lock DATSUN 210 1979 Owner's Manual

2

Install

piston
rings

Install
so
that

stamped
mark
on

ring
faces

upward

Note

a
There
are
two

types
of

top
rings

One
is
conventional

special
cast

iron

ring
the
other
is
steel

ring

which

is
called

a

high
power

ring

b

Second

ring
has

larger
taper
surface

than

top
ring

c
In
combined
oil

ring

upper
rail
is

same
as
lower

one

I
lnT

10

EM158

Fig
EM

57
Installing
Piston

Ring

3

Fix

bearings
on

connecting
rod

and

connecting
rod

cap

VALVE
ROCKER
SHAFT

ASSEMBLY

Install

parts
as
shown

in

Fig

EM
58
in

place
on
rocker
shaft

@

EM491

Fig
EM
58
Valve
Rocker

Shaft

As

embly

ENGINE

ASSEMBLY

I
The
first

step
in

engine
assembly

is

to
bolt

Engine
Attachment

KV
10
102500
to

right
hand
side

of

cylinder
block
In
succession
install

block
in

Engine
Stand

ST0501S000

with

engine
bottom

up

2

Apply
a

light
coat
of

engine
oil
to
Engine
Mechanical

sliding
surfaces
of
valve
lifters
insert

lifters
in

holes
in

cylinder
block

3

To
install
camshaft
be
sure
to

coat
sliding
surfaces
of
camshaft
bush

ings
with

a
light
coat
of

engine
oil

Insert
camshaft
in

cylinder
block
from

front
side
of

engine
exercising
care

not
to

damage
camshaft

bushings

4

Install
camshaft

locating
plate

and

tighten
bolts
to

specified

torque

i
l

Tightening
torque

Camshaft

locating
plate

0
4
to
0

5

kg
m

2
9
to
3
6
ft

Ibl

Note
Set

locating
plate
so
as
the

Lower
mark
comes
to

engine

bottom
side

Fig
EM
59

Installing
Camshaft

Locating
Plate

5

Install
baffle

plate
and
steel
net

6
Set
main

bearings
at

proper
por

tion
of

cylinder
block
and

caps

No
1
2
3

0

0
0

0
0
0

I
I

J

upperW

r

Lower
J

EM492

Fig
EM
60
Main

Bearings
and

Caps

Note

a
Center

bearing
No
3
is

a

flanged

type
for
thrust
force

b
Two
internal

bearings
No
2
and

No
4
are
of
the

same

type

c
Front

bearing
No
I
is
the

same

type
as
rear

bearing
No
5

EM

13
d
All

bearings

except
No
2
and
No
4

are
not

interchangeable
between

upper
and
lower

bearings

7

Apply
engine
oil
to
main

bearing

surfaces
on
both
sides
of

cylinder

block
and

cap

Install

crankshaft

8

Install
main

bearing
cap
and

tight

en

bolts
to

specified
torque

lil

Tightening
torque

Main

bearing
cap

5
0

to
6
0

kg
m

36

to
43

ft
lb

Note

a

Apply
seal
to
each
rear
main
bear

ing
contact
comer
of

cylinder
block

as
shown
in
F
EM

61

EM493

Fig
EM
6

Applying
Sealant

b

Arrange

parts
so
arrow
mark

on

bearing
cap
faces
toward
front
of

engine

c

Prior
to

tightening
bearing
cap

bolts

place
bearing
cap
in

proper

position
by

shifting
crankshaft
in

axial
direction

d

Tighten
bearing
cap
bolts

gradually

in
two
to
three

stages
outwardly

from
center

bearing
in
the

sequence

shown
in

Fig
EM
62

e
After

securing
bearing

cap
bolts

ascertain
that
crankshaft
turns

smoothly

@I

EM494

Fig
EM

62
Torque
Sequence
of

Cap
Bolts

m
k

camSM9tJ
down
hole

Key
groove

EM767

Fig
EM
11

Setting
No

I
Piston

atT
D
C

18

Tighten
camshaft

sprocket
bolt

ifl

Tightening
torque

Camshaft

sprocket
bolt

4
to
4
8

kg
m

29

to
35
fHbl

EM502

Fig
EM
72

Tightening
Camshaft

Sprocket
Bolt

19
Install
chain
tensioner
and

tight

en
tensioner

attaching
bolts

ifl

Tightening
torque

Tensioner

enaching
bolt

0
6
to
0
8

kg
m

14
3

