catalytic converter DATSUN PICK-UP 1977 Service Manual

General
Information

APPROXIMATE
REFILL
CAPACITIES

I
Uter
u
s

measure

Imper
measure

Fuel
tank

I
45
J
IUi

gal
9

Ji

gal

Cooling
system
ManUal
transmission

I
8

0J

I
8Jiqt
7

qt

with
heater

Automatic
tr
smission

I
7

8J

I
8Y

qt

6Jiqt

Engine
lubrication
with
oil

f1lter

I
4

3J

I
4
Ji

qt
3

qt

system

without
oil
f1lter

I
3

8J

I
3Xqt
4

ql

I
4

speed
transmission

I
1

7J

I
3X

pl
3

pI

Manual
transmission

I
5

speed
transmission

I
2
0

I
4Y

pt
3Mpt

Automatic
transmission

I
5
s
J

I
5Uqt
4Uqt

Steering

gear
box

I
0
33J

I
pt
pt

Differential

carrier

I
1
0
J

I
2M

pI
I

pt

RECOMMENDED
FUEL

Use

an
unleaded
or
low
lead

gasoline
with
a
minimum
octane

rating
of
91

RON
Research

Octane

Nuniber
For
California

models
use
only
unleaded

gasoline
to

protect
the

catalytic
converter
from
contamina

tion

RECOMMENDED

LUBRICANTS

RECOMMENDED
SAE

VISCOSITY

NUMBER

C

ENGINE

on

12O
II
O
10Vt4ll
10Wf
2

I
ICWI
I

ao
40

J

SAE
5W
20
oils

ate
not
lecom

mended
for
sustained

high
speed

drivin

GEAR
On

I

J

w

c

30
20
0

20
40
60
80
100

Temperature
Range

Anticipated
Before

Next
Oil

Change
OF

GI
8

CHECKING
CHOKE

MECHANISM
Choke

plate
and

linkage

1
Check
choke

valve
and
mech

anism

for
free

operation
and
clean
or

replace
if

necessary
A
binding
can

result
from

petroleum

gum
formation

on
choke
shaft

or
from

damage

2

Check
bimetal
cover

setting

Index
mark

on
bimetal

cover
is

usually

set

at
center
of
scale

Note

Always
align
the
index

mark
on

bimetal
cover
with
the
center
index

mark
on
choke

housing

3

Every
day
before

starting
engine

depress
the
accelerator

P
dal
to
see
if

choke
valve
is
closed

automatically

If
it
fails
to
be
closed
the

chances

are
that
link
movement
is
unsmooth
Engine
Tune

up

or
that
bimetal
is

out
of
order
Refer

to
Carburetor
in
Section
EF

CHECKING
FUEL

LINES
Hoses

pipings
connections

etc

Check
fuel
lines
for

loose
con

nections

cracks
and

deterioration

Retighten
loose
connections

and
re

place
any
damaged
or
deformed

parts

REPLACING
FUEL

FILTER

Check
for
a

contaminated
filter
and

water

deposit
All

engines
use
a

replaceable

cartridge
type
fuel
filter
as
an
as

sembly

@

Fig
ET

19
Fuel

filler
ET011

EMISSION
CONTROL
SYSTEM

CHECKING
CRANKCASE
EMISSION

CONTROL
SYSTEM

REPLACING
P
C
V
VALVE
AND

FILTER

CHECKING
VENTILATION
HOSE

CHECKING
EXHAUST
MANIFOLD
HEAT

CONTROL
VALVE

CHECKING
SPARK
TIMING

CONTROL

SYSTEM

SPARK
DELAY
VALVE

Automatic
transmission
models

only

INSPECTION

CHECKING

AUTOMATIC
TEMPERATURE

CONTROL
AIR

CLEANER

OPERATING
PRESSURE
OF

BOOST

CONTROLLED
DECELERATION
