!

I \ INDEX CHAPTER ,

L I

SERVICE
MANUAL

TRUCK & VAN

 -
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, in-
spection 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:

K77 002001 and after Truck and Flat Bed Truck

Right-Hand
Drive Model
K87 002001 and after Van and Delivery Van

K77L 5iOOOl andl after Flat Bed Truck

Left-Hand
, Drive Model
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.
 CHAPTER 1 : GENERAL INFORMATION

Page
11
. . IDENTIFICATION NUMBERS ........................................................... 1-2
12
. . CAUTION LABELS ........................................................................... 1-2
13
. . RECOMMENDED FUEL ................................................................... 1-2
14
. . RECOMMENDED LUBRICANTS .................................................... 1-2
1-5 . RECOMMENDED COOLANT AND BRAKE FLUID ...................... 1-3
16
. . REFILLING CAPACITY OF OIL AND COOLANT ....................... 1-3
17
. . L l FTlNG POtNTS AND TOWING HOOKS ..................................... 1-4
1-1. IDENTIFICATION NUMBERS 1-2. -..-CAUTION LABELS

1. Engine serial number 1. Tire inflation pressure label

The die stamped engine serial number is Tire inflation pressure label is stuck on the
located on the front of the crankcase as shown end of driver's side door.
in Fig. 1-1.

Fig. 1-1 Engine serial number location Fig. 1-3 Tire inflation pressure label

1-3. RECOMMENDED FUEL

The SUBARU 600 engine is designed to get
2. Chassis serial number satisfactory engine performance by using gaso-
The die stamped chassis serial number is line no less than 83 octane.
located at the chassis frame as shown in Fig.
NOTE:
1-2.
Octane as selected by Research method.

1-4. RECOMMENDED
LUBRICANTS

1. Recommended SAE viscosity

number
1) Engine oil
AP1 SAE viscosity No. and Applicablc Temperature
Classifi-
cation -30°C (-20°F) O°C (30°F) 30°C (90°F)
T l I T T
-2s0C (-1O0F)
Fig. 1-2 Chassis serial number location
30,2OW-40,
20W-50
SE

NOTE: low-30, low-40,

1OW-50
Engine and chassis numbers are used for
factory communications such as Technical
reports, Service bulletins and other informa- I (5W-30 is not recommended for
sustained high speed driving) I
tion. I I I I I
- -- . .

2) Transtnission gear oil NOTE:

Use "SUBARU genuine coolant" when re-
placing or refilling the coolant.

SUBARU COOLANT (net 18 liter)

Parts No. 000016218

2. Brake f l u i d

Heavy Duty Brake Fluid

NOTE: (FMVSS NO. 1 16, DOT3)
Each oil manufacturer has i t s base oil and High boiling point
additives. Thus do not mix two or more
brands. NOTE:
a. Avoid mixing brake fluid of different brands
to prevent the fluid performance from de-
grading.
b. When brake fluid is supplemented, be careful
1-5. RECOMMENDED COOLANT not to allow any dust into the tanks.
AND BRAKE FLUID

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

1-6. REFILLING CAPACITY O F O I L A N D COOLANT

Liter U.S. measure Irnp. measure

Fuel Tank 31 8.2 gal. 6.8 gal.

(Oil pan capacity) 2.5 2.6 q t . 2.2 qt.

Engine oil
(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.

1-7. L I F T I N G POINTS A N D 1) Front
TOWING HOOKS 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.
2) Rear
When jacking up the rear of the vehicle,
NOTE: place the chocks at the front side of the front
Never get under the vehicle while it is wheels to hold them.
supported only by the jack. Always use
safetv stands to suooort bodv when vou
7 --Ti
have ;o get under the'&.

Fig. 1-7 Rear jack up point

3. Towing hooks
Fig. 1-5 Pantograph jack
Towing hooks are provided in front and rear
ends of vehicle.

NOTE:
2. Garage jack
a. Before towing the car, make certain that the
NOTE: parking brake is released and transmission is
After jacking up the vehicle with garage jack, in neutral.
be sure to support the vehicle with safety b. Never turn the ignition key to the ,"LOCK"
stands for safety. position while the car is being towed.
Fig. 1-8 Front towing hook Fig. 1-9 Rear towing hooks
I
 CHAPTER 2: SPEC1FICATIONS

!
I
-,'... 2-1. ENGINE SPECIFICATIONS ......................................................... 2-2
. , 2-2.
*; 4.. .
BODY. .SPEC1FlCATlONS
; .$
...........................................................
. . ............ ....
2--6
.. .
I . . .
- +$. ! I

.- '; sW4.d
d , ! 4 i ' 2 4 . . . .
-h
8
. .
. : : - ?.
*,.-r$, + - - c L L ' - - ~ - -- ' ,,: L. .:
-
-
.................. - .~
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
kg/cm2 (psi) 10.5 (149.31)
(at 300 rpm)

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)

626 x 562 x 416 (24.6 x 22.1 x 16.4)
(Length x width x height)

Weight of engine without transmission

61 (134.5)
(Including engine oil) kg (lb)

Engine location Rear

Material of piston Aluminum alloy

Number of piston rings Compression : 2, Oil : 1

Opening B.T.D.C. 26"

Intake valve timing
Closing A.B.D.C. 66"

Opening B.B.D.C. 66"

Exhaust valve timing .
Closing A.T.D.C. 26"
 Intake 0.13 - 0.17 mm (0.005 - 0.007 in)
Valve clearance (cold)
Exhaust 0.23 - 0.27 mm (0.009 - 0.01 1 in)

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
Ignition coil
Manufacturer Diamond electrical manufacturing company

Type of ignition advancer Vacuum x Centrifugal type

Type BP6ES L45PW W2OEP

Manufacturer NGK HITACHI NIPPON DENS0

Spark plug
Thread size M14 x 1.25

Spark gap 0.8 mm (0.032 in)

ELECTRICAL SYSTEM

Type NT50-N24

Battery Voltage 12V

Capacity 26AH

Model 02 1000-2920
Alternator
Manufacturer NIPPON DENS0

Voltage 12V
Alternator
Capacity 35A

Type Tirille type (Model 026000-2750)

Voltage regulator
Manufacturer NIPPON DENS0
 Type Magnetic shift type

Starter motor Manufacturer HITACHI LTD.

Voltage &
12V-0.7KW
Output
FUEL SYSTEM

Type Zenith-Stromburg

Manufacturer HITACHI LTD.

Model x Number HCE30-70 x 1

Throttle bore 30mm(1.18 in)

L t

S Venturi dia. (Large x small) 25 x 9 mm (0.98 x 0.35 in)

2
1
Main jet x Main air bleed #I22 x #SO
U

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

Air cleaner type Dry

LUBRICATION SYSTEM

Lubrication method Forced feed and splash type

Oil pump Trochoid type

Oil filter Cartridge

Without oil
2.5Q (2.6 USqt., 2.2 Imp.qt)
filter
Volume of engine oil
With oil filter 2.8Q (3.0 USqt., 2.5 1mp.qt)

COOLING SYSTEM

Cooling method Liquid cooling

Water pump Centrifugal type

Thermostat Wax pellet type

POWER TRANSMISSION SYSTEM

TYpe Dry single plate diaphragm

Number of clutch discs 1

s '
G
Clutch disc lining (inner dia. x 160x l l O x 3 m m
outer dia. x thickness) (6.299 x 4.331 x 0.1 18 in)

Type 4-forward speeds with synchromesh and 1-reverse

1st 4.363
C
0
.A
V1 2nd 2.625
'g
V)

E Gear ratio ' 3rd 1.809

b
4th 1.107

Reverse 4.272

Type of gear Helical

Final reduction gear
Reduction ratio 5.733
2-2. BODY SPECIFICATIONS

K77 K87
Vehicle type
Flat Bed Delivery
Truck Truck Van Van

DIMENSIONS

Length mm (in) 3,195 (125.8)

Width mm (in) 1,395 ( 54.9)

Height mm (in) 1,625 (64.0) 1,635 (64.4)

Length mm (in) 1,990 (78.3) 2,010 (79.1) 1,660 (65.4) 1,795 (70.7)

Cargo bed Width mm (in) 1,330 (52.4) 1,220 (48.0)

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)

Minimum road clearance mm (in) 185 (7.3)

Height of center of
mm (in) 490 (19.3) 590 (23.2)
gravity

Wheelbase mm (in) 1,820 (7 1.7)

Front mm (in) 1,210 (47.6)

Tread
Rear mm (in) 1,190 (46.9)

Front kg (lb) 295 (651) 300 (662) 315 (694) 310 (683)
Vehicle weight
Rear kg (lb) 280 (617) 290 (639) 345 (761) 340 (750)
(unloaded)
Total kg (lb) 575 (1,268) 590 (1,301) 660 (1,455) 650 (1,433)

Number of passengers 2 2 4 2

Maximum loading
600 (1,323) 500 (1,102)
capacity kg (lb) (1,102) 400
500 (882)

FRAME

Type Ladder type

 K77 K8 7
Vehicle type
Truck Flat Bed Van Delivery
Truck Van

STEERING SYSTEM

Steering gear type Rack and pinion

Steering wheel diameter mm (in) 380 (15.0)

Turns, lock to lock 4.6

Inner 3 7"
Turning angle
Outer 34"

AXLE AND SUSPENSION

TYpe Semi-trailing arm type independent

Toe-in mm (in) 1N 12 (0.47)

Camber 2"lO'
Front axle
Caster 15'25'

King pin inclination 6"25'

Trail mm (in) 113 (4.45)

Type Semi-trailing arm type independent

Rear axle Toe-in mm (in) 1N 12 (0.47)

Camber 3'15'

Front
Tire size 5.00-1 0-6PR ULT
Rear

Front
Torsion bar 19.5 x 504.5 mm (0.77 x 19.86 in)
(dia. x Total length)
Spring
Rear
Torsion bar 22.5 x 527 mm (0.89 x 20.7 in)
(dia. x Total length)

Front
Shock absorber Hydraulic double action
Rear
 K77 K87
Vehicle type
Truck Flat Bed Van Delivery
Truck Van

BRAKE SYSTEM

Front Hydraulic, two leading

TYpe
Rear Hydraulic, leading and trailing

Brake line Dual circuit system

Front
Material Resin mould
Rear

Front
35.0 x 173.0 x 5.0 (1.38 x 6.81 x 0.20)
2 Dimensions mm (in)
'a.-
4
(Width x length
x thickness) Rear
S 30.0 x 181.0 x 4.4 (1.18 x 7.13 x 0.17)
2 mm (in)
m
cA Front
3 6 0 (9.3) x 2 pieces x 2 wheels
cm2 (in2)
E
P Area
a,
v Rear
54 (8.4) x 2 pieces x 2 wheels
2
b)
cm2 (in2)
C A .

Front
180 (7.09)
mm (in)
Drum dia.
Rear
170 (6.69)
mm (in)

TYpe Tandem
Master cylinder
Inner dia.
19.0 (0.75)
mm (in)

Brake fluid reservoir capacity

110 (6.71)
cc (in3)

Front
23.8 (0.94)
mm (in)
Inner dia. of
wheel cylinder
Rear
19.0 ( 0.75)
mm (in)
 K77 K87
Vehicle type
Flat Bed Delivery
Truck Truck Van Van

TYpe Mechanical on rear

m

2 Dimensions (Width x length x

30.0 x 181.0 x 4.4 (1.18 x 7.13 x 0.17)
on
thickness) mm (in)
G
Area cm2 (in2) 54 (8.4) x 2 pieces x 2 wheels

Material Resin mould

FUEL SYSTEM

Capacity 3111 (8.2 US gal, 6.8 Imp. gal)

Fuel tank
Location Under floor

Fuel pump Centrifugal type

COOLING SYSTEM

Radiator Corrugated fin type

Volume of coolant 6.011 (6.3 US qt, 5.3 Imp. qt)

Thermoswitch "c (OF) ON: 9 2 (198)

Motor 12V-60W or less

Electric fan
Fan dia. mm (in) 190 (7.48)

Radiator core dimensions 334 x 240 x 32 (13.1 x 9.45 x 1.3)

1)
(Width x height x thickness'

HEATING SYSTEM

Heating capacity Kcallh 2100-10% or more

TYpe Sirocco fan

Heater fan Number of blades 28

Diameter mm (in) 110 (4.33)

Fan motor 55W or less

Heater core dimensions

mm (in) 97 x 115 x 6 6 (3.8 x 4.53 x 2.7)
(Width x height x thickness)
 K77 K87
Vehicle type
Truck Flat Bed Van Delivery
Truck Van
ELECTRICAL SYSTEM

Fuse 25Ax 1,20Ax 2,15Ax 1 , 5 A x 1

Right hand drive 12V-50/40W x 2

Headlight
Left hand drive 12V-45/4OW x 2

Turn signal light 12V-23W x 2

Front
combination Clearance light 12V-5W x 2
light
Parking light 12V-5W x 2

Turn signal light 12V-23W x 2

Stop light 12V-21W x 2

Rear
combination Tail light 12V-5W x 2
light
Back-up light 12V-12W x 1 12V-12W x 2

Parking light 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

Oil pressure 12V-3.4W x 1

Charge 12V-3.4W x 1

Warning & High beam 12V-3.4W x 1

indicator
lights Turn signal 12V-3.4W x 2

Parking brake 12V-3.4W x 1

Brake fluid level 12V-3.4W x 1

Horn 30W 100-1 10 dB

Wiper motor 1-speed

 CHAPTER 3: ENGINE TUNE-UP

CHECKING A N D SERVICING BATTERY .................................3- 2

CHECKING A N D SERVICING LUBRICATING O I L ................. 3- 2
CHECKING A N D SERVICING COOLANT ................................. 3- 3
CHECKING A I R CLEANER .........................................................3- 3
REPLACING FUEL STRAINER ..................................................3- 4
CHECKING A N D ADJUSTING ALTERNATOR DRIVING
V-BELT ...........................................................................................3- 4
CHECKING CAMSHAFT D R I V E BELT ......................................
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
MEASURING CY LINDER COMPRESSION ................................. 3-10
INSPECTING A N D ADJUSTING CARBURETOR ...................... 3-1 1
INSPECTING A N D ADJUSTING THROTTLE OPENER ........... 3-13
I 3-1. CHECKING A N D SERVICING and grounding cable connectors.
! BATTERY

II 1. Measuring specific gravity

Measure specific gravity of the electrolyte in
3-2. CHECKING A N D SERVICING
the individual cells and convert the reading to
LUBRICATING OIL
one at 20°C (68OF).
A converted value within the rang!e from
1.220 to 1.280 is acceptable. Engine oil capacity

S2o = St + 0.0007 (t - 20) 2.8L(3.0 U.S. qt.,

With oil filter
2 .S Imp. qt.)
S2o = Reading gravity at 20°C
St = Actual reading gravity at t°C 2.SL(2.6 U.S. qt.,
0.0007 =Constant Without oil filter
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.
If the oil is contaminated with coolant or

1 2. Maintenance

Add distilled water when the electrolyte

level is below "LOWER LEVEL". Bring electro-
lyte level in each cell within normal range
gasoline, first locate and eliminate the cause of
contamination, then change the oil.
Replace the oil filter at the same time in this
case.

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 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
level engine is heated, because hot coolant may
level spout
c. Use the SUBARU genuine coolant only.

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
Check the reserve tank and hoses for leak- Fig. 3-5 Air c.ktm.er
age. Take special care in checking hose joints.

2. Coolant level
Check coolant level as follows.
1) 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
I ) Remove the cover COMPL to draw out the
element.
2) Lightly tap the element or direct com-
pressed 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.
 2. Replacement 3-6. CHECKING A N D ADJUSTING
ALTERNATOR DRIVING
Clean the air cleaner element every 2,500 V-BE L T
km (1,500 miles). Replace the element after it
has been cleaned 3 to 5 times or after 10,000 1) Check belt tension and adjust if necessary.
km (6,000 miles), whichever comes first. It is
recommended that the element be replaced
earlier if vehicle often runs on dusty roads.
V-belt tension 10 - 15 mm at 10 kg

a genuine air cleaner element is

2) Wipe off oil and water.
essential for long engine life. Never use an
3) Replace the belt if cracking or other
inferior imitation as a replacement part or
damage is found.
drive the vehicle 'with a broken air cleaner
element or without an element.

3-5. REPLACING F U E L STRAINER

1. 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. Checking for gasoline leakage

I 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 b. Remove valve rocker cover.
DRIVE BELT 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 loosen-
ing 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.

d. Retighten lower side bolt (A) and then

upper side bolt (B).
e. Rotate the crankshaft one turn.
----- 15
Timing hole
Mating surface Adjust valve clearance for rocker arms
of engine and loosend in step (b).
transmission \
f. Install valve rocker cover.
Fit the rubber plug (tirningabeltcover).
2) Replace the belt if cracking or other
' T D C mark damage is found. (Carefully check the backside
Pointer of the belt for evidence of cracks.)
When installing new Camshaft drive belt,
adjust belt tension in cold engine condition.
T3-002 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
Fig. 3-10 T.D.C. mark alignment during servicing.
 3-8. CHECKING AND SERVICING 4) Contact r
CONTACT BREAKER
Check the following items and adjust, repair 500 - 700 g
Standard value
or replace any defective parts. In addition, (17.6 - 24.7 OZ)
lubricate all moving components.
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 char-
acteristics.
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
1. 3-12 Contact breaker
contact and make sure that there are no leaks.
9) Check wiring harness in breaker case for
roJlowing Items damage and dis m.
1) Oil leakage from oil seal of camshaft.
2) Inside deposits.
3) Braker point gap.

Standard value 0.30 - 0.40 mm 3-9. CHECK1NG AND ADJUSTING

of the gap (0.012 - 0.01 6 in) VALVE CLEARANCES
1) Prior to adiustment,- retighten
- the cylinder
head mounting bolts as occasion demands.

6.5 + 0.4 kg-m

Tightening torque
(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) Fig. 3-14 Retightening cylinder head
mounting bolt

I 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

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
Fig. 3- 15 Adjusting valve clearance cylinder piston with one additional complete
rotation of the crankshaft pulley.
4) Check the val Ice by inserting a

Intake 0.15 mm (0.0059 in)

=I
clearance adjusting value (in cold) thickness gauge bc
rocker arm.
l e valve and the

5) Using Adjuster (4~8.167000), loosen the

nut (8 x 4) and turn the screw (on the rocker
Exhaust 0.25 mm (0.0098 in) arm) in or out until proper clearance is ob-
tained. Retighten the nut.
6) Recheck valve clearance

Nut (8 x 4) +
2.0 0.2 kg-m
tightening torque (14.46 2 1.446 ft-lb)
3-10. C H E C K I N G AND S E R V I C I N G
SPARK PLUGS

NOTE:
The following special tool is available for
tightening two bolts located on the middle
portion of cylinder head.
399982100
Special tool
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.
1. 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. Cleaning 3-11. CHECKING S P A R K P L U G
CORDS
1) Remove accumulated carbon from elec-

-
trode 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.

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. Fig. 3-1 7 Spark plug cords

Standarc1 3 p d 1 5ap
~ 0.8 111111 ( ~ . ~ in)
32
1) Remove caps with spark plug cord from
the spark plug and ignition coil, check the
following items and, if necessary, clean or
4. Installation replace.
a. Rubber caps for cracks or any damage.
Check the spark plug for proper sparking
with a spark plug tester before installing in the b. Spark plug cord for damage.
engine. Be sure t o align the spark plug with the c. Terminal metals for deterioration and dis-
installation hole in which it is to be screwed in. coloration.
d. Inner surface of the rubber caps for dirt.

2.1 + 0.3 kg-m 2) Measurement of spark plug cord resist-

Tightening torque
(15.18 + 2.17 ft-lb) ance.
Connect the circuit tester t o both ends of
the metal terminals and measure the resistance,

NOTE:
a. Set the spark plug in place by turning it 2 or 7

3 threads with finger force. 'standard reslsrance va.--

b. Then, tighten them to the specified torque
with a special plug wrench. #1 Side
4.09 - 5.63 kS2
(Short one)

5. R e c o m m e n d e d spark p l u g #2 Side
12.42 - 16.89 kS2
(Long one)
N.G.K. BP6ES
HITACHI 5PW
NIPPON DEN! OEP
3) When installing the spark plug cords, make
Replace the sparn plug cvery 10,000 km sure #1 and #2, and certainly insert the cords
(6,000 miles). 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
NOTE:
Digits indicated on the clutch cover shows
B.T.D.C. (Before Top Dead Center) degrees.
1) Check the hoses for connection.
2) Check the hoses for cracks or any damage.
1. Checking ignition timing
3) Check the hoses for mal-installation.
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
3-13. CHECKING AND ADJUSTING spark plug cord.
IGNITION TIMING 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
B.T.D.C. 10" Light. Make sure that the timing mark
Adjusting value
at 1,000 k 50 rpm (10" B.T.D.C.) appears in the correct loca-
tion as shown in Fig. 3-20.

Fig. 3-19 Location of timing hole Fig. 3-21 Checking with timing light

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 align-
ment with the pointer in the timing hole, the
tester needle should start to return since the
contact point opens.
Fig. 3-23 Adjusting timing

Breaker
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.
, 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 counter-
clockwise for retarded timing. After completion
of the adjustment, securely tighten the mount-
ing bolts and recheck the timing.
INSPECTION D U R I N G
ENGINE WARMING-UP
Warm up the engine until the coolant tem-
perature 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. 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.
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
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 re-
duced to 2% to 4%.

Standard com- 10.5 kglcm2 at 300 rpm

pression value (149.3 psi at 300 rpm)
2. Adjustment of fuel level

1) Remove the drain plug and copper gasket

Difference underneath the float chamber.
Less than 0.5 kglcm2
between
(Less than 7.1 psi)
cylinders

Allowable mini-
9 kg/cm2 (128.0 psi)
mum compression

Float chamber
3-16. INSPECTING AND
ADJUSTING CARBURETOR

1. 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).
Fig. 3-25 Adjusting idling speed 3)- Feed fuel into the float chamber.

3-11
 -
4) Read the "L" dimension by means of the
float level gauge as shown in Fig. 3-26.
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.

5) If not correct, adjust by bending the float

lever and measure again. 6. Checking slow cut valve
6) After measurement replace the copper
gasket with new one and retighten the drain
plug.

3. Checking accelerator pump

Stop the engine, then open the throttle valve
suddenly. Check the spout condition of fuel.

Accelerator pump
0.63 cc/l stroke
discharge volume

4. Checking choke system Fig. 3-28 Slow cut valve

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.
Clearance C1 1.2 mm (0.047 in)
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 -330 to -370 mrnHg
Fig.
 Table 3-1 Vacuum gauge readings and troubleshooting

Vacuum gauge Defect

1. Pointer stops at a position lower than the a. Leakage from gasket (intake mani-
normal position fold), gasket (carburetor)
b. Retarded ignition timing or narrow
valve clearances
c. Crack on vacuum hoses

2. Pointer intermittently drops from the a. Leakage from cylinder head gasket
normal position to a lower position. b. Too much clearance between valve
guide and valve stem

3. Pointer in a narrow range above and be- a. Defective ignition system

low the normal position b. Poor carburetor idling adjustment
c. Weak or broken valve spring

' NOTE:
In case of first 1,000 km (600 miles) inspec-
the specified range, readjust the engine speed to
specified value.
tion, there is some possibility that pointer
stops at lower position than -330 mmHg. Standard value
+
2,200 100 rpm
at Full stroke
4) When pointer deflection of the vacuum
gauge is abnormal or not within the normal
range, take corrective action in accordance with 2) Adjustment of opening angle
Table 3- 1.

3-17. INSPECTING A N D
ADJUSTING THROTTLE
OPENER

NOTE:
Before carrying out inspection, warm up the
engine and confirm the following items.

B.T.D.C. 10'
Ignition timing
at 1,000 rpm
Fig. 3-29 Adjusting opening angle
Idling speed 1,000 rpm + 50 rpm Loosen lock nut of adjusting screw at the
throttle opener lever and turn the adjusting
Idling CO % 3%+ 1% screw for adjustment.
-
Screw:
1. Inspection o f throttle opener Clockwise: Increase engine speed
opening angle Counterclockwise: Decrease engine speed

1) Push the throttle opener lever fully, and After completion of adjustment, tighten
read engine speed. If the engine speed exceeds 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. D I S M O U N T I N G ENGINE
W I T H TRANSMISSION
1. 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.
Fig. 4-1 Removing engine hood or
2. Dismounting rear bumper

1) Open the engine hood (Truck) or rear

bumper (Van). Open the back door (Van)
4)
2) Removing battery 5) Remove trap door by loosening two 8 mm
a. Remove the 6 mm nut attaching both the bolts.
battery holder and cover, and remove the 6) Disconnecting accelerator and choke
cover. cables.
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.

NOTE:
When disconnecting the positive cable from
the battery, the tool may contact the vehicle
body and cause shortcircuit or battery dam-
age 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 Fig. 4-2 Disconnecting

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 discon-
nect the harness as the back-up light is in-
corporated 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.
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)

Hc
LDram plug
. I
(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 f. Disconnect the block connector from the
clamp holding the hoses onto the bodv. alternator.
11) Removing wiring harness g. Remove the 6 mm nut fastening the ter-
minal-B onto the alternator.

lock cc

Fig. 4-8 Fig. 4-10 Releasing terminal-B

h. Disconnect the slow cut valve harness (black

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.
cord).
i. Disconnect the thermometer harness(yel1ow-
red).
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.
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

c. Disconnect two back-up light switch har-

nesses (red-white cord).
--- a
----- -- 3 .-

I
d. Remove the clip holding starter harness
(black-yellow), battery cord and back-up I
I.
light switch harness from the starter.
e. Disconnect the contact breaker harness at
the terminal by removing the 5 mm terminal
nut. Fig. 4-1 1 Removing drain plug

4-4
NOTE: 16) Disconnecting clutch cable
a. Be careful not to damage or lose the drain a. Remove the clutch return spring.
alus sasket.
b. TO "facilitate the draining, open the flap on
front pannel and remove the radiator reser-
voir cap. Raising the rear of the body further
quickens the draining.

moving uinder cover

Fig. 4-14 Disconnecting clutch cable

b. Disengage the cable from the clip on the

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.
transmission.
c. Remove the two clutch cable bracket in-
stalling bolts (6 mm) and detatch the cable
from the release lever.
NOTE:
Tie down the cable to the vehicle body so
that the cable is not damaged while dis-
mounting 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
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. 4-1 7 Disconnecting cooling hose
NOTE:
It is better to disconnect hoses when dis-
mounting 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.
NOTE:
I f the black tape outside battery box is
rerr ocket wrench can be used.
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 appro-
priate 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.
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.
 NOTE: Tighten the nut a
until the washer
a. Tightening torque: comes to contact with the cushion rubber
8.
Crossmember 4.0 - 5.0 kg-m Then tighten the nut @ to the specified
installing bolt (29 - 36 ft-lb) torque 0.9 to 1.5 kg-m (7 to 11 ft-lb), at this
time the specified clearance is obtained.
Front engine mount- 2.0 - 3.0 kg-m a Confirm the clearances between the cushion
ing nut (14 - 22 ft-lb) rubbers 8 and the washers @ be equal
under the condition the wheels touch to
Gear shift rod con- the ground.
necting nut to trans-
2.0 - 4.0 kg-m
(14 - 29 ft-lb)
I f not, readjust by the nutsa and 0.
mission e. Refill the cooling system as follows:
a Set the heater lever to "HOT" position.
Pitching stopper 0.9 - 1.5 kg-m Open the engine hood and remove the plugs
adjusting nut (7 - 11 ft-lb) from the engine air vent hoses under the
floor by loosening the clip.
Pitching stopper 1.6 + 0.15 kg-m
bracket installing bolt (1 1.6 f 1.I ft-lb)
~e
gine ail vc
-Drainiipli
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
1 and clutch release lever connecting portion
by adjusting nut.
d. Adjustment of pitching stopper:
/

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) 5 Pitching stopper

2 Nut (8 mm) 6 Cushion rubber
3 Bolt (8 mm) 7 Washer
4 Bracket 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, in-
stall 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 con-
nected 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.
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 discon-
nect 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.

2. 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 4) Open the back door (Van)
bumper (Van). 5) Remove trap door by loosening two 8 mm
2) Removing battery bolts.
a. Remove the 6 mm nut attaching both the 6) Removing wiring harness.
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.

NOTE:
When disconnecting the positive cable from
the battery, the tool may contact the vehicle
body and cause shortcircuit or battery dam-
age i f the ground cable is still connected.
Therefore, be sure to disconnect the ground Fig. 4-23 Removing wiring
cable first. harness

4-8
 a. Disconnect the harness (black-yellow cord) f. Disconnect air intake hose (air cleaner to
from the plug-socket type terminal on the frame) from the air cleaner case.
starter.
b. Disconnect the battery cord from the starter
bv removing the 8 mm terminal nut covered

Fig. 4-25 Dkconnecting air intake hose

g. Remove the air cleaner case by removing a

8 mm bolt @ and loosening slightly two 6
I mm bolts @I
I Fig. 4-24 Disconnecting battery cord

c. Disconnect two back-up light switch har-

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

NOTE:
clip
Tie down the above wirings to the vehicle T5-009
body so that they are not damaged while
dismounting or remounting the transmission. Fig. 4-26 Removing air cleaner case

7) Removing air cleaner 8) Remove the starter motor by loosening

a. Disconnect blow-by hose from the air clean- the two 8 mm nuts.
er.
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. Fig. 4-27 Removing starter motor
 9) Removing pitching stopper

Fig. 4-30 Removing heat insulating plate

5 Pitching stopper
6 Cushion rubber b. Remove the three 8 mm bolts attaching the
3 Bolt (8 mm) 7 Washer 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

14) Removing the clutch cable

Fig. 4-33 Removin muffler from
f
cylinder ead a. Remove the clutch return spring.
b. Disengage the cable from clip of cross-
member and transmission.
NOTE: c. Remove the two clutch cable bracket attach-
Don't detach the flange on the exhaust ing 6 mm bolts and remove the cable from
manifold. the lever (release york shaft).
e. Remove the two 8 mm bolts at the center 15) Disconnecting the gear shift rod from the
transmission
bracket on the muffler, and take out the a. Remove the 10 mm nut connecting the gear
muffler. shift rod to the transmission.

Fig. 4-34 Removing bolts at center Fig. 4-36 Disconnecting gear shift rod
bracket

b. Remove the gear shift rod return spring.

NOTE:
a. Use care not to damage the flange when NOTE:
removing the muffler. Be careful not to lose the bushings and
b. Note that stainless nuts are used for connee- washer (gear shift).
tion 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 16) Decrease lifting height of the vehicle
disconnect the axle shaft. 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.
Fig. 4-3 7 Removing front mounting
18) Remojring rear nnounting (left)
a. Remove :a lOmm bolt @ tightening the
.. ana lower side of transmis-
rear mounzing
sion.
Fig. 4-38
b. Remove two 10 mm nuts @ at the con-
-
necting 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. 4-39 Removing transmission
b. Push the engine toward the rear and pull
down the transmission.
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 c. Adjustment of clutch cable:
TRANSMISSION Adjust the clutch free play to 1.2 to 2.4 mm
(0.047 to 0.094 in) measured at the cable
NOTE: and clutch release lever connecting portion
Fasten the clutch release fork with wire by adjusting nut.
since the release bearing and holder are d. When installing the D.O.J. spring pin, always
subject to come off when remounting the use new pin.
transmission. e. Adjustment of pitching stopper:

1. Remounting

Remount the transmission in the reverse

order of the dismounting. Be sure to keep the
following notes.
1 Nut (8 mm) 5 Pitching stopper
NOTE: 2 Nut (8 mm) 6 Cushion rubber
a. Installing the muffler: 3 Bolt (8 mm) 7 Washer
Strictly follow 19-4 on page 19-4. -1 "l l

b. Tightening torque:
Fig. 4-4 0 Adjusting pitching stopper
10 mm bolts connect-
4.2 - 4.8 kg-m
ing transmission and
engine
(30 - 35 ft-lb)
Tighten the nut @ until the washer
comes to contact with the cushion rubber
a
0.
10 mm bolts and nuts 2.0 - 3.0 kg-m a Then tighten the nut @ to the specified
on rear mounting (14 - 22 ft-lb) torque 0.9 to 1.5 kg-m (7 to 11 ft-lb), at this
time the specified clearance is obtained.
10 mm bolts on front 2.0 - 3.0 kg-m a Confirm the clearances between the cushion
mounting (14 - 22 ft-lb) rubbers 0and the washers be equal
under the condition the wheels touch to the
Gear shift rod con- ground.
2.0 - 4.0 kg-m
necting nut to I f not, readjust by the nuts @ and 0 .
(14 - 29 ft-lb)
transmission f. Clean the air cleaner related hoses and boots
before installing them to the air cleaner.
8 mm starter 2.2 - 2.8 kg-m
installing nut (16 - 20 ft-lb) 2. Inspection after remounting

Pitching stopper 0.9 - 1.5 kg-m 1) Start the engine and check that there is
adjusting nut (7 - 11 ft-lb) no exhaust gas leakage.
2) Be sure to check transmission oil level.
Pitching stopper 1.6 * 0.15 kg-m
bracket installing bolt (1 1.6 f 1.1 ft-lb)
Transmission oil 0.9Q (0.95 US qt,
* As to muffler related bolts and nuts, refer quantity 0.79 Imp qt)
to 19--4.

I
 CHAPTER 5: ENGINE

Page

5- 1. OUTLINE OF THE ENGINE ...................................................... 5 - 2

i
I
52
. . DISASSEMBLY ..........................................................................5 - 9
I 53
. . INSPECTION AND REPAIR ........................................................ 5-18
I
i 54
. . ASSEMBLY ...................................................................................5-29
55
. . TROUBLESHOOTING ................................................................... 5-40
5-1. OUTLINE OF THE ENGINE

Fig. 5-1 Outside view of EK23BE engine

1. Features is inevitable as the crankshaft is driven by the

reciprocating motion of pistons. As a result,
In designing the new EK23BE engine, special vibration and noise incidental to engine opera-
consideration was given to economy, durability, tion are considerably reduced.
quiet operation, and ease of maintenance. The
engine is tough enough to display full perform-
ance over its entire working range. This is a
light, compact, water-cooled, two-cylinder in
parallel, single overhead camshaft type four-
cycle 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 effi-
ciency. In addition to the effective cooling
performance of the cylinder head, adoption of
a high-combustion-efficiency multispherical
cross-flow combustion chamber contributes not
Fig. 5-2 EK23BE engine
only to large output, but also to a reduction in
harmful exhaust emissions. The special casting
crankshaft combined with the fillet roll ma- The balancer shaft is driven by a non-
chined pins and journals provides superior backlash steel gearing from the crankshaft so
fatigue strength. Triple-layer kelmet metal is that it is rotated at the same rotating speed and
employed for the main bearings and the con- in the opposite direction of the crankshaft.
necting rod big-end metals to improve the Problems of noise and reliability accompanying
initial break-in characteristics and fatigue the use of a V-belt is solved by directly connect-
strength. Interchangeable front and center main ing the water pump to the balancer shaft end.
bearil-gs, a single united rear and thrust metal, The toothed rubber belt for driving the
and adoption of bearing caps greatly facilitate camshaft is effective in reducing the belt noise,
assembly of the crankshaft. A single-shaft bal- and the one step spring-load tensioner for
ancer is newly adopted in this engine to negate instant setting of the belt tension provides easy
uneven torquing force on the crankshaft which maintenance. Since the camshaft journals are
directly supported by the cylinder head with-
out use of any bearing, and the lubricating oil is
directly delivered to cam surfaces and journals
through the hollow camshaft, operational re-
liability 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.
\
Connect
5-3 Piston and piston r i ~
%gig.
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 com-
bined with a water pump directly connected to
the balancer shaft end and with an electric fan
effectively eliminates noisy pump operation
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.
Fig. 5-4 Balancer shaft and
water pump
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 reciprocat-
ing motion of the pistons. This large inertia
force is harmful to smooth crankshaft revolu-
tion, thus causing serious engine vibration and
uncomfortable driving conditions. To reduce
engine vibration by negating the uneven distri-
bution 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
Fig. 5-5 Function of balancer
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 approxi-
mately 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 hori-
zontal component F1 will be negated because
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 pro-
vide 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 crank-
shaft rotation so as to negate the remaining
component of inertia force indicated by F2
relating to the shaft 11. As a result, the inte-
grated inertia force of two pistons is negated by .
the sum of the centrifugal force produced, by
the crankshaft-counterweight and the balancer-
shaft-counterweight rotating in opposite direc-
tions of each other, thus making the EK23BE
engine well balanced and keeping it free from
vibration, thereby permitting comfortable
driving.
2) 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.mecha-
nism 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
Chloroprene rubber
Kevlar cord Nylon canvas
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
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
ankshafi
k
.-.
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 connect-
ing-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 direc-
tion 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
Spring force
non-backlash to prevent rush sound genera-
tion when rotating. 1 Drive gear
Spacer is press-fitted on the crank i
2 Sub-gear ~5-006

bearing for sub-gear.

