1977 DATSUN PICK-UP heating

DESCRIPTION

INSPECTION

CLEANING
AND
REGAP

DESCRIPTION

The

spark
plugs
are
of
the

conven

tional

type
having
14
mm
0

551
in

threads
The

spark
plug
gaps
are
1
0
to

1
1
mm
0
039
to
0
043
in
on
Cali

fomia
models
and
0
8

to
0
9
mm

0
031
to

0
035
in
on
non
California

models
The

inspection
and

cleaning

should
be
made
every
suitable
mainte

nance

period
If
necessary
replace

Note
All

spark

plugs
installed
on
an

engine
must
be

of
the
same
brand

and
the

same
number
of
heat

range

INSPECTION

L
Remove

spark
plug
wire

by

pulling
on

boot
not
on
wire
itself

2
Remove

spark
plugs

3

Check
electrodes
and
inner

and

outer

porcelains
of

plugs
noting
the

type
of

deposits
and
the

degree
of

electrode
erosion

Refer
to

Figure

EE
96

Normal
Brown
to

grayish
tan
de

posits
and

slight
electrode
wear

indicate
correct

spark
plug
heat

range

Carbon
fouled

Dry
fluffy
carbon

deposits
on
the
insulator
and

electrode
are

usually
caused

by

slow
speed
driving
in

city
weak

ignition
too
rich
fuel
mixture

dirty
air
cleaner
etc

It
is

advisable
to

replace
with

plugs

having
hotter
heat

range

Oil
fouled
Wet
black

deposits
indi

cate
excessive
oil
entrance
into

combustion
chamber

through
worn

rings
and

pistons
or
excessive
clear

ance
between
valve

guides
and

stems
If
the
same
condition
re

mains
after

repair
use
a
hotter

plug
Engine
Electrical

System

SPARK
PLUG

CONTENTS

EE
4B

EE
47

EE
47

EE
47
SERVICE
DATA
AND
SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS
EE
4B

