1977 DATSUN PICK-UP check oil

EM410

Fig
EM
II

Engine
on

engine
land

Remove

oil
level

gauge

6
Remove

carburetor
from
intake

manifold

1
Disconnect
cylinder
block
to

P
C
V
valve
hose
at
P
C
V

valve

2

Disconnect
A
B
valve
to
E

G
R

passage
hose

at
E
G
R

passage

3
Disconnect
vacuum
tube
to

carburetor

hoses
white
and

yellow
at

vacuum
tube

4
Disconnect
fuel

hose
from

carburetor

5

Remove
dash

pot
bracket
from

intake
manifold

6
Remov
carburetor

attaching

bolts
and

remove
carburetor

assembly

and

gasket

7
Disconnect
distributor

high
ten

sion
cables
from

sparkplugs

8
Disconnect
vacuum
hose

from

distributor
and

remove
distributor
as

sembly

9

Disconnect
fuel

hose
from
fuel

pump
and

remove
fuel
and

vacuum

hoses
combined

from

cylinder
head

10
Remove
fuel

pump
assembly

from

cylinder
head

EM412

Fig
EM
12

Removing
fuel
pump

IJ
Remove
in
take
and
exhaust

manifold

assembly
from

cylinder
head

1
Disconnect
vacuum
hose

from

air
control
valve
and
remove
air
con

trol

valve
for
California
and
a
r
hoses

as
an
assembly
Engine
Mechanical

1
Air
control
valve

2
Distributor
EM531

Fig
EM
13

Removing
air
control

valve

Californio
model

2
Remove
carburetor
air
cleaner

bracket

3
Disconnect
vacuum
hose
from

E
G
R
valve

4
Remove
check
valve
from
air

gallery

pipe

5
Disconnect
E
G
R

tube
from

E

G
R

passage
and
exhaust
manifold

6
Remove
E

G
R

passage
and

E
G
R
valve

from
intake

manifold

I
E

G
R

passage

2
E
G
R
tube

Fig
EM
14
EM532

Removing
E

G
R

tube
and

passage

7
Remove
F
l

C
D

bracket
from

cylinder
head

if
so

equipped

8

Disconnect
vacuum
hoses
from

thermal

vacuum
valve

and
remove

thermostat

housing
and

gasket
from

cylinder
head

EM089

Fig
EM
15

Removing
thermostat

housing

EM
5
9
Remove

cylinder
block
to

P
C
V

valve
hose
blow

by
gas
hose

from

cylinder
block

10
Remove

manifold

attaching

bolts
and
remove
intake
and

exhaust

manifold

assembly
and

gasket
from

cylinder
head

Fig
EM
16

Removing
intake
and

exhaust

manifold
assembly

11
Remove
intake

and
exhaust

manifold

attaching
bolts
and

separate

intake

manifold
from

exhaust
mani

fold

12
Remove
air

gallery
pipes
from

exhaust

manifold

12
Remove

left

engi
e

mounting

bra
et

from

cylinder

blopk

13
Remove
air

pump
and
cooler

compressor
bracket

14
Remove

crankshaft

pulley
in

stalling
bolt
and

washer
and
then

remove

pulley
with
a
two

jaw
puller

15
Remove
water

pump
assembly

16
Remove
rocker

cover

17

R
emove

spark
plugs

18
Remove
fuel

pump
drive
earn

19

Remove
camshaft

sprocket

Refer
to
the

following
note

during

operation
when

removing
camshaft

sprocket
from

engine
installed
on
car

EM091

Fig
EM
17

Removing
cammaf

sprocket

r

Engine
Mechanical

INSPECTION
AND
REPAIR

PREPARATION
FOR
INSPECTION

CYLINDER
HEAD
AND
VALVE

CHECKING
CYLINDER
HEAD
MATING

FACE

VALVE
ASSEMBLY

VALVE
SPRING

ROCKER
ARM
AND
VALVE

ROCKER

PIVOT

VALVE
GUIDE

VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARING

CAMSHAFT

BEARING
CLEARANCE

VALVE
TIMING

CAMSHAFT
ALIGNMENT

CYLINDER
BLOCK

HOW
TO
MEASURE

CYLINDER
BORE

CYLINDER

BORING

PREPARATION
FOR

INSPECTI
N

I

Before

cleaning
check

for

signs

of
water

and
oil
leaks
in

cylinder
block

and

head

2
Clean
