Nissan LZ20B Manual

F F '::

:

I

L?OBENGINE Group 2/Group

4

CONT ENT S .: JB E\GI\E TTINE-UPSPECIFICATIONS......, .. P.\RTS CONFIGURATION AND DETAILS OF TUNE.UP C\'LINDER BLOCK OIL PAN CYLINDER HEAD CYLINDER HEAD C.{M COVER PISTON.CONrr-ECTING CRA\KSHAFT AND FLYWHFF I CLUTCH E\G I).1ERE A R P LA TE ,... ENGINE ]\,IOUNTING BRACKET CAMSHAFTDRIVE. VALVE MECHANISM. FRO NT COV E R A ND OIL S E A L . . . . . . . . . OIL PUI!'IP OIL COOLE R INTA K E S Y S TE ]\{......, EXHAUST \IA\IF'OLD .. ., WATER PUMP. WATER OUTLET. FAN BLADE

RAD IA I OR ENG INE E LE CTR]CA LS Y S T E M EXH AUS TS Y S II \1 ... TEST RUN P RE CA UTIONS SERVICEDAT,.\ BONDINGAND SE.\ L I\'] ACENTS

.. I .. 3 ,. 3 .. 4 .. 5 .. t3 . . t4 . . 14 . . t0 ..21 . . ll . . lt .. 3t .. 33 .. 39 ..4t .48 .48 . 5l .. 5l 56 .. 57 . 58 ..

bl

L 2 OB Engine( Gr oups2 and 4\

L'TOB ENGINE TUNE-UP SPECIFICATIONS (s.o.H.c.) c-2 L?0B

L20B(D.O.H.C.) G4

--t-*{@m1rccr:-e

" LR20B: in-line,4cylinder-S.O.H.C

l!'ra rl?n'=-€rr # ral :n1

r,952(r19,11)

h rn c r

85.0x 86.0 (3.346x 3.386)

lrElrl

* IZ20B, inline 4-cylinder-D.O.H.C.-4V

icrryrmrno

1 0 .8to I 1 .0

@oNtrFrt

195 PS/7,200rpm (A/Horn)

rpm (A/Horn) 230PS/7,500

@tolque

206N.m(21 ke-m,152frlb)i 5,600rPm

216N m (22ks-m,159ftlb)/ 6,000rpm (Ai Horn)

7,500rpm

8,000rpm

Modificationto standardZ20B unit I2O B

-

NLt:

[:--] s?eed

friu:et

i].ock

(1}rt'e: iead

i s uti l j zed. L l 8 o p tro n a unrt l

aluminumunit Forge-strengthened is newly developed. C:-:1ing

Unit for D.O.H.C.-4valveis newly developed. -

(The shapediffers from that of

c,2.)

Unit usingCM40strengthened malerialis newiy developed.

rod

a---:{s!ufi

unit is CM40tulftride'processed n e w l y ' d e v e l oped.

i'':'::eei

L24 optionalunil is utiljzed.

tJ?3i lraln

(Detailsof modificationdifler from thoseof C-2.)

Disc

L:4 optionalunit is urilized.

Cover

C 2 2 5 Si y p ' e ,5 ,39aN(550 kg. 1 .2 1 3l b ) o r 7 ,846N(800 kg. r,7 6 4 l b ) Gears:Ll4 (4V) optionalunits are utilized.

L2OB Engine(Groups2 and 4) Specificarion

i

G-2 L20B(S.O.H.C.)

Item Csmshaft Valve

mm (in)

Ll8 rally optionalunit is utilized.

Ll8 (4V) rally optionalunit is utilized.

2/l cyl. [ntake: a4 (1.73)lia., Exhaust:36 (1.42)dia.l

4/l cyl. Untake:33 (1.30) dia., E xhaust:29.5(l .l 6l ) di a.l Ll8 (4D rally optionalunit is utilized.

Intake manifold Exhaust manifold

G-4 r20B(D.O.H.C.)

Stainless steelpipe 4'2-l type is newly developed.

Carburetor

S O L E X5 0 P H H r l w i n

Air cleaner

L24 optionalunit is utjLized.

Dstributor

CDIoptionalunit is MITSUBTSHI utilized.

Alternator

Rally spec.80A or 60A

Oil sumpsystern

Wetsump

Radiator

asAl0 rally unit. Newly developed

OiI cooler

HS30optionalunit is utilized-

Exhaustsystem

asA10 rally uritNewly developed

+

(The shapeis different from thar of

c2.)

