1977 DATSUN PICK-UP ECO

r
EC350

Fig
ET
43

Cleanill
l
E
G
R
control

lJ
Jlue

Thermal
VBCuum
valve

Dismount
thermal
vacuum
valve

from

engine

Note
Before

dismounting
drain
e

gine
coolant
from

engine

Apply
vacuum
to
thermal
vacuum

valve
and
check
to
be
sure
that
ther

mal
vacuum
valve

opens
or
closes
in

response
to

engine
coolant

tempera

lurt
i1
i

iYCl
lt
lt
U

Thermal
vacuum
valve
should

open

at
a

temperature
of
57
to
630C
134

to
1450F

completing
the
vacuum

passage

Note
Do
not
aUow
water
to

get

inside
the
thermal
vacuum
valve

EC
242

Fig
ET
44

Checkill
lthermallXlCuum

valve
Engine
Tune

up

CHECKING

EVAPORATIVE

EMISSION
CONTROL

SYSTEM

Vapor
Rnes
and
fuel

vepor

control
valve

Checking
fuel
tank

vapor

liquid

separator
and

vapor
vent
line

I
Check
all
hoses
and
fuel
tank

roler

cap

2
Disconnect
the

vapor
vent
line

connecting
carbon
canister
to

vapor

liquid
separator

3
Connect
a
3
way
connector
a

manometer
and
a
cock
or
an

equiva

lent
3
way

charge
cock
to

the
end
of

the
vent
line

4

Supply
fresh
air
into
the

vapor

vent
line

through
the

cock
little

by
little
until

pressure
becomes
368

mmH20
14
5
inH20

5

Shut
the
cock

completely
and

leave
it
unattended

6

After
2
5
minutes

measure
the

height
of
the

liquid
in

the
manometer

7

Variation
of

height
should
remain

with
25

mm
l20
0
98
inH20

8
When
filler
cap
does

not
close

completely
the

height
should
drop
to

zero
in

a
short
time

9
I
f
the

height
does
not

drop
to

zero
in

a
short
time
when
filler

cap
is

removed
it
is
the

cause
of
a

stuffy

hose

Note
In

case
the

vent
line

is
stuffy

the
breathing
in

fuel
tank
is
not

thoroughly
made

thl
causing
in

suffICient

delivery
of
fuel
to

engine

or

vapor
lock
It
must
therefore
be

repaired
or

replaced

3
way
connectoT

36
mmH20

14
5
inH20

c

s
I

W

@

Carbon
canister

r

EC786

Fig
ET
45

Checking
evaporative
emission
control

By
tem

Checking
carbon
canister

purge

control

valve

Check
for
fuel

vapor
leakage
in
the

distributor
VC
line
at

diaphragm
of

carhon
canister

purge
control
valve

To
check
for

leakage

proceed
as

follows

1
Disconnect

rubber
hose
in

the

line
between
T
connector
and
carbon

canister
at
T

connector

2
Inhale
air
into

the

opening
of

rubber
hose

running
to
VC
hole
in

carbon
canister
and
ensure
that
there

is

no
leak

ET

22
I

I

L

I

ET349

Fig
ET
46

Checking
carbon
cani
ter

purge
control
valve

Replace
bulb
if

bulb
is
burned

ou
t

If

bulb
is
not
burned
trace

wireis

back

to

ignition
switch

Repair
or

replace
if

necessary

2

Be
sure
that

floor

temperature
is

cool

below
800C

1760F
before

carrying
out
the

following
procedure

1
Remove
rear
seat

2

Ignition
switch
is
turned
to

the

Temperature

sensing
switch
Temperature

warning
lamp

Contact
close
Off

Contact

open
On

Note

Avoid

heating
floor

tempera

ture

sensing
switch
directly

If

lamp
does

not

glow
check
floor

temperature
sensing
switch
connector

for

continuity
with
a
circuit

tester

If

continuity
should
exist

after

heated

surrounding
areas
of
floor
tern

rv
wnTP
sen
cinq
S
Vitch

reolace
tem

perature
sensing
switch

If

continuity
does
not
exist

trace

the

wiring
back
to

relay
or
check
the

following
step
3

Repair
or

replace

wire

s
if

necessary

Note
The
floor

temperature
sensing

switch

may
be
heated

through
the

floor

by
