TOYOTA

REPAIR MANUAL

INCLUDES2R

TOYOTAMOTORSALESCO' LTD.
 sEcTtoN
tltDEX
GTIITRA1I }I ]ORIIAIION
ENGII{tTU]IE-UP
EI{GINE
II{TAKI & EXHAUST
SYSTTM
]UEl SYSITM
lUBRICATIlIG
SYSTEM
c001il{GsYsTEm
CHARGIl{G SYSTEIN
STARTIiIGSYSTEM
IGIIITIO]I
SYSTEM
SPECIFICATIOlIS
 cENEFAL INFORMATION- Generat

CENERAL

Fig:I I CrossSectiondt
SideView yrt00

The 2R or l2R engile equipped on the Toyota Corona scries.Toyoia HiAcc. loyota
HiLux and Toyota Toyo-Ace seriesis of a four cylinderover-head
valvesquaretype

The constructionof the enginccqulppedon the eachvclicle is the same,l)ut their relaied
specfication slightly difler. Therefore. the specification ior each enginc is sepNjttely
describedin the gencralspecifrcation

The cylinderhead assemblyis composcdof the head with the valveguides,valves.dual type
valvesprings,rocker arms, shaft and supports,spark phrgs,thermostat,water outlet, ther-
mostatcaseand the intake and exhaustmanifolds

The two-balrel type carburetor is molrnted onb ihe jntlke mtnifold The carburetor
equippedon the Corona seriesis provided wiih Lheautornatic choke while thc carburctor
equippedon the Lighi-Truckis providedwith thc manualtvpe chokc.

The cylinder block and upper crankcase are iniegral cast wlth passagesin ihe block for
coolingthe entire length of thc cylinders.The block forms the major portion of the enginc
with crankshaft.camshaft,pistonsand other relatedcomponents.
1-2 GENEBALINFORMATION- General

Fis l-2 CrossSectionalFrcnt View v5541

The crankshaft which rs either the forged or cast iron type is sialically and dynamically
balancedto contribuie to smooth operation of thc engineespeciallyat hlgh speeds. The
crankshaft is supported with the thrce preciion type bearing inse s and bearing caps with
the center bearing servingas a thrust bearing

The camshaftis of cast iron with the cam lobe su aceschill treated,and is offset from ihe
valve lifter to elimmate the wear of the cam. The camshaft is supported with the three
precrslon type bea ngs which are rcplaceablefor seflice. The camshaft bearingjournals and
the cam lobe sudaces are precislon finished for quiet and efficient operation of the valves-

The connecting rods are of "1" beam section forged steel with a bronze piston pin bushing at
the small end and precision type bearing inserts for the large end.

The pistonsare of light alloy and have slightly oval shopedskirtsso as to providecloserfit
at operatingtemperature The piston pin holes are offset 1.5 mm or 0.059" toward the
camshalt to provide smooth operation Three piston ring grooves are cut above the piston
pln boss
The piston rings consistof two compressionnngs and one oil ring

The crankshaftpulley dlivesthe water pump, fan and alternatorwith a V-belt The drstribu-
tor is mounted on the right sideofthe engrnewhich is drivenby the carnshafiintegralgear
 - Ceneral 1 . 3
GENERALINFORIVIATION

The oil pump is mountedto the lowerend of thedistnbutorshaft,and.otatesat the same

speedasthe distnbutor.

The fuel pump is mounted on the right side of the engine,and is operatedby the integral
cam of the camstlaft

The valverocker arm cover is providedwith an air inlet cap which is also an oil filter cap.

The intake manifold is of a circular section,and is of an aluminumcast. The main passage

is designedto be levelwhen the engmeis mounted

The flywheel is of a high gradecast iron, and is attachedonto the rear end of the crank-
shaft with six bolts The ring gearis fitted outsideof the flywheel to providethe meshing
with the startermotor pinion The flywheel is also staticallyand dynamicallybalancedto
minimize the enginevibration The rcar surfacers smooth machinefinished for proper
contact with the clutch disc.

Precaution
Wheneverany work is performed on the customer'scar, specialcare should be taken to
preventsciatchingthe body, fender or spoilingthe seatsor door t m To pedorm a satis-
factory work, fendercoversand seatcoversmust be utilzed duaingthe operation,

The use of Special ServiceTools must be emphasizedas thesetools are so designedto

preventdamagingof the components,and also will quicken the work.

Duringdisassemblingof any component it is essentialthat partsdisassembled from the car

or maln assemblyshoutd be placed In sequence to facihtate the final inspection and
assembly. Certain mating pa s should be marked before drsassemblmg from the main
assemblylo idenlify the matingpositionor for balancingwrth the main assembly.

Torque Specificationsshouldbe adheredwhenevertighteningthe bolts or nuts

wrth torque
1.4 GENERAT INFORMATION- GENE'AI

GENERAL SP'ECIFICATION

ITEMS 2R ENGINE 12R ENGINE

Tvp€ 4 cylinderin line, cycleO.H.V Sameasleft

Borex Stroke 78x78mm(307x30?') 80.5x 78 tnm (3.17x 3.07")
Pistondi+lacement 1490c c (90.9cu.in) ls87 c.c.(96.8cu.in.)
Conpressionratio 83tol 8.5to 1
Conpressiorpressure 11 0 ks/crn'?(15s psi)at 2s0 fpn Sameasleft
Max. horse-power(SAE) 82 I-IPat 5200 rpn 90 HP at 5400
Max. torque (sAE) 12 4 m-ks(90 ft-lb) at 2800ryrn 13.sm-ks(98 tulb) at 3000rpn
Numberofpistonrngs:
Two Srmeaslefl
on One Sameasleft

')
Iniake(hot) 0.203rnrn(0 008 Sane asleft
Exhaxst(hot) 0.3s6rnm(0 014") Sameasleft
Ignition tim g 8" B.T.Dc. at 550ryrn Sane asleft
Ffting order t-3-4 2 Sam€asleft
Sparkplug size 14x 19nm (0 55 x 0.7s") Sameasleft
Sparkpluggap 0 8 mm (0.031") Sameasleft
Felt element(RT), Sameasleft
Air clean€rtYPe Paper€lement(R}I, RN, RY)
Carburetortype Down-draft,two bariel Sameasleft
Fuel pump tlTe Draphragm Sameasleft
Glassballtype (old), SameasIeft
Fuel filter type Cartddsetype (new)
Oil pump i}?e Tfochoid Sameasleft
Oil filter element Paper Sameasleft
O[ capacity:
Clank case 3 5 hter(3 7 USqts,3.1 Imp q1s) Sameasleft
Oil filter 0.8hter(0 85 USqts,070 Sameasleft
lmp.qts)
R?diatortype Corrugatedfh and tube Sameasleft
WaterpumptlTe Centrifugal Sarneasleft
Tliermostatt,?e Sameasleft
Battery 12volt,35'50 Afl Sane asleft
12volt, 0.48kw Sa.measleft
Starter 12voli,1.1ps Sam€asleft
Coolant capEcity:
PI&RY 7.0liters(7.4US qts,6.2Im! qts)
RH 6.7 titers(7.I US qts,5.9 rnp.qts)
RN 6.5liters(5.9USqts.5 7 Inp qts)
Fuel trnk capacity:
RT, RH 45liters(11.9USgal,9 9Imp.gal)
RN 45 titers(12.1USgal,10 I Lnp.sa1)
RY 50liters(13.2USgal,1l.0lmp gal)
 GENERALINFORMATION-Recommended
SpccialService
Tools I5

RECOMMENDEDSPECIAL SERVICE TOOLS

Engine
09850-00030 EngineAdlustKit
09303-35010 Input ShaftFront BearingPu11er
09213-60014 CrankslraftPullcy & GearPuller
09201-60010 ValveGuide BushingRemover& Replacer
09222-30010 Conneciing Rod BushngRemover & Replacer
0 9 2 1 0 - 3 110 1 TimingGearTool Scl
09215-31010 CanlshaftBea.jngRelrover& Replacer
09304-30012 Input ShaftFrcnt Bc ing Replacer
09301-36010 ClutchGuidcTool
092r4-60010 CrankshaftPulleyand (iear Replacer-

Carburetor
0 9 8 6 01 1 0 t 0 CarburetorScrewdriverSet
09240,00010 Cerburetor Adjust (;augcKit

WaterPump
0 9 2 3 52 0 0 1 1 WaterPumpPulleySeatPuller
0 9 2 3 93 1 0 1 0 WaterPumpRotorPrller
0923840010 WeterPump BearingRemovcr& Roplacer

Alternator
09286-4601I InjectionPump SplmePuller
09325-12010 OilPll g
Transmission
't,6 GENERAL INFORMATION- TorqueSpecification

StandardBolt
91111 40620 PartNs umber
LengthofBolt:20mm
BasicMajorDiaofThrcad: 6 mm
Bolt HeadMark*
* Bolt Headlvlarkhasthe followingindications

5
Tovota srandard ch$ifi crtlon 5T 7'f
Tensilesiicnelh (ks/mm2)
Brinel Hrrdnes Nunber t2r -209 t47 -227 227-217
Rockvell Hardness Nunber B 7 0- 9 5 889- 98 C 2 A- 2 a

SpecifiedTorque for StandardBolt

TorqueLimrr: m-kg(frlb)
o-k€ (ft-lb)
6 I 34) 0,4- 0.1 2.9 -
'1.3- s.0)
6 t25 ru 8-0) r0- 16 116)
10 1_25 2,25 16,3) 19- 3.1 L3.7- 22.4)
10 15 2 1 4 1 55 ) 1,8- 30 1 30 - 2L1)
L2 1.25(r50) 4 4 Q 32.8) 3_5- 5.5 35.3- 39.1)
t2 15 3,89 2 8 D 35- 5.5 25_3- 39 8)
t2 L15 3 . 7 4 21 O) 3,0- 50 2L7-
IJ 1.5 5 0 8 36 8) 4,5- 1.O 32.5- 50.6)
1.5 6 , 3 3 45 8) 5,0- 8_0 162- 5? 8)
l4 2 5 9 3 42.8) 4 , 1- 7 . 1 3 40 -
l6 1.5 9,5',1 69 2) - 1.0
16 2 9 1 0 65_8) 'l.l5 - t10,6
7 542-
51.3-
19.6)
767)
5T 6 I o 7 L( 5 . 1 ) 0.5- 0.9 4.4- 6.5
8 t25 I 6 6 ( t2.o) t5- 2,.2 10.9- 15.9
0 t25 3 . 3 4( 2 4 . L ) 3,0- 45 2 L1 - 3 2 5
0 1.5 3_22, ( 23.3) Z? - 4.2 19.5- 30.4
2 2 . 2 5( 1 5 0 ) 6 6 0( 4 1 1 ) 5_0- 8.0 36.2- 57.4
2 1,5 5 8 4( 42 2) 50^ ?.0 36.2- 506
2 115 5 , 6 1( 4 0 6 ) 48- 6.8 34.1- 49 2
l 1.5 1 . 6 3( 5 5 . 2 ) 5.5- 9.0 4?_0- 65_1
15 E.90( 6 5 . 3 ) 70^ 10.5 506- ?59
2 9 . 5 0( 6 8 . ? ) 7 . 5- 1 1 , 0 542- 196
6 1,5 L 43 6(103.8) r2.O- 1,7O 86-E-123.0
6 2 1 35 8 ( 9 8 1 ) 1r.5-16.5 a3 2 - 1L9.2
7'f 1 0.95( 6 9) 0.8- 1.2 5 8 ^ 86
8 r.25 2.2L{ L6,l) 2 . 0 - 3 . 0 L45 - 21.1
10 L_25 4 . 4 9( 3 25 \ 4 . 0 - 5 . 5 2 89 - 3 9 . 8
l0 15 4_2.9 ( 3r.0) 3 , 1 - 5 . 2 2 68 - 3 ? . 6
L2 12s(150) 8 8 0 ( 6 35 ) 7 5 - 1 0 . 5 5 42 - ? 5 . 8
t2 15 1 . 1 8( s 6 . 2 ) 7 0 - 9 0 5 06 - 6 5 _ 1
L2 L,',l5 ? . 4 8( 5 4 . 1 ) 6 , 0 - 8 , 5 43,3- 61,4
13 l5 1 0 1 ?( 7 35 ) 8 . 0 - 1 20 5 7 8 ^ 8 6 8
15 12.61( 9 \.6) r00-t5 0 123-tOA5
2 1 r . 8 6( 8 5 . 8 ) 9 , 5 - 1 4 , 0 68,7- t0t,2
t6 l5 1 9 1 5( 1 3 85 ) 1 5 . 0 - 2 3 . (01 0 E .-5 1 6 62
t6 2 1 8 . 1 I( 1 3 t . 0 ) 14,0- 22,0o 0 1 . 2 - 1 5 9 . 0

Note: The abovc specified tishreni4 tolque is applicrble only aor ledalc rhle.ds cut inio a$cel nalerit
Il the aenale rhleads re cut in olhei nl!ftirls than $cel, and also rishtening sutface lre €n.ounteicd to hear or
vibrarions, thcsc apecdied tighlenine brque mu* be reconsidered
 E N G I N ET U N E . U P 2 . 1

General
ln ordcr to rlintrin ihe full perfornranccorlgrnrlly bLriltin th!'clrgnlc. ir periodic.rrgrne
tune up is essenti.rl If irny dcfficieDcyis encountcrcclduring opefrLionof th! crr, rL usL
be diagnosedxnmediately.rnd proper carc should be t.Lkerltr!, rLl]lingul tlre engine T|r
progressol rnodcrn engrncering slandardhas been developedso q lckjy rhrl ir DcLcssrr. rr\
the use of proper instrunerlt, anLlwell tr.ined mechanics Th!'corlll)rcssronrxLLoIls In
creased.also rncorporatesa numerousclcctrical cquipment.rLndother componcrlf\whlclr
can only be txken carc with specialknowlcdgcrnd propere.ue In ord.r to ilcco rplish the
work correclly, and properly, a relirble luneup cqujpmentrre neccssary Thc procedures
describedin the following ordersshouklbe carefullysludicd

To llcrforn the cngine rdjustmenr. it $ recolllrncndedto Lrscrhe Engine Adlusl Krt

09850 00030 lhis Kit conLainsthc orl stonelor brerkcf poilltsdressing. open cnrt $rcncjr
(7 mm x 8 rnm) for the distributor primary le.rdwire ternifrl nuts, sp.Ik flLrgtsrt,grugr
(0trnmx09mrr) n d t h e f e c l e rg a u g ei n c l u d i n g i b tr h c p o i t g L r p u n dt h e v r l v cc t e L L r L L l l
acljustnlcnls

lnspection& Adjushnent
tsattery d l s t i l l c fw r t e f
I Inspectthe specificgravity with I hydro-
I ('heek thc tcrnrnrls ibr coflosion lId
I .oe.ilic rr.rirj "ull) . f i .r f ( , 1 I cltctive conncction
r h o r l ' b e \ 0 o ( (llcrn end tighfcn lhcnr rf neces\rfy
L rl l c f ! I l c , 0r ' . \,'-'rl '
It th( frr!r,y pr''!.\ r , p I orc ll. r'
'll0. . t'- i. i. ..d ro...r':(, ( l(lr'.k r . b.r.r1 c or .,...u
batlery.
If il showsgrrvity of I 190 - I 2-10the lf (lcfective.repl.rccthc bil|t.fy
batlery must be chargcd wlth r quick
chargef 5 C i e a r t h e L o po f t h c b r t t c r y r n | r p f l y
A l , h r \ l ' ' _ 1 cl l c b . r l r e r )b r " . J . . l l c grerseonlo thc tcrininiLlsto rerrRl fLrF
must be rcmovcd lionl lhe brttcry ter- Lnercorlosron
minal as the car is equipped wLth the
alternrlor EngineOil
If ihe gmvity is less than I 190, thc
I ( \ rl r" r" orl lc.rl . nLl .l l(rl
battery must bc removed Iiom the crr
fo. proper scrvicing of the batLery
stalion
I Clrcck the oil lix l:letcriorltion.lnd il
lf therc is a diflerence of more thrl
cxccssively dirly, fepLlcclhc oil
0 025 betweenthe gravityvaluesmeasur-
l l t l r . . o . t . . . . u . \ o . r . , f r , . . _ 1 1r r t l _
e d i n e a c h c e l l - t f L r !l c h . r ! , - . , , ,
r rlr" orl | . , r h . , l r r ' o . - , 1 .. , r , 1
d r l i o n .r l r eb a l t e r y, h o u l JL , e. n . " d r t
propcr crrc shouldbc trkcn
thebattcryservicestation
The recournendcdengjneoil ro be utiliz
ed shorLldbc rbove SC. SD class(API
2 Checkthe eleclrolytelevelin the b ltery
servicc classiiication)with prcpcr oil
cells.
\ o r m b l ( l e i r r n l ]l c l e v e .l l r u r l L bl c . r b o L l
Erlgire oil capacjtywith orl frltefl
l0 mm (0.4") abovethe plates
4 3 litcrs (4 6 US qts.3 8 hnp qrs)
If necessary,replenish the celLswilh
2.2 E N GI N ET U N E . U P
Coohnt
I Check tne coolirlg systeln lbr leak, soft
hoses, loose hose clamps and correct
Replenrshwith drinkable water if neces-
sary.
2. Use r reliable brand antifieeze in cold
Clooling systemcapacity:
RT RY series
7 0 liters(7 4 USqts,6 2 In)p qts)
RH series:
6 . 7l i t e r s( 7 I U Sq t s . 5 . 9rmp qrs)
RN scries:
6 5 l i L e r(s6 9 U Sq t s , 57 Imp qts)
Fan Belt (v-belt)
I Check the fan belt for cracks. stretch
and wcar, rnd if delective,replace the
fan belt.
2. Check and rdjust if necessary to correct
tension
l he speciliedtensionis 8- l3 mm (0 31
-0.51") when depresseda1 midway of
Ihe belt with l0 ks (22 lb).
Fig. 2 I Checktns Fan Belt Tension
Fuel Filter (Glassbowl type)
1 Check the fuel filter bowl for crack. and
check the body for deformation.
Replaceas necessary,
Clean the element if excessivelydirty,
and check for damege
Replace the element with the Kit if
Afu Cleaner
L Clean the element with compressedair
of low pressure-
Replece the element if damaged or ex-
cessivelydirty
2. Clean the insidc of the air cleanercase,
and chcck the seal washer and the
gasKers
Il deiective,replaceas necessary
Spark Plugs
I Check each plug individually for cxcas-
sive electrodeswear. glazed.broken or
blistered porcelain
Replecethe plugsil necessary-
2 .Clean the spark plugs thoroughly usirg
a sandblastclerner
When cleaningwith thc abrasivecleaner,
do not prolong the cleaningto prevent
porcelaindamage.
3 Chcck cach spark plug lbr nrake and
neat runge.
All spark plugs must be of sxrre nake
and alsowith the srmc heat range
If cxcessivecarbondcpositsare obsewed
on the insulationtip, replaccwith a hot
rangc type spark plugs
c4850
ln.l cares norma cond iiof
B
c
D ind'cates abnofmal wear
Fig 2-2 Spa* Plug Conditi.ti! V22(H

If the spark plugs show burning white or
rapid electrode wear, replace with a cold
ftnge rype
4. Adjust the spark plug gap by bending
the ground electrode to obtain the spec-
ified gap of 0.8 mm or 0.031" with the
sparkplug gauge
0.8 tnm(0.031")
Fig. 2-3 AdjusnngPtus Cap v2t65
Distributor
l-Clean the distributor cap, and inspect
for crack, cafbon track, and bumt or
corroded terminals
2. Clean the rotor, rnd check for damage.
\ Replacethe rotor if dcfective
3. Check the dislributor centrifugal ad-
vancemechanismby turning the rotor in
- the clockwise direction as far as possible
with the fingers, and see if the rolor
retumsto its origrnalposition
r If the rotor does not retum readily the
CentrifugalAdvontr Y320a
E N G I N ET U N E - U P
distributor must be disassembled,and
the cause of the trouble should be cor-
rected
4, Check the vacuum advancer mechanism
by pushingin the octane selector,then
rcleasethe selector to see if the seleclor
returns to its rctarded position_
Any stiffness in the operation of the
vacuum advancer mechanism will affect
the ignition timmg.
Corect any intorference or binding
5 Clean the breaker points with a point
frle if necessary.
If the points are excessively burnt or
pitted, replace the breaker points, ancl
lt ls recommended that the condenser
capacity should be checked
6 Chcck the breaker arm tension with a
spnng tension tester by pulling at .ight
angle to the breaker arm point
Read the tester just when the point
The tension should be 400-550 grams
( l 4 . l - 1 9 . 4o z ) .
7. Checkand adjustthe point gap.
The gap shouldbe 0.45 mm or 0.018".
8.Check the cam dwell angle wlth the
tester The angleis 50 - 54 "
9. Lubricate the "A" portions of the cam
lobes shown in the figure, breaker arm
Fig- 2-5 Lubdcating Portions 80737
 E N G I N ET U N E . U P

rubbing block, breaker arm pivot and

thc distributorshaft hollow portiorl with lf the enginepingsexcessively,tum the
Distributor Grease.and the "8" portion octanc selecrortoward the "R" mark to
oi the dist.ibutor shaft oil cap and the retard rhe timing-
octane selectorsliding sudace wilh en lf Lhe engine does not ping, turn the
glne oli. rdjustcr toward the "A" mark to ad-
vxncc the tining
Ignition Timing
t. Inspectthe ignition timing usinga hming Note:
light with ihe engineat ldhng speed,and . , . ( ) r . r g r " d u 1 , . o r J f r l e J d j L s t e ri i
adjust so that the timing pointer wlll erlual to l0 40 of the crankshafl
align with the tirning ball At this timc, angle-
the octane selectormust be set at zero b The octane selector has no relatiol
with thc chaftrcterisiic of the vecuurrr
The ignition timing is 80 BTDC at 550 advancer,
rpm,

C€rter ine Sett'ng Ine Sett'nC

Fig 2 6 lgnuton Tining Mark c085J Fig. 2-7 OctaneSele.tor GOJlO

2 To adjust, loosen the distliburor cjamp Valve Clearance

bolt, and then turn thc distributorhous- l.Warm up the engine till the coolanl
ing in thc direction requiredto align the
l e m P e r a l u r er e a c h e \? 5 - q s o ( t l 5 _ -
timing marks
1850F)
To advancethe timing, turn the distrib
utor housing counterclockwise,and to
2. Tighten the cylinder head bolts and the
retard the liming, turn it clockwise
rocker shaft support bolts to specified
torque
Octane Selector
Specified torque:
l. Dependingon the gasolineoctanerati!ts, Cylinderheadbolts:
the ignition timing must be adjusted 1 0 . 3- 1 1 . 7m k g ( 7 4 . 1- 8 4 2 f i - l b )
To test, run the car at 25 to 30 kph Rockershaft supportbolts:
(16 -' lC mph) in top gear,and depress l8.'25m-kg(13- 1 8f t l b )
the accelcriltorpedal all the way to the
floor 3 Sei the cngine at idling speedto about
550 rpm. and inspectthe valveclearance
2. tf the engine has a slight ignition ping, between the rocker arm and the valve
and it fadcs out graduelly as the car stem with a feeler gauge
p i . k \ r r p l h ( \ p i ( J . t h i i g n . l i o nl r m r r gi s Thc specified clearance is 0 203 mrr

(0 00E")for the intake side,and 0.360
( 0 0 r 4 " )for the exhaustside
Fig. 2 8 Adjuyinq Vabe Clerrun.e v3211
t/3215
4 To adjust, loosenthe lock nut, and turn
the adjushng screw until the specified
clearanceis obtained
Tighten the lock nut securely afier ad
justment.and recheckthe clearance.
Carburetor
I Check if the fuel level aligns with the
line on the lcvel gauge glassat engrne
idling
If the level is in.orrect, check and adlust
or repatl tlle float level,fuel pump outlct
prcssureand the needlevalveseating.
2. Adjust ihe engine idlmg speed as the
followingproccdures.
The adjustment of thc engine idling
shouldbc perforned with the air clcaner
installed.
a. Removethe intake manifoldsuction
hole plug, and installthc adapterto
connectthe vacuumgaLrge-
Connectthe vacuutngaugehoseto the
adapter.
b. Connecta tachometer
onto the igni-
tion coil.
c. Turn the throttle adjustingscrewuntil
the engineoperatessmoothlywithout
stallingat lowestpossiblerevolutlon
E N G I N ET U N E - U P 2.5
d Turn the idle adjustingscrewand the
throttle adjustingscrewalternatelyto
obtain a steady maximum vacuum
readingwith smooth engineoperation
at lowestpossiblerevolution.
The engine idling speed should be
approximately550 rpnl, and the vacu
um readingshouldbe more than 400-
5 0 0 m m H g ( 1 5 6 t o 1 9 . 5i n H g ) .
Notel
Adjust the engineidlmg speedat the
"D" range for the car equrpped with
the Toyoglide Automatic transmls-
3 Check the accelerationpump
To check. rernove the air cleaner on RT
& RN se es and the air intake connector
on RH & RY se es.
Next, open the throttle valvecompletely
liom the closed positjon, and obse e
the condition of the fuel spray from the
Pumpjet
4 On RT series,check the automaticchoKe
If ncccssary,adjust the choke by .efer-
nng to the Carburetorin Fuel System.
On RH, RN and RY series,check if the
choke valve opens and closessmoothly
CompressionTest
I Afler warmrng up the engine to operat-
rng tcmperature,removeall spark plugs
.2 Di.(onnccl lhc secondarywire from tne
ignition coil to cut-off the secondary
circuit
3. Insert a compression gauge into the
spark plug hole, open the throttl€ valve
fully, and measurethe compressionof
each cylinder.
Alurys use fully .h:rged ba (r] to
"
obtain the englne revolution of more
than 250 rpm.
2.6 ENGINETUNE-UP

4. The specified compression pressure The differenceof the compressionread

shouldbe more than 11.0kg/cm'(156 ing betweenthe _cylindersshould be
psirar 250 rpm. and the limil i\ 8.0 w r t h i nO . ? k g i c m l { l 0 p s i l .
kg/cm' (l15 psi).
 ENGINE

TROUBLE SHOOTING 31

MAJORSERVICF,
Removal... 3-5
O n R H ,R Y s e r i e s . . 3-5
OnRl,R\series....... 3-6
Dicacsembly. ',7
3-
Tn\peclion & Repair. 310
C y l i n d ehre a d . 3 - t0
Valveteal 3-t I
Valveguidebushing 3-t2
Valve.. 3-13
Valve \pring . 3-13
Valverockerarm & rockershaft . 3-14
V ! l v el i f i e r . 315
Pushrod. . . 3-15
Cylinderblock 3-15
C y l i n d ebr o r e . 3,16
Cylinder\leeve 3-t'7
PrsLon & pisronpin 3-r8
P i s L orni n g . 3 -1 8
C o n n e c l i n g r o d. . . . . . . . 3 -1 9
Connecling rod bearing. . 3-20
Crankshafl. 2-22
Crankshaftbearing .... 3-22
CrankshaftLiminggear. . 3-23
Cam\hdft . 3-24
C a m s h a fLt i m i n gg e a r .. 3'24
Camshattbe"ring 3-25
Flywheel . . 3-26
c r a n k s h d f t o irl e t d i n e r . . . .... 3-26
Assembly.. 3-2',7
Installation. 3-32

MEMORANDUM.. ...... 3_33

 ENGINE- TroubleShooting 3-l

TROUBLE SHOOTING

The possiblefaults,and their remediesarelistedin the following table Whenthe symptoms

of troublesare detected,proper caremust be taken immediatelybefore proceedingto the
next probablecauses-

Symptoms & ProbableCauses Remedies

Lack of Power
I Poor compression
a. lnconect valveclearance Adjust valveclearance
b. Compression leak from valveseat Lap valvesand seats
c Sticky valvestem Replacevalvesand guides
d. Weakor broken valvesprings Replacevalvesprings
e. Leaky cyhnderheadgasket Replacegasket
f. Sticky or brokenpiston rings Replacepistonrings
g. Worn piston ringsor cylinder Overhaulengine

2. Ignition systemimproperlyadjusted
a. lncorrectignition timing
b. Defectivesparkplug/s
c. Defectivedftributor points
d, lncorrect octaneselector
Adjust ignition timing
Clean,adjustor replacesparkplug/s
Correcl or replacepointr. and inspec(
condensercapacity
Adjust octaneselector

3. Lack of fuel
a. Cloggedcarburetorjet Disassemble and cleancarburetor
b. Cloggedfuel pipe Cleanfuel pipe
c. Dirt in fuel tank Cleano. replacefuel tank
d. Air in fuel system Checkconnections,and tighten
e. Fuel pump not functiorungproperly Repairor replacefuel pump
f. Clocgedfuel filter element Cleanor replacefilter element

4. Insufficientcarburetorair intake
-fl: Rest ctedair cleaner Cleanarr cleaner
b. Chokevalvepartially closed Repairor replacechokemechanism

$"Overheating
l, 6rlnsufficientcoolant Replenishcoolant
b. Loosefan belt Adjust fan belt
b. Fan belt worn or damaged Replacefan belt
d. Inoperativethermostat ReplacethermosJa!
e. Inoperativewaterpump Repairor leplacEwaterpump
Srclqggedor leaky coolingsystem Clean,repairor replapeaoplingSystem
g, Incorect ignition timing Adjust ignition.timing
h. tncoxrec.tignition system Tune-upengine
i Brakesdmgging Adjust bmkes
llirc6iddli xqlve clearance Adjust valveclearance
Bxhaust systempartially restricted Cleanor replaceexhaustsystem
 ENGINE" TroubleShooting

l. lncorrect grade, and viscosrty oil being used Replacewith correctoil

m, Fuel mlxture too lean Overhaulor adjust carburetor
n. Radiator fins cloggedor obstructed Cleanradiatorfins

Excessive Oil Consumption

l. Oil leak
a. Oli pan drain plug loose Tightendrain plug
b. Oil pan attachingbolts loose Tighten altaching bolts
c Oil pan gasketdamaged Replacegasket
d Timrng gearcoverattachingbolts loose Tighten attaching bolts or replace gasket
or gaskeidamaged
e Oil seeldanlaged Replaceoil seal
f Cylinder head cover gasket damagedor Replacegasket
valve push rod cover gasket dalnaged
g Fuel pump attachingbolts looseor Tighten fuel pump attaching bolts or
gesketdamaged replacegasket
h. Oil filter attachingbolt looseoi gaskel Tighten attaching bolt or replace gasket
damageo

2 Excessiveorl consumption
a. Defectiveprstonrrngs Replacepjstonrings
b Ring gapsin hne Correct gap positions
c Piston nngs worn or nng groovesshcky Replacepiston rings
d Carbondepoet in oil return hole of oil Replacenngs
nng
Pistonor cylinderworn excessively Replacepistonsor bore cylinders
f. valve stem "O" ring damaged Replace"O" ring
Valve and guide bushing worn Replacevalveand guidebushjng

Hard Starting
1. Slowcrrnking
a lmproperoil viscositY Changeto proper viscositY oil
b Dischargedbattery Chargebattery
c. Defective
battery Replacebattery
d. PoorbatterYconnections Clean and hghten or replace battery con-
nections
e. Deiectivestartermotor Overhaul and repair or replace starter

2. Defectiveigniiion system
a. Bumt drstributorpoints Replacepoints
b. Pointsincorrectlyadjusted Adjust points
c. Sparkplugsgapsinco[ectly adjusted Adjust spark plug gap
d. Looseor defectivesparkplug wires Tightenor replacesparkPlugwres
e Defectiveignition coil Replaceignition coil
f. Looseprimary circuit connections Tighien connections
g, Defectivecondenser Replacecondenser
 ENGINE- Trouble Shootine

3 Enginecondition
a. Burntvalves Repairor replacevalves
b Leaky manifoldgasket Tighten manifold bolts or replace gasket
c- Plstons,piston rings,and cylinde$ worn Overhaul engine
d Defectivecylinderheadgasket Replacegasket
e Loosecarburetor mountingbolts Tightenbolts

4 Carburetion
a. Chokeoperating improperly Adjust or repaf choke mechanism
b [ncorect engmeidling Adjust engineidling
c. Carburetordirty and passages
rcstticted Overhaul and clean carburetor
d Loosecarburetorattachingbolts Tighten attaching bolis
e, Carburetoroverflows Repaircarburetor

Popping. Spittingand Detonation

l Ignition system
a Loosenconnectionsin tgnitlon system
b. Defectivesparkplugs
c IncoIIectignitiontimrng
d. lncorrectheatrangeplugs
Inspectand tightenconnections
Cleanandadjustor replacesparkplugs
Adjustignitiontjming
Replacewith correctheatrangeplugs

2. Air-fuel m1xture
a. Lean combustionmixture
b Fuel pipe dirty or restricted
c Air leak at carburetoror intake manrfold
Cleanandadjustcarburetor
Cleanor replacefuel pipe
Tighten carburetorattachingbolts or
manifoldattachlngboltsor replacegasket

3 Valves
a, Incorrectvalveclearance Adjust valveclearance
b. Valvessticky Repai or replacevalves
c Weakvalvesprings Replacesprings

4. Cylinderhead
a. Carbondeposrtsin combustionchambers Removecarbon
b. Cylinderheadwater tube parhally clogged Cleanor replacewater tubes
c. Cylinderheadgasketdefective Replacegasket

Routh Engine Idling

L Carburetor
a. lncorrectidling adjustment Adjustidling
b. Carburetor Iloat needlevalvenot sealing Cleanand adjustor replace
properly

2. Air leaks
a. Leakingheatinsulator,and intake Tightencarburetorattachingbolts or re-
manifoldgasket placeheat insulatorand intake manifold
gasket
, b. Crackedintake manifold Replacemanifold
 ENGINE- Trouble Shooting

3. Valves
a. lncorrect valve clearance Adjust valve clearance
b. Valve not seatedProperly Lap valves
c Excessivecleamncebetween valve stem Replacevalve and valve guide
and valve guide bushing

4 Cylinder head
a Leaky cylinder head gesket Rephce gasket

Engine Missesat Acceleration

l. Carburetor
a CloggedacceleratingsYStem and clean
Disassemble
b. Lean fuel mixture Overhauland repaircarburetor

2. Ignition system
a. Defective sperk plugs Cleanor replacesparkplugs
b. Defective ignition wires Replacewlres
c. lncorrectlyadjusteddistrtbutorpoints Adjust or replacepoints
d. Defectivelgnitioncorl Replace ignitioncoil

3. Engine
a. Burnt or incorrectlyadjustedvalves Adjust or replacevalves
b Poor compresslon Overhauland rcpar engine
c Leaky cylinderheadgasket Replacegasket
d Leaky manifoldgaskets Tightenmanifoldor replacegaskets

Noisy Engine
One of the most difficult of all trouble shooting operation is to locate the sourceof noise in
the engine Every rotating or reciprocating part is a poteniial source of noise
Ceflain noises possesscharactedsiics which can be delected. These characteristlcsvary, and
experience is the best guide in most cases

I Crankshaftbearing
a Wom bearings Replacebearingsor grind crankshaft
b. Worn crankshaftjoumals Grind or replace crankshaft
c Meltedclankshaftbearings Replace bearings and check lubricating
system

2- Connecting rod bearings

rod & connecting
a Worn connectingrod bearings Replacebearingsor grind crankshaft
b. Worn crankpinjoumals Grind or replace crankshafl
c. Bent connectingrod Cofiect or replace connecting rod
d. Meltedbearings Replace bearings and check lub cating
system
e. Worn connechngrod bushing Replace bushing

3- Piston, piston pin & Piston rings

a Excessive cylinderwear Bore and hone cyltnders, and install new
pistons and rings
 ENGINE- TroubleShooting 3.5

b. Wornpistonor pistonpin Replacepiston and pin

c Burntpiston Replacepiston
pistonrings
d. Defective Replacerings

4. Other components
a ExcessivecamshaftthrLst clearance Replacecamshaft thrust plate
b Worn crankshaftthrust washer Replecetlrrust washer
c- Worntinringgear Replacetiming gear
d Wornvalvelifters Replacevalvelifte$
e Excessivevalveclearance Adjust clcarance

MAJOR SERVTCE
Removal- On RH & RY series lead wire from the dlstrlbutor termi-
I Dmin the coolantfrom the cooling nal
system-
1 2 . Jack up the vehicle, and support 1r
2 Disconnectthe batterygroundcable wlth stands
from the batteryterminal-
1 3 . Remove the prcpeller shaft
3 . Lift the ccnterseat,and removc lne
carburetorair inlet T 4 Disconnect the speedolneter cable
4 Removethe throttleand choke wires liom the transmissron,
from the carburetorand the clalnpon
the rocker arm cover l5 Disconnect the back-up light switch
lead wires from the switch

Remove the radiator inlei hose, and
dlsconnect the coolant tenrperature
sendergaugeleadwire
Removethc alternatorretainingbolts
and the lead wrcs, and remove the
altcrnatorassemblyupward,
Removethe radiatoroutlet hosc
8- Drsconnectthe high tcnsronwire from
the ignitron coil
l 6 _ Remove the cross-shaft and the gear
shiftrng rod No 3
1 1 Remove the engineunder cover LH,
and disconnect the oil pressureswitch
leadwire from the switch.
1 8 Remove the liont exhaust plpe.
1 9 . Rernove the clutch release cylinder
together with the clutch flexible hose
set plate ftom the transmission-

9. Drsconnectthe fuel pump inlet hose 20. Place an engine holder onto the Jack,
from the fuel pump and support the engine with thejack

1 0 . D r t c o n n e ct h
t r b a l r e r yl o \ l a l l e r c a b l e 2 1 . Remove the englne under cover RH,
and the lead wlres liom the starter and remove the engine front mounting
terminals, insulator RH.

11. Disconnect the distributor primary 22. Remove the engine front mounting
3.6 ENGINE' MajorService

bracket LH togetherwith the mount_ 1 3 . Disconnect the clutch releasecylinder

ing insulator. to flexible hose tube from the flexible
hose, and remove the flexible hose
23. Remove the enginerear mounting clip from the flexible hose bracket.
retainingbolts To prevent the clutch fluid from flow-
ing out, plug the air vent hole located
24 Lower the jack gradually,and care- aI tne reservof cap.
fully remove the engine with the
tmnsmissionfrom underneaththe ve- l4 Disconnect the alternator lead wires,
hicle
Take carenot to damagethe radiator 1 5 . Disconnect the coolant temperature
or the othercomponents sendergaugelead wire from the gauge

Removal- on RT & RN series Remove the accelerator wire clamp,

and disconnect the wire from the
1. Drajn the coolantfrom the cooling
acceleratorwire lever bracket.
system

2, Remove thehoodsupport,and remove t ' 7 . Disconnect the oil pressure switch

lead wire from the switch.
the hood
l8 Remove the exhaust PiPe flange re
3. Disconnectthe batterygroundcable
taining nuts.
from lhe battery terminal

4. Removethe radiatorgrrlle.(RT) 1 9 . Jack up the car, and supPort it with

stands
5. Removethe radiatorupperbaffle.(RT)
20 Removethe exhaustPiPeclamp, and
drsconnect the exhaust pipe iiont
6. Removethe radiatorinlei and outlet
from the manifold.
hoses.

7. Removethe diator.
2t. Remove the equalizersuppo bracket
and the tension spdng, and then dis-
connectthe parkingbrake cableNo. I -
8 Removetheair cleaner,and disconnect
e la l e rh o ( e sf r o ml h ee n g i n c
L h e h e a tw
if rnstalled. 22. Remove the propeller shaft
. To prevent the oil leak fiom ihe
tmnsmission rear, insert any available
9 Disconnectthe hightensionwtre from
universaljomt sleeveyoke.
the ignitioncoil

10. Drsconnectthe fuel pump inlet hose

23 Disconnect the sPeedometer cable
from the tmnsmission.
from the fuel pump

1i. Disconnectthe batteryto startercable 24. Disconnectthe low speedconnecting

rod from the shift outer lever
and the lead wires from ihe starier
terminals
2 5 . Disconnect the high speed connecting
rod from the cross-shaft
l2 Disconnectthe distributorprinary
leadwire-
2 6 Remove the gear shift rod from the
 E N G I N E - M a j oSre i c e 37

cross-shaft.

2',7
. Removethe crossshaftassembly,

28 Support the : transmissionwith the

jack, and removc the enginerear
supportmemberliom the bracket

29. Remove the engine rear mounting

i n s L l a l o lrr o m r h e e n g i n rm o u n l t n g
support
Fis. _t-1 R v3lll
30 Removethe enginemounting front
insulatorretaining
bolts. I{emovethc carburetorfuel pipe and
8
Ine vacuumplpe
3l lnstall a lifiing hook onlo the engine
hangers, and carefully remove the
9 . Loosen the distributor clamp, and re,
engine with the transmission lront
move the disrributortogetherwith the
ward and upward using a suitrblc
sparkplLLgand the ignition coil cords
no1st.
Takc .a'( nor ro Ja r"!e rhi .rl.r
1 0 Removethe starterasse,nbly
components
Remove thc spark plugs using the
Disassembly spark plug wrench
l- Removethe stilfener plate on RT
seriesif installed t2 Remove the fuel pump

2. Remove the flywheel housing under 1 3 . Remove the engine fuont mounting
bracket RH

J , R e m o v er h e t r a n s m r . s i of n' o m r n c e n - T 4 Remove the water hose throughjoint

gme if necessary

4 Stamp the mating marks onto the l5 Remove the fan. pulley and the fan
clutch cover and the fywheel to belt.
. r e l o . d l cl l e o r i g i n - l f o \ r l r o n , u f o n
a\\imbly. rhen rerno\. r\i .l rr'h Removethe aiternatorassemblyonly
coverand the clutch disc on RT series
Do not dirty the clutch disc with oil
1 7 Remove the engine front mounhng
5 . I f l h e i n p u t s h d l l f r o n l b e r r i n gm L . r bracketLH only on RT series
be replaced,
removethe bearingusing
the lnput Shaft Front BearingPuller l8 Removethe oil filter assembly.
09303 35010
1 9 Remove the automatic choke sto\re
the engine onto a work stand, plpesonly on RT scrics
drain the engineoil.
2.0. Removethe crrburetor essemblyend
ie the oil level gauge the heat insulator
3-8 ENGlNE.MajorService

2I. Removethe mainfoldassemblies bottom side of the engine upward,

2 2 . Remove the water outlet, and lemove
the thermostat. 30
2 3 . Remove the water Pump by-passhose,
and removethe water pump assembly
then removethe oil Pan
Loosenthe oil pipe union nuts (1),
a n d r e m o v et h e o r l P u m Pf 2 ) w i l h
the strainer.

Remove the coolant tenperature

sender gauge and the oil Pressure
switch.

