engine DATSUN 510 1968 Service Workshop Manual

ENGINE
ELECTRICAL
SYSTEM
101

8
To

separate
the
stator
from
the
dIode
end

housmg
assembly
unsolder
the
three

negatIve

dIodes

from
the
three
co1l1ead
WIres
The

nega

tIve
dIodes
are
marked
WIth
black

figures
and
the

posItIve
ones
With
red

figures

CAUTION

Use

extreme
care
when

unsoldenng

the
diodes
to

prevent
excessive
heat

from
damagmg
thi
m
Use
a
100
to

200
watt

soldermg
Iron

for
no
more

than
two
seconds
at

the
dIOde

Junction

9
Remove
the
brush
cover

by
unscreWIng
the

two
set
screws

10
Unsolder
the

negatIve
terminal
lead
wire

Separate
dIOde
end
from
stator

Figure
33

@

11
Remove
the
heat
smk
and
the
brush
holder

from
the

rear
cover

by
unscrewmg
the
setscrews

as
shown

m

Figure
34

@
12
DIsassemble
the
brush
holder

by
unsolder

ing
the
F
lead
WIre
black
whIte
E
lead
WIre

black
and
the

negatIve
and

pOSItIve
brush

holder
Wires

Figure
35
shows
the
brush
holder

dIsassembled

O
tlII

I
@

13
To
remove
a
dIode
from
the
heat

smk
sup

port
the
heat
SInk
WIth
a
swtable
stand

Figure

36
and

push
out
the
dIode
With
an
arbor

press

Do
not

attempt
removal
WIth

a
hammer
as
the

shock

may
damage
all
the
dIodes
ill
the
heat
SInk

Press
out
so
as
not
to

Injure
the

mounting

bore
01
the
frame
or
the
heat
Sink

14
To

replace
a

dIode
m
the
heat
smk

support

the
heat
SInk
With
a
SUItable
stand
and

press
the

dIode
mto

place
as
shown
m

Figure
37

Inspection
and

Repair

I

InspectIon
of
the
alternator
Includes
electncal

testmg
and
mechanIcal

InspectIon
of
all

parts

for

damage
or
exceSSIve
wear
An
electrIcal

tester

proVIdmg
reSIstance

anI
contmUlty
testlng

IS

requIred
Before

dIsassembly
of
the
alternator

ENGINE
ELECTRICAL

SYSTEM

103

2
Check
the
lead

Wires
of
the
armature
coil

Includmg
the

neutral
wire

for

ground
as
shown

In

Figure
42

HIgh
reSIStance
no
current
flow

indicates

gqod
condItion

If

not
the
stator
must

be

replaced

DIODE

INSPECTION

The
diodes
can
be

inspected
through
the
use

of
a

lamp
and

battery
or
with

a
tester
The

lamp

and

battery
test
can
be
made
Without

disassembl

ing
the
alternator
wh1le
the

tester
should
be
used

when
the
dIodes

are

dIrectly
acceSSIble

1
Positive
Dwde
Test
Connect

the

battery

negative
terrmnal
WIth
the

connector
A
terrmnal

WhIte
and
the

battery

pOSItIve
terminal
With

the
connector
N

terrmnal

yellow
as
shown

m

Figure
43
The

lamp
m
the
circuit
should

hght

@

Reverse
the
connection
as

shown
m

Figure
44

If
the

lamp
does
not

hght
the

pOSItIve
diodes

are

satisfactory
If
the

lamp
does

light
one
or

all
of

the

pOSItIve
dIodes

are
defective
and
must

be

replaced
@

Qg

2

Negative
DIOde
Test

Connect
the

battery

negatIve
termmal
to

the
connector
N
terrmnal

yellow
and
the

battery

pOSItIve
termInal
to
the

connector
E
termmal

black
The

lamp
m
the

CIrcUit
should

lIght
Reverse

the
connectIons
If

the

lamp
does

not

lIght
the

nega1
ve
dIodes
are

satlsfactory
If
the

lamp
does

lIght
