Ruice Manual: Jt3, Jt5

RUICE
MANUAL
MODEL
J t 3 ,J t 5 & JI 6 SERIES
ENGINES
.-.
M
!,<.t-
NISSANMOTORCO.,LTD. i
17-1,Ginza6-Chome,
Chuoku,Tokyo104,Japan
,,/({..
?
SERVICE
MANUAT
MODEL
J13, J15 & J16 SERIES
EilGIIIES
NISSANMOTORCO.,LTD.
17l, Ginz8rchorne, Chuoku,Tokyo1Ot,Japan
I
FOREWORD
This servicemanualhasbeen preparedfor the purposeof assistingservicepersonnelof

of the ModelJ 13,
our ilistributorsand dealersin plovidingeffectiveserviceand maintenance
Jl5 and J16 SeriesEngines.
Sinceproper maintenanceand serviceare absolutelyessentialto satisfyour customers,

this lnanual should be read carefully.The following mattersshouldbe noted for effective
utilizationof this manual.
1. Pleaserefer to the following SERVICEMANUALS in addition to this manualfor

complete details of the car, becausethis manual describesthe information
concerningthe Jl3, J15andJl6 SetiesEngines
only.
o and Body
SERVICEMANUAL DatsunPick-upModel620 SeriesChassis
o SERVICEMANUAL Nisen HomerModelT20 SeriesChassisand Body
o and Body
SERVICEMANUAL ModelA32l Se esChassis
) All part namesin this manualconform to the PARTSCATALOGModel620, Model

T20 and Model A321, and only the genuineserviceparts listed in this PARTS
CATALOGmust be usedfor replacements.
3 . AII information, iUustrstionsand specificationscontainedin this manualare based

on the latestproductinformationavailableat the time of publicationapproval
4 . It shouldbe emphasized that thos€who use this manualareresponsible for revising
the contents according to the Service Journal and Se ice Data And Specilications
i$suedby the factory, which cany the latestfactory approvedservicingmethods
and methodsat any time are reserved.
5. Rightsfor alterationof specifications
NISSAN MOTOR CO, LTO

14. Gin2aSchom,ChuokuTokvo1O4,Japan
l
O I9?2 NISSAN MOTOR CO, LTD- Printcdin .ranan
f.".
S E C T I O NC O
cooHNG
MODEL SYSTEM
E1{GilES
SYSTIl'l. . . . .
C00Ll1{G . . . .. c 0I -
sPECtftcATt0t{s c0.0
TRoUELE
0tA0t{0sEs
Al{D
c0Rntcil0ils c0-6
Cooling System
COOLINGSYSTEM
CONTENTS
DESCRPTION co2 l N S P . C t . 0 NA \ D A D . I U S T \ , 4 F. N
. .T. . co4
COOLA\_ LFVEL co-3 TPFRI/OSTAT ........ co4
D F A I N I N GA N D F L U S HN G PI IVOVALA\D INSIAL .A I ION . , , . . co4
-!E
C O O L T NSCY S T E I. V ............. co,3 INSD-CT ON co5
WA_IF OU\,4O co-3 R A D | A T O .q_ . . . co-5
R T \ 4 O V A LA N D I N S A L L A T I O N . . - - . . co3 q C V O V Â l \D lNclAlAl ON ..... co5
DISASS.VB.V A N D A S S \I 4 8 1 Y. . . . , . . co4 I N S PC I O N co-5
DESCRIPTION
The coolingsystemis ofa conven- the cooiing systemat high€r than coolantremainsin ihe cylinderh€ad
tional pressur€type. A cenirifugal atmospheric pressure, andblock for swift warmingup of the
pump,installedon the cylinderblock, The higherpressure raise!lhe boil- engine.After it reachesnomal op"
servesto circulatethe coolant.The ing poini of the coolanttnd incr€ases eratingtemperature, the cooiant ci-
pressuretype radialor filler cap is the coolingefficiencyof the radiator. culatesthroughthe radiator.
installedon the radiatorand operates When the thermostatb closed,th€
nn]$q
coo32
FE. CO 1 CooIinEc$tem
co-2
Cooling System
COOLANTLEVEL DRAININGAND WATER PUMP

The coolant level should be
FLUSHING The waterfu,.npis of a centrifugal
checkedand maintainedabove the THE COOLING SYSTEM type, wtuchis mounredon the cylin-
baffleplateofthe radiatoruppertdnl(. der block. The fan and pulley ar€
To drain the cooling systemj re- bolted at the pulleyhub. The punp
Caution:To avoid s€riousperconal move radiator crp, releasedfain cock shaftis sulpo(ed by a doublerow of
injury, neverremoveradiatorcap at the bottom of radirtor and drain ball bearingspressfit.in the pump
quickly*hen engineis hot. Sudden plug on the sid€ of cylinder block. If body. A mechanicals€alis sentedln
releaseofcoolingsyst€mpressureis the henter system is instailed, set ihe wat€r pump body betwe€nthe
heaier temperature control !'dve to van€andbearingassembly.
n it is necessryto removeradiator olen position. After the coollnt is The pun! containsan impellerthai
capwhen radiatoris hot, turn the drain€d completely, close drain cock turnson a steelshaftwhich rotdiesin
capslowlycounterclock\rise to the Theinl€t of the pump
the bal bearing.
and plug and refill the sysl€m with
first stop. After a[ pr€ssurcin the is connectedto the radiator'slower
coolingsystemis r€leased, turn cap
passing the stopandremoYe it.
-n€
.Dl
@)
&V
tl
."A
1 BeadnSarsembly
2 Mechrnicalseal
3 Vlne
4 Lock wne
5 Pulleynub
6 covcr
7 Fan Fuuey
Iig. CO-2 Etploded deu of uater pump
REMOVAL AND lnstallatlon

IiISTALLATION 1. Be sureto clern the gaskelsur-
purnp.
.+. Rcnove pump assembly faccsin contactwilh pumpand cylin-
Removal andgas-
der b1ock.Always use new gasket
kci from cylindclblock.
l. Drain coolantcompletelyinto a wheninsl lingpurnpassenbly.
waterpump,
Note: Prior to remoYing 2. Aftcr insiallingpump assembly,
2. Loosenbelt, andihen renovefan cl€an the cooling system with fiI1coolingsystemdnd checktbr leaks
bladeandpu11ey
fron hub. MSSAN CSC (Cooling System
inlet hosefrom wxtcr
3. Disconnect Cleanet. 3. Instal fan pulley and fan blade.
c03
Cooling System
and tighten fixing bolts securely. 5, Remove mechanicalseal f;onl 4. Inspectmechanical

sealfor wear
4. lnstal fan belt and adjust for purnpbody. or damage-
Assembly Adiu5tmcnt
DISASSEMBLY AND l. Instal bearine assembiyinto Fan belt shouidbe kcpt adjusted
pump body by appllng pressureto prop€rly at ali times. A tight belt
ASSE'{ELY
outerrace,afterfitting mechanical
seal causeswear of alternaiorand water
1
DbaBselnbly into pump body. Be sureto usenew pump bearings.A loose belt brings
sealwhenassembling wat€rpump. about jmproperoperationof coolirg
1. Removecoverand gas,kets from 2. Insert lock wire into the groove fan,waterpurnpandof aiternator.
purnpbody. of bearingthough th€ slit of punp Checkthe frn belt slackbetween
2. Removehub by usinga puller.ln body to fix bearingassembly. alternatorand fan puley by a forceof
this case,be carcfulnot to damage 3. Install vane on shaft of bearing 10ks (221b).
cast-iron
hub. assembly by usinga pressso that the
3, Carefullyremovecast-ironvane of fanbelt:
Slackn€ss
correctclearancc betweenthevanetip
by usinga puiler. 8 to 12nm (0.31to 0.47in)
and pump body is obraineda! show.
4. Pull out lock wire with a screw' in FigureCO-3, lf adjustrnentis necessary,Ioosen
driver,and then take off bearingas- 4. Instal hub on shalt of bearins boli retainingalternatoradjustjngbar
s€mblyfrom pump body by usinga assembly by usinga pressso that the to altefirato.,Movealiernatorioward
pres9, distancebetweenlhe surfaces of pul- or awayfrom engineuntil ihe conect
Note: Be sure to align b€aringass€m- I€y hub and pump coverbecomes the tensionis obtained.
bly with a pressarbor, holding specifiedvalue as shown in Figure
pump body in a viseso as not to CO-3.This is very importantfor the
dunagepumpair€mbly. fanbelt operation.
THERMOSTAT
A wax lellet type thermostatis
90.3to 90.7'in mountedin th€ th€rmoslathousingat
(3,56lo 3.5?in)
the cylinde!headoul1el.
The functioningof the thermostat
is to control ihe flow of coolant,
fscilitatingfast enginewarmup and
regulatingcoolant lemperaiure,The
ihermostaiis designedto open and
closeat predetermined temperatules
and,if not operalingproperly,should
be removedand testedas described
(0.016to 0.024in)
REMOVALAND
INSTALLAIION
1. Draincoolantpartialy.
FiC.CO3 Sectionaluieuofudtet pump 2. Disconnecitop hose at water
ouUei.
INSPECTIONAND Note: Bearingass€mbly is of a pe.ma- 3. Loosen two securingbolts and
ADJUSTMENI nent seal€dand lubricatedtype and then removewater outlei, gasketand
must not be washed in cleaning themoslat from thermostathousing.
InBpcctlon 4. After checkingtherno'stat,re,
instal with a new housinggasketin
Ifany of the followingconditionsis 2. Inspeci respective component p1ace.
found, replacedefectiveparts with partsfor cracks,or€xcessiyewear. 5. Reinstallthermostat,gaskeiand
newones. 3. Inspect bearing assernblyfor wateroutletand tbentightensecuring
1. Washa[ partsexceptfor bearing roughness or excessiv€
endplay.Clean bolts.
assemblyand rubber sealingpads in off rust or scaleon the shaft or outer 6. Replenishcoolantand checkfor
raceof b€aJing assembly. leaks.
co,4
Cooling Systdm
INSPECIION
A stigked thefnostat wil prevert water soc (9oF) abovetfie tempera-
tlrc cooling system from functioning ture specified
in the folowingtable.
properly. If tl1e tlEmostat stick in 2. Put a mark on a screwdriverat
th€ open position,the enginewarms about8 n'Jn(0.3150in) from the tip,
up very slowly. [f the thermostat and checkthe lift of valv€by inserting
sticks in the closed position,over- thisscrewdver.
heating will rerult. Therefore,the 3. Now, placeihermostatin water
tlEmostat should be inspectedfor 5oC (9oF) below the specifiedtem-
perature.Under the abovecondition,
valvesshouldbe closedcompletely. FE. CO-4l4spectingthetu@tdt
1. Submerge thermostat in hot
If ihemostat doesnot operateat
the above specifiedtemperature,it
mustbe replaced
because it cannot be
repaireal.
Standard For tropicalareas
Vatveopeningtemperature 82'C(180.F) 88'C (190'F) (l?0oF)

76.5oC
above8 mm at 95oC above8 mm at l00oc above8 mm at 90oC
Maximumvalvelift
(0.31sin at 2030F) (0.315in ai 212oF) (0.315in at l94oF)
Note: It is nec$saryto checka new

theftostat before imtalling it in NETUOVALAI{D
the engine. INSTALLAIION
l. Drain coolani completelyinlo a
RADIATOR cleancontainer.
Theradiatoris a conventional down 2. Disconnectradiatortop andbot"
flow typ€ havingthe top andbottom
tar*s to disiributethe coolantflow 3. Removeradiator retainingboltt
uniforrnlythroughthe verticallube of and then removeradiatordownward
radiaiorcore. (the ModelsT20 andA32l) or upward
Theradiatorfiller capis designedto (theModel520).
maintain a pre"set pressure [0.9 4. Instel radiator in the reverse
kg/cm, (13 psi)l aboveatmospheric sequenceof removal.
pressure,The reliefvalveconsisting of
a blow-off and vacuumvaive,helps
preventcoolsnt from boiling by giving Also, inspect radiator for water
pressureto it, On the contrary,when INSPECTION leakag€using the cap tester at a
the pressure is reducedbelowatrnos- Radjatorcapshouldbe ch€cked for pressureof 1.6kg/cm2(22.8psi).
pheric presswe,vscuumvalvealows working prersureat reSulartune-up
air to re-enterinto the radiatorpre- intervd. First, checkrubber sealon
ventingthe formationof Yacuumin cap for tear, cracksor deierioration
the coolingsystem. after cleaningit. Then,installradiator
capon a tester.Ifcapdoesnoi holdor
will not releaseat the specifiedpr€s-
fie- CO 7
If $e above defect is detected,

repaL or replace radiator.
co-5
Co0ling System
SPECIFICATIONS
Model T20 620 L32l
Engine Jl6 Jl3& Jl5 Jl3& Jl5
Dmensiofl of core 330x446x49 33Ox446 x 32 300x488x49

(Height x Width x Thickne$) rnn (in) ( 1 3 . 0 x 1 7 . 6 x 1 . 9 )( 1 3 . 0 x 1 7 . 6 x 1 . 3 )( 1 1 . 8 x 1 9 . 2 x 1 . 9 )
ed tin andtu
Capworkingpresure kg/cm, (psi) 0.9(13)

pressure
Testing ks/cm?(pst 1.6(23)
watercaPacity liters 5 . 5( 1X , 1 X ) s.4(t%,t%) 6 . 3( t % , t % )
(u.S.sal.,Imper.sal.) ' 7 . 2( l
6.s (2 %, I N) 6.0(tX,t%) %,1 %)
Fanouterdia. [mm (in)] x No. ofblades 3a0(ll.a) z a 310(t2.2\x 4 340(13.4)

x4
AND CORRECTIONS
TROUBLEDIAGNOSES
Condition Correclive
action
Lossofwater Damagedradiatorseams, Repah.

wearin waterpump,
Excessive Replace.
of heaterhoses.
Lesksat connections Repair.
Leakat wat€ftemperaturegauge, Tighten.
Loosejoint!. Tighi€n.
Defectiverubberhoses. Replace.
D€f€ciiv€cylinderheadgasket. Replace.
dndrefill
Checkengineoil for contamination
cylinderblock.
Cracked Replace.
Pull out and seeengineoil levelgaugeto
checkfor waterin crankcase.
Crackedcylinderhead. Replace.
Loosecyiinderh€adbolts. TiBhten.
Overheating Defeciiv€thermostat. Replace.

Radiaiorfins chokedwiti mud, clEff, elc. Cleanout air passage
thorougllyby utingair
preslurefrom the enginesideofthe radirtor.
Incorrectignitionandvalveliming.
Dirty oil anddudgein engine. Refill.
waterpump.
Inoperative Replace.
Looselan belt. Adjust.
radiator.
Restricted Flushradiator.
Inaccurate gauge.
t€mperature Replace.
knpurityin water. Usesoftcleanlvater.
Cooling Systgm
co,7
MODEL
Et{Gt1{ES
EngineElectricalSystem
STARTINGCIRCUIT
The electricalsystemk a 12 volt Startingmotor Infomation on body electrical

sFtem. This sectionis subdividedinto systemssuch as lighting, instrum€nt,
the following subsectionsfor el€ctrical R€gulator and windshield wipers is deecribedin
parts which are required for engine Dstributor s€ction BODY ELECTRICAL in
opention. Ignitioncoil CIIASSISANP BODY.
. Battery Sparkplug
BATTERY
CONTENTS
RE\,4OVAL AND II\STALLATIO\ ,, ,, Ea-2 B A T T E R YF R E E Z I N G.. EE.3
RETVOV . .A
. .L. . . . . . . EE.2 ADJUSTING S P E C I F I CF A V I T Y, . . , , . . , , , E E - 4
G
\STALLATION EE.2 C H A R G TCNTGR C U. .T. T. . . . . . . . . . . . . . . . . . . E
. E.4
ELECTROLY LE TE V EC L H E C,<, , , , , , , , TROUELEDIAGNOSES AND
S P E C TG
FRTC ATVYC H E C < . . . . . . . . . . EE-3 conREcTtoNs ....... EE-s
REMOVALAl{D
Itt|STALLATIOt{ ffi J=l=
@
l_r
REMOVAL
l Disconnect
tarminals.
andposltlve
negative
2. Renovenutsfiombatteryclamp;
#@
+
tal(eout clamps,
1r
3. R€move battery.
tI{sTAttAiflo
l. Install and tighten clamps 3€.
curely.
2. After clampshavebeen tightened,
cleanbattery cableterminalsand ap"
ply gr€as€ to retard formation of fig. EE-1 l$pecting electrolrte le@l
corrorion.
ELECTROLYTE
LEVEL CHECK
Ch€ck the electrolyte level in each l. Unscr€weachfiller aap and in,
battery cell onc€a month. spectfluid level,which canbe deter
mined by glancing into the cap
In caseof batterywitl fluid level
openings.SeeFigure EEI
lines, check to se€that the level is
Determine asshownbelow:
betweenthe upper and the lower lev€l
lines. Fig. EE-2 lupecAry electrclrte leuel
(uith te@l tines)
EE.2
Engine Electrical System
lf the fluid levelis low, and distiled A corr€ction can ther be madeby The state of chargeof battery can
water for each cell to raise the level usingthe following formula: be determinedby the following tabl€s
approximately l0 to 20 nm (0.394to Sro = St + 0.0007(t 20) if the specificgravity of electrolyte is
0.787 in) sbovethe plates.ln cale of knorvn.Beforechecking,checkto be
battery with l€vel lines, add distilled S?o: Specific gravity ofelectrolyte sure tbat cells are filled to correct
$ater to the upper level. Do not correctedat 20oc (68oF) lev€1.
overfill. St: Specificgravity of electrolyte
at toc
t: Electrolytetemperature
.O
For example; A hydrometerreading 3
of 1.260 at 30oC (86oF) would be C
1267 whencorrected at 20oC(68oF), g
indicating fully clnrged battery. On L
SPECIFICGRAVITY the other hand,a hydrometerreading
ol 1.220at -IooC (14oF) would be
CHECK 1.199whencorrected at 20oC(680F),
Ee002
FiE.EE-4 Relationbetueenspecific
Specificgra ty of batteryelectro_ indicatinga partiallychargedbattery. Ertoitr ond chotRinq condition
lyte is testedby a hydrometer.
l. When measuring speclficgravlty,
place your eyes in line with scaleto
readhighestlevel(elecholytedsesat
edgedueto surfacetension)ofeleclro..
lyte. SeeFigureBB-3. Conv.ttcdspscificgrdlty (S20)
sNffi
l-\ <t-h
E
[<
iL-F
iL-F
-'i
s
'6
-'j
:l ih-h
-u
--1=-l'--
L- tL
0
ffi
f"(T-l
1l 2a Ja "-ii --fr
Elecilolyk temprEtu,. roC)
FiE-EE-, ChanAesof Epecific ercuity in rcsponse to
electrolrte t?mp.tutur..hohg. (oC)
Fig-EE-3 CheckingspecificErcvity
2. If the stateofchargeof batieryis
607, full, or specific-gravityreadingis
below 1.20 las correctedat 20oC
(68oF)l, batieryrnustbe recharged or
batteryalectrolyte concentration must BATTERY FREEZING battery is completelydischargcdand
be adjusted. wili freezer€adilywhentemperatures
Add or subtractgravitypointsac' Temperatures at whichbatteryelec- fall below freezingpoint. SeeFigure
cording to lrihether t}e electrolyte trolyte l-reezesvary with acid con- EE{.
temperatureis aboveor below20oC centrationor its specilicgravity.A
(68"F) standard. battery vrith an insufficient state of
The gravity of electrolyt€ changes chargewil freezeat low temperatures. Note: Us€ extrerne caution to avoid
0.0007 for every l"C (33.8oF)ten- If specificgravity of a battery fails freezingbattery sinceit will usualy
below1.100,th€ indicationir tlat the ruin the battsy.
0 CHARGINGCIRCUIT
iEi!*-
- -i0 Baitery must be rechargedwhen
i -zo
tiiijh standard €lectroh/te.gravity reading
falls belorv 1.200wiih electrolj,'televel
E being satisfactory.If battery is quick-
& . ^
'6 chargedto bring it up to fuu charge,
-40 \
F ''{}} th€ operation should be cafiied out
with negativeterminal rcmoved.
I
!
-50
*ft\ Prior to charging,corroded termi
nals should be cleanedwith a brush
E -50 'ti\ and commonbaking-soda solution.In
E fi addition, the following items should
?i
-80 $f be oblervedduringrechaqingbatteryi
t . 0 0 L o 4 1 . 0 8 l . l 2 1 . 1 61 . 7 0 1 . 2 41 . 2 81 . 3 2 l. Be surethat elecirolytel6vel ls
Specific giady of electrolyo abovetop of eachplate.
2. K€ep removedplu$ in a safe
I'ig. EE.6 lrcezinc point ofelectrclyte location.
AD'U6II1{G SPECIIIC 3. Do noi allow electrolytetem-
perahrre togo over45oC(1l30F).
GRAVITY Whenlower,adddilutedsulphurlcacid 4. After recharging,check to be
Besureto checkelectrolyle speclfic lspecificgravityof which is 1.400at certainthat stsndardspecificgravity
gavity after firlly charglng battery. 20.c(68.F)l. doesnot excoed1.260 ht 20oC(680
Standardsp€cilicgravity b 1.260at Whenadjustin8speclJlcgravily,be F)l . Corr€ctioncsn be madeby add-
20oc (68oF). sure to conv€rtmeasured sp€cific ing disiilledwaierto collsasnecesrary.
Wh€nspecificg.avity i6 higherthan gravityto standard specific gravityat 5, Keep batt€ry away fiom open
the stlndrrd value,add distilled wster, 20oc(68oF). flamewhilolt l!being recharged.
6, After all vent plu$ have been
tlghtened, cleanupperfaceofbattery.
tp.cillc lrlvlty rl.40O
!g 2ao
t; 11
:E 18!
!E l::
€in
i6 go
El *
;F :3
r,?70r.?& r?90!.3o
t,2!J .Un r.?!0r.?60,
1,121
So.cllicrrlvlty llt 2ooc l68oFll
Fig. EE-7 Adjwtins specific gftuitr
EE-4
-TROUBLE DIAGNOSES AND CORRECTIOT{S
Battery is not chargedcorrectly.

l. Correctly adjustbelt tensionof alternatot.
2. Completeconnectionsin charglngsystem.
3. Securelyconnectbatterytelminals.
Lightingloadtest
1. MakeiurethatelectrolytelevellsconeCt.
(wlth ignltionsystemop€n).
2. Clankenginefor tlueeseconds
3. Turn on headlightoow beam)for oneminute,andthenmeasuespecilic
gravityof€achcellofbattery.
Specificgravityof eachcell is lels Specificgroviiy of somecella ia Specificgravityof eachcellIsabove

than1,200. above1.200but the otle$ show 1.20.
l. Wh€nspecific gravitycsnnotbe. lower
sp€cificgravity.
raisedabove1.200by charglng,
thebatteryIr defective.
Unbalance
is within 005 Unbalanceof spedfic gravity be-
l. DischarSedbattery. Charge it tweencellsexceed!005.
lnd repeatllghtingloadt$t. l. B.tteryisdefective.
ld wllhln 005.
Unbalance Unbalanceof speciflcgrevlty be.
l. Baiteryls satisfactory. tw€€nc€lls€rrceeds
0.05.
l. Battery
is defective;
f
Engine ElectricalSystem
STARTINGMOTOR
CONTENTS
D - S C oD r O \ P ] N I O NC A S EB E A R ] N GM E T A L , . , , , . , . E E . 9
OPERATION E E 6 MAGNET1C S W I T C HA S S E M B L Y, . , . , , , , E E 9
c o N st c . .- o \ A S S E I \ 4 B 1 Y . .. .. .. . . . . . . . . . . . . . . . . . . . . E E -9
F.[/OVAI A\D \S-a tA tO\ ... ... T E S T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _E. E .to
D < ^ . ) t t v B t\ PERFOFN4AN TE CS E T. . . _ . . . . . . . . . . . . . . . E E - ] O
c r f a \ ' \ - A \ D \ J P tC t O \ . . . . . . . . . . E E .8 DIAGNOSE O SF T E S T. . . . . . . . . . . . . . . . . . . E E - I O
_FF\4
\A1 .,. EE 8 M A G N E T I CS W T C H A S S E N I B L T YE S T
F t l - L DC O t ' ., EE.IO
... EE 8 S E F V I C ED A T A A N D S P E C I FC A T O N S , , . , E E 1 ]
B R U S H L SA \ D B R J S - AD W R EE.8 S E R V I CDEA T A. . . . . . . . . . . . . . . . . . . . . . . . E E _ 1 1
B D L I C SHP R . \ ' T F N S O \ . . . . . . . . . . E E 8 SPECC I FA T I O N. S_ . . . . . . . . . . . . . . . . . . . . .E E t 2
^ D \ r A T U o a 5 _ t V BY t .TBOUB
..... .. EE.8 LE DIAGNOSES AND
( _u - c - a J 5 : \ 4 8 Y . E E 9 C O R R E COTN S
-fq . . . . . . E E1 3
BRUShHO_DrB ' oc Gqou\D
EE.9
DESCRIPTION energyis suppliedfron thc ba$ery, coil bccomeszefo. The relurn spring
Thefunctionofthe startingsystem, the solcnoidcompletesthe oircuit to then actuatesthe shift lever rvhich
consislingof the battery, ignilion operrte the startingrnotor, and then puilsthe plungcr,andallowsit to opcn
sw'tch,sta(in8 molor and solcnoid,is the motor carricsout the actualcrdnk. the solcnoidswitch conraols.Conse-
to crank the engine.Tbe electrical ingof the enginc. quenlly,thestartingnrotorstops,
a,
@
o
3 Shilt l.vcr
4 Ovclrurning ctutcll
@ @
I Stdtionrry contlct 8 Shill tevel
2 Sericscoil 9 Drivc pinion
FiE. EE-8 Sectionaluiew of startinemotor 3 lAnition switch 10 Rinr scrr
4 Solcnoid 1l linion slccvesprins
5 Shuntcoil 12 Annarurc
OPERATION 6 Plunecr l3 MovableoontdrLr
Whenthe ignition swilchis turned 7 Relurn sprins t4 Brttcry
coil of the solenoid,the nagneric pull
tully clockwiseto the START posi- of thc "shunt" coil beirB sufficient to Fig, EE-g SLartiag molar cncuit
tion! batt€ry current flows through hold thc pinion in mesh aftcr thc
"series" and "shunt"
coils of the shifling has beenperforned- More positjvemcshingand dcrncsh
solenoid.magnetizingthe sol€noid. A f t e r t h e e n g i n es t a r t sr u n D i i g , l h e ing of the pinion and the rins gear
The plungeris pull€dinto the solcnoid d.iver feleasesthe ignition key and it tccth are sccured by mcans of the
so that il operaiesrhc shift ievcr to automatically retuins to the ON posi- overiunning clutch. Thc over-running
move the drive pinion into the fly,
clutch ernploys a shift lcvcr to slide
wheel fing gear.Then the solenojd
This breaks the solenoid circuit so the pinion akrng thc annrt!rc shaft,
switch conracrscloseafr€r the drive
thal revene currcnl flows th.ough th€ into or out of mesh with ihe ringgear
pinion is partially engaged with the serics coil. and the magnetic fi€ld teeth. The over-running clurch is de-
ringgear. builds up in fte direciion in whjch the sgned to transmit driving torque from
Closingof the solcnoidswitchcon- plunger nrovesbnck. As this happcns, the motor armature to rhe ring gear,
tacts causesthe molor to crank the the resullant force of the ma-qnetic but pen it lhc pinion ro ovelrun the
engjneand also cut out rhe'\eries" fields in rhe shunt coil and rhe series a f m a t u r ea f t e r t h e e n g i n eh a ss r l r r e d .
EE-6
CONSTRUCTION
Magnelicswiich terminal
I 6 Piniol' u Shifl lever

2 Bneh t 2 M4neticswitchassembly
3 t3
t4
5 15
EE'63
FE.EE-10Erptodeduieuof ato'iingnotor
REMOVALAND 2, Loosennut used io securecon-

INSTALLATION nectingplste to magneticawitch"M"
Disconnectbatterygroundcable, terminal.R€movetwo scr€ws usedto
L
Dirconnectblack wire wiih yellow secwe magneticswitch, and remove
magneticswitchassembly.
tracerfrom magn€ticswitcht€rminal,
and black batterycablofrom battery
terminal of magjleticswitch.
2. Removetwo bolts securingstart"
ing motor to gear case,Pull starter
a$emblyforwardandrenovestarting
Fie. 8E.13 Renouing rcdr cov.r ond
3. lnstall startingmotor in reverse
DISASSEMBLY 4. Withdrawthe amature assembly

1. Remov€th€ brushcoverandtake and dift lever.
out thebrush.
/\
#
Fig- EE-12 Removingmogneticsaitch
ossemblr
td 3. Removetwo tbroughbolts and

then remove rcar cover and yoke
Fig.EE 11 n assemblyby lighdy tapping with a Fig. EE-i4 RemouingsnLlue
woodenmalletor plasticmallet. dwmblr .nd shift lerer
EE.1
5- Remove pinion stopper from BRUSHSPRINGTEI{SIOI{

amature slaft end. To remove Check brush springtensionby a
stopper,Iirst, push the stopperto springscaleas shownin FigureEE-18.
clurch side. After removingstopper The readingshodd be 0.8 ks 0.81b).
clip, remov€stopp€r togethei with Replacespdngif tensionis lowerthan
over-ruruing clulch. Withdraw ov€F 0.7kg (i.5lb). _
running clutch assemblyfrom arma'
ture shalt.
Fig. EE-16 Conti.uity test of field coil
To.tlng ti.ld ooll tor Stound r

