Datsun C210 series User manual

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21
O
TSUN
SERV
CE
flU
Model
C210
Series
v
1
J
M
QUICK
REFERENCE
INDEX
N
SSAN
M0101l
to
10
10KYO
JAI
tJ I

FOREWORD
This service manual
has been
prepared
for the
purpose
of
assisting
service
persoimel
of
our
distributors
and dealers in
providing
effective
service and maintenance of
the model ClIO series
Sinceprope
main
ena 1ceand
service are
absolutely
essential in
satisfying
our customers this
manual should be
kept
in
a
h mdy place
for
ready
reference and should
tie carefully
studied
This manual includes
procedures
for
maintenance
adjustments
minor service
operations
removal
and instaJiation and for
disaSsembly
and
assembly
of
components
Some
of these
service
operations require
the use of
Special
Tools
especially
designed
for
effective
perfonnance
of service
operations
The
special
tools are
presented
at
the end of the
each section
As
you
read
through
th
maintenance
procedures
in this
service manual
you
will
occasionally
come
across
paragraphs
headed NOTE
CAUTION or
WARNING A
NOTE
is
supplemental
information
that
is
important
to
a
particular procedure
CAUTION
and
WARNING
warn of
steps
that
must
be
followed
to
prevent
damage
to some
part
of the car and
or
per
onal
injury
The
Quick Referenc e
Index
on
the
first
page
enables the user
to
quickly
locate
tlJe
desired
section
At
the
beginning
of
each
individual
section is a table of cOntents which
gives
the
page
nUlnber
on
which each
major subject
begins
i
All
parts
in this manual conform
to
the PARTS
CATALOG Model
C210
and
only
the
genuine
service arts
liSted
in
this P
A TS
CATALOG rriust be used
for
replacements
All
information
illustrations
and
specifications
contained in
this manual
are based on the
product
information
available
as
of
October
1971
I
It should
be
emphasized
that those who use this manual are
responsible
for
revising
the
ontents
according
to
the SERVICE JOURNAL SUPP
EMENT of SERVICE MANUAL and SERV CE DATA
AND
SPECIFICATIONS
issued
by
the
factory
which
carry
the latest
factory
approved
service
methods
Rights
for
alteration at
any
time of
specifications
and methods
are reserved
Liability
for
any personal iiljury
or
property damage
occasioned
by
the
use
of this service
D1anual
in
effecting
maintenance
or
repair
of the car is in
no
way
assumed
by
Nissan Motor Coo Ltd
Accordingly anyone using
a service
procedure
or
tool which is not
pecifically
recommen led by
Nissan
must
first
completely
satisfy
himself that neither his
safety
nor
the
car s
safety
will be
jeopardize
d
by
the servic
method
selected
NISSAN
MOTOR CO
LTD
TOKYO JAPAN
@ 1917 NISSAN MOTOR CO L ro Printed in
Japan
Not to
be
reproduced
in whole
or in
part withol
It the
prior
written
permission
of
Nissan Motor
Company
Ltd
Tokyo
Japan
l

DATSUN
f
Model
C2JO
Series
SECTIONGI
GENERAL
INFORMATION
CONTENTS
MODEL VARIATION
IDENTIFICATION NUMBER
CAR IDENTIFICATION PLATE
CHASSIS NUMBER
ENGINE
SERIAL
NUMBER
COLOR CODE
NUMBER LABEL
MANUAL
TRANSMISSION
NUMBER
AUTOMATIC TRANSMISSION NUMBER
APPROXIMATE
REFILL
CAPACITIES
RECOMMENDED
FUEL
1
1
RECOMMENDED LUBRICANTS
RECOMMENDED
LUBRICANTS
RECOMMENDED
SAE
VISCOSITY
NUMBER
LIFTING INTS AND TOWING
PANTOGRAPH JACK
GARAGE
JACK
AND SAFETY STAND
TOWING
TI E
DOWN
SPECIAL
TOOL
GI 2
GI 2
GI 2
GI 2
GI 2
GI 3
GI 3
GI 3
GI 3
GI 3
GI 4
GI 4
GI 4
GI 5
GI 5
GI 5
GI
6
GI 6
GI 6
I
1
I
I
0
J

General Information
MeDEL VARIATION
I
Differential carrier
Engine
Wheelbase
Model Transmission
Model Gear ratio
Sedan
MGC210VFM
FS5W7IB
MGC2 IOYAM
3N71B
L24S
Long
wheelbase
RI80
3 900
Hard
top
KMGC210VFM
FS5W71B
KMGC210VAM
3N71B
L24S L24
engine
with
single
carburetor
Preftx and SuffIx
Designations
II
K
Hardtop
o
Sedan
M L24
engine
G
Long
wheelbase
o means no indication
The unit
and car
numbers
are
stamped
and
registered
at the
factory
The car
and
engine
identification
numbers are used on
legal
documents
These numbers
are
used for
factory
communications such as Teclulical Re
ports
Warranty
Claims Service Jour
naIs and other information
CAR IDENTIFICATION
PLATE
The
car identiftcation
plate
is
located
on the
center
of the cowl
top
in
the
engine
compartment
CHASSIS NUMBER
The chassis
number is
stamped
on
the cowl
top
in the
engine compart
ment and is broken
down
as
shown in
the
foUowing figure
K
M
G C210 V
F M
I
M
L
Y
IDENTIFICATION NUMBER
I
l
M GC
lO OOOOU
I
I
LC014
Fig
01 1
Identification
Plate
and
Cha8 i6 Number Location
Model
Sedan
MGC210 xxxxxx
KMGC210 xxxxxx
Hardtop
GI 2
For Australia
5 speed
manual
transmission
Automatic transmisSion
Grand
Touring
r
r
ENGINE SERIAL
NUMBER
The
engine
serial number is
stamped
on
the
right
hand side of
the
cylinder
block
The number is broken
down as shown in
the
fgllowing chart
according
to the
type
of tl
Oengine
Engine
model
Engine
number
L24 L24
xxxxxx
j
G1329
Fig
GI 2
Engine
Serial Numbu
Location

