air condition DATSUN PICK-UP 1977 Service Manual

Yellow

line

Spark
delay
valve
to

distributor

Spark
delay
valve
to
vacuum
tube

Distributor

to
vacuum
tube

Vacuum
tube
to
carburetor

Vacuum
tube
to
canister

Green
line

Anti

backfire
valve
to
intake
mani

fold

Air

control
valve
to

emergency
air

relief
valve

Intake
manifold
to
vacuum
hose

connector

Intake

manifold
to
canister

CHECKING
ENGINE

COMPRESSION

COMPRESSION
PRESSURE

TEST

I
Warm

up
engine
sufficiently

2
Disconnect

all

spark
plugs

3
Disconnect
anti

dieseling
solenoid

valve
connector

4

Properly
attach
a

compression

tester
to

spark

plug
hole
in

cylinder

being
tested
Engine
Tune

up

I

ET010
Different

compression
in
two
or

more

cylinders
usually
indicates

an

improperly
seated
valve
or
broken

piston
ring

9
Low

compression
in

cylinders
can

result
from
worn

piston
rings
This

condition

may
usually
be

accompanied

by
excessive

fuel

consumption

TEST
RESULT

If

compression
in

one
or
more

cylinders
is
low

pour
a
small

quantity

of

engine
oil
into

cylinders
through

the

spark
plug
holes
and
retest
com

pression

I

If

adding
oil
increases
the
com

pression
pressure
the
chances
are
that

rings
are

faulty

2

If

pressure
stays
low

probable

cause
is

that
valve
is

sticking
or

seating

improperly

3
If

cylinder
compression
in

any

two

adjacent
cylinders
is

low
and
if

adding
oil
does
not

help
the

compres

sian
there
is

leakage
past
the

gasket

surface

Oil
and
water
in

combustion
cham

bers

can
result
from

leakage

IGNITION
AND

FUEL
SYSTEM
Fig
ET
10

Teding

compression

pressure

5

Depress
accelerator

pedal
to

open

throttle
and
choke
valves

Note
Do

not

pump
pedal

6
Start

engine
as

quickly
as

pos

sible

7

Compression
pressure

kg
cm2

psi
at

rpm

Standard

12
0

171
350

Minimum

9

0
128
350

8

Cylinder
compression
in

cylinders

Should
not
be
less
than

80
of

highest

reading

CONTENTS

CHECKING
BATTERY
ET
9

CHECKING
DISTRIBUTOR
CAP
ROTOR

CHECKING
AND

ADJUSTING
IGNITION
AND
CONDENSER
ET
11

TIMING
ET
10

CONDENSER
ET
11

ADJUSTING
IGNITION
TIMING
ET10

ADJUSTING
CARBURETOR
IDLE
RPM

CHECKING
AND
REPLACING
SPARK
PLUG
ETlO
AND
MIXTURE
RATIO
ET

11

CHECKING
DISTRIBUTOR
OPERATING
IDLE

LIMITER
CAP
ET
12

PARTS
AND

IGNITION
WIRING
ETlO
CHECKING
CARBURETOR
RETURN
SPRING
ET

12

BREAKER
POINTS

lNon
California
models

ET
10
CHECKING
CHOKE
MECHANISM

AI
R

GAP
lCalifornia
models
ET11
Choke

plate
and

linkage
ET13

DISTRIBUTOR
ET
11
CHECKING
FUEL

LINES

IGNITION
WIRING

ET
11
Hoses

pipings
connections
etc

ET
13

REPLACING
FUEL
FILTER
ET
13

CHECKING
BATTERY

Check

electrolyte
level
in

each
bat

tery
cell
I
Unscrew

each
filler

cap
and

inspect
fluid
level
If
the
fluid
is
low

add
distilled
water
to

bring
the
level

up
approximately
10
to
20
mm
0
39

H
9
to
0
79

in
above
the

plates
Do
not

overfill

2
Measure
the

specific
gravity
of

battery
electrolyte

p

r

ET002

Fig
E1
11

Checking
specific
gravity

of
bottery
electrolyre

Clean

top
of

battery
and
terminals

with
a
solution
of
bakin

soda
and

Pennissible

value

Frigid
climates
Over
1

22

Tropical
climates

lOver
1
18

Other
climates

lOver
1
20

CHECKING
AND

ADJUSTING

IGN

ITIONTIM
iNG

AD
IUSTING
IGNITION

TIMING

I
Check

spark
plugs
and
distributor

breaker

points
for
condition

2

Thoroughly
remove
dirt
and
dust

from

timing
mark
on
crank

pulley
and

timing
indicator
on
front
cover

3
Warin

up
engine
sufficiently

4
Imtalla
timing
light
on
No
I

cylinder
spark
plug
wire
and
install
a

tachometer

5
Set

idling
spero
toapproxintate
y

750

rpm

6
Check

ignition
timing
with
a

timing