Overheating
White
or

light

gray
in

sulator
with
black
or

gray
brown

spots
and
bluish
burnt
electrodes

indicate

engine
overheating
More

over
the

appearance
results
from

incorrect

ignition
timing
loose

Normal

Overheating

EE079

4
After
cleaning
dress
electrodes

with
a
smaU
fine
file
to
flatten
the

surfaces
of
both
center
and
side

electwdes
in

parallel
Set

spark
plug

gap
to

specification

5
InstaU

spark
plugs
and

torque

each

plug
to
L5

to
2
0

kg
m

11
to
14

ft
Ib

6
Connect

spark

plug
wires

CLEANING

AND
REGAP

Clean

spark
plugs
in

a
sand
blast

type
cleaner
Avoid
excessive

blasting

Clean
and
remove
carbon
or
oxide

deposits
but
do
not

wear
away

porcelain
If

deposits
are
too
stubborn

EE
47
spark
plugs
low
fuel

pump
pres

sure

wrong
selection
of
fuel
a

hotter

plug
etc

It
is
advisable
to

replace
with

plugs

having
colder
heat

range

Ir

i

Carbon
fould

Worn

Fig
EE
96

Spark
plug

discard

plugs

After

cleaning
spark
plugs
renew

firing
surface
of
electrodes
with
me

mentioned
aboVe
Then

gap
spark

plugs
to

specified
values
with
a
round

wire
feeler

gauge
All

spark
plugs
new

or
used
should
have
the

gap
checked

and
reset

by
bending
ground
electrode

EEOBO

Fig
EE
97

Setting
park
plug
gap

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

2
The
allowable
maximum

out
of

round
of
brake
drum
is
0
02

mm

0

0008
in

Re

condition
or

replace
brake
drum

if

specified
limit
is
exceeded

3

Measure
for

tapered
brake
drum

If

specified
limit
of
0

02
mm
0

0008

in
is

exceeded
as
measured
at

a

position
where
the
distance
of
4S
mm

177
in
is

kept
away
from
inlet

re
condition
or

replace
brake
drum

4

Contact
surface
with
which

linings
come
into

contact
should
be

finished
to

such
an
extent
that
it
is

ground
by
a
No
120
to
150
sand

paper

S

Using
a
drum

racer
finish
brake

drum

by
machining
if
it

shows

any

sign
of
score
marks

partial
wear
or

stepped
wear
on
its
contact
surface

Note
After
brake
drum
is

completely

re
conditioned
or
renewed
check

drum
and
shoes
for

proper
contact

pattern

Brake

assembly

I
When
brake
shoe

linings
are

cracked

incompletely
seated
uneven

Iy
worn

andlor
deteriorated
due
to

excessive

heating
or
soiled
with

oil

grease
and
brake
fluid

replace

2

Replace
linings
if
the
thickness
is

worn
down
to
less
than
1
0
mm
0
039

in

Note

When
brake
shoe

lining
is
in

stalled

grind
brake
shoe

lining
face

to
diameter

equal
to
that
of
brake

drum

lining
dimension

Width
x
Thickness
x

Length

4S
x

4
S
x

244
mm

1
77
x
0

177
x

9
61
in

3

Check

adjuster
for
smooth

oper

ation

4

Replace
shoe
return

springs
which

are
broken
or

fatigued
Brake

System

Standard
dimensions
of
shoe

springs

Free

length
Dia

of

spring
No
of
Installed

Item

lengthlload

mOl

in
mOl
in

coils

mm

kg
in
lb

Upper
136
5

2
0
0

079
37
IS9
S
14

to
16

S

37
6
28
31

to
3S

Lower
134
S

2
3
0
091
35
IS9
5
21

to
23

5
30
6
28
46
to

Sl

After
shoe
83
2

1
4
O
OSS
27
S
99
4

to
S

3
28
3

90
9
to
II

Wheel

cylinder

I

Replace

any
cylinder
or

piston

which
is
scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS
mm

0
OOS9
in

Wheel

cylinder
inner
diameter

19
0S
mOl

Y
in

3

Replace
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

S

Replace

damaged
dust
cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its

threaded

portion

INSTALLATION

Install
front
brake
in
the

reverse

sequence
of
removal

paying
particular

attention
to
the

following
instructions

I

When

assembling
adjuster
assem

bly

apply
brake

grease
to

adjuster

housing
bore

adjuster
wheel
and
ad

juster
screw

When
installing
adjuster

assembly

to
brake
disc

apply
brake

grease
to

disc

adjuster
and

retaining
spring
slid

ing
surfaces

to
slide

adjuster
smoothly

Measure

adjuster
