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Service Manual Model G18 Engine

1. 26 IGNITION CIRCUIT 30 DISTRIBUTOR EE 30 NISSAN MOTOR CO LTD IGNITION mm EE 40 TOKYO JAPAN SPARK PLUGS DEET EE 41 ENGINE ELECTRICAL SYSTEM STARTING CIRCUIT The electrical system operates on 12 volts This section of the manual is subdivided into the following sections which pertain to engine electrical 1 Starting motor 2 Alternator 3 Regulator 4 Ignition coil 5 Spark plugs Information pertaining to body electrical such as the lighting circuit instrument and windshield wipers will be found in section BE STARTING MOTOR CONTENTS SPECIFICATION 1 Over running clutch assembly EE 7 DESCRIPTION Loro recct neon EE 2 Brush holder test for ground EE 7 OPERATION Pagar EE 2 Pinion case bearing metal EE 8 CONSTRUCTION ee citet errore ul ba EE 3 Magnetic switch assembly EE 8 REMOVAL insidet edens EE 3 ASSEMBLY EE 8 DISASSEMBLY TEST 8 CLEANING AND INSPECTION EE 5 Performance test sss EE 8 5 Diagnosis of test En EE 9 Field ayasa asas kaqa 5 Magnetic switch assembly test EE 9 Brushes and brush lead wire EE 6
2. EM 19 Camshaft bearing clearance check EM 12 Fitting bearings EM 20 Valve timing check EM 13 MISCELLANEOUS COMPONENTS 21 Camshaft alignment EM 13 Crankshaft sprocket camshaft CYLINDER BLOCK EM 14 Sprocket EM 21 How to measure cylinder EM 14 Chain tensioner and chain guide EM 21 Ewe 5 21 PREPARATION FOR INSPECTION 1 Check the cylinder head and the cylinder block for traces of water leaks before cleaning 2 Wash all the parts to clean them completely of oil strains carbon deposits fur and sealing material 3 Ascertain if all the oil holes are clear by blowing air into them 4 Use every caustion to secure proper as sembly CYLINDER HEAD AND VALVES Checking head mating face 1 Make a visual check for cracks and flaws 2 Measure the surface of the cylinder head on the cylinder block side for warping If it is EM 8 ENGINE MECHANICAL found to be beyond the limit designated below regrind the affected surface with a surface grinder Fig EM 24 Intake and exhaust valve 2 The valve face or valve stem end surface should be refaced by using a valve grinder Fig EM 22 Checking the cylinder head surface omm e Head sur
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5. L Anti backfire Check valve Special calibrated Air injection nozzle carburetor Fig EC 3 Nissan air injection system EC 3 ENGINE NA LS is basically an air injection sys tem combined with engine modifications to increase its effectiveness The basic elements of the system are en Engine driven air pump Air injection into each exhaust port e Engine modifications EN Recommended annual maintenance The air injection pump receives clean air by means of a hose connected to a fitting on the underside of the carburetor air cleaner This rotary vane type pump has been de signed to draw the air in and produce maximum air flow with quiet operation A fresh air line from the air injection pump is routed so that it goes to an anti backfire valve and then to a check valve which prevents exhaust gas from entering the air pump in the event exhaust mani fold pressure is greater than air injection pressure or in the case of an inoperative pump The compressed fresh air is injected through an injection nozzle to the exhaust ports An anti backfire valve has been installed to eliminate popping in the exhaust system when the throttle is closed at a high speed coast Controls which have been incorporated to assure reliable system operation include an anti back fire valve and a check valve Engine driven air pump The air injection pump is a positive dis
6. ENGINE AIR PUMP TEST Check for the air leakage of relief valve with engine speed at 1 500 r p m No leaky pressure is felt Leaky pressure is felt Disconnect the air supply hose at the anti backfire valve Plug up it Check the air leakage of relief valve with engine speed at 1 500 r p m No leaky pressure is felt Leaky pressure is felt U Insert the open pipe end of the test gauge adaptor in the air supply hose to the check valve at the anti backfire valve Clamp the hose securely engine speed at 1 500 r p m observe the pressure produced at the test gauge special tool STECP200006 Air pressure more than 3 4 psi less than 3 4 psi less than 3 4 psi more than 3 4 psi valve and observe Air pump and relief Air pump is func valve are functioning tioning properly again the pressure less than 3 4 psi more than 3 4 psi 1 Replace relicf valve Aire pressure than 3 4 less than 3 4 psi less than 3 4 psi more than 3 4 psi I 1 1 Relief valve is stuck Replace with new one Plug up the relief Air pressure i Disconnect and plug the air hose to the air pump suction line at the anti backfire valve With engine speed at 1 500 r p m observe the pressure produced at the test gauge special tool STECP200006 Air pump is functioning properly Inspect a
7. Exchange the oil with proper one and change the element Change the element Previously mentioned Check the fuel system Previously mentioned Reassemble with the designated clearances Previously mentioned Check the fuel system SERVICE JOURNAL OR BULLETIN REFERENCE ENGINE SERVICE JOURNAL OR BULLETIN REFERENCE o gt m 2 e PAGE No JOURNAL or BULLETIN No DATE ET 14 MD MONDE DATSUN 1800 SER EE SERVICE MANUAL MODEL G18 ENGINE NISSAN MOTOR 0 LTD TOKYO JAPAN SECTION EM ENGINE MECHANICAL GENERAL DESCRIPTION nnm EM 1 ENGINE DISASSEMBLY EM 5 INSPECTION AND REPAIR EM 8 ENGINE ASSEMBLY cm EM 22 SERVICE DATA AND SPECIFICATIONS EM 31 TROUBLE DIAGNOSES AND CORRECTIONS EM 36 ENGINE MECHANICAL GENERAL DESCRIPTION CONTENTS GT8 ENGINE rece erento ee EM 1 CYLINDER HEAD rien EM 3 CYLINDER BLOCK een EM 2 CAMSHAFT EM 3 CRANKSHAFT eioan EM 2 VALVES AND VALVE ROCKER ARMS EM 3 PISTONS AND CONNECTING RODS EM 2 CAMSHAFT DRIVE SYSTEM EM 4 MANIFOLDS a aa aun EM 4 G18 ENGINE The G18 engine is a short stroke bore x stroke 85 x 80 mm 3 346 x 3 150 in power house with 1 815 110 8 c i displacement and its maximum output is 105 at 5 600 rpm SAE From low to high spee
8. 2 TESTING 2 DESCRIPTION Crankcase emissions are controlled by use of the so called combination system with valve controlled by intake manifold vacuum and tube to air cleaner device This system provides Carburetor for the return of blowby gases to both the in air cleaner take manifold and carburetor air cleaner During part throttle operation of the engine the intake manifold sucks the crankcase blowby gases through the variable orifice valve tapered prunger type Normally the capacity of the valve is suf ficient under these conditions to handle the blowby plus an adequate amount of ventilating Ee Control valve air The ventilating air is then drawn from the variable clean side of the carburetor air cleaner orifice valve through the tube connection into the crankcase Under full throttle conditions the manifold vacuum is insufficient to draw the blowby flow through the valve and the blowby flow goes through the tube to air cleaner in the reverse direction In cars having excessively high blowby some of the flow will go through the tube connection to the carburetor air cleaner under all conditions The control valve was shown to be capable Fig EC 1 Positive crankcase ventilation of operating longer with much less clogging part throttle operation eo 5 79 o eo E 5 u EC 1 ENGINE TESTING With engine
9. ENGINE MECHANICAL 2 Determine piston oversize according to the amount of wear of the cylinder Piston for service 84 958 84 990 mm 8 345 3 946 in 25 0 8 85 220 85 240 mm 8 355 3 356 in 85 470 85 490 mm 3 365 3 366 in 85 720 85 740 mm 5 5 62418 8 210 mi 100 0 8 85 970 85 990 mm 1250 5 3 3846 3 3854 in 3 By measuring piston to be installed at piston skirt side thrust face and adding the wear of clearance specification the finish hone cylinder measurement can be determined 86 220 86 240 mm 3 394 3 395 in Fig EM 39 Measuring piston diameter Cylinder bore to be treated A B C 0 015 to 0 035 mm 0 0006 to 0 0014 in Outer diameter of piston skirt A Piston cylinder clearance B 0 030 to 0 050 mm 0 0014 to 0 0022 in Hornning allowance C 0 02 mm 0 0008 in 4 Machine the cylinder bore to the determined inner diameter Note To prevent strain due to cutting heat bore the cylinders in the order of 2 4 1 3 5 Do not cut too much out of the cylinder bore ata time but cut 0 05 mm 0 0020 in or so at a time 6 Measurement of the cylinder bore just machined requires the utmost care since it is expanded by cutting heat 7 Finish the treated cylinder bore to final finish bore by honing 8 Measure the finished cylinder bore for el liptic or tapered part Note If the cylinder bore has worn beyond the wea
10. MODEL 618 ENGINE NISSAN MOTOR CO LTD TOKYO JAPAN 4 QUICK REFERENCE INDEX DATSUN 1800 SERVICE MANUAL MODEL G18 ENGINE lt NISSAN MOTOR CO LTD TOKYO JAPAN This service manual has been prepared for the purpose of assisting service personnel of our distributors and dealers for effective service and maintenance of model 618 engine Since proper maintenance and service are most essential to satisfy our customers by keeping their cars in the best condition this manual should be carefully studied The followings should be noted for effective utilization of this manual 1 Since only the informations concerning the engine are described herein please refer to both this and the DATSUN C30 SERVICE MANUAL for complete details of the car All the parts names in this manual conform to both DATSUN C30 PARTS CATALOG and only the genuine service parts listed in this parts catalog should be used as replacements All informations illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval is emphasised that those who use this manual revise the contents according to the SERVICE JOURNAL issued by the factory which carries the latest factory approved servicing method Rights for alteration in specifications and others at any time are reserved DATSUN 1800 SERVICE MANUAL
11. 5 37200618 Engine attachment SE 2 SERVICE EQUIPMENT Note 9 H ST37100000 DATE Engine stand SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or BULLETIN No PAGE No SUBJECT ENGINE SERVICE JOURNAL OR BULLETIN REFERENCE O uJ a gt Ke n PAGE No JOURNAL or BULLETIN No DATE Printed in Japan Publication No 48331 30330250
12. EE 35 EE 30 ENGINE ELECTRICAL SYSTEM Distributor model Applied engine 0416 57 eevee Ss ps G18 0423253 G18 with emission control system Fig 77 0416 57 SPECIFICATIONS Make HITACHI HITACHI G18 G18 with emission control system 1 3 4 2 Counter clockwise 5 600 A T D C 49 55 0 20 0 24 475 Applied engine 1 3 4 2 Counter clockwise 8 600 B T D C 49 55 0 20 0 24 550 Firing order Rotating direction Ignition timing Dwell angle Condenser capacity Start rpm Centri 11 5 1 400 11 5 1 000 fugal 16 5 2 800 23 5 2 600 vance charac teristic Start mmHg 80 Vacuum Maximum 5 200 degree rpm CONSTRUCTION AND OPERATION Figure EE 78 shows ignition diagram of part centrifugal advancing angle part vacuum gasoline engine Functionally the distributor advance mechanical part and driving part consists of high tension voltage part switch off Figure EE 79 and EE 80 show its structure EE 31 ENGINE iti itch ignition sw Ignition engine Condenser Breaker Distributor Ignition coil Fig EE 78 Ignition diagram D416 57 D423 53 Vacuum controller Rotor head Knock pin Condener Breaker head Contact arm Go
13. ET 12 M MM U U Renew the oil sea1 Renew the gasket or tighten it but not too much Renew the gasket and tighten it with the pro per torque Renew the oil pressure switch or tighten it Overhaul the cylinder and renew the piston Remount the piston rings Renew the rings Repair or renew piston and cylinder Renew the piston and piston ring Replace the seal lip with a new one Renew the valve or the guide Use the designated oil Previously mentioned Adjust it to the desig nated rpm Adjust it Repair or tighten the connection of fuel pipes Use the designated oil Previously mentioned Dismantie the oil pump and repair or renew it Excessive wear on the sliding parts Seizure of sliding parts ENGINE TUNE UP Functional deterioration of oil pump Blocked oil filter Increased clearance in various sliding parts Blocked oil strainer Trouble in the oil gauge pressure switch Oil pressure decrease Defective quality or contamination of oil Defective air cleaner Overheat or overcool Improper fuel mixture Principally to cylinder walls Decrease of oil pressure Too small clearances Overheat Improper fuel mixture Repair or replace it with new one Renew it Dismantle and replace the worn parts with new ones Clean it Replace it with a new one Previously mentioned
14. Loose or damaged oil pan gasket Loose or damaged chain cover gasket ET 11 Replace the water pump with a new one Adjust Adjust the tension of the chain Dismantle the engine and renew the main bearing bush Renew the bush and adjust the drive shaft Adjust the ignition tim ing Use specified plugs spark Replace them with new parts Dismantle the carbure tor and check it Adjust the level and check the needle valve Adjust Adjust it Remove the head and get rid of the carbon Replace it with a new one Tighten it Renew the tighten it Renew the gasket or tighten it gasket or Excessive oil consumption Others POOR FUEL ECONOMY See the explanation of the power decrease Others TROUBLE IN OTHER FUNCTIONS Decreased oil pressure ENGINE Defective oil seal in front and rear of the crankshaft Loose or damaged locker cover gasket Improper tightening of oil filter Loose or damaged oil pressure switch Cylinder and piston wear Improper location of the ring split or reversed assembly of it Damage or seizure of rings Wear of piston ring groove and rings Fatigue of valve oil seal lip Wear of valve stem In adequate quality of engine oil Engine overheat Exceeding idling revolution Defective acceleration recovery Fuel leakage Inadequate oil quality Overheat Defective function of oil pump regulator valve
15. 1 8 1 Engine Check ignition timing every 3 000 M 3 000 12 000 Check engine idling Engine tune up Check spark plugs 3 000 Replace spark plugs 12 000 Check high tension cables 12 000 3 000 12 000 Check for pitting and wear of distributor breaker points Replace distributor breaker points Apply grease to distributor rotor shaft 12 000 12 000 24 000 Apply grease to distributor cam and wick Replace carburetor air cleaner element Crank case emission control Check hoses and hose connections for leaks Check for proper function of crankcase ventilation control valve 3 Exhaust emission control Check for proper function of air pump 12 000 12 000 Check for proper function of relief valve Check for proper function of check valve 12 000 12 000 12 000 Check for proper function of anti backfire valve Check air gallery and nozzle connections for leaks 12 000 3 000 Check hoses and hose connections for leaks Check air pump belt tension EC 19 ENGINE SERVICE DATA AND SPECIFICATIONS Type of crankcase emission control Closed type Type of exhaust emission control Carburetor NIHONKIKAKI Nissan Air Injection System Downdraft dual throat 1 181 dia 23 mm dia 0 906 in dia Large venturi Small venturi 0 276 in dia
16. 4 ADDITIONAL PROCEDURE For diagnoses purposes it is sometimes necessary to proceed further than the basic tune up procedure The following steps plus a road test are included in a complete or major tune and test procedure Compression pressure test each cylinder Note If this test is to be performed it should be done when plugs are removed for service during basic tune up procedure Unless checking for worn rings or for the cause of low speed miss compression check should not be necessary Test compression with engine warm all spark plugs removed and throttle and choke open No cylinder should be less than 80 of the highest cylinder Excessive variation be tween cylinders accompanied by low speed missing of the cylinder or cylinders which are low usually indicates a valve not properly seating of a broken piston ring Low pressures even though uniform may indicate worn rings This may be accompanied by excessive oil con sumption Compression pressure 11 3 kg cm 156 8 in oz to 12 3 kg cm 170 8 in oz at 350 rpm Clean and inspect high tension wires distributor cap and rotor Note This operation is to be performed while checking distributor points during the basic tune up procedure Inspect distributor cap for cracks and flash over External surfaces of all parts of secondary System must be cleaned to reduce possibility of voltage loss All wires should be removed from distributor cap and coil so that
17. ENGINE nip P dp NISSAN MOTOR CO LTD TOKYO JAPAN ENGINE GENERAL EXTERNAL VIEW OF ENGINE E871 MAIN SPECIFICATIONS ee E6 2 RECOMMENDED LUBRICANTS PETROL AND COOLAN T ascectuatesteeeone vo EB 2 UNIT SERIAL NUMBER LOCATION EB 4 AND MAINT ENAN EB 5 SPECIAL SE FOR EMISSION CONTROL SYSTEM onn 6 ENGINE GENERAL EXTERNAL VIEW OF ENGINE External view of model G18 engine Fig EG 2 Left hand side EG 1 ENGINE MAIN SPECIFICATIONS Valve arrangement 3 Stroke mm in 80 3 150 Displacement cu in 1 815 110 8 Maximum power SAE HP at rpm 105 at 5 600 Maximum torque SAE m kg ft 1b 15 9 115 0 at rpm 3 600 Capacities Oil pan 3 8 U S qts U K qts 4 0 3 3 Coolant 8 6 U S qts U K qts 9 1 7 6 The table specifies the quantity of oil which is required for periodic oil replacement when oil filter is not replaced Should also the filter be replaced the total quantity is about 4 4 4 7 U S qts 3 9 U K qts RECOMMENDED LUBRICANTS PETROL AND COOLANT Use the following grades of oil gasoline and coolant Above 32 C 90 F average SAE 30 10W 30 SAE 20 20W 10W 30 SAE 10W 10W 30 SAE 10W 10W 30 32 to 0 C 90 to 32 minimum 0 to 12 C 32 to 10 F minimum Below 12 10 F minimum EG 2 ENGINE GENERAL Recommended lubricant
18. Oil pump Cylinder head Block installing surface near to oil Expanision plug exit Rubber plug Rear Manifold heat pipe Rocker cover Chain cover gasket both sides Tapping screw of buffle plate installing SPECIFICATION a Valve mechanism Valve clearance cold 0 25 0 0098 0 25 mm 0 0098 Reference value 0 28 mm 0 011 in 0 28 0 011 in Valve head diameter 42 1 654 1 348 Valve stem diameter In Ex 0 3150 Valve length In 4 58 4 61 Valve lift 0 354 Valve spring free length Outer 1 673 in Innter 1 630 in Valve spring loaded length Outer 1 142 in Innter 1 024 Valve spring assembling height Outer 1 457 Innter 1 339 Valve spring effective wind number Outer 4 5 mm 0 1772 in Innter 6 25 mm 0 2461 in EM 32 ENGINE MECHANICAL Valve spring wire diameter Outer 4 2 mm 0 1654 Innter 2 9 mm 0 1142 in Valve spring coil diameter Outer 27 5 mm 1 083 in i Inner 19 9 mm 0 733 in Valve guide length 48 mm 1 890 Ex 60 mm 2 362 in Valve guide height from cylinder head In Ex 16 7 mm 0 657 in Valve guide inner diameter In Ex 7 mm 0 2756 in Valve guide outer diameter In Ex 14 2 mm 0 559 Valve guide to stem clearance In 0 025 0 055 mm 0 0010 0 0022 in Ex 0 04 0 077 mm 0 0016 0 0030 in Valve guide
19. 0 0020 in Clearance of rocker shaft and rocker bushing 0 07 mm 0 0028 in 17 566 Rocker shaft 17 584 mm outer diameter 0 6915 0 6922 in 17 6 17 618 mm 0 693 0 694 in Bushing inner diameter EM 13 ENGINE CYLINDER BLOCK 1 Check visually for defects and flaws such cracks 2 Measure the top face of the block cylinder head mating face for warping If the warp ex ceeds the limit value correct it 3 Measure the cylinder bore for out o round or excessive taper with a bore gauge If ex cessive wear taper out of round are tected on the cylinder wall rebore the cylinder walls by a boring machine 4 When the wear taper and out of round are not excessive to the limit remove the step at the topmost portion of the cylinder by using a ridge reamer or the like How to measure cylinder bore A bore gauge is used Measure cyl inder bore at top middle and bottom points in each direction A and B as illustrated and record the measured values Wear of the cylinder bore is the difference of the maximum and minimum value 0 2 mm 0 0079 Difference of each four cylinder bore 0 2 mm 0 0079 0 05 mm 0 0020 Fig EM 38 Measuring cylinder bore Boring of cylinder 1 When any of the cylinders needs boring all other cylinders must be bored at the same time 14
20. 220 Slow economizer 1 6 mm in 0 0551 0 063 m mm 0 0472 0 5 2 5 2 9 Weight kg Ibs 5 5 EF 23 m ENGINE Main jet variation Jet Model BAK340 Altitude 115 12 3 000 10 000 ft 4 000 m 13 300 ft Note Jets for model D3034C carburetor should not be changed because of the special calibration for emission control SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL BULLETIN No PAGE No SUBJECT DATE EF 24 4 M SECTION EC SERVICE EMISSION MANUAL CONTROL SYSTEM MODEL G18 ENGINE GENERAL DESCRIPTION EG 1 POSITIVE CRANKCASE VENTILATION SYSTEM EC 1 NISSAN MOTOR CO LTD aaner CONTROL gem s TOKYO JAPAN EMISSION CONTROL SYSTEM GENERAL DESCRIPTION There are tow types of emissions that must Injection System N A L S be controlled These are the crankcase emis Periodic inspection and required servicing sions and the exhaust emissions Crankcase of these systems should be carried out at the emissions are controlled by use of the Positive recommended intervals to assure a cleaner Crankcase Ventilation System Exhaust emis better performing longer lasting engine and sions are controlled by use of the Nissan Air almost complete elimination of air pollution POSITIVE CRANKCASE VENTILATION SYSTEM CONTENTS DESCRIPTION alat 1 PERIODIC SERVICE iacit
21. 33 15 Fig KE 51 Conduction test of field coil 2 Ground test of field coil Check the conduction between slip ring and rotor core If the conduction exists replace rotor assembly because in this case field coil or slip ring must be grounded Fig EE 50 Installation of the diode Fig 52 Ground test of field coil EE 21 ENGINE 3 Inspection of rotor eccentricity Check the eccentricity of rotor as shown in Figure EE 53 using a dial gauge Repair or replace if the eccentricity is over 0 10 mm 0 0039 in Fig EE 53 Inspection of rotor eccentricity Inspection of stator 1 Conduction test If the neutral wire of stator connected to the lead wire N white color is conductive with each lead wire of armature coil the condition is all right Fig EE 54 Conduction test 2 Ground test If each lead wire of armature coil including neutral wire is not conductive with stator core the condition is all right Fig EE 55 Ground test Inspection of diode Using lamp and battery 1 Positive side diode Connect the battery negative terminal with the terminal BAT at rear cover and the battery positive terminal with connector N terminal white color as shown in Figure EE 56 Lamp in the circuit will light Fig 56 Inspection of positive side diode Nextly if lamp does not light when the connection is made reversely as shown in Figure EE 57 the positive side diode is
22. Clearance between pivot and hole 0 01 0 046 mm 0 0004 0 0018 in EE 39 ENGINE IGNITION COIL SPECIFICATION SS Wake HANSHIN Gis G18 with emis sion control Primary voltage 12 Ez NE Spark gap more than more than mm in 6 0 2362 6 0 2362 Primary resis tance at 20 C 3 8 3 8 i i d Applied engine Q Secondary resis tance at 20 C KQ DESCRIPTION Fig 98 HP5 10E The ignition coil is a oil type HP5 10E and pitch type coil HM 12F Dirty ignition coil is not available because it generates high voltage The case and cap should be cleaned and protect ed from dust oil and water 55655 WANNA NSA x REARS NAAR AAAS S LAR Z H x H H H H i f 5 4 D Washer Seal Cap Washer Secondary terminal plate Secondary termian Primary termiani Contact spring Seal Solder Guide ring Primary insulating paper Secondary tube Outside iron core Primary tube Insulator Secondary coil Case Oil Primary coil SY Sn e m gt gt Fig EE 99 Construction 5 10 EE 40 ENGINE ELECTRICAL SYSTEM PRIMARY CURRENT 1 405 ILN ap mei eae DISTRIGUTOR ROTATION Fig EE 100 Characteristic curve SPARK PLUGS CONTENTS SPECIFICATI
23. EM 27 ENGINE 13 Install the oil pump Temporarily tighten the mounting bolts Crank pulley Note Apply sealing agent Three Bond No 4 or 2 Oil flinger equivalent onto the pump mounting surface as shown in Figure EM 75 Fig EM 77 Installation of oil flinger Apply sealing agent here 16 Install the chain cover Note a Apply sealing agent Three Bond No 1 equivalent onto the gasket b Ensure that the boss on the back of the chain cover is located between the timing chain c Cut off the upper and lower projecting Fig EM 75 Application of liquid packing 14 Install the oil pump chain together with the two sprockets Tighten the nut securing the oil portions of the gasket pump sprocket to the pump drive shaft and bend the lock washer Note Adjust the tension of the oil pump chain by moving the oil pump body with the pin as the central point Then tighten the oil pump mounting bolt securely Fig EM 78 17 Install the crankshaft pulley and tighten the nut to the specified tightening torque Then bend the lock washer Tightening torque 15 to 20 kg m 108 5 to 144 6 ft lb 18 Install the oil strainer Fig 76 Adjusting oil pump chain tension 19 Install the oil pan 20 Turn the engine up side down and set the 15 Install the oil flinger in the direction shown No 1 cylinder piston to the dead center in Figure EM 77 position of the compre
24. This engine uses a cartridge type strainer so if the malfunction is detected replace an assembly Fig 11 Removing fuel strainer Inspection of cooling system Inspection of radiator cap Apply reference pressure 0 9 kg cm 12 7 lb in2 to the radiator cap and the reservoir tank cap by means of a cap tester to see if it is satisfactory Replace the cap assembly if necessary ENGINE Fig ET 12 Radiator cap test TROUBLE DIAGNOSES Cooling system pressure test With radiator cap removed apply reference pressure 0 9 kg cm 12 7 2 to the cooling system by means of a tester to check for leakes at system component AND CORRECTIONS CANNOT CRANK ENGINE Improper grade oil OR SLOW CRANKING Discharged battery Replace with proper grade oil Charge battery Defective battery Replace Loosen fan belt Adjust Trouble in charge system Inspect charge system Wiring connection trouble in starting Correct circuit Defective starter switch Repair or replace Defective starter motor Repair or replace Trouble shooting procedure on starting circuit Switch on the starting motor with light put on When light goes off or dims a considerably Check battery Check connection and cable Check starter motor Check wiring connection between battery and starter motor Check starter switch Check starter motor ENGINE TUNE UP ENGINE WILL CRANK NORMALLY BUT WIL
25. 14 mm dia 0 551 in dia Slow jet Main air bleed 0 5 mm dia 0 020 in dia x 5 Emulsion hole Slow air bleed Slow economizer Power jet Cushion jet Secondary 34 mm dia 1 339 in dia 28 mm dia 1 102 in dia 8 mm dia 0 315 in dia 16 mm dia 0 630 in dia 155 80 80 0 5 mm dia 0 020 dia 5 220 1 6 mm dia 0 063 dia Power system Vacuum piston Piston spring Vacuum acting type 9 mm dia 0 354 in dia 100 gr 0 220 lbs 31 mm 1 22 in Power valve spring Actuating vacuum 40 gr 0 0882 lbs 8 6 mm 0 339 in 140 110 mm Hg 5 51 4 33 in Hg Accelerator pump Piston vivas Pump discharge 14 mm dia 0 551 in dia 0 2 c 0 0122 cu in 2 0 4 c 0 0244 cu in 3 0 6 c c 0 0366 cu in Pump nozzle 0 5 mm dia 0 020 in dia titi n n EC 20 EMISSION CONTROL SYSTEM Main nozzle 2 3 mm dia S 2 8 mm dia 0 0906 in dia 0 110 in dia Throttle valve Fully closed angle S 20 opening Choke valve Fully closed angle Throttle opening at full Distributor Spark plug Air pump ECP 200 1A 200 rev 120 120 1 00 4 2 mAg 6 psi Air by pass type 1 3 1 7 sec at 500 Hg 19 7 in Hg Check valve 0 15 maq 5 91 Aq Cooling fan Spider 370 mm 14 57 in dia x 4 Fan coupling R