light
if
it
is

specified
value

If

necessary

adjust
it

as
follows

1
Loosen
setscrew
until
distribu

tor

can
be
moved

by
hand

2

Adjust
ignition

timing
to

speci

fied
value

3
0
Lock
distributor
setscrew

ai1d

make

sure
that

timing
is
correc
Engine
Tune

up

water

Rinse
off
and

dry
with
com

pressed
air

Top
of

battery
must
be

clean
to

prevent
current

leakage
be

tween
terminals
and
from

positive

terminal

to
hold
down

clamp

In
addition
to
current

leakage
pro

longed
accumulation
of
acid

and
dirt

o
n

top
If
l

l
ry
may

ca
u
iCbli
t

rj
I
g

of
the
material

covering
connector

straps
and
corrosion
of

straps
After

tightening
terminals
coat
them
with

petrolatum
vaseline
to

protect
them

from
corrosion

Full

charge

value

at
200C
680F

1
28

1
23

1
26

oo

I

ET169

Fig
ET

13

Checking
ignition
timing

Ignition

timing

Manual
transmission

120
750

rpm

Non
California
models

100
750

rpIll

California
models

Automatic
transmission

120

650

rpin

in

0

position

ET
10
CHECKING

ANb

REPLACING

SPARK

PLUG

I

Remove

and
clean

plugs
in

a
sand

blast
cleaner

2

Inspect
insulator
for
cracks
or

chips

3

Check
both
center
and

ground

electrodes

If

they
are

excessively
worn
re

place
with
new

spark

plugs

4

Spark
plug
gap

Breaker

points

type

0

8
to
0
9

mm

0
031
to
0
035
in

Transistor

ignition

type

1
0

to
1
1

mm

0
039
to
0
043
in

Tightening

torq

1
5
to
2
0

kg
m

11
to
A4
ft
lb

Fig
ET
14

Checking

spark
plug
point

gap

CHECK
I
G

DISTRIBUTOR

OPERATING

PARTS

AND

1

lrI9N

WIRING

BREAKER

POINTS

Non

California
models

Check
the
distributor
breaker

points
for
abnonnal

pitting
and
wear

Replace
if

necessary
Make
sure

they

are

properly

aligned
and
that

point

dwell

and

gap
are
correct
Clean
and

apply
distributor

grease
to
the
carn

lobes

Note
00

not

apply
grease
excessively

Point

gap

0

45
to
0
55
mm

Om8
to
0
022

in

Owell

angle

49
to
55

degrees

EE322

Fig
ET
15
Checking
diltribu
tor

point

gap

AIR
GAP

California
models

For

inspection
procedures
and

reference
data
refer

to
the

topic
Air

Gap
in

Section
EE

page
EE
29

DISTRIBUTOR

Check

centrifugal
advance
unit
for

loose
connection
or

improper
opera

tion
If
it
is
not

operating
properly

the

problem
may
be

due
to
a

sticky

spring
or
excessively
worn

parts
This

operation
needs
a
distributor
tester

For

inspection
procedures
and

ref

erence
data
refer
to

relative

topic

under
Distributor
in

Section
EE

If
vacuum
advance
mechanism
does

not

properly
operate
check
for
the

following
items
and

correct
the

prob

lem

as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
connection
If

necessary

retighten
or

replace

2

Check
vacuum
diaphragm
for
air

leak

If

necessary
replace
diaphragm

3

Inspect
breaker

plate
for
smooth

movement

If

plate
does
not
move
smoothly

this
condition
could
be
due

to

sticky

steel
balls
If

necessary
replace
break

er
plate
assembly

IGNITION
WIRING

Use

an
ohmmeter
to
check
resist

ance
of

secondary
cables
Disconnect

cables
from

spark

plugs
and
install
a

proper
adapter
between
cable
and

spark
plug
Remove

distributor
cap

and
secondary
cables
as
an

assembly

Do
not
remove
cables
from

cap

Check
resistance
of
one
cable
at
a

time

Connect
ohmmeter
between

spark

plug
adapter
and

corresponding
elec

trade
inside
cap
If
resistance
is
more

than
30
000
ohms
remove
cable
from
Engine
Tune

up

cap
and
check
cable
resistance

only
If

resistance
is
still
more
than

30
000

ohms

replace
cable

assembly

EF125

Checking
high
tension

cable

CHECKING

DISTRIBUTOR
CAP

ROTOR
AND

CONDENSER

Note
