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 QUICK REFERENCE INDEX

DATSUN ENGINE EG
GENERAL
1800

ENGINE TUNE ET
UP
SERVICE
MANUAL

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ENGINE EM
MECHANICAL
MODEL G1I
ENGINE LUBRICATION
ENGINE EL
SYSTEM

COOLING SySTEM CO

FUEL SySTEM EF

EMISSION CONTROL
EC
SYSTEM
INISSAN I
ENGI NE ELECTRICAL SYSTEM H

NISSAN MOTOR CO LTD

SERVICE SE
EQUiPMENT
TOKYO JAPAN
 t
r I
r

I W@ffim1 i IR
W l

This seroic manual has been prepared for the

purpose of assisting icnJice personnel
of ollr disfribllton and dealer for effeetive eroice and mainfenance of model G 8
engine
Since proper maintenance and mroicp are most essential La ati
fy uur udomen

by keeping their curs in the be d eondition thi manual should be camfuJly studied
The following hould be noted for effective utilization of this manual

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1 Since the thfl described
only informations concaning engine are huetn please
refer to both thi and the DATSUN 30 SEIiVIU MANUAL for complete detaiL

of the car

2 411 the part names in this manllal conform fa both VA TSIJN C30 PARTS CA T4
and only the genuint seroice parts listed in this parts catalog should be used 03

replacement

3 All illustrations and

informations specification contained in this manual are based
on the latest product information available at the time of publication approval

4 It is empha ised that tho who Il thi manual w lhe

rtmi t ontents aCf
ording
to the SER VICE JOUIiNAI is ued by the factory which CIlrrie the late t factory
approved scroidng mdhod

J
5 R ights for alteration in and othen at
tpecification any time are reseroed
 1 1 I l 1 I I

i DATSUN
f 1800
r l I

SECTION EG
SERVICE ENGINE GI
MANUAL GENERAL

MODEL G11

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ENGINE

EXTERNAL VIEW Of ENGINE EG t

MAIN SPECifICATIONS EG 2
RE COMMENDED LUBRICANTS
PETROL AND COOLANT EG 2
UNIT SERIAL NUMBER LOCATION EG 4
PERIODICAL INSPECTION AND
MAINTENANCE EG S
NISSAN MOTOR CO LTD
SPECIAL MAINTENANCE FOR
TOKYO JAPAN EMISSION CONTROL SYSTEM EG 6
 ENGINE GENERAL

EXTERNAL VIEW OF ENGINE

External view of model GIS engine

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Fig EG l Right hand side

EG 2 Left hand ide

Fig
EG l
 ENGINE

MAl N SPECIFICATIONS

Engine model GI8

Number of cylinders in line 4

Valve arrangement ORC

Bore mm in 85 3 346

Stroke mm in 80 3 150

Displacement c c cu in 1 815 110 8

Compression ratio 8 3 1

Maximum power SAE RP at rpm 105 at 5 600

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Maximum torque SAE m
kg ft lb 15 9 115 0
at rpm 3 600

Capacities Oil pan L 3 8

U S qts U K 0 3
qts 4 3

Coolant L 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
quantit
is about 4 4 L 4 7 U S qts 3 9 U K
qts

RECOMMENDED LUBRICANTS
PETROL AND COOLANT

Use the of oil gasoline and coolant

following grades

Temperature Engine oil MSI

Above 320 C 900 F average SAE 3D 10W 30

320 to 00 C 900 to 320 F minimum SAE 20 20W 10W 30

00 to 120 C 320 to 100 F minimum SAE lOW 10W 30

Below 120 C 100 F minimum SAE lOW 10W 30

EG 2
 ENGINE GENERAL

Recommended lubricants

Engine oil Multi purpose

Regular single grade grease

Maker Multi grade
or double grade

Marfak All Purpose

Havoline Motor Oil Grease
Havoline Motor Oil
TAXACO INC
IOW 30 20W 40 lOW 20W 40 30 40 Marfak Multi Purpose
Grease

RPM Special Motor Oil RPM Multi Motive

RPM Supreme Motor Oil
CHEVRON OIL CO
lOW 20W 20 30 40 Grease
IOW 30 20W 40

Marfak All Purpose

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Five Star Motor Oil Five Star Motor Oil Grease
CALTEX
IOW 30 20W 40 lOW 20W 20 30 40 Marfak Multi Purpose
Grease

MobiloillOW
20
Mobiloil Super IOW 40 Arctic
MOBIL Mobil Grease MP
Mobiloil Special lOW 3D A 30

AF 40

Shell Super Motor Oil

IOW 40 Shell X IOO
Retinax A
SHELL
Shell X IOO 20W lOW 20 30 40

lOW 3D 20W 40

E sso Motor Oil E sso Multi Purpose

Esso Extra Motor Oil
ESSO
IOW 30 20W 40 20W 30 lOW 40 Grease

BP Super Viscostatic
BP HD Motor Oil
BP
Motor Oil BP Energrease L2
lOW 20 30 40
British Petroleam
5W 20 IOW 30

Castrolite IOW 30
Castrol 5WHD
Castrol XL 20W 40 Castrolease LM
CASTROL 10WHD 20W 20HD
Castrol Super
30HD 40HD
IOW 40 20W 50

Engine Carburetor Linkage Distributor cam heel

Lubricating points Distribulor Shaft

EG 3
 ENGINE

Nissan long life coolant LL C

This L L C is an ethylene glycol base pro freely transfers heal efficiently and will noi

duct conlaining chemical inhibitors to protect clog the passages in ibe cooling system
the cars cooling against rusting and L L C must not be mixed with other product
sytem
corrosion L L C does not contain any This coolant can be used
glycer through out the seasons

methyl alcohol It will not evapo of the year and

ine ethyl or exchange period is two years or
rate or boil away and can be used with either total running mileage of 40 000 km 24 000

low temperature ibermostats If flows miles

high or

Boiling point Oc oF I

Percent o 9 kg cm2 0 32
Freeze
concen Sea level cooling sys
protection 10 14
tration tern pressure

20 4 I

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106 C 124 C 15 C I

30 I
221 F 255 F F 30 22
5 I
1

I
40 40 I
109 C 127 C 35 C I
50
228 F 261 F 31 F 50 58
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 repealed 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

T Engine model
Fig f 4 f ngine serial and model

number

EG 4
 mZ Q Z m Q m Z m r

nU 0 00 0 0 00 0 0 0 00 00 0 0 0 0
no 0

n 88 00 uf
0 0 0 0

n U 000 0 00 0 00 0 0 0 0 00 00

E ui N
E 88 00 l
1J
0 0 0 0

CALENDR E
E

88 00
N

0
N
0 00 0 0 00 0 0 0 0 0 0 0 00 0 0

MAINTEC
E
0 0 0 0
E
U

MAINTEC nU
E

U
C

O 0 00 0 00 0

0
0 0

0
0 0 0 0 0

0 0

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E
0

0 0
n U MN 0 0

E
0
0 0
E
88 0

AND 0 0 0 0 0 0

INSPECTO ENGIE
shaft
AND necsary arm elctroye flange

POINTS if

up

top
and beel
shaft earn
linkage rot r
COlANT level batery
LIFE of
gali pipe

exhaust
and
point terminals
function cylindel carbueto vco2n1tvroel Change
elctroye mhaenifoaldd
level parts
distrbuo ravity regulator of

LPERIODCAL UBRICATON CHEKING

level of and
water wate LONG color
and 01
fit ng
d i s t r b u o
R

cords function el ment

rotor
engine enginl carbueto diltrbuo
oil oil to

l
s p e c i f
cco ling o ling NIS AN batery staring timng tension stralU
gre c l e a n pan
m o u n t i g s
oil
t r a i n cap f i t n g s v o l
cleau cap batery mot r
t a g e c l e a u f u n c t i o n c h a m b e r
pre
of v e n t i l a o
engm cylinder carbueto belt from engine leak ge filter plugs p l u g s i d l i n g Sup ly
Check Change Lubricate Lubricate Ap ly Check Change Change Check Measure valve igntiol1 leak fuel fuel fuel park spark distrbuo engint filer dirt altern o stare fuel jets conden crank se
Engm Gte tlghtel tighten tIghteu Repla
fan t
oil
air oil
of p u m pair
f l o a
compresin
t
Check
Oil Fluid Re Re Re Replace
Check Adjust Check Check Check Check Check Replact Check Check Check Check Clean Check R e
Check Check Check p l a c t l e an Measure C Check Check o

nU U
0 0 n 0 0

EV RY nU
ID

O
0 0 0 0 0 00 0 0 0 0 0

MAINTEC FREQUNCY E

E
E

E
@@
U
NN

1
0
0
0

0
0 0 0

0 0 0 0
0

M Cl I
 m Z G Zm

S
t
o o o o o o o o o o o o
ES
U O
o o o o

@
o o o o o
ES i
V

EM S
S U
f
O

o
o o o o o

SYSiI PERIODS E

t
U
N
N
o o o o o

E
U ON
o o o o o o o o o o o o o o o

MAINTEC
S

1
0

U o o o o o

CONTRL
i
S

c
So S @ o
o o o o o

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o o o o o
E
S @ OD

N
o o o o o
S

EMISON
E

S
88 o
o o o

valve
sy tem points control t10n5
valve
FOR control breakr vconetis entilao conec
POINTS emison distrbuo
of pomt5
shaft and
rot r carn
wick
elment hose cranklIe
valve
relief check anti
fire

pump valve back nandoz le conetis

IOle
clea1t of of of of of

MAINTEC
with
cable andwear breakr
and
galery and
tenlon
function functlon Cunetou functlOI functiulI
CHEKING distrbuo distrbuo
Up air hOlel hOle t

timing tdling tunc plugs plug

equiped s p a r k
tension fit ng distrbuo to to
e
of

carbRueetopla leaks proper proper proper proper proper

of

leak
of

leakl pump
bel

19nItion engine major spark Replac hIgh for gre

grea for for for for

Engi es
tl for for for for

Check Check Engintl Check Check Check I

Replace Ap ly Ap ly Check Check Check Check Check Check Check Check Check
0
6Ii
u i
I

lh

SPECIAL MAINTEC FREQUNCY

l
E m o
E

EV RY z U Ln
o o o o

t
E ID

U o

l
E NN
o o o o o o o o o o o o
ci

S
E
o
U 0

1 Cl
t I
 ENGINE GENERAL

advisable however to check the tension re

AFTER FIRST 1 000 KM
gularly so that the need for adjustment is not
600 MILES
overlooked With the engine switched off and
Changing Engine Oil
the bonnet up push the belt gently downwards
Second replacement at 3 000 km You should be able to depress it about 10 mm

2 000 miles 1 2 in If the fan belt has become slack

Third replacement at 6 000 km through wear loosen the fixing and adjusting
4 000 miles bolts and move the whole of tbe alt rnator to

Fourth replacement at 10 000 km ward or away lhe engine

from This will take

6 000 miles up lhe slack Tighten the bolts again and

000 km recheck to make sure the belt has the required

Thereafter every 5
3 000 miles free play If you tighten il too much itwill
wear rapidly and also overload the water pump
Draining is best done after a good run when
will flow and alternator bearings
the oil being thoroughly warm readily
and freely
Place a large bowl or other shallow contain
EVERY 10 000 KM
under the Then the oil pan
er engine remove

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6 000 MILES
drain Do this carefully the oil will
plug as

be hot and it will spurt out with some force

water
After completely draining the dirty oil off se
Changing cooling
Scale or sediment accumulated in water
curely replace the oil drain plug and finally
jacket or radiator is obstructive to heat radia
refill the engine in the usual way up to the F
tion The system should be thoroughly flushed
mark on the dipstick Make sure the car is on
surface while and the out opening the two drain plugs one at the
a level draining filling
bottom of the radiator and oiber at the left side
engine
of the cylinder block until clean water comes
Oil pan capacity 3 8L 4 0 U S qts
out
including oil filter 4L 7 U S
4 qtsl
Always clean soft water for filling the
use

radiator Immediately ibe cold weaiber ar

AFTER FIRST 3 000 KM rives the coollng system should be protected
2 OOOMILES against frost by a good anti freeze solution such
as a NISSAN LONG LIFE COOLANT To allow

Replacing oil filter when

for expansion when hot the level cold
Second and thereafter every 10 000 km should be just visible at ibe bottom of the filler
6 000 miles neck Do not overfill the This coolant
system
L L C should be changed every 40 DUO km
Remove the body of the oil fil ter alid the
24 000 miles
element can be taken off A t the same time

replace the body gasket and center shaft gasket

The tightening torque of center shaft is 2 8 to EVERY 40 000 KM

3 2 20 to 23 ftlb 24000 MILES
kg m

Replacing air cleaner element

wet paper type
The air cleaner is of a wet paper type ele
ment viscous As this element has been
AFTER FIRST 6 000 KM type
performed special treatment there is no need
4000 MILES
to clean the element for normal driving condition
until replaced by 40 000 km
Fan belt tension it is new one at

24 000 miles This element will lock so dirty

Second and thereafter every 5 000 km to be
as required dust but never try to clean
3 000 miles
since there is no fear to reduce the cleaning
Care must be taken not 10
Incidentally we can it ibe fan belt but also action injure filter
it drives the water pump and alternator It is element

EG 7
 ENGINE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or No SUBJECT
DATE PAGE
BULLETIN No

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EG 8
 l DATSUN t
f

1800 t
L SECTION ET
SERVICE ENGINE
TUNE UP
MANUAL
MODEL G18

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ENGINE

NISSAN MOTOR CO LTD ENGINE TUNE UP n 1

TROUBLE DIAGNOSES ANO CORRECTIONS n 6

TOKYO JAPAN
 ENGINE TUNE UP

ENGINE TUNE UP

CONTENTS

GENERAL DESCRIPTION ET 1 Valve clearance adjustment ETA

BASIC PROCEDURE ET 1 ADDITIONAL PROCEDURE ETA

Connect tune up equipment ET 1 Compression pressure test each

Battery inspection ET 2 cylinder ET 5

Spark plugs remove and Clean and inspect high tension wires

recondition ET 2 distributor cap and rotor ET 5

Clean and adjust distributor o istribu tor I ubricate ET5

intake manifold and
points ET 2 Tighten
Set ignition timing ET2 carburetor attaching nuts ET 5
I nspection of oi I fi Iter
Inspection of fan belt ET 3 ET 5

oil Inspection of air cleaner

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Inspection of engine ET 3 ET 5

Inspection of fuel strainer ET 6

Carburetor overhaul and
of cooling system
adjustment ETA Inspection ET 6

2 Timing light
GENERAL DESCRIPTION
1 Positive lead to positive battery terminal
A minor tune and test consists of testing
battery cleaning regapping or replacing if 2 Negative lead to ground
required spark plugs and distributor points
3 Trigger lead to number 1 spark plug
adjusting distributor dwell angle ignition tim
carburetor idle mixture and hot idle
ing
3 Tachometer
speed
The complete or major tune and test pro Positive lead to distributor side of coil
1
cedure consists of these basic items plus other
compression elec rical and carbu
2 Negative lead to ground
ignition
retor checks and a final road test to ensure
4 Dwell meter
continued trouble free operation

1 Positive lead to distributor side of coil

BASIC PROCEDURE 2 Negative lead to ground

Connect tune up equipment

Follow manufacturer recommendations for
the use of testing equipment Fig ET 1 shows

a basic schematic for instrumentation

will apply to many types of test equipment and
which
r fl
Timing light
may be used as a rough guide if equipment ij
manufacturer s instructions are not available

Connections shown in figure ET 1 are made Spark plugs Trigger lead

Dwell meter Tachometer
as follows

1 Voltmeter

1 Positive lead to resistor side of coil

Fig ET 1 Simple chematic of tuneup

2 Negative lead to ground instrumentation

ET 1
 ENGINE

Battery inspection Clean and adjust distributor points

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

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ET 3 Checking di5tributor point gap
Fig

Remove distributor and

cap inspect point
for excessive burning or pitting Replace
points if necessary Use a point file to clean

contaci area and remove scale from points

Fig ET 2 ln peeting battery Filing is for cleaning purposes only Do not

attempt to
remove all roughness Apply a trace
ofbearing lubricant to the breaker cam
Clean top of battery and terminals with a
Adjusi
distributor dwell angle to 49 to 55 degrees and
solution of baking soda and water Rinse off
point gap O 45 to O 55 mm 0 0177 to O 0217
and dry with compressed air of battery
Top in
must be clean to prevent current leakage be
tween terminals and from positive terminal to
hold down clamp Set ignition timing
In addition to current leakage prolonged With distributor vacuum line disconnected
accumulation of acid and dirt ontop of battery and car operating at normal idle speed or below

may cause blistering of the material covering set ignition timing

connector straps After tightening terminals
coat them with petrolatum to protect them from

corrosion

Spark plugs remove and recondition

See that correct spark used
plugs are

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 b O 031
in When reinstalled
plugs are use new

gaskets and tighten plugs to 3 0 to 4 0 kg m

22 0 to 30 0 ft lb ET 4
torque Fig Checking ignition timing check

ET
Z
 0
r j 8 TlK
T Tl

SEE FIt
S

ENGINE UP
TUNE

The timing can be observed by the station 1 Check if the engine oil has been deierioraIed
at the front cover and the by invading cooling water or gasoline Drain
ary poinier markings
on the crankshaft pulley with a device called a and refill the oil if necessary

stroboscopic light also referred to as a timing

light as shown in Figure ET 4

Note a A milky oil indicates the presence of cooling
Ignition timing is 80 BTDC 600 rpm
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 1
lev

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Fig ET 5 Timing mark

Inspection of fan belt

Fig ET 7 Checking oil level

Carburetor overhaul and adjustment

Fig ET 6 Checking fan belt fen ion

1 Check for a cracked V belt

or damaged
Replace if defective

2 Adjust the belt tension if necessary

Permissible slackness of fan belt 8 to 12 mm

0 315 to 0 473 in Belt tension measuring

point Between fan pulley and alternator pulley

Inspection of engine oil

Oil capacity of engine

3 8 L l 0 U S gal
Oil pan capacity
0 8 U K gal
Engine dried 5 0 L 13 U S gal Fig ET B Adjruting idle rpm
1 1 U K gal
ET 3

k
 ENGINE

Overhaul ADDITIONAL PROCEDURE

The detailed informaiion for carburetor For
diagnoses purposes it is sometimes
is outlined in section
overhauling EF ENGINE
necessary to proceed further than the basic
FUEL SYSTEM tune up procedure The following steps plus a
road test are included in a complete or major
Adjuslment tune and test procedure

Adjust carburetor to get best idling engine Compression pressure test

speed 600 rpm each cylinder

Note If this test is to be performed it should be done

when plugs are removed for service during basic
Valve clearance adjustment tuneup procedure
This adjustment is impossible when the
engine is in operation Follow the procedure Unless checking for worn rings or for the
described below cause of low speed miss compression check

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should not be necessary
1 Standard adjustment is made while the engine Test compression with engine warm all
is cold Adjust to the following clearances spark plugs removed and throttle and choke

open No cylinder should be less than 80 of

When cold Both intake and exhaust 0 2 mm
the highest cylinder Excessive variaiion be
0 0079 in
tween cylinders accompanied by low speed
When hot Both intake and exhaust O 28 mm
missing of the cylinder or cylinders which are
reference 0 011 in
low usually indicaies a valve not properly
seaiing of a broken piston ring Low pressures
2 Locate the top dead center of
compression even though uniform may indicate worn rings
each cylinder in turn Loosen the valve screw This may be accompanied by excessive oil con
lock nut and turn the adjusting screw to set
sumption
valve clearance to the specified value
Tighten the lock nut and recheck clearance Compression pressure
11 3 kg cm 156 8 in to
Follow the same manner for the remaining oz

12 3 kg cm 170 8 in oz at 350 rpm

cylinders
To rotaie the crankshaft of the engine
manually tighten tile fan belt and pull Clean and inspect high tension
wires distributor cap and rotor
Inspection of timing chain
Note This operation is to be performed while checking
Tension of the timing chain is adjusted by distributor points during the basic tuneup
turning the adjusting screw aitached to the procedure Inspect distributor cap for cracks
right hand side of the chain cover by observing and flash over

following items at running engine

1 External surfaces of all parts of secondary
Chain noise is not high ai idling rpm
2 system must be cleaned to reduce possibility of
Chain noise is no high at 2 000 rpm
voltage loss All wires should be removed from
After adjusting the tensioner lock it with lock distributor cap and coil so that terminals can
nut securely be inspected and cleaned Burned or corroded
Tile wiEith ael9SS flats of the lock uut 10 l
tU g uJit
i it lA thitl WiU b llul
wt lt flilt
mm 2 16 in same as thai of spark pings seaied which caused arcing between end of
Use the spark plug wrench wire and terminal When replacing wires in
After adjustment at 10 000 km 6 000 miles terminal be sure they are fully seated before
when the initial period ends additional adjusl rubber nipple down
pushing over tower Check
ment is not necessary until 100 000 km 60 000 distributor rotor for damage and distributor
miles is reached can for cracks

ET 4
 ENGINE TUNE UP

or for 40 000 km 24 000 miles running under

Di s tributor Iubrica te
normal conditions
Wipe a very small amount of special cam

and ball bearing lubricant on cam lobes when

servicing

Tighten intake manifold and

carburetor attaching nuts
Intake manifold attaching bolts and nuts on

be to
engines should tightened proper iorque

Carburetor attaching nuts should be tightened

securely Leaks at these areas can cause

rough idle surging deceleration popping or

deceleration whistle

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Inspection of oil filter

1 Check for oil leaks at oil filter body gasket Fig ET 10 Removing air cleaner element
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 Inspection of fuel strainer
replace each gaskets and tighten each bolts
This engine uses a cartridge type strainer
under the prescribed torque 2 8 to 3 2 kg m
so if the malfunction is detected replace as an
3 to 23 2 lb ft
20 assembly

2 Replace oil filter element each 10 000 km

6 000 miles running

stroiner
Fig ET 11 Removing fuel

Inspection of cooling system

ET 9 Inspection of radiator
Fig Removing oil filter cap

Apply reference pressure 0 9 kg cm2 12 7

1l in2 to the radiator cap and the reservoir

Inspection of air cleaner
tank cap by means ofcap tester to see if it is
a

Viscous type element makes cleaning un satisfactory Replace the cap assembly if
necessary until the engine used for two years necessary

ET 5
 ENGINE

Cooling syslem pressure test

With radiator cap removed apply reference

pressure kg cm2
0 9 12 7Ib in2 to the
cooling system by means of a tester to check
for leakes at system
component

Fig ET 12 Radiator cap te t

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TROUBLE DIAGNOSES AND CORRECTIONS

Troubles Possible causes Rem ed ies

CANNOT CRANK ENGINE Improper grade oil Replace with proper grade
OR SLOW CRANKING oil

Discharged battery Charge battery

Defective battery Replace

Loosen fan bel t Adjust

Trouble in charge system Inspect charge system

Wiring connection trouble in starting Correct

circuit

Defective starter switch Repair or replace

Defective starter moior Repair or replace

Trouble shooting procedure on starting circuit

Switch the moior with

on starting light put on

When light goes off or dims considerably

a Check battery

b Check connection and cable

c Check starter moior

a Cbeck wiring connection between battery and

starter moior

b Check starter switch

c Check starter motor

ET 6
 ENGINE TUNE UP

ENGINE WILL CRANK NORMALLY BUT WILL NOT START

In this case trouble cause exist but in many causes ignition system or fuel
following may

system is in trouble

Ignition system in trouble

Fuel system in trouble
Valve mechanism does not worl 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 a Check spark plug

b Check ignition timing

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c Check fuel system
d Check cylinder compression

No spark occurs Check the current flow

in primary circuit

Very high current Inspect primary circuit

for short
Check breaker point
operation

Low or no current Check for loose termi

nal or disconnection in

prirn3 ry circuit
Check for burned points

Ignition system in trouble Distributor point burned Repair or replace

Improper point gap Adjust

Defective condenser Replace

Rotor cap and rotor leak Replace

Defective spark plug Clean adjust plug gap

or replace

Improper ignition timing Adjust

Defective ignition coil Replace

Disconnection of high tens ion cable Replace

Loose connection or disconnection in Repair or replace

circuit
primary

Fuel system in trouble Lack of fuel Supply

Dirty fuel strainer Clean or replace

Dirty or clogged fuel pipe Clean

Fuel pump will not work properly Repair or replace

ET 7
 ENGINE

Adjustment of f10allevel no good Correct

Improper idling Adjusl

Dirty or clogged carburetor Disassemble and clean

C logged breather Clean

pipe

Low Incorrect
compression spark plug Tighten to normal torque
tighlening defective gasket replace gasket

Improper grade engine oil or viscosity Replace with proper

droppi ng grade oil

Incorrect valve clearance Adjust

Compression leak from valve seat Remove cylinder head

and lap the valves

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Stick valve stem Correct or replace valve

