checking oil DATSUN PICK-UP 1977 User Guide

Standard

Taper
and
out
of
round

of

journal
and
crank

pin

mm
in
less
than

0
01
0

0004

3
Crankshaft
bend
can
be
checked

by

placing
it

on
V
blocks
and

using
a

dial

gauge
with
its

indicating
finger

resting
on
center

journal

Standard

Crankshaft
bend
mm

in
less
than

0
05
0

0020

Note

When
measuring
bend
use
a

dial

gauge
Bend
value
is

half
of
the

reading
obtained
when
crankshaft
is

turned
one
full
revolution
with
a

dial

gauge
attached
to
its
center

journal

4

After

regrinding
crankshaft
finish

it
to

the
necessary
size
indicated
on

page
EM
18

by
using
an

adequate

undersize

bearing
according
to

the

extent
of

required
repair

5

Install
crankshaft
in
cylinder

block
and
measure
crankshaft
free
end

play
Engine
Mechanical

Maximum

0
Q25
0
0010

EM137

Fig
EM
64

Checking
crankshaft
bend

Maximum

0
10
0
0039

Fig
EM

65
Checking
crankshaft
end

play

Standard
Wear

limit

Crankshaft
free
end

play
mm
in
0
05
to
0

18

0
0020
to
0

0071
0
3
0
0118

6
At
the
rear
end
of
crankshaft

check
crankshaft

pilot
bushing
for

wear
or

damage
Replace
it
if

any
fault

is
detected
To

replace
crankshaft
rear

pilot

bushing
pro
ceed
as
follows

I
Pull
out

bushing
using
Pilot

Bushing
Puller
STl66
1000
I

EM

17
STl6610001

EM425

Fig
EM

66
Pulling
out

pilot

bushing

2
Before

installing
a
new

bushing

thoroughly
clean

bushing
hole

Press

fit

bushing
so
that
its

height
above

flange
end
is
4
5

to
5
0

mm
0
177

to

0
197
in
Do
not

oil

bushing

EM418

Fig
EM
67
Press

fitting
new

pilot

bush

ng

BUSHING
AND

BEARING

MEASUREMENT
OF

MAIN
BEARING
CLEARANCE

I

Thoroughly
clean
all

bearings
and

check
for
scratches
melting
score
or

wear

Replace
bearings
if
any
fault
is

detected

2

Crankshaft

journals
and

bearings

should
be

clean
and
free
from
dust
and

dirt
before
oil
clearance
is
measured

3

Set
main

bearing
on
cap
block

4

Cut
a

plastigage
to
width
of
bear

ing
and

place
it
in

parallel
with
crank

pin
getting
clear
of
the
oil
hole
Install

cap
on
the
assembly
and

tighten
them

together
to
the

specified
torque

Tightening
torque

4
5
to
5
5

kg
m
33
to

40
ft
lb

I
Turn

engine
until
No

I

piston
is

at
T
D
C
on

its

compression
stroke

Determine

whether
camshaft

sprocket

location
notch
comes

off
the
left
end

of
the

oblong
groove
on
camshaft

locating
plate
If
the
location
notch

is

off
the

left
end
of
the

oblong
groove

chain

stretch
is

beyond
limits

40150

EMl46

Fig
EM
74

Camshafllocating
plate

2

Turn

engine
until
No

I

piston
is

at
T
D

C

on
its

compression
stroke

setting
camshaft
on

No
2
location

hole
in

camshaft

sprocket
This
No
2

notch

should
then
be

on
the

right
end

of
the

oblong

groove
When
No
2
hole

is

used
NO
2

timing
mark
must
also

be
used

The
amount

of
the

modifica

tion
is
a

40
rotation

of
crankshaft

3

When
modification
becomes
im

possible
even

by
transferring
camshaft

location

hole

replace
chain

assembly
Engine
Mechanical

CHAIN

TENSIONER
AND

CHAIN
GUIDE

Check
for

wear
and

breakage
Re

place
if

necessary

r

I

L

EM147

Fig
EM
75
Cam

haft
dri
mechanilm

FLYWHEEL

I

Check
clutch
disc

contact
surface

with

flywheel
for

damage
or
wear

Repair
or

replace
if

necessary

2

Measure
runout
of
clutch
disc

contact
surface

with
a
dial

gauge
fit

exceeds
0
15

mm
0
0059
in

total

indicator

reading

replace
it

EM
20
EM426

Fig
EM

76
Checking
flywheel

deviation

3

Check

tooth
surfaces
of

ring
gear

for
flaws

