ECU DATSUN PICK-UP 1977 User Guide

The

pump
shaft
is

supported
by
a

double
row

of
ball

bearings

press
fit
in

an
aluminum
die
cast

pump
body
The

bearings
are

permanently
lubricated

and
sealed

to

prevent
loss
of
lubricant

and

entry
of

dirt

The

pump
is

provided
with
an

impeller
which
turns
on
a
steel

shaft

The

steel
shaft
rotates

together
with

the

torque

coupling
wheeL
The
volute

chamber
is
built
in
the

engine
front

cover

assembly

The
inlet
of
the

pump
is

connected

to

the
radiator
s
lower
tank

by
a
hose

i

o

CQ047

Fig
CO
2
Water

pump
and

engine

front
cover

REMOVAL
AND

INSTALLATION

Removal

in
to
a
clean

con

assembly

I

CQ048

Fig
CO
3
Removing
water

pump

Installation

1
Be

sure
to
clean
the

gasket
sur

faces
in
contact
with

pump
and
front

cover

Always
use
new

gaskets
when

installing

pump
assembly
Be
sure
to

tighten
bolts
Cooling
System

Tightening

torque

0
4
to
0
5

kg
m

3
0
to
3
6
ft
lb

2

Fill

cooling
system
and
check
for

leaks
at

pump

3

Install
fan
blade
and

tighten
at

taching
bolts

securely
Install
belt
and

adjust
for

specified
tension

4

Operate
the

engine
at
fast

idling

and
recheck
for
leaks

5
Install
fan
shrouds

Note
Ensure
that
clearance
between

shroud
and
Can
is

even
at

any

place

DISASSEMBLY

Water

pump
is

made
of
aluminum

and
its

bearing
outer
race
is
of
a

press

fit

type
For
this

reason
water

pump

should
not
be
disassembled

INSPECTION
AND

ADJUSTMENT

Inspection

Inspect
pump
assembly
for
the

fol

lowing
conditions
and

replace
if
nee

essary

1

Badly
rusted
or
corroded

body
as

sembly
and

vane

2

Excessive
end

play
or

roughness
of

bearings
in

operation

3
Reduced

cooling
efficiency
due
to

deteriorated
silicone
oil

4
Oil

leakage
in

torque
coupling
Adjustment

Fan

belt
should
be

properly
ad

justed
at
all
times
A

tight
belt
causes

wear
of

alternator
and
water

pump

bearings
A
loose
belt

brings
about

improper
cooling
fan
water

pump

and
alternator

operation

Check
the
belt
slack
between
alter

nator
and
fan

pulley
by
force
of
10

kg

22
lb

Slackness
of
fan
belt

8
to
12

mm

0
31
to
0
47
in

If

adjustment
is

necessary
loosen

bolt

retaining
alternator

adjusting
bar

to
alternator
Move

alternator
toward

or

away
from

engine
until
the
correct

tension
is
obtained

TORQUE
COUPLING

Except
air

conditioner

equipped

models

The

torque
coupling
keeps
the
fan

speed
at
2
500

rpm
rated
or
below

to

conserve
horsepower
at

high
engine

speed
It
also

helps
reduce
fan
noise
to

a
minimum

during
high
speed
opera

tion

This
unit
is
filled
with
a

special

silicone
oil
used
as
a

fluid

coupling

which
controls
the

fan

speed
Silicone

oil

can
not
be

replenished

1

Torque
coupling
wheel

2

Torque
coupling
cover

3

Torque
coupling
bearing

4
Pulley

5
Water

pump

C0060

Fig
CO
4
Sectional
view
of

torque
coupling
and
water

pump

00
3

TEMPERATURE
SENSOR

The

temperature
sensor
is

attached

to
the

inside
of
the
air

cleaner
The

bimetal
built
in

the
sensor
detects
the

under

hood
air

temperature
and

opens

or

closes
the
vacuum

passage
in
the

sensor

The
construction
of
the

tempera

ture
sensor
is
shown
in

the

following

CD
V
00
@

