ALIGNMENT DATSUN PICK-UP 1977 Service Manual

EM103

EM411

Fig
EM
29

Remouingpi
tonpin

Fig
EM
26
Remouing
rear
oil
eal

41
Remove
crankshaft

42
Remove
baffie

plate
and
cyl

inder
block
net

Fig
EM
27
Removing
baffle
plate
and

nel

PISTONS
AND

CONNECTING
RODS

Remove

piston
rings
with
a

ring

remover

O

EM102

Fig
EM
28

Removing
pilton
rings

2
Press

piston
pin
out
with
Piston

Pin
Press
Stand
STl3030001
Engine
Mechanical

3

Keep
disassembled

parts
in
order

CYLINDER

HEAD

I

Remove
valve
rocker

springs

Loosen
valve

rocker

pivot
lock
nut
and

remove
rocker
arm

by
pressing
valve

spring
down

Fig
EM
3D

Removing
rockerarrm

2

Remove
locate

plate
and
remove

camshaft

EM105

Fig
EM

31
Remouing
cammaft

EM
7
Note
Be

careful
not
to

damage
eam

shaft

bearings
and
earn
lobes

3
Remove

valves

using
Valve
Lifter

STl2070000

STl2070000

Fig
EM
32

Removing
ualves

Notes

a
Take

care
not
to
lose
valve

spring

seat
oil
seal
valve
collet

and
valve

rocker

guide

b
Be
sure

to
keep
camshaft

bearings

intact

or
the

bearing
center
is

liable

to
come
out
of

alignment

61

8

Exhaust
Intake
EM101

Fig
EM
33
Value
components

r

Engine
Mechanical

INSPECTION
AND
REPAIR

PREPARATION
FOR
INSPECTION

CYLINDER
HEAD
AND
VALVE

CHECKING
CYLINDER
HEAD
MATING

FACE

VALVE
ASSEMBLY

VALVE
SPRING

ROCKER
ARM
AND
VALVE

ROCKER

PIVOT

VALVE
GUIDE

VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARING

CAMSHAFT

BEARING
CLEARANCE

VALVE
TIMING

CAMSHAFT
ALIGNMENT

CYLINDER
BLOCK

HOW
TO
MEASURE

CYLINDER
BORE

CYLINDER

BORING

PREPARATION
FOR

INSPECTI
N

I

Before

cleaning
check

for

signs

of
water

and
oil
leaks
in

cylinder
block

and

head

2
Clean
oil
carbon

deposits
and

sealant
from
an

parts
Remove

gasket

3
Clean
all

oil
holes
with
solvent

and

dry
with

compressed
air

Make

sure
that

they
are

not
restricted

CYLINDER
HEAD

AND
VALVE

CHECKING
CYLINDER

HEAD

MATING
FACE

EM407

Fig
EM

34
Cylinder
head
CONTENTS

EM
8

EM
B

EM
8

EM
8

EM
9

EM
lO

EM
l0

EM
11

EM

12

EM
12

EM
12

EM
13

EM

13

EM
13

EM
14
PISTONS
PISTON
PINS
AND

PISTON
RINGS

CONNECTING
ROD

CRANKSHAFT

BUSHING
AND
BEARING

MEASUREMENT

OF
MAIN

BEARING

CLEARANCE

MEASUREMENT
OF

CONNECTING
ROD

BEARING
CLEARANCE

FITTING

BEARINGS

MISCELLANEOUS
COMPONENTS

CRANKSHAFT
AND

CAMSHAFT

SPROCKETS

CHAIN

TENSIONER
AND
CHAIN

GUIDE

FLYWHEEL

FRONT
COVER
AND

REAR
OIL
SEAL

Note

Never

remove
camshaft
bear

ings
unless

you
have
a

Suitable

machine

or

boring
Camshaft
bear

ing
in
line
If

you
once
remove

camshaft

bearings
bearing
centers

will
come
out

o

alignment
reo

conditioning
is

very
difficult
with

out
center

borings

L
Make

a
v

isual
check
for
cracks

and
flaws

2

Measure
the
surface
of

cylinder

head
on

cylinder
block

side
for

warpage
If
it
is

found
to
be

beyond

the
limit

designated
below

regrind
the

affected
surface

with
a
surface

grinder

Fig
EM
35

Checking
cylinder
head

8JJrface

EM
8
Head
surface
flatnes

Standard

less
than
0
05

mm
0
0020
in
O
lmm

0
0039
in
EM
15

EM
16

EM
16

EM
17

EM
17

EM
1B

EM
18

EM
19

EM
19

EM
20

EM
20

EM
20

Maximum

VALVE
ASSEMBLY

Check
each
intake

and
exhaust

valve
for
worn

damaged
or
deformed

valve

caps
or
stems

Correct
or

replace

any
valve
that
is

faulty

2
Valve

face
or
valve
stem
end

surface

should
be
refaced
with
a
valve

grinder

10

L
I
I

I

EM109

Fig
EM
36
Intak
and

exhaust
valve

dimensions