26. 3 Connecting rod d pm Fig EF 27 Adjustment of starting interlock opening Model DAK340 Carburetor 2 Float valve seat Throttle valve Float valve Adjusting gasket Stopper Fig EF 26 Fuel level adjustment D3034C Fig EF 28 Adjustment of starting interlock opening EF 15 ENGINE The choke valve at a full close position auto matically opens the throttle valve at an optimum angle 14 for DAK340 model and 13 5 for D3034C model for starting the engine through a link mechanism As for model DAK340 carbu retor after reassembly or in a check on the interlocked opening angle bend the choke con necting rod for adjustment so that a fully closed choke valve will bring the clearance G1 shown in Figure EF 28 to 1 1 mm 0 0433 in Adjustment of interlock opening of primary and secondary throttle valve lt lt Model DAK340 Carburetor 4 Throttle chamber 5 Throttle valve Fig EF 29 Model DAK340 carburetor 1 Connecting lever 2 Return plate 3 Adjust plate Figure EF 29 shows the primary throttle valve opened 60 When the adjust plate fixed to the primary throttle valve is open 60 it comes to contact with the connecting lever at When the throttle valve is further opened the point B where the connecting lever is in contact with the stopper is detached permitting the secondary system to start actuating The linkage between the primary and sec ondary th
27. EE 24 ENGINE ELECTRICAL SYSTEM speed Then the alternator output voltage should be kept to 14 volts Note Increasing the alternator speed would cause to increase the output 8 Read the output current when the revolution of alternator is 5 000 rpm 9 The specified current should be as follows AS2030B1 more than 30 Ampere AS2040P more than 40 Ampere 10050A Load resistance Fig EE 64 Circuit diagram for output inspection Note Use the battery charged in full up to the normal capacity ASSEMBLY In case of AS2030B1 Assembly is a reversal of disassembly pro cedure However the brush holder and brush cover should be installed at the last procedure In case of AS2040P 1 Install the brush holder to the diode end housing by two securing screws 2 Insert two brushes to the brush holder and push it against spring tension Secure the brushes by an iron wire as shown in Figure EE 65 3 Install the stator to the diode end housing 4 Join together both end housings by three through bolts EE 25 5 After the all parts have been assembled remove an iron wire then brushes and slip rings come in contact Iron wire Fig EE 65 Installation of brush holder AS2040P ENGINE REGULATOR CONTENTS REMOVAL EE 26 Adjustment of gap EE 27 INSTALLATION 26 Adjustment of voltage EE 29
28. Then the warning lamp turns on EE 12 ENGINE ELECTRICAL SYSTEM When the alternator begins to operate three phase alternating current is induced in the armature This alternating current is rectified by the positive and negative silicon diodes This rectified current of direct current output comes between the alternator and terminal Figure EE 26 On the other hand the neutral point voltage comes between and terminal nearly a half of the output voltage and this causes to flow the current from voltage regulator terminal to E terminal or ground through the coil as shown by the dotted arrows Then the coil VC1 is excited and the movable con tact point 5 comes in contact with voltage winding side contact point P6 This action causes to turn off the warning lamp and com plete the voltage winding circuit as shown by the heavy arrows When the alternator speed is increased or the voltage starts to go too high the movable contact point P2 is separated from primary Alternator Side contact P1 by the magnetic force of coil VC2 Therefore register R1 is inserted in the field circuit and output voltage is de creased As the output voltage is decreased the movable contact point P2 and primary side contact P1 comes in contact once again and the alternator voltage increases Thus the rapid vibration of the movable contact point P2 or inserting and removing
29. as shown in Figure EE 24 With the ignition switch on measure the gap between the pinion front edge and the pinion stopper Fig EE 25 Measurement of gap e SERVICE DATA 8114 104 gt m 0 032 0 0013 Armature shaft diameter pinion side 11 0 0 050 0 4331 70 0020 in 0 032 Armature shaft diameter rear end 11 970 050 mm 0 4528 Amendment limit of shaft diameter 0 1 mm 0 0039 in 0 0013 5 0 0020 P Amendment limit of shaft bent 0 08 mm 0 0031 in Clearance between shaft and bush 0 03 0 1 mm 0 0012 0 0039 in Amendment limit of dittoed clearance 0 2 mm 0 0079 in Outer diameter of commutator 35 0 mm 1 3780 in Wear limit of commutator diameter 2 0 mm 0 0787 in Brush length 18 5 mm 0 7283 in Wear limit of dittoed length 6 0 mm 0 2362 in remaining brush should be more than 12 5 mm 0 4921 in Brush spring tension 0 8 kg 1 76 lbs 0 0 Front bracket metal inner diameter 11 020 018 um 0 4331 10 0007 in 0 0 021 0 0 0008 Rear cover metal inner diameter mm 0 4528 im EE 10 ENGINE ELECTRICAL SYSTEM TROUBLE DIAGNOSES AND CORRECTIONS Starting motor will not operate Possible causes Remedies Discharged battery Charge or replace the battery Defective solenoid switch Repair or replace the solenoid switch Clean and tighten the termi
30. placement vane type which is permanently lubricated and requires no periodic mainte nance Relief valve Stripper Fig EC 4 Sectional view of air pump The die cast aluminum air pump assembly attached to the front of the engine is driven by an air pump drive belt A rotor shaft drive hub relief valve and intake and exhaust tubes are visible on the pump exterior A rotor vanes carbon shoes and shoe springs makeup EC 4 the rotating unit of the pump The rotor located in the center of the pump is belt driven The vanes rotate freely around the off center pivot pin and follow the circular shaped pump bore The vanes produce three chambers in the housing intake compression and exhaust EMISSION CONTROL SYSTEM Side seal Ball bearing 1 End cover Fig EC 5 Sectional view of air pump Each vane completes a pumping cycle in every revolution of the rotor Air is drawn into the intake cavity through a tube connected to the air cleaner The air is sealed between the vanes and moved into a smaller cavity the compres sion area After compression the vanes pass the exhaust cavity The vanes then pass the Stripper a section of the housing that separates the exhaust and intake cavities Continuing the cycle the vane again enters the intake cavity to repeat its pumping cycle The relief valve located in the exhaust cavity encloses a pre loaded spring a seat and a pressure setting plug I
31. scars and burrs Replace bushings if any defects are detected 2 Wipe off oil and dust especially the rear of the bushing 3 Set the main bearing on the cap block PLASTIGAGE Fig EM 51 Plastigage 4 Cut a plastigage to the width of the bearing and place it in parallel with the crank pin getting clear of the oil hole Install the cap and tighten them together under the specified torque Tightening torque 10 to 11 kg m 72 3 to 79 5 ft lb Fig EM 52 Checking bearing clearance by plastigage Note Be sure not to turn the crankshaft when the plastigage is inserted 5 Remove the cap and meaure the width of the compressed plastigage at its widest part with the scale printed in the plastigage envelope before removing it from the crankshaftor bear ing Measurement of connecting rod bearing clearance 1 Measure the connecting rod bearing clear ance in the same manner Tightening torque 4 5 to 5 0 kg m 32 6 to 36 2 ft 1b Bearing oil clearance em Wear limit 0 03 Main bearing 0 06 mm 0 1 mm clearance 0 0012 0 0039 in 0 0024 in 0 03 0 06 mm 0 0012 0 0024 in Connecting rod bearing clearance 0 1 mm 0 0039 in 2 If clearance proves to be in excess of the specified value replace the bearing by under sizes and consequently grind out the crank shaft journal EM 19 ENGINE Fitting bearings 1
32. 0 02 0 06 mm 0 0008 0 0024 0 02 0 06 mm 0 0008 0 0024 in 0 35 0 55 mm 0 0138 0 0217 in 0 3 0 5mm 0 0118 0 0197 in 0 35 0 55 mm 0 0138 0 0217 in Ring height 0 01 0 0004 0 03 mm 0 0787 0 0012 in 0 01 0 0004 0 03 mm 0 0787 0 0012 in 0 01 0 0004 0 03 mm 0 1575 0 0012 in Piston pin interference fit of piston pin 0 0 09 mm to piston 0 0 0035 in Clearance between piston pin and connecting 0 003 0 013 mm rod bushing 0 0001 0 0005 in Piston pin outer diameter 21 991 22 0 mm 0 8658 0 8661 in Piston pin hole diameter of piston 21 987 21 996 mm 5 J 0 8656 0 8660 in Connecting rod bushing inner diameter 21 995 22 008 mm 0 8659 0 8664 in EM 35 ENGINE TROUBLE DIAGNOSES AND CORRECTIONS I Noisy engine Loose main bearing Replace Burnt bearing Replace Knocking of crankshaft and bearing Uneven wear of journal Regrinding Bent of crankshaft Repair or replace Too much end play of crankshaft Replace center bearing Loose bearing Replace Burnt bearing Replace Piston and connecting rod knocking Loose piston in cylinder Recondition cylinder Loose piston pin Replace pin or bushing Broken piston ring Replace Connecting rod alignment is not made Disassemble and repair or replace Loose bearing Replace Too big axial play Replace bearing thrust plate Rough teeth of gears Repair Broke
33. 17 PROCEDURE iem Ern EC 8 MAINTENANCE 2 222 2 20 EC 17 ettet toii ee fete Pede eoe EC 8 General maintenance EC 18 Drive pulley EC 11 Periodic recommended maintenance EC 19 Anti backfire valve EC 11 SERVICE DATA AND Check ve EC 11 SPECIFICATIONS EC 20 DESCRIPTION The Nissan Air Injection System A I S is designed to reduce air pollution caused by engine exhaust tailpipe gases by treating the unburned hydrocarbons and carbon monoxide as they are expelled from the combustion cham bers into the exhaust manifolds A sealed bear ing pump driven by the engine compresses distributes and injects clean filtered air into the exhaust port of each cylinder Here the clean air combines with the unburned hydrocarbons EC 2 and carbon monoxide at high temperatures in a chemical reactions producing a treated exhaust below the maximum allowable level for air pollution The elements of the 1 5 include an air cleaner a belt driven air injec tion pump a check valve an anti backfire valve and related connecting tubes and hoses A special calibrated carburetor and distributor are also used with the air injection system EMISSION CONTROL SYSTEM Fig 2 Model G18 Engine NISSAN AIR INJECTION SYSTEM Carburetor air cleaner
34. 2 21 4 lbs 4 55 4 85 2 64 7 69 0 lbs sq in Opening pressure Fig EL 8 filter Oil filter is of full flow type and the element is replaceable which is mounted to the cylinder block at the right hand side by two bolts The oil fed by oil pump is filtered by oil filter and supplied to main gallery Filter element is set between the element set spring and the retainer The filter body is mounted to the filter cover by center shaft The oil by pass valve is located in the filter cover If the pressure difference between inlet and outlet of oil filter reaches 0 8 kg cm2 11 38 lb sq in by clogging of filter element the released valve permits oil to be by passed then ENGINE LUBRICATION SYSTEM the pressure of oil supplied to main gallery is kept at specified level It avoids the engine trouble caused by pressure dropping Disassembly 1 Loosen the oil filter center shaft and separate the cover and body 2 Take off upper retainer element lower retainer and set spring from the body 3 Remove by pass valve plug from the cover and draw off valve washer valve spring and valve in sequency Inspection Check the by pass valve spring according to the following specifications Free length 54 5 56 0 mm I 2 14 2 20 in Pressured length 49 0 mm 1 93 in Assembly Assembly is a reversal of disassembly pro cedure Note a When tightenin
35. 3 Loose hose clamps Tighten clamps 4 Leaky water pump shaft seal Replace the water pump 334 x 465 x 38 mm 13 15 x 18 31 x 1 50 in Corrugated fin type 2 3 mm 0 091 in 0 9 kg cm2 12 8 lb sq in 3 1 3 3 U S quart CO 5 ENGINE SERVICE JOURNAL OR BULLETIN REFERENCE O Lit 2 Ka JOURNAL or BULLETIN No PAGE No DATE DATSUN 11800 i SECTION EF SERVICE FUEL SYSTEM MANUAL ENGINE AIR CLEANER 4 4 TTT EE E F 1 STRAINER 4 EF 1 NISSAN MOTOR LTD ru PUMP EF 2 CARBURETOR 4 4 g TOKYO JAPAN FUEL SYSTEM AIR CLEANER DESCRIPTION Fig EF 1 Air cleaner for single carburetor of G18 engine The air filter element used is viscous paper type element and does not require any cleaning ragardless of contamination until it is replaced at every 40 000 km 24 000 miles of operation Note Never treat the element by brushing or air blasting before the time for replacement FUEL STRAINER DESCRIPTION The fuel strainer is of the cartridge type A fiber mat is used as a strainer element This strainer should be replaced at intervals not to exceed 40 000 km 24 000 miles 2 REMOVAL Nylon 6 Disconnect the inlet and outlet fuel pipes and the fuel strainer assembly is easily Fig EF 2 Sectional view of cartridg
36. 80 to 0 90 mm 0 0315 to 0 0355 in using the proper Fig EC 22 Spark plug check adjusting tool Spark plug should be replaced every 20 000 km 12 000 miles 4 High tension cable test Fig EC 23 High tension cable test Use an ohmmeter to check resistance on secondary cables Remove cable from spark plug and install the proper adaptor between cable and spark plug Remove the distributor cap from the distributor with secondary cables attached Do not remove the cables from the cap Connect the ohmmeter between the spark plug adaptor and the corresponding electrode inside the cap If resistance is more than 15 000 ohms remove the cable from cap and check cable resistance only If resistance is still more than 15 000 ohms replace cable assembly EC 18 EMISSION CONTROL SYSTEM 5 Battery check Periodic recommended maintenance Test the battery specific gravity with an accurate hydrometer Specific gravity should be at least 1 220 more with temperature cor rections Add mineral free water as required to bring fluid upto proper level Clean battery posts and cable terminals After tightening clamps coat the battery posts and clamps with light grease to retard correc tions Periodic inspection and required servicing of these system should be carried out at the recommended intervals to assure cleaner better performing longer lasting engine and almost complete elimination of air pollution
37. Expirty of plug s life Replace 2 When the engine rotates but does not run and it is difficult to point to the right cause smoothly but considering the ignition system only pay In this case causes are many and varied special attention to the following points EE 44 ENGINE ELECTRICAL SYSTEM Correct Engine misses Distributor Dirty point very often Improper point gap Correct Leak of electricity of cap and rotor head Clean or replace Defective insulation of condenser Replace Defective insulation of lead wire Correct of condenser Oil the shaft Defective arm Correct or re place Defective spring of arm Near breakage of lead wire Correct Worn out and shaky breaker plate Worn out and shaky distributor Shaft Correct Correct Layer short circuit or use of in ferior quality Replace with good one Ignition coil Deterioration of insulation and Replace leak of electricity High tension code Spark plugs Dirty Clean or replace Electricity leak at the upper Clean celain insulator Correct the fit ting Correct or place Distributor Engine cause Improper and advance timing knocking very often Coming off or breakage of gover nor spring Worn out a pin or a hole of gover nor p
38. Fig EG 4 Engine serial and model number ENGINE GENERAL 8 e 4jddng 10 42205 O UONLTNUIA 5 ROBY JO 12 12puo2 422345 syaf gt aimssaid uorgss iduro5 amsta W uonoury ang 2305 jUdUIa 3 19 uonounj 1030ur 1911035 429u2 uonounj 8 e8ri oA 342342 pue spos 19338q JO 30212 ro 58 XIII Bul pt autZua 552425 10101 ded io1nqinstp 552345 S ntd yaeds 3119 yseds 42995 iej n any 42992 19112133 I urens ant ued 42982 uotsu2 1194 422342 syed Buniy 1 Burun 1 2942 EG 5 gt 1 15 snf py aBueyj adid peay gt 813 5 ysneyxa jo 10102 8 1 jo 29312245 omseojq 3 1 1 1 13 4 422025 LNVIOOD DNO NVSSIN 8 19184 ut ooS euaryD 19384 323412 252218 ATddy 178 WIE 10101 JOINGINSIp
39. S parts Check valve test This test can be performed at the same time as the air pump test a Operate the engine until it reaches normal operating temperature b Inspect all hoses and hose connectors for obvious leaks and correct as necessary be fore checking the valve operation c Disconnect air supply hose at the check valve d Visually inspect the position of the valve plate inside the valve body I should be lightly positioned against the valve seat away from the air distributor manifold Insert a probe into the valve connection on the check valve and depress the valve plate Fig EC I7 Check valve test It should freely return to the original posi tion against the valve seat when released H the hose disconnected and start engine Slowly increase the engine speed to 1 500 r p m and watch for exhaust gas leakage at the check valve There should not be any exhaust leakage The valve may flutter or vibrate at idle speeds but this is normal due to the exhaust pulsations in the manifold g If the check valve does not meet the recom mended conditions replace it Anti backfire valve test a Operate the engine until it reaches normal operating temperature b Inspect all hoses and hose connections for ovbious leaks and correct them before checking the anti backfire valve operation if necessary c Accelerate the engine in neutral allowing the throttle to close rapidly Th
40. Set the bushings on the main bearing cap and the cylinder block bearing recess and install the bearing cap to the cylinder block bearing recess then tighten the bolts to the specified torque Main bearing cap tightening torque 10 to 11 kg m 72 3 to 79 5 ft tb 2 Loosen the cap bolt on one side and Measure the clearance between the cap and block 3 Ascertain that the clearance is within double the figures listed below If it is not replace the bearing 4 Handle the connecting rod bearing in the same manner Connecting rod cap bolt tightening torque 4 5 to 5 kg m 32 6 to 36 2 ft 1b Main bearing under size 25 U S 100 U S Connecting rod bearing under size S T D 25 U S Bearing thickness Crank journal diameter 2 485 2 505 mm 0 0978 0 0986 2 612 2 625 mm 0 1028 0 1033 in 2 737 2 750 mm 0 1078 0 1083 in 2 862 2 875 mm 2 987 3 000 mm 0 1176 0 1181 in D D Bearing thickness Crank pin diameter 1 483 1 499 mm 0 0584 0 0590 in 1 609 1 622 mm 0 0633 0 0639 in 1 734 1 747 mm 0 0683 0 0688 in Tighten to the prescribed torque Release the bolts after tighten to the prescribed torque Fig 53 Bearing crush check 0 0 0016 in Connecting rod 0 0 04 mm bearing 0 0 0016 in 55 971 55 990 mm 2 2036 2 2043 in 55 721 55 740 mm 2 194 2 195 in 5
41. a number of ways such as wasting gas power loss loss of speed hard starting and general poor engine performance Spark plug failure in addition to normal wear may be due to dirty or leaded plugs ex cessive gap or broken insulator Dirty or leaded plugs may be evident by black carbon deposits or red brown yellow or blistered oxide deposits on the plugs The black deposits are usually the result of slow speed driving and short runs where sufficient engine operating temperature is seldom reached Worn piston rings faulty ignition over rich carburetion and spark plugs which are too will also result in carbon deposits Red or brown oxide deposits and a consequence of the use of leaded fuel usually result in spark plug failure under severe operating conditions The oxides have no adverse effect on plug op eration as long as they remain in a powdery state But under high speed or hard pull the powder oxide deposits melt and form a heavy glaze coating on the insulator which when hot acts as a good electrical conductor allowing current to follow the deposits and short out the plug Excessive gap wear on plugs of low mileage usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used addition electrode wear may be the result of plug overheating caused bv combustion gases leaking through the threads and gasket due to in
42. and dry with compressed air Top of battery must be clean to prevent current leakage be tween terminals and from positive terminal to hold down clamp In addition to current leakage prolonged accumulation of acid and dirt on top of battery may cause blistering of the material covering connector straps After tightening terminals coat them with petrolatum to protect them from corrosion Spark plugs remove and recondition See that correct spark plugs are used Spark plug insulators should be thoroughly cleaned to prevent possible flash over Thoroughly clean lower insulator and cavity by sand blasting File both electrodes flat rounded surfaces increase voltage required to fire plugs and set gap to 0 7 to 0 8 mm 0 028 to 0 031 in When plugs are reinstalled use new gaskets and tighten plugs to 3 0 to 4 0 kg m 22 0 to 30 0 ft lb torque Clean and adjust distributor points Fig ET 3 Checking distributor point gap Remove distributor cap and inspect point for excessive burning or pitting Replace points if necessary Use a point file to clean contact area and remove scale from points Filing is for cleaning purposes only Do not attempt to remove all roughness Apply a trace of bearing lubricant to the breaker cam Adjust distributor dwell angle to 49 to 55 degrees and point gap 0 45 to 0 55 mm 0 0177 to 0 0217 in Set ignition timing With distributor vacuum line disconnected and car operating at normal idle
43. damaged it will result in frac tures or leakage Therefore the removal of the air gallery pipe and injection nozzle should be done only when they are damaged 1 Lubricate around the screwed portion of the air injection nozzle with engine oil 2 Remove the screwed plug connecting air gallery to injection nozzle exhaust manifold And then remove the air gallery from the ex haust manifold Note a Apply engine oil to the screwed portion in several times during the above sequence work b Take care not to damage other correct parts 3 Insert a hard wire with hooked tip through the injection nozzle and hook nozzle with it and then remove EC 11 ENGINE 4 Check the air gallery and nozzle for 6 Tighten the screwed plug connecting the air fractures or leakage Clean the air injection gallery to injection nozzle exhaust manifold to nozzle with wire brush a torque of 5 0 to 6 0 kg m 36 to 43 ft ib Note Before installation apply the anti seize com 5 At the time of installation the air injection pound such as LED PLATE 250 at the nozzies must be correctly positioned into the screw exhaust manifold 7 Check the engine running DIAGNOSIS AND TESTING Diagnosis general exhaust system ed below as an aid in trouble shooting the ex A preliminary Diagnosis Guide is includ haust emission control system Trouble Possible cause Excessive backfire in exhaust Anti backfire valve vacuum line collap
44. flushed out opening the two drain plugs one at the bottom of the radiator and other at the left side of the cylinder block until clean water comes out Always use clean soft water for filling the radiator Immediately the cold weather ar rives the cooling system should be protected against frost by a good anti freeze solution such as a NISSAN LONG LIFE COOLANT To allow for expansion when hot the level when cold should be just visible at the bottom of the filler neck Do not overfill the system This coolant 1 1 should be changed every 40 000 km 24 000 miles EVERY 40 000 KM 24 000 MILES Replacing air cleaner element wet paper type The air cleaner is of a wet paper type ele ment viscous type As this element has been performed special treatment there is no need to cleanthe element for normal driving condition until it is replaced by new one at 40 000 km 24 000 miles This element will lock so dirty as to be required dust but never try to clean since there is no fear to reduce the cleaning Care must be taken not to injure filter element ENGINE SERVICE JOURNAL OR BULLETIN REFERENCE j 79 m 2 PAGE No JOURNAL or BULLETIN No DATE DATSUN 1899 SECTION SERVICE ENGINE MANUAL TUNE UP Lr ENGINE NISSAN MOTOR CO LTD aeu B5 TOKYO JAPAN TROUBLE DIAGNOSES AND CORRECTIONS ET 6 ENGINE TUNE UP ENGINE TUNE UP CONT
45. highly durable acryl rubber and a flinger and at the rear end by means of a graphite jute oil seal PISTONS AND CONNECTING RODS The piston made of a cast aluminum alloy is oval in shape with cross slits The piston crown is flat surfaced except for the cutout for valves The piston pin is made of special steel and carburizing heat treatment is applied full floating system is used for fitting the connecting rod to the piston and a circlip is used at each end to limit the travel of the piston pin There are two compression rings and one oil ring The compression ring has a tapered face and the entire surface is plated with hard chrome to improve the resistance to wear The oil ring is equipped with a coil expander which boosts tension and functions to block the down flow of oil during high speed operation The connecting rods are made of forged carbon steel and cross section provides ample strength To insure good balancing dur ing operation weight adjusting bosses are located at both the large and small ends Bearings are made of three layer kelmet metal and bushings of lead bronze with steel backing Fig EM 4 Piston and connecting rod ENGINE MECHANICAL CYLINDER HEAD The die cast aluminum alloy cylinder head produces good cooling effects and results in lightweight and excellent strength qualities and smooth combustion chamber surfaces Valve layout is V shaped and symmetrical for intake and ex
46. p m for automatic transmission by turning the throttle adjust Screw MAINTENANCE To make certain that exhaust emissions are maintained at a low level it is recommended that inspection be basically made every 12 months or every 20 000 km 12 000 miles ENGIN Whichever occurs first Best engine operation and minimum exhaust emissions will be obtained with regular inspections and recommended services at these interval General maintenance 1 Carburetor check Check the choke setting and adjust to spe cifications as required Proper carburetor idle mixture adjustment is imperative for best exhaust emission control Refer to the article given in Setting ignition timing and adjusting idle speed and mixture 2 Distributor check Fig EC 21 Distributor check Check the distributor cam dwell angle and point condition and adjust to specifications or replace as required Check the ignition timing and adjust it to the specification Clean and apply distributor grease to the cam and wick Breaker points should be replaced at inter vals not to exceed 20 000 km 12 000 miles 3 Spark plug test Remove and clean plugs in a sand blast cleaner Inspect each spark plug cer tain that they are of the specified heat range Inspect insulator for cranks and chips Check both center and ground electrodes If they badly worn replace with new spark plugs File center electrode flat Set the gap to 0
