Erigine
crankcase
EI
gine
cooling
system
Transmission
case
Final
drive
case
housing
Steering
gear
box
Fuel
tank
Air
conditioning
system
Refrigerant
Compressor
oil
f
tl
It
J
4
i
1
protect
the
catalytic
cop
verter
froitr
contamination
t
n
General
Information
APPROXIMATE
REFILL
CAPACITIES
Without
oil
filter
AI4
Al5
w
Al5
M
T
AfT
MiL
A
T
Liter
US
measure
3
2
3
qt
2
8
3
qt
3
7
llLgt
33
3
qt
5
2
5
qt
5
0
5Y
qt
5
9
6
Y
at
57
6qt
1
3
2
Y
ot
1
2
2
pt
53
5
qt
0
9
1
pt
0
25
pt
50
13
Y
I
0
8
tol
Okg
1
8
to
2
2
1b
0
237
8
0
floz
Withoil
Without
heater
With
heatfr
MaDllal
soeed
5
spee
Automatic
1
1
Includes
2
7
liters
2
US
qt
2
Imp
qt
for
torque
converter
RECOMMENDED
FUEL
Use
an
unleaded
or
low
lead
gaso
line
with
a
minimum
octane
rating
of
91
RON
Research
Octane
Number
For
cars
equipp
d
with
the
Cataly
tic
converter
California
and
FU
mod
els
use
only
unleaded
gasoline
to
RECOMMENDED
Lubricant
GasOline
engine
oil
Gear
oil
Transmission
and
steering
Differential
Au
omatic
TIM
fluid
Multi
purpose
grease
Brake
and
clutch
fluid
Anti
freeze
L
NDED
LUBRICAN
COMMENDED
i
I
VISCOSITY
NUMBER
t1
NGON
0
L
J
I
j
H
I
IlL
I
t
l
I
lc
30
ItM
7
l
t
U
I
ItM
I
L
L
tJ
30
I
I
fu
JIl
inld
do
o
II
L
liOwl
1
I
I
1
10
I
I
I
I
t
I
I
j
r
I
I
J
1
21
l
1
I
71
c
DIUt
I2lItMOl
UGIIII
FI
R
NIl
I
01
a
Specifications
Remarks
APISE
API
GL4
Further
details
refer
to
recommended
SAE
viscosity
chart
API
GL
5
Type
DEXRON
NLGI
No
2
Lithium
soap
base
DOT
US
FMVSS
No
116
Ethylene
glycol
base
GI
5
Imp
meas4re
2
qt
2
qt
3Y
qt
2
it
4
qt
4
q
5Y
qt
5
qt
2Y
pt
2
pt
4
qt
I
pt
pt
II
gal
1
8
to
2
2
lb
83f1
oz
Ji
j
j
Condition
Loss
of
water
Poor
circulation
Corrosion
Overheating
Over
cooling
Cooling
System
TROUBLE
DIAGNOSES
AND
CORRECTIONS
Probable
cause
Damaged
radiator
seams
Leaks
at
heater
connections
or
plugs
Leak
at
water
temperature
gauge
Loose
joints
Damaged
cylinder
head
gasket
Cracked
cylinder
block
Cracked
cylinder
head
Loose
cylinder
head
bolts
Restriction
in
system
Insufficient
coolant
Inoperative
water
pump
Loose
fan
belt
Inoperative
thermostat
Excessive
impurity
in
water
Infrequent
flushing
and
draining
of
system
Inoperative
thermostat
Radiator
fin
choked
with
mud
chaff
etc
Incorrect
ignition
and
valve
timing
Dirty
oil
and
sludge
in
engine
Inoperative
water
pump
Inoperative
torque
coupling
or
tem
coupling
Loose
fan
belt
Restricted
radiator
Inaccurate
temperature
gauge
Impurity
in
water
Inoperative
thermostat
Inaccurate
temperature
gauge
CO
7
Corrective
action
Repair
Repair
Tighten
Tighten
Replace
Check
engine
oil
for
contamination
and
reml
as
necessary
Replace
Check
engine
oil
in
crankcase
for
mixing
with
water
by
pulling
oil
level
gauge
Replace
Tighten
Check
hoses
for
crimps
and
clear
the
system
of
rust
and
sludge
by
flushing
radiator
Replenish
Replace
Adjust
Replace
Use
soft
clean
water
rain
water
is
satis
factory
Cooling
system
should
be
drained
and
flush
ed
thoroughly
at
least
twice
a
year
Permanent
antifreeze
Ethylene
glycol
base
can
be
used
throughout
the
seasons
of
the
year
and
change
periodically
at
intervals
recommended
Replace
Clean
out
air
passage
thoroughly
by
using
air
pressure
from
engine
side
of
radiator
Adjust
Refill
Replace
Replace
Adjust
Flush
radiator
Replace
Use
soft
dean
water
Replace
Replace
INSPEctiON
Check
clutch
pedal
parts
for
