ESP DATSUN 210 1979 User Guide

Emission
Control

System

EARLY
FUEL
EVAPORATIVE
E
FE

SYSTEM

DESCRIPTION

@
jl
D

W

o

0
0
UL
@

1

Intake
manifold

9
Screw

2

Stove

gasket
10

Thermostat

spring

3
Mar
fold
stove
11

Heat
control
valve

4
Heat
shield

plate
12
Control

valve
shaft

5

Snap
ring
13
Exhaust

manifold

6

Countczwcight
14

Cap

7

Key
15

Bushing

8

Stopper
pin
16

Coil
spring

The

early
fuel

evaporative
system
is

provided
with
a
chamber
above
a

manifold
stove
mounted
between
the

intake
and
exhaust

manifolds

During

engine
warming
up
air

fuel
mixture
in

the
carburetor
is

heated
in

the
cham

ber

by
exhaust

gas
This
reuslts
in

improved
evaporation
of
atomized
fuel

droplets
in

the
mixture

and
in

smaller

content
of

hydrocarbons

HC
in
the

exhaust

gas

especially
in
cold
weather

operation

OPERATION

The

counterweight
rotates
counter

clockwise
and

stops
at

the

stopper
pin

mounted
on

the
exhaust
manifold

while
the

engine

temperature
is
low

With
this
condition

the
heat
control

valve
is
in

the

fully
closed

position

obstructing
the
flow

of
exhaust

gas
As

engine

temperature
goes

up
and
the

ambient

temperature
becomes

high

enough
to
actuate

the
thermostat

spring
the

counterweight

begins
to
j

@

l

7

1
1

5

If

@

I

Exhaust
gas
flows

valve
dosed

valve

opened

EC247

Fig
EC

8
Early
Fuel

Eaaporatiae
E
F
E

System

rotate
clockwise
and

again
comes
into

contact

with
the

stopper
pin
With
this

condition
the

heat
control
valve
is
in
the

full

open
position
and
exhaust

gas

passes
through
the

exhaust
manifold

without

heating
the
manifold
stove

REMOVAL
AND
INSTALLATION

1

Snap
ring

2
Lock
bolt

3

Key

4

Counterweight

5
Thermosta
t

spring

6
Coil

spring

7

Heat
controlvalve

EC913
8
Valve
shaft

Fig
EC

9
KF
E

Sy
tem
Component

EC

8

Note
When
tho
vaCUUm
hose

is
dis

connected

plug
it

up
or

engine
will

stumble

EC
47A

FiJ
Fig
EC
49

Disconnecting
Vacuum

Hose

from
C
A

C
Valve

5

Connect

hand
operated
vacuum

pump
in

place
and

manipulate
it
in

order

to

apply
a

pressure
of
2oo
to

250

mmHg
7
87

to
9
84

inHg

to

C
A
C

valve
Increase

engine
speed

to
3
000

rpm
and
confIrm
that

no
air

leaks
from
C

J
C
valve

Fig
EC

50

Checking
C
A
C

Valve

1

6
With
the
above

condition
discon

nect
air
hose
at
check
valve
and

plug
it

up
At
this

point
confirm

the
air

leaks

from

C
A

C
valve

ECl48A

Fig
EC

51

Checking
C
A
C
Volve
2
Emission

Control

System

7
If

teshesults

satisfy
3
4
5

and
6

the
C
A
C
valve

is

properly
function

ing

AIR
INDUCTION

SYSTEM
A
I
S

DESCRIPTION

The
air

induction

system
A
1
s
is

adopted
on
the
FU
model
and
Canada

models
and
is

designed
to
send
see

ondary
air
to
the

exhaust
tube
utiliz

ing
a
vacuum
caused

by
exhaust

pulsa

tion
in
the

exhaust
tube

Air
inductIon
valve

A
reed

valve

type
check
valve
is

installed
in

the
air

cleaner
When
the

exhaust

pressure
is
below

atmospheric

pressure

negative
pressure

secondary

air

is
sent
to
the
exhaust
manifold

When
the
exhaust

pressure
is

above

atmospheric
pressure
the

reed
valve

prevents

secondary
air

from

being
sent

back
to
the
air
cleaner

EC
t8
The

exhaust

pressure
in

the
exhaust

tube

usually
pulsates
in

response
to

the

opening
and

closing
of

the
exhaust

valve
and

it
decreases

below
atmos

pheric
pressure
periodically

If
a

secondary
air
intake
is

opened

to
the

atmosphere
under

vacuum
con

ditions

