DATSUN 210 1979 Service Manual

DESCRIPTION

The
alternator

incorporates
an
Ie

voltage
regulator
which
maintains
volt

age
within
the

specified
range
and

prevents

output
voltage
from

rising

higher
than
the

specified
value

Except

for
the
Ie
circuit

alternator

parts
are

essentially
the

same
as
those
of

the

conventional

type
alternator

Service

procedures
outlined
in

this

section
are
restricted
to
information

on

other
than
the

voltage
regulator

In
the

alternator
a

magnetic
field
is

CD
Engine
Electrical

System

ALTERNATOR

produced

by
the
rotor
which
consists

of

alternator
shaft
field
coil

pole

pieces
and

slip

rings
The

slip
rings

pressed
in
the

shaft
conduct

only
a

small

field
current

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
The
stator
has
three

windings
and

generates
three

phase

alternating
current
Silicon
diodes
act

like
a

one

way
valve
for

electricity
so

that

charging
current

passes
easily
but

reverse
current
is
shut
out

In
this
alternator

pack
type
silicon
diodes
are
used

as
main
diodes

Nine

diodes
three

negative
three

positive
and
three

sub
diodes
are

installed
in

positive
and

negative
plates

as
an

assembly

These

diodes
are
direct

soldered
at

their

tips
and

constructed
with

posi

tive
and

negative
conjunction

They
are
mounted
on
the
two

plates
which
combine
the

function
of

heat

dissipating
plate
and

positive

negative
terminals
and
are

light
in

weight
and

easy
to

service

EE13
1

Pulley
assem
bly

2
Front
cover

3
Front

bearing

4
Rotor

Qj
5
Rear

bearing

6
Stator

7

Diode
Set

plate

assembly

8
Brush

assembly

9
Ie

voltage
regulator

10
Rear
cover

11

Through
bolt

EE647

Fig
EE
30
Alternator

REMOVAL

1

Disconnect

battery

negative

cable

2

Disconnect
two

lead
wires
and

oonnector
from
alternator

3

Loosen

adjusting
bolt

4

Remove
alternator
drive

belt

5

Remove

parts
associated
with

alternator
from

engine

6
Remove
alternator

from
car

DISASSEMBLY

I
Remove

through
bolts

Separate

front
cover
with
rotor

from
rear
cover

with
stator

by
lightly

tapping
front

bracket
with
a

wooden
mallet

rnJ

J

i

EE525

Separating
Front

COI
T

Fig
EE

31

2

Place
rear
cover
side
of

rotor
in
a

vise

with
soft

jaw
and

remove

pulley

nuts
Then
remove

pulley
and
fan

from
rotor
shaft

3

Remove

setscrews
from

bearing

retainer
and

separate
rotor
from
front

EE526

Fig
EE
32

Removing

Pulley
and
Fan

tr

s

0
27

Fig
EE
33
Removing
Rotor
Engine
Electrical

System

4
Pull

rear

bearfug
off
rotor

assem

bly
with
a

bearing
puller
or

press

EE037

Fig
EE
34

Pressing
Out

Rear

Bearing

I

EO

Fig
EE

35
Pulling
Out
Rear

Bearing

5

When

removing
IC

regulator

only

proceed
as
follows

I

Using

soldering
iron

disconnect

wire

connecting
diode

set

plate
to

brush
at
brush

terminal

2

Remove

bolt

securing
diode
set

plate
to
rear
cover
side
face

3

Remove
nut

securing
battery

terminal
bolt

4

To
facilitate
removal

s1ighly
lift

stator

coil

together
with
diode
set

plate
from

re
r
cover
Then
remove

screw

connecting
diode
set

plate
with

brush

5

Separate
stator
coil
and
diode

together
with

rear
cover
and

remove

brush
and

IC

regulator

6
Disconnect
stator

coil
lead
wires

from
diode
terminals
with

a

soldering

iron

Remove

screws

securing
brush
re

move
stator
from

rear
cover

EE648

Fig
EE
36

Removing
Stator

Coil

EE
14
7

Disconnect
wire
from
diode
tor

minal
at
brush
terminal
with

soldering

iron

Remove

brush

assembly
with
IC

regulator
by
loosening
screws

8
Remove
diode

holder

by
loosen

ing
screws

acefii
li

E
E649

Fig
EE

37

Removing
Diode
Holder

INSPECTION
AND

REPAIR

ROTOR
INSPECTION

I

