear 20 cm gr 0 28 in oz between retaining plate 0 031 0 041 in Universal joint and snap ring Spider diameter 14 72 mm 0 5795 in Gear assembly Wear limit 14 595 mm 0 5746 in Total end play 0 25 0 50 mm Journal swinging torque 3 8 cm kg 2 6 6 9 in lb 0 010 0 020 in Planetary...

Page 328: ...1 0 mm 0 004 in Temperary spare ti re 4T 14 Max wheel angle on full lock Tire Wheel on inside of curve 40 00 1 2 Front rear 165SR13 185 70SR13 Wheel on outside of curve 33 50 I 2 Temperazy spare ti re Tl25 70Dl4 Minimum turning radius 4 8 m 15 ft 7 in Inflation pressure Steering geometry Front rear 26 p s i King pin inclination 10 36 Tcmpcrary spare tire 60p S I Camber 1 14 30 Max permissible diff...

Page 329: ...ver 1 8 2 7 13 20 Rear axle Ring gear 7 5 8 5 54 61 Transmission Differential side bearing 3 8 5 3 27 38 Shift lock spring cap 1 0 1 5 7 11 caps Plug for interlock pin hole 1 0 1 5 7 11 Companion llange to pinion 13 0 18 0 94 130 Control lever to control 2 8 3 4 20 25 rod end Steering Shift fork set bolts 1 2 1 6 9 12 Steering wheel nut 4 0 5 0 29 36 Main shaft lock nut Steering gear housing to 4 ...

Page 330: ...6 76 Lower arm to axle casing 7 7 10 5 56 76 ST Lower arm to frame 7 7 10 5 56 76 6 mm bolt nut 0 8 1 2 6 9 Upper link to axle casing 7 7 10 5 56 76 8 mm bolt nut 1 8 2 7 13 20 Upper link to flange 7 7 10 5 56 76 10 mm bolt nut 3 7 5 5 27 40 Lateral rod to axle casing 7 7 10 5 56 76 12 mm bolt nut 6 4 9 5 46 69 Lateral rod to frame 7 7 10 s 56 76 14 mm bolt nut 10 4 14 0 75 101 UnleS otherwise spe...

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Summary of Contents for 626 1981

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Mazda 626 1981, Workshop Manual

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Summary of Contents for 626 1981

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