secondary
air

can
be

drawn

into

the
exhaust
tube
in

proportion
to

the
vacuum

Therefore
the
air
induction

system

A
I
s
reduces
CO

and
HC
emissions

in

exhaust

gases

operatiug
the
same
as

the
air

injection

system
A
I
s
The

system
cpnsistsof
an
air

in

tJctio

valve

a
filter
an

A
B
valve

and
hoses

fl

V

t

5

1

Air

ind9ction
valve

2
Air

c
eancr

3
Carburetor

4

Exhaust
manifold

5

Anti
obRcldlre
valve

EC919

Fig
EC
52

Ai
Induction

SYltem

1

Reed
valvo

2

Stopper

EC920

Fig
EC

53
Air
Induction

Val

Emission
Control

System

ATloN

The

operation
of
the
E

G
R

system
is

as
follows

U

S
A

models

Except
FU
model

Thermal

Water

temperature
Oc
OF

vacuum
valve
B
P
T
valve

Exhaust

pressure
mmH20
inH20
E
G
R

system

Below

SO
to

63

I22
to
145
Open
Exhaust

pressure

Below
21

to
33
0
82
to
1
30
Open

Not

actuated

Above

21
to

33
0
82
to

1
30
Closed

Exhaust

pressure

Open
Not
actuated

Aliove

Closed
Below
21
to
33

0
82
to
1
30

SO
to

63

I
22

to
145

Above
21
to
33

0
82

to
130
Closed

Actuated

FU
model

Water

temperature
Oc
F
Thermal
B

P
T
valve

E
G
R

system

vacuum
valve

Exhaust

pressure

mmH20
inH2O

Below
Below
21
to
33
0
82
to

1
30

Open

Closed
Not
actuated

40
to
63
104
to
145

Above
2
to

33
0
82
to
1
30
Closed

Above
Below
21

to
33

0
82
to
1
30

Open
Not
actuated

40
to
63
104
to
145
Open

Above
21
to

33
0
82
to
1
30
Closed
Actuated

Canada
models

Water

temperature
Oc
OF
Thermal

vacuum
valve
E

G
R

system

Below
40

to
63

I04
to
145

Closed

Not
actuated

Above
40
to
63

I04
to
145

Open
Actuated

E
G
R
control
valve

The
E

G
R
control

valve

controls

the

quantity
of
exhaust

gas
to
be
led

to
the
intake

manifold

through
vertical

movement
of
the

taper
valve
con

nected
to
the

diaphragm
to
which
vacuum
is

applied
in

response
to
the

opening
of

the
carburetor
throttle

valve

E
G
R

control
valve
construction

and

type
vary
with

transmission

type
and
car
destination
For
identification

purposes
the

part
number

is

stamped

on
the
recessed

portion
at
the

top
of

the
valve

EC22

INSPECTION

Entire

system

I

Make
a

thorough
vjsual
check
of

E

G
R

control

system
If

necessary

wipe
away
oil
to
facilitate

inspection

If

any
hoses

are
cracked
or

broken

replace

2

With

engine
stopped
inspect

E

G
R

control
valve
for

any
indication

of

binding
or

sticking
by

moving
dia

phragm
of
control
valve

upwards
with

a

finger

3
With

engine
running
inspect

E

G
R

control
valve
and
thermal
vacu

um
valve
for
normal

operation

1
When

engine
coolant

tempera

tun
is
low

Make
sure
that
E

G
R

control
valve

does

not

operate
when

engine
speed
is

increased
from

idling
to
3
000
to

3

500

rpm

Place
a

finger
on
the

diaphragm
of

E
G
R

control
valve
to
check
for
valve

operation

EC773

Fig
EC
73

Checking
E
G
R
Control

2

When

engine
coolant

tempera

tureishigh
Emission
Control

System

Make

sure
that
E
G

R
control
valve

operates
when

engine
speed
is
in

creased
from

idling
to
3
000
to
3
500

rpm
Place

fingers
on
the

diaphragm
of

E

G
R
control
valve
to
check
for
valve

operation

If
E
G

R
control
valve
does

not

operate
check
as
follows

Disconnect
one
end
E

G
R

control

valve
side

of
vacuum
hose
connect

ing
ihermal

vacuum
valve
to

E
G
R

control
valve

Increase

engine
speed
from

idling
to

3
000
to
3

500

rpm

Make
sure
that

thermal
vacuum

valve
is

open
2

port
type
or

closed
3

port
type
