1977 DATSUN PICK-UP Service Manual

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

The
non
California

type
operates
as

follows

secondary
air
is
sucked

through
the
air

pump
air

cleaner
into

the
air

pump
driven

by
the
crank

pulley
It
is

then

discharged
through

the

check

valve
to

the
air

gallety
where

it
is

distributed
to
each

exhaust

porL

The

secondary
air
is
then

injected

from
the

injection
nozzle

into
the

exhaust

port
near
the
exhaust
valve

The
air
relief
valve

opens
only
when

the

discharge
pressure
of
the
air

pump

surpasses
the

spring
force
of
the
air

relief
valve

during
high
speed
opera

tion

When
the
air

relief
valve

opens

the

secondary
air
is

discharged
in
to

the

carburetor
air
c1eaner

The
anti

backfire
valve

opens
when

the
intake
manifold
vacuum

reaches
a

predetermined
value

during
decelera

tion

and

permits
fresh
air
to
now
into

the
intake

manifold
from
the
air

cleaner

f

I

Jl

rn
l

I
Air

pump

2
Air

pump
air

cleaner

3

Emergency
air

relief
valve

4

Air

relief
valve
riu

Qj

j

I

@
Emission
Control

System

To
intake

manifold

The
California

type
includes
in

addition
to
the

components
of
the

non
California

type
an

air

control

valve

and
an

emergency
air
relief
valve

The
air

control
valve

opens
when

the
sum
of
the
air

pump

discharge

pressure
and

the
intake

manifold
vacu

um

applied
to
the

diaphmgm
reaches
a

predetermined
level
and

discharges

the

secondary
air
into
the

air
cleaner

When
the

pressure
becomes
low
the

valve
doses

with
the

spring
force
of

3

5
Air

cleaner

6

Check
valve

7

Air

gallery

pipe

8

Carburetor

EC

13
To

intake

manifold

Air

diSlcharge
to

intake
manifold

Secondary

air

EC297

Fig
EC

23

Operation

of
A

B
lve

the
air
control
valve

and

stops
dis

charging
the

secondary
air

F
igure

EC

25

When
the

intake
manifold

vacuum

applied
to
the

diaphragm
reaches

a

predetermined
level
E
A

R
valve

operates
to

discharge
the

secondary
air

into
the

atmosphere
When
the

pres

sure

becomes

high
the
valve

closes

by

spring
tension
of
E
A
R
valve

and

stops

discharging
the

secondary
air

fl

t

9
Air
control
valve

10

Injection
nozzle

II
Exha
l
t

manifold

12
Anti
backfire
valve

EC780

Fig
EC
24

California

type
A
I

S

9
From
air

pump

l

h
1

Not
actuated

REMOVAL
AND

INSTALLATION

Air
p
mp
sir
cleaner

Remove
air
hose

then
detach
air

cleaner

from

hoodledge
Air
cleaner

element
and
Ii
r
deancr
lower

body
are

built
into
a
unit
construction

Replace

air
cleaner
clcl

nen
and

lower

body
as

an

assembly

J

J

tt
c

t
o

J

EC
323

Fig
EC
26
Replacing
oir
cleaner

element

Air

pum

Remove
air
hoses

from
air

pump

2
Loosen
air

pump
adjusting
bar

mounting
bolts
and
air

pump
mount

ing
bolts
then

remove
air

pump
drive

bell

3
Remove
air

pump
pulley

4
Remove
air

pump
from
bracket

Air
control
valve

California
models

l
Disconnect

air
hoses
and
a
vacu

um
hose
from
air
control
valve

2
Remove
air
con
trol
valve
from

bracket

E
A

R
valve
California
modela

Remove
vacuum

pipe
and
air

hose

and
dismount
E

A
R
valve
Emission
Control

System

o

jJ
To

Intake
mamfold

rF
vacuum

r

To
air

cleaner

From
air

pump

EC781

Fig
EC
27
Locotion

of
E
A
R
wive

Antl
backflravalve

Disconnect
air
hose
and
vacuum

hose
from
anti
backfire
valve

Check
valve

Disconnect
hose
and
remove
check

