warning DATSUN PICK-UP 1977 Service Manual

Fig
GI
9
Manual
trammiuion
number

location

Automatic

transmission

number

The
transmission

serial
number
is

attached
to
the

right
hand
side
of

transmission

case

Numbering
system

X
XXXXX

I

Serial
number

monthly

Month
of

manufacture

I
2

9
X
Y
Z

last

figure
of

year
of

manufacture

AT344

Fig
01
10
Automatic
trammi

sion

number
location

LIFTING
POINTS

AND
TOWING

LIFTING

POINTS

Screw

jack

Before

using
the

jack
proceed
a

follows
Generallnforml
ition

Apply

parking
brake

firmly
and

block
rear
wheels
if
the
front

of
the

vehicle
is
to

be
raised

Notes

a
Never

get
under
the
vehicle

while
it

is

supported
only
by
the

jack

Always
use

safety
stands
to

support

frame

or
rear
axle

case
when

you

have

to

get
beneath
the
vehicle

b
In
no
event
should
the

jack
be

applied
to

any
points

except
the

following
specified
portions

When

jacking
up
the
front
side

place
a
screw

jack
under
side
frame

about
520
nun

20
5
in
at
rear

of

front
axle
center

WT012

Fig
GI
ll
Front

lifting
point

When

jacking
up
the

rear
side

place

a
screw

jack
under
rear
axle
case
close

to
the
side

of
rear

spring

WH077

Fig
GI
12
Reor

lifting

point

Notes

a
When

the

yellow
mark

appean
on

the
screw

jack
it
indicates
the

maximum

permissible
height
Do

not

jack
up
further

b

When
the

jack
is
at
lower
llinit
do

not

add

large
force
downward

GI
6
YeDow
mark

WHOSO

Fig
GI

13

Warning

ogai
t

over
stroke

Garage

Jack

Note
When

carrying
out

operntions

with
a

garage

jack
be
sure
to

support
the
vehicle
withstands
in

a
safe
manner

When

jacking
up
the
front
end

apply
garage
jack
to
front
cross

member
or
center

portion
of
sus

pension
member

When

jacking
up
the
rear
end

apply
the

jack
to
rear
axle
case

r
J

uc

I

GI075
n9

Fig
GI

14
Front

lifting
point

GI076

Fig
GI
15
Rear

lifting

point

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

r

CHECKING
B
C

D
D

SOLENOID
VALVE

I
Turn
on

engine
key
Do
not
start

engine

2
Ensure
that
solenoid
valve

clicks

when

intermittently
electrified
as

shown
in

Figure
ET
37

Fig
ET

37

Checking
solenoid
uolV
l

I

l

EF264

2

Turn

ignition
key
to
ON

posi

tion

3

Ensure
that
tester

pointer
deflects

when

ignition
key
is

turned
on

4

If

tester

panter
does
not
deflect

when

solenoid
valve

and

speed
detect

ing
switch

circuits

are

functioning

properly
amplifier
is

faulty
Engine
Tune

up

3
If
a

click
is

heard
solenoid
valve

is
normal

4

If
a
click
is
not
heard

at
all
check

for

continuity
with
a
circuit

tester
If

discontinuity
is

detected

replace
sole

naid
valve

CHECKING

AMPLIFIER

Manual
transmission

models

The

amplifier
is

installed
at
the

rear

of
the

speedometer
To

check

proceed

as
follows

1
Set
circuit

tester
in

d
c

ampere

range
IA

min
full
scale

connect
test

probes
of
tester
as

shown
in

Figure

ET
38

Do

not
confuse

positive
line

with

negative
line

M

p
1

II

L
o

A

I
of

j
t
J

f

T

1

Ignition
key

2

Amplifier

3

Speed

detecting
switch

4
B

C
D

D

solenoid
valve

Fig
ET
38

Checking

amplifiu

REPLACING
AIR

PUMP
AIR
CLEANER

ELEMENT

Remove
air

hose
then
detach
air

cleaner
from

hoodledge
Air
cleaner

element

and
air

cleaner
lower

body
are

built
into

a
unit
construction

Replace

air

cleaner
element
and
lower

body
as

an

assembly

ET

20
EC323

Fig
ET
39

Repl4cing
air
cleaner

element

CHECKING

EXHAUST

GAS

RECIRCULATION

E
G

R

CONTROL

SYSTEM

Checkln

E
G
R
control

system
In
Ita

