height DATSUN PICK-UP 1977 Service Manual

Fig
GI
9
Manual
trammiuion
number

location

Automatic

transmission

number

The
transmission

serial
number
is

attached
to
the

right
hand
side
of

transmission

case

Numbering
system

X
XXXXX

I

Serial
number

monthly

Month
of

manufacture

I
2

9
X
Y
Z

last

figure
of

year
of

manufacture

AT344

Fig
01
10
Automatic
trammi

sion

number
location

LIFTING
POINTS

AND
TOWING

LIFTING

POINTS

Screw

jack

Before

using
the

jack
proceed
a

follows
Generallnforml
ition

Apply

parking
brake

firmly
and

block
rear
wheels
if
the
front

of
the

vehicle
is
to

be
raised

Notes

a
Never

get
under
the
vehicle

while
it

is

supported
only
by
the

jack

Always
use

safety
stands
to

support

frame

or
rear
axle

case
when

you

have

to

get
beneath
the
vehicle

b
In
no
event
should
the

jack
be

applied
to

any
points

except
the

following
specified
portions

When

jacking
up
the
front
side

place
a
screw

jack
under
side
frame

about
520
nun

20
5
in
at
rear

of

front
axle
center

WT012

Fig
GI
ll
Front

lifting
point

When

jacking
up
the

rear
side

place

a
screw

jack
under
rear
axle
case
close

to
the
side

of
rear

spring

WH077

Fig
GI
12
Reor

lifting

point

Notes

a
When

the

yellow
mark

appean
on

the
screw

jack
it
indicates
the

maximum

permissible
height
Do

not

jack
up
further

b

When
the

jack
is
at
lower
llinit
do

not

add

large
force
downward

GI
6
YeDow
mark

WHOSO

Fig
GI

13

Warning

ogai
t

over
stroke

Garage

Jack

Note
When

carrying
out

operntions

with
a

garage

jack
be
sure
to

support
the
vehicle
withstands
in

a
safe
manner

When

jacking
up
the
front
end

apply
garage
jack
to
front
cross

member
or
center

portion
of
sus

pension
member

When

jacking
up
the
rear
end

apply
the

jack
to
rear
axle
case

r
J

uc

I

GI075
n9

Fig
GI

14
Front

lifting
point

GI076

Fig
GI
15
Rear

lifting

point

r
EC350

Fig
ET
43

Cleanill
l
E
G
R
control

lJ
Jlue

Thermal
VBCuum
valve

Dismount
thermal
vacuum
valve

from

engine

Note
Before

dismounting
drain
e

gine
coolant
from

engine

Apply
vacuum
to
thermal
vacuum

valve
and
check
to
be
sure
that
ther

mal
vacuum
valve

opens
or
closes
in

response
to

engine
coolant

tempera

lurt
i1
i

iYCl
lt
lt
U

Thermal
vacuum
valve
should

open

at
a

temperature
of
57
to
630C
134

to
1450F

completing
the
vacuum

passage

Note
Do
not
aUow
water
to

get

inside
the
thermal
vacuum
valve

EC
242

Fig
ET
44

Checkill
lthermallXlCuum

valve
Engine
Tune

up

CHECKING

EVAPORATIVE

EMISSION
CONTROL

SYSTEM

Vapor
Rnes
and
fuel

vepor

control
valve

Checking
fuel
tank

vapor

liquid

separator
and

vapor
vent
line

I
Check
all
hoses
and
fuel
tank

roler

cap

2
Disconnect
the

vapor
vent
line

connecting
carbon
canister
to

vapor

liquid
separator

3
Connect
a
3
way
connector
a

manometer
and
a
cock
or
an

equiva

lent
3
way

charge
cock
to

the
end
of

the
vent
line

4

Supply
fresh
air
into
the

vapor

vent
line

through
the

cock
little

by
little
until

pressure
becomes
368

mmH20
14
5
inH20

5

Shut
the
cock

completely
and

leave
it
unattended

6

After
2
5
minutes

measure
the

height
of
the

liquid
in

the
manometer

7

Variation
of

height
should
remain

with
25

mm
l20
0
98
inH20

8
When
filler
cap
does

not
close

completely
the

height