valve
from
air

gallery
pipe

Air

ganery
pIpe
andinJactlon

nozzles

It
is

very
difficult
to
remove
the
air

gallery
from
the
exhaust
manifold

without

bending
the

pipe
which
could

result
in
fractures
or

leakage
There

fore

removal
of

the
air

gallery
pipe

and

injection
nozzles
should
be
under

taken

only
when

they
are

damaged

I
Lubricate
around
the

connecting

portion
of
air

injection
nozzle
and
air

gallery
with

engine
oil

2
Hold
air

injection
nozzle

hexagon

head
with
a

wrench
and
unfasten
flare

screw

connecting
ait

gallery
to

injec

tion
nozzle
Remove
air

gallery

EC
14
To
intake

manifold

vaCUl
lm

r

Y

4
9
Gf

T

I
To

air
cleaner

I

Actuated

EC299

Fig
EC
25

Operation
of
air
control
value

Notes

a

Apply
engine
011
to
rews
several

times
during
above

work

b
Be
atreful
not
to

damage
other

parts

3
Unfasten
air

injection
nozzle

from

cylinder
head

applying
engine
oil

to
screwed

portion
several
times

4

Check
air

gallery
and
nozzle
for

fractures
or
leakage
Clean
air

injection

nozzle
with
a
wire
brush

5

At
time
of
installation
hold
air

injection
nozzle

hexagon
head
with

a

wrench
and

tighten
air

gallery
flange

screw
to
a

torque
of
5
0
to
5
9

kg
m

36
to
43
ft
lb

6
Check

cylinder
head
air

injection

nozzle
and
air

gallery
for
leaks
with

engine
running

Air

pump
relief
vslve

Loosen
carburetor
air
cleaner

mounting
sc
ews
and

remove
air

pump
relief
valve

InstallatIon

Install
in
the

reverse
order
of
reo

moval

DISASSEMBLY
AND

ASSEMBLY

Disassembly
of
air
pump

1
Remove
four

pulley
drive
bolts

and
remove

pulley
from
hub

2

Secure
air

pump
drive
hub
in

a

vise

as
shewn
in

Figure
EC

28
and

remove
four
end
cover
bolts

Note
Never

clamp
on
the

aluminum

housing

EC302

Fig
EC
28

Removing
cover

3
Remove
end
cover

by
carefully

tapping
around
dowel

pin
with

a

plas

tic
mallet
and
lift

up
straight

4
Put
match
marks
0
on
rotor

ring
and
side
of
rotor
to
ensure
correct

reassembly
and
remove
four
screws

that
retain
rotor

ring
to

rotor

using
a

Hexagonal
Wrench
STl9810000

Notes

a

Generally
match
marks
are
indi

cated
on

both
rotor

ring
and
rotor

by
the
manufacturer

ECll1

Fig
EC
29

Removing
rotor
ring
Emission
Control

System

b
Discard
screws
which
were
re

moved

Always
use
new
ones
when

installing

5

Remove
vane
from
rotor

EC661

Fig
EC

30
Remooing
vanes

6
Remove
four
carbon

shoes
and

two
shoe

springs
from
rotor

using

needle
nose

pliers
or
tweezers

Note
Carbon
shoe
A

0
039
in
wider
than

confuse
them
is
I
mm

B
Do
not

If

replacement
of
front

bearing
is

necessary

proceed
as
follows

7
Remove
air

pump
drive
hub
with

standard

puller

EC
15
8
Remove
four
screws

securing

front

bearing
cover
in

place
and
de

tach

bearing
cover

9

Support
the
rear
end
face
of
air

pump
housing
with
Rotor

Adapter

STl9890000
Drive
rotor
out

by
push

ing
rotor
shaft
with

Bearing
Pressing

Tool
STl9940000

STl9940000

1Ul

STl9890000

I
I

EC303

Fig
EC
32

Removing
rotor

shaft

10

Support
the
front
end
face
of

housing
with

Bearing
Adapter

STl9930000
Attach

Bearing
Driver

STl9910000
to
front

bearing
on
the

inside
of
air

pump
housing
iuid

press

out

ll

I
I

STl9910000

i

L

9930000

J

1

EC304

Fig
EC
33

Remouing
ball

bearing

11

Keep
disassembled

parts
in

rder

Emission
Control

System

Assembl
of
air

pump

I
Front

bearing

Support
the
