1977 DATSUN PICK-UP brake

EC527

Fig
EF
39
Mea

uring
throttle
valve

clearance

MfT

AfT

3
To

check
fast

idling
cam

setting

by
engine

speed
proceed
as
follows

Warm

up
engine
sufficiently
Set
Engine
Fuel

Fast

idling
earn

steps

o

04th

l

2nd

1st

EC528

Fig
EF
40
Fast

idling
cam

steps

2
The
clearance
should
be

specified

value
in

the

following
table
If
not
ad

just
the
clearance

by
turning
fast

idling
screw

Clearance
A
mm
in

1
33
to
I

47
0

0524
to
0

0579

1
58
to
1

72
0

0622
to
0

0677

fast

idling
cam
at
2nd

step
and
read

engine

speed
Fast

idling
cam
is

prop

erly
set
if

engine
speed
is
within

Engine
speed

rpm
Fast

idling
earn

MfT

AfT

VACUUM
BREAK

I

Close
choke
valve

completely

2
Hold
choke
valve

by
stretching
a

rubber
band
between
choke

piston

lever
and

stationary
part
of
carburetor

3

Grip
vacuum
break
rod
with

pliers
and

pull
straight
out

4
Under
this
condition

adjust
the

clearance
between
choke
valve
and

carburetor
body
B
in

Figure

EF
42
to

specified
value

by
bending

vacuum
brake
rod
I
900
to
2
800

2nd

step

2
200

to
3
200

S
B

j
CK
iXo

LL

r
I

il

L
J

1

Choke

piston
rod

2

Choke

spring

3
Choke

piston
EF516

4

Diaphragm
cover

5
Choke

piston
lever

6
Choke
valve

Fig
EF
42

Adjusting
vacuum
break

EF
23
Z

ET033
Fast

idling
carn

Nut

Fast

idling
screw

Choke
valve

Choke

connecting

rod

Throttle
valve

Fig
EF
41

Adjusting
the
clearance

of
throttle
valve

Fast

idling
earn

1st

step

specifications
below
Clearance
A
in

2nd

step
is

reference
value

Clearance
A

mm
in

0
94
to
1
18
0
0370
to
0
0465

L16
to
I
40
0
0457

to
0
0551

CHOKE
UNLOADER

Close
choke
valve

completely

2
Hold
choke
valve

by
stretching
a

rubber
band
between
choke

piston

lever
and

stationary
part
of
carburetor

3
Pull
throttle
lever
until
full

open

Under
this
condition

adjust
clear

ance
between
choke
valve
and
carbure

tor

body
to

2
45
mm
0
096
in

by

bending
unloader

tongue

Note
Make
sure
that
throttle
valve

opens
when
carburetor
is
mounted

on
the
vehicle

If
throttle
valve
rails
to

open
un

loader
becomes

inoperative
resulr

ing
in

poor
acceleration
after

engine

is
started

REMOVAL

AND

INSPECTION

Removal
and

inspection
can
be

done

as
follows

Removal

Catalytic
converter

1

Apply
parking
brake

2

Place
wheel
lock
under
each
tire

3

Jack

up
the
vehicle

4
Remove
lower
shelter
of

catalytic

converter

5
Dismount

catalytic
converter

EC453

Fig
EC
69
Removing

catalytic

conuerter

Inspection

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including

ho
s

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I
S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nor

