clock DATSUN PICK-UP 1977 Service Manual

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

r

ADJUSTMENT
OF
SET

PRESSURE
OF
BOOST

CONTROLLED
DECELERATION

DEVICE
B

C
D
D

Generally
it
is

unnecessary
to

ad

just
the
B
C
D

D
however
if
it

should

become

necessary
to

adjust
it

the

procedure
is

as
follows

Prepare
the

foUowlnB
tools

I

Tachometer
to
measure
the
en

gine

speed
while

idling
and
a
screw

driver

2
A

vacuum

gauge
connecting
pipe

Note
A

qui
k

response
type
boost

gauge
such
as
Bourdon
s

type
is

recommended
a

mercury

type

manometer
should
not
be
used

To

properly
set
the

B

C
D
D

set

pressure

proceed
as

follows

I

Remove
the

harness

of
solenoid

valve

TO
D
D

solenrod

VT

FJ

1
B
C
D
D

solenni

valve
harness

J

ri

y

EF262

F
g
ET

32
Removing
harneS5

of

solenoid

valve

2
Connect
rubber
hose
between

vacuum

gauge
and
intake
manifold
as

shown

Fig
ET

33

Connecting
vacuum

gauge

3

Warm

up
the

engine
until
it
is

heated
to

operating

temperature

Then

adjust
the

engine
at
normal
Engine
Tune

up

idling
setting
Refer
to
the

item

Idling
Adjustment
in

page
ET
II

Idling

engine
speed

Manual
transmission

750

rpm

Automatic
transmission

in

D

position

650

rpm

4

Run
the

engine
under
no

load

Increase

engine
speed
to
3
000
to

3
500

rpm
then

quickly
close
throttle

valve

5
At

the
time
the

manifold
vacuum

pressure
increases

abruptly
to
600

mmHg
23
62

inHg
or
above

and

then

gradually
decreases
to
the
level

set
at

idling

6
Check
that
the

B
C
D
D
set

pres

sure
is
within
the

specified
pressure

Specified

pressure
0
m
sea
level

and

760

mmHg
30

inHg
atmos

pheric
pressure

Manual
transmission

510
to

550

mmHg

20
1
to
21
7

inHg

Automatic
transmission

490
to
530

mmHg

19
3
to
20

9

inHg

Note

When

checking
the
set

pressure

of
B
C
D
D

find
the

specified
set

pressure
in

Figure
IT

36
from
the

atmospheric
pressure
and
altitutde

of
the

given
location

For

example
if
a

manual
transmis

sion

model
vehicle
is

located
at

an

altitude

of
1
000
m

3
280
ft
the

specified
set

preSsure
for
B

C
D
D

445

mmHg
17
5

inHg

7

If
it
is

higher
than
the
set

level

turn
the

adjusting
screw

counter

clockwise

or
nut

clockwise
until

correct

adjustment
is

made

Non
California

models

Adjusting
screw

type

California

models

Adjusting
nut

type

Note
When

adjusting
B
C
D
D

for

California

models
turn

adjusting

nut
in

or
out

with
lock

spring
in

place

Always
set

lock

spring

prop

erly
to

prevent

changes
in
set

pres

sure

ET

18
Non
california

models

1

Adjusting
screw

2

Cover
e

ET037

California
models

r

1

Adjusting
nut

2

Lock

spring

EC692

Fig
ET
34

Adjusting
Bet

pressure

8

Race
the

engine
and
check
for

adjustment

9
If
it
is

lower
than
the
set
level

turn
the

adjusting
screw
or

nut
until

correct

adjustment
is
made

10
Race
the

engine
and
check
for

adjustment

If

engine
speed
cannot

be
decreased

to

idling
when

checking
B
C
D
D
set

pressure
proceed
as
follows

When
the

engine
speed
does

not
fall

to

idling
speed
it

is

necessary
to

reduce
the

negative
idling

pressure
of

the
manifold
to
lower

than
the
set

pressure
of
