
STEERING
SERVICE 
DATA 
AND
SPECIFICATIONS
Type
Gear 
ratio
Steering 
wheel 
diameter
Oil
capacity
Steering 
angle 
inner 
wheel
outer 
wheel
Play 
steering 
wheel
Standard
thickness 
of 
worrn
bearing 
shims
Initial
turning 
torque 
of
column
assembly
Clearance 
of
adjusting 
screw 
to
sector
shaft
Length 
of
side 
rod
Tightening
torque
Steering 
wheel 
lock
nut
Steering 
post 
clamp 
to
steering
post 
bracket 
bolls
Collapsible
Steering 
column 
hole
cover 
bolts
Column 
to
gear 
housing 
bolts
Side 
cover 
to
gear 
housing 
bolts
Adjusting 
screw
lock 
nut
Sector 
shaft 
to
pitman 
arm 
nut
Gear
housing 
to 
side 
main
bar
bolts 
and
nuts
Idler 
arm 
nut 
Recirculating 
ball
type
mm 
in
L
US
pt 
Imp 
pt 
15 
I 
I
400 
157
0 
24
I 
2 
3 
8
430
360
mm 
in 
20 
to 
25
0 
787 
to 
0 
984
mm 
in 
0
5 
0 
0197
kg 
em 
in
oz 
2 
0
to 
5 
0
27 
8 
to 
69 
4
mrn 
in
mm 
in 
0 
05 
0
0020
296 
8
11 
69
kg 
m
ft 
lb 
3 
0
to 
3 
5 
217 
to 
25
3
kg 
m 
ft 
lb
kg 
m 
ft 
Ib
kg 
m
ft 
lb
kg 
m
ft 
lb
kg 
m 
ft 
lb
kg 
m 
ft 
lb
kg 
m
ft 
lb 
0 
8
to 
1 
0 
5
8 
to 
7 
2
1 
5
to 
1 
8 
10 
8
to 
13
0 
8 
to 
1 
0 
5
8 
to 
7 
2
1 
5 
to 
2 
5
10 
8 
to
18 
1
I 
7 
to 
2 
8
12
3 
to 
20 
2
2 
0 
to 
3 
0
14 
5
to 
21
7
14 
101
kg 
m 
ft 
lb
kg 
m
ft 
lb 
1 
9 
to
2 
6
13 
7
to 
18 
8
57
to 
6
3
41
2 
to 
45
6
Idler 
arm 
to 
side 
main
bar 
bolts 
and
nuts
kg 
m 
ft 
Ib
Ball
stud 
nuts
kg 
m 
ft 
lb
Side 
rod 
bar
lock 
nuts
kg 
m 
ft 
lb 
1 
9
to 
2 
6 
13 
7
to 
18 
8
3 
0
to 
5 
0 
21 
7
to 
36 
2
8 
0
to 
10 
0 
57 
8 
to 
72
3
ST 
17 

BODY
Fig 
BF 
19 
R
g 
male 
side
of 
the
hood 
lock
Fig 
BF 
20
Removing 
female 
side
of 
the 
hood 
lock
3
Remove 
three
screws 
and
remove 
the
hood 
lock
control 
lever
Fig 
BF 
21
Removing 
hood 
lock 
control 
lever
Adjustment
Centering 
the 
hood 
lock
The 
male
side 
hook 
lock
is
provided 
with 
a 
3 
mm
0 
118 
in
adjusting 
stroke 
toward 
left 
and
right 
sides
of 
the
vehicle 
and 
the 
female 
side 
with 
a 
3
rnm 
0 
118
in
adjusting 
stroke
toward 
front 
and 
rear
sides 
of 
the
vehicle
Loosen 
the 
installation
bolts 
and
align 
the 
center
correctly
Dovetail 
bolt 
lock 
nut
Tightening
torque 
1 
5 
to
2 
5
kg 
m
10 
8 
to 
18 
1 
ft 
lb
flL 
t1t
m
m 
Male 
and 
female
111 
l 
111m 
attaching 
bol
W 
TIghtening
I
lb 
I
I 
torque 
0 
38
to 
0
51
kg 
m
l 
i 
2 
7 
to 
3 
7 
ft
Ibl
j
rffi
u
Ilillr
iji
Displacement 
of 
center
3 
mm
0 
512 
in 
max
Fig 
BF 
22
Section 
view
of 
hood 
lock
Adjusting 
hood 
lock
control 
lever
operating 
force
When 
the
control 
lever
operating 
force 
is 
excessive
loosen 
the 
dove
tail 
bolt
retaining 
nut
@ 
increase
dove
tail 
bolt
CD 
installed
length 
and 
reduce
tension 
of 
the
spring
Tightening 
tore 
ue
t
I
ili
4r 
ti
llt4
t 
j
Dove 
tail 
bolt
retaining 
nut
S 
r
1
5
to 
2
5
kg 
m
10 
