Subaru 600 Service Manual

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SERVICE MANUAL TRUCK & VAN

INDEX

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FOREWORD This servict: manual 1has been 1prepared to provide

service personnel with the

necessary information and data for the correct maintenance and repair of SUEARU 600 Truck and Van with 4 cycle engine. The service manual covers the construction, function, disassembling, reassembling, inspection and adjustment of EK2:

!e, transmission and body for guidance of both

the fully qualified and the lessexl

mechanics.

Please peruse and utilize this manual fully to ensure complete maintenance and repair work for satisfying our customers by keeping their vehicles in optimum condition. When replacement of parts during maintenance is needed, be sure to use

suer\Ru

genuine parts. All information,. illustrations and specifications contained in this service manual are based on the latest product information available at the time of publication approval. Applicable vehicle identification numbers of this service manual are as follows:

Right-Hand Drive Model

Left-Hand Drive Model

,

K77

002001 and after

Truck and Flat Bed Truck

K87

002001 and after

Van and Delivery Van

K77L

5iOOOl andl after

Flat Bed Truck

2 K87L

5iOOOl andl after

Van and Delivery Van

FUJI HEAVY INDUSTRIES LTD.

and @ are trademarks of FUJI HEAVY INDUSTRIES LTD. Copyright 1977 FUJI HEAVY INDUSTRIES LTD. Not to be reproduced in whole or in part without the prior written permission of FUJI HEAVY INDUSTRIES LTD., Tokyo, Japan.

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CHAPTER

1 : GENERAL INFORMATION

Page

11 .

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IDENTIFICATION NUMBERS ...........................................................

1-2

12 .

CAUTION LABELS

...........................................................................

1-2

...................................................................

1-2

RECOMMENDED LUBRICANTS

1-2

RECOMMENDED COOLANT

.................................................... AND BRAKE FLUID ......................

1-3

16 .

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.......................

1-3

17 .

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L l FTlNG POtNTS AND TOWING HOOKS

.....................................

1-4

13 . 14 . 1-5

RECOMMENDED FUEL

REFILLING CAPACITY OF OIL AND COOLANT

1-1. 1.

IDENTIFICATION NUMBERS Engine serial number

1-2. -..-CAUTION LABELS 1.

Tire inflation pressure label

The die stamped engine serial number is located on the front of the crankcase as shown in Fig. 1-1.

Tire inflation pressure label is stuck on the end of driver's side door.

Fig. 1-1 Engine serial number location

Fig. 1-3 Tire inflation pressure label

1-3. 2.

Chassis serial number

The die stamped chassis serial number is located at the chassis frame as shown in Fig. 1-2.

RECOMMENDED FUEL

The SUBARU 600 engine is designed to get satisfactory engine performance by using gasoline no less than 83 octane.

NOTE: Octane as selected by Research method.

1-4. 1. 1)

RECOMMENDED LUBRICANTS Recommended SAE viscosity number Engine oil

AP1 SAE viscosity No. and Applicablc Temperature ClassifiO°C (30°F) 30°C (90°F) cation -30°C (-20°F) T

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T

T

-2s0C (-1O0F)

Fig. 1-2 Chassis serial number location 30,2OW-40, 20W-50 SE

NOTE: Engine and chassis numbers are used for factory communications such as Technical reports, Service bulletins and other information.

low-30, low-40, 1OW-50

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(5W-30 is not recommended for sustained high speed driving) I

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2)

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NOTE: Use "SUBARU genuine coolant" when replacing or refilling the coolant.

Transtnission gear oil

SUBARU COOLANT (net 18 liter) Parts No. 000016218

2.

NOTE: Each oil manufacturer has i t s base oil and additives. Thus do not mix two or more brands.

Brake f l u i d

Heavy Duty Brake Fluid (FMVSS NO. 1 16, DOT3) High boiling point

NOTE: a. Avoid mixing brake fluid of different brands

1-5.

1.

RECOMMENDED COOLANT AND BRAKE FLUID

to prevent the fluid performance from degrading. b. When brake fluid is supplemented, be careful not to allow any dust into the tanks.

Coolant

Coolant is anti-freeze, anti-corrosive ethylenglycol coolant. The coolant used is especially made for the SUBARU vehicle. Avoid using any coolant or only water other than this designated type t o prevent corrosion.

1-6.

REFILLING CAPACITY O F O I L A N D COOLANT Liter

U.S. measure

Irnp. measure

31

8.2 gal.

6.8 gal.

(Oil pan capacity)

2.5

2.6 q t .

2.2 qt.

(Oil capacity)

2.8

3.0 qt.

2.5 qt.

Transmission oil

0.9

1.0 qt.

0.8 qt.

Engine coolant

6 .O

6.3 qt.

5.3 qt.

Fuel Tank

Engine oil

1-7.

L I F T I N G POINTS A N D TOWING HOOKS

1) Front a. When jacking up the front of the vehicle, place the chocks behind the rear wheels to hold them. b. Apply the garage jack undei: the frame as shown in Fig. 1-6. .,

Fig. 1-4 Lifting points 1.

Pantograph jack

Fig. 1-6 Front jack up point

Mark shows each pantograph jack setting positions.

Rear When jacking up the rear of the vehicle, place the chocks at the front side of the front wheels to hold them. 2)

NOTE: Never get under the vehicle while it is supported only by the jack. Always use safetv stands to suooort bodv when vou have ;o get under the'&.

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Fig. 1-7 Rear jack up point 3. Fig. 1-5 Pantograph jack

2.

Garage jack

NOTE: After jacking up the vehicle with garage jack, be sure to support the vehicle with safety stands for safety.

Towing hooks

Towing hooks are provided in front and rear ends of vehicle.

NOTE: a. Before towing the car, make certain that the parking brake is released and transmission is in neutral. b. Never turn the ignition key to the ,"LOCK" position while the car is being towed.

Fig. 1-8 Front towing hook

Fig. 1-9 Rear towing hooks

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2:

CHAPTER

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2-2. I

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ENGINE SPECIFICATIONS

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SPEC1FICATIONS

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BODY. .SPEC1FlCATlONS ; *;

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2-2 2--6 ';

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2-1.

ENGINE SPEC1FlCATlONS

Engine

EK23BE

Transmission

4-speed manual

ENGINE Manufacturer

Fuji Heavy Industries Ltd.

TYpe

Gasoline engine

Number of cylinder and arrangement

Two, in-line with a balancer shaft

Cycle

Four cycle

Cylinder liner

Dry type

Bore x Stroke

mm (in)

76.0 x 60.0 (2.99 x 2.36)

Piston displacement

cc (cu.in)

544 (33.2)

Compression pressure (at 300 rpm)

kg/cm2 (psi)

10.5 (149.31)

Compression ratio

8.3 : 1

Maximum output (SAE Net)

27 HP at 6,000 rpm

Maximum torque (SAE Net)

3.9 kg-m (28 ft-lb) at 3,500 rpm

Engine dimensions mm (in) (Length x width x height)

626 x 562 x 416 (24.6 x 22.1 x 16.4)

Weight of engine without transmission (Including engine oil) kg (lb)

61 (134.5)

Engine location

Rear

Material of piston

Aluminum alloy

Number of piston rings

Compression : 2, Oil : 1 Opening

B.T.D.C.

26"

Closing

A.B.D.C.

66"

Opening

B.B.D.C.

66"

Closing

A.T.D.C.

26"

Intake valve timing

Exhaust valve timing

.

Intake

0.13 - 0.17 mm (0.005 - 0.007 in)

Exhaust

0.23 - 0.27 mm (0.009 - 0.01 1 in)

Valve clearance (cold)

Starting system

Starter motor

Idling speed

1,000 rpm

Crankcase emission control system

Sealed crankcase ventilation

IGNITION SYSTEM Ignition system

Battery

Firing order

1-2

Ignition timing

B.T.D.C.

10" at 1,000 rpm

Model

LW-13

Manufacturer

Diamond electrical manufacturing company

Ignition coil

Vacuum x Centrifugal type

Type of ignition advancer Type

BP6ES

L45PW

W2OEP

Manufacturer

NGK

HITACHI

NIPPON DENS0

Thread size

M14 x 1.25

Spark gap

0.8 mm (0.032 in)

Type

NT50-N24

Voltage

12V

Capacity

26AH

Model

02 1000-2920

Manufacturer

NIPPON DENS0

Voltage

12V

Capacity

35A

Type

Tirille type (Model 026000-2750)

Manufacturer

NIPPON DENS0

Spark plug

ELECTRICAL SYSTEM

Battery

Alternator

Alternator

Voltage regulator

Starter motor

Type

Magnetic shift type

Manufacturer

HITACHI LTD.

Voltage & Output

12V-0.7KW

FUEL SYSTEM Type

Zenith-Stromburg

Manufacturer

HITACHI LTD.

Model x Number

HCE30-70 x 1

Throttle bore

30mm(1.18 in)

Venturi dia. (Large x small)

25 x 9 mm (0.98 x 0.35 in)

Main jet x Main air bleed

#I22 x #SO

Slow jet x Slow air bleed

#48 x #I50

Accelerator pump nozzle

0.4 mm (0.016 in)

Choke mechanism

Manual

Air flow direction

Side draft

L t

S

2

1

U

Air cleaner type

Dry

LUBRICATION SYSTEM Lubrication method

Forced feed and splash type

Oil pump

Trochoid type

Oil filter

Cartridge Without oil filter

2.5Q (2.6 USqt., 2.2 Imp.qt)

With oil filter

2.8Q (3.0 USqt., 2.5 1mp.qt)

Volume of engine oil

COOLING SYSTEM Cooling method

Liquid cooling

Water pump

Centrifugal type

Thermostat

Wax pellet type

POWER TRANSMISSION SYSTEM

s

G

TYpe

Dry single plate diaphragm

Number of clutch discs

1

Clutch disc lining (inner dia. x outer dia. x thickness)

160x l l O x 3 m m (6.299 x 4.331 x 0.1 18 in)

Type

4-forward speeds with synchromesh and 1-reverse

'

1st

4.363

2nd

2.625

3rd

1.809

4th

1.107

Reverse

4.272

Type of gear

Helical

C

0

.A

V1

'g V)

E

Gear ratio

'

b

Final reduction gear Reduction ratio 5.733

2-2.

BODY SPECIFICATIONS K77

Vehicle type

K87 Flat Bed Truck

Truck

Delivery Van

Van

DIMENSIONS Length

mm (in)

3,195 (125.8)

Width

mm (in)

1,395 ( 54.9)

Height

mm (in) Length mm (in)

Cargo bed

Width

mm (in)

1,635 (64.4)

1,625 (64.0)

2,010 (79.1) 1,660 (65.4) 1,795 (70.7)

1,990 (78.3)

1,220 (48.0)

1,330 (52.4)

Height mm (in)

360 (14.2)

285 (1 1.2)

1,220 (48.0)

Cargo bed ground height mm (in)

440 (17.3)

655 (25.8)

405 (1 5.9)

185 (7.3)

Minimum road clearance mm (in) Height of center of gravity

mm (in)

Wheelbase

mm (in)

1,820 (7 1.7)

Front

mm (in)

1,210 (47.6)

Rear

mm (in)

1,190 (46.9)

Front

kg (lb)

295 (651)

300 (662)

315 (694)

310 (683)

Rear

kg (lb)

280 (617)

290 (639)

345 (761)

340 (750)

Total

kg (lb)

575 (1,268)

590 (1,301)

660 (1,455)

650 (1,433)

590 (23.2)

490 (19.3)

Tread

Vehicle weight (unloaded)

Number of passengers Maximum loading capacity

2

kg (lb)

600 (1,323)

2

400 500 (882) (1,102)

FRAME Type

4

Ladder type

2

500 (1,102)

K8 7

K77 Vehicle type Truck

Flat Bed Truck

Van

Delivery Van

STEERING SYSTEM Steering gear type

Rack and pinion

Steering wheel diameter

mm (in)

Turns, lock to lock

380 (15.0) 4.6

Inner

3 7"

Outer

34"

Turning angle

AXLE AND SUSPENSION Semi-trailing arm type independent

TYpe Toe-in

mm (in)

1N 12 (0.47)

Camber

2"lO'

Caster

15'25'

King pin inclination

6"25'

Front axle

Trail

mm (in)

Type Rear axle

Toe-in mm (in) Camber

113 (4.45) Semi-trailing arm type independent 1N 12 (0.47) 3'15'

Front 5.00-1 0-6PR ULT

Tire size Rear Front (dia. x Total length)

Torsion bar 19.5 x 504.5 mm (0.77 x 19.86 in)

Rear (dia. x Total length)

Torsion bar 22.5 x 527 mm (0.89 x 20.7 in)

Spring

Front Hydraulic double action

Shock absorber Rear

K77 Vehicle type Truck

K87 Flat Bed Truck

Van

Delivery Van

BRAKE SYSTEM Front

Hydraulic, two leading

Rear

Hydraulic, leading and trailing

TYpe Brake line

Dual circuit system Front

Material

Resin mould Rear

2

'a.-

4

S

Dimensions (Width x length x thickness)

2 m

cA

3 E P

Front mm (in)

35.0 x 173.0 x 5.0 (1.38 x 6.81 x 0.20)

Rear mm (in)

30.0 x 181.0 x 4.4 (1.18 x 7.13 x 0.17)

Front cm2 (in2)

6 0 (9.3) x 2 pieces x 2 wheels

Rear cm2 (in2)

54 (8.4) x 2 pieces x 2 wheels

Area

a,

v

2

b)

C A .

Front mm (in)

180 (7.09)

Rear mm (in)

170 (6.69)

Drum dia.

TYpe Master cylinder

Inner dia. mm (in)

Tandem 19.0 (0.75)

Brake fluid reservoir capacity cc (in3)

110 (6.71)

Front mm (in)

23.8 (0.94)

Rear mm (in)

19.0 ( 0.75)

Inner dia. of wheel cylinder

K87

K77 Vehicle type Truck

Flat Bed Truck

Van

Delivery Van

Mechanical on rear

TYpe m

2 on

Dimensions (Width x length x mm (in) thickness)

30.0 x 181.0 x 4.4 (1.18 x 7.13 x 0.17)

G

Area

cm2 (in2)

54 (8.4) x 2 pieces x 2 wheels Resin mould

Material FUEL SYSTEM Capacity

3111 (8.2 US gal, 6.8 Imp. gal)

Location

Under floor

Fuel tank

Centrifugal type

Fuel pump COOLING SYSTEM

Corrugated fin type

Radiator

6.011 (6.3 US qt, 5.3 Imp. qt)

Volume of coolant

"c (OF)

Thermoswitch

ON: 9 2 (198) 12V-60W or less

Motor Electric fan Fan dia.

mm (in)

Radiator core dimensions (Width x height x thickness'

1)

190 (7.48) 334 x 240 x 32 (13.1 x 9.45 x 1.3)

HEATING SYSTEM Heating capacity

Kcallh

Sirocco fan

TYpe Heater fan

Number of blades Diameter

mm (in)

28 110 (4.33) 55W or less

Fan motor Heater core dimensions (Width x height x thickness)

2100-10% or more

mm (in)

97 x 115 x 6 6 (3.8 x 4.53 x 2.7)

K77 Vehicle type Truck

K87 Flat Bed Truck

Van

Delivery Van

ELECTRICAL SYSTEM Fuse

25Ax 1,20Ax 2,15Ax 1 , 5 A x 1 Right hand drive

12V-50/40W x 2

Left hand drive

12V-45/4OW x 2

Turn signal light

12V-23W x 2

Clearance light

12V-5W x 2

Parking light

12V-5W x 2

Turn signal light

12V-23W x 2

Stop light

12V-21W x 2

Tail light

12V-5W x 2

Headlight

Front combination light

Rear combination light

Back-up light Parking light

12V-12W x 2

12V-12W x 1 12V-5W x 2

Side turn signal light

12V-6W x 2

Room light

12V-8W x 1

Licence plate light

12V-1OW x 1

Warning & indicator lights

Horn Wiper motor

Oil pressure

12V-3.4W x 1

Charge

12V-3.4W x 1

High beam

12V-3.4W x 1

Turn signal

12V-3.4W x 2

Parking brake

12V-3.4W x 1

Brake fluid level

12V-3.4W x 1 30W 100-1 10 dB 1-speed

CHAPTER

3:

ENGINE TUNE-UP

.................................3CHECKING A N D SERVICING LUBRICATING O I L ................. 3CHECKING A N D SERVICING COOLANT ................................. 3CHECKING A I R CLEANER .........................................................3REPLACING FUEL STRAINER ..................................................3CHECKING A N D SERVICING BATTERY

2 2

3 3 4

CHECKING A N D ADJUSTING ALTERNATOR DRIVING V-BELT ...........................................................................................3- 4

......................................

3- 5 CHECKING A N D SERVICING CONTACT BREAKER .............. 3- 6 CHECKING A N D ADJUSTING V A L V E CLEARANCES ........... 3- 6 CHECKING A N D SERVICING SPARK PLUGS ........................ 3- 7 CHECKING SPARK PLUG CORDS ........................................ 3- 8 CHECKING VACUUM HOSES ....................................................3- 9 CHECKING A N D ADJUSTING IGNITION TIMING .................. 3- 9 INSPECTION DURING ENGINE WARMING-UP ........................ 3-10 CHECKING CAMSHAFT D R I V E BELT

................................. 3-10 CARBURETOR ...................... 3-1 1 THROTTLE OPENER ........... 3-13

MEASURING CY LINDER COMPRESSION INSPECTING A N D ADJUSTING INSPECTING A N D ADJUSTING

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3-1.

1.

CHECKING A N D SERVICING BATTERY

and grounding cable connectors.

Measuring specific gravity

Measure specific gravity of the electrolyte in the individual cells and convert the reading to one at 20°C (68OF). A converted value within the rang!e from 1.220 to 1.280 is acceptable.

3-2.

CHECKING A N D SERVICING LUBRICATING OIL

Engine oil capacity

S2o = St + 0.0007 (t - 20) S2o = Reading gravity at 20°C St = Actual reading gravity at t°C 0.0007 =Constant

With oil filter

2.8L(3.0 U.S. qt., 2 .S Imp. qt.)

Without oil filter

2.SL(2.6 U.S. qt., 2.2 Imp. qt.)

0.9L(0.95 U.S. qt., 0.80 Imp. qt.)

.. Check the oil level in the oil pan and the transmission case. Add oil if oil level is below the lower level indicated on the level gauge. (Make sure that the vehicle is on a level surface when checking oil levels.) Fig. 3-1 Battery

2.

1

2.

Maintenance

Add distilled water when the electrolyte level is below "LOWER LEVEL". Bring electrolyte level in each cell within normal range between "LOWER LEVEL" and "UPPER LEVEL" lines indicated on the longer side wall of the battery. Filling beyond the "UPPER LEVEL" will lead to overflow while the vehicle is in motion. Never use diluted sulfuric acid in place of distilled water. Check to see that the case, caps, jumpers, compound, and terminals are free from breaks and cracks. Wash away foreign matter with water, removing all traces of acid deposits, and dry with a clean rag. Burnish well terminals and apply a thin coat of grease to prevent corrosion and rust. Securely retighten the battery cable

If the oil is contaminated with coolant or gasoline, first locate and eliminate the cause of contamination, then change the oil. Replace the oil filter at the same time in this case.

Fig. 3-2 Engine oil level gauges

NOTE: a. After replenishing, even if a small quantity of coolant may spout while or after driving, it i s not an abnormal sign. b. The radiator is of the high pressure type. When replenishing the coolant, open the reservoir cap after the engine temperature is decreased. It is dangerous to open the cap while the engine is heated, because hot coolant may spout c. Use the SUBARU genuine coolant only.

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level level

Fig. 3-3 Transmission oil levelgauges

3.

Coolant replacement

Replace the coolant at the specified intervals. Always use SUBARU genuine coolant.

3-3.

CHECKING A N D SERVICING

COOLANT 3-4.

CHECKING A I R CLEANER

The air cleaner uses a dry paper element.

Reservoi r

tank

Fig. 3-4 Tank cap clip T5-009

1.

Checking leakage

Fig. 3-5 Air c.ktm.er

Check the reserve tank and hoses for leakage. Take special care in checking hose joints.

. 2.

Coolant level

Check coolant level as follows. Turn the ignition-starter switch "ON". 2) If the coolant is lacking, the warning buzzer will sound in the combination meter. When the coolant is lacking, add the coolant up to the mouth piece of the reservoir. (Refer to the information stuck behind of the flap).

Cleaning

Remove the cover COMPL to draw out the element. 2) Lightly tap the element or direct compressed air from inside to outside of the element to remove dust and dirt. Be careful not to damage the element. 3) Clean the inside of air cleaner case. 4) After cleaning, reassemble the air cleaner.

I )

1)

.

2.

Replacement

Clean the air cleaner element every 2,500 km (1,500 miles). Replace the element after it has been cleaned 3 to 5 times or after 10,000 km (6,000 miles), whichever comes first. It is recommended that the element be replaced earlier if vehicle often runs on dusty roads.

a genuine air cleaner element is essential for long engine life. Never use an inferior imitation as a replacement part or drive the vehicle 'with a broken air cleaner element or without an element.

3-5. 1.

3-6.

1)

CHECKING A N D ADJUSTING ALTERNATOR DRIVING V-BE L T Check belt tension and adjust if necessary.

V-belt tension

10 - 15 mm at 10 kg

2) Wipe off oil and water. 3) Replace the belt if cracking or other damage is found.

REPLACING F U E L STRAINER Replacement

Fig. 3-7 V-belt

1

Fig. 3-6 Fuel strainer

To replace the fuel strainer, remove hose clamps, hoses and nut in that order.

NOTE: The cartridge type strainer does not require cleaning. Replace the strainer every 20,000 km (12,000 miles) or 12 months.

2.

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Checking for gasoline leakage

Check the fuel tank, strainer, carburetor and fuel hoses for leakage. Replace fuel hoses every Fig. 3-8 V-belt tension

3-7.

CHECKING CAMSHAFT DRIVE BELT

b. Remove valve rocker cover. Fully loosen the adjusting screws of rocker arms on one cylinder where the piston is positioned in the exhaust T.D.C. c. Remove the rubber plug provided in the cam belt cover 11. Loosen two 8 mm bolts (A & B).

Fig. 3-9 Camshaft drive belt

1)

Check belt tension, and if necessary ad-

just.

NOTE: To rotate the cam shaft smothly by loosening the rocker arm adjusting screws, adjust the timing belt tension as follows.

Fig. 3-11 Tensioner bolts

Adjusting procedure a. In cold engine condition, turn the crankshaf until T.D.C. mark on the clutch cover comes into alignment with the pointer in the timing hole.

----- 15 Timing hole

Mating surface

of engine and transmission

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' T D C mark Pointer

T3-002

Fig. 3-10 T.D.C. mark alignment

d. Retighten lower side bolt (A) and then upper side bolt (B). e. Rotate the crankshaft one turn. Adjust valve clearance for rocker arms loosend in step (b). f. Install valve rocker cover. Fit the rubber plug (tirningabeltcover). 2) Replace the belt if cracking or other damage is found. (Carefully check the backside of the belt for evidence of cracks.) When installing new Camshaft drive belt, adjust belt tension in cold engine condition. 3) Wipe off any oil or water on the belt, after investigating and eliminating the cause. 4) Be careful not to bend the belt sharply during servicing.

3-8.

CHECKING AND SERVICING CONTACT BREAKER

Contact

4)

Check the following items and adjust, repair or replace any defective parts. In addition, lubricate all moving components.

r

Standard value

5)

Condenser capacity

Standard value

0.225 - 0.275pF

6) Operating conditions of governor and vacuum advancer. Refer to Chapter 9 (ENGINE ELECTRICAL), for details of advancer characteristics. 7) Apply a thin coat of grease to the cam surface, cam head and breaker point arm heel. 8) Check individual cord caps for proper contact and make sure that there are no leaks. 9) Check wiring harness in breaker case for m. damage and dis

1. 3-12 Contact breaker

roJlowing Items 1) 2) 3)

500 - 700 g (17.6 - 24.7 OZ)

Oil leakage from oil seal of camshaft. Inside deposits. Braker point gap. Standard value of the gap

3-9.

0.30 - 0.40 mm (0.012 - 0.01 6 in)

CHECK1NG AND ADJUSTING VALVE CLEARANCES

the cylinder 1) Prior to adiustment,- retighten head mounting bolts as occasion demands.

Tightening torque

6.5 + 0.4 kg-m (47 + 3 ft-lb)

Fig. 3-13 Checking breaker point gap

*Polish point surface if poor contact is found.

NOTE: Standard value of cam closing angle is as follows:

102 3 3O (when the point gap is 0.35 mm or 0.0138 in)

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Fig. 3-14 Retightening cylinder head mounting bolt

3 -6

2) Adjust valve clearances of a cold engine. [Coolant temperature is within the range from 20°C to 40°C (68OF to 104OF)I.

Fig. 3-16 Timinj marks

Fig. 3- 15 Adjusting valve clearance

=I

clearance adjusting value (in cold) Intake

0.15 mm (0.0059 in)

Exhaust

0.25 mm (0.0098 in)

Nut (8 x 4) tightening torque

+

2.0 0.2 kg-m (14.46 2 1.446 ft-lb)

NOTE: The following special tool is available for tightening two bolts located on the middle portion of cylinder head.

Special tool

a. Set the T.D.C. (Compression) of one cylinder piston with reference t o the T.D.C. mark in the timing hole. b. Set the T.D.C. (Compression) of the other cylinder piston with one additional complete rotation of the crankshaft pulley. Ice by inserting a 4) Check the val l e valve and the thickness gauge bc rocker arm. 5) Using Adjuster (4~8.167000), loosen the nut (8 x 4) and turn the screw (on the rocker arm) in or out until proper clearance is obtained. Retighten the nut. 6) Recheck valve clearance

399982100 Socket wrench (14)

3) When adjusting valve clearance, bring the piston of the cylinder to Top Dead Center (T.D.C.) of compression state as follows.

3-10.

1.

C H E C K I N G AND S E R V I C I N G SPARK PLUGS Checking

Remove all spark plugs with a plug wrench, check the following items and, if necessary, clean or replace. 1) Insulator for cracks or any other damage.. 2) Electrode for wear. 3) Carbon accumulation. 4) Center electrode for burning condition. 5) Gasket for damage and deterioration.

NOTE: a. Replace a spark plug blacked with carbon with a hotter type. b. Replace a spark plug burned white or with its electrode excessively worn with a colder type.

2.

3-11.

Cleaning

1) Remove accumulated carbon from electrode with a spark plug cleaner or wire brush. Blow away particles with compressed air. 2) Remove foreign matter and rust from the insulator and terminal.

CHECKING S P A R K P L U G CORDS

-

NOTE: A sandblast type cleaner may hurt the insulator threads. Finish cleaning within the shortest possible time.

3.

A d j u s t i n g spark p l u g gap

Check the gap with a spark plug gap gauge and, if necessary, readjust.

Standarc1 3 p d 1 5ap ~

4.

0.8

111111

( ~ . ~ in) 32

Installation

Check the spark plug for proper sparking with a spark plug tester before installing in the engine. Be sure t o align the spark plug with the installation hole in which it is to be screwed in.

Tightening torque

2.1 (15.18

+ 0.3 kg-m + 2.17 ft-lb)

NOTE: a. Set the spark plug in place by turning it 2 or 3 threads with finger force. b. Then, tighten them to the specified torque with a special plug wrench.

5.

R e c o m m e n d e d spark p l u g N.G.K. HITACHI NIPPON DEN!

Replace the sparn (6,000 miles).

BP6ES 5PW OEP plug

cvery 10,000 km

Fig. 3-1 7 Spark plug cords

1) Remove caps with spark plug cord from the spark plug and ignition coil, check the following items and, if necessary, clean or replace. a. Rubber caps for cracks or any damage. b. Spark plug cord for damage. c. Terminal metals for deterioration and discoloration. d. Inner surface of the rubber caps for dirt. 2) Measurement of spark plug cord resistance. Connect the circuit tester t o both ends of the metal terminals and measure the resistance,

7

'standard reslsrance va.-#1 Side (Short one)

4.09 - 5.63 kS2

#2 Side (Long one)

12.42 - 16.89 kS2

3) When installing the spark plug cords, make sure #1 and #2, and certainly insert the cords t o ignition coil.

3-12. CHECKING VACUUM HOSES Timing hole Mating surface

\

C T3-003

Fig. 3-20 Ignition timing mark alignment

~ i g 3-18 . Vacuum hoses

1) 2) 3)

NOTE: Digits indicated on the clutch cover shows B.T.D.C. (Before Top Dead Center) degrees.

Check the hoses for connection. Check the hoses for cracks or any damage. Check the hoses for mal-installation.

3-13.

1.

Prior to checking, make sure that the breaker point gap is adjusted t o the standard value (0.35 mm, 0.0138 in). 1) Checking with Timing Light a. Check vacuum hoses for connection. b. Warm up the engine. c. Connect the timing light to the #2 cylinder spark plug cord. Operate the engine at idling speed (1,000 rprn f SO rpm) and illuminate the timing mark in the timing hole with the ~ i r h i n g Light. Make sure that the timing mark (10" B.T.D.C.) appears in the correct location as shown in Fig. 3-20.

CHECKING AND ADJUSTING IGNITION TIMING

Adjusting value

Checking ignition timing

B.T.D.C. 10" at 1,000 k 50 rpm

Fig. 3-21 Checking with timing light

Fig. 3-19 Location of timing hole

3-9

NOTE: Be sure to completely push in the choke knob after the engine has been warmed up. 2) Checking with circuit-tester a. Connect the tester positive (+) lead t o the primary terminal of contact breaker and the tester negative (-) lead t o the engine. b. Turn the crankshaft clockwise by applying a wrench on the crankshaft pulley bolt. When B.T.D.C. 10" mark comes into alignment with the pointer in the timing hole, the tester needle should start to return since the contact point opens.

Breaker

Fig. 3-23 Adjusting timing

NOTE: Remember to fit the rubber plug (clutch housing timing hole),

-

3-14. T3-004

Fig. 3-22 Checking with circuit tester

3)

Checking without instruments. With the ignition switch turned to "ON" position, remove the breaker case cover and turn the crankshaft clockwise. When B.T.D.C. 10" marking comes into alignment with the pointer in the timing hole, .the contact point should open, producing a spark. Verify this atate.

Warm up the engine until the coolant temperature reaches between 76OC (168OF) and 82OC (180°F). During the warming-up period, check the followings: 1) Ensure that oil pressure and charging condition are normal. 2) Make sure that there is no oil or water leakage, or abnormal noise.

3-15. ,

Adjustment

To adjust the timing, loosen two bolts fastening the contact breaker case, and turn the case in either direction. Turn the case clockwise for advanced timing, turn the case counterclockwise for retarded timing. After completion of the adjustment, securely tighten the mounting bolts and recheck the timing.

INSPECTION D U R I N G ENGINE WARMING-UP

MEASURING CYLINDER COMPRESSION

Check cylinder compression by setting a pressure gauge in the respective spark plug holes. 1) After warming-up the engine sufficiently, turn off the ignition switch. 2) Make sure the battery is fully charged. 3) Remove all spark plugs. 4) Fulley open the throttle valve.

The adjustment of idling speed should be performed after the engine is satisfactorily warmed up. 1) Turn the idle adjusting screw in fully and then unscrew it 1 to 2 turns. Turn throttle adjusting screw in 2 to 3 turns. Then start the engine. 2) Gradually turn the throttle adjusting screw in or out to obtain an engine speed of 1,000+ 50 rpm. Stop the throttle adjusting screw at that position. 3) Slowly turn the idle adjusting screw in or out within a quarter of a turn in each turning direction and stop turning it at the point where engine revolution is highest and smoothest. 4) Unscrew the throttle adjusting screw to lower the engine speed to 1,000_+50 rpm. 5) Repeat the above sequence and adjust until engine revolution becomes smoothest and carbon monoxide (CO) concentration is reduced to 2% to 4%.

5) Check the starter motor for satisfactory performance. 6) Drive the engine by means of the starter motor and read the maximum value on the gauge when the pointer is steady. 7) Measure each cylinder at least two times to insure accuracy.

Fig. 3-24 Measuring compression Standard compression value

10.5 kglcm2 at 300 rpm (149.3 psi at 300 rpm)

Difference between cylinders

Less than 0.5 kglcm2 (Less than 7.1 psi)

Allowable minimum compression

9 kg/cm2 (128.0 psi)

2.

Adjustment of fuel level

1) Remove the drain plug and copper gasket underneath the float chamber.

Float chamber

3-16.

1.

INSPECTING AND ADJUSTING CARBURETOR

Adjustment of engine idling speed se t w o copper gaskets

Fig. 3-26 Installing gauge

2) Install the carburetor float level ga (Special Tool: 899377800). 3)- Feed fuel into the float chamber.

Fig. 3-25 Adjusting idling speed 3-11

-

4) Read the "L" dimension by means of the float level gauge as shown in Fig. 3-26.

5) If not correct, adjust by bending the float lever and measure again. 6) After measurement replace the copper gasket with new one and retighten the drain plug.

3.

2) In this condition, the primary throttle valve gives an opening by the linkage, which is appropriate (14.5") for starting. To adjust, bend the choke connecting rod so that the choke valve is fully closed when C i dimension shown in Fig. 3-27 is as indicated.

6.

Checking slow cut valve

Checking accelerator pump

Stop the engine, then open the throttle valve suddenly. Check the spout condition of fuel. Accelerator pump discharge volume

4.

0.63 cc/l stroke

Checking choke system

Check if the choke valve opens fully, and the link mechanism operates smoothly.

5.

Adjustment of starting interlock opening.

1) Keep the choke valve fully closed and measure the gap between the throttle valve and the inner wall of the throttle chamber with a gauge. 1.2 mm (0.047 in)

Clearance C1

Fig. 3-28 Slow cut valve

1 ) Start the engine, and idle it at 1,000 rpm +50 rpm. Then disconnect the wire of slow cut valve. If the engine stopped, the function of the valve is normal. 2) If the wire of slow cut valve is connected and the engine could not keep idling speed, check the damage of the wire of slow cut valve. 3) When turning off the ignition switch, and if after-fire occurred, check the clog in the slow cut valve.

7.

Measuring vacuum

1) Measure the vacuum after warming-up the engine sufficiently. 2) Remove the plug (118") from the intake manifold and install the vacuum gauge in its place. 3) Keep the engine at idling speed (1,000 .50 rpm) and read vacuum gauge.

+

. Standard value Fig.

-330 to -370 mrnHg

'

Table 3-1 Vacuum gauge readings and troubleshooting

'

Vacuum gauge

Defect

1.

Pointer stops at a position lower than the normal position

a. Leakage from gasket (intake manifold), gasket (carburetor) b. Retarded ignition timing or narrow valve clearances c. Crack on vacuum hoses

2.

Pointer intermittently drops from the normal position to a lower position.

a. Leakage from cylinder head gasket b. Too much clearance between valve guide and valve stem

3.

Pointer in a narrow range above and below the normal position

a. Defective ignition system b. Poor carburetor idling adjustment c. Weak or broken valve spring

NOTE: In case of first 1,000 km (600 miles) inspection, there is some possibility that pointer stops at lower position than -330 mmHg. When pointer deflection of the vacuum gauge is abnormal or not within the normal range, take corrective action in accordance with Table 3- 1.

the specified range, readjust the engine speed to specified value. Standard value

+

2,200 100 rpm at Full stroke

4)

3-17.

2)

Adjustment of opening angle

INSPECTING A N D ADJUSTING THROTTLE OPENER

NOTE: Before carrying out inspection, warm up the engine and confirm the following items. Ignition timing Idling speed Idling CO %

1.

B.T.D.C. 10' at 1,000 rpm 1,000 rpm

Fig. 3-29 Adjusting opening angle

+ 50 rpm

3%+ 1%

-

Inspection o f throttle opener opening angle

1) Push the throttle opener lever fully, and read engine speed. If the engine speed exceeds

Loosen lock nut of adjusting screw at the throttle opener lever and turn the adjusting screw for adjustment. Screw: Clockwise: Increase engine speed Counterclockwise: Decrease engine speed After completion of adjustment, tighten lock nut securely.

CHAPTER 4:

DISMOUNTING AND REMOUNTING ENGINE

Page

4-1.

DISMOUNTING ENGINE WITH TRANSMISSION

....................

4-

2

4-2.

REMOUNTING ENGINE WITH TRANSMISSION

.................... 4-

6

4-3.

DISMOUNTING TRANSMISSION

................................................ 4-

8

4-4.

REMOUNTING TRANSMISSION

............................................. 4-13

4-1.

1.

D I S M O U N T I N G ENGINE W I T H TRANSMISSION P r e p a r a t i o n a n d precautions for d i s m o u n t i n g

NOTE: Use care in handling the hood or bumpe since the entire surfaces of these parts arr painted.

1) Prior to dismounting the engine, prepare necessary equipments and tools; a lift, engine stand, bar 4.8 mm (0.19 in) in diameter, and other standard tools. 2) Raise the vehicle body with the parking brake released so that the rear wheels may rotate freely. 3) Be careful not to soil the interior of the vehicle, especially the seat and glasses. 4) Be careful not to spill brake fluid or coolant over the painted surfaces.

2.

Fig. 4-1 Removing engine hood or rear bumper

Dismounting

1) Open the engine hood (Truck) or rear bumper (Van). 2) Removing battery

a. Remove the 6 mm nut attaching both the battery holder and cover, and remove the cover. b. Loosen the nut attaching battery holder to battery rod. c. First disconnect the battery ground cable and then the positive cable, and take out the battery.

Open the back door (Van) 5) Remove trap door by loosening two 8 mm bolts. 6) Disconnecting accelerator and choke cables.

4)

NOTE: When disconnecting the positive cable from the battery, the tool may contact the vehicle body and cause shortcircuit or battery damage if the ground cable is still connected. Therefore, be sure t o disconnect the ground cable first. 3) Removing the engine hood (Truck) or rear bumper (Van) a. Disconnect the back-up light harness and license plate light harness at the connector, and spread two clip bands on engine hood. On Van models, it is unnecessary to disconnect the harness as the back-up light is incorporated in the rear combination light. b. Remove the engine hood or rear bumper by removing two 8 mm nuts on right side and two 8 mm bolts on left side.

Fig. 4-2 Disconnecting

a. Remove the accelerator cable outer by loosening 6 mm nut and disconnect the inner cable end from the carburetor. b. Remove the choke cable outer by loosening 6 mm nut and disconnect the inner cable end from the carburetor by loosening 4 mm screw.

7)

Removing fuel hose

Fig. 4-5 Disconnecting air intake hose Fig. 4-3 Disconnecting fuel hoses

9)

Removing pitching stopper

Loosen the clips and disconnect the fuel hoses (delivery, return) from the carburetor. 8) Removing air cleaner related parts a. Remove the boot (air intake) from the air cleaner. b. Disconnect air breather tube from the air cleaner by spreading the clip. c. Remove the hose (air cleaner) by loosening the hose clamps.

NOTE: Place the cover on the carburetor to keep it free from foreign material.

Fig. 4-6 Removing pitching stopper

a. Loosen the two 8 mm nuts @ and 0 b. Remove the two 8 mm bolts @ . 10) Removing hoses (engine air vent)

LDram plug . I

Hc (Et ,!.,I~,u SIl (

h

Fig. 4-4

d. Disconnect air intake hose (air cleaner to frame) from the air cleaner case.

Fig. 4-7 Removing hoses (air vent)

.

Remove the two hoses (air vent) from the clamp holding the hoses onto the bodv. 11) Removing wiring harness

f. Disconnect the block connector from the alternator. g. Remove the 6 mm nut fastening the terminal-B onto the alternator.

lock cc

Fig. 4-10 Releasing terminal-B

Fig. 4-8

,

h. Disconnect the slow cut valve harness (black cord). i. Disconnect the thermometer harness(yel1owred). j. Disconnect the oil pressure switch harness (blue-red cord) and disengage it from the clip. k. Disconnect the two spark plug cords from the ignition coil.

a. Disconnect the harness (black-yellow cord) from the plug-socket type terminal on the starter. b. Disconnect the battery cord from the starter by removing the 8 mm terminal nut covered by boot.

NOTE: Tie down the above wirings to the vehicle body so that they are not damaged while dismounting or remounting the engine. 12) Lift up the vehicle. 13) Remove drain plug of radiator and drain coolant.

Fig. 4-9 Disconnecting battery cord

I

I.

--I a

----- --

c. Disconnect two back-up light switch harnesses (red-white cord). d. Remove the clip holding starter harness (black-yellow), battery cord and back-up light switch harness from the starter. e. Disconnect the contact breaker harness at the terminal by removing the 5 mm terminal nut.

3

.-

Fig. 4-1 1 Removing drain plug 4-4

NOTE: a. Be careful not to damage or lose the drain alus sasket. b. TO "facilitate the draining, open the flap on front pannel and remove the radiator reservoir cap. Raising the rear of the body further quickens the draining.

16) Disconnecting clutch cable a. Remove the clutch return spring.

moving uinder cover

Fig. 4-14 Disconnecting clutch cable

b. Disengage the cable from the clip on the transmission. c. Remove the two clutch cable bracket installing bolts (6 mm) and detatch the cable from the release lever. Fig. 4-12 Removing under cover

Remove the under cover by loosening the four 8 mm bolts, two 6 mm tapping screws, two 8 mm nuts and two 10 mm bolts. 15) Removing the axle shaft (D.O.J.) spring pin.

NOTE: Tie down the cable to the vehicle body so that the cable is not damaged while dismounting and remounting the engine. 17) Disconnecting the gear shift rod from the transmission Remove the 10 mm nut connecting the gear shift rod to the transmission.

NOTE: Be careful not to lose the bushings and washer (gear shift).

Fig. 4-13 Tapping out springpin

Tap out the axle shaft spring pin by using a bar 4.8 mm (0.19 in) diam. and disconnect the axle shaft.

NOTE: a. Don't reuse the spring pin. b. Be careful not to damage the D.O.J. boot.

Fig. 4-15 Disconnnectinggear shift rod

18)

Removing the front engine mounting

NOTE: I f the black tape outside battery box is rerr ocket wrench can be used.

Fig. 4-16 Removing front engine mounting Remove the 10 mm nut attaching the front engine mounting. 19) Disconnecting hoses (radiator, heater and engine inlet) a. Release band to detach air intake hose (air cleaner to frame) from engine inlet hose. b. Loosen clamps and get hoses (radiator, heater and engine inlet) ready to disconnect from pipes on the body.

Fig. 4-18 Removing crossmember

22) Dismounting the engine Recheck the engine for all above-mentioned steps to make sure that none have been omitted. Then, dismount the engine from the vehicle with the muffler and crossmember fitted.

NOTE: a. When dismounting the engine, put an appropriate container under the cooling hoses (Refer to Fig. 4-17) and disconnect three hoses while pulling the engine. b. When pulling the engine out of the vehicle, be careful that the cables and harnesses are not caught by the engine.

Fig. 4-1 7 Disconnecting cooling hose

NOTE: It is better to disconnect hoses when dismounting the engine since coolant is spilled out. 20) Suspending vehicle body, place an engine stand beneath the engine. 21) Removing the crossmember Remove the four 10 mm bolts attaching the crossmember to the body.

4-2.

REMOUNTING ENGINE WITH TRANSMISSION

Prior to remounting, the engine mounting rubber and the gear shift rod bushing shall be checked for wear or damage.

1.

Remounting

Remount the engine in the reverse order of the dismounting. Be sure to keep the following notes.

a

Tighten the nut until the washer comes to contact with the cushion rubber

NOTE: a. Tightening torque:

8.

4.0 (29

Front engine mounting nut

2.0 - 3.0 kg-m (14 - 22 ft-lb)

Gear shift rod connecting nut to transmission

2.0 - 4.0 kg-m (14 - 29 ft-lb)

Pitching stopper adjusting nut

0.9 - 1.5 kg-m (7 - 11 ft-lb)

Then tighten the nut @ to the specified torque 0.9 to 1.5 kg-m (7 to 11 ft-lb), at this time the specified clearance is obtained. a Confirm the clearances between the cushion rubbers 8 and the washers @ be equal under the condition the wheels touch to the ground. and 0. I f not, readjust by the nuts e. Refill the cooling system as follows: a Set the heater lever to "HOT" position. Open the engine hood and remove the plugs from the engine air vent hoses under the floor by loosening the clip.

a

1.6 + 0.15 kg-m (1 1.6 f 1.I ft-lb)

Pitching stopper bracket installing bolt

1

- 5.0 kg-m - 36 ft-lb)

Crossmember installing bolt

b; When installing the front engine mounting rubber, be sure that the locator be fitted into the locator hole. c. Adjustment of clutch cable: Adjust the clutch free play to 1.2 to 2.4 mm (0.047 to 0.094 in) measured at the cable and clutch release lever connecting portion by adjusting nut. d. Adjustment of pitching stopper:

-Drainiipli

~e gine ail vc

/

Fig. 4-20 Plugs (engine air vent hose)

Open the flap on front panel, and remove caps on the breathing hoses connected to the radiator and heater.

.

1 Nut (8 mm) 2 Nut (8 mm) 3 Bolt (8 mm) 4 Bracket

5

Pitching stopper

6 Cushion rubber 7 Washer T4-002

Fig. 4-19 Adjusting pitching stopper

Fig. 4-21 Removing caps

Pour the coolant through reservoir. When the coolant starts to flow from the two engine air vent hoses continuously, install the drain plugs and then attach the hoses to clamp under the floor. Fill the reservoir up to the mouth piece with the coolant, then install reservoir cap. Install caps on the air vent pipes connected to the radiator and heater. Start the engine, and idle it at constant speed of approx. 3,000 rpm for more than 5 minutes (until radiator becomes hot). Stop the engine, and wait until the engine temperature is decreased. Add the coolant up to the mouth piece of the reservoir and install cap securely.

2.

3) Removing the engine hood (Truck) or rear bumper (Van) a. Disconnect the back-up light harness and license plate light harness at the connector, and spread two clip bands on engine hood. On Van models, it is unnecessary to disconnect the harness as the back-up light is incorporated in the rear combination light. b. Remove the engine hood or rear bumper by removing two 8 mm nuts on right side and two 8 mm boths on left side.

NOTE: Use care in handling the hood or bumper since the entire surfaces of these parts are painted.

Inspection after remounting

1) Check the choke cable and accelerator cable and pedal for correct installation and operation, and make sure that the choke and throttle valves open and close correctly. 2) Make certain that there is no fluid leakage on the cooling system. 3) Check the related parts for any other failure.

4-3.

DISMOUNTING TRANSMISSION

Fig. 4-22 Removing engine hood or rear bumper

1) Open the engine hood (Truck) or rear bumper (Van). 2) Removing battery a. Remove the 6 mm nut attaching both the battery holder and cover, and remove the cover. b. Loosen the nut attaching battery holder to battery rod. c. First disconnect the battery ground cable and then the positive cable, and take out the battery.

4) Open the back door (Van) 5) Remove trap door by loosening two 8 mm bolts. 6) Removing wiring harness.

NOTE: When disconnecting the positive cable from the battery, the tool may contact the vehicle body and cause shortcircuit or battery damage i f the ground cable is still connected. Therefore, be sure to disconnect the ground cable first.

Fig. 4-23 Removing wiring harness 4-8

a. Disconnect the harness (black-yellow cord) from the plug-socket type terminal on the starter. b. Disconnect the battery cord from the starter bv removing the 8 mm terminal nut covered

f. Disconnect air intake hose (air cleaner to frame) from the air cleaner case.

Fig. 4-25 Dkconnecting air intake hose

I

I

Fig. 4-24 Disconnecting battery cord

I

c. Disconnect two back-up light switch harnesses (red-white cord). d. Remove the clip holding starter harness (black-yellow), battery cord and back-up light switch harness from the starter. e. Disconnect the contact breaker harness at the terminal by removing the 5 mm terminal nut.

1

NOTE: Tie down the above wirings to the vehicle body so that they are not damaged while dismounting or remounting the transmission. 7) Removing air cleaner a. Disconnect blow-by hose from the air cleaner. b. Disconnect air breather tube from the air cleaner by spreading the clip. c. Remove the boot (air intake) from the air cleaner. d. Remove air cleaner case cover and take out air cleaner element. e. Remove the hose (air cleaner) by loosening the hose clamps.

NOTE: Place the cover on the carburetor to keep it free from foreign material.

g. Remove the air cleaner case by removing a 8 mm bolt @ and loosening slightly two 6 mm bolts @I

clip T5-009

Fig. 4-26 Removing air cleaner case

8) Remove the starter motor by loosening the two 8 mm nuts.

Fig. 4-27 Removing starter motor

9)

Removing pitching stopper

5 Pitching stopper

3 Bolt (8 mm)

6 Cushion rubber 7 Washer

Fig. 4-30 Removing heat insulating plate

b. Remove the three 8 mm bolts attaching the muffler bracket (outer) to the transmission at the rear and the four 8 mm bolts at the front.

Fig. 4-28 Removing pitching stopper

a. Loosen the two 8 mm nuts @ and 0. b. Remove the two 8 mm bolts @. 10) Lift up the vehicle. 11) Removing under cover a. Remove the under cover by loosening the four 8 mm bolts, two 6 mm tapping screws, two 8 mm nuts and two 10 mm bolts. b. Remove a 8 mm bolt to remove engine room cover. Fig. 4-31 Removing bra, I

c. Remove the two 8 mm bolts arlac;rilIlg the muffler bracket (inner) to the transmission at the rear and the three 10 mm bolts at the front. ---

Fig. 4-29 Removing under cover

12)

Removing muffler

a. Remove the three 6 mm bolts attaching the heat insulating plate and remove the plate.

Fig. 4-32 Removing bracket compl.

d. Remove the four 8 mm nuts attaching the muffler to the cylinder head exhaust ports.

Fig. 4-35 Removing axle shaft spring pin Fig. 4-33 Removin muffler from cylinder ead

f

NOTE: Don't detach the flange on the exhaust manifold. e. Remove the two 8 mm bolts at the center bracket on the muffler, and take out the muffler.

Fig. 4-34 Removing bolts at center bracket

14) Removing the clutch cable a. Remove the clutch return spring. b. Disengage the cable from clip of crossmember and transmission. c. Remove the two clutch cable bracket attaching 6 mm bolts and remove the cable from the lever (release york shaft). 15) Disconnecting the gear shift rod from the transmission a. Remove the 10 mm nut connecting the gear shift rod to the transmission.

Fig. 4-36 Disconnecting gear shift rod

b. Remove the gear shift rod return spring.

NOTE: a. Use care not to damage the flange when removing the muffler. b. Note that stainless nuts are used for conneetion of muffler and manifold. 13) Tap out the axle shaft spring pin by using a bar 4.8 mm (0.19 in) in diameter and disconnect the axle shaft.

NOTE: Be careful not to lose the bushings and washer (gear shift).

16) Decrease lifting height of the vehicle body by supporting the engine with a jack.

NOTE: Lowering the lifting height of the vehicle body and supporting the engine with a jack are necessary precautions to prevent the engine from falling due to removal of front and rear mounts in the succeeding steps. It will also facilitate the subsequent work.

17) Removing the engine front mounting Remove two 10 mm bolts @ and 0.

b. Remove two 10 mm nuts @ at the connecting part between the mounting bracket and transmission. c. Remove two 10 mm bolts @ tightening the rear crossmember and rear mounting and remove the rear mounting.

NOTE: Raising the engine a t the transmission side end will facilitate removal of the mounts. However, it is necessaly to exercise care so that other parts will not be effected by the raising of the engine.

19) Removing the transmission a. Remove the four 10 mm bolts connecting transmission and engine.

Fig. 4-3 7 Removing front mounting

18) Remojring rear nnounting (left) a. Remove :a lOmm bolt @ tightening the .. ana lower side of transmisrear mounzing sion. Fig. 4-39 Removing transmission

b. Push the engine toward the rear and pull down the transmission.

Fig. 4-38

NOTE: a. Removing the transmission can be done safely and easily by two persons. b. Be careful not to damage D.O.J. boot.

-

4-4.

REMOUNTING TRANSMISSION

NOTE: Fasten the clutch release fork with wire since the release bearing and holder are subject to come off when remounting the transmission.

1.

c. Adjustment of clutch cable: Adjust the clutch free play to 1.2 to 2.4 mm (0.047 to 0.094 in) measured at the cable and clutch release lever connecting portion by adjusting nut. d. When installing the D.O.J. spring pin, always use new pin. e. Adjustment of pitching stopper:

Remounting

Remount the transmission in the reverse order of the dismounting. Be sure to keep the following notes. 1 Nut (8 mm) 2 Nut (8 mm) 3 Bolt (8 mm)

NOTE: a. Installing the muffler: Strictly follow 19-4 on page 19-4. b. Tightening torque: 10 mm bolts connecting transmission and engine

4.2 - 4.8 kg-m (30 - 35 ft-lb)

10 mm bolts and nuts on rear mounting

2.0 - 3.0 kg-m (14 - 22 ft-lb)

10 mm bolts on front mounting

2.0 - 3.0 kg-m (14 - 22 ft-lb)

Gear shift rod connecting nut to transmission

2.0 - 4.0 kg-m (14 - 29 ft-lb)

8 mm starter installing nut

2.2 - 2.8 kg-m (16 - 20 ft-lb)

Pitching stopper adjusting nut

0.9 - 1.5 kg-m (7 - 11 ft-lb)

-1

"l

5 Pitching stopper 6 Cushion rubber 7 Washer

l

Fig. 4-4 0 Adjusting pitching stopper

a

Tighten the nut @ until the washer comes to contact with the cushion rubber

0.

Pitching stopper bracket installing bolt

1.6 (1 1.6

* 0.15 kg-m f

@ to the specified torque 0.9 to 1.5 kg-m (7 to 11 ft-lb), at this time the specified clearance is obtained. a Confirm the clearances between the cushion be equal rubbers 0and the washers under the condition the wheels touch to the ground. I f not, readjust by the nuts @ and 0 . f. Clean the air cleaner related hoses and boots before installing them to the air cleaner. a Then tighten the nut

2.

Inspection after remounting

1) Start the engine and check that there is no exhaust gas leakage. 2) Be sure to check transmission oil level.

1.1 ft-lb)

* As to muffler related bolts and nuts, refer

Transmission oil quantity

0.9Q (0.95 US qt, 0.79 Imp qt)

to 19--4.

I

CHAPTER

5: ENGINE

Page 5- 1.

i

52 .

I

53 .

I

54 .

I

i

55 .

. . . .

OUTLINE OF THE ENGINE DISASSEMBLY

..........................................................................5 - 9

INSPECTION AND REPAIR ASSEMBLY

...................................................... 5 - 2 ........................................................ 5-18

...................................................................................5-29

TROUBLESHOOTING

................................................................... 5-40

5-1.

OUTLINE OF THE ENGINE

Fig. 5-1 Outside view of EK23BE engine

1.

Features

In designing the new EK23BE engine, special consideration was given to economy, durability, quiet operation, and ease of maintenance. The engine is tough enough to display full performance over its entire working range. This is a light, compact, water-cooled, two-cylinder in parallel, single overhead camshaft type fourcycle gasoline engine with a total displacement of 544 cc (33.2 cu.in). The monoblock casting cylinder case provides improved durability and quietness. A unit construction of the cylinder head and rocker support is made of aluminum die casting which offers superior cooling efficiency. In addition to the effective cooling performance of the cylinder head, adoption of a high-combustion-efficiency multispherical cross-flow combustion chamber contributes not only to large output, but also to a reduction in harmful exhaust emissions. The special casting crankshaft combined with the fillet roll machined pins and journals provides superior fatigue strength. Triple-layer kelmet metal is employed for the main bearings and the connecting rod big-end metals to improve the initial break-in characteristics and fatigue strength. Interchangeable front and center main bearil-gs, a single united rear and thrust metal, and adoption of bearing caps greatly facilitate assembly of the crankshaft. A single-shaft balancer is newly adopted in this engine to negate uneven torquing force on the crankshaft which

is inevitable as the crankshaft is driven by the reciprocating motion of pistons. As a result, vibration and noise incidental to engine operation are considerably reduced.

Fig. 5-2 EK23BE engine

The balancer shaft is driven by a nonbacklash steel gearing from the crankshaft so that it is rotated at the same rotating speed and in the opposite direction of the crankshaft. Problems of noise and reliability accompanying the use of a V-belt is solved by directly connecting the water pump to the balancer shaft end. The toothed rubber belt for driving the camshaft is effective in reducing the belt noise, and the one step spring-load tensioner for instant setting of the belt tension provides easy maintenance. Since the camshaft journals are

directly supported by the cylinder head without use of any bearing, and the lubricating oil is directly delivered to cam surfaces and journals through the hollow camshaft, operational reliability of these parts is considerably increased. Aluminum die cast pistons, oval tapered with each pin hole offset 1 mm (0.0394 in) are employed. Two compression rings and one combination-type oil ring are used.

and reduces the loss of engine horsepower. SUBARU COOLANT employed in this engine greatly facilitates proper maintenance of the cooling system. During cold weather, a portion of the cooling system is utilized to form an effective heater.

\

Connect

Fig. 5-4 Balancer shaft and water pump

%gig. 5-3 Piston and piston r i ~

lightweight valve control mechanism uesigrleu for S.OHC V-type valve arrangement permits the valves to follow perfectly the high speed rotation of the engine, thus ensuring stable engine operation. A full-flow type forced lubrication system with a trochoid oil pump is adopted. The oil pump built in the crankcase cover is driven by the crankshaft through the nylon resin reduction gear that reduces the rotation speed of the crankshaft by one half. The forced circulation cooling system combined with a water pump directly connected to the balancer shaft end and with an electric fan effectively eliminates noisy pump operation

1)

Necessity of balancer shaft In a 4-cycle, 2-cylinder engine pistons move simultaneously upward or downward because the difference of crank angles between two pistons is kept at 360 degrees. Integrated inertia force resulting from the hgh speed reciprocating motion of the pistons. This large inertia force is harmful to smooth crankshaft revolution, thus causing serious engine vibration and uncomfortable driving conditions. To reduce engine vibration by negating the uneven distribution of inertia force during each rotation of the crankshaft, a counterbalance mechanism called the balancer is adopted.

