light DATSUN PICK-UP 1977 Service Manual

p

r

ET002

Fig
E1
11

Checking
specific
gravity

of
bottery
electrolyre

Clean

top
of

battery
and
terminals

with
a
solution
of
bakin

soda
and

Pennissible

value

Frigid
climates
Over
1

22

Tropical
climates

lOver
1
18

Other
climates

lOver
1
20

CHECKING
AND

ADJUSTING

IGN

ITIONTIM
iNG

AD
IUSTING
IGNITION

TIMING

I
Check

spark
plugs
and
distributor

breaker

points
for
condition

2

Thoroughly
remove
dirt
and
dust

from

timing
mark
on
crank

pulley
and

timing
indicator
on
front
cover

3
Warin

up
engine
sufficiently

4
Imtalla
timing
light
on
No
I

cylinder
spark
plug
wire
and
install
a

tachometer

5
Set

idling
spero
toapproxintate
y

750

rpm

6
Check

ignition
timing
with
a

timing
light
if
it
is

specified
value

If

necessary

adjust
it

as
follows

1
Loosen
setscrew
until
distribu

tor

can
be
moved

by
hand

2

Adjust
ignition

timing
to

speci

fied
value

3
0
Lock
distributor
setscrew

ai1d

make

sure
that

timing
is
correc
Engine
Tune

up

water

Rinse
off
and

dry
with
com

pressed
air

Top
of

battery
must
be

clean
to

prevent
current

leakage
be

tween
terminals
and
from

positive

terminal

to
hold
down

clamp

In
addition
to
current

leakage
pro

longed
accumulation
of
acid

and
dirt

o
n

top
If
l

l
ry
may

ca
u
iCbli
t

rj
I
g

of
the
material

covering
connector

straps
and
corrosion
of

straps
After

tightening
terminals
coat
them
with

petrolatum
vaseline
to

protect
them

from
corrosion

Full

charge

value

at
200C
680F

1
28

1
23

1
26

oo

I

ET169

Fig
ET

13

Checking
ignition
timing

Ignition

timing

Manual
transmission

120
750

rpm

Non
California
models

100
750

rpIll

California
models

Automatic
transmission

120

650

rpin

in

0

position

ET
10
CHECKING

ANb

REPLACING

SPARK

PLUG

I

Remove

and
clean

plugs
in

a
sand

blast
cleaner

2

Inspect
insulator
for
cracks
or

chips

3

Check
both
center
and

ground

electrodes

If

they
are

excessively
worn
re

place
with
new

spark

plugs

4

Spark
plug
gap

Breaker

points

type

0

8
to
0
9

mm

0
031
to
0
035
in

Transistor

ignition

type

1
0

to
1
1

mm

0
039
to
0
043
in

Tightening

torq

1
5
to
2
0

kg
m

11
to
A4
ft
lb

Fig
ET
14

Checking

spark
plug
point

gap

CHECK
I
G

DISTRIBUTOR

OPERATING

PARTS

AND

1

lrI9N

WIRING

BREAKER

POINTS

Non

California
models

Check
the
distributor
breaker

points
for
abnonnal

pitting
and
wear

Replace
if

necessary
Make
sure

they

are

properly

aligned
and
that

point

dwell

and

gap
are
correct
Clean
and

apply
distributor

grease
to
the
carn

lobes

Note
00

not

apply
grease
excessively

Point

gap

0

45
to
0
55
mm

Om8
to
0
022

in

Owell

angle

49
to
55

degrees

r

CHECKING
B
C

D
D

SOLENOID
VALVE

I
Turn
on

engine
key
Do
not
start

engine

2
Ensure
that
solenoid
valve

clicks

when

intermittently
electrified
as

shown
in

Figure
ET
37

Fig
ET

37

Checking
solenoid
uolV
l

I

l

EF264

2

Turn

ignition
key
to
ON

posi

tion

3

Ensure
that
tester

pointer
deflects

when

ignition
key
is

turned
on

4

If

tester

panter
does
not
deflect

when

solenoid
valve

and

speed
detect

ing
switch

circuits

are

functioning

properly
amplifier
is

faulty
Engine
Tune

up

3
If
a

click
is

heard
solenoid
valve

is
normal

4

If
a
click
is
not
heard

at
all