or
wear

Replace
if

necessary

FRONT

COVER
AND

REAR
OIL
SEAL

First
check

front
cover

an
rear
oil

seal
for

worn
or
folded
over

sealing
lip

or
oil

leakage
If

necessary
install
a

new
seal
When

installing
a
new

seal

pay
attenti
on
to

mounting
direction

Note
It
is

good
practice
to

replace
oil

seal
whenever

engine
is

overhauled

Frant
t
r

r

J
I

Front

Real

EM150

Fig
EM

77
Oil

eals

of
crank

haft

6
Make

sure
that

crankshaft
has

proper
end

play

Crankshaft
end

play

0
05
to
0
18

mm

0

0020
to
0
0071
in

Fig
EM
89

Checking
crankshaft

end

play

7

Install
side
oil
seals
into

rear
main

bearing

cap
Prior
to

installing
apply

sealant
to
seals

Fig
EM
90

Driving
side
oil
seal

8
Install
rear
oil
seal

using
Crank

shaft
Rear

Oil
Seal
Drift

STI5310000

r

STl5310000

r

EM163

Fig
EM
91

Installing
rear
oi
seal
Engine
Mechanical

Note
When

installing
oil
seal

give

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and

fold

ed

lip
Also

give

coating
of
oil
to

periphery
of
oil

seal

9

Install
rear
end

plate

10
Install

flywheel
securely
and

tighten
bolts
to

specified

torque

Tightening

torque

14

to
16

kg
m

101
to
116
ft
lb

I
I

Insert

pistons
in

corresponding

cylinder

using
Piston

Ring
Compressor

EM03470000

EM03410000

I

EM544

Fig
EM
92

Installing
pi8ton
rod

a
Sembly

Notes

a

Apply
engine
oil

to

sliding
parts

b

Arrange
80

that
notch
mark
on

piston
head
faces
to
front
of
en

gine

c
Install

piston
rings
at
1800
to

each

other

avoiding
their
fit
in
the

thrust
and

piston
pin
directions

6
Top
ring

I
iilring

Piston

pin
ireClioJ

EM165

Fig
EM

93
PUtan

ring
direction

12
Install

connecting
rod

caps

Tightening
torque

4
5
to
5
5

kg
m
33
to
40
ft
lb

EM
23
Fig
EM

94

Installing
connecting
rod

cap

Note
Install

connecting
rods

and
con

necting
rod

caps
80
that
their

as

signed
numbers
are

positioned
on

the

same
side
and
in
the
SlIme

direction
with

respect
to

cylinders

13
Make
sure
that

connecting
rod

big
end
has

proper
end

play

Fig
EM

95

Checking
big
end

play

Big
end

play

0
2
to
0
3
mm

0
008
to
0
Ql2
in

14

Install

cylinder
head

assembly

Fig
EM
96

Tightening
sequence

01

cylinder
head
bolts

J
Thoroughly
clean

cylinder
block

and

head
surface

Do

not

apply
sealant
to

any
other

part
of

cylinder
block
and
head

sur

face

ENGINE
LUBRICATION
SYSTEM

2
Fill

pump
housing
with

engine

oil

then

align
punch
mark
of

spindle

with
hole
in
oil

pump
as
shown
in

Figure
EL

3

Punch
mark

EL009

Fig
EL
3

Aligning
punch
mark

and
oil
hole

3

Using
a
new

gasket
install
oil

pump
and
drive

spindle
assembly
so

that
the

projection
on
its

top
is

located
in
II
25
a
m

position
at

this
time
the
smaller
bow

shape
will

be

placed
toward
the
front
as
shown

in

Figure
EL
4

JI

I
c

J

V

Front
J

@
9@

tr
i

d

L
It
I

I
EL010

Fig
EL

4
Setting
drive

pindle

o

EL011

Fig
EL

5
Imtalling
oil

pump

Ascertain
whether

or
not

the
en

gagement
is
in
order

by
checking
the

top
of

spindle
through
distributor
fit

ting
hole

4

Tighten
bolts

securing
oil

pump

to
front
cover
Disassembly

and

assembly

I
Remove

pump
cover

attaching

bolts

pump
cover
and
cover

gasket

and
slide
out

pump
rotors

2
Remove

regulator

cap
regulator

valve
and

spring

3

Install

pressure
regulator
valve

and
related

parts

4
Install

outer
rotor
inner
rotor

and
shaft
in

pump
body
and
do
not

turn
cover

gasket
up

CD

El012

r

@
@

CD@

1

Oil

pump
body

2
Inner
rotor
and