should
drop
to

zero
in

a
short
time

9
I
f
the

height
does
not

drop
to

zero
in

a
short
time
when
filler

cap
is

removed
it
is
the

cause
of
a

stuffy

hose

Note
In

case
the

vent
line

is
stuffy

the
breathing
in

fuel
tank
is
not

thoroughly
made

thl
causing
in

suffICient

delivery
of
fuel
to

engine

or

vapor
lock
It
must
therefore
be

repaired
or

replaced

3
way
connectoT

36
mmH20

14
5
inH20

c

s
I

W

@

Carbon
canister

r

EC786

Fig
ET
45

Checking
evaporative
emission
control

By
tem

Checking
carbon
canister

purge

control

valve

Check
for
fuel

vapor
leakage
in
the

distributor
VC
line
at

diaphragm
of

carhon
canister

purge
control
valve

To
check
for

leakage

proceed
as

follows

1
Disconnect

rubber
hose
in

the

line
between
T
connector
and
carbon

canister
at
T

connector

2
Inhale
air
into

the

opening
of

rubber
hose

running
to
VC
hole
in

carbon
canister
and
ensure
that
there

is

no
leak

ET

22
I

I

L

I

ET349

Fig
ET
46

Checking
carbon
cani
ter

purge
control
valve

Engine
Mechanical

Valve

head
diameter

I
In
42

0
to
42

2
1

654
to
1
661
VALVE
SPRING

H
1

Check
valve

spring
for

squareness

mm
in

Ex
35
0

to
35
2
1
378

to
1
386
using
a
steel

square
and
surface

plate

In
114

9
to
115
2
4
524
to

4
535
If

spring
is

out
of

square
more
than

Valve
length
1

6
mm
0

063
in

replace

L

mm
in
2

Measure

lhe
free

length
and
ten

Ex
1157
to

116
0
4
555
to
4
567

sion
of

each

spring
If
the

measured

Valve
stem
diameter
In
7
965

to
7

980
0
3136
to

0
3142
value
exceeds

specified
limit

replace

D

mm
in
spring

Ex
7
945

to
7

960
0
3128
to

0
3134

Valve
seat

angle
In
45030

a

Intake
and
Exhaust

Ex
45030

EM110

Fig
EM
37

Checking
valve
tern

diameter

Spring

specifications

Valve

spring
free

length

Intake

and
exhaust

Outer

Inner

Valve

spring
pressured

length

valve

open

Intake
and
exhaust

Outer

Inner

Valve

spring
assembled

height

valve

close

Intake
and
exhaust

Outer

Inner
EMll1

Fig
EM

38

Regrinding
valve

face

Note

When
valve
head
has
been
worn

down
to
0
5
nun

0
0197
in
in

thickness

replace
the
valve

Grinding
allowance
for

valve
stem

end
surface
is
0

5
mm
0
0197
in

or
less

mm
in

mmlkg
in
lb

mmlkg
in

lb

EM
9
I

i

J
T

EM112

Fig
EM
39

Measuring
spring
quareneu

1

EM113

Fig
EM

40
Measuring
apring
ten
ion

49
98
1

968

44

85
1
766

29
5
49
0
1
161

108

24
5
25
5
0
965156
2

40
0

21
3
1
575
47

0

35

0
12
3
1

378
27
I

Standard

Camshaft
bend

mm
in
0

02
0
0008

CAMSHAFT

ALIGNMENT

I
Check
camshaft
camshaft

journal

and
earn
surface
for
bend
wear

or

damage
If

damage
is

beyond
limits

replace
affected

parts

2
A
bend
value
is
one
half
of
the

reading
obtained
when
camshaft
is

turned
one
full
revolution
with
a
dial

gauge

applied
to
2nd

and
3rd

journals

Standard

height

of
tam
mm
in
I
Intake

1
Exhaust

Wear

limit
of
earn

height
mm
in

Allo
able
difference
in

diam
ter

betweim
max
worn

and
min

mm
in

worn

parts
of
c

mshaft

journal
Engine
Mechanical

Bend
limit

0
05
0
0020

I

Fig
EM

50
Checking
camMa
t
bend

40
30
to
40
35

1

5866
to
1
5886

0
25
0

0098

0
05
0
0020

Maximum
tolerance
in

j01
irri

mm
in
0
1

0
0039

diameter

CamShaft
end

play
mm
in
0
08
to
0
38

0
0031
to
0
0150

Standard

Surface
flatness

mm
in
less
than

0
05
0
