413
SECTION 1 .
ENGINE P
GENERAL DESCRIPTION =) ‘
“TROUBLESHOOTING FOR ENGINE
CAUTIONS FOR HANDLING
‘The engine includes mary pacts which were cut and The endjine oyiinderS are identified byinumbers of No.
grinded in the tolerance of 1/1000mm and it should be No.2, and No3(from the crank pulley side to flywheel
hanatee with special caren terns OF cleanness upon” side) sepia ey 3
checking and repairingits inside parts. Itis importantto Bye ie
keep the engine clean as a hatitual manner upon
repairing ts processed-ara abraded suriace
*+ Upon reassembly, apply erough engine oil on the
abraded suriace for protactve lubrication.
* Upon removing valves, pistons, piston rings, con
eating rods, connecting ‘od bearings, cfanksha
and jourral bearings, arrange it in order not to be
confused when itis reassembled
* Disconnect (—) cable from the batery before the
‘pair of engine to avoidthe possible damagesorithe
‘leotical pars or harness,
1. No.1 Cyinder
2. No2 Cyinder
3. No3 Cynder
FIG. 1 1 NUMBERS OF CYLINDERS.4
CAUTIONS FOR ENGINE INSPECTION
AND MAINTENANCE
Keep the following cautions to prevent possible dam-
age and obtain the best performance upon checking
‘and maintaining engine.
+ Keep the jack away from the bottom part of oil pan
while supporting the engine. Due to the narrow gap
betwee ollpan andi pump strainer, gettingthe jack
touchedeil pan can cause damage to the strainorby
direct contac.
* Disconnect) cable of battery for sure upon engine
work.
‘+ When to remove the air cleaner orintake manifold,
install a protective cover on the intake to prevent
the engine from foreign material input. If foreign
materialis come into the cylinder throuch the intake
manifold, it may cause a serious damage upon
running engine
CAUTIONS FOR FUEL SYSTEM INSPEC-
TION AND MAINTENANCE
+ Work ina place with excellent ventiation and no fre
source. No smokng is allowed.
+ When fastenthe plugbolt on the urion bolt such as
fuelfiterunion bots, the gasket should be replaced
with new one and tighten it with specified torque,
+ When tighten the fuel pipe flare nut, tighten it with
hand first and then wi specified torque
+ The connecting methods of fuel hose depend upon
the pipe types. Rofer to the msthoss stawn in the
figure
* Check the fuel system first for fuel leakage and then
take the following procedures.
+ Apply the pressuira to the tuo! line by operating fuel
pump in accordance with*On-carsewvicepracedures
of fel pump’
+ Check theleaking pointot tho fuel eyctomin this stato
= Fate —
| Astor the short pipe, insert the hose unti it contacts |
| tome pipe
| sing
er
Insert the hose up to the lug of pipe |
Asforthe bentpipa, insertihe hose up tothe bentpant
of the pipe. Joining length is about from 25mm to
aoe 25-30mn
Asfor the staightpipe, inser the hose wih the joinng
longth of 25mm — 30mm
VETTE,
= F—f=— 25-30ern
Clemo
37am
FIG. 12 HOSE CONNE
ron |1-15
SSS ee a
TROUBLESHOOTING FOR ENGINE
Condition Probable Cause Correction
Haid starting Malfunction of ignition system
Replace
Clean, adjust the plug
gap oF replace
(wih normal ranking) | + Fuse
+ Fauty spark plug
+ Electric leakage at high tension cord + Replace
+ Poo: connection of high tension cord orlead wires + Replace
+ Misadjustment of signal rotor air cap + Adjust
‘+ Improper ignition ming + Aajust
+ Fauty ignition col + Replace
+ Damage or loosening of distributor rotor and cap + Replace
Malfunction of the fuel system
+ Lack of fuel in the fuel tank + Feed fuel
+ Diny or doggad tue! fiter + Replace
+ Clogged fuel pipe + Clean
+ Malfunction of fue! pump + Replace