47. pilot bearing at the rear of the crankshaft for wear and damage Replace it if any defects are detected The pilot bearing can be removed by using special Fig EM 47 Checking crankshaft bend tool ST49700000 as illustrated in the Figure ic nsu mI RM 49 FI Before installing the pilot bearing clean Sunda Maximum the bearing hole and apply oil to the bearing Tess outer side then press the pilot bearing into the 0 03 mm 0 05 hole as illustrated in the Figure EM 50 by using 0 0008 in 0 0020 in Crank shaft bend a drift After that apply multi purpose grease 2 grams 0 071 oz into the hole Note For measuring the bend use a dial gauge Bend values are half as much as the readings obtained when the crankshaft is given a tum with the dial gauge applied to its center journal 3 After regrinding the crankshaft finish it to the necessary size indicated in the lists on page EM 20 and by using an adequate under size bearing according to the extent of re quired repair 4 Install the crank shaft in the cylinder block and measure the thrust clearance If it exceeds the specified value replace the center shims Fig EM 49 Removing pilot bearing EM 18 ENGINE MECHANICAL 16 mm 0 236 in PILOT BEARING Fig EM 50 Fitting pilot bearing BUSHING AND BEARINGS Measurement of main bearing clearance 1 Check all bearing and bushing for exfolia tions melts
48. should be as listed above Fig EM 42 Measuring ring gap Note a When the piston ring only is to be replaced without the cylinder bore being corrected measure the gap at the bottom of the cylinder where the wear in minor Oversize piston rings are available for service 25 50 75 100 125 oversize 4 Measure the piston pin hole in relation to the outer diameter of the pin If wear exceed ing the limit is indicated replace such piston pin together with the piston on which it is in stalled ere Interference fit 0 0 09 mm Clearance of piston pin 0 to piston 0 0035 in 0 0002 in Clearance be tween piston 0 006 0 013nm pin and con 0 0002 necting rod 0 0005 in 0 0012 in bushing Piston pin outer diameter 21 991 22 0mm 0 8658 0 8661 in 21 987 21 0mm 0 827 9 866 21 995 22 008 mm Piston pin hole diameter of piston Connecting rod bushing inner diameter 0 8659 0 8664 in EM 16 ENGINE MECHANICAL CONNECTING ROD 1 If a connecting rod has any flaw within the both sides of the thrust face and the big end correct or replace it Fig EM 43 Connecting rod aligner 2 Check for bend or torsion using a connect ing rod aligner If bends or torsion exceeds the limit correct or replace the connecting rod 0 246 mm 0 3
49. specified pressure NOISY ENGINE Car knocking Mechanical knocking Crankshaft bearing knocking Connecting rod bear ing knocking Piston and cylinder noise Piston pin noise ENGINE Dragging brake Clutch slipping Overloading to engine Carbon knocking Timing knocking Fuel knocking Preignition misusing of spark plug This strong dull noise increases when the engine is accelerated To locate the place cause a misfire on each cylinder If the noise stops by the misfire this cyl inder generates the noise This is a little higher pitched noise than the crankshaft knocking and also in creases when the engine is accelerated Cause a misfire on each cylinder and if the noise deminishes almost completely this crankshaft bearing generates the noise When you hear an overlapping metalic noise which increases its magnitude with the revolution of the engine and which decreases as the engine is warmed up this noise is caused by the piston and eylinder To locate the place cause a misfire on each cylinder This noise is heard at each highest and lowest dead end of the piston To locate the place cause a misfire on each cyl inder ET 10 Adjust Adjust Use right gear in driv ing Disassemble head and carbon cylinder remove Adjust ignition timing Use fuel specified octane Use specified plug spark This is caused by the worn or damaged bear ings or une
50. the camshaft rocker arm shafts and rocker arm assemblies from the cylinder head by removing cam bracket clamping nuts Note Disused bolts should inserted in the No 1 and No 5 bracket holes since the cam bracket will fall from the rocker arm shaft when it is removed 2 Remove the camshaft 3 Remove the cotters by using the special tool ST47450000 and disassemble valves springs and retainers Note Make sure that disassemble parts are grouped together to preserve the original order ENGINE Fig EM 20 Removing rocker assembly Fig EM 21 Removing valve spring INSPECTION AND REPAIR CONTENTS PREPARATION FOR INSPECTION 8 Boring of cylinder _ EM 14 CYLINDER HEAD AND VALVES EM 8 PISTON PISTON PIN AND PISTON RING EM 15 Checking head mating face EM 8 CONNECTING ROD a EM 17 Valve assembly EM 9 CRANKSHAFT EM 17 Valve springs 222 2 2 EM 9 BUSHING AND BEARINGS EM 19 Rocker arm and valve rocker pivot EM 10 Measurement of main bearing I Valve guide EM 10 Clearance eee decet EM 19 Valve seat insert EM 12 Measurement of connecting rod CAMSHAFT AND CAMSHAFT BEARINGS EM 12 bearing
51. the resistance in the alternator field circuit maintains an alternator output voltage to constant When the alternator speed is increased further or the voltage starts to go further high at last the movable contact point P2 comes contact with secondary side contact point Then the field current is shut off and alternator output voltage is decreased immediately This action causes to separate movable contact P2 from secondary contact P3 Thus the rapid vibration of the movable contact point P2 or breaking and completing the field circuit main tains an alternator output voltage to constant S k a z E o E 5 To ignition coil 1 5 Voltage regulator Fig EE 26 Charging circuit I EE 13 ENGINE Alternator 3 lt Lal EI ES 56 s 2 SC c Voltage regulator Fig EE 27 Charging circuit 2 ALTERNATOR CONTENTS DESCRIPTION aea 14 Inspection of diode EE 22 REMOVAL xni eterne ERR Ree ENTRE Siga EE 15 Inspection of diode with tester EE 23 DISASSEMBLY 18 Inspection of brush EE 24 DIODE REMOVAL _ EE 20 Spring pressure test EE 24 DIODE INSTALLATION 21 Inspection of outpu
52. valve oil geal ring located at the top of the valve guide blocks the downflow of oil The rocker arms are made from special forged steel To im prove resistance to wear toughtelite processing is applied to cam contact surfaces after carburizing heat treatment Lubrication is accomplished by oil ejected from the jet in the stem of the rocker arm Fig EM 7 Rocker arm ENGINE Fig EM 8 Valve CAMSHAFT DRIVE SYSTEM The camshaft is driven from the crankshaft by a double row endless roller chain at a reduction ratio of 2 1 Chain tension adjust ment is accomplished from the outside by means of the adjusting screw attached to the chain cover A chain stop is located on the chain tensioning end and serves to eliminate vibration The jet at the top part of the crank sprocket provides active lubrication holding chain elongation and sprocket wear toa minimum Fig EM 9 Camshaft drive system EM 4 MANIFOLDS The intake manifold is made of aluminum alloy and is located on the right side of the engine Coolant from the rear of the cylinder head passes through the riser portion of the intake manifold heating this portion and is returned to the water pump The exhaust manifold is made of cast iron No 1 No 4 and No 2 No 3 cylinders are grouped together The semi duel system which combines exhaust gas flow at the point of exhaust pipe connection produces good exhaust ing efficiency An oiled sheet is u
53. 0 0276 in If interference is less than 0 3 mm the oil seal ring or the cover must be replaced EM 22 ENGINE MECHANICAL Gap 0 3 0 7 Seel ring cover Oil seel ring Spring sheet Fig EM 59 Interference of oil seal ring 2 Assemble the outer and inner valve springs and retainer and mount the cotter by pressing the spring with the special tool 2 3 FRONT Front camshaft 3 Assemble the camshaft bracket valve rocker seat spacer and spring on the valve rocker shaft in the manner shown in Figure EM 62 Note a The exhaust rocker shaft have the identifica tion marks but the intake rocker shaft does not b Both rocker shaft should be assembled so that the oil hole points to the direction shown in Figure EM 62 Fig EM 61 Rocker shaft assembly To prevent the camshaft bracket slipping out of the rocker shafts it is advisable to insert bolts any bolt will do into the bolt holes of No 1 and No 5 camshaft brackets as sembly REAR e Camshaft bracket No 3 Spring Indication mark hole 7 On front face of the cocker shaft bracket bracket Sectional view of AA Install rocker shaft hole as shown in the figure Fig 1 62 Detail of rocker shaft assembly EM 23 ENGINE 4 Mount the camshaft onto the head mount the Note a Heat the piston to a temperature of from valve rocker assembly and tighten the nuts 50 to 60
54. 2 Insert the oil seals into the grooves of the cylinder block and the rear bearing cap and hold down by using the special tool ST49750000 Then cut off the excessive seal ends with a knife Fig EM 68 Installing oil seal to cylinder block Fig EM 69 Installing oil seal to rear bearing cap 3 Apply a screw sealing agent on the cylinder block oil hole plug and install to the cylinder block 4 Fix the main bearings onto the cylinder block and the bearing caps Note The same type bearings are used at all five locations 5 Lubricate all main bearings with engine oil Then install the crankshaft and the bearing cap Tighten to the specified tightening torque Tightening torque 10 to 11 kg m 72 3 to 79 5 ft lb Note a Apply liquid packing Three bond 2 or equivalent to the fitting surface of the rear bearing cap Apply liquid packing here Fig EM 70 Application of liquid packing EM 25 ENGINE b Install the thrust washer on both sides of the No 2 bearing The thrust washer shoutd be installed so that oil channel faces to the crankshaft thrust face Fig EM 71 Installing thrust washer Arrange the bearing cap so that the arrow mark faces toward the front of the engine 6 Install the rear bearing cap side seal The rear bearing cap side seal must project from 0 2 to 0 6 mm 0 0079 to 0 0236 in from the lower portion of the cylinder block Note App
55. 4 4 0 U S qts including oil filter 4 4 4 7 0 5 415 Thereafter AFTER FIRST 3 000 KM 2 000MILES Replacing oil filter Second and thereafter every 10 000 km 6 000 miles Remove the body of the oil filter arid the element can be taken off At the same time replace the body gasket and center shaft gasket The tightening torque of center shaft is 2 8 to 3 2 kg m 20 to 23 ft 1b AFTER FIRST 6 000 KM 4 000 MILES Fan belt tension Second and thereafter every 5 000 km 3 000 miles Incidentally we call it the fan belt but also it drives the water pump and alternator Itis EG 7 action advisable however to check the tension re gularly so that the need for adjustment is not overlooked With the engine switched off and the bonnet up push the belt gently downwards You should be able to depress it about 10 mm 1 2 in If the fan belt has become slack through wear loosen the fixing and adjusting bolts and move the whole ofthe alternator to ward or away from the engine This will take up the slack Tighten the bolts again and recheck to make sure the belt has the required free play If you tighten it too much itwill wear rapidly and also overload the water pump and alternator bearings EVERY 10 000 KM 6 000 MILES Changing cooling water Scale or sediment accumulated in water jacket or radiator is obstructive to heat radia tion The system should be thoroughly
56. 5 471 55 490 mm 2 184 2 185 in 55 221 55 240 mm 2 174 2 175 in 54 971 54 990 mm 2 164 2 165 49 975 49 991 1 967 1 968 49 725 49 741 1 9576 1 9582 in 49 475 49 491 1 9477 1 9483 in 20 ENGINE MECHANICAL 75 U S MISCELLANEOUS COMPONENTS Crankshaft sprocket camshaft sprocket 1 Check tooth surface for flaws and wears Replace defective sprocket if any defects are found 2 Install the camshaft sprocket in position and check for run out If it is found to exceed 0 1 mm 0 0039 in replace the sprocket camshaft Fig EM 54 Checking camshaft run out 3 Check chain for damage severe wear and stretch at its roller links Replace a defective chain Chain tensioner and chain guide Check for wear and breakage Replace if necessary 1 857 1 872 mm 0 0731 0 0737 in 1 984 1 997 mm 100 U S 0 0781 0 0786 in 49 225 49 241 mm 1 938 1 939 in 48 975 48 991 mm 1 928 1 929 in Fig EM 55 Camshaft drive mechanism Flywheel 1 Check the clutch disc contact surface of th flywheel for damage and wear Repair or replace if necessary 2 Measure deviation of the clutch disc contact surface with a dial gauge If it exceeds 0 1 mm 0 0039 in replace it 3 Check tooth surfaces of the ring gear for flaws and wear Replace if necessary Note Replace th
57. 6 Removing cylinder head 17 Turn the engine upside down and remove the oil pan 18 Remove the chain cover and remove the oil flinger 19 Remove the nut which holds the oil pump sprocket in place Pull out this sprocket with the chain in place on the crankshaft oil pump sprocket ENGINE MECHANICAL 20 Remove the oil pump without together with removing the strainer Note Two of the oil pump mounting bolt are pipe guides 21 Remove the timing chain 22 Remove the crankshaft sprocket 23 Remove the chain tensioner and chain stop 24 Remove piston and connecting rod as semblies Note Keep the parts tor cylinder arrangement to avoid the possibility of confusion when re installing Fig EM 18 Removing piston assembly 25 Remove the flywheel 26 Remove bearing caps Note Do not hurt or damage the pipe guides since positioning is accomplished by them 27 Remove the crankshaft and detach the main bearings Note Make sure that bearings are grouped to preserve the original order EM 7 Disassembly of piston and connecting rod assembly 1 Remove the piston rings 2 Remove the piston clips 3 Pull out the piston pin Fig EM 19 Removing piston pin Heat the piston to 50 to 60 C 122 to 140 F before extracting the piston pin Note Make sure that disassembled parts are grouped together to preserve the original order Disassembly of cylinder assembly 1 Remove
58. ADJUSTMENT 26 TROUBLE DIAGNOSES AND Check of regulated voltage EE 27 CORRECTIONS EE 29 INSTALLATION Movable contact support Primary side contact Secondary side contact Primary side contact Secondary side contact support Movable contact Fig EE 66 Regulator The voltage regulator RQA2220B is temper ature compensated so that the charging voltage copes with the climatic variations and two units are housed in the regulator box a voltage regu lator relay and a pilotlamp relay The effect of temperature fluctuation on their relay setting is minimized by the use of bi metal spring REMOVAL To remove the voltage regulator disconnect the 6 way multiple connector and remove the Screw securing the regulator to the longitudinal bulkhead of the engine room Installation is a reversal of removal pro cedure ADJUSTMENT In the temperature compensated regulator it is necessitated to measure the temperature of the regulator cover as the regulating voltage is varied according to the surrounding temper ature In this case use the thermometer 90196 0001P or cylindrical thermometer with putty as shown in Figure EE 67 1 Thermometer 2 Cylindrical thermometer Fig EE 67 Measuring of regulator cover temperature EE 26 ENGINE ELECTRICAL SYSTEM 1 Connect the battery almost charged in full as Check of regulated voltage shown
59. C 122 to 140 F and the At this time align the punch marks on the piston pin can be installed by finger flange of the camshaft with the arrow mark the No 1 camshaft bracket Fig EM 65 Pressing piston pin Fig EM 63 Setting camshaft b The assembling direction of the piston and the connecting rod is shown in Figure EM 66 Note a Adjust the adjusting screw on the valve rocker ie arrange so as the arrow mark on the so that tip of the screw is slightly over the piston head is directed toward the engine rocker front b Take sufficient care in positioning the rocker since the tip of the bolt is apt to get out of Arrow mark the valve stem as shown in Figure EM 64 Correct Incorrect Fig EM 66 Assembling piston and connecting rod Fig EM 64 Setting of rocker arm 2 Install the piston pin clips on both sides of the piston pin PISTON AND CONNECTING ROD 1 Assemble the piston piston pin and con Note Use new piston pin clips The clip must be necting rod for each cylinder installed as shown in Fig EM 67 24 ENGINE MECHANICAL Install the clip Fig 67 Installing clip 3 Install the piston ring with the punch mark facing up 4 Fix the bearings onto the connecting rod and the connecting rod cap Note Make sure that no dust or other foreign matter adheres to the back of bearings ASSEMBLING OF ENGINE 1 Place the cylinder block on the engine stand
60. CIFICATIONS GENERAL SPECIFICATION Cylinder arrangement Bore and stroke Displacement Valve arrangement Max brake horse power SAE Max torque Firing order Engine idle rpm Compression ratio Vacuum pressure of intake manifold at idle Oil pressure TIGHTENING TORQUE 4 in line 85 x 80 mm 3 346 x 3 150 in 1 815 110 8 cu in OHC 105 HP 5 600 rpm 15 9 kg m 115 ft lb 1 3 4 2 600 rpm STD 8 3 1 More than 495 mmHg 19 8 inHg 4 1 5 5 kg cm2 66 8 78 2 Ib in2 3 000 rpm Main bearing cap bolt Connecting rod bolt EM 31 10 11 4 5 5 kg m kg m 72 3 79 5 ft lb 32 6 36 2 ft Ib ENGINE Flywheel bolt 10 11 kg m 72 3 79 5 ft lb Crankshaft nut 15 20 kg m 108 5 144 6 ft lb Cylinder head bolt 8 9 57 9 65 1 ft tb Camshaft center bolt 4 5 5 5 kg m 32 6 39 8 Spark plug 3 4 kg m 21 7 28 9 ft Ib Oil filter center bolt 2 8 3 2 kg m 20 3 23 2 ft lb Water pump blind plug 15 2 10 9 14 5 ft lb Carburetor bowl set screw 0 15 0 2 kg m 1 1 1 4 ft lb Rocker cover securing screw 0 33 0 4 kg m 2 4 2 9 ft 1b LIQUID PACKING APPLICATION Cylinder block Cylinder head gasket Cylinder block side Oil gallery blind plug Expansion plug Gas breather guide Control valve Rear bearing cap fitting surface Angle tube connector Rear bearing cap side seal both ends Intake manifold
61. ENTS GENERAL DESCRIPTION ET 1 Valve clearance adjustment 4 BASIC PROCEDURE e ET 1 ADDITIONAL PROCEDURE ET 4 Connect tune up equipment ET 1 Compression pressure test each Battery inspection ET 2 55225 5 Spark plugs remove and Clean and inspect high tension wires recondition 2 distributor and rotor ET 5 Clean and adjust distributor Distributor lubricate ET 5 DOWNS ei ee ET 2 Tighten intake manifold and Set ignition timing ET 2 carburetor attaching nuts ET 5 Inspection of fan belt Et ET 3 Inspection of filter ET 5 Inspection of engine oil ET 3 Inspection of air cleaner ET 5 Carburetor overhaul and Inspection of fuel strainer 6 adjustment 4 Inspection of cooling system ET 6 GENERAL DESCRIPTION A minor tune and test consists of testing battery cleaning regapping or replacing if required spark plugs and distributor points adjusting distributor dwell angle ignition tim ing carburetor idle mixture and hot idle speed The complete or major tune and test pro cedure consists of these basic items plus other i
62. Full throttle at high speed ENGINE Float system There is only one float chamber while two carburetor systems primary and secondary are provided Fuel fed from the fuel pump flows through the filter and needle valve into the float cham ber A constant fuel level is maintained by the float and needle valve Because of the air vent type of the float chamber ventilation the fuel consumption will not influenced by some dirt accumulated in the air cleaner The needle valve is made of special hard steel and will not wear for all its considerably long use ADJUSTMENT Idling adjustment Idling adjustment is made by the throttle adjust screw and idle adjust screw As for the engines equipped with Nissan emission control system special adjustment is required Therefore refer to page EC 00 for detail Ordinal adjusting method is as follows 1 Give the idle adjust screw approximately three turns starting from the fully closed position Screw in the throttle adjust screw two or three turns and start the engine 2 Screw out the throttle adjust screw gently until the engine is about to rotate unevenly after the engine speed gradually drops 3 Screw in the idle adjust screw until the engine runs smoothly at the highest speed 4 Readjust the throttle screw to drop the engine speed Repeat these operations until a smooth engine speed of approximately 550 rpm has been attained Note Do not attempt to screw dow
63. L NOT START In this case following trouble cause may exist but in many causes ignition system or fuel system is in trouble Ignition system in trouble Fuel system in trouble Vaive mechanism does not work properly Low compression Check spark plug firstly by following procedure Disconnect high tension cable from one spark plug and hold it about 10 mm 0 3937 in from the engine metal part and crank the engine Good spark occurs No spark occurs Ignition system in trouble Fuel system in trouble Very high current Low or no current Distributor point burned Improper point gap Defective condenser Rotor cap and rotor leak Defective spark plug Improper ignition timing Defective ignition coil Disconnection of high tension cable Loose connection or disconnection in primary circuit Lack of fuel Dirty fuel strainer Dirty or clogged fuel pipe Fuel pump will not work properly ET 7 Check spark plug Check ignition timing Check fuel system Check cylinder compression Check the current flow in primary circuit Inspect primary circuit for short Check breaker operation point Check for loose termi nal or disconnection in primary circuit Check for burned points Repair or replace Adjust Replace Replace Clean adjust plug gap or replace Adjust Replace Replace Repair or replace Supply Clean or replace Clean Repair or replac
64. M Field coil Check the field coil insulation If the insu lation of the coil is damaged or worn it should be replaced Field coil test for continuity Connect the test probe of a circuit tester or an ohmmeter to field coil terminals If the tester shows no conduction the field circuit or coil is open Fig EE 12 Field coil test for continuity Field coil test for ground Place one probe of the circuit tester onto the yoke and the other on to the field coil lead Fig EE 11 Disassembly positive terminal If very little resistance is read the field coils are grounded CLEANING AND INSPECTION Clean all disassembled parts but do not use grease dissolving solvents for cleaning the over running clutch armature assembly mag netic switch assembly and field coils since such a solvent would dissolve the grease packed in the clutch mechanism and would damage the coils or other insulators Check them for excessive damage or wear and they should be replaced if necessary Terminal Check for damage and wear and replace if necessary Fig EE 13 Field coils test for ground EE 5 ENGINE Field coil test for short Dissolder the connecting section of each coil and proceed to the same mentioned above If a defective coil is found it should be replaced Brushes and brush lead wire Check the condition of the brush contact Surface and wear ofthe brush Ifa loose con tact may be found it should be repla
65. ON The cooling system is a closed pressure type with high cooling capability Cooling water flowing through resistance free water passages in the cylinder head and block is maintained at adequate temperature range at all times by means of an ample capacity water pump of a corrugated fin type radiator with high cooling efficiency and a pellet type thermostat NAN NA NN d 2 Y 7 Fig CO 1 Cooling system G18 engine CO 1 ENGINE WATER PUMP The water pump is a centrifugal water pump with an aluminum diecast pump body The volute chamber is built into the chain cover assembly and a high pressure sealing mecha nism is adopted to prevent the water leakage and noise thoroughiy The water pump with fluid coupling will be equipped for the models with the torque con vertor or the air conditioner and for U S A models Fig CO 2 Water pump and chain cover Removal 1 Drain cooling water completely 2 Take the fan belt off the pulley Fig CO 3 Water pump removal CO 2 3 Remove fan and pulley 4 Remove the water pump Disassembly By reason of an aluminum make the water pump body is preferably not to be disassembled Inspection Pump body o Replace it if it has badly rusted or corroded vanes o Replace it if it grows up excessive bearing noise or squeak with the engine running COOLING SYSTEM Note To prevent a squeak use Nissan CSP Cooling System Protector Pri
66. ON AND SERVICE 41 INSPECTION a 42 DATA up PME 41 CLEAN AND REGAP EE 43 DESCRIPTION 41 TROUBLE DIAGNOSES AND PERIODIC SERVICE EE 42 CORRECTIONS 44 SPECIFICATION AND SERVICE DATA BP 6E Applied engine G18 with emission control system 14 19 14 x 19 xreach mm in 0 55 x 0 75 0 55 x 0 75 Plug gap 0 84 0 9 0 74 0 8 mm in 0 0314 0 035 0 028 0 031 Torque kg m 1 5 2 0 1 5 2 0 10 8 14 5 NGK B 6E G18 Size screw diameter ft Ib 10 8 14 5 CENTER ELECTRODE GROUND ELECTRODE Fig EE 101 Cross section of spark plug BP 6E EE 41 rM ULIIX UUUI s gt ENGINE LLLLLILLLLLLLLLLIIIXV UUIIW a lll PERIODIC SERVICE Periodically actual time depending on operating conditions plugs should be removed for cleaning inspection and regapping INSPECTION Spark plug life is affected toa large extent by operating conditions and plug life varies accordingly To insure peak performance spark plugs should be checked cleaned and regapped every 12 months or 20 000 km 12 000 miles Worn or dirty plugs may give satisfactory operation at idling speed but under operating conditions they frequently fail Faulty plugs are evident in
67. SERVICE DATA 10 Brush spring tension EE 6 TROUBLE DIAGNOSES AND Armature assembly EE 6 CORRECTIONS u ua EE 11 SPECIFICATION No load current voltage Less than 60 Amps 12V No load starter revolution More than 7 000 rpm Shift type of pinion gear Magnetic shift ENGINE Number of teeth on pinion gear Number of teeth on ring gear Weight wee enone DESCRIPTION The starting system permits the engine to be cranked by turning the ignition switch to start position While the ignition switch is turned to start position the starting motor continues operation until the engine starts running on its own power then the starting motor current is opened and the motor is disengaged by turning the ignition switch on to ON position This starting motor utilizes an enclosed over running clutch type and the compound motor as described following The solenoid switch is mounted onto the yoke Fig 1 8114 104 OPERATION When the ignition switch is turned on to start position current flows through the series and shunt coils of the solenoid and magnetize the solenoid The plunger is pulled into the solenoid so that it operates the shift lever to move the drive pinion into engagement with flywheel ring gear and then closes the solenoid switch EE 2 2 ANTE Stationar
