1977 DATSUN PICK-UP check engine light

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

j

EC231

Thermal

vacuum
valva
o

o

m
Emission

Control

System

0

o

o

o

l

l
@

The
thermal
vacuum
valve

is

mounted
in

the

engine
thermostat

housing
It

detects

engine
coolan
t

tem

perature
by
means
of
a

built
in

bi

metal
and

opensor
closes
the

vacuum

passage
in
the

thermal
vacuum

valve

mt

li

t

00
t

EC232

Fig
EC
54
Thennal

vacuum
valve
To
E

G
R
control
valve

From
carburetor

1

Spring

2
Bi
metal

3

O

ring

E
G
R

warning

system

The

E
G
R

warning
system
install
1

Diaphragm
spring

2

Diaphragm

3
Valve
shaft

4

Valve

5
Valve

Seat

6
Valve
cham
ber

Fig
EC
53
E
G

R
control
value

When
the

vacuum

passage
is

open
the

carburetor
suction

vacuum
is

applied

to
the

diaphragm
of
the
E
G
R

con

trol
valve
to

actuate
the

taper
valve

connected
to
the

diaphragm

theconsiiiictlo

nlie
thermal

vacuum
valve
is

shown
below

ed

independently
of
the

E
G
R

con

trol

system
monitors

the
distance
the

car
has
travelled
and

indicates
when

EC
22
the
E

G
R

control

system
must
be

checked

The
E
G
R

warning
system
consists

of

an
odometer
switch

detector
drive

counter
E

G
R

warning

lamp
and

harnesses

When
the

earn
in
the

odom

eter
switch
connected
to

the

speed

ometer
turns

once
for

each
OAkm
4

mile
the

contact

point
of
the
elec

trica
circuit
closes

allowing
electric

current
to
flow

through
the

magnet

coil
of

the
detector

drive
counter

Thus

energized
the

magnet
coil
ac

Wates

the
latchet
to

turn
the
c
unter

wheel

by
one

pitch
When
the

number

of

counts
reaches
50
000
the
latchet

drops
in

a

groove
provided
on
the

periphery
of

the
counter
wheel
to

activate

the
detector

drive
counter

switch

Then
the

E
G
R

warning

lamp

comes
on

indicating
that
the
E
G
R

control

system
Should
be
checked

The

detector
drive

coun
teT
is

equip

ped
with
an
odometer
which

can
tell

when
to
service

the
E

G
R
contr0
I

system

After

completing

periodic
check

reset
the
odometer
to

zero
by
hand

proceeding
as
follows

1
Remove

grommet
installed
on

the
side

surface
of

detector
drive

counter
unit

2
insert

a
bar

or
a
screwdriver

tip

into
the

hole
from

which

grommet
has

been

removed
and

press
down
knob

provided
in

the
detector
drive
counter

for

resetting

The
E

G
R

warning

lamp
comes

on

under
the

following
circumstances

1
When
the
number
of

counts
has

reached
50
000
In
this

case
the

lamp

indicates
that
E

G
R

control

system

must
be
checked

2
When

operating
starter
motor

Notes

a
It
is

an
indication
of

problem
in

the

E

G
R

warning
lamp
or

problems

in
the

point
or
in
the
harnesses
if

the

lamp
does
not

light
at

50
000

counts

b

The
E

G
R

warning
system
is

mounted

on
all
620
models

except

those

bound
for
California
and

Canada

4