This

operation
is

to
be

per

formed
while

checking
distributor

points
Inspect
distributor

cap
for

cracks
and

flashover

External
surfaces
of
all

parts
of

secondary
system
must
be
cleaned
to

reduce

possibility
of

voltage
loss
All

wires
should
be
removed
from
distrib

utor

cap
and
coil
so
that
terminals

can

be

inspected
and
cleaned
Burned
or

corroded
terminals
indicate
that
wires

are
not

fully
seated
which

causes

arcing
between
end
of
wire
and
ter

minal
When

replacing
wires
in

ter

minai
be

sure
they
are

fully
seated

before

pushing
rubber

nipple
down

over
tower
Check
distributor
rotor
for

damage
and
distributor
cap
for

cracks

CONDENSER

I
Clean

outlet
of
condenser
lead

wire

and
check
for

loose
setscrew

Retighten
if

necessary

2
Check

condenser
with
a
con

denser
tester

Condenser

capacity

0
20
to
0
24

IF

Micro
Farad

Condenser
insulation
resistance

5Mn

Mega
ohms

ADJUSTING

CARBURETOR
IDLE

RPM
AND
MIXTURE

RATIO

Cautions

a
On
automatic
transmission

equip

T
11
ped
models
check
should
be

per

fonned
in

the
D

position

Be
sure

to

engage
parking
brake
and

to
lock
both
front
and
rear

wheels

with
wheel
chocks

b

Keep
your
foot
down
on
the
brake

pedal
while

depressing
the
accelera

tor

pedal
Otherwise
vehicle

surges

forward

dangerously

Notes

a
Do
not

attempt
to
screw
the
idle

adjusting
sc
ew
down

completely

Doing
so
could
cause

damage
to

tip

which
in

turn
will
tend
to
cause

malfunctions

b

If
idle
limiter

cap
obstructs

proper

adjustment
remove
it

To
install
idle
limiter

cap
refer
to

Idle
Limiter

Cap

c

After
idle

adjustment
has

been

made
shift
the
lever
to
the
N
or

P

position
for
automatic
trans

mission

d
When

measuring
CO

percentage
in

sert

probe
into

tail

pipe
more
than

40
em
15
7
in

CO
idle

adjustment
with

CD
meter

Idle
mixture

adjustment
requires

the
use
of
a

CO
meter

especially
for

California
models
When

preparing
to

adjust
idle
mixture
it
is

essential
to

have
the
meter

thoroughly
warmed

up

and
calibrated

I
Check
carburetor

pipes
for

proper

connection

2

Warm

up
engine
until
water
tem

perature
indicator

points
to
the
middle

of

gauge
The

procedure
to
warm

up

engine
is
not

specifically
recom

mended
Either

driving
vehicle
or

oper

ating
engine
at

no
load
will
be

good

3
Make

sure
that
water
tempera

ture
indicator

points
to

the
middle

Further

keep
engine
running
at
about

2

000

rpm
for
about
5
minutes
with

out

applying
load
to

engine
in

order
to

stabilize

engine
condition
Engine

hood
should
be

open

4
Run

engine
for

about
10
minutes

at
idling
speed
During
this
10

minutes

proceeq
as
described
i

steps

5

to
9
below

5
Remove
air
hose
between
3

way

connector
5

way
connector
for
Cali

fornia
models
and
air

check
valve
as

shown
in

Figure
ET
17

Plug
the

dis

r

connected

hose

to

prevent
dust

from

entering

To

air
check

valve

Fig
ET
17
Disconnect
air
hose

from
ojr
check
valve

6

Race

engine
1
500
to
2
000

rpm

two
or
three
times
under
no

load
then

run

engine
for
one
minute

at

idling

speed

7

Adjust
throttle

adjusting
screw

until

engine
is
at

specified
speed

Engine
speed

Manual
transmission

750

rpm

Automatic
transmission

in
D

position

650

rpm

8
Check

ignition

timing
If

neces

sary

adjust
it
to

specifications

This

operation
need
not
be
carried

out

at
1
600

Ian

1
000

miles
service

Ignition
timing

Manual

transmission

120
750

rpm
Non

California

100
750

rpm
California

Automatic
transmission

in
D

position

120

650

rpm

9
At
about
10

minutes
after

engine

is

run
at

idling
speed

adjust
idle