and

that
car

buretor
vacuum
is

present
at
the

end
E
G
R

control
valve
side
of

vacuum
hose

If

vacuum
is

weak
or

not

present
at

all

replace
thermal

vacuum
valve
If

vacuum
is

present
check
E
G
R

control
valve
or
B
P

T
valve

If

any
difficulty
is
encountered
in

judging
the
condition
of

any
com

ponent
during
above

inspection
check

the

questionable

component
in

dependently
as
follows

U

S
A

models

Ie

EC160A

Canada
models

ET429

Fig
EC
74

Checking
Vacuum

of

E
G
R
Control
Valve

EC
25
E
G
R
control
valve

Dismount
E
G

R
control
valve

from

engine

I

Apply
vacuum
to
E
G
R
control

valve

referring
to
the

following
figure

If
the
valve
moves
to
full

position
it
is

normal

E

G
R

control
valve
will
remain

open
for
more
than

30
seconds
after

vacuum
has
cut
off

5t
orr

rl

1

1

Fig
EC
75
EC129A

Checking
E
G
R
Control

Valve

2

Visually
check
E
G
R
control

wive
for

damage
wrinkle

or
deforma

tion

3

Clean
the

seating
surface
of

E
G
R
control
valve
with
a

brush
and

compressed
air
and

remove

foreign

matter
from
around
the
valve
and

port

Fig
EC

76

Cleoning
E
G
R
Control

Valve

Thermal
vacuum
valve

3

port
type

Remove
thermal
vacuum
valve
from

engine
Inhale
air

from

port
ofE
G
R

system
and
check
to
be
sure
that

thermal
vacuum
valve

opens
or
closes

in

response
to
its

temperature

Thermal

vacuum
valve

dosing

temperature

Above
50

to
630
C

122
to
1450
F

CAUTION

Do
not
allow
water
to

get
inside
the

thermal
vacuum
valve

EC161A

Fig
EC
77
Ch

c

jng
Th
rmal
Vacuum

Valve

3

port
type

Thermal

vacuum

valve

2

port
type

Dismount
thermal

vacuum
valve

from

engine

Note

Before

dismounting
drain
en

gine
c
oolant
from

engine

Apply
vacuum
to
thermal

vacuum

valve
and

check
to
be
sure

that
ther

SPARK
TIMING

CONTflOL

SYSTE
VI

DESCRIPTION

The

spark

timing
control

system
is

designed
to
control

the
distributor

vacuum
advance

under

varying

driving

conditions
so

as
to
reduce
He
and

NOx
emissions
Emission
Control

System

mal

vacuum
valve

opens
or
closes
in

response
to

engine
coolant

tempera

ture

as

specified

Thermal

vacuum
valve

should

open

at

a

temperature
specified
below

com

pleting
the
vacuum

passage

Thermal

vacuum
valve

opening

temperature

40
to

63
c
104
to
1450

Fl

CAUTION

00

not
allow
water
to

get
inside
the

thermal1
acuum
valve

Jl
i

g

J

eC
42

Fig
EC
78
Ch

ckjng
Thermal
Vacuum

Valve

M
T
model

When

the
transmission

is
shifted

into
the

4th
or
5th

gear
the
electric

current
flows
into

the
vacuum

switch

ing
valve
The
vacuum

switching
valve

is

then
actuated
and

close
the
vacuum

passage
As

a

res
li
the

distributor

fully
advances

its

ignition

liming

When
the
transmission
is

shifted

into

any
gear
other

than
4th
and
5th

current
flow
is

interrupted
The

vacu

umswitclting
valve
is

then
deactuated

and
the

vacuum
leak

passage
is

E026
BoP

T
valve

1

DiSCOIUlect
two
vacuum
hoses

on

BY
T
valve

2

Plug
one
of
two

port
of
BY
T

valve

Apply
a

pressure
above
SO

nimH20

1
97

inHP
to
B
P
T
valve
and

orally
suck
back
other

port
of
B
P
T

valve

as
shown
below

to
check
for

leakage
If

a
leak
is
noted

replace

valve

Apply
pressure
above

SO
mmH10
2
inH10

EC311A

Fig
EC
79

Checking
B
P
T
Valve

opened
This
weakens
the
vacuum

signaUransmitted
from
the
carburetor

As
a
result
the

ignition
timing
of
the

distributor
is

slightly
advanced

On
U
s
A
models

except
for

the

