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AV C MANUAL
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INDEX
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QUICK
DATSUN
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MODE
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620 SER
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1 ISSAtlIA0101l
0KYO
J Atl
FOREWORD
This service manual has been prepared for the purpose of assisting service personnel of
authorized NISSAN DATSUN dealers fu providing effective service and maintenance of the
fu the Datsun
Since proper maintenance and service are
absolutely essential satisfying
owners this la1 should be
inan kept fu a
handy place for ready reference and should be
carefuny studied
ma futenance 1justrnents
ac minor service operations
This la1 fucludes
man procedures for
remowl and installation and for disassembly and assembly of components
As you read through the maintenance procedures in this service manual you will
Reference Index the first page enables the user to quickly locate the
The Quick on
Rights for alteratiohat any time of specifications and methods are reserved
Accordingly anyone
himself that neither his safety nor the
mended by Nissan must fust completely satisfy
vehicle s safety wi11be jeopardized by the service method selected
TOKYO JAPAN
SECTION GI
GENERAL
DATSUN PICK UP INFORMATION
MODEL 620 SERIES
GENERAL INFORMATION GI 3
I NISSAN I
GI 2
General Information L
GENERAL INFORMATION
CONTENTS
TIE DOWN GI 7
MODEL VARIATION
Differential
Pay load
Destination Class Model Engine Transmission carrier model
kg Ob
and gear ratio
I HL620TUV F4W7lB
Standard
wheelbase I HL620FTUV FS5W71 B
S
E
I HL620KTUV 3N7lB
Ol
E
u
0
0
E
I HLG620TUV F4W7lB
Long
0
0
wheelbase I HLG620FTUV FS5W71B
8 a
0
0 Ol
u I HLG620KTUV 3N7lB
Ol
u
I KHL620TUV F4W7lB
Deluxe
Cab I KHL620FTUV FS5W7lB
Hl90
KHL620KTUV 3N7lB 500 100
L20B 375
4
i
u
0 HL620TU F4W71 B
Standard
HL620FTU FS5W7l B
wheelbase
U 3N7lB
HL620KTU
S 0
0
0
E
8
I HLG620TU F4W7lB
Long
I
0
HLG620FTU FS5W7lB
wheelbase
Q u
0
Z
0 IHLG620KTU 3N7lB
KHL620TU F4W71B
Deluxe
Q KHL620FTU FS5W7l B
Cab
I KHL620KTU 3N7lB
GI 3
r General Information
Differential
Pay load
Destination Class Model Engine Transmission carrier model
HL620TUN F4W71B
Standard
wheelbase
HL620KTUN 3N71B
E HLG620TUN F4W7IB
Long
wheelbase 2 Hl90
Canada
I HLG620KTUN L20B 3N71B
375
4
500 100
1
Deluxe Z
0 I KHL620TUN F4W71B
I KHL620KTUN 3N7J B
Model identification
KHLG620KTUV
V California model
N Canada model
K Automatic transmission
G Long wheelbase
I Standard wheelbase and Deluxe Cab
o
H Equipped with L20B engine
K Deluxe Cab
4
GI
General Informa tion
tW
The serial number is
engine
The unit and vehicle numbers are stamped on the right hand side of the
ments
factory
These numbers
communications
are used
such
for
as
I Serial number
I il
j
Technical Reports Warranty Claims
Service Journals and other informa Engine model
tion
SP031
SP029
number
I Serial number
The transmission serial number is
stamped on the front upper face of
transmission case
Vehicle model
Number system
x X XXXXX
GI326
I Serial number
Fig 01 6 Color code number label
location monthly
Month of
j manufacture
e
M VS S c rtlflcatlon label 2 9 XY Z
G1268
The M V S S certification label is Line code of
Fig 4 Vehicle serial number
GI
location located at the driver side lock pillar manufacture
Gl 5
iGetneiraolnfonrml
Notes
I Serial number
Fig GI ll Front lifting point apply the jack to rear axle case
last figure of
year of When jacking up the rear side place
manufacture a screw jack under rear axle case close
J
r
to the side of rear spring uc
I
GI075 n9
Fig GI 14 Front lifting point
AT344
WH077
Fig 01 10 Automatic trammision
number location
LIFTING POINTS
AND TOWING Notes
a When the yellow mark appean on
LIFTING POINTS
the screw jack it indicates the
maximum permissible height Do
Screw jack
not jack up further
Before using the jack proceed a b When the jack is at lower llinit do GI076
follows not add large force downward Fig GI 15 Rear lifting point
6
GI
General Information
age
Automatic transmission
v
GI078 TIE DOWN
Fig GI 17 Rear supportable points
The front two tie down hooks are
GI 7
General Information
Fuel tank
I 45 J IUi gal 9 Ji gal
ManUal transmission
Cooling system I 8 0J
I 8Jiqt 7 qt
with heater
Automatic tr smission
I 7 8J
I 8Y qt 6Jiqt
Engine lubrication
system
with oil f1lter
I 4 3J
I 4Ji qt 3 qt
I 4 speed transmission I 1 7J
I 3Xpl 3 pI
Manual transmission
I 5 speed transmission
I 2 0
I 4Y pt 3Mpt
Automatic transmission
I s J
5
I 5Uqt 4Uqt
Differential carrier
I 10 J
I 2M pI I pt
RECOMMENDED FUEL
Use an unleaded or low lead of 91 RON Research Octane only unleaded gasoline to protect the
gasoline with a minimum octane rating For California models
Nuniber from
use catalytic converter contamina
tion
RECOMMENDED LUBRICANTS
ENGINE on
I ICWII
ao 40
J
SAE 5W 20 oils ate not lecom
mended for sustained high speed
drivin
GEAR On
30 20 0 20 40 60 80 100
8
GI
General Information
LUBRICANT SPECIFICATIONS
Furthermore refer to
SAE Classification
Gasoline engine oil SAE recommended viscosity
SD or SE
table See Poge GI B
Transmission
0
and API 4
GL
steering
Differential API GL S
GI 9
SECTION ET
ENGINE
DATSUN PICK UP TUNE UP
MODEL 620 SERIES
ENGINE TUNE UP ET 2
ENGINE TUNE UP
CONTENTS
ET 2
Engine Tune up
cv
2 Check valve
3 Altitude compensator in air cleaner
4 Air gallery pipe
5 choke
Auto qj
6 Automatic temperature control air
cleaner
7 Anti Backfire valve A B valve
8 Boost Controlled Deceleration
Device B C D O
9 P C V valve
10 Airrelief valve
11 E G R control valve
12 6 C D D control valve and solenoid
valve
13 Emergency air relief valve
ET3
r
Engine Tune up
ET367
4
ET
Engine Tune up
ET368
ET5
lIIIII
mJ Crl lc Jl c0
AfT X X X X X X
x X X X X X alvc
ula 11Ie
CalifJl rlodet I I I
alvc relief
I
I
I
I
I
I
I
I
I I I
j r
T r R
Non X X X X X X X X X X X X
M
ktiu dclay l
G
cncy
E
L20H 620 H
1
I
I
I
I I
I
AHmjcL
b
AfT X X X X X X X X X X X X X X X X X
Anu Emer dll u Vacu m Tup E
CalifornIa modcb I
I
I
I
1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I I I
Jlvc
V
T
M X X X X X X X X X X X X X X X X X
S
vl ve R R V E
B A CO C
I I
AJ
I
I
I
I
I
I
I
I
I
I
I
I
I
A E E V T
I
Cilnad X X X X X X X X X X X X X X
lIem
I
I
I
I
I
I
I
I
I
I
I
I
I I I I I I
1
I
I
Califor models Except Can da
T
M
FlU NOll X X X X X X X X X X X X X
sy tem
recnultO
I
I
I
I I I I I
I
I I I I
hfor
C models X X X X X X X X X X X X X X X X X
dov
advam gu
T
X X X X X X X X X X X X vacum exhausl
declration contrled contrled nasduce
DEVICS
A
Can da I
I
I
I
I
I
I
I
I
I
I
I
I I I I I I I I
AI4 M
X X X X X X X X X X X X X X
valve
contrled ulI
preure
I
I
I
I
I
I
I
I
I
I
I I
I
I
I
I
I
I
I
I
I
I
I I I
mlu delay
AlT
TransmlS Back Vacum
lPI
L X X X X X X X X X X X X X
I
CONTRL lIodch forC
D
T
M
X X X X X X X X X X X X 0 S V E T
C C DC P c
I
8 TS T B V
I
1
I
I
I
I
I
I
I
I
I
I I I I I I I I
I
AlT
Automalcns temprau
X X X X X X X X X X X X X X X X
nt
valve
EMISON
control
I
I I I I
I I I I I I I I I I I I
temprau vacum
i
oLir
ill
valvel
Maoulrmn Automaic Positve Thermal Combined
I
alor
ilUde m1JC
Enj
Jn
Jc
compcn
tlitlji
body T
C
T
Ch V C
V A
to
AlT PT
ilt udc Rcliefva l
M A T C
l
TO
with
lI1OfCuiol
R
val
fo
II s
c
r
valve E
A
R
C
E
mile
5Vlcm
Oiltrbuo
X
12
wilh with
onlrol with unIt valve cleaner eonlro T
sv
R
G
ry
l
e
fuclvporatYe
fo all P
1er l
Jtrc1anr deaner
aulchnk without ncr fAir
Thermal AlP valve valve valve VUI lD fThermal ITon device
Ive cut ln
mocratue
C
T
A
dl
lliT air
e e
TT
A A
comDenlatr
hlle
due
air
lh
F Early
C
T
P
with
OO
c C
a 8
0
D
o
0n S
TS T
arkdelayvalvc
Sn
V V
DV
pump
Air
t
A
C Airconlt Rcliervac
R
A
E
R
G
E
lvr
v
LG
J
C
unit
CLEANR
t
I A
R
G
E SY TEM CATLYZER Newly
epl
l
l E
ml c
Engine Tune up
CONTENTS
AND CONNECTIONS ET B
SECURING NUTS ET7
CHECKING ENGINE COMPRESSION ET 9
CHECKING ENGINE OIL ET B
COMPRESSION PRESSURE TEST ET 9
REPLACING OIL FILTER ET B
TEST RESULT ET 9
CHANGING ENGINE COOLANT ET B
clearance is
Valve adjustment
impossible when the engine is in oper
ation Compressor pulley
1 Loosen pivot locking nu t and
0 315 to 472
0 in
8 to 12 mm
turn pivot screw until the specified Idler pulley
clearance is obtained while cold
Water pump pulley
Using service tool tighten pivot
locking nut securely after adjustment
8 to 12 mm 0 315 to 0 472 in
and recheck the clearance
2 Warm up engine for at least
several minutes and stop it Measure
valve clearance while hot If out of
Alternator
Intake 0 20 0 008
Cold
Exhaust 0 25 0 010
AC456
Intake 0 25 OmO
Fig ET 6 Driue belt tension
Wann
I Exhaust 30
0 0 012
CARBURETOR 6 0 kg m 43 ft Ib
Engine Tune up
ManifolJ nuts
2 When installing oil filter tighlen
I 2 to 16 kg m by hand
8 7 to I 6 ft lb
Note Do not overtighten oil flIt
Carburelor nuls
lest leakage should occur
5
0 to 10 kg m
3 6 to 7 2 fl tb
COOLANT
COOLNG SYSTEM
PRESSURE TEST
PERMANENT ANTI FREEZE
COOLANT With radiator cap removed apply
reference pressure 1 6 kg cm2 23
Permanent anti freeze coolant is an
Fig ET 7 Tightening s quence psi to the cooling system by means
8
ET
Engine Tune up
tester to spark plug hole in cylinder Should not be less than 80 of highest Oil and water in combustion cham
CONTENTS
Tune up
Engine
r water Rinse off and dry with com CHECKING ANb
pressed air Top of battery must be REPLACING SPARK
clean to current leakage be
prevent
tween terminals and from
PLUG
positive
terminal to I Remove and clean
down
hold clamp plugs in a sand
on top If l l ry may ca u
iCbli t g
I
rj chips
ET002 of the material covering connector 3 Check both center and ground
Checking specific gravity electrodes
Fig E1 11 straps and corrosion of straps After
ofbottery electrolyre If they are excessively
tightening terminals coat them with worn re
Clean top of battery and terminals petrolatum vaseline to protect them place with new spark plugs
with a solution of bakin soda and from corrosion 4 Spark plug gap
Tightening torq
Tropical climates
lOver 1 18 123 5 to 2 0
1 kg m
11 to A4 ft lb
Other climates
lOver 120 26
1
CHECKING AND
ADJUSTING
IGN ITIONTIMiNG
ADIUSTING IGNITION
TIMING
ET 10
Engine Tune up
Connect ohmmeter between spark RATIO 5 Remove air hose between 3 way
plug adapter and corresponding elec connector 5 way connector for Cali
is more Cautions
trade inside cap If resistance fornia models and air check valve as
than 30 000 ohms remove cable from a On automatic transmission equip shown in Figure ET 17 Plug the dis
T 11
r
Engine Tune up
to the specified speed with throttle for manual transmission models and
adjusting screw 670 rpm for automatic transmission
models in D position Adjustment
CO Idle adjustment without in step 9 can be carried out right after
COmeter step 7
II Turn the idle adjusting screw
If CO meter is not available the clockwise until engine speed drops off
following procedures may be used below specified rpm
I Check carburetor pipes for proper
Fig ET 17 Disconnect air hose Engine speed drops off
connection
from ojr check valve Manual transmission
2 Wann up engine until water tern
60 to 70 rpm
6 Race engine1 500 to 2 000 rpm perature indicator points to the middle
of gauge Automatic transmission
two or three times under no load then The procedure to warm up
in D position
engine is
run engine for one minute at idling specifically recom
not
15 to 25 rpm
speed mended Either driving vehicle or oper
7 ating engine at no load will be
Adjust throttle adjusting screw good
12 Connect air hose to air check
until engine is at specified speed 3 Make sure that water temperature
valve
indicator points to the middle Further
Engine speed If engine speed increases readjust it
keep engine running at about 2 000
Manual transmission the with throttle
rpm for about 5 minutes without
to
specified speed
750 rpm
applying load to engine in order to adjusting screw
Automatic transmission
stabilize engine condition Engine
in D position IDLE LIMITER CAP
hood should be open
650 rpm
4 Run engine for about 10 minutes Do not remove this idle limiter cap
at idling peed unless If this unit is
8 Check ignition timing If neces
During this 10 necessary
120 750 rpm Non California connected hose to prevent dust from tained in exhaust gases meets the
750
100 rpm California entering established standard
Automatic transmission 6 Race engine 1 500 to 2 000 rpm 2 Install idle limiter cap in position
in D sure that the adjusting screw
position two or three times under no load then making
120 650 rpm further turn 1 8 rotation in the
run engine for one minute at idling
speed CORICH direction
9 At about 10 minutes after engine 7 Adjust throttle adjusting screw so
is idle
run at idling speed adjust that indicated
Carburetor
engine speeds are as
stopper
adjusting screw so that CO percentage below
is at specified level
CO percentage
Engine speed
Manual transmission
Manual transmission
815 rpm
tI
2 750 rpm at
Automatic transmission
Automatic transmission
D
in D in position
position
670 rpm 3lSo ldle limiter cap
tI
2 at 650 rpm
T ET031
10 Repeat procedures as described 8 Check ignition timing if neces
Fig ET 18 Setting idle limiter cap
in steps 6 7 and 9 above so that CO saryadjust it to the value
required by
percentage is at specified level Check specifications
This operation need not
CHECKING
ing idle CO in step 9 can be carried out be carried out at 1 600 Ian 1 000
right after step 7 miles service CARBURETOR
11 Race engine I 500 to 2 000 9 At about 10 minutes after engine RETURN SPRING
rpm two or three times under no load is run at idling speed adjust idle Check throttle return spring for
and make sure that specified CO per adjusting screw until maximum rpm is cracks s or defonnation if
squarene
centage is obtained obtained
necessary replace with a new one
ET 12
Engine Tune up
Note Always align the index mark on Retighten loose connections and re
bimetal cover with the center index
place any damaged or deformed parts
mark on choke housing
CONTENTS
ET 23
CHECKING AUTOMATIC TEMPERATURE CHECKING CATALYTIC CONVERTER
AIR ET 15 INSPECTION ET 23
CONTROL CLEANER
PRESSURE OF BOOST CHECKING FLOOR TEMPERATURE
OPERATING
WARNING SYSTEM ET 23
CONTROLLED DECELERATION DEVICE
B CD D I ADJUSTMENT ET 17 INSPECTION ET 23
CHECKING B C DD CIRCUIT WITH
FUNCTION TEST CONNECTOR ET 17
CHECKING
CRANKCASE
EMISSION CONTROL
SYSTEM
with the following method noise will be heard as air passes
REPLACING P C V VALVE With engine running idle remove the valve and
at through a
strong vacuum
AND FILTER ventilator ose from P C V valve If should be felt when
immediately a
Check P C V valve in accordance the valve is properly working a hissing finger is placed over valve inlet
ET 13
Engine Tune up
3
8affle pia te
Flame arrester
ing
2 Stopper pin for bend and count
4 Filter
5 P C V valve er weight stop position for dislocation
6 Steel net 3 Check heat control valve for
7 Baffle plate malfunction due to break of key that
locates counterweight to valve shaft
4 Check axial clearance between
heat control valve and exhaust mani
fold Correct clearance is 0 7 to 5
1
mm 0 028 to 0 059 in
1fiI o
control valve and valve shaft for any
indication of crack or flaking
6 Rotate heat control valve shaft
with a fmger and check for
binding
Fresh air between shaft and bushing in closing
EC716
and opening operation of heat control
Blow by gas tem
Fig ET 20 Crankcaae emi ion control8 valve If any binding is felt in rotating
operation move valve shaft in the
rotation direction several times If this
3 When heat control valve is in the
CHECKING VENTILATION does
full operation not correct binding
HOSE
open positioncounterweight
condition it is due to seizure between
moves further clockwise exceeding the
CHECKING SPARK
CHECKING EXHAUST EC245
TIMING CONTROL
MANIFOLD HEAT 1 Counterwe ht SYSTEM
2 Stopper pin
CONTROL VALVE 3 Heat control valve
This system is installed on non
ET 14
Tune up
Engine
CHECKING
AUTOMATIC
Distributor side
TEMPERATURE
Brown CONTROL AIR
CLEANER
2 1 Vacuum hoses
or
Be careful
ET 15
Engine Tune up
R R
3 Check that air control valve grad
Note Vacuum hose position
the ually opens to under hood air inlet
side of Nissan mark top of
on
scribed in step 2
for more than 30
seconds and that hot air inlet is open
If diaphragm spring actuates the air
control valve by its spring force to
phragm
Fig ET 27 Impecting lJalv position EF221
the end of air valve is the reverse of 2 2 1 under Note Before replacing temperature
Place a mirror at
hood air inlet is closed and hot air sensor check idle compensator as
cleaner inlet pipe and check to see if
inlet is open described in Section EF page 8
EF
air control valve is in correct position
ET 16
Engine Tune up
BC D D circuit is functioning
properly if continuity exists and volt
meter reading is 0 volt d c in step 2
l r 1 Ignition key
E
2 Fuse
below 3 Amplifier
4 Speed detecting switch
If continuity does not exist check
Above 10 mph OFF
for disconnected connector and or
Below 10 mph ON
faulty amplifier speed detecting 5 Function test connector
switch or B C D D solenoid valve
6 B C D D solenoid valve
2 Check for presence of voltage
across@ and @ at a speed of more
than 16 km h 10 MPH Refer to
EF711
Figure ET 31
of more than 16 km h 10
speed
circuit is
MPH functioning prop
erly
If voltmeter is not 0 volt
reading
check for disconnected connector
burned fuse faulty amplifier
BC D D solenoid valve or speed 1 Ignition key
detecting switch 2 Inhibitor switch
N P positions ON
3 If by above checks faulty part or I 2 D R positions
OFF
it should be removed 3 D C D D solenoid valve
unit is located
4 Function test connector
and tested again If necessary replace
5 Inhibitor relay
models
Fig ET 31 Checking B C D D circuit with function tfst connfctor
I With inhibitor switch ON UN
Automatic transmiMion modtla
or P position check for presence of
and
voltage across @ @ Refer to
Figure ET 30
Engine Tune up
r
then gradually decreases to the level
gauge such as Bourdon s type is
recommended a
set at idling
mercury type 6 Check that the BC D D set pres
manometer should not be used
sure is within the specified pressure
To set the
properly B C D D set
pressure proceed as follows
Specified pressure 0 m sea level 1
I Remove the harness of solenoid Adjusting nut
and 760 mmHg 30 inHg atmos 2 Lock spring
valve EC692
pheric pressure
Fig ET 34 Adjusting Bet pressure
TO D D solenrod Manual transmission
VT FJ
BC D D solenni
510 to
20 1 to
Automatic transmission
550 mmHg
7 inHg
21
8
adjustment
Race the engine and check for
1 valve harness
J
490 to
3 to
19
530 mmHg
20 9 inHg
9
turn the
If it is lower than the set level
adjusting screw or nut until
correct adjustment is made
g ET 32 Removing harneS5 of
F atmospheric pressure and altitutde pressure proceed as follows
solenoid valve of the given location
When the engine speed does not fall
For if a manual transmis
example it
to idling speed is necessary to
2 Connect rubber hose between sion model vehicle is located at an
reduce the negative idling pressure of
altitude of 1 000 m 3 280 ft the
vacuum gauge and intake manifold as
the manifold to lower than the set
shown specified set preSsure for B C D D
pressure of the B C D D The engine
445 mmHg 17 5 inHg
speed will not drop to idling speed
when the negative idling pressure is
7 If it is higher than the set level higher than the set pressure of the
turn the adjusting screw counter B C D D
clockwise or nut clockwise until In this the be
case engine must
ET 18
Engine Tune up
Intake
dJi 1
3 Raise rear axle housing by stand
2 Otassis dynamometer up
I Road te t
ET133
29
23
28
22
700
550
27
21
26
20
650
500
25 a
19
a Co
11 1
Co
v
24
Co
g 18
0
600
450 E
8
0
23
17
22
16
550
400
2
15
0 20
14
500
350
19
13
300 1
4 5 000 6 000 ft
o 1 000 2 000 3 000 000
Altitude
10 5
1 2 0 km
o 0 5
EF55B
ET 19
r
Engine Tune up
shown in Figure ET 37
CHECKING AMPLIFIER
Manual transmission EC323
l I
E G R
M ake a
control
thorough visual
system
check of
If necessary
M wipe away oil to facilitate inspection
1
p II
If hoses cracked
are or broken fe
o
L
A place
I of
ET 20
Engine Tune up
Below Above
Detector Drive Counter
50 000 counts 50 000 counts
ON OFF ON
E G R Warning Lamp
E GR control valve
EC253
J
hC
2 When engine coolant tempera control valve ET152
liquid separator
a Note In case the vent line is stuffy
3 Connect a way
3 connector
Thermal VBCuum valve in fuel tank is
cock the breathing not
manometer and a or an equiva
Dismount thermal valve causing in
vacuum
lent way
3 charge cock to the end of thoroughly made thl
from engine the vent line suffICient delivery of fuel to engine
4 Supply fresh air into the vapor or vapor lock It must therefore be
Note Before dismounting drain e vent line through the cock little by repaired or replaced
@ s
r
passage
EC786
ET 22
Engine Tune up
u
warmed up
I @
ET369
rpm two
and make
or three times under
that specified CO per
sure
no load
Fig 49
ET Fuel filler cap
centage is obtained
I1 Remove and connect air
cap
1 Cover
hose to air check valve
2 Diaphragm
3 Retainer CHECKING If idlingspeed increases readjust it
4 Diaphragm spring CATALYTIC to specified speed with throttle ad
justing screw
ET350 CONVERTER Warm up
12 engine for about four
Fig ET 47 Carbon caniater purge
minutes at 2 000 rpm under n load
control valve INSPECTION
13 Measure CO percentage at idling
valve is in good mechanical condition Refer to page ET 12 warning lamp lights when ignition
Note also that by further inhaling air 7 Check ignition timing If neces switch is turned to the S position
the resistance should be disappeared sary adjust it to specifications Refer If not check lamp for burned
with valve clicks to page ET 10 bul bs
ET 23
Engine Tune up
Replace bulb if bulb is burned ou t IGU position results do not satisfy the above reo
If bulb is not burned 3 Ensure that floor place the floor temperature relay
trace wireis tem perature
carrying out the following procedure temperature warning lamp glows when
4 03
UJ 2
3
To floor temperature
warning lamp
From S
From
position
GOt position
4 From ignition switch
Fig 50
ET Checking floor temperature relay
ET 24
Engine Tune up
Automatic transmission
Valve clearance
Belt tension
Fan mm in 8 to 12 315
0 to 472
0
10 22 is applied
Pressure kg lb
12 0 171
Standard kg cm2 psi
Minimum kg em2 psi 9 0 128
Cooling system
kg cm2 1 6 23
Leakage testing pressure Psi
680F 1 26
Battery specific gravity at 200C
Distribu tor
Condenser capacity IF 0 20 to 0 24
Mil 5
Condenser insulation resistance
Spark plug
Gap mm in 0 8 to 0 9 0 031 to 0 035
Breaker points type
10 to 1 0 039 to 0 043
ET 25
r
Engine Tune up
A TC air cleaner
Tightening torque
Cylinder head bolts
1st turn ft b
kg m 4 0 29
2nd turn kg lll ft lb 6 0 43
3rd turn kg m ft lb 5 to 8 5
6 47 to 61
Carburetor nuts kg m ft lb 0 5 to 10 3 6 to 7 2
Spark plugs kg m ft lb 1 5 to 2 0 II to 14
ET 26
Engine Tune up
CANNOT CRANK Improper grade oil Replace with proper grade oiL
ENGINE OR SLOW
Discharged battery Charge battery
CRANKING
Faulty battery Replace
Loose fan belt Adjust
Malfunction in charge system Inspect
Trouble circuit
shooting procedure on starting
Switch on the starting motor with light ON
a Check battery
b Check connection and cable
c Check starter motor
In this case the following trouble causes may exist but in many cases ignition system or fuel system is in trouble
ET 27
Engine Tune up
Low ion
comp sparle plug tightening
Incorrect or faulty Tighten to normal torque or replace gasket
gasket
Improper grade engine oil or low viscosity Replace with proper grade oil
cylinder compression
ET 28
Engine Tune up
IMPROPER ENGINE
IDLING
Loose air hoses or air fuel mixture hoses of Check for loose connections
carburetor
Previously mentioned
Low compression
Malfunction of vacuum motor sensor or Check for loose hoses Replace system com
High engine idle Dragged accelerator linkage Check and correct accelerator linkage
speed Incorrect idle adjustment Adjust idle speed
Malfunction of B CDD system Check for loose vacuum hose and harness
connections
replace if necessary
ET 29
Engine Tune up
ET 30
Engine Tune up
NOISY ENGINE
Mechanical knocking
Crankshaft bearing This strong dull noise increases when engine This is caused by worn or damaged bearings
is accelerated To locate the place cause a or unevenly worn crankshaft Renew
Imocking
misfire on each cylinder If the noise stops and adjust or change crankshaft
bearings
the misfire this cylinder generates the Check lubrication system
by
noise
This is little noise than the Same as the case ofcrankshaft bearings
Connecting rod a higher pitched
crankshaft and also increases
bearing knocking Imocking
when engine is accelerateda misfire Cause
on each
cylinder and if the noise deminishes
of
Piston and cylinder When you hear an overlapping metalic noise This may cause an abnormal wearing
which increases its magnitude with the cylinder and lower compression which in
noise
revolution of engine and which decreases as turn will cause a lower out put power and
is warmed up this noise is caused by excessive consumption of oil
engine
piston and cylinder To locate the place
cause a misfire on each cylinder Overhaul engine
Piston pin noise This noise is heared at each highest and This may cause a wear on piston pin or
This noise be caused by worn or Replace water pump with a new one
Water pump noise may
earings by the uneven surface
damaged or
of sliding parts
An excessive end play on crankshaft Disassemble engine and renew main bearing
Wear on clutch pilot bushing Renew bush and adjust drive shaft
ET31
Engine Tune up
ABNORMAL
COMBUSTION
backfue afterflre
run on etc
out of Damaged carburetor or manifold gasket Replace them with new parts
Fuel system
order backfue afterfire
Disassemble carburetor and check it
Cloled carburetor jet
l
function of the float Adjust the level and check needle valve
Improper
Uneven idling Run on Adjust
Malfunction of choke
auio Adjust
Others Malfunction of A T C air cleaner Check for loose vacuum hoses Replace if
necessary
Inoperative backfue
ariti valve Replape
EXCESSIVE OIL
CONSUMPTION
it
Loose or damaged oil pan gasket Renew gasket or tighten
Renew tighten it
Loose or damaged chain cover gasket gasket or
Worn oil seal in front and rear of crankshaft Renew oil seal
much
Loose or damaged oil pressure switch Renew oil pressure switch or tighten it
ET32
Engine Tune up
Se the xplanation
of the pow r dec
Adjust it
Inoperative acceleration recovery
Malfunction of B C D D Adjust
PROBLEM IN OTHER
FUNCTIONS
it with
Functional deterioration of oil pump Repair or replace a new one
Increased clearance in various sliding parts Disassemble and replace the worn parts with
new ones
change element
Floor temperature too Problem in fuel system Refer to Inspec Check and repair
ET33
SECTION EM
ENGINE
DATSUN PICK UP MECHANICAL
MODEL 620 SERIES
GENERAL DESCRIPTION EM 2
ENGINE DISASSEMBLY EM 4
ENGINE ASSEMBLY EM 21
GENERAL DESCRIPTION
CONTENTS
EM 2 CAMSHAFT EM 3
MODEL L20B ENGINE
EM 3 VALVE MECHANISM EM 3
CYLINDER BLOCK
EM 3 CAMSHAFT DRIVE EM 3
CRANKSHAFT
ROD EM 3 MANIFOLDS EM 3
PISTON AND CONNECTING
EM 3
CYLINDER HEAD
EM536
EM535
Main specifications
L20B
CRANKSHAFT
The crankshaft is steel
Oisplacemen t cc cu in 1 1191
952 a special
forging Fully balanced it turns out
MIT Manual Transmission AIT Automatic Transmission up end thrust of the crankshaft
EM 2
Engine Mechanical
are lubricated from oil holes which isoperated by spring and oil pressure
lead to the main oil gallery of the The rubber shoe type tensioner damps
Fig EM 3 Crankshafl cylinder head vibration of the chain and controls its
Concentric passages are drilled in tension
the front and rear parts of the earn
0
5 01 Fig EM 6 Camshafl
MANIFOLDS
The intake manifold is of an alumi
The valve system has the pivot type design and incorporates a heat control
valve in it The heal control valve is
rocker arms that are activated directly
used to warm the intake manifold
by the earn mechanism this has made
CYLINDER HEAD A is installed on the outer
its moving parts considerably lighter plate
The cylinder head is made of a face of the manifold to draw hot
and provides ideal high speed perform
intake air out it The exhaust
light strong aluminum alloy with good ance through
is connected to the flanged
cooling efficiency it contains wedge Dual type valve springs are in pipe sur
h
a
press fitted @l
if
EM 3
r Engine Mechanical
I
I
ENGINE DISASSEMBLY
CONTENTS
CLEANING AND front chain cover oil pan and oil filter er
compressor and idler pulley if so
gaskets lInd crankshaft and water equipped
INSt
ECTION of 7 Remove starter motor from trans
pump seals for signs leakage past
Before disassembling engine note mission
their gasketed surfaces
the following 2 Check carburetor and fuel pump 8 Visually inspect cylinder head
I Fuel oil or water may leak past for condition fuel hoses for deteriora cylinder block rocker C Ner front
head chain cover oil pan and all other outer
cylinder and block Prior to tion cracks or leakage of fuel past
check cylinder parts for oil water and fuel leaks
disassembling head their jointed or connected surfaces
2 Check valve
3 Altitude
compensator DISASSEMBLY
in air cleaner
To remove engine from vehicle
4 Air gallery pipe
S choke
Auto
refer to the instructions under the
6 Automatic temperature Engine Removal and Installation
control air cleaner ER section
7 Anti 8ackfire valve A B valve
I Remove transmission from en
8 Boost Controlled Deceleration
I Remove
E T366
cooling fan
2 Remove right engine mounting
Fig EM 0 Emiuion control devic s California mod 18 bracket
3 Remove oil filter with Oil Filter
3 Remove carburetor air cleaner Disconnect air cleaner to A B valve Wrench STI9320000
Remove fresh air duct 4 Remove oil pressure swi tch
hose at air cleaner
Disconnect hot air duct from air Disconnect 5 Install
air cleaner to related engine attachment to
cleaner part vacuum hoses at air cleaner cylinder block utilizing bolt holes in
Disconnect air cleaner to air pump Loosen air cleaner band bolt and alternator bracket and water drain
hose at air cleaner remove carburetor air cleaner as hole
Disconnect air cleanef to rocker from carburetor 6 Set stand
sembly engine on
cover hose at rocker cover 4 Plug up carburetor air horn to Engine Attachment
Disconnect air cIeaner to air prevent entry of
con foreign matter ST05260001
trol valve hose at air cleaner Cali 5 Remove alternator drive belt Engine Stand
fornia models only alternator and alternator bracket ST050I SOOO
4
EM
Engine Mechanical
2 Distributor EM531
EM410
Fig EM 13 Removing air control
Fig EM II Engine on engine land valve Californio model
EM412
trol valve for California and a r hoses Fig EM 15 Removing thermostat Fig EM 17 Removing cammaf
housing sprocket
as an assembly
EM 5
r
Engine Mechanical
28 Remove cylinder head assembly 29 Invert engine 36 Remove piston and connecting
Use Cylinder Head Bolt Wrench 30 Remove oil pan and oil strainer rod a mbly Extract connecting rod
STl0120000 to remove cylinder head bearings keeping them in order
bolts Loosen bolts from CD to @ as
shown in Figure EM 18
EM094
I
Fig EM 20 Removing oil traintir
Fig EM 23 Removing pilton and
and oil pump
connecting rod aatm b y
Fig EM IS Cylinder head bolt
loosening equence
EM539
6
EM
Engine Mechanical
EM103 STl2070000
CYLINDER HEAD
Fig EM 32 Removing ualves
I Remove valve rocker springs
Loosen valve rocker pivot lock nut and
remove rocker arm by pressing valve
spring down
Notes
a Take care not to lose valve spring
seat oil seal valve collet and valve
rocker guide
b Be sure to keep camshaft bearings
intact or the bearing center is liable
Fig EM 27 Removing baffle plate and to come out of alignment
nel
PISTONS AND
CONNECTING RODS 61
8
camshaft
O Exhaust Intake
EM102
EM105
2 Press piston pin out with Piston
EM 7
r
Engine Mechanical
CONTENTS
10 I I
L
I
EM109
EM407
8
EM
Engine Mechanical
VALVE SPRING
H
Valve head diameter I In 42 0 to 42 2 1 654 to 1 661
1 Check valve spring for squareness
mm in
Ex 35 0 to 35 2 378
1 to 1
386 using a steel square and surface plate
If spring is out of square more than
In 114 9 to 115 2 524
4 to 4 535
Valve length 1 6 mm 0 063 in
L
replace
2 Measure free
mm in
Ex 1157 to 116 0 555
4 to 4 567 lhe length and ten
sion of each spring If the measured
In 7 965 to 7 980 3136
0 to 0 3142 value exceeds specified limit replace
Valve stem diameter
D
mm in spring
Ex 7 945 to 7 960 3128
0 to 3134
0
In 45030
Valve seat angle
a
Intake and Exhaust
Ex 45030
I
i
T
J
EM112
EM110
1
Note When valve head has been worn
Spring specifications
Outer 49 98 1 968
44 766
Inner 1
85
Inner 35 12
0 3 1378 27 I
EM 9
rr
Engine Mechanical
guide
Measure clearance
and valve stem
between valve
If clearance
J 10 0 425
8
S9 0 2 323
0 299 to 0 307
1 Unit mm
dia
in
exceeds designated limit replace worn EM572
dl7 flH
O
IV
l
II
In take valve Exhaust valve
in guide 4797
0 to 4802
0
0 0011 to 0 0019 in
EM115
4 Ream bore with valve guide press
Fig EM 42 Mea uring clearance
between valve tern ed in using Valve Guide Reamer Set EM419
and valve gu ide KVIOI039S0 Fig EM 44 Reaming valve guide
EM 10
Engine Mechanical
I
recess
Unit mm in
Intake
For service insert 500
45 to 516
45 1 7913 to I 7920
EM 11
Engine Mechanical
600
Intake
38 1 496I dia
W 39 6 I559Ildia
18 16457 dia
45 71l1
1
Unit mm in
30
Exhaust
30 l1
811 di
32 6 2835 dia
I
34 6 1 3622 dia
137 1 4567 dia
EM121
Unit mm m
0 038 to 0 067
Oil clearance mm in 0 1 0 0039
0 0015 to 0 0026
B DC
EM 12
Engine Mechanical
of
out round or taper is excessive re
Camshaft bend bore cylinder walls with a boring
0 02 0 0008 0 05 0 0020
mm in I
machine Measuremen t should be
taken along bores for taper and around
bores for of round
out See Figure
CAMSHAFT ALIGNMENT
EM 52
I Check camshaft camshaft journal
and earn surface for bend wear or
X Y
damage If damage is beyond limits Qu t of round
A B
replace affected parts Taper
2 A bend value is one half of the
t bend
Fig EM 50 Checking camMa
M12
Standard height
of tam mm in
I Intake
30
40 to 35
40
1 5866 to 1 5886
1 Exhaust 4 When wear
taper or out of round
B
100
lll
3 94
el 1
Cy LlNDER BLOCK
I Visually check cylinder block for
cracks or flaws
r
2 Measure
EM 22
age If warpage exceeds limits correct
it EM540
EM 13
Engine Mechanical
85 000 to 85 050
Inner diameter 0 2 00079
3465
3 to 3484
3
Cylinder bore
mm in Out of round ot5
O 00006
CYLINDER BORING
7
cording to amount
6 m
A
o 7323in
aboull r
Oversize pistons spec Hicetlons
C Machining allowance 0 02 mm
0 0008 in
3 The size to which cylinders must
be honed is determined by adding Standard clearance f im
in 0 025 to 0 045 0 0010 to 0 0018
piston cylinder
to clearance to the
largest piston diameter at
piston skirt Feeler gauge mm in 004 0 0016
in thrust direction
Extracting force kg Ib 0 2 to 1 5 O 44 to 3 31
EM 14
Engine Mechanical
Notes
PISTONS
a When measuring clearance slowly
PISTON PINS AND
pull feeier gaUge siraight upward
b It Is reConUnended that piston and PISTON RINGS
cylinder be hel ted to 200C 680F I Remove carbon from piston and
ring grooves with
a ca bon scraper and
00
in bottom land of oil ring groove
2 Check for damage scratches and
wear Replace if necessary
Notes
t a When piston ring only is to be
replaced without cylinder bore
being corrected measure gap at
f
J bottom of cylinder where wear is
rr 11 1 I
minor
ing rod
tight pre s fit into connect
0 030 0 070
I
to
Second ring
I 0 0012 to 0 0028
Oil ring
f
I I
4 Push ring into cylinder with pis feeler gauge
in Ring should be placed to diameter
ton so as place it
to squarely
measure ring with a at upper or lower limit of ring travel
cylinder gap
EM131
0 25 to 40
0
Top ring 0 0098 to 0 0157
30
0 to 0 50
Second ring 1 0 0 0394
0 0 II8 to 0 0197
EM132
0 30 to 0 90
Oil ring Fig EM 60 Measuring pi ton pin
0 0118 to 0 0354
diamet
EM 15
r
Engine Mechanical
Unit mm in
CRANKSHAFT
1 Whenever crankshaft is removed
Piston pin outside diameter 20 993 to 20 998 0 8265 to 0 8267
from engine it should be cleaned
in a suitable solvent
Piston pin hole diameter 21001 to 21008 0 8268 to 0 8271 thoroughly After
cleaning check crankshaft journal and
either side of the thrust face or the torsion rod Ifjournals or crank pins are tapered
on using a connecting aligner
end correct or it If bend or of
out round beyond limits replace
large replace or torsion exceeds the limit
with a new shaft
q rrect or replace
A B
EM133
tt
30 32
181 106 1
2 60
in
mm
43 l 69
O
3 When
I
replacing connecting rod
1
select rod so that weight difference
between
gr 0 25 oz
new and old ones is within 7
All main
E journa All crank pm
Do not use a combination of new 59 942 to 59 955
49 961 to 49 974
and former 2 3599 l 2 3604
connecting rod big end o
1 9670 to 19675
nuts and connecting rod bolts which EM424
Standard Maximum
0 2 to 0 3
Big end play mm in 0 6 0 0236
0 0079 to 0 01 18
EM 16
Engine Mechanical
Standard Maximum
STl6610001
EM137
bend
Fig EM 64 Checking crankshaft
Standard Maximum
less than
Crankshaft bend mm in 0 10 0 0039
0 05 0 0020
EM418
Note When measuring bend use a
Fig EM 67 Press fitting new pilot
dial gauge Bend value is half of the bush ng
reading obtained when crankshaft is
turned one full revolution with a
journal
BUSHING AND
4 After regrinding crankshaft finish BEARING
it to the necessary size indicated on
MEASUREMENT OF
page EM 18 by using an adequate
undersize bearing according to the MAIN BEARING CLEARANCE
extent of required repair clean all bearings and
I Thoroughly
5 Install crankshaft in cylinder check for scratches melting score or
0 05 0 18
plastigage to width of bear
Crankshaft free end to
00118 4 Cut a
03
in 0 0020 to 0 0071 it in with crank
play mm ing and place parallel
pin getting clear of the oil hole Install
them
cap on the assembly and tighten
6 At the rear end of crankshaft To replace crankshaft rear pilot
together to the specified torque
for bushing proceed follows
check crankshaft pilot bushing as
EM 17
Engine Mechanical
plastigage is being inserted size bearing and grind crankshaft jour The standard bearing crush value is
nal adequately listed below
5 Remove cap and compare width
of the plastigage at its widest part with
FiniNG BEARINGS
the scale printed in plastigage enve
Bearing crush
50
0 0 0197 2 077 to 2 085 59442 to 59 455
Undersize 0 0818 to 0 0821 2 3402 to 2 3407
EM 18
Engine Mechanical
1493 to 1
506 49 961 to 49 974
SID
0 0588 to 0 0593 1 9670 to 1 9675
0 0032 to 0 0150 in
Location match
3
EMl48
EM 19
Engine Mechanical
Turn
I engine until No I piston is CHAIN TENSIONER AND
at T DC on its compression stroke
CHAIN GUIDE
Determine whether camshaft sprocket
Check for wear and breakage Re
location notch comes off the left end
if necessary
of the camshaft place
oblong groove on
EM426
t
setting camshaft on No 2 location
hole in camshaft sprocket This No 2
Frant
notch should then be on the right end FLYWHEEL
of the oblong groove When No 2 hole I Check clutch disc contact surface
JI
is used NO 2 timing mark must also
with flywheel for damage or wear
be used The amount of the modifica
Repair or replace if necessary Front
tion is a 40 rotation ofcrankshaft 2 Measure runout of clutch disc
Real
3 When modification becomes im contact surface with a dial gauge fit EM150
possible even by transferring camshaft exceeds 0 15 mm 0 0059 in total
location hole replace chain assembly indicator reading replace it Fig EM 77 Oil eals of crank haft
EM 20
Engine Mechanical
ENGINE ASSEMBLY
CONTENTS
000
to them
o
3 Use new packing and oil seals Points to be applied sealant EM151
4 Do not reuse lock washers
Fig EM 79 Applying sealanl
5 Keep tools and work benches Main bearing cap and Fig EM 81 Installing valves
clean cylinder block
and tools Notes
6 Keep necessary parts
a Ensure that valve face is free from
near at hand
3 Cylinder block Step portions at
7 Be sure to follow specified tight foreign matter
four mating surfaces cylinder block to b The L20B engine uses double type
ening torque and order
8 front chain cover and cylinder block valve springs
Applying sealant
to rear main bearing cap See Figure
Use sealant to eliminate water and
2 Valve rocker pivot assembly
EM 80
oil leaks Parts requiring sealant are
Screw valve rocker pivots joined
Front cover and corners of cyl Note
I Do not apply too much sealant with lock nuts into pivot hushing
inder block See Figure EM 78 3 Camshaft assembly
Set locating plate and carefully
install camshaft in cylinder head Do
CYLINDER HEAD
Valve assembly and valve spring
Using Valve Lifter STl2070000 set
valve pring seat in position and fit
valve with oil seaL
guide
2 Main bearing cap and cylinder Assemble valve in the order shown
block Each side of rear main bearing below valve inner and outer valve
of cylinder block retainer valve collet
cap and each corner springs spring Fig EM 82 Installing camshaft
See Figure EM 79 and valve rocker guide sprocket
EM 21
Engine Mechanical
Install rocker arms by pressing b Arrange that oil of connect 3 Install baffle plate including cyl
5 so jet
valve springs down with a screwdriver ing rod big end is directed toward inder block net
j c6J
en
84
EM Installing piston pin from center bearing in the sequence
Fig
The first step in engine assembly 88
EM
as shown in Figure
is to bolt Engine Attachment
e After securing bearing cap bolts
ST0526000 I to right hand ide of
ascertain that aankshaft turns
cylinder block Next install block on
smoothly
another Engine Stand ST0501S000
with engine bottom up
2 Set main the proper
bearings at
portion of cylinder block
@
EM157 Rear Front
Fig 85
EM Assembling piston and
connecting rod III III m It IlL
Notes
a Piston is pressed into connecting
D D D D D i
rod with fitting force of 0 5 to 5 d
tons aid of Piston Pin Press
Stand STl303000 I is necessary l
bolt
and small end of connecting rod Fig EM 87 Main bearings cap
EM 22
Engine Mechanical
6 Make sure that crankshaft has Note When installing oil seal give
coating of oil
proper end play engine to mating
shaft to prevent scratches and fold
Crankshaft end play
ed lip Also give coating of oil to
0 05 to 18
0 mm
9 Install end
rear
plate
10 Install
flywheel securely and Fig EM 94 Installing connecting rod
tighten bolts to specified torque cap
Tightening torque
14 to 16 kg m
Note Install connecting rods and con
101 to 116 ft lb
necting rod caps 80 that their as
II Insert pistons in corresponding signed numbers are positioned on
cylinder using Piston Ring Compressor the same side and in the SlIme
EM544
Notes
oil to
a Apply engine sliding parts Big end play
b Arrange 80 that notch mark on
0 2 to 3 mm
0
piston head faces to front of en
0 008 to Ql2
0 in
gine
14 Install cylinder head
Install at 1800 to each assembly
c piston rings
other avoiding their fit in the
thrust and piston pin directions
Fig EM 90 Driving side oil seal
r
I iilring
Piston pin ireClioJ Fig EM 96 Tightening sequence 01
cylinder head bolts
STl5310000
EM165
EM 23
Engine Mechanical
b Install Cront cover with head gasket
2 Turn crankshaft until No I pis 17 Install chain slack side guide to
in place
ton is at TD C on its compression cylinder block
c Check height diCCerence between
stroke 18 Install chain tensioner
cylinder block upper Cace and Cront
3 Make sure thai camshaft sprock
notch and plate oblong
Note Adjust protrusion oC chain ten cover upper Cace DifCerence must
et location
correct
sionerspindle to 0 mm 0 in be less than 15
0 mm 0 0059 in
groove are aligned at their
d Note that difCerent types oC bolts
positions are used
4 When installing cylinder head
e Before installing front cover on
make sure that all valves are apart
cylinder block apply coating oC
from heads of pistons
engine oil 10 sealing lip of oil seal
5 Do not rotate crankshaft and
camshaft separately or valves will hit
heads of pistons
6 Temporarily tighten two bolts
sJiown in Fig
re EM 96
CD V
Tightening torque
2 kg m 14 ft b
Fig EM 98 lmtalling chain tensioner
15 Install crankshaft sprocket and
and fit oil
oil pump drive gear
thrower EMS11
2 Chain guide
3 Chain tensioner
4 Crank sprocket
5 earn sprocket
6 Chai guide
EM439
EM 24
Engine Mechanical
2nd turn
I
43 ft lb Notes
6 0 kg m
Tightening torque
A
5 0 to 6 0 kg m 36 to 43 ft lb
EM 176
sary 8 7 to 13 0 ft lb
23 Install oil pump and distr butor Note Do not forget to install fuel
Fig EM I05 Adjusting valve clearance
driving spindle in front cover between
pump spacer and packing
Tightening torque spacer and block spacer and fuel
b After engine has been assembled
1 to 1 5 kg m pump
run it for at least several minutes
8 0 to 10 8 ft lb
Install oil strainer oil pan gasket and to the
25 finally adjust clearance
and oil pan warm specifications
Notes
a Assemble oil pump and drive spin
die aligning driving spindle face
with oil pump hole
b Install oil pump together with drive
position At this point the smaller 27 Install rocker cover to cylinder 29 Install intake manifold to ex
shape
bow will be facing toward the haust manifold The intake manifold
head
front face which comes into contact with
Note Make sure that one of the
Do not forget to install gas et with that of
c
than the gasket should be even
rocker cover bolts is longer
exhaust manifold Note that two dif
others It secures IC D
F assist
ferent sizes of attaching bolts are used
bracket
EM 25
Engine Mechanical
31 Install air gallery pipe on ex 46 Connect all air vacuum and fuel
haust manifold hoses and then secure with clamps
32 Install manifold gasket and I Cylinder block to P C V valve
KV30100200
Tighteningtorque
2 to 2 2 kg
1 m
8 7 to 15 9 ft lb
EM613
EM 26
Engine Mechanical
GENERAL SPECIFICATIONS
L20B
Engine model
4 in line
Cylinder arrangement
1 952 J 19 1
co in
Displacemen t cc
85 x 86 3 35 x 3 39
Bore and stroke mm in
O HC
Valve arrangement
I 42
3
Firing order
8 5
ratio
Compression
SPECIFICATIONS
a Valve mechanism
Intake 0 25 0 010
30
0 0 012
Exhaust
Exhaust 0 25 0 010
diameter mm in
Valve stem
7 965 to 7 980 3136
0 to 3142
0
Intake
Exhaust 7 945 to 7 960 3128
0 to 3134
0
49 98 1968
Intake and exhaust Outer
Inner
44 85 J 766
EM 27
Engine Mechanical
Outer 5 49 0 1
29 IM 108
Inner 24 5 25 5 0 965 56 2
EM 28
Engine Mechanical
c Connecting rod
59
Crankshaft free end play in
mm 0 05 to 0 18 0 0020 to 0 0071
e Piston
3648
3 to 3667
3
100 0 0394 Oversize mm in 85 965 to 86 015
3 3844 to 3 3864
Ring groove width mm in
f Piston pin
EM 29
Engine Mechanical
g Piston ring
in
Ring height mm
Ring gap mm in
Top 0 25 to 040 0 0098 to 0 0157
Oil 30
0 to 0 90 0 0118 to 0 0354
h Cylinder block
i Cylinder head
Surface flatness in
mm less than 0 05 00020
TIGHTENING TORQUE
head bolts kg fl lb 5 to
6
Cylinder m 5
8 47 to 61
ft Ib 14 to 16 101 to 116
Flywheel fixing bolts kg m
ft lb 0 6 to 0 9 3
4 to 5
6
Camshaft locating plate bolts kg m
Carburetor nuts kg m ft lb 5 to 1 0 3 6 to 7 2
0
ft lb 1 2 to 18 8 7 to 13 0
Fuel pump nuts kg m
6 mm 0 236 in dia 4 to 0 6 2 9 to
0 3
4
EM 30
Engine Mechanical
I Noisy engine
Loose main bearing Replace
Knocking of crankshaft
and bearing Seized bearing Replace
Bent crankshaft Repair or replace
Worn and or
damaged chain Replace
Worn sprocket Replace
EM 31
Engine Mechanical
32
EM
IFfIDrnJrnJ 1r DfA 1r ijJJlk1 PlfIDrnJ1r
1
3u e u
Sa e
S
WHIPPL E AT VETERANS TEL EPHONE 3155 6390
NAME DATE I r
DDR E55 CU5T ORDER NO
OUAN
I PART NO
rETe rDS I DESCRIPTION
I J
LIST NET
1 I 1
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k I w
r Ji i idP
I II
I
J JJ
HI 1 ll
tl Y J
plt
h
1 Ii If
is
NO REFUND
For Reference
Tool number
page or
No Description use
ST050 11000
Engine stand
ST050 12000
Base
SE184
EM II
2 ST0526oo0l This engine attachment is installed to engine stand Ll6 Fig
ST0501S000 in disassembling or assembling engine Ll8
Engine attachment L20B
Q
li
SE185
EM 18
3 STl 0120000 Special hollow set bolts are used in tightening cylinder heads All Fig
in series
L engines This wrench is used to torque cylinder L series
Cylinder head bolt head bolts and its head can be inserted into the torque
1 rench wrench
10 0 39 SE186
in Fig EM 105
4 STl 064000 I This tool is used togetller with a torque wrench
tightening pivot lock nut for valve clearance adjustment series
L
Pivot adjuster