mounted

condition

I

M
ake
a

thorough
visual
check
of

E

G
R
control

system
If

necessary

wipe
away
oil
to

facilitate

inspection

If

hoses
are

cracked
or

broken
fe

place

2
With

engine
running
check

E
G
R

warning
system
for

proper

function
Make
sure
that
E

G
R
warn

ing
lamp
light
when

ignition
switch
is

turned
to
START

position
starter
mo

tor
runs
If
E
G
R

warning
lamp
does

not

light
inspect
harnesses
and
con

nectors
or

replace
warning
lamp
Then

turn

ignition
switch
to

ON

position

and
check
the

following
items

I

If
odometer
of
detector
drive

counter
has
not
reached
50

000

counts
make
sure
that
E

G
R

warning

lamp
does
not

light

2

If
odometer
of
detector
drive

counter
has
attained
50

000
counts

make

sure
that
E

G
R

warning

lamp

lights

If

warning

lamp
does
not

light

check
harnesses

connector
and
de

tector
drive
counter

replace

warning

lamp
or
detector
drive

counter
if

necessary

Note

Operation
of
E

G
R

warning

lamp
is

as
follows

Ignition
Switch
Position
START

Detector
Drive
Counter

E

G
R

Warning
Lamp
ON

a
After

completing
inspection
of

E
G
R
control

system
be
sure
to

reset
odometer
of
detector
drive

counter
to
zero

b
This
item

applies
to
620
models

except
those
bound
for
California

and
Canada

3
With

engine
stopped

inspect

E
G
R
control
valve
for

any
indication

of

binding
or

sticking
by
movirig
dia

phragm
of
control
valve

upwards
with

fmgers
Engine
Tune

up

ON

Below

50

000
counts
Above

50
000
counts

OFF
ON

4
With

engine
running
inspect

E
G
R
control
valve
and
thermal

vacu

um
valve
for

normal

operation

I
When

engine
coolant

tempera

ture
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

fingers
on
the

diaphragm
of

E
G

R
control
valve
to
check
for
valve

operation

2

When

engine
coolant

tempera

ture
is

high

I
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

2
If
E

G
R

control
valve
does
not

operate
check
as
follows

Disconnect
one
end
E
G
R
control

valve
side
ofvacuum
hose
connect

ing
thermal
vacuum
valve
to

E
G
R
EC253

Fig
ET
40

Checking
E
G
R
control
valve

control
valve

Increase

engine
speed
from

idling
to

3

000
to
3
500

rpm

Make
sure

that
thermal
vacuum

valve
is

open
and
that
carburetor

vacuum
is

present
at
the
end

E
G
R
control
valve

side
ofvacu

urn
hose

If
vacuum
is
weak
or
not

present
at

all

replace
thermal
vacuum
valve
If

vacuum
is

present
replace
E

G
R

con
trol
valve

ET
21
EC254

Fig
ET
41

Checking
thermal

vacuum

valw

If

any
difficulty
is
encountered
in

judging
the
condition
of

any

compo

nent

during
above

inspection
check

the

questionable
component
independ

ently
as

follows

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

0

r11

hC

J

ET152

Fig
ET
42

Checking
E
G
R
control

VGlve

2

Visually
check
E
G
R
control

valve
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

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

Replace
bulb
if

bulb
is
burned

ou
t

If

bulb
is
not
burned
trace

wireis

back

to

ignition
switch

Repair
or

replace
if

necessary

2

Be
sure
that

floor

temperature
is

cool

below
800C

1760F
before

carrying
out
the

following
procedure

1
Remove
rear
seat

2

Ignition
switch
is
turned
to

the

Temperature

sensing
switch
Temperature

warning
lamp

Contact
close
Off

Contact

open
On

Note

Avoid

heating
floor

tempera

ture

sensing
switch
directly

If

lamp
does

not

glow
check
floor

temperature
sensing
switch
connector

for

continuity
with
a
circuit

tester

If

continuity