check

for

continuity
with
a
circuit

tester
If

discontinuity
is

detected

replace
sole

naid
valve

CHECKING

AMPLIFIER

Manual
transmission

models

The

amplifier
is

installed
at
the

rear

of
the

speedometer
To

check

proceed

as
follows

1
Set
circuit

tester
in

d
c

ampere

range
IA

min
full
scale

connect
test

probes
of
tester
as

shown
in

Figure

ET
38

Do

not
confuse

positive
line

with

negative
line

M

p
1

II

L
o

A

I
of

j
t
J

f

T

1

Ignition
key

2

Amplifier

3

Speed

detecting
switch

4
B

C
D

D

solenoid
valve

Fig
ET
38

Checking

amplifiu

REPLACING
AIR

PUMP
AIR
CLEANER

ELEMENT

Remove
air

hose
then
detach
air

cleaner
from

hoodledge
Air
cleaner

element

and
air

cleaner
lower

body
are

built
into

a
unit
construction

Replace

air

cleaner
element
and
lower

body
as

an

assembly

ET

20
EC323

Fig
ET
39

Repl4cing
air
cleaner

element

CHECKING

EXHAUST

GAS

RECIRCULATION

E
G

R

CONTROL

SYSTEM

Checkln

E
G
R
control

system
In
Ita

mounted

condition

I

M
ake
a

thorough
visual
check
of

E

G
R
control

system
If

necessary

wipe
away
oil
to

facilitate

inspection

If

hoses
are

cracked
or

broken
fe

place

2
With

engine
running
check

E
G
R

warning
system
for

proper

function
Make
sure
that
E

G
R
warn

ing
lamp
light
when

ignition
switch
is

turned
to
START

position
starter
mo

tor
runs
If
E
G
R

warning
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
odometer
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

connector
and
de

tector
drive
counter

replace

warning

lamp
or
detector
drive

counter
if

necessary

Note

Operation
of
E

G
R

warning

lamp
is

as
follows

3
If
there

is
a
leak

remove

top

cover
from

purge
contiol
valve
and

check

for
dislocated
or

cmcked
dia

phragm
If

necessary
replace
dia

phmgm
kit

which
is
made

up
of
a

retainer

diaphragm
and

spring

I
@

1
Cover

2

Diaphragm

3
Retainer

4

Diaphragm
spring

Fig
ET
47
ET350

Carbon
caniater

purge

control
valve

Carbon
unlster

filter

Check
for
a
contaminated

element

Element
can
be
removed
at

the

bottom
of
canister

installed
on
vehicle

body

Fig
ET
48

Replacing
carbon

canister

filter

Fuel
tank

vacuum
relief

valve

operation

Remove
fuel
filler

cap
and
see
it

functions

properly

I

Wipe
clean
valve

housing
and
have

it
in

your
mouth

2

Inhale
air
A

slight
resistance

ac

companied
by
valve
indicates
that

valve
is
in

good
mechanical
condition

Note
also
that

by
further

inhaling
air

the
resistance
should
be

disappeared

with
valve
clicks
Engine
Tune

up

3
If
valve

is

clogged
or
if
no
resist

ance
is

felt

replace
cap
as
an
assem

bled
unit

r

u

ET369

Fig
ET
49
Fuel

filler
cap

CHECKING

CATALYTIC

CONVERTER

INSPECTION

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including
hoses

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I

S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nOf

mal
or
not
can
be
checked

by
ob

serving
variation
in
CO

percentage

The

checking
procedure
is

as
follows

Apply
parking
brake
Shift

gears

into

Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks

2
Remove
air

hose
between
5

way

connector
and
air

check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3
Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5
Race

