1977 DATSUN PICK-UP height adjustment

Condition

Excessive

pedal
travel

Spongy

pedal

Poor

braking
effect

Brakes

drag
Brake

Syst
em

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Probable
cause

Low
brake
1uid
level
or

empty
master

cylinder
reservoir

Leakage
in
master

cylinder

Deteriorated
check
valve

Air
in

system

Faulty
brake

adjustment

Low

1uid
level
in
master

cylinder

Air
in

system

Faulty
brake

adjustment

Reservoir
filler

cap
vent

hole

clogged

Swollen
hose
due
to
deterioration

or
use
of

poor
quality
hose

Distorted

brake
shoes
or

excessively
worn

or

cracked

brake
drum

Soft
or
swollen

caliper
seals

Use
of
a
brake

1uid
with

too
low

boiling

point

Fluid

leakage
in

brake
lines

Low

brake
1uid
level

or

empty
master

cylinder
reservoir

Air
in

brake
lines

Excessive
shoe
ta
drum

clearance

Grease
oil

mud
or

water
on

linings
or

pads

Deterioration
of

linings
or

pads

Local
fit
of

linings
or

pads

Linings
or

pads
excessively
worn

Master

cylinder
or
wheel

cylinders
in

poor

condition

Binding
mechanical

linkage
at
brake

pedal

and
shoes

Clogged
brake
lines

Incorrect

adjustment
of

wheel

bearings

Improper
shoe
t

drum
clearance

Weak
shoe
return

springs

No
free
travel
in

brake
shoe

return

BR
22
Corrective
action

Fill
and
bleed
as

necessary
Test

for
source

of

leakage
by
examining
all
lines

connec

tions

and
wheel

cylinder

Overhaul
master

cylinder

Replace
check
valve
and
bleed

system

Bleed

system

Adjust
shoe
to
drum
clearance

Inspect

auto

adjuster
operation

Top
with
1uid
and

inspect
for

leakage

Correct
as

necessary

Adjust
shoe
to

drum
clearance

Inspect

aut

adjuster

operation

Clean
and

bleed

system

Replace
hose
and

bleed

system

Replace
faulty

parts

Drain

hydraulic
system
flush
with
alcohol

and

replace
all
seals

Replace
with

specified
brake

1uid
and
bleed

system

Check

master

cylinder

pIpIng
and
wheel

cylinder
for
leaks
and

repair

Fill
and
bleed

as

necessary

Bleed

system

Adjust

Clean
brake
mechanism
and
check
for

cause

of

problem

Replace
linings
or

pads

Replace

Shave
or

replace

Replace

Repair
or

replace

Free

up
as

required

Check
and

clean

Adjust
or

repair

Adjust

Replace

Adjust

pedal
height

Engine
Control
Fuel
Exhaust

Systems

REMOVAL
AND

INSTALLATION

Accelerator

wire

I

Remove
air
cleaner

assembly

2

Disconnect
accelerator
wire

from

carburetor

3

Loosen
lock

nut
and
disconnect

accelerator
wire
outer
case
from
wire

holder
See

Figure
FE
I

4

Remove

spring
clamp
and

discon

nect
accelerator
wire

from
accelerator

pedal
arm

S

Remove
two

screws

securing
ac

celerator
wire
outer
case
to

body
and

detach
accelerator
wire

6
To

install
reverse
the
order

of

removal

Apply
recommended
multi

purpose
grease
slightly
to

portion

MG
shown
in

Figure
FE
I

Accelerator

pedal
assembly

I
Remove

spring
clamp
then
dis

connect
accelerator
wire
from

tip
of

pedal
ann

2
Remove

two
screws

securing
ac

celerator

pedal
bracket

to

body

3
Remove

accelerator

pedal
from

dash

panel
See

Figure
FE
I

4
To
install
reverse
the
order
of

removal

INSPECTION

I
Check
accelerator

pedal
return

spring
for

rust

fatigue
or

damage

Replace
if

necessary

2

Check
accelerator
wire

cases
and

fastening
locations
for
rust

damage
or

looseness

Repair
or

replace
if

necessary

ADJUSTMENT

Accelerstor

pedal
and
wire

Adjust
pedal

stopper
bolt

Section
A

so
as
to
obtain

specifi

ed

height
E
as
shown
in

Figure

FE
I

Secure

pedal
stopper
bolt
with

stopper
lock
nut
Refer

to
Figure

FE
I
E

78
mOl
3
07

in

Tightening
torque
01
nut

0
38

to
0
4S

kg
m

2

7
to
3
2

ft
b

2

Release
auto

choke
effect
since

throttle
lever
is

opened
by
fast
idle

earn
until

engine
warms

up

I

Keep
choke
valve

fully
open

with

fingers

2

Pull
throttle
lever

up
by
hand

1

Adjust
nut

2
Lock
nut

3
Accelerator
wire

4
Dust
co

r

5
After

completing
the

adjustment

as

previously
explained
check
the

following

I

Make
sure

that
accelerator

system
functions

smoothly
and

quietly

without

disturbing
any
adjacent

parts

2

Depress
accelerator

pedal
down

until

throttle
valve

fully

opens
Make

sure
that

the
clearance
T
between

accelerator

pedal
reverse
side
and
dash

floor
is
2
to
4
mm
0
08
to

0
16
in

without
floor

mat

Adjust
pedal

stop

per
bolt
and
lock
nut
if

beyond
limits

3

Check