Place one probe of circuit tester
onlo yoke and the other onto field
coil lead(positiv€terminal).
If very litde resistance
is read,field
coilis ground€d. Fig,EE-18 Impectionof brurhsping
Fis.EE-15 RenoulngooeHunni^8 tentton
clutcha$enbly
ARMAIURE ASSEMBLY
CLEANINGAI{D Checkexternalappearanc€
of arna.
tureandcommutator,
II{SPECTION
L M€asurearmaturestlaft fof bend
Cleanall disassembledparts,but do
by a dial gauge.Replacearmature
not use greasedissolving solventsfor
shaft if the bend exceeds0.08 mn
cleanlngover-running clutch,armature (0.c031'n).
assembly,magneticswitch assembly
and field coils llnce such a solv€nt EE170
woulddhsolvegrease packedin clutch
!tE, LL-LI t'rouô tesl ol letd cot
mechanism andwoulddamage coilsor
oth€rinsulaiors,
Check them for excessivedamage Flald coll t.rtcr for short!
or weaf,andreplaceifflecesssry. Unsolderthe connecred portionof
each coil and proceedas mention€d
EEOl9
If a detectivecoil is found, it Fie.88.19 tnipectionof amatwe
TERMI AL stlouldbe replac€d. Bhaftfot b.nd
Check terminal for damage and
wear,andreplaceifnec€ssary. 2. lnspectcommutator.If the sur-
faceof commutatoris rough,it must
BRUSHES AND BRUSH bc sanded lightly with a No.500
LEADWIRE emery cloth. Commuiatormust be
Check the surface condition of ch€ckedalso for outof-round.If tl€
FIELD COIL out4f-round is'more ttan 0.2 mm
brushcontactandwearof brush.If a
Checkfield coil for insulation.If loosecontactis found, it shouldbe (0.0079in), or ihe depthof insulating
the insulationof coil is damagedor replaced. mica is lcssthan 0.2 mn (0.0079in)
worn,il shouldbe r€plac€d. If brush is wom and its lengthis frcrn commulatorsurtace,commuta-
lessthan 9-5 nn (0.374in). r€place. tor (arnalure)shouldbe turn€don a
T..tlng fi.ld Goil for Checkthe connectionof leadclip lathe,so that the out-of-roundis less
conthuity: andleadwire. tllan 0.05 rnm (0.0020in). Insulating
Cornect tlle probe of a circuit Checkbrushholdersandspringclp mica shouldalso be undercutso that
lester or an ohmmeterto field coil to s€ethat they are not d€formedor the depth of it is 0.5 to 0.8 rnm
positive(+) terminaland positive(+) bent, and will properlyhold brushes (0.019? to 003ls in).
brushholder. against the commutator. The wearhnit of commutatordi-
If testershowsno conduction,
iield If brushes or brush holden are ameteris 2 mm (0.0787in). If com-
circuitor coil is open. dirty, theyshouldbe cl€aned. mutatoris beyondrepair,r€place.
EE.8
Engine Electrical$ystem
- Note: It is recornrnendeilto rephce
commutator as an assemblyif wofn
or damag€d.
@@0
Fiet EE"24 O|ettunninA clutch
. ar3enbtr
EE02O
Fie. EE-20 hlspectio| of commutatot
for out.of-tound BRUSI{ HOLDERTES'
FOR GROUI{D
Usinga circuittester,placeonetest
prooe onto negativesidebrushholder
and anotllet onto positive side. If
testershowsconduciiod,brushholder
h shortedto ground.Replacean insu-
latoror brushholder.
EE 0 2 1
Fig. EE-21 Uidercutting insuldting mico
EE172
FiE.EE-26 Grou4.I test of brushhotdel
3. lnspecl solderedconnectionof
amature lead and comrnutator.If PII{IOI{ CA3E BEARIiG
loogeconn€ctionis found, soldertl IIIETAL
usinSrorlnflux, Inrpectbearing
metaifor wearor
4. Armaturetestfor ground side play. lf the cl€arancebetween
Usinga clrcuittester,placeonetest bearingmetal 0nd annstur€shaft is
probe onlo ,rmrture shaft and oth€r morethan0.2 mm (0,0079in), replace
onto eachcommutatorbar, metal. Pressin a new bearingand
If tesler showsconductive,arma- adjustthe cl€{nnce to 0.03 to 0.lO
ture h gfoundedandmustbe replaced. EE023
FiE.EE-23 Armdhte test for
nun (0.0012 to 0.0039 tn). Bearing
metalshouldbe pressed in so that th€
short cicuit
end of the bearingmetalis flushwith
6. Check amature for continuity by
placing probes of tester on two seg_
menh side by side. If tesrer showsno
conduction,the circuil is open.
IIIAGNETIC SWITCH
ASSEMBLY
OVER.RUTI{Il{GCLUTCH Inspectmagnetic switchcontacts.
If
ASSEiIBLY a rough welding is found on the
FE. EE-22 Amatute test forercund
contact,it shouldbe repair€d.
Inspect pinion ,isembly and screw
sleeve.Screwsle€vemust slidefreety
alongarmatur€shaft splines.If damage ASSEMBLY
is foud or resistanceis felt when Reassemble startingmotor in re-
5. Check armature for short by sliding,it must be repaired.Inspect versesequence of disassembly.
placingit on armatufeterierGrowler) pinion teeth If excessive bbing is wlen assenbling, be sureto apply
with a piece of iron over armature found on teeth,it $ould be replaced. greaseto gear case and r€ar cover
core, rotaiing armature.If the plate Flywheel ring gear also must be in- bearingnetal, andapplyoil to pinion
vibmtes,armatureis shorted. sligltly.
EnginerElectricalSystem
TEST be determined.A bri€f outline of th€ 3. Low current draw and low no'
test is givenbelow. load speedwould causehigh internal
resistance due to loose conneclions,
PERFORMANCETEST defectiveleads,dirty connutator and
tloJo.d teit
Startingmotof shouldbe subjected causeslistedon itern2-(3)-
. Connect stailing motof in series
to a "noload" lest wheneverit has with specified (12 volrs) battefy and
been overhauledto ensurcthat its an ammeter capable of indicating
performance will be salisfactorywhen
I ,000 amperes.
installedon engine. Starting motor Specified current draw and revolu-
shouldalsobe subjected to testwhen tion in this test is shown in
"speci-
the causc of abnornal operation is to
MAGNETIC SWITCH
ASSEMBLY TEST
v.llN.1$ A ri'rrr
[ig. EE-27 Circuitofmagneticsuitch
osemblyt6t
li the slarting molor check is
"OK," checkmagneticswitchassem-
Fig.EE-26 No-loadt$l bly. Connoctcablesbctwe€n"nega-
live" battery terminaland starting
motor "M" terminal,"posiiive" bar
DIAGNOSES OF TEST 2. Failurcto opcralcwith highcuF
tery terminal!nd startingmotor "S"
renl draw nrayresullfrom the follow-
l. Low speedwith noload andhigh terninal conn€cling ignitionswitchin
ingilcms,
currenadraw may resull from the series asshownin FigureEE-27.
(l) A sroundedor open field coil:
followinBcauses. Wiih ignilion switch on, measule
Inspcot thc connectionrnd lrrce
(l) Tisht,dirty or wom bcadrss. lhc gap '2" betweenpinion front
(2) Bentarmalufeshafior loosened circuitby, circuilteslcr.
cdgeandpinionstopper-
fi€ldprobe. (2) Aunaturecoil docsnot opcrale:
(3) Shortedarmatur€; lnspect commutatorfor excessivc
Cheokarmatur€further. burning.In thiscase.arcmay occuron
(4) Aground€d armature or fieldl defectiveconnnulaiorwhen motor is ( 0 . 0 1 1t8o 0 . 0 5 9 i1n )
a. R€moveinput terninal. operatedwilh noload.
b. Raise two negativesidc brushes (3) Burnedoui comnutatorbar:
from commutaior. Wcakbrushspringtension,broken
c. Using a circuil tcsle!, place one brushspring,rubberbush,thfust oul
pfobe onio input terminaland the of mioa in commuiatoror a loose
contactbetweenbrushandcommula-
d. If testerindicatesconduction,rais€ tor would causeburned-outcommutr-
the other 1wo brushesand check
field and armatureseparutely10
deierrninewhether field or arma-
tureis grounded. FiE. EE-28 Medsuring gap "1. '
EE-10
EngineElectrioatr
System
.SERVICEDATAATD SPECIFICATIONS
SERVICE EATA
BrushI€ngth
ftn (in)
W€arlimit mm(in)
6.s(0.256
in)
Brulhspringtension ks0b) 0.80.8)
Commutator
_ Outerdiarneter mrn(in)
Wearlimit tun (in)
Taperlimit nm Qn)
Depthof mica
Wear
limit rnrn(in)
0.2(0.0079)
Repairaccuracy nrn (in)
0.5to 0.8(o.Ol97
roO.O3l
S)
Clea$ncebetween
armaturo
rhsft andbearing
Wearlimit run (in)
0.2(O.OO79)
Ropaireccuracy mn (ln)
0.03to 0.1(0.0012
to O,OO3
Armatureshafidiameter
Pinionside nm (in)
l3 (0.s12)
Rearend rnm(in)
r r.5(0.453)
Wear
limit rnln(in)
0.1(0.003e)
Bendlimit mrn(in)
0.08(0.0031)
Capt.r" bctwe€nl,inionfront edle
andpinionstopper rnm(in)
1.5(0.0118to0
E€.l1
I--.;ji-
EngineElectricatSystem
SPretFrcAflol{s . 1:1,
v l2
..................................-.........................,.....
l2
v .....................,....,..............................,.,,...,.
le$ than 60
morethrn7,000
0.9(6.5)
kFn (ft-lb) ....................................................
Magnetig
switch
h Sedos
coilr$lstsnce . ...... . 0.33[at20'C(68oF)
Shuntcoilrcsist.nc€ .......,.,.1.36lat 20oC(68oF)]
EE.12
TROUBLEDIAGNOSESAND CORRECTIONS
Condition Probablecause
Startingmotorwill not Chargeor replacebattery.

oP€rate. Defectivesolenoidswitch. Repairor replacesotenoidswitah.
Looseterminalconnections. Cleanand tighien termin.l.
Defectivebrulhes. Replace
brushes.
Defectivestartingmotor. Removestartingmotorandtest.
motor.
Noirystarting Looresecuring
bolt. Tightenbolt,
Wompiniongeal. plnlongear.
Replace
Poorlubricaiion. Add oil.
Disassemble
motor.
Wombrushes, brushes.
Replace
Starting
motor Disclurged
battery. Chargeor replace
battery.
slowly.
crenl<s Looseconnection
of terminal. Cleanandtightenterminal.
Wombrushes. Replaccbrush€s.
Lockedbiushes. lnspectbrushspringtenslonor rePa brush
holder,
Dirtyworncommutator, Cleanandreprir,
Armaturerubsfieldcoil. Replaceassembly.
Defective
solenoldswitch. Repairor replace
swltch.
Shrtingmotor Wornpinion plnion.

Replace
butdoesnot
operates Lockedpinionguide. pinionguide.
Repair
crankengine.
Wornringgear. Replace
ringgear.
motorwill not
Startin8 Defectivelolenoid switch. Repairor replacesolenoldswitch.
dk€ngageev€n Defectivegeart€eth. ReplacedefectiYegeor.
whenignltlonswitch
isturnedoff.
CHARGING
CIRCUIT
The chargingcircuit consistsof the Then,the warninglamplights. "P2" is separatedfron the prirnary
battery, alternator, regulator and side contact "P1" by the magnetic
. llhen the alternator begins to "VC2." Therefore,
necessary wiring to connect these operate,three-phase alternatingcur. forc€ of coil
"Rl"
parts. The puryoseof tlus systemis to rent is inducedin the staiorcoil. This rcgistor is appliedinto therolor
convert mechanical eneryy from the altematingcurrentis rectifiedby the circuitandoutputvoltageis decreased.
engineinto elecirical €nergy which is positiveand negativesilicon diodes. As the outputvoltageis decreased, the
"P2" and
usedto operateall electricauy operat- The rectified direci curreni output movable contact point
€d unitsand to k€eptle batteryiuly reachesthe alternator"A" and .,E' primarysidecontact"P1" comesinto
cnaryeo. contactonceagain,aod the altemator
When the ignition s'ivitch is set to On the other hand, the neutral voltage increases.Thus, the rapid
"ON," currentflowsfrom the battery point voltagereaches"N" and "E" vibntion ofthe movablecontactpoint
"P2," maintainsan alternatoroutput
to groundthroughthe ignitionslvitch, telminals(nearlya half of th€ output
voliageregulatorIG terminal,primary voltage), and cunent flows from
"P1," movable voltageregulator"N" t€rminnlto "E ' Whenthe alternalorspeedis furthel
side coniact point
contactpoint "P2," voltageregulator .ermjnal or ground throughthe coii increased or the voltagestarts1o rise
"F" terminal,altenator"F" terminal, "VCl" as lhown in
FigureEE-30by €xcessively,the movablecontactpoint
"E" telminal, "P2" comes into contact
field coil and alternator the dottedlinearrowmarks.Then,ihe with
as shownin Fture EE-29bY ful line coil "VCl" is excited, and the secondarysid€ contact point "P3."
a[ow marks.Then the rotol in the movablecontact point "P5" comes Then,the rotor currenlis shutoff and
alternatoris excited. On the other into contrct 'rith vollagewindingside alternatoroutput voltageis d€cr€ased
hand,currentflows ftom the batterY contactpoint '?6," Thisactioncauses immediately.This action causesio
to groundtfuoughthe ignitionswitch, io turn off th€ warninglump and separatemovabl€contaci "P2" from
"L" compleiethe voltagewindingcircuit, secondarycontact "P3." Thus, the
warninglamp, voltager€gulator
terminal, larnp side contact Point asshownby the full linearrowmlrks. rapidvibrationof the movableconlact
"P4," movablecontact point "P5," When ihe alternatorspeedis in. point "P2" or bleaking and com-
andvoltageregulator"E" terminal,as deasedor the voliagestarls to rise plelingthe rotor circuit maintainsan
shown by dott€d line arrow marks. excessiv€ly, the movablecontacipoinl altematoroutputvoltageconstant.
l t - I E
-l
ii
I"
I
I
i
Fie. EE-29 Chdteinscncuit (I)
EE-I4
_l
l-_----_--_-- lgnition sq
Almaturc
= Battery
T
.E.i
L_____-
-____- -i
F.A
rt:
I
Altolnator
I,ig. EE-30 Chdrsits circuit (n)
ALTERNATOR
CONTENTS
DESCF IPTION EE,15 T N S P E C T TOOcN B R U S H.............
REI\4OVAL AND INSTALLATION EE.16 SPRINGPRESSURE TEST. . . . . . . . . . . . . . . . EE , ] 9
D'SASSEIVIBLY . ,,,, E E .6] ASSE[,481V ........... E E .9]
]NSOECTIO AN D B E P A I R EE.17 A L T E R N A TTOEFS T , , . . , . . , , , . , . . . . EE.19
F O T O BI N S P E C T T O N EE.17 SERVICEDATA AND SPECIFICATIONS EE.21
TNSPECTTON OF STATOB. . . . . . . . . . . . EE.18 SERVICEDATA
INSPECTIO ONF D i O D E 8E.18 S P E CI C
F ATIONS EE21
DESCRIPTION like a one-wayvalvefor electricityso

that chargingcunentpasses easilybur
reve$e curent h shut out. In this
Alternator Applied engine tlternator, six diodes (lhree negative
and three positive), are installed in
LTt35-13B J13,Jl5 andJ16 positive and negativepiates as an
asernbly.
LTr5045 Jl3, Jls andJ16(Option) Packlypesilicondiodesareusedin
this aliernato..Thes€diodesare di-
rectsolderedat their tips, and con-
structed *ith positive and negative
In the alternator,
a magnetic Iieldis smallfi€ld curent- Output currentis conjunction. They aremountedon the
producedby the rotor which consists generatedin the amatur€ coilslocated iwo plates which combhe the func,
of alternatorshaft, field coil, pole in the. stator- The stator has ihree tion of heatdissipating plafeandposi.
pieces, and slip rings, The slip .in8s windings and Seneratesthree.phase tive/negaliveterminalsand are light in
pr€ssedin the shaft conduct or y a alternatiogcurrent.Silicondiodesact w€ighlandeasyto service.
EE.15
o
oo@
I
t
r@o@
2
l
r--------------
0tr --J t0
I
7
8
9 Diode serplale asenbly
@ .."",
FE. EE-31 Etploded uieu of altendtor
DISASSEMBLY
L Removepulley nut, pulley rim,
I
-D!U^ I
@ffi
@oo
I
2
3 FiE-EE33 RemouinEpuller and fan
Fig. EE'32 Sectiotul Dieb of altenatol
REMOVALAl{D 2. Rernove brush holder fixinS

INSTALUTTION 4. Removealternatordrivebelt.
scr€ws, and remove brush holder
cover.Removebrushholder forward,
l- Disconnect negativebattery ter- 5- RemoYeparts associatedwith
and remove brusheslogelh€r with
minal. alternalorfrom engin€. brustrhotder.
2- Disconnect two lead wires and 6. Rernovealtemato.from vehicle.
connectorfrom alternator. 7. Installaliernatorin reve6€order Note: Do not disconnect"N" termi
3. Loosenadjustingbolt. nal fron stator coil l€adwire.
EE.16
I
II
Fig. EE 37 Pulling out of rcar
I
I Fig-EE'34 Remouing
brush
3. Loosen and remov€ throu8h

bolts.Separatefront coverwirh rotor Fie. EE-4o Inspectinsaltemator
from rear coverwith statorby lightly
tappingfront bracketwith a wooden
ROIOR I]{SPECT|O
mallet. Iig. EE'38 Pullingout of rcar
bedrins(II) 1. Conduction lestof rotorcoil
Apply teslerbetw€enslip ringsof
6- Renrovedjodecov€rfixiogscrew,
rotor as shown in Figurc 8E.41. lf
and removediode cover.Disconncct
threestatorcoil leadwiresfrom diode thefe is no conduction,discontinuity
terminalwith a soldering of fieldcoil mayexist.Whenreshtance
iron.
7. Remove"A" terminalnut and h approximalely 4.4O at normalambi-
diode installalion nut, and femove ent lemperature, conditionis $tk,
diodeassembly. factory.
o!@:ir*l
O
lr
Fig. EEAS Sepatutingfront cover
uith rotor frcm rcar couer f\ ,, }ir, 4\û, )r
\J I 'r l.!'
"':q f " ,,'
I Djodc a$ehbly
4. Removethree se1 scrcwsfrom 2 Diode cover
bearingretainer,and separateroior Iig. EE-41 Conductiont6t of
from front cover. Fig. EE-39 RemouinEdiode Nembly
rotor coil
Not€: Use c,5rein handling diode as-

s€mbly to prevent an undue stress
2. Ground lesl ofrolor coil
Check conduclion betweenslip ring
and rotor core. If conduction exish,
INSPECTIOI{AI{D replace rolor ass€rnbly,becausefield
REPAIR coil or slip ring rnay be gfounded.
Removeattematorfrom vehicleand
! @@ apply lester between lead wire F
(whitewith blacklracer)andleadwire
rig. EE-36 Remoui/tgrotor
E (blackcolot.
Whenthe resistance is approximate-
ly 5s,,the conditionofbrushandfield
coil is satisfactory-
Whenno conduc
tion existsin brush or field coil, or
5. Pull out rea. bearingfrom roror whenresistance diff€rsrcmarkabtybe
assemblywith a press or bearing tween those parts. disassenbleand Fig. EE 42 Testinqrotor coit for
puller. grcund
EE.]7
INSPECTIOIIOF SIATOR saiisfactory.Il there i3 conduction Diode installedon O plate is a

stato.coil is grounded. negalivediode which alows cu(eni
l. Conduclion test flowing from O Plale to terminal
Stalor is normal when ther€ is only. In olher wods, currentdoesnot
conduction between individual stator flow from termiralto O plate.
coil terminals. When there is no con-
duction between individual terminals,
cableis broken.
Replacewith stator assembly.
Fig.EE'.14 Testitrgstator for

Eround
INSPEC'ION OF DIODE
Pefform a conduction lest on dio.le
FE EA47 ln|pe.tne negatiDe
diod€s in both direclions,using an
FiE.EE-43 Testingstatorfor
conduction ohmmeter.A totil of six diodesare
used;threeare mountedon th€ posi-
2. Groundtest tiv€ O plste, and other threeare on If cuncnt flows towardboth posi-
If eschleadwire of armaturecoil ihc negativeO plate.The conducijon tive rnd negativedirections,diodc is
(includingneutralwirc) is no! conduc- lest should be performedon each lf 0urron!flowsin the
short.circuited.
tive with stutol corc, condition is diod€,betweenlhe teminnl andplate. samedhectiononly, diodc is in good
condilion.If ihereis a defectivediode,
rcplaceall diodesGix diod€t as an
ass€mbly.(See below table.) Th€se
diodesafeunsewiceable.
{ie.EE 45 ConductiDe.lir.ctio^ af.Iio.te
Diodeinstalledon O plate is a posi-

tive diode which alows currenlflow-
ing from terminalto @ plale only.In (
other words, curreni does not flow
from G) plateto tenninal.
Fig. EE 16 tnspectin' needti@ dio.te
EE.I8
Testprobeofa circuittester
Conduction
o o
G) plate o
O plate terminal
terminal O plate
O plate terminal o
O plat€ O plate o
@ plate O plate
Fig.EE-48 lnspectingdiode6
I]{SPECTIONOF BRUSH
Check movemenlof brush and if down to Iessthan the specifi€dlimit, rnsulatin8bush 4 Sratorcoil leadwirc
movementis unsmoolh,checkbrush replace
brushassembly. Redi cover 5 A tqhinat bolt
holderandcleanit. Diodeasonbly 6 Diodecovcr
Checkbrush pig tail and,if found
Checkbrushfor wear.If it is worn defective,
replace. Fie.EE-61Sectionot
oieu of diode
o\d A terminol
3. Tightenpulley nur with tighien-

ing torqueof 350 ro 400 kg-cm(301
to 344 inlb), Whenpulley is tighn
ened, make lure that deflectionof
V.groove h lessthan0.3 mm (0.01l8
n,r,
Fie.5E-49 Brwh uear limit
SPRIIIG PRESSURETEST ASSEMBLY

With brushproj€ct€dapproximai€- Reassemblealternatorin ihe reverse
ly 2 mm (0.078? in) from brusl' sequence
of disassemblynotingfollow-
holder,measurebrush springpressure mgmarrcrs:
by the use of a springbalance.Nor. Fie. EE-52 Tiehteningpulley nut
l. When solderingeachstaior coil
mally, the rated pressureof a new Ieadwire to diodeassembly rerminal,
brush springis 255 to 34s g (9.0 to carry out the operationas fast as
12.2 oz). possible.
Moreover,when brush is worn, 2. Wheninstallingdiode"A" termi"
pressure d€creases
approxinately209 nal, insta insulatingbush and insu- ALTERNATORTEST
(0.7oz) p€r l mm (0.0394in)wear. latingtub€corectly. Before conducting an alternatoi
test,make surel}Iar the baitery is fully
charged-
To conduct a test, it i! n€cessary to
use a 3o-volt voltneter and suitable
Set up a test circuit as shown in

Figure EE-53 and tesr alrernarorin the
manner indicated in th€ flow chart
Fie. EE 50 Meosurina slnng Praure
EE.I9
l. Disconnectconnectonat altemator-
2. Connectonetestprobefrom voltmeterpositiveterminalto "N" terminaloi "BAT" terminal.Connectt}Ieother
testprobetoground.Makesurethat voltneterregisters batteryvoltage.
3. Tum on headlights
andswitchto MainBeam.
4. Startengine.
5. Increase
enginespeedgraduallyuntil it is approximately
I ,l 00 rpm,andtaketh€ voltmeterreading.
Measured value:Below12.5volts Measuredvalue:Over12.5volts

Altemator is defective.Removeand checkit Alternatoris in goodcodition.
for colldiiion.
a. Do not run engin€at more than

1,100rpn rvhiletestis beingcon-
duct€donaitemator.
b. Do not raceengine.
?iE. EE-63 T6tin9 altemdtor
EE.20
SERVIGE DATA A]{D SPECIFICATIONS

SERVICE DATA
- LTIJ5.t3B,LTl50-05>
Statorcoil
Resistaftep€r a phase 0.17lat 20oc(58oF)]
Rotorcoil
Registance 4.4 [at20oc(68eF)]
Brustl
Br:ush
length 14.5(0.571)
Wearlimit 1(0.27s6)
Springpressure 0.25to 0.35
(0.5sto 0.7?)
Slipring
Outerdfumeter 31(t.220)
Reduction
limit l (0.0394)
Repairaccuracy 0.05(0.0197)
SPECIFICAT|Ol{3
Item LT135.l3B LT150-05(Option)
Make HITACHI HITACHI

Nominalriting l2v-35A t 2v-50A
Groundpola.ity Negatlve Nogativ€
Revolution 1,000
to 13,500rpm I ,000to 13,500
rpm
Minimum revolution underno load LessthanI ,000rpn L€ssthanI ,000rpm
Outputcurreni 284 (14V,2,500rym) 37.5A(14V,2,500rpm)
Pulley ratio 2.25 2.25
Appliedregulatormodel TLtZ-61 TL\Z4l
REGULATOR
CONTENTS
D F S ' RP T I O N .. EE.22 C I A R G I N BCF L A Y , , ,
MEASUREMENT OF REGULATOR S F V ' E D A T AA N D S P I C| I C A T I O N S, . EE 26
VOI TACt EE23 T R O U E L ED I A G N O S EASN D
ADJUSTIVTNT EE.24 C O F c - C T I O \(S1 l d 1 9 " I e r . d r o .r .' . . . . . . . EE27
V O L T A CR| I - C U I A T O
. .B
...........
DESCRIPTION
The regulatorconskisbasicaliyofa cirouitdifect to ground:andthc uppel
voltageregulatorand a chargerelay. conlacts,when closed,completethe
The voltaSeregulatorhas two setsof field circuitto groundthrougha resh!
contactpoinls,a lowef sel and upper ance(field coil), andproducesalterna.
rct, to control alternatorvoltage,An IOf OUIpUL
armatureplateplacodbc|weenthe two The chargerelay is similarin con-
lets of conlacts,noves upward or structionto thevoltageregulator.
downwardor vibrales,The lowercon- Whenthe uppercontactsarcclosed,
tacts,whenclosed,completethe field ignilionwarninglampgoeson. 2
EE146
Regulatofmodel Appltcdengjn€ Appliedaliernator
Fig. EE-54 Vietr ofrcmovins couer
TLt2.6) J l 3 ,J l 5 a n dJ 1 6 LTt35.l38
As for construction, the voltage
LTl50-05 (Option)
regulalor is very similar to the charge
relayasshownin Figure8E.55.
10
ll 2
l2 l 12 Co
l 3 3 m n ( 0 , 1 1 8 1 i nd)i a .
l3 5
6 t 4 4 m m ( 0 . 1 5 7 5i i ) d i a .
l4 1
l5 8
9 VoltJgeregulatorconlact
(b) Co$truction of chaqe rclay
(a) construction of uoltagerecutotor
Fig. EE 55 Stuctutol uieu of rclay
EE.22
.MEASUREMENT
OF REGULATOR
VOLTAGE
Regulatorvoltageis measured with

regulatorassembled with altemator.
Whenmeasuringvoltagewith regulator
mountedon vel cle,it is necessary to
Shortcircuitlere (letween
rotateengineat highspeed. fus iide lerminaland(-)
Connect DC voltmeter(15-30V), t€ininalof anmebt befit€
DC ammeter(15-30A),battery and
resfutor(0.25f,,) witll cablesasshown.
1. Checkto be surethat all electrical
Ioadssuchaslamps,cooler,radio,etc.
aredhcoftrected.
2. Beforestartingenginejbe sureto
(10A) (30v)
make short circult with a cablebe-
tween fuse side terminal of resistor
(0.25Q)and negative EEO55
sideterminalof
amneter.Failureio follow this cau- ti9. EE-66 Meatutingrceulatoruoltogeuith regulatoron uehicb
tion cauresneedle of ammeterto
swingviolentlyandreversely, rcsulting 3. Refer the following chan to partsarein gooalcondition:
in a damaged ammeter. determineif regulator and relaiive
l. Startengine,
2. Rotateengineat 2,500rpm for several
minutes.
After racingfor severalminuies,ammeterreading After racing for severalminuteg,ammeter

- below5A. reading- over5A.
Fully charged
batteryavailable. Fully charged
batt€rynot available.
L R€place'rvithfully chargedbattery. l. Connecta 0.25Qresistorin series.
2. Ch€ctto seeifcurrent fallsb€low54.
Curcnt falh below5A. Currentdocsnot fall below5A.
Recha'ge
bdtre'yandseeifcuflenrfailsbelow5A.
Reduceenginespeedto idling and then raiseit to 2,500 rpm while observingneedleof voltmeler.
Needle ol voltmeter held within lirnits shown in the iable Needleofvoltmeterout of limitsshownin the
followinBchart.
Regulatorfunctionhgproperly. ReSulatorout of order. Haveil repaireda!
ADJUSTMENT 4. Adjustingpoint gap

Loosenscrew [3 mm (0.1181in)
VOLIAGE REGULAIOR dian€terl used to secureuppercon-
As the resultof aboYeneasure- tact, and moveuppercontactupward
ment,whenregulating voltaged€viates or downwardadequately. SeeFigure
ftom ratedvalu€,adjustregulatorin EE,58.
accordancewith the followinginstruc-
l. lnspect contact surface,and if I

rough, lightly polish surfacewith fine 2
emerypaper(#500or 600). 3
2. Measureeach!ap, and adjustif
necessary. Adjust coregap analPoint Fi8- EE-59 AdjBting requlotineuoltoge
gap in that order.No adjustmentis
requiredfor yoke gap.
3. Adjustingcoregap
Loosenscr€lr [a mm (0.15?5in)
diameter] which is us€d to secure
contactseton yoke,andmovecontact 1
upward or downwardproperly. S€e 2 3 m n ( 0 . 1 l 8 li r ) d i r . 6 c r o w
FigureEE.57. 3
UDDe! contart
Fig. EE-58 Atljusting point gdp
5. Adjustingvoltage CI{ARGII{GRELAY
Adjust regulatingvoltage as fol-
Normalr€layoperatingvoltaSeh 8
Loosenlock nut securingadjusting to 10V asmeasured at alternator"A"
2 screw,Turn this screwclockwiseto terminal. Relay itself, however,op.
3 4 mm (0.1575h) dh. scles incresse,or counierclockwiseto de. eratesat 4 to 5V.
Ctossh€adsqewdrivo! EEo66 crease,regulatingvoltage.SeeFigure Use a DC voltmeter,and set up a
Fi'.8E.57 Adjwting core$ap EE.59, circuitasshownin FigureEE-60.
EE.24
l. Connect positiveterminal of voltmeter to regutatorlearl conn€ctor..N,,

lerminal with negativeterminal
gromded.
2. Start engineandkeepit idle.
3. Takevoltmeter r€ading.
0 Volt B€lolr5.2 Volts Ov€r5.2Volts

1. Checkfor continuitybetlveen (Pilot lamp remainslit) (Pilotlarnpremains
"N" teminals lit)
of regulatorard l. Ch€ckfan belt tension. Pilot lamp relay coil ot contact
altornatot, 2, If conect, remove regulator pointsout of ord€r.
2. Alternatot circuit dofectlve if andadju8tasnecesssry. Replace regulator.
continuity exirts.
Over5.2Volts
(Pilotlempdoesnot light.)
PilotIamprelayossembly
ia in goodcondition,
L (WR) IG (WL)
F(WB)
E (B)
fig. EE40 T$trng chaEingrcW

t *
SERVICE DATA AND SPECIFICATIONS
Voltag€regulator
Mod€l 'tLtz4l
Regulatingvoltage
(with fuly chargedbattery) V 13.8to 14.8
Voltagecoil resistance O 10.3lat 20oc (68"F)]
Rotor coil insertingresistance O 10
Voltageco_ilseriesr€sistance O
Smoothingresistance O 4l
Corcgap
Pointgap
Charge
rclay
Releasevoltag€ V 8 1ol0 at "A" terminal
Voltagecoil rclistrnce O 3l .9 lai 20oC(68oF)]
Coregap n.'Jn(in) 0,8to 1.0(0.0315 to 0.0394)
Pointgap mm (in) 0.4100.6(0.015? to 0.0236)
EE.26
TROUBLE DIAGNOSESAND CORREGTIONS(lncludingalternator)
Condition
No output Stickingbrushes. Corr€ctor replacebrushes

andbrushsprings.
Dirty brushes
andsliprings. Clean.
LooseconnectioNor brokenleads. Retightenor solderconnections.
Replaceleadsif necessary.
Openstatorwinding. Repairor replacestator.
Openrotor winding. R€place
rotor.
Opendiodes. Replace
diodes.
shortedrotot. Replace
rotor.
Shortedstator. Repa or replacestator,
Crounded"BAT" terminsl. Replace
lnsulator.
Brokenfsn belt. Replace
belt.
Excessive
output Brokenneutralwire(colorofwtre tNwhite.) R€place
wire.
Defective
voltageregulator. Check regulator of'eratlon and repair or
rcplaceasrequired.
Poor gioundingof alternatorand voltage Retightentermlnalconnection.
regulator"E" terminol,
wire (coloror wire h black.).
Brokenground Replace
wire.
Low output l-oos€

or womfanbelt. Retight€nor replacebelt.
Sticking
brushes. Correct or replacebrushesand springsif
necessary.
Lowbrushspringiension. Replace
brushspringr.
Delective
voltage
regulator. Check regulatorop€rationand repalr or
rcplaceasrequired.
Dirtysliprings. Clean.
Psrtialshort,gound, or open in stator R€place
stator.
Mnding.
shodedor grounded
Partially rotorwinding. Replace
rotor.
Openor defectivediode. Replace
diod€.
Noisyalternator Loor. mountinS. Retightennountingbolh.

