Page 135 of 513

BRAKE
CYLINDER 
SIDE
PISTON 
SIDE
COMPR 
ESSION
DECOMPRESSION
Movement
exceeding 
the
elastic
displacement 
is
released 
with
slipping 
on
the 
seal 
surface 
Returns 
in 
elastic
displacement 
of
the
seal
Fig 
BR 
21 
Piston
seal 
automatic
adjusting 
operation
Brake
pad
Replacement
1 
Jack
up 
front 
unit 
of
the 
vehicle 
and 
remove 
lhe
front
wheeL
2 
Remove
clip 
from 
the
retaining 
pin 
and
supporting
the 
brake
pad 
remove 
the
retaining 
pin 
and 
coil
spring
I
I 
Brake
pad
2
Retaining 
pin
I 
31 
Clip
Fig 
BR 
22
Removing 
retaining 
pin
3 
Unhook
the
hanger 
spring 
and 
withdraw 
the 
brake
pad 
and 
shim 
with 
a
pair 
of
pliers
BR 
ll 
Fig 
HR 
2
Withdrawing 
brake
pad 
and 
shim
Note 
When 
the 
brake
pad 
is 
removed 
do 
not
depress 
the
brake
pedal 
or 
otherwise 
the
piston 
will 
come 
out
Inspection
Clearance 
between 
the
brake
pad 
and 
rotor 
is
adjusted
automatically 
Check 
the 
brake
pad 
for 
wear
after 
the
first 
10 
000 
km 
6 
000
miles
driving 
and
every 
5 
000
km 
3 
000
miles 
thereafter
1
Clean 
the 
brake
pad 
with 
carbon 
tetrachloride 
or
gasoline
2 
When 
oil 
and 
or
grease 
is
heavily 
sticked 
on 
the
pad
or 
when 
deteriorated 
or 
deformed 
due 
to
overheating
replace 
the
pad 
with
a 
new 
one
3 
When 
thickness 
of 
the
friction 
material
pad 
is 
less
than 
1 
6 
mm 
0 
0630 
in
replace
Replace 
when 
total
pad 
thickness 
is
less 
than 
6 
1 
mm
0 
2402 
in
Note 
Replace
pads 
as 
a 
set
Replacement 
at
only 
one
position
may 
cause 
uneven 
brake 
effect 
It 
is
recommended 
that 
rotation 
of
pads 
be 
made
periodically
4 
Check 
the 
rotor 
Refer 
to 
Rotor
inspection
Reinstallation
1 
Clean 
the
calipers 
and
piston 
pad 
installing 
parts
Note 
Do 
not 
use 
mineral 
oil 
Be 
careful 
not 
to
apply 
oil
on 
the 
rotor
2
Depress 
the
piston 
into 
the
cylinder 
so 
that 
new
pad
can 
be 
installed 
     
        
        Page 335 of 513

Air 
intake
system 
in
trouble
Overheating
Overcooling
Others
NOISY
ENGINE
Car
knocking
Car 
knock 
when
coasting 
ENGINE
Diny 
ur
clogged 
fuel 
strainer
Fuel
pump 
will 
not 
work
properly
Clogged 
carburetor
jets
Clogged 
air 
cleaner
Air
inhaling 
from 
manifold
gasket 
or 
carbu
retor
gasket
Insufficient 
coolant
Loosened 
fan 
belt
Worn 
or 
defective 
fan 
belt
Defective 
thermostat
Defective 
water
pump
Clogged 
or
leaky 
radiator
Defective 
radiator 
filler
cap
Air
mixing 
into
cooling 
system
Improper 
grade
engine 
oil
Incorrect
ignition 
timing
Defective 
carburetor
lean 
mixture
Defective 
thermostat
Low
octane 
fuel
Improper 
tire
pressure
Dragging 
brake
Slipping 
clutch
Overloading 
to
engine
Carbon
knocking
Timing 
knocking
Fuel
knocking
Preignition 
misusing 
of
spark 
plug
Incorrect 
throttle
opener 
adjustment
Trouble 
in 
PCV 
valve
ET 
30 
Replace
Repair 
or
replace
Disassemble 
and 
clean
Replace 
element
Replace 
gasket
Replenish
Adjust
Replace
Replace
Replace
Flush
repair 
or
replace
Replace
Retighten 
each
part 
of
cooling 
system
Replace 
with
proper 
grade 
oil
Adjust
Overhaul 
carburetor
Replace
Replace 
with
specified 
octane 
fuel
Adjust 
to
the 
specified
pressure
Adjust
Adjust
Use
right
gear 
in
driving
Disassemble 
cylinder 
head 
and 
remove
carbon
Adjust 
ignition 
timing
Use
specified 
octane 
fuel
Use
specified 
spark 
plug
Adjust 
throttle
opener
Replace 
PCV 
valve 
     
