1977 DATSUN PICK-UP tow

Speci
ol

Cylinder
Head
Bolt

Wren
h

8110120000

Tightening
torque

1st
turn

4

0

kg
m
29

ft
lb

2nd
turn

6
0

kg
m
43
ft
lb

3rd
turn

6
5

to
8
5

kg
m

47
to
61
ft
lb

B
O

A

A

B

A

A
B
O

B
O

R
O

EM
176

Fig
EM
I02

Cylinder
head
boll

Notes

a
Be
sure
to

tighten
two
small
bolts

b
After

engine
has
been

operated
for

several
minutes

retighten
if
neces

sary

23
Install
oil

pump
and
distr
butor

driving

spindle
in

front
cover

Tightening
torque

1
1
to
1
5

kg
m

8
0

to
10
8
ft
lb

Notes

a
Assemble
oil

pump
and
drive

spin

die
aligning
driving

spindle
face

with
oil

pump
hole

b
Install
oil

pump
together
with

drive

spindle
so
that
the

projection
on
its

top
is
located
at
the
II
25
a
m

position
At
this

point
the
smaller

bow
shape
will
be

facing
toward
the

front

c
Do
not

forget
to
install

gas
et
Engine
Mechanical

I

Fig
EM

I04

11l6lalling
oil

pump

24
Install
fuel

pump
water
inlet

elbow
and
front

engine
slinger
in

their

positions

Fuel

pump
tightening
torque

1
2

to
1
8

kg
m

8
7

to
13

0
ft
lb

Note
Do
not

forget
to
install
fuel

pump
spacer
and

packing
between

spacer
and
block

spacer
and

fuel

pump

25
Install
oil
strainer
oil

pan
gasket

and
oil

pan

27

Install
rocker
cover
to

cylinder

head

Note
Make

sure
that
one
of
the

rocker
cover
bolts
is

longer
than
the

others
It
secures
F
I
C
D
assist

bracket

28
Install
air

pump
bracket
and

cooler

compressor
to

cylinder
block

EM
25
Tightening
torque

Oil
strainer

bolts

0

8
to
I
l

kg
m
5

8
to
8
0
ft

lb

Oil

pan
bolts

0
6
to
0
9

kg
m
4
3

to
6
5
ft

lb

Notes

a

Apply
sealant
to
the

step
portions

at

four

mating
surfaces

as
shown

in

Figure
EM
80

b

Oil

pan
should
be

tigh
tened
in

criss
cross

pattern
to
a
final

torque

of
0
6
to
0

9

kg
m
4
3
to
6
5
ft
lb

26

Adjust
valve
clearance
to
the

specified
dimensions

Special
tool

Pivot

Adj
iier
STl064000l

Tightening
torque

5

0
to
6
0

kg
m

36
to
43
ft
lb

Fig
EM
I05

Adjusting
valve
clearance

b
After

engine
has
been
assembled

run
it
for
at
least
several
minutes

and

finally
adjust
clearance
to
the

warm

specifications

29

Install
intake
manifold
to

ex

haust
manifold
The
intake
manifold

face
which
comes
into
contact
with

gasket
should
be
even
with
that
of

exhaust
manifold
Note
that
two
dif

ferent

sizes
of

attaching
bolts
are
used

Tightening
torque

2
5

kg
m

18
0
ft

lb

ENGINE
LUBRICATION
SYSTEM

2
Fill

pump
housing
with

engine

oil

then

align
punch
mark
of

spindle

with
hole
in
oil

pump
as
shown
in

Figure
EL

3

Punch
mark

EL009

Fig
EL
3

Aligning
punch
mark

and
oil
hole

3

Using
a
new

gasket
install
oil

pump
and
drive

spindle
assembly
so

that
the

projection
on
its

top
is

located
in
II
25
a
m

position
at

this
time
the
smaller
bow

shape
will

be

placed
toward
the
front
as
shown

in

Figure
EL
4

JI

I
c

J

V

Front
J

@
9@

tr
i

d

L
It
I

I
EL010

Fig
EL

4
Setting
drive

pindle

o

EL011

Fig
EL

5
Imtalling
oil

pump

Ascertain
whether

or
not

the
en

gagement
is
in
order

by
checking
the

top
of

spindle
through
distributor
fit

ting
hole

4

Tighten
bolts

securing
oil

pump

to
front
cover
Disassembly

and

assembly

I
Remove

pump
cover

attaching

bolts

pump
cover
and
cover

gasket

and
slide
out

pump
rotors

2
Remove

regulator

cap
regulator

valve
and

spring

3

Install

pressure
regulator
valve

and
related

parts

4
Install

outer
rotor
inner
rotor

and
shaft
in

pump
body
and
do
not

turn
cover

gasket