33
EM
SE187
Al
Engine Mechanical
Unit mm in on Figure No
tool name
S KV10 1039S0
set Lseries
o Pressing used guide out of place
and
0 Driving a new guide into place
STIlO81000 A series
0 Finishing the bore of new guide
Reamer
12 2 mm dia
STlI 032000
Reamer
8 0 mm dia
STl1320000
Drift
V
SE192
6 STll6S0001
SE193
7 STl2070000
action of its eam and lever thereby facilitating the removal models Fig 8l
EM
SE194
34
EM
Engine Mechanical
8 ST13030001 This tool is used with a press to drive pin into or out of All Fig EM 29
L series Fig EM
84
connecting rod
Piston pin press stand
1 20 0 79
I
8
M
120 4
0
722
SE1BS
EM 9l
9 ST153 10000 This tool is used to push a lip type rear oil seal for Lseries All Fig
engine into place by giving hammer blows series
L
Crankshaft rear oil
seal drift
SE189
10 KVI01041S0 This tool is used to remove the cap from main bearing All Fig EM 25
When using thds tool turn its adapter into the threaded hole Lseries
Crankshaft main in main bearing cap
bearing cap puller
KVI0104110
Body
250 9 8
l
ST165 12001
Adapter
se1g0
SE191
35
EM
r
Engine Mechanical
tool on
name
Unit mm in Figure No
12 STl742000l This tool is used to prevent chains from falling out of place All Fig EM 19
40 S1
1
r SE196
13 STl9320oo0 This tool is used to take oil filter out of place All
n
tightening Page EM4
the filter do not this tool to prevent models
Oil filter wrench
use excess tightening
120 4 7
SE197
14 KV30100200 This tool is used to install clutch assembly to engine All Fig EM 107
Lseries
Clutch bar
aligning
SEGOl
15 EM03470000 This tool is used to compress piston rings while piston is All Fig EM 92
being inserted into cylinder models
Piston ring
compressor
SE199
36
EM
SECTION EL
ENGINE
DATSUN PICK UP LUBRICATION
MODEL 620 SERIES
SYSTEM
CONTENTS
OIL PUMP
The oil pump is secured on the
bottom of the front cover with four
bolts and driven by the oil pump drive
LUBRICATION maximum of 5 6 kg
em 80 psi
CIRCUIT
The pressure lubrication of the cylinder head to provide lubrication
engine is accomplished by a tro of the valve mechanism and timing
choid type oil pump This pump chain as shown in Figure EL2
draws the oil through the oil strainer Removal
into pump and then forces it
housing I Remove distributor
through the full flow type oil filter 2 Drain engine oil if necessary
into the main oil gallery Part of the 3 Remove oil pump body with
oil is supplied to all crankshaft drive spindle assembly
bearings chain tensioner and timing
chain Oil supplied to crankshaft
bearings is fed to connecting rod
bearings through the drilled passages
in the crankshaft Oil injected from
jet holes on connecting rods Iubri Installation
cates the cylinder walls and piston
I Before
The
installing oil pump on
pins other part of the oil is
ELOSO engine turn crankshaft so that No I
brought to the oil gallery in the
is at TD C
Fig EL 2
Lubricating vallie mechanism piston
EL 2
ENGINE LUBRICATION SYSTEM
wear
2 Fill housing with engine
pump Disassembly 3 Check inner rotor shaft for
oil then align punch mark of spindle
shown in
and assembly looseness in pump body
with hole in oil pump as
4
Figure EL 3 I Remove pump cover attaching Inspect regulator valve for wear
EL009
CD
Fig EL3 Aligning punch mark
and oil hole
located in II
this time
25 a m position
the smaller bow shape will
at
@
r
@ CD@ 1 Outer rotor to body clearance
be placed toward the front as shown
2 Tip clearance
in Figure EL 4 1 Oil pump body 6 Regulator spring
Inner rotor and shaft 7 Washer
3 Gap between rotor and straight edge
2
JI 8 4 Gap between body and straight edg e
c I 3 Outer rotor Regulator cap
J V 4 Oil pump cover 9 Cover gasket Fig EL 7 Checking rotor clearance
5 Regulator valve
J 9@
@
tr
Fig EL 6 Oil pump
7 the
Place a straight edge across
Front
i
L It
d
I
face of pump and depress it slightly as
shown in Figure EL 7 Check gap 4
between body and straight edge or gap
Inspection 3 between rotor and straight edge
I EL010 Wash all parts in cleaning solvent The gap should be 0 03 to 0 06
Fig EL 4 Setting drive pindle and dry with compressed ir mm 0 0012 to 0 0024 in then
o I Inspect pump body and cover rotor side clearance rotor to bottom
for cracks or excessive wear cover clearance with gasket should
2 Inspect pump rotors for excessive satisfy the specifications
EL 3
ENGINE LUBRI CATION SYSTEM
Tightening torque
4 to 5 29 to 36
Regulator valve cap nut kg m ft lb
Specifications
to 40
Oil pressure at idling kg cm2 psi 0 8 to 2 8 II
em2 35 to 5 0 50 to 71
Regulator valve opening pressure kg psi
STl9320000
EL016
EL015
4
EL
ENGINE LUBRICATION SYSTEM
0 15 toO 21 05
Outer rotor to body clearance mm in
0 0059 to 0 0083 0 0197
34 8 1370
Pressured length mmOn
kg em2 psi 5 to 5 0 50 to 71
3
Regulator valve opening pressure
Tightening torque
Oil pump bolt kg m ft lb 1 to 5 8 0 to 10 8
1
ft lb 0 7 to 1 0 5 1 to 7 2
Oil pump cover bolt kg m
ft Ib 4 to 5 29 to 36
Regulator valve cap nut kg m
EL 5
ENGINE LUBRICATION SYSTEM
STl9320000 This tool is used to take oil f1Iter out of place In tightening All EL 9
Fig
the f1Iter do not use this tool to prevent excess tightening models
Oil filter wrench
I 120 4 7
SE197
6
EL
SECTION CO
COOLING
DATSUN PICK UP SYSTEM
MODEL 620 SERIES
COOLING SYSTEM CO 2
TROUBLE DIAGNOSES
CO 7
AND CORRECTIONS
LNISSAN I
COOLING SYSTEM
CONTENTS
DESCRIPTION CO 2 OISASSEMBL Y 4
CO
COOLANT LEVEL CO 2 INSPECTION 4
CO
DRAINING AND FLUSHING THE TEM COUPLlNG 4
CO
COOLING SYSTEM CO 2 INSPECTION CO 5
WATER PUMP CO 2 THERMOSTAT CO 5
REMOVAL AND INSTALLATION CO 3 REMOVAL AND INSTALLATION CO 5
DISASSEMBLY CO 3 INSPECTION CO 5
INSPECTION AND ADJUSTMENT CO 3 RADIATOR CO 5
TORQUE COUPLING CO 3 REMOVAL AND INSTALLATION CO 5
REMOVAL AND INSTALLATION 4
CO INSPECTION CO 6
DESCRIPTION
The cooling system is of the con the of the
creases cooling efficiency If it is necessary to remove radiator
ventional pressure type A centrifugal radiator cap wben radiator is hot turn cap
pump installed on the timing chain When the thermostat is closed the slowly counterclockwise to the r
cover serves to circulate the coolant coolant remains in the cylinder head step After all pressure in the cool
The pressure type radiator filler cap and block for swift warming up of the
ing system is released tom cap
installed on the radiator operates the engine After it reaches normal oper passing the stop and remove it
cooling system at higher than atmos ating temperature the coolant circu
pheric pressure latesthrough the radiator
The higher pressure raises the The cooling fan drive is of a
C0055
CO 2
Cooling System
CQ048
Be C0060
installing pump assembly sure to
00 3
Cooling System
pump
1 Bi metal thermostat
2 Slide valve
3 Reserve chamber for OFF
6 4 Bearing
5 Driving chamber for ON
6 ouplingpart labyrinth
coon
is ation is
coupling
Tem a type of fan placed under OFF condition system is placed under ON con
coupling which is provided with a and the fan slips at about 1 650 rpm dition
temperature control system The coiled bimetal thermostat When the valve closes silicone oil is
The conventional coupling always installed the front center portion of
on not supplied to the driving chamber
slips the fan at a high speed under a the Tem coupling detects temperature oil in the driving chamber is accumu
constant ratio regardless of the engine of air passing through the radiator lated on periphery due to the centrif
cooling requirement The air temperature is directly ugal force and led into the reserve
The slipping ratio of the Tern relative to the engine coolant tempera chamber Now oil is eliminated from
coupling however is properly changed ture and the inside slide valve is the driving chamber and the system is
with the cooling requirement closed
opened or as required and thus placed under OFF condition
ON denotes that cooling is re the ON OFF control With this system when fan cooling
is performed
quired and the fan operates up to When the air is not required the is
temperature rises the output loss
about 2 150 rpm When high
cooling is bimetal is expanded and the valve is minimized and noise can be far
not required during cold season with opened silicon oil is forwarded to the reduced
the engine warmed up etc the oper groove that transmits torque and the
4
CO
Cooling System
F INSPECTION
Z
Tern coupling A sticking thermostat will prevent
WATER PUMP SPEED the cooling system from functioning
properly If the thermostat sticks in
C0029
the open position the engine warms
Fig CO 6 Characteristic of
Tern coupling up very slowly If the thermostat
sticks in the closed position over
INSPECTION heating will result Therefore the ther Fig CO S Impecting therm06t t
and if must be replaced because it cannot be combined with the radiator to cool
predetermined temperatures
should be re repaired transmission fluid
not operating properly
moved and tested as described below
REMOVAL AND
REMOVAL AND
INSTALLATION
INSTALLATION RADIATOR
Drain coolant into a clean con
I Drain coolant partially The radiator is a conventional down
tainer
2 Disconnect upper radiator hose at flow type having top and bottom
2 Disconnect radiator upper and
water outlet tanks to distribute the coolant flow
lower hoses On models with auto
3 Remove bolts and remove water uniformly through the vertical tube of
matic transmissions disconnect cooler
outlet gasket and thermostat from radiator core
CO 5
r
Cooling System
direction when hoses are assembled after cleaning it Then install radiator If a leakage is detected repair or
3 Ensure that clearance between cap on a tester If cap does not hold or replace radiator
radiator hose and any will release at the specified pres
adjacent parts is not
stalling
Thermostat
Temperate Frigid type Tropical type
type
Valve oC F 5 to 83 5
80 5 to 89 5
86 75 to 78
opening temperature
177 to 183 187 to 193 167 to 172
Radia tor
Type
Manual transmission Corrugated fin type
Automatic transmission fin type equipped with oil cooler
Corrugated
Cap relief pressure kg em psi 0 9 3
1
Cooling system
Fan
6
CO
Cooling System
Poor circulation Restriction in system Check hoses for crimps and clear the system
of rust and sludge by flushing radiator
Radiator fin choked with mud chaff etc Clean passage thoroughly by using air
out air
CO 7
SECTION EF
ENGINE FUEL
DATSUN PICK UP
MODEL 620 SERIES
AUTOMATIC TEMPERATURE
CONTROL A T Cl H 2
AIR CLEANER
IDLE COMPENSATOR H 7
FUEL FILTER H 8
CARBURETOR H 14
l NISSAN I
CONTENTS
DESCRIPTION
The air cleaner removes dust and and to remove carburetor icing between the exhaust manifold and hot
dirt from the air before it enters the The A T C air cleaner system con air duct is led to the air cleaner
carburetor and engine It also muffles sists of the following devices the hose
through
noise resulting from the intake of air 1 Air cleaner element
4 Blow by gas filter
into the engine The air cleaner element employed is The blow by gas nIter removes dirt
The air cleaner especially designed a viscous paper type It requires only and oil from the blow by gas sucked in
for improved exhaust emission control periodical replacment and should not the air cleaner from the engine rocker
is referred to as Automatic be cleaned
Tempera cover
ture Control Air Cleaner In order to 2 Automatic control 5 Fresh
temperature air duct Except for
reduce HC emission when the under air cleaner Canada
hood temperature is below 300C In the A T C air cleaner the air The fresh air duct leads the outside
860F the automatic temperature control valve is actuated by intake fresh air directly to the air cleaner
control system maintains the tempera manifold to control the intake Idle compensator
vacuum 6
ture of air to be sucked in the carbure air flow circuit The temperature sen See Idle Compensator
paragraph
tor at 30 to 540C 86 to 1290F sor detects the temperature inside the Page EF 7
thereby enabling lean for air cleaner and opens or closes the
setting 7 Altitude compensator California
carburetor calibration n addition to vacuum models
passage
this the automatic 3
temperature con Hot air duct Seeparagraph Altitude Compensa
twl system is effective to improve The hot air duct is mounted on the tor Page EF 20
warm up characteristics of the engine exhaust manifold The air warmed up
EF 2
Engine Fuel
EF713
OPERATION
The automatic temperature control load condition of the engine The inlet ated by the engine intake vacuum
by the inlet air temperature and the sensor and the vacuum motor is actu
Below 60 mmHg
Open cold air
Below 300C 36
2 inHg
Close
860 F
Above 210 mmHg
Close hot air
8 27 inHg
Above 55 oC
Open cold air Open
1310F
the to intro
When the under hood air tempera the intake manifold and vacuum vacuum motor diaphragm
ture is low the sensor air bleed valve motor With this condition the vacu duce hot air into the air cleaner
remains in the closed position and urn at the intake manifold side actu through the hot air duct on the ex
establishes vacuum
passage between ates the air control valve attached to haust manifold
EF 3
Engine Fuel
A T C AIR CLEANER
COLD AIR OPERATION
ID s
6
Vacuum hose passage is established between the in
Diaphragm spring take manifold and the vacuum motor
Ittl ID closed
Temperature sensor
applied to
vacuum
motor dia
is small or
Holair assembly
when the engine is
EF114 operating under
Fig EF 2 Hota r delivery mode During cold engine operation 1004 the air control valve opens
eavy
widely irrespective of the temperature
around the sensor to introduce the
under hood air cold air for increased
7
power of the engine
2 When under hood air temperature
To manifold Small vacuum is high
Dr 1 Air inlet pipe The sensor air bleed valve opens
2 Air control to shut off the vacuum passage
air
Underhood
valw fully
3 Hot air pipe
between the intake manifold and the
4 Diaphnp
I motor Due to the force of the
@ S V leuum hoses vacuum
motor the
6 Diaphragm prinl vacuum
diaphragm spring
7 Air bleed valve air control valve closes the hot air pipe
closed of the air cleaner and introduces the
II Temperature senSOr
under hood air cold air
assembly EF20S
f liP omanifold
1
2
Air inlet
Air
pipe
control valve When the sensor air bleed valve is
Underhood
air Vacuum hoses
of the intake manifold With the air
Diaphragm spring
I Air bleed valve control valve open
half the cold air
@ fully open and hot air are sucked together and
8 Temperature mixed for of the air tem
sensor
controlling
assembly of the air to be introduced to
EF715 perature
Fig EF 4 Cold air delivery mode During hot engine operation the air cleaner
ID
f
@ fjr
ow
R lfl Air inlet pipe
2 Air control valve
4
EF
Engine Fuel
The is attached
temperature sensor hose secure hose with the clip
to the inside of the air cleaner The
bimetal built in the sensor detects the I Pipe Note Be sure to install vacuum hose
under hood air temperature and opens 2 Calch Correct position is R H
correctly
or closes the vacuum passage in the 3 Fixed with mark at the top
side to Nissan
adhesive
sensor face of sensor for intake manifold
4 Hose
The construction of the tempera L H side for vacuum motor
5 Tab
ture sensor is shown in the following 6 Clip
7 Gasket
EC019
CD V 00 @
I Fig EF B Removal of semor
I
2 Disconnect hose from sensor VACUUM MOTOR
3 Take off clip from sensor vacuum
1 Remove screws securing vacuum
tube and dismount sensor body from
motor to air cleaner
air cleaner
I 2 Disconnect valve shaft attached
Protector cover Note The gasket between sensor and air
j
@ to vacuum motor diapluagm from
I Screw
air cleaner is bonded to the air valve
control and remove cacuum
Adjusting frame
1 Air temperature bimetal
cleaner side and should not be motor assembly from air cleaner
to
pr
I
1 Valvespring
2 Diaphragm
00
@ 3 Retainer
Removal
EF518
Using pliers flatten clip con Fig EF I0 Removal offresh air duct
EF 5
r
Engine Fuel
Hose Air air sensor is for intake manifold L U and cut off air from vacuum hose In
control vaive to
cleaner California models only side of the mark is for vacuum
this condition check that air control
motor valve maintains the condition de
3 To install reverse the removal
scribed in step 2 for more than 30
procedure
2 2 Vacuum motor seconds and that hot air inlet is open
If diaphragm spring actuates the air
INSPECTION I With engine stopped disconnect control valve by its spring force to
1 AIR CLEANER fresh air duct under hood air inlet within 30
open
ELEMENT Place a mirror at the end of air seconds replace vacuum motor as an
cleaner inlet pipe as shown and check assembly since this may be resulted
Viscous paper type air cleaner ele
to see if air con trol valve is in correct from air leak at vacuum motor dia
ment does not require any cleaning
position phragm
operation until it is replaced periodi
cally Brushing or blasting operation
will cause clogging and result in enrich
2 3 Temperature ensor
ment of carburetor mixture and
should never be conducted For reo
Check temperature sensor for func
placement interval of air cleaner ele tion by proceeding as follows Be sure
ment refer to Maintenance Sched
to keep engine cold before starting
ule
test
I With engine off check air control
2 HOT AIR
valve for condition In this case under
CONTROL SYSTEM EF213 hood air inlet is open Use a mirror for
In warm weather it is difficult to Fig EF 11 Inspecting valve position inspection as 2 2 1 above
find out malfunction of hot air control 2 Start engine and keep idling
system In cold wea thee however Air control valve is in correct posi Immediately after engine starting
malfunction of air control valve due to tion if its under hood air inlet is open check air control valve for correct
disconnection or deterioration of vacu and hot air inlet is closed Check air described above In this
position as
um hose between intake manifold and control valve for condition of air control
linkage case correct
position
vacuum motor and insufficient dura 2 Disconnect inlet valve
vacuum motor is the reverse of 2 2 I under
bility of air control valve will cause vacuum hose and connect another hood air inlet is closed and hot air
insufficient automatic control opera hose to the inlet to apply vacuum to inlet is open
tion for intake air and result in engine vacuum motor Vacuum can be ap 3 Check that air control valve grad
disorder including plied by breathing in the hose end as ually opens to under hood air inlet
I Stall hesitation of engine oper
or shown side as engine warms up When en
ation Place mirror at the end of air
a vironmental temperature around tern
2 Increase in fuel consumption cleaner inlet pipe and check to if
see perature sensor is low spend more
3 uck of power air control valve is in correct time for
position engine warming up operation
6
EF
Engine Fuel
to facilitate smooth operation of air element will not be affected by air 5 Carry out test as described in
control valve flow Then install air cleaner cover steps I 2 and 3 above When air
If the above test reveals any prob control valve begins to open to under
lem in the operation of air control hood air inlet side several minutes
valve carry out the following test after engine starting read the indica
4 Remove air cleaner cover Set tion of thermistor or thermometer If
temperature sensing element of ther reading falls within the working tern
IDLE COMPENSATOR
CONTENTS
OPERATION EF 7 INSPECTION EF 8
3 Rubber valve
valve Two idle compensators having EF222
OPERATION No 60 to 70 C
1 Close to open
140 to l580F
70 to 900C
No 2 Close to open
158 to 1940F
EF 7
Engine Fuel
2 bi metal
When temperature is
above the specified operating tempera
ture visually check to see if the valve
is in open position If valve is not
assembly
EF718
Watcr
Fig EF 15 Location of idle compenl otor Observe temperature
valve
Remove air cleaner cover air If excessive air leakage is found at No 1 Bknctal
2 Remove hose connecting idle the valve replace idle compensator as 60 to 70De
11t
3 way connector 140 to 1580F
compensator and an assembly Note that two idle com
NO 2 metal
Bi
3 Loosen screws securing idle com
pensators are mounted to air cleaner
70 to 900C
pensator to air cleaner then remove and that it is necessary to plug the 158to 1940F
idle compensator valve of one of these idle compensa
tors so as to prevent air leak while EF226
Notes checking the other one
a When removing idle compensator Fig EF 17 Checking idle compensator
remove gasket and plate
b When removing screw securing idle
@
compensator to air cleaner be care
INSPECTION
tl 2 Check rubber valve seat of idle
faulty conditions
I Check tha t valve IS m closed 1 Orifice
position when bi metal temperature is 2 Rubber valve
EF225
lower than operating temperature To
check breathe air into tube or suck Fig EF 16 Checking idle compelll lor
FUEL FILTER
DESCRIPTION REMOVAL
2
3
1 Body
Paper element
Cover
1 EFOO5
Note Before disconnecting fuel lines
EF 8
Engine Fuel
CONTENTS
CAPACITY TEST EF 10
DESCRIPTION
1
The fuel pump transfers fuel from
the tank to the carburetor in sufficient
quantity to meet the engine require
ments at any speed or load
The fuel pump is a pulsating type
designed for easy maintenance It con
FUEL PUMP
TESTING
A fuel pump is operating properly STATIC PRESSURE TEST
when its pressure is within specifica The static pressure test should be Note Locate this Tconnector as
EF 9
Engine Fuel
4 Run the engine at varying speeds 2 Take off cap and cap gasket by
5 The gauge indicates removing cap screws
pressure
staticfuel pressure in the line The 3 Unscrew elbow and connector
8
phragm return spring or a diaphragm
that is too tight Both of these condi
tionsrequire the removal of pump
assembly for replacement or repair
o
CAPACITY TEST
I fuel pump cap
2 Cap gasket
The capacity test is made only 6 3 Valve packing
when static
pressure is within the 4 fuel pump e
val
@
REMOVAL AND Fig EF 21 ure
Slruc offuel pump
DISASSEMBLY
EF 10
Engine Fuel
CONTENTS
DESCRIPTION EF 11 DISASSEMBLY EF 12
INSPECTION EF 11 ASSEMBL Y EF 12
REMOVAL AND INSTALLATION EF 12 TROUBLE DIAGNOSES AND
CORRECTIONS EF 13
DESCRIPTION
The electric fuel pump is adopted The silicon transistor type fuel pump noid a
pump mechanism and filter
on air conditioner models consists of a transistor diodes a sole
equipped parts
J
ev
I T nsistor
2 Re f ist I
3 Dinde
4 Signal coil
5 Main coil
6 Resistor 3
7 Zener dlOdl
I Tr lOsistor 6 Ou tIet valve 8 Resistor 2
2 Plunger 7 Return spring
3 Diaphragm 8 Filter
4 Diode 9 Magnet
5 Magnet coil 10 Inlet valve EF719
INSPECTION
I Disconnect fuel hose at pump Note If diameter is too small the 3 With hose outlet in
higher posi a
EF 11
Engine Fuel
854 co in in one minute or less b Do not let fall pump as it may ASSEMBLY
If no gasoline or only a little flows damage electronic components
from open end of pipe with pump c Do not apply overvoitage max I Before assembly clean all parts
l8Y Overvoltage starting by
operated or if pump does not work with gasoline and compressed air com
with
f Tighten cover with wrench to the
stopper
@
1 Cover 8 Oring
2 Magnet 9 Inlet valve
3 Cover gasket 10 Retutn PIing
4 Filter 11 Plunger
5 Gasket 12 Plunger cylinder
6 Spring retainer 13 Body
7 Washer EF721
EF 12
Fuel
Engine
Insufficient fuel Air in fuel hose through connections Apply a coating of end sealing compound to
Low float level Hose necked down or bent Check and correct
at idling Fuel tank breather tube bent or necked Check and correct
down
Fuel pump is actuated Air sucked through connection fuel hose Apply a coating of end sealing compound to
frequently than Fuel hose on suction side bent Check and correct
under normal condi Clean
fIlter or replace fIlter
tion Clogged
EF 13
Engine Fuel
CARBURETOR
CONTENTS
EF 14
Engine Fuel
jli@
I
tZrJ
I III
I Fuel nipple
2 Fuel filter
3 Needle
4 Float
PRIMARY SYSTEM into the engine through the idle hole the idle hole and bypass hole via the
and bypass hole sow sysem passage
main
Prlmar sstem
Adoption of the submerged type of
Theprimary main system is a slow jet eliminates such hesitation as
Stromburg type Fuel flows as shown occurs on sudden deceleration of the
in Figure EF 25 through the main jet vehicle
mixting with air which comes in from Slow economizer system obtains
the main air bleed and passes through Accele atlns mechanism
smooth deceleration at high speeds
the emulsion tube and is pulled out Small opening of the throttle valve
with the
into the venturi through the main at idling or partial load creates a large The carburetor is equipped
mechanism
nozzle vacuum pressure in the intake mani piston type accelerating
linked to the throttle valve When the
fld
throttle valve shown in
By this vacuum pressure fuel is primary
IdUns and slow sstem
measured through the slow jet located Figure EF 26 is closed the piston
low engine speed as shown and fuel flows from the float
During behind the main jet And air coming goes up
in Figure EF 25 fuel flows through from the 1st slow air bleed is mixed chamber through the inlet valve into
the slow jet located on rear right side with fuel in the emulsion hole the space under the piston When the
of main nozzle mixing with air com This mixture is further mixed and throttle valve is opened the piston
ing from the 1st slow air bleed again atomized with air coming from the goes down opening the outlet valve
EF15
Engine Fuel
1
L
if
1 Pump injector
2 Piston
3 Spring
4 Weight
5 Damper spring
6 Piston return spring
7 Inlet valve
8 Outlet valve
EF023
I
1
11
1
of
llW l
11
1
Diaphragm spring
S Diaphragm
6 Secondary throttle
valve
7 Primary theo nle
1 Vacuum piston
2 Power valve a
ET02 v valve
512
EF
Fig EF 27 Sectional view of po r
EF 16
Engine Fuel
Step system HI h speed circuit richer jet high speed enricher air
The high speed circuit improves bleed and richer nozzle When the
velocity of suction air flowing through
The construction of this system high engine output performance
during high speed driving the carburetor secondary bore in
may correspond to the idling and slow
This circuit operates only when creases additional fuel is drawn out of
system of the primary system
the richer nozzle
Tlris system aims at the proper driving at high speed It consists of a
filling up of the gap when fuel supply
is transferred from the primary system @ 2
to the secondary one The step port is
air bleed
is pulled against the diaphragm
phragm 3 Richer nozzle
spring force and then secondary throt
tie valve is opened Fig EF 29 High speed circuit
The other side
during low speed
running as the primary throttle valve
ANTI DIESELlNG SYSTEM
opening does not reach 500 the is brought into operation shutting off
secondary throttle valve is locked to The carburetor is equipped with the
an supply of fuel to the slow circuit
close completely by the locking arm anti dieseling solenoid valve As the The following figure shows a see
which is interlocked with primary ignition switch is turned off the valve tiorial view of this control
throttle arm by linkage
When the primary throttle valve
opening reaches wider position than
500 the secondary throttle valve is
CD
ready to open because the locking
arm revolves and leaves from the se 1 g
condary throttle arm
1
@eI
EF230
1 dieseling
Anti solenoid va1
2 Ignition switch
3 Battery @
l
Fig EF 30 Schematic drawing of anti dieseling sydtm
EF 17
Engine Fuel
FLOAT SYSTEM determined value the B C D D intro The amount of the mixture is con
complete combustion because of the as to open the vacuum control valve When the shift lever is in N or
reduced of mixture per cyl
amount @ This causes the manifold vacuurn P position the inhibitor switch
inder per rotation of engine with the to be introduced into the second mounted on the transmission turns on
result that a large amount of hydrocar vacuum chamber and actuates dia to open the vacuum control solenoid
bons is emitted into tile atmosphere
phragm ll@ valve
The B C D D has been designed to When diaphrngm II operates the
correct this problem mixture control valve @ opens the
It opern tes as follows when the passage and introduces the additional
manifold vacuum exceeds a pre mixture into the manifold
EF 18
Engine Fuel
11
6
I
@
fI3 r
101
1
j @ i
W @
r
JJ
I
t i J
l
I Ignition switch
2 Amplifier
below
3 Speed detecting switch
10 M P H ON for manual
transmission ru
I
r
4 Inhibitor switch N p
ON for automatic
transmission lJ
i7
5 Solenoid valve
6 Vacuum control valve
7 Altitude corrector
I To intake
manifold
1
J
To air
cleaner
I
LlJ
I
l f L8 J
l
E F235
EF 19
Engine Fuel
D H L Lever
Il
H position
@@
r Should be used for general driving
EF232 in those areas designated by law as
1 Alternator High Altitude Counties
2 Automatic
choke relay
3 Automatic
choke cover L position
4 P T C heater A
EF 20
Engine Fuel
a The idle rpm and CO vary accord more above sea level have been connected hose to prevent dust from
High Altitude
ing to the altitude Therefore they designated by law as entering
when Counties For further details refer
should be properly adjusted 0
rID
mOl
If Low altitude Ll
n
n
0
I
EF259
adjusting screw down completely ture indicator points to the middle CO percentage
could damage to tip Further keep engine running at about Manual transmission
Ooing so cause
which in turn will tend to cause 2 000 rpm for about 5 minutes with tl
2 at 750 rpm
Automatic transmission
malfunctio11ll out applying load to engine in order to
b If idle limiter cap obstructs proper stabilize engine condition Engine in 0 position
hood should be open tI
2 at 650 rpm
adjustment remove it
Run engine for about 10 minutes
To install idle limiter cap refer to 4
P position for automatic trans 5 Remove air hose between 3 way ing idle CO in step 9 can be carried out
EF 21
Fuel
Engine
rpm two or three iimes under no load is run at idling speed adjust idle in Figu re EF 37
and make sure that specified CO per adjusting screw until maximum rpm is When H is approximalely 7
0 283
centage is obtained obtained mill in lOp float position is
correct
12 Connect air hose to air check 10 Repeat procedures as described
valve in steps 6 7 and 9 above until engine The top float position can be ad
If engine speed increases readjust it speed at best idle mixture is 815 rpm justed by bending float seat
for manual transmission
to the specified speed with throttle models and Upon completion of the adjust
adjustingsqew 670 rpm for automatic transmission ment check fuel level wi th attached
models in D position Adjustment level gauge
COidle edJustment without in step 9 can be carried out right after
p
CO meter step 7
3 After adjustments in
5 to 9 below of installation To adjust proceed as steps I and
2 above have been made make sure
5 Remove air hose between 3 way follows
5 way connector for Cali that when fuel is delivered to the float
connector I After
adjusting throttle or idle
chamber the fuel level is maintained
fornia models and air check valve speed adjusting screw check to be sure
within the range of23 mm 0 91 in
shown in Figure EF 35 Plug the dis that the
as
amount of CO contained in
shown in FigureEF 38
connected hose 19 prevent dust from
exhaust gases meets the established
entering standard
6 Race engine 1 500 to 2 000 rpm 2 Install idle limiter cap in position
two or three times under no load then
making sure that the adjusting screw
run engine for one minute at idling can rotate another 1 8 turn in the
speed CO RICH direction
7 Adjust throttle adjusting screw so
Carbo to per CO rich
that engine speeds are as indicated
below
rotation
450 lIS
Engine speed
Manual transmission H 23 mm 0 91 in EF260
CO lean
815 rpm
Automatic transmission
in D
670 rpm
position t J
SQ
1dle lim Iter
Fig EF 38 Checking ruellevel
ET031 cap
FAST IDLE
Fig EF 36 Setting idle limiter cap
8 Check ignition timing if neces
I With carburetor assembly reo
it to the value required by
sary adjust moved from engine measure throttle
specifications This operation need not FUEL LEVEL
valve clearance A with a wire gauge
be carried out at 1 600 km 1 000 1 Turn down float chamber to al placing the upper side of fast idling
miles service low float to come into contact with screw on the first step on fast idling
9 At about 10 minutes after engine needle valve and measure Hu shown cam
EF 22
Engine Fuel
04th
Fast idling carn
Nut
EC527
l1st
2nd
Fast idling screw
Choke valve
Choke connecting
rod
Z
EC528 Throttle valve
Fig EF 39 Mea uring throttle valve
clearance Fig EF 40 Fast idling cam steps
ET033
1st step
A in
3 To check fast idling cam setting fast idling cam at 2nd step and read specifications below Clearance
by engine speed proceed as follows engine speed Fast idling cam is prop 2nd step is reference value
Warm up engine sufficiently Set erly set if engine speed is within
Fast Clearance A mm in
Engine speed rpm idling earn
I 900 to 2 800 0 94 to 18
1 0 0370 to 0 0465
MfT
2nd step
j
iXo
CK 2
rubber
Hold choke valve by stretching
band between choke piston
a
lever and stationary part of carburetor lever and stationary part of carburetor
3 Grip vacuum break rod with 3 Pull throttle lever until full open
pliers and pull straight
4 Under this condition
out
adjust the
LL r I ance
Under this condition
between choke valve and carbure
adjust clear
il
clearance between choke valve and
J L torbody to 2 45 mm 0 096 in by
carburetor body B in Figure bending unloader tongue
42
EF to specified value by bending
vacuum brake rod Note Make sure that throttle valve
EF516
is mounted
opens when carburetor
1 Choke piston rod 4 Diaphragm cover on the vehicle
2 Choke spring 5 Choke piston lever
If throttle valve rails to open un
3 Choke piston 6 Choke valve
loader becomes inoperative resulr
break in poor acceleration after
Fig EF 42 Adjusting vacuum
ing engine
is started
EF 23
Fuel
Engine
2 Make an operational check of
ELECTRIC AUTOMATIC Automatic choke
automatic choke relay as shown in
CHOKE de
I Before starting engine fully
Figure 46
EF
celerator pedaJ to ensure that
Checklna automatic choke press al 2 volts across termi
Apply c
d
Figure 44
EF them If results satisfies the above
I engine not running check
With
automatic choke relay is functioning
for continuity between A and B as Note Do not set b metal cover index
properly if not replace choke relay
shown in figure 43
Ef mark at any position except the
If continuity exists heater is func center of choke housing index
2
P T e heater circuit
y
J
as shown in figure 43
EF 3 4
If vohmeter reading is zero check Bi metal chamber Fig EF 46 Checking automatic choke
2 Thermostat housing relay
for disconnected connector open ET034
3 Groove
circuit or faulty automatic choke
Fig EF 44 Bi tting
metol Automatic choke heater
relay
I Measure resistance of choke
3 Replace faulty parts heater as shown in figure 47
EF
ified san ce is 3 7 to 8 9
spe re
Automatic
FEF261
choke relay
j INTERLOCK OPENING OF
1 ignition key
2 Automatic choke relay PRIMARY AND SECONDARY
Engine stop OFF THROTnE VALVE
Engine start ON
3 Automatic choke heateI Figure 48
EF shows primary throt
EF710
4 Function test connector tie valve SO When primary
opened
5 Altema tor
EF278 throtlle valve is opened 50 the adjust
Fig EF 43 Checking oulomalic
plate integrated with throttle valve is
choke heater circuit with Fig EF 45 Location of automatic
led connector choke relay in contact with return plate at A
fu nc non
EF 24
Engine Fuel
L
l below
If continuity does not exist check
for disconnected connector and or
t
7
Figure EF 50
1 Roller 4 Adjust plate ANTI DIESELING I Raising up rear axle housing with
2 Connecting lever stand
5 Throttle c amber SOLENOID VALVE
3 Return plate 6 Throttle valve If engine does not stop when igni 2 Chassis dynamometer test
Fig EF 48 Adjusting interlock opening tion switch is turned off this indicates If voltmeter reading is 0 volt at a
8
3
4
1
2
Ignition Icey
Fuse
Amplifier
Speed detecting switch
Above 10 mph OFF
5 Make that
sure engine speed Below 10 mph ON
drops smoothly from 2 000 to 1 000 5 Function test connector
EF711
EF 25
Engine Fuel
AUtomatic trailamlsalon modela check for resistance between A and B 3 Warm up the until it is
engine
I With inhibitor switch ON UN Refer to Figure EF 51 heated to operating temperature
P check for presence of Then
or position If ohmmeter reading is 25 ohms or adjust the engine at nunnal
voltage across A and B Refer to below circuit is idling setting Refer to the item
functioning prop
Figure EF 51 erly Idling Adjustmenl in page EF 21
If ohmmeter
If voltmeter ading is 12 volts readingis 32 ohms or Idling engine speed
above check for poor connection
dc BC D O circuit is func Manual transmission
of connec or faulty B C D D sole
tioning properly 750 rpm
If voltmeter noid valve or inhibitor relay Automatic transmission
ading is zero check
solenoid valve m inhibitor switch unit is located it should be moved 650 rpm
and tested
2 With inhibitor switch OFF again If necessary replace 4 Run the engine under no load
HI 2 IY oR Increase engine speed to 3 000 to
or position
3 500 rpm then quickly close throttle
@
valve
yu 5
mmHg
At the time the manifold
p ssure increases
abruptly to
23 62 inHg or
600
above and
vacuum
set at idling
6 Check that the B C D D set pres
1 Ignition key sure is within the specified pressure
2 T switch
Inhibit Specified pressure 0 m sea level
@ N P positions ON and 760 mmHg 30 inHg atmos
I 2 D R positions OFF
pheric pressu
3 D C D D solenoid valve
4 Function test connector
Manual transmission
5 Inhibitor relay
510 to 550 mmHg
EF712
20 1 to 7inHg
21
Fig EF 51 Checking B C D D circuit with unction t st connector
Automatic transmission
for automatic transmision
490 to 530 mmHg
Set pressure To B D D
19Tto 20 9 inHg
solenoid valve
of Boost Controlled
Deceleration Device B C D O 1 Notes
BC D D olenoid valve
a When atmospheric pressure is
Generally it is unnecessary to ad harness
known operating pressure will be
just the B CD D however if it should
found by tracing the arrow line
become necessary to adjust it the
A See Figure EF 56 When alti
procedure is 3S follows
tude is known operating pressure
will be found by tracing the arrow
Prepare the foUowing tool EF262
line B See
Fig EF 52 Removing harness of
FiguEF 56
I Tachometer to the b When the set of
measure en
solenoid valve checking pressu
gine speed while B CD D find the specified
idling and a screw set
2 Connect rubber hose between
driver in Figure EF 56
pressu from the
vacuum gauge and intake manifold as and altitude
2 A vacuum gauge and connecting atmospheric pressure
shown
of the given location
pipe
if an automatic trans
For example
Note A quick hoost
response type mission model vehicle is located at
gauge such as Bourdon s type is an altitude of 1 000 m 3 280 ft
recommended a mercury type the set for
specified p ssu
EF 26
Engine Fuel
adjustment
1 Adjusting screw s CD If engine speed cannot be decreased
2 Cover e
to idling when checking B C D D set
ET037
California models pressure proceed as follows
t
reduce the negative idling pressure of
M
Intakema
gjl 11 Road test
V 9iI
21 Chas amomeler 3
iY
n
Raise up rear axle housing by stand
ET133
EF 27
300 n 6 000 ft
1 3 000 4 000 5 000
o 000 2 000
Altitude
1 5 2 0 km
o 0 5 10
EF558
EF 28
Engine Fuel
I v
t
Q0
1
EF733
EF264
Fig EF 61 Checking altitude
1 Ignition key compensator
2 Amplifier
3 Speed detecting switch
4 B C D D solenoid valve
Inhibitor relay
Automatic transmission
it pletely disassembling which will allow
deaning of all parts and passages the
carburetor can be maintained its origi
At high altitudes
shown in Figure 60
EF Open a When disconnecting fuel lines do
Apply 12 volts c
d across termi Notes
not spill fuel from fuel pipe
that continuity b When removing carburetor do not
nals 1 and 4 to ensure a The idle Pm and CO vary accord
exists between terminals 2 and 3 ing to the altitude Therefore they drop any nut or bolt into intake
manifold
that continuity does not should be
Check properly adjusted when
c Be careful not to bend or scratch
exist between terminals 2 and 3 when the position of the H L lever is
is them any part
no voltage applied across changed
EF 29
Engine Fuel
Fuel chamber
16
17
Automatic choke
Automatic choke body and
cover
parts
8 Accelerating pump parts diaphragm chamber
Q
@
f 9 Altitude compensator pipe
California models
tng
ail bleed adJ
18Richer jet
19 Coasting air bleed I
20 Primary main jet
21 Secondary main jet
22 Secondary slow air bleed
J
ID
23 Secondary slow jet
@ 24 Plug
25 Air bleed
tJ
@ 26 Coasting jet
@ @1 27 Secondary main
28
29
Power valve
Primary main air bleed
air bleed
@ 30 Plug
31 Primary slow jet
32 No 2 primary slow air bleed
I 34
35
venturi
J 3 Thr9ttle dj t
5Crew
spring
44 Primary and secondary throttle
valve
45 B C D D California models
46 Vacuum control solenoid valve
47 B C D D Califomia
Non models
Ill
@
EF725
Disassembly screws and nuts and care must be 3 Do not attempt to remove any
Properly filling wrenches and ex ercised not to damage any parts parts marked with an asterisk CO in
screwdrivers be used the 2 Clean the carburetor
must on thorougWy Figures EF 62 EF 63 EF 64 and
nozzles and jets as well as on the beiore disassembly EF 66
8 Richer jet
9 Automatic choke body and
diaphragm chamber
10 Coasting air bleed
@
Note Do not remove the parts
fi
1i
8 I
J
l
EF 225
EF 31
Engine Fuel
Sets 2 B CD D
3 Coasting jet
4 Secondary slow jet
5 ptug
6 Air bleed
1 Secondary slow air bleed
8 Secondary main air bleed
9 Power valve
10 Primary main air bleed
11 Weight and outlet valve
12 ptug
13 Primary slow jet
14 slow air bleed
Ptirnar
15 Accelerator pump assembly
16 AntkUeselingsolenoid vain
17 Fast idle earn
18 Choke connecting rod
19 Fast idle earn shaft
20 Ventuci stopper screw
@
l Note Do not remove the parts
marked with an asterisk
It
EF726
Float
i
i j
1 L 4 S JlJ
4 2
V @ I
Ji
c 4 6
@
11
e4
Yr
Qll1D
J 1 tt
c 1
@5
1
lil I
1 Secondary main jet
u
p r
i r 2 Primary main jet
1 CJi 3 Float chamber parts
U 4 Fuel inlet assembly
if
I
7 4
44
45
Hi
2
3
5
Filter set
Fuel f1Iter
Fuel nipple
screw
lv
8rtj Fig EF 65 Removing float
EF227
EF 32
Fuel
Engine
@ff EF827
Assembly
EF 33
Engine Fuel
careful and
Carburetor performance depends
dcpends upon cleaning quires replacemen 1 That is why
on jet and air bleed
inspection while servicing if they
3 Inspect gaskets 0 see
these components must be fabricated
I Blow all and or briUle or if edges are
passages castings appear hard with utmost care To clean them use
with compressed air and blow off all torn or distorted If any such condi solvent and blow air on them
cleaning
parts until dry tion i noted they must be replaced numbers the
Larger inner tamped on
is noted damaged parts must be re and make throtlle lever operate Check they bear larger numbers the smaller
placed the following condition of fuel injection from the the numbers the richer the fuel
Note especially
EF 34
Engine Fuel
Nl n
California modell California modeb
Manual transmiSsion
I Automatic transmission Manual transmission
I Automatic transmission
Airclelllcr
Air ntrol valve fuUy opens oCeF above 55 131 above 55 131
metal
Bi No 2 70 to 90 158 to 194 70 to 90 158 to 194
Fuels
Stem
Fuel prtuure kpJcm2 poi 0 21 to 0 27 2 99 to 3 84 0 21 to 0 27 2 99 to 3 84
C rbu tor
Venturi diameter in
mm 24 0 945 310 220 24 0 945 31 1 220 24 0 945 31 1220 24 0 945 31 1220
Main jet 199 1160 199 1160 1101 1160 101 1160
Main air bleed 170 160 170 160 170 60 170 60
1
Slowjet 148 1100 148 1100 148 1100 148 180
Power val 143 143 140 140
Float level U mm in 23 0 906 23 0 906 23 0 906 23 0 906
Adjustment
Engine idling Ignition timingIdle speed COat 120 650 rpm 0 120 650 rpm 0
1201750 rpm CO 2 1 750rpm
100 t 1
C02
mloro position CO t 1
2 position CO t
2 1
h 13 to 17 1 3 to 17 13 to 17 13 to 17
0 051 to 0 067 0 051 to 0 067 0 051 to 0 067 0 051 to 0 067
in
mm 0 0524 to 0 0579 0 0622 to 0 0677 0 0524 to 0 0579 0 0622 to 0 0677
Bi metalsettinl
metal
Bi resistance at 2Ioe 700F n 3 7 to 89 3 7 to 8 9 3 7 to B 9 3 7 to 8 9
metalsettina
Bi Center of the ndex mark Center of the index mark
to 650
1 to 850
1 1 900 to 2 100 1 650 to 1 850
Duh pot adjustment without loadin Im 900
1 2 100
diclClinasolenoid
Anti C
valV
tiahtenina torque 180 350 304
180 to 350 156 to 304 180 to 350 156 to 304 180 to 350 156 to 304 to 156 to
ka m lb
in
EF 35
Engine Fuel
BC D D adjustment incorrect
Adjust
Vacuum control solenoid damaged Replace
Stuck anti stall dash pot Replace
EF 36
Engine Fuel
properly
Altitude compensator setting incorrect Cali Correct H L lever position
fornia models
Damaged dieseling
anti solenoid Replace
EF 37
SECTION EC
EMISSION
DATSUN PICK UP CONTROL
MODEL 620 SERIES SYSTEM
GENERAl DESCRIPTION EC 2
CRANKCASE EMISSION
EC 2
CONTROL SYSTEM
EXHAUST EMISSION EC 3
CONTROL SySTEM
EVAPORATIVE EMISSION
EC 30
CONTROL SYSTEM
GENERAL DESCRIPTION
There are three types of control 2 Exhaust emission control system seCV1Clng of these systems should be
system These are 3 Evaporative lhsion
ell control sys carried out to reduce harmful emis
tem sions to a minimum
J Closed type CIllnkcase emission
control system Pericxiic inspection and required
DESCRIPTION INSPECTION
The ventilating air is then drawn
to from the dust side of the cadlUretor P cV VALVE AND FILTER
This system returns blow by gas
air cleaner tluough the tube con
both the intake manifold and carbure Checking P C V valve in accord
tor air cleaner necting carburetor air cleaner to rock
into the crankcase
ance with the following method
er cover
The positive crankcase ventilation With engine running at idle remove
C V valve is provided to conduct Under full tluottle condition the
p the ventilator hose from P C V valve
manifold vacuwn is insufficient to
crankcase blow
by gas to the intake if the valve is working a hissing noise
manifold draw the blow by flow tluough the
air passes
and its flow goes through the
will be heard as through the
During partial throttle operation of valve
valve and a strong vacuwn should be
the engine the intake manifold sucks tube connection in the reverse diree
felt immediately when a fmger is
the blow by gas through the P C V tion
placed over valve inlet
valve On vehicles with an excessively high
Replace P C V valve and filter in
Normally the capacity of the valve blow by some of the flow will go
accordance with the maintenance
is sufficient to handle any blow by and through the tube connection to carbu
schedule
retor air cleaner under all conditions
a small amount of ventilating air
4
VENTILATION HOSE
Lkf 1
If any
obstructions
hose
replace
cannot
II tll
TIL 1j
c Fresh air
GUuuu
1 Sealtypc oil level gauge
2 Bame plate
Blow by gas
3 Flame arrester
4 Filler
5 P C Y valve
6 Steel net
7 Bame plate
EC716
EC 2
Emission Control System
CONTENTS
7 CATALYTIC CONVERTER EC 26
INSPECTION EC
SPARK TIMING CONTROL SYSTEM EC 7 DESCRIPTION EC 26
7 OPERATION EC 26
DESCRIPTION EC
REMOVAL AND INSPECTION EC 27
SPARK DELAY VALVE
EC 7 EC 27
Automatic transmissiom models only INSTALLATION
INSPECTION EC 8 FLOOR TEMPERATURE WARNING
EC 27
AIR INJECTION SYSTEM EC 8 SYSTEM
EC 27
DESCRIPTION EC 8 DESCRIPTION
EC 28
OPERATION EC12 OPERATION
EC 28
REMOVAL AND INSTALLATION EC 14 REMOVAL
EC 29
DISASSEMBLY AND ASSEMBLY EC 14 INSTALLATION
EC 29
INSPECTION EC 17 INSPECTION
3
EC
Emission Control System
IV
ID
models
Fig EC 2 Exhaust emission control system Non California
4
EC
Emission Control System
solenoid valve
13 Emergency air relief valve
14 Air pump air cleaner
15 Carbon canister
16 Air control yai e
17 Air pump
ET368
EG S
Emission Control System
EARLY FUEL
EVAPORATIVE
4
EC A control valve welded to the spring and counterweight which are
SYSTEM E F E valve shaft is wtalled on the exhaust assembled on the valve shaft projecting
manifold through This the outside of the exhaust
DESCRIPTION bushing con to rear
rI 1 @
rW
1 Intake manifold 9 Sc w
EC532
The early fuel evaporative system is is changed in direction as shown by With this condition the heat control
6
EC
Emission Control System
EC 7
Emission Control System
C bur tor
I Distributor side
EC219
1 way
One umbrella valve
2 Sintered metal disc Fig EC 11 Checking spark d tay valve
EC284
Fig EC 8 Spark delay valve
that it properly oriented Tlus valve placed over port on distributor side