Piston inertia force

Crank angle vs. inertia force

Centrifugal force

Replacement of inertia force

Cornl>osition of forces (total to zero) T5-004

two vectors are opposite in direction with each other, while the vertical component F2 is doubled because two vectors are in the same direction. To negate the resulting vertical force 2F2 which corresponds with the inertia force of a piston as mentioned before, an additional two pendulum weights A' must be revolved around the respective shafts I and 11, keeping 180 degrees of the difference in angle from the pendulum weights A. A crankshaft-counterweight usually adopted on conventional engines corresponds with the pendulum weight A' on the shaft I. This method called "half-balancing" is only to provide centrifugal force balanced with that of the pendulum A revolving around the shaft I in the same direction as that of the crankshaft. Therefore, inertia force at high crankshaft speed will still remain unbalanced. On the EK23BE engine a blancer shaft rotates in the opposite direction of the crankshaft rotation so as to negate the remaining component of inertia force indicated by F2 relating to the shaft 11. As a result, the integrated inertia force of two pistons is negated by . the sum of the centrifugal force produced, by the crankshaft-counterweight and the balancershaft-counterweight rotating in opposite directions of each other, thus making the EK23BE engine well balanced and keeping it free from vibration, thereby permitting comfortable driving.

Fig. 5-5 Function of balancer

2)

The correlation between the crank angle and the inertia force accompanying the up and down motion of a piston is shown in the figure on the right. The variation of inertia force can be approximately replaced by the sum of the centrifugal forces occuring between two pendulum weights (A) that revolve around the respective shafts I and I1 at the same angular velocity as that of the crankshaft and in opposite directions of each other. That is, when the centrifugal force F', at each pendulum weight A, is decomposed into vertical and horizontal forces, the horizontal component F1 will be negated because

Toothed timing belt The O.H.C. drive mechanism in which the valves are operated by roker arms from the camshaft is used to provide engine speed-high enough to obtain the atrnost driving power. Usually, the camshaft in the O.H.C.mechanism is driven by a noisy gearing or a timing chain. To solve this noise problem the EK23BE engine employs a special chloroprene rubber timing belt which is kevlar cord reinforced and covered by a nylon canvas. The belt is always kept properly tensed by means of a tensioner, which is necessary to prevent the belt from skipping over the gear wheel teeth thus causing gap of ignition timing, as well as to maintain durability of the belt.

NOTE: Be careful not to pick or pry the belt with a screwdriver or to sharply bend the belt when removing or installing it. This will break the kevlar cord fabric, resulting in reduced belt durability.

I

NOTE: a. Inspect belt (camshaft drive) tension. If the belt tension is too slack and the belt touches to the cover (making noise) at racing the engine, readjust belt tension. b. The belt is tensed, when properly adjusted, by 7.5 to 12.5 kg (16.5 to 27.6 Ib).

2. Construction and main components Chloroprene rubber

Kevlar cord

ankshafi

Nylon canvas

.-. k T5-005

Fig. 5-6 Sectional view of belt

1

-

'

3)

One-step spring-loaded tensioner The tensioner is designed with a one-step setting for easy maintenance. Proper belt tension can be automatically spring-adjusted by only loosening two bolts (A and B in Figure 5-7). The belt tension is maintained at that setting by retightening the bolts.

Fig. 5-7 Tensioner

Fig. 5-8 Crankcase and crankshaft

1)

Crankcase The crankcase is a cast iron, deep skirt type. A dry type cylinder liner and casting caps for holding crankshaft bearings are used. Six 11 mm dia. bolts are used to fasten three caps. 2) Crankshaft a. The crankshaft is made of special cast iron. The journals and crankpins are fillet-roll machined for improved fatique-resistance. Plane metal made of triple-layer kelmet alloy is matched with each journal and connecting-rod large-end. b. Two gears for driving the balancer shaft and the oil pump, respectively, are press-fitted on the crankshaft end (at the crank pulley side). c. The other end of the crankshaft (opposite side to the crank pulley) is provided with six threads (8.5 x 1.0 mm) for installation of the flywheel.

d. The sub-gear type non-backlash mechanism has been adopted on driving side of balancer gear. Sub-gear, having the same number of teeth as drive gear, is being twisted in one direction toward drive gear by means of spring. When driven gear meshes with drive gear, sub-gear is always pushed toward driven gear by means of spring back force and gets non-backlash to prevent rush sound generation when rotating. i Spacer is press-fitted on the crank bearing for sub-gear.

Spring force

1 Drive gear 2 Sub-gear

~5-006

Fig. 5-9 Non-backlash mechanism

1 2 3 4 5 6

7

Balancer shaft Balancer driven gear Balancer drive gear Spring Sub-gear Spacer Sub-gear set T5-007

Fig. 5-10 Components of balancergear 5-6

3)

Cylinder head .

.

.

-

. ..

.

.

,

.- ..

...--

I1 II i

1 I

I

a. The piston is made of a high siliconaluminum die casting having a low coefficient of expansion. The piston head is provided with recesses t o receive the valves. The piston skirt has a unique barrel shaped taper, providing a good fitting with the cylinder. T o reduce piston weight, the skirt is cut short in its depth. b. There are three piston ring grooves at the t o p in which the piston rings are fitted to seal the gas and oil. c. The piston pin hole is offset 1.0 mm toward the thrust side.

Fig.5-1I Cylinder head

i I

a. The cylinder head is made of die cast aluminum which is superior in heat transmission, and is provided with multispherical combustion chambers which give high combustion efficiency with smooth gas flow. Intake and exhaust valve are arranged in a "V" on the cylinder head. b. Four threaded holes (6 x 1 mm) are machined for installation of the. rocker cover. c. Two 8 rnm dia. stud bolts and two threaded holes (8 x 1.25 mm) are provided for installation of the intake manifold. d. Four threaded holes (8 x 1.25 mm) are machined for installation of the flange (Exhaust port). e. The cylinder head is attached t o the crankcase by means of six 11 mm head bolts with a head gasket inserted to prevent leakage of gas, oil or water. 4) Piston

5)

Piston rings

5181

?(r--

(

,~

11

1

c-> J 1

a

Fig.5-12 Piston, connecting rod, etc.

ona rlng

Fig.5-13 Piston rings

The piston rings contain gas under high pessure in the combustion chamber and prevent the lubricating oil in the crankcase from creeping up to the combustion chamber. a. The top ring is made of special cast iron and is treated by parkerizing. With improved wear-resistance due to hard chrome plating provided on the cylinder wall contact surface, the top ring serves as the compression ring. b. The second ring is made of special cast iron and is treated by parkerizing. A tapered cylinder wall contact surface provides proper fitting of cylinder wall during engine breakin and backs u p the top ring in making the cylinder completely air-tight.

c. The third is an oil ring which is composed of a spacer inserted between two rails and serves to prevent lubricating oil in the crankcase from creeping up to the combustion chamber. The rails are treated by parkerizing and their cylinder wall contact surfaces have imeroved wear-resistance due to hard chrome plating. 6 ) Connecting rod a. The connecting rod, the joint converting the reciprocating motion of the piston to the rotation of the crankshaft is made of forged steel and is compact and rigid. b. The connecting rod and its cap are joined together by two 8 mm through bolts inserted into 8.2 mm dia. holes. 7) Balancer shaft

8)

Camshaft

-

-3

Fig. 5-15 Camshaft

The camshaft is made of special cast iron and applied with surface treatment all around. The camnose is made by special chill hardening process to facilitate fitting of the cam during engine break-in and to make the cam well matched with the rocker arm. b. The front end of the camshaft is provide'd with the camshaft driven pulley while the rear end is provided with the contact breaker.

T.D.C.

!

I

Intake opens

Exhaust closes

Fig. 5-14 Balancer shaft Exhaust opens

B.D.C. r5-008

a. The balancer shaft is made of cast iron and has an unbalanced mass at its middle portion to provide total matching of the engine cranking system. b. The front end of the balancer shaft is press-fitted with a ball bearing and a steel gear which drives the balancer shaft. c. The rear end of the shaft is provided with plain bearings. d. Water pump impeller is installed to the front end of this shaft.

Fig. 5-1 6 Valve timing diagram

c. The front and rear journals are directly attached to the cylinder head without use of any bearing. d. A thread (6 x 1 mm) for installation of the spark advancer unit is machined on the rear end of the shaft.

5-2.

DISASSEMBLY

NOTE: Before separating the transmission, remove the starter to facilitate the work.

I

I

1) Install the engine on the Stand compl. 4998 11300 (Engine), and drain engine oil.

ine stand

!

Fig. 5-17 Fitting up engine stand

, I

I

! ~-

Fig. 5-19 Removing transmission

2) Removing air cleaner a. Disconnect blow-by hose from the air cleaner. b. Release clip holding the transmission air breather on the air cleaner.. c. Remove air cleaner case cover and take out air cleaner element. d. Remove air cleaner case by removing a 8 mm bolt @ and loosening slightly two 6 mm bolts @.

4) Remove clutch cover and clutch disc. a. Insert a special tool "Clutch Disc Guide" (499745400) into the clutch disc. b. Unscrew six bolts and then remove clutch cover and clutch disc from flywheel. Bolt (6 x 18 mm): 6

NOTE: Be careful not to soil the disc compl. (clutch) with oil or water.

Guide

clip T5-009

Fig.5-18 Removing air cleaner case

Separate the transmission from the engine. Fig. 5-20 Removing clutch

Bolt (10 x 45): 4 5 -9

5) 6)

10) Remove the stay and dismount the alternator assembly, and remove the V-belt.

Remove the gauge compl. (oil level). Remove the spark plug cords.

Bolt (8 x 110 mm): 1 Bolt (8 x 22 mm): 1 301t (8 x 28mm): 1 remove the bracket compl. (alternath bracket I1 (alternator).

3,

3olt (8 x 16 mm): 4

Seali

11) Remove the hose (water bypass) @ at the carburetor side.

Sparl

cord

Hose clamp (12): 1

Fig. 5-21 Removin~

dug cord

NOTE: Be sure t o keep the sealing (spark plug cord) attached t o the cover II (cam belt). Remove the hose (vacuum) f rom the v;acuum advance unit. 7)

Fig. 5-23

12) Remove the intake manifold compl. together with the carburetor assembly.

.

3olt (8 x 40 mm) : : gut (8 mm) : 2 ,hose

Fig. 5-22 Removing hose

0,

@ and 8) Remove hoses (engine outlet) hoses (engine overflow) 0,@ (Fig. 5-23). 9) Loosen bolts, installing bracket (oil level gauge guide) and cover (water pump) (Fig. 5-23). Bolt (6 x 13 mm) : 1 Bolt (6 x 20 mm) : 1

Fig. 5-24 Removing intake manifold 5 - 10

13) Draw out the pulley compl. (crankshaft) by means of the Adjuster compl. (cam timing) 49871 1300 and Puller Assembly 89952 1421.

15) Remove the spring (cam belt tensioner) and the tensioner compl. Washer-based-head bolt (8 x 15 mm): 1 (8 x 4 0 mm): 1 with 1 spacer

Fig. 5-25 Removing crankshaft pulley

Bolt (12 x 23 mm) : 1 Washer (12.5 x 36 x 4 mm) : 1

NOTE: The Adjuster compl. is to block the rotation of the pulley.

!

1

14) Remove the cover I1 (Cam belt), plate compl. (Cam belt cover) and Stay compl. I1 (Spark plug cord). .

1

Tapping Bolt (6 x 30) with 1 spacer I

0: 1

Tapping Bolt (6 x 60)@: 2 with 2 spacers Bolt (6 x 60) 0:3 Bolt (6 x 65)@: 1 Nut 6 mm: 1 Washer 6.5 x 16 x 1: 3

Fig. 5-26 Removing cover II (cam belt)

Fig. 5-27 Removing tensioner

16) Remove the plate (camshaft drive pulley) then remove the belt (camshaft drive).

NOTE: a. Before removing the belt, put a mark indicating the running direction of the belt with a felt pen or the like. b. Do not attempt to pry the belt with a screwdriver or the like. Use only the hands to remove the belt. 17) Remove the pulley (camshaft drive) and the plate (camshaft drive pulley). 18) Remove the pulley (camshaft driven) with the Adjuster compl. (cam timing) 49871 1300. Bolt (12 x 2 3 mm) : 1 Washer (12.5 x 35 x 4.5 mm) : :

Fig. 5-28 Removing camshaft driven pulley

19)

Remove the cover (cam belt). Special bolt (6 x 3 1) : 1 Bolt (6 x 40) : 1 (with spacer) Spacer : 1

Fig. 5-31 Removing flywheel

21)

Remove the hanger (crankcase). Bolt (8 x 20 mm) : 2

22)

Remove the housing compl. (flywheel).

Fig. 5-29 Removing cover (cam belt)

Bolt(6x 13 mm): 2 23) 20)

Remove the oil pan compl. Bolt (6 x 13 nim) : 20

Remove the flywheel compl. Bolt (8.5 x 19 mm): 6

NOTE: To keep the crankshaft stopped, temporarily install the crankshaft pulley to the crankshaft and install the ca-m timing adjuster to the pulley with two bolts.

Fig. 5-32 Removing oil pan

24)

25) Fig. 5-30

Remove the gasket from the oil pan. Remove the cover (valve rocker). Washer-based-head bolt (6 x 33 mm) : 4

Remove the gasket (valve rocker cover).

Fig. 5-33 Removing valve rocker cover

1

!

I

26)

Remove the cover (contact breaker case).

Also remove stay compl. (spark plug cord).

Fig. 5-35 Removing contact breaker assembly

29)

Fully loosen the screws (valve rocker). Nut (8 x 4 mm) : 4

27) Remove the gasket from the contact breaker case.

Draw out the shaft (valve rocker) from the cylinder head compl. Remove the arm (valve rocker), spring washer (rocker shaft), spacer (valve rocker shaft) and arm I1 (valve rocker) in that order. (Fig. 5-36)

NOTE: Be careful not t o confuse the arm (valve rocker) with the arm II (valve rocker) in sequence of removal.

Fig. 5-34 Removing cover (contact breaker case)

28)

Remove the contact breaker assembly. Bolt (6 x 13 mm) : 1 Washer (6.5 x 20 x 2.3 mm) : 1 Bolt (6 x 22 mm) : 1 Bolt (6 x 60 mm) : 1 Washer (6.5 x 16 x 1) : 1

Fig. 5-36 Removing valve rocker shaft

30)

Remove the camshaft. (Fig. 5-37)

NOTE: Be careful not to lose the straight pin (3 x 7.5 mm).

TE: (eep the impeller stopped by blocking the balancer shaft with a suitable screwdriver or the like.

-

Fig. 5-39 Removing waterpump impeller Fig. 5-3 7 Removing camshaft

31)

Remove the head complete (cylinder). Washer-based-head bolt (I 1 x 102 mm) : 6 Washer (1 1.5 x 23 x 4) : 6

34) Remove the cover assembly (crankcase). (Fig. 5-40) Bolt (8 x 25 mm) : Bolt (8 x 45 mm) : 4 Bolt(8 x 55 mm) : 2 (pass through the protector) Also, remove the protector.

NOTE: Keep the oil strainer compl. fitted on the crankcase cover adsembly. Keep both the oil filter assembly and the oil pump cover fitted on the crankcase cover assemblv.

Fig. 5-38 Removing cylinder head

32)

Remove the water pump cover. Bolt (6 x 20 mm) : 4 Bolt (8 x 80 mm) : 1

Remove the gasket (water pump). 33) Remove the impeller (water pump). Bolt (6 x 18) : 1

Fig. 5-40 Removing crankcase cover assembly

-

35) 36)

Remove Engine Stand (49981 1300). Remove the caps (connecting rod). Nut (connecting rod) : 4

NOTE: Be careful not to hurt the connecting rod bearings.

Fig.5-42 Removing crankshaft

NOTE: Lightly tap the caps with a mallet to remove them.

Fig. 5-41 Removing the cap (connecting rod)

39) Disassembling balancer drive gear. Set the crankshaft compl. on the press. Press the end of crankshaft to remove balancer drive gear set and oil pump gear at the same time.

37) Remove the piston and connecting rod as an assembly.

NOTE: Push out the assembly by pressing the connecting rod from the bottom side of the engine, using a hammer handle as a pusher. Chalk the cylinder number on each piston head so as not to confuse them.

Fig. 5-43 Disassembling balancer drive gear 38) Remove the cap (crankcase), cap I1 (crankcase), cap 111 (crankcase) and crankshaft compl.

40) Drive out the balancer shaft compl. (If necessary)

Washer-based-head bolt (10 x 47 mm): 6 Remove the oil seal (57 x 77 x 14 mm)

NOTE: Lightly tap the shaft with an aluminum bar to remove it.

Fig. 5.4 4 Remcwing balncer shaft

Fig.

-

Removing carbu retor and thermostat.

5 - d

1.6 Removing carburetor assembly and thermostat

) Removing exhaust flange -.emove bolts (8 x 22: four) and remo. lust flange with gasket.

. . ., Remove carburetor rrom intake manifolfl

Nut (8 mm) : 2 At that time, loosen nut @ attar;~u~m throttle opener and separate connecting rod @ from oiener lever (A)@. Then, remove carburetor gasket, insl~lntor and O-ring.

3sket

F,ig.

5-47 Eixhaust flange

Removiing valves and valve springs Jsing the Press P~ssembly (valve spring) t~l l l ekey (valve spring re724 100, i blllvvb - . tainer) from each valve spring ret ainer, and then remove the va lve and S F)rings. "Pmr,..P

Fig. 5-45

..

Remove the cover (thermostat) from rne manifold compl. (intake), remove the gasket (thermostat case cover) and take out the thermostat. Bolt (E

-

TE: :balk each valve with an identification narking so as not t o confuse them. Set the gress (valve spring) 3997221 00 as an adjust!r on the press assembly. le careful not to hurt or break oil seal lips n intake and exhaust valve auides during emoval.

46) Re moving oil filter and oil pum p cover --A a. Remo ve the oil filter with the ren1uvc1-anuinstaller tool. Remove the cover (Oil pump). Bolt (6 x 18 mm) : 2 Bolt (6 x 32 mm) : 2 Remove the gasket (Oil pump).

NOTE: The gear compl. (oil pump driven) is pressfitted on the shaft (oil pump). I f replacement of the gear compl. and rotor is required, draw them out from the shaft with a press.

Fig. 5-4I8 Remor

44) Disassembling piston and connecting rod compl. Remove a circlips (1 7 x 1.4 mm) at end of a piston pin (One side of the piston) to disasserr ble the piston and connecting rods.

NOTE: Be careful not to confuse disassembled part with each other. Always keep the prope combinations between the piston and piston pin and between the connecting rod and its cap. Fig. 5-50 Removing oil filter a oil pump cover

b. Remove the switch assembly (oil pressure). 47) Removing water pump mechanical seal a. Press the seal out with a press compl. (mechailical seal).

amic se at Impt isassemb li'ngpis ton zd connecting rod

45) Disassembling piston Remove piston rings fro expander

with a ring

NOTE: Keep the remotved pistoln rings in good orde SO as not to colnfuse thern.

I

1~1t;~hanical seal

UII

~ G U I

Fig, 5-51 Removing- n . , ~ ~ , ~ ~ . , ~ , ~

b. Remove the cer.amic seat

5-3.

INSPECTION A N D REPAIR

Precautions before inspection and repair a. Before cleaning, check for leakage in parts which carry coolant or oil. b. Check oil seals for damage to their lips. c. Thoroughly clean all parts to remove dirt and deposits. d. Blow air through oil passages to make sure they are not clogged. e. Arrange all related parts in an orderly fashion so as not t o confuse them with each other. 1) Cylinder head a. Check for cracking or other damage. .-addition t o visual inspection, inspect important portions by means of a red check. b. Check the mounting surface to the crankcase for warping with a straight edge. c. If warping exceeds 0.05 m m (0.0020 in), regrind the surface with a surface grinder.

NOTE: a. When correction is required, check the intake and exhaust valve stems and valve guides for wear, and the springs for perpendicularity and tension. Replace them if defective and then proceed to the valve seat grinding.

-

!. 5-52 Correction of intake valve seat 298

Limit of strain on the surface to be fixed to cylinder block

0.05 mm (0.0020 in)

Cutting limit on the surface to be fixed to cylinder block

0.5 m m (0.020 in)

388 1.501 dia.

-

(1.I41 dia.

Unit: .mm (in1 T5-011

NOTE: a. Since unbalanced tightening of cylinder heau mounting botls may cause warping of the mounting surface, pay special attention to the even torquing of mounting bolts when assembling the cylinder head. b. Be sure to place the removed cylinder head upside down on a clean cloth.

d. Inspect the intake and exhaust valve seats, and correct the contact surfaces if defective or damaged, in accordance with the following.

Fig. 5-53 Correction of exhaust valve seat

b. Grind the seat contact surfaces with a seat cutter and a seat grinder to the dimensions indicated in Figures 5-52 and 5-53. Finish with fitting compound until proper contact appears on the periphery and overall width of the mating valves.

e. Check the sinking value of the valve seats. Replace cylinder head, if its valve seat sinking exceeds the limit.

.

,

:

Standard "A" dimension

Fig. 5-54 Sinking of valve seat

*

Intake

40.5 0.1 mm (1.594 ? 0.0039 in)

Exhaust

41.2 ? 0.1 mm (1.622 0.0039 in)

Sinking limit (for both intake and exhaust)

1.0 mm (0.0394 in)

*

f. Check the clearance between the valve stem and the valve guide (Intake valve and Exhaust valve). Replace any guide if the clearance exceeds 0.15 mrn (0.0049 in), in accordance with the following.

Intake

-0.035 -000 14 in) 7'0 -0.050 mm (0.2756 -0.0020

Exhaust

-0.05 5 -0.0022 . 7.0 -0.070 mm (0.2756 -0.0028 ln)

Intake

7.0 -O

mm (0.2756

Exhaust

7.0 ;","l5

mm (0.2756

Standard clearance between valve guide and valve stem

Intake

0.035 - 0.065 mm (0.0014 - 0.0026 in)

Exhaust

0.055 - 0.085 mm (0.0026 - 0.0033 in)

Fit tolerance (valve guide against cylinder head)

Intake

0.031 - 0.060 mm (0.0012 - 0.0024 in)

Exhaust

0.031 - 0.060 mm (0.0012

Intake

55.0 mm (2.1653 in)

Exhaust

57.0 mm (2.2441 in)

Standard diameter of valve stem

Standard inner diameter of valve guide

Overall length of valve guide

g. Check valve stem and oil seals (intake valve, exhaust valve). Replace if damaged or worn.

in)

t_Odooo6

in)

- 0.0024 in)

NOTE: a. Place the cylinder head on a Table (cylinder head) 399762101. Using the Remover (valve guide) 399762103, remove the guide by pressing or hammering. b. Using the Adjuster (valve guide) 399762102, press in a new guide until i t s protrusion from the cylinder head reaches the standard value. c. When replacing guide, always use O.S. valve guide, and correct Head compl. (Cylinder) using reamer (valve guide) 399762104.

Valve guide protrusion from the cylinder head

Intake

17.0 mm (0.6693 in)

Exhaust

17.0 mm (0.6693 in)

2) Intake and exhaust valves a. Check the condition of the flange and stem of each valve. Replace valves if burnt, worn, deformed or if the thickness of valve head " H is less than the wear limit shown in the below.

H

H

a,,

1 f

-

Exhaust valve

&

:ake valve.

Press

T5-013

Fig. 5-57 Checking valve head thickness guide) 2103 7

rable (Cylir

Standard "H" dimension

3997,621C

Intake

1.0 mm (0.0394 in)

Exhaust

1.0 mm (0.0394 in)

1tem

Allowable "H" dimension

Intake

0.5 mm (0.0197 in)

Exhaust

0.5 mm (0.0197 in)

Fig.5-55 Removing valve guide

Press. Valve

g

4 b. When the contact surface of the valve is damaged or the end of the stem is recessed, correct with a valve refacer.

Fig. 5-56 Installing valve guide

NOTE: Correct the surface of the stem end so that it is at right angles to the valve axis.

3 Grinding valve

Valve seat contact angle

Overall length

Intake

45 O

111.0mm (4.370 in)

Exhaust

45O

1 10.3 mm (4.343 in)

Fig. 5-59 Checking spring tension

NOTE: To measure perpendicularity of the valve springs, stand the spring on a flat surface plate and measure its deflection at the top using a try square.

c. Put a small amount of lapping compound on the seat surface and lap the contact surfaces between the valve and the seat. ) Check valve springs for damage, free :ngth, maximum compressed length and tenion. Replace any spring damaged or below the pecified limits.

*

Valve spring specifications OUTER

INNER

Free length

51.55 mm (2.0295 in)

45.08 mrn (1.7748 in)

Wear limit of free length

50.5 mm (1.9882 in)

4 4 mm (1.7323 in)

Maximum compressed length

31.5 mm(1.2401 in)

29.5 mm (1 .I614 in)

Tension at maximum compressed length

44 5 3.08 kg (97.00 6.79 Ib)

+

29 (63.93

+ 2 kg + 4.41 lb)

4) Rocker arm a. Check the inner diameter of arm and the outer diameter of rocker arm shaft to determine whether the clearance between the two is within the standard range. If the clearance exceeds the allowable limit, replace either the arm or shaft worn more excessively.

~ c k e rarm d\

Spacer

a

\

Spring wa sher

I

r

Val!

.

. ..

Fig. 5-60 Rocker arm and shaft

between rocker arm and shaft

Allowable warping limit

35 mm (0.0020 in)

Allowable grinding limit

Less than 0.4 mm (0.0158 in)

c. Check for clogging of oil passages. d. Using a cylinder bore gauge, measure each cylinder bore in both axial and thrust directions at positions shown in Fig. 5-61. If the bore shows wear or taper exceeding the allowable limits or if it is excessively scratched, repair the cylinder bore by reboring to allow it to match with the next oversize piston.

Wear limit

0.15 mm (0.0059 in) or less

Taper limit

0.05 mm (0.0020 in) or less

Ellipticity limit

0.05 mm (0.0020 in) or less

-

(0.000630 0.002047 in) Thrust dlrectoor

b. When the contact surfaces of the rocker arm S l l-d l^L to the valve stem end and to the c a rLL cam are noticeably worn, replace eithc:r the adjust screw or arm. For more stepped wear, correction with a valve refacer may be adopted. c. Replace fatique spring washers (rocker shaft). 5) Crankcase compl. Check the crankcase for the following items and repair or replace if defective. a. Visually check for cracks and other damage. Inspect important parts by means of red check. b. Check the matching surface to the cylinder head for warping with a straight edge.

Fig. 5-61 Cylinder bore measuring points

e. Measure the outer diameter of the piston skirt to be used in combination with the cylinder with a micrometer.

NOTE: a. Measurement should be performed at a position 41 mm (1.614 in) below the piston top at a room temperature of 20°C (68OF).

i

Piston size

I I

Nominal size

Outer diameter of piston

IOTE: Measure after the cylinder cools down ro 20°C ( 6 8 O F ) .

I

Standard

75.950 - 75.974 mm (2.9901 - 2.991 1 in)

Oversize (0.5 n ~ n i )

76.450 - 76.474 mm (3.0098 - 3.0108 in)

Ovcrsize ( I .O mm)

76.950 - 76.974 mm (3.0295 - 3.0305 in)

f. On the basis of the diameter of piston to be used, rebore the cylinder to finish it to a desired bore size which will be determined through consideration of such conditions as the piston-to-cylinder clearance, honing allowance and accuracy of the boring machine.

between piston and cylinder at 20°C (68'F)

0.038 - 0.062 mm (0.001 5 - 0.0024 in)

NOTE: Measurement of cvlinder bore immediatelv after boring will be accompanied by som;! error due to heat of machining.

i. Cylinder bore enlarging limit Replace the crankcase when the cylinder bore diameter reaches the allowable expanding limit due to repeated reborina. Cylinder bore enlarging limit

/

1.0

6) Piston and piston pin a. Check for scratches, cracks, pin d~amerer, pin hole bore as well as wear and damage of ring grooves. Replace the piston or piston pin if defective.

b. Piston ring 1) When replacing damaged, broken, worn or insufficiently tense piston rings or when replacement is necessary due to replacement of the piston, select rings properly matched with the piston to which the rings are fitted. 30'--1'

Top ring end hard ~ted.

g. Finish the cylinder bore to final form by honing.

Honing allowance

Less than 0.02 mm (0.0008 in)

h. Measure the cylinder bore diameter.

Taper

Ellipticity limit

Less than 0.05 mm (0.0020 in) Less than 0.05 mm

Piston ring groove dimensions

Unit: mm

T5-015

Fig. 5-62 Sectional view of piston rings

NOTE:

a. Letters "1 R" and "2R" are stamped on the top ring and the second ring, respectively, near the ring gap. Face these marks to the piston top when installing piston rings on the piston. b. The oil ring is a combination of a spacer inserted between two rails. Be careful not to misarrange the combination. c. Tension of each ring is specified below.

Piston ring tension I

I

I

Top ring

1.05 - 1.50 kg (2.3 1 5 - 3.307 Ib)

Second ring

0.95 - 1.37 kg (2.094 - 3.020 lb)

Oil ring

2.70 - 4.10 kg (5.953 - 9.039 lb)

Standard clearance betwec:n the pis1ton ring and ring groove. Top ring

0.035 - 0.075 rnm (0.00 14 - 0.0030 in)

Second ring

0.025 - 0.065 mm (0.0010 - 0.0026 in)

Oil ring

7) Crankshaft a. Clean crankshaft completely and check for cracks by means of a ;ed check or magnetic flux inspection, etc. Replace if defective. b. Check bending condition of crankshaft, and correct or replace if it exceeds the allowable limit.

Bending limit

2) Squarely place the piston ring in the cylinder bore and check the piston ring gap with a thickness gauge.

Standard piston ring gap Top ring

0.2 - 0.4 mm (0.0079 - 0.0158 in)

Second ring

0.2 to 0.4 mm (0.0079 - 0.01 58 in)

Oil ring (Rail only)

0.3 to 0.9 mm (0.01 18 - 0.0354 in)

3) Measure the clearance between the piston ring and ring groove of piston installed. NOTE: Clean the piston ring and groove before performing the measurement.

n)

0.03 mm (0.00 12 in)

NOTE: To check, p~at;e u u ~ the ~ i front and rear journals on blocks located on the surface plate, and measure by applying a dial gauge to the center journal.

c. Check crankshaft journals for wear. If any of them exceed the allowable limit, replace the relative bearing with an undersize one and correct the journal by grinding.

Ellipticity limit

0.03 mm (0.0012 in)

Taper limit

0.02 m m (0.0008 in)

Grinding limit

" "5

m m (0.0098 in)

NOTE: When grinding a crank journal, finish it to any of the following dimensions depending upon the dimension of the bearing to be used.

Dimensions of crankshaft journal Standard size

41.949 - 41.960 mm (1.65 15 - 1.6520 in)

Undersize (0.05 mm)

41.899 - 41.910 mm (1.6496 - 1.6500 in)

Undersize (0.25 nim)

41.699 - 41.710 mm (1.6417 - 1.6421 in)

F&. 5-64 Checking oil clearance

d. Check the thrust clearance of the crankshaft at the rear bearing. Replace the bearing if the clearance exceeds the allowable limit.

Allowable max. oil clearance

Fig. 5i63 Checking thrust clearance

0.020 - 0.059 mm (0.0008 - 0.0023 in)

Standard oil clearance

0.075 mm (0.0026 in)

NOTE: Check with a Plastigage in the following sequence. 1) Remove the bearing cap and wipe off the oil, dust, etc. from the bearing insert and crankshaft journal. 2) Install bearings in the crankcase and set the crankshaft in position. 3) Cut the Plastigage in each bearing width and place it on journal, but avoid oil passage. Reinstall the bearing cap and tighten the cap bolts to the specified torque. Standard tightening torque

I1 I

Standard clearance

0.080 - 0.177 mm (0.003 1 - 0.0070 in)

Allowable thrust clearance

0.3 mm (0.01 18 in)

e. Inspect the individual bearings for signs of flaking, seizing, melting and contacting. Replace if defective. f. Check the oil clearances on the individual bearings.

4.5 (32.6

+ 0.3 kg-m + 2.2 ft-lb)

During this work, the crankshaft must not be turned and crankcase must not be turned over. 4) Remove the bearing cap. The flattened plastigage will be found adhering to either the bearing or the crankshaft 5) Compare the width of the flattened plastigage at its WIDEST point with the graduations on the envelope. The number within the graduation on the envelope indicates the bearing clearance in thousandths of an inch or in millimeters depending on which side of the envelope is used.

g. As a result of this inspection, replace any defective bearing with undersize one. Dimensions of crankshaft bearing Bearing size

Bearing thickness measured at center

Standard size

1.502 - 1.510 mm (0.059 1 - 0.0594 in)

Undersize (0.05 mm)

1.527 - 1.535 mm (0.0601 - 0.0604 in)

Undersize (0.25 mm)

1.627 - 1.635 mm (0.0641 - 0.0644 in)

limit per 100 mm (3.9370 in)

0.1 mm (0.0039 in)

c. Fit each connecting rod compl. to the crankpin, and check the side clearance (thrust clearance). If it exceeds the allowable limit, replace the connecting rod.

8)

Balancer drive gear Check balancer drive gear and sub-gear for damaged or worn gear teeth. Check fitting surface between sub-gear and spacer for excessive wear. Replace if defective.

NOTE:

Fig. 5-65 Checking side clearance

Be sure to replace sub-gear and spacer as the set.

Sub-gear inner dia.

45.000 - 45.050 mm (1.7717 - 1.7736 in)

Spacer outer dia.

44.975 - 44.991 mm (1.7707 - 1.7713 in)

Standard clearance

0.009 - 0.075 mm (0.0004 - 0.0029 in)

Wear limit clearance

0.150 mm (0.00591 in)

Connecting rod compl. a. Replace the connecting rod if the large-end thrust surface is damaged. b. Check for bend or twist with a connecting rod aligner. Correct or replace if the bend or twist exceeds the allowable limit.

d. Inspect connecting rod bearings for flaking, seizing, melting and contacting condition. Replace if defective. e. Check the oil clearance on the individual bearing.

NOTE: Check with a Plastigage in the following sequence.

1) Remove the bearing cap and wipe off the oil, dust, etc. from the bearing insert and crankpin. 2) Install bearing in the connecting rod and i t s cap. 3) Cut the Plastigage in each bearing width and place it on crankpin, but avoid oil passage. Reinstall the connecting rod and tighten the cap bolts to the specified torque. Connecting rod bolt tightening torque

3.8 (27.5

+ 0.3 kg-m + 2.2 ft-lb)

During this work, connecting rod and crankshaft must not be turned and crankcase must not turned over. 4) Remove the connecting rod. The flattened Plastigage will be found adhering to either the bearing or the crankpin. 5) Compare the width of the flattened Plastigage at i t s WIDEST point with the graduations on the envelope. The number within the graduation on the envelops indicates the bearing clearance in thousandths of an inch or in millimeters depending on which side of the envelope is used.

g. Check the piston pin hole in the small-end of the connecting rod for wear or damage and repair or replace if defective. Standard clearance between piston pin and con-rod small end

0.007 - 0.029 mm (0.0003 - 0.001 1 in)

10) Camshaft a. Check the camshaft thrust clearance. If it exceeds the allowable mimit, grind the contact breaker mounting surface o n the cylinder head t o bring the thrust clearance into the permissible range.

Standard thrust clearance

I

0.03 - 0.38 mm (0.0012 - 0.0150 in)

Allowab

NOTE: Keep the contact breaker case installed in place when checking the camshaft thrust clearance. b. Inspect the camshaft journals and replace if damaged or worn. c. Inspect the cam surface for damage and measure the total height of the cam. Replace the camshaft if the cam is damaged notice-

f. As a result of this check, replace defective bearings with undersize ones. Bearing thickness measured at center

Crankpin diameter

Standard size

1.482 - 1.490 mm (0.0583 - 0.0587 in)

37.989 - 38.000 mm (1.4956 - 1.4961 in)

Under size (0.05 mm)

1 .SO7 - 1.5 15 mm (0.0593 - 0.0596 in)

37.939 - 37.950 mm (1.4937 - 1.4941 in)

Under size (0.25 mm)

1.607 - 1.615 mm (0.0633 --0.0636 in)

37.739 - 37.750 mm (1.4858 - 1.4862 in)

Bearing size

,

-.

ably or worn beyond the allowable limit. Minor scratches in the cam may be corrected by grinding it with an oilstone.

(0.0012 - 0.0038 in) Allowable limit

0.2 mm (0.0079 in)

NOTE: To replace the balancer shaft bearing, draw the shaft compl. (balancer) and drive out the plug. Then drive out the bearing with an appropriate remover-installer. Install the plug and the bearing in that order using the Press compl. (mechanicel seal) 498835400.

Fig. 5-66 Cam lobe shape

37.65 - 37.75 mm Standard total cam (1.4823 - 1.4862 in) height (for both intake and exhaust) Wear limit of cam

0.3 mm (0.01 18 in)

11) Balancer shaft compl. a. Check the gear (Balancer shaft driven) for damaged or worn tooth surface. Replace the gear if necessary. b. Check the ball holder and balls of the ball bearing (30 x 72 x 19 mm) for damage and replace if necessary. c. Check fitting condition of the ball bearing. Replace the ball bearing if improperly fitted.

Outer race fit tolerance

0.0 15 - 0.054 mm (0.0006 - 0.0021 in)

Inner race fit tolerance

0.002 - 0.019 mm (0.0001 - 0.0008 in)

d. Check the journals for damage or seizure. If necessary, replace the bearing (balancer shaft). e. Check for oil clearance

12) Oil seal (30 x 46 x 8 mm) (camshaft front) Check the lip for wear, damage or hardening. Replace the oil seal if necessary. 13) Oil seal (57 x 7 7 x 14 mm) (crankshaft rear) a. Check the lip for wear, damage or hardening. Replace the oil seal if necessary. b. Check fit around the oil seal. Replace the oil seal if necessary.

Standard fit tolerance

0.12 - 0.35 mm (0.0047 - 0.0138 in)

NOTE: Use the Press (crankshaft rear oil seal) 398722100 to install the oil seal.

14) Cover compl: (crankcase) a. Check the gear compl. (oil pump driven) for damaged or worn gear teeth. Replace the gear if necessary.

NOTE: To replace the gear, draw out the oil pump shaft with a press. Then install a new gear by pressing it in until the shaft end becomes even with the gear.

d. Replace gaskets with new ones. Moreover, use. liquid packing where necessary to prevent leakage. e. Replace keys, pins and bolts with new parts as required. f. Recheck each component during installation, although they have been checked and adjusted previously. 1) Press the balancer shaft into the crankcase with the Press compl. (balancer) 498735400.

Fig. 5-67 Removing gear (Oil pump driven)

Standard fit tolerance

.

NOTE: a. Be sure to use the Press compl. (balancer). Never depress the gear of balancer shaft b. Keep the ball bearing outer race even with the crankcase.

0.020 - 0.05 (0.0008 - 0.0022 in)

-*

b. Oil seal (23 x 40 x 7 mm) (balancer shaft front) Check the oil seal lip for wear, damage or hardening. Replace the oil seal if necessary. c. Oil seal (30 x 46 x 8 mm) (crankshaft front) Check the oil seal lip for wear, damage or hardening. Replace the oil seal if necessary. 15) Belt (Camshaft drive) Check the belt teeth for cracks, weal damage or hardening. Replace the belt i necessary.

Press COMPL

NOTE: Pay special attention to cracks and damag, on the back side of the belt. 16) Tensioner compl. Check for abnormal noise or leakage of grease. If defective, replace the tensioner.

5-4.

ASSEMBLY

* Precautions for assembling the engine. a. Thoroughly clean every part. Special attention should be given to the engine oil passage, pistons, cylinder bores, bearings, etc. b. When assembling, apply lubricating oil to such rotating and sliding parts as the pistons, cylinder bores, bearings, gears, etc. c. Apply engine oil to oil seal lips.

Fig. 5-68 Pressing in balancer shaft

Press the mechanical seal into the crankcase cover with the Press compl. (mechanical seal) 498835400. Press in both the oil seal (30 x 46 x 8 mm) and oil seal (23 x 40 x 7 mm) with a suitable installer until they are even with the cover. (Fig. 5-69) 2)

NOTE: a. Apbly engine oil to the oil seal lips. b. Coat the press-fit periphery of mechanical seal with NEJI-LOCK Super No. 1010 or equivalent.

1

5)

Assembling crankshaft Press the balancer drive gear onto the crankshaft and insert one end of the spring into the 4 mm d.ia. hole in the gear. Ins;tall the subgear onto the crankshaft with + h a "bamfered side of the 4 mm dia. hole facing the b:alancer drive gear so that the other end of the S]?ring can be inserted into the 4 mm dia. L-1rlule : In the subgear. Center the spacer on the subgear and press it together with the oil pump drive gear onto the crankshaft. Make sure tl moves smoothly. L11V

Fig. 5-69 Pressing in mechanical seal

3) Insert the inner rotor of oil pump in the crankcase cover and press in the oil pump driven gear with a press. Insert the outer rotor and, install the gasket and oil pump cover (Fig. 5-70).

L.1

NOTE: a. The subgear and spacer regulate axial clearance and should be used as a matched set. b. Apply a coat of engine oil to the bores of the subgear and spacer before installing. c. Always support the crankshaft at its 1st web when pressing parts onto it. I f it is supported at the rear end, the crankshaft may deform, resulting in damage.

NOTE: a. Support the oil pump shaft to keep it up against the press-in force. Do not attempt to support the crankcase cover. b. Press in the gear until it is even with the shaft end.

;]

11

.&

Rotor COMPL (OiLpump inner)

1 Balancer drive gear 2 Spring 3 Sub-gear 4 Spacer

Fig. 5-70 Pressing in oil pump driven gear

Install the crankcase on the Stand compl. lengne) 4998 1 1300. 3)

I

.

5 Crankshaft 6 4mm (0.16in) hole 7 Supporting surface T5-0 17

Fig. 5-71 Assembling crankshaft

6 ) Install the crankshaft bearing and crankshaft bearing I1 in the crankcase. Fit the crankcase cap, crankcase cap I1 and 111with six washer-based-head bolts to install the crankshaft in place. Bolt tightening

4.2 - 4.8 kg-m (30.4 - 34.7 ft-lb)

Pay attention during assembly to keep the proper thrust clearance and the engine oil passage free from clogging.

NOTE: a. Crankshaft must be installed as follows. i) Twist sub-gear clockwise about 6 O to align 5 mm hole in sub-gear with that in balancer drive gear. "Inserting 5 mm dia pin in the above holes facilitates the work. ii) While aligning punch mark on balancer driven gear with the 5 mm holes, install crankshaft to the crankcase. "After installation, pull out the pin.

7) Fit a circlip (17 x 1.4 mm) on the piston and install the connecting rod on the piston with the pin inserted into them.

NOTE: a. Assemble the connecting rod so that the mark @ on the connecting rod faces in the same direction as the mark ( F ) on the piston head. b. Check the piston pin for proper clearance with the pin hole.

Fig. 5-73 Assembling piston and connecting rod rir the piston rings on the piston. Install 0 the spacer of oil ring first, then the upper rail and lastly the lower rail. (Perform this work by hand.) Install the top and second rings with a piston ring expander.

NOTE: a. Arrange ring gaps in the directions shown in

Figure 5-74. b. Check the rings for proper clearance with the respective grooves.

Fig. 5-72 Aligning balancer drive gear, sub-gear and balancer driven gear

b. Insert a rubber seal coated with bonding agent (Fuji-Bond C or equivalent) into the cap III (crankcase). c. Face each cap with arrow marking to the front. Fit the cap with a single arrow first and, thereafter, in sequence of the increase in the number of arrows.

011ring lor*er rail Second ring

Approx.3d Oil ring upper rail Top r i n ~

Fig. 5-74 Piston ring gap pistons

9) Install the piston on which rings are fitted as shown in step 8, in the crankcase with the Guide (piston) 498745400. NOTE: a. Face the mark ( F ) on the piston head to the front of the engine.

Fig. 5-76 Fitting connecting rod

NOTE: a. Be sure to face the cap in the proper direction according to the identification mark on the cap. b. Check the connecting rod for proper side clearance.

Fig.5-75 InstalIing piston b. Before installation, lubricate the mating surfaces between the piston and the cylinder bore with engine oil. c. Do not allow the ring gap positions to slip excessively out of the preset positions during installation. d. Be sure that the following are satisfied without fail: a) Proper facing of pistons to the front of the engine. b) Proper arrangement of #I and #2 pistons. (#2 piston must be located on the clutch side.) c) Marks "1R" and "2R" stamped in the piston rings face the piston head side. e. When installing the piston in the crankcase, be careful not to damage crankpin by the threaded part of connecting rod bolts. 10) Fit the connecting rod cap to each connecting rod with the nuts.

Nut tightening torque

3.5 - 4.1 kg-m (25.3 - 29.7 ft-lb)

--l l I

11) Press the oil seal (57 x 77 x 14) into the rear end of the crankshaft with the Press (crankshaft rear oil seal) 398722 100.

NOTE: Lubricate the oil seal lip with engine oil before installation.

Fig.5-77 Pressing in oil seal 12) Install the crankcase cover assembly to which the rotor and gear have been assembled in step (3) together with the crankcase cover gasket and O-ring.

NOTE: The mounting bolts for the crankcase cover are common with those of the protector (oil filter).

-

NOTE: Block the rotation of balancer shaft with a screwdriver or the like during installation of impeller. 14) Install the water pump cover with its gasket. 15) Install the oil filter.

.

(case cov

Fig. 5- 78 Installing crankcase cover assembly

13) Insert the ceramic seat into the impeller (water pump) by hand and install the impeller onto the balancer shaft.

Fig. 5-80 Installing oilfilter

NOTE: a. Before reinstalling, apply coolant to t h ~ contact surface between mechanical seal ana ceramic seal. b. Ensure that painted mark surface of the ceramic seal is faced to the rubber seal side.

Bolt tightening torque

0.95 - 1.05 kg-m (6.87 - 7.06 ft-lb)

16) Fit the intake valve, exhaust valve, valve springs I and I1 to the cylinder head. Fit the intake valve oil seal to the intake valve guide with the Installer compl. (oil seal) 398852 100, and fit the exhaust valve oil seal to the exhaust valve guide. Apply engine oil to the valve stems and insert the valves into the valve guides. Fit the valve spring and retainer on each valve guide. With the Press (valve spring) - -. 399722100 set to the Press assembly (valve spring) 899724 100, compress the spring to fit it with a valve spring retainer key. NOTE: a. After installation of spring, tap them lightly with a mallet to seat them firmly. b. Be careful not to damage the lip of oil seal when inserting the valves into the valve guides. c. Install valve springs so that close-coiled end of each spring faces the cylinder head. d. Pay attention to the difference between intake valve oil seal and exhaust valve oil seal.

Fig. 5-79 Installing impeller 5 - 33

NOTE: Be sure to insert the gaskets so that the burr appeared side faces t o the bottom of the groove.

Tightening torque Exhaust

2.9 - 3.5 kg-m (20.97 - 25.32 ft-lb)

Intake Unit: mm (in) T5-019

Fig. 5-81 Intake and exhaust valve oil seals

,Installer

COMPL (Oil seal) 00 seal

Fig. 5-84

exhaust port flange

18) Install a new cylinder head gasket and the cylinder head compl. on the crankcase c o m ~ lwith . washer-based-head bolts. Fig. 5-82 Pressing in valve oil seal

'ghtening torque

I

+

6.5 0.4 kg-m (47.0 + 2.89 ft-]b)

NOTE: Tighten the bolts in the sequence stated in Figure 5-85. - -- --

?SS

- --

(Valve

Fig. 5-83 Fitting valve spring

17) Insert the gaskets into the grooves on the flange complete (exhaust port) and install them on the cylinder head.

Fig. 5-85 Cylinder head bolt tightening sequence

I I

19) Insert the camshaft into the cylinder head compl.

Fig. 5-88 Temporarily fitting contact breaker

Fig.5-86 Installing camshaft

20) Install the valve rocker arm 11, rocker shaft spring washer, spacer and valve rocker arm I in that order, on the valve rocker shaft from the camshaft pulley side.

22) Securely install the spark advancer unit together with a washer. 23) Check for proper point gap and then install the contact breaker cover together with the gasket.

24) Install the oil pan compl. together with the gasket. 25) Install the flywheel housing compl. !6) Install the flywheel on the crankshaft nd. Fig. 5-87 Installing rocker arm

Bolt (8.5 x 19 x 16.5 mm) : 6

!

I

I

NOTE: Fit the four rocker shaft caps to both ends of each valve rocker shaft

Tightening torque

4.2 -+ 0.4 kg-m (30 + 3 ft-lb)

21) Temporarily fit the contact breaker assembly.

NOTE: Align the contact breaker so that the groove in the spark advancer unit coincides with the guide pin on the camshaft.

NOTE: The flywheel can be installed only in one position.

NOTE: Set the key groove ill UIC c~a~~kshaft compl. in the vertical downward direction of the cylinder axis (piston bottom dead center). 31) Temporarily fit the cam belt tensioner compl. 32) Set the Adjuster compl. (cam timing) between the crankshaft and the camshaft driven pulley, and then install the camshaft drive belt.

Fig. 5-89 Crankshaft end

r. 5-91 Fig. 5-90 Flywheel

27) 28)

Install the crankcase hanger. Install the cam belt cover.

NOTE: Check the mount compl. [cam belt cover and spacer (cam belt cover)] for proper fit 29) Install the pully (camshaft driven) with the washer using the Adjuster compl. (cam timing) 49871 1300. Bolt tightening torque

6.0 kg-m (43.4 ft-lb)

30) Install the plate (camshaft driven pulley), the pulley (camshaft drive), in that order, on the crankshaft.

Match marks

NOTE: a. Properly align the match mark on the pulley with that on the adjuster compl. b. Set the belt so that it runs in the same direction as it ran before disassembly. (Marking with felt pen indicating the proper direction is recommended before removing the belt.) c. Avoid any sharp bending of the belt. d. Do not use any tool for installation of the belt. Use only hands. 33) Install the plate (camshaft drive pulley) on the crankshaft. 34) Install the cover I1 (cam belt) by bolt with spacer on the cover compl. (cam belt).

NOTE: a. Use spacers for three installing points of the cover (crankcase). b. Tapping bolts are used for installing the cover, so, be sure to keep the following tightening torque.

Tightening torque When the cover (crankcase) is new one

0.6 - 0.8 kg-m (4.34 - 5.79 ft-lb)

0.45 - 0.55 kg-m When the cover (crankcase) is reused one (3.25 - 3.98 ft-lb)

Be sure t o check fitting of the sealing (cam belt cover). ,5) Bolt the crankshaft pulley compl. with washers.

Tightening torque

5.5 - 6.5 kg-m (40 - 47 ft-lb)

NOTE: Use the Adjuster compl. (cam timing) 498711300 t o block the rotation of the crankshaft during tightening.

Fig. 5-93 Assembling intake manifold

38) Insert the thermostat into the intake manifold. Bolt the thermostat case cover together with its gasket.

NOTE: The thermostat must be installed with the iioole pin at the highest position.

itting thermostat

'ig. 5-92 ~nstallingpulley

- 6 ) Install the intake manifold compl. on the cylinder head with its gasket, nuts (8 mm) and bolts. 37) Install the carburetor assembly with its gasket, heat insulator, gasket I1 and O-ring on rhe intake manifold using two 8 mm nuts.

39) Install the alternator bracket compl. and the bracket I1 in plack, and temporarily fit the alternator assembly to the brackets. 40) Install the V-belt (10.7 x 8 x 722 mm) and adjust its tightness so that specific tension can be obtained.

Standard V-belt tension

10 - 15 mm/lO kg (0.394 - 0.591 in122 lb)

41) Securely tighten the bolts which were temporarily tightened in step (39). 42) Fit the hose (water bypass) to the intake manifold compl. 43) Fit the vacuum hose to the vacuum advancer unit. 44) Fit hoses (engine outlet) and hoses (engine overflow). 45) Adjust belt (camshaft drive) tension as follows. a. Turn the crankshaft pulley until the top dead center (T.D.C.) mark on the crankshaft pulley comes into alignment with the arrow mark on the crankcase cover to get cylinders T.D.C. point.

46)

Adjust the valve clearance.

Standard valve clearance (when cold) Intake

0.13 - 0.17 nim (0.005 1 - 0.0067 in)

Exhaust

0.23 - 0.27 111111 (0.009 1 - 0.0 106 in) I

I

NOTE: Refer to "CHECKING AND ADJUSTMENT OF VALVE CLEARANCE" previously mentioned in Chapter 3. "ENGINE TUNE-UP' for the details of adjustmen

\

1

After complcuurl uf the adjustment, install the valve rocker cover.

Tightening torque of the bolt

Fig. 5-95 Timing mark alignmenf b. Fully loosen the adjusting screw of rocker arm on one cylinder where the piston is positioned in the exhaust T.D.C. c. Remove the plug (timing belt cover) provided in the cam belt cover 11, and tighten first the lower 8 m m bolt and then the upper bolt on the tensioner.

Tightening torque

* *

1.6 0.15 kg (1 1.7 1.08 ft-lb)

NOTE: a. Tighten the tensioner bolts through two round holes. b. Loosen first and then retighten the tensioner compl. mounting bolts in step (45) if they were tightened before step (45).

0.75 2 0.05 kg-m (5.42 5 0.36 ft-lb)

I U U I c:

Tighten rocker cover bolts to the specified torque in three steps. 47) Remount the clutch cover and the clutch disc onto the flywheel.

i

NOTE: Use the Guide (clutch disc) 499745400 to help in centering of the clutch disc. (Refer to Chapter 10. CLUTCH. page 10-6. Installation.)

48)

Connect the transmission to the engine.

1

1

i

I

1 Tightening torque

4.2 - 4.8 kg-m (30.4 - 34.7 ft-lb)

I

i

.9)

!

1

a. Refill the engine oil and coolant.

Adjust the ignition timing.

Engine oil quantity: 2.8 liters (includes 0.3 liter for oil filter) (3.0 U.S. qt., 2.5 Imp. qt.)

NOTE: Refer to "CHECKING AND ADJUSTMENT OF IGNITION TIMING" in Chapter 3, and "ENGINE TUNE-UP" for necessaw adjustment procedure.

Coolant Standard ignition timing

10"/1,000

SUBARU COOLANT 6.0 liter

+ 50 rpm NOTE: a. Be sure to use recommended brands of

engine oil. b. Be sure to use SUBARU-COOLANT. 50) Securely tighten the breaker case mounting bolts which were temporarily tightened in tep (21). 1) Install the oil level gauge. 2) Install air cleaner. 33) Remove the Engine Stand.

*

After completion of remounting of the ngine on the vehicle, perform the following lspections and adjustments.

b. Bleed air from the brake system. c. Tune up the engine.

NOTE: Check the engine oil level after completion of engine tune-up work. Check for leakage of engine oil and coolant.

-

d. Make sure that wire harnesses, ex ha^1st muffler, etc. do not contact with the bod.Y.

5-5.

TROUBLESHOOTING

When signs of trouble appear on the engine, immediately take appropriate corrective action '-ouble

Starter motor does not operate

so as not to allow the defect to become worse. The following table shows some common troubles which may appear, the possible causes, and what corrective action to be taken.

and possible cause

Corrective action

1) Defective key switch contact

Inspect and repair or replace

2) Open line between the key switch and starter

Replace

3) Open line between battery and starter motor

Replace

4) Discharged battery

Charge or replace

5) Defective battery terminal contact

Inspect, clean and repair

6) Defective magnetic switch on starter motor

Inspect, clean and repair or replace

7) Defective starter motor internal mechanism

Repair or replace

8) Bearing seizure on crankshaft, connecting rod, etc.

Inspect and repair or replace

9) Piston seizure or sticking

Inspect and repair or replace

1) No gasoline

Check fuel tank and add fuel

2 ) No continuity of ignition current (open ignition system cord, ignition coil, distributor, and blown fuse, etc.)