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

r

Piston

pin
outside
diameter

Piston

pin
hole
diameter

Piston

pin
to

piston
clearance

I

Interference
fit
of

piston

pin
to

connecting
rod

CONNECTING

ROD

I
If
a

connecting
rod
has

any
flaw

on
either
side
of
the
thrust
face
or
the

large
end

correct
or

replace
it

EM133

Fig
EM
61
Ch

cking
rod

alignment

Connecting
rod

bend

or
torsion

per
100
mm

or
3
94
in

length

mm
in

3

When

replacing

connecting
rod

select
rod

so
that

weight
difference

between
new
and
old

ones
is

within
7

gr
0
25
oz

Do

not
use

a
combination
of
new

and

former

connecting
rod

big
end

nuts
and

connecting
rod
bolts
which

affect

specified
weight
variations

4
Install

connecting
rods
with

bear

ings
on
to

corresponding
crank

pins

and

measure
thrust
clearance

Ifmeas

ured

value
exceeds

limit

replace
Engine
Mechanical

Unit

mm
in

20
993
to
20
998
0

8265
to

0
8267

21

001
to
21
008
0

8268
to
0
8271

0
003
to
0
015

0
0001
to

0
006

0
015

to
0
035
0

0006
to
0
0014

2
Check

connecting
rod
for
bend
or

torsion

using
a

connecting
rod

aligner

If
bend
or
torsion
exceeds
the

limit

q
rrect
or

replace

Standard

Maximum

0
03
0

0012
0
05

0
0020

Fig
EM
62

Checking
big
end

play

Standard

Maximum

Big
end

play
mm

in
0
2

to
0
3

0

0079
to
0
01
18
0
6
0
0236

EM

16
CRANKSHAFT

1

Whenever
crankshaft
is
removed

from

engine
it

should
be

cleaned

thoroughly
in

a
suitable

solvent

After

cleaning
check

crankshaft

journal
and

crank

pin
Jor
score
bias

wear
or

cracks

Rep
air

or

replace
as

required

If

damage
is
minor

dress
with
fine

crocus
cloth

2

Check

journals
and
crank

pins
for

taper
and

out
of

round
with
a
micro

meter

Measurement
should
be
taken

along
journals
for

taper
and
around

journals
for

out
of
round

See

Figure

EM
63
for

detailed
information

If

journals
or
crank

pins
are

tapered

or
out
of
round

beyond
limits

replace

with
a

new
shaft

A
B

Out
of

round

X
Y

Taper
A
B

Unit
mm
in

19
5

0
768

tt
30
27

32

181
1
06
1
260

43

O
l
69

I

E
1

All

main

journa

59
942
to
59
955
All
crank

pm

2

3599
l
2

3604
49
961
to
49

974

o

1
9670
to
1

9675

EM424

Fig
EM
63

Crankshaft
and

journal

dimensions

Engine
Mechanical

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition

I

Noisy
engine

Knocking
of
crankshaft

and
bearing

Knocking
of

piston

and

connecting
rod

Camshaft

knocking

Timing
chain
noise

Camshaft
and
valve

mechanism

knocking

Water

pump
knocking
Probable
cause

Loose
main

bearing

Seized
bearing

Bent
crankshaft

Uneven
wear

of

journal

Excessive
crankshaft
end

play

Loose
bearing

Seized

bearing

Loose

piston
pin

Loose

piston
in

cylinder

Broken

piston
ring

Improper
connecting
rod

alignment

Loose

bearing

Excessive
axial

play

Rough
gear
teeth

Broken
eam

gear

Improper
chain
tension

Worn
and
or

damaged
chain

Worn

sprocket

Worn
and
or

broken
tension

adjusting

mechanism

Excessive
camshaft
and

bearing
clearance

Improper
valve
clearance

Worn

adjusting
screw

Worn
rocker
face

Loose
valve
stem

i1
1
guide

Weakened
valve

spring

Seized
valve

Improper
shaft
end

play

Broken

impeller

II
Other
mechanical
troubles

Stuck
valve

Improper
valve
clearance

Insufficient
clearance
between
valve
stem

and

guide

Weakened
or

broken
valve

spring

Biting
or

damage
of
valve
stem

Poor

Quality
of
fuel

EM
31
Corrective