Loosedrive pulley. R€tighten
pulleycorr€ctly.
Defeciivebal beariry. Replace
bearing.
brushes.
Improperlyseated Seatbrushes
correctly.
EE.21
DISTRIBUTOR
CONTENTS
rB .c ro\
coNS EE.28 A D V A N C E I T l E C HNA r s t !.1. .s. . . . . . . . . . . . EE,3O
.
C N T T K \ CA N DA D I U S T V | N
......... EE.29 D I S A S S E I V ] B LAYN D A S S E I / ] .B. L . .Y. . . . . . . .
c A PA \ D C O OP q c A D .......... EE29 D SASSEMBLY EE.31
POt\T .......... EE.29 A S S E M B .L.Y. . . . . . . . . . . . . . __ . . . . . . . . . . . E E3 2
c o N D\ r' r q EE30 S E F VC E D A T AA N D S P E C I F I C O AT N S . . . . . E E3 3
CONSTRUCTION
The distributorconsistsol breaker
Distributor lnodel Applied engine plate wilh contacipoints,centrilugrl
advance mechanism,vacuum unit,
D4l l-68 drive shaft. and rotor. Figure EE-61
and 62 showa seclionalview of the
D4t3-84
unit.
D4l1.81 J15
I
2
l
8
9
Fig. EE 61 Constructian
Engine Electrical System
I
6
t
ll Lcodwirea3smbly
l2 Roto!ttead.lsenbly
13 Cond.nsia$embly
l4 Tcrninalasrnbly
15 Yacuuncontrolarsembly
16 Capa!!€trbly
l? Calbonpoiitassehbly
8 BF.ker plalc asmbly
19 Oring
10 Edth vLe as!.,nbly
FE. EE-62 Conponenttof .Jbtributot
CHECKINGAND
ADJUSTMEl{T POITI
Standardpoint gapi! 0.45 to 0.55 paper (No.500 or 600) or with oil
CAP AI{D ROTOR HEAD nn (00177 to O-O2t7in). In casesize
Cap and rotor head must be in- is off the standaid,ad.iustmertis made At t}Iistime,greasemustb€applied
spected at r€8ular intervals. Every by looseningpoint screws.Gtp gauge to camshaftheadand camheel.
5P00 km (3,000miles)of operstion, is requircdfor adjustment. When wear on breaker points is
remove cap and clean all dusi and Point gap must be checked every noticeable, replace points together
carbond€positsfrom capandrotor.If sp00 kln (3,000niles) of operation. with conlact arm. To replac€,proceed
cap is crack€d or is leating, replace When point surfaceis rough, take
off any irr€sularities with fine sand-
EE.29
F
fig. EE-65 Disosemblinscontdct
arn dad contactPoinl
3 Prnnalylcadtcrminrl
CONDENSER
Fig, EE'63 Breaher
Satisfactoryperformanc€of con-
denserdcpends oo capacityanddegree
of insulation,requiringatt€ntionto be
wireconnectionjusl farenough
to full sure that terminalsare cl€anand set
out prinary leadteaninal.
Ref€ningto Figrre1.i1.63,
unscrcw Chccking ofcondenser ismad€by a
two contact sct lixnrg screwsand capa.itytester.Thk canalsobe made
by n circuit testerwith its rangcsstto
While holdirrgcontactrnn by iin- high reshlancereirding.Wh€nneedle
gers,pu]l out contactseltowardyou of tester swingsviol€ntly and then
by raisinSit slightly.Contrct point movesback to infinite gradually,it is
and alm can lhen be rcmovedt0- an indicationthat condensor is in good
point gaP gelher.
Fig.EE-64 Madsuting
Installnew contactponrtrnd anrl If n€€dlcshows ny steadyrcading
assemblyin rcverscsequ€nceof r€- or if it regist€rs
zero,the likelihoodis
First turn out sel screwsI to 1,5 moval.Coatcrnr hccl andcamshaft that translbrmeris out of order,call-
lurnsat conlactarmandprnnary lead headwilh a lightcoating
ofgrc sc. ingfor replacemenl.
ADVANCE MECHANISM
<Pe.fo,rnances>
2A
2050x1
9
2050x1
Bro
5 205(Jx?. .l:
0
65{t;2.1
J1 t?st6,,,
500 1000 1500 2000 2500 1000 0 150 200 250 300 350 ,1110
Distribniorrolriion Gpr) VacuunGrnHg)
Fie. rF.66 Pcr[armon.ectru. lor Mo.lel Dd I I 6A

EE.30
3 1 0 310
1000 1500 2000 2500 100 150 200 250 300 350
(rpnt
rotation
Distribulor vacuumCmmHg) E E1 7 5
Fig. EE'67 P.tfotnance cutuefot Mo.tel D413.84
810 310
1000 1s00 2000 2500 r0o 150 200 250 300 350
(ryn)
Diltibrto!roldtion VacuumCnnHs)
Fie.EE-68Petormdnce.utuefor ModelD4| I-81
<Vacuum sdvancemechanism <Centrifugaladvance DISASSEMBLYAND

parts>
mechanical parts>
rnechanicai ASSEMBLY
If vacuumodvanc€mechanism failg When causeof enginetlouble is
to operateproperly, check for the tracedto centrifugal advance m€chani-
DISASSEIIIELY
followingitemsand correctth€ trou- cal part,us€dhtributortesterto check
ble asreq ired. its characteristic. follow the proce-
To disassemble,
$,hen nothinS is wrong with its
l. Check vacuumifllet for signsof
characteristic,conc€ivable causesare l. Takeoff capanddisconnect
rotor
leakage If necessary,
at its connection.
def€ctiveness or abnormalwearing-out
retightenor replacewith a newone.
of driviflSpartor otherpart. 2, Removevacuumcontroller,
2. Checkvacuumdiaphragmfor air
Do not disass€mble it. In cas€of
leak.
impropercharacteristic, removeon-off
If leakis found,replacediaphragm
switch part and check closelycam
assembly, govemorweight.shaft and
3. Inspectbreakerplaaefor smooth
Sovernor sprng.elc.
If plate doesnot movesmoothly, Whencentrifugal advance mechani-
this condition could be due to sticky cal part is reassembled, be sure to
steel bslls or pivot. Apply greas€to check advancecharacteristic by dis' d
steel balls or, if necessary, replace d
breakerplateasan assenbly.
Fie. EE 69 Dins@mblirq odcuud
contrcUer
EE31
3. Rlmovecontactbreaker. 6. mrcn caln is to be removed,first ASSEMBLY

Referto PageEE,30,whencontact remove set scrcw since shalt head is Assemblycan be made in reverse
fasten€dby the screwto hold cam
sequenceof disassembly.Refer to
down.Put natch markacrosscamand
s
Figurc 8E,75 for replacementand
t shaftso that originalcombinationcan reassemblyof govemor spring and
be restoredat assembly.
7. Whengovernorweightand spring
are disconnected, be car€fulnot to
stretchor deformgovernorsping.
applygrease
After disassembling, to
governorweights.
Fig.88.70 Renoving contact set
Fi|- EE-74 Renouing con
Fig.88.71 Renovingcontdctbrcaker
4. When contact br€aket is disas-

sembled,be cafefulnot to lose steel
balls between breaker sprtng and
plate.
brea.ker
5. Pull knock pin out and dhcon-
necl collar to removethe entire ro-
talng Frts-
' I2
8 Govenorspins{A)
3 9 Rotorpositio.inglip
FA. EE-72 Remouingknochpia
5
Fig. EE-75 Settinggouemorspringand @m
Fig.EE-73 Renodag rototioh parts
EE.32
SERVICE DATA AND SPECIFICATIONS

SERVICE DATA
< All distributofs>
Pointgap rnm(in) 0.45to 0.s5(0.0177to 0.0217)

kc 0b) 0.s0to 0.65(1.10to 1.43)
shaft dia'neter(lowerpart) rnm(in) 12.430to 12.440(0.4894 to 0.4898)
Housinginnerdiameter nm (in) 12.450to 12.468(0.4902 to 0.4909)
Clearanceb€tweenshaft andhousing nnr'(in) 0.010to 0.038(0.0004 to 0.0015)
Repairlirnit of clearance mm(in) 0.08(0.0031)
Shaftdiameter(upp€rpart) nJn (in) x- :9-!9! ,6 -- -9!!9?1

--,,.6 -0.0006
0_014
CaIninnerdiameter mm(in) 8.000to 8.015(0.3150
to 0.3156)
Clearance
beiweenshaftandcam mrn(in) 0.005to 0.029(0.0002
to 0.0011)
Weightpivot diameter mm(in) (0
4.972to 4.990 ,1959to 0.1965)
Weightholedianeter mm(in) 5.000to 5,018(0.1969
to 0.19?6)
betweenpivot andhole
Clearance mm(in) 0.01to 0,046(0.0004
to 0.0018)
SPECIFICATION3
Distributortype D411.68 D4r3-84 D{ I l.8l
Make HITACHI HITACHI HITACHI

Appli€dengine Jl3 Jl5 Jt6
Firingorder 1-3-4-2 1"3.4.2 1.34.2
Rotatingdirection Counterclockwis€ Counierclockwise
Ignitiontiming(B.T.D.C.) degree-rpm 80/600 8'/600 8o/600
Dwell angle degre€ 49o to 55o 49oto 55o 49oto 550
Condenser
capacity !F 0.2OIo 0.24 0.20to 0.24 0.20to 0.24
EE.33
COIL
IGNITION
The ignition coil is of an oil-filied

type. The ignition coil caseis filled
with oil whichhasgoodinsulating and
heatradiating characteristics-
High sparkingvoltageis produced
from startingto enginehighrevolution
by the exlernalresistorwhich is used
in the ignitioncoil cncuit for 6R'200.
(Extefnalresistorb not equippedfor
C1Z-200.)The internalresistorlimih
to a maximumsafeflow ofthe prirna-
ry currertthroughthe coil anddistrib-
utor contactpoints.Thus,it pfotects
the contactpointsduringslow speed
operationwhen th€y ar€ closedfof
longintervals. 2 Se.ondary
teiminal
3 Cap
4 Spring
10 Seg'nen1
ll Casc
FE. EE.76 Construction
SPECtFtCATtOttS
Makeandtype...............-. HTTACHI(6R.200) HITACHI(cr2-200)
Prinaryvoltage v ......................_....._........................
12 12
Sparkgap nn (jn) ..........................
. .. .. . ......Morcthan? (0.2756) Morethan7 (0.2756)
Primaryresislance
at 20oC(68oF) o ...................................................
1 . 5t o 1 . 7 4.2It)3.4
Secondary
resistance
at 20"C(68oF) KO 9-5lo l l.6 9tol1
Externalresistor O ..........-..-..................-....................
t.6
8E,34
SPARKPLUG
CONTENTS
D E S CPRT I O N .,..... EE,35 SERVICE D A T A A N D S P E C IC

F A T I O N S. . . . , E E . 3 6
NSPECTION ........ EE-35 TROUBLE D I A G N O S EASN D
N D B E G A PNPG . . . . , , , , , . . . . . E E . 3 5
C L E A N I NAG C O R R E COTN S -...., EE'36
DESCRIPTION Overhealing:Whiteor light grayinsu- spafk plugs,low fuel pump pres-

The sparkplugsare of the resistel lalor with black or gray brown sure, wrong selectionof fuel, a
typ€.having14 mm (0.551in) threads spots and bluis,hburnt electrodes hotterrangeplug,€lc.
and0.8 to 0.9 nm (0.031to 0.035tn) indicat€engineoverheating. More- to replacewith plugs
It is advisable
grp. Insp€ctionandcleaning shouldbe over, the appeuanceresultsfrom havingcolderheatrange.
rnadeerery 10,000km (6,000miles), incorrect ignition timing, loose
and replacement shouldbe carriedout
.vcry 20,(Imkrn ( l2,000milet,
Note: A[ sFrft phgs install€d on an
eo8ine,must ba of the samebrand
atrdheat nog€.
l1{sPECTtOl{
l. Removesparkplug wire by pull.
ingon boot, not on wir€ itrelf,
2. Remov€sparkplugs.
3. Ch€ck electrode!and inner and
outer porcelainsof plugs,noting the
type of depositsand the degreeof
€lectrodeerosion.Referto FigureEE-
77.
Lifc
Normal: Brown to grayish{an de.
posih afld slight electrodewear E€079
indicate correct spark plug heat Fie. EE-77 Spothplug
nnge.
Caronfouled: Dry fluffy carbonde- 4. Afl€r cleaning,dresselectfodes type cleaner.Avoid €xcessiveblasting.
positson the insulatorand elec- with a smaufine file to flatlcn ule Clean ard remove carbon oi oxide
trode are mostly causedby slow surfacesof both centerand sideelec- deposih, but do not wear away porce-
speeddrivingin city, weakignition, trodesin parallel.Setsparkpluggapto lain. If deposiis are too stubborn,
too rich fuel mixture, dirty air specification. discardplugs.
cleaner,etc. 5. Instal spark plugs and torque After cl€aning spark plugs, renew
to replacewith pluSs
It is advisable ezchplugto 1.5to 20 kg,m(l t to 14 fir'ns surface of electrodeswith file
havinghotterheatrange. fl,rb). mentioned above. Th€n gap spark
Oil fouled: Wet black depositsshow 6. Connectsparkplugwires. plugs to 0.8 io 0.9 mm (0.031 to
excessive oil enlranceinto conbus- 0.03s in) using a round wire feeler
tion chamber through worn rings gauge. A[ spark plugs new or used
and pistons or excessiveclearance should have the gap rhecked and reset
betweenvalveguidesand stems.If
CLEANINGAND by bendinggmund electrode.
the samecondition renainsafter REGAPPING
repair,usea hotterplug- Cleansparkplugsin a sandblast
EE.35
fie. EE-78 Setting 6pdrhplug Eop
SERVICE DATA AND SPECIFICATIOI{S

Modelandmal@ BP-sES.
NGK
L46PW;HITACHI
Size(screw
dia.x reach) mm(in) ......................... la x 19(0.551x 0.748)
....................
Pluggap mm(in) ..........,,.,,....,..... 0.8to 0.9(0.031ro 0.035)
.............,,.,..,
Tightening
torque kg-m(ft-lb) ...............-... ....................
1.51o2.0(l1to14)
TROUBLEDIAGNOSESA1{DCORRECTTOI{S
l. Whenenginedoesnot start, high t€nsion cable from spalk plug, After checkinSthis, repair as neces'
Ifthere is no houblein fuel system, startingengineand obsefvingcondi. sary.
ignition system should be checked. tion of sparkthat oc.ursbetween
high
This canb€ easilydoneby d€laching a tensioncableand sparkplugterminal.
SparkIength Troublelocation Probablecause Corrective

action
No sparksat all Distrbutor Defectiveinsulationof condenser. Replace,

oflead.wireon low tensionside,
Breakage Repair.
insulationofcap androtorhead.
Defective Replace.
Pointdoesnot openor close, Repair.
Ignitioncoil Wirebreakage
or shorlcircuitof coil. Replace
with a n€wone.
HEh tensioncable Wirecomingoff. Repair.
D€fcctiveinsulation. Replac€.
I to 2 nm (0.0394 Distributor Pointgaptoo wide. Correct.

to 0.0?87in) or Oil stickingon point. Clean.
irregular.
Pointburnt too much. Replace.
Lessthan 6 mln Sparkplugs Electiodegaptoo wide.

(0.2362in) Cleanor replace.
Brokenneckof insulator. Replace.
Expirationof pluglife. Replace.
'2.
f,rhcn enginetums over but does rcsulting from tlre ignition systemand spection of ignition syst€mshould be
not run sxnootl y. other engin€conditions not related tb
In this cas€,there are many caus€s igntion. Therefore, first complete in-
Trouble Troublelocation Probablecause Corrective

action
Enginemisses. Distributor Dirty point. Clean.
Improperpointgap. Correct.
IJak of €lectricityof capandrotor.head. Repairorraplace.
Defectiveinsulationof condens€r. Replace.
Defectivearm. Oil straft.
Defective
springolaIm. R€plaaeassembly.
Breokrge
ofleadwire. R€place.
Womout or shakybreakerplate. Replaceassembly.
Wornout or shakydistributorshaft. Replaceassembly.
lgnitloncoil L,ayer$ort circuitor useofinferior quality. Replace
with goodone.
Hight€nsioncode Deterlorationof insulation and leak of Replace.
elechicity.
Sparkplu8s Dirty. Clean.
L€ak ol electricityat upper porcelainlnsu- Repairor replace.
lator.
Engineknocks Distribuior Improperandadvance timlng, Correctthe fi ing,

veryoften.
Coming off or breakageof governor
sprjng. Cprr€ctor replace.
A pin or a holeof govefiorportionworn Replace.
Sparkplugr Burnttoo much, R€place.
Bnginedoesnot Distributor Improperandretarded timing. Correci tlle fitting.

give€ndugh
power. Defective
functionof Sovemor, Replace
assembly.
Drti point. Clean.
Pointgaptoonarrow. Correct.
Sparkplugs Drty, Clean.
MODEL
HtGtltES
Enginetuel
AIR CLEANER
DESCRIPTION It should be cleaned and replaced which doesnot rcquneany cleaning,
periodically.Availabieasan option is a regardless
of contamination,
until it is
The air cleaneris a dry tapertype.
vrscouspaper type air cleane.el€ment replaced period.
in the designated
FUEL STRAINER
DESCRIPIION REMOVAL
Th€ fuel strain€ris a cartride€
type. Disconn€ctinlet and outier fuel
It usespaperelementas strainerele- lines from fuel strainer,nnd remove
ment whichcanbe clrcckedfor condi,
tion f-romthe outside.This strainer
shouldbe replacedevery20,000km Note: Befor€disconnecting fuel tiner,
(12,000 milet und€f normal coodi, use a containerto receive the
tions.SeeFigureEF-i. remainingfuel in lines.
IiE. EF-l Sectiondluieu of

cdrttidgetype fuel jttuiner
FUELPUMP.MECHANICAL
CONTENTS
DESCR PTION CAPACITYTEST EF.3
INSPECTION EF-2 FEMOVALAND D SASSEMBLY EF.3
FUEL PU[/4P
TESTING ASSENIELY
STAT]CPRESSURE
DESCRIPTION INSPECTION FUEL PUMP TESTING

The fuel pump transfersgasoline l. Cheok upper body and lower A luel punp is operatingproperly
fron th€ tank to the carburetorin when its pressureis within specifi-
sufficient quantity to meet engine 2- Check valve asscmblyfor wear of calionsand ih capacityis equalto the
requirements at anyspeedor load- valve and valve spring. Blow valve engine'sr€quir€nents at all speeds.
The luel punps usedon the model assembly by breath to examine its Pre$ure and capacity must be
Jl3 and J15 enginesar€ of the dia- d€terminedby two tests, wiih the
phragmtyp€. 3. Check diaphragmfor snaU holes, pumpnounted on rhe enSine. Besure
The firel punp consistsof a body, that thereis gasolirein the tanl wher
rocker arm and link assembly,fuel 4. Check rocker arm for wear at the conduciing thesetests.
diaphrag'n,fueldiaphragm spring,s€al, poriion in contact with the camshafi-
inletandoutletvalves. 5. Check rocker arm pin for wear STATIC PRESSURE TEST
The fuel diaphragmconsistsof sinceaworn pin nay cauk oil leakage.
speciallytrcatedrubber,which is not 6. Check all other componentsfor The staticpressure
test is conducr
a11bc1ed by gasoline,held togeiher any abnormalities and rcplace wirh
wii}I two metaldiscsanda pull rod. new partsas requrcd. l Disconnect
ca$uretorfuel lineat
EngineFuel
CAPACITY TEST REMOVALAND
2. Instal the necessary adapterand DISASSEMBLY
"tee" fitiing to The capacitytestis usedonly when
fuet ljne and atracha
suitablepresNregauge. the siaticpressure is within specifica- Removefuel pump assembiyby
3. Start ensineand run at varying tions. The capacirytest is conducted unscrewingtwo mountingnuts and
asfollows: disassemblc in the folowingorder.
4. The readingon gaugeis the static l. Disconnectfuel pipe at carbu- i. Separateupper body and lower
fuel prcssureaod this shouldremain body by unscrewing body serscrcws.
within thefolowinglimits. 2. Placea suitablecontainerat the 2. Take off cap and cap gasketby
€ndofpipe. removing capscrew.
3. Start enginernd run at 2,000 3- Unscr€w elbowandconnector.
Jl3 Engine
4. Take olT the valve retainerby
0.18ks/cm2(2.56psi) 4. On rnodel Jt3 ongine,pump unscrewlng two screws, andtwo valves
J15Engine
shoulddeliyer400 cc (24.4 cu in) of
0.2t kslcm2Q.9g psi:) fuelin oneminuteor less. 5. Pressdowndiaphragncounterio
thc force of djaphragmspdng and
Pressurebelow the lower limit On nlodelJl5 engine: unlockthe rcctangular prrt ir the low
indicaaes exlremewearon onepartor 1,200cc (73.2cu in) end of pLrllrod from rockcrann.Then
a small amount of wear on €ach r€movediaphrrgm,djapl agm spring
workingpart. If no gasoline,
or only a littlc flows andlowerbody sealfrcm lowerbody.
This may alsoindicatea ruptured from open end of pipe, frlel pip€ is 6. Dive ou1rockerarmph by press
diaphragm,worn, warped, dirty or clogg€dor pump is malfunctioning.
gummingvalvesand seatsor weak Belbre removingpump, removegrs
diaphragm rehlln spring. Pressure tank cAp, disconn€crboth inlet and
above the upper limit jndicaresan outlet pipesand blow throughthem
excessively strongdiaphragmthrt is vrith an air hose ro makc sure th l
too tight. th€y are clear. This witl elirni ato
This conditionrequifesr€movalof possiblecloggedgas s|lainer in fuei
fuel pump assemblyfor replacement tank. Reconnecipiposto pump and
EFI6A
FE. EF.2 Rehoual of pull rod
F
I
2
1
4 Fuel pun? vrlve a$embly
5
6
7
9
l0
lt
I2
1 3 Rocter arn sidespa€r
l4
t5
t 6 Rockerdn sid€Da€r
t1
Fig. EF 3 Sttucturc of fuet puap

EF3
Engine Fuel
ASSEMBLY 1. Usenewgasket. abovefuellevelwith a pipeconnecting

2. Lubricaterockerarm iink, rocker fuel pump and fuel strainerand oper-
Assemblyis done in reverseorder ann pin and lever pin before instal- ate rocker arm by hand. If fuel is
of disassenbly.For reassembly and dfawn up soon after rocker arm is
rcinstallation,the fo owing matiers 3. To testthe function,positionfuel reieased,the function of purnp is
pumpassembly nboui I meter(3.3ft)
FUELPUMP-ELECTBIC
CONTENTS
DESCBIPTION ,,,.,,. EF.4 DISASSE[/]8LY AND ASSEMBLY EF.6
O P E F AOTN .....,,,, EF . 4 DSASSEMB . .L. .Y. . . . . ........ EF-6
T 8 SNTG................ ........... . E. F 5 .
A S S E M B. L. .Y. . . . . . . . . . ..... .. EF-6
T B O U B L ED I A G N OSS A N D NSPECT .
ON . . . . . . . . . . . . . . . . . . . . . ....... EF'6
COFRECTIONS ,,.,,. E F5
DESCRIPTION
The Silicon Transistortype fuel
pump consislsof transistot,diodes
solenoid, pump mechanism and
I Diapltngm
This hanshrorfuel pump pr€s€nts
severaldislinclfe turesasfollowsI 3 Diodc
l- No vaporlookin torridzones.
2. SlrrLspunrpinginmediatclyas
th€ ignitionswilchis turnedon.
3. Builtin filter and magnetkeep
out dust and iron filingsof fuel, and 9 FiLlet
add to pump and enginelite. See
FigureEF4.
Fig. EF-4 CoBttuctioh of luel pump

OPERATION
I
2
3
5
'7
8
9
10
Fuel pump circuit .tiagam

Engine Fuel
: (2) As the transhtor is cut off, the Nore: If th€ diam€rerfu too smrll, th€
Wllen the ignition switch is tumed
on, cun€nt flows thrdugh the con and plunger is puslrcd up by the retum Foper deliv€ry caFcity c{n not be
resistorO to the transistor. spring, forcing fuel out. Then ule obtain€d €ven if putrrp functions
The current furtler incrcasesin pluager sucks up fuel at the bottom properly.
strengthas it passesthrough the signal end of the plung€r through the inl€t
coil. valve.SeeFigureEF'7.
Whenthe curent flows through tlrc
main coil, there is then a rnagnetic
pull, pulling the pluager against the
force of the return spdng. 3. With th€ hoseoudet in the higher
Men the pl nger is so pulled position than pump, operate PumP
down, revefte cuffent beginsto flow and check the delivery capacity for
through the sigral circuit, cutting off morethanl5 seconds.
the traNistor.See FiguresEF"3 and 4. Tlle capacityshouldbe I,400 cc
(853 cu in) in oneminuie or l€ss.
EF4.
(1) Suctionstroke If no gasollne,or only a little flows
When current flows through the from open end of pipe with pump
maln coll, this causesthe plungerto be operated,or if pump doesnot work,
pulled down by the mrgneiic force. As follow the following diagnosis.
this takes place, fuel pushesup the
FE,EF-7 Dbchdqesiohe Notesr
outlei valveand entersthe top end of
the plunger,FigureBF-s. a. Do not connect battery in rcvene
poladiy, 13thls would dunagc han.
The samesequenceof eventstakes
sbtor cLcuit and dilabl€ the pump.
placeto continuesupplyingfuel to tlle
b. Do not let the pipe fal, a3 tt m8y
engme,
damagethe electronlccomponenk.
Theseprocesses@ and @ are
c, Do not rpply overvoltage,(max.
repeatedcontinuously,
l.E V) Ovdvoltage shrtlng by
qrdck chrryeor overvoltagerurmiig
TESTING would detedorate ot d.mrg6 elec-
trcnic components.
1 fuel hoseat pump
Dkconnect
outi€t.
2. Connecta suitablehoselapproxi-
mately6 nm (0.0236in) tnnerdta-
Iie. EF-6 Suctionsiohe meter]io thopumpoutlet.
TROUBLE DIAGNOSESAI{D CORRECTIOI{S

Condltion Corrective
action
Fuelpumpfallsto Termoalsor connections loose. Retighten.

operarc. Rust on terninals or groundingmeial. Clearl.
Frozenliquid in plungprstick or pump. Cleanplungerassembly.Replacepump if
plungeris stuckor seized.
Fuel pump falls to Cloggedfilter. Cleanpumpinterior.Cl€anand,ifnecessary,

disclargesufficient
flo\li. lnsufficient fuel. Replenish.
lnsufficient fuel Fuelhosedbconnected.
dischargeduring Air in fuel hosethroughconnections Apply a coating of end sealinScompound to
h4h speedtraveling. connections, and retighten.
lnw float level
Hoseneckeddown or bent. Checkand correct.
at idling.
Fuel tank breather tube beni or necked
Wealenedretum spring. Replace.
EF.5
Engine Fuel
Condition
Air sucked through connection (fuei hose Apply a coatingof end sealingcornporlndlo
morefrequentlylhan and f'rel pump joint). connection,andretigit€n.
undernormalcondition. Fuel hose(on suction side)bent. Checkandcorrect.
Cloggedshainer. Cleanor replacestrainer.
Rattling noise Mounting bolts loose. RetiShten.
DISASSEMBLYAND 2. Whenrenovingplunger,take out Nolesi

spfingretainerfrom plungertube. Take crre not to deformtrbe as it
ASSEMBLY 3. Then, take out washer,O.ring, h thin.
DISASSEMBLY inlet valve,returnspringand plunger a. A$€mbl€ plung€r, return spring,
from tube.SeeFigureEF-8, inlet valve,O-ring,washerand set
l. Removecoverwith wrenchand springretrinerin thisorder.
take out cover gasket,magnel,and Note: Do not disass€mble
€leclronic b. Assemblefilter, gasketsnd cov€r
filter from pumpbody, compon€nts.If neces$ry,r€plac€ with magnet.
c. Tight€ncoverwith wr€nchto the
stopp€r.
INSPECTIOt{
lf Wrshfilter andstrainerwith clean
casolineandblow dustoffwith a blast
ot air. Whencleaningth€ parts,check
filter andSasket.If defective,
replace.
Noter Filter must be cleaned every

10.000km (6,000mil€s).
2- Washplunger,plungertube and
7 Oiine inlet valvewith clean gasoline,and
blow dust off with a blast of air.
Checkthen for wearanddefect.
If tley are found defeciive,
replace
12 Body
Fig. EF-8 Explotlettlieu of fuet punp 3. lnsert plunger assenbly inio

plunger tube of body and apply
Notes: electriccurren!to it.
ASSEMBLY
If gasket or filter is def€ctive,re- Movethe assembly up anddown.
Belore asscmbly. clean all parts placeit with a new one. If the assembly doesnot move,it
with ga$ljne and compressedair con, b . Especialy cleanmagnetand cover shows that the electric unit is defec-
pletely. for defect. tive,andit mustbe replaced.
EF-6
Engine Fuel
TWO-BARREL
CARBURETOR
CONTENTS
DI SCRIPTON EF. I A C C E L E R A TPOUFN T P . . . . . . . . . . . . . . . . .E. F . -13
c A R B U q r t oTRV P -. . . . . . . . . . . . . . . . J E TA , I R B L E E De ,t c .. . . . . . . . . - . . . . . . . . . E F l 3
s - I F U ILu R l A N D O P E q A T j O N . . . . . . . EF,7 [ / ] A J OSRE R V T COEP E R AOTN - . . . . . . . . . . E F - l 3
P R I I V A RS YY S T I M, , , . EF.8 R E M O V A L . . . . . . . . . .. .. . . . . . . . . . .E F - 1 3
S E C o N D A FSYY SL l l . . . . . . . . . . EF.11 DISASSEIVIBLY . . . . . . . . . . . . . . . . . . . . . . . . . . EF-13
AD-US]MtN] E F] 1 C L E A N I NAGN D ] N S P E C T |.O. .N. . . . . . . . . E F1 7
IDiINCAD,USIMLNT. E F1 1 A S S E M B LAYN D I N S T A L L A T I O. .N. . . . . . . E F l j
TUT- LEVLL ADJUSTMENT E F . ]1 J E T .S. . . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . .E. F . -17
ADJUSTIIIENT OF INTERLOCK SERVICE D A T AA N D S P E C I F I C A T I O. N . .S
.. EF,1B
OPENING OF PRIMARY AND TROUBLEDIAGNOSES AND
S F C O N D A FT Y H R O T _ LVEA L V E S .,...... EF-12 CORBECTIONS ..,... EF-19
ADJUSTN,,IENT OF STARTING
I N f T R L O CVKA L V EO P E N I \ G .. . .. ... EF,12
As almost all the mechanisms of

DESCRIPTION thesecarburetonarequitesimilar,the
general explsnatlondpplies to all
TYPE
CARBURETOR exceptfor minorvariations,
Theseare downdrafttypesand are
Carburetor
type Appliedengine bodynumber
Car.s designedto ircrease power and fuel
economy.
2t4282-124 GN62OU
N62OU, These carburetorspresentsev€ral
distinctfeaturesof importanceto ih€
NL620,GNL520,
214282-r32 J15wlth manual 1'NL620,
NL52OT, A summaryof featuresis as fol-
transnrisrion GNL62OT
a The secondary switchover systemis
PA32l.WA321, the mechanical throttle valvetype
214282-141 CKPA32t whichusesthe auxiliaryvalve.
. The power valve mechsnism, so-
T2OU,VT2OU,T2OHU calledvacuumpistontype, affords
214282-t11 J16with manual highspeedpeformance.
LT2O,LT2OH . Accele.ating pump gives excellent
214282-l8l
214260-t22 520U,G620U,
U620U
STRUCTUREAND
J13with nanual L620, LG620,UL620, OPERATION
214260-t32 L620T,uJ620'l
These carburetors consist of tlle
primary system fbr normal running
214260.111 A32I
andthe secondary systemfor full load
running.
The float systen which is com-
*The diff€.encss h performance are explained in the fo owing specification table.
mor y usedby primary rnd secondary
systems,the secondaryswitchover
mechad$n, the startingmechanisn,
acceleratingmechanism,etc- are also
attached.
On thesecarbur€tor,both primary
and secondarysystemsadopt zedth
stromberg typenozde.
EF.7
F n g i n eF u e l
(a
T
:
,6
l:l Sccondaryslos air blecd 23
14 l,rimrry hdn rirbleed 24
15 trinruy nrin nozrlc l5
(Prirhdy $tr{ll venturi) 26
l6 2l
t7 28
? Outlct chcokvalvc a o c r e t o r p u m Pn o z z l c 29
8 Acccl*!t$ pun! piJto! l 9 SccondaryDrin nozzlc l0
( S c c o n d d ys n l d l l ! c n t ! r i ) li
l0 Prir{ry slo{ xtr blccd 2(J Sccondfy nuin !n b[cd J 2 Sccondrrythroltlc valve
ll 33
22
Fk. u-FI S.ctionol tieu of cdrbLre tor
PRIMARY SYSTEM ldlina and slow syslem
Primary gy5teln Dudrg low enginc spccd, asshown

in FigurcEF,l l, fuel flowsthmgh
The prnnary systenris of zenith th€ slowjel, lnixnrgwith airconnring
slrombergtype. Fuel flows as shDwn from the lst slowair bleed,rnd passes
in FigureEF-10throughthc mrin jet, $rough the siowc.onomizerjet,again
niting with air which conesin flom mjxingwith iir comingffom rhe 2nd
the main ajr blecdand passesthrough slow air bleedand thcn is puled oul
the cmulsiontube, and is pu ed out into the enginethroughthc idlo hole
into the small venturi through the (or the idle nozzle)andby-pass hole.
mainnozzle-Du€ Lothe smallventuri, Mode1.2t4282.111 and -l8l arc
the highervelocityair curfentpasslng equipped wjth the idle nozzle as
Fig. EF-11 Idlinganl610b sy3tem
tluoughthe nrainrlozzlcpromotesthe slown in FigurcEF-12.Throughthis
nozzle, idling mirrufc is further
alomizedby air streamb.low throule
valveandensures stableidliig
Fig. EF l0 Prinary main stst.m Fie. EF-12 ldL nozzlesrstem

