transmission DATSUN PICK-UP 1977 User Guide

CHECKING
CHOKE

MECHANISM
Choke

plate
and

linkage

1
Check
choke

valve
and
mech

anism

for
free

operation
and
clean
or

replace
if

necessary
A
binding
can

result
from

petroleum

gum
formation

on
choke
shaft

or
from

damage

2

Check
bimetal
cover

setting

Index
mark

on
bimetal

cover
is

usually

set

at
center
of
scale

Note

Always
align
the
index

mark
on

bimetal
cover
with
the
center
index

mark
on
choke

housing

3

Every
day
before

starting
engine

depress
the
accelerator

P
dal
to
see
if

choke
valve
is
closed

automatically

If
it
fails
to
be
closed
the

chances

are
that
link
movement
is
unsmooth
Engine
Tune

up

or
that
bimetal
is

out
of
order
Refer

to
Carburetor
in
Section
EF

CHECKING
FUEL

LINES
Hoses

pipings
connections

etc

Check
fuel
lines
for

loose
con

nections

cracks
and

deterioration

Retighten
loose
connections

and
re

place
any
damaged
or
deformed

parts

REPLACING
FUEL

FILTER

Check
for
a

contaminated
filter
and

water

deposit
All

engines
use
a

replaceable

cartridge
type
fuel
filter
as
an
as

sembly

@

Fig
ET

19
Fuel

filler
ET011

EMISSION
CONTROL
SYSTEM

CHECKING
CRANKCASE
EMISSION

CONTROL
SYSTEM

REPLACING
P
C
V
VALVE
AND

FILTER

CHECKING
VENTILATION
HOSE

CHECKING
EXHAUST
MANIFOLD
HEAT

CONTROL
VALVE

CHECKING
SPARK
TIMING

CONTROL

SYSTEM

SPARK
DELAY
VALVE

Automatic
transmission
models

only

INSPECTION

CHECKING

AUTOMATIC
TEMPERATURE

CONTROL
AIR

CLEANER

OPERATING
PRESSURE
OF

BOOST

CONTROLLED
DECELERATION
DEVICE

B
CD
D
I
ADJUSTMENT

CHECKING
B
C
DD
CIRCUIT

WITH

FUNCTION
TEST

CONNECTOR

CHECKING

CRANKCASE

EMISSION

CONTROL

SYSTEM

REPLACING
P
C
V
VALVE

AND
FILTER

Check
P

C
V

valve
in

accordance
CONTENTS

ET
13

ET
13

ET
14

ET
14

ET
14

ET
14

ET
15

ET
15

ET
17

ET
17
ADJUSTMENT
OF
SET
PRESSURE
OF

BOOST

CONTROLLED
DECELERATION

DEVICE
B

CD
D

CHECKING
B
C
D
D
SOLENOID
VALVE

CHECKING
AMPLIFIER
Manual

transmission
models

REPLACING
AIR
PUMP
AIR
CLEANER

ELEMENT

CHECKING
EXHAUST
GAS
RECIRCULA

TION
E
G
R
CONTROL
SYSTEM

CHECKING
EVAPORATIVE
EMISSION

CONTROL

SYSTEM

CHECKING
CATALYTIC
CONVERTER

INSPECTION

CHECKING
FLOOR
TEMPERATURE

WARNING
SYSTEM

INSPECTION

with
the

following
method

With

engine
running
at

idle
remove

ventilator
ose
from
P
C
V

valve
If

the
valve

is

properly
working
a

hissing

ET
13
ET
18

ET
20

ET
20

ET
20

ET
20

ET
22

ET

23

ET
23

ET

23

ET
23

noise
will
be

heard
as
air

passes

through
the

valve
and
a

strong
vacuum

should
be
felt

immediately
when

a

finger
is

placed
over
valve
inlet

Fresh
air

Blow

by
gas

CHECKING

VENTILATION

HOSE

1

Check
hoses
and
hose
connec

tions
for
leaks

2
Disconnect
all
hoses
and
blow

them
out
with

compressed
air

If

any
hose

cannot
be
free
of

obstructions

replace

Ensure
that
flame

arrester
is

surely

inserted
in
the

hose
between
air

cleaner
and
rocker
cover

CHECKING
EXHAUST

MANIFOLD
HEAT

CONTROL
VALVE

Run

engine
and

visually
check

counterweight
to
see

if
it