Weak or defective valve springs Replace valve springs

Compress ion leak at cylinder head gasket Replace gasket

Piston ring sticking or defective Replace piston rings

Worn pis ton ring or cylinder Overhaul engine

Trouble shooting procedure

Pour the engine oil from plug hole
and then measure cylinder compres
sion

Compression increased Trouble in cylinder or

piston ring

Compression unchanged Compression leak from

valve cylinder head or
head gasket

IMPROPER ENGINE
IDLING

Fuel system in trouble Clogged carburetor jets Clean replace

or damaged or

Incorrecl idle adjustment Adjust

Clogged air cleaner Replace element

Defective gaskets of manifolds or Replace gasket

carburetor insulator

Adjustment of float level no good Adjus t

LUW

Others Incorrect valve clearance Adjust

low revolution Adjust

Extremely

ET 8
 ENGINE TUNE UP

ENGINE POWER NOT UP

TO NORMAL
Low compression Previously mentioned

Ignition system in trouble Incorrect ignition timing Adjust

Defective spark plugs Clean adjust or replace

plugs

Defective distribuior points Dress or replace points

also check condenser

Incorrect octane seLector Adjust octane selector

setting

Fuel system in trouble Malfunction of choke system Adjust

Clogged fuel pipe Clean

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clogged fuel strainer Replace
Dirly or

Fuel pump will nol work properly Repair or repLace

C logged carburetor jets Disassemble and clean

Air intake system in Clogged air cleaner Replace element

trouble
Air inhaling from manifold gasket or Replace gasket
carburetor gasket

Overheating Insufficient coolant Replenish

Loosen fan belt Adjust fan belt

Worn or defective fan belt Replace

Defective thermostat Replace

Defective water pump Replace

Clogged or leaky radiator Flush repair or replace

Defective radiator filler cap Replace

Air mixing into cooling system Retighten each part of
cooling system

Improper grade engine oil Replace with proper

grade oil

Incorrect ignition timing Adjust

Defective carburetor lean mixture Overhaul carbureior

Overcooling Defective thermostat Replace

Others Low octane fuel Replace with specified

octane fuel

tire pressure Make specified pressure

Improper

ET 9
 ENGINE

Dragging brake Adjust

Clutch slipping Adjust

NOISY ENGINE

Car knocking to engine Use right gear in driv

Overloading
ing

Carbon knocking Disassemble cylinder

head and remove

carbon

Timing knocking Adjust ignition timing

Fuel knocking Use specified octane

fuel

Preignition misusing of spark ping Use specified spark

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plug

Mechanical knocking

Crankshaft bearing This strong dull noise increases when the This is caused by the
knocking engine is accelerated To locate the worn or damaged bear
place cause a misfire on each cylinder ings or unevenly worn
If the noise stops by the misfire this cyl crankshaft Renew the
inder generates the noise bearings and adjust or

change the crankshaft

Check the lubrication

system

Connecting rod bear This is a little higher pitched noise than Same as the case of

ing knocking the crankshaft knocking and also in crankshaft bearings

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

Piston and cylinder When hear

you an overlapping metalic This may cause an ab
noise noise which Increases its magnitude with normal wearing of the
the revolution of the engine and which cylinder and lower
decreases the in
as engine is warmed up compression which
this noise is caused by the piston and turn will cause a lower

cylinder To locate the place cause a out put power and ex

misfire on each cylinder cessive consumption of

oil

Overhaul the engine

Piston pin noise This noise is heard at each highest and This may cause a wear

lowest dead end of the piston To locate on the piston pin or

the place cause a misfire on each cyl piston pin hole

inder
Renew the piston and

piston pin assembly

ET IO
 ENGINE TUNE UP

Water pump noise This noise may be caused by the worn or Replace the water pump

by the with a new one

damaged bearings or uneven sur

face of sliding parts

of the valve Adjust

Others An improper adjustment
clearance

Noise of the Adjust the tension of

timing chain
the chain

An excessive end play on the crankshaft Dismantle the engine

and renew the main
clutch slightly
Remarks Disengage the
bearing bush
and this noise will stop

Wear on the clutch pilot bush Renew the bush and

adjust the drive shaft

Remarks This noise will be heard when

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the clutch is disengaged

ABNORMAL COMBUSTION

back fire after fire

run on etc

tim
Improper ignition timing Improper ignition timing Adjust the ignition
ing

Use
Improper heat range of the spark plugs specified spark
plugs

Fuel system in trouble Damaged carburetor or manifold gasket Replace Ibem with new

back fire after fire parts

Defective carburetor jet Dismantle the carbure

tor and check it

Improper function of the float Adjust the level and

check the needle valve

Uneven idling Adjust

Defective cylinder head Improperly adjusted valve clearance Adjust it

etc
Excess carbon in Ibe combustion Remove the head and

chamber get rid of the carbon

Damaged valve spring back fire after Replace it with a new

fire one

EXCESSIVE OIL
CONSUMPTION

Oil leakage Loose oil drain plug Tighten it

oil pan gasket Renew Ibe gasket or

Loose or damaged
tighten it
chain gasket Renew Ibe
Loose or damaged cover gasket or

tighten it

ET ll
 ENGINE

Defective oil seal in front and rear of Renew the oil seal
the crankshaft

Loose or damaged locker cover gasket Renew the gasket or

tighten it but not too

much

of oil filter Renew the and

Improper tightening gasket
tighten it with the pro

per torque

Renew the oil

Loose or damaged oil pressure switch pressure
switch it
or tighten

Excessive oil consumption Cylinder and piston wear Overhaul the cylinder
and renew the piston
location of the ring split or Remount the piston
Improper
reversed assembly of it rings

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seizure of Renew the rings
Damage or rings

Repair or renew the

piston and cylinder

Wear of Renew the piston and

piston ring groove and rings
piston ring

of valve oil seal lip Replace the seal lip

Fatigue
with a new one

Wear of valve stem Renew the valve or the

guide

Use the designated oil

Others In adequate quality of engine oil

Previously mentioned
Engine overheat

POOR FUEL ECONOMY

See the explanation

of the powet dectease

Others Exceeding idling revolution Adjust it to the desig

nated rpm

Adjust it
Defective acceleration recovery

Repair or tighten the

Fuel leakage
connection of fuel

pipes

TROUBLE IN OTHER
FUNCTIONS

Use the designated oil

Decreased oil pressure Inadequate oil quality

Overheat Previously mentioned

Defective function of oil pump regulator Dismantle the oil pump

and it
valve repair or renew

ET l2
 ENGINE TUNE UP

Functional deterioration of oil pump Repair or replace it

with new one

Blocked oil filter Renew it

Increased clearance in various Dismantle and replace

sliding
parts the worn parts with new
ones

Blocked oil strainer Clean it

Trouble in the oil gauge pressure switch Replace it with a new

one

Excessive the Oil pressure decrease mentioned

wearon Previously
sliding parts

Defective quality or contamination of oil Exchange the oil witI1

proper one and change

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the element

Defective air cleaner Change the element

Overheat or overcoal Previously mentioned

Improper fuel mixture Check the fuel sys tem

Principally to cylinder walls

Seizure of sliding parts Decrease of oil pressure Previously mentioned

Too small clearances Reassemble with the

designated clearances

Overheat Previously mentioned

Improper fuel mixture Check the fuel system

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

ET 13
 ENGINE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

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ET 14
 i DATSUN
1800
I r
I
t SECTION EM
SE RYICE ENGINE
MECHANICAL
MANUAL
MODEL G11

II

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ENGINE

GENERAL DESCRIPTION y

EM 1

ENGINE DISASSEMBLY EM 5
INSPECTION AND REPAIR EM B

ENGINE ASSEMBLY EM 22
NISSAN MOTOR CO LTD SERVICE DATA AND SPECIFICATIONS EM 31

TOKYO JAPAN TROUBLE DIAGNOSES AND CORRECTIONS EM 36

 ENGINE MECHANICAL

GENERAL DESCRIPTION

CONTENTS

G18 ENGINE EM l CYLINDER HEAD EM 3

CYLINDER BLOCK EM 2 CAMSHAFT EM 3

CRANKSHAFT EM 2 VALVES AND VALVE ROCKER ARMS EM 3

PISTONS AND CONNECTING RODS EM 2 CAMSHAFT DRIVE SYSTEM 4

EM

MANIFOLDS 4
EM

G 18 ENGINE

The G 18 engine is a short stroke bore x aluminum alloy cylinder head which has cross

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stroke 85 x 80 mm 3 346 x 3 150 in J power flow ports and a V
shaped valve layout a single
house with 1 815 c c 110 8 c 1 displacement overhead camshaft and five journal crankshaft
maximum It is sufficiently durable at high continuous
and its output is 105HP at 5 600 rpm
SAE From low to high speeds this engine speeds and maintenance and inspection opera
exhibits excellement performance made possible tions are easily performed Gasoline with a

by adoption of new mechanisms such as an standard octane value of 88 is used

fig EM Sectional view of G 18 engine

EM l
 ENGINE

CYLINDER BLOCK on journal 112 Oil sealing at the front end is

accomplished by a lip type oil seal made of
Thecylinder block is a special monoblock
highly durable acryl rubber and a flinger and
casting with deep skirts and five bearing at the rear end by means of a graphite jute oil
support system Rigidity is high and resist
seal
ance to wear excellent Coolant is forced
through the space between cylinders to maintain
PISTONS AND
uniform cylinder block temperature The
CONNECTING RODS
passage for oil from the cylinder head is located
at the rear portion 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 A
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

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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
Fig EM 2 Cylinder block
The connecting rods are made of forged
carbon steel and the I cross section provides
ample strength To insure dur
good balancing
CRANKSHAFT ing operation weight adjusting bosses are

The crankshaft is a carbon steel forging and located at both the large and small ends

is provided with five beariug journals and four Bearings are made of three layer kelmet

balancing weights As a result it possesses metal and bushings of lead bronze with steel
high rigidity and there is little vibration The backing
surfaces of the main journals are hardened by

high frequency induction improving the resist

to
ance wear Highly durable threelayer
kelmet metal is used for main bearings The
thrust bearings made of aluminum are located

o
tl

Fig EM 3 Crankshaft Fig EM 4 futon and connecting rod

EM 2
 ENGINE MECHANICAL

The camshaft is a special alloy casting

CYLINDER HEAD
which has excellent resistance to wear Lobes
The die cast aluminum alloy cylinder head
are chill hardened and lubrite processing ap
produces good cooling effects and results in
plied to obtain good operation between the
lightweight and excellent strength qualities and rocker arm and camshaft Five journals are
smooth combustion chamber surfaces
employed and they receive the thrust by the
Valve layout is V shaped and symmetrical Bolts
front flange and cylinder head groove
for intake and exhaust Cross flow ports are
with left hand threads are used to attach a
used to obtain good intake and exhaust efficien
sprocket and the distributor drive gear to the
cy Valve seats are cast into the cylinder head
end of the camshaft
and special iron is used for intake valve seats
and 1113 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
VALVES AND VALVE
tos which contains a steel net and is protected
ROCKER ARMS

by a stainless steel grommet giving excellent

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A rocker arm shaft is located on each side
gas sealing effects 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
to wear a high engine
improving the resistance
temperature and speed A 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 valve

oil seal ring located at the top of the valve guide

blocks the downflow of oil The rocker arms

made fromspecial forged steel To im

are

prove resistance to wear tOughtelite processing

is applied to cam contact surfaces after

carburizing heat treatment Lubrication is

Fig EM S Cylinder head accomplished by oil ejected from the jet in the
stem of the rocker arm

CAMSHAFT

rf
rf1y

f
A o

7 i
O
o
I
1
1
i
ff
f

Fig EM 6 Camshaft Fig EM Rocker arm

EM 3
 ENGINE

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
e nlJl 0 CJ intake manifold heating this portion and is
fJllll0
II 0 returned to the water pump

o The exhaust manifold is made of cast iron

o No I No 4 and No 2 No 3 cylinders are

grouped together The semi duel system

I which combines exhaust gas flow at the point of
exhaust pipe connection produces good exhaust

ing efficiency
An oiled sheet is used for the intake gasket
and steel filled asbestos for the exhaust
Fig EM 8 Valve gasket

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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 oil

jet at the top part of the
crank sprocket provides active lubrication
holding chain elongation and sprocket wear to a
minimum

Fig EM 1O Intake manifold

oe
lie

Fig EM 9 Camshaft drive system

Fig EM ll Exhaust manifold
EM 4
 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 EM 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 airhorn to avoid any infiltration of

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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 EM 12 the

Fig Placing engine on

engine stand
4 Oil pan Check for excessive rust
6 Remove the clutch

7 Remove the exhaust manifold and heat baffle

plate

DISASSEMBL Y
engine with transmission is placed on
The
theengine 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

Fig EM 13 Removing exhaust wnifold
Install the attachment STa7200G18 to
4 engine 8 Remove the fan blades At the same time
the cylinder block
remove the water pump pulley and fan belt

5 Place the engine on the engine stand ST371 9 Remove the rocker cover hose manifold

00000 heat hose and bypass hoses

EM 5
 ENGINE

the bracket and oil take off the

10 Remove generator removing the distributor drive gear
filter sprocket from the camshaft

11 Remove the breather assembly by extract Note Mounting bolts have left hand threads
from above The breather is
Ing upward
fitted to the guide with O ring pressed into the 16 Remove the cylinder head as an assembly
cylinder block 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

ff4lII if
1 W IItf r

if

f
t y
t 0
Z

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1Jtl

I
Fig EM 14 Breather a
embly v
I
r I

t
12 Remove the water pump The generator
is removed at the same time
adjusting arm

Fig EM 16 Removing cylinder head

13 Flatten the lock washer and unscrew the
nut and then pull out the crank pulley 17 Turn the engine upside down and remove

the oil pan

Note When the crank pulley cannot be easily removed
use 8 puller ST44820llOO
18 Remove the chain cover and remove the oil
Do not fit the puller so that it hooks in the
V lIroove flinger

14 Remove the rocker cover 19 Remove the nut which holds the oil pump

sprocket in place Pullout this sprocket with

15 Remove the rubber plug located on the
the chain in place on the crankshaft oil pump
front portion of the cylinder head Straighten
sprocket
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 IS Removing camshaft sprocket EM 17

Fig Removing oil pump sprocket

EM 6
 ENGINE MECHANICAL

20 Remove the oil pump without together with Disassembly of piston and
removing the strainer connecting rod assembly

Remove the
Note Two of the oil pump mounting bolt are pipe 1 piston rings
gu ides Remove the
2 piston pin clips

3 Pull out the piston pin

21 Remove the timing chain

22 Remove the crankshaft sprocket

23 Remove the chain tensioner and chain stop

24 Remove and connecting rod as

piston
semblies

Note the parts for cylinder arrangement to

Keep
of confusion when re
avoid the possibility

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installing

Fig EM I9 Removing puton pin

Hest thepiston 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 the camshaft rocker arm shafts

and rocker arm assemblies from the cylinder

head by removing cam bracket clamping nuts

Fig EM 18 Removing puton assembly

Note Disused bolts should be inserted in the No 1

and No 5 bracket holes since the cam bracket

25 Remove the flywheel
will fall from the rocker ann shaft when it is

26 Remove bearing caps removed

2 Remove the camshaft

Note Do not hurt or damage the pipe guides since
positioning is accomplished by them
3 Remove the cotters by using the special tool
and disassemble valves
ST47450000
27 Remove the crankshaft and detach the main springs and retainers

bearings

Note Make sure that bearings are grouped to preserve Note Make sure that disassemble parts are grouped
the original order together to preserve the original order

EM 7
 ENGINE

EM 20 rocker
Fig Removing assembty Fig EM 21 Removing valve pring

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INSPECTION AND REPAIR

CONTENTS

PREPARATION FOR INSPECTION EM B Boring of cylinder EM 14

CYLINDER HEAD AND VALVES EM B PISTON PISTON PIN AND PISTON RING EM 15
Checking head mating face EM B CONNECTING ROD EM 17
Valve assembly EM 9 CRANKSHAFT EM 17
Valve springs EM 9 BUSHING AND BEARINGS EM 19
Rocker arin and valve rocker pivot EM l0 Measurement of main bearing
Valve guide EM l0 clearance EM 19
Valve seat insert EM 12 Measurement of connecting rod
CAMSHAFT AND CAMSHAFT BEARINGS EM 12 bearing clearance EM 19
Camshaft bearing clearance check EM 12 Fitting bearings EM 20
Valve timing check EM 13 MISCELLANEOUS COMPONENTS EM 21
Camshaft alignment EM 13 Crankshaft sprocket camshaft
check
CYLINDER BLOCK EM 14 sprocket EM 21
How to measure cylinder bore EM 14 Chain tensioner and chain guide EM 21
Flywheel EM 21

PREPARATION FOR INSPECTION 4 Use every caustion to secure proper as

sembly
1 Check the cylinder head and the cylinder
block for traces of water leaks before cleaning

CYLINDER HEAD AND VALVES

2 Wash all the parts to clean them completely
of oil strains carbon deposits fur and sealing
Checking head mating face
material
1 Make a visual check for cracks and flaws

3 Ascertain if all the oil holes are clear by 2 Measure the surface of the cylinder head on

air into them the cylinder block side for warping If it

blowing is

EM 8
 ENGINE MECHANICAL

found to be beyond the limit designated below

regrind the affected surface with a surface lnab

grinder 99
t

o
o 3JI 0 2
1099
151
O 1
us 4
116 4

ull
Ext
8
f9

L 0 5
o
015
llo

11S
2O 2

tO 1
7
4
1I7 2

Fig EM 24 Intake and exhaust valve

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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

Standard Maximum

Head sur Less than 0 03 mm 0 1 mm

face flatness 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 2S Valve grinder

Note When the valve head has been reduced to

05 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

Fig EM 23 Checking valve stem diameter

EM 9
 ENGINE

Outer Inner

42 5 mm 41 4 mm
Free length 1 630 in
1 673 in

37 0 mm at 19 4 1 0 kg 34 0 mm at 10 8 0 5 kg
Valve closed
1 1 lb
1 457 in at 42 8 2 2 lb 1 339 in at 23 8

29 0 mm at 47 6 2 4 kg 26 0 mm at 22 5 1 1 kg
Valve open
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

48 o
CDll
1

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CIt 0
C 1 16 7 Q
00
Q

Q
N

Fig EM 27 Guide intake over size

CDll ci
60
EM 26 valve
Fig Checking spring

Rocker arm and valve rocker

pivot
Check the valve rocker adjusting screws and
the cam contact for damage or wear If defects
Fig EM 28 Guide exhaust aver size
are found replace them

Intake valve Exhaust valve

Valve guides 0 025 0 055 0 04 0 077

Measure the clearance between the valve Stem to guide mm mm

and the valve stem If the clearance clearance 0 0010 0 0016

guide
exceed the limit the worn o 0022 in o 0030 in
designated replace
parts or both valves and valve guide In this
Max tolerance
it is 0 1 mm 0 1 mm
case essential to determine it such a
of above
clearance has been caused by a worn or bent 0 0039 in 0 0039 in
clearance
valve stem or by a worn valve guides

EM lO
 ENGINE MECHANICAL

Determining clearance

Precise measurement of clearance between

the valve stem and the valve 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

in valve
Inspect telescope hole gauge guide
Subtract the
bore measuring at center
diameter from
highest reading of valve stem
valve guide bore measured to obtain its clear
ance from the two center diameter to obtain
valve to valve guide clearance As an emer

gency expendient a valve is pushed in the valve

to the left and the right at
guide and moved
which point if its tip deflects about 0 2 mm
it will be known that the Fig FM 30 Fitting valve guide
0 0079 in or more

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clearance between the stem and the guide
exceeds the maxtmum limit of O 1 mm 0 0039 hole at
2 Ream cylinder head side guide room

in set ST49710000
temperature using reamer

Note The valve should be moved in parallel with

the rocker arm Generally a large amount
02 mm
of wear occurs in this direction
Standard 0 0079 in

over siz e
Replacement of valve guide
14 0 14 2
A valve guide found defective must be re
14 018 mm 14 218
Cylinder head mm

placed in the following manner

valve hole 0 551 0 559
guide
o 552 in o 560 in
of a press
1 Take out the old guide by means

set ST49730000 under

and valve guide replacer
This job may be carried
a 2 ton pressure

out at room temperatures but with better effect

3 Press the new valve guide into the guide hole
at higher temperature
witb care so that it will fit smoothly after heat
the cyiinder head to temperature of about
a

800 C 176 F using valve guide replacer

The valve guides of 0 2 mm 0 0079 in

oversize diameter are available for service

Interference fit of o 040 0 069 mm

valve guide to 0 0016

valve guide hole o 0027 in

4 Ream the bore of the valve guide pressed in

fig f M 29 Rf valve guid using a valve guide reamer set

ofJiflg

EM ll
 ENGINE

wide scrape intake side by 150 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
ping

Exhaust

a 1

EM 31 valve
316
8
Fig Reaming guide b 3
e 346
8

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Valve guide reamer set ST497l0000 c

Reaming bore 8 000 to 8 015 mm

0 3150 to 0 3156 in
Fig EM 33 Dimension for seat correction
5 Correct the valve seat surface with the new

valve guide as the axis Note As the valve seat inserts of this engine are

united into cylinder head by casting replace

Valve seat insert ment of the valve seat cannot be done

Check the valve seat inserts for any evi

dence of pitting at valve contact surface and CAMSHAFT AND CAMSHAFT

valve if the valve
reseat seat inserts seat BEARINGS
insert is worn out excessively
Camshaft bearing clearance check
Valve seat correction
Check the clearance by measuring the dif
In case of some deformation of pitching are ference of the camshaft bearing inner diameter
found at the valve contacting face of valve seat and camshaft journal outer diameter or by using
correct the valve seat by a valve seat cutter plastigage
ST49720000 If the wear outruns the limit replace as

Firstly scrape the seat by 450 cutter after the cylinder head assembly
that if the width of the contacting face is too Tightening torque 0 9 to 1 4 kg m

6 5 to 10 1 ft lb

Standard Wear limit

O 025
Clearance
0 075 mm 0 1 mm

0 0010 0 0039 in
o 0030 in

37 5

Camshaft 37 525 mm
bearing
inner diameter 1 476

1 477 in

37 45

Camshaft journal 37 475 mm

outer diameter 1 474

Fig EM 32 Correcting valve seat 1 475 in

EM 12
 ENGINE MECHANICAL

Valve timing check

If the camshaft shown no apparent damage

althougr some valve operation troubles have

been detected 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

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Fig EM 3S Checking camshaft bend

Valve rocker

Check the valve rocker for cracks cam

between rocker
contacting surface clearance
shaft and etc
EM 34 Valve Replace if same cracks are found
Fig timing dingrom
If wear or nibble is found at cam contacting
surface the valve rocker In this
replace
b

I I I case check cam heels of camshaft at the same

2 0 250 58
GI8 time Slight damages at cam contacting surface
of the valve rocker and cam heel can be cor
Unit degrees
rected by oil stone
In case of clearance of rocker shaft and
Camshaft alignment check rocker bushings is excessive replace the worn

1 CheCK the camshaft camshaft journal and part

cam surface for bend wear or damage If the
defects are beyond the limits replace the
affected parts
Standard Wear limit
2 Bend values expressed in terms of half
are

values of the readings obtained when the cam

Clearance of 0 016
shaft is given a turn with a dial gauge applied
rocker shaft O 052 mm 0 07 mm
to the center journal
and rocker 0 0006 0 0028 in

bushing o 0020 in
Standard Limit

17 566
36 53 mm 36 0 mm
Cam height Rocker shaft 17 584 mm
1 438 in 1 4l7in l
outer diameter 0 6915
0 01 mm O 03 mm o 6922 in
Camshaft bend
0 0004 in 0 0012 in
17 6
0 07
Bushing inner 17 618 mill

O 148 mm 0 693
End play diameter
0 0028 o 694 in
o 0058 in

EM 13
 ENGINE

CYLINDER BLOCK
1 Check visually for defects such as cracks
10mm
and flaws

J
2 Measure the top face of the block cylinder

EB
head mating face for warping If the warp ex

ceeds the llit value

li correct it

EM 37 bore
Fig Cylinder measuring position

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Standard Limit

0 035
85 000
0 mm 0 2 mm
Cylinder bore
0014 0 0079 in
3 347
0 in

Fig EM 36 Checking cylinder block flatness 0 02 mm

Ellipse taper
0 0008 in

Standard Limit Difference of

0 05 mm 0 2
each four mm

0 0020 in 0 0079 in
Less than cylinder bore
O 10 mm
Surface flatness 0 03mm

0 0012 in
00039 in

3 Measure the cylinder bore for out of round

or excessive taper with a bore gauge If ex
cessive out of round
are de
wear taper or

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

Fig EM 38 Measuring cylinder bore
A bore gauge is used Measure the cyl
inder bore at top middle and bottom points
in each direction A and B as illustrated and Boring of cylinder
record the measured values 1 When any of the cylinders needs boring all
Wear of the cylinder bore is the differehce other cylinders must be bored at the same

of the maximum and minimum value time

EM l4
 ENGINE MECHANICAL

2 Determine piston to the 4

oversIze according Machine the cylinder bore to the determined
amount of wear of the cylinder inner diameter

Note To prevent strain due to cutting heat bore the

Pis ton for service cylinders in the order of 2 4 1 3

Piston size Outer diameter 5 Do not cut too much out of the cylinder bore
at a time but cut 0 05 mm 0 0020 in or so
84 958 84 990 mm
S T D at a time
3 345 3 346 in

85 220 85 240 mm 6 Measurement of the cylinder bore just

250 S
3 355 3 356 in machined requires the utmost care since it is

expanded by cutting heat

85 470 85 490 mm
500 S
3 365 3 366 in
7 Finish the treated cylinder bore to a final
85 720 85 740 mm finish bore by honing
750 S
3 375 3 376 in