FU
model
a
thermal

vacuum
valve

3

port
type
is
added
on
the

vacuum

line
between
the
carburetor
and
dis

tributor

The
vacuum

signal
is
controlled

by

this
thermal

vacuum
valve

in
accord

ance
with
variation

in

engine
cooling

water

temperature

INSPECTION

Entire

system

U
S
A
MIT

models

except
FU
mo

el

1
Ensure
that

wiring
connectors
are

tight
in

pla
ce

2
Ensure
that

vacuum
hoses

are

properly

cof
1o
c
ed
to

their

positions

3
Ensure
that
distributor
vacuum

controller

properly
functions

4

Set

timing
light
and
start

engine

S

While

engine
cooling
water
tem

pefature
is
below

SOOC

I220F

check
function
of

system
as
follows

WARNING

To

protect
against
accidental
for

ward

surge
engage

parking
brake

firmly
while
above
check
is

being

made

I
Run

engine
and

keep
it

at

ap

proximately
1
600

rpm

2

Disengage
clutch
Shift

gears
in

top
3rd
then
neutral

positions
Read

spark

timing
in

respective
shift

posi

tions

The

system
is

properly

functioning

if

spark
timir
g
does
not

change

If
t

changes
check
thefmal
vacuum

valve

3

port
type

Note

Ensure
that
thermal
vacuum

wIve

is
closed
when

cooling
water

i
below

5
to
lSoC
41
to

640F
or

above
SO

to
630C
122
to
14S0F

I

6

After
the

engine
has
been

warmed

up
sufficiently
check
the

function
of
the

system

again
in
the

I

Same
manner

The

system
is

properly
functioning

if

spark
iimin
advances
in

top
posi

tion

If

not
check
thefmal
vacuum
valve

control

circuit
or
vaeu
um

switching

valve

Entire

system

FU
model
and

Canada
MIl
models

I
Ensure
that

wiri
lg
connectors
are

tight
in

place
Emission

Control

System

2

Ensure
that

vacuum

hoses
are

properly
connected
to
their

positions

3

Ensure
that

distributor
vacuum

controller

properly
fu
ctions

4

Set

timing
light

WARNING

To

protect

against
accidental
for

ward

surge
engage
parking
brake

firmly
while
above
check

is

being

made

5
Run

engine
and

keep
it
at

ap

proximately
1
600

1
m

6

Disengage
clutch
Shift

gears
in

4th

5th
ihen
neutral

positions
Read

spark
timing
in

respective
shift

posi

tions

The

system
is

properly
functioning

if

spark
timing
advances
in

top
gear

position

If

spark

timing
does
not

vary
at
all

in

tests
des
rilied

in

step
6
above

check

control
circuit
or

vacuum

switching
valve

Entire

system

California
AIT
models

I
Ensure
th
t

wiring
connectors

are

tight
in

place

2

Ensure
that
vacuum
hoses
are

properly
coIDwcted
to

thejr
positions

3

Ensure
that

distributor
vacuum

controller

function
s

properly

4
Set

timing
light
and
staft

engine

S

While

engine
cooling
water
tem

perature
is
below
SOOC
1220F

check
the
function
of
the

system
as

follows

WARNING

To

protect
againSt
accidental
for

ward

surge
engage

parking
brake

firmly
while
above
check
is

being

made

I
Run

engine
and

keep
it
at

ap

proximately
1

600

rpm
at
P

range

2

Make
a

short
circuit

between
the

specified
two
terminals
at
function

te
t

connector

EC31
The

entire

system

except
for
the

top
switch
is

properly

functioning
if

spark
timing
does
not

change
If

it

changes
check
the

thermal
vacuum

valve

3

pori

type

CAUTION

Pay
attention
not
to
make
a
short

circuit
between
other
terminals
than

the

specified
terminals
or
electrical

system
of
car
will

get

damaged

4

EC328A

Fig
EC
94

Making
Short
Circuit

6

After
ihe

engine
has
been

warmed

up
sufficiently
check
the

function