sliding
resistance

Adjust
by
adjuster
shim
when

sliding

resistance
is

in
rrect

BR
ll
Adjuster
sliding
resistance

S
to

12

kg
II
to
261b

2

When

installing
wheel

cylinder
be

sure
to
secure
the

cylinder
with
R

mark

to
right
hand
disc
and
the
one

with
L
mark
to

left
hand
disc

Otherwise
brake
hoses

may
interfere

with
other

adjacent
parts
As

to
the

connecting
instructions

of
brake
hose

no
twist
or

contact
is
existed
on

brake

hose

referring
the

related

topic
Brake

line

Tightening

torque

Wheel

cylinder

SA
to

6
6

kg
m

39
to
48
ft

lb

Connector
bolt

1
9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
hose

1
7
to
2

0

kg
m

12
to
14
ft
lb

Air
bleeder

0
7

to
0
9

kg
m

5
to
7
ft

Ib

Brake
disc

4
2

to
S
O

kg
m

30

to
36
ft
lb

3

Before
installing
brake
shoe
as

semblies

apply
brake

grease
to
wheel

cylinder
and

adjuster
brake
shoe
in

stalling
grooves
and
brake
disc
and

brake
shoe

assembly
contact
faces

two

places
Exercise

care
not
to

allow

grease
to

come
into
contact
with

linings
and

adjuster

DISASSEMBLY
AND

ASSEMBLY

Wheel

cylinder

Remove
dust
cover
and

pull
out

piston
head
and

piston
assembly

Refer
to
Wheel

Cylinder
of

Front

Brake

CD

l
ID

345

0

1
Dust

cover

2

Piston
head

3
Piston

4

Piston
Cll

p

5

Wheel

cylinder

housing

6

Bleeder

cap

7

Bleeder
screw

8

Connector

9
Washer

10
Connector
bolt
BR318

Fig
BR
22

Rear
wheel

cylinder

INSPECTION

Brake
drum

Check
brake

drum
in

the
same

manner
as

outlined
in
the
Front
Brake

Drum

Brake

assembly

I
When

brake
shoe

linings
are

cracked

incompletely
seated
uneven

ly
worn
andlor
deteriorated
due
to

excessive

heating
or

soiled
with
oil

grease
and
brake
fluid

replace

2

Replace

linings
if
the
thickness
is

WOol
down

to
less
than

1
0
rom
0
039

in

Note
When
brake

shoe

lining
is
in

stalled

grind
brake

shoe

lining
face

to
diameter

equal
10

lha
I

of
brake

drom

Lining
dimemion

Width
x
Thickness
x

Length

4S

x
4

5
x
244

rom

1
77
x
0
177
x
9
61
in
Brake

System

3
Check

adjuster
for
smooth

oper

ation
4

Replace
shoe
return

springs
which

are

broken
or

fatigued

Standard
dimensions

of
shoe

springs

Dia
of

spring
No

of
Installed

Free

length

lengthlload
Item

mOl
in

mOl
in

coils

mmlkg
in
lb

175

2

0
0
079
32
5
184
11
to
13

Upper

6
89

7
24
24
to
29

158

2
3

0

091
30
176
18

to
20

Lower

6
22

6
93
40
to
44

83
2

1
4
0
055

27
5
99
4

to
S

After
shoe

3
276

3

90
9

to

II

20
5

1

6
0
063
3
5
12
3

S
to
4
5

AntiratUe

0
807

0
47
8
to
9
9

Wheel

cylinder

I

Replace
any
cylinder
or

piston

which
is

scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS

rom

0

00S9
in

Wheel

cylinder
inner

diameter

19

0S
rom

Xin

3

Replace
piston
cup
which

is
worn

or

damaged

4

Replace
if

contacting
face
of

cyl

inder

and
shoe

is
worn

locally
or
in

step

5

Replace
damaged
dust

cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its
threaded

portion

INSTALLATION

Install
rear

brake
in

the
reverse

sequence
of
removal

paying
particular

attention

to
the

following
instructions

I

Rear

adjuster
assembly
is

the

same
as
front
Refer
to
the

paragraph

covering
Front
Brake
Installation

Adjuster
sliding
resistance

S
to
12

kg
II
to
261b

BR
13
2

When

assembling
toggle
lever

and

after
brake
shoe

assembly

adjust
clear

ance
between

toggle
lever
and

after

brake
shoe

assembly
to
0
to
0
3
mOl
0

to
0

012
in
with

a

properly
selected

toggle
pin
washer

Toggle

pin
washer

No

Thickness
rom
in

I
2
0
0
079

2
2
3
0
091

3
2

6
0
102

4
2
9
0
114

S

3
2
0
126

3

Before
installing
brake
shoe

as

semblies

apply
brake

grease
to
the

following

places

1
Brake
shoe

installing
grooves
of

adjuster
and
wheel

cylinder

2
Extension
link

installing
grooves

3