2 5 . Remove the cylinder head cover'

)6 Remove the valve rocker shal1 asscm

bly, and removethe Pushrods
The push rods should be erranged ln
the order of the cylinder number io Fis. 3-3 Oil Punp Remorol Y3117
re-install into the ofiginal posttions
upon assembly 31. Removethe crankshaftpulley reiain-
ing bolt, and remove the crankshall
27. Remove the cylinder head bolts, and pulley using the CrankshaftPullev &
remove the cylinder head and tne GearPuller09213-60014 or the Ttm-
gasket. rngGearTool Set09210-3I01 I
When loosening ihe cylinder head
bolts. follow the order in accofdancc 0921360014
with the numbersshown in figure 3-2
in three prcgressivesteps

F i g 3. - 4 O a n k s h at uf tl l e lR e n o t a M l l S

32 Remove the timing gear covel

3 3 . I n ' p e c tr h e l r m i n gg e a rb a c k l a s u
hsing
a dial gauge.
Fi8 3 2 uea.tBoltsLooseniryOhiet V3115
The backlash limit is 0 3 mm or
0 012"
28. Remove the valve lifter cover, and
If the backlash exceeds the limit,
remove the valve lifters.
replace tlre camshaft timing gear and/
Th€ ,alve lifters should be arrangedrn
or the crankshaft timing gear referring
the der of the cYlindernumben
to the camshaft timing gear and the
c r . r n k . h d fl i m i n g g e a r o f I n . p e . t i o I .
29 Turn the engrne, and Position the
& Repairin this section.
 ENGINE- MajorService 3.9

Fit. 3-5 M"asunngBuckhsh v3l l9 Fig.3 7 hston Renoral V3]2J

3 8 . Relnove thc crunkshaft bcariDgcaps

34 Remove the camshaft thrust plate
retainingbolts (l), and removethe
camshaftwith the timing gearwlthout
damagingthe camshaftbearings.
togetherwith the bearngs
When looseningthe cap bolts. ibllow
the order oi the nunbers as shown in
flgure 3-8 in three progressivesteps.

Fig. 3 8 CapBolts Looseningoklel v3124

Fts.3-6 CanshaftRemo'at v3120

39. Remove the crankshaft, and remove
the crankshaft upper bearings.

35. Removethe timing gearoil nozzleand

the endplate(2)

36. Removethe connectingrod capsto-

, getherwith the bearings,and rcmove
.-' the pistonswilh Lheconnecringrods

Removethe flywheel. Figi 9 Yalv?Renoval ,t t::

f:

310 E N G I N E - M a j oSr e r v i c e

40 R c m o r e r h e \ e n l i l d r i o nl u b c a \ s c m - Do not mix the mated parts of the

blv piston, piston pin and the connecting
rod with the others
4\. Mark the valves, and remove the
valvesusing a valve spring compressor
Inspection & Repair
4 2 . Remove the valve rocker shaft lock
Wash the disassembledparts thoroughly
springs (l), and remove the tcnsion
before jnspection and repair to remove the
springs(3), exhaustvalverocker arms
dirt, oil carbon and water scale.
(4), valve rocker supports(5). intake
Check ihe cylinder block and the cylinder
vatve rockcr rrms (6) and rhe com-
head lbr cracks and for tracesof water leak
pression springs (7) from the valvc
beibre washing;
rocker shaft (2)
Blos -ll pa-cg(\ wirl_ compre..ed air.
and removethe deposits-
Check that the passagesare not clogged
Remove the carbon depositsfrom the top
of lhe pistons,combustionchambersin the
cylinder head, and also remove from the
valveswithout damagingthe parts
Do not mix the mated parts with the

Cylindei Head
Fi&410 Rocker
Am Disassembly V3126 l. Check the cylinder head for crack, and
inspect the gasket surfacc for burs and
43. Usinga suitablepiston ring expander, nlcks.
removethe piston rings Replacethe cylinder head rf defectrve.
The removed piston rings should be
laid 1n accordancewith the cylinder 2. Check for water leak from the cylinder
numbers. head by applying water pressureof zl 0 -
4.5 kg,/cmzor 5'7 - 64 psi, and water
temperatureof 40'C ( 104'F).
If defective, repaf or replace the cyhn-
der head.

L mit o osmm (o oo2')

Fig- 3 11 nsbn Ring RemotLl v3127

44 Remove the piston pin hole snap
rings.and heat the piston to 40 to
5 0 ' C ( 1 0 4 . - 1 2 2 " F )w i t h a P i s t o n
heater.thenremovetile pistonpin Fig. 3 12 MeatunnsHead Warwse v3128
 ENGINE-Major S€ffice 3-ll

3 Check the flatnessof the cylinder heaLl 2- To reface the valve scat with the valve
gasketsurfacewith a straighredgeand a seatcutters.it is most common to follcJw
feeler gauge. the following procedures..
lf the waryage exceeds 0 05 mm
a Fi$t, grind the ssat coniact face of
(0.002"). grind the gasketsurfacewilh
the valve using a valve refacer. and
a surface grinder,
check the contact of the valve wrl
The measuringpoints of flatnessare as
l"e 'e"t lor vrl!e \edt .'ullirg r, , r
shown in figure 3-13.

b Cut the seat slrrfaccroughly

15' cutter
Next, cut the seatsurfaccto approx-
imate contact width using t h e 7 5 "
cutter
Finally.cut the seatcontactface to
correctwidthof 1.2^-I 6 mm ( 0 . 0 4 1 -
0 063") usingthe 45' cuttcr

Fis. 3-13 MesswingPointslor waryase t 3I 29

Valve Seat
I Check the valve seat for damageand

If necessaryto reface the valve seat.

f | | s l c h e c k r h e v a l \ e g u i J <b u ) h i r ! \ l o r
wear, and replace the bushings 1f thcsc

Fit. J-15 Refo.insValveSeat V3t30

Next, reface the valve seat with a valve
seatgrinderor other cutter c Aflcr cutting the seat, the valve
The valve seat should bc flnished as shor,ld coniact the valve seat exactly
shown in figure 3-14. at the center
Therelbre,whcn cutting the seatusing
rhe l5' and the 75" cutters,cut the
scatcheckingihe valvecontact
T o c h . . k r h . c o n { a r t .a p p l y d l h r . 1
coat of red lead onto the seat, and
inseftthe valve.
Apply a light prcssureonto the valve
to checkthe contact
lf the seatingis too high, use the 15"
and the 45" cutters,and iftheseating
is too low, use the 75" and the 45'
cutters,

3 . Lap the valveand the seaiwith a lapping

Fis.3'14 ValveSeatDimension G0826 compound to match the seat
3.12 ENGINE'MajorService

After lapping, clean the valvesand the Move the vaivestem toward the left and
valveseatsthoroughly. right in pamliel wiih the rocker arm-
Measure the clearance turning the valve
Valve Cuide Bushing slighlly to obtain the maximurn worn
portion
I Check the clearancebetweenthe v;lve
If the movement oi the valve stem ex-
slem rnd the valveguidebushing.
ceeds U I nrm (0.004"), lhe (le"ran,'e
If the clearance exceeds 0 1 mm
may exceed0 I mm or 0 004"
(0.00,1"), replace ihe valve/s and the
valve guide bushing/s with the Valve
3 Install the guide bushinginto lhe cylin
Gujde Bushing Remover & Replacer
der head with the Valve Guide Remover
09201 60010
& Replacer 09201 60010 so that the
The specifiedclearancestre as follows:
protr 'ior of the guide DL,shing will be
lntake side: 0 025 - 0 060 mm
wrthin the specified dimension
(0 0010- 0.0024")
Protrusion dimension:
sidei 0.035^- 0.070mm
Exhaust
( 0 . 0 0 1 -' t 0 . 0 0 2 8 " ) Intake: 250-260mm
( l 0 0- 1 . 0 2 " ) 2 R
Ilxhaust: 220-230mm
(0 87"- 0.9r") - 2R
Intake 1 8m m ( 0 - 7 1 " ) 1 2 R
09201-600to
& I-lxhrust:

Fis 3'16 CrideBushingRepkcemenL y3134

2. To check the clearanceeasily,insert the

v a l ! e i n t o l h e g u i d c b u s h r n ga. n d p o . i - Fig. 3-18 ValveGuideBushingPrctrusion G0828
tion a dial gaugeasshown in figure 3_17
4 After installing the gulde bushing, ream
At thrs time, the plunger of the dial
gauge sholtld be placed near the upper the guide bushing until the specjfied
clearancesare obtained.
end ofthe guidebushing

Fis. 3-17 EasyMethod G0829 Fis.3-19 ReaninsVolveCuideBushins V3150

 ENGINE- MajorService

Valve
I Check the valveface and the vahe head
edgefor pits, grooves,scoresand other
def-ects.
Replaceif necessary.

2 Checkthe valvestemfor bent, and check

the stemend for groovesand scores,
Replaceif necessary

3. Check the valve head for burns or ero-

sion,warpageand cracks. Fig. 3 21 Gnndins Yalve v07t6
Defects,suchasminor pits, grooves,etc.,
may be removedby refacing.
Replacethe valveswhich are excessively
damaged.

4. lf {efacingis necessary,gind the valve

with a valve refacerto obtain a smooth
and correctangle.
Grmd ihe valveto 45', removingonly
sufficient stock to correct the run out,
and to removethe pits and grooves.

F8.3.22 Crindins YalveSten End v07t 7

6. Lap the valves slightly with a lapprng
compound for ProPer seating
Clean all compound thoroughly from the
valve and the seat after lapping

Valve Spring

3.20 YalveHeadEdge G0830 L Measurethe installedlength of the valve

If the thicknessof the valveheadedgels
less than 0 7 mm (0.028") for the
intake and lessthan 0.? mm (0 028")
for the exhaust after grinding, replace
the valve.
iR.6moveall groovesand scoresftom the
end of the valvestem, tben chamleras
2. Measurethe springtensionat the instalf
Ilot gind the valve stem end more
,0.5mm(0.02").
overall length of both intake and
valvesarc 115.8mm (4.56")for
or 109.0mm (4.29")for 12R.
springas shown in ligure 3-23-
I f l h e I n s t a l l e dl e n g t he \ ( ' i e d \ a p p r o r i -
mately 2 mm (008"). check the valve
seat depth, and check the valve spring
r e l a i n ear n d t h e r e t a r n el ro . k sf o r w e a r .
If wom, replacethem.
The limil ofthe valveseatdepth is 2 mm
(0.08")
ed height of the valve spring with a
springtester.
Replaceit if the tensionis lessthan the
limit.
3 t4 ENGINE - MajorServic€

Valve Rocker Arm & Rocker Shafl

I Check the valverocker arm and the shail

lf excessivclyworn, rcplace the.ockcr

arn bushingor the shaft
The spccified clearance between tlis
'lrJlr .
" r d r h c b U . l r1 s ' \ o u t d h e 0 0 t -
0 051 mm (0 -
0007 0.0020") for 2R or
ii0l0 - 0 03s mltl (0 0008 - 0 0014")
lbr l2R

I;ig 3-23 XlcasuringSpriagInsta ed (;0831

Length

3 Inspecr the valve spring squareness Lls

ing a steelsquareand the surface plele
Placethe springagainstthe squarcedg..
and rotate the springslowly
The spacebetween the top coil oi rhe
spring and the square edge should be
wilhin the limit- If it exceedslhe lilllit.
replacethe spring

Fis 3 25 Musutins Bushins& Shaft v07t8

v4719

2 To replacerhe bushingfor 2R, use the

flonnecting Rod Bushing Rcmover c
Replacer09221-30010and a press

Fis 3-21 ChetkingSpins Squarcness GA$2

valle sprrng \pecrtrcatron:

2R t2R

5 26 n n ( 2 0 7 " )

454nm(183') Fig 3-26 Bushng Rqlacemeht VJ]J'

5 6 k s ( 1 2I l b ) 6 4k-! (14 1 lb)
26 0k(57 3 rb) 2 3 . 3 k g ( s l 3 l b )
3 . 6 k s( 7 9 l b ) 5 i k g ( 1 1 2 l b )
22 6ks(498 lb) 1 9 0 k g ( 4 18 l b )
1 6 d m ( 00 6 3 " ) 1 6mn(0 063 ')
3 To intall the bushingibr lR. apply oil
betqreenthe valve rocker arm and trc
bushingand install the bushingonto ttle
rocker arm aligningthe bLrshingoil hole
with the rocker arm oil hole
 ENGINE 'Major Seryice 3-15

After installing, finish the bushing with Bore finisheddialnetcr:

an adjustablereameror a pin hole grind- 22 20?- 22.214mm
er to oblain the specified clearance - 0.8?46").
(o P,'t13
Mark3
4. If the valve rocker arm shows exccsslve Liftcr diameter.
wear at the valve stem contact face, 22.192 - 2 2 . 1 9 9n m
replace the rocker arm, (0 8737- 0.8740")
If the wear is little, and the rocker arm Borefinisheddiameter:
is still serviceable,reface the rocker arm 2 2 2 1 1 - 2 2 . 2 2 1m m
wlth a valve ref-acer. (0.8?46- 0.8748")

Fig.3 27 RelacingRocker Atm v3136

ValveLifter
I Check the valve lfters for wear and
pitting, and lf necessary,replace the
lifter.
Fi& 3-28 Meatuins I ifter Bore v3137
Push Rod
Check the push rods for bend and damagc
If dcfective.replacethe push rod

2 Inspect the clearancebetweenthe valve Cylinder Block

lifter and the lifter bore I Check the cylinder block for cracks and
If the clearanceexceeds 0.1 nxn damage
(0.004"),replacewith an oversize valve Minuie cracks not vrsible to the naked
lifters reaming the borcs to obtain the eyesmay be detcctedwith an cquipment
clearance of 0 015 to 0.029mm (0.0006 if available
- 0.0020"). Replacethe block if not serviceable-
Valvelifter specificationi
Mark I 2 lnspectthe water leak from the cylinder
Lifterdiameter' block by applying water pressure of
2 2 . 1 1 8- 2 2 . l ' 8 5n m 4.0-4 5 kelcm 1 (5'7- 64 psi). and water
(08731- 0 8734") temperatureof 40'C ( 104"F).
Borefinisheddrameter:
22 2O0- 22 201 mm 3 Inspectthe flatnessof the cylinderblock
(08740-08?43") gasket surface following the procedure
Mark 2 recommendedibr the cylinderhead
Lifterdiameter: lf the warpage excecds 0 05 mm
22.185- 21 192mm (0 002".).grind the girskctsurfacewrth a
(o 8'734- O.8737't suitablcsurfrcegrinder
316 ENGINE- MajorSe ice

8 0 5 0 - 8 0 . 5 5r n m( 3 . 1 7 0- 3 . 1 7 1 " . )
@oa2) t2R
Wear& taperlimit: 0.2 mm(0 008")

xl
Fig. 3 29 Measuri g Cylindet Block v3138

Cylinder Bore
I l\leasurerhe cylinder bore for out_of- Fig.3-31Mea .ing CtlinderBorc v3139
round and taper with a cylinder bore
gauge. 3. lf the cylinder walls haveminor surface
defects, but the ouFof-round and the
The measurementof eachcylinder bore
taper are within the limit, removethe
should be performedat the top, middle
ridgewith a ridgereamer,and honethe
and the bottom of the thrust direction
cylinderwalls
and of the axial direchon placing the
Next, selectand jnstallthe pistonsof
gaugeat ght angle.
largef diameter among the same size
pistonsshown in ihe following table of
the next paragraph4.

Fig.3-30Mea rinsPaintsofcllindet G08]j

2. If the cylindersare scoredbadly,burncd

and/or worn out-of_round or tapered
more than 0.2 mm or 0.008", borethe
cylindet,and usepioper oversizepistons.
If one cylinder bore requlresboring,the
restalsorequirebo ng.
Standardcylinderbore:
7 E . 0 0- 7 8 . 0 Jm m 1 3 . 0 " 1 J 0 ' l l
2R
Fig. 3-32 Rnmins Top ofBorc v0725
4 To bore the cylinder-selectthe cylinder
with the most wear first to determine
the oversizepistonto be used,and select
the proper oversizepiston in the follow-
ing table.
 ENGINE'MaiorService 3 1 7

Note: The measurementshould be perlbrmed

The mark of each size piston and the
pislon diameterare markedon lhe piF
ton package,and also the diameterof
the standardsize pistons installed onto
the engineis markedwith the "indent"
on the piston headto indicatethe piston
diameter
PistonDiameter
I 77 965 (3 0595) 8 04 s 5( 3 l 6 1 5 )
2 71 915 (1 0699) 8 0 . 4 6 (53 l 6 ? 9 )
3 7? 985 (3 0?03) 8 04 ? so l 6 8 l )
8 04 8 5( 3 1 6 8 7 )
5 8 0 _ 4 9(53 1 6 9 1 )
o/s 0 2 5 , 05 0 , 0 . 1 51, 0 0 . 1 2 5t , s 0
5. Measurethe selectedpiston at rtght angle
to the piston pin boss with a micro-
meter.
The piston pin shouldbe removedbefore
measu ng, and the temperatureshould
be about20" C or 68" F when measur_
ingthe piston diameter.
After measuringthe piston, bore ihe
cylinderswith a boring machineaccord-
ingto the piston diameter.
! v h e nL h ( r c n p e r J l u l (o f I h e . y l i n d e r i s
a b o u t2 0 ' C ( 6 8 ' F ) .
7 Inspect the clearancebetween the cy-
linder bore and the piston.
l h e . l . a . . r n c e' l ' o r l J b e $ t l l r i n o U . l '
0.05(0 00r2 - 0.0020")
To check the clearance, position the
feeler gaugeof 0.03 mm or 00012"
r h i . k n e \ .a n d o i l ) - l 5 r n m t 0 5 -
0 6") wide into tlre cylnder extcnding
the entirc lengthof the prstonat 90"
from the pistonpin bosslocation
Invert the piston,and installinto the
cylinderborewith ihe pistonpin parallel
to the crankshaftoxis.
Attrch a pull scale,and pull up straight-
ward readingthc pull scale
The corfect reading shoLrld be \,r'ithin
I . 0. ' 2 . 5k s ( 2 2 - 5 . 5l b ) .
'.",.:i

Fis. 3-34 MeasunngPiston Fit v3143

Cylindersleeve
l. The use of the cylinder sleeveis recom-
mendedonly when the cylinderbore is
worn excessively, and the O/S-1.50
pistonscannotbe utilized
3-33 M@suin|Pisron Dtametet vJ 140
Cylindersleeveouter diameter

After boring, check fhe cylinder bore o/s 2R 12R

br taper,out-of-roundand differenceof
ib_ore diameterbetweeneachcylinder.
The taper and the out-of-round should
lessthan 0.02mm or 0.008",and the
ilifference of bore diameter should be
lessthan 0.05 mm (0 002")
o/s 4 00 8 2 0 9 1 ^ 4 2 1 2 6 m n 84 590-84 65omn
( 3 2 3 1 9 " 32 1 3 3 ' ) ( 3 1 3 0 3 - 3 1 3 2 1 " )
O / S- , 1 5 0 82 591^42626mn 85-090^45150mm
( 3 2 s r 6 - 3 2 5 3 0 " ) c_3500^-3_1524',)
83-091^-83-l26nm 590^4565onn
o / s - 5 0 0 (3 2113-3 2721") 85
(3 3697^4 3120 )
3.18 ENGINE - Major Seflice
2 To remove the sleeve, press out the
sleeve toward the cylinder head with a
If the removal is difficult with the press,
bore the sleeveto facilitrte the removal
wrth the boring machine-
3 T o r n s l a l l h e s l e ( ! e .b o r i ' h e c y l i n d e ri . l
accordancewlth the oversizesleeveto be
installed
The fitting tolerancebetween the cyl-
inder block and the slecve should be
0.056 - 0 126 mm (0.0022 io 0.0050")
4. The installing pressurerequired is 2,000
- 3,000 kg (4,400 ' 6,600 lbs), and the
sleevemust be installedso that ihe top
of the sleeve is flush with the cylinder
block gasketsurface
lf the pressurerequired is less,select ihe
next oversizesleeve.
2,OOO-3,OOOkg
(4,4OO-6,600lb5)
Fis. 3-35 ltlstalling Crlider Sleeve
5. Atler insialhng the sleeves, bore and
'hone
lhe \lrevc\ lo Ll lhe slandardsize
plstons
Piston & Piston Pin
I lnspect the plston and the piston ng
grooves for wear, bur$ or nicks, and if
necessary,replacethe pistons,
Note:
The standard size piston installed into
the engineis marked wrth an "indent"
indicating the piston pin size, piston
diameter and the front mark on the
piston head
For the piston diameter, refer to the
CylinderBore of the Inspection& Re-
pairin thissecrion.
2 Measurethe ring groovesfor wear by
referring to the Piston Rlng in the next
paragraph
Fts.3-36 PistonMtks on Head v3144
3 Check thc piston pin fitnessby pressjng
in the pin with the thumb with thc
p : \ r nr t r a t < d t o 4 0 - h 0 ' ( | 1 0 4
I40'F')
lf ihe fitnessis loose,replaceboth prn
andthe pistonasa set.
Piston Ring
l.Check the rings for wear and other
defects.
GA$4 If the pistons are replaced, the rings
should be replaced at the same time
The ng sizemust be selectedto corres-
pondthe sizeofthe piston.
The rngs are providedwith the marksas
shown in figure 3 37, but the standard
size piston ings do not have the STD
mark,
Face these marks upward upon rnstal-
latl0n_
2lnstall each ring individually into the
cyhnder bore, and check the end gap of
the ring wiih a feeler gauge
T h e e n d g a p .s n o u l db r w i t \ i r I h c 5 p ( c i -
fied clearances

If only the rings are replacedwlthout
refinishingthe cylinderbores, inspect
the ring end gap by placrngthe ring at
the lower position in the cylinder bore
wherethe wearis minimum.
Specified end gap:
Compressionring No.
02-04mm
( 0 . 0 0 -E 0 . 0 1 6 " )
Fi& 3-37 Pisbn RinsMa*s v3145
Compression ring No. 2:
0l-03mm
( 0 . 0 0 4- 0 . 0 1 2 " )
Oil ring:
0l-0.3mrn
( 0 . 0 0 4- 0 . 0 1 2 ' l
3-38 Meatu.ins RingEnd Gap
the ring to piston ring groove
with a feelergaugeby inserting
the ring and its lower land
,cleamnce shouldbe within ihe speci,
cleaaance
ENG INE - Major Service 3.19
Replacethe pistonsif necessary.
Specifiedclearances:
CompressionringNo. l:
0 03 - 0.07mm
(0.0012- 0.0027")
Compression
ringNo. 2l
0 030 - 0 070 utn
(0.0012- 0 0024")
Oil ring:
0.025- 0.070mm
(0.0010- 0 0028,,)
Fig 339 MeasunryGrcove
Cleannce V3147
Connecting Rod
I Check rhc curn\ citng roJ for damageal
the thrLrstsufaces on both sides.
Replacethe connecttng rods if necessary
I f r e D l a c e lIl h. e c y l i n d e rn u m b e rs h o u l o
be marked on the camshaft side on the
connectingrod,
2 lnspect the connecting rod for bend and
l w i s r w i t h a C o n n e c r i n gR o , l A l r g n c r
T h e a l l o $ a n c eo [ t h e b e n d r n d l w i \ r i \
0 05 mm (0.002") per 100 mm (3.94")
I f i L e r c e e d sl h e l i m i r , r o r r r . ' r i r s o l h a r
the three point: on lhe "V blo.k
contact with the face plate evenly, or
replacethe connectlng rod.
r'
3.20 E N G I N E - M a j oSr e r v i c e
Fis 3-40 Aecking Rend& T\|ist
3. lnstall the connecting rod onto the
crankshaft, and measurethe thrust clear-
fhe lhrust clcaranceshould be 008 -
0.24 mm (0 003 - 0.010") and the limit
i s0 . 3m m( 0 . 0 1 2 " ) .
Replace the connecting rod if necessary
F'ig.3-11Me4uninsThrustCleomce
4 Check the connecting rod bushing 1br
wear, burrs or nicks,
If defective, replace the bushing wlth
the ConnectingRod BushingRemover&
Replacer 09222 - 30010 and a press.
when installingthe bushing,align ihe oil
hole of the bushingwith that of the con-
nectingrcd
After instalting the bushing, hone the
b L r s h i n$gi t h d p i n h o l e h o n r n gm d c h i n e
or a reamerto obtain the proper fitness
wrth the pistonpin.
The piston pin fitnesscanbe determined
by pushingin the pin into the bushrng
with ihe thumbapplyingengineoil onto
the piston pin at normal temperatureof
20'C or 68' F.
os222:'Oa a
Y3148
v3t49
Fig. U2 BushingReplacenent v3162
Connecting Rod Bearing
The connectiog rod bearings arc of insert
type, micrc-precisron finjshed wlth high
quallty and close tolerance,
Do not scrape or insert any shim, and also
do not file or lap the bearing cap or bearing
to obtain the specified clearance.
L Check the beadng lbr poor contact,
worn thin, partially melted or heavily
scored
If necessary,replace the bearings
V3t22
2. Check the oil cleamnce in the following
manner with a Plastigage
Clean the crankpin journal and the con-
necting rod bearings.
Place a piece of the Plastigageonto the
crankpin journal at full wrdth of the
bearing, and parallel io the crankshaft,
avoiding the oil hole in the joumal.
lnstall the connecting rcd bearing and
t f e . a p , a n d l l g h l c nl h e n u t s t o 4 . 0 .
5.0 m kg (29 0 - 36 0 ftlb) torque with
r torque wrench
 ENGINE- MajorSerrice 3-21

Do not turn the cranksLdftwhile the STD

Plastigage is in placc Ilearingthickness:
Remove the cap, and check ihe width I zl94 ^- l 500 mm
of the Plastigagewith the Plastigage ( 0 . 0 5 E-8 0 0 s 9 1 " )
scaleprinted on the cover Crankpinfinisheddiameter
Read the widest point in order to obtain 49 985 - 50 000 mrn
the minimum clearance, (1.9679 - 1.9685")
Oil cle.uance:
u/s-0.05
0 0 1 6 - 0 0 4 0 m m ( 0 . 0 0 0 6" 0 . 0 0 1 6 " ) Bearingthickness:
]R
1 5 l | - 1 . 5 1 ?m m
0 024 - 0 048 Jnn1(0 000e - 0 0020") (0 0595- 0.059?")
rlR Crankpinfinisheddiameterl
Limitr0.1 inm (0 004")
Oil clerrance 4 9 . 9 8 5, 5 0 . 0 0 0 m m
(196?9-19685")
u/s-0.2s
Beadngthickness:
I 6 l I - ' 1 . 6 1 7m m
( 0 0 6 3 4- 0 . 0 6 3 ? " )
Crankpinfinisheddiameter.
49.'756 - 19.166mm
( 1.9589 - 1.9593")
u/s-0.
s0
Bearingthickness:
n ! ! Or
1.'736-1-14)mm
(0 0684- 0.0686")
Fig.343 Meds.iing Oil Clearunce V3I6] Crankpinfinrsheddiameter:
49506-49516mm
If the clcaranceexceedsthe limit, re ( r 9 4 9 1- 1 . 9 4 9 5 " )
place the bearingsselectingthe propcr u/ s-075
undersizebearings with the following Bcanngthickness:
procedures, 1 . 8 6 1, 1 8 6 7m m
If a new crrnksluft is to be used.always ( 0 0 7 3 3. - 0 s 7 3 5 " )
usethc standardsizebea ngs Crxnkpinfinishecl di.rmeter:
When the oil clearancccxceedswith the -
19 256 49 266 nn
standardbcarings,useU/S 0.05 be rings. (19392-'19396")
lf the cleannce exceedswith the U/S u/s,l 00
0.05 beanngs,gind rhe crankpinjour- Bearingthicknessi
nals, and use U/S 0-25 or U/S-0 50 1 . 9 8 6 ' 1 . 9 9 2m m
bearings (0.0782' 0 0?84")
Even after gfinding the crankpin journals Crankpinfinisheddiameter:
to ihe regulardimcnsion,always check 49 006- 49.016mm
the oil clearanceupon assemLrly (19294- 1.9298"'
Connectingrod bearings:
3-22 E N G I N E ' M a j o rS e r v i c e

Crankshaft 3. Check the crankshaft thrust clearanceat

the thrust berrrng
1. Check the crankshaft for bend
The specifiedclearanceshouldbe withrn
lf the run out exceeds 0 05 mm
0 - 0 I8 mn] (0 - 0.007"). and the limit
(0002"), correct or replcce the crank-
i s0 3 m n ( 0 0 l 2 " ) .
shalt
If thc cleeranceexceedsthe limit, adlust
To measurctlle bend. placea dial gauge
the thrust clcarancesclectingthe proper
onto the crankshaftcenter journrll. and
beaflngs listcd in thc following table
rotate the crankshaftone completc llrrn
ThrLrstbearirgs:
slowly to read the maximum rnd mlnl

The bend is one half of the diflercnce

between the maximuln value ilnd lrrnl- STD:
mum valuc. T h i c k n e s s2: 9 5 0 - 3 0 0 0 m r n
(0 ll6l - 0 1181")

o / - 0r 2 5 :
Thickness 3 013 - 3.063mm
( o . l 1 8 6- 0 . 1 2 0 6 " )

o / s0 . 2 5 '
Thickness:3.075^- 3 1 2 5m m
(0 l2l1 - 0.1230")

o/s-050:
Run-out v3164
Fig J41 Meafl ns Crankshaft
Thickness:3 200 ' 3 2 5 0m m
( o 1 2 6 0- 0 1 2 8 0 " )
2 Chcck the crankpin journals and rbe
crankshaftjournals for wear and scores,
When installingthe thrust bearings,thc
and if the out-of-roundor taper exceeals
\ide $'rh the orl groove\ n-u.l bc pori
0 0 1 m n r ( 0 . 0 0 0 4 " r ,g r i n d r h c ' r r r k T i r r
tioned toward the crankshaftthrust sur'
journals and/or the crankshaftjournrls
referring to the connectingrod. bearing
and crankshaftbearingof Inspection&
Repairrn this section. Crankshaft Bearing
The cmnkshaft bearings are also of the
insert type and selectivefit with micro-
precision finished Therefore, the same
proceduresof inspectionand oil clearance
check should be perlormedas the connect
rng rod bearings.

I C heck thc bearing lor poor conlact.

\,,'orn rhin. patlrally mclted or hcavily

rephcc the berrings

lf ncccssary.
Fit. 3 45 Meosuiry Jaurnal v3165
 ENGINE- MajorServic€ 3.23

2 Measurethe oil clearancewith the Plas Journalfinisheddiameter:

tigage. 57 976 - 58 000 mm
The tightening torque of the crankshaft (2.2825- 2.2835")
bea ng cap bolts is 9 E to 11 2 m-kg u/s-005
(706-80.6ft-tb). Bcaringthicknessi
Specified oii clearance: I 8 0 9^ - 1 . 8 1 5m m
0.020- 0 044mm (0.0008 - 0 0017") ( 0 0 7 1 2- 0 . 0 7 t 6 " )
2R Journalfinisheddiameter:
0.028- 0.052mm (0 0011- 0 0022.") 57.9?6- 58.000mm
12R (22825-22835"\
O11 limit- 0 I mn (0 00,+")
clearance u/s-0.25
Bcaringthickness
1909-l9l5mm
(00'752- 0 0'754")
Journalfinisheddiameter:
57 750- 57 760 mrn
(22'/36 - 2 2',710")
u / s0 . 5 0
Bearingthickness:
2 034- 2.040nm
( 0 0 8 0 1- 0 0 8 0 3 " )
Journalfinisheddtameter:
5 7 5 0 0 - 5 7 5 1 0m m
(2 2638- 2.2642"\
u/s-0.7s
Fis. 3-46 MeotunnsOil Aearcnce v3167 Bearingthickness:
2 1 5 9- 2 1 6 5m n r
J If rhe clearance'(.ecd'lhe limil, re (0.08s0^- 0 0852")
place the beafings, selecting the proper Journalfinisheddiameteri
undersue bearings with the following 57 250- 57 260 mln
methods. (2.2539- 2 2543")
If a new crankshaftis to be used.alr{,ays u/s-1.00
use the standard size bearings Bearing thickness.
When the oil clearanceexceedswith the 2.284- 2290mm
standard bearings,use U/S-0_05 bearings ( 0 0 8 9 9- 0 0 9 0 2 " )
If the clearanceexceedswith the U/S, Journalfinrshed diameter:
' 0 . 0 5 b e a r i n g 'g. r n d l h e . f J n k \ l r d l j o r r - 5 7 . 0 0 0- 5 7 0 1 0r n m
nals, and usc U/S-o 25 or U/S 0 50 (2.244t- 2.2445")
beanngs
Even after grinding the crankshaftjour- CrankshaftTimingCear
nals to the regular dimension, always
The crankshaft timinggearshouldbe only
c h e c k t h e o i l c l c a t a n ( 'ur p o n r s ' c m h l
removedwhenit is to be replaced. aDdthc
timing gearreplacement can be performed
Crankshaftbearings: on the car by usjngthe TimlngGearTool
STD S e t0 9 2 1 0 - 3 1 0 1 1 .
Bearingthickness.
I 7 8 9- 1 . 7 9 5m m l.Check the crankshafttiming gcar for
(0.0704- 0 0707") wear,damageandchippedteeth
lf defectrve,replacethe timing gerr
-
324 ENGINE- MajorScrvice
0 9 20 . 3 t 0 o
0 9 2 1 03 t 0 0
Fis 347 Replaciry Tining Gear 80276 80278
'lo
2 remove and install the timirg gear,
use the Timing Gear Tool Set U92lG
3l010 as shown in figure 3-47
Camshaft
I Inspectthe camshaflfor bend with a dial
gauge
To lneasure the bend, place the dial
gaugconto the centerjournal,and rotate
the camshaft one complete turn slowly
to read the maximum and minimum
values
The bend is one-half of the differencc
between the maximum value and the
minimum value.
Medsuriry Bend oJ Cdmshdft V3170
lnspect the canshaft thtust clelllance.
.rnd if thc clearanceexcceds 0-3 mm
(0 012") for 2R or 0 2 mru (0 008") for
12R, replacethe thrust plate rcfcring to
the CamshaftTimirlg Geat oflrspection
'fbe
& Repair in this section. spccified
clearaicesholrld be within 0 06 - 0 I22
'nm (0.0014 to 0 004E")
3 Check the camshaftctm lobes for lits.
scoresand abnormalweer
ll dcfectlve,replrce thc cemshrft
If the cam lobcs are pitted or scored
slighLly.rnd the pilting or scoringis not
, l r l r ' c n - l l J r l - i , , p . - " t t or o f t l . c J t n -
shrft. thc lobe\ mry he dressedwith !n
O - 2m m ( 0 0 0 a " ) l2F
Fis.349 Mwring Thtust Cleawte V3I 71
4 Inspect the cam lobe herght,and if the
cam lobe height is less than the limrt,
replacethc camshaft.
Cam lobe hcrght:
Intakc; 38 36 - 3iJz16rnm
(l5t0-' 1.514")
Exlr usl 3il 25 - -1835 mm
(r506-r510")
Carlrlobe heightlimit:
lnirkei 38 29 rnrn (l 508")
Lxh.rust: 3E l9 mm (1.504")
5 Check the distributor drive gear on the
carnshxft for wear or danage lf defec
tive. replacethe camshaft
6. Inspect the camshaft journtls for pits
and abnormalwear.
If thc out-of-roundor tapcr exceeds0.05
r m l0 u02"). Erind lh( c"mshrfl Jour-
nals.and the undclsizebearingsmust be
installed Refer to the CamshaftBearing
of Inspeclion & Repair in this section.
Camshaft Timing Cear
The camshaft timing gear should be also
removed only for replacement,and the
rcplaccmerltol the tirrurg gearcan be per-
 ENGINE- Major Service 3-25
formed on the car by using the Tlmroa
G c a rT o o l S e t 0 9 2 1 03 1 0 1 1s a m ea s t h e
crankshalttirninggear. 09210
31011
0921G31011
1 Check the tinring gear for cracks,dam
age,wearand chippedteeth.
If defective,.eplacethe hming gear.

2 Inspect the timing gear for runout, and

if it exceeds0.25 mm (0.01"), replace
the timing gear.
L,/
Fig.3.sl RepbcinsTtningGeor EO2EI
80283

CamshaftB€aring
I Check the camshaftbearingsfor poor
contact, worn thin, partially melted or
heavilyscored
lf necessary,
replacethe bearings.

2 Inspect the oil clearanceby measuring

the difference between the camsharr
Fis.3-50Measunns
TimingGea.Run-out V3172
J o u r n adl i a m e l e ar n d t h e b e d r i n g
Inner
(]lameler
3. Inspectthe backlashbetweenthe crank-
The oil clearanceshouldbewithin 0.025
shait timing gear and the crankshaft
- 0 066 mm (0 0010 to 0 0026"),and
timing gearif necessary.
thelimit is 0 I mm (0 004")
For the detailson the backlashmeasure-
nent. re[er lo rhe Di\a\,emblyin this
sectlon.
lf the backlash exceeds 0 3 mxr
(0.012"), replacethe camshafthmina
gear and/or the crankshafttiming gear_
Thc backlasb shouldbe 0 02 to 0.13inrll
1 0 . 0 0 0 -8 u 0 0 5 2 " ) t o f l R o r 0 . 0 ( J 6
.
0.,170 mm (0 0027- 0 0067")
4.To removethe camshafttiming gear,
removethe gear retaining bolt and the
washers,then remove the timing gear
usingthe Timingcedr Tool Set 09210- Fis.3 52 MeasunngOit Cteamnce v3173
3 1 0 1I .
To assemblethe camshaft timing gear, 3. If the oil clearanceexceedsthe limit,
installthe th.ust plate and the key, then grind the camshaftjournals accordingto
install the timing gear onto the cam- the size as in the following table for
shaft, using the Timing Gear Tool Ser selechonof the undersrzebearings
092r031011 Camshaftjournal finisheddiameter;
After installation, install the washer! Bearingsrzei STD
and the retaming bolt, then check the No.I journal 46.459- 46 4j5 m\rl
, camshaftthrustclearance, (l rj29l _ l 8297")
3.26 ENGINE - Major Service

No 2 lournal 4 6 2 0 9 - .16225 mm holes

( 1 . 8 1 9 3- 1 8 1 9 e " ) The bearingsshould be installedonc at a
N o . 3j o u r n a l 4 5 . 9 5 9- 45 975 mm tjme individually
(l 8094- I 8r00") Afler installing the bearings,rerm the
Beains size. U/S-o125 bearingswith a line reamerto obtain the
No I journal 46.335 - 46 345 mm specifiedoil clearance
(l ir242 - | 8246") If the bearingsilre correctly installed.
No 2 journal 46 085 - 46 095 mm only a slighireamingis requrrcd.
( L81.1,1- L 8 1 4 8 ' , ) Install ihe new expansionplug apphed
No 3 journal 4 5 8 3 5 - 45 845 mm with liquid sealer into the cylindc.
(l 80.1s-' 1 8 0 4 9 " ) block
Bearingsizcr U/S-O.250
No I journal zt6210 -' 4 6 2 2 0 n m Flywheel
(1 8193^- I 8197")
I Check the clutch disc contactingsufface
No2 joumal zt5960 - 45 970 mm
of the flywheel for wear and darnage.
( 1 . 8 0 9 s- ' 1 8 0 9 E " )
lf defective, replace the flywhcel
No.3 journal , 1 57 1 0 - 4 5 . 7 2 0m m
( 1 7 9 9 6- 1 8 0 0 0 " )
2lnspect the contactingsurfaceof thc
Bearingsize: Ui S-0.500
flywheel for run-out with a dial gauge
No I journ l ,+5960 - 45 910 rnnr
lf the run-out exceeds 0 20 mm
( l 8 0 9 5 ' r 809rJ")
(0 008"), replacethe flywheel.
No 2 journal 4 5 7 1 0 - ,15?20 lnrn
( l 7 9 9 6- t . 8 0 0 0 " )
Llmlt O 2omm (O,OOA')
No 3 journal 45 ,160 ^- 45 414 nn
( r 7 E 9 8- | 1902")

,1 Repl ce the bc.lflngsrdhering the fol-

lowing procedures
Removc thc expxnsionplug installcdrt
the rear of the cemshaftNo.3 bearing
Remove the bearings with the Camshaft
Bearing Remover & Replacer 09215
31010
Fig. 3 54 MeasunngFly\9heelRun-out I/3175
o 9 2 1 5 . 3 l Ol O
3. Check the ng gear lbr chipped teeth,
cracksand wear.
If defective, replace the ring gear.
To remove the ring gear, heat the ring
gear to about 150 - 200"C (300 to
390'F) evenly, and remove the nng
gearby tappinglightly.
To install, heat the ing gcar to about
200'C (390'F), and install the rjns gear
while still hot-
Fis.3 53 Camshaft
BetnnsRemoval V3t71

5 . l n \ r a l ll h ( n e w \ c l e c l c db e a r i n gw i l h l h e Crankshaft Oil Retainer

c r m r h a f r B e a f l n gR c r r o v c r& R e p l a . t r It 1s recommendedthat the oil retainer
0 9 2 1 5 - 3 1 0 1 0a l i g n i n g t h e b e e r i n g o i l s h o u l db e r c p l d c e d\ 4 h e n e \ etrh e e n g r n ei .

overhauled
To rernovc thc retainer frolr t n e t l m l n g
gearcover,pry our rne rctaLncr
fro nt.
To install, use the Crankshaft PLrlley&
Gear Replacer09214 60010
Fig ]55 Installing jil Rttainel
Assembly
Beforc assenbling. thoroughly clcxn the
disassenbledparls erpecially tle oil pi-
sages.bearings.bearingholcsan( tl)e cyLn
der walls
Apply engrneoil onto the slidingor rotat-
rng portion of the cylinder wxJls.pisto|s,
bcarings, gearsand ct. It s rcronlDcnded
that a1l gaskets.packing\ arrd scrls be rc
placeclwith new oncs
Recheck lhe oil clcarance.birck1lr{hrnd
thrustclearanccupon assern bly
I Heat Lhe piston to about ,10 - 60'C
(l0r 1 4 0 F ] , a n d i n . , . l l r h eL o r n i . ' l
ing rod, pisLon and the hole sn p rings
Fig. 3 56 Piston Ftunt Mdtk
ENGINE-lla1or 321
towa.d camshaft srd€
Ftg. 3 57 lssenblint hston &
ConDettin!!Roll
The front orrrk ol rhe piston is indicated
with the "ln(lent" .rnd rl)rr of thc con-
-I'
n c c t r n gr o d j s i n d i c r r e dw i t h t h e
t/3176
W h e n r s s e r n b l r ntgh e p i s t o n w r l h l h r
connertrngrod irlign both froIt mrfk\
t t h i , it l n r c .f h oo i l b o l ep r o r i d f dl r r h c
shoulderof the conDectingrod LLrgrrrd
wlLllircclow.rrdthe rirmshrft sid.
l n s t a l lt h c p i \ t o n n n g s o n t o t h . l ) l s t o n
The piston rlugs itre provid.d !virh the
m ! r k s i r s\ l r o w ni n f i g u r cI 5 8
W h r n l n s f i L l l L tnhgc r i n g \ i i r c eL h c| r r r k \
L'|!,"urd r n L l i n \ t r l l t h c n n s s! o l h r l 1 | c
r i n g n L r r b u r w i l l h . i n o r L l c rf r o n r t h c
p i \ ( o nh c r ( ls i d c
Mak6r Rlns No
Fis.3 5u PistonRings V:I Ih:
( ' l c a n t h e b c i r i n g f i L r i n gf o r L o J l o l t h !
c o r n c c i r n gr o d . r n d l h t r i ) u i r n g s l n s t r l
t h t b e r L n n g s , l n dt h c . i r | \ i n d t i g l ) l c n
v3t11 thc nufslighrly
3-24 ENGINE - MajorService

4 Assemblethe rocker arm componcnts if the rctainer locks are properly rnstal-
rocker
springs,
tlrecomptession
rnstalling led inlo the virhe sten groovcs
arms. rocker supports,tcnsion springs
and the lock springsonto the rocker 6 lnslrll LheoiL scal into the groove locat-
shaft. ed at Lheretr end of the cylinder block
The "F" mark of the valverockersup and rhe rear bca.ingcap risinga cylindrr
d e l 3 ' e d l o $ d r d l h ' e n g i r'
f o r l . s h o L r lb
froni, and ihe oil hole provrdedon thc Cut the lrotruding portion ol the seal
rocker shaft should be placed towtlld ends
the engine rear

Fis. 3-59 AssembhnsRockerAm Y3179 v3181

oil s&l
Fis 3-61 Instdning
Lomponenrs

5 Place the valve (l) into the valveguide 7. Install ihe upper halvcsof the crankshaft
after applyingengineoil, and inslall thc No. 1, No 2 and No. 3 bcaringsonto the
o i l \ e . r l( 2 r . I n r ( r \ n r i n g { 3 r ' n u t c r ' p r i n g cylinderblock.
(4) and the spring retainer (5) lnto the
posltlon 8 Install the crankshaft, and insert thc
C o m p f e \ ' l h e v a l v es p r i n F '$ r l i - " \ p r i n g upper halves of the crankshaft thrust
comprcssor,end installthe rctainerlo'ks bearings
(6) onto the valvestem The groovesside of thc thrust bearrngs
must be faced toward the crankshaft
thrust surface,

i?
]l
65

ValveC'omponenls V3180
Fig 3-60 Assembhng

The side painted "yellow" of the inner Ftg 3-62 Insefins Thrust lrasher v3182
and the ouier valve sP ngs should be
faced toward the cylinder head sidd 9. Install the lower halvesof the crankshaft
After insialting the retainer locks, chcck beeringsand the thrust bearingsonto the

bea ng caps,and then install the bear-
rngcapsonto thc cylinderb1ock.
Wheninstallingthe bearingcaps.thc
"Arrow" mark on the bearingcaps
must be facedtowardthe front o[the
cylinderblock.
Tighten the cap bolts following the
order of the numbersin three progres-
sive steps,and finally securethe bolts
to 9 8 - I1.2 m-kgor 70 6 - 80.6ff
lb torque-
Aftcr tightening,check f the thrust
clearancels proper.
Fis. 3.63 TEhrcninsCapaohs V3124
10. Drive in the sidepackmgsof the rear
bearrng cap into the gaoovesafter
applyingthe liquid sealer
. Insiall the flywheel onto the crank-
shaft,and tightenthe boltsto 5 8 to
6.6 m-kg (41.7 - 47 5 ft-tb) torque,
and then lock the lock platessecurely.
l 2 Install the piston into the cylinder
block using a piston ring compressot
faclng the piston front mark toward
the front of the cylinderblock_
When installing the piston, it is ad-
visableto insertvuyl tubesonto each
connecting rod cap bolt to prevent
scodngthe cylinder wall or the crank-
pinjournal
Make sure that the end ofeach ng is
not directedto the thrust face of the
piston, and also that eachring is not
ENG|NE.MajorService 3.29
coinsidedwith the other ring end gap
as shown in fjgure 3-64.
t '-.
FiB.3-64 PositioninsRingEnd Gop G08.J9
Fia 365 rnsta ina piston v3184
l3 Install the connectingrod bearingcaps
aligningthe mating ma.ks of the con-
necting rod and of the cap, and
tightcn the nuts to 4.2 - 4.9 m_rg
(300-345ftlb)torque
i4 Install the front end plate with the
gasket
15 Install the camshaft assembly alignilg
the lnating marks on the camshaft anal
lhe cranlshaft timing gearq.and righl-
en the thrust plate retaining bolts to
1.4 - 2.0 m-ke (10.0 - 14.5 fr-lDr
torque,
After installingthe camshaft,recheck
the timing gearbacklash_
16. Screwin the timing gear oil nozzte
onto thc cylinderblock,and lock tne
oil nozzlein placeby punchingat two
330 E N G I N E \ 1 .i', , r S e rt i c €

1 r \ l r L ll h c o r Lt ) r r \ \ i t h l I c g u \ k t t u n d
Li!|t. r tlrf l,o l\ lo {1.+ - (JI Lr-lig
{l() - -it lt-lb)lor(tu. ( hr.k iJtLr.
. n g i r c o i l d r r r n 1 ) l u gr r s c c u f c

o9214 6001o

,I
l\t 3.ah Al!s,rtg litttu+ 110k\ t,/\j

t ) l r c r st o p r e v e r litt l r o I l l o o s ! r r r n g
W h e n r n s t a l l i n gt l l c o l l n o z r l . P o \
t i o n t l r c o i l s u p t ) l yh o l c o l t l r c o r l
nozrle to di\chrrgc lhc oil orrlo tlrf
tim ing geurs
a t o l 0 - l r o l l I m k l i ( 1 . + 5 - i i . +6
t;_,_,
.t a|l l|wltitl! Pullc vtlE6
] TLl|r thf frg rf rn(l Io\itL!)nlrt toll
s r L i tr L t )
l n \ t r L l l L l r t . y l i n d e r l r c r L d$ L L l r l l r t
! . 1 \ l i f t I l ] d t r g h t t n t h c c y l | 1 r ( l f rh ! . r d
bolts lollow fg the ordcr ot tlrc rlLrrrl
b r f s i L \ s r o $ 1 l r n l i g u f e 3 ( r 9 .i D L h f c .
|ft)rrfs\r!. \tcfs. rnd !fcurr thc bolLs
It lh) torluc fI)llly

l i g . - l 6 7 P o s t t b n u l s0 i l N . . z l r

jj.:"1 ',i ,"'ii"',','

,: ,i" ,.
1 6 n-kg (7 0 .' ll0lt b) Lor(ltr.