Continuity
test
of
rotor
coil

Apply
tester
between

slip

rings
of

rotor
If

there
is

no

continuity
field

coil
is

open

Replace
rotor

assembly

Fig
EE

38

Continuity
Test

of

Rotor
Coil

2

Ground
test
of
rotor
coil

Check

continuity
between

slip
ring

and

rotor
core
If

continuity
exists

replace
rotor

assembly
because
rotor

coil

or

slip
ring
may
be

grounded

EE532

Fig
EE
39
Te

ting
Rotor
Coil

for
Ground

INSPECTION
OF
STATOR

Continuity
test

Stator
is
normal
when
there
is

continuity
between
individual
stator

coil

terminals
When
there
is

no
conti

nuity
between
individual
terminals

cable
is

broken

Replace
stator

assembly

EE533

Fig
EE
40

Testing
Stator

for

Continuity

2

Ground
test

If
each
lead

wire
of
stator
coil

including
neutral
wire
is

not
conduc

tive
with
stator
core
condition
is

satisfactory
If
there
is

continuity

stator

coil
is

grounded

EE534

Fig
EE
41

Testing
Stator

for

Ground

INSPECTION
OF
DIODE

Perform
a

continuity
test
on
diodes

in

both
directions

using
an
ohmmeter

There
are
six
main

diodes
and
tluee

sub
diodes
attached
to
set

plate
Three

main
diodes
are
attached

to

positive

EEl
plate
and
three
others

to

negative

8
plate
Three
sub
diodes
are

attached

to
terminals

The

continuity
test
should
be

per

formed
on
each
diode
between

the

terminal
and

plate
Engine
Electrical

System

Conductive
direction

EE045

Main
diode

installed
on

8
plate

is
a

positive
diode
which
allows

cur

rent
to

flow
from
terminal
to

EEl
plate

only
In

other
words
current
does
not

flow
from

8
plate
to

terminal

1

plate

2

Terminal

Fig
EE
43

Impecting
Positive

Diode
EE046

2

Main
diode
installed
on

Gplate
is

a

negative
diode

which
allows
current

to
flow
from

Gplate
to
terminal

only

In

other
words
current
does
not
flow

from

terminal

toGplate

1

plate

2

Tenninal

Fig
EE
44

Impecting
Negatiue

Diode
EE047

EE
15
rp

m

1

plate

2

ptate

3
Diode

Fig
EE

42
Conductive
Direction

of
Diode

3
Correct
direction
of

current
flow

for
three
sub

diodes
is
shown
in

Fig

EE
4S

Direction
of

electric
current

EE650

Fig
EE
45

Sub
Diode

If

current
flows
in
both

positive

and

negative
directions
diode
is
short

circuited
If
current
flows
in
one

direc

tion

only
diode
is
in

good
condition

If
there
is
a

faulty
main

diode

replace

all
diodes
as
an
assembly
See

table

below
These
diodes
are
unservicea

ble

Test

probe
of
a
circuit
tester

e
8J

terminal
EB

plate

@
plate
terminal

terminal
e
plate

e

plate
tenninal

e

plate
8J
plate

EB

plate
e
plate

Sub
diodes
can
be

replaced
individ

ually

CAUTION

If
it
is

necessary
to

remove
sub
diode

pinch
diode
lead
wire
with

a

pair
of

pliers
to

prevent
heat
transfer
from

soldering
iron
to
diode
when
unsolder

ing
connection

INSPECTION
OF
BRUSH

Check
movement
of
brush
and
if

uv
ent
is
not
smooth
check
brush

holder
and
clean
if

necessary

Check
brush
for
wear
If
it
is
worn

down
to
less
than
the

specified
limit

replace
brush

assembly

Check
brush

pig
tail
and
if

damaged
replace

EE651

Fig
EE
46
Brush
Wear
Limit

SPRING
PRESSURE
TEST

With
brush

projected
approximate

Iy
2

mm
0
08
in
from
brush
holder
measure
brush

spring

pressure
by
the

use
of

a

spring
balance

Normally
the

rated

pressure
of
a

new
brush

spring
is

255
to
345

gr
8

99
to
12
17

oz

Moreover
when
brush
is
worn

pressure
decreases
a

pproxirnately
20

gr

O
71

oz

per
I
mm
0
04
in

wear
Bru
h
lift

0

0

lJrJ

EE540
Engine
Electrical

System

Conduction

o

o

o

t
2

mm
0
08
in

L

ee049

Fig
EE
47
Mea

uring
Spring

Pressure

ASSEMBLY

Assemble
alternator
in
the
reverse

sequence
of
disassembly

noting
the

following

I
When

soldering