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8 Measure the finished cylinder bore for el
85 970 85 990 mm
100 0 S liptic or tapered part
3 3846 3 3854 in
Note If the cylinder bore has worn beyond the wear
86 220 86 240 mm
125 0 S limit use the cylinder liner
3 394 3 395 in
Undersize cylinder liners are available for service
Interference fit of cylinder iiner to cylinder
block 0 08 to 0 09 mm 0 0031 to 0 0035 in
3 By measuring piston to be installed at piston
skirt side thrust face and adding the wear of
Cylinder liner for service
clearance specification the finish hone cylinder
measurement can be determined
Outside diameter Inside diameter

89 091 89 126mm 83 5 84 5 mm
400 U S
3 507 3 509 in 3287 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

G
Fig EM 39 Measuring puton dwmeter

Cylinder bore to be treated A B C A

o 015 to 0 035 mm 0 0006 to 0 0014 in

Outer diameter of piston skirt A

Piston cylinder clearance B O 030 to 0 050
mm 0 0014 to 0 0022 in

allowance O 02 mm 0 0008 in
Hornning C
Fig EM 40 futon a
sembly

EM 15
 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 42 MetUuring ring gap

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Note a When the piston ring only is to be replaced
without the cylinder bore being corrected

EM 41 ide earonce
c measure the gap at the bottom of the cylinder
Fig Measuring
where the wear in minor
b Oversize piston rings are ailable for service
Side clearance
25 50 75 100 125 oversize

Standard Limit
4 Measure the piston pin hole in relation to
0 04 008mm 0 Imm the outer diameter of the pin If wear exceed
Top ring 0 0016 0 0031 in 0 0039 in ing the limit is indicated replace such piston
pin together with the piston on which it is in
002 006mm o Imm
Second ring stalled
0 0008 0 0024 in 0 0039 in

002 006mm 01 mm
Oil ring
0 0008 0 0024 in 0 0039 in Standard Limit

Interference fit 0 o 09 mm Clearance

of piston pin 0 o 005 mm

to pis ton o 0035 in 0 0002 in

Ring gap
Clearance be
Standard Limit tween pis ton 0 006 0 0l3mm

0 35 10 pin and con 0 0002 003mm

055 mm mm

Top ring nee ting rod o 0005 in 0 0012 in

0 0138 0 0217 in 0 0394 in
bushing
o 3 05 mm 1 0mm
Second ring Piston 2l 99l 22 Omm
0 0118 0 0197 in 0 0394 in pin
outer 0 8658
o 35 0 55 mm 1 0 mm
Oil ring diameter o 8661 in
0 0138 0 0217 in 0 0394 in
Piston pin hole 21987 210mm

diameter of 0 827
3 Place the ring at the bottom of the ring O 866 in
piston
traveled part of cylinder bore in which it will
be used Connecting rod 21995 22 008
Square ring in bore by pushing it into
the head bushing inner mm
position with piston
Measure diameter 0 8659
the gap between ends of ring with
o 8664 in
feeler gauge Gap should be as listed above

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 44
EM Checking big end end play

CRANKSHAFT

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1 Check the shaft journal and crank for
pin
scars biased wear and cracks

Repair or replace affected parts

UO o1

Fig EJI1 43 Connecting rod aligner

2 Check for bend or torsion using a connect

ing rod aligner If bends or torsion exceeds

the limit correct replace the
or connecting
rod

Standard Limit

0 110

0 246 mm 0 3
Big end end play 0 0043 0 0118 in Fig EM 4S Dimension for crankshaft measurement

o 0097 in Measurement of taper and out or round

Torsion bend o 05mm 0 Imm Measure A B or X Y direction shown in the

Figure EM 46 by a micrometer
per 100 mID 0 0020 in 0 0039 in

3 In A B
replacing the
connecting rod select the
rod so that the weight diference between new B 1
A
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 ex

ceed the limit replace such connecting rod EM 46

Fig Measuring point for crankshaft
EM 17
 ENGINE

Taper Difference hetween A and B

Out of round Difference between X and Y

Standard Limit

Less than
Taper Out of
o 01 mm 003mm
round
0 0004 in 0 0012 in

2 Check the crankshaft for bend If the bend

exceeds the specified value repair or replace
the crankshaft

EM 48 Checking cronk haft end play

Fig

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Standard Wear limit

o 060

C rankshalt o 192 mm 03 mm

end 0 0024 0 0118 in

play
o 0076 in

5 Check the main drive shaft pilot bearing at

the rear of the crankshaft for wear and damage

Replace it if defects are detected The
any

pilot bearing can be removed by using special

Fig EM 47 Checking cronkshaft bend tool ST49700000 as illustrated in the Figure
EM 49

Before installing the pilot bearing clean

Standard Maximum the bearing hole and apply oil to the bearing
outer side then press the pilot bearing into the
Less than
C rank shaft
o 05 hole as illustrated in the Figure EM 50 by using
03 mm o
bend a drift After that apply multi purpose grease
0 0008 in 0 0020 in
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
PILOT BEARING
obtained when the crankshaft is given
with the dial gauge applied to its
a turn

center
c
f
jou mal
Un
3 Alter regrinding the crankshaft finish it to

the necessary size indicated in the lis ts on

under
page EM 20 and by using an adequate
size bearing according to the extent of re

quired repair
rl
4 Install thE crank shalt in the cylinder block
and measure the thrust clearance If it exceeds
the specified value replace the center shims M l9
fig I Removing I ilol bear llf

EM 18
 ENGINE MECHANICAL

16mm
r 0 236 in

PILOT BEARING

Q t
Apply grease

Fig EM SO Fitting pilot bearing Fig EM S2 Checking bearing clearonce by plastigage

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Note Be sure not to turn the crankshaft when the
BUSHING AND BEARINGS
plastigage is inserted

Measurement of main bearing

clearance 5 Remove the cap and meaure the width of the
compressed
plastigage widest part withat its
1 Check all bearing and bushing for exfolia
the printed in the plastigage envelope
scale
tions melts scars and burrs
before removing it from the crankshaftor bear
Replace bushings if any defects are detected
ing

2 Wipe off oil and dust especially the rear of

the bushing

Measurement of connecting rod

3 Set the main bearing the cap block
on
bearing clearance
1 Measure the connecting rod bearing clear
ance in the same marmer

4 5 to 5 0
Tightening torque kg m

32 6 to 36 2 ft lb

l
SCALE
Bearing oil clearance

Standard Wear limit

i
OJ

o 03

Main o 06
bearing mm o lmm
PLASTIGAG clearance 0 0012 0 0039 in
o 0024 in

o 03
Connecting rod
o 06 mm o lmm
Fig EM Sl Plastigage bearing 0 0012 0 0039 in
clearance
4 Cut aplastigage to the width of the bearing o 0024 in

and place it in parallel with the crank pin

getting clear of the oil hole Install the cap
and tighten them together under the spec ilied 2 If clearance proves to be in excess of the

torque specilied value replace the bearing by under

Tightening torque 10 to 11 kg m sizes and consequently grind out the crank
72 3 to 79 5 It lb shaft journal

EM 19
 ENGINE

Fitting bearings
the main Tighten to the
1 Set the bushings on bearing cap and Release the bolts
prescribed torque
the cylinder bearing recess and install the
block aher tighten to the
prescribed torque
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 lb

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 listed below If it is not replace

figures crush check
Fig M 53 Bearing
the bearing

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Bearing crush Standard

4 Handle the connecting rod bearing in the

o 0 04 mm
same manner Main bearing 0 0 0016 in
Connecting rod cap bolt tightening torque
4 5 to 5 32 6 to 36 2 ft lb Connecting rod 0 004mm
kg m
0 0 0016 in
bearing

Main under size

bearing

Bearing size Bearing thickness Crank journal diameter

2 485 2 505 mm 55 971 55 990 mm

S T D
0 0978 0 0986 in 2 2Q36 2 2Q43 in

26l2 2625mm 55 721 55 740 mm

25 U S
0 1028 0 1033 in 2 194 2 195 in

2 737 2 750 mm 55 471 55 490 mill

50 U S
0 1078 0 1083 in 2 184 2 185 in

2 862 2 875 mm 55 221 55 240 mm

75 U S
0 1127 0 1132 in 2 174 2 175 in

2 987 3 000 mm 54 971 54 990 mm

100 U S
0 1176 0 1181 in 2 164 2 165 in

under size
Connecting rod bearing

Crank pin diameter

Bearing size Bearing thickness

1 483 1 499 mill 49 975 49 991 mm

S T D
0 0584 0 0590 in 1 967 1 968 in

1 609 1 622 mm 49 725 49 741 mm

25 U S
0 0633 0 0639 in 1 9576 1 9582 in

1 734 1 747 mm 49 475 49 491 mm

50 US
0 0683 0 0688 in 1 9477 1 9483 in

EM 20
 ENGINE MECHANICAL

1 857 1 872mm 49 225 49 241 mill

75 US
0 0731 0 0737 in 1 938 1 939 in

1 984 1 997 Dim 48 975 48 991 mm

100 U S
0 0781 0 0786 in 1928 1 929 in

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

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check for run out 1f it is found to exceed
o 1 mm 0 0039 in replace the camshaft

sprocket

EM SS Camshaft drive mechan

m
Fig

Flywheel
1 Check the clutch disc contact surface of the

flywheel for damage and wear Repair

or replace if necessary

2 Measure deviation of the clutch disc contact

dial 1f it exceeds 0 1
surface with a gauge
mm 0 0039 in replace it

3 Check tooth surfaces of the ring gear for

flaws and wear Replace if necessary

at about 1800 to 2000C

Note Replace the ring gear

3560 to 3920F When press the ring gear

into the flywheel pay attention to the direction
of the chamber on the teeth

Fig EM S4 camshaft run out

Checkifl

3 Check the chain for damage severe wear and

Flywheel
stretch at its roller links Replace a defective Ring gear t

chain

Chain tensioner and chain guide

Check for wear and breakage Replace if

necessarv Fig EM 56 Fitting ring gear

EM 2l
 ENGINE

Front oil seal

Replace front oil seal if oil leaks or dam When install oil seal
a new pay attention to the
are found using front oil seal replacer direction of the oil seal
ages
ST49740000

LJ

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Fig EM S7 Replacing oil seal EM S8 Installation
Fig of oil seal

ENGINE ASSEMBLY

CONTENTS

PRECAUTIONS EM 22 PISTON AND CONNECTING ROD EM 24

CYLINDER HEAD EM 22 ASSEMBLING OF ENGINE EM 25

PRECAUTIONS
1 Use thoroughly cleaned parts Particularly 6 Be sure to follow specified tightening torque
check whether oil holes are clear of foreign and orders where necessary

matter or not

2 In
installing sliding parts such as bearings
CYLINDER HEAD
proceed after applying engine oil to them as

required 1 Set the valve spring seat in position and then

the valve Install the oil seal ring onto the
3 Use and oil seals valve stem and put the seal ring cover over the
new
packings in principle
oil seal ring
4 Keep tools and work benches clean and clear
of dust and oil stains Note Make that interference at the oil seal
sure ring
is trom 0 3 to 0 7 mm 0 0118 to 00276 in
5 Keep the necessary parts and tools ready It interference is less than 0 3 mm the oil seal
near at hand be
ring or the cover must replaced

EM 22
 ENGINE MECHANICAL

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 52

Fig EM S9 Interference of oi seal ring

2 Assemble the outer and inner valve springs

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and retainer and mount the cotter by pressing
the spring with the special tool o

Go
o
0

Fig EM 61 Rockershaft assembly

c 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
EM 60
Fig Assembling valves

FRONT REAR
Camshaft Camshaft
Front Seat bracket No 2 Spring A
camshaft bracket No 3 B
Spring
bracket

I
10011
I

Indication mark 011 hole I I

I Seat
On Iront lace of
cker haft
the
LA Center
camshaft Rocker shaft Rea
CllmShllft
bracket bracket

l
Install rocker shaft oil hole hown the figure

EH 62 Detail of rocker shaft assembly

Fig
EM 23
 ENGINE

4 Mount the camshaft onto the head mount the Note Heat the
a piston to a temperature of from
valve rocker assembly and tighten the nuts 50 600C
to 1220 to 1400F and the
At this time align the punch marks the
on piston pin can be installed by finger
flange of the camshaft with the arrow mark on

the No 1 camshaft bracket

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EM 6S
Fig Pressing puton pin

EM 63 ettin
Fig 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 6arrow mark on the

so that tip of the screw is slightly over the piston head is directed toward the engine
front
rocker
b Take sufficient care in positioning the rocker

since the tip of the bolt is apt to get out of o

Arrow mark
valve stem shown in EM 54
tile as Figure

Correct Incorrect
0 Oil jet

hr
i
07 II 0
iI J
j J y
I I
I c
j
J

i
1
Fig EM 66 4ssemblillg piston and rud
connecting

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

rod for each installed shown in Fig EM 67

necting cylinder as

EM 24
 ENGINE MECHANICAL

TOOI

Crankshaft gap

Tool

Fig fM 67 Installing dip Fig EM 69 Installing oil seal to rear bearing cap

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3 Install the piston ring with the punch mark 3 Apply a screw sealing agent on the cylinder
facing up block oil hole plug and install to the cylinder
block
4 Fix the bearings onto the connecting rod and

the connecting rod cap 4 Fix the main bearings onto the cylinder block
and the bearing caps
Note Make sure that no dust or other foreign matter
Note The same type bearings are used at all five
adheres to the back of bearings locations

5 Lubricate all main bearings with engine oil

ASSEMBLING OF ENGINE
Then install the crankshaft bearing and the
1 Place the cylinder block the stand to the
on engine cap Tighten speCified tightening torque
Tightening torque 10 to 11 kg m 72 3 to
2 Insert the oil seals into the grooves of the 795 ft lb

cylinder block and the rear bearing cap and

Note a Apply liquid packing Three bond No 2
hold down the special tool ST49750000
by using
Then cut off the with
or equivalent to the fitting surface of the
excessive seal ends a

knife rear bearing cap

Apply liquid packing here

Vig f M 68 oil seal to

Installin r1inder block Fig FM 7U Application of liquid packing
EM 25
 ENGINE

b Install the thrust washer on both sides of the 9 Lubricate the crankshaft journals pistons
No 2 bearing The thrust washer should be and cylinder bores with engine oil and install
the piston rod assembly
installed so that oil channel faces to the

crankshaft thrust face

1
1 1 Note a Install the piston rings so that their gaps are

V
cc f
0 1 at 1800C 356 F to each other is avoiding
I
the gaps face to the thrust side of the piston
1
I
or piston pin axial directions

t
r
b The mark the top of the
arrow on piston
l
r should face the front of the engine

r J1
v 10 Install the connecting rod cap
t
I

0 t Bolt tightening torque 4 5 to 5 0 kE m

t i 32 6 to 36 2 ft lb

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L

Fig EM 71 Installing thrust washer

Note a Install the caps to the connecting rod so that
c Arrange the bearing cap SO that the arrow the mark on the big end side faces to the
mark faces toward the front of the engine same side
b After tightening the bolt to the specified
6 Install the rear
bearing cap side seal The torque bend the lock washer as show in
rear bearing cap side seal must project from Fig EM 73
0 2 to 0 6 mm 0 0079 to 0 0236 in from the
lower portion of the cylinder block

Note Apply liquid packing the

to projecting tip

F EM 3 Illstallatiun of piston assembly

Fig EM 72 Installing cap side seal

11 Install the oil jet on the front of the cylin

7 Install the engine rear plate der block Then install the chain tensi6ner and

stopper
8 Install the flywheel After the
tightening 12 Install the crankshaft sprocket and
bolts to the specified torque lock the bolts timing
chain
using new lock washer

Tightening torque 10 to 11 kg m Note Align the timing mark of the chain with the
72 3 to 795ft lb mark of the sprocked

EM 26
 ENGINE MECHANICAL

CAM SPROCKET

TIMING MARK

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ADJUSTING SCREW

f
CHAIN TENSIONER

Oil JET

CHAIN GUIDE

CRANK SPROCKET

TIMING MARK

Fig EM 74 Timing mechanism

EM 27
 ENGINE

13 Install the oil pump Temporarily tighten

the mounting bolts Crank pulley
Note Apply sealing agent Three Bond No 4 or

equivalent onto the oil pump mounting surface

as shown in Figure EM 75

Fig EM 77 Installation of oil flinger

Apply sealing agent here

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16 Install the chain cover

Note a Apply sealing agent Three Bond No 1 or

equ ivalent onto the gasket

b Ensure that the boss on the back of the chain
EM 7
Fig pplicatinn ofliquid packing cover is located between the timing chain
c Cut off the and lower
14 Install the oil pump chain together with the upper projecting
portions of the gasket
two sprockets Tighten the nut securing the oil

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
centralpoint Then tighten the oil pump
mounting bolt securely

Vip EM 7Il

17 Install the crankshaft pullev and tighten the

nut to the specified torque
tightenin Then
bend the lock washer

Tightening torque 15 to 20 kg m

108 5 to 144 6 ft lb

18 Install the oil strainer

f M 76
Fig 4dj ting 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 Top dead center
in EM 77
Figure position of the compression stroke

EM 28
 ENGINE MECHANICAL

Note a Align the notch on the crank pulley to the

T mark on the ain

ct cover

3 6 B

7 5 2 4 10

Fig J M HI Cylinder head tightening urder

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22 Pull the chain from the chain
EM mark ou t timing
Fig 9 Timing
cover and set the chain on the camshaft
sprocket
b Even when the engine was turned upward making their mating marks meet each other
Then strike the camshaft sprocket with chain
the timing chain does not fall into the chain
onto the camshaft
cover since the timing chain is supported
with the rear boss of the chain cover Under
23 Install the distributor drive gear on the
this condition when the crankshaft is rotated
camshaft and tighten the bolt to the specified
the chain will not run off the sprocket
torque
Tightening torque 4 5 to 5 5 kg m 32 6 to
21 Install the cylinder bead assembly
39 8 ft lb

Note a the block Then bend the lock washer

Apply sealing agent onto cylinder
side of the head gasket Three Bond No 4

or equivalent At this time make sure that Note The camshaft bolt has left hand threal s

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 lb
ft

fJI rocket
Fig H Inslalliag camshaft I

24 Adjust the valve clearance

Note Adjustment of valve clearance is made with each

FiJ I fW IWitf dillaf rlwar cylinder set at the top dead center of the
W
o

EM 29
 ENGINE

compression stroke 30 Install the generator bracket and alterna

Specified clearance At room temperature tor

0 2 mm 0 0079 in for both intake and

exhaust 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 tension by changing the position
of the alternator to establish the specified
tension between the water pump pulley and the
alternator

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Fig EM 83 Adjusting valve clearance

Ref When warmed 0 25 mm 0 0 8 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

EM 84 belt tension
Note Apply sealing agent to the rear rubber plug Fig Adju ting fan
Three Bond No 2 or equivalent 33 Install the oil filter

34 Install the rocker cover hose

27 Install the chain adjusting screw
35 that the
Install the distributor so vacuum

controller and the rotor are in positions shown

Note Adjustment of the chain tension is made in
in Figure EM 85 Temporarily tighten the
the following sequence
a Rotate the crankshaft clockwise and establish lock nut

correct chain tension

b After threading in the adjusting screw fully
by hand back it off 1 2 turn and lock with

the lock nut

c As the width of across flat of the lock nut
is 21 t0 3
6 that of the
same as spark plug
the nut can be tightened or loosened with the
spark plug wrench

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

Fip EM 8S J Qcation of di tributor 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 hreather

Note The clamp of the pipe i tightened in company

with the exhaust manifold Fig EM 86 Installation of exhaust manifold gasket

Note Install the exhaust manifold gasket with the

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steel plate surface of the grommet facing in
37 Install the spark plug and connect the high the direction of the manifold
tension cable
39 Install the clutch

40 Remove the engine from the engine stand

38 Install the exhaust manfiold At the same and install the transmission intake manifold

time install the heat shield plate and engine with carburetor starter motor engine mount

slinger and tighten them together oil pressure warning switch gasol ine drain

tube etc

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATION
4 in line
Cylinder arrangement
85 x 80 mm 3 346 x 3 150 in
Bore and stroke
1 815 c c 110 8 cu in
Displacement
Valve arrangement eHe
105 HP 5 600 rpm
Max brake horse power SAE
15 9 kg m 115 ft lb
Max torque
1 3 4 2
Firing order
600 rpm STD
Engine idle rpm
8 3 1
Compression ratio
More than 495 mmHg 19 8 inHg
Vacuum pressure of intake manifold at idle
cm2 66 8 78 2 Ib in2
Oil pressure 4 7 5 5 kgl
13 000 rpm

TIGHTENING TORQUE

Main 10 11 72 3
bearing cap bolt kg m 795 ft lb

Connecting rod bolt 4 5 5 36 2 It lb

kg m 32 6

EM 3l
 ENGINE

bolt 10 11 kg 72 3 79 5 ft lb
Flywheel m

Crankshaft nut 15 20 108 5 144 6 ft lb

kg m

57 9 65 1 ftlb
Cylinder head bolt 8 9 kg m

5 5 5 32 6 39 8 ft lb
Camshaft center bolt 4 kg m

Spark plug 3 4 kg m 21 7 28 9 ft lb

Oil fil ter center belt 2 8 3 2 3 23 2 ft lb

kg m 20
Water pump blind plug 1 5 2 kg m 10 9 14 5 ft lb

Carburetor bowl set sc rew o 15 0 2 kg m 1 1 1 4 ftlb

Rocker o 33 0 4 m 24 29 lb
ft
cover securing screw kg

LIQUID PACKING APPLICATION

fL Cylinder block 4 Cylinder head gasket Cylinder block side

Oil gallery blind plug

5 Intake manifold
Expansion plug

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Gas breather guide Control valve

Rear bearing cap fitting surface Angle tube connector

Rear bearing cap side seal both ends

6 Oil pump

head Block installing surface to oil

Cylinder near

Expanision plug exit

Rubber plug Rear

Manifold heat pipe 7 Rocker cover

3 Chain cover both sides Tapping screw of buffle plate installing

gasket

SPECIFICATION
a Valve mechanism

Valve clearance cold In o 25 mm 0 0098 in

Ex o 25 mm 0 0098 in

Hot Reference value

In o 28 mm 0 011 in

Ex o 28 mID 0 011 in

Valve head diameter In 42 mm 1 654 in

Ex 35 mm 1 378 in

Valve stem diameter In Ex 8 mm 0 3150 in

Valve length In 116 4 mm 4 58 in

Ex 117 2 mID 4 61 in

9 0 mm 0 354 in
Valve lift
Outer 42 5 1 673 in
Valve spring free length mm

Innter 41 4 IDm 1 630 in

Valve spring loaded length Outer 29 0 mm 1 142 in

Innter 26 0 mm 1 024 in

Valve spring assembling height Outer 37 0 mID 1 457 in

Innter 34 0 mm 1 339 in

Valve spring effective wind number Outer 4 5 mm 0 1772 in

Innter 6 25 IDm 0 2461 in

EM 32
 ENGINE MECHANICAL

Outer 4 2 mm 0 1654 in
Valve wire diameter
spring
Innter 2 9 mm 0 1142 in

27 5 mm 1 083 in
Valve spring coil diameter Outer
Inner 19 9 mm 0 733 in

In 48 mm 1 890 in
Valve guide length
Ex 60 mm 2 362 in

In Ex 16 7 0 657 in
Valve guide height from cylinder head mm

In Ex 7 mm 0 2756 in
Valve guide inner diameter

In Ex 14 2 mm 0 559 in
Valve outer diameter
guide
In o 025 0 055 mm
Valve guide to stem clearance
0 0010 0 0022 in

o 04 0 077 mm
Ex
0 0016 0 0030 in

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In Ex o 040 0 069 mm
Valve guide interference fit
0 0016 0 0027 in

In Ex o 1 mm 0 0049 in
Max tolerance of above clearance

In Ex 2 05 2 33 mm
Valve seat width
0 0807 0 0917 in

In Ex 90
Valve seat angle

b Camshaft and timing chain

o 07 0 148 mm
Camshaft end play
0 0028 0 0058 in

36 53 mm 1 438 in
Cam height

Camshaft journal diameter 37 45 37 475 mm

1 474 1 475 in

0 01 0 0004 in
Camshaft bend mm

37 5 37 525 mm
Camshaft bearing inner diameter
1 476 1 477 in

to clearance o 025 0 075

Camshaft journal bearing mm

0 0008 0 0030 in

c Connecting rod

Center distance 140 mm 5 51 in

o 110 0 246 mm
Big end end play
0 0043 0 0097 in

o 05 0 0020 in
Connecting rod bearing clearance mm

Connecting rod bend o 03 0 06 mm

0 0012 0 0024 in

EM 33
 ENGINE

size
Connecting rod bearing under

Bearing size Bearing thickness Crank pin diameter

1 483 1 499 mm 49 975 59 991 mm

S T D
0 0584 0 0590 in 1 967 1 968 in

1 609 1 622 mm 49 725 49 741 mm

25 U S
0 0633 00639 in 1 9576 1 9582 in

1734 1747 mm 49 475 49 491 mm

50 US
0 0683 0 688 in 1 9477 1 9483 in

1 857 1 872 mm 49 225 49 241 mm

75 U S
0 0731 0 0737 in 1 938 1 939 in

1 984 1 997 mm 48 975 48 991 mm

100 U S
0 081 0 0786 in 1 928 1 929 in

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d Crankshaft and main bearing

