service DATSUN PICK-UP 1977 Owner's Guide

DESCRIPTION

REMOVAL

DISASSEMBLY

INSPECTION
AND
REPAIR

ROTOR
INSPECTION

INSPECTION
OF

STATOR

DESCRIPTION

In
the
alternator
a

magnetic
field
is

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

@God

A
tfff
Engine
Electrical

System

ALTERNATOR

CONTENTS

EE
15

EE
16

EE
16

EE
16

EE
17

EE
17
INSPECTION
OF
DIODE

INSPECTION
OF
BRUSH

SPRING
PRESSURE
TEST

ASSEMBL
Y

ALTERNATOR
TEST

SERVICE
DATA
AND
SPECIFICATIONS
EE
17

EE
1B

EE1B

EE

1B

EE19

EE
19

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

di
odes

are
used

Six

diodes
three

negative
and
three

positive
are
installed
in

positive
and

negative
plates
as
an

assembly

These
diodes
are
direct
soldered
at

their

tips
and
constructed
with

posi

3

2

I
4

e

o

e

9
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

The

pulley
mounted
on
the
air

conditioner
models
is

different
from

that
on
the

standard
models
without

air
conditioner

1

Pulley
usem

bly

2
Front
cover

3
Front

bearing

4

Rotor

5

Rear

bearing

6
Stator

7
Brush
assembly

8
Rear
cover

9

Diode
set

plate
assembly

10
Diode
cover

11

Through
botrs

EE
15
EE345

Fig
EE
26

Exploded
view

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

DESCRIPTION

MEASUREMENT
OF
REGULATOR

VOLTAGE

ADJUSTMENT

VOLTAGE
REGULATOR

DESCRIPTION

The

regulator
consists

basically
of

a

voltage
regulator
and
a

charge

relay

The
voltage

regulator
has
two
sets
of

contact

points
a
lower
set

and
an

upper
set
to
control
alternator
volt

age
An
armature

plate
placed
between

the
two
sets
of
contacts
moves

upward

or
downward
or
vibrates
The
lower

contacts
when
closed

complete
the

jCV
ID@
@

GJ
I

@

@

@
Engine
Electrical

System

REGULATOR

CONTENTS

EE
20
CHARGING
RELAY

SERVICE

DATA
AND

SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Including
alternatorl

EE
25
EE
23

EE
24

EE

20

EE

23

EE
23

field
circuit
direct
to

ground
and
the

upper
contacts
when
closed

complete

the
field

circuit
to
ground

through
a

resistance
field
coil
and

produce

alternator

output

The

charge
relay
i
similar
in

construction

to
the

voltage
regulator

When
the

upper
contacts
are
closed

charge
warning
lamp
goes
on
v

1

Charge
relay

2

Voltage
regulator

EE285

Fig
EE
46
View

of
removing
cover

As

regards
the
construction
the

voltage
regulator
is

very
similar
to
the

charge
relay
as
shown
in

Figure
EE47

@

r

J
CD

@

@

@
Q
@
ID@

ID@

J
t

L

T

@
r

b
r
CD

L
@

j
1

g

f

@

@
EEJ97

J
I1Jlccting
spring

2
Y
kt

g
p

3
Armaturc

4
Core

go

5
Low

Sllccd
lnlacl

h
Point

ap

7

High
speed
conlat
t

8
Contact
c
9

3111111
0
118
ill

di

10

41l1I11W
157in
c1ia
few

II

Cuil

12

lock
nut

J3

Adjllslin
screw

14

Adjll
sting
sprin

15
Yoke
9

Adjusting
screw

10
Lock

nut

11
Coil

12
4mm

0
157
in

dia
screw

13
3mm
0
118
in

dla
crew

14
Contact

iet

15

Voltage

cgulatm
contact

a

Cnl1
Tlll
tion
f

lltagl
l

j
llIOltllT
I
Point

gilp

2

Charge
relay
contllct

3
Core

gap

4

ArlllatlJre

5

Connecting

sprin

6
Yoke

gap

7
Yoh

B

Adjusting
pring

b

Construction
of

charge
relay

Fig
EE
47
Structural
vi
w

EE
20

Engine
Electrical

System

RegulatoI

r
Yellow
terminal

A
W
L
WR

IG
WL

N

Y
E
B
F
WB
Voltmeter

Fig
EE

52
Tuting

charging
re
Qy
EE348

SERVICE
DATA