operates

properly

I
For

some
time

after

starting

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
Engine
Tune

up

CoOl
1

Oil
level

gauge

2

8affle

pia
te

3

Flame
arrester

4

Filter

5
P
C
V
valve

6

Steel
net

7

Baffle

plate

1fiI

o

EC716

Fig
ET
20
Crankcaae
emi
ion

control8
tem

3
When
heat

control
valve
is
in
the

full

open

position
counterweight

moves
further

clockwise

exceeding
the

position
described

in
1

1
above
and

stops

again
coming
into

contact
with

stopper

pin

ct

t

C

EC245

1

Counterwe
ht

2

Stopper
pin

3

Heat
control

valve

Fig
ET
21
Cold

operation
of
counte

weigh
t

EC246

1

Counterweight

2

Stopper
pin

3
Heat
control
valve

Fig
ET

22
Hot

operation
of
counter

weight

ET

14
2
With

engine

stopped
visually

check

E
F
E

system
for
the

following

items

I
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

with
a

fmger
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

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

imme

iately
upon
deceleration

The

valve
is

designed
for
one

way
opera

tion

and
consists

of
a
one

way
umbrel

la
valve
and
sintered
steel
fluidic

restrictor

OPERATI
NG

PRESSURE
OF

BOOST
CONTROLLED

DECELERATION

DEVICE
B
C
D
D

ADJUSTMENT

CHECKING
a
C
D
D
CIRCUIT

WITH
FUNCTION
TEST

CONNECTOR

Manual
transmission
models

I

Check
for

continuity
between

@

and@
at
a

speed
of
zero
km
Refer

to

Figure
ET
30

B
C
D

D
circuit
is

functioning

properly
if

continuity
exists
and
volt

meter

reading
is
0
volt
d
c
in

step
2

below

If

continuity
does
not
exist
check

for
disconnected
connector
and
or

faulty

amplifier
speed
detecting

switch
or
B
C

D
D
solenoid
valve

2
Check
for

presence
of

voltage

across

@
and

@
at
a

speed
of
more

than
16
km
h

10
MPH
Refer
to

Figure
ET
31

Conduct

this
test

by
one
of

the

following
two

methods

i
Raising

up
rear
axle

housing
with

stand

2
Chassis

dynamometer
test

If
voltmeter

reading
is

0
volt
at

a

speed
of

more
than
16

km
h
10

MPH
circuit
is

functioning
prop

erly

If
voltmeter

reading
is

not
0
volt

check
for
disconnected
connector

burned
fuse

faulty

amplifier

B
C
D
D

solenoid
valve
or

speed

detecting
switch

3

If

by
above
checks

faulty
part
or

unit
is
located
it

should
be
removed

and
tested

again
If

necessary
replace

Automatic
transmission

models

I

With
inhibitor

switch
ON
UN

or
P

position
check
for

presence
of

voltage
across

@
and

@
Refer
to

Figure
ET
30

If

voltmeter

reading
is

12
volts

d
c

B
C
D
D

circuit
is

func

tioning
properly
Engine
Tune

up

If
voltmeter

reading
is

zero
check

for
disconnected

connector

faulty

solenoid
valve
or
inhibitor
switch
erly

If
ohmmeter

reading
is

32
ohms
or

above
check
for

poor
connection

of

connector

faulty
B

C
D
D

sole

noid
valve

or
inhibitor

relay

3

If

by
above
checks

faulty
part
or

unit
is

located
it
should
be
removed

and
tested

again
If

necessary
replace
2

With
inhibitor

switch
OFF

41
2
D
or
R

position

check