I

I

@
j
I

I

1
Protector
cover

Screw

Adjusting
frame

Air

temperature
bi

metal

Rivet

Valve
seat
frame

Lower
frame

Air
bleed
valve

Gasket

Fig
EF

6

Temperature
senior
EF206

VACUUM
MOTOR
AND

AIR
CONTROL
VALVE

The
vacuum

pressure
which
varies

with

opening
of
the
carburetor
throt

tle
acts

upon
the
vacuum
motor

dia

phragm
The
valve

shaft
attached
to

the

diaphragm
is
then
moved

up
or

down
in

response
to
the
vacuum
on

the

diaphragm
This
movement
of

the

valve
shaft

actuates
the
air
control

valve
to

control
the

temperature
of
the

air
to

be
introduced
into

the
air

cleaner

pr
to

I

1
Valve

spring

00
2

Diaphragm

@
3
Retainer

E
F

207
4
Valve
shaft

Fig
EF
7
Vacuum
motor

REMOVAL
AND

INSTALLATION

TEMPERATURE
SENSOR

Removal

Using

pliers
flatten

clip
con
Engine
Fuel

neeting
vacuum
hose
to
sensor
vacuum

tube

I

Pipe

2
Calch

3
Fixed
with

adhesive

4
Hose

5

Tab

6

Clip

7
Gasket

EC019

Fig
EF
B
Removal

of
semor

2

Disconnect
hose
from

sensor

3

Take
off

clip
from
sensor
vacuum

tube
and
dismount
sensor

body
from

air
cleaner

Note
The

gasket
between

sensor
and

air
cleaner
is
bonded
to
the
air

cleaner
side
and
should
not
be

removed

Inatallatlon

Mount
sensor
on
the

specified

position

For

mounting
position
of
sensor

see
the

following

EF717

Fig
EF
9

lalling
se
or
2
Insert

clip
into
vacuum
tube

of

sensor
After

installing
each
vacuum

hose
secure
hose
with
the

clip

Note
Be
sure
to
install
vacuum
hose

correctly
Correct

position
is
R

H

side
to
Nissan
mark
at
the

top

face
of

sensor
for
intake
manifold

L
H
side
for
vacuum
motor

VACUUM
MOTOR

1

Remove
screws

securing
vacuum

motor
to
air
cleaner

2
Disconnect
valve
shaft
attached

to

vacuum
motor

diapluagm
from
air

control
valve

and
remove
cacuum

motor

assembly
from
air

cleaner

3
To
install
reverse
the
removal

procedure

FRESH
AIR
DUCT

I
Disconnect
fresh
air
duct
at
air

cleaner

2

Fresh
air

duct
is

provided
with

projections
on
its
air
inlet
side
end

Hold
fresh
air
duct
with
a
hand
and

carefully

pull
out
from
radiator
core

support
while

turning
it
in
either

direction

3
To

install
reverse
the
removal

procedure
Be
sure
to

insert

projec

lions
of
fresh
air
duct

securely
into

mounting
hole
in

radiator
core

sup

port

EF518

EF
5
Fresh
air
duct

Air
cleaner

Duct

mounting
hole

Radiator

Radiator
core

support

Fig
EF

I0
Removal

of
fresh
air
duct

r

AIR
CLEANER

1
Loosen

bolts

securing
air
cleaner

to
air
cleaner
bracket

2
Loosen
air

cleaner
lock
bolt
and

remove
air

cleaner
from
carburetor

Disconnect
the

following
hoses
when

dismounting
air

cleaner

Under
hood
air
inlet

hose

Hot
air
inlet

hose

Vacuum

hose
Sensor
to
intake

manifold

Vacuum
hose
Sensor
to
vacuum

motor

Vacuum
hose

Idle

compensator
to

intake
manifold

Hose
Air

pump
to
air
cleaner

Hose
AB
valve

to
air
cleaner

Hose
Carburetor
to
air

cleaner

Blow

by
hose
Air

cleaner
to

rocker

cover

Hose
Air

control
vaive
to
air

cleaner
California

models

only

3
To

install

reverse
the
removal

procedure

INSPECTION

1
AIR
CLEANER

ELEMENT

Viscous

paper
type
air
cleaner

ele

ment
does
not

require
any
cleaning

operation
until
it

is

replaced
