1977 DATSUN PICK-UP check engine

REMOVAL

CHECKING
ELECTROLYTE
LEVEL

CHECKING
SPECIFIC
GRAVITY

REMOVAL

I
Disconnect

negative
and

positive

cables

2
Remove

nuts
from

battery

clamps
take
off

clamps

3
Remove

battery

CHECKING

ELECTROLYTE
LEVEL

Remove
six

vent

plugs
and
check

for

electrolyte
level
in
each
cell

If

nccessaJ

pour
distilled
water

CHECKING

SPECIFIC

GRAVITY

Specific
gravity
of

battery
electro

lyte
is
tested

by
a

hydrometer
If
the

srate

of

charge
of

battery
is

60
or

specific
gravity

reading
is
below
1
20

as
corrected
at
200e
680F
bat

tery
must
be

recharged
or

battery

electrolyte
concentration

adjusted

Add
or
subtract

gravity
points

according
to
whether
the

electrolyte

temperature
is
above

or
below
200e

680F

standard

The

gravity
of

electrolyte
chlll

ges

0

0007
for

every
Ioe
1
80F
tem

petature
A
correction

can
then
be

made

by
using
the

following
formula
Engine
Electrical

System

BATTERY

CONTENTS

EE
2

EE
2

EE
2
BATTERY
FREEZING

CHARGING

INST
ALLA
TION

S

20
St
0

0007
t
20

Where

St

Specific
gravity
of

electrolyte

at
tOe

520

Specific
gravity
of

electrolyte

corrected
at
200e
680F

t

Electrolyte

temperature

For

example
A

hydrometer

reading
of

1
260
at
300e

860F

would

be
1
267
corrected

to
200e

6goF

indicating
fully
charged

battery
On
the
other
hand
a

hydro

meter

reading
of
1
220
at
lOoe

140
F
would
be
1
199
corrected
to

200e
680F

indicating
a

partially

charged
battery

The
state
of

charge
of

battery
can

be
determined

by
the

following
table

if

the

specific
gravity
of

electrolyte
is

known
BefOIe

checking
be
sure
that

cells
are
filled
to
correct
level

G
U

o

N

b
t

E

u

ol

1
lilt

I
i
I

m
J

I
I

I
I

J
1
I

J
Sf
to
7
1
II

It
100

0wJIztI
COJJditioD

EE002

Fig
EE
2

ChaJ
ffing
condition

EE
2
1
28

@

126

S

Sow

E

l

l

u

o

o

l

e

u

0

U21

1

101
EE

3

EE

3

EE
3

Read

top
level

with
scale

1
Thermal

gauge

2

Hydrometer
feOOl

Fig
EE

l

Checking
pccme
gravity

Converted

specific
gavity

20

1
Je

I

dOldlOiJ
OSQ

Electrolyte
temperature
oC

EEOO3

Fig
EE
3

Specific
lNWity
at

eiectroly
te
temperature

BATTERY
FREEZING

Battery
electrolyte
freezing
point

varies
with
acid
concentration
or
its

specific
gravity
A

battery
with
an

insufficient

charge
will
freeze
at
lower

temperatures
If

specific
gravity
of
a

battery
falls
below
1
1
this
is

an

0

10

20

30

g

40
I
u

il

SO
I
0

e

60
0

E

70
Engine
Electrical

System

indication
that

battery
is

completely

discharged
and
will

freeze

readily

when

temperatures
fall
below

freezing

Note
Use
extreme
caution
to
avoid

freezing
battery
since

freezing
will

generally
ruin
the

battery

1

80

1
00
1
04
1
08
t
l2
1
16
t
20
1
24
1
28

Specific
gravity
of

electrolyte

CHARGING

I

f
electrolyte
level
is

satisfactory

battery
must
be

charged
when
electro

lyte
gravity
reading
falls
below
1
20
If

battery
on

car
is

quick
charged
to
1
32

EEOQ4

Fig
EE

4
Froezing
point
of
electrolyte

bring
it

up
to
full

charge
the

opera

tion
should
be
carried
out

with
nega

tive
cable
removed

Prior

to
charging
corroded
termi

EE
3
nals
should
be

cleaned
with
a

brush

and
common

baking
soda
solution
In

addition
the

following
items

should

be
observed
while

battery
is

being

charged

I
Be

sure
that
electrolyte
level
is

above

top
of

each
plate

2

Keep
removed

plugs
in

a
safe

place

3
Do

not
allow

electrolyte
tempera

ture
to

go
over
450C
I130F

4

After

charging
check
to
be
cer

tain
that

specific
gravity
does
not

exceed
1
260
at
200C
680P
Cor

rection
can
be
made

by
adding
dis

tilled
water
into

cells
as

necessary

5

Keep
battery
away
from

open

flame
while
it
is

being
charged

6
After
all
vent

plugs
have
been

tightened
clean
all

sprayed
electrolyte

off

upper
face

of

battery

INSTALLATION

1
Install
and

tighten
clamps
secure

Iy

2
After

clamps
have
been

tightened

clean

battery
cable
terminals
and

apply
grease
to
retard
formation
of

corrosion

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