EF€
Engine Fuel
The lst slow air bleed on ihe bureto$ is differentfrorn othertypes Slow economizersystemis useful
2 1 4 2 8 2 - 1a
7n1 dl 8 l (Jl6) type car- (Jl s andJ13). to obtainsmoothdeceleration
ai high
J15,113'iype
Fie. EI'-13 lst stou dit bleed
Accslerrting mechanlsm
Theca$utetoris equt!pcdwitl the

piston typc accelerating nrechanism
linked to the throttlevalvc.Whcnthe ii
primary throttle valve, shown in
Figure EF-14, is closed,the piston
gocsup, and fu€l llows lionr thc flo:r!
chamb€rlhroughdrc inlet valvejnto
the spaceunder the piston.Whcnthe
lhrotile valve is opcncd,the pisror
gocsdown, openingthe outlct valve,
il
and th€n fu€l is stray€d againstthc
sidcwall of the snall venturi.broken
up inro small dropleis,and suppljcs
additionalfuel to errich the air-fucl
lrixture. Thc dnounr of fuel io be
sprayedcan be adjustedby ohanging
the positionof thc pump rod on rhe
pumpam.
2 Clip
FiE.Et 14 Acceletutionntechanisa
Startint m€chanism
Pull the chokeknob io closerhe quate angle automatically, ivhich optimum engine speed can b€ ob-
choke valve fu1ly, then srart the prevents overchoknre and ensures lained. With ihe chok€ valve closed
engine.This providesa rich mixrure, smooth engineperfomance. fully. ltle prinary throttle valve is
naldng it possibl€to startlhe engine While the engine is being wanned causedto open througl a link nech-
quickty Whenthe cngineis srarted, up, it increas€sin s!€ed dr steps,and anism at an ,ngle besl suited for
the chokevalveis openedat an ade by reteasing rhe choke knob an starting.
EF.9
E n g i n eF u e l
r j-!
ql.
)
<J (
-"t
)
A: I d t n s ( o r T n r o t t l ec L o s d )
!
B' : Iast idle (or Throttlc opcncd)
EF196 To.1lhif6ld
Fig. EF-15 8tafti\g mechanism FE.EF-16 Pouerodllemechonbm
Powot velva mechahlgm the vacuumbelowlhe throtilevalveis Throttle valvG

ioweredduring full load or rccelera-
The power valvemechanism,so. Thc primaryihrottle valveopemles
iion the spring pushesthe vacuum
callcdvacuumpistontype,ulilizesthe pistondownward,openingthe power tluough 80o for the Jl5 and Jl6
vacuurnbelowth€ throltlc valve.When €ngrne,an0dJ_rorrrr engrne,
valve1ofurnhhfu€I,
the throttlc valve is slightly opened Th€ sccondarylhrottle vaiveopcr-
Thc powervalvecomesinto func-
duing light load running, a high alcsthrough 70o for Jl5. Jl5 AndJl3
lion wheDthc vacuumis 115to 145
vacuumis createdin the intakemani- mmHg(4.531o5.71inHg)for thcJ1s cngine,
fold. This vacuumpulls the vacuun ard I l0 to 140 11is connected to the chokevalve,
engineandJ16engine,
piston upward against th€ springJ acceleralorpump throughihe system
mmHg(4.33to 5.51inHs)for theJl3
leavingthe powervalveclosed,When ergin€, linkagc.The designis suchthat when
th€ primarythrottle valveh opencd
s0o (Jls, Ji6), or s30 (Jl3), the
sccondary throttlevalvestarlsto open.
T|es€ ar€ op€nedfully at thc same
Secrisun lil-21
/.
f
50"( r 5,.116)
5 3 "( J l 3 )
7 0 o( J1 5 ,J 1 6r n dI l 3 ) 8 o o( J t s ,J 1 6 )
83'(Jt3)
2 o o( J 1 5J, 1 6a n dJ l 3 )
1 o o( J 1 5J, r 6 )
I
2
l
FiC. EF-17 Throttle lalte
EF.1O
Enginefuel
.SEOOI{DARY SYSTEM 1u Checkto be surcthat float levelis
Secondary Bwltchover
machari3m cofi€ct whjle rurning engine at idle
Secondary sy3tem
speed.
As the linkage, shown in Figure 2. Using a suitable screwddYer
The secondarysystemis of zenith
EF-l?, cau!€sthe secondary throttle stariing from tully closed position,
strombergtype. Air-fuel mixture pro.
valve not to open urtil the primary turn oux idle Edjust screw approxi-
duced by tle functions of &e main
tfuottle valveopeningreachesapproxi nately 2 (J15) or l%(lt6) or
jet, mainair bleedand emulsiontube,
mately50o (J15, J16), or 53o (Jl3), 2%(J13)tur . Tum in tirottle adjust
in the sarnemarner as in the primary
fuel consumption duringnolmal oper. screw two or three tums and start
system, is puled out into the small
ationis not excessive. engine.
venturi tfuough the main nozzle.
When the primary throtde valv€ 3. Turn throttle adjust soew gendy
The structure is akflost ihe sameas
opening reacheswider position than in or out untll speclJledenglne idle
the primary-side, but ventudandjeXs 50o (15, J16), or s30 (Jt3), the speedis approximatelyobtained.
are different. Take carc not to as-
au\iliary valvefu readyto open. 4. Tum idle adjust screwin ol out
sembleimproperly.
The auxiliary valve, shown in uniil engine runs smoothly at the
Figuie EF.17, is a specialy shaped htghestipe€d.
buttetlly valv€ and is eccentrically 5, Tum out ihroiile adjust screw
mountedabovethe throttlevslve.Itis until speclfled engine rpeed is ob.
connected to the valve arm which tained.
incorporates a weight.Thevrlveopens 6, Readjust idle screw until €ngine
and closesautomaticallyto provide nrns smootl y at the highest speed
the correctair.fuelratio. (wtth hig.hestvacuumreading).
7. Repeat ihes6 operstionsuntil
smooth and specifiedenginespeed
Flo.l ryatsm (600 rpm or .bove) is obtalnodand a
conc€ntrationof 3% CO has been
The float systemconsistsof a floai obtained.
chember,a floet and a needlevalveas
Flg. EF-18 Secondory noin atten rhown, Fuel from the fuel pump
ent€rsthrough the fuel strainerand
noedlevalveinto the float chamber,
Thls wlll causethe float to moveup,
pushingthe needlevalv€into the valve
3t.p .yrt.m s€at.As the result,the fuel inlet is FUEL LEVEL ADJUSTMEI{T
closed,so that no fuel can enter,As
The construction of this sFtem the fuel level lowe$, the float moves A constant fuel level is maintained
maycorespond to thedowsyst€m of down and opensthe fuel inlet, thus by float andballvalve.lfthefuel Ievel
the pdmarysystem.Thissystemalrns maintaining ille level constant.Since k in accordwitl levelgaugeline,float
at the proper filling up of t]le gap the needlevalveis spflngloaded, it is levelis properly set.If float level ls not
when fu€l supplyis transfefiedfrom hardly influencedby extenal forces correct, adjust it by bendinSfloat arm
the prtnary systemto the secordary due to vibraiions (float) when driving asslbwn in FisuroBF-21.
one.The stepport is locat€dnearthe on roughroad,
secordarythrottle valveedgein its The float chmber is v€ntedinto
fully closedstate. the carburetoran horn and doesnot
open to the atmosphere.In other
words,air pressure is the samein the
float chamber and air hom. This
eliminatesthe effect of a cloggedair
cleaner,which otherwisewould ble€d
too much fuel due to inoeasedmani-
fold negativepressur€.
ADJUSTMENT
IDLING ADJUSIMENI
Idlingadjustmentis madeby throt-
Fig. EF-19 Secontlary step clstem tle, adjustscrewrnd idleadjustscrew.
EF.lI
Enginefuel
Figue EF-23 stlows that pdmary
ttuottle valveopens50o (J1s, J16)or
53o (J13). mer primary throxtle
valve opeff 50o or 53o, connecting
link is contacted with riSlrt hand end
of a groove on primary tluoitle arm
(A).
When throttle valve further opens,
secondsry ftrotde valve beguN to
open. Linkage between primary and
secondarytirottles *ill operateprop-
erly if clearancaGt beween ihrotde
valve end lnner wall of tfuottle cham-
I Slairer ber, amounts to specificatio as
2 BaUwr!€
Gl dimention
mm (mJ
FE. EF-20 FueIleuelddiwhnent
5.89(0.27r)
lifted up by bendingfloat atopPer.
*H: I O mm (0.0394in) 6.89(0.27t)
6.45(0.254)
Adjwtmentis madeby bending

connocting
lin*.
AD'U3TME'IT OF STARTIXG
PE. EF-21 ?Ioot.n odjuatnett INTEFLOCX VALVE OPENING
Adjwtmentshouldb€ performed
Appioxim.tely *ll mm h rcquired wlth chokevslvefully closed.Without
for effectlv€ltrok€ of boll valve.So dbturbing {bove settlng, check to
adjuit grip blt*een valve stem and EFOlA
determlne lf cloarance between
float arm to *H mm with flost fully trig, EF-22 Floot stoppet adjustmant prlnary throttlo valveand innerwall
of throttle chamberis held within
specifiedljmlts. Allo geeif openinS
oPEt{tr{G
oF
SECO]IDARY
VALVES
t*****^"f''-.r,
AD'USTMENIOF II{TERLOCK
angleof primorythrottlovalveis 1?o
(Jls,Jl3)or 19o(J16).
If necessary,bend choke con"
nectinglod as requiredso that cl6ar-
ance"C2" fallswithin specifiedtoler-
ances,asshownin.FiguftEF-24.
1?"(!15,J13)
5 o o( J t 5 , J 1 5 )
53o (J13)
(seeFig. EFl5)
tie. EF-24 Me@ing startiie
Fb. EF-23 Adjusrte interloch openine tuterloch nolre openina
EF.12
E n gi n e tuel
AGCELERATOR
PUMP If th€ tlueadsof the parts and oiher
it
G2 dimention fitting parts of rhe throttle shaft and
Acceleratorpump can be checked
mm (in) chokeshaft are roo tight, cleanrhem
w'th enginestationaryandair cleaner
well with gasolinebefore assembting
remov€d. To testpump,op€nthrottle
1.33(0.0s2)
valve fuly at a stretch and seehow
1.s7(0.062) All the parts of these carburetors,
much fuel pump wifl feed. Be sureto includiq the small ventud, €an be
1.03(0.041) repeatthis procedurel0 to 20 times disass€mbled
and careshouldbe taken
to obtainaveragereading: to identify very sirnilar parts for rhe
primary side and for the secondary
men disassembling rhe carburetor,

Holein pumparm it is easyto dividethe work into the
nearthe pump arm shaft following six Sroups.
l. Linlegesand rod arouddthe car-
0.72cc
0.6 cc 2. Acceiemtor pumpparts.
3. Air hornparts.
0.6 cc
4, Bodyparts.
Dependingon position of connecting 5. Floatparts
rod in holesin pumparm.
6. Flangeparts.
Among the abovegroups,the float
anq acceleratorpump parts are rel.
atively easy to djsssenble inde-
JET,AIR BTEED,ETC. REMOVAL pendently.
All jets, air bl€edholeaetc.,should

L Removesir cleaner
be cleanedwith rpprovedsolventand
2, Disconnect the lacuumpipecon.
checked for cloggingand stgn of
nectingto thedistributor,
damage. Th€y shouldneverbecleaned 3. Disconnect fueliine.
with wires, for this will enia4e th€ 4. Removethroiile end chokewtrc.
oPenrngs, 5. Removefour nuts and washers
retainingcarburetor Llnkrgo part.
to manifold.
6. Life carburetor offmanifold. l. Takeoff ihe clip at thepumparm
7. Removethe gasketusedbetween anddisconnect the pumpconnecting
calburetorandmanifold.R€plac€ it, if roo xom thepdmarythrorrletever.
2. Disconnect the starting con.
MAJOR SERVICE nectingfod fron th€ startingthrottle
OPERATION lever.
The perfectca6uretordeliversthe
properair andfuelratiosfor alt speeds
of the particr ar enginefor which it
was designed.By conpletely disas- DISASSEMBLY
sembling at reguiar intewqh, which
will aliow cleaning of atl pans and G€n6ral inglructlonr
passages, the carburetorcanbe rctum-
ed to its original condition and it wifl Usewtenchesand driversof siz€s
then deliver the proper ratios as it did wellfittedto thenuts,screws andjers,
to avoiddanageto them.
To maintain the accuratecalibra. The smal parts disassembled or
tion of pas$g€sand dischafgeholes, rernovedshould b€ kept aranged ac-
extreme care must be taken in clear- cording to the individual systemand
ing. Use only carburetor solv€nt and be checked for werr and damage.
compressedair to clean all passages Replacethe d€fective parts with new
anddischarge holes.Neverusewire or
other pointed insrrument to clean as
the calibration of ca$ureror wil be
Clean a[ the parts with gasoline,
blow air though tlle $nall holesin the
iil
partsanddry them by air.
i
EF.I3 riii
Enginefuel
I Cotterph (1 dia.)
2 Plainwasler(4 dia.)
3 Rod slring
5 Erins (4 dja.)
8 Slarlinglev€rconnccting
roal
9 Eiins (1.9dia.)
EF2O1
Fig. EF-26 Lithaee pa .lba$emble
Acc.l.rrtlnS Purnp pumpplungerassenbly canbe taken the ball inlet valve by removing the
the linkagethe
By disconnecting out. Takeout the pumPskainerand rtrainerclip.
I AceleratorPumPPston
2 Clip
l
EF205
Fig.El-26 Removatol occeletutingpumb
Afu horn
the air hom to the body, the choke
By taking off three bolts holding wire hold€r,air hom, clalllpetc.,and
EF.I4
Engine Fuel
I
. 2
3
5
6
' 18
' 9
o'oiir""e'.qp
10 rh'ottturuqmjprtnr
rEf206
PE.EF-27 Aenowl of ai hon
Note: Th€ vdcuumpiston arsembly B€c{r€fulnot to damsgethem,and hold the body to the flange,th€ body
for.the potfu!Jet,thFrchokrlslve, do not removethen fton air hom. it r€movod. TVo of these bolts ar6
thc choke shgft, chdkeleverand Body tightenedfrom th€ body sid€ and one
rpdrg are indall€dlh th€ air hom id from-th€ flangeside.
rssernbly,
_,,r : 1. By tlkiog off threebolts which
I B9dv
2
3
FE.E?-28
2. Renovethe jetsandan bb€djets

installed on the upper surfaceof the moving the slow paslageplug at the lst slow an bbed phg at the wall of
body. upp€r surfaceoftne body, the slowjet th€ primary sidebody, the lst dow aif
Model 214282-171,181, by rc- is taken out and then by removingthe bl€edjet is tal(en out.
EF.15
Enginetuel
I Plug
2 Garkei
4 outlet klle (Ba[)
6 Se@nilsryslowai! bleedjet
7 Piindy main6ir blee.ljet
8 Pdhary small@ntlri
10 Primaryb4e venturi
lt Se@ndary nah dr bLedjel
12 S.condary sm.llEntud
13 Casker
l4 SopJet
l5 St p lir Ue.djet
EF2OS
FE,8F.29 Remoualof iat etc.
3. By refilovirlgthe pump passage $mbly with theddver. At float plr, thete ls a collar for
phg, the pumpweightandthe purnp 6. Tal€ off the mainjet aftet re- keeplogfloet position.
oud6tvalveOall) &e takenout. movlngth€ mainpassage plug at the Pay atlentlon to the stnallr€lated
Do not rcmovotte pump nozzle bottomsurface of thebody. partswhichmay comeoff at r€movrl
Ilxedinto thebody. of thefloat,
4. R€movethe small venturl bY Flo.t 2. Removeih€ bolt holding the
takingoff two screws. union nipple,by removingthe nipplo,
5. Be careful not to dsmag€the 1. Loosenthreescrewsholdingthe thebellr.lve s€atlr removed.
valvettp of the powerjet valveas. levelgaugeglassandiakeoff thefloat.
FlanSe
Primaryeide
1. Removeidle edjust sr$w afld its
spring. By taking off the prtrnary
throttle shaft nut, the thrcttle shafi
lever, the ihrotde shaft arm and the
starti[g throttle leverarc remov€d,
I Fuel niplle et rcrew
2 Plain walhor (8 dia)
2. R€movethe plug ofprimary slow
3 F@l nippl€ port.
3. Model 214282.1'l| , I8l, take off
5 Float%lw seal the idle nozzle and its gasket after
6 Float varve removingthe idle nozzleplug.
8 Level SauBe@wr
4. Do not r€mov€th€ primary throt
9 Floal cltdber gastet ile valve and ttuottle shaft from
l0 I?rel9.lge flange.
11 Rubt er seal
EF2o9
gie. EF30 Reno@l of float
EF.I6
Engine Fuel
3. Inspectidle adjustingscrewfor
A*
\<'--l/-:\
burrsor ddges.R€place asrequired.
Inspect gaskets whether they
appearhard or brittle, or whether
\- \, edgesaretorn or distorted.Ifanysuch
\t \\a -
tr
condition is detected,they must be
replaced.
Check filter screen for clogging.
Cleanand replaceif it is dhtortedor
@ remairsplugged.
Checkventuriclustersfor loos€or
2 wom parts. If damageor looseness
l exists,r€placeclusterassembly.
Checklinlage for operatingcondi,
5
tion.
6
7 Idle adjustinE screw spring Inspect .the operaiion of ac-
eF210 celeratingpump. Pour gasolineioto
Fiq.EF.31 Redouatof flance(Primory) float chamberand operatethrotue
2. Removethe plug of the second-
l. By taking off the throttle lever ary stepport. Ch€ck condition of gasolinein"
set screw,the secondary throttlelevet 3. Do not removethe secondary jectionfrom accelerating nozzl€. l,r
and the spring ar€ removedfrom the throttlevalve,its shaft,auxilialyvalve
secondarythrottl€s,\aft. andit, shaftassembly from flange, ASSEMBLY AND l
INSTALUITION ii
@. -.>..-
Assemble
in reverse
and instalithe carburetor
sequence
Replace
ofdisassembly
gaskets,
if necessary.
and ti
N.y
Whendisassembling and assembling
interlocklink andr€latedcomponents,
be carefulnot to bendor deformth€
Reassenble carefullyafldcorrectly
so that all int€rlock links operate
li
$noothly.
JETS
I The carbur€tor performance
2 5 Secondary
throttL returnspring depends on jets andair bleeds.Thafis
3 Secondaryihrottle lewr EF211
Fig.8F.32 Remoualof flonse(seconddrN) why these componenisare manufac-
turedwith utrnostcare.
Blow all passages and castings wiih ' To cleanthem,usecleaning
Note: In the flang€, two throttle solvent
valvesareinstall€d. compressed air and blow offa paris and blow air on them.Larger nunbers
Be careful nol to damag€them and until dry. stampedon the jets indicatelarger
do not renor€ them frorn flange. diameten.Accodingly,mainandslow
Otherwise, stable idling and slow Note: Do not pass drills or wir€s jet with largernumbersprovidericher
sp€ed p€rformance will not be through calibrated jets or passag€s mixturc, and the smaller numbers
obtained. as this may enlarge orifice and provide the leanerrnixtur€-
seriously affect carburetor calibIa- Inversely, the main and slow air
CLEANING AND INSPECTION bleed,which air passes illrough,makes
fuel mixrureleanerif they bearlarger
Dirt, gun, waterorcarboncontam- Checkall parts for wear.Replace numbers, andthe smalernurnbers the
ination in or on the exterior moving wom parts. Esp€cialythe fo owing richer fuel mixture.
parts of carburetorare often rcspon- mattersshouldbe checked: Replac€meni of designatedjets to
sible for unsatisfactoryperformance.
For this reason,efficient carbu-
l. Check float valve (ba[) and seat
for wear.Replaceassembly,
retion dependsupon carefutcleaning 2- Check throttle and choke bore
if wom.
meet the sefliceconditionof the car,
must be carriedout with the above
dnectionsin mind.To cite a practical
i
and inspeciionwhile servicing. example,when it becomesnecessary
EF.17 I
EngineRrel
to economize fuel at the limited specified. use larg€r main jets or slow jeh, or
sacrifice of output to meet frequent This shouldmeet the purpose. smaller main air bl€€ds or slow air
liSht-loadoperation, use smaler main Invenely, when increasingoutput bleeds. This will bring a satisfactory
jets or slow jets, or larger main air at the sacrifice of fuel consumption, rcsult.
bleedsor slow air bleedsthan regularly
SERVICE DATA AIID SPECIFICATIOI{S
Carburetormodel 214282.t24,
t32, I4l 214282-11
1, 181 132,17|
214260.122,
Applied engine J15 J16 It3
Prlmary I Secondary Prinary Secondary Prlrnary Secondary
Inlet diam€ter mm (ln) 65(2.559) 6s(tr.559) 6s(2.5s9)

Oudetdirrheter fiun (in) 28(r.r.02) 32(1,.260) 28(1.rO2) 32(t260)
Venturi diameter
Lalge rnrn(in) 2r (0.827) 27(1.063) 23(0.905) zg(r.riz) 20(O.187) 27(r.063)
Medlum rffn (in) 1 4 ( 0 . s s l )14(o.ss
l) 14(0.5s1) 14(0.5s1)
smalr run un, 8 (0.315) 7 (0.276) 7 (0.276) 7 (0.276) 8 (0.31s) 7 (0.276)
Mrln nozzle mm (in) 2.2(0.087) 2.5(0.098) 2.3(0.091) 2.5(0.098) 2.3(0.091) 2.s(0.098)
Mainjet # 100 # lso # 102 f 160 #88 # l4s

Slowjet t46 t70 f46 t60 #48 f70
Mainair bleed f50 i60 #50 #60 #60 #8 0
lst slow air bleed # 100 # r00 il 100
2nd slow air bleed # 200 # 22O t 200 # 200 # 240 r90
PowerI€t #4s # 45 #s0
Float lever inrn (in) 21.5(0.846) 2r.sI ).846) 2r.s(0.846)
uppor surfaceofbody)
Fuel pr€ssur€ kelcr"2 (ps) 0.24(3.4r4) o.24(.\.414) 0.18(2.560)

1
Throtde valveclos€dangle 100 200 200 70 I 200
I I
Secondarythrottle valve
50" 50 53'
openingangle
Chokevalveclosedangl€ too 10 too
(exarnple) # 200 rcpresents 200/100= 2.00 mm (0.0787)diarneter

EF-18
Engine Fuel
TROUBLE DIAGNOSESAND CORRECTIONS
In the folowing table, the troubles.It sometimeshappensthat defective.Th€refore,whenevertlle

symptonsand causesof carburetor i}Ie completelyeffectivecarbur€tor €nginehastroublesthe el€ctricsystem
troublesand remediesfor them are seems apparently to have some mustb€ checkedfiIst beforeadjusring
listedto facilitaiequickrepairs. troubleswhen the electricsystemis
Thereare variouscauses of engine
Condifion Probable
cause
Overflow Dirt accumlated

on float valye. Cieanfloat valve.
Fuelpumppressure
too highfloat valyesear Repairpump. Lap or replace.
Excessive
fuel
improper.
Fueloverflow. S€eabove.
i
consumption Eachmainjer,slowjet too large. Replace.
Eachmainair bleedclogged. Clcan.
Chokevalvedoesnot open. Adjust.
Outlel valveseat of accelerator
pump im. l,ap.
proPer.
Linked op€ningof secondary
ihrottle valve Adjust.
Pow€rshortage Eachmainjetclogged.
Eachthrotllevalvedoesnot fuly open.
Clean.
Adjust.
fi
Fuelpumpoper ted improperly. Repair.
Fuelstrainerclogged. Clean.
Vacuumjet clogged. Clean.
Air clean€rclogged. Clean.
Powervalveoperating
improperly- Adjxsl.
Improperidling slowjet clogged. Cl€an.

Each lhrottle valvedoesnot close.
Each throltle valveshaft wedr. Replace.
Packingbetwee, nanilbld/cafburcior defec, Replacepacking.
Manifold/carburetortighiefling improper. Corect tightening.

Seethe first it€m.
Enginehesitation Eachmainjet,slowjet closged. Clcan.

By-prsshole,idlepassage
clogged. C1ean.
Emulsioniube clogged. Clean.
Idlingadjustment
Secondary
incorrect.
throttlevalveandauxiliaryvalve overhaulandclem. i
i
EF.]9 I
Engine Rlel
Enginedo€snot stari S€€tlrc fust iteft.

Ch€ckpump,fuel pipeandfloat vElv€.
Cofiectrdjuhnbnt.
' Correctadjustrnent.
Overhaul, cleon.
EF.2O
MODEL
J 1 3 . J 1 5 & J16 SERTES 'i
HtGilEs
EngineGeneral
Fig. EGl Left Bidevieu for 620
fig:. Ee2 Left tide oieu fo. T2O

EngineGeneral
SPECIFICATIONS
Engine nodel
Numberof cylinders,type 4, In line
Valve afiangemellt Overhead valve
Bore x stroke nrn (in) x 3.06) '78x82 (3.O7x 3.23)

73 ,17 .6 (2.87^ 3.06) 78 x 77.6(3.O1
DspLacem€nt c{ (cu in) 1,299Q9.3\ 1,483(90.5) |,s67(9s.6)

Compressionratio
Firing order t-3-4-2
Numberof
piston ngs
Numb€r
ofmainbearings
Capaciti€s 3.0(3X,2%\
liters(U.S.qt., 3 . 7( 3% , 3 X )
Imper,qt.)
4 . 4( 4% , 3 % \
VEHICLEREFERENCE
Ihis sectlon conteim the lnforma. manual of chassisand body for com- vehicleson which the Jl3, Jls and
tion rogarding engin€s only. Pleaso pl€te detailsof the vehlcles. Jl6 engin$areequipped.
refer io both thb manual and the The table that follows lists the
J13 J15 Jl6
620U PA32I N62OU 'r20u

R.H. drive A32l G62OU VPA32I cN520U T2OHU
U62OU KPA32I VT2OU
t 520 NL62O LT20
tn620 GN162O LT2OH
L.H. drive uL620 uNr-620
t-620'l NL62OT
tt]6207 GNL62OT
t
EngineGeneral
. RECOMMENDEDLUBRICANTS,
AND COOLANT
GASOLINE(FUEL)
RECOMMENDEDSAE
VISCOSITY NUMBER
Use the folowing grades of oil,
gasoline(fuel) and coolant.
10w
20w.20
30
GeafOil
90
-22 -4 14 32 50 68
TempemtweRangeAnticipated
t
t\
FG.A
EngineGeneral
',
5
Er." ;8d
I
!
i
E Z : le 9 3
t:e 5.9 E €;€
;E:F Fsdi 53s SsEsg Ei! ad;6
F3
:
;> E ;
:x
&t R
E
1r; lF: s
I i
E;EF3;R
E
fi
!*iiR 8d dB 83
E sgE ! i
E6 9 t 3
g * . * d 9i: i
iEE 5 doO
a ,"i 6: :} E'
s
; c E3
Jg:
! ::id E: d eFd
6:at 4.1
Er?=
9*!E3 F{
6r
an a-.e E
F ,&c
* E'
d3
EI
I x
2
('
E: ge
E
o
D
{*
r: =J ;t'^
i?e E:icffi€E
EFiE!E
o a I
!t t {
o
- 5-= .t
ut
= ' 3 {
= 5 4 5 I
o F
o 'IIO
!
€
IJ iINICNI
E
E n g i n eG e n e r a l
RECOMMEl{DED
GRADE OF GASOLINE
Enginenodel OctaneNo. of gasoline

JIJ
J15 morethan85
Jl6
NISSAN LONG LIFE

cooLANT(L.L,c)
This L.L.C. is an ethyleneglycol rateor boil arrayandcanbeusedwith products.This coolant can be used
bas€product containingchemicalin- either high or low temperature ther. throughoutthe seasonsof the yearand
hibiton to protectthe coolingsystem mostat.It flows fieely, hansfersheat erchangeperiodis two yearsor total
from rusting and cor|os,on.L.L.C. efficiently,and will not clog the pas. runningmileage of36,000krn (24,000
doesnol containany glycerine,ethyl sagesin the cooling sysrem.L.LC. milet.
or melhyl alcohol.lt will not evapo. must not be rnixed with any olher
0132)
Boilingpoint
-lo (t4t
0.9ks/cm,(13psi)
Sealevel -20 t4l
-30 \-221
3Oo/o l06oc(2230F) -lsoc (soF)
-40 {-40)
s0% ro9oc (228'F) t27oc(26roF) -35oC (-3loF)
.501-58)
10 20 30 ,rc 50
FiE. EG.3 Prctection .oncenndtion
UNIT SERIALNUMBERLOCATION
numbcrs.Thesenurnbersareindicated catedin an easy-to{eadposition.
unit identitication:engine and cllassis in the vehicleidentificationplate lo-
ENGINESERIAL J XXXXXX
NUMBER Jt5 X XX X X X
J16 XXXXXX
The engineserialnunber is stanp- ---T--
ed on the rear right sideof cylindel
block, at cylinderheid contactface. I
-tl-r-'-
SeeFigureBG-4.
The number is Fecededby the
I Serialnumber
ensinemodel,J(Jl3),lls or J15. Enginemodel Fig. EG-4 Engine @riol nunbet tedtian
EG.6
E n g i n eG e n e t a l
PERIODICAL
INSPECTION
AND MAINTENANCE
lrlxlE rlx x x EicclxlE xlx xlxlxlcclx
F
=
-
z
z
F
=
E
!
5
E
:
€ E
6
fl
o
E E .9
z E .9 .9
z d I
tr g E 3 I
E .t E
-6 -6 .=
E 'd
I e 'a E .:
.9 E
z I
E
!
I
P s .9 E
z '6 .9,
9
': =
F > .E .! .E ! : a
= '-i
. B
.E
i 5
n ,9 ! n
MODEL
Iil0tilEs
EngineLubricationSystem
ENGINELUBRICATION
SYSTEM
CONTENTS
I u B B t a A T tcot\c c u t T ............... EL-2 INSPECTION . -..... EL-3
o t l P U M .P. . . . _ . . EL.2 O I L P F E S S U RBEE G U L A T I NVGA L V E . . , , , , , EL-3
c E I V O V .A. .L. . . . . . . . EL-2 OILFILTER .. ,.,, EL4
t N sr A rI A I t o \ EL,2 O I L P R E S S URREEL 1 EVFA L V E . . . . , . . . . . . .- EL4
DISASSEV V BALN DA q S E \ , Y
4B. I - EL.2 OIL PRESSUW R EA F N I N S
G W I T C .N. . . . . . . . . EL-4
outerandinnerrotors,
The springloaded oil pressure
regu.
latingvalvelimits the oil pressure
to a
maximumof 5.8 kg/cm2(82.5psi) at
2,20Otprt.
REMOVAL
1. Drainenglneoil.
2. Rernove oil pan.
3. Remove oil pump body with
drlvespindleassembly.
INSTALLA'ION
1. Ustng a new gasket,lnstdl oll
pump and driv€ spindleass€mblyto
cylinderblockwith boltsandnut.
ELO34
FE. EL-l LubncatinS

circuit
LUBRICATION
CIRCUIT
The pressurelubrication of ihe cant is deliveredto the oil galleryin
€ngineis accomplished by a trochoid. th€ rockersbaft from the rearcrank-
type oil pump. This pump draws the shaftbearing.
oil through the oil strainer into the Th€ valve mechanism,push rods
pump housing and then forces it and valves, is tubricat€d tfuough oil
though th€ ful-flow type oil filter passeges in rockerarms.Cam profiles Fig.EL-2 Instaingoil pump
into the mainoil gallery.A portionof of the camslHftis lubdcateddown 2. Instal oil pan with a new gasket
the oil is suppLiedto all cra*shaft along push rods. Lubricating oil tien in placeon cylinderblock.
bearings,and is fed to the connecting returnsto the oil pan.
rod bearingsttuougl the dril€d pas"
sagesin the cranlduft. Oil inject€d DISASSEMBLY
ftorn jet holes on conn€ctingrbds AND ASSEMBLY
lubricatesthe cylinderwallsandpiston OIL PUMP l Remove pump cover attaching
pins. Camshaftbearinglubricationis The oil pump is bolted to the boltsandslideout pumprotors.
made by carrying oil through oil pas- bottom of the cylinder block and 2. Removeregulatingcap,regulating
sages from the cranl$lEft b€adng. driven by the oil pump drive spindle valveandspring,
Timing clBin and chain tensioner als€mblywhich is drivenby the helical 3. Remov€ oil strainer from pump
receivelubrication from tlle oiljet and gearon the camshaft.
an additionaloil passagediveged from The oil pllmp assemblycoffists of 4. Assembl€oil pump in tlle rcvene
the front cranlshaft bearing. Lubri- an oil pressurere8ulating valve md order of disaeseflbly.
EL.2
EngineLubricaiionSy$em
INSPECTION
lyash a[ parts in cleaning solvent

and dry with compressedair. Use a
brush to clean the insid€ of pump
housing and pressweregulatingvalve
charnber:Be sure a[ dirt and metal
particler are rcmoved.
1. Inspect pump body and covel for
craaksor exc$sivewear.
2. INpect pulnp rotors for daflage E!O13
3. Check inner rctor shaftfor loose- 3 Oui.r rotor to body

nessin pumpbody,
4. lfipect r€gulating!a1vefor wear 4 Rotorro botromcovo!
or sloring. cleahnco
Er-036 5. Check regulating spring to see FE. EL4 Cheching rctot cledftnces
that it k not wom on ih 3ide or
I Dr c gpindle collapsed.
2 Gasklt 6. Chec&&gulatingvalvefor free 8, Placea straightedg€,acrorsthe
3 Oil purn?body 8 RcgrlatorspriAr operatlonin thoborc.
9 Oil rrral|.l
faceofprmpasshowninFigursiEL4,
5Inn.!roto!dndBhaft ?. Uring a feeler gaugE,checktip Checkside clearinoe(outer to Inner
clearanceand outer rotoFto.body rotor) and grp b€tvoon body and
Ii'. EL-g Oll pump cl€arancesshownln FlguroBL4. stralghtedge.
Standard Woarllnlt
Rotor sldacleannce 0.04to 0,08

.
(outefto lnnerrotor,
mm tlnl
(0.0016to 0.0031)
0.2(o.oo8)
I,e3sth.an
Rotortip cl€annco tun (ln)
0.12(0.00{7) 0.2(0.008)
Outerrotor to bodv 0.15to 0.21

mmtlnl
(0.0059 0.5(0.020)
to,0.0083)
Rotorto bottoncover l,essth.n
. mm{llrl
0.04(0.0016) 0.2(0.00E)
Noter Outer and inner rotors rrc not OIL PRESSURE

s€rvic€dsepsrately.
lf oil pump body is damagedor
REGULATINGVALVE
wom, rcplac€ tfie entire oil pump The oil pressureregulatingvalveis
assgnbly. not adjustable.At the releasedposi-
tion, the r€lve permits the oil to
by-pass through the passagein the
pumP co!€r to the inlet side of the
pump. CheckregulatingyalvesprinSto
ensurethat springtensionis correct. FiA. EL-5 neguldting udlle
Engine LubricationSystem
Specificationg
Oil pressure
at idling 1.0to 2.0
ke/cm,(pst ............................
(14.2to 28.4)
valYespring
Regulatins
Freelength 46.7(1.839)
mr' (in) ......................................
lnstalledlength/load mm/ks(in/lb) 39.01s.7
(.r.s3s
I t2.6)
Regularingvalveopening
2.8to 2.9
kg,ic'n,(psi)................................
(39.8to 41.3)
OIL PRESSURE OIL PRESSURE

OIL FILIER RELIEF VALVE WARNING SWITCH
The oil filter is of a cartridgetype. The relief va1ve,localedin the oil Thcoilwarningswitchis locatedon
The oil filter elementshouldbe re- filler bracket,by-passes the oil into right hand rear of cylinderblock and
placed€very9,000 klTl(6,000 milet the main gallerywhen th€ oil filtet wiredto the oil pfessure watninglighl
of operation,with thc useofOjl Filtel elementis €xcessively clogged. in the instrunrent
clustcr.
Wfench ST19320000. With drain plug removed,check The wafninglight glowswhencver
WhenremovinS an oil filter, loosen valve for opefation, Inspect lor a lhc oil prcssurc
dropsbelow0.2 ro 0.4
it after stoppingengineabout sevelal crackcdor broken valve.If replace" kglcm2(2,8to 5.7 psi).
minulesto drain out rh€ oil from oil ment is necessary, removevalveand Priorto installingswitchto cylinder
filtef to oil pan. inslalla newone, block, be sure to apply conductive
Whcninstallingan oil filter, fasten seal€rio ilueadsofnew swtch,
it on cylinderblockby hand.
Note: Do not overtidl€n filter, or oil
leakagemayoccur.
I
2
3
Fig. EL-O Eemouincoil filter FiE. EL-z Retiefuatre
EL-4
Engine LubricationSystem
SERVICEDATAAND SPECIFICATIONS
Oil pump
Studed Wearlimit
Rolor sideclearance
(outerto innerrotor) mrn (in) 0.04to 0.08 0.2(0.008)
(0.0016to 0.0031)
Rotor tip clearance mm (in) Lessthan0.12 0.2(0.008)
(0.0047)
Outerrotor to body clearance mm (1n) 0.15to 0.21 0.s(0,020)
(0.00s9to 0.0083)
Rotorto bottomcoverclearance mm (in) kss than0.04 0.2(0.008)
(0.0016)
Oil pressure
r€gulating
vatve
Oil pressurc
rt idling kg/cm, (psi) .. . . . 1.0to 2.0(142 to 28.4)
Regulaiing
valvespringl
Freelength rnrn (in) 45,7(r.839)
Installedl€ngth/load
valveopeningpre$ure
Regulating
torque
Tightening
Oil pumpmountingbolts
Oll pumpcoverbolts
wlve capnui
Regulating
Oil panmountingbolts
AND CORRECTIONS
TROUBLEDIAGNOSES
Condition Probablccaus€
Oil l€akag€ Damaged

or clackedbody cover. Replace.
f ron gask€t.
Oil leakag€ Replace.
from regulalorvalvc.
Oil leakage Tightenor replace.
from blindplug.
Oil leakage Replace.
ojl pressurc
Decreased t€ak ofoil in engineoil pan. Conect.
Dkty oil strainer. Cleanor replace.
or worn pumprotors.
Damaged Replace.
regulator.
Defective Replace.
Useofpoor qualiiyengineoil. Replace.
Warninglight remains oil pressure.