action

Replace

Replace

Repair
or

replace

Correct

Replace
cen
ter

bearing

Replace

Replace

Replace
pin
or

bushing

Recondition

cylinder

Replace

Realign

Replace

Replace
bearing
thrust

plate

Repair

Replace

Adjust

Replace

Replace

Replace

Replace

Adjust

Replace

Replace

Replace
guide

Replace

Repair
or

replace

Replace

Replace

Adjust

Clean
stem
or
ream
guide

Replace

Replace
or
clean

Use
ood
fuel

Condition

Seized
valve

seat

Excessively
worn

cylinder
and

piston

Faulty
connecting

rod

Faulty
crankshaft

bearing
Engine
Mechanical

Probable

cause

Improper
valve

clearance

Weakened
valve

spring

Thin
valve
head

edge

Narrow
valve
seat

Overheating

Over

speeding

Stuck
valve

guide

Shortage
of

engine
oil

Dirty

engine
oil

Poor

quality
of
oiL

Overheating

Wrong
assembly
of

piston
with

connecting

rod

Improper
piston

ring
clearance

Broken

piston

ring

Dirty
aii

cleaner

Mixture
too
rich

Engine
over

run

Stuck
choke
valve

Overchoking

Shortage
of

engine
oil

Low
oil

pressure

Poor

quality
of

engine
oil

Rough
surface
of

craokshaft

Clogged
oil

passage

Bearing
worn
or

eccentric

Bearingimproperly
assembled

Loose

bearing

Connecting
rod

alignment
incorrect

Shortage
of

engine
oil

Low

oil

pressure

Poor

quality
of

engine
oil

Craokshaft

journal
worn
or

out
of
round

Clogged
oil

passage
in

crankshaft

Bearing
worn

or
eccentric

Bearing
improperly
assembled

Eccentric

craokshaft

or

bearing

EM
32
Corrective
action

Adjust

Replace

Replace
valve

Reface

Repair
or

replace

Drive
at

proper
speeds

Repair

Add
or

replace
oil

Clean

crankcase

replace
oil
and
oil
niter

element

Use

right
oil

Repair
or

replace

Repair
or

replace

Adjust

Replace

Clean

Adjust

Drive
at

proper
speeds

Clean

and

adjust

Start

correct

way

Add
oiL

Correct

Use

proper
oil

Grind
and

replace

bearing

Clean

Replace

Correct

Replace

Repair
or

replace

Add
or

replace

Correct

Use

proper
oil

Repair

Clean

Replace

Correct

Replace

In

these
cases
the

transmission
must

be

repaired

Notes

a
In

checking
oil

level
use

special

paper
cloth
to
handle
the
level

gauge
and
be
careful
not
to
let
the

scraps
of

paper
and
cloth
stick
to

the

gauge

b
Insert
the

gauge
fully
and
take
it

out

quickly
before

splashing
oil

adheres
to
the

gauge
Then
observe

the
level

c
Use
automatic
transmission
fluid

having
DEXRON
identifications

only
in
the
3N71B
automatic
trans

mission

d

Pay
attention
because
the
oil
to
be

used
differs
from
that
used
in

the

Nissan
Full
Automatic
TranSJTIis

sion
3N71A
Never
mix
the
oils

INSPECTION
AND
REPAIR

OF
OIL
LEAKAGE

When
oil

leakage
takes

place
the

portion
near
the

leakage
is
covered

with
oil

presenting
difficulty
in

detecting
the

spot
Therefore
the

places
where
oil
seals
and

gaskets
are

equipped
are
enumerated
below

11
Converter

housing

Rubber

ring
of
oil

pump
housing

Oil
seal
of
oil

pump
housing

Oil
seal
of

engine
crankshaft

Bolts
of
converter

housing
to
case

2
Trarismission
and
rear
extension

Junction
of
transm
ss
ion

and
rear

extension
J

Oil
cooler
tube
connectors

Oil

pan

Oil

pressure
inspection
holes
Refer

to

Figure
AT
il2

Mounting
portion
of
vacuum
dia

phragm
and
downshift
solenoid

Breather
and
oil

charging
pipe

Speedometer
pinion
sleeve

Oil
se
l
of
rear
extension

To

exactly
locate
the

place
of
oil

leaka
le
proceed
as
follows

Place
the
