DOWNLOAD PDF Toyota Land Cruiser 2F Engine Repair Manual

FOREWORD This manual describes the repair procedures for the 2F engine equipped on the TOYOTA LAND CRUISER and TRUCKS. Under DISASSEMBL Y and ASSEMBL Y, you will find disassembled views which

carry numbers indicating

the sequence of operation procedure.

The operations can be accomplished by following these numbers. To facilitate understanding, there are also some figure numbers after operation numbers showing the locations of work details. The texts have different symbol marks which supersede the figure explanation.

This manual provides complete information on the maintenance and service of this engine , and it is hoped that it will see much use.

For service of emission control devices for USA , refer to the Emission Control Repair Manual (Pub. No. 98117).

All information contained in this manual is the most up-to-date at the time of publication, and we reserve the right to make any ehanges without further notice.

TOYOTA MOTOR SALES CO., LTD.

© 1974 T OY OTA M OT OR SALE S CO. , LT D .

SECTION INDEX I

NAME

. .

I

GENERAL

_

I

ENGINE TUNE-UP

_

I

ENGINE SERVICE

..

I LUBRICATING

SYSTEM

..

I

COOLING SYSTEM

_

I

FUEL SYSTEM

_

[ STARTING SYSTEM

..

IGNITION SYSTEM

..

I

I CHARGING SYSTEM

•

I SST & SPECIFICATIONS.

GENERAL Page

GENERAL REPAIR INSTRUCTIONS

1-2

ABBREVIATIONS USED IN THIS MANUAL

1-3

SYMBOL MARKS

1-4

1-2

GENERAL - General Repair Instructions

GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat, and fl oor covers t o keep the car clean and prevent damage.

2. During disassembly, keep parts in order f or reassembly.

3. Before performing elect r ical w ork, di sconnect th e cab le to th e posit ive (+ ) battery t erminal.

4. Always repla ce gaskets and O-ring s w it h new ones.

5. A lways use sealer on gasket s to prevent leaks.

6. Carefull y observe all specif icat ions for bolt torqu es. Al w ay s use a torqu e w rench.

7. Use genu ine T oy ot a part s.

8.

If the veh icle is t o be jacked up only at the front or rear end, be sure t o bl ock th e w heels in order t o ensure safet y.

9. A f te r the vehic le is jack ed up, do not fail t o suppo rt it on sta nds. It is ext remely dangerous t o do any wo rk on th e vehic le raised on jack alone, 'wen f or a small job that can be fini shed qui ckl y .

10. Use o f a special service to ol (SST) may be required, depend ing on th e nature of th e repair. Be sure t o use SST w here speci f ied and foll ow th e pr oper w ork pr ocedure. A li st of the SST is found at th e back o f th is manual.

GENERAL - A bbreviat ions Used In T h is Manua l

ABBREVIATIONS USED IN THIS MANUAL For conv enience, the f ollowi ng code s are used in t h is manual .

Abbrevi ation

T erm

Def in ition

SST

Special Service Tool

Thi s term designat es too ls th at have been manufa ctured specially for t he serv icing of thi s veh icle .

Their part numbers are show n in t he ]. text enclosed by [

STD

Standard

Thi s t erm ref ers to th e dimension of the part when or igina ll y manufac­ tured .

OIS

Over size

Sizes larger tha n STD are ind icat ed as O/S .

UIS

Und ersize

Sizes smaller t han STD are indi cat ed as U/S .

MP

Mu lti purpose

Use in the case of MP grease.

BTDC

Before T op D ead Cente r

TI M

Tr ansmission

1-3

1-4

GENERAL - Symbol Marks

SYMBOL MARKS The follow ing symbols have been adapted for simplicity and f or easy comprehension.

1..:·\

1·:..1

B El

ASSEMBLY

DISASSEMBL Y

INSTALLATION

REMOVAL

~

INSPECTION

~

MEASUREMENT

rm

TIGHTENING

~

CLEAN

&

IMPORTANT

ENGINE TUNE-UP Page

ENGINE OIL

2- 2

COOLING SYSTEM

·..·..·..·..·..····2- 3

DRIVE BELT

2- 4

AIR CLEANER

2- 5

HEAT CONTROL VALVE

2- 5

BATTERY

2- 6

SPARK PLUG

,2- 6

HIGH TENSION CORD

2- 7

DISTRIBUTOR

2- 8

'

VALVE CLEARANCE

2-10

CARBURETOR

2-11

INITIAL IDLE SPEED

2-12

FAST IDLE

2-14

THROTTLE POSITIONER

2-14

COMPRESSION PRESSURE

2-15

•

2-2

ENGINE TUNE-UP - Engine O il

ENGINE OIL LEVEL CHECK and REPLENISHMENT

Fig. 2-1

~

Oi l level should be up to the F line on the level gauge. If low, add oi l up to the F line.

Use API service SE classificat ion engine oil.

QUALITY CHECK

Fig. 2-2

~

Pullout the oi l level gauge and examine the oil adheri ng on the graduated part. The oil should not be discolored or th in .

OIL FILTER REPLACEMENT

Fig. 2-3

EJ

1.

2.

Remove the oi l filter by using SST [ 09 228-440 1OJ. For installation , tighten f irmly the oil fi lter by hand .

Fig. 2-4

~ 3.

After start ing the engine, check fo r oi l leak and recheck th e oil level.

ENGINE TUNE-UP - Cooling Sy st em

2-3

COOLING SYSTEM Fig. 2-5

~

COOLANT LEVEL CHECK and REPLENISHMENT If coola nt is low, fill resorv oir tank up to " F ull" line.

COOLANT QUALITY CHECK

Fig. 2-6

~

Fig. 2-7

~

There shou ld not be any excessive' deposit of rust or scales around th e radiator cap or radiator filler hole, and th e coolan t should also be free from oil .

Replace the coo lant if excessively dirty.

INSPECTION of COOLING SYSTEM PARTS There shou ld be no defects such as li sted belo w : 1.

Dam age, deteriorat ion, or loo se clamps in radiator hoses, w ater ho ses.

2.

Leakage du e to cor rosion or damage in rad iator core.

3.

Leakage du e to loo se water drain cock .

4.

Leakage from water pump .

Fig. 2-8

~

5.

Faulty operat ion of radiator cap.

Inspect th e rad iator cap pressure regulating and vacuu m valves fo r spri ng tensi-on and seati ng cond it ion. If th e valve opens at a pressure level below the specifi ed value or is o therw ise de­ fecti ve, repl ace the radi ator cap; ' Valv e opening pressure limit 0.6 kg/cm 2 ( 8.5 psi) Standard

. 0.9 kg/cm 2 ( 12.8 ps il

2-4

ENGINE TUNE-UP - Driv e Bel t

DRIVE BELT VISUAL CHECK

Fig. 2-9

~

Th ere should be no defects such as li sted below : 1.

Cracked , deteriorated, stret ched , or worn belt.

2.

Ad herence of oi l or grease.

Fig. 2-10 GOOD

~ 3.

BAD

Improper cont acting of belt against the pulley.

TENSION CHECK and ADJUSTMENT

Fig. 2-11

~

Fig. 2-12

~

B

Ai r Pump

Only f or USA

When the belt is pressed down with 10 kg (22 lb ] fo rce, the belt should deflect the specified amount.

A: 7-10 mm (0.28-0.39 in) B: 13-15 mm (0.51-0.59 in) c . 7-10 mm (0.28-0.39 in)

ENGINE TUNE-UP - Air Cleaner, Heat Control Valve

2-5

AIR CLEANER ELEMENT CLEANING

Fig. 2-13

~ .

;':ij

1.

2.

3.

, :/,.-

In removing the air cleaner or element and af ter rem oval, use care not to dr op dirt and dust down into th e carbu reto r.

In cleani ng th e element, b low air fr om the inner side .

In case the elemen t is torn or excessively di r ty , rep lace with new one.

Fig. 2-14 Dip

OIL

Element

Case

~

Oil Bath Type

~

Check air control valve operat ion.

Valve sho uld cl ose cold air inta ke wh en co ld, hot air intake wh en warm.

Wash th e element and case wi th cleaning solvent , and d ry th em th or oughIy befo re reuse.

F ill the case with engine oi l to its specified level.

tdJ - ~ HOT AIR INTAKE

Fig. 2-15

Hot Air

- - - - --al Cool - - - - - - - - at Hot

HEAT CONTROL VALVE

Fig. 2-16

~

INSPECTION When th e heat con trol valve shaft is tur ned by hand , t he valve shou ld move smoot h ly t o t he stop per , and wh en released, it should ret urn to t he ot her stopper.

2-6

ENGINE TUNE-UP - Battery , Spark Plug

BATTERY VISUAL CHECK

Fig. 2-17

~

If very di r ty , remove and clean before checking.

There should be no defe cts such as listed below : 1.

Rusted battery mounting hardware.

2.

Damage or leakage in battery, 3.

Loose connection, rusting, deterioration or corrosion of battery term inals.

SPECIFIC GRAVITY MEASUREMENT

Fig. 2-18

~

Hold the hydro meter so tha t th e f loat wi ll not co n tact against the cy li nder wa ll and read the graduation.

Spec ific gravity

Fig. 2-19

Black case batter y Lo w er level

Fig. 2-20

~

1.25-1 .27

ELECTROLYTE LEVEL CHECK and REPLENISHMENT Th e electrolyte level should be up to the upper level. If low, add disti lled water (or purified wa ter).

:D: SPARK PLUG

riiitil VISUAL CHECK

~ Conditio n is good if non e of the fol lowing defe cts are present : 1.

Cracks or damages in th e th reads or insu lat or.

2.

Wear on the electrodes.

3.

Damaged or deteriorated gaskets.

4.

Burnt condit ion of electrode and unde­ sirab le carbon deposit.

ENGINE TUNE -UP - High Ten sion Cord

2-7

CLEANING

Fig. 2-21

~2

1.

3.

Do not use spark plug cleaner longer t han necessary .

Bl ow off cleaning compound and carbon on th e threads thorough ly w ith air .

Clean off dirt from th e ou ter surface of in sulator and thread s.

GAP ADJUSTMENT

Fig. 2-22

~

Check th e p lug gap with plu g gap gauge. If not to specif ied value, adjus t by bendi ng t he ground (outer) electrod e,.

Plug gap

0.8 mm (0.031 in) 1.0 mm (0.039 in) for USA

HIGH TENSION CORD

Fig. 2-23

&

- Note When pull ing out th e spa rk plug cord from th e plug, always grip th e end of plug cord.

~

Check th e resistance of resist ivit y cord .

Fig. 2-24

~

Resistance

Less than 25 k D pe r cord.

ENGINE TUNE-UP - Distributor

2-8

d

DISTRIBUTOR CAP INSPECTION

Fig. 2-25

~

Di r tv, Corrosion, Burning Spring Action

Clean the distributor 'cap and inspect the cap and rotor for: 1.

-Crac k s. damage, dirty cor d hol e, co rrosion, burning.

2.

Center piece spring acti on .

3.

Burnt electrode terminal.

POI NT GAP ADJUSTM ENT

Fig. 2-26

~

1.

If

2.

pi tted, rep Iace th e breake r po in ts.

Ad jus t po int gap.

Point gap 0.45 mm (0.018 in)

t he p oin t s are excessive ly

burnt or

DWELL ANGLE

Fig. 2-27

~

40

Check if d w ell angle is w ith in th e specified val ue.

Dwell angle 39-43° Variation Within 3° (at idling to 2000 rpm) - CautionOn the vehicle equipped with transistorized ignition system, do not connect dwell tacho tester lead to distributor terminal, but to ignition coil terminal to prevent misfire.

IGNITION TIMING

Fig . 2-28

v~

~

Set the engi ne revo lu tion at id le speed and align the timing marks by turnin g dist ribut or body.

Ignition timing 7° BTDC (at idle speed) The octane selector mu st be set at st andard position.

ENGINE TUNE-UP - Distributor

KJ

Fig. 2-29

~

2-9

GOVERNOR OPERATIONAL INSPECTION 1.

2.

Rotor should return qui ckly when turned cloc kwise by hand and released .

Rotor shouId not be excessively loo se.

Fig. 2-30

~ 3.

~

Star t the engine and d isconn ect the vacu­ um hose fr om the di stributor. The tim ing mar k sho uld vary in accordan ce with th e opening and clo sing of throttl e valve.

ogq~.

.o...0 0

""" . .

,.

,­

Fig. 2-31

~

Fig. 2-32

~

VACUUM ADVANCE OPERATIONAL INSPECTION (Except for USA) Di sconne ct the d istributor vacuum hose and suck th e hose with mout h while th e engine is id li ng. Check if t imi ng advances wh en sucked.

VACUUM RETARD OPERATIONAL INSPECTION (For USA) D isconnect the di stributor vacuum ho se and suck the hose w ith mo uth while th e engine is idl ing. Check if t iming retards when sucked.

2-10

F ig. 2-33

ENGINE TUNE-UP - Va lve Clearance

I

VALVE CLEARANCE

(? 1 1.

/'?

Check th e coolant temperatu re.

80°C (180°F ) 2.

T ighten th e rocker suppo rt bo lts specified to rqu e.

Torque 3-4.5 kg-m (22-33 ft- Ib)

to

Fig. 2-34

~ 3.

Make adju stment . ( 1) Set th e engine at id le speed. and check th e valve clearance. Ad just if necessary. Valve clearance (Hot) Intake 0.20 mm (0.008 in) Exhaust 0.35 mm (0.014 in)

&

(2)

Ret ighten the lock nuts secure ly af ter adju stm ent.

&

(3)

Recheck th e valve clearance.

Fig. 2-35

Fig. 2-36

ENGINE TUNE-UP - Carburet or

2-1 1

CARBURETOR Fig. 2-37

~

LOOSENESS and OPERATIONAL CHECK 1.

2.

The various se t screw , p lugs and union bol ts shou ld be in properly t ightened and correct ly installed state.

The links shou ld be fr ee fr om ex cessive wear, th e snap rings (ring pins) shou ld all be present, and th e throttle shaf t sho uld not be wo rn.

Fig. 2-38

~ 3.

Check th rottle valve fu ll open.

The throttle valve sho uld open fully wh en t he accelerator pedal is stepped all the w ay down.

~ 4.

Check chok e valve act ion . ( 1) Choke valve should be fu lly closed when the choke butt on is fully pulled.

(2) A t th is t ime, open choke valve w i th f inger and release it. I t should close fully .

~ 5.

Check th e accelerating pump operat ion.

Gasoline should shoo t out w ith good force fro m the jet w hen the throttl e valve is opened.

Fig. 2-39

Fig. 2·40

2-12

ENGI NE TUNE-UP - Init ial Idle Sp eed

Fig . 2-41

~ 6.

Check f loat level.

F loat level is satis factory i f th e f uel level is up to t he stand ard line w hen th e engine is id li ng. Fo r adj ustme nt , refer to carbu­ retor secti on.

INITIAL IDLE SPEED Check the followi ng i tems befor ehand.

1.

Coo lant temp eratur e A pp roxi mately BO°C ( 180° F) 2.

Cho ke valve - Ful l open 3.

A ccessory parts (w ipers, heater, ligh ts, air cond i t ioner , etc. .l - A ll sw it ched off .

4.

Vacuu m lin es - A ll lines connected.

5.

Ignit ion t iming - Ini t ial set position 6.

T ransmission - In "N"

BEST IDLE (Except for USA and ECE)

F ig. 2-42

1.

Set to 650 rpm by turn ing th e id le speed adjust ing screw .

2.

Set to th e m ax. speed or max. vacuu m by turning the id le m ix ture adj usting screw .

Repeat th e above adj ustments unti l the specified rpm and max imum vacuu m wi ll be obtained .

650 ± 50 rpm Idle speed 420 mmHg (16.5 inHg) Vacuum

Idle Mi xture Ad jus t in g Scr ew

Id le Speed Ad j ust in g Screw

Fig. 2-43 Ini ti al id le sp eed

600

3.

ENGI NE TUNE·UP - Init ial Idl e Speed LEAN DROP IDLE (Only for USA and ECE)

Fig. 2-44 Idle Mi xture Speed

1.

600

2.

3.

Only for ECE

2-13

... .•.

Only for USA

Fig. 2-45 Initial Idle Speed

600

Set t o th e maxi m um speed by turning the id le m ix ture adj usting screw .

Set to th e id le mi xt ure speed by turning the idle speed adjusti ng screw.

Keep on repeating the adj ustme nts (1) and (2) un t il th e maxi mu m speed will not ri se any fu rth er no matter ho w muc h the idl e mi xture adjust ing screw is adjusted before mov ing to th e nex t step .

Idle mixture speed 690 rpm For USA 675 rpm For ECE

4.

Set to th e init ial id le speed by screw ing in the idl e mixtu re adjus ting screw .

Initial idle speed 650 ± 50 rpm

~ 5.

Check if the engin e returns to idle speed when sudd enly and slowly accelerated.

~ 6.

Check th e engine condi ti on.

Opening throttl e valve gr aduall y sho uld cause engine to speed up smoot h ly in rel ation to amo unt o f valve opening.

Fig. 2·46

600

Fig. 2·47

2-14

ENGINE TUNE-UP- Fast Idle, Throttl e Posit ioner

FAST IDLE

Fig. 2-48

~

1.

2.

Pull th e chok e button f ully .

Open chok e valve w ith a screwd river and start the engi ne.

3.

Set t o the specified rpm by tu rn ing th e f ast idl e adjust ing screw.

Fast idle speed 1800 rpm

Fig. 2-49

tJP3

THROTTLE POSITIONER

Fig. 2-50

~

1.

Warm up t he engine and check th e idl e speed.

~ ~:

Disconnect the TP diaph ragm hose.

Open th r ottle valve slight ly and release it T P adju stin g screw shou ld hoo k on t o th e throttle valve lever.