adjusting
screw
so

that
CO

percentage

is
at

specified
level

CO

percentage

Manual

transmission

2
t
I
at

750

rpm

Automatic
transmission

in
D

position

2
t
I
at
650

rpm

10

Repeat

procedures
as
described

in

steps
6
7

and
9
above
so
that
CO

percentage
is
at

specified
level
Check

ing
idle
CO
in

step
9
can
be
carried
out

right
after

step
7

11

Race

engine
I
500
to
2
000

rpm
two

or
three
times

under
no
load

and
make
sure
that

specified
CO

per

centage
is
obtained
Engine
Tune

up

12
Connect
air

hose
to
air
check

valve

If

engine
speed
increases

readjust
it

to
the

specified
speed
with

throttle

adjusting
screw

CO
Idle

adjustment
without

CO
meter

If
CO
meter
is
not

available
the

following
procedures

may
be
used

I

Check
carburetor

pipes
for

proper

connection

2
Wann

up
engine
until
water

tern

perature
indicator

points
to
the
middle

of

gauge
The

procedure
to

warm

up

engine
is

not

specifically
recom

mended
Either

driving
vehicle

or

oper

ating
engine
at
no
load
will
be

good

3

Make
sure
that
water

temperature

indicator

points
to
the
middle
Further

keep

engine

running
at
about

2
000

rpm
for

about
5
minutes

without

applying
load
to

engine
in
order
to

stabilize

engine
condition

Engine

hood
should

be

open

4

Run

engine
for
about

10
minutes

at

idling
peed

During
this
10

minutes

proceed
as
described
in

steps

5

to
9
below

5

Remove
air
hose
between
3

way

connector
5

way
connector
for
Cali

fornia

modeis
and
air

check
valve

shown
in

Figure
ET
17

Plug
the

dis

connected
hose

to

prevent
dust
from

entering

6
Race

engine
1

500
to
2

000

rpm

two
or
three

times
under

no
load
then

run

engine
for

one
minute

at

idling

speed

7

Adjust
throttle

adjusting
screw
so

that

engine
speeds
are
as
indicated

below

Engine
speed

Manual
transmission

815

rpm

Automatic
transmission

in
D

position

670

rpm

8
Check

ignition
timing
if
neces

sary
adjust
it

to
the

value

required
by

specifications
This

operation
need

not

be
carried
out
at
1

600
Ian

1
000

miles
service

9
At
about

10
minutes
after

engine

is
run
at

idling
speed
adjust
idle

adjusting
screw
until
maximum

rpm
is

obtained

ET
12
10

Repeat
procedures
as
described

in

steps
6
7
and

9
above

until

engine

speed
at
best
idle
mixture
is

815

rpm

for
manual
transmission

models
and

670

rpm
for
automatic

transmission

models
in
D

position

Adjustment

in

step
9

can
be

carried
out

right
after

step
7

II

Turn
the
idle

adjusting
screw

clockwise
until

engine
speed
drops
off

below

specified
rpm

Engine

speed
drops
off

Manual
transmission

60
to
70

rpm

Automatic
transmission

in
D

position

15
to
25

rpm

12
Connect
air
hose

to
air
check

valve

If

engine
speed
increases

readjust
it

to
the

specified
speed
with

throttle

adjusting
screw

IDLE
LIMITER
CAP

Do
not
remove
this
idle

limiter

cap

unless

necessary
If
this
unit

is

removed
it
is

necessary
to

readjust
it

at
the
time
of

installation
To

adjust

proceed
as
follows

1

After

adjusting
throttle
or

idle

speed
adjusting
screws
check
to
be

Sure

that
the
amount
of

CO
con

tained
in

exhaust

gases
meets
the

established
standard

2

Install
idle
limiter

cap
in

position

making
sure
that
the

adjusting
screw

further
turn
1

8
rotation
in
the

CO
RICH
direction

Carburetor

stopper

3lSo
ldle

limiter

cap

T

ET031

Fig
ET
18

Setting
idle
limiter

cap

CHECKING

CARBURETOR

RETURN

SPRING

Check
throttle

return

spring
for

cracks

squarene
s
or

defonnation

if

necessary

replace
with
a
new
one

Fresh
air

Blow

by
gas

CHECKING

VENTILATION