DEVICE

B
CD
D
I
ADJUSTMENT

CHECKING
B
C
DD
CIRCUIT

WITH

FUNCTION
TEST

CONNECTOR

CHECKING

CRANKCASE

EMISSION

CONTROL

SYSTEM

REPLACING
P
C
V
VALVE

AND
FILTER

Check
P

C
V

valve
in

accordance
CONTENTS

ET
13

ET
13

ET
14

ET
14

ET
14

ET
14

ET
15

ET
15

ET
17

ET
17
ADJUSTMENT
OF
SET
PRESSURE
OF

BOOST

CONTROLLED
DECELERATION

DEVICE
B

CD
D

CHECKING
B
C
D
D
SOLENOID
VALVE

CHECKING
AMPLIFIER
Manual

transmission
models

REPLACING
AIR
PUMP
AIR
CLEANER

ELEMENT

CHECKING
EXHAUST
GAS
RECIRCULA

TION
E
G
R
CONTROL
SYSTEM

CHECKING
EVAPORATIVE
EMISSION

CONTROL

SYSTEM

CHECKING
CATALYTIC
CONVERTER

INSPECTION

CHECKING
FLOOR
TEMPERATURE

WARNING
SYSTEM

INSPECTION

with
the

following
method

With

engine
running
at

idle
remove

ventilator
ose
from
P
C
V

valve
If

the
valve

is

properly
working
a

hissing

ET
13
ET
18

ET
20

ET
20

ET
20

ET
20

ET
22

ET

23

ET
23

ET

23

ET
23

noise
will
be

heard
as
air

passes

through
the

valve
and
a

strong
vacuum

should
be
felt

immediately
when

a

finger
is

placed
over
valve
inlet

3
If
there

is
a
leak

remove

top

cover
from

purge
contiol
valve
and

check

for
dislocated
or

cmcked
dia

phragm
If

necessary
replace
dia

phmgm
kit

which
is
made

up
of
a

retainer

diaphragm
and

spring

I
@

1
Cover

2

Diaphragm

3
Retainer

4

Diaphragm
spring

Fig
ET
47
ET350

Carbon
caniater

purge

control
valve

Carbon
unlster

filter

Check
for
a
contaminated

element

Element
can
be
removed
at

the

bottom
of
canister

installed
on
vehicle

body

Fig
ET
48

Replacing
carbon

canister

filter

Fuel
tank

vacuum
relief

valve

operation

Remove
fuel
filler

cap
and
see
it

functions

properly

I

Wipe
clean
valve

housing
and
have

it
in

your
mouth

2

Inhale
air
A

slight
resistance

ac

companied
by
valve
indicates
that

valve
is
in

good
mechanical
condition

Note
also
that

by
further

inhaling
air

the
resistance
should
be

disappeared

with
valve
clicks
Engine
Tune

up

3
If
valve

is

clogged
or
if
no
resist

ance
is

felt

replace
cap
as
an
assem

bled
unit

r

u

ET369

Fig
ET
49
Fuel

filler
cap

CHECKING

CATALYTIC

CONVERTER

INSPECTION

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including
hoses

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I

S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nOf

mal
or
not
can
be
checked

by
ob

serving
variation
in
CO

percentage

The

checking
procedure
is

as
follows

Apply
parking
brake
Shift

gears

into

Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks

2
Remove
air

hose
between
5

way

connector
and
air

check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3
Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5
Race