Fig. 2-51

I

~

ENGINE TUNE-UP - Comp ression Pressu re

2-15

Fig. 2-52 4.

Check th e engine speed.

If no t at specified rpm , adjust by turn ing the TP adjusti ng screw .

TP setting speed 1200 rpm

~ ~:

Reconnect the TP d iaphragm ho se.

Open t hr ott le valve slight ly and release it.

Engin e should return to id Ie speed.

I

Fig. 2-53

COMPRESSION PRESSURE

Fig, 2-54

1.

2.

3.

Warm up the engine.

Remo ve all spark pl ugs.

D isconnec t the h igh tension cord fro m igni t ion co il to cu t-o ff the seco ndary circu it.

~ 4.

I nsert a compressi on gauge into th e spark p lug hol e, open t he th rottle valve f u lly, and measure th e comp ression pressure wh il e cran k ing the engine w it h starter mo to r.

Compression Pressure 10.5 kg/cm 2 (149.3 psi) Limit 8.0 kg/cm 2 (113.8 psi) (at 200 rpm)

EJ

Fig, 2-55

OW3V\1

ENGINE SERVICE Page

CYLIN DER H EAD

,

,

,

3· 4

Includes: Cylinder Head, Valve and Spring Rocker Arm, Manifold

/

DISASSEMBLY INSPECTION & REPAIR ASSEMBLY

TIMING GEAR

3· 4 3- 7 3-15 3-19

Includes: Valve Lifter, Camshaft Timing Gear DISASSEMBLY II\lSPECTION & REPAI R ASSEMBL Y

CYLINDER BLOCK

3.19 3-22 3-25 3-29

Includes: Cylinder Block , Piston and Ring Crankshaft and Bearing Cylinder Boring, Camshaft Bearing Input Shaft Bearing Crankshaft Rear Oil Seal DISASSEMBLY INSPECTION & REPAIR ASSEMBLY

3-29 3.32 3-40

•••••

3~IIU:l3S 3NH:>N3

l-£

&

3:::>IAI:I3S 3NIDN3

3-4

ENGINE SERVICE - Cylinder Head

CYLINDER HEAD DISASSEMBLY Disassembl e in num eri cal ord er.

4

.~

. ~t;:~t~~;iJtt~~~:rtt~~!;fi~;Jf:~ .i ;te;,}-~:'~~:,: \~~ /~~ :;. ::.~! t~:.~i> ;\' ~ < : ::, ~~y, ~ .~: . :':~}~J~:8;~~':: ,::::'~!:r}:~:~~fJ:~}.·;;;

5

.~

6 - - ­- - ---.,

3

11//

/I

11/1

"

Fig.3-4

7

~ 1'1 /I

8

~>:

Fig.3 -7 Fig.3·8

Fig.3-5 Fig.3-6

1

Fig. 3-3

""'II

Fuel pipe

5

Valve Rocker Ass'y

2

Manifold

6

Push Rod

3

Spark Plug

7

Cylinder Head Ass'y

4

Cylinder Head Cover

8

Valve and Spring

ENGINE SERVICE - Cy linde r Head

3-5

Fig. 3-4

&

Remove caref ull y pl ug cords by pulling rubber boot.

&

Gradually loosen cy linder head bolts in tw o to thr ee stages in th e seq uence as show n.

El

If diffi cult to lift up cy linder head. insert a screw d river into th e notch and pry off as shown.

El

Compress the valve sp ri ng wi t h SST [09202­ 4301 1 J.

Fig. 3-5

10

1

5

9

13

14

12

6

2

8

4

Fig. 3-7

•

SST

.s

"JapJO u! sa" le" daa>!

/

W peaH Japu!IA::> - 3::>IJ\H3S 3NIDN3

9-£

ENGINE SERVICE - Cylinder Head

3-7

INSPECTION & REPAIR

Fig. 3-9

~

Cylinder Head 1.

Clean combust ion chamber and remove all gasket materi al f rom mani fold and head surfa ce.

~ 2.

Using a precision straigh t edge, check head surface for f lat ness.

~3.

If war page exceeds Iim it, correct by machining or repl ace head.

Head surface warpage limit 0.15 mm (0.0059 in)

Fig. 3-10

Fig. 3-11

Fig. 3-12

~

Valve, Guide and Seat 1.

Clean valves.

ENGINE SERVICE - Cyl inder Head

3 -8

Fig. 3-13

~ 2.

Qui ck -check valve stem and guid e wear by insertin g correct valve in guide and movin g valve as shown . I f mo vemen t exceeds 0.25 mm (0. 0 1 in) for intake and exhaust , additi onal measuremen ts are necessary.

~ 3.

Measure valve stem and guide. Measure inside diam et er of valve guid e and valve stem dia met er. Sub t ract stem measure­ ment. Repla ce guid e and valve if clearance exceeds limi t.

Cl earance lim it 0.10 mm (0.0039 in) Intake 0.12 mm (0.0047 in) Exhau st

4

Using SST [092 0 1-600 11] • dri ve ou t guid e fr om th e top end tow ard the comb ust io n chamber.

Fig. 3-14

Fig. 3-15

1• • 1 .

SST

•

Fig. 3-16

A

Intake

Th ere are tw o types of valve guides and length es are below.

Intake : 54 mm (2.13 in) Exhaust: 59 mm (2.32 in)

ENGINE SERVICE - Cylinder Head Fig. 3·17 1'0

...... ..., .~.--

.-. ~

[fl]

5.

3-9

Using SST [09 20 1-600 11], drive in new guide un t il i ts end pro ject s fro m cy li nder head the di st ance noted below.

Projection distance 17 mm (0.67 in)

Fig. 3-18 6.

Using a sharp 8 mm reamer, ream guide t o obta in speci fi ed clearance.

Intake 0.03-0.06 mm (0.0012·0.0024 in) Exhaust 0.04-0.07 mm (0.0016·0.0028 in)

7.

Gr ind all valves. Remove on ly enough metal to remove pits and carbon.

Valve face angle : 45 °

8.

Check marg in.

If valve head margin is less tha n speci­ fi cation , replace valve.

Margin limit

Fig. 3-19

Fig. 3-20

Intake 0.8 mm 10.031 in) Exhaust 1.0 mm (0.039 in)

Marg in

, --==== __

..~_ ~ 5°

"Y

3-10

ENGINE SERVICE - Cylinder Head

Fig. 3-2 1 9.

If valve stem tip has been w or n by ro cker arm , resurface with valve gr ind er.

Do not gr ind mo re th an 0.5 m m (0.0 2 in) .

10.

Resurface valve seats w ith 45° carb ide cu tte r.

Remov e on ly enough met al to clean seat.

11.

Coat valve fa ce wi th p russion b lue or whi te lead. Loca te contac t poin t on valve by rotating valve against seat.

Fig. 3-22

Fig. 3-23

- NoteSeat contact should be in middle of valve face with following width: Intake 1.4 mm (0.055 in) Exhaust 1.7 mm (0.067 in )

Fig. 3-24 12.

1.4 mm - Intak e 1.7 mm - Exhau st

Corr ect seat position .

T o co rrect seati ng tha t is too high, use 30° and 45 ° cut ters. If sea ti ng is too low, use 65° and 45 ° cu tters.

EN GI I\l E SERVICE - Cylinder Head

3-11

Fig. 3-25 13.

Check valve concentr icity .

Lightly co at seat with pr ussian bl ue. Install 0 valve and rotate. If blu e appears 360 around face, valve stem and face are concentric. If not, repla ce valve.

14.

Check seat/guide concent ri city .

A pp ly a light co at of prussian b lue on valve f ace. In stall and rot at e valve. If b lue 0 appears 360 around valve seat, guide and seat are concent ric . If not, recut seat.

Fig. 3-26

Fig. 3-27

~

Valve Spring 1.

Check squareness of valve springs w it h steel squar e. If spring is out of square more th an li mit, replace .

Lim it {intake and exhaust} 2 mm (0.079 in)

~ 2.

Measure free height of all sp rings.

Replace any spring that is ou t of speci­ fication .

Free height 51.5 mm (2.028 in)

Fig. 3-28

3-12

ENGINE SERVICE - Cyl inde r Head

Fig. 3-29

~ 3.

Using a spr ing tester, measure tension of each spring at the speci f ied inst alled height. Replace any spring that does not meet specif icat ion.

Limit 27 kg (59.5 Ib) Standard 32.5 kg (71.6 Ib)

Fig. 3-30

~

Rocker Arm and Shaft 1.

Check rocker arm to shaft c learance by moving rocker arm as show n. Litt le or no movement shoul d be ind icated.

If movement is fel t, di sassemb le and inspect.

~ 2.

If movement was fe lt above, measure roc ker o il clearance with d ial indi cator and outside m icr om eter. If clearance is excessive, repl ace rocker arm bu shings and/ or shaf t.

Clearance 0.01·0.04 mm (O.0004-0.0016 in)

3

To remove the rocker arm bu shing, use SST [09 222-300 10] .

Fig. 3-31

Fig. 3-32

1•• 1 .

ENGINE SERVICE - Cy linde r Head Fig. 3-33

A

3-13

When assembl ing bushing, al ign o il hole w ith that of the rocker arm.

After assembling, ream b ushing to obtain specif ied oi I clearance.

4.

Fig. 3-34 5.

If th e valve rocker arm surf ace contact ing the valve stem end is worn exc essively, repla ce the rocker arm . If only a ligh t ridg ed we ar, correct w ith valve refacer and oil stone .

Fig. 3-35

r

r/~M'

O il Hol e

A 6.

A ssemble r ockers and shaft .

Ther e are two ty pes of rocker arm s and ro cker suppo rts. Boss of roc ker suppor ts Oil hole is shou ld be pointed f ront . provid ed on fourth suppor t. Th ese should be assembled as shown .

",'"-14

ENGINE SERVICE - Cylinder Head

~

Manifolds 1.

Inspect surfaces cont act ing cy l inder head fo r w arpage, and repl ace if w arped over th e lim it.

Warpage lim it 2 mm (0.08 in)

~ 2.

When t he heat cont rol valve shaf t is turned by hand, t he valve shou ld move smoo t hly t o th e sto ppe r, and w hen released , it shou ld return t o the other stopper.

Fig. 3-37

ENGINE SERVICE - Cylinder Head

3- 1

ASSEMBLY Assemble in numeri cal order .

• •

Thoroughly clean the parts to be assembled.

Apply clean engine oil on the sliding and rotating surfaces of the parts before assembly.

8

-,

4

~

Fig .3·45 Fig.3-46 Fig.3·47

3

.

7

~r

~1!!

\ 1

2

Fig.3-39 Fig.3-40 Fig.3-41 Fig.3-42

;>~

Fig.3-43 Fig.3 -44

6

III

Valve and Spring

2

Cylinder Head

3

Push Rod

4

Valve Rock er Ass'y

5

Manifold

6

Fuel Pipe

7

Spark Plug

8

Cylinder Head Cover

Fig. 3-38

11.

5 Fig.3 -4g

3-16

ENGINE SERVICE - Cylind er Head

f:i:1 Assemble spring seat and oi l seal as shown .

00

The oil seal. sh ou ld be inserted until it s end contac ts spring seat top .

Fig. 3-40

EJ

Install valve spring in di rection as show n.

Painted surface shou ld be po inted tow ard the cyl inder head.

EJ

Com pr ess the valve spr ing with SST [09 202 · 43011] and install retainer locks.

Fig. 3-41

Fig. 3-42 After assembling valve spring, tap stem lightly t o assu re prop er f it .

ENGINE SERVICE - Cylinder Head

3-17

Fig. 3-43

&

Put head gasket on cy linder block , mating oil hole as show n.

Fig. 3-44

5

9

15

4

1

rm

8

Gradually tighten cy linder head bol t s in tw o t o th ree stages in th e seq uence as shown.

Torque 11.5-13.5 kg-m (83-98 ft-lb]

1 - j­' i 13

3

11

2

6

10

14

Fig. 3-45 Set NO. 1 cy linder to TOe /compression.

A li gn T iming mark (groo ve) w it h poin ter .

The d istr ibutor ro to r should face toward th e positi on as show n.

Fig. 3-46

Front . . . . .

r;;-;

~-

~

. <- ~- , .- -=.---.:~

, 0, "1\,~ ~r~ r I ! ~' ~; ~ ~ ~ 1\

~n4~~~rf ~~,1~~'r ~ ~: .

1 2

3

5

,7

9

Adjust valve cl earances ind icated by arrows on ly .

Clearance (Hot) Intake 0.20 mm (0.008 in) Exhaust 0.35 mm (0.014 in)

ENGINE SERVICE - Cyli nder Head

3-18

Fig. 3-47 Turn crankshaft one complete revo lution and ali gn t imi ng marks. Adjust remaining valves indi cated by arrows ,

Front . . . . .

II~~t ~~~ ~~~~Jh ~ ~-'~ 1 I ~ ~ ~ iiJ) I~ ~(j\) dfJ ~ (lb~-J

Irreso~t-"-f'ccp- gH'f" 4

6

~

10 1112

Fig. 3-48

rm 4

3

Tig hten t he manifold securing nuts in sequence as shown .

Torque 3.9-5.1 kg-m (28·37 ft-Ib]

the

ENGINE SERVICE - Timing Gear

3-19

TIMING GEAR DISASSEMBL Y Di sassemble in numeri cal order.

2

1

3

4 . Fig.3·50 Fig.3·51

5 ~ ~ ~ ~

l:lJ bl l:il l:1J

6 Fig.3-52

Fig. 3-49

8

9

Fig.3·53 Fig.3·54

Fig.3-55 Fig.3-56

Distribu tor

6

Crankshaft Pulley

2

Fuel Pump

7

T iming Gear Cover and Oil Sl inger

3

Valve Lifter Cover

8

Camshaft

4

Valve Lifter

9

Crankshaft Tim ing Gear

5

Fan and Belt

3-20

ENGINE SERVICE - Tim ing Gear

Fig. 3-50

B

&

Fig. 3-51

Pullout valve lifter.

T urn cranksh aft to lift up lifters.

Keep lifters in order .

/2.

/ Fig. 3-52

B -

Using SST [092 13-600 15] , pull out cran kshaft pu lley .

SST

Fig. 3-53

OOJ

Measure T im ing gear b ack lash. I f it exceeds li mi t, replace bo th cam and crank gears.

Backl ash lim it 0.2 mm (0 .008 in) Standard 0.05-0.13 mm (0.0020 ·0 .0051 in)

ENGINE SERVICE - Tim ing Gear

3- 21

Fig. 3-54

E]

Remo ve t w o bolts ind icated by arr ows and slide ou t cam shaf t.

- Note Take care not to damage camshaft bearing.

E]

Remove pulley key fr om cran kshaft bef ore rem oving crankshaf t gear.

E]

Using SST [0921 3-60015], pullout cran kshaf t gear.

Fig. 3-55

Fig. 3-56

ENGINE SERVICE - Timing Gear

3-22 Fig. 3-57

~

.

INSPECTION & REPAIR V alve Lifter In spect li f ter surfaces indicated by arrow s for wea r and pittin g, and replace if necessary .

...

F ig. 3-58

Crankshaft Fran t 0 iI Seal Inspect o il seal l ip for we ar and defo rm at io n.

Replace oil seal using SST [09 515-35010J .

SST ______________

Fig. 3-59

~

T im ing Gear

~

Camshaf t

Inspect gear for cracks, wear and ch ipp ed teeth .

If d amaged, repl ace bo th t im ing gears.

Fig. 3·60 1.

Inspect d istr ibu tor drive gear. If d amaged, rep lace. and also inspect dist r ibu tor gear.

EN GI N E SERVICE - Timi ng Gear

3-23

Fig. 3-61

~ 2.

Measure thru st clearance. If it exceeds limit, replace t hru st plate .

Thrust clearance limit 0.2 mm (0.008 in)

Stand ard 0. p9 -0.15 mm (0.003 5-0.00 59 in)

Fig. 3-62

~ 3.

Measure cam lobe heigh t. If wear exceeds limi t , rep lace camshaf t.

Height limit Intake 38.0 mm (1.496 in) Exh aust 37.9 mm (1.492 in)

~ 4.

Measure camshaft journal.

If wear is exc essive, camshaft sho u ld be reground or rep laced .

Journal diameter (STD) No.1 47 .955-47.975mm(1.8880-1.8888 in) No.2 46.455-46.475mm (1.8289-1.8297 in) No.3 44 .955-44.975mm( 1.7699-1 .7707 in) No.4 43.455-43.475mm(1 .7108-1.7116 in) For u/s bearing, ref er to page 3-38.

~ 5

Measure runou t. replace camshaf t.

Runout limit

Fig. 3-63

Fig. 3-64 If

it

exceeds limit,

0.15 mm (0.0059 in)

3-24

ENGINE SERVICE - T iming Gear

Fig. 3-65

6

1.... 1

'"

.

Camshaft gear repl acement (1) Take out snap ring .

(2) Press out camshaft as shown .

Fig. 3-66 (3 )

Assem b le thru st p late and gear in direction as show n .

(4 )

Press in cam gear and lo ck w it h new snap ring.

1..: .. 1

c

~~ ~ :

e

Fig. 3-67

1..: .. 1

ENGINE SERVICE - Timing Gear ASSEMBLY A ssemble in numeri cal order .

• Thoroughly clean the parts to be assembled.

• Apply clean engine oil on the sliding and rotating surfaces of the parts before assembly.

7

6

J­

9

fSl f.n ~ rnJ l:fJ l:!J l:1J liJ

4 Fig.3-73 Fig.3-74 Fig.3 -75 Fig .3-76 Fig.3-77

Fig. 3·68

3

2

1

Fig .3 -n Fig .3 -70

Fig .3 -69

Fig.3 -71

1

Crankshaft T iming Gear

6

2

Cam shaft

7

Fuel Pump

3

Key and Oil Slinger

8

D istributor

4

Timing Gear Cover and Pulley

9

Fan and Belt

5

Valve Lifter

Valve Lifter Cov er

3-25

3-26

ENGINE SERVICE - Timing Gea r

...

