1977 DATSUN PICK-UP service

DATSUN
PICK
UP

MODEL
620
SERIES

I
NISSANI

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
EC

EMISSION

CONTROL

SYSTEM

EC
2

GENERAl
DESCRIPTION

CRANKCASE
EMISSION

CONTROL
SYSTEM

EXHAUST
EMISSION

CONTROL
SySTEM
EC

3

EVAPORATIVE
EMISSION

CONTROL
SYSTEM

SPECIAL
SERVICE
TOOLS
EC
2

EC
30

EC
32

j

EC231

Thermal

vacuum
valva
o

o

m
Emission

Control

System

0

o

o

o

l

l
@

The
thermal
vacuum
valve

is

mounted
in

the

engine
thermostat

housing
It

detects

engine
coolan
t

tem

perature
by
means
of
a

built
in

bi

metal
and

opensor
closes
the

vacuum

passage
in
the

thermal
vacuum

valve

mt

li

t

00
t

EC232

Fig
EC
54
Thennal

vacuum
valve
To
E

G
R
control
valve

From
carburetor

1

Spring

2
Bi
metal

3

O

ring

E
G
R

warning

system

The

E
G
R

warning
system
install
1

Diaphragm
spring

2

Diaphragm

3
Valve
shaft

4

Valve

5
Valve

Seat

6
Valve
cham
ber

Fig
EC
53
E
G

R
control
value

When
the

vacuum

passage
is

open
the

carburetor
suction

vacuum
is

applied

to
the

diaphragm
of
the
E
G
R

con

trol
valve
to

actuate
the

taper
valve

connected
to
the

diaphragm

theconsiiiictlo

nlie
thermal

vacuum
valve
is

shown
below

ed

independently
of
the

E
G
R

con

trol

system
monitors

the
distance
the

car
has
travelled
and

indicates
when

EC
22
the
E

G
R

control

system
must
be

checked

The
E
G
R

warning
system
consists

of

an
odometer
switch

detector
drive

counter
E

G
R

warning

lamp
and

harnesses

When
the

earn
in
the

odom

eter
switch
connected
to

the

speed

ometer
turns

once
for

each
OAkm
4

mile
the

contact

point
of
the
elec

trica
circuit
closes

allowing
electric

current
to
flow

through
the

magnet

coil
of

the
detector

drive
counter

Thus

energized
the

magnet
coil
ac

Wates

the
latchet
to

turn
the
c
unter

wheel

by
one

pitch
When
the

number

of

counts
reaches
50
000
the
latchet

drops
in

a

groove
provided
on
the

periphery
of

the
counter
wheel
to

activate

the
detector

drive
counter

switch

Then
the

E
G
R

warning

lamp

comes
on

indicating
that
the
E
G
R

control

system
Should
be
checked

The

detector
drive

coun
teT
is

equip

ped
with
an
odometer
which

can
tell

when
to
service

the
E

G
R
contr0
I

system

After

completing

periodic
check

reset
the
odometer
to

zero
by
hand

proceeding
as
follows

1
Remove

grommet
installed
on

the
side

surface
of

detector
drive

counter
unit

2
insert

a
bar

or
a
screwdriver

tip

into
the

hole
from

which

grommet
has

been

removed
and

press
down
knob

provided
in

the
detector
drive
counter

for

resetting

The
E

G
R

warning

lamp
comes

on

under
the

following
circumstances

1
When
the
number
of

counts
has

reached
50
000
In
this

case
the

lamp

indicates
that
E

G
R

control

system

must
be
checked

2
When

operating
starter
motor

Notes

a
It
is

an
indication
of

problem
in

the

E

G
R

warning
lamp
or

problems

in
the

point
or
in
the
harnesses
if

the

lamp
does
not

light
at

50
000

counts

b

The
E

G
R

warning
system
is

mounted

on
all
620
models

except

those

bound
for
California
and

Canada

I
Emission

Control

System

Ignition
switch

Ignition

key
Off

T

I

I

I

Battery

I

J

77

77
Relay

J

Floor

temperature

sensing
swi

tch
Floor

temperature

warning

lamp

77
77

EC332

Fig
EC

70
Win

ng
diagram
of
floor
temperature
warning
system

r
l

J
@

1

Floor

temperature

Ij

cr

EC556

Fig
EC
71
Location

of
iJoor

temperature
sensing
switch

OPERATION

Floor

temperature
will
exceed

nor

mal
level

when

temperature
rise
in

the

exhaust

system
succeeding
the
cata

lytic
converter
is
caused

byeilher
an

engine
malfunction

or
severe

driving

conditions

Under
this
condition
the

floor

temperature
sensing
switch
turns

off

causing
the

starting
switch
line
of

the
floor

temperature
relay
to
turn
off
and
the

ignition
switch
line
to
turn
on

as
a
result
the
floor

temperature

warning

lamp
comes
on

When
the
floor

temperature
is

lower
t

an
the

specific

temperature

the

floor

temperature
sensing
switch

turns

on
The

ignition
line

of
the
floor

temperature
relay
turns
off
while
the