Dry sump

*: Nomenclature usedin Nissan

-2 -



;^---

|

lrt

T-T_-

|

tt

I

:nginqpump

F\

ssurepump

i\

5-----

o " " " ' "n Ii tank

L--

li

| I

l\l

/G\

-1 n-

o

c

tli. iil '

T-

L

I

Part Name

Q'tv

21001 1s010

PumpAssembly'Oil

0t

150662100t

Gasket-OilPumP To CoYer

01

1503621000

Bolt-OilPump

02

h---l I

Remarks

I

li?,fl'1'r aH:?:!8fi:I,".?lLiTJll;11' rI

I

02

89-15438-l

Washer-Pla:in

04

I

89-15138-1

Washer-Sp!ing

04

I

1504021001

PumPDrive Spindld-Oil

0l

l s0s047660

StrainerAssemblY-Oil

0l

15055U8000

Tube-Suction

0l

15051A7660

Screen-Strainer

01

8r-20620-62

Bolt-Hex

0l

1505973400

Gasket-OilStrainer

0l

8l -10825-62

Bolt-Hex(Oil Strainer)

02

1523847660

Filter BracketAssembly-Oil

01

-34Jn,.{

oir tank

The L-seriesenginestandardunit is used'

1503721000

i,, t

I

uaru, , neourato,

PUMP G2 specification Part Number

\

B reather

----.--

@

I

t light'weightunit Option,small-sized,

_I I L

I Option; for installation of oil cooler

L 2 OB E ngine( Gr oups2 and 4\ Remarks .

Q'ty

Part Name

Part Number

t5241A766Q

Connector-Oil

0i

Assembleafter applying"Araldite"

15236N3120

O-Ring

01

LY 26 option

0l

Option

1523'1A7660 l5 21469800

washer-Stud

01

152t3 A766Q

S tu d -O i lF i l te r

0l

Option

1520865011

ElementAssembly'OilFilter

0l

Unit for L-seriesengineis aPplicable.

and The oil-pump incorporatesthe scavenging pressurizinggear pumps on the sameshaft. The oil pump is driven by the timing belt from tlre end of the crankshaft at l/2 the crankshaft speed.(External driving system) When assemblingthe oil pump, the oil pump drive and driven pr-rlley must be carefully aligned.

During high speed operatiott. the OIP drive spindle (15040 ll00l) and its mating drive gear( I 5043 21000) nriy be worn utrdercertain conditions. In sttch a case. please contact Nissan Moior Co., Ltd. ds a slrengtherledtrial ' production unit of a different nraterialis available. @ G4 specification a The Ll8(4V) optional unit is used.This oil pump has an increasedcapacityto matchtlte dry sump system.

O,l puhp

( | ) Oil pump construction

dr i v e s h€ft

Oi l pump dri ve gear S cavengi ngoi l

Oil pump pulleyadapter

Oil pumpplate Oi l pump dri ve gear

D ri ve shaft p;n

Pressureoil pump bodY

Oil p u m p co ve r Oi l pump gasket

Oil p u m p d r ive n sh a ft

-35-

Oi l pump dri ven sha{t

L20B Engine( Gr oups2 and 4) r The oil pump gasketsare availlble itt tlrree al.^^"-

or cL.atc

- - ^- - .

cn

tl l r t

value) s (Reference Clearance

the

Clearancemm (in)

fol lowing clearance(sicle clerrartce)cln be obtained.

(Cl) Sideclearance

0.04- 0.1I (0.0016- 0.004

Thickness mm (in)

Tip cleararce(C2)

Lessthan0.12(0.0047)

Part Name

Part Number

Oil pump gasket

1 5 0 1 3N 7 1 7 0

0.085-0.115 (0.0033- 0.004s)

Oil pump gasket

15013N7r7l

0.r05- 0.135 (0.0041- 0.00s3)

Oi] pump gasket

15013N7r72

.0.155 0_125 , 0.0061) (0.0049

wheneverthe pump is Checkeachclearance

t I I

(2) Oil pump fitting

t I

t @

$a^ft /

@----

6B). AXi,/

*

\:jjl

-{N "KW L-o \ Ff-. ^@'. )D

Key No.

o

PartNumber

@

u Front

/

a,

A__*

Part Name

Remarks

Q'ty 0l

14003N7171

Manifold-lntake

02

89.31304-l

Plug-Btind(PT t i4-19)

03

Connector-PiPe

0l

oootr "ArAOit"-to #4 pott Uefot"inst"lli"g' Ll8 (4v) option

1-la00l

@

14035 N7170

Gasket-lntakeManifold

04

@

89.15436-t

Washer-Plain

l2

@

89-15136-l

Washer-Sprilg

11

o

89-t1206-l

Nut-Hex(M8)

tz

@

t617414610

Insulator-Carburetor

04

o

i61?514610

Gasketlnsulator, Manifild

04

F -

Ll8 (4V) option

Manifold AssemblY'lntake

N7171

L lr'ctseqtot

)

\@

ht o /f

4 I

;

I Ll6option

I

L 2 OBE n gine( Gr oups2 and 4) Key No.