Less than o 01 mm 0 0004 in

Journal taper and out of round

o 060 0 192 mm
Crankshaft free end play
0 0024 0 0008 in

o 3 mm 0 0118 in
Wear limit of ditto clearance

Less than o 01 0 0004 in

Crank pin taper and out of round mm

o 03 0 06 mm
Main bearing clearance
0 0012 0 0024 in

o 1 mm 0 0039 in
Wear limit of ditto clearance

size
Main bearing under

Beadng size Bearing thickness Crank journal diameter

2 485 2 505 mm 55 971 55 990 mm

S T D
0 0978 0 0986 in 2 2036 2 2043 in

2 612 2 625 mm 55 721 55 740 mm

25 U S
0 1028 0 1033 in 2 194 2 195 in

2 737 2 750 mm 55 471 55 490 mm

50 US
0 1078 0 1083 in 2 184 2 185 in

2 862 2 875 mm 55 221 55 240 mm

75 U S
0 1127 0 1132 in 2 174 2 175 in

2 987 3 000 rom 54 971 54 990 mm

100 U S
0 1176 0 1181 in 2 164 2 165 in

Crankshaft bend Less than 0 02 mm 0 0008 in

EM 34
 ENGINE MECHANICAL

e Piston

Piston diameter 84 968 85 0 mm 3 345 3 346 in

diElf elirpencese o 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 ill mm 0 1575 0 0004 in

Piston to bore clearance 0035 0 55mm

0 0014 0 0022 in

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Piston ring side clearance Top 0 04 0 08 mm

0 0016 0 0031 in

Second 0 02 0 06 mm

0 0008 0 0024 in

Oil 0 02 0 06 mm

0 0008 0 0024 in

Ring gap Top 0 35 0 55 mm

0 0138 0 0217 in
Second 0 3 0 5 mm

0 0118 0 0197 in
Oil 0 35 0 55 mm

0 0138 0 0217 in

Ring height Top 0 01 0 0004

2 0 03 0
mm 0787 0 0012 in
Second 0 01 0 0004
2 0 03 mm 0 0787 0 0012 in

Oil 0 01 0 0004
4 0 03 mm 0 1575 0 0012 in

Piston pin interference fit of piston pin o 0 09 mm

to piston 0 0 0035 in

Clearance between piston pin and connecting 0 003 O 013 mm

rod bushing 0 0001 O 0005 in

Piston pin outer diameter 21991 220mm

0 8658 0 8661 in

Piston pin hole diameter of piston 21 987 21 996 mm

0 8656 0 8660 in

rod inner diameter 21995 22 008 mm

Connecting bUshing
0 8659 0 8664 in

EM 35
 ENGINE

TROUBLE DIAGNOSES AND CORRECTIONS

Trouble Cause Correction

I Noisy engine

Loose main bearing Replace

Burnt bearing Replace

Knocking of Bent of crankshaft Repair or replace
crankshaft and

bearing Uneven wear of journal Regrinding

Too much end play of crankshaft Replace center bearing

Loose bearing Replace

Burnt bearing Replace

Piston and

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Loose piston pin Replace pin or bushing
conne cting rod

kno cking Loose piston in cylinder Recondition cylinder

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

Camshaft

knocking Rough teeth of gears Repair

Broken cam gear Replace

Chain tension not adequate Adjust

Wear and of chain Replace

damage

Timing chain Wear of sprocket Replace

noise
Wear or breakage of tension adjusting Replace
mechanism

Clearance of camshaft and bearing too Replace

big

Valve clearance not correct Adjust

Wear of adjusting screw Replace

Camshaft and Wear of rocker face Replace

valve mechanism
Loose valve stem in guide Replace guide
knocking
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

Correction
Trouble Cause

II Other mechanical trouble

Not correct valve clearance Adjust

of valve stem with Clean stem or ream the guide

Small clearance
guide
Sticked valve
Yielded or broken valve spring Replace

Biting or damage of valve stem Replace or clean

Bad fuel Use good fuel

Not correct valve clearance Adjust

Yielded valve spring Replace

Thin valve head edge Replace valve

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Burnt valve seat
N arrow valve seat Refacing

Overheat Mentioned

Drive right
Over speed

Sticked valve guide Repair

Shortage of engine oil 9heck 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

rod
necting

Not correct clearance of piston ring Adjust

Exceseive wear

of cylinder and Broken piston ring Replace

piston air cleaner Clean periodically
Dirty

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

Low oil pressure Refer

Defective

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
 ENGINE

Wrong assembly of bearing Repair

Defective

connecting rod Loose bearing Replace

Connecting rod alignment is not made Repair or replace

Shortage of engine oil Check every day

Low oil pressure Mentioned

Not adequate engine oil Use right oil

Wear or out of round of crankshaft

Defective journal
crankshaft
Clogged oil passage in crankshaft Clean
bearing
Wear or eccentricity of bearing Replace

Wrong assembly of bearing Repair

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Not concentric crankshaft or beariug Replace

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

EM 38
 1 1 1 1 1

i DATSUN
f I
1800
a
I SECTION EL
SERVICE ENGINE
LUBRICATION
MANUAL
SYSTEM
MODEL G18

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ENGINE

NISSAN MOTOR CO LTD

LUBRICATION SYSTEM EL 1
TOKYO JAPAN
 ENGINE lUBRICATION SYSTEM

LUBRICATION SYSTEM

CONTENTS

DESCR IPTION EL 1 EL 3
Assembly
LUBRICATION CIRCUIT EL 2 OIL PRESSURE RELIEF VALVE EL 3
of relief valve ELA
OIL PUMP EL 2 Specification
Description EL 2 OIL FILTER ELA
Removal EL 2 Disassembly EL 5

Installation EL 2 EL 5
Inspection
Disassembly EL 2 Assembly EL 5

Inspection and repair EL 3 OIL WARNING SWITCH EL 5

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1 itI I J llbrif aliofl irr uit 8 CIlMifW

DESCRIPTION
The lubricating system is Pressure feed functional components suited for high perform
and is composed of highly efficient 1 e high out put and high speed running
type system ance

EL l
 ENGINE

LUBRICATION CIRCUIT 6 Remove the oil pump body by removing four

Oil is drawn from the oil oil pumps
pan through the attaching bolts
inlet screen and tube to the inlet side of the oil
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 Installation

The main oil gallery supplies oil to the is
Installation a reversal of removal pro
crankshaft main bearings and drilled passages cedure
in the crankshaft direct oil from main bearings In this case adjust the tension of the oil
to connecting rod bearings pump drive chain as shown in Figure EL 2
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

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Furthermore 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

Fig EL 2 Ten oil pump drive chain

ioning
OIL PUMP

Description
The oil Disassembly
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 cm2 65 4
to 74 0 lh in
Isq

Removal
1 Drain engine oil

2 Remove the distributor

3 Remove the cylinder head fan belt

assembly
crankshaft pulley and oil pan

4 Remove the chain with oil

cover flinger
Fig EL 3 Dwsembly of oil pump
5 Remove the oil pump sprocket with the oil
pump crankshaft sprocket and the oil pump
drive chain 1 Separate the body cover from the oil pump

EL 2
 i

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 spring 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

and scores
Fig EL S InspectiDn of clearunce

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3 Check the following

Assembly
Gear backlash O 1 O 5 mm 1 Assembly is a reversal of disassembly pro

0 0039 0 0195 in cedure

Side clearance between

O 016 O 15 2 In this case the mark dotted on gear should
gear and body
mm

0 0006 O 0059 in be faced to the oil pump body cover

Clearance between drive

shaft and body O 016 O 1 mm

0 0006 O 0039 in

Clearance between
drive shaft and body
cover O 02 O 1 mm

0 00078 O 0039 in

Clearance between
idler gear and
idler shaft 0 016 O 1 mm

0 0006 O 0039 in

Fig EL 6 Dotted mark of pump gear

OIL PRESSURE RELIEF

VALVE
The oil Iressure relief valve is not adjust
able At the released po ition the valve

permits that oil is by passed through a passage

on the pump body to the oil pan

Check the relief valve pring dimension to

Fig EL 4 backltuh ensure that it has not lost its tension

ImpectiDn of

EL 3
 ENGINE

Specification of relief valve

Free length of
spring 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 2 21 4Ibs

Opeuing pressure 4 55 4 85 kg crn2

64 7 69 0 Ibs sq in

Oil pan

Fig Et 7 Relief valve

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OIL FILTER

Fig EL 8 Oil filter

Oil filter is of foil flow type and the element The filter body is mounted to the filter
is replaceable whicb is mounted to the cylinder cover by center shaft The oil by pass valve
block at the right hand side by two bolts is located in the filter cover

The oil fed by oil pump is filtered by oil If the pressure difference between inlet and
filter and supplied to main gallery outlet of oil filter reaches O 8 kg cm2 11 38
Filter element is set between the element lb I sq in by clogging of filter element the
set spring and the retainer released valve permits oil to be by passed then

EL 4
 ENGINE lUBRICATION SYSTEM

the pressure of oil supplied to main gallery is Assembly

kept specified level
at It
avoids the engine
Assembly is a reversal of disassembly pro
trouble caused by pressure dropping
cedure

Note a When tightening the filter body to the cover

Disassembly
bolt tighten with the specified
by center
1 Loosen the oil filter center shaft and
2 8 to 3 2 m kg 20 25 to 23 15
and body torque
separate the cover
Ibsq in l

2 Take off upper retainer element lower

b The oil filter body gasket and center shaft
retainer and set spring from the body should be replaced with one
gasket new

in case of reassembling
3 Remove by pass valve plug from the cover

and draw off valve washer valve spring and

valve in sequency

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OIL WARNING SWITCH
Inspection
The warning switch is located on right
oil
Check the by pass valve spring according to
hand center ofcylinder block and wired to an
the following specifications indicator lamp in the instrument cluster
Free 54 5 56 0 mm The low pressure light glows whenever the
length
2 14 2 20 in oil pressure drops below 0 5 kgl cm2 7 11

Pressured length 49 0 mm 1 93 in lb sq in

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

EL 5
 ENGINE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
SUBJECT
DATE PAGE No
BULLETIN No

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EL 6
 t
l
l f J SECTION CO
SERVICE COOLING
YSTEM
MANUAL
MODEL Gll

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ENGINE

CI

NISSAN MOTOR CO LTD

Co l
TOKYO JAPAN
COOLING SYSTEM
 COOLING SYSTEM

COOLING SYSTEM

CONTENTS

DESCRIPTION COo THERMOSTAT CO 3

WATER PUMP CO 2 Removal CO 3
Removal CO 2 Inspection 4
CO

Disassembly CO 2 Installation CO 4

Inspection CO 2 RADIATOR CO 4
FLUID COUPLING CO 3 Removal CO 5
Lubrication CO 3 Inspection CO 5
SPECIFICATIONS CO 5

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DESCRIPTION
The cooling system is a closed pressure adequate temperature range at all times by
of anample capacity water pump of a
type with high cooling capability Cooling water means

flowing through resistance free water passages corrugated fin type radiator with high cooling
in the cylinder head and block is maintained at efficiency and a pellet type thermostat

Fig COol system G 18 engine

Cooling

CO I
 ENGINE

WATER PUMP
The water pump is a centrifugal water pump and noise thoroughly
with aluminum die cast The The water pump with fluid coupling will be
an pump body
volute chamber is built into the chain cover equlpped for the models with the torque CO

assembly and a high pressure sealing mecha vertor or the air conditioner and for U S A
nism is adopted to prevent the water leakage models

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Fig CO 2 Water pump and chain cover

Removal

1 Drain cooling water completely 3 Remove fan and pulley

2 Take the fan belt off the 4 Remove the water pump
pulley

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

Replace it if it grows up excessive

o beariug
CO 3 Water pump removal noise or squeak with the engine running
Fig

CO 2
 COOLING SYSTEM

Nissan CSP overhaul After

reassembly it must be
Note To prevent a squeak use Cooling an

System Protector filled with silicon oil of exactly 11 5 c c 0 702

Prior to installing the pump clean it with cu in using an injection syringe

Nissan CSC Cleaner
Cooling System

FLUID COUPLING

In the models with the converter or

torque
the air conditioner and the U S A models a

fluid is combined with the water pump

coupling
to maintain cooling efficiency and to orevent

power loss at high speed operation

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Cl

Fig COoS 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 the coupling installed in the

Fig CO 4 Fluid coupling
engine
The quantity of oil to be replenished must not
1 Ifmalfunction due to foreign matters
a or

to deteriorated oil detected exceed 5 c c 0 305 cu in

sticking due are

disassemble the coupling for interior cleaning

Note Wash the coupling gasoline in this

in case
THERMOSTAT
take care so that rubber seal will be kept away
A pellet type thermostat is used in the water
from gasoline
outlet to control the flow of coolant
passage
2 Check for seizure and a gelatinized oil a providing fast engine warm up and regulating
A pellet in the
phenomenon of oil thickened into a semi solid coolant temperatures wax

thermostat expands when heated and contracts

form Change such oil because thickened oil
At the when cooled The pellet is connected through a
will make bearings and grooves sticky
same time examine the condition of seal and piston to a valve and when the pellet is heated
A blackened seal and bear is exerted against a diaphragm with
bearing thoroughly pressure
the the is
ing due requires the replacement of
to seizure forces to open valve As pellet
the pump body assembly cooled the contraction allows a spring to close

the valve

lication
Lubl

Silicon oil is to be used

Removal
1 Drain cooling water

1 If a malfunction and oil leakage are detected

in the fluid coupling remove the water pump for 2 Remove radiator hose

Co3
 ENGINE

3 Remove water outlet Then take out the Valve open

thermostat temperature 800 C 1 50 C 17SO F 2 70 F

Max valve lift above 8 mm at 900 C

0 315 in at 1940 F

Installation
1 In apply binding agent
installing Three

Bond to both sides of the packing for preven

tion of water leakage

2 Install 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

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valve incorporated in the radiator filler cap
CO 6 Thermostat removal controls the pressure at approximately
Fig
o 9 kgl cm2 12 8 lb I sq in

Inspection
To test the thermostat for proper operating
temperature submerge the unit in a container

of water Heat the water and observe the

temperature
I
S
1 Measure the wben the ther
temperature
mostat valve just starts rising

c
Fig CO 8 If adiator removed

For the models with torque converter the

oil cooler to cool the torque converter oil will
be combined with the radiator

CO 7 Thermostat
Fif inspection
Provide screwdriver with Inspect by in the
rting
marking at a point about marked screwdriver at C
9Cf

8 mm 0 315 in from the 1940F

tip

2 Measure the maximum lift of the thermostat

valve CO 9 Radiator with oil couler

Fig

CO 4
 COOLING SYSTEM

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

1
4 Sight be
glass can removed by turning
counter clockwise to clean it

Inspection
If the radiator requires frequent top ups
Fig CO lO Radiator shroud
the trouble must be traced to one of the follow

ing causes

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1 Excessive water evaporation from overheat

ing as a result of a clogged radiator Clean

Also the radiator shroud is combined with
the radiator
the radiator in the models with the torque con
verter or the air conditioner and the U S A
2 Defective valve radiator filler cap
model safety on

Replace the cap

3 Loose hose clamps Tighten clamps

4 Leaky water pump shaft seal Replace

the water pump

SPECIFICATIONS

334 x 465 x 38 mm
Dimensions of radiator core

width thicknees 13 15 x 18 31 x 1 50 in
height x x

Corrugated fin type

Type
2 3 mm 0 091 in
Radiator fin spacing

Cap working pressure 0 9 kg cm2 12 8 lb Isq in

3 1 t 3 3 U S quart
Water capacity

CG 5
 ENGINE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

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CQ 6
 1 I 1

f t

i DATSUN
1800
l
SECTION EF
SERVICE FUEL SYSTEM

MANUAL
MODEL G11

cardiagn.com
ENGINE

411

AIR CLEANER HI

FUEL STRAINER HI
NISSAN MOTOR CO LTD FUEL PUMP H 2

CAilBURHOR H B
TOKYO JAPAN
 FUEL SYSTEM

AIR CLEANER

DESCRIPTION

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EF 1 4ir cleaner for single carburetor
Fig
C 18 ine
of ell

The air filter element used is viscous paper

Never the element by brushing or air
Note treat
type element and does not require any cleaning
blasting before the time for replacement
ragardless of contamination until it isreplaced
at every 40 000 km 24 000 miles of operation

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

REMOVAL
Disconnect the inlet and outlet fuel pipes t
and the fuel strainer assembly is easily Fig EF 2 Sectional view of cartridge type
removed fuel strainer

EF l
 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

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Fig EF 3 Cartridge type fuel strainer

FUEL PUMP

CONTENTS

DESCRIPTION EF 2 REMOVAL EF 7

CONSTRUCTION EF 3 DISASSEMBL Y EF 7

EFA INSPECTION EF 7
OPERATION
TESTING EF 6 ASSEMBLY AND INSTALLATION EF 7

TROUBLE DIAGNOSES AND

CORRECTIONS EF 6

DESCRIPTION
1 No vapor lock in torrid zones
The fuel pump is of the electric type consist
2 the
ing of a contact mechanism solenoid relay Starts pumping immediately as ignition
swi tch is turned on
pump mechanism and a strainer unit
This is located in the center of the spare
3 Built in type filter keeps dust out and adds to
wheel house in the trunk compartment
pump and engine life
This electric pump presents several distinct

features as follows 4 Reduced power consumption

EF 2
 FUEL SYSTEM

Coil

Piston

Strainer

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EF S Contact mechanism
Fig

2 Solenoid relay

The solenoid relay is constructed as illus

trated in Figure EF 6 Inside the brass cyl

inder 9 plunger @ which at its
the hollow iron

EF 4 Electric fuel pump lower part is connected to a piston @ by means

Fig
of a connecting rod iJJ can freely slide and is
attacbed so that it is pushed up between a

damper spring is above and a plunger spring

CONSTRUCTION
@ below mounted on the frame W Encircling
The type EP 3 fuel pump consists of a this cylinder g a driving coil tj is mounted
contact mechanism solenoid relay pump concentrically and the coil @ is surrounded by
mechanism and a strainer unit Its details are a leakage type solenoid relay covered by iron
as follows yokes @ and an end yoke Ql
An arc suppressing resistor Q is connected

in parallel to the driving coil

1 Contact mechanism

In the contact mechanism as shown in

Figure magnet A 2 and B @ are attached

EF 5

to each end of
a L shaped magnet holder D

The magnet holder is mounted on 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 @ 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 tbe magnet holder a point arm @ at

tached to the horizontal part of the magnet

that the contact
holder moves up and down so

A Wattached to its end will come into contact

BOO fixed relay stay q to make switching

on the

The arc suppressing resistor and conden er

are connected in parallel to the contacts A and

Fig EF 6 Solenoid relay

B

EF 3
 ENGINE

3 Pump mechanism This unit is constructed shown in

as Figure
EF 8 Around the frame i a wire netting
filter 2 is attached concentrically and on the

under side of the lower end of the frame a

P magnet
iron filings
C riJ is mounted

Enclosing the
to remove

filter
any
a
fine

glass
strainer i is fixed on the frame l by a band

8 using the seal packing

OPERATION
1 Operation of electromagnetic unit

20 Before operating the fuel pump as the

stays pushed up inside the cylinder
plungeru

9
by the plunger spring il mounted on the
frame
1 the magnet A on the end of the

magnet holder fof the contact mechanism is

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attracted to the cylinder and the point arm

mounted on the horizontal part of the

22 magnet
holder L is pressed downward
making contact
between contacts A r and B 8
f ig IF mechanism
rump
1 When turning the engine switch A on the
As shown in Figure EF 7 the piston z is
connected to the the electric current flows from the battery
plunger 10 through con

il driving coil IIJ contact B ij

necting rod
It is mounted in the contact A t point arm yoke if
cylinder B jjl fitted in the
central hole z of the frame so that it can slide ground and this current makes the driv
act as Then
freely An inlet valve fJ is provided at the ing coil l an electromagnet
the is attracted downward
plQunger against
lower end
the plunger spring i and given potentiai
energy by the plunger spring pressure
4 Strainer unit
As the plunger 9
1 moves down the distance

between the plunger ill and the magnet A

r increases and the attractive force of the
I magnet A 1l becomes zero Thus the at
I

I tractive force working between the magnet B

and the yoke 1 becomes predominant
B to the ilT
drawing the magnet ac yoke and
disconnect the contacts At and B oBi

@ 2 When the contacts A 7 and B are sepa

rated the driving coil J loses its electro

5J i rW magnetic force and the plunger is

gradually pushed position held prior up to the

to the operation potential energy of the the
by
@ t plunger spring pressure When the plunger

reaches the position held prior to the

operation the distance between the plunger

10 and the A decreases the
magnet 2

contacts A i is drawn to the plunger ill and

the contacts A 1 and B becOlnes connected
that is it returns to the state as
original
fF 8
Fig Fuel strainer described above

EF 4
 FUEL SYSTEM

Thereafter this process is repeated and the goes up gradually to the position held prior
plunger carries on regular reciprocat
a to the operation as the contacts A C1J and B @

ing motion while the engine switch A remains becomes disconnected Then as shown in

on Figure EF ll the opening at the upper por

tion of the piston closes as the its upper

inside wall contacts with the spherical
surface of the connecting rod and the inlet

val ve 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 the fuel quantity contained
governed by

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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

decreases that is the number of

discharge
the pump operations is reduced After the

needle valve becomes closed the discharge

almost stops Then the number of the pump

is one per five or six seconds

@ operation

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 1j

utilizes the power of the electromagnet and the

lr
force of the plunger spring in the opposite
Open
direction of the power and owing to these forces
the piston continues the reciprocating motion

1 Turning the engine switch A on makes the

piston t connected to the plunger @ drop

quickly the of the
very against pressure

plunger spring 114 In this movement the

upper portion of the inside wall of the piston

IJ becomes open due to the reaction to its

very fast drop as shown in Figure EF 10 and E f 10

Fig Pump operation
the inlet valve it closes and therefore the

fuel contained between the piston and the

it TESTING
inlet valve moves upward
1 Disconnect the fuel hose at the pump outlet

2 The piston M lowered is given potential

energy by the plunger spring pressure and 2 Connect a suitable hose r approximately 6 mm

EF 5
 ENGINE

0236 in inner diameter to the pump outlet fuel

0 J not lie in the pump but in some othe r

unit Check other units for possible causes

Note If the diameter is too small the following as follows
proper delivery capacity can not be obtained
even if the pump functions properly Voltage drop of battery

Poor grounding
3 With the hose outlet in the higher position
Poor grounding of battery
than the pump operate the pump and check the
delivery capacity for more than 15 seconds I
Incorrect or loose wiring

Incorrect connection of inlet or outlet or

4 The capacity should be 1 400 c c 3 24 U S

less clogged piping

pts in one minute or

If no gasoline or only a little flows from Trouble in carburetor

open end of the pipe with the pump operated or

if the pump does not work follow the following

2 When the fuel pump does not operate and
diagnosi s
discharge fuel

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TROUBLE DIAGNOS IS AND
In this case the cause of the trouble lies in
CORRECTIONS the pump Check it as follows

When a fuel pump is found to be faultly

check it in the following procedure
If the current flows this will be indicated by
sparks at the terminal
1 Remove the fuel pump from the vehicle

The cause is the plunger or piston binding in

2 Connect the fuel pump to a battery properly motion Therefore disassemble the pump
charged and operate it to see if the pump dis
and remove any dust inside
charges fueL

If the current does not flow

The cause is the breaking of a coil or lead

wire Therefore replace the fuel pump with
a new unit

3 When the fuel pump discharges only a small

fuel
t quantity of
The cause is trouble in the inlet valve dis

Close 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 bol ts retaining fuel pump cover

to floor panel
Fig EF II Pump operation
2 Remove two bolts retaining fuel pump to fuel

1 When the fuel pump cover

pump operates and discharges
fueL 3 Disconnect the lead wire

In this case the cause of the trouble does 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 re

placed as a complete unit

INSPECTION
1 Wash thestrainer filter and gasket with
clean gasoline and blow dust off with a blast of
EF 12 Fuel pump removal
Fig cover

air When cleaning the parts check the fil ter

and gasket If defective replace it

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Note Filter must 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 into the

plunger assembly 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 filter

spring
strainer seal and band
locking
ASSEMBLY AND INSTALLATION
3 Remove the snap ring
Follow the disassembly and removal pro
4 Remove the four of the yoke and take cedure in the if
screws reverse Replace gaskets
off the electric unit necessary

EF 7
 ENGINE

CARBURETORS

CONTENTS

DESCRIPTION EF 8 Adjustment of the injection amount of

STRUCTURE AND OPERATION EF 8 the accelerati ng pu mp

Primary system EF 8 D3034C carburetor EF 16

Secondary system EF 11 MAJOR SERVICE OPERATIONS EF 17

Float system EF 14 Removal EF 17
ADJUSTMENT EF 14 Disassembly EF 17
Idling adjustment EF 14 Cleaning and inspection EF 20
Fuel level adjustment EF 14 Assembly and installation EF 21
Adjustment of starting interlock valve JETS EF 21

opening EF 15 TROUBLE DIAGNOSES AND

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Adjustment of interlock opening of CORRECTIONS 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 OPERATION

draught type Model DAK 340 is of the solex These carburetors consist of the primary
type manufactured by the mTA CHI system for normal running and the secondary
Model 00034C is of the strongburg The float system
type system for full load running
manufactured by the NIHON KIKAKI and instal which the primary and secondary systems use
led on the exhaust emission control engine in common the secondary switch over mecha

Each carburetor has two variations for nism the starting mechanisln accelerating
manual and automatic transmissions mechanism etc are incorporated