the
following
items
correcting
neces
sary
I
Bent
pedal
2
Weakened
return
spring
3
Worn
or
deformed
clevis
pin
and
fulcrum
bwhings
4
Cracks
at
welded
part
INSTAl1
ATION
To
install
clutch
pedal
reverse
the
order
of
removal
Observe
the
follow
ing
I
Apply
coating
of
recommended
multi
purpose
grease
to
sliding
por
tions
and
return
spring
Lt
of
I
ii
CL352
Fig
CL
5
Lubricating
Point
2
Fit
return
spring
in
hole
in
pedal
bracket
and
securely
fit
E
ring
in
slit
of
fulcrum
pin
3
Insert
clevis
pin
through
clutch
pedal
from
left
to
right
side
4
After
installing
clutch
pedal
check
the
clutch
pedal
height
AdjUst
if
necessary
Refer
to
Adjwtment
CLUTCH
MASTER
CYLINDER
REMOVAL
I
Remove
snap
pin
from
clevis
pin
2
Pull
out
clevis
pin
3
Disconnect
clutch
tube
from
mas
ter
cylinder
4
Remove
master
cylinder
Clutch
CAUTION
When
disconnecting
clutch
tube
use
suitable
flare
nut
wrench
Never
use
an
open
end
wrench
or
adjus1able
wrench
DISASSEMBLY
Note
When
disconnecting
dutch
tube
be
sure
to
receive
draioillll
clutch
fluid
into
a
container
Use
of
rags
is
also
suggested
to
keep
adja
cent
parts
and
area
clean
@
@
1
Reservoir
cap
6
Return
prina
11
Primary
cup
16
StOppel
rins
2
Reservoir
7
Sprina
seat
12
Piston
17
Dust
cover
3
Rescrvou
band
8
Valve
sprina
3
Secondary
cup
18
Lock
nut
4
Cylinder
body
9
Supply
valve
rod
14
Push
rod
5
Supply
yalYe
stopper
10
Supply
valve
15
Stopper
CL345
Fig
CL
6
Clutch
Mcuter
Cylind
r
I
Remove
dwt
cover
and
take
off
stopper
ring
from
body
2
Then
the
push
rod
and
stopper
can
be
taken
out
3
Loosen
supply
valve
stopper
and
take
it
out
4
The
piston
spring
seat
and
reo
turn
spring
can
be
taken
out
Note
Discard
piston
cup
and
dust
cover
CAUTION
Never
detach
reservoir
If
it
is
removed
for
any
reason
discard
it
and
instill
new
one
CL
4
INSPECTION
CAUTION
To
clean
or
wash
all
parts
of
masler
cylinder
clean
brake
fluid
must
be
used
Never
use
mineral
oils
such
as
gasoline
and
kerosene
It
will
ruin
tha
rubber
parts
of
tha
hydraulic
syslBm
I
Check
cylinder
bore
and
piston
for
score
or
rust
and
if
found
replace
2
Check
cylinder
bore
and
piston
for
wear
If
the
clearance
between
cylinder
bore
and
piston
exceeds
the
specified
value
replace
piston
assem
bly
or
master
cylinder
assembly
3
Check
the
condition
of
piston
cup
and
dust
cover
Always
replace
them
after
disassembly
4
Check
all
recesses
openings
and
internal
passages
to
ensure
that
they
Fig
MT
5
Removing
Rear
1IIline
Mounting
Croamember
Manual
Transmission
13
Remove
starling
motor
14
Remove
bolts
securing
transmis
sion
to
engine
and
gusset
Then
support
the
engine
and
trans
mission
with
jacks
and
slide
trans
is
sion
rearward
away
from
engine
and
remove
from
the
car
CAUTION
Take
care
in
dismounting
trammission
not
to
strike
any
adjacent
parts
and
main
drive
gear
INSTAUATION
Install
the
transmission
in
the
re
verse
order
of
removal
paying
atten
tion
to
the
following
points
MT
4
I
Before
installing
cJean
mating
surfaces
of
engine
rear
plate
and
trans
mission
case
2
Before
installing
lightly
apply
grease
to
spline
parts
of
clutch
disc
and
main
drive
gear
And
also
apply
grease
to
moving
surfaces
of
control
lever
and
striking
rod
3
Remove
filler
plug
and
fill
trans
mission
with
recommended
gear
oil
to
the
level
of
the
plug
hole
Oil
capacity
1
3
liter
2
US
pt
2
Y
Imp
ptl