rear
end
face
of
air

pump
housing
with
RotOL

Adapter

STl9890000
Press
front

bearing
into

place
with
a

press
arid

Bearing
Ptessing

Tool
STl9940000

I
I

STl9940000

X8
03

Fig
EC
35

Pressing
ball

bearing
L

2

Bearing
cover

Torque
four

bearing
cover

securing

bolts
to
0

1
to

0
2

kg
m
0
7

to
1
4

ft
lb

3
Rotor
shaft

Support
the
inward
bottom
of

rotor
with
Rotor
Stand
STl9920000

Press
rotor
into

place
with
a

press

and

Bearing
Drive
STl9910000
until

the

stepped
portion
of
rotor
shaft

touches
front

bearing
inner
race
C
1

ST
19910000

ST19920000

I
EC3Q7

Fig
EC
36

Pressing
rotor
shaft

Notes

a
Be

sure
to
drive
front

bearing
inner

race
in

b
After
rotor
is
installed
in

place

ensure
that
the
rotor
end
is

pos

tioned
below
the
end
face
of
air

pump
housing

Position
of
rotor

end
below
air

pump

housing

0
050

to
0
150
mm

0
0020
to
0
0059
in

4

Air

pump
drive
hub

Support
the
inward
bottom
of

rotor
with
Rotor
Stand
STl9920000

EC
16
EC562

Fig
EC
34

Componenbr
of
two
vane

type

Press
drive
hub
into

place
with
a

pre
and

Bearing
Driver
STI
991
0000

until
the
end

face
of
drive
hub
touches

froE
c
ing
in
n
c

j

STt9910000

STl9920000
e

r

EC308

Fig
EC
37

Pressing
air

pump
drive

hub

5

Carbon
shoe

1
Place
air

pump
drive
hub
in
a

vise

2

Clean
carbon
dust
etc
from

shoe

grooves

3

Align
rotor
with

housing
proper

ly
Refer
to

Figure
EC
38
Then
insert

carbon
shoes
into

place
noting
their

directions

EC540

Fig
EC

38
Install

carbon
shoe

Notes

a

Carbon
shoe
A

is
1
mm
0
039

in

wider
than
B

Do
not
confuse

them

b
If
carbon

shoes
are

exposed
beyond

the
rotor

end
face
remove

carbon

shoes
and
clean
shoe

grooves

Reassemble

carbon
shoes

6

Vane

1
Pack
vane

bearing
with

high

melting
point
grease
MIL
G
3545
A

Esso

ANDOK260
or

equivalent
and

insert

dummy
shaft
into
the

Vane

bearing

STl9900000

EC563

Fig
EC
39
Vane

assembly

2
Install
vane
in

place
on
rotor

using

Dummy
Shaft

STl9900000
as
a

guide

Note
The
vanes

may
require
6
to
16

km
4

to
10

miles
wear
in

running

time
In
the

event
a

slight
squeaking

still

remains
drive
the
car
about
64

to
80
km
h
40
to
50

MPH
In

most

cases
6
to
16

km
4
to

10

miles
will
be
sufficient

for
wear
in

7

Shoe

spring

Place
shoe

springs
in

deeper
groove

of
shoe
Emission
Control

System

i

111

11

EC123

Fig
EC
40

Installing
shoe

spring

Note
When

instaUing
a
shoe

spring

make
sure
that
the
outward
bend

ing
side

faces
in

shoe
and
that
both

ends

of

spring
face
in
the

wall
of

shoe

groove

Be
sure

to

push

spring
in

so
that

spring
end
face
is
flush
with

rotor

8
Rotor

ring

Install

rotor

ring
by
correctly
align

ing
the
rear
end

face
of
rotor

with
the

0
mark

in
rotor

ring
and

tighten

four

screws
to

the

specified

torque

with

Hexagonal
Wrench
ST19810000

Tightening
torque

0
5

to
0
7

kg
m

3
6
to
5
1

ft
lb

5T19810000

EC124

Fig
EC
41

In8talling
rotor

ring

9
Removal
of

dummy
shaft

Carefuny
withdraw

dummy
shaft

from

vane

10

Vane
shaft

Pack

rear

bearing
with

high

melting

point

grease
MIL
G
3545

A

so

ANDOK
260
or

equivalent

Apply
thin

coating
of

grease
to
vane

shaft
and
rotor

ring
and
insert

vane

shaft

into
its

bearing

EC
17
Notes

a

Do
not

apply
an
u
tue
stress

to

vane
shaft
when

inserting

b

If
two
vanes
are
dislocated
when

inserting
vane
shaft

correctly

align