one

or
all

I

of
the

negatIve
dIodes

are
defectIve
and
must
be

replaced

To
test
the

indiVIdual
dIodes
With
a
tester

proceed
as
follows

1
There

are
two
kInds
of
diodes
as
shown
m

Figure
45
Check
dlOd
reSIstance

usmg
a
tester

In
both
dIrectIons

as

jl
own
in

Figure
46

f

Current
flow
@

Current
flow

re

ack

flgUre

e

terminal

r

Positive
diode

Negative
diode

@

ENGINE

ELECTRICAL
SYSTEM

105

VOLTAGE

REGULATOR

REMOVAL

To

remove
the

voltage
regulator
dISconnect

the
6

way
multIple
electrIcal

COlInector
and
the

screws

holdmg
the

regulator
to
the
SIde
wall

lJ

R
ftl5
C

Wt

Str

Ii

DISTRIBUTOR
W
I
vE

Dlstnbutors
used

on
models

covered
m
this

manual
are
SImilar

except
that

some
have
a

dual
contact

pomt
system
rather
than

a

single

contact

system
The
dual

pomt
system

applies

to
1970
and
newer
models

eqUIpped
With
the

exhaust
and

evaporatIve
ermsslOn
control
deVIce

The

pomts
are

placed
m

parallel
In
the
circuIt

so
that
there
IS
a

pqase
dIfference

In
their

opera

tIon
Phase
dlfference

IS
5

degrees
on
1970

19
71

models
and
31h

degrees
on
1972
models

This

can
be

adjusted
With
the

adjustIng
screw
on

what
IS

called
the
retarded
breaker
Figure
51
shows
the
dual

point
distributor

FunctIonally
the
dIStnbutor
consists

of
the

hIgh

voltage
electrical

system
the

ignitIon
switch
the

centrifugal
advance
mechanISm

a
vacuum
ad

vance

mechanIsm
and

a
mechanIcal

driving

mechanISm

Figure
52

next

page
IS
an

ignItion

diagram
that
shows

parts
of

the

IgnItIon
CIrCUIt

The
dIstributor
shown

IS

typIcal
of
the

single

contact

pomt
system

CONSTRUCTION

Figure
53
shows

a

typical
distributor
used
and

Figure
54
shows

the
dIStnbutor
in
an

exploded

VIeW

Figures
55

page
107
and
56

page
108

provide
detaIled

exploded
VIews
of
the

lugh

tenSIon
cable

system
and
the

single
point
contact

system
Figure
57

page
109
covers

dIStrIbutors

With
the
dual

pOInt
system
The

descnptions

given
below

for

dIsassembly
and

repair
apply

espeCIally
to
the

smgle
pOInt
system
but
are

generally
true
for
the
dual

point
system

@

@
ADVANCED
BREAKER

PHASE
DIFFERENCE

5

DEGREES

106
CHAPTER
NINE

@

Igmtlon
switch

IgnItion

plug

engine

Condenser

IgnItIon
cod

@

II

9

ft

O

CHECKING
AND
ADJUSTMENT
foreIgn
matenal
or
cracks
Qean
the

cap
thor

oughly
Replace
it
If
cracks
are
found

Inspect

the

hIgh
tensIon
cables
to
see
that
all
connectIons

are

firmly
made
and
that
the
cables
are
not

cracked

Replace
any
defective
cables
Do
not

try
to

tape
or
mend
them
Cap
and
Rotor
Head

The

cap
and
the
rotor
head
must

always
be

kept
clean

to

prevent
lugh
voltage
leaks

Inspect

the

cap
penod1cally
for

SIgnS
of
carbon

bwldup

ENGINE
ELECTRICAL
SYSTEM
111

@

7
WIth

a
hammer
and

punch
knock
out
the

pm
holdmg
the
collar
set
to
the
shaft
Be
certain

to
mark
the
relatIve
locatIon
of
the
collar
set
to

the
shaft
before
removal
See

Figure
61

@

8
Remove
the
shaft
and
cam
as
shown
m

Figure
62

@

V
t

0

ao
9
Remove