Lower
surface
of

spring
seat

4

Contact
surfaces
between
brake

disc
and
brake
shoe

assembly
six

places

At
this
time

be
sure
not
to
coat

brake

grease
to
brake

linings

DESCRIPTION

Cables
are
covered
with
color

coded

vinyl
for

easy
identification
In

the

wiring
diagram
colors
are
indicated

by

one
or

two

alphabetical
letters

It
is
recommended
that
the

battery

be
disconnected
before

performing

any
electrical
service
other
than

bulb

or
fuse

replacement

In
addition
to
fuses
a
fusible
link

has
been

installed
to

protect
wiring

The
fusible
link
functions
almost
the

same
as
a

fuse

though
its
eharac

teristics

are
slightly
different
than

normal
fuses

CABLE
COLORS

Cable
colors
are

indicated

by
one
or

two

alphabetical
letters

B

Black
Be
Brown

G
Green

L
Blue

Lg
Light

green

R

Red
W
White
Y
Yellow

The
main

cable
is

generally
coded

with

a

single
color
The

others
are

coded
with
a

two
tone
color
as

follows

BW

Black
with
white

stripe

gR

Light
green
with
red

stripe

INSPECTION

Inspect
all

electrical

circuits
refer

ring
to

wiring
or

circuit

diagrams

Circuits

should
be

tested
for
conti

nuity
or

short
circuit

with
a

conven

tional
test

lamp
or

low

reading
volt

meter
Before

inspection
of

circuit

ensure
that

I
Each
electrical

component

part
or

cable
is

securely
fastened
to

its
con

nector
or
terminal

2
Each
connection

is

firmly
in

place

and

free
from
rust
and
dirt

3

No
cable

covering
shows

any

evidence
of
cracks

deterioration

or

other

damage

4

Each
terminal

is
at

a
safe

distance

away
from

any
adjacent
metal

parts

5
Each

cable
is
fastened

to
its

proper
connector
or
terminal
Body
Electrical

System

BODY
ELECTRICAL

WIRING

6

Each

grounding
bolt
is

firmly

pbnted

7

Wiring
is

kept
away
from

any

adjacent
parts
with

sharp
edges
or

high

temperature
parts
such

as
exhaust

pipe

8

Wiring
is

kept
away
from

any

rotating
or

working
parts
fan

pulley

fan
belt
etc

9

Cables
between
ftxed

portions

and

moving
parts
are

long
enough
to

withstand
shocks
and

vibratory
forces

Notes

a
Before

starting
to

inspect
and

repair

any
part
of
electrical

system
or

other

parts
which

may
lead
to
a

short
circuit

disconnect
cables
at

battery
terminals
as
follows

Disconnect

cable
at

negative

terminal

and
then
disconnect
cable

at

positive
terminal

Before

connecting
cables
to

battery

terminal
be
sure
to
clean
terminals

with
a

rag
Fasten

cable
at

positive

terminal
and
then

ground
cable

at

negative
terminal

Apply

grease
to

top
of
these

terminals
to

prevent
rust
from

developing
on

them

b
Never

use
a

screwdriver
or
senrice

tool
to
conduct

a

continuity
test

Use
test
leads

c
Never

ground
an

open
circuit
or

circuits
under
no
load
Use

a
test

lamp
12V
3W

or
circuit
tester
as
a

load

FUSE
AND

FUSIBLE

LINK

DESCRIPTION

The
fuse
and
fusible
link

are

protec

tive

devices
used
in

an
electrical
cir

cuit

When
current

increases

beyond

rated

amperage
fusible
metal

melts

and

the

circuit
is

broken

BE
2
MAINTENANCE

INSTRUCTIONS

Fuse

The
fuse

block
is
installed

under

the
instrument

panel
on
the
left

hand

drive

vehicle

BE848A

Fig
BE
1

Fuse
block

When
for
one
reason

or
another

fuse

has
melted
use

systematic
pro

cedure
to
check
and
eliminate
cause
of

problem
before

installing
new
fuse

Notes

a
If
fuse
is

blown
be
sure
to
elimi

nate
cause
of

problem
before
in

stalling
new
fuse

b
Use

fuse
of

specified

rating
Never

use
fuse
of
more
than

specified

rating

Co

Check
condition
of

fuse
holders
If

much

rust
or
dirt
is
found

thereon

clean

metal

parts
with
fine

grained

sandpaper
until

proper
metal
to

metal
contact
is
made

Poor

contact
in

any
fuse
holder
will

often
lead
to

voltage
drop
or

heating
in