E
G
R

warning
system

EC251

Detector
drive
counter

Detecfor
drive
counter
is
secured

on
the

top
of
R
H

hoodledge
panel
in

engine
room
To

remove
detector
drive

counter
disconnect
w
COJUlector

and

loosen
two
bolts

securing
detector

drive
counter
to
hoodledge

panel

2

E
G
R

warning
lamp

E
G
R

warning
lamp
is
mounted
at

the

top
cen
ter
of
instrument

pad
To

remove
E
G

R

warning
lamp
proceed

as
follows

1
Remove

masking
panel

On
models

equipped
with
radio

remove

warning
lamp
from
under
in

strument

panel

2

E
G
R

warning
lamp
is

a
twist

type

Remove

lamp
and
socket

as
an

assembly
Push
and
twist

lamp
off

can

EC554

Fig
EC
60
Removing
E
G
R

warning

lamp
Emission
Control

System

3
Odometer
switch

Odometer
switch
is
mounted
on
the

back
side
of

speedometer
Cam
in
the

odometer
switch
is
rotated

by
the

speedometer
To

dismount
odometer

switch

proceed
as
follows

I

Dismount
combination
meter
as

sembly

2
Remove
meter
front
cover
and

take
off

clips
and
screws
to

dismount

shadow

plate

3

Loosen
screws

securing
speed

ometer
to

printed
circuit

housing
then

remove

speedometer

4

Remove
two
screws

securing

odomete
switch
to
the

back
side
of

speedometer
and
detach
odometer

switch

EC239

Fig
EC
61

Removing
odometer

switch

InstaUatlon

To
install
reverse
the
removal

pro

cedure

EC24
V

r
CID

1
Detector
drive
counter

2
E
G
R
warning
lamp

3
Speedometer

Fig
EC
59
E
G
R

warning
y
tem

INSPECTION

Checking
E

G
R
control

system
in

its
mounted
conditionS

I

Make
a

thorough
visual
check
of

E

G
R
control

system
If

necessary

wipe
away
oil
to

facilitate

inspection

If

any
hoses
are
cracked
or

broken

replace

2

With

engine
running
check

E

G
R

warning
system
for

proper

function
Make
sure
that
E

G
R
warn

ing
lamp
lights
when

ignition
switch
is

turned

to
START

position
starter

mo

tor
runs
If
E
G
R

wanung
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
odomete
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
connectors
and
de

tector
drive
counter
replace
warning

lamp
or
detector
drive
counter
if

necessary

Notes

Operation
oC
E
G
R

warning
lamp

is
as
Collows

REMOVAL

AND

INSPECTION

Removal
and

inspection
can
be

done

as
follows

Removal

Catalytic
converter

1

Apply
parking
brake

2

Place
wheel
lock
under
each
tire

3

Jack

up
the
vehicle

4
Remove
lower
shelter
of

catalytic

converter

5
Dismount

catalytic
converter

EC453

Fig
EC
69
Removing

catalytic

conuerter

Inspection

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including

ho
s

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I
S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nor

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
Emission
Control

System

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
o
e
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
10