mal
or
not
can
be
checked
by
ob

serving
variation
in

CO

percentage

The

checking

procedure
is

as
follows

Apply
parking
brake
Shift

gears

into
Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks
Emission
Control

System

2
Remove
air
hose
between

5

way

connector
and
air
check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3

Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5

Race

engine
1

500
to
2
000

rpm

two
or
three
times

under
no
load
then

run

engine
for
o
e
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
10

7
Check

ignition
timing
If
neces

sary
adjust
it
to

specifkations
Refer

to

page
ET
10

B

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adju
stment

process
as

described
in

steps
5
to
8
above

until

specified
CO

percentage
is
obtained

Note

Adjustment
in

step
9
should
be

made
ten

minutes
after

engine
has

wanned

up

10
Race

engine

1
500
to
2
000

rpm
two
or
three
times

under
no
load

and
make
sure
that

specified
CO

per

centage
is
obtained

11
Remove

cap
and
connect
air

hose
to

air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
WaRn

up
engine
for

about
four

minutes
at
2
000

rpm
under
no
load

13
Measure
CO

percentage
at

idling

speed
After

step
12
has
been
coin

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14
If
CO

percentage
measured
in

step
13
is
less
than
0
3

the

catalytic

converter

is
normal

15
If
CO

percentage
measured
in

step
13
is
over
0
3

recheck
A
I
S

and

replace
air
check
valve
Then

perform
inspection
steps
12
and
13

EC
27
16
If
CO

percentage
is

still
over

0
3
in

step
15

catalytic
conyerter
is

malfunctioning
Replace
catalytic
con

verter

INSTALLATION

To
install

reverse
the
removal

pro

cedure

Bolt

lightening

torque

specifications

Tightening

torque

Catalytic
converter

2
6
to
3
4

kg
m

19
to
25
ft
Ib

FLOOR

TEMPERATURE

WARNING
SYSTEM

DESCRIPTION

The
floor

temperature
warning

system
consists
of
a
floor

temperature

sensing
switch
installed

on
the
vehi

cle
s
floor
floor

temperature
relay
and

a

warning

lamp
on
the
instrument

panel
and
wires
that
connect
these

parts

When
the
floor

tempera
ture
rises
to

an
abnormal
level
the

warning
lamp

will

light
to
call
the
attention
of
the

driver
The

wiring
diagram
of
this

system
and
location
of
the

floor

temperature
sensing
switch
are
ilIus

trated
in

Figures
EC
70
and
EC
71

Floor
temparature
warning

lamp

Refer

to

Figure
EC
74

for
the

loca

tion
of
this

part

L

1t

1

RAt

Fig
EC
74
Location
of
floor

temperature
warning
lamp

INSTALLATION

To
install
reverse
the
order
of

rem
ovaL

INSPECTION

Floor
warning
temperature

system

Apply
parking
brake
Shift

gears

into
Neutral
foI
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1
Ensure
that
floor

temperature

warning

lamp
lights
when

ignition

switch
is
iumed

to
the
S

position

If

not
check

lamp
for
burned

bulbs

Replace
bulb
if
bulb
is
burned
out

If

bulb
is

not
burned
trace
wire
s

back
to

ignition
switch

Repair
or

replace
if

necessary

2
Be

sure
that
floor

temperature
is

cool
below
800C

1760Fj
before

carrying
out
the

following
procedure

I
Remove
rearseat

2

Ignition
switch
is

turned
to
the

IG

position

3
Ensure
that
floor

temperature

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
the

specifications
as

shown
in
the
table
below
Emission
Control

System

Temperature

sensing
switch

Contact
close
Temperature

warning
lamp

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
tem

perature
sensing
switch

replace
tem

perature
sensing
switch

If
con

tinuity
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
and
disconnect
floor

