So now they are saying that all they require is:
1) an EGR valve between the exhaust manifold and inlet mainfold
2) an emissions test (<2.5% CO and <250ppm hydrocarbons at idle)

Well an EGR valve cannot simply be added. You need to use an exhaust/intake manifold combo that has EGR ports.

It looks like you already have an EGR type intake, but someone filled the ports (below the PCV fitting):

crap! im moving back to adelaide next month....

am i going to have the same troubles? mines a 82 with none of that gear...

do they go over the whole car with an identity check?

You only need it if the 1200 originally came with it. Most 1200s did not have EGR.

They originally said that I would need all of the original pollution control kit for an 85 model (i.e. carbon canister, etc etc) as shown in the pic at http://datsun1200.com/modules/mediawi ... hp?title=Carbon_Canister. Because they couldn't give me a statement of requirements of what this actually was, they agreed that if I put in an EGR and the emissions test came back OK, then they'd pass it mechanically.

Shakn, for the ID check they seem to just check the compliance plate and engine number (mine didn't match) but they won't pass me through ID until the vehicle standards guys sign off on the above stuff, as well as get a letter from the office of consumer affairs giving me permission to "interfere with an odometer". It is a pain in the neck.

The upshot of all of this is that I will either need to replace my exhaust manifold to one with an EGR, or have one welded in. Anyone got an exhaust manifold that they want to part with?

The only modification to the Exhaust Manifold to enable EGR is the casting was changed to add a threaded port to which a tube is fastened. The tube goes up to the EGR Valve.

Look to see if your manifold has it. It will look something like the tube on this one:

I have aftermarket hurricane extractors so no joy: http://datsun1200.com/uploads/newbb/14202_4cd64b5046fd2.jpg

Looks like you'll need to source both exhaust manifold and intake and with EGR parts attached. And an exhaust pipe to attach to the manifold instead of the extractor.

Some late model intake manifolds are cast for the EGR body but not machined -- that's what your photo of the intake manifold looks like.

Nice extractor:

Does anyone have a manifold (any type) with an EGR valve on it they're willing to sell?