spark plugs DATSUN 210 1979 Service Manual

DATSUN
210
Model
8310
Series

SECTIONET

ET

ENGINE
TUNE
UP

CONTENTS

EMISSION
CONTROL
DEVICES

BASIC
MECHANICAL
SYSTEM

ADJUSTING
INTAKE
AND
EXHAUST

VALVE
CLEARANCE

CHECKING
AND
ADJUSTING
DRIVE

BELTS

CHANGING
ENGINE
OIL

REPLACING
01
L
FI
L
TER

CHANGING
ENGINE
COOLANT

CHECKING
COOLING
SYSTEM
HOSES

AND

CONNECTIONS

CHECKING
ENGINE
COMPRESSION

IGNITION
AND
FUEL

SYSTEM

CHECKING
BATTERY

CHECKING
AND
ADJUSTING

IGNITION
TIMING

CHECKING
IGNITION
WIRING

CHECKING
AND
REPLACING
SPARK

PLUGS

CHECKING
AND
ADJUSTING
CARBURETOR

IDLE
RPM
AND
MIXTURE
RATIO

CHECKING
CHOKE
MECHANISM

Choke

plate
and

linkage

CHECKING
FUEL
SHUT
OFF
SYSTEM

FU
models
ET
2

ET
3

ET
3

ET
3

ET
3

ET
3

ET
4

ET
4

ET
4

ET
5

ET
5

ET
5

ET
6

ET
6

ET
7

ET
9

ET
9
REPLACING
FUEL
FILTER
ET
10

CHECKING
FUEL
LINES

Hoses

piping
connections
etc
ET
10

REPLACING
AIR
CLEANER

FILTER
ETlO

CHECKING
AUTOMATIC
TEMPERATURE

CONTROL
AIR
CLEANER
ET
10

EMISSION
CONTROL

SYSTEM
ET
11

CHECKING
VACUUM
FITTING
HOSES

AND
CONNECTIONS
ET
11

REPLACING
AIR
PUMP
AIR
CLEANER
FILTER

Except
FU
models
and
Canada
models
E

1122i

REPLACING
AIR
INDUCTION
VALVE
FILTER

FU
models
and
Canada
models

E
tlil1r2
C

REPLACING
PCV
VALVE
AND
FILTER

ETf

CHECKING
VENTI
LATION
HOSES

E1P12

CHECKING
VAPOR
LINES

Eli
J2

CHECKING
FUEL
TANK
VACUUM
RELIEF
I

f
III

VALVE

ET
13

REPLACING
CARBON
CANISTER
W

FILTER
ET
d

SERVICE
DATA
AND

SPECIFICATIONS
ET
14

TROUBLE
DIAGNOSES
AND

CORRECTIONS
ET
16

SPECIAL
SERVICE
TOOL
ET
23

pl
ice
mter
as

an

assembly

2

When

installing
oil
mter

tighten

by
hand

Note
Do
not

overtighten
oil
filter

lest

leakage
shoUld
occur

CHANGING
ENGINE

COOLANT

PERMANENT

ANTI
FREEZE

COOLANT

Note

The

permanent
anti

freeze

coolant
is
an

ethylene
glya
l
base

product

containing
chemical
in

hibitors
to

protect
the

cooling

system
from

rusting
and
corrosion

The
anti

freeze
does
not
cOntain

any
glycerine
or

ethyl
alcohol
It

will
not

evaporate
or
boil
a

ay
and

can
be

ilsed
with
either

high
or
low

temperature
thermostats
It

flows

freely
transfers
heat

efficiently

and
will
not

clog
the

passages
in

the

cooling

system
The
anti
freeze

must
not
be
mixed

with
other

product
This
coolant
can
be
used

throughout
the
seasons
of
the

year

Whenever
coolant
is

changed
the

cooling

system
must
be
flushed
and

refilled
with
a
new
coolant
Check
the

coolant
level

See
instructions

attached
to

the

anti
freeze
container
for

mixing
ratio

of
anti
freeze

to
water

CHECKING
COOLING

SYSTEM
HOSES

AND
CONNECTIONS

Check
hoses
and

fittings
for
loose

connections

or
deterioration
Re

tighten
or

replace
if

necessary

INSPECTION
OF
RADIATOR

CAP

Apply
reference

pressure
0

9

kgj
cm2
13

psi
to

radiator

cap
by

means
of
a

cap
tester
to

see
if
it
is

satisfactory
Replace

cap
assembly
if

necessary
I

j
ngine
Tune

up

ET012

Fig
ET

3

Testing
Radiator

Cap

COOLING
SYSTEM

PRESSURE
TEST

Witli
radiator

cap
removed

apply

reference

pressure
1
6

kgfcm2
23

psi
to
the