shuuld be replaced periodically Refer air flow resistance is greater than that
TOdi
ribUI0 carburClor hydrocarbons and carbon monoxide in
exhaust lris through combustion
re
EC
lCiJr There
and the
are
type is mounted
two
other is
types of
on
A I
S
One
California models
on non California
Fig EC 9 Operation 01 park delay models The non California type con
value Carburetor side sists of an air pump air cleaner an air
Distributor side
pump a relief valve a check valve an
anti backfIre valve an air gallery and
tor side then through the other port EC346 These valves prevent ahnonnal tem
on distributor side Spark delay valve Fig EC IO Checking park delay valve perature rise of the catalytic converter
8
EC
Emission Control System
1 Check valve
2 Air gallery pipe
3 Automatic temperature control
air cleaner
9 3 way connector
10 Air hose air hose connector to
air pump
EC776
air pump
16 Air hose air pump to air pump
air cleaner
17 Air pump
EC777
EC 9
Emission Control System
Air pump aIr cleaner The die cast aluminwn air pump the outlet cavity Subsequently it
The air cleaner element is assembly attached to the front of the passes the stripper and a section of the
a viscous
engine is driven by air pump drive that separates the outlet and
paper lype and requires periodic re
an
housing
belt A rotor shaft drive hub inlet and inlet cavities and again reaches the
placement The air pump air cleaner is
outlet tubes are visible on the inlet cavity to
bolted to the left front of the hood pump repeat the pumping
exterior A rotor vanes carbon shoes cycle
ledge
and shoe make up the rotating Carbon shoes
springs in the slots of the
unit of the pump The rotor located in rotor support the vanes They are
the center of the pump is driven
belt designed to penni t sliding of the vanes
The vanes rotate freely around the and to seal the rotor interior from the
ofT center pivot pin and follow the air cavities Leaf springs which are
circular shaped pump bore In the behind the leading side of the shoes
two vane type the vanes form two compensate for shoe abrasion
chambers in the housing Each vane The rotor ring is a steel bolted to
i
I
lJ1
Jr
l
j j
1 Air pump drive hub 7 Shoe spring
2 HOII ing 8 Stripper
3 Rotor ring Rotor shan
9
4 End cover with needle 10 Ball bearing
bearing II Front bearing cover
5 Vane 12 Pulley
6 Carbon shoe 13 PuDey for air con itioner
EC560
EC IO
Emission Control System
quantity of
secondary air fed from the
tic converter c
I Tointake
manifold
vacuum
F rom
m
in pump
The construction is as shown
A check valve is located in the air The secondary air fed from the air
The valve pre
pump discharge lines pump goes through the check valve
to
ven ts the backflow of exhaust gas the air gallery where it is distributed to
c lr J
air cleaner
n
EC291
manifold vacuum to
by intake
prevent backfire
y
in the exhaust system
of deceleration
at the ini tial
L
period
At this period the mixture in the
intake manifold becomes too rich to
exhaust manifold
The anti backfire valve provides air
r
to the intake manifold to make the
nected to the air cleaner and the outlet Fig EC 19 Air injection into exhaust port
EG 11
Emission Control System
I
I
t
1
r
EC 12
Emission Control System
fl
f
I t
Qj
riu
Jl
rn l
3
j I
@
EC 13
Emission Control System
To intake
o jJ To
vacuum
Intake mamfold
manifold
lm
vaCUl
rF
r
To air cleaner
r
To air cleaner
Actuated EC299
Not actuated
Fig EC 25 Operation of air control value
engine running
Fig EC 26 Replacing oir cleaner Check valve
element
Disconnect hose and remove check
Air pum valve from air gallery pipe Air pump relief vslve
Remove air hoses from air pump Loosen carburetor air cleaner
2 Loosen air pump adjusting bar mounting sc ews and remove air
Air ganery pIpe andinJactlon
mounting bolts and air pump mount pump relief valve
then remove air pump drive nozzles
ing bolts
bell
It is very difficult to remove the air InstallatIon
3 Remove air pump pulley
gallery from the exhaust manifold
4 Remove air pump from bracket Install in the reverse order of reo
without bending the pipe which could
moval
result in fractures or leakage There
Air control valve
fore
removal of the air gallery pipe
California models DISASSEMBLY AND
and injection nozzles should be under
l Disconnect air hoses and a vacu taken only when they are damaged ASSEMBLY
um hose from air control valve
I Lubricate around the connecting
2 Remove air con trol valve from Disassembly of air pump
portion of air
injection nozzle and air
bracket Remove four drive bolts
gallery with engine oil 1 pulley
Hold air injection nozzle and remove pulley from hub
2 hexagon
E AR valve California modela 2 Secure air pump drive hub in a
head with a wrench and unfasten flare
vise as shewn in Figure EC 28 and
Remove vacuum pipe and air hose screw connecting ait gallery to injec
tion nozzle Remove air remove four end cover bolts
and dismount E A R valve gallery
EC 14
Emission Control System
the aluminum b Discard screws which were re 8 Remove four screws securing
Note Never clamp on
STl9940000
I I
3 Remove end by carefully
cover 6 Remove four carbon shoes and EC303
tapping around dowel pin with a plas two shoe springs from rotor using Fig EC 32 Removing rotor shaft
tic mallet and lift up straight needle nose pliers or tweezers
match marks 0 rotor
4 Put on 10 Support the front end face of
ring and side of rotor to ensure correct Note Carbon shoe A is I mm housing with Bearing Adapter
reassembly and remove four screws 0 039 in wider than B Do not STl9930000 Attach Bearing Driver
that retain rotor ring to rotor using a STl9910000 to front bearing on the
confuse them
Hexagonal Wrench STl9810000 inside of air pump housing iuid press
out
Notes
a Generally match marks are indi ll
cated on both rotor ring and rotor
I I
by the manufacturer
STl9910000
9930000
J 1
EC304
EC 15
Emission Control System
EC562
I Front bearing
1
C preand Bearing Driver STI 991 0000
until the end face of drive hub touches
Support the rear end face of air
froE c ing in n c
ST19920000
STl9940000 STt9910000
I EC3Q7
L
e
Notes
X8 03
STl9920000
a Be sure to drive front bearing inner r
race in
EC308
Fig EC 35 Pressing ball bearing b After rotor is installed in place
ensure that the rotor end is Fig EC 37 Pressing air pump drive hub
pos
2 Bearing cover
tioned below the end face of air
Torque four bearing cover securing
pump housing
bolts to 0 1 to 0 2 kg m 0 7 to 4
1 5 Carbon shoe
ft lb Position of rotor end below air
1 Place air pump drive hub in a
3 Rotor shaft
pump housing vise
0 050 to 150
0 mm
2 etc from
Support the inward bottom of Clean carbon dust
00020 to 0 0059 in
rotor with Rotor Stand STl9920000 shoe grooves
Press rotor into place with a press 3 Align rotor with housing proper
and Bearing Drive STl9910000 until 4 Air pump drive hub ly Refer to Figure EC 38 Then insert
the stepped portion of rotor shaft Support the inward bottom of carbon shoes into place noting their
touches front inner race rotor with Rotor Stand STl9920000 directions
bearing
EC 16
Emission Control System
Notes
0 mark in rotor
1 Pack vane bearing with high ring and tighten
melting point grease MIL G 3545 A four screws to the specified
torque
Esso ANDOK260 or equivalent and with Hexagonal Wrench ST19810000
insert dummy shaft into the Vane
Tightening torque
bearing 5 to 0 7
0 kg m
STl9900000 3 6 to 5 1 ft lb
EC302
Fig EC 42 ling
Insla end cover
12 Pulley
Tighten four pulley securing bolts
to the specified torque
5T19810000
EC 17
Emission Control System
ing and screw with a clamp Repeat pump check air pump relief valve in
tures when the tests are performed EC311 4 Disconnect vacuum hose from
Prior to performing any extensive diag Fig 44
EC Checking air pump relief B A R valve as shown in Figure EC
nosis of the exhaust control system it valve 46
EC 18
Emission Control System
for presence of discharged air If air is CONTROL SYSTEM models except those bound for Coli
felt E A R valve is normaL E G R fornia and Canada
5 If E A R valve does not function When the E G R con trol valve is
properly at above steps replace E AR DESCRIPTION open some of the exhaust gas is led
valve from the exhaust manifold to the
In the exhaustgas recirculation EG R chamber through the E G R
system a part of the exhaust gas is The exhaust gas is then con
passage
returned to the combustion chamber in R
trolled quantity by the E G
to lower the spark flame temperature valve and is introduced into the intake
in
during combustion This results a
manifold
reduction of the nitrogen oxide con c1ose operation of the E G R
Open
tent in the exhaust gas control valve is controlled by the
To air
pump
The exhaust gas recirculation sys thermal vacuum valve which opera tes
tem consists of an E G R passage
I on carburetor vacuum and engine cool
E G R trol valve thermal vacuum ant
con temperature
volve EG R tube and hose A warn
ET267
1 D
t
Fig EC 46 Cheeking E A R volve
@
I I Y1
VI
Anti backfire valve A valve
Warm up engine
I ID 4
thoroughly
2 Disconnect hose from air cleaner
JO 0
valve
2 E C R control valve
3 E C R passage
4 Intake manifold
6 E C R tube
OPERATION
Operation of E G R system is as
shown below
Fig EC 47 Checking anti backfire valve
Intake manifold E G R
E G R system operating Thermal Remarks
EG R control valve
water temperature oC OF valve
vacuum vacuum
Close Close
Below 570C 135OF
california
Non
Above models Idling
MfT only
Not Above 57 to 630C 70 mmHg Close
Open 76 inHg
actuated 135 to 145OF
California models
Below and N on Fullthrollle
f alifomia
AfT
models
Above 57 to 6 oC Above 50 mmHg Open
Actua ted Open 197 inHg
135 to 145OF
EC 19
Emission Control System
E G R OFF operation this recirculation of exhaust gas must It remains closed while engine coolant
When off for a few minutes after temperature is low and keeps the
engine coolant temperature be cut
is low recirculated exhaust gas causes engine has started The thermal vacu E G R control valve closed thereby
irregular engine operation To prevent um valve is provided for this purpose culling off the E G R circuit
rn I
jS
11
lW
r
L 1 Throttle valve
e7
E G R controlval
le clo R not
Fig 49
EC E G actuated
2 When engine coolant temperature of the throttle valve enginedu ring though intake manifold vacuum is
is abovethe working temperature of idling for improved idling operation high and E G R control valve remain
the thermal vacuum valve At this point vacuum does not closed
I The valve port come to the top actuate the E GR control valve
D
T l
J
JllrI
L
t
i
Throttle valve
r
II
2 In the full throttle driving posi um passage does not surpass the vacu control valve
tion the suction vacuum the
on vacu um required to actuate the E G R
EC 20
Emission Control System
6
Thermal vacuum valve Open
E G R ON operation
The E G R circuit is completed is above the working temperature of retor suction vacuum is large enough
only when engine coolant temperature the thermal vacuum valve and carbu to open the E G R control valve
l fj 1t 3 0 l P@ 0f Y f
1
i0 Wg
i3
m
Y
m
iiA
EN
d
ti t1f
nk il i
1
Throttle valve
L r
EC794
movement of the taper valve connect E G R con trol valve construction The construction of the EG R
EC 21
Emission Control System
j o
0
o
of an odometer switch detector drive
counter
harnesses
E G R
When the
warning
earn
lamp
in the odom
and
o
o
m o
eter switch connected
ometer turns once for each OAkm 4
to the speed
l 1
2
Diaphragm spring
Diaphragm
wheel by one pitch When the number
of counts reaches 50 000 the latchet
l @
4
3 Valve shaft
Valve
drops in a groove provided on the
EC231
switch
Fig EC 53 E G R control value Then the EG R warning lamp
comes on indicating that the E G R
control system Should be checked
The detector drive counteT is equip
ped with an odometer which can tell
Thermal vacuum valva when to service the E G R contr0 I
When the vacuum passage is open the
1 Spring Notes
2 Bi metal
3 Oring t a It is an indication of problem in the
E G R
t warning lamp or problems
00 EC232 in the point or in the harnesses if
Fig EC 54 Thennal vacuum valve the lamp does not light at 50 000
counts
trol system monitors the distance the those bound for California and
The E G R warning system install car has travelled and indicates when Canada
EC 22
Emission Control System
1 1I
I
I Ignition switch
1 v v E G R warning lamp
I I
I
I
I f
I
I
I
I
Ignition switch start position 1
I Odometer switch
I
I Fuse 1 A r
I
I
I I
0 v
I I
I
I I
I
I
U
EC541
I I
I
I
I
Magnet coil i lQ 1 Fig EC 57 Removing E G R passage
I
L mi
L J
Detector drive counter
mounted
REMOVAL AND
Vacuum hose carburetor to ther
INSTALLATION mal vacuum valve
EC234
Removal
Fig EC 56 Removing KG R control
valve
I E G R control valve
EC 23
Emission Control System
V r
EC251
on the top of R H hoodledge panel in back side of speedometer Cam in the its mounted conditionS
rotated by the
engine room To remove detector drive odometer switch is I of
Make a thorough visual check
To dismount odometer
counter disconnect w COJUlector speedometer E G R control system If necessary
and loosen two bolts securing detector switch proceed as follows
wipe away oil to facilitate inspection
drive counter to hoodledge I Dismount combination meter as
panel If any hoses are cracked or broken
2 E G R warning lamp sembly replace
E G R warning lamp is mounted at 2 Remove meter front cover and 2 With engine running check
the top cen ter of instrument pad To take off clips and screws to dismount E G R warning system for proper
remove E G R warning lamp proceed shadow plate function Make sure that E G R warn
as follows 3 Loosen screws securing speed ing lamp lights when ignition switch is
2 E G R warning lamp is a twist speedometer and detach odometer turn ignition switch to ON position
lights
If warning lamp does not light
check harnesses connectors and de
InstaUatlon
Notes
EC554
EC24
Emission Control System
START ON
Ignition Switch Position
E GR control valve
normal
EG R control valve will remain
open for more than 30 seconds after
vacuum has cut off
EC253
la
Fig EC 62 Checking E G R control valve
ET152
EC 25
Emission Control System
tion
CONVERTER process requires the proper a
mount of air which is supplied by the
DESCRIPTION
air pump Refer to the item AJ S
The catalytic converter accelerates This air is caUed secondary air The
EC350
3 4
c Secondary air
Carbon monoxide
hydrocarbon
Carbon dioxide gas
water
EC242 EC444
EC 26
Emission Control System
REMOVAL AND 2 Remove air hose between 5 way 16 If CO percentage is still over
in
INSPECTION connector and air check valve Plug the 03 step 15 catalytic conyerter is
disconnected hose to prevent dust malfunctioning Replace catalytic con
Removal and inspection can be
from entering Refer to page ET 12 verter
done as follows
3 Check carburetor pipes for proper
connection
1 Visually check catalytic converter and replace air check valve Then temperature sensing switch are ilIus
for damage or cracks perform inspection steps 12 and 13 trated in Figures EC 70 and EC 71
EC 27
Emission Control System
J
I Battery
I Relay lamp and sensing switch
J
Floor
L
temperature
warning
77 77
Floor temperature lamp
sensing swi tch
Contact close
ECJ40
77 77
EC 70
EC332
I
Fig Win ng diagram offloor temperature warning system
rl Contaclopen
@ 6witch
J 1
Floor temperature
REMOVAL
Floortemperature
OPERATION
and the ignition switch line to turn on
Floor temperature will exceed nor as a result the floor temperature
floor temperature sensing switch turns temperature relay turns off while the EC783
off causing the starting switch line of starting switch side is in on The floor Fig EC 73 Location of floor
the floor temperature relay to turn off temperature warning lamp goes out ttmperature relay
EC 2B
Emission Control System
1t
Note Avoid heating floor tempera a circuit tester
1 ture
If
sensing
lamp
switch directly
does not glow check floor
temperature sensing switch connector
Referring
temperature relay
trace wire s
to
back
the
if
to
following floor
relay is normal
ignition switch
RAt
for continuity with a circuit tester Repair faulty wiring
If continuity should exist after
heated surrounding areas of floor tem Floor temperature relay
transmission
bulbs
If not check lamp
S position
for burned
J To floor temperatwe
EC344
cool below 800C 1760Fj before
carrying out the following procedure Fig EC 75 Checking floor temperature relay
I Remove rearseat
floor is heated to the specifications as the following items Refer to Inspec 8 Air cleaner
shown in the table below lion of Fuel System
EC 29
Emission Control System
3 Check ignition system with regard 3 Ignition coil Note Even if there is nothing wrong
to the
following items
Refer to 4 High tension code with engine the warning lamp may
Inspection of Ignition System 5 Spark plug come on if vebicle is being driven
1 Ignition AMP
4 Check idle CO adjustment Refer
on a steep slope continuously in
2 Distributor
to Idle CO lower gears at high engine speeds
Inspection of Adjustment
CONTENTS
EF274
Fig EC 76 Schematic
drawing of lIaporotive emiaion control6ydem
OPERATION
Fuel vapors from the sealed fuel The canister is fined with activated when the engirie is at rest or at idlin
ll
tank are led into the carbon canister charcoals to absorb the fuel vapors See Figure EC 77
30
EC
Emission Control System
Close at idling
Open at rest
J
i
i
j
J
f
17
Fuel vapor
12 Filter
1 Fuel tank 6 Canister purge line
2 Fuel f1l1er cap with vacuum 7 Throttlevalv 13 Purge control valve
14 Spring
relief valve 8 Engine
3 9 Carbon canister 15 Diaphragm
Liquid vapor separator
4 16 Fixed orifice
Vapor vent line 10 Activated carbon
As the throttle valve opens and the purge control valve to open and intake manifold through the canister
JL
rHL I
J
o I
Fuel vapor
Fresh air
EC785
vent line through the cock little by 9 I f the height does not drop to
AND VAPOR VENT LINE
little until pressure becomes 368 zero in a short time when filler cap is
I Check all hoses and fuel tank mrnH20 14 5 inH20 removed it is the cause of a stuffy
mler cap 5 Shut the cock and hose
completely
2 Disconnect the
vapor vent line leave it unattended
connecting carbon canister to vapor 6 After 2 5 minutes measure the Note In case the vent line is stuffy
the in fuel tank is
liquid separator height of the liquid in the manometer breathing not
3 Connect a 3 way connector a 7 Variation of height should remain thoroughly made thus causing in
EC 31
Emission Control System
1 connectur
3
368 mmH20 14 5 inH20
LL
COCk
IPO
@ 36 ET37Q
Carbon canister
follows
I Wipe clean valve housing and have
I Disconnect rubber hose in the it in your mouth
@
line between T connector and carbon 2 Inhale airA slight resistance ac
l u
32
EC
Emission Control System
STI98 10000 For removing and installing the rotor ring assembly L20B Fig EC 29
A14 Fig 41
EC
Hexagon wrench
SE279
Dummy shaft
SE284
3 STl9890000 Used as a mount when rotor is removed and when bearing is installed L20B Fig EC 32
A14 fig IlC 35
Rotor adapter f
SE347
4 STl9940000 Used when rotor is removed and when front bearing installed L20B Fig EC 32
A14 Fig EC 35
Bearing Pressing
tool
d
9E348
This service tool is designed for use in disassembly and assembly of the air pump
33
EC
Emission Control System
Bearing adapter
E9 SE349
6 STl9910000 Used as a drift when front bearing is installed Also used as a support L20B Fig EC 33
when rotor is installed Al4 Fig EC 36
Fig EC 37
Bearing driver
SE350
o
Rotor stand
SE351
8 ST19870000 Used as a adapter when air injection pump pressure is tested L20B Page EC 18
Al4
Air pump test
gauge adapter
SE389
EC 34
SECTION EE
ENGINE
DATSUN PICK UP ELECTRICAL
MODEL 620 SERIES
SYSTEM
BATTERY EE 2
STARTING EE 4
MOTOR
CHARGING CIRCUIT EE 12
EE 15
ALTERNATOR
REGULATOR EE 20
IGNITION CIRCUIT EE 26
DISTRIBUTOR
EE 30
Non California models
IGNITION COIL EE 46
BATTERY
CONTENTS
EE 2 BATTERY FREEZING EE 3
REMOVAL
EE 2 CHARGING EE 3
CHECKING ELECTROLYTE LEVEL
EE 2 INSTALLA TION EE 3
CHECKING SPECIFIC GRAVITY
REMOVAL
I Disconnect negative and positive
cables
2 Remove nuts from battery
clamps take off clamps
Read top level
3 Remove battery with scale
1 Thermal gauge
feOOl
2 Hydrometer
CHECKING
ELECTROLYTE LEVEL Fig EE l Checking pccme gravity
m
according b t eiectroly te temperature
temperature is above
680F standard
or below 200e E
u JI I I
ol I
lilt I
1
The gravity of electrolyte chlll ges J 1 I
I i J Sf to 1
7 II It 100
EE 2
Engine Electrical System
il 40
I tilled water into cells
5 Keep battery away from open
as necessary
e SO
I flame while it is being charged
6 After all plugs have been
vent
70
80
100
1104 108 l2
t 1 16 t 20 24
1 28
1 1 32
EEOQ4
CHARGING Iy
it up to full charge the opera 2 After clamps have been tightened
If electrolyte level is satisfactory bring
clean battery cable terminals and
tion should be carried out with nega
battery must be charged when electro to retard formation of
tive cable removed apply grease
lyte gravity reading falls below 1 20 If
to Prior to charging corroded termi corrosion
battery on car is quick charged
EE 3
Engine Electrical System
STARTING MOTOR
CONTENTS
DISASSEMBL Y EE 7 ASSEMBLY EE 9
DESCRIPTION
The function of the starting system
5 @
which consists of the battery ignition
switch motor and solenoid is
starting
to crank the engine The electrical
energy is supplied from the battery
the solenoid completes the circuit to I Brush
operate the starling motor and then 2 Field coil
the motor carries out the actual crank 3 Magnetic switch
4 Pludgcr
ing of the engine
5 Torsion spring
6 Shifll r
7 Overrunning clutch
8 Pinion
9 9 Armature
EE315
4
EE
Engine Electrical System
INHIBITOR RELAY
INHIBITOR SWITCH
FUSIBLE LINK
A
O
1Y b Y
I J
@
I
A
BATTERY rJ
f
l
STARTING MOTOR
BWI
000
rBW 000
fB WBBYBY
@@@@
B
I
I
I
j
EARTH POINT CJ
Bd
f
FUSIBLE lIN
BW
T
H
f
00
00
00
r
00
BATTERY
Q
I I I BW
I
@@@ @ @
Y B Y BY
l
BY
BW
9
IGNITION SWITCH
BY BWWB BY WB BY BY
@@@ @ @ @ @
I I I BW
I
AfT Equipped with cooler @ M T Equipped with cooler
COLOR CODE
I a
b
Notes
@
@
T only
M
A T only
Inhibitor switch is
B Black on in neutral
OW Black with white stripe
BY Black with yellow stripe
W White
L
WB White with black stripe
eE491
EE 5
Engine Electrical System
OPERATION
When the ignition switch
turned
More positive meshing and into or out of mesh with the ring gear
demeshing of the pinion and the ring teeth The
overrunning clutch is de
gear teeth are secured by means of the signed to transmit driving torque from
overrunning clutch The overruIUling the motor armature to the ring gear
clutch employs a shift lever to slide but prevent the armature from over
the pinion along the armature shaft running after the engine has started
6
EE
Engine Electrical System
CONSTRUCTION
V
S
4
O
o
8
f
w
il
I
jl
I
15 Yoke
Adjusting washer P
t6 Field coil assembly
3 Torsion pring
4 Shift lever 17 Armature assembly
5 Dust cover
18 Center plate SI14 1808 only
bolts and
REMOVAL 4 Remove two through
rear cover
Disconnect battery ground cable
Disconnect black wire with 5 Remove b rushes from their hold
yellow
stripe from magnetic switch terminal er by moving each brush spring away
and black battery cable from battery from brush with a hook
Remove brush holder
terminal of magnetic switch
2 Remove two bolts securing start
@ 6 Remov yoke assembly and with
ing motor to transmission case Pull @ draw armature assembly and shift
starter assembly forward and lever
O
remove
Pinion stopper
EE 7
Engine Electrical System
EE016
o
Fig EE I2 Testing field coil
for continuity
@
TestIng field coD for ground
Place one probe of circuit tester
EE018
onto yoke and the other onto field
coil lead positive tenninal Fig EE 14 Inspecting brush spring tension
If very little resistance is read field
coil is grounded
8
EE
Engine Electrical System
l File
0
L0 5 to 0 8 mm Commutator
Segmen t
71j
Correct
IWMica
Incorrect
Fig EE 19 Testing brush for
Ee026
round
EE021
BEARING METAL
Fig EE 15 Undercutting i118ulating mica
Inspect bearing metal for wear or
2 Inspect soldered connection of 5 Check armature for continuity by bearing metal and armature shaft is
armature lead and commutator If placing probes of tester on two seg more than 0 2 mm 0 0079 in replace
loose connection is found solder it ments side by side If tester shows no metal
OVERRUNNING CLUTCH
onto each commutator bar tinuity between S terminal of mag
ASSEMBLY netic switch and switch body metal If
If tester shows continuity armature
ASSEMBLY
EE022
starting motor in re
Reassemble
Fig EE 16 Testing annature for
verse sequence of disassembly
ground
When assembling be sure to apply
4 Check armature for short by bearing metal and apply oil lightly to
j l holder and another onto positive side should also be subjected to the test
EE023 If tester shows continuity brush when the ofabnormal operation
cause
Fig EE 17 Testing annature for holder is shorted to ground Replace is to be determined A brief outline of
ahort brush holder the test is given below
EE 9
Engine Electrical System
load
No test MAGNETIC SWITCH
ASSEMBLY TEST
Connect starting motor in series Specified current draw and revolu
12 volts tion in these test shown in
with specified battery and are
Switch
an ammeter capable of indicating Specifications
1 000 amperes
o
Switch
Battery
6 Et IB I
Starter motor
Fv I D
Battery Starter motor
EE351
assembly ted
from commutator brush spring rubber bush thrust out 0 012 to 0 059 in
l
c Using a circuit tester place one of mica in commu tator or a loose
probe onto input tenninal and the contact between biush and com
raise the other two brushes and check 3 Low current draw and low
field and armature separately to noload speed would cause high
determine whether field or armature is internal resistance due to loose con
Fallure EE029
2 to operate with high mutator and causes listed on item
EE10
Engine Electrical System
transmission
Optional
Manual for manual
transmission transmission
v 12
System voltage
No load
V 12
Terminal voltage
in More than 12 47
0
Brush length mm
Ib 4 to IS
1 3 1 to 4 0
Brush spring tension kg
EE ll
Engine Electrical System
CHARGING CIRCUIT
The charging circuit consists of the marks Then the warning lamp lights P2 is separated from the primary
battery alternator regulator and When the alternator begins to op side PI
contact by the magnetic
necessary wiring to connect these erate three phase alternating current is force of coil VC2 Therefore
parts The purpose of this system is to induced in the stator armature coil registor RIapplied into the rotor
is
convert mechanical energy from the This alternating current is rectified by circuit and output voltage is decreased
into electrical energy which is the and silicon
engine positive negative AJ the output voltage is decreased the
used to operate all electrically operat diodes The rectified direct current
movable contact point P2 and
ed units and to keep the battery fully output reaches the alternator A and primary side contact Pin comes into
E terminals
charged contact once again and the alternator
When the ignition switch is set to On the other hand the neutral increases
voltage Thus the rapid
current flows from the battery reaches N and E
ON point voltage vibration of the movable contact point
to ground through the ignition switch terminals nearly a half of the output IPl maintains an alternator output
voltage regulator IG terminal primary voltage and current flows from
voltage constant
side contact point PI movable voltage regulator N terminal to E When the alternator speed is further
contact point P2 voltage regulator terminal or ground through the coil increased the
or voltage starts to rise
IF terminal alternator IF terminal VCI as shown in Figure EE 24 by
excessively the movable contact point
rotor field coil and alternator E the dotted line arrow marks Then the P2 comes into contact with
terminal shown in Figure EE 23 by
as coil VCI is excited and the side P3
secondllJ contact point
full line arrow marks Then the rotor movable IPS Then the rotor current is shut off and
contact point comes
in the alternator is excited On the into contact with voltage winding side alternator output voltage is decreased
other hand current flows from the contact P6 This action causes
point immediately This action causes
battery to ground through the ignition to turn off the warning lamp and movable contact n to separate
switch warning lamp voltage regula the voltage winding circuit
complete from secondary contact P3 Thus
tor L terminal lamp side contact as shown by the full line arrow marks the rapid vibration of the movable
point P4 movable contact P2
point When the alternator speed is in contact point or breaking and
P5 and voltage regulator E termi the rotor circuit
creased or the voltage starts to rise completing maintains
nal as shown by dotted line arrow alternator output
excessively the movable contact point an voltage constant
EE 12
Engine Electrical System
r l
I I
I
i r Ye
Ff p
I
11
c t
FF vw Fusible link
I
I RI t 8
L c
5 9 J
c c
R
Rot r field Coil
i
e 0
I I J
Battery
I I u
Alternator
I
J 1
Voltage regulator
J
t
EE029
ns
p
Slator ar ature coil
teJ I
U 2iI I
e PS
I
I
t I I
g
M j t
i H
U
Battery
Lh J
A l a o
L V
It g t
f
EE030
EE 13
Engine Electrical System
WR
WL
L2
VOLTAGE REGULATOR
co
I WLI
LW LW
cJ IB
P
r
m
I
B
WR WR
FUSIBLE LINK
t
EARTH POINT
CHARGE
00 WARNING lAMP
m g
00000
I I I I m
CLB
Equipped with cooler TjT W
WB B YWR
I I I I
I
W
1 l LW
I
BW
BwtIl IGNITION SWITCH
B
ALTERNATOR
rn j
M IG
J
COLOR CODE lOA
C o 0 0 0
B Black
0 0 FUSE BLOCK
o
OW Black with white stripe
W White M 0 0 0
lOA
WB White with black stripe
WR White with red stripe
Ii
WL White with blue stripe
California models
LO Blue with black stripe
LW Blue with white stripe
Y Yellow
E E492
EE 14
Engine Electrical System
ALTERNATOR
CONTENTS
EE 15 INSPECTION OF DIODE EE 17
DESCRIPTION
REMOVAL EE 16 INSPECTION OF BRUSH EE 1B
ASSEMBL Y EE 1B
INSPECTION AND REPAIR EE 16
DESCRIPTION
field is like way valve for electricity tive and
so
In the alternator a
magnetic a one negative conjunction
the rotor which consists that charging current passes easily but mounted the
produced by They are on two
of alternator shaft field coil pole reverse current is shut out plates which combine the function of
and slip rings The slip rings heat dissipating plate and
pieces In this alternator pack type silicon positive
pressed in the shaft conduct only a di odes are used negative terminals and are light in
small field current Output current is Six diodes three negative and three weight and easy to service
generated in the armature coils located positive are installed in positive and The pulley mounted on the air
in the stator The stator has three negative plates as an assembly conditioner models is different from
three that the standard models without
windings and generates phase These diodes are direct soldered at on
@God
tfff
A
3
3 Front bearing
4 Rotor
5 Rear bearing
4 6 Stator
7 Brush assembly
I Rear
8 cover
e
9 Diode set plate assembly
o
e
10 Diode cover
9 11 Through botrs
EE345
REMOVAL 3 Remove through bolts Separate 6 Remove diode cover fIXing screw
front cover with rotor from rear cover and remove diode Disconnect
cover
1 Disconnect negative battery ter three stator coil lead wires from diode
with stator by lightly tapping front
minaL terminal with a soldering iron
bracket with a wooden mallet
2 Disconnect two lead wires and
7 Remove A tenninaJ nut and diode
connector from alternator installation nut and remove diode
3 loosen adjusting bolt assembly
Remove alternator drive belt J
4 J
5 Remove parts associated with
alternator from engine
CD
6 Remove alternator from vehicle
DISASSEMBLY
4 AJ
1 Remove pulley nut and pulley
EE035
C
O
e
f ecA
1 Diode assembly
assembly Fig EE 29 Separating front cover
oo
2 Diode cover
with rotor from rear cover EE039
C on it
@@@ EE033
L I EE037
E A
O o
1
EE346
1 N terminal
2 Brush holder ld
3 Brush holder co r Q
EE040
Fig EE 28 Remouing brush Fig EE 3I Pulling out of roar bearing Fig EE 33 Inspecting alternator
EE 16
Electrical System
Engine
2 Ground test INSPECTION OF DIODE
ROTOR INSPECTION
If each lead wire of stator coil
1 Continuity test of rotor coil Perform a continuity test on diodes
including neutral wire is not conduc
in both directions
Apply tester between slip rings of using an ohmmeter
tive with stator core condition is
rotor as shown in Figure EE 34 If A total of six diodes are used three
satisfactory If there is continuity
there is no continuity field coil is are mounted on the positive EEl plate
stator coil is grounded
open
and other three are on the negative e
Replace rotor assembly plate The continuity test should be
Stator core
Ee044
EE041
Fig EE 37 Teding stator for
Fig EE 34 Continuity test of rotor Ound
P
coil
I plate
2 ptate
3 Diode
EE045
INSPECTION OF STATOR
1 Continuity test
Diode installed e plate is a
Diode installed on EEl plate is a on
Stator is normal when there is
positive diode which allows current negative diode which allows current
continuity between individual stator
flowing from terminal to EEl plate flowing from e plate to terminal
coil tenninals When there is no conti
current does not
only In other words current does not only In other words
nuity between individual terminals
flow from EEl plate to terminal flow from terminal to e plate
cable is broken
Replace with stator assembly
v
1 ptate
EE046
2 Terminal I plate
EE043 EE047
2 Terminal
Fig EE 36 Testing stator for
EE 39 Inspecting positive diode diode
continuity Fig Fig EE 40 Insp cting negative
EE 17
Engine Electrical System
If current flows in both positive If there is faulty diode ASSEMBLY
a
replace all
and negative directions diode is short diodes ix diode as an assembly Reassemble alternator in the reverse
circuited If current flows in one direc See table below These diodes are
sequence of disassembly noting the
tion diode is in good condition unserviceable
only
following
I When soldering each stator coil
lead wire to diode assembly terminal
Test probe of a circuit t ter
carry out the operation as fast as
Conduction pas
sible
e Gl 2 When installing diode A terminal
install insulating bush correctly
terminal EEl plate o
EJ plate terminal
terminal e plate
e plate terminal o
e plate @ plate o
Xl plate e plate
1 Imulating bush
INSPECTION OF BRUSH SPRING PRESSURE TEST 2 A terminal bolt
3 Diode cover
Check movement of brush and if With brush projected approximate 4 Rear cover
movement is not smooth check brush ly 2 mm 0 079 in from brush holder 5 Diode a
sembly
EE347
holder and clean if necessary measure brush spring pressure by the
Check brush for Fig EE 43 Sectional view of diode
wear If it is worn use of a pring balance Normally the
down to less than the specified limit and A term inal
rated pressure of a new brush spring is
replace brush assembly 255 to 345 gr 9 0 to 12 202
Check brush pig tail and if dam Morevover when brush is 3
worn Tighten pulley nut with tighten
aged replace pressure decrease approximately 20 g ing torque of 3 5 to 4 0
kg m 3 to
25
Brush line
0 7 02 per 1 mm 0 0039 in wear 29 0 ft Ib When pulley is tightened
wear limiting
make sure that deflection of V groove
is less than 3 mm 0 01 IS in
0
t m 0 079 in
q
or f
EE127
EEO
9 t
ffl EE051
Fig EE 41 Bnlsh wear limil Fig EE 42 M CJuring pring preaure Fig EE 44 Tightening pulley nut
EE lB
Engine Electrical System
ALTERNATOR TEST
Before conducting an alternator A 30 V olt voltmeter and suitable Figure EE45 and test auernator in the
make th tthe
test sure battery is fully test probes 3re
necessary for the test manner indica ted in the flow chart
Notes
a Do Dot run engine at the speed of
more than 1 100 rpm while test is
l
Battery
i 9
I
IV
EE052 Voltmeter
35 5 000 38 5 000
Pulley ratio 2 25 2 25
Brush
EE 19
Engine Electrical System
REGULATOR
CONTENTS
DESCRIPTION
The regulator consists basically of a field circuit direct to ground and the
voltage regulator and a charge relay upper contacts when closed complete
The voltage regulator has two sets of the field circuit to ground through a
contact points
upper set to control alternator volt
a lower set and an resistance
alternator output
field coil and produce
v
age An armature plate placed between The charge relay i similar in
the two sets of contacts moves upward construction to the voltage regulator
or downward or vibrates The lower When the upper contacts are closed 1 Charge relay
2
contacts when closed complete the charge warning lamp goes on Voltage regulator
EE285
Fig 46
EE View of removing cover
@ Q ID@
@ ID@
GJ I
IjDC@V J
r
CD @ JbL
r
T
t
r
L
CD
@
@ j 1
@
@ @
@
gf
@ @ @ EEJ97
h Point ap
14 Adjll sting sprin 6 Yoke gap 14 Contact iet
7 conlat
t 15 Yoke 7 Yoh
High speed 15 Voltage cgulatm contact
8 Contact c B Adjusting pring
Tlll tion f
a
Cnl1 lltagl l
jllIOltllT b Construction of charge relay
Fig EE 47 Structural vi w
EE 20
Engine Electrical System
MEASUREMENT
OF REGULATOR Rqulator
VOLTAGE
Genera tor
Regulator voltage is measured with
regulator assembled with alternator
When measuring voltage with regulator A Connector
mounted on car it is necessary to
rotate engine
Connect
at high speed
DC voltmeter l5 30Y
r
iJ Wire harness
circuit
Short here
fuse side tenninal and
between
to swing violently resulting in a dam 3 Refer to the chart parts are in good condition
following to
EE 21
Engine Electrical System
I Start engine
2 Rotate engine at 2 500 rpm for several minutes
Reduce engine speed to idling and then raise it to 2 500 rpm while
observing needle of voltmeter
table at left
Notes is cold
regulator
Do not measure
3 voltage immediate b To measure voltage raise engine
ly after driving Do this while
speed gradually from idling to rated
EE 22
Engine Electrical System
4
circuit as shown in Figure EE 52
Upper contact
Adjust charge relay in the same
Fig EE 50 Adjusting point gap manner as that for voltage regulator
5 Adjusting voltage
Adjust regulating voltage as
follows
Loosen lock nut securing adjusting
EE398
I Contact set screw Turn this screw clockwise to
2 ThicknesJ gauge increase or counterclockwise to
3 4 0 157 in dia screw decrease See
mm
regulating voltage
4 Crosshead Jcrewdriver
Figure EE 5 J
core gap
Fig EE 49 AdjUJJting
Over 5 2 Volts
EE 23
Engine Electrical System
Yellow terminal
RegulatoI r
A W L WR IG WL
Voltmeter
N Y E B F WB
EE348
Voltage legulator
Type TLl Z S5C
Smoothing resistance 40
uge
Ch lay
EE 24
Engine Electrical System
replace asrequired
Poor grounding of alternator and voltage Retighten terminal connection
regulator En terminal
Broken ground wire color of wire is black Replace
necessary
replace as required
Dirty slip rings Clean
in stator
Partial short ground or open stator Replace
winding
EE 25
Engine Electrical System
IGNITION CIRCUIT
CONTENTS
through the primary circuit It consists winding of the coil moves through the ule In addition apply grease NLGl
of the ignition switch resistor secondary winding of the coil inducing consistency No I containing MoS2 or
primary winding of the ignition coil high voltage The high voltage is equivalent to distributor shaft and
distributor contact points condenser produced every time the contact grease MIL G l0924B containing
and all connecting low tension wiring points open The high voltage current MoS2 or equivalent to cam as reo
The high voltage current is pro flows through the high tension wire quired
duced by the ignition coil and flows to the distributor cap Then the rotor The remainder of the ignition
through the secondary circuit result distributes the current to one of the component parts should be inspected
ing in high voltage spark between the spark plug terminals in the distributor for only their operation tightness of
electrodes of the spark plugs in engine electrical terminals and wiring con
0
Battery
cl IR
IB I
is 21
g
J
Re5istor
To starter
Ignition coil
Secondary winding
Cap
Breaker point
f
Rotor head
Distributor
EE060
EE 26
Electrical System
Engine
E
CJI2t
W
Bf o R
00
00
fOl
FUSIBLE LtNK
Wj
BW
BR
IGNITION SWtTCH
BL
I DISTRtBUTOR
L
oj
ti
J
C
L
RESISTOR
IGNITION COIL
COLOR CODE
B
OW
DR
Black
Black with white stripe
Black with red stripe
jjjSPARK PLUGS
EE493
EE 27
Engine Electrical System
CALIFORNIA MODELS
The ignition circuit consists of igni resistor voltage is produced time the
primary winding of the igni every
tion switch transistor ignition unit tion coil transistor ignition unit and primary circuit opens
distributor wiring spark plugs and all connecting low tension wiring The high voltage current flows
battery The high voltage current is pro through the high tension wire to the
The distributor is of the contactless duced by the ignition coil and flows distributor cap then the rotor distri
and is equipped with pick butor cap then the rotor distributes
type a up through the secondary circuit result
coil which electrically detects the igni ing in high voltage spark between the the current to one of the spark plug
tion timing signal in place of the electrodes of the spark plugs in engine terminals in the distributor cap
circuit breaker of the conventional Then the spark occurs while the
cylinders
distributor The transistor ignition unit This circuit contains the secondary high voltage current jumps the gap
is a new addition which generates the winding of the ignition coil distribu between the insulated electrode and
signal required for the make and break tor high tension wires to coil and the ground side electrode of the
spark
of the primary electric current for the
spark plugs distributor rotor and cap plug This process is repeated for each
ignition coil When the ignition switch is turned power stroke of the engine
The circuit isequipped with a and the distributor reluctor rotates
on The sparkplug should be inspected
resistor During cranking electrical the primary current flows through the cleaned and regapped at tune up
current bypasses the secondary resis
primary winding of the coil and Spark plugs should also be replaced
tor thereby connecting the ignition through transistor ignition unit to periodically as specified in the Main
coil through the primary resistor This
ground tenance Schedule
makes battery voltage available at ef When the prim ary circuit is opened The remainder of the ignition com
ficiently and keeps ignition voltage as by circuit of transistor ignition unit ponent parts should be inspected for
high as possible the magnetic field built up in the only their operation air gap of distri
The primary resistor selVeS to pro primary winding of the coil moves butor tightness ofelectrical terminals
tect transistor ignition circuit through the secondary winding of the and wiring condition
The low voltage current is supplied coil inducing high voltage This high Apply grease NLGI consistency
by the battery or alternator and flows No I containing MoS or equivalent
Primary Secondary
Battery
I
Ignition coo
I
Secondary winding
Transis tor
ignition I
r unit I
rcoil
Pick up
r
Rotor head
R5 nl
1 U1f J
Retuctor oi
r l f
S park plugs
EE287
EE 28
Engine Electrical System
IHIIl II II
BW BW
BBV RG
EARTH POINT
r
I I
111
a B
lof1 @
00
00
W 00 SR
00
b 00
Et liiI
FUSIBLE
LINK
BATTERY
TERMINAL BLOCK
c
r
BR
B
ml
lliJ LldJ0
IGNITION SWITCH
d
L
l
j
ilR
i in D1STRliUTOR
@
BW
10
c 0
RESISTOR
i9
IGNITION COIL
COLOR CODE
OW
DR
R
Black
Black with white stripe
Black with red stripe
White
Blue
Red
J SPARK PLUGS
G Green
EE494
EE 29
Engine Electrical System
CONTENTS
CONSTRUCTION
The distributor consists of breaker
plate with contact points centrifugal
advance mechanism vacuum control
ler distributor shaft and rotor
i
@
t Cap assembly
2 Rotor head assembly
3 Condenser assembly
4 Ground wire assembly
5 Lead wire assembly
6 Contact set
Fig EE 57
EE 30
Engine Electrical System
wire connection just for enough to denser depends on capacity and degree
CAP AND ROTOR HEAD pull primary lead terminal
out
of insulation requiring attention to be
For Canada
Fig EE 58 Adju ting point gap If vacuum advance mechanism fails When cause of engine malfunction
to operate properly check for the is traced to centrifugal advance me
following items and correct the mal
chanical part use distributor tester to
function as required check its characteristic
1 Check vacuum inlet for signs of See the specifications above
leakage at its connection Ifnecessacy When nothing is wrong with its
EE 31
Engine Electrical System
EE075
ASSEMBLY
To assemble reverse the order of
lowing instructions
Align match marls so that parts
are assembled to their original posi
tions
EE323
2 Apply grease to the top of cam
Fig EE 61 Removing contact tel
assembly as required
EE326
3 Check the operation of governor
Fig EE 64 Removil1l rotation paTta
before installing distributor on engine
EE 32
Engine Electrical System
Firing order 1 42
3 4 2
13
Counterclockwise Counterclockwise
Rotating direction
0 40 to 0 55 0 40 to 0 55
Point pressure lb
kg
0 88 to 121 0 88 to 121
0 20 to 0 24 0 20 to 0 24
Condenser capacity JlF
Mrl 5 5
Condenser isolate resistance
Mrl 50 50
Cap isolate resistance
50 50
Rotor head isolate resistance Mrl
mm in 10 39
0 10 0 39
Cap carbon point length
For Canada
CONTENTS
EE 33 ADVANCE MECHANISMS EE 33
CONSTRUCTION
EE 33 DISASSEMBLY EE 35
CHECKING AND ADJUSTMENT
CAP AND ROTOR HEAD EE 33 ASSEMBLY EE 35
CONSTRUCTION
In the conventional distributor the piece faces the protrusion of the re unit utilizes this electric signal to
is detected by the cam luctor and then the electrical signal is restore the primary coil to the original
ignition liming
state after cutting off the primary
and breaker arm while in this transis generated in the pick up coil
tor ignition unit it is detected
by the This electric signal is conducted current for a fIXed time
reluctor on the shaft and the pick up into the transistor unit which The centrifugal and vacuum ad
ignition
coil provided in place of the breaker in turn breaks tI e primary coil current vance mechanisms employ the con
The pick up coil consists of a magnet running through the ignition coil and ventional mechanical type The con
coil etc The amount of magnetic flux generates high voltage in the secondary tactor is used to eliminate vacuum
passing through the pole piece in the winding Also this transistor ignition and centrifugal advance hysteresis
coil is changed at the moment the pole
I
EE 33
Engine Electrical System
@
tl t3 l
1 Cap assembly
2 Rotor head a55embly
9 3 Roll pin
4 ReJuctor
S Pick up coil
6 Contactoi
7 Breaker plate assembly
8 Packing
9 Rotor shaft
10 Governor spring
11 Governor weigh t
l
12 Shaft Jscmbly
a
13 Cap setter
J @ 14 Vacuum controller
r
9
15 Housing
V 16 Fixing plate
@ fW
17 O ring
18 Collar
@
EE327
their positions
ADJUSTMENT
the
spected periodically as specified in
Maintenance Schedule Remove cap
and clean all dust and carbon deposits
from cap and rotor from time to time EE328
EE329
To remove pick up cail disconnect
distributor harness at terminal block Fig EE 68 Remouing pick up coil
and remove screw securing pick up coil
AIR GAP
ADVANCE MECHANISMS
Standard air gap is 0 2 to 4 mm
0
Specifications
0 008 to 0 016 in
If the gap is off the standard Type D4F4 04 Q3
D4F4
mould be made by loos
adjustment
ening pick up coil screws Item Manual Automatic
is required for adjust
Gap gauge
ment Air gaps must be checked from Vacuum advance
00 150 5 91
time to time Distributor degrees 30 250 9 84
Distributor mmHg inHg
Air gap 0 2 to 4
0 mm
EE34
Engine Electrical System
mechanical parts
controller assembly
3 Inspect breaker plate for smooth 3 Remove pick up coil assembly
moving 4 9 Mark one of the governor springs
Using two pry bars pry reluctor
If plate does not move smoothly and its bracket Also mark one of the
from shaft Be careful not to distort or
this condition could be due to sticky
the teeth of reluctor governor weights and its pivot pins
damage
steel balls or pivot Apply grease to
Remove roll pin 10 Carefully unhook and remove
steel balls or if necessary replace S Remove breaker plate setscrews governor springs
distributor assembly 11 Remove governor weights
and remove breaker plate assembly
Apply grease to governor weights
after disassembling
Centrifugal advance