shaft

3
Outer
rotor

4
Oil

pump
cover

5

Regulator
valve
6

Regulator
spring

7
Washer

8

Regulator
cap

9
Cover

gasket

Fig
EL

6
Oil

pump

Inspection

Wash
all

parts
in

cleaning
solvent

and

dry
with

compressed
ir

I

Inspect
pump
body
and
cover

for
cracks
or
excessive

wear

2

Inspect
pump
rotors
for
excessive

Rotor
side
clearance

rotor
to
bottom

cover
Olm
in

Rotor

tip
clearance

@
mOl
in

Outer
rotor
to

body

clearance

D
mm

inl

EL

3
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
2
and

outer
rotor
to

body

clearance
I

shown
in

Figure
EL
7

1
Outer
rotor
to

body
clearance

2

Tip
clearance

3

Gap
between

rotor
and

straight
edge

4

Gap
between

body
and

straight
edg
e

Fig
EL
7

Checking
rotor
clearance

7

Place
a

straight
edge
across
the

face
of

pump
and

depress
it

slightly
as

shown
in

Figure
EL
7

Check

gap
4

between

body
and

straight
edge
or

gap

3
between

rotor
and

straight
edge

The

gap
should
be
0
03
to
0

06

mm

0
0012
to
0
0024
in
then

rotor
side

clearance
rotor
to
bottom

cover
clearance
with

gasket
should

satisfy
the

specifications

Standard
Wear

limit

0
04

to
0

08

0
0016
to

0
0032
0
20
0
0079

Less

than

0
12
0

0047
0

20
0
0079

0

15
to
0
21

0
0059

to
0
0083
0
5

0
0197

Conventional

COUplin9

WATER
PUMP
SPEED

F

Z

Tern

coupling

WATER
PUMP

SPEED

C0029

Fig
CO
6
Characteristic

of

Tern
coupling

INSPECTION

Check
Tem

coupling
for
oil

leakage

or
bend
of
bimetal

If
the
above

symptoms
are
found

replace
it
with

a
new
one
as
an

assembly

THERMOSTAT

A
wax

pellet
type
thermostat
is

mounted
in
the
thermostat

housing
at

the

cylinder
head
water
outlet

The
function
of
the
thermostat
is

to
control
the

flow
of
coolant
facili

tating
fast

engine
warm

up
and

regu

lating
coolant

temperature
The
ther

mostat
is

designed
to

open
and
close
at

predetermined
temperatures
and
if

not

operating
properly
should
be

re

moved
and
tested
as
described
below

REMOVAL
AND

INSTALLATION

I

Drain
coolant

partially

2
Disconnect

upper
radiator
hose
at

water
outlet

3

Remove
bolts

and
remove
water

outlet

gasket
and
thermostat
from

thermostat
housing

Fig
CO
7

Removing
therm06t
t
Cooling
System

4

After
checking
thermostat
re

install
with

a
new

housing
gasket
in

place

5
Reinstall
water

outlet

6

Replenish
coolant
and
check
for

leaks

INSPECTION

A

sticking
thermostat
will

prevent

the

cooling
system
from

functioning

properly
If
the
thermostat
sticks
in

the

open
position
the

engine
warms

up
very
slowly
If
the
thermostat

sticks
in

the
closed

position
over

heating
will
result
Therefore
the
ther
mostat
should
be

inspected
to

make

sure
that
it
is
in

good
condition

1
Measure
coolant
temperature

when
thermostat
valve
starts
to

open

2
Measure
the
maximum
lift

of

thermostat
valve

Fig
CO
S

Impecting
therm06t
t

Temperate
Frigid
Tropical

type

type
iype

Valve

opening

80
5
to
83
5
86
5
to
89
5
75

to
78

temperature

177
to
183
187
to
193

167
to
172

oC
OF

Maximum

valve
lift
8
95
8
1
00
8
90

mm
oC

in
F
0
31
203

0
31
212
0
31

194

If
thermostat
does
not

operate
at

the
above

specified

temperature
it

must
be

replaced
because
it
cannot
be

repaired

RADIATOR

The
radiator
is

a
conventional
down

flow

type
having

top
and

bottom

tanks
to

distribute
the
coolant
flow

uniformly
through
the
vertical
tube
of

radiator
core

The

radiator
filler

cap
is

designed
to

maintain
a

pre
set

pressure
0
9

kg
cm2
13

psi
above

atmospheric

pressure

The
