check engine light DATSUN PICK-UP 1977 Service Manual

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

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

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

Engine
Tune

up

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition
Probable
cause

CANNOT
CRANK

ENGINE
OR

SLOW

CRANKING
Improper
grade
oil

Discharged
battery

Faulty
battery

Loose

fan
belt

Malfunction
in

charge
system

Wiring
connection
loose
in

starting
circuit

Faulty
ignition
switch

Faulty
starler
motor

Trouble

shooting
procedure
on

starting
circuit

Switch
on
the

starting
motor
with

light
ON

When

light
goes
off
or
dims

considerably

a
Check

battery

b
Check
connection
and

cable

c
Check
starter
motor

When

light
stays
bright
Corrective
action

Replace
with

proper
grade
oiL

Charge

battery

Replace

Adjust

Inspect

Correct

Repair
or

replace

Repair
or

replace

a
Check

wiring
connection
between

battery
and
starter

motor

b
Check

ignition
switch

c
Check
starter
motor

ENGINE
WILL
CRANK

NORMALLY
BUT

WILL
NOT

START

In
this
case
the

following
trouble
causes

may
exist

but
in

many
cases

ignition

system
or
fuel

system
is
in

trouble

Ignition

system
in
trouble

Fuel

system
in
troubk

Valve
mechanism
does
not
work

properly

Low

compussion

Trouble

shooting
procedure

Check

spark
plug
firstly
by

following
procedure

Disconnect

high
tension
cable
from
one

spark
plug
and
hold
it

about
10
mm
0
39
in

from
the

engine
metal

part
and
crank

the

engine

Good

spark
occurs

Check

spark
plug

b
Check

ignition
timing

c
Check
fuel

system

d
Check

cylinder
compression

Check
the
current
f10
in

primary
circuit

Very
high
current

Inspect
primary
circuit
for
short

Check
breaker

poiIit
operation

except
tran

sistor

ignition
system
No

spark
occurs

ET

27

2
Turn
crankshaft
until
No
I

pis

ton
is
at
T
D
C

on
its

compression

stroke

3
Make

sure
thai
camshaft
sprock

et
location
notch
and

plate
oblong

groove
are

aligned
at
their
correct

positions

4

When

installing
cylinder
head

make
sure

that
all
valves
are

apart

from
heads
of

pistons

5
Do

not
rotate
crankshaft
and

camshaft

separately
or
valves
will
hit

heads
of

pistons

6

Temporarily
tighten
two
bolts

CD

V
sJiown

in
Fig

re
EM
96

Tightening
torque

2

kg
m

14
ft
b

15
Install
crankshaft

sprocket
and

oil

pump
drive

gear
and
fit
oil

thrower

Note
Make
sure
lhat

maling
marks
of

crankshaft

sprocket
face
10
Cront

16
Install

timing
chain

Noles

a
Make

sure
that
crankshaft
and
cam

shaft

keys
point

upwards

Fuel

pump
drive

earn

2
Chain

guide

3

Chain
tensioner

4

Crank

sprocket

5
earn

sprocket

6
Chai

guide

EM439

b
Set

timing
chain

by

OOgning
its

mating
marks
with
those
oC
crank

shaft

sprocket
and
camshaft

sprock

et
at
the

right
hand
side
There
are

forty
four
chain
links
between
two

mating
marks
of

timing
chain

c
NO
2
hole
is

Cactory

adjusted

When
chain
stretches

excessively

adjust
camshaft

sprocket
at

No
3

hole

d
Use
a

set
of

timing
marks
and

location
hole

numbers
Engine
Mechanical

17
Install
chain
slack
side

guide
to

cylinder
block

18
Install
chain
tensioner

Note

Adjust
protrusion
oC
chain
ten

sioner

spindle
to
0
mm
0
in

Fig
EM
98

lmtalling
chain
tensioner

19
Press
new
oil
seal
in

front
cover

Notes

a
Front

cover
oil
seal
should
be
reo

placed
when
Cront
cover
is

disas

sembled

b
BeCore

pressing
oil
seal
into
Cront

cover

give
coating
of

engine
oil
to

periphery
of
oil
seal

c
This
oil
seal
is
a
threaded
seal

type

which
has

improved
sealing
charac

teristics
Do
not

apply
grease
to

sealing

lip

20
Install
front
cover
with

gasket
in

place

1

Timing
mark

2

Timing
mark

EM545

Fig
EM

99

Installing
fronl
COlHlr

Notes

a