Fig. 3-69

-

B

Use SST [09 214· 600 10].

T imi ng mar k stamped on gear shou ld be faced toward f ron t.

&

Carefu lly inser t camshaft and mesh gears match ing tim ing mar ks. Bolt on th rust pl ate and check gear backla sh.

Torque 1-1.6 kq-rn (7·12 ft-lb]

Fig. 3·70

Backlash

0.05-0.13 mm (0.0020-0.0051 in)

- NoteAt this time, No.6 cylinder is at TDe/com­ pression.

Fig. 3·71

&

If oi l nozzl e was removed , screw in and stake the p late at tw o places.

O il hol e shou ld be faced t o pos it ion show n.

B

Fit pu lley key t o cran kshaft and install o il slinger in directi on as sho w n.

Fig. 3·72

_""·,........

IIIE!"-""".

I· ....

ENGINE SERVICE - Tim ing Gear

3-27

Fig. 3-73

&

Install t im ing gear cover and pulley as follows : Bo lts locations Arrow - Longer bol t Ap pl y liquid sealer onto lower two bolts t hreads.

Fig. 3-74 C ' l (1)

Screw in all bol ts to f inger ti ght ness.

1.... 1 (2)

Using SST [092 14-60010]. drive in pul ley to locate t he timing gear cover correct ly .

1.... 1 (3)

After installin g the pul ley . t ighten cover bol ts.

~

Fig. 3-75

•

SST

Fig. 3-76

3-28 Fig. 3-77

ENGINE SERVICE - Timing Gear

r::1 (4) ~

Tighten claw nut and lock with lock plate.

Torque 16-20 kg-m (116-145 ft-Ib)

ENGINE SERVICE - Cylinder Block

3-29

CYLINDER BLOCK DISASSEMBL Y Di sassemb le in num eri cal or der

8 Fig .3-83

ij I

7

3 Fig.3-80 Fig.3-81 Fig.3-82

4

eD·'" " 'I

U

(J)

~

~

'Vl!J

1~:'

9

ool

Fig.3-84

5

Fig. 3-78

2

6

1

Input Shaft Bearing

5

Oil Pan

8

2

Flywheel

6

Oil Pump and Strainer

9

Main Bearing Cap

3

Flywheel Housing

7

Conne cting Rod Cap

10

Crankshaft

4

Front End Plate

Piston with Connecting Rod

1 Fig.3-79

3-30

ENGING SERVICE - Cyl inde r Block

Fig. 3-79

EJ

Usin g SST [09303-5501OJ. remove input shaft bearin g.

~

Measure connecti ng rod thrust clearance. If it exceeds limit , rep lace connect ing rod .

Thrust clearance limit 0.3 mm (0.012 in)

Fig. 3-80

Stand ard 0.11-0.23 mm (0.0043-0.0091 in )

Fig. 3-81

&

Mark connecting reassembly .

&

Co ver rod bo l ts wi th a sho rt length of ho se to

rod

and

cap

f or correct

Fig. 3-82 protect crankshaft from damage.

ENGINE SERVICE - Cylinder Block Fig. 3-83

&.

3-31

Keep connecting rod and bearing in order.

Fig. 3-84

[iI]

If it Measure cran kshaft th rust clearance. exceeds limit, replace bearing as a set.

Thrust clearance limit 0.3 mm 10.012 in) Standard 0.06-0.16 mm 10.0024-0.0063 in)

ENGII\lE SERVICE - Cylinder Block

3-32

-

Fig. 3-85

~

INSPECTION & REPAIR Cylinder Block 1.

Check b lock gasket surface f or fl atn ess.

If wa rpage exceeds li mi t, co rrect by ma­ chining or replace block .

Warpage limit 0.15 mm (0.0059 in)

~ 2.

Visually inspect cylinders for verti cal scratches. If deep scratches are present , cy linde r must be rebore d.

3.

Measure cylinders at t he top, middl e, and bottom as shown .

If cylin der exceeds specif icat ion, it must be rebored.

Wear limit 0.2 mm (0.008 in) Standard bore 94.00-94.05 mm (3.7008-3.7027 in)

Fig. 3-86

Fig. 3-87

-

-.LA f

B

l

T C l

A : B : C :

15mm 60mm 60mm

E9

1

Thrust Dire ction

2

Ax ial Directi on

Piston and Ring

Fig. 3-88

~

1.

Check pin f it by t ry ing to rock piston at ri ght angle to p in. If any movement is f elt , piston with p in must be replaced.

ENGINE SERVICE - Cy linder Bloc k

3-33

Fig. 3-89

&

1 Fig. 3-90

A fter di sassembling, keep pi ston, pin , ring and rod in ord er.

2

&

2.

~

Measure r ing end gap.

(1 ) Insert ring into pi ston .

(2 )

cy linder using a

Measure end gap. If it exceeds speci­ fi cat ion , ring mu st be replaced.

End gap

0.20-0.38 mm (0.0079-0.0150 in)

Fig. 3-92

~

3.

Measure ring groove clearance.

If it exceeds specif icat ion , replace ring and/or pi ston.

Top ring 0.03 -0.06 mm (0.0012-0.0024 in) 2nd ring 0.02·0.06 mm (0.0008-0.0024 in)

ENGINE SERVICE - Cylinder Block

3-34 Fig. 3-93

~4.

Measure piston clearance.

(1) Measure piston diameter at right angle to piston pin center line.

Measurement must be made at normal temperature (20°C or 6SoF).

Piston diameter (STD) 93.97-94.02 mm (3.6996-3.7016 in)

~

(2)

25 mm (O.9S'"

Fig. 3-94

Fig. 3-95

& -Notch

• ~

5.

Measure cylinder bore and subtract piston measurement.

If clearance exceeds specification, replace piston.

Piston clearance 0.03-0.05 mm (0.0012-0.0020 in)

Assemble piston and connecting rod.

(1) Assemble piston and rod aligning piston notch and rod hole as shown .

O il Hole

Fig. 3-96

& A'

A

A= A'

B

B'

B = B'

(2)

Center piston pin in the piston, and connecting rod in cen ter of two piston pin bosses.

Tighten pin bolt.

Torque 5.4-7 kg-m (39-51 ft-lb)

ENGINE SERVICE - Cylinder Block Fig. 3·97

&

6.

3-35

Position two comp ression ri ngs w ith code marks facing up. A ssembl e rings.

Fig. 3·98

~

Crankshaft and Bearing 1.

Inspect beari ngs for fl ak ing or scor ing. If beari ngs are damaged, rep lace.

2.

Measure crank pi n oil clearance. ( 1) Lay st rip of p lastigage across pin.

Fig. 3-99

Fig. 3-100

'"

~

(2)

T ighten cap nut s to specif ied t orque.

Torque 4.8·7.6 kg-m (35 -55 ft-Ib)

- NoteDo not turn connecting rod.

3-36

ENGII\IE SERVICE - Cylinder Block

Fig. 3-101 (3)

~

Measure p lastigageat i t s wid est point.

I f clearance is not w ith in speci­ f ication , repl ace bearing s.

Clearance 0.02-0.06 mm (0.0008-0.0024 in)

Fig. 3-102 3.

Fig. 3-103

rm

Measure main journal oil clearance. ( 1) Lay st ri p of p lastigage across main journa l.

(2)

T ighten cap bo lts to specif ied torqu e.

Torque No.1-No.3: 12.5-15 kg-m (90 -108 ft -Ib) No.4 : 10.5 -13 kq-rn (76 -94 ft-Ib)

(3 )

Measure plastigage at its w idest point.

If clearance is not w ith in speci­ fi cation, replace bearings.

Fig. 3·104

~

Clearance

0.020-0.044 mm (0.0008-0.0017 in)

ENGINE SERVICE - Cy linder Block

3- 37

Fig. 3-105

~ 4.

Measure crankpin and main journals .

If wear is excessi ve. crank shaf t must be reground or repl aced.

Standard Fro nt Second Th ird Rear

66.972-66.996 mm (2. 6367-2.637 6 in) 68 .472-68.496 mm (2.6957-2.6967 in) 69 .972-69.996 mm (2.7548-2.7557 in) 71 .472-71.496 mm (2.8139-2.8148 in)

Crank pin and main journ al U/S bearings.

U/S bearing sizes: U/S 0.05 U/S 0.25 U/S 0.50

Fig. 3-106

~ 5.

Check crankshaf t for runout and if it exceeds limit, replace.

Runout limit 0.1 mm 10.004 in)

CYLINDER BORING 1.

Piston sizes:

O/S 0.50 O/S 1.00 O/S 1.50

94.46-94.51 mm (3. 7 189-3.72 09 in) 94.96-95.01 mm (3.7386-3.7405 in) 95.46-95 .51 mm (3.7583-3.7602 in)

2.

If cy linder bore is worn or tapered over limit or if cy li nder w all is scored , rebore cy li nder and install oversized p istons.

O/S piston s with pins are available in the sizes listed . Replace pistons in matched sets based on cy linder to be rebored .

EI\IGINE SERVICE - Cylinder Block

3-38

Fig. 3-107

~ 3.

Check piston clearance.

Insert into cy linder . pi ston and feeler gauge as ill ustrated. If th e correct scale readi ng is ind icated, th e pist on to cy li nder clearance is correct .

0.03·0.05 mm (0.0012-0.0020 in) 1.0-2.5 kg (2.2·5.5 Ib)

Feeler gauge Scale pull

CAMSHAFT BEARING

Fig. 3-108

1.

[ij] 2

../ "p @ II ·

>( .

~~ . : .

Inspect bearing surface for f lak ing, melting, and burning, and repl ace if d amaged .

Inspect th e oil clearance by measuring th e difference between the camshaft jo urnal dia met er and th e bearing in ner d iameter.

I f clearance exceeds specif icat ion, repl ace beari ng and lor regrou nd camshaf t.

0.025-0.075 mm Clearance (0.0010-0.0030 in)

Camshaft UI S bear ings U/S bearing sizes: U/S 0.25 U/S 0.50

Fig. 3-109

El

Camshaft Bearing Replacement 1.

2.

Drive out plug from cylin der block .

Using SST [0921 5-60010] , rem ove fro nt and second bearings t owa rd s front , third and rear bearing s t oward s rear. >

~

/

.

- .......

, ~

ENGINE SERVICE - Cy linder Block

3-39

Fig. 3-110

~ 3.

4.

A li gn the bearing oi l ho le, install new selected bearings using SST [09 2 15-600 101.

If bearings are correc t ly installed, only a slight reaming is req uired .

Install new plug app lied wi t h liqu id sealer.

ENGINE SERVICE - Cylinder Block

3~40

ASSEMBLY A ssemble in numerical ord er.

•

Thoroughly clean the parts to be assembled.

•

Apply clean engine oil on the sliding and rotating surfaces of the parts before assembly.

6

" Fig .3-12l Fig.3-122

5

~ >----4 Fig .3-117

Fig .3-l19 Fig.3-120

Fig .3-l18

~.. ""

." "

Ifi['\

Y!I

~

e1J

11

-~

1

I-Ig.;j-ll;j~

2 -----=---------nbjJJJjJL .....l _..l!

3-----l Fig.3 -114 Fig.3 -115 Fig .3 -116

8

10

7

Fig.3-123

Fig.3-'"

12

Fig.3 -125 Fig.3-126

1

Main Bearing

5

Connecting Rod Cap

9

Input Shaft Bearing

2

Crankshaft

6

Front End Plate

10

Crankshaft Rear Oil Seal

3

Main Bearing Cap

7

Oil Pump and Strainer

11

Flywheel Housing

4

Piston with Connecting Rod

8

Oil Pan

12

Flywheel

9 Fig.3-124

ENGINE SERVICE - Cylinder Block

3--41

Fig. 3-112

&

Front (No .1) and rear (No.4) bearings provided oi l hole must be installed at cy linder blo ck side.

!1\11 1\~~I\III5~~1

m!'!'!~!l~

No.1

&

A ll main bearings are d ifferent. Insta ll bearings in block and caps, lubricating face on ly.

1I1 111~ 111111

11I111f tll ll l l'

No .2

NO.3

No.4

Fig. 3-113

1, ..

Cap Side

&

Fig. 3-114

Face the arrow mark tow ard fro nt.

..

/

Fig 3-115

~

Tighten bearing cap to specified torq ue.

Torque No.1-No.3: 12.5-15 kg-m (90 -108 ft-Ib) No.4 : 10 .5-13 kg-m (76-94 ft-Ib)

ENGINE SERVICE - Cyl inder Block

3-42

Fig. 3-116

~

Check cran kshaf t t hrust clearance.

Thrust clearance 0.06 -0.16 mm (0.0024-0.0063 in) Make sure the crankshaft rotate s smooth ly.

&.

Fig. 3-117

Position ri ng gap in di rectio n as show n.

Front

Compression R ing No.1

Fig. 3-118 Notc h

.J,

Fig. 3-119 -~

8

Cover rod bolts with a ho se to protect crank shaft from damage.

Push cor rect ly numbered piston /rod assembly with notch forward . eEl mark on conn ecting rod should face rearward.

c:1 Align rod and cap marks, fit the cap. ~

ENGINE SERVICE - Cylinder Block Fig. 3-120

rm

3-43

Ti ghte n rod cap to specified to rque and check rod t hrust clearance.

Torque 4.8 -7.6 kq-rn (35 -55 ft-Ib] Thrust clearance 0.11-0.23 mm (0.0043-0.0091 in) Make sure the crank shaf t rotates smooth ly.

Fig. 3·121

&

Fig. 3-122

Fig. 3-123

rm &

Apply liquid sealer onto end p late gasket bo th surfaces.

Ti ghte n the under cut f lat head screws to locate end p late correct ly , then t ighte n t he bol t.

A ppl y liqu id sealer at f our pla ces as shown.

3-44

ENGINE SERVICE - Cylinder Block

Fig. 3-124 SST

B

Install input shaf t bearing using SST [09-304­ 470 10] .

B

App ly MP grease onto oil seal lip and insta ll oi l seal using SST [09 223-60010] .

~ .-

Fig. 3-125

, i i i ji lli , ~ i il j i iii jj i iU ~j iUi i i j ~ i iilu i l i i i\i

Fig. 3-126 Coat f lywheel bolt threads w ith liquid sealer.

Tighten f lywh eel to speci f ied t orqu e.

Torque 5.7-7.3 kg-m (41-53 ft-lb)

LUBLICATING SYSTEM Page

LUBRICATING SYSTEM CIRCUIT

4-2

OIL PUMP

4-3 ' 4-3 4-4 4-6

DISASSEMBLY INSPECTION ASSEMBLY

4-2

LUBRICATING SYSTEM - Lubricating System Circuit

LUBRICATING SYSTEM CIRCUIT

Fig. 4-1

LUBRICATING SYSTEM - Oil Pump

OIL PUMP DISASSEMBLY Disassemble in num eri cal order .

I

I

4

-\ 1

5

@ ~

04.'II\1lMl ,r..(\.llJi

(}l

~

Fig. 4-2

2

3

Oil strainer

4

D rive Gear

2

Pump Cove r

5

Driven Gear

3

Relief Valve

4-3

4 ~4

LUBRICATING SYSTEM - Oil Pump INSPECTION

Fig. 4-3

~

1.

Measure tip clearance. If it exceeds limit, replace gear and/or pump assem b ly .

Lim it 0.2 mm (0.008 inl Standard 0.03 -0.11 mm (0.0012-0.0043 in)

~ 2.

Measure backl ash.

If it exceeds lim it, repl ace gears.

Limit 0.95 mm (0.0374 in) Standard 0.05-0.07 mm (0.0020-0.0028 in)

~ 3.

Measure side clearance. If it exceeds limit, replace gear and/or pump assembly . limit 0.15 mm (0.0059 in) Standard 0.03-0.09 mm (0.0012-0.0035 in)

~ 4.

Measure cover wear.

I f th e clearance exceeds li m it , replace cover.

Limit 0.15 mm (0.0059 in)

Fig. 4-4

Fig. 4-5

Fig. 4-6

LUBRICATING SYSTEM - Oil Pump

4-5

Fig. 4-7

~ 5.

Inspect relief valve for scori ng and wear.

If d amaged , rep lace valve or pump as­ sembly .

~ 6,

Inspect o il strainer for rust , tear and clog.

If d am aged, rep lace.

Fig. 4-8

LUBRICATING SYSTEM - Oil Pump

4-6

ASSEMBLY A ssemb le in numerical order .

I

i

@ ~

~lg

2

f' .".

F i 9 .4-10~'

~ Fig. 4-9

FigA -11 Drive and Driven Gear 2

Pump Cover

3

Relie f V alve

LUBRICATING SYSTEM - Oil Pump

4-7

Fig. 4-10

B

Install pump cover in direction as show n.

Di scharge hol e should be pointed toward pump body bolt hole.

~

Check pump operati on.

Submerge pump inlet pip e into fr esh engine oil, and turn the shaft clockwi se with a screw dr iver.

Thi s shou ld cause the oil to come out from di scharge hole.

Close the d ischarge hole with thu mb, and turn the shaft as before. Make sure that the shaf t becomes heavy.

Fig. 4-11

OIN31N

COOLING SYSTEM Page

COOLING SYSTEM CiRCUiT

5-2

WATER PUMP DISASSEMBLy ASSEMBLy

5-3 5-3 5-4

FLUID COUPLING

5-6

RADIATOR

5.7

THERMOSTAT

5.7

COOLING SYSTEM - Cooling System Circuit

5-2

COOLING SYSTEM CIRCUIT

Radiator

Thermostat

Fan

Fig. 5-1

Wate r Pump

COOLING SYSTEM - Water Pump

5-3

WATER PUMP DISASSEMBLY Disassemble in num erical or der.