For model D3034C carburetor the power

val ve mechanism is provided to make high

speed drive better a fuel cut off valve is

attached to cut fuel supply when the ignition key

is switched off and a idle limitter is also pro

vided to control the emissions under a certain

Carburetor
level So that the movement of the idle
model Application adjust
screw is limited in a certain range

DAK340 IA lvIanual transmission

DAK340 2A Automatic transmission

Primary system
1 Primary main
Exhaust emission control system
D3034C lB engine with manual Fuel flows as shown in Figures EF 14 and
transmission EF 15 through the main jet mixing with air
which comes in from the main air bleed and
Exhaust emission control passes through the emulsion tube and is pulled
D3034C 2B with automatic
engine out into the venturi through the main nozzle
transmission The multiholed main nozzle insures a proper
atomization of fuel and a low fuel consumption

EF 8
 FUEL SYSTEM

Model DAK340 Carburetor

20

5242322 21

Primzry

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1 lin
SM I 6 Needle lIve I S Throttle valve 16 P Slow jet 21 P Mainjer
2 S Small 7 Float 12 Choke aIve 17 Slow omizer 22 Idlelimitter

3 S Main air bleed 8 S Emuhion ub 13 P Main air hleed 18 P Slow air hleed 23 Idle hole

d 19 Air 24 P
4 S Slow jet 9 SMainjet 14 PMain By pass hole
P Throttle alve
5 5 Slow air bleed 10 S By pass hole 15 Economi7 er bleed 20 Level gauge 25

FigEF 14 Sectional view

Model D3034C Carburetor

21

23

34

33 I I
32 31 3029

25
2

Soooo

28 P Throttle alve
1 Float Olive 7 Air 13 Pump weight 21 Pump plunger
Vacuum 8 P Main ilir bleed 14 Discharge check alve Inlet check alve 29 Idle port
piston
S Small un 23 SMainjet 30 Slow port
3 P Slow bleed 9 PMain I 15
31 Idle adjust
4 Slow jet 10 PSmall nturi 17 S Main air bleed 24 Diaphragm spring w

Slow omizcr I Choke alve 18 Step air bleed 25 Diaphragm 32 P main jet
5
6 P slow bleed 12 zlc 19 26 Step port 33 Powerjet
Pump Pump m

20 27 Idle port 34 Float

Step jet

EF IS Sectional view
Fig

EF 9
 ENGINE

shown in Figures EF 16 and EF 17 is closed

2 Idling and slow system
the piston goes up and fuel flows from the float
The throttle valve is opened at a small angle
chamber through the inlet valve into the space
when idling and in slow
speed running with a under the piston When the throttle valve is
large negative pressure prevailing down stream opened the piston goes down opening the outlet
of the fuel system This negative pressure
valve and fuel is forced out through the
acts on the slow speed system equipped with a
injector The piston return spring in the cyl
slow economizer Through this action fuel the smooth movements of
inder not only assures
measured through the jet seciion of the slow jet
the linkage but also serves to place inlet valve
assembly located immediately behind the main in position so that the piston goes down quickly
economizer bleed
jet and air coming from the and fuel is forced out the
through injector
are mixed in the emulsion hole This mixture
is further mixed with air coming from the slow Model D3034C Carburetor
bleed the slow economizer and
7
air through
atomized The atomized mixture is supplied to
the engine from the idle hole and by pass hole

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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

Model DAK340 Carubretor

L Pump d 5 Inlctvalve

2 Pump etum
spring 6 Valve weight
3 Float chamber 7 Outlet valve

4 Pump plilnger 8 P throttle wlve

Fig EF 17 During accelerating

4 Starting mechanism

Pull the choke button to close the choke valve

fully then start tbe engine This provides a

rich mixture making it possible to start the

When the engine is started the

1 Main air bleed 5 Piston eturn
spring engine qui ckly
2 Main zIe 6 Inlet valve choke valve is opened at adequate angle auto
an

3 Pump njector 7 Outlet valve matically which prevents overchoking and

4 Piston 8 Throttle valve While
ensures a smooth engine pe rformance
the engine is warmed up it increases in
being
Fig EF 16 During accelerating speed at steps releasing the choke
and by
button an optimum engine speed can be obtained
with the piston With the choke valve closed fully the primary
The carburetor is equipped
accelerating mechanism linked to the throttle valve is caused to open at an angle best
type
throttle valve When the primary throttle valve suited for starting through a link mechanism

EF lO
 FUEL SYSTEM

5 Dash pot mechanism through the main nozzle promotes the fuel
atomization
andD3034C 2B
only for Model DAK340 2A
Carburetors equipped with Automatic Trans
2 Step system
mission

The construction of this system may cor

This carburetor is equipped with dash pot
a

with throttle valve respond to the idling and slow system of the
interlocked the primary
The dash pot which primary system
through a link mechanism
The system aims in the proper filling up of
is exclusively installed on cars equipped with a
the gap when fuel supply is transferred from
torque converter intended to prevent engine
is
the primary system to the secondary one The
stall that would otherwise result from quick
application of the brake immediately after the step port is located near the secondary throttle
valve in its fully closed state
car ran or from the quick release of the
accelerator pedal after giving only small
pressure 3 Secondary switch over mechanism
When the primary throttle valve is closed

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full secondary throttle valve is linked to the
The
near angle 1 800 to 2 000 r p m in engine
throttle lever strikes the dash pot diaphragm which is actuated by the vacuum
speed a
created in the venturi A vacuum jet is pro
stem shown in Figure EF 18 making the
each of the
throttle valve and vided at primary and secondary
primary gradually open
venturies and the composite vacuum of these
keeping the engine running
actuates the diaphragm
jets
As the linkage shown in Figures EF 19 and
Secondary system EF 21 causes the secondary throttle valve not

to primary throttle valve opening

open until the
1 Secondary main system
reaches approximately 51 fuel consumption
Fuel air mixture produced by the functions during normal operation is not excessive
of the main jet main air bleed and emulsion During high speed running as the vacuum at
tube in the in the the venturi is increased the diaphragm is
same manner as primary
system is pulled out through the main nozzle pulled against the diaphragm spring force and
into the small venturi then secondary throttle valve is opened
Due to the double venturi of the secondary The atmospheric side in the diaphragm
system the higher velocity air current passing chamber is connected to the atmosphere

0
L
j

1 Lock ut
r
2 Choke wire arm
L
Ln
3 Dash pot

4 Throttle lever

5 Throttle chamber

6 Throttle valve

5 6

18 Dash pot mechanism

Fig

EF ll
 ENGINE

Model DAK340 Carburetor z Model P AK340 Carburetor

6 6
If
1

2 1

i w 5

4 5 I I

j I Secondary Primary
Seoondary Primary

1 S Vacuum jet 4 Diaphragm chamber

1 S jet J 5 Diaphragm ad Diapmilgm chamber 5 Diaphu gm ad
Vacuum Diaphragm
2 4 Diaphragm 6 Vacuum jet 6 P Vacuum jet
Diaphragm

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chamber chamber J Diaphragm

Fig EF 19 Full throttle at low speed Fig EF 20 Full throttle at high speed

Model D3034C Carburetor

6 7 89 10

2 3 4 5
I

20

21

22

r I
31 30 29 28

2 1 25 24

Primary
1

1 Vacuum piston 7 P Main air bleed 13 Discharge check valve 19 Pump plunger 25 511llottlevalve

2 P Slow air bleed 8 P Main d 14 S Small venturi 20 Inlet check valve 26 P l11rottle valve

3 Slow jet 9 P ill

Sm nturl IS S Main air bleed 21 S Main jet 27 Idle port

4 SI amner 10 Choke nlvc 16 Step air bleed 22 Slow port

Diaphragm spring 28
5 Slow air bleed 11 d o
P Pump 17 Pump arm 23 phngm 29 Idle adjust screw

6 AU on 12 Pump weight 18 Stepjet 24 Step port 30 P Mainjcr

31 ll
PO erjcr

Fig EF 2 Full throttl at luw speed

EF 12
 FUEL SYSTEM

Model D3034C Carburetor

20

21

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22

31 30 29 2B 26

24

271
25

Primary Secondary
1

1 Vacuum piston 11 Pump lie 2l SMainjet

P Slow bleed 12 22
Pump weight Diaphragm spring

3 Slowjct 13 Discharge check alve 23 Diaphragm

4 Slow omizer 14 S Small nturi 24 Step port

5 P Slow air bleed 15 S Main air bleed 25 S Throttle alve

6 Au 16 P
Step air bleed 26 Throttle alve

7 P Main air bleed 17 Pump airm 27 Idle port

8 P Main I 18 Step jet 28 Slow pon

9 I1 uri 19 Pump plunger 29 Idle adjust w

PSm

10 Choke alve 20 Inlet check illve 30 PMainjet

31 Powcrjet

Fig EF 22 Full throttle at high speed

EF 13
 ENGINE

Float system Fuel level adjustment

There is only one float chamber while two
Model DAK340 Carburetor
carburetor systems primary and secondary
provided A constant fuel level is maintained the
are by
Fuel fed from the fuel pump flows through float and needle valve
the filter and needle valve into the float cham
ber A constant fuel level is maintained by the
2
float and needle valve
Because of the air vent type of the float
3

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

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H 1 5 mm oD591

ADJUSTMENT Float Float stopper

1 SRt 3
2 Flo 1 4 Needle alve

Idling adjustment
Idling adjustment is made by the throttle Fig EF 23 Fuel level adjustment
adjust screw and idle adjust screw DAK340 carburetor
As for the engines equipped with Nissan
emission control system special adjustment is If the fuel level is in accord with the level
required Therefore refer to page EC OO for gange line the float level is properly set If
detail the float level is not correct adjust it by bend
Ordinal adjusting method is follows
as
ing the float seat as shown in Figure EF 23

Approximately H mm is required as the

1 Give the idle adjust screw approximately effective stroke of the needle valve So adjust
three turns starting from the Mly closed the gap between the valve stem and the float
position Screw in the throttleadjust screw seat to H mm with the float fully lifted up by
two or three turns and start the engine bending the float stopper
H 1 5 mm 0 00591 in
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 tbe

adjust screw until
engine runs smoothly at the highest speed

4 the throttle
Readjust screw to drop the

engine speed
Repeat these operations until smooth
a engine
speed of apprOximately 550 rpm has been
attained

Note Do not attempt to screw down the idle adjust

screw completely to avoid damage to the tip
which will tend to cause malfunctions Fig EF 24 Adjustment of float seal DAK340

EF 14
 FUel SYSTEM

Adjustment of startinl interlock

valve opening

Model D3034C Carburetor

in
J
J

Fig EF 2S Adjustment of float stopper DAK340 3

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Model D3034C Carburetor
1
If the fuel level is in accord with the level

gauge line the float level is properly set If J

L
the float level is not correct adjust it by the L
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 levcr 4 Connecting lever

2 Choke valve S Throttle lever

3 Connecting rod

EF 27 Adjustment of starting interlock

Fig
opening
I

Model DAK340 Carburetor

40

1 Float

Float valve scat Throttle chanber G1 Throttlevlltve

3 Floatvalve

4 Adjusting gasket
5 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 Model D3034C Carburetor
matically opens the throttle valve at an optimum
angle 14 for DAK340 model and 13 50 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
I
interlocked opening angle bend the choke con I
necting rod for adjustment so that a fully closed
lr
choke valve will bring the clearance Gl shown
in Figure EF 28 to 1 1 mm 0 0433 in J
Adjustment of interlock openin of 0S i

1
50DIsof
primary and secondary throttle valve 1 1
Model DAK340 Carburetor
2

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I 1

600
i
i
L

1 S Throttle arm 3 Link

2 S Throttle ctum lever 4 P Throttle nm

5 P Throttle valve
Secondilry Primary

f oo Fig EF 30 Model D3034C carburetor

EF 30 shows the
Figure primary throttle
I valve opened 50 When the primary throttle
fixed to the throttle valve is open
arm primary
4 JGL 5 50 it comes to contact with the connecting

1 Connecting lever 4 Throttle chamber link

Return Throttle lIve
plOlte
3 Adjust pl2te
Adjustment of the injection amount
EF 29 Mudel lIAK HO carburetur of the accelerating pump
Fig
D3034C carburetor
EF 29 shows the fuel amount forced out from
Figure primary throttle The the pump
valve opened 60 When the adjust plate fixed injector during acceleration can be controlled
to the primary throttle valve is open 60 it by selecting a fitting hole of the pump arm

to contact with the

comes
connecting lever at Ordinarily the hole of the middle position
@ When the throttle valve is further opened should be used But according to the temper
the point @ where the connecting lever is in ature select the proper position of the hole as

contact with the stopper is detached shown in the table

permitting
the secondary system to start actuating
The linkage between the primary and sec
Position of Injection amount
ondary throttles operates properly if the Tempera ture
the hole per one stroke
distance between the throttle valve and inner
Inner O tic c O 0366cu in Below C 32Of
wall of the throttle chamber G2 amounts to
Hddle 0 4 cc O 0244 ell in C
3O F
86
7 38 mm 0 3937 in The O 32
adjustment is made
by bending the point @ of the adjusting plate Outer O 2c c O D122eu in Above C
3O S6OF

EF 16
 FUel SYSTEM

MAJOR SERVICE OPERATIONS

The perfect carubretor delivers the proper

gasoline and air all speeds of the

ratios for

particular engine for which it was designed

By completely disassembling at regular inter

vals which will allow 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
of passages and dis
n
Accurate calibration

charge holes require that extreme care be

taken in cleaning Use only carburetor solvent

and compressed air to clean all passages and

Never use wire or
passage discharge holes
fF 3 removal
other pointed instrument to clean as calibration Fig inkage
of carburetor will be affected

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Remove four end take off choke
5 fixing screws

chamber

Removal
1 Remove air cleaner

2 Disconnect fuel line vacuum line and choke

wire in case of auto choke choke heat from

carburetor
Q J
3 Remove the throttle lever

4 Remove four nuts and washers retaining

carburetor to manifold

5 Lift carburetor off manifold EF 32 Choke chamber removal

Fig

6 Remove and discard carburetor to manifold

6 Remove stop pin and four fixing screws

gasket Separate throttle chamber from float

chamber

Disassembly

Model DAK340 Carburetor

A
l
o

1 Carburetor assembly i
1 Remove primary throttle return spring 0
2 Remove E ring and take off pump and con

rod
necting

3 Remove split pin and take off choke con

rod
necting EF 33 Throttle chamber removal from
Fig
floal chamber
4 Remove secondary throttle return spring

EF 17
 ENGINE

2 Choke chamber chamber cover gasket level gauge rubber

packing and float

0
il
c

Fig EF 34 Choke chamber

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Fig EF 36 Float chamber disassembly
1 Remove two screws and take off choke wire
arm 4 Remove filter take
fixtng screw and off

2 Remove two screws and take off choke valve nipple and filter

5 Remove needle valve

3 Remove choke shaft and choke valve spring
4 Remove choke lever and choke lever spring 6 Remove two fixing screws and take off cyl
inder
by taking off the clip
cover pump cover piston piston
return spring and inlet valve
3 Float chamber 7 Remove injector fixing screw and take off
1 Remove three
pump injector injector spring and outlet
fixing screws and take off
valve
diaphragm chamber cover diaphragm spring
and diaphragm 8 Remove primary main air bleed

9 Remove secondary main air bleed and

emulsion tube

It
10 Remove three fixtng screws and take off

small venturi

I
4Jl A
f
GL
0

0
1 0
l
0
Fig EF 3S
Dinphragm chamber disassembly 0
j I
2 Remove three fixing screws and diaphragm
chamber and gasket

3 Remove four fixing screws and take off float

Fig EF 37 Float chamber disassembly

EF 18
 FUel SYSTEM

11 Remove and secondary slow jets

primary
and slow air bleeds

12 Remove drain plugs and take off primary v

and se condary main jets

4 Throttle chamber

1 Remove throttle and

e
adjust screw spring

2 Remove idle adjust screw and spring

3 Remove nut and take off throttle lever

spring hunger sleeve connecting lever

Fig EF 39 Air horn
return plate and adjust plate

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3 Remove pump rod slow jets primary and
4 Remove two fixing screws and take off
secondary small venturies
primary tnrottle valve

5 Remove primary throttle shaft

fl
6 Remove two fixing screws and take off c
secondary throttle valve
b

7 Remove secondary throttle shaft

b

Fig EF 40 Removal of jets and venturies

tPo J
4 Remove primary and secondary linkage

i
parts

Q
or
@

Fig EF 38 Throttle chamber duassembly PO

p

Model D3034C Carburetor A

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

three and take off

5 Remove fixing screws

diaphragm chamber
and diaphragm
cover diaphragm spring
r a

ai
4
ceO
f F 44 Float chamber di
Fig a
embly

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l

9 Remove fuel inlet strainer and float valve

seat

10 Remove main jets

Fig EF 42 Diaphragm chamber diw embly
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

P
o

EF 45 Fuel cut
Fl oJ valve

Cleaning and inspection

Dirt gum water or carbon contamination

in or on the exterior moving parts of a carbu

EF 43 Float chamber removal from throttle retor are often responsible for unsatisfactory
Fig
chamber performance For this reason efficient
carhuretion depends upon careful cleaning and

8 Remove three inspection while servicing

screws and take off float
chamber cover glass gaskets float and 1 Blow all passages and castings with com

check valve air and blow off all

pressed parts until dry

EF 20
 FUEL SYSTEM

and reassembling the

Note Do not pass drills or wires through calibrated In 1isassembling
interlock link and related components be care
jets or passages as this may enlarge orifice
affect carburetor calibration ful not to bend or deform any of the components
and seriously
Reassemble so that all interlock links operate

smoothly
Check all If is noted
2 parts for wear wear

defective must be replaced Note es

parts
pecially the following JETS
The carburetor performance depends on jets
1 Check float needle and seat for wear If
and air bleeds That is why these components
noted the must be re
wear is assembly are fabricated with utmost care To clean
placed and blow air them
them use gasolir e on

2 Check throttle and choke shaft bores in Larger numbers siamped on the jets indicate
throttle body and cover castings for wear or larger diameters Accordingly main and slow
out of round jets with larger numbers provide richer mix
ture and the smaller numbers the leaner
adjusting needles for burrs

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3 Inspect the or
the main and slow air
mixture Inversely
ridges Such a condition requires replace bleeds which are for air to pass through make
ment and
the fuel leaner if they bear larger numbers
the smaller numbers the richer fuel
3 Inspect gaskets to see if they appear hard or meet the
Replacement of designated jets to
brittle or if the edges are torn or distorted
service condition of the car must be carried out
If such condition is noted they must be
any with the above directions in mind To cite a

replaced when it becomes necessary

practical example
to economize fuel at the limited sacrifice of
4 Check filter screen for dirt or lint Clean
output to meet frequent light load operation use
and if it is distorted or remains plugged
smaller main jets or slow jets or larger main
replace slow air bleeds than regularly
air bleeds or

This should meet the purpose

specified
5 Check venturi clusters for loose or worn
Inversely when increase in output is desired at
parts If
damage or looseness exists replace the limited sacrifice of fuel consumption use

cluster assembly main slow jets or smaller main

larger jets or

air bleeds or slow air bleeds and that should

6 Check the linkage for operating condition
bring a satisfactory result

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 the

accelerating nozzle
TROUBLE DIAGNOSES
rod of AND CORRECTIONS
8 Push in the connecting diaphragm
chamber and block the passage of vacuumby In the following tablethe sympioms and
finger And when free the connecting rod causes of carburetor troubles and remedies for
check the leakage of air and tbe damage of
them are listed to facilitate quick repairs
diaphragm There are various causes of engine troubles
It sometimes happens that the carburetor which

defect apparently to have some

has no seems

Assembly and installation troubles when electricsystem is defective

Therefore whenever the engine has troubles
Follow the disassembly and removal proce
electric must be checked first before
dure in reverse system
Replace the gaskets if necessary starting carburetor adjustment

EF 21
 ENGINE

Troubles Possible causes Remedies

Overflow Dirt accumulated on needle valve Clean needle valve

Fuel pump pressure too high Repair pump

Needle valve seat improper Lap or replace

Excessive fuel Fuel overflow See above item

consumption Each main jet slow jet too large Replace

Each main air bleed clogged Clean

Choke valve does not fully open Adjust

Outlet valve seat of accelerator Lap

pump improper

Linked opening of secondary Adjust

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throttle valve too early

Power shortage Each main jet clogged Clean

Each throttle valve does not fully Adjust

open

Fuel pump operated improperly Repair

Fuel strainer clogged Clean

Vacuum jet clogged Clean

Air cleaner clogged Clean

Diaphragm damaged Replace

Power valve operated improperly Adjust

Improper idling Slow jet clogged Clean

Each throttle valve does not close Adjust

Secondary throttle valve operated Overhaul and clean

improperly

Each throttle valve shaft worn Replace

Packing between manifold carbu Replace packing

retor defective

Manifoldl carburetor tightening im Correct tightening

proper

Fuel overflow See the first item

Engine hesitation Each main jet slow jet clogged Clean

By pass hole idle passage clogged Clean tube

Emulsion tube clogged Clean

EF 22
 FUEL SYSTEM

Idling adjustment incorrect Correct adjustment

Secondary throttle valve operated Overhaul and clean

improperly

not Fuel overflows See the first item

Engine does
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

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SPECIFICATIONS AND SERVICE DATA

r
OAK 340 D3034C
model
Item

Se condary Primary Se condary

Primary

30 34 30 34
Outlet diameter
in 1 1811 1 3386 1 1811 1 3386
mm

Venturi diameter 23 29 x 9 23 x 14 x 7 28 x 16 x 8

mm in 0 9055 1 1417 x 0 9055 x 0 5512 1 1024 x O 6299

0 0354 x 0 2756 x O 3149

Main jet 11119 II 165 102 11155

11220 II 100 II 60 II 80
Main air bleed

II 48 II 90 II 50 II 80
Slow jet

Slow air bleed 11130 11100 160 x II 150 II 220

Slow economizer 1 4 1 6

mm in 0 0551 0 063

Economizer bleed 1 2

mm in 0 0472

o 5
Power mm in
jet 0 0197

2 5 2 9
Weight kg lbs
5 5 5 87

EF 23
 ENGINE

Main jet variation

Jet ModeIDAK340
Altitude
Primary Secondary

1 000 m 3 300 ft 2 000 m 6 000 ft 115 160

2 000 m 6 000 ft 3 000 m 10 000 ft 112 155

3 000 m 10 000 ft 4 000 m 13 300 ft 108 150

Note Jets for model D3034C carburetor should not

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be changed because of the special calibration
for emission control

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

EF 24
 l
t
DATSUN lt
L
1800 t
J
SECTION EC
SERVICE EMISSION
CONTROL
MANUAL SYSTEM
MODEL G11

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ENGINE

GENERAL DESCRIPTION EC 1

POSITIVE CRANKCASE VENTIlATION SYSTEM EC 1

NISSAN MOTOR CO LTD EXHAUST CONTROL SYSTEM EC 2

TOKYO JAPAN
 EMISSION CONTROL SYSTEM

GENERAL DESCRIPTION

There are tow types of emissions that must Injection System N A I S

be controlled These are the crankcase emis Periodic inspection and required servlCmg
out at the
sions and the exhaust emissions Crankcase of these systems should be carried
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

sysTE M

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CONTENTS

DESCRIPTION EC 1 PERIODIC SERVICE EC 2

TESTING EC 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 e
air cleaner
for the return of blowby gases to both the in o

take manifold and carburetor air cleaner 6

During part throttle operation of the engine o

u

the intake manifold sucks the crankcase blowby

through the variable orifice valve
gases II c

tapered plUnger type

is suf
Normally the capacity of the valve
ficient under these conditions to handle the

blowby plus an adequate amount of ventilating

The air is then drawn from the
air ventilating
clean side of the carburetor air cleaner

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
of the flow will through the tube
blowby some go
cOlmection 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

EC l
 ENGINE

TESTING

lith at idle the 1 Check hoses and hose connectors for leaks
engine running remove

ventilator hose from the rocker cover If the

valve is working a
hissing noise will be heard 2 Disconnect ail hoses and blow them out with
as air passes through the valve and a strong compressed air

vacuum should be felt immediately when a finger

If any hose cannot be freed of obstructions
is placed over the valve inlet
replace with new hose
If valve is plugged do not attempt to clean
it Replace with a new valve
3 Check for proper function of ncase
cra
PERIODIC SERVICE ventilation control valve

Once a year or at 20 000 km 12 000 miles If the val ve is found defective replace with a

the Positive Crankcase Ventilation System new assembly

should be serviced as follows

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EXHAUST CONTROL SYSTEM

CONTENTS

DESCRIPTION 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 Diagnosiasl
gener exhaust system EC 12
Airinjection into each exhaust port EC 5 Diagnosis air pump EC 12
Engine modifications EC 7 Testing EC 14
Recommended annual maintenance EC 8 SETTING IGNITION TIMING
REMOVAL AND DISASSEMBLY ADJUSTING IDLE SPEED MIXTURE EC 17
PROCEDURE EC 8 MAINTENANCE EC 17
Air pump EC 8 General maintenance EC 18
Drive pulley EC 11 Periodic recommended maintenance EC 19
Anti backfire valve EC 11 SERVICE DATA AND
Check valve EC 11 SPECIFICATIONS EC 20

