ECU DATSUN 210 1979 Service Manual

GI417

Fig
GI
15
Front

Towing
Hook

REAR
SIDE

Rear

towing
hooks

are

provided
on

bot
rear
sides

GI418

Fig
GI

16
Rear

Towing
Hooks

Special
Tools

play
very
important

role
in

the
maintenance
of
cars
These

are
essential
to

the
safe
accurate
and

speedy
servicing

The

working
times

listed
in

the

column
under
FLAT
RATE
TIME
in

FLAT
RATE

SCHEDULE
are
com

puted
based
on
the
use
of

Special

Tools
General

Information

CAUTION

a
Before

towing
make

sure
that
the

transmission
axles

steering
system

and

p
r
train

are
in

good
order

If

any
unit
is

damaged
a

dolly

must
be
used

If
the
transmission
is

inoperative

tow
the

car
with

the
rear
wheels
off

the

ground
or
with
the

propeller

shaft
removed

c
When
the
car
is
towed
with
its
front

wheels
on
the

ground
secure
the

steering
wheel
in
a

straight
ahead

position
with
the

ignition

key

turnedin
OFF

position

d
When

towing
an
automatic
trans

mission
model
on
its
rear
wheels

do

not
exceed

30
km
h
20
MPH

and
a

distance

of30
km

20
miles

e

Release
the

parking
brake
and
set

the

gearshift
lever
in
Neutral

position
before

starting
to

tow
the

car

TIE
DOWN

FRONT

51
DE

Use
front

towing
hooks
for
tie

down
at
the

front
side

SPECIAL

TOOLS

The

identification
code
of

ffi
linte

nance

tools
is
made

up
of
2

alphabeti

calletters
and
8
digital

figures

The

heading
two
letters

roughly

classify
tools
c

equipment
as

STOOOOOOOO

KVOOOOOOOO
Special
Tool

Special
Tool

GI
l0
REAR
SIDE

Use

rear

towing
hooks
for
tie

down

at
the

rear
side

EMOOOOOOOO

GGOOOOOOOO

lMOOOOOOOO

HTOOOOOOOO
Engine

Overhauling

Machine

General

Gauge

Garage
Tool

Hand
Tool

Refer
to

Service
Bulletin
DATSUN

210

fOJ

Special
Tool
List
and
further

information
of

Special
Tools

Engine
Tune

up

BASIC
MECHANICAL
SYSTEM

ADJUSTING
INTAKE

AND
EXHAUST

VAL
fE
CLEARANCE

Note
After

tightening
cYlinder
head

bolts

adjust
intake
and
exhaust

valve

clearances

Valve
clearance
ai
ljustment
cannot

be

made
while
the

engine
is
in

opera

tion

To

adjust
proceed
as
follows

I
Start

engine
and

warm
it

up
uritil

water

temperature
indicator

points
to

the
middle
of

gauge
Then

stop
engine

2
Rotate

crankshaft
to

bring
No
I

cylinder
in

top
dead
center
on
its

compression
stroke

3
Remove

valve
rocker

cover

Adjust
valve
clearance
at

following

four

points
while

engine
is
still
hot

CD
Exhaust
valve

of
No
I

cylinder

@
Intake
valve
of
No
I

cylinder

@
Intake
valve
of
No
2

cylinder

@
Exhaust

valve
of
No
3

cylinder

Note

Numbers
in

circle

agree
with

those
in

accompanying
sketch

tiri

Fig
ET
1

Adjusting
Value
Clearanu

4

Again
rotate
crankshaft
one
turn

so
that

No
4

piston
is
in

top
dead

center
on
its

ompression
stroke
Ad

just
following
valve

s

CID
Exhaust

valve
of
No
2

cylinder

@
Intake
valve
of
No
3

cylinder

j
Intake
valve
of
No
4

cylinder

@
Exhaust
valve
of
No
4

cylinder

Adjustment
should
be
made
while

engine
is
hot
After
all
valves
have
been

adjusted
correctly
tighten
lock

nut

firmly
to
secure
ihe

adjustment