engine
1
500
to
2
000

rpm

two

or
three
times
under
no
load
then

run

engine
for

one
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
12

7

Check

ignition
timing
If

neces

sary

adjust
it
to

specifications
Refer

to

page
ET
10

ET
23
8

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adjustment
process
as

described
in

steps
5
to

8
above
until

specified
CO

percentage
is

obtained

Note

Adjustment
in

step
9
should
be

made
ten
minutes
after

engine
has

warmed

up

10
Race

engine
1
500
to
2
000

rpm
two
or
three
times
under

no
load

and
make

sure
that

specified
CO

per

centage
is
obtained

I
1
Remove

cap
and
connect
air

hose
to
air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
Warm

up
engine
for
about
four

minutes
at
2
000

rpm
under
n
load

13
Measure

CO

percentage
at

idling

speed
After

step
12
has
been
com

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14

If
CO

percentage
measured
in

step
13
is
less
than
0
3
the

catalylic

converter
is

normal

15
If
CO

percentage
measured
in

step
13
is

over
0
3
recheck
A
I
S

and

replace
air

check
valve
Then

perform
inspection
steps
12

and
13

16
If
CO

percentage
is
still

over

0
3
in

step
15

catalytic
converter
is

malfunctioning
Replace
catalytic
con

verter

CHECKING
FLOOR

TEMPERATURE

WARNING
SYSTEM

INSPECTION

Floor

warning
temperature

system

Apply
parldng
brake
Shift

gears

into
Neutral
for

manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Ensure
that
floor
tern

perature

warning

lamp
lights
when

ignition

switch
is

turned
to
the
S

position

If
not
check

lamp
for
burned

bul
bs

Emission
Control

System

EXHAUST
EMISSION
CONTROL
SYSTEM

DESCRIPTION

EARLY

FUEL
EVAPORATIVE
SYSTEM

E
F
E

DESCRIPTION

OPERATION

REMOVAL

AND
INSTALLATION

INSPECTION

SPARK
TIMING

CONTROL
SYSTEM

DESCRIPTION

SPARK
DELAY
VALVE

Automatic
transmissiom
models

only

INSPECTION

AIR

INJECTION
SYSTEM

DESCRIPTION

OPERATION

REMOVAL
AND
INSTALLATION

DISASSEMBLY
AND

ASSEMBLY

INSPECTION

DESCRIPTION

The
exhaust
emission
control

sys

tem
is

made

up
of

the

following

I

Early
fuel

evaporative
system

2

Spark
timing
control

system

3

Air

injection
system
A
I

S
EC
3

EC
6

EC
6

EC
6

EC
7

EC
7

EC
7

EC
7

EC
7

EC
8

EC
8

EC
8

EC12

EC
14

EC
14

EC
17
CONTENTS

EXHAUST
GAS
RECIRCULATION

CONTROL
SYSTEM
E
G
R

DESCRIPTION

OPERATION

REMOVAL
AND

INSTALLATION

INSPECTION

CATALYTIC

CONVERTER

DESCRIPTION

OPERATION

REMOVAL

AND
INSPECTION

INSTALLATION

FLOOR
TEMPERATURE
WARNING

SYSTEM

DESCRIPTION

OPERATION

REMOVAL

INSTALLATION

INSPECTION
EC
19

EC
19

EC
19

EC
23

EC
24

EC
26

EC
26

EC

26

EC
27

EC
27

EC
27

EC
27

EC

28

EC
28

EC

29

EC

29

7
Altitude

compensator
California

models
4
Exhaust

gas
recirculation
E
G
R

control

system

5

Catalytic
converter
California

models

6
Boost
controlled
deceleration
de

vice
B

C
D
D
As

regards
the
last
two
units
refer

to

the

Engine
Fuel
section

EC
3

Emission
Control

System

C
bur
tor

I

EC284

When

installing
this
valve

ensure

that
it

properly
oriented
Tlus
valve

shuuld
be

replaced
periodically
Refer

to
Maintenance
Schedule

Note
Carburetor
side
Black

DisInDutor
side

Brown

horn
distributor

To

carburetor

TOdi

ribUI0
carburClor

EC
lCiJr

Fig
EC

9
Operation
01

park
delay

value

INSPECTION

Remove

spark
delay
valve

2
Blow

air

through
port
on
carbure

tor

side
then

through
the

other

port

on
distributor
side