should
exist

after

heated

surrounding
areas
of
floor
tern

rv
wnTP
sen
cinq
S
Vitch

reolace
tem

perature
sensing
switch

If

continuity
does
not
exist

trace

the

wiring
back
to

relay
or
check
the

following
step
3

Repair
or

replace

wire

s
if

necessary

Note
The
floor

temperature
sensing

switch

may
be
heated

through
the

floor

by
a

proper
heater

3
Turn

ignition
switch
to
the
IG

position
anf
disconnect
floor

temper

ature

sensing
connector
The

lamp

should
remain

on
If
not

check
floor

4
0
3

UJ

GJO
Engine
Tune

up

IGU

position

3
Ensure

that
floor
tem

perature

warning

lamp
goes
out

4

Heat

surrounding
areas
of
floor

temperature
sensing
switch
with
a

proper
heater

to
ensure
that
floor

temperature
warning

lamp
glows
when

floor
is

heated
to

lh

specifications
as

shown

in
the
table
below

Floor

temperature

Below

1050C

22IOF

Above
1050C

2210F

temperature
relay
for

continuity
with

a

circuit
tester

Referring
to
the

following
floor

temperature
relay
if

relay
is
normal

trace

wire
s
back
to

ignition
switch

Repair

faulty
wiring

Floor

temperature

rela

To

check
floor

temperature
relay

remove
it

and

proceed
as

follows

1
Check
for

continuity

between@

and

@
Continuity
should

exist

Check
for

continuity
between

D

and@
Continuity
should
exist

Check
for

continuity
between

D

and@
Continuity
should
not
exist

2

Apply
a
12
volt
doC

across@and

@
to

ensure
that

continuity
exists

between

D
and@and
that

continuity

does
not
between

D
and

@
If
test

r
I

141

ET
24
results
do
not

satisfy
the
above
reo

place
the
floor

temperature
relay

When
floor

temperature

warnln8
lamp
118hts

Check
floor

temperature
warning

lamp

I

Open
or

short
circuit
in

wiring

harness

2

Check
fuel

system
with

regard
to

the

following
items
Refer
to

Inspec

tion

of
Fuel

System

I
Floa

t
level

2

Choke

3

Normal

fuel

supply
system
Prima

ry
and

secondary

4

Accelerator

pump

5

Power
valve

6

B
C
D
D

7

Fuel
strainer

8
Air

cleaner

3
Check

ignition
system
with

regard

to

the

following
items
Refer

to

Inspection
of

Ignition
System

I

IgnItion
AMI

2

Distributor

3

Ignition
coil

4

High
tension

code

5

Spark

plug

4

Check

idle
CO

adjustment
Refer

to

Inspection
of
Idle

CO

Adjust

roeoC

Note
Even

if
there
is

nothing
wrong

with

engine

warning
lamp
may

come
on
if
vehicle
is

being
driven

on
a

steep
slope
continuously
in

lower

gears
at

high
engine

speeds

To
floor

temperature

warning
lamp

2
From
S

position

3
From
GOt

position

4

From

ignition
switch

5
To
floor

temperature

sensing
switch

EC343

Fig
ET
50

Checking
floor

temperature

relay

ENGINE

LUBRICATION
SYSTEM

SERVICE
DATA
AND

SPECIFICATIONS

Oil

pump

Standard
Wear
limit

mm
in
0
04
to

0
08

0
0016
to
0
0032

less
than
0
12
0
0047

0
15
toO
21

0
0059
to
0

0083
0
20

0

0079

0
20

0
0079

0
5

0

0197
Rotor
side
clearance

rotor
to
bottom
cover

Rotor

tip
clearance
mm
in

Outer
rotor
to

body
clearance
mm
in

Oil

pressure
regulator
valve

Oil

pressure
at

idling

Regulator
valve

spring

Free

length

Pressured

length

Regulator
valve

opening

pressure
kg
cm2

psi
0

8
to
2
8

II
to
40

mm
in

mmOn

kg
em2

psi
52
5
2
067

34
8
1
370

3
5
to
5

0
50
to

71

Tightening
torque

Oil

pump
bolt

Oil

pump
cover
bolt

Regulator
valve

cap
nut
kg
m
ft
lb

kg
m
ft
lb

kg
m
ft

Ib
1
1
to
1
5
8
0

to
10
8

0

7
to
1

0
5
1

to
7
2

4
to
5
29

to
36

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition
Probable
causes
Corrective
actions