DESCRIPTION

The Nissan Air Injection System N A IS and carbon monoxide at in a

high temperatures
is designed to reduce air pollution caused chemical reactions treated
by producing a

engine exhaust tailpipe gases by treating the exhaust below the maximum allowable level for

unburned hydrocarbons and carbon monoxide as air The elements of the N A I S

pollution
they are expelled from the combustion cbam include an air cleaner a belt driven air injec
bers into the exhaust manifolds A sealed bear tion pump a check valve an anti backfire

ing pump driven by the engine compresses valve and related connecting tubes and hoses

distributes and injects clean filtered air into the A special calibrated carburetor and distributor
exhaust port of each cylinder Here the clean are also used with the air injection system
air combines with the unburned hydrocarbons

EC 2
 EMISSION CONTROL SYSTEM

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EC 2 Model CI8
Fig Engine

NISSAN AIR INJECTION SYSTEM

Air pump

Relief
valve

Carburetor air cleaner

Vacuum sensing line

Special catibratad
carburetor

Fig EC 1 Nissan air injection system

EC 3
 ENGINE

N A I S is basically an air injection sys goes to an anti backfire valve and then to a
tem combined with engine modifications to check valve which prevents exhaust gas from
increase its effectiveness entering the air pump in the event exhaust mani
The basic elements of the system are fold pressure is greater than air injection
pressure or in the case of an inoperative pump

1 Engine driven air pump The compressed fresh air is injected through an

injection nozzle to the exhaust ports

2 Air injection into each exhaust port An anti backfire valve has been installed to
eliminate popping in the exhaust system when
the throttle is closed at coast
3 Engine modifications a high speed
Controls which have been incorporated to assure

4 Recommended annual maintenance reliable system operation include an anti back

fire valve and a check valve

The air injection pump receives clean air by
means of a hose connected to a fitting on the
drEngiivenne air pump
underside of the carburetor air cleaner
injection pump is a positive dis

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This rotary vane type pump has been de The air

signed to draw the air in and produce maximum placement vane type which is permanently
air flow with quiet operation A fresh air line lubricated and requires no periodic mainte
from the air injection pump is routed so that it nance

Housing Vane

Relief valve
Stripper

Fig EC 4 Sectional view of air pump

The die cast aluminum air pump assembly the rotating unit of the pump The rotor located

attached to the front of the engine is driven by in the center of the pump is belt driven The

an air pump drive belt A rotor shaft drive vanes rotate freely around the off center pivot
hub relief valve and intake and exhaust tubes pin and follow the circular shaped pump bore
are visible on the pump exterior A rotor The vanes produce three chambers in the
vanes carbon shoes and shoe springs make up housing intake compression and exhaust

EC 4
 EMISSION CONTROL SYSTEM

Side seal
Ball bearmg
j I
I Pulley hub

Needle bearing
V

Vane shaft

Rotor ring

Needle bearing

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Fig EC S Sectional view of air pump

Each vane completes a pumping cycle in every are attached to each end The plates also seal
and end to confine the air
revolution of the rotor Air is drawn into the off the housing cover

intake cavity through a tube connected to the air to the pump cavities Air that leaks by the
cleaner The air is sealed between the vanes front carbon seal is exhausted through a small

and moved into a smaller cavity the compres hole in the housing
lUlit is steel ring
sion area Completing the rotating a

After compression the vanes pass the bolted to the rotor end This ring prevents the

exhaust The then pass the rotor from spreading at high r p m and also
cavity vanes

stripper a section of the housing that separates positions and holds the rear bearing and the
the exhaust and intake cavities the carbon seal
Continuing
the vane again enters the intake cavity to The front and rear bearings which support
cycle
The relief valve the rotor are of two types The front bearing
repeat its pumping cycle
located in the exhaust cavity encloses a pre uses ball bearings and the bearing uses
rear

loaded spring a seat and a pressure setting needle bearings The hubbearings are the
plug Its function is to relieve the exhaust air needle bearing type All bearings have been

flow if the pressure exceeds a pre set value greased for life
machined into the housing
Metering grooves
wall located in both the intake and exhaust into each exhaust port
Air injection
cavities provide a quiet transition from intake

to compression to exhaust The fresh air from the air pump is injected
Carbon shoes support the vanes from slots into the individual exhaust ports of the cylinder
in the rotor The shoes are designed to permit head in the vicinity of the exhaust port

sliding of the vanes and to seal the rotor Pressurized air is transmitted through
from the air cavities Leaf springs hoses and air distribution manifold
interior
which are behind the follower side of the shoes A schematic of the exhaust port is shown in

compensate for shoe wear and vane articulation Figure EC 6

Air into the rotor is exhausted through In addition to air injection certain controls
leaking
two small holes in the end cover The rotor is have been incorporated to assure reliable

further sealed by flexible carbon seals which system operation as follows

EC 5
 ENGINE

Air injection nozzle

Air gallery pipe

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Fig EC 6 Air injection into exhaust port

Anti backfire valve

This valve is controlled by intake manifold

vacuumvand is required to prevent exhaust sys Dis
hlfVltllir
to check yalve
tem baClUires 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 the
system during By pas air
first pre determined period of deceleration so
to
ir pump nlet

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
sucticn line

Since the valve action can have a deleterious

ce restriction
BaI

effect on emission reduction its operation is orifice

set under a fine compromise between adequate

backfire suppression and minimum emission
effects
EC 7 Sectional view
Fig of anti backfire valve

EC 6
 EMISSION CONTROL SYSTEM

If the valve does not work properly backfire Engine modifications

or emission deterioration will result

Check valve The Air ection

Inj System includes some

engine modifications necessary to reduce ex

haust hydrocarbons and carbon monoxide

concentrations

Carburetor

In consideration of air injection effective

ness engine performance fuel economy and
drive feeling the GIS engine for this system is

equipped with special calibrated carburetors

with narrow to tolerance for fuel flow

Ignition distributor

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The ignition distributor used with the Air
Injection System is provided with a different
advance curve from that used on engines without
exhaust emission control
an system
Idle ignition timing is retarded by 13
Fig EC 8 Sectional view of check valve
degrees

Check valve is set between the air pump and

Idle speed
the air injection nozzle It prevents a back

flow of exhaust gas The idle speed is set at a

Normally it passes air higher r p m
into the air distribution manifold in the air Specifications are 700 r p m for manual trans

When mission equipped vehicles and 650 r p m for

injection system exhaust manifold
automatic transmission
pressure exceed air injection pressure as it equipped vehicles
r Ee I Ref
will at high speed or when the air pump drive F
belt fails the air Carburetor idle mixture
injection nozzle is in the path
of the exhaust gases and the exhaust manifold
On equipped with the Air Inje ction
cars
pressure will exceed air injection pressure
System slightly rich adjustment of the idle
backing up exhaust gas which is prevented from mixture is required
entering the check valve
system by the whicb
closes it off
Cooling system

A modified engine cooling system will be

used due to increased engine heat at
Air pump relief valve rejection
idle caused by retarded ignition timing
The air pump relief valve is mounted in the Cooling system changes such as larger fans
discharge cavity of the air pump and accom higher fan speeds are incorporated
plishes the following functions without affecting
the exhaust emission control effec
system s
Fluid fan coupling
tiveness

Hold the increase in maxtmum exhaust gas The larger fans increase fan noise

temperatures to a minimum A fluid fan coupling is used on Air

Injection
Minimize horsepower losses resulting from equipped engines When the engine speed rises
air injection into the exhaust system to some predetermined speed the fluid fan
Protect the pump against excessive back coupling is activated and therefore reduces fan
pressures noise and fuel consumption

EC 7
 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 maintenance

must be performed
The details of annual maintenance are

described in chapter MAINTENANCE

REMOVAL AND DISASSEMBLY

Fig EC 9 Removing end cover
PROCEDURE

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The exhaust emission control
system should 3 Remove housing end cover by carefully tap
not be removed generally and full inspection ping on vicinity oflarge dowel pin with
must be done prior to removal plastic hammer and lifting straight up

4 Scribe rotor ring and side of rotor to assure

Air pump proper reassembly and then remove six

screws that retain rotor ring to rotor using
Removal hexagon wrench special tool STECP
20000
1 Disconnect hoses from air pump housing
cover Note Generally manufacture already gives coincidence
marks on both rotor ring and rotor
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 from car

assembly

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 Fig EC 10 Remolling rotor ring

1 Remove four drive
pulley hub bolts and
5 Remove rotor ring and side carbon seal from
remove pulley from hub
rotor
2 Clamp air drive hub in a vise
pump as
6 If it is necessary to replace rear bearing it
shown in Figure EC 9 and remove four
may be pressed out of rotor
ring on a press
housing end cover bolts
using support for disassembling rotor ring
Note Never clamp on the aluminum housing special tool STECP 20001 and attachment

EC 8
 EMISSION CONTROL SYSTEM

for pushing needle bearing special tool

STECP 20002

Note Support rotor ring carefully to avoid distortion

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EC 13 Removing relief valve
Fig
Fig EC 11 Removing rear rotor bearing
10 No further disassembly should be at

7 Remove vanes from rotor temped

8 Remove three sets of carbon shoes and three

Cleaning inspection Iubrication
shoe springs using pair of tweezers or needle

nose pliers 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

t8 w
i 1
00

EC 12 Removing carbon shoe

Fig

9 If it is necessary to replace the relief valve

for out relief valve
use bridge pulling spe

cial tool STECP 20004 and standard puller Fig EC 14 Air pump components

EC 9
 ENGINE

squeaking during initial operation The

Inspection
vanes may require five to ten miles wear in
Inspect all parts for chipping scoring
running time In the event a slight squeaking
we ar and roughne s s
still persists the vehicle should be run through
All damaged parts must be replaced to ensure
two or three full throttle shift points In
quiet and efficient operation If especially
most cases five to ten miles will be sufficient
side carbon seal is scored replace with new
for wear in
one

Carbon dust may be present in the housing

and is usually an indication of normal wear
4 Insert one carbon shoe on each side of
every vane
Lubrication
Note Each carbon shoe must the positioned so that
The rear bearing and vane 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
5 Insert three shoe into the deeper of
springs
equivalent Work grease into each bearing to
shoe slots

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insure adequate lubrication

Note Bearings for with Note When springs are properly positioned they
service are already packed
will be flush or below rotor surface The
high melting point grease
curved portion of spring will be against the

shoe and ends will be against wall of shoe slot

Assembly of air pump

1 Place air pump housing in a vise clamping

pump drive hub between 6 If rear bearing removed bearing
jaws was a new

may be pressed into rotor ring using at

2 Assemble vanes correctly on dummy shaft
tachment for pressing in needle bearing
9 s special tool
5 STECP 20005
special tool STECP 20003 The bearing
should be about 0 8 mm 0 0315 in below
rotor ring surface

Note Press only on lettered end bearing surface

and support rotor ring to prevent its distortion

7 Pos tion 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

Fig EC IS Vane ssembly
a

housing end cover assembly into position

indexing vane shaft into vane bearings Do

3 Place vanes into rotormaking sure that one
not force cover on as this will distort vane
vane is against housing stripper Do not
bearing and or vane bearing alignment
remove dummy shaft at this time
11 Seat end cover to housing and starting with
Note a Pack in vane hub bearing with high melting
bolt adjacent to large dowel torque four end
point grease such as ESSO ANDOK 260
cover bolts to 100 to 130 kg cm 7 2 to 9 4
b Installation of a new vane set in air injec
Ibft Remove from vise
tion pump may result in vanes chirping or

EC lO
 EMISSION CONTROL SYSTEM

12 Insert relief valve into housing mounting check the valve operation and inspect all hoses
hole With protective plate over valve tap and hose connections for leak

with hammer until valve shoulders on

housing 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

000 Note a Take care not to damage

b No further disassembly should be done
the air gallery pipe

3 Installation of check valve is reversal of

T procedure given for removal

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Note a Before installation apply the anti seize com
M pound such as PLATE
LED No 250 at the
screw

b Tightening torque 9 0 to 10 5 kg m 65 to
76 Ib ft

Fig EC 16 Specinl tool

4 After installation check the valve hoses and
Note Care must be observed to prevent distortion hose connections for air leakage
of air pump housing
Air gallery pipe and
Set silencer to relief valve by hand
13
injection nozzles
It is very difficult to remove injection
Installation of air pump
nozzles from the exhaust manifold without
Installation of air pump is reversal of pro damaging If damaged it will result in fra

cedure given for removal noting following tures or leakage Therefore the removal of the
air gallery pipe and injection nozzle should be
points
done only when they are damaged
Adjust the belt tension so that it has 8 to 12

mm 0 315 to 0 472 in of slack under 7 to 10

1 Lubricate around the screwed portion of the
kg 1 5 to 2 2 Ib of load
air injection nozzle with engine oil
Note Do not pry on the die cast pump housing
2 Remove the screwed plug connecting air

gallery to injection nozzle exhaust manifold

Dri ve pulley And then remove the air gallery from the ex

1 Loosen the air supply pump adjusting bar nut haust manifold

and bolt to relieve the belt tension

Note a Apply engine oil to the screwed portion
Remove the drive in several times during the above sequence
2 pulley attaching bolts
work
b Take care not to damage other correct parts
Anti backfire valve

The removal of the anti backfire valve 3 Insert a hard wire with hooked tip through
requires disconnecting the hoses further No the injection nozzle and hook nozzle with it and

disassembly should be done After installation then remove

EC ll
 ENGINE

the air
4 Check 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 lb

Note Before installation apply the anti seize com

5 At the time of installation the air injection pound such as LED PLATE No 250 at the

be correctly positioned into the screw

nozzles must
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 Guide is includ haust emission control

Diagnosis system

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Trouble Possible cause

Excessive backfire in exhaust Anti backfire valve vacuum line collapsed 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 leak at the anti backfire valve vacuum

line or at the anti backfire valve vacuum chamber

Enginesurges at all speeds Improper carburetor adjustment idle speed idle fuel
choke etc
mixture solting

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
2 Check hoses to insure that they are not
less Under normal conditions noise rises
loose leaking or touching other parts of
in pitch as engine speed increase
car
If excessive noise is heard the following
steps should be taken 3 Check relief valve for escaping air

EC 12
 EMISSION CONTROL SYSTEM

Noise internal cause 2 Inspect carbon seal This seal should not
show holes caused by wear or be broken or
1 Vane noise
cracked Such condition commonly results
A chirping or squeaking noise is most com
from rear andlor vane bearing failure
rubbing in
monly associated with vanes
A failed seal must be replaced
housing bore Vane chirping is most

noticeable at low speed and is heard inter 3 With rear rotor ring and carbon seal re

mittently moved pull out vanes Vane bearing failure

Additional wear in time may eliminate this is also indicated by absence of grease or
condition If additional wearin time does caked grease Inspect vane shaft to confirm
not eliminate chirp pump must be disas this bearing failure All corners of vanes

sembled vanes and carbon shoes replaced should be square Broken edges require
vanes be replaced
2 Bearing noise
A rolling sound indicatesbearing noise shoes
4 Remove carbon and inspect surface
This sound will be noticeable at all speeds
contacting vane Small grooves in shoes are
but does not necessarily indicate bearing
normal chipped or broken shoes require
failure However if noise increases to

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replacement Broken shoes indicate impro
objectionable level bearing may have to be
per assembly of shoe springs Damaged
replaced shoes must be replaced and springs must be

properly installed
Off car

1 With pump removed from car rotate drive 5 Carbon dust may be present on vanes and in
hub in jerks three quarters of turn forward housing This is indication of normal wear
not failure Remove carbon dust
and one quarter of turn backward If rough by blowing
ness or bumps are felt remove rear cover air on parts in question

Trouble Possible cause Remedies

Inoperative pump Trouble in pump Replace with new pump

Excessive slackness of drive belt Adjust drive belt tension to specifi

ed data

Insufficient Damaged vane hub bearing Replace defective parts

delivering air
Worn vane Replace worn parts

Worn carbon shoe Replace worn parts

Worn side seal Replace worn parts

Air leakage Leakage from hoses connectors Ammend or tighten

or clamps
Replace if necessary

Leakage from relief valve Replace relief valve

Abnormal noise Stick of air pump Replace with new assembly

Slackness of drive belt Adjust drive belt tension

in accelerating

Leakage from hoses connectors Retighten or replace

or clamps

EC 13
 ENGINE

It should return to the original posi

Testing freely
tion the valve seat when released
against
The following procedures are recommended
V
for checking andlor verifying that the various
1 fe
Lea the hose disconnected and start the
components of the exhaust emission control
engine Slowly increase the engine speed to
system are operating properly The engine and
500 r p m
1 and watch for exhaust gas
all components must be at normal operating
leakage at the check valve There should
temperatures when the test are performed not be any exhaust leakage The valve may
Prior to performing any extensive diagnosis of
flutter or vibrate at idle speeds but this is
the exhaust control system it must be deter
normal due to the exhaust pulsations hi the
mined that the engine as a unit is functioning
manifold
prope rly Die conne ct the anti backfire valve

vacuum sensing hose Plug the anti backfire

g If the check valve does not meet the recom
valve vacuum sensing hose to close the passage
mended conditions replace it
to the intake manifold N A IS After check
ing the engine normal operation reinstall all
the N A I S parts
Anti backfire valve test

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Check valve test a Operate the engine until it reaches normal

operating temperature
This test can be performed at the same time

as the air pump test

b Inspect all hoses and hose connections for

a Operate the engine until it reaches normal ovbious leaks and correct them before

operating temperature checking the anti backfire valve operation if

necessary
b Inspect all hoses and hose connectors for
obvious leaks and correct as necessary be
c Accelerate the engine in neutral allowing
fore checking the valve operation
the throttle to close rapidly The valve is
c Disconnect air supply hose at the check operating satisfactorily when no exhaust
valve system backfire occures

d Visually inspect the position of the valve

plate inside the valve body It should be

positioned against the valve seat

lightly
away from the air distributor manifold

e Insert a probe into the valve connection on

the check valve and depress the valve plate

J i f 8 Inli ba lest
kfirc valvf

d If a further check is disconnect

necessary
the by pass hose to air pump suction line at

the anti backfire valve

EC 17 Check valve lest

fig

EC 14
 EMISSION CONTROL SYSTEM

and close the throttle valve Air pump test

e Open rapidly If

air flow is felt for half a second to one by a

a Operate the engine until it reaches normal
finger at the anti backfire valve outlet to the
operating temperature
air pump suction line the valve is function

ing properly If air flow is not felt or air

b Inspect all hoses and hose connections for
flow is felt continuously more than two
leaks and correct as necessary before check
seconds the valve should be replaced the air supply
ing pump

f Disconnect the vacuum sensing hose from the

c Check the air pump belt tension and adjust to
intake manifold at the anti backfire valve
specifications
Insert a suitable plug in the hose and fasten

it securely d Install a tachometer on the engine Start the

If engine idle speed varies excessively from engine and slowly increase the engine speed
the case the vacuum sensing hose is connect
to 1 500 r p m Check the air pump in the
ed with the valve the valve function is not
following order
proper and it should be replaced

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To pressure gauge

1
To air pump

Air pump test gauge

STEep 20006

0 9 4ir pump le 1
Fig gauge

EC 15
 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

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No leaky pressure is felt Leaky pressure is felt

Insert the open pipe end of the test gauge adaptor in the air supply
Relief valve is stuck
hose to the check valve at the anti backfire valve
Replace with new one
Clamp the hose securely
With engine speed at 1 500 r p observe the pressure produced at
m
the test gauge special tool STECP200006

Air pressure less than 3 4 psi than 3 4

more psi

Air pump is func

Air pump and relief Plug up the relief
valve are functioning valve and observe tioning properly
again the pressure
properly

Air pressure

Disconnect and plug the air hose to the air pump suction Replace relief
valve
line at the anti backfire valve
With engine speed at 1 500 rp m observe the pressure

produced at the test gauge special tool STECP200006

Aire pressure

Air pump is functioning Replace or repair air Air pump is functioning

properly pump properly
I nspect air leakage Inspect air leakage
from anti backfire from anti backfire
valve hose or hose valve hose or hose
connections connections

EC 16
 EMISSION CONTROL SYSTEM

SETTING IGNITION TIMING Note Care must be taken that the throttle shaft
ADJUSTING IDLE SPEED MIXTURE ann should never be pressed by the throttle

shaft arm adjust screw

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

is equipped with automatic trans

If the

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car
7f
it rNote
4 Turn
mission make
interfere with

the throttle
sure the

throttle closing

shaft arm
dash pot does

adjust screw
not
ITHROTTLE
ARM ADJUSTSCREW
SHAET

counter clockwise so that the tip of it does not

Fig EC 20 Model D3034C carburetor
touch the throttle shaft arm
Note If you set idle speed and mixture by using
5 Set the idle speed at 700 r p m 650 r p m CO meter the followin procedure should be
done after above item 3
for automatic transmission adjusting the
by
throttle adjust screw and adjust the ignition tim a Disconnect the air supply hose at the check

at 50 A T D C valve Insert a suitable plug in the check

ing
valve inlet
700 650
Adjust the idle adjust screw and throttle b Set the speed at r r
6 p m p m

adjust screw until the most satisfactory 700 for automatic transmission by adjusting the
r 650 r p m for automatic transmission throttle adjust screw and adjust ignition
p m

engine speed is obtained timing at 50A T O C

c Adjust the percentage of the carbon monoxide

7 Turn the idle adjust screw clockwise for 1

to 6 0 at 700 r p m 650 r p m for
leaner mixture until the point where the engine 0 5

idle speed begins to drop approximately 10 automatic transmission by turning the idle

r p m adjust screw and throttle adjust screw

d Check the ignition timing Timing should

8 Turn the idle adjust screw counter clockwise remain at 50A T O C at 700 r p m 50
for richer mixture one turn one and a half for A T OC at 650 rp m for automatic trans

automatic transmission mission

e Connect the air supply hose at the check valve

the at 700 650

9 Set engine speed r p m f If the engine speed changes adjust the engine
r p m for automatic transmission by adjusting speed at 700 rp m 650 r p m for automatic
the throttle adjust screw Check the ignition transmission by turning the throttle adjust
timing Timing should remain at 50 A T D C screw

at 700 r p m W A T D C at 650 r p m for

MAINTENANCE
automatic transmission
To make certain that exhaust emissions are

10 Turn the throttle shaft arm adjust screw maintained at a low level it is recommended
that the tip of it just touches the that inspection be made 12
clockwise so basically every

throttle shaft arm months or every 20 000 km 12 000 miles

EC 17
 ENGINE

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
Fig EC 22 Spark plug check
2 Distributor check

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adjusting tool Spark plug should be replaced
every 20 000 kIn 12 000 miles

4 cable test
High tension

Fig EC 21 otributor
Di check

Check the distributor cam dwell angle and

point condition and adjust to specifications or

replace as required Check the ignition timing
Fig EC 23 High tension cable test
and adjust it to the specification
Clean and apply distributor grease to the cam
Use an ohmmeter to check resistance on
and wick
secondary cables Remove cable from spark
Breaker points should be replaced at inter
plug and install the proper adaptor between
vals not to exceed 20 000 kIn 12 000 miles
cable and spark plug Remove the distributor

cap from the distributor with secondary cables

3 Spark plug test
attached Do not remove the cables from the

Remove and clean in sand blast

plugs a cap
cleaner Inspect each spark plug Make cer Connect the ohmmeter between the spark
tain that they are of the specified heat range plug adaptor and the corresponding electrode

Inspect insulator for cranks and chips Check inside the cap If resistance is more than
both center and ground electrodes If they are 15 000 ohms the cable from cap and
remove

badly worn replace with new spark plugs File check cable resistance only If resistance is
center electrode flat Set
the gap to 0 80 to still more than 15 000 ohms replace cable
0 0315 to 0 0355 in
0 90 mm
using the proper assembly

EC 18
 EMISSION CONTROL SYSTEM

Periodic recommended maintenance

5 Battery check

Test the with

battery specific gravity an
Periodic inspection and required servicing
accurate hydrometer Specific gravity should of these system should be carried out at the
be at least 1 220 or more with temperature cor intervals to cleaner
recommended assure a
rections Add mineral free water as required better performing longer lasting engine and
to fluid upto proper level
bring almost complete elimination of air pollution
Clean battery posts and cable terminals
After tightening clamps coat the battery posts
and clamps with light grease to retard correc

tions

N A IS

Item Interval

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1 Engine
3 000 M
Check ignition timing every

3 000
Check engine idling

12 000
Engine tune up

3 000
Check spark plugs

12 000
Replace spark plugs
12 000
Check high tension cables

of distributor breaker points 3 000

Check for pitting and wear

12 000
Replace distributor breaker points

to distributor rotor shaft 12 000

Apply grease

to distributor cam and wick 12 000

Apply grease

Replace carburetor air cleaner element 24 000

2 Crank case emission control

12 000
Check hoses and hose connections for leaks

12 000
Check for proper function of crankcase ventilation control
valve

3 Exhaust emission control

12 000
Check for proper function of air pump

12 000
Check for proper function of relief valve

12 000
Check for proper function of checkvalve

12 000
Check for proper function of anti backfire valve

12 000
Check air gallery and nozzle connections for leake

12 000
Check hoses and hose connections for leake

3 000
Check air pump belt tension

EC 19
 ENGINE

SERVICE DATA AND SPECIFICATIONS

Type of crankcase emission control Closed type

Type of exhaust emission control Nissan Air Injection System

Carburetor Make NIHONKIKAKI

Model D3034C

Type Downdraft dual throat

Barrel Primary Secondary

Bore 30 mm dia 34 mm dia

1 181 in dia 1 339 in dia

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Large venturi 23 mm dia 28 mm dia
0 906 in dia 1 102 in dia