of
the

system
again
in
the

same
manner

The

system
except
for
the

top

switch
is

properly

fU
lctioning
if

spark

timing
is

approximately
greater
than

that
without

a
short
circuit

If

not
check
the

thermal
vacuum

valve

control
circuit
or

vacuum
switch

ing
valve

7
As
the
final

step
of

checking

entire

system
top
switch
should
be

checked

as
follows

1
Start

engine
and

keep
at

idling

speed

2

Disconnect
lead
wires
from
vacu

um

switching
valve

at
connetors

CAUTION

Never

forget
this

operation
otherwise

the
circuit

tester
will

get
damaged

EC173A

Fig
EC

95

Disconnecting
Vacuum

Switching
Valve
Connector

3

Apply
parking
brake
and

keep

brake

pedal
fully

depressed

4

Check

continuity
between
two

specified
terminals
ai

function
test

connector
with

gearshift
lever
in
R

or
N

position

The

top
detecting
switch
is

func

tioning
properly
if
the

continuity
is

as

following
table

If
not

replace
the
switch

N

position
No

R

position
Yes

Note
At

idling

CAUTION

Never

race
the

engine
or
car
will

creep

r

q

EC329A

Fig
EC
96

Checking
Top

Detecting

Switch

Arr
model
Emission
Control

System

Entire

system

Non
California
AfT
models

except
Canada

1

Ensure
that
vacuum

hoses
are

properly
connected
to

their

positions

And

confirm
that

gearshift
lever
is
in

P

position

2
Disconnect

vacuum
hose
atdis

tributor

vacuum
controller

3

While

engine
cooling
wat
r

is
be

low
SOoC

1220F
race

engine
and

check
vacuum
for
distributor
If
vacu

um
is
felt
check

thermal
vacuum
valve

3

port
type

4

After

engine
is

sufficiently

warmed

up
repeat
the
above

opera

tion

In

this
case
vacuum
should
be
felt

If
not
check
thermal

vacuum
valve

Vacuu
m

switching
valve

If

spark
timing
does
not

vary
at
all

in

checking
entire

system
check
vacu

um

switching
valve
i
follows

I
Warm

up
engine

sufficiently

2

Disconnect

vacuum

switching

valve

lead
wires

3

Set

timing
light
and

keep
engine

speed
at

approximately
1

600

rpm
On

AfT
models

geaishiftlever
should

be

in

N
or
P

4

Apply
l2V

battery
voltage
to

one
of
two

lead
wires

from
vacuum

switching
valve
Then
connect
the

other
lead
wire

to

ground

At

this
time

spark
timing
should

change

appioximately
by
50

If
it
does
not

replace
vacuum

switching
valve

EC175A

Fig
EC

97

Checking
Vacuum

Switching
Valv

Thermal
vacuum
valve

3
port

type
U
s
A
models

except
FU

model

Remove

thermal
vacuum

valve
from

engine
Inhale
air
from

port
of

spark

EC32
timing
amttol

systetn
andcheck
to

sure
that

thermal
vacuum
valve

opens

or
closes
in

response
to
its

tempera

ture

Thermal

vacuum
walye

closing

temperature

Above
50
to

63
c

122
to
1450
F

Below
5
to

1SoC

41
to

64
Fl

J

EC161A

Fig
EC
98

Checking
Thermal

Vacuum

Valv

CAUTION

Do

not
allow

water
to

get
inside

the

thenna

vacuum
valve

Top
detecting
switch

M
T
models

To

check

top
detecting
switch
for

proper
ON
OFF

operation
contact

leads
of

an
ohmmeter

with
swiich

lead

wires
and
shift
transmiosion

from

TOP
to
other
forward

gear
and

vice

versa
If

switch
does
not

operate
prop

erly
replace

Continuity
of

top
detecting
switch

should
be

a
follows

Other
than

4th
and
5th
No

4th

and
5th

Yes

Note
In

checking

continuity
oCthe

switch

keep
the

ignition
switch

OFF
Otherwise
the

circuit
tester

will

get

damaged

Engine
Electrical

System

Battery
Ignition
switch

CG

1

e
@

P
L
JO

L
J

Ignition