Valve
clearance

Hot

Intake

0
35

mm
0
014

inl

Exhaust
0
35
mm

0
014

in

tJl
Tightening
torque

Valve

rocker

adjusting
nut

1
6

to
2
2

kltm

12

to
16
ft
lb

Alternator

Crankshaft

pulley

Unit
mm

in

Idler

pulley

Fig
ET
2

CHANGING
ENGINE

OIL

1

Check
if
oil
is
diluted
with
water

or

gasoline
Drain
and
refill
oil
if

necessary

Note

a
A

milky
oil
iiulicates
the

presence

of

cooling
water
Isolate
the
cause

and
take
corrective
measure

b
An
oil

with

extremely
low

viscosity

indicates
dilution
with

gasoline

2
Check

oil
level
If
below
the

specified
level
raise
it

up
to
the
H

level

3

Change
engine
oil
in

accordance

with
the
maintenance

schedule

Engine
oil

capacity

A14

With
oil
filter

3
7
liters

3
U
US

qt
3
Yo

Imp
qtl

ET3
CHECKING
AND

ADJUSTING
DRIVE

BELTS

I

Check
for

cracks
or

damage
Re

place
if

necessary

2

Normal
drive

belt
deflection
is

showndI
figure
below
when

moderate

thumb

pressure
is

applied
midway

between

pulleys

Thumb

pressure
10

kg
221bl

Idler

pulley

Compressor
p1
111ey

AC710

Checking
Drive
Belts

for
Deflection

Without
oil
filter

3
2
liters

3

USqt
2

U

ImP
ltl

A15

With
oil
filter

3
3
liters

3
US

qt
2
U

Imp
qd

Without
oil
filter

2
8
liters

3
us

qt
2

Imp
qd

REPLACING
OIL

FILTER

The
oil
filter
is
a

cartridge
type
and

can
be

removed

using
Oil
Filter

Wrench
STl9320000

I
Check
for

oil
leaks

past
gasketed

Oange
If

leakage
is

found
retighten

just
enough
to

stop
leakage
If
reo

tightening
is

no

longer
effective
re

sion

pressure
chances
are

that

piston

rings
are

worn
or
damaged

2

If

pressure
stays
low

the
likeli

hood
is
that
valve
is

sticking
or

seating
Engine
Tune

up

improperly

3

If

cylinder
compression
in

any

two

adjacent
cylinders
is
low

and
if

adding
oil
does
not

help
the

compres
sion
there
is

leakage
past
the

gasketed

surface

Oil
and

water
in
combustion
cham

bers
can
result
from
this

problem

IGNITION
AND

FUEL
SYSTEM

CHECKING
BATTERY

I

Remove
six
vent

plugs
and
check

electrolyte
level
in
each

battery
cell
If

necessary
pour
distilled
water

Overflow
Correct

Shortage

t
t
j

t

t
t

EE358

Fig
ET
6

Checking
Electrolyte

Level
2
Measure
the

specific
gravity
of

battery
electrolyte

E
T372

Fig
ET
7

Checking
Specific
Gravity

of
Battery
Electrolyte

Over
1
22
Full

charge
value

at
200C
680F

1
28

1
26
Permissible
value

Frigid
climates

Other
climates

Note

a
Clean

top
of

battery
and

terminals

with
a

solution
of

baking
soda
and

water
Rinse
off
and

dry
with
com

pressed
air

Top
of

battery
must

be

c1
n
to

prevent
current

leakage

between
terminals
and
from

posi

tive
terminal
to
hold
down

clamp

b
In

addition
to
current

leakage

prolonged
accumulation
of
acid
and

dirt

on

top
of

hattery
may
cause

blistering
of
the
material

covering

ronnector

straps
and
rorrosion
of

straps

c
Afte
r

tightening
terminals
coat

them
with

petrolatum
vaseline
to

protect
them
from
corrosion

CAUTION

If
the

battery
cables
are
disconnected

they
should
be

tightly
clamped
to
the

battery
terminals
to
secure
a

good