Small venturi 1st 7 mm dia 8 mm dia

0 276 in dia 0 315 in dia

2nd 14 mm dia 16 mm dia

0 551 in dia 0 630 in dia

Main jet 11102 11155

Slow jet II 50 II 80

Main air bleed II 60 80

Emulsion hole O 5 mm dia 0 5 mm dia

0 020 in dia x 5 10 020 in dia x 5

Slow air bleed 1st 11160

2nd 150 220

Slow economizer 1 6 mm dia 0 063 in dia

Power jet II 50

Cushion jet 11120

Air jet 11150

Power system Vacuum acting type

Vacuum piston 9 ffim dia 0 354 in dia

Pistonspring 100 gr 0 220 lbs 31 mm 1 22 in

Power valve spring 40 gr 0 0882 Ibs 8 6 mm 0 339 in

Actuating vacuum 140 110 mm Hg 5 51 4 33 in Hg

Accelerator pump

Piston 14 mm dia 0 551 in dia

Pump discharge 1 O 2 c c 0 0122 cu in

2 0 4 c c 0 0244 cu in

3 0 6 c c O 0366 cu in

Pump nozzle O 5 mm dia 0 020 in dia

EC 20
 EMISSION CONTROL SYSTEM

Main nozzle P 2 3 mmdia S 2 8 mm dia

0 0906 in dia 0 110 in dia

Throttle valve

P 10 S 20
Fully closed angle
Idle opening Approximately 5

Choke valve

Fully closed angle 10

Throttle opening at full
choke 13 5

Distributor Make HITACHI

Model D423

Spark plug BP 6E

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Air pump Model ECP 200 1A

Capacity 200 c c Irev

Air pump pulley ratio 120 120 1 00

Relief valve opening pressure 4 2 mAq 6 psi

Antibackfire valve

Air by
Type pass type

Model DV54

Duration time 1 3 1 7 sec at 500 Hg 19 7 in Hg

Check valve AMC type

Type
o 15 mAq 5 91 in Aq
Opening pressure

Cooling fan Type Spider

Outer dia x blade no 370 mm 14 57 in dia x 4

4 000
Fan coupling Revolution ratio Fan rpmlwater pump rpm 3 300

W IPump 120 103 1 17

Pulley ratio Fan

Tune up data Basic timing 5 A T D C

Idle r 700 rpm 650 rpm

p m

Distributor dwell 49 55 at O 02 in of point gap

angle
0 0315 0 0355 in 0 YY
Spark plug gap 0 go 0

Choke setting Manual

at the pump disconnected

CO percent setting 6 0
6 5

EC 2l
 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 6 174 It lb

Nut air pump to adjusting bar

Nut A B valve bracket to rocker COver

Screw A B valve to bracket 0 40 O 65 Kg m

Nut vacuum sensing lamp

hose to rocker 2 9 4 7 ft lb

cover c

Screwed plug air gallery to exhaust 5 0 6 0 kg m

manifold 36 2 43 4 It lb

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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 O 472 in of slack under

7 10 kg 1 54 2 20 lb of load

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

EC 22
 f 1

i DATSUN t
r
1800
a a I a I
t SECTION EE
SERVICE ENGINE
ELECTRICAL
MANUAL
SYSTEM
MODEL G11

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ENGINE

STARTING CIRCUIT 1

STARTING MOTOR 1

CHARGING CIRCUIT EE 12

ALTERNATOR EE 14

R GULATOR EE 26

IGNITION CIRCUIT 30

DISTRIBUTOR EE 30
NISSAN MOTOR CO LTD IGNITION CDlL EE 40

SPARK PLUGS EE 41
TOKYO JAPAN
 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

to body electrical such as the lighting circuit instrument and windshield

Information pertaining
found in section BE
wipers will be

STARTING MOTOR

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CONTENTS

EE 7
SPECIFICATION EE 1 Over running clutch assembly
DESCRIPTION EE 2 Brush holder test for ground EE 7

EE 2 Pinion bearing metal EE 8

OPERATION case

EE 3 EE 8
CONSTRUCTION Magnetic switch assembly
EE 3 ASSEMBLY EE 8
REMOVAL

EE 3 TEST EE 8
DISASSEMBLY
EE 5 Performance test EE 8
CLEANING AND INSPECTION
EE 9
Terminal EE 5 Diagnosis of test

Field coil EE 5 Magnetic switch assembly test EE 9

Brushes and brush lead wire EE 6 SERVICE DATA EE 10

Brush EE 6 TROUBLE DIAGNOSES AND

spri ng tension
Armature EE 6 CORRECTIONS EE 11
assembly

SPECIFICATION

HITACHI S114 104

Type
12V
Voltage

Output 1 0 KW

Less than 480 Amps 6V

Starting current voltage

Lock torque More than 1 15 kg m 8 31 ft lb

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

EE l
 ENGINE

Number of teeth on pinion gear 9

Number of teeth on ring gear 120

Weight 5 3 kg 11 68 Ibs

DESCRIPTION
The starting system permits the engine to be
1
cranked by turning the ignition switch to start

position While the ignition switch is turned to

I
start Klsition the starting motor continues

operation until the engine starts running on its

own power then the starting motor current is

13
opened and the disengaged by turning
motor is

the ignition switch on to ON position This

starting motor utilizes an enclosed overrunning

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clutch type and the compound motor as 12 11 10
described following The solenoid switch is

mounted onto the yoke

1 Stationary ntact
8 Shift lever

2 Series oil 9 Drive pinion

J Ignition switch 10 Ring gear

Solenoid II Pinion sleeTe spring
5 Shunt oil 12 Armature

6 Plunger 13 Movable ntactor

7 Return spring H Battery

EE 2
Fig Starting motor circuit

Closing of the contacts stationary and

movable causes the motor to crank the engine
and also cuts out the series eoil 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 ON position the series
Fig EE l 5114 104 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
OPERATION
of the pinion and the
ring gear teeth are secured
When the ignition switch is turned to of the
on by means running clutch overThe
start position current flows through the over running clutch shift leve
employs a r to
series and shunt coils of the solenoid and slide the pinion along the armature shaft and
magnetize the solenoid The plunger is pulled into or out of mesh with the ring gear teeth
into the solenoid that it operates the shift The
so
running clutch is designed to transmit
over

lever to movethe drive pinion into engagement driving torque from the motor armature to the
with flywheel ring gear and then closes the ring gear but permit the pinion to over run the
solenoid switch armature after the engine has started

EE 2
 ENGINE ELECTRICAL SYSTEM

CONSTRUCTION

Shift Gear case Shift IsvBr Magnetic switch ass y

Armature Thrust washer
Dust cover Dust cover

O
000
llking Stopper
washer
Stopper clip

ij 6
r
Thrust washer
@o@
@
Plmon
stopper
Over

Pinion
running clutch

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Metal
I Rear cover
Th rough bolt

Bruslle Brush holder ass y

Yoke B
Brush Brush spring

Magnetic switch terminel

Fig EE 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 two bolts securing the starting motor

Pull starier
U
I
li
to the clutch housing assembly
forward and remove starting motor

DISASSEMBLY
o
1 Loose the nut securing the connecting plate
to themagnetic switch M terminal Remove

three securing magnetic switch and EE 4 Removing magnetic witch

screws Fig
remove magnetic switch assembly embly
EE 3
 ENGINE

2 Remove two through bolts and brush cover 5 Remove the pillIOn 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 overrunning
clutch Withdraw the over running clutch
assembly from the armature shaft

U
tU

Fig EE 5 Removing the brush cover

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3 Remove the yoke assembly by hitting lightly
with a wooden hammer

oeo

EE B Removal
Fig of the over running clutch

assembly

6 Dissolder the brushes using a soldering

iron and remove each brush

Fig EE 6 Removing thc yoke assembly

4 Withdraw the armature assembly and shift

lever

R i
i
o

Fig EE 7 Removing the armature assembly

and hift lever Fig EE 9 Removing bru h

EE 4
 ENGINE ELECTRICAL SYSTEM

Field coil
Check the field coil insulation If the insu
it should
lation of the coil is damaged or worn

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 IO Removing brush holder

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o

0 liAr
EE 12 Field coil te t for
o Fig continuity
@

Field coil test for ground

000
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

solvents for cleaning the

grease dissolving
over running clutch armature assembly mag
netic switch assembly and field coils since such
in
a solvent would dissolve the grease packed

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
Fig EE 13 Field coil te t for ground
necessary

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 he

replaced

Brushes and brush lead wire

Check the condition of the brush contact

surface and wear of the brush If a loose con

tact may be found it should be replaced

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 hrush holders and spring clip to see
Fig EE 15 In pection of armature haft

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that they are not deformed or bent but will for bend
properly hold hrushes against the commutator
If the brushes or brush holders are dirty
they should be cleaned 2 Inspect the commutator If the surface of
the commutator is it be sanded
rough must
Brush spring tension with 00 The
lightly a No sandpaper commu

Check the brush spring tension hy tator must be checked also for out of round
a spring
scale as shown in Figure EE 14 The reading If the out of round is more than 0 2 mm

should he O 8 kg 1 761bs Replace the spring 0 0079 in or the depth of the insulating mica
if the tension is lower than 0 7 kg 1 54 lbs 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 O 5 to O 8 mm

0 0197 to 0 0315 in
The wear limit of the commutator diameter is
2 mm 0 0787 in If the commutator is be
yond repair replace it

Fig EE 14 In pection of brush spring

ten ion

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 16 In pection of commutator

EE 6
 ENGINE ELECTRICAL SYSTEM

S Ej
Correct Incorrect

Fig EE 17 Undercutting in ulating mica EE 19 Armature test for hort

Fig

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3 Inspect the soldered connection of armature 6 Check armature for continuity by placing the
lead and commutator If the loose connection probes of tester on two segments side by side

is found solder it using rosin flux If the tester shows no conduction the circuit is

open

4 Armature test for ground

a circuit tester test Over running clutch assembly
Using place one probe
and screw
on to armature shaft and other on to each com Inspect the pinion assembly
mutator bar sleeve Screw sleeve must be freely slid along
If damages are
If the tester shows conductive armature is the armature shaft splined

grounded and must be replaced 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

1 ji OeO

Fig EE 18 Armature test for ground Fig EE 20 Over running clutch mbly

5 Check armature for shorts by placing on the

Brush holder test for ground
armature tester and with hack saw blade over Using a circuit tester place one test probe

armature core rotate armature If saw blade on to rear cover and another on to positive side
vibrates armature is shorted brush holder If the tester shows conduction

EE 7
 ENGINE

the brush holder is shorted to ground Replace has been overhauled to ensure perfor
that its

an insulator or brush holder 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

Noload test

starting motor in series with

Connect the

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

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Fig EE 21 Brush holder test for ground
Switch

Starter
Pinion case bearing metal motor
s
Inspect the bearing metal for wear or side B

If the clearance between the bearing

play
metal and the armature shaft is more than 0 2
E
0079 in the metal Press in
mm 0 replace
a new bearing and adjust the clearance to 0 03

to o 10 mm 0 0012 to O 0039 in The bear

ing metal should be so pressed In that the end of

Voltmeter Ammeter
the bearing metal would be equal to gear case

end plane

Magnetic switch assembly

Inspect the magnetic switch contacts If a Fig EE 22 No load test

rough welding be found on the contact it should

be repaired

ASSEMBLY
Assembling is a reversal of the disassembly
Torque test
procedure
When assembling pack the grease in the Torque testing equipment should be used to
rear case and apply light coat of oil to the rear determine the torque the motor will develop
resistance
cover bearing metal and pinion A high current carrying variable
should be connected into the circuit so that the

specified voltage at the starting motor may be

TEST
obtained since a small variation in the voltage
will produce a marked difference in the torque
Performance test
development
The starter motor should be subjected to a Specified power voltage and torque are

no Ioad and a lock torque test whenever it shown in Figure EE 23

EE 8
 ENGINE ELECTRICAL SYSTEM

1 A open field coil

Performance curve grounded or

Inspect the connection and trace the circuit

by a circuit tester

2 The armature coil does not operate

Inspect the commutator for excessive burned

GI

oE a EjDI l out In this case arc may occur on defec

g Is 0
a
tive commutator when the motor is operated
12 000 1 2 12
with no load
10 000 1 0 10

3 Burned out commutator bar

8 000 08 8

Weak brush spring tension broken brush

6 000 06 6
spring rubber brush thrust out of mica in

4 000 04 4
the commutator or a loose contact brush and
commutator would cause to burn the com

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2 000 02 2
mutator bar

0 0 0
300
0 100 200 400 3 Low torque low current draw and low no

Current flow A
load speed would caU6e high internal resistance
due to loose connections defective leads dirty
commutator and causes listed on item 2 3

4 High no load speed with low developed torque

would cause grounded field coil Replace the
EE 23 5114 104
Fig field coil and check for improvement in per

fonnance

Diagnosis of test

1 Low speed with no load and high current

Magnetic switch assembly test
draw may result from followings

1 Tight dirty or worn bearings

2 Bent armature shaft or loosen field probe Ignition switch

3 Shorted armature

Check armature further B

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 BMS

tester place one probe on insulated terminal

and another on rear cover If the tester
indicates conduction remove other two

brushes and check fields and armature Battery 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 a
embly
test
may result from followings

EE 9
 ENGINE

If the starting motor check is OK check

the switch assembly Connect jumper
magnetic
cables between the negative hattery terminal
and the starting motor M terminal the posi
tive battery terminal and the starting motor
S terminal connecting ignition switch in series
as shown in Figure EE 24
With the ignition switch on measure the gap

between the front edge and the

pinion
pinion stopper

Fig EE 25 urement
Me of gap L

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SERVICE DATA

S114 104jl

0 032 0 0013
side 11 0 0 4331 ill
Armature shaft diameter pinion mm
0020
0 050 0

0 032 0 0013
11 5 0 4528
Armature shaft diameter rear end mm
0 0020
m
0 050

Amendment limit of shaft diameter O 1 mm 0 0039 in

Amendment limit of shaft bent 0 08 mm 0 0031 in

Clearance between shaft and bush 0 03 O 1 rom 0 0012 0 0039 in

Amendment limit of dittoed clearance 0 2 mm 0 0079 in j

Outer diameter of commutator 35 0 mm 1 3780 in

Wear limit of commutator diameter 2 0 mm 0 0787 in

Brosh length 18 5 mm 0 7283 in

Wear limit of dittoed length 6 0 mm 0 2362 in

remaining hrosh should be more than 12 5 mm 0 4921 in

Brush spring tension 0 8 kg 1 76 Ibs

0 018 0007
Front bracket metal inner diameter 11 0 mm 0 4331 in
0

021 0008
Rear cover metal inner diameter 11 5 mm 0 4528 in

EE I0
 ENGINE ELECTRICAL SYSTEM

TROUBLE DIAGNOSES AND

CORRECTIONS

Troubles Possible causes Remedies

motor will Discharged battery Charge replace the battery

Starting or

not operate Defective solenoid switch replace the solenoid

Repair or

switch

Loosen conne ctions of the ter Clean and tighten the termin
i1
minal

Defective brushes Replace the brush

Defective starting motor Remove the starting motor and

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make test

bolt Tighten the bolt

Noisy starting Loose securing
motor
Worn pinion gear Replace the pinion gear

Poor lubrication Fill in oil

Worn commutator Disassemble the motor

Worn brushes Replace the brush

Starting motor Discharged battery Charge or replace the battery

cranks slowly
Loose connection of the terminal Clean and tighten the terminal

Worn brushes Replace the brush

Locked brushes Inspect the brush spring tension or

the brush holder

repair

Dirty or worn commutator Clean and repair

The armature rubs the field coil Disassemble the motor

Defective solenoid switch Repair or replace the switch

Starting motor Worn pinion Replace the pinion

but does
operates Locked pinion guide Repair the pinion guide
not crank the

engine Worn ring gear Replace the ring gear

Starting motor will Defective solenoid switch Repair or replace the solenoid

not disengage even switch

the ignition switch Defective gear teeth Replace the defective gear
is turned off

EE ll
 ENGINE

CHARGING CIRCUIT

The charging circuit includes the battery energy from the engine into electrical energy
all electrically operated units and
alternator regulator and necessary wiring to to supply
connect these parts The purpose of this keep the battery fully charged
system is to convert just enough mechanical

SPECIFICATIONS

Alternat or Regulator

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AS2030B 1 AS2040P RQA22208
Item Item

Applied engine GI8 G18 option Applied alternator AS2030Bl

AS2040P
Maker MITSUBISHI MITSUBISHI
Applied engine G18

Nominal output 14 V 30 A 14 V 40 A

Maker MITSUBISHI
N egati ve N egati ve
Pole
ground ground Type Tirril type

1 000 1 000

Revolution 12 000 12 000 Constant voltage

Element
rpm rpm relay and pilot
lamp relay
No load
Less than Less than
minimum
000 rpm 1 000 rpm
Constant voltage 3 contact point
1
revolution relay type
30 A 14 V 40 A 14 V
Output current
No load 14 3 15 3 V
5 000 rpm 5 000 rpm regulating
voltage 4 000 rpm

Pulley ratio 2 04 2 04 l20 C 68 F

When the current flows from

ignition switch is turned on exited On the other hand
the ignition switch
current flows from the battery to ground through the battery to ground through
the ignition switch voltage regulator IG termi warning lamp voltage regulator L terminal
nal primary side contact point PI movable lamp side contact point P4 movable contact
contact point P2 voltage regulator IF ter point P5 and voltage regulator E terminal
minal alternator F terminal field coil and as shown by dotted arrows Then the warning

alternator E terminal shown by the heavy turns

as lamp on

arrows Then the rotor in the alternator is

EE 12
 ENGINE ELECTRICAL SYSTEM

When the alternator begins to operate three side contact by the magnetic force of coil
PI

VC2 Therefore
register Rl is inserted
phase alternating current is induced in the
in the field circuit and output voltage is de
armature This alternating current is rectified
This creased As the output voltage is decreased
by the positive and negative silicon diodes
the movable contact point P2 and primary
rectified current of direct current output comes
between the alternator B and E terminal side contact PI comes in contact once again
and the alternator increases Thus the
Figure EE 26 voltage
On the other hand the neutral point voltage rapid vibration of the movable contact point
N and Et terminal nearly a P2 or inserting and removing the resistance
comes between
the alternator field circuit maintains an
half of the output voltage and this causes to flow in

the current from voltage regulator N terminal alternator output voltage to constant

to E terminal or ground through the coil When the alternator is increased

speed
VCl asshown by the dotted arrows Then
further or the voltage starts to go further high
the coil VCl is excited and the movable con
at last the movable contact point P2 comes in
tact point P5 comes in contact with voltage
contact with secondary side contact point
winding side contact point P6 This action
Then the field current is shut off and alternator
causes to turn off the warning lamp and com
immediately This

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is decreased
output voltage
plete the voltage winding circuit as shown by action causes to separate movable contact P2
the heavy arrows
from secondary contact P3 Thus the rapid

When the alternator speed is increased or vibration of the movable contact point P2 or
the voltage starts to go too high the movable breaking and completing the field circuit main
output voltage to constant
tains an alternator
n
contact point P2 is separated from primary

r
I
I
I

I c
I
I j E
l
Armature
co
I 1

I c is
I

I
t T Battery
c I
I
I
2 I
I o
I I
I
I
Field e I
I
ES

r
I c 0
coil I
I
I 1
I
I
I I
I
I
I
I
I I
I I
I

J I I
Lu J L J

Alternator Voltage regulator

Fig EE 26 Charging circuit I

EE 13
 ENGINE

r i
I
I
I
I

Ell
I Armature c
I 2 0 Battery
00
L C T

c t L
i c

Field e
t

I
o

coil l
e

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I
I I
I

Alternator Voltage regu lator

EE 27 Charging circuit 2
Fig

ALTERNATOR

CONTENTS

DESCRIPTION EE 14 Inspection of diode EE 22

REMOVAL EE 15 Inspection of diode with tester EE 23

OISASSEMBL Y EE 18 Inspection of brush EE 24

DIODE REMOVAL EE 20 Spring pressure test EE 24

DIODE INSTALLATION EE 21 Inspection of output EE 24

INSPECTION AND REPAIR EE 21 ASSEMBLY EE 25

Rotor inspection EE 21 I n case of AS2030B 1 EE 25

I nspection of stator EE 22 I n case of AS2040P EE 25

DESCRIPTION
Different from the DC generator an alter three phase alternating current Silicon diodes
nator turns the magnetic and fixes the act like
pole one
way valves for electricity so that
armature In the alternator a magnetic field is charging current passes easily but reverse

produced by the rotor which consists of alterna current is shut out In this alternator six
tor shaft field coil
pole pieces and slip rings diodes are used three negatives and three posi
The slip ring pressed in the shaft conducts only tives and these six diodes are installed in

a small field current Output current is gener positive and negative heat sink voltage control
ated in armature coils located in the stator system is also basically same to D C system
The stator has three windings and generates in principle

EE 14
 ENGINE ELECTRICAL SYSTEM

11

B
12

13

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9 10

1 Brush S Pulley 8 Rm 11 Heat sink ssembIy

2 Brush holder 6 Brush 9 Stator ssembly 12 Positive diode

J Rotor sscmbly 7 Ball br aring 10 Front 13 Negative diode

Ball bearing

EE 28 Schematic view AS2030Hl

Fig

REMOVAL
Disconnect the terminal 4 Remove the alternator drive belt
1 negative battery
2 Remove two leads at the alternator and con
5 Remove the bolts which retain the alternator
nector

3 Loosen the adjusting bolt 6 Remove the alternator from a car

ni 29 4S2030H I Fig EE 30 AS2040l

Fig

EE 15
 ENGINE

Pulley assembly

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Front hearing Rotor assembly
I
Bearing retainer

Slip ring

3 Diode

Through bolt

Brush assembly

Rear cover
Brush cover

EE 31 Alternator assembly AS2030PI

Fig

EE 16
 ENGINE ELECTRICAL SYSTEM

Pulley assembly

Front cover

Rotor assembly

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Front bearing

Slip ring

Connector cfIi Rear bearing

EBDiode

eDiode

Heat sink assembly

f ig EE 32 Alternator 101
AS20
assembly

EE 17
p

ENGINE

DISASSEMBL Y
1 Unscrew the through bolts

Fig EE 36 Drive end hou ing and diode end

hou ing sepamled

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EE 33 Removal bolt I 3 Vise the rotor of the drive end housing as
Fig of through
sembly carefully not to injure the rotor
Remove the pulley nut pulley rim fan and the

spacer

Fig EF 34 Remuval of through bolt 2

2 Separate the diode end housing from the drive

f f 37 the rotor
end housing assembly by means of two drivers Fig Dua embling

eooo

Fig EE 35 Separating of diode end hou ing

from drive end housing Fig EE 38 Removal of pulley

EE 18
 ENGINE ELECTRICAL SYSTEM

Pull out the from the rotor

4 Remove the rotor from the drive end housing 6 rear bearing
assembly by hitting the drive end housing assembly using an arbor press or bearing
slightly with a mallet puller

c I

I
Z
L 1

r II

rr
L N a I
J
I
1
I
1

I
11
Ii
1 L

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Fig EE 39 Removal of rotor Fig EE 42 Pulling out of rear bearing I

5 Remove the bearing retainer by unscrewing

three set and out the bearing
screws push
using an arbor press

iL0Qi
I C
A Fig EE 43 Pulling out of rear bearing 2
r

l
0 o 7 To separate
housing assembly
the stator

disconnect the negative three

from the diode end

diodes from three coil lead wires and each lead

wire between diodes by melting solder with a

Fill EE 40 Removal of bearing retainer soldering iron

h
I

Fig EE 4l 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 l
I

tfl
v

fJI

4
Fig EE 47 Removal brush holder

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4S2040P

10 Disassemble the brush holder

Dissolder lead wire F black white color lead
wire E black color and the brush holder wires
EE s
4
Fig Diode end and stator negative and positive using a soldering iron

separoled
Note There are two kinds of diode Positive and
Note When the internal temperature of a diode Negative
goes up over 1500C 3000F the diode will The positive diode is marked with red figure
lose its function so use the electric iron 100W on the bottom of the diode and the negative
to 200W for around 2 seconds at the soldered diode is marked with black in
figure 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 screws washers and hushings

Red or Black figures

Fig EE 48 Diode identification

DIODE REMOVAL
To remove a diode use a suitable tool to
support the heat sink and push the diode out by
I f 16
Fig Removal of bru h holder
using an arhor press as shown in Figure EE 49
AS2030Bl

EE 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

not to

injure the mounting Rotor

bore of the frame or
inspection
1 Conduction test of field coil
the lt
he ink

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 0 at normal room temperature the

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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

33 Ibs
f 5 Condudion test coil
fig of field

2 Ground test of field coil

Check the conduction between slip ring and

J rotor

rotor
core If the conduction exists
assembly because in this case
replace
field coil
i I
or slip ring must be grounded
Ai I
l j

Fig EE 50 Installation of the diode fig J 52

f I round k offield mil

EE 21
 ENGINE

3 rotor eccentricity neutral wire is not conductive with stator core

Inspection of
the condition is all right
Check the eccentricity of rotor as shown in

Figure EE 53 using a dial gauge

replace if the eccentricity is over
Repair or

0 10 rom 0 0039 in

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Fig EE 55 Ground te t

Inspection of diode
Fig EE 53 In pection of rotor eccentricity
Using lamp and battery

1 Positive side diode

Connect the battery negative terminal with

the terminal BAT at rear cover and the battery
Inspection of stator
positive terminal with connector N terminal
1 Conduction test white color as shown in Figure EE 56