Fig. 5-9 Non-backlash mechanism

1 Balancer shaft
2 Balancer driven gear
3 Balancer drive gear
4 Spring
5 Sub-gear
6 Spacer
7 Sub-gear set
T5-007

Fig. 5-10 Components of balancergear

5-6
 3) Cylinder head a. The piston is made of a high silicon-
. . . - . .. . . , .- .. ...-- aluminum die casting having a low coeffi-
cient of expansion. The piston head is
I1 provided with recesses t o receive the valves.
The piston skirt has a unique barrel shaped
II 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
i t o p in which the piston rings are fitted to
1 seal the gas and oil.
I
c. The piston pin hole is offset 1.0 mm toward
I the thrust side.
Fig.5-1I Cylinder head
a. The cylinder head is made of die cast 5) Piston rings
aluminum which is superior in heat transmis-
i sion, and is provided with multispherical 5181

c->
combustion chambers which give high com-
bustion efficiency with smooth gas flow.

?(-
I

Intake and exhaust valve are arranged in a

"V" on the cylinder head. r-- ,~ (
b. Four threaded holes (6 x 1 mm) are ma- 11 1 J 1
chined for installation of the. rocker cover. a

c. Two 8 rnm dia. stud bolts and two threaded

holes (8 x 1.25 mm) are provided for
installation of the intake manifold. ona rlng
d. Four threaded holes (8 x 1.25 mm) are
machined for installation of the flange (Ex-
haust port).
e. The cylinder head is attached t o the crank- Fig.5-13 Piston rings
case by means of six 11 mm head bolts with
a head gasket inserted to prevent leakage of
gas, oil or water.
4) Piston The piston rings contain gas under high
pessure in the combustion chamber and pre-
vent 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 sur-
face, 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 break-
in and backs u p the top ring in making the
Fig.5-12 Piston, connecting rod, etc. cylinder completely air-tight.
 c. The third is an oil ring which is composed of 8) Camshaft
a spacer inserted between two rails and - -3
serves to prevent lubricating oil in the
crankcase from creeping up to the combus-
tion 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 insert-
ed into 8.2 mm dia. holes. Fig. 5-15 Camshaft
7) Balancer shaft
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.
!
Intake opens Exhaust closes

I
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:
I
Before separating the transmission, remove

I 1) Install the engine on the Stand compl.

4998 11300 (Engine), and drain engine oil.
the starter to facilitate the work.

ine stand

! Fig. 5-17 Fitting up engine stand

Fig. 5-19 Removing transmission

2) Removing air cleaner

a. Disconnect blow-by hose from the air 4) Remove clutch cover and clutch disc.
cleaner. a. Insert a special tool "Clutch Disc Guide"
b. Release clip holding the transmission air (499745400) into the clutch disc.
breather on the air cleaner.. b. Unscrew six bolts and then remove clutch
,
I
c. Remove air cleaner case cover and take out cover and clutch disc from flywheel.
air cleaner element.
I
d. Remove air cleaner case by removing a 8 mm Bolt (6 x 18 mm): 6
!
~- bolt @ and loosening slightly two 6 mm
bolts @.
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.

Bolt (10 x 45): 4 Fig. 5-20 Removing clutch

5 -9
5) Remove the gauge compl. (oil level). 10) Remove the stay and dismount the alter-
6) Remove the spark plug cords. nator assembly, and remove the V-belt.

Bolt (8 x 110 mm): 1

Bolt (8 x 22 mm): 1
301t (8 x 28mm): 1
3, remove the bracket compl. (alterna-
th bracket I1 (alternator).

Seali 3olt (8 x 16 mm): 4

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).

7) Remove the hose (vacuum) f rom the v;acu-

um advance unit.

Fig. 5-23

12) Remove the intake manifold compl. to-

gether with the carburetor assembly.

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

Fig. 5-22 Removing hose

8) Remove hoses (engine outlet) 0,

@ and
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) 15) Remove the spring (cam belt tensioner)
by means of the Adjuster compl. (cam timing) and the tensioner compl.
49871 1300 and Puller Assembly 89952 1421.
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 Fig. 5-27 Removing tensioner
NOTE: 16) Remove the plate (camshaft drive pulley)
The Adjuster compl. is to block the rotation then remove the belt (camshaft drive).
! of the pulley.
NOTE:
1 14) Remove the cover I1 (Cam belt), plate a. Before removing the belt, put a mark indi-
1 compl. (Cam belt cover) and Stay compl. I1
(Spark plug cord). .
cating the running direction of the belt with
a felt pen or the like.
b. Do not attempt to pry the belt with a
Tapping Bolt (6 x 30) 0:
1 screwdriver or the like. Use only the hands
with 1 spacer to remove the belt.
Tapping Bolt (6 x 60)@: 2 17) Remove the pulley (camshaft drive) and
I
with 2 spacers the plate (camshaft drive pulley).
18) Remove the pulley (camshaft driven)
Bolt (6 x 60) 0:3 with the Adjuster compl. (cam timing)
Bolt (6 x 65)@: 1 49871 1300.
Nut 6 mm: 1 Bolt (12 x 2 3 mm) : 1
Washer 6.5 x 16 x 1: 3 Washer (12.5 x 35 x 4.5 mm) : :

Fig. 5-26 Removing cover II (cam belt) 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) Remove the oil pan compl.

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

Bolt (8.5 x 19 mm): 6

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

Fig. 5-32 Removing oil pan

24) Remove the gasket from the oil pan.

25) Remove the cover (valve rocker).
Washer-based-head bolt
Fig. 5-30 (6 x 33 mm) : 4
 Remove the gasket (valve rocker cover). Also remove stay compl. (spark plug cord).

Fig. 5-33 Removing valve rocker cover Fig. 5-35 Removing contact breaker assembly

1 26) Remove the cover (contact breaker case). 29) Fully loosen the screws (valve rocker).
!
Nut (8 x 4 mm) : 4

Draw out the shaft (valve rocker) from the

cylinder head compl. Remove the arm (valve
27) Remove the gasket from the contact
rocker), spring washer (rocker shaft), spacer
I breaker case.
(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) TE:
(eep the impeller stopped by blocking the -

NOTE: balancer shaft with a suitable screwdriver or

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

Fig. 5-39 Removing waterpump impeller

Fig. 5-3 7 Removing camshaft
-
34) Remove the cover assembly (crankcase).
31) Remove the head complete (cylinder). (Fig. 5-40)
Washer-based-head bolt Bolt (8 x 25 mm) :
(I 1 x 102 mm) : 6 Bolt (8 x 45 mm) : 4
Washer (1 1.5 x 23 x 4) : 6 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) Remove Engine Stand (49981 1300).
36) 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.

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
Fig. 5-41 Removing the cap (connecting rod) 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 40) Drive out the balancer shaft compl. (If
necessary)
compl.
Washer-based-head bolt NOTE:
(10 x 47 mm): 6 Lightly tap the shaft with an aluminum bar
Remove the oil seal (57 x 77 x 14 mm) to remove it.
 Fig. 5.4 4 Remcwing balncer shaft Fig. 5 - d 1.6 Removing carburetor
assembly and thermostat

-
Removing carbu retor and thermostat.
. .
., Remove carburetor rrom intake manifolfl
) Removing exhaust flange
-.emove bolts (8 x 22: four) and remo.
Nut (8 mm) : 2 lust flange with gasket.

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)
724 100, i blllvvb t~l l l ekey (valve spring re-
"Pmr,..P
- .
tainer) from each valve spring ret ainer, and then
Fig. 5-45
remove the va lve and S F)rings.
.. -
TE:
:balk each valve with an identification
Remove the cover (thermostat) from rne narking so as not t o confuse them. Set the
manifold compl. (intake), remove the gasket gress (valve spring) 3997221 00 as an adjust-
(thermostat case cover) and take out the !r on the press assembly.
thermostat. le careful not to hurt or break oil seal lips
n intake and exhaust valve auides during
Bolt (E emoval.
 46) Re moving oil filter and oil pum p cover
a. Remo ve the oil filter with the ren1uvc1-anu-
--A

installer 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 press-
fitted on the shaft (oil pump). I f replace-
ment of the gear compl. and rotor is
Fig. 5-4I8 Remor required, draw them out from the shaft with
a press.
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
I
1~1t;~hanical
seal UII ~ G U I

NOTE:
Fig, 5-51 Removing- n . , ~ ~ , ~ ~ . , ~ , ~
Keep the remotved pistoln rings in good orde
SO as not to colnfuse thern. b. Remove the cer.amic seat
5-3. INSPECTION A N D REPAIR NOTE:
a. When correction is required, check the in-
Precautions before inspection and repair take and exhaust valve stems and valve
a. Before cleaning, check for leakage in parts guides for wear, and the springs for per-
which carry coolant or oil. pendicularity and tension. Replace them if
b. Check oil seals for damage to their lips. defective and then proceed to the valve seat -
c. Thoroughly clean all parts to remove dirt grinding.
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 im-
portant 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.

!. 5-52 Correction of intake valve seat

Limit of strain on the

surface to be fixed to
cylinder block
0.05 mm
(0.0020 in)
388
1.501 dia.
298
-
(1.I41 dia.

Cutting limit on the 0.5 m m

surface to be fixed to
(0.020 in)
cylinder block

Unit: .mm (in1

T5-011

NOTE:
a. Since unbalanced tightening of cylinder heau Fig. 5-53 Correction of exhaust valve seat
mounting botls may cause warping of the
mounting surface, pay special attention to
the even torquing of mounting bolts when b. Grind the seat contact surfaces with a seat
assembling the cylinder head. cutter and a seat grinder to the dimensions . ,

b. Be sure to place the removed cylinder head indicated in Figures 5-52 and 5-53. Finish
upside down on a clean cloth. with fitting compound until proper contact :

appears on the periphery and overall width

of the mating valves.

d. Inspect the intake and exhaust valve seats,

and correct the contact surfaces if defective e. Check the sinking value of the valve seats.
or damaged, in accordance with the follow- Replace cylinder head, if its valve seat
ing. sinking exceeds the limit.
 Standard "A"
dimension

Intake
*
40.5 0.1 mm
(1.594 ? 0.0039 in)

41.2 ? 0.1 mm
Exhaust
*
(1.622 0.0039 in)

Sinking limit (for

both intake and 1.0 mm (0.0394 in)
exhaust)

Fig. 5-54 Sinking of valve seat

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

-0.035 -000 14 in)

Intake
7'0 -0.050 mm (0.2756 -0.0020
Standard diameter of
valve stem
-0.05 5 -0.0022 .
Exhaust 7.0 -0.070 mm (0.2756 -0.0028 ln)

Intake 7.0 -O mm (0.2756 in)

Standard inner diameter
of valve guide
Exhaust 7.0 ;","l5 mm (0.2756 t_Odooo6 in)

Standard clearance Intake 0.035 - 0.065 mm (0.0014 - 0.0026 in)

between valve guide
and valve stem Exhaust 0.055 - 0.085 mm (0.0026 - 0.0033 in)

Fit tolerance (valve Intake 0.031 - 0.060 mm (0.0012 - 0.0024 in)

guide against cylinder
head) Exhaust 0.031 - 0.060 mm (0.0012 - 0.0024 in)
Intake 55.0 mm (2.1653 in)
Overall length of valve
guide
Exhaust 57.0 mm (2.2441 in)

g. Check valve stem and oil seals (intake valve,

exhaust valve). Replace if damaged or worn.
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.
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.

a,,
c. When replacing guide, always use O.S. valve
guide, and correct Head compl. (Cylinder)
using reamer (valve guide) 399762104.

H
1
17.0 mm f - Exhaust valve
Intake
Valve guide pro- (0.6693 in)
trusion from the
cylinder head
Exhaust
17.0 mm
(0.6693 in)
H &
:ake valve. T5-013

Fig. 5-57 Checking valve head thickness

Press
guide)
2103

rable (Cylir Standard "H" dimension

3997,621C

Intake 1.0 mm (0.0394 in)

Exhaust 1.0 mm (0.0394 in)

Fig.5-55 Removing valve guide

1tem Allowable "H" dimension

Intake 0.5 mm (0.0197 in)

Press.
Exhaust 0.5 mm (0.0197 in)
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.

NOTE:
Correct the surface of the stem end so that it
Fig. 5-56 Installing valve guide is at right angles to the valve axis.
 3 Grinding valve

-
Valve seat
Overall length
contact angle

Intake 45 O 111.0mm
(4.370 in)

Exhaust 1 10.3 mm
45O Fig. 5-59 Checking spring tension
(4.343 in)

c. Put a small amount of lapping compound on NOTE:

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 ten-
ion. Replace any spring damaged or below the
pecified limits.
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.

* 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 com- 44 5 3.08 kg 29 + 2 kg

pressed length +
(97.00 6.79 Ib) (63.93 + 4.41 lb)
4) Rocker arm
a. Check the inner diameter of arm and the Allowable warping 35 mm
outer diameter of rocker arm shaft to limit (0.0020 in)
determine whether the clearance between
the two is within the standard range. If the Allowable grinding Less than 0.4 mm
clearance exceeds the allowable limit, re- limit (0.0158 in)
place either the arm or shaft worn more
excessively.
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.
~ c k e rarm If the bore shows wear or taper exceeding
Spacer Spring wa sher
d\ a \ I r Val!
. . .. the allowable limits or if it is excessively
scratched, repair the cylinder bore by re-
boring 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

Fig. 5-60 Rocker arm and shaft
-

between rocker (0.000630 -

arm and shaft 0.002047 in)
Thrust dlrectoor

b. When the contact surfaces of the rocker arm

to the valve stem end and to the c a rLLS l l-d l^L

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 IOTE:
Measure after the cylinder cools down ro

I I Nominal size
I
Outer diameter of piston

75.950 - 75.974 mm
20°C ( 6 8 O F ) .

i. Cylinder bore enlarging limit

Standard Replace the crankcase when the cylinder
(2.9901 - 2.991 1 in)
bore diameter reaches the allowable expand-
Oversize 76.450 - 76.474 mm ing limit due to repeated reborina.
(0.5 n ~ n i ) (3.0098 - 3.0108 in)

Ovcrsize
( I .O mm)
76.950 - 76.974 mm
(3.0295 - 3.0305 in)
Cylinder bore
enlarging limit
/ 1.0

6) Piston and piston pin

f. On the basis of the diameter of piston to be a. Check for scratches, cracks, pin d~amerer,
used, rebore the cylinder to finish it to a pin hole bore as well as wear and damage of
desired bore size which will be determined ring grooves. Replace the piston or piston
through consideration of such conditions as pin if defective.
the piston-to-cylinder clearance, honing al-
lowance and accuracy of the boring ma-
chine.

between piston 0.038 - 0.062 mm b. Piston ring

and cylinder at (0.001 5 - 0.0024 in) 1) When replacing damaged, broken, worn
20°C (68'F) or insufficiently tense piston rings or
when replacement is necessary due to
replacement of the piston, select rings
properly matched with the piston to
NOTE: which the rings are fitted.
Measurement of cvlinder bore immediatelv
after boring will be accompanied by som;!
error due to heat of machining. 30'--1' Top ring end
hard
~ted.

g. Finish the cylinder bore to final form by

honing.

Less than 0.02 mm

Honing allowance
(0.0008 in)

h. Measure the cylinder bore diameter.

Less than 0.05 mm

Taper
(0.0020 in)

Piston ring groove dimensions Unit: mm

Less than 0.05 mm T5-015
Ellipticity limit
Fig. 5-62 Sectional view of piston rings
NOTE: Standard clearance betwec:n the pis1ton ring and
a. Letters "1 R" and "2R" are stamped on the ring groove.
top ring and the second ring, respectively,
near the ring gap. Face these marks to the 0.035 - 0.075 rnm
Top ring
piston top when installing piston rings on (0.00 14 - 0.0030 in)
the piston.
b. The oil ring is a combination of a spacer 0.025 - 0.065 mm
Second ring
inserted between two rails. Be careful not to (0.0010 - 0.0026 in)
misarrange the combination.
c. Tension of each ring is specified below. Oil ring n)

Piston ring tension 7) Crankshaft

I I I a. Clean crankshaft completely and check for
1.05 - 1.50 kg cracks by means of a ;ed check or magnetic
Top ring flux inspection, etc.
(2.3 1 5 - 3.307 Ib)
Replace if defective.
0.95 - 1.37 kg b. Check bending condition of crankshaft, and
Second ring correct or replace if it exceeds the allowable
(2.094 - 3.020 lb)
limit.
2.70 - 4.10 kg
Oil ring
(5.953 - 9.039 lb)
Bending limit 0.03 mm (0.00 12 in)

2) Squarely place the piston ring in the NOTE:

cylinder bore and check the piston ring To check, p~at;e u u ~ the
~ i front and rear
gap with a thickness gauge. journals on blocks located on the surface
plate, and measure by applying a dial gauge
to the center journal.

Standard piston ring gap c. Check crankshaft journals for wear. If any of
them exceed the allowable limit, replace the
0.2 - 0.4 mm relative bearing with an undersize one and
Top ring
(0.0079 - 0.0158 in) correct the journal by grinding.

0.2 to 0.4 mm
Second ring
(0.0079 - 0.01 58 in)
Ellipticity limit 0.03 mm (0.0012 in)
Oil ring 0.3 to 0.9 mm
(Rail only) (0.01 18 - 0.0354 in) Taper limit 0.02 m m (0.0008 in)

Grinding limit " "5 m m (0.0098 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.
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

41.949 - 41.960 mm
Standard size
(1.65 15 - 1.6520 in)

Undersize 41.899 - 41.910 mm

(0.05 mm) (1.6496 - 1.6500 in)

Undersize 41.699 - 41.710 mm

(0.25 nim) (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 Standard oil 0.020 - 0.059 mm
the clearance exceeds the allowable limit. clearance (0.0008 - 0.0023 in)

Allowable max.
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
Fig. 5i63 Checking thrust clearance torque.

Standard tightening 4.5 + 0.3 kg-m

torque (32.6 + 2.2 ft-lb)
Standard 0.080 - 0.177 mm During this work, the crankshaft must
clearance (0.003 1 - 0.0070 in) not be turned and crankcase must not be
turned over.
I1 Allowable thrust 4) Remove the bearing cap.
I 0.3 mm (0.01 18 in)
clearance The flattened plastigage will be found
adhering to either the bearing or the
crankshaft
5) Compare the width of the flattened plasti-
gage at its WIDEST point with the gradua-
e. Inspect the individual bearings for signs of tions on the envelope. The number within
flaking, seizing, melting and contacting. Re- the graduation on the envelope indicates the
place if defective. bearing clearance in thousandths of an inch
f. Check the oil clearances on the individual or in millimeters depending on which side of
bearings. the envelope is used.
g. As a result of this inspection, replace any
defective bearing with undersize one. 0.1 mm
limit per 100 mm
Dimensions of crankshaft bearing (3.9370 in) (0.0039 in)

Bearing thickness measur-

Bearing size
ed at center
c. Fit each connecting rod compl. to the
1.502 - 1.510 mm crankpin, and check the side clearance
Standard size (thrust clearance). If it exceeds the allowable
(0.059 1 - 0.0594 in)
limit, replace the connecting rod.
Undersize 1.527 - 1.535 mm
(0.05 mm) (0.0601 - 0.0604 in)

Undersize 1.627 - 1.635 mm

(0.25 mm) (0.0641 - 0.0644 in)

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 45.000 - 45.050 mm
dia. (1.7717 - 1.7736 in)

Spacer outer 44.975 - 44.991 mm

dia. (1.7707 - 1.7713 in)

Standard 0.009 - 0.075 mm

clearance (0.0004 - 0.0029 in) d. Inspect connecting rod bearings for flaking,
seizing, melting and contacting condition.
Wear limit 0.150 mm Replace if defective.
clearance (0.00591 in) e. Check the oil clearance on the individual
bearing.

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.
NOTE: g. Check the piston pin hole in the small-end of
Check with a Plastigage in the following the connecting rod for wear or damage and
sequence. repair or replace if defective.

1) Remove the bearing cap and wipe off the

oil, dust, etc. from the bearing insert and Standard clearance 0.007 - 0.029 mm
crankpin. between piston pin
(0.0003 - 0.001 1 in)
2) Install bearing in the connecting rod and and con-rod small
i t s cap. end
3) Cut the Plastigage in each bearing width
and place it on crankpin, but avoid oil
passage. 10) Camshaft
Reinstall the connecting rod and tighten a. Check the camshaft thrust clearance. If it
the cap bolts to the specified torque. exceeds the allowable mimit, grind the con-
tact breaker mounting surface o n the cyl-
-.
inder head t o bring the thrust clearance into
Connecting rod bolt 3.8 + 0.3 kg-m the permissible range.
tightening torque (27.5 + 2.2 ft-lb)
Standard thrust 0.03 - 0.38 mm
During this work, connecting rod and clearance (0.0012 - 0.0150 in)
crankshaft must not be turned and crank-
case must not turned over. I Allowab
4) Remove the connecting rod. The
flattened Plastigage will be found
adhering to either the bearing or the NOTE:
crankpin. Keep the contact breaker case installed in
5) Compare the width of the flattened place when checking the camshaft thrust
Plastigage at i t s WIDEST point with the clearance.
graduations on the envelope. The number
within the graduation on the envelops b. Inspect the camshaft journals and replace if
indicates the bearing clearance in damaged or worn.
thousandths of an inch or in millimeters c. Inspect the cam surface for damage and
depending on which side of the envelope measure the total height of the cam. Replace
is used. the camshaft if the cam is damaged notice-

f. As a result of this check, replace defective

bearings with undersize ones.

Bearing thickness measured

Bearing size Crankpin diameter
at center

1.482 - 1.490 mm 37.989 - 38.000 mm

Standard size
(0.0583 - 0.0587 in) (1.4956 - 1.4961 in)

1 .SO7 - 1.5 15 mm 37.939 - 37.950 mm

Under size (0.05 mm)
(0.0593 - 0.0596 in) (1.4937 - 1.4941 in)

1.607 - 1.615 mm 37.739 - 37.750 mm

Under size (0.25 mm)
(0.0633 --0.0636 in) (1.4858 - 1.4862 in)
,
 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.

12) Oil seal (30 x 46 x 8 mm) (camshaft

Fig. 5-66 Cam lobe shape front)
Check the lip for wear, damage or hardening.
Replace the oil seal if necessary.
Standard total cam 37.65 - 37.75 mm
height (for both (1.4823 - 1.4862 in) 13) Oil seal (57 x 7 7 x 14 mm) (crankshaft
intake and exhaust) rear)
a. Check the lip for wear, damage or hardening.
Wear limit of cam 0.3 mm (0.01 18 in) Replace the oil seal if necessary.
b. Check fit around the oil seal. Replace the oil
seal if necessary.

11) Balancer shaft compl.

a. Check the gear (Balancer shaft driven) for Standard fit 0.12 - 0.35 mm
damaged or worn tooth surface. Replace the tolerance (0.0047 - 0.0138 in)
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. NOTE:
c. Check fitting condition of the ball bearing. Use the Press (crankshaft rear oil seal)
Replace the ball bearing if improperly fitted. 398722100 to install the oil seal.

Outer race fit 0.0 15 - 0.054 mm 14) Cover compl: (crankcase)

tolerance (0.0006 - 0.0021 in) a. Check the gear compl. (oil pump driven) for
damaged or worn gear teeth. Replace the
Inner race fit 0.002 - 0.019 mm gear if necessary.
tolerance (0.0001 - 0.0008 in)

NOTE:
d. Check the journals for damage or seizure. If To replace the gear, draw out the oil pump
necessary, replace the bearing (balancer shaft with a press. Then install a new gear by
shaft). pressing it in until the shaft end becomes
e. Check for oil clearance even with the gear.
 d. Replace gaskets with new ones. Moreover,
use. liquid packing where necessary to pre-
vent leakage.
e. Replace keys, pins and bolts with new parts
as required.
f. Recheck each component during installa-
tion, although they have been checked and
adjusted previously.
1) Press the balancer shaft into the crankcase
with the Press compl. (balancer) 498735400.

NOTE:
a. Be sure to use the Press compl. (balancer).
Fig. 5-67 Removing gear (Oil pump Never depress the gear of balancer shaft
driven)
b. Keep the ball bearing outer race even with
. the crankcase.
Standard fit 0.020 - 0.05
tolerance (0.0008 - 0.0022 in)

-*
b. Oil seal (23 x 40 x 7 mm) (balancer shaft Press COMPL 1
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.

NOTE:
Pay special attention to cracks and damag, Fig. 5-68 Pressing in balancer shaft
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 atten-
tion 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.
2) Press the mechanical seal into the crank-
case 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)
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.
 5) Assembling crankshaft
Press the balancer drive gear onto the crank-
shaft 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
L11V L.1

the b:alancer drive gear so that the other end of

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).
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.
the S]?ring can be inserted into the 4 mm dia.
rlule :
L-1-
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.
NOTE:
a. The subgear and spacer regulate axial clear-
ance 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.

;] Rotor COMPL
.& 11 (OiLpump inner)

Fig. 5-70 Pressing in oil pump driven 1 Balancer drive gear 5 Crankshaft
gear 2 Spring . 6 4mm (0.16in) hole
3 Sub-gear 7 Supporting surface
4 Spacer
T5-0 17
3) Install the crankcase on the Stand compl. I
lengne) 4998 1 1300. Fig. 5-71 Assembling crankshaft
6 ) Install the crankshaft bearing and crank-
shaft bearing I1 in the crankcase. Fit the
crankcase cap, crankcase cap I1 and 111with six
washer-based-head bolts to install the crank-
shaft 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.
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.

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. Fig. 5-73 Assembling piston and
"After installation, pull out the pin. connecting rod
0 rir the piston rings on the piston. Install
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
Approx.3d Oil ring
b. Insert a rubber seal coated with bonding 011ring lor*er rail upper rail
Second ring
agent (Fuji-Bond C or equivalent) into the Top r i n ~

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. 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
Fig.5-75 InstalIing piston clearance.

11) Press the oil seal (57 x 77 x 14) into the

b. Before installation, lubricate the mating sur- rear end of the crankshaft with the Press
faces between the piston and the cylinder (crankshaft rear oil seal) 398722 100.
bore with engine oil.
c. Do not allow the ring gap positions to slip
excessively out of the preset positions during NOTE:
installation. Lubricate the oil seal lip with engine oil
d. Be sure that the following are satisfied before installation.
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 con-

necting rod with the nuts.
Fig.5-77 Pressing in oil seal

12) Install the crankcase cover assembly to

which the rotor and gear have been assembled
3.5 - 4.1 kg-m
Nut tightening torque in step (3) together with the crankcase cover
(25.3 - 29.7 ft-lb)
gasket and O-ring.

-- -l l I
NOTE: NOTE:
The mounting bolts for the crankcase cover Block the rotation of balancer shaft with a
are common with those of the protector (oil screwdriver or the like during installation of
filter). impeller.

14) Install the water pump cover with its

- . gasket.
(case cov
15) Install the oil filter.

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 ~
16) Fit the intake valve, exhaust valve, valve
contact surface between mechanical seal ana springs I and I1 to the cylinder head.
ceramic seal. Fit the intake valve oil seal to the intake
b. Ensure that painted mark surface of the valve guide with the Installer compl. (oil seal)
ceramic seal is faced to the rubber seal side. 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
Bolt tightening 0.95 - 1.05 kg-m
the valve guides. Fit the valve spring and
torque (6.87 - 7.06 ft-lb)
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
Fig. 5-79 Installing impeller seal.

5 - 33
 NOTE:
Be sure to insert the gaskets so that the burr
appeared side faces t o the bottom of the
groove.

2.9 - 3.5 kg-m

Tightening torque
(20.97 - 25.32 ft-lb)
Exhaust 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.
I
Fig. 5-82 Pressing in valve oil seal
'ghtening torque
+
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 Fig. 5-85 Cylinder head bolt tightening I
on the cylinder head. sequence
I
 19) Insert the camshaft into the cylinder
head compl.
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.
Fig. 5-87 Installing rocker arm
!
I NOTE:
I
Fit the four rocker shaft caps to both ends
of each valve rocker shaft
21) Temporarily fit the contact breaker as-
sembly.
NOTE:
Align the contact breaker so that the groove
in the spark advancer unit coincides with the
guide pin on the camshaft.
Fig. 5-88 Temporarily fitting contact breaker
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.
Bolt (8.5 x 19 x 16.5 mm) : 6
4.2 -+ 0.4 kg-m
Tightening torque
(30 + 3 ft-lb)
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 Match marks

NOTE:
a. Properly align the match mark on the pulley
Fig. 5-90 Flywheel
with that on the adjuster compl.
b. Set the belt so that it runs in the same
27) Install the crankcase hanger. direction as it ran before disassembly. (Mark-
ing with felt pen indicating the proper
28) Install the cam belt cover.
direction is recommended before removing
NOTE: the belt.)
Check the mount compl. [cam belt cover c. Avoid any sharp bending of the belt.
and spacer (cam belt cover)] for proper fit d. Do not use any tool for installation of the
belt. Use only hands.
29) Install the pully (camshaft driven) with
the washer using the Adjuster compl. (cam 33) Install the plate (camshaft drive pulley)
timing) 49871 1300. on the crankshaft.
34) Install the cover I1 (cam belt) by bolt
with spacer on the cover compl. (cam belt).
Bolt tightening 6.0 kg-m
torque (43.4 ft-lb) NOTE:
a. Use spacers for three installing points of the
cover (crankcase).
30) Install the plate (camshaft driven pulley), b. Tapping bolts are used for installing the
the pulley (camshaft drive), in that order, on cover, so, be sure to keep the following
the crankshaft. tightening torque.
 Tightening torque

When the cover 0.6 - 0.8 kg-m

(crankcase) is new one (4.34 - 5.79 ft-lb)

When the cover 0.45 - 0.55 kg-m

(crankcase) is reused one (3.25 - 3.98 ft-lb)

Be sure t o check fitting of the sealing (cam

belt cover).

Fig. 5-93 Assembling intake manifold

,5) Bolt the crankshaft pulley compl. with
washers.
38) Insert the thermostat into the intake
5.5 - 6.5 kg-m manifold. Bolt the thermostat case cover to-
Tightening torque gether with its gasket.
(40 - 47 ft-lb)

NOTE:
NOTE: The thermostat must be installed with the
Use the Adjuster compl. (cam timing) iioole pin at the highest position.
498711300 t o block the rotation of the
crankshaft during tightening.

itting thermostat

39) Install the alternator bracket compl. and

'ig. 5-92 ~nstallingpulley 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
- 6 ) Install the intake manifold compl. on the can be obtained.
cylinder head with its gasket, nuts (8 mm) and
bolts.
37) Install the carburetor assembly with its Standard V-belt 10 - 15 mm/lO kg
gasket, heat insulator, gasket I1 and O-ring on tension (0.394 - 0.591 in122 lb)
rhe intake manifold using two 8 mm nuts.
41) Securely tighten the bolts which were 46) Adjust the valve clearance.
temporarily tightened in step (39).
42) Fit the hose (water bypass) to the intake
manifold compl. Standard valve clearance (when cold)
43) Fit the vacuum hose to the vacuum
advancer unit. 0.13 - 0.17 nim
Intake
44) Fit hoses (engine outlet) and hoses (0.005 1 - 0.0067 in)
(engine overflow).
45) Adjust belt (camshaft drive) tension as 0.23 - 0.27 111111
Exhaust
follows. (0.009 1 - 0.0 106 in)
a. Turn the crankshaft pulley until the top
I
dead center (T.D.C.) mark on the crankshaft
I
pulley comes into alignment with the arrow \
mark on the crankcase cover to get cylinders NOTE:
T.D.C. point. Refer to "CHECKING AND ADJUSTMENT
OF VALVE CLEARANCE" previously
mentioned in Chapter 3.
1
"ENGINE TUNE-UP' for the details of
adjustmen

After complcuurl uf the adjustment, install

the valve rocker cover.

Tightening torque 0.75 2 0.05 kg-m

of the bolt (5.42 5 0.36 ft-lb)

I U U I c:
Fig. 5-95 Timing mark alignmenf
Tighten rocker cover bolts to the specified
torque in three steps.
b. Fully loosen the adjusting screw of rocker
arm on one cylinder where the piston is
47) Remount the clutch cover and the clutch
positioned in the exhaust T.D.C. disc onto the flywheel.
c. Remove the plug (timing belt cover) pro-
vided in the cam belt cover 11, and tighten
first the lower 8 m m bolt and then the
upper bolt on the tensioner.
NOTE:
Use the Guide (clutch disc) 499745400 to
help in centering of the clutch disc. (Refer
i
Tightening torque
*
1.6 0.15 kg
*
(1 1.7 1.08 ft-lb)
to Chapter 10. CLUTCH. page 10-6. Installa-
tion.)
1
1

NOTE:
a. Tighten the tensioner bolts through two
48) Connect the transmission to the engine. i
I
1
round holes.
b. Loosen first and then retighten the tensioner 4.2 - 4.8 kg-m I
compl. mounting bolts in step (45) if they Tightening torque
(30.4 - 34.7 ft-lb)
were tightened before step (45). i
 .9) Adjust the ignition timing. a. Refill the engine oil and coolant.
Engine oil quantity:
NOTE:
2.8 liters (includes 0.3 liter
! Refer to "CHECKING AND ADJUSTMENT
for oil filter)
1 OF IGNITION TIMING" in Chapter 3, and
(3.0 U.S. qt., 2.5 Imp. qt.)
"ENGINE TUNE-UP" for necessaw adjust-
ment procedure.

SUBARU COOLANT
Coolant 6.0 liter

Standard ignition
timing 10"/1,000 + 50 rpm
50) Securely tighten the breaker case mount-
ing 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.
NOTE:
a. Be sure to use recommended brands of
engine oil.
b. Be sure to use SUBARU-COOLANT.
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 muf-
fler, etc. do not contact with the bod.Y.
5-5. TROUBLESHOOTING so as not to allow the defect to become worse.
The following table shows some common
When signs of trouble appear on the engine, troubles which may appear, the possible causes,
immediately take appropriate corrective action and what corrective action to be taken.