0020

Cy
LlNDER
BLOCK

I

Visually
check

cylinder
block
for

cracks
or
flaws

2
Measure

top
of

cylinder
block

cylinder
head

mating
face
for

warp

age
If

warpage
exceeds
limits
correct

it
Maximum
tolerance

0
10
0

0039

EM540

Fig
EM
51

Cheching
cylinder
block

au
rface

EM
13
j

Using
a
bore

gauge
measure
cyl

inder

bore
for
out
of
round
or

taper
If

out
of

round
or

taper
is
excessive

re

bore

cylinder
walls
with
a

boring

machine
Measuremen
t
should
be

taken

along
bores
for

taper
and
around

bores
for

out
of
round
See

Figure

EM
52

Qu
t
of
round

Taper
X

Y

A

B

M12

Fig
EM

52

Measuring
cylinder
bore

diameter

4
When
wear

taper
or

out
of

round

is
minor
and
within
limits

remove

step

at

topmost
portion
of

cylinder
using

a

ridge
reamer
or

other
similar
tool

HOW
TO
MEASURE

CYLINDER
BORE

A

bore

gauge
is
used
Measure

cylind
r
bore

at

top
middle
and
bot

tom

positions
toward
A
and
B
direc

tions

as
shown
in

Figure
EM
53

and

record
the
measured
values

A
I

120
0
79

IlL

60
2
36

lll

B

100
3
94

el
1

Unit
mm
m

EM
22

r

Fig
EM
53

Cylinder
bort
me08Uring

positions

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

2
Turn
crankshaft
until
No
I

pis

ton
is
at
T
D
C

on
its

compression

stroke

3
Make

sure
thai
camshaft
sprock

et
location
notch
and

plate
oblong

groove
are

aligned
at
their
correct

positions

4

When

installing
cylinder
head

make
sure

that
all
valves
are

apart

from
heads
of

pistons

5
Do

not
rotate
crankshaft
and

camshaft

separately
or
valves
will
hit

heads
of

pistons

6

Temporarily
tighten
two
bolts

CD

V
sJiown

in
Fig

re
EM
96

Tightening
torque

2

kg
m

14
ft
b

15
Install
crankshaft

sprocket
and

oil

pump
drive

gear
and
fit
oil

thrower

Note
Make
sure
lhat

maling
marks
of

crankshaft

sprocket
face
10
Cront

16
Install

timing
chain

Noles

a
Make

sure
that
crankshaft
and
cam

shaft

keys
point

upwards

Fuel

pump
drive

earn

2
Chain

guide

3

Chain
tensioner

4

Crank

sprocket

5
earn

sprocket

6
Chai

guide

EM439

b
Set

timing
chain

by

OOgning
its

mating
marks
with
those
oC
crank

shaft

sprocket
and
camshaft

sprock

et
at
the

right
hand
side
There
are

forty
four
chain
links
between
two

mating
marks
of

timing
chain

c
NO
2
hole
is

Cactory

adjusted

When
chain
stretches

excessively

adjust
camshaft

sprocket
at

No
3

hole

d
Use
a

set
of

timing
marks
and

location
hole

numbers
Engine
Mechanical

17
Install
chain
slack
side

guide
to

cylinder
block

18
Install
chain
tensioner

Note

Adjust
protrusion
oC
chain
ten

sioner

spindle
to
0
mm
0
in

Fig
EM
98

lmtalling
chain
tensioner

19
Press
new
oil
seal
in

front
cover

Notes

a
Front

cover
oil
seal
should
be
reo

placed
when
Cront
cover
is

disas

sembled

b
BeCore

pressing
oil
seal
into
Cront

cover

give
coating
of

engine
oil
to

periphery
of
oil
seal

c
This
oil
seal
is
a
threaded
seal

type

which
has

improved
sealing
charac

teristics
Do
not

apply
grease
to

sealing

lip

20
Install
front
cover
with

gasket
in

place

1

Timing
mark

2

Timing
mark

EM545

Fig
EM

99

Installing
fronl
COlHlr

Notes

a

Apply
sealant
to
Cront
cover
and

corners
oC

upper
section
of

cylinder

block

as
shown

in

Figure
EM
78

EM
24
b
Install
Cront
cover
with
head

gasket

in

place

c

Check