the
cam

by
removmg
the
set
screw

at
the

top
of
the
shaft
and

pulling
the
cam
off

Be
certam
to
mark
the
cam
location

relatIve
to

the
shaft
before
removal
See

Figure
63

@

10

Inspect
all

parts
carefully
for

SIgnS
of
wear

or

damage
Replace
defectIve

parts

Assembly
of
the
dIStrIbutor
IS
the

reverse
of

disassembly
Make
certam
all

parts
are
rein

stalled

m
the
same
relative
location
to
the
shaft

1S
when
removed
Refer
to

Figure
64
for

setting

the

governor
springs
and
cam
See
Table
1

page

112
for
Distributor

SpecIficatIons

@
5

2

3

1
Go
emor

Welgbt
5
Carn

plate

2
Clearance
lor

advanCing
6

Welgbt
pin

angle
7
Circular
hook

3

Rectangular
hook
8
Governor

spnng
A

4
Go
ernor

spnng
8
9
Rotor

posltlomng
lip

IGNITION
COIL

The

IgnItion
COllIS
shown
m

Figure
65
and

IS
a
HItachI
model
C
14
51

Repair
of
the

IgnitIon

ENGINE
ELECI
RICAL

SYSTEM

113

i

Normal

plug
appearance
noted

by
the
brown

to

graYlsll
lan

depOSits
and

slight
eleclrode

wear
This

plug
indicates
the
correct

plug
heal

range
and

proper
air
fuel

ratio

jI

Jo

t
Ql
i

Carbon

fouhng

distinguished
by

dry
fluffy
black

carbon

depOSits
which

may
be
caused

by
an

over

rich

alr
lue
mixture
excessive
hand

choking

clogged
air

filler
or
excessl
e

Idling

t
I

j
if

r
l

1

tfc
ji

0
1

fouling
indicated

by
wet

o
ly
depOSits
caused

by
011

pumping
past
worn

rings
or
down
the
Intake

valve

gUIdes
A
hotter

plug

temporanly
reduces

011

depOSits
but
a

plug
that
IS

too
hot
leads

to

pre

Ignition
end

possible

engine
damage
@

Red
brown

yellow
and
white

coatings
caused

by

luel
and
011
addltl

es
These

depOSits
are

not
harm

ful
If

they
remain
In
a

powdery
lorm

pr

11

L
J

J

S

C

ShinY
yellow

glaze
on
Insulalor
cone
IS

caused
when

the

powdery

depOSits
from
fuel

and
011
addltl
es

melt

Melting
occurs

during
hard

acceleration
alter

prolonged
Idling
This

glaze
conducts

electnclty

and

shorts
out
the

plug

e

1

A
I

A

I

7

Overheated

plug
indIcated

by
burned

or
blistered

Insulator

tiP
and

badly
worn
electrodes
ThiS
condl

J

tlon

may
be

caused

by
pre
Ignition

cooling
system

defects
lean
alr

luel
ratiOS
low
octane
luel

or
o
er

advanced

Ignition
timing

Spark
plUI
condition

photos
courtesy
of
AC

SPIr1l
Plug
Olv
s
on

Gene
MolDrs

Corporlllon

CHAPTER
TEN

EMISSION

CONTROL
SYSTEM

ThIs

chapter
covers
emission

control
and

exhaust

systems
The
emission

devices
used
in

clude
crankcase
ermssion

controls
an
exhaust

ermssion

system
and

evaporative
emission
con

trols

EXHAUST
EMISSION

CONTROL
SYSTEM

Two
methods
of
exhaust
emission

control
are

used

on
the
Datsun

One
is

an
aIr

injection

system
the
other
consists

of

engine
modifica

tIons
Datsuns

were

equipped
With
the
air

injec

tIon

system
only
through
1970
SInce
then
all

models

have
combined
aIr

mjection
with

engine

modIficatIons
EmisSIon

servicing
IS

complex

and

should
be
left
to

qualIfied

professionals

Figure
1

Illustrates
the

system