8
to
Up 
ft 
lb
Adjusting 
hood
tightness
After
closing 
the 
hood
panel
completely 
push 
the
center 
of 
the
front
portion 
of 
it
by 
hand 
and 
check
whether 
there 
is
a 
free
play 
of 
2
to 
6
mm 
0 
079 
to
0 
236 
in
If 
it 
is
out 
of 
the 
above 
mentioned
range 
adjust 
the
length 
of 
the 
dove 
tail 
bolt
CD 
to 
increase 
or
decrease
tension
of 
the
spring
2 
to 
6 
mm 
0 
079 
to 
0 
236
inl
Fig 
BF 
23
Checking 
free 
play 
of 
hood
panel
After
adjusting 
tighten 
the
dove 
tail 
bolt
retaining 
nut
to 
above 
the
tightening 
torque
SF 
15 

INSPECTION
Referring 
to 
the
wiring 
diagram 
check 
the
wiring
harness
for 
connection 
with 
electrical
equipment 
and
connector 
for 
conned 
ion 
and 
installation 
When
checking
the
wiring 
harness
note 
the
following 
matters
Connected 
unit 
should
not 
be
loose 
rusted 
or
contaminated
2
Cable 
insulator 
cover 
should 
not 
be
damaged 
crack
ed 
or
insulating 
material
should 
not 
be 
deteriorated
3 
For 
those
parts 
which
are
grounded 
through 
the
installation
bolts 
the 
bolts 
should 
be 
in 
contact 
with 
the
body 
completely 
so 
that
continuity 
is
provided 
in
between 
the
body 
and 
bolts
4 
Terminals
of 
unit
through 
which
current 
flows
should 
not 
come
into 
contact 
with
other 
metal
parts
5 
No
erroneous 
connection 
should 
be
present
DESCRIPTION
When 
an 
overcunent
exceeding 
the 
rated
amperage
flows 
to 
a 
circuit 
the
fuse 
is 
heated 
and 
melted 
the
circuit 
is
interrupted 
and
thus 
cables 
and
electrical
equipment 
are
protected 
from
damaging 
due 
to
burning 
or
damaging 
is
limited 
to 
the
minimum 
This 
vehicle
is
equipped 
with 
six
fuses 
and
one 
fusible 
link 
The 
fuses
are
located
in 
the
fuse 
box 
and 
used
to
protect 
illumination
signal 
and 
other
systems 
and 
the 
fusible 
link 
is
adopted
in 
the 
cable 
between 
the
battery 
and 
alternator 
to
protect
the
charging 
and
starting 
circuits
FiJ 
BE 
16 
Fuse 
box 
BODY
6 
Cables 
should 
be
damped 
so 
that
they 
do 
not 
come
into 
contact 
with
sharp 
corner 
or
part 
lernperature 
of
which
rises
highly
7 
Cables 
should 
be
securely 
clamped 
in
posItions
sufficiently 
separated 
from
rotating 
parts 
such 
as 
fan
pulley 
fan 
belt
etc
8 
Cables 
should 
be
provided 
with 
an
optimum 
extra
length 
at 
sections
stationarity 
on 
the
body 
or 
at 
sections
where 
vibration
occurs 
due 
to
engine 
operation 
and
others
Note 
a 
When
inspecting 
or
performing 
other 
mainte
nance
service 
and 
no
power 
supply 
is
required
particularly 
or 
when 
it 
is
anticipated 
that 
a
part
may 
be 
short 
circuited 
disconnect 
the
battery 
H
terminal
b 
In 
no 
event 
should 
an 
unloaded 
circuit 
be
directly 
connected 
with 
ground 
Be 
sure 
to 
use 
a
test
lamp 
or 
circuit
tester
fUSE
Fig 
BE 
17 
Fusible 
link