4
Apply
sealant
to
threads
of
filler
plug
and
install
fdler
plug
to
transmis
sion
case
IiJ
Tightening
torque
Filler
plug
2
5
to
4
0
klt
fll
18
to
29
ft
Ib
o
Fig
MT
70
R
movi7l
lB
ar
Ensi
Mounting
Croum
mber
Manual
Transmission
3
Remove
starting
motor
14
Remove
bolts
securing
transmis
sJon
to
engine
and
gusset
Then
support
the
engine
and
trans
mission
with
jacks
and
slide
transmis
sion
rearward
away
from
engine
and
remove
from
the
car
CAUTION
Take
cate
in
dismounting
transmission
not
to
strike
any
adjacenl
parts
and
main
drive
gear
INSTALLATION
Install
the
transmission
in
the
re
verse
order
of
removal
paying
atten
tion
to
the
following
points
MT18
t
Before
installing
Clean
mating
surfaces
of
engine
rear
plate
and
trans
mission
case
2
Before
installing
lightly
apply
grease
to
spline
parts
of
clutch
disc
and
main
drive
gear
And
also
apply
grease
to
moving
surfaces
of
control
lever
and
striking
rod
3
Remove
filler
plug
and
fill
trans
mission
with
recommended
gear
oil
to
the
level
of
the
plug
hole
Oil
capacity
t
2
liters
2
US
pt
2
Imp
ptl
4
Apply
sealant
to
thread
of
filler
plug
and
install
filler
plug
totransmis
sian
case
l
l
Tightening
torque
Filler
plug
2
5
to
4
0
kg
m
t8
to
29
ft
bl
4
Bolt
converter
to
drive
plate
Note
Align
chalk
mark
painted
a
cro5S
both
parts
during
disas
sembling
p
S
After
converter
is
installed
rotat
r
nkshait
veral
turns
and
check
to
be
sure
that
transmission
rotates
freely
without
binding
6
Pour
recommended
automatic
transmission
fluid
up
to
correct
level
through
oil
charge
pipe
7
Connect
manual
lever
to
shift
rod
Operation
should
be
carried
out
with
m
mual
and
selector
levers
in
N
8
Connect
inhibitor
switch
wires
Automatic
Transmission
NOte
a
Refer
to
page
AT40
for
Checking
and
Adjusting
Inhibitor
Switch
b
Inspect
end
edjust
switch
as
abo
whe
ever
it
has
to
be
removed
for
servi
e
9
Check
inhibitor
switch
for
op
eration
Starter
should
be
brought
into
op
eration
only
when
selector
lever
is
in
P
and
N
positions
it
should
not
be
started
when
lever
is
in
D
n
and
Ru
positions
Back
up
lamp
should
Iso
light
when
selector
lever
is
placed
in
R
position
10
Check
level
of
oil
in
transm
sion
For
detailed
procedure
see
page
AT39
AT
26
II
Move
selector
leve
through
all
positions
to
be
sure
that
transmission
operates
correctly
With
hand
brake
applied
rotate
engine
at
idling
Without
disturbing
the
above
seUlng
move
selector
lever
through
N
to
D
to
2
to
I
and
to
R
A
slight
shock
should
be
reU
by
handgripping
selector
each
time
transmission
is
shifted
Note
See
page
AT40
for
Checking
Engine
Idling
Revolution
12
Check
to
be
sure
that
line
pres
sure
is
correct
To
do
this
refer
to
page
AT
43
for
Line
Pressure
Test
13
Perform
stan
test
as
described
in
page
AT41
Fig
AT
70
MeG6Uring
Clearonce
Clearance
between
seal
ring
and
ring
groove
Stendard
0
04
to
0
16
mm
10
002
to
0
006
in
I
31earance
Seal
ring
w
I
J
7
r
11
AT1
5
II
Fig
AT
71
MeG6Uring
Clearance
As
mblr
L
Set
up
pump
housing
with
inner
and
outer
pump
gears
on
it
2
Using
Oil
Pump
Assembling
Gauge
ST2SS80001
instan
pump
cover
to
pump
houaing
AT166
Fig
AT
72
Centering
Oil
Pump
3
Temporarily
tighten
pump
secur
ing
bolts
4
Set
the
cunout
of
oil
pump
cover
within
specified
total
indicator
read
ing
Automatic
Transmission
Total
indicator
reading
Lell
than
