1977 DATSUN PICK-UP check engine

Engine
Electrical

System

SERVICE
DATA
AND
SPECIFICATIONS

California

models
Non

California

models

For
Canada

except
for

Canada

BP6ES
ll
BP6ES

BPR6ES
Standard

L45PW
ll
L45PW

BP4E
ll
BP5ES
ll
BP4E

BP5ES
BPR4ES

Type
Hot

type

L46PW
ll

L47PW
ll

L46PW
L47PW
BPR5ES

Cold

type
BP7ES
ll

BP7ES

BPR7ES

LMPW
ll
LMPW

1
0
to
l
l
0
8
to
0

9
0
8
to
0
9

Plug

gap
mm

in

0

039
to
0
043
0

031
to
0
D35
0
031
to
0

035

Tightening
torque
kg
m
ft
Ib

I
1
5
to
2

0
11
to
14

TROUBLE

DIAGNOSES

AND

CORRECTIONS

When

engine
does
not
start

If
there
is

no

problem
in

fuel

system
ignition
system
should
be

checked
This
can
be

easily
done

by

detaching
a

high
tension
wire

from
spark

plug
starting

engine
and

ob

serving
condition
of

spark
that

occurs

between

high
tension

wire
and

spark

plug
terminal

After

checking
this

repair
as

necessary
Note
On
California
models

disc
on

nect
anti

dieseling
solenoid

valve

connector
to

cut
off

supply
of
fuel

to

engine
and

then
observe

the

condition

of

spaIks
while
starter

motor
is

in

operation

Condition
Location

Probable

cause
Corrective
action

No

spark
at
all

Distributor

Faulty
insulation
of
condenser

Non
Cali

Replace

fomia

models

Breakage
of
lead
wire
on
low
tension
side

Repair

Poor
insulation
of

cap
and
rotor
head

Replace

Seized

points
Non
California

models

Repair

Open
pick
up
coil
California
models

Replace

Air

gap
wider
than

specification
Cali

Adjust

fornia

models

Ignition
coil

Wire

breakage
or
short
circuit

of
coil

Replace
with
new
one

High
tension
wire

Wire

coming
off

Repair

Faulty
insulation

Replace

Transistor

ignition
Faulty
transistor

ignition
unit

Replace

unit

California

models

EE
4B

l
t

tJ
I

P

o

CUll

Fig
CL
9

Lubricating
poinu
of

withdrawal
lever
and

front
cover

4

Contact
surfaces
of
transmission

main

drive

gear
splines
lithium
base

grease
including
molybdenum
disul

phide

Note

Very
IIIIJllII
amount
of

grease

should
be
ated
to
the
above

points
If
too
much
iubricant
is

applied
it
will
run
out
on
the

friction

plates
when
hot

resulting

in
d

gi
dutch
disc

facings

3
Install
retainer

spring
to
with

drawal
lever
Fit
holder

spring
to

release

bearing
and
sleeve

assembly

then
assemble
withdrawal
Iever
and

bearing
sleeve
as
a
unit
Install
this

assembly
on

transmission
case
Then

install
dust

cover

Pilot

bushing

Before

installing
a
new

bushing

thoroughly
clean

bushing
hole
Install

bushing
in
crankshaft

using
a
soft

hammer

Bushing
need
not
be
oiled

INSPECTION

Wash
all
the
disassembled

parts

except
release

bearing
and
disc
assem

bly
in
suitable

cleaning
solvent
to

remove
dirt
and

grease
before

making

inspection
and

adjustment

Flywheel
and

pressure
plate

Check
friction
surface
of

flywheel

and

pressure
plate
for

scoring
or

roughness
Slight
roughness
may
be

smoothed

by
using
fme

emery
cloth

If
surface

is

deeply
scored
or

groov

ed
the

part
should
be

replaced

Clutch
disc
at
llembly

Inspect
clutch
disc
for

worn
or

oily

facings
loose

rivets
and
broken

or

loose

torsional

springs
CLUTCH

I
If

facings
are

oily
the
disc
should

be

replaced
In
this
case

inspect
trans

mission
front
cover
oil
seal

pilot

bushing
engine
rear
oil
seals
and
other

points
for
oil

leakage

2
The
disc
should

also
be

replaced

when

facings
are
worn
locally
or
worn

down
less
than
0
3
mm
0
0118
in

at

revels
See

Figure
CL
IO

DePth

ll
I

gauge

II

1
i
h

1

j1
t

f

Above

0
3
rom

10
012
in

CL089

Fig
CL
I0
Me
JIuringclutch

lining

3
Check
disc

plate
for
runout
when

ever
the
old
disc
or
a

new
one
is

installed

4
If

runoutexceeds
the