contact
Over
I

20

CHECKING
AND

ADJUSTING

IGNITION
TIMING

Check

spark
plugs
for
condition

2

Thoroughly
remove
dirt
and
dust

from
crank

pulley
at

timing
mark

location

and
front
cover
at

timing

indicator

3
Warm

up
engine
sufficiently

4
Connect

engine
tachometer
and

timing
light
in
their

proper
positions

5

Adjust
idling
speed
to
the

specifi

ed
value

Idling
speed

Manual
transmission

700

pm

Automatic
transmission

6S0

rpm

in
0

position

ET
S
WARNING

When
selector
lever
is
shifted
to

0

position
apply
parking
brake

and
block
both
front
and
rear

wheels
with
chocks

Note

a
On
FU
models

set

idling
speed

with

distributor
vacuum
hose
dis

connected

b
Disconnect

distributor
vacuum

hose

at

distributor

diaphragm
side
and

plug
hose
with
blind

plug
See

Fig

ET
8

ET501

Fig
ET

B
Disconnecting
Distributor

Vacuum
Hose

6
Check

ignition
timing
with
a

timing
light
to
ensure
that
it
is

adjust

ed
to

specifications
indicated
below

Ignition
timing

Manual
transmission

SO
B
T
0
C
f700

rpm

California
FU
models

100
B
T
0
C
f700

pm

Non
California
Canada

models

Automatic
transmission

SO
B
T
0
C
f6S0

rpm

California
models

make

sure
throttle
valve

operates

click

sound
is
heard

or

continuity

turns
to

OFF
when

engine
speed

decrease
to

idling

If

not

adjust
throttle
valve
switch

Fig
ET
19

AdjlUting
Throttle
V
ve

Switch

FU
models

If
throttle

valve
switch

g1f1not
be

adjusted
to

specification

replace
Engine
Tune

up

Note

If
it
is
difrlCUlt
to

judge
open

tion
of
throttle
valve

switch

by

hearing
Click
sound
caused

by

microswitch
check

as
follows

1

DiscollI
ecl

throttle
va1ve

switch

ronnector

and
connect
circuit

tester
to
throttle
va1ve
switch

2

Run

engine
under

no
load

Increase

engine
speed
slowly
and
make
sure

it
is

within
the

specified
range
when

throttle
valve
switch
is
turned

on

Then
decrease

engine
speed
slowly

and
make
sure
it
is

within
the

specified
range
when
throttle
va1ve

switch
is

turned
off

If
not

adjust
throttle
valve
switch

3
Make

sure

continuity
of
throttle

vaIve
switch
turns

to
OFF
in
the

operation
desaihed

in

step
6

Engine
operation
Engine
speed
when

throttle
valve

switch

operates
Throttle

valve
switch

continuity

When

engine
speed

increases
1

150
i200

rpm

1

000
1
200

rpm
When

engine
speed

decreases

REPLACING

FUEL

FILTER

I

Check
for
a

contaminated
filter

and

water

deposit

0

9

ET011

Fig
ET
20
Fuel
Filter

All

engines
use
a

replaceable
car

tridge
type
fuel
filter
as
an

assembly

2

Replace
fuel
filter
in
accordance

with
maintenance

schedule
OFF

ON

ON

OFF

CHECKING

FUEL

LINES

Hoses

piping

connections
etc

Check
fuel
lines
for

loose
connec

tions
cracks

and
deterioration
Re

tighten
loose

connections
and

replace

any
damaged
or

deformed

parts

REPLACING
AIR

CLEANER
FILTER

Viscous

paper
type
air

cleaner
filter

does

not

require
any
cleaning
opera

tion
until

it
is

replaced
periodically

Sushing
or

blasting
operation
will

cause

clogging
and

result
in

enrich

ment
of
carburetor

mixture
and

should