4 2 , Fig.5-3

3 Fig.5-4

~

~ 2

Seat Plat e

3

Bear ing

Pulley Seat

4

Rotor and Seal

Fig. 5-2

Fig. 5-3

- r::l Using SST [09 235 -6001OJ. remove pulley seat. ~

Fig. 5-4

El I

SST

Using SST [09238-40010]. press bearin g out o f t he pu mp body .

COOLING SYSTEM -Water Pump

5-4

ASSEMBLY A ssemble in numeri cal order.

4

2 Fig.5-11

1 Fig.5-7

3 Fig .5-6

5 Fig .5 -8 Fig .5-9 Fig .5-10

Ollll®

~ Seal

4

Pulley Seat

2

Bearing

5

Seat Plate

3

Rotor

Fig. 5-5 Fill. 5-6 Sealer

B

A ppl y a small amount of liqu id sealer to pu mp b ody seal installi ng surface, press seal into body , using 26mm sock et w rench.

B

Using SST [09 238-400 10 ] , press new bearing in to bod y unt il its end surfa ce is fl ush with body end .

Fig. 5-7

-SST

COOLING SYSTEM - Water Pump Fig. 5·8

5-5

D:1 A ssemble rubber seal and thru st p late into rotor.

,

M

Fig. 5·9

EJ

Ap ply a small amount of silicone oil or engine oil to the seal surf aces . Press in rotor un t il its surf ace indi cated by arrow is fl ush w ith bearing shaf t end.

~

Make sure th at the rotor end is f lush w ith pump body end surface.

~

Support th e shaf t f rom th e ro tor end w i th a sui table bar and press in pu lley seat to the depth as shown.

- NoteAfter assembling the rotor, chec k it for smooth rotat ion w ith the water pump plate in installed cond ition.

Fig. 5-10

Fig. 5·11

COOLING SYSTEM - Fluid Coupl ing

5-6

FLUID COUPLING Fig. 5-13 Fig. 5- 14

~"

~- - - -

~

..

,

...: ~ ! ~;;L\.I :\ : !". ;' : r.~_~ ~ .

.

~

.-., .

Silico ne Oil Visco sity 1000 est, Capacit y 35 cc

Fig. 5-12 Fig. 5-13

r-.

B

Suppor t pulley w it h sui table anvils and press out pump assemb ly , using SST [09236-36010 1.

SST

- CautionRemoved coupling cannot be reused.

SST

Support pump bearing shaft end f rom the ro tor end w ith a sui table bar and press in new coupling, using SST [092 36-360101 .

Fig. 5-14

~-

1..:·1

- NoteTake care not to drop silicone oil when sepa­ rat ing new coupling.

COOLING SYSTEM - Radiato r, Thermostat

5-7

RADIATOR INSPECTION

Fig. 5-15

OOJ

1.

Inspect th e radiato r cap reguIat ion pressure, and vacuum valves for spri ng tensi on and sea t ing. If the p ressure gauge dro ps rapid Iy and excess ively, repl ace th e rad iator cap.

Valve opening pressure limit 0.6 kg/cm 2 ( 8.5 psi)

Standard

Fig. 5·16

-

OOJ

2.

0.9 kg/cm 2 (12.8 psi)

Inspect t he cooling system f or leaks.

A ttach the pressure tester to th e rad iator, pump the tester t o th e specified pressure.

If th e pressure gauge d rops, inspec t all hoses and fittings f or an ext ernal leak. If no ex ternal leak is fou nd an internal int ake manifold , b lo ck or heater core leak sho uld be suspected .

THERMOSTAT

Fig. 5-17

OOJ

INSPECTION 1.

2.

Repl ace if the valve rema ins open at normal temp erature or d oes not have proper tight ness w hen fu lly closed .

Imm erse th e th erm ostat in t he w ater, and check the valve ope ning temper atu res by heating the w ater gradually.

T he valve is sat isf act ory if it st arts to open at 80 .5° to 83. 5°C (177 ° to 182°F) and open s to more th an 8m m (0.3 2 in .) at 9 5°C (20 3°F l.

Rep Iace if necessary.

o VII 3 VII

FUEL SYSTEM Page

FUEL PUMP DiSASSEMBLy INSPECTION ASSEMBLY

6- 2 6- 2 6- 3 6- 3

CARBURETOR

6- 6

CARBURETOR CIRCUITS · · DiSASSEMBLy INSPECTION ASSEMBLY .· .. ·· ·· ·.. · ADJUSTMENT

··

·

·

6- 6 6- 8

6-13 6-17 6-24

FUEL SYSTEM - Fuel Pump

6-2

FUEL PUMP DISASSEMBLY D isassemble in numeri cal order .

:\1\

1

I

2

10-7"'"

3

4 F ig.6 -2

~ Pump Cover 2

A ir Chamber Diaphragm

3

Upper Body

4

Diaphragm and Spr ing

Fig. 6-1

Fig. 6-2

El

Remove diaphragm by t urning it 90 degrees clo ckwise or coun terclock wi se whi le pushing.

FUEL SYSTEM - Fuel Pump Fig. ~3

INSPECTION

~

Inspect d iaphr agms f or tear and check valves f or defect ive operat io n. Repl ace if d amaged.

ASSEMBLY A ssemb le in nu merical orde r.

r-------3 Fig.6·9

2

~

Fig.6·B

1 Fig .6·5 Fig .6·6 Fig .6·7

Diaphragm and Spr ing

Fig. ~4

6-3

2

Upper Body

3

Cover and Diaphragm

6 -4 Fig. 6-5

FUEL SYSTEM - Fuel Pump

[Xl Assemb le spring, retainer and o il sea l onto

M

di aphragm rod .

Fig. 6-6

B

I nsert d iaphragm rod into lower body ho le.

Whil e compressing th e spri ng turn di aph ragm 90 degrees clockw ise or countercloc kw ise t o mesh t he rod and rocker arm .

Fi~ 6-7

&

After assembling , th e tab of d iaphragm must face th e posit ion ind icated by arro w .

&

Assemb le lower and upper bod y in di rection as shown .

Fig. 6-8

·peu 5l1 e aq p jno us sll eM 5u !1-eJedes Jeqwe LjJ rau no pue 1-elul ·w 5eJLjd el p eLj1-

9-9

JeAO

JeAOJ

pue

"'poq

radd n

elqw ess\;f

dwnd lan~ - W31SAS 13n:l

-------

~I

/

1

3

2

/

/

4

/

5

/ r-i kl

6

/

7

9

8

/

INLET

/

nOlO) »» I

:D

em

~c

-1:0

Om

e"

~O

r

:D-4 ~:o

e

-I

(')

'".....c­

CD

........ ...0

ern

~

"- ,

7

Solenoid Valve

13

1st Th rottle Valve

2

2nd Slow Jet

8

Powe r Piston

14

Idle Mixture Adjusting Screw 1st Slow Jet

3

2nd Main Nozzle

9

Needle Valve

15

4

Pump Jet

10

2nd Main Jet

16

tsr Main Jet

5

1st Main Nozzle

11

Diaphragm

17

Power Valve

6

Choke Breaker

12

2nd Throttle Valve

rn -< rn -I m

S

"0

Pump Plunger

m

rn m x

1

0)

O::J:O

I 0

c

.....

<1l ....

0

.....

~I

/

1

2

/ I

/

3

4

5 ritf(6

/ /

/

7

/

8 INLET

/

9

Ii ::0

m

~

0

::0 (")

::0 (")

C ~

en 0

::J

-e

...

0

c

en

-

l>

"T1

C

m r

en -< en

~

m

s: I

o

'" a­ 1

Pump Plunger

7

Solenoid Valve

13

2nd Throttle Valve

2

2nd Slow Jet

8

Power Piston

14

1st Throttle Valve

3

2nd Main Nozzle

9

Needle Valve

15

Idle Mixture Adjusting Screw

4

Pump Jet

10

2nd Main Jet

16

1st Slow Jet

5

1st Main Nozzle

11

AAP

17

1st Main Jet

6

Choke Breaker

12

Diaphragm

18

Power Valve

c

...Qro O'l

I

"-J

FUEL SYSTEM - Carburetor

6-8

DISASSEMBLY Di sassemble in num er ical ord er.

USE SST [09860-11010) FOR CARBURETOR SERVICE.

6

4

3

1

7

5

Pump Arm

2

2

Pump Connecting Link

3

Choke Br eaker Connecting Link

4

Fast Idl e Conn ecting Link

5

Throttl e Positioner Connecting Link

6

Th rottl e Positioner (Choke Break er!

7

A ir Horn

Fig. 6-12 Fig. 6-13

1.... 1 Lift out air horn .

FUEL SYSTEM - Carburetor AIR HORN Disassemble in numer ical order.

to ~

II

6 ';9.6·16

7­

o~

--­

Fig .6-17

5

...

4 Fig.6-15

-­'II"

2

~m

~lill

1

Fig. 6-14

Float

5

2

Needle Valve and Seat

6

Choke Valve

3

Pump Plunger

7

Choke Shaft

4

Power Piston

Solenoid Valve

6-9

6-10

FUEL SYSTEM - Carburetor

Fig. 6-15

B

Fig. 6-16

Fig. 6-17

Remove power pi ston and spr ing. T ake care no t to lose th e spring.

r::l Unpeen set screw s and remove cho ke valve. ~

r::l Unhook spring and pul lou t choke shaft. ~

FUEL SYSTEM - Carburetor

6-11

BODY Di sassembl e in numeri cal order.

8

1 Fig.6 -19

2

1

.J....

I~ G

-----­ I I

4

w:\

I

IlL

JII

I

~\\1fh ~~10

®I

,

GI

III

,

\~ \.

3

I

I

!

1ll::1..""

I

5 Fig.6-20

' <, <, ~ l1 l l1 ---...: lJJ ~

6

'7 ~ I

~ ~

......

'>

,,//.. . .

7

,....-""­

9 Fig.6-21 Pump Outlet Ball and Spr ing

Fig. 6-18

6

Power Valve

2

Pump Dampi ng Spring

7

Ma in Jet

3

Pump I nlet Ball

8

Venturi

4

Slow Jet

9

AAP Diaphragm and Housing (For USA)

5

AAP Check Ball (For USA)

10

Secondary Diaphragm

6-12

Fig. 6-19

FUEL SYSTEM - Carburetor

c:l Drop out pump outlet bal l and spring s. ~

Fig. 6-20

EJ

Loosen screw plug and dr op out AAP out let ball and spring.

El

Remove AAP ho using and d iaphragm .

Do not turn the AAP adjust ing screw (Arrow).

Fig. 6-21

FUEL SYSTEM - Carbu retor

6 -13

INSPECTION - Precaution ­ 1.

Before inspect ing t he parts, wash them thoroughly in carburetor cleaner. Using compressed air, blow all d irt and other foreign matter from the jets and sim ilar parts, and from the fuel passages and restrict ions in the body.

2.

Never clean the jets or orifices with wire or a drill. This could enlarge the openings and result in excessive fuel consumpt ion.

Fig. 6-22

~

Inspect t he fo llowing parts and rep lace any part d amaged.

Air Horn Parts

•

1.

Ai r horn : Cracks, damaged threads, and wear on chok e shaf t bo res.

~ 2.

Float: Bro ken lip, wear in float pivot pin hol es.

Need le valve surfa ce con tacti ng valve seat.

Strainer : Ru st, br eaks.

Power piston : Scratches, excessive wear.

Power pi ston spring bro ken or deformed.

Fig. 6-23

3.

4.

5.

I "11 1111, • • "tll l

II

' II '

'.

Fig. 6-24

~ 6.

Cho ke valve: Deformat ion . Cho ke shaft worn, bent, or not fitting properly into hou sing.

FUEL SYSTEM - Carb ureto r

6-1 4

Body Parts

Fig. 6-25

1.

Body : Cracks, scored mo un ting surfaces, damaged th reads.

~ 2.

Jet s: Dam aged contact ing surface, damaged thr eads and screw d river slot s.

Power valve: Faulty opening and closing act ion, damaged contact ing surface and th reads.

~

Fig. 6-26

3.

Fig. 6-27

~ 4.

Vent ur i : Damaged.

~ 7.~:

Pump damping spri ng: Def orm at ion, ru st.

Pump check ball : Damaged, rusted .

Pump plunger : Wear at slidi ng surf ace, def ormed or damaged leather .

Fig. 6-28

~

FUEL SYSTEM - Carburetor

6-15

Fig. 6-29

~ 8.

AAP check ball : Faulty opening and closing act ion or damaged diaphragm.

~ g.

Secondary diap hragm : Damaged.

Fig. 6-30

\

.

Flange Parts

Fig. 6-31

~

1.

2.

Flange: Cracks, inj ured mounti ng surfaces, damaged threads, wear at throttle shaft bearings.

Thr ot tl e valves: Wear or de forma tion in valves. Wear, bending , tw isting , or f aulty movement inside housing o f shaf t.

....

Fig. 6-32

~ 3.

Idl e mi xture adjust ing screw : Damage at tapered tip or threads.

6-16

FUEL SYSTEM - Carburetor

Fig. 6-33

~

Solenoid Va lve

~

Choke Breaker (Throttle Positioner)

Check operat ion of solenoid valve.

Connect w ir ing to th e battery po sitive termin al and grou nd the body . Th e need le valve shou ld be pulled in .

Fig. 6-34

.

"

Connect hose to choke breaker di aphragm (t hr ott le positioner) and suck th e hose wi th mou th.

Th e d iaphr agm shou ld move. If not. replace it.

FUEL SYSTEM - Carburetor ASSEMBLY AIR HORN A ssemble in num eri cal order.

E1

~~ 3

....

4 Fig.6-38

;: . -

~ :; -

I®

III"I

~

6

~

Fig.6-39

~

~~

~ .

7

Fig .6-40 Fig .6 -41

Fig. 6-35

Choke Shaft

5

Pump Plunger

2

Choke Valve

6

Needle Valve and Seat

3

Solenoid Valve

7

Float

4

Power Piston

6-17

6-18 Fig. 6-36

FUEL SYSTEM - Carburetor

r::i:l Insert choke shaf t and hook the sprin g as show n.

lY:J

Fig. 6-37

&.

Install cho ke valve , then peen screws.

Fig. 6-38

El

Fig. 6-39

I nstall power piston and spring.

Make sure that the piston move s smoo thl y :

r::l Fi t need le valve, spring and plunger in order. ~

.

FUEL SYSTEM - Carburetor

6-19

Fig. 6-40

r

A dj ust fl oat level.

A llow th e f loat t o hang down by i ts ow n weight.

Th en check th e clearance betwe en th e f lo at t ip and air horn w it h SST [0 9240-00011 ]. Ad just by bendi ng t he (A) part of float li p.

Standard 7.5 mm (0.295 in) - NoteThis measurement is always made without any gasket on air horn.

Fig. 6-41

~

A d just lowered positi on.

L ift up the fl oat and check th e clearance between th e needl e valve p lunger and fl oat lip wi t h SST [09240- 00 011] . Ad ju st by bend ing th e (B) part of fl oat lip .

Standard 1.1 mm (0.043 in)

6-20

FUEL SYSTEM - Carburetor

BODY A ssemble in numer ical order .

10

9 Fig.6-50

~8 Fig.6-49

I 2

I, _

-

i

Fig.6-44

j] . ,.

i

I

~

~,

~

,'fC J L--J> ~_ ' 6:i I

5

6

~(

.1~-U; ~ ©,

t

9 .6-4 6

~, ~ O 3 Fig .6-45

7 Fig.6-47 Fig.6-48

Fig. 6-42

Venturi

6

Pump Inlet Ball and Reta iner

2

Slow Jet

7

AAP Diaphragm and Housing (For USA)

3

M ain Jet

8

Secondary Di aphragm

4

AAP Check Ball (Fo r USA)

9

Pump Outlet Ball and Sp ring

5

Power Valve

10

Pump Damping Spring

FUEL SYSTEM - Carburetor

6-21

Fig. 6-43

El

In stall ventu ris over gasket.

Primary and secondary venturi s are different.

El

Install slow jets.

Lo nger or larger size jet should be installed at secondary side.

El

Install main jet s ove r gasket.

8

I nstall AAP check balls.

Primary Secondary

Triple venturi Double venturi

Fig. 6-44

Fig. 6-45 Primary jet Secondary jet--

Brass colored Chrome colored

Fig. 6-46

- NoteThere are two sizes of balls.

Smaller ball: For AAP and pump inlet Larger ball: For Pump outlet

6-22

FUEL SYSTEM - Carburetor

Fig. 6-47

r::l Fit AAP spring in directi on as show n. ~

Fig. 6-48

r:D A ssemble AA P d iaphragm in order as shown .

M

Fig. 6-49

rX1 A sse mble secondar y diaphragm in order as

M

show n.

®~

Fig. 6-50

r::l Install pump outlet ball and spring. ~

FUEL SYSTEM - Carburetor

6-23

BODY Al\ID AI R HORN Assemb le in nu meri cal or der .

2

4

1

5

7

. Fig.6-52 .

3

1

Air Horn

5

Choke Break er Connecting link

2

Choke Brea ker (Throttle Positioner)

6

Pump Connecting link

3

Throttle Positioner Connecting link

7

Pump Arm

4

Fast Idle Co nnec ti ng lin k

Fig. 6-51

Fig. 6-52

Ci:1 Assemble bod y and air ho rn over new gasket.

00

T ake care not t o damage p ump plunger leath er.

6-24

FUEL SYSTEM - Carbureto r ADJUSTMENT

Fig. 6-53

Use SST [09240-00011] to make adjustments .

Fig. 6-54

~ 1.

Throttle valve openings Open th e prima ry and secondary throttle valves separately and check if the throttle valves will be perpendicular to the flange Ad just by surface when fu lly opened. bending the respective thrott le lever stoppers at the primary (1) and secondary sides (2) .