vehicle
in

a

pit
and

by

sampling
the
leaked
oil
determine
if
it

is
the

torque
converter
oil
The

torque

converter
oil
has
a
color
like
r
d
wine

So
it
is

easily

distinguished
from

engine

oil
or

gear
oil
Automatic
rransmission

Wipe
off
the

leaking
oil
and
dust

and
deiecl
the

spol
of
oil

eakage

l
se

nonflammable

organic
solve
t
s
ch
as

carbon
tetrachloride
for

wiping

Raise

the
oil

tcmperalure
by

op

erating
the

engine
and

shift
the
lever

to
D
to
increase

the
oil

pressure

The

spot
of
oil

lcakage
will
then
be

found
more

easily

Note
As
oil

leakage
from
the
breaih

er
does
not
take

place
except
when

running
at

high
speed
it
is

impos

sible
to
locate
this

leakage
with

vehicle

stationary

CHECKING
ENGINE
IDLING

REVOLUTION

The

engine
idling
revolution
should

be

properly
adjusted

If
the

engine
revolution
is

too
low

the

engine
does
not

operate
smoothly

and
if
too

high
a

strong
shock
or

creep
develops
when

changing
over

from
N
to
D
or

R

CHECKING
AND
ADJUSTING

KICK

DOWN

SWITCH
AND

DOWNSHIFT

SOLENOID

When

the
kickdown

operation
is

not

made

properly
or
the

speed
chang

ing
point
s
too

high
check
the
kick

down
switch
downshift
solenoid
and

wiring
between
them
When
the

igni

li
n

key
is

pqsitioned
a
t

the
I

st

stage

nd
the
accelerator

pedal
is

depressed

deeply
the
switch
contact
should
be

closed
and
the
solenoid
should
click
If

it
does
not
click
it
indicates
a
defect

Then
check
each

part
with
the

testing

instruments
See

Figure
ATl09

d

I

t

AT10S

Fig
AT
109

Downshift
solenoid

Note
Watch
for
oil

leakage
from

transmission
case

AT
4Q
INSPECTION
AND

ADJUSTMENT
OF
MANUAL

LINKAGE

The

adjustmcnt
of

manual

linkage

is

equaUy
important
as

Inspection
of

Oil
Level
for
the
automatic
transmis

sion
Thereforc

great
care
should
be

exercised
because
incorrect

adjustment

will

rcsult
in
the
brcakdown
of
the

transmission

Inspection

Pull
the
selector
lever
toward

you

and
turn
it

as
far
as
P

to
I

range

wherc
clicks
will
be
felt

by
the
hand

This
is
the

detcnt
of
manual
valve
in

the
valve

body
and
indicates
th

correct

position
of
the

lever

Inspect
whether

the

pointer
of

selector
dial

corresponds
to
this

point

and
also
whether
the
lever
comes

in

alignment
with
the

stepping
of

posi

tion

plate
when
it
is
released

Adjustment

This

procedure
can
be

accomplish

ed

by
refcrring
to

page
AT
35

for

Removal
and
Installa
tion

CHECKING
AND

ADJUSTING

INHIBITOR
SWITCH

The
inhibitor
switch

lights
the
re

verse

lamp
in

the

range
R
of
the

transmission

operatio
l
and
also

rotates

the
starter
motor
in
the

ranges
N

and
P

CD

@
b
ell

If

L
t

7
4l

@

1l

j7
@
@

@
dl

AT109

6
Washer

7
Nut

8
Inhibitor
switch

9
Range
select
lever
t
Inhibitor
switch

2
Manual
shaft

3
Washer

4
Nut

5
Manual

plate

Fig
AT
110
Construction

of
inhibitor

switch

Using
the

tester
check
the

two

black

yellow
BY
wires
from
the
in

hibitor
switch
in
the

ranges
N

and

I
and
the

tw
re
d

black

RBj
wir
s

in

the

range
R
for

continuity
Turn

range
select
lever
in
both

directions

from

each
lever
set

position
and
check

each

continuity

range
It

is
normal
if

the

electricity
is

on
while
the
lever
is

within
an

angle
of
about
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continl
ity

range
is
obvious

ly
unequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
of
the

range

selector
lever