temper

ature

sensing
connector
The

lamp

should
remain

on
If

not
check
floor

temperature
relay
for

continuity
with

2
00

r
I

141

J

To
floor

temperatwe

warning
lamp

2
From

S

position

3
From

IG

position

4

From

ignition
switch

5
To
floor

temperature

sensing
switch
O

When
floor

temperature

warning
lamp
lights

Check
floor

temperature
warning

lamp

1

Open
or

shorj
circuit
in

wiring

harness

2

Check
fuel

system
with

regard
to

the

following
items

Refer
to

Inspec

lion
of
Fuel

System

EC
29
Floor

temperature

Below
1050C
221
OF

Above

1050C
221
OF

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
relay

When

checking
floor

temperature

relay
for
unit

remove
it
and

proceed

as
follows

1

Check
for

continuity
between

@

and

ID
Continuity
should
exist

Check
for

continuity
between

CD

and@
Continuity
should
exist

Check
for

continuity
between

CD

and

@
Continuity
should
not

exist

2

Apply
a
12

volt
doc
across

@
and

ID
to

ensure
that

continuity
exists

between

CD
and

@
and
that

con
ti

nuity
does

not
between

CD
and

@
If

test
results
dn

not

satisfy
the
above

replace
the

floor

temperature
relay

EC344

Fig
EC
75

Checking
floor
temperature
relay

1
Float
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

CLUTCH

CYLINDER

MASTER

Removal
and

installation

Removal

I

Remove
clcvis

pin
at

push
rod

2

Disconnect

clutch

tube
from

master

cylinder
and
drain
clutch
fluid

3

Remove
bolts

securing
master

Disassembly
and

assembly
CLUTCH

cylinder
to
the
vehicle

and
dismount

master

cylinder

Note
Remove
dust

cover
from
master

cylinder
body
on
the

side
of
driv

er

s
seat

Installation

To
install

reverse
the
order
of

removal

Closely
observe
the

following

instructions

1

Adjust
pedal

height
by

changing

pedal

stopper
length

Disassembly

1

Remove
dust

cover
and

remove

stopper
ring
from

body

2

Remove

push
rod

and

piston
as

sembly

3

Take
off

piston

cups

4

Remove

spiing
seat
from

piston

and
take
off

supply
valve
if

necessary

See

Figure
CL

19

Note
Discard

piston
cup
supply

valve
and

spring

seat
after
removal
Assembly

To

assemble
reverse
the
order
of

disassembly

Closely
observe
the
fol

lowing
instructions

I

Dip
piston
cup
in
brake
fluid

before

installing
Make

sure
that
it
is

correctly
faced
in

position

2

Apply
a

coating
of

brake
fluid
to

cylinder
and

piston
when

assembling

3
Press

piston
into

spring
seat
when

assembling

CL
7
2

Bleed
air

out
of

hydraulic

system

Tightening
torque

Master

cylinder
to

dash

panel

0
8

to
1
2

kg
m

5
8
to
8
7
ft

lb

Clutch
tube

connector
Flare
nut

1
5

to
1
8

kg
m

II
to
13
ft

lb

3

Using
Flare

Nut

Torque
Wrench

GG94310000

tighten
each

connector

to
the

specified

torque

1
Reservoir

cap

2
Reservoir

3
Reservoir
band

4

Cylinder
body

5

Supply
valve

stopper

6
Return

spring

7

Spring
seat

8
Valve
spring

9

Supply
valve
rod

10

Supply
valve

11

Primary
cup

12
Piston

13

Push
rod

14

Secondary

cup

15

Stopper

16

Stopper

ring

17
DU5t
cover

18
Lock
nut

CL265

Fig
CL
19

Exploded
view

of
maater
cylinder

Note

The
clutch
master

cylinder
is

available
in
both
NABCO
make
and

TOKICO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between

NABCO
and

TOKlCO
makes

When

replacing
the

repair
kit

or

component
parts
ascertain
the

brand
of

the
clutch
IIIBSter

cylinder

body
Be
sure
to
use

parts
of
the

same
make
as
the
former

ones

Inspection

Note
To
clean
or
wash
all

parts
of

master

cylinder

operating
cylinder

and

piping
clean
brake
fluid
must

be
used
Never
use
minera10ils
llUch

as

gasoline
and
kerosene
It

will

ruin
the
rubber

parts
of
the

hydrau

lic