Apply
sealant
to
Cront
cover
and

corners
oC

upper
section
of

cylinder

block

as
shown

in

Figure
EM
78

EM
24
b
Install
Cront
cover
with
head

gasket

in

place

c

Check

height
diCCerence
between

cylinder
block

upper
Cace
and
Cront

cover

upper
Cace
DifCerence
must

be
less
than
0
15

mm
0
0059
in

d

Note
that
difCerent

types
oC
bolts

are
used

e

Before

installing
front
cover
on

cylinder
block

apply

coating
oC

engine
oil
10

sealing
lip
of
oil

seal

EMS11

Fig
EM
lOD
Front

cover
bolts

Tightening
torque

Size
M8
0
315
in

1
0
to
1
3

kg
m
7

2
to
9
4

ft
lb

Size
M6
0
236
in

0
4
to
0
6

kg
m
2

9
to
4

3
ft
lb

21
Install
crankshaft

pulley
and

water

pump
assembly
then
set
No
I

piston
at
ToO
C
on
its

compression

stloke

Crankshaft

pulley
nu
I

tightening
torque

12
to
16

kg
m
B7
to
116
ft

lb

EM546

Fig
EM
Ol

lnstallingcran
haft

pulley
and

water

pump

22

Finally

tighten
head

bolts
to

the

specified
torque
in

three

steps

according
to
the

lightening
sequence

shown
in

Figure
EM
96

Note
thai
Iwo

types
of
bolts

are

used

30
Install
heatshieid

plate
on
mani

fold
assembly

31
Install
air

gallery
pipe
on
ex

haust
manifold

32
Install
manifold

gasket
and

manifold

assembly
on

cylinder
head

Tightening
torque

1
2to
1

6kg
m

8
7
to
11
6
ft
lb

33

Install
blow

by
gas

pipe
on

cyl

inder

block
and
tighten
with
rear

engine
slinger

34
Install
thermostat
housing

gas

ket
thermostat

housing
and

thermo

stat

35
Install
thermal
vacuum
valve
on

thermostat

housing
Before

installing

apply
a

liquid
packing
slightly
to
the

threads

36

Install
FJ

C
D
bracket
on

cylin

der

head

37

Install
E
G
R

passage
and

E
G
R
valve
on
intake
manifold

38
Connect
E

G
R
tube
to
E

G
R

tube
and

exhaust
manifold

39
Install
check
valve

on
air

gallery

pipe

40
Install
air
cleaner
bracket
on

intake
manifold

41
Install
air
control
valve
on
air

cleaner
bracket
California
models

42
Install
vacuum
and
fuel
tubes

combined
on

cylinder
head

43
Install
distributor

assembly

44
Install

heatshield
plate

joint

seat

and
carburetor

Carbure10r
tightening

torque

0
5

to
1

0

kg
m
3

6
to
7
2

ft
lb

Note
When

instalUng
joint
seat
be

sure
to

put
the
duct
into

primary

hole
in

intake
manifold

S

J

Heatshield

plate
4
Joint

seat

2

Primary
hole
5

Secondary
hole

3
Duct

EM534

Fig
EM
I06

Installing
carburetor

joint
seat
Engine
Mechanical

45
Install
dash

pot
bracket
and

dash

pot
to
intake

manifold

46
Connect
all
air

vacuum
and
fuel

hoses

and
then

secure
with

clamps

I
Cylinder
block
to

P
C
V
valve

hose

2
A
B

valve
to
E

G
R

passage
vac

uum
hose

3
A
B

valve
to
E
G

R

passage
air

hose

4
Vacuum
tube
to
carburetor
vac

uum
hoses

5
Fuel
ube

to
carburetor
fuel

hose

6
Fuel
tube
to
fuel

pump
fuelhose

7
Distributor
to
vacuum
switch
or

spark
delay
valve
vacuum
hose

8
Air
control
valve
vacuum
hose

9
Check
valve

to
air

control
valve

hose

10
Thermal
vacuum
valve
to

E
G
R
valve
vacuum
hose

I
I
Thermal
vacuum
valve
to

vacuum
tube
hose

47
Install
carburetor
air

cleaner
on

carburetor
and
then
connect
air

and

vacuum
hoses

as
follows

I

Air
cleaner
to

exhaust
manifold

hot

air
duct

2

Air
c1eaner
to
air

pump
hose

3

Air
cleaner
to
rocker

cover
hose

4

Air
cleaner

to
air
control
valve

hose

5

6

48
Install

spark
plugs
in

place

49
Connect
all
distributor

high
ten

sion

cables
to

spark
plugs

50
Install
air

pump
drive
belt
cool

er

compressor
and
idler

pulley

51

Install
left

engine
mounting

bracket

52
Install
clutch

assembly
on

flywheel
with
Clutch

Aligning
Bar

KV30100200
Air

cleaner
to
A
B

valve

hose

Other
vacuum
hoses

Tightening
torque

1
2
to
2
2

kg
m

8

7
to
15
9

ft
lb

EM
26
I

I

KV30100200

EM440

Fig
EM
I07
In

talling
clutch