to
5
8
ft
b

EM503

Fig
EM
73

Installing
Chain

Tensioner

20
Check

projection
L
of
ten

sioner

spindle

If

projection
L
exceeds
the

speci

fied
limit

replace
chain
Engine
Mechanical

Correct

projection
L

Less

than

15
mm
0
59
inl

lEM504

Fig
EM
74

Checking
Projection
of

Tf

nsioner

Spindle

21

Correctly
install
oil
thrower
in

front
of
camshaft

sprocket

22
Press
new
oil
seal
in

timing
chain

cover
F
ran
t

cover
oil
seal
should
be

replaced
when
front
cover
is

disassem

bled

23
Install

timing
chain
cover
with

gasket
in

place

Note
When

inatalling
oil
seal

apply

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and
fold

ed

lip
Also

apply
coating
of
oil
to

periphery
of
oil
seal

ifl
Tightening
torque

Timing
chain

cover
bolts

0
5
to
0
7

kg
m

3
6
to
5
1
ft
Ib

Z5

1
o

j

I

t
f

4

EM455

Fig
EM
75

Installing
Timing
Chain

Covtr

24
Install
water

pump
with

gasket

in

place

ifl
Tightening
torque

Water

pump
attaching
bolts

0

9
to
1
4

kg
m

16
5
to
10
1
ft
bl

25
Install
crank

pulley
then
con

firm
and
set
No
I

piston
at
T

D
C
on

compression
stroke

EM
15
ifl
Tightening
torque

Crank

pulley
nut

15to
20

kg
m

108
to
145
ft
b

26
Invert

engine
Install
oil
stniiner

and
oil

pan
using
new
gasket
and

oil

seal

Note
Give

coating
of
sealant
to
seam

between
oil

pan
gasket
and
oil

pan

oil
seal

ifl
Tightening
torque

Oil

pan
bolts

0
4
to
0
6

kg
m

12
9
to
4
3
ft
lb

27
Install

gasket
and

cylinder
head

Note
Do
not

apply
sealant
to

any

other

part
of

cylinder
block

and

head
surface

28

Tighten
cylinder
head
bolts

ifl

Tightening
torque

Cylinder
head
bolts

7
0
to
7
5

kg
m

51
to
54
ft

IM

Note

a
One

of

cylinder
head
bolts
is
smal

ler

in
diameter
than
others
and
has

a
hollow
head
It
should
be
install

ed
on

right
side
center
of

cylinder

head

b

Tightening
should
be
made
in

two

or
three

steps
finally
torquing
to

specification

c

Retighten
cylinder
head
bolt
after

engine
has
been
warmed

up

Refer
to
Carburetor
Idle
R
P
M

and
Mixture
Ratio
EF
Section
for

Adjustment
and

Inspection

EM505

Fig
EM
76
Cylinder
Head
Bolt

Tightening
Sequence

29

Apply
engine
oiho
both
ends

of

push
rods
and
insert
in

proper
se

quence

30

Apply

engine
oil
to

valve
stem

end
and

rocker
arm
contact

surfaces

Position
rocker
shaft

assembly
on

cyI

inder
head

31

Tighten
rocker
shaft
bracket

bolts
to

specified
torque

fJ

Tightening
torque

Rocker
shaft
bracket
bolts

2
0
to
2
5

kg
m

14
to
18
ft

b

Note

Tightening
should
be
done

in

two
or
three

stages
outwardly
from

center
bracket

EM506

Fig
EM

77
Rocker

Shaft
Bolt

Tightening
Sequence

32

Adjust
valve

clearance
to

speci

fied
value

Note

a
First

set
clearance
to
0

25

mm

0
0098

in
when

engine
iscold

b
After

engine
has
been
assembled

warm
it

up
for
at
least
several

minutes

finally

adjust
clearance
to

specification
For
details
refer
to

Adjusting
Intake
and
Exhaust
Valve

Clearance
in
ET

Section

EM507
or

Wrench

2
Screwdriver

3
Feeler

gauge

Fig
EM
78

Adjusting
Value

Clearance
Engine
Mechanical

Valve

clearance

Intake
and

exhaust

hot

0
35
mm
0
014
in

cold

0

25
mm
0
010
in

fJ

Tightening
torque

Velve
rocker

adjusti
g
nut

1
6
to
2
2

kltm

12
to
16
ft
b

33

Install
rocker

cover

34

Install
intake
and

exhaust
mani

