1977 DATSUN PICK-UP height

J

1
Fuel
tank

2

Fuel
f1l1er

cap
with

vacuum

relief
valve

3

Liquid
vapor

separator

4

Vapor
vent
line

5
Vacuum

signalUne

As
the
throttle
valve

opens
and

vehicle

speed
increases

vacuum

pres

sure
in

the
vacuum

signal
line
forces

rHL
JL

I

EC785

INSPECTION

FUEL
TANK

VAPOR

LIQUID
SEPARATOR

AND

VAPOR
VENT
LINE

I

Check
all
hoses
and
fuel

tank

mler

cap

2
Disconnect
the

vapor
vent

line

connecting
carbon
canister
to

vapor

liquid
separator

3
Connect
a
3

way
connector

a
Emission

Control

System

Close
at

idling

Open
at
rest

i

J

17
f

Fuel

vapor

6
Canister
purge
line

7
Throttle
valv

8

Engine

9
Carbon
canister

10
Activated
carbon

11

Screen
12
Filter

13

Purge
control
valve

14

Spring

15

Diaphragm

16
Fixed

orifice
i

j

EC784

Fig
EC
77

Evaporative
emu
ion
control

sy
tem

Fuel

vapor
flow
when

engine
i6

at
red
or

idling

the

purge
control
valve
to

open
and

admits
an

orifice
to
intake
manifold

and
fuel

vapor
is

then
drawn
into
the

I

J

o
I

Fuel

vapor

Fresh
air
intake

manifold

through
the
canister

purge
line
See

Figure
EC
7B

Fig
EC
78

Evaporative
emiuion
control

system

Fuel

vapor
flow
when

engine
i

running

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

mrnH20

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

EC
31
with
25
mmH20
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
thus

causing
in

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

Stroke
30
mm

Jt
i
I
1
18
in

Sj

1

i
J
o

Fig
CL
15
Non

adj
table

operating

cylinder

CLUTCH
PEDAL

Removal
and

installation

Removal
See

Figure
CL
16

1

Pry
off
cotter

pin
and
take
out

clevis

pin
disconnect

push
rod
from

pedal
assembly

2
Unhook

return

spring
Loosen
off

fulcrum

pin
and
remove

pedal
as

sembly

CfJ

W5
6

3

ch

fD

ij

ll

i
A
1
aevis

pin

2
Cotter

pin

3
Return

spring

4
Pedal
boss

S
Pedal

assembly

6
Bush

7

Nut

8
Push
rod

9
Fulcrum

pin

Fig
CL

16

Exploded
view

of
clutch

pedal

Note
Before

removing
clutch

pedal

note
toe
board

clearance
at

pedal

pad

Installation

To

install

reverse
the

order
of

removal

Apply
multi

purpose
grease

to

the
friction
surfaces
of

the
disas

sembled

parts
as

shown
in

Figure

CL
17

Tightening

torque

Pedal

installation
bolt

Fulcrum
pin

1

9
to
2
4

kg
m

14
to
17
ft
Ib

Lock

nuts
A
and
B

0
8
to
1
2

kg
m

5
8
to
8
7
ft
lb
CLtJTCH

Note
Refer
to

Figure
Clot8
for
the

correct
direction
of
return

spring

1

Pedal

assembly

2
Push
rod

3
Return

spring

eL116

Fig
CL

1B

Hooking
return

pring

Inspection
and

adjustment

Clean
all
the

following
parts
in

cleaning
solvent
and
check
for
wear

damage
or

any
other
abnormal
condi

tion

Replace
the

parts
which
are

faulty

1
Return

spring

2
Bush

3
Pedal
boss

etc

CL
6
1

Lock
nut

A

2
Lock

nut
8

Pedal

beiBht
a

53
mm

6
02
in

Pedal
full

stroke
b
117
10
23
4
6
104

84
in

@
Multi

purpose
grease

CL102

Fig
CL

17
Adju
ting
pedal
height

1

Adjust
the

pedal
height
to
153

mm
6
02
in

by

adjusting
pedal
stop

per
and

tighten
lock
nut
A

to
the

specified

torque
0
8
to
1
2

kg
m
5
8

to
8
7
ft
lb

2

Turn
in

or
out

push
rod

adjusting

screw
until
a

play
of
I
to
3
mm
0

039

to
0

118
in
at
clevis

pin
is

obtained

Then

tighten
lock
nut
B