and
two

fastening
bolts

of
the
switch

body
and
then
remove

the
machine
screw
under
the
switch

body
Adjust
the
manual
shaft
correct

ly
to
the

position
N

by
means
of
the

selector
lever

When
the

slot
of
the

shaft

becomes
vertical
the
detent

works
to

position
the
shaft

correctly

with
a

clicking
sound

MSlVe
the

switch

slightly
asj
Je
so

that
the
screw
hole
will
be

aligned

with
the

pin
hole
of
the
internal
rotor

combined
with
the
manual
shaft
and

check
their

alignment
by
inserting
a

1
5
mm
0
059
in
diameter

pin
into

the
holes
If

the

alignment
is
correct

fasten

the
switch

body
with
the
bolts

pull
out
the

pin
tighten

up
the
screw

in

the
hole
and
fasten
the
selector

lever
as
before
Check
the

continuity

again
with
the
tester
If

the
malfunc

tion
still

remains

replace
the
inhibitor

switch
Chcck
whether
the

reverse

lamp

and
the
starter
motor

operate
normal

ly
in
these

ranges
If
Ihere
is

any

lrouble

first
check
the

linkage
If

no

fault
is
found
in

the

linkage
check
the

inhibitor
switch

Separate
the
manual
lever
from
Ihe

remote
control
selector

rod
and
turn

the

range
selcct

lever
to

N

Note

In
the

position
N

the
slot
of

the

manual
shaft

is
vertical

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revolutions
of

the

engine
while
Automatic

Transmission

vehicle
is
held
in
a

stalled

condition

The
carburctor
is
in

full
throttle

opera

tion
with

the
selector
lever
in

ranges

f
2

and
I

respectively
Com

pare
the

measured
results
with
the

slandard

values

Components
to

be
tested

and

test

items

I
Clutches
brake

and
band
in
trans

mission
for

slipping

2

Torque
converter

for

proper
fune

tioning

3

Engine
for
overall

properly

STALL
TEST

PROCEDURES

Before

Icsting
c
heck
the

engine
oil

and

torque
converter

oil
warm

up
the

engine
cooling
water
to
suitable
tem

perature
by
running
at

1
200

rpm
with

the
selector
lever
in

the

range
P
for

several
minutes
Warm

up
the

torque

converter
oil
to
suitable

temperature

6010
1000C
140
to

2l20F

I

Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

fro

the
dri
er
s
seat
and

put
a
mark

on

specified
revolutions
on
the
meter

2

Secure
the
front
and
rear
wheels

with
chocks
and

apply
the
hand
brake

Be
sure
to

depress
the
brake

pedal

fumly
with
the
left
foot
before
de

pressing
the
accelerator

pedal

3
Throw
the
selector
lever
into

the

range
1

4

Slowly
depress
the
accelerator

pedal
until
the

throttle
valvc
is

fully

opened

Quickly
read
and
record
the

engine
revolution
when

the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5

Shift
the
selector
lever
to
N

and

operate
the

engine
at

approxi

mately
1
200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

ver
ter
oil

and
coolant

6

Make
similar
stall
tests
in

ranges

2
I
and
RIO

Note
The
stall
test

operation
as

speci

f
d
in
item
4

should
be

I
l3de

wiihin
five
seconds
If
it

takes
too

long
the
oil
deteriorates
an

the

clutches
brake

and
band
are
ad

versely
affected
Sufficient
cooling

time
should
be

given
between
each

AT
5O
test
for
the
four

ranges
0
2

I
and
R

JUDGEMENT

High
stall
revolution
more

than

standard
revolution

If
the

engine
revolution
in
stall

condition
is

higher
than
the
standard

values
it

indicates
that
one

or
more

clutches
in

the
transmission
are

slipping
and
therefore
no
further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High

