oil level DATSUN PICK-UP 1977 Service Manual

r

ManifolJ
nuts

I

2
to
1
6

kg
m

8
7
to
I

6
ft
lb

Carburelor
nuls

0
5
to
1
0

kg
m

3
6
to
7
2
fl
tb

Fig
ET
7
Tightening
s

quence

CHECKING
ENGINE

OIL

Check
if
oil
is
diluled
with
water

or

gasoline
Drain
and
refill
oil
if

necessary

Notes

a
A

milky
oil
indicates
the

presence

of

cooling
water
Isolate
the
cause

and
take
corrective
measure

b
An
oil
with

extremely
low

viscosity

indicates
dilution
with

gasoline

2
Check
oil
level
If
below
the

specified
level

raise
it

up
10
the
H

level

Engine
oil

capacity

including
oil

filter

Maximum
H
leven

4
3
liters

4

MUS
qt
3
Y

Imp
qt

Minimum
L

level

3
3
liters

3
f
US

qt
2
U

Imp
ql

REPLACING
OIL

FILTER

The
oil
mter
is

a

cartridge
type
and

can
be
removed

using
Oil
Filter

Wrench
STI9320000

I
Check
for
oil
leaks

past
gasketed

flange
If

leakage
is

found

retighten

just
enough
to

stop
leakage
If

retight

ening
is

no

longer
effective

replace

mter
as
an

assembly
Engine
Tune

up

2
When

installing
oil

filter

tighlen

by
hand

Note
Do
not

overtighten
oil

flIt

lest

leakage
should
occur

CHANGING
ENGINE

COOLANT

PERMANENT
ANTI
FREEZE

COOLANT

Permanent
anti

freeze
coolant
is
an

ethylene
glycol
base

producl
conlain

ing
chemical
inhibilors
10

protect
the

cooling
system
against
corrosion

The
anti
freeze
does
not
contain

any

glycerine
ethyl
or
methyl
alcohol

It
will
not

evaporate
or
boil

away
and

can
be
used
with
either

high
or
low

temperaturethennoslat

It

flows

freely
transfers
heat
effi

ciently
and
will

not

clog
passages
in

the

cooling
system

The
anti
freeze
must
not
be
mixed

with
other

products

This
coolant
can
be
used

through

out

the
seasons
of
the

year

Whenever
coolant
is

changed
the

cooling

syslem
should
be
flushed
and

refilled
with
a

new
coolant

Check
the
level
See
the
instruc

lions
furnished

by
the
manufacturer

for
the
mixture
ratio

of
anti
freeze
10

water

CHECKING

COOLING

SYSTEM
HOSES

AND
CONNECTIONS

Check
hoses
and

fittings
for
loose

connections
or
deterioration
Re

tighten
or

replace
if

necessary

INSPECTION
OF

RADIATOR

CAP

Apply
reference

pressure
0
9

kg
cm2
13

psi
1
to
radiator

cap
by

means
of

a

cap
tester
to
see
if
it
is

satisfactory
Replace
cap
assembly
if

necessary

ET
8
Fig
ET
fJ

Teltill
l
rod
ioto

cop

COOLNG
SYSTEM

PRESSURE
TEST

With
radiator

cap
removed

apply

reference

pressure
1

6

kg
cm2
23

psi
to
the

cooling
system
by
means

of
a
lesler
to
detect

any
leakage

Water

capacity

Without
heater

7
4
liters

7
U
US

qt
6
f

Imp
qt

With
heater

8
0
liters

8
f
US

qt
7

Imp
qt

CHECKING
VACUUM

FITTINGS
HOSES

AND
CONNECTIONS

Check
the
condition
of

filtings
and

hoses

Retighten
or

replace
if
neces

sary

All
vacuum
hoses
can
be
identified

by
colors

White
line

Vacuwn
tube
to
carburetor
E

G
R

Tube

Vacuum
tube
to
thermal
vacuum

valve

Thennal
vacuum
valve
to
E
G
R

control
valve

Yellow

line

Spark
delay
valve
to

distributor

Spark
delay
valve
to
vacuum
tube

Distributor

to
vacuum
tube

Vacuum
tube
to
carburetor

Vacuum
tube
to
canister

Green
line

Anti

backfire
valve
to
intake
mani

fold

Air

control
valve
to

emergency
air

relief
valve

Intake
manifold
to
vacuum
hose

connector

Intake

manifold
to
canister

CHECKING
ENGINE

COMPRESSION

COMPRESSION
PRESSURE

TEST

I
Warm

up
engine
sufficiently

2
Disconnect

all