coil

r

Spark
timing

signal

I

oni
1oring

Clfcwt

0
R

Lock

Pi
k
il
preventing

c

up
co

circuit

Ln
n

Distributor
2P

fJ
1I
connector

8C

H
uty
control

ClICUlt
Power

switching

circuit

Current

limiting

circuit

Ie

ignition
unit

EE749

Fig
EE
66
Ie

Ignition
Unit
Circuit

Diagram

REMOVAL
AND

INSTALLATION
5
Disconnect

pick
up
coil
wire
from

IC

ignition
unit

Note
Holding
connector
with
needle

nose

pliers
as
shown
in

Fig
EE
68

disconnect

pick
up
coil
terminal
Be

careful
not
to

pull
lead
wire
I
Disconnect

battery
ground
cable

2

Take
off
distributor

cap
and
re

move
rotor
head

3

Disconnect
harness
connector

4

Remove
Ie

ignition
unit

securing

screws

rf

I
I

EE751

Fig
EE
68
Di
Connecting
Pick

up
Coil

Term
inal

eE750

Fig
EE
67

Removing
Ie

Ignition

Unit
6

InstaU
IC

ignition
unit
in

the

reverse
order

of
removal

EE
25
CAUTION

Before

instelling
IC

ignition
unit
mike

sure

mlting
surfaces
of

IC

ignition
unit

end
distributor
Ire
cleen
and
free
from

dust

sand
and
moisture

Note

a
When

connecting
lead
wires

to
unit

insert
lead
wire
terminal
with
fin

ger
as
shown
in

Fig
EE
69

b

Connect
lead
wires

according
to

color
marked
on

upper
face
of

grommet

EE752

Fig
EE
69

Connecting
Pick

up
Coil

Terminal

CHECKING
IC

IGNITION
SYSTEM

DESCRIPTION

To
check
the
IC

ignition

system

use
a
circuit

tester
The

ignition
per

fannance
of
the

ignition
system
at
a

high
speed
cannot
be
measured

direct

ly
However

it
can
be

checked

by

operating
a
vehicle

actually
at
a

high

speed
The
IC

ignition
system
can
be

checked

easily
by
referring
to
the

Inspection
Table
For
the

method
of

inspection
refer
to

respective
items

12

Disconnect

speedometer
cable

from
rear
extension

housing

13

Remove
transmission
control

linkage

I

For
cars

equipped
with
manual

transmission

remove

gear
shift
control

lever

Fig
ER
6

Removing
Gear
Shift

Control
Lever

2

For
cars

equipped
with
auto

matic
transmission
disconnect
selector

range
lever

e

a

EA163

Fig
ER

7
Di8connecting
Selector

Range
Lever

14

Disconnect
exhaust
front
tube

from

exhaust
manifold
and
exhaust

mounting
bracket
rom
transmission

I

liJ
Tightening
torque
I

ER370

Front
tube

to
exheust

manifold

1
9
to
2

5kg
m

14

to
18

ft
Ibl

Fig
ER
S

Disconnecting
E
chaust

Front
Tube
Engine
Remov
1
Installation

15

Hang
front
tube
end

with
a

suitable
thread
or
a
wire
to

prevent

tube
from

falling

J
6
Remove

propeller
shaft

Refer
to

Propeller
Shaft
Section

PO

for
removal

Plug
the

opening

end

of
rear
extension

housing
to

pre

vent
oil

leakage

P0315

liJ
Tightening
torque

Propeller
shaft
to

companion

flange

2
4
to
3
3

kg
m

17
to
24
ft
bl

Fig
ER
9

Removing

Propeller
Shaft

Note

Pul
me
tch
mark
on
both
shaft

and

companion
flange
so
that
shoft

can
be
reinstalled
in

original
posi

tion

17

Support
transmission
with

jack

18

Remove
bolts

securing
rear

engine
mounting
member
to
the

body

19
Attach

Engine
slinger

10006H7202
as
shown
in

Fig
ER
IO
Note

Use

slinger
only
wheo

engine
is

removed
from

or
installed
on
car

Be

sure
to
remove
it
efter
Ulle

This

slinger
is
listed
in

Parts
Cet

log

as
a
service

optiop

20

Connect

suitable
wire

or
chain

to

Engine

Slingers
and
raise

engine
a

little
to
take

weight
off
front
mount

ing
insulators

WARNING

For

sofety
in

subsequent

steps
ten

sion

of
wire
or
chain
should

be

slackened

against
engine

21
Remove

