check engine DATSUN 210 1979 Manual Online

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

CHECKING
AND

ADJUSTMENT

CAP
AND
ROTOR
HEAD

Cap
and
rotor
head
should
be

in

spected
periodically
as

specified
in
the

Main
teoanee
Schedule
Remove

cap

and
clean
all

dust
and
carbon

deposits

from

cap
and

rotor
from
time

to
time

If

cap
is
cracked
or
is

leaking
replace

wi
th

a
new
one

ADVANCE
MECHANISMS

SpecHlcatlons

Refer
to
Service

Data
and

Specifica

tions

for
distributor

Vacuum
advance
mechanism

mechanical

parts

If

vacuum
advance
mechanism
fails

to

operate
properly
check
for
the

followin
B
items

and
correct
the

mal

function
as

required

I

Check
vacuum
inlet
for

signs
of

leakage
at

its
connection

If

necessary

retighten
or

replace
with
a

new
one

2
Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controUer

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

plate
does
not
move

smoothly

this

condition
could
be

due
to

sticky

steel
balls
or

pivot
Apply
grease
to

steel
halls
or

if

necessary
replace

breaker

plate
as
an

assembly

Centrifugal
advance

mechanical

parts

When
cause
of

engine
malfunction

is

traced
to

centrifugal
advance
mecha

nical

parts
use
distributor
tester
to

check
its

characteristics

If

nothing
is

wrong
with
its

charac

teristics

conceivable

causes
are

faulty

or
abnormal

wear
of

driving
part
or

others
So

do
not
disassemble
it

In
the
event
of

improper
character

istics

check

closely
rotor

shaft
assem

bly

governor
weight
and
shaft

If

any
of
the
above

parts
are
mal

functioning
replace
the

parts
Engine
Electrical

System

DISASSEMBLY

AND
ASSEMBLY

DISASSEMBLY

I
Take
off

cap
and

remove
rotor

head

2
Remove

Ie

ignition
unit
Refer
to

IC

Ignition
Unit
for
removal
and
in

stallation

3
Remove
stator
and

magnet
by

removing
stator

securing
screws

4

Remove
vacuum
controller
by

removing
securing
screws

EE746

Fig
EE
59
Removing
Vacuum

Controller

5

Using
two

pry
bars

or
suitable

puller
pry
reluctor
from
shaft

CAUTION

When

removing
reluctor
be
careful

not
10
distort
or

damage
the
teeth

6
Remove
roll

pin

7
Remove

pick
up
coil

assembly

8
Remove
breaker

plate
setscrews

and
remove
breaker

plate
assembly

EE703

Fig
EE
60

Removing
Breaker
Plate

Setscrews

9
Punch
knock

pin
out
and
remove

pinion

EE
23
EE704

Fig
EE
61

Removing
Knock
Pin

10
Remove
rotor
shaft
and
drive

shaft

assembly

EE705

Fig
EE
62
Removing
Rotor
Shaft
and

Drive

Shaft
Assembly

11

Mark
rotor
shaft
and
drive

shaft

Remove

packing
from
the

top
of
rotor

shaft
and
unscrew
rotor
shaft
setscrew

Remove

rotor
shaft

EE706

Fig
EE
63
Removing
Rotor

Shaft

12

Mark
one
of
the

governor

springs
and
its

bracket
Also
mark
one

of
the

governor
weights
and
its

pivot

pins

13

Carerully
unhook
and

remove

governor

springs

14
Remove

governor
weights

A
r

ply
grease
to

guvernor
weights
after

disassembling

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Carefully
observe
the

fol

lowing
instructions

CAUTION

B
tfore
installi
lg
IC

ignition
unit
make

sure

mating
surfaces
of
IC

ignition
unit

and
distriblitor
are
clean
and
free
from

dust
sand
and
moisture

Align
match

marks
so

that

parts

are
assembled
to

their

original
posi

tions

2

Ensure
that
reluctor
is

properly

oriented

when

installing
on

shaft
Al

ways
drive
in
roll