Spark
delay
valve
Distributor
side

1
One
way
umbrella
valve

2
Sintered
metal

disc

Fig
EC
8

Spark
delay
valve

is
in

good
condition
if
when

finger
is

placed
over

port
on
distributor
side

air

flow
resistance
is

greater
than
that

on
the

other
side
See

Figur
ET
lO

3
If
a

considerable
air
flow
resist

ance
is

fell
at

port
on
distributor
side

in

step
2

above
and
if

the
condition
of

spark
delay
valve
is

questionable
dip

port
on
carburetor
side
into
a

cup

filled
with

water
Blow
air

through
the

other

port
Small
air
bubbles
should

appear

Carburetor
side

Distributor
side

EC346

Fig
EC
IO

Checking
park
delay
valve

EC
8
EC219

Fig
EC

11

Checking
spark
d

tay
valve

Note
Be
careful
to
avoid

entry
of
oil

or
dirt
into
valve

AIR
INJECTION

SYSTEM

DESCRIPTION

The
Air

Injection

System
A

LS
is

aeSigiieino

iiiject
coin

pressed
air
sec

ODllary
air

corning
from
the
air

pump

into
the
exhaust
manifold
to
reduce

hydrocarbons
and
carbon
monoxide
in

exhaust
lri
s

through
re
combustion

There

are
two

types
of
A

I

S
One

type
is
mounted
on
California
models

and
the
other
is
on
non
California

models
The
non
California

type
con

sists
of
an
air

pump
air

cleaner
an
air

pump
a
relief

valve
a
check
valve
an

anti

backfIre
valve
an
air

gallery
and

hoses
The
California

type
has
in

addition
to
the

components
of
the

non
California

type
an
air
control

valve
and

an

emergency
air
relief
valve

These
valves

prevent
ahnonnal
tem

perature
rise
of
the

catalytic
converter

Minimizes
exhaust

gas
tempera

lure
rise

2
Minimizes

horsepower
losses
re

suiting
from
air

injection
into
the

exhaust

system

3
Protects

pump
from
excessive

back

pressure

The
air

pump
relief
valve
is
installed

as
shown
in

Figure
EC

20

The

secondary
air
is

discharged

from
the
air

pump
relief
valve

to
the

dust
side
of
the
carburetor
air
cleaner

To
carburetor

air
cleaner

Secondary

air

To
carburetor

air

cleaner

J
erCOndary

r

r

EC294

Fig
EC
20
Air

pump
relief
valve
Emission
Control

System

Emargency
air
retial
valve

E
A
R
Valve

California
models

The

emergency
air
relief
valve
con

trols
the

quantity
of
secondary
air

fed

from
the
air

pump
according
to

load

condition
and
it

discharges
the
see

ondary
air
into
the

atmosphere
to

prevent
overheating
of
the

catalytic

converter

The

emergency
air
relief
valve
con

sists
of
a

diaphragm
a

spring
and

a

valve
which
is

coupled
to

diaphragm

1

Diaphragm

2

Val

3

Spring

4

Diaphragm
chamber

EC536

Fig
EC

21

mergency
air

relief
valve

OPERATION

As
mentioned

previously
there

are

two

types
of
Air

Injection
Systems

A
I

S
a

non
California

type
and
a
California

type
The
California
stand

ard

type
includes
a

system
which

controls

injection
of

secondary
air

so

as
to
assure

proper
function
of
the

catalytic
converter
and
a

system

which
controls
the

supply
of
second

ary
air
to

prevent
abnormal

tempera

tUfe
rise
in
the

catalytic
converter

The
A
I
S
consists
of
the

following

systems

L
A

system
which
allows

injection

of

secondary
air
into
the
exhaust

port

2
A

system
which

bypasses
sec

ondary
air

from
the
air

pump
relief

valve

to
the

carburetor
air

cleaner

during

high
speed
engine
operation

3
A

system
which

supplies
air

from

the
carburetor
air
cleaner

to
the
intake

manifold

by
means
of
the
anti

backfire

valve
so
as
to

prevent
after
fire

during

deceleration

4
A

system
