able
of
Contents
MAINTENANCE
TUNE
UP
DIsassembly
32
InspectIOn
RepaIr
33
VALVE
CLEARANCES
6
AdJustmg
Regulator
33
ENGINE
OIL
6
Assembly
33
OIL
FILTER
7
COOLANT
7
COMPRESSION
7
ELECTRICAL
SYSTEM
BATTERY
8
IGNITION
TIMING
8
STARTER
36
DIstributor
Breaker
Pomt
9
Removal
37
Condenser
9
InstallatIOn
37
Spark
Plugs
9
Trouble
Shootmg
37
Carburetor
9
ALTERNATOR
36
Idle
LImIter
Cap
10
Removal
37
Dash
Pot
automatic
transmISSIOn
11
InstallatIOn
37
model
only
11
REGULATOR
39
Carburetor
Return
Sprmg
11
DeSCriptIOn
39
Fuel
Filter
11
Trouble
Shootmg
40
ENGINE
IGNITION
SYSTEM
DESCRIPTION
14
DISTRIBUTOR
44
REMOVAL
14
ConstructIOn
44
INSTALLATION
14
Checkmg
and
Adjustment
44
CLEANING
INSPECTION
14
SP
ARK
PLUGS
46
DISASSEMBL
Y
14
DeSCriptIOn
46
INSPECTION
REPAIR
18
InspectIOn
46
PreparatIOn
18
Cleamng
Regap
47
Cyltnder
Head
18
Valve
Assembly
18
Valve
Spnng
19
Valve
Rocker
Shaft
Rocker
Arm
19
FUEL
SYSTEM
Valve
LIfter
Push
Rod
20
Camshaft
Camshaft
Bearmg
20
FUEL
FILTER
50
Valve
Tlmmg
20
DESCRIPTION
50
Cyltnder
Block
21
REMOVAL
50
PIston
Piston
Pm
Plsto
LRmg
21
INSTALLATION
50
Connectmg
Rod
23
FUEL
PUMP
50
Crankshaft
24
DeSCriptIOn
50
Bushmg
Bearing
24
Testmg
51
Crankshaft
Sprocket
Removal
DIsassembly
52
Camshaft
Sprocket
25
InspectIOn
52
Flywheel
25
Assembly
52
ASSEMBL
Y
25
CARBURETOR
52
PrecautIOn
25
DeSCription
52
Cyltnder
Head
25
Adjustment
53
PIston
ConnectIng
Rod
26
Removal
58
Engme
26
DIsassembly
58
OIL
PUMP
32
Cleanmg
InspectIOn
59
Removal
Engme
m
vehicle
32
Assembly
InstallatIOn
60
I
fable
of
Contents
BODY
WORK
SPECIFICATIONS
I
HOOD
112
SERVICE
DATA
130
Removal
112
ENGINE
134
InstallatIOn
112
General
SpeCificatIOn
134
HOOD
LOCK
112
Tlghtemng
Torque
134
Removal
112
SpeCIficatIOn
135
Adjustment
112
Coohng
System
139
LubncatlOn
114
Fuel
System
140
TRUNK
LID
LOCK
116
Starter
142
Removal
116
Alternator
143
Adjustment
116
Regulator
144
TRUNK
LID
TORSION
BAR
116
Dlstnbutor
145
DOOR
CONSTRUCTION
117
IgnItIOn
Cot
145
WIRING
DIAGRAMS
118
CLUTCH
146
BULB
SPECIFICATIONS
120
NOTES
174
HEADLAMP
121
THERMOMETER
AND
FUEL
METER
122
OIL
PRESSURE
AND
IGNITION
WARNING
LAMPS
126
I
I
t
I
3
ainteDaDee
TUDe
up
VAL
VE
CLEARANCES
Valve
clearance
adjustment
should
be
made
while
engme
IS
stationary
To
adjust
proceed
as
follows
Start
engme
and
run
It
until
It
IS
heated
to
operatIng
temperature
or
at
least
more
than
17S
of
engIne
011
temperature
then
stop
engIne
Rotate
crankshaft
to
bnng
No
1
cylInder
In
top
dead
center
on
ItS
compressIOn
stroke
Remove
valve
rocker
cover
to
gaIn
access
to
valve
operatIng
mechamsm
Adjust
valve
clearance
at
follOWing
four
pOints
while
engIne
IS
still
hot
1
Exhaust
valve
of
No
1
cylinder
2
Intake
valve
of
No
1
cylinder
3
Intake
valve
of
No
2
cylinder
5
Exham
t
valve
of
No
3
cylInder
ote