~ 2.

Kick up With the primary throttle valve fully opened, check the secondary throt tle valve Adjust by bending secondary opening. throttle lever.

Standard 28 ° from bore 25° from bore (Only for California I

~ 3.

Fast idle With choke valve full y closed, check the clearance between bore and primary throttle valve. Adjust by turn ing fast id le adjusting screw (1).

Standard clearance 1.3 mm (0.051 in)

Fig. 6-55

Fig. 6-56

/J

FUEL SYSTEM - Carbu retor

6-25

Fig. 6-57

~ 4.

Choke breaker Push in choke breaker rod t o open choke valve and check the choke valve angle.

Adjust by bendin g th e choke breaker lin k.

Standard

38 ° from bore

Fig. 6-58

~ 5.

T hrottle posit ion er Conta ct thro tt le positioner adjust ing screw ( 1) to th ro ttle lever tab (2). check the clearance between bore and pr imary A djust by tu rning the thrott le va lve. adjusting screw.

Standard clearance 0.8 mm (0.031 in)

Fig. 6-59 6.

Idl e m ix ture adjusting screw Screw in the id le mi xtu re adjus t ing screw and then unscrew it by t he f ollowi ng amou nt.

Standard (Reference only) Returned about 1% turns from full closed - Caution Take care not to screw in too tightly and damage the screw tip.

Fig. 6-60 I~ ~

I

I

7.

Acce lerating pump Ad just th e pu mp st roke by bend ing par t A.

St andard 9.5 mm (0.374 in) - NoteAfter adjustment is made, be sure to check the linkage to see that it operates smoothly.

OW3W

STARTING SYSTEM ·Page

STARTING SYSTEM CIRCUITS

7- 2

STARTER

7- 3

DiSASSEMBLy INSPECTION AND REPAIR ASSEMBLy

7- 3 7- 6 7-13

PERFORMAI\ICE TEST

7-17

7-2

STARTING SYSTEM - Starting System Circuits

STARTING SYSTEM CIRCUITS

Ign it ion Sw i tch Side

ACC~AM

IG~ST

" 30 " Term inal " 50 " Terminal " C" Terminal

Fig. 7-1

Ignition Switch

"50" Term in al Fusible Link

I.l /

V,

"30" Termin a~

[

.,.

I

I I I I

I

I -L-

Field Coil

Fig. 7-2

STARTING SYSTEM - Starte r

7-3

STARTER DISASSEMBL Y Disassem ble in n ume rica l order .

~

==

4

2

5

7

«([[- [tc 1 2 3 4

Magnetic Switch Bear ing Cover Lock Plate Bolt

5 6 7

Commutator End Frame Yo ke with Brush Holder Drive Leve r Bolt

8 9

Arm ature and Drive Lever Sn ap Ring

Fig. 7-3

rCD

10 9 Fig. 7-7 Fig. 7-8

10

Stop Collar

11

Clutch with Pinion Gear

12

Center Bearing

7-4

STARTING SYSTEM - Sta rter

Fig. 7-4

B

Disc onnect lead wi re before removing magnet ic swit ch.

~

Check th e armatu re shaft t hru st c learance.

Thrust clearance 0.05-0.35 mm (0.002-0.0138 in)

Fig. 7-5

Fig. 7-6

Fig. 7-7

Cl Pry off th e yoke, using a screwd ri ver. ~

r::l T ap in stop co llar , using a socke t wrench . ~

STARTING SYSTEM - St art er Fig. 7-8

......--

....

El

7-5

Pry the snap ring , using a screwdri ver.

Fig. 7-9

&

Fig. 7-10

....

El

I f diffi cult to pullout th e pinion , repair the shaf t with an 0 i I st one.

Ta ke off br ushes and remov e brush

holder.

7-6

STARTII\IG SYSTEM - Start er

Fig. 7-11

~

INSPECTION AND REPAIR Armature Shaft & Bearings 1.

Inspect armature and po le shoes for signs of con tact .

Replace drive hou sing bush ing and end frame bushing if any con tact suspected.

~2.

Inspect armature shaft end, d rive housing bushing and end frame bushi ng for wear or damage.

Oil clearance limit 0.2 mm (0.008 in)

3.

BUSHING REPLAC EMENT (1) Pry out th e bushing cover and press out t he bushing .

(2) Press in new bushing and ream to ob t ain the specified clearance Oil clearance 0.05 mm (0.0020 in)

Fig. 7-12

Fig. 7-13 i

Fig. 7-14

El

(3 )

Clean the bore, bush ing cover.

and

install new

STARTING SYSTEM - Starter

~

7-7

Commutator Inspect for the followi ng items and repair or replace.

Dirty or burnt surfa ce.

1.

Corre ct by sandpaper or lathe if necessary .

Fig. 7-16 Use # 400 sandpaper.

Fig. 7-17

~ 2.

Runout: Corr ect on a lathe if it exc eeds the limit.

Runout limit 0.4 mm (0.016 in) 0.05 mm (0.0020 in) Standard

~ 3.

Surf ace wear . If belo w the lim it , replace armature .

Limit 31 mm (1.22 inl Standard 32.7 mm (1.287 in)

~ ~~~

~

Fig. 7-18

7-8

STARTING SYSTEM - Starter

Fig. 7-19

~ 4.

Depth of segment mi ca.

Limit 0.2 mm (0.008 in) Standard 0.5-0.8 mm (0.020-0.031 in)

Fig. 7·20 Corre ct with a hacksaw blad e.

A f ter cor rect ing, elim inate ch ips using sandpaper.

Fig. 7-21

~

Fig. 7-22 ....-­

Cent er Bearing 1.

Inspect cen ter bearing for wear or damage.

Replace if necessary .

Clearance limit 0.2 mm (0.008 in)

~ 2.

I nspect spring holder, spring and arm atu re shaft f or cracks, w ear or damage. Repla ce if necessary.

STARTING SYSTEM - Start er

~ .

7-9

Arm ature Coil 1.

Ground test Check commutator and armatu re coil cor e.

If there is continui ty. the armature is grounded and must be rep laced .

~ 2.

Open-circuit test Check for con ti nu itv between th e seg­ ments . If there is no continuity at any test point, there is an open-circuit and armature must be replaced.

~

""-!.

--­

~=-~

Fig. 7-24

Fig. 7-25

~

Fi eld Coil 1.

Open-circuit test Check for continuity between the lead wire and fie ld coil brush soldered con­ nection. If there is no continuity, there is an open-circuit in the field coil , and it shou ld be repla ced.

~ 2.

Ground test Check for cont inui ty between fie ld coil end and field frame.

If there is cont inui ty , repair or rep lace the fie ld coil.

Fig. 7-26

7 - ~0

STARTING SYSTEM - Starter

Fig. 7-27

-

Fig. 7-28

L.IiiIIll-..iiiiiiiiiiiiiliiiiil. 1

~

Brushes Measure the brush length and replac e if bel ow th e lim it .

13 mm (0 .51 in) Limit 19 mm (0.75 in) Standard

I:i:l Brush Replacemen t

M

So lder bru sh lead f irmly .

Fig. 7-29

~

Brush Holder

~

Drive Lever

Check insulation between th e (-l b rush holder and (+l brush holder. Repair or repla ce if con­ tinuity is indi cated .

Fig. 7-30 Inspect the drive lever and sp ring for wear.

Replace if necessary.

STARTING SYSTEM- Starter

7-11

Fig. 7-31

- -

~

Starter Clutch and Pinion Gear 1.

2.

Inspect spline teeth for wear and damage.

Replace if necessary.

Inspect pin ion for smoo t h movement .

~ 3.

Inspect piruon gear teet h and chamfer if w orn or damaged .

~ 4.

Ro t ate p inion.

It shouId turn fr ee in clockw ise di recti on and lock w hen turned co unterclo ckwise .

,

Fig. 7-32

Fig. 7-33

Fig. 7-34

~ ~ r~ I I

I> OI"III ' II' t, 1 1 1 11 1 1 1

'

llllll~~l~;

' 1[ . . - -

;liiW III-+ Return

\

,

,, ,,

I

I

~

Magnetic Switch 1.

Push in p lunger and release it.

Th e p lunger shou ld return quickly to it s original posit ion.

STARTI NG SYSTEM - Starter

7 -1 2 Fig. 7-35

,

~ 2.

Measure di stance from switch mounting surfac e to stud end.

Standard approx. 34 mm (1.34 in) To adjust. loosen the lock nut and screw st ud in or out.

~ 3.

Pull-in coil open circuit test.

Check for con t inuit y betwee n the " 50 " terminal and "C " termi nal.

~ 4.

Hold -in coil open circu it test.

Check for continuity bet ween the "50" terminal and sw itch body .

I~I 5.

I.G. terminal cont in uity test .

Push in plunge r unti l it stops. Check fo r continuity between "30" term inal and lead w ire.

Perform the switch operation test afte r assembl ing it to the motor.

See page 7-17.

I

Fig. 7·36

"e" te rm inal

Fig. 7-37

Fig. 7-38 "IG" term inal I

Push "3 0 ~ ' term inal

STARTI NG SYSTEM - Starter ASSEMBLY Assemble in n umer ical order.

~

I

CD

~o

2

1

y 5 Fig. 7-44

7 Fig. 7-45 Fig. 7-4 6 Fig_ 7-47 Fig. 7-48

~,

=

11

109

8

Fig. 7-50 Fig. 7-49

1

Cente r Bearing

2

Clutch with Pini on Gea r

3

Sto p Colla r

4

Sna p Ring

5

Armature and Drive Lever

6

Drive Lever Bolt

7

Yo ke with Brush Holder

8

Commu ta tor End Frame

9

Loc k Plate

10

Bear ing Cover

11

Bolt

12

Magne ti c Sw itch

Fig. 7-39

12 Fig. 7-51

6

3 4

F ig. 7-40 Fig. 7-41 Fig. 7-42 Fig. 7-43

7-13

7-14

STARTING SYSTEM - Sta rt er

Fig. 7-40 , . . ., Fit snap r ing in to shaft groove.

Fig. 7-41 , . . ., Compress th e snap r ing w ith a vi se.

Fig. 7·42

.r ::l T ap pi n ion t o slid e the st op co llar onto snap ~ rin g.

.&.

Fig. 7-43 Sto p Co llar

Sna p R ing

Make su re that th e snap r ing fi ts correct ly .

STARTING SYSTEM - Starter

.&

Fig. 7-44

7- 15

Assemble drive lever in di recti on as shown.

Fig. 7-45

B

A lign the dowe l w ith hol es of cent er bearing suppo rt and d rive end housing.

. .....

.: .

.

'

'

: r.'.

Fig. 7-46

['Xl A ssemb le br ushes, being carefu l not to damage

00 them.

-

Fig. 7-47

.&

A fte r installation , position the holder as shown.

7 -16

STARTING SYSTEM - Starte r

Fig. 7-48

&

Check that the (+) w ires are not grounded . · Fie ld co il · Brush (+) leads · T hrough bo lts

Fig. 7-49 Insta ll the lock plate and measure the armature shaft thrust clearance. If clearance exceeds t he specif ied value , correct by in creasing th e number of shims.

Thrust clearance 0.05-0.35 mm (0.002-0.0138 in) 0.5 mm (0.02 in) Adjusting shim thickness

Fig. 7-50 Inst all end frame cap not mo re than half ful l of grease.

Fig. 7·51

EJ

Hook the magneti c swi tch join t on the drive lever spri ng from the lower side.

STARTI NG SYSTEM - Starter

7-17

PERFORMANCE TEST - Precaution These tests must be performed in short ti me (3·5 seconds) to prevent the coil from burning.

Disconnect the field coil lead from "C" terminal.

Check t he magnet ic sw itch perf ormance and pinion gap as fo llows:

Fig. 7-52

~ 1.

Pul l-in test Con nect magnet ic switch to battery as show n. (ns qati ve side t o " C" ter mina l and sw i tc h body; po sitive side to " 50" termi ­ nal). If the pin ion has defi nitely ju mped out, the pul l-in coi l is sati sf act or y .

~ 2.

Ho ld-in test Nex t discon nect the " C" termina l.

The pinion shou ld remain in jumped-out cond it ion.

~ 3.

Check the p lunger return .

When di sconnecting the sw itch body , t he pinion sho u ld retu rn quickl y .

Fig. 7·53

Fig. 7-54

7-18

STARTING SYSTEM - Starter

,-

Fig. 7-55

I

......

~4.

Check the pinion clearance.

(1) Conn ect the magneti c swit ch to battery as shown.

Fi eld coi l lead to "C" termi n al Battery negative side t o body Bat tery posi tive side t o 50 term inal

~

(2)

Move the p ini on to armatu re side t o elim inate th e slack , and check the clearance between th e pini on end and sto p collar.

Standard clearance 0 .2-4.0 mm (0.008-0 .16 in)

(3)

A dju st if necessary after loosening lock nut.

Clearance Stud Too large .. Screw in Too small .. Screw out

Fig. 7-56

s

•

Fig. 7-57

Fig. 7-58

~5.

No-load perf ormance test Connect the fi eld co il lead to th e " C" ter mi nal, makin g su re t hat the lead wi re is not grounded .

Connect sta rter to battery . If th e starter shows smoot h and steady ro t ation wi th the pin ion jumping out and draws less than specif ied current, it is satisfacto ry.

Specified current 50 A Less than

IGNITION SYSTEM Page

IGNITION SYSTEM CIRCUITS

. 8- 2

DISTRIBUTOR (Except For USA)

. 8- 4

DISASSEM BL Y INSPECTION & REPAIR ASSEIVIBLY ADJUSTMENT

DISTRI BUTOR (For USA)

. . . .

·

···

··..·

8- 4 8- 6 8-10 8-12

.. 8-13

DISASSEMBLY .

INSPECTION & REPAIR .

ASSEMBLY •................ .......................................... ..

ADJUSTMENT ; ..

INSTALLATION .

8-13 8-15 8-19 8-21 8-23

IGNITION COIL

8-24

HIGH TENSION CORD

8-25

SPARK PLUG

8-26

IGNITER

8-27

IGNITION SYSTEM - Ignition Syst em Circuits

8-2

IGNITION SYSTEM CIRCUITS

=~

~~ == ~ ~

=~

=~ ~~ := ~

--

~ ~I

- --~ =-­

Fig.8·'

Distri butor

Igni tion Switch

-

"T

Ignition Coil

I I I

-L

I Fig. 8-2

~ W;;/)/I/}J/$;/$)//§;;'

IGNITION SYSTEM - Ignition System Circuits

Fig. 8-3

From Starter External resistor-------, +JTerminal

Distributor

,.

I

...L.

1 Fig. 8-4

8-3

8-4

IGNITION SYSTEM - Distributor (Except For USA)

DISTRIBUTOR (Except For USA) DISASSEMBLY D isassemb le in nu merical order.

1

~ ~ -!__

I

~

3

~~

5

4

~

6

[~

7

2 - - -~~-::-~ -­ C.

~ Gil ~~

~ -

.>

@~., ~-:~~----~

~\jj- (01~

Fig. 8-5

1

Cap. Rotor and Cover

2

Terminal

3 4

Breaker Points Vacuum Advancer

5

Breaker Plate

6 7

Cam Springs and Weights

IGI\IITION SYSTEM - Distributor (Except For USA)

} •

~~

Breaker Plate Stationary Plate

~ ~-Cl---'l-----Adjusting Washer '£\ _

Steel Ball-- - -- - - 0

Breaker Plate Spring

~~~

Snap R ing

~ •

Steel Washer

~

Bakelite Washer Steel Washer

if)

~ -

Governor Shaft

'i

i,

i

~

~

~ •

C ~--~-

"0" ring

(9) •

St eel Washer

cQ;l -

Bakel ite Washe r­

~ •

Steel Washer

~~ .

Fig. 8-6

Housing

G", Pin

8-5

8-6

IGNITION SYSTEM - Dist ributor (Except For USA)

Fig. 8-7

~

INSPECTION & REPAIR Cap Inspect fo r cracks , carbon tracks, bu rnt or cor roded terminals, and check center conta ct for wear .

Fig. 8-8

~

Rotor Inspect f or cracks, carb on tra cks, burn t or corro ded termina ls.

Fig.8-9

~

Breaker Plate Check breaker plate for smooth rotation.

Fig. 8-10

~

Governor Weights and Pin Check t he f itt ing portions of governor wei ghts w it h support pins for binding .

IGNITION SYSTEM - Dist ributo r (Excep t For USA)

8 -7

Fig.8-11

Vacuum Advancer Diaphragm

~

Suck the tube with mouth . sho uld move.

~

Inspect cam for wear, damage, and fit betw een cam and shaft.

The diaphragm

Fig. 8-12

Cam and Shah

Fig. 8-13

~

Governor Shah and Housing 1.

Check shaft th rust clearance.

Thrust clearance 0.15-0.5 mm (0.006-0.020 in)

Fig. 8-14

,.... 1 2.

Remov e gear and pin .

Grind off the pin end , th en remove the pin and gear.

8-8

IGNITION SYSTEM - Dist ributor (Exce pt Fo r USA)

Fig. 8-15

~ 3.

Inspect govern or damage.

~ 4.

Inspect hou sing bushing s, and ring for wear, defo rmation, and damage.

shaft

fo r

wear

and

Fig. 8-16

a

Fig. 8-17

5

A ssemb le washers in order as shown.

6

Assembl e washers and gear in ord er as shown and check thrust clear ance. If it exceeds specif ied value, ad just the clearance w ith steel washer.

1. . . 1 .

Fig. 8-18

1".1

.

6-8

(VSn J0 :J l da oX3 ) JOl nqplS! O - lN31.SAS NOll.IN81

8~10

IGNITION SYSTEM - Distributor (Except For USA)

ASSEMBLY Assemble in numer ical or der.

7

!

(

5 -~~~-

4

3-

-

-

-

-

­

2

~

1

[0#'~ ~

~('1l'i\\"'"

Fig. 8-22

6

~--<~

r..>.~®®l~ .>

~~~

-, , '

~

~;: _ '_ ~ T

f:P

Fig. 8-20

» >: "

~

c::::®

-

lr'-~=

IS

\ l;:'­'

1

Springs and Weight s

2 3 4

Cam Breaker Plate Va cuum Adv ancer

5

Breaker Points

6 7

Terminal Cove r, Rotor and Cap

IGNITION SYSTEM - Distributo r (Except For USA)

Bre aker Plate

) •

~

~ J •

Station ary Plate

j Steel Ball--- - - -

';;:,,) _ ( ~~

Adjusting Washer Breaker Plate Spring

•

Snap ring

~1

Steel Washer

~ _

Bakelite Washe r

L ~J

•

Steel Washer

~J-

Governo r Shaft

,

t

j

~

:1 •

Hou sing

C:)­

" 0 " ring

•

©:I

Bakelite Washer

~-

Steel Washer

~ ~.