cooling
system
by
means

0

no

Fig
ET
4

Water

capacity
M
Tmodelsl

Without
heater

5
2
liten

5
1f
US

qt
4

Imp
qt

With
heeter

5
9
Iiten

6
4
US

qt
5

Y

Imp
qt

Water

capacity
AfT
modelsl

Without
heater

5
0
liters

5

y
US

qt
4

Imp

qt

With
heater

5
7
liten

6
US

qt
5

Imp
ill

CHECKING
ENGINE

COMPRESSION

Note

a
To
check

cylinder

compression
it
is

essential

to
remove
all

spark
plugs

The

purpose
of
this
test
is
to

ET
4
determine
whether
there
is
exces

sive

leakage

past
piston
rings
head

gasket
etc
To
test

engine
should

be
heated
to
the

operating
t
M

ture
and
throttle
valve

opened

b

Cylinder
compre
on
in

Cylinders

should
not
be
less

than
llO
of
the

highest
reading
Different

compres

sion

in
two
ore
more

cYlinder
usual

ly
indicates
an

improperly
seated

valve
or
broken

piston
ring

c
Low

compression
in

cylinders
am

result
from
worn

piston

rings
This

trouble

may
usuaDy
be
accom

panied
by
ex
ssive
fuel

consump

tion

I

Warm

up
engine
sufficiently

2

Disconnect

aU

spark

plugs

3
Disconnect
anti
dieseling

solenoid

valve
connector

4

Properly
attach
a

compression

tester
to

spark

plug
hole
in

cylinder

being
tested

FiI
ET
S
ET529

Testing
Compre
sion

Pr
s8ure

5

Depress
accelenit6r

pedal
to

open

throttle
and
choke

valves

Note
Do
not

pump
pedal

6
Start

engine
as

quickly
as

pos

sible

Compression
pressllre

kg
cm2
ii
at

rpm

Standard
13

5
192

350

Minimum
12
5

1781
350

If

cylinder

compression
in
o
e

or

more
cylinders
is
low

pour
a

small

quantity
of

engine
oil
into

cylinders

through
the

spark

plug
holes
and
retest

compression

I

If

addingoil
helps
the

compres

sion

pressure
chances
are

that

piston

rings
are

worn
or
damaged

2

If

pressure
stays
low

the
likeli

hood
is
that
valve
is

sticking
or

seating
Engine
Tune

up

improperly

3

If

cylinder
compression
in

any

two

adjacent
cylinders
is
low

and
if

adding
oil
does
not

help
the

compres
sion
there
is

leakage
past
the

gasketed

surface

Oil
and

water
in
combustion
cham

bers
can
result
from
this

problem

IGNITION
AND

FUEL
SYSTEM

CHECKING
BATTERY

I

Remove
six
vent

plugs
and
check

electrolyte
level
in
each

battery
cell
If

necessary
pour
distilled
water

Overflow
Correct

Shortage

t
t
j

t

t
t

EE358

Fig
ET
6

Checking
Electrolyte

Level
2
Measure
the

specific
gravity
of

battery
electrolyte

E
T372

Fig
ET
7

Checking
Specific
Gravity

of
Battery
Electrolyte

Over
1
22
Full

charge
value

at
200C
680F

1
28

1
26
Permissible
value

Frigid
climates

Other
climates

Note

a
Clean

top
of

battery
and

terminals

with
a

solution
of

baking
soda
and

water
Rinse
off
and

dry
with
com

pressed
air

Top
of

battery
must

be

c1
n
to

prevent
current

leakage

between
terminals
and
from

posi

tive
terminal
to
hold
down

clamp

b
In

addition
to
current

leakage

prolonged
accumulation
of
acid
and

dirt

on

top
of

hattery
may
cause

blistering
of
the
material

covering

ronnector

straps
and
rorrosion
of

straps

c
Afte
r

tightening
terminals
coat