COLOR CODE
NUMBER LABEL
The color code number label
is
stuck
on
the
inner side of the
hood as
shown
in
the
following
figure
Label
01387
Fig
G 3
Color
Code Number Label
Lo otion
General Information
MANUAL
TRANSMISSION
NUMBER
The transmission serial
number is
stamped
on
the front
upper
face of
the
transmission case
TM235
Fig
GI 4 Manual Tranlmiuion
Number ctltion
AUTOMATIC
TRANSMISSION
NUMBER
The
plate
is
attached
to the
right
side
qf
the
transl
ission
case
as
sho Yfl
in the
following figure
r
AT344
Fig
GI
5
Automatic Trammiuion
Number Location
r
APP
OXIMATE
REFILL CAPACITIES
Li er
Imp
measure
Fuel tank
C
Sedan and
lard
top
60
l3X
gal
Cooling system
i
t
Without heater 8si
7 i qt
With heater 95 8 qt
J
Engine
oil
1
Without fIlter
5 0
4
qt
With fIlter 55
4U
qt
J
Transmission
l 2
0
5speed
ldanual
3 i
pt
Automatic
5
5 4U
qt
I
Differential cairier
RI80
1 0
I Yo
pt
I
Manual
steering gear 0
29 i
pt
Power
steering
oil
11
I
qt
Air
conditionirig system
Refrigerant
1 2
kg 2 6 lb
Compressor
oil 0 25 88
fl
oz
RECOMMENDED
FUEL
Use a
proper
grade gasoline
of above 88 octane
rating
GI 3

General Information
RECOMMENOED
LUBRICANTS
RECOMMEptDE
D LUBRICANTS
Item
0
c
EO
c
Gasoline
Diesel
Specifications
SAE
classification
SD or SE
MIL L
21
O4B
SAE classification
CC
or
CD
MIL
IA6152 or
MlL
L
2104C
API GL 4
MiL
L 2105
API GL 5
MlLL
2105B
0 Manual
tr ission
and
steering
I
Differential
Automatic
T M
and
power
steering
fluid
Multi purpose
grease
Brake
and
clutci
fluid
Anti freeze
Type
DEXRON
N L
G
1 2
OOT 3 FM V
S S No 116
Remark
Refer to
Recommended
SAE
r
Viscosit
Chart
I
I
I
I
Uthium
soap
base
F MY
SS
Federal
Motor Vehicle
Safety
Standard
Permanent anti freeze
Ethylene
glycol
base
RECOMMENDEDSAE
VISCOSITY
NUMBER
I
l
I I
I
I
2OW 40
2OW 50
I
J
I I t
15W 60
I
IOW 30
lOW 40
lOW 50
I
II I
40 to
I
30
1
pow
2OW
I
I
lOW
5W 30
5W
20
Not com
ended
for
II
s
ed
hIgh speed
0
dnvlng
GEA Ol
I
t
75w l
SSW
L
90
I
fNGINE
OIL
I
I
I
l l l
29 is
7 4 15
27 38
Oc
20
to 201
40 60
lSOl 100
oF
Temperature
Range Anticipated
Before
Next
Oil
Change
GI 4
d
1

General
Information
LIFTING
POINTS
AND TOWING
PANTOGRAPH
JACK
Place wheel
chocks
at
both front
and back
of
tlie
wheel
diagonally
opposite
the
jack position
GlOSS
Fig
GI 6 Whee
Chocks
Apply
the
pantograph
jack
fur
nished
with the car to the
position
indicated
elow in
a
safe manner
WARNING
a Never
get
under the car while it
is
supportedJ only by
the
jack
Always
use
safety
stands
to
support
frame when
you
have to
get
under the car
b Block the wheels
diagonally
with
wheel chocD
TA004
Fig
GI 7 Jack
Up
Point
GARAGE
JACK AND
SAFETY STAND
WARNING
When
carrying
out
operations
with
the
garage
jack
be sure to
support
the car with
safety
stands
FRONT SIDE
I
When jacking
up
the front
of the
car
place
the chocks behind
the
rear
wheels to hold them
2
Apply
the
garage jack
under the
front
suspension
member
Be sure not
to lift
up
the
engine
oil
pan located
just
behirid
the
suspension
member
1
I
1
GI388
Fig
Gl S
Front Jack
Up
Point
3
Jack
up
the car
gently
just
high
enough
to
place
thehafety
Stands
uiiderl both
the side members
Place
the Csta
ndsatthe
position
indicated in
Fig
GI 9
JJ
ll
L Io
t
11
GI359
ill
lif
1 Front
jack
up
point
2
Front
supporting point
Fig
GI 9 Front Jack
Up
and
Supporting
Points
4
Release
the
jack
slowly
GI
S
h
REAR
SIDE
I When
jackiEg
up
the
ear
of
the
car
place
the cliocks at the front
side
of
the front wheels to
hold them
2
Apply
the
garage
jack
under the
suspension
member
iJ
Fig
GI IO Rear Jack
Up
Point
3 Jack
up the
car
gently just high
enough
to
place
the
safety
stands
under
the rear
suspension
member
or
the side member
Place
the
stands at
the
positions
indicated below
1 Rear
j
ck
up poin
2 Rear
5upporting point
Fig
GI
l1
Rear Jack
Up
and
Supporting
Points
4
Release the
jack slowly