INSPECTION
In 
the
most
cases 
fuse 
can 
be
checked
visually
However 
when
it 
is 
difficult 
to
check
visually 
a 
circuit
tester
may 
be 
used
The 
fusible 
link 
can
be
inspected
visually 
or
by
feeling 
on
finger
tip 
However 
the 
fusible
link 
can 
be
inspected 
more
correctly
by 
using 
a 
circuit
tester
BE
6 

EMISSION 
CONTROL 
AND
TUNE 
UP
Appearance
1 
First
inspect 
whether 
vacuum 
hoses
are 
connected
to 
correct
positions
2
Inspect 
hoses
for 
cracks 
distortion 
or
plugging
Checking 
of 
vacuum 
motor
I
With
engine 
shut 
down
inspect 
the
position 
of 
valve
placing 
a 
mirror 
at 
the 
end 
of 
inlet
pipe 
for
inspec
tion
The 
correct 
condition 
of 
valve 
is 
that 
it
keeps 
the
inlet 
of 
underhood 
air
open 
and 
that 
of 
hot 
air
closed
Otherwise
inspect 
the
linkage 
of 
valve
Fig 
ET 
34
Inspecting 
valve
position
2 
Disconnect 
hose 
at 
vacuum
motor 
inlet 
and 
direct
ly 
apply 
vacuum 
of 
manifold 
to 
vacuum 
motor
by
connecting 
another 
hose
sucking 
by 
mouth
may 
be
substituted 
for 
this
process 
If 
underhood 
air 
inlet 
is
closed
by 
valve 
valve 
is 
in
good 
condition
Inspect
linkage 
if 
found 
otherwise 
And 
then 
no
defect 
is
found 
even 
in
linkage 
it
signifies 
the 
trouble 
of
vacuum 
motor
Fig 
ET 
35
Checking 
vacuum 
motor
ET 
21 
3 
The 
valve
shows 
correct 
condition 
if 
it
keeps
underhood 
air 
inlet 
closed 
when 
the
passage 
in
the 
hose
is
stopped 
by 
twisting 
or
clamping 
it 
while
applying
vacuum 
If 
otherwise 
it 
is 
an 
indication 
of
leakage
taking 
place 
in 
the 
vacuum 
motor
4 
When 
defect 
is 
found
in 
vacuum
motor
through 
this
check 
replace 
the 
air 
cleaner
assembly
Checking 
of 
sensor
I 
Perform 
the
engine 
test
by 
keeping 
the
temperature
around 
the
sensor 
below 
300C 
860F 
Make
sure 
that
the
engine 
is 
cooled 
down
before 
the 
test 
is 
conducted
2 
Before
starting 
the
engine 
make 
certain 
that 
the
valve
on 
underhood 
air 
side
fully 
opens
3 
Start 
the
engine 
and
operate 
it
at 
an
idling 
speed
The 
valve 
is 
in
good 
condition
if 
underhood 
air 
side
fully 
closes
immediately 
after
starting
4
Carefully 
watch 
the 
valve
to 
ascertain 
that
it
gradually 
begins 
to
open 
as 
the
engine 
warms
up 
But
when 
the 
ambient
temperature 
is 
low 
it 
takes
con
siderable
length 
of 
time
for 
the 
valve 
to
begine 
to
open
or 
in 
some 
case 
it
hardly 
opens 
This 
should
not
however 
be
regarded 
as 
trouble
If 
the 
valve 
does
not
operate 
satisfactorily 
or 
if 
the
condition 
of 
the 
valve 
is
questionable 
further 
conduct
the
following 
test
5 
Remove
the 
air
cleaner 
cover 
and
put 
a 
thermister
or 
a 
small 
thermometer 
as 
close 
to 
the
sensor 
as
possible 
with 
adhesive
tape 
Install 
the
air 
cleaner
cover
again
Fig 
ET 
36
Checking 
sensor
1 

ENGINE