mechanical parts
T
DISASSEMBLY
setscrew pin
EE 35
Engine Electrical System
EE299
Type D4F4 03 04
D4F4
Firing order 1 4 2
3
Duty 70 20 to 40 at idling
Air gap mm in 0 2 to 0 4 O OOS to 0 016
CONTENTS
DESCRIPTION
is provided This cuts off the
TRANSISTOR IGNITION 2 The duty control circuit sets the ing
rate of make and break within one prilnaCY electric current in the ignition
UNIT
cycle ie this maintains good ignition coil when the ignition switch is turned
The transistor ignition unit provides
characteristics of engine from low on with the engine not running
the following functions speed high speed and is equal to
to Each component part of this unit is
L It makes and breaks the electric the dweU angle in the conventional however
highly reliable should any
current in the primacy circuit of the breaker type distributor part be found faulty the entire assem
EE 36
Engine Electrical System
45
EE The thick lines indicate the
objective of each individual item
Power Duty Spark timing Lock
check
1 1 j
r1
switching control Signal mom preven ling When checking a circuit with an
circuit circuit toring circuit circuit
oscilloscope or a circuit tester be
Fig EE 75 Transistor ignition unit circuit diagram a timing light in parallel with an
Transistor ignition unit is located faulty ignition system check the igni
tion system as follows
on the right hand dash side panel in
CHECKING WITH AN
OSCILLOSCOPE DC 50 volt range
L
An oscilloscope can be used for
checking almost all the items in a
TESTER
Fig EE 77 Checking power supply
A circuit tester can not be used for wiring and batt ry
the duty control circuit and power
tests Criterion
t18nsistor performance Both
Fig EE 76 External view of ignition
methods use of an oscilloscope and a When power source battery
unit
circuit tester are described in this voltage is indicated OK
section Lower or no indication N G
EE 37
Engine Electrical System
If the result is N C Take the harness respectively for proper con
ductance
following measures
In Fig 89
EE Resistance
4 PICK UP COIL POWER
1 range
oscilloscope
C ooneet
as
a cireui t tester
shown in Figure EE 78
or an
ro valve connector
2
in the
Connect a circuit tester as shown
DC 50volt range
Criterion
S
tf When approximately 1 6 to
2 0 ohm is indicated
OK AC 2 volt
S range
More than 2 0 ohm N C
EE303
EE 3B
Engine Electrical System
to
positive lead of
R olor wire and
an
a
Oscilloscope
8W
o 8
r
negative lead of an oscilloscope to
0
G color wire 0
3 Set a SLOPE select switch of EB C
EE307
EE268
Criterion @
When the wave form takes
the shape of a full line OK
When the wave form takes the
shape of dashed line when
a or
@
there is no wave form N G
EE452
Procedure If the result is N G the fault lies If the result is N G the fault
either in the transistor unit or in the
I Connect coil and dis lies either in the transistor unit or in
ignition
secondary high tension wire
tributor harness to ignition coil exter the secondary high tension wire
EE 39
Engine Electrical System
5 2 Checking operation
of duty DC 50 volt range
Procedure B fJ
rC
O
BW
the
While the
wave ronn
engine
on
is idling
the oscilloscope in
observe
8
t 1 V
the same way as stated in item 5
Figure EE 83 Determine the ratio tiT
as shown in Figure EE 85
I
x 100 20 to 1
401
T
EE357
at idling
Fig EE 86 Checking lock p uentive circuit
h
T
1
Lt Criterion
Figure EE 83
same
or
way as
Figure 86
EE
shown in
Turn
is indicated OK on ignition switch
When Check to see whether the wave
EE257 approximately zero voltage
form the
is indicated N G on oscilloscope rises up to
Fig EE 85 Wove form ofduty pulse the power source voltage within about
If the result is N G Take the 10 seconds after is
ignition switch
following measures turned on
Criterion
Replace transistor ignition unit
When a standard ratio of about
20 to 40 is obtaiiied If
OK an oscilloScope is uSetl
When the ratio obtained is
less than 20 Procedure Criterion
or
Oy
Procedure
1 Connect a circuit tester as shown
t
in Figure 83
EE or EE
86 positive Ignition switch ON
terminal of tester is connected to L EE430
color wire and negative terminal of Fig EE 87 Wave form of lock preventive circuit
tester is grounded
40
EE
1 Al13 c
n
l1
5 l1
rn
bat e
c
E438
E
and
r I
y
1
o
timing
prev nti g item
for
lonltoriOi
l
1
sign
t
oClt cl cuit ram
sparlt circui l8
di
Wiring
P 88
am
c
EE
s
Fill
Harne
L R G
II
llW
oC
r b
Terminal
auemblY
coil
BR
IgnitOn Utstnot
tC
l
nitonS o i
It
11
3
0c f
3D WC
l
rn llO
0
439
eE
con o
switcnlOS DUtY circuit
unit
on
lng
tiR monitrng cltCuit Itev nti s circuit
1
K
Loc
Spade oIgn
alnP
c
o
Harnes
L R G
Il IlW
r
k
OC
Terminal
asemblY
coil
IlR
igniton
o DistrbuO
Wb
l IlS3 blY
O
rn l0
r Wo
EeA40 ncoi1
0
1
ing
tdl cont o unit
Iln1
i
nll
putY ciIcuit
sVI R
o oth1
t
for
cirCuit
K
lflc
a
sign
atK
S1 citcuit dioS
Wirinl
clarnp 90
@ EE
rnesSa
H
Fig
G
R
ll L
OC
r
o
ina
let1
uW
auefC
coll
P
iUO
llR 19t
Dutot
tri
o
sWitch
O
gn1t10
b
01Il f
I Iu 5
l
l lll
EE44
o
lTcofO
l
unl
powet CltCU1l
tn
o
onitoifl preyen
f
t
titrllt
LOCK circuit
tl
l
St signacircuit
cump
@ e
Ratt
l G
I
B
BW
blocK
r oa
Ter n
I
rntM
a
CO
l
ll
Of
t
f1
bUlot
o OliU
Witch
s
on
gni
Wt
it
l
svstel
O
El19ine
ElectriCal
j
g
j
0 15
l i
0
5
l
J
i CI C
g
t 0 e
0
t
l
l
2
0
l t
a a I S l
e
ll 1
t
ll u
1
oJ
ll
foil
i
i
0
0
u
0 S
a
CD 0
0
4S
EE
Engine Electrical System
IGNITION COIL
EE314
1 R bber cap for ignition coil 8 Side core
Notes
Do disconnect
a not high tension
wires from spark plugs during en
gine mnning California models
only
I EE354
b RoD up high tension wire mbber
1 High tension wire
2 Rubber cap
cap and instaD high tension wire to
ignition coil securely Refer to
Figure EE9S
Fig EE 94 Correcl installation of high
t Mjon win Fig EE 95 Installing high tension wire
SPECIFICATIONS
Non California
California models
models
Type 618
C6R HS 15 18 CIT 16 STC 9
Primary voltage V 12 12
46
EE
Electrical System
Engine
SPARK PLUG
CONTENTS
EE 4B
DESCRIPTION 47
EE SERVICE DATA AND SPECIFICATIONS
EE 47 TROUBLE DIAGNOSES AND
INSPECTION
CORRECTIONS 4B
EE
CLEANING AND REGAP 47
EE
INSPECTION
L Remove spark plug wire by
pulling on boot not on wire itself
EE96
indicate heat with a smaU fine file to flatten the After cleaning spark plugs renew
correct spark plug
surfaces of both center and side firing surface of electrodes with me
range
electwdes parallel Set spark plug
in mentioned aboVe Then gap spark
Carbon fouled Dry fluffy carbon
to specification plugs to specified values with a round
deposits on the insulator and gap
electrode usually caused by
are
5 InstaU spark plugs and torque wire feeler gauge All spark plugs new
47
EE
Engine Electrical System
BP6ES ll BP6ES
Standard BPR6ES
L45PW ll L45PW
BP7ES ll BP7ES
Cold type BPR7ES
LMPW ll LMPW
10 to l 0 8 to 0 9 0 8 to 0 9
Plug gap mm in 0 039 to 0 043 0 031 to D35
0 0 031 to 0 035
Tightening torque kg m ft Ib
I 5 to 2
1 11
0 to 14
Ignition coil Wire breakage or short circuit of coil Replace with new one
models
4B
EE
Engine Electrical System
More than 6 rnm Spark plugs Spark plug gap too wide Correct or replace
0 236 in Too much carbon Clean or replace
models
2 Engine rotates but does not run system or other engine condi Hons not complete inspection of ignition system
related to ignition Therefore first a should be carried out
smoothly
This may be caused by the ignition
dels
coil
49
EE
Engine Electrical System
Leak of electricity at
upper porcelain Repair or replace
insulator
models
Engine does not Distributor Improper ignition timing too retarded Correct
deliver enough
Improper functioning governor Replace assembly
power
Point gap too narrow Non California Correct
models
EE 50
SECTION ER
ENGINE
DATSUN PICK UP REMOVAL
MODEL 620 SERIES INSTALLATION
CONTENTS
ER 2
Engine Removal Installation
ER207
and jack it up
21 Loosen two rear engine mount
E R367
ing bolts CD
Loosen two exhaust tube Fig ER 5 Lifting engine
22 hanger
bolts V California models only
23 Remove four bolts CID securing
ER271
1 Bracket RH
2 Insulator R H @
3 Bracket LH
4 Heat shield plate
5 Insulator L H
6 Rear support
iC 7 Rear insulator
E A279
8 Exhaust tube hanger
California models only Fig ER 6 Structual view of engine mounting
EA278
Note In this r
an care should the engine and transmission two are signs of separation or deterioration
always be taken not to allow the located at the left and right of the Be sure to keep insulator free from
hit cylinder block and at the transmis oil or
unit to against any adjacent one grease
sion rear extension housing
parts
ER 3
Engine Removal Installation
TIGHTENING TORQUE
4
ER
SECTION CL
CLUTCH
DATSUN PICK UP
MODEL 620 SERIES
CLUTCH CL 2
CLUTCH CONTROL CL 5
CLUTCH
CONTENTS
e
M
0
s 8 62
o
2 44
8
dia
6
I
l150 5 91 dia
225 8 86 dia 260 10 2 dia
o
CL231
C
Unit mm in
CL2
CLUTCH
00
l J
lo
I
7
R
1 Release bearing
I
2 Release
sleeve
bearing
1
3 Holder spring J
rr CL109
4
5
6
Dust cover
Withdrawal
Retainer
lever
spring CL119
Fig CL 7 1
1
tailing
CL215
e bearing
rele
Fig CL 3 l talling clutch cover
assem bly Fig CL4 Exploded view ofclutch 2 Before or during assembling lu
releaae mechaniam
bricate the following points with a
3 Install six bolts to tighten clutch
light coat of multi purpose grease
cover assembly to flywheel squarely 3 Take clutch release
Each bolt should be
out bearing
tightened one
from bearing sleeve using a universal I
turn at a time to the specified torque Inner groove of release bearing
puller See Figure CL 5 sleeve See Figure 8
CL
15 to 2 2 kg m II to 16 ft Ib
Connect n
6 push rod of clutch op
erating cylinder to withdrawal lever
Fig CL 5 D embling
b
C L014
e
rele
JQt CL216
ASSEMBLY
4 Remove pilot bushing in crank 2 Contact surfaces of withdrawal
shaft by Pilot Bushing Puller lever lever ball pin and bearing sleeve
Disassembly ST16610001 if necessary See Figure 3 Contact surfaces of transmission
I Clutch cover assembly can not be 6
CL front cover See Figure CL 9
CL3
CLUTCH
I If facings are oily the disc should If excessive wear is found replace
be replaced In this case inspect trans clutch cover as an assembly
lt
mission front cover oil seal pilot 2 Measure the height of diaphragm
bushing engine rear oil seals and other spring as outlined below See Figure
points for oil leakage CL 12
tJ I
f
phide Above 0 3 rom STl0050100
10 012 in
Note Very IIIIJllII amount of grease
I Tl 05001O
should
points
be
If too much
ated to the above
iubricant is
rJrf
f
applied
friction
in d
it will
plates
run
when hot
dutch disc
out on
resulting
the
Fig CL I0 JIuringclutch
Me
CL089
lining C L23
7
STl005Q051
gi facings
Fig CL 12 uring the height of
Me
3 Install retainer spring to with 3 Check disc plate for runout when
diaphragm pring
drawal lever Fit holder the old disc a is
spring to ever or new one
ST20050240
INSPECTION
Wash all the disassembled parts
smoothed by using fme emery cloth clutch disc or main drive gear should
3 Inspect thrust rings for wear or
If surface is deeply scored or groov be replaced that is backlash exceeds
damage As these parts invisible are
ed the part should be replaced 04 mm 0 016 in at the outer edge of from outside shake cover assembly up
clutch disc and down to listen for chattering
Clutch disc llembly
at
noise or lightly hammer on rivets for a
Clutch cover
Inspect clutch disc for worn or oily assembly slightly cracked noise Any of these
facings loose rivets and broken or I Check the end surface of dia noises mean requirement for replace
loose torsional springs phragm spring for wear ment as a complete assembly
4
CL
CLUTCH
it
pin and bearing sleeve replace
CLUTCH CONTROL
CONTENTS
DESCRIPTION CL 5 Inspection CL B
forwards clutch fluid to the operating adjustable type that uses no return
DESCRIPTION unit the withdrawal to
The cylinder via a pipe line The movement spring In this
hydraulic clutch control con is
sists of a pendent pedal a master
of the operating cylinder piston push rod play adjustment is not neces
transmitted to the withdrawal lever sary since the 8 as shown in Figure
cylinder an operating cylinder and a CL 15 serves automatically compen
through the push rod thus disengaging to
withdrawal lever
the clutch sate for wear on the clutch disc
When the clutch pedal isdepressed
the master cylinder
The operating cylinder is a non
piston of the
l 5
10 Clutch disc
5 Operating cylinder
Fig CL14 Clutch operating system
CL 5
CLtJTCH
Stroke 30 mm
18
1 in
I
i
Jt
Sj 1
Fig CL 15
J
i
Non adj table operating
o
cylinder
1 Lock nut A
2 Lock nut 8
CLUTCH PEDAL
Pedal beiBht a 53 mm 6 02 in
Removal and Pedal full stroke b 117 10 23 4 6 104 84 in
installation
Removal See Figure CL 16
@ Multipurpose grease
CfJ 6
3 per and tighten lock nut A to the
W5
specified torque 0 8 to 12 kg 5 8
ch m
fD to 8 7 ft lb
CL 6
CLUTCH
CLUTCH CYLINDER cylinder to the vehicle and dismount 2 Bleed air out of hydraulic system
master cylinder
MASTER Tightening torque
Note Remove dust cover from master Master cylinder to dash panel
Removal and cylinder body on the side of driv 0 8 to 1 2 kg m
er s seat 5 8 to 8 7 ft lb
installation
Installation Clutch tube connector Flare nut
Removal 5 to 1 8
1
install kg m
To reverse the order of
II to 13 ft lb
I Remove clcvis pin at push rod removal observe the
Closely following
2 Disconnect clutch tube from instructions 3 Flare Nut
Using Torque Wrench
master cylinder and drain clutch fluid 1 Adjust pedal height by changing GG94310000 tighten each connector
3 Remove bolts master
securing pedal stopper length to the specified torque
1 Reservoir cap
2 Reservoir
3 Reservoir band
4 Cylinder body
5 Supply valve stopper
6 Return spring
7 Spring seat
8 Valve spring
9 Supply valve rod
10 Supply valve
11 Primary cup
12 Piston
13 Push rod
14 Secondary cup
15 Stopper
16 Stopper ring
17 DU5t cover
18 Lock nut
CL265
1 Remove dust cover and remove To assemble reverse the order of available in both NABCO make and
TOKICO make There is inter
stopper ring from body disassembly Closely observe the fol no
and take off supply valve if necessary correctly faced in position ascertain the
component parts
2 Apply a coating of brake fluid to
See Figure CL 19 brand of the clutch IIIBSter cylinder
cylinder and piston when assembling
body Be sure to use parts of the
Note Discard piston cup supply 3 Press piston into spring seat when
same make as the former ones
valve and spring seat after removal assembling
CL 7
CLUTCH
uneven wear or damage and if neces be bled whenever clutch line has been
disconnected or air has entered it
sary replace
If the clearance between When pedal action has a spongy
2 cylinder
and is than 15
0 feeling it is an indication that air has
piston more mm
1
replaced 6
when wear or deformation due to I Remove reservoir cap and top up
fatigue or damage is found with recommended brake fluid
Cl11B
4 Damaged dust cover oil reservoir
1 Push rod 5
2 Thoroughly clean mud and dust
Piston cup
or capshould be replaced of operating cyl
2 Dust cover 6 Operating cylinder from bleeder screw
Return spring and valve spring must 3 Piston spring 7 Bleeder screw inder so that outlet hole is free from
also be replaced when they are broken 4 Piston
any foreign rnaterial Install bleeder
or weak Fig CL 20 Exploded view of
hose vinyl hose on bleeder screw
5 clutch hose and tube if operating cyUnder
Replace Place the other end of it in a clean
any abnormal sign of damage or de
container
fro ti is found
n
Assembly 3 Have a co worker depress clutch
Assemble in the order of pedal two three times With clutch
OPERATING reverse
or
loosen bleeder
disassembly Closely observe the fol pedal depressed fully
CYLINDER to bleed air out of clutch sys
lowing instructions screw
tern
Removal and 1 Prior to assembly dip piston cup
in clean brake fluid
4 Close bleeder screw quickly as
installation clutch is on down stroke
When particular pedal
installing cup pay
Allow clutch
Removal attention to its direction
5 pedal to return
Bleed air thoroughly from clutch ponent parts between NABCO and out of bleeder screw in a solid
hydraulic system TOKICO makes stream without air bubble
2 Do not install return When replacing the repair kit
Pay close attention to clutch fluid
or
spring or c
clutch will be component parts ascertain the
not disengaged level in reservoir during bleeding
properly brand of the clutch operating cyl operation
inder bndy Be sure to use parts of d Do not brake fluid drained
Tightening torque reuse
the same make as the former ones
during bleeding operation
Operating cylinder securing bolt Exercise care not to splash brake
e
5 to 3
2 5 kg m 18 to 25 ft lb
fluid on exterior fInish as it will
Bleeder screw
0 7 to 09 m 5 1 to
kg 5 ft Ib
6
Inspection damage the paint
Visually inspect all disassembled f Pour brake fluid into reservoir up
Clutch hose connector
to specifIed level
parts replacing those found worn or
17 to 2 0 kg m 12 to 14 ft b
rl Q
CLUTCH
Clutch cover
distance in 33 to 35 1 23 to 1
38
Diaphragm spring to flywheel mm
Clutch disc
Facing size
Free mm in 8 3 to 8 9 327
0 to 0 350
Allowable minimum of
depth mm in 3
0 0 012
rivet head from surface
Allowable in 5
0 0 020
facing run out mm
Tightening torque
Clutch assembly to flywheel securing bolt kg m ft lb 1 5 to 2 2 lito 16
Bleeder screw
kg m ft Ib 0 7 to 0 9 5 1 to 6 5
CL 9
CLUTCH
Clutch slips Slipping of the clutch may be noticeable when any of the following symptoms is encountered
during operation
I Vehicle will not respond to engine speed during acceleration
2 Insufficient vehicle speed
3 Lack of power during uphill driving
Some of the above conditions are also experienced when engine problem is oc urring First
detennine whether engine or clutch is causing the problem
If slipping clutch is left unheeded wear and or overheating will occur on clutch facing until it is
no longer serviceable
TO TEST FOR SLIPPING CLlJfCH proceed as follows
During upgrade travelling engine run at about 40 to 50 km h 25
to 31 MPH with
gear shift
lever in 3rd speed position shift into highest gear and at the same time rev up engine If clutch
is slipping vehicle will not readily respond to depression of accelerator pedal
Clutch drags Dragging clutch is particularly noticeable when shifting gears especially into low gear
I Start engine Disengage clutch Shift into reverse gear and then into Neutral Gradually
increase engine speed and again shift into reverse gear If clutch is dragging gear grating
is heard when shifting from Neutral into Reverse
2 Stop engine and shift gear Conduct this test at each gear position
3 Gears are smoothly shifted in step 2 but drag when shifting to 1st speed position at
idling
a If dragging is encountered at the end of shifting check condition of synchro
mechanism in transmission
If dragging is encountered at the beginning of shifting 4 below
b proceed to step
4 Push change lever toward Reverse side depress pedal to check for free travel
5 Check clutch control pedal height pedal free travel withdrawal lever play etc
If no abnonnal condition exists and if pedal cannot be depressed further check clutch
condition
CL10
CLUTCH
A noise is heard when vehicle is suddei11y staited offwith clutch partially engaged
Replace
Damaged pilot bushing
I
off from standing start
Clutch grabs When grabbing of clutch occurs vehicle will not start smoothly a or
CLll
Ul CFf
Cl
y S30
2 ST20050051
Set bolt
SE002
q
3 ST20050 100
Distance
@
piece 7 8 mm
0 31 in
@1 @J SEOQ3
SE032
5 KV30100200 This tool is used to conduct disc centerilg by inserting the tool 620 Fig CL 2
into pilot bush in flywheel when installing clutch assembly to 710
Clutch Fig CL 3
flywheel 610
aligning bar
S30
SEaOl
SE191
CL 12
CLUTCH
For Reference
Tool number use page or
No Description
on Figure No
tool name Unit mm in
All Page CL 7
7 GG94310000 This tool is used to tighten and loosen brake and clutch tube flare
models
torque limiting wrench is provided to
assure torque
nut A built in
Flare nut
accuracy
torque wrench
y SE227
CL 13
SECTION MT
MANUAL
DATSUN PICK UP TRANSMISSION
MODEL 620 SERIES
SPEEo
4 TRANSMISSION
MT 2
TYPE F4W71 B
5 SPEED TRANSMISSION
MT 14
TYPE FS5W71 B
CONTENTS
DESCRIPTION
The transmission is of a 4 speed pUshed the inner teeth of the coupling The transmission assembly consists
forward fully synchronized constant sleeve slide over the synchronizer hub of three main parts a transmission
mesh type that uses helical gears and mesh with the outer teeth which case with clutch housing adapter plate
The reverse gear is ofa sliding mesh are provided on the mainshaft gear to which an gears and shafts are
type using spur gears The synchronizer hub is fitted to installed and rear extension
In construction the main drive gear the mainshaft by splines so the main The cast iron adapter plate supports
is meshed with the counter drive gear shaft gear turns together with the the mainshaft countershaft reverse
which is keyed to the countershaft mainshaft idler shaft and three fork rods and
The forward speed gears on the coun The baulk ring serves to synchro bolted at the front to the transmission
tershaft are in constant mesh with the nile the coupling sleeve and mainshaft case and at the rear to the rear
mainshaft gears which ride on the gear extension by means of through bolts
mainshaft freely through the needle Placing the control lever in reverse By removing these bolthroughts all
When is position brings the idler gear
bearing shifting accom reverse gears and shafts are stripped
into mesh with mainshaft reverse gear
TM 858
1 Front cover
2 Transmission case
3 Adapter plate
4 Bearing retainer
5 Rear extension hOUsing
o
cCl
@
4
@ 1 Striking lever
fl 2 Lock pin
3 Oring
4 Striking guide
5 Oil sea1
6 Striking rod
E ring
t
7
8 Stopper guide pm
@ 9 Return spring plunger
10 Return spring
11 Reverse check spnng
12 Return spring plug
13 Check ball plug
14 Check spring
15 Check baD
16 Interlock ball
o
17 Retaining pin
18 1st 2nd shift ork
f1f@ 20
21
22
23
3rd
Reverse
3rd
4th fork rod
fork rod
4th shift fork
TM045A
3
MT
Manual Transmission
Figure 6
MT
I Disconnect battery ground cable
from terminal
2 Place transmission control lever in
neutIal position
3 Remove E ring and control lever
pin from transmission striking rod
guide and remove control lever See
E A277
Figure 4
MT
Fig 8
MT Removing engine mounting
rear support
companion flange of gear carrier by away from engine and remove from
@ transmissionjack
13 Remove exhaustpipe btacket
by unscrewing attaching bolts 2
California models only See Figure
8
MT
1 Speedometer cable
2 Reverse lamp switch 14 Remove rear engine mounting
3 Outch operating cylinder insulator securing bolts I and rear TM337
4
MT
Manual Transmission
qJiiiiiI
TM341
TM344
to special tool MT 17
2 Remove counter drive gear snap
ring
DISASSEMBLY OF GEAR
3 Draw out counter drive gear com
ST23540000
TM343
MT 5
Manual Transmission
4 Remove snap ring and then thrust sembly together with countershaft by 2 Press out I st gear mainshaft bush
washer from mainshaft front end lightly tapping the rear end with a soft ing together with 2nd gear and 1 st
Draw out 3rd 4th synchronizer hammer while holding the front of 2nd speed synchronizer using Bearing
assembly and remove 3rd gear as mainshaft gear assembly by hand Puller STJ0031000 See Figure
Be careful not to drop off gear
sembly MT 2l
5 Release caulking on mainshaft shaft See Figure MT 20
nut and loosen it See Figure MT 19 Note When r
out bushing
h ft
hold by hand so as not to
drop it
IJ H
t I
TM346
TM347
Fig MT 19 Removing maimhaft nut
Fig MT 20 Driving out gear Cl embly
30031000
S1
7 Remove snap ring from counter 1 Remove thrust washer steel ball
shaft rear end and remove reverse I st gear and needle Be careful
bearing TM049A
idler gear not to lose steel ball retaining thrust Fig MT 21 R moving lItgear
8 Draw out mainshaft gear as washer mtUlIIhaft bu hing
12
1 Pilot bearing
assembly
to Coupling sleeve
II Shifting insert
12 Shifting insert spring
13 Synchronizer hub
14 1st main gear
15 Needle bearing
16 1st gear bushing
17 Thrust weher
18 Maimhaft bearing
19 ReftllSe main gear
20 Thrust washer
21 Nut
22 Steel ball
23 Thrust washer
24 Snap ring
TM348
6
MT
Manual Transmission
1 Remove main drive gear snap ring Install Bearing Puller STJOO31000
rod
Bearing Puller ST30031000 and a suit
able piess See Figure MT 23 See Figure MT 25
III
cl iiiiiE l
TM351
TM350
Fig MT 25 Removing countershaft
Fig MT 24 Exploded view of main drive gear bearing
q
e 1 f
@ @
j
3 Snap ring
4 Countenhaft drive gear
5 Woodruff key
6
1
Countenhaft
Countershaft rear bearing
i
TM352
8 Reverse counter gear
9 Snap ring
MT 7
Manual Transmission
e 2
1 Control lever
Striking rod guide
3 Striking rod
4 Striking lever
5 Return spring plug
6 Stopper pin
TM353
ADAPTER PLATE Remove all nicks projection or 2 Check shaft for bending crack
DISASSEMBLY sealant with a frne stone wear and worn spline if necessary
I Remove six 6 3 If extension bush is
bearing retainer rear worn or replace
attaching screws with an impact cracked replace it as an assembly of 3 Measure backiasii in gears
wrench and remove bearing retainer bush and rear extension housing Standard
from adapter plate 005 10mm
to0
2 Remove reverse idler shaft BEARING
0 0020 to 0 0039 in
3 Remove mainshaft bearing from
I clean bearing and dry
the rear extension side Thoroughly If the above limits are exceeded
with a compressed air drive and driven gears
replace as a set
2 When race and ball surfaces are 4 Measure gear end play
worn or rough or when balls are out 1st gear
INSPECTION of round or rough replacebearihg 0 32 to 39
0 mm
with See MT 28
Wash all parts in a suitable cleaning
a new one Figure 0 0126 to 00154 in
solvent and check for wear damage or 2nd gear
other faulty conditions 0 12 to 19
0 mm
0 0047 to 00075 in
Notes
3rd gear
a Be careful not to damage any parts
0 13 to 37
0 mm
with scraper
0 0051 to 0 0146 in
b 00 not clean wash or soak oil seals
in solvent
I
TM372
TRANSMISSION CASE AND
Fig MT 28 l pecting ball bearing
REAR EXTENSION HOUSING
8
MT
Manual Transmission
25 to 160 rom
lr
5 1 0 0492 to 0 0630 in
Front
Baulk ring
h
TM355
OIL SEAL Insert striking rod with striking rod in adapter plate by lightly tapping
guide through rear extension around it with a soft hammer
Discard O ring or oil seal which is
3 Install striking lever on front end
once removed Replace oil seal if of striking rod Install lock pin and
sealing lip is deformed or cracked
torque screw to 0 9 to 12 kg m 7 to
Also discard oil seal if spring is out of
9 ft Ib
position
GEAR ASSEMBLY
ADAPTER PLATE ASSEMBLY
ASSEMBLY Clean all parts in solvent and dry
1 Place dowel pin mainshaft bear with compressed air
To assemble reverse the order of
ing and oil gutter on adapter plate and
disassembly Observe ihe following
tap with a soft hammer until they are Synchronizer 888embly
instructions
properly positioned in place
Assemble synchronizer assembly
Use a new dowel pin
COVER ASSEMBLY Position shifting insert springs and
FRON1 Bend oil gutter on front side and
shifting inserts in three 3 slots in
clean seal front expand on rear side See Figure
I Wipe seat in
synchronizer hub put coupling sleeve
cover then press fit oil seal in place MT33 on synchronizer hub
Front
J
Upper
Front
r
J f
Front r
7
M356
3rd 4th 15t 2nd
TM351
J
C
TM354 MT 35 Installing synchronizer
Fig
MT 31 Front cov oil eol Fig 33
MT Oil gutter hub
Fig
MT 9
Manual Transmission
I Assemble 2nd gear needle bear I Place new woodruff keys in 1 Using Transmission Adapter
ing 2nd gear baulk ring 1st 2nd grooves in countershaft and tap them ST23800000 press main drive bearing
speed synchronizer assembly st gear lightly until they are seated securely onto the shaft of main drive gear
baulk ring I st gear bush needle bear Use a soft hammer to avoid dam Make sure that snap ring groove on
ing I st gear steel ball and thrust aging keys shaft clears bearing
washer on mainshaft Before installing 2 Place main drive bearing spacer
2 Place adapter plate assembly and
main
a steel ball apply grease to it See mainshaft assembly so that counter on main drive bearing and secure
Figure MT 36 shaft
drive bearing with thicker snap ring
rear bearing rests on Transmis
that will eliminate end play See
sion Press Stand KV31100400 prop
Figure 4l
MT
erly
3 Install countershaft into adapter
See Available snap ring
plate by pressing it Figure MT 39
No Thickness mm in
1 80 0 0709
2 1 87 0 0736
TM358
3 1 94 0 0764
Fig MT 36 l talling thrust washer
4 2 01 0 0791
2 Set Transmission Press Stand
KV311 00400 and place adapter plate 5 2 08 0 0819
assembly it See MT 37
on Figure TM440 6 2 15 0 0846
Fig 39
MT l talling countersha
t
38
MT Installing haft TM441 drive gear and main drive gear
Fig mai
em bly Fig 40
MT l talling snap ring simultaneously
MT l0
Manual Transmission
map ring
TM442 L
Use snap ring to give a minimum C kg m 14 x to
Fig 42
MT l talling haft
counte
drive gear gear end play See Figure MT 45 L O lO
L
Available counter drive gear map ring 17 x
L 10
0
No Thickness mm in
No Thickness mm in or
I 14 0 055
L
I 14 0 055 2 15 0 059 C ft lb 101 x to
L 33
0
2 15 0 059 3 16 0 063 L
16 0 063 123 x
3
L 33
0
II
Where
ST22520000 c
Torque wrench
Fig 45
MT Imtalling
o
counter
gear
TM361
reverse
nap ring
Lm ft
h I
Example
When a 0 40 m 31
1 ft long tor
ST22520000
KV3 II00400
TM443
haft TM768
Fig 44
MT Installing counte
front bearing Fig 46
MT Tightening mainshaft nut
MTll
Manual Transmission
6 1r
c
with check ball See Figure MT 50
u
c
14
100
9 13
f fdl
Converted torque
S
c
90
o
I
Lower limit line
80 11 TM367
U
Fig MT 50 l talling 1st 2nd
fork rod
70
10
ter driVe gear should be handled as Apply sealant to check ball plug
to 17 0 kg m 101 to 123 ft lb
matched set and install it in place
torque and stake mainshaft nut to a
Align notch in 3rd 4th fork rod
groove of main shaft with a punch See When you replace a main drive gear
counter drive gear with check ball by sliding 3rd 4th
Figure MT49 or be sure to
mbly
I Place 1st 2nd shift fork in
in 1st 2nd sleeve
groove coupling
and slide 1st 2nd fork rod through
Fig 49
MT Staking haft nut
mai 3rd 4th coupling sleeve Fig MT 51 Installing 3rd 4th
fork rod
Note Shift forks for 1st 2nd and
3rd 4th are one and the same
Make sure that they are held within fork for lot 2nd is the idler gear
placed on
the specified values counter gear side and the end Slide reverse fork rod
long through re
For details refer to the instructions for 3rd 4th is the shift fork and
on e verse adapter plate and
under topic Inspection side with
secure a new retaining pin
MT12
Manual Transmission
6 Install check ball and check ball end of transmission case to counter
7 3 52 to 3 61 0 1386 to 0 1421
lon
Tranmis ea mbly
8 3 62 to 3 71 0 1425 to 0 1461
adapter plate by lightly tapping with a cover and transmission case bly on rear extension After making
soft hammer until case bears against Apply grease to shim selected to Sure that lock plate is lined up with
adapter plate retain it on front cover install front groove in speedometer pinion sleeve
Carefully install main drive bearing transmission with gasket install
cover to case
through bolts and torque to 04
and countershaft front bearing in place to 0 5 kg m 3 to 4 ft lb
Make certain that mainshaft rotates Install through bolts with washers 4 Install back up lamp switch and
freely under them and tighten to 1 6 to 2 1 torque to 2 0 to 3 0 kg m 14 to 22
3 Fit main drive bearing snap ring kg m 12 to 15 ft lb torque ft lb
to groove in main drive bearing by sealant threads of Be
Apply to sure to apply sealant before
using Expander See Figure MT 53 through bolts before installation installation
MT13
Manual Transmission
CONTENTS
DESCRIPTION
The transmission is of a 5 speed overdrive position of it in over
Placing the control lever
forward with overdrive 4 OD The overdrive gear rides the drive position brings the
on reverse OD
speed fully synchronized constant mainshaft freely through the needle coupling sleeve reverse main
gear on
mesh type that uses helical gears roller bearing and counter overdrive shaft into mesh with overdrive clutch
The 5 speed transmission covered in gear is fitted to the countershaft by gear The reverse OD synchronizer
this section is similar in all respects to splines hub is fItted the mainshaft
to by
the 4 speed transmission type The overdrive synchronizer system splines so the overdrive gear on main
F4W71B stated previously except the is on the mainshaft rear side shaft turns together with the main
shaft
MT14
Manual Transmission
j
I
@
00
b
7
@
f
1 Front cover
5 Adapte plate
f 6 Maimhaft bearing
7 Bearing retainer
8 Rear extension
9 Breather
@3
TM046A
MT15
Manual Transmission
W
h
I
l
1 Main drive gear
2 Baulk ring
3 Shifting insert
4 Shifting insert spring
5 Synchronirr
c hub
6 Coupling slee
7 3rd main gear
g Needle bearing
9 Mainshaft
10 2nd main gear
11 Bushing
12 1st main gear
13 O revcrse synchronizer hub
14 Rever gear
15 Circlip
16 Thrwt block
t7 Brake band
18 Synchronizer ring
19 Overdrive main gear
20 Overdrive gear bushing
21 Washer
22 Mainshaft nut
13 Overdrive mainshaft bearing
24 Speedometer drive gear
25 COlplteBhaft mt bearing shim
fr
26 Countershaft front bearing
27 Countershaft drive gear
28 Coontcrshaft
29 Countershaft bearing
30 Reverse counter gear spacer
31 C counter
Rever gear
32 rdrive counter gear
33 Countershaft zear bearing
34 C untershaft nut
3S Reverse idler lIhaCt
36 Reverse idlcrthrust washer
37 Reverse idler gear
38 nc idler gear bearing
Reye
TM041A
MT 16
Manual Transmission
I Striking lever
2 Lock pin
3 Q ring
4 Striking guide
5 Oil seal
6 Striking rod
7 Expansion plug
t j 8
9
10
Stopper guide pin
Return spring
Return spring plug
e
11 Return spring plunger
12 Check ball plUS
13 Check spring
@ 14 Check ball
Retaining pin
CD Interlock ball
17 ist 2nd shift fork
18 1st 2nd fork rod
19 3rd 4th fork rod
20 Reverse OD fork rod
4th shift fork
o
O
21 3rd
Revene OD shift fork
Con trol1ever
24 Con trol1cver pin
25 Con trollever bushing
TM048A
control component
Fig MT 58 FS5W71B trammi ion shift
REMOVAL
as means of a gear puller
DISASSEMBLY OF GEAR
ASSEMBLY 4 Rem6vesnap ring and then thrust
washer from mainshaft front end
Fork rod Draw out 3rd 4th synchronizer
assembly and remove 3rd gear assem
Same as for the F4W71 B
bly
5 Remove snap ring and then draw
Geer sembi
out speedometer gear and bearing
I With gears doubly engaged draw from mainshaft rear side
MT 17
Manual Transmission
IT
TM757
Fig 61
MT Removing counterahaft
nut
TM761
Fig 65
MT Driving outgear sembly
tw Malnahaft
Note When mainshaft
removing as
KV32101330
sembly loosen mainshaft nut TM160
Same as for the F4W7IB
k
8 Remove counter reverse idler gear
and spacer
9 Remove countershaft by lightly
J
l
tapping the rear end with a soft
hammer
Be careful not to drop off gear J
shaft
10 Remove reverse idler gear snap
ring
r 1
2
3
Striking lever
Striking rod
Stopper pin
4 Control lever
5 Striking rod guide
6 Reverse select plunger
7 Reverse select plug
TM759
Fig 63
MT Removing reverse idler TM767
gear nap ring Fig MT 66 Exploded view of shifting mechanilm
MT1B
Manual Transmission
ADAPTER PLATE If the above limits are exceeded 3 Install striking lever on front end
DISASSEMBLY replace drive and driven gears as a set of striking rod Install lock pin and
4 Measure gear end play torque screw to 0 9 to 1 2 kg m 7 to
0 13 to 37
0 mm of reverse idler shaft is lined up with
Notes ASSEMBLY
a Be careful not to damage any parts
To assemble reverse the order of
with scraper
disassembly Observe the following in
b Do not clean wash or soak oil seals
structions
in solvent
ASSEMBLY
BEARING I Wipe clean seal seat in rear exten 7 Install countershaft rear bearing
Same as for the F4W7l B sion housing press fit oil seal in place in adapter plate by lightly tapping
Coat oil seal and bushing with gear around it with a soft hammer
oil for initial lubrication See Figure
68
MT GEAR ASSEMBLY
GEARS AND SHA S
r Clean all parts in solvent and dry
I Check all gears for excessive wear
with air
I compressed
chips or cracks replace as required Front
2 Check shaft for bending crack
Synchronlz r embly
wear and worn spline if necessary
Same as for the F4W71 B
replace
3 Measure backlash in gears
r
Ov rdrlve r ynchronlz
TM355 mbly
Main drive and
Fig MT 68 R ar extemion oil sea
I Assemble reverse OD synchro
counter drive gear
nizer assembly
0 05 to 0 10 mm
2 Apply multi purpose grease to 2 Assemble overdrive gear assem
0 0020 to 00039 in
and
1st 2nd 3rd 5th and
O ring plunger grooves in striking bly
rod Position synchronizer ring band
reverse gears
Insert striking rod with striking rod brake thrust block and anchor block
0 05 to 0 20 mm
rear extension overdrive clutch gear install circlip
0 0020 to 0 0040 in guide through on
MT19
Manual Transmission
tighten it temporarily
4 Install counter reverse gear
counter 5 th gear bearing and new
h I
Same as for the F4W71 B
L
Main drive gear assembly
u TRANSMISSION ASSEMBLY
Procedures are the same as for the
MT 20
Manual Transmission
1 3 1 3 5
II
Shift type
T
i i 1
2 4 R 2 4 R
Gear ratio
1st 592
3 321
3
2nd 2 246 2 077
3rd 1 415 308
1
5th 0 864
Reverse 3 657 382
3
MT 21
Manual iTransmission
TIGHTENING TORQUE
Gear assembly
SPECIFICATIONS
MT 22
Manual Transmission
Causes Jor difficu t gear shifting are classi Worn gear shaft and or bearing Replace
fied to troubles concerning control system Insufficient operating stroke due to worn or pair or replace
and When gear shift lever is
transniissioo loose sliding part
heavy and it is difficult to shift gears clutch
Faulty or damaged synchronizer Replace
disengagement may also be unsmooth First
make sure that clutch operates correctly
and inspect o
transmissi
Noise
When noise occurs with engine idling and Insufficient or improper lubricant Add oil or replace
when with designated oil
ceases when clutch is disengaged or
noise occurs while shifting gears it is an Oil leaking due to faulty oil seal or sealant Clean Of replace
that th e noise is from transmis
indicati90 clogged etc
breather
sion
Worn bearing High humming occurs at a Replace
Transmission may fa ule during engine
t high speed
idling
Damaged bearing Cyclic knocking sound Replace
Check air fuel mixture and ignition
also
occurs at a 19W speed
timing
After above procedure readjust engine Worn spline Replace
idling Worn bushing Replace
MT 23
Manual Transmission
For Reference
Tool number
Description or
No use page
Unit mm in
on Figure No
tool name
L i
10 0 39 dia
480 18 90
outer dia 44 1 73
SE037
inner dia 31 122
Fig MT 15
Setting plate 45
MT
Fig
adapter
74 2 SE132
91
MT 24
Manual Transmission
For Reference
Tool number
Description use page or
No Unit mm in
on Figure No
tool name
SE313
Counter gear
drift
outer dia 38 50
inner dia 331
30 SE039
0 Q 0
J
I
0 TM438
All Fig MT 21
8 STJ0031000 For replacing bearing
models Fig MT 23
Bearing puller Fig MT 25
80 3 15
50 1 97
SE041
MT 25
Manual Transmission
bearing FS5W
Bearing puller
7IBT M
11
300 81
SE308
MT 26
SECTION AT
AUTOMATIC
DATSUN PICK UP TRANSMlsSIO N I
DESCRIPTION At 2
TROUBLLDIAGNOSES AND
AHD
ADJUSTMENT
DESCRIPTION
dimulstipcle brake a band brake and vehicle speed and prevents the trans
a one way sprag clutch provide the mission from shifting out of second
friction elements required to obtain gear
the desir d function of lhe two plane I I can be selected at
range
AT344
tary gear sets any vehicle speed and the transmission
The two planetary gear sets give will shift to second gear and remain in Fig AT I Identification number
three forward ratios and one reverse
second until v hicle speed is reduced
Changing of the gear ratios is fully 10 40 50 kmfh 25
approximately to
automatic in relation to vehicle speed to 30 MPH
and engine torque input V chide speed
I range position prevents the Identification of number
and engine manifold vacuum signals
transmission from shifting out of low
are constantly fed to the transmission Arrangements
gear This is particularly beneficial for
toprovide the proper gear ralio for See below
maintaining maximum engin braking
maximum efficiency and performance
when continuous low gear operation is
at all throttle openings desirable
The model 3N71 B has six selector
The torque converter assembly is of
1 R N D 2 1
9sition
LP welded construction and Model code
can nOlbe
disassembled for service
I Park position positively locks
the output shaft to the transmission JAPAN AUTOMATIC
case by means of a locking
prevent the
pawl to
vehicle from rolling in
0J TRANSMISSION CO LTD
position
FLUID RECOMMENDATION
Use automatic transmission fluid
J
having DEXRON identifications
Unit number
R Reverse enables the only in the 3N71 B automatic transmis
range
sion
vehicle to be operated in a reverse
AT 2
Automatic Transmission
J
o
II
IIlI
r
I
r
AT288
CD T 0 25 10 0 35 2 to 3
AT3
Automatic Transmission
CONTENTS
tains an oil
FUNCTIONS OF pump for packing p oil solenoid These parts work in conjunc
from the oil pan through the oil tion with valves in the valve
HYDRAULIC CONTROL A shift control is provided by
body
strainer assembly located in the base of the
UNIT AND VALVES two centrifugally operated hydraulic transmission The valves regulate oil
governors on the output shaft vacuum pressure and direct it to appropriate
The hydraulic control system con control diaphragm and downshift transmission components
I I I
Oil pump
I I
Control valve
I
Torque converter
1
Manual linkage Front clutch
I Rear clutch
Vacuum diaphragm
Downshift solenoid
I Low and reverse brake
Band brake
Governor valve
I
I Lubrication
r
OIL PUMP housing delivery port Transmission MANUAL LINKAGE
case delivery port Lower body
delivery port Control valve line The hand lever motion the hand
The oilpump is the source of
pressure circuit lever is localed in the driver s
compart
control medium i oil for the
e ment mechanically transmitted from
control system
lhe remote control linkage is further
The oil pump is of an internal transmitted to the inner manual lever
involute gear type The drive sleeve is a
in the transmission case from the
range
part of the torque converter pump selector lever in the right center par
impeller and serves to drive the pump tion of the transmission case through
inner gear with the drive sleeve direct
the manual shaft The inner manual
ly coupled with the engine operation lever is thereby turned
The oil flows through the following A pin installed on the bottom of
route
AT071 the inner manual lever slides rhe manu
Oil pan Oil strainer bottom of the al valve spool of the conlrol valve thus
I Housin 4 Inner gear
control valve Control valve lower positioning the spool opposite rhe
2 Cover 5 Crescent
body suction port Transmission case 3 Ouler gear appropriate select posilion
suction port Pump housing suction The parking rod pin is held in rhe
port Pump gear space Pump Fig AT 3 Oil pump groove on the top of Ihe inner manual
4
AT
Automatic Transmission
erate al the
speed as thar iJf tile
same
torque
output shaft thai is they operate at a
speed in proportion 10 the vehicle
To lkc
inl manifold speed The line press retis applied to
those valves s the input from the
control valve through the transmission
case rear flange and oil distributor
CD
The governor pressure in proportion
to the ouiput shaft speed vehicle
ATOB7
speed is led to the shift valve ofthe
1 Manual pia te Parking rod
2 Inhibitor switch
AT088 control valve through the opposite
Manual shaft
route of the output In this manner
controlled
pressed and the buretor is fU IIy whole stroke the a ccel rator 1
ped govcr lOr pressurc yhich bali1 nced
opened but th engirie sp eed is not should be correctly adjusted so as with th spr ng force occurs on IS
the manifold I
AT S
Automatic Transmission
m r @
Line t
pressure @
l
0
AT090
V
Operation of prlmar
I
2
Primary governor
Secondary governor
4
5
Oil di lributor
Output lft
sh
aBUlllI8
iUQlli
3 Governor valve body
governor valve
JlAU AT092
j I
n
the circuil 5
P range
7 4 SDV and TBV
5 FSV 12 TBV and
Pressure regulator valve Low reverse brake
PRV
R range
Thepressure regulator valve re 7 4 same as above
ceives valve spring force force from 5 same as above
the plug created by the throttle pres 6 PRY and SSV F C
and line
sure 16 pressure 7 and and band release
force of the throttle pressure 18 N 7 None
With the interaction of those forces 11 range
clutches
When
presscd
Ihe accelerator
the throttle pressure 16 in
pedal is de
u 1dIil lt
JJX dlMIi W ld IiIb
g4Vhl It i B J
as described in the preceding
j L@
l tJj fitMi td
creases x
x
jj
is
jd
paragraph oil pressure applied to
forced upward
the PRV is contrarily
21
port
P R N 17 l AT096
AT7
Automatic Transmission
1 c5
governor pressure 15 is applied to retained only by the throttle pressure
Ihe right side of the FSV and the FSV 13 16 and the throttle pressure 16 is
is forced toward the left Contrarily slightly Idwer than that toward the
the line pressure I togelher with the right which is while
applied shifting
spring force force the FSV toward the from 2nd to 3rd
right opposing the governor pressure I Consequently the SSV is returned
15 0 to the 2nd position at a slightly
When the vehide speed exceeds a lower from 3rd
speed Shifting to
certain level the governor pressure 2nd occurs at a speed slightly lower
15 exceeds the sum of the throttle t 1 than that for 2nd to 3rd shifting
pressure and Ihe spring force and
FSV is forced toward the left
the r
I When kicked down at 3rd line
I pressure 13 is led from the SDV and
When the FSV is depressed 10 a
SSV
certain
q the is forced toward the right
position the lire pressure I is AT091 Although the governor pres ure is con
closed and only the spring depresses siderably high the valve is forced
the FSV toward the right and it is Fig AT 12 lsl 2nd shift valve loward the right and tht
completely
depressed to the end for a moment As
2nd 3rd shift valve SSV is thus returned to 2nd posi
SSV
the
a
resull line p ressure lJ is for tion fhis operation is called K cli
warded to 8 the band servo is The down shift
SSV is a transfer valve which
engaged through the SLY and the shifts gears from 2nd to 3rd When the shift iever is shifted to
speed is shifted to 2nd With the When the vehicle is the SSV 2 or I range at the 3rd speed
stopped
accelerator pedal depressed the FSV is forced toward the line pressure 3 if diained at the
the right by the
remains iIi the Low position unless spring and is in the 2nd position It MNV Consequently the front clutch
the governor pressure IS increases to is so d however and band servo releasing oils are
design that the FSV
a high leVel corresponding to the line can decide to shift either to Low or
drained As a result the transmission is
pressure I since the line pressure I 2nd shifted to 2nd or low speed ai
increase when the accelerator pedal is When the vehicle is running the though the SSV is in the 3rd posi
tion
depresse9 governor pressure 15 is applied to
Contrarily when vehicle speed de When the specd IS shifted io the
the right end surface and th SSV is
creases the governor pressure 15 forced toward the left Contrarily the 1
3r a one way orifice 24 on the
decrease Howeve f the gear is not topof the SSV relieves oil transmitting
l force
Spri line pressure 3 and
shifted to Low nless the governor throttle press re 19 force the SSV velocity from the line pressure 3 to
pressure 15 becomes zero since the toward the right the line pressure 10 and reduces the
force depressing the FSV toward the When vehicle speed exceeds a cee shock generated fioni the shifting
right is being delivered only by the tain level the governor
pressure sur Contrarily when the lever is shifted
spring passes the sum of the spring force line to 2 or I range and the speed is
Low
in range I is led to the pressure and throttle pressure and the shifted from 3rd to the 2nd the
low and reverse clutch from line pres valve is forced toward the left The orifice checking valve spring 24 is
sure 5 through line prbssure 12 line pressure 3 is then closed Con depressed the throttle becomes in
2nd is simultaneousiy led to the ieft sequently the forces being rapjdly effective the line pressure 10 is
end spring unit Consequently al unbalanced the force depressing the drained quickly and delay in shifting