68. Take out the old guide by means of a press and valve guide replacer set ST49730000 under a 2 ton pressure This job may be carried out at room temperatures but with better effect at higher temperature Fig EM 29 Removing value guide EM 11 Fig EM 30 Fitting valve guide 2 Ream cylinder head side guide hole at room temperature using reamer set 5749710000 Do de 14 0 Cylinder head 14 018 mm valve guide hole 0 551 0 552 in 0 2 mm 0 0079 in over size 14 2 14 218 mm 0 559 0 560 3 Press the new valve guide into the guide hole with care so that it will fit smoothly after heat the cylinder head to a temperature of about 80 C 176 F using valve guide replacer The valve guides of 0 2 mm 0 0079 in oversize diameter are available for service 0 040 0 069 mm 0 0016 0 0027 in Interference fit of valve guide to valve guide hole 4 Ream the bore of the valve guide pressed in using a valve guide reamer set ENGINE Fig 31 Reaming valve guide Valve guide reamer set ST49710000 Reaming bore 8 000 to 8 015 mm 0 3150 to 0 3156 5 Correct the valve seat surface with the new valve guide as the axis Valve seat insert Check the valve seat inserts for any evi dence of pitting at valve contact surface and reseat valve seat inserts if the valve seat insert is worn out excessively Valve seat correcti
69. agnet Then the plunger i is attracted downward against the plunger spring 4 and given potential energy by the plunger spring pressure As the plunger i moves down the distance between the plunger 48 and the magnet increases and the attractive force of the magnet A 2 becomes zero Thus the at tractive force working between the magnet B 3 and the yoke becomes predominant drawing the magnet 3 to the yoke 47 and disconnect the contacts and B 8 2 When the contacts A 7 and sepa rated the driving coil 16 loses its electro magnetic force and the plunger d is gradually pushed up to the position held prior to the operation by the potential energy of the plunger spring pressure When the plunger reaches the position held prior to the operation the distance between the plunger the magnet 7 decreases contacts 2 is drawn to the plunger 44 and the contacts A 7 and B 8 becomes connected that is it returns to the original state as described above FUEL SYSTEM Thereafter this process is repeated and the goes up gradually to the position held prior plunger 4 carries on a regular reciprocat to the operation as the contacts and ing motion while the engine switch A remains becomes disconnected Then as shown in on Figure 11 the opening at the upper por tion of the piston closes as the its upper inside wall contacts with the spherical surface of the connectin
70. alve stem If the clearance clearance 0 0016 exceed the designated limit replace the worn 0 0022 in 0 0030 in parts or both valves and valve guide In this ae i Max tolerance case it is essential to determine it such a 0 1 mm 0 1 mm clearance has been caused by a worn or bent ot above 0 0039 0 0039 in valve stem by worn valve guides clearance EM 10 ENGINE MECHANICAL Determining clearance Precise measurement of clearance between the valve stem and the vaive guide needs the aid of a micrometer and a telescope hole gauge By using these gauge check the diameter of the valve stem in three places center and bottom Inspect telescope hole gauge in valve guide bore measuring at center Subtract the highest reading of valve stem diameter from valve guide bore measured to obtain its clear ance from the two center diameter to obtain valve to valve guide clearance an emer gency expendient a valve is pushed in the valve guide and moved to the left and the right at which point if its tip deflects about 0 2 mm 0 0079 in or more it will be known that the clearance between the stem and the guide exceeds the maximum limit of 0 1 mm 0 0039 in Note The valve should be moved in parallel with the rocker arm Generally a large amount of wear occurs in this direction Replacement of valve guide A valve guide found defective must be re placed in the following manner 1
71. ard TESTING 1 Disconnect the fuel hose at the pump outlet Fig EF 10 Pump operation 2 The piston 12 lowered is given potential energy by the plunger spring pressure and 2 Connect a suitable hose approximately 6 mm EF 5 ENGINE 0 0236 in inner diameter to the pump outlet Note If the diameter is too small the following proper delivery capacity can not be obtained even if the pump functions properly 3 With the hose outlet in the higher position than the pump operate the pump and check the delivery capacity for more than 15 seconds 4 The capacity should be 1 400 c c 3 24 U S pts in one minute or less If no gasoline or only a little flows from open end of the pipe with the pump operated or if the pump does not work follow the following diagnosis TROUBLE DIAGNOSIS AND CORRECTIONS When a fuel pump is found to be faultly check it in the following procedure 1 Remove the fuel pump from the vehicle 2 Connect the fuel pump to a battery properly charged and operate it to see if the pump dis charges fuel Ei 38 4 E Fig 11 Pump operation 1 When the fuel pump operates and discharges fuel In this case the cause of the trouble does not lie in the fuel pump but in some other unit Check other units for possible causes as follows Voltage drop of battery Poor grounding Poor grounding of battery Incorrect or loose wiring Incorrect conn
72. ce marks on both rotor ring and rotor Fig EC 10 Removing rotor ring 5 Remove rotor ring and side carbon seal from rotor 6 If it is necessary to replace rear bearing it be pressed out of rotor ring a press using support for disassembling rotor ring special tool STECP 20001 and attachment EMISSION CONTROL SYSTEM for pushing needle bearing special tool STECP 20002 Note Support rotor ring carefully to avoid distortion TR H H HE as H H 4 Fig 11 Removing rear rotor bearing Remove vanes from rotor 8 Remove three sets of carbon shoes and three shoe springs using pair of tweezers or needle nose pliers Fig EC 12 Removing carbon shoe 9 If it is necessary to replace the relief valve use bridge for pulling out relief valve spe cial tool STECP 20004 and standard puller EC 9 Fig EC 13 Removing relief valve 10 No further disassembly should be at temped Cleaning inspection lubrication Cleaning Clean rear bearing and vane hub bearings in petroleum solvent Clean carbon dust from pump housing and rotor assembly with an air hose Note Do not use cleaning solvent on pump housing and rotor assembly Fig EC 14 pump components ENGINE Inspection squeaking during initial operation The vanes may require five to ten miles wear in running time the event a slight squeaking still persists th
73. ce must be performed The details of annual maintenance are described in chapter REMOVAL AND DISASSEMBLY PROCEDURE The exhaust emission control system should not be removed generally and full inspection must be done prior to removal Air pump Removal 1 Disconnect hoses from air pump housing cover 2 Remove bolt securing air pump to belt ad justing bar 3 Remove bolt securing air pump to mounting bracket and remove air pump drive belt 4 Remove air pump assembly from car Periodic service Since the bearings in the pump have perma nent type lubrication no periodic maintenance is required Every 4500 km 3000 miles the belt tension should be inspected and adjusted Note Mask the two holes in the end cover when washing the car with steam cleaner Disassembly of air pump 1 Remove four pulley drive hub bolts and remove pulley from hub 2 Clamp air pump drive hub in a vise as shown in Figure EC 9 and remove four housing end cover bolts Note Never clamp on the aluminum housing Fig EC 9 Removing end cover 3 Remove housing end cover by carefully tap ping on vicinity of large dowel pin with plastic hammer and lifting straight up 4 Scribe rotor ring and side of rotor to assure proper reassembly and then remove six screws that retain rotor ring to rotor using hexagon wrench special tool STECP 20000 Note manufacture already gives coinciden
74. ced If the brush in its length is less than 12 5 mm 0 4921 in replace it Check the connection of the lead clip and lead wire Check brush holders and spring clip to see that they are not deformed or bent but will properly hold brushes against the commutator If the brushes or brush holders are dirty they should be cleaned Brush spring tension Check the brush spring tension by a spring scale as shown in Figure EE 14 The reading should be 0 8 kg 1 761bs Replace the spring if the tension is lower than 0 7 kg 1 54 lbs Fig EE 14 Inspection of brush spring tension Armature assembly Check external appearance of the armature and the commutator 1 Measure the armature shaft for bend by a dial gauge Replace the armature shaft if the bend exceeds 0 08 mm 0 0031 in Fig EE 15 Inspection of armature shaft for bend 2 Inspect commutator If the surface of the commutator is rough it must be sanded lightly with No 00 sandpaper The commu tator must be checked also for out of round If the out of round is more than 0 2 mm 0 0079 in or the depth of the insulating mica is less than 0 2 mm 0 0079 in from the commutator surface the commutator armature should is less than 0 05 mm 0 0020 in Insulating mica should be also under cut so that the depth of it is from 0 5 to 0 8 mm 0 0197 to 0 0315 in The wear limit of the commutator diameter is 2 mm 0 0787 in If the commu
75. crews washers and bushings Red or Black figures Fig 48 Diode identification DIODE REMOVAL To remove a diode use a suitable tool to support the heat sink and push the diode out by Fig 46 Removal of brush holder using an arbor press as shown in Figure EE 49 45203081 20 ENGINE ELECTRICAL SYSTEM INSPECTION AND REPAIR Remove the alternator from the vehicle and put the tester between the lead wire F black white color and the lead wire E black color When the resistance is approximately 5 to 60 the condition is all right Heat sink or end frame Press out so as not to injure the mounting Rotor inspection bore of the frame or Pe hace 1 Conduction test of field coil As shown in Figure EE 51 put the probes of the circuit tester between the slip rings of rotor If there is no conduction the field coil Fig EE 49 Removal of the diode will be open When the resistance is approxi mately 4 47 Q at normal room temperature the condition is all right Note Do not strike the diode as the shock may damage the other diodes DIODE INSTALLATION Support the heat sink with a suitable tool and then press the diode into the heat sinks by using the tool which fits over the outer diode edge A portion Press down perfectly the diode into the mounting bore of C portion to the lower edge of B portion of the diode Replaced diode should not be taken out with a force smaller than 15 kg
76. d would cause high internal resistance due to loose connections defective leads dirty commutator and causes listed on item 2 3 Current flow A 4 High no load speed with low developed torque would cause grounded field coil Replace the field coil and check for improvement in per formance Fig 23 S114 104 Diagnosis of test 1 Low speed with no load and high current draw may result from Magnetic switch assembly test 1 Tight dirty or worn bearings 2 Bent armature shaft or loosen field probe Ignition switch 3 Shorted armature Check armature further 4 A ground armature of field Remove copper connector Remove negative side brush and insulate it from the commuta tor before inspection Using a circuit tester place one probe on insulated terminal and another on rear cover the tester indicates conduction remove other two brushes and check fields and armature Starter motor separately to determine whether it is the fields or armature that is grounded 2 Failure to operate with high current draw Fig EE 24 Circuit of magnetic switch assembly may result from followings test EE 9 ENGINE If the starting motor check is OK check the magnetic switch assembly Connect jumper cables between the negative battery terminal and the starting motor terminal the tive battery terminal and the starting motor S terminal connecting ignition switch in series
77. ds this engine exhibits excellement performance made possible by adoption of new mechanisms such as an aluminum alloy cylinder head which has crogs flow ports and a V shaped valve layout a single overhead camshaft and five journal crankshaft It is sufficiently durable at high continuous speeds and maintenance and inspection opera tions are easily performed Gasoline with a standard octane value of 88 is used Fig EM 1 Sectional view of G18 engine EM 1 ENGINE CYLINDER BLOCK The cylinder block is a special monoblock casting with deep skirts and five bearing support system Rigidity is high and resist ance to wear excellent Coolant is forced through the space between cylinders to maintain uniform cylinder block temperature The passage for oil from the cylinder head is located at the rear portion Fig EM 2 Cylinder block CRANKSHAFT The crankshaft is a carbon steel forging and is provided with five bearing journals and four balancing weights As a result it possesses high rigidity and there is little vibration The surfaces of the main journals are hardened by high frequency induction improving the resist ance to wear Highly durable three layer kelmet metal is used for main bearings The thrust bearings made of aluminum are located Fig EM 3 Crankshaft EM 2 on journal 2 Oil sealing at the front end is accomplished by a lip type oil seal made of
78. e Low compression IMPROPER ENGINE IDLING Fuel system in trouble Others ENGINE Adjustment of float level no good Improper idling Dirty or clogged carburetor Clogged breather pipe Incorrect spark plug tightening defective gasket Correct Adjust Disassemble and clean Clean Tighten to normal torque replace gasket Improper grade engine oil or viscosity Replace with proper dropping Incorrect valve clearance Compression leak from valve seat Stick valve stem Weak or defective valve springs grade oil Adjust Remove cylinder head and lap the valves Correct or replace valve Replace valve springs Compression leak at cylinder head gasket Replace gasket Piston ring sticking or defective Worn piston ring or cylinder Trouble shooting procedure Pour the engine oil from plug hole and then measure cylinder compres sion Compression increased Compression unchanged Incorrect idle adjustment Clogged air cleaner Defective gaskets of manifolds or carburetor insulator Adjustment of float level no good Incorrect valve clearance Extremely low revolution ET 8 Clogged or damaged carburetor jets Replace piston rings Overhaul engine Trouble in cylinder or piston ring Compression leak from valve cylinder head or head gasket Clean or replace Adjust Replace element Replace gasket Adjust Adjust Adjus
79. e Broken edges require vanes be replaced Remove carbon shoes and inspect surface contacting vane Small grooves in shoes are normal chipped or broken shoes require replacement Broken shoes indicate impro per assembly of shoe springs Damaged shoes must be replaced and springs must be properly installed Carbon dust may be present on vanes and in housing This is indication of normal wear not failure Remove carbon dust by blowing air on parts in question Replace with new pump Adjust drive belt tension to specifi ed data Replace defective parts Replace worn parts Replace worn parts Replace worn parts Ammend or tighten Replace if necessary Replace relief valve Replace with new assembly Adjust drive belt tension Retighten or replace ENGINE Testing The following procedures are recommended for checking and or verifying that the various components of the exhaust emission control system are operating properly The engine and all components must be at normal operating temperatures when the test are performed Prior to performing any extensive diagnosis of the exhaust control system it must be deter mined that the engine as a unit is functioning properly Disconnect the anti backfire valve vacuum sensing hose Plug the anti backfire valve vacuum sensing hose to close the passage to the intake manifold N A I S After check ing the engine normal operation reinstall all the N A L
80. e at low speed Fig EF 20 Full throttle at high speed lt Model D3034C Carburetor gt 13 Vacuum piston P Slow air bleed Slow jet Slow economizer P Slow air bleed Air vent 7 Main air bleed P Main nozzle 9 P Small venturi Choke valve Pump nozzle Pump weight Discharge check valve S Small venturi S Main air bleed Step air bleed Pump arm Step jet Pump plunger Inlet check valve S Main jet Diaphragm spring Diaphragm Step port Fig EF 21 Full throttle at low speed EF 12 S Throttle valve P Throttle valve Idle port Slow port Idle adjust screw P Main jet Power jet FUEL SYSTEM lt Model D3034C Carburetor 5 HOUT VITA AIN 3 FA TC HT Primary Secondary Vacuum piston Pump nozzle Main jet P Slow air bleed Pump weight Diaphragm spring Slow jet Slow economizer P Slow air bleed Air vent P Main air bleed P Main nozzlc P Small venturi Choke valve Discharge check valve S Small venturi S Main air bleed Step air bleed Pump airm Step jet Pump plunger Inlet check valve EF 13 Diaphragm Step port S Throttle valve P Throttle valve Idle port Slow port Idle adjust screw P Main jet Power jet Fig EF 22
81. e ring gear at about 180 to 200 C 356 to 3929F When press the ring gear into the flywheel pay attention to the direction of the chamber on the teeth Fig EM 56 Fitting ring gear EM 21 ENGINE Front oil seal Replace front oil seal if leaks or dam ages are found using front oil seal replacer 5749740000 When install new oil seal pay attention to the direction of the oil seal Fig 57 Replacing oil seal Fig EM 58 Installation of oil seal ENGINE ASSEMBLY CONTENTS 22 PISTON AND CONNECTING ROD EM 24 CYLINDER 22 ASSEMBLING OF ENGINE EM 25 PRECAUTIONS 1 Use thoroughly cleaned parts Particularly check whether oil holes are clear of foreign matter or not 2 In installing sliding parts such as bearings proceed after applying engine oil to them as required 3 Use new packings and oil seals in principle 4 Keep tools and work benches clean and clear of dust and oil stains 5 Keep the necessary parts and tools ready near at hand 6 Be sure to follow specified tightening torque and orders where necessary CYLINDER HEAD 1 Set the valve spring seat in position and then the valve Install the oil seal ring onto the valve stem and put the seal ring cover over the oil seal ring Note Make sure that interference of the oil seal ring is from 0 3 to 0 7 mm 0 0118 to
82. e type removed fuel strainer EF 1 ENGINE SERVICE REFERENCE This fuel strainer has no pet cock therefore the strainer carburetor lines and fuel pump should not be removed or cleaned when the tank is full unless absolutely necessary If requir ed place the tube at the rear of the strainer above the top of the fuel tank Fig EF 3 Cartridge type fuel strainer FUEL PUMP CONTENTS DESCRIPTION arn da re EF 2 REMOVAL EF 7 CONSTRUCTION aU prassi iniret EF 3 DISASSEMBLY EF 7 OPERATION 54 senatu d ae EF 4 INSPECTION lac E EF 7 TESTING Sciences RA AR es EF 6 ASSEMBLY AND INSTALLATION EF 7 TROUBLE DIAGNOSES AND CORRECTIONS tits iss EF 6 DESCRIPTION The fuel pump is of the electric type consist ing of a contact mechanism solenoid relay pump mechanism and a strainer unit This is located in the center of the spare wheel house in the trunk compartment This electric pump presents several distinct features as follows EF 2 1 No vapor lock in torrid zones 2 Starts pumping immediately as the ignition switch is turned on 3 Built in type filter keeps dust out and adds to pump and engine life 4 Reduced power consumption FUEL SYSTEM Fig EF 4 Electric fuel pump CONSTRUCTION The type EP 3 fuel pump consists of a contact mechanism solenoid relay pump mechanism and a strainer
83. e vaiveis operating satisfactorily when no exhaust system backfire occures Fig 18 Anti backfire valve test d if a further check is necessary disconnect the by pass hose to air pump suction line at the anti backfire valve EC 14 EMISSION CONTROL SYSTEM e Open and close the throttle valve rapidly IF air flow is felt for half a second to one by a finger at the anti backfire valve outlet to the air pump suction line the valve is function ing properly If air flow is not felt or air flow is felt continuously more than two seconds the valve should be replaced Disconnect the vacuum sensing hose from the intake manifold at the anti backfire valve Insert a suitable plug in the hose and fasten it securely If engine idle speed varies excessively from the case the vacuum sensing hose is connect ed with the valve the valve function is not proper and it should be replaced To air pump Air pump test gauge STECP 20006 Air pump test a Operate the engine until it reaches normal operating temperature b Inspect all hoses and hose connections for leaks and correct as necessary before check ing the air supply pump c Check the air pump belt tension and adjust to specifications d Install a tachometer on the engine Start the engine and slowly increase the engine speed to 1 500 r p m Check the air pump in the following order To pressure gauge Fig 19 Air pump test gauge EC 15
84. e vehicle should be run through two or three full throttle shift points In most cases five to ten miles will be sufficient for wear in Inspect ali parts for chipping scoring wear and roughness All damaged parts must be replaced to ensure quiet and efficient operation If especially side carbon seal is scored replace with new one Carbon dust may be present in the housing and is usually an indication of al wear 4 Insert one carbon shoe on each side of 7 every vane Lubrication ty Note Each carbon shoe must the positioned so that Th beari d i aring hub bearings chamfered end of shoe faces to vane must be lubricated with a high melting point grease such as ESSO ANDOK 260 or its equivalent Work grease into each bearing to 5 Insert three shoe springs into the deeper of insure adequate lubrication shoe slots Note Bearings for service are already packed with Note When springs are properly positioned they high melting point grease will be flush or below rotor surface The curved portion of spring will be against the Assembly of air pump shoe and ends will be against wali of shoe slot 1 Place air pump housing a vise clamping pump drive hub between jaws 6 If rear bearing was removed new bearing may be pressed into rotor ring using at tachment for pressing in needle bearing special tool STECP 20003 bearing should be about 0 8 mm 0 0315 below rotor ri
85. ected in the engine compare valve timing data with the valve timing diagram to see whether the stroke beginning and end in various cylinders are complying with specified advance and retard figures Fig EM 34 Valve timing diagram RENNES EE es oso m e e Unit degrees Camshaft alignment check 1 Check the camshaft camshaft journal and cam surface for bend wear or damage Ifthe defects are beyond the limits replace the affected parts 2 Bend values are expressed in terms of half values of the readings obtained when the cam shaft is given a turn with a dial gauge applied to the center journal x Sow 36 53 mm 36 0 mm 1 438 in 1 417 in 0 03 mm 0 0012 in Cam height Camshaft bend 0 01 mm 0 0004 0 148 mm End play 0 0028 0 0058 in Fig EM 35 Checking camshaft bend Valve rocker Check the valve rocker for cracks cam contacting surface clearance between rocker shaft and etc Replace if same cracks are found If wear or nibble is found at cam contacting surface replace the valve rocker In this case check cam heels of camshaft at the same time Slight damages at cam contacting sur ace of the valve rocker and cam heel can be cor rected by oil stone In case of clearance of rocker shaft and rocker bushings is excessive replace the worn part see renim 0 016 0 052 mm 0 0006
86. ection of inlet or outlet or clogged piping Trouble in carburetor 2 When the fuel pump does not operate and discharge fuel In this case the cause of the trouble lies in the pump Check it as follows If the current flows this will be indicated by sparks at the terminal The cause is the plunger or piston binding in motion Therefore disassemble the pump and remove any dust inside If the current does not flow The cause is the breaking of a coil or lead wire Therefore replace the fuel pump with new unit 3 When the fuel pump discharges only a small quantity of fuel The cause is trouble in the inlet valve dis charge valve the malfunction of packings or choking of filter mesh Therefore disas semble the pump and make the necessary servicing REMOVAL 1 Remove two bolts retaining fuel pump cover to floor panel 2 Remove two bolts retaining fuel pump to fuel pump cover 3 Disconnect the lead wire 4 Disconnect fuel hoses EF 6 FUEL SYSTEM 5 Gently press down the plunger and remove the inlet valve packing cylinder and plunger assembly Note The electric unit cannot be disassembled since it is sealed If it is defective it must be placed as a complete unit INSPECTION 1 Wash the strainer filter and gasket with clean gasoline and blow dust off with a blast of air When cleaning the parts check the filter and gasket If defective replace it Note Filter mu
87. eight pin for governor spring with circular hook comes in long rectangular hole It leaves clearance at the start and end of advancing Meanwhile weight pin on opposite side comes in short rectangular hole It does not leave clearance either at the start and end of advancing When assembly is completed set it to engine after checking advance characteristic and confirming performance Be sure to make adjustment of ignition timing after this Adjustment must be made to let off the dis tributor point at degree position of upper dead point of first cylinder compression of engine Fig EE 95 Point pressure test EE 38 ENGINE ELECTRICAL SYSTEM Fig EE 96 Point gap measure SERVICE DATA lt All distributors gt Point gap 0 45 0 55 mm 0 0177 0 0217 in Point pressure 0 50 0 65 kg 1 10 1 43 lbs 0 0004 0 010 0 0008 11 0 020 0 01 0 000 Housing inner diameter 12 4577919 mm 0 4902 20 0091 in Clearance between shaft and housing 0 010 0 038 mm 0 0004 0 0015 in Shaft diameter lower part 12 45 mm 0 4902 Amendment limit of clearance 0 08 mm 0 0031 in 0 005 0 0002 6 014 3150 0 0006 1 0 0 8 2 mm 0 3150 20 in 0 005 0 029mm 0 0002 0 0011 in 0 010 0 0004 5 mm 0 19697 0010 1 0 028 0 0007 i 0 Shaft diameter upper part 8 Weight hole diameter mm 0 1969 0 018 5 0
88. etainer by unscrewing three set screws and push out the bearing using an arbor press Fig 43 Pulling out of rear bearing 2 7 To separate the stator from the diode end housing assembly disconnect the negative three diodes from three coil lead wires and each lead wire between diodes by melting solder with a soldering iron Fig 41 Pulling out of bearing Fig EE 44 Removal of stator EE 19 ENGINE 8 Remove the brush cover by unscrewing each setscrew Disconnect N terminal lead wire by melting solder then the diode end and the stator can be separated Fig EE 47 Removal brush holder 452040 10 Disassemble the brush holder Dissolder lead wire F black white color lead wire E black color and the brush holder wires Fig EE 45 Diode end and stator negative and positive using a soldering iron separated Note There are two kinds of diode Positive and Note When the internal temperature of a diode Negative goes up over 150 C 3009F the diode will The positive diode is marked with red figure lose its function so use the electric iron TOOW on the bottom of the diode and the negative to 200W for around 2 seconds at the soldered diode is marked with black figure in the portions same manner as shown in Figure EE 48 9 Remove the heat sink and the brush holder from the rear cover by unscrewing each set Screw Be careful not to lose small parts such as s