Inspect and repair or replace

3) Defective starter motor internal mechanism

Repair or replace

4) Open or loose connecting slow cut valve wiring

Repair or replace wiring

5) Malfunction of slow cut valve

Replace slow cut valve

1) Discharged battery

Charge

2 ) Defective contacts in line between battery and starter motor

Clean and repair

3) Defective contacts in line between battery and ground

Clean and repair

-

Y

3 CI " I

.L

0

C u

V)

0

a

z

.-

M

r5

Starter motor operates but engine does not start

Starting speed too low

Corrective action

Trouble and possible cause V)

0)

0

E

- 2 0)

2

W

Starting speed too low

4) Defective starter motor

Repair or replace

5) Incorrect engine oil

Change engine oil for recommended one

1) Contact breaker

Damaged or corroded cord contacts

Replace or clean

Damaged or burnt points or improper gap

Clean and adjust or replace

Defective condenser

Replace

Improper ignition timing

Adjust

2) Spatk plug Defective ignition system

a

Improper ignition gap

Adjust gap

Defective insulation

Replace

Contamination due to carbon

Clean

3) Ignition coil

-

w

.5 * LC

Defective ignition coil

Replace

Poor connection in primary line

Inspect and repair

Corroded high tension cord socket

Clean

Y Y)

.-(1

4) Defective cord or defective wiring

-

X

Replace

4

3 U

1) Fuel pump

t2 5

Defective operation

Replace

Clogged fuel filter element

Replace

-- -

Defective fuel system

2 ) Improper gasoline or gasoline mixed with water

~e~lade

3) Carburetor

Defective choke valve operation

Adjust choke system or replace

Excessive gasoline intake

Fully open choke and throttle valves and operate engine

Contaminated or clogged carburetor

Disassemble and clean

ouble and possible cause

M

.-c

Corrective action

1) Defective cylinder head tightening

Inspect and retighten

2) Damaged cylinder head gasket

Replace

3) Defectivevalveseat contact

Correct

4) Seizure of valve stem

Correct or replace

5) Deterioration or damage t o valve spring

Replace

6) Improper valve clearance or valve

Adjust

4 L

cd

Y

V)

.Ei

-5 x

Engine

holding open

U

7) Worn piston, piston rings, and cylinder

Disassemble and repair

8) Leakage from intake manifold gasket

Retighten or replace gasket

9) Loosened carburetor installing

Re tighten

bolts

10) Defective spark plug tightening

Retighten

1) Improper valve clearance

Inspect and adjust

2) Defective valve seat contact

Correct

3) Seizure of valve stem

Correct o r replace

4) Deterioration or damaged valve spring

Replace

5) Leakage from cylinder head gasket

Replace gasket

6) Seized or worn piston ring

Replace

7) Worn piston ring or cylinder

Disassemble and repair

8) Leakage from spark plug gasket

Retighten spark plug or replace gasket

Y

3

a O

3

2

Poor compression

-

Trouble and possible cause

1) Improper ignition timing

Corrective action Adjust

2) Distributor Defective ignition system

Defective points

Correct or adju

Defective vacuum and spark advancer

Replace

Defective condenser

Replace

3) Defective spark plug

Clean, and adjust or replace

1) Clogged carburetor

Disassemble and repair

2) Defective fuel pump operation

Replace

3 ) Clogged fuel filt~

Replace

4) Clogged fuel pipe

Clean

5) Air mixed in the fuel system

Inspect coupling and re tighten

6) Improper gasoline or gasoline mixed with wptpr

Replace

1) Clogged air cle aner

Replace

2) Defective choke valve

Repair or replace choke system

1) Clogged mufflr

Replace

1) Insufficient coolant

Add

2) Defective thermostat function

Replace

3) Defective water pump function

Replace

4) Clogged radiator or coolant leaking from radiator

Clean and repair, or replace

5) Clogged coolant passage or coolant leaking from passage

Inspect, clean and repair or replace

6 ) Defective tlzermoswitch function

Replace

7) Defective fan motor

Replace

4

3

a * 3

0

el

Defective fuel system

Insufficient intake air

Defective exhaust system

a0

C .C-l m

5 al

6

Engine

I

Trouble and possible cause

Engine

Corrective action

8) Defective connection between fan motor and thermoswitch

Inspect and repair or replace

9) Improper ignition timing

Adjust

10) Improper engine oil

Change, using recommended oil

11) Mixture too lean

Inspect and adjust or repair carburetor and intake system

12) Improper valve clearance

Adjust

13) Excessive resistance in exhaust system

Inspect and adjust or replace

cjo

.5 Y

rn

a,

5 Q)

6

Causes other than engine

Carburetor a

8 a. V)

-2

1) Slipping of clutch

Inspect and adjust or replace

2) Dragging of brake

Inspect and adjust or replace

3) Improper transmission oil

Change, using recommended oil

1) Improper idling adjustment

Readjust

2) Clogged slow-system passage

Inspect and clean

3) Open a loose connecting slow cut valve wiring

Repair or replace

1) Leakage from joints of intake system

Inspect and retighten or replace gasket

2) Vacuum pipes (crack or damage)

Replace

1) Improper valve clearance

Adjust

2) Leakage from valve seat

Correct

M

.*C

Q)

S

Intake system

Y V)

5 Valve system

Trouble and possible cause

Corrective action -

Valve system

3) Excessive clearance between valve stem and guide

Replace

Cylinder head

1) Leakage from gasket

Replace

1) Improper ignition timing

Adjust

2) Poor spark plug action

Adjust o r replace

1) Excessive cooling

Inspect and replace thermostat

1) Loose oil pan drain plug

Re tighten

2) Defective oil pan drain plug gasket

Replace

3) Loose oil pan mounting bolts

Re tighten

4) Defective oil pan gasket

Replace

5 ) Loose oil pump mounting bolts

Retighten

6) Defective oil pump gasket

Replace

7) Defective oil filter sealing

Inspect and retighten

2

8) Defective crankshaft oil seals

Replace

0,

9) Defective rocker cover gasket

Replace

a Q)

Q)

2

-ac

.d

Ignition system c

3

&

Cooling system

Oil leakage c 0 .-*

5

# .d

0 Q)

.-c w

5

10) Loose crank case cover mounting bolt

Retighten

1 1)

Replace

Q)

.-> "I Q)

Defective camshaft oil seal

U

w"

Oil creep i n t o combustion chamber

Oil sucked into combustion chamber through valve guide

1) Improper piston ring gap or defective oil ring

Replace

2) Seizure, wear or defective contact of piston ring

Replace

3) Excessive wear or piston and cylinder liner

Replace

1) Damaged retainer rubber

Replace

2) Excessive clearance between valve stem and guide

Replace

Trouble and possible cause

Defective fuel system

Corrective action

1) Improper idling adjustment

Readjust

2) Worn o r improper main jet

Replace

3) Clogged main air bleed

Clean or replace

4 ) Defective needle valve or float level too high

(

5) Choke does not fully open

Correct or replace

6) Defective accelerator pump

Replace

7) Defective auxiliary valve operation

Correct or replace

8) Damaged carburetor gasket

Replace

9) Excessive fuel pump pressure

Inspect anu

1) Improper ignition timing

Adjust

2) Defective ignition advancer operation

Correct or replace

3) Improper breaker point gap

Adjust

4) Improper gap o r contamination of spark plug

Adjust or clean

1) Improper valve clearance

Adjust

2) Poor compression

Inspect and correct or -eplace

3) Excessive cooling

Inspect thermostat and temperature gauge

1) Slipping of clutch

Inspect, and adjuster or replace

2 ) Dragging of brakes

Inspect and adjust

3) Improper tire size or air pressure

Replace and adjust

replace

I C ~ ~ I I

C

0 .4 C

a

5

Y)

d

o

2e, e,

Defective ignition system

0 Y) '

e,

2

W

Defective engine

Causes other than engine

.-

-

Trouble and possible cause

Defective ignition system

Corrective action

1) Loose ignition line connections

Inspect and retighten

2) Defective or improper spark plug

Clean, adjust o r replace

3) Improper ignition timing

Adjust

1) Mixture too lean o r t o o rich

Clean and adjust carburetor

2) Contamination inside carburetor

Overhaul and cl---

-

-

Defective fuel system

C

.0

C I I )

3

-

lmination or clogge d fuel lint: Clean or replacc

4) Leakage from carburetor and intake manifold

Re tighten or replace gasket

1) Improper valve clearance

Adjust

2) Valve seizure

Replace

3) Weak valve spring

Replace

1) Carbon deposit in combustion chamber

Clean

2) Clogged exhaust port

Clean

3) Leakage from cylinder head gasket

Replace

4) Maladjustment of belt ten:

Adjust o r replace

1) Carbon deposit in mufflc

Clean or replacc

P

E

0

v

C1

cJ

2

Defective valve

9

d

Defective cylinder head

Defective exhaust system

I and corre

I ) Defective spark plug (defective or contaminated gap)

2) Defective ignition coil

2

%

E c 'G C w

Defective ignition system

3) Defective breaker Defective condenser

t Repla ce

Replace

Improper point adjustment or defective arm 4 ) Defective cords

Repla

ace

r

Trouble and possible cause Defective ignition system

5

Defective fuel system

'2

5)

cbefective c:ontacts of wiring

Corrective action Inspect and repair

CIonnection S

6) Improper ignition timing

Adjust

1) Mixture too lean

Overhaul

2) Clogged carburetor

Overhaul

3)

Improper carburetor idling adjustment

Adjust

4)

Leakage at carburetor gasket

Retighten or replace

e,

c

.d

2

5) Improper gasoline or gasoline

W

Drain fuel and replace gasoline

mixed with water 1) Damaged valve or i~ilproper adjustment

Adjust o r replace

2) Weak valve spring

Rc

3) Poor compression

I~lspectand adjust or replace

4) Excessive cooling

Inspect thermostat and temperature gauge

1) Defective ignition wiring

Replace or repair

2) Defective vacuum advancer

Replace

3) Improper ignition timing

Adjust

1) Clogged slow jet and/or slow air bleed

Inspect and clean

1) Clogged air cleaner

Replace

u

2 ) Leakage from joints of intake system

Inspect and retighten or replace gasket

.-2

1) Poor compression

Inspect and correct o r replace

2) Improper valve clearance

Adjust

Engine

Defective ignition system .c)

2

Defective carburetor

cl

0

C

2, 3

8

Defective intake system

0 A

2

Engine

M

.-C

E 3 .f! G 4

Improper way of stopping engine

Stopping engine just after racing it

Don't race engine

Improper adjustment of throttle opener

Insufficient throttle opener opening angle

Adjust

Engine

Engine misfire

Inspect and adjust

Engine noise

1

In most cases, engine noise consists of combined sound, i.e., sound from the various rotating and sliding parts. Hence, it is difficult to determine the source and cause of these different sounds. However, when an unusual noise occurs, try to locate the cause and then take proper corrective action immediately.

Type of sound Sound like metal striking together, or softer thumping sounds.

Increase engine speed

+ When valve clearance

is normal

Sound like striking stone with a heavy hammer or tapping stone with a small hammer.

Low Inspect oil pressure Normal

High pitched metalic sound

Cause

Method of confirmation

Generated when accelerating with an overload

-+ Engine knocking

x

Improper valve clearance

x

Worn vlave rocker arm

x

Broken valve spring

x

Worn cam nose

x

Worn crankshaft main bearing

x

Worn connecting rod bearing (big end)

x

Loose flywheel mounting bolts

x

Damaged engine mounting

x

Ignition timing too fast

x

Accumulation of carbon inside combustion chamber

x

Wrong spark plug

x

Defective breaker advancer operation

x

Defective gasoline

Type of sound

Method of confirmation

Cause x

Worn crankshaft main bearing

x

Worn bearing; at piston connecting rc)d

x

Worn cylinder liner ana piston ring Worn bearing at piston end of connecting rod

Knocking sound when engine speed is medium (about 3,000 rpm with no load)

Short circuit spark plugs one after another +

Knocking sound when engine is warm and operating at idling speed.

Short circuit spark plug one after another 4

Knocking sound when engine is operating under idling speed and engine is warm.

Short circuit spark plugs one after another +

x

Worn piston pin and connecting rod bearing (Big end)

Sound is extinguished

x

Unusually worn valve rocker arm

+ Sound is not extinguished.

x

Insufficient backlash of balancer gear

Sound like scratching glass witha nail.

x

Insufficient AC generator lubrication

Sound like a shower, or tapping light metal with heavy metal at high frequency.

x

Defective AC generator brush and rotor contact

Dragging sound when starting the engine.

x

Defective starter switch

x

Worn ring gear and starter pinion

Sound like polishing glass with a dry cloth or normal starter sound.

x

Loose V-belt

Sound like air leaking or being blown out

x

Leaking of compression

High level noise (whistling) just after racing the engine.

x

Overtension of timing belt.

Sound is extinguished.

Sound is extinguished

x

CHAPTER

6:

ENGINE LUBRICATION SYSTEM

61 .

.

GENERAL

...................................................................................

6-2

6.2

.

OIL PUMP

.....................................................................................

6-3

63.

.

OIL FILTER

6 - 4.

OIL

................................................................................... 6-7 PRESSURE SWITCH ............................................................. 6-8

6-1.

GENERAL

Cylinder

r

T

t Crankcase n~airigallery

Valve(0il bypass)

t Oil pump

1.0 kgjcm2 (14.22 psi)

6 - 7.7Llmin (1.59 - 2.03 U.S. gal.) (1.32 - 1.70 Imp. gal.) 2.5 - 3.6 kgIcm2 (35.56 - 51.21 psi)

T6-001

Fig. 6-1 Engine lubrication diagram

The lubricating system is a pressure-feed, all-filtration type driven by a trochoid oil pump which contains a built-in oil relief valve. The oil-bypass valve is built in the oil filter assembly. The oil pump is driven from the crankshaft through a reduction gear t o run at a half of cranking speed. The drive gear and the driven gear are made of sintered ferro-alloy and nylon resin respectively t o reduce the noise. Oil from the oil pump is sent under pressure to the crankshaft journals, and balancer shaft journals through the crankcase main gallery. From the crankshaft journals oil goes to the crankpins and then to the big-end of each connecting rod, where the oil is sprayed to the connecting rod small-ends and cylinder bore surfaces.

To lubricate the camshaft, oil is fed from the main gallery to the top surface of the crankcase and, therefrom, oil is led to the camshaft journals through the cylinder heads. From the camshaft journals oil is led to each cam through the hollow provided in the camshaft, so that oil lubricates the sliding contact surfaces between the cam and the rocker arm as well as between the valve stem and the rocker arm adjust screw. The rear journals of the camshaft is lubricated by oil spray. If the effect of the oil filter element is somewhat reduced, oil is forwarded directly to the main gallery through the bypass valve built in the oil filter. Moreover, if the oil pressure increases abnormally, excessive oil pressure opens the oil relief valve to return it t o suction side of the oil pump through the relief valve.

6-2. 1.

OIL PUMP Specification

Trochoid type

Type

6 4 m i n . or more, (6.33 U.S. qt., 5.27 Imp. qt.)

Delievery rate Delivery Performance 1

Delievery pressure

2.5 kg/cmZ (35.56 psi)

Oil pump speed

1,500 rpm

Oil temperature

80°C (176OF) 7.7Llrnin. or more, (8.14 U.S. qt., 6.78 Imp. qt.)

Delivery rate Delivery Performance 2

Delivery pressure

3.6 kg/cm2 (5 1.20 psi)

Oil pump speed

3,000 rpm

Oil temperature

80°C (176OF)

Valve (oil relief) operating pressure

3.0 t:-25

Valve (oil by-pass) operating pressure

1.O f.0.2 kg/cm2 (14.22

Standard tip clearance between inner rotor and outer rotor

kg/cm2 (42.67

t3.56

2.8 psi)

0.02 - 0.12 mm (0.0008 - 0.0047 in)

-

Standard side clearnace between rotor a] oil pump case

0.01 -0.16mm (0.0004 - 0.0063 in)

Standard case clearance between outer rotor and oil pump case

0.15 - 0.21 mm (0.0059 - 0.0083 in)

Free length of relief valve spring

46.8 mm (1.84 in)

. PSI)

asket

Valve (Oil relief) Spring (Relief valve)

2 Oil pump component parts

2.

Removal Precautions for Removal

A. Carefully check the oil pump before removing it for any evidence of oil leakage. B. When replacing the oil filter and the oil pump gasket, remove the oil filter with a suitable tool and then remove four bolts fastening the oil pump cover. 1) Drain engine oil and coolant. 2 ) Remove the oil level gauge COMPL.

Remove the generator assembly. 'Draw out the crankshaft pulley. Remove the cam belt cover 11. " Remove the cam belt tensioner spring and the tensioner COMPL. Remove the camshaft drive belt. Remove the camshaft drive pulley and two plates. Remove the camshaft driven pulley. Remove the cam belt cover COMPL. 10) Remove the flywheel housing COMPL. 11) 3)

4) 5)

12) Remove the oil pan COMPL. 13) Remove the water bypass hose (6 x 12) and engine inlet hose from the crankcase cover assembly. 14) Remove the water pump cover by loosening three 6 x 18 mm bolts, a 6 x 20 mm bolt and a 8 x 80 mm bolt. Then, remove the water pump gasket.

Fig. 6-4 Removing crankcase cover assembly

Fig. 6-3 Removing water pump cover

15) Remove the water pump impeller by loosening a bolt.

17)

Remove the oil filter assembly.

'3.

Disassembly

1) Remove the oil pump cover by loosening two 6 x 18 mm bolts and two 6 x 32 mm bolts. Remove the gasket.

NOTE: Prevent rotation of the impeller by inserting a screwdriver between the balancer shaft weight and the crankcase. 16) Remove the crankcase cover assembly by loosening the following: 8 x 25 mm bolt, four 8 x 45 mm bolts and two 8 x 55 mm bolts (passing through the protector to fasten it together).

NOTE: Take special care not t o damage the oil seal lips on the crankshaft front -and balancer shaft front.

I

Fig. 6-5 Disassembling oil pump

cover

2) Take off the oil pump outer rotor. 3) Draw out the oil pump shaft with a press. 4) Remove the plug ( I 4 x 9 mm) and take up the relief valve spring and valve.

^,.I Relief valve

Y--c,. inner)

pun Cove r (Oil .. .. II

(Oil

ssure

outer)

4

Fig. 6-7 Checking tip clearance

Fig. 6-6 Disassembling relief valve and oil pressure switch

5)

4.

Remove the oil pressure switch assembly

Inspection and repair

Wash disassembled parts, inspect the following items, and repair or replace if defective. 1) Oil pump shaft Inspect the periphery, and replace the shaft if excessively worn or damaged. 2) Oil pump inner and outer rotors a. Check each rotor and replace if excessively. worn or damaged. When replacing the inner rotor, remove the oil pump shaft pin.

Outer diameter Inner rotor

Outer rotor

29.70 - 29.74 mm (1.1693 - 1.1709 in) 40.53 - 40.56 mm (1.5957 - 1.5968 in)

1 i

:

b. Tip clearance Check the tip clearance. Replace the rotor assembly if the clearance exceeds the allowable limit.

Standard tip clearance

0.02 - 0.12 mm (0.0008 - 0.0048 in)

Allowable maximum tip clearance

0.2 mm (0.0079 in)

c. Side clearance Check the side clearanck (between the inner rotor and the oil pump cover). Replace either the rotor or the case, if the side clearance exceeds the allowablelimit.

Standard side clearance

0.01 - 0.16 mm (0.0004 - 0.0063 in)

Allowable maximum side clearance

0.2 mm (0.0079 in)

d. Case clearance Check the case clearance (between the outer diameter of outer rotor and the crankcase cover). Replace either the rotor or the cover, if the clearance exceeds the allowable limit.

6)

Oil pump cover Inspect the cover for damage to oil filter fitting threads and cracks or any other defect in the cover.

5.

Reassembly

Reassemble the oil pump in the reverse order of disassembly. I

NOTE: Use new aluminum washers, gasket and O-rings.

rllcKrless gauge

ig. 6-8 Checking case clearance

Standard case clearance Allowable maximum case clearance

0.15 - 0.21 mm (0.0059 - 0.0083 in)

6-3.

OIL FILTER (CARTRIDGE TYPE)

0.25 mm (0.0098 in)

810 cm2 (125.55 in2)

Filter area Oil relief valve and relief valve spring Inspect the valve for fit and damage, and the relief valve spring for damage and permanent strain. Replace them if necessary.

3)

Bypass valve operating pressure

46.8 mm (1.8425 in)

Fitted length

33.5 mm (1.3189 in)

Setting load

3.3 50.15 kg (7.28 5 0.33 lb)

Valve (oil relie0 operating pressure

t:25 (42.67

t3.50

0.2 kg/cm2

+ 2.84 psi)

16Llmin. (4.23 U .S. gal, 3.52 Imp. gal.)

Delivery rate Free le

1.O (14.22

-

kg/cm2 .

PSI)

Oil pump cover Inspect the oil pump cover for clogging of oil passage, cracks or any other defect. 5) Crankcase cover Inspect the cover for wear and cracks in the rotor housing.

4)

I

1 Oil filter 2 Bypass valve 3 O-ring

4 Spring 5 Spring 11

Fig. 6-9 Oil pump

~6-003

2.

1.

Inspection

1) Check.the O-ring for deformation or damage. Replace the oil filter if the O-ring is defective. 2) Check the oil filter body for deformation or breaking. Replace it if defective.

3.

Type

secure the oil filter t o the specified torque.

0.9 - 1.4 kg-m (6.48 10.08 ft-lb)

NOTE: a. Be careful not to damage the O-ring installation of the filter. b. Apply a small amount of grease to the O-ring. c. After installation of the oil filter, start the engine and check to see that no oil leakage appears an the sealing surfaces.

6-4.

O I L PRESSURE SWITCH

Oil contact

12V

Voltage

Installation

Tightening torque

Specifications

Bulb

12V-3.4W or less

Closing pressure

0.3 (4.3

Opening pressure

+ 0.1 kg/cm2

+ 1.4 psi) 0.3 + 0.1 kg/cm2

(4.3 f. 1.4 psi)

-

Withstand pressure Weight

r.

10 kg/cm2 or more (142.23 psi) 40gr. (1.41

02)

Construction

The oil pressure switch consists of a diaphragm which operates under oil pressure, electrical contact points which open and close (ON- OFF) with movement of the diaphragm and a spring which determines operating pressure at the opening of contact points. These parts are sealed in the hexagon nut type housing combined with the terminal and phenol resin mold.

Operation

3 1 Point

2 Diaphragm

T6-004

3 Spring 4 Wire fixing bolt

Fig. 6-10 Sectional view of oil pressure switch

The spring is set to the rated pressure by the adjust screw so that the contact points are kept closed when there is no oil pressure. This allows the warning lamp to light up when the ignition switch is turned on. After the engine starts and when the oil pressure reaches the rated value (0.3 kg/cm2), the pressure in the diaphragm overcomes the spring pressure and acts on the points which results in the light going off. It may be considered normal for the light to be off during running of the engine, irrespective of running state of the vehicle. Lowering of oil pressure below 0.3 kg/cm2 during engine running will cause the warning lamp to come on.

Page

1I

II I

I1 .

-I 1

7-

1.

.

GENERAL DESCRIPTION

.....................................................

2

............

6

7- 2

CONSTRUCTION OF ENGINE COOLING SYSTEM

7- 3.

SPECIFICATIONS

7- 4.

COOLANT REPLACEMENT

7- 5.

RADIATOR ASSEMBLY

7- 6.

MOTOR FAN ASSEMBLY

7- 7.

RESERVOIR TANK

7- 8

.

7- 9.

. 1.

.........................................................................7 - 7

.........................................................

............................................................... 7-10

...........................................................7-11

...................................................................... 7-11

COOLANT LEVEL WARNING DEVICE CHECK VALVE

..................................... 7-

.............................................................................7-19

7-10

THERMOSWITCH ASSEMBLY

7-1

HOSE (Radiator inlet and outlet)

...................................................

.

HOSE

7-13

.

HOSE

71.4

.

COOLING PIPES

71.5

.

HOSE (Check valve outlet. reservoir tank inlet and reservoir tank outlet) .........................................

..........................................................

................................................. 7-17 . THERMOSTAT ................................................ 7-18 . THERMOMETER ............................................, .

7-15

................................................ 7-16 (Water pump inlet. thermostat outlet and heater) ................. 7-16 (Air vent of engine. radiator and heater) ............................... 7-17

7-12

71.6

7-8

WATER PUMP

a

7-1.

GENERAL DESCRIPTION

1.

Engine cooling employs a water cooling system combining a superb heat dissipation down flow type radiator and motor fan and is an enclosed type cooling system having a tank at the front. The radiator is installed to the bottom of the floor and is connected to the rear engine by water pipe which is fitted under the floor at the right side of the body. Coolant level warning device has been equipped to warn that coolant level is under the specified level.

When the coolant temperature is under 82OC (180°F), the coolant is only circulated through the by-pass system and heating system (when heater control valve is opened), and when the temperature is over 82OC (180°F), the thermostat (Jiggle pin type) is operated and the coolant is also sent to the radiator. When the coolant temperature exceeds 92OC (198O~), the motor fan installed to the rear of the radiator is automatically operated by the thermoswitch and forced cooling is performed. The coolant temperature is therefore balanced between 8 2 ' ~and 9 2 ' ~(180°F and 198OF).

1) At a coolant temperature below 82OC (180°F)

Cap

>k3/

Cap w ~ t hpressure valve

Reservoir tank

Plug

Heater air vent

Thermostat

E n g ~ n ealr vent

Check valve

T7-001

Fig. 7-1

Heater control valve: Opened Thermostat: Closed

Coolant is circulated to reservoir tank, heater, front by-pass and water pump.

2)

At a coolant temperature between 82OC and 92'C ( 1 8 0 ' ~ and 198'~).

Fig. 7-2

The thermostat is opened and coolant is also circulated to radiator.

Heater control valve: Opened Thermostat: Opened

-

3)

At a coolant temperature above 9 2 ' ~(198'~)

Fig. 7-3 7-3

coolant). In order to prevent evaporation of the coolant, an air chamber is provided at the reservoir tank and a 0.9 kg/cm2 (12.8 psi) safety valve is installed. Coolant volume is approximately 6.0 L and is circulated by a centrifugal water pump mounted to the end of the balancer shaft.

Heater control valve: Opened Thermostat: Opened Thermoswitch for electric fan: ON Electric fan mounted behind radiator is operated by thermoswitch provided in the radiator and when the coolant temperature is decreased to 88OC (190°F), the thermoswitch is out automatically.

3.

2.

Function of re check valve

ank and

1) Reservoir tank for separator of coolant and vapour.

The coolant is a long life coolant (SUBARU

6 Gas, vapor or air leaks in from hoses, cooling pipes and engine etc. 7 Cooling water containing a small amount of air bubbles 8 Cooling w ning no air bubbles 9 Heater 10 Check vat 11 Radiator ~7-004

1 Air bubbles are discharged here. 2 Reservoir tank 3 Cooling water and air bubbles are repeatedly separated. 4 Gas, vapor or ai 5 Engine

When coolant temperature exceeds llO°C (230°F) and the engine is suddenly stopped.

2) Reservoir tank and check valve for preventing coolant overflow 7-4

1 Cooling water alscnarged from engine enters reservoir tank where it overflows. 2 Occurrence of vapors forces cooling water out of engine and empties it. 3 Normal water level

T7-005

1 Vapors are discharged here. 2 Water level rises in response t o amount of cooling water inside water line from which vapors are discharged. 3 Normal water level 4 Concentrated vapors flow through this lime. 5 Occurrence of vapors inside engine does not discharge cooling water out of engine extremely. 6 Check valve

Fig. 7-6 With check valve

/

3) Reservoir tank compensates for the gradual leakage of the coolant from the cooling system and absorbs the amount of expansion by the coolant temperature rises.

1 Valve to regulate the pressure lnslae coodng system. 2 Reservoir tank always contains approx. 1.& cooling water. T7-007

Fig. 7-7 Reservoir tank

7-2.

CONSTRUCTION OF ENGINE COOLING SYSTEM

38

T7-008

1 2 3 4 5 6 7 8 9 10 *11 12 13 *14 15 16 17 18 19 20

Bracket (Tank) Flange nut Reservoir tank cover Bolt assy Clip (Fuel system) Clip (Engine cooling) Hose (Heater air vent) Reservoir tank assy Cap Level sensor (Reservoir tank) Hose (Radiator air vent) Grommet Hose clamp Hose (Check valve inlet) Hose clamp Grommet Hose clamp Clamp (Cooling pipe) Cooling pipe B Cooling pipe C

21 22 23 24 25 26 27 *28 29 *30 31 32 33 34 35 36 37 *38 39 40

Hose (Engine inlet) Hose (Engine outlet) Hose (Engine outlet) Clamp (Upper) Clamp (Lower) Bolt & washer Cooling pipe A Hose (Radiator inlet) Check valve Hose (Check valve outlet) Flange nut Fan Fan motor Grommet (Fan) Spacer (Fan) Washer Bolt &washer Radiator assy Thermoswitch O-ring

41 42 43 44 *45 46 47 48 49 50 51 52 53 54 55 *56 57

*

Drain plug (Radiator) Gasket (Radiator) Washer Flange nut Hose (Reservoir tank inlet) Grommet (R.H.D. only) Hose clamp Hose (Reservoir tank outlet) Hose clamp Grommet Overflow tube Clip 12 Connector (Overflow) Boot (Overflow) Cap Hose (Radiator outlet) Lock washer

Different parts between R.H.D. and L.H.D.

Fig. 7-8 Components of engine cooling system

Item

Core dimension Radiator Fin pitch Radiation capacity * 1 Capacity

Reservoir tank Cap

Fan diameter

Fan

Motor specifications Air flow capacity *2

Thermoswitch

Specification

Conditions

Width x Height x Thickness 334 x 240 x 32 mm (13.1 x 9.45 x 1.3 in)

2.0 f.p. -8,700 Kcal/h

Water flow: 45.41 min. Temperature difference between coolant and ambient atmosphere: 6S°C (149OF) Front air velocity: 8 m/sec.

Approx. 1.6.L Pressurle type Positive pressure 0 .8 - 1.O kg/cm2 (1 1.4 - 14.2 psi) Negative pressure 0.05 - 0.1 kg/cm2 (0.7 - 1.4 psi)

190 mm dia. x 6 blades Magnet motor Input: under 6r

- *2

7.5 m3/min.

ON

90° - 94OC (194 - 201°F)

OFF

86 - 90°C (187 - 194OF)

Temperature at which valve starts to open

*1

A P a = 7 mmAq

3.S°C (177 - 182OF)

Thermostat

Without jiggle pin Temperature at which valve fully opens

bS°C (203OF)

7-4.

COOLANT REPLACEMENT

Replace the coolant every 40,000 km (25,000 miles) or every 2 years. Always use genuine [SUBARU Coolant] . Since an aluminum engine is employed, when the use of another coolant or water is unavoidable, replace it with [SUBARU Coolant] as soon as possible. (Refer to Table 1 below.)

1.

Draining the coolant -1 I Disconnecting hoses

Filling coolant Set the h eater levc:r to "HC IT" position. -

-

Fig. 7-9 Draining coofunt 1) Obtain a container having a wide opening. 2) Remove the radiator drain plug. 3) Open the front flap and drain coolant from the- radiator by removing the reservoir tank cap. (Fig. 7-10)

Fig. 7-12 Heater lever 2) Open the engine hood, detach the two engine air vent hoses from clamp under the floor and remove the drain plugs.

i

>

Drajn plug

jtnglne alr vent) Clam0 )\

Fig. 7-10 Removing cap 4) Jack up rear side of the vehicle and drain coolant further. 5) Disconnect radiator hoses (inlet and outlet) and heater hose from cooling pipes and drain coolant further.

Fig. 7-13 Drain plugs

7-8

3) Open the front flap, and remove caps from the air vent pipes connected to the radiator and heal

4) Pour the coolant through reservoir. 5) When the coolant starts to flow from the two engine air vent hoses continuously, install the drain plugs and then attach the hoses to clamp under the floor. 6) Fill the reservoir up to the mouth piece with the coolant,then install reservoir cap. 7) Install caps on the air vent pipes connected to the radiator and heater. 8) Start the engine, and idle it at constant speed of approx. 3,000 rpm for more than 5 minutes (until radiator becomes hot). 9) Stop the engine, and wait until the engine temperature is decreased. Add the coolant up to the mouth piece of the reservoir and install cap secur~ ely.

Fig. 7-14 Removing caps

Reservoir tank Engine air vent hose

Heater air vent Radiator air vent

-

Plug

T7-009

Fig. 7-15 Cooling system (Whenfilling coolant)

3.

Coolant SUBARU Coolant to water mixture ratio (in volume) should be determined for the lowest atomospheric anticipated temperature according to the table below.

(Net 18 liter) Parts No. 000016218

I

I

Coolant Specifications

I atmospheric anticipated temperature

coolant-to*water ratio (Volume)

Above -lS°C (S°F)

30 to 70

Below -lS°C (S°F)

50 to 50

at loOclat2 0 0 lat ~ 3 0 0 ~at 1 40°clat 50°C

* It is recommended that distilled water be used. 7-9

Freezing point

7-5.

lnspection

R A D I A T O R ASSEMBLY

Drain t he~coolant. Disconnect the radiator ai, .,llL ,,, &J the left side ()f shroud in cabin (RHD) or 2it the righ.t side of slhroud in c:abin (LHD). 1)

1) Check the tube ana welaea part between radiator tank (inlet and outlet) and tube for leakage. When defective, repair or replace.

'r)G a L

F&

zdiator (RHD) Inlet tank

Fig. 7-16 Radiator air vent 1wse ( RHL

.

.

Fig. 7-19 Radiator (L1 3tor air hose

2) Check th.e fins of the radiator core and repair with a stcrewdrive:r, etc. whc:n the air path is blocked. 3) Wash witn warer when the fins are muaay or dirty. '

J 3

Fig. 7-1 7 Radiator air vent hose (LHD)

3. 3) Remove front combination light. 4) Remove front bumper. 5) Disconnect the harness from the thermoswitch. 6) Disconnect the radiator hoses (inlet and outlet) fromcooling pipes. 7) Remove the radiator by removing four 6 mm flange nuts. 8) Finally, remove the inlet and outlet hoses connected to the radiator.

I

I1 II

Installation stallation is the reverse of removal.

E: hen installing the radiator hose, always lint the hose clamp to the prescribed direction as viewed from the bottom. The same also applies to the water tube and hose connections. Otherwise, retightening of the hose clamp will be impossible after cle. mounting to the vehi~

I 1

!

I

I

NOTE: Be careful not to damage the radiator core when removing the fan.

Toward the top right

Toward the top right

lant upward 1

2

Outlet hose Inlet hose T7-010

Fig. 7-20 Installing radiator hoses

'

b. Insert the inlet hose and outlet hose bv 23 to 30 mm (0.9 to 1.2 in) and the air vent i hose by 20 to 25 mm (0.79 to 0.98 in). ( c. Fill completely with coolant. (Refer to "Filling coolant".) 1 d. Check for any coolant leakage after installation. I

'

7-6.

1.

-' I

1 I

MOTOR F A N ASSEMBLY Features

1) Superb cooling performance (especially effective when vehicle is running at low speed) 2) Engine output improved Since the cooling fan is not driven by the engine, there is no power loss and engine output is increased. As a result, acceleration and climbing ability are improved and fuel economy is improved. 3) Since the fan is not usually operating, there is little noise caused by the fan. (The fan is automatically operated when the coolant temperature reaches 92OC (198OF) and is automatically stopped when the coolant temperature drops to 88OC (190°F) by means of a thermoswitch.)

Fig. 7-21 Installed position of motor fan

3.

Inspection

1) Replace the packing and cover when they are ozone cracked. 2) Check the bracket for damage or cracking. 3) Check the operation of the motor.

4.

Installation Installation is the reverse of removal.

NOTE: a. Be careful to provide a clearance between the fan and radiator. b. Provide a clearance of over 10 mm (0.39 in) between the motor and radiator inlet hose and clearance of over 15 mm (0.59 in) between the motor and horn.

7-7. 1.

2. 1)

Removal Disconnect the motor lead wire and har-

ness. 2) Remove the two 6 mm bolts of the bracket mounting the motor assembly.

RESERVOIR T A N K Operation

The reservoir tank is installed at the highest position of the cooling system and serves as the coolant inlet, separates the air remaining in the system when coolant is added, and keeps the system filled with coolant at all times. (If the

air in the system is circulated, the cooling performance of the radiator will drop, and the engine will become overheated.) The coolant in this tank also compensates for the gradual leakage of the coolant from the cooling system and larger allowable coolant loss volume will be obtainable.

6)

NOTE: Allowable coolant loss volume: The coolant level a t which the engine is seized when the coolant is gradually removed from the cooling system. To be precise, the allowable coolant loss volume indicates the permissible limit of coolant leakage and the larger this volume the greater the safety of the cooling system.

Remove the reservoir tank cover.

~t hose

Fig. 7-23 With cover removed (LHD)

7) Remove the inlet hose and outlet hose from the reservoir tank.

NOTE: Obtain a container since the coolant in reservoir tank will spill out.

2.

8) Detach the overflow tube from the boot. 9) Remove the bracket and pull out the tank to the rear.

Removal

1) Remove the reservoir tank cap and drain the coolant. (Refer to Chapter 7-4). 2) Remove glove box (LHD) or combination meter (RHD). 3) Remove defroster duct. 4) Disconnect the connector and unclip the wiring harness from the reservoir tank cover. 5) Remove tapping screws attaching heater control lever bracket.

3. 1)

2)

4.

Replace tank if cracked or leaky. Replace poor cap sealing.

Installation

servoir

aaling tape

\

Fig. 7-24 Attaching sealing tape 7-12

'

lnspection

1) Attach the new sealing tape to the body. (Do not use old one of sealing tape.)

Fig. 7-22

-

'

2) Install in the reverse order of removal. 3) Perform leakage test around the tank, and when leakage is detected, repair. 4) Hoses are inserted by 25 to 30 mm (1.0 to 1.2 in)

7-8.

(/

I

5) Always install the hose clamps. in the specified direction. (Fig. 7-23) 6 ) Refill the coolant. (Refer to Chapter 7-4.) 7) Always confirm that there is no coolant leakage after installation.

COOLANT LEVEL WARNING DEVICE

Use of this warning buzzer helps prevent the engine from overheating and facilitates day-today water level check.

From engine

~7-011

Fig. 7-25 Coolant level warning device

1.

Function

3.

Level sensor (Reservoir tank)

In the water level warning device, a magnet floating switch is located inside the reservoir tank. When the cooling water drops below the specified level, the warning buzzer sounds to warn the driver that cooling water must be replenished. The warning device is actuated while the ignition key is turned ON, regardless of whether the engine is in motion or not. Level

i

7

voir tank

2.

Checking and servicing coolant

Refer to 3-3. in CHAPTER 3 ENGINE TUNE-UP.

Fig. 7-26 Level sensor

1) Removal a. Drain the coolant in reservoir tank. b. Loosen the level sensor and remove from reservoir tank. 2) Inspection a. Replace the float if damaged. b. Using a circuit tester, check for continuity with the float at the lowest position. Replace if no continuity exists.

7-9. 1.

CHECK VALVE Construction

Fig. 7-28 Check valve unit

From reservoir tank

4

." , . 2 Fig. 7-27 Checking continuity O-ring

3)

Installation Installation is the reverse of removal. a. When screw the level sensor into the! reservoir tank, be careful not to twist or j i Irn the O-ring with edge of reservoir tank.

Float

Lower case T7-012

-

Fig. 7-29 Construction

Torque

*

0.15 0.03 kg-m (1.1 0.2 ft-lb)

*

b. After connecting the connector, check the level sensor for operation. If the buzzer does not sound, wiring harness or buzzer etc. are defective. c. Fill the coolant. d. Confirm that there is no coolant leakage after installation.

The check valve consists of upper case and lower case, float and valve, and operates as one way valve. The coolant flow from reservoir tank can pass through the check valve but can not reurn to the reservoir tank.

Operation 1) When engine is stopped, the valve in the check valve unit contacts the sealing face of upper case by the buoyancy force of the float. 2) When operating the engine, the valve in the check valve moves toward the lower case side by flow of coolant from reservoir tank.

7-10.

3) When coolant temperature exceeds 110°C (230°F) and the engine is abruptly stopped, vapour produced in the engine will press the coolant toward the reservoir tank through the water pipes (connected to radiator). Then, if there is no check valve in the cooling system, the coolant in the water pipes (connected to radiator) and radiator will force out from reservoir tank, but in case there is check valve in the cooling system, the coolant will not force out through the pipes (connected t o radiator). (Refer to Figs. 7-5 and 7-6.)

3.

1.

THERMOSWITCH ASSEMBLY Functions

The thermoswitch is an enclosed wax type. The volume change in accordance with the temperature of the wax is utilized. When the temperature of the water exceeds 92OC (198OF), the shaft is pushed upward, closing the contacts automatically, hence current flows to the fan assembly, and forced cooling is started.

Removal

1) Drain the coolant. 2) Remove the front under cover. 3) Remove the radiator. 4) Remove the check valve from the inlet hose. 5) Remove the outlet hose from the check valve. Movina contact

--'-A

Fig. 7-31 Constr uc.uvn @ Check

2.

,

I

Hose(Check valve, outlet) '

I I

Fig. 7-30 Check valve (Left-hand drive)

4.

I

1

Installation

Specifications

1

t

Model

Enclosed wax type

Operating temperature

ON 90 - 9 4 O ~(194 - 201'~) OFF 86 - 9 0 ' ~(187 - 194'~)

Current capacity

3.

DC 12V, 7 Amp.

Removal

I

1

Install in the reverse order of removal.

' NOTE: a. Make sure the check valve is installed in correct direction. b. When refilling the coolant, refer t o Chapter 7-4. c. Always confirm that there is no coolant leakage after installation.

Unscrew the ~ ~ ~ I I I I U ~ W I ILI UL UI I~I L I I ~ ~screw and detach the switch through a hole in the front under cover under the radiator.

4.

Inspection

Immerse the sensitive section of the therrnoswitch in 100°C (212OF) hot water and confirm that it is turned ON using a circuit tester.

Installation Installation is the reverse of removal.

mounting screw)

(2.2 ft-lb)

Connect the harness of the thermoswitch securely and clip the harness. (Missing to clip will result in short circuit.) 1)

7-1 1. HOSE (Radiator inlet and outlet)

1.

Removal Refer to radiator removal item.

2.

Inspection

2) Inspection a. Replace when the reinforcement of the outer cover of the hose is damaged. b. Replace hoses which are noticeably hardened. 3) Installation Installation is the reverse of removal. a. Hose insertion depth is 25 to 30 mm (1 .O to 1.2 in). b. Install the hose clamps in the specified direction. (From the standpoint of retightening) c. When installing the hose, provide a clenrance of 30 mm (1.18 in) or more between the Ise and under cover, and the hose and .C.G.cover. djust so that the hoses are not contacting each other. e. Fill the coolant. f. Confirm that there is no coolant leakage after installation.

Thermostat outlet hose and heater hose

1) Replace the hose when the reinforcement of the outer cover is damaged. 2) Replace hoses which are noticeably hard.

3.

Installation

Installation is the reverse of removal. 1) Hose insertion depth is 23 t o 30 mm (0.9 to 1.2 in). 2) Confirm that the clearance between the inlet hose and fan motor assembly is 10 mm (0.39 in) or more. Fig. 7-32

-12. HOSE (Water pump inlet, thermostat outlet, and heater)

1.

Water pump inlet hose

1) Removal a. Drain the coolant b. Remove the trap door at the top of the engine compartment. c. Remove the under cover. d. Loosen the hose clamp and remove the hose.

1) Removal a. Drain the coolant. b. Remove the trap door at the top of the engine compartment. c. Remove the boot connecting air cleaner and carburetor. d. Loosen the bolt and release the clamp then disconnect the hose. e. Loosen the hose clamps and disconnect the hose.

.--

I

2) Inspection a. Replace when the reinforcement of the outer cover of hose is damaged. b. Replace hoses which are noticeably hardened. 3) Installation a. Hose insertion depth is 25 to 30 m 1.2 in). b. Install the hose clamps in the specified direction. (From standpoint of retightening.) c. When installing the hose, provide a clearance of 30 mm (1.18 in) or mor between the hose and under cover. d. Arrange so that the hoses do not contact each other. e. Fill the coolant. f. Confirm that there is no coolant leakage after installation.

d. Open the engine hood, detach the engine air vent hoses from clamp under the floor. e. Loosen a bolt and remove hoses with clamp from engine. f. Remove the drain plugs from the hoses. 2) Inspection a. Replace when the reinforcement of the outer cover is damaged. b . Replace hoses which are noticeably hardened. 3) Installation a. Hose insertion depth is 25 to 30 mm (1 .O to 1.2 in). b. Install the hose clamps in the specified direction. c. Confirm so that the hoses are not contacting with spark plug cord. d. Bleed all the air from the cooling system after installation. e. Confirm that there is no coolant leakage after installation.

2.

7-13. 1.

I

HOSE (Air vent of engine, radiator and heater)

Air vent hose of engine

1) Removal a. Do not open the cap of reservoir tank. b. Remove the trap door at the top of the engine compartment. c. Prepare plugs. Loosen the clamps and remove the hoses, then put the plugs to the pipes of engine side.

Fig. 7-33 Engine air vent hose

Air vent hose of radiator and heater

1) Removal a. Radiator air vent hose 1) Drain the coolant. 2) Remove the reservoir tank cover. 3) Disconnect the hose from air vent pipe by loosening hose clamp. 4) Disconnect the hose from radiator by loosening hose clamp. (Refer to Figs. 7-16 and 7-17). b. Heater air vent hose 1) Drain the coolant. 2) Remove the reservoir tank cover. 3) Disconnect the hose from air vent pipe by loosening hose clamp. 4) Remove the heater assy. 5) Disconnect the hose from heater assy. 2) Inspection a. Replace when the reinforcement of the outer cover of hose is damaged. b. Replace any hose that is noticeably hard. 3) Installation Installation is the reverse of removal. a. Hose insertion depth is 20 to 25 mm (0.8 t o 1.0 in). b. Always install the hose clamp in the specified direction. (From the standpoint of retightening.)

c. Bleed all the air from the cooling system after installation. d. Confirm that there is no coolant leakage after installation.

7-14. 1.

COOLING PIPES

Installation

Installation is the reverse of removal. 1) Hose insertion depth is 25 to 30 rnrn (1 .O t o 1.2 in). 2) After installation of the hose, coat the sealant on the grommet t o prevent water leakage. 3) Fill with coolant. 4) Confirm that there is no coolant leakage.

Removal

1) Drain the coolant. 2) Remove the front under cover. 3) Loosen the hose clamps, and disconnect the hoses. 4) Loosen the bolts of front and rear clamps, and remove the clamps behind the front suspension and in front of rear suspension. 5) Disconnect the gear shift lever from gear shift rod (front side). 6 ) Remove the clutch cable clamp (rear). 7) Remove fuel tank. 8) Remove the hand brake cable. 9) Remove cooling pipes (A, B, C).

2.

2.

7-16. 1.

Specifications 5.5 L lmin. (1.453 U.S.gal., 1.210 Imp. gal.) or more

Installation Delivery rate

Installation is the reverse of removal. 1) Hose insertion depth is 25 to 30 mm (1 .O to 1.2 in). 2) When installing, confirm that the pipe is in its original position. 3) Fill with coolant. 4) Confirm that there is no coolant leakage.

Pump speed Total head

8

Water temperature

E,

1.

HOSE (Check valve outlet, reservoir tank inlet and reservoir tank outlet)

1,000 rpm 0.22 mmAq 75 - 8 5 ' ~ (167 - 1 8 5 ' ~ )

Delivery rate

5 0 L/min. (13.21 U.S. gal., 1 1.0 Imp. gal.) or more

Pump speed Total head

8,000 rprn 1.5 mmAq

&

7-15.

-

WATER PUMP

-

Water temperature Impeller dia. x Number of vane

75 - 85OC (167 - 185'~) 54 mm(2.13in) x 6

Removal

1) Drain the coolant 2) Remove the radiator 3) Loosen the hose clamps and disconnect the hoses.

Revolution ratio agaist crankshaft Clearance between impeller and case

1: 1 0.3 - 0.9 mm (0.012 - 0.035 in)

h , - Cam timina adius

imic sei31 lmpe \ I

Cover

I

I

Mechanical

Fig. 7-34 Water pump

Fig. 7-35 Removing belt and cover

3.

2.

Removal

Prior t o removal, check minutely the various parts of water pump for evidence of water leakage. 1) Drain engine oil and coolant. 2) Draw out the oil lever gauge COMPL. 3) Draw out the spark plug cord C O W L from the spark plug. 4) Remove the V-belt. 5) Remove the water inlet hose and the water bypass hose 11. 6) Remove the crankshaft pulley COMPL by means of the special tools 4987 11300 Cam timing adjuster COMPL and 899521421 Puller assembly. 7) Remove the cam belt cover 11. 8) Remove the cam belt tensioner spring and the tensioner COMPL. 9) Mark the running direction on the camshaft belt. 10) Remove a camshaft drive pulley plates and take off the camshaft drive belt. 11) Remove the camshaft drive pulley and its plate. 12) Remove the camshaft driven pulley using the special tool 498711300 Cam timing adjuster COMPL. 13) Remove cam belt cover COMPL. 14) Remove the flywheel housing COMPL. 15) Remove the oil pan COMPL.

Disassembling

1) Remove the water loosening bolts.

pump cover by

6 m m x 18 Bolt: 4 6 mm x 20 Bolt : 1 8 mm x 8 0 Bolt : 1 And remove the gasket. 2) Remove the water pump impeller by loosening a 6 mm bolt. 6 mm x 18 Bolt : 1

NOTE: Block the rotation of the impeller by inserting a screwdriver between the balancer shaft weight and the crankcase. 3) Remove an oil strainer COMPL mounting 6 mm bolt at the crankcase side. NOTE: The oil strainer COMPL is unnecessary to be removed from the crankcase cover. 4) Remove the crankcase cover assembly by loosening the following bolts.

8 mm x 25 Bolt : 1 8 mm x 45 Bolt : 4 8 mm x 55 Bolt : 2 (Tighten with the protector)

5) Push out the mechanical seal by means of the press COMPL 398832100 and an applicable press. 6) Drive out the oil seal (23 x 40 x 7) using an appropriate installer.

4.

Inspection

1) Check the mechanical seal contact surface of the water pump impeller for wear or damage. 2) Check the water pump impeller for damage and corrosion. Replace the impeller if remarkably defective. 3) Check the oil seal (23 x 40 x 7) for worn, damaged or stiffened lips. Replace the oil seal if defective. 4) Check various parts for cracks, wear damaged, and replace if any defective.

5.

two sheets of spacer inserted between the impeller and the water pump shaft. 5) Securely tighten the impeller t o the water pump shaft.

Tightening torque (6 mm Bolt)

6) Install the water pump cover with its gasket.

6. 1)

Assembly

Installation Installation is the reverse of removal. Adjust tension of the V-belt.

Standard belt sag

When replacing the balancer shaft, refer to Chapter 5. (Page 5-3). 1) Fit the oil seal (23 x 40 x 7) with its dust lip faced inward to the crankcase cover. Press in the seal until it comes even with the cover surface. 2) Assemble the crankcase cover with its gasket to the crankcase.

NOTE: Be careful not t o damage the lips of oil seals at the ends of both the balancer shaft and the crankshaft during assembly of the crankcase cover. 3) Assemble the oil strainer to the crankcase. 4) Press the water pump impeller to the water pump shaft with a hand and check the tip clearance between the impeller and the crankcase cover. Standard value of tip clearance

0.3 - 0.9 mm (0.012 - 0.035 in)

Limit of tip clearance

1.1 mm (0.043 in)

If the clearance exceeds the allowable limit, replace the impeller. After replacement of the impeller, recheck the tip clearance with one or

1.0 f.0.05 kg-m (7.23 2 0.036 ft-lb)

11 mm/lO kg

2) Adjust the camshaft drive belt tensioner for proper setting of it. Refer to Chapter 5 "Engine" for the details of adjustment procedure. 3) Adjust the ignition timing. 4) After reinstallation of the water pump and after completion of necessary adjustments, start the engine running to check water leakage at various parts and abnormal noise from the water pump.

7-17.

1.

THEF Construc _.-

The thermostat piston is provided with a guide pin which is locked slantwise in a groove to prevent the piston from unsteadily sliding due to foreign substances and incrustation in the water. This construction is also effective to prevent the piston pin from escaping even under excessive opening of the thermostat valve which is necessary to relieve the engine from overheating, thus ensuring reliable function of the thermostat to prevent the overheating of the engine. The jiggle valve provided in the valve facilitates air bleeding from the thermostat when the cooling system is refilled with water.

d

1 2 3 4 5

6 7 8

Seat Valve Supporter Cap Pi (Thermostat) Frame Spring Cover

T7-014

7

Pin(Thermostat)

i

Groove

Looked state

1 2 3 4

Intake manifold Pin (Thermostat) Thermostat cover Jiggle valve 5 Air vent

Weight =0.55 Or Dimension of jiggle pin T7-015

Fig. 7-37 Function of thermostat 7 -21

T7-016

Fig. 7-38 LOlcked pin

2.

7-18.

Specifications *

TYpe

Wax pellet type

Valve actuating temperature

82 t 1.S°C (179.6 2.7OF)

Valve open temperature Valve lift Valve diameter Valve (Jiggle pin) weight

3.

+

8 mm (0.3 150 in)

17.3 - 14.9

96.9 - 100

lOO(212)

29.3-26.2

83.0-86.2

80 (176)

56.8 - 47.5

63.6 - 68.3

5 0 (122)

178.9 - 123.9

29.9 - 37.1

+ 0.066 g

-

Removal

Inspection

Replace the thermostat if its valve does not close completely at a normal water temperature or if it is found defective under the following temperature test. 1) Temperature test of the thermostat a. Immerse the thermostat and a thermometer in water. Gradually increase the water temperature at which the valve comes fully opened. Also, measure the lifting height of the valve. During the test be sure t o stir up the water to ensure even temperature distribution. b. As a result of this test, replace the thermostat if the measurements differ considerably from the rated values in temperature or in lift height of the value.

5.

Current mA

120 (248)

3 1 mm (1.2205 in) 0.55

Specifications

Temperature Resistance value a "C (OF)

9S°C (203OF)

Remove the thermostat cover by loosening two 8 x 40 mm bolts. Remove the gasket and lift out the thermostat.

4.

1.

THERMOMETER

Installation

When reinstalling the thermostat use a new gasket. Put close the thermostat seat to the case compl. Install the thermostat case cover.

2.

Construction

The water temperature gauge consists of the gauge and the thermistor unit, and these parts are installed on the combination meter assembly and the cylinder head, respectively. The thermistor unit is composed of the thermistor, which is completely sealed in a case with a hexagon nut, lead wire, spring, terminal plate, epoxide resin, etc.

3.

Function

The thermistor in the unit is a kind of semiconductor as like a transistor or diode. The thermistor features that extremely large changes of resistance can be obtained with it under a slight change of temperature, in contrast to ordinary conductors in which the resistance is only doubled even at several hundred degrees of temperature rise. The thermistor is warmed by the coolant and its resistance changes in proportion to the temperature of coolant at that time. The resistance controls current flowing to the temperature gauge circuit.

Leadwire

Thermister

Epoxy resin(f3lack) T7-017

gauge, so that the gauge pointer indicates a low temperature. Temperature increases, the resistance of the thermistor lowers and more current flows in the gauge circuit, causing the pointer to deflect to a higher temperature range. The thermistor unit has no contacts to control the current flow which may be liable to cause the variation of the current at the heater wire in the gauge when there is some fluctuation of the source voltage. In order to eliminate such an unfavorable condition, the thermistor unit type temperature gauge system is fitted with a voltage regulator.

Fig. 7-39 Structural view of thermistor unit

4.

Voltage regulator T7-018 4

Fig. 7-40 Wiring diagram of water temperature gauge system

When the coolant temperature is low, small current flow due to high resistance of the thermistor merely excites the bimetal of the

Precautions for handling of the gauge

1) When testing the gauge system, do not apply the battery voltage directly to only the gauge or thermistor unit, but be sure to aupply the voltage to both the gauge and thermistor unit connected in series. If the battery is connected to one unit alone, the lead wire in the gauge or the thermistor may be burned out. 2) Be careful to connect the terminals securely. When a pointer reading is unsteady, inspect not only the gauge but also the wiring harness for grounding or the unit for loose terminals. 3) Do not short or ground terminals or wiring. Such a mistake will result in the burning of wiring or thermistor. 4) Be careful not to drop or strike either the gauge or thermistor unit. Otherwise, precision construction of them will be easily damaged. 5) It is normal that the pointer indicates "C" as long as the engine starting switch key is kept to "OFF' position.

5.

Troubleshooting Trouble and possible causes

Defective indication

No indication

Pointer out of scale

Corrective action

1) Defective terminal contact

Correct

2) Stuck gauge pointer

Correct

3) Broken lead wiie

Replace

4) Defective thermister

Replace

1) Disengaged pointer

Correct

2) Broken lead wire

Replace

3) Broken wiring harness

Correct

1) Grounded wiring harness

Correct

2) Short circuited or grounded lead wire

Replace

CHAPTER

8: CARBURETOR

Page 81 .

.

FEATURE

............................. .......................................................... 8-2 ;

8-4

. . .

8-5

.

OVERHAUL OF CARBURETOR

86 .

.

THERMO CONTROL VALVE

8-2 8-3

......................................................................... CONSTRUCTION AND OPERATION ......................................... SPECIFICATIONS

8-2 8-3

...........................................

8-5

..............................................

8-6

INSPECTION AND ADJUSTMENT

.....................................................

8-1.

-

FEATURE

-v--nn-nzr.l.i--

d

1) The carburetor is of the butterfly valve type with sidewise draft, compact in size, light in weight, and easy t o handle. 2) Adoption of a horizontal multi-hole nozzle, double venturi, and full-scale emulsion tube gives superior atomization of fuel, giving good driving perpormance from low speeds through high speeds. 3) With an accelerator pump which is interlocked with the throttle valve in acceleration, the carburetor can prevent hesitation of acceleration by eliminating transient rarity of the mixture.

Fig. 8-1 Carburetor

Model

HCE 30-70

Manufacturer

Hitachi Ltd.

Air horn diameter

46 mm (1.8 in)

Throttle bore

30 mm (1.2 in)

Venturi dia. (large x small)

--

25 x 9 mm (0.98 x 0.35 in)

Needle valve diameter

1.2 mm (0.047 in)

Air vent system

Closed vent system

Float chamber ventilation system

Inner vent dia.:

Main nozzle

Inner dia.: 1.8 mm (0.07 in) Outer dia.: 4.0 mm (0.16 in) Hole dia. - number: 1.2 mm (0.0047 in) - 6

Emulsion tube

2.2 mm (0.087 in) Inner dia.: 3.8 mm (0.150 in) Outer dia.: Hole dia. - number: 0.6 mm (0.024 in) - 2 1.0 mm (0.039 in) - 16

Settings of jets

.

6 mm (0.24 in)

Main jet

#I 22

Main air bleed

# 50

Slow jet

#48

Slow air bleed

#I 50

--

0.6 mm (0.024 in) x 1,0.8 mm (0.032 in) x 1, 0.9 mm (0.035 in) x 2

Bypass hole diameter Accelerator pump (nozzle diameter x amount of discharge)

0.4 mm (0.016 in) x 6.3 cc (0.38 in3)/10 strokes

Fuel level (from float chamber upper face)

20 5 1 mm (0.79

Throttle valve opening for starting (Throttle valve opening with choke valve fully closed)

8-3.

I

I

1.

+ 0.04 in)

14.5~ Throttle valve clearance: 1.2 mm (0.047 in)

CONSTRUCTION A N D OPERATION

fuel pump and then enters the float chamber via a needle valve. The fuel level in the float chamber is always kept constant by means of the needle valve and float. The fuel level in the float chamber is 20 mm 1 mm (0.79 0.04 in) below the top of the float chamber. The fuel level can be adjusted by correcting the float lever.

This carburetor consists of a float system, main system, slow system, accelerating system, and starting system. :

1

1.0 mm (0.039 in)

Idle hole diameter

+

Float system Fuel from the fuel tank passes through the

+

Float chamber

T8-001

Fig. 8-2 Float system

8-3

2.

Main system

thC l l l a l u ,d, mixed 1 oming out of the 1 1 bleed passage emulsion tube via tll= 1 1 ~ ~ ~dir and main air bleed, and sprayed in to the venturi from the main nozzle.

The main system supplies fuel for normal driving other than idling and low speed driving. The fuel in the float chamber is regulated by

'I (Metering) 1

jtube= Emulsion

Main alr bleed passa

Main air bleed

Fuel

0Air

a Mixture /

Emulsion tube

~8.002

Fig. 8-3' Main sy:stem

3.

Slow system

regulated by the slow jet, and mixed with air from the slow air bleed. Then the mixture passes through the slow passage and sprayed out of the bypass and idle holes.

The slow system supplies fuel for slow speed (light load) driving. Fuel from the main jet is

4

[wain j e t H Slow jet (Metering)

1 slow air bleed]

J

-*

Slow air bleed

Fuel lir

dixture Slow jet

~8-003

Fig. 8-4 Slow system ..

4.