pin
with
its
slit

toward

the
outer
end

of
shaft
See

Fig
EE
64
Be

sure
to

use
a
new

roll

pin

DESCRIPTION

The

IC

ignition
unit

utilizes
a
semi

conductor
IC
device
and
is

mounted

on
the

side
surface

of
the
distributor

The

IC

ignition
unit

has
the
fol

lOwing
circuits

Spark
timing
signal
monitoring

circuit

This
circuit

detects
the

ignition

signal
sent
from
the
distributor

pick

up
coil

and

amplifies
the

signal

2

Lock

preventing
circuit

This
circuit

cuts
off
the

ignition

coil

primary
current
when
the

ignition

switch
is

ON
and
the

engine
is

sta

tionary

If
the

ignition
coil

primary
current

is

allowed
to
flow
under
such

condi

tions

excessive
current
will

be
drawn

because
of
low
internal
resistance
of

the

ignition
coil
Engine
Electrical

System

r

5

EE747

Fig
EE
64

Driuing
in
Roll
Pin

3

When

installing
pinion
on
shaft

be

sure
to

install

pinion
gear
correctly

to

position
where

it

was
installed

4

Apply
grease
to

the

top
of
rotor

shaft

as

required

5

Check
the

operation
of

governor

before

installing
distributor
on

engine

Ie

IGNITION
UNIT

This
can
result
in
an

abnormal

temperature
rise
in

the

ignition
coil

or

discharged
battery
These

malfunc

tions

can
be

prevented
by
this
lock

preventing
circuit

3

Duty
control
circuit

This
circuit

controls
the
ratio
of
the

ignition
coil

primary
current
ON
OFF

time

periods
in

one

cycle
of

ignition

operation

111is
is

equivalent
to
the
dwell

angle

of
the
conventional

point
type
dis

tributor
In
order
to

provide
high

performance

spark
ruing
over
a

wide

range
of

driving
speeds
this

duty
can

be
controlled

by
the
source

voltage

and
the

ambient

temperature
as
well

as

by
the

engine

rpm

4

Power

switching
circuit

This
circuit
is

used
to
make
or

break

directly
the

primary
circuit
cur

EE

24
6

Properly
eenterstatOr
and
reluc

tor
before

tightening

Standard
air

gap

0
3
to
0
5
mm

0
012
to
0
020
in

0
3
to

0
5
mm

0
012
to
0
020
in

Fig
EE

65
EE748

Air

Gap

7

Adjust
ignition
timing
after
distri

butor
is

installed
on

engine

rent
of
the

ignition
coil

5

Current

limiting
circuit

This
circuit

controls
the

current

value
so
that
excessive
current

will
not

flow

through
the

power

switching
cir

cuit

To
ensure

efficient

operation
of
the

IC

ignition
unit
these
five

circuits
are

manufactured
in

one

assembly
as

shown
in

Fig
EE
66

The

semi
conductor
IC
is

utilized

for
all
these
circuits

except
the

power

switching
circuit
The

power
switching

circuit

uses
one

power
transistor
and

the
circuit
is

arranged
on
the
ceramic

substrate

together
with
resislors

capa

citors

and
diodes

Each

component
part
of

this
unit
is

highly
reliable

however
should

any

part
be
found

faulty
the

entire
as

sembly
musl
be

replaced

Engine
Electrical

System

Battery
Ignition
switch

CG

1

e
@

P
L
JO

L
J

Ignition
coil

r

Spark
timing

signal

I

oni
1oring

Clfcwt

0
R

Lock

Pi
k
il
preventing

c

up
co

circuit

Ln
n

Distributor
2P

fJ
1I
connector

8C

H
uty
control

ClICUlt
Power

switching

circuit

Current

limiting

circuit

Ie

ignition
unit

EE749

Fig
EE
66
Ie

Ignition
Unit
Circuit

Diagram

REMOVAL
AND

INSTALLATION
5
Disconnect

pick
up
coil
wire
from

IC

ignition
unit

Note
Holding
connector
with
needle

nose

pliers
as
shown
in

Fig
EE
68

disconnect

pick
up