relief
valve

consisting
of

a

blow
off

valve
and
a

vacuum
valve

helps
to

prevent
the
coolant
from

boiling
by
giving

pressure
to
it
How

ever
when

the

pressure
is
reduced

below

atmospheric

pressure
the

vacu

um
valve
allows
air

to
re
enter

the

radiator

preventing
the
formation
of
a

vacuum
in
the

cooling
system

CO
5
On
models

equipped
with
auto

matic
transmission

the
oil
cooler
is

combined
with
the

radiator
to
cool

transmission
fluid

REMOVAL
AND

INSTALLATION

Drain
coolant
into
a
clean
con

tainer

2

Disconnect
radiator

upper
and

lower
hoses
On
models
with
auto

matic
transmissions
disconnect
cooler

inlet
and
outlet
lines
from
radiator

3

Remove
fan
shroud
retaining

bolts
and

remove
fan
shroud

4

Remove
front

grille

5

Remove
radiator
retaining
bolts

and
then

remove
radiator

upward

6
Install
radiator
in
the
reverse
se

quence
of
removal
Note
the
fol

lowing

I
Insert
hoses
in

their

positions

until

they
bottom

2
Ensure
that
arrow
marks
on

hoses
are

clearly
visible
from

upper

There
are
three

types
of
control

system
These
are

J

Closed

type
CIllnkcase
emission

control

system
Emission
Control

System

of

GENERAL

DESCRIPTION

2

Exhaust
emission

control

system

3

Evaporative
ell
lhsion

control

sys

tem

Pericxiic

inspection
and

required
seCV1Clng
of
these

systems
should
be

carried
out

to
reduce

harmful
emis

sions
to
a
minimum

CRANKCASE
EMISSION
CONTROL

SYSTEM

c

01

Lkf

If
1

TIL
II
tll

1

j

GUuuu
DESCRIPTION

This

system
returns

blow

by
gas
to

both
the
intake
manifold
and
carbure

tor
air

cleaner

The

positive
crankcase
ventilation

p
C
V

valve
is

provided
to
conduct

crankcase
blow
by

gas
to
the
intake

manifold

During

partial
throttle

operation
of

the

engine
the
intake
manifold
sucks

the
blow

by
gas
through
the
P
C
V

valve

Normally
the

capacity
of
the

valve

is

sufficient
to
handle

any
blow

by
and

a
small
amount
of

ventilating
air

4

c
Fresh
air

Blow
by

gas
The

ventilating
air

is
then

drawn

from

the
dust
side
of
the
cadlUretor

air
cleaner

tluough
the
tube

con

necting
carburetor
air
cleaner
to
rock

er
cover
into
the

crankcase

Under
full
tluottle

condition
the

manifold
vacuwn
is

insufficient
to

draw

the
blow

by
flow

tluough
the

valve
and
its

flow

goes
through
the

tube
connection
in
the

reverse
diree

tion

On
vehicles
with
an

excessively

high

blow

by
some
of
the
flow
will

go

through
the
tube

connection
to

carbu

retor
air
cleaner
under
all
conditions

1

Sealtypc
oil
level

gauge

2
Bame

plate

3
Flame
arrester

4
Filler

5
P
C
Y
valve

6
Steel
net

7
Bame

plate

EC716

Fig
EC

l
Crankcase
miaion
control

ay
tem

EC

2
INSPECTION

P
c
V
VALVE
AND

FILTER

Checking
P
C
V
valve
in

accord

ance

with
the

following
method

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
vacuwn
should
be

felt

immediately
when
a

fmger
is

placed
over
valve
inlet

Replace
P
C
V
valve
and

filter
in

accordance
with
the
maintenance

schedule

VENTILATION
HOSE

1

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

Ensure
that
flame
arrester

is

surely

inserted
in

hose
between
air
cleaner

and
rocker
cover

REMOVAL
AND
INSTAUATION
Emission
Control

System

EC533

Remove

snap
ring
D
and
lock
bolt

@
and
the

following
parts
can
be

detached
from
heat
control
valve

shaft

Key
00

Counterweight
@

TherI
lostat
spring
CID

Coil

spring

@

Note
As

previously
descnoed
heat

control
valv

1
is

welded
to
valve

shaft

@
at
exhaust
manifold
and

cannot
be