which

controls

injection

of
the

secondary
air

by
means
of
the

air

control
valve

so
as
to
maintain
the

catalytic
converter
at
an

optimum

temperature
level
under

lightly
loaded

condi
tions

Califomia

type
only

5
A

system
which
controls
the

sup

ply
of

secondary
air

through
the
emer

gency
air

relief
vilve

io
pfevent
ab

normal

temperature
rise
of
the

cataly

tic

converter

California

type
only

A
I

S

operation
is

as
follows

I

I

t

1
r

9

I
Air

pump
6

Check
valve

I
0
L
2
Air

pump
air
deaner
7
Air

gallery
pipe

3
Air

relief
valve
8
Injection
non
e

r
4
Air
cleaner
9

Exhaust
manifold

5

Carburetor
10

Anti
backflIe
valve

EC179

Fig
EC
22
Non

California
type
A
I
S

EC
12

EC350

Fig
EC
65

Cleaning
E

G
R
control

valve

Thermal

vacuum

valve

Dismount
thermal

vacuum
valve

from

engine

Note
Before

dismounting
drain
en

gine
coolant

from

engine

Apply
vacuum
to
thermal
vacuum

valve
and

check
to
be
sure
thaI
ther

mal
vacuum
valve

opens
or
closes
in

response
to

engine
coolant

tempera

ture
as

specified

Thermal
vacuum
valve

should

open

at
a

temperature
of
57
to
630C

135

to
1450F

completing
the

vacuum

passage

Note
Do

not
allow
water
to

get

inside

the
thermal
vacuum
valve

EC242

Fig
EC
66

Checking
hennal

vacuum

valve
Emission
Control

System

CATALYTIC

CONVERTER

DESCRIPTION

The

catalytic
converter
accelerates

the
chemical
reaction
of

hydrocarbons

HC
and
carbon
monoxide
CO
in

the

exhaust

gas
and

changes
them
into

non
harmful

carbon
dioxide

C02

OPERATION

Exhaust

gas
emitted

from
the
en

gine
contains

some
harmful
substances

due
to

incomplete
combustion
in
the

combustion
chamber
The

air

injection

system
is

designed
to

reduce
the
con

tent
of
such
substances
in

the
exhaust

gas
In

this

system
the

secondary
air

is

led
from
the
check
valve

and

injected

into
the

exhaust
manifold

With
this

injection
of
the

secondary
air

hydro

EC444

EC
26
and
water

H20
This
chemical
reac

tion

process
requires
the

proper
a

mount

of
air

which
is

supplied
by
the

air

pump
Refer
to

the
item
AJ

S

This
air
is
caUed

secondary
air

The

catalytic
converter
is
mounted

on
the

vehicles
destined

for
California
Refer

to

Figure
EC
67

3
4

1
Front
tube

2

Catalyti
converter

3
Center
tube
4
Main
muffler

5
Rear
tube

EC782

Fig
EC
67

Location

of
catalytic
converter

car

ons

He
and
carbon

monoxide

CO
in
the
exhaust

gas
are

gradually

oxidized
with

oxygen
02
in
the

secondary
air
and
converted

into
non

harmful
carbon

dioxide

C02
and

water

H20

The

catalytic
converter

further

cleans

engine
exhaust

gas
Through

catalytic
action
it

changes
residual

hydrocarbons
and
carbon
monoxide

contained

in
exhaust

gas
into
carbon

dioxide

and
water
before

exhaust

gas

is

discharged
to
the

atmosphere

c
Secondary
air

Carbon
monoxide

hydrocarbon

Carbon
dioxide
gas

water

F
EC
68

Operution
of
catalytic
corwerter

REMOVAL

AND

INSPECTION

Removal
and

inspection
can
be

done

as
follows

Removal

Catalytic
converter

1

Apply
parking
brake

2

Place
wheel
lock
under
each
tire

3

Jack

up
the
vehicle

4
Remove
lower
shelter
of

catalytic

converter

5
Dismount

catalytic
converter

EC453

Fig
EC
69
Removing

catalytic

conuerter

Inspection

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including

ho
s

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I
S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nor

