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
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
Ignition
Sptem
The
standard
breaker
pOint
spring
tensIOn
IS
1
1
to
1
4
lb
Replace
If
devIated
Performance
of
condenser
IS
affected
by
Im
proper
setting
contaminatIOn
and
reductIOn
of
In
ulatlOn
resIstance
Thus
pellOdlcal
checking
I
I
eqlJ
lred
to
maintain
the
outlet
of
lead
wire
clean
and
to
prevent
et
screw
from
loosening
Checking
the
condenser
capacIty
IS
checked
USing
a
capacity
meter
It
may
be
also
checked
condenser
Isolate
resl
tance
USing
a
tester
by
adjusting
ItS
I
ange
to
measure
large
I
eSlstance
value
When
the
condenser
IS
normal
the
tester
pOinter
SWings
1m
gely
and
rapIdly
and
moves
gradually
back
to
the
Infimte
SIde
When
the
pOinter
does
not
stay
stili
or
It
points
Zero
In
reSIstance
replacement
IS
necessary
Fig
82
AdJusllng
POint
gap
Fig
83
Measunng
breaker
POint
spnng
tension
g
SPARK
PLUGS
Description
The
spark
plugs
are
of
the
re
lster
type
haVing
0
551
In
threads
and
0031
to
0035
11i
gap
Note
All
spark
plugs
installed
on
an
engme
must
be
of
the
same
brand
and
number
of
heat
range
Inspection
Remove
spark
plug
wIre
by
pulhng
on
boot
not
on
WIre
Itself
Remove
spark
plugs
Check
electrodes
and
Inner
and
outer
por
celams
of
plugs
noting
the
type
of
depOSits
and
the
degree
of
electrode
erO
lOn
Refer
to
Figure
85
Normal
Brown
to
gl
aYlsh
tan
depoSits
and
shght
electrode
wear
indIcate
correct
spark
@
I
Pnmary
terminal
2
Secondary
terminal
3
Cdp
4
Sprang
5
SIde
core
6
Prrmary
coil
7
Secondary
COIl
8
Insulator
011
9
enter
lore
10
Segment
II
Case
Fig
84
Construction
Icnition
Sptem
Ovcrhc
Jtmg
Norm
Jl
i
r
rJ
I
ttr
I
i
V
Carbon
fould
Fig
85
Spark
plug
Life
plug
heat
range
Carbon
fouled
Dry
fluffy
carbon
depo
lts
on
the
Insulator
and
electrode
were
mostly
caused
by
slow
speed
dnvlng
In
cIty
weak
Ig
nltlOn
too
nch
fuel
mixture
dirty
aIr
cleaner
etc
It
IS
advIsable
to
replace
WIth
plugs
havmg
hotter
heat
range
011
fouled
Wet
black
depoSits
show
excesSive
oIl
entrance
Into
combusllon
chamber
through
worn
rmgs
and
pIstons
or
excessIve
clearance
between
valve
gUIdes
and
stems
If
the
same
condition
remams
after
repair
use
a
hotter
plug
Overheatmg
WhIte
or
hght
gray
msulator
WIth
black
or
gray
brown
spots
and
blUIsh
burnt
electrodes
indIcate
engme
overheatIng
Moreover
th
e
appearance
results
from
in
correct
IgnitIon
tIming
loose
spark
plugs
low
guel
pump
pressure
wrong
selectIOn
of
fuel
a
hotter
plug
etc
It
IS
adVisable
to
replace
WIth
plugs
havmg
colder
heat
range
After
cleaning
dress
electrodes
With
a
small
fine
file
to
flatten
the
surfaces
of
both
center
and
Side
electrodes
In
parallel
Set
spark
plug
gap
to
specification
FIg
86
Settmg
spark
plug
gap
Install
spark
plugs
and
torque
each
plug
to
11
to
15
ft
Ib
Connect
spark
plug
wires
Cleaning
and
Regap
Clean
spark
plugs
In
a
sand
blast
type
cleaner
A
VOId
excessIve
blasting
Clean
and
remove
carbon
or
OXide
depoSits
but
do
not
wear
away
porcelain
If
depos1ts
are
too
stub
born
discard
plugs
After
cleaning
spark
plugs
renew
firing
sur
face
of
electrodes
With
file
mentioned
above
Then
gap
spark
plugs
to
0
030
to
0
035
In
uSing
a
round
wire
feeler
gauge
All
spark
plugs
new
or
used
should
have
the
gap
checked
and
reset
by
bending
ground
electrode
II
pront
Suspension
Qj
@
@
I
Strut
mounting
Insulator
2
Strut
mounllng
bearing
3
Upper
pnng
o
r
at
4
Oumpu
rubblf
5
DU
tlOVU
6
P
ton
rod
7
F
ool
pring
8
Irut
embly
q
Hub
b
t
mbly
10
5pmdh
II
Ball
JOint
12
Trd
nwu
link
1
J
Tln
lon
rod
14
StJblluLr
15
SU
p
mIOn
mlmbt
r
Fig
146
Front
axle
and
suspension
assembly
I
DESCRIPTION
The
front
suspensIOn
IS
of
a
strut
type
The
shock
absorber
and
spIndle
are
combIned