bolts

securing
front

engine

mounting
brackets
to
froni

engine
mounting
insulators

22
Reise

engine
and

transmission

and
remove
from

car
as

a

single
unit

See

Fig
ER
IO

CAUTION

a
Before

raising
engine
10gether
with

transmission
make
sure
that

all

hoses
and
wires
connected

thereto

are
disconnected
or
removed

b
When

raising
engine
be

especially

careful
not
to
knock
it

against

adjacent
parts

ER
4
EA225

Fig
ER
IO

Removing
Engine

t

Prior
to

lWembly

dip
a
new

piston
cup
in
clean

brake
fluid
To

install

piston
cup
on

piston
pay
par

ticular
auention
to
its

direction

2

Dip
cylinder
and

piston
in

clean

brake

fluid
before

assembly

INSTALLATION

Install

operating
cylinder
in
the

reverse
order
of

removal
Observe

the

following

1

Bleed
air

thoroughly
from
clutch

hydraulic
system
Refer
to

Bleeding

Clutch

System
for

bleeding

2

Adjust
clutch

pedal
free
travel

Refer
to

Clutch
Pedal
Free

Travel
for

adjustment

Note

a

Use
new

gasket

b
When

operating
cylinder
is
removed

from
or

instaUed
on
clutch
haus

ing
without

disconnecting
clutch

hose
from

operating
cylinder
loos

en
bleeder

screw
so
that

push
rod

mo

lightly

c
E
xer

e

care
not
to

p
or
wist

clutch
hose
Be

sure
to
install

clutch
hose

away
from

exhaust

tube

d
When

tightening
flare

nut
hold

pipe
by
hand
to

prevent
it
from

twisting

CAUTION

When

connecting
dutch
tuhe

uSe

Flare

Nut

Torque
Wrench

G694310000

@
Tightening
torque

Bleeder

screw

0
7
to
0
9

kg
m

5
1
to
6
5
ft
Ihl
Clutch

o

cylinder
to
clutch

housing
securing
bolts

3
1
to
4
1

kg
m

22
to
30
ft
lbl

Clutch
hose
to

operating

cyli
nder

1
7
to
2
0

kg
m

12
to
14
ft

lbl

Flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
Ibl

CLUTCH
LINE

INSPECTION

Check
clutch
lines
tube

and
hose

for
evidence
of
cracks
deterioration
or

other

damage

Replace
if

necessary

If

leakage
occurs
at
or

around

joints
retighten
and
if

necessary
re

place
damaged

parts

REMOVAL

CAUTION

When

disconnecting
clutch
tube

use

suitable
flare

nut
wrench

Never

use
an

open
end
wrench
or

adjustable
wrench

1

Qisconnect
clutch
tube
from

clutch

hose
at
bracket
on
side
mem

ber

2
emove
lock

spring
then
disen

gage
hose
from
bracket

3

Remove
clutch
hose
from

oper

ating
cylinder

4

Disconnect
clutch
tube
from
mas

ter

cylinder

5

Remove

clamp
fIxing
clutch
tube

to
dash

panel
and
side

member

CL
6
INSTALLAnOlll

Wipe
the

opening
ends
of

hydraulic

line

to
remove

any
foreign
matter

before

malting
connections

I
Connect
clutch
tuhe
to

master

cylinder
with
flare
nut

2
Fix
clutch
tube
to
dash

panel

and
side

member
with

clamp

3
Then

tighten
flare

nut

@

Tightening
torque

Flar
nut

1
5
to
1
8

kg
m

11
to

13
ft

Ibl

2
InstaU
clutch
hose
on

operating

cylinder
with
a

gasket
in

place

Note

Use
new

gaslcet

@
Tightening
torque

1
7
to
2
0

kg
m

12
to
14ft
lbl

3

Engage
opposite
end
of

hose
with

bracket
InstaU
lock

spring
fIxing
hose

to
bracket

Note

a
When

tightening
flare

nut
hold

pipe
by
hand
to

prevent
it
from

twisting

b
Exercise
care
not
to

warp
or
twist

clu1ch
hose

4

Connect
clutch
tube
to

hose
with

flare
nut
and

tighten
it

5
Check
distance

between
clutch

line
and

adjacent
parts

especially
be

tween
hose
and
exhaust
tube

6

Bleed
air
out
of

hydraulic
system

Refer
to

Bleeding
Clutch

System

for

bleeding

CAUTION

When

tightening
flare

nut
use

Flare

Nut
Wrench

G
G9431
0000