Numbers
in
parenthesis
agree
with
those
10
accompanY1Og
sketch
AgaIn
rotate
crankshaft
one
turn
so
that
No
4
piston
IS
In
top
dead
center
on
ItS
com
pressIOn
stroke
Adjust
follOWIng
valves
4
Exhaust
valve
of
No
2
cylinder
6
Intake
valve
of
No
3
cylinder
7
Intake
valve
of
No
4
cylInder
8
Exhaust
valve
of
No
4
cylinder
Rg
1
AdJustmg
valve
clearance
8
Adjustment
should
ue
made
whIle
engIne
IS
hot
After
all
valves
have
been
adjusted
correctly
tighten
lock
nut
firmly
to
secure
the
adjustment
Checking
and
adjusting
drive
belt
Check
for
a
cracked
or
damaged
V
belt
Replace
If
defective
Adjust
the
belt
tenSIOn
If
necessary
Belt
deflectIOn
when
thumb
pressure
of
220
Ib
IS
applied
midway
between
pulleys
0394
to
o
590
In
ENGINE
OIL
011
capacity
of
engIne
IncludIng
011
filter
Capacity
MaXimum
VB
US
gal
Imp
gal
MInimum
5IB
US
gal
III
Imp
gal
Make
sure
that
engIne
011
IS
not
detenorated
With
cooling
water
or
gasolIne
DraIn
and
refill
the
011
lf
necessary
Notes
a
A
m1lky
011
indlcates
presence
of
cooling
water
Valve
clearance
Hot
Intake
0014
In
Exhaust
Fig
2
AdJustmg
dnve
belt
tension
aintenIDce
une
up
Find
the
cause
for
necessary
corrective
action
b
Oil
with
extremely
low
viscosity
in
dicates
dllutton
with
gasoline
Check
011
level
If
found
below
L
mark
refill
to
H
mark
on
gauge
OIL
FILTER
The
011
filter
IS
of
a
cartndge
type
Check
for
011
leaks
through
gasketed
flange
If
any
leakage
IS
found
retIghten
shghtly
If
nece
sary
replaLe
filter
as
an
assembly
When
mstalhng
an
011
filter
tIghten
by
hand
Note
Do
not
overtighten
011
fIlter
or
oil
leakage
may
result
I
I
Fig
3
Checking
engine
011
level
Oc
OF
I
0
121
20141
30
21
401401
5015BI
I
EGOQl
I
10
20
Fig
4
Protection
concentration
COOLANT
L
L
C
IS
al
ethylene
glycol
base
product
con
tammg
chemical
mhlbltors
to
protect
the
coohng
system
from
rustmg
and
corrosIOn
The
L
I
C
does
not
con
tam
any
glycerme
ethyl
or
methyl
alcohol
It
wIll
not
evaporate
or
bOll
away
and
can
be
used
wIth
either
high
or
low
temperature
thermostat
It
flows
freely
transfers
heat
effiCiently
and
will
not
clog
the
passages
m
the
coohng
system
The
L
L
C
must
not
be
mIxed
wIth
other
products
ThiS
coolant
can
be
used
throughout
the
seasons
of
the
year
Whenever
any
coolant
IS
changed
the
coohng
system
should
be
flushed
and
refilled
wIth
a
new
coolant
Check
the
level
COMPRESSION
Compression
pressure
test
Note
To
test
cylinder
compression
remove
all
spark
plugs
and
hold
tester
fit
Percent
BOllIng
pomt
concen
09
kg
cm2
Freeze
tra
lion
Sea
level
coolmg
sys
protectIon
tern
pressure
30
2210F
2550F
50f
50
2280
F
2610F
31oF
ETO
104
Fig
5
Testing
compressIon
pressure
7
BDgiDe
Fig
49
Valve
installatIon
STl
303001
EM156
Fig
50
Piston
pin
installation
FIg
51
Piston
and
connecting
rod
assembly