folds

fJ

Tightening
torque

Manifold
nuts

1
5
to
2
0

kg
m

11
to
14

fHb

Note

When

installing
intake
and
ex

haust

manifolds
locate
bolt

in

center
of

fitting
hole

EM528

Fig
EM
79

Installing
Manifolds

35
Install
E
G
R
control

valve

36

Install
baffle

plate
and

carbure

tor

fJ
Tightening

torque

Carburetor
nuts

0
4

to
0
6

kg
m

2
9
to
4
3
ft

Ibl

37
Install
vacuum

control
valve
as

sembly
and
bracket

38
Install

air
cleaner

bracket
and
air

cleaner

39

Connect
air

vacuum
and

blow

by
hoses
to
air

cleaner

40
Install

pipe
connector
to
control

valve
hose
and

engine

mounting
brack

etLR

41

Install

distributor

EM

16
CAUTION

a
8e
sure
to
set
No
1

piston
to

LD
C
of

compression
stroke

b
Before

instaliation
return
distribu

tor
rotor

approximately
30

degrees

from
its
correct

position
Insert

distributor

meshing
distributor

drive

gear
and
driven

gear

c
After
installation
distributor
rotor

should

align
with

mark
on
rotor

cap

J

No
1

mark

EM508

Fig
EM

80
Cornct
P05ition

of

Rotor

42

Dismount

engine
from

Engine

Stand

ST0501S000
and

place
it

on

suitable

engine
stand

Re

move

Engine
Attachment

KVlOI
2500

43

Install

spark
plugs
and

engine

mounting
bracket
R
H

44

Install
oil

pump
and
ftIter

assem

bly

45
Install
thermostat

and
water

outlet

46
Install
fuel

pump
and
fuel

lines

Do
not

forget
to

install

spacer
and

gasket

47

Install
distributor
vacuum
line

48
Install
distributor

cap
and

high

tension

cables
as
an

assembly
Connect

high
tension

cables

49
Insert

oil
level

gauge

50

Install
fan
fan

pulley
and
fan

spacer

Lock
bolt

by
bending
lock

washers

51

Install
alternator
bracket

adjust

ing
bar
water

pump

pulley
alternator

CYLINDER
BLocK

t
60
2
36

20
0
79

I
100

CI
94

rJ

L
II

E9

I
Unit
mm
in

EM479

Cylinder
liner
for

service

4
0
0
157

Undersize

4
5

0
177
Undersize
Engine

MechanicliIl

Surface
flatness

Inner
diameter

Cylinder
bore
Out
of
round

X
V

Taper
A
B

Differential
in
inner
diameter

between
cylinders

Piston

to

cylinder
block
clearance

Outside
diameter

80
00
to
80
05

3
1496

to
3
1515

80
50
to

80
55

3
1692
to
3
1712

PISTON
PISTON
RING
AND
PISTON
PIN

Piston

e

e

5

51

co
ED
I

H

EM4S0
Standard

Over
size
0
50
0
0197

1
00
0
0394

EM

26
Standard

Less
than

0
05
0
0020

76
000

to
76

050

2

9921
to
2
994i

Less
than

O
oI5
0
0006

Less
than

O
oI5
0
0006

Less
than

0
05
0

OO20

0
025
to
0
045

0
0010
to

0
0018

Unit
riun
in

Inside
diameter

75
50

to
75
60

2
9724
to
2

9763

Piston
diameter
Unit
mm

in

Wear
limit

0
1

0

0039

0
20

0
0079

0
20

0
0079

Unit

mm
in

75
967
to
76
017
2

9908
to
2
9927

76
467
to
76
517
3
0105

to
3

0124

76
967
to
77

017
3
0301
to
3

0321

OIL

PUMP

The
oil

pump
and
filter

assembly
is

bolted
to

the

right
side

of
the

cylinder

block
and
can
be
removed

with
the

engine
in

pl
c
The
oil

pump
which
is

driven

by
a

gear
on
the
camshaft

has

the

full
flow

element

type
filter
in

stalled
to
the

oil

pump
cover

REMOVAL

I

Place
a
suitable
container

under

oil

pump

2
Remove
three

bolts

attaching
oil

pump
and
filter

assembly
and

with

draw

assembly

3

Separate
oil

filter
from
oil

pump

4

Ciean
off
old

gasket
from

mating

surfaces

i

E

L043

F
EL

2
R

moving
Oil

Pump

Asso