rpm
in

all

ranges
low
Iine

pressure

High
rpm
in
D
2
and
I

and

normal

rpm
in
R
Rear
clutch

slipping

High
rpm
in
0

and

normal

rpm
in
I

clutch

slipping

High
rpm
in
R

only
Front

clutch
or
low
and
reverse

brake

slipping

To

determine
which
is

slipping

front
clutch
or
low

and
reverse
brake

a
road
test
is
nceded

If
whilc

coasting
after

starting

with
the
lever
in
1

range
engine

braking
does

not
work

properly
the

low
and

reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is

diffi

cult
to
ascertain

However
if
it

occurs

with
the
lever
in
2

range

engine

revolution
increases

Jp
to
thesarne

level
as
in

I

strange
It

is

impossible

to
check

it
in
the
stall
test
2
and

One

way

2
Standard
stall
revolution

If
the

engine
revolution
in

stall

condition
is
within

the
standard

values
the
control
elements
are

nor

mally

operating
in
the

ranges
0

2
I

and
R

Also

tIle

engine
and
one

way

clutch
of
the

torque
converter
are

normal
in

performance
and

operation

The
one

way
clutch
of

the

torque

converter
however
sometimes

sticks

This
is
determined
in

the
road
test

3
Lower
stall
revolution
than
stand

ard
revolution

If
the

engine
revolution
in
stall

condition
is

lower
than
the
standard

Front
Axle

Front

Suspension

FRONT
AXLE
AND

FRONT
SUSPENSION

CONTENTS

GENERAL
DESCRIPTION

FRONT
AXLE

REMOVAL
AND
INSTALLATION

WHEEL
BEARING
ADJUSTMENT

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

SHOCK
ABSORBER

REMOVAL
AND
INSTALLATION

INSPECTION

STABILIZER

REMOVAL
AND
INSTALLATION

INSPECTION

TENSION
ROD
FA
2

FA
3

FA
3

FA
4

FA
4

FA
5

FA
8

FA

8

FA
8

FA
8

FA
8

FA

8

FA
8
REMOVAL

AND
INSTALLATION

INSPECTION

TORSION
BAR

SPRING

REMOVAL
AND

INSTALLATION

INSPECTION

UPPER
AND
LOWER
LINKS

FjEMOVAL
AND

INSTALLATION

DISASSEMBLY

AND
ASSEMBLY

INSPECTION

ADJUSTMENT

VEHICLE
POSTURE

WHEEL

ALIGNMENT

STEERING
ANGLE

GENERAL
DESCRIPTION

uUl
FA

8

FA

9

FA

9

FA
9

FA

9

FA
10

FA
l0

FA
ll

FA
ll

FA
Il

FA
ll

FA

12

FA
12

FA224

Fig
FA
j
SectionallJiew

of
fronta
xle
and

fron
t

suspension

FA
2

WHEEL
ALIGNMENT

Correct
front
wheel

alignment

attains

proper
vehicle

handling
charac

teristics
and
the
least

steering
effort

with
a
minimum
amount
of
tire
wear

Before

adjusting
front
wheel

align

ment
make
sure
to

carry
out
a

pre

liminary
inspection
of
the
front
end

parts
for
the

following
conditions

1
Tire

pressure
and

balance

2
Wheel

bearings
and
nuts

3

Steering

gear
play

4

Steering
gear

housing
at
frame

S

Steering
linkage
and
connections

6
Shock
absorber
action