If the neutral wire of stator connected to Lamp in the circuit will light

the lead wire N white color is conductive with

each lead wire of armature coil the condition

is all right

itive
Fig EE 56 Inspection of po
side diode

Fig EE 54 Conduction t t
Nextly if lamp does notlight when the

connection is made reversely as shown in

2 G round test
side diode in
Figure EE 57 the positive is

If each lead wire of armature coil including good working condition

EE 22
 ENGINE ELECTRICAL SYSTEM

Fig EE 57 Inspection of positive side Fig EE 59 Inspection of negative

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diode side diode

side diode Inspection of diode with tester

2 Negative
There are two kinds of diodes as shown in
Connect the hattery negative terminal with
Figure EE 60 Each diode can he descriminat
connector N terminal white color and the bat
ed its polarity by the color of the printed
tery positive terminal with connector E terminal figures on each diode as follows
black color as shown in Figure EE 58
Lamp in the circuit will light

Cu rrent flow Current flow

Red figUre ack figUre DIode

M
terminal

Positive diode Negative diode

Fig EE 60 Diode

Check diode resistance using a tester in

Fig EE 58 Inspection of ncgative a current flow direction and a reverse direction

side diode as shown in Figure EE 61

When one side shows low resistance and the
other shows resistance the diode condition
high
Nextly if lamp does not light when the con is all right
nection is made reversely as shown in Figure If both sides are low there will be a short
EE 59 side diode is in circuit and if both sides are infinite there will
the negative good work
be open circuit In both cases replace diode
ing condition a

EE 23
 ENGINE

Spring pressure test

Place a suitable block on a platform scale

and press down brush holder with brush and
the block until brush sinks in the
spring on

holder to 1 mm 0 0394 in height from the

holder The reading subtracted the hlock
shows the spring pressure The spring
weight
pressure should be 0 35 kg 0 77 Ibs If the

pressure is small than 0 2 kg 0 44 Ibs

replace it

Fig EE 6l Diode te t

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Inspection of brush

Check the movement of brush and if the

movement is unsmooth check hrush holder and
clean it
The standard of brush is 13
length mm

0 512 in If brush wore off smaller than

7 mID 0 276 in replace the brush with new

one
Fig EE 63 Spring pre oure te t

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 Kl on and excite the rotor

r7 mm

13 mm

3 Drive the alterna1ure with motor and in

crease its speed gradually until the ammeter

indicates Izero

4 Turn off the switch Kl and further increase

the speed of the alternator until the voltmeter
EE 62 Bru h limit indicates 14 volts
Fig wear

5 The specified revolution when the voltmeter

AS2030B 1 AS2040P indicates 14 volts is approximately 1 100 rpm

Brush length 13 0 512 20 0 787 6 Make the load resistance the maximum and
mm in
turn the switch K2 on

Wear limit
7 0 276 14 0 552 7 Raise the load current by decreasing the load
mm in
resistance gradually and increase the alternator

EE 24
 ENGINE ELECTRICAL SYSTEM

speed Then the alternator 8 Read the output current when the revolution
output voltage
should be kept to 14 volts of alternator is 5 000 rpm

9 The specified current should be as follows

Note I ncreasing the alternator speed would cause to AS2030Bl more than 30 Ampere
increase the output AS2040P more than 40 Ampere

KI

K2
CD

c Ammeter 10nSOA
Load resistance

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Voltmeter

Battery

Fig EE 64 Circuit diagram for output inspection

in full up to the normal

Note Use the battery charged
capacity

ASSEMBLY

5 After the all parts have been assembled

In case of AS2030Bl
remove an iron wire then brushes and slip
Assembly is a reversal of disassembly pro
rings come in contact
cedure However the brush holder and brush
cover should be installed at the last procedure

I ran wire
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 Fig EE 65 Installation of brush holder

through bolts AS2040P

EE 25
 ENGINE

REGULATOR

CONTENTS

EE 27
REMOVAL EE 26 Adjustment of gap
INSTALLATION EE 26 Adjustment of voltage EE 29

ADJUSTMENT EE 26 TROUBLE DIAGNOSES AND

CORRECTIONS EE 29
Check of regulated voltage EE 27

INSTALLATION
7
Installation is a reversal of removal pro
cedure
B

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9

ADJUSTMENT
In the temperature compensated regulator
2 it is necessitated to the temperature
measure

of the the
3 regulator cover as regulating voltage
varied to the surrounding temper
is according
ature
6 In this the thermometer
case use 90196
5 0001P or cylindrical thermometer with putty as
4
shown in Figure EE 67

1 Movable ntact
uppon 5 Primary side ntact

2 Secondary side ntact

6 Primary side ntact

3 Secondary ide ct
upport
support 7 Spring
MoyabIe ntact 8 Bimetal
9 Armature

Fig EE 66 Regulator 2

The voltage regulator RQA2220B is temper

ature compensated so that the charging voltage J
copes with the climatic variations and two units
are housed in the regulator box a voltage regu
lator relay and a pilot lamp relay The effect
of temperature fluctuation on their relay setting
is minimized by the use of bi metal spring

1 Thermometer
REMOVAL 2 Cylindrical thermometer
To remove the voltage regulator disconnect
the 6 way multiple connector and remove the
cover
screw securing the regulator to the longitudinal Fig EE 67 Measuring of regulator
bulkhead of the engine room temperature

EE 26
 ENGINE ELECTRICAL SYSTEM

1 Connect the battery almost charged in full as

Check of regulated voltage
shown in Figure EE 68

B 8

Voltage regulator

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Connector

A Ammeter
V Voltage meter

Wire harness

EE 68 iUeler and indrument connection

Fig

2 Measure the temperature of regulator cover

Adjustment of gap
as shown in Figure EE 67
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
000 revolution 1 960 to 2 450
5 rpm engine
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 G2

16 0

15 5

Stopper
l

15 0
I I

1 Frame
114 5

14

Point gap G3
13 5
20 10 0 10 20 30 40 50 60
Regulater cover t ratur C

Fig EE 69 Fig EE 70 RQA2220B

EE 27
 ENGINE

ROA22208

O 8 1 1
Gl
0 0315 O 0433
Movable
Constant voltage G2 g2 gap
O 8 1 2 contact
relay G2 support
0 0315 O 0472
rom in

O 3 0 4
G3
0 0118 O 0157
Primary
contact
0 75 1 1 support
gap
gl 0 0295 0 0433 G3 I3
Pilot lamp
O 9 12
relay g2 0 0354 0 0472
rom in EE 72
Fig 4djusting gap
0 75 11

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g3
0 0295 0 0433

The voltBge regulator and the pilot lamp

relay the ad
are the same type Accordingly
justing method is also the same

Adjust these gaps in order of Gl g1 G2

g2 and G3 g3 if these are out of specifi

cations

Back gap GI or gl

Loose the armature hinge screw and adjust

the position by sliding the armature
EE 73 G2 g2
Fig Adjusting gap

Point gap G3 or g3

Adjust the gap by bending the secondary

contact support as shown in Figures EE 72 and
EE 74

EE 71 Gl
Fig Checking gl

Top air gap G2 or g2

Adj ust the gap by bending the movable con

tact supports as shown in Figures EE 72 and

EE 73 Fig EE 74 Adjusting G3 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
H ighten voltage

I Lower voltage

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FE 76 the voltage
Fip EE 75 Adjusting the voltage Fig Adjusting

TROUBLE DIAGNOSES AND CORRECTIONS

Troubles Causes Remedies

brush and brush

No output Sticking brushes Free replace
spring

Dirty brushes and slip rings Clean the brushes and slip rings

Loose connections or broken Tighten or solder connection

leads Replace leads

Open stato r winding Repair or replace the stator

Open rotor winding Replace the rotor

Replace the diodes

Open diodes

Replace the rotor

Shorted rotor

replace the stator

Shorted stator Repair or

Grounded BAT terminal Replace the insulator

Broken fan belt Replace the belt

Excessive Broken neutral point wire color Replace the wire

output
of wire is white

Defective voltage regulator Check the regulator operation

Poor grounding of the alternator Tighten the terminal connection

E termi
and voltage regulator
nal

EE 29
 ENGINE

Broken ground wire color of wire Replace the wire

is black

Low output Loose or worn fan belt replace the belt

Tighten or

Sticking brushes Free replace brushes and spring

if necessary

Low brush spring tension Replace the brush spring

Defective voltage Check the regulator operation

regulator

Dirty slip rings Clean the slip ring

Partial short ground or open in Replace the stator

stator winding

Partial short or ground of rotor Replace the rotor

winding

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Open diode or defective diode Replace the diode

Noisy alternator Loose mounting Tighten mounting bolts

Loose drive pulley Tighten pulley

Defective ball bearings Replace the bearing

Improperly seated brushes 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 EE 35
part
CHECKING AND ADJUSTMENT EE 34 DISASSEMBLY AND ASSEMBLY EE 36
Cap and rotor head EE 34 Disassembly EE 36
Point EE 34 Assembly EE 38
Condenser EE 34 SERVICE DATA EE 39

Vacuum advance mechanical part and

switch on off part EE 35

EE 30
 ENGINE ELECTRICAL SYSTEM

Distributor model Applied engine

D416 57 GI8

D423 53 G18 with

emission control system

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EE 77 D4l6 57
Fig

SPECIFICATIONS

0416 57 0423 53

Make HIT ACHI HITACHI

Applied engine G18 G18 with emission

control system

Firing order 1 3 4 2 1 3 4 2

Counter clockwise Counter clockwise

Rotating direction
80 600 B T D C 50 600 A T D C
Ignition timing
Dwell 49 550 490 550
angle
Condenser capacity I F 0 20 0 24 0 20 0 24

550 475
Start rpm
Centri 11 50 1 400 11 50 1 000
Maximum
fugal 16 5 2 800 23 50 2 600
Advance degree rpm

charac
Start mmHg 80 80
teristic

Vacuum 30 120
Maximum
6 50 200 80 400
degree rpm

kg lbs 1 2 2 646 1 2 2 646

Weight

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

Ignition switch
Ignition
plug
engine

Condenser

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Battery
o

Primary coil
Distributor
Ignition coil

Fig EE 78 Ignition diagram D4l6 5 D423 53

10

1 Vacuum ntroller 5 Rotor head 9 Knock pin

Condener 6 Breaker head 10 C p

J Contact 7 Governer weight 11 Cubon

em point
4 C 12
m 8 Oil seal Shaft

13 Pinion

Fig EE 79 Structure D4l6 57J

EE 32
 m ZG Z m mr m r VI VI m 3

A o ai 6 o S0 Vi

nion
ring Washer
P

Condesr
seal seal contrle

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Oil
Dust

Clip
Vacum
moC@
t1

Shaft I

OO
f1il
Iii

G
plate
G
@

II

spring Break r
set
Cam erner
O@
l
f
Go
J Contac
wire head
arth
E

1 Rot r
Cap

t
1 1
t l
t l
t

jt
tj I
 ENGINE

CHECKING AND ADJUSTMENT

point are also to he replaced with Details for
replacement is as undermentioned
Cap and rotor head First loosen by 1 to 1 5 turns of screw at

Clip aIld rotor head must always be kept contact arm and primary lead wire connection
clean to maintain good insulation durability part to pull out primary lead terminal In this

since high tension voltage from ignition coil is case however notice not to loosen the screw

imposed on them Sometimes inside of cap excessively Refer to Figure EE 82

and rotor head is covered by only fine carbon As shown in Figure EE 82 take off the
powder and dust cleaning is required by gaso from stem bar hold contact
stopper and the
line in it month Whenever crack or trace
once point by fingers and pullout toward you elevat
of leakage is found on the cap it must be ing it a little The both contact point and con
replaced with a new one tact arm can be disconnected together
When new contact set do justis connected

in opposite order Apply slightly grease on

both arm pivot receiver and surface of cam
Point

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Standard size of point gap is 0 45 to 0 55

mm 0 0177 to O 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 smooth fine
sand oily
paper No 500 or 600 or whetstone

must be applied for smoothing At this time

grease must be supplied to both pivot re

arm

ceiver and surface of earn In case wearing of

ill
point is remarkable it must be replaced with a
new one In this case contact arm and contact

EF 82 the contact and

Fig Duassembling arm

contact point

ADJUSTER Condenser
Performance of condenser depends on the
setting and insulating condition Thus frequent
checking is required to clean the outlet of lead
SET SellE wire and to prevent set screw from loosening
of condenser made by
Checking is capacity
meter Without capacity meter it can be
checked by tester by adjusting its range to
resistance value When con
EARTH TERMINAL measure large
denser is normal tester indicator swings
largely instantly and gradually moves back to
the infinite In case the indicator never stays
or it points Zero in resistance the transformer
EE 8l
Fig Breaker is out of order and must be replaced with

EE 34
 ENGINE ELECTRICAL SYSTEM

and 2 is to replace it with a new one

Vacuum advance mechanical part and
Solution for 3 is as follows
switch on off part

Vacuum advance characteristic 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

10
pivot receiver of fixed side

I Does this pivot receiver move

In case of assembly be sure to put in 3 steel

j
5 balls for each up and down side and to apply

grease

61 5
0
o 300 500
200

Vacuum nwnHg
Centrifugal advance mechanical
part

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When cause of engine trouble is traced to
centrifugal advance mechanical part use dis
Fig n 1l3 D416 57 tributor tester to check its characteristic
When nothing is with its characteristic
wrong
conceivable causes are defectiveness or ab
normal wearing out of driving part or others
So do not disassemble it In case of improper
1a characteristic take off switch on off part and

1 0 400 check closely cam assembly governor weight

0 shaft and governor spring etc
400

In case centrifugal advance mechanical part

5

is reassembled be sure to check advance

characteristic by distributor tester

o os

o 200 300 400 500 Centrifugal advance characteristic

Vacuum mmHg

20

Ef 1l4
Fig D423 53 17 5 2 800

Check whether vacuum advance mechanism 5

operates or not by operation indicator attached 1

0
to vacuum advance mechanism

the for
g 10

Followings are causes considered

non operation
5

1 Leakage of air due to incomplete fastening of

vacuum inlet
o
o 500 1 500 2 000 2 500 000
3
2 Leakage due to defective diaphragm Oiatributor rotation rpm

3 Fixed side and moving side of breake

r plate
is sticked

Solution for 1 is to make complete fastening Fig EE 85 D4l6 57

EE 35
 ENGINE

25
3 Take off contact breaker

I I Refer to page EE 34 when contact set is to be

disconnected
20

r I

1 1

JI t
5

251 1
f
ro
05

i I
5

0 4
t
o
o 1 500 2 000 500
2 3000

OiRributor rot Hon rpm

EE 86 D423 53
Fig ft

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DISASSEMBLY AND ASSEMBLY
set
Fig EE 88 Removal of contact
Disassembly
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

4

t Fig EE 89 Removal of contact breaker

l 4 When contact breaker is disassembled take

off clip to disconnect breaker plate fixed

o
putting down moving breaker plate
V 0 Be careful not to lose steel balls between break
those
o er spring and breaker plate as well as

o between breaker plates

Pull knock disconn6ct gear to pull out

5 pin and
whole rotation part However before pulling
out put counter mark
on gear and shaft or
remember the relation between coupling direc
Fig EE 87 Duassembly of vacuum controller
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 In this case also put counter

mark on cam and shaft or remember the rela
tion with ignition timing

Fig EE 90 Removal of knock pin

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Fig EE 92 Removal of cam

7 When governor weight and spring are dis

connected be careful not to stretch or deform

the When disassembly is

governor spring
completed apply grease to weight pivot

93 shows the exploded view

Fig EE 9l Removal of rotation part 8 Figure EE

L 0
l f
6
of
I

i r
r c
h

Fig EE 93 Exploded view D4l6 57 D423 53

EE 37
 ENGINE

Assembly Refer to Figure EE 94 at the time of replace

In case of reassembly do it in and
just reverse ment reassembly of governor spring and

way of disassembly earn

Governor weight Carn plate

Clearance for start and

end of advancing angle
Weight pin

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Rectangular hook

Circular hook

Governor 8 Governor A
spring spring

Rotor positioning tip

Fig EE 94 Setting of governor spring and ram

At the time of assembly rotor head posi

tioning tip at carn is to be set to governor

spring circular hook side Then weight pin for

A with circular hook comes in
governor spring

long rectangular hole It leaves clearance at

the start and end of Meanwhile
advancing
weight pin on opposite side comes in short
rectangular hole It does not leave clearance
either at the start and end of When
advancing
assembly is completed set it to after
engine
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

EE 96
Fig Point gap measure

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SERVICE DATA

All distributors

Point gap 0 45 0 55 mm 0 0177 O 0217 in

Point pressure O 50 O 65 kg 1 10 1 43 Ibs

0 010 0 0004
Shaft diameter lower pari 12 45 mm 0 4 9 02 m
0 020 0 0008

0 018 0 0007
Housing inner diameter 12 45 mm 0 4902 m
0 0

Clearance between shaft and housing 0 010 0 038 mm 0 0004 0 0015 in

Amendment limit of clearance O 08 mm 0 0031 in

0 005 0 0002
Shaft diameter upper part 8 mm 0 3150 m
0 014 0 0006

0 015 0 0006
Cam inner diameter 8 mm 0 315 0 m
0 0

Clearance between shaft and cam O 005 O 029mm 0 0002 O 0011 in

0 010 0 0004
Weight pivot diameter 5 mm 0 1969 m
0 028 0 0010

0 018 0 0007
Weight hole diameter 5 mm 0 1969 m
0 0

Clearance between pivot and hole O 01 0 046 mm 0 0004 O 0018 n

i

EE 39
 ENGINE

IGNITION COIL

oil type HP5 10E and

SPECIFICATION The ignition coil is a

pitch type coil HM 12F Dirty ignition coil is

e HANSHIN not available because it generates high voltage

The case and cap should be cleaned and protect

Model
HM 12F HP5 10E d from dust oil and water
Item

Applied G18 GI8 with emis

engine sian control

system

Primary voltage 12
12
V
1
Spark gap more than more than
in 6 0 2362 6 0 2362 2

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mm

resis
Primary 3
tance at 20 C 3 8 3 8

0
4
Secondary resis
5 15
tance at 20 C 11 2 16 8 11 2 16 8

KO
6 16

17

DESCRIPTION 18
7

19
8

1
20
30

I
9
I

10 21

11 9 HM tV
Vig
1 Secondary rmi ml 12 Washer

Primary rmianI D Seal

3 Contact spring 14 C p

4 51 IS Washer

5 Solder 16 Secondary rminal ate

pl
6 Guide ng 17 Primary ulating paper
7 Secondary ube 18 Outside iron

8 Primary tube 19 Primary il

9 Insulator 20 Secondary il

10 Case 21 Oil

EE 98 HPS lOE EE 99 truc ion mpS lOE

fig Fig Con

EE 40
 ENGINE ELECTRICAL SYSTEM

I
I

i ui ll

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r

DIIT
o
OIDT T

EI
100 Characteristic
Fig CUniC

SPARK PLUGS

CONTENTS

SPECIFICATION AND SERVICE EE 41 INSPECTION 42

EE
DATA EE 41 CLEAN AND REGAP EE 43
DESCRIPTION EE 41 TROUBLE DIAGNOSES AND
PERIODIC SERVICE EE 42 CORRECTIONS EE 44

SPECIFICATION AND
SERVICE DATA

RING CENTER EL
ECTRODE

NGK NGK
REACH GAP

Item BP 6E B 6E

Applied engine G1S with emission

Gl8
control system
TERMINA NUT
Size screw diameter 14 19 14 x 19
x ach mm in 0 5S x 0 75 0 55 x 0 75
A
INSUI
T

Plug gap O 8 O 9 0 7 0 8
mm in 0 03h O 03S 0 0 031
028

Torque kg m 1 5 2 0 I 5 2 0
ft lb 10 8 14 5 10
8 14 5 Fig EE lOl CrosHcction of Sf ark plug BP 6f

EE 41
 ENGINE

Too lean carburetion will also result

PERIODIC SERVICE seat

in excessive electrode wear

Periodically actual time depending on Broken insulators
are usually the result of
operating conditions plugs should he removed
improper installation or carelessness when
fo cleaning inspection and regapping
regapping the plug Broken upper insulators

usually result from a poor fitting wrench or an

outside blow The cracked insulator may not

INSPECTION make itself evident immediately but soon oil or

moisture will penetrate the fracture The

Spark plug life is affected to extent
a large fracture is usually just below the crimped part
by operating conditions and plug life varies
of shell and may not be visible
accordingly To insure peak performance
Broken lower insulators usually result from
spark plugs should be checked cleaned and
carelessness when regapping and generally are
regapped every 12 months or 20 000 km 12 000
visible In fajrly rare instances this type of
miles
break may result from the plug operating too
Worn or diriy plugs may give satisfactory
hot such as encountered in sustained periods
operation at idling speed hut under operating

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ofhigh speed under
operation or extremely
conditions they frequently fajl
Faulty plugs
heavy loads When regapping a spark plug to
are evident in a number of
ways such as wasting
avoid lower insulator hreakage always make
gas power loss loss of speed hard starting
the gap adj ustment by bending the ground side
and general poor engine performance
electrode Spark plugs with hroken insulators
Spark plug failure in addition to normal
should always he replaced
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 too

plugs which are

cold 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 they remain in a powdery
long as

state But under high speed or hard pull the Fig EE 102 Normal

powder oxide deposits melt and form a heavy

the insulator which
glaze coating on when hot
acts as good electrical conductor allowing
a

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 In addition electrode wear may

be the result of plug overheating caused bv
combustion gases leaking through the threads
and gasket due to insufficient compression of
the spark plug gasket dirt under the gasket EE 103
Fig Wet

EE 42
 ENGINE ELECTRICAL SYSTEM

EE 104
Fip Overheating I

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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 9ap file center electrode flat

In adjusting spark plug gap never bend center

electrode which extends through porcelain center

Always make adjustments by bendin9 ground

EE 105
Fig Overheating 2
side electrode

Fig EE 106 Overheating 3 Fig E 108 Measuring spark plug gap

EE 43
 ENGINE

TROUBLE DIAGNOSES AND

CORRECTIONS

1 When the not stari

engine does

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 he sparks that occur between the high tension cord
easily done by detaching the high tension cord and cylinder hlock After checking this use

from spark plugs start the engine by the start the proper countermeasures

Trouble location Causes Remedies

Spsrk gsp

No sparks at all Distributor Defective insulation of condenser Replace

Breakage of lead wire on low ten Repair

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sian side

Defective insulation of and Replace

cap
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 or
Oil sticking on point Clean
irregular
Point hurnt too much Replace

Layer short circuit Replace with good

one

Less than 6 mm Electrode gap too wide Correct

Spark plugs or re

0 2362 in place

Too much carbon Clean or replace

Broken neck of porcelain Replace

insulator

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

Trouble location Causes Remedies

Spark gap

Engine misses Distributor Dirty point Correct

very often Correct

Improper point gap

Leak of electricity of cap and Clean or replace

rotor head

Defective insulation of condenser Replace

Defective insulation of lead wire Correct

of condenser

Defective arm Oil the shaft

Defective spring of arm Correct or re

place

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Near breakage of lead wire Correct

Worn out and shaky breaker plate Correct

Worn out and shaky distributor Correct

shaft

Ignition coil Layer short circuit or use of in Replace with good

ferior quality one

High tension code Deterioration of insulation and Replace

leak of electricity

Spark plugs Dirty Clean or replace

Electricity leak at the upper por Clean

celain insulator

Distributor Improper and advance timing Correct the fit

Engine cause
knocking very ting
often Correct
Coming off or breakage of gover or re

nor spring place

Worn out a pin or a hole of gover Replace

nor portion

Spark plugs Burnt too much Replace

not Improper and retarded timing Correct the fit

Engine does Distributor

give enough ting

power Defective function of governor Correct

Dirty point Correct

Point gap too narrow Correct

Spark plugs Dirty Clean

EE 45
 ENGINE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

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EE 46
 f
DATSUN t
i 1 SECTION SE
SERVICE SERVICE
EQUIPMENT
MANUAL
MODEL Gll

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ENGINE

NISSAN MOTOR CO LTD

ENGINE TOOLS SE 1
TOKYO JAPAN
 SERVICE EQUIPMENT

ENGINE TOOLS

Tool number Tool name Figure Note

ST49700000 Pilot bush puller

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Valve guide reamer
4
8mm

ST49710000 Valve guide reamer set

Valve guide reamer

for cylinder head
14 2 mm

IN 43 dia 45
II g mm deg
IN 43 dia 30
mm
deg
ST49720000 Valve seat cutter dia
EX 36 mm 45 deg
Pilot

Gi Cross bar

Valve guide replacer

set

Valve guide replacer Use when out

qT drawing
the guide

ST49730000 Valve guide replacer U sewhen pressing in

the guide

Use for getting the

Spacer for valve
e specified length when
guide replacer
pressing in the guide

SE l
 ENGINE

Tool numbe Tool name Note

Figure

ST49740000 Front oil seal replacer

Rear oil seal drift set

t
c
seal drift
Rear oil
1

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ST49750000

Stand for rear oil

seal drift

ST49760000 Engine slinger

If

ST49770000 Engine carrier

ST37200G18 Engine attachment

SE 2
 SERVICE EQUIPMENT

Note
Tool number Tool name Figure

ST37100000 Engine stand

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SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

SE 3
 ENGINE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

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SE 4
 cardiagn.com
INISSANI

Printed in Japan Publication No 48331 30330250