mbly

INSTALLATION

I

Install
oil
filter
to
oil

pump

2

Locate
oil

pump
and

filter
as

sembly
or

cylinder
block

using
a

spacer
and
new

gasket
Secure
with

three

bolts

l
l
Tightening

torque

Oil

pump
securing
bolts

0
9
to
1
4

kg
m

6
5
to
10
1
ft

lbl

3

Check
oil
level

and
add
oil
if

necessary

4

Start

engine
and

check
for
oil

leaks

5

Remove
the
container
Engine
Lubrication

System

DISASSEMBLY
AND

ASSEMBLY

I

Remove
bolt

securing

pump
cover

to

pump

body
Separate
pump
cover

from

pump
body

2

Slide
out
outer
rotor

from

pump

body

3

Remove
oil

pressure

regulator

plug
washer

shim

spring
and
valve

4

Assemble
oil

pump
in
reverse

order
of

disassembly

Note

a

When

placing
oil

pump
in

a
vice

use
extreme
care
not
to
distort

pump
body
and
cover
in
the

jaws

b
Do

not

pull
out

drive
shaft

pin

securing
drive
shaft

and
inner
rotor

Shaft
is

press
fitted
to
rotor
with

the

pin
caulked

EL044

Fig
EL
3
Oil

Pump

l
l
Tightening

torque

Oil

pump
cove
bolt

0
39

to
0

5
2

kltm

2
8

to
3
8

ti
Ib

Regulator
valve

plug

4
0
to
5
0

kltm

29
to
36
ft

bl
INSPECTION

Wash
all

parts
in

cleaning
solvent

and

dry
wiih

compressed
air

I

hispect
pump
body
and

cover

for
cracks
or
excessive
wear

2

Inspect
pump
rotors
for

excessive

wear

3
Check
inner

rotor
shaft
for

looseness
in

pump
body

4

Inspect
regulator
valve
for
wear

or

scoring

5
Check

regulator

spring
to

see
that

it
is

not
worn
on
its

side
or

collapsed

6

Using
a
feeler
gauge
check

tip

clearance

00
and
outer
rotor
to

body

clearance

CD
shown
in

Fig
EL
4

EL059

1
Outer
rotor
to

body
clearance

2

Tip
clearance

3

Gap
between

rotor
and

stnight
edge

4

Gap
between

body
and

straight
edge

ig
EL
4

Checking
Rotor

Clea
nce

7

Place
a

straight
edge
across
the

face
of

pU
mp
and

depress
it

slightly
as

shown
in

Fig
EL
4

Check

gap

@

between

body
and

straight
edge
or

gap

@
between
rotor
and

straight
edge

Gap

0
03
to
0
06
mm

0
0012
to
0
0024
in

Rotor
side
clearance
rotor
to
bot

tom

cover
clearance
with

gasket

should

satisfy
the

specifications

Standard
Wear
limit

Rotor

side
clearance

mm
in
0

04
to
0
08

rotor
to
bottom

cover

0
0016
to
0
031
0
20
0

0079

Rotor

tip
clearance

V
mm
in
Less
than

0
20
0
0079

0
12
0
0047

Outer
rotor
to

body

mm
in
0

15
to
0
21

0
50
0
0197

clearance

CD
0
0059
to
0
083

EL3

DESCRIPTION

The

cooling
system
is
of
the

con

ventional

pressure
type
A

centrifugal

1P

a

COOLANT
LEVEL

Pour
coolant
into
the

radiator

up
to

the

cap
and
also
into
the
reservoir

up

to
the
MAX
level

CAUTION

To
avoid
serious

personal
injury
never

remove

radiator

cap
quickly
when

engine
is

hot
Sudden
release
of

cool

ing
system
pressure
is

very
dangerous

If

it
is

necessary
to
remove
radiator

cap
when
radiator
is
hot
turn

cap

slowly
counterclockwise
to
the
first

step
After
all

pressure
in
the
cool

ing

system
is
released
turn

cap
passing

the

stop
and
remove
it

DRAINING
AND

FLUSHING

THE
COOLING

SYSTEM

To
drain

the

cooling
system
re

move
radiator

cap
release
drain
cock
C09ling
System

COOLING
SYSTEM

pump
installed
on
the

timing
chain

cover
serves
to
circulate
the

coolant

The

pressure
t
pe
radiator
filler

cap

at
the
bottom
of
radiator
and
drain

plug
on
the
left

side
of