'-ouble and possible cause Corrective action

1) Defective key switch contact Inspect and repair or replace

2) Open line between the key switch Replace

and starter

3) Open line between battery and Replace

starter motor

4) Discharged battery Charge or replace

Starter motor
5) Defective battery terminal contact Inspect, clean and repair
does not
operate
6) Defective magnetic switch on Inspect, clean and repair or
starter motor replace

7) Defective starter motor internal Repair or replace

mechanism

8) Bearing seizure on crankshaft, Inspect and repair or replace

connecting rod, etc.
Y
3
-
"I
CI

.L
9) Piston seizure or sticking Inspect and repair or replace
0
C
V)
u 1) No gasoline Check fuel tank and add fuel
0
a
z
.-
M
2 ) No continuity of ignition current Inspect and repair or replace
(open ignition system cord, igni-
r5 tion coil, distributor, and blown
Starter motor fuse, etc.)
operates but
engine does 3) Defective starter motor internal Repair or replace
not start mechanism

4) Open or loose connecting slow cut Repair or replace wiring

valve wiring

5) Malfunction of slow cut valve Replace slow cut valve

1) Discharged battery Charge

2 ) Defective contacts in line between Clean and repair

Starting speed battery and starter motor
too low
3) Defective contacts in line between Clean and repair
battery and ground
 Trouble and possible cause Corrective action
V)
0)
0 E
- 2 4) Defective starter motor Repair or replace
0)
Starting speed
2
W
too low 5) Incorrect engine oil Change engine oil for
recommended one

1) Contact breaker
Damaged or corroded cord Replace or clean
contacts
Damaged or burnt points or Clean and adjust or replace
improper gap
Defective condenser Replace
Improper ignition timing Adjust

2) Spatk plug
Improper ignition gap Adjust gap
Defective igni-
tion system a Defective insulation Replace
Contamination due to carbon Clean

3) Ignition coil
Defective ignition coil Replace
Poor connection in primary Inspect and repair
line

-
w
.5
*
LC

Y
Y)
Corroded high tension cord
socket
Clean

.-(1 4) Defective cord or defective wiring Replace

-X
4

3
U
t2 1) Fuel pump
5 Defective operation Replace
Clogged fuel filter element Replace
-- -

2 ) Improper gasoline or gasoline ~e~lade

Defective fuel mixed with water
system
3) Carburetor
Defective choke valve Adjust choke system or
operation replace
Excessive gasoline intake Fully open choke and
throttle valves and operate
engine

Contaminated or clogged Disassemble and clean

carburetor
 ouble and possible cause 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 Replace

M spring
.-c
L
4

cd
Y
V) 6) Improper valve clearance or valve Adjust
.Ei holding open
-5
x
U
Engine

7) Worn piston, piston rings, and Disassemble and repair

cylinder

8) Leakage from intake manifold Retighten or replace gasket

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

Y
3
a 4) Deterioration or damaged valve Replace
Poor
O
compression spring
3
2 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
 Trouble and possible cause Corrective action

1) Improper ignition timing Adjust

2) Distributor
Defective points Correct or adju
Defective igni-
tion system Defective vacuum and spark Replace
advancer
Defective condenser Replace

3) Defective spark plug Clean, and adjust or replace

1) Clogged carburetor Disassemble and repair

2) Defective fuel pump operation Replace

4
3
a
*
3 3 ) Clogged fuel filt~ Replace
0

el
Defective fuel
system 4) Clogged fuel pipe Clean

5) Air mixed in the fuel system Inspect coupling and

re tighten

6) Improper gasoline or gasoline Replace

mixed with wptpr

1) Clogged air cle aner Replace

Insufficient
intake air 2) Defective choke valve Repair or replace choke
system

Defective ex-
1) Clogged mufflr Replace
haust system

1) Insufficient coolant Add

2) Defective thermostat function Replace

3) Defective water pump function Replace

a0
C
.-
C-l
m 4) Clogged radiator or coolant Clean and repair, or replace
Engine
5 leaking from radiator
al
6 5) Clogged coolant passage or coolant Inspect, clean and repair or
leaking from passage replace

6 ) Defective tlzermoswitch function Replace

7) Defective fan motor Replace

I
 Trouble and possible cause Corrective action

8) Defective connection between fan Inspect and repair or replace

motor and thermoswitch

9) Improper ignition timing Adjust

Engine 10) Improper engine oil Change, using recommended

oil
cjo
.5
Y
rn 11) Mixture too lean Inspect and adjust or repair
a,
5 carburetor and intake
Q)
system
6
12) Improper valve clearance Adjust

13) Excessive resistance in exhaust Inspect and adjust or replace

system

1) Slipping of clutch Inspect and adjust or replace

2) Dragging of brake Inspect and adjust or replace

Causes other
than engine 3) Improper transmission oil Change, using recommended
oil

1) Improper idling adjustment Readjust

2) Clogged slow-system passage Inspect and clean

Carburetor
a 3) Open a loose connecting slow cut Repair or replace
8
a.
V)
valve wiring
-2
M
.*C
1) Leakage from joints of intake Inspect and retighten or
-
Q)
Intake system
system replace gasket
S
Y
V)

2) Vacuum pipes (crack or damage) Replace

5
1) Improper valve clearance Adjust
Valve system
2) Leakage from valve seat Correct
 Trouble and possible cause Corrective action
-

3) Excessive clearance between valve Replace

Valve system
a stem and guide
Q)
Q)

2
Cylinder head 1) Leakage from gasket Replace
-ac
.d

1) Improper ignition timing Adjust

Ignition
system
c 2) Poor spark plug action Adjust o r replace
3 &

Cooling 1) Excessive cooling Inspect and replace

system 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

Oil leakage
c 7) Defective oil filter sealing Inspect and retighten
0
.-*
2 8) Defective crankshaft oil seals Replace
5
0, 9) Defective rocker cover gasket Replace
#
.d

0
Q)

.-c 10) Loose crank case cover mounting Retighten

w
5 bolt
Q)
.->
"I 1 1) Defective camshaft oil seal Replace
Q)
U

w" 1) Improper piston ring gap or Replace

defective oil ring
Oil creep i n t o
2) Seizure, wear or defective contact Replace
combustion
of piston ring
chamber
3) Excessive wear or piston and Replace
cylinder liner

Oil sucked 1) Damaged retainer rubber Replace

into combus-
tion chamber 2) Excessive clearance between valve Replace
through valve stem and guide
guide
 Trouble and possible cause 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 ( replace

level too high
Defective fuel
5) Choke does not fully open Correct or replace
system
6) Defective accelerator pump Replace

7) Defective auxiliary valve Correct or replace

operation

8) Damaged carburetor gasket Replace

9) Excessive fuel pump pressure Inspect anu I C ~ ~ I I

C
0
.4
-
C
a 1) Improper ignition timing Adjust
5
Y)
-
d
o 2) Defective ignition advancer Correct or replace
2e, Defective operation
ignition
e,
system 3) Improper breaker point gap Adjust
0
'
Y)

e,
2
W
4) Improper gap o r contamination Adjust or clean
of spark plug

1) Improper valve clearance Adjust

2) Poor compression Inspect and correct or

Defective
-eplace
engine
3) Excessive cooling Inspect thermostat and
temperature gauge

1) Slipping of clutch Inspect, and adjuster or

replace

Causes other 2 ) Dragging of brakes Inspect and adjust

than engine .-
3) Improper tire size or air pressure Replace and adjust
 Trouble and possible cause Corrective action

1) Loose ignition line connections Inspect and retighten

Defective
ignition 2) Defective or improper spark plug Clean, adjust o r replace
system
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 lmination or clogge d fuel lint: Clean or replacc
system -
-
C
.0
C
I
I

3
)
4) Leakage from carburetor and
intake manifold
Re tighten or replace gasket

P
E
0
v 1) Improper valve clearance Adjust
C1
cJ
Defective 2) Valve seizure Replace
2
9
valve
d 3) Weak valve spring Replace

1) Carbon deposit in combustion Clean

chamber

Defective 2) Clogged exhaust port Clean

cylinder head
3) Leakage from cylinder head gasket Replace

4) Maladjustment of belt ten: Adjust o r replace

Defective
exhaust 1) Carbon deposit in mufflc Clean or replacc
system

I ) Defective spark plug (defective or

I and corre ace
contaminated gap)

2
%
E
c
'G
w
C
Defective
ignition
system
2) Defective ignition coil

3) Defective breaker
Defective condenser
tRepla ce

Replace
Improper point adjustment or
defective arm

4 ) Defective cords Repla

r

Trouble and possible cause Corrective action

5) cbefective c:ontacts of wiring Inspect and repair

Defective
CIonnection S
ignition
system
6) Improper ignition timing Adjust

1) Mixture too lean Overhaul

2) Clogged carburetor Overhaul

3) Improper carburetor idling Adjust

Defective fuel
adjustment
system
5
'2
e,
4) Leakage at carburetor gasket Retighten or replace
c
.d

2
W
5) Improper gasoline or gasoline Drain fuel and replace gasoline
mixed with water

1) Damaged valve or i~ilproper Adjust o r replace

adjustment

2) Weak valve spring Rc

Engine
3) Poor compression I~lspectand adjust or replace

4) Excessive cooling Inspect thermostat and

temperature gauge

1) Defective ignition wiring Replace or repair

Defective
ignition 2) Defective vacuum advancer Replace
system
3) Improper ignition timing Adjust
.c)

2 Defective 1) Clogged slow jet and/or slow air Inspect and clean
carburetor bleed
cl
0
C
2, 1) Clogged air cleaner Replace
3
8 Defective
intake system 2 ) Leakage from joints of intake Inspect and retighten or
0 system replace gasket
u
.-2
A
1) Poor compression Inspect and correct o r
2
replace
Engine
2) Improper valve clearance Adjust
 Improper way
of stopping Stopping engine just after racing it Don't race engine
M engine
.-C
E
3 Improper
.f! Insufficient throttle opener opening
adjustment of Adjust
G angle
4 throttle opener

Engine Engine misfire Inspect and adjust

Engine noise

In most cases, engine noise consists of combined sound, i.e., sound from the various rotating
1 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 Method of confirmation Cause

Sound like metal striking
together, or softer
thumping sounds.
Increase engine speed
+ When valve clearance
is normal
x Improper valve clearance
x Worn vlave rocker arm
x Broken valve spring

x Worn cam nose

Sound like striking stone x Worn crankshaft main bearing

Low
with a heavy hammer or
tapping stone with a Inspect oil x Worn connecting rod bearing
small hammer. pressure (big end)

x Loose flywheel mounting bolts

Normal
x Damaged engine mounting
-
High pitched metalic Generated when accel- x Ignition timing too fast
sound erating with an overload
x Accumulation of carbon
inside combustion chamber
-+ Engine knocking
x Wrong spark plug

x Defective breaker advancer

operation

x Defective gasoline
 Type of sound
Knocking sound when
engine speed is medium
(about 3,000 rpm with
no load)
Knocking sound when
engine is warm and
operating at idling speed.
Knocking sound when
engine is operating under
idling speed and engine is
warm.
Sound like scratching
glass witha nail.
Sound like a shower, or
tapping light metal with
heavy metal at high
frequency.
Dragging sound when
starting the engine.
Sound like polishing glass
with a dry cloth or normal
starter sound.
Sound like air leaking or
being blown out
High level noise (whistling)
just after racing the engine.
Method of confirmation Cause
Short circuit spark plugs x Worn crankshaft main bearing
one after another +
x Worn bearing; at piston
Sound is extinguished. connecting rc)d
Short circuit spark plug x Worn cylinder liner ana piston
one after another 4 ring
x Worn bearing at piston end of
Sound is extinguished connecting rod
Short circuit spark plugs x Worn piston pin and connect-
one after another + ing rod bearing (Big end)
Sound is extinguished x Unusually worn valve rocker
arm
+ Sound is not extin- x Insufficient backlash of
guished. balancer gear
x Insufficient AC generator
lubrication
x Defective AC generator brush
and rotor contact
x Defective starter switch
x Worn ring gear and starter
pinion
x Loose V-belt
x Leaking of compression
x Overtension of timing belt.
 CHAPTER 6: ENGINE LUBRICATION SYSTEM

61
. . GENERAL ................................................................................... 6-2
6.2 . OIL PUMP ..................................................................................... 6-3
63. . OIL FILTER ................................................................................... 6-7
6 - 4. OIL PRESSURE SWITCH ............................................................. 6-8
6-1. GENERAL
Cylinder
t
Crankcase
n~airigallery
Oil pump
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 assem-
bly. 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.
T r
Valve(0il bypass) 1.0 kgjcm2
(14.22 psi)
t
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
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 cam-
shaft, 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. OIL PUMP

1. Specification

Type Trochoid type

Delievery rate 6 4 m i n . or more, (6.33 U.S. qt.,

5.27 Imp. qt.)
Delivery
Delievery pressure 2.5 kg/cmZ (35.56 psi)
Performance
1
Oil pump speed 1,500 rpm

Oil temperature 80°C (176OF)

7.7Llrnin. or more, (8.14 U.S. qt.,

Delivery rate
6.78 Imp. qt.)
Delivery
Delivery pressure 3.6 kg/cm2 (5 1.20 psi)
Performance
2
Oil pump speed 3,000 rpm

Oil temperature 80°C (176OF)

t3.56 .
Valve (oil relief) operating pressure 3.0 t:-25 kg/cm2 (42.67 PSI)

Valve (oil by-pass) operating pressure 1.O f.0.2 kg/cm2 (14.22 2.8 psi)

Standard tip clearance between inner 0.02 - 0.12 mm

rotor and outer rotor (0.0008 - 0.0047 in)
-
Standard side clearnace between rotor a] 0.01 -0.16mm
oil pump case (0.0004 - 0.0063 in)

Standard case clearance between outer 0.15 - 0.21 mm

rotor and oil pump case (0.0059 - 0.0083 in)

Free length of relief valve spring 46.8 mm (1.84 in)

 asket

Valve (Oil relief)

Spring (Relief valve)

2 Oil pump component parts

2. Removal Remove the generator assembly.

3)
4)
'Draw out the crankshaft pulley.
Precautions for Removal
Remove the cam belt cover 11.
5)
"
A. Carefully check the oil pump before re- Remove the cam belt tensioner spring and
moving it for any evidence of oil leakage. the tensioner COMPL.
B. When replacing the oil filter and the oil Remove the camshaft drive belt.
pump gasket, remove the oil filter with a Remove the camshaft drive pulley and two
suitable tool and then remove four bolts plates.
fastening the oil pump cover. Remove the camshaft driven pulley.
1) Drain engine oil and coolant. 10) Remove the cam belt cover COMPL.
2 ) Remove the oil level gauge COMPL. 11) Remove the flywheel housing COMPL.
 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

17) Remove the oil filter assembly.

'3. Disassembly
Fig. 6-3 Removing water pump cover
1) Remove the oil pump cover by loosening
two 6 x 18 mm bolts and two 6 x 32 mm bolts.
Remove the gasket.
15) Remove the water pump impeller by
loosening a bolt.

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 I cover
(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. Fig. 6-5 Disassembling oil pump
 2) Take off the oil pump outer rotor.
3) Draw out the oil pump shaft with a press.
Y--c,.
4) Remove the plug ( I 4 x 9 mm) and take up inner)
the relief valve spring and valve.

Cove r (Oil
..
pun
..
Relief valve
^,.I II
ssure (Oil
4 outer)

Fig. 6-7 Checking tip clearance

Fig. 6-6 Disassembling relief valve

and oil pressure switch Standard tip 0.02 - 0.12 mm
clearance (0.0008 - 0.0048 in)
5) Remove the oil pressure switch assembly
Allowable
maximum tip 0.2 mm (0.0079 in)
clearance
4. Inspection and repair
Wash disassembled parts, inspect the follow-
ing items, and repair or replace if defective.
1) Oil pump shaft
c. Side clearance
Inspect the periphery, and replace the shaft
Check the side clearanck (between the inner
if excessively worn or damaged.
rotor and the oil pump cover).
2) Oil pump inner and outer rotors Replace either the rotor or the case, if the
a. Check each rotor and replace if excessively.
worn or damaged. When replacing the inner side clearance exceeds the allowablelimit.
rotor, remove the oil pump shaft pin.

Standard side 0.01 - 0.16 mm

Outer diameter clearance (0.0004 - 0.0063 in)
29.70 - 29.74 mm Allowable
Inner rotor
(1.1693 - 1.1709 in) maximum side 0.2 mm (0.0079 in)
clearance
40.53 - 40.56 mm
Outer rotor
(1.5957 - 1.5968 in)

1 d. Case clearance
Check the case clearance (between the outer
i
: b. Tip clearance diameter of outer rotor and the crankcase
Check the tip clearance. Replace the rotor cover).
assembly if the clearance exceeds the allow- Replace either the rotor or the cover, if the
able limit. 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 rllcKrless gauge NOTE:

Use new aluminum washers, gasket and
O-rings.
ig. 6-8 Checking case clearance

Standard case 0.15 - 0.21 mm

clearance (0.0059 - 0.0083 in) 6-3. OIL FILTER
(CARTRIDGE TYPE)
Allowable
maximum case 0.25 mm (0.0098 in)
clearance
-
Filter area 810 cm2 (125.55 in2)
3) Oil relief valve and relief valve spring
Inspect the valve for fit and damage, and the Bypass valve 1.O 0.2 kg/cm2
relief valve spring for damage and permanent operating pressure (14.22 + 2.84 psi)
strain. Replace them if necessary.
16Llmin.
Delivery rate (4.23 U .S. gal,
3.52 Imp. gal.)
Free le 46.8 mm (1.8425 in)

Fitted length 33.5 mm (1.3189 in)

-

3.3 50.15 kg
Setting load
(7.28 5 0.33 lb)

Valve (oil relie0 t:25 kg/cm2

operating pressure t3.50 .
(42.67 PSI)

4) Oil pump cover

Inspect the oil pump cover for clogging of 1 Oil filter 4 Spring
oil passage, cracks or any other defect. 2 Bypass valve 5 Spring 11
I 3 O-ring ~6-003
5) Crankcase cover
Inspect the cover for wear and cracks in the
rotor housing. Fig. 6-9 Oil pump
2. Inspection 1. Specifications

1) Check.the O-ring for deformation or dam-

age. Replace the oil filter if the O-ring is Type Oil contact
defective.
2) Check the oil filter body for deformation Voltage 12V
or breaking. Replace it if defective.
Bulb 12V-3.4W or less
3. Installation
0.3 + 0.1 kg/cm2
secure the oil filter t o the specified torque. Closing pressure
(4.3 + 1.4 psi)
0.3 + 0.1 kg/cm2
0.9 - 1.4 kg-m Opening pressure
Tightening torque (4.3 f. 1.4 psi)
(6.48 10.08 ft-lb) -
10 kg/cm2 or more
Withstand pressure
NOTE: (142.23 psi)
a. Be careful not to damage the O-ring
installation of the filter. Weight 40gr. (1.41 02)
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. r. Construction
The oil pressure switch consists of a dia-
phragm which operates under oil pressure,
electrical contact points which open and close
(ON- OFF) with movement of the diaphragm
6-4. O I L PRESSURE SWITCH and a spring which determines operating pres-
sure 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
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
3 spring pressure and acts on the points which
T6-004
results in the light going off. It may be
1 Point 3 Spring considered normal for the light to be off during
2 Diaphragm 4 Wire fixing bolt running of the engine, irrespective of running
state of the vehicle. Lowering of oil pressure
Fig. 6-10 Sectional view of oil below 0.3 kg/cm2 during engine running will
pressure switch cause the warning lamp to come on.
 Page

1I
7- 1. GENERAL DESCRIPTION ..................................................... 2
7- 2 . CONSTRUCTION OF ENGINE COOLING SYSTEM ............ 6
7- 3. SPECIFICATIONS .........................................................................7 - 7
7- 4. COOLANT REPLACEMENT ......................................................... 7-8
7- 5. ............................................................... 7-10
a
II
RADIATOR ASSEMBLY
7- 6. MOTOR FAN ASSEMBLY ...........................................................7-11
7- 7. RESERVOIR TANK ...................................................................... 7-11
7- 8 . COOLANT LEVEL WARNING DEVICE ..................................... 7-
7- 9. CHECK VALVE .............................................................................7-19
7-10 . THERMOSWITCH ASSEMBLY ................................................... 7-15
7-1 1. HOSE (Radiator inlet and outlet) ................................................ 7-16
I
. (Water pump inlet. thermostat outlet and heater) ................. 7-16

I1 .
7-12
7-13
71.4
.
.
HOSE
HOSE (Air vent of engine. radiator and heater) ............................... 7-17
COOLING PIPES ..........................................................
.
-I 71.5 HOSE (Check valve outlet. reservoir tank inlet and
reservoir tank outlet) .........................................

1 71.6
7-17 .
. .................................................
WATER PUMP
THERMOSTAT ................................................
7-18 . THERMOMETER ............................................,
7-1. GENERAL DESCRIPTION
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.
1.
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 ther-
mostat (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 per-
formed. 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/
Heater air
vent
Cap w ~ t hpressure valve

Reservoir tank
Thermostat
E n g ~ n ealr vent
Plug

Check valve

T7-001

Fig. 7-1

Heater control valve: Opened Coolant is circulated to reservoir tank,

Thermostat: Closed 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

Heater control valve: Opened The thermostat is opened and coolant is also
Thermostat: Opened circulated to radiator.

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

Fig. 7-3

7-3
 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.
2.
The coolant is a long life coolant (SUBARU
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.
3. Function of re ank and
check valve
1) Reservoir tank for separator of coolant
and vapour.

1 Air bubbles are discharged here. 6 Gas, vapor or air leaks in from hoses, cooling
2 Reservoir tank pipes and engine etc.
3 Cooling water and air bubbles are repeatedly 7 Cooling water containing a small amount of
separated. air bubbles
4 Gas, vapor or ai 8 Cooling w ning no air bubbles
5 Engine 9 Heater
10 Check vat
11 Radiator ~7-004

2) Reservoir tank and check valve for pre- When coolant temperature exceeds llO°C
venting coolant overflow (230°F) and the engine is suddenly stopped.

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 Bracket (Tank) 21 Hose (Engine inlet) 41 Drain plug (Radiator)

2 Flange nut 22 Hose (Engine outlet) 42 Gasket (Radiator)
3 Reservoir tank cover 23 Hose (Engine outlet) 43 Washer
4 Bolt assy 24 Clamp (Upper) 44 Flange nut
5 Clip (Fuel system) 25 Clamp (Lower) *45 Hose (Reservoir tank inlet)
6 Clip (Engine cooling) 26 Bolt & washer 46 Grommet (R.H.D. only)
7 Hose (Heater air vent) 27 Cooling pipe A 47 Hose clamp
8 Reservoir tank assy *28 Hose (Radiator inlet) 48 Hose (Reservoir tank outlet)
9 Cap 29 Check valve 49 Hose clamp
10 Level sensor (Reservoir tank) *30 Hose (Check valve outlet) 50 Grommet
*11 Hose (Radiator air vent) 31 Flange nut 51 Overflow tube
12 Grommet 32 Fan 52 Clip 12
13 Hose clamp 33 Fan motor 53 Connector (Overflow)
*14 Hose (Check valve inlet) 34 Grommet (Fan) 54 Boot (Overflow)
15 Hose clamp 35 Spacer (Fan) 55 Cap
16 Grommet 36 Washer *56 Hose (Radiator outlet)
17 Hose clamp 37 Bolt &washer 57 Lock washer
18 Clamp (Cooling pipe) *38 Radiator assy
19 Cooling pipe B 39 Thermoswitch * Different parts between R.H.D.
20 Cooling pipe C 40 O-ring and L.H.D.

Fig. 7-8 Components of engine cooling system

 Item Specification Conditions

Width x Height x Thickness *1

Core dimension 334 x 240 x 32 mm Water flow: 45.41 min.
Radiator (13.1 x 9.45 x 1.3 in) Temperature difference
between coolant and
Fin pitch 2.0 f.p. ambient atmosphere:
6S°C (149OF)
Radiation capacity * 1 -8,700 Kcal/h Front air velocity: 8 m/sec.

Capacity Approx. 1.6.L

Pressurle type
Positive pressure
Reservoir 0 .8 - 1.O kg/cm2
tank Cap (1 1.4 - 14.2 psi)
Negative pressure
0.05 - 0.1 kg/cm2
(0.7 - 1.4 psi)

Fan diameter 190 mm dia. x 6 blades

Fan Magnet motor

Motor specifications
Input: under 6r
- *2
Air flow capacity *2 7.5 m3/min. A P a = 7 mmAq

ON 90° - 94OC (194 - 201°F)

Thermo-
switch
OFF 86 - 90°C (187 - 194OF)

Temperature at which
3.S°C (177 - 182OF)
valve starts to open
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 > jtnglne alr vent)

Drajn plug Clam0 )\

Fig. 7-10 Removing cap

4) Jack up rear side of the vehicle and drain
coolant further.
5) Disconnect radiator hoses (inlet and out-
let) 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
Fig. 7-14 Removing caps
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 con-
nected 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.

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
(Net 18 liter) lowest atomospheric anticipated temperature
Parts No. 000016218 according to the table below.

I Coolant Specifications I

I
atmospheric coolant-to-
Freezing point
anticipated *water ratio at loOclat2 0 0 lat
~ 3 0 0 ~at
1 40°clat 50°C
temperature (Volume)

Above
30 to 70
-lS°C (S°F)

Below
50 to 50
-lS°C (S°F)

* It is recommended that distilled water be used.

7-9
7-5. R A D I A T O R ASSEMBLY lnspection

1) Check the tube ana welaea part between

radiator tank (inlet and outlet) and tube for
1) Drain t he~coolant. leakage. When defective, repair or replace.
-
&J Disconnect the radiator ai, .,llL ,,,
'r)G a L

the left side ()f shroud in cabin (RHD) or 2it the

righ.t side of slhroud in c:abin (LHD).

F& zdiator (RHD)

Inlet tank

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

. .

Fig. 7-19 Radiator (L1

3tor air 2) Check th.e fins of the radiator core and

'

hose repair with a stcrewdrive:r, etc. whc:n the air path

is blocked. I

3) Wash witn warer when the fins are muaay J 3 I1

Fig. 7-1 7 Radiator air vent hose (LHD) or dirty. II
3. Installation
3) Remove front combination light. stallation is the reverse of removal.
4) Remove front bumper.
5) Disconnect the harness from the thermo- E:
switch. hen installing the radiator hose, always I
6) Disconnect the radiator hoses (inlet and lint the hose clamp to the prescribed 1
outlet) fromcooling pipes. direction as viewed from the bottom. !
7) Remove the radiator by removing four
6 mm flange nuts.
The same also applies to the water tube and
hose connections. Otherwise, retightening of
I
8) Finally, remove the inlet and outlet hoses
connected to the radiator.
the hose clamp will be impossible after
mounting to the vehi~ cle.
I
 Toward the top right
NOTE:
Be careful not to damage the radiator core
when removing the fan.

Toward the top right

lant upward 1 Outlet hose

2 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). Fig. 7-21 Installed position of motor fan
( c. Fill completely with coolant. (Refer to
I "Filling coolant".)
3. Inspection
1 d. Check for any coolant leakage after installa-
'tion. 1) Replace the packing and cover when they
are ozone cracked.
2) Check the bracket for damage or crack-
7-6. MOTOR F A N ing.
ASSEMBLY 3) Check the operation of the motor.
1. Features 4. Installation
-' 1) Superb cooling performance (especially
effective when vehicle is running at low speed)
Installation is the reverse of removal.
2) Engine output improved
I Since the cooling fan is not driven by the NOTE:
1 engine, there is no power loss and engine a. Be careful to provide a clearance between
I output is increased. As a result, acceleration the fan and radiator.
and climbing ability are improved and fuel b. Provide a clearance of over 10 mm (0.39
economy is improved. in) between the motor and radiator inlet
3) Since the fan is not usually operating, hose and clearance of over 15 mm (0.59 in)
there is little noise caused by the fan. (The fan between the motor and horn.
is automatically operated when the coolant
temperature reaches 92OC (198OF) and is auto-
matically stopped when the coolant tempera-
ture drops to 88OC (190°F) by means of a
thermoswitch.)
7-7. RESERVOIR T A N K

1. Operation
2. Removal
The reservoir tank is installed at the highest
1) Disconnect the motor lead wire and har- position of the cooling system and serves as the
ness. coolant inlet, separates the air remaining in the
2) Remove the two 6 mm bolts of the system when coolant is added, and keeps the
bracket mounting the motor assembly. system filled with coolant at all times. (If the
air in the system is circulated, the cooling per- 6) Remove the reservoir tank cover.
formance 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.

NOTE:
Allowable coolant loss volume: ~t hose
The coolant level a t which the engine is
seized when the coolant is gradually re-
moved from the cooling system. To be
Fig. 7-23 With cover removed (LHD)
precise, the allowable coolant loss volume
indicates the permissible limit of coolant
leakage and the larger this volume the 7) Remove the inlet hose and outlet hose
greater the safety of the cooling system. from the reservoir tank.

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

2. Removal 8) Detach the overflow tube from the boot. '

9) Remove the bracket and pull out the tank

1) Remove the reservoir tank cap and drain to the rear.
the coolant. (Refer to Chapter 7-4).
2) Remove glove box (LHD) or combination 3. lnspection
meter (RHD).
3) Remove defroster duct. 1) Replace tank if cracked or leaky.
2) Replace poor cap sealing.
4) Disconnect the connector and unclip the
wiring harness from the reservoir tank cover.
5) Remove tapping screws attaching heater
4. Installation
control lever bracket. 1) Attach the new sealing tape to the body. '

(Do not use old one of sealing tape.)

servoir

aaling tape
\

Fig. 7-22 Fig. 7-24 Attaching sealing tape

7-12
 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)
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.

7-8. COOLANT LEVEL WARNING DEVICE

(/ Use of this warning buzzer helps prevent the

engine from overheating and facilitates day-to-
day water level check.
I

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 re-
plenished.
The warning device is actuated while the ig-
nition key is turned ON, regardless of whether
the engine is in motion or not.
Level i

2. Checking and servicing coolant

7
voir tank

Refer to 3-3. in CHAPTER 3 ENGINE

TUNE-UP. Fig. 7-26 Level sensor
1) Removal 7-9. CHECK VALVE
a. Drain the coolant in reservoir tank.
b. Loosen the level sensor and remove from 1. Construction
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.

Fig. 7-28 Check valve unit

From reservoir tank

4
." , . 2
Fig. 7-27 Checking continuity
O-ring

Float
3) Installation
Installation is the reverse of removal.
a. When screw the level sensor into the! reser- Lower case
T7-012
voir tank, be careful not to twist or j i Irn the
O-ring with edge of reservoir tank.
-
Fig. 7-29 Construction

The check valve consists of upper case

and lower case, float and valve, and operates as
*
0.15 0.03 kg-m one way valve.
Torque
*
(1.1 0.2 ft-lb) The coolant flow from reservoir tank can
pass through the check valve but can not
reurn to the reservoir tank.

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.
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.
 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.)
7-10. THERMOSWITCH
ASSEMBLY
1. 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.

3. 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. Specifications

1
1

Hose-
I t
(Check valve, ' Model Enclosed wax type
outlet)
Operating ON 90 - 9 4 O ~(194 - 201'~)
temperature OFF 86 - 9 0 ' ~(187 - 194'~)
Current DC 12V, 7 Amp.

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

I 3. Removal
I 4. Installation
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 therrno-
switch in 100°C (212OF) hot water and con-
firm that it is turned ON using a circuit tester.
 Installation 2) Inspection
a. Replace when the reinforcement of the
Installation is the reverse of removal. outer cover of the hose is damaged.
b. Replace hoses which are noticeably hard-
ened.
3) Installation
mounting screw) (2.2 ft-lb) Installation is the reverse of removal.
a. Hose insertion depth is 25 to 30 mm (1 .O to
1.2 in).
1) Connect the harness of the thermoswitch b. Install the hose clamps in the specified
securely and clip the harness. (Missing to clip direction. (From the standpoint of retighten-
will result in short circuit.) ing)
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.
7-1 1. HOSE (Radiator inlet and
djust so that the hoses are not contacting
outlet)
each other.
e. Fill the coolant.
1. Removal
f. Confirm that there is no coolant leakage
after installation. .--
Refer to radiator removal item.

2. Inspection Thermostat outlet hose and I

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) Removal
a. Drain the coolant.
1. Water pump inlet hose b. Remove the trap door at the top of the
engine compartment.
1) Removal c. Remove the boot connecting air cleaner and
a. Drain the coolant carburetor.
b. Remove the trap door at the top of the d. Loosen the bolt and release the clamp then
engine compartment. disconnect the hose.
c. Remove the under cover. e. Loosen the hose clamps and disconnect the
d. Loosen the hose clamp and remove the hose. hose.
 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 hard-
ened.
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. Air vent hose of

7-13. HOSE (Air vent of engine, radiator and heater
radiator and heater)
1) Removal
1. Air vent hose of engine a. Radiator air vent hose
1) Drain the coolant.
1) Removal 2) Remove the reservoir tank cover.
a. Do not open the cap of reservoir tank. 3) Disconnect the hose from air vent pipe
b. Remove the trap door at the top of the by loosening hose clamp.
engine compartment. 4) Disconnect the hose from radiator by
loosening hose clamp.
c. Prepare plugs. Loosen the clamps and
(Refer to Figs. 7-16 and 7-17).
I remove the hoses, then put the plugs to the
pipes of engine side. 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
Fig. 7-33 Engine air vent hose retightening.)
c. Bleed all the air from the cooling system 2. Installation
after installation.
d. Confirm that there is no coolant leakage Installation is the reverse of removal.
after installation. 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.
7-14. COOLING PIPES
4) Confirm that there is no coolant leakage.
1. 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 sus-
pension 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). 7-16. WATER PUMP -
7) Remove fuel tank.
1. Specifications
8) Remove the hand brake cable.
9) Remove cooling pipes (A, B, C).
5.5 L lmin.
2. Installation (1.453 U.S.gal.,
Delivery rate
1.210 Imp. gal.)
Installation is the reverse of removal. or more
1) Hose insertion depth is 25 to 30 mm (1 .O
to 1.2 in). Pump speed - 1,000 rpm -
2) When installing, confirm that the pipe is in Total head 0.22 mmAq
its original position.
8 75 - 8 5 ' ~
3) Fill with coolant. Water temperature
(167 - 1 8 5 ' ~ )
4) Confirm that there is no coolant leakage. E,
5 0 L/min.
& (13.21 U.S. gal.,
Delivery rate
1 1.0 Imp. gal.)
or more

Pump speed - 8,000 rprn -

Total head 1.5 mmAq

7-15. HOSE (Check valve outlet, 75 - 85OC

Water temperature
(167 - 185'~)
reservoir tank inlet and
reservoir tank outlet) Impeller dia. x Number of
54 mm(2.13in) x 6
vane
1. Removal
Revolution ratio agaist
1: 1
1) Drain the coolant crankshaft
2) Remove the radiator 0.3 - 0.9 mm
Clearance between
3) Loosen the hose clamps and disconnect impeller and case (0.012 - 0.035 in)
the hoses.
 h , - Cam timina adius
imic sei31 lmpe Cover
- \ I I

Mechanical
I

Fig. 7-34 Water pump Fig. 7-35 Removing belt and cover

3. Disassembling
1) Remove the water pump cover by
2. Removal loosening bolts.
Prior t o removal, check minutely the various 6 m m x 18 Bolt: 4
parts of water pump for evidence of water 6 mm x 20 Bolt : 1
leakage. 8 mm x 8 0 Bolt : 1
1) Drain engine oil and coolant.
2) Draw out the oil lever gauge COMPL. And remove the gasket.
3) Draw out the spark plug cord C O W L 2) Remove the water pump impeller by
from the spark plug.
loosening a 6 mm bolt.
4) Remove the V-belt.
5) Remove the water inlet hose and the water 6 mm x 18 Bolt : 1
bypass hose 11.
6) Remove the crankshaft pulley COMPL by NOTE:
means of the special tools 4987 11300 Cam Block the rotation of the impeller by insert-
timing adjuster COMPL and 899521421 Puller ing a screwdriver between the balancer shaft
assembly. weight and the crankcase.
7) Remove the cam belt cover 11.
8) Remove the cam belt tensioner spring and 3) Remove an oil strainer COMPL mounting
the tensioner COMPL. 6 mm bolt at the crankcase side.
9) Mark the running direction on the cam-
shaft belt.
NOTE:
10) Remove a camshaft drive pulley plates The oil strainer COMPL is unnecessary to be
and take off the camshaft drive belt. removed from the crankcase cover.
11) Remove the camshaft drive pulley and its
plate.
4) Remove the crankcase cover assembly by
12) Remove the camshaft driven pulley using loosening the following bolts.
the special tool 498711300 Cam timing ad-
juster COMPL. 8 mm x 25 Bolt : 1
13) Remove cam belt cover COMPL. 8 mm x 45 Bolt : 4
14) Remove the flywheel housing COMPL. 8 mm x 55 Bolt : 2
15) Remove the oil pan COMPL. (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 dam-
age 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. Assembly
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 crank-
case 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 crank-
case cover.
Standard value of tip 0.3 - 0.9 mm
clearance (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
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 1.0 f.0.05 kg-m
(6 mm Bolt) (7.23 2 0.036 ft-lb)
6) Install the water pump cover with its
gasket.
6. Installation
Installation is the reverse of removal.
1) Adjust tension of the V-belt.
Standard belt sag 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 pro-
cedure.
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. THEF
1. 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 thermo-
stat when the cooling system is refilled with
water.
 d

1 Seat
2 Valve
3 Supporter
4 Cap
5 Pi (Thermostat)
6 Frame
7 Spring
8 Cover T7-014

Pin(Thermostat)

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
i
Groove

Looked state

T7-016

Fig. 7-37 Function of thermostat Fig. 7-38 LOlcked pin

7 -21
2. Specifications 7-18. THERMOMETER

* 1. Specifications
TYpe Wax pellet type

Valve actuating 82 t 1.S°C

Temperature Resistance value Current
temperature +
(179.6 2.7OF)
"C (OF) a mA
Valve open
9S°C (203OF) 120 (248) 17.3 - 14.9 96.9 - 100
temperature
lOO(212) 29.3-26.2 83.0-86.2
Valve lift 8 mm (0.3 150 in)
80 (176) 56.8 - 47.5 63.6 - 68.3
Valve diameter 3 1 mm (1.2205 in)
5 0 (122) 178.9 - 123.9 29.9 - 37.1
Valve (Jiggle pin)
weight
0.55 + 0.066 g

3. Removal
Remove the thermostat cover by loosening
two 8 x 40 mm bolts. Remove the gasket and
lift out the thermostat.
4. 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 tem-
perature 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 dis-
tribution.
b. As a result of this test, replace the thermo-
stat if the measurements differ considerably
from the rated values in temperature or in
lift height of the value.
5. 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 assem-
bly 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 con-
trast to ordinary conductors in which the
resistance is only doubled even at several
hundred degrees of temperature rise. The ther-
mistor is warmed by the coolant and its
resistance changes in proportion to the temper-
ature of coolant at that time. The resistance
controls current flowing to the temperature
gauge circuit.
 gauge, so that the gauge pointer indicates a low
Leadwire Thermister temperature. Temperature increases, the resist-
ance 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 fluctua-
Epoxy resin(f3lack) tion of the source voltage. In order to eliminate
such an unfavorable condition, the thermistor
T7-017
unit type temperature gauge system is fitted
with a voltage regulator.
Fig. 7-39 Structural view of
thermistor unit

4. Precautions for handling

of the gauge

1) When testing the gauge system, do not

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
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 secure-
ly. 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 Corrective action

1) Defective terminal contact Correct

Defective 2) Stuck gauge pointer Correct

indication
3) Broken lead wiie Replace

4) Defective thermister Replace

1) Disengaged pointer Correct

No Replace
2) Broken lead wire
indication
3) Broken wiring harness Correct

1) Grounded wiring harness Correct

Pointer
out of scale
2) Short circuited or grounded lead wire Replace
 CHAPTER 8: CARBURETOR

Page

81
. . FEATURE ............................. .......................................................... 8-2
;

8-2 . SPECIFICATIONS......................................................................... 8-2

8-3 . CONSTRUCTION AND OPERATION ......................................... 8-3
8-4 . INSPECTION AND ADJUSTMENT ........................................... 8-5
8-5 . OVERHAUL OF CARBURETOR .............................................. 8-6
86
. . THERMO CONTROL VALVE .....................................................
8-1. FEATURE -v--n-
n-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 noz-
zle, 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 inter-
locked with the throttle valve in acceleration,
the carburetor can prevent hesitation of ac-
celeration 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.: 6 mm (0.24 in)

Inner dia.: 1.8 mm (0.07 in)

Main nozzle Outer dia.: 4.0 mm (0.16 in)
Hole dia. - number: 1.2 mm (0.0047 in) - 6

Inner dia.: 2.2 mm (0.087 in)

Outer dia.: 3.8 mm (0.150 in)
Emulsion tube
Hole dia. - number: 0.6 mm (0.024 in) - 2
1.0 mm (0.039 in) - 16

Main jet #I 22

Main air bleed # 50

Settings of jets .
Slow jet #48

Slow air bleed #I 50

 1
Idle hole diameter 1.0 mm (0.039 in)

0.6 mm (0.024 in) x 1,0.8 mm (0.032 in) x 1,

Bypass hole diameter
0.9 mm (0.035 in) x 2

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 + 0.04 in)
Throttle valve opening for starting 14.5~
(Throttle valve opening with Throttle valve clearance: 1.2 mm (0.047 in)
choke valve fully closed)

8-3. CONSTRUCTION A N D
OPERATION fuel pump and then enters the float chamber
This carburetor consists of a float system, via a needle valve. The fuel level in the float
main system, slow system, accelerating system, chamber is always kept constant by means of
and starting system. the needle valve and float.
The fuel level in the float chamber is 20 mm
: 1. Float system + 1 mm (0.79 +
0.04 in) below the top of
I the float chamber. The fuel level can be

I Fuel from the fuel tank passes through the adjusted by correcting the float lever.