thougp the goverflor pressure in SSV toward the right decreases and speeds is thus eliminated
creases the valve is still forced toward thus the SSV is depressed to the l ft The throttle of line pressure 6
the right and the SFV is fixedjn the end for a moment With Ihe SSV transmits Hie oil transmitting velocity
Low position When kicked down to depressed toward the left end lhe line from line pressure 6 to line pressurc
the 2nd speed the SDV operates pressure 3 is connected with the line 10 wtien the lever is shifted to the
and the line pressure 13 forces the pressure 10 the band servo is re R range and transmits drain veloci
FSV toward the right Although the leased the front clutch is engaged and ty from line pressure 10 to line
8
AT
Automatic Transmission
pressure 6 when shif ing from 3rd generated the piessure loss is added to 16to circuit 18 This throttle
to 2nd at D range Thus the the spring force and the plug is lhus pressure 18 is applied to the top of
throttle of line pressure 6 reduces forced back from the right to the left the PRV and the force of the line
the shock generated When this pressure 19 increases ex pressure source 7 is reduced Contra
froshifting
A plug in the SSV left end readjust cessively the plug is further depressed rily when the vehicle speed decreases
the throttle piessu e I 6 which varies toward the left space from the lhrot arid the governor ipressure 15 de
tle pressure 19 to the drain circuit creases the force toward the fight
depending on the engine throttle con
FSV when kickdowri is performed Wheri performing kickdowri the throttle pressure and the governor
I
3 15
f ng valve AT099
1
Jit 24
3
I
15
I
Fig AT 14 Pre
Vacuum thro
The vacuum t
ure
le valve
rottle
modifier valve
VTV
valve is a
L
I
I i
I Js the vacuum
dia
engine
phragm yories
diaphragm
throt le
depending
condition
The vacuum
on
negative
the
t
ATOgS
ilr
pressure in the inta e line
rH
When the line pressure 7 is ap
Fig iT 13 2nd 3rd shift vallJe
plied to the bottom through the valve
Compared to the operating pressure which is applied to the right side of 16 to the drain circuit 17 is about
the PMV is low the valve is forced the throttle
required in starting th vehicle the to
open In this operation
toward the right by the throttle ines becomes lower than the
ppwer trimsinitting capacity of the pressure 16
clutch that is required operating pres sure 16 applied to the area differ ureY btthe
s
p e sur
9 iv
retained at a high level up to a high circuit 18 is closed However when diaphragm is balanced wit Ii thethrot
vehicle speed shock gerieraled from vehicle speed increases andl the gaver tie pressure 16 a pplied upward tOlthe
the shirring increases arid the oil nor pressure 15 exceeds a certain bottom
pump loss also jncrdases In order to level the governor pressure toward the When the erigine torque is high Ihe
prevent his the t lrott pressure must
le left which is applied to the right side negative pressure in the intake iirie
be l hanged over with the operation of exceeds the spring force and the throt rises tending ioward atmospheric
the governor pressure 15 to reduce tle pressure 16 toward thc right the pressure and the force of the rod to
Ihe line pressure The PMV is used for valve is depressed loward the lefi and depress the valve increases As a result
this purposc the throttle pressure is led from circuit the valve is depressed downward the
AT 9
Automatic Transmission
space from the throttle pressure 16 17 to Ihe upper drain about to open
to the drain r
17 decreases and the the back up pressure 17 which is
space from the line pressure 7 to Ihe lower than the line pressure 4 by the
throttle pressure 16 increases loss due to the space from
pressure
Consequently the throttle pressure circuit 4 to circuit 17 is balanced
16 increases and the valve is bal with the spring force
anced Contrarily when the engine Further when gear is shifted from
torque lowers and the negative pr 2nd to Low at the range I line
sure in the intake line lowers
tending pressure is led from circuit 12 and
toward vacuum the force of the rod the line pressure is applied pward to
depressing the valve decreases and the the bottom of the valve through the
throttle pressure 16 also decreases valve hole Consequently the valve is
When pressure regulated by the throt forced upward and locked As a
tle p valve
back described in the result the space from the line pressure
subsequent paragraph is led to circuit 4 to the back up pressure 17 is
17 a high pressure is applied through closed completely and the back up
the space from the circuit 17 to the 17 is drained upward
pressure
throttle pressure 16 Consequently
AT102
the VTV is unbalanced the throttle
Fig AT 17 Solenoid hift valve
dow
pressure 16 becomes equal to the
back up pressure 17 and the valve is Second lock valve SLY
locked upward This valve is a transfer valve which
assists the shift valve in determining
the fixed 2nd speed at the 2
range
In the D the sum of the
range
AT 10
Automatic Transmission
2nd 3rd timln valve TMV the upward force exceeds the down
ward force the valve is locked upward
This valve is a transfer valve which and passage from circuit l0 2nd
lower than the governor pressure IS orifice 22 is bypassed Fig JlT 19 2nd 3rd timing valve
ATll
Automatic Transmission
ern
d
n
lLU J
I
A1094
Fig AT 20 Controloolve
AT 12
Automatic Transmission
HYDRAULIC SYSTEM
AND MECHANICAL
OPERATION
The operating system of oil pres
sure in each range is described below
Others 14 15
f
0
pressure 14 pressure 10
Torque converter pressure 14 0
Governor feed pressure l
Rear clutch Servo t ightening
Rear iutch surc
prc 1
pressure l
ho L
0 1 pressure 9 lJ L
I
c
FTOOI c1 tL h prc ur It I
IT reverse brake pressure 12
J1 011 pump Sllctlon hole Front clutch
U 0
r
F T
LIO
M
pressure 11 rrOil J
pump suction hol
CJf
JC II
O
An07
IIJ1iIII AT105
Fig AT 21 Identification of oil channels in oil pump Fig AT 23 Identification of oil channels in case face
AT 13
Automatic Transmission
P RANGE PARK
AT086
The oil discharged from the oil Clutch Low Band ervo On
Gw Parkin
AT 14
Automatic Transmission
P range Park
A
L
r k
8r k
ll
FrOl
I
ter
Torqu Con Clutch Au
tth
0
I ump
rr
f
4
1 1
r
I
I
r
CID VK
TIlro
to Sol
BI Cow
n
1ft v t
I V lv
011 Coo
I 1
AM Lubr tlo
1111
I j
II
D
i
1111 III il
t V l
I
Front
o v
n Llrll r I Orlflc
v
K
rt Throttl
Dr ln
2
ID Mocl
1 5
v
II
I
@
11 2nd 3
5
d
Timing
J
w
V l
JQ
I
r R I 3J
IKOnd Lock V l
I
II I l rr
t rJ I q 3
D
R tOl V
II
V V l
nu l
I
u J2 n
ll
J
L II P 21 r A J1
I
I
J
Not
LlMl pr
t rk
r
Or ln
10010r
1
BIeOM IV
I Irlmarv
OOllnor Y M OoverrwJf VIIfve
Oo or It
Throttl
AT 15
Automatic Transmission
R RANGE REVERSE
R
In R the front clutch and
range
the low and reverse brake are applied
The power flow is through the input
shaft front clutch and connecting
shell to the sun gear Clockwise rota
m i
1
ATOBS
inoperative
AT16
Automatic Transmission
R range Reverse
Low a Aev
Br k
B k
I
Con Front
Torq R
ltc
Cll Il
Clutch
r f
rr
III I
CID VEL 1
Thrc r
V I I
Oil Cool r
I 1
11
A r Lubtlcetlon
IU 11
111
T
Ilrfl
o
iL
0
Vel
I Front
Ir l II
II I
r
Orlflc
LJ
r
Check
n
jL
Velve
or ln l
J
ID
Throttl
D ln p e
Mc lf v
2f
v
If I
@lnd 3rdShlft
v
22
n D h
x
@ 2nd 3n
l lil
Timl
I
5
r
II 1i t
Q
A uletor Val
U
nu
rII
ni
l3
1 15 15
p O nOl ft p
L Ll r
a nor v Q V 1ve
Goy l norpreat
Torque rmrp
Throttl p
AT 17
Automatic Transmission
N RANGE NEUTRAL
Park on on
AT la
Automatic Transmission
P range Park
Brllk
ar
Front Bond
Con
Torqu u
Cluteh
ID VK
Th o I
IftY
V II
all Coo
A k tlon
Lb
II
1 e
I Front
n
LubrkIt Orltlc
Check
O ln I V
ThrOttle
D ln
V
21
j r
tUI lor V h
@ V hI
5
I
I
N01 M
Line
rked X
pr
r D ln
Go nor tdpr
y
Iecond
I X
no V Gover V
Ocw
J
L Q RO p
J
c Torq co p f
Th ottl p
AT IS
Automatic Transmission
R RANGE REVERSE
R
In R range the front dutch and
ATOS5
and
pressure circuits 5 6 The
k on on
II Low 2 458 on on
AT 16
Automatic Transmission
R range Reverse
LowaoA
B k
e k
Front B
TOlQuaConverter
Clutdt Clutch
0
o
IIi
ou
14
ID VK
n @ ftV 1
V lv
FI Lu IUt O I
j
Front
Lub lc Otlflce
Check
V III
O lnV ly
Throttle
O in
V
@lnd 3rdShih
V
zz
If @ 2nd
V Iy
rd TIm
Second Lock V
I
3
Zl
R MO V l
Not M dX
k er 0 1
LI p O nOf f P co
s 0
O V O V
G preau
J Torqu
I 00 pr
Throttl p 1
II
AT 17
Automatic Transmission
N RANGE NEUTRAL
PIlIi on on
CD
AT 18
Automatic Transmission
N ranee Neutral
I a
a
nd
VK
Th o
J
Vtlv
@
I
Vtlv
011 Coolei
Lubrlc tlon
11
D ln I
D lnV
Ol
I
v
OIIt
Lubrlut O lfIC
Check
Vtlv
I
T uott
O in
v
8Jl
12
ht 2nd Shift y tve
CD
Rl9UlttO Vtlv
Nott M
1
rkedX
or
no
oov
r
p
D in
IOonOf fNd IH
liia cs
ond
a Ol
y
V o V tve
z
c Torqu con
er pr
Throttl p
AT 19
Automatic Transmission
range
The rear c1utdl is applied as III
I range but the one way clutch
holds the connecting drum The power
now is the same as in 1
J range That
is the power now takes place
through
Ihe input shaft and into the rear
t
pedal depression presses Ihe pressure
tt low 2 458 on on
L A
Front
I
Torque Conven
Clul
Clutch
Q
TIC 011 p
V
ID Th O
v
V
011 Cool
RUf LubtJuflon
n
IO lln Ii
V l
F ont
D nV V
l
ThroW
L
01
V I
13
12
tt llttY
2NtSt
Q P P
tOO V
Note U
Llnep
X Ir or
IO
n
nor feed
Iecotodary
nOl V
QoY
i Y
roo
Oew v
no
GoY p
Torque co p
Th on
uD 1 Low gear
Fig A T 32 Oil pressure circuit diagram range
AT 21
Automatic Transmission
In this case
rear the h
c1ut IS
applied and the band brake holds the
fronl h drum
dUh the connecting
shell and the gear from rotating
sun
ratio pawl
Fronl Rur brake Optrltion Release clutch
PlIk on on
Revtne 2 182 on on on
Neutral
When the car speed increases while
1
by locking the band servo obtains the Low 4S8
2 on on
II
2nd gear condition
AT 22
Automatic Transmission
I
I
I
7 Throttle
V
k up
lftV
II
I ont
Lubtlclt n Orifice
CKk
C alnV I
Val
Th ottle
O n 2
S Mod V l
Valve
IS
13
@2rlCl 3 dShlft
V
13
2nd Shift V l
311ft
S
CD
Regulator V
Manual
V
PR
Nota M
LI p
norp
Gov
X r Dr
r
nor
IGov fINd P
ieconoery
Gov nor V
I n
1 O nof Vaw
i
J
c 00
TORI pr
Iiiiiiiiiiiiiii Thronle pr
AT 23
Automatic Transmission
carrier
A T083
on on
03 Top 1000 on on
1 Second t 4S8 on on
12 Second 1 458 on on
t
I Lo 2 458 on on
AT 24
Automatic Transmission
Low A
lI eke
e
B
I
I
011 COO
R Lubfkatlon
VK
Thro
V
mf J
V va
J
y
o Ot al
oi v
L
Front
Lubric 1 n Oriliu
Check
O nV 1 1
Th onla P M lflM V I
O eln 2
Vah 5
22
i2J
1n 2nd Shift v 1Ye
3
5
j Pr
R I Of 1 1
Manue
Val
5
PRND2
Nota
11
Oo no p
r
Marked
Dr ln
IOono feold P
G
ond
y
nor Val
rs Goy
l
y
rnor Val
c on np
Torq
Th onl pr
0 RANGE KICKOOWN
appruximately Ran e
nUo
ltr5e
rf
Release clutch
pawl
Fronl Rear brake Opcullon
55 MPII a kick 3rd 2nd downshift
by fully de
an be accomplished Park on
on
the accelerator
pressing
on
A kick 3rd lst or 2nd lst Reverse 2 82 on on
t on
12 Second 1 458 on
f
the governor pressure 15 thc at
AT 26
Automatic Transmission
Low a A
8
e e
8
Front a
To queeO t Clutch
14
Oil COO
VK
Th
V
o
lv
7 Throttle
BKk up
V hl
ID So COw
e
1 iftV 8
R Lubrication
n
0
Drain 4
1
j v
I
Front
Lub icet P Ifk
Check
p o
n I V I
5
1
Mod Yo
Thron
24
p ain
I
V I
@2nCl lilr
3rdSl
12
ht 2nd Shih V
3
5
j V I
gu
R ato I
r
1
M
0
nual
I
J
f4fL
PR
L
Not Ma
Li
ked X
pr
r p
IGo
n
no fdp l COnd
S
I Primary
X
norValve
G rw Va Gov
Governor p
c Torque CO I1 p
ThrOWepr
AT 27
Automatic Transmission
2 RANGE 2ND GEAR
range
put shaft at a reduced speed compared
to the speed of the input shaft with
an increase in torque As the low and
reverse brake is not
engaged the clock
wise rotation the of
output shaft
causes clockwise rotation of fear inter
nal gear and the rear
planet carrier also
rotates around the sun in
gear a
J
increasing thc throttle pressure li 6
tt Low 2 458 on on
The line pressure 7 is therefore
increased and the
quickly tightens
band
2 position causing the line pres decrease from 3rd gear to 2nd
sure circuit 3 to be drained In this case the speed
N 3rd gear
gear change
e
DJ range to 2 Therefore the line pressure circuit takes
quickly place because the line
range is situated at the release
10 which pressure 7 and other pressure are
If DJ 3rd gear is shifled
range side of the front clutch and servo is
2
heightened by the action of the line
to the
range during operation also drained through the 2nd 3rd pressure 4 in the same manner as
manual valve V is also shifted to shift val e @ forcing the speed to described under 2 range
AT 28
Automatic Transmission
l ow A
B ke
Br
Fron
Torqu Con
Clutch
12
i
12
7
ID v
Th ot
T onl
Beck up ID So
0
Id
1ft v
IL Valve
V
011 Cool
Front
Orltic
Lubric t
Check
e Va
Or lnVal
P Va
Modif
Throttle
15
Dr in
V l
BJl
If @ 2nct 3rd
Ve
Tim
12
2nd Stolt
3 1
21
Se l onc Lock Va
I
3
J I r
Gr v
A ul
2 w
Valve
PR 02 1
Jl
I
s
Note Merltedl
Line p
D a n
d pr
nOf f
IOo ond
I G v
a nor v
r
G no p
oTorque
c con pr
re
Thron p
2nd gear
Fig A T 42 Oil pressure circuit diagram 2 range
AT 29
Automatic Transmission
clockwise
Fig AT 43 Power transmission during 1 J
range
Counterclockwise rotation of the
sun gear turns the rear planetary gear
clockwise
The planet carrier splined to
rear Fai1
the connecting drum is held from
rotating by the low and reverse brake
The clockwise rotation of the rear
the output shaft rotates at a lower Fig AT 44 Operation of each mechanism during JJ range
semblies
2 Second 1 458 on on
2 Second IAS8 on on
1 low 458
2 on on
When the manual valve Vis posi the rear clutch and governor The line pressure 15 which acts on the
tioned at I the line pressure 7 4
is pressure acts in the same manner as I st 2nd shift valve does not increase
applied into the line pressure circuits in 2 range until it overcomes the combined force
I 4 and 5 The oil pressure in 5 Similar to that of the D range of the line 12 and the
pressure
actuates the luw and reverse brake the line pressure reases with the
inr spring causing no st 2nd speed
after being introduced into the circuit
degree of accelerator pedal depression cha nge
12 through Ihe 1st 2nd shift valve and the line pressure decreases with
ID and the line pressure I acts on the increase of car speed The governor
AT 30
Automatic Transmission
ift
Down
Oid
llll
14
VK
Th o @50 D
I
IttV
10 v
il
Dr in 14
I Front
Lubrlc t Oritlc
ChKk
V
O mV I i
P Modif t
Th on
0 1
11 IS
V
1M 2nd hlf
23
J
6
g M
V l
nu
PR
i
NOI M
11
keel X
P
Ir 0 1
11
nOt
IOov tMod P
sond
I I V
v
V Oov
Of
1
O
no
O p
Torqul con pr
Tn ont pr
II
Fig A 45
T Oil pressure circuit diagram II range Low gear
AT 31
Automatic Transmission
1 ran 2nd ar
L l
ak
v u Co nro O h
0
So OId
r fi v
Th o IhV
ou Coo V we
L UIIoft
O ein
iv
Lubolcat
OtHIc
0 v CO
v
Tlwont MOdIf
Q in
v
1
0 V joy
h1
ll v
iJl
N 8I1l 1
0
L1 p 10011 0 fdP
lli Onct Y
a v 0 V
nor
a no
Torq conv
Th on pt
Fig A 46
T Oil pr ure circuit diagram 1 z range 2nd gear
AT J2
Automatic Transmission
CONTENTS
AT 33 ADJUSTMENT AT 35
INSTALLATION
TRANSMISSION 8 Disconnect vacuum tube from bolts support engine and transmission
vacuum diaphragm and wire connee with jack and lower the jack gradually
ASSEMBLY lions at downshift solenoid until transmission can be removed and
When the automatic cable take out transmission under the car
dismounting 9 Disconnect speedometer
transmission from vehicle at from
a pay rear extension
tention to the following points 10 Disconnect oil charging pipe Note Plug up the opening such as oil
II Disconnect oil cooler inlet and charging pipe oil cooler tubes
1 Before dismounting the trans
etc
mission rigidly inspecl it by aid of the outlet tubes at transmission case
excessive force converter to drive plate See Figure Turn crankshaft one full turn and
4
AT t with indi
measure drive plate mnou
REMOVAL 0 5 mm 0 020 in
out
flowing
2 Installation of torque converter
14 Remove rear engine mount
AT 33
Automatic Transmission
AT 34
Automatic Transmission
4 j B
L120N
p
4 G
AT273
of
1 Control lever knob Tightening torque 1
2 Pusher nuts and screw kg m ft lb
C8i T 0 8 to 1 6 to 8
REMOVAL AND
important as Inspection of oil level 3 Loosen adjust nuts @ Set
INSTALLATION
for the automatic transmission control lever @ and selector lever @
1 Disconnect control knob from Therefore should be at N position moreover set the
great care J
To install reverse the order of 2 Install control knob on lever At correctly and that selector lever oper
removal the same time check the dimension ates properly without any binding
B and adjust it to 1 to
0 1 mm If levers do not operate satisfactori
ADJUSTMENT 0 004 to 0 043 in by turning pusher ly readjust or replace parts as neces
AT 35
Automatic Transmission
CONTENTS
AT 54
Fig Removing valve body
AT 36
Automatic Transmission
Ii AT127
AT124
AT121
Fig AT 61 Remouin rear extension
12 With the aid of Snap Ring Re 16 Pull out output shaft remove oil
7 Pull out input shaft
8 Withdraw oil pump using Sliding mover HT69860000 pry snap ring off distributor CV together with governor
Hammer ST25850000 Do not allow output shaft See Figure AT 59 valve CD See Figure AT 62
Fig AT 62 Remouinggouernorand
Fig AT 59 Remouing sruzp ring oil distributor
AT122
Fig AT 56 Removing oil pump 13 Remove connecting drum and 17 Pry off snap ring using a pair of
inner gear of rear planetary carrier as pliers Remove retaining plate drive
an assembly See Figure AT 60 plate driven plate and dish plate in
that order See Figure 63
AT
9 Remove band strut This can be
done stem further
by loosening piston
See Figure AT 57
AT126
front gear connecting drum one way clutch slotted bolts as shown in Figure
10 Remove brake band
outer race and one way clutch in that AT 64 To do this use Hex head
clutch and rear clutch as an assembled
oroer Extension ST25570001
unit
by ST25570000 One way clutch inner
11 Remove connecting shell rear 15 Remove rear extension
return
race thrust washer piston
clutch hub and front planetary carrier loosening securing bolts See Figure
spring and thrUst spring ring can now
as a unit See Figure AT 58 61
AT
be removed
AT 37
Automatic Transmission
Clearance
j
i 0
Up
I
t
V
@ J1i 1
Seal dng
ll J
iL
ST25570001
1
0
t
lli
I1
l
Ii
@
P
i
p
l 1
l
0
61 j
j rr
Lj Y l
i
J ry
j J
w h
1 AT130 Fig AT 67 Removing manual plate
AT133 I
I
Fig AT 64 Removing hex head slotted
bolt
22 Remove inhibitor switch and
manual shaft by loosening two secur
19 Blowout low and reverse brake
ing bolts AT134
piston by directing a jet of air into
ig r 68
A Me qsuringseal ring to
holeJn cylinder See Figure AT65
ring groove clearance
ASSEMBLY
AP rings
inner race
fWl1
011 distributor 2 After low and reverse brake has
AT132
been assembled measure the clearance
I Check for signs of wear on seal
Fig AT fiB Removing bond servo between snap ring CD and retaining
ring and ring groove replacing with
plate @ Select proper thickness of
new ones if found worn beyond use
retaining plate to give correct ring to
21 Pry snap rings CD from both Check that clearance between seal
plate clearance See Figure AT 70
ends of parking brake lever @ and ring and ring groove is correct If out
is Low and reverse brake
remove the lever Back off manual of specification replace whichever
limits Correct clearance clearance
shaft lock nut ID and remove manual worn beyond
is from 0 04 to 16
0 mm 0 0016 to 0 80 to 1 05 rom
plale @ and parking rod CID See
67
AT 0 0063 in See Figure 68
AT 0 0315 to 0 0413 in
Figure
AT J8
Automatic Transmission
AT 72
Rear
c
i
clutch
N edle bearing
Bearing race
I AT139
Fig AT 70 Measuring ring to plate Fig AT 75 Measuring the distance
clearance
A and C
AT142
2 Measure the distance B and
Available retaining plate
Fig AT 72 Installing planetary carrier D of oil pump cover as shown in
Figure AT 76
Thickness mm in 8 Assemble connecting shell and
other parts to front Clutch in
IL
up
12 0 0472
12 2 0480 I Oiipi mp
124 0488
12 6 0496
12 8 0 504
AT140
mITIJ
L W Thickness of bearing race
I inserted mm in
temporarily
r
CD
Available oil pump cover bearing
L
o oml AT137
Total end
I
play
@
J
1
race
Thickness mm in
2
1 047
0
Fig AT 71 One way clutch
I 4 0 055
AT138
4 Afterinstalling rear extension Front clutch 5 Trammission case 1 6 0 063
torque attaching bolts to 2 0 to 2 5 thrust washer 6 Oil pump gasket 1 8 0 071
2 Oil pump cover
kg m 14 to 18 ft lb Place manual 7 Oil pump cover
3 Front clutch bearing 2 0 0 079
range and check to be sure
race
lever in P
4 Rear clutch
that rear output shaft is securely 2 0 087
ly at this
stage of assembly 1 Measure the distance A and Specified total end play
vernier shown in 25100
0 50 mm
6 Place rear clutch assembly with C by calipers as
H
n
stalled check to be sure that it op
ni i
t front dutch thrust washer by
Sele For
erates properly in each range
calculating the following formula
detailed procedure page AT
refer to
II
TF C D 02 mm
49 for ing
Checl and Adjusting Inhibi
c A
iif
where tor Switch
between L
L
TF Required thickness of front 13 Check the length 1
29 00 142
u
Under25 55 l OO59
Thickness mm in
25 65 to 26 05 1 0098 to 1 0256 29 1161
5
5
1 0 059
15
26 to 55
26 10295 to 1 0453 30 0 1 81
I 7 0 067
26 65 to 27 05 10492 to 1 0650 30 5 1201
1 9 0 075
Over 15
27 1 0689 310 I O
2 1 0 083
23 0 091
5
2 0 098 COMPONENT PARTS I Pry off snap ring D with a
clutch drum
40
AT
Automatic Transmission
L 1
1 E 5
Eo
20 l mm
AT148 3 0 079 in
AT150
Lub ication hole
3 spring retainer f and
Take out
Fig AT B4 Testing front clutch
spring @ See Figure AT 78
Fig AT 82 Inserting clutch plate
4 Blowout piston by directing a jet
of air inlO hole in clutch drum See
AT 8l REAR CLUTCH
Figure 3 After clutch is assembled make
sure that clearance between snap
ring
and Disassembly
CD retaining plate @ is held
within specified limits If necessary
Specified clearance
I 6 to 1 8 mm
0 063 to 0 071 in
10 6 0417
AT153
10 8 0425
Inspection
1 Rear clutch drum 6 Driven plate
I Check for signs of wear or dam 11 0 0 433
2 Front clutch piston 7 Dished plate
to clutch drive plate facing If
age 112 0441 3 Snap ring 8 Spring retainer
found worn or damaged excessively 4 Retaining plate 9 Coil spring
II 4 0 449
discard See Service Data for limits 5 Drive plate
If necessary replace with new ones I Take out snap ring @ retaining
Spring retainer should also be in plate @ drive plate @ driven plate
spected for warpage @ and dished plate f Same tech
nique can be applied as in disas
sembling front clutch See Figure
Assembly AT 85
2 Remove snap ring from coil
I Assembly is in reverse the order
spring retainer See Figure AT 86
of disassembly Dip all parts in clean
automatic transmission fluid before
AT151
installing
2 Line up driven plates so that
Fig AT 83 Measuring ring to plate
stripped arcs are properly aligned clearance
41
AT
Automatic Transmission
Figure AT 87
Ai 1
between snap ring and retaining plate
I i is within specified limits If necessary
i
j
3 use other plates of different thickness
until correct
P2 clearance is obtained
V i Specified clearance
0 80 to 1 05 rom
J
i 0 0315 to 0 0413 in
AT157
Inspection
Assembly
Check piston for wear damage or
I After low piston is reverse
other faults which might interfere with
installed assemble thrust spring ring
proper brake operation
retum spring thrust washer and
one way clutch inner race Using
Hex head Extension ST25570001
v
ST25570000 torque hex head slot r 0
ted bolt 3 to
I 18 9 to 13
kg m
AT156 111
ft lb
Fig AT SS Measuring ring to plate 2 Insert dished plate driven plate
clearance drive plate and retaining
transmission case in that order
plate into
Install
Ll 7
2 Testing rear clutch
sn p ring to secure the installation J
Install rear clutch on oil I
pump
cover Note The number of drive and driven
Blow compressed air into oil hole plates wries with type of vehicle AT159
shown in Figure 89
AT Service Data Specifications Fig AT 91 Removing pi3ton
AT42
Automatic Transmission
valve
spring seat primary governor
3
I Check valve for faulty condition
Apply
4 Release Replace spring if found weakened
11 5
6
7
Return
Band
spring
piston
servo
@ @
I 8
9
Servo retainer
Brake band assembly nor slides freely without binding
AT290
nor is in good condition blow air
Fig AT 92 Sectional view ofseruo piston under light pressure into hole at A
and listen for noise like that of a
assemble brake I
i 1S Reverse disassembly procedure to
assemble governor
avoid dam Y
2 Use extreme care to
3 Blow compressed air from apply t 9c fa installation check that spring is not
GOVERNOR
OIL PUMP
Disassembly
c
1r
ror1
f
7 f A
tributor
nor
by unscrewing attaching bolts
To disassemble secondary gover
remove spring seat spring and
I Free pump
1 I @ AT 95
1
O j To control 3
L IV I
val Inspection
iJ fl
i
n
0
5MI
AT160
n
Fig AT 93 Testing piston gear teeth Replace rubber ring if
Apply side found damaged beyond use
r
ID 2 Using a straight edge and feelers
Ii
I measure pump and gear clearances as
follows
43
AT
Automatic Transmission
CONTROL VALVE
ST255801JOO
u AT264
The control valve assembly consists
of many preci ion parts and requir s
extreme care when it has to be reo
I Seal ring
Note When
sembling Gauge
former Oil Pump
is to be used make
As
becomes fouled
sembly should be
the control valve as
di ssembled and
q
Disassembly
I PLANETARY CARRIER
I Remove bolts and nuts which
The
1n l
planetary carrier cannot be retain oil Bolts may be
trainer re
J
000
Clearance
I HT61000800
I I
JL
AT166
11 2 Remove attaching bolts With
separate
are
removed
free
plate
for
lower
and upper valve
removal
valve
See
body
body
Figure
3 Temporarily lighten
ing bolts
pump secur
I AT 102
Note Do not it
I w
off with screw
1
screws not
screwdriver
F D
l t
a
f
J n
Ull IU P
C
19l1 J
o
IODrR
SJQIl2J
CJ
CC t
lhl
fB LL6 rt
AT169
Fig AT 103 Removing manual val
f
@iO
I g
y
hl
2I r
l J
JI t Io j
SecOni
J lOCltvalYi 1
i
S
2nd 3rd taltimivneg
0 r
r
x
en
t
i i
C 1iJrilth rottle lI
lY e
3 1
a
M
2i1d
st 2nd S
dSt1itLvalv
3
ft
alVSY
aIvel
I j1
If
f
2i 3 CP g
fI
so iit a stiift i
V81v
hrottle
f
iicnjp yi
VB
P ie mo i
Inspection
r
I Check valves for sign of burning tension if necessary replace 5 Check oil passages in valve b dy
and if necessary replace 4 Examine for any sign for sign of and other condi
oLdamage damage
2 Check to be certain that oil marks on separate plate If tions which
or score might interfere with prop
strainer is in good condition If found left unheedcd oiL will bypass correct er valve operation
damaged in any manner disCard oilpassages causing many types of 6 Check bolts for threads
stripped
3 Test valve for weakened
springs abnormalities in thesystem
Replace as required
AT45
Automatic Transmission
Installed
Mean coil
Wiredia No of free length
Valve spring dia
in
mm active coil
mm in
mm in Length Load
mm in kg lb
3
1 6 0 15 0
Manual detent 4
32 26 5 5 5
0 051 0 236 1276 1043 1
12
2
1 5
10 13 0 43 0 5
23 2 8
Pressure regulator
0 047 413
0 1 693 0 925 6 2
4
0 80 5 0 5
18
Pressure modifier 9 0 0 1
0 016 0 315 0 728 354
0 02
06 6 0 6 0 32 0 16 0 0 625
1st 2nd shift
0 024 0 236 1 260 0 630 378
1
07 6 2 80 410 17 0 1 40
2nd 3rd shifl
0 028 0 244 1 614 0 669 3 09
0 7 5 5 15 0 5
32 27 0 0 55
2nd 3rd timing
0 028 0 217 1280 1 063 21
1
08 6 5 14 0 36 0 18 8 1 92
Throule back lIP
0 031 0 256 1417 0 740 4 23
55
0 5 0 12 0 22 0 0 60
Solenoid downshift 12 5
0 0217 0 197 0 866 0 492 32
1
0 55 5 0 16 0
Second lock 33 5 210 0 60
0 0217 0 197 319
1 0 827 32
1
0 9 5 6 14 0 26 8 19 0 2 9
Throule relief
0035 0 220 1055 0 748 483
0 23 4 77 12 0 J5 5 11 5 01
0
Orifice check
0 0091 1878
0 0 610 453
0 0 02
45
0 3
8 5 0 21 8 5
7 0 215
Primary governor
0 0177 327
0 0 858 295
0 474
0
0 7 8 5 5 5 25 1 10 5 I 10
Secondary governor
0 028 335
0 0 988 413
0 43
2
Free
Assembly ifications when designated
A installed
f
i
n
n
lenglhm DO
ri
Wire dia
Assemble in reverse order of disas
sembly However observe the follow
ing assembly noles Refer to Valve
Spring Chart and illustralion in as
I Slide valve into valve
particularly careful
forced in any way
2 Install side plates
that
using Torque
body arid
they are
be
not
AT172 sembling valve springs Dip all parts in Driver ST25160000 Hexagon
and
clean automatic transmission fluid Wrench HT6 I 000800 See Figure
Fig AT 106 Value spring before assembly Tighten parts to
spec AT l 07
AT46
Automatic Transmission
ST25160000
HT6 1 000800
4 Install upper and lower valves
AT174
See Figure AT 108
Fig AT 108 Installing valve body
J Tightening torque
AT173
0 25 to 35
0 kg m
Fig AT 107 Installing side plate 2 to 3 ft lb
5 Install oil strainer
3 Install orifice check valve valve Reamer bolt tightening torque Tightening torque
25
0 to 35 kg
0 m
spring throttle relief valve spring and 5
0 to 0 7 kg m
2 to 3 ft Ib
steel ball in valve body 4 to 5 ft lb
AT47
Automatic Transmission
CONTENTS
AO
T
Automatic rransmission
In these cases the transmission must Wipe off the leaking oil and dust INSPECTION AND
and if too high a strong shock or alignment with the stepping of posi
INSPECTION AND REPAIR
tion plate when it is released
creep develops when changing over
OF OIL LEAKAGE
from N to D or R
leakage takes place the
When oil
portion near the leakage is covered Adjustment
with oil presenting difficulty in This be accomplish
CHECKING AND ADJUSTING procedure can
11 Converter housing
Rubber ring of oil pump housing When the kickdown operation is
Oil seal of oil pump housing not made properly or the speed chang CHECKING AND ADJUSTING
Oil seal of engine crankshaft ing point s too high check the kick INHIBITOR SWITCH
Bolts of converter housing to case
down switch downshift solenoid and
The inhibitor switch lights the re
the
2 Trarismission and rear extension wiring between them When igni in the R of the
verse lamp range
ion and rear li n key is pqsitioned a t the I st stage
Junction of transm ss transmission peratio and also rotates
ol
extension J nd the accelerator pedal is depressed the starter motor in the ranges N
deeply the switch contact should be
Oil cooler tube connectors and P
closed and the solenoid should click If
Oil pan
it does not click it indicates a defect
CD
Oil pressure inspection holes Refer
Then check each part with the testing
toFigure AT il2
instruments See Figure ATl09 @
Mounting portion of vacuum dia
@ b ell If
phragm and downshift solenoid L t dl
@
Breather and oil charging pipe
leaka
le t
6 Washer
t Inhibitor switch
Place the vehicle in a pit and by 7 Nut
2 Manual shaft
AT10S
the leaked oil determine if it Inhibitor switch
sampling 3 Washer 8
5 Manual plate
converter oil has a color like r d wine
So it is easily distinguished from engine Note Watch for oil leakage from Fig AT 110 Construction of inhibitor
switch
oil or gear oil transmission case
4Q
AT
Automatic Transmission
Chcck whether the reverse lamp vehicle is held in a stalled condition test for the four ranges 0 2
and the starter motor operate normal The carburctor is in full throttle opera I and R
ly in these ranges If Ihere is any tion with the selector lever in ranges
lrouble first check the If f 2 and
linkage no I respectively Com
JUDGEMENT
fault is found in the linkage check the pare the measured results with the
inhibitor switch slandard values High stall revolution more than
fumly with the left foot before de Otherwise the front clutch is slipping
shaft becomes vertical the detent
works to position the shaft pressing the accelerator pedal Slipping of the band brake is diffi
correctly
with
3 Throw the selector lever into the cult to ascertain However if it
a
clicking sound occurs
the holes If the alignment is correct release the accelerator pedal If the engine revolution in stall
5 Shift the selector lever to N condition is within the standard
fasten the switch body with the bolts
and operate the engine at approxi values the control elements are nor
pull out the pin tighten up the screw
lever as before Check the continuity minute to cool down the torque con 2 I and R
verter oil and coolant Also tIle engine and one way
again with the tester If the malfunc
6 Make similar stall tests in ranges clutch of the converter
tion still remains replace the inhibitor torque are
ble by measuring the maximum num versely affected Sufficient cooling If the engine revolution in stall
bers of revolutions of the engine while time should be given between each condition is lower than the standard
AT 5O
Automatic Transmission
opening
Throttle opening mmHg Gear shift Vehicle speed km h MPH Propeller shaft rpm
51 to 65 32 to 40 1 840 to 2 340
Dl D2
92 to 106 57 to 66 3 340 to 3 840
0
D2 D3
Kickdown
96 to 82 60 to 51 3 460 to 2 960
D3 D2
49 to 36 30 to 22 1 790 to 1 290
D2 Dl
9t023 6toI4 330to 830
Dl D2
48 to 61 30 to 38 1 720 to 2 220
D2 D3
Half throttle 200
D3 D2 or
37 to 24 23 to 15 1 350 to 850
D3 Dl
19 12 700 Max
D2 Dl
I 51 to 38 32 to 24 1 860 to 1 360
Fuol throttle 0
12 1
Reduce the speed by shifting to I range from D range output shaft 2 000 rpm
2x 1f x rx Np x 60
V
RF x 1 000
375
4
RF
r 0321 6 00 14
AT 51
Automatic Transmission
CHANGING CONDITION
hk
3
D2 D3 effected In
are
R
Fig AT 111 Shift IChedule
increase
range the speed does not
2 The kickdown operates properly
LINE PRESSURE TEST
3 By moving the lever from D to
I gear changes D 12
2 1 When any slipping occurs in clutch
1
I
crease pressure gauge attached to two pres
5 Should be quickly fixed at 2 sure measuring holes after removing l
1
blind
c
D
plugs
c
located at transmission 7
range
o
AT S2
Automatic Transmission
10 0 to 12 0 5 5 to 7 0 78 to 100
Fulllhrotlle 0 142 to 171
2
Minimum throttle 450 6 0 to 12 0 85to171 5 5 to 70 78 to 100
Notes a The line pressure during idling corresponds to the oil pressure before cut down at minimum throttle
b The oil pressure After cut back means that after the pressure modifier valve has operated
valve B lge
Ra select linkage
LINE PRESSURE checked C Inhibitor switch and wiring
Vacuum leakage is by
directly measuring the negative pres D Vacuum diaphragm and piping
Low idling line pressure in the
sure after removing the vacuum pipe E Downshift solenoid kickdown
ranges D 2 I R and pH
A of the dia switch and wiring
puncture vacuum
This can be atlributed to trouble in F
phragm can be easily ascertained Engine idling rpm
the pressure supply system or too low
because the oil is G Oil pressure throttle
torque converter
output of power caused by H Engine stall rpm
absorbed into the engine and the
I A worn oil pump exhaust pipe emits white smoke I Rear lubrication
2 oil pressure leak in the oil
An J Control valve manual
4 Items to be checked when the
valve body or case K Governor valve
pump line pressure is increasing
3 A sticking regulator valve L Band servo
In this check the line pressure
M Transmission air check
2 Low idling line pressure in cer should be measured with vacuums of
N Oil quantity
tain ranges only 450 mmHg and 0 mmHg in accordance o Ignition switch and starter motor
This is presumably caused by an oil with the stall test procedure
leak in the devices circuits con P Engine adjustment and brake in
or I If line pressure do not n
nected to the relevant ranges
the spection
crease despite the vacuum decrease
check whether the vacuum rod is
I When there is an oil leak in the 2 Inspection after inspecting auto
rear clutch and governor the line incorporated matic transmission on vehicle
AT 53
Automatic Transmission
Trouble ABeD
EFGHIIJKL MNOP tnnqr stuv wxy
P
ngine does not start in N
2 3 1
ranges
from N
Sharp shock in shifting to
2 1 3 4 @
0 range
somewhat
I
Clutches brakes slip
or
1 2 6 3 5 7 4 @@
in starting
I 3 2
Vehicle in N
runs range
allained
Maximum speed not
1 2 4 5 7 6 3 8 OO I@
Acceleration poor
1
Excessive creep
No creep al all I 2 3 5 4 @@ 1
@
Failure 10
dumge gear from 2nd
I 2 3 5 6 8 7 4 @ @
to 3rd
AT 54
Automatic Transmission
I J KL MNOP mnqr s t u v w x y
Trouble ABCD EFGH
Failure to
change gear from 1 3 4 6 5 2 1@ @
3rd to 2nd
I
Races extremely or slips in changing
from Jrd to 2nd when 1 2 4 6 5 3 f@ @ @
depressing pedal
Failure to change from 3rd to nd
when changing lever into 2 range
I 2 4
51 3 @ j
range
55
AT
Automatic Transmission
Trouble ABeD E F G H I J K L
1M NO P
1m n q r s t u v
Iw x
y
Gear frum I sr
change lu 2nd
from 2nd to 3rd in I 1 2
or
@
range
P range
AT 56
Automatic Transmission
Checking Oil level gauge Check gauge for oil level and leakage before and after each
test
6 Vacuum pressure of vacuum Check whether vacuum pressure is more than 450 mmHg
1
Stall test I Oil pressure before tesling Measure line pressures in D 2 I and R range while
idling
2 Stall test Measure engine rpm and line pressure in D 2 I and
R ranges during full throttle operati n
Notes
a Temperature of torque converter oil used in test should
be from 600 to 1000C 1400 to 2120F i e sufficiently
warmed up but not overheated
b To cool oil between each stall test for D 2 I
Road test Slow acceleration Check vehide speeds and engine cpm in shifting up Ist
lever in
I st 2nd 2nd range and Jo3rd
2nd range while running with
200 I11I1lHg
2nd3rd D range and engine vacuum pressure of about
2 Quick acceleration Same as item 1 above except with engine vacuum pressure
lst 2nd of 0 mmHg ie in position just before kickdown
2nd3rd
3 Kick down operation Check whether the kickdown operates and measure the time
AT 57
Automatic Transmission
4 Shift down Check vehicle speeds and engine rpm in shifting down from
5 Shift down Check for shifting down OJ 12 and engine braking and
1 further for shifting down 12 I and engine braking after
DJ 12
shifting I range with the accelerator pedal
the lever into
released and the engine vacuum pressure of 0 mmHg while
driving at about 50 km h 30 MPH in OJ range
6 Shift down Check for quick shifting down 0 2 and engine biaking
DJ 2 after shifting the lever into 2 range while driving at about
50 km h 30 MPH in OJ range
Further check for locking of the transmission in 2nd gear
ratio regardless of vehicle speed
7 Shift up Check for failure of the transmission to shift up during
I 12 acceleration when starting in I range
8 Shift up or down when start Check the transmission for not shifting up or down during
iog in 2 range acceleration or deceleration when starting in 2 rang
Others Abnormal shock oil leakage Enter into record conditions observed during these tests
such as gear noise abnormal clutch noise and acceleration
performance
58
AT
Automatic Transmission
Torque converter
Type Symmetrica13 element I stage
2 phase torque converter
Transmission
Band brake I
2nd 1458
3rd 1 000
Reverse 2 182
Oil pump
Number of pump
Capacity 5 5 liters
4Ulmp qt
s qt
SUU
Approximately 2 7 liters
s qt 2XIrnp qt
2UU
in torque converter
AT59
Automatic Transmission
Front clutch
Rear clutch
12 2 0480
12 4 0 488
12 6 0496
12 8 O S04
Brake band
Big dia 64 2 S2
S all dia 40 1
57
Governor assembly
60
AT
Automatic Transmission
TIghtening torque kg m ft lb
61
AT
Automatic Transmission
For Reference
Tool number
use page or
No Description
tool name
on Figure No
3N71B AT 11 2
ST2S0SS001 Use for checking hydraulic pressure Fig
and
Oil pressure gauge 3N71A
set AfT
SE119
SE120
JIB
SE121
compressor AIT
SE 122
SE123
62
AT
Automatic Transmission
6 ST2S490000 Socket extension to connect torque wrench GG93010000 with 3N71B Fig 69
AT
W square socket wrench AIT
Socket extension
V SE124
SE125
3N71B AT S9
8 HT69860000 Use for removing and replacing snap ring Fig
and
Snap ring remover
3N71A
AIT
SE126
9 ST2S320001 Use for removing and replacing snap ring 3N71B Fig AT 79
and Fig AT 86
Snap ring remover
3N71A
AIT
SE305
10 ST2SS70001 Use for removing and installing one way clutch inner race with 3N71B Fig 64
AT
AIT Fig AT 69
torque wrench
Hex head flat width Page 42
AT
Drive angle W square and 6 mOl across
extension
SE128
AT I
AutomaJic Transmission
SE129
12 HT61000800 Use for disassembling and assembling control valve 3N71B Fig AT IOI
and Fig AT 104
Hexagon wrench
3N71A Fig AT I07
AIT Fili AT 108
0
SE130
and Fig AT 99
Oil pump
3N71A
Ssemlbing
l gauge
AIT
SE131
AT 1l
A
0
SECTION PD
PROPELLER
DATSUN PICK UP SHAFT
MODEL 620 SERIES DIFFERENTIAL
CARRIER
DIFFERENTIAL CARRIER
PD 5
TYPE H19D
i 2
t tl J
I
I O
750 53
29
148 5 5 85 483 19 02 987 38 86 35
38
1
Long wheelbase and
Fig PD l ctional
Crou v w of propelkr hafl
The
propeller shaft on the 620 INSTALLATION companion flange of differential car
series is 3 rier See Figure PD 3
joint type I Raise vehicle on hoist Put match
The propeller shaft and universal marks both on propeller shaft and
joint assembly is carefully balanced companion flange so that shaft can be
during original assembly that is the reinstalled in the original position
dynamic unbalance is under 35 cm
gr 2 Remove bolts retaining center
49
0 in oz at S 800 rpm bearing bracket See Figure PD 2
If the propeller shaft has to be
assembled it must be made carefully
so that the above limit is not ex
PD 2
PROPELLER SHAFT DIFFERENTIAL CARRIER
mission end yoke be careful not to damage correctly that joint moves under
so
propeller shaft is
with journal for movement When grease whenever
overhauled
journal does not move smoothly dis INSPECTION
assemble Use related snap rings of the same
I Check journal pin for dent or
thickness and be sure that play is
1 Mark propeller shaft and journal brinell marks and yoke hole for sign
below 0 02 mm 0 0008 in
so that the original combination can of wear or damage
be restored at assembly Snap ring bearing and seal ring
Available snap ring
2 Remove snap ring with a standard should also be inspected to see if these
screwdriver deformed Re
are damaged worn or
Thickness Color
3 Lightly tap base of yoke with a place if necessary
mm in identification
hammer and withdraw bearing race 2 heck center bearing by rotating
See Figure 4
PD bearing race If it is rough noisy or
2 00 00787 White
damaged discard Cracked bearing
2 02 0079S Yellow insulator cannot be tolerated here
Q4 0 0803
2 Red 3 Check propeller shaft tube sur
10
2 0 0827 Right Brown
12
2 0 83S No paint
PDOO5 2 14 00843 Pink
Fig PD 4 Remo i bearing
PD 3
PROPELLER SHAFT 8l DIFFERENTIALCAAR ER
CHECKING AND anced propeller shaft proceed as road test disconnect propeller shaft at
CQRRECTING follows differential carrier companion flange
UNBALANCED I Remove undercoating and other rotate companion flange 180 degrees
PROPELLER SHAFT foreign materials which could upset and reinstall propeller shaft
shaft balance and check shaft vibra 3 check shaft vibration
Again If
tion by road test vibration still persists replace pro
To check and correct an unbal 2 If shaft vibration is noted during peller shaft assembly
SERVICE DATA
Propeller shaft front and rear out of round mm in Less than 0 6 0 024
Tightening torque
Shaft to conipanion flange Gear carrier bolt kg m ft lb 2 4 to 3 17 to 24
PD 4
PROPELLER SHAFT DIFFERENTIAL CARRIER
Scraping noise Dust cover on sleeve yoke rubbing on Straighten out dust cover to remove inter
transmission rear extension Dust c ver on
ference
companion flange rubbing on differ mtial
carrier
CONTENTS
DESCRIPTION
The differential carrier on the 620 the drive pinion and the rear bearing these shims
varying The ring gear is
series has a gear ratio of 37S
4 The differential case is supported in bolted to the differential case The
The drive pinion is rnounted in two the carrier by two tapered roller side case houses two side gears in mesh
tapered roUer bearings which are pre bearings These are preloaded by in with two pinion mates mounted on a
loaded by pinion bearing adjusting serting shims between the bearings and pinion shaft The pinion shaft an
spacer and washer during assembly the differential case The differential chored in the case by lock pin The
The drive pinion is positioned by a case assembly is for proper
positioned mates and side gears are backed
pinion
washer located between a shoulder of ring gear and drive pinion backlash by by thrust washers
The carrier is of malleable cast iron
PO 5
CARRIER
8 DifFERENTIAL
PROPEllEff SAAFT
TYPE H19O
Q@
nut
1 Drive pinion
4
2 Companion flange
3 Oil al
4 Front bearing
adjusting washer
@ 5 DIive pinion bearing
Adjust pinion bearing preload by
ecting @ and @
@ 6 Drive pinion beating spacer
1 Drive pinion
8 Rem bearing
wamer
9 Drive pinion adjusting
10 pin
loci
mint
11 Side bearing adjusting
and
side bearing preload
@ Adjust
@ backlash betwam ring geu
ting @
and cIrive pinion by
12 Side bearing
@@ @ 13 Side gear
14 nUust washer
mate to side gear
Adjust pinion
backlash Of the clearance
face of side
between the teat
washer to 0 02 to
ttuust
gear and
10 0 0031 in
0 08 nun 0 0008
@ by@
15 Differential cast
16 Thrust washer
@ 17 Pinion mate
18 Pinion sbaft
19 Ring gear
Backlam between ring gear
and drive pinion
0 t5 to 0 20 nun
in
0 0059 10 0 0079
cap boll
20 Bearing
21 Thrust block
22 Ring gear bolt
23 Lock strap
of
Tightening torque f
m ft lb
bollS and nut kg
101 to 123
@T 14 0 to t7 0
36
@T 4 0 to 5 0 29 10
L
@ @T 7 0108 0 5110
58
4010
198 198 55 nun
L
in
1 8110107 8169
P0229
carner
uiew of differenwl
Fig PD 6 croectional
6
PD
PROPELLER SHAFT DIFFERENTIAL CARRIER
PD205
PRE DISASSEMBLY P0203
Fig PD 10 Removing pinion rear
INSPECTION Fig PD B Removing differenlwl bearing inner race
canier
Fig PD 7 Holding differential
pattern adjustment
Note Oil seal must not be used Fig PD 12 Removing ide bearing
PD 7
PROPElli ER SHAfT DIFFERENTIAL GARRIERf
mate for scores and signs of wear and 2 Fit pinion shaft to differential
2 Remove ring gear by spreading
replace as
required case so that it meets lock pin holes
out lock strap and loosening ring gear
Follow the same procedure for side 3 Adjust pinion mate toide gear
bolts in diagonally
gear and their seats on differential backlash or the clearance between the
3 Punch off pinion mate shaft lock
case rear face of side gear and thrust
pin from ring gear side using Solid 3 all washer to 0 02 to 0 08 mOl
Inspectbearing races and 0 0008
Punch ICV31100300 to 0 0031 in
rollers for
scoring chipping or evi by selecting side gear
dence of excessive wear They should thrust washer
be in tiptop condition such as not
Side gear thrust WlISber
worn and with mirror like surfaces
Replace if there is a shadow of doubt
oil their efficiency as an incorrect Thickness nun in
bearing operation may result in noises
and gear seizure Over 0 7S to 0 80 0 029S to 0 03IS
4 Inspect thrust washer faces Small
KV31100300 Over 80
0 to 8S
O Om IS to 0 033S
faults can be corrected with sand
Over 0 8S to 090 0 033S to 003S4
paper If pinion mate toide gear
backlash or the clearance between Over 090 to 0 9S 0 03S4 to 0 0374
PD022 side gear and thrust washer exceeds
limits 0 02 to 0 08 nun 00008 to
4 Lock pinion shaft lock pin using a
Fig PD 13 Removing lock pin 0 0031 in replace thrust washers
S punch after it is secured into place
Inspect carrier and differential
S Apply oil to gear tooth surfaces
case for cracks or distortion If either
Note Lock i cauIked at pin hole
pin and thrust surfaces and check if they
condition is evident replace faulty
mouth on differential case Do not turn properly
parts
punch it off forCibly without 6 Place ring gear on differential case
6 As a
general rule oil seal should
checkins how it is uIked and install bolts and lock washers
be replaced at each disassembly
Torque bolts to specification and
4 Draw outpinion shaft and re bend up lock strap
move thrust block pinion mates side
gears and thrust washers Tightening torque
ASSEMBLY AND 7 0 to 8 0 kg m
8
PD
PROPELLER SHAFT DifFERENTIAL CARRIER
Rear Where
ST306 II 000 and T Required thickness of rear bearing
ST3062I 000
adjusting washers mOl
I
N Measured value with thickness
1
2 Fit rear bearing on carrier and mOl
gauge
install Dummy Shaft Sf3 I 942000 and H Figure marked on the drive pinion
Standard Collar ST3197oo00 on rear bearing head See Figure PD 18
gauge and place Height Gauge ST31941000 0 Figure marked on the dummy
on carrier shaft
S Figure marked on the height
gauge
ST31941000
Fig PD 14 uring bearing width
Me 0 and S
Figures for H are dimen
sional variations in a unit of 1 100 mOl
Set numblr
PD2 b
J
t Head
number
ST33230000 Fig PD 16 Adjusting pinion height
HI
I
P0186
drive pinion
the end surface of dummy shaft using
thicknes
a gauge
Examples of calculation
P0244
Ex I
Fig PD 15 ln talling side bearing
N 0 5Imm H 2 0 1
cone
S O
T N D S xO 01
H
2 18
51
0 2 I 0
x ol
O 18
2
ADJUSTMENT OF DRIVE O SI 2 t 1 0 x 0 01
P0235 18
2
PINION HEIGHT