for
resistance

between

@
and

@
Refer

to

Figure
ET
31

If

ohmmeter

reading
is
25
ohms
or

below
circuit
is

functioning
prop

l

E
r
1

Ignition

key

2

Fuse

3

Amplifier

4

Speed
detecting
switch

Above
10

mph
OFF

Below

10

mph
ON

5

Function
test
connector

6
B
C
D
D

solenoid
valve

EF711

Fig
ET

30
B
C
D
D
circuit
with

function
tedconnectoT

Manual
transmission
modela

@

1

Ignition

key

2

Inhibitor
switch

N
P

positions
ON

I
2

D
R

positions
OFF

3
D
C
D
D
solenoid
valve

4

Function
test
connector

5
Inhibitor

relay

EF712

Fig
ET
31

Checking
B
C
D
D
circuit
with
function
tf
st
connf
ctor

Automatic
transmiMion
modtla

ET
17

r

ADJUSTMENT
OF
SET

PRESSURE
OF
BOOST

CONTROLLED
DECELERATION

DEVICE
B

C
D
D

Generally
it
is

unnecessary
to

ad

just
the
B
C
D

D
however
if
it

should

become

necessary
to

adjust
it

the

procedure
is

as
follows

Prepare
the

foUowlnB
tools

I

Tachometer
to
measure
the
en

gine

speed
while

idling
and
a
screw

driver

2
A

vacuum

gauge
connecting
pipe

Note
A

qui
k

response
type
boost

gauge
such
as
Bourdon
s

type
is

recommended
a

mercury

type

manometer
should
not
be
used

To

properly
set
the

B

C
D
D

set

pressure

proceed
as

follows

I

Remove
the

harness

of
solenoid

valve

TO
D
D

solenrod

VT

FJ

1
B
C
D
D

solenni

valve
harness

J

ri

y

EF262

F
g
ET

32
Removing
harneS5

of

solenoid

valve

2
Connect
rubber
hose
between

vacuum

gauge
and
intake
manifold
as

shown

Fig
ET

33

Connecting
vacuum

gauge

3

Warm

up
the

engine
until
it
is

heated
to

operating

temperature

Then

adjust
the

engine
at
normal
Engine
Tune

up

idling
setting
Refer
to
the

item

Idling
Adjustment
in

page
ET
II

Idling

engine
speed

Manual
transmission

750

rpm

Automatic
transmission

in

D

position

650

rpm

4

Run
the

engine
under
no

load

Increase

engine
speed
to
3
000
to

3
500

rpm
then

quickly
close
throttle

valve

5
At

the
time
the

manifold
vacuum

pressure
increases

abruptly
to
600

mmHg
23
62

inHg
or
above

and

then

gradually
decreases
to
the
level

set
at

idling

6
Check
that
the

B
C
D
D
set

pres

sure
is
within
the

specified
pressure

Specified

pressure
0
m
sea
level

and

760

mmHg
30

inHg
atmos

pheric
pressure

Manual
transmission

510
to

550

mmHg

20
1
to
21
7

inHg

Automatic
transmission

490
to
530

mmHg

19
3
to
20

9

inHg

Note

When

checking
the
set

pressure

of
B
C
D
D

find
the

specified
set

pressure
in

Figure
IT

36
from
the

atmospheric
pressure
and
altitutde

of
the

given
location

For

example
if
a

manual
transmis

sion

model
vehicle
is

located
at

an

altitude

of
1
000
m

3
280
ft
the

specified
set

preSsure
for
B

C
D
D

445

mmHg
17
5

inHg

7

If
it
is

higher
than
the
set

level

turn
the

adjusting
screw

counter

clockwise

or
nut

clockwise
until

correct

adjustment
is

made

Non
California

models

Adjusting
screw

type

California

models

Adjusting
nut

type

Note
When

adjusting
B
C
D
D

for

California

models
turn

adjusting

nut
in

or
out