1 b . lnst.rll thc .rLnkshrlt lullcy u\rrr! thc

CrankshafLPullc-v& (ltLrr R.rlrLccl
09:1,1 60010 or tht Ii,n||rg ('cirr t.ig l.a, lrKhnhotg)ftlu l/-ll l-,
T o o l S c t 0 9 1 1 0 3 l U l l i ' | r ( lt u l r t f r r
i h e b o l t w l t h t h e w r L s l r et .rr ' 1 l - 5 5 ll l I S t . L l tl h t \ . ! N c l i l t c r sl r d t h c p t r s h
n ) ' k g( 1 9 7 - 3 ' ) 8 i t - l b ) r o r q u e r o r \ . i L r ( il l r s t l Ltlh f v r l v . r o r k r r s l r r i t
'r 'llrrJ r'l r'
'l t h ! r o c k .r {up
lnstrLl thc oil pump togcthc wrt| ilrc l|g lhr r n u r ko n
oil punlp outlct fipe. .rnd lighten tl'c t ) ( i r Lr o $ x r ( t l r r f J o n t o l t h c c y l r n d c r
sccuring boli to ] .+ - I 0 m-kg ( l0 |
^- 14 5 ft lb) torque T L g h r c ni l r c L c t x i r rgr b o l t sr o L 7 5 t o
l.lir|kg(lll- ll I lLlb) forqlre
 ENGINE- MajorService 3-31

23. Installthe pushrod cover,oil pressure bolts togctherwith the lucl and vacu,
switchandthe ventilationtube um plpe suppoll

2.1. Install the manifoldswith the gaskets, 3 6 Install the distribuLorciamp. and in-
and tighten the retainingbolts to 2 8 stall the dist butor referring to the
' 3.5 m kg (20.3 - 25 3 ft-lb) torque Distributorin the Ignition System.

2 5 lnstall thc carburetor assemblywith 3 7 Installthe starterassembly.

the hcat insulator
After installingthe carburetor,covcr j8- Install the sparkplugsand the oil level
the carburetor air horn with a clcan gauge.
cloth to prevent entry of dust or dirt.
39 lnstall the input shaft front bearingif
26 Instau the automaticchoke stoveinlet it wasremoved
and outlet pipeson RT sedes To install, pack the bea ng with
multipurposegreascinto the bearing,
27 Installthe oil filter asscrnbly
with the and instali the bearingusingthe lnput
gasket- Shaft FronL BcaringReplacer09304,
30012
28- Install the engine front bracket LH
As the rear bolt holc for the engine
bracket is drilled through the eylinder
block, apply liquid sealer onto the
bolt

29 Installthe alternator
assembly

30. Installthe waterpurnpassembly

with
the packingand with the fan belt ad
justingbar.

Fig. 3 70 Insta ins Bafing BI0lt V4700

3l Install the water pump by-passhose
and the coolant tempcraturcsender .10 Install the clutch disc and the clutch
gauge
cover assembly,eligning the mating
marks and using the Clutch Guide
32. Install the fan be1t.and adjustthe belt

3 3 . lnstall thc engine front bracket RH

with the same proceduresprcscrtbed
on the assembling
of thc front bracket
LH

34. Install the fuel punp wilh the gasket

and the insulator.and install the luel
pipe and the vacuumpipe.

3 5 . I n s l a l lt h e r h i r m o \ t d la n d l h e w a L c r
outlet wrth the gasket,and tighten the F4- 3.71 InnalltnsCtutchADer 81013 y4701
3'32 ENGINE- Major Service

Tool 09301 36010,and tightenthe Eachcapacityis asfollows

b o l t st o t . 0 - I 6 m - k g( 7 . 2t o l l o Engineoil.
ft-lb) torque. 42 liters (4.5 US qts, 3.7 Imp. qts)
Coolant RT, RY, RN series
41. lnstall the transmissionassemblyand 7 0 liters (7.4 US qts, 6 2 Imp. qtt
the flywheel undercover. Coolant:RH series
6 7 liters (7 I US qts, 5 9 ImP qts)
qn RT .erie.
4 2 . l n 5 t a lllh es l r f f e n eprl a l e o
if installed. 3 Check the transmlssiongear lub cant
Installation If necessary,rgfrll the caseup to the
T o i n s l a l l ,o l l o wl h er e m o \ a l p r o r e d u fi e
n\ l r l h g e a lru b r i c a nwl i t ht h e v i s c o \ i -
l e v ew
the reverseorder, and after installation, ty of SAB-90, and with the grade of
pedorm the following operations- GL 4 (API se ice classification).

1. Bleedthe air liom the clutchhydrau-
llc system referring to the Chassrs
ReparManual
2 Refill the enginewith the engineoil
markedSC, SD (API serviceclassifica-
tion) and the coolant.
4 Tune up the engineby refening to the
EngineTune'upsection.
5. Afler performing the engine tune-up,
recheck if the oil level is cofiect, and
checkfor water and oil leaks.
 INTAKE & EXHAUST MANIFOLDS

INTAKE & EXHAUST MANIFOLDS 4-l

Description
Removal
Inspection& Repair 4-2

EXHAUST PIPE

POSITIVE CRANKCASEVENTILATION SYSTEM (Optional) . .

VentilationValve 4-5
Inspection

MEMORANDUM +6
 INTAKE & EXHAUSTSYSTEM- Intake & ExhaustManifolds 4.1
INTAKE & EXHAUST MANIFOLDS

Description

Fit. 4 1 Sectioml view ol Manifod on RT Se.ies

-S

Fis 12 ManifoldsComponents
an t.isht Tru& seie!
 INTAKE & EXIIAUST SYSTEIV' Intake & ExhaustManifolds
and the
The intake manifold is of aluminum alloy which has superlorheat conductance,
exhaustmanifold is of castiron
and the llange
Each nanifold is arranged in parallel as shown in the above illustrahon
exhaust gas to
bottom side of the intake manifold is directly exposedto the heat of the
warm the air_fuel mixture drawn in from the carburetor
pipe This
On RT series,the intake manifold is providedwith the automatic choke stove
pipe is also exposedto the heat of the exhaustgas This warms the air enteringfrom the arr
tfrtoujn the automatic choke stove inlet pipe' and the warmed air enters the
coiL'
thermostatca; to control the choke valveautomaticallythroughthe bi-metal
"t"un".

intakc
On Light-Truck series, since the carburctor is equippedwith a manuel choke. the
choke stovepipe and ihe relatedparts
manifold is not providedwlth the aLLtonrirhc

Removal
I Remove ihc air cleaner on RT & RN 4 Remove the manifolds retaining bolts,
senes,and the mtake air connector on and
and removethe manifold assemblies
RH & RN series the gaskets.

2. Remove the carburetor and the heai 5. Remove the alrtomatic choke slove inlet
insulator and the outlet PiPeson RT series-

3. Remove the exhaust pipe retaining nuts, 6 Remove the intake manifold from the
and disconnect the exhaust pipe flange exhaust manifold if necessary
from the exhaust manifold

Inspection & Repair

1 Check the manifold lbr gasketsurfacewith a straightedgeand a
or other damage. feelergauge
lf defective, repair or If the distortion exceeds 0 4 mm
sary ( 0 0 1 6 " ) , g n d t h e m a n i f o l d sw i t h a
surfacegrinder,or replacethe manjfolds
2. lnspectthe distortionof the manifold

Installation
Follow the removal procedures in thc
reverse order. and follow the following
precnutions

I Always replacethe gasketsupon instal

2 Tighten the manifoldsretainingbolts to

Fis.43 MeatunnsMtnifM Distortion v3t87 2 8 - 3 5 m-kg (20 - 25 ft lb) torque
 INTAKE & EXHAUSTSYSTEM. ExhaustPiDe

EXHAUST PIPE

Fis. +4 Exha st SystemComponentson RT Senes Y5509

*h*
nB*

LsR\
Fig. 4-5 Exh@stSystemComponenson Ry Serks G3803
 Pipe
INTAKE& EXHAUSTSYSTEM-Exhaust

@.
r-t

6
o
?
s
tt

Fis 4 6 ExhaustSystemComponents
on RH Senes G3804
 INTAKE & EXHAUST SySTElvl, positiveCrankcase
VentilationSvstem
POSITIVE CRANKCASE VENTILATION SYSTEM. (Oprional)

The posrtive c.ankcaseventilation sysiem is

optional as prcvious.and the systemis ofa
valve type
T h i . i ' o f J n c j \ . ' r l l . rI l \ p c w h r .h d r - w \ I r
the bloFby gas by force into the intake
maniibld through the ventilation valve to
dNposewlth the fuel mixture.

F g. 1 7 Porinw Crankcaseyentitation Slstem

Ventilation Valve
Normally, the blow-by gas created volume For this rcason, the ventilation valve (pCV)
r affccted by the manifold vacuum (engme is providcd inte.lnediately to counteract
lo3d) due to engme revolution, and by the variatlon of flow area by the manifold
sunply connecting the cylinder head cover
and intake nranifold with an orifice, defi- Further, when the blow by crcating volume
ciency will be encountered as blow-by gas
overcones the ventilation valve suction
crcatmg volume will be less dunng light
efilciency (in full load), the blow-by gas ls
load when the manifold vacLrumls high due drawl m fiom the air cleener by the tuDe
Lo high efii.icnc] of \u.'rion. bur cluring Jonnccling t h c c y l i n d c rh e . d c o v e ra n d a i r
iull load, the creating volume will be high
due to the lowering of suciion efficiency.

d
-9 ;
<6)

AT rpLll\G l F- NoRMALSFEEp-l

Fig. 1.8 Ventitation Vatve Opemtion

Inspection
l Replaceworn of defectivehose
2 With the engine idling, press the hose
severaltimes. If noiseemitswhenpress
ed, the PCV operationis satisfactory.
 FUEL SYSTEM

DESCRIPTION ,, 5- I

T R O U B L ES H O O T I N G . , , , ,,, 5-2

CARBURETOR
Description 5'4
Construction& Operation.
Float chamber& air vent system . 5-5
Idling& low speedsy5tem. 5-6
P r i m a r hy i g hs p e e sdy s t e m ....... .....
Secondary highspeedsystem.. . . )-a
Powersystem
Acceleratingsystem
Automaiic chokesystem(RT) . 5-10
Frcf i,lle rDT\
5 - li
Unloader(R I) )-t I
ThermoslaLic valve 5-t2
C a r b u r e rAo rd j u s r m e n t. . .....
Floatlevel 5-12
Secondarythrottle valveopeningangle
Highspeedvalve 5 , t3
F a s ti d l e . ...... ....5-13
U n l o a d e.r. . .. .. . .. 5-14
A u t o m a t icch o k e .. ......... S-14
H i g hs p e e vda l v es t o p p el er v e r. . .........5-14
I d l ea d j u s t i nsgc r e w. . . . . .. ._._.5_14

C A R B U R E T OoRn R T S e r i e s. . ... .5-14

Removal . 5-14
Disassembly .. . 5-15
M a i nb o d yg r o u p ._.. ...5-15
F l a n g ge r o u p ..... ... 5_19
Ailhorn$oup. .. ....5-19
I n s p e c t i o.n .. . .. .. 5-20
A i r h o r ng r o u p- ...... ....5-21
M a i nb o d yg o u p ......... .5-21
Flangegroup . . . . . . . . . . . . . . 5-21
Assembly.. ......5-22
Air hom group. . . . . . . . , . . . . . . 5_22
M a i nb o d yg J o u p . . . . .. .... 5-23
Flangegroup . . . . . . . . . . . . 5-24
Installation ...........5-25

CARBURETORon Light Truck . . 5-25

Removal.. .. 5-25
Disassembly .. .. 5-25
Main body group . .. 5-28
 5-29
Air horn grouP 5-30
r r \ P ( ( rr o r l 5-30
{\\rllI DIy 5-30
5-30
5-31
5-32
Installation 5-33

SOLENOIDVALVE

ET EI EII TED / )D\ 5-35

Descrlption 5-35
Removal 5-35
Disassembly 5-35
Inspection 5-35
Assembly
Installation 5-35

FUEL PUMP 5J5

Descrlption..-......
Removal ... 5-3',7
Drsassembly 5-3',7
Inspection . . 5 37
Assembly . 5-31
Installation 5-38
Test
Performance 5-38

FUELTANK & FUELPIPE, . 5-39

Fue!TankRemoval 5-4l
lnspectjon 5'.11
Installation 5-41

AIR CLEANER 542

ACCELERATORLINKAGE 5-44
Descriptron

MEMORANDUM 5-46
 FUELSYSTEM. DescriDtion 5,1

DESCRIPTION

Carridge Type FLe F ker

Fis. 5-l FuelSysteman CnrctnSedonSeries Y5766,y5767

The fuel systemconsistsof the luel tank. fuel filter, fuel pump,carburetor
and the prpes
whichconnectthe components, and thefuel sendergauge.

The fuel tank on RT seriesis installedonto the luggagccompartmentfloor, and the upper
panelof the fuel tank actsasa floor of the car
That on RT wagonseriesis mstalledonto the t_1oor memberof the rearfloor end. On RH,
RY,,RN series,the fuel tank is installed onto the left side of the rear aleckwrth two
retainingbands,while the RHltV, B, c and RHI68-8 seriesis providedunalerlne rea.
floow wrth six retaning bolts

The fuel in the fuel tank is drawn into the fuel filter by the suction of the fuel pump
through the fuel pipe. The fuel passesthe filter elementfrom the outsideto the insideof
the element,and the fuel is filtered to removedirt or water if containedwithin the tuel

The fuel pump producesa constantcontrolledfuel pressure,and suppliesthe filtered luel

into the carbLrretor
throughthe fuel pipe which is requiredfor engineoperahon_

The carburetormixes adequatelythe fuel dehvercdfrom the fucl pump through the fuel
filter with the air drawn in from the arr cleangrfor varjousoperatingcondit;ns of the
englne
5.2 FUEL SYSTEM. Trouble Shooting

TROUBLE SHOOTING

Fuel Pump
Symptoms& ProbableCauses Remedies
I Fuel leaksfrom fuel pump
a. LoosepumPcoverscrews Tighten screws
b Defeciiveor deteriorateddiaphragr Replacediaphragm
c D e f e ci vr eL h r e a do sl u n i o n t i t t i n g o r Replaceiitting/s
crackedfitting

2 Oil leaksfrom fuel pump

a. Loosefitting of rockerarm pin Replace pump body and Pin or rcPlace
pump assembly
b. Loosefuel pump mounting Tlghten aliachrngbolts or replacegaskef

3. Insufficientfuel delivery
a Loosefuel pipe connections Tightenconnections
b Defechvediaphragm Replacediaphragm
c. Defectivevalves Replacevalves
d Crackedor broken fuel pipes Replace fu el pipes

4 Noisy fuel pump

a Loosefuel pump mounting Tighten mounting bolts
b Worn or defectiverocker arm Replacerocker arm
c Brokenor weakrockerarm sping Replacesp ng

5 Excessivefuel delivery
a. Improperdiaphragm spring Replacewith a proper spnng

Carburetor
Before diagnosing the trouble shooting of the calburetor, check the manifold mounting
bolts, cylindercompression,and the ignitionsystem

Symptoms& ProbableCauses Remedies

I Flooding
a Improperseating or damaged float Dressor replace the needlevalve and seat
needlevalveandseat
b. Incorrectfloat level Adjust float level
c. Worn float tab Replace float
d. Worn float pin & relatedpa s Replace float pin & related parts
e- Defectiveair-homgasketor loose Replacegasket& tighten screws
attachrngscrews
f Fuel pump excessive pressure Check fuel pump

2. Roughidling
a. lncorect idle adjustment Adjust idling
b Defectiveldle adjustingscrew Replaceidle adjustingscrew
c. Pluggedidle passage & idle Port Cleanpassage & port
 FUEL SYSTEM- Trouble Shootins

d. Pluggedlow speedjet Cleanlet

e. Improperlow speedjet seating Tightenor replacejet
f. Worn throttle shaft Replaceshaft
g, Loosevacuumpipe union Tightenunion
h. Pluggedeconomizerjet Cleanjet
i Improperlow speedsystempassage seal Tightenplug or replaceseal
j. Defectivebody flangegasket Replacegasket
k. lmproper operationof thermostattcvalve Replacethermostaiicvalve

Excesslve fuel consumption

a. Float leveltoo high Adjust noat level
b Pluggedalr bleeder Cleanor replaceair bleeder
c. Looseplug or jet Replaceplug orjet
d. Defeciivegaskets Replacegaskets
Vacuumleaksfrom power pistonvacuum Checkvacuumpassage
passage
f Checkvalveopensimproperly Check& repar automaticchoke,choke
hkage & relatedparts
g. Clutch sllppage Adjust o. replaceclutch
h. Draggingbrake Adjusibrakes
i- Incorrect tire inflation Correcttire mflation

Poor acceleration(Lack of ch fuel mixiure for acceleration)

a Defective acceleratingpump Replaceplunger
b Pluggedpump jet Clean pump jet
c. Dischargecheck valve operating improperly Replacedischargecheck valve
d Defective accelerator linkage Adjust linkage
e Defectivcoperationofpower piston Replacepower prston spring
f, DefectLvepowea valve Replacepower valve
g. Pluggedpowerjet Clean or replacejet
h. Float level too low Adjust float level
i. lncorrect throttle opemng Adjust throttle linkage

Stauing (Lack of fuel mixture at high speed)

a Pluggedmain Jet Cleanmain jet
b lncorrect float level Adlust float level
c Defectiveoperationof power piston Replacepower piston spring
d Defective power valve Replacepower valve
e. Worn throttle velve shaft Replaceihrottle valve shaft
f. Defective gaskets Replacegaskets
g. lncorrect throttle opening Adjust throttle linkage
h- Defective operation of high speedvalve Repair hlgh speedvalve opemtjon

Poor cold weatheroperation

a. lmproper choke operation Check related parts or replace choke
assembly
b. Incorrect fast idle Adjust fast idle
c. Improper unloader AdJust unloader
 - Carburetor
FUEL SYSTEI\4

CARI]URETOR

Description
The carburctof installcdon the 2R or l2R engincis a two-barcLtype to lnslrreeilicient
performances of the carburetor undcl varioLrsoperittions IL is similaf to hvo single blll]cl
carburctorsbuilt into one singleunii with spccialieaturcs The prlmary systcnlincorporcte\
a double type ventufi whilc the secondarysystemis provided with a ifiple type veDtun
Ijach systcm consistsof the air horn, nain nozzle and throttle vllvc One set forms the
prirnary while the othcr set iorms the secondarysidc The prilrafy systcmcomposesofthe
iow spced.high speell.powcr valve,accelerating and choke systcms,and is able to supply
the aiFfucl rrixturc for normal operatjon Whcr the throttle vaLveis openedwide for full
load or for accelerahon,the secondarysystern.llsooper tes to supply thc aif-fue1rnixturc
logethcf wilh the primary systcm lhc thrcitle valve'iol both the prim ry and the
secorlclarysystemsafe operatedwith linkagc,and are interlockedcnablingbotlr the throttte
valvcsto operl lully simulta eously
The high speedvalveinstalledin the seconclllry systelutog€therwitlr the power vrlve enables
lhc perlbr- anccs extremely smooth
The carbureior equippedon RT sedesis incofporatcdwith thc xuiomatic choke system,
while thc Lighi-Truck sericsis provided with the rranual choke system
Thercfore, ihe constructiorland ihe opcration of each cirrburetoris the s'l]nc with the
exception of the choke systenl
Specification:

*Y.lH j
Type D o w nJ J l t h \ , - h x n c l

At hone outer dlxmeter m,n (in) 0(248)

nn (in)
Primafy Manr 23 0 (0.91)
Small n 0 ( 03 2 )
Sccondary Main 2R- 2?.0(l.06)
l2R- 2n 0 (1.12)
Snall 2R 7 0 (0lE)
rzR- e0(036)
Throttle bore diameter ln,n(in)
30 0 (r 18.)
Secondary 2 R 3 20 ( t 2 6 )
l l R 3 1 0( r 3 4 )
Mdnjet diameter
2R l 08 (0 143) t.06(0 042.) l.l r (0.044)
r2R- 1 03 (0 041) I 03 (0 04r.) I 03 (0.041)
2R r 40 (0 05s) I 60 (0 063) I 47 (0 OsE)
12R r 62 (0 064) 1 . 5 6( 0 0 6 i ) 1 6s (0 06s)
nm (in ) 2R- 0.ss(0 022) 0 4 3 s( 0 0 1 9 ) 0 52s(0 02r)
l2R 0-50(0 020) 0 47 (o.0le) 0.47(0 019)
nrm (r) 2R- 0 75 (o 030) 0 60 (0.02,1) 0 70 (0 02rJ)
12R 0 50 (0 020) 0 s8 (0 021) 0.60(0 021)
0 4, (0 019)
0 50 (o 020) 0 s0 (0 020)
0 50 (0 020)
0 80(0.03
r) 0 80 (0.031) 0 80 (0.031)
Econornizerletdianreter 1.00(0010) r 00 (0.040)
 FUELSYSTEI/l- Carburetor 5-5

Mainair bleeddrrmeter nm (in)

2R- 0 70 (0 028) 0.50(0 ut0l 0.70(0.028)
i2R- 0 50 (0 020) o.s0(0.020)
2R 0.70(0.028) 0.s0(0020) 0 70(0 02rJ)
l2R, 0.50(0 020) 0.s0(0 020)
Power piston operaiingvacuum mm (in) 2 R 1 i 0 - 1 3 0 70-90 1 1 0- 1 3 0
(,13 - 5.i) (28-35) (4 3 - 5.r)
t2R- 120- t40 120^- I ,10 'tzo-
140
(4.7- -5.s) (4.7- 5.5) (4.7- s s.)
Float level
Raisedposition (from air hom fitling
3 s (0 140)
Lowered posrtion(bctweenneedtevalve
push pin and float tab) 0 9 (0 035)
Idlemixtureadjustingscrewpreser

for 2R s c r e wo L , h o d r: - l .um\ i erJightt) \edlinB.

lor l2R Screwoui about 2 Lurnsafter slightly seating
Tnrottlevalveluly closedangle:
Pn nary
24"
Fastidler Primarythrotuevdveshould 2R r2' 12' l3'
opcnrt Rightdesreefrom closed t 2R r3' 11' 11"
pos'tionwhenthe ctrokevalveis
Iuily closed
2R 30"
l2R 27"
Thernostalicvalveoperatingtemperature Fully closedat 60'C (140"F)
F u l l y o p e n e da t 7 5 ' C ( 1 6 7 " F )

Construction & Operrtion

The clrburetor is of a three group constructionconsistilgof the !if horn group.
trrarnbody
group and the flangegfoup
Eachgroup cotnposesthc primary ilnd the seconorryDorcs
The primary bore provided witll I double vcnturi consistsof the slow systcln,
high speed
syslem,acceleratjngsystem,choke systernilnd the thermostutrcvalvesystelnenabling
thc
air fuel mixture to be supplied to the cngrneas requircd lbr nornlal driving
conditions
The iecondary bore providcctwith I tnplc venturi consistsonly of the high specd
systemto
meet the requirementfor high speedand ibr suddcnaccclcfttion

l. Float chanlber& air vent systenr

The float chalnberscrvesas a constant
level fuel rescrvoir
It is necessaryto maintain the fuel lcvel
at a constant height rcgtrdlessof whe-
ther small or large amount of fuel is
beingwrthdrawn.
The level gaugeglassls insialled at the
float chamber as a cover fof vishal
inspectionof the fltel level.
The fuel forced out from the fuel pump
entcrs into the float chanlber through
the stminer (l ) and the needlevalve(l).
56 FUELSYSTEM- Carburetor

23 9 t0 214

2 1 2 0 22 2X 24 25 26 30

2 Secondary ma'n atr bleeder 14 Slow air bleedNo 1

3 Secondary main nozzle 26 Primarythrotde v6lve
4 Secondary sm.ll venturi

6 Pnmary sm6ll venturi 1B Secondarymarnjer 29 ldle adiusting$rew

9 Pilmary mdin nozzle 21 Pumpdhchargeweiqhr

1O Primary mai. air bleed6r
23 Secondarvthroltle valve 34 Thermostatic!alve
1 1 S l o w a i r b l e e dN o 2

Fis. 5-2 CrossSectionalview o1 Carbuletor Y5447

and the fuel level is reglrlatedat constant
hpight causingto the opening and closing
of the needle valve by the buoyance ol
the float (3)
2 ldling & low speedsystem
Since the flux of the fuel from each jet
is detemined under the condition that
the fuel level is the specified height, the
lmproper fuel level influences the per-
formances of the carburetor remarkably
The ar horn is provided with the vent
tubes(4), and these tubesare connected
with the floai chamber to maintain the
same air pressurein the air horn and the
float chamber.
This type compensates the out-ol-
balanceof the air-fuel mixture causrngto
the cloggingof ihe air cleaner
The idling and the low speed system
supplies the air-fuel .mixture to the
e n g r n ew h e n r h c p l | m a r y t h r o t l l e v a l v e
i s s l i g h l l yo F c n c d o r f u l l y c l o s e d .v i l :
the engine js operated at idling speed or
light load and slow speed.
The fuel from the float chamber flows
through the primary main jet to the slow
jet (l), and the fuel 1scontrolled 10 the
minimum quantity by the slowjet

Fig. 5-3 noat Chambet& An Vent G1352
3 from the prinary mirin .rir blecder (1.)
5
Fis. ,4 ldle & Low SpeedSystem G1 3 5 3
The controlled fuel mixes wlth the ar
from the slow air bleederNo I (2), and
after passingthe economizerjet (3),
mixes with the air from the slow air
bleederNo.2 (4) extensively,and flows
down into the slowport (5) andthe idle
FUELSYSTEM- Carburetor 5-1
po (6) to be dischargedin spray form
xrto the intake manifold
When the throttle vahre starts to open
slightly, and as the cdge of the throt e
valve movcs past the slow port. the
intake manifold vacuum is applied onro
l h e J o w p u f l - n d I n r sp o f l \ l d r l r ( o d i s -
charge the air,fuel mixture same as the
idle port.
The amount of air-fuelmixture discharg-
ed liom the idle port is regutatedby
adjustingthe idle adjustingscrew(7)
3 Primaryhigh speedsystem
This sysiem is provided to suppty the
airjuel mixture ibr internediate tlirottle
opening or part-load oper.rtingrequire-
I n e l l \ . J n d t l ( f u ( l c o n s u n - p r i o ni \
mainly controlledby this system
The fuel is controllcd by thc prirrilry
m a i nj e t ( l ) l o c a t e da t r h c b o t t o r no f r c
l l J J | , ' h " m b ( r .- n J i . . , . . ( J $ r t . . ( J i r
Thc nixture is withdruwn lrorn the
primrry main nozzle (3) to the prLm,rry
small venturi (4) in nccordancewith tirc
air strearnllowing througb the vcnLur|.
FiC.55 Prinary Hish SpeetlStsten C1J54
58 FUEL SYSTEM. Carburetor
4 Secondaryhigh speedsystem
The luel syslernof thc sccond.tr,v high
speed is separated from that of the
primary high speedsystem completely,
but the constrlrction is very similar to
the primary high spccdsysiem
HighSpee.lSysten
Fi& 5-6 Secondary Gl3'5
The fuel is controlledby the secondary
main jet (l), rnd is mjxed with tlte .ur
from the secondaryrnain air bleedgr(2),
Fig. 5 7 Hish Speed Yalw }Perdrion
rnd is wiLhdr.rwn from the secondLrry
nlirin nozzle (3) to the second ry smxll
vertulr(:+)
Whenever]nore erlginepower is rcquired,
pedrl is depressed,
and .rs the.Lccelerator
the prim.rry thrcttle veh,e is opened
approxiJnirtely50", the secondarythroC
lle v.Llve(5) is startcd to open by thc
lilrkNgc.and rlso both valves xre lully
opened xt the silrre tirne llowever,
while the enginerevolution is not high
cnough, the high speedvalve(6) renlains
at closed position even though bolh
valves are fully opened, therefore. the
secondary high spccd systcm rcmains
At this tirne.the mixture requiredto the
engine is orlly supplicd by the primary
high speedsystem lhis causcsthc ail
flow through the primary venturi to
qUickerl ccompLishing a cornpleleaLomi
zation of the air-fuelrnixturc to tlre cyl
As the enginc rsvolution increrses,the
air llow bccomesst.ong enough to over-
co re thc weighl of the high speedvalve
wcight. lhen the high speedv lve opens
graduirlly,rnd rhe mixture stlrts to be
withdmwn from the secondary main
DOZZIe
Gl J56, C1357,Gl358

5- Power system
The pimrry and the sccondary high
speedsysternsare dcsignedto deliverthe
most econornicalair-fue1mixtufe
However, whcn full enginepowcr is de-
sired. it is necessaryto supply the rich
mrxturc
To obt.riD this rich Drixture.the power
systenlis incorporatcdin the cnrbureror
When thc throttle valveis partiallyopen
r d , l I d s h c n t h r ' l r J n i r u l J\ . r ' J L | l . i .
high, thc mrnifold vaclrumpLrllsup the
power pisLon (l) to close the power
v lve (3)
Fig. 5-8 Power Systen G t359
As ihe primary throttle valve is fully
opened.the manifoldvacuumdrops.and
the power piston is pushcddown by the
spring tcnsion which opens the polver
valvc
When thc power valve opens, thc fuel
flows dowl1beingcontrolledthroughthe
power jet (l), and ioins wrth the fuel
from the prirnrry main jet
Thus, extra fuel is dischrrgedfrom the
prinary nain nozzlc (5) to the small
venturi (6).rfter mixrng wirh the air
from the p.imrry nraiDrir blccder(4).
FUEL SYSTEM- Carburetor 5-9
6 AcceleraLing
system
The carburetor is Drovided !v1rh the
acceleratingsystern to obtrtn the rich
Inixrurc trolnenrtrily in itccord nce wirn
the dcpressionof the accelefttor pcdal
when rilpid enginercvollrtronis rcquired.
When the accelcrrLtor pedal is suddenly
depressedlbr quick 0cccicr.rtion,tne
p t u n g e r( l ) c o n n e c t e dt o t h e t h r o t t l e
valvc is pLrsheddown into thc pump
cylinder Thus, thc inlet sidc stcel ball
(5) is closcd,end the fuel pushesthe ou1
tet side stccl brll (l) rnd the discharge
wcight (3). thcn thc luel is discharged
Fiq. 5-q A.celeratint System G136A
trorn thc punp jet (,1)into the ventun to
supply rich mixture nccessaryfor ac-
When the throttle vxlve is closed, the
PUmppllrngeris pulled upwardsand the
outlct srdesteelball is ctosedby the dis-
ch.rrgeweight,and at the sametime, the
inlei side port is opened to relill the
pump cylinder with fuel from the float
AIso when the ecceleratorpedal is lully
depressed,and as the manifold vacuunr
drops. the power valve is opened. and
the fucl is rlso suppliedfrorn the power
5-10 FUELSYSTEIM
? Automatic choke sysiem (RT)
The automatic choke system consists ol'
the cbil housing installed wiih the ther-
mostatic bimetal co1l, thernostat case
prcvided with the vacuum piston, choke
shaft, fast idle cam, etc, and lne aulo-
matic chokestovepipe which is connect
ed with the air cleaner and the coil
housing.
The air from the air cleaner is wamlcd
up while passingthe stovcpipe (2) instal_
leal on the intake manitbld (l) bv the
heat within the exhaust manifold (3),
an.l passesthe coil hoLlsing(4), then thc
air rs dra\rn irlto the intake manifold
pushingdown t),e vecuun piston (5)
Fig.5-10 Aubmlk Aoke Slstem v577l
Fig.5-ll hltartutic ChokeOlerunon
The choke valve is opened fully when
the vacuum piston is pushed down all
the way, and also since thc choke valve is
instdlledeccentricallyrgainst the choke
shaft, the choke valveis openedaccord-
ing to the rir irltake pressure created
when the rk is dmwn into the cylinders.
The thcrmostaticbirnctalcotl is adjusied
to close the choke valve fully at 25'C
(77"F), therefore, beLow this iernper-
ature, the choke valve will be closed
compleLelY.
When startingthe enginein cold weather,
as the chokevalveis cbsed, high vacuum
is created within the int.lke manifold
r ' r d r l - ev J . r u r n p i . l o n r ' D L r l l ed r w n -
!rard In ofen lhc chok( \dr\r rn oPPu-
. i t r o n . o l ' e c \ p i r r \ r o l l i l ju f t n i b i m e i a
coil, in addition, rs the ai. intake pres
\ u r ( i \ J l s or p p l r < do n l o r h FL ' h o k .\ J l \ ( .
the chokev.llvetendsto open slightly
I o r t h e . ( r e l ' o n . , l h e c ' r o k cv - l \ e r l l o \ \
l , r e d r a u i n o f n e ! e s \ r r yJ r r l J r \ i J f l i n P
r , , ( c n g r n c S i n c er h c b i l r r l a l , o i l ( \ -
pansibility increasesin accordancewlth
r h c r c m p e r r { u f ed e c r c c \ . t n t , p c n l r g
J n g l eo f I ' r e c n n k c v - l v e b e c o m e ' m J l -
l < r ,J n J r e u l l " n l l y l h < m i r l L r l cb r c o m e '
Iich lJ l cililal< Ihc 5lcfling nf tlle
enginein cold weather
Gt36t,Cr362,G1363

After starting the engme, as the vacuum
applyingonto the vacuumpiston and the
air intake pressure exerted on the choke
valve increase, and the choke valve is
opened further (approx- 15") balancing
with the bimetal coil expansrb ity until
proper engine revolution is obtained.
As the engine warms up, and since the
air entermg into the thermostat case is
heated by the exhaust manifold, the ex-
pansibility of the bimetal coil will de
crcase gradually, and finally the choke
valveis openedcompletely
If the throtile valve is opened suddenly
during the engine warm-up, the choke
valve will close momentarily due to de-
creaseof vacuumwithin the intake mani-
fold to maintain a smooth acceleration
of the engine.
Fast Idle (RT)
The fast idle ls to maintain higher revo-
lution of the enginethan the idling speed
whlle the engine is started, and is for
warmrng up. When the carburetor is in
choked position, the fast idle cam
Fig.512 Fastldle Operution G13M
FUELSYSTEM 5.1r
fbllowcr (2) mstalled on the slidjng rod
(l) which is connected to the throttle
valve shaft contacts againsl the fast idle
cam (:l), and the thrcttle valve is opened
slightly
For thjs reason, the idling revollrtion
becomes slightly higher. As the fast idle
cam is of the four steps type, the revo-
Iuhon is obtained in accordancewith the
choke valve opening angle.
Even after the engine is warmed up, and
the choke valve is fully opened, the fast
idlc is shll in operation.
To obtain a normal idling, depress the
acceleraior pedal slighily to return the
cam to its original position.
Also when starting a cold engine, as the
fast idle cam is obstructed by the cam
follower, the choke valve is not closed
Consequently,it is necessaryto depress
the acceleratorpedal one time and all
the way to close the choke valve
9 Unloader (RT)
When starhng to d ve with a cold engine
without warming up the engine, and
Fig.5-13 U der Operation c1365
512 FUELSYSTEM- Carburetor
trying lo accelcratc,the choke valvehas
to opcn to a certainposition,othcrwise.
the enginewrll strll
To avoid enginc frorr s1aLling,Lhe ac
celeratoris provided wiLh the unloader
lhe choke valve is so designedthat it
will opel approximately l5' mechanr
cally from the fully closedpositionwhen
thc throttle valveis fully opened.
As ihe acceleraiorpedalis depressed, the
choke shaft (3) is rotated by the cam
follower (2) installedon ihe slidingrod
( I ) to open the choke valve forcibly
l0 Themostatic valve
When thc temperature around tl're crrbu-
retor risesas in summerseasonwith slow
cruising specd, the fuel will evaporate
rapidly.
I Thermosralcvave
2 Thermostabcvarvecover
4 "A tns
Fig. 5-14 mermostaticYafue c0221
Co|sequcntly, engine stalling, rough
i d l i | l g r n J h . , r . r. r J I | i r J c r l 1 e e p r n e
lnry rcsult
This thennoslaticvalvc eli inatesihcse
'lhe
thermosiaticvalvestads to open nt
6 0 ' C ( 1 4 0 " F ) , a n d i s f u l l y o p e n e da t
7 5 " C ( 1 6 7 " F ) , . r n d a l l o w st h e a i r f l o w
into the lntake nranifold direcaiy
ihrough the port installcdon the flange
l o d u l . l h e o \ ( r r . . h m r \ r u r cs i l l - d i r .
Carburetor Adjustment
Float Level
Tltc iloat level adjustmentis perfornredby
bending the float tabs. but it should bc
checkedby thc lcvelline on the levelgauge
glasswhile the engjneis operatedat idling
speed.
Fis.5-15 Float Tabs v217u
l. Raisedposition
Inspect the distancebetweenthe cnd of
Fig i 16 Che(kns RaisedPostuoa v2841

the float and the air horn gasketsurfacc
with thc G uge 092,10-31020when the
float is lowercdby invcrtingthe air horn
This distanceshould be 3 5 mn] (0 1,1,,).
and to obtain a correct distance,bend
the tab "A" as shown in figure 5 15.
2 Lowered posrtion
Lift up the flort and check the gap
bc{w(cn rhe needle valve bushing pin
and the lloat lip with the whe gauge
09240-00010.
gap| 2 nm (0 O41")
Standard
Fis 5 17 CheckrryLo1\'ercdPostion
V39gJ
SecondaryThrottle ValveOpeningAngle
Hold the primary rhror e valveat rhe fully
opened position, and inspeca if thc
Fig 5)8 Checking yatve OpetingAngte Gl366
FUEL SYSTEM- Carbureror 5- 13
sccondtry throttle valve is verticaly
agixrst the llange surface wrth the Gauge
0 0 1 1 0 - l l U ' 0 . h u u ni n i i g u r r : t E .
",
If necessary,djust thc openingrngle by
bendingthe rhrotrteshxfi ljnk ( I ) After
adlusting the link, check if the link
nrotion is smooth,
High Speed Valv€
lnspect the clcarance between the high
speed valve and ths bore when the high
speedvitlve is at fully closed position.
The clearanceshould be within 0_10 ao
0 2 5 m m ( 0 0 0 4- 0 0 1 " ) .
l l n e c i , \ i i y . J d J u srl h c I n . l . r l l l l i o np o . i l i o n
of the high speed valve by looseningthe
valve retainingscrews After adjustingthe
c l i : r r a n c i ., \ e c k i f t h ( v J l v eo p e r a l i o ni \
snooth, and then calk the retainingscrew
endsto preventthet]rfrom Ioosening.
Note:
The fbliowing adjusrmentsshould be
perforrned afte. assemblingahe darbu-
Fast Idle
On RT series:
Position the choke valve at fully closed
position, and adjusi the clearanccbetwecn
the prim.rry throttle valve(t ) and the borc
to bc 0 75 mrn (0 03") with the fast rdle
adjustingscrew (2) using the Wire Gauge
09240-00010
Fis 5-19 Adiusnns Fast |dte
5-14 FUEL SYSTEM- Carburetoron RT series

position wherl the co holtsing is iurned

On Light Truck series
counterclockwise-
Disconnect the fast idle connecting link
when the idle adjustment is perfortned
after installing the carburetor onto the
englne.
Bend the fast idle connectinglink so that lt
$ j l l b e . o n n e . ' l ( dl r c e l y " f l e r p e r f o r m i n g
the idle adjLrstlneni

Unloader
Hold the throttle valves at fully opened
position, and apply the 45" angle Geuge
09240-00010 onto ihe choke valve'
Fis 5-21 Autoiatic Choke A.liustned B0lo7
Adiust the opening angle of the choke valve
(1) so that ii will open 30" for 2R and 27'
High Speed Valve StoPPer l-ever
for 12R from the closed position by bend-
ing the fast idle cam follower (2) or the lip Adjust the unlockingmotion of the stopper
(3) of the choke shaft lever by the bending the liP of the slopper
l e v c rs o l \ a l l h c . e c o n d a r ryh r o t t l ev a l v ei s
unlocked at the same time when the
secondarythrottle valve starts to open.