never
be

conducted

Replace
air

cleaner
filter
in

accord

ance
with
maintenance

schedule

ET
10
CHECKING

AUTOMATIC

TEMPERATURE

CONTROl
AiR

CLEANER

I
Check

that
vacuum
hoses

Intake

manifold
to
3

way
connector
3

way

connector
to

temperature
sensor

3

way
connector
to
idle

compensator

temperature
sensor
to
vacuum
motor

are

securely
connected
in

C9rrect

posi

tion

2

Check
each
hose
for

cracks
or

distortion

3
Check
A
T
C

system
for
function

by
proceeding
as
follows

ConfIrm
that

engine
is
cold
before

starting
test

With

engine
stopp
d

distonnect

fresh
air

duct

Place
a

mirror
at

the
end
of
air

c1eaner
inlet

pipe
as

shown
and
check

to

see
if
air

control

valve
is
in

correct

pOsition

2J

v
7

EF210

Fig
ET
21

Inspecting
Valve
Position

Air

control

va
ve
is
in

correct

posi

tion

if
its

cold
air
inlet
is

open
and
hot

air

inlet
is

closed

4

Start

engine
and

keep
idling

Immediately
after

engine
starting

check
air
control

valve
for
correCt

position
as
described
above
In

this

case
correct

position
of
air

control

valve
is

the
reverse
of

step
3
under

hood
air
inlet
is

closed
and
hot
air

inlet

is

open

5

Check
that
air
control

valve

gradually
opens
to
cold
air
inlet

side
as

engine
warms

up
When
environmental

temperature
around

temperature

sensor
is

low

spend
more
time
for

engine

warning
up
operation
of

facili

tate
smooth

operation
of
air

control

valve

If
the

above

test
reveals

any
prob

lem

in
the

operation
of
air

control

valve

carry
out
the

further

inspection

described
in

Section
EF

R
EPIACING
AIR

PUMP
AIR

CLEANER
FILTER

Except
FU
models

and
Canada
models

When

replacing
air
cleaner
filter

remove
ir

cleane

frO
ho

od

legge

and
detach
lower

body
and
filter
as
an

assembly

ET530

Fig
ET
23

Replacing
Air
Cleaner

Filter

REPI
ACINGAIR

INDUCTION
VALVE

FILTER

FU
models

and
Canada
models

Remove

screw

securirtg
valve

to
air

cleaner
Air
induction
valve
fIlter
can

be
taken

out
easily
Replace
fIlter

periodically
in
accordance
with
main

tenance
schedule

2

C

l
11
l

r
r

EC9

Fig
ET

24
R

pklcing
Air
Induction

Value
Filter

REPLACING
P
C
V

VALVEANb
FILTER

I
Check
P

C
V
valve
as
follows

With

engine
running
at
idle
remove

the
ventilator
hose
from
P

C
V

valve

if
the
valve
is

working
a

hissing
noise

will
be
heard
as

air

passes
through
the

valve
and

a

strong
vacuum
should
be

felt

inunediately
when
a

finger
is

placed
over
valve
inlet
Engine
Tune

up

2

Replace
P
C
V
Valve
and
filter
in

accord
with
maintenance

schedul

ET531

Fig
ET
25
Replacing
P
C
V
Value

and
Filter

CHECKING

VENTILATION
HOSES

I
Check
hoses
and
hose
connec

tions
for
leaks

2
Disconnect
all
hoses
and
clean

with

compressed
air

If

any
hose
cannot
be

free
of

obstructions

replace

Confirm

that
flame
arrester
is
locat

ed

correctly
in
hose
between
rocker

cover
and
air
cleaner

ET277

Fig
ET
26

Cleaning
Ventilation
Hose

ET

12
CHECKING
VAPOR

LINES

I
Check
all
hoses
and
fuel
tank

flller

cap

2
Disconnect
vapor
vent
line
con

necting
carbon
canister
to
fuel
tank