spark
plugs

3
Disconnect
anti

dieseling
solenoid

valve
connector

4

Properly
attach
a

compression

tester
to

spark

plug
hole
in

cylinder

being
tested
Engine
Tune

up

I

ET010
Different

compression
in
two
or

more

cylinders
usually
indicates

an

improperly
seated
valve
or
broken

piston
ring

9
Low

compression
in

cylinders
can

result
from
worn

piston
rings
This

condition

may
usually
be

accompanied

by
excessive

fuel

consumption

TEST
RESULT

If

compression
in

one
or
more

cylinders
is
low

pour
a
small

quantity

of

engine
oil
into

cylinders
through

the

spark
plug
holes
and
retest
com

pression

I

If

adding
oil
increases
the
com

pression
pressure
the
chances
are
that

rings
are

faulty

2

If

pressure
stays
low

probable

cause
is

that
valve
is

sticking
or

seating

improperly

3
If

cylinder
compression
in

any

two

adjacent
cylinders
is

low
and
if

adding
oil
does
not

help
the

compres

sian
there
is

leakage
past
the

gasket

surface

Oil
and
water
in

combustion
cham

bers

can
result
from

leakage

IGNITION
AND

FUEL
SYSTEM
Fig
ET
10

Teding

compression

pressure

5

Depress
accelerator

pedal
to

open

throttle
and
choke
valves

Note
Do

not

pump
pedal

6
Start

engine
as

quickly
as

pos

sible

7

Compression
pressure

kg
cm2

psi
at

rpm

Standard

12
0

171
350

Minimum

9

0
128
350

8

Cylinder
compression
in

cylinders

Should
not
be
less
than

80
of

highest

reading

CONTENTS

CHECKING
BATTERY
ET
9

CHECKING
DISTRIBUTOR
CAP
ROTOR

CHECKING
AND

ADJUSTING
IGNITION
AND
CONDENSER
ET
11

TIMING
ET
10

CONDENSER
ET
11

ADJUSTING
IGNITION
TIMING
ET10

ADJUSTING
CARBURETOR
IDLE
RPM

CHECKING
AND
REPLACING
SPARK
PLUG
ETlO
AND
MIXTURE
RATIO
ET

11

CHECKING
DISTRIBUTOR
OPERATING
IDLE

LIMITER
CAP
ET
12

PARTS
AND

IGNITION
WIRING
ETlO
CHECKING
CARBURETOR
RETURN
SPRING
ET

12

BREAKER
POINTS

lNon
California
models

ET
10
CHECKING
CHOKE
MECHANISM

AI
R

GAP
lCalifornia
models
ET11
Choke

plate
and

linkage
ET13

DISTRIBUTOR
ET
11
CHECKING
FUEL

LINES

IGNITION
WIRING

ET
11
Hoses

pipings
connections
etc

ET
13

REPLACING
FUEL
FILTER
ET
13

CHECKING
BATTERY

Check

electrolyte
level
in

each
bat

tery
cell
I
Unscrew

each
filler

cap
and

inspect
fluid
level
If
the
fluid
is
low

add
distilled
water
to

bring
the
level

up
approximately
10
to
20
mm
0
39

H
9
to
0
79

in
above
the

plates
Do
not

overfill

2
Measure
the

specific
gravity
of

battery
electrolyte

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

Replace
bulb
if

bulb
is
burned

ou
t

If

bulb
is
not
burned
trace

wireis

back

to

ignition
switch

Repair
or

replace
if

necessary

2

Be
sure
that

floor

temperature
is

cool

below
800C

1760F
before

carrying
out
the

following
procedure

1
Remove
rear
seat

2

Ignition
switch
is
turned
to

the

Temperature

sensing
switch
Temperature

warning
lamp

Contact
close
Off

Contact

open
On

Note

Avoid

heating
floor

tempera

ture

sensing
switch
directly

If

lamp
does

not

glow
check
floor

temperature
sensing
switch
connector

for

continuity
with
a
circuit

tester

If

continuity
should
exist

after

heated

surrounding
areas
of
floor
tern

rv
wnTP
sen
cinq
S
Vitch

reolace
tem

perature
sensing
switch

If

continuity
does
not
exist

trace

the

wiring
back
to

relay
or
check
the

following
step
3

Repair
or

replace

wire

s
if

necessary

Note
The
floor

temperature
sensing

switch

may
be
heated