periodi

cally
Brushing
or

blasting

operation

will
cause

clogging
and

result
in
enrich

ment

of
carburetor
mixture

and

should
never
be

conducted
For

reo

placement
interval
of
air

cleaner
ele

ment
refer
to
Maintenance
Sched

ule

2
HOT

AIR

CONTROL
SYSTEM

In

warm
weather
it
is

difficult
to

find

out
malfunction
of
hot
air
control

system
In

cold
wea
thee

however

malfunction
of
air
control
valve

due
to

disconnection
or

deterioration
of

vacu

um

hose
between
intake
manifold
and

vacuum
motor
and

insufficient
dura

bility
of
air
control
valve

will
cause

insufficient
automatic
control

opera

tion

for
intake
air
and

result
in

engine

disorder

including

I

Stall

or
hesitation
of

engine

oper

ation

2

Increase
in

fuel

consumption

3

uck
of

power
Engine
Fuel

These

phenomena
reveal
malfunc

tion
of
hot
air
control

system
If
these

phenomena
should
occur
check
hot

air
control

system
as

described
in
the

following
before

carrying
out

inspec

tion

of
carburetor

2
1
Vacuum

hose

Intake
manifold
to
3

way
connec

tor
3

way
connector
to

temperature

sensor
3

way
connector
to

idle
com

pensator
temperature
sensor
to
vacu

um

motor

I

Check
that

vacuum
hoses
are

se

curely
connected
in

correct

postion

2

Check
each
hose
for

cracks
or

distortion

hose

clip
for

condition

Note

Vacuum
hose

position
R
H

side
of
Nissan

mark
on
the

top
of

sensor
is
for

intake
manifold
L
U

side
of

the
mark

is
for

vacuum

motor

2
2
Vacuum

motor

I

With

engine
stopped
disconnect

fresh
air

duct

Place
a
mirror

at
the
end
of
air

cleaner
inlet

pipe
as
shown
and

check

to

see
if
air

con
trol
valve

is
in

correct

position

EF213

Fig
EF
11

Inspecting
valve

position

Air

control
valve
is
in

correct

posi

tion
if
its
under
hood
air

inlet
is

open

and
hot
air
inlet
is

closed
Check
air

control
valve

linkage
for

condition

2

Disconnect

vacuum
motor
inlet

vacuum
hose
and
connect

another

hose
to
the
inlet
to

apply
vacuum
to

vacuum
motor
Vacuum
can
be

ap

plied
by
breathing
in
the

hose
end

as

shown

Place
a
mirror

at
the

end
of
air

cleaner
inlet

pipe
and

check
to

see
if

air

control
valve

is
in
correct

position

EF
6
EF217

Fig
EF
12

Inspecting
valve

position

Correct

position
of
air

control
valve

is

the
reverse
of

paragraph
J
above
Air

control
valve
is
in
correct

position
if

under
hood
air
inlet
is

closed
and
hot

air

inlet
is

open

3
With

hot
air

inlet
in

open
posi

tion

as
described
in

paragraph
2

above

pinch
vacuum
hose
with

fingers

and
cut
off
air

from
vacuum
hose
In

this
condition
check
that
air

control

valve

maintains
the

condition
de

scribed
in

step
2

for
more
than
30

seconds
and
that
hot
air

inlet
is

open

If

diaphragm
spring
actuates
the
air

control
valve

by
its

spring
force
to

open
under
hood
air
inlet

within
30

seconds

replace
vacuum
motor
as
an

assembly
since
this

may
be

resulted

from

air
leak
at
vacuum
motor
dia

phragm

2
3
Temperature
ensor

Check

temperature
sensor
for
func

tion

by

proceeding
as
follows
Be

sure

to

keep
engine
cold
before

starting

test

I

With

engine
off

check
air

control

valve
for
condition
In

this
case
under

hood