Part Number

@

Part Narne

Q-ty

1617614610

Carburetor Gasket-lnsulator,

04

@

89-15138-l

Washer-Spring

l6

@

89-1I108-1

Nut-Hex

lo

(D

1601022010

AssemblY-Twin 0l Carburetor

16360H587s

Kit-Throttle, Unkage

0l

@

16361H58?0

Drum-Throttle

0l

@

r6362H5820

Lever-Throttle

0l

@

16376H5820

Stopper-Tfuottle

0l

@

163?9H5820

Scfew-Tluottle Adjust

0l

Sprihg-AdjustScrew

0l

;

Remarks L16 opti on

Ll 6 opti on,S OLE X50 P H H L 14(4V) option, R/H drive car only

@

t- 1637814600

@

161:625510

Washer

02

Fitted to carburetor

@

16r2415520

Nut

02

Fitted to carburetor

@

l6l l4 25520

Screw-Adjust

0l

@,

r 6 r 3 22 5 5 20

Nut

0l

@

16184li 510

PushRod

@

r614525s20

Spring-Adjust

@

t6292 25520

Rhg-Snap

@

83-60525-65

uvrr

@

t60'71)5521

Screw

0?

Fitted to carburetor

16360A76?0

Kit-Throttle, Linkage

01

L/H drivecar only, option

1636147670

Drum Assembly-Tfuottle

0l

t6362.A'1670

Drum-Tfuottle

0l

Lever'Throttle

0l

T [

L ro:o:eroro

D^ tr lir < - n a \ \F,J

^

I 0l

v.u,

0l I 0l

0r

0l

16362H5820 16376H5820

Stopper-Throttle

0l

16379H5820

Screw-Throttle Adjust

0l

1637814600

Spring-Adjust Screw

01

t63?6 A7610

Wire Bracket-Accelerator

0l

Installto intakemanifold

L2OBEngine( Gr oups2 and 4l Key No.

Part Name

Part Number

83-60514-14 118100

47670

L terotozoto -r l8 100A7660 r- t8lol 47660

Remarks

Q'tv

Screw-Machine(M5 x 0'8)

0l

Wire Assembly-Accelerator

0l

Wire-Accelerator

0l

T F

RiH drivecar only, option

I -Li H drive car only, oPtion(G2)

Wire Assembly-Accelerator

0l

Wire-Accelerator

0l

T S O L E Xs O P HHCA RB UR E T O R FICATIONS SPECI Unit'

* Remove the existing throttle Iinkage from SOLEX 5OPHH.and install the optional part.

Specification

t

G2 Item

MODIFICATION OF INSIDE SURFACE OF INTAKE MANIFOLD PORT r The inside surfaceof the intake manifold port like the cylinder head port must be modified by grinding, for improved intake efticiency, while paying attention to the following items: O Grind the portion to be installed to the cylinder head smoothly together with the manifold gasketwithout any steP. @ brina the inside surface of carburetor side smoothly without any step, and make the surfaceflush with the insulator diameter.

Throttle Bore Diameter

s0(1.e7)

1

Outer Venturi Diameter

43(r.69)

43

Air Horn Length

s0(1.97)

50

Main Jet

#180

Main Air Jet

#150

Float Level

24(0.e4)

#EL 22''

+ Adjust the float level. This combination of jets recommende is basedon the conditions existing at sEa

laltitude0m (0 ft)l in Japan'and mE

according to the actual field co Adjustment to the best carburetorq! should be made by the user through actual

run.

o The size and part numbers-of availa jets and main airjets are listed below' O Mainjet Palt Number

SizeNo.

Part Number

SizeNo.

#t20

t6033 25924

#160

1603325528

t6033 25925

#l o)

t6033 25529

t@33 25926

#t70

16034 25523

#130

t6034 25524

t6033 2592'l #t4t)

16033 25928

#180

16033 25520

#t45

1603425572

#l8s

1603425525

#150

t60342ss2r

#r90

1603325521

#r55

16034 25520

#r9s

t6034 25526

-46-

PartNumber

L 2 0 B Engine( Gr ouPs2 and 4) @ Mainairjet PartNumber

SizeNo.