89. evolution ratio Fan rpm water pump rpm 3 300 4 000 Pulley ratio Fan amp W Pump 120 103 1 17 Tune up data Basic timing Idle r p m 700 rpm 650 rpm Distributor dwell angle 49 55 at 0 02 in of point gap Spark plug gap 0 0315 0 0355 in 0 90 0 40 Choke setting CO percent setting 0 os at the pump disconnected ENGINE TIGHTENING TORQUE Nut air pump bracket to cylinder head Bolt adjusting bar to bracket 1 60 2 40 kg m Bolt air pump to bracket 11 6 17 4 ft lb Nut air pump to adjusting bar Nut A B valve bracket to rocker cover Screw A B valve to bracket 0 40 0 65 kg m Nut vacuum sensing hose to rocker 2 9 4 7 ft lb cover D Screwed plug air gallery to exhaust 5 0 6 0 kg m manifold 36 2 43 4 ft 1b Check valve to air gallery 9 0 10 5 kg m 65 1 75 9 ft lb AIR PUMP DRIVE BELT SLACKNESS 8 12 mm 0 315 0 472 in of slack under 7 10 kg 1 54 2 20 Ib of load SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or BULLETIN No PAGE No SUBJECT EC 22 DT eden as en Pay h DATSUN 1800 section EE SERVICE ENGINE MANUAL ELECTRICAL SYSTEM ENGINE STARTING CIRCUIT ua pe ks aie Raw pes Pen nie H D STARTING MOTOR EE 1 CHARGING CIRCUIT EE 12 ALTERNATOR sonpacacsasoocsccannoaceesoann EE 14 REGULATOR 84 86
90. face flatness Less than 0 03 mm 0 1 mm 0 0012 in 0 0039 in Valve assembly 1 Check each of the intake and exhaust valve assemblies for worn damaged or deformed valve heads or stems Correct or replace the valve if any excessive defects are defected Fig EM 25 Valve grinder Note When the valve head has been reduced to 0 5 mm 0 0197 in or less in thickness replace the valve Grinding allowance for the valve stem end surface is 0 5 mm 0 0197 in or less Valve spring 1 Measure the free length and the tension of each spring If the measured valve exceeds the specified limit replace the spring ENGINE 42 5 mm 41 4 mm Bove tener 1 673 in 1 630 in 37 0 mm at 19 4 1 0 kg 34 0 mm at 10 8 0 5 kg Valve closed 1 457 in at 42 8 2 2 lb 1 339 at 23 8 1 1 lb 29 0 mm at 47 6 2 4 kg 26 0 mm at 22 5 1 1 kg 1 142 in at 104 9 5 3 lb 1 024 in at 49 6 2 4 lb 2 Check the deformation of each spring with a Square Any springs with the deflection of 1 6 mm 0 0630 in or more must be replaced Fig EM 27 Guide intake over size Fig EM 26 Checking valve spring Rocker arm and valve rocker pivot Check the valve rocker adjusting screws and the cam contact for damage or wear If defects are found replace them Fig EM 28 Guide exhaust over size Valve guides Measure the clearance between the valve Stem to guide guide and the v
91. fficient carburetion depends upon careful cleaning and inspection while servicing 8 Remove three screws and take off float chamber cover glass gaskets float and 1 Blow all passages and castings with com check valve pressed air and blow off all parts until dry EF 20 FUEL SYSTEM Note Do not pass drills or wires through calibrated jets or passages as this may enlarge orifice and seriously affect carburetor calibration If wear is noted Note es 2 Check all parts for wear defective parts must be replaced pecially the following 1 Check float needle and seat for wear If wear is noted the assembly must be re placed 2 Check throttle and choke shaft bores in throttle body and cover castings for wear or out of round 3 Inspect the adjusting needles for burrs ridges Such a condition requires replace ment 3 Inspect gaskets to see if they appear hard or brittle or if the edges are torn or distorted If any such condition is noted they must be replaced 4 Check filter screen for dirt or lint Clean and if it is distorted or remains plugged replace 5 Check venturi clusters for loose or worn parts If damage or looseness exists replace cluster assembly 6 Check the linkage for operating condition 7 Inspect the operation of accelerating pump Put in the gasoline in the float chamber and make the throttle lever operate And the check the injection condition of the gasoline from
92. g by removing the relief valve plug Inspection and repair 1 Clean the disassembled parts with cleaning solvent 2 Inspect the drive shaft for excessive wear 6088 Fig EL 5 Inspection of clearance 3 Check the following Assembly Gear backlash 0 1 0 5 mm 1 Assembly is a reversal of disassembly pro 0 0039 0 0195 in cedure Side clearance between gear and body 0 016 0 15 mm 2 In this case the mark dotted on gear should 0 0006 0 0059 in be faced to the oil pump body cover Clearance between drive shaft and body 0 016 0 1 mm 0 0006 0 0039 in Clearance between drive shaft and body cover suyay 0 02 0 1 mm 0 00078 0 0039 in Clearance between idler gear and jdler shaft 0 016 0 1 mm 0 0006 0 0039 Fig EL 6 Dotted mark of pump gear OIL PRESSURE RELIEF VALVE The oil pressure relief valve is not adjust able At the released position the valve permits that oil is by passed through a passage on the pump body to the oil pan Check the relief valve spring dimension to Fig EL 4 Inspection of backlash ensure that it has not lost its tension EL 3 ENGINE E IN Fig EL 7 Relief valve OIL FILTER Specification of relief valve Free length of Spring a es 64 0 66 0 mm 2 51 2 60 in Pressured length of spring 50 mm at 7 8 9 7 kg 1 96 in at 17
93. g rod and the inlet valve opens thus allowing the fuel flow into the cylinder simultaneously with its discharge These processes 1 and 2 are repeated continuously Note The number of operations of the fuel pump is governed by the fuel quantity contained inside the carburetor When the carburetion is empty the pump discharges the fuel at its full rate As the fuel quantity increases in the carubretion the needle valve operates to close the pressure rises up and thus the discharge decreases that is the number of the pump operations is reduced After the needle valve becomes closed the discharge almost stops Then the number of the pump operation is one per five or six seconds Fig EE 9 Operational principle 2 Operation of pump unit As described above in respect of the opera tion of the electromagnetic unit the fuel pump utilizes the power of the electromagnet and the force of the plunger spring in the opposite direction of the power and owing to these forces the piston continues the reciprocating motion 1 Turning the engine switch A on makes piston 42 connected to the plunger d drop very quickly against the pressure of the plunger spring 48 In this movement the upper portion of the inside wall of the piston 4 becomes open due to the reaction to its very fast drop as shown in Figure EF 10 and the inlet valve 2 closes and therefore the fuel contained between the piston 42 and the inlet valve moves upw
94. g the filter body to the cover by center bolt tighten with the specified torque 2 8 to 3 2 m kg 20 25 to 23 15 Ib sq in b The oil filter body gasket and center shaft gasket should be replaced with new one in case of reassembling OIL WARNING SWITCH The oil warning switch is located on right hand center of cylinder block and wired to an indicator lamp in the instrument cluster The low pressure light glows whenever the oil pressure drops below 0 5 kg cm2 7 11 lb sq in SERVICE JOURNAL OR BULLETIN REFERENCE EL 5 ENGINE SERVICE JOURNAL OR BULLETIN REFERENCE ul T gt e PAGE No JOURNAL or BULLETIN No DATE ore ae s s DATSUN __1800 SECTION SERVICE COOLING MANUAL ENGINE NISSAN MOTOR CO LTD TOKYO JAPAN COOLING SYSTEM 0 1 COOLING SYSTEM COOLING SYSTEM CONTENTS DESCRIPTION neta cec CO 1 THERMOSTAT CO 3 WATER PUMP use reete paste ehe Bet CO 2 Removal ceret evi CO 3 stehe rr La Rat CO 2 Inspection 4 Disassembly 2 Installation 4 I Spector hte CO 2 RADIATOR Suyu a t s e Eee CO 4 FLUID COUPLING 222 222 2 22 CO 3 Removal COP EubriCatiOnz soe en CO 3 Inspection COP SPECIFICATIONS 5 DESCRIPTI
95. gnition compression electrical and carbu retor checks and a final road test to ensure continued trouble free operation BASIC PROCEDURE Connect tune up equipment Follow manufacturer recommendations for the use of testing equipment Fig ET 1 shows a basic schematic for instrumentation which will apply to many types of test equipment and may be used as a rough guide if equipment manufacturer s instructions are not available Connections shown in figure ET 1 are made as follows 1 Voltmeter 1 Positive lead to resistor side of coil 2 Negative lead to ground 2 Timing light 1 Positive lead to positive battery terminal 2 Negative lead to ground 3 Trigger lead to number 1 spark plug 3 Tachometer 1 Positive lead to distributor side of coil 2 Negative lead to ground 4 Dweil meter 1 Positive lead to distributor side of coil 2 Negative lead to ground Battery Balancer gt Timing light Spark plugs Trigger lead Dwell meter Tachometer Fig ET 1 Simple schematic of tune up instrumentation ENGINE Battery inspection 1 Check the level of the electrolyte in battery cells Check the level line on the case with the battery electrolyte If necessary replenish with distilled water 2 Measure the specific gravity to the battery electrolyte Fig ET 2 Inspecting battery Clean top of battery and terminals with a solution of baking soda and water Rinse off
96. haust Cross flow ports are used to obtain good intake and exhaust efficien cy Valve seats are cast into the cylinder head and special iron is used for intake valve seats and 13 chrome steel for exhaust valve seats Both cylinder head and cap surfaces are used for camshaft bearings without modification The cylinder head gasket is made of asbes tos which contains a steel net and is protected by a stainless steel grommet giving excellent gas sealing effects Fig EM 5 Cylinder head CAMSHAFT Fig EM 6 Camshaft BEN e At EM 3 The camshaft is a special alloy casting which has excellent resistance to wear Lobes are chill hardened and lubrite processing ap plied to obtain good operation between the rocker arm and camshaft Five journals are employed and they receive the thrust by the front flange and cylinder head groove Bolts with left hand threads are used to attach a sprocket and the distributor drive gear to the end of the camshaft VALVES AND VALVE ROCKER ARMS A rocker arm shaft is located on each side of the camshaft Intake and exhaust valves are made of heat resistant steel Special heat resistant steel is used for the head of exhaust valves and stellite is used for the valve seats improving the resistance to wear at high engine temperature and speed dual valve spring system is used to elevate the characteristic frequency of the springs and insure the opening and closing of valves at high speed The
97. he movement is unsmooth check brush holder and clean it The standard length of brush is 13 mm 0 512 If brush wore off smaller than 7 mm 0 276 in replace the brush with new one Fig EE 62 Brush wear limit Bern dn Bn 13 0 512 20 0 787 mm in Wear limit 552 mm in 7 0 276 14 0 552 Spring pressure test Place a suitable block on a platform scale and press down brush holder with brush and spring on the block untii brush sinks in the holder to 1 mm 0 0394 in height from the holder The reading subtracted the block weight shows the spring pressure The spring pressure should be 0 35 kg 0 77 lbs Ifthe pressure is small than 0 2 kg 0 44 bei replace it Fig EE 63 Spring pressure test Inspection of output The procedure of output inspection is as follows 1 Remove the alternator from the vehicle and connect wiring as shown in Figure EE 64 2 Turn the switch K1 on and excite the rotor 3 Drive the alternature with motor and in crease its speed gradually until the ammeter indicates zero 4 Turn off the switch 1 and further increase the speed of the alternator until the voltmeter indicates 14 volts 5 The specified revolution when the voltmeter indicates 14 volts is approximately 1 100 rpm 6 Make the load resistance the maximum and turn the switch K2 on 7 Raise the load current by decreasing the load resistance gradually and increase the alternator
98. he coupling installed in the engine The quantity of oil to be replenished must not exceed 5 0 305 cu in THERMOSTAT A pellet type thermostat is used in the water outlet passage to control the flow of coolant providing fast engine warm up and regulating coolant temperatures A wax pellet in the thermostat expands when heated and contracts when cooled The pellet is connected through a piston to a valve and when the pellet is heated pressure is exerted against a diaphragm with forces to open the valve As the pellet is cooled the contraction allows a spring to close the valve Removal 1 Drain cooling water 2 Remove radiator hose ENGINE 3 Remove water outlet take out the thermostat Then Fig CO 6 Thermostat removal Inspection To test the thermostat for proper operating temperature submerge the unit in a container of water Heat the water and observe the temperature 1 Measure the temperature when the mostat valve just starts rising as Fig CO 7 Thermostat inspection Provide a screwdriver with Inspect by inserting the a marking at a point about marked screwdriver at 90 C 8 mm 0 315 in from the 194 F tip 2 Measure the maximum lift of the thermostat valve 4 Valve open temperature Max valve lift above 8 mm at 90 C 0 315 in at 194 80 C 1 5 C 176 F 2 7 Installation 1 In installing apply bi
99. he purpose Inversely when increase in output is desired at the limited sacrifice of fuel consumption use larger main jets or slow jets or smaller main air bleeds or slow air bleeds and that should bring a satisfactory result TROUBLE DIAGNOSES AND CORRECTIONS In the following table the symptoms and causes of carburetor troubles and remedies for them are listed to facilitate quick repairs There are various causes of engine troubles It sometimes happens that the carburetor which has no defect seems apparently to have some troubles when electric system is defective Therefore whenever the engine has troubles electric system must be checked first before starting carburetor adjustment EF 21 ENGINE Troubles Possible causes Remedies Excessive fuel consumption Power shortage Improper idling Engine hesitation Dirt accumulated on needle valve Fuel pump pressure too high Needle valve seat improper Fuel overflow Each main jet slow jet too large Each main air bleed clogged Choke valve does not fully open Outlet valve seat pump improper Linked opening of throttle valve too early of accelerator secondary Each main jet clogged Each throttle valve does not fully open Fuel pump operated improperly Fuel strainer clogged Vacuum jet clogged Air cleaner clogged Diaphragm damaged Power valve operated improperly Slow jet clogged Each throttle valve does not close Seco
100. i tt nre eee a EL 2 Specification of relief valve dE EL 4 Description Er EL 2 QUE EL 4 Removal er eg EL 2 Disassembly 02 EL 5 Installation EL 2 Inspection EL 5 Disassembly EL 2 Assembly oett st EL 5 Inspection and repair EL 3 OIL WARNING SWITCH EL 5 y 43 L Fig Lubrication circuit 618 engine DESCRIPTION The lubricating system is Pressure feed type system and is composed of highly efficient functional components suited for high perform ance i e high out put and high speed running EL 1 ENGINE LUBRICATION CIRCUIT Oil is drawn from the oil pan through the inlet screen and tube to the inlet side of the pump then delivered by oil pump through the oil gallery to the inlet side of the full flow oil filter and to the main oil gallery The main oil gallery supplies oil to the crankshaft main bearings and drilled passages in the crankshaft direct oil from main bearings to connecting rod bearings Oil injected from jet holes on connecting rods lubricates the cylinder walls and piston pins The oil distributed from the cylinder block front oil gallery lubricates the timing chain through the jet located near the chain Further
101. ime may eliminate this condition If additional wear in time does not eliminate chirp pump must be disas sembled vanes and carbon shoes replaced 2 Bearing noise A rolling sound indicates bearing noise This sound will be noticeable at all speeds but does not necessarily indicate bearing failure However if noise increases to objectionable level bearing may have to be replaced Off car 1 With pump removed from car rotate drive 5 hub in jerks three quarters of turn forward and one quarter of turn backward If rough ness or bumps are felt remove rear cover Trouble Inoperative pump Insufficient delivering air Air leakage Abnormal noise Trouble in pump Excessive slackness of drive belt Damaged vane hub bearing Worn vane Worn carbon shoe Worn side seal Leakage from hoses connectors or clamps Leakage from relief valve Stick of air pump Slackness of drive belt accelerating Leakage from hoses connectors or clamps EC 13 Inspect carbon seal This seal should not show holes caused by wear or be broken or cracked Such condition commonly resulta from rear and or vane bearing failure A failed seal must be replaced With rear rotor ring and carbon seal re moved pull out vanes Vane bearing failure is also indicated by absence of grease or caked grease Inspect vane shaft to confirm this bearing failure corners of vanes should be squar
102. in good working condition 22 ENGINE ELECTRICAL SYSTEM Fig 57 Inspection of positive side diode 2 Negative side diode Connect the battery negative terminal with connector N terminal white color and the bat tery positive terminal with connector E terminal black color as shown in Figure EE 58 Lamp in the circuit will light Fig EE 58 Inspection of negative side diode Nextly if lamp does not light when the con nection is made reversely as shown in Figure EE 59 the negative side diode is in good work ing condition Fig EE 59 Inspection of negative side diode Inspection of diode with tester There are two kinds of diodes as shown in Figure EE 60 Each diode can be descriminat ed its polarity by the color of the printed figures on each diode as follows Current flow Current flow lt Red figure j 4 lack figure Diode terminal Positive diode Negative diode Fig EE 60 Diode Check diode resistance using a tester in a current flow direction and a reverse direction as shown in Figure EE 61 When one side shows low resistance and the other shows high resistance the diode condition is all right If both sides are low there will be a short circuit and if both sides are infinite there will be a open circuit In both cases replace diode EE 23 ENGINE Fig EE 61 Diode test Inspection of brush Check the movement of brush and if t
103. in Figure EE 68 Alternator Connector Ammeter V Voltage meter Wire harness Fig EE 68 Meter and instrument connection 2 Measure the temperature of regulator cover Adjustment of gap shown in Figure BES 61 The gap adjust values of the constant voltage relay and the pilot lamp relay must be as 3 Raise the alternator revolution to 4 000 to follows 5 000 rpm engine revolution 1 960 to 2 450 rpm 4 When the charging current is less than 5 ampere and the voltage of this time is within the limit of Figure EE 69 it is all right Air gap 62 Regulater voltage Point gap G3 Fig EE 69 Fig 70 RQA2220B EE 27 ENGINE 8422208 0 8 1 1 0 0315 0 0433 0 8 1 2 0 0315 0 0472 0 3 0 4 0 0118 0 0157 Constant voltage relay mm 0 75 1 1 0 0295 0 0433 0 9 1 2 0 0354 0 0472 0 75 1 1 0 0295 0 0433 The voltage regulator and the pilot lamp relay are the same type Accordingly the ad justing method is also the same Adjust these gaps in order of G1 gl G2 g2 and G3 g3 if these are out of specifi cations Pilot lamp relay mm in Back gap Gl or gl Loose the armature hinge screw and adjust the position by sliding the armature Fig EE 71 Checking G1 gl Top air gap G2 or g2 Adjust the gap by bending the movable con tact supports as shown in Figu
104. in the vicinity of the exhaust port Pressurized air is transmitted through hoses and air distribution manifold A schematic of the exhaust port is shown in Figure EC 6 In addition to air injection certain controls have been incorporated to assure reliable system operation as follows ENGINE Air injection nozzle Air gallery pipe y Exhaust manifold Fig EC 6 Air injection into exhaust port Anti backfire valve This valve is controlled by intake manifold vacuum and is required to prevent exhaust sys Discharge air 4 to check valve tem backfires during deceleration During deceleration the mixture in the intake manifold is too rich to burn and ignites when combined with the injected air in the exhaust manifold The anti backfire valve is used to shut off air delivered to the exhaust system during the first pre determined period of deceleration so that backfires are prevented A schematic of the anti backfire valve is Shown in Figure EC 7 The anti backfire valve inlet is connected to the air pump discharge line one of the outlets to the check valve and the other to the air pump suctian line Since the valve action can have a deleterious effect on emission reduction its operation is set under a fine compromise between adequate backfire suppression and minimum emission effects Fig EC 7 Sectional view of anti backfire valve EC 6 EMISSION CONTROL SYSTEM If the valve does not wor
105. interference fit In Ex 0 040 0 069 mm 0 0016 0 0027 in Max tolerance of above clearance In Ex 0 1 mm 0 0049 in Valve seat width In Ex 2 05 2 33 mm 0 0807 0 0917 in Valve seat angle In Ex 90 b Camshaft and timing chain Camshaft end play 0 07 0 148 mm 0 0028 0 0058 in Cam height 36 53 mm 1 438 in Camshaft journal diameter 37 45 37 475 mm 1 474 1 475 in Camshaft bend 0 01 mm 0 0004 in Camshaft bearing inner diameter 37 5 37 525 mm 1 476 1 477 in Camshaft journal to bearing clearance 0 025 0 075 mm 0 0008 0 0030 Connecting rod Center distance 140 mm 5 51 Big end end play 0 110 0 246 mm 0 0043 0 0097 in Connecting rod bearing clearance 0 05 mm 0 0020 in Connecting rod bend 0 03 0 06 mm 0 0012 0 0024 in EM 33 eee ENGINE _ _ _ _ Connecting rod bearing under size Bearing thickness Crank pin diameter 1 483 1 499 mm 49 975 59 991 mm POST 0 0584 0 0590 in 1 967 1 968 in 25 U S 1 609 1 622 mm 49 725 49 741 mm id 0 0633 0 0639 in 1 9576 1 9582 in eine 1 734 1 747 mm 49 475 49 491 mm 0 0683 0 688 in 1 9477 1 9483 75 U S 1 857 1 872 mm 49 225 49 241 0 0731 0 0737 in 1 938 1 939 in 100 U S 1 984 1 997 mm 48 975 48 991 mm HA 0 081 0 0786 in 1 928 1 929 in d C
106. ion EF 20 Fuel level adjustment EF 14 Assembly and installation _ EF 21 Adjustment of starting interlock valve JETS eee astaq tc EF 21 ODenIng seo ee AE EF 15 TROUBLE DIAGNOSES AND Adjustment of interlock apening of CORRECTIONS esee ree EF 21 primary and secondary throttle valve EF 16 SPECIFICATIONS AND SERVICE DATA EF 23 DESCRIPTION STRUCTURE AND The carburetors are of the two barrel down draught type Model DAK 340 is of the solex type manufactured by the HITACHI Model D3034C is of the strongburg type manufactured by the NIHON KIKAKI and instal led on the exhaust emission control engine Each carburetor has two variations for manual and automatic transmissions Carburetor ds DAK340 2A Automatic transmission Exhaust emission control D3034C 1B engine with manual D3034C 2B transmission Exhaust emission control engine with automatic transmission EF 8 OPERATION These carburetors consist of the primary System for normal running and the secondary system for full load running float system which the primary and secondary systems use in common the secondary switch over mecha nism the starting mechanism accelerating mechanism etc are incorporated For model D3034C carburetor the power valve mechanism is provided to make high speed drive better a fuel cut off valve is attached to cut fuel supply when the igniti
107. ir leakage Air pump is functioning properly Inspect air leakage Replace or repair air pump from anti backfire valve hose or hose connections from anti backfire valve hose or hose connections 16 gl SI EMISSION CONTROL SYSTEM SETTING IGNITION TIMING amp ADJUSTING IDLE SPEED MIXTURE Engine tune up must be done according to Nissan Specifications with necessary equipments recommended The following procedures are recommended 1 Install the air cleaner 2 Warm up the engine thoroughly with the transmission in neutral position 3 Connect ignition tachometer and timing light Note If the car is equipped with automatic trans mission make sure the dash pot does not interfere with throttle closing 4 Turn the throttle shaft arm adjust screw counter clockwise so that the tip of it does not touch the throttle shaft arm 5 Set the idle speed at 700 r p m 650 r p m for automatic transmission by adjusting the throttle adjust screw and adjust the ignition tim ing at 5 A T D C 6 Adjust the idle adjust screw and throttle adjust screw until the most satisfactory 700 r p m 650r p m for automatic transmission engine speed is obtained 7 Turn the idle adjust screw clockwise for leaner mixture until the point where the engine idle speed begins to drop approximately 10 r p m 8 Turn the idle adjust screw counter clockwise for richer mixture one turn one and a ha
108. it tester place one test probe on to rear cover and another on to positive side brush holder If the tester shows conduction EE 7 ENGINE the brush holder is shorted to ground an insulator or brush holder Replace Fig EE 21 Brush holder test for ground Pinion case bearing metal Inspect the bearing metal for wear or side play If the clearance between the bearing metal and the armature shaft is more than 0 2 mm 0 0079 in replace the metal Press in a new bearing and adjust the clearance to 0 03 to 0 10 mm 0 0012 to 0 0039 The ing metal should be so pressed in that the end of the bearing metal would be equal to gear case end plane Magnetic switch assembly Inspect the magnetic switch contacts rough welding be found on the contact it should be repaired ASSEMBLY Assembling is a reversal of the disassembly procedure When assembling pack the grease in the rear case and apply light coat of oil to the rear cover bearing metal and pinion TEST Performance test The starter motor should be subjected to a no load and lock torque test whenever it EE 8 has been overhauled to ensure that its perfor mance will be satisfactory when installed to the engine The starter motor should also be subjected to these tests when the cause of ab normal operation is to be determined A brief outline of the two tests is given below No load test Connect the starting moto
109. k properly backfire or emission deterioration will result Check valve Le ed 4 t N t Fig EC 8 Sectional view of check valve Check valve is set between the air pump and the air injection nozzle It prevents a back flow of exhaust gas Normally it passes air into the air distribution manifold in the air injection system When exhaust manifold pressure exceed air injection pressure as it will at high speed or when the air pump drive belt fails the air injection nozzle is in the path of the exhaust gases and the exhaust manifold pressure will exceed air injection pressure backing up exhaust gas which is prevented from entering the system by the check valve which closes it off Air pump relief valve The air pump relief valve is mounted the discharge cavity of the air pump and accom plishes the following functions without affecting the exhaust emission control system s effec tiveness Hold the increase in maximum exhaust gas temperatures to a minimum Minimize horsepower losses resulting from air injection into the exhaust system Protect the pump against excessive back pressures EC 7 Engine modifications The Air Injection System includes some engine modifications necessary to reduce ex haust hydrocarbons and carbon monoxide concentrations H Carburetor In consideration of air injection effective ness engine performance fuel economy and drive feeling the G18 engine f