air

inlet
is

open
Use
a
mirror

for

inspection
as
2
2
1

above

2

Start

engine
and

keep
idling

Immediately
after

engine
starting

check
air
control
valve
for

correct

position
as
described
above
In

this

case
correct

position
of

air
control

valve

is
the
reverse
of
2
2
I

under

hood
air

inlet
is

closed
and
hot

air

inlet
is

open

3
Check
that
air
control
valve

grad

ually
opens
to
under
hood
air

inlet

side
as

engine
warms

up
When
en

vironmental

temperature
around
tern

perature
sensor
is

low

spend
more

time

for

engine
warming
up
operation

Engine
Fuel

REMOVAL
AND
INSTALLATION

Remove
air
cleaner

cover

2
Remove
hose

connecting
idle

compensator
and
3

way
connector

3
Loosen
screws

securing
idle
com

pensator
to
air

cleaner
then
remove

idle

compensator

Notes

a
When

removing
idle

compensator

remove

gasket
and

plate

b
When

removing
screw

securing
idle

compensator
to
air

cleaner
be
care

ful
not
to

miss
the
saew

4
To
install
reverse
the
removal

procedure

INSPECTION

I
Check

tha
t
valve
IS
m
closed

position
when
bi

metal

temperature
is

lower

than

operating

temperature
To

check
breathe
air
into

tube
or
suck

DESCRIPTION

The
fuel
fJlter
is

a

cartridge

type
It

uses
a

paper
element
which
can
be

checked
for
condition
from
the
out

side
EF718

Fig
EF
15
Location

of
idle

compenl
otor

air
If
excessive
air

leakage
is
found

at

the
valve

replace
idle

compensator
as

an

assembly
Note
that
two
idle
com

pensators
are
mounted
to
air
cleaner

and
that
it
is

necessary
to

plug
the

valve
of
one
of
these
idle

compensa

tors
so
as
to

prevent
air
leak
while

checking
the
other
one

@

CD

I

tl

1
Orifice

2
Rubber
valve

EF225

Fig
EF

16
Checking
idle

compelll
lor

FUEL
FILTER

1

Body

2

Paper
element

3
Cover
1

EFOO5

Fig
EF

18
Sectional
view

of
cartridge

type
fuel
filter

EF

8
Note

When

checking
idle

compensa

tor
on
vehicle
disconnect
hose

leading
to
idle

compensator
and

connect
other
hose
then

carry
out

check
as
descn
bed
above

2

When
bi
metal

temperature
is

above
the

specified
operating

tempera

ture

visually
check
to
see
if
the
valve

is
in

open
position
If

valve
is
not

open
replace
idle

compensator
as
an

assembly

Watcr

temperature
Observe

valve

11t
No

1
Bknctal

60
to
70De

140
to
1580F

NO
2
Bi
metal

70
to

900C

158to
1940F

EF226

Fig
EF
17

Checking
idle

compensator

3
Others

I
Check

hoses
for

correct
installa

tion

distortion
or
cracks

2

Check
rubber
valve
seat
of
idle

compensator
for

sticking
or

any
other

faulty
conditions

REMOVAL

Disconnect
inlet
and
outlet
fuel

lines
from
fuel

fJlter
and
remove
fuel

fJlter

Note

Before

disconnecting
fuel
lines

use
a
container
to

receive
the
fuel

remaining
in
lines

DESCRIPTION

FUEL

PUMP
TESTING

STATIC
PRESSURE
TEST

CAPACITY
TEST

DESCRIPTION

The
fuel

pump
transfers
fuel
from

the
tank
to
the
carburetor
in
sufficient

quantity
to
meet
the

engine
require

ments
at

any
speed
or

load

The
fuel

pump
is
a

pulsating
type

designed
for

easy
maintenance
It

con

sists
of
a

body
a

rocker
arm

assembly

a

fuel

diaphragm
a
fuel

diaphragm

spring
seal
inlet
and
outlet

valves

Figure
EF
19

shows
a
cross
sectional