up

CD

El012

r

@
@

CD@

1

Oil

pump
body

2
Inner
rotor
and
shaft

3
Outer
rotor

4
Oil

pump
cover

5

Regulator
valve
6

Regulator
spring

7
Washer

8

Regulator
cap

9
Cover

gasket

Fig
EL

6
Oil

pump

Inspection

Wash
all

parts
in

cleaning
solvent

and

dry
with

compressed
ir

I

Inspect
pump
body
and
cover

for
cracks
or
excessive

wear

2

Inspect
pump
rotors
for
excessive

Rotor
side
clearance

rotor
to
bottom

cover
Olm
in

Rotor

tip
clearance

@
mOl
in

Outer
rotor
to

body

clearance

D
mm

inl

EL

3
wear

3

Check
inner

rotor
shaft
for

looseness
in

pump
body

4

Inspect
regulator
valve
for

wear

or

scoring

5

Check

regulator
spring
to
see

that

it
is
not

worn
on
its

side
or

collapsed

6

Using
a

feeler

gauge
check

tip

clearance
2
and

outer
rotor
to

body

clearance
I

shown
in

Figure
EL
7

1
Outer
rotor
to

body
clearance

2

Tip
clearance

3

Gap
between

rotor
and

straight
edge

4

Gap
between

body
and

straight
edg
e

Fig
EL
7

Checking
rotor
clearance

7

Place
a

straight
edge
across
the

face
of

pump
and

depress
it

slightly
as

shown
in

Figure
EL
7

Check

gap
4

between

body
and

straight
edge
or

gap

3
between

rotor
and

straight
edge

The

gap
should
be
0
03
to
0

06

mm

0
0012
to
0
0024
in
then

rotor
side

clearance
rotor
to
bottom

cover
clearance
with

gasket
should

satisfy
the

specifications

Standard
Wear

limit

0
04

to
0

08

0
0016
to

0
0032
0
20
0
0079

Less

than

0
12
0

0047
0

20
0
0079

0

15
to
0
21

0
0059

to
0
0083
0
5

0
0197

The

pump
shaft
is

supported
by
a

double
row

of
ball

bearings

press
fit
in

an
aluminum
die
cast

pump
body
The

bearings
are

permanently
lubricated

and
sealed

to

prevent
loss
of
lubricant

and

entry
of

dirt

The

pump
is

provided
with
an

impeller
which
turns
on
a
steel

shaft

The

steel
shaft
rotates

together
with

the

torque

coupling
wheeL
The
volute

chamber
is
built
in
the

engine
front

cover

assembly

The
inlet
of
the

pump
is

connected

to

the
radiator
s
lower
tank

by
a
hose

i

o

CQ047

Fig
CO
2
Water

pump
and

engine

front
cover

REMOVAL
AND

INSTALLATION

Removal

in
to
a
clean

con

assembly

I

CQ048

Fig
CO
3
Removing
water

pump

Installation

1
Be

sure
to
clean
the

gasket
sur

faces
in
contact
with

pump
and
front

cover

Always
use
new

gaskets
when

installing

pump
assembly
Be
sure
to

tighten
bolts
Cooling
System

Tightening

torque

0
4
to
0
5

kg
m

3
0
to
3
6
ft
lb

2

Fill

cooling
system
and
check
for

leaks
at

pump

3

Install
fan
blade
and

tighten
at

taching
bolts

securely
Install
belt
and

adjust
for

specified
tension

4

Operate
the

engine
at
fast

idling

and
recheck
for
leaks

5
Install
fan
shrouds

Note
Ensure
that
clearance
between

shroud
and
Can
is

even
at

any

place

DISASSEMBLY

Water

pump
is

made
of
aluminum

and
its

bearing
outer
race
is
of
a

press

fit

type
For
this

reason
water

pump

should
not
be
disassembled

INSPECTION
AND

ADJUSTMENT

Inspection

Inspect
pump
assembly
for
the

fol

lowing
conditions
and

replace
if
nee

essary

1

Badly
rusted
or
corroded

body
as

sembly
and

vane

2

Excessive
end

play
or

roughness
of

bearings
in

operation

3
Reduced

cooling
efficiency
due
to

deteriorated
silicone
oil

4
Oil

leakage
in

torque
coupling
Adjustment

Fan

belt
should
be

properly
ad

justed
at
all
times
A

tight
belt
causes

wear
of

alternator
and
water

pump

bearings
A
loose
belt

brings
about

improper
cooling
fan
water

pump

and
alternator

operation

Check
the
belt
slack