a

proper
heater

3
Turn

ignition
switch
to
the
IG

position
anf
disconnect
floor

temper

ature

sensing
connector
The

lamp

should
remain

on
If
not

check
floor

4
0
3

UJ

GJO
Engine
Tune

up

IGU

position

3
Ensure

that
floor
tem

perature

warning

lamp
goes
out

4

Heat

surrounding
areas
of
floor

temperature
sensing
switch
with
a

proper
heater

to
ensure
that
floor

temperature
warning

lamp
glows
when

floor
is

heated
to

lh

specifications
as

shown

in
the
table
below

Floor

temperature

Below

1050C

22IOF

Above
1050C

2210F

temperature
relay
for

continuity
with

a

circuit
tester

Referring
to
the

following
floor

temperature
relay
if

relay
is
normal

trace

wire
s
back
to

ignition
switch

Repair

faulty
wiring

Floor

temperature

rela

To

check
floor

temperature
relay

remove
it

and

proceed
as

follows

1
Check
for

continuity

between@

and

@
Continuity
should

exist

Check
for

continuity
between

D

and@
Continuity
should
exist

Check
for

continuity
between

D

and@
Continuity
should
not
exist

2

Apply
a
12
volt
doC

across@and

@
to

ensure
that

continuity
exists

between

D
and@and
that

continuity

does
not
between

D
and

@
If
test

r
I

141

ET
24
results
do
not

satisfy
the
above
reo

place
the
floor

temperature
relay

When
floor

temperature

warnln8
lamp
118hts

Check
floor

temperature
warning

lamp

I

Open
or

short
circuit
in

wiring

harness

2

Check
fuel

system
with

regard
to

the

following
items
Refer
to

Inspec

tion

of
Fuel

System

I
Floa

t
level

2

Choke

3

Normal

fuel

supply
system
Prima

ry
and

secondary

4

Accelerator

pump

5

Power
valve

6

B
C
D
D

7

Fuel
strainer

8
Air

cleaner

3
Check

ignition
system
with

regard

to

the

following
items
Refer

to

Inspection
of

Ignition
System

I

IgnItion
AMI

2

Distributor

3

Ignition
coil

4

High
tension

code

5

Spark

plug

4

Check

idle
CO

adjustment
Refer

to

Inspection
of
Idle

CO

Adjust

roeoC

Note
Even

if
there
is

nothing
wrong

with

engine

warning
lamp
may

come
on
if
vehicle
is

being
driven

on
a

steep
slope
continuously
in

lower

gears
at

high
engine

speeds

To
floor

temperature

warning
lamp

2
From
S

position

3
From
GOt

position

4

From

ignition
switch

5
To
floor

temperature

sensing
switch

EC343

Fig
ET
50

Checking
floor

temperature

relay

Condition

POOR
FUEL
ECONOMY

Se
the

xplanation

of
the
pow
r

dec

Oth
n

PROBLEM
IN

OTHER

FUNCTIONS

D
cr
d

oil

p
ssure

Excessive
wear
on
the

sliding

parts

Scuffing
of

sliding

parts

Floor

temperature
too

high
California

only
Engine
Tune

up

Probable
cause

Exceeding
idling
revolution

Inoperative
acceleration
recovery

Fuel

leakage

Malfunction
of
B

C
D
D

Malfunction
of
A
r
C
air

cleaner

Inadequate
oil

quality

Overheat

Worn

oil

pump
regulator
valve

Functional
deterioration
of
oil

pump

Blocked
oil
f1lter

Increased
clearance
in
various

sliding
parts

Blocked
oil
strainer

Inoperative
oil

gauge
pressure
switch

Oil

pressure
decreases

Improper

quality
or
contamination
of

oil

Damaged
air
cleaner

Overheat
or
overcoal

Improper
fuel
mixture

Decrease
of
oil

pressure

Insufficient
clearances

Overhea
t

Improper
fuel

mixture

Problem
in

fuel

system
Refer
to

Inspec

tion
of
Fuel

System

Problem
in

ignition
system
Refer
to
In

spection
of

Ignition
System

ET33
Corrective
action

Adjust
it

to
the

designated