embly

53

Using
an
overhead
hoist
and

lifting
cable
hoist

engine
away
from

engine
stand
and

then
down
onto

engine
carrier

54
Install

right
engine
mounting

bracket
oil
filter
oil

pressure
switch

oil

level

gauge
and
water

drain

plug

When

installing
oil

filter
fasten
it
to

cylinder
block

by
hand

Note
Do
not

overtighten

flit
or
oil

leakage
may
occur

55
Install
alternator
bracket

adjust

ing
bar
alternator

cooling
fan

and

belt

56

Adjust
the
deflection
of
drive

belts
when

thumb

pressure
is

applied

midway
between

pulleys
A

pressed

force
is
above
10

kg
22
0
lb

Deflection

of
drive
belts

8
to
12
mm

0
315

to
0
472
in

EM613

Fig
EM
lOB
Fan
belt
tension

57
Fill

engine
oil

up
to

specified

level

ENGINE
LUBRICATION
SYSTEM

2
Fill

pump
housing
with

engine

oil

then

align
punch
mark
of

spindle

with
hole
in
oil

pump
as
shown
in

Figure
EL

3

Punch
mark

EL009

Fig
EL
3

Aligning
punch
mark

and
oil
hole

3

Using
a
new

gasket
install
oil

pump
and
drive

spindle
assembly
so

that
the

projection
on
its

top
is

located
in
II
25
a
m

position
at

this
time
the
smaller
bow

shape
will

be

placed
toward
the
front
as
shown

in

Figure
EL
4

JI

I
c

J

V

Front
J

@
9@

tr
i

d

L
It
I

I
EL010

Fig
EL

4
Setting
drive

pindle

o

EL011

Fig
EL

5
Imtalling
oil

pump

Ascertain
whether

or
not

the
en

gagement
is
in
order

by
checking
the

top
of

spindle
through
distributor
fit

ting
hole

4

Tighten
bolts

securing
oil

pump

to
front
cover
Disassembly

and

assembly

I
Remove

pump
cover

attaching

bolts

pump
cover
and
cover

gasket

and
slide
out

pump
rotors

2
Remove

regulator

cap
regulator

valve
and

spring

3

Install

pressure
regulator
valve

and
related

parts

4
Install

outer
rotor
inner
rotor

and
shaft
in

pump
body
and
do
not

turn
cover

gasket
up

CD

El012

r

@
@

CD@

1

Oil

pump
body

2
Inner
rotor
and
shaft

3
Outer
rotor

4
Oil

pump
cover

5

Regulator
valve
6

Regulator
spring

7
Washer

8

Regulator
cap

9
Cover

gasket

Fig
EL

6
Oil

pump

Inspection

Wash
all

parts
in

cleaning
solvent

and

dry
with

compressed
ir

I

Inspect
pump
body
and
cover

for
cracks
or
excessive

wear

2

Inspect
pump
rotors
for
excessive

Rotor
side
clearance

rotor
to
bottom

cover
Olm
in

Rotor

tip
clearance

@
mOl
in

Outer
rotor
to

body

clearance

D
mm

inl

EL

3
wear

3

Check
inner

rotor
shaft
for

looseness
in

pump
body

4

Inspect
regulator
valve
for

wear

or

scoring

5

Check

regulator
spring
to
see

that

it
is
not

worn
on
its

side
or

collapsed

6

Using
a

feeler

gauge
check

tip

clearance
2
and

outer
rotor
to

body

clearance
I

shown
in

Figure
EL
7

1
Outer
rotor
to

body
clearance

2

Tip
clearance

3

Gap
between

rotor
and

straight
edge

4

Gap
between

body
and

straight
edg
e

Fig
EL
7

Checking
rotor
clearance

7

Place
a

straight
edge
across
the

face
of

pump
and

depress
it

slightly
as

shown
in

Figure
EL
7

Check

gap
4

between

body
and

straight
edge
or

gap

3
between

rotor
and

straight
edge

The

gap
should
be
0
03
to
0

06

mm

0
0012
to
0
0024
in
then

rotor
side

clearance
rotor
to
bottom

cover
clearance
with

gasket
should

satisfy
the

specifications

Standard
Wear

limit

0
04

to
0

08

0
0016
to

0
0032
0
20
0
0079

Less

than

0
12
0

0047
0

20
0
0079

0

15
to
0
21

0
0059

to
0
0083
0
5

0
0197

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

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

Air

pump

I

Operate
engine
until
it
reaches

normal

operating
temperature

2

Inspect
all
hose
hose
connec

tions
and
air

gallery
for
leaks
and

correct
if

necessary
before

checking

air

injection

pump

3
Check
air

injection
pump
belt

tension
and

adjust
to

specifications
if

necessary

4

Disconnect
air
supply
hose