disassembled

To
install

reverse
the
removal

pro

cedure

INSPECTION

I
Run

engine
and

visually
check

counterweight
to

see
if
it

operates

properly

1
For
some
time
after

starling

engine
in
cold
weather

counterweight

turns
counterclockwise
until
it

comes

into
contact
with

stopper
pin
installed

to

exhaust
manifold

Counterweight
gradually
moves

down
clockwise
as

engine
warms

up

and

ambient

temperature
goes
higher

around
exhaust
manifold

2
When

engine
speed
is

increased

discharge

pressure
of
exhaust

gases

causes

counterweight
to

move
down

ward
clockwise

3

When
heat

con
trol
valve
is
in
the

full

open
position
coun

terweight

moves
further
clockwise
exceeding
the
1

Snap
ring

2

Lock
bolt

3

Key

4

Counterweight

5
Thermostat

spring

6
Coil
spring

7

Heat
control
valve

8
Valve
shaft

9
Stove
gasket

10
Manifold
stove

11
Heat
shield

plate

Fig
EC
5

Exploded
view
of
E
F
E
stem

position
described
in
1

1
above

and

stops
again
coming
into
con
tact
with

stopper
pin

j

EC246

1

Counterweight

2
S

topper
pin

3
Heat
control
valve

Fig
EC
6

Operation
of
counterweight

when

engine
is
cold

EC246

1

Counterweight

2

Stopper
pin

3
Heat
control

valve

Fig
EC
7

Operation
of
counterw
ight

when
ngine
is
hot

EC
7
2

With

engine
stopped
visually

check
E
F
E

system
for
the

following

items

1
Thermostat

spring
for
dismount

ing

2

Stopper
pin
for
bend
and
count

er

weight
stop

position
for

dislocation

3

Check
heat
control
valve
for

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
1

5

mm
0
028
to
0
059
in

5
Check
welded

portion
of

heat

control
valve
and
valve
shaft
for

any

indication
of
crack
or

flaking

6
Rotate
heat
control
valve
shaft

by
a
finger
and
check
for

binding

between
shaft
and

bushing
in

closing

and

opening
operation
of
heat

control

valve
If

any
binding
is
felt
in

rotating

operation
move
valve

shaft
in
the

rotation
direction
several
times
If

this

operation
does

not
correct

binding

condition
it
is
due
to
seizure
between

shaft
and

bushing
and
exhaust
mani

fold
should
be

replaced
as
an
assem

bly

CHECKING
SPARK

TIMING
CONTROL

SYSTEM

DESCRIPTION

The

spark
tirnin
control

system

serves
to
control
the
distributor
vacu

um
advance
under

varying
travelling

conditions
so
as
to
reduce
HC
and

NOx
emissions

This

system
is
installed
on
non

California
automatic
transmission

models

SPARK
DELAY
VALVE

Automatic
transmission

models
only

This

valve
delays
vacuum

spark

advance

during
rapid
acceleration
it

also
cuts
off
the

vacuwn

spark
advance

immediately
upon
deceleration
The

valve
is

designed
for
one

way
opera

tion
and
consists
of
a
one

way
umbrel

la
valve
and
sinlered
steel
fluidic

restrictor

Emission
Control

System

C
bur
tor

I

EC284

When

installing
this
valve

ensure

that
it

properly
oriented
Tlus
valve

shuuld
be

replaced
periodically
Refer

to
Maintenance
Schedule

Note
Carburetor
side
Black

DisInDutor
side

Brown

horn
distributor

To

carburetor

TOdi

ribUI0
carburClor

EC
lCiJr

Fig
EC

9
Operation
01

park
delay

value

INSPECTION

Remove

spark
delay
valve

2
Blow

air

through
port
on
carbure

tor

side
then

through
the

other

port

on
distributor
side

Spark
delay
valve
Distributor
side

1
One
way
umbrella
valve

2
Sintered
metal

disc

Fig
EC
8

Spark
delay
valve

is
in

good
condition
if
when

finger
is

placed
over

port
on
distributor
side

air

flow
resistance
is

greater
than
that

on
the

other
side
See

Figur
ET
lO

3
If
a

considerable