Decleased Previously
mentioned.
"on" - enginerunning
Oil pr€ssur€switchuns€rviceable
. Replace.
fault.
Blectrical Checkcircuit.
Noise in purnprotors.
backlash
Excessive Replace.
EL.5
EngineLubricationSystem
SPECIALSERVICE.TOOLS
For Refer€nce
No. & Description pageor
tool name Unit: mm (in) on figure No.
sT19320000 This tool is usedto taLeoil frltor out of place.In iightening A1l Fig. EL6
the filtor, do not usethls tool to preventexcesstightening. models
oi1 filt6r Mencli
1 2 0m m ( 4 . t i n )
sEl€7
EL€
SECTIONEM
ENGINE
rcDEL MECHANICAT
13, 1 6 SERIES
HGIIIES
0Et{ERAt"
0fscntP]t0il til. 2
il{Grilt
0tsAssti|Bt-Y tir.4
It{sPtcTt0l{
AN0 ... .. . tlt|-I
RtPAtR
tt{0liltASSIII|B|Y "' El'1.23
"'"diiirirt'frriiii
stRl|tctDAIA
Al{0 E1'r.2s
TR0UBLt
t)IA0
0SES...............
ru-2a
AilDC0nRtCTt0ilS
sPECtAt
SIRI||CE
T00tS ttl-38
l:
( '
EngineMechanical
GENERAL
DESCRIPTION
CONTENTS
J 1 3J, ] 5 A N D J 1 6 E N G I N E S EM2 CANISHAFT EM-3
CYLINDEHBLOCK EIV].3 ROCKERSHAFT EM.4
CFANKSHAFT Etvt-3 VALVE I\4ECHANISI\4 EM4
PISTON A N D C O N N E C T I NRGO D . EM3 ]\4ANIFOLDS EM.4
CYLINDER NEAD EM.3
J 1 3 , t 1 5 A N DJ 1 6
, rrENGll{ES jourMls
with 3 mainbearing exlaust manifold ls equippedwiti the
.. . mechanism
r. O.tt.V.typ" valve . 2-banel,downdraftcarburetorfor
, , r De€pski , cast'ironcylinderblock thorough air-fuelmixing Sinceth€ Jls is a bored.outversion
with cast.incylinders of the J13, and the Jl6 is a length-
. Csst-hon cylinder head including The exhaust manifold is of semi. ened.veion of the Jl5. The way in
bathtubtype combustion chambers for the bonnettype
dual construction which they are serviced is seldom
. Fully counterbalancedcrankhaft models.For caballtype models,the different except that some iechnical
datemustbe adjusted.
Enginemejordrtr
BngineModel Jl3 Jl5 J16
Diiplacement cc (cu in) | 299(19.3) (90.5)

1,483 (9s.6)
1,557
Bore x stroko mm (il) 73x7't.6(2.81x 3n6) 78x 71,6 (3.0'lx 3,06) 18x 82Qn1 x 3.23)
Ratio
Compression 8.2 8,3 8.3
Isnition timins
-
B-.T-D,C.
rPm 8o/600 8Y600 8o/600
EIM.2
Engine Mechanical
cylinder walls are lubricatedby oil

squirtedfiom the oil jets locatedat
the corn€ctingmd big erds.
Fig. DM-4 Pi|ton
JGF Il5,ll5
Fig. EM-l Croessectionaloieo (J16 enEine'bonnettlpe nodeb)
0
CYLINDERBLOCK
The crankshaftis a fully counter
baianced,3.bearingtype desjgnedto
increased wear resistance.
The crank.
shaft has drilled passages through
which oil can flow to the mainbear-
ingsto lubricateandat the sametime
K o -
turn out smooth,dependable pow€r. The centermain
to cool the bearings. Fig. EM"5 Connectingrod
Wate! is forced through the wrter beadng is equipped ivith thrust
jackeh to depdve the cylindersof washersto take up end thnst of the
unwanted combustion h€at. The crankshaft.
engineidertificationmarks"T0i" for CYLII{DER HEAD
the Jls and Jl6 and "B34" for the The cylinderh€adis madeof steel
J13 areembossed on the right rearol casting. It contains baihtub type
ihe engineblock. combustlon chambers. A specialsinte!"
ed alloy valveseatis installedon the
€xhaustvalve.It is press-fiit€d.
FE. EM-3 Crdnkshaft
PISTON AND
Fic. EM-2 Cllinder bloch CONNECTING ROD
EM-345
The pistonsaremadeof aluminum
Fig. EM-6 Cylin.t r hed.l
aloy casting.Itis Autothermictypeto
CRANKSHAFT assurcperfectroundness whenheated
The cranLshaftis of sp€cialsteel to operatingtemperature. The piston
pin is a full floaling fit to th€ piston
CAMSHAFT
forginSwith 3 main bearingjournals.
To providebalance,4 counterOal- while it is pr€ssfitted to the con- The camshaftis of specialste€l
ance)weightsarc providedjust op' necting rod snall end. The connecting casting and is supportedby 3 rnain
posite t}Ie crants. The main bearing rod is a specialsteelforging.On the bearings.The cam lobes are cas€
joumalsand connectingrod joumals J13, the piston pin is bolted to tlle hardened and finished to extreme
(crank pins) are case hardened and snall end to preYentit from wo*ing $noothness for inu€asedwear resist-
linished to extreme smoothnessfor out of place during operation.The
:.
EIM.3
E n g i n eM e c h a n i c a l
springtype, innerand outer.Only for MAI{IFOLDS

the A321models,the valv€springis of
single type. The valve oil seal iing is Cast-i.onmanifolds are used 1o
carrythe exhaustgases awayfrom the
cylindersand to admit fie ai.fuel
mixture to the combustionchambe..
The exhaustmanifoldis of seni-dual
constructionfor bonnettype mod€ls
and is equippedwith a heat control
valvefor caballtypemodels.Theseare
Iig. EM-7 CdnshLft bolted to the cylinderheadwirh the
gasketsinse(ed in between.The €x-
haust pipe is flangemountedto the
ROCKERSHAFT
Fie. EM-g Voluemechanism
The rockershaftis madeofcarbon
steel: it is also case hardenedfor
jncreas€d dumbility.The valverocker
arms are lubricatedby leakrgeof oil
from th€ oil passagedriled in the
rockershaft.
Fur bonnerryfc nrodel!
EM349
Fig. EM-8 Ro.ker shoft a$embly
VALVEMECHANISM
The valve train consistsof the
camshaft,pulh rod, v?iverockerarm,
and valve; motion h transmitted
throughthesefour partsin rhe order
listed.Th€ valvespringis of doubie Fi!. EM la Exhaust& Ihtohe manifods
ENGINEDISASSEMBLY
CONTENTS
P B E L I M I N A RCYL E A N I N G
AND PISTON
A N D C O N N E CNTG B O D EN/t,7
I N S P E CI T
NG EN,45 C Y L I N D E RH E A D EM.7
D SASSEI/]BLY El/l-5 V A L V E R O C K E RA S S E M B L Y EM.7
i
Et\,14
PRELIMINARY rcmoveoil filter, useOil Filter Wrench
CLEAIING AND sT19320000.
I1{SPECTING
Beforedisassembling engine,note
the fo owing:
l. Fu€l, oil or water may leakpast
cylind€r head and block. Prior to
disassembling,check cylinder head,
front chain cover,oil pan afld oil {ilter
gasketsand crankshaftand water FE. EM-14 Re ovingboterpunp
pump sealsfor signsof leatagepast
theirgasketed surfaces.
11. Back off bolts securingcarnk.
2. Checkcarburetorand fuel pump
Fig.EM-l1 EnEineonenginestand shaftpulleyin position:removecrank.
for condition;fuelhosesfor deteriora-
shaftpuney.
tion, cracksor leakageof fuel pasi
thei(jointedor conflectedsurfaces. 4. Removefan andfan pulley.
3. Removeeir cleaner,alternator, 5. Disconnect carburetor ffom
distributorand starter,and plug up intakemanifold.
carburetor air-hom add distributor 6. Remov€boih intakeandexbaust
hole to prevent entry of foreign maf manifoldsiogetllerwith gaskets.
ter.
4. Wipedudtandmud offengine.
5. Inspectblock,rockercover,front
chaincover,oil panandall otherouter
partsfor vbualdefectsandbrokenor
missingparts suchasboltsandnuh. EM35A
6. Test all pipings and electrical crcnhpuller

Fi.. EM'16 Removine
circuih for discontinuityor brokenor
&msgedinsulation. 12. Applying suitablewrench,un-
screwboits which hoid timing chain
DISASSEMBI.Y coverin place;takeoff covertogether
with gasket.
To removeengin€ from vehicle, Fig. EM-12 Bemouingintake dnd
13. Remov€timing chainlensioner.
rcfer to relatedtopic under "Engine eth.utt manifolds
14. Back off bolh which secure
Removaland Installation"in Chassis 1 . Removefuel pump. camshaftgear to camshaft;remove
and BodySe iceManual,SectionER. camshaftwasher.At the sametime,
l. Removetransrnisslon from enBine iake out oil thrower on crankshaft
completewith clutch. side.
2. Thoroucldy drain €n8in€oil and 15. Removecamshaftand crank-
coolantbyremoving bottomplugs. shaft gea6 with cham hung around
3. In succession, r€movethe follow" gearteeth-It is good practiceto use
rn8pa|ls: CrankshaftCear Pullef 5T16530000.
. Hightensioncables
. Sparkptugs
. Rightenginemouniingbracket
. Oil filter bracket and oil filter
. Oil pressureswitch
. Oil levelgause
Iig. EM-L3 Reno\inq fuel PumP
. Fanbelt
After above st€pshave been com-
plet€d, attach Engine Attachment
5T05280000to dght sid€of engine. 8. Back off bolts and removeleft
With the useof an overheadhoist and handenginemountingbracket.
lifting cable, hoist engine up away 9. Back off bolts securingwater
frorn the engin€ cari€r and place it outlet; removewater outlet and i}Ier'
down in Engirc StandSm501S000.
The engineattachment is commonto 10. Removelrater pump together
the J13, J15 and J16 €ngines.To withSasket. FA.EM-16 Fenouing timing chain
EiTS
E n g i n eM e c h ainc a l
16. Renove camshaftand cranl- 24. Rernove oil pum! with oi1 can be reinslaled in their original
shaftkeysfro k€y,ways in gea( (two sirainerassemblyand oil pump drive
for crantshaftandone for camshaft). sljndle by backingoff bolis which
17. Straightcntabsof lock wishers
andbackoffbolis sccuring flywheelto
flanse erd of crankshaflrcar. Fiy-
wheel can dren be take oul. Be
carefulrot to drop it- At thissiagcof
disrssembly, removeenginerearplaie
togetherwith gasket.
18. Back off bolts which hold
rocker cover 10 the to! of cylinder
head; renove rocker coyer together
with gaskerundercover.
19. Back off valve rocker shaft Fig. EM-21 Withtlrouingpiston and
cannectinqrod oseftblr
brrcket bolls ard cylinderherd stud
nuts in two or threeprogressilc sleps
ard in sequenceshown. Fie. EM-19 R.mouine oiLpump ond
oilpump driuespitdle 30. Rlck off bolls lolding crank-
slnll beuing c!ps to engine block
saddlcs:scprr te crps ofi srddles !o"
g c l h e r w i L h t h n r s l w a s h e r sa n d b e a r -
2 5 . F r € e c a n l s h a f tl o c a f i r g p h t c ; n l g s .l l i s n c c c s s a r1yo u s c C r r n k s h N l t
withdraw crmshaft towLlrd thc lio l M r n r B c a r i n g( l a p I ' u l l c rS f i 6 5 l l 0 0 0
of engine.When renrovi|8 shrft. cxcr. w h e n r e m o v i n gc c n t e ra n d r c i r b c a r i r g
c i s e c a r e n o t ! o d L u n a g cc r s h x J l
bcarings as woll rs crnr lobes, rvhich
w o L r l dm r k e t h e m u f i i f o r f L r ( | c l
Fig. EM-17 Rocher shdft btochel

boLtdnd.cyliidet hcdd
trut loosenihg sequence
10. Tlkc off valvc rocker shan !s

semblyftorr cylinder head.
2 1 . L i f t o u t p u s hr o d sf r o m h o l e si n
c y l i n d c rh c a d .
22. Lift cylinder herd strright up
away irom cngineblock togetherwilh Fig. EM 22 Rehauing rnaih
saskct undcr hcad. Every caution Deonhg caP
shouldbe taken not to damagethreads
of stud bohswhile head is beinglilled. 31. Renovc crankshrfl ald mair
Fig. EM-2a Withdnung conlshoft
bearings.Makesureto placeihern in
corfecl o.der ir pats fack, so-that
they can be instatledin their original
16. Pull oui valvclifters from block.
:7. Renovc ffont plate by backnrg
offbolts seou|ingii to engineblock.
18. Rotate engin€ block on engine
standfor easyaccessto pistons_
29. Remove bolts which hold con
necting rod caps ifl placet separate
connecting rod caps iogether wirh
bedring hserts. Push con ecting rod
Fig. EM tB RPnaling.!Lindet hedd
and piston assemblyout to! of cyl,
inder with lr bar or hmdle end of a
23- Invert engnreblock 180" so that hanner. Avoid danaging piston .ings
oil pan is facing u!; renove bolts wher removingpiston and connecring
which secureoil lan to engineblock. rcd. Phce all disassenbledparis in
Remove oit pan togetherwith Basket. paft rack in corect order so that rhey FE. EM'23 Remouine.runk\haft
ENrt.6
Engine Mechanical
PISTOI{ AND 3. Using suitable wrench, back off

OONI{ECTIIIGROD, bolt secuiingpiston pin in place.Using:
l. Removepiton ringsfrom around Pision Pin PiessStand 5T13040000,
piston using Pislon Ring Expander removepin underpress(Jl3).
EM03500000.
Note: Exercise caution in renovirg

piston rings. Excessiverpreadingof
rings wil cau3edarnsgeand render
them unJit for furthe( servicedile
to br€akageor relaxedtemion,
FE. EM-27 Renouing ualve
EM365
fE. EM"26 Remoolng pirton pin
bolt (J13)
VALVE ROCXER ASSEMBLY
Withdrawcotterpinr from€achend
ol rockerslnfti removevalverocker,
Note: Be sure to place removedpins
FE. EM-24 Renouins pistot ring valve rocker bra4ket and sprlng ln
in conect ord€r in pad rack so that
orderListed.Therearmodbracketll,s
they csn be r€install€din ihe same
a s€tgcrewwhichlecureSrockershaft
2. Removeplston pin with Piston pbtoff from which lhey ve.e re-
ln plsceto preventit frofi worklng
Pln Prers Stand ST13060000under loosedu ngoperaiion,
pr€ss(Jl5 andJ16).
CYLINDER HEAD
(J15,Jl
sTl3060000
Compress valvespringswith Valve
Ufter 5T12070000. Removerubber A
Ws N
rings, valve colleh, springrotainers, \@ \
valve springs,valve oil seal rings
EM36?
(option) and valver.Placermoved
Fig. EM-26 Eenoving piltton pin parh in correctorderin partsrackso Fig, EM-28 Dkastembling rccher
(J16 ontl J16) that they can b€ ninstrlled in their 6oemblr
odginallocations.
El\4-7
Engine Mechanical
AND REPAIR
INSPECTION
CONTENTS
PREPARATION FOR NSPECTION .,,,... Et1 I c y L N D E BB O RN G . . . . . . . . . . . . . . EM'16
C Y LN D - R - f ^ D A \ D V A V t EM-8 P I S T O NP,] S T O N
PN AND
H E A DI V A TN G
C H E C K L NCGY L ] N D E R p t S T O NR T N G S . EM-17
E M 8 C O N N E C TR TOND G. . . . . . . . . . . . . . . . . ENI-19
v A - v r -^ , v B lY . . . . . . . . . ... E M 8 CFANKSHAFT .,.... EIV].19
V A t v r - | r r . FA \ D D U S H qOD..... Etvt-I B U S H I NAGN D B E A R I N.G .............. - E|\,,1-21
VALVI SPPING E[/]- 9 MEASUBE]\4ENT OF CONNECT NG ROD
ROCKEFARIV]AND VALVE B E A R T NCGL E A R A N C. E . . . . . . .. Etvt_2l
R O .< E c o t v o T EM-10 MEASUFEMEN OT F I \ 4 A I NB E A RN G
V A IV E C U I D f E M1 O CLEARANCE . . EM'21
VALVI SIAT EM,]2 FlrrlNG BEABNG " ev-zz
CAMSHAFT AND CAMSHAFT M I S C E L L A N E OCUOSf u 1 P O N E N T S , . ., . . , EM.23
B | - A B T N C . . . .. . EM.]3 C B A N K S H A FSTP F O C K EATN D
(AVS*A_ BEAE.NC G- ^ C A \ ' E . , EIV].13 C A M S H A FSTP B O C K E, T .,, ,,,,,,, EM.23
VA-VF TI\,1INC EM.14 C H A I NA N D C H A I NT E N S I O N E. B , . , . EM.23
C A I I S H AIL A I I C\ V t N EM-14 F L Y W H E .E. L. . . . . . . . . . . .. . . . . . . . . . EM'23
C Y L I N D EBF- O C < , EM.15 F R O N TC O V E FO L S E A L. . . , , , , . , , , , EM'23
NOWTO N4EASU FE CYLINDER
EM.15
PREPARATIONFOR Headsurfaceflatn€ss
INSPECTION
L Bciorc clcaning,checkfor signs Maximumallowable
standrrd mm (in)
ofwaterandoit Leaks in cylinderblock limit nun(in)
andhead.
2. Clean o and cafton deposits Transversc
warpage on
gasket
0.r(0.0039) 0.2(0.00?9)
from all parts.Th€y shouldbe clcan lhce
contacting
fromgaskero! sealant.
3. Cleana[ oil holeswith solvent Surface
Brindinglimii 1.5(0.0s9r)
ard dry with compressed air. Make
surethri lh€y arenot resiricted.
Surfacegrindinglirnit
CYLINDERHEAD The grindinglimit of cylinderhead
AND VALVE is availableby the cylinder block
grindingin an engine..
CHECKINGCYLINDERHEAD Depth of cylinderheadgrindingis
MATINGFACE
1. Make a visual checkfor cracks Depth of cylinder block grinding is
2- Measuretnc surfaceof cylinder Thelimit is fo owing;

head (on cylinder block side) for A+B= 2.0 mm (0.0784in)
waryage.If it is found to be beyond
the limit designated
below,regrindthe VALVE ASSEMBLY
affectedsurface grinder.
with a surface
Fig. EM 29 Checkikecrlinder h.dd
suta.e 1. Check each iniake and exhaust
EMA
Engine Mechanical
valve for worn, darnagedor deformed VALVELIFTER AND

valvecap3or stems.Conector replace PUSH ROD
2. Valve face or valve ltem end Valve lilter

surfaceshouldbe refacedby usinga
valve8rinder. Check valve lifiers for excessive
Fig. EM30 Intahe and erhawt ualue wear on the face that contactswitl
cam lobe.The end that contactspush
rod shouldalso be smootl. Replace
Unit: mn (in) with new onesif wom beyondrepai..
Corroci valve lifter to lifter hole
34.8to 35.0
In. clearanceis 0.016 to 0.052 mm
(1.370to 1.378)
(0.0006to 0.0020in).
J13
299 to 30.1
Ex,
( 1 . 1 7t7o 1 . 1 8 5 )
valve head Pu3h rod
37.8to 38.0
In, l lnspect push rod tbr excessive
(1.488to 1.496)
wear on the face that contactswith
J16 valverockerbal end Gphericalface).
31.9to 32.1
The facethat contaclswith valvelifter
(1.2s6ro 1.264)
shouldalsobe smooth,replacing those
wom or damaged beyondrepair.
109.35to 109.65
In. 2. Checkpushrod for bendor twist
(4.30s1to 4.3169)
lvith a dial gaugeor on a surfaceplat€.
J13
to 10835
108.55
L Valvelength (42736to 4.28s4)
J15 In.& to 109.6s Unit: mrn(in)

109,35
Jt6 (4.30s1
to 4.3169)
Valvestem 8.680to 8.693

D In & Ex' (0 341'7to 0,3422')
diam€ter
0.2(0.00?9)
valveceatangle ln. & Ex. 45030'
Grinding allowance for the !"lve

sten €ndsurfac€is0.5 mm (0.0197
in) or les, VALVESPR]NG
L Checkvalvespringfor squareness
usinga steeisquareandsurtac€plate.
If slring is out ofsquare"S" in Figure
8M.33 beyondspeciliedlimit, replace
Fig.EM 31 Medsuring
stemdbmeter
Note: Wh€nvalveheadhasb€enworn
down to 0.s mn (0.0197in) in
thickn€ss,replacethe valv€. FE. EM.32 Reetinding DstDefdce
Ell,l€
l' Engine Mechanical
I Valre sprin$Aecifi cations
A32l
J13,J15andJl6 J 1 3a n d J l 5
Valvespringlengtn Double
sprhgtrT,€ Singlespringtype
Outer nm (in) s2(2.U7)
Inner mm(in) s0(1.969)
47.r(r.8s4)
Valvespringpressedlength (valveopen)
Outer 'nm/ks(in/lb) 30.7 .8(r .2091l0s)
147
Inner mrn/ks(in/b) 30.'tl7o.6(t .2o91156)
(\.r30l4't)
28.712r.3
Valvespringassembled
height (r"tve ctose)
Orter rnm/ks(in/lb) .0(1.s3t164)
38.9129
lnner run/kg (in,{b) (1.0t6/?8)
38.9/3s.4
(t.453129)
36.9113.1
("S")
Outof square
Outer ftn (in) r.6(0.063)
Innor rnrn(in) 1.6(0.063)
1.2(0.047)
2. Measur€froe length and teNion placing those worn or damaged the worn parieor both valveandvalve
of eachspring.lf the messured value beyond llfiits. Correct oil clearance guide.
€xceedsthe specified llrdt, replace betweenrockorarln and rocker ghaftis In this case,it is esseniial
to doier.
spdng. 0Ol io 0.05 mm (00004 ro 0,0020 nine if such s clearancehas been
m). cauledby e wom or bentvalvestemor
2. Check rocker arm for wear or by a worn valveguide.
damageto the endthat contactswith
valvestemend.The facethat contacts
lwiih pushrodshouldalsobe inspected
for roughness,Replaceil wom of
damaged beyondrepat.
-rtffi VALVEGUIDE
rig. EM-38 M.aludns sprw M€asureclearoncebetwoenvalve
EM36A
guide and valve!tem. If iie cleaonc€
Fig. EM.35 Intdke andexhoust uatue
exce€dsihe designaied limit, r€place
Euidedi,ne6iot,, ( for Sevice)
Valveguidedinensions(for Seryice)
Unit: ftn (in)
Valveguide 7.6to 7.A

Dr In. & Ex.
(0.299to 0.30?)
Fig. EM-34 Medsving spring t.tuio4
Valveguide 14.313to 14326
D2 In.& Ex.
outer diam€ter (0.s63sto 0.s640)
ROCKERARIII AI{D
VA.LVEROGKERPIVOT In. 47.6(r.874)
Valvesuide
L
l. Checkrockerarmfor signofwear length
oi damageto rocker slnft hole, r€. Ex. s6nQ.20s)
Et\4-10
Engine Mechanical
- €mergencyexpedient, push (0.003ein). Max.alowabtedeflecxon

0.2nn (0.0079in)
i valve guide and move to the
he right. If its tip deflects Note: Valve should be moved in 3 0n m ( 1 . 1 8 1 i n )
0, mm (0.0079in) or more, paralel with rocker arn. (Gen€tal-
&drace betw€enstem and guide ly, a largeamountof w€aroccus in
tle maximumlimit of 0.1 mm this ditection..)
Fie- EM-36 Measutinq cledra\ce

betueen odluestem
an l vahreguide
E* luide s?ecilicstions
Intake Exhaust Wearlimit
14.2811o14.300
valve guidehole diameter mm (in)
(0.5622
to 0.5630)
Cuideto suidehole 0.013to 0.045

nrmllni
(0.000sto 0.0018)
Valvequideinner 8.732to 8.745 8.144$8.751

.. : mmtrn,
(0.3438to 0.3443) (0.3443to 0.3448)
Valvestemouter 8.680
to 8.693
.- mmttn,
(0,3411roO.3422)
0.039to 0.065 0.051to 0.077

Guideto stemclearance mm (in) 0.r0(0.0039)
(0.0015to 0.0026) (0.0020ro 0.0030)
R.pl.cem.nt of valva gulde 2. New guidesshouldbe installedto

proper depth and ream€dto size of
t. To remov€old guides,usea drift nomal room temperatures. Standard (0.610!o0.626in)
and drive them out of combustion diamet€!of hole io which guideis
chamber sid€ toward rocker cover. fitted is 14281to 14.300mm (0.5622
Heating cylinder head wil facilitate ro 0.5630in).
3. Wheninstaling new guideswith
an arborpress,it is recommended to
heat cylioder head to about 80oC
(176oF).Then,pressthem into place
in valveguide holes from rocker cover
side. Guides must be installed to
proper depth so tlat height abov€
valvespring$at is 15.5to 15.9mm FA- EM-38 l@taUtne ualueSuide
(0.6t 0 to 0 .626in) asshownin Figure
EM-38. Int€rfer€nce between valve
guide and guide hole should be held
witlin 0.013to 0.045lnm (0.0005to
0O018in). 4. Ream the bore with valveSuide
Fig. EM-37 Drioing elue Ei.i.te pressedin, using Valve Guide Reamer
ort frcm crlintler heod HTs6900870.
EIIIl
EngineMechanical
Valveguideinner diam€ter
Unitl lnm (in) -! dia.
4.-"...s"
8]32 to 8.145
(0.3438to 0.3443)
8.744to 8.75'7
l"tC rios"
ls"
(0.3443to 0.34a3)
I'
Unit: mm(ir)
J13 J l 5 ,J l 6
tT569008?0
Intak€ A 40 (1.575) 40(r.s75)
B 34.5(1.358) 37.5(t.4'76t
C 32.2(t .268) 35.2(1.386)
0,2 to 0.4 0.2to 0.4
D (0.0079to 0.0157)
(0.0079 io 0.01s7)
Exhaust 32.s(r.280) 3 5( 1 . 3 7 8 )
B 29.4(1.t57) 31.6(1.244\
EM37] c 26.8(l.os5) 29.0(1.t42)
1 . 0t o 1 . 2 O.2to 0.4
FE. EM-39 Redninc uolvesuAe D (0.0079
(0.0394 to 0.0472) to 0.0157)
EM375
Fig. EM-41 Voloe sedt dime$io@
5. Correct valv€ seat surfacewilh
newvaiveguideasthe axis.
Rogrlnding v.lve seatt 3. Apply snal amountoffine grind-
ing compoundto valvecontacting face
l- Wh€nvalveseatis found to be and put valveinto guide.Lap valve
VALVE SEAT wide b€yondspecificarions,
ir should aga,rst its seat until propei valve
grinding
b€ narrowedwith a 45.d€gr€e seatingis obrained.Removevalveand
when a valveseatis badlydamaged
or wom excessiv€ly to a poini wher€ thencleanvalveandvalveseat.
2. Width of valveseats,\ouldthen
pmper valvefunction is impaked,ii
be adjusted10 1.6 to 1.7 mm (0.053
nust be refac€dwith Valve Seat to 0.067 in) by making upper and
CoutterST11600001. Valveseatinsert
lower cutsasshownin FigureEM42- Repleclng valvo Beal In.ort
of 0.5 mm (0.0197 in) oversizeis
To do this, use a ls-degre€grinding
availablefor service exhaustvalve.
in
1. Old in$it can be removedby
boring out until it collapses.The
machinedepth stop shouldbe s€t so
that boring cannotcontinuebeyond
the bottom fac€of the ins€rtrecess
in
ooo
cylinderhead.
2. Selecla suitablevalveseatinsert
sT1600001 andcheckits outsidediameter.
3. Machinecylinderh€ad recessto
ihe concentriccirclesof valveguide
x x o
c€nter so that insert will have th€
4. Reamthe cylinderheadrecess
at
Fig. EM40 value seot contactinq FE. EM42 Cti4ding uolue6eat 5. Pressins€rte$uring that it beds
face uith Srin lina cutter on the bottomfaceofits recess.
-12
Et\r
Engine Mechanical
- 6. Valve seatsnewly fitted shouldbe 7. Lap valveagainstits seat,follow- CAMSHAFT AND

cut or ground at the specilieddirnen- ingabovernentioned
procedure. CAMSHAFT BEARING
sionsasshownin Figur€8M41.
CAMSHAFT BEARING
32,5?0ro 32.580 35.0?0to 35,080 GLEARAI{CE
( 1 , 2 8 2t o 1 . 2 8 1 )d i a , ( 1 . 1 8 0t o 1 . 1 8 1 d
) ia.
Joumaldiameters shouldbe check-
ed with a micrometerand bearings
with an inside dial gauge.Measure-
ments should then be compared to
determinewhether bearlngsare worn.
2 6 . 8( r . 0 s 5 d
) ia. 29 (r.1,42tdi^, If found worn beyond 0.18 mm
(0.00?in), replacewith new ones.ln
.Ir5,J16 pr€ss-fittinga new bearing, make
Fie. EM.43 Standordethouttalue seat.lim2 rcn' certain that oil holes in block and
Cylirder herd r€c$s diametd bearingareproperlyaligned.
: Unit: mm (in)
J13 J l 5 a n dJ l 6
32.500to 32.516 35.000to 35.016

For standard
insert
(l,2195ro 1,2802)(1.3780
to L3786)
Exhaust
For servic€
insert
33.00to 33.016 35.500 to 35.516
(1.2992to r.2998)(1.3976
to 1,3983)
fit nrn (in) I Exhaust| 0.054to 0.080(0.0021

Interference to 0.0031)
Crmshaftjournrl to beedngcleannct Unitr mm (in)
Frcnt Cenier Rear
journaldiameter 45.434to 45.447 43.891to 43.910 4l .218to 4l .231

Camshaft (1.?887 (r .7282to 1.7287) (1.6228to | .6233)
to 1.7892)
45.474 to 4s.484 43.948to 43.961 4l .257to 4l,267

Bearlnginnerdiameter (1,6243to | .6247)
(r ,7903to 1,1901) (1.7302to 1.7307)
0.027to 0.050 0.038to 0.064 0.026to 0.049

Beadngclearance (0.0015 (0.0010
(0.0011to 0.0020) to 0.0025) to 0.0019)
Bearingclearancelimlt 0.18(0.007r)
Camshaftjoumal to beirlng sp€cifications Unit: mm (in)
Beadng Camshaftjournal
Size Bearingthickness
position outer diameter
1 . 5 ?t o l 5 9 45.43to 45.45
Standard (0.0618to 0.0625) (1.7886to 1.7894)
o.25 1.69to l.?l 45.tab 45.20

(0.0098) (0.0665to 0.0673) (I ;7787to 1.779s)
Front
0.s0 1.82to I .84 44.93to 4495
Under size (o.o7r'7to 0.0724) (r.7689to 1.7697)
(0.0197)
o.75 l.94Io 1.96 44.6ato 44.70

(0o295) 64 ro O.0'7'72)
<O.O'7 (1.7s91
to 1.?s98)
EM-I3
EngiineMechanical
Bearing Bearingthickness Camshaftj oumal

Size
position
1.57to 1.59 43.89to 43.91

St ndard (0.0618to 0.0626) (r ;1279to 1.128'7)
o.25 1.59to 1.71 43.64to 43.66

(0.0098) (0.0665to 006?3) ( 1 . 7 1 8 111.o7 1 8 9 )
Center
0.50 1.82to 1.84 43.39to 43.41
Und€rsize (1.7083to l.?091)
(0o197) (O.0117
roO.0724)
0.75 L94to 196 43.14to 43.16

(0o29s) (o.o764ro 0.0112) (1.6984to 1.@92)
1.57to 1.59 41.21to 41.23

Standard (0.0618to 0.0626) (t .6224to 1.6232)
0,25 L69to 1.?1 40.96to 40.98

(0.0098) (0.0665
to 0.0673) (1,6126
to 1.6134)
Rear
0.50 1,82to I .84 40,7| to 40.73
Under size (0.0197) (O.O117 (1.6028io 1.6035)
to 0.0724)
0.75 1.84to 1.96 40.46to 40.48

(0.0295) (0.0754to 0.0772) (1.s929to 1.s937)
VALVErl ll{G 3. Csmsh{ftendplay canbe check.

ed by lnstalllng camshaft, camshaft
This diagramwtll apply to a[ cyl. locatlng plate and cam$aft gear in
ind€rs,If any valveis found beyond their respectiveposiiions.Bnd play
speclfl@tiom,one possibilitylr that will thenbe indicatedwlth a dialgauge
cam lobe is worn or damag€dexc$- or a feelergaugB. If end play €xceeds
sively,calling for replacementof cam.
0.35mm (0.0138in), replacelocatinS
shaft. plate.
Fig. EM-44 VolveE ning dia$sm
& b d f
Jl3 244 244 t4 50 t2 52
J 1 5J, l 6 252 252 18 54 16 56
FE.EM46 Me6uing .omthoft end