the
B

C
D

D
The

engine

speed
will
not

drop
to

idling
speed

when
the

negative
idling
pressure
is

higher
than
the

set

pressure
of

the

B

C
D
D

In

this
case
the

engine
must
be

labored

by
I
road
test
or
2
chassis

dynamometer
or
3

by
raising
up
rear

suspension
member
on
a

stand
accel

erating
the
vehicle
to
64
to
80

krn
h

40

to
50
MPH
in

top
gear
manual

transmission
or
in
D

position
auto

matic
transmission

and
then

releasing

the
accelerator

pedal
and

letting
the

vehicle

decelerate
After

doing
this

check

whether
the
B

C
D
D
set

pres

sure
is
at
the

predetermined
value

or

not

DESCRIPTION

COOLANT
LEVEL

DRAINING
AND
FLUSHING
THE

COOLING
SYSTEM

WATER
PUMP

REMOVAL
AND

INSTALLATION

DISASSEMBLY

INSPECTION
AND
ADJUSTMENT

TORQUE
COUPLING

REMOVAL
AND

INSTALLATION

DESCRIPTION

The

cooling
system
is
of
the
con

ventional

pressure
type
A

centrifugal

pump
installed
on

the

timing
chain

cover
serves
to
circulate
the

coolant

The

pressure
type
radiator
filler

cap

installed
on
the
radiator

operates
the

cooling
system
at

higher
than

atmos

pheric
pressure

The

higher

pressure
raises
the

boiling
point
of
the

coolant
and
in
Cooling
System

COOLING
SYSTEM

CONTENTS

CO
2

CO
2
OISASSEMBL
Y

INSPECTION

TEM
COUPLlNG

INSPECTION

THERMOSTAT

REMOVAL
AND

INSTALLATION

INSPECTION

RADIATOR

REMOVAL
AND

INSTALLATION

INSPECTION
CO
2

CO
2

CO
3

CO
3

CO
3

CO
3

CO
4

creases
the

cooling
efficiency
of

the

radiator

When
the

thermostat
is
closed

the

coolant
remains
in
the

cylinder
head

and

block
for
swift

warming
up
of
the

engine
After
it
reaches

normal

oper

ating

temperature
the

coolant
circu

lates

through
the
radiator

The

cooling
fan

drive
is
of
a

coupling
type

COOLANT

LEVEL

The

coolant
level
should

be
check

ed

and
maintained
at
SO

mm
1
97
in

below

the

upper
face
of
filler

neck

when
the

engine
is
cold
C0055

Fig
CO

I
Cooling

ry
lem

Caution

To
avoid
serious

personal

injury
never
remove
I3diator

cap

quickly
when

engine
is
hot
Sudden

release
of

cooling

system
pressure
is

very

dangerous

CO
2
CO
4

CO
4

CO
4

CO
5

CO
5

CO
5

CO
5

CO
5

CO
5

CO
6

If
it
is

necessary
to
remove
radiator

cap
wben
radiator
is
hot
turn

cap

slowly
counterclockwise

to
the
r

step
After
all

pressure
in
the
cool

ing
system
is
released
tom

cap

passing
the

stop
and
remove
it

DRAINING

AND
FLUSHING

THE

COOLING

SYSTEM

To
drain

the

cooling
system
re

move
radiator

cap
release
drain

cock

at
the
bottom

of
radiator
and
drain

plug
on

the

right
side
of

cylinder

block
If
the

heater

system
is
installed

set
heater

temperature
control
valve
to

open
position
After
the

coolant
is

drained

completely
close
drain

cock

and

plug
and
refill
the

system
with

clean
soft
water

WATER
PUMP

The

water

pump
cooling
fan

pulley

and

torque

coupling
are

a
unitized

construction

The
water

pump
is
of

a

centrifugal

type
which

is
mounted
on
the

engine

front
cover

rpm
two
or
three

iimes
under
no

load

and
make

sure
that

specified
CO

per

centage
is
obtained

12

Connect
air

hose
to
air

check

valve

If

engine
speed
increases

readjust
it

to

the

specified
speed
with
throttle