between
alter

nator
and
fan

pulley
by
force
of
10

kg

22
lb

Slackness
of
fan
belt

8
to
12

mm

0
31
to
0
47
in

If

adjustment
is

necessary
loosen

bolt

retaining
alternator

adjusting
bar

to
alternator
Move

alternator
toward

or

away
from

engine
until
the
correct

tension
is
obtained

TORQUE
COUPLING

Except
air

conditioner

equipped

models

The

torque
coupling
keeps
the
fan

speed
at
2
500

rpm
rated
or
below

to

conserve
horsepower
at

high
engine

speed
It
also

helps
reduce
fan
noise
to

a
minimum

during
high
speed
opera

tion

This
unit
is
filled
with
a

special

silicone
oil
used
as
a

fluid

coupling

which
controls
the

fan

speed
Silicone

oil

can
not
be

replenished

1

Torque
coupling
wheel

2

Torque
coupling
cover

3

Torque
coupling
bearing

4
Pulley

5
Water

pump

C0060

Fig
CO
4
Sectional
view
of

torque
coupling
and
water

pump

00
3

CONSTRUCTION

O

o

8

w

il
Engine
Electrical

System

V

1

Magnetic
switch
assembly
13
Brush

spring
jj

JI

2
Dust
cover
t4
Brush

Adjusting
washer
15
Yoke

P

3
Torsion

pring
t6
Field
coil
assembly

4
Shift
lever
17
Armature

assembly

5
Dust

cover
18

Center

plate
SI14
1808
only

6
Thrust
washer
19
Pinion
assem
bly

7
E

ring
20
Dust
cover

8
Rear
cover
metal
21
Pinion

stopper

9

Through
bolt
22

Stopper
clip

10
Rear
cover
23
Gear
case

tl
Brush
holder

assembly
24
Gear
case
metal

12
Brush

REMOVAL

Disconnect

battery
ground
cable

Disconnect
black
wire
with

yellow

stripe
from

magnetic
switch
terminal

and
black

battery
cable

from

battery

terminal
of

magnetic
switch

2
Remove
two

bolts

securing
start

ing
motor
to
transmission

case
Pull

starter

assembly
forward
and
remove

starting
motor

DISASSEMBLY

I
Disconnect

connecting
plate
from

M

terminal
of

magnetic
switch
Re

move
two
screws

securing
magnetic

switch
and

remove

magnetic
switch

assembly

2
Remove
dust

cover
E

ring
and

thrust
washer
s
EE317
@

@

O

Fig
EE

9
Remouing
dUlt
cover
E

ring

and
thrust
washer
s

3
Remove

two
screws

securing

brush

holder

assembly

EE318

Fig
EE
IO

Removing
brush
holder

d
crt

w

EE
7
S

4

f

I
jl

I

EE316

Fig
EE
B

Exploded
view

of
starting
motor

4
Remove
two

through
bolts

and

rear
cover

5
Remove
b
rushes
from
their

hold

er

by
moving
each
brush

spring
away

from
brush
with
a
hook

Remove

brush
holder

6
Remov

yoke
assembly
and
with

draw
armature
assembly
and
shift

lever

7
Remove

pinion
stopper
located
at

the
end
of

armature
shaft
To
remove

stopper
first
move
stopper
toward

pinion
and

after

removing
stopper
clip

remove

stopper
with

overrunning

clutch
assembly
from
armature
shaft

Pinion

stopper

Pinion
stopper
clip

EE277

Fig
EE
l1

Removing
pinion
stopper

CHECKING
AND

ADJUSTMENT

CAP
AND
ROTOR
HEAD

Cap
and
rotor
head
should
be
in

spected
periodically
as

specified
in
the

Maintenance
Schedule
Remove
cap

and
clean
all
dust
and
carbon
deposits

from

cap
and
rotor
If

cap
is
cracked

or
is

leaking
replace
with
a
De
one

CONTACT
POINT

Contact

point
should
be

replaced
in

accordance
with
the
Maintenance

Schedule

Standard

point
gap
is
0
45
to
0
55

mm
O
OIS
to
0

022
in
In

case
size

is
off
the
standard

adjustment
is
made

by
loosening
point
screws

Gap
gauge

is

required
for

adjustment

When

point
surface
is

rough
take

off

any
irregularities
with

fine
sand

paper
of
No
500
or
600
or
with
oil

stone

When
wear

on
contact

points
is

noticeable
replace
points
together

with
contact

arm
To

replace

proceed

as

follows

EE322