system

I

Check
cylinder
and

piston
for

uneven
wear
or

damage
and
if
neces

sary
replace

2
If
the
clearance
between

cylinder

and

piston
is

more
than

0
15
mm

0
0059
in

replace
cylinder

3

Renew

piston
cup
when
dis

assembled
It
must
also
be

replaced

when
wear
or
deformation
due
to

fatigue
or

damage
is

found

4

Damaged
dust
cover
oil
reservoir

or

cap
should
be

replaced

Return

spring
and
valve

spring
must

also
be

replaced
when

they
are
broken

or
weak

5

Replace
clutch
hose
and
tube
if

any
abnormal

sign
of

damage
or
de

fro

ti

n
is
found

OPERATING

CYLINDER

Removal
and

installation

Removal

1

Detach
clutch
hose
from

operat

ing
cylinder

2
Remove
two
bolts

securing
op

erating
cylinder
to
clutch

housing

Installation

Install

in
the
reverse
order
of
re

moval

Observe
the

following
instructions

Bleed
air

thoroughly
from
clutch

hydraulic
system

2
Do
not

install
return

spring
or

clutch
will

not
be

disengaged

properly

Tightening
torque

Operating
cylinder
securing
bolt

2
5
to
3
5

kg
m

18
to
25
ft
lb

Bleeder
screw

0
7
to
0
9

kg
m
5
1

to
6
5
ft
Ib

Clutch
hose
connector

1
7
to

2
0

kg
m
12
to
14
ft

b
CLUTCH

Disassembly
and

assembly

Disassembly

1
Remove

push
rod
with
dust

cover

2
Remove

piston
assembly
and

pis

ton

spring

3
Remove

bleeder
screw

1
6

Cl11B

5

Piston

cup

6

Operating
cylinder

7
Bleeder
screw
1

Push
rod

2
Dust
cover

3
Piston

spring

4

Piston

Fig
CL
20

Exploded
view

of

operating
cyUnder

Assembly

Assemble
in
the

reverse
order
of

disassembly
Closely
observe
the
fol

lowing
instructions

1

Prior
to

assembly

dip
piston
cup

in

clean
brake
fluid

When

installing
cup
pay
particular

attention
to
its
direction

2

Dip
cylinder
and

piston
in
clean

brake
fluid
before

assembly

Notes

a
Be

sure
to
install

piston
assembly

with

piston
spring
in

place

b
The
clutch

operating
cylinder
is

available
in
both
NABCO
make
and

TOKICO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between
NABCO
and

TOKICO
makes

When

replacing
the

repair
kit
or

component
parts
ascertain
the

brand
of
the
clutch

operating
cyl

inder

bndy
Be
sure
to
use

parts
of

the

same
make

as
the
former
ones

Inspection

Visually

inspect
all
disassembled

parts
replacing
those
found
worn
or

rl

Q
damaged
too

badly

beyond
speci

fications

BLEEDING
CLUTCH

SYSTEM

The

hydraulic
clutch

system
must

be
bled
whenever
clutch
line
has
been

disconnected
or
air

has
entered
it

When

pedal
action
has
a

spongy

feeling
it
is
an
indication
that
air
has

entered
the
system

Bleeding
clutch

system
is

an
es

sential

part
of

regular
clutch
service

I

Remove
reservoir

cap
and

top
up

with
recommended
brake
fluid

2

Thoroughly
clean
mud
and
dust

from
bleeder
screw
of

operating
cyl

inder
so
that
outlet
hole
is

free
from

any
foreign
rnaterial
Install
bleeder

hose

vinyl
hose
on
bleeder
screw

Place
the
other
end
of
it
in

a
clean

container

3
Have
a
co
worker

depress
clutch

pedal
two
or

three
times
With
clu
tch

pedal
depressed
fully
loosen
bleeder

screw
to
bleed
air
out
of
clutch

sys

tern

4
Close
bleeder
screw

quickly
as

clutch

pedal
is

on
down
stroke

5
Allow
clutch

pedal
to
return

slowly
with
bleeder
screw
closed

6

Repeat
steps
4
and
5
until

no
air

bubble
shows
in

the

vinyl
hose

7

Operate
clutch
several
times

then
check
connections
for
external

hydraulic
leaks

Notes

a
Brake
fluid

containing
air
is
white

and
has
visible
air
bubbles

b
Brake
fluid

containing
no
air
runs

out
of
bleeder
screw
in
a
solid

stream
without
air
bubble

c

Pay
close
attention
to
clutch
fluid

level
in
reservoir

during

bleeding

operation

d
Do
not

reuse
brake
fluid
drained

during