AND
SPECIFICATIONS

Voltage
legulator

Type

Regulating
voltage
with

fully

charged
battery

Voltage
coil

resistance

RotOI
coil

inserting
resistance

Voltage
coil

series
resistance

Smoothing
resistance

COle

gap

Point

gap

Ch
uge
lay

Release

voltage

Voltage
coil

resistance

Core

gap

Point

gap
v

fl

nun
in

nun
in

V

fl

nun
in

mID
in
TLl

Z
S5C

14
3
to
15
3
at

200C
680F

10
5
at
200C
680F

10

31

40

0
6
to
1
0
0
024
to
0
039

0
35
to
0
45

0
014
to
O

OIS

4
2
to
5

2
at
N
terminal

37
S
at
200C
680F

0
8

to
1
0
0
031
to
0
039

0
4
to
0
6
0
016
to
0
024

Standard

tempelatUIe
gIlIdient
O
OISV
oC

EE
24

Engine
Electrical

System

DISTRIBUTOR
Non
California
models

CONTENTS

CONSTRUCTION

CHECKING
AND
ADJUSTMENT

CAP
AND
ROTOR

HEAD

CONTACT
POINT

CONOENSER
EE
30

EE
31

EE
31

EE
31

EE

31
ADVANCE
MECHANISMS

DISASSEMBL
Y

ASSEMBLY

SERVICE
DATA
AND
SPECIFICATIONS
EE
31

EE
32

EE
32

EE
33

CONSTRUCTION

The
distributor
consists
of
breaker

plate
with
contact

points

centrifugal

advance
mechanism
vacuum
control

ler
distributor
shaft
and

rotor

D

@

t

Cap
assembly

2
Rotor

head

assembly

3
Condenser

assembly

4

Ground
wire

assembly

5
Lead
wire
assem

bly

6
Contact

set

7

Breaker

plate
assembly

8

Packing

9
earn
assembly

10
Governor

spring

11
GoVernor

weight

12
Shaft

assembly

13
Vacuum
controller

14
Terminal

assembly

IS

Housing

16

Fixing

plate

17

O

ring

IS
Collar
v

i

@

D

@

EE32Q

Fig
EE
57

EE
30

Engine
Electrical

System

SERVICE
DATA
AND
SPECIFICATIONS

D4A4

06
D4A4
07

Type
D4A6
07
D4A6
08

Firing
order
1
3
4
2
13
4
2

Rotating
direction
Counterclockwise
Counterclockwise

Owen

angle
degree
490
to
550
490

to
550

Point

gap
mm
in
0

45
to
0

55
0
45
to
0
55

0
018
to

0
022
0
018
to
0

022

Point

pressure
kg
lb
0
40

to
0
55
0
40
to
0
55

0

88
to
1

21
0
88
to
1
21

Condenser

capacity
JlF
0
20

to
0
24
0
20

to
0
24

Condenser
isolate
resistance
Mrl
5
5

Cap
isolate
resistance
Mrl
50
50

Rotor
head
isolate
resistance
Mrl
50
50

Cap
carbon

point
length
mm
in
10

0
39
10
0
39

For
Canada

DISTRIBUTOR
California
models

CONSTRUCTION

CHECKING
AND
ADJUSTMENT

CAP
AND

ROTOR
HEAD

AIR

GAP

CONSTRUCTION

In
the
conventional
distributor
the

ignition
liming
is

detected

by
the
cam

and
breaker
arm
while
in
this
transis

tor

ignition
unit
it
is

detected

by
the

reluctor
on
the
shaft
and
the

pick
up

coil

provided
in

place
of
the
breaker

The

pick
up
coil
consists
of
a

magnet

coil
etc
The
amount
of

magnetic
flux

passing
through
the

pole
piece
in
the

coil
is

changed
at
the

moment
the

pole
CONTENTS

EE
33

EE
33

EE
33

EE
33
ADVANCE
MECHANISMS

DISASSEMBLY

ASSEMBLY

SERVICE
DATA
AND
SPECIFICATIONS
EE
33

EE
35

EE
35

EE
36

piece
faces
the

protrusion
of
the

re

luctor

and
then
the
electrical

signal
is

genera
ted
in
the

pick
up
coil

This
electric
signal
is

conducted

into

the
transistor

ignition
unit
which

in

turn
breaks
tI
e

primary
coil
current

running
through
the

ignition
coil
and

generates

high
voltage
in
the

secondary

winding
Also
this
transistor

ignition

EE
33
unit

utilizes
this
electric

signal
to

restore
the

primary
coil
to
the

original

state
after

cutting
off
the

primary

current
for
a
fIXed
time

The

centrifugal
and
vacuum
ad

vance
mechanisms

employ
the
con