adjustingsqew

CO
idle
edJustment
without

CO
meter

If
CO

meter
is
not

available
the

following
procedures
may
be
used

L
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

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

speed

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
models
and
air

check
valve

shown
in

Figure
EF

35

Plug
the
dis

connected
hose

19
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
km
1

000

miles
service

9
At
about

10
minutes
after

engine
Engine
Fuel

is

run
at

idling

speed
adjust
idle

adjusting
screw
until
maximum

rpm
is

obtained

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

11
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

cep

Do
not

remove
this
idle

limiter

cap

unless

necessary
If
this
unit
is
re

moved
it
must

be

readjusted
at
lime

of

installation
To

adjust
proceed
as

follows

I

After

adjusting
throttle

or
idle

speed

adjusting
screw
check

to
be
sure

that
the
amount

of
CO
contained
in

exhaust

gases
meets

the
established

standard

2

Install
idle
limiter

cap
in

position

making
sure
that
the

adjusting
screw

can
rotate
another
1
8

turn
in

the

CO

RICH
direction

Carbo
to

per

CO

rich

450
lIS
rotation

t
CO
lean

J

SQ

dl
lim

ET031
1
e
Iter

cap

Fig
EF

36

Setting
idle
limiter

cap

FUEL

LEVEL

1

Turn

down
float

chamber
to
al

low
float
to

come
into

contact
with

needle

valve
and
measure

Hu
shown

EF
22
in

Figu
re
EF

37

When
H

is

approximalely
7

mill
0
283

in

lOp
float

position
is

correct

The

top
float

position
can

be
ad

justed
by

bending
float

seat

Upon
completion
of
the

adjust

ment

check
fuel
level
wi
th

attached

level

gauge

p

j

i

I

it

I
Float
seat

2

Float

3

Float
chamber

4
Needle
valve
t
I
IIf

ET032

Fig
EF
37

Adjusting
float
level

2

Adjust
bottom
float

position
so

that
clearance
h
between

float
seat

and
needle

valve
stemis
I

3
to
L
7

mm

0
051
to
0
067
in
when

Iloat
is

fully

rals
n

Jloa
t

goppe

q
re

3

After

adjustments
in

steps
I
and

2

above
have
been
made

make
sure

that

when
fuel
is

delivered
to
the
float

chamber

the
fuel
level
is
maintained

within
the

range
of23
mm

0
91
in

as

shown
in

FigureEF
38

H
23

mm
0
91
in

EF260

Fig
EF
38

Checking
ruellevel

FAST
IDLE

I
With

carburetor

assembly
reo

moved
from

engine
measure
throttle

valve

clearance
A

with
a

wire

gauge

placing
the

upper
side

of
fast

idling

screw
on
the
first

step
on
fast

idling

cam

Non
California
models

Adjusting
screw

Counterclockwise

California
models

Adjusting
nut

Clockwise

Non
California

models

1
2

1

Adjusting
screw
s

2

Cover
e

California
models

t

1

Adjusting
nut

2

Lock

spring

EC692

Fig
EF
54

Adjusting
et

pressure

vacuum

gauge

Intake

gjl

11
Road
test
CD

ET037
Engine
Fuel

Note
When

adjusting
B

C
D
D
for

California
models
turn

adjusting

nut
in

or
out
with
lock

spring
in

place
Always
set
lock

spring

prop

erly
to

prevent
changes
in
set

pres

sure

8
Race

the

engine
and

check
for

adjustment

9
If
it

is
lower
than
the
set
level

turn
the

adjusting
screw

or
nut

until

correct

adjustment
is

made

10
Race
the

engine
and

check
for

adjustment

If