rpm

Adjust
it

Repair
or

tighten
the
connection
of

fuel

pipes

Adjust

Check
and

replace

Use
the

designated
oil

Previously
mentioned

Disassemble
oil

pump
and

repair
or
renew
it

Repair
or

replace
it

with
a

new
one

Renew
it

Disassemble
and

replace
the
worn

parts
with

new
ones

Oeanit

Replace
it
with
a
new
one

Previousiy
mentioned

Exchange
the
oil
with

proper
one
and

change
element

Change
elemen
t

Previously
mentioned

Check
the
fuel

system

Previously
mentioned

Readjust
to
the

designated
clearances

Previously
mentioned

Check
the
fuel

system

Check
and

repair

Check
and

repair

Standard

Camshaft
bend

mm
in
0

02
0
0008

CAMSHAFT

ALIGNMENT

I
Check
camshaft
camshaft

journal

and
earn
surface
for
bend
wear

or

damage
If

damage
is

beyond
limits

replace
affected

parts

2
A
bend
value
is
one
half
of
the

reading
obtained
when
camshaft
is

turned
one
full
revolution
with
a
dial

gauge

applied
to
2nd

and
3rd

journals

Standard

height

of
tam
mm
in
I
Intake

1
Exhaust

Wear

limit
of
earn

height
mm
in

Allo
able
difference
in

diam
ter

betweim
max
worn

and
min

mm
in

worn

parts
of
c

mshaft

journal
Engine
Mechanical

Bend
limit

0
05
0
0020

I

Fig
EM

50
Checking
camMa
t
bend

40
30
to
40
35

1

5866
to
1
5886

0
25
0

0098

0
05
0
0020

Maximum
tolerance
in

j01
irri

mm
in
0
1

0
0039

diameter

CamShaft
end

play
mm
in
0
08
to
0
38

0
0031
to
0
0150

Standard

Surface
flatness

mm
in
less
than

0
05
0
0020

Cy
LlNDER
BLOCK

I

Visually
check

cylinder
block
for

cracks
or
flaws

2
Measure

top
of

cylinder
block

cylinder
head

mating
face
for

warp

age
If

warpage
exceeds
limits
correct

it
Maximum
tolerance

0
10
0

0039

EM540

Fig
EM
51

Cheching
cylinder
block

au
rface

EM
13
j

Using
a
bore

gauge
measure
cyl

inder

bore
for
out
of
round
or

taper
If

out
of

round
or

taper
is
excessive

re

bore

cylinder
walls
with
a

boring

machine
Measuremen
t
should
be

taken

along
bores
for

taper
and
around

bores
for

out
of
round
See

Figure

EM
52

Qu
t
of
round

Taper
X

Y

A

B

M12

Fig
EM

52

Measuring
cylinder
bore

diameter

4
When
wear

taper
or

out
of

round

is
minor
and
within
limits

remove

step

at

topmost
portion
of

cylinder
using

a

ridge
reamer
or

other
similar
tool

HOW
TO
MEASURE

CYLINDER
BORE

A

bore

gauge
is
used
Measure

cylind
r
bore

at

top
middle
and
bot

tom

positions
toward
A
and
B
direc

tions

as
shown
in

Figure
EM
53

and

record
the
measured
values

A
I

120
0
79

IlL

60
2
36

lll

B

100
3
94

el
1

Unit
mm
m

EM
22

r

Fig
EM
53

Cylinder
bort
me08Uring

positions

Engine
Mechanical

Standard

Wear
limit

Inner
diameter
85
000

to
85
050

0

2
0
0079

3
3465
to
3
3484

Cylinder
bore

mm
in
Out
of
round
O
ot5
0
0006

Taper
0
015
0
0006

Difference
in

cylinder
bore

0
05
0
0020

0
2
0
0079

mm
in

CYLINDER

BORING

I
When

any
cylinder
needs

boring

all
other

cylinders
must
also
be
bored

at
the

same
time

Oversize

pistons

spec
Hic
etlons

Piston
diameter
mm
in

Servioe
standard

0
50
0
0197

Oversize

1
00

0
0394

oversize

3
The
size

to
which

cylinders
must

be

honed
is

determined

by

adding

piston

to
cylinder
clearance
to
the

largest
piston
diameter
at

piston
skirt

in

thrust
direction

EM126

Fig
EM
54

Measuring
piston
diamet
r
2

Determine

piston
oversize
ac

cording
to
amount
of
wear
of

cylinder

84
985
to
85
035

3