specified

value
at

the
outer
circumference
Ie

place
or

repair
disc
See

Figure
CL
II

Runou

t

0
5
mm
0
020
in

total
indicator

reading

R

from
the

hub
center

107
5
mm
4

23
in

CL112

Fig
CL

ll

MeOlUring
disc
runout

5
Check
the
fit
of
disc

hub
on

transmission
main
drive

gear
for

smoothly
sliding
If

splines
are
worn

clutch
disc
or
main
drive

gear
should

be

replaced
that

is
backlash
exceeds

0
4

mm
0
016
in

at
the
outer

edge
of

clutch
disc

Clutch

cover

assembly

I
Check

the
end
surface
of

dia

phragm
spring
for
wear

CL
4
If
excessive
wear
is

found

replace

clu
tch
cover
as
an

assembly

2
Measure
the

height
of

diaphragm

spring
as
outlined
below

See

Figure

CL
12

a
Place
Distance
Piece
ST20050100

on
Base
Plate
ST20050010
and

then

tighten
clutch
cover

assembly

on
the
base

plate
by
using
Set
Bolls

ST20050051

b
Measure

diaphragm
spring
toe

height
A

at
several

points
with
a

vernier

caliper

depth
gauge

STl0050100

rJrf
I
Tl

05001O

f

7

C
L23

STl005Q051

Fig
CL
12

Me
uring
the

height
of

diaphragm
pring

If
the

height

A
of

spring
end
is

beyond
the

specified
value
of
33
to
35

mm
1
23

to
1
38
in

adjust
the

spring

height
with

Diaphragm
Adjusting

Wrench
ST20050240
See

Figure

CL

13

If

necessary
replace
clutch

cover
as

an

assembly
Also
unevenness
of
dia

phragm
spring
toe

height
should
be

less
than
05
mm
0
020
in

ST20050240

CL152

Fig
CL
13

AdjlUting
the

spring
height

3

Inspect
thrust

rings
for
wear
or

damage
As
these

parts
are
invisible

from
outside
shake
cover

assembly
up

and
down
to
listen
for

chattering

noise
or

lightly
hammer
on
rivets
for
a

slightly
cracked
noise

Any
of
these

noises
mean

requirement
for

replace

ment
as
a

complete
assembly

CLUTCH

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Probable
cause
and

testing

Clutch

slips
Corrective
action

Slipping
of
the

clutch

may
be

noticeable
when

any
of
the

following
symptoms
is

encountered

during
operation

I
Vehicle
will

not

respond
to

engine

speed
during
acceleration

2
Insufficient
vehicle

speed

3
Lack
of

power
during
uphill
driving

Some
of
the

above
conditions
are
also

experienced
when

engine

problem
is

oc

urring
First

de
tennine
whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear
and
or

overheating
will
occur
on
clutch

facing
until
it
is

no

longer
serviceable

TO
TEST
FOR
SLIPPING
CLlJfCH

proceed
as
follows

During
upgrade
travelling
run

engine
at

about
40
to
50
km

h
25
to
31

MPH
with

gear
shift

lever
in

3rd

speed
position
shift
into

highest
gear
and
at
the
same
time

rev

up
engine
If
clutch

is

slipping
vehicle
will
not

readily

respond
to

depression
of
accelerator

pedal

Clutch

facing
worn

excessively

Oil
or

grease
on
clutch

facing

W

r
d
clut
h
cov
r

pressure
plat
Replace

Replace

tpa
o
e
lace

Dragging
clutch
is

particularly
noticeable
when

shifting
gears
especially
into

low

gear

TO
TEST
FOR
DRAGGING
CLlJfCH

proceed
as
follows

I
Start

engine
Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine
speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is

heard
when

shifting
from
Neutral
into

Reverse
Clutch

drags

2

Stop
engine
and
shift

gear
Conduct
this
test
at
each

gear
position

3
Gears

are
smoothly
shifted
in

step
2
but

drag
when

shifting
to
1st

speed
position
at

idling

a
If

dragging
is
encountered
at
the
end
of

shifting
check
condition
of

synchro

mechanism
in
transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4
Push

change
lever
toward
Reverse
side

depress
pedal
to
check
for
free
travel

a

If

pedal
can
be

depressed
further
check
clutch
condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5
below