oil
carbon

deposits
and

sealant
from
an

parts
Remove

gasket

3
Clean
all

oil
holes
with
solvent

and

dry
with

compressed
air

Make

sure
that

they
are

not
restricted

CYLINDER
HEAD

AND
VALVE

CHECKING
CYLINDER

HEAD

MATING
FACE

EM407

Fig
EM

34
Cylinder
head
CONTENTS

EM
8

EM
B

EM
8

EM
8

EM
9

EM
lO

EM
l0

EM
11

EM

12

EM
12

EM
12

EM
13

EM

13

EM
13

EM
14
PISTONS
PISTON
PINS
AND

PISTON
RINGS

CONNECTING
ROD

CRANKSHAFT

BUSHING
AND
BEARING

MEASUREMENT

OF
MAIN

BEARING

CLEARANCE

MEASUREMENT
OF

CONNECTING
ROD

BEARING
CLEARANCE

FITTING

BEARINGS

MISCELLANEOUS
COMPONENTS

CRANKSHAFT
AND

CAMSHAFT

SPROCKETS

CHAIN

TENSIONER
AND
CHAIN

GUIDE

FLYWHEEL

FRONT
COVER
AND

REAR
OIL
SEAL

Note

Never

remove
camshaft
bear

ings
unless

you
have
a

Suitable

machine

or

boring
Camshaft
bear

ing
in
line
If

you
once
remove

camshaft

bearings
bearing
centers

will
come
out

o

alignment
reo

conditioning
is

very
difficult
with

out
center

borings

L
Make

a
v

isual
check
for
cracks

and
flaws

2

Measure
the
surface
of

cylinder

head
on

cylinder
block

side
for

warpage
If
it
is

found
to
be

beyond

the
limit

designated
below

regrind
the

affected
surface

with
a
surface

grinder

Fig
EM
35

Checking
cylinder
head

8JJrface

EM
8
Head
surface
flatnes

Standard

less
than
0
05

mm
0
0020
in
O
lmm

0
0039
in
EM
15

EM
16

EM
16

EM
17

EM
17

EM
1B

EM
18

EM
19

EM
19

EM
20

EM
20

EM
20

Maximum

VALVE
ASSEMBLY

Check
each
intake

and
exhaust

valve
for
worn

damaged
or
deformed

valve

caps
or
stems

Correct
or

replace

any
valve
that
is

faulty

2
Valve

face
or
valve
stem
end

surface

should
be
refaced
with
a
valve

grinder

10

L
I
I

I

EM109

Fig
EM
36
Intak
and

exhaust
valve

dimensions

Intake
Engine
Mechanical

I

600

38
1

496I
dia

W
39
6
I
559Ildia

1
8
1

6457
dia

45
1
71l1

Unit
mm
in

Exhaust
30

30
1
l811
di

I
32

6
2835
dia

34
6
1
3622
dia

137

1
4567
dia

Unit
mm
m

CAMSHAFT
AND

CAMSHAFT
BEARING

CAMSHAnBEARING

CLEARANCE

Measure
inside
diameter
of
earn

haft

beating
with
an
inside
dial

gauge

and
outside
diameter
of
camshaft

jour

nal
with
a
micrometer
If
wear
is

found
inside
of

bracket

replace
cyl

inder
head

assembly
EM121

Fig
EM
47
Standard
value
aeat
dimensions

EM119

Fig
EM

48

Checking
cam

haft
bearing

Camshaft

journal
to

bearing
clearance

Standard
Wear
limit

Oil

clearance
mm
in
0
038
to
0
067

0
0015
to
0

0026
0
1

0
0039

Inner
diameter
of
earn

shaft

bearing
mm
in
48
000
to
48
016

1
8898
to
1
8904

EM

12
VALVE

TIMING

This

diagram

applies
to
all

cyl

inders
If

any
valve
is
found
out
of

specifications
one

possibility
that

carn
lobe
is

worn
or

damaged
This

calls
for

replacement
of
camshaft

B
D

C

EM421

Fig
EM

49
Value
timing
diagram

Engine
Mechanical

Notes

a

When

measuring
clearance

slowly

pull
feeier

gaUge
siraight
upward

b
It
Is

reConUnended
that

piston
and

cylinder
be
hel

ted
to
200C
680F
PISTONS

PISTON
PINS
AND

PISTON
RINGS

I

Remove
carbon
from

piston
and

ring
grooves
with

a

ca
bon

scraper
and

a
curved
steel
wire

Clean
out
oil

slots

in

bottom
land
of

oil

ring
groove

2

Check
for

damage
scratches
and

wear

Replace
if

necessary

3

Meas1
1re
side

clearance
of

rings
in

ring
grooves
as
each

ring