used

through

model

year
1969

Figure
2
IS
the

system
used

after
1970

Figures
3

through
7
offer
detaIls
of

various

emission

components

Maintenance
and

Testing

Penodlc

mspection
and
service

should
be

done

every
12
months

or
12
000
miles
The

engine
must
be

in

good
working
order
to
main

tain

a
low

level
of
harmful
emissions
There

fore

perform
a

general
tune

up
as

spec1fied
in

Chapter
Four
before

followmg
the

procedures

below
CRANKCASE
EMISSION

CONTROL
SYSTEM

The
crankcase

emission
control

system
is

shown
in

FlgDre
8
It
IS
a
closed

system
that

pre

vents
crankcase

gases
from

escaping
to
the
at

mosphere

Blowby
gases
are
dIrected

to
the

intake

manifold

through
the
ventilation

control

valve

Normally
capacity
of
the

valve
is

suffi

cient
to
handle
the

blowby

gas
plus
a
small

amount
of

ventIlating
air
drawn
from
the

air

cleaner

through
a
tube

leading
to
the
crankcase

Under
fun

throttle
condItIons
manifold
vacuum

is

Insufficient
to
draw
the

blowby
through
the

valve
When
this

happens
b10wby
flows

through

the

system
In
the
reverse
dIrection

General

1
Start
the

engine
and

bring

up
to

operating

temperature

2
Check

hoses
and
hose
connections
for

leaks

3

Examine
the
hoses
for

signs
of

cracks
or
de

terioraoon

Replace
as

required

Crankcase

Ventilation

Control
Valve

1
Start
the

engme

2
Remove

the
ventIlator
hose
from
the
crank

case
ventilatIon
control
valve
A

htssmg
nOISe

EMISSION

CONTROL
SYSTEM
117

ENGINE
EMISSION
CONTROL
COMPONENTS

CD

1
Relief
valve

2
Air

pump

3
Check

valve

4
Anti
backfire

valve

AIR
INJECTION
SYSTEM

CD

SILENCER

CHECK
VALVE

NOZZLE

c

122

CHAPTER
TEN

1
Start
the

engIne
and

bnng
It

up
to
normal

operatIng
temperature

2

Inspect
all
hoses
and
connectIons
for
leaks

and
detenoratIon
Shut
off
the

engme
Replace

any
defectIve
hoses

3
Remove
the
hose
attached
to
the
check

valve

4

VIsually
Inspect
the

posItIon
of
the
valve

plate
InsIde
the

valve

body
See

Figure
10
It

should

be

lIghtly
posItIoned
agaInst
the

valve

seat

away
from
the
aIr
dlstnbutor
manifold

5
Insert
a

probe
Into
the
valve
connectIon
on

the
check
valve

Depress
the
valve

plate
It

should
return

freely
agaInst
the
valve
seat
when

released

6
Leave
the
hose
dISconnected
and
start
the

engme

7

Slowly
Increase

engine
speed
to
1
500

rpm

Watch
for
exhaust

gas
leakage
at
the
check

valve
There
should

not
be

any
The
valve

may

flutter

or
VIbrate
at
Idle

speeds
ThIS
IS
normal

Replace
the
valve
u

defecuve

Anti
Backfire
Valve

1
Start
the

engme
and

bnng
to

operating

temperature

2

Inspect
all
hoses
and
hose
connectIons
for

leaks
and
detenoratIon

Replace
as

required

3
DIsconnect
the
hose
at
the
antI
backfire

valve

leading
to
the
Intake

manuold
Insert
a

plug
ill

the

hose
and
fasten

securely

4

Open
and
close
the
throttle
valve

rapidly
See

Figure
11
Place
a

finger
over
the
valve
outlet
to

the

m
take
manuold
If

arr
flow
IS
felt
for

one
to
two
seconds
the