engine
speed
cannot
be
decreased

to

idling
when

checking
B
C

D
D

set

pressure
proceed
as
follows

When

the

engine
speed
does
not

fall

to

idling

speed
it
is

necessary
to

reduce
the

negative
idling

pressure
of

the

manifold
to
lower
than
the

set

pressure
of
the
B
C
D
O
The

engine

speed
will

not

drop
to

idling
speed

when
the

negative
idling

pressure
is

higher
Ihan
the

sel

pressure
of
the

B
C
O

O

acuum

gauge

Intakema
M

V
9iI

21
Chas
amomeler
In
this

case
the

engine
must

be

labored

by
I
road

test
or

2
chassis

dynamometer
or
3

by
raising
up
rear

suspension
member
on

a
stand

accel

erating
the
vehicle
to
64
to

80

km
h

40
10
50

MPH
in

top

gear
manual

transmission
or
in

0

position
auto

matic

transmission
and
then

releasing

the

accelerator

pedal
and

letting
the

vehicle
decelerate

After

doing
this

check
whether

the
B
C
O
D
set

pres

sure
is
at

the

predetermined
value
or

not

Vacuum

gauge

n
i
Y

3
Raise

up
rear
axle

housing
by
stand

ET133

Fig
EF
55

Testing
sel

pre
ure

of
the
B
C
D

D

EF
27

Emission
Control

System

EARLY

FUEL

EVAPORATIVE

SYSTEM
E

F
E

DESCRIPTION
spring
and

counterweight
which
are

assembled
on
the

valve
shaft

projecting

to
the

rear
outside
of
the
exhaust

manifold
The

counterweight
is
se

cured
to
the
valve
shaft
with

key
bolt

and

snap
ring
EC
4
A

control
valve
welded
to

the

valve
shaft
is

wtalled
on
the

exhaust

manifold

through

bushing
This
con

trol

valve
is

called
Heat

control

valve
The
heat
control

valve
is

ac

luated

by
the

coil

spring
thermostat
Construction
of
the

early
fuel

evap

orative

system
is

shown
in

Figure

r
I

1

@

rW

9

Sc
w

10
Thennostat

spring

11

Coil
spriiig

12
Control
valve
shaft

13
Heat
control

valve

14

Bushing

15

Cap

16
Exhaust
manifold
1
Intake
manifold

2
Stove

gasket

ManifoktstOve

4
Heat
shield

plate

5

Snap
ring

6

Counterweight

7

Key

g

Stoppel
pin

EC532

Fig
EC
4
Early
Fuel

Evaporutive
tem
E
F
E

The

early
fuel

evaporative
system
is

provided
with
a
chamber
above

a

manifold
stove
moonted
between
the

intake
and
exhaust

manifolds

During

engine

warming
up
air
fuel
mixture
in

the

carburetor
is

heated
in
the
cham

bet

by
exhaust

gases
This
results
in

improved
evaporation
of

atomized
fuel

droplets
in
the
mixture
and
in

smaller

content
of

hydrocarbons
He
in
the

exhaust

gas
especially
in

cold
weather

operation

The
exhaust

gas
flow
from
the

engine
is

obstructed

by
the
heat
con

trol

valve
in
the

exhaust
manifold
and
is

changed
in

direction
as
shown

by

the
solid

lines
in

Figure
EC
4
The

exhaust

gas
heats
the
manifold
stove

Open
close

operation
of
the

heat

control
valve
is
controlled

by
the

counterweight
and
thermostat

spring

which
is
sensitive
to
the

ambient
tem

perature
around
the

exhaust
manifold
With
this
condition
the

heat
control

valve
is
in

the

fully
closed

position

obstructing
the
flow
of

exhaust

gas
As

engine
tempera
lure

goes
up
and

the

ambient

temperature
becomes

high

enough
to
actuate
the
thermostat

spring
the

counterweight
begins
to

rotate
clockwise
and

again
comes
into

con

tact
with

the

stopper
pin
With
this

condition