air
flow
resist

ance
is

fell
at

port
on
distributor
side

in

step
2

above
and
if

the
condition
of

spark
delay
valve
is

questionable
dip

port
on
carburetor
side
into
a

cup

filled
with

water
Blow
air

through
the

other

port
Small
air
bubbles
should

appear

Carburetor
side

Distributor
side

EC346

Fig
EC
IO

Checking
park
delay
valve

EC
8
EC219

Fig
EC

11

Checking
spark
d

tay
valve

Note
Be
careful
to
avoid

entry
of
oil

or
dirt
into
valve

AIR
INJECTION

SYSTEM

DESCRIPTION

The
Air

Injection

System
A

LS
is

aeSigiieino

iiiject
coin

pressed
air
sec

ODllary
air

corning
from
the
air

pump

into
the
exhaust
manifold
to
reduce

hydrocarbons
and
carbon
monoxide
in

exhaust
lri
s

through
re
combustion

There

are
two

types
of
A

I

S
One

type
is
mounted
on
California
models

and
the
other
is
on
non
California

models
The
non
California

type
con

sists
of
an
air

pump
air

cleaner
an
air

pump
a
relief

valve
a
check
valve
an

anti

backfIre
valve
an
air

gallery
and

hoses
The
California

type
has
in

addition
to
the

components
of
the

non
California

type
an
air
control

valve
and

an

emergency
air
relief
valve

These
valves

prevent
ahnonnal
tem

perature
rise
of
the

catalytic
converter

4
E
G
R

warning
system

EC251

Detector
drive
counter

Detecfor
drive
counter
is
secured

on
the

top
of
R
H

hoodledge
panel
in

engine
room
To

remove
detector
drive

counter
disconnect
w
COJUlector

and

loosen
two
bolts

securing
detector

drive
counter
to
hoodledge

panel

2

E
G
R

warning
lamp

E
G
R

warning
lamp
is
mounted
at

the

top
cen
ter
of
instrument

pad
To

remove
E
G

R

warning
lamp
proceed

as
follows

1
Remove

masking
panel

On
models

equipped
with
radio

remove

warning
lamp
from
under
in

strument

panel

2

E
G
R

warning
lamp
is

a
twist

type

Remove

lamp
and
socket

as
an

assembly
Push
and
twist

lamp
off

can

EC554

Fig
EC
60
Removing
E
G
R

warning

lamp
Emission
Control

System

3
Odometer
switch

Odometer
switch
is
mounted
on
the

back
side
of

speedometer
Cam
in
the

odometer
switch
is
rotated

by
the

speedometer
To

dismount
odometer

switch

proceed
as
follows

I

Dismount
combination
meter
as

sembly

2
Remove
meter
front
cover
and

take
off

clips
and
screws
to

dismount

shadow

plate

3

Loosen
screws

securing
speed

ometer
to

printed
circuit

housing
then

remove

speedometer

4

Remove
two
screws

securing

odomete
switch
to
the

back
side
of

speedometer
and
detach
odometer

switch

EC239

Fig
EC
61

Removing
odometer

switch

InstaUatlon

To
install
reverse
the
removal

pro

cedure

EC24
V

r
CID

1
Detector
drive
counter

2
E
G
R
warning
lamp

3
Speedometer

Fig
EC
59
E
G
R

warning
y
tem

INSPECTION

Checking
E

G
R
control

system
in

its
mounted
conditionS

I

Make
a

thorough
visual
check
of

E

G
R
control

system
If

necessary

wipe
away
oil
to

facilitate

inspection

If

any
hoses
are
cracked
or

broken

replace

2

With

engine
running
check

E

G
R

warning
system
for

proper

function
Make
sure
that
E

G
R
warn

ing
lamp
lights
when

ignition
switch
is

turned

to
START

position
starter

mo

tor
runs
If
E
G
R

wanung
lamp
does

not

light
inspect
harnesses
and

con

nectors
or

replace
warning
lamp
Then

turn

ignition
switch
to
ON

position

and

check
the
following
items

I

If
odometer
of
detector
drive

counter
has
not
reached
50
000

counts
make
sure
that
E
G
R

warning

lamp
does
not
light

2
If
odomete
of
detector
drive

counter
has
attained
50
000
counts

make
sure
that
E
G
R

warning