PartNumber

t6036HO222

#190

16036 25521

#130

16036H0224

#200

1603625723

#140

16036H0226

#2to

16036 25522

SizeNo.

t6036 25524

16036H0228 #160

t6036 25'720

#230

1603625s23

#170

160362512l

#240

160362s52'.7

#180

1603625722

1603625520 After'warming up the engine,open the throttle valve fully beginning from approximately 1,000 rpm in any gear position, and raise engine speed to the level at which the maximrim output can be obtained.In this case;

* Use the jet block having"OB" mark on it. PRECAUTIONSIN CARBURETOR SETTING As the atmosphericpressurelises, increasethe main jet size number (decreasethe main airjet size number); as the atmospheric pressure drops, make the reverseadjustments. @ As the temperaturedrops, increasethe main jet size number (decrease the main air jet size number); as the temperaturerises,make the reverseadjustments. @ When the weather is cloudy, increasethe main jet size number (decreasethe main air jet size number). When other than cloudy (fine or rain). make the reverseadjustments. @ n tnict mixture will lower the temperature of exhaust gas (and lean mixture will cause the temperature to rise). To lower exhaust gas temperature,increasethe main jet size number properly (or, decrease the main air jet size number.) O Whether the main jet size and main air jet size are selectedproperly can be judged by observing the color of the center insulation of spark plug. If an excessively large difference is observed between the size numbers recommended above and those selectedin the field, check whether the heat value of the spark plug has been properly selected. @ When the outer venturi diameter is increased, the engine performance becomesa high-speed type; when decreased,the engine performance becomesa low-speedtype. O The air horn length significantly'affectsengine performance.When shortened,the engine exhibits higir-speedtype performance (that is, torque characteristics).When extended, the engineexhibits a low-speedtype.

o

IRelerence] When setting the carburetorby test driving only

@ If insufficient output is felt at high speed (though the low and middle speedsare normal); a. Reduce the main air jet size number by #10 to #20 so as to thicken the mixture in high speed range. If desired output is obtained, test also the adjacent size numbers to determine the optimum one. b. If desired output is not obtained, increase the main air jet size number to make the mixture in high speedrangeleaner. @ lf the output is insufficient at low and middle speeds,though high speedoperation is normal; a. lncrease the main jet size number by #10 to #20 so as to thicken the mixture. If desired output is obtained, also test the adjacent size numbers to determine the optrmum one. b. lf desired output is not obtained (or the situation becomes worse), reduce the matn i pf ci"p n r nhPr and make the mixture leaner. @ lf the high speed range becomesworse while the middle and low speedrangesare improved; a. If the main jet size has been enlargedfrom the original one, enlarge the main air jet size. b. lf the main jet size has been reduced from the original one, reduce the main air jet slze. in engineresponseis felt If a slight sluggishness O upon sudden acceleration,it is an indication of excessivedelivery of acceleratingpump; if the engine is apt to stall, the pump delivery is insufficient. Adjust the pump delivery by changingthe position of the acceleratingpump

-47:-

L20B Engine( Gr oups2 and 4\ A I R CL E A NE R

rod cotter pin in tlie carburetor. * The nozzle hole is a very sntlll hole, and can be easily cloggedwith t1irt. To cle'an air: the hole, be sure to ttse conrpressed never use wire tbr cleaning. * The Weber carburetornray be installedby the user. user.

o lf air cleaner is needed, use the L24 op unit. The Mg casting strengthenedversio L2R is availableupon request.

t-

Part Number

L

Part Name

Q'tv

16500E46tr

CleanerAssembly.Air

02

E46lo 16s46

ElementAssembly-Air

02

16500E4620

CleanerAssembly-Air

02

. It is convenient to use a tire tube cut into e round slice as lhe band to retairl lhe elenrer)t.

Remarks

124optionGplittype)

EXHAUST MANIFOLD

il

T

. The stainless steel pipe exhaust manifold ir 4-2-l integral system is availableas an o for both Gl and G4 engines.

I

O G2 specification

Option, for R/H and L/H drive cars

14004A7660 14035N7120

@ G4 speciiication

Option, for R/H and L/H drive cars

t4004A7670

89-15r36-1 89-l1206-l

WATER PUMP, WATER OUTLET, FAN BLADE

as an option is made of iron Plate'

t uFtlride-treat ed to provideadditional againstbendingduring high speedopera

. Both G2 and G4 engines use the L-series6 cylinder engine-use a water pump with increasedcapacity.The thn blade that is available _48_

Water manifold;The unit fbr G2 is cast integral part oi the intake manifold. G4

r he L I 8(4V)optionalunit.