coil
terminal
Be

careful
not
to

pull
lead
wire
I
Disconnect

battery
ground
cable

2

Take
off
distributor

cap
and
re

move
rotor
head

3

Disconnect
harness
connector

4

Remove
Ie

ignition
unit

securing

screws

rf

I
I

EE751

Fig
EE
68
Di
Connecting
Pick

up
Coil

Term
inal

eE750

Fig
EE
67

Removing
Ie

Ignition

Unit
6

InstaU
IC

ignition
unit
in

the

reverse
order

of
removal

EE
25
CAUTION

Before

instelling
IC

ignition
unit
mike

sure

mlting
surfaces
of

IC

ignition
unit

end
distributor
Ire
cleen
and
free
from

dust

sand
and
moisture

Note

a
When

connecting
lead
wires

to
unit

insert
lead
wire
terminal
with
fin

ger
as
shown
in

Fig
EE
69

b

Connect
lead
wires

according
to

color
marked
on

upper
face
of

grommet

EE752

Fig
EE
69

Connecting
Pick

up
Coil

Terminal

CHECKING
IC

IGNITION
SYSTEM

DESCRIPTION

To
check
the
IC

ignition

system

use
a
circuit

tester
The

ignition
per

fannance
of
the

ignition
system
at
a

high
speed
cannot
be
measured

direct

ly
However

it
can
be

checked

by

operating
a
vehicle

actually
at
a

high

speed
The
IC

ignition
system
can
be

checked

easily
by
referring
to
the

Inspection
Table
For
the

method
of

inspection
refer
to

respective
items

INSPECTION
TABLE

I

No

spark
occur

Check

high
tension
cable

NG
OK

Repair
and

lor
replace
ngine
Electrical

System

START

Check

sparking
performance

J
J
Sparks
oci
1u

IC

IGNITION
SYSTEM
OK

Check
power
supply
circuit

NG

Repair
and
or

replace
OK

Check

primary
circuit
Proceed
to

A

Proceed
to
A
NG

epair
an
or

replace
OK

Proceed
to
A
DISTRIBUTOR
ASSEMBLY
NG

lC
IGNITION
UNIT
AND
OR

PICK
UP

COIL
NG

Mealure

pick
up
coil
resistance

as
a

distributor
assembly

Except
approx
4000

Measure

igilition
coii

8terminalvoltage

Battery
voltage

t
OV

Measure

pick
up
coil
resistance

I
Ie
IGNITION
UNIT
NG

Except
approx
400n

Approx
400n

PICK
UP
COIL
NG

1
PICK

UP
COIL
OK
Replace

IC

IGNITION

Replace

I
UNI
NG

l
Meuure

pick
up
coil
resistance

Except
approx
4000
I

Check

sparking
performance

I
Replace

I

r
PICK
UP
COIL
NG

1

No

spark
occun

Sparks
occur

I
IC
IGNITION

flc
IGNITION
Proceed
to
A

Replace

UNIT
NG

i
UNIT
OK

Proceed
to
A

Replace

Proceed
to
A

CHECKING

PROCEDURE

Sparking
performance

check

L
Turn

ignition
switch
to

OFF

position

2
Disconnect
anti
dieseling
solenoid

valve
connector
to
cut
off

supply
of

fuel
to

engine

3

Disconnect

high
tension
cable

from

spark
plug

4

Keeping
high
tension

cable
end
4

to
5

mm
0

16
to
0
20
in

away
from

engine
block
rotate
starter
motor
and

check
whether
sparks
occur
across
the

clearance
JUDGMENT

Sparks
occur

IC

ignition
system
OK

In

this
case
IC

ignition
system
and

component
parts
need

not
be
checked

beyond
this

No

spark
occurs

IC

ignition
system
NG

In
case
of
NG
check

High
Tension

Cables

Nole

This
check
is

designed
to

deter

mine

only
ignition

spark
perform

ance
when

cranking

engine
If

test

results
are

satisfactory
Ibis
does

EE

26
I

Approx
400n

PICK
UP
COIL
OK

1C
IGNITION

UNIT
NG

I
Repair
and
or

replace

I
Proceed
to
A

Approx
400n

l
PICK
UP

COIL
OK

1

not

alwaY
indicate

performance

sufrlcienl
for

high
speed

operation

IOgh
tension

cable
check

Refer
to

Engine
Tune

up
for
Check

ing
Ignition
Wiring
Distributor

Cap

and
Rotor

JUDGMENT

If

high
tension

cable
is
OK
check

Power

SupplY
Circuit

If