Low compression pressure * 5
| = Poo’ tightening spark plug or poor condition of + Tighten to the specified
gasket torque or replace gasket
+ Inadequate valve clearance + Adjust
= Leakage of valve seat + Repair seat
Interference of vave siem
Repair or replace valve
or valve guide
+ Low elasticity or damage of valve spring + Replace
+ Leakage at cylinder head gasket _ + Replace
+ Abnormal interference or damage 6f pistons and cylinders | * Replace giston ring
«+ Excessive wear o' pistons, rings, ard cyinders Replace rng ard piston
‘and boring or replace
oylinder
Others
+ Broken valve timing belt + Replace
* Malfunction of P.C.V, valve + Check and replace it
necessary
+ Loosening, damage or leakage of vacuum hese + Connect correctly or |
replace the hose
Lack of engne Low compression pressure | + See above |
Power Malfunction of igntion system
+ Improperigaiton tming + Adjust
+ Fauky spark plug + Adjust orteplace
+ Distibutor | + Repar orreplace
| including rotor
+ Eleatic leakage 01 poor connection of high tension + Replace or connect
cord correctly
+ Malfunction of advance angle system. Adjust or teplace |Condition Probable Cause | Correction
Lack of engine power Malfunction of fuel system
+ Clogged carburetor + Disessemble and clean
+ Clogged fuel ripe + Clean
+ Dirty or clogged ful fiter + Replace
* Diy oF clogged aircleaner element + Repiace or clean
+ Poor intake manifold gasket + Replace
Others.
+ Dragging brakes + Repair or replace
* Slipping cutch * Adjust or replace
+ Poor qualty gasoline
Rough engine Iding | Malfunction of fuel system
* Carburetor is dirty and clogged * Disassemble and clean
+ Dirt and blocking in air clearer element Clean orroplace
+ Poor manifold, cylinder head gasket Repace
Malfunction of ignition system
+ Malfunction of igniton system Adjust or replace
+ Electric leakage, poor connection of high tension card | + Replace or connect
correctly
+ Abrasion of distributor rotor + Repace
+ Poor ignition timing + Adjust
+ Loosening or damage of distributor eap + Ropiace
Low compression pressure
See preceding page
Others
+ Poor connection or camage or leakage of vacuum hose | + Replace or eannact
correctly
+ Maltunction of P.C.V. valve + Cheok and replace it
necessary
Engine hesitate Malfunction of ignition system
(Upon pressing |» Poor ignition timing | = Adjust
accelerating peda, | + Poor spark plug, poor adjustment of plug gap | + Repiace, adjust the gap
the engine makes | + Electric leakage, poor conection of high tension cord | + Replace or connect
delayed response | Malfunction of fuel system correctly
This situationis | + Malfunction of air leaner system + Clean or replace
remarkable wen | » Leakage at manifold gasket + Replace
cruising or staring) | Low compression pressure
Engine Surging Malfunction of fuel system
(Engine power + Clogged fuel fiter
makes fluctuation in| + Clogged o damaged fuel hose or pipe
afixed speedand | » Vacuum leakage at the intake passago.
See preceding page
Replace
Clean or modity
Repacegasketandtighten |
speed changes bolts or ruts
vnithout operating the | Malfunetion of ignition system.
accelerating pedal) | + Improper ignition timing + Adjust
+ Malfunction of distributor advance angle system Check, replace if
(govemer or vecuum advance angle system) necessary Hf17
Condition
Engine Surging
(Engine power
makes fluctuation in
a fixed speed and
speed changes
without operating the
accelerating pedal.)
(According to the
‘opening range of
throttle valve, knocking
sound of motallc is,
made with abnormal
explosion.)