ventional
mechanical

type
The
con

tactor
is
used
to
eliminate
vacuum

and

centrifugal
advance

hysteresis

I

EE299

Fig
EE
74

Driving
in
roll

pin
Engine
Electrical

System

4

Apply
grease
to
the

top
of
rotor

shaft
as

required

5

Check
the

operation
of

governor

before

installing
distributor
on

engine

6

Adjust
ignition
timing
after

distri

butor
is
installed

on

engine

SERVICE

DATA
AND
SPECIFICATIONS

Type

Firing
order

Rotating
direction

Duty

Air

gap
mm
in

MU

Cap
insulation
resistance

Rotor
head

insulation
resistance
MU

Cap
carbon

point
length
mm
in
D4F4
03
D4F4
04

1
3
4

2

Counterclockwise

70
20
to
40
at

idling

0
2
to
0
4
O

OOS
to
0

016

More
than
50

More
than
50

10
0
39

TRANSISTOR

IGNITION
UNIT

California
models

DESCRIPTION

TRANSISTOR
IGNITION
UNIT

REMOVAL
AND

INSTALLATION

INSPECTION

1
POWER

SUPPLY
WI

RING
AND

BATTERY

CHECK

DESCRIPTION

TRANSISTOR

IGNITION

UNIT

The
transistor

ignition
unit

provides

the

following
functions

L
It

makes
and
breaks
the
electric

current
in

the

primacy
circuit

of
the

ignition
coil
2

CONTINUITY
CHECK

OF
PRIMARY

CIRCUIT

3

PICK
UP

COIL
CONTINUITY
CHECK

4
PICK
UP
COIL
POWER

SIGNAL

PULSE

CHECK

5
TRANSISTOR

IGNITION
UNIT
CHECK
CONTENTS

EE

36

EE

36

EE
37

EE
37

EE
37

2

The

duty
control

circuit
sets
the

rate
of
make

and
break
within

one

cycle
i
e

this

maintains

good

ignition

characteristics
of

engine
from
low

speed
to

high
speed
and
is

equal
to

the

dweU

angle
in

the

conventional

breaker

type
distributor

3

A

preventive
circuit

against
lock

EE
36
EE
36

EE
38

EE
38

EE
39

ing
is

provided
This

cuts
off
the

prilnaCY
electric
current
in

the

ignition

coil
when
the

ignition
switch
is

turned

on
with
the

engine
not

running

Each

component
part
of
this
unit

is

highly
reliable
however

should

any

part
be
found

faulty
the
entire
assem

bly
must
be

replaced

DESCRIPTION

INSPECTION

CLEANING
AND
REGAP

DESCRIPTION

The

spark
plugs
are
of
the

conven

tional

type
having
14
mm
0

551
in

threads
The

spark
plug
gaps
are
1
0
to

1
1
mm
0
039
to
0
043
in
on
Cali

fomia
models
and
0
8

to
0
9
mm

0
031
to

0
035
in
on
non
California

models
The

inspection
and

cleaning

should
be
made
every
suitable
mainte

nance

period
If
necessary
replace

Note
All

spark

plugs
installed
on
an

engine
must
be

of
the
same
brand

and
the

same
number
of
heat

range

INSPECTION

L
Remove

spark
plug
wire

by

pulling
on

boot
not
on
wire
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

Figure

EE
96

Normal
Brown
to

grayish
tan
de

posits
and

slight
electrode
wear

indicate
correct

spark
plug
heat

range

Carbon
fouled

Dry
fluffy
carbon

deposits
on
the
insulator
and

electrode
are

usually
caused

by

slow
speed
driving
in

city
weak

ignition
too
rich
fuel
mixture

dirty
air
cleaner
etc

It
is

advisable
to

replace
with

plugs

having
hotter
heat

range

Oil
fouled
Wet
black

deposits
indi

cate
excessive
oil
entrance
into

combustion
chamber

through
worn

rings
and

pistons
or
excessive
clear

ance
between
valve

guides
and

stems
If
the
same
condition
re

mains
after

repair
use
a
hotter

plug
Engine
Electrical

System

SPARK
PLUG

CONTENTS

EE
4B

EE
47

EE
47

EE
47
SERVICE
DATA
AND
SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS
EE
4B