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
emulsion tube via tll= 1 1 ~ ~ ~dir
1 1 bleed passage

The main system supplies fuel for normal and main air bleed, and sprayed in to the
driving other than idling and low speed driving. venturi from the main nozzle.
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
The slow system supplies fuel for slow speed passes through the slow passage and sprayed
(light load) driving. Fuel from the main jet is out of the bypass and idle holes.

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 to decrei

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 elimi-
I
nated and smooth revolution is ensured, since Idle adjusting screw
' the choke valve slightly opens automatically
permitting fresh air to enter after starting.

I Fig. 8-5 Adjusting idling speed

I 8-4. INSPECTION AND
ADJUSTMENT
2. Fuel level adjustment
Idling adjustment

Idling speed 1,000 k 50 rpm

Graduation with
I 1) Warm up the engine until it reaches
normal operating temperature. Float chamber
.2) Adjust the throttle adjusting screw so that
---- enpine
the ---c idling speed is between 950 rpm and
1,050 I.pm without roughness.
3) A djust the idle adjusting screw so that the
engine revolution is highest and smoothest.
se two copper gaskets
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. T8-004

Fig. 8-6 Float level measurement

1) ~ e m o v ethe drain plug and copper gasket 3. Checking slow cut valve
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),
cut valve
the gasoline level is correct.
5) If not correct, adjust by bending the float
lever and measure again. n
6) After measurement retighten the drain
plug and replace the copper gasket with new
one. .
Fig. 8-8 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
2. Adjustment of valve slow cut valve is normal.
openings for starting 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.

2.0 - 2.5 kg-m

Tightening torque
(14.5 t o 18.1 ft-lb)

8-5. OVERHAUL O F
CARBURETOR

1. Float chamber cover

Fig. 8-7 Starting valve openings -

--- ---
t chamber cover
----
Conne
lever

ft (Float)
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'. Gask-.
If not, adjustment should be made by bending
the choke connecting rod. Fig. 8-9 Component parts
 1) Remove the float chamber cover and 3. Slow jet
gasket by unscrewing the five 5 mm screws and
removing a cotter pin connecting the connect- The slow jet can be removed from outside
ing lever and rod. without removing the float chamber cover.
2) The float chamber cover has a needle (Fig. 8-11)
valve, connecting lever, piston, float, etc.
3) Pull out the float shaft and remove the 4. Main air bleed and slow
float. air bleed
4) Remove the 5 mm screw and washer and
detach the connecting lever, pump cover, and
piston.
Slow air blc
Then remove the needle valve.

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 ac-
celerator pump cylinder. n' air bleel
After overhauling the accelerator pump
~rts,operate the pump to see if fuel jets
ut of the nozzle. I f not, overhaul again and
Removing air bleeds
ietk fuel injection after making sure that
the accelerator pump is correctly fitted.
Remove the float chamber cover and then-
2. Main jet remove the main air bleed and slow air bleed.
The emulsion tube can be pulled out if main air
he main jet can be removed from outside
bleed is removed. The main air bleed and slow
out removing the float chamber cover.
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

Remove the drain plug and gasket at the

bottom of float chamber and then remove the blain nozi
setting sc
1 main jet from the float chamber. Replace the
\ pacK' ing with new one when reinstalling the
drainI plug. Fig. 8-12 Removing main nozzle
I
I
 Remove the nozzle set screw. The main
nozzle can be removed by holding the carbure-
tor 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. Power jet
Pistol
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.

\ 8-6. THERMO CONTROL

VALVE

The EK23BE engine is provided with Ther-

mo Control Valve (T.C.V.). The T.C.V. controls
coolant flow in the coolant passage of the in-
take manifold by coolant temperature, and
Fig. 8-13 Removing power jet the]n temper;lture of carburetor slow system is
Disassemble and service the power jet taking aut~ r controlled. (Fig. 8-14)
~maticallj
care not to damage the jet valve at the center of
- :jet. 2. Uperation

ITE: If the coolant temperature is below 45OC

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.
(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 car-
buretor is prevented.

1 Carburetor

3 Manifold CP (Intake)
4 Gasket 2 (Intake)
5 Insulator (Carburetor)

Fig. 8-14

8-8
 5

-E 4 -
-
E
3 -
Y
g 2.5 c close
Gi 2- I
I
I
I

-
0 .
T. C. V

- 1 , I
I

O 1; I I I I + open
45 55 60 70 80
Coolant temperature (OCI . I I
T8-007

Fig. 8-15

3. Inspection

Fig. 8-1 7 Measuring " $"

Fig. 8-1 6 Measuring " 5 "
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 "!$" dimen-
sion.
1) Measure "fj" dimension at normal tem- 3) If " $" minus " 5''
is 2.5 mm (0.098 in)
perature [below 45OC (1 13.s°F)] . or less, the T.C.V. is normal.
I
4. Troubleshooting

Condition and probable cause Remedy

1) Defective T.C.V.
Hesitation when starting or unstable idling speed at Replace
(stick in open)
hot seasen (summer, eary autumn etc.)
2) Clogged T.C.V. Clean

Unstable idling speed at cold seasen (winter, early 1) Defective T.C.V.

eplace
spring etc.) (stick in close)
,
 CHAPTER 9: ENGINE ELECTRICAL SYSTEM

Page

91
. . DISCRIPTION ............................................................................... 9-2
92
. . BATTERY ..................................................................................... 9 - 2
93
. . STARTER .................................................................................... 9-4
94
. . ALTERNATOR ............................................................................ 9-10
95
. . VOLTAGE REGULATOR ........................................................... 9-16
96
. . CONTACT POINT BREAKER .................................................... 9-19
97
. . IGNITION COIL ........................................................................... 9-21
 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.
-1
bber bulb

1
2) Generator and voltage regulator -Rubber pl
This is a device that controls the field - Tube
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 Fig. 9-1
f the spark plug.
) Contact breaker Relationship between specilTic gravit
The contact breakel X G I L G I ~ L <aShigh voltage - - ..-I-SIIUI
electrolyte and state of battery 1s as I-

in the ignitioln coil. the next chart.

5) Spark pllug
The spark plug provlaes a spark to ignite the
con pressed nnixture of 'air and f~lel.
State of batter)
of electrc
- -
1,28C Fully (
9-2. BATTERY - -
1,25C L IUII L I I ~ I ~ ~

Specif
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
Use a hyclrometer for checking the q heck cell, cover, filler cap, a
vity of the electrolyte. Place the hydrometer and -), for damage, cracks and soils. wasn tne
tically into the electrolyte and carefully take battlery exteriors with water to remove sul-
fluid into the grass chamber. Remove from phuiric acid and clean off with dry cloth.
Pnn4
L u a I:ing
terv and shake sliehtlv
" to loosen float - the terminals (t and -) with grease ~1"'
nd make four readi ng. prev ent corro:

Y - L
i 2) Inspection of specific gravity and tempera-
ture, 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 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
I 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 elec-
trolyte 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.
3) Voltage measurement
Battery voltage should always be about 2V
I per cell in its static condition, a condition in
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 elec-
trolyte. 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
- remains over 1.5V and the mutual
voltage
differences between each of the cells are under
0.1 V, the battery is all right.

Voltage Recovery Curve Voltage Recovery Curve

After Charging After Discharging

2.5 2.2
2.4 2.1
2.3 ( V ) 2.0
(v) 2.2 1.9
2.1 1.8
2.0 1.7
0 5 10 15 20 0 5 10 15 2(
20 15 10 5 0 20 15 10 5
Time Time

Fig. 9-2
 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
' .
pi nion unit that engages with the ring gear to
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
1
1The magn~eticswit ch starts and stop1s the
star ter by o pening and closing tlle main ccIntac-
LUI,it pushes. U-..*U L LLIIC:
'A- L-
pinion thluusl~
--..-I- +L-
LIIC b l l l l L
Fig. 9-3 Starter
lever at starting, holds it in mesh with thie ring
.. ~. gear during starting, and disengages it after
starting. I

Manufacturer HITACHI L l'D.

-.
Part No. 4299 15400
JWS~M spring

Model S114-226

Nominal ,voltage
12V-0.7 KW
and o u t pIt~

4 p:hases, Se r:ies
Phase and
connection tj!Pe

Modu
Pinion
Numk h: 9

Couriterclockvvise
Fig. 9-4 COU~
Rotating direction (whe n viewed from
pinic)n side)

Brush length 16 rr 9 in) i

The pinio n unit is provided with an over-
. .
,,,ning clutch, the construction of which is '
Setting load of
brush spring
1.6 kg (3.5 lb
A

shown in Fig. 9-5. Rollers are provided be- i,

tween the pinion collar and the outer part of
Diameter of the clutch which is meshed with the helical
commutater 33 mm (1.2992 in) spline of the armature shaft.
The rollers are under constant pressure from I
Yoke outer dia. 80 mm (3.150 in) the springs, and the outer clutch grooTve, in
which each roller is placed, is tapered. ThuIS,the
Overall length pinion and outer clutch can race inI one
direction. In the opposite direction, rotat ion is
. -
kg (1 1.4 1b) delivered through the clutch engaged by the
I
roll1ers acting a s a key. I
 When the ring gear has came to turn faster
1 than the piston after starting, the pinion alone
/ races to set the armature free of engine rota-
!
tion, thereby protecting the armature and other
parts.
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.

Outer clt~tcll

\
Pinion collar
T9-005

Fig. 9-5 Construction of overruning clutch

a. Key switch is turned on.

Series coil
b. An electric current flows through the mag-
Stationary cont
netic 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
T9-006
battery directly into the motor to turn the
Fig. 9-6 Connection diagram 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
2) Operation the same time the connection between the
: The connection diagram is given in Fig. 9-6
and the operating sequence is as follows.
contactors is broken and the motor comes
into a stop.
3. Adjustment 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.

ion

Fig. 9-7 Checking clearance L

Slop ring

a. Advanced position of pinion Gear case

1-0.3-1.5mm -
The clearance L of the pinion from the T9-008
pinion stopper is normal if it is 0.3 to 1.5
mm (0.0118 t o 0.0591 in) when the pinion
Fig. 9-9 Installing adjusting plates
is pushed by the magnetic switch.

b. Adjusting gap of magnetic switch plunger

When the plunger gap is beyond the specifi-
1 ed limit [L= 0.3 mm to 1.5 mm (0.01 18 to
Switch
0.0591 in)], adjust it to the specified value
by installing adjusting plates (Fig. 9-9) be-
tween the magnetic switch and gear case.
Ba
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
L= 0.3- 1.5 mm adjustment of approximately 0.6 mm
(0.0118 - 0.0591 in) (0.0236 in) is possible by using 0.4 mm
T9-007
(0.0158 in) plate and that of approxi-
Fig. 9-8 Wiring for adjusting plunger gap mately 1.3 mm (0.0512 in) by 0.8 mm
(0.03 15 in) plate.

If the above clearance is out of the specified NOTE:

range, adjust the plunger gap of the magnetic Be sure t o install the adjusting plate with its
switch in accordance with Item (b) below. metal plate facing the gear case.

9-6 1
 4. Troubleshooting
I
I
1 a. Pinion will not move even when starter switch is turned on.

Faulty part Prob;able cause Cemedy

Broken wires or loose! connection at batt Repair or tighte:n

Wiring
and/or switch termin,als.
-
a. Electric current c ~ u c aI I U L IIUW uuc LU laulLy Repail cur1iar;r
con tact. point or replace
Starter switch -
b. Pinion does not move due to seized threaded Repair threaded
part meshing with pinion. part

Faulty operation of magnetic switch plunger, or Repair or replace

Magnetic switch
broken or short-circuited coil.
-

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

Faulty part Probable cause .emedy

Wiring connecting battery and magnetic switch Repair, tighten

Wiring is broken or grounded. Wires connecting or replace wires
magnetic switch and motor terminals are loose.
-
a. Faulty mesh of pinion with ring gear. Correc:t gear tee th

b. Improper installation. Re-ins

-
c. Worn brush or interfering blrush sprir Replac
Starter
d. Contaminated commutator. Clean

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.

Faulty part Probable cause Remedy

Improper clearance between pinion and pinion Adjust

Magnetic switch stopper due to failure in adjusting plunger gap.
(Incorrect gap L in Item 3, "Adjustment")

Starter Fatigued pinion sleeve spring. Replace

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

Faulty part Probable cause Remedy

Starter Faulty overrunning clutch. 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

Electric current cannot be cut off even when Repair or replace

Key switch
switch is turned off.

Contactor in constant contact due to Repair or replace

Magnetic switch
displacement.
 vice dati

tandard Ie:ngth 16 mm (0.629

Brush -
Wear limit

Brush spring Standard setting load - .5 kg (3.5 Ih)

Standard outer
33 mm (1.2992 in)
I diameter
alameter
Wear limit 2 mm (0.078;7 in)
~ - - .
Standard mm (0.0020 in)
Commutator ~nd -
L ~ r n(0.0156 in)

C nm
Standard

I .
Depth of
mica - (0.01'

0.2 mm (0.0079 in)

15 in)

0.03 - 0.08 mm
hranaara
Clearanc:e betweer (0.0012 - 0.003 1 in)
shaft anci journal
Limit 0.2 mm (0.0079 in)

Wear linlit of arm; t diameter 0.1 n 19 in)

Allowable detlection of armature shaft 0.08 mm (u.uu~-' '

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

Brush side
[ole diameter O in)

1 haft diam
- 0.032
mm (0.49:

L
eter - 0.050
Standare Pinion slic
diametei portion
[ole diame o.oso mm (0.492
12" + 0.030

Pinion sidp - haft diam eter

[ole diame
- 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
U'UUVU,
Jig.9-10 External uliew of alt nator
diding outstanding high speeld perforrrlance. assembly

Itor specifications

Batter y voltage
I Rotating field three phase type

12v

Nominal ourpui 17V-15A/4,000 rnm

I
ty on groi~ n dside Negative

Rotati,ng directi on (when observed

Clockwist
from I3ulley side:>

:ure conne

Full-wave rectification by six

Rectif ying syste
selfcontained silicon diodes

Usable: speed to 4,000

Revolution speed at 14V 20°C (68'F) I

I Revolution

Ou tpu.t current

I Current

Pulley outer diameter j9 in)

I
Pulley ratio
I
Total

Weigh 5 kg (7.9 I
9 - 10
 nstructicIn and fu

1 Nl 10 Retainc:r plate Brush holdc:r COMPL

2 SP 11 Spacer (Armature: Rear cover
3 Pu 12 R o t o r (SOMPL Rectifier en~dframe
4 Fa., 13 Ball be;....,or,"" Bushing
5 Spacer collar 14 Through bolt Rectifier en~dholder Cc
6 Drive end f r ame
~ COMPL IS Stator COMPL Washer (Insulation)
7 Oil felt 16 Rectifier end-frame COMPL Washer (Insulation)
r?ver I (Oil f;- I . \ L7 Bushing (Insulatio -, Brush sprinl
111bearing :(Insulatio Brush

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

-
 The generator assembly consists of a rotor When a cc placed in a magnetic field
assembly, stator assembly, front cover (alterna- lts the magnetic tield, an electric current
tor), and rear cover assembly. The rear cover vs through the conductor. This princi:ple of
assembly is self-ventilated and equipped with
silicon diodes to rectify the alternating current
generated in the stator coil.
_ eration is the same as tllat of a D.C.
W C ; V..
erator. The alternator, ~ O...*..-.. ~ ~s eL s,a
rotating field (the magnetic poles rotate) and an
alternating current is produced in the stator
a. Magnetized part . . . Rotor
" coil. This alternating current is rectified by the
-
Unit generating alternating- L U I I G I I L . . . J L ~ -
silic:on diode and led outside.
tor
I7ig. 9-12 shows the principle of the alterna-
Unit rec tifying a1lternating current . . . Sili-
1. 3 tor. The conductors C, C' wound around the
con aioaes
stat or are stationary. When the magnetic N
d. Rotating part . . . Rotor
and S poles (Rotor) rotate in the direction of
e. Part transferring rotation . . . Pulley
arrc)w, an electric current flows through con-
f. Part allowing field currentt f l ~ ~ .x .r . Brush
,,,L 3~
auctors in the direction of arrow and runs into
~

and slip I
the battery tl?rough thc:diode "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

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
,
i
electric current tries to flow in the reverse i
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 1

full wave rectification, so that a direct current
woxre form illustrated by the bold line in Fig.
1
I
3 is obtained. 1

Silicon diode
silicon (liode allows an electric current to
11
I
flovv in one clirection but stops it from flowing
. .
...
in tne
, opposite direction. This is known as a
Fig. 9-1 1 tor operai'ing princi rect.ifying cha~racteristic.

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
1 silicon diode, a positive type semi-conductor
I with positive holes carrying a positive charge
(plus electricity) and a negative type semi-con-
ductor 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)
-I
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
I 5) When charging the battery from outside,
and N type semi-conductor, making it easy for
electric current to fl~
DW.
When the P side: is chargt:d negati~ rely and
the N side positively, as -- nl
1.. :-
(b).
, ,, the positive
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
the PN junction anu preventing me I low of
electric current.
Precuations in handling
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.
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 Corrective Action

a I) Defective contact or broken Repair or replace lamp
-5 Lamp
filament in lamp
23
'g 0 - Wiring and 1) Broken wire, short circuit, or Inspect, and repair or
fuse defective contact replace
g, 8
sv-
s
v Regulato I) Defective voltage relay Repair or replace

' 1) Loosened belt Adjust

I) Broken, grounded, or Replace

short-Icircuited stator coil wire
-
!) Broke n wire in rotor coil
L Replace
-
3) Defec tive bru!sh and slip ring Replace or clean
*; Alternator con tac:t
0
%
+ 4) Defective terminal insulai Repair
0
c -
V)

8 5) Defective silicon diode Replace

a
a
-5
M
-
6) Short-circuited condenser Replace

.-d I) Defective charge relay point Adjust or replace

S
Q)
s !) Broken wire or defective contact Inspect, and repair or
F
m nagulaLo1 r. r P F and N terminal
replace

I -
C
0
1) Impro per core gap of voltage Adjust
.-o---tor
re0111n
- -
I) Broken wire or defective connec- Inspect
tion between key switch iand IG
Wiring and terminal
fuse
2) Blown fuse or defective contact Replace
 Trouble and Possible Causes Corrective Action

V-blet 1) Loosened belt Adjust

1) Layer short in rotor coi- Replace

2) Layer short or broken vvire in Replace

statc- --:'
-
Alternator 3) Defe:ctive brus;h and s l iI ~ring Replace or clea
. ..
(contact)
-
4) Defe:ctive silicon diode Replace
-
5) Defective condenser Replace
-
2
0)
c)
.c)
1) No-load voltage is lower rrlarl ~ n a t Adjust
m of the rated value
s
L
0
-
.-2 Regulator
-
2) Defective voltage regulator points Adjust or repla
EJ
2
vl
ma1 short circuit of coil
or resistor
Replace
S
k
0)

6 1) Insufficient electrolyte Replenish with distilled

water
Battery
2) Defective pole plate Replace

1) Broken wire or defective connec- Inspect and repair

tion between key switch and IG
terminal
-,
Wiring and
2) Broken wire or defective connec- Inspect and repair
fuse
tion between regulator F terminal
and alternator F termianl

3) Blown fuse or defective contact Replace

eo
c
1) unusual no-load voltam
3 2) Defective regulator ground wire
-s
LC
Regulator 3) Broken coil lead wire Repair or replace
0

2
+
c
.'
4) Defective voltage regulator points Adjust or replace
2
5) Charge is not Adjust
 wble and Possible ( Action

1) Place from whf:re the insulated r or replac

cover has wirin g sometinies short
Wiring -.- -...
,: A -
CI~CUI
:.-
- - - L a :-"..I - & : - -
-A

cover

I) lnitlal symptom 01 layer shnrt Replac

2) Detel r broken t Replac

sprin~
or
3) Dirty slip ring Clean

4) Initial symptom of coil wire Repair or replac

broken

1) Improper regulating voltage Readjust

-
2) Defective key switch Redplace

3) Dirty points I Clean

9-5. VOLTAGE REGULATOR The regulator is a 2-pole Tirril type which

[for alternator) 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: relay cut-

voltage

Fig. 9-15 Exte ma1 view

 Operating principle of voltage
regulator
When the voltage of the generator is at the
specified level, the charging resistor connected
in series to the rotor coil (inside the gen-
erator) 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
Fig. 9-1 6 Voltage regulator the armature against the force of the spring. As
a result, because the moving point parts from
I
the lower point and the exciting current passes
through the charging resistor, the current flow-
ing in the rotor coil decreases and hence the
generator voltage drops.
When the voltage of the generator drops
2. Construct~onana operation below the specified value, the current passing
through the voltage coil decreases and the
1) Voltage reguk~ t o r magnet lowers in attraction, so that the moving
The Tirril type: voltage regulator regulates and lower points are losed to short-circuit the
the electric current of the rotor coil and charging resistor, enabling more current to flow
maintains the voltage produced by the genera- in the rotor coil and increasing the voltage of
tor constant. It uses a charging resistor con- the generator.
nected in series to the rotor coil which is When the generator runs at low speeds and
short-circuited and charged by opening and under heavy loads, the voltage regulator repeats
closing the point. Its construction is shown in the above operation to keep the voltage con-
Fig. 9-17 stant.
Should the rotational frequency of the
generator increase, the voltage of the generator
rises since the resistance of the charging resistor
Arn~afure gap
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
Angle ga ~rmature.Thus, the rotor coil is short-circuited
I
o stop the exciting current from flowing,
Iropping the voltage.
Poi111(H d When the voltage drops, the attraction of the
roltage coil becomes small and the point is
side) Poinl g i
)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.
 Charg

. .
f
Moving
I 7
Fuse

Key switch

! Rattnrv

Charge re1
--
'oltage regulator

Fig. 9-18 Connection diagram of k e r r c r u r v r urru - GI",

peration c~fcharge r elay

. e relay
2:) -. Charg
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-
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, ter-
minal 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 bat-
ry.
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 (Breaker)
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
b,"LE
p ~ o n t a c breaker
t -
conclude immediatl the generator or
regulator is out of a ck the wirings and kGovernor o
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
Fig. 9-21 Components of brea~erassemblv
generator and regulator may be regarded as
normal. (To measure the no-load voltage, dis-
connect the regulator terminals, run the genera-
tor at the specified speed. and check the voltage
"
between terminal tor and 1) The breaker assembly employs a simulta-
ground.) neous ignition system which is compact and
The regularor must pe aajusrea 11 irs no-loaa lightweight as compared to a conventional
voltage is out of the specified range. Adjust- stributor.
ment of the regulator requires knowledge and 1 The combined use of a gc Jvancer
experience, and it is recommended that the job td vacuum advancer insures ( ignition
be given to an expe,rt or to a service station of ning fron1 low spee:d to high speed, in(:reasine
the manufacturer. IJnder nor ma1 working con- t reducing Iharmful e:~ h a u s gas
~ t p u and t
dition, the regulator should pr ovide trouble-free
operation for about 50,000 to 60,000 km
(31,000 to 37,000 miles) without adjustment.

, Spec
-
ONTACT POINT
-.- .L .#,-- Ignition system aimulraneouns ~ ~ ~ I L I U I I

!
-
Point gal? + 0.05 mm
tv.vt8, - 0.002" ;n\
--
Lifter pr

Firing antgle
-
Cam closing 102' + 3" [at Point gap
angle 0.35 mr

Capacity of
condenser
Fig. 9-20 'External view of breaker assembly

I
2. Advancing characteristics of governor and vacuum

17.5°/5,500
20 -
12°/200

- 14 -
12 -------------------------
\ 1
m

--X:
0 10-
-u-
0)
al m
F 8- 5 10-
a
l
C
-
" U s -

J
1a 4- B
2 - I
I I
I I
, I ,

50 100 150 200 1.000 2,000 3,000 4,000 5,000 6,000

(I -97) (3.94) (5.91 (7.87)
Vacuum rnrnHg (inHg) Engine speed (rprn)
T9-01 6
-
Fig. 9-22.Advancing characteristics -

3. Removal 4. Disassembly
1) Disconnect the primary cord 1) Loosen nut on the terminal and remove
2) Pull the breaker vacuum hose out from the cords for contact breaker unit and condenser.
vacuum advancer side. 2) Remove the contact breaker unit by
3) Loosen two bolts (6 x 13) and remove the loosening the screws.
cover (Breaker case) and the gasket (Breaker 3) Remove the clip and screw (pan head),
case). and detach the vacuum advancer unit.
4) Loosen the bolt holding the governor
5 x 8 screw : 1
assembly.
4) Loosen the screw (pan head) and remove
6x13 Bolt lpc. the contact breaker unit.

5) Remove the case (Breaker) ,I

6 x 22 Bolt NOTE:
Also remove spark advancer unit. I
6 x 60 Bolt
5) Remove a screw (pan head), and remove ;
NOTE: the condenser unit. 1
Remove the O-ring carefully so as not to 6) Remove the oil seal (22 x 35 x 6).
damage it. 7) 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 re-
moved. Clean it I~eforeins1tallation.
. 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 re-
moved. Be sure to adjust ignition timing and
~ o i ngap
t after installation.
OTE:
For adjusting proceaure, refer to the
"Chapter 3".

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 func- 9-7. 1c COIL
tion and the diaphragm for damage. Replace if .--;NITION
Vith resister)
necessary.

NOTE:
'
Place mouth over the hose connection and
suck to see if the vacuum advancer is
operating properly by the movement of the
I contact breaker.

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.
wear, damare or
--a ?I-'
Replace if neces-
I sary.
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
1
t the 0-rir~gin the c:ase (Breal

NOTE:
After i n check the 0-ring is not
twisted Fig. 9-24 Resistor (
 Speciification!5 of ignition coil (with re!sister)

Battery voltage

Sparkil~g perforn
ante (I~ n g t h
of
spark measurea at
negative side when
positive side gap
between 3 needler
I
oil
remnerature

remperature

80°C
(1760~)
Spark ga:
between

(0.2756 in)

( ~ 2 3i
6n)~
P
3 needle S

81

12\
7Resister

Short-
. ..

80QC
I No-load 15\ )O rpm with 1.5
(176OF)

:d resister 1.5 + 0.15R

. .
Standard resistar
valve for ;econdary coil I

2. Connection diagram of ignition coil

i \
/
.--.
Key switcli

I
High t e

ST /

Battery 2
c s--.
If t

Con tact Brakc ser

Fig. 9-25 Connectic o n coil

9 - 22
 3. Consrrucr~c perat ion chargea m ltenn (d) abc)ve is completely
...
of ignition discharged (capacltlve spark) and then the
discharge of the energy stored in the coil in
1) Ignitioncoil the form of magnetic flux (induced spark)
follows.
1 coil F. The magnetic flux drops close to zero where
it cannot maintain the voltages required for
1 sparking, and hence the discharge spark
'

1
c
Primary disappears.
g. The slight residual energy in the coil pro-
Co~itact A ker
duces damped oscillation in the secondary
Point
and primary coils and dies out as a resistance
can1 G Batter
- loss of the circuit.
'T h. Then, after an open-circuit period deter-
mined by the open-circuit angle of the cam,
the ignition coil repeats the entire process.
i 2) A large current flows t o the starter when
Fig. 9-26 Lonnectron diugram 03 ignition coil starting up the engine. This drops the voltage at
the ignition coil terminals and causes starting
1 The ignition cc)il consist s of an iron core, a failure due to the dropped discharge voltage
1 primary coil of 30u turns , ,r\
of a 0.32 mm enamel and a weak spark. For this reason, a drop in the
1 wire, and a secondary coil with approximately discharge voltage is supplemented by reducing
the internal resistance of the ignition coil and,
j 22,000 winds of a 0.06 mm enamel wire with
thin, superior insulation paper provided be- to prevent the coil from burning at times other
/ tween each layer. than whe 5 the en!
1 When the camshaft and crankshaft arc
installed.

I 1
rotated with the ignition coil connected a1
shown irI Fig. 9 -2 16 ,"a high voltage is produced
i
1 in the secondary coil thrc)ugh the following
process.
-I a. When the contact breaker points are short-
4. ot
E1.r~ lgnltlon sys
j
) circuited, the primary current flows as indi- :arting
I cated by an arrow and produces magnetic
i flux (flux of 1i1nes of ma gnetic for,ce) in the
I

:
iron core.
b. Next, when the points are open1ed by the
cam, the magnetic

zero.
.. IIUX
n
proauced by the
primary current rapidly starts tc drop to
541
Starter switch
I
Starter
c. The great change in the magnetic flux and
the 1;irge number of urinds cause a high
nition coi
voltage in secon.dary coil.
-,.
",...,...,. charges the se-
d. The fugh voltaarj 5r;llr;lated I
conda ry coil first, which starts charging thc
high 1tension cords and plug as its voltage
I Contact bieak
increa ses and gradually continues to built
UP. tension c
e. When the volta] .lue where
:
it can jump *I.. :--l..~.-:...
Lne plug gap, 11.sLarLs ulscnarging
and a.t the same time thle discharge voltage
1
Plug
sudde nly drop: le electri.c current
2) At times other than when starting 6. Inspection

aIgnition switch ON
Check for the following items using a precise
tester, and replace coil if necessary.
1) Conductivity of primary coil

0Resistor
Standard resistance of
primary coil:
1.98 t o 2.42S-2

-Q Ignition coil

L
act breake
2) Conductivity of secondary coil:
Standard resistance of
secondary coil:
13.6 t o 18.4 kCl

NOTE:
I High I An extremely low resistance is an indication
of a short-circuit.

.-
7. Installation
To install the ignition coil, follow the reverse
5. Removal o f ignition coil order of removal.
1) Remove the high tension cord cap.
2) Remove two 5 mm nuts on the ignition
coil and disconnect the primary coil terminals. NOTE:
3) Remove 6 mm flange nut at the bracket Connect the breaker condenser to the nega-
and remove the ignition coil. tive (-) side of the primary terminals.
 CHAPTER 10: CLUTCH

Page

'0.1 . DESCRIPTION ................................................................................10-2

'0.2 . CLUTCH DISASSEMBLY AND REASSEMBLY .......................... 10-3
'0.3 . TROUBLESHOOTING ................................................................. 10-7
10-1. DESCRIPTION The clutch control mechanism is a mecha-
nical type of simple construction as shown
1. Construction in figure. The clutch cover is an overcover type
strap drive system. The spring is a diaphragm
type which has an excellent characteristics such
1 Clutch disc as less change of installed spring setting load
2 Clutch cover
3 Clutch release bearing against the wear of the clutch disc and can be
4 Clutch release fork operated with light pedal pressure. Woven
5 Clutch cable asbestos is used for the facing material of the
6 Clutch pedal clutch disc. The clutch disc is provided with
torsion springs (coil springs) t o absorb rota-
tional shock at clutch engagement.

T10-001

Fig. 10-1 Clutch system

2. Specifications

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)

Cover
Setting load of diaphragm spring 120 5 10 kg (264.55 5 22 lb)

Fitted height
24.1 + 0.8 mm (0.9488 + 0.03 15 in)
installing surface of flywheel)

Facing material Woven asbestos

Number of facing 2

Dimensions (Out. dia. x Inn. dia. 160x l l O x 3 m m

x Thickness) (6.2992 x 4.3307 x 0.1 181 in)
Disc
Compressed thickness 7.1 + 0.2 mm (0.2795 + 0.0079 in)
Free thickness 7.9 + 0.2 mm (0.3 110 + 0.0079 in)

Number of torsion spring 6

Number of spline hub teeth 23

10-2. CLUTCH DISASSEMBLY AND
REASSEMBLY

T10-002

I
I 1 Clutch disc Release bearing holder spring
2 Clutch cover Clutch release fork
3 Bolt(6x18x18) 8 Straight pin (5 x 22)
4 Clutch release bearing 9 "0" ring (10.8 x 1.9)
5 Release bearing holder 10 Clutch release lever
I
1

Fig. 10-2 Exploded view of clutch

1. Clutch lever 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.

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. Fig. 10-4 Driving in straight pin
d. Using a special tool "Remover I1 (straight
pin)", drive out straight pin (5 x 22) @ b. Apply grease (equivalent to Unilube No. 2)
until the clutch ielease lever compl. @ can t o groove of the clutch release bearing
be pulled out. 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.
39879 1600 Join the pawl of release fork and release
Special tool
(Remover 11) bearing holder with the release bearing
holder springs.
,
Remove the clutch release fork 8and lever
compl. @ .
Inspection
If the bearing is damaged, seized, or un-
smooth in rotation, replace the clutch re-
lease 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 exces-
sive. (Also check condition of the transmis-
sion 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.
499745400
Special tool
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.
NOTE:
Be careful not to let the disc facing get
soaked with grease or oil.
.&."
Guide (
Fig. 10-6 Removing clutch
2) 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.
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.
Clutch
I
Fig. 10-7 Inspecting clutch
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 fly-
wheel.
 Tighten it with six bolts (6x1 8x18 mm).
499745400
Special tool
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 3. Oil-soaked clutch facing. Replace.
I
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 Adjust.
tips.