Idle Adjusting Scr€\v

I he rdle adju\ringscrcw \hould bc correcl
ty adjusteclafter the carburctor is installed
onto the engine,but for Pre_adjustment,
screw in the idle adjusting screw until it
seatsslightly, then screwit out about two
and one-half of a turn
Do not screwin Lhescrewsecurely lf the
Fig.5-20 Adiustins Unloader G1367 l a p e r e d c n d o f l h ' t r d l u ' t r n g' c r e w i \
damaged,a smooth idling operation and
the vacuumare not obtainable
Automatic Choke
T,heautomaticchokc shouldbe adjustedto
supply adeqLlate aiFfuelmrxture for engrne CARBURETOR on RT series
starting in accordance with the climatic
condition, but generally, align the groove Removal
o n l h r c o i l h o u , i n gw i t h l h e c t n l e r l i n e I Removethe air cleancr.
located on the thermostat case 2 Disconnect the automatic choke stove
At this time, the choke valve will be closed outlet pipe from the carburetor
f u l l ya t 2 5 " C ( ? ? ' F ) . 3 Disconnect the accelerator link connect-
The variahon of one graduation on the ing rod from the carburetor.
thermostatcaseis equalto 5'C (9"F). 4 Disconnectthe vacllumpipe and the fuel
To adjusi the choking etfect, turn the corl pipe from the carburetor
housing counterclockwise to richen the
5. Remove the carburctor retaining nuts,
mixturc, and illrn the coil housjng clock-
wise to lean the mixture after checklnglf and rcmove the carburetor and the
the choke valve is closed from fully opened acceleratorbcll crank

6 Removethe heat insulatorfrom the
manifold if necessary
Disassembly
For disassembling and assembling the car
buretol,the CarburctorAdjustKit 0924G
00010 togetherwith the Carburetor
Screw-
driver Set 0986G11010shouldalwaysbe
ut rzed
Properwrencheswith ccrrectsizesshould
be used, and the removed parts must be
thoroughly washedwiht clean gasolineor
carburetorcleaningsolvent
The removed pa s should be kept in a
clean container to facilitate the assembly.
0 9 a 6 0 |- t o t o
Fit. 522 Cafiwetor Sttewdrirer Set
1 Removethe pump arm retainingscrew
(l), and removethe pump connecting
link (3) togetherwith the pump lever
(2)
,. Removethe fast idle connechnglink (4).
Fi& 5-23 ConnectingLinks Renoval
. Carburetoron RT s€ries
FUEL SYSTEII4 5.15
3 Remove the sbw passageplug, and
remove the ail horn straightupward by
removjngthe six retainingscrews,
zl Removethe pump dampingspring.
5 Invert thc carburetor,and take out tne
stopper(l), dischargeweight (2) and the
steel ball (3)
I
Fig. 5-24 SteelBull Reno'at 80t10
6 Remove the four flange retaining scrpws,
and separatethe main body from the
flange
Main Body Croup
80108
7. Remove the stopper lever retaining
, c r e w ,a n d r e m o v el h e . r o p p e rl e v e r(
together with the stopper lever spdng
8 Renovc ,he high speedvalvearrnrelain-
rng nut, then remove the valve alm (2)
iiom the high speedvalve shaft
R0109 Fis.5.25 Lever& AmRenoval aol11
 FUELSYSTEM-Carburetoron RT seties

12 1314
15
4a 16

42. '...
./17
43

45
I
\;:z:
46

24
25
48 26
27
2A
29
49
30

52
33
53
34

55
56
57
58
59

61 .@.€t
62

7 9 A Oa 1 A 2 7 2
6 7 6 A 6 9 7 o 7 17 2 1 3 75 76

fot RT Seties
Cnmponents
Fi& t26 Carbureror Y5772
 FUEL SYSTEM- Carburetoron RT series 5-17

'l
Chokeshaft 42 Coilhousing
2 Fastidlecam 43 Pistonconnector
3 Secondary smallventuri 44 Fastidlecamfollower
4 Fastidlecamsprjng 45 Vacuumpiston
5 Venturigasket 46 Slidingrod
6 Thermostatcase 47 Pistonpin
7 Casegasket 48 Fastidleconnecting link
I Chokevalve 49 Primarysmallventuri
9 Valveretaining screw 50 Thermostaticvalvecover
10 Air horngasker 51 Thermostatic valve
1i Pumplever 52 "O" ring
12 Powerpistonspring 53 Highspeedshaft
13 Air horn 54 Retaining screw
14 Uniongasket 55 Shim
'15
Uniontitting 56 Stopperleverspring
16 Uniongasket 57 Highspeedvalvestopperlever
17 Unionbolt with strainer 58 Highspeedvalveshaftarm
18 Pumparmretaining screw 59 Pumpconnecting link
l9 Needle valve 60 Pumparmpushspring
20 Float 61 l\4a
in body
21 Powerpistonstopper 62 Throttle adjustingscrew
22 Floatleverpin 63 Adiustingscrewspring
23 Powerpiston 64 Thrortteshaftlink
24 Pumpptunger 65 Adjustingscrewspring
25 Powervalve 66 Primarythroflleshaftarm
26 Powerjet 67 Secondarythrottle lever
27 Pumpdampingspring 68 Secondary throttlereturnspring
28 Weightstopper 69 Secondarythrottle shaft
29 Levelgaugegasket 70 Fastidlelever
30 Levelgauge glass 71 Faslidleadjusting screw
31 Levelgaugeclamp 72 Betainerring
32 Pumpdischarge weight 73 Shim
33 Ballcheckretainer 74 Body flangegasket
34 Steelball (intet) 75 Highspeedvalve
35 Steelball (ourtet) 76 Flange
36 [/ain passage plug 77 Secondary throttlevalve
37 l\4ainjet 78 Primarythrottlevalve
38 Slowjet 79 Adjusting screwspring
39 Retainer ring 80 ldleadjusting screw
40 Coilhousingplate 81 Primarythrottleshaft
41 Coilhousing gasket
518 FUELSYSTEM-Carburetoron RT setie\

9 Remove the small venturl re{alrung

screws(1), and removethe Primary
small venturi (2) and the secondary
smallventuri(3)

Fis. 5 29 Po\")et Valve RemoYal 801r3

valve covel, thermostatic valve (4) and

the "O" ring (5 ).
Ing.5-27 VenLunRemaYat B0l12 Do not disassemblethe thermostatrc
valve.
l0 R e n ' o \ e l l l e ( h e . k b a l l r e l a . n e rI
located at the bottom of the PumP
cylinder.and remove Ihe steelball (2)
by inverlingthe rnainbody-

s
VatveRemowl
Fig.5-30Thermostatic 801t4

15. Remove lhe ptimary and the secon-

alary main PassagePlugs (1), and re-
FiE.5-28 SteelRaIlRenoval v1860 move the primary main jet (2) and the
secondarymainj€t with the gaskets'
111 Removethe slow jet This slowjet
canbe removedwitboutremovingthe 2
I
ail horn 1f necessary.

12. Removethe power valve using the

Power Valve wrench, and removethe
powerjeifrom the Powervalve'

13 Removethe level gaugeclamp (.,'

glass(2) and the gasket(3) bv remov-
ing the two letainingscrews,

Removethe threethermostatic valve Fis. 5 3l Main Jet Removal B0l15

l4
and removethe B0I16
coverretainingscrews,
 FUEL SYSTEM- Csrburetoron RT \erie\
16. Remove the high speed valve retain-
ing screws, then remove the high
speedvalve
Since the ends of the retaining screws
are calked, file off the calked po.tion
of the screw ends slightly b€fore
removmg.
Fig:532 Hith SpeedValreRemoeal BOIIT
l? Remove the retainer ring, and remove
the high speedshaft
Flange Group
18. Remove the idle adjusting screw (l)
and the throttle adjusting screw (2)
together with the screw springs.
1 9 . Removethe snapring on the throttle
shaft link and the arm retainingnut,
then remove the throttle shaft arm
(3)
20. Remove the lever retainingnltt, and
,remove the secondarythrottle lever
(4) with the return spnng
FiA 5 33 Screw& Lerer Remowl BOI18
5.r9
2l Remove the primary throttle valve
(1) and the retainernngs (2), and
then remove the prrmary throttle
shaft(3)
As the ends of the throttle valve
rctanmg screws are calked, remove
them after fiting off the calked por-
tionsof thescrews,
Aho \inre rhe adjusring qhim\are in-
stalled onto both shaft ends for ad-
justment of the primary throttle shaft
thrust play, do not lose the shims
22. Remove the secondarythrottle valve
(4) in the samemanneras the primary
side.and removethe secondary Ihrol-
tle shaft(5)-
S h i m2 |
crf
I
FiE 5-34 ThrottleSlEfi Ualves
Air Horn Croup
23. Remove the pump plunger and the
boot.
24 Pull out the float leverpin (l), and
remove the float (2), valve push pin
Fit. J.35 Needle Valve Remoral v3997
5-20 FUEL SYSTEM- Carburetoron RT seti€s
(3), needlevalve push spring (4) and
the needlevalve(5)' then removetne
needlevalveseat(6)
25. Removethe powerpistonstopper(',,
and removethe Power Piston(2) and
the piston sP ng (3).
Frg.5-36Pou)erPistonRercwl 1t3998
26. Remove th€ union fltting and the
union bolt with the stminer'
2?. Removethe threecoil housingretain-
ing scrcws,and removethe coil houy
ing. housinggasketand the housing
plate
When removing the coil housing,do
not deform the thermostaticbimeta!
coll
28. Remove the fast idle cam follower
retaining screws,and removethe fast
idle cam follower (l) and the sliding
, rod (2).
FE. 5-37 SkdinsRod Reno'al v3999
29 Removethe vacuumplston connector
retaining screw, and the choke valve
in the same manner as the Primary
throttle valveremovaland removeth€
choke shaft.
e"
Fis. j"38 Aoke ShaftRetwat v4000
30 Remove the fast idle cam with the
cam springfrom the chokevalveshaft'
31. Take out the vacuumpistonwlth the
connector.
V4001
nA t3g Voaum PistonRenoval
32. Pull out the Pistcnpin, and remove
the connectorfrom the Piston.
33. Removethe thermostatcaseretarnrng
screws,and remove the thermostat
caseand the gasket.
lnspection
Washall the disassembled partsthoroughly
in cleangasoline,blow the air and fuel Pas-
sagesand the jets with compressedar to
 FUELSYSTEM.Carburetoron RT series 5-21

Wash the die-castparts with a soft brush,
and wash and clean the carbon deposits
arolrndthe throttle valve
Never use a wire for cleaning the jets
2 Check the Jets for defectivethreadsand
slot
3. Check the power valve for proper opera-
tion. defectivethreadsand other defecrs

4. Check the pump plunger for wear of rne

sliding surface. defechve leahter and
weak sprng

5 Check the pump damping spring for

weaknessand defotmation

6 Check the discharge check ball for rust

and proper seating_

I Ch'ck 'lle I ign .prid vJhe for

Fig.Y0 Clanins Passages
lnspect the following items, and rf defe-
tive, repairor replacethe defectivepart/s
Air Horn Group
I Check the ah hom for cracks, scorcs,
clamagedthreads and wom shaft bor€.
defor
rnation,end the shaft for bend and wear
Flange Group
I Check the flange fo. cracks, damage of
fitiing surfacesand delective and wear
Also check for wear of the throttle shaft
bores and damageof the idle adjustrng

2 Check the choke valvefor deformahor,

2 Check ihe throttle valves for wear and
and ihe choke shaft for bend and wear
deformation, and check for wear, bend
of the shafts and proper operation in the
3 Check the power plston for wear, and
ilangeshaft bores
for proper operation1nthe housingbore.
Also check the power piston springfor
3. Check the rdle adjusting screw for dam-
weakness and deformatton.
age of the threadsand taperedportton.

4. Check the float for deformation and

defectiveiabs, and also check for wcar
of the float leverpin hole,bracketand
the leverpin

5. Check the needlevalveand the seat for

proper seating.

6. Check the strainer for clog and rust

Main Body croup

1. Check the body for cracks,damageon
the fitting surfaces,defectNethrcadsand n8.541 Checkinsldle Adjusting v1873
thejet fitting surfaces Screv,
5,22 FUEL SYSTEM' Carburetor
on RT series

Assembly
Before assembling.clean each part wttn
gasoline,and alwaysreplacethe gasketsand
the packingsupon assembly All slidingor
rotating portions should be coated with
engineoil, and be sure to checkfor proper
operation Lafter assembly

Air Horn Group

t. Install the thermostatcasewith the gas-
kei onto the air horn-
Fis.5-43 Assemblis ChokeShaft v400s
Two crown head and one flat head
screwsare utilized for installation of the
mostat case, and assembleihe fast idle
thermostat case,and the flat head screw
cam followel onto the sliding rod
is installed above the vacuum piston

2- Assemblethe piston connector(2) onto

the prston (l) with the piston pin (3),
and install the vaclrulnpiston into the
cylinder of the thermostat case

E:
Fis.5-14 Assenblinslnride of v4006
Thermostnt Cdte

7. Assemblethe coil housingplate' gasket

and the coil housing onto the thermoslat
case wlthout damagmg the thermosiat
V40nJ bimetal coil
' 5 42 A\tenblins vacuumh\ton
Fip.
w0a4 Check if the choke valve operallon rs
satjsfactory before tightening the coll
3. Assemblethe fast idle cam (2) and the housina retaining screws- The choke
fast idle cam sprlng(3) onto the choke urlve must be closed from the fully
shaft(1) openeal position when the coil houslng
is turned counterclockwlse
For the seihng positionofthe coll bous-
4. lnstall the choke valve onto the choke
ing, refer to the CarbureiorAdjustmenr
shaft, and after checking for proper
operation,calk the retamingscrewends' in this section

5 Connectthe piston connectoronto rne 8. tnstall the union fitting (2) and the
c h o k e. h a f tw r t ht h ec o n n ( c t orre l a i n i n g gaskets(l) with the union bolt ( 3 )
togetherwith the strarner.

6. lnstall the slidlng rod into the ther_ 9 Install ihe power piston spring (4) and
 FUEL SYSTEM- Carburetoron RT series s-23
Fig.5.45 AssembtinsCoilHousing v4007
the power piston (5) inlo thc power
plston cyltnder.end retain thcm with
the stopper(6).
After installing, check if rhe power
piston movementis smooth
Fig. 546 Fitting & Powerhston v4008
Assenbly
10. Installthe needlevalveseat(6) wtth
the gasket,and assemble the needle
, valve(5), valvespring and the push
(4)
Fis. 5-47 noat Assemblr V3997
pin (3), then install the float (2) with
thc float leverpin (1)
Main Body Croup
ll Install the high spcedshaft,and install
the retainer ring onto the shaft end.
Next, install the high specdvalvead
justing the installationposition of the
valve referring to the Carburetor Ad-
justmcnt rn this section
After tightening the valve retaining
screws. check the high sgeedvalve for
propel opention, then calk the valvc
rerarnlngscrewends
Assemblethe gaskct,fuel level gauge
glassand the glassclamp in order,and
tighten the retaining screws cvenly.
l3 Install the "C" ring, ihermostatic
valvcirnd the valvecover
l4 Install the high speedvaiveshaft arxr
(l ) onto the high speedshaft, and in
stall the high spcedr,alvestopper lever
(2) and thc spring(3)
Fig 5-18ShaftAnn& Stopper R0t19
Let'etAssembly
15. Installthe p mary and the secondary
mainjets and the gaskets,
and install
eachpassagepiug-
The primarymainjet diameteris I 08
mm (0.043"),and the secondary main
jet diameteris 1.40 mm (0055")
16 lnstall the powerjet into the power
524 on RT series
FUELSYSTEM-Carburetor

valve,and installthem onto the body

usingthe PowerValveWrench
t'7 lnstall the slowjet
1 8 . Install both Primary and the secon-
dary smallv€nturieswith the gaskets
l9 Install smaller steel ball compared
with the other into the bottomof the
pump cylinder,and retainit with the
checkball retamer.

FlangeGroup Fry. 5-50 Shalt ShimAssembtl c0t17

20. lnsiall both prlmary and the secon-
dary throttle shaftsonto the flange,
analinstalleachthrcttle valveonto the
shafts
The pnmary throttle valve h thinner
than the secondarythrottle valve,and
both valvesshauld be lnstalledunder
thc shafts
andthe throt-
2 2 Installthe idleadjusting
ile adjusting screws with the screw
spdngsonto eachPosition
23 lnstall the throttle shaft link (2) onto
the secondarythrottle lever (l), and
install them onto the secondarythrot-
tle shaftthroughthe return sp ng (3).

Install the fast idle lever(5) and fast

idle adjustingscrew(6) wtth the screw
springonto the primary throttle shaft
arm (4), ttlen install them onio the
primarythrottle shaftconnectlng the
throttle shaft link wtth the primarv
throttle shaftarm

549 ThrotfleValvesAssemblY
Fas. v4009

2l Adju.t th" position of the Primary

throttle valve by lnserting the shims
between the retainer rings of both
shaft endsand both endsof the shall
bore.
When inserting the shims, insert the
thick shim to the throttle shaft arm
side, and the thin shim to the other Fig.5-51Link & Am AssemblY BOI20
side.
After installing both valves,check if 25 Assemblethe mam body with the
the valve wlll contact against the gasketonto the flange,and tightenthe
throttle bore comPletelywhen the four retainingscrews.
valvesarc fully closed,then calk the l h e i w o r c r e w a. m o n gl h ei o u r r e l d i n -
retainingscrewends ing screwsprovtdedwith the vacuum
 FUEL SYSTEM- CarburetorLight Truck 5-25
passageslbr the power piston and thc CARIIURETOR on Light Truck
vacLrumpiston
Removal
l6 Inscrt the stccl bxll. dischnrgeweight
i Rcmove the intokc eir con ector from
and the stopper under the punp jet
the air hofl1
27 InsLallthc pump damping springand
2. Remove the acccleretorancl the choke
l i c l l | n , p p l J n f . f u i r L o U .d e f o f ' n i r r g
wiresfrom the carburetor
the plunger ieathcr, and hold the
plungcr in its position
3. Disconncctthe fuel pipe and the vacuum
pipe from the cnrburetor.
t 8 . Asselublethe rir horn onto tne maln
body
4 Remove the cirrburetorretaining nuts,
and removethc cerburetor.
2 9 Install tl)e slow passageplug with thc
gasketand thc plungerboot
Disassembly

_10 Connect the puolp connecting link f o r d i \ " , \ ( t n b ln ! - 1 d tlr( cir-

(l) onto the throttle shaft arm (2)
and lhe pump lever(3), and insrallthe
pump lcveronio the air horn
".\(mbltnp
buretor. use the ('arburetor Adjust Kit
09240-00010togetherwrth the Carbureror
Screwdriver Set 09860 I1010 which arc
utilizcd on thc carbu.etor on R'[ serics.
Also the same procedurestnd prccautions
prcscribed for rhe RT serics should be
adhered.

I Remove the puinp arm reLainingscrew

(l). end rcmove the pump connecting
link (3) with the pump lever(2)

2 Remove lhe fast idle connector (2,/,

prlnary rhrottle return spring(5), throt-
tle connectinglink (6), accelcratorlever
rod (7) nnd the accclerelorlink support
Fit- 5-52 Punp Levet& Link Asembty (5)
B0t2l

3 1 . Instail the fast idle connect1ngljnk.

Installation
1. Follow the removalprocedures
in the

After the engineis warmedup, check

the fuel level and the flrel leaks,then
perform the idle adjustmentreferringto
to the EngineTune-Upsectlon

Fig J.53 ConnecnnsLinks Renowl 80954

5-26 FUEL SYSTEM- Carburetoron Light Truck

%,'@

30 29 2B 27 26 25 24 23 22

2a P!mp dGcharqew€'shr
16 F o a t l e v e rP i . 29 Dis.h6fgeweighistoPPer
3 Chokel*ersPrinq gu!.ro 1? P u m PP ! u n s e r
18 L e v eq a u s e c l a m p 3 1 P r i m a f vs m a l vr e n t u a
4 Chokevalverelief sp.ing 32 A ting
5 Chokevalv€returnspring 19 Lasl gauseg ass
6 Chokcshaft adapter 20 Levelgaugegasket
21 Main Passase Pl!s 34 Thermo$aticvalve
22 PrimarvmarnJet 35 Thermonaricvarvecover
P u m Pd a m P l n s s P n r q smallvenlLn
36 SecondarY
23
24 Checkba I reia'ner
25 Steelba | (in!et)
26 s r e e r b a l(l o ! t e d
13 Unlo.boltw/strainer

Com?anetlts No v6959
fig. 5 54 CLrbwe,or
 FUEL SYSTEM- Carburetoron Light Truck 5 27

1 High speedvalvea.m 1 l P u m pc o . n e c t i n sI n r k 21 Throftr. connectinglink

2 Stopperlwerspring
3 High speedvalvestopporlever
4 Hrghspeedv5rvesh6fi
6 Adelerator leverrod
7 Acceler.torlink sopport
9 Pumparm *t Erow
l2 Body flangeqasket 22 Prim.ry rhrottle shaft am
13 Secondarythrotle shaft 23
24 Fastidle connectinslink
r5 Primarythroltle shart 25 Primarythrenle returnsprinq
l6 ldle adjusiingsrew 26 Throttle adiu$ing.crew sprinq
17 ldre adjusrinssf€wsprinq 21 Thrortle adiustins*ew
2A S€condarythrolde lder
19 Pnmarythrotne va ve 29
20 Sscondarythrort e valve 30 Secondarynlrotle returnspnns

Fig. 5 55 Cltburctor Conponents No 2 on RH Seies Y6964

3 . Remove the slow passageplug, and 4. Removethe pump damping

move the air horn straight upward by
rernovingthe six retainingsdews 5 Invert the carburetor,and take out the
5-24 FUELSYSTEM- Carburetor
on LightTruck

e e i g h l( l ) r n d
s t o p p e f( l ) , d i s c h . r t sw
the stcelball (.1)-

5:;:--',
FiB. 5-58 Ventun RemaYdt 80112

R09'l locrted at rhe bottom of the Punlp

FiE.5 56 SteclRollRemotdl
cy|nder. irnd renlovc the steelbell (l)
6 Remove the lbur flange retaining by invertrnglhe maln lroclY
screws,and separatethe main body
from the flange

Main Body Group

7 Remove the stopper lever retalnlng
screw) and remove the stopper iever
(l) together with the stopper lever
sprrng

8 Remove the high speedvalve retaining

nut. then remove the valve arm (2)
from high speedvalve shaft. yIu60
Fig. 5 59 SteelRall Remordt

II Remove the slow jel fhis slow jet

can be .emovedwithout removingthe
at horn if necessary

12 Remove tbe Power valve usrng lne

l'ig. 5 57 Le,et & Arn Remornl ROlI]

9. Remove the small veniuri retaining

screws(1), and rernovethe prllnrry
small venturi (2) and the secondary
smallventuri(3)

Il0t l3
l0 Remove lhe check ball retainer (l) I"ig 5 60 Povr VulveRcnoral
 FUELSYSTEM- Carburetor
on LishtTruck 5 29

Power Valve Wrcnch,and remove tue are calkcd.frle off the calkedportions
powcljct fronr the power valve oi the s(rrewends slightly bcfore re-
novrng
l3 Renove the level gaugc clamp ( ,,
glass(2) and the gasket(3) by renrov-
ing the two retxiningscrews

14 Remove the three thermostaticcover

retalnjng screws) and rentove the
valve cover,thermostaticvalvc(4) and
the "O" ring a5)
D o n o l J ' ' J \ . e n t b l cl h e t h < n o \ t a l i c

Fig 5-63 Hith SpeedvalveRemoval lt1l17

l7 Relnovethe retainerring. and remove

the high speedshaft

Flange Group
l8 Remove the idle adjusting screw (l)
and the throltle adjusting screw (2)
I t.2 3 with the screwsl)rings

Fig 561 Themostat,cYalveRemoval B0 4 19 Remove the snap ng on the throttte

Shaft link and the arm retalningnut.
15 Remove ihe primary and the secon-
then remove the throttle shlft a.m
da.y main passageplugs (l). and re- (3) and the fast idle Icver(zl)
movc the prnnary mrin jet (2) and thc
secondaryrn!in je1 togctherwith the
20 Remove the lever rettining nut. tnd
gaskets.
.cmovc the secondaryLhrottle lever
(5) with the returnspring_

ftg 5 62 Mon Jet Removal R0l t5

BAIt6
FiE. 5-61 Scrcws
& LeLrs Renowt 80955
Removc the high speedvalveretrintng
screws. then remove the high speed 2l Remove the prirnafy throttle valvc
( I ) .rnd thc ret iner.imgs(2), and then
Sincc the ends of the retainingscrews rernovelhe pr'ma.y throttle shaft (3)
5.30 FUELSYSTEM- ( :rrburelor
on I ighl frtrcL

As the ends of the throttle valve re n e e i l l e! a l v e ( 5 r . t h e n r e m o \ e I : r e

taining screws are calked, remove needlevalve seat (6)
them after filing off slightlv the calk
25. Removethe powerpiston stopper(1),
ed portions of the screws
and rcmove the Power Piston (2) and
Also since the adjusting shims are m
the piston spring(3).
stalled onto both shaft ends for the
aaljustment of the primary thrctile
shaft th.ust PlaY, do not lose the
shims

22. Remole the secondarythrottle valve

(4) in the samemanner as the primary
side, and remove the secondarythrot-
tle shaft (5).

Shim 2 |
Fic j"67 PowerHstonRemoval 80956

2 6 Remove the union fitting and the

union bolt with the strainer'

<=t
I
Shim
27 Removethe choke valve in the same
Fig 5 65 Throt e Shafts& vdl|es v1876
manneras the primary throttle valve
removal,and removethe choke shaft
Air hom C'roup
Inspection
23. Remove the PumP Plunger and the parts accordrngto
Inspect all drsassembled
boot. on lhe R I teri"'
procedufcs
the Inspeclion
in this section.
24. Pull oul lhe floeLleverpin I I I and re-
move the float (2), valvePushPin (3),
' needle valve push spring (4) and the Assembly
Before assembling,clean each pa with
gasohne, andalwaysreplace the gaskets
and
the packingsupon assembly
All sliding or rotating portions should be
coated with engineoil, and be sure to
checkfor proper operationafter assembly-

Air Hom Group

I Install the choke shaft and the choke
valve, and after cheking the valve for
2 proper operatlon cdlk lhe relaining
screwendsto preventthem fiom loosen-
Fis 5 66 Needle YolE Renovat v3997 rnc
 - Carburetoron Light Truck
FUEL SYSTEI\4 5'31

2 Installthe union fitting,gaskets

and the
unionbolt with the strainer

3 Installthe power piston springand the

I Power piston into the power pisLon
cylindcr,and retainthem with thc stop'
per
After installing,check if the power
pistonmovementis smooth

4 Instalithe needlevalveseat(6) and thc t?

gasket,and assemblethe needlevalve Frs. 5-69 Cruse Glass& B0l14
/ 5 ) . v a l ! es p l | n gr 4 r a n d l h e p u s hp i n ThetmostatitYal"eArsemblj
(3), thcn install the float (2) with the
lloat leverpin ( 1).
l0 Install the high speedvalveshaft arm
r l ) o n l o t h c h r g h. p e c d\ h r l r , a n d i n -
stall the high speedvalve stopper lever
(2) and the retutn spring(3).

Fit 5-68 noat Assenbly v3997

Main Body Croup

? Install the high speedshaft, and install Fis. 5-70 Shaft Arm & R0119
the retainer ring onio the sh.lft end StopperLeverAsembl!
Next, inst2ll the high speedvalveadjust
ing the installatronpositron of the high II lnstall the primary and the secondary
speed valve referring to the Carburetor m : r J ni i r \ w i r h r h e g a \ k c t sa, n d i n s t a l l
Adjustmentin thls section. eacn passageptug
After tighiening the valve retaining
screws,check the valvefor proper opera- 12 lnstallihe powerJet onto the powe.
tion, ihen calk the valveretainingscrew valve,and install them onto the body
ends usingthe PowerValveWrench.

8. Assemble the gasket(1), fuel levelgauge 13 Installthe slowjet.

glass(2) and the clamp(3) rn order,and
tightentheretamingscrews evenly.
9. Insiall the "O" r1ng (5), thermostatic
valve (4) and the thermostatic valve
14. Install both primary and the secon-
dary smallventurieswith the gaskets
l5 Install the smallersteelball ofthe two
steel balls into the bottom of the
532 - CarburetorLight Truck
FUEL SYSTEI\4

pump cylinder.and retain it wrih the After installing both valves,check if

check ball retalner. the valve w l contact against the
rf'orrri I'orc ,'orpl.lcly whcn rLre
Flange Group valves are fully closed, and calk the
rctatnlng screw enos-
16. Install both primary and the secon'
dary shaftsonto the flange,and install
It Install the idlc adjust screw wiih the
each throttle valve onto the shalls
screw sprlng
The primary throttle valve is ihinner
than the secondary throttle valve,and
1 9 Install the throitle shaft link (2) onto
both valves should be installed under
the seconda.ythrottle lever (1). and
the shafts
install them onlo the secondarythrot-
Ile shaft through the return spring
( 3) .

2 0 Install the fast rdle lever (5) and the

throttle adjustingscrew (6) wjth the
screw spring onto the prlmary throttle
shaft arm ('1), then install them onto
the primary throttle shaft connecting
the throttle shaft link with the prl-
mary throtile shaf-tarm.

FiA 5-71 Throttle ValvesAssembly V4009

17. Adjust the position of the primary

throttle valve by insertingthe shims
between the retaining rings of both
shaft ends and both ends of sltafi
bores
When inserting the shims, insert the
lhick shim to the throttlc shaft a.m Fis. 5 73 Link & Am AssenblY R0955
side. and the thln shim to the other
21 Assenble the main body with the
gaskct onto the flange, and tighten
the four .etainingscrcws

22- Insert the steel ball dischargeweight

and the stopper under the PumPJer

23 Install the pump dampng sprrngand

the pump plungerwithout deforming
the plungerlcalher,and hold the plun
Retaini.gFing Shim gcr in its Posihon.

24 Assemblethe air horn onto the lnain

Fis. 5 72 Shllt Shns AssenbLY GauT body
 FUELSYSTEM- Carburetor 5 33

25 lnstall the sbw passage

plug with thc
gasketand thc plungerboot

26 Install the fast idle connector(l), ac-

celeratorleverrod (2), acceleratorlink
support (3). primary throttle return
spring(.1)and the throttle connectilrp
link (5).

FiB.5-75PumpLevet& Link Assembly 80957

Installation
I Follow the removalproceduresin the re-

I A f r e _t l c e n g . n er . s a r m c d r p . c h e c kr n e
f u e l l c \ c . . r n J h c t r e l l e a k \ .r h e n p e F
Fit. 5-71 Links Assenbu 80954 form the idle adjuslment refelring to the
EngineTune Up section
2 1 . ConnecL thc pump connecting li;k
( I ) onio the throttle shalt arm (2) and
the pump leve. (3), then install the
Pump leveronto the a[ horn

Solenoid Valve
To preyert engincrunningon. the solenoid againstidling positionwhen the ignition
v d l v eh e \ b r e n i n . r a l t ( do r r o l h c . r ( . t r i - switch is turned off and ihe solenotdvalve
tor. so as to further closethe Lhrottlevalvc roo IeIullls,

Low idle adjustinsscrew

Throttte shaft

Throttle adjusiingscrew

PBODUCTION
EFFECTIVE:
FromEngine (February,
No. t2R-0000001 i97t)
 FUEL SYSTEM

IDLE ADJUSTMENTPROCEDURES

l. Warmup the enginesutTiciently-

(Newlv
2 Adjust ihe engineidling revolution to 550 I 50 r p rn- by throttle adjustscrew
installedpart)

3 Disconnect thc wire hafness tcrminal of solenoid valve and check if the idling revolution
falls below .tr00r.p.n1 or the engine stops
Adjust the low idle adjusting scrcw, if necessary,as lbllows
An;ther method is to turn low idle adjusiing scre\{r clockwrse, uniil the engine idlc
revolution jncreases,analthen tLrrnback thc low idle adjusting screw to I /2 tur'

Igniiion switch Ttuottleadjusting l/)w idle Throttle Enginerpm

ON
ZrV 550150

* Below400 (Also
ON
possiblewhenensrne
(D$comcct solenoid $ at stop)

NOTE:
l.The throtile adjusting screw is a newly installed p.lrt, which controls the engine idlmg
revolution, also, the low idle adjust scrcw is the fomer throttle adjust screw, which
prevents the throtllc valve from closing completely
2 Pleese note that there is somc changc in fomler engine starting and also avoid
nrisinterpretation of poor engine stariing from the user To start the englne, pleaseturn
on the ignition key, while stepping gradually on the acceleratorpedal to lrn ihe starter
When run the starter, it rs unnecessaryto step on the accelemtor pedal

Ig
)

1 Low idle adiustingscrew

2 Throttle adJustingscrew
3. S o l e n o i dv a l v ew i r e h a r n e s s
 FUEL SYSTEIM- Fuel Filter (2R) & FuelPump 5-35

FUEL FILTER (2R)

Remova.l
L Disconnectthe inlei and the outlet hoscs
from the union fithng of the filter.
1 Fuel fiker sqpport
2. Removethe firel filter assemblyftom the
support by removiru the filter retaining
nuL

7 Fuelfilterel€ment
I El.mantattachinqspring

Fig. 5-77 Fuel Filtet Components Y7686

Disassembly
Loosenthe filter bowl ba nut, and remove
the filter bowl, sprmg, element and the
gasket.
Inspection
Wash all the parts with clean gasoline
I If the elementis defectiveor excessively
dirty, replacethe element
2. Checkthe body and the bowl for cracks,
damageand deformation.
If defective,replaceas necessary,
FUEL PIJMP
Assembly
Position the new gasket,elementand the
springcorrectly,and assemblethe bowl and
the bowl bail, then tighten the bail nLrt
securely,
Inslalla tion
Follow the removalp.oceduresin the
verseorder,
Aft€r mstallation,operate the engineand
checkfor fuel leak.

Fig. 5-78 (loss SecnonalViewot FuethnD cr774

536 FUEL SYSTEM FuelPrtmP

Description
ol the inlet and outlct valves'
The fuel pump is of a diaphragmtype' and is composed
d r a D h r - s nr.J . k r r J I m u p p c ta n d l o w e rb o d r - '
arm which in turn convertsrnto
irr" i",ru"""r Jnot'on oi it * (rmllralt rctuates the 'ocker
the reciprocation of the diaphngm
pump. and alsodeliversout the fuel with
This diaphragm movement draws the luel into the
ircment of the cngine ihrough the car
specified pressure and volume to mcet the req
buretor

Specification:
l vpe Diaphragm
Deliverycapacity Over 1.0 liter/rnin ( 1 0 6 U S q l t l n i n 0 8 8 l m p q t s / m r n r) t
1.000rprr of crmshalt
Dclivery t.essure 0 2 2 . ' 0 . 3 2 k g ic m : ( 3 I - 4 5 P s i )
Over ,+00mmHg( i5 7 inHg)

1
2 F u e l p u m p c o v e rg a s k e r
3

5
6

ro
Oi seal Packrng re16rner
12
t3
l5

t9
20

@D

0@@

Fis. 5 79 Fuel Pultp Co,llonenLs G2018


Removal
I R e n o r e t t r e e n g i n cu n d e f . o v e r o n R l l
sefles
) Disconnect
the inlethoseandoutletp l p e
liom thepunp
Removethe pump retainingbolts,
removetbe pump assembly
Discssembly
l. Removethe upper body rctainingscfews,
and remove the upper body from the
lower body.
2 Remove the vrlve retainer retaining
screws.and remove the retainer,valves
and the packings.
Fis. 5 8u ValvcsRenovdl
3 Remove the pump cover retaining
screws. and remove the puinp cover and
tlregasketfrom the upper body.
4 Pressdown thc diaphragrninto the pump
lower body. and unhook the diaphragrI
rod from lhe rocker arm link. then rc,
move the diaph gm lrom the lower
5 Remove the diaphragm spring, oil seal
spring retainer,oil seal packingand the
oil scal packing retainer.
6 Driveoul thc rocker arm pin towardsthe
serration using a blunt
- Fuel Pump
FUEL SYSTEII4 5.37
move tnc rocKerarm, link and the rocker
arm spnng_
Fig. 5.81 Dnection ol hn Renoval V3991
lnspecfion
Wash all the pa s in clean gasoltne,and
blow the passages with comprcssedair
Check the followineitems,and rf defective,
replace as necessary,
I Check the coverand the body for crtcks.
delectivcthreadsand worn pin holes_
2 Check the diaphragm for tear and wor!
pull rod
3. Check the valvesfor proper operahon
4 Check lhe \p||ng tor weikners and cor-
v3990
5 . a h e c k t h r r o c k e ra r m . l i n k a n d r h e p i n
ior wetr
Assembly
Always replace the gasketswiill the new
grskeis upon assembly
1 Place the rocker arm and the link inro
th( lowef body. ,jnd holJ I hcin Ir ftJir
2. Install the rocker arm pin from none-
serrationsidc of the pin. and inslall tne
rocker arm spring onto the rocke. rfln
locator on the rocker arnl
3 lnslall the oil seal packing retainer.oil
 FUELSYSTEM- FuelPumP
seal packing.oil sealspring retainerand
the diaphmgm spring onto thc Lowcr
body.
4. tnstall ihe diaphragm, and hold it in the
pump lowcr bod). lhen houk lhr ,lir'-
phragm roJ onlo lhe rocker arm linl
Fig. 5-82 Diaqhnsm AssanblY v3992
5. tnstall the coverwith the gasketonto the
upperbody.
Fis. 5 83 Poitionins Inlet & v4766
Outlet Yalres
6lnstall the packing and the vaivescor_
f ( \ t r y I n l r L n eu p p e l b o d ! i l \ " o \ \ n i 1
figure 5-83. and secllrethe valveswith
the valve retainer and the screws.
7. Assemblethe upper body onto the lower
body jnsuring that all secu ng scrcws
passihrough the holes in the diaphragm
without tearing the fabic, then tighten
the screwsevenly and securely
8 Checkthe pump fot proper operation
Installation
Follow the removal procedures in ihe re-
Always replace the gasketswith the new
gasKels
operatethe engineand
After installation,
check for fuel and oil leaks.
PerformanceTest
l Disconnectthe fuel pump outlet pipe
anal connect a pressuregaugeonto the
pump outlet fitting
2. Operatethe engine,and measurethe
pump delivery Pressure
lf lhe prc\\urcdoe\ lrol mecl the speci
fied pressure,replace the diaphragm
sprrng
DeLverypressure:
022 - 032 kg/cm'1
(3.1 - 4.5 Psi)
 FUEL SYSTEM- Fuel Tank & Fuel PiDe 5-3S

FUEL TANK & FUEL PIPE

F'

Fig.5-84 Fuel Tank & pipe Cotnponentson Bt Seies

G
e

Fiq. 5-85 Fuel Tank & PiDeComDonenEon RY Sel[es

5 40 - Fuel Tank & Fuel Pipe
FUEL SYSTEIVI

i:'t:\
-\*

6 F u e l i n l € r u p p ePr r P e

a I n l e lp r p e . o n n e c t o r

on RHI]V B'G&l5BBSenes
Fi!- 5-86FuelTank& PipeComponents G3846

an NIta Senes
Fis. 5 87 FueLTank& Lpe G,nponenLs B8A7
 FUEL SYSTEM- Fuel Tank & Fuel PiDe
Fuel Tank Removal
I Draln the fuel, and disconnect the fuel
pipe liom the luel tank.
2 Removc the fuel sendergaugecover, and
disconnect the gaugewire
3 Remove the tank cap, and aemove ane
inlet pipe shield from the tank inlet prpe.
4 Remove the fuel tank rclainmg bolts,
r n d r e m o v e( h e f u e l t a n k a s s e m b l y .
Note:
The fuel tank upper panel acts as a floor
of the car. Therefore, when installnrg,
use a sealerwith water resistanceaDd
non-drying qualities between the body
and the installtng surface of the tank ro
prevent water or dust ente ng into the
comPartment,
5 Removeihe fuel sendergauge
lnspection
I Inspcct the firel tank lbr cracks, cor-
rosion and leak.
lf any defect is present.repairor rcplace
2 Check the fuel hose or pipe and unions,
and if defechve, replace as necessary.
3. Waterand dust accumulationin the fuel
tank will causemalfunction of the carbu,
retor, fuel filter or the fuel pump.
If ihe accumulatronof sedimentin the
fuel tank and the fuel filier is excessiv€,
the fuel tank should be removed and
flushed, and the fuel pipe should be
Installation
Follow the removal procedures in the r€-
F u e l l i n e . m J . l b e ' ( c u t e l y l a s L e n e di n
posrhon with the clamps,and all connec-
hons should be tightened securely
To prevent fuel leak, use a liquid sealer
wlth fuel-proof qualities for the installing
surface of the sender gauge if necessary,
 FUELSYSTEM- Air Cleaner

AIR CLEANER

C>
fl
ll
I

on RT & RN SPti's
Components G3128
Fis. 5-88AtuCtennet

qg)

I Intake arf connector

on RH Seies
Fis 5-89AtuAeanerComponents c3808
 FUELSYSTEM-Air Cleaner 5.43

ou ,.no )li, r-*ale ^ c,nRy seies

"r**
InstructionTipson Felt Element:
1. For cleaningthe eienrentwith compressed
all, b]owout iiom the insicle
towardthe
outsrdewlth low pressure
air

2 If the elementis spoiledwith oil or fat, washwith a soft soapor

cleangasoline,and dry
it thoroughly.
It is recommendedthat the washingof the elementshouldbe perlbrned
only thrlce
3. Never wash the element wjth a clcaningsolvent except
with cleangasolineor warer
. with soft soap

If^the element is washed,it may discolor,but the fittration

efficiencywill nor oe
affected.