CAMSHAFT ALIGI{MENT
1. Checkcamshaft,camshdtjournal
and cafi surfac€ for bend, wear or
damage.If ilefects are beyond limits,
replaceaffectedpafts.
2. A bent valve is one-half of the
reading obtain€d when camshaft is
tumed one tull revolution witll a dial
joumat.
gaugeapp&q(a th! .c,e!t-el Fig. EM45 Measurine .amshaft betd
Etv.14
Canshaft specificatioB
Standard
Canshaftbend nm (in) Lessthan0.03(0.0012) 0.05(0.oo2o)
J13 37.60lo37.70(1.4803
to 1.4842) 37.40(.1.4724\
Camshaftlobe hcight mn (in)
J15
3?.605io 37.650(1.4805
ro 1.4823) 37.3s(l.470s)
Jl6
endplay
Camshaft mm (in) 0.05to 0.29(0.0020
to 0.0114) 0.3s(0.0138)
CYLINDER BLOCK HOW IO MEASURE

CYLINDERBORE
1. Check flatnessof block gasket
surfacewith a straightedge and a A bore gaugc is used. Measure
feelergaugert lwo diagonaland five cylinder borc ri top, middlc and
positions.
longirudinal bottom positionstoward A rnd B
2. Plac€ ihe straigh! edse alons dnectionsas shorvnin FigureEM-49
diagonallinesof block planeand the ondrccordlhe measuredvalues.
longihrde,and inspectfor levelusinga
feelergauge.
Fig. EM-48 Measurihgcttin.ler bote
3. Usinga bore gauge,measure cyl-

Surface Lessthan inderborefor out.of-round
or tAper.lf
flatness 0.05 oufof'round or tap€r is cxcessive,
mm (in) (0.0020) r€borethc cylindcrwallsby melnsof
a boringmachine.Measurement should
be t ken along bores for iaper and
Surfacegrindinglinit around bores fof out.of'round.S€c
The grindinglimit ofcylinderblock FigureEM-49.
is availableby thecylinderh€adgrind-
ing in an cngine. Outof-round X.Y
Taper A-B
Depth of cylinderheadglindingis
U n i r :$ D ( i n )
4. Wl1enwear,trper or oui ot-round
Depihof cylindefblockSfindinsis is minor andwithin the limit, removc
"B"
the stcp at th€ topmostportion of
Thelinit is: cylinderusinga ridgereameror other
A+B=2.0inn(0.0784in) Fig. EM-49 Cllinler borc measwing
similartool. po$non3
Fie. EM-47 Chechinecrlindet bloch

Bytace
Et\,1-15
Cylinderbore sp€cifications
Standard
J13 J 1 5J, l 6
73.000io 73.050 77.950to 78.000

Innerdiameter
(2.8'740to 2.8760) (3.0689to 3.0709)
0.r5(0.005e)
Cyljnderbore
nm (in) Oufol-round 0.020(0.0008)
Taper 0.02(0.0008)
0.1(0.0039)
Diilerencecylinder
borebetw€encylindcrs mm (in) 0.02(0.0008)
CYLINDERBORING
L Whenany cylinderneedsboring, cording to the amount of wear of
all othercylindersmust alsobe bored 2. Detemine piston ovenize ac- cylinder.
pistonsspecifi
Ovelsize cations Unit: mm(in)
Jl3 Jl5,Jt6
Siandardsize 72.987lo 73.037

(2.8735to 1.8755) 77.935to 77.98s(3.0683
to 3.0703)
0.50(0.0r97) 73.467to 73.5L7 ().8924to I 8944) 78.415to 78.465(3.0872!o 3.0892)
Ov€rsiz€ .00(0.0394) 13.961ro 14.011(.2.9t21 ta 2.9140) 78.91s (3.1069

to 78.s65 to 3.1089)
1.s0(0.0s91) 74.461 (.2.9315

ro 74.517 to29337) 79.41sto 79.465(3.1266to 3.1285)
3. The sizeto which cylindcrsmust Note: To prevenistrah dueto cutting

be honedis determinedby adding1o heat,borethe cylindersin the oder
the laryestpistondiameier(at piston of 2-41-3.
skit in thrust directjon) piston-to-
9tt
a b o u t2 0 n m ( 0 . 7 8 7 4i n )
4. Do not cut too much out of
cylinderbore at one time. Cut 0.05
mm (0.0020in) or soai a time.
5. Measurementof cylinder boro
just machjn€d requires
the utmostcare
FiC.DM 51 MeosutihApbton Ekirt sinceit is expanded
by cuttingheat.
didneter 6. As a final sre!, cylindersshould
Reboredsizecalculation
D= -{ + B C = A + [ 0 - 0 0 5r o 0 . 0 2 5 7. Measure the finished cylinder
ffm (0.0002 to 0.0010 in)l borefor out-otuoundor taperedpart.
8. Measur€pistonto cylinderclear'
D: Honed diameier
Ar Skirt diametefasmeasured This cleamncecan be checked
B: Piston to-wxll clearance easilyby usinga feelerSaugeand a
C: Machinins alowanc€ [0.02 sping balancehookedon feelergauge,
Fig. EM-'0 Measutingpxton d.idtueter !m (0.0008 in)l measuringthe arnountof forcerequi!-
Efu'I.16
E n g i n eM e c h a ni c a l
ed to pull oui gaugefrom beiween Note: ff cylinder bor€ h3s wom

pistonandcylinder. beyond the wear limit, us€{ylind€r
liner.
Undersizecylinderlinersare avail-
a. When measudg the clearanc€, able.
slowly pul the feelergaugestraight Interferenc€fit of cylind€r liner in
cylind€r block should be 0.08 to
that pislonand I
b. It is recommended 0.09mm (0.0031to 0.0035in).
cylinderbe heatedto 20oC(68oF).
Fig. EM 52 MedsurinEpiston fit

I
in cYlinder
JI5,Jt6
0.023to 0.043 0.025to 0.045

mn (in) (0.0009to 0.0017) (0.0010to 0.0018)
Fe€lerBauge
0.04(0.0016)
mm (in)
Exlractingforc€
kc0b) 0.s1o1.5(1.1to 3.3)
Cylind€rliner for service Unir: mm('n)
Jl3 J1 5 J, l 6
Oursid€diamete! Inncrdiame!€r Ouhidediameter

'77 ta 77.Os
4.0(0.ts7s) .OO 8L95 to 82.00
Undersizc (3.031sio 3.0335) (3.2254\o 3.2283)
'12.45 'l'l.45to'77.55
4.5(0.1772') 17.soto 1'1.SS to72.55 82.45to 82.50
Undersize (3.0512to 3.0531) (2.8524
to 2.8s63) (3.2461to 3.2480) (3.0492 to 3.0s31)
5.0(0.r969) 78.00to 78-05 82.95ro 83.00

Undersize (3.0709to 3.0728) (3.265'7
ta 3.2677)
Ring should be placed !o diamerer

PtsToN, P|STON P|NS at upper or lower limit of ring travel.
AND PISTON RII{GS

1. Removecarbonfrom pistonand
ling grooveswith a carbonscraperand
a curvedsteelwire. The wire will be
usefulin cleaning bottom landof ring
groove.Cleanout oil slotsin bottom
landof oil rins groove.
2. Checkfor damage,scratches and Fig. EM-5s Me$uriag ptston ring
wear. Replaceif such a defect is sitl. .ledtunce
detected-
3. Measur€the side clearanceof 4. Push ring inlo cylinder with a
rings in rhg groovesas each ring is piston so as ro place it squarely in
installed.Clearance with new pistons cylinder; measure ring gap with a
andringsshouldbe a!fo]1ows. feelergauge. FiC- EM-s! Meosuring ing Eop
E[/],17
Engine Mechanical
Sidecleamnc€ Unit: rnm(in)
Notes:
a. l{hen piston dng obly is to be Standard
replnced, without cylindg bore Wearlimit
beitrg corr€cted,m€asurethe gapat Jl3, J15andJ16
th€ bottom of cytnder where the
Top dng 0.036to 0.076(0.0014to 0.030)
Properdng fit in ring grooYeis very 0.r (0.0039)
important for propet performance Secondring 0.036to 0.076(0.0014to0.030)
and long life. A sticky ring ca$es
blow"by ot oil.up, iesulting in
prenature wear on ring and cyl- Ring gap Unit: mm (in)
inder wall. ff it is too loose, this
acceleratB w€ar on sid€s of ring Standard
grooveto aggramt€ring play. Wearlimit
b. Oversizepiiton rings are available. J13 J l 5 ,J t 6
[0.5 mn (0,0197 in), 10 nn
(00394 in) orcruizel, 0.20to 0.33 0.20to 0.35
Top rlng
(0.0079xo0.0130)(0.00?9
to 0.0138)
0.20to 0.33 0.14to 0.29

dng
Second
(0.0079 1.0(0.0394)
to 0.0130)(0.0055to 0.01l4)
Oil ring
0.30to 0.90 0.3to 0.9
(0.0118io 0.0354)(0.0118
to 0.0354)
Ov€$izeplstonringout€ralitmeter Unit: mrn(in)

---------.-.'.--
113 Jl5,J15.
St.ndard 13.00(2.8740) 1't.95(3.0689)
0.50(0,0197) 73.sO(2.8937) 78.4s(3.0886)

Over
size
1O0(0.0394) 14.00Q.9t34) (3.1083)
78.9s
1.s0(0.0591) 74.s0(2,933r) 19,4s(3.1279)
Fig"8M"66 Pitton pin flttiê
5. Measurepiston pin hole in rela" 6. Determinethe fitting ol piston

tion to the out€r diameterof pin. lf pin into piston pin hole to such an
wear exceedstlle limit, replacepiston €xtent that it canbe {inger press€dat
pin tog€therwith piston on which it is room temperature. This piston pill
insta ed. must be a tight pr€ss fit into con-
n€ctingrod.
FiC. EM-56 Measwing piston pin
diametet
Etll,18
Engine Mechanical
Unit: mm (in)
J13 J 1 5 J, l 6
Pistonpin outsidediameter 17.44'7to I7 .452(0.6869to O.6811) 20.993to 20.998(0.826sto 0.8267)
Pistonpin hole diameter 17.453 (0.68?lto 0.6874)

to 1?.460 21.001 (0.8268
ro21.008 to 0.82?1)
Pistonpjn to pistonclearance 0.001to 0.013(0.00004

to 0.000s) 0.003to 0O15(0.00012to 0.00059)
fit of piston
Interference 0.01sto 0O33(0.000s9
to 0.00130)
Bolt clamp
pin to connectingrod
CONNECTINGROD
J l 3 ,J l 5 a n dJ 1 6 Maximum
l. If a connecting rod hasany flaw
on bolh sidesof the thust faceand Connecting rod bend
it.
the largeend,corrector replace or torsion(per I 00
0.03(0o012) 0.1(0.0039)
mm or 3.94in length)
mm (in)
Connecling
rod big 0.20to 0.3
0.5(0o197)
endplay mm (in) (0.0079
to 0.0118)
EM133 CRAI{KSHAFT
Fig. EM67 Chechingrcd otign ent
s
L Whenevercrarlshaft is remov€d J 1 3 J, l 5 3 8 . 8( 1 , 5 2 8 )
from engine, thor'
it shouldbe cleaned 41.00.646)
2. Checkconnecting rod for bendor oughly in a suitablesolvent.Afier
torsion usingconnectingrod aligner.If cleaning,checkcrankshaft joumaland
crank pin for score,bias wear or 41.640to 41,652 dia.
bend or torsion exceodsthe limit, ( 1 . 8 7 5t6o 1 . 8 7 6 1 )
cracks.Repairor replaceas required,
3. When replacingconnectigrod, If defectssre mjnor, dresswith fine 50.813to 50.825dia
crocuscloth, .0005102.0010)
s€l€ct rod so that weiSht differ€nce
betwe€nnew and old onesis within 6 2. Checkwith micrometerjournals
and crank pins for taperand outof'
sr (0.2116oz),
4. lnstallconnectilgrodswit]bear" mund. Measurement shouldbe talen
ings on to conespondingcrnnk Pins along joumals for taper and around
journalsfor out-of-round.SeeFigure
and measurcthe thrust clearance.If
the measuiedvalue€xceeds the limit, EM-59for detailedinformation.
replaceconnectingrod.
Out-of-round x-Y 3 4( 1 . 3 3 9 )
Taper A.B
t 8 . 7( 0 , ? 3 6 2 )
/n tr-l
\l7I{
Fig.EM-59 Croftshdft andiourtul
.lime6ion
Ifjournalsor crankpinsaretapered
or out-of-roundbeyondlirnits;repiace
EM.lS
E n g i n eN 4 e c h a n i c a l
using a dial gaugewith its indicating If end play exceedsseflice limits

finser rcstingon centerjoumal. above, replace thrusi washerswith
thosethat give propercranlshafiend
ptav.
Thrusrwasherthickness
(upperandlowet mm (in)
2.235Ia 2.286
(0.0880to 0.0900)
Fig- EM-60 MeasutiaCjou dl diometpr 2.286ro 2.337

(0.0900to 0.0920)
3. Crankshafican
bend by piacingit Fig. EM 61 Chechingctunhshaftbend :.337to 2.388
(0.09:0 to 0.09210)
J 1 3 ,J l 5 a n dJ l 6 2.388io 2.438
Maximum
(0.0940ro 0.0960)
Taperandourof"round
ofjorunalandcrankpin 0.01(0.00r2) 6. At the rear end of crankshaft,
0.01(0.0004) check crankshaft pilot bushing for
mm (in)
w c x r o r d a n a g e .R e p l a c ei t i l d c f c c ti s
To replace crnnkshaft rear pilot

JI 3 ,J 1 5 Standard b u s h i n g! r o c e e da si o L l o w s l
(l) PulL out bushins usins Pild
Crankshaft
bend B u s h i n gP u l l € rS T l 6 6 l 0 0 0 l .
(in) 0.0s(0.0020)
mm
\ r'uuronn'
Noter When measurinS bend, us€ a cranksluftas far €ndwiscas posiblc
djal gauge.Bendvalueishaf ofthe and inserta feelcrgaugein cleanncc
readingobtainedwhencrankshaft is bctwe€nbiock and centerrnainbear-
turned one full revolutionwith a 'nc.
dinl guageattahcedto its center
journal.
4. After regrinding crankshaft,finish

it to the necessary
sizeindicaiedin dre Fis. EM-63 Pulling out pilot
bwhing
list on pag€EM-21by ushg an ade-
quate undersizebearingaccordingto
(2) Before installing a new bushing,
theextentof requiredrcpair.
rhoroughly clean bushing holc. Press
5- After grindingjournalsor crank-
fit bushing so thai its heisht above
pins,crankshaftshouldbe checked for
tlangecnd js 8.0 to 8.3 mn (0.315 to
end play-This canbe doneby instail.
0 - 3 2 7i n ) . D o n o t o i l b u s h i n g .
ing shaft in engineblock with main
bearingsand bearingcapstorquedto
( 0 . 3 1 t o0 , 3 3i n )
10 to l1 kg'rn (72 to 80 fi-lb). Fig. EM 62 Chechinscrcnhshaftend
Wilhout disiurbingabovesetting,bar
Crankshaftfreeend 0.05to 0.20

play mrn(in) (0.0020to 0.0079)
0 . 3( 0 . 0 1 r 8 ) Fig, EM-61 Presefitting netupilot
bwhirg
Er\,1-20
BUSt{t]{c Al{D w€ar,scorssor pitting,replacing

those (3) Loosen bolts securingcap in
BEARIl{G foundbeyondmaximu,nlinits. place.Compareflatlenedwidth with a
MEASUREMENT OF 2. Measurecleamncebetweencon- specialscalesuppliedwith the plas-
CON}IECTING ROD BEARING nectins rod journal and bearinsto ti8aseenvelope. If difference
between
CLEARANCE deternine jf it is within specified maximumand mirimun width in a
1. Checkconnecting
rodbearing
for limits. strip exce€ds 0.03 lnm (0.0012in), it
is an indicationlhal journal is wom
locally,callingfor furtherse.vice.
Brrring oil clearsnce Noter Do not tum crankshaftwith
plastigage
installed.
Maximurn
3. If measurement revealsthat oil
Connecting rod
0.011lo 0.052 clearanceexceeds0.10 mm (0.0039
ciearance(bigend) 0.10(0.0039)
(0.0004to 0.0020) in). usecorreclundersiz€
bearing.
mln (in)
To measureclearance,proceedas (2) Placea sirip ofplastisase lensth-

folows: wise on journal. Instal bearingon
(1) Beforemeasuring, journah and joumal and right€nto 2.5 to 3,5 kg.m
bearingsshouldbe wiped cleanof oil (18to 25 frlb).
Connecting andjoumalspecifications
rod bearing
Unitr mm(in)
rodjoumal
Connecling
Bearing
rhickness
outerdianreter(crsnkpin)
L83 ro l 84 4l.64 ro4'7.65

Standard
(0.0720lo0.0724) (l.8756to 1.8?60)
0.08 1.8610L87 47.58to 41.59

(0.0031) (0.0732to 0.0736) (1.8732
to 1.8736)
0.l2 t.89 to l 90 4'7.51ro 4'7.53
(0.0047) (0.0744to 0.0748) ( 1 . 8 7 0 9 1Lo8 7 1 3 )
0.25 1.95to l.9a) 47.40ro1'7.41

(0.0098) (0.0768to 0.0772) (1.8661
!o 1.866s)
Undersize
0.50 2.08to 2.09 4'7.t4ra4'7.ts
(0.0197) (0.0819to 0.0823) ( l . 8 5 5r9o 1 . 8 5 6 3 )
0.75 2.2410o2.2r 46.90to 46.91

(0.0295) (0.0866to 0.0870) (l.8465to 1.8468)
1.00 2.33to 2.14 216.64to 46.65

(0.0394) (0.0917to 0.0921) ( 1 . 8 3 6 2r o 1 . 8 3 6 6 )
MEASUREMENTOF MAIN
BEARINGCLEARANCE
Note: Since bearinssare of precision surfac€swith an emery cloih to Thoroughly clean all beatings.
insert type, it is not necessaryto conect b€aringclearance. Check for scratches.
file bearingcapsor to gdnd b€aring r€phcing those found beyond limits.
Etv-2l
Engine M echanical
Bearingoil clearance Whennew bearingsare us€d,bear-

ins fit, or mor€ specifically,
oil clear-
anceshouldalwaysbe inspected. If if
exceeds0.10 mm (0.0039in) (maxi-
Main b€aring cl€arance 0.02to 0.05 mun), corr€ct undersize bearings
0.10(0.0039) shouldbe selected or journalsshould
mm (m) (0.0008to 0.0020i
be groundto fit next unde.size bear'
proceedasfollows:
To measureoil clearance, mgs.
1. Crankshaftjournalsand bearings Note Do not turn crankshaftwhile Note: Sincebearingsare of pr€cision

shouldbe wipedcleanof oil andalty plastigageis install€d. insert type, it is not n€cessaryto
oaherforeign materialssuch as dust file bea.ingcapsor to grind bearing
and dirt beforethey canbe neasu.ed surfa€€swith an em€ry cloth to
conectb€aringclearanc€.
2. Use plastigage, placingit length-
wise on joumal. lnstal bearingand
bearingcapin positionandtightento
10 to 11 kg.m(72 ro 80 ftlb) t€nsio..
3. Removecap and measurewidth
of plastigageflattenedby comparing
with a specialscal€print€d on plas. Fig.8M.65 Measwingmdin beoring
tigageenvelope,
Main bearingandjoumal specifications Unir: mm(in)
j ournaI
Crankshaft
Bcaringthickncss
1.822
to 1.83s 50.81
to 50.82
Standard (2.000
(0.o711roO.o722, to 2.001)
L947to 1.960 50.57to 50.59

0.25(000e8) (O.O'767
ta O.O7
72) ( l . 9 9 1t o 1 . 9 9 2 )
2.0721(l
2.085 50.31to 50.33
(0.0re7)
0.s0 (0.0816
to 0.0821) ( 1 . 9 8 0t7o l 9 8 1 s )
Undersize
2.197to 2.210 50.07 to 50.09
0.75(0.029s)
(0.086sto 0.0870) (t .9'7| to I .9'72)
2.322to 2.335 49.81to 49.83

1.00(0.0394)
(0.0914to 0.0919) (1.961to 1.962)
FIITING BEARINGS back surface is completely flush
Bearingsare manufaciuredwith
crush io nahe them fit snugly into Pressweight:
their bores.To measurelhis, proceed abou!500kg (1,100lb)
1- Properlysetmainb€aringin mair
beadngcap recessor cylinderblock
3. Then,measure bearingc sh "H"
2. Lock one sideof rhe bearingand with a feelergauge.SeeFigureEM{6.
press i]Ie ofher side ti11ihe bearing Th€ standardbearingcrush%lueis 0
ro 0.0smn] (0 to 0.0020in). Fig. EM-66 Cheching bedrinc crBh
EM22
E n g i n eM e c h a ni c a l
MISCELLANEOUS 3. Measure flywheel for run out. FROI{TCOVER

COMPONENTS This can b€ checkedwiih a dial gauge, OIL SEAL
by iotaiing jl in either direction with
indicating finger resting on flywheel First check front cover of oil seal
CRANKSHAFT SPROCKET
facc la hest from center. If 'un out for deflected wiping edge or oil
AND GAMSHAFT SPROCKET
exceeds0.05 mn (0.0020 in), replac€ leakag€.If it is denec&d or the'e it
any sign ol oil teak,replacelvith a n€w
1. Chcckcrankshaft and camshaft flywhee1.
sprockets
for wearor scores
onsprock- seal. When insraling a new sea1,pay
pariicular atlention to mounting direc
et teeth. Replaceif wom or damaged
b e y o n dI i m i t s .
2. lnstall camshaft sprocket and
cleck to determinethat geafrur out is
held withfi 0.1 Jn'n (0.0039 in). If
CHAIN AND CHAIN

TENSIONER
i. Chcck chain for stcppcdw€ar,
scratchcsor othcr problcmsto roller FiC.EM-67 Measurinqflydheel tun
links.Replaceilnecessary.
2. Chcck chain tensioncrfor wear,
brerkag€or rny other defectswhich
would intcrfcrc wilh proper chrin Noter Removal and installationof Fig. EM'68 InstaUineoil seal
functbn. Replace if necessrry. ringgearrequiresuseofa hydmulic
presr. It is also nec€ssaryto heat
FLYWHEEL ring gearas thh expandsit, thus
facililatingremoval0ndinstallation. Noi€s:
1. Cheokring gcar. Ii found to bc
Do not heatring gearto morethan a. It is goodpnctice to renewoil serl
worn or danagedcxocssiycly,rcplace.
2. Clutch contactingface of fly- 300oC (572oF). To do so could when€ver engin€is overhauled.
wheelshouldbc smooth.lf it is wo|n, resultin inpaired hardness of ring b. Apply lithiumgrease to wipingedge
gerr. of oil s€al.
d nagedo! roughcncdbcyondlimits.
ENGINEASSEMBLY
CONTENTS
PRECAUTION EM 23 V A L V ER O C K ESRI ] A F TA S S E M B L Y , ,, . EM.24
C Y L\ D ' R A D .. . . . , . . . EM 24 A S S E N 4 B LE
I NNG
G I N.E. , , . . , , , , . . - . . . . . . EN,1.25
P I S T OANN D C O N N E C T JFNOGD. . . , , , , . EM 24
and oil sealsshoutd be rcplacedwith possibiliiyof watcr, oil and gasleak.

PRECAUTION 6. Prior to assembling, all sliding
Before dssemblingcnginc, obscrve 3. Under no cncunsrances should surfacesshouldbe oilcdlibera11y.
the fo]lowing precautions: lockwashersbe reused. 7. Propertighteningis essentialto
1. Clean all disasscnbledparls with ,1. Place bolts. nuts and washers successful pefomancc of all vehicte
clean solvent- Al1 oil holes in crant- back in their originrl parts or places repairs.It is alsoimpodanlto lbllow
shaft, camshaft.valverocker shaft. etc. ffom which they were removed. correctsequence of lighieningin pul-
should be cleaned thorcugHy to re- 5. Most packings serve best when ingup cylinderhead.Beon the aleriat
move all traces of grinding chips or Liquid packing is applied to iheif a]l tines to th€ amountof cleannce
lint. Always use cleansolvent. sealingsurfaces.When designated,use
2. In genelal,uscd gaskets,packings suitable liquid packing io elimjnate
EM.23
Engine Mechanical
8. Cleanliness of toolsor partssu€h 2. To install pistonwith piston dngs

as work bench usedin makinga repan properly spacedarourd it, usePistor
is essential.When setting up a job Ring ExpanderEM035m000.BYery
every pr€cautionshould be taken tiat €ution should be taken that dngs are
toolsor partsarefreeofdirt, mudand not interchangedbetweenring groov€s
oil. Do not work in dustandgrit, for in piston.
they are pdmary causeof w€ar in any sT13050000o15.J16) Be sureto install compressionrings
engine. with surfaces having marked end
towardpistonhead:
Notes:
Iie. EM-70 ln6tdlli4Spitton p 1 a. Top ring is chromim-plated on
linercontactingface.
CYLINDER HEAD b. Secondring haslargertapersurface
than top ring.
Use Velve Lifter 5T12070000,1o
c. In the combinedoil ring, upperrail
install intake and exhaustvalves,valve
is the ssmeaslowerone,
springs, valv€ spring retainers, valve
colletsand rubber rings to cylind€r
hesdin the orderlisted.
EM365
Fe. EM-71 IiShteninssnotten4
bott ( 3)
Not$;
a. Do not intercha$ge\alvesbetween
cylind€rs,for th€lr slidingor seating
su acer haveundergonewearing-in EMI68
or hsve been hpped at s$lembly,
forning specific coniact with their Fis. EM-73 ttutalling pbton rine
matingpart3.
b. Ch€ck to be sule thlt valv$ are 3. Installconnectingrod bushingin
properly seatedon valveseatswith-
btg end half and cap.M&kesurethat
out for€rgn padicles stuck in be. dust and dirt arc not ca.ried ln bo-
EM32I
Fis.EM"72 Astemblingpietondnd lween iheir matingcl€aronce.
connectingrod
Notes: VALVE ROCKER SHAFT

a. For the Jls and Jl6 engine pbton ASSEMBLY
is pr€$ed into connecting rod, and
fitting forceis from 0.5 to 1.5tons; Install parts, as shown in'Figure
the aid of Piston Pin hess Stand EM-74,in placeon rocker slEft; secure
ST13050000 (Jls, J16) or with cotter pins on both €nals of
STl30OO00(J13)b nec€ssary. rocker shaft. Instrll set screwin hole
When pressingpiston pin in con- in rearmost bncket and tighien to
n€ctingrod, apply engineoil to pin prevent shaft from working loose
and smallendof connectingrod. duringoperation.
FE.EM-69 IrctauingDalue
b. A[ pistonsarc marftedwith a notch
in piston head and "F" ma*
around pislon pin hole. B€ sureto
install pistons in cylind€n with
PISTON AND thes€ markslacing toward front of
CONNECTINGROD engrne. , b \
l. Heat pistonto 20oC (68oF);as- c. Cotrnectingrod shouldbe instaled
sembleconnectingrod, piston pir and with bottotn oil jet placrd on right
pistonto8€therby hand.On the J13, slle.
tiShten connectingrod s.nallend bolt d. Do dot givedirect hanEn€rblows to
to 2.s to 3.s ks-m (18 to 2s ftlb) pidon pin whenfitting it hto place FiC.EM-74 ksembling Mlue rochq
usinga suitabletorque wrench. in pi*on. shoft d*emblr
EM.24
Engine Mechanical
.ASSEMBLING 4. Cleanmain bearingshells,bearing Note: Apply liquid prcking to bearing

E1{GINE saddlesand bearing caps. Place slpll saddletouching ends of r€{r main
hrtves in b€arjng Naddlesin cylinder b$ring csp.
l. The first stepin €ngnrcassembly blo€k; place other hlves in bearing
is to bolt Engine Attaclunert caps. Next, install thrust washerson 7. tnstal rcar bearing side s€al and
5T05280000 to dght hand side of each side of center b€arh8. Make front seal. Prior io installing, apply
cylinder block. Next, instal anotlrcr ceriain that lug on eachhalf of shell aalhesiveto theseseals.B€ careful not
EngineStand ST0501S000 in block. fits in a notch in bearing saddleand Xo damag€ sealing lips which could
2. Thorougt y clean groove in oil bearingcap. result in oil leak.
sealhousingof oankslBft rearbearing;
placeofl sealin groovewith finger and
Notei Thrust washels should be in"
thumb. Usine an oil seal replacer
stauedwiih side oil gloov€sfacing
Guide), lighdy tap with a harnmer towaid outer sid€of bearingc$p.
until oil seal is installed coffectly.
T.im seal flush with ends of housing
block. Install oil seal in rear bearing
FiE.8M.79 DtiuinSrcn be&ins
EM3A7
FE.8M.77 Mdin bedringcdps
dd beaing.
5. Liberally apply cleanengineoll to

EM3A5
bearing shelk; place cranlshaft on
Fig.EM-76 INtaUinE crunhahaftrc.r shellsin cylinderblock.
oll eeol
6. To instal main bearingcaps,be
rure that arrow mark in cap head h a
3. Apply a light coat of engin€oil io placedtowardlront of engine,Install
sliding surfccesof velve lifters; lnsert thrust lrasherson each sid€ of center
lifters in holos in clinder block. To Fig. EM40 INto ing frcnt Beal
main bearingcap. Main bearingcap
inatell camshaft,be sureto coat sliding bolis should be tightened In the
surfacesof camslEft bushingswith a equenceasshownandin threeto four 8. Install engine rear plate and
Ilght cost of englno oll. Insert cam" st€psgraduaUy. After abovestepshave Sasketand tightenbolts to specifiod
shaft in cylinder block from f$nt side been completed,checkto dotermine torque.
of €ngine, exercising carc not to tlat cnnl(shaft tums fr€ely.
darnage camshaft bushtngs. Toque
locatingplate 1o 0.5 to 0.8 kg-rn(3.5
to 53 fdb) using a suitable torque Mainbeadngcaptighteningtorque: 3.0 to 4.0 kg"m
10 to 1l kg-m 9/16" bolt
Q2 ro 29 rt.lb)
(72 to 80 ftlb)
09 to 1.5kg-rn
(6.5toll ft-lb)
9. Position fl]^vheel in place on

llange end of crantshaft; instull and
tighten attaching bolis to 4.0 to 5.0
EM4O4 ks-m (29 to 36 ftlb). Bend ends of
FiC. EM-78 Toryue equence of lockwash€rsup aSain$ sides of at-
Fig. EM-76 lastolling lo@tinA pldte cop bohs tachingbolts to secureinsta ation.
Elt4-25
4
Engine Mechanical
(2) After abovestephasbeencom.

pleted, instail crankshaft sprocket,
chainand camshaftsprocketwith their
markingsproperlyaligned.Oil sprock-
et t€eth and chain wlth liSht engine
oil. Tightencamshaftsprocketbolt to
4.0 to 5.0 kg-m (29 to 36 ft-lb) by
meansofa suitableiorquewrench,
F is. Elll-83 tnsLollingphton

Fig. EM-81 Installins flyuheel
Note: Always use new lockwashers

and tight€n them up againstbolts
10. Using Piston zung Compressor

EM03470000,install pistonsso they
are below top of cylinders.Notesin Fig.EM-86 Aligningmothings
inslallingpistons: EM166
(1) Marking "F" in piston head F ie. EM-84 T iehtenine.onnecting tod 13. lnstall chain tensioner.Correct
shouldbe placedtowardthe front ol cop proj€clion"L" ot spindleis bclow 15
cngine. mm (0.591 in). Rephcespindlewh€n
11. lnstall engine fiont platc with
(2) Eachconn€ciingrod is number- gasket under jt and tighten bolls to
it is foundlo be overthisiimit.
ed, beginingat the front of engine, specifiedtorque.
Pistonand connectingrod &ssemblies
shouldbe installedin respeclivecyl"
inder so that number on rod cor- 0.5to 1.0kg-m
respond!with cylindernunber, 7116"bol\
(3.6 to 7.2 fr"lb)
(3) Piston ring end gapsshouldbe
strggered l80o apad from €achoiher, 0.9to L5 kg.m
l/2" bolt
being careful not to locatc them in (6.stollft.lb)
thrustandpistonpin directions.
12. Installclankshaftsprocket, cam-

EM334
shaftsprockelandchainin t|e follow-
Fig.EM'87 In'ta|ing chaihtensionr
ingmanner:
(1) Insert keys in keyways.Tem-
porarily install both crankshaftand
14. Install oil ttuower in froni of
camshaftsprocketsand checkto s€c camshaflsprocketcorrectly.
thai th€y are flushwith eachother.If
differencein height falls below 0.5
mm (0.020 in), place a 0.15 mm
Se.6nd rinA_ (0.00s9 in) washerund€r crankhaft
Fig.EM 82 Pistoning diection
(4) Numberson connecting rod and

bearingcap must be on the sameside
with oiljets properlypoiried. Referto
Note "c" underihe paragraph "Piston
and ConnectingRod." Instan con-
nectingrod capswith light engineoil FE. EM-88 Imtalling oil thrcber
on both joumal and bushingcontact-
ing surfaces. Draw tiem up to 2.8 to ls. Instal froni (chain)coverwith
3.5 ks-m (20 to 25 ftlb); insta pal gasketinsededin between.At this
t nutsto secure the iflstallation, Fie. EM-85 Meaturingspto.ket heiSht time, coat gasketsurfaceand Saskei
Etvl-26
Engine Mechanical
contact surface of engirc block with same liquid packing to cylinder

suitable liquid packing before in- head on surfacein which pushrod
ita ing gasket.Apply a littuum grease holesarc castout.
to wiping edgeof front cover oil seal.
16. Instal and tighten crankshaft (2) Insertpushrods.
puley to 12 to 14 kg-m (87 ro 101 (3) Position rocker shaft assembly
ftlb) torque.Be sureto bendlocking on top of cylinderhed.
tab of lockwasherto s€curethe in. (a) Tiehten cylinder head stud nuts
stallation. andvalverockershaftbfacketboltsar
FiC- EM-92 A.ljuiting &lue-tdppet