to
the

specified

torque
0
8
to

1
2

kg
m
5

8

to
8
7ft
Ib

Note
Exercise

care
in

adjusting
the

play
not
to
block

the

port
or

master

cylinder
A
blocked

port

may
result
if
too
small

play
at

clevis

pin
exists

3
After

adjusting
check

the

pedal

full
stroke

is
in
117

to
123
mm
4

61

to
4
84

in

Note

Depress
and
release
clutch

pedal
over
its
entire
stroke
to

en

sure
that
the
clutch

linkage
op

erates

smoothly
without

squeak

noise
interference
and

binding

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

CLUTCH

SERVICE

DATA
AND

SPECIFICATIONS

Clutch
cover

Clu
tch

cover

type

Diaphragm
spring
to

flywheel
distance

Unevenness
of

diaphragm
spring
toe

height

Full
load

Out
of
flatness
of

pressure
plate

Allowable

refacing
limit
of

pressure
plate

Clutch
disc

Facing
size

Outer
dia
x
inside
dia
x
thickness

Thickness
of
disc

assembly

Free

Compressed

Number
of
torsion

springs

Allowable
minimum

depth
of

rivet

head
from
surface

Allowable

facing
run
out

Allowable
free

play
of

spline

at
the
outer

edge
of
disc

Clutch

pedal

Pedal

height

Play
at

clevis

pin

Full

stroke

Clutch
master

cylinder

Dia
of
master

cylinder

Allowable
maximum
clearance

between

cylinder
and

piston

Clutch

operating
cylinder

Dia
of

operating
cylinder

Tightening
torque

Clutch

assembly
to

flywheel
securing
bolt

Pedal

installation
bolt
Fulcrum

pin

Pedal

stopper
lock
nut

Push

rod
lock

nut

Master

cylinder
to
dash

panel
securing
bolt

Clutch

tube
connector
Flare
nut

Clutch

hose
connector

Operating
cylinder
to

clutch

housing
securing

bolt

Bleeder
screw
mm
in

mm
in

kg

Qb

mm
in

mm
in
Diaphragm
C225S

33

to
35
1
23

to
1
38

less
than
0
5

0
020

400

882

0
1

0
004

1

0
0
040

mm
in
225
x

150
x
3
5
8

86
x

5
91
x
0

138

mm
in

mm
in
8
3
to

8
9
0
327
to
0

350

7

6
to
8
0
0
299

to
0
315

6

0
3
0
012

0
5

0
020

0
4
0
016
mm
in

mm
in

mm
in

mm
in

153
6
02

mm
in
I

to
3

0
039

to
0
118

mm
in
117

to
123
4

61
to
4
84

mm
in

15

87
5
8

mm
in

0
15

0
0059

mm
in

19

05

Yo

kg
m
ft
lb
1

5
to
2

2
lito

16

kg
m
ft

Ib

1
9
to
2
4

14
to
17

kg
m
ft
b
0

8
to
1
2
5

8
to
8
7

kg
m

ft
lb

0
8
to

1
2
5
8
to
8
7

kg
m
ft
Ib
0
8
to
1
2
5
8
to
8

7

kg
m
ft
lb

1
5
to

1
8
11
to

13

kg
m
ft
lb

1
7
to
2
0
12
to
14

kg
m
ft
lb

2
5
to
3
5
18
to
25

kg
m
ft
Ib

0
7
to
0
9
5
1

to
6
5

CL
9

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

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
CLUTCH

Probable
cause
and

testing
Corrective
action

Clutch

chattering
is

usually
noticeable
when
vchicle
is

just
rolled
off
with
clutch

partially

engaged

Weak
or
broken
clutch
disc
torsion

spring

Oil
or

grease
on
clutch
facing

Clutch

facing
out
of

proper
contact
or

clutch
disc

runout

Loose
rivets

Warped

pressure
plate
or
clutch
cover

surface

Unevenness
of

diaphragm
spring
toe

height

Loose

engine
mounting
or
deteriorated

rubber

A
noise
is
heard
after
clutch
is

disengaged

Damaged
release

bearing

A
noise
is

heard
when
clutch
is

disengaged

Insufficient

grease
on
the

sliding
surface

of

bearing
sleeve

Clutch
cover
and

bearing
are
not
installed

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or
replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
vehicle
is