with
lock

spring
in

place

Always
set

lock

spring

prop

erly
to

prevent

changes
in
set

pres

sure

ET

18
Non
california

models

1

Adjusting
screw

2

Cover
e

ET037

California
models

r

1

Adjusting
nut

2

Lock

spring

EC692

Fig
ET
34

Adjusting
Bet

pressure

8

Race
the

engine
and
check
for

adjustment

9
If
it
is

lower
than
the
set
level

turn
the

adjusting
screw
or

nut
until

correct

adjustment
is
made

10
Race
the

engine
and
check
for

adjustment

If

engine
speed
cannot

be
decreased

to

idling
when

checking
B
C
D
D
set

pressure
proceed
as
follows

When
the

engine
speed
does

not
fall

to

idling
speed
it

is

necessary
to

reduce
the

negative
idling

pressure
of

the
manifold
to
lower

than
the
set

pressure
of
the
B

C
D

D
The

engine

speed
will
not

drop
to

idling
speed

when
the

negative
idling
pressure
is

higher
than
the

set

pressure
of

the

B

C
D
D

In

this
case
the

engine
must
be

labored

by
I
road
test
or
2
chassis

dynamometer
or
3

by
raising
up
rear

suspension
member
on
a

stand
accel

erating
the
vehicle
to
64
to
80

krn
h

40

to
50
MPH
in

top
gear
manual

transmission
or
in
D

position
auto

matic
transmission

and
then

releasing

the
accelerator

pedal
and

letting
the

vehicle

decelerate
After

doing
this

check

whether
the
B

C
D
D
set

pres

sure
is
at
the

predetermined
value

or

not

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

SERVICE
DATA
AND

SPECIFICATIONS

Ignition
timing
and

idling

Manual
transmission

Automatic
transmission

in
D

position

Valve

clearance

Cold
Intake

Exhaust

Intake

Exhaust
Hot

Belt
tension

Fan

Air

pump

Air

coo

compressor

Pressure

Compression
pressure
at
350

rpm

Standard

Minimum

Radiator

cap
relief

pressure

Cooling
system

Leakage
testing
pressure

Battery
specific

gravity
at
200C
680F

Distribu
tor

Point

gap

Air

gap

Dwell

angle

Condenser

capacity

Condenser
insulation

resistance

Spark
plug

Gap
degree
rpm
120
B
T
D

C
j750
Non
Calif

models

100

B
T
D

C
j750
California
models

degree
rpm
l20B

T
D

C
j650

mm
in

mm
in

mm
in

mm
in
0
20
0
008

0
25

0
010

0
25
0
010

0
30
0
012

mm
in

mm
in

mm
in

kg

lb
8
to
12
0
315
to
0
472

8to
12
0
315

to
0
472

8

to
12
0
315
to

0
472

10
22
is

applied

kg
cm2

psi

kg
em2

psi

kg
em
2

psi
12
0

171

9
0
128

0
9

13

kg
cm2

Psi
1
6
23

1

26

mm
in

mm
in

degree

IF

Mil
0
45
to
0
55
0

018
to
0
022

0
2
to
0
4
0

008
to
0
016

490
to
550

0
20
to
0
24

5

mm

in
0
8
to
0
9
0
031
to
0
035

Breaker

points
type

1

0
to
1
1
0
039

to
0
043

Transistor
ignition
type

Checking
CO

percent
at

idling
speed
No
air

Manual
transmission
model

rpm

Automatic
transmission
model

rpm

Adjustment
of

operating
pressure
of
B

C
D
D

B
C
D
D

set

pressure

Manual
transmission

Automatic

transmission
2
1

1
750

2
1
1
650

mmHg
in

Hg

mmHg
in
Hg
510
to
550
20
1

to
21
7

490
to
530
19
3
to
20
9

ET
25

Engine
Mechanical

GENERAL
DESCRIPTION

MODEL

L20B
ENGINE

CYLINDER
BLOCK

CRANKSHAFT

PISTON
AND