each

stator
coil

lead
wire

to
diode

assembly
terminal

carry
out
the

operation
as
fast

as

possible

2
When
installing
diode
A
terminal

install
insulating
bushing
conectly

3

Tighten
pulley
nul

dJ
Tightening
torque

Pulley
nut

4
5

to
6

0

kg
m

33
to
43
ft
lbl

When

pulley
is

tightened
make
sure

that

deflection
of
V

groove

EE

16
V
grOove
deflection

0
3

mm
0
012
in

slik

1I
I

I
EE051

Fig
EE
48
Tightening
Pull

y
Nut

4
Before

installing
front
and
rear

sides
of
alternator

push
rear
cover

brush

up
with

fingers
and
retain

brus
J

as
shown
in

Fig
EE
49
by
inserting

brush
tift
into
brush
lift
hole
from

outsi4e

Fig
EE

49
I

rUng
Bru
h

Lift

S
After

installing
front
and
rear

sides
of
alteniator

pull
brush
lift

by

pushing
toward
center

Note
Do
not

puD
brush
lift

by
push

ing
toward
outside
of

cover
as
it

will

damage
slip
ring
sliding
surface

Engine
Electrical

System

6

Tighten
through
bolts

rfl
Tightening
torque

Through
bolts

60
to
70

kg
cm

52
to
61
in
lb
ALTERNATOR
TEST

Before

conducting
an
alternator

test
make
sure
that
the

battery
is

fully

charged

A
30
Volt
voltmeter
and
suitable

INSPECTION
TABLE

With
alternator

aide
L
tenninal

grounded
internal

short
occurs

when
diode
is
short

circuited

@
test

probes
are

necessary
for
the

test

The
alternator

can
be

checked
easi

ly
by

referring
to
the

Inspection
Table

Bumed
out

bulb

Replace

and
Proceed

toUA

Ignition

switch

ON

Check

light

for

operation
Disconnect
Light
OFF

f

Light
OFF
connector
S

L

and

ground

L

lead
wire

Light
ON

Check

light

for

operation
Light
ON

I
Faulty
IC
RG

Replace
Connect
con

nector
S
L

and

ground
F

a1light
Light
OFF

I
FaultyA
C

G

I

Dim

light
for

operation

tf
i
rs

1
I
Faulty
A

C
G

I

Light
ON
I

Contact

positive
lead
of

voltmeter
on
B

lennina
and

negative
lead
to
L
tenninal
Light
ON

1

Engine
idling

Check

light

for

operation

Light
OFF

I
Engine
idling

Measure
the

voltage
across

B

and
L

terminals

Engine
speed

1

500

rpm

Ligh
tin

switch

ON

Check

light

for

operation
r
Dim

light

Light
OFF
Note

1
Use

fully
charged

battery

2

Light
Charge

warning
light

A

C
G
Alternator

parts
except
IC

regu
tor

IC
RG
IC
n

guJator

OK
IC
altemator
is
in

good
condition

3

When

reaching
Faulty
A
C
G
remove

alter

nator

from
car
and
disassemble

inspect
and

correct
or

replace
faulty
parts
Engine
speed

1
500

rpm

Measure
B

terminal
volt

sge

Make
sure
S

terminal
is

con

nected

correctly

4

Method
of

grounding
F

terminal

Contact

tip
of
wire
with

brush
and
attach

wire
to

alternator

body

Suitable
wire
I

Fig
EE
50

Grounding
F
Terminal

5
Terminals

S
L
BA
Tn

and
E
are

marked
on
rear
cover
of

alternator

EEl7
More

thanO
5V

I
Faulty
A
e

G

1

Less
thanO
5V

I
OK

T
Mon
than

15
5V

I
Z
C
RG

I

I3
to
15V

Engine
idling

Lighting

switch
ON

Check

light

for

operation

Light
ON

I
Faulty
A
C

G

I

Light
OFF

I
OK

DESCRIPTION

The

regulator
consists

essentially
of

in

egrated
circuits

incorporating
tran

sistors

These
transistors
int

errupt
and

admit

current
flow

to
the
alternator

rotor

coil
thus

maintaining
its

output

voltage
at
a
constant
value
Unlike
in
a

mechanical

type
regulator
an
electron

ic

relay
employing
transistors
is
uti

lized
These
transistors

are
enclosed
in

a

very
compact
sealed

case
The

electronic

relay
is

soldered
to
the

Brush

Ie

regulator

R

J

DIO

F

i
ZD

Tn
Engipe
Electrjcal
Syst
em

REGULATOR

brush

assembly
inside
the

alternator

Should

any

problem
with
the

relay

arise
it

should
be

replaced
together

with
the

brush

assembly
In
the

charge

warning
lamp
circuit
a
diode
is
at

tached
to
the
stator