-

Fig. 8-21

Steel Wash er

~..

G~, Pin

8-11

8-12

IGNITION SYSTEM - Dist ribu tor (Except Fo r USA)

Fig. 8-22

r::::l In stall governor sp ri ngs in direction as show n. ~

ADJUSTMENT

Fig. 8-23

Install breaker poin ts and adju st th e gap.

Point gap 0.45 mm (0.018 in)

Fig. 8-24 Set the oc tane selecto r at stand ard lin e.

Fig. 8·25

~

~

Check breaker p late f or smoo th rot ati on . Suck the tu be w ith mou th .

T he breaker pl ate shou ld mo ve.

For installation. refer t o page 8-23.

IGNITION SYSTEM - Distributor (For USA)

DISTRIBUTOR (For USA) DISASSEMBL Y Disassemb le in numeri cal order.

~

J ~

~

~

s

~

<3tl

7

~

fit

~

8

5

Q fj}

2

Fig. 8-26

-

1

CaP. Rotor and Cover

2

Terminal

3

Breaker Points and Cover

4

Damping Spr ing

5

Vacuum Retarder

6

Breaker Plate

7

Spring and Weights

8

Cam

8-13

8-14

IGNITION SYSTEM - Distributor (For USA)

Steel Washer -~ Bakelite Washer------------~Steel Washer

• (LJll) ~J

- L

Governor Shaft

] ::

~;'

Hou sing--- - - - - ­

,..-- "0·· ring

~

Pin

~

Steel Washer Bakelite Washer

tS-

•

©)

• ~

Steel Washer

~ .

Gear

~

_

£'fJ

Fig. 8-27

IGNITION SYSTEM - Di st ri buto r (For U.SA) Fig. 8-28

~

8-15

INSPECTION & REPAIR Cap Inspec t for cracks, carbon tra cks, burnt or corro d ed term in als, and check center contact for wea r.

Fig. 8-29

~

Rotor Inspect for cr acks, carb on tra cks, burnt o r corroded term in als.

Fig. 8-30

~

Breaker Plate Check b reaker p late fo r smoo th r otat ion .

Fig. 8-31

~

Governor Weights Inspect govern or we ights fo r dam age.

8-16

IGNITION SYSTEM - Distributor (For USA)

Fig. 8-32

~

Governor Weights and Pin Check the f i tt ing portion s of governor weights w ith support pins for binding.

Fig. 8-33

~

Vacuum Retarder Diaphragm Suck the tube with mouth. should move.

The diaphragm

Fig. 8-34

~

Cam and Shah

~

Governor Shah and Housing

I nspect cam fo r wear , damage, and fi t between cam and shaft.

Fig. 8-35 1.

Check shaft thru st clearance.

Thrust clearance 0.15-0.5 mm (0.006-0.020 in)

IGNITION SYSTEM - D istrib uto r (Fo r USA)

1""1

2 .

8-17

Remove gear and pin Grind off the pin end, th en remo ve th e pin and gear .

Fig. 8-37

~ 3.

Inspect governor damage.

~ 4.

Inspect ho using bushings, and 0 ring fo r wear , deformat io n, and damage.

1""1

A ssemble w ashers in orde r as show n.

shaft

for

wear

and

Fig. 8-38

Fill. 8-39 5.

8-18

IGNITION SYSTEM - Distributor (For USA)

Fig. 8-40

j·.. 1

6 .

Assemb le washers and gear in order as shown and check thr ust clearance. If it exceeds specified value , adjust t he clearance wi th steel washer .

Fig. 8-41 7.

Peen both pi n ends wi t h a vise.

IGNITION SYSTEM - Dist ributor (For USA)

8-19

ASSEMBLY A ssemb le in num erical orde r.

8

I

5

I

(fW~~

, e~7~

~

~~ - -~---' ~ ~:---

3

-----~

2 1';'· 8-45

I

Fig. 8-44

.~

(j!J

s

-hlli

~ <51>

Q

6

4

~ fj)

7---------:::---:

Fig. 8-42

1

Cam

2

Springs and Weigh ts

3

Breaker plate

4

Vacuum retarder

5

Breaker Points and Cover

6

Damping Spring

7

Terminal

B

Cove r. Rotor and Cap

8-20

IGNITION SYSTEM - Distributor (For USA)

~

56

Steel Washer Bakelite Washer

•

Steel Washer

.. (t.-JIJ)

Governor Shaft

~

,

] ;-

Housing

Steel Washel

.. il

•

Steel Washer

Gear

~

• ~

Bakelite Washer

•

..

C9

@j _

fFJ

~

Fig. 8-43

Pin -

IGNITION SYSTEM - Di stribu tor (F,or USA)

8-21

Fig. 8-44

&

Match 15 mark w ith stopper. fit on t he cam and tighten w ith screw .

E1

A ssembl e govern or weights and lock w i th E ring .

Install governor spr ings.

Fig. 8-45

Fig. 8·46

ADJUSTMENT Install breaker points and adjust the gap.

Point gap 0.45 mm (0.018 in)

Fig. 8-47 Install dam ping spri ng and adjust it .

Damping spring gap 0.1-0.4 mm 10.004-0.016 in)

8-22

IGNITION SYSTEM - Distributor (For USA)

Fig. 8-48

~

Check breaker pl ate fo r smoo th rot ati on.

Suck the tu be w ith mou th. The breaker p late shou ld move.

IGNITION SYSTEM - Di stributor (For USA) Fig. 8-49

8-23

INSTALLATION 1.

Set No . 1 cy linder" to 7° BTD C/ com­ pressio n. A li gn the ti m ing ball with poi nter. A t this ti me, rocker arms on NO.1 cy linder sho uld be loo se and rockers on NO. 6 shoul d be tigh t.

2.

Set the o il pu mp shaft slo t in d irect ion as shown.

3.

Begin insertion o f d ist rib u to r wi t h d ia­ ph ragm and rotor po int ing the posit ion as show n.

When f ull y instal led, ro to r shoul d po int to ward th e bolt (arro w).

Rotate dis­ tributor b ody to th e posi tion w here the po int s are j ust opening.

4.

Check igniti on t im ing in idl ing cond it ion.

For adjus tment, turn d ist rib utor body and align ti m ing ball w ith po in ter .

Fig. 8-50

Fig. 8-52

Make su re that th ere is oi l pressu re at engine ru nni ng.

8-24

IGNITION SYSTEM - Ignition Coil

IGNITION COIL INSPECTION

Fig. 8-53

~

1.

2.

Clean the coi l and inspect it for carbon path s around th e term inals, and check the outside body f or cracks.

Inspect th e high t ension cord insert ion hol e for carbon deposit or corro sion.

Fig. 8-54

~ 3.

Measure the foll owing resistances.

If th e reading is not w ith in th e specif ied resistance, repl ace coil.

Primary coil resistance (Reference only) WID resistor type 2.6-4.0Q wI resistor type 1.3-1.6Q

Fig. 8-55

~

Secondary coil resistance (Reference only) WID resistor type 6.0-9.0kQ WI resistor type 9.5-14.5kQ

~

External resistor resistance (Reference only) 1.3-1.7 Q

Fig. 8-56

IGNITION SYSTEM - High Tension Cord

8-25

Fig. 8-57

Insulation resistance Over 10MQ at 500V

Fig. 8-58

& ~~~t~n~EN510N CORD 1.

Fig. 8-59 Bad Good

Fig. 8-60

&2.

Remove carefully high tension cords by pulling the rubber boot.

Do not bend cords so as to conductor from broken.

INSPECTION

--

I ...

~

1.

Check the cond i tion of the cord termina l.

If any termi nal is corroded, clean it, and if it is broken or di storted, replace the cor d.

8-26

IGNITION SYSTEM - Spark Plug

Fig. 8-61

~ 2.

Check the resistance of each cord between both ends. If th e read ing exceeds the lim it , rep lace the cord .

Resistance

Less than 25 kS1

SPARK PLUG

Fig. 8·62

~

INSPECTION In spect for the fol lowing it ems. Clean or replac e plug s if necessary.

1.

Crack s or damages in the threads or insu lator .

2.

Damaged or det eriorated gasket s.

Fig. 8·63

~ ~:

Wear on the elect rodes.

Burnt cond it ion of electrode and amount of carb on deposit.

GAP ADJUSTM ENT

Fig. 8-64

,/

Check the plug gap w ith plug gap gauge.

If not to specif ied value , adjust by bending the ground (outer) elect rode.

Spark plug gap 0.8 mm (0 .031 in) 1.0 mm (0.039 in) for USA

IGNITION SYSTEM -

Ignit er

8-27

IGNITER INSPECTION

Fig. 8-65

[SJ

,

Fig. 8-66

1.

Inspect ign ition coi I resis tance befo rehand .

Refor to Ignit ion Coil section.

~ ~:

Turn the ignition key to ON position.

Check if t here is battery vol tage at resistor termina l as shown .

12V -GOOD If not Check ignition switch or wir ing harness.

~ 4.

Disconnect primary ignition wire and h igh tension cord fr om dis t rib utor.

Keep th e cord end to gro und d istance about 5 mm (0 .2 in) .

~

" O N"

CD Fig. 8-67

~

j

5.

Fig. 8-68

~6.

j

7.

Make pr imary ignition wire ON-O FF con tacts wi th grou nd .

Check if sp ark is pr odu ced at t his ti me.

Spark is produced Igniter is satisfactory.

Spark is not producedIgniter is unsatisfactory..

011\1311\1

CHARGING SYSTEM Page

CHARGING SYSTEM CIRCUITS

9- 2

ON-VEHICLE INSPECTION

g- 4

ALTERNATOR (Conventional Type)

9- 9 9- 9 9-12 9-15

DISASSEMBLY INSPECTION AND REPAIR ASSEMBLY

,

ALTERNATOR (Heavy Duty Type)

9-21

ALTERNATOR (With Vacuum Pump Type)

9-29

ALTERNATOR REGULATOR

9-37 9-37

INSPECTION AND ADJUSTMENT

9-2

CHARGING SYSTEM - Charging System Circuits

CHARGING SYSTEM CIRCUITS

<, Engine Fuse 15A

Fig. 9-1

[~gUlato~

~l ternatoJ

Engine Fuse Ignition Switch Resistor

I'~;CO;' Ammeter I I

Fusible

link

T

I I

L~_

Rotor Coil

·

I

I~

Voltage Regulator Coil

Fig. 9-2

I I -L

1

CHARGI NG SYSTEM - Charg ing Syst em Circuits

9-3

Ign iti on Swi tc h Sid e

A C C~A M IG~ ST Heate r F use 20A

Fig. 9-3

[!~ rn~o~

~~ u la~~ Cha rge Warn ing Light Resistor

8 Rect ifier Type On ly

)

\~""'-----] I

I

Fus ibl e Lin k

T

, ,J'r ,

)

/

, ,(

R el ay Coi l

Fig. 9-4

II

.-L /

9-4

CHARG II\lG SYSTEM - Chargi ng Syst em Circu its

ON-VEHICLE INSPECTION

Fig. 9-5

~

Inspect system components as fol lows.

1.

Drive belt tension

Fig. 9-6

~ 2.

Fu ses Engin e fu se Heater fuse

~ 3.

Instal led condition of wi ri ng for alternator and regulator.

~ 4.

Batte ry ter m inal and fus ibl e lin k.

Loose Corroded Burn t

15A 20A

Fig. 9-7

Fig. 9-8

CHARGING SYSTEM - On-Vehicle'Tnspect io n

9-5

Fig. 9-9

~ 5.

AI ternato r on-vehicle condi t ion Ab no rma l noi se from al ternato r w hen engi ne is running.

~ 6.

Specifi c grav ity

Fig. 9-10

Fig. 9-11

~

1.25-1 .27

PERFORMAI\ICE TEST 'JSING VOLT· METER AND AMMETER Con nect voltmeter and ammeter as illust rated, and swi tc h off all accessory parts .

Fig. 9-12

14

IS

~I v

20

A

~

No -load Performance test Regulated voltage Current Engine speed

13.8 ~ 14.8 V Less than 10 A Idling to 2000 rpm.

CHARG.~NG SYSTEM - On-Veh icle

9 -6

Inspect ion

Fig. 9-13

1D ~

A

Load Performance test 1.

2.

Crank th e engine w ith igni tion co il h igh tension cord d iscon nected for abou t 5 to 10 second s.

Turn on head lights and accessor ies.

~tff!!

Fig. 9-14

~ 3.

2

'" J~ "