3459

to
3
3478

85
465
to
85
515

3
3648
to
3

3667

85

965
to
86
015

3
3844
to
3

3864

Standard
clearance

ffim
in

Feeler

gauge
mm

in

Extracting
force

kg
Ib

Notes

a

To

prevent
strain
due
to

cutting

heat
bore
the

cylinders
in
the
order

of

2
4
1

3

b

Before

boring
any
cylinder
install

main

bearing
caps
in

place
and

tighten
to
the

specification
so
that

the
crankshaft

bearing
bores
will

not
become
distorted

from
the
bor

ing
operation

4

Do
not
cut

too
much
out
of

cylinder
bore

at
a
time
Cut

only
0
05

mm
0
0020
in

or
so
in
diameter

at
a

time

EM
14
L

7
A

aboull
6
m

o
7323in

r

127

Fig
EM
55

MeCUJlJring
piston
skirt

diameter

Rebored
size

calculation

o
A
B
C
A
0
005
to

0
Q25
mm

0
0002
to
0
0010
in

where

D
Honed

diameter

A

Skirt
diameter
as
measured

B
Piston
to
wall

clearance

C

Machining
allowance
0
02
mm

0
0008
in

0
025

to
0

045
0

0010
to
0
0018

0
04
0

0016

0
2

to
1

5
O

44
to

3
31

5

Measurement

of
a

just
machined

cylinder
bore

requires
utmost
care

since
it

is

expanded
by

cutting
heat

6

As
a
final

step
cylinders
should

be

honed
to
size

7

Measure
the

finished

cylinder

bore
for

out
of
round
or

tapered
part

8
Measure

piston
to

cylinder
clear

ance

This

clearance
can
be
checked

easily
by
using
a
feeler

gauge
and
a

spring
balance
hooked

on
feeler

gauge

measuring
the
amount
of
force

re

quired
to

pull

gauge
out
from

between

piston
and

cylinder

Engine
Mechanical

Notes

a

When

measuring
clearance

slowly

pull
feeier

gaUge
siraight
upward

b
It
Is

reConUnended
that

piston
and

cylinder
be
hel

ted
to
200C
680F
PISTONS

PISTON
PINS
AND

PISTON
RINGS

I

Remove
carbon
from

piston
and

ring
grooves
with

a

ca
bon

scraper
and

a
curved
steel
wire

Clean
out
oil

slots

in

bottom
land
of

oil

ring
groove

2

Check
for

damage
scratches
and

wear

Replace
if

necessary

3

Meas1
1re
side

clearance
of

rings
in

ring
grooves
as
each

ring
is

installed

Side
clearance

should
be

as
follows
00

I
EM542

Fig
EM

58

Measuring
ring

gap

Notes

a
When

piston
ring
only
is
to
be

replaced
without

cylinder
bore

being
corrected
measure

gap
at

bottom
of

cylinder
where
wear
is

minor

b
Oversize

piston
rings
are
available

for

serv
ce

Oversize

0
5
mm
0

0197
in
and

1

0
mm
0
0394
in

5
Measure

piston
pin
hole
in
rela

tion

to
outer
diameter
of

pin
If
wear

exceeds
limit

replace
each

piston

pin

together
with
the

piston
on
which
it
is

installed

6
Determine
the

fitting
of

piston

pin
into

piston
pin
hole
to
such
an

extent
that
it

can
be

finger
pressed
at

room

temperature
This

piston
pin

must
be
a

tight
pre
s
fit
into

connect

ing
rod
t

J

f

rr

11

1

I

EM541

Fig
EM
56

Measuring
piaton
fit

in
cylinder

Fig
EM
57

Measuring
piston
ring

side
clearance

Side
clearance

Unit
mm
in

I

Second

ring

I

I
Wear
limit
Standard

0
040
to

0
073

0
0016

to
0
0029

0
030
to

0
070

I
0
0012
to

0
0028

I
Top
ring

0
1
0
0039

Oil

ring

f

feeler

gauge

Ring
should
be

placed
to
diameter

at

upper
or
lower
limit
of

ring
travel
4

Push

ring
into

cylinder
with

pis

ton
so
as
to

place
it

squarely
in

cylinder
measure

ring
gap
with
a

EM131

Ring
gap
Fig
EM

59
Piston

pin

fitting
Unit
rom
in

Standard
Wear

limit

0
25
to
0
40

0
0098
to
0
0157

0
30
to
0
50

0
0
II
8
to
0
0197
Top
ring

Second

ring
1

0
0
0394