L 2 0 B Engine(Groups2 and 4)

o G2 specilicat ioti

Unit: mm (in Part Name

Part Number

Remarks

Q'tv

Standardfor L-series6 cylinder engine

21010E3027

PumpAssemblY-Water

0l

4 2 1000 2101

PumP Casket-Water

0l

2107821002

Bolt-Hex(M8)

0l

89-l5138-l

Washer-Spring

02

2107921002

Bolt-Hex(M6)

0l

89-15136-1

washer-Spring

0l

8t-2062?'62

Bolt-Hex(M6)

02

21051N7120

Pulley-Fan

0l

L l8-option

21061N7l l0

Front BIade-Fan.

01

Ll8 option.300(11.81)dia'T

21062N7120

Blade-Fan,Rerr

0l

21064N7170

Spacer-Fan

82-26622-l

-srud (M6)

I

0l

l'6 (0'063) -

T = 3.2(0 126) Ll8 (4V)option,

I oo

89-ii136-1

washer-Spring

04

89.r1206-l

Nut-Hex(M6)

04

llT l0Nl l l 0

Belt-Far

01

Ll8 option, BAN FLEX I lM-825

21200H780?

Thermostat AssemblY

01

V ai veopens/o.) L (l /u ry

0l

OPtion

11060.47660 Outlet-Water l r062N7l 20

Water Oasket-Outlet

0l

8r .r 0816-62

Bo l I.H e x(M 8 )

03

2508089900

TemPerature Gauge-Water

0i

2525137700

\ut-Ground, Water TemperatureCauge

0l

-49-

.::.,.\:,

L20B Engine(GrouPs2 and 4\ @ G4 specification

Unit: mm (in) Part Name

Part Number

Remarks

Q'tv

6 cytinderengine Standardfor L-series

2t0to E3027

PumpAssembly-Water

0l

2101421000

PumP Casket-water

OI

8r.?0800-l

Bolt-Hex(M8)

Q2

89-15138-l

Washer-Spring

02

21079H5820

Bolt-Hex(M6)

01

89-ls I l6-t

Washer-Spring

0l

8t.20622-62

Bolt-Hex(M6)

02

1

I

Ll4 (4V) option

I

-l

21051N7170

Pulley-Fan

0l

Ll8 (4V) oPtion

21061N7120

Blade-Fan,Front

0t

300(l l 8l ) dia,r= t uj oull_I Ll 8 option,

21062N7120

Blade-Fan,Rear

0t

21064N7170

Spacer-Fan

82-26622-t

I Stud(M6)

|

I

I

! r ra /4v\^nri^n T=32(0.126)

0l

I

04

I

i36-1 89-15

Washer-Spring

04

89-11206-1

Nut-Hex(M6)

04

I i720N7120

Belt-Fan

0l

L18option,BANFLEX l lM-825

2\200 H7802

ThermostatAssembly

0l

valveopens76.5'c (1?0"F)

11061N7170

Manifold-Water

0l

Ll8 (4V) option

Ll4(4v)option

I

-----l

I1062H5821

Outlet,B Gasket-Water

02

89-15138-l

washer-Spring

04

89-lI108-l

Nut-Hex(M8)

04

l1060u0100

Outlet-Water

01

r 1062s0600

Gasket-WaterOutlet

0l

81.10828-62

Bolt-Hex(M8)

02

27070H5000

Connector-Heater

0l

2s08089900

Gauge-WaterTemPerature

01

F

252513'l'700

Nut-Ground,Water Gauge Temperature

0l

I

* Thermostatis unnecessaryin torrid zones' -50-

I

L 2 OB Engine( Gr ouPs2 and 4) duced weight and increasedcooling capacity to meet rally requirements,and is availableas an option. @ G2 specification

RADIATOR

. The radiatorproperis commonto G2 and G4' aredifferent' only the hoses is . ihZ radiator madeof aluminttm'with re-

Option, aluminum

21400A1660 21501w5301 21503K2405

n @ G4 specificatio Part Number

Part Name

Remarks

Q'ty

2140Q A'1660

Radiator Assembly

01

Option,aluminum

2r50t A76'10

UPPer Hose-Radiator,

0l

Option

2t503 A767Q

Hose-Radiator,Lower

01

Option

87-23144

Clamp-Hose

04

. The ignition coil and amp. utilize the El0 (Cherry) optional Parts. o The high tension cable and spark plug differ between G2 and G4 sPecifications. O G2 specification

ENGINEELECTRICALSYSTEM IGNITION SYSTEM . The competition proven MITSUBISHICDI systemis adoPtedasrally specification. Part Name

Part Number

Q'tv

Remarks

22100A7601

DistributorAssembly

0l

L14 (4V) option, common to G2 and G4

2211821000

Support-Distributor

OI

Commonto G2 and G4

83-60614-14

Machine-Screw

0l

89-r5436-i

Washer-Plain

0l

81.10628-62

Bolt-Hex(M6)