~

~

~ \) 20 30

12 V More than 30 A

PERFORMANCE TEST BY AL TERNA­ TOR CHECKER

Fig. 9-15

~,

/ ..._ .~

~ V

">y

~~~1

~ ~2~-:IDJ I

l~

St art engine, and run it at approximate ly

2000 rpm .

Regulated voltage Current

• -~

1.

Unplu g the al ternator regu lator con nector and p lug in th e checker connecto r.

Push "20 V" switch .

'= .

::>

Fig. 9-16

~ 2.

fa

~ B_ N

IQ 'y III I TI F

Check " B " term inal vo lt age.

Push " B" sw i tch.

Raise engine speed f ro m idl ing to 2000 rpm .

Stand ard voltage 13.8 to 14.8 V

CHARGING SYSTEM - On-VehiCfe l1ns'pp.eti o n 9 - 7 Fig. 9-17

S_N_F

~ 3.

Check "F " term inal voltage.

Push "F" sw itc h.

Graduall y raise engine speed. TI'e checker reading should gradually decrease from 12 volt to 3 volt.

~4.

Check " N" term inal voltag e.

Push "N" swi tch.

Maintain engine speed at approx . 1500 rpm . The po inter should be at a half of " S" terminal voltage .

,8"i\J

O

Fig. 9-18

~ -/~S o~o..

10

.

,

"

. .

.

Fig. 9-19

ALTERNATOR INSPECTION

~

1.

Negative side rectifier sho r t test.

Connect an ohmmeter (-) lead to terminal and (+) lead to E ter min al.

Met er should indic ate inf ini t y.

N

Fig, 9-20

~ 2.

:

--:0­

B

Posit ive side rectifi er short test.

Connect an ohmmeter (-) lead to S terminal and (+) lead to E term inal.

Meter sho uld indi cate infinity.

9-8

CHARGING SYSTEM - On-Veh icle Inspecti on

Fig. 9-21

~ 3.

Check rotor coiI resistance.

~ 4.

Turn ignit ion sw itch to ON posit ion, and check if there is battery voltage at F termi nal. If not, check ENG I NE fu se.

Resistance 5-9 S1

Fig. 9-22

CHARGING SYSTEM - Alternator (Conventional Type)

9-9

ALTERNATOR (Conventional Type) DISASSEMBLY Disassemb le in numeri cal or der .

2

5

3

Fig. 9 -26

Fig. 9-23

1

Drive End Frame A ssembly

2

Pulley and Fan

3

Rotor

4

Rear Bearing

5

Front Bearing

4 Fig. 9-27

aJ!M peal Japlo H 4 sn J8 Japl oH Ja!!!paH pu e Jap lOH 4sn J8 Japl OH J9!!!lJ9H pue I!O:) JOl el S

6 8 L 9

6

.'

----­.. ----------r'113r--~ ~- -(@ . . '

.---1 9

I

(adA.L IIWopualluoJ) JOll?UJa1l'it -

1N3.lSAS DN JDl:IV'H::l

Ol-6

CHARGING SYSTEM - A lter nato r (Conventional Type)

9- 11

Fig. 9-25

El

Pry dri ve end f rame from stator .

Do no t pry co il w ires.

El

Remove rotor fro m dri ve end fram e using a press.

El

Remove rotor shaft rear beari ng using SST [09286-460 11] .

El

Remove brush holder assembly using a 10 mm socket wrench and vi se.

Fig. 9-26

..

Fig. ~27

Fig. 9-28

r AIlE9W

9-12

CHARGING SYSTEM - A lternato r (Con ventional T yp e) INSPECTION AND REPAIR

Fig. 9-29

~

Rotor 1.

Open circ uit t est

Standard resistance

4.1-4 .3 ,Q

Fig. 9-30

~ 2,

Gro und t est Meter sho uld ind icate infin ity.

~ 3.

Check slip r ing for being dirty or b urnt.

Fig. 9-31

Fig. 9-32

~

Bear ing Check bear ing for wear or roughn ess.

CHARGING SYSTEM - Alternator (Conventional T y pe)

9-13

Fig. 9-33

~

Stator 1.

Open circuit test Test all f our leads for cont inui ty.

Fig. 9-34

~ 2.

Ground t est.

Met er sho uld indi cate infinity.

Fig. 9-35

Brush and Brush Holder

~

Check exposed brush length.

Minimum exposed length

B

When replacing brushes, assemb le them as shown .

Exposed length 12.5 mm (0.49 in)

5.5mm (0.22 in)

Fig. 9-36

9-14

CHARGING SYSTEM - Alternator (Conventional Type)

~

Rectifier 1.

Rectifier holder posi ti ve side Connect an ohmmeter (+ ) lead t o the rectifie r holde r, and the (-) lead of the meter to the rectifi er terminal. If th ere is no cont inui ty, recti fier assemb ly must be rep laced.

Fig. 9-38

~

Reverse po larity of test leads and check If th ere is cont inuity , rect ifier again. assemb ly must be replaced.

~ 2.

Rectifier holder negati ve side Connect an ohmmeter (+) lead to the rect if ier termi nal, and th e (- ) lead of t he meter to the rect if ier hol der. If th ere is no cont inuit y , rectifi er assemb ly must be replaced.

~

Reverse pol arit y of test leads and check If there is con t inuit y, rectifier again. assemb ly must be repl aced

Fig. 9-39

o

Fig. 9-40

CHARGING SYSTEM - Alternator (Conventional Type) ASSEMBLY Asse mb le in nu meri cal ord er.

2 Fig. 9-45

Fig. 9-43 Fig. 9-44

Fig. 9-46

3 Fig. 9-47 Fig. 9-48

~

; -- -- -@ ~

J

j

-@

Fig. 9-41

1

Lead Wire

2

Brush Holder

3

Brush Holder and Rectifier Holder

4

Stator. Coil and Rect ifier Holder

~

,-@ ®ll

4 Fig. 9-49 Fig. 9·50

9-15

CHARGING SYSTEM - Alternator (Conventional Type)

9-16

8

6

7

Fig. 9-55

Fig. 9-53

Fig . 9-54

5

F ig. 9-51 Fig. 9-52

9 Fig . 9-56 F ig. 9-57

Fig. 9-42

5

Rear Bearing

6

Front Bearing

7

Rotor

8 9

Pulley and Fan Drive End Frame Assembly

CHARGING SYSTEM - A ltern ator (Conv entional Type)

9-17

Fig. 9-43

'• •1 Solder negativ e side rectifiers.

8 Re c ti fier Type

Fig. 9·44

EJ 6 Rect ifier Type

Fig. 9-45

EJ

In sert insul ator between posi tive recti fier ho lder and brush hold er.

EJ

Install bru sh holder on to rectifier holder using socket wren ch and a vise.

9 -18

CHARGING SYSTEM - Alt ernat or (Conve ntion al T y pe)

Fig. 9-47

&

Connect stator coi l "N" lead onto (+ ) rectifier ter m in al and brush holder terminal.

(8 Rectifier Typel

&

Conn ect st at or coi I "N" lead onto bru sh hol der term inal, and solder each stator lead and rectifier lead to positive rect ifier .

B

Assemb le rear end fram e and rectifier ho lder with insulators.

8 Rec ti fi er T y pe

Fig. 9-48

6 Rectifi er T ype

Fig. 9-49

In sulator

Fig. 9-50

....

EJ In sul ato r

Assemb le rear end cover wi th insulators.

CHARGING SYSTEM -

A

Fig. 9-51

Alternator (Conventional Type)

9-19

Install rear beari ng facing it s sea led side for w ard .

Fig. 9-52

B

Press rear beari ng onto rot or shaft, using a p ress.

Fig. 9-53

A

Instal l t he fr ont bearing fa cing its sealed side rearw ard .

Fig. 9-54

B I :'

'S ST

Press drive end fr ame assemb ly onto rot or shaft, using SST [0932 5-12010] .

9-20 Fig. 9-55

CHARGING SYSTEM - Alte rnator (Conventional Type)

rm

Tighten nut to spec ifie d tor que.

Torque 5-6.5 kq-rn (36-47 f t-Ib]

Fig. 9-56

&

Push in brush es and temporar ily lock in pla ce w ith wi re in serted th rough access hole in end frame.

Position lead wire s to clear rotor .

~

Rem ove lock ing wire fr om the rear end fra me and make sure th e rotor rotates sm ooth ly .

Fig. 9-57

CHARGING SYSTEM - Alternator (Heavy Duty Type)

ALTERNATOR (Heavy Duty Type) DISASSEMBL Y Disassemble in numeri cal order.

1 Fig. 9-60

2

4

3

Fig . 9-61

Fig, 9-58

1 2

Drive End Frame Assembly Pulley and Fan

3

Rotor

4

Front Bea ring

9 -21

9-22

CHARGING SYSTEM - Alternator (Heavy Duty Ty pe)

7

l~

@P I€ ) ..0

5

8 F ig. 9· 62

6

®::=;;" @I

9

Fig. 9-59

5

Sta to r Coi l

6

Bru sh Hol de r

7

T erm in al Socket

8

Rear Beari ng

9

Posit iv e Rect ifier

CHARGING SYSTEM - Alternato r (Heavy Duty Type)

9-23

Fig. 9-60

El

Pry d r ive end f rame from stato r.

Do not pry coil wires.

El

Remov e rotor from dr ive end fram e using a press.

Fig. 9-61

Fig. 9-62

r::l Tap ou t rear bearing . using a socket wrench. ~

INSPECTION

Fig. 9-63

h'l

~

Check brus h length and replace if be low the l im it.

Standard 18.5 mm (0.73 in) Limit 8 mm (0.31 in) For ot her ite ms. see INSPECTIO N secti on of Convent io nal Ty pe Alte rnator.

9 -24

CHA~II\IG SYSTEM -

Alt ernato r (Heavy Duty Type)

ASSEMBLY Assemble in numeri cal ord er.

0\

3

1

Fig. 9-68

Fig. 9-6 6

4 Fig. 9-69

Fig. 9-64­

1

Front Bear ing

2

Rotor

3

Pulley and Fan

4

Positive Rect ifier

2 F ig. 9-6 7

1,

CHARGI NG SYSTEM - Alternator (Heavy D I.:V Type)

\

...

------5 Fig. 9 -71

0j)8®®®

I

7

6

Fig . 9-72

10 Fig . 9 ·75

Fig. 9 -70

Fig. 9-76 Fig. 9-77

~~)(6\ ~ ~® ~

9

8

Fig . 9-73 Fig . 9-74

5

Term inal Socket

6

Brush Holder

7

Stator Coil

8

Drive End Frame A ssembly

9

Rear Bearing

l O B Terminal Insulators

Fig. 9-65

9-25

9-26

CHARGING SYSTEM - Al ternato r (Heavy Dut y Type)

Fig. 9-66

&

Install front bearing rearward .

facing it s sealed side

E1

Press drive end frame assemb ly o nt o shaf t, using SST [09325-120 10J.

lm

T igh ten nut to specif ied torq ue.

Torque 3.5-8 kg-m {25-58 ft-Ibl

E1

Inser t in sul ato rs between h older and end frame .

Fig. 9-67

..... -

·58:1

Fig. 9-68

Fig. 9-69 positive rectifier

CHARGING SYSTEM - Alternator (Heavy Duty Type)

9-27

Fig. 9-70 Steel Washer Negat ive Side Brush InsulatoY

~~

B

Assemb le brush holder with insu lat ors onto rear end fr ame as show n.

Have th e bru shes lifted up.

B

Insert th e " F" , "N" and "E" lead termin als into th e connecter socket as show n.

B

Connect stator co il leads onto posi tive and negative side recti fier ter m inals.

Fig. 9-71 ~

l!:

Fig. 9-72

Fig. 9-73

r::l Install rear bearin g, f acing its sea led side front. ~

• 9 -28

CHARGING SYSTEM - Alternato r (Heavy Duty T vps ]

Fig. 9-74

EJ

Fig. 9-75

Fig. 9-76

Fig. 9-77

-,­

Instal l rear bearing cover not more than half fu II o f grease.

r::1 Assemb le insu lators onto B terminal bolt. ~

r::1 Lower brushes and hold with springs. ~

11fI51 Make sure t he rotor rotates smooth ly.

• CHARGING SYSTEM - Alternator (With V acuum Pump Type)

ALTERNATOR (With Vacuum Pump Type) DISASSEMBL Y Disassembl e in numeri cal order.

1 Fig. 9-80

L

-- - 1

i1ll=

©JC~;»>)))) M),

3 Fig. 9-81 Fig. 9 -82

Fig. 9-78

4

1

Vacuum Pump

Fig . 9-83

5

2

Rear End Fr ame

Fig. 9-84

3

Pulley and Fan

4

Lock Nut

5

Roto r

9-29

6up e8S l UOJ:l lO>pOS pue J8PIOH 4 snJS JaploH J8!I!lJ8tj 41!M I!O:> JOlelS

8 L 9

8

(adAl. dwnd wnn~el\ 41!M) JOleuJallV - W3.LSAS DI\IIDHVHJ

O£-6

CHARGING SYSTEM - Alt ernato r (With Vacuum Pump Type)

9 -31

Fig. 9-80

EJ

Lightl y tap the vacuum pump w it h a p lastic hamme r to remove it.

Fig. 9-81

~__

Secure SST [09841- 560 10]

in a vise, and

J;:;l secure th e rotor core onto the SST. ..., CJ

- Note Take care not to damage the stator coil.

Loosen pulley nut.

Fig. 9-82

~ -

SST

EJ

Remove pulley w ith f an, using SST [09950· 200 10] .

EJ

Remove bearing lock nu t.

The lock nut has left-hand thread .

Fig. 9·83

~

Loosen

CHARGING SYSTEM - Alternator (With Vacuum Pump Typ el

9-32 Fig. 9-84

:;::::::=­

i ..

El

Remove rotor w it h SST [09950-20010] .

Take care no t to damage the stat or co il.

8

D isconn ect stator co il " N " lead f rom bru sh holder, and remo ve stat or coi l w ith rect ifi er

SS T

INSPECTION

Fig. 9-86

~

..

FOR OTHER ITEMS, SEE INSPECTION SECTION OF CONVENTIONAL TYPE Al TERNATOR .

ho lders.

Inspect oil seal and bearing .

Measure vacuum pum p bearing bore and if exceeds limit, replace vacu um pu mp asse mb ly.

Bore limit 16.14 mm (0.6354 in) Standard 16.04-16.06 mm (0.6315-0.6323 in)

CHARGING SYSTEM - Alternator (With Vacuum Pump Type)

9-33

ASSEMBLY Assemble in num eri cal order.

r 2

I

Fig. 9-89 (,I

C)

lOll

r-;: ~=

@

=(QJ @

1

3

Fig. 9 -90 Fig. 9 -91 Fig. 9 -92

Q \\,; 1

6

Fig . 9-95

5

4 Fig. 9-93

F ig. 9-94 1

Fron t Bear ing

2 3 4 5

Bru sh Holder and Socket

6

Fig. 9-87

Stator Coil with Rect i fier Holder Rotor Loc k Nut Pulley and Fan

,

1

_

dwnd wnn:>e/\

8

aweJ:l p U 3 Jea~

L

- -- - --, I

(adA.L dwnd Wnn::lB/\ 41lM) -lOlBU-lalIV -

1A13LSAS ~NI~H::I'v'H~

v£ -6

CHARG ING SYSTEM - Alternator (With Vacuum Pump Type)

9-35

Fig. 9-89

EJ

Fig. 9-90

Tie th e lead wire s and solder th e "F" t erminal onto t he brush holder.

Connect " E" terminal.

r::l Solder rect ifier lead s onto stator coil. ~

Fig. ~91

EJ

Assemb le th e rectifi er holders and stato r co il with insulat ors onto t he d rive end fr ame.

Position insulators between B term inal and d rive end fram e, th en in stall B term inal bolt.

EJ

Solder the stator coi I "N" lead and socket " N " lead on to bru sh holder.

9-36 Fig. 9-93

CHARGING SYSTEM - Alternator (With Vacuum Pump Type)

.&.

Lift up b rushes and lock wi th a w ire.

Fig. 9-94

~

Fig. 9-95

rm

Tigh t en bear ing lock nut.

Torque

5.6-8 kg-m {41-58 ft-Ib}

- NoteLock nut has left-hand thread.

Take care not to damage the stator coil.

Tighten pulley nut.

Torque

3.5-8 kg-m (25-58 ft-Ib)

Fig. 9-96

El

A lign th e vacuum pump ro tor splin e hole against the rear cover hol e and th en f it in th e alt ernator rot or shaft spli ne.

CHARGING SYSTEM - Alte rnat o r Regulato r

9-37

ALTERNATOR REGU LATOR Cha rge Wa rn ing Lamp T ype

Am met er Ty p e

INSPECTION AND ADJUSTMENT

Fig. 9-97

~

,/

-

Check connecto r fitti ng inspect ing regulator.

cond ition

before

,

Fig. 9-98

11 RlSI A lways be sure to have the regulator connector

U-

pulled ou t w hen in specting and adju sting.

9-38

CHARGING SYSTEM -

Alternator Regulator

Fig. 9-99

~

Inspect each point surface for burn or excessive damage. Replace if defective.

Fig. 9-100 Voltage adjustment To adjust, bend the voltage regulator adjusting arm.

13.8-14.8V Regulated voltage

Fig-101

Fig. 102 Voltage relay adjustment Check the actuating voltage of voltage relay and adjust if faulty.

4.5-5.8 V Relay actuating voltage (Reference only)

CHARGING SYSTEM - Alternator Regulator

9-39

Fig. 9·103

~

Resistance measurement between terminals.

Charge warn ing light t y pe.

IG-F At rest OD Voltage Regulatorl Pull ed in approx . 11D

I

Fig. 9·104

I~ I,L E Volt age Relay

I

At rest

---:::--aD

Pull ed in app rox . 100D

E

L

Fig. 9-105

At rest

infinity

Pull ed in approx. lOaD

E

Fig. 9-106

~ B-L Voltage Relay

At rest Pull ed in

B

infinity

on

•

9 -40

CHARGING SYSTEM - Alternator Regulator

Fig. 9-107

~ N-E approx . 25D.

E

N

Fig. 9-108

~

Ammeter type

IG- F At rest

OD.

Pulled in approx. 11 D.

Fig. 9-109

~

IG- E At rest

appro x. 100 D.

Pulled in

infinity

E

Fig. 9-110

[jD] F -Ei~--::--_ A t rest

Pulled in

appro x. 100 D.

aD.

9

SST & SPECIFICATIONS Page

SST (SPECIAL SERVICE TOOL)

10-2

STANDARD SOLT TIGHTENING TORQUE

10-4

MAIN PARTS TIGHTENING TORQUE

10-5

ENGINE SPECIFICATIONS

10-5,

SERVICE SPECiFiCATIONS

10-6,

-

10-2

SST & SPECIFICATIONS - SST

SST (SPECIAL SERVICE TOOL) lllustratioa

Tool Number

~ '---I

09081-00010

Alternator Checker

09201-60011

Valve Stem Guide Remover & Replacer

09202-43011

Valve Spring Compressor

09213·60015

Crankshaft Pulley & Gear Puller

09214·60010

Crankshaft Pulley & Gear Replacer

09215-60010

Camshaft Bearing Remover & Replacer

Gdll;~"""g" " ,,,"~g

09222-30010

Connecting Rod Bushing Remover & Replacer

~

09223-60010

Crankshaft Rear Oil Seal Replacer

~

09228-44010

Oil Filter Wrench

~

09235-60010

Water Pump Pulley Seat Puller

~

09236-36010

Water Pump Overhaul Tool (For Fluid Coupling Service)

,

OWfI

,

~r-:tJrt~ ~

<»0:=-

SF>

~

gil

~

~

a .,;·."",, · ~

~

D~

I , ~

~~~

Tool Name

SST & SPECIFICATIONS - SST

Illustration

Tool Number

Tool Narm

ewz:z;~

09238-40010

Water Pump Bearing Remover & Replacer

S£~

09240-00011

Carburetor Adjusting Gauge Set

09286-46011

Injection Pump Spline Shaft Puller (For Alternator Service)

! F~

09303-55010

Input Shaft Front Bearing Puller

ca-;y -e . . ,

09304-47010

Input Shaft Front Bearing Replacer

~

09325-12010

Transmission Oil Plug (For Alternator Service)

~

09515-35010

Rear Wheel Bearing Replacer (For Crankshaft Front Oil Seal Installation)

or-~~

09841-56010

Alternator Stand

--­--

09860-11010

Carburetor Driver Set

Ji:}

09950-20010

Universal Puller (For Alternator Service)

~ ~

~ es:

"

~

~

tW

Jii6

~

10-3

10-4

SST & SPECIFICATIONS - Standard Bolt Tightening To rque

STANDARD BOLT TIGHTENING TORQUE STANDARD BOLT CLASSIFICATION 9 1111-40620

- Part s Number Length of Bolt : 20 mm ~ Basic Major Dia. of Th read. 6 m m Bolt Head Mark* ,. Bol t Head Mark has the follow ing ind ications .

Tl T-

~$-~'

STANDARD BOLT TIGHTENING TORQUE Class

Basic Di a.