is

installed

Side
clearance

should
be

as
follows
00

I
EM542

Fig
EM

58

Measuring
ring

gap

Notes

a
When

piston
ring
only
is
to
be

replaced
without

cylinder
bore

being
corrected
measure

gap
at

bottom
of

cylinder
where
wear
is

minor

b
Oversize

piston
rings
are
available

for

serv
ce

Oversize

0
5
mm
0

0197
in
and

1

0
mm
0
0394
in

5
Measure

piston
pin
hole
in
rela

tion

to
outer
diameter
of

pin
If
wear

exceeds
limit

replace
each

piston

pin

together
with
the

piston
on
which
it
is

installed

6
Determine
the

fitting
of

piston

pin
into

piston
pin
hole
to
such
an

extent
that
it

can
be

finger
pressed
at

room

temperature
This

piston
pin

must
be
a

tight
pre
s
fit
into

connect

ing
rod
t

J

f

rr

11

1

I

EM541

Fig
EM
56

Measuring
piaton
fit

in
cylinder

Fig
EM
57

Measuring
piston
ring

side
clearance

Side
clearance

Unit
mm
in

I

Second

ring

I

I
Wear
limit
Standard

0
040
to

0
073

0
0016

to
0
0029

0
030
to

0
070

I
0
0012
to

0
0028

I
Top
ring

0
1
0
0039

Oil

ring

f

feeler

gauge

Ring
should
be

placed
to
diameter

at

upper
or
lower
limit
of

ring
travel
4

Push

ring
into

cylinder
with

pis

ton
so
as
to

place
it

squarely
in

cylinder
measure

ring
gap
with
a

EM131

Ring
gap
Fig
EM

59
Piston

pin

fitting
Unit
rom
in

Standard
Wear

limit

0
25
to
0
40

0
0098
to
0
0157

0
30
to
0
50

0
0
II
8
to
0
0197
Top
ring

Second

ring
1

0
0
0394

EM132

0
30
to
0
90

0
0118
to
0
0354
Oil

ring

Fig
EM

60

Measuring
pi
ton
pin

diamet

EM
15

Standard

Taper
and
out
of
round

of

journal
and
crank

pin

mm
in
less
than

0
01
0

0004

3
Crankshaft
bend
can
be
checked

by

placing
it

on
V
blocks
and

using
a

dial

gauge
with
its

indicating
finger

resting
on
center

journal

Standard

Crankshaft
bend
mm

in
less
than

0
05
0

0020

Note

When
measuring
bend
use
a

dial

gauge
Bend
value
is

half
of
the

reading
obtained
when
crankshaft
is

turned
one
full
revolution
with
a

dial

gauge
attached
to
its
center

journal

4

After

regrinding
crankshaft
finish

it
to

the
necessary
size
indicated
on

page
EM
18

by
using
an

adequate

undersize

bearing
according
to

the

extent
of

required
repair

5

Install
crankshaft
in
cylinder

block
and
measure
crankshaft
free
end

play
Engine
Mechanical

Maximum

0
Q25
0
0010

EM137

Fig
EM
64

Checking
crankshaft
bend

Maximum

0
10
0
0039

Fig
EM

65
Checking
crankshaft
end

play

Standard
Wear

limit

Crankshaft
free
end

play
mm
in
0
05
to
0

18

0
0020
to
0

0071
0
3
0
0118

6
At
the
rear
end
of
crankshaft

check
crankshaft

pilot
bushing
for

wear
or

damage
Replace
it
if

any
fault

is
detected
To

replace
crankshaft
rear

pilot

bushing
pro
ceed
as
follows

I
Pull
out

bushing
using
Pilot

Bushing
Puller
STl66
1000
I

EM

17
STl6610001

EM425

Fig
EM

66
Pulling
out

pilot

bushing

2
Before

installing
a
new

bushing

thoroughly
clean

bushing
hole

Press

fit

bushing
so
that
its

height
above

flange
end
is
4
5

to
5
0

mm
0
177

to

0
197
in
Do
not

oil

bushing

EM418

Fig
EM
67
Press

fitting
new

pilot

bush

ng

BUSHING
AND

BEARING

MEASUREMENT
OF

MAIN
BEARING
CLEARANCE

I

Thoroughly
clean
all

bearings
and

check
for
scratches
melting
score
or

wear

Replace
bearings
if
any
fault
is

detected

2

Crankshaft

journals