Cylinderhead 5.0 to 6.0kg.m
(36 to 43 ftlb)
21. Instflll sidecov€r.Tightenbotts
2.0 to 3.0kg-m which hold it in plae to 0.4 to 0.8
(ls to 22 tulb) kg-m(2.9to s.8 ft-lb) torque.
22, lnstall water pump assembly
In tightening,note the followingi with gask€t placed under it. Coat
Tighteningshouldbe madein two gasket surfacewith suitable liquid
or ihree steps,finally torquingto peckingbeforeinstalling grsket.lnstall
EM396
specificrtions. and tightenattachingbolts to specifi.
Fig.EM'89 Irctalling uantuhaft puller
Tightnessof nuts andbolts should cations.lt shouldbe between1,2 and
b€ rcchecked afier enginehasbeen 1.8kg.m(8.7to 13 ft.lb).
17. Insiall oil pump &ive spindle
operatedfor severalminutes;if
and oil pump assemblywith gasket
necessary,reiighten,
placedunderthem.Correcttightening
is l 2 to 1.8kg.m(8.7to 13tulb).
IiR. EM-93 lwtalling wdt$ pump

EM39A
Fig.EM-qI T@htening sequence 23. Install thermostatand water
outl€t.Do nol forgetto insta gasket.
EM397 20. Afier valv€nappet clearnace has
Pig.EM-90 Intd ing oil pump been adjustedproperly, instat valve
rocker covei. Correct valvelappet
18. At ihis stage,oil pan shouldbe clearance is 0.35 mm (0.0138in) for
installed io fianged end of engine both intakeand exhaustvalveswhen
blockwith gasketinsertedin b€rween. engineis hot. To achievethis, first set
Tightening should be performed in clearanceto 0.35 mm (0_0138in)
criss"crosspattemto 0.5 to 1.0kg-m when engineis cold.Afrer engjnehas
(3.6to ?.2 ft.lb) tension. been assembled, run it for at least
19. The next step in engine as- sevenlminutesand recheckclearance,
€M4oO
sembly is to install cylinder head and For d€tails,referto 'Adjustingintake
Fig. EM-94 l6taUing thetmutot
rockershaftassernbly. and exhausi valve clearance" in ET on l uoter outlet
(1) Positioncylinderhead in place 24- Coat cylinder block to fuel
on top of engineblock.Do not fo4et pump mountiag fac€s with suitable
to install gasketb€tweenhead and Intakeand liquid packing and position gasketon
block. Exiaust Valves fuel pump mounting lace of block;
instal pump and tighten to 12 to l 8
kg,m (8.7 to 13 ft-lb) tensionusing a
Note: Coat gasket surfac€ of engine 0.3s(0.0138) suitable torque wr€nch. Heat shield ,.
block with suitable liquid paddng plate shortd be installedsimultan€ous- .:itL
before imtaling gasket.Also apply 1y. ::.i
Engine lvlechanical
26. Instaflalternatorbrack€l,adjust- 27. Position oil filter brackei in

ing bar, alternator,fan pulley,fan and place with gasLetplaced under it;
fan belt in that order.Then,checkto tightento 1.6 to 2.4 kg-n (12 to 17
b€ surethal deflectionof fdn belt is ftlb) usinga suitabletorquewrench.
held wilhin 8 to 12 mm (0.315 to 28. Fastenoil lilter on oi1 filter
0.472 in) when thumb lressure is
appliedmidwaybelw€enpul€ys.
Note: Do not overtighten
filter, ot oil
lskag€may occur.
29. lnstall distributorin the fofow-

Fis.EM 95 Installingfuelpump
(1) Brins No. I pistonin T.D.C.on
25. Position intake and exhaust its comlression
stroke,
manifoidson cylinder block; install (2) Driv€ spindleshouldbe located
bolts which secure manifolds and ( 0 . 1 1 5 r0o0 . 4 7 2 4
ini as shownby usingDistlibutorDrive
torqueto 1.7 to 2.3 kg-n (12 to 17 SpindlePullerST19550000.
ftlb). Next, instal carbureto!and air (3) Install distribuior bracket and
clean€r.Engineslingerandai! cleaner
suplort shouldalso be tiShlenedto'
getherwiih manifolds.
Fig. EM-98 Meosuringdeflection of Note: Be carefulnot to d(op drive
fon belt spindleinto oil pan.
Notes:
r. Carburetor gasketshould
insulating
be installedwith notch facingup.
b. Extl" caution shouldbe takento

pr€ventdust and sbrasiYes from
enteringcarbur€tor.
C{$uretornutstighteningtorque:
0.8 to 1.2kg"m
(s.8ro 8.7 ftlb)
Fig. EM-96 Instdlling mdnifoU sTr9s50000
Fig.8M.99 Mountinq ditection of distibutordtiue spindle
30. Instal spark !1ugs,hish tension or surounding pads.

cabl€s,oil pressur€switch and oil level 32. Fill with engine oil to specified
gauge. level.
31. Insrall fuel pipes and vacuum 33. Using an overhead hoist and
lifting cable, hoist engine up away
At]. pipes and hoses should be fiom enginestandand ihen down onto
Fie. EM-97 Iastollingcdtburetor clampedsecurely,being careful not 1o enginecanier. Instal clutch assenbiy,
allow them to interfere with adjacent stading motor and enginemountings.
El\l -28
Engine Mechanical
GENERAL SPECIFICATIOI{S
Jl5 J16
4 in line 4 irl lin€
Disphcernent 1t99 (79.3)
,cc(cuir) -.....-......... r,483(90.s) | ,56't(95.6)
Bore x stroke rnln(in) .........,.........
73 x 77.6 78x 71.6 18 x 82.o
(3O7x 3.06) (391 x 3.23)
o.H.v. o.H.v.
t-3-4-2
Engineidle speed rpm .........................
600 600 500
Cofirpr$sion ratio ..,......,......,..8.2 8.3 8.3
Otl capacity(lncludingoil fllt€r)
Llt6$(U.S.qt,,Lnp.ql) ..,,..,.. 3.4to 4.4(3%, 4% to 4%, 3%)
EM-29
Engine Mechanical
TIGHTENINGTORQUE
Model Jt6
Cylinderheadstudnut
s.0to 6.0(36to 43)
kg-m (ftlb)
Rockershaftbmcketbolt
kg-m (ft-lb)
2.0to 3.o(14to 22)
Connecting
rod bigendnuts
ks.m(tulh) 2.8to 3.5(20to 2s)
Connecting rod smal endbolt

2.5to 3.s(18to 2s)
kg-m (ft-1b)
Flywheelfiing bolts
4.0 to 5.0 (29 to 36)
ks-m(tulb)
Malnbearingcapbolts
10to 1l (72to 80)
kg.m (fr-lb)
Camshaft sprocketbolt
4.0 to 5.0 (29 1o36)
kg-m (ft.lb)
Oil panbolts
0.5to 1.0(3.6to 7.2)
ks.m (ftlb)
Oil pumpbolts
1.2to 1.8(8,7to 13)
ks-m (ft.lb)
Oil pandrainplug
2.0to 3.0(14.5to 21.7)
kg"m(ftlb)
Locatingplatebolh
ks'm (f b) 0.5ro 0.8(3.6to 53)
Carburetor nuts
0.8to 1.2(s.8to 8.7)
kg-m (ftlb)
Manifoldnuh
1.7ro 2.3(12ro l7)
kg.m (ft.lb)
Fueipumpnuts
1.2to 1.8(8.7to 13.0)
kg.rn (ft.lb)
Crankpulleybolt
l2 to l4 (87to 101)
ks-m (ftlb)
Enginefront plate bolts

kg-m (ftlb)
7/16"bolts 0.5to 09 (36 to 5.5)
l/2" bolts 0.9to 1.5(6.5to 11)
Enginerearplate bolts
ks-m (ftlb)
9/16" bolts 3.0to 4.0(22to 29)
l/2" bolts 0.9to 1.5(6.5to 11)
Engine Mechanical
Waterpunp bolts 1.2to 1.8(8.7to 13)

kg'rn (tulb)
Oil iilter bolt! r.6 to 2.4(12to 1'7

kg-m (ftlb)
)
Sidecoverbolt
0.4to 0.8(2.9to 5.8)
ks-m ({t"lb)
SPECIFICATIONS
Model J16
a) VehE mechanbm
Valveclo.rance(hot)
lntak€ andexhaust . 0.3s(0.0138)
mm (in)
Valveheaddia.
mm (in)
-Intake 349(r.3740) 37.9(1.492t)
-Exhaust 3 0 . (01 . r 8 l l ) 32.0(t.2s98)
Valvestemdia.
mm (in)
Intake andexlaust 8.680to 8.693(0.341?
io 0.3422)
Valvelength
mm (in)
-lntake 109.35to 109.55 (4.305to 4.31?)
(4.305to 4.31?) to 109.65
109.35
-Exhaust 108.55to 10835 109.35 (4.305to 4.317)

to 109.65
(4.274to 4,28s)
Valve springfree lengih

Inm (in) Model620,T20 (J13,Jls andJ16) ModelA32l (JI3,Jls)
-Outer 52 Q.047)
-Inner s0 (1.969) 47.r (r854)
Valve springpressured
length (valveopen)
mn/kg (in/lb)
-Outer 30.714'7.8 (t .209ll0s) 30.717O.6
28.7l2t .3(t .130147 O 2Ae1156)
Inner )
Valvespringassembled
height
(valveclose)
nrn/ks (in/lb)
Outer 38sl29n
Q.s3r164) 38I135A (t s3r 178)
Inne! 369113.r
(r.4ssl29)
Etv,31
Engine Mechanical
Model Jl6
Valve spdngeffectiveturns Model520,T20 (J13,Jl5 andJl6) ModelA321(J13,Jl5)

mrn (in)
-Outer 4.s(0.1772) 3.7s(0.14'76)
Inner 6.s(0.2ss9)
Vaivespringwire dia.
mm (in)
-Outer 4.0(0.1s75)
' 4.s(0.r772)
Inner 2.8(0.1102)
Valvespringcoil dia.
mm (in)
-Outer 2s.2(0.992r) 2s.2(09921)
-Inner 18.4(0,7244)
Valveguidelength
nm (in)
4'7.6 (1.874)
s6.0(2.20s)
Valveguideheightfrcm
heedsurface 15.5to 15.9(0.510
to 0.626)
rnm(in)
Valveguideinnerdia.
mm(n')
8.732to 8.745(0.3438
to 0.3443)
8.714to 8.751(0.3443
to 0.3/'48)
Valveguideouterdia.
mm (tn)
Intake andexlaust 14.313 (0.5535
to 14.326 to0.5640)
Valveguideio st€mclearance
mm (in)
-lniake 0.039to 0.065(0.0015
to 0.0026)
_Exlaust 0.051to 0.07?(0.0020
to 0.0030)
Valveguideinterferencefit
nJn (in) 0.013to 0.04s(0.000sto 0.0018)
Valve seatwidth
mm (in)
Intat€ andexiaust L6 to L7 (0.0630to 0.0669)
lntake andexiaust
fit
Valveseatinterference
lr)In (in)
0.054to 0.080(0.0021io 0.0031)
E[4-32
Model J16
b) canshaft and tinins chain
Camshaftendplay
0.05to 0.29(0.0020
to 0.0114)
mm (in)
Camshaftlobe height
6.15(0.242r)
mm (in)
Camshaft journaldia.
(standerdsize)
mn (in)
_F!ont 45.434to 45.441(l ;7887to I;7892)
-Center 43.89'lto 439lO(1.1282to | ,128'7)
-Rear 4l .218to 4t .231(1.622Ato | .6233)
Ca.rnshafibend
Lessthan0.03(0,0012)
mm (in)
journalto beartng
Camshaft
mm (in)
_Front 0.027to 0.050(0.0011
io 0.0020)
-Center 0.038to 0.064(0.0015
to 0,002s)
-Rear 0.026to 0.049(0.oo10
ro o.oo19)
Camshaftbearinginnerdia.
mm (in)
-Front 45.474 to 45,484(1,7903to 1.7907)
-Center 4.94a b 43.961 (1.1302 to 1,7307)
Rear 41.257Ia 4l .267(l .6243to 1,6247)
c) Rockerarm lev€rratio t.4
d) Connectingrod
Centerdistance
nrn (in) (s.51?)
t42.67 (5.s06)
13e.8s
Bearingmaterial F500 F770
(S.T.D.)
Bearinethickn€ss 83to 1.84(0.0720
to 0.0724)
mrn (in)
Bigendplay
0.20ro 0.30(0.0079ro 0.0118)
ffn (in)
Connectingrod bearingclearan
0.011to 0.052(0.0004to 0.0020)
mn (in)
Connectingrod bendor iorsion

(per 100lnm or 2.937in) l-e$ ihan0.03(0.0012)
nm (in)
Model J16
e) Crukshaft andnain bearing
Joumaldia.
s0.813to 50.825(2.0005
to 2.0010)
mn (in.)
Journaltaper& oulof,round
mm (in)
LEss
than0.01(0.0004)
Crankshaftfreeend play
mm (in)
0.05to 0.20(0.0020
to 0.0079)
Wearlimit of dittoedplay
mm (in) 0.3(0.01r8)
Crankpin dia.
mm (in)
47.640to 47.652(1.8756
ro |.8761\
Crankpin taper& oufof-round

nm (in)
Lessthan0,01(0,0004)
Mainbearingnaterial F770
Mainbearingtlickness(S.T.D.)
mm (in)
1.822to 1.835(O.0717
to 0.0722)
Mainbearingclearance
mm (in)
0.02to 0.0s(0.0008
to 0.0020)
Wearlimit of dittoedclealanc€
mm (in) 0.10(0.0039)
Cranlchaft bend
mm (in) Lessihan0.03(0.0012)
f) Piston
Pistondia. -S.T.D. '72987

to73.037
mm (in) (2.873s ??.935 (3.Q583
to 77.98s to 3.0763)
to 2.8755)
0.s0(0.0197) 73.467
to73.517
Oversize (2.8924
to 2.8944) ?841sto 78.46s
(30871ro3.0892)
1.00(0.0394) '73.961
ro 74.017
Oversize (2.9r2rta 29140) 78.915 (3.1069
to 78.965 to 3.1089)
1.5(0.0s91) 74.467ta 74.517 '79.415

Oversize to '79.465(3.1266
to 3.1285)
Q.9318to 29337)
Elipsedifference
nm (in) 0.07to 0.17(0.0028to 0.0067)
Jl6
Ring groovewidth
2.0(0.0787)
2.0(0,0781)
4.0(0.rs7s)
Piston to bore cl€arance 0.023to 0.043
mm (in) (0.0009to 0.0017) 0.025to 0.04s(0.0010
to 0.0018)
Pistonpin hol€ off-sei 0

mm (in)
0.95to L05 (0.0374
to 0.0413)
Pisionpin hoiediameter 17.453to 17.460

mrn (in) (0.6871to 0.6874) 21.001 (0.8258
to 21.008 to 0.8271)
g) Plstonpin
Pin dia. I7 .141to 17.452

rnn (in) (0.6869 to 0.6871) 20.993to 20.998(0,8265
to 0.8267)
Pin length 65.23to 65.48

mrn (in) (2,5681 66,40to 66.sS(2,6t42to 2.6240)
ro 2,5780\
Pistonpin to phton clearance 0.001to 0.013

mm (in) (0.00004 0.003io 0.015(0.00012
to 0.00059)
to 0.00051)
fit of pistonpin
Interfer€nce
to conneciingfod bushing Bolt clarnp 0.015to 0,033(0.0006
to 0.0013)
mm(nr)
h) Pistonring
Ringheight
rnrn(in)
-ToP (0.0781)
1.984
-Second (0.0781)
1.984
Sideclealance
nm (in)
-Top 0.036to 0.076(0.0014
ro0.0030)
-'Secord 0.036to 0.076(0.0014
to 0.0030)
Ringgap
rnm (in)
0.20to 0.33
(0.0079to 0.0130) 0.20to 0.35(0.0079
to 0.0138)
0.20to 0.33
(0.0079to 0.0130) 0.14to 0.29(0.0055
to 0.0114)
0.30to 0.90(0.0118to 0.03s4)
AND CORRECTIONS
T R O U B L ED I A G N O S E S
Condition
I. Noisy engin€
Knocking of crankshafl Loosemarnbearing. Reptace.
andbearing. Seized
bearing. Replace.
Bent crankshafi. Repairor replace.
wearofjournal.
UneYen Corr€ct.
cranLshaftend play.
ExcessiYe centerbearing.
Replace
Pistonandconnecting Loosebea.ing. Replace.

rod knocking Seizedbearing. Replace.
l,oosepistonpin. pin or bushing.
Replace
lrose pistonin cylinder. Recondition
cylinder.
Brokenpistonfing. Replace.
rod alignment.
Improperconnecting Realign.
Camslnftknocking lrose bearing. Replace,

axiaiplay,
Excessive bearingthrustplate.
Replace
Roughgearteeth, Repair.
Brokencamgear, Replace.
Timingchalnnoise Improperchaintension. Adjust.

chain.
Worn.nd/or damag€d Replace.
Replac€,
Wom and/or broken iension adjusting Replace.
andb€aliogclearance-
camshaft
Excessive R€plac€.
Camshaftand valve Improperyalv€clearance. Adjust.

nechanismknocking Wornadjustingscrew. Replace.
Replace.
Loosevalvestemin guide. guide.
Replace
valvesprinS.
Weakened Replac€.
valve.
Seized Repairor replace.
Waterpunp knocking Impropershafi€ndplay. R€place.

Brokenimpeller. Replace.
lI. Other mechanic{ltrcubles

Stickingvalve- Irnpropervalveclearance. Adjust.
Insufficientclearancebetweenvalve stem Cleanstemor r€amguide.
andguide.
Weakened
or brokenvalvespring. Replace.
Seizedor damaged valvestem.
Poor fuel quality.
EM.36
EngineMechanibal
Cordition Probabl€cause Co(ective action
Seiz€dvalveseat Improper valveclearance. Adjust.

W€alcnedvalvespring. R€place.
Ihin valveheadedge. ReplacevalYe.
Na-ffowvalveseat. Relace.
Overheating Repairor replace.
OYerspeeding. Ddve within proper speed.
Stickingvalveglide. Repair.
Excessiv€iy
worn Shortage
of engineoil. Addor replaceoil.
cylinderandpiston Drty engtneoil. Cleancrankcese,
r€place
element,
Poorqualityof oil. Usedghtoil.
Overheating. Repair
or replace.
Fallty asseftblyof pistonwith conneciing Repair
or replace.
rod.
lrnproper fristonringcleerance. Adjusi.
Broken pirtonrlng, Replace.
Dirty alr clean€r. Clean.
Toorichrni\ture. Adjust.
Engineoverrun, Driveat properspeeds.
Stickingchokevalve, Cloan,nd adjust.
Overchoking. Startcorrectly,
Dofective Shortoge of engineoil. Md oil.

confl€ctirurod I-owoil pressurc. Correct.
Poorqualityof engineoil. Useright oil.
Roughsurfaceof crar*shaft. Gdndandreplacebearing.
Cloggdd oil passage. Clean.
Dearlng wearor eccentdcity, Replace,
Improper bearinga$embly. Conect.
loosebearing. Replac€.
Corur€cting
rod alignm€ntincorrect. Repairor replace.
Def€ctlvecranlshsft Shortageof engin€oil. Add or replace.

bearing l,ow oil pressurc. Correct.
Poor quality of engineoil. Useright oil.
Gankshaft journal wom or out-of-round. Repair.
Cloggedoil passage
in crankshaJt. Cl€an.
Bearing*'ear or ecc€ntricity. Replace.
Improper beadngassembly. Correct,
EccentriccranlGhaftor bearing. Replsce.
EM.37
SPECIALSERVICETOOLS
Description pageor
No- & Uniti mn (in)
figureNo.
1. sTo501s000 Thisenginestandassembly is usedfor disassembling

or assembling All PageEM-5
engineblock or differential carrierthroughout360' in all PaseEM-25
Enginestand
dir€ctions. Fis.EI{-l1
?ssembly
I
fsTos011000
J Ensinestand
l1ST05012000
Base
2. sTo5280000 Thisengine
attachmentis installedto enginestandST05015000 J13 PageEM-s
or assembling
in dhass€mbling engifle. J15 PageEM"25
Engine
J16 Fig.EM'lI
3. sT13040000 installingthe pistonpin.

For removingand Jt3 PageEM-?
PaseEM.24
Plstonpin
pressstand
sT13060000 Thistool is us€dwitha prcsgto drivepin into, or out oi, connecf Jl5 PageEM-7
ng rod. l\6 Fig.EM-25
Pistonpin
L2OA PageEM-24
20 (0.?87)dia
Fis.EM-70
120(4.72)S
2 0 ( 0 . 7 8 7 d) i a ;
EM.38
Engine Mechanical
For Reference
Desc.iption
No. & paceor
Unit: rrun (in)
figurc No.
5. sT12070000 This tool is usedto compressvalvespringby the combinedaction Alt PageEM-7

Valvelifter of its carnandlever,therebyfaciliiaiing the removalor installation models P^geEM-24
of collect(for generaluse). Fig. E[,]-69
6. sTt1600001 This valves€atcutter setis usedto or refinish a valveseat. Jl3 PageBM.l2

Valveseat J15 Fig.EM42
J16
P
sEl93
't.
sTl6s11000 Thistool fuus€dto removeihe cepfrommeinboaring.When J13 PageEM.5
Crankshaft usingthistoo1,tuin itr adapterlnto thethreaded
holein maln J15 F|E,8M.22
malnbearing Desrulgcap. Jt6
cappurcr AI
L.
Series
2 5 0( 9 . 8 )
2 8 0( 1 r . 0 )
8. sT16530000 This tool is usedto rcmovecamshaftand crankshaftsean with Jl3 PageEM"s

Crankshaft chainhung aroundgearte€th. J15
gearpul€r J16
H20
H30
Elvl-39
Engine Mechanical
Tool number For Reference

Descdpiion
No. & pageoi
Unjt: nu (in)
luure No.
9. sTr661000r Thjsiool is usedtopushpjlot bushour ofplace. J13 PageEM"20

Pilotbush J15 Fig.EM-63
puuer J16
Ll3
Lt4
L16
L18
L2OA,
G18
10. sT19550000 Thislool is usedto removeandinstalldistributordrivesDindle. J13 Pag€EM-28

Distributor J15 Fig.EM-99
drivespindle J16
puller
ll. EM03500000 Thistool is us€dto rcmoveandinstallth€pistonrings. AII PageBM-1

Pision ring mod€ls PageEM'24
expand€r
t2. EM03470000 This tool is usedto compresspiston ringswhile piston is being A| Pag€
BM-26
Phtonring insertedinto cylinder. inodels
EM40
Engine Mechanical
Toolnumber For
Desqiption
No. & pa€eor
Unit: mm (in)
figure No.
sT19320000 This tool is usedto take oil filter out of plsce.In tightening All PegeEM-5
the lilt€q do noi usethis filter, to pr€ventoxcesstightening. models
Oil lilt€r
sE197
14. Irts6900870 Ihe reamerisusedfor finisldngtheboreof newguide, Jl3 Fig.EM.39

Vrlveguide J15 P6geEM.l1
ftamer J16
EM.4I
SECTIONET
ENGINE
MODEL TUNE.UP
Jls, J15 & J15 SERTES
EilGnES
tt{0il{tTtJl{t-l|P "tT.2
SERI|ICT
OATA
AI{D'',,,'''..,'''
.' ..tT.9
sPECtflCATt0t{S
Tno|JsLr
D|AGI{0sts
AltD tTtI
c0RRtcTt0ils
sPtctAt
stnvtct
I00t tl.li
EngineTune-up
ENGINE
TUNE-UP
CONTENTS
DESCF IPTo N . . . . . . . . R E P L A CN G A R C L E A N E RF L T E R
BASC MEC H A N I C ASLY S T E.M . EI.2 ( v s c o ur sY P E ). . . . . . . . . . . ET5
ADJUSTN G I N T A K E A N D E X H A I J S T C L E A N I N GO R R E P L A CN G A B C L E A N E F
V A L V EC L E A F A N C E S Er-2 F I L T E F1 D R YT Y P E,). . . . . . . , . . . E T5
CHECK N G A N D A D J U S TN G F A N F E P L A C I N GF U E L F L T E R ET5
BELT.. ET.3 C L E A NN G F I ] E L F I L T E R C O U P L E DW T F
BETIGNTENIN CGY L N D E FH E A D N U T S , E L E C T F TPCI I M P ......... ET5
MAN FOLD BOLTSAND NUTSAND A D J U S T N G C A R B U R E T O R . I D L ERP [ 4
L A R B - RT O o I L U F I \ ' \ U - S . . . ET.3 M XTURERATO ET5
( n L L K I N Gr N C N t L O I V D R5 0 \ . . . ET-3 C H E C KN G F U E L L I N E S ( H O S E SP, I PN G S ,
L U B R I C A T I NAGC C E L E B A T OLBN K A G E . . E T 4 C O N N E COT N S ,e r c . )F O B L E A K S . . . . . . . . ET-6
I G NT l O N S Y S T E .N. 4. . ET.4 L U B RC A N TA N D C O O L ] N G S Y S T E \ .4. . . . , . ET-6
C H E C K ] NB GA T T E R Y EI.4 REPLAC NG OIL F LTEB ,, ,,.... ET.6
C H E C K ] NA GN D A D J U S T I N GG NT I O N CHANG N G E N GN E O I L . , . , . . . . . . . . . . ET.O
T M | N G. . . . . C F ] E CN K G E N G I N EO L F O R L E A K S. . . . . ET.7
C H E C K ] ND G S T R I B U T OBBF E A K E R C H A N GN G E N GN E C O O L A N T . . . . . . . . . ET.7
P ON T . . . . ET,4 C N A N GN G E N G N E C O O L A N T( L . L C , ) . . , E T7
CHECK N G O R R E P L A C I NSGP A F K C F ] E C K I N GC O O L N G S Y S T E M F ] O S E SA N D
P L U G .S. . . . . . ET.5 CONNECTION FSO F L E A K S. , . , , , , , E 11
C N E C K I NA GN D C L E A NN G H G H C F A N K C A S EE M S S O N C O N T R O L
TENSION W F E S ,D S T RB U T O RC A P S Y S T E f .i ,4. . ,,. .. ET-8
AND ROTOR D E S CPFT | O N . . . . . . . . . . . . . . . . . . . . . . .E. T 8
G R E A S I ND GI S T RB U T O FS H A F TA N D C H E C KN G V E N T L A T I O N H O S E S
CAN4HttL ET,5 ( A L L T 2 OA N D A 3 2 ] N 4 O D E L S E F I E SA N D
r-UtLSVSTIv ET.5 O T H E B SO N t Y F O R A U S T R A A L ) ....,, ET.8
bc Inadcwhilc cngincis strLlonnry.

DESCRIPTION To ,diust, procecdxs tbllows:
li may be needlcssto say, howevef, 1 . S i a r t c n g i n €a n d r u n i t u n t i l i l i s
to restorcpowcr and perfonnrncelhnt h c a l c dt o o p e r a t i n gt e m t e r a t u i eo, r r t
has leen lost though wea!, cotrosion, least,more thrn 80oC (1760F) of
or deteriorrtion, periodicnl mainte- e glnc oil tenrperatLrreithen slop
nanc€tenglnetune'up) ts n€cessary.
Ii is cven nore inportant that the 2. Rotatc orritshrft io bring No. 1
engine tune-up be done accurately cylinder in iop dead center on its
accordingto the maintcnancescheduLe
3. Renove valve rocker cover lo ET09A
shown in the applicrble Owneas
Manual. gain rcccss to valve operating mech- Fie. ET 1 AdjustinE udlDecteomnce
This clupter descrlbesaciual opel
ating proceduresfor the maintenance Adjust valvc cicarance at the ,1. Again,rotatecrankshaftoncturn
operationofitens to be inspectcd. following four pojnts while engine is so lhat No. 4 piston is in top dead
sllll hot: center on its compressionstroke.
Adjustfollowinsvalves:
O ExhaustvalveofNo. I cylindcr
@ ExhaustvalveofNo.2 cylinder
e) Intrke valvcof No. 1 cylinder
htake valveof No. 3 cylinder
BASIC MECHANICAL Or Inrakevalveof No. 2 cylinder @
lntakevalveofNo.4 cylinder
O
SYSTEM O Exhaust valveofNo. 3 cylindel
@ ExhaustvalveofNo. l cylinder
ADJUSIING INTAKE AND
EXHAUST VALVE Adjushlent shouldbe mddewhiLe
engineis hot. Atler aI valvcshave
CLEARANCES been ,djrsted correctly.tightenlock
Note: Nmbers in par€nthesisagree
Valve clearanceadiustment shol d with those in accompanyingsketch. nut fifmly to secufethe adjusiment.
Er2
E n g i n eT u n e - u p
CHECKING
ENGINE
COMPRESSION
0 . 3 5i n m
Noter If this test is to be p€rformed,
( 0 . 0 1 4i n )
it shouldbe done wh€n plrgs are
remoYedfor seric€ during basic
tune-upprocedue.
CHECKINGAND ADJUSTING Unlesscheckh madefor worn rings

or lbr the cnuseof low speed,con-
FAN BELT
Fig. ET's TiehteninEserruene pressioncheckshouldnot be neces-
With the engine switched off dnd sary.
the hood u!. push th€ b€Lt gentiy
downward. You shoL d be able to
d e p r e s si t a b o u t i 0 ] n m ( l / l i n )
Tighieningtorque
midway between fan pulley and
Cylindcrhcadstudnut:
a l i c r n a t o rf u l l e y b y r f o r c e o f l 0 k g
( 2 2 . 0 l b ) . I f t h e f a n b e l t h a sb e c o m e
5.0 to 6.0 kg-nr
(36 ro 13 fflb)
s l i c k t h r o L r s hw e a r , l o o s e nt h e f i x j n g
Vdlverockcrshaftbrackel
and ad.justnrsbolts. ard rnovc thc
aliernitor away tuonl the engine.This
2.0to 3.0kg-m
will eli in!Le tho shck. Tighlcn thc
(i4lo 2? ftJb)
b o l 1 sa E d i i . r n d n r u k cs u r c t h r t L h c
b c L l h a s b c c n t i g h t c n c dc o f l e c l l y . I f
t i g h t c n e d c x c e s s i v c l yi t w i l l w e r r Fig. ET-4 Tejting comprc*ion
rrpidly .lnd rlso ovcrlord lhe wrtet pressur.
p u r r p a n d r l l c n r a t o rb c a r i n g s .
Whcnthe €ngincis wrm, lighton
Fln bcli dcflcction: thc bolts nnd nuts to r iorqu€0.5 Test comprcssion rvith enginc
8 L o 1 2n n n
kg n (3.6 ft lb) higherthnnthe specifi- wrrn1, r11 spark plugs rcmoved and
( 0 . 3 1 5 0r o 0 . 1 1 7 2i40
t h r o t t l c a n d c h o k e o p o n e d .N o . c y l -
inder compressionshouid be lessthun
80% of highest cylindefs. Exccssivc
variatjon betwe€n cylind€rs, ac-
companied by low sp€ed missing ol'
10k-s(22 !b) lhc cylinder or cylindcrs which are
]ow, usually indicatcs a valve not
proFrly sealing or a broken pislon
Intake and cxhausr nwrifold bolts ring. Low pressures, ev€n thougll
and nuts slrculd be tightened to the uniform, may indicaieworn Iings.This
may be xccornpaniedby excessiveoil
FiE.ET-2 Adiustins fan belt Tighteningl0que:

Intake and enlaust manifold:
L7 to 2.3 kgin
(12 to 17ftlb) Il one of more cylinders read]ow,
CYLINDER
RETIGHTENING inject about one tabl€spoonof engine
HEADNUTS,MANIFOLD oil on top ofthe pistonsin low reading
cylinders through spa.k plug porl.
BOLTSAND NUTS AND
C{rburetor iNtallaiion nuts should Repeat compressionchcck on these
CARBURETORSECURING
be tjghteDed securely. Lcaks a1 this cylinders.
NUTS l[ If compression improves con-
xrca may crnse .ough idlc. surging.
Cyljnderheadnursandvalverockel deceleration fopping or deceleralion siderably,piston.ings are defective.
shaftbracketboltsl whistle. 2. If compressiondoesnot impfove.
Whenthe engineis cold, tightening ,ralvesar€ sticking or not sealingprop-
shouldbe madein severalstelsandin Tighreningtorque: erly-
the scquenccshown in Figure ET-3, Carburctornuts 3. If lwo adjacenicylindersindicate
starlingwith lhe centerand moving 0 . 8 t o 1 . 2k g - n low compressionand injecting oil on
(6ro9ft1b) pisions does not increasecompresslon,
ET3
EngineTune-up
the causcmay b€ a cylinderhead

gasketlcak between the cylinders. vdue
Fully charged
Permissible
value
Engine oi1 and coolanr in cylhder (at20oC,680F)
couldresullfrom thisploblem.
Frigid climatcs O\et 1.22 1.28
Compression pressure
ks/cn2 (psi)at rpm Tropicalclimates OverL 18 1.23
(r7r)/3s0
12.0 Otherclimates Over1.20
r0.0(142y3s0
Clean the top of baltery and ter- Adjusi the tining to the specifi-
minals with a solution of bxkirg soda cations, tuming distributor body
and water. Rinse off and dry with loosenedsccuringbolt.
LUBRICATING ACCELERATOR
conpr€ssed air. Thc top of bxttery
LINKAGE must be clean to prevent currenl lerk.
Apply a light coatof nn tipurposc age between temrindh rnd ho posi
greascto ail slidinSor trictionsurfaccs tjve temrinal to hold.down chrrp.
exceptball joints. The entife ljnkage In addition to currenl leakrge,
shouldbe rnspectcdwhclhcr or not prolonged accumulation oi acid and
foot rcsl rctums to nornal hcight dirt on (he lop of battcry nray cduse
smoothlywhenreleasing foot from ii. corrosjon of slmps. After tigfitening
This test shouldbc madcwith cngine teflninals, coa! thcm i!ilh petrolatunr
funning.Added careshouldbe takcn (vaseline)to protcct thcn fronr cor
in checkingitems that affect proper
linkagcfunclion. Fig. ET-7 Atljusting ignition litning
CHECKINGAND ADJUSTING
IGNITIONSYSTEM IG ITION TIMING
Wiih disLriburor li']cdis-
vacuunr
CHECKING BATTERY
connecled and vehicl€ opcrrlirg nt lanition timing (B.T.D.C/rpm)
Checkthe electrolyte
levelin each normal idle sp€ed or below, set J l 3 ,J l 5 a n dJ l 6 8 0 / 6 0 r0y m
battc!y cell. jgnjtion tiIning.
The iiming can be observedby Lhc
siatio|ary pointer ai frcnt covcr lnd
l4 Unsct€w o&ch filler cr! and tle groovcson craikshaft pulley with
inspect fluid icvel. lf the fluid is low. a d€vice called a slruboscopic light CHECKINGDISTRIBUTOR
add distiled walcr io bring the lcvcl (alsofefer.ed lo as a tining lighl). BREAKER POINT
up approxinately 10 lo 20 mrn (0-394 Note that the pullcy groove is
to 0.787 in) abovethe plates.Do not gnduated 5o per scale division in
overfill. tern$ of the crank rngle. Thc to! dcad
2. Mexsure the specific gravity of center is locrted to lhc extrernelefl as
viewedfrom rhe inspeclor'sside.
Fie. ET 8 Che.hitc dkhibutor

potnr gdp
' - f
Fie. ET-' che.kine the specific
eruuitr of bdttery electrollte Fis. ET 6 Checkinqignitian timins
ET-4
Rernovedistdbulorcapandinspecr External surfacesol a[ parts of CLEANING OR REPLACII{G

burningor pitting.
pointsfor excessive secondafy be
systemmust cleaned to AIR CLEANER FILTER
Replacepoints if necessary. Use a reducepossibiliiyof voltage1oss.AI (DRY TYPE)
point file to cleancontaclareaand wires shouid be removedfrom dis- It is necessaryto clean the elemeni
removescalefrom points.Adjustdis- tribuior ca! and coil so lhdt terminals or replace ii at the recomnended
tributor point g!p. Filing is tbr canbe inspecl€daDdcieancd- Burned interval, nore often under dusty
cleaningpurposesonly. Do not af or corrodedterninals indicatelhat driving condilions.
tempt to removeall roughness.Adjusi wifes were not fully seated,whioh
distributordwel angleon rll engin€s. causes arcingbetweenend ofwire and REPLACING FUEL FILTER
terminal.Whenreplacingwiresin ter-
Check for a conianinated elernent,
Distributorpointgap: minal, be surethey are fLllly sealed
0.45io 0.55nm before pushingrubber nipple down
(0.o177 to o.o2l7in) overiow€r.Checkdistriburorrotor for
Dwe[ ansle: drmagc,anddislributorcapfor cncks.
49oto 55o
GREASING DISTRIBUTOR
CHECKING OR REPLACING SHAFT AND CAM HEEL
SPARK PLUGS
Clcan and apply multi-purlose
grease
to camandwick.
Note: Do not apply greaseexces-

sively.
lE. ET'I1 Fuel sttainel
FUEL SYSTEM All engines us€ a cartljdge tYPe

shriner, so if r malfunction is
REPLACINGAIR CLEANER delecled,replaceasan assembly.
FILTER (VISCOUS TYPE)
Fig.ET-g Ch.chingsparhpluqgop The nif clerneruscsu wet papet CLEANING FUEL FILTER
lypc clerncr olcment (viscous lype). COUPLEDWITH EIECTRIC
See tMt conect spark plugs are As this elenrenl has becn manu- PUMP
us€d.Sparkplus rnsulatofs
shouldb€ faclured under speciNilreatmcnt, lhere
ro preventpossible
thoroughlycleancd is ro need of cle ning until ii is
replacedwith a new one.Allhough the
Thoroushly clean lower insulator cleaner clcment looks dirly, do noi
and cavityby blast type clcaner.Filc atlenrpl to clern. Thc clcaning peF
bolh eleclrodcsilat Goundedsurfirccs formanoe in con(antly maintained
incrcasevoltagerequiredro fire pluBt though it looks contaminated.Cme
and set gap.Tightenplugs!o ldque. must b€ taken noi to injurc clcancr
Sparkpluggap: Repl ce elemenl wiih a new one ar

J13 recommended interval, norc often
0.7 to 0.8 mn Fis. ET 12 Replacingfuet putup
under dusty driving cordiiions. filt.r
(0.0276 to 0.031sin)
J 1 SJ, 1 6 Check for a coniamindtedliltel and
0.8 to 0.9 nu warer deposil. If filier is def€clive,
(0.0315 to 0.0354in) replaceit wiih a new one.
Tightening torqxe: Also check packngs and o-rings, if
1.5ro 2-0kg-m they rre defective, replace with new
(11 to 14 tt.lb)
CHECKING AND CLEANTNG ADJUSTING

H|GH TENSTON W|RES, CARBURETOR-IDLERPM
DISTRIBUTOR CAP MIXTURE RATIO
AND ROTOR
is madeby throtlle
Idleadjustment
Note: This op€rationis to be per' adjustscrewand idle adjxst screwafter
formed while checkirg distributor Fig. ET 10 Reptacinqdir.Ieaner engine is warmed !p. See Figure
filter ET-13.
ET.5
For cabovcrtype tuck

assemblyusing oil Filtcl Wrench
ST1932000.Whcn installingan ojl
filter, fastenft on cylinderblock by
hand.
2. Thc oil filter elemenlshouldbe
re!lacedat reconn1cnded inteNah.
Notes:
a. Do not overtightenfilter, or oil
leikngemayoccur.
b. Whenassenblingoil the sealring
lightly.
2 Throtucadjuslsrew
Fig. ET t3 ldling adiBhnent
f i C E f l 4 R . , n u r L n +o i t / i | L . l
1. Checkto be surethal float levelis
correctwhilecngineis al idlespeed. Jl3,JlsandJ16
2. Usinga suitablescrewdriver, lLrn
out idle adjusl screwapproximately CHANGINGENGINEOIL
two or threelurns,startingfrom fully
clos€dposition.Turn in throttleadjust l. Chcck if cngiic oil hrs bcen
screwtwo or lhree lurns dnd stlrt Enginemanilbld d c l c r i o n r c db y l i v x d i n 8c o o l i n gw a l c l
o r g r s o l i D c .D n i n r n d r c i l l o i l , i f
3. Turn out lhrottle adjust screw speed
genilyuntil specjfied
engineidl€speed tumHg (inHg) 2. Drrinlig rs bcsl donc rlicr a good
is approxinatelyobrained. run, whcn drc oil, being thoroughly
4. Turn in or out idie adjustscrew wrrn, will flow rerdily ir d freely xnd
until engine runs srnootNy at the CHECKINGFUEL LINES
xny forcign malter will bc hcld in
higheslspeed. (HOSES,PTPTNGS,
5. Turn oul throttle adjus! screw CONNECTIONS,etc.)
until specified€rgine speedis ob- FOR LEAKS Placeit hrgc bowl or olher shxilow
tained. cont.riner undcr ll1c cngine. Then rc-
Checkfuel lines for loosecon-
6. Readjustjdle adjusl screwuntil move thc oil pan dr.rin !lug. Do this
nections,
cracks
anddeterior.rtion.
Re,
engineruns smootl y al the high€st carefully. as ihe oil will bc hot and it
tighten
looseconnectionsi
if recessary,
speed (ltith the highesl vacuum will spufi out with somc force. AfLer
replace any damaged or defeciive
reading). complerely drainins the dnLy oil off
7. Then, throttle ddjustscrewmusi sccurelyfephce the oit drain plug and
be bdjusledso ihdt enginespeedis 20 finally refill the engine jn thc usual
rpm fastefthanspecified.
LUBRICANTAND "H" nark on thc
wry up to lhe
8- Finaly, turn in idle adjustscrew COOLINGSYSTEM dipslick. Mrkc surethrt the cm is on a
until specified
enginespeedis attained- level surlioe wlnle drahing lnd fi1ling
REPLACING OIL FILTER
the €ngiic-
The oi1 filter is of .t full-flow
a. Items 7 and 8: B€st n€thod to cadridge type. The on I'iller elementn
elininate carbor mononde in ex- sealedin the containeras a unit. It can a. A nilky oii indicatesthe presence
haustenission. b€ easily removed by lrrnd with a of coolingwater.
b. Do not att€mptto screwdown th€ specialtool. Discover the cause for necessary
idle adjust screw completely.ff l Check for oil leaks at packing
damageto the tip may resultwhich flan8e. If any leakagejs discovered, b. An oil with extremelylow vismsity
will tend to csusenalfunctions. lighten a iittle, or rellace o tilter suggestsdilution with grsoline.
EngineTune-up
3. Checkoil levei,andif it is below samegradeup to the H level. CHECKINGENGII{EOIL FON

the specifi€d
level,replenish
oil of the LEAXS
Check cylinder head, front chain
cover,oil pan, rockercover,oil filter
gasket,etc. or other parts for si8n
of leakspast their gasketedsurfaces.
.If necessary,replace gaskets or
def€ctiveparts.After maintenance las
beendone,checkthereplaced partsto
seeif nayleaksoccur.
CHANGING ENGII{E COOLANT

FE. ET-15 Checkingenqineoil leuel
Scaleor sedimentaccumulated in
Oil c{pacity of ensine(includingoil filter) water jacket or radjatorharmsheat
radiation.Thoroughlyflushtho system
Maximum (H level) nfter opcningiwo drainplugs,(on€at
4 . 4L ( 4 % , 3 % ) the bottom of the radiatorand the
J13 (U.S.qt,,Irnp.qt.)
J15 other at the riglt sideof the cylinder
Jl6 Minimum (L level) block),until cleanwatercomesout.
(U.S.qt.,lmp. qt.)
3.41(3%,3) Alwaysusecleansoft waterin the
radiator,Whencold season arrives,
the
cooling systelhshould be protected

againstfreezingby a goodanti-ffeeze Botlingpoint
solution suchas NISSANLONO LIFE Percent Freez€
COOLANT, 0,9k8/cmz(13psi)
Sealevel cooling
system
To allow for expansionwhenhot,
the level,whencold,shouldbe visible
just below the liller neck, Do not 1050c 1240c -150c
30% (2230F) (25soF)
overfill the system. This coolant
(L.L.C) shouldbe changed everyrec-
1090c 127"C -3soc
ommended interval. 50% (228'F) (261'F) (-3loF)
GHANGING ENGINE
CIOLANT (L.L.C.)
o (32) In3pection of radlrtor cap
l{laarn long lif€ coolanl
" 1 0{ 1 4 1 Apply refercnce pressure [0.9
L.LC. is an ethylen€glycol base kg/crnz(13 psi)l to radiatorcap by
product containingchemicalinhibitors -20 (41
meansof a captesterto seeif it is in
to protect tne cooling system frorn -N t-221 goodcondition.Replacecapassembly
rustingand corrosion.The L.LC. does ifnecessary.
not contain any glycerine,ethyl or 40 {-40)
methyl alcohol. [t will not evaporat€
-50i-58)
or boil away and can be usedwith 10 20 30 4() 50
€iiher high or low temperature
thermosiat.It flows freely, tra$fe$ Fig. ET-16 Ptutection .orcehttution
heat effici€ntly, and wi not clog the
passagesin the cooling sj,stem.The CHECKING COOLING
L.LC. must not be mixedwith other SYSTEM HOSES AND
products.This coolant can be used CONNECTIONSFOR LEAKS
throughoutthe sealonsof the year-
lvheneverany coolant is changed, Checkcoolingsyst€mhosesand
the cooling systemshould be flushed fittings for loose connectionsand
andrefiIed\tith a newcoolant. deterioration.Retightenor replaceas
Checkthe level. Fie- ET-U TettinA rc.li4tor cap
EngineTune-up
Cooling 3yatem prcssure test referencepressure[1.6 kg/cn2 (23 systemcomponents.

pstl to thp coolingsystembY means
With radiatorcaprenoved,aPPIY of a tester to checklor leaksat the
620 A32l T20
Withheater(u.S.qt.,Imp. qt.) 6 . 0 1( 6 % , 5 ) 6 . 5L ( 2 %, 1 % ) 8L(8X,1)
Withoutheatei(U.S.qt.,Irnp.qt.) s.4L(s%,4%) s . s 1 . ( D t , 1 % ) '7r, ('t%, 04)
rnodeiseriesand othersexported1o CHECKING VENTILATION

onlyAustralia. HOSES(ALL T2O AND
The controi systemconsistsof a 4321 MODEL SERIES
hosc connccledto the Yalverock€r AI{D OIHERS ONLY FOR
coverfrom ihe crrburetorair cleaner. AUSTRALtA)
This is feferred to as a "sealed
system"whichprovides an escapepath
gas
for the blow-by with no provision
for the intfoductionot ventihtionair l Cheokhoseand hoseconnections
ior leaks.
FiS.ET-18 ?atine cooling sytem Flow of blow-by gas is inducted 2. Disconnectall hose and blow
inlo th€ hoscby tlrc ncgativepressrr€ themout with compfessed ajr.
croatedwhen thc enginesucks th€ Il any hosecannot be madefteeol
freshair ihioughthe air cleaner. obstruclions,replacewith a new on€.
CRANKCASE The oil filler capandoil levelgauge
EMISSION CONTROL areof a sealedtype1l)preventblow-by
SYSTEM gasin cfankcss€ from escaping inlo the
DE3CRIPTlOT{
This systemis adoptedin all T20
andA32l
FE. ET 19 Sealedtrpe crdnhc$. uentilationslstem

ET.8
EngineTune-up
mm ain\
Iniake 0.35 (0.0138)

Hot
Exha st 0.35 (0.0138)
Fanbelt deflection (lnllb).......,.........

mnvkg 8 to t2lro(0.31
to0.47122)
Compression prcssure
Standad Rg/crn-$sr) at rpm (17r\13s0
12.0
Mlnlnum Kg/cm-$sr) at rpm (142y3s0
10.0
Batterylpeciflcgravity
Permfusible
valu€ FuUychargedvalue
(at20oC,68oF)
Frlgidclimatos O\er1,22 1.28
Tropicalcllrnates Overl.18 t.23
Other cllrnateg Over1.20 t.26
Ignitiontiming 8o/600
Distributorpointgsp 0.45to 0.55
(0.0177to 0.02I7)
Dwellangle 49to 55
Sprrkpluggap
J13 0.7to 0.8(0,028to 0.031)
J15,J16 0.8to 0.9(0.032to 0.035)
O capacityofengino (including oil flter)
J 1 3 J, l s a n dJ 1 6
4.4L (4%U-5.qt , 3%Imp. qt.)
3.4/ (3%U.S.qr, 3 Imp.qt.)
ET.9
EngineTJne-up
Coolingsystem
Testingpressureof radiatorcap tg,/cln2(ps)......... ...... .........0.9 (13)
Testingpressureof coolhg gYstem
(psi) .... ..........
ks,/cm2 ..'....r.6Q3)
Watercapacity
620 A32l T20
With heater
(U.S.qt.,Inpiqt.)
6 . 0 L( 6 % , s x ) 6.sL(2%,
r%\ 8 L ( 8 X , 7)
Withoutheater 5.4L(5%,4%\ s . 5 L ( r xr,N ) 1 L (7%,6h' )

(U.S.qt,,lnp. qt.)
torque
Tighterung
headrtudnut
Cylinder
shaftbrackot
Rocker bolt
Manifoldnuk
Intake& exhaust
socuring
Carbur€tor nutd
Sparkplug
ET.IO
EngineTune-up
AND CORRECTIONS
TROUBLEDIAGNOSES
Condition
CANNOTCRAIK lmpropergradeoil. Replacewith propergradeoil.

ENGINEOR SLOW Dischargedbattery. Charge
batlery.
CRANKING
Defectivebattery. Replace.
lrose fanbelt. Adjust.
Troublein charSesystem. Indpect.
wlring connectiontrouble in 8t&ting circuit. Corr€ct.
Defectivestarterswitch. R€pairor rcplace.
Defectivestartermotor. Repairor rcphc€.
(frouble-shootlng
procodure on stsrtingcircuit)
Switchon theshrtingmoto.with ltght 'ON."
whonllght 90e3off or dlrnsco8idonbly.
Check
bottery.
endcable.
b . Chcckconn€ctlon
Checkstsrtcrmotor.
Whcnlight strysbright.
Checkwlring conncctionbetweenbatt€ry and rtarter
motor.
b . Ch.ct strrterswitch.
Checkstlrtarmotor.
ENGINEWILL CRANK NORMALLY BUT WILL NOT START
In thls crr6, th€ following trouble crusesmay exist,but ln many casesiSnition tysternor fuel systemis in trouble,
IgnltlonVste,nnouble
Vabetn chadsmaoeraot uoth ptopetly
(Trolble-slwotlry prbcetute)
Chocksparkplugfirst by followinSproc€dure
Disconnocthigh temioncablefrcm one sparkplug andhold it
.bout l0 mm (0.3937tn) from dre€ngin€metalpsrt andcrank
theengine.
lfgoodspa.koccuru-
a. Checksparkplug.
b. Ch€ckignition tining.
c. Ch€ckfuel system.
d. Checkcylinder compre$ion.
If no sparkoccurs. Checkthe current flow in primary cncuit.
Veryhighcurrent. IrBpect for sho ed pdrnary circuit.

Checkbre.ter poht operation.
ET.lI
EngineTirne-up
Condition Correctrve
action
Lworno cunent. Checkfor loos€terminalor disconnectionin
Checkfor burnedpoints.
Isnition Bum€ddistrlbutorpoint. Repairor replace.

rrouble Improper pointgap. Adjust.
Defective condinser. Replace.
laak at rotor capandrotor. Cleanor replace.
Defective sparkplug. Clean,sdjustpluggapor replace.
Improperignitiontiming. Adjust.
Defectlve ignitioncoil, Replace.
Disconneciion of hight€nsion
cable. Replace.
loose connoctionor disconnection in Repairor replace.
primarycircult.
Fuolwrtamtroubla Lackof fuel. Supply.

Dirtyfuelstniner. Replace.
fuel piFe.
Dirty or clogged Clean.
Fuelpumpwill notworkprcperly. Repairor rcplace,
Carburetor chokenrlllnotworkproperly. Checkandadjust.
Improper adjulimentof floatlev€I. Correct.
Irnpropcridllng. Adjust.
Dlrtyor cloSg€dcarburetor. Disassemble
rnd clean.
CloggedbreEtherpipeof fireltrnk. Repairandclean,
Incorrectsparkplug tlghtenlngor defective Tlghtento normaltorqueor replac€gssket.

gasket.
Improper gradeengin€oil or low vhcosity. Rephcewith propergradeoil,
lncorrectwlv€ clearance. Adjust,
Compression leakfromvalveseat. Removecylind€r headand lap !"ives.
Stlckyvalvestem. Corrector replacevah€ andvalveguide.
Weakor defectivevalYesprings. Replacevalv€springs.
Compression lo.k at cylind€rheadgasket. R€placegalk€t.
Stickingor defectivepistonrin8. Replacepiston rings.
Wo|npistonringor cylinder. Overhaulengjne.
(TroubleNhootingprocedur€)
Pour engin€oil into plug hole, and then meaiur€cylind€r
compressron.
Comprescjon
increases. Troublein cylinderor pistonring.
Compressiondoesnpt change. Compressionleaksfrom valve,cylinder h€ad
or headgasket.
EI-12
EngineTune-up
Condition conectiveaction
ENGINE
IMPROPER
IDLING
Fu6l syrtemt.oublo Cleanor replace.

Adjust.
Replac€element.
Replacegasketor rnsulator.
Adjust.
Previouslymentioned.
Othsr! Adjust.
Adjust.
ENGINEPOWERNOT
UP TO NORMAL
Pr€viously
mentioned.
l0nlllonry3Fmtroubla Incorrectignltloniiming. Adjwt.

Defectivesplrk plugs, plu8t.
Cleln,adjustor reploce
distributorpoints.
Defective Dresr, or replace potnts. Also check
Fu6l rylt m roublr Malfunctionof cho*e syst€m. Adjust.

ClogSedfuelpipeor floatlngvalve.
fuel strainer.
Dirty or clogged Replace.
Fuelpumpwill not work properly. ReFir or replac€,
Clogged jets.
carburetor andcl.{n.
Dlsassemble
Throttlevrlvedo€snot openfully. Readjust.
.
Fu€lpumpout of adjustment, Runajqtt.
Cloggedair clean€r, Replac€element.

troub16 Air inhaling from rnanifold gasket Replac€gasket.
overheatins Insufficientcoolant. Replenish.

Loosefanbelt. Adjustfanbelt.
fanbelt.
Womor def€ctive Replace.
Defectiv€thermostat. Replac€.
Defectiv€water pump. Replace.
Cloggedor lealy radiator. Flush,rcpairor replace.
ET-13
EngineTune-up
Condition action
Corrective
Defective
radiatorfiller cap. R€plac€.
Air in coolingsystem. R€tighteneachpartof coolingsystem.
Improperengineoil grade. with propergradeoil.
Replace
Incorrectignitiontiming. Ad.iust.
carbur€tor(leanmixtur€).
Defectiv€ Overhaul
carburetor.
Ovo.cooling Defective
thermostat. R€place.
Orh€rs Inproperoctanefuel. Replace

with specified
octanefu€l.
Imprcpertire pressure, pressure.
Inflateto specified
Draggine
brake.
Clutchslipping.
NOISYENGINE
Carknod(ing Overloaded
engine. Userightgearin driving.
Carbonkno€king. Disassernble
cylinder head and remove
Timingknocking. Ad.iustignitiontimtng.
Fu€lt(nocking. Usespecifi€d
octansfuel.
(misusinS
Preignition of sparkplug). sparkplug.
Usespe€ified
Moch6nic!l
knockins
Crankshaft
bearing Thh stronSdull nohe increas€s wh€nengine This is causedby wornor drmagedb€anngs,
knockinB. is accel€rat€d.'Iolocateth€ place,causea or un€v€nly worn crankshaft. Renew
misfireon eachcylind€r.lf the nois€stops bearings andadjustor chrngecranksllAft.
by the rnisfire,this cylinderg€nerat€s
the Ch€cklubricationsystem.
ConneciinSrod noisethanthe
This is a little highel-pitched Sameasth€ cac€ofcrankshaftbearings.
bearingknocking. crantshaft knocking, and aho incr€ases
whenengineis acc€lerated. Causea misfire
on eachcylinderand if the noisediminishes
alrnostcompletely,this crankshaftb€arin8
Senerates the noise.
Pistonandcylinder Whenyou hearan overlapping m€ralicnoise This may cause an abnormal wearing of
which increasesits magnitudewith the cylinder and low€r compression which in
revolutionof engineandwhich decreas€sas turn will causea lower out-put powerand
by
engineis warmedup, this noiseis caus€d excessiveconsumptionof oil,
phton and cylinder.To locatethe place,
caus€a misfireon e3chcylinder. Overh.ulengine.
This noise is heard at each highestand This rnay causea weai on piston pin, or
lowest dead end of piston.To locatethe pistonpin hole.
place,causea misfueon eachcylinder. Renewpistonandpistonpin ass€mbly.
This noise may be causedby worn or waterPumPwith a newone.

Replace
darnagedb€arings,or by the unevensurface
of slidingparts.
ET.14
EngineTune-up
Cotdition Probablecause Cofiectiveactlon
Othe$. An improper adjustmentof valv€cl€srrnce. Adjust.

Nois€of timing chain. Adjust the tensionofchein.
An exc$;ive €nd-playon crankshaft, Dsassembleengineand r€newmaln bearing.
Note: Thir troire w l b€ h€ord when clutch
b direqaged,
Wearon clutch pilot busbing, Rene],bushand adjustdrive shaft.
Noter Thir noisewill be heardvhetr clutch

is dir.ngsged.
ABNORMAL
coMausTtott
(backflre, afterflre
ru["onetc,)
lmprop.lignitioniining Ift properlgnltlontlrnlng. Adjuit tgnltlontlning.

lnlproparheatftngeof sporkplugs. Usespeclned iparkplugs.
Fualryiofi troubla Danagedca6uretoror manifoldgasket, themwlth nowpart3.

Replace
Oackflre, afrcrnrc).
crrburltorjet.
Daf€ctlv€ Dlsr$€mblecarburetorandchecklt.
Inproperfunctionof th€float. valve,
Adjwt thelevel,andcheckne€dle
Un€venidling.(Runon) Adjust.
Drtrctlvacyllndarh.ad, lnprop€rlyadjultedr€lveclearance. Adj$t.

elc. Excorsorrbonin combustlon chlmber, Remowh6rdrnd g€trid of crrbon.
D&maged valvespring(backftle, after flr€). Replsceit wlth r n€iwon€.
EXCESSTVE
OtL
CONSUMPTION
Oll loakago Looseoil dralnplug. Tightenit,

loose or damagedoil pangasket. Ren€wgrskct or tighten it.
loose or damagedchaincov€rgasket, Renewgasketor tightenit.
Defective oil seal in front and r€ar Ren€woil seal,
crankslEft.
lrose or drmagedlocker covergasket. Renew gasket or tlghten il (but not too
rnuch).
otoil filter.
ImpropertighteninS Renewgasketand tight€n it with the p.op€r
torque.
l-ooseor damagedoil pressur€switch. Renewoil pr€ssur€switch or tiShtenit.
Exc4.ive bil Cylinderand pirton wear. Overhaulcylinder andrenewpiston.

tmproper location of piston riflg gap Remountpiston rings.
reverselyassembled piston ring.
Damagepiston rings. Renewrings,
Repairor ren€wpiston and cylinder.
ETIS
EngineTune-up
Cofldition Probabl€cause Corrective

action
lvorn piston ring grooveanalring. Renewpiston andpiston ring.

Fatigueofvalveoil seallip. Replaceseallip with a new one.
Renewvalv€or guide,
Olhaas Inad€quetequality of engineoil. Usethe designatedoil.

Engineoverh€at. Predouslymentioned,
POORFUEL
ECONOMY
S.. thooel.oation
of lha porr€rdaqaaro
Olh.ri Bxceeding idllngrevolutlon. Adjult lt to the designatedrpm.

recovery.
Dcfectivescc€leration Adj$t it.
Fuelle.lag€. Repair or tighten the cormection of fuel
pipes.
TROUSLEIN OTHEN
FUNCTIONS
Dacr€rrd 9ll prot.un oil quallty.

Inadequate oll.
Usethedesignated
Overhest. mentioned.
Previously
Defectivefuncdon of oil pump regulator oil pumpandrepairor rcnewit.
Dis!$emble
Functionaldeterlor.tionof oil pump. R€pairor replaceit with a newo'Ie,

Blockedoil fllter. R6nowit.
Increasedcleannce in various sliding Par$, and roplate th€ worn partawith
Disass€mble
Blockedoil strainer. Cleanit.

Troubl6 in oil gaug€pressureswitch. Replaceit with a new one,
Ercr-lvo w6aron tho Oil pressuledecreases. Previously

mentioned.
.ldin0p.rtr Defectiv6qualily or contamlnatlonof oil. Exhangethe oil with porp€r olte andchsnge
Defective
air cl€n€r. Chaeelement.
Overheator overcoot. Previously
m€ntioned.
lmprope. fu€l nixture. Checkthe fuel syst€m.
Sdtffing of Ciding in oil pr€ssure.

Decr€ase Previouslym€ntioned.
partt Ineufficient cloarances. Readjurtto the designatedclearances.
Overheat. Previouslym€ntioned.
lnproper fuel ftixture. Checkthe fuel system.
EngineTune-up
SPEC]ALSERVICETOOL
Tool rumb€r For Reference
Description
No. & use pageor
toolname Unit: rnm(in)
figure No.
l. sT19320000 This tool is usedto take oil filter out ofphce. In tightening All
the filter, do not uselhis tool, to proventoxcesrtightening. FisBT"l4
Oil filt€r models
120(4.1'
;
ET-I7
MODEL
Jt3, J15 & J16 SERTES
BEilES
Service Equipment
EOUIPMENT
SERVICE
GENERAL
SPECIFICATIONS CLASSIFICATION OF SPECIAL TOOL
SpecialTools play Yeryimportant Classification
role in the maintenanceot cars.
These are essentialto the safe, ac_
curat€andspe€dY seNicing.
The working limes listed in llrc lnspecrion
andminor
column under FLAT RATE TIME in repair
FLAT RATE SCHEDULE are com-
pured based on the use of Special Generaldisassembly
It_
Tools. Th€ ideniificalion code of andassembly
maintenrncctools is made uP of 2
alphab€tical letters and 8"digitai Sp€cialdisassembly
I]I,
ligures. andassembly
The headingtwo lctters roughly
tooh or equipments
classifies as: A. lmporlant c. Minorunit disassembly
a. Exclusivewith no aliemative ll. ceneraldisassembty andassembly
5T00000000: SpecialTool a. Ceneral djsassemblysuch as
b. Partslikely will be damasedif
8M00000000i EngineOvcrhauling rcpairedwithoutspecialiool. engin€, differential, transmis.
Machinc sion.
c. Gauges
Ill. Specialdhassembly and assembly
B, General a. Dhassemblyof exclusiveparts
a. To €aseservicing such as automalictransmission
I. Inspection andminor repair and€lectricalaccessories
a. lnspectionandmaintenance b. Specialwork suohasbofine.
b. Unit replacement c. Workveryrarelyrequired
TOOL LIST
Tool Number Tool Nrme Class Remark
Engine
sTo501s000 Enginestandassembly Former
toolNo.sT05010000
f--
I
srosortooo Enginestand
t- ST05012000 Base
sTo5280000 Engineattachment 5
sTl1600001 3 Forner tool No. ST11600000
sT12070000 Valvelifter 5
sT13040000 PiStonpin pressstand 2 For J13engine
sT13060000 Pistonpin pressstand 2 ForJl5 andJl6 engines
sT16511000 Crankshaftmain bearingcappuiler 2
sT16530000 Crankshaftgearpuler 5
sT16610001 Pilot bushpdler 3 Formertool No. ST16610000
ri sT19320000
sT19550000
Oil filter wrench
Distdbutor drive spindlepuler
I
2
il 8M03470000 Pistonring compressot 2
|n
l,{
ti
8M03500000 Pistonringexpander 5

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RUICE

This servicemanualhasbeen preparedfor the purposeof assistingservicepersonnelof

Sinceproper maintenanceand serviceare absolutelyessentialto satisfyour customers,

1. Pleaserefer to the following SERVICEMANUALS in addition to this manualfor

) All part namesin this manualconform to the PARTSCATALOGModel620, Model

3 . AII information, iUustrstionsand specificationscontainedin this manualare based

NISSAN MOTOR CO, LTO

COOLANTLEVEL DRAININGAND WATER PUMP

Iig. CO-2 Etploded deu of uater pump

REMOVAL AND lnstallatlon

and tighten fixing bolts securely. 5, Remove mechanicalseal f;onl 4. Inspectmechanical

Standard For tropicalareas

Vatveopeningtemperature 82'C(180.F) 88'C (190'F) (l?0oF)

Note: It is nec$saryto checka new

If $e above defect is detected,

Dmensiofl of core 330x446x49 33Ox446 x 32 300x488x49

Capworkingpresure kg/cm, (psi) 0.9(13)

Fanouterdia. [mm (in)] x No. ofblades 3a0(ll.a) z a 310(t2.2\x 4 340(13.4)

Lossofwater Damagedradiatorseams, Repah.

Overheating Defeciiv€thermostat. Replace.

The electricalsystemk a 12 volt Startingmotor Infomation on body electrical

Fig. EE-7 Adjwtins specific gftuitr

Battery is not chargedcorrectly.

Specificgravityof eachcell is lels Specificgroviiy of somecella ia Specificgravityof eachcellIsabove

I 6 Piniol' u Shifl lever

REMOVALAND 2, Loosennut used io securecon-

DISASSEMBLY 4. Withdrawthe amature assembly

td 3. Removetwo tbroughbolts and

5- Remove pinion stopper from BRUSHSPRINGTEI{SIOI{

Fig. EE-16 Conti.uity test of field coil

To.tlng ti.ld ooll tor Stound r

Startingmotorwill not Chargeor replacebattery.

Shrtingmotor Wornpinion plnion.

Fie. EE-29 Chdteinscncuit (I)

I,ig. EE-30 Chdrsits circuit (n)

DESCRIPTION like a one-wayvalvefor electricityso

Fig. EE'32 Sectiotul Dieb of altenatol

REMOVALAl{D 2. Rernove brush holder fixinS

3. Loosen and remov€ throu8h

Not€: Use c,5rein handling diode as-

INSPECTIOIIOF SIATOR saiisfactory.Il there i3 conduction Diode installedon O plate is a

Fig.EE'.14 Testitrgstator for

{ie.EE 45 ConductiDe.lir.ctio^ af.Iio.te

Diodeinstalledon O plate is a posi-

Fig. EE 16 tnspectin' needti@ dio.te

3. Tightenpulley nur with tighien-

Fie.5E-49 Brwh uear limit

SPRIIIG PRESSURETEST ASSEMBLY

Set up a test circuit as shown in

Measured value:Below12.5volts Measuredvalue:Over12.5volts

a. Do not run engin€at more than

?iE. EE-63 T6tin9 altemdtor

SERVIGE DATA A]{D SPECIFICATIONS

Item LT135.l3B LT150-05(Option)

Make HITACHI HITACHI

Regulatorvoltageis measured with

After racingfor severalminuies,ammeterreading After racing for severalminuteg,ammeter

Curcnt falh below5A. Currentdocsnot fall below5A.

ADJUSTMENT 4. Adjustingpoint gap