ESP DATSUN 210 1979 User Guide
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1979, Model line: 210, Model: DATSUN 210 1979Pages: 548, PDF Size: 28.66 MB
Page 127 of 548
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
Page 137 of 548
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
Page 141 of 548
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
Page 144 of 548
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
Page 145 of 548
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
Page 150 of 548
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
Page 151 of 548
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
Page 183 of 548
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
Page 200 of 548
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
Page 208 of 548
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