r
rOWlMG
The
towing
hook
is located
on
the
torsion bracke s
on ach
side
GI353
Fig
GI 12 Front Towing
Hook
To
tow another
car connect a
rope
to the
right
side rear towing
hook
The left side rear
hook is installed
for
the
tie down
use
only
G 3
4
Fig
G1 13
R ar
Towing
Hook
Special
Tools
play
very important
role
in the maintenance of
cars
These
are essential
to the safe accurate and
speedy
servicing
The
working
times listed in the
column under
FLAT
RATE
TIME in
FLAT RATE
SCHEDULE
are com
puted based
on
the use of
Special
Tools
General Information
CAUTION
B Before
towing
make lUre
that the
trallSmission
axles steering
system
Bnd
pOW1 r
train
Bre in
good
order
If
any
unit
is
damaged
a
d011ey
must be
used
b I
the
transmission
is
inoperative
tow the car with the rear
wheels 011
the
ground
or with
the
propeller
shaft
removed
c
When the ClIr is
towed with
its front
wheels on
the
ground
secure the
steering
wheel
in a
stJ8ight
ahead
position
with
the
ignition
JleY
turned in
OFF
position
d When
towing
en
automatictrBns
mission
model on its
rear wheels
do not
exceed
30 km h 20
MPH
Bnd a distance
of
10
km 6
miles
e Release till
parking
brake
and set
the
gearshift
lever in
Neutrar
position
before
starting
to tow the
car
f A
towing
rope
should
not be cog
nelted
to
the tie down
hook
or
any
other
positions
except
those
desaibed above
gDo
not
take
up
slack
in the
rope
too
quickly
h
Always pull
the
rope
in a
stJ8ight
direction with
respect
to the
hook
Do not
apply
forca
to the hook
in
side
direl tion
SPECIAL TOOL
The identification
code of
mainte
nance tools
is
made
up
of 2
alphabeti
calletters and 8 digital
figures
The
heading
two
letters
roughly
classify
tools or
equipment
as
GI 6
TIE DOWN
Front tie down
hooks
are located
on
both
tension
rod brackets
Rear tie down hooks
are
installed
on both sidesofthe floor
CAUTION
Do not tow
car
with left
hand tie
down
hook
1
z
J
L
GI363
Fig
G1 14 Rear Tie down
Hook
Special
Tool
Special
Tool
Engine
Overhauling
Machine
GGOOOOOOOO
General
Gauge
LMOOOOOOOO
Garage
Tool
HTOOOOOOOO
Hand Tool
Refe
to Service Bulletin
DATSUN
1801
240K GT
for
Speciai
Tool
list and
further information on Spe
cial Tools
STOOOOOOOO
KVOOOOOOOO
EMOOOOOOOO

DATSUN
Model C210
Series
SECTIONET
ENGINE
TUNE UP
CONTENTS
ENGINE TUNE UP ET 2 REPLACING FUEL
FILTER ET 7
DESCRIPTION
ET 2
CHECKING FUEL LINES Hoses
piping
BASIC MECHANICAL SYSTEM
ET 2
connections etc ET 7
ADJUSTING
INTAKE AND EXHAUST
REPLACING AIR CLEANER
VALVE CLEARANCES ET 2
FILTER ET 7
CHECKING
AND ADJUSTING DRIVE
EMISSION CONTROL SYSTEM ET B
BELTS ET 2 CHECKING VACUUM
FITTINGS
HOSES
RETIGHTENING
GYLlNDEFI HEAD BOLTS
AND CONNECTIONS
ET B
MANIFOLD NUTS
AND CARBURETOR
REPLACING P C V VALVE AND
SECURING NUTS
ET 3 FILTER
ET B
CHANGING ENGINE OIL
ET 3
CHECKING
VENTILATION
HOSES ET
B
REPLACING OIi FI L
TER ET 3
CHECKING
EXHAUST GAS
RECIRCULATION
CHANGING
ENGINE
pOOLANT
ET 3 E G R 1 CONTROL SYSTEM
ET B
CH
ECKING COOLlNG
SYSTEM
HOSES
CHECKING VAPOR
LINES
Hoses
AND
CONNEc
I O S ET 4 connections
etc AND FUEL
CHECKING ENGINE COMPRESSION
ET 4
VAPOR CONTROL
VALVE
ET 9
IGNITION AND FUEL
SYSTEM
ET 5
CHECKING
FUEL TANK
CHECKING
BATTERY
ET 5 VALVE
ET 10
CHECKING AND
ADJUSTING
IGNITION SERVICE DATA
AND
TIMING
ET 5 SPECIFICATIONS
ET 11
REPLACING
DISTRIBUTOR
BREAKER TROUBLE DIAGNOSES AND
POINT ET 6 CORRECTIONS
ET 12
CHECKING AND REPLACING
SPARK
EMISSION TROUBLE
SHOOTING
ET 19
PLUGS ET
6 EXCESS HC OR CO EMISSION
CHECKING IGNITION WIRING
ET 6 IN
EXHAUST GASES
ET
19
ADJUSTING
CARBURETOR
IDLE RPM
MAIN CAUSES FOR
EXCESS CO
AND MIXTURE RATIO
ET 6 HC AND NOx IN
EXHAUST
CHECKING
CHOKE
MECHANISM GASES ET 20
Choke
plate
and
linkage
ET 7
SPECIAL SERVICE TOOLS
ET 21