the
circuit
and
could

result
in

improper
circuit

operation

Fusible

link

Fusible
link

protects

lighting

starting
charging
and

accessory
cir

cuits

Body
Electrical

System

AIRFLOW

OFF

VENTILATING

Push
Vent
valve

Heater
core

c

n

e
NlL
fAl

u

c
J
u
IUl

g

Push

Pull

DEFROSTING

VENTILATING
HEATING

0
tTIlsl

IU
lI

D
WI
Push
Pull

g

IIt
J

L

I
I

Pull

Pull

DEFROSTING

HEATING

n
C
IU

n

HU

I
ff

UIUI

C
J

CIl

JIlT

Ill

Pull
J

11

Pull

BE397

Fig
BE

47

Airflow

8E

28

J

I

1
Air

Conditioning

J

lJ

R

J

g

j

ru

Fig
A
C
l8

Euacuating

system
First

step
AC736

Fig
AC

19

Euacuatingsystem
Second

step
AC737

CHARGING

REFRIGERANT

I
Install

manifold

gauge
to

system

Refer
to

Handling
Manifold

Gauge

Notes

a

Be
sure
to

purge
air
from
the

high

and
low

pressure
charging
hoses

b
If
air
is

mixed
with

refrigerant
gas

in

system
evacuation
of

system

should
be

performed
Refer
to

Evacuating
System

2

Attach
center

charging
hose
of

manifold

gauge
to

refrigerant
can

through
can

tap
Break
seal
of

refriger

ant
can
to

allow

refrigerant
to
enter

manifold

gauge
Loosen

charging
hose

at
the
center

fitting
of
manifold

gauge

and

purge
air

from
inside

charging

hose
Refer
to

Handling
Can

Tap

3

Open
high
and
low

pressure

valves
of
manifold

gauge
and

charge

refrigerant
into

system
See

Figure

AC
20

Notes

a

When

refrigerant
charging
speed
is
1

j

jJ

i

j

Fig
AC
20
Charging
refrigerant
AC738

slow
immerse

refrigerant
can
in

water
heated
to

a

temperature
of

about

400C

l040F
However

note
that
this
is

dangerous
when

water
is

hot
See

Figure
AC
21

Cautions

a

Under

any
circumstances
the

refrig

erant
can
must
not
be

warmed
in

water
heated
to
a

temperature
of

over
520C

l2S0F

b
A

blow
torch
or

stove
must
never

be
used
to
warm

up
the
can
R

121
Immerse
in
water

heated

to
about

400C

1040F

Note
that

hot

water
is

dangerous

AC252

Fit
AC

21
Heating

refrigerant

AC13

Air

Conditioning

PERFORMANCE
TEST
DIAGNOSES

Condition

Discharge
air
too
warm

a
Both

discharge
and
suction

pres

sure
too

high

b
Both

discharge
and
suction

pres

sure
too
low

c
Discharge

pressure
too

high
and

suction

pressure
too
low

d
Suction

pressure
too

high
and

discharge

pressure
too
low

e

Discharge

pressure
normal
and

suction

pressure
too

high

t
Discharge

pressure
normal
and

luction

pressure
too
low

g
Suction

pressure
normal
and

discharge
pressure
too

high

h
Both

discharge
and
suction

pres

sure
normal

Air

conditioning
is

operating

properly

Discharge
air
normal

or
too
cold

a

Discharge
pressure
normal
and

suction

pressure
too
low
Probable
cause

Air

mixed
with
refrigerant
in

system

Overcharge
of

refrigerant

Loose
fan
belt
or

engine
over

heating

Obstructed
or

dirty
condenser
fins

Insufficient

refrigerant
charge

Over

filling
of

compressor
oil

Damaged
compressor
valve
or

pack

ing

Loose

compressor
drive
belt

Clutch

slippage

Faulty
expansion
valve

Clogged
expansion
valve
strainer

Water
has
frozen
at

expansion

valve

Faulty
expansion
valve

Faults
of
both

a
and
h
exist

Air
leaks
from

engine
com

partment

Restricted
air
flow

through
evapo

ratof

Slow
blower
motor

speed

AC
21
Corrective
action

Evacuate
and

charge
system

Discharge
some
of

refrigerant
to

correct
level

Adjust
fan
belt
or
check

cooling

system

Clean
exterior

surface
with
water

Add

refrigerant

Drain
oil
and
correct
oil
level

Refer

to

Compressor
oil
level

check

Repair
or

replace
compressor
Refer

to

Compressor

Adjust

Repair
Refer
to

Compressor

Reinstall

sensing
bulb
correctly
to

keep
it

tight
to

pipe

Replace

Clean
strainer

Evacuate
and

charge
system

Replace

Correct

sealing

Clean

evaporator
fins

Check
and

repair
blower
motor
and

wiring