check engine DATSUN PICK-UP 1977 Owners Manual

CLEANING
AND

INSPECTION

Clean
all
disassembled

parts
but
do

not
use

grease
dissolving
solvents
for

cleaning

overrunning
clutch
annature

assembly

magnetic
switch

assembly

and
field
coils
since
such
a

solvent

would
dissolve

grease
packed
in

c1u
tch

mechanism

and
would

damage
coils
or

other
insulators

Check
them
for
excessive

damage

or

wear
and

replace
if

necessary

TERMINAL

Check
terminal
for

damage
and

wear
and

replace
magnetic
switch

assembly
if

necessary

FIELD
COIL

Check
field
coil
for
insulation
If

the
insulation
of
coil

is

damaged
or

worn
it
should
be

replaced

Testing
field

coil
for

continuity

Connect
the

probe
of
a

circuit

tester

or
an
ohmmeter
to
field
coil

positive
terminal

and

positive
brush

holder

If
tester
shows
no

continuity
field

circuit
or

coil
is

open

EE016

Fig
EE

I2
Testing
field
coil

for
continuity

TestIng
field
coD
for

ground

Place
one

probe
of
circuit
tester

onto

yoke
and
the
other

onto
field

coil
lead

positive
tenninal

If

very
little
resistance
is
read
field

coil
is

grounded
Engine
Electrical

System

EE017

Fig
EE

I3

Testing
rU
ld
coil

for

ground

BRUSHES
AND

BRUSH

LEAD

WIRE

Check
the
surface
condition
of

brush
contact

and
wear
of

brush
If
a

loose
contact
is
found
it
should
be

replaced

If
brush
is

worn
so
that

its

length
is

less
than
12
mm
0
472
in

replace

Check

the
connection

of
lead

clip

and
lead
wire

o

@

EE
8
Check
brush
holders
and

spring
cUp

to
see
if

they
are
not

deformed
or

bent
and
will

properly
hold
brushes

against
the

commutator

If

brushes
or
brush
holders
are

dirty
they
should
be

cleaned

BRUSH
SPRING

TENSION

Check
brush

spring
tension

by
a

spring
scale
as
shown
in

Figure
EE

13

The

reading
should

be
1

6

kg
3
5

Ib

Replace
spring
if

tension
is

lower
than

I
4

kg
3
1
Ib

ARMATURE

ASSEMBLY

Check
external

appearance
of

armature
and
commutator

1

Inspect
commutator
If
the
sur

face

of
commutator
is

rough
it

must

be
sanded

lightly
with
a
No

500

emery
cloth
If
the

depth
of

insulating

mica
is

less
than

0
2
mm
0

0079
in

from
commutator
surface

insulating

mica
should

also
be
undercut
so

that

its

depth
is
0
5
to
0
8

mm
0
01
97
to

0
0315
in

The
wear
limit
of
commutator
dia

meter
is

2
mm
0

0787
in
If
the

diameter
of
cammu

tator
is

less
than

31
mm
1
220
in

replace
annature

assembly

EE018

Fig
EE
14

Inspecting
brush

spring
tension

L

0
5
to
0
8
mm

71j

Correct

2

Inspect
soldered
connection
of

armature
lead

and
commutator
If

loose
connection
is
found
solder
it

using
resin

flux

3

Armature
test
for

ground

Using
a
circuit
tester

place
one

test

probe
onto
armature
shaft
and
other

onto
each
commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

EE022

Fig
EE

16

Testing
annature
for

ground

4

Check
armature
for
short

by

placing
it
on
armature
tester

growler

with
a

piece
of
iron

over
armature

core

rotating
armature
If
the

plate

vibrates
armature

is
shorted

j
l

EE023

Fig
EE

17

Testing
annature

for

ahort
Engine
Electrical

System

L

File
l

0

Commutator

Segmen
t

IWMica

Incorrect

EE021

Fig
EE
15

Undercutting
i118ulating
mica

5
Check

armature
for

continuity
by

placing
probes
of

tester
on
two

seg

ments
side

by
side
If
tester
shows
no

continuity
the
circuit
is

open

OVERRUNNING
CLUTCH

ASSEMBLY

Inspect
pinion
assembly
and
screw

sleeve
Screw
sleeve

must
slide

freely

along
armature
shaft

splines
If

damage
is
found
or
resistance
is
felt

when

sliding
it
must
be

repaired

Inspect

pinion
teeth
If
excessive
rub

bing
is
found
on
teeth

replace

Flywheel

ring
gear
also
must
be
in

spected

l

EE278

Fig
EE
18

Overrunning
clutch

auem

bly

BRUSH

HOLDER
TEST

FOR

GROUND

Using
a
circuit
tester

place
one
test

probe
onto

negative
side

of
brush

holder

and
another
onto

positive
side

If

tester
shows

continuity
brush

holder
is

shorted
to

ground

Replace

brush

holder

EE
9
Ee026

Fig
EE
19

Testing
brush

for

round

BEARING
METAL

Inspect
bearing
metal
for
wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm
0
0079
in