51
0 3 x 0 01 2 18
Adjust the pinion height with
51
0 0 03 18
2
washer provided between bearing
rear Fig PD 17 Measuring clearance
2 66 mOl
inner race ld
a the back of pinion gear
PD 9
PROPELLER SHAFT DIFFERENTIAL CARRIER
0 68 02
0 2 18 2 79 0 1098
Preload without oil seal
i88 mm 82
2 0 1110
10 0 to 13 0 cm
kg
The correct washer is 2 88 mm 2 85 OJ 122 8 7 to II in lb
thick 2 88 OJ 134 At companion flange bolt hole
2 9 to 3 7
2 91 0 1146 kg
Ex 3 4 to8 2Ib
6
2 94 1IS8
0
N 0 70mm H O 0 0 2 97 1169
0
S O
3 00 1181
0
2 18
3 12 0 1228
0 70 0 x 0 01 2 18 3 IS 0 1240
0 70 0 2 18
3 18 0 I2S2
0 70 2 18
2 88 mm
S Fit determined drive pinion ad
The correct washer is 2 88 mm justing washer in drive pinion and
thick preSs fit rear bearing inner race in it
ADJUSTMENT OF DRIVE
IPIENLOADIONPI
Note If lues signifying H D and S
are not given regard them as zero AdjUst the preload of drive pinion Fig PD 19 Measuring pinion preload
and After with spacer and washer between front
n C
r
e
assembly
check to see that tooth contact is and rear
bearing inner races
If not For the This procedure has nothing to do
correct readjust
tooth contact with thickness of drive pinion adjust
pattern see page
PJ
12 for Contact Pattern ing washer
Pinion bearing adjusting spacer
This adjustment must be carried
out without oil seal inserted
SS 70 2 1929
Tightening torque
14 0 to 17 0 kg m S6 00 2 2047
101 to 123 ft lb
PD l0
PROPELLER SHAFT DIFFERENTIAL CARRIER
T2 B D H xO OI
A I B 2 C 2 0 3
Thickness O ISO F
mm in
E 0 11 mm F O IS mm
H 2
over 3 80 to 3 82 0 1496 to lS04
O Where
over 3 82 to 3 84 lS04
O to 0 ISI2 T1 thickness of left side
Required
over 84
3 to 86
3 lSI2
O to 0 IS20 bearing adjusting shim mm
3 86 to 3 88 O IS28 T2 Required thickness of right side
over lS20
O to
Left side
bearing adjusting shim mm
over 3 88 to 3 90 lS28
O to 0 IS3S
T A C 0 H 0 01
A Figure marked on the left side x
3 98 to 4 00 lS7S
O entia case l7S
O 0 11
over lS67
O to
E F These are differences in width 4 x 0 01 0 175 11
0
over 4 00 to 4 02 0 S7S to lS83
O
of left or right side bearing against 0 04 1 7S
0 0 11
over 4 02 to 4 04 lS83
O to 0 IS91
the standard width 20 00 mOl
over 4 04 to 4 06 lS9I
O to 0 IS98 32S
0 mOl
mOl
over 4 06 to 4 08 lS98
O to 0 1606 If bearing width is 19 89 the differ
over 4 08 to 10
4 1606
0 to 1614
0 ence will be as follows
20 00 19 89 0 11
3 Check and adjust tooth contact The correct shims are as follows
H Figure marked on the ring gear
pattern when former adjustment of
See Figures PD 20 and PD 2 I Thickness Quantity
bearing preload is completed Unless
07
0 x 2 0 14
anything wrong is found remove drive
for A B C 0 and H are 0 20 I 0 20
Figures x
B 0 H x 0 01
123 ft lb
S Measure preload again
71 Mark B
2
lSO
O
O ISO
3
F
0 15
2 x 0 01
O ISO
3 2
0
x
15
0 01
9 S to 12 in lb O IS
3 x O OI O ISO
At companion flange bolt hole 0 03 lSO
O lS
O
1 to 4 0 kg
3 Mark C 0 0 27 mm
6 8 to 8 81b
P0214
The correct shims are 0 07 plus
20
0 mm thick
Fig PD 20 Thickn of shim on l ft
and righ t sides
ADJUSTMENT OF SIDE
BEARING SHIMS
I If hypoid gear set carrier dif
ferential case or side bearing has been
PD ll
PROPELLER SHAFf DIFFERENTIAL CARR IER
Drift ST33230000 and Adapter tact pattern of ring gear and drive
ST33061000 pinion
Left side 3 Install differential I clean ring and drive
case assembly Thoroughly
into gear carrie
TI A C tapping with a rubber pinion gear teeth
D H x om
mallet 2 Paint ring gear teeth lightly and
0 17S E
4 mark
0 I 0 2 x 0 01
Align on bearing cap with evenly with a mixture of ferric oxide
that on gear carrier and install bearing and gear oil to produce a contact
0 I7S 0 20
cap on carrier And tight n bolts to
0 I 0 2 x 0 01 pattern
specified torque 3 Rotate pinion through several
17S
0 0 20
revolutions in the forward and
3 Om 17S
0 0 20
reverse
B D H xO 0l
T2 S Measure ring gear drive
to pinion
O ISO F
backlash
3 0 2 x om
If backlash is too small remove
O ISO 0 17 a Heel contact
shims from left side and add them to
3 0 2 x om
right side To reduce backlash remove To correct increase thickness of
0 150 17
0
shims from right side and add them to pinion height adjusting washer in order
S x 001 0 ISO 0 I7
left side to bring drive pinio close to ring gear
O OS 1S0
0 0 17
37
0 mrn
000S9 to 0 0079 in
and H are not given regard them as Fig PD23 Hul contact
zero and compute
b Toe contact
ring gear
Thickness mm in
Fig PD 22 Mccuuring back1aah
O OS 00020
10
0
bearing preload Bearing preload
0 0039
should read 12 0 to 20 0 10 to
cm
kg
0 20 00079 17 in lb of
rotating torque 3 S to
S 8 7 7 to 12 8 Ib at ring P0194 1
50
0 00197 kg gear bolt
hole Fig PD 24 To contact
PD 12
P ROPELLER SHAFT DIFFERENTIAL CARRIER
Tightening torque
Gear carrier to rear axle case
17 to 5 kg
2 m
cV t 12 to 18 ft lb
Drain and filler P0238
PD195 plug
6 0 to 10 0 kg m
Fig PD 29 Removing companion
Fig PD 25 Flank contact flange
43 to 72 ft lb
follows WrencliST31530000
P0196
t 2 Raise the rear end of vehicle and
Notes
readjust
PD 13
PROPELLER SHAFT DIFFERENTIAl CARRIER
When a differential carrier is sus tires road surface exhaust universal places cannot be corrected by adjust
pected of being noisy it is advisable to joint propeller shaft wheel bearings ment or replacement of parts in dif
make a thorough lest to determine engine transmission or differential ferential carrier
whether the noise originates in the carrier Noise which in other
originates
Seized up or damaged ring gear and drive the hypoid gear set
Replace
pinion
Seized up damaged or broken drive pinion Replace the pinion and faulty parts
bearing
bearing
Seized up damaged or broken side bearing Replace the side bearing and faulty parts
Loose bolts or nuts fIXing ring bearing Clamp them to specified torque and
gear replace
cap etc faulty parts
Noise on turn Seized up damaged or broken side and Replace faulty parts
pinion mate
PD 14
PROPELLER SHAFT IFFERENTIAl CARRIER
1
j
Seizure of breakage Shortage of oil or use of unsuitable oil Replace faulty parts and use reconunended
gear oil
Loose bolts and nuts such as ring gear bolts Replace faulty parts
PD 15
PROPELLER SHAFT DIFFERENTIAL CARRIER
Type HI90
Drive pinion
Preload cm in Ib
kg
without oil seal 10 0 to 13 0 8 7 to II
with oil seal 110 to 14 0 5 to 12
9
2 91 1146
0
2 94 0 1158
2 97 0 1169
3 00 0 1181
3 03 0 1193
3 06 0 120S
3 09 0 1217
3 12 0 1228
3 IS 0 1240
3 18 0 12S2
S6 00 2 2047
PD 16
PROPELlER SHAFT DIFfERENTIALCARRI ER
Ring gear
ft Ib
TIghtening torque kg m
14 0 to 17 0 101 to 123
Drive pinion nut
17 to 2 S to 18
Differential carrier to axle case 12
Companion flange of front shaft and
flange yoke connecting nut 4 to 3 3
2 17 to 24
PD l1
PROPELLER SHAFT DIFFERENTIAL CARRIER
Adjusting methods
Variable numbers expressed by 100
1 mOl
T2 B 0 H x 001 0 150 F
PD 18
PROPELLER SHAFT 8i DIFFERENTIALCARRIER
SE023
2 ST3I 94S000 These tools are used to adjust the pinion height 620 Fig PD 16
610 Fig PD 17
Drive pinion
setting gauge
assembly
@
H190
ST31942000
Dummy
SE209
shaft
ST31941000
Height
gauge
SE210
620 Fig PD 16
3 ST31970000 This tool is used for Type H 190 to adjust the pinion height
610
This tool is used with ST3I 94S000
Collar
35 1 38 di
30 18
1
dia
1
27 1 06
620 Fig 13
4 KV311 00300 For driving out oflock pin of pinion shaft PI
610
Solid punch 710
S30
4 5 0 177 di
95 3 74
Y
65 2 56
PD 19
PROPELEER SHAFT GIFFERENTIAl CARRIER
Tool number
Fur Reference
No Description use page or
tool name
on Figure No
Unit nUll in
5 Drive pinion outer These tools are used when drive pinion outer
assembling race 620 Page PD 9
race drift
610
ST30611000
0 0
Bar 350 13 78
i
ST306130qo
i Wt UWrflIfl
UU ti
t
l 2 83 dia
Adapter
L J2
0 0
ST30611oo0 350 13 78
1
L
j
Bar
ST3062 1000
I I II
e
G gI 2l 79
j
3 11 dia
Adapter
6 ST309OS000 This assembly clamps rear bearing inner race and pulls it out by a 620 Fig PO IO
Drive pinion hydranlic press 610 Page PD IO
Before insertion place another drift facing inner race and then
rear bearing S30
press fit
inner race
puller lb 45 1 17 dia
35 2 1 386 dia
ST3003Ioo0
Puller
ST30901000
Base l 24 0 94
80g 5 dia
ST30720000
Drift
KV38102SIO
Drift
55 5 2 185 dia
PD 20
PROPELLER SHAFT DIFFERENTIAL CARRIER
8 ST3 1530000 This tool is used to hold the Ilange to case the operation of tightening 620 Fig PD 5
and lousening drive piniun nut 8210 Fig PD Y
Drive pinion
610 Fig PD 28
flange wrench
710
SJO
b
l
54 2 13
GG91030000
CD
Turque wr nch
L
2 IIT62940000 O
Socket adapter
lJ
ct
J IIT62900000 1 4 II J x 3 8
3 8 UJ
L 2
1 r
Socket adapter
ST3JOSIOOI
Diff side
bearing
puller
STJ306 I 000 38 1 50 di
Adapter
II ST33230000 Use of this tool makes it possible to drive in bearing without 620 Fig PD IS
bearing drift
0ll
5t 1B 1
2 0t di
PD 21
r
SECTION FA
FRONT AXLE
DATSUN PICK UP FRONT
MODEL 620 SERIES SUSPENSION
CONTENTS
INSPECTION FA 8 INSPECTION FA ll
STABILIZER FA 8 ADJUSTMENT FA Il
GENERAL DESCRIPTION
uUl
FA224
FA 2
Front Axle Front Suspension
of fore and aft direction inner wheel bearings bearing washer Install front axle in reverse se
The front end of the torsion bar and grease seal from knuckle spindle quence to removal by noting the fol
spring is installed to the 7 Remove brake disc assembly from lowing matters Furthermore when
torque arm
which attaches to the lower link The the flange of knuckle spindle installing front axle lightly coat grease
the k ufkle spindle arm by the king FA225 Note Be sure to iristsll thrust bearing
pin The king pin bushings are fitted to Fig FA R mol1ing king pin loch nut to face coverea side upward
the upper and lower arm portIOns of
the knuckle and seals
spindle are
keep water and dirt from enteri g knuckle spindle support with the
The knuckle arm is connected to 10 After removing air breather re
notch in king pin and secure lock bolt
Be sure to check killJckle spindle for
the lower end of the knuckle spindle move plug from the top of king pin
transmit of the smooth movement Be certain to move
to ttLe movement with the following method Drill a
FA 3
Front Axle Front Suspension
I 3 0 to 3 S
Note When disassembled discard Torque spindle nut to
kg m 22 to 25 ft lb using torque
used lock plate
wrench
5 Pack to the r and
grea upP
lower bushings on knuckle spindle
until grease c omes out from grease
seal
fA22S
6 Fill wheel hub and cap with
Fig FA 6 Meauring bearing rotation
the described level See
grease up to atarting torque
Figure F A
4
in lower boss
dle nut clean when installing them 34
1
I
Notes I 1
a When measuring the starting force
WHEEL BEARING
D
TM NT
pull the spring balance toward tan
gential direction against normal line
II
connected between hub boll and Pla ce this position in line with
4
FA
Front Axle Front Suspension
0 7878 to 0 7888 in
Drilling diameter
118
0 in
approximate 3 mOl
for condition Re
check outer race
specified value with King Pin Bush Fig FA 10 Greasing bearing cone and
moval of outer race from drum is not
Reamer HT56802000 roller assembly
diameter necessary
Bushing inner
Shown below is the cha rt which
when fitted 5 Place inner bearing cone and rol
20 010 to 20 03S mOl ler assembly in hub Coat grease slight furnishes the necessary information on
0 7878 to 0 7888 in ly to the lips of new grease seal and Visual Serviceability Standard for
lower side use upper side as ream Visual serviceability standard for wheel bearing
ing guide to align the center line
correctly @ J
5 Press fit grease seal on arm
upper
with King Pin Grease Seal Drift @
@
ST35390000 In installing grease seal 1 Outer race
@ @ 3 Small collar
35390000
51 4 Inner race fitted surface
5 Collar surface
6 Inner race surface
7 Outer race tilted surface
10 Inner race
jJ 11 Large collar
2
CD
Q @
12 Supporter
FADD6
FA231
Fig FA 11 Wheel bearing assembly
Fig FA 9 Installing grease seal
FA 5
Front Axle Front Suspension
X Unserviceable
Judgement 6 May be used when minor
C Cause
E
Components 2
e 0
0
0
0
0 u CIl
Flaking X Service life due to rolling fatigue However this symptom occu before
the service life The following causes are considered
flaking
Recess or wear 6 6 6 Careless installation removal or other rough handling scar due to
made by pressing striking
orstriking Recess made by foreign matter
Fig e f g
FA 6
Front Axle Front Suspension
u
u
e Cause
Components 2
2 0
3
0
c t
The bearing has been placed in a highly moistened place for a long
period of time
Intrusion of moisture chemicals etc or the bearing is touched with
Fig h bare hand and no rustproof action has been taken
Discoloring The wheel bearing is serv Slight discoloring may become like oxidized oil stain due to grease
or by polishing
I
1
I I
v
n
dJ
i
f
a Inner race flaking b RoUer flaking c Cracked inner race
t c
fJ Jt
v l
t
iT
F 1ll
t 1
tt j J JJ
I
1
t 11 I l
t
1
1
ollf
c
oe
F A007
FA 7
Front Axle Front Suspension
2 Remove wheel
Damping force kg lb
3 Holdthe upper stem of shock
3 m sec
0 0 98 ft sec j
absorber and remove outs washer and
rubber bushing Rebound 76 168
torque
4 Remove bracket bolt @ from the
6 Install the upper end of shock front end of tension rod and remove
6 Install stabilizer lower link side to
absorber to body bracket and tighten tension rod with bracket
connecting rod and tighten nut to the
lock Jt
n to the specifjcations specifications as shown in Figure
Tightening torque FA 14 Then torque lock nut toJ 6
CD
1 6 to 2 2 kg m 121016 ft lb to 2 2 kg m 12 to 16 ft lb
INSPECTION
FA S
Front Axle Front Suspension
s Install tension rod at rear end 4 Remove dust cover at the rear Anchor arm setting post ion A
tighten nut to make the distance of end of torsion bar spring and detach ISt02Smm
kg m 12 to 16 ft lb 60 to 70 mOl
ward after pulling ou t anchor arm
6 Install tension rod bracket to 36
2 to 2 76 in
realWard
chassis frame bracket and torque nut
to 1 6 to 2 2 kg m 12 to 16 ft lb Installalation
When two rubber bushings are dif
UjP je
ferent in size Install torsion bar spring in the
arrange adjusting nut
of removal
Standard dimension is 11 0 mOl 433
0 reverse sequence noting Rebound bumper
the
in as shown in Figure FA 16 Torque following instructions
rubber
I Coat grease the serrations of
lock nut to 1 6 to 2 2 kg m 12 to 16 on
j
torsion bar
ft lb spring and install it to
torque arm
Il 0 11 0 433
0
Note Be sure to install right and left 4W
torsion bar springs correctly They
t lP can
and
be identified with
L Left marked
R
on
Right
the end
Fig FA 18 Setting procedure
surface
Notes
A and 8
4 1
33 315
2 Install anchor and
3
specifications are
arm tighten the
I only preliminary rough settings
adjusting nut to obtain A dimen
directions for performing the final
11 0 433
0 1 011 0 0 433 sion See Figure FA 17 When anchor
adjustment that determines the ride
is A
Adjusting nut
arm properly adjusted to
height are found on page FA II
specification upper link should be in under Adjustment
contact with rebound bumper rubber
i
Y b Discard old snap ring after re
See Figure FA 18 Install snap ring and
moving it Replace with
w
new one
dust cover Temporarily tighten adjust
during reinstallation
ing nut until B specification is
reached 3 Install wheel and lower vehicle
36 6 l 441
Adjust vehicle posture at curb weight
Unit mm
in full fuel tank no refer
FA235 passengers
Fig FA 16 Tension rod detail ring to
Adjustment
4 Torque lock nut to 3 1 to 1
4
I
kg m 22 to 30 ft lb
INSPECTION
I
INSPECTION
I
I Check tension rod for bend and Check torsion bar spring for wear
the thread for faulty condition Repair twist etc When adjusting vehicle
or replace as required
posture replace torsion bar spring
2 Check bushing rubber for wear FA236
with a new one if the specified height
and deterioration Replace if neces can not be obtained
Fig FA 17 Installing anchor arm
sary
Removal
Diameter in 219 830 0 862 x 32 68
1 Raise vehicle on a hoist or stands
x
length mOl x
2 Remove wheel
Torsional rigidity
3 Loosen nuts anchor 3 74 27 I
at spring kg m deg ft lb deg
bolt
FA 9
FrClnt Axle Front Suspension
4 Install upper link spindle to upper
UPPER AND LOWER
link mounting bracket with used
LINKS camber shims and bolts
adjusting
Torque bolt to 7 0 to 9 0 kg m SI
REMOVAL AND to 6S ft lb
INSTALLATION S Install dust seat to the lower end
of j
nuckle spindle support
Removal
6 Coatgrease on the thread of
I Raise vehicle on a hoist or stands fulcrum pin and line up the notch of
2 Remove wheel and brake drum as FA238 fulcrum pin with knuckle spindle sup
an assembly Fig FA 20 Removing upper link port for inserting cotter pin Fit
3 Remove wheel hub Refer to see spindle fulcrum pin to spindle support with a
disc spindle and remove lower link spindle 7 Coat grease to the tIuead portion
5 Remove knuckle arm torsion bar Remove lower link with torque arm of screw bushing inside liberally Posi
spimgJ stabilizer shock absorber and from mounting bracket tion knuckle spindle support at the
tension rod in t
ili order referring the 13 Using Transverse Unk Bushing center of lower link and secure screw
related sections Replacer ST36070000 to lower link bushings temporarily by hand Mter
it with hammer and ascertaining the dimensions become
6 Remove upper fulcrum bolt se bushing tap a
3
10 Pull out fulcrum pin with drift
and remove knuckle spindle support
14 1n
Front Axle Front Suspension
Note When installing fulcrum pin 4 Make sure to operate upper link Check the screw of upper link
insert it from rearward of vehicle spindle smoothly after installation spindle fulcrum pin and screw bush
5 Replace filler plug with grease ing and repair or replace if necessary
nipple and pack grease until grease
12 Install tension rod shock ab comes out from dust cover
Note Discard dust cover and dust seal
sorber I stabilizer torsion bar spring Reinstall f1ller plug
when disassembled
and knuckle arm referring to the
related paragraphs
Lower link
13 Install brake disc to knuckle
spindle and torque securing bolt to 4 2 When installing torque arm on
following instructions
2 Torque screw bushing on upper H dimension mOl in
link to 3S to 55 kg m 253 to 398
ft Ib Install new dust seal and dust All models
Condition
cover and secure them with clamp
3 Coat grease to screw bushing in
Vehicle empty no payload 79 to 84 3 11 to
side and the thread portion of upper 31
3
Notes i
a Vehicle empty no payload consists o
of the following conditions
I Full tank of gasoline radiator
f1lled and engine oil level full
2 Spare tire wheel jack and jack
handle in design position
b Vehicle loaded consists of the fol
Unit mm in I
lowing conditions
44 6 1 1
56 FA2 FA242
Fig FA 23 Upper link and upper link For all models 2 persons and SIlO Fig FA 24 Dimension for standard
spindle 103lb
leg I payload vehicle postl4re
FA
Front Axle Front Suspension
incIinal10n 60IS
Kingpin
Steering angle
I Innerwheel 10
360
I Outer wheel 10
310
FA 12
Front Axle Front Suspension
King pin
Clearance limit between the king pin
and in 0 15 0 0059
bushing mm
Wheel bearing
ft Ib 3 0 to 3 S 22 to 2S
Tightening torque kg m
40 to 700
Spindle nut returning angle
Wheel bearing rotation starting torque
When both bearing and seal are new in Ib less than IS 13 0
kg em
kg em in lb less than 7 6 1
When readjusted
At the hub bolt
kg lb less than 2 1 4 6
When both bearing and seal are new
Suspension link
kg ft Ib less than O S 3 6
Upper link sliding resistance m
ft lb less than O S 3 6
Lower link sliding resistance kg m
lightening torque kg m ft Ib
19 to 2 S 14 to 18
Brake hose connecting nut
4 2 to S O 30 to 36
Brake disc fIXing bolt
2 1 to 2 S IS to 18
King pin lock bolt
Torque arm
Arm end 2 7 to 3 7 20 to 27
Serration boss 18 to 2 6 13 to 19
74 to 8 0 S4 to 58
Lower link spindle nut
24 to 35 174 to 2S3
Upper link screw bushing
to bracket 7 to 9 51 to 6S
Upper link spindle bolt fIXing
Cotter pin lock nut 0 8 to l 5 8 to 8 0
Tension rod
Lock nut 16 to 2 2 12 to 16
1 6 to 2 2 12 to 16
Bracket bolt
Shock absorber
1 6 to 2 2 12 to 16
Lock nut of the upper end
Lower end 3 1 to 4 1 22 to 30
Stabilizer
Bracket bolt 16 to 2 2 12 to 16
0 8 to l 5 8 to 8 0
Bumper rubber bolt
FA 13
Front Axle Front Suspension
place
Unevenly worn tire or insufficient tightening Replace or tighten
Vehicle pulls to right or left When driving with hands off the steering wheel on a
fiat road the vehicle gently swerves to right or
left
tires
Difference in height of right and left tire treads Replace
FA 14
Front Axle Front Suspension
breakage
FA 15
Front Axle Front Suspension
tire
Incorrect wheel alignment Adjust
Damaged wheel bearing Replace
FA 16
Front Axle Front Suspension
ST35380000
22 2 dia
0 874
King pin bush This tool is used to drive out 620 Page FA 4
SE234
2 HTS6802000
FA 17
SECTION RA
REAR AXLE
DATSUN PICK UP REAR
MODEL 620 SERIES SUSPENSION
TROUBLE DIAGNOSES
RA 8
AND CORRECTIONS
CONTENTS
J
I
i I
LJ
o
1 @
RA132
6 Rear axle oil seal spacer 20 Rear axle case end shim 43 to 72 fHb
7 Rear axle shaft oil seal 21 Nut Nut
31
Supply wheel T 5 4 to
6 4 kg m
bearing grease to T 5 to 13 0 kg
11 m
RA 2
Rear Axle Rear Suspension
ing cages on outer rear axle case The bearing bracket and connecting shaft frame @ Cover brake hose and pipe
axle is pressed steeJ to companion flange Withdraw pro openings to
case a
Banjo prevent entrance of dirt
type housing peller shaft sleeve yoke from transmis 6 Disconnect shock absorbers at
The rear axle assembly is attached sion the shaft rearward lower end f and push shock ab
by moving
to the frame passing it under rear axle sorbers up out of the way
through semi elliptic leaf
and 4 Disconnect hand brake cable 7 Lower jack under axle
springs telescopic hydraulic shock rear case Re
absorbers Rubber bushings at either Q by removing adjusting nut @ move U bolts
spring clips @ to
end of the leaf springs and shock separate axle case from spring
absorbers are designed to absorb vibra
tion and noise
RA312
8 Place
jack under center of axle
a
Tightening torque
Pass axle
through space
REMOVAL AND case case
U bolt Spring clip
above spring and take it out to the
INSTALLATION 3 to 9 9
7 kg m
side
53 to 72 ft lb
REAR AXLE ASSEMBLY
Shock absorber lower end nut
It is notnecessary to remove the
1 6 to 2 2
reaT axle assembly for any normal kg m
12to 16ft Ib
repairs
However if the axle case is dam Brake pipe flare nut
aged the rear axle assembly may be IS to 18 kg m
RA 3
Rear Axle Rear Suspension
8 Position axle shaft in vise with I Fit wheel
REAR AXLE SHAFT AND bearing outer race by
Rear Axle Stand ST07630000
WHEEL BEARING tapping with a brass hammer evenly
9 Unbend lock washer with a screw while fitting
I Raise rearof vehicle and support
driver 2 Install
under axle case on stands Remove a new oil seal in bearing
wheel Note Do not use used lock washer cage Lubricate cavity between seal
rear
2 Disconnect rear hand brake cable again lips with wheel bearing grease after
wheel cylinder Cover brake tube and and bearing spacer on axle shaft and
Jq AA135
II Withdraw wheel bearing to Notes
a Be careful to the faced side of
Fig RA 4 Removing nuts gether with bearing cage and brake place
disc Axle Shaft Bearing nut to washer side that washer is
using Rear so
r
t
Tightening torque
Rvr IS to 20 kg m
G o
J08 to 14S ft Ib
l AA343
AA418
13
race
To
after
remove wheel
removed oil seal
bearing outer
S
apply a
Fig RA 5 Removing rear axle shaft brass drift to race side surface and i
assem bly withdraw
drift with
it
a
by tapping the lop of
hammer
11 iI j
t
J
7 Remove oil seal in axle case if i pu y Mf
Installing can be proceeded in the I
necessary and install new seal Insure reverse order of removal procedure as AA142
against damaging the seal lip follows
Fig RA IO Layout ofock nut
4
RA
Rear Axle Rear Suspension
wheel bearing and recess of axle case adjust axial end play by applying shim reverse order of removal procedure
end Axial end play 0 02 to O IS mOl Tightening torque
0 0008 to 0 0059 in Differential carrier to axle case
fixing nut I 7 to 2 5 kg m
Tightening torque of
12 to 18 ft Ib
bearing cage fixing nut
5 4 to 6 4 kg m Oil drain and fIller plug
39 to 46 ft Ib 6 to 10 kg m
43 to 72 ft lb
Lubricating portion
AA143
REAR SPRING
Fig RA l1 Lubricating portion in and
around wheel bearing 1 Raise rear of vehicle and support
under both frame members with
stands
2 Disconnect shock absorber at
U bolts
6 gear oil to the spline at the
lower end CD and remove
Apply
inner end of axle shaft Apply a coal Spring clips 2
of wheel bearing grease on the seal
Fig RA 13 Measuring axial end play
surface of the shaft
7 Install left or right shaft and
9 Install other parts in reverse se
adjust axial end play by applying rear quence to removal
axle case end shim indicated by arrow
mark
0 012 to 035
0 in
5 mm 0 059 in
1 Rear axle case may be removed and
54 to 6 4 kg m
I Raise rear of vehicle and support
39 to 46 ft lb securely under both frame members
with stands
2 Remove rear axle assembly See 3 Position jack under rear axle case
removal of rear axle assembly Raise jack and float axle case from
3 Remove rear axle shaft at both spring
sides See removal of rear axle shaft 4 Disconnect rear spring shackle by
and wheel bearing removing nuts
sembly
w
Fig RA 12 Installing rear
AA144
axle shaft
Installing
reverse
can
order of removal
be proceeded in the
procedure
Another is available
procedure as
listed below
Rear axle case end shim
I Raise rear of vehicle and support
under both frame members with
Thickness mOl in
stands
O OS 0 0020 both
2 Remove ear axle shaft at AA147
0 07 0 0028
sides Fig RA 15 Removing spring shackle
0 10 00039 3 Remove differential gear carrier
0 20 0 0079
assembly 5 Disconnect spring from body by
O SO 0 0197 4 Remove rear axle case removing spring front pin
RA 5
Rear Axle Rear Suspension
spring seat
REAR AXLE CASE
3 Disconnect upper end of shock
Check axle case for yield deforma
RA148 absorber by removing nut
2 at frame
tion cracks or oil leakage and replace
Fig RA 16 Remvoing spring pin
if necessary
RA 6
Rear Axle Rear Suspension
Applied model
All models
Item
Damping force
at 3 m
0 10 ft sec
Compression kg lb 3S to S3 77 to 1l7
Standard Option
1 200 6 3 1 200x60x 72
x 60 x
5 1 6 1
13 1 13 2
Dimensions Length x Width
Thickness Number of leaves 47 24 x 36
2 x 0 243 47 24 x 36
2 x 0 28 2
x
mOl in 0 20 1 0 24 1
0 51 1 0 512
Rear axle
O OS 0 0020
0 07 0 0028
Rear axle case end shim
0 10 0 0039
thickness mm in
0 20 0 0079
50
0 0 0197
Recommended for use on heavy load under high center of gravity such as camper loading
Tightening torque
Rear U bolt ft lb 3 to 9 9
7 53 to 72
spring Clip kg m
RA 7
Rear Axle Rear Suspension
Spring shackle ft Ib
kg m 115 to 13 0 83 to 94
Air breather kg m ft Ib 0 7 to 0 9 S I to 6 S
Differential gear carrier to axle case nut kg ft Ib 17 to 2 7
m 12 to 20
Loose one or more securing bolts Tighten the bolts to the specified torque
Lack of lubricating oil or grease Lubricate as required
Faulty shock absorber Replace the shock absorber
Incorrect adjustment of rear axle shaft end Adjust the rear axle shaft end play
play
Damaged wheel bearing
or worn Replace wheel bearing
Worn spline portion of rear axle shaft Replace if necessary
Damaged rubber parts such as leaf spring Replace the required parts
bush shock absorber moun ting bush
Damaged oil seal in rear axle case or differ Replace the damaged oil seal
ential carrier
Oil leakage from between the differential Tighten to the specified torque or
replace
carrier and axle case gasket
8
RA
Rear Axle Rear Suspension
For Reference
Tool number
Description use or
No page
Unit mOl in
tool name on
Figure No
KV40101000 This tool is used to remove rear axle shaft All Fig RA S
stand
SE402
SEll1
This tool is used to loosen and tighten rear axle bearing lock nut 620 Fig RA 7
3 ST38020000
Bearing lock
nu t wrench
SE238
All Fig RA 8
4 HT72480000 This tool is used to drive out rear axle shaft bearing rigid
axle car
SE382
RA 9
SECTION BR
BRAKE SYSTEM
DATSUN PICK UP
MODEL 620 SERIES
GENERAL DESCRIPTIDN BR 2
ADJUSTMENT BR 2
SERVICE BRAKE BR 4
HAND BRAKE BR 18
TROUBLE DIAGNDSES
BR 22
AND CORRECTIONS
GENERAL DESCRIPTION
The 620 series vehicles are equip brake The mechanical hand brake is are standard equipment on all models
brakes on the four controlled by a hand brake lever locat The Master Vac is installed to increase
ped with hydraulic
wheels and mechanical hand brakes ed in the driver s compartment braking force The N LS V ensures
on the rear wheels The front brake is For added safety the tandem greater safety and reliability
ADJUSTMENT
CONTENTS
REAR BRAKE BR 3
f
ing or interference
t Depressed height C 43 to 49
1 69 to 193
1
floor
Raise vehicle until wheel clear
9 to I I ft Ib Note Take care not to allow the push brake shoes interfere with brake drum
rod to get into master cylinder in then readjust clearance
2 Adjust the length of push rod free condition 5 Install rubber boot
BR 2
Brake System
I Clean all dirt around master cyl
t
1 reservoir
fluid
2
with
and dust
6 0
from bleeder valve so that outlet hole
0
I
is free from any foreign material
o c
bleeder valve
nJ
Install a bleeder hose on
nut
3 Depress brake pedal two or three
Fip BR 2 Adjusting front brake Fig BR 4 Adjusting lock
times then keep pedal fully depressed
REAR BRAKE
3 Fully release hand brake and Notes
With hand brake fully released rotate rear wheels No drag should be a Pay attention to brake fluid level in
brake shoe clearance For master cylinder reservoir during
adjust rear present
the service procedures refer to Front bleeding operation
Brake Notes b Do not reuse brake fluid drained
7 N LS V center
mal noise dragging twisting or
brake
Fig BR 3 Adjusting rear 5 Close bleeder valve quickly as
3 94 in in hand brake lever stroke When action has out of bleeder valve in a solid
pedal a spongy
and tighten lock nuts securely feel it is an indication that air has stream free of air bubbles
essential part of regular brake service maining brake lines to expel all air
20 to 30 kg 44 to 661b
BR 3
Brake System
SERVICE BRAKE
CONTENTS
6 INSPECTION BR 13
INSPECTION BR
BR 5 INSTAllATION BR 13
INSTAllATION
7 MASTER VAC BR 14
BRAKE LINE BR
B DESCRIPTION BR 14
REMOVAL BR
B INSPECTION OF OPERATION BR 14
INSPECTION BR
B REMOVAL BR 16
INSTAllATION BR
DISASSEMBLY BR 16
N LS V BR 9
9 INSPECTION BR 17
DESCRIPTION BR
INSTAllATION BR IB
FRONT BRAKE BR lO
BRAKE PEDAL
b
REMOVAL
i t
5
2 I Fulcrum pin
3 2 Return spring
4 BR657 3 Pedal bushings
BR766
4 Clevis pin
4
BA
Brake System
To install it follows 2 Align the in retention
3 Hook return spring to brake pedal proceed as projection
Turn retention used in the cap with the slit in the reservoir tank
assembly from accelerator pedal side I ring
of recommended retention cap fully in the REMOVE and push retention cap in the tank
4 Apply a coating
multipurpose grease to the inner and direction 3 Turn retention ring fully in the
1tr
grease
@
Grease
I
m n L I
I
g
U 00 CD
1
2
Reservoir cap
Reservoir tank
BR298 Nabco 3 Secondary piston return
5pring
Fig BH 7 Greasing place 4 Stopper screw
5 Secondary piston
6 Primary piston return
5 lnstali brake lamp switch spring
6 the brake after in 7 Primary piston
Adjust pedal BR926
Tightening torque
Fulcrum pin
1 9 to 2 4 kg m
14to 17ft ib
REMOVAL
Notes
MASTER CYLINDER a When removing brake tubes use
retention cap
To remove this cap proceed as
follows
Tum retention ring fully in the
I
REMOVE direction
2 Pull out retention cap
BR 5
Brake System
1
INSPECTION
b 01 minerai oil
sure
since this will be the
r L
r brake fluid or alcohoL When alco
hol is used for leaning these parts
do not immerse them in it longer
than 30 seconds After parts are
1 Remove reservoir cap and filter Tightening torque damaged springs and replace if neces
and drain out brake fluid Valve cap sary
screwdriver 8 t09 kg m
bled be sure to discard cups and
3 Remove stopper screw and take S8 to 6S ft Ib valves Replace any other part which
shows evidence of deformation wear
out stopper primary piston assembly Nabco
BR 6
Brake System
BRAKE LINE
BA767
BR 7
Brake System
stead
REMOVAL replace copper washer with a
new one after checking for sign of
1 Removing flare nuts on both ends
damage on seating surface Never reuse
and clips effects the removal of brake
an old copper washer
tube and brake hose
follows
badly beyond use Also inspect end 12 to 14 ft Ib
fittings and be sure that no fluid leak Hose to rotating or mOving parts
through staked end has taken place Then secure brake hose to the such as tire and rim
replace if necessary Hose with badly bracket with lock plate so as not to 40 mm 57 in and
1 more
rusted fitting should also be replaced twist or abnormally bend the hose Hose to stationary part
with a new one 2S mm 0 98 in and more
ing for collapse wear cracking swell to twist the hose when additional cannot be obtained it may be caused
is hose
or rusting Replace if foun d with any tightening required by the twisted Accordingly
of wove Use care not to damage carry out the correction with hose
brake tubes while operation connection again following the above
ly
Mter all brake lines have been Brake tube
installed retighten aU connections if
In installing a brake tube use care
necessary to assist in obtaining correct
to locate its end mating
torque In retightening at front wheel squarely on
cylinder first remove hose clamp and seat noting the fact that nut can be
loosen flare nut on opposite side to turned freely by a light finger twist
BR 8
Brake System
and frame
Master TI II
Tube to body panel cylinder
I
Over 5 mm 0 20 in
rear tube
Over 9 mOl 35
0 in
Tube to moving parts
Over 10 mm 39 in
0
I
Loop tube to hood ledge panel Attaching angle
Notes
Over 10 mm 39
0 in
l
a Brake tubes are shaped at factory D Wheel cylinder
to secure specified clearance and
may not require reshaping Discard
if they call for excessive reshaping
b In reshaping a brake tube take care
collapsing section
correct torques
Performance curve of brake fluid
Tightenint torque
Brake tube to connector pressure is as follows
ISton kg m
0
A
II to 13 ft Ib S
c
Brake tube to brake hose
0
17 to 2 0 kg m C
12 to 14 ft lb U1U oadea
o
3S
O to 4S
O kg m
5 to
2 3 ft lb
Front wheel cylinder
3 way connector fixing bolt fluid BR769
pressure
on rear axle case
Fig BR 15 Perfonnance curve offluid pressure
0 8 to 1 kg m
6 to 8 ft lb
N L S V TEST
the following occurs
N L S V When rear wheels lock stopping
Operating test distance is shorter than 13 1 m 43 0
DESCRIPTION
The test should be conducted under ft whether loaded or unloaded
be measured
The Nissan Load Sensing Valve these conditions Stopping distance should
N LS V serves to change braking Drive a vehicle with pay load and from the place where the brake pedal
in response flat is first applied to the place the vehicle
power of the rear wheels then with only driver a dry on
BR 9
Brake System
Ibove mentioned op entire brake system except Wheel cylinder can be disassembled
enter cylinder
M8 x 1 25 in holes on the flange face 2 Wheel cylinder attaching ponent parts between NABCO and
of brake drum and tighten bolts even bolt BA312 TOKICO makes
ly until brake drum is driven out 3 Rubber boot
When replacing the repair kit or
3 In order to ease operation re
Fig BR 17 Removing wheel cylinder ent ascertain the
parts
move hub assembly from knucRle
brand of the brake wheel cylinder
Refer to Front Axle DISASSEMBLY AND
spindle body Be sure to use parts of the
4 Unhook upper lower and after ASSEMBLY
same make as the former ones
shoe return springs and then remove
rr l
wheel cy linder
@
6 Loosen securing nut and remove
wheel cylinder
t
7 Remove rubber boot adjuster @
shim lock plate and retaining spring
and then
from brake disc
remove adjuster assembly a INSPECTION
BR649
10 Bleeder cap
4 Dust cover 0 OS9 in with respect to the standard
5 Retainer inner diameter of 2S4 0 rom 10 00
SR tO
Brake System
0 0008 in Installed
Free length Dia of spring No of
Re condition or
replace brake drum Item
in
lengthlload
mOl in mOl coils
if specified limit is exceeded mm kg in lb
paper
S Using a drum racer finish brake
drum by machining if it shows any Wheel cylinder Adjuster sliding resistance
sign of score marks partial wear or
S to 12 kg II to 261b
stepped wear on its contact surface I Replace any cylinder or piston
which is scratched scored or worn on
3 Check adjuster for smooth oper When installing adjuster assembly semblies apply brake grease to wheel
ation brake grease to cylinder and adjuster brake shoe in
to brake disc apply
4 Replace shoe return springs which disc adjuster and retaining spring slid stalling grooves and brake disc and
broken fatigued brake shoe assembly contact faces
are or
ing surfaces to slide adjuster smoothly
adjuster sliding
Measure resistance two places Exercise care not to
BR ll
Brake System
this section
BA313
REAR BRAKE
1 Brake disc
2 Brake shoe assembly
3 Wheel cylinder assembly
4 Return upper spring
5 Return lower spring
8 Antirattle spring
9 Spring seat
10 Adjuster assembly
11 Adjuster head
12 Adjuster head shim
13 Lock spring
14 Adjuster housing
15 Adjuster wheel
16 Adjuster screW
17 Toggle lever
18 Extension link
19 Return spring
20 Adjuster spring
21 Lock plate
22 Adjuster shim
23 Rubber boot
BA315 24 Antirattlc pin
REMOVAL toggle lever withdraw clevis pin 8 Disconnect brake tube at wheel
from
7 Disconnect toggle lever cylinder by loosening flare nut
I Jack up rear of vehicle just high hand brake rear cable 9 Remove wheel cylinder from
to remove lire and it
enough support brake disc by loosening installation
with safety stands nuts
2 Remove wheel loosen hand brake
10 Remove rubber boot
adjuster
and detach brake drum shim lock plate and adjuster springs
3 Turn pin by 900 and remove
and remove adjuster assembly from
antirattle springs brake disc
4 Open brake shoe assemblies out
ward against return spring and remove
extension link
S Remove return springs
6 Remove brake shoe assemblies
Note that after secondary brake shoe
assembly must be separated from BR316
BR 12
Brake System
Wheel cylinder
Standard dimensions of shoe springs
Remove dust cover and pull out
158 176 18 to 20
Lower 2 3 0 091 30
6 22 6 93 40 to 44
ID
CD l After shoe
83 2
14 0 055 5
27
99 4 to S
345 0 3 276 3 90 9 to II
5
20 12 3 S to 5
4
AntiratUe 1 6 0 063 3 5
1 Dust cover 0 807 47
0 8 to 9 9
BR318
2 Piston head
3 Piston
4 Piston Cll
p
5 Wheel cylinder housing
6 Bleeder cap Wheel cylinder 2 When assembling toggle lever and
7 Bleeder screw
after brake shoe assembly adjust clear
8 Connector I Replace cylinder
any or piston ance between toggle lever and after
9 Washer
which is scratched scored or worn on
10 Connector bolt brake shoe assembly to 0 to 3
0 mOl 0
itssliding contact surface to 0 012 in with a selected
2 properly
Replace worn parts if piston to
Fig BR 22 Rear wheel cylinder toggle pin washer
cylinder clearance is beyond O IS rom
0 00S9 in
19 0S rom Xin
Toggle pin washer
Brake drum
3 Replace piston cup which is worn
Check brake No Thickness rom in
drum in the same
or
damaged
manner as outlined in the Front Brake 4 Replace if contacting face of cyl I 2 0 0 079
Drum
inder and shoe is worn locally or in
2 3
2 0 091
step
Brake assembly 3 2 6 0 102
5 Replace damaged dust cover
I When brake shoe linings are fatigued piston spring or faulty 4 2 9 0 114
threaded parts
cracked incompletely seated uneven S 3 2 0 126
6 Replace tube connector which is
ly worn andlor deteriorated due to
worn on its threaded portion
excessive heating or soiled with oil
grease and brake fluid replace
2 Replace linings if the thickness is
3 Before installing brake shoe as
WOol down to less than 1 0 rom 0 039
semblies apply brake to the
in grease
INSTALLATION following places
1 Brake shoe installing grooves of
Note When brake shoe lining is in Install rear brake in the reverse
adjuster and wheel cylinder
stalled grind brake shoe lining face sequence of removal paying particular 2 Extension link installing grooves
to diameter equal 10 lha I of brake attention to the following instructions 3 Lower surface of spring seat
drom I Rear adjuster assembly is the 4 Contact surfaces between brake
dimemion same as front Refer to the paragraph
Lining disc and brake shoe assembly six
Width x Thickness x Length covering Front Brake Installation
places
4S x 4 5 x 244 rom
Adjuster sliding resistance At this time be sure not to coat
177 x 0 177 x 9 61 in S to 12 II to 261b brake grease to brake linings
kg
BR 13
Brake System
f
Note The Master Vac diaphragm dif Master Vacs are identified by the
fers from fonner ones for improved label color as follows
BR317
4 Tightening torque
Wheel cylinder
S to 1 8 kg
J m
BR321
II to 13ft Ib
11 Valveoperating rod
Connector bolt
12 Valve return spring
1 9 to 5
2 kg m
13 Poppet return spring
14 to 18 ft Ib 1 Plate and seal 6 Seal 14 Exhaust valve
Brake disc
5 4 to 4 kg
6 m INSPECTION OF OPERATION
39 to 46 ft Ib
Checking yscuum pressure
S Adjust brake shoe clearance and
I Connect a vacuum gauge in the Vac as shown in Figure BR 25
bleed brake system Upon completion
of the above line between check valve and Master
adjustments make sure
MASTER VAC
1 Check valve
2 Vacuum gauge
DESCRIPTION
BR 14
Brake System
1 I
I Air leakago at check valve Replace check valve
Inspecting check valve valve does not open replace check check valve Always inspect check
80 1 140
I 17 I
yr I
70 1 000
60 850
I f I I
0
Z I I y1 I
7I
0 50 710
5
BA3 40 570
I I I I I
Fig BR 26 Location of check valve a 30 430
I I I I I
20 280
I y1 II I
2 Using a Master Vac tester
apply a 10 140
I I I I I
vacuum pressure of 200 mmHg 7 87 L
I L
I
inHg to the port of check valve on the 5 to 15 20 25 30 35 40 45 50 55 60
22 44 66 88 110 132
Master Vac side If a pressure drop of
Pedal operating force kg lb BR772
10 mmHg 39
0 inHg is exceeded in
Fig BR 28 Performance curves of Master Vac
BR 15
Brake System
sembly
DISASSEMBLY
serve the following instructions this retainer since this win be the
a Thoroughly clean mud or dust from sure y of damaging it
Master Vac
ponent parts
Be sure to select a clean place
before disassembly Rear shell seal
or assembly
c Mark mating joints so that they off retainer with of screw
Pry use
arranged properly so that they may Do not disassemble seal assem Fig BR 34 Removing air silencer
Note
be assembled at any time retainer
readily unless
bly absolutely necessary
e Clean rubber parts and synthetic
Whenever this is to be removed use
resin 3 Pull out valve plunger stop key
parts in alcohol care not to damage it
f Mter all disassembled parts are and withdraw silencer and plunger
cleaned in a suitable clean solvent assembly
place on a clean work bench Use
care not to allow dirt and dust to Note To valve plunger stop
remove
come into contact with these parts key properly proceed as follows
With key hole facing down lightly
1 Install spacer on rear shell spacer
rW ID
Fig BR 32 Removing retainer
BRD7S
Diaphragm plate
1 Clevis Place
3 Valve body guard diaphragm plate assembly
2 Lock nut BRD7S BA180
on a clean work bench Detach dia
Fig BR 30 Removing rear hell phragm from groove in plate as shown Fig BR 35 Pulling out top key
BR 16
Brake System
ASSEMBLY AND
ADJUSTMENT
1
Assemble in the reverse sequence of
disassembly SR1S6
BA1Bl 2 Install
1 Apply a coating of Master Vac plunger assembly and
Fig BR 36 Remouing ualue operating grease to the sealing surface and lip of silencer in
diaphragm plate and lightly
rod assembly
seal and install that seal in rear shell push plunger stop key in place
with the use of Master Vac Oil Seal
Retainer Drift ST08060000 Note Diaphragm plate is made of
4 Withdraw reaction disc bakelite Exercise care in instaJJing
plunger assembly not to damage
diaphragm plate
BA286
BROB3
contact
2 Withdraw front seal assembly
Final sssembly
INSPECTION
BA1S5
Apply thin coating ofMaster Vac
I Check poppet assembly for condi Fig BR 40 Length at A
grease to the outer edges of diaphragm
tion If it shows evidence of wear or with which rear and front shells come
damage replace it and valve operating into contact before instaIling dia
rod assembly
Diaphragm plate phragm in
position
2 Check other component parts for 2 Before installing push rod assem
condition If any part shows evidence I Apply a thin coating of grease to bly in place apply a coating of
of wear or damage replace it with a the sliding contact portion on the Master Vac grease to the sliding con
new one
periphery of plunger assembly tact surface of diaphragm plate
BR 17
Brake System
in the INSTALLATION
3 Align marks scribed rear Length B
rl 0 8 to I 1 kg m
6 to 8 ft lb
Master Vac to body
J 0 8 to 1 kg
6 to 8 ft Ib
m
at this section
Fig BR 44 Lelllth B
HAND BRAKE
CONTENTS
REMOVAL BR 19 INSTALLATION BR 19
HAND BRAKE
Stick lever type
The hand brake system is of a cable wheel brake shoes All the cable ad only adjusting nut at balance lever
BR 18
Brake System
k 1
BR663
Rear cable
J replace
y
i1
b INSTALLATION
I 1
reverse sequence of removal by closely
l
observing the following instructions
II When installing apply a coating
i of grease to sliding contact surfaces
I BR773
Make Sure that each sliding part func
Fig BR 47 Control stem lions smoothly
BR 19
Brake System
Brake pedal
Free height mOl in 148 S 83
in I to 3 0 04 to 0 12
Free play at pedal pad mOl
in 43 to 49 169 to 193
Depressed height mm
Rear 12
Master cylinder
Inner diameter mm in 19 0S Yo
Master Vac
Uni servo
Type
Wheel cylinder inner diameter mm in I9 0S Yo
Lining 45 x 4 x 244
5
mOl in
Width x Thickness x Length 77
1 x 0 177 x 9 61
in 1 0 0 039
Lining wear limit mm
Duo servo
Type
Wheel cylinder inner diameter mOl in 19 0S Yo
Brake drum
PaJking brake
Stroke mm in 80 to 100 lS
3 to 3 94
S to 12 11 to 26
Adjuster sliding resistance kg lb
BR 20
Brake System
Tightening torque
Master cylinder to Master Vac kg m ft Ib 0 8 to l 6 to 8
N LS V to body kg m ft Ib 0 8 to l 6 to 8
Front ft Ib S 4 to 6 6 39 to 48
kg m
Rear kg m ft Ib 5 to 1 8 II to 13
1
Front kg m ft Ib 4 2 to S O 30 to 36
Rear ft Ib S 4 to 6 4
kg m 39 to 46
Master Vac
Push rod kg ft Ib 1 9 to 4 14
2 to 17
adjusting nut m
BR 21
Brake System
Excessive pedal travel Low brake 1uid level or empty master Fill and bleed as necessary Test for source
Spongy pedal Low 1uid level in master cylinder Top with 1uid and inspect for leakage
Air in system Correct as necessary
Swollen hose due to deterioration or use of Replace hose and bleed system
poor quality hose
Distorted brake shoes or excessively worn Replace faulty parts
or cracked brake drum
Soft swollen
or caliper seals Drain hydraulic system flush with alcohol
and replace all seals
Use of a brake 1uid with too low boiling Replace with specified brake 1uid and bleed
point system
Poor braking effect Fluid leakage in brake lines Check master and wheel
cylinder pIpIng
cylinder for leaks and repair
Low brake 1uid level master Fill and bleed
or empty as necessary
cylinder reservoir
BR 22
Brake System
Brake chatters Groove or out of round brake drum Grind or replace as required
Loose or bent brake disc Tighten support plate bolts to specified
torque or replace plate
as
Distorted brake shoes or pads Replace necessary
Brake squeals Dirty or scored brake drums Blowout assembly with compressed air or
refinish drum
Turn drum
Pedal pulsates Out of round or off center drum or
replace as necessary
Brakes fade Brake fluid has too low boiling point Drain and fill system with approved fluid
Brakes drag Pedal linkage is binding or push rod adjust Lubricate linkage check pedal return spring
ment is too long for condition and adjust push rod as neces
sary
Grease oil mud or water on linings or pads Clean brake mechanism and check for cause
Deterioration of linings or
pads Replace
Excessive wear of linings or pads Replace
BR 23
Brake System
wheel cylinder
Sticking cups Recondition or replace cylinder
Deformation of back plate Replace
Incorrect adjustment of wheel bearings Adjust or replace
Incorrect adjustment of wheel alignment Adjust
Looseness of leaf spring securing U bolts Tighten or replace
Faulty N LS V Replace
Pedal yields under Deteriorated check valve Replace check valve and bleed system
slight pressure Ex ternalleaks Check master cylinder piping and wheel
BR 24
Brake System
For Reference
Tool number
use
No Description page or
1 GG943 10000 This tool is used to tighten and untighten brake tube flared nut All Page BR 8