When

using
the

equipment
for
front

wheel

alignment
inspection
follow
the

inst

c
tions
furnished

with
the

equip

ment
Furthennore
the

inspection

should
be
made
with
the

vehicle
level

and
at

curb

weight

Camber
and

caster

Measure
camber
and
caster

and

adjust
them
in

accordance
with

the

following
procedures
if

necessary

Both
camber
and
caster

are
ad

justed
by
increasing
and

decreasing

thickness

of

adjust
shim

inserted
be

tween

upper
link

spindle
and

upper

link

mounting
bracket

To

adjust
caster

make
a

difference

between

thickness
of
front

and
rear

shims

By

adding
a
shim

I
mm
0

039

in

at
front
side

caster
will
be
de

creased

by
33

At
the

same
time

camber

will
also
be

decreased

by
6
S

To

adjust
camber
add
or
remove
an

equal
amount
of

shims
to
front

and

rear
sides

By

adding
a

pack
of
shims
I

mOl
0
039
in

thick
at
both

sides

camber

will

be
decreased

by
13

Shims

are
available
in
I

mm
0
039

in
2

mOl
0
079
in
and
4

mOl
0
157

in

thickness
Front
Axle
Front

Suspension

FA243

Fig
FA

25

Adjustingcamberand

cCJ
ter

Notes

a
Do
not
make
difference

between

front

and
rear
shims

in
thickness

beyond
2
mm

0
079
in
on
a

upper

link

spindle

b

Umit
shim
thickness
for

anyone

stack
within
6

nun
0

236
in

c
Do
not

use
shims
for

anyone
stack

more
the
2

sheets

Toe
in

Measure
toe
in

and

adjust
if
neces

sary
For

adjustment
carry
out
the

follOWIng
procedures

Turn

steering
wheel
to

straight

ahead

position
with
front
wheels
in

the
same

position
Then
check

steer

ing
gear
straight
ahead

position

Loosen
lock
nuts

@
left
hand

thread
and

ID
right
hand
thread

and
turn
cross
rod

CD
to

adjust
toe
in

Turn

cross
rod
to
forward

direction
as

shown

by
arrow
and
toe
in
is

reduced
When

cross
rod
is
turned
to

opposite

side
toe
in
is
increased

After

correct
toe
in
is

obtained

tighten
lock
nut

to
8

0
to
10

0

kg
m

S8
to

72
ft
Ib

r
J

r

CD

0

HI

r
I

e

f

FA244

Fig
FA

26

Adju6ting
toe
in

STEERING
ANGLE

Check

steering
angle
and
use
the

follow

ng
procedures
if

necessary

Loosen
lock
nut
at

stopper
bolt
and

adjust
steering
angle
with

stopper
bolt

Mter

obtaining
correct

steering

angle

secure
lock
nut

firmly

FA245

Fig
FA

27

Adjusting
steering
angle

Model
Item

All

models

mOl
in
1
2
to
3
0
079
to

0
118

Toe
in

degree
2

10
to
16

Camber

lOIS
Io

Caster
10SO

4S

I
60IS

Kingpin
inc

inal10n

I
Inner
wheel

360
10

Steering
angle

I
Outer
wheel

310
10

1
The

extreme
front
and

rear
of
the
tire

center

Unladen

2
The
total

angle
of

the
both
tires

FA
12