5
Check
clutch
control

pedal
height
pedal
free
travel
withdrawal
lever

play
etc

If
no
abnonnal

condition
exists
and
if

pedal
cannot
be

depressed
further
check
clutch

condition

Clutch
disc
runout
or

warped

Wear

or
rust

on
hub

splines
in
clutch
disc

Diaphragm
spring
toe

height
out
of
ad

justment
or
toe

tip
worn

Worn
or

improperly
installed

parts

CL10
Repair
or

replace

Clean
and
lubricate
with

grease
or

replace

Adjust
or

replace

Repair
or

replace

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be
careful

not
to

damage
any

parts

with

scraper

b

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
pecting
ball

bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND

SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4
Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0
0126
to
0
0154
in

2nd

gear

0
12
to

0
19
mm

0
0047

to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to
0

0146
in

TM374

Fig
MT

29

Measuring
end

play

Manual

iTransmission

TIGHTENING
TORQUE

Installa
tion

Engine
to
transmission

installation
bolt

Transmission
to

engine
rear

plate
bolt

Clutch

operating
cylinder
installation

bolt

Rear

mounting
insulator
to

transmission
installation
bolt

Crossmember

mounting
bolt

Propeller
shaft
to
diff
installation
bolt

Gear

assembly

Rear

extension
installation
bolt

Front
cover

installation
bolt

Bearing
retainer
to

adapter

plate
screw

Main
haft
nut

Check
ball

plug

Stri
lever

lock

pin

Reverse
select

return

plug

Speedometer
sleeve

locking

plate
nut

Reverse

lamp
switch

year
oil
Ier

pl
g

Ge
r
oil
drain

plug
Unit

kg
m
ft
lb

4
4

to
5

9
32

to
43

0

9

to
1
2
7
to
9

2
5

to
3
0

18
to
22

0
8
to
1
1
6

to
8

3

2
to
43

23
to
31

2
4

to
33

17
to

24

1

6

to
2
1

12
to
IS

1
6
to
2
1

12to
IS

1
9
to
2
S
14
to
18

14

0
to
17
0

101
to
123

1
9
to
2
S

14
to
18

0
9
to
1
2

7
to
9

0
9
1
2
7

to
9

0
4

to
O
S

3

to
4

2
0
to
3
0

14
to
22

2
S

to
3
5

18
t02S

2
S

toTS

l8
to
2S

or

SPECIFICATIONS

Gear
backlash

Maindrive

gear
to
counter
drive

gear

1st

gear

2nd

gear

3rd

gear

OD

gear

Gear

end

play

1st

gear

2nd

gear

3rd

gear

OD

gear

Counter

gear

Reverse
idler

gear

Clearance

between
baulk

ring
and

gear

All

gears

Counter

bearing

adjusting
shim
Unit

mm
in

0
05
to
0

10
0
0020
to

0
0039

0
05
to
0

20
0
0020
to
0
0079

O
OS
to
0
20
0

0020
to
0
0079

0
05
to
0
20
0
0020
to
0
0079

0
05
to
0

20
0
0020
to
0
0079

0
32
to
0
39

0
0126
to
0
0154

0
12
to
0
19

0
0047
to
0

0075

0
13
to
0
37
0
0051
to
0
0146

0
32
to
0
39

0
0126
to
0

0154

0
01
to
0
21

0
0004
to
0
0083

0
05

to
0
20
0
0020

to
0
0079

1
25
to
1

60
0
0492
to
0
0630

0
6
0
024

0
5
0
020

0
4
0

016

0
3
0
012

0
2
0
008

0
1

0
004

MT
22

Manual
Transmission

I

TROUBLE
DIAGNOSES
AND
CORREGTIONS

Condition

Difficult
to

intel11lesh
gears

Causes
Jor
difficu
t

gear
shifting
are
classi

fied
to
troubles

concerning
control

system

and
transniissioo
When

gear
shift
lever
is

heavy
and
it
is
difficult
to
shift

gears
clutch

disengagement
may
also
be
unsmooth
First

make
sure
that

clutch

operates
correctly

and

inspect
transmissi
o

Gear
slips
out
of
mesh

In
most
cases
this
trouble
occurs
when

interlock
b
all
check
ball
and

or
spring
is

worn
or
weakened
or

when
control

system

is

faulty
In
this
case
the

trouble
cannot
be

corrected

by
replacing
gears
and
therefore

trouble

shooting
must
be

carried
out

care

fully
It
should
also
be

noted
that

gear
slips

out

of
mesh
due
to
vibration

generated
by

weakened
fron
t
and
rear

engine
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indicati90
that
th
e
noise
is