height
diCCerence
between

cylinder
block

upper
Cace
and
Cront

cover

upper
Cace
DifCerence
must

be
less
than
0
15

mm
0
0059
in

d

Note
that
difCerent

types
oC
bolts

are
used

e

Before

installing
front
cover
on

cylinder
block

apply

coating
oC

engine
oil
10

sealing
lip
of
oil

seal

EMS11

Fig
EM
lOD
Front

cover
bolts

Tightening
torque

Size
M8
0
315
in

1
0
to
1
3

kg
m
7

2
to
9
4

ft
lb

Size
M6
0
236
in

0
4
to
0
6

kg
m
2

9
to
4

3
ft
lb

21
Install
crankshaft

pulley
and

water

pump
assembly
then
set
No
I

piston
at
ToO
C
on
its

compression

stloke

Crankshaft

pulley
nu
I

tightening
torque

12
to
16

kg
m
B7
to
116
ft

lb

EM546

Fig
EM
Ol

lnstallingcran
haft

pulley
and

water

pump

22

Finally

tighten
head

bolts
to

the

specified
torque
in

three

steps

according
to
the

lightening
sequence

shown
in

Figure
EM
96

Note
thai
Iwo

types
of
bolts

are

used

Valve

spring
pressured
length

valve

open

Intake
and
exhaust

Outer

Inner

Valve

spring
assembled
height

valve

close

Intake
and
exhaust

Outer

Inner

Valve

guide
length

Intake
and

exhaust

Valve

guide
height
from
head
surface

Valve

guide
inner
diameter

Intake
and
exhaust

Valve

guide
outer
diameter

service

parts

Intake
and
exhaust

Valve

guide
to
stem
clearance

Intake

Exhaust

Valve
seat
width

Intake

Exhaust

Valve
seat

angle

Intake
and
exhaust

Valve

seat
interference
fit

Intake

Exhaust

Valve

guide
interference
fit

b
Camshaft
and

timing
chain

Camshaft
end

play

Camshaft
lobe
ift

Intake
and
exhaust

Camshaft

joumal
diameter

1st

2nd
3rd
and
4th
Engine
Mechanical

mm

kg
in
lb

mm

kg
in
lb

mm
in

mIll
in

mm

in

mm

in

mm
in

mm
in

mm
in

mm
in

rnm
in

rnm
in

mm
in

Camshaft
bend

mm
in

Camshaft

journal
to

bearing
clearance
mm

in

Camshaft

bearing
inner
diameter
rnm
in

1st
2nd
3rd
and

4th
29
5
49
0
1
IM

108

24
5

25
5
0
965

56
2

40
0
21
3
1
575

47
0

35
0
12
3
1
378
27
I

59
0
2
323

10
6
0
417

8

000
to
8
018
0
3150
to
0
3157

12
223
to
12
234

0
4812

to
0
4817

0
020
to

0
053
0

0008
to
0
0021

0
040

to
0
073

0
0016
to
0
0029

1
4

to
1

6
0
0551
to
0
0630

1

8
to
2

2
0
0709
to
0
0866

450

0
081
to
0
113

0
0032
to
0
0044

0
064
to
0
096
0

0025
to
0
0038

0
027
to
0
049
0

0011
to
0

0019

0
08

to
038
0
0032
to
0
0150

7

0
0
276

47
949
to
47
962

1
8877
to
1

8883

0
02
0
0008

0
Q38
to
0
067
0
00
I
5

to
0
0026

48
000
to
48
016

1

8898
to
1
8904

EM

28

Engine
Mechanical

g
Piston

ring

Ring
height

Top
and

second

Side
clearance

Top

Second

Ring
gap

Top

Second

Oil
mm
in

mrn
in

mm
in

h
Cylinder
block

Cylinder
bore
inner
diameter
mm
in

Wear
limit
of
dittoed
inner

diameter

Cylinder
bore

taper
and
out
of
round

Difference
in

cylind
bore

Surface
flatness
mm
in

mm
in

mm
in

mm
in

i

Cylinder
head

Surface
flatness

mm
in

TIGHTENING
TORQUE

Cylinder
head

bolts

kg
m
fl
lb

Connecting
rod

big
end

nuts
kg
m
ft
Ib

Flywheel
fixing
bolts

kg
m
ft
Ib

Main

bearing
cap
bolts

kg
m
ft
lb

Camshaft
bracket
bolts

kg
m
ft
lb

Camshaft

sprocket
bolt

kg
m
ft
lb

Oil

pan
bolts

kg
m

ft
1b

Oil

pump
bolts

kg
m
ft
lb

Oil
strainer

bolts
kg
m

ft
lb

Oil

pan
drain

plug
kg
m
ft
lb

Rocker

pivot
lock
nuts

kg
m

ft
Ib

Camshaft

locating
plate
bolts

kg
m
ft
lb

Carburetor
nuts

kg
m

ft
lb