Assemble
the
parts
In
order
valve
sprmg
spnng
retamer
valve
collet
and
val
ve
rocker
gUIde
28
Note
Make
sure
that
the
valve
face
is
clear
from
foreign
matters
Piston
and
Connecting
Rod
Assemble
pIston
piston
pm
and
connecting
rod
assorted
accordmg
to
cyhnder
number
for
every
cylInder
Notes
a
P1ston
pin
is
press
fitted
to
the
connectmg
rod
tightly
and
fitting
force
is
from
1
to
3
tons
When
fitting
piston
pin
speCIal
tool
must
be
used
When
pressmg
the
piston
pin
into
the
con
necting
rod
apply
engine
oil
to
the
pin
and
the
small
end
of
the
connecting
rod
b
Arrange
the
connecting
rod
so
that
the
oil
Jet
of
the
connecting
rod
large
end
is
directed
toward
the
right
side
of
the
cylinder
block
InstallIng
piston
rmgs
Install
the
top
and
second
rings
In
nght
pOSItIOns
so
that
the
marks
are
faced
upward
FIX
bearings
on
the
connecting
rod
and
the
connecting
rod
cap
Note
Clean
the
back
side
of
the
bearmg
carefully
Engine
Set
the
cyhnder
block
on
the
workmg
stand
WIth
the
engine
bottom
faced
upSIde
Install
the
valve
hfters
Install
the
camshaft
and
retain
by
the
camshaft
locate
plate
Locate
plate
tightemng
torque
IS
2
9
to
3
6
ft
lb
Fig
52
Installing
camshaft
locate
plate
Bogine
Note
Set
the
locate
plate
so
as
the
LOWER
mark
comes
to
the
engine
bot
tom
side
Set
the
maIn
bearIngR
on
theIr
posItIOns
on
the
cylinder
block
Notes
a
The
center
bearmg
No
3
bearmg
is
a
flanged
type
for
thrust
force
b
Two
lOner
bearmgs
No
2
and
No
4
are
of
the
same
type
c
The
front
bearmg
No
1
IS
the
same
type
as
the
rear
bearmg
No
5
d
All
bearings
except
for
No
I
bearing
are
interchangeable
between
upper
and
lower
bearings
Apply
engIne
OIl
to
the
mam
bearIng
surfaces
on
both
sIdes
of
the
cyltnder
block
and
cap
Fig
53
Mam
bearing
caps
Fig
54
Crankshaft
end
play
check
Install
the
crankshaft
Install
the
mam
bearmg
cap
and
tighten
the
bolts
with
specified
torque
Tlghtemng
torque
36
to
43
ft
Ib
Notes
a
Arrange
the
parts
so
that
the
arrow
mark
on
the
bearing
cap
IS
faced
toward
the
front
of
the
engine
b
Prior
to
tightening
the
bearing
cap
bolts
place
the
bearing
cap
at
a
proper
posItIon
by
shlftmg
the
crankshaft
in
the
axial
direction
c
Tighten
the
bearmg
cap
bolts
gradually
in
separatmg
two
to
three
stages
and
out
wardly
from
the
center
bearing
d
After
securing
the
bearing
cap
bolts
ascertam
that
the
crankshaft
can
be
easily
rotated
Make
sure
that
the
crankshaft
end
play
IS
correct
Crankshaft
end
play
o
0020
to
0
0059
In
I
nstalI
the
rear
011
seal
Install
the
flywheel
securely
USIng
the
lock
washers
and
tighten
the
bolts
with
specIfied
torque
Tlghtemng
torque
47
to
54
ft
Ib
Rotate
the
engine
a
quarter
turn
and
mstall
the
piston
rod
assembly
Notes
a
Insert
the
pistons
in
the
corresponding
cyhnders
b
Apply
engine
oil
to
parts