Instruction Tips on Paper Element:

l- For cleaningthe elemenL wtth compressed
air, follow the sameprocedureson the fclt
elementtypeasprescribed above

2. D-onot washthc elementwith any solventor soapand water.

lf the elementis excessively
dirty,replace
the element
5.44 FUEL SYSTEM- AcceleratorLinkage

ACCELERATOR LINKAGE

G3809
Fig.5-gI Accelaator LinkzgeConponentson RT Se esfor RHD

de.; O''
i,.-|1.
I _ -,:

acceleratorwre clamp
AcceleBtorlleribl€ wrrc
Acceleratorstopperchannel

Fis. 5-g2 AcceleratorLinkageComponentson RT Seriesfor LHD G3810

 FUEL SYSTEM- AcceleratorLinkage

1
2
3

5
6

a Accereratorf/exibtewirc

lD@

Fis. 5-93 Accele.ato,Linkary Componentson RH Seiresfot RHD c3812

Description
Disassembly
of the acceleratorlinkageis self-explanatory.Assemblyprocedures
are equally
srmple.

When.assemblmg, llrb catethe slidingor rotatingportionswith multipurpose grease.Atter

assembling, recheckthe accelerator pedalfor smoothoperation, and checki;the throttte
sufficien y fu[y, op_enedwten the accelemtorp"jut ;, a"p..r..a ul tl" *ry.
l"ll::
I or\ rsi.l?lj
veryes\entlat to obtainrhe full peflor.n"nce
ol Lheengirc
If necessary,adjust the pedal stroke by adjustingl h e i n s t a l l r t l o pr o s i l i o n
o f r h e w i r ec l a m p
located on the rocker arm cover on RT series,and the pedal
stopperbolt on RH series
 LUBRICATING SYSTEM

DESCRIPTION 6-l
OIL PUMP. . 6-2
Descdption
R e m o v a,l . 6-2
I
Disassembly .
Inspection & Rapair 6-3
Assembly.
Installation ... 6-5
OILFILTER .. . ... 6_5
D e s cp t i o n .. .. 6-5
Removal. -.. .. .... 6_5
Disassembly. .._ .. 6_5
Inspection . 6-5
Assembly.. ... 6-6
Installation. 6_6
Oil Filter ElementReplacement_. 6_6
MEMORANDUM
 SYSTEM- DescriDtion
LUBRICATING

DESCRIPTION

FiC.&l 2R-EnEne
Lubnca ngSystem Y5512,G0842
The lubricating system utilized on the 2R, 12R engine is of an all forced-feedand
partial-flow filtering type insuring positive lubdcation, and the lub cating chcuit is as
shownin the aboveillustration

The oil dischargedfrom the oil pump dividesinto two flowing circuits;one entersinto the
cylinde. block oil hole, while the other entersinto the oil filter whichreturnsto the oil Dan
throughthe checkvalveafter filtration

As the o filter is of the partial-flowfiltering type, the filter capis providedwith the check
valveto preventthe orl pressurein the engineinternalcomponentsfrom decreasing lessthan
the specifiedpressurewhen the engineis operatingat low revolution. Therefore,the oil
pressureis regulatedby the relief valveprovidedin the oil pump to the specifiedpressure

The oil reachingthe cylinder block oil dividesinto three different directions;enginefront.
center and the rear sections. The o reachtngthe front sectionlubricatesthe camshaft
No 1 bearingand the crankshafifront bearings After lubricatingthe crankshaftbearings,
it lubricatesthe connectingrod No 1 bcarrngsthroughthe oil passage providedwithin the
crankshaft,and also spraysfrom the oil nozzle to the timing gearsfor lubrication The
centersectionoil lubricatesthe camshaftNo.2 bearing,distributordrivegearand the
crankshaftcenter bearings,and after lubricating the crankshaftcenter bearings,the oil
lubricatesthe connectingrod No. 2 and the No. 3 bearings.The rearsectionoil lubricates
the camshaftNo. 3 bearingand the crankshaftrearbearings,and after lubricaiingtbe crank-
shaft rear bearrngs.ihe oil lubiicatesthe connechngrod No- 4 bearings A part of the oil
 LUBBICATINGSYSTEM Pump

which lubrjcatedthe crmshaft No 3 berring. travelsintermittently through the oil holc 1n

the cylinder block rnal the cylindcr head to the valvc rocker suppofi No 4, and this
lublcatcs the virlverockcr shaf1.and then flows ouL ol the rockcr anrs
The oil whlch lub.icatedeach of the connectingrods spraysonto the cylinderwallsand the
prsbn pins liom the holeslocaledat the connectingrod largerend Lrpper

OIL PUMP

Description
The oil pump is of a trochoid type. and is
dfl!cn oy lhc di'lfiburor \l"afr$ iir i.
engagedwith the carnshaft Therefore,the
J e l i v .f y q u d r r r y , , f t r r c o i l p u n r p ! r l l I n
crease in proportiorl to the cngrne revolu-
tion
When thc engine is operated at high re-
volulion, the oil p.essure will increrse
above thc speciflcd pressurc For thN Fig 6 2 Reliej Vtbe operatian G0843
reason. the oil pump is providcd with a
relief valvewrthin the oil pumpcovcrlo regulatethe oil pressurc
The oil drawn in from thc straineris deliveredto the oil filter and the cylinderoil hole by
the arrow mark shown in the figure 6 2
The deliverypressurebeconlesto 37 - 4 I kg/crn, (525 -61 2 psi) in relationto thein-
creaseof the enginerevolution.which opensthe relief valvc.and the oil will be by passed
from the outlet srdernto the inlet sideto regulatethe abovespccifiedpressure

Specification:
Tvpe Trochoid
Dcliveryquantity at oil temperature O v e r 1 . 7l i t e r s( 1 . 8U S q t s , 1 . 5l m p q t s )
r 0 0 " c( 2 r 2 ' F ) per minutcai 300 rpm & at orl pressure of
Usinsoil ' SAE30 2 kg/cm, (28 4 psi)
Over19 liters(20 1 US qts, 16.7tmp qls)
per minuLeat 2.500rpm & at oil prcssure
of 3 kg/cm, (42 7 psi)
Reliefvalveoperatingpressurel Starts to open at 3.? - 43 kg/crn'?
a t o i l r e r r p e r r t u r e1 0 0 " C( 2 1 2 ' F ) (s26-6l.2Psi)
at 2.500 rpm

Removal Disassembly
I Drain thc cngincoil l. Removethe orl straincr

2 Removethe oil pan 2. Removethe rcliefvalveplugfrom the oil

pump covcr.then t?&eout the rclicf
3 Rcmovethe oil purrp outlet pipe valvespringandthe reliefvalve

4 . R c m o v cl l r c o , l t u m p ! \ i r l l ' r \ l r i r i n e l 3 Rcmoveihe purnpcover,and rernove thc

coverpacking.
driverotor rnd thedriven
 SYSTEM- Oil Pump
LUBRICATING

4 Body reEining bott

5 Pufrp coverqasket

7 C.os recesshexagonbo t
I Strainer.etainingbott

13 Relrefvatvesp.rnq

18 Oil pump ouiot pipo

"i;
Fis.6-3 Oil tump Companents y5513
Inspection& Repair Drive rotor diameter is 2 9 ' 7 0t o 2 9 ' 7 4
Washall thc partsin clerningsolvent,and m m ( 1 . 1 7 0- L 1 7 2 " ) .
checkthe followingitems. Driven rotor diameteris 40.53to 40.56
m n ( 1 5 9 7- 1 . 5 9 8 " )
L Check the oil pump roto. shaft for
excessive
wearand scores. 3Inspect the tip clearance betweentrs
If necessary,
replacethe shaft driverotor and the drivenrotor.
The clearance shouldbe within 0 07 ,
0.12 mm (0.003- 0 005"), and if rhe
clearancc exceeds0.2 mm (0 008"), re-
placethe rotors asa set.

Fia 64 CheckinsRotor Shatt v3188

2 Inspect the drive rotor and the driven
rotor for excessivewear and scores If
defective,replacethe rotorsasa set Fig: 65 Checkiry Tip Cteamnce v3189
6'4 LUBRICATINGSYSTEM'OilPumP

4. Inspectthe side clearance betweenthe Relief valve spring specification:

rotor and the installing surface of the Freelength 470mm
pump cover (L85r.)
The clearance shouldb( wllhin 0 01 - Installedlength 36.8mm
0 0 9 m m o r 0 0 0 1 2t o 0 0 0 3 5 " (1.4s")
If the clearanceexceeds0 15 mm lnstalledtension 5 . 9 9- 6 . 5 9k g
(0.006"), replacethe rotor ana!/orthe ( 1 3 2 - 1 4 . 5l b s )
pump cover.

frE 6-8 CheckinsRelief Valte v3r92

SAeAarunce
Fia 66 Checkins
5 Inspect the body clearancebetweenthe
d ven rotor and the body The clear-
anceshoutdbe within 0 l0 - 016 mm
(0.004 - 0.006") If the clearance
exceeds0 2 mm (0.008"),rcPlacethe
body or the rotor set.
V3190 7. Check the PiPe and other Pa s lor
caacks and damages,and check the
strainerfor clog and damage. Replace
if defective
Assembly
Follow the disassembly procedures in the
reverscorder, and after assembling, per-
form the delivery test of the oll pump ac'
cordingto thefollowlngeasymethod-
Submerge the oil pump inlet pipeinto the
engineoil, androtatethe rotor shaftwith a
screwdriverunhl the oil is pumped out
from the outlet Port.

@eafi?)

Aeannce
Fia 6-7 CheckingBody V3I9l

6. Check the relief valvefor proper fit' oil

passage for clog and the sliding surface
for scores,
If defective, replace the relief valve
Also check the valvespiingfol weakness v3193
Fig. G9 Oil Punp Test
and damage,and replaceasnecessary
 LUBRICATINGSYSTEM- Oil PumD.Oil Filter

At this time, the rotor shaft shouldrotate
smoothlyand lightly.
N e x t .p l u gt h e o u l l e Lp o r t w i r h r h ef i n g e r ,
and rotate the shaft continuously- lf the
oil is pumped out counteracting to the
prssure of lhe frnger. the oil pump is
satisfactory.
Installation
l.Install the oil pump and the outletprpe,
and tighten the oil pump retainmgbolt
ro 1.'7 - 2.3 m-ks (12.3 - 16.6 ft-lb)
torque,
2. Install the oil pan with the new gasket,
and trghtenthe bolts to 0-4 - 0 7 m-kg
(2.9- 5.0 ft-lb) torque
3. Fill the engineoil to spec ied level
The oil filter element is of a paper type
whichis ireatedwith a special resin.
Since the oil filte. is of the partial,flow
filtering type, when the engineis operated
at high revoluhon comparatively,the oil
delivrredlrom rhepumpflowslo rhecylin-
der block oil hole for lubricatingand to the
oil filte. for frltration
But, at low revolution,the passage to the
oil filter is closed by the check valve tn-
corpo.atedwithin the oil filter cap in order
to maintarn sufficient pressureof oil flow
io the engineinternalcomponents
Namely, when the deltverypressureof the
oil pump becomesless than 0.6 to 08
kg/cm, (8,5 - 114 psi), the checkvalve
closes, and all the quantityof orl from the
oil pump is deliveredto the engineinternal
componentsto maintainthe specifledpree
sure

Specification
OIL FILTER
Filtration type Parhal-flow
Description Elementmaterial Paper
Casecapacity Approx 0.8 liter
( 0 . 8 5U S q t . ,
0.70Imp.qt)
Checkvalveoperatingpressure
0.8- 1.2kg/crn,
( 11 . 4- 1 7 . 0p s i )

Removal
Remove the oil filter retainingbolts, and
remove the oil filter assemblyfrom the
cylinderblock

Disassembly
L Removethe drain plug,and drain the oil.

2 Remove the cartridge gulde, then dis-

assemblethe filter cap, filter element
and the filter case-

3. Removethe check valve from the filter

cap,

Inspection
Fit. 6-10 c}ossSectiotul Wew G0728 partswith the clean-
Washthe disassembled
of Oil Filter ing solvent,
6-6 LUBBICATING SYSTEM- Oil Filter

1
2
3

5
6

a E em9ntsuppoit spnng
I
10
II
12
13

Fig.6'11OilFilter v5515

1 Check the element,and replaceit with
dirty
the ElementKit, if it is excessively
or damaged.
2 Check the filter cap and the case lf
these are distorted or damaged,replace
asnec€ssary.
3 Check the check valve for fitting con'
dition and scoreson the sliding surface.
Replaceif damaged.
Assembly
Follow the disassemblyproceduresin the
reverseorder adherlng the following pre-
cautlons
new gasketonto the cylinder block, and
tightenthe bolts
2 F r l l l h e e n g i n eo i l L r pt o l h e s p e c l f i e d
level
3. Start the engine,and checkfor oil leak
from the oil filter.
Oil Filter ElementRePlacement
1. Removethe drain plug from the filter
case,and drain the engineoil-
2. Loosenthe oil filter cartridgeguide and
removethe filter casewith the cartridge
guide.

I Always teplace the gaskets uPon as-
semblY.
2 Tighten the oil filter cartridgeguide to
specifjedto.que o f 1 . 6m - k g( 1 1 . 5f t - l b )
torque.
Installation
L lnstalt the oil filter assemblywith the
3. Clean the caseand the cartridgeguide,
and install the new element with the
gasket in correct position, and then
tightenthe cart dge guideto 1.6 mkg
(11.5ft-lb) torque
4. Replenish the engine oil and check for
oil leak after operating engine
 COOLING SYSTEM

DESCRIPTION ....... . 7-

T R O U BETS H O O T T N C
.... .. .... 7- 2
WATERPUMP 7- 2
7-2
Removal-. '7- 3
u,rcJJcxrur'
'7- 3
Tncnarfi^n ,? Pahoir
Ac(amhlw

Installation.

THERMOSTAT
Description
Removal. 7-6
'7-
6
lnstallation 7-6

RADIATOR. 7-6
Description
Removal 7-7
Inspection& Repair 7-',7
Installation
 - Descriprion 7 1
COOLINGSYSTEIT4
DESCRIPTION

Fis 7.1 Ensnc CootingSl\km

Y5516

The cooiirg sysiemon the lR or l2R engineis ot a pressure

ibrced-circulation
type msuring
positive coolirg efficiency.

'l'he
constructionof the cooling systemand the circulation
of the cooiant are as srown m
the aboveiliustratton.

Thc a corrugarcd fin type which is comparatively iight,

.radtator .is and has excellent
radiation efficiency

1'he ivater Fump is a direct driven type havrng the four

blades fan for positive cooring
efficiency under excessiveheavy load operation,
and the thernrostatis'of a wax type
uttlized wlthin the coolingsystem.

The coolant is pumpedout from the lower tank of the

radiator by the water pump,and is
forcedty crculared from the cytinder wa s ro the
h",; *;i;;;;" Ju,".,".*"a
provrdedin the ensine. The cootani which "yti"d.,
hasbeen heatedis retu.".J ir," ifr. ,0o". .""*
ot the radiator through the thermostatho,sing, and flows
into the lower tanfio oe cootea
while passingthe radtatortubcsby the air

lf the coolanttemperatureis low, and as.thethermo-stat

is closed,the coolant is pLrmpedout
rro,n,the thermostaLhousing thro'gh tne by-p,sshose.
and is circuratedwithin rne warer
JacKets to warm up the enginequlckly.
12 COOLINGSYSTEM' TroubleShooting,
WaterPump

TROUBLE SHOOTINC

Symptoms & Probable Causes Remedies

1 Overheating
a Lack of coolant
b. Loosefan belt
c OiL soaked or defechve fan belt
d Defectivethermostat
e Waterpump inoperative
f. Cloggedcooling system
g lncorrect lgnition timing
h. Brakesdragging
Replenishand checkfor leak/s
Adlust fan belt tension
Replacefan belt
Replacethermostat
Repairor replacewater pump
Cleanradiatorand waterjackets
Adjust ignitron timing
Adjust brakes

2 Overcooling
a Thermostal defectlve Replacethermostai
b. Extrcmely cold weather Cover radiator

3 Lossof coolant
a. Leaky radiator
b Loose connections or defective hose
c Leaky water pump
d. Loose heater hose connections
or defective hose
e. Leak at cylinder head gasket
f Cracked cylinder head or block
Repair radiator
Tighten connechons or replace lrose
Repar or replace water pump
Tighten connections or replace hose
Tighten bolts or replacegasket
Repalr or replace

4 Noisy cooling system

a Defective water pump bearing Replacebearing assembly
b. Looseor bent fan blades Tighten,repairor replaceblades
c. Defective fan belt Replaceian belt

WATER PUMP

Description
The water pump is of the direct drrvenian
type for stable cooling effect under exces-
sive heavy load operaiion, and consistsof a
fan, pulley, pulley seat, water pump bcar_
ing, shaft serl set, pump rotor and the
pump body. The water pump body is of
aluminum alloy, and is provived wiih the
by-pass port which is connectcd with the
thermostathousjng
housing-
The pump rotor is of a centrifugal type
having six blades, and this type has the Fig 7 2 WaterPunp Section G3203
following advantages; it is compact, the
deliveryquantity rs large,and even thoughthe outlet port is made smaller,the pressurewill
 COOLINGSYSTEIM- WaterPumD 7-3

not increase,therefore,it is quite conlenient to perform the temperatureadjustment.

The water pump bearingis of dual ball bearingswlth grcasesealedtype, and the water seal
methodis of a mechanicalsealtype.

Specification:
Waterpump type Contdfugalwith six blades
Deliveryquantity 120liters(31.7US gals.,26.4Imp. gals)perminute
at 3,500rpm, at dehverypressureof approx. 0.4
kg/cm, (5.?psi)
Watersealmethod Mechanicalseal
Bearmgtype Dual ball beanngswlth greasesealed
Rotationalratio with crankshaft 13toll

't 23
8 I 10 tl

135 t3 14
ll. Pr.te Fiaininq $rR
2.
I 13 PumpreGiningbolt
9_
5, 10

Fig. 7.3 WatetPumpComponents Y5518

Removal 4 Removethe pump retainingbolts, then

removethe water pump assembly-
I Drain the coolant.
Disassembly
2. Remove the radiator inlet and outlet
hosesand rhe by-passhose Disconnecl L Removethe pulley seat with the Water
the heater hose if the car is equipped PumpPulleySeatPuller09235 2001..
with the heater.

3. Removethe fan belt, fan and the fan

Pulley
1-4 COOLINGSYSTEM WaterPump
09235.20011
Fig 74 Pu ey Seat Removal v3t94
2 Remove ihe water pump plate and the
3 Removethe water pump rolor from the
beanng shaft with the Water Pump
Rotor Pullcr 09239 3l0l 1.
0923931011
Fis. 7-5 Rotor Removal V3195
4 Remove the holc snap fing liom the
rotor, and remove the water pump seaI
set.
Fis 7-6 Bea.insRenoval v3196
5 Helt thc purnp body to ?5 - E5'C
(167 - 1i35" F), and remove the water
p!nlp bearing toward the pulley siile
Lrsirrg
the WaterPunlp llearing Remover
& Rcplaccr 09238 40010 and a press
Do not remove the bearmg unless lor
6 Rernove the lloating seat and the gasket
from the pLrmpbody
lnspection & Repair
Washal1the parts with the exceptionof the
water purnp bearing,and check e.rch part
for cracks, wear, corrosion. and othea
damagc
If delectrvc, replace as necessary The
water seai set is advisable1(r be replaccd
when thg waler pump is disassembled
Assembly
I Heat the water punp body to 75 to
E 5 ' C ( 1 6 7 - 1 8 5 ' F ) . a n d p r e s si n t h e
water pump bearing until thc bearing
end is flush with Lhe upper end of thc
pLrmpbody using the Water Punp llcar-
ins Rsmover & Replacer09218 40010
and a press-
23a-400| o
Fis.7-7 Insta ingBelr ng V3197
2- Pressin tne pulley seat onto the bearing
shaft with ihe press
3 Install the gasket and the floating seat
onto the pump body
When nstallingthe floatingseat,insertit
after wethng with water
 COOLINGSYSTEIl/- WaterPumD,Thermostat 75

4. Assemblethe water seal set onto the t h e midway of the fan belt with 10 kg
rotoa. ( 2 2lbs) pressure.

3 . Start the engine after installing, and

check if the cooling system for water
lcak.

THERMOSTAT
Description

Fis. 7-8 l$to ins Pu ey S@t v3198

5. Coat siiiconeoil or engineoil onio the
contacting surface of the floating seat
a n d t h e r h r u s tw d \ h e r .e n d l h e n p r e \ \ i n
the rotor onto the bearingshaft until the
rotor end surface and the bearing shaft
end surface are flush.
At this time, the clearancebetween trrc
rotor and the body should be 0 3 - 0.?
mm (0.012- 0.030").
Fig. 7-10 Themastat Section G1500
The thcrmostat equipped on RT & RH
seriesis of the wax type. and is rnstaleo
wlthin the thermostat housing of the cy-
lnder hcad, which rcstricts the coolant
flow rnto thc radiator Thus, the engme
warm-up period is minimized, and marn-
r a i n \ e n g i n ec ! o n o m i c a o
l p e r l , r i n lge m p e r -
ature. The wax type thermosiat has the
following excellent features

FiS 7-9 Insta ing Rotor I As it is not affectedby water pressure,it

v3199
ensure posrtrveoperation, and water leak
6Install the water pump plate with the is slight when the valve is closed-
new gasketonto the waterpump body.
2 As the water flow resistanceis small on
Installation
the thermostat,the water flow into the
Follow the removal procedures in the radiator is large.
reverseotder adheringthe following des-
cribed precautions- 3- The construction is very durable, and the
life of the thermostat is pfolonged due
1-Alwaysreplacethe gasket. to no valvevibrahon.

2. Adjust ihe fan belt deflectionto 8 - 12 4. It is heat-proof, cold-proof and pressure-

mm (0 3l - 0 47") when depressed at proof-
1'6 COOLINGSYSTEM- Thermostat,Radiator

For the operation of the thermostat, the wax inflates in the wax case according to the
incrcaseof water temperature, and tends to push out the shaft through the rubber seal,but
as the shaft is fixed, the wax casewill be pushed dcwn relatively thereby oPening the water
valve. The wax type thermostat will rest in the closed conditlon if the temperature sensjng
unit becomesinoperative

Specification :
Thermostattype Wax
Sta s to open at 80.5- 83.5"C(177- 1 8 2 " F ) 2 R
'l
at 73.5 - 6.5'C (164- 1 7 0 F
" ) 12R
Fulleyopeds at 95'C (203"F) 2R a t 8 5 " C( 1 8 5 " F -) l 2 R
Vatvelift E mm (0.315")

Remova.l
Remove the water outlet after draining
coolant and then take out the thermostat

lnspection
t Check the themostat valve for closed
condition at normal temperature Re-
place lhe thermostarif lhe valve is
openedor improperlyseated.
Fis. 7 l1 CheckinsThermostat
2. Inspect the opening operation of the
thermostatvalveas follows.
a. Prepare hot water of 95 - 100'C
(2O3 - 2l2F), and submergethe
themostat over4 minutes.
b. Hold the thermostat with Plien and
check the valve opening tftvel be-
tween the valve and the flange using
a suitablegaugeof 40 mm (0 16")
asshowntn figure7_ll.
Gsude
4 .d m m ( 0 . 1 6 ' )
10134
If the gauge can be inserted or the
valve oPening travel is morc than
4 . 0 m m ( 0 . 1 b " 1 . t h e I h e r m o s l d ti s
satrsfactory-
c Also submerge the thermostat mto
hot water of 78"C (172"F) over 4
minutes. If the valve does not oPen'
the therrnostat is satisfactory

RADIATOR
Description
Th! radiator is of the corrugatealfin and tube type designedwith largecoolingareaand
Slhobthpassages for high efficiencv
, As the radiator is of the prcssure type, the radEior cap is provided with relief valves to
tain the pressureof approximately0 3 kg/cm'1(4 psi) abovethe atmosphericpressure
coolingsystem.
pressurewithin the radiatol lncreasesabove 03 kg/cm1 (4 Psi)'the Pressure
lvg allows the prcssureto ercapethrough the over-flowpipe When the pressurc
than the atmosphericpressure,and as the coolant is cooled, the vacuum
;sifhe outsideair to enter preventingthe formation of vacuumwithin the
 COOLINGSYSTEM- Radiator 1 l

Vacuum Re er VrrveOpefaton Press!,e Re af Valve Operalon

Fu..712 OassSectiotLall:iewoI Rddiutot Cap Gllt0,GlIIl

C)nthe pressuretype radiatof, thc coolantq,ill not borl evenLhoughthe coohnt temferature
reaches 100"C'(212'li). lhereibr€, to mainlairl this cxcellent cooling efficrency, rr rs
essentiillthai the rcltcf valvesoperlte properly

Specification:
Tvp" frcssllre cool]ng
Corctype Llorrugatcdlin & tlrbe
Vr lvc openi g presslrre 0.5 ks/cm': ( 7 psi) lR
0 9 k g / c r n z( 1 3 p s i ) l 2 R

Removal ncath the vehicle

On RT & RN serics
I Drain thc coolant, and remove the raor Inspection& Repair
atorirlet rnd outleihoscs
I Inspect thc radiator ior leaksfrom rne
upfcr tank, lower tank and the core.
2 Removcthe radiatorgille
Repajr or replace if defective

3 Removc the rrdiator retaining bolts,

Lhen remove the radiator
On RH & RY series
I Jack up the vchicie. and sLrpportwith
strnds
2 Drain thc coolant, and remove thc r.ldi
ator inlct and the outlet iroses
3 Re ove thc radiator bracerod
.1 Remo\c rh. .ng nr c.t
guide
5 Remove lhe rediator retaining bolLs.
t Jc 1 r - m o \ c l h c r - d i r t o f f - o m r i n d c r -
2 Check thc radiator co.e fin for clogging
the irrr passages
If ncccssary,repair thc frns
3 ll lhe clog of the radiatorcote exceeds
20 percentofthe entire area.rephce the
radrxtorassembly
4 Check thc radiator cap press re rchei
valv€and the vacuumreliefvalvesprings
for proper tensions.and also check the
packing for damagc Rellace ;f neces-
.o\(f air sary
5 Check the radiator inlet and the outlet
hosesibr cricks or othcr delecis R.
place as ncccssary
 CHARCING SYSTEM
DBSCRIPTION 8-1
TROUBLE SHOOTING 8-2
A L T E R N A T O RR&E G U L A T O R . , . 8- 3
a^ncffl,.ti^n
3
Operation. . 8- 4
Inspectionin Car 8- 5

8-?
R e m o v a l. , 8-7
v,trcJrq,,'ury
8- '7
Ihcnp.ri^n -{, P o^"i.
8-9
Bearing . _. 8-9
8,9
8-10
Brush& brushholder. 8-10
8-11
8 - 1I
A l t e r n a t oOr u t p u T
t est .. .... 8,13
Installation. 8-13

ALTERNATOR REGULATOR,.,,,. 8-13

Removal,. . 8-13
ElectricalAdjustment 8-13
Voltagerelay 8 -l 3
Voltageregulator. 8 - t4
RegulatorCircutt Test 8-14
Inspection& MechanicalAdjustment. 8-15
Voltagerelay 8-15
Voltageregulator 8-16
lnstallation. 8-17
MEMORANDUM 8-18
 CHARGINGSYSTEM- DescriDtion 8-1
DESCRIPTION

ST

Fis. 8 I CharyinsSrstem WiringDiapam

c3813
rs.toadequately charge the batterywhichis the
el€ctrrcpowerto otherelectrical equipment in
reo.
o r a n d l h ea l t e r n a l or re g u l a l oar .n d t h e w i r i n g
t. I he properoperalion of I hecharging \yslem
rturesln comparisionwith the conventional
gcneraror. DC

I lt providesa very high output at cruishg

speedsand arsoat lower enginerevorution.
2. Sinceihe alternator usesthesiliconer
perarureciueto rhe recrificatjon there is no increaseof rem-
sDr.u,::::fjt ]:ttll':"1ion,
the Dc
rine or the alternato.is ;;;;";'#;::.:"::ll'ed.!t'ith senerator.Also as the slip
ecrrrrcarron.LhebrurhIii,eic Iongefin the allerndtor.
J . T h e n a \ i m u mr e v o j u t t oonf i h e
alternalol
oncol fhe ball bearin8s. centrifugal force(
condrttons.Therefore.the allernalor
can
generator, and the rotationalratio to rne e
reasons,the alternatorcan be designed
coml
4. As the alternatorhasa selflimitins jn Ijrnitins the.output'
cl
the diodesfor rectiri'cat;;, ;;;;.;';i1'::t-'listic and bv utilizins
controlsuchasa clrt-outrelayanda cunent
arenot requiredfor the alternator limiter

The functioning of the alternatorrealda

in the charsinssvstemis to resulate
nator output vottageto ;;;;;;;.:''"ttt the alter-
 CHARGINGSYSTEM- TroubleShooting

TROUBLE SHOOTING

Symptoms & ProbableCauses Remedies

1. Battery discharges
a. Looseor worn fan belt Adjust or replaceihn belt
b. Shofiedor openedstatorcoil Replace stator
c Openedrotor coil Replace rotor
d Poor contactbetweenbrushesand slip rings Cleanor replacebrushes
c Defectiverectifier/s Replacerectiflcr/s
f Regulatorvoltageadjustedtoo low Adjust regulator
g, Burntor poorcontactofregulator Dresspointsol replaceregulator
low speedpoints
h. MeltedregulatorhighsPeed points Replace
i. Lack or msufficientelectrolyte Rcplenishwith distilledwater or
adjustspecificgravity
J Shortedbaticry plates Replacebattery
k Poor connectionof battery terminals Cleanand tightenterminals
l Openedor poor conneciionof vr'iringbetween Repairor replace wiring
ignition switchand regulator"lG" terminrl
m , Burnt or poor contactof fuse Replaccfuseor cleanfuseholder
Openedor poor connectionof wiring between Repairor replacewring
regulator"F" temlnal and alternator"F'lter-
minal
o. Excessivecunent load Recheckcurrentdraw

2 Battery over charges

a. Poor contactofregulator"E'terminal Repaircontact
b. Opened pressurecoil of voltage regulator Replaceregulator
c Melted reglrlator low speedpoints Replacere$rlator
d Poor contactof regulatorhigh speedpoints Dresspoints
e Regulator voltage adjusted too high Adjust regulator
f Openedor poor connectionof wiring bstwccn Repairor replacewi ng
alternator"N" terminaland regulator"N"ter-
minal

3. Dqfective actuation of chargewarning light

a. Loose fan belt Adjust fan belt tension
b. Loose wiring connections Tighten or repair connections
c. Defective regulator operation Adjust or replaceregulator

4. Alternator noisy
a. Defective bearing/s Replacebearing/s
b. Malfunction of rectifier/s Replacerectifier/s
c. Grounded or shoried stator coil Replacestator
 CHABGINGSYSTEM- Altemator & R€gulator 83

ALTERNATOR& REGULATOR

Construction

I'ig. 8-2 CrossSetnonul Vietr oj A ttcrntl kr Y5l t8

'IIe
componentsand the spccificationsof re altcmalor for RI and Rll scriesere sligh y
dillercnt. but the consiructio and operatlonafe sarne.
Thc rnaiu cotnponcntsof the alternatorrre conposcd of ihe rotor. !tator, rectifiers
ano re
fiarres.
Thc rotor consjstsof two six,fingerecj. cup-shapcdhalvcs,which when assernblcd becomcI
12-polerotor
A rotor coil wound in the shapcol a ctoughnutts connccrecl to the 1wo slip rjngswhichrrc
actuated by an cxcitiig cLrrfentlionr thc two brushes.rncl the rotor js mounted
bearingslocatcdat thc end liirnes. alld revolvcswithilr rhe stetor
The stator is composedof a ]argenunber of windingsasscnrblcd on the insrdcof a lami
nated core thrt is artachcdto thc fralllcs The statot coil is ofa ihrccphasc,,y,,
type. An
arrcrn ng cu[ent generatedat the sLatorcoi] is convcrteclto a dircct current by rhe six
fectifierswhich arc mountc.l at thc rectifierholdcls
The rectificr is of I siliconediode which has a verj/ high resistance to a llow of curent tn
one dircction. but it h s a vcry low resisialce in the othcr clirechon. l.herefore,wltn
a
p'oper polrriLy, the low resistenceallows the cqrrent kr flow liom thc
staror coil ro thc
battcry. .rnd the high resist.lnce prcvcnlsa reversecurfent iiom thc b.1ti€ry.Morco\,er,ihe
st tor coil has a self-]it)ritiug
chafactcrisricin limiting ihe curenL flow irl it\ coil to I p.ir_ser
valuc cvcn lhe tevoluriorl i]rcrc sesexceeclingly l,'or these rcasons,il current contr-ol
such as
e cut out relly rDd 2 current lijnitel arc Dot rcquiredtbr the alternirtor
The .rlrefnalorrcgulator is cornposedof thc voltagercgulatorund the voltege
fet,ly Thc
function of thc voltageregulatorin thc chargirlgsyste]nis to regulatethe gcniaLiug
vortage
ol thc sratorcoil io a pre sct valLlchy controllingthe excitlngcurrcnt oi thc rotof cort
8-4 CHARGINGSYSTEM- Alternator& Regulator

The voltage relay 1s provided to prevent the flickering of the headlights and the irregular
vibrationof ihe ammeterneedlewhen the enginets operatedat idle rcvoluhon'

Specification:
RT series Light Truck
Voltage l2volts same
Max output curent 40 amperes 30 amperes
Ground Negative same
Directionof revolution Clockwiseas seen
from pulley
Stator coil connection Three-phase "Y" tYPe same
Rectrfyingmethod All waverectifiedby
six diodes
Pulleyraiio 20 169
No load characteristicat 700- 900lpm at 800- l000 rpm at
normal temPerature 14 volts,zeroampere l4 volts,zerc amPere
Output chamctedstic at Lessthan3500rpm at Lessthan 4000 rpm at
normal temPemture 14 volts,40 r percs 14volts,30 amperes.

Operauon
When the rgnitron switch is closed, the current flows from the batlery to the voltage relay
points "P0;' and "P1", through the charge warning light, thercfore, the charge warning
light glows At the same time, the exciting current from the battery llows to the rotor coll
ihrough the fuse for the turn signal,voltageregulatorpoints"PL1", "PLo", brushesand the
slip rings,causingihe rotor to magnitlze
ln these conditions, as the rotor is rotated, the three_phasealternating cur'ent is generated
within the stator coil. and the alternating current is fully rectified lnto direct cllrrent by the
six rectifiers This dlrect current voltageis actuatedbetweenthe "B" terminaland the "E"
pull-in
terminal. Also the output voltage of the stator coil neutral Point becomeshlgher' the
forie of rhe pressurecoil in the voltage relay lncreases! and the point "P0" contactsthe
point "P2" side,resultingthe chargewarninglight to go out
These points are closedwhen the neutral point voltagereachesto 4 5-5'8 volts but the
points are closed while the engine is operated normally
lf the alternator olltput voltage becomeshrgher than the voltage in the battery, the output
current starts flowing to the battery ot to the load When the output voltageincreases
further, the pull-in force of the voltage coil in the voltage reglllator increases Duetothis'
the point "PLo" opens from the low speedpoint "PLl" As the pornt opens,the exclhng
curr;nt to the rotor coil has to pass the control res$tance "Rf', and decreases, resuliingto
reduce the output voltage at "B" terminal.
 CHARGINGSYSTEM- Altemator & Regulator 8,5

Ch'rg' wErhing Light

ilghition Sw'tch

Aliern.tor R.ed;td

Fig. 8.J Ahematot GenerunryCircuit Gt553

Under light load at high revolution,the point "PLo" contacrsthe high speedpoint..pL2",
and the exciting curent is further decreasedto control the "B" terminal voltage to the
specifiedvoltage.
As the output voltageis deqeased,the pulfin force of the voltagecoil decreases,and the
point "PLO" returns to the point "PLl". Thus, the point "PLO" repeatsthe intermittent
movementto control the alternatoroutput voltage,

Inrpection In Car
L Precautionfor operation with the alter-
naIor.
a. Take carewhenconnecting any equip-
ment onto the alternatot,as the alter-
nator output "B" terminalis connect-
ed to the battery at all times,and if
the ignition switch closes,the voltage
of the "F" terminalis the same.
b. Always pay attention to the polarity
of the battery, not to connectit onto
the alternatoroppositely.
If connect€doppositely,largecurent
flows from the battery to the alter-
nator so that the rectifiersare dam-
aged,and sometimesthe flasher unit
will burn
c. For quick chargingthe battery, make
sure to disconnect the battery to
sta er cable.
If not, the rectifier will be damaged.
d. Never rotate the engineat high speed
with the "B" terminal lead wre dis-
connecteo.
If disconnected,the voltageregulator
cannot operateand the voltageof the
8.6 CHARGINGSYSTE| - Alternator& Regulator
"N" terminal inueasesabnormallyso
that the voltagerelay burns
lf it is necessaryto oPen the "B"
tiirmrnal, disconnect lhe connector
plug for the "F" termtnalat the same
time.
e. For adjustmentof the regulator,maKe
sureto disconnectthe connectorplug
If not, the Points may be melted and
the fusemay be bumt
f, Take care not to wet the alternator
rectifier diodes with water or steam
when washingthe car
g. Never connect a condenseronto the
"F'terminal.
2. Prerheck ol this test.
a Looseinstallationof the altemator'
b. Fan belt tension.
c. Burnt-outfusein the fuseblock
d. Chargingsystemwrrlngs.
J. Disconnect the "8" termlnalleadwire
from the alternator, and connect tne
regulatortester.
Fig. 84 TestCncuit c0t56
4. Check the voltageand amperageof the
altemator regulatol at normal operating
tempemture.
Start the engineand increasethe engine
revolution gradually until the engine
revolution reachesfrom 600-2,000 rPm
Read the voltagewhich shouldbe 13 E'
l a 8 \ r l t \ , a n d t h e c u f r ( n l s h o u l db e l e \ s
than 10 amperes,
A current flow considerably higher than
lhdr spe,'ilrea d b o v e i n J i c a l e sl h d t t h e
battery is discharged or the baltery
plates are shorted
I f r h e \ o l l m e l e r n e e d l cv i b r a l e ' .i t I n d i
cates that the regulator points are rough
o r i m p r u p c cr o n n e c t i o on f " f " l e t m i n a l
If the voltmeter indtcatesmorc than that
specified above, it is the indicahon of
the following sYmPtoms.
a. Voltage rcgulator low speedpomt gap
too wide.
b. Voltage regulator low speed points
melted or high Pressurecontact
c Voltage regulator high speedpornt gap
rs too wide
al.Poor coniact of voltage regulator high
speedpoint
e. Voltage regrlator or relay coil circuit
opened.
f Poor contact olvoltage relay points
5 Stop the engine, and tum the ignition
switch to flrst posltion to the rlght
Check the voltagebetweenthe "F" and
' ' t ' t e r m i n a hu ' i n g I h e I e g u l a t olre s t e -
-Fl& 8-J Aecking lloltagebetueen "F" & "E"
G0162
 CHABGINGSYSTEM- Alfemator a-7
T h e r o l t a g es h o u l db e l 2 v o l t , l r ( h <
It is recommended to djscharge
reading of the voltmetea is zero voltagc the
Darreryto perform the load test
or low voltagethan the specifiedvoltase.
it indicatesthe following symptoms.

a Openedor poor contactof fuse,regu

lator"IG" terminalwiaeor "F', termi
nal wire,
ALTERNATOR
b. Regulatorhigh speedpoints melted
Removal
6. Disconnectthe tegulatorconnectorplug,
L Disconnectthe batteay to ground
and check the resistancebetweentire caotc
rrom the battery terminal.
regulator"IG,' and ,.F' terminalswrrn
a crcutt tester,
2 Disconnect the wirings from the alterna-
Thereshouldbe no resistance_
tor
I f L h e r ei s a n y r e s i s t a n ci el ,i n d i . a r ( \
that the voitageregulatorlow speed 3. Rimoverne Ian D(ll ddjr,stjne
porntscontactpoorly. bcr botl
and rhe fan bett

-_l"L 4 Remove the altemator retainjng

borr,
a , n cr e m o v et h e a l l c j n a t o dr , \ e m b J 'f r o m
[ ]-' tne alternatorbracket.