replace

metal

MAGNETIC
SWITCH

ASSEMBLY

1

Using
a
circuit
tester

l
check

con

tinuity
between
S
terminal
of

mag

netic

switch
and
switch

body
metal
If

continuity
does
not
exist
shunt

coit
is

opened

Replace
switch

assembly

2
In
the

same
manner
as
above

check

continuity
between
terminals

S
and
M

If

continuity
does
not

exist
series

coil
is

opened

Replace
switch

assembly

ASSEMBLY

Reassemble

starting
motor
in

re

verse

sequence
of

disassembly

When

assembling
be

sure
to

apply

grease
to

gear
case
and

rear
cover

bearing
metal

and

apply
oil

lightly
to

pinion

TEST

PERFORMANCE
TEST

Starter
motor
should
be

subjected

to
a
no
load

test
whenever
it
has

been
overhauled
to
ensure
that

its

performance
will
be

satisfactory
when

installed
on

engine
Starter
motor

should
also
be

subjected
to

the
test

when
the
cause
of
abnormal

operation

is

to
be
determined

A
brief
outline
of

the
test
is

given
below

No
load
test

Connect

starting
motor
in

series

with

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Starter
motor

Diagnoses
of
test

1
Low

speed
with

no
load
and

high

current
draw

may
result
from
the

following

1

Tight
dirty
or
worn

bearings

2

Bent
armature
shaft
or
loosened

field

probe

3
Shorted
armature

Check
armature
further

4

A

grounded
armature
or
field

a
Remove

input
tenninal

b

Raise
two

negative
side
brushes

from
commutator

c

Using
a
circuit
tester

place
one

probe
onto

input
tenninal
and
the

other
onto

yoke

d
I

f
tester
indicates

continuity

raise
the

other
two
brushes
and
check

field
and
armature

separately
to

determine
whether
field
or
armature
is

grounded

2
F

allure
to

operate
with

high

current
draw

may
be

caused

by
the
Engine
Electrical

System

Specified
current

draw
and

revolu

tion
in

these
test
are

shown
in

Specifications

Switch

6
Battery

Et

Voltmeter
Ammeter

Ee026

Fig
EE
20
No
load

l
ting

following

I
A

grounded
or

open
field
coil

Inspect
the
connection
and
trace

circuit
with

a
circuit
tester

2
Armature
coil
does
not

operate

Inspect
commutator
for
excessive

burning
In
this
case
arc

may
occur
on

damaged
commutator
when
motor
is

operated
with
no
load

3
Burned
out
commutator
bar

Weak
brush

spring
tension
broken

brush

spring
rubber
bush
thrust
out

of
mica
in

commu
tat
or
or
a
loose

contact
between
biush
and
com

mutator
would

cause
commutator
bar

to
burn

3
Low

current
draw
and
low

no
load

speed
would

cause

high

internal
resistance

due
to
loose
con

nections

damaged
leads

dirty
corn

mutator
and
causes
listed
on
item

2

3

EE10
MAGNETIC
SWITCH

ASSEMBLY
TEST

Switch

o

Fv
IB
I

I

D

Battery
Starter
motor

EE351

FiN
EE

21
Circuit

ofmagndic
awitch

assembly
ted

If
the

starting
motor
check
is

OK
check

magnetic
switch
as

sembly
Connect
cables

between

negative
battery
tenninal

and
start

ing
motor
M
terminal

positive

battery
terminal
and

starting
motor

S
terminal

connecting
a
switch
in

series
as

shown
in

Figure
EE

21

With
the