Starting system

1

The starting system is of choke valve type. When the choke lever is pulled, the choke valve fully closes and the throttle valve opens slightly so as to give proper condition for starting by means of linkage that connects the throttle valve t o the choke valve. Overchoking is eliminated and smooth revolution is ensured, since the choke valve slightly opens automatically permitting fresh air to enter after starting.

'

8-4.

I

Fig. 8-5 Adjusting idling speed

INSPECTION AND ADJUSTMENT 2.

Idling adjustment Idling speed

-. to decrei

Idle adjusting screw

I I

.

Fuel level adjustment

1,000 k 50 rpm Graduation with

I

1) Warm up the engine until it reaches normal operating temperature. .2) Adjust the throttle adjusting screw so that idling speed is between 950 rpm and the ---- enpine ---c 1,050 I.pm without roughness. 3) A djust the idle adjusting screw so that the engine revolution is highest and smoothest.

epeat 2) and 3) until stable idling speed ined. (950 rpm to 1,050 rpm) easure and make an adjustment of the carbon monoxide concentration if necessary upon (:ompletion of adjustment of the idling speed.

Float chamber

se two copper gaskets

T8-004

Fig. 8-6 Float level measurement

1) ~ e m o v ethe drain plug and copper gasket underneath the float chamber. 2) Install the carburetor float level guage (special tool 899377800). 3) Feed fuel into the float chamber. 4) Read the "L" dimension by means of the float level gauge as shown in Fig. 8-6. If the "L" dimension is 20 1 mm (0.79 0.04 in), the gasoline level is correct. 5) If not correct, adjust by bending the float lever and measure again. 6) After measurement retighten the drain plug and replace the copper gasket with new one.

+

3.

Checking slow cut valve

+

cut valve

n

.

Fig. 8-8 Slow cut valve

+

2.

Adjustment of valve openings for starting

1) Start the engine, and idle it at 1,000 rpm 50 rpm. Then disconnect the wire of slow cut valve. If the engine stopped, the function of the slow cut valve is normal. 2) If the wire of the slow cut valve is connected and the engine could not keep idling speed, check the damage of the slow cut valve wiring or operation of the slow cut valve.

Tightening torque

8-5. 1. Fig. 8-7 Starting valve openings

2.0 - 2.5 kg-m (14.5 t o 18.1 ft-lb)

OVERHAUL O F CARBURETOR Float chamber cover

-

---

---

----

t chamber cover

Conne lever

1) Measure the clearance C1 between the throttle valve and bore with the choke valve fully closed as shown in Fig. 8-7. 2) In this condition, C1 should be approx. 1.2 mm (0.047 in) or opening angle of 14.5'. If not, adjustment should be made by bending the choke connecting rod.

ft (Float)

Gask-.

Fig. 8-9 Component parts

1) Remove the float chamber cover and gasket by unscrewing the five 5 mm screws and removing a cotter pin connecting the connecting lever and rod. 2) The float chamber cover has a needle valve, connecting lever, piston, float, etc. 3) Pull out the float shaft and remove the float. 4) Remove the 5 mm screw and washer and detach the connecting lever, pump cover, and piston. Then remove the needle valve.

3.

The slow jet can be removed from outside without removing the float chamber cover. (Fig. 8-11)

4.

Main jet he main jet can be removed from outside out removing the float chamber cover.

Main air bleed and slow air bleed

Slow air blc

NOTE: a. Do not disassemble the piston end since it is press-fitted. b. Be careful so that the rubber cup of the piston does not force the return spring in, when reassembling the piston into the accelerator pump cylinder. After overhauling the accelerator pump ~rts,operate the pump to see if fuel jets ut of the nozzle. I f not, overhaul again and ietk fuel injection after making sure that the accelerator pump is correctly fitted.

2.

Slow jet

n' air Removing air bleeds

Remove the float chamber cover and thenremove the main air bleed and slow air bleed. The emulsion tube can be pulled out if main air bleed is removed. The main air bleed and slow air bleed protrude from float chamber top surface when installed, but it is not unusual.

5.

Main nozzle

Main jet ;crew driv

Fig. 8-10 Removing main jet

1 \

I I

Remove the drain plug and gasket at bottom of float chamber and then remove main jet from the float chamber. Replace pacK' ing with new one when reinstalling drainI plug.

the the the the

bleel

blain nozi setting sc

Fig. 8-12 Removing main nozzle

Remove the nozzle set screw. The main nozzle can be removed by holding the carburetor body upside down and lightly tapping it. When refitting the main nozzle, match the slot of the nozzle head with the protrusion in the installation hole.

6.

7.

Overhaul o f throttle a n d choke valve

It is better not to needlessly disassemble valves. In case there is absolute necessity of cllsassembling the valves, reassemble them with utmost care so that they will not get loose. 2) Be sure to keep the throttle valve slightly open when disassembling and reassembling the throttle lever. Otherwise, power valve opening angle will be affected.

Power jet

Pistol

\

8-6.

THERMO CONTROL VALVE

The EK23BE engine is provided with Thermo Control Valve (T.C.V.). The T.C.V. controls coolant flow in the coolant passage of the intake manifold by coolant temperature, and the]n temper;lture of carburetor slow system is aut~ r controlled. (Fig. 8-14) ~maticallj

Fig. 8-13 Removing power jet Disassemble and service the power jet taking care not to damage the jet valve at the center of - :jet.

2.

ITE: a. Carefully remove and reinstall jets with screwdrivers of suitable size taking care not to damage the head grooves. b. Do not use wires or drills for cleaning jets. Be sure to use cleaning fluid and compressed air.

If the coolant temperature is below 45OC (1 13S°F), coolant circulation extends into carburetor and warms up tbe slow system. When the coolant temperature is above 55OC (131 .O°F), T.C.V. operates and the coolant circulation is blocked and overheating of carburetor is prevented.

Uperation

1 Carburetor

3 Manifold CP (Intake) Gasket 2 (Intake)

4 5

Insulator (Carburetor)

Fig. 8-14 8-8

5

-E

4 -

E

3 g 2.5

Y

Gi

c

close

2I

I I

-

O

T. C. V

1;

I

55

45

Coolant

I

60

I

I

70

80

+

open

-

.

temperature (OCI

I I

0

.

1 ,

I

I I T8-007

Fig. 8-15

3.

Inspection

Fig. 8-1 7 Measuring Fig. 8-1 6 Measuring "

5

"

1) Measure "fj" dimension at normal temperature [below 45OC (1 13.s°F)] .

"

$"

2) Heat water at 55OC (1 3 1.O°F) and put the valve into water until the valve operates full stroke. Then put out and measure "!$" dimension. is 2.5 mm (0.098 in) 3) If " $" minus " or less, the T.C.V. is normal.

5''

I

4.

Troubleshooting Condition and probable cause

Remedy 1) Defective T.C.V.

Hesitation when starting or unstable idling speed at hot seasen (summer, eary autumn etc.)

(stick in open) 2) Clogged T.C.V.

,

Unstable idling speed at cold seasen (winter, early spring etc.)

1) Defective T.C.V. (stick in close)

Replace Clean eplace

CHAPTER

9: ENGINE ELECTRICAL SYSTEM

Page

91 .

.

96 .

. . . . .

97 .

.

92 . 93 . 94 . 95 .

DISCRIPTION

...............................................................................

9-2

BATTERY

..................................................................................... 9 - 2

STARTER

....................................................................................

9-4

............................................................................ 9-10 VOLTAGE REGULATOR ........................................................... 9-16 CONTACT POINT BREAKER .................................................... 9-19 IGNITION COIL ........................................................................... 9-21 ALTERNATOR

lean off s~ n yoily substance which maY be .. ring t o the hydrometer as it may distort the r The engin'e electric;il system consists ()f the . . . . .. - . . following compunenrs. --

-

-

--A-

1)

Starter When the engme 1s startea, tne starter produces andI transmit s a large starting tsorque to the ring gear, by w hich means the eng:ine is cranked up. 2) Generator and voltage regulator This is a device that controls the field current of the generator and keeps the vl~ltage constant. 3) Ignition coil The ignitilon coil gc he high VIoltage :quired to jump a spark across the electroaes f the spark plug. ) Contact breaker The contact breakel X G I L G I ~ L
bber bulb

-1

-Rubber pl

- Tube

Fig. 9-1 Relationship between specilTic gravit - - ..-I-SIIUI electrolyte and state of battery 1s as the next chart. I-

of electrc

9-2.

1

1,28C

BATTERY

-

1,25C

Specif

State of batter) -

Fully

(

L IUII

L I I ~ I ~ ~

50% of full charge 25% o f full charge

-

Voltage

Very 1(sw charge

-

lapacity

iischarged Specific gravity

-Polarity Periodical inser Measulrement (of specific gravity

Visual in spection heck cell, cover, filler cap, a and -), for damage, cracks and soils. wasn tne battlery exteriors with water to remove sulphuiric acid and clean off with dry cloth. Pnn4 L u a I:ing - the terminals (t and -) with grease ~1"' prev ent corro:

Use a hyclrometer for checking the q vity of the electrolyte. Place the hydrometer tically into the electrolyte and carefully take fluid into the grass chamber. Remove from terv and shake sliehtlv to loosen float " nd make four readi ng. Y - L

which the battery is neither charging nor discharging. As can be seen in the following graphs, the voltage rises or drops acutely initially when charging or discharging and then gradually levels off. This takes place when the voltage reaches the starting voltage of 2V depending on the concentration of the electrolyte. This means that the condition of battery can not be determined by measuring the voltage in a static condition. It must be measured when the batter.y is being charged or discharged. A simple procedure is t o use an excel tester (4-0-4 Voltmeter). Check each cell, and check again five seconds later. If the voltage - remains over 1.5V and the mutual differences between each of the cells are under 0.1 V, the battery is all right.

2) Inspection of specific gravity and temperature, and electrolyte level. Measure the specific gravity and temperature of electrolyte, and convert the reading to 20°C. The electrolyte should be between 1.200 and 1.280. Do not allow the specific gravity t o drop below 1.220. Check the electrolyte level. If the level is below the LOWER LEVEL line, add distilled water. Be sure to check each cell for correct fluid level. Do not raise the level above the UPPER LEVEL line. The electrolyte may spill out while driving. Do not use sulphuric acid to raise electrolyte level as this will raise the specific gravity of the electrolyte and damage the plates and separators.

i

' 1 ) I

3) I

Voltage measurement Battery voltage should always be about 2V per cell in its static condition, a condition in

Voltage Recovery Curve After Charging

2.5 2.4 2.3 (v) 2.2 2.1 2.0

Voltage Recovery Curve After Discharging

2.2 2.1

0 20

5 15

10 10

15 5

( V ) 2.0 1.9 1.8 1.7

20 0

Time

Fig. 9-2

0 20

5 15

10 15 10 5 Time

2(

Construction a nd funct Construc:tion ;ig. 9-4 shows a sect:ional viev{ o f the starter. onsists of a motor that gene:rates torcrue., a nion unit that engages with the ring gear to pi triansfer rotation when starting up the engine, an~d the magnetic switch that pushes out the pin1'on at starting and starts up or stops the mot or. The motor is a series type whose field coil and armature coil are connected in series, yn"3 tiding large starting tnrnMp

.

'

n

m

T

1The magn~eticswit ch starts and stop1s the star ter by o pening and closing tlle main ccIntacL--..-I+LLUI,it pushes. U-..*U L LLIIC: pinion thluusl~ LIIC b l l l l L lever at starting, holds it in mesh with thie ring gear during starting, and disengages it after starting.

1

'A-

Fig. 9-3 Starter

.. ~.

I

HITACHI L l'D.

Manufacturer -.

Part No.

4299 15400 JWS~M spring

Model Nominal ,voltage and o u t pIt~ Phase and

Pinion

S114-226 12V-0.7 KW 4 p:hases, Se r:ies connection tj!Pe Modu Numk

h: 9

Rotating direction

Couriterclockvvise (whe n viewed from pinic)n side)

Brush length

16 rr

Setting load of brush spring

9 in)

Fig. 9-4 COU~

The pinio n unit is provided with an over. . ,,,ning clutch, the construction of which is shown in Fig. 9-5. Rollers are provided between the pinion collar and the outer part of the clutch which is meshed with the helical spline of the armature shaft. The rollers are under constant pressure from the springs, and the outer clutch grooTve, in which each roller is placed, is tapered. ThuIS,the pinion and outer clutch can race inI one direction. In the opposite direction, rotat ion is . delivered through the clutch engaged by the roll1ers acting a s a key. A

1.6 kg (3.5 lb

Diameter of commutater

33 mm (1.2992 in)

Yoke outer dia.

80 mm (3.150 in)

Overall length kg (1 1.4 1b)

i '

i, I

I

I

When the ring gear has came to turn faster than the piston after starting, the pinion alone races to set the armature free of engine rotation, thereby protecting the armature and other parts.

1

/

!

Outer

In addition, a brake is provided between the rear cover and commutator to rapidly stop the inertia rotation of the motor, making'possible easy repeat of starting operation.

clt~tcll

\

Pinion collar

T9-005

Fig. 9-5 Construction of overruning clutch

Series coil Stationary cont

T9-006

Fig. 9-6 Connection diagram

:

Operation The connection diagram is given in Fig. 9-6 and the operating sequence is as follows.

2)

a. Key switch is turned on. b. An electric current flows through the magnetic switch and shunt coil, so that the plunger is drawn and the pinion pushed out by the shifter lever. c. At the same time, an electric current passes into the.motor through the series coil. d. When the teeth of the pinion run against those of the ring gear, the plunger moves, compressing the sleeve spring. e. Thus, connection between the contactors is made and an electric current flows from the battery directly into the motor to turn the armature, bringing the pinion into mesh with the ring gear. f. The engine starts. g. When the hgine has fully started, the key switch is turned off. h. The magnetic switch loses attraction and the pinion is disengaged from the ring gear by the return spring through the shaft lever; at the same time the connection between the contactors is broken and the motor comes into a stop.

3.

Clearance L should be measured with the pinion pushed forward by the shift lever while exerting finger pressure to eliminate rattle as shown in Fig. 9-8. ClearanceL, if incorrect, will cause a grating noise and greatly affect the life of the pinion and ring gear, causing damage and rapid wear.

Adjustment

ion

Fig. 9-7 Checking clearance L

Slop ring

a. Advanced position of pinion The clearance L of the pinion from the pinion stopper is normal if it is 0.3 to 1.5 mm (0.0118 t o 0.0591 in) when the pinion is pushed by the magnetic switch.

Gear case

-

T9-008

Fig. 9-9 Installing adjusting plates

b. Adjusting gap of magnetic switch plunger When the plunger gap is beyond the specified limit [L= 0.3 mm to 1.5 mm (0.01 18 to 0.0591 in)], adjust it to the specified value by installing adjusting plates (Fig. 9-9) between the magnetic switch and gear case. 1) If the gap is over the specified value, insert adjusting plate(s). 2) If the gap is less than the specified value, remove the adjusting plate(s). Two sizes of adjusting plates are available. [0.4 to 0.8 mm (0.0158 t o ' b.0315 in)]. An adjustment of approximately 0.6 mm (0.0236 in) is possible by using 0.4 mm (0.0158 in) plate and that of approximately 1.3 mm (0.0512 in) by 0.8 mm (0.03 15 in) plate.

1

Switch

1-0.3-1.5mm

Ba

L= 0.3-

1.5 mm (0.0118 - 0.0591 in) T9-007

Fig. 9-8 Wiring for adjusting plunger gap

NOTE: Be sure t o install the adjusting plate with its metal plate facing the gear case.

If the above clearance is out of the specified range, adjust the plunger gap of the magnetic switch in accordance with Item (b) below.

9-6

1

4.

Troubleshooting

I

I

1

a. Pinion will not move even when starter switch is turned on. I

Faulty part

Prob;able cause Broken wires or loose! connection at batt and/or switch termin,als.

Wiring

a. Starter switch

Magnetic switch

II

Cemedy

-

Electric current c ~ u c aI I U L IIUW con tact.

uuc

LU

Repair or tighte:n

laulLy

Repail cur1iar;r point or replace

b. Pinion does not move due to seized threaded part meshing with pinion.

Repair threaded part

Faulty operation of magnetic switch plunger, or broken or short-circuited coil.

Repair or replace

-

b. Pinion meshes with ring gear, but starter does not turn.

Probable cause

Faulty part

Wiring

.emedy

Wiring connecting battery and magnetic switch is broken or grounded. Wires connecting magnetic switch and motor terminals are loose.

Repair, tighten or replace wires

a.

Correc:t gear tee th

Faulty mesh of pinion with ring gear.

-

b. Improper installation.

Re-ins

c. Worn brush or interfering blrush sprir

Replac

d. Contaminated commutator.

Clean

-

Starter

e.

Faulty armature or field coil.

Repair or replace

f.

Faulty contact of field coil with brush.

Repair

a.

Faulty contact of contactor.

Repair

Magnetic switch

I

b. Roughened contact surface of contactor.

Repair or replace

c. Motor rotates at full speed before pinion meshes with ring gear.

Remedy

Faulty part

Probable cause Improper clearance between pinion and pinion stopper due to failure in adjusting plunger gap. (Incorrect gap L in Item 3, "Adjustment")

Adjust

Magnetic switch

Starter

Fatigued pinion sleeve spring.

Replace

d. Pinion meshes and motor turns, but no rotation is delivered to engine.

Faulty part Starter

Probable cause Faulty overrunning clutch.

Remedy Replace

e. Motor will not stop after engine has started even when starter switch is turned off.

.d l t y part

Probable cause

Remedy

Key switch

Electric current cannot be cut off even when switch is turned off.

Repair or replace

Magnetic switch

Contactor in constant contact due to displacement.

Repair or replace

vice dati

tandard Ie:ngth

16 mm (0.629

-

Brush

Wear limit Brush spring

- .5 kg (3.5 Ih)

Standard setting load Standard outer diameter

I

33 mm (1.2992 in)

alameter 2 mm (0.078;7 in)

Wear limit ~

Standard

~nd

Commutator

-

L

I

.

~ r n(0.0156 in) C

Standard

-

Depth of mica

. mm (0.0020 in)

-

(0.01'

nm 15 in)

0.2 mm (0.0079 in) 0.03 - 0.08 mm (0.0012 - 0.003 1 in)

hranaara

Clearanc:e betweer shaft anci journal

Limit Wear linlit of arm;

0.2 mm (0.0079 in)

t diameter

0.1 n

19 in)

0.08 mm (u.uu~-' '

Allowable detlection of armature shaft Shaft diameter

- 0.032

- u.uu 13 . mm (0.492 1 - 0.0020 ln)

Brush side [ole diameter

Standare diametei

1

-

haft diam eter

Pinion slic portion

[ole diame

-

haft diam eter

Pinion sidp

O in)

[ole diame

0.032

mm (0.49:

L - 0.050

o.oso mm (0.492 12" + 0.030 - 0.032 12S - 0.050

+ 0.0010.

pact, lightweight and simp1 .- - - -- - --.

The alternator assembly is a rotating:-field type, three-phase alternator using lorlg-life silicon diodes to rectify the generated cu rrent. ". . . It is designed to withstand many hours 01 spee:d operat ion and provides the follc feat ures.

Featur 1) It offers exceptional low speed cha.nging perf 'ormance, being capable of charginlg, the batt:ery even at idling speed. -. Rectification uses silicon aifia-c thus diding outstanding high speeld perforrrlance.

Jig.9-10 External uliew of alt nator assembly

U'UUVU,

Itor specifications

I

Rotating field three phase type

12v

Batter y voltage Nominal ourpui

17V-15A/4,000 rnm

I

ty on groi~ n dside

Negative

Rotati,ng directi on (when observed from I3ulley side: rel="nofollow">

Clockwist

:ure conne Full-wave rectification by six selfcontained silicon diodes

Rectif ying syste

to 4,000

Usable: speed Revolution speed at 14V 20°C (68'F)

I

Revolution

I

Current

I

Ou tpu.t current

j9 in)

Pulley outer diameter

I

Pulley ratio

I

Total

5 kg (7.9 I

Weigh 9 - 10

nstructicIn and fu

1 2 3 4

Nl

SP Pu Fa., 5 Spacer collar 6 Drive end f r ame ~ COMPL 7 Oil felt r?ver I (Oil f;- I . \ 111bearing

10 11 12 13 14 IS 16 L7

Retainc:r plate Spacer (Armature: R o t o r (SOMPL Ball be;....,or,"" Through bolt Stator COMPL Rectifier end-frame COMPL Bushing (Insulatio -, :(Insulatio

Fig. 9-1 I ~ x b l o d e dview of ai

-

Brush holdc:r COMPL Rear cover Rectifier en~dframe Bushing Rectifier en~dholder Cc Washer (Insulation) Washer (Insulation) Brush sprinl Brush

The generator assembly consists of a rotor assembly, stator assembly, front cover (alternator), and rear cover assembly. The rear cover assembly is self-ventilated and equipped with silicon diodes to rectify the alternating current generated in the stator coil. a. Magnetized part . . . Rotor Unit generating alternating- L U I I G I I L . . . J L ~ tor Unit rec tifying a1lternating current . . . Silicon aioaes d. Rotating part . . . Rotor e. Part transferring rotation . . . Pulley f. Part allowing field currentt f l ~ ~ .x .r . Brush and slip I Part prc nd delivering cool ing air . . . Fan h. Rotor shaft bearing . . . Front cover, rear cover i. Unit allowing generated current to run out side . . . Lead term inals

"

-

1.

3

,,,L

When a cc placed in a magnetic field the magnetic tield, an electric current vs through the conductor. This princi:ple of eration is the same as tllat of a D.C. erator. The alternator, ~ O...*..-.. W C ; V.. ~ ~s eL s,a rotating field (the magnetic poles rotate) and an alternating current is produced in the stator coil. This alternating current is rectified by the silic:on diode and led outside. I7ig. 9-12 shows the principle of the alternator. The conductors C, C' wound around the stat or are stationary. When the magnetic N and S poles (Rotor) rotate in the direction of arrc)w, an electric current flows through conauctors in the direction of arrow and runs into the battery tl?rough thc:diode "I lts

_

3~

~

Fig. 9-13 3-phase full wave rectification

,

Alternator operating principle When the N, S pole turns half a turn to a position opposite to the previous position, the electric current tries to flow in the reverse direction (direction of dotted arrow), which is prevented by the diode, i.e., rectification is performed then and there. The alternator is a three-phase type and uses six silicon diodes for full wave rectification, so that a direct current woxre form illustrated by the bold line in Fig. 3 is obtained.

Silicon diode silicon (liode allows an electric current to flovv in one clirection but stops it from flowing . . ... , in tne opposite direction. This is known as a rect.ifying cha~racteristic. 11

Fig. 9-1 1

tor operai'ing princi

,

i

i

, ,

1

1

I 1

I

the PN junction anu preventing me I low of electric current. Precuations in handling Current flows

(a) When P is positive Type

P

Type N

-o--

(b) When P is negative

T9-0.12

Fig. 9-14 Operation of silicon diode Utilizing this characteristic, silicon diodes are used for rectifying alternating current and as a cut-out relays in D.C. generators. In a silicon diode, a positive type semi-conductor I with positive holes carrying a positive charge (plus electricity) and a negative type semi-conductor with negative charge electrons (minus electricity) are combined. This is called PN junction. I When the P side is positively charged and the I N side is negatively charged as illustrated in (a) of Fig. 9-14, the positive holes and electrons flow in the direction of arrow and accumulate at the junction of the P type semi-conductor and N type semi-conductor, making it easy for electric current to fl~ DW. When the P side: is chargt:d negati~ rely and -- nl :(b). , ,, the positive the N side positively, as holes are drawn toward the minus and the ' electrons toward the plus. As a result, the positive holes and electrons tend to leave from he junctic In, therby increasin g the resis 1

-I

I

1..

The alternator uses silicon diodes and extra attention must be given to the following points. 1) Pay attention to the polarity of the battery and never connect rleversely, or the diodes and battery will be short-cirruited, resulting in damaged silicon diodes and a burned wire harness (as a result of excess current flow). The polarity of the silicon diodes in alternator for a positively grounded vehicle d a negatively grounded vehicle is completely jposite. An alternator with a nameplate of (+) ust be used on a positively grounded vehicle aud one with a (-) nameplate on a negatively grounded vehicle. 2) Exercise care to connect each tc correctly. 3) When testing or adjusting an alternator, connect a condenser (0.2 to 0.5 pF betwc:en the generator output terminal (terminal A or B) and the ground wire. If a condenser is hot connected, the diode may be damaged by a spark produced by the testing device or an proper connection. Do not turn the alternator at high speed th its output terminal (terminal A or B) ulsconnected. The silicon diodes could be broken by the high voltage produced. 5) When charging the battery from outside, be sure to disconnect the output terminal (terminal A or B). 6 ) A high tension tester such as a megger must not be used in an examination between thle terminals and/or a conduction test of the dicsdes. Use of a megger will impair the diodes. A1ways use an ordinary tester.

5.

Troubleshooting

T--uble and Possible Causes a

-5

I) Defective contact or broken

Lamp

-

23 'g 0 g, 8

sv-

s v

Repair or replace lamp

filament in lamp

Wiring and fuse

1) Broken wire, short circuit, or defective contact

Inspect, and repair or replace

Regulato

I) Defective voltage relay

Repair or replace

1) Loosened belt

Adjust

I)

Replace

'

-

Broken, grounded, or short-Icircuited stator coil wire

!) Broke n wire in rotor coil

Replace

3) Defec tive bru!sh and slip ring con tac:t

Replace or clean

4) Defective terminal insulai

Repair

5) Defective silicon diode

Replace

6) Short-circuited condenser

Replace

I)

Adjust or replace

L

Alternator

*;

Corrective Action

0

%

+ 0

c V)

8

a a

-5

M

-

.-d

S

s

Q)

F m

nagulaLo1

C 0

Defective charge relay point

!) Broken wire or defective contact r. r P F and N terminal

Inspect, and repair or replace

1) Impro per core gap of voltage

Adjust

I

re0111n .-o---tor

-

I) Broken wire or defective connec-

Wiring and fuse

-

Inspect

tion between key switch iand IG terminal 2) Blown fuse or defective contact

-

Replace

Trouble and Possible Causes V-blet

Alternator

-

2

1) Loosened belt

Adjust

1) Layer short in rotor coi-

Replace

2) Layer short or broken vvire in statc- --:'

Replace

3) Defe:ctive brus;h and s l iI ~ring . .. (contact)

Replace or clea

4) Defe:ctive silicon diode

Replace

5) Defective condenser

Replace

1) No-load voltage is lower of the rated value

0)

c) .c)

m

s

Corrective Action

rrlarl ~ n a t

-

Adjust

-

L

0

.-2

Regulator

EJ

2

-

2) Defective voltage regulator points ma1 short circuit of coil or resistor

vl

S

-

Adjust or repla Replace

k 0)

6

1) Insufficient electrolyte

Replenish with distilled water

2) Defective pole plate

Replace

1) Broken wire or defective connection between key switch and IG terminal

Inspect and repair

2) Broken wire or defective connection between regulator F terminal and alternator F termianl

Inspect and repair

3) Blown fuse or defective contact

Replace

Battery

-,

Wiring and fuse

1) unusual no-load

eo

c

3

2) Defective regulator ground wire

-s LC

0

2

+ c . '

2

voltam

Regulator

3) Broken coil lead wire

Repair or replace

4) Defective voltage regulator points

Adjust or replace

5) Charge is not

Adjust

wble and Possible (

Action

1) Place from whf:re the insulated cover has wirin g sometinies short -.- -... - - - L a :-"..I - & : - -

Wiring

,: A -

CI~CUI

-A

r or replac

:.-

cover I)

lnitlal symptom

2) Detel sprin~

r

01 layer shnrt

Replac

broken t

Replac

or 3) Dirty slip ring

Clean

4) Initial symptom of coil wire broken

Repair or replac

1) Improper regulating voltage

Readjust

2) Defective key switch

Redplace

I

3) Dirty points

9-5.

VOLTAGE REGULATOR [for alternator)

Clean

The regulator is a 2-pole Tirril type which has a built-in charge relay. This is useful only as a voltage regulator to regulate the output voltage of the A.C. generator.

.

Spec

Regulating voltagc v u11itgt:

voltage Fig. 9-15 Exte ma1 view

-

relay cut-

Operating principle of voltage regulator

Fig. 9-1 6 Voltage regulator I

2.

Construct~onana operation

1)

Voltage reguk~ t o r The Tirril type: voltage regulator regulates the electric current of the rotor coil and maintains the voltage produced by the generator constant. It uses a charging resistor connected in series to the rotor coil which is short-circuited and charged by opening and closing the point. Its construction is shown in Fig. 9-17

Arn~afure gap

Angle ga I

Poi111(H side)

Poinl g i

d

When the voltage of the generator is at the specified level, the charging resistor connected in series to the rotor coil (inside the generator) is short-circuited and the exciting current flows from the lower point through the moving point. If the voltage increases higher than th~specifiedvalue, an electric current runs through the voltage coil of the voltage regulator in proportion to the generated voltage, so that the magnet increases in attraction and draws the armature against the force of the spring. As a result, because the moving point parts from the lower point and the exciting current passes through the charging resistor, the current flowing in the rotor coil decreases and hence the generator voltage drops. When the voltage of the generator drops below the specified value, the current passing through the voltage coil decreases and the magnet lowers in attraction, so that the moving and lower points are losed to short-circuit the charging resistor, enabling more current to flow in the rotor coil and increasing the voltage of the generator. When the generator runs at low speeds and under heavy loads, the voltage regulator repeats the above operation to keep the voltage constant. Should the rotational frequency of the generator increase, the voltage of the generator rises since the resistance of the charging resistor is small. This causes more current to flow through the voltage coil and the moving and upper points to be closed by the strongly drawn ~rmature.Thus, the rotor coil is short-circuited o stop the exciting current from flowing, Iropping the voltage. When the voltage drops, the attraction of the roltage coil becomes small and the point is )pened to permit the exciting current to flow, ncreasing the voltage of the generator. When he generator turns at high speeds and under ight loads, the voltage regulator repeats this )peration to hold the voltage constant.

I

Fuse

Charg

Key switch

f

Moving . .

7 ! Rattnrv

Charge re1

--

'oltage regulator

Fig. 9-18 Connection diagram of k e r r c r u r v r 2:) -. Charg . e relay

l h e charge relay turns the cnarge warning lamp in instrument panel on and off to let the driver know if the generator is charging or not. It also opens the voltage coil circuit of the voltage regulator when the engine is stopped with the key inserted in the switch, thereby preventing the flow of a discharge current from tlle battery

!I arrn

Fig. 9-

urru

-

GI",

peration c~fcharge r elay In the Izonnectio n diagram, with the key ritch turnled ori, tkie charge warning lamp is rned on t)y the electric current flowing from the positive terminal of the battery to the lamps, terminal L, charge relay point, terminal E, and ground in that order. Further, the electric current runs also to the ground through the terminal IG, voltage regulator point, terminal F, and rotor coil in that order. As the generator is driven by the engine and when an output voltage reaches the specified voltage, the charge relay point is opened to break the charge lamp circuit and the charge arning lamp is turned off. That is to say, when e charge warning is off it is an indication that e generator is producing a voltage exceeding e specifie~d voltage, and is charging the batry. The poi1~t on the regulator voltage coil side closed simu1taneous:y as the moving point rts from the point on the charge warning mp side of the charge relay, and the voltage regulator voltage coil is actuated by the current flc n terminal B to gro und.

iring spec

,Case

A voltage regulator functions properly only when it is used together with a generator. A generator of one make should not be used with a voltage regulator of a another. Always use those of the same make. Should abnormal charging occur, do not conclude immediatl the generator or regulator is out of a ck the wirings and connections of the b first. If they are in good condition, measure the no-load voltage of the generator. When the measured value is in the specified voltage, the generator and regulator may be regarded as normal. (To measure the no-load voltage, disconnect the regulator terminals, run the generator at the specified speed. and check the voltage " between terminal tor and ground.) The regularor must pe aajusrea 11 irs no-loaa voltage is out of the specified range. Adjustment of the regulator requires knowledge and experience, and it is recommended that the job be given to an expe,rt or to a service station of the manufacturer. IJnder nor ma1 working condition, the regulator should pr ovide trouble-free operation for about 50,000 to 60,000 km (31,000 to 37,000 miles) without adjustment.

b, "LE p ~ o n t a c breaker t

-.-

-

-

o

kGovernor

Fig. 9-21 Components of brea~erassemblv

1) The breaker assembly employs a simultaneous ignition system which is compact and lightweight as compared to a conventional stributor. 1 The combined use of a gc Jvancer td vacuum advancer insures ( ignition ning fron1 low spee:d to high speed, in(:reasine ~ t p u and t reducing Iharmful e:~ h a u s gas t

,

ONTACT POINT

(Breaker)

Spec

-

.L .#,-

-

Ignition system

aimulraneouns ~ ~ ~ I L I U I I

! + 0.05 mm

Point gal?

--

8,

tv.vt

- 0.002"

;n\

Lifter pr

-

Firing antgle Cam closing angle

Fig. 9-20 'External view of breaker assembly

102' + 3" [at Point gap 0.35 mr

Capacity of condenser

I

Advancing characteristics of governor and vacuum

2.

12°/200

14 -

--X:

\

1 -u-

12 -------------------------

m

10-

0

0)

m

al

F "

U

5

8-

1a

s

10-

a l C

-

J

B

42

17.5°/5,500

20 -

-

-

I I I

I I

,

50

100 150 200 (I -97) (3.94) (5.91 (7.87) Vacuum rnrnHg (inHg)

1.000

2,000

3,000

4,000

I

5,000

,

6,000

Engine speed (rprn)

T9-01 6

Fig. 9-22.Advancing characteristics

3.

4.

Removal

1) Disconnect the primary cord 2) Pull the breaker vacuum hose out from the vacuum advancer side. 3) Loosen two bolts (6 x 13) and remove the cover (Breaker case) and the gasket (Breaker case). 4) Loosen the bolt holding the governor assembly. 6x13 5)

Bolt

lpc.

Disassembly

1) Loosen nut on the terminal and remove cords for contact breaker unit and condenser. 2) Remove the contact breaker unit by loosening the screws. 3) Remove the clip and screw (pan head), and detach the vacuum advancer unit.

5 x 8 screw : 1 Loosen the screw (pan head) and remove the contact breaker unit. 4)

Remove the case (Breaker) 6 x 22

Bolt

6 x 60

Bolt

NOTE: Remove the O-ring carefully so as not to damage it.

-

,I

NOTE: Also remove spark advancer unit. 5) the 6) 7)

I

Remove a screw (pan head), and remove ; condenser unit. 1 Remove the oil seal (22 x 35 x 6). Remove the O-ring (47 x 3.5).

. 1) Check the cc3ntact br,eaker unlit point surface for wear or damage. IZepair or Ireplace it if found defective.

NOTE: When Irepairing the point surface, polish it with arI oilstone or a point dresser until the cave-in ... on the surface is completely removed. Clean it I~eforeins1tallation. 2) Check heel o f contact breaker arm for wear, and replace if worn. 3) Inspect the contact bre: tker arm spring for proper function by moving it manually .--..-I& 4) Check the spark advance1 U I U L sprmg lor cracks or damage, and replace if necessary. 5) Check the vacuum advancer unit for function and the diaphragm for damage. Replace if necessary.

lnstallation

To install the contact point breaker, follow the reverse order of removal. The ignition timing is put out of order once the case (Breaker) and contact breaker unit are removed. Be sure to adjust ignition timing and ~ o i ngap t after installation.

OTE: For adjusting proceaure, refer to the "Chapter 3".

9-7.

1c .--;NITION

COIL Vith resister)

NOTE: Place mouth over the hose connection and suck to see if the vacuum advancer is operating properly by the movement of the contact breaker.

'

I

6) Check the O-ring for damage and replace if necessary. 7) Checlk the oil seal lips (22 x 32 x 6 ) for -- ue~erioration. ?I-' wear, damare or Replace if necessary. --a

I

pnition coil COMPL

1) Press.-fit the oi1 seal (22 6) into the case (Breaker) with a suitablc er or press. 2) Insert the spark advan~ cer unit :in place, and then install the breakel assembl:y in the case (Breaker). 3) Put the vacuum advancer l l n l r in and tighten with the clip and screw. 4) Temporarily tighten the contact breaker t the 0-rir~gin the c:ase (Breal

1

NOTE: After i twisted

n check the 0-ring is not Fig. 9-24 Resistor (

Speciification!5 of ignition coil (with re!sister)

Battery voltage

I

Sparkil~g perforn ante (I~ n g t h of spark measurea at negative side when positive side gap between 3 needler

oil remnerature

Spark ga: P between 3 needle S

remperature

(0.2756 in)

80°C (1760~)

( ~ 2 3i 6n)~

80QC (176OF)

I

No-load

1.5

:d resister . . Standard resistar valve for

2.

7 Resister

Short. ..

81

12\

15\

)O rpm

+ 0.15R

I

;econdary coil

Connection diagram of ignition coil

i

.--.

Key switcli /

High t e I

\

ST

Battery 2

c s--.

/

If

t

Con tact Brakc

o n coil

Fig. 9-25 Connectic 9

ser

- 22

with 1.5

3.

Consrrucr~c of ignition

1)

Ignitioncoil

perat ion

1

Co~itact Point can1

A ker

'

1

Primary

c

coil

1

G Batter -

'T i

Fig. 9-26 Lonnectron diugram 03 ignition coil

1 1

,r\

1 j

/

1

I

1

i

1

-I

The ignition cc)il consist s of an iron core, a , primary coil of 30u turns of a 0.32 mm enamel wire, and a secondary coil with approximately 22,000 winds of a 0.06 mm enamel wire with thin, superior insulation paper provided between each layer. When the camshaft and crankshaft arc rotated with the ignition coil connected a1 shown irI Fig. 9 -2 16 ,"a high voltage is produced in the secondary coil thrc)ugh the following process. a. When the contact breaker points are shortcircuited, the primary current flows as indicated by an arrow and produces magnetic flux (flux of 1i1nes of ma gnetic for,ce) in the iron core. b. Next, when the points are open1ed by the .. IIUX n cam, the magnetic proauced by the primary current rapidly starts tc drop to zero. c. The great change in the magnetic flux and the 1;irge number of urinds cause a high voltage in secon.dary coil. ",...,...,. charges the sed. The fugh voltaarj 5r;llr;lated conda ry coil first, which starts charging thc high 1tension cords and plug as its voltage increa ses and gradually continues to built UP. e. When the volta] .lue where : it can jump Lne plug gap, 11.sLarLs ulscnarging and a.t the same time thle discharge voltage le electri.c current sudde nly drop:

j

) I

i I

:

-,.

*I..

:--l..~.-:...

chargea m ltenn (d) abc)ve is completely ... discharged (capacltlve spark) and then the discharge of the energy stored in the coil in the form of magnetic flux (induced spark) follows. F. The magnetic flux drops close to zero where it cannot maintain the voltages required for sparking, and hence the discharge spark disappears. g. The slight residual energy in the coil produces damped oscillation in the secondary and primary coils and dies out as a resistance loss of the circuit. h. Then, after an open-circuit period determined by the open-circuit angle of the cam, the ignition coil repeats the entire process. 2) A large current flows t o the starter when starting up the engine. This drops the voltage at the ignition coil terminals and causes starting failure due to the dropped discharge voltage and a weak spark. For this reason, a drop in the discharge voltage is supplemented by reducing the internal resistance of the ignition coil and, to prevent the coil from burning at times other 5 the en! than whe installed.

4.

E1.r~ ot

lgnltlon sys

:arting

541 Starter switch

I Starter

nition coi

I

I Contact bieak tension c

1 Plug

2)

At times other than when starting

a Ignition switch ON

6.

Check for the following items using a precise tester, and replace coil if necessary. 1) Conductivity of primary coil

0

Standard resistance of primary coil: 1.98 t o 2.42S-2

Resistor

-Q Ignition coil

2)

act breake

I

NOTE: An extremely low resistance is an indication of a short-circuit.

7.

5.

Removal o f ignition coil

1) Remove the high tension cord cap. 2) Remove two 5 mm nuts on the ignition coil and disconnect the primary coil terminals. 3) Remove 6 mm flange nut at the bracket and remove the ignition coil.

Conductivity of secondary coil: Standard resistance of secondary coil: 13.6 t o 18.4 kCl

L

I High

Inspection

Installation

To install the ignition coil, follow the reverse order of removal.

NOTE: Connect the breaker condenser to the negative (-) side of the primary terminals.

.-

CHAPTER

10: CLUTCH

Page '0.1 '0.2

'0.3

. . .

DESCRIPTION

................................................................................10-2

.......................... 10-3 TROUBLESHOOTING ................................................................. 10-7 CLUTCH DISASSEMBLY AND REASSEMBLY

10-1.

1.

The clutch control mechanism is a mechanical type of simple construction as shown in figure. The clutch cover is an overcover type strap drive system. The spring is a diaphragm type which has an excellent characteristics such as less change of installed spring setting load against the wear of the clutch disc and can be operated with light pedal pressure. Woven asbestos is used for the facing material of the clutch disc. The clutch disc is provided with torsion springs (coil springs) t o absorb rotational shock at clutch engagement.

DESCRIPTION Construction

1 Clutch 2 Clutch 3 Clutch 4 Clutch 5 Clutch 6 Clutch

disc cover

release bearing release fork cable pedal

T10-001

Fig. 10-1 Clutch system

2.

Specifications

Cover

Item

Value

Outer diameter of cover

206 mm (8.1 102 in)

Outer diameter of pressure plate

163 mm (6.4173 in)

Inner diameter of pressure plate

107 mm (4.2126 in)

Setting load of diaphragm spring

120 5 10 kg (264.55 5 22 lb)

Fitted height installing surface of flywheel)

24.1 + 0.8 mm (0.9488 + 0.03 15 in)

Facing material

Woven asbestos 2

Number of facing Dimensions (Out. dia. x Inn. dia. x Thickness) Disc

Compressed thickness Free thickness

160x l l O x 3 m m (6.2992 x 4.3307 x 0.1 181 in)

+ 0.2 mm (0.2795 + 0.0079 in) 7.9 + 0.2 mm (0.3 110 + 0.0079 in) 7.1

Number of torsion spring

6

Number of spline hub teeth

23

10-2.

CLUTCH DISASSEMBLY AND REASSEMBLY

T10-002

I

I

1 2 3 4 5

Clutch disc Clutch cover Bolt(6x18x18) Clutch release bearing Release bearing holder

Release bearing holder spring Clutch release fork 8 Straight pin (5 x 22) 9 "0" ring (10.8 x 1.9) 10 Clutch release lever

I 1

Fig. 10-2 Exploded view of clutch

1.

d. Replace the O-ring on the clutch release lever if worn or damaged. 3) Installation a. Apply grease (equivalent to Unilube NO. 2 ) to groove of the clutch release lever COMPL at the point indicated by arrows in Fig. 10-3, and install it to the transmission case with the pin hole aligned to that of the clutch release fork. Then drive in the straight pin (5 x 22) with its split end facing the contact surface of transmission case.

Clutch lever

Fig. 10-3 Clutch lever components

1) Removal a. Remove the transmission. (Refer to Chapter 11.) b. Remove the release bearing holder :springs

0. c. Remove the clutch release bearing @ and release bearing holder @ together. d. Using a special tool "Remover I1 (straight pin)", drive out straight pin (5 x 22) @ until the clutch ielease lever compl. @ can be pulled out.

Special tool

Fig. 10-4 Driving in straight pin

b. Apply grease (equivalent to Unilube No. 2) t o groove of the clutch release bearing holder at the point indicated by an arrow in Fig. 10-3,and put it on the transmission case guide along with the clutch release bearing. Join the pawl of release fork and release bearing holder with the release bearing holder springs.

39879 1600 (Remover 11)

,

Remove the clutch release fork compl. @ .

8and lever

Inspection If the bearing is damaged, seized, or unsmooth in rotation, replace the clutch release bearing. Replace any release bearing holder or clutch release bearing whose contact surfaces are unusually worn. Repair if the internal surface of release bearing holder and clutch release lever shaft are seized. Replace them if seizure is excessive. (Also check condition of the transmission case guide.)

Fig. 10-5 InstalUng holder spring

I0 - 4

2.

C l u t c h cover and disc

1) Removal a. Remove the transmission. (Refer to Chapter 11.) b. Insert a special tool "Clutch disc guide" in the clutch disc compl. (Fig. 10-6)

NOTE: Apply a light coat of oil or grease on 14 mm

dia. shaft, the end of clutch disc.guide.

Special tool

Clutch disc compl. a. Measure the sinkage of rivets with slide calipers. And replace the clutch disc if the facing is worn beyond the limit. Sinkage limit

0.3 mm (0.01 18 in)

b. Rep1 lutch disc if the torsion springs are broken or fatigued, or if the spline hub rivets are loose.

499745400 Guide (Clutch disc)

c. Uniformly loosen bolts (6 mm) attaching the clutch cover compl. by slow degrees, and remove the clutch cover and clutch disc compl.

Clutch

I

NOTE:

Be careful not to let the disc facing get soaked with grease or oil.

Fig. 10-7 Inspecting clutch

.&."

Guide (

Fig. 10-6 Removing clutch

Inspection and adjustment Clutch cover compl. a- Replace the clutch cover if the pawls of the diaphragm spring are excessively worn. 5. Replace the clutch cover if it makes any abnormal sound when shaken up and down, or if its riveted parts are in any way unusual. c. Replace it if the contact surface of pressure piate is worn. aarped. or dama~ed. 2)

Fig. 10-8 Measusing facing sinkage

c. Check disc plate for runout whenever the old disc or a new one is installed. d. If runout exceeds 0.5 mm (0.020 in) at the outer circumference of facing [R = 75 mm (2.95 in) from the hub center], replace or repair disc. See Fignre 10-9. e. Put a special tool "Clutch disc guide" in the clutch disc compl. and install to the flywheel.

Tighten it with six bolts (6x1 8x18 mm). Special tool

499745400 Guide (Clutch disc) ~i~htenin~'torque

1.0

+ 0.075 kg-rr

Fig. 10-9 Measuring runout

3)

Installation Install the clutch cover compl. to the flywheel by aligning two knock pin holes (clutch cover) with knock pins (flywheel).

Fig. 10-10 Knock pin holes

10-3.

TROUBLESHOOTING Condition and probable cause

Remedy

1) Slippage Though clutch slippage is difficult t o pinpoint at first, any of the following phenomena could be an indication of clutch slippage. 1. Fuel consumption increases. 2. Engine overheats. 3. Engine will not deliver full power, particularly at rapid acceleration. Vehicle cannot be accelerated in proportion t o engine speed. 4. Vehicle lacks power on an upgrade and facing gives off a burning smell. Clutch is obviously slipping when numbers 3 and 4 above occur. Remember that initial symptoms such as numbers 1 and 2 above may also be taken as engine trouble. Do not leave a slipping clutch as it is, or the disc facing will wear excessively or burn. Testing method - Fully engage parking brake, disengage clutch, and put'transmission in first gear. Gradually engage clutch as engine speed is slowly increased. If engine stalls in this test, clutch is in good condition. When vehicle does not move forward or when engine does not stall, clutch is slipping.

I

1. No clutch pedal play.

Adjust.

1

2.

No play at release fork tips.

Adjust.

I 1 I

3.

Oil-soaked clutch facing.

Replace.

I

4. Worn clutch facing.

Replace.

5. Distorted pressure plate or flywheel.

Repair or replace.

2) Improper disengagement This phenomenon is characterized by an uncomfortable grating noise while shifting gears or extreme difficulty in operation, especially frequent in shifting t o or from first gear. However, this noise often results from malconditioned synchromesh itself. Check clutch by the following test. Testing method - Release clutch and shift to reverse position. Then return t o neutral and gradually shift to reverse position while increasing engine speed by slowly depressing accelerator pedal. (Hold clutch pedal down during testing.) Clutch is considered t o be improperly disengaged if abnormal noise is heard during the test. 1.

Excessive play of clutch pedal.

Adjust.

2.

Excessive play of clutch release fork.

Adjust.

3.

Reduced stroke of clutch release fork tips.

Adjust.

4.

Rusted splines of clutch disc and main shaft.

Remove rust and grease, or replace.

5. Excessive runout df clutch disc.

Repair or replace.

6.

Repair or replace.

Defective part(s) in control, or improper installation.

!

Condition and probable cause

Remedy

3) Judder The entire body vibrates uncomfortably when vehicle starts in half-clutch condition. 1. Hardened facing.

Repair surface with emery cloth or replace.

2.

Oil-soaked facing.

Replace.

3.

Broken or fatigued torsion springs.

Replace disc compl.

4.

Improper contact of facing, or excessive runout of disc.

Replace disc compl.

5.

Distorted pressure plate or flywheel.

Repair or replace.

6. Loose disc rivets.

Replace.

7. Loose engine mounting or fatigued mounting rubber.

Tighten, or replace mounting rubber.

4) Noise or abnormal sound Examine whether the noise is generated when clutch is disengaged (l,2) or engaged (3,4,5). 1. Broken or worn release bearing, or insufficient lubrication.

Replace.

2. Eccentric clutch cover and bearing.

Repair or replace.

3.

Loosened clutch disc hub.

Replace disc compl.

4.

Cracked torsion spring retainer.

Replace disc compl.

5.

Fatigued or broken torsion springs.

Replace disc compl.

5) Rabbit-jump Clutch engages suddenly in half-clutched state when starting. Vehicle will not accelerate smoothly, but moves forward jerkily. 1. Oil- or grease-soaked facing.

Replace.

2.

Replace.

Worn facing or loose rivets.

3. Worn or rusted splines of clutch disc hub and main shaft. 4.

Fatigued or broken torsion springs.

5. Distorted or partially worn flywheel and pressure plate.

Replace, or remove rust and grease. Replace. Repair or replace.

CHAPTER

1 1 : T R A N S M I SSl ON A N D Dl FFERENTIAL

Page

........................................................... 11 2 SPECIFICATIONS .......................................................................... 11 - 2 COMPONENT PARTS OF TRANSMISSION ............................... 11 - 3 GENERAL DESCRIPTION

DISASSEMBLY INSPECTION ASSEMBLY

--

..............................................................................11 - 6

.................................................................................. 11 -1 1

.....................................................................................11 -13

INSTALLATION

............................................................................

TROUBLESHOOTING

11 -21

..................................................................11 -22

11-1.

GENERAL DESCRIPTION

rig, 11-1 Transmission

Fig. 11-2 Gear train

The transmission provides 4 forward and 1 reverse speeds; forward gears are of the inertia lock type with full synchromesh. Gear shift lever is a floor shift type. In addition to the former oil bath type lubrication system, an oil passage is provided in the main shaft to directly lubricate the bearings. This dual lubrication system improves lubrication performance. The differential is housed with the transmission in a 2-section case separable top and bottom, which is lubricated with common oil.

11-2.

SPEC1FICATIONS Mode I 1st 2n d

Gear ratio

I

3 rd 4th Reverse Final reduction gear ratio Differential Number of side gear teeth gear Number of pinion gear teeth Oil quantity

T23B 4.363 (4811 1) 2.62 5 (42116) 1.809 (3812 1) 1 . l o 7 (31128) 4.272 (4711 1) 5.733 (86115) 18 13 0.9 L (0.95 U.S. qt., 0.80 Imp. qt.)

, I

I

11-3.

COMPONENT PARTS OF TRANSMlSSlON Component parts of transmission case

1. 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Bolt and washer assy Transmission cover Gasket Air breather pipe Plug (8 x 10.5) Shifter fork rail spring Ball (6.350) Air breather nipple Accent plunger spring Selector plunger Shifter arm shaft Shifter arm Spring pin Selector arm Gear selector arm shaft Oil level gauge

18 19 20 21 22 23 24 26 27 28 29 30 31 *32 33 34 *35 36

O-ring (14.3 x 2.4) Transmission case Oil seal ( I 5 x 25 x 5) Stud (10 x 38 x 15) Washer Bolt (8 x 45 x 20) Bolt (8 x 95 x 20) Bolt and washer Bolt (8 x 65 x 20) Stud (8 x 36 x 12) Gasket (20.5 x 26 x 1.5) Oil drain plug complete Transmission case cap 3 Washer (39 x 49.5 x t) Transmission case cap Plug (13 x 5) Washer (39 x 53.2 x t) Straight pin (4 x 22)

*39 40 *41 42

Reverse shifter lever Shifter arm 2 Shifter fork Shifter fork rail

43 44 45 46 47 48 49

Shifter fork rail 2 Shifter fork rail 3 Ball (5.5563) Shifter rail plunger Bolt and washer assy Shifter rail plate Shifter rail plate

38

51 Gasket 53 54 55 56 57

Back-up light switch Clutch cable clamp Aluminum gasket Plug (14 x 9) Plug (clutch housing timing hole) 58 Accent plunger spring 2 59 Shifter fork spring * Selective parts

T I 1-001

Fig. I 1-3 Transmission case components 11 -3

2.

Transmission gear component parts

I

*1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Snap ring outer (20) Ball bearing (#6204NR) Washer (20.2 x 29 x 0.2) Ball bearing (#6204) Drive pinion spacer First driven gear Synchronizer ring Reverse driven gear Synchronizer hub spring Synchronizer hub insert Synchronizer hub Gear thrust spacer key Gear thrust spacer Second driven gear Gear thrust spacer I1

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

*

Thud driven gear Synchronizer sleeve 4thdrivengear Needle bearing (34 x 50 x 20) Race (needle bearing) Drive pinion Ball bearing (#6303C3) Washer (17.2 x 26 x 0.2) Transmission main shaft Ball bearing (#6004) Washer (31 x 40.8 x 0.5) Oil seal (19.8 x 35 x 7) Reverse idler gear shaft Straight pin (6 x 15) Reverse idler gear

Selective part

Fig. 11-4 Exploded view of transmission 11 -4

Tll-002

Differential gear component parts

I 1 2 3 *4 5 6 7

*8 9 10 11 12 13 14

Oil seal (27 x 45 x 9) Oil seal retainer Ball bearing (#6007) Washer (27.1 x 42 x t) Differential side gear Differential pinion Oil seal (27 x 62 x 9)

*

Washer (53 x 65.5 x t) Differential case Differential pinion shaft Straight pin (4 x 35) Final gear Final gear lock washer Bolt (10 x 21 x 13)

Selective parts Tl l -003

Fig. 11-5 Exploded view of differential 11 - 5

11-4.

DISASSEMBLY

1)

Removal Refer to the Chapter 4 when removing the transmission together with the engine. Also refer to the above Chapter when removing the transmission only, and follow the instructions described below.

Clutch lever Refer to the paragraph "Clutch lever" fcr removal. 2) Transmission case Pull out the oil gauge near the differenti21 chamber of the upper case. Place the transrnirsion case upside down, unscrew twenty fixin: bolts and disassemble the case into two settions. The twenty fixing bolts to be loosene? are 8 mm 18 pcs. and 6 mm 2 pcs. 8 mm Bolt: L = 4 5 mm(1.77 in) : 13 L = 65 mm (2.56 in) : 3 L = 95 mm (3.74 in) : 2 6 mm Bolt: L = 32 mm (1.26 in) : 2

Fig. 11-6 Remo ving transmission

Support the transmission with a jack. Remove the rear mounting bracket on the transmission side, loosen four bolts (10 mm) securing the transmission to the engine, and remove the transmission. Take care not to support or hold the clutch release shaft during removal and installation.

2.

Disassembly

Wipe the transmission clean of grease and dirt, loosen drain plug (20 x 10) and drain oil. Remove metal powder etc. attracted on magnet of the drain plug. Retighten the plug after oil is drained.

Tightening torque

3.5 t 0.4 kg-m (25.3 2.9 ft-lb)

+

Fig. 11-7 Disassembling transmission case

NOTE: When removing the lower case, be careful not to lose the straight pin @ on the reverse idler shaft @.

'

I

3) Main shaft, drive pinion and differential assemblies

Fig.11-10 Components of main shaft assembly

Tig. I 1-8 Disassembling transmission

Remove the washer and caps, and take out the main shaft assembly, drive pinion assembly, and differential assembly from the transmission case.

b. Remove the ball bearing @ (#6004) and two ball bearings @ (86303C3) with a washer (17.2 x 26 x 0.2) @ using a puller or press. 5) Drive pinion assembly a. Remove the snap ring with a special tool "Expander" and remove ball bearing (#6204 NR), washer (20.2 x 29 x 0.2), ball bearing (#6204) and washer (20 x 38 x 3). i

Main shaft ass'y

Expander 8994741 00

Special tool

Snap ring

\ Differential ass'y

Fig. I 1-9 Disassembling transmission 1)

Main shaft assembly. @ (19.8 x 35 x 7) and washer @ (31 x 40.8 x 0.5). (Fig. 11-10)

z. Remove oil seal

VOTE: Before removing oil seal, cover the spline of the shaft with tape t o prevent damage t o the lip.

Fig. 11-1 I Removing snap ring b. Remove the 1st driven gear, synchronizer ring, and hub assembly (1 st & 2nd speeds). Then remove the key (gear thrust spacer).

6)

Hub assembly (1 st & 2nd speeds)

Fig. 11-12 Removing key (gear thrust spacer)

0,

c. Remove the gear thrust spacer synchronizer ring @ , 2nd driven gear @, gear thrust spacer I1 @ , 3rd driven gear @ , synchronizer ring @, gear thrust spacer I1 @ ,.hub assembly (3rd & 4th speeds) @ , synchronizer ring @, 4th driven gear @ , and gear thrust spacer I1 @ in that order.

Fig. I 1-13 Disassembled drive pinion assembly

d. Remove the needle bearing @ (34 x 50 x 20).

Fig. 11-14 Hub assembly (I st & 2nd speeds)

Remove the synchronizer hub springs @ and pull out the synchronizer hub inserts @ Separate the reverse driven gear @ from the synchronizer hub 7) Hub assembly (3rd & 4th speeds)

0.

Fig. 11-15 Hub assembly (3rd & 4 t h speeds)

Remove the synchronizer hub springs @ and pull out the synchronizer hub inserts @ . Separate synchronizer hub sleeve @) from the synchronizer hub @.

8)

Differential assembly

Fig. 11-1 8 Removing side gear Fig. 11-1 6 Removing oil seal

a. Wind vinyl tape on the spline of side gear shaft to prevent damage to oil seal lips. Remove the oil seal (27 x 62 x 9) from the differential case side first. Then remove the oil seal (27 x 45 x 9) and retainer from the final gear side.

Drive the straight pin (4 x 35) @ out from the differential case @ side and then differential pinion shaft @) . Remove the differential pinion @, differential side gear @ , and washer (27.1 x 42 x t).