0
07
mm
10
0028
inl
ST2SSBOOOl
AT264
Fig
AT
73
Me
ring
Runout
S
Tighten
pump
securing
bolts
to
specified
torque
r
Tightening
torque
Oil
pump
housing
to
oil
pump
cover
0
6
to
0
8
kg
m
14
3
to
5
8
ft
Ibl
Note
Be
sure
to
align
con
ter
housini
securing
bolt
holes
6
Again
check
the
runout
of
oil
pump
cover
Note
When
former
Oil
Pump
As
sembling
Gauge
is
to
be
used
make
a
screw
hole
in
side
of
it
PLANETARY
CARRIER
The
planetary
carrier
cannot
be
divided
into
its
individual
components
If
any
part
of
component
is
defec
tive
replace
the
carrier
as
a
unit
In
p
ctlon
Check
clearance
between
pinion
washer
and
planetary
carrier
with
a
feeler
Standard
d
0
20
to
0
70
mm
0
008
to
0
028
in
AT
35
uan
r
J
II
I
AT1S7
Fig
AT
74
MeG6Uring
Pinion
Waaher
to
CanUr
Clearance
Replace
if
over
0
80
mm
0
031
in
CONTROL
VALVE
Tlte
control
valve
assembly
consists
of
many
precision
parts
and
requires
extreme
care
when
it
has
to
be
re
moved
and
serviced
It
is
good
practice
to
place
parts
in
a
part
rack
so
that
they
can
be
reassembled
in
valve
body
in
their
proper
positions
Added
care
should
also
be
exercised
to
prevent
springs
and
other
small
parts
from
being
sca
ttered
and
lost
Before
assembly
dip
all
parts
in
clean
automatic
transmission
fluid
and
check
to
be
certain
that
they
are
free
of
lint
and
other
minute
particles
If
clutch
or
band
is
burnt
or
if
oil
becomes
fouled
the
control
valve
as
sembly
should
be
disassembled
and
flushed
DI
mblr
I
Remove
bolts
and
nuts
which
retain
oil
strainer
Bolts
may
be
re
moved
with
a
screwdriver
but
it
is
recommended
that
Hexagon
Wrench
lIT61000S00
and
Spinner
Handle
lIT623S0000
b
used
with
the
pin
hole
of
the
internal
rotor
combined
with
the
manual
shaft
and
check
their
alignment
by
inserting
a
1
5
mm
0
059
in
diameter
pin
into
the
holes
If
the
alignment
is
correct
fasten
the
switch
body
with
the
bolts
pull
out
the
pin
tighten
up
the
screw
in
the
hole
and
fasten
the
selector
lever
as
before
Check
the
continuity
pin
with
the
lesler
If
Ihe
malfunc
tion
still
remains
replace
the
inhibitor
switch
STALL
TEST
The
purpose
of
this
test
is
to
check
the
transmission
and
engine
for
trou
ble
by
measuring
the
maximum
num
bers
of
revoiutions
o
the
cngine
while
vehicle
is
held
in
a
stalled
condition
The
carburetor
is
in
fullthrollle
opera
tion
with
the
selector
lever
in
ranges
1
2
and
I
respectively
Com
pale
the
measured
results
with
the
standard
values
Components
to
be
tested
and
test
itelJUl
I
Clutches
brake
and
band
in
trans
mission
for
slipping
2
Torque
converter
for
proper
func
tioning
3
Engine
for
overall
properly
STAU
TEST
PROCEDURES
Before
testing
check
the
engine
oil
and
torque
converter
oil
warm
up
the
engine
cooling
w
ter
to
suitable
tem
perature
by
running
at
1
200
rpm
with
the
selector
lever
in
the
range
P
for
sevcral
minutes
Warm
up
the
torque
converter
oil
to
suitable
temperature
60
to
lOOoC
140
to
2120F
I
Mount
the
engine
tachometer
at
a
location
that
allows
good
visibility
from
the
driver
s
seat
and
put
a
mark
on
specified
revolutions
on
the
meter
2
Secure
the
front
and
rear
wheels
with
chocks
and
apply
the
hand
brake
Be
SIIre
to
depress
the
brake
pedal
firmly
with
the
left
foot
before
de
pressing
the
accelerator
pedal
3
Throw
the
selector
lever
into
the
range
11
4
Slowly
depress
the
accelerator