engine
1
500
to
2
000

rpm

two

or
three
times
under
no
load
then

run

engine
for

one
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
12

7

Check

ignition
timing
If

neces

sary

adjust
it
to

specifications
Refer

to

page
ET
10

ET
23
8

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adjustment
process
as

described
in

steps
5
to

8
above
until

specified
CO

percentage
is

obtained

Note

Adjustment
in

step
9
should
be

made
ten
minutes
after

engine
has

warmed

up

10
Race

engine
1
500
to
2
000

rpm
two
or
three
times
under

no
load

and
make

sure
that

specified
CO

per

centage
is
obtained

I
1
Remove

cap
and
connect
air

hose
to
air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
Warm

up
engine
for
about
four

minutes
at
2
000

rpm
under
n
load

13
Measure

CO

percentage
at

idling

speed
After

step
12
has
been
com

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14

If
CO

percentage
measured
in

step
13
is
less
than
0
3
the

catalylic

converter
is

normal

15
If
CO

percentage
measured
in

step
13
is

over
0
3
recheck
A
I
S

and

replace
air

check
valve
Then

perform
inspection
steps
12

and
13

16
If
CO

percentage
is
still

over

0
3
in

step
15

catalytic
converter
is

malfunctioning
Replace
catalytic
con

verter

CHECKING
FLOOR

TEMPERATURE

WARNING
SYSTEM

INSPECTION

Floor

warning
temperature

system

Apply
parldng
brake
Shift

gears

into
Neutral
for

manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Ensure
that
floor
tern

perature

warning

lamp
lights
when

ignition

switch
is

turned
to
the
S

position

If
not
check

lamp
for
burned

bul
bs

Engine
Tune

up

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition
Probable
cause

CANNOT
CRANK

ENGINE
OR

SLOW

CRANKING
Improper
grade
oil

Discharged
battery

Faulty
battery

Loose

fan
belt

Malfunction
in

charge
system

Wiring
connection
loose
in

starting
circuit

Faulty
ignition
switch

Faulty
starler
motor

Trouble

shooting
procedure
on

starting
circuit

Switch
on
the

starting
motor
with

light
ON

When

light
goes
off
or
dims

considerably

a
Check

battery

b
Check
connection
and

cable

c
Check
starter
motor

When

light
stays
bright
Corrective
action

Replace
with

proper
grade
oiL

Charge

battery

Replace

Adjust

Inspect

Correct

Repair
or

replace

Repair
or

replace

a
Check

wiring
connection
between

battery
and
starter

motor

b
Check

ignition
switch

c
Check
starter
motor

ENGINE
WILL
CRANK

NORMALLY
BUT

WILL
NOT

START

In
this
case
the

following
trouble
causes

may
exist

but
in

many
cases

ignition

system
or
fuel

system
is
in

trouble

Ignition

system
in
trouble

Fuel

system
in
troubk

Valve
mechanism
does
not
work

properly

Low

compussion

Trouble

shooting
procedure

Check

spark
plug
firstly
by

following
procedure

Disconnect

high
tension
cable
from
one

spark
plug
and
hold
it

about
10
mm
0
39
in

from
the

engine
metal

part
and
crank

the

engine

Good

spark
occurs

Check

spark
plug

b
Check

ignition
timing

c
Check
fuel

system

d
Check

cylinder
compression

Check
the
current
f10
in

primary
circuit

Very
high
current

Inspect
primary
circuit
for
short

Check
breaker

poiIit
operation

except
tran

sistor

ignition
system
No

spark
occurs

ET

27

Fig
EM

3

Crankshafl

PISTON

AND

CONNECTING
ROD

The

pistons
are

of
a

special
alumi

num

casting
and
have

struts
to
control

thermal

expansion
two

compression

rings
and

one
combined
oil

ring
The

piston
heads

are
slightly
dished

The

piston
pil1S
are
a

special
hollow

steel

shaft

They
are
full