view
of
the

pump

The
fuel

diaphragm
consists

of

specially
treated
rubber
which
is

not

affected

by

gasoline
and
held
in

place

by
two

metal
discs
and

a

pull
rod

FUEL

PUMP

TESTING

A
fuel

pump
is

operating

properly

when
its

pressure
is

within

specifica

tions

and
its

capacity
is

equal
to
the

engine
s

requirements
at
all

speeds

Pressure
and

capacity
must
be
deter

mined

by
two
tests
while
the

pump
is

still

mounted
on
the

engine
Be
sure

there
is
fuel
in

the
tank
when

carrying

out
the
tests
Engine
Fuel

MECHANICAL
FUEL
PUMP

CONTENTS

EF
9

EF
9

EF
9

EF
10
REMOVAL
AND
DISASSEMBLY

INSPECTION

ASSEMBL
Y
EF

10

EF
10

EF

11

1

1

Outlet
valve

2

Diaphragm

3

Diaphragm
spring

4
Inlet
valve

S
Rocker
ann
EF006

Fig
EF
19
Schematic
view

of
fuel
pump

STATIC
PRESSURE
TEST

The
static

pressure
test
should
be

made
as
follows

I
Disconnect
fuel
line
between
car

buretor
and
fuel

pump

2
Connect
a
rubber
hose
to
each

open
end
of
a
T
connector
and
con

nect
this
connector
hose

assembly
be

tween
carburetor
and
fuel

pump
Note
Locate
this
T
connector
as

close
to

carburetor
as

possible

3
Connect
a

suitable

pressure
gauge

to

the

opening
of
T
connector
and

fasten
hose
between
carburetor
and

T
connector
with

a

clip
securely

EF
9

4

Run
the

engine
at

varying
speeds

5

The

pressure
gauge
indicates

static
fuel

pressure
in
the
line

The

gauge
reading
should
be

within
the

following
range

0
21
to
0

27

kg
em2

3
0

to
3

8

psi

Note
If

the
fuel
in
carburetor
float

chamber
has
run
out

and

engine
has

stopped
clip
and

pour
fuel

into

carburetor
Fasten

clip
secure

ly
and

repe
1
static

pressure
test

Pressure
below
the
lower
limit
indi

cates
extreme
wear
on
one

part
or

a

small
amount
of
wear
on
each

working

part
It

also
indicates

ruptured
dia

phragm
worn

warped
dirty
or

gum

ming
valves
and
seats
or
a
weak

diaphragm
return

spring
Pressure

above
the

upper
limit
indicates
an

excessively
strong
tension
of
dia

phragm
return

spring
or
a

diaphragm

that
is
too

tight
Both
of
these
condi

tions

require
the
removal
of

pump

assembly
for

replacement
or

repair

CAPACITY
TEST

The

capacity
test
is

made

only

when
static

pressure
is
within
the

specifications
To

make
this
test

pro

ceed

as
follows

1

Disconnect

pressure
gauge
from

T
connector
and
in
its
vacant

place

install
a

suitable
container

as
a
fuel

sump

2
Run

engine
at
1

000

rpm

3
The

pump
should

deliver
1
000

cc

2
11

US

pt
of
fuel
in

one
minute
or

less

If
little

or
no
fuel
flows
from
the

open
end
of

pipe
it
is
an

indication

that
fuel
line
is

clogged
or

pump
is

malfunctioning

REMOVAL
AND

DISASSEMBLY

Remove
fuel

pump
assembly
by

unscrewing
two

mounting
nuts
and

disassemble
in

the

following
order

1

Separate

upper
body
and
lower

body
by

unscrewing
body
set
screws
Engine
Fuel

2

Take
off

cap
and

cap
gasket
by

removing
cap
screws

3
Unscrew
elbow

and
connector

4
Take
off
valve

retainer

by
un

screwing
two
retainer

screws
and
re

move
two
valves

5
To
remove

diaphragm

press

down
its

center

against
spring
force

With

diaphragm
pressed
down

tilt
it

until
the
end
of

pull
rod
touches
the