r
DESCRIPTIO
To keep
the
engine
in
top running
condilion
at
all
times
proper
main
Engine
Tune
up
ENGINE TUNE UP
tenance
tune
up
is
necessary
More
over
it
is
importlUlt
that the
engine
b
tuned
up
in accordance with
the main
tenance shedule
The results of
proper
engine
maintenance are
among
others
minimum
e aus
emissipns
This sec
tion describes
proper
maintenance
pro
cedures
BASIC
MECHANICAL SYSTEM
ADJUSTING INTAKE
AND
EXHAUST
VALVE CLEARANCES
Valve
clearance
adjustment
cannot
be
made while
engine
is in
operation
To
adjust
proceed
as
follows
1
Start
engine
and warm
up engine
sufficiently
then
stop
engine
2 Rotate
crankshaft to
bring
No
I
cylinder
to
top
dead
center
of its
compression
stroke
3
Remove valve roc
ker
cover
LooSen
pivot
locking
nut and
turn
pivot
screw until
specified
clearance is
obtained while
engine
is
hot
Using service tool
tighten pivot
locking
nut
securely
after
adjustment
and
recheck clearance
4
Ordcr of
valve clearance
adjust
ments isas follows
All
valves can be
adjusted
by
rotat
ing
crankshaft four
complete
turns
Note When
turning
crankshaft with
starter
feptove high
tension wire
from
ignition
coil then turn it
a
Adjust
valve
clearances@ V
and
Qj
with cam lobe
CD
set
at
ex
tremeupward potition
b
Adjust
valve
clearances@ @
and
@
with
cam
lobe
@
set
at
ex
t
roe upw arjl potition
c
Adjust
valve clearance
@
with cam
lobe
Vset
t
extreme
upward
position
d
Adjust
valve clearance
@
with earn
lobe
@
set at extreme
upward
pos
ition
Note Numbers in circle
agree
with
those in
figure
T
Tightening torque
Pivot lock
nut
49
to 59 N
m
5
0 to
60
kg
m 36
to 43 ft
Ib
ET074
Fig
ET 1
Adjusting
ualv c1 aranc
ET 2
L
Valve clearance
Unit
mm
in
Hot
Intake
i
0 25 0 010
Exhaust 0 30
0
012
CHECKING AND
ADJUSTING DRIVE
BELTS
I
Check for cracks or
damage
Re
place
if
necessary
2 Normal drive belt denection is
own in
figure
below wh
en
moderate
thumb
pressure
is
applied midway
between
pulleys
Thumb
pressure
98 N
10
kg
221b