through
the

floor

by
a

proper
heater

3
Turn

ignition
switch
to
the
IG

position
anf
disconnect
floor

temper

ature

sensing
connector
The

lamp

should
remain

on
If
not

check
floor

4
0
3

UJ

GJO
Engine
Tune

up

IGU

position

3
Ensure

that
floor
tem

perature

warning

lamp
goes
out

4

Heat

surrounding
areas
of
floor

temperature
sensing
switch
with
a

proper
heater

to
ensure
that
floor

temperature
warning

lamp
glows
when

floor
is

heated
to

lh

specifications
as

shown

in
the
table
below

Floor

temperature

Below

1050C

22IOF

Above
1050C

2210F

temperature
relay
for

continuity
with

a

circuit
tester

Referring
to
the

following
floor

temperature
relay
if

relay
is
normal

trace

wire
s
back
to

ignition
switch

Repair

faulty
wiring

Floor

temperature

rela

To

check
floor

temperature
relay

remove
it

and

proceed
as

follows

1
Check
for

continuity

between@

and

@
Continuity
should

exist

Check
for

continuity
between

D

and@
Continuity
should
exist

Check
for

continuity
between

D

and@
Continuity
should
not
exist

2

Apply
a
12
volt
doC

across@and

@
to

ensure
that

continuity
exists

between

D
and@and
that

continuity

does
not
between

D
and

@
If
test

r
I

141

ET
24
results
do
not

satisfy
the
above
reo

place
the
floor

temperature
relay

When
floor

temperature

warnln8
lamp
118hts

Check
floor

temperature
warning

lamp

I

Open
or

short
circuit
in

wiring

harness

2

Check
fuel

system
with

regard
to

the

following
items
Refer
to

Inspec

tion

of
Fuel

System

I
Floa

t
level

2

Choke

3

Normal

fuel

supply
system
Prima

ry
and

secondary

4

Accelerator

pump

5

Power
valve

6

B
C
D
D

7

Fuel
strainer

8
Air

cleaner

3
Check

ignition
system
with

regard

to

the

following
items
Refer

to

Inspection
of

Ignition
System

I

IgnItion
AMI

2

Distributor

3

Ignition
coil

4

High
tension

code

5

Spark

plug

4

Check

idle
CO

adjustment
Refer

to

Inspection
of
Idle

CO

Adjust

roeoC

Note
Even

if
there
is

nothing
wrong

with

engine

warning
lamp
may

come
on
if
vehicle
is

being
driven

on
a

steep
slope
continuously
in

lower

gears
at

high
engine

speeds

To
floor

temperature

warning
lamp

2
From
S

position

3
From
GOt

position

4

From

ignition
switch

5
To
floor

temperature

sensing
switch

EC343

Fig
ET
50

Checking
floor

temperature

relay

Engine
Tune

up

Condition

Probable

cause

Low
or
no

current

Ign
tion

system
out
of

order
Burned
distributor

point

Improper
point

gap

Faulty
condenser

Leak
at
rotor

cap
and

rotor

Faulty

spark

plug

Improper
ignition
timing

Faulty
ignition
coil

Disconnection

of

high
tension

cable

Loose
connection
or
disconnection
in

primary
circuit

Fuel

system
out
of

order
Lack
offuel

Dirty
fuel
strainer

Dirty
or

clogged
fuel

pipe

Fuel

pump
will
not
work

properly

Carburetor

choke
will
not
work

properly

Improper

adjustment
of
float
level

Improper
idling

Dirty
or

clogged
carburetor

Clogged
breather

pip
of
fuel
tank

Malfunctioning
an
ti

dieseling
solenoid
valve

Incorrect
sparle

plug
tightening
or

faulty

gasket

Improper
grade
engine
oil
or
low

viscosity

Incorrect
valve
clearance

Compression
leak
from
valve

seat

Sticky
valve

stem

Weak
or

damaged
valve

springs

Compression
leak
at

cylinder
head

gasket

Sticking
or

damaged
piston
ring

Worn

piston

ring
or

cylinder

Trouble
ooting

procedure

Pour