the

heat
control
valve
is
in

the
full

open
position
and
exhaust

gas

passes
through
the
exhaust
manifold
as

shown

by
the
dotted

lines
in

Figure

EC
4
without
heati

ng
the
manifold

stove
OPERATION

The

counterweight
rotates
counter

clockwise
and

stops
at

the

stopper
pin

mounted
on
the
exhaust

manifold

while

the

engine
temperature
is
low

EC
6

REMOVAL
AND
INSTAUATION
Emission
Control

System

EC533

Remove

snap
ring
D
and
lock
bolt

@
and
the

following
parts
can
be

detached
from
heat
control
valve

shaft

Key
00

Counterweight
@

TherI
lostat
spring
CID

Coil

spring

@

Note
As

previously
descnoed
heat

control
valv

1
is

welded
to
valve

shaft

@
at
exhaust
manifold
and

cannot
be

disassembled

To
install

reverse
the
removal

pro

cedure

INSPECTION

I
Run

engine
and

visually
check

counterweight
to

see
if
it

operates

properly

1
For
some
time
after

starling

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

3

When
heat

con
trol
valve
is
in
the

full

open
position
coun

terweight

moves
further
clockwise
exceeding
the
1

Snap
ring

2

Lock
bolt

3

Key

4

Counterweight

5
Thermostat

spring

6
Coil
spring

7

Heat
control
valve

8
Valve
shaft

9
Stove
gasket

10
Manifold
stove

11
Heat
shield

plate

Fig
EC
5

Exploded
view
of
E
F
E
stem

position
described
in
1

1
above

and

stops
again
coming
into
con
tact
with

stopper
pin

j

EC246

1

Counterweight

2
S

topper
pin

3
Heat
control
valve

Fig
EC
6

Operation
of
counterweight

when

engine
is
cold

EC246

1

Counterweight

2

Stopper
pin

3
Heat
control

valve

Fig
EC
7

Operation
of
counterw
ight

when
ngine
is
hot

EC
7
2

With

engine
stopped
visually

check
E
F
E

system
for
the

following

items

1
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

by
a
finger
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

DESCRIPTION

The

spark
tirnin
control

system

serves
to
control
the
distributor
vacu

um
advance
under

varying
travelling

conditions
so
as
to
reduce
HC
and

NOx
emissions

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

immediately
upon
deceleration
The

valve
is

designed
for
one

way
opera

tion
and
consists
of
a
one

way
umbrel

la
valve
and
sinlered
steel
fluidic

restrictor

OPERATION

When
the

ignition
switch
turned

fully
clockwise
to
the
START

posi

tion

battery
current
flows

through

series

and
shunt

coils
of
the

solenoid

magnetizing
the

solenoid

The

plunger
is

pulled
into
the
solenoid

so
that

it

operates
the
shift
lever

to

move
the

drive

pinion
into

the

flywheel
ring
gear
Then
the

solenoid

switch

contacts
close
after
the

drive

pinion
is

partially
engaged
with
the

ring
gear

Closing
of
the

solenoid
switch

contacts
c
uses
the

motor
to
crank
the

engine
and
also
cut
out
the
series

coil
of

the
solenoid
the

magnetic

pull

of
the
shunt

coil

being
sufficient

to

hold
the

pinion
in

mesh
after
the

shifting
has
been

performed

After
the

engine
starts

running
the

driver

releases
the

ignition
key
and
it

automatically
returns
to
the

ON

posi

tion

The
torsion

spring
then

actuates
the

shift
lever

to

pull
the

pinion
which

allows
the

solenoid
swi

tch
contacts
to

open

Consequently
the

starting