switch
on

push

pinion

back
to

remove
all
slack
and

measure

the
clearance
l
between

pinion

front

edge
and

pinion
stopper
The

clearance
should
be

held
within
0
3
to

1
5
mm

0
012
to
0

059
in

If
neces

sary
adjust
it

by
changing
or

adding

adjusting

washer
s

Adjusting
washers

are
available
in

to
two

different
sizes

0
5
mm
0

020
in

and
O
S

mm
0
031

in

0
3
to
I
S
rom

0
012
to
0
059
in

l

EE029

Fig
EE
22
MeO

uring
clearance

t

ROTOR
INSPECTION

1

Continuity
test
of
rotor
coil

Apply
tester
between

slip
rings
of

rotor
as

shown
in

Figure
EE
34
If

there
is
no

continuity
field
coil
is

open

Replace
rotor
assembly

EE041

Fig
EE

34

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

Fig
EE

35

Testing
rotor
coil

for

round

INSPECTION
OF
STATOR

1

Continuity
test

Stator
is
normal
when

there
is

continuity
between
individual
stator

coil
tenninals
When
there
is
no
conti

nuity
between
individual
terminals

cable
is
broken

Replace
with
stator
assembly

EE043

Fig
EE
36

Testing
stator

for

continuity
Engine
Electrical

System

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

EE045
Stator
core

Fig
EE

37
Ee044

Teding
stator

for

P
Ound

Conductive
direction

I

Diode
installed
on
EEl

plate
is

a

positive
diode
which
allows
current

flowing
from
terminal
to

EEl

plate

only
In
other
words
current
does
not

flow
from

EEl
plate
to
terminal

v

1
ptate

2
Terminal
EE046
INSPECTION
OF
DIODE

Perform
a

continuity
test
on

diodes

in

both
directions

using
an

ohmmeter

A

total
of
six

diodes
are
used
three

are
mounted
on
the

positive
EEl
plate

and
other
three

are
on
the

negative
e

plate
The

continuity
test

should
be

performed
on
each
diode
between
the

terminal
and

plate

I

plate

2
ptate

3
Diode

Fig
EE
38
Conductive
direction

of
diode

Diode
installed

on
e

plate
is

a

negative
diode
which
allows
current

flowing
from

e
plate
to
terminal

only
In
other
words
current
does
not

flow
from
terminal
to

e
plate

I

plate

2
Terminal
EE047

Fig
EE
39

Inspecting
positive
diode

Fig
EE
40
Insp
cting
negative
diode

EE
17

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

Test

probe
of
a
circuit

t
ter

e

Gl

terminal

EEl

plate

EJ
plate
terminal

terminal

e
plate

e

plate
terminal

e

plate
@
plate

Xl

plate
e
plate

INSPECTION

OF
BRUSH

Check

movement
of
brush
and

if

movement
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

dam

aged
replace

Brush

wear

limiting
line

EE127

Fig
EE
41
Bnlsh
wear

limil
Engine
Electrical

System

If
there

is
a

faulty
diode

replace
all

diodes
ix

diode
as
an

assembly

See
table

below

These
diodes

are

unserviceable

Conduction

o

o

o

SPRING

PRESSURE
TEST

With
brush

projected

approximate

ly
2
mm
0
079
in

from
brush
holder

measure
brush

spring
pressure
by
the

use
of
a

pring
balance

Normally
the

rated

pressure
of

a
new
brush

spring
is

255

to
345

gr
9
0
to
12
202

Morevover
when
brush
is
worn

pressure
decrease

approximately
20

g

0
7
02

per
1
mm

0
0039