floating
fit
to
the

piston
and

press
fit
to
the

connecting

rods

The

connecting
rods
are
of
a

special

forged
steel
Oil
is

sprayed
to
the

connecting
rod
small
ends

through

drilled

passages
in

the

large
ends
of

rod

Oil
holes
in

the

connecting
rods

are
located
so
as
to
insure

optimum

lubrication
under

heavy
load

0
50
1

o

E

Moao

Fig
EM
4

Piston
and

connecting
rod

CYLINDER
HEAD

The

cylinder
head
is

made
of
a

light
strong
aluminum

alloy
with

good

cooling
efficiency
it
contains

wedge

type
combustion
chambers
A

special

aluminum
bronze
valve
seat
is

used
on

the
intake
valve
while
a
heat
resistant

steel
valve
seat
is
installed

on
the

exhaust
valve
These

parts
are

all
hot

press
fitted

EM407

Fig
EM
S

Cylinder
head
Engine
Mechanical

CAMSHAFT

The
camshaft
is

made
of
a

special

cast
iron
and
is
loca
ted
inside
the

rocker
cover
Four
aluminum

alloy

brackets

support
it
Camshaft

bearings

are
lubricated
from
oil
holes
which

lead
to
the

main
oil

gallery
of
the

cylinder
head

Concentric

passages
are
drilled
in

the

front
and

rear

parts
of
the

earn

shaft

Oil
to
each
earn
lobe
is

supplied

through
an
oil

hole
drilled
in
the
base

circle
of
each
lobe
Lubricant
is

sup

plied
to
the
front
oil

gallery
from
the

2nd
camshaft

bearing
and
to
the

rear

oil

gallery
from
the

3rd
camshaft

bearing
These

holes
on
the
base

circle

of
the

lobe

supply
lubricant
to
the

earn

pad
surface
of
the
rocker
arm

and

to
the
valve

tip
end
The
cams
feature

a

long
overlap
profile
to
reduce
NOx

emission

Fig
EM
6

Camshafl

VALVE
MECHANISM

The
valve

system
has
the

pivot
type

rocker

arms
that

are
activated

directly

by
the
earn
mechanism

this
has
made

its

moving

parts
considerably
lighter

and

provides
ideal

high
speed
perform

ance

Dual

type
valve

springs
are
in

stalled

h

@l

if

Exhaust

Intake
EM084

Fig
EM
7
Valve
mechanism

EM

3
CAMSHAFT
DRIVE

The
camshaft
is
driven

by
a
double

row
roller
chain
driven

by
the

crank

shaft
The
tension
of
the

chain
is

controlled

by
a

chain
tcosioner

which

is

operated
by
spring
and
oil

pressure

The
rubber
shoe

type
tensioner

damps

vibration

of
the

chain
and
controls
its

tension

EM537

Fig
EM

8
Chain

driving

aystem

MANIFOLDS

The
intake
manifold
is
of
an
alumi

num
cast

alloy

The
exhaust
manifold
is

of
a
dual

design
and

incorporates
a
heat
control

valve
in
it
The

heal
control
valve
is

used
to

warm
the
intake
manifold

A

plate
is
installed
on
the
outer

face
of
the
manifold
to
draw
hot

intake
air

out

through
it
The
exhaust

pipe
is
connected
to
the

flanged
sur

face
of
the
exhaust
manifold

Fig
EM

9
Intak
and
exhaust

manifolds

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

30
Install
heatshieid

plate
on
mani

fold
assembly

31
Install
air

gallery
pipe
on
ex

haust
manifold

32
Install
manifold

gasket
and

manifold

assembly
on

cylinder
head

Tightening
torque

1
2to
1

6kg
m

8
7
to
11
6
ft
lb

33

Install
blow

by
gas

pipe
on

cyl

inder

block
and
tighten
with
rear

engine
slinger

34
Install
thermostat
housing

gas

ket
thermostat

housing
and

thermo

stat

35
Install
thermal
vacuum
valve
on

thermostat

housing
Before

installing

apply
a

liquid
packing
slightly
to
the

threads

36

Install
FJ

C
D
bracket
on

cylin

der

head

37

Install
E
G
R

passage
and

E
G
R
valve
on
intake
manifold

38
Connect
E

G
R
tube
to
E

G
R

tube
and

exhaust
manifold

39
Install
check
valve

on
air

gallery

pipe

40
Install
air
cleaner
bracket
on

intake
manifold

41
Install
air
control