2 
The 
valve 
face
or 
valve 
stem 
end 
surface 
should 
be
refaced
by 
using 
a
valve
grinder
Notes 
a 
Deflection 
of 
seat 
surface
against 
axis 
should
be 
0 
03 
mm 
0 
0012 
in 
or 
less
b 
Correctness 
of
right 
angle 
and 
out
of 
round
should 
be 
0 
01 
mm 
0 
0004 
in
or
I
c
EM111
Fig 
EM 
33
Valve
grinder
Note 
When 
the 
a1ve 
head 
has 
been 
reduced 
to 
0 
5 
mm
0 
0197 
in
or
I 
in
thickn 
replace 
the 
al
e
Grinding 
allowance
for 
the 
alve
stem 
end 
surface
is 
0 
5
mm 
10 
0197 
in
or
I
Valve
spring
I 
Measure 
the
free
length 
and 
the 
tension 
of
each
spring 
If 
the 
measured 
value 
exceeds 
the
specified 
limit
replace 
the
spring
Spring
specifications
Free
length 
46 
5 
mm 
1
831 
in
38 
7
rom 
at 
23 
9
kg
1 
524 
in
at 
52 
7Ib
Valve 
closed
Valve
open 
30 
2 
rom 
at 
58 
5
kg
1
19 
in 
at 
1291b
EM 
l0 
2
Check 
each
spring 
for 
deformation 
with 
a
square
Any 
springs 
with
deflection 
of 
1 
6
mm 
0
0630 
in 
or
more 
must 
be
replaced
EM113
Fig 
EM
34 
Valve
spring 
test
Valve 
rocker 
shaft 
and 
rocker 
arm
I
Check 
the 
valve
rocker 
shaft 
and 
rocker 
arm 
for
seizure 
and 
wear 
and
repair 
or
replace 
as
required
Valve 
rocker 
arm 
to 
shaft 
oil 
clearance
0 
02 
to 
0 
05
mm 
0 
0008 
to 
0 
0020 
in
2
When 
valve
contact 
surface 
of 
the 
valve 
rocker 
arm 
is
worn
excessively 
in
step 
repair 
by 
means 
of 
a 
valve
grinder 
or 
replace
Grinding 
allowance 
for 
valve 
contact 
surface 
of 
the
valve 
rocker 
arm 
is 
0 
5 
rom 
0 
0197 
in
or 
less
t
Fig 
EM
3S
val 
Tocker
shaft 

ENGINE 
MECHANICAL
Note 
8 
When 
the
piston 
ring 
only 
is 
to 
be
replaced
without 
the
cylinder 
bore
being 
corrected 
measure
gap 
at 
the 
bottom 
of 
the
cylinder 
where 
the 
wear 
is
minor
b 
Oversize 
piston 
rings 
are 
available 
for 
service
50 
100 
150 
oversize
4
Measure 
the
piston 
pin 
hole 
in 
relation 
to 
the 
outer
diameter 
of 
the
pin 
If 
wear 
exceeds 
the 
limit
replace
such
piston 
pin 
together 
with 
the
piston 
on 
which 
it 
is
installed
Piston
pin 
diameter
mm
in 
17447 
to 
17452
0 
6869 
to 
0 
6871
65 
23 
to 
65
48
2 
5681 
to 
5 
779
Piston
pin 
length
mm 
in
Piston
pin 
hole 
dia
meter 
mm 
in 
17460 
to 
17453
0
6874 
to 
0 
6871
5
Fitting 
of
piston 
pin
Determine
the
fitting 
of
the
piston 
pin 
into
the
piston
pin 
hole 
to
such 
an 
extent 
that 
it 
can
be
rmger 
pressed 
at
room
temperature 
This
piston 
pin 
must 
be
tight 
press
fitted 
into
the
connecting 
rod
EM131
Fig 
EM 
54
Piston
pin 
fitting
EM 
19 
g
1
EM132
Fig 
EM 
55
Measuring 
piston 
pin 
diameter
Piston
pin 
to
piston
clearance
mm 
in 
0
006 
to 
0
008
0 
0002
to 
0 
0003
Interference 
fit 
of
piston
pin 
to
connecting 
rod
mm 
in 
0 
020 
0 
0008
CONNECTING 
ROD
If 
a
connecting 
rod 
shows
any 
scratch 
or 
score 
mark