CONNECTING
ROD

CYLINDER
HEAD
CONTENTS

EM
2

EM
3

EM
3

EM
3

EM
3
CAMSHAFT

VALVE
MECHANISM

CAMSHAFT
DRIVE

MANIFOLDS

out
smooth

dependable

power

The

cylinder
block
is
cast
as
a

single

unit

and

featllres
deep
skirting
This

engine
is

equipped
with
a

single
2

barrel
downdraft
carburetor
that
in

corporates
a

special
device
to
control

emissions
MODEL
L20B

ENGINE

The
L20B

engine
features
O
H
C

valves

wedge
shaped
combustion

chamber
aluminum
head
and
a

fully

balanced
5

bearing
crankshaft
to
turn

Main

specifications

Oisplacemen
t
cc

cu
in

Bore
x
stroke

mm
in

Compression
ratio

Ignition

timing

Degree
B

T
O
C

rpm
MIT

AlT

MIT
Manual
Transmission
EM535

Fig
EM
Cross
sectional
view

L20B

1

952
1191

85

X
86

3
35
x
3
39

8
5

12
750

Non
California

model

10
750

California

model

12
650
in
0
position

AIT
Automatic
Transmission

EM

2
EM
3

EM
3

EM
3

EM
3

CYLINDER
BLOCK

The

cylinder
block
a
mono
block

special

casting
structure

employs
a

five
bearing

support

system
for

quiet

ness

and

higher
durability

The

cylinder
bores
are
surrounded

by
cooling

jackets
and
machined
di

rectly
in
the
block
The
oil

ways
in
the

block

are
arranged
so
that
the

full
flow

oil
filter
is

directly
attached
to
the

right
hand
side
of
the
block

EM536

Fig
EM

2
Cylinder
block

CRANKSHAFT

The
crankshaft
is

a

special
steel

forging
Fully
balanced
it
turns
out

smooth

dependable
power
at

high

speed

The
L20B

engine
uses

eight
balance

weights

Main

bearings
are
lubricated

by
oil

pumped
through
the
main
oil

gallery

and
the
oil
holes
which
run
in

parallel

with

cylinder
bores
There

are

oilways

drilled
in

the
crankshaft
for
the
lubri

cating
oil
The
center
main

bearing
is

equipped
with
thrust
washers

to
take

up
end

thrust
of
the
crankshaft

r

I

I

PRELIMINARY
CLEANING
AND

INSPECTION

DISASSEMBL
Y

PRELIMINARY

CLEANING
AND

INSt

ECTION

Before

disassembling

engine
note

the

following

I
Fuel

oil
or
water

may
leak

past

cylinder
head
and
block
Prior
to

disassembling
check

cylinder
head

1
1ltermal
vacuum
valve

2
Check

valve

3
Altitude

compensator

in

air
cleaner

4
Air

gallery
pipe

S

Auto
choke

6
Automatic

temperature

control
air

cleaner

7
Anti
8ackfire
valve
A
B

valve

8
Boost
Controlled

Deceleration

Device
Bee
D
D

9
P
c
v

valve

to
Air
relief
valve

11
E

G
R

control
valve

12
B
C
D
D

control
valve
and

solenoid
valve

13

Emergency
air

relief
valve

14
Air

pump
air
cleaner

IS
Carbon
canister

16
Air
control

valve

11
Air

pump
Engine
Mechanical

ENGINE

DISASSEMBLY

CONTENTS

EM
4

EM
4
PISTONS
AND
CONNECTING
RODS

CYLINDER

HE
AD
EM
7

EM
7

front
chain

cover
oil

pan
and
oil

filter

gaskets
lInd
crankshaft
and
water

pump
seals
for

signs
of

leakage
past

their

gasketed
surfaces

2
Check
carburetor
and

fuel

pump

for
condition
fuel
hoses
for

deteriora

tion
cracks

or

leakage
of
fuel

past

their

jointed
or
connected

surfaces

Fig
EM

0
Emiuion
control
devic
s

California
mod
18
E
T366

3