Disassembly
rr*e$r L R e m o t er h e l h r r e d r i v ec n d t r cm e r e t a r n _
ing bolts
t-
: r r r s ( a v . r e \0 \ c l I n l o t h c n o t c h e ,
Jn
Fic. 8-6 the dnve cnd frdme. dnd wilh
?eckinT Renstuncebedeeen nry rhe
s.rewdriter Io \eparate \a,lh drive
GO]6J end
rmmt from the stator
7. Perform the load test tn the following
manner
Make the sameconnectionas shown!r
figure 8-4, and start the engine,anil run
it at approximately 1,100rpm wtth all
liglts and accessories turnedon
The ammetershouldindicatemore than
35 ampereson the RT sedes,analmorc
than 25 ampereson the Light Truck
serieswith the voltage of 13.5 to 14.5
volts.
than the specifiedamperage,the rectj
fieror statorcoil is shorteJor opened,
l f r h eb a l r e r yi s r n f u l l c h a r g esdr a t ea n d
the amperagereadingis lessthan rc
specrfiedamperage.
Fi8. 8.7 Dd"e End Fme Remoyol v2195
8.8 CHARGINGSYSTEM- Alternator

3 Removethe pulley retaining nlrt, and 4 Remove the rotor from the drive end
remove the Pulley, fan, key and the frame using a pressas shown rn figure
spacecollar. E-9

2 a Feh ri.s cover

3
1 o B e a r i n 9 r e tnae rP l a t €
5 17 R e c r i f ' e rh o l d e r
6 la R&nfrer end rrame

Fig. 8-8 Altemirot Componentton RH Senes v6841

o92a6-460I

Fig. 8-9 Rotor Removol 00038 Fit 8-10Re BeanngRemoval v1139

5. Removethe rear bearingfrom the rotor screws,and removethe felt cover(except

shaft with the tnjection Pump Spline RT series),bearingretainer,front beaf-
ShaftPuller092iJ6-4601 1 ing. felt nng coverand the felt ring from
the driveend frame.
6. Remove the bearing retainer retaining

7. Remove the rectifier holdcr retainirts
nuts, "B" terminal retainingnut and trc
brush holder retaining scrcws, then rs,
move the stator with the rectifier holders
from the rectifier end frame.
Fig. I 1I Stotor with Re.tifiet Hot jer
Removat 800J9
8 Removethe brush holder assemblyfuom
the stator coil "N" terminal in accord_
ance with the following order using a
small screwdriver_
- Alternator
CHARGINGSYSTEIVI 8.9
Inspection & Repair
Bearing
Check the be!rings for scores.roughness.
abnormalnoiseor damage
If ( efcctive.replacethe bearjng/s
Rotor
I Clre.k rhe rolor...1 t,f olil Jf \..u.1
circuit
Conn€ct a circuit rester lrom rhe slrp
ring to the other ring.
The coil resistanceshould be 4 I -' 4.3
ohn1s.
l f t l r . r , r . , | l l ( o r I o r c . i \ ' : n J L .r l . (
L ' u iol r . l o r i r g 5 l r a \ e . . l r u r lo J g f o u n J .
and considcrablyhigher rcsistancethan
I - \ p r , i . - . r b u ! \ r 1 , l . c . t i , . r n, J r c n i d
cotl or connectiondelect
Il I . lc.l ,huw, thrt h. ro.or cuil i\
\ h u r t c du r o n e n e d .r n d t l - e . l i L ,f l 1 g . J r r
d . J i . . r \ r . l l r i r o t u f r , . L m b l ) \ l l u u . db .

a Pull out the brush lead terminal froxr

the holder by slidingthe terminal

b Removcone te ninal insulator

c Remove the stator coil ..N" tcrminat

irom the holder by sljding out rhe
"N" termrnal
When removing the brush holder as
sembly, do not remove it by cLtttiirA
the "N" termmal lead or melting the
solder. Fig.8 1J testinsRotorCoitIot Open&
Shott Citcuit V2tg6

Fit. d 12 Brush Hohler Renoval R0040 f-ig. ti 11 1'.\!ugRoh, (i)itlttt;ntt l'1r/

8 .t 0 CHARGINGSYSTEM- Alternator

2. Conncct the tester from the slip rmg to the rectifier from heating, and melt the
the rotor ro rotor shaft, and check the solderedportions using an elect c sol-
r n s u l d l l o nb r r $ e e n l h e m d \ , n o $ n i n dering iron of 100-200 -watts for 2
figure 8-14
If the testerneedlemoves,the rotor coll
or slip rings are defective-
The rotor assemblyshouldbe replaced

Stator
1 Checkthe stator coil for insulation.
Connect the tester between the stato.
coil lead and the stator core.
lf the testerneedlemoves,the coil insu-
lation is defective
Repair the coil or replace the stator
assembly. Fis. &17 TestinsStatot CoiIfor Open Ci.tuit
vll15

Check the four leads of the stator coll

for conductancebetweenthem.
lf the tester needledoes not move, the
stator coil is opened, and must be

Brrrsh & Brush Holder

L Check the brush for crack and wear
If the brush is worn beyond 8 5mm
(0 335"), replacethe brushes
The brush should slide smoothly.
Ftg-8 15 TestinsStatot CoilJbr Insulation
Boul
2. Check the stator coll for open circuit
In order to perform this test, the stator
corl leadsmust be disconnected from the
rechfier leads.
To disconnectthe leads,hold the recti-
fier lead with a nose phe.s to prevent

Fig.8-18 Btush Lentth v1143

2 If replacing the brush, install the new

brush and the brush sPring into the
brushholder, then solderthe brush lead
wirc keepingthe protrudedbrushlength
t o 1 3m m ( 0 . 5 1 " )
After solderingthe brush lead,check if
G3364 the brushmovementis smooth,
FiE.8-lo MelrngSodel

{0.51'1
Fig. 8.19 ReplacingBntsh
Rectifier
Good or defective rectifier is classified by
tne aesistancevalue between the rectifrer
holder and the rectifier lead.
To perform thls test, the rectifier holder
must be separatedfrom the stator,
Refer to paragraph 2 of the Stator in the
Inspection & Repair on page g-10.
I Rectifier holder positive side.
Connect the tester (+) lead onto tlre
rectifier holdff and the (_) lead onto the
rectifier lead as shown in figure g_20,
and check the resrstance.
Good rectifier wilt indrcateno resistanc.,
and if it indtcatesa high resistance,
rectifier is opened.
Next, tum the polarity of the testerand
check again If the iester needlemoves
in either polarity, the rectifier is shorted
If the needle does not move in either
polarity, the rectifrer is opened, and
Fis. 8'20 Rectifie, Test G0172
CHARGINGSYSTEM- Altemator 8.1I
should be replaced wrth the holder
assembly,
2 Rectifier holder negativeside.
Connect the tester ( ) lead onto the
rectitier holder and (+) lead onto the
rectiller lead as shown in figure g_21,
and check the resstance.
Good reciifter will indtcate no resistance
and if it indicates hich .".ir;;;;;,-;;
rectifie. $ opgned
Next, turn the polarity of the tester.and
i
v02t6 check again. If the needleof the tester
m o ! e \ i n e j t h e rp o l a f l t y .l h e r e c t i f l e ri s
shorted
If the needle does not move in either
polarity, the rectifier is openeal, and
should be replaced.
If any one of I he negarive \ide reLtifier rs
found defective, always replace the nega
trve side recttfierswith thc holder assenF
oty.
the
Fig. 8.2 I Rectilier Test G0r73
Assembly
I Installthe statorcoil "N" terminalonto
the brush holder m the following man-
ner,
a lnsert the stator coii..N" terminal
onto the brushholder
b Installthe terminalinsulator.
c. Insert the brush terminal onto the
holderat correctposition.
412 C H A B GI N GS Y S T E M l t e r n a t o r

itlt rnrg (6) (cxccpt on Rl serics)and

Lhe fch flng cover (7) (except on RT
scries)with thrce retrining screws
When insl.tllingthe felt ring cover (7).
frcc the convcx surfaccof the feli ring
covcrtoward the roror sidc,

5 Pxck multipLrrlosegrceseirlto the reaf

bearing.and press it in onLo the rotor
shaft of the \lip I ing side

6 Install the drive end frame onto the

Fis 8 22 AtscnhLinsBrushHalder 84043 rotor lhaft bexring throLlgh the space
colLar with ihc TransmissionOil Plug
I Instxll thc rnslrlrLorwrshcrs to the re- 0 9 3 2 5 - l 2 0 1 0r n d a p r c s s -
ir r "U .tr,.fu.,rr\.,r rilrrl
holLler.arxl irrstall tltc slirior wilh the
rcctilier iroldcrs onlo lhe rcctifrcr e d
Iriilllc
InsL ll thc "B' ter))iriLl insLrhtor.Lhen o9325-
t i g t e nl h c r c t i r i n i n ng u l s

3 I n s t a l lr l r cb r u s hh o l ( l c ro n t o t h c r e c l L l i c r
h o l d e r st h f { r u g ht h e i n s u l t i o n p l i r t er n d

The brLrshholderretrinr g bolts mLrstbc

t i g h r c n c (r lh r o g h L h ei n s rh i o r s
Fts. 8 24 lrsta ins Dtirc [nd Fnme BAUS
I I r . , . 1r ' . 'r i'l: rli ,-a t.. ir. ||
"
7 Press in rhc brushesrgailrsl the brush
c o v € f( 3 ) o n t o t h c d ri v e. n r f r a m e( 1 ) s o
tri,r'.,\'.r'.. ,Il.r-f l||l
springtcnsioninLothc brushholder
t'
Noxl, mserLir wrrc thfough the lccess
co!cr will lrcc towud the pulley sidc
lrolc in the reciificr end liame. rnd rlso
Plck rrLrllipurposcgrcescinto lhe bcrr-
into the hole frovi.led ln rhe brush
ing (21),and instrLlrhc bcafrrg
l)oldcr to prcvent thc brushesfrorn fall
Nert- insrall ihe bc.rring retriner (5),
rng

3 2

o O

oos
qor,q.q
lis u 23 Dnv End Fruttetssenblr I'k. 8-25 Insta ins Witc VO2lE
 CHARGINGSYSTEM. AlternatorResulator
With the brushespositioned as above,
assemblethe drive end frame onto the
rectifier end framc, and tighten them
with the threeretarningbolts
8 lnstall the spacecollar,key, fan and the
pulley onto the rotor shaft, and insrau
the retainingnut
Alternator Output Test
Perlorm the output test in accordancewtth
the circult shown in the following illustra-
tron,
Fig.8-26 Ouput Te Citcuit Ysl20
1 Turn on the switch "S1" only, then
lncreasethe alternator revolutlon grad-
ually with a variablemotor until the
voltage rcading rcaches 14 volts, and
read the alternator revolutlon at that
time. which shouldbe ?00 - 1000rprn.
2 Tum on the swtch "S1", and "S2"
frirther holding the output voltageat 14
volts with a vaaiableresistance, increase
the altemator revolution to less than
3,500rpm for RT series, andto lessthan
4,000 rpm for RH series,and read the
ammeterat that time,
The ammetershouldbe 40 ampereson
RT series,and on RH seriesthrs should
be 30 amperes.
Installation
Follow the removal procedures in the
Ieverse order Adjust the fan belt deflec,
8-13
t i o n t o 8 - 1 3 m m ( 0 . 3 1t o 0 5 1 ) w r t ht h e
ihn belt pushedwith l0 kg (22 lbs)
ALTERNATOR REGULATOR
Removal
I Disconnectthe batteryto groundcable
lrom thebatteryterminal.
2. Disconnectthe regulator wiring harness
connectorplug,
3 Removethe regulatorretainrngbolts,
andremovetheregulator
assembly
Electrical Adjustment
lf the alternatorregulatordoesnot actuate
properlyin accordance wrth the electrical
adjustment,check the resistance of tnc
regulator circuits
If defective,repairthe defectiveporiion,
and repeat the electricaladjustmentafter
performjngthe mechanicaladjustment.
Alwaysuse a fully charged batteryto per-
form the electricaladjustment
Voltage Relay
Make the test circuit as shown jn figure
8-2',7
.
Operate the variable motor, and turn on
the switch "S"
Next, rncreasethe alternatorrevolution
gradually,and read the voltagewhen the
test lamp goesout-
nE
Fig.8-27 vottageRelayTestCucuir G0176
8 -l 4 CHARGINGSYSTEI\4- AlternatorRegulator

The voltagc relay operatingvoltrge should

be45.'58volts.
If the volt.rgeis not within thc specilied
voltage,adjust it by bendingthc adiusling
erm of the voltagerclay
Refcr to figlrre 8-30

Voltage Regulator
Make thc tcst circLlit as shown in figure 'L"
term'n6l lermina "8"
E-18
Operate the variable motor, and lurn on
the switch "S" Check ihe voltage and Fis 8'29 ResulatarWinngH.lmess
amperageby varying thc alternatol revolu- CotnectorPlug G3456
tion gradually at the time when the anr
If thcrc is any rcsistancc.the contacl of
mcter needlercgistersmaximum
the roltage regulaior points "PLl" and
lncrcasethe ahcrnatoffevoluiion,and rcad
the voltage et the iime when thc ammeter "PL0" is poor
P r c . .r l , ' qn l r r - I r l u f i , , r l h \ o l r r g e
needleregistcrsone helf of maximum arn
peragereadrng regulator,and checkthe resistirnce
Also increascthe revolution reaches3,000 Thc resistance shouldbe about 10 ohms-
rpnl. and read the voltage. lf the resistance is considerably higher
Jltigc \hould Dc wiil,in
I h c r e g L r l d t r n\ g than ihe specifiedresistancevalue,thc
13 8-14 8 volts when the ameter ncedle control resistor(Rf) rs defective.
registelsal one-halfof maximum amperage,
r n d J l \ o w h c n l h ( d l t e f n i t t ofrt \ o l u t i o n i 5 2- Connect the circuit tester between the
ar 3-000 rpln "L" and "8" terminals
lf the regulatjngvoltage is nor within thc The resistance shouldbe ze.o-
specificd voltage, adjust it by bendinethe Il thcrc is any rcsistlncc,the contact of
adjusting arm of the voLtage regulittor. thc voliagc rclay points "Pl" and "P0"
Refer to figure E-31.
Prcssdown the armatureof the regulaior
rchy, xnd checkthe resistance
The .esistanceshould be about 100

li the rcsistrnccis considerablyhigher

t'. 100 olrm\. tf. \ol . _e c, i i.

I
If thc rcsisianceis extrenlelvlorverthan
thc abole. the \'olt ge relay points"Pl "
and "P0" are nlelted or thc voltagecoil
is shortcd

Fig.8-28 vohaseRegulatorTestCircuit GAl77 l Clonncctthc circuit iester between thc

"N" and "E" terminals
Thc resisienceshould be about 23 ohlns
Regulator Circuit Test ll rlre r€sistanceis considerablyhigher
I- Connect the clrcuil tester between thc than 23 o|rni. the voltage relay coil is
"lG" and "F" tcrnlinals
should bc zcro
The resistance If ihe resistanceis extremcly lowcr than
 CHARGINGSYSTEM- AlternatorReeulator 8,15

the above. thc voltage relay coir rs

snorteo,

4. Connect the circuit tester betwccn the

"L" and "8" tcrrninals,and ptcssdolvn
thc armature of the voltagc re1ay,then
check the resistance.
Thc resistance shouldbe zero
If there is any resistarce,the contact of
ihe voltage relay points "P0" and "P2"

5 Connect ihe circuit tesier between rne

Ftg. 8-30 Nomenchtureof VoltaseRetor GAl75
"B" and "E" terminals
The resistance shouldbe infinite.
If there is any resistancc the voltdgc
relay points "P0" and "P2" are melted
Pressthe armature of thc voltagerelay,
and check the resistance
The resistance should be about 100
ohms
If the resistancels considerablyhigher
than 100 ohms, the volttge coil ts

Il ihe resistanceis extremely lower than

the abovc.the voltag€coil is shorted
Fis. tl 31 Notuenctututeof YaltageResulLtot
6 Conneci ihe circuit tester between the G0174
"F" and "E" terminals q J r e rJ r i , , r r p t h ,
t o n r , , l v J \ ' ,t h c n t h u r -
Thc resisLance shouldbe infinite oughly with cleaningsolvent.
If there is any resistance,the voltage If any of the points is burnt or pitted
regulator points "PLO" and "PL2" a.e cxcessively, replice Lheregulatorasscmbly_
meltcd.
Pressthe armature of the voltage regula- Yolrage Relay
ior, and checkthe resistance.
I Pressdown tbe armatute, and check the
The resistanccshouldbe zcro
If there is any resistance,the coniact of
the regulator pojnts "PLo" and "PL2"
rs poor

Inspection & Mechanical Adjustment

This mechaniceladjustmentdescribedhere
should be performed when the specified
values are not obtained in ihe electrical
adjustment.
Drty contact points shouldbe dressedwirn
a suiiable paper or a suitablefine emery
cloth Fig. 8-32 CheckinsSpnngDellection V2198
GAt80
 8.16 CHARGINGSYSTEM- AltematorRegulator

contaci springdellectionwith the leeLer This point gap sltould b c 0 2 5 t o 0 . 1 5

gaLrgc. n n r ( 0 0 1 0- 0 0 1 8 " )
This dcfleciiorl shouid be 0l0 to 0 45 If necessrry,rdjust thc g a p b y b c n d i n g
nlm(0 008 - 0 018") Lhe high spccd porlt h o l d c r " B " a s
ll nccess.rry.adjust it by bending tlre shorvn in figurc 8-35
point holder "A".
3 Pressthc rrmltlrre, and check the con-
I Check the point gap wlth the fcclcr trct spring deflection wiih the fcclcr
gruge gauge Fi-q 8-36
Thrs point gap should be 0.'+to 1 I lnnr This dcflectron should be 0 2^-0 6 mr!
( 0 o r 6 - 0 . 0 4 7' ) (0.008- 0.024")
L . . - y . JtJ lrlc g"D b) hcrd,nr
thc point holdcr "B .

La4l L"r.E

Fis 8-35 Ch?ckins Point GaP

Fis 8'33 Aeckins Point Cap VI185

GAB]

Voltnge Regulator
I Check thc .rrmaturcgap with tlre feeler
gxuge
This point gap should be 0 6 to 0 u mnr
- 0 032")
(0.01,1
lf nccess|ry.adjlrst the gap by bcnding
thc low spccdpoint holder "A"

I ltig I 16 Chet:king v3105

c0t83

GdP
ns. 8 34 Che.kinsAmrcturc vl1u6
I Clheck thc foirr gaf wrth the lcclcr
v2199
 CHARGINGSYSTE|- AllematorRegulator a.17

4. Pressthe armature,and check the angle Installation

gap with the feelergauge.
Follow the removal procedures in the
This gap should be more than 0.2 mm revelseordel
(0.008").
If not, replacethe regulatorassembly.
 STARTING SYSTEM
DESCRIPTION

TROUBLESHOOTING

STARTER-
9-3
Construction . .
Operation......
R e m o v a_l ,. ,
9- 6
Disassembly . .. .
Inspect&
i oR
n e p a r .. . . . ... .... . Z-i
Armature, ,
F r e t d c o i.l. ... 9;
M a g n e t si cw i t c h
..._.. 9 _E
Brushholder & brush g 9
S t a r t ecrl u t c h . . _ . . . .
910
Assembly..
.. .9_lo
T e s t i nAg f t e rA s s e m b l y. . . . . . .
j n s r a Utaoln , .. ..._..9-12
,. ,r_ll
BATTERY
Inspection& AdJustment
Charging.
9_12
MEMORANDUM
9-14
 - DescriDtion 9 1
STARTINGSYSTEIM

DESCRIPTION

-.j
ii f t
i I s'-- -, I '

.:i .a,*.a-
i A tsndd n.s,,l'r-
Resu aid
-=
i A
++-

Fts. 9-l Startins Systemttdns Diasrdm C38t,l

Thc purposeof the stNrtingsystemis to crank thc cngile to draw in thc combustibleair-fucl
Dlxlure for strrting the engine The strrting systernis composedof the starterand the
b ttery,.rnd its *,iring diagramjs as shown in the aboveillustration

'lhe
battefy storesthe cnergyin e chemicalform, and when the connectjonis madc from
the battefy to thc startefrnotor, a chemicalaction takesplaceinsidethe battery
'lhis
chemicalaction acturtes the starter molor ro convert the electricalenergyto mechan-
rcrlenergy.

The startcI motor rs incorporated with newly improvcd mechanismwithin the starter clutch,
magnetjc switch, pinion drive lever, bmke and ctc , and has the following excellent features-
It is compact and light The output is large,and the end framesare ofa sealedtype io
preventthe entry of dirt and dust
Sincethe idlc rotationaltorque of ihe startcrclutch is very little, the armatureis difficult to

The pinion dnve lever is operated through the d ve lever spring, and the drive lcver spring
acts as a cushion when meshing the geals, Thelefore, the smooth gear meshingts obtarned
without damagingthe gears
Since the a.mature brakc is designedto contact the commutator side face with the brush
holder ring plate, the brake is actuated only when the starter clutch is returned in its original
position. For this rerson,the startermotor doesnot losethe brakingapplicationduring the
starhngoperaiion.
9-2 STABTINGSYSTEM- TroubleShooting

Thc shapeof lhe magneticswitchmovingstud end is modifiedto a hook type. which

of the magnetjc
and the assenrbly
the disassembly
facrlitate switch
the
The magneticswitchcontactplatesarc alsomodifiedinto a taperedshapeto increase
durability.

TROUBLE SHOOTING
Symptoms & ProbableCauses Remedies
L Starterdoesnot turn or siartersPins,but doesnot clankthe engine

a Poor contactof starterswitch contact points RePlaceignitioDswitch

b . Burnt or poor contactof magneticswitch Clcan contact plate or replacemagnetic
contact Plate swrtclr
c. Open magneticswitch pull-in coil circuit Replacemagneticswitch
d. Open magneticswitch hold-in coil crrcuit Replacemagneticswitch
e. Poor contactof brush Dresscomnlutator and brush
f Burnt commutator Lathe cut the commutator
g Commutatormica too high Under cut mica
h. Shortedfield coil Replacefield coil
i. Shortedarmature Replacearmature
j wcak brush sp.ing tension Replacesprings
k Poor solderingof field coil Solder
I worn bushing/s Replacebushing,/s
m.Weakbattery Rechargebattery
n Shortedbattery cell/s Replace battcry
o. Poor contactof battery terminal/s Cleanand tightcn lerminal/s
p. Open circuit between starter switch Repai.
and magnetic switch
q. Poor battery ground cableconnection Cleanand tighten

2. Starterturns,but piniondoesnot meshwithringgear.

a Starterclutch prnion gcarworn Replacestarterclutch

b Defechve starterclutch Replacestarterclutch
c Defectivedrive spring Replacedrivespring
d. Poormovenentof clutchon splines Cleanand correct
e Wornstarterclutchbushing Replacestarterclutch
f Poorstarterclutchpiniontravel Adjustmagnetic switchstud
g Driveleversetbolt mssing Correct
h. Worn startcrbushing/s Replacebushing/s
i. Ringgearworn Rcplaceringgear

3. Startermotorkeepsrunning-

a. Shortedmagneticswitchcoil Replacecojl
b M e l t e dm i r g n e rsi cw r l c hc o n r d . p' l l d l < Replacelnagneticswitch
c. Starterswitchreturnspoorly Replaceignilion switch
 CHABGINGSYSTEM- Alternator a-7
The voltage shoutd be 12 volts lf rhe
It is .ecornmen{:ledto discharge thc
readingof the voltmeter rs zero voltage
battery to perform the load test.
or low voltage than the specified voltagc.
ljrs.onn., r r. c . .gh ren\.or lead rroln
lt indicatesthe following symptoms.
the ignition coil, antl turn the startertbr
s e c o n d \t o d t \ Lh c r g e l h c
a. Opened or poor contact of fuse, regu_
DattcIy.
l a r o r" l C l e r m i n a w
l ireor..l- termi_

ALTERNATOR
b. Regulator hlgh spee{lpoints melted
Removal
6. Disconnect the regulator connector plug,
I Disconnectthe battery to ground caDrc
and check the resistance between the
from the battery terminal
regulator "IG" and .,F,, terminals with
a circuit tester
2. Disconnectthe wirlngsfrom the alterna_
There should be no resistance.
tor
If there is any resistance, it lndicates
that the voltage regulator low speed 3. Remove the fan belt adjLlstingbar bolt
points contactpoorly
and the fan belt.

_l"l.-,
-lr 4 Remove the alternator rctaining bolt,
__t
I
t and removethe alternatorassemblyliom
the alternatorbracket
*i
Disassembly
/l/N\l\
[ !!..-r_ 1t L R e m o v er h c t h r ,e d r i v er n { i t r . n c r e t d r n
ing bolts.
L_
2 Insert a screwdriverinto the notchesrr
Fic. 8-6 CheckincResistonce the drive end fralne, and pry with trre
-IG" betueen
& "F" screwdlver to separute with drive encl
G0163
frame from the stator
If necessary,tap ligh y on the drive end
7. Perform the load test rn the followina
frame_witha mellet ioward the pulle,,
manner
ano lnen remove the drivc end frarrc
l\4akethe same connectio,ta, shown In
with the rotor.
frgure 8-4, and start the engine, and rLrn
it rt approximately 1,t00 rym with ax
lightsand accessories turned on.
The ammeter should indicatemore tha.
35 ampereson lhe RT series,and morc
than 25 amperes on the Light Truck
series with the voltage of t3 5 to 14 5
volts.
t h " n r h e . p e c i f i e dd m p e r a g ( I, h c r e c t i
fier or stator coil is shofied or opened
If the battery is tn full chargedstate and
the amperagereading is less than th,
specrfiedamperage.
Fi& 8.7 Dnve End Fftme Remotal
v2195
 CHARGINGSYSTEM- Altemator

3 Remove the pulley retainlngnut, and 4. Remove the rotor frcm the drive end
pulley, fan, key and the fr.lmc usrng a Pfcs\ ds :hown in ftgurc
sPacecollar' E-9.

1
2
3
1O B e a f n g r e l a ' n e rP l a t e
5 18 R e c t i l i eer n dt r a m e
6
RH Seies v6841
Fry 8 8 Attenatot Componentson

92a6-460I I

80038 FiT. &10 Reat BeannsRemoval VII39

Fig. 8-9 Rotot RenoYat

5 Removethe rear bearingfrom the rotor screws,and removethe t-eltcover(except

shaft with the lnjection Pump Sphne RT series),bearingretainer, front bear-
ShaftPuller092E6-4601 I rng. felt ring coverand the felt ring from
the driveend frame
6, Remove the bearing retainer retamlng

7. Remove the recaifier hotder retaining
nuts, "B" terminalretainingnut and tne
brush holder retarningscrews,then re-
move the statorwith the rectifierholders
from the rectifier end frame
Fig. 8-I I Stotor t4ith Red{liet Horder
BAB9
8- Removethe brush holderassemblyfrom
the stator coil "N" terminal in accord_
ance with the following order using a
small screwdriver
a. Pull out the brush iead terminal frL,rr
the holder by slidtngthe terminaj
b, Removcone terminal insulator_
c Remove the stator coil ,.N,'terminal
from the holder by sliding out the
"N" terminal
When removing the brush holdcr as-
sembly, do not remove it by cutting
the "N" terminal lead or melLingthc
Fs 8.12 BrushEotder Removat 80040
CHARGINGSYSTEM- Alternator 89
Inspection & Repair
Bearing
I l e ! ' K f r r U r - l . n a \ l o t . . . t c . . r o u g h | h, . .
abnorlnrinoiseor datnage
If defectivc,replacethe berring/s
Rotor
1 Check thc rotor coil for olen or shorr
circrit
Connect a circuit tester from the slin
rlng to the other ring
The coil resistanceshould be 4 1 - 4.3
ohms
If thefe is littlc or no resisrrncc.the
coil or slip rings luve a short or ground.
rnd considcrrby highcr resistancethun
that specjfiedabove.indicatesan opened
corl or connectiondefect
If thc test shows that the rotor coil ls
. h n r t c d, J ro n e n r d .J - d t l l ( , l r p f i n g .a r e
defective,the rotor assenbly slrollldbe
Fit.8 lJ 'testinsRotot (bit for Opcn &
Shod Cncuit y2i 96
lig.lt l1 Ii!nnBRt)tat(t lerGnrnt t2t97
g 10 - Alternator
CHARGINGSYSTEIM

2. Connect the tester irom lhe slip rjng to the rectifrer from heating. and meli the
the rotor ro rotor shaft, and chcck the solderedportions using an electric sol
i n \ u l a t i o nb ( l w . e i r n r r r r \ \ l l o s r i n dering iron of 100-200 watts ibr 2
figure8-l'l
lf the tcster needlemoves,the rotor corl
or slip ringsare defective
The rotor assembiyshouldbe replaced

Stator
I Checkthe statorcoil for insulaiion
Connect thc tesier berween the slaror
coil lead and thc staior core
lf the tester necdle oves,the coil insu_
letion is defective
Repeir the coil or replace rhe stator
- 8J7 TesnnsStatot CoiIfot Open Cirdit
Fis
v1115

Check the four leads of the stator coil

for conductancebetween them
If the tester needledoes not move, the
stator cotl is opened, and must bc
rcplaced

Brush & Brush Holder

I Check the brlrsh for crack and wear
If the brush is worn beyond 8-5rnm
(O 335"), replacethe brushes
The brush should shde smoothly.
FiE 8-15 TestingStator Coil lot Insulation L i m i t8 5 m m
B)alI

2. Check the stator coil for open circuit

ln otder to perform this iest' the stator
coil leadsmust be disconnected from the
rectifier leads.
To disconnect ihe leads, hold the recti-
fier lead with a nose pliers to prevent

Fis 8-18BrushLensth vI t43

2. If replacing the brush, install the new

h r u , n a n d l 5 e b r u \ h q P f l n gi n t o l h (
brush holder, then solder the brush lexd
wire keeping the protruded brush length
to 13mm (0 51").
After soldering ihe brush lead, check if
G3361 the brush loYement is smooth
Fit. 8-16 Melting Solder
l
J
2 RecttGerholder negatlveside.
Fis. 8-19 ReplacinsRrust1 v0216
Rectifier
Good or defeciive rectifier is classified by
the re\i\tance value berween rhe rectifier
holder and the rectifier lead.
To perform this test, the rectifler holder
must be separatedfrom the stator.
Refer to paragraph 2 of the Stator in the
Inspection& Repairon pageg-10.
I Rectifier holder posittve side.
Connect the tester (+) Iead onto the
rectifier holder and the (-) lead onto the
rectifier lead as shown in figure g_20,
and check the resistance.
Good recttfier w l indicate no resistanc",
and if tt indicatesa high resistancc,the
rectifleris opened.
Next, turn the polanty of the testerand
check again. If the tesier needle moves
in either polarlty, the rectifier is shorted
If the needle does not move rn either
Fig. 8-21 Rectifer Te\t
polarity, the rectifier is opened, and
,dssembly
1. Installthe statorcoil .,N,' terminalonlo
Fis. 8-20 Rectlier Test G0172
CHARGINGSYSTEM- Altemator 8-1l
should be replaced with the holdcr
assembly
Connect the tester ( ) lead onto drc
rectilier holder and (+) lead onto ths
rectifler lead as shown in figure g-21,
and check the resistance
Good rectifier will indicate no resistance
and if it indicates trigfr resistance, itr"
rectjfier is opened
Next, turn the polarity of the tester,and
c h e r k a g a i n . l f t h e n e e d l eo f l h e r e \ t c r
m o v e si r e i r h e rp o l d f l r y .t n e r e c t i l l e ri \
snorted
If the needle does not move in either
polarity, the rectifier is opened, and
should be replaced.
If any one of the negattvesiderectifierrs
found defective,alwaysreplacethe nega_
tive side rectifierswith the holderassen_
blv
G0t73
the brush holder in the following man_
ner.
Insert the stator coil "N" terminal
onto the brushholder.
b- lnstallthe terminalinsulator.
c. Insert the brush termmal onto the
holderat correctposition
I t2 CHABGINGSYSTEM- Allernator

felt ring (6) (except on RT series)and

the felt ring covcr (7) (excepi on RT
series)wiih three retainlng scfews
When rnstalling the felt ring cover (7),
face the convex surlaceof the felt ring
covertoward the rotor side.

5 Pack multipltrpose grease into the rear

bcaring, and pressit in onto the rotor
shaft of the slip ring srde.

6 lnstalt the drive end lrume onto the

Fis. 8-22 AssemblinsRrushHotdet 80013 rotor shaft bearing through the space
collar with the TransmissionOil Plug
09325-12010and a Press
2 lnstall the insulator washersto the rc-
l a i n . n !b u l . . ' I l , J l o ' r l i t i ' i J c r . . i l i c l
holder, anLl rnstall thc stalor with the
rectifier holders onto thc rectifier end

lnstall rhe "B" terlninal insulator,then 09325- 120 | o---\

tigten the retainlngnuts

3 lnstall lhe brush holderonto thc rectr|er

holdersthrough lhe insulationplate and
the insr.lLators,
The brush holder retainlngbolts must be
tightencdthrough the insulators
Ftg.8 24 Insta iry Dnve End Frume B0a5
I I n \ r a , ll l - . f c l l o n ! l 2 ' a n J r h c l e l l r i n g
?. Press in thc brushssagainstthe brush
cover (3)onto the drive cnd frame (l) so
sPringIensioninto the brush holder'
that the convex su.face of the felt nng
Next, inscrt a wire through the access
coverwill facetoward the pulley side
hole in the rectifler end frame, and also
Pack multipurposegreaseinto the bear-
into thc hole Provlded in the brush
ing (4), and install the bearing
holder io prevent the brushes from fall-
Next, install the bearing retainer (5),
lng-

3 2

o o

Fig. I25 Insta ins Wirc v0218


With the brushesposilioned as above.
asse)blc lhc drivc cnd iiame orto lhe
recrifief end frrnle. rnd tightcn them
with thc tlrrecrclrining bolts
t lnsrall thc spacecollarj key. fan and thc
pulley on|o the rotor shai1,and instrll
thc reirining nut
Alternator Output Test
Pcrlbrnr the ourput ted in Llccordance
( . , r ,r " . h u $ n i n t L e l b l o \ i n J i r r ' l f "
Fi!1.,\ 26 qutput Test Cir.:uil
I Turn on the switch "SI" only, then
ircrease the alternator revolution grad-
uaLly with a vari2blc motor untrl thc
volt.rge reading rcachcs 14 volts, and
read the altemrtor rcvolution at that
tinle, which should be 700 - 1000 rpm.
2 Tum on the switch "SI", .rnd "S2"
f-urtherholding the output voltageat 14
volts with a vadable resistance,increase
the altemator revolution to less than
3,500 rprn fbr RT series,and to lessthan
4,000 rpm for RH series,and rcrd the
m m e t e ra t t h a t t i m e
The ammeter should be 40 ampereson
RT scrics,and on RH se es this should
be 30 amperes
lnstallation
Follow the renoval procedures in the
reverscorder. Adjust the lan belt deflcc-
CHARGINGSYSTEM. AlternatorRequlator 8.13
t i o n t o 8 ^ - 1 3n 1 m( 0 3 l r o 0 . 5 1 ) r v l t ht h c
fan belt pushedwith l0 kg (22 lbs)
ALTERNATOR REGULATOR
Removal
I Disconncctthe battery to ground cable
iionl the batiery terminal
with 2 Disconnectthe regulator wiring harness
connectorplug
3- Remove the reguhtor rctaining bolts,
and removethe regulatorassenbly.
Electrical Adjustnrent
If the alternaftrrreguhtor docsnot actuatc
propcrly in accordancewith the electrical
acllrstrncnt,check the rcsistanceol the
regulatorcircuils
lf deitctive. repair the deitctive portion.
and repeai the electricaladjusLmenlafler
performingthe mechanicaladjustmenl
Always use a fully chargedbarlefy to per_
v5124 form the electriculedjustmenl-
Voltage Relay
Makc the tcst clrcuit as shown in figure
8 27
Operltc thc vtlliable lnotor, and turn on
'S"
thc switch
Next, rncrcascthe altcrnator rcvolution
gradually.and read the voltrge when the
tcst lanrp goesout
L ghl
E
Fig.8.27 raltuseRelar TestCin:uit c0t76
8 t4 CHARGINGSYSTEM- Altemator Regulator
Thc voltage relay operalingvc'ltageshould
be45-5.8volts
lf the voltage is not within thc specified
voltage,adlust it by bending the adjusting
arm ol the voltagcrelay
Refer to figure 8-30
Voltage Regulator
Make thc test circuit as shown in figure
8,28
Operate the vaiable motor. and turn on
thc switch "S" Check the voltage and
amperageby varying the alternatorrevolu_
l i u r g r J d u a r l ya r l h e l i m e w h c n t h e a n
meter needlcregistersmaximum
Increasethe altcrnatorrevolLrtion,
the voltage at the time when the ammeier
needle regjsters one-half of maximum am
peragereadlng
Also lncreasethe revolution reaches3,000
rpm, and read the voltage
l h e r e g u l d r i n gv o l l a g es h o u l J b i w i i h i n
l3 8-14-8 volts when the ameter needle
registersat one-halfof maximum amperage,
r n d a l \ o w h e n l h e a l l c r n d l o fr c \ o l u l i o ni .
at 3,000 rpln
If the regulalingvoltage is not within thc
specifiedvoltage.adjust it by bending the
adjusting rrrn of the voltage regulator'
Refer to figure 8 3 I
Fis.8-28 VoltaseResulotorTestCicuit
Regulator Circuit Test
l- Connect the circuit tester between the
"IG" and "F" terminals
The resistanceshould be zero
terminal "L" l.rminal "E|"
Fis. 8 29 Resulatar llnins Haness
ConnectorPIus G3456
If there is any resistance,the contact of
and read the voltagercgulator pornts "PL1" and
"PL0" is poor
Pressdown the armatureof the voltage
regulator,and checkthe resistance.
The resistance shouldbe about 10 ohms
If the resistance is considerably higher
than the specifiedresistancevalue,the
control resistor(Rf) is defective.
2. Connect the circuit tester between the
"L" and "E ' terminals.
The resistance shouldbe zerc
lf there is any resistance,
the contact of
the voltagerelay points "Pl" and "P0"
Pressdown the armatureofthe regulator
relay,.tndcheckihe resistance.
The resistanceshould be about 100
ohms.
If the resistanceis considerablyhigher
lhdn 100 o\n_.. rhr vollagc coil i\
opened
If the resistanceis ext.emely lower than
the above,the voltagerelay points "Pl"
and "P0" are melted or the voltagecoil
is shorted
G0177 J . a o n n . i t , h c c i r c u i r t e s l e rb e l w e e nr l r r
"N" and "E ' terminals
Thc resistanceshouldbe about 23 ohms
If the resislancels considerablyhigher
than 23 ohrns. the voltagerclay coil rs
opencd
If the resistanceis extremcly lower than
 CHARGINGSYSTEM- AlternatorR egulator 8,15

thc abovc, the voltagc .elay coil is

4. Connect the circuit testcr betwccn ihc

"L" and "B" rermirals,and plessdown
thc armature of the voltagerclay. tnen
check the resistance
The resistance shouldbc zero
If therc is any resistance.the contact of
the voltege rclay.points "p0" ard ,,p2,'

5 Connect the circuit tester between the

"B" and "E" termmals of yottageRetay C0175
Fry 8.la Nomenclaturc
The r€sistancc shouldbe infinite.
If there is any resistence the voltage
reiay points "P0" and "p2', arc meltcd
Pressthe armature of the voitagerelay,
and check the resistance
The resistance should be about 100
ohms
If the resrstanccis considcrablyhigher
than 100 ohms, the voltagc cott rs

lf the reslstancels extremely lower than

the above,ihe voliagecoil is shorted
Fig 8ll Nomenctaturcof I/attae?Resutator
6 Connect thc circuit tester bctween Ine ca 171
"F" and "E" terminals. \ f ( e r J f . . \ i n g , - n u i n t . .\ \ . , \ h l h i m , h c , r -
The rcsistanccshouldbe infinitc. oughly with cleaningsolvent
l f r h e r c r . a n y r e . i . ( J n r r .t h e v o l t a g e lf nny of thc pojnts is burnt or pitted
rcgulatol points "PL0" and ,,pL2" arc excessivcly. rcflacc Lhcregulatorassembly.
melted.
Pressthe armatureof ihe voltageregula, Voltage Relay
tor, and checkthe rcsistance_
The resistance 1- Pressdown the armature,and check thc
shoLlldbe zero.
lf thcre is any resrsttnce,the contact or
lhc regulator pornts ',PL0,, and ,.pL2,'

Inspection & Mechanical Adjustment

This mcchanicaladjusimentdescribedh{_re
should be perforrned when the specified
values arc not obtained in ihe electrcal
adlustmcnt.
Dirty contact points shouldbe dressedwith
a suitable paper or a surtablefine emery
Fis. B-32 CheckinsSpnngDelle.non y2t98
ca18a
8-16 CHARGINGSYSTEM' AltcrnatorRegulator
'I
contact springdcflcction with thc feeler his point gal should b c 0 2 5 t o 0 . + 5
gauge mnr(0Ul{l- 00lt")
This deflcction should bc {l-20 ro 0'15 If neccssilry,rd.tustthe gxp b]' bcndin-s
mln(0 008 - 0 018"1. thc high spccd pornt holdcr "B" as
If ncccssary,adjusLit by berding the sho{,n in figurc 8-35
point holdcr "A'
3 Ilcss the a.rreture. and c|cck thc corl
2. (lheck thc point gap wrth th tact spring deflection with rhe ieeler
glrlgc gaugc Fig-8-36
'fhis point gap Thrs dellcction should b e 0 2 - 0 6 m , n
should be 0 4 to
(0016-0041") (0.008- 0 024").
lf rrccessery,adjust the gap by
thc pornt holder " 11".

B fl.l lq 25 olE .
rJ':

PointGap
Fis.815 Checktng V2t55,G0182

Fis 8'33 LhcckinsPoint Cdp v1185

Gal8l
Voltagc Regulator
I Check thc arlnatlrregap with tlle iteler
grugc.
This point gaf shoulclbc 0 6 to 0 t rrrrr
(00r,r-0032")
1f nccesMry.adjust the gap by tr€nding
thc low speedpoint holder "A"

\ I. ig. 8 36 Checkins SpnngDefuction v3t05

GOI8J

ltit. 8 34 Chetking4maturc GaP

I Chcck the point gnp wrllt L h c l e c l c f
gauge lris.8 37 ChetkmsAnslcCap v2t19
 CHARGINGSYSTEM- Aljemator Regulator 8.17
4. Pressthe armature,and check the angle lhs tallation
gap with the feelergauge.
Follow the removal procedures in the
This gap should be more than 0.2 mrn
(0.008").
lf not, replacethe regulatorassembly.
 STARTING SYSTEM
DESCRIPTION

TROUBLESHOOTING.
9-2
STARTER,
9-3
Construction 9-3
9,4
9-6
9-6
9-1
Armature. , 9-7
Field coil . . 9-8
Magneticswitch . 9-8
Brushholder& brush.
9-9
Starterclutch.
9 -l 0
Assembly.
9 -l 0
T e s t i nA
g f t e r A s s e m b.l .y. . . . . _ 9-12
lnstallation.
9-12
BATTERY. .... ... s_t2
I n s p e c t i&
o nA d j u s t m e. n. .t . . . ...........g-12
Charging.. .... ..9-12
MEMORANDUM
 - DescriDrion 9 1
STARTINGSYSTETVI
DESCRIPTION

l-------------j
---: i /5-h iA
_i r___+__o
L--+--ri
ii 1
) ir
i.l7
^--' '-----;:n\g
'------:.\g a,/ |-I - - l
"j't ,' .-. 4 - - ' . f
9/ -)-
;l Mn h
ltHl ll i
,\--:trN! rF I i

Al'*iattr Regt dtr ;

Fig.9 I Sta inBSystemwinngDtaslam

G3814
'rhe
purposeof thestartingsystemis to crankthe cngine
to drawin the combustible air-fuel
nrixturefor startingthe engiile The startingsystemis composed
or *," ,turi". una ,rr"
battery,and tts wtringdiagramis asshownin theaboveillustrailon.