02

22t79 E3000

Packlng.Support

0l

22t80 '71200

O-Ring

0l

22020M0820

Amplifier-CDl

01

22433M0820

Coil-CDl

0r -51 -

Commonto G2 and G4, El0 oPtion

L2OB Engine(Groups2 and 4l

22401 A4617

22450u6700

YAZAKI, L20Bstandard

CoilTo Distributor

L20Bstandard SUMITOMO,

(224s0u61tO) 2245l U6000

YAZAKI,L20Bstandard

CableAssemblY-Higlt TensionNo. I

L20Bstandard SUMITOMO,

22451B80lI ?2452N6001

YAZAKI. L20Bstandard

CableAssenrblY'High T e n si onN o.2

L20Bstandard SUMITOMO,

(224srN60lI ) r1453N6001

CableAssemblY'High TensionNo. 3

YAZAKI, L20B standard

L20Bstandard SUMtTOMO,

(:2453N601I ) 22454? l00l

Cable AssemblY-Hi8h TensionNo' 4

YAZAKI,L20Bstandard L20Bstandard SUMITOMO,

(224542t0r0)

iitiliirl

2t0Lo 224',1?

W1

@ G4 specitication

I t lu ! rI f t i i r l

i tNit:t

(22401N7171)

L18 (4V) option,NGK R0l8-7

iifi1

2240rN7177

Ll8 (4v) option,NGK R018-8

ilii:r ll. ! ' l

ti

2?45t A7670

Cable AssemblY-High Tension Coil To Distributor Cable Assembly-High TensionNo. I

22452A76'70

CableAssemblY TensionNo- 2

22450u6700

: ':l

22453A'1670 22454A76'70

TensionNo. 3 Cable AssemblY-High TensionNo. 4

224'1221010

ALTERNATOR . Two types of alternators,60(A) and 80(A). are available as options. These alternators lrave increasedcapacity to meet rally requirements' e When using the optional alternator. the oDtional fan belt (BAN FLEX belt) must rlso bi used, as the groove in the pulley isdifterent -52-

'..-fu!''

tiom that of the standardalternator' When installingthe alternator to the block, alignment of PulleYst <ernator) must be properly made. The through bolt is used to attach nator to bracket. This alternator has an [C regulator b

L2OB Engine(Groups2 and 4) Part Number

Pait Name

Remarks

Q'ty 0l

Option,for G2,80(A)

23100N7170

0l

Option,for C4,80(A)

(23100N7l2l )

(01)

Option,for G2 andG4, 60(4)

23100N7120

Altemator AssemblY

1r710N7170

Bracket-Alternator

0l

Ll8 (4v) option,for C2 andG4

80.11045.1

Bolt.Hex(Ml0 x 1.5)

02

for ul ano u4

540-l 89-15

Washer-Plain

02

89-15140-l

Washer-Sprhg

02

80-30804-l

Bolt-Alternator

0l

89-15438-l

Washer.Plain

02

89-15138-1

Washer-Spring

0l

89.1l?08-l

Nut.Hex(M8)

0l

l l715u0500

Bar-AdjustAlternator

0r

ror ul

0l

For G4,Ll8 (4v) option

0l

ForC2 (for AdjustingBar)

0l

For G4 (for Adjusting Bar)

01

For G2 and G4

1r715N7170 2107821002

Bolt-Hex(M8)

8l-20895-1 89-1513&1

Washer-Spring

* When changing the alternator with external regulatorto the optional alternator with builf in IC regulator,remove the external regulator, and make the connectionas shownon the next

page,and use it in the bypasscircuit. * The alternator circuit diagrams (iC regulator built-in and external regulator type) are given for reference.

_53-

L2OB Engine(GrouPs2 and 4\ nector as shown below' To provide pro in case of charging lamp burn out, con

When changing the external regtllator type alternator to the IC regulator built-in type alternf,tor,remove the extern3lregulator,and connect i.r the bypass circuit using the con-

resistorof about 50ohm 3-wattin parallel the lamp.

Connect@ and @ usins0.5 nna (o-ooogsq id wie Connect @ana

connect 50 1oo-olrm R-watt rcsistot in parallel-

I

Circuitdiagramof lC regulatorbuilt-intype alternator(HITACHI tYPe)

F ie ld co il

I

-u-

L20B Engine(Groups2 and 4l Circuitdiagramof alternator.havingexternal regulator l gni ti on sw i tch

standardunits.