HOSE

1

Check
hoses
and
hose
connec

tions
for
leaks

2
Disconnect
all
hoses
and
blow

them
out
with

compressed
air

If

any
hose

cannot
be
free
of

obstructions

replace

Ensure
that
flame

arrester
is

surely

inserted
in
the

hose
between
air

cleaner
and
rocker
cover

CHECKING
EXHAUST

MANIFOLD
HEAT

CONTROL
VALVE

Run

engine
and

visually
check

counterweight
to
see

if
it

operates

properly

I
For

some
time

after

starting

engine
in
cold

weather

counterweight

turns

counterclockwise
until

it
comes

into

contact
with

stopper

pin
installed

to

exhaust
manifold

Counterweight

gradually
moves

down

clockwise

as

engine
warms

up

and
ambient

temperature
goes
higher

around
exhaust
manifold

2

When

engine
speed
is

increased

discharge
pressure
of
exhaust

gases

causes

counterweight
to
move
down

ward

clockwise
Engine
Tune

up

CoOl
1

Oil
level

gauge

2

8affle

pia
te

3

Flame
arrester

4

Filter

5
P
C
V
valve

6

Steel
net

7

Baffle

plate

1fiI

o

EC716

Fig
ET
20
Crankcaae
emi
ion

control8
tem

3
When
heat

control
valve
is
in
the

full

open

position
counterweight

moves
further

clockwise

exceeding
the

position
described

in
1

1
above
and

stops

again
coming
into

contact
with

stopper

pin

ct

t

C

EC245

1

Counterwe
ht

2

Stopper
pin

3

Heat
control

valve

Fig
ET
21
Cold

operation
of
counte

weigh
t

EC246

1

Counterweight

2

Stopper
pin

3
Heat
control
valve

Fig
ET

22
Hot

operation
of
counter

weight

ET

14
2
With

engine

stopped
visually

check

E
F
E

system
for
the

following

items

I
Thermostat

spring
for
dismount

ing

2

Stopper

pin
for

bend
and
count

er

weight
stop
position
for

dislocation

3

Check
heat
control

valve
for

malfunction

due
to
break
of

key
that

locates

counterweight
to
valve

shaft

4

Check
axial
clearance

between

heat
control

valve
and
exhaust
mani

fold
Correct
clearance
is
0
7
to
1
5

mm
0
028
to

0
059
in

5

Check
welded

portion
of

heat

control

valve
and

valve
shaft
for

any

indication
of
crack

or

flaking

6
Rotate
heat

control
valve

shaft

with
a

fmger
and

check
for

binding

between

shaft
and

bushing
in

closing

and

opening
operation
of
heat
control

valve
If

any
binding
is
felt
in

rotating

operation
move
valve
shaft
in

the

rotation
direction
several
times
If

this

operation
does
not

correct

binding

condition
it
is
due

to
seizure
between

shaft
and

bushing
and

exhaust
mani

fold

should
be

replaced
as
an
assem

bly

CHECKING
SPARK

TIMING
CONTROL

SYSTEM

This

system
is

installed
on
non

California
automatic
transmission

models

SPARK
DELAY
VALVE

Automatic
transmission

models

only

This
valve

delays
vacuum

spark

advance

during
rapid
acceleration
it

also
cuts

off
the

vacuwn

spark
advance

imme

iately
upon
deceleration

The

valve
is

designed
for
one

way
opera

tion

and
consists

of
a
one

way
umbrel

la
valve
and
sintered
steel
fluidic

restrictor

Engine
Tune

up

EC284

When

installing
this
valve

ensure

that
it

properly
oriented
This
valve

should
be

replaced
periodically
Refer

to
Maintenance
Schedule

I

To

distribut0
From

carburetor

Yl
r

EC278
l

Fig
ET
24
Operation
of
spark
delay

value

I

I

Carburetor
side

Distributor
side

rJmlL
lr

EC346

Fig
ET
25
Checking

spark
delay
value
Distributor
side

Brown

lOne
way
umbrella
valve

2
Sintered
metal
disc

Fig
ET
23
Spark
delay
valve

INSPECTION

I
Remove

spark
delay
valve

2
Blow
air

through
port
on

carbure

tor
side
then

through
the

other
port

on
distributor
side

Spark
delay
valve

is
in

good
condition
if
when

finger
is

placed
over

port
on
distrib
side

ajr
flow