as
required
c
Arrange
pistons
so
that
the
F
mark
on
the
piston
IS
faced
to
the
front
of
the
engine
d
Install
piston
rings
at
18
Y
to
each
other
avoIdIng
to
fit
them
In
the
thrust
and
pIston
pIn
aXial
directIOns
27
BBgiBe
Fig
70
Tlmmg
mark
Fig
71
Dlstnbutor
mstallatlon
Notes
a
Set
the
No
1
piston
to
its
top
dead
center
of
the
compression
stroke
b
Before
installation
return
the
distributor
rotqr
approximately
60
degrees
from
Its
regular
position
Insert
the
assembly
meshing
the
distributor
drive
gear
and
driven
gear
After
installation
the
distributor
rotor
should
come
into
contact
wIth
the
mark
on
the
rotor
cap
fittmg
as
shown
in
the
Figure
Install
the
spark
plugs
and
connect
the
distrIbutor
to
plug
high
tensIOn
lead
wire
Install
the
fuel
hoses
and
tubes
Install
the
clutch
cover
assembly
Install
the
engme
shngers
and
crankcase
ven
tilatIOn
hose
Fig
72
Removal
of
011
pump
TrochoId
Fig
73011
pump
OIL
PUMP
Removal
Engine
in
vehlCIe
Dram
engme
OIl
Remove
the
front
stabilIzer
Remove
the
splash
shield
board
Detach
the
011
pump
body
together
with
drIve
gear
spmdle
Disassembly
PrIor
to
dlsassembhng
check
to
determme
that
the
pump
IS
defective
Take
out
a
total
of
2
bolts
securmg
the
pump
cover
to
the
pump
body
The
outer
and
mner
Dlsmount
the
engme
from
the
workmg
stand
rotors
and
drive
shaft
can
then
be
dlsassem
Install
the
engme
mountmgs
bled
32
Bmetrlcal
Spt
The
startmg
motor
rotates
PinIOn
gear
does
not
mtermec
h
with
flOg
gear
Pillion
mtermeshes
with
nng
gc
lT
Startmg
motor
roldles
Jud
pillion
Intermeshes
With
ring
gc
n
but
r
l
IlIan
IS
tou
slow
Startmg
motor
Magnetic
SWitch
Rmg
gear
Startmg
motor
Startmg
motor
Battery
Wiring
IgnitIOn
sWltl
h
Sldelmg
motor
38
Shorted
armature
or
field
cOIl
Worn
brush
or
Improper
spring
pressure
Contaminated
commutator
or
de
fective
mica
Faulty
brush
connection
Seized
metal
Armature
contacted
With
pole
core
Insufficient
plunger
L
dimenSIOn
Faulty
contact
Brok
en
or
shorted
shunt
call
wire
Worn
teeth
Weakened
pinion
sleeve
sprmg
Worn
pm
IOn
teeth
FJulty
plOlOJl
slldmg
Dropped
oft
lever
pill
EXl
hr
plunger
L
dlll1en
IOn
Defel
tlve
over
runnmg
dutch
Over
dlscharglOg
Improper
or
lome
termmdl
con
Lid
Improperly
tightened
connection
Rough
Lontact
urtJce
Shorted
armdture
COil
or
field
cOIl
Worn
brush
or
I11sufficlCnt
spnng
pressure
Conldmmated
Lomrnutator
or
Im
proper
brush
LonldLl
DercLllVe
nllca
Lack
or
metallubneallon
Armature
Lontdcted
With
pole
core
Repair
or
replace
Repair
or
replace
Cledn
or
repair
Repair
Replace
RepJlr
or
replace
AdjUst
ReplJee
Replace
ReplJee
Replnee
Rcpldce
RepJlr
Rep
m
Adjust
Re
place
Charge
battery
Repall
l11d
retIghten
Rellghten
RepJIr
or
replaLc
Repair
or
replace
Repair
or
replace
Repair
Repau
Repdlf
or
replace
Repair
or
replace