EM132

0
30
to
0
90

0
0118
to
0
0354
Oil

ring

Fig
EM

60

Measuring
pi
ton
pin

diamet

EM
15

Engine
Mechanical

Connectlns
rod
be

rlns
undersize

SID

0
25
0
0098
Undersize

0
50
0
0197
Undersize

0
75
0
0295

Undersize

MISCELLANEOUS

COMPONENTS

CRANKSHA
AND

CAMSHA

SPROCKETS

I
Check
tooth
surface
for
flaws
or

wear

Replace
sprocket
if
fault
is

found

2
Install
camshaft

sprocket
in

posi

tion
and
check
for
rounout
If
it

exceeds
0
1

mm
0
0039
in

total

indicator

reading
repl
ce
camshaft

sprocket
Also
check

for
end

play

Camshaft
end

play

0
08

to
0
38

mm

0
0032
to

0
0150
in

EMl48

Fig
EM
71

Checking
eam

haft

sprocket
Tunaut
Unit
mm
in

Bearing
top
thickness
Crank

pin
diameter

1
493
to
1
506

0
0588
to
0
0593
49
961
to
49
974

1

9670
to
1

9675

49711
to

49
724

1
9571

to
1
9576
1

618
to
1

631

0
0637
to
0
0642

1

743
to
1

756

0
0686

to
0
0691
49461
to
49
474

1
9473

to
1
9478

1

868
to
1

881

0
0735
to
0

0741
49
211
to

49
224

1
9374
to
1
9379

Fig
EM
72

Checking

camshaft
end

play
3

Check
chain
for

damage
exces

sive

wear
or
stretch
at
roller
links

Replace
if

faulty

4
To

properly
adjust
chain
tension

or
valve

timing
camshaft

sprocket

has
a

earn

locating
plate
and
three

location
holes
Nos
I

2
and
3

Camshaft

sprocket
is

preset
at

No
I

hole
at
the

factory
If
chain

becomes
loose

adjust
it

by

setting

camshaft

sprocket
at
NO
2
hole
If

chain
is

too
loose

adjust
it

by

setting

camshaft

sprocket
at
No
3

hole

2

3

Before

adjustment
Location

match

3

After

adju5tmen
t

EM311

Fig
EM
73

Adjuating
camshaft
aprocket
location

EM
19

I
Turn

engine
until
No

I

piston
is

at
T
D
C
on

its

compression
stroke

Determine

whether
camshaft

sprocket

location
notch
comes

off
the
left
end

of
the

oblong
groove
on
camshaft

locating
plate
If
the
location
notch

is

off
the

left
end
of
the

oblong
groove

chain

stretch
is

beyond
limits

40150

EMl46

Fig
EM
74

Camshafllocating
plate

2

Turn

engine
until
No

I

piston
is

at
T
D

C

on
its

compression
stroke

setting
camshaft
on

No
2
location

hole
in

camshaft

sprocket
This
No
2

notch

should
then
be

on
the

right
end

of
the

oblong

groove
When
No
2
hole

is

used
NO
2

timing
mark
must
also

be
used

The
amount

of
the

modifica

tion
is
a

40
rotation

of
crankshaft

3

When
modification
becomes
im

possible
even

by
transferring
camshaft

location

hole

replace
chain

assembly
Engine
Mechanical

CHAIN

TENSIONER
AND

CHAIN
GUIDE

Check
for

wear
and

breakage
Re

place
if

necessary

r

I

L

EM147

Fig
EM
75
Cam

haft
dri
mechanilm

FLYWHEEL

I

Check
clutch
disc

contact
surface

with

flywheel
for

damage
or
wear

Repair
or

replace
if

necessary

2

Measure
runout
of
clutch
disc

contact
surface

with
a
dial

gauge
fit

exceeds
0
15

mm
0
0059
in

total

indicator

reading

replace
it

EM
20
EM426

Fig
EM

76
Checking
flywheel

deviation

3

Check

tooth
surfaces
of

ring
gear

for
flaws

or
wear

Replace
if

necessary

FRONT

COVER
AND

REAR
OIL
SEAL

First
check

front
cover

an
rear
oil

seal
for

worn
or
folded
over

sealing
lip

or
oil

leakage
If

necessary
install
a

new
seal
When

installing
a
new

seal

pay
attenti
on
to

mounting
direction

Note
It
is

good
practice
to

replace
oil

seal
whenever

engine
is

overhauled

Frant
t
r

r

J
I

Front

Real

EM150

Fig
EM

77
Oil

eals

of
crank

haft