high
tension
cable
is
NG

replace

cable

assembly

Power

suppl
circuit
check

Make

sure
that

ignition
switch
is

in
OFF

position

2

Disconnect
Ie

ignition
unit

con

nector
from
unit

3
Turn

ignition
switch
to
ON

position

4

Measure

voltage
at
the

terminal
as

shown
in

Fig
EE
70

I

I

1

Fig
EE
70
EE734

Checking
Power
Supply

Circuit

5
Turn

ignition
switch
to
OFF

position

JUDGMENT

Battery
voltage
is

indicated
OK

In
this
case

check

Primary
Circuit

Battery
voltage
is

not
indicated

NG

In

case
of

NG
check

power

supply

wirings
fusible

link

ignition
switch

and

connecto
s
for
condition
and
con

tinuity

Primer
circuit
check

I

Make
sure
that

ignition
switch
is

in
0
FF

position

2

Disconnect
IC

ignition
unit

con

nector
from
unit

3

Turn

ignition
switch
to
ON

position

4

Measure

voltage
at
the
terminal
as

shown
in

Fig
EE
7I

1
I
r

1

EE735

Fig
EE

7I

Checking
Primary

Circuit
Engine
Electrical

System

5
Turn

ignition
switch
to

OFF

position

JUDGMENT

Battery
voltage
is
indicated
OK

In
this
case
proceed
to
the

step
for

IC

Ignition
Unit
and
Pick

up
Coil

Check

Battery
voltage
is
not
indicated

NG

If
NG
check
condition
and

con

tinuity
of

primary
circuit

wirings
and

connectors
If
results
of

these

inspec

tions
are

satisfactory
check

Ignition

Coil

Ignition
coil
check

I

Make
sure
that

ignition
switch
is

in

OFF

position

2
Disconnect
harness

connector

from

ignition
coil8terminal

3
Measure
resistance
between
and

8terminals

Resistance
1

range

C2J

j

EE567

Fig
EE
72

Checking
Ignition
Coil

Assem

bly

JUDGMENT

If
resistance
value
is
0
84
to

1
02n

OK

If
resistance
value
is

other
than

the

specified
value
NG

Ie

Ignition
unit
end

pick
up

coli
check

If

power
supply
circuit

primary

circuit

and

high
tension

cables
are
in

good
order
IC

ignition
unit

and
or

pick
up
coil
are

malfunctioning

I

Make
sure
that

ignition
switch
is

in
OFF

position

2
Remove

distributor

cap
and
ro

tor

EE
27
3
Measure
resistance

between
two

terminals
of

pick
up
coil

as
a
distribu

tor

assembly
with
a
circuit
tester

1
Tester

probes

2
Grommet

3
Ie

ignition
urnt

EE736

Fig
EE

73

Measuring
Pick

up
Coil

Resistance

4
Measure
resistance

by
reversing

polarity
of
circuit

tester

probes

JUDGMENT

Approx
400n
are
indicated

Pick

up
coil
OK

IC

ignition
unit
NG

In

this
case

replace
faulty
IC

igni

tion
unit
with

new
one

Approx
400n
are
not
indicated

Condition
cannot
be

judged

Thus

proceed
to
item
5

Note
If
resistance
is

approx
4OOn

no

further

inspection
is

required

replace
IC

ignition
unit

5
Make
sure
2

pin
IC

ignition
unit

connector
is

securely
connected
to

unit

6
Turn

ignition
switch

to
ON

position

7
Measure

voltage
at

ignition
coil
8

terminal

8
Turn

ignition
switch
to
OFF

position

CAUTION

Turn

ignition
switch
off
after

releasing

test

probe
of
circuit

tester
from

nega

tive
terminal
of

ignition
coil
Failure

to
do

this
could
result
in

damage
to

circuit
tester

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

INSPECTION

I

Disconnect

high
tension

cables

from

spark
plugs
by
pulling
on

boot

not
on
cable
itself

2

Remove

spark

plugs

3

Check
electrodes
and
inner

and

outer

porcelains
of

plugs
noting
the

type
of

deposits
and
the

degree
of

electrode
erosion

Refer
to

Fig
EE

76

Normal
Brown

to

grayish