valve
IS

functIonIng

properly

If
there
s
no
aIr
or
If
the
flow
is
felt
for
more

than
two
seconds
the
valve
IS
defectIve
and
must

be

replaced

5
Connect
the
alr
hose
to
the
mtake
manuold

after

remOVIng
the

plug

6
DIsconnect
the
aIr
mlet
hose
from
the
air

pump
at
the
antI
backfire
valve
If
the

engine

Idle

speed
changes
excessIvely
the
valve
is
de

fectIve
and
must
be

replaced

Air

Pump

1
Check
the
atr

InjectIon
pump
belt
tension

DeflectIon
of
the
belt
should
be
0
5
In
when

pushed
In

by
thumb

pressure
Adjust
belt
u

necessary

2

Operate
the

engme
untIl
normal

temperature

IS
reached

3

Inspect
all
hoses
hose

connectIons
and
the

arr

gallery
for

SIgnS
of

leaks
or
detenoratIon

Replace
as

required

4
DIsconnect
the
air

supply
hose
at
the
check

valve

5
Insert
the

open
pipe
end
of
a

pressure
test

gauge
adapter
Into
the
air

supply
hose
See

Fig

ure
12

Clamp
the

adapter
firmly
to
the
hose

Install
the

pressure
test

gauge
to

the

adapter

PosItIon
the

adapter
and
test

gauge
so
that
the

alr
blast
emitted

through
the
dnlled

pipe
plug

Will
be

harmlessly

dislppated

6
Install
a
tachometer

on
the

engme
WIth
the

engIne
speed
set
to

1
500

rpm
observe
the

pres

sure

readmg
AIr

pressure
should
be
0
47
m

Hg

16mm
Hg

EMISSION
CONTROL
SYSTEM
123

7
If
the

pressure
does
not
meet

reqwrements

dISconnect
the

aIr

supply
hose
to
the
antI

backfire
valve

Clamp
a

plug
mto
the
hose
and

repeat
the

pressure
test

8
If
the
air

mJection
pump
does
not
meet
the

pressure
specIfication
It
should
be

replaced

NOTE

Repair
of
the
air

injection

pump
is

possible
but
have
the

lob

done

by
your
dealer

9
Close
the
hole
of
the
test

gauge
by
finger
With

the

engme
runnmg
at
1
500

rpm
See

Figure
13

If
a

leakIng
sound
is
heard

or

leakIng
air
is
felt

at
the
relIef
valve
the
relIef
valve

IS
defectIve

RepaIr
or

replace
as

reqUIred
ENGINE
MODIFICATIONS
SYSTEM

Testlng
and
mamtenance
of
the
sWitches

relays
and
solenOIds

comprismg
the

engine

modIficatIons

reqwres
SpecIal
knowledge
and

test

eqUIpment
If
the
mechanic

suspects
that

troubles
eXist
In
these

parts
check
With

a
dealer

Mamtenance
of
the
dIstrIbutor
breaker

points

and

tImmg
of

engines
is
covered

m

Chapter

Four

EVAPORATIVE
EMISSION

y
CONTROL
SYSTEM

f

Detailed
informatIon

on
the
fuel

tank
and

connecting
fuel
lines

IS

given
In

Chapter
Seven

EXHAUST

SYSTEM

Figures
14
next

page
15

page
125
and
16

page
126

are

exploded
VIews
of
the
exhaust

systems
Figure
14

applIes
to
the
sedan

FIgure

15

to
the

wagon
and

FIgure
16
to
the

pIck
up

The

system
in
sedans
and

wagons
consists
of

the
front
tube

pre
muffier
center
tube
rear

tube
mam
muffier
and
tail

pipe
The

pick

up

exhaust

system
mcludes
the
front
tube
muffier

and
rear
tube

Removal
Sedan
and

Wagon

1
Loosen

clamps
at
the
front
tube
center
tube

and
mam
muffier
connectIons
See

Figure
17

2
DIsconnect
front
tube
and
exhaust

manifold

flange
connection

3
Remove
units
from

vehicle