the

engine
oil
from

plug
hole
and
then

measure

cylinder

compression

Compression
increases

Compression
does

not

change
Low

comp
ion

ET
28
Corrective
action

Check
for
loose

terminal
or
disconnection

in

primary
circuit

Check
for

burned

points

Repair
or

replace

Adjust

Replace

Clean

or

replace

aean

adjust
plug
gap
or

replace

Adjust

Replace

Replace

Repair
or

replace

Supply

Replace

Clean

Repair
or

replace

Check
and

adjust

Correct

Adjust

Disassemble

and
clean

Repair
and
clean

Check
for

loose
terminal
or
wire
harness

Tighten
to
normal

torque
or

replace
gasket

Replace
with

proper
grade
oil

Adjust

Remove

cyljnder
head

and

lap
valves

Correct
or

replace
valve

and
valve

guide

Replace
valve

springs

Replace

gasket

Replace
piston
rings

Overhaul

engine

Malfunctiong

cylinder
or
piston
ring

Compression
leaks
from
valve

cylinder
head

or
head

gasket

Except
transistor

ignition
system

Condition

IMPROPER
ENGINE

IDLING

Fuel

system
out
of

order

Low

compression

Others

High
engine
idle

speed
Engine
Tune

up

Probable
cause

Clogged
or

damaged
carburetor

jets

Incorrect
idle

adjustment

Clogged
air
cleaner
filter

Damaged
manifold

gaskets
or
carburetor

insulator

Improper
float
level

adjustment

Loose
air

hoses
or
air

fuel
mixture
hoses
of

carburetor

Malfunctioning
carburetor
choke

Malfunctioning
anti

backfire
valve

Malfunctioning
automatic

temperature
con

trol
air

cleaner

Inoperative
idle

compensator

Carbon
canister

purge
line
hose

damaged
or

disconnected

Stick
E

F
E
valve
shaft

Incorrect
valve
clearance

Extremely
low
revolution

Faulty
malfunction
of
the

ignition
system

spark
plug

high
tension
cable
breaker

point
ignition
coil
etc

Incorrect
basic

ignition
timing

Malfunction
of
choke
valve
or

linkage

Malfunction
of
vacuum
motor
sensor
or

hoses
of
air
cleaner

Incorrect
idle

adjustment

Clogged
air
cleaner
fdter

Malfunction
of
idle

compensator
of

air

cleaner

Malfunction
of
E
G
R
control
valve

Loose
manifold
and

cylinder
head
bolts

Dragged
accelerator

linkage

Incorrect
idle

adjustment

Malfunction
of
B
CDD

system

Malfunction
of

speed
switch
and
harness

ET
29
Corrective
action

Clean
or

replace

Adjust

Replace
element

Replace
gasket
or
insulator

Adjust

Check
for
loose
connections

Check
and

adjust

Check
for
loose
connection
of
vacuum
hose

Check
A

r
C
air
cleaner

Check
for
connection
of
idle

compensator

hose

or
replace
idle

compen
tor

Connect
or

replace

Repair

Previously
mentioned

Adjust

Adjust

Replace

Adjust

Adjust

Check
for
loose
hoses

Replace
system
com

ponents
if
necessary

Adjust
idle

speed

Replace
air
cleaner
fdter

Replace

Clean
or

replace

Retighten
bolts

Check
and

correct
accelerator

linkage

Adjust
idle

speed

Check
for
loose

vacuum
hose
and
harness

connections

Adjust
or

replace
if

necessary

Check
for
loose
connections

Repair
or

replace
if

necessary

Condition

ABNORMAL

COMBUSTION

backfue
afterflre

run
on
etc

Improper

ignition
timing

Fuel

system
out
of

order

Faulty
cylinder
head
etc

Others

EXCESSIVE
OIL

CONSUMPTION

Oilloak

Excessi
lo
oil

consumption

Others
Engine
Tune

up

probable
cause

Improper
ignition
timing

Improper
heat

range
of

spark
plugs

Damaged
carburetor

or
manifold

gasket

backfue
afterfire

Clol
l
ed
carburetor

jet

Improper
function
of

the
float

Uneven

idling
Run