to
a
Ingle
Unit
whIch
IS
supported
by
the
COIl
spnng
at
the
upper
end
and
by
the
transverse
lInk
at
the
lower
end
The
spIndle
IS
Installed
on
the
bottom
of
the
strut
outer
caSIng
by
means
of
weldIng
A
ball
JOInt
IS
attached
to
the
lower
part
of
the
spIndle
The
ball
JOInt
and
the
transverse
lInk
lower
lInk
are
connected
and
they
are
fitted
to
the
suspensIOn
member
through
a
rubber
b
shIng
The
shock
absorber
mechanism
IS
bUIlt
In
the
strut
outer
caSIng
A
COIl
sprIng
IS
apphed
between
the
upper
sprIng
seat
fitted
to
the
upper
end
of
the
piston
rod
and
spring
seat
welded
to
the
outer
caSIng
These
components
assembled
to
a
SIngle
umt
are
fitted
to
the
chaSSIS
frame
at
their
upper
part
through
the
thrust
beanng
M
eover
the
1ransverse
hnk
supports
the
84
overall
forward
and
backward
strut
movements
by
means
of
the
tensIOn
rod
fitted
to
the
cha
sls
frame
through
a
rubber
bushIng
The
rubber
bushIng
adopts
a
non
lInear
shape
WIth
whICh
the
forward
and
rearward
ngldltles
are
changed
The
tor
slOn
bar
type
stabilIzer
adopted
In
thiS
suspensIOn
system
IS
used
so
that
the
strut
maIntaInS
connectIOn
between
both
Side
struts
Thus
thiS
suspensIOn
mechanism
absorbs
shocks
toward
all
directIOns
Into
the
chaSSIS
effectively
and
effiCIently
the
tensIOn
rod
ab
sorbs
forward
and
backward
shocks
the
strut
absorbs
vertical
shock
and
the
transver
se
lInk
absorbs
shock
applIed
toward
SIdeway
RECOMMENDATIONS
Due
to
the
need
for
a
large
number
of
speCial
tools
and
ahgnment
eqUIpment
It
IS
recom
mended
that
repairs
to
the
front
end
be
left
to
a
completely
e
q
pped
shop
Clutch
DESCRIPTION
The
clutch
IS
a
sIngle
dry
dIsc
diaphragm
prIng
type
clutch
The
major
components
are
clutch
cover
pressure
plate
diaphragm
sprIng
and
wire
rIngs
The
clutch
diSC
IS
provided
WIth
rIveted
plates
on
both
surfaces
and
cot
bprIngs
arranged
In
a
hnk
The
COIl
prIngs
absOl
b
shock
whIle
engagIng
the
clutch
softemng
and
smoothIng
clutch
engagement
Release
bearIng
sleeve
and
WIthdrawal
lever
dre
used
to
control
clutch
engagement
and
disengagement
Each
part
of
the
clutch
assembly
IS
secured
With
rivets
Therefore
when
a
trouble
IS
un
correctable
replace
the
clutch
assembly
With
a
new
assembly
30
1181
r
I
I
I
I
I
8
1
il
f
0
g
it
l
00
r
O
11
I
N
NN
0
to
lt
lt
ll
l
If
N
O
N
I
I
I
I
FIg
154
Construction
of
clutch
100
CLUTCH
PEDAL
Removal
Remove
the
return
sprmg
Loosen
the
lock
nut
of
the
master
cyhnder
push
rod
and
disconnect
the
push
rod
end
Remove
the
lock
nut
and
washer
of
the
pedal
shaft
and
remove
the
pedal
lever
Inspection
Thoroughly
clean
all
disassembled
parts
m
dlcated
below
and
carefully
check
them
for
wear
damage
and
other
abnormal
conditions
RepaIr
or
replace
them
With
new
ones
If
reqUIred
Pedal
head
rubber
Return
sprIng
9353
3682
00004
lIGHTENING
TORQUE
1
5
to
2
2
kg
m
108
to
159ft
lbl
UOIt
mm
Inl
i
r
1
ill
j
f
f
c
1
dii
s
f
DISTRIUTOR
llle
Ij
Ai
r
t
Make
and
type
D412
80
for
Manual
Transmission
D4
I
2
89
for
Automapc
Transmission
f
I
r
7I
i
Fmng
order
I
3
4
2
13
42
Rotatmg
directIOn
Counterclockwise
Counterclockwise
Dwell
angle
49
550
49
550
Condenser
capacity
I1F
o
20
to
0
24
o
20
to
0
24
IGNITION
COIL
j
MJk
e
mu
lVpc
Pllll1
llY
voliJge
v
HANSHIN
HITACHI
H5
152
C6R
601
12
12
more
than
7
more
t
1
an
7
028
028
17
to
I
43
I
I7
to
I
43
J
112
to
168
112
to
168
13
to
I
7
13
to
I
7
RC
15
5560R
1510
f
park
gJp
mm
m
l
lIlllJry
reSI
itdnLe
at
20o
680F
n
Seu1ndJry
rcc
lc
lllll
e
Jt
Oo
68f
F
Kn
l
tlrllJl
resistor
Jt
200
68uF
n
Applied
ft
SISlor
l
l
t
t
U
1
j
1
h
r
r
1
J
T
I
oj
f
a
11
JJf
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t
r
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k
U
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