them
with

petrolatum
vaseline
to

protect
them
from
corrosion

CAUTION

If
the

battery
cables
are
disconnected

they
should
be

tightly
clamped
to
the

battery
terminals
to
secure
a

good

contact
Over
I

20

CHECKING
AND

ADJUSTING

IGNITION
TIMING

Check

spark
plugs
for
condition

2

Thoroughly
remove
dirt
and
dust

from
crank

pulley
at

timing
mark

location

and
front
cover
at

timing

indicator

3
Warm

up
engine
sufficiently

4
Connect

engine
tachometer
and

timing
light
in
their

proper
positions

5

Adjust
idling
speed
to
the

specifi

ed
value

Idling
speed

Manual
transmission

700

pm

Automatic
transmission

6S0

rpm

in
0

position

ET
S
WARNING

When
selector
lever
is
shifted
to

0

position
apply
parking
brake

and
block
both
front
and
rear

wheels
with
chocks

Note

a
On
FU
models

set

idling
speed

with

distributor
vacuum
hose
dis

connected

b
Disconnect

distributor
vacuum

hose

at

distributor

diaphragm
side
and

plug
hose
with
blind

plug
See

Fig

ET
8

ET501

Fig
ET

B
Disconnecting
Distributor

Vacuum
Hose

6
Check

ignition
timing
with
a

timing
light
to
ensure
that
it
is

adjust

ed
to

specifications
indicated
below

Ignition
timing

Manual
transmission

SO
B
T
0
C
f700

rpm

California
FU
models

100
B
T
0
C
f700

pm

Non
California
Canada

models

Automatic
transmission

SO
B
T
0
C
f6S0

rpm

California
models

SO

B
T

D
C
l650

rpm

Non
California
models

except
Canada

100
B
T
D
C
650

rpm

Canada
models

Note
On
FU
models

ignition
timing

is
set
under

a
condition

where

distributor
vacuum
hose
is

discon

nected

If

necessary
adjust
ignition
timing

as
follows

I
Loosen
set

screw
until
dis

tributor

c
uJ
be

moved

by
hand

2

Adjust
ignition
timing
to

speci

fications

3
Lock

distributor
set
screw
and

make
sure
that

timing
is
correct

YJ

Fig
T
9

Adjusting
Ignition
Timing

7

On
FU
models

proceed
as
fol

lows

I
Remove
blind

plug
from
dis

tributor

vacuum
hose
and
connect

hose
to

distributor

diaphragm

2
If

engine
speed
varies
in
this

state
set

idling

speed
at

specified
value

with
throttle

adjusting
screw

CHECKING
IGNITION

WIRING

Use
an
ohmmeter
to

check
resist

ance
on

high
tension

cables

1

Disconnect

cables
from

spark

plugs
and

remove
distributor

together

with

high
tension

cables

Note
Do
not

remove
cables
from

cap
Engine
Tune

up

2

Connect
the
ohmmeter

between

cable

terminal
on
the

spark
plug
side

and
the

corresponding
electrode
inside

cap

3

If
the

resistance
is

more
than

30
000
ohms
remove

cable
from

cap

and

check
the
cable
resistance

only
If

resistance

is
still
more
than
30

000

ohms

replace
c3ble

assembly

Fig
ET
IO

Checking
High
Tension

Cable

u
s
A

models

Type
FU

models

Standard

Hot

type

Cold

type

U

S
A
models
Canada

models

r
1g
mm
in
FU

models

Canada
models

Tightening
torque

kg
m
ft

lb

ET
6
Stan
rd

Hot

type

Cold

type

S
aridard

Hot

type

Cold

type
CHECKING
AND

REPLACING

SPARK

PLUGS

I
Remove

and
clean

plugs
in
a

sand

blast
cleaner

Inspect
each

spark

plug

Make
sure