. .-

.-

.

~

~.~

. .

1

b. Straighten the bends of lock washers on the final gear, and remove the bolts (10 x 21 x 13) to separate the final gear from the differential case.

Fig. 11-19 Driving out straight NOTE: Keep the side gears and adjusting washer separate with reference t o the final gear side and differential case side.

Fig. 11-17 Driving out straight pin

Remove the differential side gear and washer (27.1 x 42 x t) from the final gear side.

e. Remove the ball bearing (#6007) from the final gear and differential case with a puller or press.

9)

Gear shift mechanism of transmission cover compl.

-

-. Transmission

i

cover

Fig. 11-21 Removing plug and selector plunger

Fig. 11-20 Gear shift mechanism

Loosen four 6-mm bolts (L = 25) and remove the transmission cover compl. Take out spring pin (6 x 28) @ using a special tool "Straight pin remover II", separate the gear selector arm shaft compl. @ from the selector and remove the shifter arm @ and arm 0, shifter arm shaft @.

10) Reverse accent mechanism of transmission cover (Fig. 11-21) a. Loosen the plug (8 x 10.5) @ and take out the shifter fork rail spring @ and ball (6.350) @. b. Remove the selector plunger @, accent plunger spring @ and accent plunger spring 11 @.

11) a. Loosen two 6 mm bolts (L = 12 mm). Remove the shifter rail spring plate @ , three shifter fork rail springs 0, and three lock balls (6.350 mm dia.) @ . Then remove shifter rail plate @ by loosening two 6 mm bolts (L = 12 mm).

/

2 Fig. 11-22 Removing shifter rail spring plate

b. Using special tool "Shifter fork pin extractor", remove the straight pins (4 x 22) @ for the 1st & 2nd speed shifter fork @, 3rd & 4th speed shifter fork I1 0, and reverse shifter arm I1 @ . (Fig. 11-23) Then, remove the shifter fork rail @ for 1st and 2nd speeds, shifter fork rail I1 @ for 3rd and 4th speeds, and shifter fork rail 111 @) for reverse in that order. Rail 111 should be removed after taking off the back-up light

12)

-

-

rrrrrm

Fig. 11-25 Removing reverse idler gear

Fig. 11-23 Removing shifter fork switch (with aluminum gasket). Remove the shifter forks @ and 0, shifter arm I1 @, and reverse shifter lever @ from the transmission case. c. Four interlock balls (5.55 mm dia.) are provided in the interlock holes in the transmission case, two balls each between the three shifter fork rails. Remove these balls carefully so as not to lose them. Take care not t o lose the plunger installed on rail 11.

--

Reverse idler gear

.-

Take out the straight pin (6 x 15) @ and remove the reverse idler gear compl. @ b y moving the reverse idler gear shaft @ t o the clutch side. The reverse idler gear shaft @ should be removed outside after the plug (1 3 x 5) @ is driven out.

NOTE: D o not remove the reverse idler gear shaft unless necessary.

11-5.

INSPECTION

Thoroughly clean all disassembled parts and then inspect. 1 2 3 4 5 6 7

Rail I11 (Shifter fork) Rail I1 (Shifter fork) Plunger (Shifter rail) Interlock ball (5.55) Spring (Shifter fork rail) Lock ball (6.350) Rail (Shifter fork)

NOTE: Oil seal must never be washed in gasoline as it causes their lips t o swell.

1. Tl l-007

Fig,11-24 Component parts of shifter rail and lock balls

Gears

1) Replace gears whose teeth surfaces are broken, damaged or unusually worn. 2) Replace gears if the cone surfaces with which the synchronizer rings are in contact are seized or damaged. 3) Replace any bearings whose inner walls or end faces are excessively worn or damaged. 4) Replace any spacer whose end faces are excessively worn or damaged. 5) Thrust clearance of each gear

I

Gear

I

Standard value

I

0.050 - 0.350 nim

2nd & 3rd

0.1 10 - 0.430 mm (0.0043 - 0.01 6 9 in)

3.

Gear shift mechanism

I) Check the clearance between the shifter fork and the groove of the synchronizer hu'c sleeve.

0.2 - 0.4 mln (0.0079 - 0.0157 in)

Standard clearance

0.1 10 - 0.480 mm (0.0043 - 0.0 189 in) 2) Replace the lock ball (6.350 m m dia.4 shifter fork rail spring, shifter rail plunger, an; interlock ball (5.55 mm dia.) if they arr excessively worn or deformed.

2.

Synchronizer I

-

1

o *

"9

Rin

0

1 Back lamp switch 7 Arm (Selector) 2 Rail 111 (Shifter fork) 8 Shaft (Shifter arm) 3 Rail I1 (Shifter fork) 9 Fork (Shifter) 4 Rail (Shifter fork) 10 Fork I1 (Shifter) 5 Straight pin (4 x 22) 11 Arm I1 (Shifter) 6 Arm (Shifter) 12 Lever (Reverse shifter

Cone

Tll-000

Fig, 11-26 Ring-to-cone clearance

Fig. 11-27 Inspecting gear shift mechanism

1) Replace any synchronizer rings whose internal surfaces or teeth surfaces are damaged or excessively worn. 2) Measure the clearance "C" between the ends facing each other with the ring pressed onto the cone of the gear.

Standard value of "C"

1.3 - 1.7 mm (0.05 12 - 0.0669 in)

3) Replace the shifter fork rail if the edge i lock ball groove is worn.

4.

Replace the bearing if seized, worn, noisy. r unsmooth rotation.

5. 1)

Limit value of "C"

0.5 mm (0.0197 mm)

3) Replace the ring if its contact surface with the synchronizer hub insert is excessively worn.

Bearing

Oil seals and caps

Oil seals Replace any oil seal whose lips are dsformed, hardened, or worn. Also replace if i:r periphery is damaged. 2) Caps Replace any cap whose periphery is d a r aged.

6.

Other parts

keep the clearance of outer race of the two ball bearings.

Replace any part if it is deformed, excessively worn, or defective.

7.

Differential

11-6.

Apply grease [equivalent to Uniiube No.

21 between the lips of the oil seal (19.8 x 35 x

7), wind tape around the main shaft spline and carefully install the oil seal on the shaft.

1) Replace the final gear and drive pinion if the tooth surfaces are damaged or excessively worn. 2 ) Replace the drive pinion if the contact surface with the needle bearing inner race or the gear sliding spline is excessively worn. 3) Replace the differential pinion, side gear, washer (27.1 x 42 x t), and pinion shaft if they are seized, worn, or damaged. 4) Replace the differential case if cracked or defective in any other respect.

i. V~ny l tape w'

Main shaft

Oil seal

ASSEMBLY

Fig. 11-29 Installing oil seal

The transmission and differential should be assembled in the reverse order of disassembly. Points requiring attention in assembly are described below. Be sure to apply gear oil t o each part before assembling.

1.

2)

Main shaft assembly

2.

Drive pinion assembly

NOTE: The needle bearing has installing direction, when install the bearing, set 'XI'' side to the gear side.

1) The ball bearings (#6004, #6303C3) should be press-fitted by a press with the stamped side facing out.

-

L1>L2

To gear side

1 Ball bearing (#6303C3)

PA2

1

' Inner race

h e e d l e bearing Tll-011

Fig. 11-30 Installing direction of needle bearing Fig. 11-28 Ball bearings G- washer o n main shaft

NOTE: The washer (17.2 x 26 x 0.2) is installed between the ball bearings (#6303C3) to

Hub assembly (3rd & 4th speeds) Install the synchronizer sleeve so that the *mark part in Figure 11-31 may be placed on the HI side of 38 mm dia. boss of the synchronizer hub. 1)

4)

Hub assembly (1 st & 2nd speeds)

Fig. 11-31 Assembling hub assembly (3rd G 4 t h speeds)

Set the synchronizer spring so that the cut ends of spring on both sides be in opposite direction, and make sure that the insert is properly installed. 2) The hub assembly should be installed o n the drive pinion in such a manner that the H2 side of the 38 mm dia. boss faces the 4 t h driven gear and the untoothed part of angular spline of the synchronizer hub is placed away from the oil hole in the drive pinion. (H2>H1)

NOTE: This untoothed part is where the gear thrust spacer key is set. 3) The gear thrust spacer between the 2nd driven gear and hub assembly (1st & 2nd speeds) should be inserted with the end face with a notched groove (6.6 mm wide, 1.5 mm deep) facing the 1st driven gear and aligned to the untoothed part of the above spline. Put the spacer key in the notched groove t o lock.

Fig. 11-33 Installing hub assembly (1st and 2nd speeds)

Install the reverse driven gear so that the fork groove side may be placed o n the HI side of 38 mm dia. boss of the synchronizer hub. ( H I < H2) 5) Put the hub assembly on the drive pinion with the H1 side of the 38 mm dia. boss facing the 2nd driven gear. 6) Install the drive pinion spacer with the oil groove side end face facing the 1st driven gear and with the L l side of ball bearing (#6204NR) facing the 1st driven gear. ( L , L ~ )

>

\

Washer ( t = 3)

#6204. NR (with stopper)

1 st gear

T

#6204

1

O

E

L1>L2

Washer (20.2 x 29 x 0.2) Tll-015

Fig. 1 1-34 Rear bearings o n drive pinion

Fig. 11-32 Installing gear thrust spacer

NOTE: The washer (20.2 x 29 x 0.2) is installed to keep clearance between bearing outer races.

Select a snap ring that will provide a :!earance of 0 to 0.05 mm (0 to 0.0020 in) '?etween the inner race end face of ball bearing =6204 NR) and the snap ring. Press fit the snap ring in the groove using a special tool -Press assembly" and make sure that the inap ring is securely seated in the groove. )

Fig. 11-35 Measuring clearance

I

I

YOTE: Always replace the snap ring once it has been removed.

pecial tool: ress assembly 99754100

Guide (snap ring) 8997541 21

3.

D i f f e r e n t i a l assembly

1) Press fit the ball bearings (#6007) onto the final gear and differential case in advance. 2) Select a suitable adjusting washer to adjust the differential backlash to 0.05 to 0.15 mm (0.0020 to 0.0060 in) and install on the back of the side gear.

1

1 2 3 4

Adjusting washer Pinion (Differential) Adjusting washer Gear (Differential side)

(

T~I-016

Fig. 11-36 Adjusting washer

NOTE: Selective adjusting washers must be assembled with the chamfered face of the washer toward the gear.

Press (snap ring) 899754102 Adjusting washer

ip rings Part No. Part No.

TI1ickness

805020022

2.51 k0.015 mm (0.0988 0.0006 in)

805020024

2.57 T0.015 mm (0.10 12 0.0006 in)

805020026

2.63 20.015 mm (0.1035 0.0006 in)

805020028

2.69 20.015 nim (0.1059 T 0.0006 in)

+

+

+

Thickness

803 12708 1 803 127082

1.050 mm (0.0413 in)

803 127083

1.lo0 mm (0.0433 in)

3) Tighten bolts (10 x 21 x 13) to the specified torque and bend the lock washers (final gear).

5)

Reverse idler gear

Fig. 11-39 Installing reverse idler gear Fig. 11-37 Bending lock washer

Tightening torque (1 0 mm Bolt)

6.3 (45.6

+ 0.5 kg-m + 3.6 ft-lb)

4) Apply gear oil between the lips of the oil seals (27 x 45 x 9, & 27 x 62 x 9). Wind tape around the side gear spline and install the oil seals carefully. Be sure to keep a gap of about 3 mm between the oil seal (27 x 62 x 9) and the end face of ball bearing (#6007). Keep the oil seal (27 x 45 x 9) in close contact with the oil seal retainer.

Install the reverse idler gear shaft @ on the case with the pin hole facing outside. Then, put the reverse idler gear @ on the shaft as the groove in which the lever is placed faces outside, and lock with the straight pin (6 x 15). (Apply a small amount of grease to the pin head to prevent it from falling off when assembling the case I.) Drive the plug (13 x 5) into the case.

4. 1)

I

Gear shift mechanism Transmission cover

as a guide

I

1 1 Spring (Accent plunger) 2 Spring 2 (Accent plunger) 3 Selector plunger 4 Plug[8x10.5mm(0.31x0.413in)] T l l - 0 1 7

Fig. 11-40 Transmission cover COMPL

.,

Fig. 11-38 Installing oil seal

Coat the screw of plug (8 x 10.5) with liquid packing (Fuji Bond "C" or equivalent). While inserting the shifter arm shaft into the cover as a guide of selector plunger and accent plunger

springs, screw in the plug with the selector plunger pushed fully inward until the plug head becomes flush with the cover surface. Make sure that the selector plunger pushed operates smoothly. 1) Shifter forks and shifter fork rails The shifter forks and rails should be installed in the following manner, beginning with the reverse side.

Identification mark on lever

Remarks

342772 101

A

Approach to the 1st gear side

342772 102

B

Standard

C

Approach to the 2nd gear side

Part No.

342772 103

NOTE: After having determined the lever, use washers of correct thickness to provide 0.5 to 1.0 m m (0.0197 to 0.0394 in) clearance between the lever and gear compl. (reverse idler).

Fig. 11-41 Installing shifter a m II

a. With the lock ball groove on the shifter fork rail 111 @ facing down, put the rail through the case. Install the reverse shifter lever @ in the reverse shifter lever shaft pressfitted in the case, and put the shifter arm I1 @ on top of the lever as shown in Figure 11-41. Then align the pin holes in rail 111 and arm I1 and drive the straight pin (4 x 22) therein. b. Temporarily assemble the lock ball (6.35 mm dia.) with the shifter fork rail spring, and shift the reverse shifter lever to the reverse side. Place the drive pinion assembly and main shaft assembly in the normal position (as far )ver on the clutch side as possible), and .pply red lead to the tooth surface of reverse lriven gear. Put case I over them with the tip of reverse shifter lever placed in the groove of the reverse idler gear compl. to check the mesh of the gears, and select the reverse shifter lever that provides tooth contact of 80% or more.

everse shifter lever

Fig. 11-42 Adjusting the lever position

Adjusting washer Part No.

Thickness

8030 15082

1.1 mm (0.0433 in)

803015086

0.8 mm (0.03 15 in)

8030 15087

0.4 mm (0.0157 in)

c.

d.

e. f.

Then remove case I and set the reverse shifter lever to the neutral position. Put two interlock balls (5.55 mm dia.) in the interlock holes of the case side. Apply a small amount of grease to the balls to prevent them from falling off during assembly. Install rail I1 in the case as in Step (a.) on page 11-17), assemble fork I1 with it, and lock by driving in the straight pin (4 x 22). (Fig. 11-41) Operation similar to Step (b.) Install the rail in the case in the same manner as step(a.), assemble the fork with it and drive in the straight pin (4 x 22).

Fig. 11-45 Selecting shifter fork I1

Temporarily assemble the shifter fork rail spring and lock ball (6.35 mm dia.), and place the forks in the neutral position. Select the shifter fork and shifter fork I1 so that the synchronizer sleeve and reverse gear will be set as shown in Figure 11-42 when the drive pinion assembly is placed in the normal position. Shifter fork Part No.

Identification mark on the fork

Remarks -

342012101

A

Approach to the 2nd gear side

342012102

B

Standard

342012103

C

Approach to the 1st gear side

Part No.

Identification mark on the fork I1

Remarks

3420221 11

A

Approch to the 3rd gear side

342022 112

B

Standard

342022 113

C

Approach to the 4th gear side

Fig. 11-43 Installing shifter fork

g. Selecting shifter fork and shifter fork I1

Shifter fork I1

Fig. 11-44 Selecting shifter fork 11

- 18

Tighten the shifter rail spring plate and shifter rail plate with two 6-mm bolts (L = 12 mm) each. The shifter rail spring plate should be installed with the flange for the harness clamp placed outside.

(6 mm Bolt)

(7.23

Washer

Washer (39X 53.2X t)

+ 0.54 ft-lb) Ball bkaring

i. Tighten the back-up light switch t o the

specified torque. Be sure to use the alurninum gasket.

1.8

( # 6303C3)

f

bearing

I

Fig. 11-47 Measuring cbarnace

+ 0.2 kg-m

Fig. 11-48 Measuring clearance

Fig. 11-46 Installing back-up light switch

Washer (39 x 49.5 x t) for main shaft

I ) Washers and caps 2 . Place the main shaft assembly, drive pinion assembly, and differential assembly in the standard position (where the main shaft and drive pinion assemblies are all the way over on the clutch side and the differential assembly is on the side opposite t o the clutch). Select and install a washer that provides a clearance of 0.01 to 0.2 mm between the washer and each end face of the main shaft #6303C3 ball bearing, drive pinion #6204NR ball bearing, and differential #6007 ball bearing. (Refer t o Figs. 11-47 and 1 1-48.)

Part No.

Thickness (mm)

to

80303901 1

2.2

8030390 12

t0 2'35 -0.03

8030390 13 8030390 14

-0.03

to 2'5

-0.03

to -0.03

Washer (39 x 53.2 x t) for drive pinion. Part No. 80303903 1 803039032 803039033 803039034

Thickness (mm)

to -0.03

to 2'20 -0.03

4) Joining transmission case a. Thoroughly remove oil and dirt from the mating surfaces of case I and case 11 ane apply liquid packing to case 11. Then place case I on case 11. Before doing so, move the reverse idler gear compl. to the clutch side and assemble the tip of reyerse shifter lever with the groove on the reverse idler gear compl.

+o 2'35 -0.03

to 2'50 -0.03

Washer (53 x 65.5 x t) for differential

/! 11 -

Part No.

Thickness (mm)

80305301 1

+o 2'3 -0.03

8030530 12

+o 2'5 -0.03

8030530 13

+o 2'7 -0.03

After having selected the washer for the differential, place the oil seal (27 x 62 x 9) in contact with the washer using an installer. b. Attach the caps (transmission case) to the washers on the main shaft assembly and the side of drive pinion assembly. Install cap I11 (transmission case) with its positioning notch aligned to the case side positioning groove on the front side of drive pinion assembly.

? -3qj/.&+

Q Q 3 7

a,

8 -

Bolt

I

- 8 x 45 rnm 13 pcs. A 8 x 65 mm 3 pcs

0 8 x 95 rnm 2 pcs. 6 x 32 rnrn 2 pcs. -

Tll-021

Fig. 11-50 Sequence of tightening case

b. Tighten two 6-mm bolts and eighteen 8-mm bolts in the numerical order given in Figure 11-50.

Tightening torque 6 mm Bolt

1 5 0.075 kg-m (7.23 2 0.54 ft-lb)

~smissioncase) F 7

\B@kI

Caps

'-4-a

Fig. I 1-49 Instarling cap

--

8 mm Bolt

2.5 (18.08

+ 0.2 kg-m + 1.4 ft-lb)

:. Install the oil level gauge with the transmis-

sion cover up. 5 ) Checking gear shift 2. Assemble the selector arm with the gear selector arm shaft compl. and drive in the spring pin (6 x 28). 3. Assemble the shifter arm and shifter arm shaft, and check gear shift.

11-7.

INSTALLATION

~nstallation should be performed in the reverse order of removal. First make sure that the release bearing is not projecting, and then start installation. Never install the transmission while holding the clutch release lever compl.

2. Secure the transmission t o the engine with four 10-rnm bolts.

Tightening torque (10 rnrn Bolt)

4.5 rt0.3 kg-m (32.6 5 2.2 ft-lb)

3. Fig. 11-51 Checking gear shift condition

c. Tighten the transmission cover compl. along with the gasket using four 6-mm bolts (L = 25 rnm).

Tightening torque (6 mm Bolt)

6)

+

1 U.U.15 kg-rn (7.23 2 0:54 ft-lb)

Clutch lever Refer t o Chapter 10, "CLUTCH"

Remove the oil level gauge and fill the transmission with gear oil (MP #80). Straighten the bent tip of the oil level gauge.

Oil quantity

(0.95 U.S. qt., 0.80 Imp. qt.)

11-8.

I

TROUBLESHOOTING Condition and probable cause

II

Remedy

1. Difficult gear shifting Difficult gear shifting is usually caused by a change rod failure and/or a transmission failure. At the same time, however, when the lever feels heavy and gear shifting is difficult, it may be the result of an improperly disengaged clutch. Therefore, first check that the clutch is operating properly and then check the change rod and transmission. (1) Loose or separated change rod connections.

Adjust or replace.

(2) Worn, broken or burred chamfers of internal splines of sleeve and reverse driven gear. (3) Worn, broken, or burred I gear splines.

Replace.

Replace.

(4) Insufficient operating stroke due to worn sliding part or rattling.

Repair or replace.

(5) Improper contact between synchronizer ring and ring gear cone, or worn contact surfaces.

Repair.

2.

Gear slips out.

(1) Worn shifter fork, or fatigued or broken shifter fork rail spring.

Replace.

(2) Worn lock ball groove in shifter rail.

Replace.

(3) Worn or damaged ball bearing.

Replace.

(4) Excessive clearance between synchronizer hub and sleeve splines.

Replace.

(5) Worn chamfers and flank of each gear spline.

Replace.

3.

I I

I

Noisy transmission If a noise is heard during idling but stops when the clutch is disengaged, the problem is probably in the transmission.

(1) Insufficient lubrication or use of inadequate oil.

Add oil or change to recommended oil.

(2) Worn or broken gear and bearing.

Replace.

I

Condition and probable cause

Remedy

NOTE: High humming is heard at high speeds if the wear has progressed to the extent that the tooth surface is worn. I n case of breakage rotational knocking sounds are heard even at low speeds. Replace.

(3) Worn splines. 4.

Breakage of differential (case, gear, bearing, etc.) This causes an abnormal noise and a failure in rotation, making it impossible for the vehicle t o run.

(1) Insufficient oil or use of inadequate oil.

Disassemble differential broken parts.

(2) Improper use of vehicle such as overloading, improper use of clutch.

Check parts for condition and replace as necessary.

(3) Excessive backlash due t o worn side gear, washer (27.1 x 42 x t) and pinion.

Adjust backlash and tooth contact.

(4) Bolts fixing final gear loose.

Fill recommended oil t o specified level.

5.

and

replace

Noisy differential and final gear In the case of a differential failure and final gear failure, various distinctive sounds can be heard and the source of trouble can often be isolated by listening closely t o these. Be careful not to mistake a symptomatic sound for one coming from the engine, muffler, tires, bearings, body, etc. Particularly, the sound of final gear is often confused with other gear sounds.

I

The different kinds of noises are as follows: (1) Noise at starting or gear shifting

Insufficient gear oil, improperly meshing gears, or broken gears are the cause when the noise increases as vehicle is accelerated.

I

(2) Bearing noise while accelerating or coasting

I

Cracked or broken bearing. (3) Noise produced mainly while turning Abnormal noise of differential side gear. differential pinion, and differential pinion shaft. f

I Add oil to normal level.

1) Insufficient oil.

(2) Excessive backlash between ferential side gear and pinion.

dif-

Replace gear or washer.

I

Condition and probable cause

Remedy

(3) Worn teeth of final gear and drive pinion.

Replace as a set

(4) Broken differential pinion shaft.

Replace.

(5) Seized or damaged bearing.

Replace.

(6) Worn washer (27.1 x 42 x t) and pinion shaft.

Replace.

CHAPTER

1 2:

SUSPENSION

Page

.......................................................................... 1 2 - 2 OUTLINE OF SUSPENSION ........................................................ 1 2 - 3 WHEEL ALIGNMENT .................................................................. 1 2 - 4 COMPONENT PARTS OF FRONT SUSPENSION ..................... 1 2 - 5 COMPONENT PARTS OF REAR SUSPENSION ........................ 1 2 - 6 FRONT SUSPENSION .................................................................. 1 2 - 7 REAR SUSPENSION ..................................................................... 12-19 POSTURE ADJUSTMENT ............................................................ 12-26 ADJUSTMENT OF WHEEL ALIGNMENT ................................. 12-28 TROUBLESHOOTING ................................................................... 12-32 SPECIFICATIONS

12-1.

1.

SPECIFICATIONS Front suspension Item

TRUCK (I

VAN (K87)

L

Torsion bar

Total length

504.5 mm (19.86 in)

Effective length

434.5 mm (17.1 1 in) 19.5 mm (0.768 in)

Effective diameter Number of serration teeth

Shock absorber

Helper

Outer end: 34

Spring constant

4.22 kg-m/deg. (30.5 ft-lbldeg.)

Maximum length

278.5 mm (10.96 in) 187.5mm ( 7.38 in)

Minimum length Damping force (at 0.3 m/sec)

Expansion

88 kg (194 lb)

Compression

56kg (1231b) 62"

Rubber hardness Outer Diam. x Inner Diam. Length

Bearing Inner bearing

57.5mm(2.26i1

55mm(2.17in)

Height

Outer bearing

Outer Diam. x Inner Jliam. Length

2.

Inner end: 37

10"

56.4 mm (2.22 in) x 5 1.6 mm (2.03 in) 30mm (1.18 in) 58.4 mm (2.30 in) x 53.0 mm (2.09 in: 30mm (1.18 in)

Rear suspension Item

Torsion bar

Total length

527 mm (20.75 in)

Effective length

483.5 mm (19.04 in) 22.5 mm ( 0.89 in)

Effective diameter Number of serration teeth Spring constant

Shock absorber

Helper

Rubber bushing

VAN (K87)

TRUCK (K77)

Inner end: 37

Outer end: 34

Maximum length

6.7 1 kgmldeg. (48.5 3 ft-lbldeg.) 269 mm (10.59 in)

Minimum length

213 rnrn ( 8.39 in)

Damping force (at 0.3 m/sec)

Expansion

88 kg (1941b)

Compression

64 kg (141 lb)

Height

59.5 mm (2.34 in) 50"

Rubber hardness

Outer bushing

Outer Diam. x Length Rubber hardness

52.8 mm (2.79 in) x 44 mm (1.73 in) 50"

I

NOTE: a. The length of the shock absorber is measured as shown in figure. Front shock absorber:

CI

Rear shock absorber: Length

he length of the helper is measured as shown in figure. Front helper.

Rear helper.

................. . . . . . .....

........ . . . . ,,;. . : .:' . . ..;, . . . .. .,. ..:. .. .. ... ... . .. . .. .. .. . .. . .. .. ... .. ,

',

Heigt

I

. .. . .. . .. . . . .

12-2.

O U T L I N E OF S U S P E N S I O N

The front suspension employed is of a st:mitrailin.g arm type. The front crossmember, which is integral with the chassis frame A.~ I I U locate!d ahead of the front wheel center, houses torsion bars that are the main springs for the front suspension. Both ends of the torsion bar are provi.ded with serrations; inner end is anchored at the centelr of the crossmember and the outer ertd is on"ne cted to the trailing arm.

The trailing arm swings up and down with the crossmember acting as the pivot. Slide occurs between the nylon bearing press-fitted inside the trailing arm, which is adopted to give a smooth slide, and the metal sleeve press-fitted on the crossmember. The upper end of the shock abosrber is attached to a bracket on the chassis frame and the bottom end is installed on a pin welded on the trailing arm near to the center of the wheel.

The rear suspension is of a semi-trailing, independent type using outer and inner trailing arms. A crossmember, integral with the chassis frame and located in front of the trailing arms, houses torsion bars. The inner ends of the torsion bars are connected to the center arm at the center of the crossmember, which serves as vehicle height adjuster, and the outer ends of the torsion bars to the outer trailing arms.

The inner and outer trailing arms ar -..:ted to the crossmember through ruooer bushings. The upper end of the shock absorber is attached to a bracket on the chassis frame, and the lower end to the pin on the inner arm. As an auxiliary spring, a helper is installed on a bracket welded to the chassis frame on each side.

,-.

12-3.

WHEEL ALIGNMENT

7

Front

275-305 mm (10.8-12.0 in)

Rear

260-295 mm (10.2-1 1.6 in)

leight*

Front

+30' 20 O' - 60#

Rear

30 15' -60,

Front

5"25' t45'

Camber**

Caster**

+30'

Front

IN 8-13 mm (0.3 -0.5

Rear

IN 9-1 5 mm (0.35-0.59 in)

in)

Toe-in**

Front

IN 3 mm (0.1 in) to OUT 3 mm (0.1 in)

Side slip*** Kear Turning angle** * *

Inside

37"

t2"

Outside

33"301 t2"

* Distance between ground and center of torsion bar outer end face, with vehicle unll -Difference between right and left should be less than 10 mm (0.39 in).

** With vehicle unloade.

'**

:**

With driver in vehicle. Difference between right and left should be less than 3

12-4.

COMPONENT PARTS O F FRONT SUSPENSION

-

0 I

1 Lock bolt plug 2 ~ d i s i o nbar 3 Helper bracket 4 Helper 5 Rubber bushing 6 Shock absorber 7 Washer

8 Cushion rubber 9 Torsion bar lock bolt 10 Sleeve 11 Oil seal 12 Dust cover 13 Nylon bushing 14 Dust cover

15

16 17 18 19

F ig. 12-1 Component parts of front suspension

12-5

.

Bolt Torsion bar lock bolt Expansion plug Trailing arm King pin bushing ~12-001

12-5.

COMPONENT PARTS OF .REAR SUSPENSION

1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17

Torsion bi1r Center arnn Center arnn bolt Cone point bolt Rubber bush~ng Outer trailing arm Circlip Helper Inner trailing arm Rubber bushing Shim Bolt Bracket Shock abs Washer Cushion rubber Rubber bush~ng

Fig.

J

T12-002

.

~mponentparts of rear susper

r

12-6.

1.

FRONT SUSPENSION Front suspension assembly

REMOVAL luts securing the 1) Loosen the fou rim to the brake drum. 2) Raise the vehicle front and remove the nuts the detach the wheel.

Or a. Turn the steering wheel to the left (right) fully to disconnect the right (left)-hand brake hose from the wheel cylinder.

Fig. 12-5 Disconnecting brake hose from wheel cylinder

Fig. 12-.? Jack ing

3) Disconnecting the brake hose frl brake pipe or wheel cylinder. a. Loosen the joint nut connecting the brake hose to the brake pipe. b. Pull out the clamp fixing the brake hose to the bracket, c. Pull out the brake hose from the bracket.

Fig. 12-4 Disconnecting brake hose

b. Remove the union bolt at the wheel cylinder and remove the brake hose. 4) Removing the tie-rod end. a. Remove the cotter pin and remove the castle nut. b. Disconnect the tie-rod end from the knucle arm by using the special tool (Ball stud remover: 92 1240000).

NOTE: Do not tap the knucle arm by hammer.

Fig. 12-6 Removing tie-rod end

I

1

5 ) When removing the left-hand side suspension assembly, disconnect the speedometer cable. 6 ) Remove the splashboard by loosening three 8 mm bolts.

I

pig. 12-9

Disconnectinq shock absorber

b. Loosen the two lock nuts on the upper end of the shock abosrber until the load is released from the rubber bushing at the lower end of the shock absorber. Fig. 12-7 Removing splashboard

7)

Remove the trailing arm stopper bolt.

NOTE: The lower end of the shock absorber is used as a reference line to determine the proper ground clearance while the suspension is being installed. Therefore, do not remove the upper shock absorber lock n u t unlr-shock absorber is out of order. c. Remove the lower end of the shock ab,-.,-. from the trailing arm damper pin. 9) Remove the torsion bar lock bolts on the trailing arm and at the center of the crossmember.

Fig. 12-8 Removing stopper bolt

8) Disconnecting the shock absorber lower end. a. Remove the 10 mm nuts and washers securing the lower end of the shock absorber to tho

trnilinn n n n

Fin I 7- 1 fl R o r r r n r ~ i w ntnrr;nrr hnr l n r L hnlt

10) Extract the suspension as the crossmember by hand.

rom

Fig. 12-12 Applying grease on sleeve .-

.- .

.

-

Fig. 12-1I Removing suspension assembly

INSPECTION 1) Check the bearings in the trailing arm for wear and damage. 2) Check the sleeves on the crossmember for wear and damge. 3) Check threaded parts for wear and damage. 4) Check the oil seal lips for wear and damage. 5) Check the torsion bar and trailing arm for any evidence of deformation which may have decreased their strength. Also check the painted surface of these parts for peeling, and repaint if necessary.

NOTE: I f the trailing arm coating has come off -' e trailing arm is rusted, carefully check me fected parts for cracks or damage. If cessary, use a dye test to determine normalities. 'ALLATION Before installing the front suspension assembly, throughly clean the bearings and sleeves with clean cloth and keep these parts free of dust. 2) Apply new grease (about 70 gr. (2.5 oz)) to thc:crossmember sleeves. ,

.ease

Sunlite No. 2 or equivalent.

3) Install the front suspension assembly in the reverse order of removal.

NOTE: a. When installing the torsion bar into the crossmember, align the lock bolt hole in the crossmember with the V-shaped groove at the torsion bar inner end and install the lock bolt Also align the lock bolt hole in the trailing arm with the V-shaped groove at the torsion bar outer end and install the lock bolt After completing the above job, adjust the vehicle height and side slip. b. The torsion bar lock bolts are of special design. Always use genuine SU BAR U bolts. c. Tightening torque specifications are as I ows.

Torsion bar lock bolt

3.0 - 4.4 kg-m (22 - 3 2 ft-lb)

Trailing arm stopper bolt

1.1 - 2.6 kg-m ( 8 - 19 ft-lb)

Brake hose and brake pipe connecting nut .

1.5 - 2.0 kg-m (1 1 - 14 ft-lb)

Shock abosrber lower end installing nut

1.8 - 2.6 kg-m (13 - 19 ft-lb)

Shock absorber upper end lock nut

,upper nut

1.8 - 2.6 kg-m (13 - 19 ft-lb)

lower nut

1.0 - 2.0 kg-m ( 7 - 14 ft-lb)

When installing the plugs shown in figure, always replace it with a new one and apply a sufficient amount of sealer when installing it on the suspension. Before tightening the torsion bar lock bolts and trailing arm retaining bolts, be sure to

apply a coat of sealing compound to the threads.

Recommended sealer:

Cemedine CS 11 1 Cemedine 540 or equivalent

1 Plug

2 3

Lock bolt Bolt

I I L-u--

I Fig. 12-13 Plugs and lock bolts on front suspension

ADJUSTMENT After the front suspension assembly has been installed, check the ground clearance and wheel alignment. If necessary, adjust. (Refer to "Posture adjustment" and "Adjustment of wheel alignment".)

~ 1

Torsion bar )VAL 1) Remove the front suspension assembly. (Refer to removal of front suspension assembly.) 2) Remove the torsion bar lock bolt at the center of crossmember underside.

INSPECTION 1) Check the torsion b: nage and its painted surface for peeling 2) Check the torsion bar serrations for wear. INSTALLATION 1) Remove the upper lock nuts from the upper end of the shock abosrber, and then loosen the lower lock nuts. Set the shock absorber so that three or four threads at its upper end are engaged.

Fig. 12-14 Removing torsion bar lock bolt

3) Pull the torsion bar outward by hand. If it is hard to pull by hand, tap the end of the torsion bar by using bended bar.

Fig. 12-1 7 Loosening lock nut

2) Pull the lower end of the shock absorber until it extends fully. 3) Insert the torsion bar into the trailing arm.

Fig. 12-15 Removing torsion bar

Fig. 12-1 6 Removing torsion bar b y tapping

Fig. 12-1 8 Installing torsiof..,,

With the torsion bar inserted into the trailing arm, attach the suspension assembly to the crossmember.

4)

12-1 9 Installing front suspension assembly

5) ~ t t i c h the lower end of the shock absorber to the trailing arm damper pin. 6) Manually push the torsion bar until the serration on both ends fits that of the crossmember and trailing arm.

NOTE: I f the serration is hard to fit, turn the torsion bar to locate the point where it easily fits.

7) Tighten bolts and nuts in the following order: a. Torsion bar lock bolt at lower center of crossmember. b. Torsion bar at trailing arm end. c. Trailing arm stopper bolt. d. Two lock nuts at upper end of shock absorber. e. Nut at lower end of shock absorber.

Fig. 12-20 Tightening bolts and nuts

NOTE: a. Before tightening the lock bolts, pro1lerly align the V grooves on both ends of the Ius3torsion bar with the holes in the c--"" member and trailing arm. b. Be sure to tighten all bolts and nuts t cI the specified torque setting. c. Install each torsion bar on the side from which it was removed. I f the torsion bar positions are interchanged between the right and left, early breakage may result The torsion bars are marked as follows for identification. Right-hand torsion bar

621001381 (FRH)

Left-hand torsion bar

621001391 (FLH)

d. After the front suspension has been insta check the ground clearance and rn alignment I f necessary, adjust

Bearing (Trailing arm inner and outer) and Dust cover

2) Drive out the bearing in the following manner, using the special tool (Remover: 922290000). a. Attach the hook @ to the inner side of the trailing arm. b. Open the hook @ until it catches the bearing end. c. Insert the retainer (j)from the serration side of the trailing arm to prevent the from coming off. d. Attach the cap @ to the location formerly occupied by the dust cover. e. Turn the screw @ t o tighten the cap @ and drive out the bearing.

ZMOVAL Remove the dust cover press-fitted to the ler end of the trailing arm, by using a screw .ver.

NOTE: Be careful not to damage the rubber surface of dust cover.

1 2 3 4

5 6

Retainer Hook Cap Screw Special tool: (922290000) Bearing

T12-007

Fig. 12-21 Removing trailing arm bearing 12 - 13

I

INSPECTION Check the following items ror a~normalities. If necessary, replace. 1) Bearing surfaces for wear or damage. 2) Resin and metallic areas for detachment. 3) Dust cover for (

assembly, check the trailing arm end play with a dial gauge, using the following procedure. If the dial gauge pointer deflects more than 1 mm, remove the front suspension assembly and replace the bearing.

.

INSTALLATION -. 1) With a clean cloth, wipe off dust f r-~... -. surfaces of the trailing arm, bearing an.d dust cover. 2) Install the bearing onto the end (5 1 staller : diam.) of the special tool (In; 922350000), and then insert it into thie trailing arm. 3) T o do this, drive the end of the tool with a press or hammer until it comes into contact with the end of the trailing arm. Then press the outer bearing into position.

1

Bearing (outer) Bearing installer

.--

1) Raise the front end of the vehicle until the front wheels clear the ground. 2) Remove the torsion bar lock bolt, and separate the torsion bar from the trailing arm. 3) Using a magnet stand, set a dial gauge at a position within 5 mm from the end of the trailing arm. 4) Holding the tapered portion of the trailing arm, slowly move the trailing up and down, reading the dial gauge indication.

Fig. 12-23 Installing outer bearing

F&. 12-22 Measuring trailing arm

4) Install the bearing onto the end (53.0 mm diam.) of the special tool (Installer: 922350000), and then insert it into the trailing arm. To do this, drive the end of the tool with a press or hammer until it comes into contact with the end of the trailing arm. Then press the inner bearing into position.

1 2

NOTE: Do not allow the dust cover to prolmle from the trailing arm more than 15 m (0.06 in).

Bearing (outer Bearing (inner)

Dust cover

Less than 1.5 mm (0.06 in)

T12-011

Fig. 12-26

4.

Sleeve (Inner and Outer) and Oil seal

REMOVAL 1) Insert the special tool (Puller Cap: 92260000) into the tip of the crossmember. 2) Attach the hook of the special tool (Remover: 92203000) to the end of the outer end sleeve. 3) Turn the handle of the tool to drive out the oluter sleev

Fig. 12-24 Installing inner bearing

5) Install the dust cover onto the special tool (Installer: 922360000); drive the tool with a press or hammer until the dust cover comes contact with the end of the trailing arm.

Bearing (outer) Bearing (inner) Dust cover Special tool: Dust cover installer

T12-010

Fig. 12-25 Installing dust cover 12 - 15

INSPECTION 1) Check the inner and outer sleeves for wear or damage. If necessary, replace.

NOTE: Measure the outside diameters of the sleeves at points D l and D2 shown in figure. I f the difference between D l and D2 exceeds 0.1 mm, replace with a new one.

Fig. 12-27 Removing outer sleeve

Fig. 12-29 Measuring sleeve

2)

Always replace oil seal after removal.

T o remove the inner sleeve, use the same procedure as that for the outer sleeve. Pull off the oil seal and inner sleeve at a time.

4)

INSTALLATION 1) Attach the oil seal to the crossmember. 2) Insert the inner sleeve into the special tool (Installer: 922330000) and install it onto the crossmember; drive the special tool with a hammer until it comes into contact with the crossmember. 1 Oil seal 2 Inner sleeve

T12-014

12-28 Removing inner sleeve

NOTE: Check for proper f i t of the inner -'--.*through the access hole in the special t~

5.

Shock absorber

REMOVAL 1) Remove the two 10 mrn nuts securing the shock absorber to the chassis frame bracket. 2) Pull off the washer and rubber bushing from the rod.

1 Cross member 2 Hole 3 Special tool: Oil seal and sleeve installer (922330000) 4 Inner sleeve 5 Oil seal T12-016

Fig. 12-30 Installing inner sleeve Fig. 12-32 Loosening shock absorber upper end

3) Drive the outer sleeve into the crossmember with a- rlarrlmer through the special tool (Installer: 922340000).

1 Cross member 2 Special tool: Sleeve installer (922340000)

3 Outer sleeve 4 Sleeve 5 Oil seal T12-018

T12-017

Fig. 12-31 Installing outer sleeve 12 - 17

3) Loosen the l O m m nut securing the lower end of the shock absorber to the trailing arm, and detach the shock absorber. 4) Remove the washer and rubber bushing from the damper pin.

..

Fig. 12-34 Checking oil leakage

Fig. 12-33 Removing shock absorber lower end

b. I f oil is found only on the upper andI lower portions, this does not indicate oil leakage and does not require replacement of the shock absorber.

5 ) Compress the shock absorber, and then detach the upper end of the rod from the bracket. 6) Remove the lower end of the shock absorber from the trailing arm.

INSPECTION Check the shock absorber for the following items, and replace it if any of the following abnormalities is found. 1) Excessive oil leakage or damage. 2) Improper functioning. 3) Improper travel strokes (min. and max.). 4) Deformed or damaged rubber bushing.

NOTE: a. Fully extend the shock absorber and check the length (Q) of the rod wet with oil. I f the length (9) is more than one-third of the overall length (L), replace the shock absorber.

Fig. 12-35

INSTALLATION Installation is in the reverse order of removal.

NOTE: Tighten the 10 mm nuts securing the upper and lower ends of the shock absorber to the specified torque.

Torque

1.8 - 2.6 kg-m (13 - 19 ft-lb)

6.

Helper

REMOVAL AND INSTALLATION 1) Remove the 8 mm nuts securing the helper to the chassis frame bracket, and detach the helper.

Fig. 12-37

Fig. 12-36 Removing helper

2) Installation is in the reverse order of removal.

12-7. REAR SUSPENSION 1.

NOTE: Tighten the 8 mm nuts to the specified torque.

Torque

1.5 - 2.0 kg-m (1 1 - 14 ft-lb)

INSPECTION 1) Check the helper for fatigue or damage. If necessary, replace. 2) Check the height of the helper and replace if it is less than the specified value. Truck: H = 4 9 mm (1.93 in) VAN: H=51mm(2.0in)

Rear suspension assembly

REMOVAL 1) Loosen the four wheel nuts securing the rim to the brake drum. 2) Raise the vehicle rear and remove the nuts to detach the wh

NOTE: Attach the jack to the designated points.

Fig. 12-38 jacking up

3) Remove the bolts and nuts securing the underside cover, and detach the cover. 10 mm bolt . . . . . . . . . . . . 2 bolts 8 mm nut . . . . . . . . . . . . . 2 nuts 6 mm bolt . . . . . . . . . . . . 6 bolts 6 mm tapping screw . . . . . 2 screws

Fig. 12-41 Pulling off cable

6 ) Tap out the spring pin and disconnect the axle shaft from the engine.

Fig. 12-39 Removing under cover

4) Remove the return spring, clevis pin, cotter pin and 6 mm bolt attaching the cable clamp and remove the cable. Fig. 12-42 Disconnecting axle shaft 7) Loosen the flare nut connecting the brake hose to the brake pipe at the inner arm mounting bracket, and separate the two.

Fig. 12-40 Removing cable

5)

Pull the cable with the grommet off the

-.

-

A

a-

-.

..

9

1

9

I

Loosen the lock nut, the :r bushing lock bolt.

11) Remove the rear suspension from the chassis frame by pulling it out.

e the

NOTE: T o avoid damaging the back plate, place the rear suspension assembly on a soft surface, such as rags or cardboard.

Fig. 12-44 Removing lock bolt

Remove the two bolts securing the inner mounting bracket to the crossmember, and detach the inner arm bracket.

rrllll

Fig. 12-4 7 Rear suspension assembly

DISASSEMBLY 1) Remove the flare nut securing the brake pipe to the brake assembly. NOTE: Be careful not to damage the head of the nut

Fig. 12-45 Removing inner arm bracket

10) Remove the 10 mm nut securing the lower end of the shock absorber to the trailing arm, separate the two.

Fig. 12-46 Disconnecting shock absorber

Fig. 12-48 Disconnecting brake pipe -

12-21

2)

Remove the four 12 mm bolts securing the hub to the trailing arm.

ASSEMBLY AND INSTALLATION Assembly and installation are in the re. order of disassembly and removal.

NOTE: a. Tighten the outer and inner bushing lock bolts only after all assembling and installation work has been completed, with the wheels on the ground and in an unlo condition. b. The specified torque setting for bolts; and nuts is shown in the chart below.

Fig. 12-49 Removing realh u b bolt

3) Pull off the rear axle assembly and br ake assembly as a unit from the trailing arm.

NOTE: Be careful not to damage or deform the brake pipe or the axle boot

INSPECTION 1) Check the condition of all parts. Replace parts if necessary. 2) Check for missing circlip on the trailing outer arm. If it is missing, install a new one.

uter

arm

Outer bushing lock bolt

1.8 - 2.2 kg-111 (13 - 16 ft-lb)

Inner bushing ltaching bolt

3.5 - 4.0 kg-m (25 - 29 ft-11

lner bracket attaching bolt

3.5 - 4.5 kg(25 - 33 ft-lt

Shock absorber attaching nut

1.8 - 2.6 kg(13 - 19 ft-lt

Brake hose to brake pipe securing flare nut

1.5 - 2.0 kg(1 1 - 14 ft-It

Rear hub attaching bolt

7.0 - 12.0 kl (5 1 - 87 ft-It,

c. Fit the rear torsion bar to the outer arm by properly aligning the toothless points.

Fig. 12-50 11

3)

Check the trailing inner arm and outer

arm for cracks or. damage. If necessary, use a dye test to check for abnormalities, especially on areas where coating is detached and rust C--.4:.-.-

av:n+-

Fig. 12-51

d. After the rear suspension assembly has been ins+-dln.l

h1an.l .I;- 6.n-

+hn hr.~Lnr..r+n-

USTMENT After the rear suspension assembly has installed, inflate the tires to the specified ure; also make pcIsture adjustments and 1 alignment.

54.5 mrn (2.14 in)

1 Special tool:

\O

Rubber bushing (Outer) OVAL Place the trailing outer arm in a vise. Pull off the rubber bushing with the special tool (Puller: 921330000), as follows: Insert the cap @ into the rubber bus1ling. Attach the spacer @ to the end of the :r bushing. Hold the spacer @ and rubber bushing the body @. rightening the lead screw @, remove the runner bushing.

2 Rubber bushing 3 Outer arm

'

T12-029

Fig. 12-53 Installing outer rubber bushing

3.

Rubber bushing (Inner)

REMOVAL With the special tool (Installer & Remover: 922340000) and a hand press, drive the rubber bushing out from the trailing inner arm as follows: 1) Insert the push rod @ (special tool) into the inner rubber bushing; then place onto the base @ (special tool) with a hand press. 2) Drive the inner rubber bushing out from the trailing arm by pushing the push rod @.

+

Press

6

Outer arm T12-I

Fio1. 12-52 Removing outer rubber bushi1

ALLATION Press the outer rubber bushing into place with the special tool (Installer: 921380000) and a press. I I U ~ ,1

E: ! sure to center the boss in the trailing arm and rubber bushing when installing.

3 4

Trailing arm Rubber bushing T12-030

Fig. 12-54 Removing inner rubber bushin*

,

3) Check the rubber bushing for cracks or other damage. If necessary, replace. INSTALLATION With the special tool (Installer & Remover: 922340000) and a hand press, drive the inner rubber bushing into the trailing inner arm as follows: 1) Place soapy water on the inner face of the die 0 ,and install die onto the trailing inner arm bushing. 2) Apply a coat of soapy water to the outer face of the inner rubber bushing, and install the rubber bushing into the die. Then install the die on the base @ (special tool) with a hand press. 3) Insert the push rod @ (special tool) into the inner rubber bushing. Exert pressure on the inner rubber bushing liner with the press until the end of the rubber bushing shows through the access hole in the base @. 4) Make sure that the rubber bushing is pressed to the specified value.

Fig. 12-56

NOTE: a. When pressing the inner bushing, always align the center lines of the inner trailing rubber arm of the rubber bushing, die 0, bushing and push rod @ Failure to do so may result in unusual noise while driving. b. After installing the bushing, allow the bushing face to dry for 48 hours. I f the trailing arm is installed on the vehicle while the rubber bushing is wet, the rubber bushing may slip out of place while driving, as soapy water acts as a lubricant.

4.

Torsion bar and center arm

REMOVAL 1) Before removing the torsion bar, detach the rear suspension assembly from the vehicle. Then pull off the torsion bar, grasping the serrated portion with your hand. If it is hard to remove with hand, lightly tap on the end of the other torsion bar to push it out. 2) After the left and right torsion bars have been removed, remove the center arm from the rear crossmember. 1 @ Push rod 2 @ Die 3 @ Base 4 Rubber bushing 5 Trailing arm T12-031

Fip. I 2-55 Installinp inner rubber bushing

INSPECTION Visually check the torsion bars and center arm to see if the coating is peeling or if rust is developing. If necessary, use a dyeing test to . check for cracks or damage. Replace any which are cracked.

r 1 1

INSTALLATION 1) Before installing parts, apply a coat of the same color paint to any portion from which paint has peeled. 2 ) Apply a coat of grease to the serrated portions of the center arm and trailing outer arm. 3) Insert the center arm and torsion bars into the crossmember. 4) Be sure to align the toothless points at the serration before assembling the center arm and torsion bars.

Fig. 12-57

5) Install each torsion bar on the side from which it was removed. If the torsion bar positions are interchanged between the right and left, early breakage may result. The torsion bars are marked as follows for identification.

5.

Right-hand torsion bar

621001900 RRH

Left-hand torsion bar

621001910 RLH

,Shock absorbar

REMOVAL AND INSTALLATION For the removal, inspection and installation of the rear shock absorber, follow the same procedures as for the front shock absorber. In removing and installing the upper end of the rear shock absorber, be sure to detach the trap door beforehand.

F k . 12-58 Installing torsion bar

Fig. 12-59

12-8. 1.

POSTURE ADJUSTMENT F r o n t posture adjustment

1) Park the vehicle on a flat surface and set the steering wheel in the straight-ahead position. 2) With the vehicle unloaded, inflate all tires to the following specified pressure: Front: 2.4 kglcmz Rear: 2.4 kg/cm2 Measure height "H" above ground (ground 3) clearance) at the center of the torsion bar to determine the difference (a) from the standard value. ~ ~ ~ 2 9 5 - H Where 295: Standard height

Fig. 12-61 Measuring distance L

8) Remove the wheel and su]pport the brake drum with a jack.

NOTE: a. Be careful not to scratch or damage the brake drum when jacking up. b. Failure to use a jack when removirig the torsion bar can result in damage 1to the brake hose.

Fig. 12-60 Measuring vehicle height

Fig. 12-62 Jacking up brake drum 4) Engage the parking brake. Loosen (but do not remove) the four nuts securing the front wheel. 5) Raise the front end of the vehicle with a jack. 6) Remove the nuts securing the lower end of the front shock absorber to the trailing arm, ' and detach the shock absorber to free the trailing arm. 7) Mark the body fender and wheel center cap and measure distance "L" between the two.

9) Remove the lock bolts securing the t:orsion bar to the center of the crossmember and the trailing arm. 10) Remove the plug from the center of the crossmember. Drive the torsion bar a1~d the he trailing arm cap, as an assembly, out nf -. t...crossmember by applying hammer blows to a bent crosshead screwdriver or a bent bar attached to the torsion bar end surface through the hole in the crossmember.

~ 1

NOTE: T o prevent the tentry of water through the threaded portions, be sure to apply a coat of cemedine to the threads.

Fig. 12-63 Removing torsion bar by tapping

11) Lower and raise the jack supporting the brake drum until distance "Ll" between the marl< scribed on the fender (in step 7 above) and the center of the wheel is obtained. At this poin t, the amount of adjustment (a) should be adde:d to, or subtracted from, dimension "L" as ne:cessary . (Exa.mples) .) If height "H" of the torsion bar above ground before adjustment is 270 mm, difference "a" is determined by the following: a = 295 - 270 = 25 mm Where a : Amount to be adjusted The distance between the mark on the fender and the center of the wheel is also determined by: L1 - L + 2 5 m m ) If height "H" of the torsion bar above ground before adjustment is 325 mm, difference "a" is determined by the following: a = 295 - 325 = -30 mm The distance between the mark on the fender and the center of the wheel is also determined by: Ll=L-30mm With distance "Ll" adjusted as above, 1 Ll enga,ge the serration of the torsion bar with that of the crossmember and trailing arm. 13) -, Properly align the V grooves on each side of the torsion bar with the lock bolt holes on the trailing arm and crossmember. Then tighten the lock bolts. ,

14) Lower and remove the jack supporting the brake drum. 15) Install the wheel. 16) Lower the front end of the vehicle and remove the jack. Measure the height of the torsion bar above ground. 17) Securely tighten the torsion bar lock bolts. 18) Install the lower end of the shock abosrber to the trailing arm. 19) Plug the hole in the center of the crossmember.

NOTE: Apply a coat of cemedine to the plug before installing. 20) Apply a coat of cemedine to the end of the trailing arm, and then install the plug.

NOTE: Recommended sealant: Cemedine 1115 Cemedine 540 or the equivalent 21) Tighten bolts and nuts to the specified torque settings.

Torsion bar lock bolt

3.0- 4.4 kg-m (22 - 32 ft-lb)

Trailing arm stop bolt

1.1 - 2.6 kg-m ( 8 - 19 ft-lb)

Shock absorber attaching nut

1.8 - 2.6 kg-m (13 - 19 ft-lb)

Wheel nut

3.6 - 5.4 kg-m (26 - 39 ft-lb)

2.

Rear posture adjustment

1) Park the vehicle on a flat surface, and adjust the front and rear tires to the specified pressure. 2) Measure height "H" of the torsion bar at its end t o determine difference "a" from the standard value. a = 285 - H Where a: Amount to be adjusted 285: Standard value

12-9.

1.

A D J U S T M E N T OF W H E E L ALIGNMENT Front wheel alignment

Camber and caster need not be adjusrcu. Toe-in alone is adjustable. Check the condition of the following items. If necessary, adjust or replace parts, then adjust toe-in. a) Height above ground b) Tire pressure c) Play at tie rod end ball joint d) Trailing arm-to-crossmember play e) Wheel play due to wear of kingpin bushing or wheel bearing f) Deformed trailing arm 1) Set the steering wheel in the straight-ahead position. 2) Loosen the lock nut on each side of the tie rod turn-buckle.

NOTE: The turning direction is quite different for each of the two lock nuts. Fig. 12-64 Measuring vehicle height

3) T o adjust the rear height above ground, turn the center arm adjusting bolt as required. One clockwise turn of the adjusting bolt increases the height above ground by 4.5 mm.

Fig. 12-66 Loosening lock nut

3) Adjust the length of the tie rod by turning the turnbuckle. Lengthening the tie rod increase toe-in, and vice versa.

Fig. 12-65 Vehicle height adjusting bolt

NOTE: Turn the turnbuckle equally on each side until the steering angle of the left and rear wheels are within the specifications.

:eering Outer wheel: 33.5' f 2"

1 1

1 2

Lock nut

Turn buckle

T12-035

Fig. 12-67

4) Measure toe-in or side slip to see if it is within the specifications. Then tighten the turnbuckle lock nuts in the following sequence: a. Tighten tie rod end nut and turnbuckle. b. With the tie rod push all the way backward, tighten the tie rod nut and turnbuckle.

NOTE: a. Use two wrenches when tightening the lock nut. Failure to do so can cause the tie rod to be dislocated from its end. b. Holding the turnbuckle with a wrench, tighten the nut and then lock. Torque

8 - 8.5 kg-m (58 - 6 1 ft-lb)

1 Tie rod 2

3 4 5

6 7

,

Turn buckle (19 mm in width across flats) Tie rod end Nut (22 mm in width across flats) Holding spanner (do not turn) Tightening spanner Nut (left-hand screw) (22 mm in width across flats)

Fig. 12-68

Fig. 12-69 Tightening lock nut

T1

c. After tightening the lock nut, move the tie rod to the front and back to see that it moves equally from side to side more than 35 mm (1.38 in).

Fig. 12-70

2.

Rear wheel alignment

Toe-in can be adjusted by changing the number of shims at the inner trailing arm bracket. Check the following items and, if necessary, adjust or replace parts. Then adjust toe-in. a) Tire pressure b) Height above ground (Ground clearance) c) Bearing play d) Deformed trailing arm

4.54 m m (0.179 in)

1.4 = 0.6 + 0.8

6.82 m m (0.269 in)

2.2= 0.6 + 0.8 + 0.8

2) Loosen the two 10 mm bolts securing the inner arm bracket to the crossmember. 3) To adjust toe-in, add or remove shims as required between the inner arm bracket and crossmember.

Fig. 12-71 Toe-in adjusting shim

NOTE: Use the same number of shims on both sides. 4) Tighten the two 10 mm bolts securing the inner arm bracket to the crossmember. Torque

deasure the rear wheel toe-in. To obtain tne specified value, select the necessary number of shims from among those of 0.6 mm, 0.8 mm and 1.2 mm in thickness.

3.5 - 4.5 kg-m (25 - 3 3 ft-lb)

5) Again measure toein or side slip to see if it is within the specifications.

12-10.

TROUBLESHOOTING

A. Unstable running

1

When the vehicle is driven along a flat surface at a constant speed and the hands are released from the steering wheel, it pulls to one side. The vehicle wanders immediately after a lane change, even though the steering wheel is held in the straight-ahead position. Remedy

Probable cause (1) Improper tire pressure.

Inflate properly.

(2) Wheels out of alignment.

Align.

(3) Brake dragging or not properly adjusted. (4) Trailing arm not properly installed (substantial difference in reaction between left and right arms).