at

check
valve

5

Disconnect
vacuum
hose
from
the

air

control
valve
California

type

only

6
Insert

open
pipe
end
of
Air

Pump

Test

Gauge

Adapter
STl9870000
in

air

supply
hose

Clamp
hose

securely

to

adapter
to

prevent
it
from

blowing

out
Position

adapter
and
test

lli
uge
so

that
air
blast
emitted

through
drilled

pipe
plug
will
be

harmlessly

dissipated

7
Install

a
tachometer

on

engine

With

engine
speed
at
2

600

rpm
ob

serve

pressure
produced
at

test

gauge

Air

pressure
should
be
100

mmHg

3

94

inHg
or
more

8
If
air

pressure
does

not
meet

above

specifications
proceed
as
fol

lows

I

Repeat
2
and
3

above

2
Disconnect
air

supply
hose
at

anti
backfire
valve

Plug
air

hose

open

ing
and

screw
with
a

clamp
Repeat

pressure
test

3
With

engine

speed
at
1

500

rpm

close
hole
of
test

gauge
with

finger
If

a

leaking
sound

is
heard
or

leaking
air

is
felt

by
ftnger
at
relief

valve
relief

valve
is

malfunctioning
Relief
valve

should

be

replaced
or

repaired

4

If
air

injection
pump
does
not

meet
minimum

requirement
of

pres

sure
test
it

should
be

replaced

Control
valve

The

following
procedures
are
reo

commended
for

checking
and
or
as

certaining
that
the
various

components

of
the
exhaust
emission
con
Irol

system

are

operating

properly

The

engine
and
all

components

must

be
at
normal

operating
tempera

tures
when
the

tests
are

performed

Prior

to

performing
any
extensive

diag

nosis

of
the
exhaust
control

system
it
Emission
Control

System

must
be
determined
that

the

engine
as

a
unit
is

functioning
properly

Check
valva

Warm

up
engine
thoroughly

2

Disconnect
hose

leading
to
check

valve
from
air

hose
COJUlector

3

Check
hose

opening
for

any
indi

cation
of
exhaust

gas
leaks
Ifleaks
are

detected

replace
check
valve

4

Race
the

engine

lightly
at
about

2
000

cpm
and
then

return
it
to

idling
VisuaDy
check
the
hose
for

any

indication
of
exhaust

gas
leaks
before

the

engine
returns
to

idling

speed
If

leaks
are
detected

replace
check
valve

EC310

Fig
EC
43

Checking
check
valve

Air

pump
raIle
valve

After

completing
inspection
of
air

pump
check
air

pump
relief
valve
in

the

following
steps

J

Disconnect
hoses

leading
to
check

valve
and
air
control

valve
from
air

hose

connector
and

install
blind

cap

to
the

connector

2
With

engine
running
at

about

3
000

rpm
under
no
load

place
your

hand
on
the
air

outlet
of
air

pump

relief
valve
to
check
for

discharged
air

If
no
air

is
felt

replace
the
air

pump

relief

valve

EC311

Fig
EC
44

Checking
air

pump
relief

valve

EC

18
Air
control
valve

C
U
ornla
models

I
Warm

up
engine
thoroughly

2
Before

checking
air
control

valve

check
all
hoses

for
loose
connection

leaks
etc
and

repair
or

correct
if

necessary

3

With

engine
idling
disconnect
the

outlet
side
hose
of

the
air
control

valve
and

place

your
hand
on
the
air

hose
outlet
to
check
for
air
If
no
air
is

felt

replace
the
air

control
valve

4

Pull
vacuum
hose
off
from
air

con
trol
valve
If

discharge
of
air
from

air
hose

stops
the
air
con
trol
valve

is

normaL
If

discharge
is
still
felt

replace

the
valve

Plug
up
the

removed

vacuum
hose

to

stabilize

engine
running

EC312

Fig
EC
45

Checking
air
control
valve

Emarsancy
air
rella
valve

E
A
R
Valve

lCalHornla
models

L
Warm

up
engine
thoroughly

2

Before

checking
air

control
valve

check
all
hoses
for
loose
connection

leaks
etc
and

repair
or
correct
if

necessary

3
Race

engine
approximately

2
000

rpm
under
no
load
Place

your

hand
on
air

outlet
of
E

A
R
valve
to

check
for

presence
of

discharged
air
If

no
air

is
felt

E
A

R
valve
is
normal

4

Disconnect
vacuum
hose
from

B
A

R
valve
as
shown
in

Figure
EC

46