on

Improperly
adjusted
B

C
D
D

set

pressure

Malfunction
of
anti

dieseling
solenoid
valve

Malfunction
of
auio
choke

Improperly
adjusted
valve
clearance

Excess
carbon
in

combustion
chamber

Damaged
valve

spring
backfire
afterflre

Malfunction
of

A
T
C

air
cleaner

Inoperative
ariti
backfue
valve

Loose
oil
drain

plug

Loose

or
damaged
oil

pan
gasket

Loose
or

damaged
chain
cover

gasket

Worn
oil
seal
in
front
and
rear
of
crankshaft

Loose
or

damaged
locker
cover

gasket

Improper
tightening
of
oil
filter

Loose
or

damaged
oil

pressure
switch

Cylinder
and

pioton
wear

Improper
location
of

piston
ring

gap
or

reversely
assembled

piston
ring

Damage
piston
rings

Worn

piston
ring
groove
and

ring

Fatigue
of
valve
oil
seal

lip

Worn
valve

stem

Inadequate
quality
of

engine
oil

Engine
overheat

ET32
Corrective
action

Adjust
ignition
timing

Use

specified
spark
plugs

Replace
them
with
new

parts

Disassemble
carburetor
and
check
it

Adjust
the
level
and
check
needle
valve

Adjust

Adjust

Check
or

replace

Adjust

Adjust

Remove
head
and

get
rid
of
carbon

Replace
it
with
a
new
one

Check
for
loose
vacuum
hoses

Replace
if

necessary

Replape

Tighten
it

Renew

gasket
or

tighten
it

Renew

gasket
or

tighten
it

Renew
oil
seal

Renew

gasket
or

tighten
it
but
not
too

much

Renew

gasket
and

tighten
it
with
the

proper

torque

Renew
oil

pressure
switch
or

tighten
it

Overhaul

cylinder
and
renew

piston

Remoun
t

piston
rings

Renew

rings

Repair
or
renew

piston
and

cylinder

Renew

piston
and

piston
ring

Replace
seal

lip
with
a

new
one

Renew
valve
or

guide

Use
the

designated
oil

Previously
mentioned

EM410

Fig
EM
II

Engine
on

engine
land

Remove

oil
level

gauge

6
Remove

carburetor
from
intake

manifold

1
Disconnect
cylinder
block
to

P
C
V
valve
hose
at
P
C
V

valve

2

Disconnect
A
B
valve
to
E

G
R

passage
hose

at
E
G
R

passage

3
Disconnect
vacuum
tube
to

carburetor

hoses
white
and

yellow
at

vacuum
tube

4
Disconnect
fuel

hose
from

carburetor

5

Remove
dash

pot
bracket
from

intake
manifold

6
Remov
carburetor

attaching

bolts
and

remove
carburetor

assembly

and

gasket

7
Disconnect
distributor

high
ten

sion
cables
from

sparkplugs

8
Disconnect
vacuum
hose

from

distributor
and

remove
distributor
as

sembly

9

Disconnect
fuel

hose
from
fuel

pump
and

remove
fuel
and

vacuum

hoses
combined

from

cylinder
head

10
Remove
fuel

pump
assembly

from

cylinder
head

EM412

Fig
EM
12

Removing
fuel
pump

IJ
Remove
in
take
and
exhaust

manifold

assembly
from

cylinder
head

1
Disconnect
vacuum
hose

from

air
control
valve
and
remove
air
con

trol

valve
for
California
and
a
r
hoses

as
an
assembly
Engine
Mechanical

1
Air
control
valve

2
Distributor
EM531

Fig
EM
13

Removing
air
control

valve

Californio
model

2
Remove
carburetor
air
cleaner

bracket

3
Disconnect
vacuum
hose
from

E
G
R
valve

4
Remove
check
valve
from
air

gallery

pipe

5
Disconnect
E
G
R

tube
from

E

G
R

passage
and
exhaust
manifold

6
Remove
E

G
R

passage
and

E
G
R
valve

from
intake

manifold

I
E

G
R

passage

2
E
G
R
tube

Fig
EM
14
EM532

Removing
E

G
R

tube
and

passage

7
Remove
F
l

C
D

bracket
from

cylinder
head

if
so

equipped

8

Disconnect
vacuum
hoses
from

thermal

vacuum
valve

and
remove

thermostat

housing
and

gasket
from

cylinder
head

EM089

Fig
EM
15

Removing
thermostat