3
Connect
3

way
connector
mana

meter
and

cock
or

equivalent
3
w

y

charge
cock
to
end
of
vent
line

ET532

Fig
ET
27
Vent
Line

4

Supply
fresh
air
into

vapor
vent

line

through
cock
little
by
little
until

pressure
become

400

mmH20
is
75

inH20

5
Shut

cock
completely
and
leave
it

unatiended

6
After
2
5
minutes

measure
height

of

liquid
in
manometer

7
Varilllion
in

height
should
remain

with
25

mmHp
0
98

inH20

8
When
filler

cap
does
not
close

completely
height
should

drop
to
zero

ih

a
short
time

9
If

height
does
not

drop
to
zero
in

a
short
time
when
filler

cap
is
re

moved
it
is

cause
of
a

stuffy
hose

Note
In
case
vent
tine
B

stuffy

breathing
in

fuel
tank
is
not

thoroughly
made
thlis

caming
in

sufficient
delivery
of
fuel
to

engine

or

vapor
lock
It
must
tberefore
be

repaired
or

replaced

EM303

Fig
EM

31

Checking
Cylinder
Block

Surface

Note
Surface

grinding
6mit

Grinding
limit
of

cylinder
block
is

dependent
upon
cylinder
bead

grinding
of

engjne

Depth
of

cylinder
head

grinding
is

A

Depth
of

cylinder
block

b
1

b
is

U

The
limit
is

A
B
O
imm

0
008
in

The
total
of
A
and
B
should

not
exceed
0
2
mm
0
0079
in

3
With
bore

gauge
measure

cyl

inder
bore
for
out
of
round
or

taper
If

out
f
round

or

taPer
is
excessive
re

bore

cylinder
walls
with
a

boring

machine
Measurement
should
be

taken

along
bores
for

taper
and
around

bores
for

out
f
round

Out
of
round
X
Y

Taper
A
B

60
2

36

20
0
79

I
100
3
94

Ii

B

E9

I
Unit
mm
in

EM479

Fig
EM
32

Cylinder
Bore
Mea

uring

Positions

EM478

Fig
EM
33

Mecuuring
Cylinder
Bore

Diameter
Engine

Mecha
hical

4

When
wear

taper
or

out
of

round
is

minor
and
within
limits
re

move

ridge
at

topmost

portion
of

cylinder
using
a

ridge
reamer
or
similar

tool

CYLlND
ER
BORING

I

When

any
cylin
der
needs

boring

all
other

cY
linders
must
also

be
bored

at

same
time

2

Determine

piston
oversize

accord

ing
to
amount
of

cylinder
wear

3

The
size

to
which
c

linders
must

be
honed
is

determined

by
adding

piston
to
cylinder

clearance
to
the

largest
piston
diameter
at

piston
skirt

in

thrust
direction

f

EM126

Fig
EM
34

Measuring
Piston
Diameter

E

E

5

g

or

ge

I

PI

H

i

I
lEM480

Fig
EM

35
Piston
Diameter

Measuring

Position

Calculation
of

cylinder
bore
diame

ter
to

be
machined

D

A
B
C
A
0
003
to

0
023

mm
0
0001
to
0

0009
in

Where

D

Cylinder
bore

diaIpeter
to
be

machined

A

Piston
diameter
as
measured

B

Piston
to

cylinder
bore
clear

ance
0
023
to
0
043
mm

0
0009
to
0
0017
in

C
For

honing
allowance
0
02

mm
0
0008
in

EM
8
CAUTION

a
To

prevent
strain
due
to

cutting

heat
bore
the

cylinders
in
the
order

of
2
4
1
3

b
Before

boring

any
cylinder
install

main

bearing

caps
in

place
and

tighten
to
the

specification
so
that

the
crankshaft

bearing
bores
will

not
become
distorted

from
the
bor

ing
operation

4

Do
not
cut
too
much
out
of

cylinder
bore
at
a
time

Cut
0
05
mm

0
0020
in

or
so
in
diameter

at
a

time

5

Measurement
of

cylinder
bore

just
machined

requires
the
utmost
care

since