Adjust.

(5) Broken torsion bar.

Replace.

(6) Wheel bearing worn or not properly adjusted.

Adjust or replace.

(7) Play or wear in steering system parts.

Adjust or replace.

(8) Front trailing arm bearing or crossmember sleeve worn.

Replace.

Reinstall.

(9) Loose wheel nuts. (10) Deformed tie rod or trailing arm.

Tighten.

(1 1) Play in tie rod end ball joint.

Replace.

(12) Worn kingpin bushing.

Replace.

(13) Loose trailing arm or steering system installing bolts.

Tighten.

(14) Improper tire (wrong brand).

Replace.

(15) Fatigued or deformed rear suspension outer bushing.

Replace.

Replace.

B. Incorrect vehicle posture or ground clearance

Remedy

Probable cause (1) Fatigued or broken torsion bar.

Replace.

(2) Shock absorber not functioning properly. (3) Trailing arm not properly installed.

Replace.

(4) Deformed trailing arm.

Replace.

Reinstall.

C. Hard or rough ride

Large shocks is transmitted to the seat from the wheels.

- ;hocks do not dampen out quickly after the wheels have run over obstacles. -arge shocks are felt when wheels run over concave spots. Remedy

Probable cause

(1) Broken torsion bar.

Replace.

(2) Helper is excessively deformed or has dropped off.

Replace.

(3) Tires excessively inflated.

Reduce to specified pressure.

(4) Improper ground clearance.

Adjust.

(5) Shock absorber not functioning properly.

Replace.

(6) Damaged or deformed shock absorber rubber bushing.

Replace.

(7) Incorrect shock absorber travel strokes. (8) Rear suspension outer bushing is deformed or

Replace.

I

Replace.

has dropped off.

. Rear (Drive) wheels run idle Remedy

Probable cause (1) Incorrect ground clearance.

Adjust.

(2) Insufficient shock absorber extension.

Replace.

(3) Broken torsion bar.

Replace.

(4) Insufficient swing angle of double offset joint (D.O.J.).

Correct engine installation or replace.

(5) Excessively deformed trailing a m

Replace.

E. Unusual noise

Probable cause

Lemedy

(1) Worn or damaged shock absorber parts.

Replace.

(2) Deformed or damaged shock absorber bushing.

Replace.

(3) Worn wheel bearing.

Replace.

(4) Worn double offset joint.

Replace.

(5) Worn brake drum splines.

Replace.

(6) Front trailing arm not properly installed. (7) Worn front trailing arm bearing or crossmember sleeve.

Reinstall.

(8) Front trailing lubricated.

Lubricate.

arm

bearing

insufficiently

(9) Play or wear in tie rod end ball joint.

Replace.

Replace.

(10) Loose rear suspension outer bushing lock

Tighten.

(1 1) Deformed or dislocated rear suspensicjn arm bushing.

Replac

(12) Play in rear suspension inner arm bracket

Replac

(13) Incorrect shock absorber travel strokes.

Replace.

(14) Helper is dislocated or has dropped off.

Correct or install.

(15) Steering angle not properly adjusted. (16) Broken torsion bar.

Adjust. Replace.

CHAPTER

13: WHEELS AND AXLES

Page

13.1

.

FRONT WHEELS AND AXLES

13.2

.

REAR

13.3

.

TIRES

................................................. 13- 2 WHEELS AND AXLES .................................................... 13- 7 AND RIMS ........................................................................ 13-16

13-1. 1.

FRONT WHEELS

r

General description

Backc plate

7

dometer cable

eft side-

1 Knuckle (R.H.) 2 Knuckle (L.H.) 3 0-Rin4 Cowl 5 0-Rin 6 Thrust wasner (dpper) 7 Thrust washer (Lower)

TI 3-001

8 Kingpin 9 Knock pin 10 Shim 'lug pacer 'aper roller bearing .Outer) Taper roller bearing (Inner)

5 Brake drum compkI te (Front) 6 Washer -7 Lock w ashnr 18 Cap (R.

19 Cap (L.: 20 Oil seal 71 Axle nu

Fig.13-1 Construction of fiont tvheel and axle assembly 'he tire is installed on a 3.50 D x 10 split type rim which is attached t o the brake drum. The brake drum is provided with two taper roller bearings, which rest on the knuckle spindle. Since these taper roller bearings are used with specified preload, special care should be taken during installation. The knuckle is connected t o the trailing arm by means of a

king pin. The king pin connection is designed as a maintenance-free type, consisting of an upper and lower bushings made of resin, two thrust washers of high wear resistance, and four O-rings and two plugs. The oil seals prevent the entry of foul water and consequent rusting, so that removal and installation are easily perform?.'

1

2.

Brak

1) Removal a. With the wheel on the ground, loosen the 31 .,..Cn n+4 four 10 mrn whetl llUL3 aciaching the rim to the brake drum. I 1 b. Raise the vehicle with a lift or jack and, in either case, assure the safety by locking the . lift or using safety stands. c. Remove the whe~ el nuts arid pull the wheel ! off. 1 d. Remove the three 3 mm screws attaching the cap to the drum and remove the cap. I 1

/

1

I

I

1

1

b. I f the inner bearing remains attached on the spindle when the drum is removed, install Special Tool (BEARING REMOVER: 922120000) as shown in Fig. 13-3 and remove the bearing by turning the handle. 2) Disassembly (bearings and oil seal) a. Tap the inner bearing outer race out of the drum by using a brass rod etc. Remove the oil seal at this time. (Fig. 13-4) b. Tap the outer bearing outer race out of the drum by using a brass rod etc. using ci to damage the race.

NOTE: Since the left-side cap is provided with a pin to drive the speedometer cable, be careful not to bend the pin when removing the cap. e. Spread the lock washer and remove the 30 mm (width across flats) nut, lock washer, and washer. f. Remove the drum using care not to drop the outer bearing. (Fig. 13-2)

NOTE: a. I f the drum is difficult to remove by hand because the bearings stick to the knuckle spindle, install Special Tool (ATTACHMENTS: 921420000) to the wheel mounting bolts on the drum using wheel nuts. Then, hook the pawls of a puller to the recesses of the attachments, align the lead screw with the knuckle center hole, and remove the drum by turning the lead screw. In place of the standard tool, Special Tool (BRAKE DRUM PULLER: 921120000) may also be used.

Inner bearing

Special tool BEARING REMOVEU 922120000

-

Fig. 13-3 6

inner bearing from.spindle

iring's .+-..

.+rre

Fig. 13-4 Tapping - out inner bearing A

Removing washer

tinn Inspect,.. Wipe off the grease in the bearing mounting bore in the brake drum. Clean the bearing in cleaning solvent. Inspect the disassembled parts and replace defective parts with new ones.

NOTE: When it is necessary to replace one of the bearings, always replace both the inner and outer bearings as a set. a. Brake drum 1) Check the drum bolts for damage. 2) Check the inner surface of the brake drum for wear and damage. 3) Check the outer races of the bearings for correct installation. b. Check the bearing inner races, retainers and rollers for damage, wear, seizure, rust and correct fitting in the knuckle arm. c. Check the oil seal for damage or deformation, the oil seal lip for wear, and the spacer for damage and wear. d. Check the cap gasket for damage. e. Check the cap for damage and deformation. f. Check the knuckle spindle for damage and deformation. 4) Reassembly (bearings and oil seal) Wipe off foreign matters, dust, etc. on the drum surface with clean cloth. a. Place the drum on a support and install the outer bearing outer race into the drum with Special Tool (INSTALLER: 9221 10000) by tapping it with a hammer. b. Place the drum on a support and install the inner bearing outer race into the drum with Special Tool (INSTALLER: 92 5080000) by tapping it with a hammer.

Fig. 13-6 Packing drum with grease

d. After installing the rollers and inner race of the inner bearing and packing it with grease, press the oil seal, with its lip and inner surface coated with grease, into position. e. Install the outer bearing rollers and inner race packed with grease. 5) Installation a. With the bearings installed in the drum, install the spacer and drum on the knuckle spindle, and tighten them with the 30 mm (width across flats) nut, washer and lock washer.

NOTE: After having fully tightened the nut to seat the parts, back off about 118 to 1/10 turn so that the wheel rotates with the following starting torque. (Fig. 13-7)

Shank 926080000

T 1 3-003

Fig. 13-5 Installing bearings c. Pack the drum with grease as shown in Fig. 13-6. Appropriate amount of grease to be -- packed in the drum and applied on the bearing surface is 35 to 39 g (1.23 to 1.38 oz) .

.

b. Lock the nut by bending the lock washer c. Install the cap with the gasket and three screws. d. Install the wheel, tightening the wheel nuts finger-tight. e. Lower the vehicle to the ground. f. Tighten the wheel nuts to the specification. Wheel nut tightening torque

3.6 - 5.3 kg-m (26 - 39 ft-lb)

1

' I

1 I

1

'

I

.1

Spri

rtg scale

e. Remove the upper plug oi .ing arm yoke. f. Removing the king pin Install the body @ of Special Tool (KING PIN PULLER: 921 141000) on the trailing arm yoke and then install the stopper @ and insert pin @ as shown in Fig. 13-10. Align the lead screw @ with the king pin and turn the screw to remove the king pin.

fl.2 Fig.

tsuring sta rting torq

after deAdjust the brak e shoe cl pressing the brak e pedal 2 to 3 timerb.

Knuckle (Kinn

,

in)

1) kemoval and dlisassembl: .-ururrl In : a. Remove the brake accordarlce W ~ L I I 3. 1). b. Unscrew the four 8 mm bolts attaching the back plate to the knuckle and remove the back plate.

Fig. 13-9 Removing pin at knuckle

ipecial tool LA..

Fig.

.,.,.,a.

emoving k!ingpin

Fig. 13-8 Removing back plat,

c. Remove the trailing arm iln accordaince with 12-1 in Chapter 12. .* . ,- .. d. Remove the pin at the center or tne KnucKle by tap.ping it fr om the sipindle side. (Fig. 13-9) 3

OTE: r - *,.~. ~ ror rne removal ana lnsTallarlon or rhe king pin bushing on the trailing arm, refer to Chapter 12.

2)

e. Apply a thin coat of grease on the king pin surface. f. Tap the king pin into the upper yoke bushing from the top of the yoke. g. Hold the parts assembled in .a. under the upper yoke and press the king pin down until its lower end becomes flush with the thrust washer as shown in Fig. 13-13. h. Place the knuckle fitted with O-rings between the thrust washer and lower yoke and align the king pin with the king pin hole in the knuckle while pressing the king pin down by hand to the position shown in Fig. 13-14.

Reassembly

NOTE: Be sure to keep the parts free from dust during this job. a. Put the cover, upper and lower thrust washers and O-ring together as shown in Fig. 13-11, with sufficient grease applied between the upper and lower thrust washers and on the O-ring. b. Coat the bushing inside surface with grease and also fill the oil groove in the bushing with grease. c. Coat the king pin hole in the knuckle with grease.

NOTE: Be sure to press the king pin by hand when aligning. Driving the king pin with a hammer will break the O-ring on the yoke if the king pin and the hole in the knuckle are not lined UP.

Cover

O-ring Thrust washer(Upper)

hrust washer(Lower) T 13-006 B part

01 the tralllng arm.

Fig. 13-1 1 Assembling cover, thrust washer and O-ring

d. Apply grease on the O-rings, and install them on the upper and lower yokes and both ends of the king pin hole in the knuckle.

Fig. 13-1 3 Tapping king pin into upper bushing

King p ~ n

0-rmng

3 Thrust washer (Upper) 4 Thrust washer (Lower) 7

Oil groove

KWXIB

T I 3-009

T13-007

Fig. 13-1 2 Assembled components

Fig. 13-14 Aligning king pin with knuckle 13 - 6

1

j

1

i. Direct tl the king pin so that it will fit on t l l ~I\IIU~.I\ pin, and tap the king pin with a plastic hammer down to a position slightly above the O-ring installed at the bottom of the knuckle as shown in Fig. 13-15. NOTE: Be sure to stop the king pin above the O-ring, otherwise the protruded O-ring might hinder the installation of shims or the O-ring might be cut by the shim when it is ircal+nd

I IM wtawaypl Ih l h l n ~PHI lo 11a kmck pm h& of' 1M k w k l e .

MICxl

Yoke

pdrl

Apply sealant to the knock pin and drive it into the knuckle. NOTE: Always use a new knock pin for reassembly.

1. After applying grease on the top and bottom of the king pin, install plugs on both the ends. Hit the center of the plug to spread it and stake the yoke at three points around the plug to secure it. 111. Apply sealant on the circumference of each plug to perfectly seal the gaps. NOTE: Before applying sealant, wiple grease, c~il,etc. away with clean cloth.

01 thl Ira11

T13-010 I

1

Fig. 13-15 Tapping kingpin into knuckle

1

j. Install proper shims between the knuckle and lower yoke so that the knuckle end play and rotatine resistance are as svecified below. Knuckle erlu pray

Knuckle rotating resistan

Adjusting shims (Thickness)

3 - 0.004 pprox. 2.5 - 3.7 kg-m

0.2 mm (0.008 in) 0.25 mm (0.010 in) 0.35 mm (0.014 in)

13-2. 1.

REAR WHEELS AND AXLES

General description

The engine output is transmitted t o the rear wheels through the axle shafts. The inner end nf .,.the axle shaft is connected through splines to t hf : differential side gear on the engine side, and t hf : spline connection is locked with a spring pir - 1. The outer end of the axle shaft is supported by two ball bearings housed inside the hub and connected through serrations to the brake drum, which transmit the driving power t o the wheel. The brake drum, ball bearing, spiacer and center piece are tightened at the sarne time by a castle nut. The center piece tkes it easiier to remove and install the! brake Im.

. . . ,. . . ,

1 2 3 4 5

Wheel ma Brake drum complete Axle shaft Outer race Spring pin 6 Hub 7 Spacer 8 Ball bearing

9 10 11 12 "

Ball bear'-Oil seal Oil seal ( Ball Cage Spring washer Nut Center piece (Axle)

Fig. 13-1 6

Brake drum

c. d.

e. f.

Removal d o s e n the four 10 mm wneel nuts attaching the rim to the brake drum. Raise the vehicle with a lift or jack and, in either case, support the vehicle by the rigid rack or lock the lift for safety. Remove the wheel nuts and pull the wheel off. Unscrew the two 10 mm bolts retaining the diagonal member and the eleven 6 mm bolts retaining the under cover and remove the diagonal member and under cover. Remove the center cap with the three attaching screws. Pull the cotter pin and remove the castlr:IIUL ---' (27 mrn in width across flats) on the axle

17 Castle nut 18 Cotter pix 19 Circlip 2 0 Snap ring

,.--

ar wheel cmd axle a. ,rt S ~ ~ L L .

g. Make the shcDe clearan ces larger. h. Put a flat b lade sere!vdriver against the slot .- piece . - of the center and tap the screwdr iver with a hammer to remove the center piece.

Fig. 13-17 Remo ving centt?rpiece

'ull the d rIm ~ off tlle axle shaft. If it is lifficult to remove me drum by hand, install ;pecial Tool (ATTACHMENT: 92 1420000) In the drum by utilizing the wheel nuts and lull the drum with a puller as shown in Fig;. 13-18. . l ~

NOTE In place of the standard puller, Special Tool 3AKE DRUM PULLER: 921120000) y also be used. (Fig. 13-19)

Torque (Castle nut)

NOTE: Tighten the castle nut to the above torque first and retighten further until a slot of the castle nut is aligned to the hole in the axle shaft. c. Lock the castle nut with a new cotter pin. d. Install the under cover and wheel.

3.

.

:ial tool: A TTACHMENT a21 420000 Conver puller

16.0 kg-m (1 16 ft-lb)

H u b a n d a x l e shaft assembly

1) Removal a. Remove the brake drumin accordance with 2. 1). b. Disconnect the axle shaft assembly from the engine by driving out the spring pin with a 4.8 mm (0.19 in) diameter bar. c. Remove the parking brake return spring and the cotter pin and disconnect the ,parking brak ' ~ '

Fig. 13-1 8 Remov ing brake drum

Fig. 13-20 Disconnecting parking brake cab.le

xle a. Before installing the brake drum to me a.--

d. Remove the bleeder screw and remove the brake pipe joint nut from the wheel cylinde~ e. Remove the back platc:by unsc rewing the four 8 mm attaching bolIts. - UUILS a~tachingthe f. Unscrew the four 12 mlrl hub to the trailing arm. g. Remove the axle shaft assembly together with the hub.

shaft, coat the splined portion of the shaft with grease to prevent corrosion. b. Install the brake drum, center piece and casltle nut an1d tighten 1the nut.

NOTE: Be careful not to damage the inner and outer boots.

Fig. 13-1 9 Remov ing brake drum

L->A-

2)

Installation

..A

2) Disassembly UII i a. Place the hub auu L I N G shaft asse111~1~ press and pres:s the shaft down c hub a;s shown ir1 Fig. 13-21. NOTE: Do not use a hammer siince the threads ar the shaft end may be cru:shed. b. To re mvoe the bearing (hub, inner) from the axle E;haft, pull the bearing with a puller by . ' .~~ -. inserring m e pawls between the bearing and oil seal. A,-.

Fig. 1 3

3) a.

'

oving bealring (hub, outer)

Inspection !: Check the disassembled ps~ r t sas follOWS. i Bearing Wash the bearing in a cleaning solvent an check the inner and outer races for crackin and other damage, - . and alsb check if the/ t outer race rota1tes smoot hly withc~ u noir when t he inner r ace is sup.ported. Spacer Wash Ithe space r in a clc:aning solvent andI check jFor damage and defc~rmation. i Hub Wipe the inside surtace with clean cloth and? check lFor crackiing and other damage. ! Reassembly Apply 9 g (0.33 oz) of grease to the innerll bearing and position the bearing in the hub With the 30 mm (1.2 in) diameter end o Special Tool (HUB BEARING INSTALLER: 921350000) inserted in the inner race of thei bearing, press the bearing into the hub.

4

;"i

b.

Fig. 13-21 Removing axle shaft from hub

NOTE: Do not reuse the oil seal. A damaged or worn oil seal will allow the entry of mud and water into the hub, and shorten the life o. the bearing.

c.

4) a.

I I

i

Special tool: HUB BEARING INSTALLER 921350000

j

I

I

bearing #6206-C4 ,

j

I

I

Fig. I .

!

roving bearing (hub, inner)

move the bearing (hub, outer) from thf . . rn a 3" mm (0.2 in) diameter drift an6 nuD, Ilse press ras shown iin Figure 13-23.

-

-

-

Fig

uner bec

~

b. Coat the oil !real with : I position I, n : in the hub. With t t [II (1 .L I ameter end of Special Tool (HUB BEARTG INSTALLER: 921350000) inserted to the oil seal, press the oil seal against the ring. -

--

e. Appl:y a coat of grease to the oil seal to b *.a . siae. . - Press th instahea on me outer bearing oil sea1 into th~ e hub using a 65 mm (2.56 in diamc:ter bar or block as shown in Fig 13-27 ~

~

'4

'.

Special tool: HUB BEARING INST.

-

Cross section of oil seal T13-016

Cross section of oil seal T13-018

Fig. 13-25 Installing oil seal

1

!

I

Fig. 13-27 Installing oil seal

NOTE: Press the oil seal fully1 until it bottoms. I f clearance exists at A, it will causc5 the oil seal lip to wear.

NOTE: UsingI more grcuse than specified may resul l'...l,.. *I. ..a... I. IIUIII L I I ~ U U L ~ I~earing intlr the brake drum, causing brake failure.

8 g (0.51 c. Invert the hul and app 0.65 oz) of grease to tne insiae surface the hub. d. Install the sp:acer in thc:hub. Ap . " (0.18 to -0.21 oz) ol grease to the out-, bearing and position it over the bearing hole. With the 25 mm (1.0 in) diameter end of Special Tool (HUB BEARING INSTALLER: 92 1350000) inserted ilnto the irlner race of the bearing, press the bearing in[to the hub.

." "". .....'. "..c"-yleaaaa leanaye III

I f. Installing the axle shaft into hub Prepare Special Tool (HUB INSTALLEI and the lead screv CAP: 922320000) @ and handle @ of Special Tool (HUI INSTALLER: 92 1360000). Insert the ax11 shaft into the hub by hand as far as possibl~ and secure the shaft in a vise. Install the leac screw @ onto the axle shaft end, and instal the cap 0 and handle @ as shown h Fig. 13-28 so that the cap @ presses th bearing and no load is applied to the oil seal Pull the axle shaft until it stops by turnin! the handle while holding the lead screw wit1 a wrench. 5) Installation Install the hub and axle snart assembly i~ the revel:se order c)f the removal.

0,

Special tool: HUB BEARING INSTALLER 921350000

Ball bearing #6305-C4

T13-017

Fig. I .

1 "

ter bearing 13 - 11

NOTE: a. When connecting the axle shaft t o the engine 1) Ins1tall each alxle shaft on the calrrect side as rne lengths of tlhe right-tland and The le shafts are d i f f erent. ~ left ?d w i t h a ule shaft rigt *LA

I---.

Special

-. groove f o r idelntificatiorI. (Fig.

13-29)

2) Be careful n o t t o damage the boot,

3) Use a new spring pin. b. The t w o upper bolts attaching the back plate are alse used t o secure the parking brake bracket

Axle shaft

tool 921360000

Special too1.922320000 Hub installer cap

Fig. I

D

shaft int o hub

:he axle slhaft. This D.O.J. axle shaft transmits lower wit hout fluctuation in rotational speed. Curthermore, since the balls inside the D.O.J. make a smooth rolling motion, the sliding resistance is small and there is almost no mechanical loss, 'thus permitting unnoisy opera:ion and compact construction with little unlalancing factor. Since grease is packed in the lealed svacer. the D.O.J. rarely requires ereas-

Fig. 13-29 Axle shaft identifica~

2) Disassembly a. Removing the bo ot band 1) Straighten the I---* VCIIL CIIU of the band. 2) Loosen the band by tapping its end. P q up the band with a screwdriver and rpmqve it from the boot with a pair of plier --.l

4.

A x l e s h a f t (D.O.J.)

General description (Fig. 13-31) 1 -?ar C axle is of a floating type using two .J.) at both ends of constant,velocity j c 1)

TLlllG

.W.,'.

1

,

c

Band

//*

ing the c i ~ 1) Remove the ~ U U UL U I ~ Ithe D.O.J. 2) Pry off the round-section circlip installed at the end of the outer race of the D.O.J. with a screwdriver. (Fig. 13-32) c. Removing- the outer race and balls 1) Remove the D.O.J. outer race from the axle shaft assembly. 2) Wipe off the grease, take out the balls and move the cage towards the boot.

Fig. 13-30 Removing boot band

5 Boots (Outer) 6 Clip 7 Clip

D.O.J. ass'y (Inner) D.O.J. ass'y (Outer)

8 Snap ring 9 Cuclip 10 Seal plate

Boots (Inner)

T13-020

I Cross sc

zxle shaft (D.O.J.)!

NOTE a. To remove the cage from the inner race, turn the cage by a half pitch of the ball tracks after removing the balls and pull the cage. b. Exercise care not to lose the balls.

d. Removing the sni%pring an1d inner ral " 1) Remove the suay Illla ietaining tllo race on the s:haft by using specia1 pliers. 2) Pull the inner race off the shaft.

""..

,.."rn

Fig. 13-32 Remov ing circlip

lllllG1

4) a

Reassembling Install the boot on the shaft.

Fig. 13-33 Removing snap nng

e. Take off the cage from the shaft and remove the boot.

NOTE: Be caref ul not to damage t he boot vvith the square-scection circ:lip on the! shaft.

Fig. 13-35.Installing circlip and cag

b. Place the cage on the shaft with its direc .._.. as shown in Figure 13-35. c. Install the inner race on the shaft and lo with the snap ring using special pliers.

NOTE: Make sure that the snap ring is complc inserted in the shaft groove.

Fig. 13-34 1:

ed D.O. J.

Inspection Clean all the parts and check for defects as ,110~s.Repair or replace as necessary.

2)

D.O.J. Check for seizure, corrosion, wear, e:vcessive play and other damage. u. Shaft Check for excessive bending, twisting, wear and other damage. c. Boots Check for wear, warping an(i breakage.

d. Install the cage on the inner race by aligning the protrusion of the cage with the track in the inner race. Then turn the cage by a -ha1t pitch to line up the holes in the cage with the inner race tracks.

NOTE: Apply grease to the cage holes. Use molybdenum-base grease for the D.O.J.

Grease

grease (Molytex No. : or equivalent)

I

Fig. 13-36 Installing cage on inner race

: e. Insert the six b:~ l l sinto tl

3les. (Fig.

.13-37)

Ball

Fig. 13-38 Applyinggrease t o outer' race

g. Install the outer race on the assembly of the inner race, cage and ball assembly. h. Install the circlip in the groove in the outer race.

all

I

Outer Fig. 13-3 7 Installing balls

f. Apply grease in me outer race as lnaicarea In Fig. 13-38.

: velocity:joint

loly tex NI0.2 dent)

Ci

Fig. 13-39 Installing outer race

IOTE: . Make sure that the balls, cage and inner race are completely housed within the interior of the outer race. . Do not position the ends of the circlip in the track in the outer race. . Lightly pull the axle shaft to check that the circlip is securely installed in the groc

i. Pack the inside of the D.O.J. with grease. Constant velocity joint grease (Molytex No. 2 or equivalent)

Grease

Inner D.O.J.

NOTE: When tightening the boot, exercise cart!that the air remaining in the boot is nt!ither excessive nor insufficient. 3) Further tighten the band by using Special Tool (BAND TIGHTENER: 925090000) until the band cannot be moved with fingers. 4) Lightly strike the band with the punch provided at the end of the tool.

50 g (1.8 oz)

Amount Outer D.O.J. . 100 g (3.5 oz)

. Installthe boot on the D.O.J. NOTE: Clean the boot groove in the shaft and outer race so that they are free from grease and other substance. k. Installing the boot bands 1) Wind the band twice around the boot groove, passing the band through the clip.

NOTE: Be sure to strike lightly so as not to damage the boot. 5) Cut off the surplus part of the band, ' leaving about 10 mm (0.4 in) after the clip t o bend it over the clip.

13-3. 1.

NOTE: Use a new band.

TIRES AND RIMS

Specifications

See the table for the tire and rim specifications.

2.

Wheel -(tire and rim)

1) Removal a. Apply the parking brake and loosen t he four wheel nuts. b. Jack up the vehicle.

~ e c ~ tool al n d t~ghtener

- 15090000

Fig. 23-40 Installing boot band 2) Tighten the band by pulling the end of the band with pliers while holding the clip.

OTE: Be sure to place the jack straight. The vehicle is provided with four jacking points, , one near each wheel. c. Remove the wheel nuts and washers, a n d , take off the wheel. 2) Installation Install the wheel in the reverse order of t h e r removal.

Tire and Rim Specifications 1

size

iOD x 10

Tire size

,I

5.00-10-6PR U1

Valve

TR244A

-3 Light Load Full Load

Tire inflation pressure kg/cm2 (psi

I7A\

ight Load 'ull Load

2.7 (38)

I

Tire width

$6(5.4) with inflation pressure of 2.4 k

Tire outer diameter

3.

,

n)

Approx. 518 (20.4) with inflation pressure of 2.4 kg/cm2(34.1 psi)

Inner tube

1)

Removal nnflate the tire. Since the rim is of the two piece type, the tube caln be taken out by r e m oring ~ the falur rim connecting bolts and .-.- h-l-.seDar:lting the twu 11a1vcs of the rim. It is unnecessary to remove the tire from the rim. 2) Installation a. Check the interlor surrace orF me tire and repair if necessary. Remove any foreig matter from the surface. b. Before installing the tube, tighten the tub valve! and inflate the tube. Check the tub and valve thoroughly for leaks by puttin the t ube in water. l^"^. L. 111~cit the tube through the rim gap U I L U LL LI tire and align the valve with the valve ho11 d. Inflate the tube sufficiently so that it wi not be caught between the two rim halvt when reassembling the rim. e. Match the two rim halves and join the1 together with the bolts, spring - washers anu nuts. Be sure to insert: the bolt s from the Y C I

I I

. - ! .

-

a

E

4.1 psi)

,I

outer rim half. Also use care that the drum bolt holes in the rim halves are correctly aligned. This will make the brake drum installation easier. prc:sure and f. Inflatc:the tire to the s pecified ~ attachI the valve cap.

4.

Tire

,.

To remove the tire from the rim, rc:move the . . four rim connecting bolts and separate me rim halves. If it is difficult to remove the tire, insert a large screwdriver between the rim and tire and pry - - the tire off the rim. Repeat this operation be easily around the rim and the removed.

:-A-

5.

Tire damage and possible causes

Damage due to flex, fatigue and heat The side walls of the tire flex as the tire rotates. If the tire pressure is insufficient or the vehicle is excessively loaded, the side wall flexinn will become abnormally large, leading to separatio n of the cords from the rubber and 1)

-

ultimately to cord breakage. If the vehicle is driven with a flat tire, the cords in the flat tire will break almost instantly. 2) Damage due to shock When the vehicle runs over a bump on the road at high speed, the shock may cause the cords between the beads to break. Thls is called "shock burst" and the tire will break with a straight cut or cross cut. Dislodgement of the tire will not occur in this case. This trouble is usually caused by a overinflated tire, overloading of the vehicle, or hazardously high speed operation. 3) Damage caused by the rim edge If the tire inflation pressure is insufficient, the side walls may be pinched between the rim and road surface especially when the tire passes over a bum^. This pinching will sometimes C;ause the Iside walls to break . Overloacling and

speeding a n: contribt~tingfactors to such damages. The Gqnmnnn a l r l a ~ r ; dill also occur when the vehicle is driven with a flat tire. 4) Exterior damages and punctures These damages may be caused whc:n the vehicle runs over pieces of broken glasses or nails. The damages can be easily repaired, but if they are left unrepaired, dirt and water may enter and the damages will become more serious. Always repair exterior damage and puncture as soon as possible. 5) Tire wear Normal wear and tear on tires are unavoidable, but every care must be taken to prevent abnormally accelerated wear development. The major causes are improper tire inflation pressure and incorrect wheel alignment or defective suspensions.

..

CHAPTER

14: BRAKE SYSTEM

Page

. 14-2 . 14-3 .

14-1

1

4.

14-5

.

GENERAL DESCRIPTION

..........................................

..................................................... MASTER CY LINDER ................................................................... 14-11 BRAKE FLUID LEVEL WARNING SYSTEM ....................... ..... 14-14 PARK1NG BR.AKE S'r'STEM .......................................................... 14BRAKE ASSEMBLY

14-1.

1.

GENERAL DESCRIPTION

service brake system into the front-wheel brake system and rear-wheel brake system. This ensures safety, coupled with the automatic adjuster of the front brakes. The front brakes are of two leading shoe type and the rear brakes are of leading and trailing shoe type. The parking brake system is operated mechanically, applying the braking force to the rear wheels.

Outline

The brake system consists of a service brake system and parking brake system. The service brake system employs dual hydraulic circuit with a tandem master cylinder, splitting the

2.

Specifications Service brakes Parking brakc

Item

Type

Brake drum material Brake drum inside diameter Brake lining material Lining dimensions (Width x thickness x length) Lining surface area (One piece of lining) Wheel cylinder inside diameter

Front brakes

Rear brakes

Hydraulic, internal expansion, two leading shoe type, foot-operated

Hydraulic, internal expansion, leading and trailing shoe type, foot-operated

Cast iron

Cast iron

180 mm (7.09 in)

170 mm (6.69 in)

Molded resin

Molded resin

35 x 5 x 173 mm (1.4 x 0.20.x 6.8 in)

3 0 ~ 4 . 4 181 ~ mm (1.2 x 0.17 x 7.1 in)

3 0 ~ 4 . 181 4 ~ (1.2 x 0.17 x 7.-

in2)

54.0 cm2 (8.37 in2)

54.0 cm2 (8.37 in2)

60 cm"9.30 23.8 mm (0.94 in)

19.0 mm (0.75 in)

Mechanical, internal expansion, leading and trailing shoe type, handoperated Cast iron 170 mm (6.69

Molded resi

.--,

3.

Brake piping components

'1

DETAIL '

.

4

\

DETAIL " B *

l 2 6 S . I

DETAI,L " c *

1 2 3 4

Brake pipe (Master cylinder - 2-way) Brake pipe (Master c) .way) Brake hose Brake pipe 5 Brake pipe 6 Tube 7 Brake pipe 8 Brake pipe 9 Brake pipe 10 Brake host

11 Bra:ke pipe .- - . . 12 Brake plpe 13 Connector (2-\: 14 Connector (3-1 15 Bolt 16 Grommet 17 Flange nut 18 Hose (Primary 19 Hose (Seconda I (Hose)

21 Clip 22 Master cylinaer 23 Clamp (Brake h 24 Tapping screw 25 Holder (Reservl 26 ScreW 27 Cap (Fluid leve 28 Tan1k (Reservoi 29 Bolt 30 Spring washer Tlr

14-2.

1.

BRAKE ASSEMBLY Front brake assembly 5

4

13

V

14

1 2 3 4 5 6 7

Shoe hold down pin Spring washer

8 9

Nut Tube Nut Spring washer Back plate (F. RH)

10

11 12

Back plate (F. LH) Wheel cylinder (F. UPPER. RH) Wheel cylinder (F. UPPER. LH) Return spring Brake shoe ass'y (RHJ

13 14

IS 16 17

Brake shoe ass'y (LH) Spring seat Shoe hold down spring Whet:I cylinder (F.L.OWER. RH) Whetcl cylinder (F.L.OWER. L H ) ~14-002

Fig. 14-2 Exploded view of front brake assembly

1) Disassembly a. Raise the front of the vehicle and install safety stands. b. Remove the center cap. c. Spread the lock washer and unscrew the spindle nut. Remove the spindle nut, lock washer, and washer. d. Remove the plug from the brake drum. Using a screwdriver, force the shoes in the directions of the arrows shown in Figure 14-5 to make the shoe clearances wider. e. Pull the drum and wheel off the knuckle spindle.

Fig. 14-r

moving center cap

g. Remove the shoe return springs from the wheel cylinders. . Remove the brake shoes with the au adjusters installed on them.

NOTE: To make the work easier, remove both the primary and secondary shoes from the wheel cylinder adjuster wheel sides first and then from the wheel cylinder piston sides.

Fig. 14-4 Spreading lock washer NOTE: When removing the brake drum, be careful that the wheel bearing will not fall off.

i. Remove the shoe return springs from the primary and secondary shoes.

NOTE: Do not disassemble. the automatic adjuster because its nut is ! -

)

Fig. 14-5 Removing plug 1.

r\c;llluvG

,+ I.,,,.I" LllG

set sprinr-

.

inside diameter

-5

Fig;14-6 Removing b#rakepart!

Inspection, repa.uand adjustment Measure the lining wear. lr', the thickness of the lining is less than 1.7 mm (0.07 in), replace the shoe assemblies. Always replace the primary and secondary shoes on both sides of the vehicle at the same time. Replace the shoe return springs if they are weak. Replace the back plate if warp or wear is evident. In case the inside surface of the brake drum is scored, correct with No. 60 sandpaper. Also correct or replace the brake drum if irregular wear or tapered scoring is evident, or if the drum exterior is damaged.

Limit

7 in)

Assembly Apply a small amount of brake grease to the sliding surfaces between the back plate and brake shoes, and contact points between the brake shoes and wheel cylinders. Install the shoe springs on both primary and secondary shoes, and install them onto the wheel cylinder en(is.

..OTE: Be sure to install shown in Fig. 14-1

return springs as

C. Install the shoe set pins. d. Install the brake drum onto the knuckle spindle after wiping off the oil on the brake lining surface and brake drum inside surface.

approximatley 0.3 mm (0.012 in). Therefore, pedal travel will not change even the linings wear out.

-

/

, 5 5 /

Upper side Return spring . -

Drum sliding surface

,

Shoe r spring

, ,

Brake shoe

t-

Automatic adjuster

Lower side

1 2 3 4

Shoe web Back plate Adjusting block Adjusting bolt

5 6 7

Friction plate Friction spring Nut

T 14-OC

Fig. 14-7 Installing shoe return spring

e. Install the washer; lock washer, and nut on the spindle and adjust the preload for the bearings. (See Chapter 13.) f. Test drive the vehicle at about 10 km/h (6 mph) and apply the brakes forcefully two or three times. Check the pedal travel and make sure that there is no abnormality in braking operation. 4)

Automatic adjuster

Fig. 14-8 Location of automatic adjuster

The front brakes are equipped with the automatic adjuster that automatically keeps the clearance between the brake shoe and drum at

Fig. 14-9 Cross section of automatic adjuster

When the clearance between the brake shoe and brake drum is more than the designed clearance S, namely when the clearance is S + AS, automatic clearance adjusting action takes place as follows. As the brakes are applied, the brake shoes, which have been stopped by A of the adjusting block, are forced toward the brake drum and at the same time the adjuster bolts (4) installed on the shoe webs move away from A and contact B, travelling the distance S. As the pistons further force the shoes outward overcoming the frictional resistance produced by the friction springs (6), sliding occurs between the shoe web (1) and the friction plate (5) to compensate the surplus clearance A S and eventually the shoes contact and press the brake drum. When the brakes are released the shoes move off the drum and are returned inwards by the return springs until the adjuster bolts (4) are stopped by A. The shoes do not move inward more than that since the frictional resistance of the friction spring is set greater than the pulling force of the return spring, thus maintaining the shoe clearance S. 5) Front wheel cylinder The front wheel cylinder components are shown in Fig. 14-10.

a. Reassembly 1) Thoroughly clean the wheel cylinder body and install the bleeder screw, with a rubber cap on it, into the cylinder body. 2) Wash the piston and cup in alcohol, carefully wipe them with clean cloth and soak them in clean brake fluid. 3) Install the cup into the piston, being careful about the cup direction. If the cup is damaged or deformed, replace it with a new one. 4) Insert the piston into the wheel cylinder. Be careful not to damage the lip of the cup. 5) Install the rubber boot on the cylinder body.

2.

Rear brake assembly

The components of the rear brake assembly are shown in Fig. 14-11. 1) Disassembly a. Raise the rear of the vehicle and place it on the stands. b. Remove the wheel and brake drum as described in 13-2, Chapter 13. c. Release the parking brake and loosen the cable adjusting nut at the rear end of the parking brake rod. Remove the cable return spring from the lever.

b. Torque specifications Wheel cylinder to back plate (Nut)

8 mm

1.3 - 2.0 kg-m (9 - 14 ft-lhl

6

0.6 - 1.1 kg-m ( 4 - 8 j R-lb)

-

Back plate to knuckle (Nut)

1.2 - 2.4 kg-m (9 - 17 ft-lb)

1 Boot 2 Piston 3 Cup

4 Cup spacer 5 Return spring 6 Wheel cylinder body

Fig. 14-1 0 Components of fiont wheel cylinder

I

..

REAR

(1) (2) (3) (4)

Boot Nut Spring washer Adapter ( 5 ) Cap ") Wheel cylinder assembly ) Brake shoe complete

(8) Spring (9) Lever complete (10) Anchor block assembly (11) Back plate comple:te (12) Pin (13) Seat (14) Spring

TI 4-005

I

Fig. 14-1 I Exploded view of rear brake assemuby d. Remove the shoe set springs. e. Return the brake shoe adjuster wheel of the anchor block so as to make the spring tension smaller.

Shoe set spring

\

Adjuster

Fig. 14-1 2 Removing brake parts

f. Remove the brake shoes from the anchor block first, and then from the wheel cylinder.

Remove the shoe return springs from the brake shoes. 2) Inspection, correction and replacement a. Check the linings for wear. When the lining thickness is less than 1.7 mm (0.07 in) replace the brake shoe. Always replace the leading and trailing shoes on both sides of the vehicle together with the shoe return springs at the same time. Allowable lining thickness

1.7 mm (0.07 in)

I

I'

b. Replace the shoe return springs if the tension is insufficient. c. Replace the back plate, brake shoes, and lever if deformed or worn. d. Replace the lever if excessively worn. e. Correct the inside surface of the brake drum with No. 60 sandpaper if scoring is evident. Also correct or replace the brake drum if irregular wear, tapered scoring, or external damage is found.

d. Install the brake shoes together with the return springs, by first installing the upper ends of the trailing shoe and leading shoe in this order to the wheel cylinder and then the lower ends of the trailing shoe and leading shoe in this order to the anchor block. e. Install the shoe set springs. f. Check the brake drum for abnormality and carefully install it over the brake assembly. Refer to 13-2, Chapter 13 for the installing procedure.

inside

f. Replace the boot (aust seal) and aaapter if defective. 3) Assembly a. Install the lever to the back plate. Check to see if the lever is installed on the correct side, as the left-hand and right-hand levers are different in shape. If installed on the wrong side, the lever will contact the wheel cylinder and spring and may cause damage.

NOTE: a. Be careful that nothing falls into the brake assembly. b. Do not smear grease on the inside surface of the brake drum. g. Adjust the brake shoe clearance in accordance with "4) Adjustment of shoe clearance". h. Adjust the parking brake cable at the parking brake rod end so that the cable does not pull the lever on the brake assembly. Install the pin, washer, cotter pin and return spring as shown in Fig. 14-15. i. Readjust the parking brake cable in accordance with 14-5. in this Chapter. 4) Adjustment of shoe clearance a. Raise the rear of the vehicle so that the rear wheels turn freely. b. Align the adjustment hole in the brake drum with the adjuster at the anchor block and insert a screwdrivt:r througl1 the adjustment hole to reach the a djuster.

Fig. 1 4-1 3 ~ n talling s lever

b. Assemble the brake shoes and return springs. Pay attention to the directions of the brake shoes and return springs. (Fig. 14-14) c. Apply a thin coat of brake grease to the surfaces of the back plate, wheel cvlinder piston ends and anchor shoe supporters which the brake shoes contact.

7 Hang th, ,,.Y, .,ring from back plate side.

Fig. 14-14 Direction of spring

Fig. 14-15 Connecting parking brake cable 14 - 9

5)

Rear wheel cylinder and anchor block

Piston

I

I

Piston head

Cup

j

Fig. 14-1ti Adjustment hole in brake drum

Cylinder body COMPL

\

\Adjust.,

Block COMPL

Reduce the clearance

Adjustment hole lncresse the clearance

Fig. 1.

rsting sho,

c. Turn the adjusters on both sides in the direction that dec:reases thc:shoe clearances until the wheel c:annot be rotated with one hand. d. Then back off the adjuster by 8 notches. e. After centering the shoes in the .brake drum by depressing the brake pedal 2 or 3 times, turn the wheel to see that it rotates easily and no noticeable noise is made between the shoe and drum. f. Perform the above adjustrrlent for tlle lead. ing and trailing shoes on bol:h rear wh.eels.

NOTE: a. Before starting the brake adjustment, fully release the parking brake. b. Be sure t o back off the adjuster b y 8 notches otherwise the brakes may drag. c. When the wheel is heavy t o turn or noise is distinctly audible the shoe clearance. rn-.';~-.+

Fig. 14-18 Components of rear whe cylinder and anchor bloc,.

Reassembly Rear wheel cylinder 1) Clean the wheel cylinder, attach the rubber cap on the bleeder screw and install the cap into the wheel cylinder. 2) Soak the pistorI and cupI in clean brake fluid. 3) Install the cup tc3 the pistc)n, being ca.reful .. about the cup airection. When inse: the piston into the cylinder, use care to damage the lip of the cup. Anchor block 1) One of the two supporters of the anchor block has right-handed screw threads and the other has left-handed ones. If warpane . or wear is e ~ d e n on t the threads, re1)lace the supporter together with the adju ster. 2) The adjusters are expected to be rot ated lightly with fingers. Replace the adjl if its teeth are excessively deforme worn. 3) Replace the anchor block body if the mounting bolt is defective. 4) Before assembling, clean the inside surface of the anchor block, the outtsiue surface and threaded hole of the adju ster, and the threaded part of the supporter, and apply a generous amount of grea!,,LP tn these I: 3 .

-

L-I

-l

.,

'

14-3. 1.

MASTER CYLI!

2) Operation when secondary (rear wheel) brake line leaks Since there is no pressure rise in the secondary chamber even if the push rod moves, the secondary piston reaches the inner end of the master cylinder. Hc)wever the primaqr piston compresses the fluici in the 1primary chamber, ...- -... -. thus keeping the front Lo-r- lz- -e system operative. Operation when primary (front wheel) ) rake line leaks Since there is no pressure rise in the primary chamber even if the push rod moves, the primary piston comes into contact with the secondary piston and pushes it, thus keeping he rear brake system operativ

Operation

Normal operation When the brake pedal is depressed, the primary and secondary pistons are moved in by the force transmitted from the pedal through the push rod. As soon as the return port is closed by the secondary piston, the hydraulic pressure begins to rise in the secondary chamber, consequently applying pressure to the rear wheel cylinders, and then the pressure in the primary chamber also rises, applying pressure to the front wheel cylinders. 1)

.-.

..-,.,~ -..ter cylinder

7 O-ring

Fig. 14-1' 9 Component parts of master cylinder 14-11

L

1 Secondary inlet 2 Tubeseat 3 Check valve 4 Primary inlet 5 Return port 6 Release port 7 Push rod

-

8 Boot 9 Primary piston 10 11 12 13

Secondary piston Piston stopper Returnport Cylinder T14-0

Cig. 14-20 Sectional view of master cyi

2.

Removal

a. Remove the brake fluid reservoir frclm the

instrument panel by removing the t)racket installing bolt.

NOTE: Be careful that brake fluid does not spill over painted surfaces during removal.

Fig. 14-21

Operation wht~n Primary (fro. t-wheel) E>rakeline leaks

Fig. 14-22? Removiitg brake fluid reservoir

b. Remove the flare nuts connecting the brake pipes to the master cylinder. c. Remove the cotter pin from the brake pedal-to-push rod connecting pin and separate the master cylinder from the brake pedal.

2) When washing the cylinder and inserting the piston, use case not to damage the inside surface of the cylinder and piston cup.

NOTE: Replace the cylinder and the piston if the clearance exceeds the specified limit. Piston-to-cylinder clearance Standard

0.020 - 0.105 mm (0.0008 - 0.0041 in)

Limit

0.15 mm (0.0059 in)

Assembly Fig. 14-23 Re

3.

raster cyli:nder

Disassembly

1) Remove the boot from the cylinder body. 2) Remove the snap ring and stop plate. 3) Remove the primary piston and the return spring. 4) Remove the piston stop and gasket and then remove the secondary piston. !n remove 5) Remove the cap and sez the check valve.

4.

Preparation for reassembly

The inside surface of the master cylinder must be smooth and perfectly round. Replace the master cylinder if irregular wear or defects are evident. Never correct the inside of the master cylinder with sandpaper or other abrasive material. 1) Before assembling, wash the inside surface of the master cylinder with clean brake fluid. Be careful that dust or other foreign matter does not enter the master cylindt:r during assembly.

1) Insert the secondary piston into the cylinder body with the secondary return spring. 2) Insert the primary return spring and then the primary piston into the cylinder body. 3) Install the secondary piston stop with the gasket. 4) Install the stop plate and secure it with the snap ring. 5) Insert the check valve spring into the cylinder block. 6) Install the seat end cap. 7) Install the push rod, with the boot previously installed on the push rod, to the cylinder bm~ ~'

1) Install the master cylinder in the reverse order of the removal. 2) After installing, bleed the brake system ind check the operation of the master cylinder. 3) Torque specifications

Master I 3 chassis rrame on lefthand-drive vehicle Brake pipe flare nut

8.0 - 12.0 kg-m (58 - 87 ft-lb) 1.5 - 2.0 kg-m (1 1 - 14 ft-lb)

14-4.

BRAKE FLUID LEVEL WARNING SYSTEM

the float is also lowered, and when it reaches the prescribed level the reed switch opera4-turn on the indicator light, warning the of dropping of brake fluid level. The indicator light glows when the i g ~ starter switch is turned to ON position a1nd the en the parking brake is applied and goes out wh~ parking brake is released, in order to provide a means of checking the circuit for disconnection and the bulb for burning out. + -

IICIVAI-

2.

Replenishment of brake fluid

If the indicator light glows during operation, immediately replenish the reservoir,with brake fluid to the embossed level line. Fig. 14-24 Components of brake fluid level warning system

NOTE: The brake fluid level drops as the brake lining wear develops as well as when the brake system leaks. When the vehicle jolts along a rough road, the indicator light may flicker because the float moves up and down with the waving fluid surface.

Maximum level line Approx. 21 mm (0.83 in) rning lamp turn on position

1 Reservoir 2 Magnet 3 Holder

4 Brake fluid level 5 Cap 6 Float

14-5.

PARKING BRAKE SYSTEM

1

T14-011

Fig. 14-25 Sectional view of brake fluid reservoir

The components of the parking brake system are shown in Fig. 14-26.

1.

1.

Operation

In normal condition, the float is above the reed switch; the magnetic field from the permanent magnet placed in the float does not permit the reed switch to operate, the indicator light being unlighted. As the brake fluid level drops

Parking brake lever and rod

1) Removal a. Raise the vehicle and loosen the nut at the rear end of the rod. Disconnect the rod f~.om the parking brake lever by removing the clevis pin. b. Remove the two 8 mm lever attaching bolts. c. Separate the rod and cable by removin nuts at the rear end of the rod.

1 !

1

nFTA I I

1 Rod assy (Hand brake) 2 Nut 3 Washer 4 Pipe (Hand brake) 5 Joint (Hand brake) 6 Cable assy (Hand brake) 7 Spring washer 8 Bushing 9 clam^ (Hand brake) 10 Bc)It assy

.

"

n"

II

15 16 17 18 19 20

Hancl braKe lever assy Button (Hand brake lever) Spring (Hand brake lever) Screw (Pan head) Hand brake switch assy Cord assy (Hand brake switch) Bolt (8x18) Spring washer Clevis pin Cotter pin

Fig. 14-26 Components of par 14 - 15

21 22 23 24 25 26 27 28

G~L.,.,,,,, brake) Clamp Bracket (Hand brake RH: Bracket (Hand brake LH) Spring (Hand brake cable) clevis pin Clamp (Hand brake cable) Bolt

I

d. Install the clip on the rod and attach the clip to the bracket on the crossmember. e. Adjust the cable in accordance with "2. Parking brake cable".

2.

;

A

Rod

rrer p ~ n

Fig. 14-27 Removing parking brake lever and rod

Fig. 14-28 Separating rod and cable

Inspection Check the parlung brake lever for operation. Check the ratchet and hook for wear. Check the rod for damage and wear. Check the clip and joint for damage and wear. 3) Installation a. Install the parking brake lever to the bracket on the floor. Torque (Lever attaching bolts)

0.6 - 1.4 kg-m (4 - 10 ft-lb)

b. Connect the rod to the lever. c. Install the joint, with the cable inserted in it, to the rear end of the rod, being careful about the installing order of the nuts, washers and pipe.

Parking brake cable

1) Removal a. Release the parking brake lever fully. Disconnect the cable from the levers or1 the rear brake assemblies. Remove the four cable clamps on the c:Tossmember and hub by unscrewing the 6 mm attaching bolts: Remove the cable from the rod by removing the joint. e. Remove the cable grommets on the ( trailing arms and extract the cable. 2) Inspection a. Check the parking brake cable for operation. b. Check the inner wire of the cable for :rusting and damage. c. Check the outer sheathing of the calble for wear, tear and other damage. d. Check the boots for tear and other d amage. e. Check the clevis pin for wear. 3) Installation a. Insert the cable into the hole in the ( trailing arm on each side. b. Install the four clamps, tightening t he~ attaching bolts to the specified torque.

Torque ( L I ~ I IH LI- ~ taching bolts)

d.3 - 0.6 kg-m (2 - 4 ft-lb)

c. Connect the cable end to the lever at: the brake assembly.

NOTE: Change the cotter pin with a new one an sure to bend it into anchor shape. d. Install the cable return spring on the bra cket which is attached to the hub. e. Insert the cable into the joint and instal1I tL l lhO joint on the rear end of the rod with the nuts, washers and pipe in the correct 01 rder. f. Install the clip on the rod and attach the clin t o the bracket on the crossmember.

~

g. Adjust the cablt ibed in the following item. 4) Adjustment a. Prior to the cable adjustment, complete the brake shoe clearance adjustment. b. Adjust the cable to the specification below by changing the joint position on the rod.

-

Notches

Standard lever travel [when pulled with approx. 25 kg (55 lb) of force]

3 to 4 notches

T14-013

Fig. 14-29 Parking brake lever ratchet

Limitof travel [when pulled with approx. 25 kg (55 lb) of force]

6 notches

Total notches provided

8 notches

' Joint

Torque (Joint lock nut)

0.3 - 0.6 kg-m (2 - 4 ft-lb)

Lock nut T14-014

c. Make sure that the wheel rotates lightly after adjusting the cable.

Fig. 14-30 Joint and lock nuts

CHAPTER

1 5: STEERING SYSTEM

Page GENERAL DESCRIPTION

..........................................................

15-

2

STEERING SYSTEM

3

STEERING

...................................................................... 15WHEEL ....................................................................... 15SHAFT ....................................................................... 15-

4

......................................................................15-

8

STEERING

BEVEL GEAR BOX

.............................................................

15-11

...............................................................................

15-17

....................................................................

15-18

STEERING GEAR BOX TIE-ROD END

6

TROUBLESHOOTING

15-1.

1.

GENERAL DESCRIPTION Outline

The steering gear box employed is of the rack and pinion type, which is simple and reliable. As the pinion rotates, the rack moves laterally, pulling or pushing the tie rods that connects the rack and the knuckle arm. Thus both the front wheels are turned right and left

2.

to steer the vehicle. The tie rods are ball-jointed to the knuckle arm and t o the rack. The backlash between the rack and pinion is set to 0 using a spring installed in the sleeve adjuster. In this steering system, the bevel gear box is located in front of the steering gear box; therefore, the torque from the steering wheel is reversed by the bevel gear and is transmitted through the torque rod and rubber joint to the pinion on the steering gear box.

Specifications 7.6 m (25 ft)

Minimum turning circle Inner

37"

Outer

33030'

Turning angle

22.5

Steering ratio

380 mm (15.0 in)

Steering wheel diameter TYpe

Rack and pinion

Pinion

7 teeth

Rack

28 teeth

Steering gear assembly

Backlash Thread diameter and pitch

Less than 0.05 mm (0.002 in) 18 mm x 1.5P (Left-hand screw)

Nut width across flats

22 mm

Turnbuckle width across flats

19 mm

Tie-rod

Tie-rod end ball stud

Bevel gear assembly

Pinion

15 teeth

Gear

21 teeth

Gear ratio

1.40

Backlash

Less than 0.05 rnrn (0.002 in)

Axial play of bevel pinion

Less than 0.035 mm (0.0014 in)

Toe-in (with vehicle unloaded) Side slip (with driver)

12 mm dia. x 1/10 taper

8 - 13 mm (0.32 - 0.5 1 in)

7

IN 3 mm (0.1 in) to OUT 3 mm (0. 1 in)

15-2. 1.

STEERING SYSTEM

Component parts

1 Steering wheel 2 Steering shaft cover 3 Steering shaft 4 Cover 5 Clamp 6 Dust cover

7

Bevel gear box

8 Rubber bushing 9 Torque rod 10 Rubber coupling 11 Plate 12 Steering gear box T15-001

Fig. 15-1 Component parts of steering system

15-3

2.

Installation

4) Tighten the clamp securing the torque rod to the bevel gear box.

Since this steering system employs the bevel gear assembly, it is very important to obtain correct alignment between the bevel gear box, steering gear box and steering wheel which are installed on the vehicle. When installing the steering system components, first temporarily tighten their attaching bolts and nuts. Then fully tighten them to the specifications in the order of @ t o @ as indicated in Fig. 15-1, ensuring that the components are aligned correctly with each other. 1) Tighten the bolts and nuts attaching the rubber coupling. 2) Secure the steering gear box by tightening the attaching bolts in the order of @, @, @ and @ . Make sure that there is a clearance of 4 to 8 rnm (0.16 to 0.3 1 in) between the pinion of the steering gear box and the cross member. 3) Secure the bevel' gear box with the rubber bushing and clamp by tightening the attaching bolts to the specified torque.

2.5 - 3.3 kg-m (18 - 24 ft-lb)

Torque

5) Tighten the clamp securing the steering shaft to the bevel gear box. 2.5 - 3.3 kg-m (18 - 2 4 ft-lb)

Torque

NOTE: When tightening the clamp, pull the steering shaft up so that the gap between the steering wheel and shaft cover becomes as follows. r--

I

-

1 - 3 mm (0.04 - 0.12 in)

6) ~ignren the bolts attaching the steering shaft bracket to the pedal bracket.

1.O - 2.2 kg-m (7 - 16 ft-lb)

15-3. 1.

STEERING WHEEL

Construction

1 2 3 4

Horn key Steering wheel Horn cord Cover T I 5-002

Fig. 15-2 Construction of steering wheel 15-4

1

I

I

i

2.

Removal

1) Remove the two screws at the back of the steering wheel and remove the cover.

Fig. 15-5 Cleaning contact points

Fig. 15-3 Removing cover (steering wheel) I

I I

2) Remove the steering wheel retaining nut and remove the steering wheel from the shaft.

2) With the front wheels in the straight-ahead install the steering wheel with the washer, lock washer and nut onto the shaft and tighten the nut to the specification with the steering spoke in the horizontal position.

Torque (Nut)

2.2 - 2.8 kg-m (16 - 20 ft-lb)

Fig. 15-4 Removing steering wheel retaining nut

3.

Inspection

Check all the parts for damage and poor operation, and if necessary replace defective parts with new ones.

4.

Installation

1) Clean the horn contact points and slide plate.

Fig. 15-6 Installing steering u

3) Install the cover on the steering wheel by tightening the two screws from the back of the steering wheel. 4) Check the horn operation by pushing tl horn key.

15-4.

1.

STEERING SHAFT

Construction

Right-hand

Ill L

3 4

5 6 7 8 9

ering wheel ~ u l u m ncover Combination switch Hazard warning switch Steering column Steering shaft Lower steering shaft Rubber coupling Snap ring (Right-hand drive vehicle only)

I

Fig. 15-7 Construction of steering shaft

2.

Removal

2) Remove two bolts of steering C O L U ~ I I I I installing to the pedal bracket. 3) Disconnect the combination switch and ignition-starter switch harnesses from the main harness. 4) Pull the steering shaft off the bevel shaft.