starting
switch
side
is
in

on
The
floor

temperature
warning

lamp
goes
out

EC
2B
The

lamp
is

functioning
sa
tis

factorily
if

it
is
remains
on

while
the

starting
motor
is
in

operation
The

lamp
goes
out
when

the

ignition

switch
is
in

IG

position

The

foUowing
chart

furnishes
the

information
on

the

relationship
be

tween

floor

temperatures

warning

lamp
and

sensing
switch

L

Contact
close

ECJ40

I

Contaclopen

ECJ41

Fig
EC
72

Operation

of
floor

t

mperature
sen6ing

6witch

REMOVAL

Floor

temperature

sensing

switch

1
Remove
seat

Seat
section
of

service
manual

2
Remove

sensing
sWitch
as
outlined
in

the

Body
and
Frame

floor

temperature

Floor

temperature
relay

From
under

relay
cover
remove

this

part
Refer
to

Figure
EC
73

Floortemperature

EC783

Fig
EC
73
Location

of
floor

ttmperature
relay

Emission
Control

System

SPECIAL
SERVICE
TOOLS

Tool
number
For
Reference

No

Description
use

page
or

tool
name
on

Figure
No

STI
98
10000
For

removing
and

installing
the
rotor

ring
assembly
L20B

Fig
EC
29

A14

Fig
EC
41

Hexagon
wrench

SE279

2

ST
19900000

For

assembling
the
vanes

L20B
Fig
EC
39

A14

Dummy
shaft

SE284

3

STl9890000
Used
as
a
mount
when
rotor
is
removed
and
when

bearing
is

installed
L20B

Fig
EC
32

A14

fig

IlC
35

f

Rotor

adapter

SE347

4

STl9940000
Used
when
rotor
is
removed
and
when
front

bearing
installed
L20B

Fig
EC
32

A14

Fig
EC
35

Bearing

Pressing

tool

d

9E348

This

service
tool
is

designed
for
use
in

disassembly
and

assembly
of
the

air

pump

EC
33

DESCRIPTION

OPERATION

CONSTR
UCTI

ON

REMOVAL

DISASSEMBL
Y

CLEANING
AND
INSPECTION

TERMINAL

FIELD

COIL

BRUSHES
AND
BRUSH
LEAD
WIRE

BRUSH
SPRING
TENSION

ARMATURE
ASSEMBLY

DESCRIPTION

The
function
of
the

starting
system

which
consists
of
the

battery
ignition

switch

starting
motor
and
solenoid
is

to
crank
the

engine
The
electrical

energy
is

supplied
from
the

battery

the
solenoid

completes
the

circuit
to

operate
the

starling
motor
and
then

the
motor
carries
out
the
actual
crank

ing
of
the

engine
Engine
Electrical

System

STARTING
MOTOR

CONTENTS

EE
4

EE

6

EE

7

EE
7

EE

7

EE

8

EE

8

EE
B

EE

B

EE

B

EE

B
OVERRUNNING
CLUTCH
ASSEMBLY

BRUSH
HOLDER
TEST
FOR

GROUND

BEARING
METAL

MAGNETIC
SWITCH
ASSEMBLY

ASSEMBLY

TEST

PERFORMANCE
TEST

MAGNETIC

SWITCH
ASSEMBLY
TEST

SERVICE
DATA

AND
SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS

5

@
EE
9

EE
9

EE
9

EE
9

EE
9

EE
9

EE
9

EE
O

EE

EE
11

I
Brush

2
Field
coil

3

Magnetic
switch

4

Pludgcr

5
Torsion

spring

6
Shifll
r

7

Overrunning
clutch

8
Pinion

9
Armature

9

EE315

Fig
EE
5
Sectioool
view

of

slarting
motor
Sl14
180B

EE
4

Engine
Electrical

System

SERVICE
DATA
AND
SPECIFICATIONS

Type

System
voltage

No
load

Terminal

voltage

Current

Revolution
v

V

A

rpm

Brush

length
Outer
diameter
of
commutator
mm
in

mm
in

Brush

spring
tension

kg
Ib

Clearance
between

bearing
metal
and

armature
shaft
mm
in

Clearance
L
between

pinion
front

edge
and

pinion
stopper
mm
in

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Starting
motor
will

not

operate

Noisy
starting
motor

Starting
motor

cranks

slowly
Probable
cause

Discharged
battery

Damaged
solenoid
switch

Loose
connections
of
terminal

Damaged
brushes

Starti

g
motor

inoperative

Loose

securing
bolt

Worn

pinion

gear

Poor

lubrication

Worn
commutator

Worn
brushes

Discharged
battery

Loose
connection
of
terminal

Worn
brushes

Locked
brushes

EE
ll
Manual

transmission
Automatic

transmission

Optional

for

manual

transmission

SII4
ISOB

S114
170B

12

12

Less
than

60

More

than
7

000
More
than
6
000

More
than
39

1
54

More
than
12
0
47

1
4

to
I
S
3
1
to
4
0

Less
than

0
2
O
OOS

0
3
to
1
5
0
012
to
0

059

Corrective
action

Charge
or

replace
battery

Repair
or

replace
solenoid
switch

Clean
and

tighten
terminal

Replace
brushes

Remove

starting
motor
and
make
test

Tighten

Replace

Add
oil

Replace

Replace

Charge

Clean
and
tighten

Replace

Inspect
brush

spring
tension

or

repair
brush

holder

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