Excessive detonation
Probable Cause
+ Electiic leakage, poor connection of high tension
cord
+ Malfunction of spark plug(excessive carbon
doposit, inadequate gap, melted electrod)
+ Loosening or damage of distributor cap or rotor
Low compression pressure
others:
+ Leakage of vacuum hose
‘Overneated engine
‘Malfunction of ignition system
+ Abnormal spark plug
+ Poor ignition timing
+ Electtc leakage of hgh tension cord, poor connection
Malfunction of fuel system
* Blocking fuel fiter, fuel ine
+ Leakage at intake manifold gasket
Others,
+ Excessive carbon deposit due to abnoml combuston
Overheat
Poor fuel concumpticn
+ Lack of coolant |
‘+ Malfunction of thermostat
+ Poor water pump performane
Misagjustment o ignition timing
Clogged cr leaky radiator
* Poor engine of
+ Blocking oil fiter, stainer
+ Lack of ol!
+ Poor oil pump performanca |
+ Leakage of oll |
+ Dragging brakes
+ Slipping clutch
+ Damage of cylinder head gasket
Fuel eyetem
+ Leakage of fuel
+ Clogged air cleaner alement
‘Malfunction of ignition system
+ Improper ignition timing |
+ Blecric leakage, por connection of high tension cord
Correction
Replace or connect
correctly
Replace
Replace
‘See preceding page
Replace or connact correctly
See overheated engne
section
Replace
Replace
Adjist
Replace or cannect carectly
Roplace or clean
Replace gasket
Riemove carbon
Refll
Replace
Replace
Adjust
Clean, repair, replace
Replace with specified ona
Replace or clean
Rell
Replace or repair
Repair
Repair or replace
‘Adjast or roplaco
Replace
Repair or replace
Clean or replace
Adjust
Replace or connect corracty4:18
Condition
Probable Cause
Correction
Low fuel consumption
+ Abnoimal spark plug(excessive carbon deposit,
inadequate gap, burnt electrode)
+ Malfunction of distributor acvance angle system
(governor. vacuum advance angle systern)
Low compression pressure
+ Replace
+ Check, replace nexessary
+ See preceding page
Others
+ Apnoimal valve clearence + Adjust |
+ Sipping cutch + Agjust or replece |
+ Poor operation of thermostat + Replace |
+ Low pressure of tires + Adjust
Excessive consumption | Leakage of oit
of engine oil * Loosened oil drain plug * Tighten
+ Loosened ol pan bolt + Tighten
+ Leakoge st erankshatt ol seal + Replace
+ Leakage et cylinder head cover gasket + Replace
+ Loosenedil iter + Tighten
+ Loosened oil pressure switeh + Tehten
+ Damage cf cyinde: head gasket + Replace
+ Leakage of camshatt ail seal = Replace
Low oil pressure
il mixing in combustion chamber
+ Stuckpiston ring
+ Abrasion piston, cylinder
+ Abrasion of piston ring, ring groove
+ Inadequate postion of piston ring culting part
+ Abrasion or damage of valve system
+ Inadequate oil viscosity
+ Loosening of cil pressure switch
+ Lack of ol
+ Blocking cil strane
+ Lowered function of oll puma
+ Abrasion, damage of ol pump relief valve
Engine noise
Valve noise
+ Inadequate valve dearence
+ Abrasion of valve stem, guide
+ Malfunction of valvs epring
Piston ting, cylinder noise
+ Abrasion of piston, ring or cylinder
+ Romeve carbon and
replace piston ring
+ Boring or eplace
+ Pepiace piston, piston ing
+ Adjust the postion
+ Replace
‘+ oplace with the specifios
+ Tighten
+ Refill
+ Qean
+ Replace
+ Replace
+ Adjust
+ Replace
= Replace
+ Boring or replaceCondition Probable Cause Correction
Engine noise Connecting rod noise
+ Abrasion of connecting bearing + Replace |
* Abrasion of crank pin + Replace |
+ Loosened comecting rod nut + Replace
Crankshaft noise
+ Low oil pressure + See preceding page
+ Abrasion of bearing
+ Abrasion of crankshaft journal
+ Loasened beering cap bolt
* Excessive clearance ol crankshatt thrust bearing
(end play)
See preceding page
Grind or replace
Tighten to specified toque
Adjust or replace
sea