cylinder
block

If
the
heater

system
is

instaDed
set

heater

control
valve
to

open
position

Mter

the
coolant
is

drained

complete

ly
close
drain
cock
and

plug
and
refdl

the

system
with
clean
soft
water

WATER

PUMP

The
water

pump
is
of
a

centrifugal

type
which
is
mounted
on

the

engine

front
cover

TJ
te
pump
shaft

is

sup

ported
by
a
double
row
of
baD

bear

ings
press
fit
in

an
aluminum
die
cast

pump
body
The

bearings
are

per

manently
lubricated
and
sealed
to

pre

vent
loss
of
lubricant
and

entry
of
dirt

CO
2
installed

on
the
radiator

operates
the

cooling
system
at

higher
than
atmos

pheric
pressure

To
heater

From
heater

C0126

Fig
COol

Cooling
System

C0042

Fig
CO
2
Water

Pump
and

Timing
Chain
Couer

REMOVAL

1
Drain

coolant
into

a
clean
con

tainer

2
Loosen

bolts

retaining
fan
shroud

to

radiator
and
remove
shroud

3

I
Loosen
belt
then
remove
fan

blade
fan

spacer
and

pulley
from
hub

Condition

Loss
of

water

Poor
circulation

Corrosion

Overheating

Over

cooling
Cooling
System

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Probable
cause

Damaged
radiator
seams

Leaks

at
heater
connections

or
plugs

Leak
at

water

temperature
gauge

Loose

joints

Damaged
cylinder
head

gasket

Cracked

cylinder
block

Cracked

cylinder
head

Loose

cylinder
head
bolts

Restriction
in

system

Insufficient
coolant

Inoperative
water

pump

Loose
fan
belt

Inoperative
thermostat

Excessive

impurity
in
water

Infrequent
flushing
and

draining
of

system

Inoperative
thermostat

Radiator
fin
choked
with
mud
chaff
etc

Incorrect

ignition
and
valve

timing

Dirty
oil
and

sludge
in

engine

Inoperative
water

pump

Inoperative
torque
coupling
or

tem

coupling

Loose
fan
belt

Restricted
radiator

Inaccurate

temperature
gauge

Impurity
in
water

Inoperative
thermostat

Inaccurate

temperature
gauge

CO
7
Corrective
action

Repair

Repair

Tighten

Tighten

Replace

Check

engine
oil
for

contamination
and
reml

as

necessary

Replace

Check

engine
oil
in

crankcase
for

mixing

with
water

by
pulling
oil

level

gauge

Replace

Tighten

Check
hoses
for

crimps
and
clear
the

system

of
rust
and

sludge
by
flushing
radiator

Replenish

Replace

Adjust

Replace

Use
soft
clean
water
rain

water
is
satis

factory

Cooling
system
should
be
drained
and
flush

ed

thoroughly
at
least
twice
a

year

Permanent
antifreeze

Ethylene
glycol
base

can
be

used

throughout
the

seasons
of
the

year
and

change

periodically
at

intervals

recommended

Replace

Clean
out
air

passage
thoroughly
by
using
air

pressure
from

engine
side
of
radiator

Adjust

Refill

Replace

Replace

Adjust

Flush

radiator

Replace

Use
soft
dean
water

Replace

Replace

Hot

air
Engine
Fuel

To
manifold
I
Air
inlet

pipe

2
Air

con
trol

valve

3
Hot
air

pipe

4

Diaphragm

5
V

Bellum
hose

6

Diaphragm
spring

7
Air

bleed
valve

closed

8

Temperature
sensor

assembly

Fig
EF
3

Hot
Air

Delivery
Mode
During
cold

engine
operation
EC007

COLD
AIR
OPERATION

1
When

the
vacuum
is
small
or

when
the

engine
is

operating
under

heavy
load
the

air
control
valve

opens

widely
irrespective
of
the

temperature

around
the
sensor
to
introduce
the

cold
air
for
increased

power
of
the

engine

2
When
the

engine
intake
air
tem

Cold
air

I
L
CD

mf

LlF

JII

1
perature