SE227
This tool is used to remove shell after aligning rear shell stud All Fig BR 3l
2 ST08080000 rear
SE073
ST08060000 This tool is used when rear shell seal is driven into position All Fig BR 39
3
models
Master Vac
Note Make sure that this tool is pushed in until rear guide of this
oil seal
tool touches rear shell
retainer drift
SEll5
BR 25
SECTION WT
CONTENTS
The 620 series models are equipped In order to inspect a leak apply
with 4lV 14 wheels with 25 0 98 soapy solution to tire
mOl tire
or
submerge
in offset All tires are tubeless and wheei in the water after inflating
tireto specified pressure Special in
Tire size spection for leaks should be carried
Model Tire size Wheel size along the tread Exercise care to bead
and rim where leakage occurs Wipe
All models 6 00 I 4
6PR Tubeless 4UJ 14 out water from area which leaks air
Note Tire inflation pressures should underinflation promotes wear at cen Inspect the wheel rim flange for
be measured when tires ter tread or shouider of tire bend or dents
are cold
If aU The flange should be cleaned by a
tires are
inspected frequently
wire brush when rust is found on the
and maintained correct tire pressure it
is possible to detect sharp material in flange Furthermore if excessive
sound minimum
to a resulting in checked be sure to tighten valve caps tires scrape the tread rubber off The
longer tire life that is overinflation or of tread appears feathered edge
firmly by hand wear
WT 2
Wheel and Tire
Shoulder Uneven
Uneven wear is caused by incorrect WH024
The wear may be caused by under
incorrect wheel camber or camber or caster malfunctioning sus
inflation Fig WT 4 Tread wear indicator
pension unbalanced wheel out of
continuous high speed driving on
occurs on both sides of treads wear correct the above faulty parts
wear
I
J CHANGING TIRE
I i
To change tire with wheel using a
d
following procedures
I
rod to
To remove spare tire
guide
insert
I nf I
I
Underinnation wear
t
Uneven
wear
axle gears bearing etc Meanwhile the I nuts before vehicle is jacked up
wheel
of improperly aligned front
xJ r
@ Spare side frame
rear
about S20 mOl
apply
Accordingly tire ing parking brake and blocking rear
to equalize wear
odically
The pare tire should be used
All the tires including the spare tire in an emergency only
t 1 1
@ Spare
wear
J in
indicator
tire circumference
tread
at six places around
depth
indicating
When
1 6 mm
the tires
Left front Left rear place them with new ones See Figure WT012
WT3
Wheel and Tire
paired
The wheel and tire Lateral run Qut limit
assembly be
Less 5mOl
1 0 059
comes out of ba1ance according to tltan il total
uneven tire wear Severe acceleration indicator reading
and braking or fast cornering is the
cause of wear tire in
on resulting
unbalance of tire and wheel assembly
The symptom ofunbalance appears
as tramp vehicle shake and steering
malfunction
WH077
To correct unbalance use proper
Fig WT 7 Jacking up rear side wheel balancer
4
WT
Wheel and Tire
plication
WT 5
SERVICE
SECTION ST
MANUA L 4
STEERING
DATSUN PICK UP SYSTEM
MODEL 620 SERIES
STEERING ST 2
STEERING
CONTENTS
DESCRIPTION The other end of the cross rod is ly and independently steering can be
linked to the idler arm connecting safely maintained
The with the side member located on the Steering wheel rotation is converted
steering gear used on this
opposite side of the steering gear The to gear arm motion in proportion to
model series vehicles is e same re
two side rods serve to connect the the gear ratio by the steering gear The
circulating type This steering gear is
designed especially for easy operation steering gear arm and idler arm to the gear arm motion operates the side rod
both knuckle and left hand on the same side At the same time
and high durability arms right
sides the idler arm is moved through the
The steering linkage is of a relay
arm is
With this construction even if the cross rod and the opposite side rod is
design of which gear connected
left andlor wheel vertical also moved
to one end of the adjustable cross rod right moves
ST528
Fig ST I Structural u w of l
teeriTl tem
sr 2
STEERING SYSTEM
STEERING GEAR
A
p
u
i
I
1
jj
@ @
@l
ST199
shaft
on
i
1
T201
S Remove turn signal switch as arm with the use of Pitman Arm Puller
ST3
STEERING SYSTEM
9 Remove three
bolts securing
rnST203
ST 4
STEERING SYSTEM
8
Available worm bearing adjusting Install sector shaft cover to gear
Inspection and repair
shim housing Be sure to apply sealant to
Wash clean all the disassembled
each face of sector shaft cover packing in solvent and check for condi
parts
No Thickness mOl in when installing cover
tions
an assembly
4 IS00 0 OS91 Fig ST 10 Mea uring backlash 2 Repiace column bushing which is
S 1 475 0 0581 excessive worn or deformed
If sector shaft in gear
6 I 4S0 0 0571 3 bushings
housing are found worn or damaged
14 Turn adjusting screw approxi replace as an assembly of gear housing
mately 1 8 to 1 6 turn clockwise and and bushing
then retighten lock nut to 3 0 to 4 0
Oil seal gasket and
7 Rotate ball nut by hand until it is kg m 22 to 29 ft Ib
O ring
in the center of its trovel then install Fill recommended gear oil ap
IS
sector shaft together with adjusting 33
0 liter X U S pI Do not reuse above parts which are
proximately
screw in gear housing ensuring that X Imper pt gear assembly
into removed once
ST 5
STEERING SYSTEM
1 Cro s rod
2 f
fL 5t6 mm 20 31 in
2 Side rod
3 Cross rod socket Mter adjustment of toe in be sure that dimension A at
4 Idler assembly
arm
both ends of cross rod is not less than 20 nun 0 79 in
5 Gear housing
Fig ST 11 Ball joints Ic ann side
assembly ST210
4 Remove riut securing gear armOD Fig ST 13 Adjusting cross rod assembly
sector shaft and remove gear arm with
the use of Pitman Arm Puller Idler ann
assembly
ST29020001 See Figure ST 6
S Remove idler arm assembly from
frame by backing off fixing bolt and @
nut
1 Idler body
2 Collar welded to
idler body
A 3 Plain bushing
4 Screw bushing
T529
ST 6
SYSTEM
S 42S to 504
S in
2 Before
installing idler arm assem
Idler
bly replace f iller plug with grease See Figure ST 14
arm
3B8embly
nipple and apply recommended grease Furthermore be sure to install Remove old grease and dirt and
to idler ann through this grease nipple washers correctly check idler ann assembly for wear
See Figure ST IS
until grease is forced out at the lower deformation and damage
end of the dust seal lip Remove grease
CrOBS rod side rod and
STERING
arm
gear
Check them for bending damage
and crack and replace as
necessary
I I collision
8 I
L6 comes into collision especially
front of the vehicle is damaged special
the
seen
tion
8 Sector gear breakage
ST 7
STEERING SYSTEM
9 Column shaft breakage on the 10 Deformation of body construc steering system on the body construe
welded section tion and frame tion and frame for deformation or any
In addition inspect column shaft Inspect the installation portion of other faulty conditions
for scratch
SERVICE DATA
Steering arigle
Inner wheel 35030 to 36030
Outer wheel 30030 to 31030
Tightening torque
Unit kg m ft lb
Gear arm
94 to 108
13 to IS
Steering wheel 7 to 7 S SI to S4
Bail studs of cross rod S S to 10 0 40 to 72
ST 8
STEERING SYSTEM
Steering wheel moves Wheel alignment out of specifications or air Align or inflate tires to correct pressure
Steering linkage out of adjustment Adjust and see relative topic under Front
Suspension
Steering wheel turns Wheels out of alignment or air pressure in Repair or inflate tires to correct air pressure
but sluggishly tires too low
Damaged steering linkage Replace and see relative topic under Front
Suspension
ST 9
STEERING SYSTEM
ST27I80001 This tool is used to drive out steering wheel All Fig ST4
Steering wheel models
v
o
J
SE 116
2 ST29020001 This tool is used to remove steering pitman arm from steering 620 Fig 6
ST
Pitman arm
sector shaft B210
puller 710
610
SE401
GG91030000
Torque
D
wrench
I
2 HT62940000
Socket
IJ
t
adaptor 114 3 8 YID
Go
318 1 2
3 HT62900000
Socket
adaptor
SE399
ST 10
SECTION FE
ENGINE
DATSUN PICK UP CONTROL FUEL
MODEL 620 SERIES EXHAUST
SYSTEMS
FUEL SYSTEM FE 4
CONTENTS
DESCRIPTION FE 2 INSPECTION FE 3
DESCRIPTION
The accelerator control system is of operates smoothly and the system is The choke system is automatically
flexible cable type so that the linkage not affected by engine vibration controlled
ul @
i
L
f
4 @ p
I
@ @
CV
j
Arrow B
E 78 mm 3 07 in
T 2 to 4 mm 0 08 to 0 16 in
FE 2
Engine Control Fuel Exhaust Systems
REMOVAL AND E 78 mOl 3 07 in then automatic choke effect will be
INSTALLATION released
Tightening torque 01 nut
3 Set throttle valve to completely
38
0 to 0 4S kg m
Accelerator wire closed position and with wire suf
2 7 to 2 ft b
3
ficiently slackened lighten adjust nut
I Remove air cleaner assembly
until throttle lever is about to move
2 Disconnect accelerator wire from
2 Accelerator pedal play is zero at this
Release auto choke effect since
carburetor lime See FE 2
throttle lever is Figure
3 Loosen lock nut and disconnect opened by fast idle
4 Unscrew
until adjust nut approxi
accelerator wire outer case from wire earn engine warms up
mately two and a half turns so that
holder See Figure FE I accelerator pedal play is 3
I Keep choke valve fully open mOl 0 012
4 Remove spring clamp and discon with in Tighten lock
fingers nut securely See
nect accelerator wire from accelerator 2 Pull throttle lever up by hand Figure FE 2
pedal arm
pedal ann
1 Adjust nut
celerator bracket to body
pedal 2 Lock nut @
3 Remove accelerator from
pedal 3 Accelerator wire
CD
dash See Figure FE I
panel 4 Dust co r
removal
Fig FE72 AdjU6ting accelerator wire play
INSPECTION
I Check accelerator pedal return
fastening locations for rust damage or as previously explained check the purpose grease slightly portion on the
FE 3
Engine Control Fuel Exhaust Systems
FUEL SYSTEM
CONTENTS
DESCRIPTION FE 4 INSPECTION FE 6
REMOVAL FE 5 INSTALLATION FE 6
DESCRIPTION
The fuel tank is4Sliters II Ji s
U The filler shutter is installed to the For the electric fuel pump refer to
gal 9 Ji Imper gal in capacity The filler tube on California models Section EF
tank unit is mounted to the right side The electric fuel pump is adopted
of the rear floor on air conditioner equipped models
1 Fuel tank
2 Drain plug
3 Filler tube
4 RescfYOir tank
5 Filler hose
6 Breather hose
7 Ventilation hose
8 Evaporation hose
9 Fuel outlet hose and tube
10 Fuel tank gauge unit
11 Protector
12 Bracket
13 Retainer
14 Return tube
FE194
4
FE
Engine Control Fuel Exhaust Systems
4
Detail A Detail e
Detail Bn
Detail G
@
Detail E
Detail D
Detail U
Detail F Detail T
FE261
evaporation hose and breather hose connect fuel tubes on each end FE18S
3 Remove reservoir tank securing
bolts and remove tank with protector Note Plug hose and tube openings to Fig FE S Removing fuel filter clamps
FE 5
Engine Control Fuel Exhaust Systems
2 Remove fuel filter Fuel filter is of a cartridge type 4 Install fIller hose after fuel tank
and cannot be cleaned Always replace has been mounted in place Failure to
with follow this caution could result in
INSPECTION a new one
Replace any fuel tube that is crack To install reverse the order of Tightening torque
ed rusted collapsed or deformed removal Observe the following Drain plug
I Install hose Do 5 0 to 6 0
clamps securely kg m
cording to the periodic mainte damaging hoses Fuel tank securing bolt
nance schedule 2 clips holding fuel tube on
Fasten 8 to 1
0 Ikg m
under body securely Failure to follow 6 to 8 ft Ib
4 Fuel filter this caution could result in damage to Reservoir tank securing
Replace fuel filter according to the surface of fuel tube bolt
the periodic maintenance schedule or 3 Do not kink or twist hose and 032 to 0 44 kg m
when it is clogged or restricted tube when they are routed 2 to 3 ft Ib
EXHAUST SYSTEM
CONTENTS
DESCRIPTION FE 6 INSPECTION FE 8
REMOVAL FE 8 INSTAllATION FE 8
DESCRIPTION California
Non models California models
the California models differ in front exhaust tube main muffler front exhaust tube
non a a catalytic conver
specifications from those installed on assembly with rear tube mounting ter assembly a center tube a main
the California models hangers brackets and a heat insulator muffler assembly with rear tube
FE 6
Fuel Exhaust S ys tems
Engine Control
Califomia
Non model
Qf l
tr
Qf tIJ
Si
Si
@
Qf
i I
j
l l
tr
l Qf l
i
Si
r l
t I
1 l
tr
1 Front tube
9r 2
3
Exhaust
Rear
tube clamp
tube assembly
4 Muffler assembly
8
5 Rear tube mounting
1Bi
6 Front tube mounting
California model
6
8
@@
Qf @ fit 0
J
I
1 Front tube
2 Catalytic converter
Center tube
Muffler assembly
Diffuser
I Rear tube mounting
7 Front tube mounting
FE390
Fig FE 6 t
r
E ha system
FE 7
Fuel Exhaust
Engine Control Systems
REMOVAL INSTALLATION
California
Non models Install the exhaust system assembly
ijl in reverse order of removal Observe
I Remove exhaust tube U bolt
the following
clamp
2 Break sealant off at front tube to
Notes
main muffler connectio n
a Insert front tube until it touches
3 Remove rear tube mounting bolt
emboss
and remove muffler assembly with rear
b When there is 110 clearance between
tube
front tube and floor or propeUer
4 Remove front tube heat insulator
shaft turn tube along center line of
5 Remove nuts securing front tube 4 tube the manifold
to exhaust manifold and remove front
in connecting
unit and obtain proper clearance
tube mounting bolts Then detach FE189
c Check all tube connections for ex
front tube
Fig FE 9 Tapping muffler with haust gas leaks and entire system
When disconnecting the exhaust Q rubber hammer for unusual noises with engine
tube connections pay attention to the
running
following point d After installation check that
I Break lse
antold
off at t1e mounting brackets and mounting
connection by lightly tapping around California models rubbers are free from undue stress
the tube witlJ a hammer and twisting
If any of the above parts is not
I Remove all heat insulators
muffler See Figures FE 7 and 8
FE
installed properly excessive noises
2 Remove exhaust tube U bolt
2 Using a rubber hammer tap on or vibrations may be transmitted to
the front end of muffler while pushing clamp the vehicle body
it toward rear The mumer assembly 3 Break sealant off at center tube
can then be taken out See Figure to main muffler connection e Tightening torque
4 Remove rear tube mounting bolt Exhaust manifold to
FE 9
and remove muffler assembly with rear front tube nut
tube 19 to 5 kg
2 m
14 to 18 lb
ft
5 Remove bolts securing catalytic
converter to center tube and remove U bolt securing nut
center tube mounting bolts 19 to 2 1 kg m
14 to 15 ft lb
Then detach center tube
Mounting bracket bolt
6 Remove bolts and nuts securing 1 0 to 1
2kg m
catalytic converter to front tube and
710 9 ft lb
detach catalytic converter
Front tube mounting bracket
7 Remove nuts securing front tube
bolt california models
to exhaust manifold and remove front
19 to 2 1 kg m
tube mounting bolts Then detach
FE187 14 to 15 ft lb
front tube
Fig FE 7 Breaking Bealant Catalytic converter to front
23 to 31 ft Ib
INSPECTION
FEl88 insulator that are cracked fatigued or eliminate gas leakage at the joint Be
8
FE sweated sure to observe the following
Fig Twisting muffler
FE 8
Engine Control Fuel Exhaust Systems
Noles
a The sealant should be used within
term indicated on the kit
guaranty
Fig FE IO Exhaust sealant kit
case
b nlfrnnjj
m
FE1l1
tube at a temperature over 400C
Fig FE 12 Squeezing sealant to
lJ Ij 1040F for a long time
mm
injec tor
J
@L d Thoroughly read the instruction
6 Position nozzle of injector to the sheet furnished with the kit before
FE263
FE191
FE 9
SECTION BF
BO DY FRAME
DATSUN PICK UP
MODEL 620 SERIES
REAR BODY BF 5
HOOD BF 8
DOOR BF 11
WINDSHIELD GLASS BF 16
INSTRUMENT PANEL BF 17
SEAT BF 19
I NISSAN I
On the 620 series models chassis The frame consists of right and left heavy loads The second crossmember
frames classified into three types
are side members which are linked to is located somewhat to the rear to
the standard wheelbase model long gether with crossmembers to form a permit individual replacement of the
wheelbase model and Deluxe Cab rigid structure that can withstand transmissiol
FRAME ALIGNMENT
1 587 5
J 1
r1
I
f
X 62 50
b q JA 1 I
7 Ib
9 9 8 I
1
e
e r
rd r
0
1sol
ij 6
t
00
9ClSCl 1
1
085 42
721
11
1 H
OO
1 I
l i11
175
1 4
069 42 10 1 5 37 11
942
6 89
I 284
1007 39 65
295
18
11 11 61
r r
L r
T c
8
d 8 o
BF025B
SF 2
Body Frame
l1
4 1 873 8
Ir
In
mrn
I
0 IN1
bi
b
I
o
M I f
p
v v M
0
y
r v
t c G
c
D M
IS S 0
t
r
y
M J
0
1 I 10
So
9 raj p
1
085 42
72
VN
1 350
78
Ii
I
I
I
20 63
1 d3 1
U T
r
II
L t J
n
I
e o
C
M
BF0268
o
DELUXE CAB
17 iO P b t
r
1 b c
u
N
tl 0
l
f
0 l
Jr
C y 0
I
M
t
r M 2 V 00 0
0
dJ JSO 0
o
1 00 N It
r
S
1 b t 8Qa 3
OS
o
1 085
42 72 A b U
n
j
I I li4
I
1 069 4 42 10 942 5 37 11 1 007 39 65
284 1
18
11 1161
1 I
bu I
c r
M
I
T
8
o
It
R
M
o
BF027B
BF 3
Body Frame
CAB BODY
2nd mounting
Ist mounting
1 Bolt
2 Plain washer
3 Rubber washer
4 Upper rubber
5 Bottom rubber
6 Plain w er
7 Upper washer
8 Lower washer
BF472A
Unit mm in
1st mounting 2nd mounting 3rd mounting
4
BF
Body Frame
perly
3
4
BF
Adjust
Air
hand
bleed
brake stroke pro
system thorougWy
Cab body to frame mounting
j
1Q
b
bolt torque
crru 8F630
1 6 to 2 2 kg V J
rr1
m
12 to 16 ft Ib
4 n Fig BF 5 Lifting up cab body
REAR BODY
1 Bolster
2 Shim B
3 Bolster
4 Shim A
5 Frame
6 Rubber washer
7 Plain washer
BF664
REAR BODY
REMOVAL AND tank Remove fuel tank from rear 5 Remove eight rear body attaching
INSTALLATION body bolts
BF 5
Body Frame
Notes
a When lifting rear body make sure
C s
i
SF673
6
BF
Body Frame
ZID
@
1 Hood
2 Hood support rod @
3 Hood bumper 7
Fender
4
@
5 Bumper bracket shim
6 Bumper side bracket
7 Bumper
8 Bumper stay
9 Front apron BF029B
10 Radiator grille
Fig BF 11 Body front end
B 632
1 Radiator grille
RADIATOR GRILLE 2 Guide stud
3 Guide stud hole
REMOVAL AND
4 Radiator support lower
INSTAUATION
frame
BF 7
Body Frame
hood screws Pull grille straight forward to 6 Remove nine screws attaching
I Open engine
windshield remove front fender to hood ledge See Figure
2 Remove two wiper
4 Remove air box drain BF ll
blad
above 7 To install reverse above steps
Remove cowl top 5 To install reverse steps
3 grille attaching
HOOD
HOOD
5
REMOVAL AND
INSTALLATION
1 Place protective covers over front
fender and cowl top grille
2 Open engine hood Mark hinge 1 Female lever
3 Return spring
bolts securing hood to hood hinge Use
4 Dovetail bolt
caution avoid
extra to damaging S Lock nut
painted surfaces of fender and cowl 6 Hood lock pring
top grille J 7 Spring
3 Remove engine hood
BF641A
4 To install reverse above pro
Fig BF 14 Hood lock male and female
cedures
ADJUSTMENT
Loosen hood to hinge bolts just
Four slotted holes in hood hinge
far enough to permit movement of
provide for fore aft and side adjust
hood
ment to correct space between hood
and fender
grille
and hood and cowl top
2 Shift hood in elongated hole until
BF 8
Body Frame
carried out after hood lock male holding dove tail bolt with a screw
3
completed
1 9 to 2 6
14 to 19 ft lb
kg m
dove tail bolt and turn dove tail bolt in 2 Hood lock male 3 Safety catch
JI
I
I
lPP J
jJ
i J
r
J
Sr 1
2
Dove tail bolt seat
Lock nut
I
aj I
I
J
3 Cushion rubber
f ifryI
ff U ii1iiilliiijiWI 4 Spring
r 5 Spring retainer
f
j 7 7
8
Clamp
Clamp
9 Hood lock female
JJ BF644A
8F 9
Body Frame
rusting
I Remove hood lock male by re
2 Check female lever and return
moving two attaching bolts
spring for deformation fatigue or rust
2 To remove hood lock female first
ing Improper operation of female
remove radiator grille Back off two
lever may cause disengagement be
bolts securing hood lock female in tween female lever and dove tail bolt
position Hood lock female can now 3 Make that
sure safety catch
be taken out @ hooks engine hood properly when
3 Remove two bolts attaching hood BF645A
hood latch has been disengaged
lock handle assembly to dash side 1 Hood tock handle 3 Clamp
2 Hood lock handle 4 Hole
paneL
bracket 5 Attaching bolt
0l
Disconnect cable at hood lock
female and remove cable clamps Pull Fig BF 19 1MtalIing hood lock handle
cable out into cab brocket
I
ADJUSTMENT AND BF409A
11 mm nun
they are properly aligned INSPECTION 433
0 in
5 To 0 3t5 in
install hood lock handle as
I If hood lock handle is heavy turn
sembly reverse steps observing the Fig BF 20 Safety catch lever to
dove tail bolt of hood lock male coun radiator upper support
following notes
terclockwise to reduce tension of hood acVu5tment
I Check to be certain that cable
lock spring
clamps are tight and secure
Lubrication
2 Install hood lock handle bracket Lock nut of dove tail bolt should
See Figure BF 19 If looseness is noticed hood is not hood lock lubricate the pivot catcher
tight and will vibrate To correct this and return spring of secondary latch
BF 10
Body Frame
DOOR
CONTENTS
CD
CV
CID @
@
@
1 Door sash
2 Window outside weatherstrip
3 Wmdow inside weatherstrip
4 Door weatherstrip
5 Rear glass run rubber
6 Door finish holder
7 Rear lower sash
8 Seal screen
BF030B
BF 11
Body Frame
@
CD
I
r 1
@ 1 Door sash
15
@ Glazing rubber
16 Door glass bottom channel
@ 11 Lower support
18 Upper support
19 Door ventilator assembly
BF031B
@
Fig BF 22 Door with ntilator window Optional
option opening
Fig BF 23 Supporting door To door
The weatherstrip is inserted into adjust alignment loosen
the groove on the door sash side and is bolts and move door to desired posi
lion to obtain a
attached by clips the door side 2 parallel space between
on Separate lower door hinge hole
door sides and door opening Also
cover from dash side trim
3 check to be certain that weatherstrip
While supporting door as above
DOOR back off
contacts body opening evenly to pre
body to upper and lower
vent
REMOVAL AND hinge attaching bolts accessible from entry ofmud and water
INSTALLATION inside cab three each Door can now
I
INSTALLATION
and jack or stand to avoid damaging lf
p1JJ
W 1 Remove securing inside
1
screw
i cutcheon
2 Remove screws which hold pull
handle and arm rest in position Pull
Sl
handle and arm rest can then be taken
j out
3 Pull off regulator
retaining spring
Fig BF 24 Removing door hinge handle Take out regulator handle and
bolt seat washer
8F 12
Body Frame
1
lator window remove ventilator
window frame and rear lower door
Seat washer
sash
Regulator handle
3 9 To install removal pro
BF640 Retaining spring reverse
I
important that inside door panel and 2 adhesive glass
Adhesive Apply to run
f
a re
pry
taining clips exercising care not to should be taken at corners and contact
face to assure
damage clips f a good fit
nil
Section A A Ii
ir coil
IIIII I CD
J
A
JJ
A
iif lUJJ
BF641
J
I I
a
ldI
I L Fig BF 27 Adhesive for seal screen
d
Spring
glass run ru bber
BF 13
Body Frame
CD
j
fffi I BF035
ADJUSTMENT
Fig BF 30 Door gl and regulator
I In and out and fore and aft ad
L Open door lower glass all the to the bottom of door bly raises and lowers depends on ad
way Remove ventilator frame attaching justment of rear lower sash Rear
2 Remove iflllide door handle es
bolts and lift frame straight up out of lower sash should be parallel with
cutcheon door Remove door glass by lifting it front lower sash
3 Remove pull handle is deter
straight up 2 Fore and aft adjustment
4 Remove arm rest
11 Back off the five guide channel mined by position of guide channel
5 Remove regulator handle base and front lower sash Moving front
toregulator attaching screws
6 Remove door finish
Take out regulator assembly through lower sash backward reduces play in
7 Peel off water seal screen
window
large access hole in inside door panel assembly
8 Work off outer and inner weath
erstrips from door being sure not to
scratch door paint during operation
suitable screwdriver
DOOR LOCK
Use a plain or
CID
@
1 Outet weatherstrip
BF643
2 Screwdriver
3 Piece of rag
BF 14
Body Frame
attaching screws
G I0924B or
equivalent as listed
below Fig BF 34 Door weatheratrip
BF 15
Body Frame
WINDSHIELD GLASS
5 Working from inside vehicle push 3 With aid of a helper press wind
WINDSHIELD GLASS
windshield glass out of body opening shield assembly against body opening
by hand starting at right and left from outside being sure weatherstrip
DESCRIPTION toward lip aligns ith body opening flange
upper COIners and working out
is retained in ends 4 Slowly pull cord ends from inside
The windshield glass
the 6 After removing weatherstrip from to overlap weatherstrip channel on
the body glass opening through
weatherstrip There are twelve water top and sides of body opening lift body opening flange starting at center
drain holes one on each side of the glass up sufficiently to permit removal top and working out toward ends This
bottom of the glass opening and ten of weatherstrip from bottom flange operation should be done while one
along the length of the weatherstrip pry weatherstrip out of position man pushes glass against body opening
signs of deterioration
2 Clean body openings noting if
1 Weatherstrip these are distorted or corroded
BF473A
2 Windshield glass
3 Water drain hole
INSTALLATION
Fig BF 35 Windshield glass and
L Fit
weatherstrip weatherstrip on glass making Fig BF 39 Fitting weatherstrip top
it is
sure properly seated and posi
REMOVAL tioned Adhesive need not be applied
0
3 Remove windshield mouldings if
so equipped
4 Using a putty knife or similar
BF650
flat bladed tool pry lips of weather
BF641 Fig BF 40 Fitting weatherstrip
strip out of place from top and side
Fig BF 37 Fitting weatherstrip on bottom
flanges of body opening
If glass
weatherstrip is to be reused it is
important that it not be damaged 2 Insert a draw cord completely
during this operation 5 Install windshield moldings on
around weatherstrip outer channel
weatherstrip if so equipped
6 Install inside rearview mirror and
sun visor
i
I
BF 16
Body Frame
INSTRUMENT PANEL
1 5
nesses
Disconnect relative
nectors
panel
2 Nut
BF646A 3 Instrument panel assembly
I Package tray
Fig BF 41 Instrument panel assembly
2 Side ventilator knob
8F 17
Body Frame
HEADLINING
DESCRIPTION
The headlining assembly is of a by listing wires The design is quite 2 Install listing wires in place on
roof rail
suspension type which is held in place similar to that used in a car
passenger
3 First attach front headlining to
properly place
in
6 A lamp
7 8 Install body side welts
8 9 Install windshield
BF648A glass
9
10 Install back window glass
11 Install assist rail sun visor and
Fig BF 43 Headlining
inside rearview mirror
view mirror CD
DELUXE CAB
2
screws
Remove three
and detach
sun
sun
visor attaching
visor J I REMOVAL AND
3 Remove two assist rail attaching I INSTALLATION
and detach assist rail I
CID
screws
1
Headlining cloth 4 Door glass I Move floor carpet aside
5 Open doors and remove body side 2 Clip 5 Back window glass Remove four bolts attaching back
welts on each side 2
3 Garnish
trim to floor
6 Remove windshield glass and
Fig BF 44 Removing gami8h
3 Remove five trim clips and detach
weatherstrip
7 Remove back window and weath back trim
9 Detach all cemented edges of 4 Installation is the reverse order of
erstrip headlining from flanged portion of
8 Remove the end removal
garnish securing roof rail
of headlining to rear pillar 10 Disengage listing wires from roof
Back Inside finisher
rail and detach headlining
I Remove seat belt retractor
INSTALLATION 2 Remove five trim clips and detach
I Apply adhesive cement to the back inside fmisher
outer surface of and 3 Installation is the reverse order of
flange headlining
attaching surface evenly removal
8F 18
Body Frame
center console
2 Remove two bolts from the rear
2
and remove center console
CONSOLE WITH
ARMREST
3
Back trim
Back inside imisher
Clip
1 DELUXE CAB
REMOVAL AND
INSTALLATION
removal
CENTER CONSOLE
REMOVAL AND
INSTALLATION
SEAT
DESCRIPTION
models JJ
CAUTION t qJ
In conforming with M Y s
S No
302 be sure to remove the thin 1 Seat assembly
8F 19
Body Frame
slide assembly to floor take out seat moval procedure consisting essentiaily a lap shoulder of
the vehicle
1 Head re5traint
The inner lap belt has a buckle The
2 Seat assembly
3 Reclining device buckle of the driver s seat belt includes
4 Seat slide outer a switch which functions as a seat belt
5 eat slide inner
warning device
J
CAlJI10NS
a In conformity with M V S S No
302 be sure to remove the thin
assembly
REMOVAL AND
INSTAUATION
bly
1 Inner belt 6 Installation is the reverse order of
2 Tongue stopper removal
3 Emergency locking retractor
4 Outer anchor plate Tightening torque
5 shoulder
Lap belt Anchor bolts
6 Shoulder through anchor BF036B
2 5 to 3 0 kg m
BF 20
Body Frame
assembly if necessary
BF650A
8F 21
SECTION BE
BODY
DATSUN PICK UP ELECTRICAL
MODEL 620 SERIES SYSTEM
ELECTRICAL ACCESSORIES BE 21
Each connection is
FUSE AND
2 firmly in place
and free from rust and dirt FUSIBLE LINK
3 No cable covering shows any DESCRIPTION
evidence of cracks deterioration or
other damage The fuse and fusible link are protec Fusible link
4 Each terminal is at a safe distance tive devices used in an electrical cir
away from any adjacent metal parts cuit When current increases beyond Fusible link protects lighting
5 Each cable is fastened rated amperage fusible metal melts charging and cir
to its starting accessory
BE 2
Body Electrical System
continuity test This continuity test carefully check and eliminate cause
CONTENTS
DESCRIPTION BE 4 INSPECTION BE 9
LIGHTING ILLUMINATION LAMP BE 10
SYSTEM CIRCUIT DIAGRAM BE 4 KN08
BE 3
Body Electrical System
DESCRIPTION
LIGHTING SYSTEM CI RCUIT DIAGRAM
G
jSTOPBrURH
I STOP 8 TURN
HEAOLAMP R H l TAIL
LIGHTING
SWITCH
TAIL
ll
lJ f
o 1121 BSAOC
REAR COMBINATION
UP
CR H
LllHTINIi A
r
1 I x
LAMP R H
nn
j iNAnON 8A
DIMMER
SWITCH
1
r
I J
LICE NSf
LAMP
101 ON
I
LAMP
USl LE
0
LINK I
t
lOA
CJ I3 BACIC UP
LIU
CIl
@ CJ
CJ
154
CJ
TA
ST
L
OP8TURN
TAIL
FUSE BLOCK
STOP8TURN
HEADl AMP LH
REAR COMBINATION
LAMP ILH
METE
i
EA
e LAMP ILLUMINATION
LAMP
I
Q REAR SIDE
n
I 2 IR fMP NAR
IL H l tAMP
BEBSOA
Turn signal hazard warning lamp stop lamp and back up lamp system
REAR COMBINATION
LAMP R H
BATTERY
BACK UP LAMP
SWITCH n TA I L
8ACK UP
@ 4j
Jl
P
W
FRONT
COM8IfUl1ON
E
FUSIBLE
LAMP H LINK HAZARO
FLASHER
UNIT
ON
I a 2
3
HAIARD
WA NING
SWITCH
@
FRONT
COMBINATION
h
FUSE BLOCK
FUSE
FROM IGNITION
SWITCH
r
TU N SIGNAL
FLASHER UNIT
G BACK UP
JTA
LAMP L H STOP8TURN
t CJ TAIL
J
H
EL STOP 8 TURN
LH I U t
N
I
REAR COMelNATlON
LAMP IL H
I
iH ij
TURN SIGNAL
INDICATOR
LAMP
STOP
BE851A
Fig BE 4 Turn signal Juuard warning lamp stop lamp and back up lamp system
4
BE
Body Electrical System
FUSE BLOC K
ENGINE
1 100 I 2 I
ROOM LAMP
J QA
C
I t1
J CJ
C
I 0
I
CJ CJ Wf fi
t HOOD
1
SWITCt
f
FUSIBLE
ROOM LAMP
LINK
6
t I I 1 lA
II C
o
BATTERY FUSE
I I I c
I
DOOR SWITCH LH l DOOR SWITCHIR H l
BE852A
AIMING ADJUSTMENT
if
ii i tooi
HEADLAMP BEAM
Note Do not disturb aiming adjust
REPLACEMENT
I Remove radiator grille retaining
screws
1
J i 4
Y nnn
and radiator 3
I
4
Horiz tal adjustment
screws remove grille Remove retaining ring by rotating
2
ring
Loosen three
screws
headlamp retaining
It may be unnecessary to
it clockwise
4 Remove headlamp beam from
l BE30l
remove screws mounting ring and disconnect wiring Fig BE 7 Aiming adjustment
8E 5
Body Electrical System
G
L
wt
hi i
H iiI
10 m 32 8 ft
10 m
02 8 n
W2
d
20
I
h2
H2
02
I
10 m 32 8 ft
I
f
HI WI 01 hI H2 W2 O2 h2 d
mm mm mm mm mm mm mm
0
CO
in in in in in in in
I 392 349
All models
28 15 30 71 51
5 I 28 15 11 45 67 12018 is 43 13 74
BE302
BE 6
Body Electrical System
FRONT
COMBINATION LAMP
BULB REPLACEMENT
REMOVAL AND
INSTALLATION
1 Screw
To remove lamp body disconnect
2 Lens
wiring at connector and remove wire
3 Bulb
REMOVAL AND 2
INSTALLATION
5 Lens
and rim and withdraw lamp body from
6 Screw
vehicle
BE699B
Install new lamp assembly in the
Fig BE IO Side marker lamp
reverse sequence of removal
BE 7
Body Electrical System
REMOVAL AND
ROOM LAMP
INSTALLATION
BULB REPLACEMENT
I Disconnect wiring assembly at
cormector
new one
J Install in the
5 new lamp assembly
reverse sequence of removal
CD
1 Lens
2 Bulb
3 Lamp body O lux Cab
4 Screw
8E700B
LICENSE LAMP
Fig HE ll Room lamp
BULB REPLACEMENT
Remove lens from lamp housing housing from roof rail and disconnect
Install in the
from socket new lamp assembly
3 Push new bulb into socket reverse sequence ofremoval
4 Install lens
REMOVAL AND
INSTALLATION
To remove lamp assembly discon REAR
J
i
nect battery ground cable remove two COMBINATION LAMP
retaining screws with lens removed
from lamp housing dismount lamp BULB REPLACEMENT
1 Screw
2 Bracket
3 Lens
4 Bulb BE702B
new one
1 Screw
2 3 Install lens
Lens
3 Bulb
4 Rim
5
Lamp body REMOVAL AND
I NSTALlATI ON
@ BE70tB
retaining screws
8E 8
Body Electrical System
SWITCH
I
I P T10N
TERMINAL
2
F
ICI
I I
2
6 terminal
I 4
I I b
1
I 3
Screw
2
3
Bracket
Bulb
I 6
BE 7038
Engine compartment lamp switch ILLUMINATION tion lamps of the combination meter
can be replaced by disconnecting lead
heater
wire at connector and switch CONTROL RHEOSTAT control wiper and lighting
pulling
switch knob it is a variable resistor
assembly out of its bracket To install
This illumination control rheostat and its value be controlled
switch assembly to bracket clean dirt
can by a
controls the brightness of the iliumina knob
dust and rust from the opening groove
of bracket and press down on switch
head until it fits in with bracket
LIGHTING SWITCH 0@
REMOVAL AND BE 7048
escutcheon and spacer 2 Remove ring nut retaining switch meter When switch is in the OFF
4 Reach up from underneath instru to instrument panel position continuity must not exist In
ment panel disconnect lighting switch 3 Disconnect lead wires for switch the ON position resistance between
BE 9
Body Electrical System
The illumination lamp is located on 3 Disconnect multiple connector lead wire to instrument harness wiring
the illumination control rheostat and lead wire from instrument harness 10 Clip wiring assembly at lower
This lamp illuminates the knob of wiring instrument panel
the light through their tubes with the jacket and remove switch assembly INSPECTION
inner reflective walJ 6 Position switch assembly to steer
ing column jacket Make sure that a Test continuity through lighting
location tab or screw fits in with switch by using test lamp or ohm
3 terminal
4 terminal
7 terminal Dimmer
CID
1 Bulb socket
2 Screw
3 Lamp body 8E705B
BULB REPLACEMENT
Ll r vt
I
I Reach up from under the instru
ment panel and pull out socket with
I 4JN l
ER L
PlOSITlON RI
j LASH n I I
bulb from lamp body 12 STOP 9 91
2 Pick up bulb and install a new I JFRe I I II
one L I III 11
3 Installation is in the R I II 161
I
reverse se
I 61616
quence of removal
BE706B
2 Disconnect lead wires for REMOVAL AND closed with plunger projected
illumination lamp at connector INSTALLATION
3 Remove screw retaining lamp
Stop lamp switch is mounted at the DOOR SWITCH
body to instrument panel Lamp body
bottom of pedal and steering post
can then be taken out easily Door switch is installed on both
bracket
4 Installation is in the reverse se
H and R H front door pillars
L
quence of removal I Disconnect battery ground cable
2 Disconnect lead wires at coonee
INSPECTION
I Remove steering wheel tor
Refer to the related section When plunger is pressed into switch 4 Installation is in the reverse se
8El0
Body Electrical System
2 Remove shell covers
INSPECTION Upper FLASHER UNIT
3 Remove two screws attaching
Test continuity through door switch to lower shell cover and remove There are two flasher units One is
switch by using test lamp or ohm switch for turn signal and the other for
meter 4 Install hazard switch in the re hazard
When plunger is pressed into switch verse sequence of removal They are located at both sides of
door switch contacts
assembly are instrument panel near steering column
Contacts closed when
open are
They can be distinguished from each
plunger is projected other by their shape
meter
1 Disconnect multiple connector
SWITCH
I
POSITION
TERMINAL
OFF ON
I
I 2
li ill
I 5
1 Hazard flasher unit
I 8
7 terminal
I 7
I
REPLACEMENT
To flasher unit
bottom of unit
4 terminal
3 Remove screw retaining flasher
5 terminal
unit
BE308
6 terminal 4 Installation is in the reverse se
BE 11
Body Electrical System
BULB SPECIFICATIONS
Bulb
Item
Wattage SAE trade number
Candlepower
Inner 5W
37 4001
Headlamp 5 S0W
37 4002
Outer
A B C 8W 4C 67
Stop lamp
Back up lamp D D 23W 32C 1073
5W
Room lamp
HEADLAMP
Faulty light relay Check light relay for proper operation and
replace if necessary
No ground Clean and tighten ground terminal
High beam cannot Faulty dimmer switch Conduct continuity test and replace if neces
beam or vice versa Check light relay for proper operation and
Faulty light relay
replace if necessary
BE12
Body Electrical System
Headiamps dim Partly discharged or faulty battery Measure specific gravity of electrolyte and
recharge orreplace battery if necessary
sary
with
Flashing cycle is Bulbs having wattage other than specified Replace specified one
wa ttage is used
Correct and
Both right and left Burnt fuse cause replace
lamps do not light Conduct continuity test and replace if neces
Inoperative stop lamp switch
sary
Falllty back up lamp switch Conduct continuity test and replace if neces
sary
BE13
Body Electrical System
CONTENTS
COMBINATION METER
Meter illumination lamps
COMBINATION METER
Turn signal M T only
CIRCUIT DIAGRAM
indicator lamp
L H
9 9 Turn sq nal
indicator lamp
lL J R H
Tj
iJ
O
l
rl8 i
o
I
I
g
J Voltage
regulator
OIL CHG
TEMP
0
BEAM
FUEL
0
C
BRK Q Speed
switch
BE856A
I Speedometer
2 Thermometer
3 Fuel meter
4 Tachometer Option
5 Cluster lid
6 Speedometer cable
7 Speed switch amplifier
Manual transmission only
BE6828
Fig BE 21 Cuit
Ci1 diagram of combination meter
BE 14
Body Electrical System
IGNITION SWITCH
1 lOA
0 I
BATTERY
r
FUSIBLE
Jon
LINK g lOA r 0 HAZARD
KG FLASHER
G 0 I 15A t
r j UNIT
15A i Z
a J
L
l
J
J
I IIl
Z2 ll Z ll Z
LlJ
lIa LlJ
I
LlJ J a J a
IZ J
I I
I I
Z 1 1
az Z
J
z a
i 5a 00
Zza
7
HAZAR D
g LlJ
z
u
a a LlJLlJ
ll ll a a SWITCH
o a I
ll I aa
I 04LlJ I OFF ONI
l1
B FUEL TANK J
o l I I
S 02 I 2 I
M u3
I 3 I
D
14
ii
LIGHT
RELAY I 5 61
6
i2i 16 9 I
mm
76 I
S FROM
J
AMP FLASHER
e UNIT
l1 l1
J
J
CJ
00
TURN SIGNAL
LlJLlJ
z z
SWITCH
I L RI
B COO CUT
n lFLA I
SOLENOID
i IR R I
OIL IR L I
PRESSURE
SWITCH f IF
IF
R
L u
u I
I
THERMAL a VOLTAGE HAND FROM L1GHT
TRANSMITTER
REGULATOR BRAKE RELAY DIMMER
I SWITCH SWITCH
J IOFF
TO LIGHT
RELAY
TERMINAL
l
B 21
I
I
I X X
LIGHT
SWITCH
BEB57 A
BE 15
Body Electrical System
REMOVAL AND 2 Remove meter front cover and The water temperature gauge con
INSTALLATION shadow plate by removing clips and sists of a gauge and thermal transmit
ter assembly to lower panel of instru ture gauge are provided with a bi metal
ment arm and heater coil When the ignition
4 Withdraw cluster lid slightly For switch is set to ON current flows to
ccess to switches knobs etc follow the heat coil and the heat coil is
the procedures given in each section ODOMETER SWITCH heated With this heat the bi metal
5 From behind combination meter is bent and thus the
arm pointer
disconnect cable REMOVAL AND connected to the bi metal arm is oper
speedometer at
speedometer head and multiple con INSTALLATION ated The characteristics of both
nector instrume nt wire assembly
I Remove speedometer as outlined gauges are the same
from printed circuit under A tolerance may occur on the water
Speedometer
6 On vehicle with clock disconnect temperature gauge or fuel gauge due to
2 Remove odometer retaining
wires at each connection on meter source voltage fluctuation The voltage
screws
printed circuit
3 Install odometer in the reverse regulator is used to supply a constant
7 Remove four screws retaining that the water
sequence of removal
voltage so temperature
me ter assembly to cluster lid gauge and fuel gauge operate correctly
8 Remov combination meter The operating part of the
as regulator
sembly consists of a bi metal arm and a heater
sembly Follow the procedures under installed on the float base and thus sembly and remove meter
Removal and Installation in Combina controls current to the fuel 4 Install meter in the reverse se
flowing
tion Meter
gauge quence of removal
BE16
Body Electrical System
Fuse M OIL PRESSURE SWITCH
Meter voltage regulator
YR
To replace oil pressure switch dis
connect lead wire from switch termi
lffi
r@
Water temperature gauge
YW l nal and unscrew switch from engine
Ignition B f cylinder block
switch
Prior to installing switch to cylinder
1 Y Fuel gauge
block be sure to apply conductive
sealer to threads of new switch
Fusible
I link
YW
Thermal transmitter
t L Fuel tank
BE261
IGNITION
jt ignition switch to the warning lamp
and grounds through the regulator
SWITCH Oil PRESSURE
BE 27 1 When the engine is
WARNING LAhlP Fig
started and the generator comes into
YB YB
tl
BATTERY
N increases the solenoid is more
energized and the pilot lamp relay
contacts are open in effect it oreaks
Fuse box
i
J other
ft
t
To other
UTO
A A
warrung
hr
warning
r
L ignition lamps
J
To ignition
coil WR
IQlamps r Glj fCOil
i
WR Charge
tI j
Charge warning lamp
Warning lamp relay
warning lamp
f
T
J
T
I
War
I
lamp relay
I BE264
Generator
Generator v bt Voltage regulator Fig BE 27 2
ge
it e
g Fig BE 27 1
Circuit ofcharge warning system
BE17
Body Electrical System
Ignition 5 tch
I Item
SAE Trade
Bulb No
Wattage
Candle power
W e
1 lamp 161 17 I
From battery
1 Oil pressure warning lamp 161 I 7 I
in
crease driving speed
Inoperative speedometer Replace
8El8
Body Electrical System
Inaccurate odometer Improperly meshed second and third gear Replace speedometer
worn gears
operation
Faulty feeding due to deformed odometer Replace speedometer
and pinion carrier
fuse
Both water temperature Burnt fuse Correct cause and replace
gauge and fuel gauge Replace water temperature gauge
Inoperative gauge voltage regulator
do not operate
Water temperature
gauge
loose terminal thermal transmitter or correct
Water temperature Faulty thermal transmitter or Replace
gauge does not connection terminal connection
thermal transmitter yellow white
operate When
wire is grounded gauge pointer fluctuates
BE 19
Body Electrical System
Probable cause
Corrective action
Condition
Fuel gauge
unit loose unit terminal Replace tank unit or correct terminal con
Fuel gauge does not Faulty tank or
connection nection
operate
indicates half level when a 35U
pointer a
Open circuit
lamp
Inoperative oil pressure switch or loose Replace switch OJ correct terminal connee
Lamp does not light
switch terminal connection tion
when ignition switch is
Open circuit
Lack of engine oil Check oil level and add oil as required
Lamp does not go out
while engine is being Oil pressure too low Inspect engine oil pressure system
operated
Inoperative oil pressure switch Replace oil pressure switch
when ignition switch is Warning lamp does not light when voltage
set to ON regulator white red wire is grounded
Open circuit
Lamp does not go out Faulty charging system Inspect charging system
when engine is started
BE 20
Body Electrical System
ELECTRICAL ACCESSORIES
CONTENTS
BE 21 HEATER CORE 8E 29
HORN
BE 29
DESCRIPTION BE 21 FAN MOTOR
BE 29
REMOVAL AND INSTALLATION BE 21 CONTROL ASSEMBLY
8E n 8E 29
IGNITION SWITCH ADJUSTMENT
BE 22 SPECIFICATIONS BE 30
REMOVAL AND INSTALLATION
BE 22 TACHOMETER BE 30
INSPECTION
BE 30
AND WASHER BE 23 REPLACEMENT
WINDSHIELD WIPER
BE 23 8UL8 REPLACEMENT 30
8E
REMOVAL AND INSTALLATION
8E 31
BE 23 SEAT 8ELT WARNING SYSTEM
INSPECTION
BE 31
BE 25 DESCRIPTION
RADIO
AND INSTALLATION BE 31
REMOVAL AND INSTALLATION BE 25 REMOVAL
LAMP BULB REPLACEMENT 8E 31
BE 25 WARNING
ADJUSTMENT
8E 31
BE 25 INSPECTION
CLOCK
REMOVAL BE 25 TROUBLE DIAGNOSES AND
BE 33
I NST ALLATION BE 26 CORRECTIONS
HORN 8E 33
HEATER BE 26
8E 34
DESCRIPTION BE 26 WINDSHIELD WIPER AND WASHER
BE 35
AIRFLOW BE 28 RADIO
HEATER UNIT ASSEMBLY BE 29
supplied through the solenoid and allows the current to flow to the horn quence of removal
Horn relay
Qi
Fu
2 Disconnect horn relay wire con
sequence of removal
HIBQ
I
J
t
JJI
Qm L J
Hornrelay
BE859A
BE 21
Body Electrical System
1 Voltage regulator
2 Horn relay
3 Headlamp relay
4 Ignition relay California only
5 choke
Auto heater relay
6 Compressor relay
Au conditioner equipped model
7 Floor sensor relay California only
8 Inhibitor relay Automatic
tran5mission only
BE683B
Fig BE 30
BE861A
IGNITION SWITCH
REMOVAL AND
INSTALLATION
4 Disconnect wiring
from the back of ignition
connector
switch
ST terminal
A terminal F
F
C
C 1
B terminal B o
5 Replace ignition switch with a
IG
j
new one
ST
6 Connect ignition switch to wiring
connector A u u I
7 Position ignition switch to shell R
I
cover opening install and tighten BE6848
escutcheon and secure ignition switch
Fig BE 32 Ignition witch
to shell cover
8E 22
Body Electrical System
Washer pump
WINDSHIELD WIPER AND WASHER
The washer pump and washer fluid
REMOVAL AND INSTALLATION
tank are integral parts and are serviced
as an assembly
operation
I Be sure to use only washing solu
tion
Never mix or
use powder soap
detergent with solution
1 Windshield wiper blade 2 Do notoperate windshield washer
2 Windihield wiper arm
3
continuously more than 30 seconds or
Wiper motor
without washer fluid This often
4 Wiper motor bracket
5 Connecting rod causes improper windshield washer
6 Pivot
operation Normally windshield wash
should be 10 seconds
BE685B er operated or
connecting rod to wiper motor arm and pull out wiper motor forward Washer nozzele
5 Remove wiper motor linkage as 5 Install in the reverse
wiper motor
Access for washer nozzle removal is
sembly sequence of removal
obtained by disconnecting vinyl tube
6 Install wiper motor linkage in the
and removing washer nozzle retaining
reverse sequence of removal
screw from cowl top
When washer nozzle is installed or
450 450
72 1772
r l
j217
Fig BE 36
BE 34 270
Ii 1 00 Li
L
1 3 94
L J
Fig Removing wiper linkage Wiper and washer switch to 63
1
7 Install wiper arm and blade Press in switch knob turn it
1
assembly in correct sweeping angle counterclockwise and pull it out of
Unit in
See Figure BE 35 for correct installing switch
nun
BE863A
JCI r
ment panel
multiple connector
disconnect wiper switch
remove I
Wiper motor
BE 23
Body Electrical System
plug
3 To check wiper low speed opera
Blue white
tion connect L terminal to ground
with ground cable or connect L termi
nal in the in 3
same manner as step
make sure that wipers sweep fast
5 During low speed operation con H tenninal
nect E terminal to ground and conlect
o @
P and L terminals with lead wire as
position C
specified
6 Wiper is in good condition if BE864A
rt Battery
Cl e Ignition witch
Continuity test
Remove wiper switch from vehicle
as outlined in Wiper Switch
WQ5hcr motor Test continuity through wiper
Fuse box
I switch by using test lamp or ohm
O
Y meter
Dj
Wiper motor switch
Wiper
LR B terminal
y P tenninal
1
21
I L L terminal
b I
191 1
E terminal
w rmjrW
r II
H t
I r
J BE865A
I SlOIT01 POSIl10N I
TERMINAL
I OFF 2
I 1 2
b
4 5
Switch position
ii
2 I
Z
I
Z I
I
I
I
10 I
I
I m
3 2
BE686B
Fig 40
BE Wi r witch
8E 24
Body Electrical System
Removal
Pull radio knobs offradio control
shafts
wires
5
panel
power lead
Remove radio
and speaker
from
lead
instrument
t BEB67 A
ADJUSTMENT
Antenna trimmer
on dial
Noise may be generated but dis
regard it
Fig BE 41 Radio
Installation Installation
m
Fr behind instrument panel Remove rubber plugs that cover
position radio to instrument panel antenna mounting opening in front
2 Install radio bezel to the front of pillar when installing radio antenna
on vehicle that is not equipped with
radio
SE133
3 Install washers and nuts on radio radio
control shafts and them 2 Thread mounting stud of antenna Fig BE 43 Adjwting antenna trimmer
tighten secure
BE 25
Body Electrical System
INSTALLATION
panel
cable
4 Connect battery ground
Fig BE 44 Clock
HEATER
DESCRIPTION
7 Ventilator knob
1 Defroster nozzle L U
8 Heater core
2 Deflortcr duct LR
Heater 9 Conuol cable clip
3 control