inne

wall
of

body
Then
release

diaphragm
to
unhook

push
rod
Be

careful

during
this

operation
not
to

damage
diaphragm
or
oil
se
L

i
J

EFOO7

Fig
EF

20
Remouing
pull
rod

6
Drive
rocker
arm

pin
out
with
a

press
or
hammer

8

o

6

7

8

@

INSPECTION

I

Check

upper
body
and
lower

body
for
cracks

EF
10
I
fuel

pump
cap

2

Cap
gasket

3
Valve

packing

4

fuel

pump
val
e

assembly

S
Valve
retainer

6

Diaphragm
assembly

7

Diaphragm
spring

8
PuRro

9

Lower
body
seal

washer

10
Lower
body
seal

11
Inkl
connector

12
Outlet
connector

13
Rocker
arm

spring

14
Rocker
arm

I
S
Rocker

artyl
side

pin

16
Fuel
pump
packing

17

Spacer
fuel

pump

fo
cylinder
block

EF510

Fig
EF
21
Slruc
ure
of
fuel

pump

2
Check

valve
assembly
for
wear
on

valve
and
valve

spring
Blow
valve

assembly
with
brea
th
to
examine
its

function

854
co
in
in
one
minute
or
less

If
no

gasoline
or

only
a

little
flows

from

open
end
of

pipe
with

pump

operated
or
if

pump
does

not
work

perform
the

following
diagnosis

Notes

3
Do
not

connect
battery
in
reverse

polarity
which
if
left
for
a

long

time
would

damage
transitor

circuit
and
disable

pump
Engine
Fuel

b
Do
not
let
fall

pump
as
it

may

damage
electronic

components

c
Do
not

apply
overvoitage
max

l
8Y

Overvoltage
starting

by

quick
charge
or

tage
running

would
deteriorate
or

damage
elec

tronic

components

Fuel

pressure
maximum

0
32

kg
cm
4
6

psi

REMOVAL
AND
INSTALLATION

Flom
fuel
tank

Electric
fuel

pump
is
installed
on

bracket
with
two
bolts
This
bracket
is

located
on
R
H
side
member

adjacent

to
fuel
tank

I
Remove
inlet
hose
from
fuel

pump
Also
remove
outlet
hose
run

ning
to

engine
Receive
fuel

remaining

in
fuel
hose
in
a
suitable
container

2
Disconnect
harness
at

connector

3
Remove
bolts

securing
fuel

pump

to
bracket
and
detach
fuel

pump

4

Installation
is

the
reverse
order
of

removal

9

@

1
Cover

2

Magnet

3
Cover

gasket

4
Filter

5
Gasket

6

Spring
retainer

7
Washer
8
O

ring

9
Inlet
valve

10
Retutn

PIing

11
Plunger

12

Plunger
cylinder

13

Body
To
carburetor

1
Elecuic
fuel

pump

2

Mounting
bracket

3
Fuel
mter

EF72D

Fig
EF
23
Electric
fuel

pump

DISASSEMBLY

Do
not
disassemble
unless

pump
is

faulty

I
Remove

cover
with
wrench
and

take
out
cover
gasket
magnet
and

filter
from

pump
body

2
When

removing
plunger
take
out

spring
retainer
from

plunger
tube

3
Then
take
out
washer
O

ring

inlet
valve
return

spring
and

plunger

from
tube

Note
Do
not
disassemble
electronic

components
If

n

replace

with
new
ones

6

EF721

Fig
EF
24

Exploded
view

of
electric
fuel

pump

EF
12
ASSEMBLY

I

Before

assembly
clean
all

parts

with

gasoline
and

compressed
air

com

pletely

Notes

a
If

gask
t

an
d
fdterare

faulty
r

place

b
Clean

magnet
and
cover
for
fault

c
Take
care
not
to
defonn
thin
tube

d
Assemble

plunger
return

spring

inlet
valve
O

ring
washer
and
set

spring
retainer
in
that
order

e

Assemble
filter

gasket
and
cover

with

f

Tighten
cover
with
wrench
to
the

stopper

If

component
parts
are

dirty
after

disassembly
clean
as
follows

Wash
fIlter
and
strainer
with
clean

gasoline
and
blow
with

compressed

air
When

cleaning
parts