110. lf for automatic transmission 9 Set the engine speed at 700 650 r p m for automatic transmission by adjusting the throttle adjust screw Check the ignition timing at 700 r p m 5 A T D C at 650 for automatic transmission 10 Turn the throttle shaft arm adjust screw clockwise so that the tip of it just touches the throttle shaft arm EC 17 Timing should remain at 5 A T D C Note Care must be taken that the throttle shaft arm should never be pressed by the throttle shaft arm adjust screw ROTTLE SHAFT ARM ADJUST SCREW Fig EC 20 Model D3034C carburetor Note you set idle speed and mixture by using CO meter the following procedure should be done after above item 3 a Disconnect the air supply hose at the check valve Insert a suitable plug in the check valve inlet b Set the speed at 700 r p m 650 r p m for automatic transmission by adjusting the throttle adjust screw and adjust ignition timing at 5 A T D C Adjust the percentage of the carbon monoxide to at 700 r p m 650 r p m for a automatic transmission by turning the adjust screw and throttle adjust screw d Check the ignition timing Timing should remain at 5 A T D C at 700 r p m 59 A T D C at 650 r p m for autornatic trans mission e Connect the air supply hose at the check valve f the engine speed changes adjust the engine speed at 700 r p m 650 r
111. llow cleaning of all parts and passages the carburetor can be returned to its original condition and it will then deliver the proper ratios as it did when new Accurate calibration of passages and dis charge holes require that extreme care be taken in cleaning Use only carburetor solvent and compressed air to clean all passages and passage discharge holes Never use wire or other pointed instrument to clean as calibration Fig EF 31 Linkage removal of carburetor will be affected 5 Remove four fixing screws end take off choke chamber Removal 1 Remove air cleaner 2 Disconnect fuel line vacuum line and choke wire in case of auto choke choke heat from carburetor 3 Remove the throttle lever 4 Remove four nuts and washers retaining carburetor to manifold p Lift carhuretar manstold Fig EF 32 Choke chamber remoual 6 Remove and discard carburetor to manifold gasket 6 Remove stop pin and four fixing screws Separate throttle chamber from float chamber Disassembly lt Model DAK340 Carburetor gt 1 Carburetor assembly 1 Remove primary throttle return spring 2 Remove E ring and take off pump and con necting rod 3 Remove split pin and take off choke con necting rod Fig EF 33 Throttle chamber removal from 4 Remove secondary throttle return spring float chamber EF 17 ENGINE 2 Choke chamber Fig EF 34 Choke chamber 1 Remove two screws and take
112. lls between break er spring and breaker plate as well as those between breaker plates 5 Pull knock and disconnect gear to pull out whole rotation part However before pulling out put counter mark on gear and shaft or remember the relation between coupling direc Fig EE 87 Di bl troll tion and setting groove of cam rotor head EE 36 ENGINE ELECTRICAL SYSTEM 6 When cam is disconnected take off set screw first since shaft head is fastened by screw to hold cam down this case also put counter mark on cam and shaft or remember the rela tion with ignition timing Fig EE 92 Removal of cam When governor weight and spring are dis connected be careful not to stretch or deform the governor spring When disassembly is completed apply grease to weight pivot 8 Figure EE 93 shows the exploded view Fig EE 93 Exploded view 0416 57 0423 53 EE 37 ENGINE Assembly In case of reassembly do it in just reverse way of disassembly Governor weight Clearance for start and end of advancing angle Rectangular hook Governor spring B Refer to Figure EE 94 at the time of replace ment and reassembly of governor spring and cam Cam plate Weight pin Rotor positioning tip Fig EE 94 Setting of governor spring and cam At the time of assembly rotor head posi tioning tip at cam is to be set to governor spring circular hook side Then w
113. ly liquid packing to the projecting tip Fig EM 72 Installing cap side seal 7 Install the engine rear plate 8 Install the flywheel After tightening the bolts to the specified torque lock the bolts using new lock washer Tightening torque 10 to 11 kg m 72 3 to 79 5 ft lb 9 Lubricate the crankshaft journals pistons and cylinder bores with engine oil and install the piston rod assembly Note a Install the piston rings so that their gaps are at 180 C 356 F to each other is avoiding the gaps face to the thrust side of the piston or piston pin axial directions b The arrow mark on the top of the piston should face the front of the engine 10 Install the connecting rod cap Bolt tightening torque 4 5 to 5 0 ke m 32 6 to 36 2 ft lb Note a install the caps to the connecting rod so that the mark on the big end side faces to the same side b After tightening the bolt to the specified torque bend the lock washer as shown in Fig EM 73 Locking plate Fig EM 73 Installation of piston assembly 11 Install the oil jet on the front of the cylin der block Then install the chain tensioner and stopper 12 Install the crankshaft sprocket and timing chain Note Align the timing mark of the chain with the mark of the sprocked EM 26 ENGINE MECHANICAL CAM SPROCKET TIMING MARK ADJUSTING SCREW OIL JET CHAIN GUIDE TIMING MARK Fig EM 74 Timing mechanism
114. mm Big end end play o943 0 0118 in 0 0097 in Torsion bend 0 05 mm 0 1 mm 100 mm 0 0020 in 0 0039 in 3 In replacing the connecting rod select the rod so that the weight diference between new rods and old one become within 6 gr 0 212 oz in unit weight 4 Install connecting rods with bearing on to the corresponding crank pins and measure the thrust clearance If the measured value ceed the limit replace such connecting rod Fig EM 44 Checking big end end play CRANKSHAFT 1 Check the shaft journal and crank pin for scars biased wear and cracks Repair or replace affected parts 10 0 330 3228 3100 1104 1 289 1 261 aul 73 1016 in Fig EM 45 Dimension for crankshaft measurement Measurement of taper and out of round Measure A B or X Y direction shown in the Figure EM 46 by a micrometer Fig EM 46 Measuring point for crankshaft EM 17 ENGINE Taper Difference between A and B Out of round Difference between X and Y Keen 0 03 mm round 0 0004 in 0 0012 in Be 2 Check the crankshaft for bend If the bend 2 exceeds the specified value repair or replace T S CG the crankshaft zx k Y EE e Fig EM 48 Checking crankshaft end play 0 060 Crankshaft 0 192 mm 0 3 mm end play 0 0024 0 0118 in 0 0076 in 5 Check the main drive shaft
115. more lubricant is supplied to cyl inder head main oil gallery rocker shaft through the camshaft bracket and the camshaft bearing on the cylinder head are fed directly from this gallery The rocker arm and valve are lubricated by the oil through the rocker arm gallery from the cylinder head main oil gallery rocker shaft PUMP Description The oil pump assembly is installed to the cylinder block by four bolts and driven by the rotor chain in the crankshaft The oil pump is a gear type The oil pressure is regulated by the regulator valve to 4 55 to 4 85 kg cm 65 4 to 74 0 1b sq in Removal 1 Drain engine oil 2 Remove the distributor 3 Remove the cylinder head assembly fan belt crankshaft pulley and oil pan 4 Remove the chain cover with oil flinger 5 Remove the oil pump sprocket with the oil pump crankshaft sprocket and the oil pump drive chain EL 2 6 Remove the oil pump body by removing four oil pumps attaching bolts Installation Installation is a reversal of removal pro cedure In this case adjust the tension of the oil pump drive chain as shown in Figure EL 2 Fig EL 2 Tensioning oil pump drive chain Disassembly Fig EL 3 Disassembly of oil pump 1 Separate the body cover from the oil pump ENGINE LUBRICATION SYSTEM body by unscrewing four securing bolts and take out the drive gear assembly and idler gear from the pump body 2 Take out the valve and sprin
116. mp injector Outlet valve Piston Throttle valve Fig EF 16 During accelerating The carburetor is equipped with the piston type accelerating mechanism linked to the throttle valve When the primary throttle valve EF 10 shown in Figures EF 16 and EF 17 is closed the piston goes up and fuel flows from the float chamber through the inlet valve into the space under the piston When the throttle valve is opened the piston goes down opening the outlet valve and fuel is forced out through the injector The piston return spring in the cyl inder not only assures the smooth movements of the linkage but also serves to place inlet valve in position so that the piston goes down quickly and fuel is forced out through the injector lt Model D3034C Carburetor gt 1 UM i ER i H 6273 Inlet valve Valve weight Outlet valve P throttle valve Pump nozzle Pump return spring Float chamber Pump plunger Fig EF 17 During accelerating 4 Starting mechanism Pull the choke button to close the choke valve fully then start the engine This provides a rich mixture making it possible to start the engine quickly When the engine is started the choke valve is opened at an adequate angle auto matically which prevents overchoking and ensures a smooth engine performance While the engine is being warmed up it increases in speed at steps and by releasing the choke button an optimum engine speed ca
117. n be obtained With the choke valve closed fully the primary throttle valve is caused to open at an angie best suited for starting through a link mechanism FUEL SYSTEM 5 Dash pot mechanism lt only for Model DAK340 2A andD3034C 2B Carburetors equipped with Automatic mission 5 This carburetor is equipped with a dash pot interlocked with the primary throttle valve through a link mechanism The dash pot which is exclusively installed on cars equipped with a torque converter is intended to prevent engine stall that would otherwise result from quick application of the brake immediately after the car ran or from the quick release of the accelerator pedal after giving only small pressure When the primary throttle valve is closed near full angle 1 800 to 2 000 r p m in engine speed a throttle lever strikes the dash pot stem shown in Figure EF 18 making the primary throttle valve gradually open keeping the engine running Secondary system 1 Secondary main system Fuel air mixture produced by the functions of the main jet main air bleed and emulsion tube in the same manner as in the primary System is pulled out through the main nozzle into the small venturi Due to the double venturi of the secondary System the higher velocity air current passing through the main nozzle promotes the fuel atomization 2 Step system The construction of this system may cor respond to the idling and sl
118. n cam gear Replace Chain tension not adequate Adjust Wear and damage of chain Replace Timing chain Wear of sprocket Replace Boise Wear or breakage of tension adjusting Replace mechanism Clearance of camshaft and bearing 00 Replace big Valve clearance not correct Adjust Wear of adjusting screw Replace Camshaft and Wear of rocker face Replace valve mechanism knocking Loose valve stem in guide Replace guide Yielded valve spring Replace Burning of valve Mention later part Water pump End play of shaft Replace knocking Broken impeller Replace EM 36 ENGINE MECHANICAL Other mechanical trouble Not correct valve clearance Adjust Small clearance of valve stem with Clean stem or ream the guide guide Sticked icked valve Yielded or broken valve spring Replace Biting or damage of valve stem Replace or clean Badfuel Use good fuel Not correct valve clearance Adjust Yielded valve spring Replace Thin valve head edge Replace valve Burnt valve seat e Narrow valve seat Refacing Overheat Mentioned Over speed Drive right Sticked valve guide Repair Shortage of engine oil Check every day Dirty engine oil Clean crankcase replace oil filter element Inadequate oil Use right oil Overheat Mentioned Wrong assembly of piston with con Repair or replace necting rod Exosacive Wear Not correct clearance of piston ring Adjust of cylinder a
119. n the idle adjust screw completely to avoid damage to the tip which will tend to cause malfunctions Fuel level adjustment lt Model DAK 340 Carburetor gt A constant fuel level is maintained by the float and needle valve 1 5 mm 0 0591 1 Float seat 3 Float stopper 2 Float 4 Needle valve Fig EF 23 Fuel level adjustment DAK340 carburetor If the fuel level is in accord with the level gauge line the float level is properly set If the float level is not correct adjust it by bend ing the float seat as shown in Figure EF 23 Approximately H mm is required as the effective stroke of the needle valve So adjust the gap between the valve stem and the float seat to H mm with the float fully lifted up y bending the float stopper H 1 5 mm 0 00591 in Fig EF 24 Adjustment of float seal DA K340 EF 14 FUEL SYSTEM Adjustment of starting interlock valve opening lt Model D3034C Carburetor 2 Fig EF 25 Adjustment of float stopper DAK340 lt lt Model D3034C Carburetor gt If the fuel level is in accord with the level gauge line the float level is properly set If the float level is not correct adjust it by the gaskets between the body and needle seat Never adjust it by the float hunger Approxi mately 7 mm 0 02756 in clearance is required as shown in Figure EF 26 1 Choke lever KSC 2 Choke valve 5 Throttle lever
120. nal 1 Loosen connections of the ter minal Defective brushes Replace the brush Remove the starting motor and make test Defective starting motor Noisy starting Loose securing bolt Tighten the bolt motor Replace the pinion gear Fill in oil Worn pinion gear Poor lubrication Worn commutator Disassemble the motor Worn brushes Replace the brush Charge or replace the battery Starting motor cranks slowly Discharged battery Loose connection of the terminal Clean and tighten the terminal Worn brushes Locked brushes Replace the brush Inspect the brush spring tension or repair the brush holder Clean and repair Dirty or worn commutator The armature rubs the field coil Disassemble the motor Defective solenoid switch Repair or replace the switch Starting motor Worn pinion Replace the pinion operates but does not crank the engine Locked pinion guide Repair the pinion guide Worn ring gear Replace the ring gear Repair or replace the solenoid switch Starting motor will Defective solenoid switch not disengage even the ignition switch is turned off Replace the defective gear Defective gear teeth EE 11 ENGINE CHARGING CIRCUIT The charging circuit includes the battery alternator regulator and
121. nd Broken piston ring Replace piston Dirty air cleaner Clean periodically Too rich mixture Adjust Engine over run Drive right Sticked choke valve Clean and adjust Overchoking Start correct way Shortage of engine oil Check oil daily Defective Low oil pressure Refer connecting rod Not adequate engine oil Use right oil Rough surface of crankshaft Grind and replace bearing Clogged oil passage Clean Wear or eccentricity of bearing Replace EM 37 Defective ENGINE Wrong assembly of bearing connecting rod Loose bearing Defective crankshaft bearing Connecting rod alignment is not made Shortage of engine oil Low oil pressure Not adequate engine oil Wear or out of round of crankshaft journal Clogged oil passage in crankshaft Wear or eccentricity of bearing Wrong assembly of bearing Not concentric crankshaft or bearing Repair Replace Repair or replace Check every day Mentioned Use right oil Clean Replace Repair Replace SERVICE JOURNAL OR BULLETIN REFERENCE EM 38 DATSUN L 1800 SECTION EL SERVICE ENGINE LUBRICATION MANUAL ENGINE NISSAN MOTOR LTD TOKYO JAPAN LUBRICATION SYSTEM nn EL 1 ENGINE LUBRICATION SYSTEM LUBRICATION SYSTEM CONTENTS DESCRIPTION KE EL 1 Assembly si eget EL 3 LUBRICATION CIRCUIT sess EL 2 OIL PRESSURE RELIEF VALVE EL 3 OL PUMP eerie ter
122. ndary throttle valve operated improperly Each throttle valve shaft worn Packing between manifold carbu retor defective Manifold carburetor tightening im proper Fuel overflow Each main jet slow jet clogged By pass hole idle passage clogged Emulsion tube clogged EF 22 Clean needle valve Repair pump Lap or replace See above item Replace Clean Adjust Lap Adjust Clean Adjust Repair Clean Clean Clean Replace Adjust Clean Adjust Overhaul and clean Replace Replace packing Correct tightening See the first item Clean Clean tube Clean FUEL SYSTEM Idling adjustment incorrect Correct adjustment Secondary throttle valve operated Overhaul and clean improperly Engine does not Fuel overflows See the first item start No fuel Check pump fuel pipe and needle valve Gauge plate adjustment incorrect Correct adjustment Idling adjustment incorrect Correct adjustment Fast idle adjustment incorrect Correct adjustment Bimetal rod in contact with bimetal Adjust case SPECIFICATIONS AND SERVICE DATA Carburetor model Outlet diameter mm On DAK340 D3034C 30 30 1 1811 1 a 1 1811 1 20 29 x 9 23x 14x T 28x 16x 8 1 1417 x 0 9055 x 0 5512 1 1024 x 0 6299 Venturi diameter mm in us 0 9055 bo S a
123. nding agent Three Bond to both sides of the packing for preven tion of water leakage 2 Instail by the removal procedure in reverse RADIATOR The radiator is a conventional side flow type with sight glass The system is pressurized and the relief valve incorporated in the radiator filler cap controls the pressure at approximately 0 9 kg cm2 12 8 lb sq in Fig CO 8 Radiator removed For the models with torque converter the oil cooler to cool the torque converter oil will be combined with the radiator Fig CO 9 Radiator with oil cooler COOLING SYSTEM Fig CO 10 Radiator shroud Also the radiator shroud is combined with the radiator in the models with the torque con verter or the air conditioner and the U S A model SPECIFICATIONS Dimensions of radiator core height width x thicknees Radiator fin spacing Cap working pressure Water capacity Removal 1 Drain cooling water 2 Disconnect the radiator upper hose and lower hose 3 Detach the radiator assembly by removing the four fixing bolts 4 Sight glass be removed by turning counter clockwise to clean it Inspection If the radiator requires frequent top ups the trouble must be traced to one of the follow ing causes 1 Excessive water evaporation from overheat ing as a result of a clogged radiator Clean the radiator 2 Defective safety valve on radiator filler cap Replace the cap
124. ne glycol base pro duct containing chemical inhibitors to protect the cars cooling sytem against rusting and corrosion L L C does not contain any glycer ine ethyl or methyl alcohol It will not evapo rate or boil away and can be used with either high or low temperature thermostats If flows Boiling point 0 9 kg cm Sea level cooling sys tem pressure C Freeze protection 124 C 255 15 5 F 106 221 127 C 261 F 35 31 109 228 freely transfers heat efficiently and will not clog the passages in the cooling system L L C must not be mixed with other product This coolant can be used through out the seasons of the year and exchange period is two years or total running mileage of 40 000 km 24 000 miles 0 32 10 14 20 4 30 22 A0 40 50 58 EE 10 20 30 40 50 Fig EF 3 Protection concentration UNIT SERIAL NUMBER LOCATION There are two serial numbers for unit iden tification the engine number and the chassis number These numbers are repeated in the car identification plate which is located in an easy to read position Engine serial number The engine number is stamped in the rear left side of cylinder block at cylinder head contact surface The number is preceded by engine model G18 000001 Serial No Engine model 4 ANM OIL LEBEL EXHAST GAUGE MANIFOLD
125. necessary wiring to connect these parts The purpose of this system is to convert just enough mechanical SPECIFICATIONS Alternator Maker AS20306 1 Applied engine G18 option Nominal output 14V 30A 14V 40A No load minimum revolution 30 14 40 14 V d utput current 5 000 rpm 5 000 rpm Negative ground Negative ground Less than 1 000 rpm Less than 1 000 rpm When the ignition switch is turned on current flows from the battery to ground through the ignition switch voltage regulator IG termi nal primary side contact point P1 movable contact point P2 voltage regulator ter minal alternator F terminal field coil and alternator E terminal as shown by the heavy arrows Then the rotor in the alternator is energy from the engine into electrical energy to supply all electrically operated units and keep the battery fully charged Regulator Applied alternator AS2030B1 AS2040P Constant voltage relay Constant voltage relay and pilot lamp relay 3 contact point type 14 3 15 3 V 4 000 rpm 20 C 68 F No load regulating voltage On the other hand current flows from exited the battery to ground through the ignition switch warning lamp voltage regulator L terminal lamp side contact point movable contact point 5 and voltage regulator E terminal as shown by dotted arrows
126. ng surface 7 2 Assemble vanes correctly on dummy shaft 9 56 special tool STECP 20005 Note Press only on lettered end bearing surface and support rotor ring to prevent its distortion 7 Position new carbon seal on rotor ring so that holes line up 8 Position rotor ring so that scribe marks on rotor ring and side of rotor line up 9 Apply thread locking material to six rotor ring retaining screws and tighten them to 30 to 50 kg cm 2 2 to 3 6 lb ft 10 Remove dummy shaft from vanes and start housing end cover assembly into position indexing vane shaft into vane bearings Do not force cover on as this will distort vane bearing and or vane bearing alignment Fig EC 15 Vane assembly 3 Place vanes into rotor making sure that one vane is against housing stripper Do not remove dummy shaft at this time 11 Seat end cover to housing and starting with bolt adjacent to large dowel torque four end cover to 100 to 130 kg cm 7 2 to 9 4 lb ft Remove from vise Note a Pack in vane hub bearing with high melting point grease such as ESSO ANDOK 260 b Installation of a new vane set in air injec tion pump may result in vanes chirping or EC 10 EMISSION CONTROL SYSTEM 12 Insert relief valve into housing mounting hole With protective plate over valve tap with hammer until valve shoulders on housing Fig EC 16 Special tool Note Care must be observed to prevent distortion of air pum
127. nothing is wrong with its characteristic conceivable causes are defectiveness or ab normal wearing out of driving part or others So do not disassemble it In case of improper characteristic take off switch on off part and check closely cam assembly governor weight shaft and governor spring etc In case centrifugal advance mechanical part is reassembled be sure to check advance characteristic by distributor tester lt Centrifugal advance characteristic gt 2 3 s gt 9 1 000 1 500 Distributor rotation rpm Fig 85 0416 57 35 ENGINE 3 Take off contact breaker Refer to page EE 34 when contact set is to be disconnected 500 1 000 1 500 2 000 2 500 3 000 Distributor rotation rpm Fig EE 86 0423 53 DISASSEMBLY AND ASSEMBLY 1 ig EE 88 R l of contact set Disassembly Fig emoval of When distributor is disconnected from engine position of distributor and rotor head for housing must be well remembered or marked If distributor is set to wrong place no operation become possible Disassembly is to be made in the following order 1 Take off cap and disconnect rotor head 2 Take off vacuum controller Fig EE 89 Removal of contact breaker 4 When contact breaker is disassembled take off clip to disconnect breaker plate fixed putting down moving breaker plate Be careful not to lose steel ba
128. nsion by changing the position of the alternator to establish the specified tension between the water pump pulley and the alternator Fig EM 84 Adjusting fan belt tension 33 Install the oil filter 34 Instail the rocker cover hose 35 Install the distributor so that the vacuum controller and the rotor are in positions shown in Figure EM 85 Temporarily tighten the lock nut Fig EM 85 Location of distributor rotor EM 30 ENGINE MECHANICAL Note Apply sufficient oil to the distributor driven gear Adjustment of ignition timing is performed in the time of running in engine or after the engine installed on the vehicle 36 Install the gas breather Note The clamp of the pipe is tightened in company with the exhaust manifold 37 Install the spark plug and connect the high tension cable 38 Install the exhaust manfiold At the same time install the heat shield plate and engine slinger and tighten them together Install the gasket facing steel Plate to exhaust manifold Exhaust manifold Fig EM 86 Installation of exhaust manifold gasket Note Install the exhaust manifold gasket with the steel plate surface of the grommet facing in the direction of the manifold 39 Install the clutch 40 Remove the engine from the engine stand and install the transmission intake manifold with carburetor starter motor engine mount oil pressure warning switch gasoline drain tube etc SERVICE DATA AND SPE
129. off choke wire arm 2 Remove two screws and take off choke valve 3 Remove choke shaft and choke vaive spring 4 Remove choke lever and choke lever spring by taking off the clip 3 Float chamber 1 Remove three fixing screws and take off diaphragm chamber cover diaphragm spring and diaphragm Fig EF 35 Diaphragm chamber disassembly 2 Remove three fixing screws and diaphragm chamber and gasket 3 Remove four fixing screws and take off float EF 18 chamber cover gasket level gauge rubber packing and float Fig EF 36 Float chamber disassembly 4 Remove filter fixing screw and take off nipple and filter 5 Remove needle valve 6 Remove two fixing screws and take off cyl inder cover pump cover piston piston return spring and inlet valve 7 Remove injector fixing screw and take off pump injector injector spring and outlet valve 8 Remove primary main air bleed 9 Remove secondary main air bleed and emulsion tube 10 Remove three fixing screws and take off small venturi Fig EF 37 Float chamber disassembly FUEL SYSTEM 11 Remove primary and secondary slow jets and slow air bleeds 12 Remove drain plugs and take off primary and secondary main jets 4 Throttle chamber 1 Remove throttle adjust screw and spring 2 Remove idle adjust screw and spring 3 Remove nut and take off throttle lever spring hunger sleeve connecting lever return