lamp

lights

If

warning
lamp
does
not

light

check
harnesses
connectors
and
de

tector
drive
counter
replace
warning

lamp
or
detector
drive
counter
if

necessary

Notes

Operation
oC
E
G
R

warning
lamp

is
as
Collows

CHECKING
AND

ADJUSTMENT

CAP
AND
ROTOR
HEAD

Cap
and
rotor
head
should
be
in

spected
periodically
as

specified
in
the

Maintenance
Schedule
Remove
cap

and
clean
all
dust
and
carbon
deposits

from

cap
and
rotor
If

cap
is
cracked

or
is

leaking
replace
with
a
De
one

CONTACT
POINT

Contact

point
should
be

replaced
in

accordance
with
the
Maintenance

Schedule

Standard

point
gap
is
0
45
to
0
55

mm
O
OIS
to
0

022
in
In

case
size

is
off
the
standard

adjustment
is
made

by
loosening
point
screws

Gap
gauge

is

required
for

adjustment

When

point
surface
is

rough
take

off

any
irregularities
with

fine
sand

paper
of
No
500
or
600
or
with
oil

stone

When
wear

on
contact

points
is

noticeable
replace
points
together

with
contact

arm
To

replace

proceed

as

follows

EE322

Fig
EE
58
Adju
ting
point

gap

EE321

I

Primary
lead
termina

2
Ground
lead
wire

3
Set
screw

4

Adjuster

5
Screw
Fig
EE
59
Breaker
Engine
Electrical

System

First
turn
out
set

screws
1
to

1
5

turns
at
contact
arm
and

primary
lead

wire

connection

just
for

enough
to

pull
out

primary
lead
terminal

Referring
to

Figure
EE

59
unSCrew

two
contact
set

fixing
screws

and

remove
lead
wire

While

holding
contact
arm

by

fingers

pull
out
contact
set

toward

you
by

raising
it

slightly
Contact

point
and

afm
can

then
be

removed

together

Install
new
contact

point
and

arm

assembly
in

reverse
sequence
of

removal

Coat
cam
with
a

light
coating

of

grease

ADVANCE
MECHANISMS

Specifications

Application

Vacuum
advance

Distributor

degrees
distributor

mmHg
inHg

Centrifugal
advance

Distributor

degrees

distribu
tor

rpm

For
Canada

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate
properly
check
for
the

following
items

and
correct
the
mal

function
as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
its

connection

Ifnecessacy

retighten
or

replace
with
a
new
one

2
Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controller

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

pia
te
does
not

move

smoothly

this
condition
could
be
due
to

sticky

steel
balls
or

pivot
Apply
grease
to

steel
balls
or
if

necessary

replace

breaker

plate
as
an

assembly

EE
31
CONDENSER

Satisfactory
performance
of
con

denser

depends
on

capacity
and

degree

of
insulation

requiring
attention

to
be

sure

that
terminals
are
clean
and
set

screws
are

tight

Checking
of

condenser
is
made

by
a

condenser
tester

D4A4
06

D4A6
07
D4A4
07

D4A6
0S

Automatic

transmission
Manual
transmission

00
150
5

91

30
250
9

S4
00
170
6

69

6
50
300

1I
S1

00
550

11
0

2

300
00
600

110
1
950

Centrifugal
advance

mechanical

parts

When
cause
of

engine
malfunction

is

traced
to

centrifugal
advance
me

chanical

part
use
distributor
tester
to

check
its
characteristic

See
the

specifications
above

When

nothing
is

wrong
with
its

characteristic
conceivable
causes
are

break
down
abnormal

wearing
out
of

driving
part
or
others
So
do

not

disassemble

it

In

case
of

improper
characteristic

take
off
contact
breaker

assembly
and

check

closely
cam

assembly

governor

weight
shaft
and

governor
spring
etc

In
case

centrifugal
advance
me

chanical

part
is
reassembled
be

sure
to

check
advance
characteristic

by
dis

tributor
tester