mal
or
not
can
be
checked
by
ob

serving
variation
in

CO

percentage

The

checking

procedure
is

as
follows

Apply
parking
brake
Shift

gears

into
Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks
Emission
Control

System

2
Remove
air
hose
between

5

way

connector
and
air
check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3

Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5

Race

engine
1

500
to
2
000

rpm

two
or
three
times

under
no
load
then

run

engine
for
o
e
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
10

7
Check

ignition
timing
If
neces

sary
adjust
it
to

specifkations
Refer

to

page
ET
10

B

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adju
stment

process
as

described
in

steps
5
to
8
above

until

specified
CO

percentage
is
obtained

Note

Adjustment
in

step
9
should
be

made
ten

minutes
after

engine
has

wanned

up

10
Race

engine

1
500
to
2
000

rpm
two
or
three
times

under
no
load

and
make
sure
that

specified
CO

per

centage
is
obtained

11
Remove

cap
and
connect
air

hose
to

air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
WaRn

up
engine
for

about
four

minutes
at
2
000

rpm
under
no
load

13
Measure
CO

percentage
at

idling

speed
After

step
12
has
been
coin

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14
If
CO

percentage
measured
in

step
13
is
less
than
0
3

the

catalytic

converter

is
normal

15
If
CO

percentage
measured
in

step
13
is
over
0
3

recheck
A
I
S

and

replace
air
check
valve
Then

perform
inspection
steps
12
and
13

EC
27
16
If
CO

percentage
is

still
over

0
3
in

step
15

catalytic
conyerter
is

malfunctioning
Replace
catalytic
con

verter

INSTALLATION

To
install

reverse
the
removal

pro

cedure

Bolt

lightening

torque

specifications

Tightening

torque

Catalytic
converter

2
6
to
3
4

kg
m

19
to
25
ft
Ib

FLOOR

TEMPERATURE

WARNING
SYSTEM

DESCRIPTION

The
floor

temperature
warning

system
consists
of
a
floor

temperature

sensing
switch
installed

on
the
vehi

cle
s
floor
floor

temperature
relay
and

a

warning

lamp
on
the
instrument

panel
and
wires
that
connect
these

parts

When
the
floor

tempera
ture
rises
to

an
abnormal
level
the

warning
lamp

will

light
to
call
the
attention
of
the

driver
The

wiring
diagram
of
this

system
and
location
of
the

floor

temperature
sensing
switch
are
ilIus

trated
in

Figures
EC
70
and
EC
71

Engine
Control
Fuel
Exhaust

Systems

2
Remove
fuel

filter

INSPECTION

Fuel

tanle

Check
fuel

tank
for

cracks
or

deformation
If

necessary
replace

2
Fuel
hose

Inspect
all
hoses
for
cracks

fatigue

sweating
or
deterioration

Replace
any

hose
that

is

damaged

3
Fuel
tube

Replace
any
fuel
tube
that
is

crack

ed
rusted

collapsed
or
deformed

Note

Inspect
hoses
and
tubes
ac

cording
to
the

periodic
mainte

nance
schedule

4

Fuel
filter

Replace
fuel
filter

according
to

the

periodic
maintenance
schedule
or

when

it
is

clogged
or
restricted

DESCRIPTION

REMOVAL

DESCRIPTION

The
exhaust

systems
installed
on

the
non
California
models
differ
in

specifications
from
those
installed
on

the
California
models
Fuel
filter
is

of
a

cartridge
type

and
cannot
be
cleaned

Always

replace

with
a
new
one

5
Fuel
tank

gauge
unit

Check

gauge
unit

for
rust
deforma

tion
or

deterioration
If

necessary

replace

INSTALLATION

To
install
reverse
the
order
of

removal
Observe
the

following

I

Install
hose

clamps
securely
Do

not

tighten
excessively
to

avoid

damaging
hoses

2
Fasten

clips
holding
fuel
tube
on

under

body
securely
Failure
to
follow

this
caution

could
result
in

damage
to

the
surface

of
fuel

tube

3
Do
not
kink

or
twist

hose
and

tube
when

they
are
routed

EXHAUST
SYSTEM

CONTENTS

FE
6

FE

8
INSPECTION

INSTAllATION

Non
California
models

The
exhaust

system
consists

of
a

front
exhaust
tube
a
main

muffler

assembly
with
rear

tube

mounting

hangers
brackets
and
a
heat

insulator

FE
6
4
Install
fIller
hose
after
fuel

tank

has
been
mounted
in

place
Failure

to

follow
this
caution
could
result
in

leakage
from

around
hose
connections

5
When

installing
fuel
tank

gauge

unit

align
the

projection
of

tank

gauge

unit
with
the

notch
in
fuel

tank
and

tighten
it

securely
Be

sure
to
install

gauge
unit

with
O

ring
in

place

6
Run

engine
and
check
for
leaks
at

connections

Tightening

torque

Drain

plug

5

0
to
6
0

kg
m

36

to
43

ft
Ib

Fuel
tank

securing
bolt

0
8
to
1
I

kg
m

6
to
8
ft
Ib

Reservoir

tank

securing

bolt

032
to
0
44

kg
m

2

to
3

ft
Ib

FE
8

FE
8

California
models

The
exhaust

system
cOllsists
of

a

front
exhaust

tube
a

catalytic
conver

ter

assembly
a
center
tube
a

main

muffler

assembly
with
rear
tube

mounting
hangers
brackets
and
heat

insulators

The

catalytic
converter
is
COD

nected
to
the
front

tube
and
the

center

tube
with
bolts
and
nuts

Engine
Control
Fuel
Exhaust
S
t

ys
ems

Non
Califomia
model

Qf

@
Si
tr
l

Qf

Si
tIJ

i
Qf

I

l
j

l
tr
l

r
Qf

Si
i
l

l

t
1

I
tr
l

9
r

8

1Bi
1
Front
tube

2
Exhaust

tube

clamp

3
Rear

tube

assembly

4
Muffler

assembly

5

Rear
tube

mounting

6
Front

tube
mounting

California
model

6

@@
8

Qf

@
fit
J
0

I

1

2

I

7
Front
tube

Catalytic
converter

Center
tube

Muffler

assembly

Diffuser

Rear
tube

mounting

Front
tube

mounting

FE390

Fig
FE
6
E
r

ha
t

system

FE
7