Manifold
bolts

kg
m
ft
lb

Fuel

pump
nuts

kg
m

ft
lb

Crank

pulley
bolt

kg
m
ft
lb

Water

pump
bolts

kg
m
ft
Ib

Front
cover
bolts

kg
m
ft

lb

EM

30
1
977
to
1
990
0

0778
to

0
0783

0
040
to
0
073
0
0016
to

0
0029

0

030
to
0

070
0
0012
to
0

0028

0
25
to

0
40
0
0098
to
0

0157

0

30
to
0

50
0
0118
to

0
0197

0
30
to
0

90
0

0118
to
0
0354

85
000
to
85
050

3
3465

to
3
3484

0
2

0
0079

om
5
0

0006

0
05
0
0020

less
than
0

05
0

0020

less
than
0
05

0
0020

6
5
to
8
5

47
to
61

4
5
to
5
5

33
to
40

14

to
16

101
to
116

4
5
to

5
5
33
to
40

1

8
to
2

0

13
to
15

12
to

16
87
to
116

0
6

to
0
9
4
3
to
6
5

I
J
to
1
5

8
0
to

10
8

0
8
to
1
1
5
8
to
8
0

2
0

to
3
0

14
to
22

5
0
to

6
0

36
to
43

0
6

to
0
9

4
3
to
6
5

0
5
to
1

0
3
6

to
7
2

1
2
to
1
6
8
7

to
11

6

1
2
to
1
8
8
7
to
13

0

12
to

16
87
to
116

0
4
to

0
5
2
9

to
3
6

8
mm
0
315
in

dia

6
mm
0

236
in
dia
1

0
to
1
3
7
2
to

9
4

0
4
to
0
6
2

9
to
4
3

J

1
Fuel
tank

2

Fuel
f1l1er

cap
with

vacuum

relief
valve

3

Liquid
vapor

separator

4

Vapor
vent
line

5
Vacuum

signalUne

As
the
throttle
valve

opens
and

vehicle

speed
increases

vacuum

pres

sure
in

the
vacuum

signal
line
forces

rHL
JL

I

EC785

INSPECTION

FUEL
TANK

VAPOR

LIQUID
SEPARATOR

AND

VAPOR
VENT
LINE

I

Check
all
hoses
and
fuel

tank

mler

cap

2
Disconnect
the

vapor
vent

line

connecting
carbon
canister
to

vapor

liquid
separator

3
Connect
a
3

way
connector

a
Emission

Control

System

Close
at

idling

Open
at
rest

i

J

17
f

Fuel

vapor

6
Canister
purge
line

7
Throttle
valv

8

Engine

9
Carbon
canister

10
Activated
carbon

11

Screen
12
Filter

13

Purge
control
valve

14

Spring

15

Diaphragm

16
Fixed

orifice
i

j

EC784

Fig
EC
77

Evaporative
emu
ion
control

sy
tem

Fuel

vapor
flow
when

engine
i6

at
red
or

idling

the

purge
control
valve
to

open
and

admits
an

orifice
to
intake
manifold

and
fuel

vapor
is

then
drawn
into
the

I

J

o
I

Fuel

vapor

Fresh
air
intake

manifold

through
the
canister

purge
line
See

Figure
EC
7B

Fig
EC
78

Evaporative
emiuion
control

system

Fuel

vapor
flow
when

engine
i

running

manometer
and
a
cock
or
an

equiva

lent
3

way

charge
cock
to

the
end
of

the

vent
line

4

Supply
fresh
air
into

the

vapor

vent
line

through
the
cock
little

by

little
until

pressure
becomes
368

mrnH20

14
5
inH20

5
Shut
the
cock

completely
and

leave
it

unattended

6
After
2
5
minutes

measure
the

height
of
the

liquid
in
the

manometer

7

Variation
of

height
should
remain

EC
31
with
25
mmH20
0
98
inH20

8
When
filler

cap
does
not
close

completely
the

height
should

drop
to

zero
in

a
short
time

9
I
f

the

height
does
not

drop
to

zero
in

a
short
time
when
filler

cap
is

removed
it
is

the
cause
of
a

stuffy

hose

Note
In

case
the

vent
line
is

stuffy

the

breathing
in
fuel
tank
is
not

thoroughly
made
thus

causing
in

l
t

tJ
I

P

o

CUll

Fig
CL
9

Lubricating
poinu
of

withdrawal
lever
and

front
cover

4

Contact
surfaces
of
transmission

main

drive

gear
splines
lithium
base

grease
including
molybdenum
disul

phide

Note

Very
IIIIJllII
amount
of

grease

should
be
ated
to
the
above

points
If
too
much
iubricant
is

applied
it
will
run
out
on
the

friction

plates
when
hot

resulting

in
d