that

they
are
of
the

specifi

ed

heat

range

2

Inspect
insulator
for
cracks
or

chips
Check
both

center
and

ground

electrodes

3

If

they
are

excessively
worn
re

place
with
new

spark
plugs

4

Replace
spark

plugs
in

accordance

with
the
maintenance

schedule

BP
ES
ll

L46PW

l

BP4E
ll

L47PW
ll

BP7ES
ll

BP6ES
ll

L44PW
II
L4
PW
11

BP5

EQ
13
L46PM
13

BP4EQ
13
L47PM
13

BP6EQ
13

L45PM
13

BP7EQ
13
L44PM

13

BPR5ES

BPR4ES

BPR6ES

1

0
to
1
1

LQ39
to
0

043

l
l

to
1
3
0
043
to

0
051

0
8
to

0
9
0

031
to

0
035

1
5

to
i
6

P
to
14

Condition

ENGINE
POWER
NOT

UP

TO
NORMAL

Low

compmsion

Ignition
system
out
of

order

Fuel

system
out
of

order

Air
intake

system
out

of

order

Emission
control

Overheating

J

f
H
r

Overcooling
Engine
liune
up

Probable
cause

Malfunction
of
throttle
valve
switch
and

linkage
FU

models

Incorrect

ignition
timing

Damaged

spark
plugs

Wom
distributor

points

Malfunction
of

T
C
S

cMalfunction
of
S
D
V

Milfunction
of
choke

system

Clogged
fuel

pipe
or

floating
valve

Dirty
or

clogged
fuel
filter

Fuel

pump
will
not
work

properly

Clogged
carb

retor

jets

Clogged
air
cleaner

Air

aling
from
manifold

g
sket
r

carburetor

gasket

Malfunction
of
E

G
R
valve

Stick
E

F
E
valve
shaft

Insufficient
coolant

Loose
fan
bel

Wom
or
oiled
fan
belt

Inoperative
therinostat

Wom
ater

pu
p

Clogged
or
leaky
radiator

Wom
radiator
filler

ca

Air
in

cooling
ystein

Improper
engine
oil

grade

Incorrect

ignition
timing

Clogged
carburetor

lean
miiture

Inoperative
thermostat

1

ET
19
Corrective
action

Check
throttle
valve
switch
and

linkage

Adjusi
i
r

replace
if

necessary

Previously
m
entioned

Adjust

Clean

adjust
or

replace
plugs

Dress
or

replace
points
Also
check

condenser

Check
and

correct

Check
and

replace

Adjust

Clean

Replace

Repair
or

replace

t
J
Disassemble
and
clean

Replace
element

Replace

gasket

Check
and

replace

Repair

Replenish

Adjust
fan
belt

Replace

Replace

Repl
ce

Flush

repair
or

replace

ReplaCe

Retightin
e
ch

part
of

cooling
system

Replace
with

proper
grade
oil

Adjust

Overhaui
carburetor

Replace

Condition

ABNORMAL

COMBUSTION

backfire
afterfire

run
on
etc

Improper
ignition
timing

Fuel

system
out
of

order

Feulty
cylinder
heed

etc

Others

EXCESSIVE
OIL

CONSUMPTION

Oilleek8111
Engine
Tune

up

Probable
cause

Surging
A
T
C
air

cleaner
vacuum
motor

Note
This
noise
will
be
hmnl
when
clutch

iI

disengaged

We
r
on
clutch

pilot

bushing

Not
e
This
noise
will
be
heared
when

utch
iI

disengaged

Improper
ignition
timing

Improper
heal

range
of

spark
plugs

Damaged
carburetor
or
manifold

gasket

backfire
aftedire

Clogged
carburetor

jet

Improper
function
of
the
float

Uneven

idling
Run
on

Improperly
adjusted
T
O
C
S
set

pressure

Except
FU

models

Malfunction
of
anti

dieseling
solenoid
valve

Malfunction
of
fuel
shut
off

system
FU

models

Malfunction

or
auto
hoke

Improper
y

adjusted
valve
clearance

Excess
carbon

in
combustion
chamber

Da
laged
alve

spring

