air condition DATSUN PICK-UP 1977 Workshop Manual

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

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

Primary
winding

1

Ignition
coo

I

Secondary

winding
CALIFORNIA
MODELS

The

ignition
circuit

consists
of

igni

tion

switch
transistor

ignition
unit

distributor

wiring
spark

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

circuit

breaker
of
the
conventional

distributor
The
transistor

ignition
unit

is
a
new
addition
which

generates
the

signal
required
for
the
make

and
break

of
the

primary
electric
current
for
the

ignition
coil

The
circuit
is

equipped
with
a

resistor

During
cranking
electrical

current

bypasses
the

secondary
resis

tor

thereby
connecting
the

ignition

coil

through
the

primary
resistor
This

makes

battery
voltage
available
at
ef

ficiently
and

keeps
ignition
voltage
as

high
as

possible

The

primary
resistor

selVeS
to

pro

tect
transistor

ignition
circuit

The
low

voltage
current
is

supplied

by
the

battery
or
alternator
and
flows

through
the

primary
circuit

It
consists
of
the

ignition
switch
Engine
Electrical

System

resistor

primary
winding
of
the

igni

tion

coil
transistor

ignition
unit
and

all

connecting
low
tension

wiring

The

high
voltage
current
is

pro

duced

by
the

ignition
coil
and

flows

through
the

secondary
circuit

result

ing
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
wires
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
transistor