suddei11y
staited
off
with
clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
vehicle
will
not
start
off

smoothly
from
a

standing
start
or

clutch
is

engaged
before
clutch

pedal
is

fully

depressed

Oil
or

grease
on
clutch

facing

Clutch

facing
worn
or
loose
rivets

Wear
or
rust
on

splines
in

drive
shaft
and

clu
tch
disc

Warped
flywheel
or

pressure
plate

Loose
mountings
for

engine
or

power

train
units

CLll
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

2
RANGE
2ND

GEAR
Automatic
Transmission

In
2

range
the

gear
rario
is

IOI
keJ

III
the
2nd

forward

speed
In

this
case

the
rear

dutch
is

engaged
and
the

band

brake
holds

the
front

clutch
drum
the

connecting
shell
and
sun

gear
from

rotating

The

power
flow
takes

place

through

the

input
shaft
inlo

the

rear
clutch

and

the
front
internal

gear
With
Ihe

sun

gear
held

stationary
the
front

planetary

gears
rotate
around

the
sun

gear
carrying
the

front

planet
carrier

with
them
The
front

planet
carrier

being
splined
to
the

output
shaft

causes
clockwise
rotation

of
the
OUI

put
shaft
at
a

reduced

speed

compared

to
the

speed
of
the

input
shaft
with

an
increase
in

torque
As
the
low
and

reverse

brake
is
not

engaged
the
clock

wise

rotation
of

the

output
shaft

causes
clockwise
rotation

of
fear
inter

nal

gear
and

the
rear

planet
carrier
also

rotates
around

the

sun

gear
in
a

clockwise

direction
The

one

way

clutch

will
act

to
allow

clockwise

rotation
of

connecting
drum

When
the

manual
valve

V
is

posi

tioned
at
2

the
line

pressure
7
is

introduced
into

the
line

pressure
cir

cuits
I
2

and
4

The

line

pressure

I
is
led

to

the

governor
rear
clutch

and

I
st

2nd
shift
valve

CID
as
in
the

case
of

D

range
The

line

pressure

2
locks

the
second
lock

valve

@and

is
led
to

thc

tightening
side
of
Ihe

band

servo

The

2nd

gear
is

therefore
fixed

regardless
of
vehicle

speed
When

DJ

range
3rd

gear
is

shifted
to
2

range
the

line

pressure
4
enters
Ihe

throttle

back

up
valve

V
and

produces

a

high
pressure
in
the
circuit
17

increasing
thc

throttle

pressure
li
6

The

line

pressure
7

is

therefore

increased

and

quickly
tightens
the

band

N

e

DJ
range
3rd

gear
to
2

range

If

DJ

range
3rd

gear
is

shifled

to
2

range

during
operation
the

manual
valve

V
is
also
shifted

to
A

T078

Fig
AT

40
Powu

tTansminion
during
2
H

range

A
1079

Fig
AT
41

Operation

of
each
mechanism

during
2

range

Clutch
Low

Band
ser
o
On

Parking
Gw

Ran8t

utio
w

pa

Front
Rear

brake
Operalion
Release

dutch

Pui
on

on

Revtrs
e

2
182
on

on
on

Neutral

01
Low

2
458
on
on

Drive
02
Second

1
458
Oft
Oft

OJ

Top
1
000
on
on

on
on

1
Second

1
458

on
Oft

12
tocond
1458

on
on

J

tt
Low
2
458

on
on

2

position

causing
the
line

pres

sure
circuit
3
to

be
drained

Therefore
the

line

pressure
circuit

10
which
is

situated
at
the

release

side
of
the
front
clutch

and
servo
is

also

drained

through
the
2nd

3rd

shift
val

e
@

forcing
the

speed
to

AT
28
decrease
from
3rd

gear
to
2nd

gear
In

this
case

the

speed

change

quickly
takes

place
because
the
line

pressure
7

and
other

pressure
are

heightened
by
the
action
of
the
line

pressure
4
in

the
same

manner
as

described
under
2

range