STARTERMOTOR o The G2 and G4 engines. usethe sameL-series

PartNumber 23300U0102

Remarks

Part Name

Q'ty

StarterMotor Assembly

0t

by HITACHI lkw, manufactured

0l

by MITSUBISHI lkW, manufactured

23300U01ll

. The part numbersgivenabovearetypicalones. Any starter motor, if it is for the L-series

4-cycle engine,can be used.

L2OB Engine(Groups2 and 4l model. User modiiication is necessary., o The rally exhaust system has larger, tube diameter and greater exhaust n( pared than the production unit. This must therefore not be used on any c one modilled lbr a rally.

EXHAUST SYSTIi M . Although enginediff :rs betweenG2 and G4, the exhaustsystem afl:er the exhaustfront tube is not d ifl'erent. . Optional rally parts are available for PA l0

?7

"@ 6

:

@-€ tr---@ I

-o

@

|,.e:

o-ffi.^

il"r"l*__ff _I ffir-

/-\

?

I

l^ a\'

f / r- ',:,Wb

i rGl

,/

6 6 6 y g i- $

6

./

\

\

l+

A\ -

--_LL

i ruok ftoor

/A A

flti

,,4-fl-l-\n-1 Exhaustrear*ffi

I \,,/

@6

steelpipingor bellowstub( Stainless mendedtor part @ for higherdurab Properlyinstallbolt,@ andnut @.

Part @ is not included in the optional unit. Preparea suitable pi1re accordingto the actual dimensionsof other parts. In this case. weld portions@and@r igidly. Key No.

o o o

Part Number

Part Name

Remarks

Q'tv

I

r

2060r A7660

Plate-FixingTube

0l

Option

20604N6320

Collar-FixingTube

0t

710 opti on

81-30838-l

Bolt-Exlaust Flange

o4

@

20602S0600

Nut"Exhaust

o4

o

89-15438-l

Washer-Plain

04

\q/

2003147660

Adapter.Ex-tnust Center

0l _56-

ta

F Option

-Ir

L20B Engine(GrouPs2 and 4) Key No.

Part Name

Part Number

Remarks

Q'tv

20621 A7660

Clamp-ExhaustCenter, A

0l

@

20622 A7660

Clamp-ExhaustCenter, B

0l

o

20622 28501

MountingRubber,Exhaust

0?

@

20050A7660

Rear Tube-Exhaust,

0l

o

206t2 A'1660

Tube Clamp-Exhaust

0l

@

10040A7660

Muffler AssemblY

0l

@

20134A7660

Clamp-Muffler

02

@

56124H 1001

Bush-Rubber

02

@

5611373000

Washer

02

Option

Option

@ Valveclearance G2 specification; ' lntake 0.25mm (0.010in) I Exhaust0.30mm (0.012in) | G4 specit'ication: I Intake 0.30mm (0.012in) | Exhaust0.35mm (0.014in) J

TEST RUN PRECAUTIONS O Adjustnrent oi tinting chain tension in G4 specificltiort . Apply a force of approximately 49 N ( 5 kg. I I lb) as shown below: a depressionof I - 3 mm (0.08 - 0. I I in) rnust resr.tlton the chain. . AIr excessiveiy tight clrlin mly cluse trouble in gear be:rringo1'thege r traill. the 4th . After completing adjtlstment.be sure to tighten the lock nut.

Adjust with englne warm.

@ Specifiedengineoil Use mineral oil of SAE viscosity#30 or above in the SC, SD, SE, CC, or CD classof A.P.I. classitlcation.

Presswith a force o f 4 9 N { 5 kg , I 1 lb ) '

IExample]

.'

2 - 3 m m ( 0. 08. 0. 12 in l

Maker

Ignitiontiming G2 specification: B.T,D.C.30"/4.000 rpm G4 specification; B.T.D.C.28'/4,000 rpm This setting. however, may be modified correspondingto the octane value of the gasoline which differs t'rom place to place provided that no knocking is clused.

SHELL

x-100(#40),MYRINAOtL(20w40), RoTELI-ASX ROTELLAOIL (20W50), orl- (#30,#40)

MOBIL

(10ws0) MOBILS.H.C.

IDEMITSU

AloLLorL FASTGT (#30,#40), FAST1000(l0ws0) APOLLOIL

CASTROL

351(equiv.to CASTROLPRODUCT (#40) GTX #40),cAsTRoL

TOTAL

CTS(2OW5O) ALTIGRADES

@ Proper oil temperature G2 sPecification: . ln oil pan, aPProx.100'C (212'F)' above 130'C Watch for temperatures ( 266'F). G4 sPecification: In oil tank. aPProx.80oC( 176'F)

-57 -

I L 2 O BE n g in e( G r o u P2s a n d4 \ o The criticaloil pressureis 294 kPa(2.94 kg/cm'? , 43 psi)/4,000rPm.(While @ Coolingwatertemperature a The temperature shouldbe 80 - 8'5'C I 85"F) duringactualrunning.