or 
is
pitted 
on
both 
sides 
of 
the 
thrust 
face 
and 
the
large
end
correct 
or
replace 
it
EM133
Fig 
EM 
56
Connecting 
rod
aligner
2 
Check
for 
bend 
or 
torsion
using 
a
connecting 
rod
aligner 
If
bend 
or 
torsion
exceeds 
the 
limit 
correct 
or
replace 
the
connecting 
rod 

ENGINE
Standard
IMaXimum
Connecting 
rod 
bend
or 
torsion
per 
100 
mm
or 
3 
94 
in
length
mm
in 
o 
os
0 
0020
0 
07
0 
0028 
0 
1
0
0039
bend
torsion
3
When
replacing 
the
connecting 
rod 
select
the 
rod
so
that
weight 
difference 
between 
new 
and 
old
rods 
is
within
S
gr 
0
18 
oz 
in
unit
weight
4 
Install
connecting 
rods
with
bearings 
on 
to 
the
corresponding 
crank
pins 
and 
measure 
the 
thrust 
clear
ance 
If
the 
measured
value 
exceeds 
the 
limit
replace 
such
connecting 
rod
Stan 
dard 
Maximum
Big 
end
play
mm 
in 
0 
2
to 
0 
3
0
0079 
to 
0
Ql18 
0
4
0
0IS7
l 
8ig 
end
plav
A
t
f
L
Fig 
EM 
57
Big 
end
play 
check
CRANKSHAFT
Check 
the 
crankshaft
journal 
and
crank
pin 
for 
scars
biased 
wear
and
cracks
Repair 
or
replace 
as
required
EM 
20 
27 
00 
to 
27 
05 
1 
063 
to 
1 
065
19
1Ot01940
r 
19 
10t019 
40
fO 
752 
to 
0 
764
Ii 
10 
75Z 
to 
0 
764
I
c
1
r
1tf 
1
I
J 
X 
I
34 
97 
to
35 
03
t
11
377 
to 
1 
379
49 
951
to 
49
964 
dia
11 
9666
to 
1
96711
ALL 
MAIN 
BEARING
JOURNALS
Fig 
EM 
58
Crankshaft
Standard
Taper 
out 
of 
round
of 
crank
journal 
and
crank
pin 
mm
in 
0 
01
0
0004 
44 
961 
to 
44 
974 
die
11 
7701 
to 
1
7706
ALL 
CRANK 
PINS
UNIT 
ffim
in
Maximum
0 
03
0 
0012
2
Check 
the
crankshaft 
for 
bend 
If 
the
bend 
exceeds
the 
limit
replace 
the
crankshaft
Bending 
limit
0 
05mm 
0 
0020 
in
Standaia 
0 
015mm 
0
0006 
in 
or 
less
Fig 
EM 
59
Crankshaft 
bend 
check 

ENGINE
SPECIFICATION
a 
Valve 
mechanism
Valve 
clearance 
Hot
Intake 
mm 
in
Exhaust 
0
35 
0 
0138
0
35 
0 
0138
Valve 
clearance 
Cold
Intake
Exhaust 
mm
in
0 
25 
0 
0098
0 
25 
0 
0098
Valve 
head 
diameter
mm
in
Intake 
35 
1
378
29 
1
142
Exhaust
Valve 
stem 
diameter
mm
in
Intake 
7
970 
to 
7 
985
0
3138 
to 
0
3144
7
945 
to 
7
960 
0
3128 
to 
0
3134
Exhaust
Valve
length 
mm 
in
Intake
Exhaust 
102
35
to 
102 
65 
4 
030 
to 
4
041
102
35
to 
102
65 
4 
030
to 
4 
041
Valve
spring 
assembled
height 
111m
kg 
in 
lb 
8
5 
0
3346
46 
5 
1 
831
30 
2 
58 
5 
1
I99
129
38 
7 
23 
9 
1 
524 
52 
7
5 
0
Valve 
lift
mm 
in
Valve
spring 
free
length 
mm
in
Valve
spring 
loaded
length 
mm
kg 
in 
lb
Valve
spring 
effective 
turns
Valve
guide 
length 
111m
in 
4 
100 
0
1614
26
4 
1
031 
1
53 
2 
087
Valve
spring 
wire
diameter 
mm
in
V 
alve
sp 
g 
coil 
diameter
inm 
L
Valve
guide 
height 
from
head
surface 
111m
in 
18 
0 
709
Valve
guide 
inner 
diameter
mm 
in
Intake 
8 
015
to 
8 
000 
0
3156 
to 
0
3150
Exhaust 
8 
015 
to 
8 
000 
0
3156 
to 
0
3150
EM 
34