in

wear

t

m
0
079

in

or
f

EEO
9

Fig
EE

42
M
CJ

uring

pring
preaure

EE

lB
ASSEMBLY

Reassemble

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

pas

sible

2
When

installing
diode
A

terminal

install

insulating
bush

correctly

1

Imulating
bush

2

A

terminal
bolt

3
Diode

cover

4
Rear

cover

5
Diode
a

sembly

EE347

Fig
EE

43
Sectional
view

of
diode

and
A
term
inal

3

Tighten
pulley
nut
with

tighten

ing
torque
of
3
5

to
4

0

kg
m
25
3

to

29
0
ft
Ib

When

pulley
is

tightened

make

sure
that
deflection
of
V

groove

is

less
than
0
3
mm

0
01
IS
in

q

ffl
t
EE051

Fig
EE

44

Tightening
pulley
nut

Engine
Electrical

System

ALTERNATOR
TEST

Before

conducting
an

alternator

test
make
sure
th

tthe

battery
is

fully

charged
A

30
V
olt

voltmeter

and
suitable

test

probes
3re

necessary
for
the
test

Set

up
a
test
circuit

as
shown
in
Figure
EE45
and
test

auernator
in

the

manner
indica
ted
in

the
flow

chart

below

1
Disconnect

connectors
at
alternator

2
Connect
A

terminal
to
F

terminal

3
Connect

one

test
probe
from

voltmeter

positive
terminal
to

A
terminal

Connect
the
other
test

probe
to

ground

Make
sure
that
voltmeter

registers
battery
voltage

4

Turn
on

headlights
and

switch
to

High
Beam

5

Start

engine

6
Increase

engine
speed
gradually
until
it
is

approximately
1
100

rpm
and

take
the

voltmeter

reading

Measured
value
Below
12
5
Volts

Alternator
is
in

trouble
remove
and
check
it

for
condition
Measured
value
Over
12
5
Volts

Alternator
is
in

good
condition

Notes

a
Do
Dot
run

engine
at
the

speed
of

more
than
1
100

rpm
while
test
is

being
conducted
on
alternator

b
Do
not
race

engine

i
9
l

IV
I
Battery

EE052
Voltmeter

Fig
EE

45
Testing
alternator

SERVICE
DATA
AND
SPECIFICATIONS

Nominal

rating
V

A
LT138
IB

LTl35
36B
For
air

conditioner

1235

12
38

Negative
Negative

1
000
1

000

28
2
500

30
2
500

35
5

000
38
5
000

2
25

2
25

More
than

7
5
0
295
More
than
7
5
0
295

255

to
345
255

to
345

9
0
to

12
2

9
0
to

12
2

More
than
30
1
181
More
than

30
1
181

EE

19
Type

Ground

polarity

Minimum
revolution

when

generating

14V
with
no
load

rpm

Hot

output
current

Nrpm

Pulley
ratio

Brush

Length

Spring
pressure
mm
in

gr
oz

Slip
ring
outer
diameter
mm

in

MEASUREMENT

OF
REGULATOR

VOLTAGE

Regulator
voltage
is
measured
with

regulator
assembled
with
alternator

When

measuring
voltage
with

regulator

mounted
on

car
it
is

necessary
to

rotate

engine
at

high
speed

Connect
DC
voltmeter

l5
30Y

DC

ammeter

l5
30A

battery
and
a

O

25fl

resistor
rated

at
25W
with

cables

as
shown

I

Check
to
be
sure
that
all
electrical

loads
such
as

lamps
air

conditioner

radio
etc
are
turned
off

2

Before

starting
engine
be
sure
to

make
short
circuit
with
a

cable
be

tween
fuse
side
terminal
of
resistor

O
25fl

and

negative
side
terminal
of

ammeter
Failure
to
follow

this

pre

caution

will

cause
needle
of
ammeter

to

swing

violently
resulting
in
a
dam

aged
ammeter