vanes

by
inserting
dummy
shaft

Then
draw
out

dummy
shaft
and

insert
vane

shaft

c
When

wear
occurs
on
vane
shaft

or

when

replacement
of

rear

bearing
is

necessary
replace
rear
cover
as

sembly

Jl
End
cover

Position
end

cover
in

place

Snugly

tighten
the
bolt
close
to

the
dowel

Then

tighten
four
bolts

to
the

speci

fied

torque

Tightening
torque

0

7
to
0

9

kg
m

5

1

t06
5
ft4b

EC302

Fig
EC
42
Insla
ling
end

cover

12

Pulley

Tighten
four

pulley
securing
bolts

to
the

specified
torque

Tightening
torque

0
7
to
0

9

kg
m

5

lt06
5
ft

lb

INSPECTION

Air

InJection
system
hosas

Check
air

system
hoses
for
loose

connections
cracks
or
deterioration

Retighten
or

replace
if

necessary

Air

ystem
manifold

Check
air

gaUery

pipe
and

injection

nozzles
for
loose
connections
and

cracks

Retighten
or

replace
if
neces

sary

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

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
air
is

felt

E
A
R
valve
is
normaL

5

If
E
A
R

valve
does
not
function

properly
at
above

steps

replace
E
A
R

valve

To

air

pump

I

ET267

Fig
EC
46

Cheeking
E
A
R
volve

Anti
backfire

valve
A
valve

Warm

up
engine

thoroughly

2
Disconnect
hose

from
air

cleaner

and

place
a

finger
near
the
outlet

3
Run

engine
at
about
3

000

rpin

under
no
load
then

quickly
cetum
it

to

idling
If

you
feel
a

pull
or
suction

force
on

your
finger
the
anti

backfire

valve

is

functioning
normally
If
no

suction
is
felt

replace
the

anti
backflre

valve

Fig
EC
47
Checking
anti

backfire
valve
1
t
D

I
Y1

VI
I

ID
4

JO
0

2
E

C
R
control
valve

3

E
C
R

passage

4
Intake
manifold

5

Thermal
vacuum
valve

6
E
C
R
tube

7
Exhaust

manifold
Emission
Control

System

tXHAUST
GAS

RECIRCULATION

CONTROL
SYSTEM

E

G
R

DESCRIPTION

In
the

exhaust

gas
recirculation

system
a

part
of
the
exhaust

gas
is

returned
to
the

combustion
chamber

to
lower
the

spark
flame

temperature

during
combustion
This
results
in
a

reduction

of
the

nitrogen
oxide

con

ten
t

in
the
exhaust

gas

The
exhaust

gas
recirculation

sys

tem
consists

of
an
E
G
R

passage

E
G
R

con
trol
valve
thermal

vacuum

volve
E
G
R

tube
and
hose
A

warn

@
I
ing
system
which
indicates
when
the

E
G
R

control

system
must
be

in

spected
is
also
installed
in

all
620

models

except
those
bound
for

Coli

fornia
and
Canada

When
the
E

G
R
con
trol

valve
is

open
some
of

the
exhaust

gas
is

led

from
the

exhaust
manifold
to
the

E
G

R
chamber

through
the
E
G

R

passage
The
exhaust

gas
is

then
con

trolled
in

quantity
by
the
E
G
R

valve

and
is
introduced
into
the

intake

manifold

Open
c1ose

operation
of
the
E
G
R

control
valve

is
controlled

by
the

thermal

vacuum
valve
which

opera
tes

on

carburetor
vacuum
and

engine
cool

ant

temperature

EC349

Fig
EC
4
Exhaust
Gas
Recirculation

system
E
G
R

E
G
R

system
operating
Thermal
Intake
manifold
E
G
R

Remarks

E
G
R

water

temperature
oC
OF
vacuum
valve
vacuum
control
valve

Below
570C
135OF
Close
Close

Non
california

Above

MfT
models

only
Idling

Not
Above
57

to
630C

Open
70

mmHg
Close

actuated
135
to
145OF
76

inHg

California
models

Below

and
N
on
Fullthrollle

f

alifomia

AfT

Above
57
to
6
oC
models

Actua
ted

Open
Above
50

mmHg

Open

135
to
145OF
1
97

inHg

EC
19
OPERATION

Operation
of
E
G
R

system
is
as

shown
below