!
4. Rusted splines of clutch disc and Remove rust and grease, or replace.
main shaft.
5. Excessive runout df clutch disc. Repair or replace.
6. Defective part(s) in control, or im- Repair or replace.
proper 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 re-

place.
2. Oil-soaked facing. Replace.
3. Broken or fatigued torsion springs. Replace disc compl.
4. Improper contact of facing, or exces- Replace disc compl.
sive runout of disc.
5. Distorted pressure plate or flywheel. Repair or replace.
6. Loose disc rivets. Replace.
7. Loose engine mounting or fatigued Tighten, or replace mounting rubber.
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 Replace.

insufficient lubrication.
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. Worn facing or loose rivets. Replace.
3. Worn or rusted splines of clutch disc Replace, or remove rust and grease.
hub and main shaft.
4. Fatigued or broken torsion springs. Replace.
5. Distorted or partially worn flywheel Repair or replace.
and pressure plate.
CHAPTER 1 1 : T R A N S M I SSl ON A N D Dl FFERENTIAL

Page

GENERAL DESCRIPTION ........................................................... 11 2 --

SPECIFICATIONS .......................................................................... 11 - 2
COMPONENT PARTS OF TRANSMISSION ............................... 11 - 3
DISASSEMBLY ..............................................................................11 - 6
INSPECTION .................................................................................. 11 -1 1
ASSEMBLY .....................................................................................11 -13
INSTALLATION ............................................................................ 11 -21
TROUBLESHOOTING ..................................................................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 T23B I
1st 4.363 (4811 1)
2n d 2.62 5 (42116)
Gear ratio 3 rd 1.809 (3812 1)
I
4th 1 . l o 7 (31128)
Reverse 4.272 (4711 1)
Final reduction gear ratio 5.733 (86115)
Differential Number of side gear teeth 18
gear Number of pinion gear teeth 13
-
Oil quantity 0.9 L (0.95 U.S. qt., 0.80 Imp. qt.)
I
11-3. COMPONENT PARTS OF TRANSMlSSlON

1. Component parts of transmission case

2 Bolt and washer assy 18 O-ring (14.3 x 2.4)

3 Transmission cover 19 Transmission case
4 Gasket 20 Oil seal ( I 5 x 25 x 5)
5 Air breather pipe 21 Stud (10 x 38 x 15)
6 Plug (8 x 10.5) 22 Washer
7 Shifter fork rail spring 23 Bolt (8 x 45 x 20)
8 Ball (6.350) 24 Bolt (8 x 95 x 20)
9 Air breather nipple 26 Bolt and washer
10 Accent plunger spring 27 Bolt (8 x 65 x 20)
11 Selector plunger 28 Stud (8 x 36 x 12)
12 Shifter arm shaft 29 Gasket (20.5 x 26 x 1.5)
13 Shifter arm 30 Oil drain plug complete
14 Spring pin 31 Transmission case cap 3
15 Selector arm *32 Washer (39 x 49.5 x t)
16 Gear selector arm shaft 33 Transmission case cap
17 Oil level gauge 34 Plug (13 x 5)
*35 Washer (39 x 53.2 x t)
36 Straight pin (4 x 22)

*39 Reverse shifter lever

40 Shifter arm 2
*41 Shifter fork
42 Shifter fork rail

43 Shifter fork rail 2

44 Shifter fork rail 3
45 Ball (5.5563)
46 Shifter rail plunger
47 Bolt and washer assy
48 Shifter rail plate
49 Shifter rail plate
38

51 Gasket

53 Back-up light switch

54 Clutch cable clamp
55 Aluminum gasket
56 Plug (14 x 9)
57 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

*1 Snap ring outer (20) 16 Thud driven gear

2 Ball bearing (#6204NR) 17 Synchronizer sleeve
3 Washer (20.2 x 29 x 0.2) 18 4thdrivengear
4 Ball bearing (#6204) 19 Needle bearing (34 x 50 x 20)
5 Drive pinion spacer 20 Race (needle bearing)
6 First driven gear 21 Drive pinion
7 Synchronizer ring 22 Ball bearing (#6303C3)
8 Reverse driven gear 23 Washer (17.2 x 26 x 0.2)
9 Synchronizer hub spring 24 Transmission main shaft
10 Synchronizer hub insert 25 Ball bearing (#6004)
11 Synchronizer hub 26 Washer (31 x 40.8 x 0.5)
12 Gear thrust spacer key 27 Oil seal (19.8 x 35 x 7)
13 Gear thrust spacer 28 Reverse idler gear shaft
14 Second driven gear 29 Straight pin (6 x 15)
15 Gear thrust spacer I1 30 Reverse idler gear
* Selective part
Tll-002

Fig. 11-4 Exploded view of transmission

11 -4
 Differential gear component parts

I
1 Oil seal (27 x 45 x 9) *8 Washer (53 x 65.5 x t)
2 Oil seal retainer 9 Differential case
3 Ball bearing (#6007) 10 Differential pinion shaft
*4 Washer (27.1 x 42 x t) 11 Straight pin (4 x 35)
5 Differential side gear 12 Final gear
6 Differential pinion 13 Final gear lock washer
7 Oil seal (27 x 62 x 9) 14 Bolt (10 x 21 x 13)
* Selective parts
Tl l -003

Fig. 11-5 Exploded view of differential

11 - 5
11-4. DISASSEMBLY
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.
1) 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 transrnir- '
sion case upside down, unscrew twenty fixin:
bolts and disassemble the case into two set-
tions. The twenty fixing bolts to be loosene?
are 8 mm 18 pcs. and 6 mm 2 pcs.

8 mm Bolt: I
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. Re-

move the rear mounting bracket on the trans-
mission side, loosen four bolts (10 mm) se-
curing the transmission to the engine, and
remove the transmission. Take care not to
support or hold the clutch release shaft during
removal and installation. Fig. 11-7 Disassembling transmission case

2. Disassembly NOTE:
When removing the lower case, be careful
Wipe the transmission clean of grease and not to lose the straight pin @ on the reverse
dirt, loosen drain plug (20 x 10) and drain oil. idler shaft @.
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)
3) Main shaft, drive pinion and differential
assemblies

Fig.11-10 Components of main shaft

assembly

b. Remove the ball bearing @ (#6004) and

Tig. I 1-8 Disassembling transmission two ball bearings @ (86303C3) with a
washer (17.2 x 26 x 0.2) @ using a puller
or press.
Remove the washer and caps, and take out
5) Drive pinion assembly
the main shaft assembly, drive pinion assembly,
a. Remove the snap ring with a special tool
and differential assembly from the transmission
"Expander" and remove ball bearing (#6204
case.
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
Special tool
8994741 00

Snap ring
\
Differential ass'y

Fig. I 1-9 Disassembling transmission

1) Main shaft assembly.

z. Remove oil seal @ (19.8 x 35 x 7) and Fig. 11-1 I Removing snap ring
washer @ (31 x 40.8 x 0.5). (Fig. 11-10)
b. Remove the 1st driven gear, synchronizer
VOTE:
ring, and hub assembly (1 st & 2nd speeds).
Before removing oil seal, cover the spline of
Then remove the key (gear thrust spacer).
the shaft with tape t o prevent damage t o the
lip.

Fig. 11-12 Removing key (gear thrust spacer)
c. Remove the gear thrust spacer 0, synchro-
nizer 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).
6) Hub assembly (1 st & 2nd speeds)
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 0.
7) Hub assembly (3rd & 4th speeds)
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
Drive the straight pin (4 x 35) @ out from
the differential case @ side and then dif-
a. Wind vinyl tape on the spline of side gear ferential pinion shaft @) . Remove the dif-
shaft to prevent damage to oil seal lips. ferential pinion @, differential side gear @ ,
Remove the oil seal (27 x 62 x 9) from the and washer (27.1 x 42 x t).
differential case side first. Then remove the
oil seal (27 x 45 x 9) and retainer from the . .- .- . ~ ~.~ . .

final gear side. 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.

e. Remove the ball bearing (#6007) from the

Fig. 11-17 Driving out straight pin final gear and differential case with a puller
or press.
Remove the differential side gear and washer
(27.1 x 42 x t) from the final gear side.
9) Gear shift mechanism of transmission - -.
cover compl.
Transmission cover
i

Fig. 11-21 Removing plug and selector

plunger

Fig. 11-20 Gear shift mechanism 11)

a. Loosen two 6 mm bolts (L = 12 mm).
Remove the shifter rail spring plate @ ,
three shifter fork rail springs 0,and three
Loosen four 6-mm bolts (L = 25) and
remove the transmission cover compl. Take lock balls (6.350 mm dia.) @ .
Then remove shifter rail plate @ by loosen-
out spring pin (6 x 28) @ using a special tool
"Straight pin remover II", separate the gear ing two 6 mm bolts (L = 12 mm).
selector arm shaft compl. @ from the selector
arm 0, and remove the shifter arm @ and
shifter arm shaft @.

10) Reverse accent mechanism of transmis-

sion cover (Fig. 11-21)
a. Loosen the plug (8 x 10.5) @ and take out
the shifter fork rail spring @ and ball /
2
(6.350) @.
b. Remove the selector plunger @, accent
plunger spring @ and accent plunger spring Fig. 11-22 Removing shifter rail
11 @. spring plate
b. Using special tool "Shifter fork pin extrac-
tor", 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

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 trans-
mission case.
c. Four interlock balls (5.55 mm dia.) are
provided in the interlock holes in the trans-
mission 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.
1 Rail I11 (Shifter fork)
2 Rail I1 (Shifter fork)
3 Plunger (Shifter rail)
4 Interlock ball (5.55)
5 Spring (Shifter fork rail)
6 Lock ball (6.350)
7 Rail (Shifter fork) Tl l-007
Fig,11-24 Component parts of shifter
rail and lock balls
12)
.- --
Reverse idler gear
- - rrrrrm
Fig. 11-25 Removing 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.
NOTE:
Oil seal must never be washed in gasoline as
it causes their lips t o swell.
1. 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
 3. Gear shift mechanism
I Gear I Standard value I
I) Check the clearance between the shifter
0.050 - 0.350 nim fork and the groove of the synchronizer hu'c
sleeve.

0.1 10 - 0.430 mm
2nd & 3rd 0.2 - 0.4 mln
(0.0043 - 0.01 6 9 in) Standard clearance
(0.0079 - 0.0157 in)
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)
Cone 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
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 3) Replace the shifter fork rail if the edge i
or excessively worn. lock ball groove is worn.
2) Measure the clearance "C" between the
ends facing each other with the ring pressed 4. Bearing
onto the cone of the gear.
Replace the bearing if seized, worn, noisy. r -
unsmooth rotation.
Standard value 1.3 - 1.7 mm
of "C"
5. Oil seals and caps
(0.05 12 - 0.0669 in)
1) Oil seals
Limit value of Replace any oil seal whose lips are ds-
0.5 mm (0.0197 mm)
"C" formed, hardened, or worn. Also replace if i:r
- periphery is damaged.
2) Caps
3) Replace the ring if its contact surface with Replace any cap whose periphery is d a r -
the synchronizer hub insert is excessively worn. aged.
6. Other parts keep the clearance of outer race of the two
ball bearings.
Replace any part if it is deformed, exces-
sively worn, or defective.
2) Apply grease [equivalent to Uniiube No.
21 between the lips of the oil seal (19.8 x 35 x
7. Differential
7), wind tape around the main shaft spline and
1) Replace the final gear and drive pinion if carefully install the oil seal on the shaft.
the tooth surfaces are damaged or excessively
worn.
2 ) Replace the drive pinion if the contact
surface with the needle bearing inner race or i.
the gear sliding spline is excessively worn. l tape
V~ny
3) Replace the differential pinion, side gear, w'
washer (27.1 x 42 x t), and pinion shaft if they
are seized, worn, or damaged.
Main shaft
4) Replace the differential case if cracked or
defective in any other respect. Oil seal

11-6. 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 de- 2. Drive pinion assembly
scribed below. Be sure to apply gear oil t o each
part before assembling. NOTE:
The needle bearing has installing direction,
1. Main shaft assembly 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 PA2
Ball bearing (#6303C3) 1

' Inner race h e e d l e bearing

Tll-011

Fig. 11-30 Installing direction of

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
needle bearing
1) 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 synchro-
nizer hub.

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. 11-32 Installing gear thrust spacer
4) Hub assembly (1 st & 2nd speeds)
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 ~ )
#6204. NR
Washer ( t = 3) (with stopper)
\ 1 st gear T O E L1>L2
#6204 1 Washer (20.2 x 29 x 0.2)
Tll-015
Fig. 1 1-34 Rear bearings o n drive pinion
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.
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 Adjusting washer
2 Pinion (Differential)
Fig. 11-35 Measuring clearance 3 Adjusting washer
1 4 Gear (Differential side) (
T~I-016

I YOTE: Fig. 11-36 Adjusting washer

Always replace the snap ring once it has
I been removed.

NOTE:
Guide (snap ring) Selective adjusting washers must be as-
pecial tool: 8997541 21 sembled with the chamfered face of the
ress assembly washer toward the gear.
99754100 Press (snap ring)
899754102

Adjusting washer
ip rings
Part No. Thickness
Part No. TI1ickness
803 12708 1
2.51 k0.015 mm
805020022
+
(0.0988 0.0006 in) 803 127082 1.050 mm (0.0413 in)

2.57 T0.015 mm 803 127083 1.lo0 mm (0.0433 in)

805020024 +
(0.10 12 0.0006 in)

2.63 20.015 mm
805020026
+
(0.1035 0.0006 in)

2.69 20.015 nim

805020028 (0.1059 T 0.0006 in)
3) Tighten bolts (10 x 21 x 13) to the
specified torque and bend the lock washers
(final gear).
Fig. 11-37 Bending lock washer
Tightening torque 6.3 + 0.5 kg-m
(1 0 mm Bolt) (45.6 + 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.
.,
Fig. 11-38 Installing oil seal
5) Reverse idler gear
Fig. 11-39 Installing reverse idler gear
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. Gear shift mechanism
1) Transmission cover
I 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
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 Identification
becomes flush with the cover surface. Make Part No. mark on lever Remarks
sure that the selector plunger pushed operates
smoothly. Approach to
1) Shifter forks and shifter fork rails 342772 101 A the 1st gear
The shifter forks and rails should be installed side
in the following manner, beginning with the
reverse side. 342772 102 B Standard

Approach to
342772 103 C the 2nd gear
side

NOTE:
After having determined the lever, use wash-
ers of correct thickness to provide 0.5 to 1.0
m m (0.0197 to 0.0394 in) clearance be-
tween 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 everse shifter lever

rail 111 @ facing down, put the rail through

the case. Install the reverse shifter lever @
in the reverse shifter lever shaft press-
fitted 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 Fig. 11-42 Adjusting the lever position
mm dia.) with the shifter fork rail spring,
and shift the reverse shifter lever to the
reverse side. Adjusting washer
Place the drive pinion assembly and main
shaft assembly in the normal position (as far
)ver on the clutch side as possible), and Part No. Thickness
.pply red lead to the tooth surface of reverse
lriven gear. Put case I over them with the tip 8030 15082 1.1 mm (0.0433 in)
of reverse shifter lever placed in the groove
of the reverse idler gear compl. to check the 803015086 0.8 mm (0.03 15 in)
mesh of the gears, and select the reverse
shifter lever that provides tooth contact of 8030 15087 0.4 mm (0.0157 in)
80% or more.
 Then remove case I and set the reverse
shifter lever to the neutral position.
c. 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 assem-
bly.
d. 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)
e. Operation similar to Step (b.)
f. Install the rail in the case in the same Fig. 11-45 Selecting shifter fork I1
manner as step(a.), assemble the fork with it
and drive in the straight pin (4 x 22). 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

Identification
Part No. mark on Remarks
the fork
-

Approach to
342012101 A the 2nd gear
side
Fig. 11-43 Installing shifter fork
342012102 B Standard
Approach to
342012103 C the 1st gear
g. Selecting shifter fork and shifter fork I1 side
Shifter fork I1

Identification
Part No. mark on Remarks
the fork I1

Approch to
3420221 11 A the 3rd gear
side

342022 112 B Standard

Approach to
342022 113 C the 4th gear
Fig. 11-44 Selecting shifter fork side

11 - 18
 Tighten the shifter rail spring plate and
shifter rail plate with two 6-mm bolts (L = Washer Washer (39X 53.2X t)
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 + 0.54 ft-lb)

f
Ball bkaring
( # 6303C3) bearing I
i. Tighten the back-up light switch t o the
specified torque. Be sure to use the alurnin-
um gasket. Fig. 11-47 Measuring cbarnace

1.8 + 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
Part No. Thickness (mm)
assembly, and differential assembly in the
standard position (where the main shaft and to
drive pinion assemblies are all the way over 80303901 1 2.2
-0.03
on the clutch side and the differential
assembly is on the side opposite t o the t0
8030390 12
clutch). Select and install a washer that 2'35 -0.03
provides a clearance of 0.01 to 0.2 mm
between the washer and each end face of the 8030390 13
to
main shaft #6303C3 ball bearing, drive pin- 2'5 -0.03
ion #6204NR ball bearing, and differential to
#6007 ball bearing. (Refer t o Figs. 11-47 8030390 14
-0.03
and 1 1-48.)
Washer (39 x 53.2 x t) for drive pinion. 4) Joining transmission case
a. Thoroughly remove oil and dirt from the
Part No. Thickness (mm) mating surfaces of case I and case 11 ane
apply liquid packing to case 11. Then place
80303903 1
to case I on case 11. Before doing so, move the
-0.03 reverse idler gear compl. to the clutch side
and assemble the tip of reyerse shifter lever
803039032
to with the groove on the reverse idler gear
2'20 -0.03 compl.
+o
803039033
2'35 -0.03

803039034
to
2'50 -0.03

Washer (53 x 65.5 x t) for differential

/!
11
-
Part No. Thickness (mm)

+o
? Q
80305301 1
2'3 -0.03
-3qj/.&+ Q 3
7
8030530 12
+o a,
8
-
2'5 -0.03

+o
8030530 13
2'7 -0.03

After having selected the washer for the Bolt I

differential, place the oil seal (27 x 62 x 9)
in contact with the washer using an installer.
- 8 x 45 rnm 13 pcs.
A 8 x 65 mm 3 pcs
b. Attach the caps (transmission case) to the 0 8 x 95 rnm 2 pcs.
washers on the main shaft assembly and the 6 x 32 rnrn 2 pcs.
side of drive pinion assembly. Install cap I11 - Tll-021
(transmission case) with its positioning
notch aligned to the case side positioning
groove on the front side of drive pinion Fig. 11-50 Sequence of tightening case
assembly.

b. Tighten two 6-mm bolts and eighteen 8-mm

bolts in the numerical order given in Figure
11-50.

Tightening torque

1 5 0.075 kg-m
6 mm Bolt
(7.23 2 0.54 ft-lb)
~smissioncase)
F 7

2.5 + 0.2 kg-m

'-4-a
\B@kI

Caps 8 mm Bolt
(18.08 + 1.4 ft-lb)
Fig. I 1-49 Instarling cap

--
:. 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 4.5 rt0.3 kg-m

(10 rnrn Bolt) (32.6 5 2.2 ft-lb)

3.
Remove the oil level gauge and fill the
transmission with gear oil (MP #80). Straighten
Fig. 11-51 Checking gear shift condition the bent tip of the oil level gauge.

c. Tighten the transmission cover compl.

along with the gasket using four 6-mm bolts Oil quantity (0.95 U.S. qt.,
(L = 25 rnm). 0.80 Imp. qt.)

Tightening torque +
1 U.U.15 kg-rn
(6 mm Bolt) (7.23 2 0:54 ft-lb)

6) Clutch lever
Refer t o Chapter 10, "CLUTCH"
11-8. TROUBLESHOOTING

I 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 con- Adjust or replace.

nections.
(2) Worn, broken or burred chamfers of Replace.
internal splines of sleeve and reverse
driven gear.
(3) Worn, broken, or burred I Replace.
gear splines.
(4) Insufficient operating stroke due to Repair or replace.
worn sliding part or rattling.
(5) Improper contact between synchro- Repair.
nizer ring and ring gear cone, or worn
contact surfaces.

2. Gear slips out.

(1) Worn shifter fork, or fatigued or Replace.

broken shifter fork rail spring.
I
(2) Worn lock ball groove in shifter rail. Replace. I

(3) Worn or damaged ball bearing. Replace.

I
(4) Excessive clearance between synchro- Replace.
nizer hub and sleeve splines.
(5) Worn chamfers and flank of each Replace.
gear spline.

3. Noisy transmission

If a noise is heard during idling but stops when the clutch is disengaged, the problem is
probably in the transmission.
I
(1) Insufficient lubrication or use of Add oil or change to recommended oil.
inadequate oil.
(2) Worn or broken gear and bearing. Replace.
 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 knock-
ing sounds are heard even at low
speeds.

(3) Worn splines. Replace.

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 Disassemble differential and replace

oil.
(2) Improper use of vehicle such as over-
loading, improper use of clutch.
(3) Excessive backlash due t o worn side
gear, washer (27.1 x 42 x t) and
pinion.
(4) Bolts fixing final gear loose.
broken parts.
Check parts for condition and replace as
necessary.
Adjust backlash and tooth contact.
Fill recommended oil t o specified level.

5. 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.

The different kinds of noises are as follows:

I
(1) Noise at starting or gear shifting

Insufficient gear oil, improperly meshing gears, or broken gears are the cause when the
I
noise increases as vehicle is accelerated.

(2) Bearing noise while accelerating or coasting

Cracked or broken bearing.

I
(3) Noise produced mainly while turning

Abnormal noise of differential side gear. differential pinion, and differential pinion shaft.
I
f 1) Insufficient oil. I Add oil to normal level.
(2) Excessive backlash between dif- Replace gear or washer.
ferential side gear and pinion.
 Condition and probable cause Remedy

(3) Worn teeth of final gear and drive Replace as a set

pinion.
(4) Broken differential pinion shaft. Replace.
(5) Seized or damaged bearing. Replace.
(6) Worn washer (27.1 x 42 x t) and Replace.
pinion shaft.
 CHAPTER 1 2: SUSPENSION

Page

SPECIFICATIONS.......................................................................... 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
12-1. SPECIFICATIONS

1. Front suspension

Item TRUCK (I VAN (K87)

L

Total length 504.5 mm (19.86 in)

Effective length 434.5 mm (17.1 1 in)
Torsion bar Effective diameter 19.5 mm (0.768 in)
Number of serration teeth Inner end: 37 Outer end: 34
Spring constant 4.22 kg-m/deg. (30.5 ft-lbldeg.)
Maximum length 278.5 mm (10.96 in)
Shock Minimum length 187.5mm ( 7.38 in)
absorber Damping force Expansion 88 kg (194 lb)
(at 0.3 m/sec) Compression 56kg (1231b)
Height 55mm(2.17in) 57.5mm(2.26i1
Helper
Rubber hardness 62" 10"
Outer Diam.
56.4 mm (2.22 in) x 5 1.6 mm (2.03 in)
Outer bearing x Inner Diam.
Length 30mm (1.18 in)
Bearing
Outer Diam.
58.4 mm (2.30 in) x 53.0 mm (2.09 in:
Inner bearing x Inner Jliam.
Length 30mm (1.18 in)

2. Rear suspension

Item TRUCK (K77) VAN (K87)

Total length 527 mm (20.75 in)
Effective length 483.5 mm (19.04 in)
Torsion bar Effective diameter 22.5 mm ( 0.89 in)
Number of serration teeth Inner end: 37 Outer end: 34
Spring constant 6.7 1 kgmldeg. (48.5 3 ft-lbldeg.)
Maximum length 269 mm (10.59 in)
Shock Minimum length 213 rnrn ( 8.39 in)
absorber Damping force Expansion 88 kg (1941b)
(at 0.3 m/sec) Compression 64 kg (141 lb)
I
Height 59.5 mm (2.34 in)
Helper
Rubber hardness 50"
Outer Diam.
52.8 mm (2.79 in) x 44 mm (1.73 in)
Rubber x Length
Outer bushing
bushing Rubber
50"
hardness
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:mi-
trailin.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)

leight*
Rear 260-295 mm (10.2-1 1.6 in)

+30'
Front 20 O' - 60#
Camber**
+30'
Rear 30 15' -60,

Caster** Front 5"25' t45'

Front IN 8-13 mm (0.3 -0.5 in)

Toe-in**
Rear IN 9-1 5 mm (0.35-0.59 in)

Front
Side slip*** IN 3 mm (0.1 in) to OUT 3 mm (0.1 in)
Kear

Inside 37" t2"

Turning angle** * *
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 8 Cushion rubber 15 Bolt

2 ~ d i s i o nbar 9 Torsion bar lock bolt 16 Torsion bar lock bolt
3 Helper bracket 10 Sleeve 17 Expansion plug
4 Helper 11 Oil seal 18 Trailing arm
5 Rubber bushing 12 Dust cover 19 King pin bushing
6 Shock absorber 13 Nylon bushing
7 Washer 14 Dust cover ~12-001

F ig. 12-1 Component parts of front suspension

12-5 .
12-5. COMPONENT PARTS OF .REAR SUSPENSION

1 Torsion bi1r
2 Center arnn
3 Center arnn bolt
4 Cone point bolt
5 Rubber bush~ng
6 Outer trailing arm
7 Circlip
8 Helper
9 Inner trailing arm
10 Rubber bushing
11 Shim
12 Bolt
13 Bracket
14 Shock abs
15 Washer

J
16 Cushion rubber
17 Rubber bush~ng
T12-002

Fig. . ~mponentparts of rear susper

r
12-6. FRONT SUSPENSION Or
a. Turn the steering wheel to the left (right)
1. Front suspension assembly fully to disconnect the right (left)-hand
brake hose from the wheel cylinder.
REMOVAL
1) Loosen the fou luts securing the
rim to the brake drum.
2) Raise the vehicle front and remove the
nuts the detach the wheel.

Fig. 12-5 Disconnecting brake hose from

wheel cylinder

b. Remove the union bolt at the 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.
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. 12-4 Disconnecting brake hose Fig. 12-6 Removing tie-rod end
 5 ) When removing the left-hand side suspen-
sion assembly, disconnect the speedometer
cable.
6 ) Remove the splashboard by loosening

I three 8 mm bolts.

I pig. 12-9 Disconnectinq shock absorber

b. Loosen the two lock nuts on the upper end

Fig. 12-7 Removing splashboard
NOTE:
7) Remove the trailing arm stopper bolt.
of the shock abosrber until the load is
released from the rubber bushing at the
lower end of the shock absorber.
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 cross-
member.

Fig. 12-8 Removing stopper bolt

8) Disconnecting the shock absorber lower

end.
a. Remove the 10 mm nuts and washers secur-

1 ing 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 rom
the crossmember by hand.

Fig. 12-12 Applying grease on sleeve

.- .- . . - 3) Install the front suspension assembly in
Fig. 12-1I Removing suspension assembly the reverse order of removal.

NOTE:
INSPECTION a. When installing the torsion bar into the
1) Check the bearings in the trailing arm for crossmember, align the lock bolt hole in the
wear and damage. crossmember with the V-shaped groove at
2) Check the sleeves on the crossmember for the torsion bar inner end and install the lock
wear and damge. bolt
3) Check threaded parts for wear and damage. Also align the lock bolt hole in the trailing
4) Check the oil seal lips for wear and arm with the V-shaped groove at the torsion
damage.
bar outer end and install the lock bolt
5) Check the torsion bar and trailing arm for After completing the above job, adjust the
any evidence of deformation which may have
vehicle height and side slip.
decreased their strength. Also check the painted
b. The torsion bar lock bolts are of special
surface of these parts for peeling, and repaint if
design. Always use genuine SU BAR U bolts.
necessary.
c. Tightening torque specifications are as
I ows.
NOTE:
I f the trailing arm coating has come off
-' e trailing arm is rusted, carefully check me 3.0 - 4.4 kg-m
Torsion bar lock bolt
fected parts for cracks or damage. If (22 - 3 2 ft-lb)
cessary, use a dye test to determine
normalities. Trailing arm stopper 1.1 - 2.6 kg-m
bolt ( 8 - 19 ft-lb)
'ALLATION
, Before installing the front suspension Brake hose and brake 1.5 - 2.0 kg-m
assembly, throughly clean the bearings and pipe connecting nut . (1 1 - 14 ft-lb)
sleeves with clean cloth and keep these parts
free of dust. Shock abosrber lower 1.8 - 2.6 kg-m
2) Apply new grease (about 70 gr. (2.5 oz)) end installing nut (13 - 19 ft-lb)
to thc:crossmember sleeves.
,upper 1.8 - 2.6 kg-m
Shock absorber nut (13 - 19 ft-lb)
upper end
.ease Sunlite No. 2 lock nut lower 1.0 - 2.0 kg-m
or equivalent. nut ( 7 - 14 ft-lb)
 When installing the plugs shown in figure, apply a coat of sealing compound to the
always replace it with a new one and apply threads.
a sufficient amount of sealer when installing
it on the suspension.
Before tightening the torsion bar lock bolts Cemedine CS 11 1
Recommended
and trailing arm retaining bolts, be sure to Cemedine 540
sealer:
or equivalent

1 Plug
2 Lock bolt
3 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 "Adjust-
ment of wheel alignment".)
 Torsion bar
~ )VAL
1) Remove the front suspension assembly.
(Refer to removal of front suspension assembly.)
1 2) Remove the torsion bar lock bolt at the
center of crossmember underside.
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. 12-15 Removing torsion bar
Fig. 12-1 6 Removing torsion bar b y tapping
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. 12-1 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. 12-1 8 Installing torsiof..,,
4) With the torsion bar inserted into the
trailing arm, attach the suspension assembly to
the crossmember.
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 cross-
member 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
torsion bar with the holes in the c--"" Ius3-
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
621001381 (FRH)
torsion bar
Left-hand
621001391 (FLH)
torsion bar
d. After the front suspension has been insta
check the ground clearance and rn
alignment I f necessary, adjust
 Bearing (Trailing arm inner and 2) Drive out the bearing in the following
outer) and Dust cover manner, using the special tool (Remover:
922290000).
ZMOVAL a. Attach the hook @ to the inner side of the
Remove the dust cover press-fitted to the trailing arm.
ler end of the trailing arm, by using a screw b. Open the hook @ until it catches the
.ver. 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
NOTE: occupied by the dust cover.
Be careful not to damage the rubber surface e. Turn the screw @ t o tighten the cap @
of dust cover. and drive out the bearing.

1 Retainer
2 Hook
3 Cap
4 Screw
5 Special tool:
(922290000)
6 Bearing

T12-007

Fig. 12-21 Removing trailing arm bearing

12 - 13
 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 suspen-
sion assembly and replace the bearing.
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.
I F&. 12-22 Measuring trailing arm
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
diam.) of the special tool (In; staller :
922350000), and then insert it into thie trail-
ing 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
.--
Fig. 12-23 Installing outer bearing
4) Install the bearing onto the end (53.0 mm
diam.) of the special tool (Installer:
922350000), and then insert it into the trail-
ing 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.
 NOTE:
Do not allow the dust cover to prolmle
1 Bearing (outer from the trailing arm more than 15 m
2 Bearing (inner) (0.06 in).

Dust cover

Less than
1.5 mm (0.06 in) T12-011

Fig. 12-26

4. Sleeve (Inner and Outer) and Oil

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.
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

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.

4) 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.

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
NOTE:
Check for proper f i t of the inner -'--.*-
12-28 Removing inner sleeve 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 cross-

member with a- rlarrlmer through the special
tool (Installer: 922340000).

1 Cross member 3 Outer sleeve

2 Special tool: 4 Sleeve
Sleeve installer 5 Oil seal
(922340000) 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

b. I f oil is found only on the upper andI lower

portions, this does not indicate oil leakage
Fig. 12-33 Removing shock absorber lower end 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
Fig. 12-35
items, and replace it if any of the following
abnormalities is found.
1) Excessive oil leakage or damage.
2) Improper functioning. INSTALLATION
3) Improper travel strokes (min. and max.). Installation is in the reverse order of removal.
4) Deformed or damaged rubber bushing.
NOTE:
Tighten the 10 mm nuts securing the upper
NOTE: and lower ends of the shock absorber to the
a. Fully extend the shock absorber and check specified torque.
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 Torque 1.8 - 2.6 kg-m (13 - 19 ft-lb)
absorber.
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 12-7. REAR SUSPENSION

removal.
1. Rear suspension assembly
REMOVAL
NOTE: 1) Loosen the four wheel nuts securing the
Tighten the 8 mm nuts to the specified rim to the brake drum.
torque. 2) Raise the vehicle rear and remove the nuts
to detach the wh

NOTE:
Attach the jack to the designated points.
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) 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 mount-
ing bracket, and separate the two.

Fig. 12-40 Removing cable

5) Pull the cable with the grommet off the

-. - A a- -. .. 9 1 9
 Loosen the lock nut, the e the 11) Remove the rear suspension
:r bushing lock bolt. from the chassis frame by pulling it out.

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

I
Remove the two bolts securing the inner
mounting bracket to the crossmember, and
rrllll

detach the inner arm bracket.

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
Fig. 12-45 Removing inner arm bracket nut
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 ASSEMBLY AND INSTALLATION
hub to the trailing arm. 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 installa-
tion 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.

Outer bushing lock 1.8 - 2.2 kg-111

bolt (13 - 16 ft-lb)
Fig. 12-49 Removing realh u b bolt
Inner bushing 3.5 - 4.0 kg-m
3) Pull off the rear axle assembly and br ake ltaching bolt (25 - 29 ft-11
assembly as a unit from the trailing arm.
lner bracket 3.5 - 4.5 kg-
NOTE: attaching bolt (25 - 33 ft-lt
Be careful not to damage or deform the
brake pipe or the axle boot Shock absorber 1.8 - 2.6 kg-
attaching nut (13 - 19 ft-lt

Brake hose to brake 1.5 - 2.0 kg-

INSPECTION
pipe securing flare nut (1 1 - 14 ft-It
1) Check the condition of all parts. Replace
parts if necessary.
Rear hub attaching 7.0 - 12.0 kl
2) Check for missing circlip on the trailing bolt (5 1 - 87 ft-It,
outer arm. If it is missing, install a new one.

c. Fit the rear torsion bar to the outer arm by

uter arm
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 Fig. 12-51
a dye test to check for abnormalities, especially
on areas where coating is detached and rust d. After the rear suspension assembly has been
C--.4:.-.- av:n+- ins+-dln.l h1an.l .I;- 6.n- +hn hr.~Lnr..r+n-
 USTMENT 54.5 mrn (2.14 in)
After the rear suspension assembly has
installed, inflate the tires to the specified
ure; also make pcIsture adjustments and
1 alignment.

1 Special tool:

Rubber bushing (Outer) \O 2 Rubber bushing '

3 Outer arm
OVAL T12-029

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.
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
I I U ~ ,1

Press the outer rubber bushing into place

with the special tool (Installer: 921380000)
3 Trailing arm
and a press. 4 Rubber bushing ,

E: T12-030
! sure to center the boss in the trailing arm
and rubber bushing when installing. 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 Fig. 12-56
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 NOTE:
the inner rubber bushing. Exert pressure on the
a. When pressing the inner bushing, always
inner rubber bushing liner with the press until
align the center lines of the inner trailing
the end of the rubber bushing shows through
arm of the rubber bushing, die 0, rubber
the access hole in the base @.
bushing and push rod @ Failure to do so
4) Make sure that the rubber bushing is
may result in unusual noise while driving.
pressed to the specified value.
b. After installing the bushing, allow the bush-
ing 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 INSPECTION
3 @ Base Visually check the torsion bars and center
4 Rubber bushing arm to see if the coating is peeling or if rust is
5 Trailing arm
T12-031 developing. If necessary, use a dyeing test to
.
check for cracks or damage. Replace any
Fip. I 2-55 Installinp inner rubber bushing which are cracked.
r INSTALLATION
1 1) Before installing parts, apply a coat of the
1 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.
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.
Right-hand
621001900 RRH
torsion bar

Left-hand
621001910 RLH
torsion bar

Fig. 12-57 5. ,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. POSTURE ADJUSTMENT

1. 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
3) Measure height "H" above ground (ground
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 1
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
trailing arm cap, as an assembly, out nf -. t...-
he
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.
 NOTE:
T o prevent the tentry of water through the
threaded portions, be sure to apply a coat of
cemedine to the threads.