Water
pump
pulley
E T398
Altern tor
Crankshaft
pulley
RETIGHTENING
CYLINDER HEAD
BOLTS MANIFOLD
NUTS AND
CARBURE TOR
SECURING
NUTS
Refer to the
following tightening
torque specifications
Tightening torque
J
Cylinder
heaa liolts
1st
turn
39N
m
40
kg
m 29 ft lb
2nd turn
59N
m
60
kg
m
3 ft ib
3rd turo
i
69 to
83 N m
7
0 to 8 5
kg
m
5rto
61 ft Ib
t
Notes i
a When
engine
is
cold bolts should
be
tightened
in two or
three
steps
in the
sequence
shown in
Figure
ET 3
starting
from center and
working
out
toward
ends
b
Retighten
cylinder
head bolts after
engine
has wanned
up
Manifold nuts
12 to 16 N m
12 to 1 6
kg
m 9 to 12 ft Ib
Carburetor nuts
12
to 18 N m
1 2
to
1
8
kg
m 9
to
13
ft lb
Engine
Tune up
Idler
pulley
Unit
mm
in
Fig ET 2 Drive belt tension
Fig
ET 3 Cylinder
head bolt
tightening
sequence
CHANGING
ENGINE
OIL
1 Check if oil
is
diluted with water
or
gasoline
Drain
and refill oil if
necessary
Tightening torque
Oil
pan
drain
plug
20 to 29 N m
20
to 3 0
kg
m
14
to 22
ft
Ib
Notes
a A
milky
oil
indicates the
presence
of
cooling
wnter Isolate
cause
and
take coriective measure
b An oil with
extremely
low
viscosity
indicates dilution
with
gasoline
2 Check
oil level If below the
specified
level
raise it
up
to
the
Hlevel
ET 3
Engine
oil
capacity
including
oil filter
Maximum
H
level
5 7
liters
6
US
qt
5
Imp
qt
Minimum
I
level
47
liters
C
5
US
qt
4
Imp qt
3Change
engine
oil in accordance
with the maintenance schedule
REPLACING
OIL FILTER
The
oil filter
is a
cartridge type
and
can
b removed
using
Oil Filter
Wrench ST19320000
I
Ch ck for
oil
leaks
p
t
gasketed
flange
f
leakage
is
found
retighten
just enough
to
stop leakage
If
reo
tightening
is no
longer
effective re
place
filter as an
assembly
2
When
installing
oil filter
tighten
by
hand
Note
Do not
overtighten
oil ftlter
lest
leakage
should
occii
CHANGING
ENGINE
COOLANT
PERMANENT
ANTI
FREEZE
COOLANT
Note
The
permanent
anti freeze
coolant iI
an
ethylene glycol
base
product
con
taining
chemiCal inhibitors
to
protect
the coolirig systein
from
rusting
and
corrosion
The anti
freeze doeS not
contain
any glycerine
or
ethyl
alcohol
It
will not
eVaporate
or boil away
and
can
be used with either
high
or low
temperature
thermostats It
flows free
ly
transfers heat
efficiently
and
will
not
clog
the
JBssages
in the
cooli
system
The anti freeze must not
be
mixed with other
product
This
cool
ant can be used
throughout
the
sons of the
year

Whenever coolant
is
ch iged
the cool
ing syStem
must be flushed and refilled
with a new coolant Check the coolant
level
See instnictions attached to the
anti
freeze
c
tain
r for
mixing
atio
of
anti
freeze to water
CHECKING COOLING
SYSTEM HO SE
AND
CONNECTIONS
Check hoses and
fittings
for loose
connections
or deterioration
Retight
en or
replace
if
necessary
INSPECTION OF RADIATOR
CAP
Apply reference
pressure
88 kPa
0 9
kgJem2
13
psi
to
radiator
cap
by
means of a
cap
tester
to see if
it is
satisfactory
Replace
cap assembly
if
necessary
Fig
ET
4
Te
ti
radiator
cap
COOLNG
SYSTEM
PRESSURE TEST
With radiator
cap
removed
apply
reference
pressure
157 kPa
1
6
kgJcm2
23
psi
to the
cooling system
by means of a
tester to detect
any
1e
ge
Engine
Tune
up
Water
capacity
Without heater
8 2 liters
8 05
qt
7 Yo
lmp qt
With heater
8 9 liters
9
XUSqt
7 i
Imp
qt
Fig
ET
5
Coo
i
sy
tem
pressure
test
CHECKING
ENGINE
COMPRESSION
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
Ii
n
It
ET010
Fig
ET 6 T
tingcompreuion
preuure
ET 4
5
Fully
open
choke
valve
6
Depress
accelerator
pedal
to
open
throttle valves
Note
Do
not
PIlDIP pedal
7
Start
engine
as
quickly as
possi
b e
Compression pressure
kPa
kg
cm2
psi
at
rpm
Standard
1 177
12
0 171 350
Minimum
883
9 0 128 350
Note
Cylinder
r
Dn in
cyl
inders should not be less than
80
of tbe
bighest reading
If
cylinder
compression
in
one or
more cylinders
is
low
pour
a
smaIl
quantity
of
engine
oil
into
cylinders
through
the
spark
plug
boles and retest
compression
I
If
adding
oil
helps
the
compres
sion
pressure
the chances
are that
piston rings
are worn or
damaged
2 If
pressure stays
low
the likeli
hood
is that valve is
sticking
or
seating
improperly
3 If
cylinder
con
pr
sion in
any
two
adjacent cylinders
is low
and if
adding
oil does
not
help
the
compres
sion there is
leakage past
the
gasketed
surface
Oil and water
in combustion cham
bers can result from
this malfunction