        
        Page 457 of 513

ENGINE 
ElECTRICAL 
SYSTEM
SPECIFICATIONS
Make 
and
type
Primary 
voltage 
v
Spark
gap 
mm 
in
Primary 
resistance
at 
200C 
680
F 
n
Secondary 
resistance
at 
200C 
680F 
Kn
External 
resistor
at 
200C 
680 
F 
n
Applied 
resistor 
HANSHIN 
HITACHI
H5 
15 
2 
C6R 
601
12 
12
more 
than 
7
more 
than 
7
0 
28 
0 
28
1
17 
to 
I 
43 
l
l 
7
to 
I 
43
11 
2 
to 
16 
8 
11 
2
to 
16 
8
l
3tol7 
l
3tol7
RC 
15 
5560R 
151O
SPARK 
PLUG
CONTENTS
DESCRIPTION
INSPECTION
CLEANING 
AND
REGAP 
EE 
37
EE 
37
EE 
38
DESCRIPTION
The
spark 
plugs 
are 
of 
the 
resister
type 
having 
14 
mm
0 
551 
in 
threads 
and 
0 
8 
to 
0 
9 
mm 
0 
031 
to 
0
Q35 
in
gap
Note 
All
spark 
plugs 
installed 
on 
an
engine 
must
be 
of
the
same 
brand 
and 
number 
of 
heat
range
INSPECTION
1 
Remove
spark 
plug 
wire
by 
pulling 
on 
boot 
not 
on
wire 
itself
2 
Remove
spark 
plugs
3
Check 
electrodes 
and 
inner 
and 
outer
porcelains 
of
plugs 
noting 
the
type 
of
deposits 
and 
the
degree 
of
electrode 
erosion
Refer 
to
Figure 
EE 
74
Normal 
Brown
to
grayish 
tan
deposits 
and
slight 
elec
trode 
wear 
indicate 
correct
spark
plug 
heat
range 
SPECIFICATIONS 
AND
SERVICE 
DATA
TROUBLE
DIAGNOSES 
AND
CORRECTIONS 
EE 
38
EE 
39
Carbon 
fouled
Dry 
fluffy 
carbon
deposits 
on 
the
insula
tor 
and
electrode 
were
mostly 
caused
by 
slow
speed
driving 
in
city 
weak
ignition 
too 
rich 
fuel 
mixture
dirty 
air
cleaner 
etc
H 
is
advisable 
to
replace 
with
plugs 
having 
hotter 
heat
range
Oil 
fouled 
Wet
black
deposits 
show
excessive 
oil
en
trance 
into 
combustion
chamber
through 
worn
rings
and
pistons 
or 
excessive
clearance 
between
valve
guides
and
stems 
If 
the 
same
condition 
remains
after
repair
use 
a
hotter
plug
Overheating 
White 
or
light 
gray 
insulator 
with 
black
or
gray 
brown
spots 
and
bluish 
burnt 
electrodes 
indicate
engine
overheating 
Moreover 
the
appearance 
results
from 
incorrect
ignition 
timing 
loose
spark 
plugs 
low
fuel
pump 
pressure 
wrong 
selection
of 
fuel 
a
hotter
plug 
etc
H 
is 
advisable 
to
replace 
with
plugs 
having 
colder
heat
range
EE 
37 
     
        
        Page 458 of 513

ENGINE
Overheating
Normal 
Carbon 
fould
Fig 
EE 
74
SpaTk 
plug 
Life
4
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
5
Install
spark 
plugs 
and
torque 
each
plug 
to 
1 
5
to 
2
0
kg
m
ll 
to 
15 
ft 
lb
6 
Connect
spark 
plug 
wires
CLEANING 
AND 
REGAP
Clean
spark 
plugs 
in 
a
sand 
blast
type 
cleaner 
Avoid
excessive
blasting 
Clean 
and 
remove 
carbon
or 
oxide
deposits 
but 
do 
not 
wear
away
porcelain 
If
deposits 
are
too 
stubborn 
discard
plugs
Mter
cleaning 
spark
plugs 
renew
firing 
surface
of
electrodes 
with 
me 
mentioned 
above 
Then
gap 
spark
plugs 
to 
0 
8 
to
0 
9 
mm 
0
030 
to 
0 
035
in
using 
a 
round
SPECIFICATIONS 
AND 
SERVICE 
DATA
Make
Model
Size 
Screw 
dia
x 
Reach
mm 
in
Plug 
gap 
mm 
in
Tightening
torque 
kg 
m 
ft 
b
EE 
38 
wire
feeler
gauge 
All
spark
plugs 
new 
or 
used 
should 
have
the
gap 
checked 
and 
reset
by 
bending 
ground 
electrode
Fig 
EE 
75
Setting 
spaTk 
plug 
gap
NGK
HITACHI
BP5ES 
1A6PW
14 
x
19 
0 
55 
x 
0
75
0
8 
to 
0
9 
0 
031 
to 
0 
035
1 
5 
to
2 
5 
11 
0 
to 
15 
0