Engine
Electrical

System

Genera

tor

A

r

iJ

IG

Fuse
box

i
B
Rqulator

Connector

Wire
harness

Short
circuit
here
between

fuse
side

tenninal
and

terminal
of
ammeter

before

starting
the
operation

Ammeter

lOA
V

Voltmeter
30V

EE055

Fig
EE
48

Measuring
regulator
voltage
with

regulator
on
vehicle

3
Refer
to
the

following
chart
to

determine
if

regulator
and
relative

EE
21
parts
are
in

good
condition

Engine
Electrical

System

I

Start

engine

2
Rotate

engine
at
2
500

rpm
for
several

minutes

Mter

racing
for

several
minutes

ammeter

reading

below
SA
After

racing
for

several
minutes

ammeter

reading
over
5

A

Fully

charged
battery
available

I

Replace
with

fully
charged

battery

2
Check

to
see
if
current
falls

below
SA
Fully
charged

battery
not
available

I
Connect
a

0
25
ohm

resistor
in
series

Current
falls
below

SA

Current
does

not
fall
below

SA

Recharge
battery
and

see
if

current
falls

below

SA

Reduce

engine
speed
to

idling
and
then

raise
it

to
2
500

rpm
while

observing
needle
of
voltmeter

Needle
of

voltmeter
held
within
limits

shown
in

the
below

table

Regulator

functioning
properly
Needle
of
voltme
ter
ou
t
of
limits
shown
in

the

following
chart

Adjust
or

replace
regulator

Regulator
type
TLI

Z
85C

Temperature
Oc
OF

Voltage
V
speed

c

Voltage

may
be

approximately

0
3
V

higher
than
rated
for
two
to

three
minutes
after

engine
is

start

ed
or
more

specifically
when

regu

lator
becomes
self
heated

Measure

ments
should

then
be
made

within

one
minute

after

starting
engine
or

when

regulator
is

cold

d
The

regulator
is

of
a

temperature

compensating
type
Before
meas

uring
voltage
be

sure
to
measure

surrounding
temperature
and
cor

rect

measurements

according
to
the

table
at
left
10

14

0

32

10

50

20
68

30
86

40
104
14
75
to
15

75

14
60
to
15
60

14
45
to
1545

14

30
to

15
30

14

15
to
15
15

14

00
to

15
00

Notes

3
Do

not
measure

voltage
immediate

ly
after

driving
Do
this
while
regulator
is
cold

b

To
measure

voltage
raise

engine

speed
gradually
from

idling
to

rated

EE
22

ADJUSTMENT

VOLTAGE
REGULATOR

When
regulating
voltage
as
meas

ured
above
deviates

from
rated
value

adjust
regulator
in

accordance
with
the

following
instructions

I

Inspect
contact
surface
and
if

rough
lightly
polish
with
fine

emery

paper
1
500
or
600

2
Measure
each

gap
and

adjust
if

necessary
Adjust
core

gap
and

point

gap
in
that
order
No

adjustment
is

required
for

yoke

gap

3

Adjusting
core

gap

Loosen
screw
4
mm
0
157
in

diameter
which
is
used
to
secure

contact
set
on

yoke
and
move
contact

upward
or
downward

properly
See

Figure
EE
49

Core

gap

0
6

to
1
0
mm

0
024
to
0
039
in

EE398

I
Contact

set

2
ThicknesJ
gauge

3
4

mm
0
157
in
dia
screw

4

Crosshead
Jcrewdriver

Fig
EE
49

AdjUJJting
core
gap
Engine
Electrical

System

4

Adjusting

point
gap

Loosen
screw
3

mm
O
lIS
in

diameter
used
to
secure

upper
con

tact
and
move

upper
contact

upward

or
downward
as