coil
to

monitor

generating
voltage
at
the
stator

so
that

when
the

monitored

voltage
and

charging
voltage
are

equal
during
re

charging
the

charge

warning
lamp
is

turned
off

Accordingly
a

charge

warning
relay
is

not

employed
in

this

circuit

s

r
t

E

F
L
S
B

EE629

Fig
EE
51
lC

Voltage
RegultJtor

I

B

S

L

I

R

R

E
B
S
L

E
F
Terminal

R
Resistor

Rh
Thermistor

Tr
Transistor

ZD
Zener
diode

EE766

Fig
EE
52

Circuit
of
RegultJtor

EE
18
INSPECTION

To

check
the

IC

regulator
proceed

as
follows

Remove
IC

regulator
and

brushes
as

an

assembly
as
outlined
in

Disas

sembly
and

Assembly
section
under

the

heading
Alternator

CAUTION

When

performing
test

continuously

resistor

may
generate
heat
If

it
be

comes

high
temperature
stop
testing

for
a

while
to
avoid

burning

The

following
test

equipment
and

accessories
are

required

I
Resistor
R
10

ohms
20

watts
x
I

2

Variable
resistor

Rv
0
to
300

ohms
20
watts
x
I

3

Batteries
I

and
2
12

volts

x2

4
DC

voltmeter
0
to
30
volts

x
I

2
Connect

wiring
as
shown
in

Fig

EE
S3
and

perform
tests
as
follows

I

Measure

voltage

VI
at

battery
If

it
is

not
within

10
to
13

volts
re

charge
or

replace
battery
as

necessary

2
Disconnect
lead
wire

at
terminal

s

measure

voltage
V

2
between

terminals
F

and
E
If
it
is

below

2
0
volts

regulator
is

functioning

properly
Connect

lead
wire

to
termi

nalS

3

Measure

voltage
V

3
total
volt

age
of

batteries
I

and
2

If
it

is
not

within

20
to
26
volts
re

charge
or

replace
either
or

both
batteries

4

Gradually
decrease
resistance
of

variable
resistor

Rv
from
300
ohms

and
measure

voltage
V

2
between

terminals
En
and
F
As
resistance

15
5

v

v

o

o

Q

z

o
15
0

14
5

14

0

13
5

13
0
Engine
Electrical

System

l

c

regula
tor

c

j
F

F

T

BATI

1

i

Cf

CO
I

r

J

BAT2

EE631

Fig
EE

53
Testing
Regulator
1

N

N
0
N
0

0
N

0

C
e
0

c

0

S
0

S
0
0

0
0
0

0
0
0
0
0

0

I
c
o

I

Regulator
case

temperature
DC
OF

EE632

Fig
EE

54

Testing
Reguhltor
5

j
I

C

regulator

E
F
L
S

BATI

1

I

i
R

Cf
Cf

I
l

BAT2

EE633

Fig
EE
55

Testing
Regulator
6

EE

19
varies

voltage
V

2
should

at
a
certain

point
increase
to

as

high
as

voltage
V

I

which

is
measured
in

Step
I
If
there

is

such
a
variation

the

regulator
is

functioning
properly
Hold

variable

resistor
Rv

at
the
same

voltage
as

VI

If
there
is
no

voltage
variation

regula

tor
is

out
of
order

and
must
be

replaced

5

Measure

voltage
V

between

center

tap
of
variable

resistor
R
and

terminal
E

With
Rv

resistance
set

at
a

value

obtained
in

step
4

above

measure

voltage
V

4
to
s
e

if
it
is
within

specified

range
indicated
in

Fig

EE
54

If
it
is
not

regulator
is
not

functioning
properly
Replace

6

Reconnect

wiring
as

shown
in

Fig
EE
55
and

repeat

steps
4

and

5
If

voltage
V
is

0
5
to
2
0

volts

higher
than
that
in

step
5

regulator

is

functioning

properly
If
it
is
not

replace

DESCRIPTION

The

ignition
circuit
consists

of

igni

tion

switch
Ie

ignition
unit
dis

tributor

winng

ipark
plugs
and

battery

The

distributor
is

of
the

contactless

type
and
is

equipped
with
a

pick
up

coil
which

electrically
detects
the

igni

tion

timing
signal
in

place
of
the

ircuit

I
rea
r

of
the
conventional

distributor
The
IC

ignition
unit
is

a

new
addition

which

generates
the

signal
required
for
the

make
and
break

of
the

primary
current
for
the

ignition

coil

The

primary
current
is

supplied

by
the

battery
or
alternator
and

flows

through
the

primary
circuit

It
consists

of
the

ignition
switch

primary

winding
of
the

ignition
coil

IC

ignition
unit

and
all