Engine
Tune
up
IGNITION
AND
FUEL
SYSTEM
CHECKING BATTERY
I Remove six
vent
plugs
and check
electrolyte
level in
each
battery
cell If
necessary
po
r
distilled
water
OverfloW Correct Shortage
t t
j
t
1
t
EE358
Fig
ET 7 Ch ckin electrolyt
kvel
2
Measure the
specific
gravity
of
battery electrolyte
Fig
ET 8
E T372
Checking specific gravity
of battery electrolyte
Over
1 22
Over
I
20
Full
charge
value
at
200C 680F
1 28
1 26
Permissible
value
Frigid
Climates
Other climates
Notes
a
Oean
top
of
battery
and terminals
with
a
olutiOli of
baking soda
and
water Rinse off and
dry
with
compressed
air
Top
of
battery
must
be clean
to
r
current
leakage
L terminals arid from
positive
termini
l to hold down
clamp
f I
b In addition to current
leakage
pro
longed
a
umulation of acid and
dirt
M
tOP
of
battery I11IY
cause
blistering
of the I11Iterial
covering
connector
straps
and corrosion
of
straps
cAfter
tightening
tenninaIs c
t
them with
petrolatum
tine
to
protect
them from cortOllion
Caution
If the
battery
cables are dis
connected
they
mould be
tightly
clamped
to
the
battery
terminals to
secure a
good
contact
CHECKING
AND
ADJUSTING
IGNITION
TIMING
I
Check
spark
plugs
and di tributor
breaker
point
for condition
2
Thoroughly
remove dirt and dust
from
timing
mark
on crank
pulley
and
timing
indicator
on
front
cover
3Wa
1 up engine sufficiently
ET 5
4
Install
a
timing
light
on
No I
cylinder spark
plug
wire and install
a
tachometer
5
Set
idling speed
to
the
following
specifications
650
rpm
M T
700
rpm
A
T
N
position
6 Check
ignition timing
with a
timing
light
if it i
100
B T D
C
Before
Top
Dead
Center
di
or
Top
dead center mark
Fig
ET 9
Checking
ignition timing
Ignition timing
M T A T
Timing
B T
D C
rpm
100
700
100 650
C
N
posi
tion
If
necessary
adjust
it as follows
I
Loosen
etscrew until distributor
can be moved
by hand
2
Adju
t
ignition timing
to
100
B T
D C
3 Lock distributor setscrew
and
make
sure
that
timing
is correct

r
ET399
Fif
ET 10
Adjusting ignition liming
REPLACING
DISTRIBUTOR
BREAKERPOlin
Check d istributor breaker
points
fr abnormal
pitting
and
wear
Re
place
points
periodically Make sure
they
are
properly
aligned
and tHat
point
dwell and
gap
are
correct
Clean
and
apply
distributor
grease
to
cam
lobes
Note Do not
apply
grease
excessive
Iy
ET400
Fig
ET
11
Checking
distributor
point
gap
Point
gap
0 45 to 0 55
nun
0
018 to 0
022 in
Dwell
angle
350
to
410
degrees
CHECKING AND
REPLACING
SPARK
PLUGS
I
Remove and
clean
plugs
in
a
sand
blast cleaner
Inspect
each
spark
Engine
Tune
up
plug
Make sure that
they
are of
the
specified
heat
range
2
Inspect
insulator for cracks or
chips
Check both
center and
ground
electrodes
3
If
they
are
excessively
worn
replace
with
new
spark plugs
4
Replace
spark
plugs
in
accordance
with the maintenance
schedule
Fig
ET 12
Cheching sparh plug
gap
Tightcning
torque
15
to 25
N m
15 to
25
kg
m lito
18 ft lb
Spark
plug gap
0
8
to
0
9 mOl
0 031 to
0 035 in
Hellt
range
BP6ES
L45PW
CHECKING IGNITION
WIRING
Use an ohmmeter to check resist
ance on
high
tension cables
I
Disconnect cables from
spark
plugs
and
remove distributor
together
with
high
tension
cables
Note
Do not remoy
cables
f
I cap
2 Connect the ohmmeter between
cable
terminal on the
spark
plug
side
and the
oorresponding
electrode
inside
cap
3 If the
resistance is more than
30 000 ohms remove cable Cram
cap
and check the cable resistance
only
If
resistance is still
more
than
30
000
ohms
replace
cable
assembly
ET
6
f7 l
Fig
ET
13
Checking high tension
cable
ADJUSTING
C
RBURETOR IDLE
RPM AND MIXTURE
RATIO
Notes
a Do
not
attempt
to
screw in idle
adjusting SCTe V
completely
Doing
so
could ause
damage
to
iip
which
in
turn will
tend
ocause
malfunctions
b On
automatiC
transmission models
adjustment
should
be made in
N
p
sition
c In air
conditioner
equipped
models
idle
adjustment
should be carried
out while air
conditioner is OFF
Idle
adjustment
is
made
by
throttle
adjusting
screw and
idle
adjusting
screw
after
engine
ds
warmed
up e
Figure
ET
14
fig
ET 14
I
ttle
End idl
adju tingscrelU
With CO meter
CO meter
is
very
useful
tool
for idle
mixture
adjustment
When
preparing
to
adjust
idle
mixture it
is essential
that meter be
thoroughly
w rmed and
calibrated
Warm
up engine
sufficiently
and