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.
Fig. 12-63 Removing torsion bar by tapping 18) Install the lower end of the shock
abosrber to the trailing arm.
19) Plug the hole in the center of the cross-
member.
11) Lower and raise the jack supporting the
brake drum until distance "Ll" between the NOTE:
marl< scribed on the fender (in step 7 above) Apply a coat of cemedine to the plug before
and the center of the wheel is obtained. At this installing.
poin t, the amount of adjustment (a) should be
adde:d to, or subtracted from, dimension "L" 20) Apply a coat of cemedine to the end of
as ne:cessary . the trailing arm, and then install the plug.
(Exa.mples)
,.) If height "H" of the torsion bar above NOTE:
ground before adjustment is 270 mm, Recommended sealant: Cemedine 1115
difference "a" is determined by the Cemedine 540 or the
following: equivalent
a = 295 - 270 = 25 mm
Where a : Amount to be adjusted
21) Tighten bolts and nuts to the specified
The distance between the mark on the torque settings.
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 Torsion bar lock 3.0- 4.4 kg-m
The distance between the mark on the bolt (22 - 32 ft-lb)
fender and the center of the wheel is also
determined by: Trailing arm stop 1.1 - 2.6 kg-m
Ll=L-30mm bolt ( 8 - 19 ft-lb)
1 Ll With distance "Ll" adjusted as above,
enga,ge the serration of the torsion bar with Shock absorber 1.8 - 2.6 kg-m
that of the crossmember and trailing arm. attaching nut (13 - 19 ft-lb)
13)
-, Properly align the V grooves on each side
of the torsion bar with the lock bolt holes on
3.6 - 5.4 kg-m
the trailing arm and crossmember. Then tighten Wheel nut
(26 - 39 ft-lb)
the lock bolts.
2. Rear posture adjustment 12-9. A D J U S T M E N T OF W H E E L
ALIGNMENT
1) Park the vehicle on a flat surface, and
adjust the front and rear tires to the specified 1. Front wheel alignment
pressure.
2) Measure height "H" of the torsion bar at Camber and caster need not be adjusrcu.
its end t o determine difference "a" from the Toe-in alone is adjustable.
standard value. Check the condition of the following items.
a = 285 - H If necessary, adjust or replace parts, then
Where a: Amount to be adjusted adjust toe-in.
285: Standard value 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 bush-
ing 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.

NOTE:
Turn the turnbuckle equally on each side
until the steering angle of the left and rear
Fig. 12-65 Vehicle height adjusting bolt wheels are within the specifications.
 :eering
Outer wheel: 33.5' f 2"

1
1

1 Lock nut
2 Turn buckle

T12-035

Fig. 12-67

4) Measure toe-in or side slip to see if it is NOTE:

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.
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 Turn buckle (19 mm in

width across flats) Fig. 12-69 Tightening lock nut
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) c. After tightening the lock nut, move the tie
(22 mm in width across flats)
T1 rod to the front and back to see that it
moves equally from side to side more than
Fig. 12-68 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 4.54 m m (0.179 in) 1.4 = 0.6 + 0.8
b) Height above ground (Ground clearance)
c) Bearing play
d) Deformed trailing arm

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.

NOTE:
Fig. 12-71 Toe-in adjusting shim 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 3.5 - 4.5 kg-m (25 - 3 3 ft-lb)

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 5) Again measure toein or side slip to see if
and 1.2 mm in thickness. it is within the specifications.
12-10. TROUBLESHOOTING

A. Unstable running
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.
1 The vehicle wanders immediately after a lane change, even though the steering wheel is held in the
straight-ahead position.

Probable cause Remedy

(1) Improper tire pressure. Inflate properly.

(2) Wheels out of alignment. Align.
(3) Brake dragging or not properly adjusted. Adjust.
(4) Trailing arm not properly installed (substantial Reinstall.
difference in reaction between left and right
arms).
(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 Replace.
sleeve worn.
(9) Loose wheel nuts. Tighten.
(10) Deformed tie rod or trailing arm. Replace.
(1 1) Play in tie rod end ball joint. Replace.
(12) Worn kingpin bushing. Replace.
(13) Loose trailing arm or steering system installing Tighten.
bolts.
(14) Improper tire (wrong brand). Replace.
(15) Fatigued or deformed rear suspension outer Replace.
bushing.

B. Incorrect vehicle posture or ground clearance

Probable cause Remedy

(1) Fatigued or broken torsion bar. Replace.

(2) Shock absorber not functioning properly. Replace.
(3) Trailing arm not properly installed. Reinstall.
(4) Deformed trailing arm. Replace.
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.

Probable cause Remedy

(1) Broken torsion bar. Replace.

(2) Helper is excessively deformed or has dropped Replace.
off.
(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 Replace.
bushing.
(7) Incorrect shock absorber travel strokes. Replace. I

(8) Rear suspension outer bushing is deformed or Replace.

has dropped off.

. Rear (Drive) wheels run idle

Probable cause Remedy

(1) Incorrect ground clearance. Adjust.

(2) Insufficient shock absorber extension. Replace.
(3) Broken torsion bar. Replace.
(4) Insufficient swing angle of double offset joint Correct engine installation or replace.
(D.O.J.).
(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 Replace.
bushing.
(3) Worn wheel bearing. Replace.
(4) Worn double offset joint. Replace.
(5) Worn brake drum splines. Replace.
(6) Front trailing arm not properly installed. Reinstall.
(7) Worn front trailing arm bearing or crossmember Replace.
sleeve.
(8) Front trailing arm bearing insufficiently Lubricate.
lubricated.
(9) Play or wear in tie rod end ball joint. Replace.
(10) Loose rear suspension outer bushing lock Tighten.
(1 1) Deformed or dislocated rear suspensicjn arm Replac
bushing.
(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. Adjust.
(16) Broken torsion bar. Replace.
 CHAPTER 13: WHEELS AND AXLES

Page

13.1 . FRONT WHEELS AND AXLES ................................................. 13- 2

13.2 . REAR WHEELS AND AXLES .................................................... 13- 7
13.3 . TIRES AND RIMS ........................................................................ 13-16
13-1. FRONT WHEELS r
1. General description

Backc plate

dometer cable

eft side- TI 3-001

1 Knuckle (R.H.) 8 Kingpin 5 Brake drum compkI te (Front)

2 Knuckle (L.H.) 9 Knock pin 6 Washer
3 0-Rin- 10 Shim -7 Lock w ashnr
4 Cowl 'lug 18 Cap (R.
5 0-Rin pacer 19 Cap (L.:
6 Thrust wasner (dpper) 'aper roller bearing 20 Oil seal
7 Thrust washer (Lower) .Outer) 71 Axle nu
Taper roller bearing
(Inner)

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 per-
form?.'
1 2. Brak b. I f the inner bearing remains attached on the
spindle when the drum is removed, install
1) Removal Special Tool (BEARING REMOVER:
a. With the wheel on the ground, loosen the
1
922120000) as shown in Fig. 13-3 and
four 10 mrn whetl 31 .,..Cn
llUL3 aciaching the rim to
n+4
remove the bearing by turning the handle.
/
I
the brake drum.
1 b. Raise the vehicle with a lift or jack and, in 2) Disassembly (bearings and oil seal)
1 .
either case, assure the safety by locking the
lift or using safety stands.
c. Remove the whe~ el nuts arid pull the wheel
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)
! off. b. Tap the outer bearing outer race out of the
1 d. Remove the three 3 mm screws attaching the drum by using a brass rod etc. using ci
I cap to the drum and remove the cap. to damage the race.
NOTE:
Since the left-side cap is provided with a pin
I
to drive the speedometer cable, be careful
I
not to bend the pin when removing the cap.

1 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
1 outer bearing. (Fig. 13-2) Inner bearing Special tool
BEARING REMOVEU
NOTE: 922120000

a. I f the drum is difficult to remove by hand -

because the bearings stick to the knuckle
Fig. 13-3 6 inner bearing from.spindle
spindle, install Special Tool (ATTACH-
MENTS: 921420000) to the wheel mount-
ing bolts on the drum using wheel nuts.
Then, hook the pawls of a puller to the
recesses of the attachments, align the lead iring's
.+-.. .+rre

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.

- out inner bearing

Fig. 13-4 Tapping
A

Inspect,..
tinn

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
Removing washer 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. Fig. 13-6 Packing drum with grease
c. Check the oil seal for damage or deforma-
d. After installing the rollers and inner race of 1
tion, the oil seal lip for wear, and the spacer
the inner bearing and packing it with grease,
for damage and wear.
d. Check the cap gasket for damage. press the oil seal, with its lip and inner '
e. Check the cap for damage and deformation. surface coated with grease, into position. I
e. Install the outer bearing rollers and inner 1
f. Check the knuckle spindle for damage and
deformation. race packed with grease. I

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.
5) Installation 1
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.
I
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

b. Lock the nut by bending the lock washer

c. Install the cap with the gasket and three
T 1 3-003 screws.
d. Install the wheel, tightening the wheel nuts
finger-tight.
Fig. 13-5 Installing bearings e. Lower the vehicle to the ground.
c. Pack the drum with grease as shown in Fig. . f. Tighten the wheel nuts to the specification.
13-6. Appropriate
-- - amount of grease to be
packed in the drum and applied on the
Wheel nut 3.6 - 5.3 kg-m
bearing surface is 35 to 39 g (1.23 to 1.38
tightening torque (26 - 39 ft-lb)
oz) .
 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 @
.1
Spri
rtg scale
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

Adjust the brak e shoe cl after de-

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 Fig. 13-9 Removing pin at knuckle
back plate to the knuckle and remove the
back plate.

ipecial tool
LA.. .,.,.,a.

Fig. emoving k!ingpin

Fig. 13-8 Removing back plat,

c. Remove the trailing arm iln accordaince with

12-1 in Chapter 12. OTE:
. ,- .. .* r - *,.~. ~
3
d. Remove the pin at the center or tne KnucKle ror rne removal ana lnsTallarlon or rhe king
by tap.ping it fr om the sipindle side. (Fig. pin bushing on the trailing arm, refer to
13-9) Chapter 12.
2) Reassembly e. Apply a thin coat of grease on the king pin
surface.
NOTE: f. Tap the king pin into the upper yoke
Be sure to keep the parts free from dust bushing from the top of the yoke.
during this job. g. Hold the parts assembled in .a. under the 1
upper yoke and press the king pin down j
a. Put the cover, upper and lower thrust until its lower end becomes flush with the 1
washers and O-ring together as shown in thrust washer as shown in Fig. 13-13.
Fig. 13-11, with sufficient grease applied h. Place the knuckle fitted with O-rings be-
between the upper and lower thrust washers tween the thrust washer and lower yoke and
and on the O-ring. align the king pin with the king pin hole in
b. Coat the bushing inside surface with grease the knuckle while pressing the king pin
and also fill the oil groove in the bushing down by hand to the position shown in
with grease. Fig. 13-14.
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
Cover pin and the hole in the knuckle are not lined
UP.
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) KWXIB

T I 3-009
7 Oil groove T13-007

Fig. 13-1 2 Assembled components Fig. 13-14 Aligning king pin with knuckle

13 - 6
 i. Direct tl the king pin so that it will Apply sealant to the knock pin and drive it
fit on t l l ~I\IIU~.I\ pin, and tap the king pin into the knuckle.
with a plastic hammer down to a position
slightly above the O-ring installed at the NOTE:
bottom of the knuckle as shown in Fig. Always use a new knock pin for reassembly.
13-15.

NOTE:
Be sure to stop the king pin above the
O-ring, otherwise the protruded O-ring might 1. After applying grease on the top and bottom
hinder the installation of shims or the O-ring of the king pin, install plugs on both the
might be cut by the shim when it is ircal+nd ends. Hit the center of the plug to spread it
and stake the yoke at three points around
I the plug to secure it.
111. Apply sealant on the circumference of each

plug to perfectly seal the gaps.

NOTE:
MICxl IM wtawaypl Ihl h l n ~PHI
lo 11a kmck pm h& of' 1M k w k l e . Before applying sealant, wiple grease, c~il,etc.
away with clean cloth.

Yoke pdrl 01 thl Ira11

T13-010
I

1 Fig. 13-15 Tapping kingpin into knuckle

1 j. Install proper shims between the knuckle 13-2. REAR WHEELS AND AXLES
and lower yoke so that the knuckle end play
and rotatine resistance are as svecified be- 1. General description
low. The engine output is transmitted t o the rear
wheels through the axle shafts. The inner end
Knuckle erlu pray .,.the axle shaft is connected through splines to
nf
3 - 0.004 t hf : differential side gear on the engine side, and
t hf : spline connection is locked with a spring
pprox. - 1. The outer end of the axle shaft is sup-
pir
Knuckle rotating
2.5 - 3.7 kg-m
resistan ported 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,
0.2 mm (0.008 in)
Adjusting shims spiacer and center piece are tightened at the
0.25 mm (0.010 in)
(Thickness) sarne time by a castle nut. The center piece
0.35 mm (0.014 in)
tkes it easiier to remove and install the! brake
Im.
 . . . ,. . . ,
1 Wheel ma 9 Ball bear'-- 17 Castle nut
2 Brake drum complete 10 Oil seal 18 Cotter pix
3 Axle shaft 11 Oil seal ( 19 Circlip
4 Outer race 12 Ball 2 0 Snap ring
5 Spring pin " Cage ,.--
6 Hub Spring washer
7 Spacer Nut
8 Ball bearing Center piece (Axle)

Fig. 13-1 6 ar wheel cmd axle a.

,rt
S ~ ~ L L .
Brake drum
g. Make the shcDe clearan ces larger.
Removal h. Put a flat b lade sere!vdriver against the slot
. - -
.- piece
d o s e n the four 10 mm wneel nuts attaching of the center and tap the screwdr iver
the rim to the brake drum. with a hammer to remove the center piece.
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.
c. Remove the wheel nuts and pull the wheel
off.
d. 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.
e. Remove the center cap with the three
attaching screws.
f. Pull the cotter pin and remove the castlr:IIUL
---'
(27 mrn in width across flats) on the axle Fig. 13-17 Remo ving centt?rpiece
 'ull the d rIm ~ off tlle axle shaft. If it is
. l ~
lifficult to remove me drum by hand, install Torque (Castle nut) 16.0 kg-m (1 16 ft-lb)
;pecial Tool (ATTACHMENT: 92 1420000)
In the drum by utilizing the wheel nuts and NOTE:
lull the drum with a puller as shown in Tighten the castle nut to the above torque
Fig;. 13-18. first and retighten further until a slot of the
castle nut is aligned to the hole in the axle
NOTE shaft.
In place of the standard puller, Special Tool

3AKE DRUM PULLER: 921120000) c. Lock the castle nut with a new cotter pin.
y also be used. (Fig. 13-19) d. Install the under cover and wheel.

3. H u b a n d a x l e shaft assembly
1) Removal
.
:ial tool: A TTACHMENT
a21 420000 a. Remove the brake drumin accordance with
Conver 2. 1).
puller
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

d. Remove the bleeder screw and remove the

brake pipe joint nut from the wheel cyl-
inde~
e. Remove the back platc:by unsc rewing the
Fig. 13-1 9 Remov ing brake drum four 8 mm attaching bolIts.
f. Unscrew the four 12 mlrl - UUILS a~tachingthe
L->A- ..A

hub to the trailing arm.

2) Installation g. Remove the axle shaft assembly together
a. Before installing the brake drum to me a.--
xle with the hub.
shaft, coat the splined portion of the shaft
with grease to prevent corrosion. NOTE:
b. Install the brake drum, center piece and Be careful not to damage the inner and outer
casltle nut an1d tighten 1the nut. boots.
2) Disassembly
a. Place the hub auu L I N G shaft asse111~1~
UII i

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
A,-.
between the bearing and
oil seal.
Fig. 1 3 oving bealring (hub, outer) '

3) Inspection !:
Check the disassembled ps~ r t sas follOWS. i
a. 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/
outer race rota1tes smoot hly withc~ u noir
when t he inner r ace is sup.ported.
t
4
;"i

Fig. 13-21 Removing axle shaft from hub

b.

c.
Spacer
Wash Ithe space r in a clc:aning solvent andI
check jFor damage and defc~rmation.
Hub i
I
Wipe the inside surtace with clean cloth and?
NOTE: check lFor crackiing and other damage. !
Do not reuse the oil seal. A damaged or 4) Reassembly
worn oil seal will allow the entry of mud and a. Apply 9 g (0.33 oz) of grease to the innerll
water into the hub, and shorten the life o. bearing and position the bearing in the hub
the bearing. With the 30 mm (1.2 in) diameter end o
Special Tool (HUB BEARING INSTALLER: I
921350000) inserted in the inner race of thei
bearing, press the bearing into the hub.

Special tool:
j
i
HUB BEARING INSTALLER I
921350000

bearing #6206-C4 ,
I
j
I

I
!
Fig. I . roving bearing (hub, inner)
move the bearing (hub, outer) from thf - -
~
. . rn
nuD, Ilse -
a 3" mm (0.2 in) diameter drift an6
press ras shown iin Figure 13-23. Fig uner bec
 b. Coat the oil !real with : I position e. Appl:y a coat of grease to the oil seal to b
in the hub. With t t
- --
I, n
[II (1 .L I
: *.a
instahea '4
on me outer bearing
~ ~ . siae.
. - Press th
ameter end of Special Tool (HUB BEAR- oil sea1 into th~
e hub using a 65 mm (2.56 in
TG INSTALLER: 921350000) inserted diamc:ter bar or block as shown in Fig
to the oil seal, press the oil seal against the 13-27 '.
ring.

Special tool:
HUB BEARING INST. -

Cross section
of oil seal
T13-016 Cross section
of oil seal
Fig. 13-25 Installing oil seal T13-018

1 NOTE: Fig. 13-27 Installing oil seal

!
Press the oil seal fully1 until it bottoms. I f
I
clearance exists at A, it will causc5 the oil seal
lip to wear.
NOTE:
c. Invert the hul and app 8 g (0.51 UsingI more grcuse than specified may resul
." ""......'. "..c"--
l'...l,.. *I. ..a... I.
0.65 oz) of grease to tne insiae surface IIUIII L I I ~ U U L ~ I~earing
intlr
1"
IIIyleaaaa leanaye
the hub. the brake drum, causing brake failure.
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.
I
With the 25 mm (1.0 in) diameter end of
Special Tool (HUB BEARING INSTALLER:
92 1350000) inserted ilnto the irlner race of f. Installing the axle shaft into hub
the bearing, press the bearing in[to the hub. Prepare Special Tool (HUB INSTALLEI
CAP: 922320000) 0, and the lead screv
Special tool: HUB BEARING INSTALLER @ and handle @ of Special Tool (HUI
921350000 INSTALLER: 92 1360000). Insert the ax11
shaft into the hub by hand as far as possibl~
Ball bearing #6305-C4
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
T13-017
a wrench.
5) Installation
Install the hub and axle snart assembly i~
Fig. I . ter bearing the revel:se order c)f the removal.

13 - 11
NOTE:
a. When connecting the axle shaft t o the
-. groove f o r idelntificatiorI. (Fig.
-
2) Be careful n o t t o damage the boot,
13-29)

engine 3) Use a new spring pin.

1) Ins1tall each alxle shaft on the calrrect side b. The t w o upper bolts attaching the back plate
as rne lengths of tlhe right-tland and
*LA I---.
are alse used t o secure the parking brake
left le shafts are d i f f erent.
~ The bracket
rigt ule shaft ?d w i t h a

Axle shaft
Special 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 un-
lalancing 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---* --.l
VCIIL CIIU of the band.
4. A x l e s h a f t (D.O.J.)
2) Loosen the band by tapping its end. P q
1) General description (Fig. 13-31) up the band with a screwdriver and
-?ar
TL-
lllG
1 C axle is of a floating type using two rpmqve it from the boot with a pair of
.W.,'.

constant,velocity j c .J.) at both ends of plier

 1 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.
c 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.
Band //*
Fig. 13-30 Removing boot band

D.O.J. ass'y (Inner) 5 Boots (Outer) 8 Snap ring

D.O.J. ass'y (Outer) 6 Clip 9 Cuclip
7 Clip 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
,.."rn
tllo
lllllG1

race on the s:haft by using specia1 pliers.

Fig. 13-32 Remov ing circlip 2) Pull the inner race off the shaft.
 4) Reassembling
a 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 Fig. 13-35.Installing circlip and cag
square-scection circ:lip on the! shaft.

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.

d. Install the cage on the inner race by aligning

the protrusion of the cage with the track in
Fig. 13-34 1: the inner race. Then turn the cage by a -ha1t
ed D.O.
J.
pitch to line up the holes in the cage with
the inner race tracks.
2) Inspection
NOTE:
Clean all the parts and check for defects as
Apply grease to the cage holes. Use molyb-
,110~s.Repair or replace as necessary.
denum-base grease for the D.O.J.
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. Grease grease (Molytex No. :
c. Boots or equivalent)
Check for wear, warping an(i breakage.
I
Fig. 13-36 Installing cage on inner race Fig. 13-38 Applyinggrease t o outer' race

: e. Insert the six b:~ l l sinto tl 3les. (Fig. g. Install the outer race on the assembly of the
.13-37) inner race, cage and ball assembly.
h. Install the circlip in the groove in the outer
race.

Ball
all
I

Outer Ci

Fig. 13-3 7 Installing balls

Fig. 13-39 Installing outer race

f. Apply grease in me outer race as lnaicarea In IOTE:

Fig. 13-38. . Make sure that the balls, cage and inner race
are completely housed within the interior of
the outer race.
: velocity:joint . Do not position the ends of the circlip in the
loly tex NI0.2 track in the outer race.
dent) . 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. NOTE:
When tightening the boot, exercise cart!that
the air remaining in the boot is nt!ither
Constant velocity joint excessive nor insufficient.
Grease grease (Molytex No. 2
or equivalent) 3) Further tighten the band by using Special
Tool (BAND TIGHTENER: 925090000)
Inner D.O.J. 50 g (1.8 oz) until the band cannot be moved with
Amount fingers.
Outer D.O.J. . 100 g (3.5 oz) 4) Lightly strike the band with the punch
provided at the end of the tool.

. Installthe boot on the D.O.J. NOTE:

NOTE:
Clean the boot groove in the shaft and outer
race so that they are free from grease and
other substance.
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.

k. Installing the boot bands
1) Wind the band twice around the boot
groove, passing the band through the clip. 13-3. TIRES AND RIMS

NOTE: 1. Specifications
Use a new band. See the table for the tire and rim specifica-
tions.

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 OTE:
n d t~ghtener Be sure to place the jack straight. The
- 15090000 vehicle is provided with four jacking points, ,
one near each wheel.

Fig. 23-40 Installing boot band c. Remove the wheel nuts and washers, a n d ,
take off the wheel.
2) Tighten the band by pulling the end of 2) Installation
the band with pliers while holding the Install the wheel in the reverse order of t h e r
clip. removal.
 Tire and Rim Specifications

size iOD x 10 ,I

Tire size 5.00-10-6PR U1

Valve TR244A

-3
Light Load

Full Load I7A\

Tire inflation
pressure ight Load
kg/cm2 (psi
'ull Load

I 2.7 (38)

Tire width $6(5.4) with inflation pressure of 2.4 k 4.1 psi)

Tire outer
diameter n) Approx. 518 (20.4) with inflation pressure of 2.4 kg/cm2(34.1 psi)

outer rim half. Also use care that the drum

3. Inner tube bolt holes in the rim halves are correctly
, 1) Removal aligned. This will make the brake drum
installation easier.
nnflate the tire. Since the rim is of the two
Y C I
I f. Inflatc:the tire to the s pecified
~ prc:sure and
piece type, the tube caln be taken out by
I r e m oring
~ the falur rim connecting bolts and attachI the valve cap.
seDar:lting the twu.-.- h-l-.-
11a1vcs of the rim. It is
unnecessary to remove the tire from the rim. 4. Tire
2) Installation
a. Check the interlor surrace orF me tire and
. - ! . E ,I
. ,.
To remove the tire from the rim, rc:move the
four rim connecting bolts and separate me rim
.
repair if necessary. Remove any foreig halves. If it is difficult to remove the tire, insert
matter from the surface. a large screwdriver between the rim and tire and
- b. Before installing the tube, tighten the tub pry
- - the tire off the rim. Repeat this operation
valve! and inflate the tube. Check the tub around the rim and the be easily
and valve thoroughly for leaks by puttin removed.
the t ube in water.
l^"^.
L. 111~cit the tube through the rim gap U I L U LL
a :-A-
LI
5. Tire damage and possible causes
tire and align the valve with the valve ho11
d. Inflate the tube sufficiently so that it wi 1) Damage due to flex, fatigue and heat
not be caught between the two rim halvt The side walls of the tire flex as the tire
when reassembling the rim. rotates. If the tire pressure is insufficient or the
e. Match the two rim halves and join the1 vehicle is excessively loaded, the side wall
together with the bolts, spring
- - washers anu -
flexinn will become abnormally large, leading to
nuts. Be sure to insert: the bolt s from the separatio n of the cords from the rubber and
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, overload-
ing 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 dam-
ages. 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 unavoid-
able, but every care must be taken to prevent
abnormally accelerated wear development. The
major causes are improper tire inflation pres-
sure and incorrect wheel alignment or defective
suspensions.
 CHAPTER 14: BRAKE SYSTEM

Page

14-1 . GENERAL DESCRIPTION ..........................................

14-2 . BRAKE ASSEMBLY .....................................................
14-3 . MASTER CY LINDER ................................................................... 14-11
1 4. BRAKE FLUID LEVEL WARNING SYSTEM ....................... ..... 14-14
14-5 . PARK1NG BR.AKE S'r'STEM .......................................................... 14-
14-1. GENERAL DESCRIPTION
1. 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
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.

2. Specifications

Service brakes
Item Parking brakc
Front brakes Rear brakes

Hydraulic, internal Hydraulic, internal Mechanical, inter-

expansion, two expansion, leading nal expansion,
Type leading shoe type, and trailing shoe leading and trailing
foot-operated type, foot-operat- shoe type, hand-
ed operated

Brake drum material Cast iron Cast iron Cast iron

Brake drum inside diameter 180 mm (7.09 in) 170 mm (6.69 in) 170 mm (6.69

Brake lining material Molded resin Molded resin Molded resi

Lining dimensions 35 x 5 x 173 mm 3 0 ~ 4 . 4181~ mm 3 0 ~ 4 . 181

(Width x thickness x length)
Lining surface area
(One piece of lining)
4 ~
(1.4 x 0.20.x 6.8 in) (1.2 x 0.17 x 7.1 in) (1.2 x 0.17 x 7.- .--,
60 cm"9.30 in2) 54.0 cm2 (8.37 in2) 54.0 cm2 (8.37 in2)

Wheel cylinder inside 23.8 mm 19.0 mm

diameter (0.94 in) (0.75 in)
3. Brake piping components

'1

DETAIL '
4
. \

DETAIL " B *

2 6
l S. I

DETAI,L " c *

1 Brake pipe (Master cylinder - 2-way) 11 Bra:ke pipe 21 Clip

2 Brake pipe (Master c) .way)
.- - . .
12 Brake plpe 22 Master cylinaer
3 Brake hose 13 Connector (2-\: 23 Clamp (Brake h
4 Brake pipe 14 Connector (3-1 24 Tapping screw
5 Brake pipe 15 Bolt 25 Holder (Reservl
6 Tube 16 Grommet 26 ScreW
7 Brake pipe 17 Flange nut 27 Cap (Fluid leve
8 Brake pipe 18 Hose (Primary 28 Tan1k (Reservoi
9 Brake pipe 19 Hose (Seconda 29 Bolt
10 Brake host I (Hose) 30 Spring washer
Tlr
14-2. BRAKE ASSEMBLY

1. Front brake assembly

4 5

13
V

14

1 Shoe hold down pin 8 Back plate (F. LH) 13 Brake shoe ass'y (LH)
2 Spring washer 9 Wheel cylinder 14 Spring seat
3 Nut (F. UPPER. RH) IS Shoe hold down spring
4 Tube 10 Wheel cylinder 16 Whet:I cylinder
5 Nut (F. UPPER. LH) (F.L.OWER. RH)
6 Spring washer 11 Return spring 17 Whetcl cylinder
7 Back plate (F. RH) 12 Brake shoe ass'y (RHJ (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. moving center cap

14-r
 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.

i. Remove the shoe return springs from the

Fig. 14-4 Spreading lock washer primary and secondary shoes.

NOTE:
NOTE: Do not disassemble. the automatic adjuster
-

When removing the brake drum, be careful because its nut is !

that the wheel bearing will not fall off.
) 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.
Fig. 14-5 Removing plug

1. ,+
I.,,,.I"
set sprinr-
r\c;llluvG LllG
inside
diameter Limit 7 in)

-5 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 return springs as
Fig;14-6 Removing b#rakepart! shown in Fig. 14-1
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.
Upper side
Return spring
. -
Brake shoe
Automatic adjuster Lower side
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
approximatley 0.3 mm (0.012 in). Therefore,
pedal travel will not change even the linings
wear out.
-
/
,
5 Drum
5 sliding
/ surface
Shoe r ,
spring ,
,
t-
1 Shoe web 5 Friction plate
2 Back plate 6 Friction spring
3 Adjusting block 7 Nut
4 Adjusting bolt
T 14-OC
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 I
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

1.3 - 2.0 kg-m

-
Wheel cylin- 8 mm
(9 - 14 ft-lhl
der to back
plate (Nut) 0.6 - 1.1 kg-m
6
( 4 - 8 j R-lb)
Back plate to knuckle 1.2 - 2.4 kg-m
(Nut) (9 - 17 ft-lb)

1 Boot 4 Cup spacer

2 Piston 5 Return spring
3 Cup 6 Wheel cylinder body
Fig. 14-1 0 Components of fiont wheel cylinder
..

REAR

(1) Boot (8) Spring

(2) Nut (9) Lever complete
(3) Spring washer (10) Anchor block assembly
(4) Adapter (11) Back plate comple:te
( 5 ) Cap (12) Pin
") Wheel cylinder assembly (13) Seat
) Brake shoe complete (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.
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 1.7 mm
I
lining thickness (0.07 in)
Shoe set
spring
I'
b. Replace the shoe return springs if the ten-
sion is insufficient.
c. Replace the back plate, brake shoes, and
\
Adjuster lever if deformed or worn.
d. Replace the lever if excessively worn.
Fig. 14-1 2 Removing brake parts e. Correct the inside surface of the brake drum
with No. 60 sandpaper if scoring is evident.
f. Remove the brake shoes from the anchor Also correct or replace the brake drum if
block first, and then from the wheel cyl- irregular wear, tapered scoring, or external
inder. damage is found.

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.
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.
Hang th, ,,.Y, .,ring
from back plate side.
Fig. 14-14 Direction of spring
14 - 9
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.
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 accord-
ance with "4) Adjustment of shoe clear-
ance".
h. Adjust the parking brake cable at the park-
ing 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 accord-
ance 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. 14-15 Connecting parking brake cable
 5) Rear wheel cylinder and anchor block

Piston Cylinder body COMPL

I I
Piston head Cup

Fig. 14-1ti Adjustment hole in brake drum

j

\ \Adjust.,
Block COMPL

Fig. 14-18 Components of rear whe

Reduce the clearance
cylinder and anchor bloc,.

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
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
..
3 .
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 sur-
-l
face of the anchor block, the outtsiue L-I

otherwise the brakes may drag. surface and threaded hole of the adju ster,
c. When the wheel is heavy t o turn or noise is and the threaded part of the supporter,
distinctly audible the shoe clear-
rn-.';~-.+ and apply a generous amount of grea!,,LP tn .,
ance. these I:
14-3. MASTER CYLI! 2) Operation when secondary (rear wheel)
brake line leaks
1. Operation Since there is no pressure rise in the second-
ary chamber even if the push rod moves, the
1) Normal operation secondary piston reaches the inner end of the
When the brake pedal is depressed, the master cylinder. Hc)wever the primaqr piston
primary and secondary pistons are moved in by compresses the fluici in the 1primary chamber,
the force transmitted from the pedal through .-. ...- -... -.
thus keeping the front Lo-r- lz- -e system
L
operative.
the push rod. As soon as the return port is
) Operation when primary (front wheel)
closed by the secondary piston, the hydraulic
rake line leaks
pressure begins to rise in the secondary cham-
Since there is no pressure rise in the primary
ber, consequently applying pressure to the rear
chamber even if the push rod moves, the
wheel cylinders, and then the pressure in the
primary piston comes into contact with the
primary chamber also rises, applying pressure to secondary piston and pushes it, thus keeping
the front wheel cylinders. he rear brake system operativ

..-,.,~
ter cylinder
-..-

7 O-ring

Fig. 14-1' 9 Component parts of master cylinder

14-11
 1 Secondary inlet 8 Boot
2 Tubeseat 9 Primary piston
3 Check valve 10 Secondary piston
4 Primary inlet 11 Piston stopper
5 Return port 12 Returnport
6 Release port 13 Cylinder
T14-0
7 Push rod
-
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

0.020 - 0.105 mm
Standard
(0.0008 - 0.0041 in)

Limit 0.15 mm (0.0059 in)

Assembly

1) Insert the secondary piston into the cyl-

Fig. 14-23 Re raster cyli:nder inder 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
3. Disassembly gasket.
4) Install the stop plate and secure it with the
1) Remove the boot from the cylinder body. snap ring.
2) Remove the snap ring and stop plate. 5) Insert the check valve spring into the
3) Remove the primary piston and the return cylinder block.
spring. 6) Install the seat end cap.
7) Install the push rod, with the boot pre-
4) Remove the piston stop and gasket and viously installed on the push rod, to the
then remove the secondary piston.
!n remove cylinder bm~ ~'
5) Remove the cap and sez
the check valve.

1) Install the master cylinder in the reverse

4. Preparation for reassembly order of the removal.
2) After installing, bleed the brake system
The inside surface of the master cylinder ind check the operation of the master cylinder.
must be smooth and perfectly round. Replace 3) Torque specifications
the master cylinder if irregular wear or defects
are evident. Never correct the inside of the
master cylinder with sandpaper or other abra- Master I 3 8.0 - 12.0 kg-m
sive material. chassis rrame on left-
(58 - 87 ft-lb)
1) Before assembling, wash the inside surface hand-drive vehicle
of the master cylinder with clean brake fluid.
Be careful that dust or other foreign matter 1.5 - 2.0 kg-m
does not enter the master cylindt:r during Brake pipe flare nut (1 1 - 14 ft-lb)
assembly.
14-4. BRAKE FLUID LEVEL the float is also lowered, and when it reaches
WARNING SYSTEM 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 ~
IICIVAI-

starter switch is turned to ON position a1nd the

parking brake is applied and goes out wh~ en the
parking brake is released, in order to provide a
means of checking the circuit for disconnection
and the bulb for burning out.

2. Replenishment of brake fluid

If the indicator light glows during operation,
immediately replenish the reservoir,with brake
fluid to the embossed level line.

NOTE:
Fig. 14-24 Components of brake fluid The brake fluid level drops as the brake
level warning system 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 4 Brake fluid level

2 Magnet 5 Cap
3 Holder 6 Float 14-5. PARKING BRAKE SYSTEM 1
T14-011
The components of the parking brake sys- 1
Fig. 14-25 Sectional view of brake fluid tem are shown in Fig. 14-26. !
reservoir 1
1. Parking brake lever and rod
1) Removal
a. Raise the vehicle and loosen the nut at the
1. Operation
rear end of the rod. Disconnect the rod f~.om
In normal condition, the float is above the the parking brake lever by removing the
reed switch; the magnetic field from the perma- clevis pin.
nent magnet placed in the float does not permit b. Remove the two 8 mm lever attaching bolts.
the reed switch to operate, the indicator light c. Separate the rod and cable by removin
being unlighted. As the brake fluid level drops nuts at the rear end of the rod.
 nFTA I I " n"

1 Rod assy (Hand brake) II Hancl braKe lever assy 21 G~L.,.,,,,, brake) I
2 Nut Button (Hand brake lever) 22 Clamp
3 Washer Spring (Hand brake lever) 23 Bracket (Hand brake RH:
4 Pipe (Hand brake) Screw (Pan head) 24 Bracket (Hand brake LH)
5 Joint (Hand brake) 15 Hand brake switch assy 25 Spring (Hand brake cable)
6 Cable assy (Hand brake) 16 Cord assy (Hand brake switch) 26 clevis pin
7 Spring washer 17 Bolt (8x18) 27 Clamp (Hand brake cable)
8 Bushing 18 Spring washer 28 Bolt
.
9 clam^ (Hand
- brake) 19 Clevis pin
10 Bc)It assy 20 Cotter pin

Fig. 14-26 Components of par

14 - 15
 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. Parking brake cable

1) Removal
a. Release the parking brake lever fully.
Disconnect the cable from the levers or1 the
rear brake assemblies.
Rod rrer p ~ n Remove the four cable clamps on the c:Toss-
; A member and hub by unscrewing the 6 mm
attaching bolts:
Fig. 14-27 Removing parking brake lever Remove the cable from the rod by removing
and rod 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~ at-
Fig. 14-28 Separating rod and cable taching bolts to the specified torque.