Oil

leakage
Damaged
or
cracked

body
cover

Oil

leakage
from
gasket

Oil

leakage
from

regulator
valve

Oil

leakage
from
blind

plug
Replace

Replace

Tighten
or

replace

Replace

Decreased
oil

pressure
Leak
of
oil
in

engine
oil

pan

Dirty
oil
strainer

Damaged
or
worn

pump
rotors

Faulty
regulator

Use
of

poor
quality
engine
oiL
Correct

Clean
or

replace

Replace

Replace

Replace

Warning

light

remains
on

engine
running
Decreased
oil

pressure

Oil

pressure
switch
unserviceable

Electrical
fault
Previously
mentioned

Replace

Check
circuit

Noise
Excessive
backlash
in

pump
rotors

Replace

EL
5

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

j

EC231

Thermal

vacuum
valva
o

o

m
Emission

Control

System

0

o

o

o

l

l
@

The
thermal
vacuum
valve

is

mounted
in

the

engine
thermostat

housing
It

detects

engine
coolan
t

tem

perature
by
means
of
a

built
in

bi

metal
and

opensor
closes
the

vacuum

passage
in
the

thermal
vacuum

valve

mt

li

t

00
t

EC232

Fig
EC
54
Thennal

vacuum
valve
To
E

G
R
control
valve

From
carburetor

1

Spring

2
Bi
metal

3

O

ring

E
G
R

warning

system

The

E
G
R

warning
system
install
1

Diaphragm
spring

2

Diaphragm

3
Valve
shaft

4

Valve

5
Valve

Seat

6
Valve
cham
ber

Fig
EC
53
E
G

R
control
value

When
the

vacuum

passage
is

open
the

carburetor
suction

vacuum
is

applied

to
the

diaphragm
of
the
E
G
R

con

trol
valve
to

actuate
the

taper
valve

connected
to
the

diaphragm

theconsiiiictlo

nlie
thermal

vacuum
valve
is

shown
below

ed

independently
of
the

E
G
R

con

trol

system
monitors

the
distance
the

car
has
travelled
and

indicates
when

EC
22
the
E

G
R

control

system
must
be

checked

The
E
G
R

warning
system
consists

of

an
odometer
switch

detector
drive

counter
E

G
R

warning

lamp
and

harnesses

When
the

earn
in
the

odom

eter
switch
connected
to

the

speed

ometer
turns

once
for

each
OAkm
4

mile
the

contact

point
of
the
elec

trica
circuit
closes

allowing
electric

current
to
flow

through
the

magnet

coil
of

the
detector

drive
counter

Thus

energized
the

magnet
coil
ac

Wates

the
latchet
to

turn
the
c
unter

wheel

by
one

pitch
When
the

number

of

counts
reaches
50
000
the
latchet

drops
in

a

groove
provided
on
the

periphery
of

the
counter
wheel
to

activate

the
detector

drive
counter

switch

Then
the

E
G
R

warning

lamp

comes
on

indicating
that
the
E
G
R

control

system
Should
be
checked

The

detector
drive

coun
teT
is

equip

ped
with
an
odometer
which

can
tell

when
to
service

the
E

G
R
contr0
I

system

After

completing

periodic
check

reset
the
odometer
to

zero
by
hand

proceeding
as
follows

1
Remove

grommet
installed
on

the
side

surface
of

detector
drive

counter
unit

2
insert

a
bar

or
a
screwdriver

tip

into
the

hole
from

which

grommet
has

been

removed
and

press
down
knob

provided
in

the
detector
drive
counter

for

resetting

The
E

G
R

warning

lamp
comes

on

under
the

following
circumstances

1
When
the
number
of

counts
has

reached
50
000
In
this

case
the

lamp

indicates
that
E

G
R

control

system

must
be
checked

2
When

operating
starter
motor

Notes

a
It
is

an
indication
of

problem
in

the

E

G
R

warning
lamp
or

problems

in
the

point
or
in
the
harnesses
if

the

lamp
does
not

light
at

50
000

counts

b

The
E

G
R

warning
system
is

mounted

on
all
620
models

except

those

bound
for
California
and

Canada

1

1

I
I

I

1
v

v

I
I

I
I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

L
0

I

Magnet
coil

Detector
drive

counter

REMOVAL
AND

INSTALLATION

Remove
air
cleaner

before

removing

E
G
R
control

system
For
removal

and

installation
of
air

cleaner
refer
to

Air
Cleaner
section

Page
EF
S

Removal

I
E
G
R
control
valve

After

removing
the

following
parts

the
E

G
R

controi
valve
can

be
dis

mounted

Vacuum

hose
thermal
vacuum

valve
to
E
G
R

control
valve

E
G
R
control
valve

mounting
nut

Note
To
remove

vacuum
hose
flat

ten

clip
connecting
vacuum
hose
to

E
G
R
control
valve
and

pull
the

hose
off
with
hand
Emission
Control

System

Ignition
switch

E
G
R

warning
lamp

f

1
Ignition
switch

start

position

Fuse

1
A
Odometer
switch

r

I
I

I

I
v

I

I
I

i

lQ
U

1

mi

L
J

EC233

Fig
EC
55
E
G
R

warning
circuit

EC234

Fig
EC
56

Removing
KG
R
control

valve

2
E
G
R

pass
ge

After

removing
the

following

parts

the
E
G
R

passage
can
be
dismounted

Exhaust
gas
return

tube
exhaust

manifold

to
E
G
R

passage

B1ow

by
hose

cylinder
block

to

P
C
v
valve

Vacuum
hose
AB
valve
to
E
G
R

passage

E
G
R

passage
mounting
bolt

EC

23
EC541

Fig
EC
57

Removing
E
G
R

passage

3

Thermal
vacuum

valve

After

removing
the

following

parts

the
thermal
vacuum
valve
can
be
dis

mounted

Vacuum
hose

carburetor
to
ther

mal
vacuum
valve

Vacuum
hose
thermal
vacuum

valve

to
E

G
R
control
valve

Note
Drain

engine
coolant
before

dis

mounting
thermal
vacu
m
valve

Fig
EC
58

Removing
thermal

vacu
um
valve