throttle

lever
if
it

returns

to
the

original
position
as
soon
as

accelerator

pedal
is

released

FE
3
then
automatic

choke
effect
will

be

released

3

Set
throttle
valve
to

completely

closed

position
and
with
wire

suf

ficiently
slackened

lighten

adjust
nut

until
throttle
lever
is
about
to
move

Accelerator

pedal
play
is

zero

at
this

lime
See

Figure
FE

2

4

Unscrew

adjust
nut

approxi

mately
two
and
a

half
turns
so
that

accelerator

pedal
play
is
3
mOl

0
012

in

Tighten
lock
nut

securely
See

Figure
FE
2

1

I

1

CD
@

FE184

Fig
FE72

AdjU6ting
accelerator
wire

play

4

Apply
recommended
multi

purpose
grease
slightly
on
the

portion

as
shown
in

Figure
FE
I
Also
refer

to

the

periodic
maintenance
schedule

Kickdown
switch
Automatic

transmission
models
only

Kickdown
switch

adjustment
is

cor

rect
if
it
is

actuated

by
kickdown

switch
striker
when

accelerator

pedal

is

fully

depressed

Always
tighten
switch

stopper
nut

securely
after

proper
adjustment
is

obtained

COWL
TOP
GRILLE

@
@

REMOVAL
AND

INSTALLATION

I

Open
engine
hood

2
Remove
two
windshield

wiper

blad

3

Remove
cowl

top

grille
attaching

HOOD

REMOVAL
AND

INSTALLATION

1

Place

protective
covers
over
front

fender
and
cowl

top

grille

2

Open
engine
hood
Mark

hinge

locations
on
hood
and
loosen
off
four

bolts

securing
hood
to
hood

hinge
Use

extra
caution

to
avoid

damaging

painted
surfaces
of
fender
and
cowl

top
grille

3

Remove

engine
hood

4

To
install
reverse
above

pro

cedures

ADJUSTMENT

Four

slotted
holes
in

hood

hinge

provide
for

fore
aft
and
side

adjust

ment

to
correct

space
between
hood

and
fender

and
hood
and

cowl

top

grille

Loosen

four
bolts

just
enough
to

move

engine
hood

and
move
hood
to

desired

position
if

necessary
to
correct

space

To
make
vertical

adjustment
adjust

height
of

dove
tail

bolt
at
hood

lock

male
until
hood
is
flush
with
fender
Body
Frame

1

Cowl

top
grille

2

Cap

3
Air
box
dtain
seal

4

Cowl

top

5

Air
box
drain

6
Screw

6F633

Fig
BF
13
Cowl

top
grille

screws
Pull

grille
straight
forward
to

remove

4
Remove
air

box
drain

5

To
install
reverse
above

steps

HOOD

Loosen
hood
to

hinge
bolts

just

far

enough
to
permit
movement
of

hood

2
Shift
hood
in

elongated
hole
until

parallel
space
is
reached
between
hood

and
fender
or
cowl

top
grille
Tighten

bolts

securely

BF

8
However

observe
the

following
items

I
When

installing
air
box
drain

apply
adhesive
to
its
lower
end

2

Align
cowl

top

grille
with
fend

ers

FRONT
FENDER

REMOVAL
AND

INSTALLATION

I

Remove
front

bumper

2
Remove
radiator

grille

3

Remove
front

apron

4
Remove
cowl

top
grille

S
Remove
hood

bumpers
two
on

each
side

6

Remove
nine

screws

attaching

front
fender
to
hood
ledge
See

Figure

BF
ll

7
To

install
reverse
above

steps

5

1
Female
lever

2

Safety
catch
lever

3
Return

spring

4
Dove
tail
bolt

S
Lock
nut

6
Hood
lock

pring

7

Spring
J

BF641A

Fig
BF
14
Hood
lock
male
and

female

j

I

8F635

Fig
BF
15

Engine
hood

alignment

Body
Frame

Note
Vertical

adjustment
should
be

carried
out
after
hood
lock
male

and
female

adjustment
has

been

completed

3

To
correct
hood
lock

alignment

loosen

two
hood
lock
male
attaching

bolts
and

move
hood

lock
male
and

female
in

the
lateral
and
fore

and
aft

directions
as

required
D

1r

r

BF642A

Fig
BF
16

Adjusting
hood
lock

male

Tightening

torque

Male
and
female

attaching
bolts

0
45

to
0
60

kg
m

3
3

to
4
3

ft
Ib
4
Dove
tail
bolt
at

hood
lock
male

provides
for
vertical

adjustment
in

aligning
hood

to
make
it
flush
with

fender

To
correct
loosen

lock
nut
on

dove
tail

bolt
and
turn
dove
tail
bolt
in

or
out

as

necessary
to
obtain
a

correct

height

HOOD
LOCK
CONTROL

JI

I

i
I

r

lPP

J
jJ
J

Sr

aj
I

I
I

J

f
ifry
ff
I
ii1iiilliii
j
iW

r
U

I

j
Y

f
7

j

1

JJ
J

8F
9
5

Tighten
lock

nut
firmly
while

holding
dove
tail
bolt
with
a

screw

driver

to
secure

adjustment

Tightening

torque

Lock

nut
of

dove
tail

1
9

to
2
6

kg
m

14

to
19
ft
lb

BF643A

1
Lock

nut

2
Hood
lock

male
3

Safety
catch

Fig
BF

17
Doue
tail
bolt

height

adjustment

1
Dove
tail
bolt

seat

2

Lock
nut

3
Cushion
rubber

4

Spring

5

Spring
retainer

6
Dove
tail
bolt

7

Clamp

8

Clamp

9
Hood
lock

female

10
Control
cable

assembly

BF644A

Fig
BF
18
Hood
lock
and
control
cable