Fig
EE
58
Adju
ting
point

gap

EE321

I

Primary
lead
termina

2
Ground
lead
wire

3
Set
screw

4

Adjuster

5
Screw
Fig
EE
59
Breaker
Engine
Electrical

System

First
turn
out
set

screws
1
to

1
5

turns
at
contact
arm
and

primary
lead

wire

connection

just
for

enough
to

pull
out

primary
lead
terminal

Referring
to

Figure
EE

59
unSCrew

two
contact
set

fixing
screws

and

remove
lead
wire

While

holding
contact
arm

by

fingers

pull
out
contact
set

toward

you
by

raising
it

slightly
Contact

point
and

afm
can

then
be

removed

together

Install
new
contact

point
and

arm

assembly
in

reverse
sequence
of

removal

Coat
cam
with
a

light
coating

of

grease

ADVANCE
MECHANISMS

Specifications

Application

Vacuum
advance

Distributor

degrees
distributor

mmHg
inHg

Centrifugal
advance

Distributor

degrees

distribu
tor

rpm

For
Canada

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate
properly
check
for
the

following
items

and
correct
the
mal

function
as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
its

connection

Ifnecessacy

retighten
or

replace
with
a
new
one

2
Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controller

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

pia
te
does
not

move

smoothly

this
condition
could
be
due
to

sticky

steel
balls
or

pivot
Apply
grease
to

steel
balls
or
if

necessary

replace

breaker

plate
as
an

assembly

EE
31
CONDENSER

Satisfactory
performance
of
con

denser

depends
on

capacity
and

degree

of
insulation

requiring
attention

to
be

sure

that
terminals
are
clean
and
set

screws
are

tight

Checking
of

condenser
is
made

by
a

condenser
tester

D4A4
06

D4A6
07
D4A4
07

D4A6
0S

Automatic

transmission
Manual
transmission

00
150
5

91

30
250
9

S4
00
170
6

69

6
50
300

1I
S1

00
550

11
0

2

300
00
600

110
1
950

Centrifugal
advance

mechanical

parts

When
cause
of

engine
malfunction

is

traced
to

centrifugal
advance
me

chanical

part
use
distributor
tester
to

check
its
characteristic

See
the

specifications
above

When

nothing
is

wrong
with
its

characteristic
conceivable
causes
are

break
down
abnormal

wearing
out
of

driving
part
or
others
So
do

not

disassemble

it

In

case
of

improper
characteristic

take
off
contact
breaker

assembly
and

check

closely
cam

assembly

governor

weight
shaft
and

governor
spring
etc

In
case

centrifugal
advance
me

chanical

part
is
reassembled
be

sure
to

check
advance
characteristic

by
dis

tributor
tester

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate

properly
check
for
the

following
items

and
correct
the

prob

lem
as

required

1

Check
vacuum
inlet
for

signs
of

leakage
at
its
connection
If

necessary

retighten
or

replace
with

a
new
one

2

Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controller

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

plate
does
not
move

smoothly

this

condition
could
be

due
to

sticky

steel

balls
or

pivot
Apply
grease
to

steel
balls
or
if

necessary
replace

distributor

assembly

Centrifugal
advance

mechanical

parts

When

cause
of

engine
malfunction

is
traced

to

centrifugal
advance
mecha

nical

parts
use
distributor
tester
to

check
its
characteristics
See
to
the

specifications
above

If

nothing
is

wrong
with
its

charac

teristics
conceivable
causes
are

faulty

or

abnormal
wear
of

driving
part
or

others
So
do
not
disassemble
it

In
the
event
of

improper
character

istics
check

closely
rotor

shaft
assem

bly