is

high

The
s
ns
r
air
bleed
valve

opens

fully
to
break
the
vacuum

passage

between
the
intake
manifold
and
the

vacuum

motor
Due
to
the
force
of
the

vacuum
motor

diaphragm
spring
tne

air
control
valve
closes
the
hot
air

pipe

of
the

air
cleaner
and
introduces
the

cold
air
See

Fig
EF
4

I

manifold
I
Air
nlet

pipe

2
Air
control
valve

3
Hot
air

pfpc

4

Diaphragm

5
Vacuum
hoses

6

Diaphragm
spring

7
Air
bleed
alve

fully
open

8

Temperature

assembly

EF715

Fig
EF
4
Cold
Air

Deliuery
Mode

During
hot

engine
operation

TEMPERATURE
SENSOR

The

temperature
sensor
is
attached

to

the
inside
of
the
air
cleaner
The

bi
metal
built
in
the

sensor
detects
the
engine
intake
air

temperature
and

opens
or

closes
the
vacuum

passage
in

the

sensor

I
Protector
cover

2

Screw

3

Adjusting
frame

4
Air

temperature
bi
metal

5
Rivet

6
Valve

seat
frame

7

Lower
frame

8
Air
bleed
valve

9
Gasket

EF206

Fig
EF

5
Temperature
Sensor

EF
3
VACUUM
MOTOR
AND

AIR
CONTROL
VALVE

The

vacuum
signal
from
the

tem

perature
sensor
acts

upon
the
vacuum

motor

diaphragm
The
valve

shaft
at

tached
to
the

diaphragm
is
then
moved

up
or
down

in

response
to
the
vacuum

on
the

diaphragm
This
movement
of

the
valve

shaft
actuates
the
air

control

valve
to
control
the

temperature
of
the

air
to
be
introduced
into
the

air

cleaner

@

@

@
I
Valve

spring

2

Diaphragm

3

Retainer

4
Valve
shaft

EF207

Fig
EF

6
Vacuum
Motor

REMOVAL
AND

INSTALLATION

AIR
CLEANER

I
Loosen
bolts

securing
air
cleaner

to
air
cleaner
bracket

2
Loosen
air
cleaner

lock
bolt
and

remove
air
cleaner
from
carburetor

Disconnect
the

following
hoses
when

dismounting
air
cleaner

I

Fresh
air
duct

2

Hot
air
duct

3
Vacuum
hose
Sensor
and

idle
com

pensator
to
intake

manifold

4
Hose
Air

pump
relief

valve
Non

California
models

except
Canada

5
Air

induction
hose
Canada
and

FU
models

6
Hose
A
B
valve
to

air
cleaner

7
Hose
Air
cleaner
to
throttle

opener

or
vacuum
switch

8
Blow

by
hose
Air

cleaner
to
rocker

cover

3
To
install

reverse
the
removal

procedure

DASH
POT
SYSTEM

These

carburetors
are

equipped

with
a
dash

pot
interlocked
with
the

primary
thrott
Ie
valve

through
a

link

mechanism

The
dash

pot
prevents
the

throttle

valve

from

closing
abruptly
thereby

reducing
He
emissions

during
deceleia

tion
or

gear
shifting

In
automatic

transmissi9fi
models

it

also

prevents
engine
stall

resulting

from

quick
application
of
the
brake
or

from

quick
release
of
the

accelerator

pedal
after
it
s
been
tread

upon

slightly

INSPECTION

AND

ADJUSTMENT

CARBURETOR
IDLE
R
P
M

AND
MIXTURE
RATIO

CO
idle
adjustment
with

CO
meter

Refer
to
Carburetor
Idle

rpm
and

Mixture
Ratio
Section
ET
for
check

ing
and
a

justment

CO
idle

adjustment
without

CO
meter

Non
California
models

Refer
to

Carburetor
Idle

rpm
and

Mixture
Ratio
Section

ETl
fot
check

ing
and

adjustment

Idle

limiter

cap

Refer
to
Idle

Limiter

Cap

SeCtio

ET
for

checking
and

adjustment

FUEL

LEVEL

I

With

engine
idling

visually
check

fuel
level

through
sight
window
of

float
chamber

Fuel
level
is
correct

if
it

is
at
the

indicator

point

Note

Fuel
level
indicator

point
is

located
IS
mm
0
59
in
below

top

of
carburetor

body
H

as
shown
in

Figure
below
Engine
Fuel