pedal
until
the
throttle
valvc
is
fully
Automatic
Transmission
opened
Quickly
read
and
record
the
engine
revolution
when
the
engine
begins
to
rotate
steadily
and
then
release
the
accelerator
pedal
5
Shift
the
selector
lever
to
N
and
operate
the
engine
at
approxi
mately
1
200
rpm
for
more
than
one
minute
to
cool
down
the
torque
con
verter
oil
and
coolant
6
Make
similar
staU
tests
in
ranges
2
I
and
R
CAUTION
The
dill
test
operstion
81
specified
in
i18m
4
should
be
I118de
within
fiv
lIeonds
If
it
tBkes
too
long
the
oil
If
and
the
cluti
hn
blllke
and
b
nd
elll
ly
I
Suf
ficient
cooling
time
should
be
given
r
eech
test
for
the
four
IlInges
0
Z
1
end
R
JUDGEMENT
High
stall
revolution
more
than
staitdard
revolution
If
the
engine
levolulion
in
stall
condi
ion
is
higher
than
the
standard
values
it
indicates
that
onc
or
more
clutches
in
the
transmission
are
slipping
and
therefore
no
further
test
is
required
For
the
following
abnormalities
the
respective
causes
are
presumed
High
rpm
in
all
ranges
low
line
pr
ssure
High
rpm
in
0
2
and
I
and
normal
rpm
in
6R
Rear
clutch
slipping
High
rpm
in
D
and
2
and
normal
rpm
in
One
way
clutch
slipping
High
Ipm
in
R
only
Front
clutch
or
low
and
reverse
brake
slipping
To
determine
which
is
slipping
front
clutch
or
low
and
reverse
brake
a
road
test
is
needed
If
while
coasting
after
starting
with
the
levcr
in
I
range
engine
braking
does
not
work
properly
the
low
and
reverse
brake
is
slipping
Otherwise
the
front
clutch
is
slipping
Slipping
of
the
band
brake
is
diffi
cuJt
to
ascertain
However
jf
it
occurs
with
the
lever
in
1
range
engine
AT
41
revolution
increases
up
to
the
same
level
as
in
1st
range
It
is
impossible
to
check
it
in
the
stall
test
2
Standard
stall
rnoluiion
If
the
engine
revoluiion
in
stall
ondition
is
within
he
standard
values
the
control
elements
are
nOf
mally
operating
in
the
ranges
D
2n
I
and
R
Also
the
engine
and
one
way
clutch
of
the
torque
converter
are
norinal
in
performance
and
operation
The
one
way
clutch
of
the
torque
converter
however
sometimes
sticks
This
is
determined
in
the
road
test
3
Lower
stall
revolution
than
lIand
ard
revolution
If
the
engine
revolution
in
stall
condition
is
lower
than
the
standard
values
it
indicates
that
the
engine
is
in
abnormal
condition
or
the
torque
con
verter
s
one
way
clutch
is
slipping
4
O
hers
I
If
the
accelerating
performance
is
poor
until
vehicle
speed
of
approxi
mately
SO
kmfh
30
MPH
is
attained
and
then
normal
beyond
that
speed
it
can
be
judged
that
the
torque
con
verte
c
s
one
way
clutch
is
slipping
2
If
the
torque
converter
sane
way
dutch
sticks
vehicle
speed
can
not
exceed
approximately
80
kmfh
SO
MPH
in
the
road
tesl
In
such
a
case
the
torque
converter
oil
tem
perature
rises
abnormally
and
so
special
care
is
required
3
If
the
transmission
does
not
op
erate
properly
at
all
vehicle
speeds
it
indicates
poor
engine
performance
ROAD
TEST
An
accurate
knowledge
of
the
au
to
matic
transmission
is
required
for
an
exact
diagnosis
II
is
recommended
that
a
diagnosis
guide
chart
with
the
standard
vehicle
speeds
for
each
stage
of
the
up
and
down
shiftings
be
prepared
Measured
vehicle
speeds
are
to
be
filled
in
the
adjoining
column
after
each
testing
Also
it
is
advisable
to
mount
a
stopper
for
positioning
the
throttle
opening