Remove

carburetor
air

cleaner

Remove
fresh

air
duct

Disconnect
hot
air
duct
from

air

cleaner

Disconnect
air

cleaner
to
air

pump

hose
at
air

cleaner

Disconnect
air

cleanef
to
rocker

cover

hose
at
rocker
cover

Disconnect

air
cIeaner

to
air

con

trol

valve
hose
at
air

cleaner
Cali

fornia

models

only
Disconnect
air

cleaner
to
A

B
valve

hose
at
air

cleaner

Disconnect
air

cleaner
to

related

part
vacuum
hoses
at
air

cleaner

Loosen
air

cleaner
band
bolt
and

remove
carburetor
air

cleaner
as

sembly
from

carburetor

4

Plug
up
carburetor
air

horn

to

prevent
entry
of

foreign
matter

5

Remove

alternator
drive

belt

alternator
and

alternator
bracket

EM
4
6

Remove
air

pump
drive

belt
cool

er

compressor
and
idler

pulley
if

so

equipped

7
Remove
starter
motor
from
trans

mission

8

Visually

inspect
cylinder
head

cylinder
block
rocker
C
Ner

front

chain
cover
oil

pan
and
all
other
outer

parts
for
oil
water
and
fuel
leaks

breakage
or

missing
parts
such

as
bolts

and
nuts

9

Check

piping
and
electrical
cir

cuits
for
deterioration

breakage
fit

tings
discontinuity
or
insulation

DISASSEMBLY

To

remove

engine
from
vehicle

refer
to

the
instructions
under
the

Engine
Removal

and
Installation

ER
section

I

Remove
transmission
from

en

gine

2
Remove

clutch

assembly
from

flywheeL

3

Thoroughly
drain

engine
oil
and

coolan
t

by

removing
drain

plugs

Store

engine
oil
and

coolant
if

they

are

to
be

used

again

4
Place

engine
assembly
on

engine

stand

I

Remove

cooling
fan

2

Remove

right
engine

mounting

bracket

3

Remove
oil
filter
with
Oil

Filter

Wrench
STI9320000

4

Remove
oil

pressure
swi

tch

5

Install

engine
attachment
to

cylinder
block

utilizing
bolt

holes
in

alternator

bracket
and

water
drain

hole

6
Set

engine
on
stand

Engine
Attachment

ST05260001

Engine
Stand

ST050I

SOOO

Engine
Mechanical

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Engine
model
L20B

Cylinder
arrangement

Displacemen
t

Bore
and
stroke
4
in

line

cc
co
in

mm
in
1

952

J
19
1

85
x

86
3

35
x
3
39

O
H

C

I

3
4
2
Valve

arrangement

Firing
order

Engine
idle
rpm

Manual
transmission

Automatic
transmission
in
D

range
750

650

8
5

Compression
ratio

Oil

pressure
Warm
at
2

000

rpm

kg
cm2

psi
3
5
to
4
0
50

to
57

SPECIFICATIONS

a
Valve
mechanism

Valve

clearance
Warm

Intake

Exhaust

Valve
clearance
Cold

Intake

Exhaust

Valve
head
diameter

Intake

Exhaust

Valve
stem
diameter

Intake

Exhaust

Valve
length

Intake

Exhaust

Valve
lift

Intake
and
exhaust
mm
in

0
25
0
010

0
30
0
012

mmOn

0
20
0
008

0
25
0
010

mm
in

42
0
to
42
2
1
654

to
1

661

35

0
to
35
2
1

378
to
1
386

mm
in

7

965
to
7
980
0
3136
to

0
3142

7
945
to
7
960
0
3128
to

0
3134

mmOn

114
9
to
115
2
4
524
to
4
535

115
7
to
116
0
4
555
to
4

567

mmOn

Valve

spring
out

of

square
mm
in
10
5
0
413

less
than
1

6
0
063

Valve

spring
free

length
mm
in

Intake
and
exhaust
Outer

Inner
49
98
1
968

44

85
J
766

EM
27