1) Remove the bolt of the clamp securing the steering shaft to the bevel gear.

3.

Disassembly

1) Remove the steering wheel from the shaft. 2) Remove the brush from the steering column (R.H. drive vehicle only). 3) Remove the hazard knob, then the combination switch. 4) Remove the screws from each side of the cover; remove the cover from the steering column.

Fig. 15-8 Removing clamp bolt 15 - 6

NOTE: a. On the left-hand drive vehicle, the steering column and steering shaft cannot be disassembled. If the bearing o r ' t h e shaft is damaged, replace as an assembly. b. On the right-hand drive vehicle, do not replace the bearing alone, but as a steering column assembly.

5.

Fig. 15-9 Removing column cover

Assembly

1) Before assembling, wipe all frictional surfaces and apply a coat of grease to them. 2) Secure the rubber coupling to the steering shaft and lower shaft.

5) Remove the snap ring (R.H. drive vehicle only)

Torque

1.7 - 2.2 kg-m (12.3 - 15.9 ft-lb)

3) Insert the steering shaft into the steering column (R.H. drive vehicle only). 4) Fit the snap ring into the groove in the steering shaft (R.H. drive vehicle only). 5) Assemble the cover to the steering column, and temporarily tighten the screws. 6) Attach the combination switch to the cover and install the hazard knob. 7) Install the brush in the hole on the steering column, and secure it with the screw (R.H. drive vehicle only).

I I

6. Fig. 15-10 Renroving maP ring 2--L_1 A l l out the steen~~g snar't from the coluunn (R.H. drive vehicle only). 7) Remove the bolts securing the upper n~hl -,Jer coupling in place.

"I

4.

Inspection leck all disassembled parts for abnories. If necessary, replace. Zarefully check the following: Steering shaft, for bending or other iage. Bearing, for wear, unusual noise or rough tio on.

.

Rubber coupling, for damage.

Installation

1) Align the cutout on the bevel gear shaft with that on the shaft; temporarily install the shaft with the clamp. 2) Temporarily install the steering column assembly on the pedal bracket. 3) Tighten the clamp (at the bevel gear shaft) to the specified torque. Torque

2.5 - 3.3 kg-m (18.1 - 23.9 ft-lb)

4) Tighten the bolts on the lower side of the steering column, then the bolts on its upper side, to the specified torque.

'

1

J Torque

10 - 20 kg-m (72.3 - 144.6 ft-lb)

5) Install the steering wheel so that the spoke is set at the straight-ahead position, and install the steering wheel cover.

Torque

2.2 - 2.8 kg-m (15.9 - 20.3 ft-lb)

6 ) Securely tighten the cover on the steering column. Make sure that there is a clearance of 1 to 3 mm (0.04 to 0.12 in) between the lower face of the steering wheel boss and the cover. Fig. 15-1I Clearance of steering wheel and

1 Torque

15-5. 1.

colurnfi cover

0.1 - 0.15 kg-m (0.7 - 1.1 ft-lb)

7) Connect the combination switch harness to the main harness, 'and fasten it with the clip beside the pedal bracket. Do not let the harness hang down.

BEVEL GEAR BOX

Construction

1

Bevel gear (pinion)

3 4 5 6

Dust seal Bearing Gear box Bearing

8 9 10 11 12 13

Adjuster Cover Retainer Bearing Oil seal Bevel gear (gear)

T15-00

Fig. 15-12 Construction of bevelgear box 15-8

2.

Removal

1) Raise the vehicle or place it on a pit. 2) Remove the clamp bolt connecting the steering shaft to the bevel gear box and pill the steering shaft off the bevel gear box. 3) Remove the front bumper and under cover. It is unnecessary to remove the radiator and protector.

5) Remove the two bevel gear box clamp bolts, and detach the bevel gear box from the chassis frame.

Fig. 15-15 Removing bevelgear box

6 ) Remove the torque rod from the bevel gear box by removing the clamp bolt.

3. 1 I

Fig. 15-13 Removing under cover

4) Remove the two bolts at the rubber coupling and disconnect the torque rod from the pinion shaft of the steering gear box assembly.

Disassembly and assembly

Since the bevel gear box is designed to used without maintenance or adjustment, not disassemble the unit unless it is to discarded. If it is defective replace as assembly.

4.

be do be an

Installation

1) Install the clamp on the torque rod and temporarily connect the torque rod to the bevel gear shaft with the bolt, spring washer and nut. 2) Install the rubber bushing to the bevel gear box, with the marked end downward.

box

Fig. 15-14 Disconnecting torque rod from pinion shaft

Fig. 15-16 Installing rubber bushing

3) Place the clamp on the rubber bushing and temporarily install the bevel gear box on the chassis frame with the two bolts, washers and spring washers. 4) Connect the torque rod to the rubber coupling with the two bolts, spring washers and nuts.

Torque

-

8) Turn the steering wheel from lock tolock and check for operation. The condition is satisfactory if the tangential force on the steering wheel is less than 1.8 kg (4.0 lb) with one person on the seat (front).

0.9 - 1.5 kg-m

(7 - 11 ft-lb)

5) Connect the steering shaft to the bevel gear shaft and temporarily tighten the clamp bolt. 6) Fully tighten the clamp bolts attaching the bevel gear box to the chassis frame. Torque (Clamp bolt)

1.0 - 2.2 kg-m

(7 - 16 ft-lb) Fig. 15-17 Checking steering wheel operation

7) Fully tighten the clamp bolts connecting the torque rod and steering shaft to the bevel gear box assembly.

Torque (Clamp bolt)

2.5 - 3.3 kg-m (18 - 24 ft-lb)

9) Adjust the steering wheel position so that the spokes are horizontal when the front wheels are in straight-ahead position.

, 15-6.

I

1.

STEERING GEAR BOX

Construction

\

T I 5-007

1 2 3 4 5 6 7 8 9 10 11 12

Nut Lock washer Stopper Rack Cap Snap pin Spacer Clip Boot Tie rod Spring Seat

13 14 15 16 17 18 19 20 21 22 23 24

Tie rod end Nut Turn buckle Nut Tie rod Clip Boot Gear box Bushing Bushing Bushing Bushing

Fig. 15-18 Construction of steeringgear box 15 - 11

25 26 27 28 29 30 31 32 33 34 35 36 37

Oil seal Bolt Spring washer Cover Packing Retainer Lock nut Adjuster Spring Sleeve Boot Pinion Bevel gear box

2.

Removal

1) Raise the vehicle and place it on safety stands. 2) Remove the under cover. 3) Remove the two bolts connecting the pinion shaft of the steering gear box to the rubber coupling and leave the rubber coupling attached to the torque rod.

Fig. 15-21 Removing steering gear box

Fig. 15-19 Removing rubber coupling bolts

4) Loosen the 16 mm nuts of the turnbuckle. The tie rod has left-hand screw thread and the tie rod end has righ-hand screw thread.

Fig. 15-20 Loosening turnbuckle lock nuts

5) Separate the tie rod and tie rod end by turning the turnbuckle. 6) Remove the four 8 mm bolts attaching the steering gear box to the crossmember and remove the steering gear box by shifting it rearward.

1) Hold the steering gear box in a vise and remove the covers at both ends of the gear box. 2) Remove the snap pin installed in the groove in the rack by using a flat blade screw driver.

Fig. 15-22 Removing snap pin

3) Remove the cap from the rack, leaving the spacer, spring, etc. in the rack.

4) Remove the tie rod clips from the boots and extract the tie rods from the gear box. Remove the clips from the tie rods.

9) Remove the pinion cover and gasket by removing the two attaching nuts.

Fig. 15-23 Removing tie rods

Fig. 15-25 Removing pinion cover

Spread the lock washer at the rack end and remove the rack stopper, lock washer and nut. I

5)

10) Remove the retainer and take out the pinion. 11) Loosen the adjuster lock nut and remove the adjuster, spring and sleeve from the gear box.

4.

1) Thoroughly wash all the parts in cleaning solvent. 2) Hold the steering gear box in a vise and install the boot with the retaining clip at each end. 3) Apply a sufficient amount of grease to the pinion and the inside of the pinion bore in the gear box. Insert the pinion into the gear box and install the retainer. Also apply grease to the retainer.

Fig. 15-24 Removing rack stc

6) Turn the pinion shaft clockwise to pull the rack out of the gear box. 7) Take out the spacer, spring ill retaining seats from the rack.

Assembly

I

NOTE: Be careful not to damage the sliding surfaces of the rack. Remove the boot retaining clips and remove the boot from the gear box.

8)

I

NOTE: D o not pull the boot forcefully.

Fig. 15-26 Installing pinion

4) Install the pinion cover with the gasket, two 6 mm bolts and spring washers.

I

I

Torque (~01;)

1

0.5 - 0.7 kg-m (3.6 - 5.1 ft-lb)

I

5 ) Apply a sufficient amount of grease to the rack. 6 ) Insert the rack into the gear box from the side opposite to the pinion. Engage the teeth of the rack and pinion, and turn the pinion counterclockwise. 7) Apply grease to the adjuster sleeve and the inside of the adjuster bore in the gear box, and insert the sleeve into position. 8) Apply grease to the adjuster spring and insert it in the sleeve. 9) Apply sealant to the adjuster threads and screw in the adjuster into the gear box. 10) Install the stopper, lock washer and nut in this order on the rack end.

Lever I

Fig. 15-28 Measuring pinion torque

13) Insert the two gear box ball seats, spring, spring seat, spacer and rack cap into the rack hole in this order. 14) Install the tie rods after applying grease on the ball seats and tie rod ball ends.

NOTE: Do not confuse the right and left tie rods, as they differ in length. 15) Insert the tie rods into the holes in the boot and install the rubber clips in position.

Fig. 15-27 Installing rack stopper 11) Adjust the rack-to-pinion backlash by fully tightening the adjuster and then back off about 1/ 15 turn. Turn the pinion from lock to lock to see its rotating condition. If the rotation is smooth, back off the adjuster less than 1115 turn. 12) Measure the rotating torque of the pinion. The torque from the straight-ahead position should be 0.01 to 0.09 kg-m (0.07 to 0.65 ft-lb), and the maximum torque through the whole range of travel should be less than 0.22 kg-m (1.59 ft-lb). After the above condition is satisfied, lock the adjuster with the lock nut.

Fig. 15-29 Installing rubber clip 16) Tighten the rack cap until the tie rod swinging load is 0.3 to 1.2 kg (0.7 to 2.6 lb) and lock it with the snap pin. Be sure to bend the snap pin center to prevent the pin from becoming loose.

Fig. 15-30 Checking tightness of tie rodc

Fig. 15-32 Clearance between pinion shaft and cross member

3) Connect the pinion shaft to the rubber coupling with the two bolts, spring washers and nuts.

Torque

Fig. 15-31 Locking snap ring 17) Install the covers on both ends of the gear box.

5.

Installation

4) Connect the tie rod to the tie rod end by positioning the turnbuckle between them and turning it in. Be careful in engaging the threads so that the exposed thread lengths of the tie rod and tie rod end are not noticeably different. 5) Turn the steering wheel from lock to lock to check its operation.

6 ) Adjust the toe-in to specifications by

1) Install the rubber bushings on the steering gear box and position it on the crossmember bracket. 2) Place the clamps on the bushings and secure the gear box with the four 8 mm bolts, using care that the pinion shaft and torque rod are aligned. Make sure that there is a clearance of 4 to 8 mm (00 to 00 in) between the pinion shaft and cross member.

Torque (Bolt)

0.9 - 1.5 kg-m (7 - 11 ft-lb)

2.0 - 3.0 kg-m (14 - 22 ft-lb)

turning the turnbuckle, and tighten the 18 mm lock nuts.

Toe-in (with vehicle unloaded)

(0.32 - 0.51 in)

7) To tighten the lock nuts, proceed as follows: a. Tighten the tie rod end nut and turnbuckl b. Push the tie rod and its end fully backward

Torque (Lock nut)

8.0 - 8.5 kg-m (57.9 - 61.5 ft-lb)

b. When tightening the left tie rod, be sure to hold the turnbuckle with a wrench while turning the lock n u t

Fig. 15-33

c. With the tie rod and its end held in place, tighten the tie rod end nut and turnbuckle.

1 Tie rod 2 Turn buckle (19 mm in width across flats) 3 Tie rod end 4 Nut (22 mm in width across flats) 5 Holding spanner (do not turn) 6 Tightening spanner 7 Nut (left-hand screw) (22 mm in width across flats)

T12-036

Fig. 15-34 Tightening lock nut

Fig. 15-35 Tightening lock nut

NOTE: a. When tightening the lock nut, use two wrenches one to hold the turnbuckle and the other to tighten the n u t

8) Move the tie rods back and forth to make sure that they swing equally. The standard amount of swing is more than 35 mm (1.38 in).

-

Fig. 15-36 15 - 16

9) Adjust the steering wheel position so that the spoke is horizontal with the front wheels straight-ahead position.

15-7.

1.

TIE-ROD END Removal

Raise the front of the vehicle and place 1) it on the safety stand. 2) Loosen the lock nuts of the turnbuckle and remove the turnbuckle. 3) Pull the cotter pin off the castle nut connecting the tie rod end to the knuckle arm, and remove the castle nut. 4) Press the ball stud of the tie rod end out of the knuckle arm, using Special Tool (BALL STUD REMOVER: 921240000).

3.

Installation

1) Connect the tie rod end to the tie rod by positioning the turnbuckle between them, and turning it in. Be careful in engaging the threads so that the exposed thread lengths of the tie rod and tie rod end are not noticeably different. 2) Insert the ball stud of the tie rod end into the hole in the knuckle arm and install the castle nut. Tighten the castle nut to 2.5 to 3.0 kg-m (18 to 22 ft-lb) first, and then further tighten within 116 turn to align a slot in the cotter pin with the hole in the ball stud.

Castle nut tightening torque

2.5 - 3.0 kg-m (18 - 22 ft-lb) 1

3) Lock the castle nut with a new cotter pin. 4) Turn the steering wheel from lock to lock to check its operation. 5) Adjust the toe-in to the specification by turning the turnbuckle, and tighten the 18 mm lock nuts.

Toe-in (with vehicle unloaded)

IN

8 - 13 mm (0.32 - 0.5 1 in)

r

Torque (Lock nut)

I

Fig. 15-37 Removing ball stud

i

I II

2.

Disassembly and assembly

The tie rod end cannot be disassembled. Replace it as an assembly if defective. I

8.0 - 8.5 kg-m (58 - 61 ft-lb)

6 ) Grip the tie rod and check that it moves the same distance forward and rearward with the front wheels in the straight-ahead position. If it moves unequally, readjust. 7) Adjust the steering wheel position so that the spoke is horizontal with the front wheels in the straight-ahead position. For removal and

15-8.

TROUBLESHOOTING A

Trouble and possible cause

Corrective action

1. Steering wheel is heavy.

Raise the front of the vehicle until both front wheels clear the ground. Then turn the steering wheel. If it becomes lighter than the case that the front wheels are on the ground, the tire pressure or the suspension may be responsible and if it is still heavy the steering system may have some trouble.

2.

1) Tire pressure too low.

Adjust to correct pressure.

2) Incorrect front wheel alignment.

Adjust toe-in.

3) Stuck ball joint.

Replace.

4) Insufficient lubrication.

Lubricate all parts.

5) Stuck king pin and bushing. 6) Worn out tires.

Replace. Replace.

Steering wheel vibrates.

This trouble takes place mostly at high speeds, or rough roads. 1) Improper tire pressure.

Adjust t o correct pressure.

2) Incorrect front wheel alignment.

Adjust toe-in.

3) Unbalanced wheels and tires.

Correct.

4) Loose wheel nuts, drum nuts or rim nuts.

Tighten to correct torque.

5) Distorted wheel.

Correct or replace.

6) Damaged or worn wheel bearing. 7) Uneven tire pressure.

Repair or replace.

8) Damaged or worn trailing arm bearing.

Re1dace.

9) Worn king pin.

Re1,lace. Replace.

10) Unbalanced brake drum. 3.

Adjust to correct pressure.

Shocks at steering wheel. 1) Incorrect front wheel alignment.

Adjust toe-in.

2) Excessive tire pressure.

Adjust t o correct pressure.

3) Defective shock absorber.

Replace.

4)

Correct.

Incorrect engagement of steering gear or bevel gear.

5) Excessive backlash.

Correct.

I

Corrective action

Trobuble and possible cause 4.

Steering wheel pulls to one side. This condition is very dangerous to vehicles, and often attributable t o defective front suspension.

1

1) Uneven tire pressure.

Adjust to correct pressure.

2) Incorrect front wheel alignment.

Correct.

3) Damaged or worn wheel alignment bearing.

Replace.

4)

Adjust.

Brake dragging.

5. Abnormal noise. 1) Loose connections or insufficient tightening.

Tighten to specified torque.

2) Damaged or worn wheel bearing.

Replace.

3) Damaged or worn trailing arm bearing.

Replace.

4) Defective shock absorber.

Replace.

5) Damaged or worn king pin and

Replace.

bushing.

CHAPTER

16: GEAR SHIFT SYSTEM

Page 16.1 16.2 16.3

. . .

....................

16-

2

GEAR SHIFT LEVER

3

GEAR SHIFT ROD

.................................................................. 16.......................................................................16-

6

COMPONENT PARTS OF GEAR SHIFT SYSTEM

16-1.

COMPONENT PARTS OF GEAR SHIFT SYSTEM

1 2 3 4 5 6 7

8

Gear shift lever Knob Boot Bolt O-ring Bushing Spacer Self lock nut

9 asher 10 11 12 13 14 15

Bracket Bushing Washer Castle nut Cotterpin Grease nipple

16 Spacer 17 Bolt 18 Lever 19 Gear shift rod 20 Spring 21 Bushing 22 Spacer 23 Washer 24 Flange nut

Fig. 16-1 Component parts of gear shift system 16 - 2

16-2. 1.

securing the gear shift lever to the lever. 4) Remove the spacer, resin bushing, rubber washer and "0" ring.

GEAR SHIFT LEVER Removal

1) Jack up the vehicle or place it on a pit. 2) Remove the self-locking nut and bolt from gear shift rod bracket, and detach the gear shift lever. 3) Remove the bolts and self-locking nuts

NOTE: Check these fast wearing parts for wear or other damage. I f necessary, replace.

1 Gear shift lever 2 Lever 3 Bracket

T16-002

Fig. 16-2 Gear shift kver

2. 3

Rubber washer

6

Self locking nut

Disassembly a n d assembly

1) Remove the cotter pin, castle nut z - : washer; detach the gear shift lever from : boss.

T16-003

Fig. 16-3 Removing gear shift letter

5) Remove the four bolts and spring washers securing the bracket to the chassis frame. Fig. 16-6 Removing castle nut

2) Check the resin bushing and "0" ring '-wear or other damage. If necessary, replace.

NOTE: Discard the old cotter pin and install a r?. one. 3) Before assembling, clean all disassemi parts. Insert the resin bushing into the bc:: the bracket and install the "0" ring. Fig. 1 6-4 Removing bracket installing bolts

6)

NOTE: Before installing, apply a coat of greaa the bushing and "0" ring.

Remove the lever from the front side.

O-ring

T16-1::

Fig. 16-7 Assembling "0" ring

Fig. 16-5 Removing lever 16 - 4

-

ri

?TE: Be careful not to allow the "0" ring to slip out of the bushing.

I

I

II

Insert the gear shift lever assembly into boss, and secure it with the washer and :le nut.

Tighten the castle nut to the specified

1 Torque

-

1.6 - 2.4 kg-m (1 1.6 - 17.4 ft-lb)

Fig. 16-9 Installing bracket

Align a groove on the castle nut with the

- - .e in the lever, and lock with the cotter pin.

2) Attach the resin bushing, "0" ring, spacer and rubber washer to the upper boss of the gear shift lever.

' 3TE:

Do not tighten the castle nut in excess of the specified range of 1.6 to 4.0 kg-m (12 to 29 ft-lb). -

NOTE: Apply a coat of grease to the outer periphery of the resin bushing, "0" ring, rubber bushing and spacer.

Apply grease through the grease nipple at ring until old grease is forced out.

-I "0"

', OTE:

3) Attach the gear shift lever t o the lever at the boss, and tighten with the self-locking nut and bolt.

Perform lubrication every six months.

Torque

1.4 - 2.2 kg-m (10.1 - 15.9 ft-lb)

3

Rubber washer

6

Self locking nut

Fig. 16-8 Greasing through nipple

3. I

Installation Secure the lever to the chassis frame with

- e four bolts and spring washers.

Torque

T16-003

7.0 - 13 kg-m (50.6 - 94.0 ft-lb)

Fig. 16-1 0 Installing gear shift lever

16-5

4) Attach the resin bushing, "0" ring, rubber washer and spacer to the lower boss of the gear shift lever. Fit the gear shift lever in its bracket, and tighten with the bolt and selflocking nut.

Torque

16-3.

3)

Unfasten the neutral set spring.

NOTE: I f the spring is fatigued, replace it 4) Disengage the gear shift lever from the gezr shift rod. Refer to the instructions under t k e heading "Gear Shift Lever" in 16.2. 5) Remove the gear shift rod from the rec side through the clearance between the engir.5 and the car body. 6 ) The gear shift rod can be installed in tk: reverse sequence of removal.

1.4 - 2.2 kg-m (10.1 - 15.9 ft-lb)

GEAR SHIFT ROD

R e m o v a l a n d installation

NOTE: Always tighten the flanged nuts at the re?. end of the gear shift rod t o the specifiei torque.

1) Jack up the vehicle or place it on a pit. 2) Remove the flanged nuts securing the rear end of the rod to the shifter arm of the transmission; slide the circular portion of the rod, and remove the rubber bushing, spacer and washer.

NOTE: Check the rubber bushing for wear. If necessary, replace.

1 2 3 4 5 6 7

Engine mounting bracket Washer Flange nut Gear shift rod Rubber bushing Spacer Spring

T I 6-007

Fig. 1 6-1 1 Removing gear shift rod 16-6

: PEDAL SYSTEh

'age

17.1 17.2 17.3 17.4

. .

................................17- 2 BRAKE AN D CLUlTCH PEDAL ...................................................17- 3 . ACCELERATOR PEDAL ... ................................................17- 9 . CABLES .............................. ................................................17-10 COMPONENT PAR1rs OF PEDAL SYSTEM

17-1.

COMPONENT PARTS OF PEDAL SYSTEM

t

t

A

B

4

5

1 2 3 4 5 6 7 8

Plate Cover Accelerator pedal Flange nut Clip Cotter pin Pin Clutch pedal stopper 9 Bolt 10 Spring washer

11 Bolt 12 Flange nut 13 Spacer 14 Stop light switch 15 Pedal stopper 16 Nut 17 Washer 18 Bolt 19 Nut 20 Bushing

21 22 23 24 25 26 27 28 29 30

Washer Cover Clutch pedal Spring Pedal bracket Spring Brake pedal Bolt Stopper Spring washer T17-001

Fig. 17-1 Component parts of pedal system 17-2

r

17-2.

B R A K E AND C L U T C H PEDAL

4

kt

1.

Removal

NOTE: Be careful not to spill the brake fluid over the painted surfaces and floor durning removal. 1) Disconnect the steering shaft and pedal bracket by loosening bolt and nut. Fig. 17-4 Removing brake pipes

Disconnect the stop light switch harness and turn signal unit harness.

4)

Fig. 17-2 Disconnecting steering shaft

Remove the brake fluid reservoir from the voir holder by loosening the screws and emplty the reservoir. Fig. I 7-5

w

7

5) Loosen the clutch cable adj.usting nut on the e:ngine side.

I J

ig. 1 7-3 Removing brake fluid reservoir 3) Remove the brake pipes from the master cylinder by loosening the flare nuts.

Fig. 17-6 Loosening adjusting nut

6) Remove the clamp attaching the clutch cable to the pedal bracket and remove the cable from the bracket by removing the inner cable from the slit.

2.

Disassembly and assembly

1) Brake pedal a. Disconnect the master cylinder pus1h rod from the brake pedal by removing the cotter pin and clevis pin.

g. 17-7 Removing clutch cable 7) Disconnect the clutch cable from the clutch pedal hook.

Fig. I 7-10 Removing cotter pin

b. Pull out the clip and washer at the pedal shaft end. c. Pull the brake pedal with the pedal return spring and bushing off the pedal shaft.

Fig. 17-8 Disconnecting clutch cable 8) Remove the four pedal bracket attaching nuts and pull the pedal bracket off the front panel and instrument panel. Remove the brake fluid reservior at a time.

Fig. 17-12 Pulling off brake pedal

Fig. I 7-9 Removing pedal bracket

2) Clutch pedal a. Pull out the clip and the washer at the pedal shaft end.

b. Pull out the clip and the washer at tht:pedal shaft end. c. Remove the brake pedal with the pedal return spring and bushing off the pedal shaft.

Fig. 17-13 Removing clutch pedal

b. Pull the clutch pedal with the pedal return spring and bushing off the pedal shaft. 3) Assembly Assembly is the reverse order of disassembly.

, I

NOTE: Apply grease' on the bushings before installing brake pedal and clutch pedal to the shaft.

Fig. I 7-15 Removing brake pedal

2) Clutch pedal a. Loosen the clutch cable adjusting nut on the engine side.

3.

Disassembly and assembly (with the pedal bracket ! attached to the vehicle) 1) Brake pedal I i a. Disconnect the master cylinder push rod from the brake pedal by removing the cotter pin and connecting, pin.

!

Fig. 1 7-16 Loosening clutch cable adjusting nut

Fig. 1 7-14 Removing brake pedal

b. Remove the clamp attaching the clutch cable to the pedal bracket and remove the cable from the bracket by removing the inner cable from the slit.

Torque:

1.0 - 2.0 kg-m (7 - 14 ft-lb)

II

Fig. 17-17 Removing clutch cable from pedal bracket

c. Disconnect the clut ch cable from the clutch pedal hook. d. Pull out the clip and the washer at the pedal shaft end.

Fig. 17-1 9 Installing pedal bracket

2) After installing the clutch cable to the cable bracket, connect the cable to the clutch pedal hook.

e. Pull the clutch pedal with the pedal spring and bushing off the pedal shaf 3)

I

I

Fig, 1 7-18 Pulling out clip

Fig. 17-20 Installing clutch cable

3) Install the clutch cable outer end to the cable bracket by inserting clamp into the slit.

IGLULII

Assembly Assembly is the reverse order of removal.

NOTE: Apply grease on the bushings before installing brake pedal and clutch pedal to the shaft.

4.

lnstallation

1) Install the pedal bracket on the front panel and instrument panel lower side by tightening four nuts.

Fig. 17-21 Installing clutch cable 17-6

NOTE: To check the pedal play, lightly push the pedal pad with your finger until you feel the push rod contact the master cylinder piston through your finger.

4) Install the stop light switch and turn signal unit harness. 5) Connect the brake pipes to the master cylinder by tightening the flare nuts.

Torque:

1.5 - 2.0 kg-m (10.8 - 14.5 ft-lb)

(0.04- 0 021n)

rn 77-1 Fig. 1 7-23 Checking brake pedal play Fig. i 7-22 Connecting brake pipes

2) Adjust the brake pedal play by loosening the two bolts attaching the stop light switch bracket to the pedal bracket and changing the position of the stop light switch.

6) Fill the reservoir with the brake fluid and install the reservoir to the holder.

NOTE: leed air completely from the brake sys ;ee chapter 14. Brake system)

NOTE: When adjusting the pedal play, try to adjust to 1 to 2 mm (0.04 to 0.08 in) for better pedal feeling.

7) Install the steering column bracket to the pedal bracket and tighten the bolts.

5.

Adjustment

a. Brake pedal play 1) Check the play of the brake pedal, which is made by the clearance between the master cylinder and the push rod.

Standard brake pedal play

1 - 5 mm (0.04 0.02 in) at pedal pad center Fig. 17-24 Adjusting brake f>edalplay 17-7

b. Brake pedal height when depressed Full braking force must be obtained when the brake pedal is depressed with approx. 30 kg (66 lb) of force. At this time the distance between the upper surface of the pedal pad and the front pannel indicated in Figure must be as follows.

Standard rllltrh pedal pla:

10 - 25 mm (0.39 0.98 in) at pedal pad center

Brake pedal height when depressed with 30 kg (66 lb) of force Standard

150 - 160 mm (5.90 - 6.30 in)

Limit

120 mm (4.72 in)

Fig. 17-26 Adjusting clutch pedal height

Fig. i 7-25 Brake pedal height when depressed

c. Clutch pedal play 1) Adjust the clutch pedal height to the pedal height.

Fig. 17-27 Checking clutch pedal p&

4) Adjust the clutch pedal play by turning

the clutch cable adjusting nut (wing nut) at the cable end on the engine side.

2) Adjustment of pedal height must be done in adjusting of brake pedal play. 3) After pedal height adjusting, check the clutch pedal play by lightly pushing with your finger.

NOTE: When the clutch pedal play is within the standard value, the play measured at the clutch release lever pin is approx. 1 mm (0.04 in).

Fig. 17-30 Removing plate 3) Disconnect the end of accelerator outer cable from the pedal bracket, by loosening the 6 mm nut.

Fig. 17-28 Adjusting clutch pedalplay d. Clutch pedal height 1) When the clutch is completely disengaged the clutch pedal height (distance between clutch pedal pad and front pannel) must be over 100 mm (3.94 in).

front pannel and clutch pedal pad

Over 100 mm

Fig. I 7-31 Disconnecting accelerator cable Front panel

-

4) Remove the accelerator pedal as an assembly into the cabin.

-

..,celerator

pedal ass'y

T 17-004

Fig, I 7-29 Distance between front pannel and clutch pedal pad

7-3. I.

ACCELERATOR PEDAL Removal

1) Remove the under cover. 2) Loosen the nuts on the pedal cover, and move the pedal cover by removing the plate attaching the pedal cover.

Fig. 17-32 Accelerator pedalassembly

2.

lnspection Check the removed parts for any wear, damage and deformation, and correct or replace if defective. 3. Installation 1) Insert the accelerator pedal assembly into the hole of the floor from cabin side. 2) Put grease .on the end of accelerator cable and connect it to the pedal lever. ) After connecting the end of outer cable to the pedal bracket, tighten the 6 mm nut.

4) Install the pedal cover and put the plate on it, and tighten with two 6 mm nuts.

Torque:

17-4.

CABLES

1.

Cables layout

1 Choke cable

7 8

Clamp (Under floor) Accelerator cable Clip (Helper bracket) #1 Mark (White paint) Clamp (Side member) Clip (Side member) Clip (Water pipe bracket)

9 10 11 12 13 14 15 16

Clip (Rear bulkhead) Clamp (Transmission) Clutch cable Return spring Clip (Protector) Clamp (Rear crossmember) #2 Mark (White paint) #2 Mark (White paint)

T17-005

Fig. 17-33 Cable layout of Right-hand drive vehicle 17 - 10

I I

1

-%.

2 3 4 5 6

!

0.2 - 0.4 kg-m (1.4 - 2.9 ft-lb)

5) Fill the slit of pedal cover enough with sealing material for waterproofing. Sealing material cemedine CS-301 equivalent.

OTE: Refer t o the paragraph of accelerator cable in this chapter.

1

1 2 3 4

5 6

Clip (Side member) Choke cable Accelerator cable Clip (Front crossmember) Clamp (Side member) Clip (Side member)

7 Clip (Rear bulkhead) 8 9 10 11 12

Clutch cable Clamp (Transmission) Return spring Clip (Protector) Clamp (Inner trailing arm)

T17-006 1

Fig. 17-34 Cable layout of Left-hand drive vehicle

2.

Accelerator Cable

REMOVAL

1)

Remove the accelerator pedal cover.

2) Disengage the outer end of the accelerator cable from the pedal bracket.

Fig. 17-36 Removing accelerator cable (Left-hand drive vehicle)

3) Disengage the inner end of the accelerator cable from the pedal lever.

i

Fig. 17-35 Removing accelerator cable (Right-hand drive vehicle)

Open the trap door on the upper side of the engine compartment.

4)

5) Disengage the outer end of the accelerator cable from the carburetor bracket, and remove the accelerator cable together with its inner cable end from the accelerator linkage.

On Right-hand drive vehicle

(White paint)

&sf

-

tll

-_ -_ %

T17-007

Marking (White paint)

0 1:

2-

Tl7-008

On Left-hand drive vehicle

Fig. 1 7-3 7

~2&mL/l--2 ti 1

2

#1 Mark (White paint) Clamp (Side member)

6) Unfasten the clip and clamp and take the accelerator cable out from behind the fuel tank. Refer to the instructions under the heading "Cable Layout". 7) Check the cable for rough operation, rust formation or other damage. If necessary, replace.

T 17-009

Marking (White paint)

1-

2z

T17-008

Fig. 17-38 Fixing accelerator cable

5 ) Align the 2nd mark on the cable with the clip at the bracket for the rear water pipe and secure the cable (R.H. drive vehicle only).

INSTALLATION

1) From behind the fuel tank, route the accelerator cable along the upper face of the helper bracket to the outside of the side member. 2) Securely attach the front end of the inner cable to the accelerator pedal bracket. 3) Secure the outer end of the cable to the accelerator pedal bracket.

Align the mark on the outer cable with the clamp on the front end of the side member.

4)

Fig. 1 7-39

6 ) Fasten clips and clamps to retain the cable at the designated points.

3.

C h o k e Cable

REMOVAL

NOTE: Make sure the cable is not sharply bent or twisted, but is securely fastened with clips and clamps.

1) Remove the choke cable knob and dress nut.

7) Insert the inner cable into the cable end, secure the outer cable end to the bracket, and tighten the inner cable.

Fig. 17-41 Removing choke cable knob

Fig. 17-40 Installing accelerator cable

2)

Remove the clips from the front panel.

8) Apply a coat of chassis grease to the front and rear inner ends at the connections.

3) Remove the front under cover, then the clamp from the underside of the floor (R.H. drive vehicle only).

ADJUSTMENT

4) Further removal procedures are the same as for the accelerator cable.

1) After installing the accelerator cable, depress and release the accelerator pedal t o make sure that the carburetor linkage moves correspondingly in order to operate the engine at idling, full-open and full-close settings.

INSTALLATION

2) Make sure that the effort required for pedal operation is less than 8 kg (17.6 Ib).

NOTE: Keep in mind that pedal operating effort varies with incorrect assembling of the cables and/or sharply bend of clip portions.

1) Route the choke cable along the groove in the 3-way connector bracket, pass it through the floor in the driver's compartment and the hole in the instrument panel. Then attach the knob t o the cable end. 2) Align the mark at the front part of the cable with the clamp on the front of the side member, and secure the cable.

On Right-hand drive vehicle

1 #2 Mark (White paint) 2 Clip (Water pipe bracket)

T I 7-007

T17-010

Fig. 17-43 Marking (White paint)

2'

On Left-hand drive vehicle

T17-008

For further steps, follow the same procedure as for the accelerator cable.

4)

NOTE: a. Tighten the inner cable on the carburetor side in such a manner that it has no free play. b. The overall travel stroke of the choke cable is 25 t o 28 m m (1 .O t o 1.1 in), as measured -/-at the knob. / -

1 #1 Mark (White paint) 2 Clamp (Side member)

Clutch Cable vl OVAL T 17-009

1) Loosen the wing nut at the end of the clutch cable on the engine side.

Marking (White,paint)

I

2-

T17-008

Fig. 17-42 Installing choke cable

3) Align the mark at the rear part of the cable with the clip at the rear water pipe bracket, and secure the cable (R.H. drive vehicle only).

Fig. I 7-44 Loosening wing nuf

2) Remove the clamp from the outer end of the clutch cable on the pedal side, and unfasten the cable from the pedal bracket. To facilitate removal of the clutch cable, remove the boot and lower the outer cable in such a manner that the inner cable passes along the groove in the bracket.

7) Remove the cable return spring and disconnect the cable end at the clutch release lever.

Remove the grommet from the floor, and pull the clutch cable from under the floor through the grommet hole and move it toward the rear of the vehicle.

8)

\

11 1

1

I

/

I I

Fig. I 7-45 Removing clutch cable

Fig. 1 7-47 Removing clutch cable

3) Disconnect the clutch cable from the clutch pedal.

9) Check the clutch cable for roughness, improper operation, rust formation or other damage. If necessary, replace.

4) Remove the front under cover. On righthand drive vehicles, remove the clamp from under the floor.

INSTALLATION

5) Remove the clip and clamp; discon, the clutch cable. Refer to the instructi~ilr under the heading "Cable Layout."

1) Route the clutch cable along the groove in the 3-way connector retaining bracket, and pass its outer end through the hole in the floor into the passenger compartment.

6) Remove the under cover from the engine compartment, and remove the cable from the clamp at the transmission protector.

2) Secure the grommet t o the hole in the floor.

I

3) Fasten the clutch cable to the clutch pedal, pass its outer end through the bracket and securely clamp it.

4) Align the mark on the front of the clutch cable with the center of the clamp on the front of the side member, and secure the clutch cable. 5) Align the mark on the rear of the clutch cable with the clamp on the rear cross member, and secure the clutch cable (R.H. drive vehicle only).

Torque Fig. I 7-46

0.3 - 0.6 kgm (2.2 - 4.3 ft-lb)

i 8) Attach the inner end of the clutch cable to ! the clutch release lever, and tighten the wing I nut so that the play of the release lever is j approx. 1 mm (0.04 in). Marking (White paint)

(-ID r 2#

T I 7-011

Fig. I 7-48

Fig. 17-51

9)

Install the clutch cable return spring.

10) Attach the clutch cable to the clip at the transmission protector, and secure it. 1 #Mark 2 Clamp 3 Clutch cable

T I 7-012

11) Install the rear underside cover. 12) Loosen the wing nut on the cable end and adjust the play of the clutch pedal to 10 to 25 mm (0.39 to 1 in). Tighten the wing nut.

Fig. 17-49

Attach a clamp to the rubber bushing for the clutch cable, and secure it to the lower face of the transmission case with two bolts. 7)

Fig. 17-50

i

!

I I

I

:

~ i

5. 6 ) Fasten the clutch cable with clips and clamps at the designated positions.

! i

Speedometer Cable

I

REMOVAL 1) Loosen the speedometer cable securlng i bolt located to the left of the front wheel, and I pull out the cable.

Fig. 1 7-52 Loosening speedometer cable installing bolt

(

1

2)

Remove the hanger spring.

Remove the clip. 4) Remove the front underside cover (R.H. drive vehicle only). 3)

5 ) Remove the combination meter from the instrument panel and disconnect the speedometer cable.

Marks (White paint)

T I 7-013

Fig. 17-56

INSTALLATION 1) Route the speedometer cable into the passenger compartment through the hole in the floor.

Fig. 17-53 Removing speedometer cable

2) Connect the speedometer cable t o the cbmbination meter, t h e n attach the combination meter to the instrument panel.

6) Remove the grommet from the floor. Separate the clutch and choke cables, and push the speedometer cable out through the floor. 7) Check the speedometer cable for improper operation, rust formation or other damage. If necessary, replace.

Fig. I 7-54 Installing combinat,ion meter

3) Pass the (:hoke cabl e and. tulle through the grom met, and secure them to the floor panel. Attach tlle speedometer cable t o the left :1, and secure it wit11 the bolt.

.

Fig. 17-55

5) Attach the hanger spring to the speedometer cable at the #1 mark, and secure it t o the fuel tank bracket. Align the #2 mark on the cable with the clip on the cross member, and secure the cable.

NOTE: Always route the speedometer cable along the top of the front cross member when laying it out on the underside of the floor.

+

On Right-hand drive vehicle

r l " " '

_ I

j i . . . .

Match the marking position

Right-hand drive

On Left-hand drive vehicle

ig. I 7-57

6 ) Install the front under cover (R.H. drive vehicle only). 7) After positioning the speedometer cable correctly, fasten it with clips.

NOTE: Be careful not to sharply bend or twist the the speedometer cable.

Fig. 17-58 17 - 18

CHAPTER

1 8:

FUEL SYSTEM

Page OUTLINE

......................................................................................... 18-2

REMOVING AND INSTALLING FUEL TANK

................

REMOVING AND INSTALLING FUEL METER UNIT CLEANING FUEL TANK

.................. 18-5

........................... 18-5 PUMP .................................................................................. 18-6 CAP ....................................................................................18-7

REMOVING AND INSTALLING FUEL PUMP FUEL

18-4

............................................................. 18-4

REMOVING AND INSTALLING FUEL STRAINER FUEL

.............

18-3

18-1.

OUTLINE

I I

1 Clip 2 Clip (Engine cooling) 3 Clip (Hose clamp) 4 Clip (Hose clamp) 5 Fuel return hose 6 Fuel return pipe 7 Fuel return hose 8 Delivery hose 9 Delivery pipe 10 Hose 11 Pipe

12 13 14 15 16 17 18 19 20 21 22

Aiuvent tube Tube Air breather tube Fuel tube Clamp (Fuel hose) Flange nut Fuel strainer Flange nut Valve Band Clip

re 23 24 25 26 27 28 29 30 31 32

DETAIL "C"

Clip Insulator Clip Fuel filler hose Fuel filler pipe bracket Fuel filler pipe Bolt Fuel filler cap Packing Bolt and washer T18-001

Fig. 18-1 Fuel system

The fuel tank assembly is filled with gasoline through the filler pipe. The gasoline from the tank is sent to the fuel strainer through a rubber hose(tank-strainer). The impurities (dirt, etc.) in the gasoline are removed by the element of the strainer and the clean gasoline is then sent to the carburetor by the fuel pump. At this time, a fuel return system which sends the fuel not required by the carburetor back to the fuel tank through a pipe and rubber hose (fuel return) is employed and the temperature of the gasoline sent to the

carburetor is maintained at normal temperature. Blowing out of the gasoline from the air breather tube when the gasoline expands due to a rise in the temperature when the tank is full or when running on grades or turning is prevented by a valve (float) in the breather system and a constant volume air sump at the top of the fuel tank which absorbs the expanded gasoline. Moreover, a fuel vapor control device is provided to prevent atmospheric pollution due to exhausting of the fuel vapor (hydrocarbons) produced inside the fuel tank.

1.

Fuel vapor control device

Construction The vapors produced inside the fuel tank are sent t o the dirty side (element side) of the air cleaner case through the air breather tube and float valve 2) Operation The fuel vapor entering into the air cleaner case from the air breather tube floats inside the case. When the case becomes filled with vapor, a fairly large amount is stored inside the right frame. This vapor is sent to the combustion chamber with the intake air and combusted when the engine is started. The amount of fuel vapors emitted is reduced considerably by the installation of this device. 1)

0.80 - 1.OO kg-m (5.8 - 7.2 ft-lb)

Tightening torque I

I

I

.I1

ly

bolts

\

Fig. 18-3 Removing drain plug

To Fuel tank

3) Remove the protector (fuel tank) and disconnect each hose (fdler, delivery, return).

Fig. 18-2 Float valv,

-2.

REMOVING AND INSTALLING FUEL TANK

I

/

,

1.

Fig. 18-4 Disconnecting hoses

Removal

I

I

1) Disconnect the (-) battery terminal. 2) Remove the fuel tank drain plug and remove the filler cap. Drain the fuel and then install the drain plug.

4) Remove the protector (tube) from inside the wheel apron and loosen the clip of each tube (air vent, air breather). 5) Detach the filler pipe clip and pull out the hose from the tank.

6) Loosen the fuel tank,mounting bolts and place the fuel tank at an angle and pull slightly down and to the right.

NOTE: Be sure to install the washers, cushions and spacers correctly. Fuel tank mounting bolt tightening torque

t'ng bolts

, 18-3.

n plug .

.

1

, G.

Fig. 18-5 Loosening mounting bolts

7) Under this state, remove the air breather tube and air vent tube from the fuel tank and loosen the three clips holding the air breather tube. 8) Under this state remove the fuel tan1

2. 1)

1.2 - 1.6 kg-m (8.7 - 1 1.6 ft-lb)

REMOVING AND INSTALLING FUE L METE UNIT

Remove the 5 nuts holding the fuel meter unit and remove the unit. The unit can be replaced with the tank installed. Tightening torque

0.12 - 0.3 kg-m (0.86 - 2.2 ft-lb)

Installation Installation is the reverse of removal.

Fig. 18-7 Fuel meter unit

I

I

18-4. CLEANING FUEL TANK

Left hand side

When a large amount of water, dirt, etc. in the fuel tank causes the strainer to become clogged, remove the fuel tank, place a small amount of gasoline in the tank, shake the tank, and drain the dirt from the drain hole. \-'Y hen the water, etc. cannot be completely dr:lined from the tank, turn the fuel tank over and Idrain from the air breather pipe. Right hand side T18-003

Fig. 18-6 Installing the fie1 tank

Fuel tank capacity

31 L (8.1 U.S.gal., 6.8 Imp. gal.

18-5.

1.

REMOVING A N D INSTALLING F U E L STRAINER Removal

1) Remove the fuel strainer installing nut. 2) Disconnect the rubber hose (tank - strainer) and the rubber hose (strainer - pipe) from the strainer after loosening the hose clips.

Case

Element

Cap

T 18-004

:ig. 18-9 Cross-section of fuel strainer

NOTE: Fuel hose replacement Every 4 years Fuel strainer replacement Every 20,000 km (12,000 miles) or 1 year

18-6. 1.

Fig. 18-8 Removing fuel strainer

2.

REMOVING A N D INSTALLING FUEL PUMP Removal

1) Remove the fuel tank. 2) Loosen 6 fuel pump installing screws, and the fuel pump assembly is detached from the tank.

Installation Installation is the reverse of removal.

NOTE: a. Always confirm that there is no fuel leakage after installation. b. Pay careful attention to the ariow on the strainer which indicates the direction of fuel ' flow when installing the fuel st1

3.

Fig. 18-10 Removing fuel pump

Fuel strainer constructic

1

The fuel strainer is a cartridge type wlhich cannot be disassembled. I Replace the strainer every 20,000 km i, . (12,000 miles) or one year under normal usage I conditions. I

I

2.

lnstallation Installation is the reverse of r~ emoval.

1. ing screw tightening torque

Specifications

0.12 - 0.30 kg-m (0.86 - 2.2 ft-lb)

TYpe

Centrifugal type pump

Discharge pressure

Less than - 0.18 kg/cm2 @ 12V (Less than 2.6 psi @ 12V)

Discharge volume

Over 20&hr (5.2 U.S.gal./hr, 4.4 Imp. gal./hr) @ 12V Over 10L/hr (2.6 U.S.gal./hr, 2.2 Imp. gal./hr) @ 1ov

Electric current

Below 1.5A @ 12V Below 1.8A @ 15V

Starting voltage

Below 8V

NOTE: a. When installing fuel pump, apply a sealing ~ad compound "CEMEDINE 1115" on t h r""" portion of 6 installing screws. b. Be careful not to damage strainer, hose, harness, etc. When installinu fuel pump.

....

18-7.

FUEL PUhnr

Fuel pump is fitted in fuel tank.

Construction a n d operation

1

Fig. 18-11 Fuel pump assembly

1 Battery terminal 2 Grounding terminal 3 Brush holder Brush 5 Motoryork 6 Magnet

+

7 Armature 8 Fan

9 Relief valve 10 Magnet holder 11 Strainer T18-006

Fig. 18-13 Fuel pump construction

Fig. 18-12 Location of fuel pump

Runner fan connected t o motor shaft is driven by motor. Fuel sucked into the runner fan through the strainer is forced feeded into the

outlet path and finally to the carburetor by centrifugal force according to the runner fan speed. Relief valve is provided on the way of outlet path. In case higher discharge pressure than the specified pressure occurs, the relief valve is opened and the fuel is returned into the tank. Cooling and lubrication of motor is made by the fuel.

3.

18-8. -

---=

FUEL CAP .

- - -

Removal and installation Refer to 18-6.

rE: :uel pump should be replaced in fuel pump ssembly.

Fig. 18-14 Fuel cap

Fuel cap is made of plastic. When removing the cap, release lock by turning the key counterclockwise and turn the cap counterclockwise and align the nail of cap and the cut portion of filler pipe. When reinstalling the cap, take the reverse procedures of removal.

CHAPTER

1 9:

EXHAUST SYSTEM

Page 19.1

.

GENERAL DESCRIPTION .............................................................19-2

19.2

.

REMOVING AND REINSTALLING ASSEMBLY ..................................................................................

19-3

................................................................................

19-3

19.3

.

INSPECTION

19.4

.

REINSTALLATION

........................................................................19-4

19-1.

GENERAL DESCRIPTION Inner wall

Outer wall

.acket lpes and partitions

T19-001

Fig. 19-1 Inner construction of the muffir I

1)

Features: Heat insulation type exhaust system has been adopted for keeping off the compartment and exhaust system parts from thermal radiation harm. a Muffler is of double heat insulation and expansion type for preventing the heat harm by the exhaust gas. Tail pipe is also covered by the heat insulation cover. a Heat insulator is attached to the outer shell to absorb noise and to prevent the heat harm. a Inner wall of the muffler is floating type so as to absorb the thermal expansion by the exhaust gas, and keep the sideways freedom

2)

with flat plate suspension on the left side end. a Muffler inner wall, pipe and partitions have adopted stainless steel which has superior features with thermal strength and high I temperature oxidization resistance. Muffler outer wall and tail pipe cover are I using the aluminum plated steel sheet and I which has superior corrosion resistance. 1 a Tail pipe is suspended only on upper and lower sides for preventing the thermal stress 1 by exhaust gas, so the tail pipe can be moved I freely in the longitudinal direction.

Components of exhaust system:

I

Fig. i 9-2 Component parts of the exhaust system

I

'

$

I

I

19-2.

REMOVING MUFFLER ASSEMBLY

1) Removal a. Remove the engine hood (Truck) or bumper (Van). b. Remove three 6 mm bolts (one on muffler side, two on belt cover side) installing heat insulator (exhaust manifold).

d. Detach the bracket compl. from the muffler by loosening the two 8 mm bolts (on muffler side and three 10 mm bolts on transmission side). e. Disconnect the muffler from the exhaust flange by loosening the four 8 mm nuts.

Fig. 19-5 Disconnecting muffler fiom exhaust manifold

1

Fig. 19-3 Removing 6 mm bolts

1

c. Detach the bracket "E" from the muffler by loosening the seven 8 mm bolts (three on muffler side and four on transmission side).

!

NOTE: Don't detach the exhaust flange from the cylinder head. f. Take out the muffler assembly from the engine after loosening the two 8 rnrn bolts connecting the muffler center bracket-A and the bracket on transmission.

19-3.

Fig. 19-4 Removing bracket

INSPECTION

1) Inspect the installing brackets and the muffler for crack. If abnormal, replace it. 2) Confirm if any abnormal exist in the inside of the muffler by shaking it. If abnormal noise occurs brom the inside, replace it.

19-4.

REINSTALLING MUFFLER ASSEMBLY

1 2 3 4 5 6 7 8 9 10 11 12

Muffler assembly Bracket compl. Gasket Bracket-E Bolt Washer Nut Nut Spring washer Washer Bolt and washer assembly Bolt and washer assembly

T19-I

Item

Minimum allowable clearance

Location

B

Between muffler and crossmember Between bracket compl. and crossmember

30 mm (1.18 in) 20 mm (0.79 in)

C

Between muffler and bumper

D

Between tail pipe and hood stopper

40 mm (1.57 in) 15 mm (0.59 in)

A

Fig. 19-6 Construction of exhaust system 19-4

1. Install the gasket. (Be sure to use new one.) 2. Temporarily tighten the muffler installing position a, b, c, and d parts as shown in the Figure 19-7. When temporarily tightening the bolts, it is recommendable to tighten "b" part bolts first.

Fig. 19-7 Temporarily tightening bolts and nuts 3. Firmly tighten the "a" flange part) nuts diagonally.

for "a" part (manifold

1 I

1 ' I

I

part (manifold

2.7 - 3.7 kg-m (19 - 27 ft-lb)

NOTE a. Since the nuts are made of stainless steel, be sure to use genuine parts. b. Be sure to check the tightening torque twice, because the tightening torque of bolts and nuts which tighten a t the begining have a tendency to insufficient tightening torque. c. I n order to check each breacket installing position for difficulty, after tightening the nuts, turn each temporarily tightened bolt by fingers.

4. Firmly tighten "c" and "d" parts of the bolts. 5. Temporarily tighten "f' part bolts. 6 . After installing the "e" part bolts, tighten them firmly. 7. Firmly tighten "f' part bolts. 8. Lastly tighten "b" part bolts and nuts. Tightening torque for "b,d,e and f ' parts.

1.6 - 2.6 kg-m (1 2 - 19 ft-lb)

Tightening torque for "c" part.

3.4 - 4.0 kg-m (25 - 29 ft-lb)

NOTE: a. When installing the muffler, strictly follow the abovementioned order. b. Do not forcibly align the brackets bolts etc. c. After through abovementioned procedures, start the engine and check leakage of exhaust gas from the exhaust system. d. I f there is any abnormal deformation on the installing breackets (such as unmatching bolts hole of the brackets or the clearance between "f" part bracket and the muffler side installing surface of over 6 mm), change the brackets with the new ones. 9. Install the heat insulator (exhaust manifold). 10. Install the engine hood or bumper.

NOTE: a. After completion of this job, confirm the each clearances as shown in the Fig. 19-6. b. I f some of the clearances are smaller than the specified value, loosen each connecting parts and after making necessary clearances on each parts, firmly tighten them strictly following abovementioned orders.

CHAPTER

20: HEATER A N D VENTILATOR SYSTEl

Page

20.1

.

CONSTRUCTION OF HEATER AND VENTILATOR SYSTEM ......................................................................................... 20-2

20.2

.

HEATER AND VENTILATOR CONTROL LEVER

20-4

20.3

. .

VENT1LATOR DUCT

20-5

20-4

HEATER UNIT

...

................... .................................................................... ..............................................................

20-7

20-1.

1.

HEATER AND VENTILATOR CONTROL SYSTEM Construction

Outside air intake

I

1 Outside air intake shutter 2 Ventilator shutter 3 Instrument panel 4 Heater unit 5 Room shutter

i Inside air circulation

r,

T20-001

Fig. 20-1 Construction of heater and ventilator control system 20-2

2.

Ventilating and heating are accomplished by the upper (AIR FLOW CONTROL) lever and the lower (HEATER CONTROL) lever located in the middle of the instrument panel. The upper lever is equipped with a built-in heater fan switch and controls the positioning of the shutters. The lower lever regulates the temperature of the air flow discharged from the heater unit.

Heater and ventilator control levers

Air flow control lever This lever controls the opening position of the air outlets. When it is pulled out, the heater fan switch built into the lever actuates to direct the strong or weak air flow to the front windshield and foot area. 1)

Fig.20-2

1 2

Outside air intake shutter Ventilator shutter

4 Instrument panel 5 Control lever 6 Room shutter

Fig.20-3 20 - 3

a. DEF When the lever is set at the DEF position, the outside air shutter opens and the ventilator and inside shutters close. Outside air is then directed to the front windshield. b. ROOM With the lever set at the ROOM position, the outside air intake shutter and the. room shutter open and the ventilator shutter closes. Outside air is then directed to the foot area. c. VENT With the lever in the VENT position, the outside air intake, ventilator and room shutters open and outside air flows into the compartment in response to the car speed. d. CIRC With the lever set at the CIRC position, the outside air intake shutter closes and the ventilator and room shutters open. Inside air is then directed through the outlets and recirculates inside the passenger compartment.

-

Fig. 20-4 Disconnecting control cab/

3) Disconnect the control cable clan . remove the control cable from the duct as-

sembly . 4) Remove the heater fan switch harness. 5) Remove three tapping screws fixing the lever assembly to the body panel.

NOTE: Continued setting of the lever at the ClRC position will fog the front windshield. It is advisable to set it at the VENT or ROOM position under normal conditions. 2)

Heater control lever This lever regulates the temperature of air flow. When not in use, set it at the COLD position. Moving the lever to the HOT position gradually increases the temperature of the air flow.

20-2.

Fig. 20-6 Removing tapping screw of lever assembly

6 ) Remove the lever assembly by pulling it out.

H E A T E R AND V E N T I L A T O R CONTROL LEVER

REMOVAL AND INSTALLATION 1) Remove the instrument panel (See "Removal of instrument panel.") 2) Disconnect control cable clamps to remove the each control cable from the heater unit.

Fig. 20-7 Removing lever assembly

20 - 4

NOTE:

20-3.

When pulling out the lever assembly, take care the soldered portion where cables are connected to the heater fan switch is not damaged by the body '

7) Installation the lever assembly in the reverse order of removal.

V E N T I L A T O R DUCT

REMOVAL AND INSTALLATION 1) Remove the instrument panel. (See "Removal of instrument panel.") 2 ) Remove the Air flow and heater control lever. (See "Removal of air flow and heater control lever.") 3) Remove the heater unit. (See "Removal of heater unit.")

NOTE: a. When connecting control cables, confirm all shutters and cock completes are entirely closed. b. After connection, confirm the operation of each shutter and cock complete.

Fig. 20-9 Removing heater unit

Remove two screws fucing the ventilator duct to the lower part of the instrument panel.

4)

Fig. 20-8 Shutter closing position

Fig. 20-10 Removing ventilator duct installing screw

5) Remove the license plate. 6) Remove four tapping screws fixing the air flow ventilator duct to the front panel.

&

Va.

II

Screws .

*

~

'

Fig. 20-1 1 Removing ventilator duct instaffing screw

7) Remove the duct assembly after movi to left side. 8) Install in the reverse order of removal.

NOTE: a. When mounting the duct assembly, replace the urethane (671 042040) containing sealing agent by new one to prevent water leakage through the junction of the front panel and the duct. b. Apply sealing agent (Cemedine 366E) to front panel mounting screws before installation. c. Fix the control cable by attaching the firmly.

20-4.

1.

HEATER UNIT Component parts of heater unit

-

19

1 2 3 4 5 6 7 8 9 10 11

Gasket Heater shaft Case B Flange nut Screw Clip Heater shutter Hose clamp Heater core Nut Washer

12 13 14 15 16 17 18 19 20 21 22

Rubber washer Heater fan CaseA Resistor Heater air vent hose Room shutter gasket Cord Screw Drain hose Fan motor Clamp

23 24 25 26 27 28 29 30 31 32 33

Room shutter gasket Tapping screw Clip Heater cock Reservoir tank hose Hose clamp Hose Clip Screw Spring washer Washer

T20-003

Fig. 20-13 Component parts of heater unit

20

2.

I

Specifications

Heating capacity

2100-10% Kcal/H or more

Air volume

156-10% m3/H

Blower speed

2900 rpm

Input

Under 55 W

Standard voltage

12V

Core size

97x 115x66

Water and air temperature difference 6S°C Water flow 360!2/H

Sirocco fan 1 10 mm dia.