Oil level G2 specification; iame as L20B productionengine,Max' 3'8 I (4 US qt. 3-318Imp qt). min. 2.8S(3 US qt,2-I 12 Imp qt). Do not poui oil above the Max' line, or it .uy tpout out during high speedoperation' G4 specification; Olt shouldbe at the middle-level position in the oil tank. When checkingoil level, oil should exceed50"c (122'F), temperatr-rre and enginespeedshould be at 1.100 rpm' oil pressure ProDer 'pressuie should be 588 - 686 kPa (5 88 Oil 6.86 bar. 6 -1 kglcmz,85 - 100 psi) [at I l0'C (130'F) or lessl/4.000rPm.

.aA'r Warmingup after starting the engine a Avoid sudden engine speed increases. enginespeedto a maximum of 4,000 to the oil pressureimmediately attention starting. Do not race engine when oil and temperaturesare low.

SERVICEDATA

I

Maior clearances -=-----=Item

Unit: iim I

Engine

Bore Piston-To'Cylinder

O Clearance of Bearing

(0.008 - 0.016)

oil

0.3 - 0.9

(0.012- 0.03s)

MaLt

- 0.0024) 0-o5s- 0.060(0.0022

Rod Connecting

- 0.b022) 0.050 - 0.0ss(o.0o2o

2fi4

Intake

0.2s (0.010)

0.30- (0.012)

Exhaust

0.30 (0.012)

o.3s

ValveClearance

SparkPlugGap

I

- o.0o3s) 0.08-0.09 (o.0o3l o.2 .0.4

Top

zung Pisron EndGap

G4

-----t---------......-

0.7 - 0.8

(0.014)

(0.028- 0.031)

;

T

t :

L20B Engine(Groups2 and 4) Tidtiteningtorque (l) Major tighteningtorque Engine

:----===....-

N.m

Cy[nderHeadBolts (Tightenin three steps.)

C4

G2 kg-m

ft-lb

N .m

kg-m

ft-lb

lst time "0"

39

4.O

29

39

4.0

29

znd time

59

6.0

43

59

6.0

43

Final

74

t.)

54

74

7.5

54

ConnectingRod Bolt "M" (forque data is for reference.)

Elongation 0.13- 0.14mm (0.005r -0.0055i;)

s e - 6 e 1 6 . 0 - 7 . 01 4 3 - s l s 9 -6 9 | 6 . 0 -7 . 0 I. 4 3- 5 1 lst time "M"

39

4.0

29

39

4.O

29

Final

59

6.0

43

59

6.0

43

lst time "M"

59.

6.0

43

s9

6.0

43

Znd time

88

9.0

65

88

9.0

65

Final

118

12.O

87

118

12.O

8',7

CrankPulleyBolt

'M"

118

12.0

87

177

18.0

130

CamSprocketBolt

'M"

78

8.0

58

'78

8.0

58

Cam Bracket Bolt

20

2.0

15

l .)

ClutchCoverBolt

20

2.O

I4

20

2.O

l4

3.5

25

34

3.5

25

3.5

25

3.5

25

Main Beadng Cap Bolt

Flwheel Bolt

Alternator Bracket Bolt EngineMounting Bracket Bolt

34

3.5

25

oil PumpBracketBolt

34

3.5

25

*"M": *"O":

Apply "Molycote']. Apply engineoil to threadedportion. For the connectingrod bolt, apply engineoil to the washer.

-59-

34

L20B Engine( Gr oups2 and 4\ (l)

torque Standardntttsand botts tiglttening StandardTighteningTorque StandardValue

AllowableRange

0.33- 0.44 7.8 - 10.8 7.8- 10.8

0.54. 0.74

7.5- r0.5 1.'7- 10.4

108- 147 l1.0 - 15.0

on their having the tbllowing nrarks ernbossed bolts the to applicable is data The above mark: Embossed -"'- - (MaterialS20C or KMS) 4T4 (MaterialS40C) 7T-7 gT-g (MaterialCR40)

head'

L 2 OB E n g i ne( Gr oups2 and 4)

BONDINGAND S E A L I N G A G E N T S Bonding and sealingagentsto be usedfor engineasselnbly. To be appliedto:

BondingAgent or SealingAgent

ThreebondNo.4

Silicon Bond KE45

Araldite

I

Front Cover*

2.

RockerCover*

3.

Oil Pan