mo

tor

stops
Engine
Electrical

System

I

I

Ring
gear

2

Shift
lever

guide

3
Armature

4

Battery

5
Field
coil

6

Stationary
contact

7
Monble

contactor

More

positive

meshing
and

demeshing
of

the

pinion
and
the

ring

gear
teeth
are

secured

by
means

of
the

overrunning
clutch
The

overruIUling

clutch

employs
a
shift

lever
to
slide

the

pinion

along
the

armature
shaft

EE
6
F

l
cp

o

r

1

I
I

W

m

EE274

8
Shunt
coil

9

Plunger

10

Ignition
switch

11

Series
coil

12
Torsion

spring

13

Shift
lever

14

Pinion

Fig
EE

7
Starting
motor
circuit

into
or

out
of

mesh
with
the

ring

gear

teeth
The

overrunning
clutch
is

de

signed
to
transmit

driving

torque
from

the
motor
armature

to
the

ring
gear

but

prevent
the

armature
from
over

running
after
the

engine
has
started

ADJUSTMENT

VOLTAGE
REGULATOR

When
regulating
voltage
as
meas

ured
above
deviates

from
rated
value

adjust
regulator
in

accordance
with
the

following
instructions

I

Inspect
contact
surface
and
if

rough
lightly
polish
with
fine

emery

paper
1
500
or
600

2
Measure
each

gap
and

adjust
if

necessary
Adjust
core

gap
and

point

gap
in
that
order
No

adjustment
is

required
for

yoke

gap

3

Adjusting
core

gap

Loosen
screw
4
mm
0
157
in

diameter
which
is
used
to
secure

contact
set
on

yoke
and
move
contact

upward
or
downward

properly
See

Figure
EE
49

Core

gap

0
6

to
1
0
mm

0
024
to
0
039
in

EE398

I
Contact

set

2
ThicknesJ
gauge

3
4

mm
0
157
in
dia
screw

4

Crosshead
Jcrewdriver

Fig
EE
49

AdjUJJting
core
gap
Engine
Electrical

System

4

Adjusting

point
gap

Loosen
screw
3

mm
O
lIS
in

diameter
used
to
secure

upper
con

tact
and
move

upper
contact

upward

or
downward
as

necessary
See

Figure

EE
50

Point

gap

035

to
0
45
mm

0
014

to
O
D1S
in

EE399

I
Thicknes

gauge

2
3
mm

0
118
in
dia

screw

3
Cro
Sshelld

screwdriver

4

Upper
contact

Fig
EE
50
Adjusting

point
gap

5

Adjusting
voltage

Adjust
regulating
voltage
as

follows

Loosen
lock
nut

securing

adjusting

screw
Turn
this
screw
clockwise
to

increase
or
counterclockwise
to

decrease

regulating
voltage
See

Figure
EE
5

J
CD

EE400

I

Wrench

2

Crosshead
screwdriver

3

Adjusting
screw

4
l
ock

nut

Fig
EE
51

AdjUJJting
rel
Ulating
voltage

CHARGE
RELAY

Nonna

relay
operating
voltage
is
S

to
IOV
as
measured
at
alternator
A

tenninal

Relay
itself
however

oper

ates
at
4
to
5V

Use
a
DC
voltmeter
and
set

up
a

circuit

as
shown
in

Figure
EE
52

Adjust
charge

relay
in

the
same

manner
as
that
for

voltage
regulator

L

Connect

positive
tenninal
of
voltmeter
to

regulator
lead
connector
N
tenninal
with

negative
terminal

grounded

2
Start

engine
and

keep
it

idle

3
Take
voltmeter

reading

o
Volt

I
Check
for

continuity
be

tween
terminals
of
re

gulator
and
alternator

2
Alternator
circuit

inopera

tive
if

continuity
exists
Below
5
2
Volts

Charge
warning
lamp
on

I
Check
fan
belt
tension

2
If
correct
remove

regulator

and

adjust
as

necessary
Over
5

2
Volts

Charge
warning
lamp
on

Charge
relay
coil
or
contact

points
out
of
order

Replace
regulator

Over
5
2
Volts

Charge
warning
lamp
off

Charge
relay
assembly
is
in

good
condition

EE
23