Overheating
White
or

light

gray
in

sulator
with
black
or

gray
brown

spots
and
bluish
burnt
electrodes

indicate

engine
overheating
More

over
the

appearance
results
from

incorrect

ignition
timing
loose

Normal

Overheating

EE079

4
After
cleaning
dress
electrodes

with
a
smaU
fine
file
to
flatten
the

surfaces
of
both
center
and
side

electwdes
in

parallel
Set

spark
plug

gap
to

specification

5
InstaU

spark
plugs
and

torque

each

plug
to
L5

to
2
0

kg
m

11
to
14

ft
Ib

6
Connect

spark

plug
wires

CLEANING

AND
REGAP

Clean

spark
plugs
in

a
sand
blast

type
cleaner
Avoid
excessive

blasting

Clean
and
remove
carbon
or
oxide

deposits
but
do
not

wear
away

porcelain
If

deposits
are
too
stubborn

EE
47
spark
plugs
low
fuel

pump
pres

sure

wrong
selection
of
fuel
a

hotter

plug
etc

It
is
advisable
to

replace
with

plugs

having
colder
heat

range

Ir

i

Carbon
fould

Worn

Fig
EE
96

Spark
plug

discard

plugs

After

cleaning
spark
plugs
renew

firing
surface
of
electrodes
with
me

mentioned
aboVe
Then

gap
spark

plugs
to

specified
values
with
a
round

wire
feeler

gauge
All

spark
plugs
new

or
used
should
have
the

gap
checked

and
reset

by
bending
ground
electrode

EEOBO

Fig
EE
97

Setting
park
plug
gap

Engine
Electrical

System

SERVICE
DATA
AND
SPECIFICATIONS

California

models
Non

California

models

For
Canada

except
for

Canada

BP6ES
ll
BP6ES

BPR6ES
Standard

L45PW
ll
L45PW

BP4E
ll
BP5ES
ll
BP4E

BP5ES
BPR4ES

Type
Hot

type

L46PW
ll

L47PW
ll

L46PW
L47PW
BPR5ES

Cold

type
BP7ES
ll

BP7ES

BPR7ES

LMPW
ll
LMPW

1
0
to
l
l
0
8
to
0

9
0
8
to
0
9

Plug

gap
mm

in

0

039
to
0
043
0

031
to
0
D35
0
031
to
0

035

Tightening
torque
kg
m
ft
Ib

I
1
5
to
2

0
11
to
14

TROUBLE

DIAGNOSES

AND

CORRECTIONS

When

engine
does
not
start

If
there
is

no

problem
in

fuel

system
ignition
system
should
be

checked
This
can
be

easily
done

by

detaching
a

high
tension
wire

from
spark

plug
starting

engine
and

ob

serving
condition
of

spark
that

occurs

between

high
tension

wire
and

spark

plug
terminal

After

checking
this

repair
as

necessary
Note
On
California
models

disc
on

nect
anti

dieseling
solenoid

valve

connector
to

cut
off

supply
of
fuel

to

engine
and

then
observe

the

condition

of

spaIks
while
starter

motor
is

in

operation

Condition
Location

Probable

cause
Corrective
action

No

spark
at
all

Distributor

Faulty
insulation
of
condenser

Non
Cali

Replace

fomia

models

Breakage
of
lead
wire
on
low
tension
side

Repair

Poor
insulation
of

cap
and
rotor
head

Replace

Seized

points
Non
California

models

Repair

Open
pick
up
coil
California
models

Replace

Air

gap
wider
than

specification
Cali

Adjust

fornia

models

Ignition
coil

Wire

breakage
or
short
circuit

of
coil

Replace
with
new
one

High
tension
wire

Wire

coming
off

Repair

Faulty
insulation

Replace

Transistor

ignition
Faulty
transistor

ignition
unit

Replace

unit

California

models

EE
4B