apply
wheel
chocks
2 Continue
engine operation
for
one minute
at idling
speed
3
Adjust
throttle
adjusting
screw su
that
engine specd
is at
the
specified
value listed below
Transmission
model
Adjusting
value
rpm
M
T 650
A
T 700
In
N
position
4
Check
ignition timing
and if
nessary adjust
it to
specifications
5
Adjust
idle
adjusting
screw so
that CO
percentage
is
at
the
specifi
ed value check
with CO
mctcr
CO
1
5
10
5
6
Repeat
procedures
described in
itcm 3
and
5
above until CO
percentage
and
engine speed
are both
at the
specified
value
Without CO meter
Warm
up engine complerely
Check to
be
sure that float
level
and
ignition timing
are correct
while
engine
is at
idle
speed
2 Turn out
throttre
adjusti
g
screw
gently
unril
specified
engine
speed
is
approximately
obt llned
TABLE
I SPECIEIED ENGINE
r
IDLING
SPEED
M T
AIT
I
dling
speed
rpm
680
730
In
N
position
3 Turn
idle
adjusting
screw
in or
out until
engine
runs sm
Qthly
at the
highest
speed
4 Turn out throttle
adjusting
screw
until
specified
engine
speed
table I is
obtained
5
Readjust
idle
adjusting
screw
until
engine
runs
smoothly
at the
highest speed
with
the
highest vacuo
urn
reading
6
Repeat steps
4
and
5 until
engine
speed
does not
rise in
spite
of
adjust
ing
idle
adjusting
screw
7
Finally
turn idle
adjusting
screw
clockwise until
engine
speed
drops
below
specified rpm
Engine
Tune
up
TABLE II ENGINE
SPEED DROP
M T A
T
30
5
30
5
In
N
positio
Idle limiter cap
Do not remove
this idle limiter cap
unless
necessary
If
this unit is re
moved
it must be
readjusted
at
time
of
installation
To
adjust
proceed
follows
I
After
adjusting
throttlc
or
idle
speed adjusting
screw check
to be sure
that the amount of CO
contained in
exhausi
gases
meets the established
standard
2 Install idle limiter cap
in
position
making
sure
that the
adjusting
screw
can rotate
another 1
8 turn in the
CO RICH
direction
of
Iso
Idle
limiter cap
ET031
Fig
ET
15 Setting
idle limiter
cap
CHECKING CHOKE
MECHANISM Choke
plate
and
linkage
I
Check choke
valve and mecha
nism for free
operation
and clean
or
eplace
if nece
iary
A
binding
can
result
froOl
petroleum gum
formation
n choke
shaft or from
damage
2 Before
starting
engine
fully
de
press
accelerator
pedal
to ensure that
choke valve closes
properly
3 Push choke valve
with a
finger
and check
for
binding
4 Check to be sure
that bi metal
cover index
mark
is set
at the
center of
choke
housing
index mark as
shown
below
Note
Do
not set hi metal
cover index mark
at
any position
except
the center of
choke
housing
index mark
ET7
j L
4
J
e
r
7
2 Thermostat housing
I
3 Groove
CD
ID
ET034
Fig
ET 16 Bi metal
setting
REPLACING
FUEL
FILTER
I Check for
a containinated filter
and water deposit
All
engines
use
a
replaceable
car
tridge type
fuel
filter
as an
assembly
2
Replace
fuel
ifilter in
accordance
with
the maintenance
schedule
Fig
ET 17
Fuel
filter
CHECKiNG F UEL
LINES
Hoses
piping
connections etc
Check
fuel lines for loose connee
tions cracks and deterioration
Re
tighten
loose
conne
tions
and
replace
any d aged
or
deformed
parts
REPLACING
AIR
CLEANER
FILTER
Air
cleaner
employs
a wet
pape
type
cleaner
filter
viscous
type
As
this
filter has
been
specially
treated at
factory
it
need not be cleaned
before
ultimate
replacement
Even if cleaner
filter
should
look
dirty
do
not at
tempt
to
clean it
Cleaning per
formance
is
yonstantly
maintained
even
though
it
looks contaminated
Care must be taken not
to
damage
cleaner filter
Replace
filter at
recommended
intervals
or
more often under
dusty
driving
conditions

r
L
Engine
Tune up
EMISSION CONTROL
SYSTEM
CH
c
KINGVACUUM
F
ITT
INGS
HOSES
AND
CONNECTIONS
Check the condition of
fittings
and
hoses
Retighten
or
replace
if neces
sary
Carburetor to
thermal
vacuum valve
Thermal
vacuum valve to
E
G
R
control valve
Carburetor
to
vacuum
tube
Vacuum tube to distributor
Intake
manifold to
Master
Vac
Intake
manifold to
F
I C D Air
conditioner
equipped
models
1 Thermal vacuum
valwe
2 Distributor
3 E
G
Rcontrol
valve
4
B C D D
5
Carbure tor
6 Oasli
pot
ECQ49A
Fig
ET
18 Connecting
vacuum
line
REPLACING P C V
VALVE
AND FILTER
I
Checking
P C V
valve
in
accord
ancewith the
following
method
With
engin running
at idle remove
the ventilator
hose
from P
C
V valve
if
the
valve is
working
a
hissing
noise
will be heard as
air
passe through
the
valve and
a
strong
vacuum should
be
felt
immediately
when a
finger
is
placed
over valve inlet
2
Replace
P C Vvalve
and filter in
accordance with the
maintenance
sch dule
Fill
ET 19
Checking
PCV
valv
CHECKING
VENTILATION
HOSES
I
Check hoses
and hose
connec
lions fur
leaks
2 Disconncct all hoses and clean
with
compressed
air
If
any
hose cannot be freed of
obstruclions
replace
Be
sure that flame arrester is
prop
erly
inserted in hose between air
cleaner
and rocker cover
ET 8
K
EC598
E
T277
Fig
ET
20 Cleaning
wntilation hose
CHECKING EXHAUST
GAS RECIRCULATION
E G R
Cf
NTROL
SYSTEM
I
Visually
chec ntire
E
G
R
con
trol
system
Clean it for eaSe
of
inspec
tion if it is contaminat d with oil
Replace
rubber hoses if found cracked
or
broken
2Then
srart
engine
While
engine
water
is
cooi increase
engine
speed
from
idling
to 3 000 to
3 500
rpm noting
if
plate
of E G R
control val ve
diaphragm
and valve
shaft move
upwards
as
speed
is in
creased