resistance
is

greater
than
that

on
the
other

side
See

Figure
ET
25

3
If
a
considerable
air
flow
resist

ance
is
felt
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

EC279

Fig
ET
26

Checking
spark
delay
ualue

Note
Be

careful
to

avoid

entry
of
oil

or
dirt
into
valve

ET
15
CHECKING

AUTOMATIC

TEMPERATURE

CONTROL
AIR

CLEANER

1
Air
cleener
element

Viscous

paper
type
air
cleaner
ele

ment
does
not

require
any
cleaning

opera
tion

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
Schedule

2
Hot

elr
control
system

In
warm
wealher
it
is
difficult
to

find
ou

t
malfunction
of
hot
air
control

system
In
cold
weather
however

malfunction
of
air
control
valve
d

e
to

disconnection
or
deterioration
of
vacu

um
hose
between
intake
manifold
and

vacuum
motor
and
insufficient
dura

bili

ty
of
air

con
trol
valve
will
cause

insufficient
automatic
control

opera

tion
for
intake
air
and
result
in

engine

disorder

including

I

Stall
or
hesitation
of

engine

opera

tion

2

Increase
in
fuel

consumption

3
Lack
of

power

These

phenomena
reveal
malfunc

tionof
hot
air
control

system
If
these

phenomena
should
occur
check
hot

air
control

system
as
described
in
the

following
before

carrying
ou

t

inspec

tion
of
carburetor

2
1
Vacuum
hoses

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

1

Check
that
vacuum
hoses
are
se

curely
connected
in

correct

position

2
Check
each
hose
for
cracks
or

distortion
hose

clip
for
condition

Note
Vacuum
hose

position
R
R

side
of
Nissan
mark
on
the

top
of

sensor
for

intake
manifold
L
R

side
of
the

mark
is
for
vacuum

rootor

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

control
valve
is
in

correct

position

EF213

Fig
ET
27

Impecting
lJalv

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
Engine
Tune

up

EF217

Fig
ET
28

lmpecting
value

position

Correct

pC6ition
of
air

control
valve

is
the

reverse
of

paragraph
I
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
is

open
posi

tion
as
descnbed
in

paragraph
2

above

pinch
vacuum
hose
with

fingers

and
cut
of
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
sensor

Check

temperature
sensor
for
func

tion

by
proceeding
as
follows
Be

sure

to

keep
engine
cold
before

starting

test

1
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
1
under

hood
air

inlet
is

closed
and
hot
air

inlet
is

open

ET

16
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

to

facilitate
smooth

opera
tion
of
air

con
trol
valve

If
the
above

test
reveals

any
prob

lem
in
the

operation
of
air
control

valve

carry
out
the

following
test

4

Remove
air
cleaner
cover
Set

temperature
sensing
element

of
ther

mistor
or
thermometer
to

a
position

where

tempera
ture
around
sensor
can

be
measured
In
this
case
fix

wiring
of

thermistor
or
thermometer
on
the
bot

tom
surface
of
air

cleaner
with
adhe

sive

tape
in

such
a
manner
that

the
set

position
of

temperature
sensing
ele

ment
will
not

be
affected

by
airflow

Then
install
air
cleaner
cover

EF221

Fig
ET
29
Checking
temperotur
e

ensor

5

Carry
out
test
as
described
in

steps
I
2

and
3
above
When
air

control
valve

begins
to

open
to
under

hood
air
inlet
side
severa
minutes

after

engine

starting
read
the
indica

tion
of
thermistor
or

thermometer
If

reading
falls
within
the

working
tern

perature
range
of

temperature
sensor

the
sensor
is

normaL
If

reading
ex

ceeds
the

range

replace
the
sensor

with
new
one

Note
Before

replacing
temperature

sensor
check
idle

compensator
as

described
in
Section
EF

page
EF
8

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