EF088A

Fig
EF
33

Checking
Fuel
Level

To

adjust
fuel
level

proceed
as

follows

2

Remove
choke

chamber

3

Turn
down

choke
chamber

to

allow

float
to

come
into
contact
with

needle

valve
and

measure
H

shown

below

When
H

is

approximately
15
mm

0
59
in

top
float

position
is
correct

The

top
float

position
can
be
ad

justed
by
bending
float
seat

Upon

completion
of
the

adjust

ment

check
fuel

level
with

attached

level

gauge

nhH

J

1
Float

2
Float

stopper
3
Float

seat

4
Needle
valve

Fig
EF
34

Adjusting
Floot
Level

EF

14
4

Adjust
bottom
float

position
so

that
clearance

hl
between

float

seat

and
needle

valve
stem
is
1
3
to
I
7
mm

0
051
to
0
067
in
when

float
is

fully

raised
Bend
float

stopper
as

required

5

Install
choke
chamber

6
After

adjustments
in

steps
3
and

4
above
have
been

made
make

sure

that
when
fuel
is
delivered
to
the

float

chamber
the

fuel
level

is
maintained

within
the

specified
value

H

AUTOMATIC
CHOKE

MECHANISM

I
Before

starting
engine
fully
de

press
accelerator

pedal
to
ensure
that

choke

valve
closes

properly

2
Push

choke
valve
wi
th
a

finger

and

check
for

binding

3

Check
to
be

sure
that
bi

metal

cover
index
mark
is
set
at
the
center
of

choke

housing
index
mark

as
shown

below
I

Note
Do

not
set
b

metal
cover
index

mark

at

any
position
except
the

center
of
choke

housing
index

mark

CD
@

Thermosta

t
covel

Bi
metal
chamber

2
Thermostat

housing

3

Groove
E
T034

Fig
EF
39
Bi
metal

Setting

4

Check
automatic
choke
heater

source

wiring
for

proper
connection

then

start

engine

S
After

warming
up
the

engine
see

that
choke
valve
is

fully
open

6
If
automatic

choke
heater
source

wiring
is
normal
and
choke
valve
does

not

operate
after

warm

up
replace

bi

metal
cover

AUTOMATIC
CHOKE
RELAY

The
automatic
choke

relay
is

local

ed
in
the

relay
box

I
Remove
automatic
choke

relay

by

removing
two

securing
screws
Engine
Fuel

II

EF422A

Fig
EF
40
Location

of
Automatic

Choke

Relay

2
Check
the

continuity
of
the

relay

as
follows

In
normal

condition

continuity
be

tween

CV
and

@
should
exist

Then

apply
l2V

battery
voltage

across

CID
and

@
Under
this
condi

tion
contin

ity
between

CV
and

@

should

disappear

If

not
the

relay
is

faulty
replace
it

W
hWO

CID
CD

CV
o
0

@

Q
I

o
r
@

CID

@

EF989

Fig
EF

41
Checking
Automatic

Choke

Relay

AUTOMATIC
CHOKE

HEATER

I

Measure
resistance

of
choke

heater

Specified
resistance
is

3
7

to
8
9

ohms

EF
17
EF855

Fig
EF
42

Checking
Automatic

Choke
Heater

2
If

measured

value
is
not
within

the

specification
replace
bi
metal

cover

INTERLOCK
OPENING
OF

PRIMARY
AND
SECONDARY

THROTTLE
VALVES

1

Open
primary
side
throttle
valve

480
from

fully
closed

position
and

measure
clearance
G
1
between

throttle
valve
and

throttle
chamber

inside
wall
as
shown

in

Fig
EF
43

Clearance
6G1

5
83
mm
0
230
in

@

J
3

480

r
mit
GI

6

1

Connecting
rod

2

Secondary

connecting

lever

3
Throttle
lever

4

Secondary
throttle

valve

5

Primary
throttle
valve

6
Throttle
chamber

Fig
EF
43

Adjusting
Interlock

Opening
Primary
and

lecondary
throttle

values

2

Without

disturbing
above

setting

bend

connecting
rod

as
necessary
so

that
secondary
throttle
valve
is
about

to

open
E

F089A