130. on In case of some deformation of pitching are found at the valve contacting face of valve seat correct the valve seat by a valve seat cutter ST49720000 Firstly scrape the seat by 45 cutter after that if the width of the contacting face is too Fig EM 32 Correcting valve seat wide scrape intake side by 15 60 and ex haust side 15 in order to get prescribed width After finishing the correction complete the valve contact to the valve seat by doing lap d 316 0 1 346 03 Fig EM 33 Dimension for seat correction Note As the valve seat inserts of this engine are united into cylinder head by casting replace ment of the valve seat cannot be done CAMSHAFT AND CAMSHAFT BEARINGS Camshaft bearing clearance check Check the clearance by measuring the dif ference of the camshaft bearing inner diameter and camshaft journal outer diameter or by using plastigage If the wear outruns the limit replace as the cylinder head assembly Tightening torque 0 9 to 1 4 kg m 6 5 to 10 1 ft Ib Clearance 0 025 0 075 mm 0 0010 0 0030 37 5 37 525 mm 1 476 1 477 in 37 45 37 475 mm 1 474 1 475 0 1 mm 0 0039 in Camshaft bearing inner diameter Camshaft journal outer diameter EM 12 ENGINE MECHANICAL Valve timing check If the camshaft shown no apparent damage although some valve operation troubles have been det
131. on for carburetor overhauling is outlined in section EF ENGINE FUEL SYSTEM Adjustment Adjust carburetor to get best idling engine speed 600 rpm Valve clearance adjustment This adjustment is impossible when the engine is in operation Follow the procedure described below 1 Standard adjustment is made while the engine is cold Adjust to the following clearances When cold Both intake and exhaust 0 2 mm 0 0079 in When hot Both intake and exhaust 0 28 mm reference 0 011 in 2 Locate the top dead center compression of each cylinder in turn Loosen the valve screw lock nut and turn the adjusting screw to set valve clearance to the specified value Tighten the lock nut and recheck clearance Follow the same manner for the remaining cylinders To rotate the crankshaft of the engine manually tighten the fan belt and pull Inspection of timing chain Tension of the timing chain is adjusted by turning the adjusting screw attached to the right hand side of the chain cover by observing following items at running engine 1 Chain noise is not high at idling rpm 2 Chain noise is not high at 2 000 rpm After adjusting the tensioner lock it with lock nut securely mm 2 16 in same as that of spark plugs Use the spark plug wrench After adjustment at 10 000 km 6 000 miles when the initial period ends additional adjust ment is not necessary until 100 000 km 60 000 miles is reached
132. on key is switched off and a idle limitter is also pro vided to control the emissions under a certain level So that the movement of the idle adjust Screw is limited in a certain range Primary system 1 Primary main system Fuel flows as shown in Figures EF 14 and EF 15 through the main jet mixing with air which comes in from the main air bleed and passes through the emulsion tube and is pulled out into the venturi through the main nozzle The multiholed main nozzle insures a proper atomization of fuel and a low fuel consumption Main nozzle Small venturi S Main air bleed Slow jet S Slow air bleed Float valve Vacuum piston P Slow air bleed Slow jet Slow economizer P Slow air bleed lt lt Model DAK340 Carburetor gt Needle valve Float S Emulsion tube S Main jet S By pass hole FUEL SYSTEM Y WW e SN t HE ies 5 242322 Primary S Throttle valve 4 Choke valve P Main air bleed P Main nozzle P Slow jet Slow economizer P Slow air bleed Air vent Economizer bleed Level gauge Fig EF 14 Sectional view amp Model D3034C Carburetor gt Air vent P Main air bleed P Main nozzle P Small venturi Choke valve Pump nozzle sae face me wee scores 26 Primary Secondary Pump weight Pump plunger Discharge check valve S Small venturi S Main ai
133. or 49 is connected in parallel to the driving coil Fig EF 6 Solenoid relay ENGINE 3 Pump mechanism Fig EF 7 Pump mechanism As shown in Figure EF 7 the piston 42 is connected to the plunger i through the con necting rod ii It is mounted in the cylinder B fitted in the central hole of the frame so that it can slide freely An inlet valve is provided at the lower end 4 Strainer unit This unit is constructed as shown in Figure EF 8 Around the frame dp a wire netting filter 2 is attached concentrically and on the under side of the lower end of the frame a magnet C is mounted to remove any fine iron filings Enclosing the filter a glass strainer is fixed on the frame by a band using the seal packing OPERATION 1 Operation of electromagnetic unit Before operating the fuel pump as plunger i stays pushed up inside the cylinder by the plunger spring i6 mounted on the frame 2 the magnet on the end of the magnet holder of the contact mechanism is attracted to the cylinder and the point arm 5 mounted on the horizontal part of the magnet holder 4 is pressed downward making contact between contacts 7 and B 1 When turning the engine switch A on the electric current flows from the battery driving 46 contact gt contact Z point arm E gt yoke 47 ground and this current makes the driv ing coil 4 act as an electrom
134. or this system is equipped with special calibrated carburetors with narrow to tolerance for fuel flow Ignition distributor The ignition distributor used with the Air Injection System is provided with a different advance curve from that used on engines without an exhaust emission control system Idle ignition timing is retarded by 13 degrees Idle speed The idle speed is set at a higher Specifications are 700 r p m for manual trans mission equipped vehicles and 650 r p m for automatic transmission equipped vehicles Pe fey To 7 Carburetor idle mixture On cars equipped with the Air Injection System slightly rich adjustment of the idle mixture is required Cooling system A modified engine cooling system will be used due to increased engine heat rejection at idle caused by retarded ignition timing Cooling system changes such as larger fans higher fan speeds are incorporated Fluid fan coupling The larger fans increase fan noise A fluid fan coupling is used on Air Injection equipped engines When the engine speed rises to some predetermined speed the fluid fan coupling is activated and therefore reduces fan noise and fuel consumption ENGINE Spark plug Projected electrode type spark plugs are employed on all of Nissan s emission controlled engines Recommended annual maintenance For the continued proper performance of the Nissan Air InjectionSystem annual maintenan
135. or to installing the pump clean it with Nissan CSC Cooling System Cleaner FLUID COUPLING In the models with the torque converter or the air conditioner and the U S A models a fluid coupling is combined with the water pump to maintain cooling efficiency and to prevent power loss at high speed operation Fig CO 4 Fluid coupling 1 If a malfunction due to foreign matters or sticking due to deteriorated oil are detected disassemble the coupling for interior cleaning Note Wash the coupling in gasoline in this case take care so that rubber seal will be kept away from gasoline 2 Check for seizure and a gelatinized oil a Phenomenon of oil thickened into a semi solid form Change such oil because thickened oil will make bearings and grooves sticky At the same time examine the condition of seal and bearing thoroughly A blackened seal and bear ing due to seizure requires the replacement of the pump body assembly Lubrication Silicon oil is to be used 1 If a malfunction and oil leakage are detected in the fluid coupling remove the water pump for CO 3 an overhaul After reassembly it must be filled with silicon oil of exactly 11 5 0 702 cu in using an injection syringe Fig 5 Fluid coupling lubrication Note Carry out oil injection slowly to help air escape A binding agent to be used in assembling Three Bond No 1 In this type of water pump oil can be re plenished with t
136. ortion Correct the fit ting Replace Engine does not Distributor Improper and retarded timing give enough power Defective function of governor Correct Correct Dirty point Correct Point gap too narrow Spark plugs EE 45 ENGINE SERVICE JOURNAL OR BULLETIN REFERENCE ea Q a SUBJECT EE 46 PAGE No JOURNAL or BULLETIN No DATE DATSUN 1 1800 SECTION SE SERVICE SERVICE MAN UAL EQUIPMENT ENGINE NISSAN MOTOR CO LTD TOKYO JAPAN ENGINE TOOLS een SE 1 SERVICE EQUIPMENT ENGINE TOOLS ST49700000 Pilot bush puller ST49710000 Valve guide reamer set ST49720000 Valve seat cutter Valve guide replacer set Valve guide replacer ST49730000 Valve guide replacer Spacer for valve guide replacer Valve guide reamer 8 mm Valve guide reamer for cylinder head 14 2 mm IN 43 mm dia 45 deg IN 43 mm dia 30 deg 36 mm 45 deg Pilot Cross bar Use when drawing out the guide Use when pressing in the guide Use for getting the specified length when pressing in the guide SE 1 ENGINE 5749740000 Front oil seal replacer Rear oil seal drift set Rear oil seal drift ST49750000 Stand for rear oii seal drift 5749760000 Engine slinger ST49770000 Engine carrier
137. ow system of the primary system The system aims in the proper filling up of the gap when fuel supply is transferred from the primary system to the secondary one The step port is located near the secondary throttle valve in its fully closed state 3 Secondary switch over mechanism The secondary throttle valve is linked to the diaphragm which is actuated by the vacuum created in the venturi A vacuum jet is pro vided at each of the primary and secondary venturies and the composite vacuum of these jets actuates the diaphragm As the linkage shown in Figures EF 19 and EF 21 causes the secondary throttle valve not to open until the primary throttle valve opening reaches approximately 50 fuel consumption during normal operation is not excessive During high speed running as the vacuum at the venturi is increased the diaphragm is pulled against the diaphragm spring force and then secondary throttle valve is opened The atmospheric side in the diaphragm chamber is connected to the atmosphere Lock nut Choke wire arm Dash pot Throttle lever Throttle chamber Throttle valve Fig 18 Dash pot mechanism EF 11 ENGINE lt Model DAK340 Carburetor gt PAK340 Carburetor gt Di K JE Ea Primary I S Vacuum jet 2 Diaphragm chamber Diaphragm chamber Diaphragm rod cover P Vacuum jet Diaphragm Fig EF 19 Full throttl
138. p housing 13 Set silencer to relief valve by hand Installation of air pump Installation of air pump is reversal of cedure given for removal noting following points Adjust the belt tension so that it has 8 to 12 mm 0 315 to 0 472 in of slack under 7 to 10 kg 1 5 to 2 2 1b of load Note Do not pry on the die cast pump housing Drive pulley 1 Loosen the air supply pump adjusting bar nut and bolt to relieve the belt tension 2 Remove the drive pulley attaching bolts Anti backfire valve The removal of the anti backfire valve requires disconnecting the hoses No further disassembly should be done After installation check the valve operation and inspect all hoses and hose connections for leak i Check valve 1 Disconnect the air supply hose 2 Remove the check valve from the air gallery pipe holding the flange of air gallery pipe with a wrench Note a Take care not to damage the air gallery pipe b No further disassembly should be done 3 Installation of check valve is reversal of procedure given for removal Note a Before installation apply the anti seize com pound such as LED PLATE No 250 at the screw b Tightening torque 9 0 to 10 5 kg m 65 to 76 Ib ft 4 After installation check the valve hoses and hose connections for air leakage Air gallery pipe and injection nozzles It is very difficult to remove injection nozzles from the exhaust manifold without damaging If
139. plate and adjust plate Fie taa shon 3 Remove pump rod slow jets primary and 4 Remove two fixing screws and take off secondary small venturies primary throttle valve 5 Remove primary throttle shaft 6 Remove two fixing screws and take off secondary throttle valve 7 Remove secondary throttle shaft Fig EF 40 Removal of jets and venturies 4 Remove primary and secondary linkage parts Fig EF 38 Throttle chamber disassembly lt Model D3034C Carburetor gt 1 Remove starting connecting rod from choke lever and accelerating pump connecting rod 2 Remove three screws and air horn Fig EF 41 Removal of linkage parts EF 19 ENGINE 5 Remove three fixing screws and take off diaphragm chamber cover diaphragm spring and diaphragm Fig EF 44 Float chamber disassembly 9 Remove fuel inlet strainer and float valve seat 10 Remove main jets Fig EF 42 Diaphragm chamber disassembly 10 roe 11 Remove two fixing screws and take off fuel cut off valve 6 Remove three fixing screws and diaphragm chamber and gasket 7 Separate float chamber from throttle chamber by removing three fasteners Fig 45 Fuel cut off valve Cleaning and inspection Dirt gum water or carbon contamination in or on the exterior moving parts of a carbu Fig EF 43 Float chamber removal from throttle retor are often responsible for unsatisfactory chamber performance For this reason e
140. pring Fig 3 5114 104 Construction REMOVAL 1 Disconnect the battery ground cable Disconnect the black wire with yellow tracer from the magnetic switch terminal and black battery cable from the magnetic battery terminal 2 Remove twobolts securing the starting motor to the clutch housing Pull starter assembly forward and remove starting motor DISASSEMBLY 1 Loose the nut securing the connecting plate to the magnetic switch terminal Remove three screws securing magnetic switch and remove magnetic switch assembly EE 3 Fig EE 4 Removing magnetic switch assembly LEE ENGINE 2 Remove two through bolts and brush cover 5 Remove the pinion stop ring located at the assembly end of the armature shaft To remove the stop ring firstly push the stop ring to the clutch side and then after removing the snap ring remove the stop ring with the over running clutch Withdraw the over running clutch assembly from the armature shaft Fig EE 5 Removing the brush cover 3 Remove the yoke assembly by hitting lightly with a wooden hammer Fig EE 8 Removal of the over running clutch assembly 6 Dissolder the brushes using a soldering iron and remove each brush Fig 6 Removing the yoke assembly 4 Withdraw the armature assembly and shift lever Fig EE 7 Removing the armature assembly and shift lever Fig EE 9 Removing brush EE 4 ENGINE ELECTRICAL SYSTE
141. r limit use the cylinder liner P Undersize cylinder liners are available for service Interference fit of cylinder liner to cylinder block 0 08 to 0 09 mm 0 0031 to 0 0035 in Cylinder liner for service Angus 89 091 89 126mm 83 5 84 5 mm gt 8 507 3 509 in 8 287 3 327 in PISTON PISTON PIN AND PISTON RING 1 Check for seizing scratches and wear Effect a replacement when such a defect is detected Fig EM 40 Piston assembly EM 15 Second 0 02 0 06 mm 0 1mm 0 0008 0 0024 in 0 0039 in Oil ri 0 02 0 06 mm 0 1mm 108 0 0008 0 0024 in 0 0039 in ENGINE 2 Measure the side clearance of rings in ring groove as each ring is installed Clearance with new pistons and rings should be as follows Fig EM 41 Measuring side clearance Side clearance 0 04 0 08 mm 0 1 mm Pring 0 0016 0 0031 0 0039 in Ring gap Top rin 0 35 0 55 mm 1 0 mm Pring 1 0 0138 0 0217 in 0 0394 in Second rin 0 3 0 5 mm 1 0 mm 8 0 0118 0 0197 in 0 0394 in Oil rin 0 35 0 55 mm 1 0 mm ring 0 0138 0 0217 in 0 0394 in 3 Place the ring at the bottom of the ring traveled part of cylinder bore in which it will be used Square ring in bore by pushing it into position with the head piston Measure the gap between ends of ring with feeler gauge Gap
142. r bleed Step air bleed Pump arm Step jet Inlet check valve SMainjet Diaphragm spring Diaphragm Step port Idle port Fig EF 15 Sectional view EF 9 P Main jet Idle limitter Idle hole P By pass hole P Throttle valve P Throttle valve Idle port Slow port Idle adjust screw P main jet Power jet Float ENGINE 2 Idling and slow system The throttle valve is opened at a small angle when idling and in slow speed running with a large negative pressure prevailing down stream of the fuel system This negative pressure acts on the slow speed system equipped with a slow economizer Through this action fuel measured through the jet section of the slow jet assembly located immediately behind the main jet and air coming from the economizer bleed are mixed in the emulsion hole This mixture is further mixed with air coming from the slow air bleed through the slow economizer and atomized The atomized mixture is supplied to the engine from the idle hole and by pass hole via the slow speed system line As a result there is an excellent linkage between the slow speed system and the main system and the resultant stable slow speed performance is ensured 3 Accelerating mechanism lt Model DAK340 Carubretor gt DW ts ii Main air bleed Main nozzle Piston return spring Inlet valve Pu
143. r in series with the specified 12 volts battery and an ammeter capable of indicating 1 000 amperes Specified current draw and revolution in these test are shown in specification Starter motor Voltmeter Ammeter Fig 22 No load test Torque test Torque testing equipment should be used to determine the torque the motor will develop A high current carrying variable resistance should be connected into the circuit so that the specified voltage at the starting motor may be obtained since a small variation in the voltage will produce a marked difference in the torque development Specified power voltage and torque are shown in Figure EE 23 ENGINE ELECTRICAL SYSTEM Performance curve gt 1 A grounded or open field coil Inspect the connection and trace the circuit by a circuit tester 2 The armature coil does not operate Inspect the commutator for excessive burned out In this case are may occur defec tive commutator when the motor is operated with no load Revolution ue Voltage v 3 Burned out commutator bar Weak brush spring tension broken brush spring rubber brush thrust out of mica in the commutator or a loose contact brush and commutator would cause to burn the com mutator bar mw EI 2 3 3 gt gt S 3 Low torque low current draw and low no load spee
144. rankshaft and main bearing Journal taper and out of round Less than 0 01 mm 0 0004 Crankshaft free end play 0 060 0 192 mm 0 0024 0 0008 Wear limit of ditto clearance 0 3 mm 0 0118 Crank pin taper and out of round Less than 0 01 mm 0 0004 in Main bearing clearance 0 03 0 06 mm 0 0012 0 0024 in Wear limit of ditto clearance 0 1 mm 0 0039 in Main bearing under size 2 485 2 505 mm 0 0978 0 0986 in 2 612 2 625 mm 25 U S 0 1028 0 1033 in POERA 2 737 2 750 mm 55 471 55 490 mm 0 1078 0 1083 in 2 184 2 185 in es 2 862 2 875 mm 55 221 55 240 mm 0 1127 0 1132 in 2 174 2 175 in 2 987 3 000 mm 54 971 54 990 mm E 0 1176 0 1181 in 2 164 2 165 in Crankshaft bend Less than 0 02 mm 0 0008 in Crank journal diameter 55 971 55 990 mm 2 2036 2 2043 in 55 721 55 740 mm 2 194 2 195 in S T D EM 34 ENGINE MECHANICAL e Piston Piston diameter 84 968 85 0 mm 3 345 3 346 Ellipse difference 0 4 mm 0 0157 in Ring grove width Top 0 05 0 0020 2 0 0 03 mm 0 0787 0 0012 in Second 0 03 0 0012 2 0 0 01 mm 0 0787 0 0004 in Oil 0 03 0 0012 4 0 0 01 mm 0 1575 0 0004 in Piston to bore clearance 0 035 0 55 mm 0 0014 0 0022 in Piston ring side clearance 0 04 0 08 mm 0 0016 0 0031 in
145. regulator E termi nal EE 29 ENGINE Broken ground wire color of wire is black Loose or worn fan belt Sticking brushes Low output Low brush spring tension Defective voltage regulator Dirty slip rings Partial short ground or open in stator winding Partial short or ground of rotor winding Open diode or defective diode Noisy alternator Loose mounting Loose drive pulley Defective ball bearings Improperly seated brushes Replace the wire Tighten or replace the belt Free replace brushes and spring if necessary Replace the brush spring Check the regulator operation Clean the slip ring Replace the stator Replace the rotor Replace the diode Tighten mounting bolts Tighten pulley Replace the bearing Seat brushes properly IGNITION CIRCUIT The ignition circuit includes the distributor ignition coil ignition switch spark plugs high tension cable and the battery DISTRIBUTOR CONTENTS SPECIFICATIONS EE 31 Centrifugal advance mechanical CONSTRUCTION AND OPERATION EE 31 pab HEUS EE 35 CHECKING AND ADJUSTMENT EE 34 DISASSEMBLY AND ASSEMBLY EE 36 and rotor head EE 34 Disassembly ENN EE 26 cnini uti EE 34 le EE EE 29 eil EE EE 24 SERVICE DATA EE 39 Vacuum advance mechanical part and switch on off part
146. res EE 72 and EE 73 Fig EE 73 Adjusting G2 g2 gap Point gap G3 or g3 Adjust the gap by bending the secondary contact support as shown in Figures EE 72 and EE 74 Fig EE 74 Adjusting g3 gap EE 28 ENGINE ELECTRICAL SYSTEM Adjustment of voltage and down Bend upward to heighten adjust Adjust the voltage by bending the stopper up value and downward to lower adjust value Bending direction Highten voltage lower voltage Stopper Fig EE 75 Adjusting the voltage Fig EE 76 Adjusting the voltage TROUBLE DIAGNOSES AND CORRECTIONS Troubles Causes Sticking brushes Free replace brush and brush spring Clean the brushes and slip rings No output Dirty brushes and slip rings Tighten or solder connection Replace leads Loose connections broken leads Open stator winding Repair or replace the stator Replace the rotor Open rotor winding Replace the diodes Open diodes Shorted rotor Replace the rotor Repair or replace the stator Shorted stator Grounded BAT terminal Replace the insulator Broken fan belt Replace the belt Broken neutral point wire color Replace the wire of wire is white Excessive output Defective voltage regulator Check the regulator operation Poor grounding of the alternator Tighten the terminal connection and voltage
147. rottles operates properly if the distance between the throttle valve and inner wall of the throttle chamber G2 amounts to 7 38 mm 0 3937 in The adjustment is made by bending the point of the adjusting plate lt lt Model D3034C Carburetor gt S Throttle arm 3 Link S Throttle return lever 4 P Throttle arm 5 P Throttle valve Fig EF 30 Model 03034 carburetor Figure EF 30 shows the primary throttle valve opened 50 When the primary throttle arm fixed to the primary throttle valve is open 50 it comes to contact with the connecting link Adjustment of the injection amount of the accelerating pump D3034C carburetor The fuel amount forced out from the pump injector during acceleration can be controlled by selecting a fitting hole of the pump arm Ordinarily the hole of the middle position should be used But according to the temper ature select the proper position of the hole as shown in the table Position of Injection amount T the hole per one stroke Inner 0 6c c 0 0366 cu in Below 32 Middle 0 4c c 0 0244 cu in 30 C 324 867 owe 2 c c 0 0122 cu in Above 30 86 F EF 16 FUEL SYSTEM MAJOR SERVICE OPERATIONS The perfect carubretor delivers the proper gasoline and air ratios for all speeds of the particular engine for which it was designed By completely disassembling at regular inter vals which will a
148. running at idle remove the ventilator hose from the rocker cover If the valve is working a hissing noise will be heard as air passes through the valve and a strong vacuum should be felt immediately when a finger is placed over the valve inlet If valve is plugged do not attempt to clean it Replace with a new valve PERIODIC SERVICE Once a year or at 20 000 km 12 000 miles the Positive Crankcase Ventilation System should be serviced as follows 1 Check hoses and hose connectors for leaks 2 Disconnect all hoses and blow them out with compressed air If any hose cannot be freed of obstructions replace with new hose 3 Check for proper function of crankcase ventilation control valve If the valve is found defective replace with a new assembly EXHAUST CONTROL SYSTEM CONTENTS DESCRIPTIQN aa EC 2 Air gallery pipe and injection nozzles EC 11 NISSAN AIR INJECTION SYSTEM EC 3 DIAGNOSIS AND TESTING EC 12 Engine driven air PUMP EC 4 Diagnosis general exhaust system EC 12 Air injection into each exhaust port EC 5 Diagnosis air EC 12 Engine modifications EC 7 ine iie q EC 14 Recommended annual maintenance EC 8 SETTING IGNITION TIMING amp REMOVAL AND DISASSEMBLY ADJUSTING IDLE SPEED MIXTURE EC
149. s Multi grade Regular single grade or double grade TAXACO INC CHEVRON OIL CO CALTEX MOBIL SHELL BP British Petroleam Multi purpose grease Marfak All Purpose Grease Marfak Multi Purpose Grease Havoline Motor Oil 10W 20W 40 30 40 Havoline Motor Oil 10W 30 20W 40 RPM Multi Motive Grease RPM Supreme Motor Oil 10W 30 20W 40 RPM Special Motor 10W 20W 20 30 40 Marfak All Purpose Grease Marfak Multi Purpose Grease Five Star Motor Oil 10W 20W 20 30 40 Five Star Motor Oil 10W 30 20W 40 Mobiloil 10W Mobiloil Super 10W 40 Arctic 20 Mobiloil Special 10W 30 A 30 AF 40 Shell Super Motor 10W 40 Shell X 100 10W 30 20W 40 Shell X 100 20W 10W 20 30 40 Retinax A Esso Multi Purpose Grease Esso Motor Oil 20 30 10W 40 Esso Extra Motor Oil 10W 30 20W 40 BP Super Viscostatic Motor Oil 5W 20 10W 30 BP HD Motor Oil 10W 20 30 40 BP Energrease L2 Castrolite 10W 30 Castrol XL 20W 40 Castrol Super 10W 40 20W 50 Castrol 5WHD 10WHD 20W 20HD 40HD CASTROL Lubricating points Castrolease LM Distributor cam heel Engine Carburetor Linkage Distributor Shaft EG 3 ENGINE Nissan long life coolant L L C This L L C is an ethyle
150. sed plugged system disconnected or leaking Defectibe or mulfunctioning anti backfire valve Improper carburetor fuel mixture adjustment Air supply hose baked or burned Defective check valve on air distribution manifold Rough engine idle Improper carburetor adjustment idle speed idle fuel mixture choke setting etc Improper initial ignition timing Intake vacuum 1 at the anti backfire valve vacuum line or at the anti backfire valve vacuum chamber Engine surges at all speeds Improper carburetor adjustment idle speed idle fuel mixture choke solting etc Noisy air pump drive belt Drive belt improperly adjusted Seized or failing air pump Misaligned or defective pulleys Diagnosis air pump On car 1 Check pump to see that it rotates and check Noise external cause belt for proper tension Air injection pump is not completely noise less Under normal conditions noise rises in pitch as engine speed increase If excessive noise is heard the following steps should be taken 3 Check relief valve for escaping air 2 Check hoses to insure that they are not loose leaking or touching other parts of car EC 12 Noise internal cause 1 Vane noise EMISSION CONTROL SYSTEM 2 A chirping squeaking noise is most com monly associated with vanes rubbing in housing bore Vane chirping is most noticeable at low speed and is heard inter 3 mittently Additional wear in t
151. sed for the intake gasket and steel filled asbestos for the exhaust gasket Fig 10 Intake manifold Fig EM 11 Exhaust manifold ENGINE MECHANICAL ENGINE DISASSEMBLY CONTENTS CLEANING AND INSPECTING EM 5 Disassembly of piston and connect DISASSEMBLY EM 5 ing rod assembly _ EM 7 Disassembly of cylinder head assembly 7 CLEANING AND INSPECTING Wash the engine thoroughly before disas sembly Before washing remove the alterna tor distributor and starter and plug up the carburetor air horn to avoid any infiltration of foreign matter 1 The exterior of the engine Check the covers and bolts for breakage rust damage and loss 2 Cylinder block Check thoroughly the water jacket for cracks and breakage 3 Clutch housing Check for cracks 4 Oil pan Check for excessive rust DISASSEMBLY The engine with transmission is placed on the engine carrier ST49770000 now The disassembly procedure begins from this condition 1 Remove the transmission 2 Disconnect the intake manifold water hose the vacuum hose and intake manifold to oil separator hose 3 Remove intake manifold with carburetor 4 Install the engine attachment ST37200G18 to the cylinder block 5 Place the engine on the engine stand ST371 00000 EM 5 Fig EM 12 Placing engine on the engine stand 6 Remove