The batrerystorcsthe energyin a chemicar form, and whenthe connection ismade

' tiom
thc battsryto rhe starrermotor,a chemicalactiontakespf"* f".ra" tf,"irii".V
This chcmicalactionactuates thc stafiermotor to convert the electricalenergyto mecharF
tcatencrgy,

The stariermotor is incorporatedwith newryimprovedmechanism

within the startercrutch,
magneticswitch,pinion drivelever,brakeand etc and hasthe
, following excellentfeatutes
It is compactand light. The output is large,and ihe end
frrr". u.a_oi, J"a typ" to
preventthe entry of dirt and dust.
Sincethe idle rotationaltorque of the starterclutch is very
lit e, the armatureis difl.icultto
The pinion drive lever is opefttcd through the drive
lever spring, and the ddve lever spring
acts as a cushion when meshing the gears Therefo.e,
the smooth gear meshingis obtained
wrthout damagingthe gears_
since the armature brake is designedto conlact the
commutator side face with the brush
holder ring plate, the brake ls actuated onry when
the starter crutch is returned in rts original
position. For thisreason,the startermotor
doesnot losethe brakingapplicationduring the
srar!ng operation,
9-2 STABTINGSYSTEM- TroubleShootirg

The shape of the magnctic switch moving strLdend is nodified io a hook type, which
and the assemblyof thc maglleticswitch-
faciliiatethe disassembly
The magnetic switch contact platesare also modified into a taperedshapeto increasethe
durability

TROUBLE SHOOTING
Symptoms & ProbableCauses Remedies
l Starterdoesnot turn or starlerspins,but doesnot crankthe cngine

a Poorcontactofstarterswitchcontactpoints Replaceignitionswitch
b. Burnior poor of
contact swiich
magnetic Cleancontact plate or replacemagncfic
contactplate switch
c. Open magneticswitch pull-in coil circuit Replacemagneticswrtch
d- Open magneticswitch hold in coil crrcuit Rcplacemagneticswitch
e Poor contact ol brush Dresscommutator and brush
f, Burnt commutatol Lathe cut the commutator
g Commutatormica too high Under cut mica
h Shorted field coil Replacefield coil
i Shortedarlnalure Replacearmature
j. wcak brushspringtension Replacesprings
k Poor soldering ot field coil Solder
I Worn bushing/s Replacebushing/s
m Welk battery Rechargebaltcry
n Shortedbattery cell/s Rcplacebattery
o. Poor contactofbatlery terminal/s Cleanand tightenterminal/s
p. Open circuit betweenstarterswltch Repair
and magneticswitch
q. Poor battery gJoundcableconnection Clcanand tighten

2. Startertu.ns, but prnlon doesnot meshwith iing gear.

a. Starterclutch pinion gcarworn Replaccstarterclutch

b. Defective startcIcluich Replace starterclutch
c Defectivedrivespring Replace drivespring
d. Poormovement of clutchon splines Cleanand correct
e Wornstarterclutchbushing Replace starterclutch
f Poorstarterclutchpiniontravel Adjustmagnehc switchstud
g Driveleversetbolt nlissing Correct
h. Wornstarterbushing/s Replace bushing/s
i- Ringgearworn Replace ringgeer

3. Startermotor keepsrunnjng.

a. Shortedmagneticswitchcoil Replacc coil

b.Melred m a g n ( urcw i r c hc o n l a . 'pl l d l ( Replacemagneticswitch
c. Starterswitchreturnspoorly Rcplaceignition switch
 STABTINGSYSTEM- Starter 9-3

STARTER
Construction

Fig. o 2 Chss Sp.tionul Vt?w aJ Stottcl y51l5

lhe principlc componentsor the st.lrtefconsistof th€ !rnrrture, srnrrercr.tch. field

corr.
drive enCiramc, yoke. conlrnutatorend f.ame. bruslres.nd th€ magnerjcswjtch
'lh€
ficld coil is conncctedwtth thc xrmatltrecoil throughthe brushesanclthe con1]llularor
segnrentsin series The windings of the fielcl coil and the afJnatLrre coil are of l heayy
copper wire to withstand the largecurrent encountereddurirlgthe strrting
operjtton_
llte starterclutch is cngagedro the armaturcshaft wirh the leticat spiincJ i! the
starter
clulch is pushcd out by the ptnion dnve spring,rltc tlrrningofthc pinion occurs
due to the
helicalsplines.and this cnablesa smooth ergagementof thc pinion rvith the ring gcar
Also as tire strrter clutch plnion is crlgagcdwiLh the rjlrg gear.the turning force
ofthe
itrnlaturepushesLhestarterclLrtchpinion into a cornpletclneshwtthour furthe.
force of the
piniojr (lrivespring
For theserelsons,the pulling force of the rnagneiicswitch is not rcquired
to bc strong.the
magretic switch ther€fore,is dcsignedvery s'rall conlprred wirh the unit
usedon Lnecon-
vcrltionrlpush in type sterter
'lhe
starter cllrtch has xn onc{vay clLrtch,and it transnitsthe luming lbrce
ofthe arnlature
to the ring gear but the armrtu.c is not turncd by the ring gearas soon
as the englneis

The drive lcver is providedlvjth the pinion clrivespfrng.ard es thc upper end
of thrs sprilg
is hooked drectly onro thc magneticswitclLjoinr. thc dri.r.espringacis rs a cushron
rnttre
plrshr g motton of the pinion drive leverfor meshingwith Lhennggear_
AnarnaLrre o.aKe
rs provided,,t the colnmutatorend. and it is desigrlect
to usefriction beiwccrlthe conrnlrre-
tor side sLrrirccerld the brush holder plate The brake js affectedby the
Jrragneiicswitch
rctlrrn spnng through the drive rever when the stnder crutch is rcturned
in it! ongrnal
 STARTING SYSTEM- Starter

Operation

iiil F
R,ns6-"..
E

Fig 9 J Stater Cinuil G3136

On closingthe starter switch, the battery curent flows mto the hold_incoil and alsoto the
armaturecoil throughthe pull"in coil, field coil and the brushes'
Then the moving core of the magneticswitchis pulled in by meansof the magnetictblce'
and the starter clutch is slidedon the amature shaftby the drive springand the drive lever
to engagethe starterpinion vith the ring gear.
At this time, the pinion is partially engagedvith the ng gearsmoothlybeforethe magnetic
switchcontactplate is closed
when the magletic switchis closed,the battery curent flows d ectly into the field coi] and
to the amature tbrough the contact plate, and energizesthe armatureto spin creatmga
laige torque
gear,and
Ttris movis the starter clutch pinion further to completelyengagewith the ring
b ngsthe starterinto the enginecrankingcondition As the magnetic switch is closed'the
cur;nt does not flow to the pull_in coil, and the contact Plate rs retainedat ihe closed
positionby the hold'in coil until the enginestartsto operate'

With the starter switch off after the enginestarting,the curent flows from the magnetic
switch contact plate to the pull_in coil and the hold-in coil As thesecoils ale wound to
have their attractiveforces act in oppositedirections,these attmctive forces canceleach
other, and the plungerreturn springretractsthe plungermovingcoreto openthe magnetic
position' and the
switch- At the sametime, the starter clutch is returned to its original
armatureis pushedtowardsthe commutatorend framesideby the plungerreturn sprmgto
effect the armaturebmke Th€n, the armaturequickly stops,and becomesready for the
starterre-opemtion.
 STARTINGSYSTEM- Starter 9-5

Specihcation:

Type Serieswoundmotor
Ratedvoltage l2 volts
Ratedoutput power 0.8 KW
Rating 30 seconds
Directionof revolution Clockwiseasseenfrom pinion side
Numberof poles 4
Numberof pinion teeth 9
Suitablebattery capacity 35-60AH
Noload output characteristicsl
Voltageat I I volts
Amperage Lessthan50 amperes
Revolution Over5,000rpm
Lockedoutput characteristics:
Voltageat 7 ? volts
Amperage Lessthan 470 amperes
Torque Over1.2m-kg(8.6ftlb)

0@01
5,*-;@l@

s
,3 l4 ia t9 2a

15 Commutarorend trame
2 D. ve end tramebushinq
17 Commurabre.d framebusrrng
4 Pihiondrlve everw^pr nq

6 P n i o ns t o p p e r . ot a r

Fig. 94 Stortet Components Y5660

 STARTINGSYSTEM- Sta er

R€moval
L Drsconnect the battery ground clble
from the battery terminal

2- Disconnectthe battery to stafier cxble

and the wires f.om the starter

3. Removethe engincunder covcron RH &

RY series

4 Removethe starter retaining nuts, and

removethe starter Fig. 9'6 Bn'* Holder Remo'L| v1808

Disassembly 6. Removethe yoke from the drive end

frame
1. Disconnectthe field corl wire from the
lower side main terminal of the magnetrc 7 Removethe drive lever retalning bolt,
switch. and removethe armaiure,togetherwith
the starter clutch and the drive lever
2. Removethe lwo magneticswilch f€tain- from the drive end fralne.
ing screws, and d6connect the moving
stud from the drlve lever by Loweringthe
front end of the magnetic swltch as
shown in arfow mark, then rcmove the
magnetic switch.

Fig.9-7ArmatureRemoval 80033

8- Remove the snap ring and the pinion

SwitchRenoval
Fig.9-5Magnenc vluo6
LI
,(0
6m,if I 5-2 omm
(006-008)

3. Removethe bearingcap from the com-

mutator end frame,and pull out the iock
plate and ihe washer
m m( 2 3 6 )
4. Remove the two through bolts, and
Iemovc ln< commulrtol ilrLl lr''r.

5 Take out the brushes from the brush

holder, and remove the brush holdel Fig. 9-8 Storter Clutth Remordl 80034
from the armature shait ct219
 STARTINGSYSTEM- Starter 97

sbpper collar from the armature shai-t (l ll") lbr l2R, and if the lilnit e^
end, ihen removethe starterclutch. cceds.replaceihc arntatufc
To remove the snap ring. nlake a Loor T l ( . t \ . t i . . l . o r n | ' u t : r t o r, l i .n r t , - r "
similar to the one as shown in rne 38 8 rnm (1 5-1") ibf 2R, -127 mrn
illustration. ( 1 . 3 1 " )f o r I 2 R .
Drivc oLrt thc pinion stopfer coltar
'ou rfd I Check the mica depth, and file off thc
t h e \ l a l l c r c l r l c h . i d e t i 1 5 t1 . , . r !
the tool to removethe snapring_ nica if Lhe depth is less ihan 02 mrr
Next, removethe stoppcr collar ancl Llle (0 008")
starter clutch after ren)ovingthe srap The prop€rdepthshouldbe 0 5 ro 0 o
nng nm (0 02 -' 0 03")

Inspection & Repair

I lnspect the clcaranccbetween the anra-

ture shail and the bushing
The specified clearanceshould bc ress
than 0-l mm (0 004").andrf thc clear_
ance exceeds0 2 rnm (0 009"), selccr
thc proper size bushjngin the followrJtg
t a b c t u o h t : r i nl h - , p e , t t e Lc ' c .f - 1 . .
FiE. 9-9 il,IicaDepttL
Arrnatureshaft diameterl c0liI
12.Q5 -12.410 mm (0.211392 - 0.489U,,) 4. Checkthc |ratLu€ coil for grouuduvrg
Bushinginner diameter: n growler
STD: 1 2 . 5 3 5- 1 2 5 6 0 m m Clonnectone test prod on the colllru_
(0.4935 ^- 0.494-5") rator, and the other tc\t prod on ihc
U/S-0.30: 12.235 - 11.260 rnnr ir rnat re core or shaft
(.04Et'7 _ 0.4E2,7'-) If thc test lalnp lights,the arnrtture
coll
U / S - 0 . 5 0 r 1 2 . 0 3 5- t l . 0 6 0 n l m is gro ncled
(0.4138_A41$") Rcpair or replace the armature.
Thc under sizebushings re mrrked with
the idcntification linc of 3 nlrn (0 l2 )
width. Thc U/S-o 30 bushrngis mirrkcd
w i l l d \ i n g l e l i n e .: , r d r r U 5 ^ < 0 I .
markedwith double Iines

2 Chcck the comrnlltator for roughno"",

burnt or scorcd surface
If necessary,dress or cut with a latrc
1
JUS1 enoughto removestock b clc n tllc
surface.
T i l h e o r r - o f f c u n J n f t h e - . r - r I r L r .u f r s
more than 0J mm (0012,,).cur thc Fig- 9-10 TesfingAnnatweCoitlor Ctound
commutatoron a lathc y2t 86
Thc out-ol-roundshouldbe lessthan 0 l
rnm (0.0021"). 5. Check the armatLlrc coil for jntcrnal
The servicetblc lirnit of the comrnutator short by placing the arntature on tlc
growlcr, irnd hold a hacksawbladc
is 36 8 mrr (1.45") for 2R. 30 7 mllr olrr
rn€ arrrrture core while roiating thc
 STARTING SYSTEIvI- Starter
If ihe hacksawblade vibrates,the arma'
ture coil is shortcd.
Repairor replacethc armatnre
Fis 9-l I Testing Atmtturc Coil for Shott
v2187
6 Check the armature coil for op€n circr.lit
b! fhcing lhc arraturcon the growler.
and connect the two commutator seg
ments wlth the test prods,and check the
readlng.
Repeatthe tesi for all adjacentsegments
movlng one segmentat a time.
If thcrc is inconsistentreading,ri mdi
catesan opcn circurl
Repair or replace the armature.
Fis 9-12 TestingAmature Coil lor Open
Y2luu
Chcuit
Field Coil
l Check the field coil for open circult
using a circuit tester
Connect one test prod onto the field coil
lead and the other prod onto the other
fleld coil lead.
If the tester needle does not move, the
field coil has an open
Repair or replace the field coil.
Fit.9-13 TestingFieA CoiIlo. OpenCircuit
80035
2. Check the field coil for ground. Connect
one test prod onto the field corl lead and
the other lead on the Yoke
lf the tester needle moves, the field coil
has a Siroundcircuit.
Repair or replace the field coil.
Fig.914 TesnnsFiea Coilfor G.atnd
Magnetic Switch
The following magnetic switch tests des-
cribed in paragraphs I thrcugh 3 should
be pedormed with the condiiion that the
and with the specified
starter is assembled,
voliage apphcation, preventthe contact
to
pldle of rhc mdgnelicswilch lfom deform_
ing.
In testing, desconnect the fteld coil lead
from the magnetic switch terminal "F"
I Test the pull-m coil motion of the mag-
netic switch

Connect the test leads onto the .,50"
termlnal and the "F" terminal as shown
in ilgure 9, 15.
The magneticswitch should pull in the
plungerstroDglywith 8 votrs.
Fig.9-15 Pu -in CoiI Test
2 With the magnctic switch in pulfin
c o n L l i l t o r c. o n n c L tl h e b r | l e r y n < g a t i v .
lead onio the magnetic swiich body_
Next, dtsconnect the test lead of the
battery negative srde from the ,,F,'
terminal
The plungermust be pulled in, and held
in this position with 8 volts
If held, the hold-in coil is satisfacrory
Fig.9J6 Hod'in Coil Test
3. Check the plunger return motion by con-
necting the battery posihve lead onro
the "F' terminal, and the negativelead
onto the magneticswitch body.
After pulling out the pinion until it
reachesto the pinion stopper collar wrrn
the hand, .elease the hand from the
pm1()n,
STABTINGSYSTEM- Starter 9-9
At this time, if the plungerreturnswtth
12 volts,the magneticswitchis satisfac-
tory.
F{s.9 17 Ptunge,RetumTest yt 812
Gt267
Gt265 ,+ Inspect the length of the rrlagnetic
switchmovingstud
Thc length is approximatcly 34 mm
f l . l , : t f r o r , h c i 1 \ t J l l a l l o nr u r r r . c , , 1
the magnetlcswitch to the extreme end
of the rnovingstud joint hook.
If necessary,adjust the tnoving stud
length by loosening the lock nut io
obtain the correct positionof the pmion
travel.
Fis.9.18 ArcckinsMovins Stud Lensth VtSrJ
G1266 Brush Holder & Brush
l lnspect the b sh holder for insulation
using a circuit tester
Conneci the iest prods onto the positive
side brush holder,and onto the negative
side brush holder
lf the tester needle moves, the brush
holder insulatoris defective,and should
be repairedor replaced.
910 STARTINGSYSTEM- Starter
Fis. 9-19 CheckinsBtush Holder Ins lation
I Check thc brush length,and if the lengih
rs lessihan I2 mm (0 48"), replaceihc
Thc specified brush length is 19 nlm
(0.75',)
3 Check the brush spring tcnslon wrth ir
The feadixg of thc tcnsion should be
mlde when the springjustcomesoff the
brusn
Ihc specifiedspring tension should i'c
1 , 0 5 0^ - 1 , 3 5 0 g r r m s ( 2 - l t o 3 0 l b s )
when thc new brushesare installed
lf the tension is less tlran tj00 g (l 32
1bs). r€placc rhe spring/s and/or the
Fis. 9 20 CheckinsSpnne Tension
Starter Clutch
l.i lccl th( pinior Lr.lh ldr $crr ' rlJ
damage
lf defective,replace the starter clutch
asscmbly.
'rr'\| |r'.,. lrd'n..
strcky irglinst lhc lree Nh.ei nrolenrent.
a n d s l i I t ) i r g ien o I p o \ i t c d i r c c t r o nt o t h c
lrea-!!lrccl movelllcI]t
i 1 d e l f c t r v t . r e p h c c t h e s L a r r eo
r lutch
vI8tl
Fig. 9-21 Aechng Sttter Autch vl8 t7
Assembly
When assembllg each lr1rt co|t with
mulLipurlosc greaseonto the sllding sur'
face or moving portion oi the arnlrtufe
shaft splines, slancr clutch bushing, end
frame bushings.drive lever and the rnovlng
stLrcl
l - l n s t a l lt h e s l a r t e rc l u t c l t .p r r i o n s t o p p e r
cotl.rrl d the snap ring orlto thc alna
ture d1rft, end LlIcn lock thc stoppcr
L ' o l l r Ir n p J t ' L , rc r k r n 3 . . l v ' , , p o i n l \ .
Fig 9-22 Calking Stopqer Co 0 80037
vt8r6
2 tnstall the tuivc lever (2) onlo thc
starlerclulchi1J asfollows.
,Alwaysinstall the drivc lever as in the
posrtrorr
illustraled
is incorrect.the pinion
lf ihc rnstaliaiion

ruresh'ng with the ring gear will be im-
propef.
Also the steelwasher(3) must alwaysbc
installed towards the clutch side.
Fig. 9 23 Ditection of Dnye L@o lnsta ztion
3 Install the armature onto thc drlve end
f r a m - ,a n J l i E l _ l ( nl h e d n ! r l c v . r ' ( r . i n -
ing bolt.
4. Install the yoke onto the drive end
frame-
5 Inslall the brush holder onto the arma-
ture, and install the brushes into the
brush holders
Allgn the cut provided on the brush
holder with the thread holes for the
through bolts on the drrve end frame.
Fiq. 9-24 Insta iry Lock Plrte
6. lnstall the commutator end frame,and
tighten the throughbolts.
STARTINGSYSTEM- Starter 911
T lnstall the thrust washerand the lock
plate orto the armatureshrll end as
shownin figure9-24.
T h ed r m d r L r -h - l r h r u , p
r l a ) \ h o . t l ob e
0 . n 5 0 1 5 m m t 0 0 0 2 l o 0 l J r ,a n d
thc thrustplaylimit is 0 8 mm (0 03")
8 Packmultipuryose greaseinto ihe bear-
. n p c o \ ( r . . n d i n , r d l li r o r r o t h . n J
frame
vl8t8
Fig 925 InstauinsBarnns Cover v1821
9 Install the magnetic switch onto the
drive end frame
AIways hook the moving studjoint onto
the drive spring liom the underneath of
the springas illu5trated
Fic. 9 26 lnstalli s Magnetic S\+titch G0152
t 0 Checkthe clearancebetweenthe start-
er clutch pinion and ihe pinion stop-
v1820 per collar Thc clearanceshould be
I - 4 mm or 0 04 to 0.16" when thc
slarter is operatcd under no load
If necessary,adlust the clearanceby
adjustingthc movingstud length
9-12 STARTING SYSTEIM- Starter,Battery
Fk.9-27 ClutchPifiionAeannce G0153
Testing After Assembly
The following tests should be performed
after assemblingthe starter.
If suitable equipment is not available,at
least the noload test should be made
Usea fully chargedbattery for the tests.
To perform the no-load test, connect the
test leadsasshownin figure9-28.
The starter motor should rotate smoothly
at a constant speed of more than 5,000
rpm at I I volts with the current dmw of
50 amperesor less.
o.
; ing to acrd specific gravity, the follow-
i t ..
Fis 9-28 TestinsCi.cuil G0151
To perform the lock test, follow the ln-
struction and proceduresoutlined in the
instruction manual of the tester furnished
by the manufacturer
With the armaturelocked,the currentdraw
should be less than 4?0 ampercsat 7.?
volts producinga torque of 1.2 m-ke (8 o
ft-lb) or more.
lnsfallation
Follow the removal procedures in the
reverseorder.
BATTERY
Inspection & Adjusfment
I Checkthe electrolytelevelin eachcell.
Add sufficientelectrolyteto levelline.
Always use distilled water to replenish
the battery-
2. Check the specific gravity of the elec-
irolyte with a hydrometer
If the specificgavity readlngis below
1,200,and the difference betweeneach
cell rs more than 0.025, the battery
shouldbe recharged.
Electrolyte specific gravlty of a fully
chargedbaiteryshouldbe I 250-12'70
at 20qC(68'F).
The specificgavity of acrd solution to
be used as electrolyte,variesaccording
to its temperature. lt is necessary
belbre adjustingthe specificgravitythat
it is convertedaccordinglyio standard
temperaturereadingat 20"C (68'F)
For con!errioo n f t e m p e r a t u pr ee r l a r n -
ing equationshouldbe used.
S20=ST+0 0007 (t 20)
S20. .-. Specific gavity at 20'C
S T . . . . . . S p e c i f igcJ a v r tayt t ' C
Temperatureof electrolyte
0.000? . . Temperuturecoefficient
Electrolytespecificgravity
at 20"C (68"F):
I 260 is 100%fully chargedstate
I 210 is 75%fully charged siate
1.160s 50%fully charged state
L l10 is 25%fully charged state
I 060 is fully discharged
state
Charging
Beforeplacingthe balteryon lhe chargel.
clean the battery terminals, check the

electrolyte level, and replenish with dis-
tilled water as necessary,Removeall the
filler capswhile charging,and do not allow
the bailery electrolyretemperature ro ri\e
45oc (l t 3oF)
Hydrogen and oxygen gasesare produced
during normal battery chargingoperation.
This gas mixture can explode if flamesor
sparksare brought near the vent openintss
of the battery.
STARTINGSYSTEM- Battery 9-13
The sulphuricacid in the battery electro-
lyte can causea seriousburn if spilledon
the skin or spatteredin the eygs. [t should
be llushed away with large quanhties of
For qurck charging,make sure to discon-
nectthe batteryto sta er cable.
If not, the altemator tectifiers will be
damaged.
 IGNITION SYSTEM

DESCRIPTION .. -IO.

T R O U B L ES H O O T I N G , , , ,.. -, IO

1 0 -2
De\cription l0- 2
R e m o v a l , .. , , , .. _ 10-6
Disd\sembly 1 0 -6
l0 7
Dist butor shaft l0- 7
niarrih,'inr.an
1 0 -7
Breakerplare& \tirrionafyplare l0- 8
Other item . 10-8
Assembly. 10-8
PefformanceTc\t & Adju.rmenl 10-t0
Bre,ker 6^inr o.h
l0-10
Bfeakerarm sprirg len\ion t0-l0
aamd$cll a1glr. . . . l0 l0
Condenser - t01l
Advancecharacteristics l0 lt
Installation.. 10l2

l0-13
Description. .. l0-t3
Inspe.tion 10-t3

HIGH TENSIONWIRES l 0 -l 4
Descfiption 10-14
Removal, l0-r4
Ispcction 1 0 -l 4
Istallation. l 0 -1 4
S P c R K P L L J G. l0-15
Description l 0 -l 5
R e , n o v|r .. t0 16
Inspection& Adjustment .. l0-16
Installation. IG16

MEMORANDUM t0-1?
 IGNITIONSYSTEM- DescriDtion 1 0 - 1

DESCRIPTION

I
^"-..'oP4u.bri

Fig. 1Gl lgnihon Vsten Wi.ingDiagam G38t5

The rgnition system is provided io control the rgnition of the air-fuelmixture within the
enginecombustionchambers.
The function of th1ssystem is very essentialin the performances of ihe engine,and special
attcntion should be maintainedtn the servicingof the engine,so that it is alwaysin perfect
opemtingcondition
The ignition systemproduceshigh-voltage surgesof up-io 20,000volts, analdeliversthem to
l h e . p c r k p l r g \ i n ' ( i m e ' $ i l h r h ee n g r n e .
Each high-voltage surgelumps across the spark plug gap and ignltes the compressedair_fuel
mixture
The ignition system is composed of the p.imary (1ow-voltage)circuit and the secondary
(high-voltage) circuit, and the wrring diagram is as shown m the above illustration.
The primary circuit consistsoI the battery, distributorbreakerpoints, condenserand the
ignition coll primary windings.
The secondary circuit consistsof ihe lgnition coil secondarywrn{iings,distributor cap, rotor,
high-tension wi ngs and the spark plugs

When the brcaker polnts are closed, the primary current flows from the battery through the
ignition switch to the p mary windings in the coil, then to gound through the closed
breaker points.
When the breaker points open, the magnetic field buit up in the ignition coil primary wrnd-
rngsmoves through the secondary windings of the coil producing high voltage surge
The high voltage surge is produceal each time the breaker points open ihe htgh voitage
flows through the co high tension wiring to the distributor cap where the roto. dftributes
it to one of the sparkplug terminalsin the drstributorcap.
to-2 IGNITIONSYSTEM- TroubleShooting,
Distributor

TROUBLE SHOOTING

Symptoms & ProbableCauses Remedies

L Starterturns,but enginewill not start
a Weakbattery Rechargebattery
b Excessive molstureon sparkplugsor high tension Remoremoisture,and dry
wrmgs
c Crackedor leaky distributorcapor rolor Replacecap or rotor
d. Brokenwire in primarycircuit Repairor replaccwire
e. Burnt or improperlyadjustedbreakerpornts points
Adjust or repLace
f. Defectivecondenser Replaceconderscr

2. Hard starting
a Defectivesparkplug/s C'lean,adjustor replaceplug/s
b Defectivebreakerpoints Rcplacepoints
c Looseconnectionin primary circuit Tig:htenor repair
d. I)efectivecondenser Replacecondenser
e. Defectivecoil Replacecoil
f. Defectivecap or rotor Replacecap or rotor

3 Engmemisses.
a Dirty oi defectivesparkplug/s Clean, adjust or replcce plug/s
b Looseignihon wire/sor defectiveinsulahon Tighten,repairor replacewire/s
c. CrackeddistributorcaP Replacecap
d Imprope. b.eakerporntsadjustment Adjust breakerpoints

DISTRIBUTOR
Description
The clistributorconstruction is as shownin the figure102. and the distributorshaftis
drivenby the gearon ihe camshaltin time with the engine
The distributorcap is connected with the high tensionwrringsto ihe ignitioncoil and the
spark plugs,and distrrbutesthe high voltagesurgeinducedin lhc secondarywindingsoi the
ignitioncoil to eachspark plug rn turn accordingto the rolationof the rotor mountedon
the distributorcamupperend

The construclion of the brcakercomponenis is alsoasshownin the figure10-2,and consists

ofthe camwith four lobes,breakerarm and the contactpoint- Analasthe camrs fotated,
each cam lobe passesunder the breakerarm rubbing block, the breakerpoints separate,
therefore,this turns off the primarycurrent

The condenser the primary currcnt which tends

installedon the distributorhousingabsorbes
to continue flowing when the breakerpoints starts opemng,and this reducesthe arcing
at the breakerpointsto prolongthe pointslife
 IGNITION SYSTEM. Distributor r 0-3

Oil Cup

Fis. 10.2 SectionatViewof Distibutor Y5662

As it is necessaryto vary the spark timing in order to obtain efficient operation
of the
engrneaccordingto rhe rangeof speedand operatingconditions,the automatic
spark
aovancemechant)mis incorporated within rhe distfibutor

Fig. l0-3 OperarianolGovernar Adrancet cot 85,G0186

The combustion speedof the mixture is almost (onstant. consequently,
at hrgherengne
revolution, there is a shorterintervalof tjmr for the mi\ture to i;nite;nd
e;;;nd.
Therefore,in order to obtain the jllaximum dmount ol power at higher
speeds.it is neces-
sary to have the spark timmg siighily earlrerJn tht enginecycle T:his
is acco;plished by
meansof the centrifugaladvancemechanlsrn
vernor weightswhich are designedto expand
hl .upport pins. anJ lhe governor(pringqare
rts,and also the cam with the driving plate is
the cam driving pins above the weightsand
sormss.
f
1 0-4 IGNITIONSYSTEM- Distributor
outward bY the
As the distributor shaft is rotated, the govemor weights are expanded
the cam with the
centrifugal force agalnst the tension of the governor sp ngs At this tlme.
driving piate rs rotrted to thc rotating directionof the shaftby the driyingPinsln repectlo
the distributordrive shaft lo advancethe sparktiming

FiC. 10-4 Operstianof VacuumAdlancet G1273,G1274

that under heavy
Under ligilt load, it is economical to have the spark timing e lier than
even though the
load, anJ more than that obtainedby Ihc centrifugaladvancemechanism
ol tne vacuum
engineis at sxme revolution This additionaladvanceis obtained by means
advancemecnanlsm
'Ihis ihe intake
lacuum advancemechanismutilizes the increaseof the vacuum within
light load- As the vacuum
rnanifoid when the throttle valve is opened slightly under
increaseswithinthelntakemanifold,thediaphragmpullstheadvancelrodagainstthe
pulled' rotates
diaphragmspringtensiontoward the diaphrxgmslde The advancerrod when
irdvancethe spark
the breaker piate to the opposite direction of the distributor shaft to
timing furlher.

advantageof
Also the vacuum advanceris provided with the octaneselectorto oblain full
accordance
fuel for the engine performances,and it rs necessaryto adjust the spark timing in
with the quality of fuel
This octanesclectorhasno relationwith the characteristics of the vacuumadvancer

Speciflcation:
Cofidensercapacrty 0 20 - 0.2,1microfarad
Brcrker point sprlngtensron | - 1 91 o z )
4 0 0 - 5 5 0g r a m s ( 1 4
BreakerPorni gap 0 4 5 n r m( 0 0 l i l " )
Dwell angle 50 - 5,+'
Vacuumadvancecharacteristics:
Advancebcgins at 1t0 - 130mm Hg (4 3 - 5.0inHs)
Timmg advances 55-?5'at200mmFlg( 7 9 inHg)
t0 - 12' at 280 mmHe(1I 0 inHg)

Governoladvancecharactensticsi
Advance beglns at 400- 600rym
Timing advances 8.5- 105' at 1,,100 rPm
1 5- 1 7 " a t 2 , 5 0 0
rpm
 IGNITIONSYSTEM- Diskibutor lo-s

23
24

4- {8
29
30
5
9

to
@6

35

t6

25
2 C o v e r n o r s p r i nBq 26
1 5 D u t r i b u r ocra m p 27
4 G o v e r n o r s p n nAs 2A
29
3o
31 Br4ker platesersprins

Fig. IllS Distributot Components Y6801

 IGNITIONSYSTEM- Dishibutor

Removal
l. Disconnectthe hrgh tension wires fiom
the sparkplugsand the ignition coil.
As the high tension wires arc of an
internal resistancetype (Resistivecord),
care must be taken that the wires are
removedby pulling on the cord insulat-
ing fittings rather than the wire insula-
tion

2 Disconnectthe p mary wire liom the

distributor frs. IG7 RemovinsVa.uumAdvsncet v3637

3. Remove the vacuum PiPe from the 5. Removethe breake.plate with the sta-
vacuumaovancer tionaryplate.

4 Loosen the distributor clamp bolt, and

removethe distributor.

Dissssembly
l- Removethe distnbutor cap, rotol, dust
proof coverand the adjustercap,

2 Removethe breaketarm snap ring (1),

contact point retaining sffew and the
breakerarm lead wire, then removethe
breaker arm (2) with the contact point
(3) from the breakerplate. Fis IG8 RemovitsBrcokzrPlite V3677
6, Remove the distributor cam retarning
screw,and remove the distributor cam,
The retainingscrewis installedonto the
upperend ofthe distributorshaft.

FE. lG6 Remo'ingBteakerPoint v3675

3- Removethe vacuum advancerretaining
screw(l), advancerlead wre retaining
screw(2) and thesnapring(3), and then
removethe vacuumadvancer(4)
4. Removethe housing cap springs, and Fis. lG9 RemovingDistnbuttr C^m tt3678
removethe condenserand the telmrnai '7.
Remove the governor springs and the
insulators governor weights

8 Remove the prn, and thcn removc thc
spiral gcar .tnd Lhcdisrributorshaft
T o - c r n o \' r e l I ) . o r l r r . \ ( | | e Jp : t l
Ttkc care of the l^-7 washcrsinst.rlled
on tl)e distflbrLtorshaft at botlr sidesof
the Distrtbubr housing
d
Fig. IG10 Remortng
Inspection
W n s t ra U t h c p a r L sw r t h r h e e x o e f r r o no 1
r" I l .. rl
lnsIect rhe lbllo$'ing tienrs, and rep.riror
replaccany dettctlvc p rtr's
DistributorShaft
I Chccktlre shaltfor we.I ind checktlic
fllnesswith thc DistfibLrtor
horsing
lnspecLthc lhlit ibr bcnd which should
not exre.d 0 05 |rm or 0 001"
-l ('heck thc fitting portions of the gover
nor we'ghis with tl)e sLrplort pins for
Itie. la ll Ch.cltitls Pin CIeatunLe
IGNITIONSYSTEM- Distributor io 7
binarrg, and chcck the governorspring
trlting surfirccsfor \'/ear
I hc govcrnorweiShtro the pin clcrrance
h n i t i s0 2 m m o r 0 0 0 E "
l n d x l l l h e d i s t r i b r l t o rs h r f t , w l s h e r s ,
s f i l g e a rf n d t h e p i n o n t o t l r ed i s t r i b u ,
ior houslng.and thcu rnspecLthc thrust
clearcnce with a di.rl gaugc or leeler
gu.lgc
Thc clcrrance shoukl be less than 0.4
mln(0.16")
If the cleafancecxceeds0 4 mm (0 I6"),
rdlust the cle.rance with the adjLrsLing
vJ6.\a
Fts. 10.t2 Checkinsmtu Ctednncc y3681
Fts l0lJ Checkitlg
Catba Centelhece
G1275
DistributorCap
(_hcck tl)e crp for cracks. carbon tracl",
and lor bllrnl or corrodcd terminrls. Lti(
rulso chcck thc cenier carbon piece for
weaf Refer lo figure l0 l3
l h e p i e c el c n s t hr s g m m ( 0 3 5 " ) , a n d t h e
G0190 hmiL is I llrnr(0 27")
108 IGNITIONSYSTEM' Distributor

BreakerPlate& StationaryPlate At ihis time, the clearancebetweenboth

plates should be less than 0.2 mm
I Removethe snapring (1), and remove
(0 008")
the wasirer(2), set spring(3), balls(4),
washen(5), stationaryplate(6) andthe lf the clearanceexceeds, adjust the
clearance with the washer
breakerplate(7).

5321

Fig. l0J6 CheckingClednncebetweenStatiorury

fig. 1G14.DisassembliryStdtionary& Breaket & BrcskerPlates G0349
Plates v3682
Other Items
2 Coat multipurpose greaseonto the slid-
I Check the breaker points for bumt or
ing sudace of the stationary plate with
pitted condition, and if necessary,dress
the breaker plate after washlng, and
pa s with a point tile
assemblethe disassembled

2. Inspect the dist butor cam lobes for

3. Inspect the brcaker plate operating re-
scoresand wear
sistance
The resistance should be less than 500
grams (l?.? oz) 3. Inspect the condenser for capacity and
defects

4 Check the diaphragm of the vacuum

advancerfbr damage.

5 Check the spiral gear 1br wear'

'@! Assembly
I lnsert the thrust washers(2), (3) and (4)
onto the distnbutor shaft (l), and then
install the shaft onto ihe housing (5)
after l bicating the shaft with engine
oil
OpentiryResistance
Fig. l&15 Checking The bakelite washer should be insialled
G0335 beiween the steel washers,

4. Insert two scrcwdriversbeiween the

2 Assernblethe washers(6), spiral gear (?)
breakerplate and the stahonaryplateas
and the pin (8) onto the shaft, and then
shown in the fiSure 10-16,and pry the
vet both pin ends.
 IGNITION SYSTEivl- Dislributo|I0.9

'00'd'
m

Fis l0 l9 AssenhlinsUn 13678

Fis l0 17 Assemblins
DisnibutotShoft
vJ6itl

: J A s s e n b l et h c g o v € r n o rw e i g h t s( l ) a n d
(2) irnd Ihe govcrnorspringsi3) and (:1,
Take c.rreon thc assembling dircction ol
thc golemor springsas shown in figurc
t0-18
Also lubficale the connectionsand rhe
pir. ', rl .rti-- n l In , h. . tul
smooth ofeftiion

[is. 10 20 Assemhlins qredkc] Pbtc

r\s thc shape of Lhe cafi rfring i\ dlf-

ferent frour e ch olher, install the c.p
spnngsas shown in iigure l0-21

Fis. 10 l8 AsstnblinsGorernot I/3684

4 CoaLthe distributorshaft wiih rnuttiIur
pose grcase,aDd install the carnonto the
shaft
Iighten the cam retaini g scrcw.rnd iitl Ftg lU2l lnsn|ine A4' St)tut{t ta()85
thc holb$' portion .rt thc top o1-thccanl
6- Install thc vecuullt ldvirnccr itnd thc

5 lnslall the brcaker plale asscn)blvonto

7 I n s t l l t h e r e r m i n a lb o l t r n d r h c n s u l a
the housing, .rnd securc rt with ihe
tors, an( tightcn rhe nll1 frnger tight
retaining scrcw together with rhe cat
togerherwith rhc condenserlerd wire
sprurgs
1 01 0 IGNITIONSYSTEM- Distributor

8 Insrallthe conlact point and the breaker After adjustJngthe gap, righten the reLrrn
arrn onto the breakerphtc with the snap mg scrcw securety-
.ing and the retxiningscrcw
Clonnectthe breakcrarm lead wlle onto
the termirlirl,irnd tightco the nLrt
Coat the cllnl lobcs with thc Distributoi
Grease
Do not allow any oil or grcaseon the
poitlt surfaces

9 Adjust the octaneselectorto the nornal

portion as lbllows
The settlngIine should be flush with the
housing thread end
Also alignthe centerline with the setting Fis 10-23 AtljusLins Point GaP v3686
v36E7
mark
Breaker Arm Spring TeD\ion
Inspect the breekerarm springtcnsionwith
a spring tension tester by pulling at right
angle of the breakerarln pornt Rcad the
t h e n L h ep o i n t ss t a r tt o o p c n
t e s l e r j u sw
Thc specifiedtensionshould bc 200 to 500
grilrns (7 - I il oz)
lf the tension is low, replacethe brcaker
point assembly-

Fig. l0-22 OctdneSelectorNonnal Potitiut

c 1701

l0- lnstall the adjustcrcap.rnd adjustlhe

point gap referringto thc Pcrfornrance
Test in lhe lbllowing paragraph

Performance Test & Adjustment

Breaker Point Gap

Rota!cthe disLributorshaft until tlle break-
er a n rubbjng block is at the top of the
Check the point girp with a feeler gauge,
and adjustthe gapto 0.'15o. 0 0l 8"
To adjust the gap.loosenthe conlact point
retaining screw. and inscrt a slot lype
screwdriverinto rhe cut portion of the
contactpoint plate
N e \ 1 . p r y l l - . ' c I c $ d _ i v ( rl u u b l " i n I n
corred clcarance
FiE.10-21 CheckinsS\ins Tension V3688
Cnnr Drvell Angle
Check the crnl dwcll anglc lvrth the dis-
T h e r n g l es h o u l db e w i t h j n 5 0 - 5 4 ' .
T I c J d i Ur ( , l . r r h c m . d . b 1 , 1 . ' i , . . r n p
the breakerpoint gap
l f t h e g a p i s w i d e ,t h e a n g l ew i l l b e s m a l l ,
and if rhc grp is ncr.ow, thc anglewill be
large
 IGNITIONSYSTEM- Disrriburor l 0 1 1

When the tests are performed, test the

governor advance f-irst as the vacuum ad_
vancer is influenced by the governor

Fig. 1O25 Checking
&n DweI Angte
Condenser
Check Lhe condenser for minimumseries
resistance,maximum insulation res$tance
and the capacitywith the distributortestcr.
The seriesand the insulation resistances
should be within the permissiblerangeon
Also the capacityshouldbe 0.20 to 0.24
micrcfarad,
If defective,replacethe condenser.
AdvanceCharacteristtcs
Check the govemoradvanceand the vacu-
um ddvancewith the disrflbulor test(r.
I Govemor advancer.
Operate the distributor in the direction
ol rotation, and adjust the speedto the
initial rpm setting listed in the specifica_
t10n.
Move the protruded scale so that one of
the flashes aligns with the zero degree
mark.
W68g
Slowl! increaserhe rDm to setring\peci_
fication for the first advance readinp
hstedin the specification
lf the correct advanceis not indicatedar
tllls rpm, rcplace the governor spings.
Operate the distributor both forward
and reversein the rpm ranges,
Governoradvanccspecification:
Distributorrpm Advance angle
400^ 600
1,400 8s- l0 5'
2.s00 rs0^, 170"
2 Vecuumadvancer.
Connect the test sct vacuum line onro
the fitting on the vacuurn advancer

20"

l6

Gover.or Advance Anqle

12
10

vaccuumadvanceangle

o2 4 6 a 10 12 14 16 ft 20 22 24 26 2a 30 32 34 36
D s t r i b u t or p mt r I O O )

Fig. 10-26 Dittributor AdvanceAtncterhtics G1276

10.12 - Distributor
IGNITIONSYSTEIVI
Set the tesier to 0" advance, zero
vacuumat the distributor 1.000rpnr
Check the advanceat lhe first vacuum
settingspecificalionin the speciiic.Ltion
If necessrry.replacethe advancer
Vacuum rLlvance \recificillion:
(mnlHsor inllg.)
| 10- I30 (4.3- 5 0) Advancebcgrns
2OO( '79t 5 . s- 7 . 5 '
2 8 0( 1 10 ) 1 0- 1 2 "
Installation
I Position the No. I pistonat TDC of the
compressionstroke,
At this time, be sureto checkif the push
rods of the No.l cylindcr are movable
with the fingers
Next, align the timing pointer on the
timing gear cover with the timing ball
installedon the crankshaftpulley
This will set the timing at BTDC 6
degrees.
Fis. 10-27 Ignition Timins Matks
2. Hold the distributor without the distrib'
utor cap at correct installing posilion,
and position the rotor so that the rotor
t e f m i n a lw i l l a L g n w i l h r h e N . I l ( r n _ i
nal of the disfributor cap. and in addi-
tron to that the cam, which is rotated
clockwise, will start ihe breaker point to
separatefrom the contact Point.
-l With the abovc positions,align the slot
of thc oi1 purnp drivc shail upper cnd
with rhc distributor shaft .end using a
Ncxt. fotrte lhe rotor beforehrndto 30'
(about one tooth on the spiral gear)
clockwisc, then insert the distributor
onb the cylinderblock.
Fig 10-28 Distributor Inttallins Posiion v3692
4. Adjust ihe ignition trming by rotating
the distributorhousingso that the break-
er point starts io separate from the
contact point by ihe cam, then tighten
the distfibutor clamp bolt
5 . Connectthe primarywire and the vacu
um plpe
6 . Insiall ihe dust proof cover, rotor and
the distributorcap.
'7.
Insert the high tension wires securely
with the firing order of 1-2-4-3
8 Run thc engineai 550 rpm, and check
if thc timing pointer aligns with the
timrng ball usingthe timmg light
G0853
If necessary,adjust the ignition timing
by rotating the distributor housing- Do
not align the ignihon timing with the
octane selecior,and also when checking
the ignition timing, the octane selector
must be positionedat the standardposi-
tion
9. Adjust the octane selector by referring
to the Engine Tune-Up sectron
 IGNITIONSYSTEM- IsnitionCoil 10,13

IGNITION COIL

Description
The ignition coil is uhlized to transforrn
the battery voltage to the high voltage
sufficient to spark aclossthe spark plugs
cap.
It is composedof the pdmaty and seconda-
ry windings, and the latter is wound to
thousandsof windings of very fine wire.
By this wmdings,the voltageis increasedto
about 20,000 volts which is sufficient to
sparkacrossthe sparkplug gapwithout any
difficulty
The vollageinducedin the recondary wind- pjc lL29 lSnition Cotl Section G0t94
ing rs strongeslwhenthe primarycircuiti\
openedbecause of the differenceof speedof movementof the magneticlinesof force.
Whenthe breakerpoints are closed,the cur.ent flows throughthe primarywindrngscausrng
magneticlinesof force to moveawayfrom the soft iron corc,
Becauseof thet attmction to the core,they more relativelyslow Whenthe primary circurt
is opened,the magneticline of force snapbackto the corebecauseof their attractionto rt.