from
transmis

sion

t
Transmission

may
fa
ule

during
engine

idling

Check
air

fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gear
shaft
and
or

bearing

Insufficient

operating
stroke
due
to
worn
or

loose
sliding

part

Faulty
or

damaged
synchronizer

Worn
interlock
ball

Worn
check
ball

and
or

weakened
or
broken

spring

Wom
fork
rod
ball

groove

Wom
or
damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due

to

faulty
oil

seal
or

sealant

clogged

breather
etc

Worn

bearing

High
humming
occurs
at
a

high
speed

Damaged
bearing
Cyclic
knocking
sound

occurs
also
at
a

19W
speed

Worn

spline

Worn

bushing

j

MT
23
Corrective
action

Replace

pair
or
replace

Replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace

with

designated
oil

Clean
Of

replace

Replace

Replace

Replace

Replace

Starter

should
be

brought
into

op

eration

only
when
selector

lever
is
in

P

and
N

positions
it

should
not

be
started

when
lever
is
in
D
2

I

and
R

positions

Back

up
lamp
should
also

light

when

selector
lever
is

placed
in

R

position

S
After

converter
is
installed

rotate

10

Check
level
of
oil
in
transmis

crankshaft
several
turns
and
check

to

be
sure
that
transmission

rotates

freely
sion

For
detailed

procedure
see

page

AT48

without

binding

6
Pour

recommended
automatic
II

Move
selector
lever

through
aU

positions
to
be

sure
that
transmission

transmission

fluid

up
to
correct
level

operates
correctly

through
oil

charge
pipe

verter
to
transmission
measure

dis

With
hand

brake

applied
rotate

tan
A

to
be
certain

that

they
are
7

Connect
manual
lever
to
shift

engine
at

idling
Without

disturbing

correctly
mbi
d

S
F
rod

Opeiationsliould
oecaTrie
f
bue

the
above

sclUng
ffiovTSelector
lever

AT

50
with

manual
and
selector
levers
in

through
N

to
D
to
2

to
I

Distance
A
N

and
to
R
A

slight
shock
should
be

More
than
21

5
mm
0
846
in
8
Connect

inhibitor
switch
wires

felt

by
hand

gripping
selector

each

time
transmission
is
shifted
Automatic
Transmission

4
Bolt
converter
to
drive

plate

Note

Align
chalk
marks

painted
a

cross
both

parts
during
disas

sembling

processes

AT116

Fig
AT
49

Torque
converter

aligning
cu
t

3
When

connecting

torque
can

A

ATl17
Notes

a
Refer
to

covering
topic

under

Checking
and

adjusting

inhibitor
switch
n

on

page

AT
49

b

Inspect
and

adjust
switch
as

above
whenever
it
has
to

be

removed
for
service

Fig
AT
50

Installing

torque
converter
9
Check
inhibitor
switch
for

op

eration

AT
34
Note

See

page
AT

49
for

checking

engine
idling

12

Check

to
be

sure
that
line

pres

sure
is

correct
To
do
this

refer
to

relative

topic
under

Testing
line

pres

sure
on

page
AT

52

13

Perform

stall

test
as

per
the

instructions

on

page
AT

50

Automatic

Transmission

MAJOR

REPAIR

OPERATION

SERVICE
NOTICE
FOR

DISASSEMBLY

AND

ASSEMBLY

TORQUE
CONVERTER

INSPECTION

TRANSMISSION

DISASSEMBL
Y

INSPECTION

ASSEMBL
Y

SERVICE
NOTICE

FOR