ignition
unit
to

ground

When
the

prim

ary
circuit
is

opened

by
circuit

of
transistor

ignition
unit

the

magnetic
field

built

up
in
the

primary
winding
of
the
coil
moves

through
the

secondary

winding
of
the

coil

inducing
high
voltage
This

high

Battery
Primary
Secondary

I

Resistor

To

starter

r
Transis
tor

ignition

unit
I

I

Pick
up

rcoil

r
Rotor
head

nl

J
R5

U1f

1

Retuctor
r
oi

l
f
S

park

plugs
voltage
is

produced

every
time
the

primary
circuit

opens

The

high

voltage
current
flows

through
the

high
tension
wire
to

the

distributor

cap
then
the
rotor

distri

butor

cap
then
the

rotor
distributes

the

current
to

one
of

the

spark
plug

terminals
in

the
distributor

cap

Then
the

spark
occurs
while
the

high

voltage
current

jumps
the

gap

between
the
insulated
electrode

and

the

ground
side
electrode
of
the

spark

plug
This

process
is

repeated
for

each

power
stroke
of

the

engine

The

spark

plug
should
be

inspected

cleaned
and

regapped
at
tune

up

Spark
plugs
should
also
be

replaced

periodically
as

specified
in
the
Main

tenance
Schedule

The

remainder
of
the

ignition
com

ponent
parts
should

be

inspected
for

only
their

operation
air

gap
of

distri

butor

tightness
of
electrical
terminals

and

wiring
condition

Apply
grease

NLGI
consistency

No
I

containing
MoS
or

equivalent

to
distributor
rotor
shaft
as

required

EE287

EE
28
Fig
EE
55

Ignition

8Y3tem
circuit

diagram

CHECKING
AND

ADJUSTMENT

CAP
AND
ROTOR
HEAD

Cap
and
rotor
head
should
be
in

spected
periodically
as

specified
in
the

Maintenance
Schedule
Remove
cap

and
clean
all
dust
and
carbon
deposits

from

cap
and
rotor
If

cap
is
cracked

or
is

leaking
replace
with
a
De
one

CONTACT
POINT

Contact

point
should
be

replaced
in

accordance
with
the
Maintenance

Schedule

Standard

point
gap
is
0
45
to
0
55

mm
O
OIS
to
0

022
in
In

case
size

is
off
the
standard

adjustment
is
made

by
loosening
point
screws

Gap
gauge

is

required
for

adjustment

When

point
surface
is

rough
take

off

any
irregularities
with

fine
sand

paper
of
No
500
or
600
or
with
oil

stone

When
wear

on
contact

points
is

noticeable
replace
points
together

with
contact

arm
To

replace

proceed

as

follows

EE322

Fig
EE
58
Adju
ting
point

gap

EE321

I

Primary
lead
termina

2
Ground
lead
wire

3
Set
screw

4

Adjuster

5
Screw
Fig
EE
59
Breaker
Engine
Electrical

System

First
turn
out
set

screws
1
to

1
5

turns
at
contact
arm
and

primary
lead

wire

connection

just
for

enough
to

pull
out

primary
lead
terminal

Referring
to

Figure
EE

59
unSCrew

two
contact
set

fixing
screws

and

remove
lead
wire

While

holding
contact
arm

by

fingers

pull
out
contact
set

toward

you
by

raising
it

slightly
Contact

point
and

afm
can

then
be

removed

together

Install
new
contact

point
and

arm

assembly
in

reverse
sequence
of

removal

Coat
cam
with
a

light
coating

of

grease

ADVANCE
MECHANISMS

Specifications

Application

Vacuum
advance

Distributor

degrees
distributor

mmHg
inHg

Centrifugal
advance

Distributor

degrees

distribu
tor

rpm

For
Canada

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate
properly
check
for
the

following
items

and
correct
the
mal

function
as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
its

connection

Ifnecessacy

retighten
or

replace
with
a
new
one

2
Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controller

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

pia
te
does
not

move

smoothly

this
condition
could
be
due
to

sticky

steel
balls
or

pivot
Apply
grease
to

steel
balls
or
if

necessary

replace

breaker

plate
as
an

assembly

EE
31
CONDENSER

Satisfactory
performance
of
con

denser

depends
on

capacity
and

degree

of
insulation

requiring
attention

to
be

sure

that
terminals
are
clean
and
set

screws
are

tight

Checking
of

condenser
is
made

by
a

condenser
tester

D4A4
06

D4A6
07
D4A4
07

D4A6
0S

Automatic

transmission
Manual
transmission

00
150
5

91

30
250
9

S4
00
170
6

69

6
50
300

1I
S1

00
550

11
0

2

300
00
600

110
1
950

Centrifugal
advance

mechanical

parts

When
cause
of

engine
malfunction

is

traced
to

centrifugal
advance
me

chanical

part
use
distributor
tester
to

check
its
characteristic

See
the

specifications
above

When

nothing
is

wrong
with
its

characteristic
conceivable
causes
are

break
down
abnormal

wearing
out
of

driving
part
or
others
So
do

not

disassemble

it

In

case
of

improper
characteristic

take
off
contact
breaker

assembly
and

check

closely
cam

assembly

governor

weight
shaft
and

governor
spring
etc

In
case

centrifugal
advance
me

chanical

part
is
reassembled
be

sure
to

check
advance
characteristic

by
dis

tributor
tester

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate

properly
check
for