Specification:
Primaryvoltage l2 volts
Primaryresistance 3.3 - 4.3 ohms
Secondaryresistance 7,500- 10,000ohms
Secondaryvoltage Sparkingdistancefrom centerio three negativeelectrodesshould
be more than 8 mm (0.2'76") at distributor revolutionof 75 rpm
with 12 volts.
Sparkingdistancefrom centerto tlree negativeelectrcdesshould
be more than 6 rnm (0 236") at distributorrevolutionof 3,000
rpm with 12 volts-

Inspection
Beforetestingthe coil,alwaysheatthe coil
to normaloperatingtemperature

I Check the primary resistance wlth a

The reading should be w i t h i n 3 3 t o 4 3

ohms-

2 Checkthe secondaryresrstance
The rcsistance shouldbe withtn 7,500-
10,000ohms.
If the readingis not within the specified
resistance,
the coil is openedor shorted. Fig. 1G30 CheckingCoiI Resistance G1278
to-14 IGNITION SYSTEM- Ienition Coil. Hiah Tensionwires

3. Checkthe insulationresistance between 4. Chcckthe secondaty voltagewith a coil

the caseand the terminal with a 500 tester following the instruction manual
volts megohmmeter, of the tester furnishedby thF manufac-
The insulationresistanceshouldbe more turer
than 50 megohms. The sparkingdistance from the centerto
the three negativeelectrodesshould be
more than8 mm (0.276")at distributor
revollltionof ?5 rpm with l2 volts.
Also the sparkingshouldbe more than 6
mm (0.236")at distributorrevolutionof
3,000rpm with l2 volts

Fas 1G3l htelbhon Test v2203

HIGH TENSION wlRES

Description
Internal resistancetype spark plugsand ignitron coil wres are installedon the enginehigh
tension circuit. These wires are of a radio resistancetype whrch thc core is carbon
impregnatedlinen. These wires are deslgnedto eljminate the high freqr.rencyelectrical
impulsesthat are the sourceof ignitionnoiseinterference,but are alsosuperiorin resistance
to cross-fire. The resistivewires, however,are more easilydamagedby carelesshandling
than copper cored wires, For this reason,caremustbe takenthat the wiresareremovedby
pulling on the wire insulatingfittings ratherthan on the wire insulahon.

Removal
To disconnect the high tension wres, pull Bend the wires to check for briitle and
only on the end insulatingfitting. cracks or loose connection
Do not pull or jerk the wire, becausepull-
mg 04 the wire mlght cause damage of the L Check the condrlion of lhc wire lernri-
conducting core of the wre, nal,
If any terminal is corroded, clean it, and
Inspection if rt is broken or distorted, replace the
l . C h e i k l h e r e \ i \ l a n c ev a l u eo f e r c h w i r r
betweenboth ends Nevertry to alter the lengthof the wire,
The resistancevalue should be less tha! and do not make a sharp bend in the
25,000 ohms, and if it exceeds the
spectfiedvalue, replace rhe wire.
lnstallation
2. Wipe the high tensionwires with a cloth Insert the wire securelyas it was installed
moistened with cleaning solvent, and before,and do not allow the wire to con-
wipe them dry. tact any metal sudace.
 IGNITIONSYSTEM. SparkPlug tGls

SPARK PLUG

Housins Spec at G ass ssal

Fis. tG32 Spa* PtusSection(Densowt 7ES) G1279

Description
The temperatureof the electrodeportion must be within the specificrange (it is called
"Self-CleaningTemperature")to obtain the enginepedormancessufficiently.
If the temperatureis maintainedunder 5OO"C(930"F), suchas the engineis operatedfor
long period in slow speedat part throttle opening,the plug tendsto foul that the lnsutaror
tip and the electrodeswill becomecoveredwith carbonand other productsof combustion,
and this will resultmissingor roughnessbecause of their lowet resistance.
On the other hand, if the temperature exceeds500oC(930.F), the carbonor olner
products rs burnt and dispersed.
Hewever,tt is not necessarily good conditlonthat the temperaturcof the electrodesexceed
over500'C (930'F).
If rt exceeds870'C (1,600"F),for instance, the engineis operateal for longperiodunder
approximatelyat full load conditions,the mixture will occur preignitionand deronauon.
and the engineperformances decrease
It is, therefore,advisableto always maintain the tempemtureof the electrocleswlthin
500-8?0"C (930-1,600'F) by utilizingthe properplugwith heatrangebasedon average
drivingconditions.

Specification:
Type DENSOW2oESor NGK BP6-ES
Plugsize& reach l 4 m mx 1 9m m( 0 5 5 1x 0 . 7 4 8 " )
Pluggap 0 ? - 0 . 8m m( 0 0 2 ?- 0 0 3 1 " )
 SPECIFICATIONS

GENERAL SPECTFICATION
, - 11- I

ENGINE SPECIFIEDPARTSTIGHTENINGTORQUE ..... 11- 2

E N G I N ET U N E - U P -- . . 1 1 -l
Battery.... .. 1l- 3
Engme Oil .. lt- 3
Coolant 1l- 3
Sparkplug.. ... ....1t- 3
F a nB e l t . . . .. . I l- 3
Distributor 1l- 3
I i- 4
Carburetor I t- 4
CompressionPressure I 1- 4

ENGINE ,.....1I- 5
C y l i n d eHr e a d .. .. .. .. . I l- 5
ValveGuideBushmgs .. .. . . I l- 5
Valve ... 1 1 -5
ValveSprings I 1- 5
Vdlve Rocker Arln, & RockerShlft I l- 6
Valve Lifte$ 1l- 6
Cylinder Block 1l- 6
Cylinder Sleeves I t- 6
P i s t o n s. - ,7
il-
PistonRings l1- 1
C o n n e c t i nRgo d s _. ....11- 1
C o n n e c t i nRgo dB e a r i n g. s. . . . . .. .. 1l- 8
Crankshaft 1l- 8
CrankshaftBearings 1l- 8
T i m i n gG e a r s .. .. 8
Camshaft I 1, 9
F l y w h e e .l . . ... _. 1 1 -9
Marufolds.- ll- 9

FUEL SYSTEM I I In
Carburctor I t_tn
FuelPump 11 - 1 1

LUBRICATING SYSTEM I t-11

Oil Pump I i-11
Oi1Filter I I-t2

COOLING SYSTEM lt 12
W a t eP
r ump ll 12
Thermostat .. __. ll 12
Radutor . ..... 12
C H A R G I N GS Y S T E M . . . . . . . . . I l-13
Alternalor I l-13
AlternatorRegulator I l-t 4

STARTINGSYSTEM.. l1-14
Slarter . , . I1-14
B a t t e r y. . . I1-15

ICNITION SYSTEM l1-16

DistribuLor l1-t6
IgnilionCoil I t-16
Higi TensjonWires .. .. 1t-16
SparkPlugs l t - t?

s s T ( S P E C I ASLE R V T CTEO O L S ) ........ ....11-18

MEMORUNDUM 11-20

sl '
I-I I
t
 SPECIFICATIONS ' General SDecifications 11-1

GENERAL SPECIFICATION
VehicleModel: RT series,RN se es,RH series,RY series.

ITEMS 2R ENGINE I2R ENGINE

Type 4 cylinderrnline,4-cycleO H V. Sure
Borex Stroke 78 x 78 nm (3.07x 3 07') 805x78mm
(3.t7x3.A'7")
Pistondisplac€men1 1490cc (90 9 cu.in.) 1 5 8 7c c ( 9 6 . 8c u i n )
83tol 85tol
Compressionpressur€ I1.0kg/cm,(lss psi)at 2s0rpm Sain€
Max.horse'power(SAE) 82 HPat 5200rpm 90 HP at 5400 rprn
Max.to.que(sAE) 12.4m-ks(90 frlb) at 2800rpm l3.s m,kg (98 fr-lb)
at 3,000 rpm
Numberofpiston rio8s.
Two Same
oil One Same

lntake(hot) 0.203mm (0.008")

Exnaust(hoo 0 356 mJn(0 014") Same
Ignitiontiming 8 ' B T D . C a t 5 5 0r p m Same
1-3-4-2 Sam€
Sparkplugsize 14x l9 nm (0 5s x 0.7s") San€
Sparkpluggap 0 8 mm (0.031") Sa,'ne
Felt element(RI), Paperelement (RH, RN Same
RY)
Dolln-&afl, two barrel Sane
Fuelpunp type DaphIagn
Fuelfilter type Glassbrll type (Old),Carr.edse
rype(New)
Oil pumptype Trochoid Sane
Oil fiter element Paper Same
Oil capacity
Crankcase 3.5 liter (3 7 USqts-,3 I Imp qts)
Oil filter 0.8liter(0 85 USqts,0.70Imp.qts) Same
Radiatortype Corugatedfin andtube Same
Centnfugal
Thennostattype
Battery 12 volt, 35 ^- 50 AH
12volt,0.48 kW
Starter 12volt,llps
Coolantcapadty:-
RT&RY 7 0liters (7.4 USqrs.,6 2 In1p.qts )
RH 6 T liten (7.1US qti , 5 9 Imp qts )
RN 6 5lilen (6.9USqts,5-7Inp. qts.)
Fueltank capacify:
RT, R}I 45liters(11.9USgal.,9.9Inpgal-)
RN 46liters(12.1USgal.,10.1In1p.gai)
RY 50liters(13.2USgal.,1l 0Imp. gal.)
11-2 SPECIFICATIONS- EngineSpecifiedPartsTighteningTorque

ENGINE SPECIFIEDPARTS TIGHTENING TORQUE

Tightening Parts TighteningTorque

m-ks (ft-lb)

9.8 I r.l (.'7

| 8l)
Crankshafl bearinPcap to cyllnder block

Flywheel to crankshalt 58 6.6 (42 48)

Connecting rod cap to connecting rod 4.0 5.0 (.29 36)

Camlh.rfl lhrusl plate lo cylinder block |4 20 (10 t4)

Timing gear cover to cylinder block |4 20 (r0 14)

Crankshaft pulley to crankshaft 4.1 5.5 (30 - 40)

Oil purnp to cylinder block 14 20 (10 - 14)

Oil pan to cylinder block 0.4 0.8 (3 6)

Oil pan drain plug to oil pan 3.5 4.5 (2s 33)

Cylinder head to cylrnder block 1 0 . 3- r 1 . 7 (?5 85)

L8 2.5 (13 lE)

Valve rocker support to cylinder bead

Manifotds lo cylinder head (20 2s)

Spark plug to cylind€r head t.5 2.1 01 - ls)

Oil filter to cartridge guide 1..1 2.o (r0 14)

Cylinder head cover to cylinder head 0.2 0.4 ( I 3)

Clutch cover to flywheel 1.0 16 (1 12)

 - EngineTune-up r1,3
SPECIFICATIONS

ENGINE TUNE.UP

Batte.y

Batteryelectrolytespecific
gravityat 20oC(68oF) L250 - 1,2'tO
Batterychargedconditionat 20oCor 68oF (refercnce):
Over 1.230 Over75%charged,requiringno cha4ing
Between1.190 1.230 50- 75% chaqed,canbe chargedwith
Quick Charyer
Below 1.190 Below50%charged,requiresBenchCharge
Battery electrolytelevel Over l0 mm (0.4") aboveplates

Engine Oil

Engine oil capacity: Cmnkcase 3.5 liten (3.7 US qts., 3.1 Imp. qts)
oil filter Approx. 0.8 liter (0.85 US qts.,
0.70 Imp. qts)

Coolant

Cooling systemcapacity:
RT&RY se es 7.0 lite$ (? 4 US qts.,6 2 tmp qts)
RH series 6.7 liters(?.1 US qts , 5 9 Imp. qts)
RN se es 6.5 liters(6.9US qts,5 7 Imp.qts)
Spark Plug

Sparkplug gap O.'l 0.8 rnm (0.028 0031")

Recommendedspark plugs: NIPPONDENSO w20ES
NGK BP-6ES
BOSCH W2OOT27
CHAMPION NIO-Y

Fan Belt

Fan belt slack 8 - 13 mm (031 - 0.51')with 10 kg

(22 lbs) depressed
Pressure

Distributor

Breakerpoint gap 0.1 0.smm(0.016 0020")

Cam dwell angle 50 540
Breakerpoint springtension '100 550 grams(14 19 oz)
Condensercapacity 0-20 - 0.24 microta.3d
Ignition timmg 80 B.T.D.Cat 550 rpm
 . EngineTune-up
11-4 SPECIFICATIONS

Vake

valve clearance(hot): Intake 0.203mm (0.008")

Exhaust 0.360mm (0.014")
Cylinder head bolts tighteningtorque 10.3 11.'7n-kg (74 86 ft-lb)
Rocker shaft support bolts
tighteningtorque 1 . 8 - 2 . 5 m - k e( 1 3 l8 ft-lb)

Carburetor

Engine idling speed 550 rpm

Manifold vacuum at idling Over 430 mm Hg ( 17 rn Hg)

CompressionPressure

Compressionpressureat 250 rpm over I I.0 kg/cn2 (156 psi)

Comprcssionpressurelimit 8 . 0 k g / c m 2( l l 5 p s i )
Differcnceof pressure
betweencylinders Lessthan 0.7 kg/cm2(10 psi)
 FICATIONS- Ensine 11-5
SPECI

ENGINE

Cylinder Head

Cylinder head water leak testing pressure 1.0 4,5 ks/cm2 (57 64 psr)
Cylinder head instalhngsurface
warpagelimit 0.05rnm (0.002")
Valve seatrcfacrngangle 15(),45(),75t)
Valveseatcontactingwidth 1.2 L6 mm(0.05 0 06")

Valve Guide Bushings

Valve guide bushingmner diameter 8 . 0 1 8 0 3 m m ( 0 . 3 15 0 316")

Valve guide bushingouter diameter
Valveguidebushingprotrusion:
Intake 2R
Exhaust 2R
Intake& Exhaust l2R
1m (0.ss2l 0.5s28")
1 4 . 0 2 3 1 4 . 0 . 1m
2 5 . 0 2 6 0 m r n( 1 . 0 I 0 2 " )
2 20 2 3 0 ] n n ( 0 . 8 7 0 9 1 " . )
l8 mn (07l ")

Valveheaddiameter: lntake 3 9 l n m ( 1 . 5 4 " ) -2 R , 4 0 m m ( l 5 7 " ) 1 2 R

Exhausi 3 3m n ( l . 3 0 " ) 2 R , 3 4 m m ( 1 3 , 1 " ) 1 2 R
Valve overall length I 1 5 . 8m m ( 4 5 6 " ) 2 R , 1 0 90 m m ( 4 2 9 " ) l 2 R
Valve overall length limit 1 1 53 m m ( . 1s 4 " ) 2 R , 1 0 85 m m ( 4 . 2 7 " ) 1 2 R
'7-9'70 '7.985mm (0.3138 0 3144")
Valvestem diameter: Intake
'7.9'75 (0 3134 0.3140")
Exhaust 1 960 rnm
Valve stem to bushingoil clearance:
Intake 0.025 0 060lnm(0 0010 0.024")
Exhaust 0.035 0 070mm(0 0014 0 002E")
Valve stem to bushingoil clearancelimit'
Intake 0.08mm (0 003")
Exhaust 0.10mm (0.0021")
Valve head edgethlcknesslimit:
Intake 0.7rnm(0 028")
Exhaust 0.7mm(0 028")
Valve head contactingface angle 450

Valve Springs
2R t2R
Free length Inner 46 mm (r 8r") 3 9 . ?m m ( 1s 6 " )
Outer ,<2.6mm (2.01") 3 4 . 5m m i '/9")
Installedlength: I n n e r 404mm (l.s9") 3 4 . 2m m (l 3s")
Outer 46.4mm (l 83") 40-0mm I s7')
lnstallediension:Inner 56kg ( r 23 l b ) 64kg (14l lb)
Outer 260kg (s73 lb) 233ks (sl 3 lb)
 - Ensine
11.6 SPECIFICATIONS

Installedtension limit:
Inner 36ks (7 9 rb) ( 1 12 l b )
5 . 1k g
Outer 2 2 . 6k s (4e8 rb) I 9 . 0k s (418 rb)
Squarenesslimit:Inner l6mm (0.063") I 6 m m (o.063")
Outer l.9mm (007s") 1 . 9m m (0.07s")

Valve Rocker Arms & Rocker Shaft

Rockeralm bushingouter dalmeter 2R 21.Cr75 21.Ii5 nm(0829/-08313 ")

r i a m e r e- r 2 R
R o c k ear r mb L l ( h i rign n e d 18.500 l8 521 mrn(O'7283 0'/292")
Rockershaftdiameter 2R 1 8 . 4 7 0 1 8 1 8 1m n r 0 . - ) 7 2 0 . 7 1 " - " ,
Rockershaftdiameter l2R 1 8 . 4 7 4 1 8z l 8 7m m ( 0 7 2 7 3 0 . 7 2 ' t 8 " )
Rockershaftto bush g oil clearancc 2R 0 . 0 1 7 0 0 5 1m m ( 0 . 0 0 0 ? 0 0 0 2 0 " )
Rockershaftto rockerarm bore clearanc. 0.020 0.03smm (0 0008 0 0014")
- l2R
Valve Lifters

Valvelifter diameter: STD 2 ) 1 1 8 2 2 1 8 5m m r 0 8 " J l 0 . 8 7 3 4 " y

o/s 0.075 22.185 22 Is2mm(08734 0.87J7")
o/s 0 125 22 t92 22 199mn (0 8737 0.8740")
Lifter bore finisheddiameter: STD 22.2.00 22 20'7rnm(O8140 0.8743")
o/s 0 075 2 2 . 2 0 - 2 ) ) 1 . 1m m r 0 8 4 3 . O E 1 4 b " )
o / s 0 . 1 2 52 2 . 2 1 4 2 2 . 2 2 m
1 mr 0 8 7 4 o 0 . 8 ' 4 1 " )
Valvelifter to bore oil clearance 0 . 0 1 5- 0 0 2 9m m ( 0 0 0 0 6- 0 . 0 0 1 1 ' 1
Valvelifter to boreoil cieamnce Iimlt 0.1 mm (0 004")

Cylinder Block

Cylinder block upper surfacewarpage

limii 0.05 mm (0 002")
Cylinder block water leak testing
pressure 4.0 1.5 kelcm2(5'7 64 psi)
Cylinderbore diameter(STD) 2R 78 00 78.03mm (3 0'11 3.012")
Cylinderborediamcter(STD)- l2R 8 0 . 5 0 8 0 . 5 5m m ( 3 . 1 7 0 3 . 1 7 1 " )
Cylinderborewearl1m1t 0.2 mm (0 008")
Differenceof borebetweencylinders Lessthan0.05mm (0 002")
Cylinderboretaper & out of-roundlimit 0.02mm (0.0008")

Cylinder Sleeves

Sleeveouter diamter: o/s 4 00 2R 82.0n1 8 j l , 1 6m - nt J . 2 3 l o J 2331",

o/s 4 00 l2R 84.590 8 4 6 5 0m m ( 3 3 3 0 3 3.3327")
o / s4 5 0 2R 82s9l - 8 2 . 6 2 6m m ( 3 . 2 5 1 6 3 2530')
o / s4 5 0 12R 85.040 8 5 1 5 0m m ( 3 . 3 5 0 0 3.3s.14")
o/s 5.00 2R 83 091 83.126mm (3.2'713 3.2'72'7")
o / ss . 0 0 l2R 85 590 85 650 nm (3 369? 3 3720")
Sleeve fltting tolerance u.05b 0 .l 2 b m m ( u . 0 0 2 2 0 0 0 5 0 " i
 FICATIONS- Ensine 117
SPECI

Sleeveinstalling prcssure 2,000 3,000 ke (4,400 6,600 tb)

Pistons

Pistondiameterat 20oC(68oF)

Identmark 2R mm (in) l2R mm(in)

1 7 7 . 9 6(s3 . 0 6 9 5 ) 8 0 . 4 s (53 1 6 7 5 )
2 '7',7
915(3.0699) 8 0 . 4 6(53 1 6 7 9 )
l 7'7985(3.0'/03) 8 0 . 4 7(s3 1 6 8 3 )
4 8 0 . 4 8(53 1 6 8 7 )
5 8 04 9 5( 3 . I 6 9 1 )
o/s 0 . 2 5 , 0 . s 0 , 0 . 7150,0 I, . 2 5 ,1 5 0

Piston Rings

Pistonring end gap:

Compressionring No I 02 0.4 mm (0 008 0.016,,)
Compressionring No.2 0.1 0.3 mnl (0.004 0.012,,)
Oil rins 0.1 0.3 rnm (0.004 0012,,)
Piston ring to ng groove clearancel
Compressioning No.l 0.03 0.0? mm (0.0012 0 002?,,)
Compression ring No.2 0.03 - 0.07 mm (0.0012 OOO27',\
Oil rms 0.025 0.07 mm (0.0010- OOO27',)

ConnectingRods

Connecting rod bend and twlst limit
Connecting rod thrustclearance
Connectingrod thrust clearancelinit
Pistonpin to bushingoil clearance
Piston pin to bushingoil clearancelimit
0.05 mm (0.002")per 100 mn (3,94',)
0.08 0.24 nm (0.003 0.010,,
0.3 mm (0.012,,)
0.006 0.010rnm (0.0002 0.0004")
0,015 mm (0 0006,,)
 - Engine
1i 8 SPECIFICATIONS

Connectint Rod Bearings

Crankpinjournal finisheddiameter:
STD beerings 4 9 . 9 8 5 5 0 0 0 0m m ( l . 9 6 7 9 1 9 6 8 5 " )
U/S 0.05bearings 49.9ii5 50 000 mm (l 9679 1 . 9 6 8 s " )
U/S 0.25bearings 49 756 49 766 mm (l 9589 1 9 5 9 3 " )
U/S 0.50 bearings 4 9 5 0 6 4 9 5 1 6m m ( 1 . 9 4 9 1 1 . 9 4 9 s " )
U/S 0.75bea ngs 49 2.56 49 266 mm (1 9392 1 9 3 9 6 " )
U/S 1.00 bearings 49.006 49.016mm (l 9294 - 1 . 9 2 9 8 " )
Connectlngrod bearingoil clearance 2R 0 016 0.040mm (0.0006 0 0 0 1 6 " )
Connechngrod bearingoil clearance 12R 0.024 0 048 mm (0.0009 0 0020")
Connectmgrod bearingoil clearancelimit 0.10mm (0.004")

Crankshaft

Crankshallbend limit 0.05 mrn (0 002")

Crankshaftthrust clearance 0 0.lE mm (0 - 0.007")
Crankshaftthrust clearancelimrt 0.3mm (0.012")
Crankshaftjoumal taper and
out-of{ound limit 0.05 mm (0.002")
Crankprn journal taperand
out-of-roundlimit 0.05 mm (0.002")
Crankshaftthrust bearingthickness:
STD bearings 2.950 3 . 0 0 0m m ( 0 . 1 1 6 1 0 118r")
O/S-0.125 bearings 3.013 3 . 0 6 3m m ( 0 . l l l t 6 0 1206")
O/S 0.250 bearings 3.075 3 . 1 2 5m t n ( 0 . 1 2 1 I 0.I230")
O/S 0.500 bearings 3.200 3 . 2 5 0m m ( 0 . 1 2 6 0 0 1280")

Cenkshaft Bearings

Crankshaftjournal finished diameter:

STD bearings s7.976 58.000(2.2825- 2.2835")
U/S 0.05 bearings 5 ? . 9 ? -6 5 8 . 0 0 (2.2825
0 - 2.2835")
U/S 0.25 bearings 5'7.750 - s7.',760 mn (2.2736- 2.2740")
' -
U/S-0.50 bearings 57.500 57.510 mm (2.2638 2.2642"\
U/S 0.75 bearings s'7.250 5'.7 .260 mm (2.2539 22543")
U/S 1.00 bearings 5 7 . 0 0 -0 5 7 . 0 1 0
nm (2.2141 2 2445")
Crankshaftbearingoil clearance 0.020 0.044
Crankshaftbearingoil clearancelimit 0.1 mm (0 004")

TimiDg Gearc

Timing gearbacklash 0.020 0.130mm(0.0008 - 0.00s2")- 2R

-
0 068 0 I70 mm(0 0027 0 . 0 0 6 7 " ) l 2 R
Timing gearbacklashlimit 0 3 m m( 0 0 1 2 " )
Camshafttiming gearrun-outlimit 0.25mln(0.01")
 , Engine 1t-e
SPECIFICATIONS
Camshaft

Carnshaft
bendlimit 0 05 mn (0002")
Camshaftthrust clearance 0 06 0 I22 ,nm (0 0024 0.0048,,) 2R
0 0 s 0 I 3 0 m m( 0 0 0 2 0 0 . 0 0 s 2 , , ) 1 2 R
Camshaftthrust clcarancelimit 0 . 3m r n( 0 . 0i 2 " ) l R
0 2 m m( 0 0 0 8 " ) t 2 R
Cam lobe heighti lntake
3 E . 3 6 3 8 . 4 6n r n ( 1 . s1 0 I 5 1 2 1 " )
Exhaust 3 8 . 2 - 5 3 8 . 3 5m m ( l 5 0 6 I 5 t 0 " )
Cam lobe heightlimit: Intake
3 8 . 2 9m m ( t . 5 0 8 , . )
Exhaust 3 E . l 8m m ( 1 5 0 3 . , )
Cam liiti Intake 6.31 6.44 nln (0.250_ o.2s4")
Exhaust 6 . 1 5 6 . 5 5m m ( 0 2 5 4 - 0 . 2 5 8 " )

CamshaltBearings

jou.nal jintshedcliameteri
Camshaft
STD bearings: No.l journai 4 6 . 4 5 9 . 1 6 . 4 7I5n m ( 1 . 8 2 9 1- i . 8 2 9 7 - )
No.2 iournal 4 6 . 2 0 9 4 6 . 2 1 5m m ( 1 . 8 t 9 3 1 . 8 1 9 9 , . )
No 3 journai 4 5 . 9 5 9 4 5 . 9 7 5m r n ( l . 8 0 9 4 I 8 1 0 0 - )
U/S-0.125 bea.ings:
No.I journal 46.335 46.34smnl (1.8242 1.8246,,.)
No.2iournal 4 6 . 0 8 5 4 6 . 0 S 5n m ( t . 8 1 4 . 1 1 . 8 i 4 8 - )
No.3 journal 4 5 . 8 3 5 4 5 . 8 4 5m m ( 1 . 8 0 4 5- I 8 0 4 9 , , )
U/S-0.250 bearings.
No.l journal 4 6 . 2 1 0 4 6 . 2 2 0r n m ( 1 . 8 1 9 3 1 . 8 1 9 7 - )
No.2 journal 4 5 . 9 6 0 4 5 . 9 7 0n 1 m( 1 . 8 0 9 5 1 . 8 0 9 8 , . )
No.3 joumal 45.'710 45120 mm (t.'t996 I 8000-)
U/S 0.500 bearinss
No.I jou.nal 4 5 . 9 6 0 4 5 . 9 7 0m m 0 . 8 0 9 s 1 . 8 0 9 8 - )
No.2 joumal 45.'/t0 45.'72omm 0]996 I8OO0-)
No.3 journal 45.460 45.470mm (1.7898- 1.t902.,)
Camshaftbearingoil clearance 0.025 0.066rnm (0.0010 0.0026-)
Camshaftbearingoil clearancelimit 0.1 mm (0.004")

Flywheel

Flywheel run-out limit 0.2 mm (0 008")

Manifolds

Manifold fitting su ace warpagelimit 0.4 mm (0016")

11 1o SPECIFICATIONS- Fuel System

FUEL SYSTEM

Carburetor

RT RY, RH RN
T) pe Do
An honeouterdiameter 63.0(2 48)
ffn (in)
Prinrary N'lain 2 30 ( 0 9 r )
Smdll 8 0 (0.32)
2R- 27 0 (1.06)
r2R-2E0( )
2R 70(028)
Small
12R 90(036)
Throttle bore diameler
30 0 (1 18)
2R- 32 0 (1 26)
l2R- 34 0 (l 34)
Mdnjer diameter mn (in)
2R- 1.08(0 143.) 1.06(0.042) 1.11(0.044)
l2R- 1 0s (0 04r) 1.03(0.041) r.03(0.04r)
2R- l 10 (0 05s) 1 60(0.063) 1.47(0.058)
t2R- I 62 (0 064) l.s6(0.061) 1.65(0 06s)
2R- 0 55 (0 022) 0 43s(0.017) 0 525(0 021)
'nm (in)
l2R- 0.50(0.020) o 47(0.019) o.4-1lo o19)
2R 0 7s (0.030) 0.60(0 024.) 0.70(0.028)
r2R o so(0.0:o) 0.58(0023) 0.60(0.024)
0.47(0.019)
0 s0 (0 020) 0.50(0.020)
0 s0 (0.020)
2R- 0.80(0031) 0.80(003r) 0.80(0.031)
Economizerjet dirmeter mm (in)
i 2R, 1.00(0 040) 1.00(0.040)
Main air bleeddrmeter
2R, o.7o(o 028) 0.s0(0.020) 0.70(0.028)
12R 0.s0(0 020) 0.s0(0 020)
2R, 0.?o(0.028) 0.s0(0.020) 0.70(0 028)
Second y
12R-0.so(0.020) 0.s0(0.020)
'70-
2R- 110- 130 90 ll0-130
(43-s.l) (2 8 - 3.s) ( 43- s . r )
Powerpistonoperatinsvacuum mn 0n)
12R-t20- I40 120- 14D 120- 140
(4.7^- s s) (4.7- s s\ (4.7- s.s)
mn (in)
Rarsedposition (from air horn fitling
3 5 (0.r40)
Loweredposition (behveenneedlevdve
0 9 (003s)
push pin and flod1trb)
screwpreset
Idlemixturcadjusting

for 2R Screwout about 2 l/2 tLrrnsalier slighrly seating.

for 12R Screwout about 2 tu.ns after slghtly seating
 F ICATIONS- FuelSystem Lubricating
SPECI System 11.11

Throttle valv€fuUy clos€dangle

l,ri'nrry
20"
F_rstidle: Itrnraiy thJottlevalveshould 2R 12' 12" 13"
open !l Rigl't dcgreefrom closed 12R 13' 11"
pos'lur \!lrc tl'e choke valveis
lully closcd
2R 30"
t2R 27'
Thermostrtic vrlv! operatingremperatufe Fully closcdat 60'C (140'F)
F u l l y o p e n e dd t 7 5 ' C ( 1 6 ? ' F )

Fuel Pump

Type Mechanicaldiaphragm
Dehverycapacity Over 1,000cc (1.06 US qts,,0.88 Irnp. qts)
p€r minuteat 1,000rym of camshaft.
Dehverypressure 0.n 0 . 3 2 k g / c m 21 3 . 1 4 . 5 p s i )
Suctionvacuum Over 400 mm Hg (15.7 in Hs)

LUERICATTNGSYSTEM

Oil Pump

Type Trochord
Delivery capacity O v e r1 7 l i t e . s( 1 8 U S q h . , t 5 I m p . q t s )
per minuteat pump;3,000rpm,
oil temperature; I00oC (2l2oF),
oil pressure; 3.2 kg/cm2(45 5")
Reliel 'ralve operatinSpressure 3 . 1 4 J k g c m l r s j . n o t . , t p s i ra l
pump; 2,500rym, oit tempemture;l00oC
(2120F)
Pump shaft to body oil clearance 0.013- 0.050mrn (0.000s 0 0020")
Tip clearance 0 . 0 7- 0 . 1 2m m ( 0 . 0 0 3 0 . 0 0 5 " )
Tip clearancelimit 0.2 mm (0 008")
Side clearance 0.03 0.09 mm (0.001 -. 0 004")
Side clearanc€limit 0 . 1 5m m ( 0 . 0 0 6 " )
 System- CoolingSystcm
- Lubricating
1112 SPECIFICATIONS

Body clearance 0 . 1 0 0 . 1 6m r n ( 0 0 0 . 1 0 0 0 6 " )

Body clearanceIimit 0.2 mm (0 008")

Oil Filter

Filtrationiype FulFflow
Elementmaterial Paper
Casecapacity Approx. 0.8ljter (0.85 US qts., 0 70 Imp. qts)
By-passvalve operatmgpressure 0.8 1 . 2 k g / c m 2( 1 1 . 4 1?.0psi)

COOLING SYSTEM

Water Pump

Water pump type Cent fugal pump

Delivery capacity
Water seal method
Bearingtype
Rotational ratio to crank pulley
Water pump bearingfitting temperature
Water pump iotor to body clearance
Over 120 liters(31.7 US gals.,26.4 In,p.
gals)per minuteat pump; 3,500rpm,
deliverypressure;approx. 0.4 kg/cm2
(s.7 psi)
Mechanicalseal
Dual ball bearingswith greasesealed
13to 11
Waterpump body shouldbe heatedto
'75
U5oC(167 l85oF) for bearing
replacement.
0.3 0.?mm (0.012 0030".)

Thermostat

Type
Valveopeningtelnperture:
Startsto openet 80.s 83.5"C (r77 182'F) 2R
7 35 7 6 . s ' C( 1 6 4 1 7 0 " F ) l 2 R
[.u1]opcnstt 7 5 ' C( 2 0 3 ' F ) 2 R
8 s ' c (1 8 5 ' l ' ) l r R
Valveopeningtravel Over8 nm (0 315")

Radialor

Type Pressudzedcorrugatedfin and tube

Radiatorcap openingprcssure 0 5 ks/cm?(7 psi) 2R
0 . 9k g / c m '(?1 3 p s i ) l l R

CHARGING SYSTEM
Alternator
Nominal voltage
Nominal output current: RT series
Lighr Truck
Ground
Di.ection of rcvolution
Stator coil connection
Rectifrcation
Pulley ratio. RT scrres
Light Ruck
Ncload characteristicsat normal
temperature:RT se es
Lfight Truck
Load characteristics
at norrnal
temperature:RT40 series
Light T.uck
Siip rjng Lliameter
Slip ring diameterhmit
Brush protruded length
Brushp.otrudedlengthlimit
tsrushspringtension
ljrush sprjng tension limit
Rotor shaft bend limit
Rotor coil resistance
Stator coil resistance
Pulley retaining nut tightenrngtorque
Rechfier characteristics:
Correct di.ection characteristic
Reverscdircction characieristic
Note: The correctdirectioncan be definedwlth directionin which positive
voltage is actuated at rectifier body side, and negatrvevoltage at lead
- Charging
SPECIFICATIONS System 11 . 1 3
12volts
40 amperes
30 amperes
Negative
Clockwise as seen from pulley
Three-phase,"Y" shape
Full wave rectifjcatton by six integral
siliconediodes
2.0
L69
700 900 rpm at 14 volts,zelo ampere
800 1 0 0 0r p n -d l l 4 v o l t s .z e r oa m p e r c
Lessthan 3500 rym at 14 volts,40 anrperes
Lessthan 4000 rpm at 14 votts,30 anrperes
32 mm (l 259")
316 mm (l 243")
1 2 . 5m m ( 0 5 0 " )
8.5 mn (0 3zl")
, 1 5 0 5 5 0 g r a m s{ 1 5 . 9 1 9 . 4o z )
3 5 0 g r a m s( 1 2 . 3o z )
0.1 mm (0 00,1")
4.1 4.3ohms
Approximately0.24 ohm
0.35 0.50 m-kg(2.5 3.6 ft-lb)
At normal tempcrature, when dircct currenr or
2l amperesls applied. the voltage difference
betweenthe rechfierleadand the body
shouldbe lessthan 1.2 volts.
At normal temperature, when dircct current
voltage of 100 volts is actuated, the reverse
currentshouldbe lessthan 1.5 milliamperes.
tr 14 SPECIFICATIONS- ChargingSystem- StartingSystem

Altemator Reguhtor

Voltageregulatorregulatingvoltage 1 3 . E I 4 , Uv o l t s
Voltagerelayoperatingvoltage 4.5 - 5.8volts
Regulatorcircuit resistancevalues:
BetweenIG terminal& F terminal(actuated) Approximatelyl0 ohms
Between[G terminal& F terminal(not actuated) Zero ohm
BetweenL teminal & E terminal(actuated) Approximately100 ohms
BetweenL terminal& E terminal(not actuated) Zero ohm
Betwe€nN terminal& E terminal(not actuated) Approximately23 ollms
BetweenB terminal& L terminal (actuated) Zero ohm
BetweenB terminal& E terminal(not actuated) Infinite
Between B terminal & E terminal (actuated) Approximately100ohms
BetweenF terminal& E terminal(not actuated) Infinite
F
Between terminal & E terminal (actuated) Zero ohm
Voltageregulatormechanicaladjustingvalues:
Angtegap(actuated) Over0.2 mm (0.008")
Pointgap(not actuated) 0.25- 0.45mm (0.010 0 018")
Contactspringdeflection(actuated) Oler 0.2 mm (0 008")
Armaturegap(not actuated) 0.6 - 0.EInm (0.024 0.031")
Voltagerelay mechanicaladjustingvalues:
Pointgap(not actuated) 0 4 - l 2 mrn(0 016 0 047")
Contactspringdeflection(actuated) 0.20 - 0.45 mm (0-008 - 0.018")

STARTINGSYSTEM

Sfarter

Motor type Direct current,serieswoundw/magneticswitch

Nominal voltage & output Power 12 volts,0.8 kW (l.l ps)
Rating time 30 seconds
Direction of revolution Clockwiseas seenfrom Pinion side
Number of poles Four
Number of pinion teeth Nine
Suitablebatiery 12 volts 40 - 60 AH
: Voltage
No-load characteristic At 11.0volts
Ampemge Lessthan 45 amPeres
Revoluhon More than 5,000rpm
Locked characteristic:
Voltage At 7.? volts
Amperage Lessthan 470 amPeres
Torque More than 1.2 m-kg (8.6 fllb.)
Armature shaft diameter 1 2 . 5 0m m ( 0 4 7 2 " )
 SPECIFICATIONS- StartingSysfcm i1 j5

Armatureshalt b!shinginner (tiameter:

STI)
u/s 0 30
u/s 0.50
Shall to buslling clearance
Shalt to bushingcleannce limii
Shaft thrust clearancc
Shaft throst cleamncelimit
[bmmu tator diameter
Comnrutatordiameter limit
CoinDlutatorout-ofround
(ornmutator ou t-ol:round limit
Conrnrutato.mica depth
Commutator mica depth limit
Brush lcngrh
Brush length lirnii
Brush spring tcnston
Brush spring tcnsion limit
Magneiic switch movng stud length
Pinion to stop collar clearancc
Magneticswitch pull-in test
Magneticswitch holding test
MagneticsMtch return test
I2 s35 -. I 2.560mm (0.4935 O4.)45'-)
12.235 I2.260 mm (0.481.t- 0 482.7,,\
i 2 . 0 3 s - I 2 . 0 6 0m m ( 0 . 4 ? 3 8- O 4 t 4 8 , ' \
u.l mm (0 004,,.)
0.2 mm (0 008,,)
tj.05 0 35 mm (0.002 0 13")
0.umm (0.03")
- l t l8 I n r n ( 1 5 3 " ) 2 R , 3 2 7 r n m ( i 3 t , , ) 1 2 R
3 6 8 m r n( 1 4 5 " ) 2 R . 3 07 m r n( t . 2 1 " ) l 2 R
0.1 rnrn (0.004,,)
0 . 3 m m ( 0 . 0t 2 " )
0.5 0.8 mm (0.02 0 03-)
0.2 mrn (0 008")
l9 mrn(0.75")
12 mm (0 47")
1,050 1,350grarns(2.3 3.0 lbs)
600 grarns( 1.3 lbs)
Approximate34 mm (1.34")
I 4 mm (0 04 0.16") w/pinion
pushedout.
Plungershould be fully pulled in with
8 voits at pull-in coil.
Plungershould be held by holding coil
with E volts alte. beingpulled-in.
Wiih holdrngcoil and pull in coil
connected in series,the plungershould
be return lully with I2 volts.

Battery

Electrciyte specificgmvity at 20oC (680F)'

r,250 |,210 I00% charged state
I,210 ?5% charged state
1,160 50% charged state
I , 11 0 25% charged state
1,060 Fully discharged state
Batterycapacityat 20 H R.
l'li powcr,10 35 - 3 8 A H
N4O 40 AH
N5O 50AH
NsOZ 60 AH
I1.16 SPECIF ICAT IONS - Ignition System

IGNITION SYSTEM

Distributor

Condensercapacity 0.2O- 0.24 micrcfarad

Breakerpoint spring tension 400 550srarns(14 1 9 o z )
Breakerpoint gap 0.4 0.5 mm (0.016- 0.020")
Dwell angle 50 540
Govemor advancecharacteristics:
Distributor 400 600 rpm Advance begins
1400 rym 8.5 10.50
2500 rpm 15.0 17.00
Vacuum advancecharacterislics:
Vacuum| 10 130minHe(4.3-5.0 in Hg) Advance begins
200 mmHg (7 9 in Hs) 5 . 5- 7 . 5 0
280 mmHg (l1.0 inHg) t0 120
Distributorshaft bendlimit 0.0?mm (0 003")
Governorweightto support pin
clearanc€limit 0.2 mrn (0.008")
Distributorshaftth st clearancelimit 0,4 mm (0.016")
Distributor cap carbon piece length 9 mm (0.35")
Distributor cap carbon piece length limit 7 rr.rn (0 28" )
Breakerplate operatingrcsistance 200 500 grams(7 lE oz)
Breakerplate to stationaryplate clearance L€ssthan 0.2 mm (0.008"j

Ignition Coil

Primary voltage 12 volts

Secondaryvoltage
Primary coil resistance
Secondarycoil resistance
Insulationresistance
Sparkingdistancefrom center to three
negativeelectrodesshould be more than
8 mm (0 32") at distdbutor revolution
of 75 rym and more than 6 mm (0.34")
at 3,000 rpm with 12 volts.
3.3 4.3 ohms
7,500 10,000ohms
50 megohmsw/500 volt MegohmMeter

'Iension wircs
High

Wire end to end resistancelimit 25,000ohmsper unit

 - IgnitionSystem 1l-17
SPECIFICATIONS

O.'7 0.8 mm (0.027 0.031")

1 4 m m x 1 9 m m ( 0 . 5 5 1x 0 . 7 4 8 " )
sparkplug:
NIPPONDENSO W2OES
NGK BP-6ES
CHAMPION NIOY
BOSCH w200T2'7
tighteningtorque l . s - 2 . 1 m - k g( l l - l 5 f t - l b )
11 18 SPECIFICATIONS- SpecialService

SST (SPECIAL SERVICETOOLS)

t14l

(1s)

,#
-1,-. &

{161

@P
(12)

_€\

113)

SpecinlSenice Tool List lor 2R Ensine

 SPECIFICATIONS- SpecialServiceTools 1119

(t) 0 9 3 1 0 - 3 1l 0 1 Timing Gear Tool Sei

(2\ 09213-60012+ CrankshaftPulley & Gear Puller
(3) 0921+600t CrankshaftPulley & Gear Replacer
(4) 09201-60010 V d l v eS r e mC u i d eR e m o r e&
r Replace-
(s) 09222-30010 Connectlng
Rod BushingRemover& Replacer
(6) 0990s-00010 SnapRing ExpanderNo.I
(7) 0 9 2 1 5 - 3 100 r CamshaftBearingRemover& Replacer
(8) 0e301-36010 Clutch Gurde Tool
(e) 09303-35010 lnput Shaft Front BearingPuller
( t0) 0930+30012 Input Shait Front tsearing
Replacer
(lt) 09238-40010 Water Pump BearingRemover& Replacer
(12) 0 9 2 3 9 - 3 I00 t Water Pump Roior Puller
(13) 0 9 2 3 52 0 0 1 1 Water Pump Pulley Seat Puller
(14) 09240-00010 CarburetorAdjust Kit
(ls) 0986G11010 CarburetorScrewdriverSet
(l6) 09850{0030 EngineAdjust Kit
(17) 0928G460r
I Injection Pump Spline Shaft Putlcr
(18) 0 9 3 2 51-2 0 1 0 TransmissionOil Plug

a. It is recommended that the removaland installationof the

crankshaft pulley and the timing gearsbe peformed utilizing
the TimingGearTool Set 09210-3101Iinsteadof the Crankshaft
Pulley& GearPuller09213-60014 and the Crankshaft
Pulley&
GearReplacer 0921+60010.
Tlxr To"l Setr\ disignedalsofor on-Carseni.r.

b.The Injection Pump Spline Shaft Pulle. 0928646011is for

the removalof the alternatorrear bearingand the Transmission
Oil Plug 09325-11010is for the assemblyof the alternator
dive end fiame.