check

fllter
for
fault
If

faulty
replace

Wash

plunger
plunger
cylinder
and

inlet
valve
with
clean

gasoline
and

blow
dust
off

with

compressed
air

2
Check

c
v
m
lI

parts
for
wear

or

damage

If

they
are
found

faulty

replace

them

3

Insert

plunger
assembly
into

plunger
cylinder
of

body
and

apply

electric
current
to
it

Move
the

assembly

up
and
down

If
the

assembly
does
not
move
it

shows

that
the
electric

uuit
is

faulty

and
it
must
be

replaced

9
From
air

pump

l

h
1

Not
actuated

REMOVAL
AND

INSTALLATION

Air
p
mp
sir
cleaner

Remove
air
hose

then
detach
air

cleaner

from

hoodledge
Air
cleaner

element
and
Ii
r
deancr
lower

body
are

built
into
a
unit
construction

Replace

air
cleaner
clcl

nen
and

lower

body
as

an

assembly

J

J

tt
c

t
o

J

EC
323

Fig
EC
26
Replacing
oir
cleaner

element

Air

pum

Remove
air
hoses

from
air

pump

2
Loosen
air

pump
adjusting
bar

mounting
bolts
and
air

pump
mount

ing
bolts
then

remove
air

pump
drive

bell

3
Remove
air

pump
pulley

4
Remove
air

pump
from
bracket

Air
control
valve

California
models

l
Disconnect

air
hoses
and
a
vacu

um
hose
from
air
control
valve

2
Remove
air
con
trol
valve
from

bracket

E
A

R
valve
California
modela

Remove
vacuum

pipe
and
air

hose

and
dismount
E

A
R
valve
Emission
Control

System

o

jJ
To

Intake
mamfold

rF
vacuum

r

To
air

cleaner

From
air

pump

EC781

Fig
EC
27
Locotion

of
E
A
R
wive

Antl
backflravalve

Disconnect
air
hose
and
vacuum

hose
from
anti
backfire
valve

Check
valve

Disconnect
hose
and
remove
check

valve
from
air

gallery
pipe

Air

ganery
pIpe
andinJactlon

nozzles

It
is

very
difficult
to
remove
the
air

gallery
from
the
exhaust
manifold

without

bending
the

pipe
which
could

result
in
fractures
or

leakage
There

fore

removal
of

the
air

gallery
pipe

and

injection
nozzles
should
be
under

taken

only
when

they
are

damaged

I
Lubricate
around
the

connecting

portion
of
air

injection
nozzle
and
air

gallery
with

engine
oil

2
Hold
air

injection
nozzle

hexagon

head
with
a

wrench
and
unfasten
flare

screw

connecting
ait

gallery
to

injec

tion
nozzle
Remove
air

gallery

EC
14
To
intake

manifold

vaCUl
lm

r

Y

4
9
Gf

T

I
To

air
cleaner

I

Actuated

EC299

Fig
EC
25

Operation
of
air
control
value

Notes

a

Apply
engine
011
to
rews
several

times
during
above

work

b
Be
atreful
not
to

damage
other

parts

3
Unfasten
air

injection
nozzle

from

cylinder
head

applying
engine
oil

to
screwed

portion
several
times

4

Check
air

gallery
and
nozzle
for

fractures
or
leakage
Clean
air

injection

nozzle
with
a
wire
brush

5

At
time
of
installation
hold
air

injection
nozzle

hexagon
head
with

a

wrench
and

tighten
air

gallery
flange

screw
to
a

torque
of
5
0
to
5
9

kg
m

36
to
43
ft
lb

6
Check

cylinder
head
air

injection

nozzle
and
air

gallery
for
leaks
with

engine
running

Air

pump
relief
vslve

Loosen
carburetor
air
cleaner

mounting
sc
ews
and

remove
air

pump
relief
valve

InstallatIon

Install
in
the

reverse
order
of
reo

moval

DISASSEMBLY
AND

ASSEMBLY

Disassembly
of
air
pump

1
Remove
four

pulley
drive
bolts

and
remove

pulley
from
hub

2

Secure
air

pump
drive
hub
in