It is normal condition if
diaphragm
does
not
move at all If not
replace
thermal vacuum valve
ET344
Fig
ET 21
Checking
E G R control
valve
3 After
engine
has warmed
up
thoroughly
increase
engine speed
again
from
idling
to
3 000
to
3
500
rpm
noting
if
plate
of
E G R
control
valve
diaphragm
moves
upwards
as
speed
is
increased
It
is normal if
diaphragm
moves
upwards
If
not
ch ck thermal vacu
um
valve as described in
step
4
4
Make
sure
that thermal vacuum
valve
is
open
and
that c
rburetor
vacuum
is
present
at the end E G
R
control valve
side of vacuum hose If
vacuum
is weak or not
present
at all
replace
thermal vacu
u TI
valve
EC652
Fig
ET 22 Checking
thermal vacuum
valve
5
With
engine
running
at
idling
speed push up
E G R control valve
diaphragm
by manually pressing
bot
tom dish
It is normal if
engine
loses
stability
6
Remove E G R control valve
from intake manifold
Visually inspect
E G R control
valve for
sign
of
damage
wrinkle
or
otherwise
deformation
Engine
Tune up
Clean
E
G R control valve seat
with brush and
compressed
air
to
eliminate
clogging
for E G R
conrrol
valve
Fig
ET 23
Cleaning
E G R control
valve seat
CHECKING VAPOR
LINES Hose
connections etc
AND FUEL
VAPOR
CONTROL VALVE
Fuel unk
and vapor vent line
I
Check
all hoses and fuel tank
filler
cap
2 Disconnect
vapor
vent line
con
necting
flow
guide
valve
to
fuel tank
3 Connect a 3
way
connector
a
manameterand a cock
or an
equiv
alent
3
way change
cock to
the
end
of
the
vent
line
4
Supply
fresh
air into
the
vapor
vent line
through
the cock little
by
little
until
the
pressure
becomes 3 923
kPa 400
mmH20
15
75
inH20
5
Shut the cock
completely
and
leave it that
way
6
After 2
5 minutes
measure
the
height
of the
liquid
in the manometer
7
Variation
in
height
should remain
within 0 245
kPa
25
mmH20
0
98
i
J j20
8
When the filler
cap
does not
close
completely
the
height
should
drop
to
zero in a short time
9
If
the
height
does not
drop
to
zero
in
a
short time when the fiiler
cap
is
removed an obstructed hose is indi
cated
Note
In
case
the
vent line is blocked
the
breathing
in
fuel tank is not
thoroughly
made thus
causing
in
sufficient
delivery
of fuel to
engine
or
vapor
lock It must therefore be
repaired
or
replaced
3W
j1J t
923
kPa
400
mmH20
15 75
inH20
ay
connectur
Cock
Ai
Manometer
IT
Fucl IiIIcr
cap
F10wguidcvatvc
I
J
Cheek valve
EC052A
Fig
ET 24
Checking evaporative
emi aion
controlsy tem
Flow
guide
valve
I Disconnect all hoses
connected
to
the flow
guide
valve
2 While
lower
pressure
air is
pressed
into
the
flow
guide
valve from the
ends
of vent line uf fuel tank side the
air should
go
through
the
valve
and
flow to crankcase side If the
air
does
ET
9
not
flow
rhe valve should be
replaced
But when
the
air is blown from crank
case
side
it
should never
flow to
the
other two
vent lines
3
While the
air is
pressed
into
rhe
flow
guide
valve from the carburetor
air cleaner side
it
flows
to
the
fuel
tank
side
and
or
crankcase side

4 This valve
opens
Vnen the
imler
pressure
is 13 kPa
10 mmHg
039
inHg
In
case of
improper operations
or
breakage replace
it
J
l
From
J
c1e
ner
From fuel tank
I
To
7
nnkcase
k
EC030
Fig
ET 25 Flow
guide
valve
CHECKING FUEL
TANK VALVE
ti J
Frunl
I
Check vulvc
2
Fuel
t
ank
EC053A
Fig
ET 26
Localionof check value
Engine
Tune up
I Disconl1ecthoses
from check
valve
2
Remove
check
valve
J
Suck
air
through
portion
A of
check valve
A
large
air flow
should be
felt when sucked
forCedly labove
2 7
kPa 20
mmHg
0 79
inHg and
should not
when sucked
softly
4
Suck air
through
portion
B of
check valve
A
largeair
flow should
be
felt
when
sucked
forcedly
above 1 3
kPa
10 rnmHg
039
inHg and
should not when
sucked
softly
5 Suck air
through
portion
B while
closing
portion
Awilh
finger
A
large
air
flow should
be
felt when sucked
forcedly
above 4 T kPa
35
mmHg
1 38
inHg
and
should not when
sucked
softly
If
any
of
above
test
results
is not
satisfactory
replace
check valve
ET10
Air
c
To
now
guide
valve
From
fuel
tank
EC054A
Fig
ET
27 Check valve