valve
on
air

cleaner
bracket
California
models

42
Install
vacuum
and
fuel
tubes

combined
on

cylinder
head

43
Install
distributor

assembly

44
Install

heatshield
plate

joint

seat

and
carburetor

Carbure10r
tightening

torque

0
5

to
1

0

kg
m
3

6
to
7
2

ft
lb

Note
When

instalUng
joint
seat
be

sure
to

put
the
duct
into

primary

hole
in

intake
manifold

S

J

Heatshield

plate
4
Joint

seat

2

Primary
hole
5

Secondary
hole

3
Duct

EM534

Fig
EM
I06

Installing
carburetor

joint
seat
Engine
Mechanical

45
Install
dash

pot
bracket
and

dash

pot
to
intake

manifold

46
Connect
all
air

vacuum
and
fuel

hoses

and
then

secure
with

clamps

I
Cylinder
block
to

P
C
V
valve

hose

2
A
B

valve
to
E

G
R

passage
vac

uum
hose

3
A
B

valve
to
E
G

R

passage
air

hose

4
Vacuum
tube
to
carburetor
vac

uum
hoses

5
Fuel
ube

to
carburetor
fuel

hose

6
Fuel
tube
to
fuel

pump
fuelhose

7
Distributor
to
vacuum
switch
or

spark
delay
valve
vacuum
hose

8
Air
control
valve
vacuum
hose

9
Check
valve

to
air

control
valve

hose

10
Thermal
vacuum
valve
to

E
G
R
valve
vacuum
hose

I
I
Thermal
vacuum
valve
to

vacuum
tube
hose

47
Install
carburetor
air

cleaner
on

carburetor
and
then
connect
air

and

vacuum
hoses

as
follows

I

Air
cleaner
to

exhaust
manifold

hot

air
duct

2

Air
c1eaner
to
air

pump
hose

3

Air
cleaner
to
rocker

cover
hose

4

Air
cleaner

to
air
control
valve

hose

5

6

48
Install

spark
plugs
in

place

49
Connect
all
distributor

high
ten

sion

cables
to

spark
plugs

50
Install
air

pump
drive
belt
cool

er

compressor
and
idler

pulley

51

Install
left

engine
mounting

bracket

52
Install
clutch

assembly
on

flywheel
with
Clutch

Aligning
Bar

KV30100200
Air

cleaner
to
A
B

valve

hose

Other
vacuum
hoses

Tightening
torque

1
2
to
2
2

kg
m

8

7
to
15
9

ft
lb

EM
26
I

I

KV30100200

EM440

Fig
EM
I07
In

talling
clutch
embly

53

Using
an
overhead
hoist
and

lifting
cable
hoist

engine
away
from

engine
stand
and

then
down
onto

engine
carrier

54
Install

right
engine
mounting

bracket
oil
filter
oil

pressure
switch

oil

level

gauge
and
water

drain

plug

When

installing
oil

filter
fasten
it
to

cylinder
block

by
hand

Note
Do
not

overtighten

flit
or
oil

leakage
may
occur

55
Install
alternator
bracket

adjust

ing
bar
alternator

cooling
fan

and

belt

56

Adjust
the
deflection
of
drive

belts
when

thumb

pressure
is

applied

midway
between

pulleys
A

pressed

force
is
above
10

kg
22
0
lb

Deflection

of
drive
belts

8
to
12
mm

0
315

to
0
472
in

EM613

Fig
EM
lOB
Fan
belt
tension

57
Fill

engine
oil

up
to

specified

level

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

ENGINE

LUBRICATION
SYSTEM

SERVICE
DATA
AND

SPECIFICATIONS

Oil

pump

Standard
Wear
limit

mm
in
0
04
to

0
08

0
0016
to
0
0032

less
than
0
12
0
0047

0
15
toO
21

0
0059
to
0

0083
0
20

0

0079

0
20

0
0079

0
5

0

0197
Rotor
side
clearance

rotor
to
bottom
cover

Rotor

tip
clearance
mm
in

Outer
rotor
to

body
clearance
mm
in

Oil

pressure
regulator
valve

Oil

pressure
at

idling

Regulator
valve

spring

Free

length

Pressured

length

Regulator
valve

opening

pressure
kg
cm2

psi
0

8
to
2
8

II
to
40

mm
in

mmOn

kg
em2

psi
52
5
2
067

34
8
1
370

3
5
to
5

0
50
to

71

Tightening
torque

Oil

pump
bolt

Oil

pump
cover
bolt

Regulator
valve

cap
nut
kg
m
ft
lb

kg
m
ft
lb

kg
m
ft

Ib
1
1
to
1
5
8
0

to
10
8

0

7
to
1

0
5
1

to
7
2

4
to
5
29

to
36

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition
Probable
causes
Corrective
actions