7
Check

ignition
timing
If
neces

sary
adjust
it
to

specifkations
Refer

to

page
ET
10

B

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adju
stment

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

wanned

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

11
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
WaRn

up
engine
for

about
four

minutes
at
2
000

rpm
under
no
load

13
Measure
CO

percentage
at

idling

speed
After

step
12
has
been
coin

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14
If
CO

percentage
measured
in

step
13
is
less
than
0
3

the

catalytic

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

EC
27
16
If
CO

percentage
is

still
over

0
3
in

step
15

catalytic
conyerter
is

malfunctioning
Replace
catalytic
con

verter

INSTALLATION

To
install

reverse
the
removal

pro

cedure

Bolt

lightening

torque

specifications

Tightening

torque

Catalytic
converter

2
6
to
3
4

kg
m

19
to
25
ft
Ib

FLOOR

TEMPERATURE

WARNING
SYSTEM

DESCRIPTION

The
floor

temperature
warning

system
consists
of
a
floor

temperature

sensing
switch
installed

on
the
vehi

cle
s
floor
floor

temperature
relay
and

a

warning

lamp
on
the
instrument

panel
and
wires
that
connect
these

parts

When
the
floor

tempera
ture
rises
to

an
abnormal
level
the

warning
lamp

will

light
to
call
the
attention
of
the

driver
The

wiring
diagram
of
this

system
and
location
of
the

floor

temperature
sensing
switch
are
ilIus

trated
in

Figures
EC
70
and
EC
71

sufficient

delivery
of
fuel
to

engine

or

vapor
lock
It
must
therefore
be

1

3
connectur

COCk

Air
Manometer
Emission
Control

System

repaired
or

replaced

368
mmH20

14
5
inH20

LL

IPO
liqUid
epo
o

36

r
@

Carbon
canister

EC786

Fig
EC
79

Checking

evaporative
emmion

control

syatem

CARBON

CANISTER
PURGE

CONTROL
VALVE

Check
for
fuel

vapor
leakage
in

the

distributor
vacuum
line
at

diaphragm

of

carbon

canister

purge
control
valve

To

check
for

leakage
proceed
as

follows

I

Disconnect
rubber
hose
in

the

line

between
T
connector

and
carbon

canister
at
T

connector

2

Inhale
air
into
the

opening
of

rubber
hose

running
to

vacuum
hole
in

carbon

canister
and

ensure
that
there

is
no

leak

ET349

Fig
EC
so

Checking
carbon
canuter

purge
control
valve
3
If
there
is

a
leak

remove

top

cover
from

purge
control
valve

and

check
for
dislocated

or
cracked
dia

phragm
If

necessary

replace
dia

phragm
kit

which
is
made

up
of
a

retainer
a

diaphragm
and
a

spring

@

@

1
Cover

2

Diaphragm

3
Retainer

4

Spring

ET350

Fig
EC
81
Carbon

catU
ter

purge

control
valve

CARBON

CANISTER
FILTER

Check
for
a
contaminated

element

Element

can
be
removed

at
the

bottom
of

canister

installed
on
vehicle

body

EC
32
ET37Q

Fig
EC
s2

Replacing
carbon

canuter

filter

FUEL
TANK

VACUUM

RELIEF
VALVE

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

3
If

valve
is

clogged
or
if

no
resist

ance
is

felt

replace
cap
as
an
assem

bled

uni
t

l

u

ET369

Fig
EC

83
Fuel

filler
cap

CLEANING
AND

INSPECTION

Clean
all
disassembled

parts
but
do

not
use

grease
dissolving
solvents
for

cleaning

overrunning
clutch
annature

assembly

magnetic
switch

assembly

and
field
coils
since
such
a

solvent

would
dissolve

grease
packed
in

c1u
tch

mechanism

and
would

damage
coils
or

other
insulators

Check
them
for
excessive

damage

or

wear
and

replace
if

necessary

TERMINAL

Check
terminal
for

damage
and

wear
and

replace
magnetic
switch

assembly
if

necessary

FIELD
COIL

Check
field
coil
for
insulation
If

the
insulation
of
coil

is

damaged
or

worn
it
should
be

replaced

Testing
field

coil
for

continuity

Connect
the

probe
of
a

circuit

tester

or
an
ohmmeter
to
field
coil

positive
terminal

and

positive
brush

holder

If
tester
shows
no

continuity
field

circuit
or

coil
is

open

EE016

Fig
EE

I2
Testing
field
coil

for
continuity

TestIng
field
coD
for

ground

Place
one

probe
of
circuit
tester

onto

yoke
and
the
other

onto
field

coil
lead

positive