backfire
after
he

Malfunction
of
A
T
C
air
cleaner

Inoperative
anti4lackfire
valve

Loose
oil

tain
plUI

ose
or

damaged
oil

pan
gasket

Loose
or

damaled
chain
cover

gasket

Wom
oil
seal
in
front

and
rear
of
crankshaft

Loo
or

damaged
locker

cover

gasket

Improper
lilhtening
of

oU
filter

Loose
or

damaled
oil

pressure
switch

ET
21
Corrective
action

Repair
or

replace

Renew
bush

and

adjust
drive
shaft

Adjust
ignition
liming

Use

specified
spark
plugs

Replace
them

with
new

parts

Disassemble
carburetor
and
check
it

Adjust
the
level
and
check
needle
valve

Adjust

Adjust

Check

or

replace

Check
fuel
shut
off

system

Adjust
or
re

place
necessary

Adjust

Adjust

Remove
head
and

get
rid
of
carbon

Replace
it
wit
a

new
one

Check
for
loose
vacuum
hoses

Replace
if

necessary

Replace

Tighten
it

Renew

lasket
or

tighten
iI

Renew

gasket
or

lighten
it

Renew
oil
seal

Renew

gasket
r

lighten
it
but

not
too

much

Renew

gasket
and

tighten
it
with
the

proper

torque

Renew
oil

pressure
switch
or

tighten
it

PRELIMINARY

CLEANING
AND

INSPECTION

Before

disassembling
engine
ob

serve
the
following
items

I

Prior
to

disassembling
check

outer

parts
for

sign
of
leak

past
their

gasketed
surfaces

2
Check
carburetor
and
fuel

pump

for
condition
fuel
hoses
for
deteriora

t
ion

cracks
or
otherwise

leakage
of

fuel

past
their

jointed
or

connected

surfaces

3

Wipe
dust
and
mud
off

engine

4

Inspect
outer

parts
for
visual

faults
and
broken
or

missing

parts
such

as
bolts
and

nuts

5
Check

piping
and
electrical
cir

cuits

for
deterioration
breakage

fittings
discontinuity
or
insulation

DISASSEMBLY

To

remove

engine
from
car
refer
to

Section
ER

for
Removal

1
Remove

starting
motor
then
re

move
transmission
from

engine

2
Remove
clutch
assembly

3
Remove

alternator
fan
belt
alter

nator
bracket
and
alternator
adjusting

bar

4
Remove

idler
pulley
air

pump

belt
and
idier

pulley
bracket

If
so

equipped

Note
Loosen
idler

pulley
nut
and

belt

adjusting
bolt
in
that
order

@

1

Idler

pulley
nut

2
Belt

adjusting
bolt

3
Air

pump
belt

4
Idler

pulley
bracket
EM527

Fig
EM
2

Removing
Idle

Pulley

Air

Pump
Belt
and
Idle

Pulley
Bracket
Engine
Mechanical

ENGINE
DISASSEMBLY

5

Remove
air

pump
pulley
air

pump
and
air

pump
bracket
If

so

equipped

6
Remove
fan
fan

spacer
and

pul

ley

7
Remove

oil
level

gauge

8
Remove

distributor

cap
and

high

tension

cables
as
an

assembly

9
Disconnect
distributor
vacuum

line
from
distributor
and
remove
dis

tributor

10
Disconnect

fuel
line
from

carbu

retor

II
Remove
fuel

pump
and
fuel
line

12
Remove
water
outlet
and

thermostat

13
Remove

engine
mounting
brack

et
R
H

14
Remove

oil

pump
and
filter
as

sembly

EL043

Fig
EM

3

Removing
Oil

Pump

15

Remove

spark
plugs

16

Install

Engine
Attachment

KVlOI02500
to

cylinder
block

using

engine

f1
ounling
bracket

R
H
attach

ing
studs
fuel

pump
attaching
studs

and
alternator

bracket

attaching
bolt

holes

17
Mount

engine
on

Engine
Stand

ST050I