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

Use
of

poor
quality
engine
oiL
Correct

Clean
or

replace

Replace

Replace

Replace

Warning

light

remains
on

engine
running
Decreased
oil

pressure

Oil

pressure
switch
unserviceable

Electrical
fault
Previously
mentioned

Replace

Check
circuit

Noise
Excessive
backlash
in

pump
rotors

Replace

EL
5

Engine
Fuel

CARBURETOR

CONTENTS

DESCRIPTION

EF
14
CHOKE
UNLOADER

EF
23

STRUCTURE
AND

OPERATION
EF
14

ELECTRIC
AUTOMATIC
CHOKE
EF

24

PRIMARY
SYSTEM

EF
15
INTERLOCK
OPENING
OF
PRIMARY
AND

SECONDARY

SYSTEM
EF
16
SECONDARY
THROTTLE
VALVE

EF
24

ANTI
DIESELING

SYSTEM
EF
17
DASH
POT

EF
25

FLOAT

SYSTEM
EF
18
ACCELERATING
PUMP

EF

25

BOOST
CONTROLLED

DECELERATION
ANTI
DIESELING
SOLENOID
VALVE

EF

25

DEVICE

B
C
D
D
EF
1B

B
C

D
D
CIRCUIT
WITH

FUNCTION

ELECTRIC

AUTOMATIC

CHOKE
EF
20
TEST

CONNECTOR

EF
25

DASH
POT
SYSTEM
EF
20

ALTITUDE
COMPENSATOR

ALTITUDE

COMPENSATOR

California
modelsl
EF

29

California

models

EF
20
MAJOR
SERVICE

OPERATION
EF

29

ADJUSTMENT
AND

INSPECTION
EF
21
REMOVAL
EF
29

CARBURETOR
IDLE
RPM
AND
DISASSEMBLY
AND
ASSEMBLY
EF

30

MIXTURE

RATIO

EF
21
CLEANING
AND

INSPECTION
EF
34

FUEL
LEVEL

EF
22
SERVICE
DATA
AND

SPECIFICATIONS
EF

35

FAST

IDLE

EF
22
TROU8LE

DIAGNOSES
AND

VACUUM
BREAK

EF
23
CORRECTIONS
EF

36

DESCRIPTION

The

carburetors
are
of

down
draft

two

barrel

types
which

produce
the

optimum
air
fuel
mixture
under

all

operating
conditions

They
present
several

distinct

features
of

importance
to
the

vehicle

owners

A

summary
of
the

features
is

as

follows

1
A

slow
economizer
to

make
a

smooth

connection
with

acceleration

or
deceleration

during
light
load

run

ning

It

also

assures
stable
low

speed

performance

2

An
idle

limiter
to

reduce
harmful

exhaust
emissions
to

a
minimum
3
A

B
C
D

D

device
for

reducing

hydrocarbon
H
C
emissions

4

An

electric
automatic

choke
to

facilitate
cold

starting
and
to
reduce

exhaust
emissions

5

An
anti

dieseling
solenoid
to

eliminate

dieseling
run

on

6
A

power
valve

or
vacuum
actu

ated
booster
to

ensure

smooth

high

speed
operation

7

The

carburetor

comes

equipped

with
dash

pot
which
ensures

smooth

deceleration

without

engine
stall

under

all

operating
conditions

8

The
hand

operated
altitude

com

pensator
is

installed
in
the
California

models

EF
14
STRUCTURE
AND

OPERATION

These

carburetors
consist
of

a

primary
system
for

normal

running

and
a

secondary

system
for
full
load

running

A

float

system
common
to
both

primary
and

secondary
systems
a
se

condary
switch

over
mechanism

an

accelerating
mechanism
etc
are

also

attached

An

anti

dieseling
solenoid
valve

and

a

power
valve
mechanism
are
also

installed

The
hand

operated
altitude

com

pensator
corrects
air

fuel
mixture

to

an

optimum
ratio