it
is

expanded
by

cutting
heal

6
As

a
final

step
cylinders
should

be
honed

to
final
size

7

Measure
finished

cylinder
bore

for
out
of

round

or

tapered

part

8

Measure

piston
to

cylinder
clear

ance

This
clearance
can

be
checked
easi

ly
with
a
feeler

gauge
and
a

spring

balance
hooked

on
feeler

gauge
meas

uring
amount
of
force

required
to

pull

out

gauge
from
between

piston
and

cylinder

Feeler

gauge
used

0
04
mm

0
0016

inl

Extracting
force

0
5
to
1

51rg

1
1

to
3
3
b

Note

a

Whenmeasuringcleanmce
slowly

pull
feeler

gauge
straight
upward

b
It
is
recommended
that

piston
and

cylinder
be
warmed
to
20

C

680F

r

EM379

Fig
EM
36

Measuring
Pi

ton
Fit
in

Cylinder

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

t
IGHTENING

TORQUE

Cylinder
head
bolt

Rocker
shaft
bracket
bolt

ain

bearing
cap
bolt

Flywheel
fixing
bolt

Drive

plate
fixing
bolt
Al4

AlS

Connecting
rod

cap
nut

Camshaft

sprocket
bolt

Locating
plate
bolt

Valve
rocker

adjusting
nut

Oil
strainer
bolt

Oil

pan
bolt

Oil

pan
drain

plug

Timing
chain

cover
bolt

Crank

pulley
bolt

Water

pump
bolt

Fuel

pump
bolt

Spark
plug

Engine
mounting
securing
bolt
Engine
Mechanical

Unit

kg
iii

ft
lb

7

0
to

7
5
51

to
54

2
0t02
5

14to
18

5

0
to

6
0
36

to
43

8

0
to
9
0
58
to

65

8
0
to
9
0

58
to

65

8
5
to
9
5
61
to
69

3
2
to
3

8
23
to

27

4
0

to
4
8

29
to

35

0

5
to

0
8

3
6
to
5
8

1
6
to
2
2
12to

16

0
9
to
I
4

6
5
to

10
1

0
4

to
0

6
2

9
to
4
3

2

0
to
3

0
14
to
22

0
5
to
0
7
3

6
to
5
1

15to
20

l08
to
145

0
9
to
I
4

6
5
to

1O
l

0
9
to
I
4
6
5
to

10
1

1
5
to
2

0
11

to
14

1
9
to
2
5
14to

18

EM
30

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

Engine
Lubrication

System

SERVICE
DATA
AND
SPECIFICATIONS

Oil

pump
Standard
Wear
limit

Rotor
side
clearance
nun
in
0
04
to
0
08
0
20
0
0079

Rotor

to
bottom
cover

0

0016
to
0

0031

Rotor

tip
clearance
mm
in
less
than

0
20
0
0079

0
12

0
0047

Outer
rotor
to

body
clearance
nun
in
0

15
to
0
21

0
50
0
0197

0
0059

to
0
0083

Oil

pressure
regulator
valve

Oil

pressure
a
t

idling

Oil

pressure
at
3

000

rpm

Regulator
valve

spring

Free

length

Installed

length
load
kg
cm2

psi

kg
cm2

psi
more

than
0
8
II

3
8

to
5
2
54

to
74

nun
in

nun

kg
in

lb
43
49
I

7122

30
3
3
67
1
193

8
09

Tightening
torque

Oil

pump
securing
bolts

Oil

pump
cover
bolt

Regulator
valve

cap
nut
kg
m
ft
lb

kg
m
ft

lb

kg
m
ft
lb
0
9
to

I
4

6
5
to
10
1

0
39
to
0

52
2
8

to
3

8

4

0
to
5
0
29

to
36

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition
Probable
cause
Corrective
action

Oil

leakage
Damaged
or
cracked

body
cover

Oil

leakage
from

gasket

Oil

leakage
from

regulator
valve

Oil

leakage
from
blind

plug
Replace

Replace

Tighten
or

replace

Replace

Decreased
oil

pressure
Leak
of
oil
in

engine
oil

pan

Dirty
oil
strainer

Damaged
or
worn

pump
rotors

Faulty
regulator

Used
of

poor
quality
engine
oil
Correct

Clean
or

replace

Replace

Adjust
or

replace

Replace

Noise
Excessive
backlash
in

pump
rotors
Replace

EL
5