governor
weight
and
shaft

If

any
of
above

parts
are
malfunc

tioning
replace
distributor

assembly

DISASSEMBLY

To

disassemble
follow
the

pro

cedure
below

1
Take
off

cap
and
remove

rotor

head

2
Remove
two
screws
shown
in

Figure
EE
69
and
detach
vacuum

con

troller
Engine
Electrical

System

EE291

Fig
EE

69

Removing
vacuum

controller

3
Remove

pick
up
coil

assembly

4

Using
two

pry
bars

pry
reluctor

from
shaft
Be
careful
not

to
distort
or

damage
the
teeth
of
reluctor

Remove

roll

pin

S
Remove

breaker

plate
setscrews

and
remove

breaker

plate
assembly

E330

Fig
EE
70

Removing
breaker
plate

etscrews

6
Pull
roll

pin
out
and
remove

collar

7
Remove
rotor
shaft
and
drive

shaft
assembly

EE331

Fig
EE
71

Removing
rotor

shaft
and

drive

shaft
assembly

8
Mark
rotor
shaft
and

drive
shaft

Remove

packing
from
the

top
of

rotor

shaft
and
unscrew
rotor
shaft

setscrew

EE

35
EE075

Fig
EE
72

Removing
rotor

shaft

9

Mark
one
of
the

governor
springs

and
its
bracket
Also
mark

one
of
the

governor

weights
and
its

pivot
pins

10

Carefully
unhook
and
remove

governor

springs

11
Remove

governor
weights

Apply
grease
to

governor
weights

after

disassembling

ASSEMBLY

To

assem
ble

reverse
the
order
of

disassembly

Carefully
observe
the
fol

lowing
instructions

1

Align
match
marks
so
that

parts

are
assembled
to
their

original

posi

tions

2

If
for

any
reason
contactor
is

removed
from
breaker

plate
adjust

cam
to
contactor
clearance

to
0
3

mm

0
012
in

as
shown
in

Figure
EE
73

after
installation

T

EE298

Fig
EE
73
Cam
to
contactor

clearance

3

Ensure
that
reluctor
is

properly

orien

ted
when

installing
on
shaft

Always
drive
in

roll

pin
with
its

slit

toward
the
outer
end
of
shaft
See

Figure
EE

74
Be

sure
to
use
a

new
roll

pin

Fig
ER
2
ER207

Removing
front
engine

mounting
bolts

20
Place
a

jack
under
transmission

and

jack
it

up

21
Loosen

two
rear

engine
mount

ing
bolts

CD

22
Loosen
two

exhaust
tube

hanger

bolts

V
California
models

only

23
Remove
four
bolts

CID
securing

engine
mounting
rear

support
to
side

member
and
detach
rear

support

j
r

O

1

ER271

Fig
ER
3
Removing
rear

engine

mounting
support

24
Remove

steering
idler
arm
secur

ing
bolts
and

push
down

cross
rod

iC

EA278

Fig
ER

4
Removing
idler
arm

25
Pull

engine
towards
front
as
far

as

possible
and

carefully
raise
if
and

transmission
with
a
hoist
and
cable

Note
In

this

r
an

care
should

always
be
taken
not
to
allow
the

unit
to
hit

against
any

adjacent

parts
Engine
Removal
Installation

INSTALLATION
E
R367

Fig
ER
5
Lifting
engine

Install

engine
with
transmission
in

reverse
order
of

removal

observing
the

following

I
When

installing
first
secure

rear

2

Front

1
Bracket
R
H

2

Insulator
R
H

3
Bracket
LH

4

Heat
shield

plate

5
Insulator

L
H

6
Rear

support

7
Rear
insulator

8
Exhaust
tube

hanger

California
models

only
engine
mounting

support
to

body

2
Refer
to

applicable
section
when

installing
and

adjusting
any
parts

@

E

A279

Fig
ER

6
Structual
view

of
engine
mounting

ENGINE
MOUNTING

INSULATORS

Three
insulators
are
used
to

mount

the

engine
and
transmission

two
are

located
at

the
left
and

right
of
the

cylinder
block
and
one
at
the
transmis

sion

rear
extension

housing
Replace
any
insulator
that
shows

signs
of

separation
or
deterioration

Be
sure
to

keep
insulator
free
from

oil

or

grease

ER
3

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