SOOO

Fig
EM
4

EM
3
18
Remove

engine
mounting
brack

et

L
H

19
Disconnect

air
vacuum
and

blow

by
hoses
from
air

cleaner

20
Remove
air
cleaner
and
air

cleaner
brackets

21

Remove
vacuum
control
valve

assembly
and
bracket

as
a
unit

22
Remove
carburetor
and
baffle

plate

23

Remove
E
G
R
control
valve

24

Remove
intake
and
exhaust

manifold
assemblies

EM528

Fig
EM
5

Removing
Manifold

25
Remove
P
C
V

hose

pipe
con

nector
to
control
valve

26
Remove

rocker
cover

27
Loosen
valve
rocker

adjusting

nut
and
turn

adjusting
screws
out
to

disengage
push
rods
Then

evenly

loosen
rocker
shaft
bolts

28
Remove
rocker
shaft

assembly

EM453

Fig
EM
6
Removing
Rocker

Shaft

Assembly

29
Withdraw

push
rods
and

keep

them
in

correct
order
1

30
Loosen

cylinder
head
bolts

a

little
at
a
time

in
the

sequence
shown

in

Fig
EM
and
remove

cylinder

head

29

Apply
engine
oiho
both
ends

of

push
rods
and
insert
in

proper
se

quence

30

Apply

engine
oil
to

valve
stem

end
and

rocker
arm
contact

surfaces

Position
rocker
shaft

assembly
on

cyI

inder
head

31

Tighten
rocker
shaft
bracket

bolts
to

specified
torque

fJ

Tightening
torque

Rocker
shaft
bracket
bolts

2
0
to
2
5

kg
m

14
to
18
ft

b

Note

Tightening
should
be
done

in

two
or
three

stages
outwardly
from

center
bracket

EM506

Fig
EM

77
Rocker

Shaft
Bolt

Tightening
Sequence

32

Adjust
valve

clearance
to

speci

fied
value

Note

a
First

set
clearance
to
0

25

mm

0
0098

in
when

engine
iscold

b
After

engine
has
been
assembled

warm
it

up
for
at
least
several

minutes

finally

adjust
clearance
to

specification
For
details
refer
to

Adjusting
Intake
and
Exhaust
Valve

Clearance
in
ET

Section

EM507
or

Wrench

2
Screwdriver

3
Feeler

gauge

Fig
EM
78

Adjusting
Value

Clearance
Engine
Mechanical

Valve

clearance

Intake
and

exhaust

hot

0
35
mm
0
014
in

cold

0

25
mm
0
010
in

fJ

Tightening
torque

Velve
rocker

adjusti
g
nut

1
6
to
2
2

kltm

12
to
16
ft
b

33

Install
rocker

cover

34

Install
intake
and

exhaust
mani

folds

fJ

Tightening
torque

Manifold
nuts

1
5
to
2
0

kg
m

11
to
14

fHb

Note

When

installing
intake
and
ex

haust

manifolds
locate
bolt

in

center
of

fitting
hole

EM528

Fig
EM
79

Installing
Manifolds

35
Install
E
G
R
control

valve

36

Install
baffle

plate
and

carbure

tor

fJ
Tightening

torque

Carburetor
nuts

0
4

to
0
6

kg
m

2
9
to
4
3
ft

Ibl

37
Install
vacuum

control
valve
as

sembly
and
bracket

38
Install

air
cleaner

bracket
and
air

cleaner

39

Connect
air

vacuum
and

blow

by
hoses
to
air

cleaner

40
Install

pipe
connector
to
control

valve
hose
and

engine

mounting
brack

etLR

41

Install

distributor

EM

16
CAUTION

a
8e
sure
to
set
No
1

piston
to

LD
C
of

compression
stroke

b
Before

instaliation
return
distribu

tor
rotor

approximately
30

degrees

from
its
correct

position
Insert

distributor

meshing
distributor

drive

gear
and
driven

gear

c
After
installation
distributor
rotor

should

align
with

mark
on
rotor

cap

J

No
1

mark