!

Pressure check

3. 1) 2)

3) unit.

2 kg/(

Removal Remove the ground cable from the battery. Completely drain the engine coolant. Remove the defroster duct from the heater

Fig. 20-15 6) Remove the three tapping screws securing the control lever assembly, and detach the control lever assembly.

Fig. 20-14

Remove the instrument panel. Refer to the instructions under the heading "Instrument Panel." 5) Unfasten the clamp from the control cable; disconnect the cable from the heater unit and duct assembly. 4)

Fig. 20-16

7) Lift out the defroster duct on the driver side.

11) Remove the three 8 mm flanged nuts securing the heater unit, and remove the heater unit.

NOTE: The right side of the heater unit is secured together with the reservoir tank bracket

Fig. 20-17

, Jisconnect the heater wiring harness from the connector. 9) Remove the cover from the coolant reservoir tank. 10) Disconnect the inlet and outlet hoses from the heater unit, and then the air vent hose from the heater tube.

Fig. 20-20

4.

Fig. 20-18 Removing water outlet hose

Fig. 20-1 9 Removing air vent tube

Disassembly a n d assembly

1) Remove the two screws securing the heater cock assembly. 2) Remove the six 4 mm tapping screws and separate the heater case into two halves. 3) Remove the heater core. 4) Remove the 5 mm nut securing the fan to the motor, and remove the fan. 5) Remove the three 5 mm screws securing the motor to the heater case, and detach the motor.

Fig. 20-21

6) Assembly is in .the reverse order of disassembly.

5.

Installation

The heater unit is installed in the reverse order of removal.

Fig. 20-22

NOTE: a. Clamp the control cable when the shutters and cock assembly are closed. After clamping it properly, make sure all shutters and the cock assembly function properly.

b. Make sure hose clamps are facing in their correct directions when installing. c. For coolant replenishment, refer to the "Engine Cooling System," in Chapter 7.

CHAPTER

21 : BODY

Page

El- 1 . COMPONENT PARTS OF BODY CONSTRUCTION .......... 21-1 21- 2. CHASSISFRAMEDATUMPOINT ........................ 21-5 212121El-

3. 4. 5. 6.

................................... 21-6 DOORS .... ................................... 21-15 WINDSHIELD GLASS ...... ............... 21-29 BODY PARTS

INSTRUMENT PANEL

.....

............... 21-31

21- 7. SEAT ................... ...................... 21-38 ...................... 21-40 1- 8. INNER TRIM ............. 1- 9. INNER ACCESORIES .................................. 21-42 1-10 . 'OUTER ACCESORIES ................................. 21-43

21-1.

.

COMPONENT PARTS OF BODY CONSTRUCTION Flat bed truck

DETAIL 'A'

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Reservoir tank flap Front pillar Pillar Front rail Roof panel Drip rail Weather strip Shutter Front panel Back panel Cushion rubber Guard bar Hanger Center pillar Cab floor

16 17 18 19 20 21 22 23 24 25 26 27 28 29

Bracket Front fender Side gate Rear gate Side gate lock Rear fender Hinge Floor Chassis frame Front under cover Center under cover Rear under cover Engine room cover Under cover bracket T21-001

Fig. 21-1 Component parts of body construction

2.

Low bed truck

b

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 Reservoir tank flap 2 Front pillar 3 Pillar 4 Front rail 5 Roof panel 6 Drip rail 7 Weather strip 8 Shutter 9 Front panel 10 Back panel 11 Cushion rubber 12 Guard bar 13 Hanger 14 Center pillar 15 Cab floor 16 Bracket

Front fender Side gate hoc Side panel Floor Rear gate Hinge Side gate Gate lock Side panel Gate lock Chassis frame Front under cover Center under cover Rear under cover Engine room cover Under cover bracket

Fig. 21-2 Component parts of body construction 21 -3

T21-002

3.

VAN

1 2 3 4

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Reservoir tank flap Pillar Front pillar Front panel 5 Weather strip 6 Drip rail 7 Shutter 8 Front rail 9 Roof panel 10 Rear rail 11 Cab floor 1 2 Fender 13 Back panel 14 Hand brake cable protector 15 Reinforcement 16 Center floor panel

Bracket Rear shelf Center pillar (Inner) Side rail Lower slide rail Rear quarter panel (Inner) Rear quarter panel (outer) Upper slide rail Center pillar (Outer) Gusset Chassis frame Front under cover Center under cover Rear under cover Engine room cover Under cover bracket ~2 1-003'

Fig. 21-3 Component parts of body construction 21 - 4

-2.

CHASSIS FRAME D A T U M POINTS

Fig. 21-4 Chassis frame datum points

21-3. 1.

BODY PARTS

3) Remove two 8 m m bolts -under the bumper from the front under cover.

Front bumper

REMOVAL AND INSTALLATION 1) Remove front combination light.

Fig. 21-7 Removing bolt

4) Remove two 10 mm bolts from the combination light mounting holes to disconnect the bu:mper. Fig. 21-5 Removing front combination light

2) Remove screws on both sides of the bumper.

Fig. 21-8 Removing front bumper

Fig. 21-6 Removing screw

5)

Installation is the reverse order of removal.

2.

Engine hood (truck & flat-bed truck) or rear bumper (van)

REMOVAL AND INSTALLATION 1) Remove two 8 mm bolts from the apron at the end of the left frame. Remove two 8 mm nuts from the apron a t the end of the right frame.

Fig. 21-9 Removing rear bumper

2)

3.

Fig. 21-1I Removing bolt

3) Remove two 8 mm bolts under the front bumper.

Installation is the reverse order of removal.

Front under cover

Fig. 21-12 Removing bolt

On the right-hand drive vehicle, remove two 6 mm bolts installing the under cover to the body.

4)

Fig. 21-10 Component parts of front under cover

REMOVAL AND INSTALLATION 1) Remove a 8 mm bolt threaded into the horn cover. 2) Remove two 8 mm bolts installing to each side of chassis frame.

Fig. 21-13 Removing front under cover (Right-hand drive vehicle) 21 - 7

On the left-hand drive vehicle, remove a 8 mm bolt and 6 mm bolt installing the under cover to the body.

Fig. 21-14 Removing front under cc eft-hand drive vehicle)

5 ) Install the front under cover in the reverse order of removal.

4.

Center under cover (flat bed truck only)

5.

Rear under cover

Fig. 21-16 Component parts of rear under cover

REMOVAL AND INSTALLATION Loosen bolts and nuts as shown in the figure. When installing the under cover, loosely fit all bolts and nuts first, and then firmly tighten them.

6.

'

Body

1. PREPARATIONS OF REMOVAL 1) Place the car over a pit or jack up it on a

trestle. 2) Prepare a hoist or chainblock. 3) Prepare body suspension rope, M blocks or substitutes. 4) Disconnect the minus(-) terminal or me battery. 5) Clean the body and chassis if required. Fig. 21-15 Component parts of center under cover

The center under cover shall be disconnected from the frame by removing four 8 mm bolts.

2 . REMOVAL

1) Remove the front bumper. 2) Remove the gear shift lever from the rod and lever complete by removing locknuts and bolts.

NOTE: Since the choke cable knob mounting screw may be lost, unscrew it only about 3 turns. b. Unbend all clip and pull the choke cable and meter cable together with the grommets out to under the body. c. Unbend the clips of the accelerator and choke cables inside the engine room. 6) Remove the steering shaft assembly. a. Disconnect the bevel gear box and steering shaft. Fig. 21-1 7 Removing gear shift lever

3) Remove the clutch cable. a. Loosen the clutch cable end nut (engine side).

Remo -

Fig. 21-19 Disconnecting bevelgear and steering shaft

b. Disconnect the combination switch and ignition starter switch wiring harnesses. c. Disconnect the steering shaft mounting bracket and instrument panel connection and remove the shaft assembly. Fig. 21-18 Loosening clutch cable adjusting nut

.

b. Disconnect the clutch cable from the clutch pedal hook. 4) Remove the accelerator cable. a. Separate the accelerator cable end and pedal. b. Unbend the cable clip underneath the cab. 5 ) - Disconnect the choke cable and meter cable. a. Disconnect the choke cable from the instrument panel.

Fig. 21-20 Removing steering sheft assembly

7) Remove the electrical equipment. a. Disconnect the connector between the front wiring harness and rear wiring harness inside cab.

Fig. 21 -23 Draining brake fluide

9 ) Disconnect the brake pipe and Zway and 3-way connectors from underneath of the body. Fig. 21 -21 Disconnecting connector

b. Unbend all clips and pull the harness together with the grommets out to under the body. c. Remove the rear combination lights. d. Unbend the clips of the thermometer harness, back-up light switch harness and rear harness. Remove the harness from the body. (Including removal of trap door.) 8) Drain the brake fluid from the brake fluid tank. Fig. 21-24 Disconnecting brake pipe

NOTE:

10)

When draining the brake fluid, use rags, etc. to keep the oil off the floor.

Drain the coolant from the radiator.

NOTE: I n order to prevent splashing, open the front tank cap after loosening the radiator cock.

rain plug

Fig. 21-22 Disconnecting brake fluid tank

I

Fig. 21-25 Draining coolant 21 - 10

11) Disconnect the two radiator hoses from the cooling pipes. Disconnect the reservoir tank inlet hose and heater hose from the pipes.

14) nut.

Unscrew the fuel filler pipe mounting

Fig. 21-28 Loosening nut

Fig. 21-26 Disconnecting hose 15) Remove two 4-mm fuel filler pipe and fender coupling screws.

12) Remove the front seat cushion and take out the jack and spare tire. 13) Unbend the clips of the air vent and air breather inside the tire housing, and disconnect air breather tube from the fuel tank

Fig. 21 -29 Removing screw

Fig. 21-27 Disconnecting air breather tube

The filler pipe. and body can be easily separated when the clips connecting the filler pipe and fuel hose are loosened. 16) Remove the front and rear splaskboads. 17) Disconnect the body from the chass frame by loosening the connection bolts.

a. Van.

(Connecting body .and undercover)

T21-015

Fig. 21-30 Body and chassis frame connection points

b. Truck

(Connecting body and undercover)

L8 mm bolt

8 mm bolt

10 mm bolts

10 mm bolts 'T21-016

Fig. 21-31 Body and chassis frame connections 1 c. Flat bed truck

---(Connecting body and undercover)

T21-017

Fig. 21-32 Body and chassisfiarne connection points 21 - 13

NOTE: a. Two rear seat mounting bolts marked with "A" are tightened with the body. (Van only) b. Disconnect the both side frame end and cab coupling section.

UBARU

I

Truck and flat bed truck Connect a rope to both sides and lift the setback with a hoist or chainblock. 2) After removing the setback, remove the cab by lifting with a hoist or chainblock.

,

NOTE: a. Pay the same attention as described in the Van body removing. Only the cab itself cannot be removed and installed, but must be removed after removing the setback.

3.

installation Installation is the reverse order of removal.

Fig. 21-33 Disconnecting frame end and cab

18) Remove the body from the chassis frame. a. Van After removing all bolts, lift the body with a hoist or chainblock.

NOTE: a. Place rags, etc. between the body and rope and timer to prevent damaging the body. b. Tie the rope securely and lift the body slowly to insure safety. c. Confirm that there are no parts which have not been disconnected while gradually lifting the body.

NOTE: a. Connect the fuel tank and air breather tube when the body has been lowered to such an extent that work between the body and chassis frame is possible. To connect the chassis frame and body [including cab and setback), first align each tightening point, temporarily tighten all bolts, and then tighten all bolts securely. c. Confirm that the harness and cables are not wedged between the body and other parts. d. Prescribed tightening toques.

~ p e. treno eacn c ~ securely. f. Bleed all the air from the brake line for all four wheels.

21-4. A.

DOORS COMPONENT PARS OF DOORS

DETA l L "A"

DETAIL "B"

1 2 3 4 5 6 7

Cab door panel Sash Spring Cab door hinge Weather strip Cab door regulator Regulator handle 8 Outer handle 9 Sealing cover 10 Pull handle

DETAIL "C"

11 Cab door latch 12 Striker wedge 13 Door striker 14 Spacer 15 Run channel 16 Door glass 17 Cab door remote control 18 Escutcheon 19 Door handle

Fig. 21-34 Component parts of cab door

T21-018

-

DETAIL "D" DETAIL

Weather strip Slide glass rail Slide glass frame Slide glass Slide door panel Slide door upper arm Outer handle Slide door lower arm 9 Slide door stopper 10 Striker

11 12 13 14 15 16 17 18 19 20

1 2 3 4 5 6 7 8

"B"

Suspender Plate Inner handle Escutcheon Slide door remote control Door latch Wedge Spacer Striker Slide door arm

T21-019

Fig. 21-35 Component parts of slide door 21

- 16

DETAIL ' A "

DETAIL 'C"

1 2 3 4 5

"

DETAIL "D'

8 Key lock 9 Latch 10 Striker 1 1 Stop nut 12 Back door hinge 13 Back door stay 14 Stopper

Weather strip Weather strip Joint Moulding Back door glass Sack door panel 31ip

T21-020

Fig. 21-36 Component parts of back door 21 - 17

B.

CABDOOR

1.

Door lock striker

ADJUSTMENT Move the door lock striker mounting position up and down and left and right, and adjust in the front and rear with shims so that the door is closed easily and does not rattle. 1)

2.

Door hinge

1) INSPECTION a. When the door rattles in the axial direction and right angle direction, tighten the hinge mounting bolts. b. When the hinge pin section rattles, repla1 the hinge assembly. 2) ADJUSTMENT a. Perform adjustment using the door hinge s bolt wrench. Adjustment is also possible with a commc,, tool if the front grille and front bumper are removed. b. Adjust the door in the vertical and transversal directions by loosening the pillar side hinge bolts.

Door hin

Fig. 21-37 Atijusting door lock striker

NOTE: After adjusnient of the door, confirm there is no play around the door when the outer handle is depressed with the door closed. Play, if found, shall be removed according to the following procedure. 1) Loosen four screws. 2) Turn the .wedge around the pin with the wedge centering on the wedge receiver. 3) Loosen screws. 4) Close the door to check play of the door.

Fig. 21-38

Fig. 21-39 Adjusting door hinge

c. Small amount of adjustment in the door transversal direction and vertical direction can be performed by loosening the door side hinge.

Fig. 21-40 Adjusting door hinge

3.

Door window regulator

1) REMOVAL a. Remove the regulator handle, inner remote handle and door inner pull handle, and remove the door trim.

d. Turn the glass while rotating the regulator handle, remove the glass from the regulatc and hold the glass so that it doesn't fall.

NOTE: When removing the glass, hold its front or rear side up and remove upward.

Fig. 21-41 Removing door trim

b. Remove,the sealing cover. Fig. 21 -44 Removing glass Sealing cover

e. Remove the window regulator mounting bolts and remove the regulator from the working hole.

Fig. 21-42 Removing sealing cover

c. Place the glass in the middle position (vertical) and remove two regulator rail mounting bolts.

Fig. 21-45 Removing regulator

2)

Fig. 21-43 Removing bolts

INSTALLATION Installation is the reverse of removal. Pay careful attention to the direction of the pull handle, the regulator handle and remote handle installation angle.

4.

Cab door glass

1) REPLACEMENT a. Remove the glass assembly from the regulator in the same manner as removing the regulator. b. Installation is the reverse of removal.

NOTE: To hold the glass horizonatally and move up and down without inclination, finely adjust the rail of the regulator sub arm up and down.

5.

-

Fig. 21-47 Rerno.ving rear <

Door lock

1) REMOVAL AND REINSTALLATION a. Remove the door trim, and the service hole cover, and raise the glass to the top. b. Remove the safety knob, and disconnect the outer handle and inner remote wire connection. c. Unscrew the door lock mounting screws, and remove the lock through the working hole. d. Installation is the reverse of removal.

b. Remove the stopper (sliding door) from the lower rail.

Slide

Removing stopper (sliding door)

c. kemove the stopper (center arm) from the center rail. Marking the mounting position during removal will facilitate installation.

Fig. 21 -46 Removing door b c k

C.

S L I D I N G DOOR

1.

Sliding door

Stopper (c

1) REMOVAL a. Remove the rear quarter trim (refer to trim panel item).

Fig. 21-49 Removing stopper (center arm) 21 - 20

'

d. Move the door to the rear end, pull the lower arm out from the lower rail and the upper roller from the upper rail. When moving the door, be careful that the door is not slanted.

Floor

the stopper clearance.

T2 1-022

Fig. 21-52 Installing stopper (sliding door)

--

-- -

-

Fig. 21-50 Removing sliding door

e. Slide the door to the front end and remove the center arm from the center rail.

Fig. 21-53 Stopper (sliding door)

e. Fasten the door stopper (center arm) temporarily (so that it can be moved by hand).

Fig. 21-51 Removing sliding door

2) INSTALLATION a. Fit the upper arm to the upper rail. b. Fit the lower arm from the rear end of the lower rail. c. Slide the door to the front end and fit the center arm to the center rail. d. Install the stopper (sliding door). At this time, insert the flange of the stopper securely between the flanges of the rail.

r (center arm)

Fig. 21-54 Stopper (center arm)

f. With the door closed (striker and ratchet perfectly meshed), tighten the stopper (center arm) securely. g. Install the rear quarter trim.

NOTE: Tightening torque: Stopper (sliding door) 8 mm bolt: 1.2 to 1.4 kg-m (8.7 to 10.1 ft-lb) 5 mm bolt: 0.25 to 0.30 kg-m (1.8 to 1.0 ft-lb) Stopper (center arm) 8 mm bolts: 1.O to 1.2 kg-m (7.2 to 8.7 ft-lb)

uuur

\

loor

Fig. 21-56 Adjusting sliding door

When inequality has appeared between door and pillar, adjust it by moving the upper arm or striker to the left or right.

Removing and installing the galss The glass can be removed and installed together with the rubber. 3)

Fig!.21-57 Moving upper arm

Fig. 21 -55 Removing glass

4)

Adjustment of the sliding door When the sliding door is inclined, adjust it moving the lower arm up and down.

Fig. 21-58 Moving striker

NOTE: When performing above procedure, pay a. tention to the contact between striker an suspender.

5) Inspection of the arms a. Is there any rattling at the staked section of each arm ? -- Staking. b. Is there any leaning wear on the roller ? -Replace roller. c. Is the spring of the center arm abnormal ? -- Replace when permanently strained or broken. d. Does the roller turn smoothly ? -- Apply grease on the roller axis.

NOTE: Tightening torque: Upper arm, lower arm 8 mm bolts: 1.30 to 1.50 kg-m (9.4 to 10.9 ft-lb) Center arm 6 mm screws: 0.45 to 0.50 kg-m (3.3 to 3.6 ft-lb)

Fig. 21-59 Suspender

6)

Door latch -.

Safety r Difference of the each center line should

i

1

Connector

I

3r Sliding door

Fig. 21-60 Contact between sl and suspender

T21-023

Rennote cotrol wire C

'""' rter handle

Fig. 21-61 Component parts of door kztch

a. Adjustmc.. 1) Fix the connector so that there is no looseness when the wire is stretched fully. 2) Adjust and install the outer handle so that the push lever and adjusting screw contact when the safety rod is pushed down. After adjustment, push the pushbutton, and confirm moving of the phion by hand.

t ) Remove the mounting bolt and two

mounting screws, then remove the latch.

,

4 Push lever

T:

Fig. 21-64 Removing latch

Fig. 21-62 Adjusting screw b. Removal 1) Remove the stopper bushing and inner handle. 2) Remove the trim panel (refer to trim panel item). 3) Remove the connector screw. At this time, be careful not to drop the screw or washer inside the door.

5) Raise the safety rod upward and re the outer handle. At this time, be careful not to drop the mounting nut insicle the door. 6) Remove the safety rod knob while rwssing it. 7) Remove the remote by removing two mounting bolts.

I ,Ren

Fig. 21-63 Removing connector screw

Fig. 21-65 Removing remote

7)

Sliding door inspection

Symptom

Cause

Door closes poorly.

Striker (latch) position incorrect.

Inspection and corrective action Is vertical direction good? Is the door too far inside?

Good if door is locked when pushed by hand.

Move in arrow direction.

Fig. 21-66

I

topper (center arm) position incorrect.

Temporarily fasten the stopper, close the door complete, and then retighten the stopper.

Stopper (center arm) bushing deformed or

Replace bushing. (Install a bushing which can be easily rotated by hand.) Coat the inside and outside periphery of the bushing with grease.

/

topper (center arm)

Fig. 21-67

Symptom Door closes poorly.

Cause

Inspection and corrective action

Latch pinion cover and striker mesh when the door opened and closed.

Insert the spacer under the striker as required for adjustment.

-*

sw Pinion

Latch

T2 C1 W-025 w

Fig. 21-68

Rattles when vehicle is moving.

Striker protrudes too far.

1 inside. I

ker

Fig. 21-69

Suspender and striker (suspender) position incorrect.

Adjust so that the difference between the suspender and striker (suspender) position is within 1 mm (0.04 in) When the striker (suspender) is eccentrically worn. replace.

Strker (svsprd..)

Fig. 21-70

Cause Rattles when the door is slide. Door doesn't slide smooth.

Door doesn't open sufficiently . (Door does n o t fly open when outer handle push button depressed.)

I

I

Inspection and corrective action

Roller is n o t moving.

Apply grease between the roller and shaft.

Roller eccentric wear and inside and outside diameter wear.

Replace the roller, coat the shaft with grease, and confirm that rotation of the roller is smooth.

Foreign matter such as the sand, mud, etc. are fitted on the roller

Remove the foreign matter and keep clean inside of the rail.

Center arm spring perma. nently strained o r spring coils are rubbed each other.

Coat the spring with enough amount of grease. When the spring is permanently strained, replace.

Fig. 21-71

2.

Sliding door rail

2) Remove the rear quarter trim. 3) Loosen and remove six 6 m m flange nuts under the rail. 4) Reinstallation is the reverse of removal.

iide moulding

d ~ n gdoor r a ~ ltnstallat~onnuts

1F

Fig. 21-72 Sliding door rail

REMOYAL AND REINSTALLATION

1)

Remove the sliding door from body.

Fig. 21-73 Removing sliding door rail

.

D.

BACKDOOR

1.

Door lock striker

ADJUSTMENT Move the installation position to the front and rear and right and left, and use shims in the vertical direction so that there is no rattling when the door is closed lightly.

Fig. 21-75 Adjusting door hinge m R

lock strike

c. Perform door transversal and longitudinal adjustment by loosening the rear pillar side hinge bolts.

Fig. 21-74 Adjusting door lock striker

Fig. 21-76 Adjusting door hinge

3. 2.

Door hinge

INSPECTION a. When the door hinge rattles in the front and rear, left and right, or top and bottom directions, tighten the hinge bolts. b. When the hinge pin is loose, replace the hinge assembly. c. Adjust door drooping, joggling and split line as follows. 2) ADJUSTMENT a. Perform adjustment using a spanner or box wrench. b. Perform door vertical and longitudinal adustment by loosening the door side hinge 3olts. 1)

Stay

1) REMOVAL a. Remove the nuts mounting the stay upper from the door (hinge) with the door opened. -

.-

Fig. 21-77 Removing stay

b. Remove two stay lower mounting bolts from the body.

Fig. 21-80 Installing door lock

Fig. 21 -78 Removing stay

2)

4.

INSTALLATION Installation is the reverse of removal.

Door lock

1) REMOVAL a. Remove the door trim. b. Remove the door lock mounting bolts and remove the lock from the working hole.

21-5.

WINDSHIELD GLASS

REMOVAL AND INSTALLATION 1) Remove the wiper arms. 2 ) Bend the weather strip inwards and push the glass, outwards by foot from the inside of the passenger compartment. Then glass is removed.

I

Fig. 21-79 Removing door lock

2)

INSTALLATION Installation is the reverse of removal.

Fig. 21 -81 Pushing windshield glass

3) When installing windshield glass to the body, fit the weather strip onto the windshield glass and insert the work cord into the weather strip.

NOTE: a. Overlap the ends of the work cord at the top of the glass. b. After the work cord is fitted to the weather , strip, coat all around with clean gasoline.

5) Pushing the glass from the outside, graduallv pulling the work cord at a right angle to the glass. NOTE: a. Fitting is carried out from the upper center of the glass to the left and right. b. Install the glass sufficiently to the body, gently pushing it with hands from the outside. c. Fit the weather strip on the outside of the body correctly. d. Apply a sealing compound (Cemedine #366E) into the groove of the weather strip.

1 Work cord 2 Weatherstrip

Fig. 21-82 Fitting work cord Fig. 21-84 Applying sealing compound

Put the glass into the correct position from the outside, pull the work cord into the inside of the body.

4)

Body .panel Sealing compound

A24-090

L

~ r kcord

Fig. 21-83 Installing windshield glass

6 ) Return the wiper arm to surface of the glass.

1 I

21-6. 1.

INSTRUMENT PANEL

Component Parts

RIGHT-HAND DRIVE VEHICLE

11 12 13 14 15 16 17 18 19 20

1 2

Front panel stay Instrument panel retainer 3 Instrument panel 4 Instrument panel cushion 5 Instrument panel 6 Lighting switch 7 Fuse box lid 8 Wiper switch 9 Washer pump 10 Label

Ash tray holder Ash tray Glove box lid Lock Pocket Defroster nozzle Defroster duct Ventilator duct Ventilator duct Control lever

Fig. 21-86 Component parts of instrument panel 21 - 31

T21-027

LEFT-HAND DRIVE VEHICLE

1 2 3 4 5 6 7 8 9 10

11 Ash tray holder 12 Ash tray 13 Glove box lid

Front panel stay Instrument panel retainer Instrument panel Instrument panel cushion Instrument panel Lighting switch Fuse box lid Wiper switch Washer pump Label

14 15 16 17 18 19 20

Lock Pocket Defroster nozzle Defroster duct Ventilator duct Ventilator duct Control lever

Fig. 21-87 Component parts of instrument panel 21 - 32

T2 1 -028

2.

,

Combination meter

3.

Ash tray

REMOVAL AND INSTALLATION 1) Remove four combination meter installing screws.

REMOVAL AND INSTALLATION 1) Pull out the ash tray. 2) Remove two 5 mm tapping screws mounting the holder and remove the holder.

Fig. 21 -88 Removing combination meter

Fig. 21 -90 Removing holder

2) Disconnect the speedometer cable. 3) Take out the combination meter and then disconnect speedometer cable and wiring harness junction block from back side of the combination meter.

3)

Installation is the reverse order of removal.

4.

Glove box lid.

REMOVAL AND INSTALLATION 1) Remove three 5 mm screws under the lid.

Fig. 21-91 Removing lid Fig. 21-89 Disconnecting wiring harness

4)

Installation is the reverse order of removal.

2) Pull out the glove box lid from the instrument panel. 3) Installation is the reverse order of removal.

5.

Glove box lid lock.

2) Pull out the fuse box lid from the instrument panel. 3) Installation is the reverse order of removal.

After removing the instrument panel, perform removing the glove box lid lock.

7.

Instrument panel

REMOVAL AND INSTALLATION 1) Prior to removing the instrument panel, remove the steering wheel. 2) Remove the combination meter. 3) Pull out the ash tray and remove the ash tray holder. 4) Remove the glove box lid by removing the installing screws.

1 2 3 4

Flange nut Retainer Instrument panel Lid

5 6 7

Screw Lock Tapping screw T21-031

Fig. 21-94 Removing glove box lid

Fig. 21-92

6.

Fuse box lid

5) Remove the fuse box lid by removing the installing screws.

REMOVAL AND INSTALLATION 1) Remove 5 mm screw under the lid.

Fig. 21-95 Removing fuse box lid

Fig. 21 -93 Removing screw 21 - 3 4

NOTE: When loosening the screws on the top of the instrument panel, it is recommendable to use short Pillips screwdriver or "L" shaped one.

6 ) Remove 5 mm screw at the underside of the instrument panel center.

9 ) Remove the control knobs from air flow control lever and heater control lever.

Fig. 21 -96 Removing screw

7) Remove 5 mm flange screw installing rightside of pocket and two 5 mm tapping screws installing luggage shelf. (Right-hand drive vehicle only). Fig. 21-99 Removing control knob 10) Take out the instrument panel and disconnect the wiper switch wiring harness and windshield washer pipe.

Fig. 21-97 Removing screw

8) Remove four 5 mm screws upper the instrument paneland remove the retainer. Fig

Fig. 21-98 Removing retainer

Removing instrument panel

Fig. 21-101 Removing wiper switch wiring harness 21

- 35

8.

Front luggage shelf (Right-hand drive vehicle only)

3) Disconnect the control cable clamp to remove the control cable from the duct assembly. 4) Remove the heater fan switch harness. 5) Remove three tapping screws fixing the lever assembly to the body panel.

1) Remove the instrument panel. (Refer to Removal of instrument panel.) 2) Remove four 5 mm tapping screws and take out the luggage shelf.

Fig. 21-102 Removing luR4ade she1

Fig. 21-1 04 Removing tapping screw of lever assembly

6)

Remove the lever assembly by pulling it

out.

9.

Air flow and heater control lever

REMOVAL AND INSTALLATION 1 ) Remove the instrument panel (See "Removal of instrument panel.") 2) Disconnect control cable clamps to remove the each control cable from the heater unit.

Fig. 21-1 05 Removing lever assembly

NOTE: When pulling out the lever assembly, take care the soldered portion where cables are connected to the heater fan switch is not damaged by the body panel.

Fig. 21 -1 03 Disconnecting control cable 21

- 36

7) Installation the lever assembly in the reverse order of removal.

Remove two screws fucing the ventilator duct to the lower part of the instrument panel.

4)

NOTE: a. When connecting control cables, confirm all shutters and cock completes are entirely closed. b. After connection, confirm the operation of each shutter and cock complete.

--

Fig. 21-1 08 Removing ventilator duct installing W

5) Remove me license plate. 6) Remove four tapping screws fucing the air flow ventilator duct to the front panel.

Fig. 21-1 06 Shutter closing position

10. A i r f l o w ventilator duct REMOVAL AND INSTALLATION 1) Remove the instrument panel. (See "Removal of instrument panel.") 2) Remove the Air flow and heater control lever. (See "Removal of air flow and heater control lever.") 3) Remove the heater unit. (See "Removal of heater unit.")

L

ews

-

IrV. . *.,b

$

h3,.

.I

Fig. 21-109 Removing ventilator duct installing screw

7) Remove the duct assembly after moving it to left side. 8) Install in the reverse order of removal.

Fig. 21-107 Removing heater unit

NOTE: a. When mounting the duct assembly, replace the urethane (671042040) containing sealing agent by new one to prevent water leakage through the junction of the front panel and the duct. b. Apply sealing agent (Cemedine 366E) to front panel mounting screws before installation. c. Fix the control cable by attaching the firmly.

21-7. 1.

SEAT

Component parts of seat Front seat

1 2 3 4

Rear seat (Van only)

5 6 7

Front seat back rest Front seat cushion Rear seat back rest Rear seat cushion Hook Band Rear seat bracket

T2 1 -035

Fig. 21-1 I0 Component parts of seat 21 - 38

2.

Removal a n d installation

FRONT SEAT 1) Remove the cushion by lifting the front end of it while pushing it to the rear.

Fig. 21 -1 13 Removing back rest 3)

Installation is the reverse order of removal.

NOTE: The seat cushion has two positioning pins on right and left sides of it. Mount the cushion so that the pins are inserted in predetermined holes.

Fig. 21- 111 Rem oving cusi

2) Remove the frame under the back rest from the hook attached to the lower part of the back panel. Remove the back rest by lifting.

Fig. 21-1 14 Seat cushion positioning hole

REAR SEAT 1) For the van rear seat, remove two bolts threaded to the floor after foldine the seat.

Fig. 21-1 12 Removing back rest

For truck and flat bed truck, first remove the back rest fromthe lower hook, then remove the back rest from the upper hook with the back rest moved upward.

Fig. 21-1 15 Rear seat installing bolt 21

- 39

21-8. 1.

INNER TRIM

Component parts

1 Roof trim seat 2 Cab door trim panel 3 Slide door trim panel 4 Rear quarter trim panel 5 Back door trim panel

DETAIL " B "

6 7

8 9

Clip Clip Shroud trim Insulator

10 T2 1-038

Fig. 21-1 16 Component part5 : of inner trim

2.

Cab door trim

REMOVAL AND INSTALLATION 1) Remove the regulator handle, pull handle and door inner remote handle. 2 ) Disconnect the resin clip from the door inner panel with a (-) screw driver to remove the door trim.

NOTE: a. When removing the resin clip, take care not to bend the trim panel. b. The resin clip can be removed easily by using the special tool shown in Fig.

NOTE: The resin clip can be removed easily ay using the special tool shown in Fig. 21-125.

Welded portion

Pipe [12 (0.47) dia.1

Fig. 21-1 17 Special to, 1 Clip 2 Trim panel 3 Special tool

T2 1-042

Fig. 21-120 Removing trim 3) 1 Trim panel 2 Clip 3 Special tool

Installation is the reverse order of removal.

NOTE: If the removed resin clip is damaged, replace it with new one.

T2 1-040

Fig. 21-1 18 Removing trim 3)

Installation is the reverse order of removal.

3.

Slide door t r i m

4.

REMOVAL AND INSTALLATION 1) Remove the resin clip from the back door inner panel with a (-) screw driver or special tool to pull out the back door trim. 2) Installation is the reverse order of removal.

REMOVAL AND INSTALLATION 1) Remove the inner remote handle. 2 ) Remove the .resin clip from the slide door inner panel with a (-) screw driver to pull out the door trim from the rail.

2 3

Screwdriver clip

Back door t r i m

I

T21-041

Fig. 21 -1 19 Removing resin clip

Fig. 21-121 Removing back door trim

21-9. 1.

INNER ACCESORIES Component parts

'.

\

1 Sun visor assembly R.H. 2 Sun visor assembly L.H. 3 Rear view mirror (inner) 4 Screw (plastic) 5 Tapping screw (pan head) 6 Assist rail 7 Screw 8 Washer 9 Spring washer

,

T21-043

Fig. 21-122 Inner accessories

2.

Sun visor

The sun visor is removed by loosening the tapping screws.

3.

Rear view mirror (inner)

The rear view mirror is fallen down resulting from breakage of the screw made of plastic in case of collision. And it can be removed by loosening the screw.

.stalling it, be careful not t o dam\ age me screw because the screw is made of plastic. The mirror is adjustable in up and down direction by turning it.

4.

Assist rail

The assist rail can be removed by loosening two screws.

21-1O.OUTER

1.

ACCESORIES

Component parts

1 Outer mirror

4

Front grille ornament

5 Center slide door rail 6

Slide rail ornament

T2 1-044

Fig. 21-123 Component parts of outer accesories

2.

Front side grille Loosen three screws, and the front side grille is removed.

3.

Rear view mirror The rear view mirror is removed by loosening two Cap nuts.

uts

Fig. 21-124

Fig. 21-1 25

4.

Splashboard

The splashboard is removed by loosening bolts and nuts.

Fig. 21-126

CHAPTER

22:

BODY ELECTRICAL SYSTEM

Page

22.1

.

. 22.3 . 22-4 . 22.5 . 22.2

..................................................................

22-2

..............................................................

22-7

........................................................................................

22-10

WINDSHIELD WIPER

COMBINATION METER HORN

TURN SIGNAL AND HAZARD UNITS

.................................... 22-12

SWITCHES ...................................................................................

22-14

......................................................................................... BOX AND WIRING HARNESS .......................................

22.6

.

LIGHTS

22-16

22.7

.

FUSE

22-20

22-1. 1.

WINDSHIELD WIPER

Construction and operation

1

Wiper blade

2 Wiper arm

6 Washer 7

Cushion A Cushion B Wiper link Packing Wiper motor bracket 12 Wiper motor

8 9 10 11

Fig. 22-1 Wiper component parts

The wiper uses a small motor as the drive source and the wiping operation is performed by driving the wiper shaft (shaft mounting the blade and arm) in a reciprocating manner with a link device by means of a clamp and rod at the rotating shaft (wiper motor output shaft) whose speed has been reduced to the specified speed by means of a reduction gear (worm reduction gear). 1) When the wiper switch is turned ON, current flows through the circuit BS2-(A)-E and the motor is operated. Refer to Fig. 22-2. 2) The motor is kept operated even after turning off the wiper switch while the ignition-starter switch is in "ON" position until the lever is pushed up and the cam inside the motor reaches the specified position, since the circuit B-(cam)S -S2-(A)-E is closed.

Wiper motor

T22-002 b

Fig. 22-2 Wiper wiring diagram

3) When the circuit is interrupted at the specified position, the circuit (A)-S2 -S1 -P-(A) indicated by the arrows in the diagram is formed and the motor is electrically braked and stops at the specified position. 4) When the wiper switch is set to OFF when the key switch is in the OFF position, no currents flow in the circuit and the motor stops. However, if the key switch is set to ON, the actions of (2) and (3) above are repeated and the motor is stopped in the specified position.

e. Remove both right and left wiper arms by loosening the wiper arm tightening bolt.

Fig. 22-4

2.

f. Pull out the rubber caps on the shaft and remove wiper link installing nuts.

Removing and reinstalling the wiper motor

1) REMOVAL a. Remove battery grounding wire. b. Remove the light ring on right-hand side (right-hand drive vehicle) or left hand side (left-hand drive vehicle). c. Loosen headlight adjusting screws and remove the right headlight (right-hand drive vehicle) or left headlight (left-hand drive vehicle), while turning it to the right. d. Loosen and remove the wiper motor installing nuts. (Three f lange nuts,)

g. Remove the steering wheel. h. Remove the combination meter. i. Remove lighting switch. j. Remove the defroster. k. Disconnect wiring harness of the wiper motor. 1. Disconnect the wiper linkage from the motor shaft. m. Take out the wiper motor assembly through the instrument panel.

I

Fig. 22-5 Removing wiper motor

2)

Fig. 22-3 Removing nfi

22-3

INSTALLATION Installation is the reverse of removal.

Troubleshooting Trouble

Location

Switch Operating speed is low Linkage

Blade

Problem with speed changing

Harness and switch

Incorrect wiper stopping

Switch

Cause

Checking method

Corrective action

Faulty switch contact.

Check voltage drop across switch and operate the switch several times.

Replace the switch.

Improper operation of switch or braking current due to short.

Check switching operation of contacts.

Replace switch.

Motor overheats.

Imminent seizure of arm shaft.

Motor growls in phase with arm movement.

Blade tends to stick to the glass surface.

Raise the arm and check unloaded operation.

Grease or replace the arm shaft.

I

Clean the blade and glass surface. Replace the blade.

Short circuit in harness.

Motor overheats.

Repair.

Loose harness connection.

Check connections.

Take appropriate action.

Loose of switching action.

Check the switching action.

Replace the switch.

Use of wrong switch.

Check the switch type.

Replace the switch with the specified c

Incorrect connection of harness.

Match color coding.

Correct connection

Connection fault or wiring error in S 1 (yellow) or B (blue) circuit.

Check the connections.

Correct connections.

Bad connection between terminals 1 and 2 of switch

Disconnect the switch. With the switch set to the off positi'on, check continuity between terminals 1 and 2.

Replace the switch.

Faulty switch contact.

Trouble

Stops at any point

Stops

Location

Motor

Harness and switch

Wiper noise

Abnormal noise

Wiping trouble

Motor

Cause

Checking method

Dirty auto stop relay contacts.

Remove the auto stop cover and check.

Clean the contacts. @o not deform the relay plate in the process.)

No break between B and C of the auto stop relay.

Remove the auto stop relay cover and check.

Correct by bending the relay plate.

Improper connection.

Match color coding and check connections. Fuse often blown.

Correct connections. Replace fuse.

Armarure contact due to worn bearings.

Vibration occurs with motor disconnected and hand held.

Replace motor.

Excessive armature shaft thrust play.

Noise appears when motor is shaken in direction of thrust.

Carefully adjust play by means of the screw for this purpose.

Deteriorated or worn blade rubber.

Check the edge of the blade rubber.

Deformed blade rubber.

Check the state of the rubber.

Poor blade pressure distribution.

Check the formed portion of the blade holder.

Worn motor brushes.

Current does not flow in armature.

Replace the armature or motor. Replace the brushes.

Seized motor shaft.

Motor overheats in four to five minutes.

Replace the motor.

Short in motor, beginning of short, or heat damage.

Wiper circuit fuse blows immediately.

Repair the short or replace the motor.

D'-wn fuse due to othc:r component i n u~ i p e circuit. r

Check other components.

Replace fuse.

Loosen or open wiring connection.

Check wiring associated with motor and connector.

Restore to normal.

Error in connection.

Match color codes.

Correct.

Ground fault.

Check ground.

Correct.

Poor contact between A and B due to foreign matter.

UIU

Wiper does not operate

Power source and harness

Corrective action

Trouble

Location Switch

Wiper does not operate

Linkage

Cause

Power not applied to motor.

Replace switch.

Other components or harness caught in linkage.

Check linkage.

Correct.

Seized or corroded arm shaft.

Shift fore and aft movement of the arm shaft should be possible.

Re-install the clip. Lubricate or replace the arm shaft.

Layer short in motor armature.

With arm lifted, current is excessive (three to five times normal).

Replace the armature or motor.

Worn motor brushes.

Motor stops under light pressure on the arm.

Replace the brushes.

Imminent seizure of motor shaft.

With arm lifted, current is excessive (three to five times normal).

Replace the motor or lubricate the bearings with engine oil.

Low source voltage.

Check the voltage, or the state of other systems (lighting).

Service the battery.

Poor connections.

Wiggle the connections or check resistance.

Remove corrosion and re tighten connections.

Short in harness.

Motor overheats.

Clear the short.

Poor ground.

Check ground point.

Retighten connection.

Power and harness

Corrective action

Faulty switch contact.

Motor

Operating speed is low

Checking method

22-2. 1.

COMBINATION METER Component parts

1 Meter visor 2 Combination meter glass 3 Combination meter window plate 4 Combination meter 5 Thermometer 6 Fuel meter 7 Printed plate 8 Bulb 9 Socket 10 Buzzer 11 Speedometer

%

Q T22-005

Fig. 22-6 Combination meter

2)

1) Remove four combination me:ter installing screws.

Disconnect the speedometer cable. 3) Take out the combination meter and then disconnect speedometer cable and wiring harnesses junction block, from back side of the combination meter.

Fig. 22-7 Removing comb in at^ion meter

Fig. 22-8 Disconnecting wiring harness

2.

Removal and ins

22 - 7

4)

3.

Installation is the reverse order of removal.

Disassembly and assembly

1) Remove four tapping screws on lower back side of combination meter and disassemble the meter visor and lens complete.

Fig. 22-1 1

Remove three nuts and remove fuel meter

Fig. 22-9

Remove two screws installing the speedometer gear.

2)

Fig. 22-1 2 Removing fitel meter unit

5 ) Remove three nuts and remove thermometer.

Fig. 22-10 Removing speedometer installing screws

3) Remove a screw on right side of combination meter panel and remove the speedometer and combination meter panel as assembly.

Fig. 22-13 Removing thermometer

6)

Assembly is the reverse of disassembly.

4. 1)

NOTE: With the- drive shaft turning a t 1,020 rpm, the nominal indication is 60 MPH.

Checking combination meter Speedometer

a. Indicated error as measured with a speedometer tester is acceptable if it conforms to values in the following table. With the drive shaft turning at 637 rpm, the nominal indication is 60 km/h.

b. When the pointer fluctuation is large, the cable may be defective or installation may be incorrect.

Kilometer indication

2)

Nominal indication (km/h)

20

Tolerance (km/h)

-1 -3.5

Mile indication

+u.4

-2.6

60

80

+2 -2

+3.8 -0.6

100

120

+5 -0

Nominal indication MPH

20

40

60

Tolerance MPH

-0.1 -1.9

tT.5 -1.1

t3.0 -0.1

Fuel mete

a. Check for a grounding or open circuit between fuel meter and unit. Check if each connection and contact are insufficient. b. When unit terminal connection is disconnected, the meter indicates "0" (empty). If the meter pointer slowly shifts toward the "1" (full) position when the disconnected lead is grounded through the pilot light (1 2V-3W), the meter is functioning properly. If the pilot light does not light in this situation, the heat coil of the meter is open. Charge warning light The charge warning light should light when the ignition switch is turned to the first position. One side of the light is connected to the ignition switch and the other side to the armature terminal of the alternator. When the alternator voltage is less than the battery voltage, current flows from the battery through the ignition switch, charge warning light, and armature circuit to ground, causing the warning light to light. When the alternator speed increases and the alternator voltage rises t o the point at which terminals A and L of the regulator are shortened, potential across the light disappears and the light goes out. If the engine is operating at high speed and the light - remains lit. check the alternator and regulator.

Charge warning light

Ignition switch

T22-013

~ i g22-1 . 4 Wiring diagram

3)

4.

Thermometer unit

Thermometer unit is located on the cylinder head.

Fig. 22-15 Thermometer location

6.

Combination meter connections

Thermometer unit Thermometer

Voltage regulator

T22-014

Fig. 22-1 6 Wiring diagram of thermometer

5.

Oil pressure switch

1 2 3 4

Oil pressure switch is located on the oil pump body and wiring diagram is as shown in the Figure.

5

6 7

8 9 10 11 12 13 14

Thermometer terminals Fuel meter terminals Meter illumination light High beam indicator light Direct terminal Meter illumination 1 Buzzer Combination meter Speedometer cable boss Left turn signal light Right turn signal light Charge indicator tight Hand brake and brake fluid level warning light Oil pressure indicator light T22-016

Fig. 22-1 9 Fig. 22-1 7 Oil pressure switch location

Oil pressurewarning light Ignitionlstartor switch

22-3. HORN c * 0 .' .-

a,

2

Ignition

1.

Specifications

E!

.

-

if

E!

.--a 0

Voltage

13V

Current

+ 0.5 A 3.0 - 1.0

T22-015

Fig. 22-1 8 Wiring diagram of oil preasure switch

Basic frequency

330-370 Hz

Sound pressure

100- l l 0 d B

2.

rzuw

Operation

Fuse

Sound energy is produced by a diaphragm set into motion by electric means. Pushing the horn switch closes a circuit which allows current to flow through the horn coil and the coil attracts the plunger. The diaphragm coupled directly with the plunger is attracted rapidly and density of air in front of diaphragm becomes low. At this time, one part of the plunger strikes the contact spring, opening the coil circuit. The magnetic field collapses and the plunger returns to its original state by virtue of spring force of the diaphragm. This action compresses air in front of the diaphragm. At the same time the contacts reclose and the sequence repeats itself. Repetition continues as long as the horn button remains depressed. Sound is generated by repeating change of air density.

-- Battery 10V renge T22-018

Fig. 22-21 Horn inspection

4.

Removal and installation Disconnect the wiring, and remove the rn installing nut.

Fig. 22-20 Horn ope...+;--

3.

Inspection

When the horn does nor souna, cneck the voltage with the tester as shown in Figure. Fig. 22-22 Removing horn

When voltage: below 2V: Horn is abnormal. over 2V: Worn horn button or faulty grour

2)

Installation is the reverse order of removal.

22-4. 1.

T U R N SIGNAL AND HAZARD UNITS

3. Operating principles Automatic flashing and snapping of those units are accomplished by expansion-contraction of a heater band and action of a snap spring.

Specifications

.

Front and rea; turn signal light: 23W x 4 A

Side turn signal light: 6Wx2

Load

Heater band

Turn signal pilot light: 3.4W x 2 72 - 98 timeslmin.

frequency

2. 1)

T22-021

Wiring diagrams

Fig. 22-25 Operation A

Turn signal unit

=

Fuse

I Bi

-Turn -- - - -signal - - - - -unit - -,

Pilot light

3w

I

I

lcb',

signal

' ' switch

=

&

Battery

Fig. 22-26 Operation B

T22-019

Fig. 22-23 Turn signal circuit

2)

4.

2ight

Hazard unit

1) When replacing the bulb, strictly use specified one as follows:

Front turn

Side turn signal light

Pilot light Hazard

,*-. B : .__, F&e

$ Battery

Front turn signal light

12V - 23W (12.8V - 1.8A)

Rear turn signal light

12V - 23W

Side turn signal light

12V - 6W

Turn signal pilot light

1 2 v - 3.4w (14V - 0.24A)

Lyi4pi

Rear turn signal light r.._.__.__-____-_ \

Cautions for handling the turn signal light

L

-.--------. ---J

Hazard unit

m

23.4

r

L

T22-020

Fig. 22-24 Hazard unit circuit

This type of unit operates by the current through the lights therefore, if wrong rated light is used in the circuit, the turn signal units

does not operate normally since different current flows through the circuit.

at the left end of the bulkhead below the instrument panel.

2) If a single bulb is burnt out, the flashing frequency does not change appreciably (keep light on).

3) Do not apply large shock on turn signal or hazard unit while handling it. 4) The turn signal and hazard units are getting hot like a vacuum valve by continuous operation, but this is not an abnromal sign.

5.

Location of turn signal and . . hazard units

q. 22-2 7 Location of turn signal and

The turn signal and hazard units are installed

6.

hazard units

Turn signal circuit troubleshooting TROUBLE AND POSSIBLE CAUSE

CORRECTIVE ACTION

Left a n d right flashing frequency differ o r o n e side only functioning properly I

1) 2) 3) 4) 5)

Burned out bulb Defective switch I m p r o p e r bulb installed P o o r ground a t bulb P o o r wiring connectic

Replace bulb R e p a i r o r replace switch Replace with specified bulb C o r r e c t the socket contact C o r r e c t connections

Both sides d o n o t light 1) Blown fuse 2) Open w i r e between battery and switch o r

Replace the fuse

poor connection 3) Defective switch 4) Both left and right pilot lights burned out 5) Defective t u r n signal unit

R e p a i r o r replace wiring Repair o r replace switch Replace bulbs Replace t u r n signal unit

Both sides remain lit 1) Defective t u r n signal unit

Replace t u r n signal unit

High flashing frequency 1) Low wattage bulb used 2) P o o r ground a t bulb 3) Defective t u r n signal unit

Replace with specified bulb C o r r e c t the socket contact Replace the t u r n signal unit

Low flashing frequency 1) Low s o u r c e voltage 2) High wattage bulb used 3) Defective t u r n signal unit

Charge the battery Replace with specified bulb Replace t u r n signal unit

22-5. 1.

SWITCHES Lighting and parking switch

This switch is actuated both by pulling and turning. Pulling the knob t o the first position lights the clearance lights. Moreover, when the headlight beam switch lever is operated, the headlights (low beam) can be lighted. While pulling the knob to the second position, these lights light together (in this case either high beam or low beam lights up). With the knob pushed in (OFF position), the parking lights are lighted by turning the knob to the right. rzg. ZZ-ZY ~ i g h t i n switch ~

REMOVAL AND REINSTALLATION a. Detach the combination meter. b. After detach the lighting switch knob, unscrew the dress nut. c. Put the hand into the inside of instrument panel through the combination meter hole and take out the lighting switch. d. Reinstallation is the reverse of removal. Pullfng

Forst posntion

o

O

Second

0

n"<,.,""

.

O

.

o

0

2.

-.

P

P L

& a

3

0

c

.

C

0 " 3

0

5

-5 :

=

Y,

o" m = a E = g,!2

- - I

Ignition-starter switch

For right-hand drive, the ignition-starter switch is attached by dress nut to the instmment panel. For left-hand drive, the ignitionstarter switch is attached with steering lock system located under the instrument panel. Connections are made by means of a junction block.

T22-023

Fig. 22-28 Lighting circuit diagram

Note that the knob cannot be pulled out while it is turned when using as the parking switch and that it can not be turned while it is pulled out when using as the lighting switch. Always operate the switch from the OFF position.

Fig. 22-30 Ignition-starter switch

4.

C o m b i n a t i o n switch

REMOVING AND REINSTALLING 1) Remove the steering wheel. (Refer to information on steering wheel in Chapter 15, 15-3, on page 15-4). 2) Remove the hazard switch knob by unscrewing it. 3) Separate the switch assembly by removing the 4 rnm screw securing it to the bracket. 4) Reinstallation is the reverse of removal.

NOTE: a. Install the steering wheel so that the horn bar lies horizontally. b. Install the canceling cam so that it is located at right angles to the turn signal lever.

T22-024

Fig. 22-31 Connections

3.

ltion switcln

Back-up l i g ht switch

REMOVAL AND REINSTALLATION 1) Open the trap door. 2) Take out the insulator. 3) Detach the back-up light switch attached .on the left side of transmission. 4) Reinstallation is the reverse of removal.

Fig. 22-33 Combination switch

5.

Wiper switch

The wiper switch is attached to the instrument panel by means of an dress nut. Loosen the screw at the bottom of the knob and remove the knob. Remove the dress nut and separate the switch from the panel.

NOTE: I n reinstalling the knob, turn it so that the screw is located at the bottom.

Fig. 22-32 Back-up light switch

22- 15

Fig.

Fk. 22-34

6.

:op light switch (Left-hand drive)

Wiper switch

Stop light switch

The stop light switch is mounted on the pedal bracket and is operated by the brake pedal.

22-6.

1.

Fig. 22-36 Stop light switch (Right-hand drive)

LIGHTS Specification

Headlight

12V - 50W/40W (Right-hand drive vehicle) 12V - 45W/40W (Left-hand drive vehicle)

Front combination light Turn signal light Clearance light

12V - 23W 12V- 5W

Side turn signal light

12V-

Rear combination light Turn signal light Stop and Tail light

12V - 23W 12V - 21W/5W

Back-up light

12V - 12W

License plate light

12V - 1OW

Room light

12V-

-

6W

8W

2. Headlight

Fig. 22-38 Removing headllight

1 2 3 4 5 6 7 8 9

Headllight assembly Screw Ring Washer Spring Set plate B Screw Sealed beam unit Set plate A

~22-025

Fig. 22-3 7 Heudllight assembly

Fig. 22-40 Front combination light

3. For Right-hand drive model, the headllight is of an all-glass sealed beam type. For Left-hand drive model, the headllight is of a bulb type. Two filaments, 50 & 40W for sealed beam, 45 & 40W for bulb, encased in the bulb and lights are changed over by means of head-light beam switch. Adjustment is performed with screws. 1) Removal and reinstallation a. Remove the headlight vessel. b. Loosen the headlamp instau rs (adjusting screws) until the spring tension becomes free. c. Hold the ring and remove the headli~ turning it to the right. d. Disconnect the wiring. e. Reinstallation is the reverse of removal.

Front combination light

Fig. 22-40 Front combination light

The front conbination light includes the turn signal light (23W), clearance and parking light (5W). 1) Removal and reinstallation a. Disconnect the wiring harness. b. Remove the lens by removing the lens mounting screws. c. Take out the light case from the body. d. Reinstallation is the reverse of removal. 2) Changing bulb Remove the lens mounting screws and lens. Remove the bulb by depressing it and turning to the left. Fig. 22-42 Side turn signal light

-8,

5.

,

License plate

Fig. 22-41 Removing bulb

4.

Side turn signal light

The side turn signal lights are installed on both (right and left) sides of the headlight vessel. When changing the bulb, remove the lens mounting screws and lens, and remove the bulb by depressing it and turning to the left.

Side turn signal light bulb

6W

Fig. 22-43 License plate light

The license plate light lights at both the first and second pull positions of the lighting switch. When changing the bulb, remove the cover and lens by unscrewing two cover mounting screws, and remove the bulb by depressing it and turning to the left.

6.

Rear combination light

I

D

1 Rear combination light ass'y 3 Bulb (12V-23W) 4 Bulb (1 2V-12W)

1) Removal and reinstallation a. Remove seven (Van) or four (Truck) lens installing screws and remove the lens. b. Disconnect the wiring harness. c. Reinstallation is the reverse of removal. 2) Changing bulb Remove the lens by removing the lens installing screws and remove the bulb by depressing it and turning to the left. 3) Back-up light (Truck) When removing, remove two lens installing screws and remove the lens, and disconnect the wiring harness. Reinstallation is the reverse of removal. When changing the bulb, remove the lens by removing the lens installing screws and remove the bulb by depressing it and turning to the left.

7 - Shade B 8 Lens complete 9 Pan-head screw

Fig. 22-46 Removing back-up light (Truck)

7.

Room light

Truck

1 2 3 4 5 6 7

Rear combination @ht ass'y Plate Bulb (12V-21/5W) Bulb (12V-23W) Packing Screw Lens complete 8 Pan head screw 9 Screw

Van

1 2 3

Room light lens Room light Bulb T22-034

Fig. 22-45 Rear combination light (Truck)

Fig. 22-47 Room light

22 - 19

REMOVAL AND INSTALLATION A. VAN 1) Pull down the lens by turning the mark position ( Q or "OEW' mark) to the lever part. 2) Remove the light assembly by loosening the screws. 3) Disconnect the wiring harness. B. TRUCK 1) Remove the lens by pushing the lens edge with fingers. 2) Remove the light assembly by loosening the screws. .3) Disconnect the wiring harness. Fip. 22-48 Replacing fuse

CHANGING BULB Remove the lens and pull out the bulb.

22-7. 1.

FUSE AND WIRING HARNESS Fuse box

The fuse box is located on the instrument panel, making fuse replacement easy. And a main fuse is adopted on the electric circuit from the battery to the fuse box. Fig. 22-49 Fuse

2. Fuse 5 (A)

1) Before carrying out operation, be sure to disconnect the battery (-) terminal. 2) When pulling out the wiring harness which runs through inside of the front pillar, rear quarter and back door, tie the wiring harness with the wire or string and pull it out 3) If the wiring harness is contacted with the clamp or other parts, protect the harness contacting point with the vinyl tape. 4) When installing the parts, do not put the harness between the parts and its fitting position. 5) When connecting the connector, be sure to confirm the color cord of the connector with the wiring diagram. 6 ) When connecting the battery cable, turn off each switch and confirm whether the wiring harness is shorted or not by contacting the battery cable t o the battery terminal.

Tail light, Licence plate light

15 (A)

Hom, Turn signal light, Blower motor, Stop light, Ignition coil

20 (A)

Hazard light, Wiper motor, Headlight (main beam), Cigarette lighter, Tail light, Radio

20 (A)

Headlight (low beam), Licence plate light, Room light, Tail light, Clearance light

25 (A)

Starter, Heater fan

Cautions for removing and reinstalling the wiring harness

22 - 20

CHAPTER 23 : MAINTENANCE SCHEDULE

,lace enaint

X - Chcck, atljust or III~I~IIIIIIII R

- Replace