bleeding
operation

e
Exercise
care
not
to

splash
brake

fluid

on
exterior
fInish
as
it
will

damage
the

paint

f
Pour
brake
fluid
into
reservoir

up

to

specifIed
level

No
Tool
number

tool
name

7
GG94310000

Flare
nut

torque
wrench
CLUTCH

Description

Unit
mm

in

This

tool
is
used
to

tighten
and
loosen
brake
and
clutch
tube
flare

nut
A

built
in

torque
limiting
wrench
is

provided
to
assure

torque

accuracy

y

SE227

CL
13
For

use

on

All

models
Reference

page
or

Figure
No

Page
CL
7

Manual
Transmission

j

W

h

I

l

1

Main
drive

gear

2

Baulk

ring

3

Shifting
insert

4

Shifting
insert

spring

5
Synchronir
c
r
hub

6

Coupling
slee

7
3rd
main
gear

g

Needle

bearing

9
Mainshaft

10
2nd
main

gear

11

Bushing

12
1st
main

gear

13
O
revcrse

synchronizer
hub

14

Rever

gear

15

Circlip

16
Thrwt

block

t
7
Brake
band

18

Synchronizer
ring

19
Overdrive
main
gear

20
Overdrive
gear
bushing

21
Washer

22
Mainshaft
nut

13
Overdrive
mainshaft

bearing

24

Speedometer
drive

gear

25

COlplteBhaft
fr
mt

bearing
shim

26
Countershaft
front
bearing

27
Countershaft
drive

gear

28
Coontcrshaft

29
Countershaft
bearing

30
Reverse
counter
gear

spacer

31
Rever
C
counter
gear

32

rdrive
counter

gear

33
Countershaft
zear
bearing

34
C
untershaft
nut

3S
Reverse
idler
lIhaCt

36
Reverse
idlcrthrust
washer

37
Reverse
idler

gear

38
Reye
nc
idler

gear
bearing

39
Reverse
idler
thrust
w8
her

TM041A

MT
16
Fig
MT
51
FS5W11B

tru
miasion

gear
componenta

ADAPTER
PLATE

DISASSEMBLY

Same
as

for
the
F4W71

B

Fig
MT
67

Removing
screws

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
Do

not
clean
wash
or
soak
oil
seals

in

solvent

TRANSMISSION
CASE
AND

REAR

EXTENSION
HOUSING

Same
as
for
the
F4W71
B

BEARING

Same

as
for
the
F4W7l
B

GEARS
AND
SHA
S

I
Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure

backlash
in

gears

Main
drive
and

counter
drive

gear

0
05
to
0
10

mm

0
0020
to
0
0039
in

1st

2nd
3rd
5th
and

reverse

gears

0
05
to
0
20
mm

0
0020
to
0
0040
in
Manual
Transmission

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

OD

gear
on
mainshaft

0
32

to
0

39
mm

0
0126
to
0

0154
in

BAULK
RING

Same
as
for
the
F4W7IB

OIL
SEAL

Same
as
for
the
F4W71
B

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COVER
ASSEMBLY

Same
as
for
the
F4W7l
B

REAR
EXTENSION

ASSEMBLY

I

Wipe
clean
seal

seat
in

rear
exten

sion

housing
press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication
See

Figure

MT
68

Front
r

I

TM355

Fig
MT
68
R
ar
extemion
oil
sea

2

Apply
multi

purpose
grease
to

O

ring
and

plunger

grooves
in

striking

rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

MT19
3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to
1
2

kg
m
7

to

9
ft
lb

4

Install

filainshaft
bearing
by

lightly
tapping
around
it
with
a

soft

hammer

5
Insert

reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the
cut
out

portion

of
reverse
idler
shaft
is

lined

up
with

inner
face
of

adapter

plate

6
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer

with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to
2
5

kg
m
14
to
18
ft
lb
and
stake
each

screw
at
two

points
with
a

punch
See

Figure
MT
69

TM764

Fig
MT
69

Stahing
screw

7
Install
countershaft

rear
bearing

in

adapter

plate
by
lightly
tapping

around
it

with
a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

compressed
air

Synchronlz
r
embly

Same
as
for
the

F4W71
B

Ov
rdrlve
r

ynchronlz
r

mbly

I

Assemble
reverse
OD

synchro

nizer

assembly

2
Assemble
overdrive

gear
assem

bly

Position
synchronizer
ring
band

brake
thrust
block
and
anchor
block

on
overdrive
clutch

gear
install

circlip