DISASSEMBLY

AND
ASSEMBLY

I
It

is
advisable

that

repair
opera

tions
be

carried
out
in
a

dust

proof

room

2
Due

to
the
differences
of
the

engine
capacities
the

specifications
of

component

parts
for

each
model
s

transmission

may
be
different

They

do
however
have

common

adjust

ment

and

repair

procedures
as
well
as

cleaning
and

inspection

procedures

outlined
hereinafter

3

During
repair
operations
refer
to

Service
Data

and

Specifications
see

tion
for

the
correct

parts
for
each

model

4

Before

removing
any
of

subas

semblies

thoroughly
clean
the
outside

of
the

transmission
to

prevent
dirt

from

entering
the
mechanical

parts

5

Do
not
use
a
waste

rag
Use
a

nylon
or

paper
cloth

6
After

disassembling
wash
all
dis

assembled

parts
and
examine
them
to

see
if
there
are

any
worn

damaged
or

defective

parts
and
how

they
are

affected
Refer
to

Service
Data
for

the

extent
of

damage
that

justifies

replacement

7

As
a
rule

packings
seals
and

similar

parts
once
disassembled
should

be

replaced
with
new
ones

TORQUE

CONVERTER

The

torque
converter
is

a
welded

construction
and

can
not
be
disas

sembled
CONTENTS

AT

36

AT

36

AT

36

AT

36

AT

36

AT
38

AT

38
COMPONENT
PARTS

FRONT

CLUTCH

REAR

CLUTCH

LOW
REVERSE
BRAKE

SERVO

PISTON

GOVERNOR

OIL

PUMP

PLANETARY

CARRIER

CONTROL

VALVE
AT

40

AT
40

AT
41

AT
42

AT
42

AT
43

AT
43

AT
44

AT

44

INSPECTION
2

Remove
bolts

securing
converter

1

Check

torque
convertf

for

any
housing
to
transmission

case
Remove

sign
of

damage

bending
oil
leak

or
torque
converter

deformation

If

necessary
replace
3
Remove

speedometer
pinion

2

Remove
rust
from

pilots
and
sleeve

bolt
Withdraw

pinion

bosses

completely
4

Remove
downshift
solenoid
and

If

torque
converter
oil
is

fouled

or
vacuum

diaphragm
Do

not
leave
dia

contaminated
due
to
burnt
clutch

phragm
rod
at
this

stage
of
disas

flush
the

torque
converter
as
follows
sembly
Rod
is

assembled
in

top
of

vacuum

diaphragm
See

Figure

I
Drain
oil
in

torque
converter

AT

53

2
Pour

non
lead

gasoline
or

kero

sene
into

torque
converter

approxi

mately
0
5
liter

I
U
S

pt
U

Imp

pt

3

Blow
air

into

torque
converter

and

flush
and
drain

out

gasoline

4
Fill

torque
converter
with

torque
converter
oil

approximately

0
5
liter
I

V
S

pt
U

Imp
pt

5

Again
blow
air
into

torque
con

verter
and
drain

torque
converter
oil

TRANSMISSION

DISASSEMBLY

I

Drain
oil
from
the

end
of
rear

extension

Mount
transmission
on

Transmission
Case

Stand
ST07870000

or
ST07860000
Remove

oil

pan
See

Figure
AT
52

AT118

Fig
AT

52

Removing
oil

pan

AT

36
Fig
AT
53
Down

hilt
olenoid
and

vacuum

dilJphragm

5

Remove

bolts
which

hold
valve

body
to
transmission

case
See

Figure

AT
54

Fig
AT
54

Removing
valve

body

6
Loosen
lock
nut

@
on

piston

stem

D
as
shown
in

Figure
AT

55

Then

tighten

piston
stem
in

order
to

prevent
front
clutch

drum
from

falling

when
oil

pump
is
withdrawn