EM508

Fig
EM

80
Cornct
P05ition

of

Rotor

42

Dismount

engine
from

Engine

Stand

ST0501S000
and

place
it

on

suitable

engine
stand

Re

move

Engine
Attachment

KVlOI
2500

43

Install

spark
plugs
and

engine

mounting
bracket
R
H

44

Install
oil

pump
and
ftIter

assem

bly

45
Install
thermostat

and
water

outlet

46
Install
fuel

pump
and
fuel

lines

Do
not

forget
to

install

spacer
and

gasket

47

Install
distributor
vacuum
line

48
Install
distributor

cap
and

high

tension

cables
as
an

assembly
Connect

high
tension

cables

49
Insert

oil
level

gauge

50

Install
fan
fan

pulley
and
fan

spacer

Lock
bolt

by
bending
lock

washers

51

Install
alternator
bracket

adjust

ing
bar
water

pump

pulley
alternator

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

JUDGMENT

OV
is

indicated

IC

ignition
unit
NG

But

condition
of

pick
up
coil
can

not
be

judged
Proceed
to
the
item

for

Pick

up
Coil

Check

Bat

tery
voltage
is
indicated

Condition
cannot
be

judged

Proceed
to
item
9

9

Remove
IC

ignition
unit

Refer
to
IC

ignition
Unit
for
re

moval

10
Measure
resistance

between
two

terminals
of

pick

up
coil

JUDGMENT

Approx
40011
are
indicated

The

ignition
coil
is

an
oil
filled

type
The

ignition
coil
case
is
filled

with
oil
which
has

good
insulating
and

heat

radiating
characteristics

The

ignition
coil
has
a

greater
ratio

between
the

primary
and

secondary

windings
to

step
up
battery
voltage
to

high
voltage
This

causes

stronger

sparks
to

jump
the

spark
plug
gap

The

cap
is

made
of

alkyd
resin

which
offers

high
resistance

to
electric

arc
and

increased
insulation

When

high
tension
cable
is
installed

to

ignition
coil
there
should
be

no

clearance
between
their

caps

Note

Do
not

disconnect

high
tension

cables
from

spark
plugs
during
en

gine
running

r

EE354

1

High
tension
cable

2
Rubber
cap

Fig
EE
74
Correct
Instalhltion

of

High
Tension
Cable
Engine
Electrical

System

Pick

up
coil
OK

IC

ignition
unit

NG

Approx
40011
are
not

indicated

Pick

up
coil
NG

Condition
of
IC

ignition
unit

can

not
be

judged
Proceed
to

item
11

II

Replace
faulty
pick
up
coil
with

new

one

12
Install

original
IC

ignition
unit

13
Check

parking
performance

JUDGMENT

Sparks
occur

IC

ignition
system
IC

ignition
unit

OK

No

spark
OCCUrs

IC

ignition
unit

NG

IGNITION
COIL
If
NG

replace

faulty
IC

ignition

unit

with
new
one

P1ck
up
coil
check

I

Make
sure
that

ignition
switch

is

in

OFF

position

2
Remove

IC

ignition
unit

Refer
to

IC

Ignition
Unit
for
removal

3
Measure
resistance

between
two

terminals
of

pick
up
coil

JUDGMENT

Approx
40011
are
indicated
OK

Approx
40011
are
not

indicated

NG

If

NG

replace
faulty
pick
up
coil

with
new

one

1

@

I

rJ

1

C

I

I

i

jllll
1

t

1

Rubber
cap
for

ignition
coil

2

Secondary
tenninal

3

Cap

4

Primary
terminal

5

Spring

6

Secondary
winding

EE
28
EE578

7

Primary
winding

8

Side
core

9
Insulator

10
Center
core

11

Segment

12
Case

Fig
EE

75
Ignition
Coit