Inspection
Check the parlung brake lever for operation. Torque ( L I ~ I IH LI- ~ d.3 - 0.6 kg-m
Check the ratchet and hook for wear. taching bolts) (2 - 4 ft-lb)
Check the rod for damage and wear.
Check the clip and joint for damage and
wear. c. Connect the cable end to the lever at: the
3) Installation brake assembly.
a. Install the parking brake lever to the bracket
on the floor. NOTE:
Change the cotter pin with a new one an
sure to bend it into anchor shape.
Torque (Lever attach- 0.6 - 1.4 kg-m
ing bolts) (4 - 10 ft-lb) d. Install the cable return spring on the bra cket
which is attached to the hub.
b. Connect the rod to the lever. e. Insert the cable into the joint and instal1I tL l lhO ~

c. Install the joint, with the cable inserted in it, joint on the rear end of the rod with the
to the rear end of the rod, being careful nuts, washers and pipe in the correct 01 rder.
about the installing order of the nuts, f. Install the clip on the rod and attach the clin
washers and pipe. t o the bracket on the crossmember.
g. Adjust the cablt ibed in the follow-
ing 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. 3 to 4
T14-013
notches
25 kg (55 lb) of force]
Fig. 14-29 Parking brake lever ratchet
Limitof travel
[when pulled with approx. 6 notches '
25 kg (55 lb) of force]
Joint
Total notches provided 8 notches

Torque 0.3 - 0.6 kg-m

(Joint lock nut) (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 ...................................................................... 15- 3
STEERING WHEEL ....................................................................... 15- 4
STEERING SHAFT ....................................................................... 15- 6
BEVEL GEAR BOX ......................................................................15- 8
STEERING GEAR BOX ............................................................. 15-11
TIE-ROD END ............................................................................... 15-17
TROUBLESHOOTING .................................................................... 15-18
15-1. GENERAL DESCRIPTION
1. 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
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.

2. Specifications
Minimum turning circle 7.6 m (25 ft)

Inner 37"
Turning angle
Outer 33030'

Steering ratio 22.5

Steering wheel diameter 380 mm (15.0 in)

TYpe Rack and pinion

Pinion 7 teeth
Steering gear assembly
Rack 28 teeth

Backlash Less than 0.05 mm (0.002 in)

Thread diameter and pitch 18 mm x 1.5P (Left-hand screw)

Nut width across flats 22 mm

Tie-rod
Turnbuckle width across flats 19 mm

Tie-rod end ball stud 12 mm dia. x 1/10 taper

Pinion 15 teeth

Gear 21 teeth

Bevel gear assembly 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) 8 - 13 mm (0.32 - 0.5 1 in)

Side slip (with driver) IN 3 mm (0.1 in) to OUT 3 mm (0. 1 in)

7
15-2. STEERING SYSTEM

1. Component parts

1 Steering wheel 7 Bevel gear box

2 Steering shaft cover 8 Rubber bushing
3 Steering shaft 9 Torque rod
4 Cover 10 Rubber coupling
5 Clamp 11 Plate
6 Dust cover 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, Torque 2.5 - 3.3 kg-m (18 - 24 ft-lb)
steering gear box and steering wheel which are
installed on the vehicle. When installing the
steering system components, first temporarily 5) Tighten the clamp securing the steering
tighten their attaching bolts and nuts. Then shaft to the bevel gear box.
fully tighten them to the specifications in the
order of @ t o @ as indicated in Fig. 15-1, 1
Torque 2.5 - 3.3 kg-m (18 - 2 4 ft-lb)
ensuring that the components are aligned cor-
rectly with each other.
NOTE:
1) Tighten the bolts and nuts attaching the When tightening the clamp, pull the steering
rubber coupling.
shaft up so that the gap between the steering
2) Secure the steering gear box by tightening wheel and shaft cover becomes as follows.
the attaching bolts in the order of @, @, @
and @ . Make sure that there is a clearance of r-- I
4 to 8 rnm (0.16 to 0.3 1 in) between the pinion 1 - 3 mm (0.04 - 0.12 in)
of the steering gear box and the cross member. -
3) Secure the bevel' gear box with the rubber
6) ~ignren the bolts attaching the steering
bushing and clamp by tightening the attaching shaft bracket to the pedal bracket.
bolts to the specified torque.

1.O - 2.2 kg-m (7 - 16 ft-lb) 15-3. STEERING WHEEL

1. Construction

1 Horn key
2 Steering wheel
3 Horn cord
4 Cover
T I 5-002

Fig. 15-2 Construction of steering wheel

15-4
I 2. Removal
I 1) Remove the two screws at the back of the
i steering wheel and remove the cover.

Fig. 15-5 Cleaning contact points

2) With the front wheels in the straight-ahead

Fig. 15-3 Removing cover (steering wheel) install the steering wheel with the washer,
I lock washer and nut onto the shaft and tighten
I
the nut to the specification with the steering
I
2) Remove the steering wheel retaining nut spoke in the horizontal position.
and remove the steering wheel from the shaft.

Torque 2.2 - 2.8 kg-m

(Nut) (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 Fig. 15-6 Installing steering u
parts with new ones.

3) Install the cover on the steering wheel by

4. Installation tightening the two screws from the back of the
steering wheel.
1) Clean the horn contact points and slide 4) Check the horn operation by pushing tl
plate. horn key.
15-4. STEERING SHAFT

1. Construction

Right-hand

Ill
ering wheel
L ~ u l u m ncover
3 Combination switch
4 Hazard warning switch
5 Steering column
6 Steering shaft
7 Lower steering shaft
8 Rubber coupling
9 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

1) Remove the bolt of the clamp securing the
steering shaft to the bevel gear.
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.

3. Disassembly

1) Remove the steering wheel from the shaft.

Fig. 15-8 Removing clamp bolt
2) Remove the brush from the steering
column (R.H. drive vehicle only).
3) Remove the hazard knob, then the combi-
nation switch.
4) Remove the screws from each side of the
cover; remove the cover from the steering
column.

15 - 6
 NOTE:
a. On the left-hand drive vehicle, the steering
column and steering shaft cannot be dis-
assembled. 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. Assembly

1) Before assembling, wipe all frictional

surfaces and apply a coat of grease to them.
Fig. 15-9 Removing column cover 2) Secure the rubber coupling to the steering
shaft and lower shaft.

1.7 - 2.2 kg-m

5) Remove the snap ring (R.H. drive vehicle Torque
(12.3 - 15.9 ft-lb)
only)

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.
I 7) Install the brush in the hole on the
I
steering column, and secure it with the screw
(R.H. drive vehicle only).

6. Installation

Fig. 15-10 Renroving maP ring 1) Align the cutout on the bevel gear shaft
with that on the shaft; temporarily install the
shaft with the clamp.
2-- -L_1
"I A l l out the steen~~g snar't from the 2) Temporarily install the steering column
coluunn (R.H. drive vehicle only). assembly on the pedal bracket.
7) Remove the bolts securing the upper 3) Tighten the clamp (at the bevel gear shaft)
n~hl
-,Jer coupling in place. to the specified torque.

4. Inspection 2.5 - 3.3 kg-m

Torque
(18.1 - 23.9 ft-lb)
leck all disassembled parts for abnor-
ies. If necessary, replace. 4) Tighten the bolts on the lower side of the '

Zarefully check the following: steering column, then the bolts on its upper
Steering shaft, for bending or other side, to the specified torque. 1
iage.
Bearing, for wear, unusual noise or rough
tio on. .
Rubber coupling, for damage. 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.

2.2 - 2.8 kg-m

Torque
(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
colurnfi cover
0.1 - 0.15 kg-m
Torque
(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.

15-5. BEVEL GEAR BOX

1. Construction

1 Bevel gear (pinion)

3 Dust seal
4 Bearing
5 Gear box
6 Bearing

8 Adjuster
9 Cover
10 Retainer
11 Bearing
12 Oil seal
13 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.
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.
Fig. 15-14 Disconnecting torque rod from
pinion shaft
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. Disassembly and assembly
Since the bevel gear box is designed to be
used without maintenance or adjustment, do
not disassemble the unit unless it is to be
discarded. If it is defective replace as an
assembly.
4. 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. 15-16 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.
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

Torque
(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 1.0 - 2.2 kg-m

(Clamp bolt) (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 2.5 - 3.3 kg-m 9) Adjust the steering wheel position so that
(18 - 24 ft-lb) the spokes are horizontal when the front wheels
(Clamp bolt)
are in straight-ahead position.
, 15-6. STEERING GEAR BOX

I 1. Construction
\

T I 5-007
25 Oil seal
1 Nut 13 Tie rod end 26 Bolt
2 Lock washer 14 Nut 27 Spring washer
3 Stopper 15 Turn buckle 28 Cover
4 Rack 16 Nut 29 Packing
5 Cap 17 Tie rod 30 Retainer
6 Snap pin 18 Clip 31 Lock nut
7 Spacer 19 Boot 32 Adjuster
8 Clip 20 Gear box 33 Spring
9 Boot 21 Bushing 34 Sleeve
10 Tie rod 22 Bushing 35 Boot
11 Spring 23 Bushing 36 Pinion
12 Seat 24 Bushing 37 Bevel gear box

Fig. 15-18 Construction of steeringgear box

15 - 11
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

1) Hold the steering gear box in a vise and

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.
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

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.
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.

Fig. 15-23 Removing tie rods
5) Spread the lock washer at the rack end
and remove the rack stopper, lock washer and
nut. I
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
retaining seats from the rack.
NOTE:
Be careful not to damage the sliding surfaces
of the rack.
8) Remove the boot retaining clips and re-
move the boot from the gear box.
NOTE:
D o not pull the boot forcefully.
9) Remove the pinion cover and gasket by
removing the two attaching nuts.
Fig. 15-25 Removing pinion cover
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. Assembly
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.
ill
I
I
Fig. 15-26 Installing pinion
4) Install the pinion cover with the gasket,
two 6 mm bolts and spring washers.

I Torque 1 0.5 - 0.7 kg-m I Lever

I

I (~01;) (3.6 - 5.1 ft-lb)

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.
Fig. 15-28 Measuring pinion torque
7) Apply grease to the adjuster sleeve and the
inside of the adjuster bore in the gear box, and
insert the sleeve into position. 13) Insert the two gear box ball seats, spring,
8) Apply grease to the adjuster spring and spring seat, spacer and rack cap into the rack
insert it in the sleeve. hole in this order.
9) Apply sealant to the adjuster threads and 14) Install the tie rods after applying grease
screw in the adjuster into the gear box. on the ball seats and tie rod ball ends.
10) Install the stopper, lock washer and nut
in this order on the rack end.
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 Fig. 15-29 Installing rubber clip
position should be 0.01 to 0.09 kg-m (0.07 to
0.65 ft-lb), and the maximum torque through 16) Tighten the rack cap until the tie rod
the whole range of travel should be less than swinging load is 0.3 to 1.2 kg (0.7 to 2.6 lb)
0.22 kg-m (1.59 ft-lb). and lock it with the snap pin. Be sure to bend
After the above condition is satisfied, lock the snap pin center to prevent the pin from
the adjuster with the lock nut. 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 0.9 - 1.5 kg-m (7 - 11 ft-lb)

4) Connect the tie rod to the tie rod end by

Fig. 15-31 Locking snap ring
17) Install the covers on both ends of the
gear box.
5. Installation
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.
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
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

Torque 2.0 - 3.0 kg-m follows:
(Bolt) (14 - 22 ft-lb) a. Tighten the tie rod end nut and turnbuckl
b. Push the tie rod and its end fully backward
 Torque 8.0 - 8.5 kg-m
(Lock nut) (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 8) Move the tie rods back and forth to make
-
wrenches one to hold the turnbuckle and sure that they swing equally. The standard
amount of swing is more than 35 mm (1.38 in).
the other to tighten the n u t

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. TIE-ROD END
1. 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).
I Fig. 15-37 Removing ball stud
i 6 ) Grip the tie rod and check that it moves
I
II 2. Disassembly and assembly
The tie rod end cannot be disassembled.
Replace it as an assembly if defective.
I
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 dif-
ferent.
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 2.5 - 3.0 kg-m
tightening torque (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 IN 8 - 13 mm
unloaded) (0.32 - 0.5 1 in)
r
Torque - 8.0 - 8.5 kg-m
(Lock nut) (58 - 61 ft-lb)
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.

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. Replace.
6) Worn out tires. Replace.

2. 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 Tighten to correct torque.
rim nuts.
5) Distorted wheel. Correct or replace.
6) Damaged or worn wheel bearing. Repair or replace.
7) Uneven tire pressure. Adjust to correct pressure.
8) Damaged or worn trailing arm Re1dace.
bearing.
9) Worn king pin. Re1,lace.
10) Unbalanced brake drum. Replace.

3. 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) Incorrect engagement of steering Correct.
gear or bevel gear.
5) Excessive backlash. Correct.
 I
Trobuble and possible cause Corrective action

4. Steering wheel pulls to one side.

This condition is very dangerous to vehicles, and often attributable t o defective front
suspension.

1) Uneven tire pressure. Adjust to correct pressure.

2) Incorrect front wheel alignment. Correct.
3) Damaged or worn wheel align- Replace.
ment bearing.
4) Brake dragging. Adjust.

1 5. Abnormal noise.

1) Loose connections or insuffi- Tighten to specified torque.

cient tightening.
2) Damaged or worn wheel bearing. Replace.
3) Damaged or worn trailing arm Replace.
bearing.
4) Defective shock absorber. Replace.
5) Damaged or worn king pin and Replace.
bushing.
 CHAPTER 16: GEAR SHIFT SYSTEM

Page

16.1 . COMPONENT PARTS OF GEAR SHIFT SYSTEM .................... 16- 2

16.2 . GEAR SHIFT LEVER .................................................................. 16- 3
16.3 . GEAR SHIFT ROD .......................................................................16- 6
16-1. COMPONENT PARTS OF GEAR SHIFT SYSTEM

1 Gear shift lever 9 asher 16 Spacer

2 Knob 10 Bracket 17 Bolt
3 Boot 11 Bushing 18 Lever
4 Bolt 12 Washer 19 Gear shift rod
5 O-ring 13 Castle nut 20 Spring
6 Bushing 14 Cotterpin 21 Bushing
7 Spacer 15 Grease nipple 22 Spacer
8 Self lock nut 23 Washer
24 Flange nut

Fig. 16-1 Component parts of gear shift system

16 - 2
16-2. GEAR SHIFT LEVER securing the gear shift lever to the lever.
4) Remove the spacer, resin bushing, rubber
1. Removal washer and "0" ring.

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 NOTE:
lever. Check these fast wearing parts for wear or
3) Remove the bolts and self-locking nuts other damage. I f necessary, replace.

1 Gear shift lever

2 Lever
3 Bracket

T16-002

Fig. 16-2 Gear shift kver

 2. Disassembly a n d assembly

1) Remove the cotter pin, castle nut z - :

3 Rubber washer washer; detach the gear shift lever from :
boss.
6 Self locking nut

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
NOTE:

6) Remove the lever from the front side.

Before installing, apply a coat of greaa -
the bushing and "0" ring.

O-ring

T16-1::

Fig. 16-5 Removing lever Fig. 16-7 Assembling "0" ring

16 - 4
r-
I
i

?TE:
Insert the gear shift lever assembly into
boss, and secure it with the washer and
:le nut.

Be careful not to allow the "0" ring to slip

out of the bushing.

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

I
-
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
' 3TE: and rubber washer to the upper boss of the gear
Do not tighten the castle nut in excess of shift lever.
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
Apply grease through the grease nipple at
"0"
-I ring until old grease is forced out. bushing and spacer.

', OTE:
Perform lubrication every six months. 3) Attach the gear shift lever t o the lever
at the boss, and tighten with the self-locking
nut and bolt.

1.4 - 2.2 kg-m

Torque
(10.1 - 15.9 ft-lb)

3 Rubber washer

II 3.
Fig. 16-8 Greasing through nipple

Installation
6 Self locking nut

I
Secure the lever to the chassis frame with
- e four bolts and spring washers.

7.0 - 13 kg-m T16-003

Torque
(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 self-
locking nut.
1.4 - 2.2 kg-m
Torque
(10.1 - 15.9 ft-lb)
16-3. GEAR SHIFT ROD
R e m o v a l a n d installation
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.
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.
NOTE:
Always tighten the flanged nuts at the re?.
end of the gear shift rod t o the specifiei
torque.

NOTE:
Check the rubber bushing for wear. If
necessary, replace.

1 Engine mounting bracket

2 Washer
3 Flange nut
4 Gear shift rod
5 Rubber bushing
6 Spacer
7 Spring

T I 6-007

Fig. 1 6-1 1 Removing gear shift rod

16-6
 : PEDAL SYSTEh

'age

17.1 . COMPONENT PAR1rs OF PEDAL SYSTEM ................................17- 2

17.2 . BRAKE AN D CLUlTCH PEDAL ...................................................17- 3
17.3 . ACCELERATOR PEDAL ... ................................................17- 9
17.4 . CABLES .............................. ................................................17-10
17-1. COMPONENT PARTS OF PEDAL SYSTEM

t
A t
B

1
Plate 11 Bolt 21 Washer
2
Cover 12 Flange nut 22 Cover
3
Accelerator pedal 13 Spacer 23 Clutch pedal
4
Flange nut 14 Stop light switch 24 Spring
5
Clip 15 Pedal stopper 25 Pedal bracket
6
Cotter pin 16 Nut 26 Spring
7
Pin 17 Washer 27 Brake pedal
8
Clutch pedal stopper 18 Bolt 28 Bolt
9 Bolt 19 Nut 29 Stopper
10 Spring washer 20 Bushing 30 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 re-
moval.

1) Disconnect the steering shaft and pedal

bracket by loosening bolt and nut.

Fig. 17-4 Removing brake pipes

4) Disconnect the stop light switch harness

and turn signal unit harness.

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 2. Disassembly and assembly
cable to the pedal bracket and remove the cable
from the bracket by removing the inner cable 1) Brake pedal
from the slit. 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

2) Clutch pedal
a. Pull out the clip and the washer at the pedal
Fig. I 7-9 Removing pedal bracket 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.

NOTE: Fig. I 7-15 Removing brake pedal

, Apply grease' on the bushings before install-
I
ing brake pedal and clutch pedal to the
shaft.
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

b. Remove the clamp attaching the clutch cable

to the pedal bracket and remove the cable
from the bracket by removing the inner
Fig. 1 7-14 Removing brake pedal 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. Fig. 17-1 9 Installing pedal bracket
d. Pull out the clip and the washer at the pedal 2) After installing the clutch cable to the
shaft end. cable bracket, connect the cable to the clutch
pedal hook.

I I
Fig, 1 7-18 Pulling out clip
Fig. 17-20 Installing clutch cable

e. Pull the clutch pedal with the pedal IGLULII

3) Install the clutch cable outer end to the
cable bracket by inserting clamp into the slit.
spring and bushing off the pedal shaf

3) Assembly
Assembly is the reverse order of removal.

NOTE:
Apply grease on the bushings before install-
ing 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
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.
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.

1.5 - 2.0 kg-m

Torque:
(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

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)
7) Install the steering column bracket to the
pedal bracket and tighten the bolts.
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.
NOTE:
When adjusting the pedal play, try to adjust
to 1 to 2 mm (0.04 to 0.08 in) for better
pedal feeling.

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.

1 - 5 mm (0.04 -
Standard brake
0.02 in) at pedal
pedal play
pad center
Fig. 17-24 Adjusting brake f>edalplay

17-7
b. Brake pedal height when depressed
Full braking force must be obtained when 10 - 25 mm (0.39 -
Standard rllltrh
the brake pedal is depressed with approx. 30 0.98 in) at pedal pad
pedal pla:
kg (66 lb) of force. At this time the distance center
between the upper surface of the pedal pad
and the front pannel indicated in Figure
must be as follows.

Brake pedal height when depressed with

30 kg (66 lb) of force

150 - 160 mm
Standard
(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 NOTE:

in adjusting of brake pedal play. When the clutch pedal play is within the
3) After pedal height adjusting, check the standard value, the play measured at the
clutch pedal play by lightly pushing with clutch release lever pin is approx. 1 mm
your finger. (0.04 in).
 Fig. 17-28 Adjusting clutch pedalplay Fig. 17-30 Removing plate
3) Disconnect the end of accelerator outer
d. Clutch pedal height cable from the pedal bracket, by loosening
1) When the clutch is completely disengaged the 6 mm nut.
the clutch pedal height (distance between
clutch pedal pad and front pannel) must
be over 100 mm (3.94 in).

Over 100 mm
front pannel and
clutch pedal pad

Fig. I 7-31 Disconnecting accelerator cable

4) Remove the accelerator pedal as an assembly
Front panel
into the cabin.
- -

..,celerator pedal ass'y

T 17-004

Fig, I 7-29 Distance between front pannel and

clutch pedal pad

7-3. ACCELERATOR PEDAL

I. 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 4) Install the pedal cover and put the plate on
Check the removed parts for any wear, it, and tighten with two 6 mm nuts. 1
!
damage and deformation, and correct or replace
if defective.
0.2 - 0.4 kg-m
3. Installation Torque:
(1.4 - 2.9 ft-lb)
1) Insert the accelerator pedal assembly into
the hole of the floor from cabin side.
2) Put grease .on the end of accelerator cable 5) Fill the slit of pedal cover enough with
and connect it to the pedal lever. sealing material for waterproofing. Sealing
) After connecting the end of outer cable to I
material cemedine CS-301 equivalent. I
the pedal bracket, tighten the 6 mm nut.

OTE: 17-4. CABLES

Refer t o the paragraph of accelerator cable 1
in this chapter. 1. Cables layout

-%.

1 Choke cable 9 Clip (Rear bulkhead)

2 Clamp (Under floor) 10 Clamp (Transmission)
3 Accelerator cable 11 Clutch cable
4 Clip (Helper bracket) 12 Return spring
5 #1 Mark (White paint) 13 Clip (Protector)
6 Clamp (Side member) 14 Clamp (Rear crossmember)
7 Clip (Side member) 15 #2 Mark (White paint)
8 Clip (Water pipe bracket) 16 #2 Mark (White paint)

T17-005

Fig. 17-33 Cable layout of Right-hand drive vehicle

17 - 10
 1 Clip (Side member) 7 Clip (Rear bulkhead)
2 Choke cable 8 Clutch cable
3 Accelerator cable 9 Clamp (Transmission)
4 Clip (Front crossmember) 10 Return spring
5 Clamp (Side member) 11 Clip (Protector)
6 Clip (Side member) 12 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 4) Open the trap door on the upper side of
(Right-hand drive vehicle) the engine compartment.
5) Disengage the outer end of the accelerator On Right-hand drive vehicle
cable from the carburetor bracket, and remove
the accelerator cable together with its inner
cable end from the accelerator linkage.

(White paint)

&sf
tll
-_
-_ - %
T17-007
Marking (White paint)

0
1: 2- Tl7-008

On Left-hand drive vehicle

~2&mL/l--2
Fig. 1 7-3 7
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".
T 17-009
7) Check the cable for rough operation, rust
Marking (White paint)
formation or other damage. If necessary,
replace.
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.
4) Align the mark on the outer cable with the
clamp on the front end of the side member. Fig. 1 7-39
6 ) Fasten clips and clamps to retain the cable
at the designated points.
NOTE:
Make sure the cable is not sharply bent or
twisted, but is securely fastened with clips
and clamps.
7) Insert the inner cable into the cable end,
secure the outer cable end to the bracket, and
tighten the inner cable.
Fig. 17-40 Installing accelerator
cable
8) Apply a coat of chassis grease to the front
and rear inner ends at the connections.
ADJUSTMENT
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.
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.
3. C h o k e Cable
REMOVAL
1) Remove the choke cable knob and dress
nut.
Fig. 17-41 Removing choke cable knob
2) Remove the clips from the front panel.
3) Remove the front under cover, then the
clamp from the underside of the floor (R.H.
drive vehicle only).
4) Further removal procedures are the same
as for the accelerator cable.
INSTALLATION
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) T17-010
T I 7-007

Fig. 17-43
Marking (White paint)

4) For further steps, follow the same proce-

2' T17-008
dure as for the accelerator cable.

NOTE:
a. Tighten the inner cable on the carburetor
side in such a manner that it has no free
On Left-hand drive vehicle 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

1) Loosen the wing nut at the end of the

T 17-009 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.
Fig. I 7-45 Removing clutch cable
3) Disconnect the clutch cable from the
clutch pedal.
4) Remove the front under cover. On right-
11 hand drive vehicles, remove the clamp from
under the floor.
1
1 5) Remove the clip and clamp; discon,
the clutch cable. Refer to the instructi~ilr
under the heading "Cable Layout."
I the passenger compartment.
/ 6) Remove the under cover from the engine
compartment, and remove the cable from the
I floor.
I clamp at the transmission protector.
I pedal, pass its outer end through the bracket
Fig. I 7-46
7) Remove the cable return spring and dis-
connect the cable end at the clutch release
lever.
Remove the grommet from the floor, and
8)
pull the clutch cable from under the floor
through the grommet hole and move it toward
the rear of the vehicle.
Fig. 1 7-47 Removing clutch cable
9) Check the clutch cable for roughness,
improper operation, rust formation or other
damage. If necessary, replace.
INSTALLATION
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
2) Secure the grommet t o the hole in the
3) Fasten the clutch cable to the clutch
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 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 i
i
9) Install the clutch cable return spring. !

10) Attach the clutch cable to the clip at the

transmission protector, and secure it. I
I

11) Install the rear underside cover.

1 #Mark I

12) Loosen the wing nut on the cable end :

2 Clamp
3 Clutch cable T I 7-012
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 i

5. Speedometer Cable I

6 ) Fasten the clutch cable with clips and REMOVAL

clamps at the designated positions.
1) Loosen the speedometer cable securlng i
7) Attach a clamp to the rubber bushing for
bolt located to the left of the front wheel, and I
the clutch cable, and secure it to the lower face
pull out the cable.
of the transmission case with two bolts.

Fig. 1 7-52 Loosening speedometer

Fig. 17-50 cable installing bolt
( 2) Remove the hanger spring.
1 3) Remove the clip.
4) Remove the front underside cover (R.H.
drive vehicle only).
5 ) Remove the combination meter from the
instrument panel and disconnect the speed-
ometer 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.
2) Connect the speedometer cable t o the
cbmbination meter, t h e n attach the combina-
Fig. 17-53 Removing speedometer cable
tion 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
Fig. 17-55
:1, and secure it wit11 the bolt.

5) Attach the hanger spring to the speed-

ometer cable at the #1 mark, and secure it t o NOTE:
the fuel tank bracket. Align the #2 mark on the Always route the speedometer cable along
cable with the clip on the cross member, and the top of the front cross member when
secure the cable. laying it out on the underside of the floor.
On Right-hand drive vehicle
rl"--"'
+
j i . . . . _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
Fig. 17-58 the speedometer cable.

17 - 18
 CHAPTER 1 8: FUEL SYSTEM

Page

OUTLINE ......................................................................................... 18-2

REMOVING AND INSTALLING FUEL TANK ................ 18-3
REMOVING AND INSTALLING FUEL METER UNIT ............. 18-4
CLEANING FUEL TANK ............................................................. 18-4
REMOVING AND INSTALLING FUEL STRAINER .................. 18-5
REMOVING AND INSTALLING FUEL PUMP ........................... 18-5
FUEL PUMP .................................................................................. 18-6
FUEL CAP ....................................................................................18-7
18-1. OUTLINE

I
I

re DETAIL "C"
1 Clip 12 Aiuvent tube
2 Clip (Engine cooling) 13 Tube 23 Clip
3 Clip (Hose clamp) 14 Air breather tube 24 Insulator
4 Clip (Hose clamp) 15 Fuel tube 25 Clip
5 Fuel return hose 16 Clamp (Fuel hose) 26 Fuel filler hose
6 Fuel return pipe 17 Flange nut 27 Fuel filler pipe bracket
7 Fuel return hose 18 Fuel strainer 28 Fuel filler pipe
8 Delivery hose 19 Flange nut 29 Bolt
9 Delivery pipe 20 Valve 30 Fuel filler cap
10 Hose 21 Band 31 Packing
11 Pipe 22 Clip 32 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 ex-
panded gasoline. Moreover, a fuel vapor control
device is provided to prevent atmospheric pollu-
tion due to exhausting of the fuel vapor
(hydrocarbons) produced inside the fuel tank.
 1. Fuel vapor control device
0.80 - 1.OO kg-m
Tightening torque
1) Construction (5.8 - 7.2 ft-lb)
The vapors produced inside the fuel tank are I I I

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 .I1 ly

frame. bolts \
This vapor is sent to the combustion cham-
ber with the intake air and combusted when the
engine is started. The amount of fuel vapors
emitted is reduced considerably by the installa-
tion of this device.

Fig. 18-3 Removing drain plug

3) Remove the protector (fuel tank) and

disconnect each hose (fdler, delivery, return).
To Fuel tank

Fig. 18-2 Float valv,

-2. REMOVING AND INSTALL-

ING FUEL TANK
Fig. 18-4 Disconnecting hoses
I
/ 1. Removal
,
I
1) Disconnect the (-) battery terminal. 4) Remove the protector (tube) from inside
2) Remove the fuel tank drain plug and the wheel apron and loosen the clip of each
remove the filler cap. tube (air vent, air breather).
Drain the fuel and then install the drain 5) Detach the filler pipe clip and pull out the
plug. hose from the tank.
I
6) Loosen the fuel tank,mounting bolts and NOTE:
place the fuel tank at an angle and pull slightly Be sure to install the washers, cushions and
down and to the right. spacers correctly.

Fuel tank mount-

ing bolt tightening 1.2 - 1.6 kg-m
torque (8.7 - 1 1.6 ft-lb)

t'ng ,
bolts
18-3. REMOVING AND
n plug INSTALLING FUE L METE
. . 1
, G. UNIT
Remove the 5 nuts holding the fuel meter
unit and remove the unit. The unit can be
Fig. 18-5 Loosening mounting bolts
replaced with the tank installed.

7) Under this state, remove the air breather 0.12 - 0.3 kg-m
tube and air vent tube from the fuel tank and Tightening torque
(0.86 - 2.2 ft-lb)
loosen the three clips holding the air breather
tube.
8) Under this state remove the fuel tan1

2. Installation

1) Installation is the reverse of removal.

Fig. 18-7 Fuel meter unit

I Left hand side 18-4. CLEANING FUEL TANK

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.

I Right hand side

T18-003

Fuel tank 31 L
capacity (8.1 U.S.gal., 6.8 Imp. gal.
Fig. 18-6 Installing the fie1 tank
 18-5. REMOVING A N D
INSTALLING F U E L
STRAINER

1. Removal

1) Remove the fuel strainer installing nut.

2) Disconnect the rubber hose (tank - strain-
er) and the rubber hose (strainer - pipe) from Case Element Cap
the strainer after loosening the hose clips.

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. REMOVING A N D
INSTALLING FUEL PUMP

1. Removal
1) Remove the fuel tank.
2) Loosen 6 fuel pump installing screws, and
Fig. 18-8 Removing fuel strainer the fuel pump assembly is detached from the
tank.

2. 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. Fuel strainer constructic Fig. 18-10 Removing fuel pump

1
I The fuel strainer is a cartridge type wlhich
I cannot be disassembled.
I Replace the strainer every 20,000 km 2. lnstallation
i, . (12,000 miles) or one year under normal usage
I conditions. Installation is the reverse of r~
emoval.
 1. Specifications
0.12 - 0.30 kg-m
ing screw tighten-
(0.86 - 2.2 ft-lb) TYpe Centrifugal type pump
ing torque
Discharge Less than - 0.18 kg/cm2 @ 12V
pressure (Less than 2.6 psi @ 12V)
NOTE:
a. When installing fuel pump, apply a sealing Over 20&hr
compound "CEMEDINE 1115" on t h r""" ....
~ad Discharge
(5.2 U.S.gal./hr, 4.4 Imp. gal./hr)
@ 12V
portion of 6 installing screws. volume Over 10L/hr
b. Be careful not to damage strainer, hose, har- (2.6 U.S.gal./hr, 2.2 Imp. gal./hr)
ness, etc. When installinu fuel pump. @ 1ov

Electric Below 1.5A @ 12V

current Below 1.8A @ 15V
18-7. FUEL PUhnr Starting
Below 8V
voltage
Fuel pump is fitted in fuel tank.

Construction a n d operation

Fig. 18-11 Fuel pump assembly

1 Battery terminal 7 Armature

2 Grounding terminal 8 Fan
3 Brush holder 9 Relief valve
+ Brush 10 Magnet holder
5 Motoryork 11 Strainer
6 Magnet
T18-006

Fig. 18-13 Fuel pump construction

Runner fan connected t o motor shaft is driv-

en by motor. Fuel sucked into the runner fan
Fig. 18-12 Location of fuel pump through the strainer is forced feeded into the
outlet path and finally to the carburetor by 18-8. FUEL CAP
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. Removal and installation

Refer to 18-6. Fig. 18-14 Fuel cap

rE: Fuel cap is made of plastic.

:uel pump should be replaced in fuel pump
ssembly.
When removing the cap, release lock by turn-
ing 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 . INSPECTION ................................................................................ 19-3
19.4 . REINSTALLATION ........................................................................19-4
19-1. GENERAL DESCRIPTION
Inner wall
lpes and partitions
Fig. 19-1 Inner construction of the muffir
1) Features:
Heat insulation type exhaust system has
been adopted for keeping off the compartment
and exhaust system parts from thermal radia-
tion harm.
a Muffler is of double heat insulation and ex-
pansion 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) Components of exhaust system:
I
Fig. i 9-2 Component parts of the exhaust system
Outer wall
.acket
T19-001
I
with flat plate suspension on the left side
I
end.
a Muffler inner wall, pipe and partitions have
adopted stainless steel which has superior
features with thermal strength and high '
temperature oxidization resistance. I
$
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. 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).
1 Fig. 19-3 Removing 6 mm bolts
c. Detach the bracket "E" from the muffler by
1 loosening the seven 8 mm bolts (three on
! muffler side and four on transmission side).
Fig. 19-4 Removing bracket
d. Detach the bracket compl. from the muffler
by loosening the two 8 mm bolts (on muffl-
er side and three 10 mm bolts on transmis-
sion side).
e. Disconnect the muffler from the exhaust
flange by loosening the four 8 mm nuts.
Fig. 19-5 Disconnecting muffler fiom
exhaust manifold
NOTE:
Don't detach the exhaust flange from the
cylinder head.
f. Take out the muffler assembly from the en-
gine after loosening the two 8 rnrn bolts con-
necting the muffler center bracket-A and the
bracket on transmission.
19-3. 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 Muffler assembly
2 Bracket compl.
3 Gasket
4 Bracket-E
5 Bolt
6 Washer
7 Nut
8 Nut
9 Spring washer
10 Washer
11 Bolt and washer assembly
12 Bolt and washer assembly

T19-I

Minimum allowable
Item Location
clearance
A Between muffler and crossmember 30 mm (1.18 in)
B Between bracket compl. and crossmember 20 mm (0.79 in)
C Between muffler and bumper 40 mm (1.57 in)
D Between tail pipe and hood stopper 15 mm (0.59 in)

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" part (manifold
flange part) nuts diagonally.
2.7 - 3.7 kg-m
for "a" part (manifold
(19 - 27 ft-lb)
1
I
NOTE
a. Since the nuts are made of stainless steel, be
1 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.
' the specified value, loosen each connecting
c. I n order to check each breacket installing
position for difficulty, after tightening the
I
nuts, turn each temporarily tightened bolt
by fingers.
I
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
1.6 - 2.6 kg-m
for "b,d,e and f '
parts. (1 2 - 19 ft-lb)
Tightening torque 3.4 - 4.0 kg-m
for "c" part. (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 ex-
haust 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 mani-
fold).
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
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. HEATER AND VENTILATOR CONTROL SYSTEM

1. Construction

Outside air intake

1 Outside air intake shutter

i
2 Ventilator shutter
3 Instrument panel
4 Heater unit
5 Room shutter

Inside air circulation

r,

T20-001

Fig. 20-1 Construction of heater and ventilator control system

20-2
2. Heater and ventilator control levers 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 temper-
ature of the air flow discharged from the heater
unit.
1) 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.
Fig.20-2

1 Outside air intake shutter

2 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 Fig. 20-4 Disconnecting control cab/
outside air intake, ventilator and room
shutters open and outside air flows into the 3) Disconnect the control cable clan .
compartment in response to the car speed. remove the control cable from the duct as-
d. CIRC sembly .
With the lever set at the CIRC position, the 4) Remove the heater fan switch harness.
outside air intake shutter closes and the 5) Remove three tapping screws fixing the
ventilator and room shutters open. Inside lever assembly to the body panel.
air is then directed through the outlets and
recirculates inside the passenger compart-
ment.