gi
dutch
disc

facings

3
Install
retainer

spring
to
with

drawal
lever
Fit
holder

spring
to

release

bearing
and
sleeve

assembly

then
assemble
withdrawal
Iever
and

bearing
sleeve
as
a
unit
Install
this

assembly
on

transmission
case
Then

install
dust

cover

Pilot

bushing

Before

installing
a
new

bushing

thoroughly
clean

bushing
hole
Install

bushing
in
crankshaft

using
a
soft

hammer

Bushing
need
not
be
oiled

INSPECTION

Wash
all
the
disassembled

parts

except
release

bearing
and
disc
assem

bly
in
suitable

cleaning
solvent
to

remove
dirt
and

grease
before

making

inspection
and

adjustment

Flywheel
and

pressure
plate

Check
friction
surface
of

flywheel

and

pressure
plate
for

scoring
or

roughness
Slight
roughness
may
be

smoothed

by
using
fme

emery
cloth

If
surface

is

deeply
scored
or

groov

ed
the

part
should
be

replaced

Clutch
disc
at
llembly

Inspect
clutch
disc
for

worn
or

oily

facings
loose

rivets
and
broken

or

loose

torsional

springs
CLUTCH

I
If

facings
are

oily
the
disc
should

be

replaced
In
this
case

inspect
trans

mission
front
cover
oil
seal

pilot

bushing
engine
rear
oil
seals
and
other

points
for
oil

leakage

2
The
disc
should

also
be

replaced

when

facings
are
worn
locally
or
worn

down
less
than
0
3
mm
0
0118
in

at

revels
See

Figure
CL
IO

DePth

ll
I

gauge

II

1
i
h

1

j1
t

f

Above

0
3
rom

10
012
in

CL089

Fig
CL
I0
Me
JIuringclutch

lining

3
Check
disc

plate
for
runout
when

ever
the
old
disc
or
a

new
one
is

installed

4
If

runoutexceeds
the

specified

value
at

the
outer
circumference
Ie

place
or

repair
disc
See

Figure
CL
II

Runou

t

0
5
mm
0
020
in

total
indicator

reading

R

from
the

hub
center

107
5
mm
4

23
in

CL112

Fig
CL

ll

MeOlUring
disc
runout

5
Check
the
fit
of
disc

hub
on

transmission
main
drive

gear
for

smoothly
sliding
If

splines
are
worn

clutch
disc
or
main
drive

gear
should

be

replaced
that

is
backlash
exceeds

0
4

mm
0
016
in

at
the
outer

edge
of

clutch
disc

Clutch

cover

assembly

I
Check

the
end
surface
of

dia

phragm
spring
for
wear

CL
4
If
excessive
wear
is

found

replace

clu
tch
cover
as
an

assembly

2
Measure
the

height
of

diaphragm

spring
as
outlined
below

See

Figure

CL
12

a
Place
Distance
Piece
ST20050100

on
Base
Plate
ST20050010
and

then

tighten
clutch
cover

assembly

on
the
base

plate
by
using
Set
Bolls

ST20050051

b
Measure

diaphragm
spring
toe

height
A

at
several

points
with
a

vernier

caliper

depth
gauge

STl0050100

rJrf
I
Tl

05001O

f

7

C
L23

STl005Q051

Fig
CL
12

Me
uring
the

height
of

diaphragm
pring

If
the

height

A
of

spring
end
is

beyond
the

specified
value
of
33
to
35

mm
1
23

to
1
38
in

adjust
the

spring

height
with

Diaphragm
Adjusting

Wrench
ST20050240
See

Figure

CL

13

If

necessary
replace
clutch

cover
as

an

assembly
Also
unevenness
of
dia

phragm
spring
toe

height
should
be

less
than
05
mm
0
020
in

ST20050240

CL152

Fig
CL
13

AdjlUting
the

spring
height

3

Inspect
thrust

rings
for
wear
or

damage
As
these

parts
are
invisible

from
outside
shake
cover

assembly
up

and
down
to
listen
for

chattering

noise
or

lightly
hammer
on
rivets
for
a

slightly
cracked
noise

Any
of
these

noises
mean

requirement
for

replace

ment
as
a

complete
assembly