housing

EM
5
9
Remove

cylinder
block
to

P
C
V

valve
hose
blow

by
gas
hose

from

cylinder
block

10
Remove

manifold

attaching

bolts
and
remove
intake
and

exhaust

manifold

assembly
and

gasket
from

cylinder
head

Fig
EM
16

Removing
intake
and

exhaust

manifold
assembly

11
Remove
intake

and
exhaust

manifold

attaching
bolts
and

separate

intake

manifold
from

exhaust
mani

fold

12
Remove
air

gallery
pipes
from

exhaust

manifold

12
Remove

left

engi
e

mounting

bra
et

from

cylinder

blopk

13
Remove
air

pump
and
cooler

compressor
bracket

14
Remove

crankshaft

pulley
in

stalling
bolt
and

washer
and
then

remove

pulley
with
a
two

jaw
puller

15
Remove
water

pump
assembly

16
Remove
rocker

cover

17

R
emove

spark
plugs

18
Remove
fuel

pump
drive
earn

19

Remove
camshaft

sprocket

Refer
to
the

following
note

during

operation
when

removing
camshaft

sprocket
from

engine
installed
on
car

EM091

Fig
EM
17

Removing
cammaf

sprocket

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

DESCRIPTION

COOLANT
LEVEL

DRAINING
AND
FLUSHING
THE

COOLING
SYSTEM

WATER
PUMP

REMOVAL
AND

INSTALLATION

DISASSEMBLY

INSPECTION
AND
ADJUSTMENT

TORQUE
COUPLING

REMOVAL
AND

INSTALLATION

DESCRIPTION

The

cooling
system
is
of
the
con

ventional

pressure
type
A

centrifugal

pump
installed
on

the

timing
chain

cover
serves
to
circulate
the

coolant

The

pressure
type
radiator
filler

cap

installed
on
the
radiator

operates
the

cooling
system
at

higher
than

atmos

pheric
pressure

The

higher

pressure
raises
the

boiling
point
of
the

coolant
and
in
Cooling
System

COOLING
SYSTEM

CONTENTS

CO
2

CO
2
OISASSEMBL
Y

INSPECTION

TEM
COUPLlNG

INSPECTION

THERMOSTAT

REMOVAL
AND

INSTALLATION

INSPECTION

RADIATOR

REMOVAL
AND

INSTALLATION

INSPECTION
CO
2

CO
2

CO
3

CO
3

CO
3

CO
3

CO
4

creases
the

cooling
efficiency
of

the

radiator

When
the

thermostat
is
closed

the

coolant
remains
in
the

cylinder
head

and

block
for
swift

warming
up
of
the

engine
After
it
reaches

normal

oper

ating

temperature
the

coolant
circu

lates

through
the
radiator

The

cooling
fan

drive
is
of
a

coupling
type

COOLANT

LEVEL

The

coolant
level
should

be
check

ed

and
maintained
at
SO

mm
1
97
in

below

the

upper
face
of
filler

neck

when
the

engine
is
cold
C0055

Fig
CO

I
Cooling

ry
lem

Caution

To
avoid
serious

personal

injury
never
remove
I3diator

cap

quickly
when

engine
is
hot
Sudden

release
of

cooling

system
pressure
is

very

dangerous

CO
2
CO
4

CO
4

CO
4

CO
5

CO
5

CO
5

CO
5

CO
5

CO
5

CO
6

If
it
is

necessary
to
remove
radiator

cap
wben
radiator
is
hot
turn

cap

slowly
counterclockwise

to
the
r

step
After
all

pressure
in
the
cool

ing
system
is
released
tom

cap

passing
the

stop
and
remove
it

DRAINING

AND
FLUSHING

THE

COOLING

SYSTEM

To
drain

the

cooling
system
re

move
radiator

cap
release
drain

cock

at
the
bottom

of
radiator
and
drain

plug
on

the

right
side
of

cylinder

block
If
the

heater

system
is
installed

set
heater

temperature
control
valve
to

open
position
After
the

coolant
is

drained

completely
close
drain

cock

and

plug
and
refill
the

system
with

clean
soft
water

WATER
PUMP

The

water

pump
cooling
fan

pulley

and

torque

coupling
are

a
unitized

construction

The
water

pump
is
of

a

centrifugal

type
which

is
mounted
on
the

engine

front
cover