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 Fig. 20-6 Removing tapping screw of lever
gradually increases the temperature of the air assembly
flow.
6 ) Remove the lever assembly by pulling it
out.

20-2. 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 "Re-
moval 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:
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 ' moval of instrument panel.")
7) Installation the lever assembly in the
reverse order of removal.
20-3. V E N T I L A T O R DUCT
REMOVAL AND INSTALLATION
1) Remove the instrument panel. (See "Re-
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

4) Remove two screws fucing the ventilator

duct to the lower part of the instrument panel.

Fig. 20-8 Shutter closing position

Fig. 20-10 Removing ventilator duct installing

screw
5) Remove the license plate. 7) Remove the duct assembly after movi
6) Remove four tapping screws fixing the air to left side.
flow ventilator duct to the front panel. 8) Install in the reverse order of removal.

NOTE:
a. When mounting the duct assembly, re-
place the urethane (671 042040) containing
sealing agent by new one to prevent water
leakage through the junction of the front
panel and the duct.
Va. b. Apply sealing agent (Cemedine 366E)
& II Screws to front panel mounting screws before
. * ~ '
-

installation.
c. Fix the control cable by attaching the
Fig. 20-1 1 Removing ventilator duct instaffing firmly.
screw
20-4. HEATER UNIT

1. Component parts of heater unit

-

19

1 Gasket 12 Rubber washer 23 Room shutter gasket

2 Heater shaft 13 Heater fan 24 Tapping screw
3 Case B 14 CaseA 25 Clip
4 Flange nut 15 Resistor 26 Heater cock
5 Screw 16 Heater air vent hose 27 Reservoir tank hose
6 Clip 17 Room shutter gasket 28 Hose clamp
7 Heater shutter 18 Cord 29 Hose
8 Hose clamp 19 Screw 30 Clip
9 Heater core 20 Drain hose 31 Screw
10 Nut 21 Fan motor 32 Spring washer
11 Washer 22 Clamp 33 Washer

T20-003

Fig. 20-13 Component parts of heater unit

20
2. Specifications
I
2100-10% Kcal/H Water and air temperature difference 6S°C
Heating capacity
or more Water flow 360!2/H

Air volume 156-10% m3/H

Blower speed 2900 rpm Sirocco fan 1 10 mm dia.

Input Under 55 W

Standard voltage 12V

Core size 97x 115x66

!

Pressure check 2 kg/(

3. Removal

1) Remove the ground cable from the battery.

2) Completely drain the engine coolant.
3) Remove the defroster duct from the heater
unit.

Fig. 20-15

6) Remove the three tapping screws securing

the control lever assembly, and detach the
control lever assembly.

Fig. 20-14

4) 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. Fig. 20-16
7) Lift out the defroster duct on the driver 11) Remove the three 8 mm flanged nuts
side. 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 Fig. 20-20
hose from the heater tube.

4. 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. 20-18 Removing water outlet hose

Fig. 20-1 9 Removing air vent tube 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.

NOTE:
a. Clamp the control cable when the shutters
and cock assembly are closed. After clamp-
ing it properly, make sure all shutters and
the cock assembly function properly.
Fig. 20-22
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
21- 3. BODY PARTS ................................... 21-6
21- 4. DOORS .... ................................... 21-15
21- 5. WINDSHIELD GLASS ...... ............... 21-29
El- 6. INSTRUMENT PANEL ..... ............... 21-31
21- 7. SEAT ................... ...................... 21-38
1- 8. INNER TRIM ............. ...................... 21-40
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 Reservoir tank flap 16 Bracket

2 Front pillar 17 Front fender
3 Pillar 18 Side gate
4 Front rail 19 Rear gate
5 Roof panel 20 Side gate lock
6 Drip rail 21 Rear fender
7 Weather strip 22 Hinge
8 Shutter 23 Floor
9 Front panel 24 Chassis frame
10 Back panel 25 Front under cover
11 Cushion rubber 26 Center under cover
12 Guard bar 27 Rear under cover
13 Hanger 28 Engine room cover
14 Center pillar 29 Under cover bracket
15 Cab floor
T21-001

Fig. 21-1 Component parts of body construction

2. Low bed truck

1 Reservoir tank flap 17 Front fender

2 Front pillar 18 Side gate hoc
3 Pillar 19 Side panel
4 Front rail 20 Floor
5 Roof panel 21 Rear gate
6 Drip rail 22 Hinge
7 Weather strip 23 Side gate
8 Shutter 24 Gate lock
9 Front panel 25 Side panel
10 Back panel 26 Gate lock
11 Cushion rubber 27 Chassis frame
12 Guard bar 28 Front under cover
13 Hanger 29 Center under cover
14 Center pillar 30 Rear under cover
15 Cab floor 31 Engine room cover
16 Bracket 32 Under cover bracket T21-002

Fig. 21-2 Component parts of body construction

21 -3
3. VAN

1 Reservoir tank flap 17 Bracket

2 Pillar 18 Rear shelf
3 Front pillar 19 Center pillar (Inner)
4 Front panel 20 Side rail
5 Weather strip 21 Lower slide rail
6 Drip rail 22 Rear quarter panel (Inner)
7 Shutter 23 Rear quarter panel (outer)
8 Front rail 24 Upper slide rail
9 Roof panel 25 Center pillar (Outer)
10 Rear rail 26 Gusset
11 Cab floor 27 Chassis frame
1 2 Fender 28 Front under cover
13 Back panel 29 Center under cover
14 Hand brake cable protector 30 Rear under cover
15 Reinforcement 31 Engine room cover
16 Center floor panel 32 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. BODY PARTS 3) Remove two 8 m m bolts -under the
bumper from the front under cover.

1. Front bumper

REMOVAL AND INSTALLATION

1) Remove front combination light.

Fig. 21-7 Removing bolt

4) Remove two 10 mm bolts from the com-

bination 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

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
Fig. 21-6 Removing screw frame.
 Fig. 21-9 Removing rear bumper Fig. 21-1I Removing bolt

3) Remove two 8 mm bolts under the front

Installation is the reverse order of removal. bumper.
2)

3. Front under cover

Fig. 21-12 Removing bolt

4) On the right-hand drive vehicle, remove

two 6 mm bolts installing the under cover to
the body.

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 Fig. 21-13 Removing front under cover
each side of chassis frame. (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)
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.
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.
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 instru-
ment 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 har-
ness, 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) Drain the coolant from the radiator.

When draining the brake fluid, use rags,
etc. to keep the oil off the floor. 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 Fig. 21-25 Draining coolant

I 21 - 10
11) Disconnect the two radiator hoses from
the cooling pipes.
Disconnect the reservoir tank inlet hose and
heater hose from the pipes.
Fig. 21-26 Disconnecting hose
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. 21-27 Disconnecting air breather tube
14) Unscrew the fuel filler pipe mounting
nut.
Fig. 21-28 Loosening nut
15) Remove two 4-mm fuel filler pipe and
fender coupling screws.
Fig. 21 -29 Removing screw
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 removing the setback.
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 gradu-
ally lifting the body.
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
3. installation
Installation is the reverse order of removal.
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.
e. treno eacn c ~ securely.
~ p
f. Bleed all the air from the brake line for all
four wheels.
21-4. DOORS

A. COMPONENT PARS OF DOORS

DETA l L "A"

DETAIL "B"
DETAIL "C"

1 Cab door panel 11 Cab door latch

2 Sash 12 Striker wedge
3 Spring 13 Door striker
4 Cab door hinge 14 Spacer
5 Weather strip 15 Run channel
6 Cab door regulator 16 Door glass
7 Regulator handle 17 Cab door remote control
8 Outer handle 18 Escutcheon
9 Sealing cover 19 Door handle
10 Pull handle T21-018

Fig. 21-34 Component parts of cab door

-

DETAIL "D"
DETAIL "B"

1 Weather strip 11 Suspender

2 Slide glass rail 12 Plate
3 Slide glass frame 13 Inner handle
4 Slide glass 14 Escutcheon
5 Slide door panel 15 Slide door remote control
6 Slide door upper arm 16 Door latch
7 Outer handle 17 Wedge
8 Slide door lower arm 18 Spacer
9 Slide door stopper 19 Striker
10 Striker 20 Slide door arm

T21-019

Fig. 21-35 Component parts of slide door

21 - 16
DETAIL ' A "

DETAIL 'C" DETAIL "D'

1 Weather strip 8 Key lock

2 Weather strip 9 Latch
3 Joint 10 Striker
4 Moulding 1 1 Stop nut
5 Back door glass 12 Back door hinge
" Sack door panel 13 Back door stay
31ip 14 Stopper

T21-020

Fig. 21-36 Component parts of back door

21 - 17
B. CABDOOR 2. Door hinge
1) INSPECTION
1. Door lock striker
a. When the door rattles in the axial direction
1) ADJUSTMENT and right angle direction, tighten the hinge
Move the door lock striker mounting posi- mounting bolts.
tion up and down and left and right, and adjust b. When the hinge pin section rattles, repla1
in the front and rear with shims so that the the hinge assembly.
door is closed easily and does not rattle. 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 trans-
versal 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. Fig. 21-39 Adjusting door hinge
2) Turn the .wedge around the pin with
the wedge centering on the wedge c. Small amount of adjustment in the door
transversal direction and vertical direction
receiver.
3) Loosen screws. can be performed by loosening the door side
4) Close the door to check play of the hinge.
door.

Fig. 21-38 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.
Fig. 21-41 Removing door trim
b. Remove,the sealing cover.
Sealing cover
Fig. 21-42 Removing sealing cover
c. Place the glass in the middle position (verti-
cal) and remove two regulator rail mounting
bolts.
Fig. 21-43 Removing bolts
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 -44 Removing glass
e. Remove the window regulator mounting
bolts and remove the regulator from the
working hole.
Fig. 21-45 Removing regulator
2) 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 regula-
tor 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. -

Fig. 21-47 Rerno.ving rear <

5. Door lock

1) REMOVAL AND REINSTALLATION b. Remove the stopper (sliding door) from the
a. Remove the door trim, and the service hole lower rail.
cover, and raise the glass to the top.
b. Remove the safety knob, and disconnect the
outer handle and inner remote wire con-
nection. Slide
c. Unscrew the door lock mounting screws, and
remove the lock through the working hole.
d. Installation is the reverse of removal.

Removing stopper (sliding door)

c. kemove the stopper (center arm) from the

center rail.
Marking the mounting position during re-
moval 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. Floor
'
When moving the door, be careful that the
door is not slanted.
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) tem-

porarily (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. r (center arm)
d. Install the stopper (sliding door). At this
time, insert the flange of the stopper secure-
ly between the flanges of the rail. 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: uuur

Tightening torque:
loor
Stopper (sliding door)
8 mm bolt:
1.2 to 1.4 kg-m (8.7 to 10.1 ft-lb) Fig. 21-56 Adjusting sliding door
5 mm bolt:
0.25 to 0.30 kg-m (1.8 to 1.0 ft-lb)
Stopper (center arm)
8 mm bolts: When inequality has appeared between door
1.O to 1.2 kg-m (7.2 to 8.7 ft-lb) and pillar, adjust it by moving the upper arm or
striker to the left or right.

3) Removing and installing the galss

The glass can be removed and installed
together with the rubber.

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
Rennote cotrol wire
3r C

Sliding door
T21-023
'""'
rter handle

Fig. 21-60 Contact between sl

and suspender Fig. 21-61 Component parts of door kztch
a. Adjustmc.. t ) Remove the mounting bolt and two
1) Fix the connector so that there is no mounting screws, then remove the latch.
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 push-
button, and confirm moving of the phion
by hand.
,

4 Fig. 21-64 Removing latch

Push lever T:

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 rwss-
ing 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 Inspection and corrective action

Door closes Striker (latch) position Is vertical direction good? Good if door is
poorly. incorrect. Is the door too far inside? locked when
pushed by hand.
Move in arrow direction.

Fig. 21-66

topper (center arm) Temporarily fasten the stopper, close the door
I position incorrect. complete, and then retighten the stopper.

Stopper (center arm) Replace bushing. (Install a bushing which can be

bushing deformed or easily rotated by hand.)
Coat the inside and outside periphery of the
bushing with grease.

/
topper (center arm)

Fig. 21-67
 Symptom Cause Inspection and corrective action

Door closes Latch pinion cover and Insert the spacer under the striker as required for
poorly. striker mesh when the adjustment.
door opened and closed.

-*
sw
Latch

Fig. 21-68
Pinion

T2
C1W-025
w

Rattles when Striker protrudes too far. 1 inside.

vehicle is
moving. I

ker

Fig. 21-69

Suspender and striker Adjust so that the difference between the sus-
(suspender) position pender and striker (suspender) position is within
incorrect. 1 mm (0.04 in)
When the striker (suspender) is eccentrically
worn. replace.

Strker
(svsprd..)

Fig. 21-70
 Cause I Inspection and corrective action I
Rattles when Roller is n o t moving. Apply grease between the roller and shaft.
the door is slide.
Door doesn't Roller eccentric wear Replace the roller, coat the shaft with grease,
slide smooth. and inside and outside and confirm that rotation of the roller is
diameter wear. smooth.

Foreign matter such as Remove the foreign matter and keep clean inside
the sand, mud, etc. are of the rail.
fitted on the roller

Door doesn't Center arm spring perma. Coat the spring with enough amount of grease.
open nently strained o r spring When the spring is permanently strained, replace.
sufficiently . coils are rubbed each
(Door does n o t other.
fly open when
outer handle
push button
depressed.)

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. Stay
1) REMOVAL
2. Door hinge a. Remove the nuts mounting the stay upper
1) INSPECTION from the door (hinge) with the door opened.
- .-
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 ad-
ustment by loosening the door side hinge
3olts. 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) INSTALLATION
Installation is the reverse of removal.

4. Door lock
1) REMOVAL
a. Remove the door trim.
b. Remove the door lock mounting bolts and 21-5. WINDSHIELD GLASS
remove the lock from the working hole.
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.

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.
1 Work cord
2 Weatherstrip
Fig. 21-82 Fitting work cord
4) Put the glass into the correct position
from the outside, pull the work cord into the
inside of the body.
L
~ r kcord
Fig. 21-83 Installing windshield glass
5) Pushing the glass from the outside, gradual-
lv 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.
Fig. 21-84 Applying sealing compound
Body .panel
Sealing compound
A24-090
6 ) Return the wiper arm to surface of the
glass.
1 21-6. INSTRUMENT PANEL

1. Component Parts
I RIGHT-HAND DRIVE VEHICLE

1 Front panel stay 11 Ash tray holder

2 Instrument panel retainer 12 Ash tray
3 Instrument panel 13 Glove box lid
4 Instrument panel cushion 14 Lock
5 Instrument panel 15 Pocket
6 Lighting switch 16 Defroster nozzle
7 Fuse box lid 17 Defroster duct
8 Wiper switch 18 Ventilator duct
9 Washer pump 19 Ventilator duct
10 Label 20 Control lever T21-027

Fig. 21-86 Component parts of instrument panel

21 - 31
LEFT-HAND DRIVE VEHICLE

1 Front panel stay 11 Ash tray holder

2 Instrument panel retainer 12 Ash tray
3 Instrument panel 13 Glove box lid
4 Instrument panel cushion 14 Lock
5 Instrument panel 15 Pocket
6 Lighting switch 16 Defroster nozzle
7 Fuse box lid 17 Defroster duct
8 Wiper switch 18 Ventilator duct
9 Washer pump 19 Ventilator duct
10 Label 20 Control lever T2 1 -028

Fig. 21-87 Component parts of instrument panel

21 - 32
 2. Combination meter 3. Ash tray

REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION

1) Remove four combination meter installing 1) Pull out the ash tray.
screws. 2) Remove two 5 mm tapping screws mount-
ing the holder and remove the holder.

Fig. 21 -88 Removing combination meter Fig. 21 -90 Removing holder

2) Disconnect the speedometer cable. 3) Installation is the reverse order of removal.

3) Take out the combination meter and then
disconnect speedometer cable and wiring 4. Glove box lid.
, harness junction block from back side of the
combination meter. REMOVAL AND INSTALLATION
1) Remove three 5 mm screws under the lid.

Fig. 21-91 Removing lid

Fig. 21-89 Disconnecting wiring harness

2) Pull out the glove box lid from the instru-

ment panel.
4) Installation is the reverse order of removal. 3) Installation is the reverse order of removal.
5. Glove box lid lock. 2) Pull out the fuse box lid from the instru-
ment panel.
After removing the instrument panel, per- 3) Installation is the reverse order of removal.
form 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 Flange nut 5 Screw

2 Retainer 6 Lock
3 Instrument panel 7 Tapping screw
4 Lid
T21-031

Fig. 21-92 Fig. 21-94 Removing glove box lid

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 -93 Removing screw Fig. 21-95 Removing fuse box lid

21 - 3 4
6 ) Remove 5 mm screw at the underside of NOTE:
the instrument panel center. When loosening the screws on the top of
the instrument panel, it is recommendable to
use short Pillips screwdriver or "L" shaped
one.
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 dis-
connect the wiper switch wiring harness and
windshield washer pipe.

Fig. 21-97 Removing screw

8) Remove four 5 mm screws upper the in-

strument paneland remove the retainer.
Fig Removing instrument panel

Fig. 21-98 Removing retainer Fig. 21-101 Removing wiper switch wiring harness

21 - 35
8. Front luggage shelf
(Right-hand drive vehicle only)
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
9. Air flow and heater control lever
REMOVAL AND INSTALLATION
1 ) Remove the instrument panel (See "Re-
moval of instrument panel.")
2) Disconnect control cable clamps to
remove the each control cable from the heater
unit.
Fig. 21 -1 03 Disconnecting control cable
21
3) Disconnect the control cable clamp to
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.
Fig. 21-1 04 Removing tapping screw of lever
assembly
6) Remove the lever assembly by pulling it
out.
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.
- 36
7) Installation the lever assembly in the 4) Remove two screws fucing the ventilator
reverse order of removal. duct to the lower part of the instrument panel.

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 "Re-
moval of instrument panel.") L

2) Remove the Air flow and heater control ews $

-
IrV.
. *.,b
h3,. .I
lever. (See "Removal of air flow and heater
control lever.") Fig. 21-109 Removing ventilator duct installing
3) Remove the heater unit. (See "Removal of screw
heater unit.")
7) Remove the duct assembly after moving it
to left side.
8) Install in the reverse order of removal.

NOTE:
a. When mounting the duct assembly, re-
place 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
Fig. 21-107 Removing heater unit firmly.
21-7. SEAT

1. Component parts of seat

Front seat

1 Front seat back rest

2 Front seat cushion
3 Rear seat back rest
Rear seat (Van only) 4 Rear seat cushion
5 Hook
6 Band
7 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 lift-
ing.

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. INNER TRIM

1. 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 Clip
7 Clip
8 Shroud trim
9 Insulator
10

T2 1-038

Fig. 21-1 16 Component part5 : of inner trim

2. Cab door trim

REMOVAL AND INSTALLATION NOTE:

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.
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:
Welded portion The resin clip can be removed easily ay using
the special tool shown in Fig. 21-125.

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) Installation is the reverse order of removal.

1 Trim panel
2 Clip NOTE:
3 Special tool If the removed resin clip is damaged, replace
T2 1-040
it with new one.
Fig. 21-1 18 Removing trim

3) Installation is the reverse order of removal.

4. Back door t r i m
3. Slide door t r i m
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION 1) Remove the resin clip from the back door
1) Remove the inner remote handle. inner panel with a (-) screw driver or special
2 ) Remove the .resin clip from the slide door tool to pull out the back door trim.
inner panel with a (-) screw driver to pull out 2) Installation is the reverse order of removal.
the door trim from the rail.

2
3
Screwdriver
clip
T21-041
I
Fig. 21 -1 19 Removing resin clip Fig. 21-121 Removing back door trim
21-9. INNER ACCESORIES

1. 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 \ .stalling it, be careful not t o dam-

age me screw because the screw is made of
The sun visor is removed by loosening the plastic.
tapping screws. The mirror is adjustable in up and down
direction by turning it.
3. Rear view mirror (inner)
The rear view mirror is fallen down resulting 4. Assist rail
from breakage of the screw made of plastic in
case of collision. And it can be removed by The assist rail can be removed by loosening
loosening the screw. two screws.
21-1O.OUTER ACCESORIES

1. 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 3. Rear view mirror
Loosen three screws, and the front side The rear view mirror is removed by loosen-
grille is removed. ing 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 . WINDSHIELD WIPER .................................................................. 22-2

22.2 . COMBINATION METER .............................................................. 22-7
22.3 . HORN ........................................................................................ 22-10
22-4 . TURN SIGNAL AND HAZARD UNITS .................................... 22-12
22.5 . SWITCHES ................................................................................... 22-14
22.6 . LIGHTS ......................................................................................... 22-16
22.7 . FUSE BOX AND WIRING HARNESS ....................................... 22-20
22-1. WINDSHIELD WIPER

1. Construction and operation

1 Wiper blade
2 Wiper arm

6 Washer
7 Cushion A
8 Cushion B
9 Wiper link
10 Packing
11 Wiper motor bracket
12 Wiper motor

Fig. 22-1 Wiper component parts

The wiper uses a small motor as the drive Wiper motor

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 igni-
tion-starter switch is in "ON" position until
the lever is pushed up and the cam inside the T22-002
motor reaches the specified position, since the b

circuit B-(cam)S -S2-(A)-E is closed. Fig. 22-2 Wiper wiring diagram

3) When the circuit is interrupted at the e. Remove both right and left wiper arms by
specified position, the circuit (A)-S2 -S1 -P-(A) loosening the wiper arm tightening bolt.
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.

-
Fig. 22-4

f. Pull out the rubber caps on the shaft and

2. 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 re-
move 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 in-
stalling nuts. (Three f lange nuts,)
remove wiper link installing 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) INSTALLATION
Fig. 22-3 Removing nfi Installation is the reverse of removal.

22-3
 Troubleshooting

Trouble Location Cause Checking method Corrective action

Faulty switch contact. Check voltage drop Replace the switch.

across switch and
operate the switch
several times.
Switch
Improper operation Check switching Replace switch.
Operating of switch or braking operation of contacts.
speed is current due Motor overheats.
low to short.

Imminent seizure of Motor growls in phase Grease or replace the

Linkage
arm shaft. with arm movement. arm shaft.

Blade tends to stick Raise the arm and Clean the blade and
Blade to the glass surface. check unloaded I glass surface.
operation. Replace the blade.

Short circuit in harness. Motor overheats. Repair.

Problem Loose harness Check connections. Take appropriate
with connection. action.
speed
changing Loose of switching Check the switching Replace the switch.
Harness action. action.
and
switch Faulty switch contact.

Use of wrong switch. Check the switch type. Replace the switch
with the specified c
Incorrect connection Match color coding. Correct connection
of harness.

Connection fault or Check the connections. Correct connections.

wiring error in S 1
(yellow) or B (blue)
circuit.
Incorrect
wiper Switch
Bad connection Disconnect the switch. Replace the switch.
stopping
between terminals 1 With the switch set to
and 2 of switch the off positi'on, check
continuity between
terminals 1 and 2.
Trouble Location Cause Checking method Corrective action

Dirty auto stop relay Remove the auto stop Clean the contacts.
contacts. cover and check. @o not deform the
Poor contact between relay plate in the
Stops at process.)
A and B due to
any Motor
foreign matter.
point
No break between B Remove the auto stop Correct by bending
and C of the auto stop relay cover and check. the relay plate.
relay.

Improper connection. Match color coding Correct connections.

Harness
and check Replace fuse.
Stops and
connections.
switch
Fuse often blown.

Armarure contact due Vibration occurs with Replace motor.

to worn bearings. motor disconnected
Wiper and hand held.
noise Excessive armature Noise appears when Carefully adjust play
shaft thrust play. motor is shaken in by means of the screw
direction of thrust. for this purpose.

Deteriorated or worn Check the edge of the

blade rubber. blade rubber.
Deformed blade Check the state of the
Wiping
rubber. rubber.
Abnormal trouble
noise Poor blade pressure Check the formed
distribution. portion of the blade
holder.

Worn motor brushes. Current does not flow Replace the armature
in armature. or motor.
Replace the brushes.
Seized motor shaft. Motor overheats in Replace the motor.
Motor
four to five minutes.
Short in motor, Wiper circuit fuse Repair the short or
beginning of short, or blows immediately. replace the motor.
heat damage.

D'-wn fuse due to

UIU Check other Replace fuse.
othc:r component components.
i n u~ i p e circuit.
r
Power
Wiper Loosen or open wiring Check wiring Restore to normal.
source
does not connection. associated with motor
and
operate and connector.
harness
Error in connection. Match color codes. Correct.
Ground fault. Check ground. Correct.
Trouble Location Cause Checking method Corrective action

Faulty switch Power not applied to Replace switch.

Switch
contact. motor.

Other components Check linkage. Correct.

Wiper or harness caught in
does not linkage.
operate
Linkage
Seized or corroded Shift fore and aft Re-install the clip.
arm shaft. movement of the arm Lubricate or replace
shaft should be the arm shaft.
possible.

Layer short in motor With arm lifted, Replace the armature

armature. current is excessive or motor.
(three to five times
normal).
Worn motor brushes. Motor stops under Replace the brushes.
light pressure on the
Motor
arm.

Imminent seizure of With arm lifted, Replace the motor or

Operating motor shaft. current is excessive lubricate the bearings
speed is (three to five times with engine oil.
low normal).

Low source voltage. Check the voltage, or Service the battery.

the state of other
Power systems (lighting).
Poor connections. Wiggle the connections Remove corrosion and
and or check resistance. re tighten connections.
harness
Short in harness. Motor overheats. Clear the short.
Poor ground. Check ground point. Retighten connection.
22-2. COMBINATION METER

1. 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
Q
9 Socket
10 Buzzer
11 Speedometer T22-005

Fig. 22-6 Combination meter

2. Removal and ins 2) Disconnect the speedometer cable.

3) Take out the combination meter and then
1) Remove four combination me:ter installing disconnect speedometer cable and wiring har-
screws. nesses junction block, from back side of the
combination meter.

Fig. 22-7 Removing comb in at^ion meter Fig. 22-8 Disconnecting wiring harness

22 - 7
4) Installation is the reverse order of removal.

3. Disassembly and assembly

1) Remove four tapping screws on lower

back side of combination meter and disassem-
ble the meter visor and lens complete.

Fig. 22-1 1

Remove three nuts and remove fuel meter

Fig. 22-9

2) Remove two screws installing the speed-

ometer gear.

Fig. 22-1 2 Removing fitel meter unit

5 ) Remove three nuts and remove thermom-

eter.

Fig. 22-10 Removing speedometer installing

screws

Fig. 22-13 Removing thermometer

3) Remove a screw on right side of combina-
tion meter panel and remove the speedometer
and combination meter panel as assembly. 6) Assembly is the reverse of disassembly.
4. Checking combination meter NOTE:
With the- drive shaft turning a t 1,020 rpm,
1) Speedometer the nominal indication is 60 MPH.
a. Indicated error as measured with a speed-
ometer tester is acceptable if it conforms to
values in the following table. With the drive b. When the pointer fluctuation is large, the
shaft turning at 637 rpm, the nominal cable may be defective or installation may
indication is 60 km/h. be incorrect.
Kilometer indication Mile indication
Nominal Nominal
indication 20 60 80 100 120 indication 20 40 60
(km/h) MPH
Tolerance -1 +u.4 +2 +3.8 +5 Tolerance -0.1 tT.5 t3.0
(km/h) -3.5 -2.6 -2 -0.6 -0 MPH -1.9 -1.1 -0.1

2) Fuel mete
Charge Ignition
a. Check for a grounding or open circuit warning light switch
between fuel meter and unit. Check if each
connection and contact are insufficient.
b. When unit terminal connection is discon-
nected, 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 situa- T22-013

tion, the heat coil of the meter is open.

. 4 Wiring diagram
~ i g22-1
3) Charge warning light
The charge warning light should light when 4. Thermometer unit
the ignition switch is turned to the first
position. One side of the light is connected to Thermometer unit is located on the cylinder
the ignition switch and the other side to the head.
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 shorten-
ed, 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. 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 Thermometer terminals

2 Fuel meter terminals
Oil pressure switch is located on the oil
3 Meter illumination light
pump body and wiring diagram is as shown in 4 High beam indicator light
the Figure. 5 Direct terminal
6 Meter illumination 1
7 Buzzer
8 Combination meter
9 Speedometer cable boss
10 Left turn signal light
11 Right turn signal light
12 Charge indicator tight
13 Hand brake and brake fluid level warning light
14 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, Ignition
2 1. Specifications
E!

- E!
.--a
0 if Voltage

Current
13V
+ 0.5 A
. T22-015

Basic frequency
3.0 - 1.0
330-370 Hz
Fig. 22-1 8 Wiring diagram of oil preasure Sound pressure 100- l l 0 d B
switch
2. Operation
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 cou-
rzuw
-- Battery
-
Fuse

pled 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
10V renge
the plunger returns to its original state by virtue T22-018
of spring force of the diaphragm. This action
compresses air in front of the diaphragm. At
Fig. 22-21 Horn inspection
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.

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. T U R N SIGNAL AND 3. Operating principles
HAZARD UNITS
Automatic flashing and snapping of those
1. Specifications units are accomplished by expansion-contrac-

. Front and rea; turn signal

light: 23W x 4
tion of a heater band and action of a snap
spring.

A Heater band
Side turn signal light:
Load 6Wx2
Turn signal pilot light:
3.4W x 2

72 - 98 timeslmin.
frequency

T22-021
2. Wiring diagrams
1) Turn signal unit Fig. 22-25 Operation A

=
-Turn
-- - - -signal - -,
- - - - -unit 3w Pilot
I I light
Fuse Bi I lcb', signal

' ' switch

= Battery &
T22-019 Fig. 22-26 Operation B

Fig. 22-23 Turn signal circuit

4. Cautions for handling the turn
signal light

2ight
2) Hazard unit 1) When replacing the bulb, strictly use speci-
fied one as follows:
Front turn
Side turn
12V - 23W

Lyi4pi
signal light
Front turn signal light
(12.8V - 1.8A)
Rear turn signal light
r.._.__.__-____-_
Rear turn signal light 12V - 23W
,*-. B : Pilot light
\

.__, Hazard Side turn signal light 12V - 6W

F&e L -.-- ----
-------. J

1 2 v - 3.4w
$ Battery Hazard unit Turn signal pilot light
23.4 m (14V - 0.24A)
r
L

T22-020 This type of unit operates by the current

through the lights therefore, if wrong rated
Fig. 22-24 Hazard unit circuit light is used in the circuit, the turn signal units
does not operate normally since different cur- at the left end of the bulkhead below the
rent flows through the circuit. 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 hazard units

6. 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) Burned out bulb Replace bulb
2) Defective switch R e p a i r o r replace switch
3) I m p r o p e r bulb installed Replace with specified bulb
4) P o o r ground a t bulb C o r r e c t the socket contact
5) P o o r wiring connectic C o r r e c t connections
Both sides d o n o t light
1) Blown fuse Replace the fuse
2) Open w i r e between battery and switch o r
poor connection R e p a i r o r replace wiring
3) Defective switch Repair o r replace switch
4) Both left and right pilot lights burned out Replace bulbs
5) Defective t u r n signal unit 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 Replace with specified bulb
2) P o o r ground a t bulb C o r r e c t the socket contact
3) Defective t u r n signal unit Replace the t u r n signal unit
Low flashing frequency
1) Low s o u r c e voltage Charge the battery
2) High wattage bulb used Replace with specified bulb
3) Defective t u r n signal unit Replace t u r n signal unit
22-5. SWITCHES

1. 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, un-
screw 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.
Forst
Pullfng posntion O o
Second 0
n"<,.,"" 0 . O . o

2. Ignition-starter switch
For right-hand drive, the ignition-starter
switch is attached by dress nut to the instm-
ment panel. For left-hand drive, the ignition-
-.
P
0
c .
C
0 5 = Y, starter switch is attached with steering lock
0 " - o" m
3 = a system located under the instrument panel.
E =
-5 :
P
L g,!2 Connections are made by means of a junction
&
a
- - I block.
3 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 un-
screwing 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

ltion switcln
3. Back-up l i g ht switch

REMOVAL AND REINSTALLATION

1) Open the trap door.
2) Take out the insulator.
Fig. 22-33 Combination switch
3) Detach the back-up light switch attached
.on the left side of transmission.
4) Reinstallation is the reverse of removal.

5. Wiper switch
The wiper switch is attached to the instru-
ment 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
Fig. 22-32 Back-up light switch screw is located at the bottom.

22- 15
 Fig. :op light switch (Left-hand drive)
Fk. 22-34 Wiper switch

6. Stop light switch

The stop light switch is mounted on the
pedal bracket and is operated by the brake
pedal. Fig. 22-36 Stop light switch (Right-hand drive)

22-6. LIGHTS

1. Specification

12V - 50W/40W (Right-hand drive vehicle)

Headlight
12V - 45W/40W (Left-hand drive vehicle)
Front combination light
Turn signal light 12V - 23W
Clearance light 12V- 5W

Side turn signal light 12V- 6W

Rear combination light
Turn signal light 12V - 23W
Stop and Tail light 12V - 21W/5W
Back-up light 12V - 12W
License plate light 12V - 1OW
Room light 12V- 8W
-
2. Headlight

Fig. 22-38 Removing headllight

1 Headllight assembly
2 Screw
3 Ring
4 Washer
5 Spring
6 Set plate B
7 Screw
8 Sealed beam unit
9 Set plate A ~22-025

Fig. 22-3 7 Heudllight assembly Fig. 22-40 Front combination light

3. Front combination light

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 (ad-
justing screws) until the spring tension be-
comes 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. 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 Fig. 22-43 License plate light
by depressing it and turning to the left.

The license plate light lights at both the first

Side turn signal light bulb
and second pull positions of the lighting switch.
When changing the bulb, remove the cover
and lens by unscrewing two cover mounting
6W screws, and remove the bulb by depressing it
and turning to the left.
 6. Rear combination light 1) Removal and reinstallation
a. Remove seven (Van) or four (Truck) lens
I 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
D
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.

1 Rear combination light ass'y 7 - Shade B

8 Lens complete
3 Bulb (12V-23W) 9 Pan-head screw
4 Bulb (1 2V-12W)

Fig. 22-46 Removing back-up light (Truck)

7. Room light

Truck Van

1 Rear combination @ht ass'y

2 Plate
3 Bulb (12V-21/5W)
4 Bulb (12V-23W)
5 Packing
6 Screw
7 Lens complete 1 Room light lens
8 Pan head screw 2 Room light
9 Screw 3 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. FUSE AND WIRING HARNESS

1. 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. Cautions for removing and

reinstalling the wiring harness
Fuse
1) Before carrying out operation, be sure to
Tail light, Licence plate light disconnect the battery (-) terminal.
5 (A)
2) When pulling out the wiring harness which
runs through inside of the front pillar, rear
Hom, Turn signal light,
Blower motor, Stop light, quarter and back door, tie the wiring harness
15 (A) with the wire or string and pull it out
Ignition coil
3) If the wiring harness is contacted with the
clamp or other parts, protect the harness
Hazard light, Wiper motor,
contacting point with the vinyl tape.
Headlight (main beam),
20 (A) Cigarette lighter, Tail light, 4) When installing the parts, do not put the
Radio harness between the parts and its fitting posi-
tion.
Headlight (low beam), 5) When connecting the connector, be sure to
Licence plate light, confirm the color cord of the connector with
20 (A) Room light, Tail light, the wiring diagram.
Clearance light 6 ) When connecting the battery cable, turn
off each switch and confirm whether the wiring
Starter, Heater fan harness is shorted or not by contacting the
25 (A)
battery cable t o the battery terminal.
22 - 20
 X - Chcck, atljust or III~I~IIIIIIII
CHAPTER 23 : MAINTENANCE SCHEDULE
R - Replace

,lace enaint