Ian
de

posits
and

slighl
electrode
wear

indicate
correct

spark

plug
heat

range

Carbon
fouled

Dry
fluffy
carbon
de

posits
on
the
insulator
and
elec

trode
are

mostly
caused

by
slow

speed
driving
in

city
weak

ignition

too
rich
fuel
mixture

dirty
air

cleaner
etc

H
is
advisable
to

replace
with

plugs

having
hotter
heat

range

Oil
fouled

Wet
black

deposits
show

excessive

oil
entrance
into

comb
us

tion
chamber

through
worn

rings

and

pistons
or
excessive

clearance

between
valve

guides
and
stems
If

the
same
condition
remains
after

repair
use
a
hotter

plug

Overheating
White
or

light
gray
insu

lator
with
black
or

gray
brown

spots
and
bluish
burnt
electrodes

indicate

engine
overheating
More

over
the

appearance
results
from

incorrect

ignition
timing
loose

spark
plugs
low
fuel

pump
pres

sure

wrong
selection
of
fuel

a

hotter

range
plug
etc

H
is
advisable
to

replace
with

plugs

having
colder
heat

range

4
After

cleaning
dress
electrodes

with
a
smaU
fme
file
to
flatten
the

surfaces
of
both

center
and
side
elec

trodes
in

parallel
Set

spark
plug

gap
to

specification

5

Install

spark

plugs
and

torque

each

plug

6
Connect

spark
plug
wires

CLEANING

AND

REGAP

Clean

spark
plugs
in
a
sand
blast
Engine
Electrical

System

SPARK

PLUG

Conventional

type

Normal

Overheating

Multi

gap
type

Nonnal

Overheating

type
cleaner
Avoid
excessive

blasting

Clean
and
remove
carbon
or
oxide

deposits
but
do
not
wear

away
porce

lain
If

deposits
are
too
stubborn

discard

plugs

After

cleaning
spark

plugs
renew

firing
surface
of
electrodes
with
file

mentioned

above
Then
check

spark

plug
gap
with
wire

feeler

gauge
All

spark
plugs
new
or
used

should
have

the

gap
checked
and
reset

by
bending

ground
electrode

EEOSO

Fig
EE
77
Setting
Spark
Plug
Gap

Except
FU
model

EE
29
Carbon

fouled

EE079

Worn

Carbon

fouled

Worn

EE601

Fig
EE

76

Spark

Plug

EE586

Fig
EE
78

Setting
Spark
Plug

Gap
FU
models

Engine
Electrical

System

III

ALTERNATOR

Including
voltage
regulator

Condition

No

output

Excessive

output

Low

output

Noisy
alternator
Probable
cause

Sticking
brushes

Dirty
brushes
and

slip
rings

Loose
connections

or
broken
leads

Open
stator

winding

Open
rotor

winding

Open
diodes

Shorted
diodes

Shorted
rotor

Shorted
stator

Ground
BAT

terminal

Broken
fan
belt

Voltage
regulator
breakdown

Poor
connection
of
alternator

S
terminal

Open
diode

Loose
or
worn
fan
belt

Slicking
brushes

Low

brush

spring
tension

Voltage
regulator
breakdown

Dirty

slip
ring

Partial
hort

ground
or

open
in

stator

winding

Partially
shorted
or

grounded
rotor

winding

Open
or

damaged
diode

Loose

mounting

Loose
drive

pulley

Broken
ball

bearing

Improperly
seated
brushes

EE

36
Corrective
action

Correct
or

replace
bru
hes
and
brush

springs

Clean

Retigliten
or

older
connection

Replace
leads
if

necessary

Repair
or

replace
stator

Replace
rotor

Replace

Replace

Replace
rotor

Replace

Replace
insulator

Replace

Check

regulator

operation
and

repair
or

replace
a

required

Correct

Replace

Retighten
or

replace

Correct
or

replace
brushes
and

springs
if

necessary

Replace
brush

spring

Check

regulator
operation
and

repair
or

replace
as

required

Clean

Replace
tator

Replace
rotor

Replace
diode

Retighten
bolts

Retighten

Replace

Seat

correctly