the

following
items

and
correct
the

prob

lem
as

required

1

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

controller

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
balls
or
if

necessary
replace

distributor

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
See
to
the

specifications
above

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
above

parts
are
malfunc

tioning
replace
distributor

assembly

DISASSEMBLY

To

disassemble
follow
the

pro

cedure
below

1
Take
off

cap
and
remove

rotor

head

2
Remove
two
screws
shown
in

Figure
EE
69
and
detach
vacuum

con

troller
Engine
Electrical

System

EE291

Fig
EE

69

Removing
vacuum

controller

3
Remove

pick
up
coil

assembly

4

Using
two

pry
bars

pry
reluctor

from
shaft
Be
careful
not

to
distort
or

damage
the
teeth
of
reluctor

Remove

roll

pin

S
Remove

breaker

plate
setscrews

and
remove

breaker

plate
assembly

E330

Fig
EE
70

Removing
breaker
plate

etscrews

6
Pull
roll

pin
out
and
remove

collar

7
Remove
rotor
shaft
and
drive

shaft
assembly

EE331

Fig
EE
71

Removing
rotor

shaft
and

drive

shaft
assembly

8
Mark
rotor
shaft
and

drive
shaft

Remove

packing
from
the

top
of

rotor

shaft
and
unscrew
rotor
shaft

setscrew

EE

35
EE075

Fig
EE
72

Removing
rotor

shaft

9

Mark
one
of
the

governor
springs

and
its
bracket
Also
mark

one
of
the

governor

weights
and
its

pivot
pins

10

Carefully
unhook
and
remove

governor

springs

11
Remove

governor
weights

Apply
grease
to

governor
weights

after

disassembling

ASSEMBLY

To

assem
ble

reverse
the
order
of

disassembly

Carefully
observe
the
fol

lowing
instructions

1

Align
match
marks
so
that

parts

are
assembled
to
their

original

posi

tions

2

If
for

any
reason
contactor
is

removed
from
breaker

plate
adjust

cam
to
contactor
clearance

to
0
3

mm

0
012
in

as
shown
in

Figure
EE
73

after
installation

T

EE298

Fig
EE
73
Cam
to
contactor

clearance

3

Ensure
that
reluctor
is

properly

orien

ted
when

installing
on
shaft

Always
drive
in

roll

pin
with
its

slit

toward
the
outer
end
of
shaft
See

Figure
EE

74
Be

sure
to
use
a

new
roll

pin

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

Condition

Spark
length

I

to
2
rnm
0
039

to
0
079
in
Of

irregular

More

than
6
rnm

0
236
in
Engine
Electrical

System

Location
Probable
cause

Distributor
Point

gap
too
wide
Non
California
mo

dels

Oil

on
point
Non
California
models

Burned

points
Non

California
models

Spark

plugs
Spark

plug
gap
too
wide

Too
much
carbon

Broken
neck
of
insulator

Expiration
of

plug
life

Air

gap
too
wide
California
models

Distributor

Transistor

ignition

unit
California

models
Faulty
transistor
ignition
unit
Corrective
action

Correct

Clean

Replace

Correct
or

replace

Clean
or
replace

Replace

Replace

Correct

Replace

2

Engine
rotates
but
does
not
run

smoothly

This

may
be

caused

by
the

ignition
system
or
other

engine
condi
Hons
not

related
to

ignition
Therefore
first
a
complete
inspection
of

ignition
system

should
be

carried
out

Condition

Engine
misses
Location
Probable

cause

Distributor
Dirty
point
Non
California
models

Foreign
mattef
on

pick
up
coil
California

models

Improper
point

gap
Non
California
mo

dels

Impropef
air

gap
California
models

Leak
of

electricity
at

cap
and
rotor
head

Damaged
insulation
of
condenser

Non

California
models

Malfunctioning
contact
arm
Non
Cali

fornia
models

Faulty
contact
arm

spring
Non
Cali

fornia
models

Breakage
of
lead
wire
Non
California

models

Breakage
of

pick
up
coil
lead
wire
Cali

fornia
models

Worn

or
shaky
breaker

plate

Worn
or
shaky
distributor

driving
shaft

Layer
short
circuit
or
inferior

quality

coil
Ignition
coil

High
tension
wire
Deterioration
of
insulation
with
con

sequent
leak
of

electricity

EE
49
Corrective
ac
ion

Clean

Clean

Correct

Correct

Repair
or

replace

Replace

Oil
shaft

Replace

Replace

Replace

Replace
assembly

Replace
assembly

Replace
with

good
one

Replace

Condition

Engine
causes

knocking
very

often

Engine
does

not

deliver

enough

power
Location

Spark

plugs

Transistor

ignition

unit

California

models

Distributor

Spark

plugs

Distributor

Spark

plugs
Engine
Electrical

System

Probable
cause

Fouled

Leak
of

electricity
at

upper
porcelain

insulator

Faulty
transistor

ignition
unit

Improper
ignition

timing
too

advanced

Coming
off

or

breakage
of

governor

spring

Worn

pin
or
hole
of

governor

Burnt

too
much

Improper
ignition
timing
too

retarded

Improper
functioning
governor

Point

gap
too

narrow

Non
California

models

Foreign
particles
stuck
in

air

gap
Cali

fornia
models

Fouled

EE

50
Corrective
action

Clean

Repair
or

replace

Replace

Correct

Correct

or

replace

Replace

Replace

Correct

Replace
assembly

Correct

Oean

Oean