necessary
See

Figure

EE
50

Point

gap

035

to
0
45
mm

0
014

to
O
D1S
in

EE399

I
Thicknes

gauge

2
3
mm

0
118
in
dia

screw

3
Cro
Sshelld

screwdriver

4

Upper
contact

Fig
EE
50
Adjusting

point
gap

5

Adjusting
voltage

Adjust
regulating
voltage
as

follows

Loosen
lock
nut

securing

adjusting

screw
Turn
this
screw
clockwise
to

increase
or
counterclockwise
to

decrease

regulating
voltage
See

Figure
EE
5

J
CD

EE400

I

Wrench

2

Crosshead
screwdriver

3

Adjusting
screw

4
l
ock

nut

Fig
EE
51

AdjUJJting
rel
Ulating
voltage

CHARGE
RELAY

Nonna

relay
operating
voltage
is
S

to
IOV
as
measured
at
alternator
A

tenninal

Relay
itself
however

oper

ates
at
4
to
5V

Use
a
DC
voltmeter
and
set

up
a

circuit

as
shown
in

Figure
EE
52

Adjust
charge

relay
in

the
same

manner
as
that
for

voltage
regulator

L

Connect

positive
tenninal
of
voltmeter
to

regulator
lead
connector
N
tenninal
with

negative
terminal

grounded

2
Start

engine
and

keep
it

idle

3
Take
voltmeter

reading

o
Volt

I
Check
for

continuity
be

tween
terminals
of
re

gulator
and
alternator

2
Alternator
circuit

inopera

tive
if

continuity
exists
Below
5
2
Volts

Charge
warning
lamp
on

I
Check
fan
belt
tension

2
If
correct
remove

regulator

and

adjust
as

necessary
Over
5

2
Volts

Charge
warning
lamp
on

Charge
relay
coil
or
contact

points
out
of
order

Replace
regulator

Over
5
2
Volts

Charge
warning
lamp
off

Charge
relay
assembly
is
in

good
condition

EE
23

Engine
Electrical

System

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Including
alternator

Condition
Probable
cause

No

output
Sticking
brushes

Dirty
brushes
and

slip
rings

Loose
connections

or
broken
leads

Open
sta
tor

winding

Open
rotor

winding

Open
diodes

Shorted
rotor

Shorted
stator

Grounded
A

terminal

Broken

fan
belt

Excessive

output
Broken
neutral

wire
COIOf
of
wire
is

yellow

Voltage
fegulator
breakdown

Poor

grounding
of
alternator
and

voltage

regulator
En

terminal

Broken

ground
wire

color
of
wire
is
black

Low

output
Loose

or
worn
fan
belt

Sticking
brushes

Low

brush

spring
tension

Voltage
regulator
breakdown

Dirty

slip
rings

Partial
short

ground
or

open
in

stator

winding

Partially
shorted

or

grounded
rotor

winding

Open
or
damaged
diode

Noisy
alternator
Loose

mounting

Loose
drive

pulley

Broken
ball

bearing

Improperly
seated
brushes

EE

25
Corrective
action

Correct
or

replace
brushes
and
brush

springs

Clean

Retighten
or
soldef

connections

Replace
leads
if

necessary

Repair
Of

replace
stator

Replace
rotor

Replace

Replace
rotor

Repair
or

replace

Replace
insulator

Replace

Replace

Check

regulator
operation
and

repair
or

replace
as

required

Retighten
terminal
connection

Replace

Retighten
or

replace

Correct
or

replace
brushes
and

springs
if

necessary

Replace
brush

springs

Check

regulator
OpefatiOn
and

repair
or

replace
as

required

Clean

Replace
stator

Replace
rotor

Replace
diode

Retighten
bolts

Retighten

Replace

Seat

correctly