and

bearings

should
be

clean
and
free
from
dust
and

dirt
before
oil
clearance
is
measured

3

Set
main

bearing
on
cap
block

4

Cut
a

plastigage
to
width
of
bear

ing
and

place
it
in

parallel
with
crank

pin
getting
clear
of
the
oil
hole
Install

cap
on
the
assembly
and

tighten
them

together
to
the

specified
torque

Tightening
torque

4
5
to
5
5

kg
m
33
to

40
ft
lb

I
Turn

engine
until
No

I

piston
is

at
T
D
C
on

its

compression
stroke

Determine

whether
camshaft

sprocket

location
notch
comes

off
the
left
end

of
the

oblong
groove
on
camshaft

locating
plate
If
the
location
notch

is

off
the

left
end
of
the

oblong
groove

chain

stretch
is

beyond
limits

40150

EMl46

Fig
EM
74

Camshafllocating
plate

2

Turn

engine
until
No

I

piston
is

at
T
D

C

on
its

compression
stroke

setting
camshaft
on

No
2
location

hole
in

camshaft

sprocket
This
No
2

notch

should
then
be

on
the

right
end

of
the

oblong

groove
When
No
2
hole

is

used
NO
2

timing
mark
must
also

be
used

The
amount

of
the

modifica

tion
is
a

40
rotation

of
crankshaft

3

When
modification
becomes
im

possible
even

by
transferring
camshaft

location

hole

replace
chain

assembly
Engine
Mechanical

CHAIN

TENSIONER
AND

CHAIN
GUIDE

Check
for

wear
and

breakage
Re

place
if

necessary

r

I

L

EM147

Fig
EM
75
Cam

haft
dri
mechanilm

FLYWHEEL

I

Check
clutch
disc

contact
surface

with

flywheel
for

damage
or
wear

Repair
or

replace
if

necessary

2

Measure
runout
of
clutch
disc

contact
surface

with
a
dial

gauge
fit

exceeds
0
15

mm
0
0059
in

total

indicator

reading

replace
it

EM
20
EM426

Fig
EM

76
Checking
flywheel

deviation

3

Check

tooth
surfaces
of

ring
gear

for
flaws

or
wear

Replace
if

necessary

FRONT

COVER
AND

REAR
OIL
SEAL

First
check

front
cover

an
rear
oil

seal
for

worn
or
folded
over

sealing
lip

or
oil

leakage
If

necessary
install
a

new
seal
When

installing
a
new

seal

pay
attenti
on
to

mounting
direction

Note
It
is

good
practice
to

replace
oil

seal
whenever

engine
is

overhauled

Frant
t
r

r

J
I

Front

Real

EM150

Fig
EM

77
Oil

eals

of
crank

haft

PRECAUTIONS

CYLINDER
HEAD

PRECAUTIONS

I
Use

thoroughly
cleaned

parts

Especially
make

sure
that
oil
holes
are

clear
of

foreign
matter

2

When

installing
sliding
parts
such

as

bearings
be
s
uIe
to

apply
engine
oil

to
them

3
Use

new

packing
and

oil
seals

4
Do
not

reuse
lock
washers

5

Keep
tools
and

work
benches

clean

6

Keep
necessary
parts
and
tools

near
at
hand

7
Be

sure
to
follow

specified
tight

ening

torque
and
order

8

Applying
sealant

Use
sealant
to
eliminate
water
and

oil
leaks
Parts

requiring
sealant
are

I
Front

cover
and
corners
of

cyl

inder
block
See

Figure
EM

78

EM153

Fig
EM
78

Applying
alant

Front
cover
and

cylinder
block

2
Main

bearing
cap
and

cylinder

block
Each

side
of
rear

main
bearing

cap
and
each
corner
of

cylinder
block

See

Figure
EM
79
Engine
Mechanical

ENGINE
ASSEMBLY

CONTENTS

EM
21

EM
21
PISTON
AND

CONNECTING
ROD

ENGINE
ASSEMBLY
EM

22

EM
22

Cylinder
block

Rear
main

bearing
cap

20to2Smm

Ill

Points

to
be

applied
sealant

EM151
s

e

00

000

o

Fig
EM
79

Applying
sealanl

Main

bearing
cap
and

cylinder
block

3

Cylinder
block

Step