a

vise

as
shewn
in

Figure
EC

28
and

remove
four
end
cover
bolts

Note
Never

clamp
on
the

aluminum

housing

EC302

Fig
EC
28

Removing
cover

3
Remove
end
cover

by
carefully

tapping
around
dowel

pin
with

a

plas

tic
mallet
and
lift

up
straight

4
Put
match
marks
0
on
rotor

ring
and
side
of
rotor
to
ensure
correct

reassembly
and
remove
four
screws

that
retain
rotor

ring
to

rotor

using
a

Hexagonal
Wrench
STl9810000

Notes

a

Generally
match
marks
are
indi

cated
on

both
rotor

ring
and
rotor

by
the
manufacturer

ECll1

Fig
EC
29

Removing
rotor
ring
Emission
Control

System

b
Discard
screws
which
were
re

moved

Always
use
new
ones
when

installing

5

Remove
vane
from
rotor

EC661

Fig
EC

30
Remooing
vanes

6
Remove
four
carbon

shoes
and

two
shoe

springs
from
rotor

using

needle
nose

pliers
or
tweezers

Note
Carbon
shoe
A

0
039
in
wider
than

confuse
them
is
I
mm

B
Do
not

If

replacement
of
front

bearing
is

necessary

proceed
as
follows

7
Remove
air

pump
drive
hub
with

standard

puller

EC
15
8
Remove
four
screws

securing

front

bearing
cover
in

place
and
de

tach

bearing
cover

9

Support
the
rear
end
face
of
air

pump
housing
with
Rotor

Adapter

STl9890000
Drive
rotor
out

by
push

ing
rotor
shaft
with

Bearing
Pressing

Tool
STl9940000

STl9940000

1Ul

STl9890000

I
I

EC303

Fig
EC
32

Removing
rotor

shaft

10

Support
the
front
end
face
of

housing
with

Bearing
Adapter

STl9930000
Attach

Bearing
Driver

STl9910000
to
front

bearing
on
the

inside
of
air

pump
housing
iuid

press

out

ll

I
I

STl9910000

i

L

9930000

J

1

EC304

Fig
EC
33

Remouing
ball

bearing

11

Keep
disassembled

parts
in

rder

Emission
Control

System

Assembl
of
air

pump

I
Front

bearing

Support
the
rear
end
face
of
air

pump
housing
with
RotOL

Adapter

STl9890000
Press
front

bearing
into

place
with
a

press
arid

Bearing
Ptessing

Tool
STl9940000

I
I

STl9940000

X8
03

Fig
EC
35

Pressing
ball

bearing
L

2

Bearing
cover

Torque
four

bearing
cover

securing

bolts
to
0

1
to

0
2

kg
m
0
7

to
1
4

ft
lb

3
Rotor
shaft

Support
the
inward
bottom
of

rotor
with
Rotor
Stand
STl9920000

Press
rotor
into

place
with
a

press

and

Bearing
Drive
STl9910000
until

the

stepped
portion
of
rotor
shaft

touches
front

bearing
inner
race
C
1

ST
19910000

ST19920000

I
EC3Q7

Fig
EC
36

Pressing
rotor
shaft

Notes

a
Be

sure
to
drive
front

bearing
inner

race
in

b
After
rotor
is
installed
in

place

ensure
that
the
rotor
end
is

pos

tioned
below
the
end
face
of
air

pump
housing

Position
of
rotor

end
below
air

pump

housing

0
050

to
0
150
mm

0
0020
to
0
0059
in

4

Air

pump
drive
hub

Support
the
inward
bottom
of

rotor
with
Rotor
Stand
STl9920000

EC
16
EC562

Fig
EC
34

Componenbr
of
two
vane

type

Press
drive
hub
into

place
with
a

pre
and

Bearing
Driver
STI
991
0000

until
the
end

face
of
drive
hub
touches

froE
c
ing
in
n
c

j

STt9910000

STl9920000
e

r

EC308

Fig
EC
37

Pressing
air

pump
drive

hub

5

Carbon
shoe

1
Place
air

pump
drive
hub
in
a

vise

2

Clean
carbon
dust
etc
from

shoe

grooves

3

Align
rotor
with

housing
proper

ly
Refer
to

Figure
EC
38
Then
insert

carbon
shoes
into

place
noting
their

directions