connecting
low

tension

wiring

The

secondary
current
is

produced

by
the

ignition
coil
and
flows

through

the

secondary
circuit

resulting
in

high

voltage
spark
between

the
electrodes

of

the

spark

plugs
in

engine
cylinders

This
circuit

contains
the

secondary

winding
of
the

ignition
coil
distribu

tor

high
tension

cables
to

coil
and

spark

plugs
distributor

rotor
and

cap

When
the

ignition
switch
is

turned

on
and
the

distributor

reluctor
rotates

the

primary
current
flows

through
the

primary

winding
of
the

coil
and

through
IC

ignitionu
nit

to

ground

When
the

primary
circuit
is

opened

by
circuit

of
IC

ignition
unit

the

magnetic
field
built

up
in

the

primary

winding
of
the
coil

moves

through

the

secondary
winding
of
the

coil
in

ducing
high

voltage
This

high

voltage

is

produced

every
time

the

primary

circuit

opens
EngineElect
ical

System

IGNITfON

CIRCUIT

The

secondary
current

flows

through
the

high
tension

cable
to
the

distributor

cap
then

the
rotor

distributes
the
current
to

one
of
the

spark
plug
terminals
in
the

distrubutor

cap

Then
the

spark
occurs

while
the

secondary
current

jumps
the

gap
be

tween
the
insulated
electrode
and
the

ground
side
electrode
of
the

spark

plug
This

process
is

repeated
for
each

power
stroke

of
t

e

engine

The

spark
plug
should
be

inspected

cleaned
and

regapped
at

tune

up

Spark

plugs
should
also
be

replaced

periodically
as

specified
in

the

Maintenance
Schedule

The
remainder

of
the

ignition

component
parti
should
be

inspected

Battery

letink

Primary

winding

1

Ignition
coil

Secondary
winding
J
for

only
their

operation
air

gap
of

distributor

tightness
of

electrical

terminals
and

wiring
condition

Apply
grease
NLGI

consistency

No
I

containing
MaS
or

equivalent

to
distributor
rotor

shaft
as

required

WARNING

When
current
is

flowing
never

touch
with
bare

hand

high
tension

cables
or

any
other

parts
with

high

vollage
If

parts
are
moist

touching

them
could
cause
an
electric
shock

even
if

they
are
insulated

Always

wear

dry
well
insulated

gloves
or

wrap
affected

parts
with

dry
cloth

before

handling

To
starter

EE
20
Ro

or
head

Ul

J

r

Spark
plugs

EE743

Fig
EE
56

Ignition
System
Circuit

Diagram

FUSIBLE

LINK

BATTERY
VIR

9

rID
B
V
II

H
Engine
Electrical

System

1

II

1l

IGNITION

COIL

IIC
IGNITION

I
UNIT

O
J

DISTRIBUTOR

EE

21
B4J
QJ

jl

SPARK
PLUG
IGNITiON

SWITCH

EE744

Fig
EE
57
Circuit

DiGgram
of
Ignition
Sy
tem

L

Engine
E
ectrical

System

DISTRIBUTOR

CONSTRUCTION
in

place
of
the

breaker
The

amount
of

magnetic
flux

passing
through
the

pick
up
coil
is

changed
when
the

reluc

tor

rotates
and

then
the

electrical

signal
is

generated
in
the

pick

up
coil

This

electric

ignal
is

conducted

into
the
Ie

ignition
unit

which
makes
In
the
conventional

distributor
the

ignition
timing
is

detected

by
the

earn

and
breaker

arm
while
in
this
distribu

tor
it

is
detected

by
the
reluctor
on

the
shaft
and
the

pick
up
coil

provided
and
breaks

the

primary
current
run

ning
through
the

ignition
coil
and

generates
high
voltage
in
the

secondary

winding

The

centrifugal
and
vacuum
ad

vance
mechanisms

employ
the

conven

tional

mechanical

type

I
l
Q

J
1

C

@

@

ID

ID

J

I

Cap
assembly

2
Rotor
head

assembly

3
RoD

pin

4

ReluctoI

@
5

Stator

6

Magnet
assembly

7
Pick

up
coil

assembly

8
Breaker

plate
assembly

9
Rotor
shaft

assembly

10
Governor

spring

11
Governor

weight

12

Shaft

assembly

13

Housing

14
Grommet

15
Ie

igniq
n
unit

@f
rw
16
VacuwncontroUcr

17

Fixing
plate

t8
Collar

EE745

Fig
EE
58
Diatributor

EE
22