portions
at

four

mating
surfaces

cylinder
block
to

front
chain

cover
and

cylinder
block

to
rear
main

bearing
cap
See

Figure

EM
80

Note
Do
not

apply
too

much
sealant

J

Apply
sealant
at
hese

points

EM152

Fig
EM
80

Applying
sealant

Cylinder
block

CYLINDER
HEAD

Valve
assembly
and
valve

spring

Using
Valve
Lifter
STl2070000
set

valve

pring
seat
in

position
and
fit

valve

guide
with
oil
seaL

Assemble
valve
in
the
order
shown

below
valve
inner
and
outer
valve

springs
spring
retainer

valve
collet

and
valve
rocker

guide

EM
21
Fig
EM
81

Installing
valves

Notes

a
Ensure

that
valve

face
is

free
from

foreign
matter

b
The
L20B

engine
uses
double

type

valve

springs

2
Valve
rocker

pivot
assembly

Screw
valve
rocker

pivots
joined

with
lock
nuts
into

pivot
hushing

3
Camshaft

assembly

Set

locating

plate
and

carefully

install
camshaft
in

cylinder
head
Do

not

damage
the

bearing
inside

Oblong

groove
of

locating

plate
must
be

directed
toward
front
side
of

engine

Camshaft
bracket

tightening

torque

1

8
to
2
0

kg
in

13
to

15
ft
lb

4

Install
camshaft

sprocket
on
earn

shaft
and

tighten
it

together
with

fuel

pump
drive
cam
to

specified
torque

Tightening
torque

12
tol6

kg
m

87
to
116
ft

lb

this
time
check
camshaft
end

Fig
EM
82

Installing
camshaft

sprocket

6
Make

sure
that

crankshaft
has

proper
end

play

Crankshaft
end

play

0
05
to
0
18

mm

0

0020
to
0
0071
in

Fig
EM
89

Checking
crankshaft

end

play

7

Install
side
oil
seals
into

rear
main

bearing

cap
Prior
to

installing
apply

sealant
to
seals

Fig
EM
90

Driving
side
oil
seal

8
Install
rear
oil
seal

using
Crank

shaft
Rear

Oil
Seal
Drift

STI5310000

r

STl5310000

r

EM163

Fig
EM
91

Installing
rear
oi
seal
Engine
Mechanical

Note
When

installing
oil
seal

give

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and

fold

ed

lip
Also

give

coating
of
oil
to

periphery
of
oil

seal

9

Install
rear
end

plate

10
Install

flywheel
securely
and

tighten
bolts
to

specified

torque

Tightening

torque

14

to
16

kg
m

101
to
116
ft
lb

I
I

Insert

pistons
in

corresponding

cylinder

using
Piston

Ring
Compressor

EM03470000

EM03410000

I

EM544

Fig
EM
92

Installing
pi8ton
rod

a
Sembly

Notes

a

Apply
engine
oil

to

sliding
parts

b

Arrange
80

that
notch
mark
on

piston
head
faces
to
front
of
en

gine

c
Install

piston
rings
at
1800
to

each

other

avoiding
their
fit
in
the

thrust
and

piston
pin
directions

6
Top
ring

I
iilring

Piston

pin
ireClioJ

EM165

Fig
EM

93
PUtan

ring
direction

12
Install

connecting
rod

caps

Tightening
torque

4
5
to
5
5

kg
m
33
to
40
ft
lb

EM
23
Fig
EM

94

Installing
connecting
rod

cap

Note
Install

connecting
rods

and
con

necting
rod

caps
80
that
their

as

signed
numbers
are

positioned
on

the

same
side
and
in
the
SlIme

direction
with

respect
to

cylinders

13
Make
sure
that

connecting
rod

big
end
has

proper
end

play

Fig
EM

95

Checking
big
end

play

Big
end

play

0
2
to
0
3
mm

0
008
to
0
Ql2
in

14

Install

cylinder
head

assembly

Fig
EM
96

Tightening
sequence

01

cylinder
head
bolts

J
Thoroughly
clean

cylinder
block

and

head
surface

Do

not

apply
sealant
to

any
other

part
of

cylinder
block
and
head

sur

face