152. speed or below set ignition timing Fig ET 4 Checking ignition timing check 7 72 SEE r4 D ENGINE TUNE UP The timing can be observed by the station ary pointer at the front cover and the markings on the crankshaft pulley with a device called a stroboscopic light also referred to as a timing light as shown in Figure ET 4 Ignition timing is 8 BTDC 600 rpm Fig ET 5 Timing mark Inspection of fan belt Fig ET 6 Checking fan belt tension Replace if defective 2 Adjust the belt tension if necessary Permissible slackness of fan belt 8 to 12 mm in Belt tension measuring point Between fan pulley and alternator pulley 0 315 to 0 473 Inspection of engine oil Oil capacity of engine pan capacity Engine dried tere ener eae 1 Check for a cracked or damaged V belt 1 Check if the engine oil has been deteriorated by invading cooling water or gasoline Drain and refill the oil if necessary Note a A milky oil indicates the presence of cooling water Discover the cause for necessary treatment b Oil with extremely low viscosity suggests dilution with gasoline 2 Check the oil level and if it is lower than necessary level replenish oil of the same grade up to the F level Fig ET 7 Checking oil level Carburetor overhaul and adjustment Fig ET 8 Adjusting idle rpm ENGINE Overhaul The detailed informati
153. ssion stroke EM 28 ENGINE MECHANICAL Note a Align the notch on the crank pulley to the T mark on the chain cover Fig EM 79 Timing mark b Even when the engine was turned upward the timing chain does not fall into the chain cover since the timing chain is supported with the rear boss of the chain cover Under this condition when the crankshaft is rotated the chain will not run off the sprocket 21 Install the cylinder head assembly Note a Apply sealing agent onto the cylinder block side of the head gasket Three Bond No 4 or equivalent At this time make sure that the sealing agent has not entered into the cylinder b Tighten in the manner shown in Figure EM 81 with the tightening torque applied is several steps Tightening torque 8 to 9 kg m 57 9 to 65 1 ft Ib amk Fig 80 Installing cylinder head Fig 81 Cylinder head lightening order 22 Pull out the timing chain from the chain cover and set the chain on the camshaft sprocket making their mating marks meet each other Then strike the camshaft sprocket with chain onto the camshaft 23 Install the distributor drive gear on the camshaft and tighten the bolt to the specified torque Tightening torque 4 5 to 5 5 kg m 32 6 to 39 8 ft lb Then bend the lock washer Note The camshaft bolt has left hand threads Fig EM 82 Installing camshaft sprocket 24 Adjust the valve clearance Note Adjustmen
154. st be cleaned every 20 000 km 24 000 miles 2 Wash the plunger piston and inlet valve with clean gasoline and blow dust off with a blast of air Check the smooth operation of the cylinder and piston If it is noted defective replace them Fig EF 13 Fuel pump removal 3 Insert the plunger assembly into the cylinder of the electric unit Move the assembly up and down If a clutter sound is heard it indicates the contacts are normally operated If not it DISASSEMBLY shows that the electric unit is defective and 1 Loosen the screws of the locking band must be replaced 2 Remove the strainer strainer spring filter strainer seal and locking band ASSEMBLY AND INSTALLATION 3 Remove the snap ring Follow the disassembly and removal pro 4 Remove the four screws of the yoke and take cedure in reverse Replace the gaskets if off the electric unit necessary EF 7 ENGINE CARBURETORS CONTENTS DESCRIPTION u R L un ee en EF 8 Adjustment of the injection amount of STRUCTURE AND OPERATION EF 8 the accelerating pump Primary system EF 8 D3034C carburetor EF 16 Secondary system deb ocak EF 11 MAJOR SERVICE OPERATIONS EF 17 Float ul ec aite EF 14 17 ADJUSTMENT 14 Disassembly EF 17 Idling adjustment EF 14 Cleaning and inspect
155. stantly and gradually moves back to the infinite In case the indicator never stays or it points Zero in resistance the transformer is out of order and must be replaced with EE 34 ENGINE ELECTRICAL SYSTEM Vacuum advance mechanical part and switch on off part lt lt Vacuum advance characteristic Advance degree Vacuum mmHg Fig 83 0416 57 Advance degree Vacuum mmHg Fig 84 D423 53 Check whether vacuum advance mechanism operates or not by operation indicator attached to vacuum advance mechanism Followings are the causes considered for non operation 1 Leakage of air due to incomplete fastening of vacuum inlet 2 Leakage due to defective diaphragm 3 Fixed side and moving side of breaker plate is sticked TONS Solution for 1 is to make complete fastening and 2 is to replace it with a new one Solution for 3 is as follows 1 Moving side of breaker plate is supported by three steel balls for each up and down side Do these balls work smoothly 2 Moving side of breaker plate is to rotate with pivot receiver of fixed side Does this pivot receiver move In case of assembly be sure to put in 3 steel balls for each up and down side and to apply grease Centrifugal advance mechanical part When cause of engine trouble is traced to centrifugal advance mechanical part use dis tributor tester to check its characteristic When
156. sting spark plug gap never bend center electrode which extends through porcelain center Always make adjustments by bending ground side electrode Fig EE 108 Measuring spark plug gap ENGINE TROUBLE DIAGNOSES AND CORRECTIONS 1 When the engine does not start If there is no trouble in the fuel system the ing motor and observe the condition of the ignition system should be checked This can be sparks that occur between the high tension cord easily done by detaching the high tension cord and cylinder block After checking this use from spark plugs start the engine by the start the proper counte rmeasures No sparks at all Distributor Defective insulation of condenser Replace Breakage of lead wire on low ten Repair sion side Defective insulation of cap and Replace rotor head Point does not open or close Repair ignition coil Wire breakage or short circuit of Replace with new coil one High tension code Wire coming off Repair Defective insulation Replace 1 2 mm 0 0394 Distributor Point gap too wide Correct 0 0787 in e 222 irregular Oil sticking on point Clean Point burnt too much Replace Layer short circuit Replace with good one Spark plugs Less than 6 mm 0 2362 in Correct place Electrode gap too wide Too much carbon Clean or replace Broken neck of porcelain Replace insulator
157. sufficient compression of the spark plug gasket dirt under the gasket seat Too lean carburetion will also result in excessive electrode wear Broken insulators are usually the result of improper installation or carelessness when regapping the plug Broken upper insulators usually result from a poor fitting wrench or an outside blow The cracked insulator may not make itself evident immediately but soon oil or moisture will penetrate the fracture The fracture is usually just below the crimped part of shell and may not be visible Broken lower insulators usually result from carelessness when regapping and generally are visible In fairly rare instances this type of break may result from the plug operating too hot such as encountered in sustained periods of high speed operation or under extremely heavy loads When regapping a spark plug to avoid lower insulator breakage always make the gap adjustment by bending the ground side electrode Spark plugs with broken insulators should always be replaced Fig 103 Wet EE 42 ENGINE ELECTRICAL SYSTEM Fig EE 105 Overheating 2 Fig EE 106 Overheating 3 EE 43 Fig EE 107 Life CLEANING AND REGAP Clean spark plugs thoroughly using an abrasive type cleaner All spark plugs must be of the same make and number or heat range Use a round feeler gauge to adjust the spark plug gaps Note Before adjusting gap file center electrode fiat In adju
158. t EE 24 INSPECTION AND REPAIR EE 21 ASSEMBLY 7 Ea EE 25 Rotor inspection EE 21 In case of AS2030B1 EE 25 Inspection of stator EE 22 In case of AS2040P EE 25 DESCRIPTION Different from the DC generator an nator turns the magnetic pole and fixes the armature In the alternator a magnetic field is produced by the rotor which consists of alterna tor shaft field coil pole pieces and slip rings The slip ring pressed in the shaft conducts only small field current Output current is gener ated in armature coils located in the stator The stator has three windings and generates three phase alternating current Silicon diodes act like one way valves for electricity so that charging current passes easily but reverse current is shut out this alternator six diodes are used three negatives and three posi tives and these six diodes are installed in positive and negative heat sink voltage control system is also basically same to D C system in principle EE 14 ENGINE ELECTRICAL SYSTEM Brush cover Pulley Rear cover Heat sink assembly Brush holder Brush 9 Stator assembly 12 Positive diode Ball bearing 10 Front cover 13 Negative diode Fig EE 28 Schematic view AS2030B1 REMOVAL 1 Disconnect the nega
159. t ENGINE POWER NOT UP TO NORMAL Low compression Ignition system in trouble Fuel system in trouble Air intake system in trouble Overheating Overcooling _ Others ENGINE TUNE UP Incorrect ignition timing Defective spark plugs Defective distributor points Incorrect octane selector setting Malfunction of choke system Clogged fuel pipe Dirty or clogged fuel strainer Fuel pump will not work properly Clogged carburetor jets Clogged air cleaner Air inhaling from manifold gasket or carburetor gasket Insufficient coolant Loosen fan belt Worn or defective fan belt Defective thermostat Defective water pump Clogged or leaky radiator Defective radiator filler cap Air mixing into cooling system Improper grade engine oil Incorrect ignition timing Defective carburetor lean mixture Defective thermostat Low octane fuel Improper tire pressure Previously mentioned Adjust Clean adjust or replace plugs Dress or replace points also check condenser Adjust octane selector Adjust Clean Replace Repair or replace Disassemble and clean Replace element Replace gasket Replenish Adjust fan belt Replace Replace Replace Flush repair or replace Replace Retighten each part of cooling system Replace with proper grade oil Adjust Overhaul carburetor Replace Replace with specified octane fuel Make
160. t of valve clearance is made with each cylinder set at the top dead center of the EM 29 ENGINE compression stroke Specified clearance 0 2 mm _ 0 0079 in exhaust At room temperature for both intake and Fig EM 83 Adjusting valve clearance Ref When warmed 0 25 mm 0 098 in 25 Supply oil to the oil bath of the cylinder head 26 Install the rubber plugs on the front and rear end of the cylinder head Note Apply sealing agent to the rear rubber plug Three Bond No 2 or equivalent 27 Install the chain adjusting screw Note Adjustment of the chain tension is made in the following sequence a Rotate the crankshaft clockwise and establish correct chain tension b After threading in the adjusting screw fully by hand back it off 1 2 turn and lock with the tock nut As the width of across flat of the lock nut is 21 6 0 3 same as that of the spark plug the nut can be tightened or loosened with the spark plug wrench o 28 Install the valve locker cover 29 Install the water pump One of the mount ing bolts of the water pump is also used to re tain the generator adjusting arm 30 Install the generator bracket and alterna tor 31 Install the water pump pulley fan blade and fan belt Note The fan bolts have a hole for lock wires After tightening the bolts lock each two bolts with a lock wire 32 Adjustment of fan belt tention Adjust fan belt te
161. tator is be yond repair replace it Fig EE 16 Inspection of commutator EE 6 ENGINE ELECTRICAL SYSTEM Round Commutator Segment Mica 0 5mm 0 8mm W Correct Incorrect Fig EE 17 Undercutting insulating mica 3 Inspect the soldered connection of armature lead and commutator If the loose connection is found solder it using rosin flux 4 Armature test for ground Using a circuit tester place one test probe on to armature shaft and other on to each com mutator bar If the tester shows conductive armature is grounded and must be replaced Fig EE 18 Armature test for ground 5 Check armature for shorts by placing on the armature tester and with hack saw blade over armature core rotate armature If saw blade vibrates armature is shorted Fig EE 19 Armature test for short 6 Check armature for continuity by placing the probes of tester on two segments side by side If the tester shows no conduction the circuit is open Over running clutch assembly Inspect the pinion assembly and screw sleeve Screw sleeve must be freely slid along the armature shaft splined damages are found or resistance would be felt when sliding it must be repaired Inspect the pinion teeth If excessive rubbing would be found on the teeth it should be replaced The flywheel ring gear also must be inspected Fig EE 20 Over running clutch assembly Brush holder test for ground Using a circu
162. terminals can be eres and cleaned Burned or corroded seated which eased arcing between end of wire and terminal When replacing wires in terminal be sure they are fully seated before pushing rubber nipple down over tower Check distributor rotor for damage and distributor can for cracks ENGINE TUNE UP Distributor lubricate Wipe very small amount of special cam and ball bearing lubricant on cam lobes when servicing Tighten intake manifold and carburetor attaching nuts Intake manifoid attaching bolts and nuts on engines should be tightened to proper torque Carburetor attaching nuts should be tightened securely Leaks at these areas can cause rough idle surging deceleration popping or deceleration whistle Inspection of oil filter 1 Check for oil leaks at filter body gasket center shaft gasket and installing surface of cover If oil leaks are found tighten it a little after that the oil leaks can not be protected replace each gaskets and tighten each bolts under the prescribed torque 2 8 to 3 2 kg m 20 3 to 23 2 1b 2 Replace oil filter element each 10 000 km 6 000 miles running Fig ET 9 Removing oil filter Inspection of air cleaner Viscous type element makes cleaning un necessary until the engine used for two years ET 5 or for 40 000 km 24 000 miles running under normal conditions Fig ET 10 Removing air cleaner element Inspection of fuel strainer
163. th fine sand paper No 500 or 600 or oily whetstone must be applied for smoothing At this time grease must be supplied to both arm pivot re ceiver and surface of cam In case wearing of point is remarkable it must be replaced with a new one In this case contact arm and contact EARTH TERMINAL Fig EE 81 Breaker point are also to be replaced with Details for replacement is as undermentioned First loosen by 1 to 1 5 turns of screw at contact arm and primary lead wire connection part to pull out primary lead terminal In this case however notice not to loosen the screw excessively Refer to Figure EE 82 As shown in Figure EE 82 take off the stopper from stem bar and hold the contact point by fingers and pull out toward you elevat ing it a little The both contact point and con tact arm can be disconnected together When new contact set is connected do just in opposite order Apply slightly grease on both arm pivot receiver and surface of cam Fig EE 82 Disassembling the contact arm and contact point Condenser Performance of condenser depends on the setting and insulating condition Thus frequent checking is required to clean the outlet of lead wire and to prevent set screw from loosening Checking of condenser is made by capacity meter Without capacity meter it can be checked by tester by adjusting its range to measure large resistance value When con denser is normal tester indicator swings largely in
164. the accelerating nozzle 8 Push in the connecting rod of diaphragm chamber and block the passage of vacuum by finger And when free the connecting rod check the leakage of air and the damage of diaphragm Assembly and installation Follow the disassembly and removal dure in reverse Replace the gaskets if necessary In disassembling and reassembling the interlock link and related components be care ful not to bend or deform any of the components Reassemble so that all interlock links operate smoothly JETS The carburetor performance depends on jets and air bleeds That is why these components are fabricated with utmost care To clean them use gasolire and blow air on them Larger numbers stamped on the jets indicate larger diameters Accordingly main and slow jets with larger numbers provide richer mix ture and the smaller numbers the leaner mixture Inversely the main and slow air bleeds which are for air to pass through make the fuel leaner if they bear larger numbers and the smaller numbers the richer fuel Replacement of designated jets to meet the service condition of the car must be carried out with the above directions in mind To cite a practical example when it becomes necessary to economize fuel at the limited sacrifice of output to meet frequent light load operation use smaller main jets or slow jets or larger main air bleeds or slow air bleeds than regularly specified This should meet t
165. the clutch 7 Remove the exhaust manifold and heat baffle plate Fig EM 13 Removing exhaust manifold 8 Remove the fan blades At the same time remove the water pump pulley and fan belt 9 Remove the rocker cover hose manifold heat hose and bypass hoses ENGINE 10 Remove the generator bracket and oil filter 11 Remove the breather assembly by extract ing upward from above The breather is fitted to the guide with O ring pressed into the cylinder block Fig EM 14 Breather assembly 12 Remove the water pump The generator adjusting arm is removed at the same time 13 Flatten the lock washer and unscrew the nut and then pull out the crank pulley Note When the crank pulley cannot be easily removed use a puller ST44820000 Do not fit the puller so that it hooks in the V groove 14 Remove the rocker cover 15 Remove the rubber plug located on the front portion of the cylinder head Straighten the locking washer of the camshaft bolt fixing the distributor drive gear and camshaft sprocket to the camshaft and remove the bolt After Fig EM 15 Removing camshaft sprocket removing the distributor drive gear take off the sprocket from the camshaft Note Mounting bolts have left hand threads 16 Remove the cylinder head as an assembly Note In addition to ten cylinder head bolts there are two 6 mm 0 2362 in bolts fixing the chain cover to the cylinder head Fig EM 1
166. tive battery terminal 4 Remove the alternator drive belt drca n deals a cote 5 Remove the bolts which retain the alternator 3 Loosen the adjusting bolt 6 Remove the alternator from a car Fig 29 452030 1 Fig EE 30 AS2040P EE 15 ENGINE Pulley assembly ON Bearing retainer Brush Rear cover Brush cover Fig EE 31 Alternator assembly AS2030P1 EE 16 ENGINE ELECTRICAL SYSTEM Pulley assembly Front cover ly gt _Connector Heat sink assembly Fig EE 32 Alternator assembly AS2040P EE 17 ENGINE DISASSEMBLY 1 Unscrew the through bolts Fig EE 36 Drive end housing and diode end housing separated 3 Vise the rotor of the drive end housing as sembly carefully not to injure the rotor Remove the pulley nut pulley rim fan and the spacer Fig 34 Removal of through bolt 2 2 Separate the diode end housing from the drive end housing assembly by means of two drivers Fig 37 Disassembling the rotor Eee Fig EE 35 Separating of diode end housing from drive end housing Fig EE 38 Removal of pulley EE 18 ENGINE ELECTRICAL SYSTEM 4 Remove the rotor from the drive end housing 6 Pull out the rear bearing from the rotor assembly by hitting the drive end housing assembly using an arbor press or bearing slightly with a mallet puller Fig EE 39 Removal of rotor 5 Remove the bearing r
167. ts function is to relieve the exhaust air flow if the pressure exceeds a pre set value Metering grooves machined in o the housing wall located in both the intake and exhaust cavities provide a quiet transition from intake to compression to exhaust Carbon shoes support the vanes from slots in the rotor The shoes are designed to permit sliding of the vanes and to seal the rotor interior from the air cavities Leaf springs which are behind the follower side of the shoes compensate for shoe wear and vane articulation Air leaking into the rotor is exhausted through two small holes in the end cover The rotor is further sealed by flexible carbon seals which EC 5 are attached to each end The plates also seal off the housing and end cover to confine the air to the pump cavities Air that leaks by the front carbon seal is exhausted through a small hole in the housing Completing the rotating unit is a steel ring bolted to the rotor end This ring prevents the rotor from spreading at high m and also positions and holds the rear bearing and the carbon seal The front and rear bearings which support the rotor are of two types The front bearing uses ball bearings and the rear bearing uses needle bearings The hub bearings are the needle bearing type All bearings have been greased for life Air injection into each exhaust port The fresh air from the air pump is injected into the individual exhaust ports of the cylinder head
168. unit Its details are as follows 1 Contact mechanism In the contact mechanism as shown Figure EF 5 magnet A and are attached to each end of a L shaped magnet holder The magnet holder is mounted a relay stay 0 by means of a hinge in such a way that along with vertically reciprocating motion of a plunger located inside a cylinder 9 indicated by the dotted line the holder makes an oscilat ing motion in the direction of the arrow as shown Accompanying with the oscilating motion of the magnet holder a point arm at tached to the horizontal part of the magnet holder moves up and down so that the contact A attached to its end will come into contact fixed on the relay stay to make switching The arc suppressing resistor and condenser are connected in parallel to the contacts and B EF 3 Fig EF 5 Contact mechanism 2 Solenoid relay The solenoid relay is constructed as illus trated in Figure EF 6 Inside the brass cyl inder 9 the hollow iron plunger 4 which at its lower part is connected to a piston by means of a connecting rod 4 can freely slide and is attached so that it is pushed up between a damper spring 4 above and plunger spring below mounted the frame 1 Encircling this cylinder 9 a driving coil d is mounted concentrically and the coil 49 is surrounded by a leakage type solenoid relay covered by iron yokes and an end yoke d An arc suppressing resist
169. venly worn crankshaft Renew the bearings and adjust or change the crankshaft Check the lubrication System Same as the case of crankshaft bearings This may cause an ab normal wearing of the cylinder and lower compression which in turn will cause a lower out put power and ex cessive consumption of oil Overhaul the engine This may cause a wear on the piston pin or piston pin hole Renew the piston and piston pin assembly Water pump noise Others ABNORMAL COMBUSTION back fire after fire run on etc Improper ignition timing Fuel system in trouble Defective cylinder head etc EXCESSIVE OIL CONSUMPTION Oil leakage ENGINE TUNE UP This noise may be caused by the worn or damaged bearings or by the uneven sur face of sliding parts An improper of the valve clearance adjustment Noise of the timing chain An excessive end play on the crankshaft Remarks Disengage the clutch slightly and this noise will stop Wear on the clutch pilot bush Remarks This noise will be heard when the clutch is disengaged Improper ignition timing Improper heat range of the spark plugs Damaged carburetor or manifold gasket back fire after fire Defective carburetor jet Improper function of the float Uneven idling Improperly adjusted valve clearance Excess carbon in the combustion chamber Damaged valve spring back fire after fire Loose oil drain plug
170. verner weight Carbon point Oil seal Shaft Pinion Fig EE 79 Structure D416 57 EE 32 ENGINE ELECTRICAL SYSTEM lt Distributor assembly gt O peau 93219 9 395 3283409 391043003 wod 2 1483 Huds 351044 leas IO jeas 3sng du weg Fig 80 D416 57 D423 53 EE 33 ENGINE CHECKING AND ADJUSTMENT Cap and rotor head Cap and rotor head must always be kept clean to maintain good insulation durability since high tension voltage from ignition coil is imposed on them Sometimes inside of cap and rotor head is covered by only fine carbon powder and dust cleaning is required by gaso lin once month Whenever crack or trace of leakage is found on the cap it must be replaced with a new one Point Standard size of point gap is 0 45 to 0 55 mm 0 0177 to 0 0217 in In case size is off the standard adjustment is required by loosen ing point screws Gap gauge is required for adjustment However without gap gauge it can be adjusted by holding down the contact arm of which the stopper is 0 5 mm 0 0197 in thick As for those with tungsten point point gap must be checked at every 4 000 km 2 500 miles run When surface of the point is not smoo
171. y contact Series coil Ignition switch Solenoid Shunt coil Pinion sleeve spring Armature Plunger Movable contactor Return spring Battery Fig EE 2 Starting motor circuit Closing of the contacts stationary and movable causes the motor to crank the engine and also cuts out the series coil of the solenoid the magnetic pull of the shunt coil being sufficient to hold the pinion in mesh after the shifting has been performed After the cranking and when the ignition switch is turned to position the series coil demagnetizes against the shunt coil then the return spring actuates the plunger to return to the original position consequently stops the motor More positive meshing and demeshing of the pinion and the ring gear teeth are secured by means of the over running clutch The over running clutch employs a shift lever to slide the pinion along the armature shaft and into or out of mesh with the ring gear teeth The over running clutch is designed to transmit driving torque from the motor armature to the ring gear but permit the pinion to over run the armature after the engine has started ENGINE ELECTRICAL SYSTEM CONSTRUCTION Shift Gear case Shift lever lever Packing Dust cover pin Stopper Stopper clip M 1 Pinion stopper Magnetic switch terminal Magnetic switch ass y Armature Thrust washer Over running clutch Through Metal Rear cover Brush holder ass y Brush s

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