4 10 Heater cock
Resistor
11 Defroster duct R H
5 Heater motor
12 Defroster nozzle R H
6 Heater case BE687B
BE 26
Body Electrical System
Operation of the heater is control the heater unit and the other for the cock opens in proportion to the lever
led by two control levers located on operation of the fan motor When the setting and allow engine coolant to
the instrument panel and a hand op lever is in the OFF position the water flow into heater core
erated knob on the center of the cock is closed and the circulation of To control the fan motor opera
tion
heater unit engine coolant through the heater core push pull the lever knob Two
or
stops When the lever is slided to any speeds provided for the fan motor
The AIR LEVER controls the air
are
valve by its other position than OFF the water by using a three position switch
intake valve and or room
rl
FUSIBlE HEATE R
core to the room valve where the air is
LINK SWITCH
distributed to the floor outlet and or
defroster outlets
position of the room
depending
valve
on the
is luJ
The VENT KNOB is
to the vent
directly linked
valve which provides fresh
air for the passenger Push the knob all
8E 27
Body Electrical System
AIRFLOW
OFF VENTILATING
Vent valve
Push
Heater core
c n
IUl
J u
NlL
fAl
e u
c g
Push Pull
Pull
Push
tTIlsl
J
IU lI g
0 D WI IIt
L
I I
Pull Pull
DEFROSTING HEATING
IU ff
UIUI
I
n
HU J
C
n J CIl
C JIlT
11 Ill
Pull Pull
BE397
Fig BE 47 Airflow
8E 28
Body Electrical System
AIR lever
Assembly
HEATER CORE I
Removal and installation
CONTROL ASSEMBLY
L Drain engine coolant
2 Remove defroster hoses
Removal and Installation
3 Disconnect water hoses from inlet
and outlet pipes of heater core I Remove three cable retaining
BE871A
4 Remove four clips and front clips and disconnect control cables
Fig BE 51 Room valve
cover from valves and cock
BE 29
Body Electrical System
SPECIFICATIONS
6 Pass tachllmeter wires through
grommet on hood lock control wire
Extremely cold
Item General use and connect to negative terminal of
weather use
ignition coil
FAN MOTOR Notes
Rated power consumption 12V less than 36W 12V less than SSW a Fix grommet with an adhesive tape
BE965
Fig BE 53 Tachometer
BE 30
Electrical System
Body
to the ON position the warning
SEAT BELT Warning lamp body
lamp comes on and the warning buz
WARNING SYSTEM zer sounds if the driver s seat belt is Warning lamp is located on instru
not fastened properly ment panel
DESCRIPTION
The seat belt warning system con I Remove cluster lid
sists of a driver s belt switch a warning 2 Disconnect lead wire at connee
Except Canada
buzzer a warning lamp and an igni tor
When the ignition switch is turned tion switch 3 Remove two screws retaining
to the ON position the warning lamp body
lamp comes on and remains on for 4 4 Installation is in the reverse se
8 seconds The buzzer
to warning quence of removal
REMOVAL AND
sounds for 4 to 8 seconds intermittent
INSTALLATION
ly if the driver s seat belt is not
fastened properly
Ignition switch
The seat belt warning system con
sists of a driver s belt switch a warning Refer to page BE 22 for Removal
buzzer a warning lamp a timer unit and Installation
and an ignition switch WARNING LAMP BULB
Timer unit REPLACEMENT
For Canada
Timer unit is fIXed on a reinforce
I Remove cluster lid
When the switch is turned ment behind glove box
ignition 2 Twist lamp socket
warning
Socket with bulb can then be taken
out
3 Pick up bulb from socket
4 Install new bulb in the reverse
sequence of removal
Bulb wattage
Seat belt warning lamp I 7W
INSPECTION
Warning buzzer
unit can then be taken out Note Make sure that negative
S Installation is in the reverse se terminal of power circuit is always
connected to @ terminal
quence of removal
Turn the ON
Warning buzzer is fIxed on a re BE967A ignition key to
inforcement behind glove box Fig BE 55 Warning buzzer position The voltage between @ and
Refer to the preceding timer unit ground must be 12V for 4 to 8
for Removal and Installation Driver s seat belt switch seconds and then go out See Figures
BE 54 and BE 56
I Remove seat belt ecuring bolt
2 Disconnect belt switch lead wire Belt switch
at connector
3 Seat belt can then be taken out Test continuity between two lead
4 Installation is in the reverse se wires from seat belt switch with ohm
BE 31
Body Electrical System
FUSE
FUSIBLE LINK lOA
p c
DRIVER S
o @ BELT SWITCH
BATTERY
@I I@
9
TIMER
f
IGNITION SWITCH UNIT
I
WARNING fS
BUZZER
LAMP
2
l
California modela
IGNITION RELAY
FUSIBLE LINK FUSE
lOA
F 9
lC 1
1
ORIVE R S
BELT SWITCH
BATTERY
f IGNITION SWITCH
9
WARNING r
i BUZZER
LAMP
J
2
I
Canada modela
DRIVER S
BELT SWITCH
LINK FUSE
FUSIBLE
lOA
aP c
9
o
BATTERY
N WARNING fS BUZZER
Cf
LAMP
J
2
I
f
IGN ITION SWITCH
BE689B
BE 32
Body Electrical System
grounded
Inoperative horn relay Replace horn relay
Horn sounds when B and H horn relay
tenninals are connected with a test lead
Damaged horn or loose horn terminal con Correct horn te inal onnection or
replace
nection horn
Horn sounds Short circuited horn button and or horn Repair horn button or its wiring
continuously button lead wire
BE 33
Body Electrical System
is too slow
Loose or poor connection Repair
Seized or rusted wiper linkage Lubricate or replace
Humming occurs on motor in wiper blade
operating cycle
Wiper blades stick on windshield glass Clean windshield glass and or replace wiper
Raise arm and operate wiper without load blade
BE 34
Body Electrical System
RADIO
Noise prevention
Position vehicle in an open area away from steel buildings run engine extend antenna to its maximum length set volume
control to maximum and set dial at a medium point without catching broadcasting wave
Ignition system
Noise occurs when engine is op High tension wire Install new high tension wire
erated
Charging system
Sound of alternating current pre Alternator Install a 0 51lF capacitor to charging termi
sents nalA
Supplement equipment
When engine starts noise presents Operative noise of water tem Install O IIlF capacitor between terminal and
Noise still presents even after perature and fuel gauges ground wire
stop
ping engine If
Note a capacitor having a larger capacity
is used indication of gauge will be de
viated
35
BE
i
to o Q m r0 C 1 Ql CIl Il l3
@ @
D v
only
models
H
L
Californa C a l i f o r n a models
lamp
distrbuo resi tor only
2
B
type
L
Low High D
cut
tcrminal only coil coil models
check headl mp block igniton condesr igniton Californa
D
only models
B
To To To To To To To To To To To
30 3t 32 33 34 3S 36 37 38 39 40
only
n
R
models California
Non
2 lamp 2
n
1 1
type type
solenid
R
No California
Non
type
link harnes c o m b i n a
H
R
t
lamp
marker
B
R
transmiter D
cut solen id
heater
only cut choke
R
L
batery fusible engine altern o headlmp headlmp ground thermal distrbuo models fuel auto headl mp
D
front side C
8
To To To To To To To To To To To To To To To
9 1
IS 16 17 18 1 20 22 23 i4 is 26 27 28 29
only
Can da only modeb
for
models
I
j
lamp
relay except CCaliforna aliforna only
harnes amplifer heater counter model relay relay relay
T
only A
models switch compart en mot r relay senor lamp relay regulator cable
@
dri
e
To To Californ a To To To To
full Califunia
Non
head horn co ler
To To To To To To To To
1 2 3 4 S 67 89
10 II 12 13 14
OJ m e OJ
ll0
ll n g
t
CDm Cl
l3
c
III
lTI 6o
l
tl oZ
only
18
6 ifornia
r ca
Non
l8
A
@
L
@
f
@ @ onlY
@
jB
DE1A U
Califotl a
a
AIL
0 DEI 11
6
1
1
13
@
BY
omY
@ ornta
i
ca
on
O
@
onlY tll
0
@ otnia
calit
on
DE1AIL
t l
8il
too i1
l
@
OJ
OJ o Q m OQ CIl II D 3
I
HARNES
I
J
n ENGt E RO M
L TO
cf
w
AlT
AfT
solenid switch cable slinger cable
Kickdown Inhibtor
1
Oip
23 45678
Oip Engine Batery Engine Batery
ii bll l if 3i
m
to o c m r0 O O Dl CJ lti 3
B
BY
solenid Transmi o switch Tranmiso switch Transmi o switch mot r harrnoesm Transmi o harrnoesm Transmi o
RB I r LB BY
RB
WB
RB 1 BW
@
RB@RB YB
kicdown Automaic rev se Manual inhbitor Automaic presu stare engine Manual engine Automaic
oil
RB 2 To fOT To for To for To To To for To for
YB
Automaic Transmi o
For fBYB
1 2 3 4 56 7
Manual
For Transmio RB BY
BY
stripe
stripe red
white with
gre n with gre n
CODE Black Brown Gre n Blue Light Red White Yelow Black Light
Transmio COL R B BI G L Lg R W Y BW LgR
Automaic
For
LB
Automaic Transmio
For
B
Transmio
Manual
For m
to l0c l s Q3
mW D
Jo Q
o m CD n Ql en Ii3
1
1
I
I
lL
flll
I
J
peratuJe
ilumnato lamp
lamp floor
te
lamp Olodels
switch
A
only harnes
ilumnato ilumnato
S
or
timer
AfT
comparten
H
R
R
lamp
switch switch lighter control control and models control warni g harnes mot r switch harnes
G
E
I
j
II
wiper wiper cigar heater radio heater belt heater buz er belt indcator co ler wiptr door engine floor
1
U IT
L
To lamp To To To To To To
California
Non
Californa To To To To To To To To To
U I
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
L
@
U@
rL Qj Can da
for
brake mot r
T
ro m light fuse tachomet r haz rd stop igniton haz rd check AMP CNonaliforna flasher kic down hand heater
combinat combinat ilumnato
M
tU
@
To To To To To To To To To To To To To To To To To To
1 2345 6789
10 11 11 13 14 IS 16 17 18
tot
lQ E S
mJ c
CD o c m o O II fJl 13
IIY
engine
comparten harnes Lt
r
J
l YA To G wRfl
oIll
R
G L RY
ll
Ri
l
LIB
GL
L
only
T
A
B
LW
AL
LW
j onl y
Can da
B
I
BG T
R
Can da L M
@ California
Non
except
except G GR
13
california
Non
GW
L
GL R GW
ft t It
B BW
t4 LG
4 LR
LW 4D @
lD m en lD
ii b
l l l
CD m
13
i rJl
tp o c TS O
l
H lt
L
R
ll
y
H
R lamp tarnP L
s
ou
lamp lamp
switch
combinato combinato market
@
haltl
@ harnesS sensor models belt unit marker amp
e
cens
1ii
Gt
instrUment co ler floorCalifornia driver tank side reat i
to To To 10
rear side
d8
0
0 fo To To 1
1 To 9
45
67 10
Gt QR 1 1
@
@
J
G
Q8
t
Gt
Q
QR
t
t
LQR
RB
Gt
ill@
8
LQR RB 8 8
CD
G
Bt
Q8
t c
Body Electrical System
CONTENTS
sensing switch installed on the vehicle WARNING LAMP Lamp body replacement
floor a floor temperature relay a
I Remove cluster lld
floor temperature warning Bulb replacement
lamp and 2 Disconnect lead wire at connee
harnesses
I Remove cluster lid tor
When the floor temperature rises to
2 Twist ng
warni lamp socket 3 Remove two screws retaining
an abnormal level the warning lamp Socket with bulb can then be taken lamp body
will come on to call the attention of out 4 Installation is in the reverse se
the driver
3 Pick up bulb from socket quence of removal
IGNITION RELAY
FUSIBLE LINK
I
P
I
i BATTERY
IGNITION
SWITCH
FLOOR l
SENSOR
I I
f
RELAY
I FLOOR SENSOR
WARNING ON FLOOR
LAMP TEMPERATURE
LOW
OFF FLOOR
TEMPERATURE
HIGH
7
BE697B
43
BE
Body Electrical System
Warning lamp does not Burnt or loose bulb Replace bulb or correct bulb socket
light in START posi
Faulty f1o r temperature relay Conduct continuity test and repair or reo
tion of ignition switch
place
Refer to Section EC
44
BE
SE B V I C E 1
SECTION AC
M A N IuI A71i
I
W
i L
AIR
DATSUN PICK UP CONDITIONING
MODEL 620 SERIES
DESCRIPTION AC 2
COMPRESSOR AC 33
DESCRIPTION
CONTENTS
OUTLINE OF AIR
CONDITIONER ment through the three outlets at the the radiator in the engine compart
The air conditioner consists es instrument panel ment
condenser receiver dryer and piping the vaporized refrigerant and is attach reservoir for storage of the liquid sent
The cooling unit secured with ed through the bracket to the loca by the condenser is located on the
three brackets is ttached to the tion occupied by the mechanical fuel
a
right in the engine compartment
location occupied by the package tray pump on the engine The piping consists of two flexible
in the dash panel The condenser cools the compres hoses and five copper tubes which
The cooled air from the duct is sed the
refrigerant vapor sent by com connect various components of the air
directed into the passenger compart pressor and is located on the front of conditioning system
AC724
AC 2
Air Conditioning
used is the
REFRIGERATION perature inside the box will drop This pIe The liquid refrigerant
is because the alcohol is evaporated R 12 The heat inside the passenger
SYSTEM
If you were to paint your finger absorbing the heat from the air insidc compartment is absorbed by changing
with alcohol your finger would feel the box If the gaseous alcohol is the refrigerant from a liquid to a gas
collected and cooled with cold and then dissipated to the outside
cold This is because the liquid alcohol water by
takes heat away from
your finger it will be changed back into a liquid by changing the refrigerant from a gas
heat back to
while it evaporates Ifa quickly evapo absorption of its by the cold a
liquid
The refrigeration system is shown
rating liquid such as alcoliol is placed water
Low pressurt
V7777 High
J pressure
l gas
lLLLLL liquid
1
Low pressure
High pressure
I
I I
L2
gas
liquid
Inside air
Outside air
i
U Condenser
i
Compressor
li
11
J6G1
1 I
ilill
t1
I
J
i
LlJ
JJ l
u
r
7 t
qIrJ
It J
ttLJ L
U Blower motor
Evaporator
1 J
Receiver dryer f 9
d
lUr
I Expansion valve
AC458
h w
t Fig AC 2 Refrigeration cycle
CONDENSER
COMPRESSOR
The condenser is installed to the compressor condenses to a liquid by
compressor is installed to the
The
front of the radiator The heated and being cooled by air passing between
side of the engine and is driven by
compressed refrigerant gas from the the fins of the condenser
crank pulley through a belt The refrig
AC3
Air Conditioning
AC728
Fig A C 4 Compressor
RECEIVER DRYER
W
purpose of the switch is to stop the
compressor operation in the event an
I Prc surc switch
excessive system pressure builds
up on r 2 Sight glass
the high pressure lines
t J J
AC230
3
4
Strainer
De kcant
4
AC
Air Conditioning
AC729 4
Sensing bulb
Fig A C 6 Expansion value
000
1 Motor 8 Resistor
2 Fan 9 Main relay
3 Lower case 10 Thermo switch
4 Cooler duct II Cable clamp
5 Evaporator 12 Cable
6 Expansion valve 13 Harness
7 Upper case
AC725
The following wiring diagram pro pressure switch and compressor relay
ELECTRICAL CIRCUIT
The blower motor fan speed is con
vides a complete description of the
whole circuit trolled by the fan switch and resistor
DESCRIPTION
When the ignition switch and the The solenoid valve is also activated
This in turn the fast idle control
The electrical circuit of the air fan switch are ON the main relay is causes
fan flow the fan motor and the speed when the vehicle is at rest with
two relays a solenoid valve a through
the engine ON
motor and a compressor magnetic magnetic clutch The magnetic clutch
clutch is activated by the thermo switch
AC 5
Air Conditioning
J
c
BW
BW ELECTRIC
oB L FUEL PUMP
B m b@ tl
n
00
B ILLUMINATION
L I
GL CONTROL
RHEOSTAT
t
FROM LIGHT SWITCH
lL
GL1J 3
ILLUMINATION
LAMP
J
c
I I MAIN RELAY
FAN SWITCH
2
LW L
W
fZP I
rRL FUSE 15A
I
D CJ B
J
r
1 I
1 H
UE
THERMO SWITCH
I I
6 1 COMPRESSOR RELAY COLOR CODE
B Black
I BW
L
Black with white
Blue
stripe
i
LW Blue with white stripe
BA RY LR Blue with red stripe
W White
G Green
@ IC PRESSU 1
RL Red with blue stripe
rlTCH IG
D J oc
c
G
t1 n
BW
m
I
F IC D SOLENOID f
L
COMPRESSOR LR
FUSE I IGNITION SWITCH
O 0
W J
ov 0
BW
OVJ
IIG
AC727
AC 6
Air Conditioning
The main relay is located on the tacts in the relay are closed Then The compressor relay is attached to
cooling unit electrical power from the battery is the receiver dryer bracket on the right
When the ignition switch and fan the blower motor and the side of the engine compartment This
supplied to
switch are both turned on the COll electrical clutch for the compressor relay is actuated by the fan switch
thermo switch and pressure switch to
turn on and off the compressor
magnetic clutch
@
Dc
1 1 l@
cv
IDe
@ ID
@e
L J
AC465
way the temperature of the air dis tached to the dash panel in the engine
charged from the cooling unit is auto compartment This valve supplies vacu
AC 7
Air Conditioning
GENERAL SERVICE
CONTENTS
8
AC
Air Conditioning
Water in the system will ice the may be the cause of gas leakage dent training Therefore it is of first
orifice when the high pressure re Before connecting pipes be sure to importance that any other personnel
frigerant changed to low pressure
is give coating of compressor oil to the than a well trained serviceman should
not be allowed to handle the refrig
refrigerant by expansion valve etc sea ting surfaces
and will obstruct the erant
refrigerant
flow
SAFETY
The following items are general PRECAUTIONS EVACUATING AND
instructions to be closely observed in
I Since direct contact of the liquid CHARGING SYSTEM
servicing the system
refrigerant with your skin will cause During servicing use caution to
I When
system line is discon
a
frostbite always be careful when keep air from getting into refrigerant
nected plug the opening immediately
handling the refrigerant Wear gloves When air enters the system all refriger
This is especially necessary to prevent
around service ant must be evacuated from
moisture condensation from forming
or wrap a piece of cloth system
valve to protect your fingers against prior to charging new refrigerant Air
in the line and to keep out dirt and
in has the following delete
dust It is also necessary the frostbite by refrigerant If any of the refrigerant
keep
to
rious effects
line at and above surrounding air refrigerant should get into your eyes
when charging the refrigerant I Since the condensation tempera
temperatures times at all When con splash
ture of the air is extremely low the air
your eyes with cool water to raise the
necting system lines do not attempt will not be condensed when
to remove the plug from the opening temperature gradually Apply a protec refrigerant
tive film to the eye to avoid infection gas is condensed in the condenser and
until ready for immediate use
the air will thus remain in gaseous
2 Do not rub your eyes Consult an eye
Always keep the working place
form Consequently the effective
clean and dry and free from dirt and specialist Always wear goggles or
thermal transmission area of condenser
dust Wipe water off with a clean glasses to protect your eyes when
for refrigerant gas will be red uced and
cloth working around the system Should
be condensed will be
refrigerant strikes your body splash refrigerant gas to
3 Have all necessary tools in pre
red ueed The pressure rise will become
on cool water and apply a protective
paration beforehand and have tools
film proportional to the volume of the air
clean and dry
in system
2 The
4 The compressor oil will easily refrigerant service container
2 When air and refrigerant are
absorb moisture when exposed to air has a safe strength However if han
mixed in system a chemical reaction
dled incorrectiy it wili explode
Immediateiy close the opening of the
Therefore will be produced and hydrochloric
container after use It is also necessary always follow the instruc
tions the label In acid which will adversely affect the
to observe the following notes
on
particular never
b The used oil should not be returned especially careful when handling it in sides of system should be measured
small confined spaces when evacuating and charging refrig
into a container
4 The refrigerant itself is nonflam erant and when diagnosing trouble in
c The oil should not be used if its
mable However a toxic gas the system The manifold gauge is used
state of preservation is not clear phosgene
gas is produced when it contacts fire for these purposes A manifold gauge
enough
and is therefore has two pressure gauges a low pressure
special care required
5 When connecting or disconnect
when checking for leaks in the system gauge and a high pressure gauge These
ing pipes from the refrigeration sys with a halide torch gauges are connected to the high and
tem use two wrenches One wrench is 5 Do the sys low side service valves of system
not steam clean on
A small scratch on the seating surface their strict observation requires suffi opened
AC 9
Air Conditioning
c 7 I
Ji
r gL r
rr1
rnFW
g
low side
rvicc valve
To vacuum
refrigerant
t
2
pump
can
OI To high
service va
ide
lve
AC243
Connection to service valve HANDLING SERVICE VALVE 2 Check valve will be half opened
during connection and disconnection
An automatic check valve is built
I Fully close both valves of mani of hoses and
into valve When this valve charging refrigerant will
fold gauge Connect high and low service
be forcefully discharged Therefore
hoses to manifold presses against the connection fitting
pressure charging connect and disconnect charging hoses
that is when charging hose is con
gauge quickly while pressing flare nut of
nected to service valve the valve is
2 Remove caps from service valves charging hose against service valve
open When charging hose is discon
Connect high and low pressure charg
nected the valve is closed automatical
To
ing hoses to service valves in system the Caution Work with fingers protected
ly Always observe following usage
The refrigerant gas wili be discharged with cloth against frostbite by re
since check valve is open when precautions
frigerant
pressing charging hose onto service install valve after
Always cap
valve service valve
3 Since close contact between the
using
thread of valve eap and the thread of
3 Next loosen the connection fit When high speed opera tion is per
servicevalve will prevent gas leakage
ting of charging hose at manifold formed without valve cap a negative
keep these sections clean and free of
build up at the
gauge side for 2 to 3 seconds
to
purge pressure will gradually
air inside charging hose by the side of system and air scratches and damage
any low pressure
addition dirt and 4 Since packing of charging hose
pressurized gas in system may be sucked in In
enter the valve result will be lost during long use always
dust will easily
the check packing prior to installing charg
ing in foreign matter entering
system ing hose J
Disconnedion from
service val v
17
mani
I Fully close both valves of
fold gauge
t
2 Disconnect two charging hoses 1
from service valves At this time the 1
L
gas will be discharged until check valve 5V t Cap
is closed Therefore disconnect hose
2 Service valve
quickly
AC733
AC 14 Service oolve
Fig
fant
l
fri
AC l0
Air Conditioning
apply to
conventional can taps firmly
4 Turn handle
For the correct usage refer to the can tap fully clock
manufacturer s instructions wise to make a hole in refrigerant
can
Caution Use can tap of good quality clockwise to raise the needle
r r Refriger
ant gas will
flow up to the center
AC734
I Connect charging hose to the fitting of manifold gauge
n
s
AC246
A rn
Purging air
n
R I2
AC247
AC
Air Conditioning
valves of manifold gauge fully charging hose to a vacuum pump there is a leak in the system In this
2 Connect two charging hoses of 3 Close both valves of manifold
case immediately charge system with
gauge fully Then start
pump vacuum
manifold gauge to their respective refrigerant and repair the leak de
4 Open low pressure valve and suck
service valves scribed in the following
3 both manifold gauge valves old refrigerant from ystem See Confirm that both valves of
Open I
slightly and slowly discharge refriger Figure AC 18 manifold gauge are fully closed and
S When low pressure gauge reading hose
ant from system See Figure AC 17 then disconnect center charging
has reached to approximately 500 from vacuum pump
mm Hg 20 in Hg slowly open high 2 Connect center hose to can tap
pressure valve See Figure AC 19 of Attach
Note Do not allow refrigerant to rush
in place vacuum pump
6 When pressure inside system has refrigerant can to can tap and pass
out Otherwise compressor oil will
dropped to 710 mm Hg 28 in Hg refrigerant to manifold gauge
be discharged along with re
fully close both of valves of manifold 3 Loosen the connection of center
frigerant
and stop Let
gauge vacuum pump fitting of manifold gauge to
purge air
stand it for 5 to 10 minutes in this from center hose
state and confirm that the reading 4 low pressure valve of mani
Open
does not rise fold gauge and charge refrigerant into
it therefrom
AC 12
Air Conditioning
1
j
J
J jJ
lJ i
R
j
I1
J
g j
AC736
ru AC737
CHARGING REFRIGERANT
Refer to
Handling Manifold
Gauge
Notes
a Be sure to purge air from the high
and low pressure charging hoses
b If air is mixed with refrigerant gas
in system evacuation of system
should be performed Refer to
Evacuating System
2 Attach center of
charging hose
121
Cautions Immerse in water
AC 20
a Under any circumstances the refrig heated to about
a When refrigerant charging speed is be used to warm up the can Fit AC 21 Heating refrigerant
AC13
Air Conditioning
When is
b When low pressure 3 he 5 refrigerant can empty
charging hquefied refrigerant
After completion of charging the fully close both Ives of manifold
into the system lith the can turned
be turn gauge and replace refrigerant can with
upside down to reduce charging compressor should always
ed Several times manually See a new one
time charge it only through high
valve but not through Figure AC 22 Before opening manifold gauge
pressure
valve to charge refrigerant from new
can be sure to purge air from inside
charging hose
UL Q
v1ifl j
4 If refrigerant charging speed slows back into refrigerant can and can
AC255
down charge it while Iunning the may explode
of charging After Measure the amount of charged
compressor for ease 2 Run the engine at idling speeds refrigerant with a scale
having taken the steps up to 3 above Make a note of the amount charged
about 1 500 rpm
proceed with charging in the following Set the control
from can
3 temperature
order
lever and fan switch at maximum
I Shut off high pressure valve of Fig AC 24 Measuring refrigerant
cool and maximum speed respectively
manifold gauge
4 Charge refrigerant while con
trolling low pressure gauge reading at
Caution Never charge refrigerant 8 kgfcm2 40 psi or less by turning
2
in out low pressure valve of mani Refrigerant capacity
through high pressure side of sys
or
tem since this will force refrigerant fold gauge See Figure AC 23
Unit lb
kg
R 12 0 7 15 0 9 2 0
AC 14
Air Conditioning
7 After the specified amount of Refrigerant is a colorless odorless I Discharge refrigerant in one or
refrigerant has been charged into sys gas and leakage from system is diffi two seconds to ascertain that system
tem close manifold gauge valves Then cult to detect Accordingly the use of has a sufficient needed for
pressure
detach charging hoses from service a leak detector facilitates check for leak detection Charge
kg I with 04
valves of system Be install leaks Two methods of checking of
sure to are lb refrigerant if necessary
valve cap to service valve available one employs a halide leak 2 Light leak detector Adjust the
8 Confirm that there are no leaks in detector which burns propane gas or height of the ilame between flame
butane gas and the other is an electric
system by checking with a leak detec adjusting lines at the top and bottom
tor type leak detector of combustion tube A reactionplate
Refer to Checking for Leaks will immediately become red hot
3 Place the end of sampling tube
Note Conducting a performance test HALIDE LEAK DETECTOR near the point of the suspected leak in
prior to removing manifold gauge is Since the propane leak detector and
system
a good ice
sen operation Refer to butane leak detector are the same in
Performance Test Notes
respect to their operation this section
describes the operation of the propane a Since refrigerant gas is heavier than
air small leaks can b easily detect
leak detector
The copper screen is heated by the ed by placing sampling tube direct
CHECKING FOR ly below the check point
burning of propane Refrigerant gas
LEAKS decomposes to color the flame when it
b Suitable ventilation is required If
refrigerant is mixed with the
Conduct a leak test whenever leak contacts the heated screen The gas to gas
be checked is drawn into the sampling surrounding air leak detector will
age of refrigerant suspected and
is
when conducting service operations tube and sent out to the burner A always a
response and
indicate
detection of the actual leak will be
which are accompanied by disassembly refrigerant leak can clearly be detected
difficult
Dr loosening of connection fittings by variations in the color of the flame
c Never bold leak detector at an
angle
Cautions
a Never inhale the fumes produced
by combustion of refrigerant gas
since they are toxic
b Never use halide torch in a
place
where combustible or explosive gas
is present
4
Sampling tube copper reaction plate always keep the
AC010
5 Strainer strainer of sampling tube and reaction
6 Gas bomb
plate clean
7 Flame adjuster 5 Major check points
compressor by hand
Oil filler plug
Butane type Flexible hose connections
Propane type
Rear cover and side cover gaskets
NO LEAK Greenish blue Pale blue Service valve
2 Condenser
SMALL LEAK Yellow Bright blue Condenser pipe fitting
LARGE LEAK Purple Vivid green Condenser inlet and outlet pipe
connections
AC 15
I
Air Conditioning
maximum position
Flared section of high pressure and LEVEL CHECK
3 Set blower to maximum speed
low pressure flexible hose
connections 4 Check sight gla after the lapse
Pipe SIGHT GLASS
rvice valve of about five minutes Judge according
Sight glass provided at the top of
is to the following table
4 Evaporator housing receiver dryer One guide for whether
Jnlet and outlet pipe connections
there is enough refrigerant in system is
Expansionvalve given by observing refrigerant flow
glass However this
through sight
ELECTRIC LEAK DETECTOR
method is unsuitable for judging the
for the operational procedures amount of refrigerant The correct
refer to the instructions furnished with level
refrigerant can be judged by
each electric leak detector
measuring t e system pressures in ac
Amount of
refrigerant Almost no reftigerant Insufficient Suitable Too much refri crant
Check item
Temperature of high pressure Almost no difference High pressure side is High pressure side is High pressure side is
and low pressure pipes between high pressure warOl and
low pressure hot and low pressure abnormally hot
and low pressure side side is fairly cold side is cold
temperature
A A M
I I r I II I
AC258
AC256 AC257
Pressure of system High pressure side is Both pressures on high Both pressures on high Both pressures on high
abnormally loW and low preSure sides and low pressure sides and low pressure sides
are slightly low are normal are abnormally high
Repa ir Stop compressor and Check for gas leakage Discharge reftgerant
conduct an overall repair as required re from service valve of
check plenish and charge 11
10 pressure side
system
AC 16
Air Condit onin
j
erant is normal In this case the measure system pressures at high pres
material clean oil 5ump with new oil
of the receiver
outlet side pipe 6 Discard the used oil and fili with
sure discharge side and low pressure
becomes considerably cold side
dryer the same amount of new oil Add oil if suction
9 Measure the temperature of dis
found less than above amount
charge air at outlet grille
10 Measure the of
PERFORMANCE TEST temperature
capin
Check for the amount of refrigerant
11 Measure ambient temperature
in the system can be made by meas
and humidity one meter 3 ft away
uring pressure ondischarge side
from condenser front Be careful not
The correct amount of refrigerant is
to expose dry buib and wet bulb to
in the if pressure on the
system
direct sunlight
discharge side is within the specified
12 Check for any abnormalities by
range For details refer to Perform
ance Test described later comparing the test results with stand
ard pressure in Performance Chart
Overcharging will show up in higher
pressure on discharge side
Fig AC 27 Filler plug
COMPRESSOR OIL
LEVEL CHECK If compressor is inoperative due to
faulty compressor or heavy loss of
The oil used to lubricate compres
refrigerant remove compressor and
sor circulates into system from the oil Notes
repair as necessary Then pour oil up
sump while c9mpressor is operating a The pressure will change in the
to correct level and install on engine
The efore to correctly measure com followi g manner with changes in
After above steps have been complet
pressor oil the amount of oil flowing conditions
oil level drain oil to
ed recheck is dis
When speed low
to
system must be considered If a excessively high
blower
correct level if level is
considerable amount of leakage of charge pressure will drop
the leakage of When the relative humidity of in
refrigerant gas happens
compressor oil is also considered take air is low discharge pressure
There will be no compressor oil leak will drop
b The temperature will change in the
age from completely sealed system
a
PERFORMANCE TEST
When system operates under satisfying following manner with changes in
The cooling performance of the air
condition the oil level conditions
compressor
conditioner changes considerably with
check is unnecessary When the ambient air temperature
changes in surrounding conditions
When checking the level of com is low the outlet air temperature
must be using the
oil or when replacing any
Testing performed will become low
pressor This is used to
correct method test
component part of the system use the
whether system is operating cor reveals that there is any
following service procedure This fa judge If the test
rectly and can also be used as a guide abnormality in system pressure isolate
cilitates to return oil to compressor
in checking for problems the cause and repair by reference to
I Operate compressor at engine
in the the Trouble Diagnoses and Cor
idling speed 1 000 rpm or below I Park the vehicle indoors or
rections
with controls set for maximum cooling shade
AC 17
Air Condition ing
REFRIGERANT
LEAKS
If leaks are noticeable leaky parts time receiver dryer must be replaced the fitting has been retightened dis
should be repaired Then system If leaks are slight and no air is present charge refrigerant from system discon
should be filled with refrigerant Do in system add refrigerant as necessary nect the fittings and check its seating
not operate compressor with refriger To detect leaks refer to relative face for damage Always replace even
ant level cessively low
e
topics under Checking for Leaks if damage is slight
If this caution is neglected a burnt Here is how leaks are stopped 3 Check compressor oil and add oil
compressor will result since heavy loss I Check torque on the connection if required
of refrigerant usually indicates heavy
fitting and if too loose tighten to the 4 Charge refrigerant and recheck
loss of compressor oil
proper torque Check for gas leakage for gas leaks If no leaks are found
If system has been with a leak detector
exposed to evacuate and charge system
atmosphere for an extended period of 2 If leakage continues even after
AC 18
Air Conditioning
CONTENTS
COOLING DIAGNOSES
INSUFFICIENT COOLING
I
I
Check amount of discharged air
j
No or insufficient discharged air
IfOK
1
Check sight glass for bubbles ChecK blower
I I
I I
I I
Check refrigeration line for leakage Performance test Repair cooling Refer to Blower motor
Refer to performance unit diagnoses
Note If there are too many bubbles
test on the following
stop compressor and check for
leaks page
IfOK lfleaks
AC 19
Air Conditioning
FUNCTION TEST
STANDARD PERFORMANCE TEMPERATURE
19
Note 1 500 rpm
18 Engine
FAN 3 position
17
16 TEMP Cold Max
15
14
13
I
12
0 6 0
5 0
40
3 0
2 0
10
20 25 30 35 40 45
REFRIGERANT PRESSURE
25
400C J05OF J2 kg cm2 170 psi 16 kg cm2 21 psi
20
IS
20 15 10 5 0
Oc
air
Temperature of dischuge
AC 20
Air Conditioning
Both and suction pres Air mixed with refrigerant in Evacuate and charge system
a discharge
sure too high system
correct level
Loose fan belt or engine over Adjust fan belt or check cooling
heating system
Obstructed or dirty condenser fins Clean exterior surface with water
c Discharge pressure too high and Over filling of compressor oil Drain oil and correct oil level
suction pressure too low Refer to Compressor oil level
check
d Suction pressure too high and Damaged compressor valve or pack Repair or replace compressor Refer
to Compressor
discharge pressure too low ing
h Both discharge and suction pres Air leaks from engine com Correct sealing
sure normal partment
Air conditioning is operating
properly
normal and Restricted air flow through evapo Clean evaporator fins
a Discharge pressure
suction pressure too low ratof
Slow blower motor speed Check and repair blower motor and
wiring
AC 21
Air Conditioning
COMPRESSOR DIAGNOSES
I COMPRESSOR TROUBLE
I j
If OK Will not turn
I
Apply 12V direct current to compressor clutch Internal problem in compressor cylinder
Then check clutch engagement Repair or
replace compressor
I
If OK
I Clutch does not
engage
I
Check voltage oflead wire for compressor on Clutch is damaged
cooler cable Repair or replace dutch assembly
I
I
IfOK No voltage
I
Internalproblem in compressor Check or repair wiring system for compressor
Repair or replace compressor clutch
AC 22
Air Conditioning
NOISE DIAGNOSES
NOISY
I
I
I Set fan switch on
j
Check the resonant sound when the engine rpm is
j
Blower motor makes noise
No resonant sound
Resonant sound
Compressor itself makes noise
Noisy only when clutch is engaged Noisy when clutch is not engaged
I
Check drive belt for slackness Remove compressor belt then turn compressor
Check for loose compressor mounting bolts pulley by hand If noise is heard repair com
I pressor clutch
I
If OK If loose
Nl1
Air Conditioning
Check fuse
In fuse block 15AW
unit
Single fuse 15A at cooling
I
j
IfOK mown fuse
I j
If OK If damaged I
I
I
I
Connect fan switch to wiring harness Replace fan switch
No voltage
I Voltage
I
I Replace main relay
Check the continuity and fitting of resistance on
cooling unit
I
Ifdamaged
I If OK
I I
resistance
Replace blower motor Replace
AC 24
Air Conditioning
CONTENTS
Notes
AC 25
Air Conditioning
R
C7
c
L 1 attachment
Compressor
2 Compressor
3 Compressor bracket
PJJ
4 AHernator
I
AC745
8
Fig AC 31 Removing compressor
l11fd
h
r
910 1 v
e l bffik kuanM
bi2 qqll
mpdi x
no
1i6 e before ready for immediate use b Cheok refrigerant leakage if neces
Jli oln L
il 1Ilf i Orb
m fler ot oldm 4l di
F n Cheo undeF r n al iturn sary correct
Wheniiinstallingccomptess
1 aQ t31
Jt
r1tIU HClJI1f t JIVU irlUI
it serWfiPtiffies SlOt
1o ifm qt
ft 31U
VI S ltlod
5 When connecting flexible hose to
dO wl Twl
bnM UfO l W I rt f r2
coat of Hfresh
kldf ti WIf nl lL lil g ncn d 9mPr
JU
ssor
UI apD t 2JIUU
l1Il
v a
r
uOHltl fl iVl 2 i l n U l bnu 1 1Z2 gf ign rb
oressor
l9Wul
necessary
CJiJi
fb
M
re
l
i
et
1Ttio
Ighten
botts if
illpuntinl
fI
qqlJ I l l
compressor
joints
1n
1
0 to
1l11 fs
JJ
aHn lurfaces of
f
J PJU Ht UlUJ jJ nojJ 2
I d
210
AC26
Air Conditioning
and 0 47 in
IDLER PULLEY 32
0 when depressed
with thumb pressure midway between
FAN BELT TENSION
the crankshaft and compressor pulleys
ADJUSTMENT
If necessary turn adjusting bolt to
The standard compressor drive belt move idler pulley up or down until
tension is between 8 and 12 mm belt tension is correct
AC766
AC456
Note Be sure to loosen locking nut 3 Connect low and high pressure
before turning adjusting bolt Re
REMOVAL AND
Notes
3 Be sure to use two wrenches when
I 11 AC767
INSTALLATION
connecting pipe joints Fig A C 35 Removing cooler ducts
Remove drive belt b Plug pipe opening immediately
To do this loosen locking nut after pipe disconnection Remove thermo
8 switch control
before Be careful
loosening adjusting bolt Drive c not to break expansion cable from connector
belt will then be detached valve This valve is wrapped with 9 Remove cooling unit and bracket
2 Remove idler pulley from bracket heat insulating tape as an assembly
by r
J1evM or king nut
t
jiwT9ff llil reverse the order of
rerr oval jldJ 1 t
Jldr J I
INSPECTiON
J JWu
cll dE m J
m
Jbm Ufl
1 ld
2
8
J
1
lEldgJ
I
COOLING UNIT 1
lc rf 1551
C765
fi vorr r
X fIlO
1i qJ j gnjlcfu2fIJ FIg lIJAh Cr P
36 R
1 7
coo mg um l51
l
vmg
emo
REMOVAL AND oM1 1UJ flip 1h tqnPff i2n
Wfi V1c ip
i j r n I1iBITJ 0HJ
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A1lIONI
INSTALl gnillslUli n C at 3duJ lsIliqrJ wlrv n
irWfiqX ani Ofm wom
L olIJgjjJpn
19qm91 crft llU2 3 6rn Gl0ql
f01
qiq H f 1I SH tc
pj ni
DiScoimecprlY ferY lgroUR hable e tworgromllets from dash
vehicleG bn y with
five rews
4q v Remo 2tl i
O
r Jv a8f1l1 q
2 Disbhargiou y tem iRefrflsll Qis panel lots n J a I ld 1 51 nc
b
AC ZA
Air Conditioning
Notes tion
a Apply a coat of fresh compressor
oil tosealing surfaces when COD
Tightening torque
necting pipe joints Copper tube joint nut
b Use two wrenches when connecting High pressure side 3 8 in
cooling pipes 2 5 to 3 5 kg m
00
1 Motor
2 Fan
3 Lower case
4 Cooler duct
5 Evaporator
6 Expansion valve
7 Upper case
8 Resistor
9 Main relay
10 Thermo switch
11 Cable c mp
12 Cable
3 Harness
AC725
I Remove bracket and lead wire 7 Upper and lower cases can now Expansion valve tightening torque
connector main relay thermo switch be separated 5 kg m 36 ft Ib
resistor motor etc from cooling 8 Remove motor and fan as an
AG28
Air Conditioning
tion
Note While cooling water is hot take
precautions against scalding INSPECTION
AC 29
Air Conditioning
J
c
BW ELECTRIC
BW
ii k
gg
B
FUEL PUMP
La gg 1 liii
J
B
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1 i
Ii
ILLUMINATION
GL @ CONTROL
RHEOSTAT
CJ Id
f 8W
lW L
@
rRl I FUSE 15A
D CJ B
J
1 B W l
1t
Ll1 THERMO SWITCH
I
o I
I
COLOR CODE
J B
BW
Black
Black with white stripe
L Blue
B y
vi
i jqt J
0
W
LR Blue with red stripe
White
tH o hm I l i I
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FUSE YR IGNITION SWITCH
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AC727
1 mtlm
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MN
Air Conditioning
When 12 volt d is
MAINTENANCE a c
applied across
MAIN RELAY
v
t
Removal and Installation
AC 31
Air Conditioning
F I C D SOLENOID VALVE
3
tube
Remove two screws securing sole
Remove glove box
tt 2
noid valve and remove solenoid valve
AC772 3 Remove duct from cooling unit
Cooling Unit
4 Disconnect resistor lead wires at
connector AC77 4
Fig AC 48 Removing lC D
F
@ solenoid valve
Inspection
AC 32
Air Conditioning
COMPRESSOR
CONTENTS
AC 35 REMOVAL AC37
ASSEMBLY
INSPECTION AC35 INSTAllATION AC37
DESCRIPTION
on compact vehicles
The compressor crankshaft is driven
As a lubricant SUNlSO NO 5 is
used Simplified
positive pressure
lubrication utilizes existing pressure
differential between suction intake
and crankcase to provide a film of
lubricating oil to bearings All internal
components have been designed to
provide more than adequate lubrica
tion to cylinder walls connecting rod
AC33
Air Conditioning
7
Magnet coil
1t
LV
8 Cylinder head t7
9 Cylinder head gasket
I
10 Cylinder gasket
11 Valve plate assembly
13 Base plate
14 Oring
H AC775
@ @
COMPRESSOR Fig A C 50 Exploded view of compressor
REMOVAL INSTALLATION
Tightening torque
Electromagnetic coil mounting
screws
AC34
Air Conditioning
the
2 Install the clutch assembly on
crankshaft
ST02371000
Note Key should be set on crank
shaft before installing clutch assem
9
bly
AC500
Installer
t
Fig AC 54 Removing snap rings KV99100610
2 Stopper
ST33061000
AC504
INSPECTION
for damage due to excessive heat or clutch wheel and V pulley should be
If cleaned with a clean lint free cloth or
excessive grooving due to slippage
clutch wheel and suitable solvent
necessary replace
V set 4 Check coil for shorted or
opened
pulley as a
KV99100700 The clearance between V lead wire Pay particular attention to
2 pulley
and clutch wheel should be 4 to 0 6
0 grounding part of coil If there is no
0 016 to 0 024 in continuity replace electromagnetic
mm
Bearing Remover
3 Using
ST33061000 press clutch wheel bear
ings out from clutch wheel
AC 35
Air Conditioning
jpL ring
ring
over end of shaft with carbon
i
L
0
Y 4
on
Move seal
shaft
assembly into position
I
I I
0
Ace07
Fig AC 61 Removing s
wft key
AC506
1
Fig AC 59 Grounding point of coil 4 Remove seal plate I
0 7 to 1 0 kg m
5 to 7 ft Ib
AC809
pressor Clutch Removal 1 Clean shaft and seal cavity with Fig AC 65 8pcing 01 plate and
3 Remove shaft key tightening cap screws
clean lint free cloth
2 Dip seal gland in clean 9 Install clutch Refer Com
refrigerant to
oil pressor Clutch Installation
AC 36
Air Conditioning
INSPECTION INSTALLATION
AND VALVES
Insufficient refrigerant compression
is likely by damaged head
to be caused
gasket damaged
or valves AC816
Prior to servicing the head and valve
Fig A C 70 Applying clean
plate both service valves should be refrigeration oil
opened to free any gas pressure which
sharp edged
cylinder gasket so discharge valve as
AC812
AC37
Air Conditioning
5 Place head gasket in position on 8 Apply thin fihn of clean
a
refrig case
valveplate dowel
pins go through 11 Insert remammg head screws
so eration oil to service valve flanges
dowel pin holes in gasket 9 Place and run in all screws until the heads
flange valve O ring in posi
6 Apply a thin film of clean refrig make contact
tion on cylinder head
eration oil on the machined surface of 10 Place service valves in position
head which
Tightening torque
cylinder matches head on proper service valve ports suction Head and service valve screws
gasket or discharge and insert two longer 2 1 to 3 2 kg m
7 Place head on cylinder head valve mountiing
screws through service 15 to 23 ft lb
gasket so dowel pins go into dowel pin pads head valve plate and into crank
holes in head
AC 38
Air Conditioning
Clutch wheel
remover
BE436
installer set
KV99100610
Installer
ST33061000
Stopper
BE437
Bearing
remover 38 50
1
BE438
Bearing
installer 50 1 96
Co
tJ BE439
AC 39
Air Conditioning
BE440
BE441
puller
BE442
B E443
BE434
40
AC
SECTION SE
SERVICE
DATSUN PICK UP EQUIPMENT
MODEL 620 SERIES
SERVICE EQUIPMENT SE 2
I NISSAN I
SERVICE EQUIPMENT
DESCRI PTION
Indicated in this column are classi As regards special tools which are
Special Tools play very important fication also applicable to models other than
ftg1lles in accordance with
role in the maintenance of vehicles
Classification of Speciai Tool those dealt ith U this inual
m this
These are essential to the safe accu
coluITUl names those other models
rate and speedy servicing
The working times listed in the col
umn under FLAT RATE TIME in CLASSIFICATION OF SPECIAL TOOL
FLAT RATE SCHEDULE are com
Tools
Important General
The identification code of mainte
nance tools is made up of 2 alpha I Inspection and minor repairs 4
In this column word All is given SPECIAL TOOL SET SET 3N71B KV0010l000
for tools applicable to all vehicle mod
See attached tool list This set is designed for use on the
els and unit types treated in this manu
The set is available for and 3N71B automatic transmission It con
al for tools applicable only to particu new
X put in this column shows and body of the 620 models without
newly added tools regard to their destination
SE 2
Service Equipment
TOOL LIST
ENGINE TOOL
tST05011000
ST050 I 2000
Engine
Base
stand
5 610 710
ST05260001 Engine attachment
STlOl20000 2 610 710 S30
Cylinder head bolt wrench
STl 0640001 Pivot adjuster I 610 710 S30
STl1320000 Drift
2 610 710 S30
STll650001 Valve seat cutter set
STl6512001 Adapter
STl6701001 Adapter
STl6610001 Pilot bushing puller 3 610 710 S30
SE 3
Service Equipment
CHAssis AND BODY TOOL
Clutch
2 Manual
transmission
3 Differential
ST31530000 Drive X 2
pinion flange wrench All B210 610 710 S30
ST33051001 Puller
ST30901000 Base
SE 4
Service Equipment
All X 2 610
ST31970000 Collar
X 2 610
ST30611000 Drive pinion outer race drift bar All
All X 2 610
KV381025S0 Oil seal fitting tool
4 Front axle
All X 2
ST35380000 Kingpin bushing drift
HT56802000 All X 2
Kingpin bushing reamer
X 2
ST35390000 Kingpin grease seal drift All
5 Rear axle
All X 2
ST38020000 Bearing lock nut wrench
6 Steering
ST2902000 I Pitman arm All X 2 B210 610 710 S30
puller
FIO B210 610 710
2
ST27 180001 Steering wheel puller All X
S30
7 Brake
GG943 10000 Brake pipe torque wrench All X 2 B210 610 710 S30
ST08060000 Master Vac oil seal retainer drift All X 3 B210 610 710 S30
SE 5
Service Equipment
SE 6
WIRING DIAGRAM
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LNISSA NISSAN MOTOR CO
J LTD
Tokyo Japan