Pitch

St andard Tor que kq-m (f t -Ib)

4T

6 8 10 10 12 12 12 13 14 14 16 16

1 1.25 1.25 1.5 1.25 (ISO) 1.5 1.75 1.5 1.5 2 1.5 2

0.47 1.11 2.25 2.14 4.40 3.89 3.74 5.08 6.33 5.93 9.57 9.10

( (

3.4) 8.0) ( 16.3) ( 15.5) ( 3 1.8) ( 28.1) ( 27.0) ( 36.8) ( 45.8) ( 42.8) ( 69.2) ( 65.8)

0.4 to 0.7 1.0 to 1.6 1.9 to 3. 1 1.8 to 3.0 3.5 to 5.5 3.5 to 5.5 3.0 to 5.0 4.5 to 7.0 5.0 to 8.0 4.7 to 7.7 7:5 to 11.0 7.1 to 10.6

2.9 to 7.3 to ( 13.7 to ( 13.0to ( 25 .3 t o ( 25.3 to ( 21.7 to ( 32.5 to ( 36.2 to ( 34.0 to ( 54.2 to ( 51. 3 t o

5T

6 8 10 10 12 12 12 13 14 14 16 16

1 1.25 1.25 1.5 1.25 (ISO ) 1.5 1.75 1.5 1.5 2 1.5 2

0.71 1.66 3.34 3.22 6.60 5.84 5.6 1 7.63 8.90 9.50 14.36 13.58

( 5. 1) ( 12.0) ( 24. 1) ( 23.3 ) ( 47 .7) ( 42.2) ( 40.6) ( 55.2) ( 65.3 ) ( 68.7) (103.8) ( 98. 1)

0.6 to 0.9 1.5 to 2.2 3.0 to 4.5 2 .7 to 4.2 5.0 to 8.0 5.0 to 7.0 4.8 to 6.8 6.5 to 9.0 7.5 to 11.0 7.0 to 10.5 12.0 to 17.0 11.5 to 16.5

( 4.4 to 6.5) ( 10.9 to 15.9) ( 2 1.7 to 32.5) ( 19.5 to 30.4) ( 36.2 to 57.8) ( 36.2 to 50.6) ( 34.7 to . 49.2 ) ( 47 .0 to 65.1) ( 54.2 to 79.6) ( 50.6 t o 75.9 ) ( 86.8 to 123.0) ( 83 .2 t o 119.2)

7T

6 8 10 10 12 12 12 13 14 14 16 16

1 1.25 1.25 1.5 1.25 1.5 1.75 1.5 1.5 2 1.5 2

0.95 2.2 1 4.49 4.29 8.80 7.78 7.4 8 10.17 12.67 11.86 19.1 5 18.11

( 6.9) ( 16.1) ( 32.5) ( 3 1.0 ) ( 63.5) ( 56.2) ( 54.1) ( 73.5) ( 9 1.6) ( 85.8 ) (138.5 ) ( 131.0)

0.8 to 1.2 2.0 to 3.0 4.0 to 5. 5 3.7 to 5.2 7.5 to 10.5 7.0 to 9 .0 6.0 to 8 .5 8.0 t o 12.0 10.0 t o 15.0 9.5 to 14.0 15.0 to 23 .0 14.0 to 22 .0

5.8 to 8.6) ( 14.5 to 2 1.7) ( 28.9 to 39.8) ( 26.8 to 37.6) ( 54. 1 to 75.8 ) ( 50.6 to 65.1 ) ( 43.3 to 61.4 ) ( 57.8 to 86.8) ( 72.3 to 108.5) ( 68.7 to 101.2) (108.5 to 166.2 ) (101.2 to 159. 0)

To rq ue Limit kq-rn (tt-lb) ( (

5.0) 11.6) 22.4) 21.7) 39.8) 39.8) 36.2) 50.6) 57.8) 55.7) 79.6) 76.7 )

(

- NoteThe above specified tightening torque is applicable only for female threads cut into a steel material.

If the female threads are cut in other materials than steel, and also tightening surfaces are encountered to heat or vibrations, these specified tightening torques must be reconsidered.

SST & SPECIFICATIONS - Main Parts Tig htening Tor que

10-5

MAIN PARTS TIGHTENING TORQUE Tightening Torque

kg-m (tt-Ib)

Cylinder head bolt

11.5-13.5

( 83- 98)

Manifold

3.9-5.1

( 28- 37)

Camshaft thrust plate

1- 1.6

(

Crankshaft pulley

16- 20

(116-145)

Piston pi n

5.4- 7

( 39- 5 1)

Connecting rod cap

4.8-7.6

( 35- 55)

No. 1-No.3

12.5-1 5

( 90-108)

No . 4

10.5-1 3

( 76-

94)

5.7-7.3

( 4 1-

53 )

Tighten ing Parts

Crankshaft bearing cap

Fly wh eel

ENGINE SPECIFICATIONS Engine model

2F

Type

6-cy linder, in-line, 4 cy cle, OHV

Bore and stroke

94 x 101 .6 mm (3.70 x 4.00 in)

Displacement

4230 cc (257 .9 cu.in )

Compression ratio

7.8 to 1

Fi ring order

1- 5- 3- 6-2-4

7- 12)

.

10-6

SST & SPECIFICATIONS - Service Specifications

SERVICE SPEC~FICATIONS ENGINE TUNE-UP Drive belt >ension at 10 kg (22 lb) Fa'l pulley - Alternator Fan pulley - Air pump (USA) Alternator belt (USA)

mm (in) 7 7 13 -

Battery speci fic gravity

10 (0.28 - 0.39) 10 (0.28 - 0.39) 15 (0.51 - 0.59)

1.25 -

Coolant capacit y FA FJ Engine oil capacit y Total Crankcase Recommended spark pi ug Conventional type Resistive type For USA

1.27

Liter appro x. 25.5 appro x. 17

US gal.

6.7 4.5

Imp . gal.

5.6 3.7

Liter 8 7

US qt.

8.5 7.4

Imp. qt.

7.0 6.2

(NO) W14EP W14EPR W14EX

(NGK) B5ES BR5ES BP5EZ

Spark plug gap

mm (in)

Dwell angle Di stributor poi nt gap Condenser capacity

mm (in) pF

39 - 43° 0.45 (0.018) 0.22 (Except for USA)

mm (in) Intake Exhaust

0.20 (0.008) 0.35 (.0.014)

Valve clearance (Hot)

7°BTDC

Ignition timing at idling Initial id Ie speed at TIM in N Manifold vacuum at idling Fast idle TP setting speed Compression pressure at 200 rpm

0.8 (0.031) 1.0 (0.039) ..... For USA

rpm mmHg (inHg) rpm rpm kg/cm 2 (psi) STD Limit

650 ± 50 420 (16.5) 1800 1200

10.5 (149 .3) 8.0 (113 .8)

SST & SPECIFICATIONS - Service Specifications CYLINDER HEAD Head surf ace w arpage lim it

mm (in)

Valve seat con tacti ng width

0.15 (0.0059) 45°

Valve seat cont acti ng surface angle mm (in ) Intake

1.4 (0.05 5)

Exhaust

1.7 (0.067)

VALVE GUIDE BUSHING mm (in) Length

Inner di amet er

Intake

54 (2.13)

Exh aust

59 (2.32 )

Both intake and exhaust

8.0 1- 8.03 (0.3154-0.3161)

17 (0.67)

Pro ject io n d istance

VALVE mm (in)

Valv e head di amet er

Inta ke Exh aust

Stem oil clearance

St em o il clearance lim it

Margin limit

37.5 (1.48) 45°

Valve face angle Stem diameter

46 (1.81 )

Intake

7.97-7.98 5 (0.3138-0. 3144)

Exh aust

7.96-7 .975 (0.3134-0. 3140)

Inta ke

0.03-0.06 (0.0012-0.0024)

Exh aust

0.04 -0.07 (0.001 6-0.0028)

Intake

0.10 (0.0039)

Exh aust

0.12 (0.0047)

Intake

0.8 (0.031)

Exh aust

1.0 (0.039 ) 0.5 (0.020)

Valve t ip cor recti ng l imit

VALVE SPRING Free height

m m (in)

51. 5 (2.0 28)

I nstalled height

mm (in)

43.0 (1.69 3)

In stalled load

k g (lb l

32.5 (71.6)

Installed load limit

kg (Ib )

27 (59 .5)

Squareness li mit

m m (in )

2.0 (0.079)

10-7

10-8

SST & SPECIFICATIONS - Servi ce Speci f icat ion s

ROCKER ARM AND SHAFT

mm (in)

Rocker sh af t diameter

18.479-18.495 (0.7275-0.7281)

Shaft to arm clearance

0 .01-0.04 (0.0004- 0.00 16)

MANIFOLD

mm (in )

2 .0 (0.08)

Manifold surfa ce warpage limit

TIMING GEAR

mm (in)

Backl ash

0.05-0.13 (0.0020-0.0051 )

Back lash lim it

0 .2 (0.008 )

CAMSHAFT

mm (in)

T hrust clearance

0.09-0.15 (0.0035-0.005 9)

Thrust clearance limi t

0.2 (0.008)

Journal oil clearance

0.025-0 .075 (0.0010-0 .00 30) 0.15 (0.0059)

Camshaft runout limit Camshaft journ al diameter

(STD) Front

47.955-47 .975 (1.88 80 -1. 88 88 )

Second

46.455- 46.475 (1.82 89-1.8297 )

Third

44.955-44.975 (1.7699- 1.7707)

Rear

43.455-43.475 (1.7108-1 .7116) 0.25

Camshaft U/S bearing s Cam lobe height

Cam lobe height limit

Intake

38.36-38.46 (1.5102-1 .5 142)

Exhaust

38.25-38 .35 (1.5059-1 .5098 )

Int ake

38 .0 (1.496)

Exhaust

37 .9 (1 .492)

CYLINDER BLOCK Cy linder bore diameter

0.50

mm (in ) (STD)

94 .00-94.05 (3.7008-3 .7027)

Cylinder bo re wear limit

0.2 (0.00 8)

Gasket surfa ce warp age lim it

0.15 (0 .0059)

SST & SPECI FICATlOI\IS - Service Speci fi catio ns PISTON AND RING Pist on dia meter

mm (in ) STD

93.97-94.02 (3.6996-3.70 16)

GIS 0.50

94.46-94.5 1 (3.7 189-3.7209)

GIS 1.00

9 4.9 6-95 .0 1 (3.7386-3.7405)

GI S 1.50

95.46-95 .51 (3.7583-3.76 02) 0.03-0.05 (0.00 12-0.0020)

Piston clearance Piston ring end gap

Top and 2nd

0.20-0.38 (0.0079 -0.0 150)

Top

0.03-0.06 (0.00 12-0.0024)

2nd

0.02-0.06 (0.0008-0.0024)

Piston ri ng to ri ng gro ove clearance

0.008-0.0 12 (0 .0003- 0. 0005)

Piston pi n to pi sto n oil clearance

CONNECTING ROD AND BEARING mm (in) Connecting rod th rust clearan ce

0. 11-0.23 (0.0043-0.009 1)

Connecting rod th rust clearance limit

0.3 (0.0 12)

Beari ng (cr an k pin ) oi l clearance

0.02-0.06 (0.0008-0.0 024)

U/S bearings

0.05

0.25

0.50

CRANKSHAFT AND BEARING mm (i n) Cran kshaft t hrus t clearance

0.06-0.16 (0.0024-0.0063)

Cran kshaft th ru st clearance Ii mi t

0.3 (0.0 12)

Runou t limi t

0.1 (0.004)

Mai n journal oil clearance

0.020-0.044 (0.0008-0.00 17)

Crank pin diameter (ST D )

53.98-54.00 (2.1252-2 .1260)

Main journa l di ameter (STD)

Main journa l U/S bearings

Fro nt

66.972 - 66.996 (2.6367-2.6376)

Second

68.472-68.496 (2.6957-2.6967)

Th ird

69 .972-69.996 (2.754 8-2 .7557)

Rear

7 1.472 - 7 1.496 (2.8 139-2 .8 148) 0.05

0.25

0.50

10-9

SST & SPECI FlCATIONS - Serv ice Specifications

10-10

OIL PUMP mm (in)

I

Gear back lash

0.05-0.07 (0.0020 - 0.0028 1

Gear back lash lim it

0.95 (0.03 74 )

Tip clearance

0.03-0. 11 (0.00 12-0.0043)

T ip clearance limi t

0.2 (0.008)

Side clearance

0.03- 0.09 (0.0012- 0.00 35)

Side clearance limit

0.15 (0.0059 )

Cover w ear lim it Relief valve ope rating pressure

0.15 (0.00591 kg/cm

2

(psi)

RADIATOR

3.5-4.5 (49.8- 64)

kg/ cm 2 (psi)

Cap valve ope n ing pressure

0.9 (12.8)

Cap valve open ing pressure lim it

0.6 (8.5)

FLUID COUPLlI\lG Silico ne oil viscosity

cst

1000

Silicone oi l capacity

cc (cu .in )

35 (2. 1)

Sta rt to open at

°c (F )

82 (180)

Fu lly opens at

°c (oF)

95 (203 )

V alve opening trav el

mm (i n )

8 (0.31)

Disc harge pressure

kq/crrr' (psi I

0 .24-0.34 (3.4-4.8)

Suct io n vacuum

mmH g (inH gl

450 (17.7)

THERMOSTAT Valv e opening temperat ur e

FUEL PUMP

D ischarge capaci ty at engi ne 2000 rpm

Mo re than 2400 cc (146.5 cu. in) /mi n .

SST & SPECIFICATIONS - Serv ice Specificat ions

10-11

CARBURETOR

Carbureto r part number

19100- 61010

19100 ':"'-6 1060

19100-61020

19100-61070

191 00-61030 19100-61050

Float raised posi tion

mm (in)

7.5 (0.295)

Float lowered posit ion

mm (in )

1.1 (0.043)

Prima ry thr ottle valve full open angle

90°

Secondary thrott le valve fu ll open angle

90°

Kick up

28° from bore mm (in )

Fast id le

25° f rom bore

1.3 (0.051 ) 38° f rom bo re

Choke breaker mm (in)

.Throttle posi tione r

Screw out 1Y, turns .

IdIe mi xtu re adjusti ng screw in iti al se tt ing (Reference o nly )

mm (in)

Accelerat ing pump stroke

0.8 (0.031)

STARTER

9.5 (0.374 )

m m (in) 28100-6004 1 , 28 100-60061

Starter part number No load characteristics

Am pere

Less th an 50

RPM

Mo re than 5000

Vol tage Ar mat ure shaft to bushing clearance Li m it

11 0.05 (0.0020) 0.2 (0.008)

Ar mature shaft thrust clearance

0.05 - 0.35 (0.002-0.01 38 )

Brush length

19 (0.75 )

Brush length lim it

13 (0.51)

Commutator runout

Less than 0.0 5 (0.0020)

Commu tato r runou t limit

0.4 (0.016)

Commutator dia meter

32 .7 (1.287)

Commu tator dia meter limit

3 1 (1.22 )

Mica depth

0.5-0.8 (0.020 -0.03 1)

Mica dept h l im it

0.2 (0.008)

Pini on end to stop collar clearance

0.2-4.0 (0.008-0. 16)

Magnet ic swit ch stud length (Reference on ly )

34 (1.34 )

A rmatu re shaf t thr ust adjus ting shim th ickness

0.5 (0.02 )

SST & SPECI FICATIONS - Servic e Speci f ications

10-12

DISTRI BUTOR

mm (in)

Shaf t thru st clearance

o 15- 0.5 (0.006-0.020)

Point gap

0.4 5 (0.0 18)

Dwel l angle

39° - 43°

Damping spring gap

0. 1-0.4 (0.004- 0.0 16)

Advance characteristics Part No. 19100-61010 19100-6 1030 Vacuum advance angle

Vacuu m

mmHg (inHg)

90 -1 10 (3.54-4.33)

Ad vance begins

200 (7.87)

4-6

300 ( 11.8)

7.5-9 .5 rpm

D istr ibu tor

Governor advance angle

Part No . 19100-60090

Advan ce begins

900

8- 10

1600

14-1 6

V acuum

mm Hg (inHgl

Part No . 19 100-610 20 Vacuu m retard angle

Advan ce begins 3-5.6

300 (11.8 )

7.5-9.5 rpm

Dis. advance angle Degree

370-5 30

Advan ce begins

900

8.2-9 .8

1600

11-1 3

Vacuum

mm Hg (in Hg)

Dis. retard angle Degree

80 (3.15)

Retard begins

120 (4.72)

4.0

D istributor

Governo r advance angle

Dis. advance angle Degree

220 (8.66)

Distri but or

Governor advance angle

Dis. advance angle Degree

400 - 500

130-1 70 (5.12 - 6.69) Vacuum advance angle

Di s. advance angle Degress

rpm

Di s. advance angle Degree

490

A dvance begins

900

7.0

1800

15.0

SST & SPECIFICATIONS - Service Specifications

10-13

IGNITION COl L (Reference only) Prima ry coil resist ance

W10 resist or t y pe

2.6 - 4.0 S1

resistor type

1.3-1. 6S1

W10 resistor ty pe

6.0- 9 .0 kS1

WI

9 .5- 14.5 kS1

WI Secondary coi l resist ance

resistor ty pe

External resistor resist ance

1.3-1.7 S1

I nsulati on resistance at 500 V

Over 10 MS1

HIGH TENSION CORD Less th an 25 kS1

End to end resistance

SPARK PLUG mm (in)

Spark pl ug gap

0 .8 (0.03 1) 1.0 (0 .039 ) .. . For USA (NO)

(N GK)

Convent ional ty pe

W14EP

B5E S

For USA

W 14 EX

BP5 EZ

Resistive type

W14EP R

BR5E S

Recomme nded spark plug

ALTERNATOR WlVacuum pump

Conventional Ty pe

Part nu mber Max imu m ou t put

A mp ere

Heavy Duty Type

2702 0­ 600 10

60020

6007 1

600 80

6003 0

60040

40

50

40

40

50

55

Brush exposed length

12.5 mm (0.49 in)

Limit

5.5 mm (0.22 in)

-

-

Br ush lengt h

18.5 mm (0.73 in)

Li mit

8.0 mm (0.31 in)

10-14

SST & SPECIFICATIONS -

ALTERNATOR REGULATOR

Service Specific at ion s

(Reference only) 27700-36010

27700-6008 0

Regu lat ing voltage

13.8- 14.8 V

+-­

Relay operat ing vo ltage

4.0 ­ 5.8 V

-

25n

-

Part number

Vo ita ge relay coiI resistan ce Vo ltage regu lat or coiI resist ance

approx . lOOn

+-­

ReguIat or resistor resistan ce

appro x .

11 n

+-­