tenninal

If

very
little
resistance
is
read
field

coil
is

grounded
Engine
Electrical

System

EE017

Fig
EE

I3

Testing
rU
ld
coil

for

ground

BRUSHES
AND

BRUSH

LEAD

WIRE

Check
the
surface
condition
of

brush
contact

and
wear
of

brush
If
a

loose
contact
is
found
it
should
be

replaced

If
brush
is

worn
so
that

its

length
is

less
than
12
mm
0
472
in

replace

Check

the
connection

of
lead

clip

and
lead
wire

o

@

EE
8
Check
brush
holders
and

spring
cUp

to
see
if

they
are
not

deformed
or

bent
and
will

properly
hold
brushes

against
the

commutator

If

brushes
or
brush
holders
are

dirty
they
should
be

cleaned

BRUSH
SPRING

TENSION

Check
brush

spring
tension

by
a

spring
scale
as
shown
in

Figure
EE

13

The

reading
should

be
1

6

kg
3
5

Ib

Replace
spring
if

tension
is

lower
than

I
4

kg
3
1
Ib

ARMATURE

ASSEMBLY

Check
external

appearance
of

armature
and
commutator

1

Inspect
commutator
If
the
sur

face

of
commutator
is

rough
it

must

be
sanded

lightly
with
a
No

500

emery
cloth
If
the

depth
of

insulating

mica
is

less
than

0
2
mm
0

0079
in

from
commutator
surface

insulating

mica
should

also
be
undercut
so

that

its

depth
is
0
5
to
0
8

mm
0
01
97
to

0
0315
in

The
wear
limit
of
commutator
dia

meter
is

2
mm
0

0787
in
If
the

diameter
of
cammu

tator
is

less
than

31
mm
1
220
in

replace
annature

assembly

EE018

Fig
EE
14

Inspecting
brush

spring
tension

L

0
5
to
0
8
mm

71j

Correct

2

Inspect
soldered
connection
of

armature
lead

and
commutator
If

loose
connection
is
found
solder
it

using
resin

flux

3

Armature
test
for

ground

Using
a
circuit
tester

place
one

test

probe
onto
armature
shaft
and
other

onto
each
commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

EE022

Fig
EE

16

Testing
annature
for

ground

4

Check
armature
for
short

by

placing
it
on
armature
tester

growler

with
a

piece
of
iron

over
armature

core

rotating
armature
If
the

plate

vibrates
armature

is
shorted

j
l

EE023

Fig
EE

17

Testing
annature

for

ahort
Engine
Electrical

System

L

File
l

0

Commutator

Segmen
t

IWMica

Incorrect

EE021

Fig
EE
15

Undercutting
i118ulating
mica

5
Check

armature
for

continuity
by

placing
probes
of

tester
on
two

seg

ments
side

by
side
If
tester
shows
no

continuity
the
circuit
is

open

OVERRUNNING
CLUTCH

ASSEMBLY

Inspect
pinion
assembly
and
screw

sleeve
Screw
sleeve

must
slide

freely

along
armature
shaft

splines
If

damage
is
found
or
resistance
is
felt

when

sliding
it
must
be

repaired

Inspect

pinion
teeth
If
excessive
rub

bing
is
found
on
teeth

replace

Flywheel

ring
gear
also
must
be
in

spected

l

EE278

Fig
EE
18

Overrunning
clutch

auem

bly

BRUSH

HOLDER
TEST

FOR

GROUND

Using
a
circuit
tester

place
one
test

probe
onto

negative
side

of
brush

holder

and
another
onto

positive
side

If

tester
shows

continuity
brush

holder
is

shorted
to

ground

Replace

brush

holder

EE
9
Ee026

Fig
EE
19

Testing
brush

for

round

BEARING
METAL

Inspect
bearing
metal
for
wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm
0
0079
in

replace

metal

MAGNETIC
SWITCH

ASSEMBLY

1

Using
a
circuit
tester

l
check

con

tinuity
between
S
terminal
of

mag

netic

switch
and
switch

body
metal
If

continuity
does
not
exist
shunt

coit
is

opened

Replace
switch

assembly

2
In
the

same
manner
as
above

check

continuity
between
terminals

S
and
M

If

continuity
does
not

exist
series

coil
is

opened

Replace
switch

assembly

ASSEMBLY

Reassemble

starting
motor
in

re

verse

sequence
of

disassembly

When

assembling
be

sure
to

apply

grease
to

gear
case
and

rear
cover

bearing
metal

and

apply
oil

lightly
to

pinion

TEST

PERFORMANCE
TEST

Starter
motor
should
be

subjected

to
a
no
load

test
whenever
it
has

been
overhauled
to
ensure
that

its

performance
will
be

satisfactory
when

installed
on

engine
Starter
motor

should
also
be

subjected
to

the
test

when
the
cause
of
abnormal

operation

is

to
be
determined

A
brief
outline
of

the
test
is

given
below