1977 DATSUN PICK-UP high

30
Install
heatshieid

plate
on
mani

fold
assembly

31
Install
air

gallery
pipe
on
ex

haust
manifold

32
Install
manifold

gasket
and

manifold

assembly
on

cylinder
head

Tightening
torque

1
2to
1

6kg
m

8
7
to
11
6
ft
lb

33

Install
blow

by
gas

pipe
on

cyl

inder

block
and
tighten
with
rear

engine
slinger

34
Install
thermostat
housing

gas

ket
thermostat

housing
and

thermo

stat

35
Install
thermal
vacuum
valve
on

thermostat

housing
Before

installing

apply
a

liquid
packing
slightly
to
the

threads

36

Install
FJ

C
D
bracket
on

cylin

der

head

37

Install
E
G
R

passage
and

E
G
R
valve
on
intake
manifold

38
Connect
E

G
R
tube
to
E

G
R

tube
and

exhaust
manifold

39
Install
check
valve

on
air

gallery

pipe

40
Install
air
cleaner
bracket
on

intake
manifold

41
Install
air
control
valve
on
air

cleaner
bracket
California
models

42
Install
vacuum
and
fuel
tubes

combined
on

cylinder
head

43
Install
distributor

assembly

44
Install

heatshield
plate

joint

seat

and
carburetor

Carbure10r
tightening

torque

0
5

to
1

0

kg
m
3

6
to
7
2

ft
lb

Note
When

instalUng
joint
seat
be

sure
to

put
the
duct
into

primary

hole
in

intake
manifold

S

J

Heatshield

plate
4
Joint

seat

2

Primary
hole
5

Secondary
hole

3
Duct

EM534

Fig
EM
I06

Installing
carburetor

joint
seat
Engine
Mechanical

45
Install
dash

pot
bracket
and

dash

pot
to
intake

manifold

46
Connect
all
air

vacuum
and
fuel

hoses

and
then

secure
with

clamps

I
Cylinder
block
to

P
C
V
valve

hose

2
A
B

valve
to
E

G
R

passage
vac

uum
hose

3
A
B

valve
to
E
G

R

passage
air

hose

4
Vacuum
tube
to
carburetor
vac

uum
hoses

5
Fuel
ube

to
carburetor
fuel

hose

6
Fuel
tube
to
fuel

pump
fuelhose

7
Distributor
to
vacuum
switch
or

spark
delay
valve
vacuum
hose

8
Air
control
valve
vacuum
hose

9
Check
valve

to
air

control
valve

hose

10
Thermal
vacuum
valve
to

E
G
R
valve
vacuum
hose

I
I
Thermal
vacuum
valve
to

vacuum
tube
hose

47
Install
carburetor
air

cleaner
on

carburetor
and
then
connect
air

and

vacuum
hoses

as
follows

I

Air
cleaner
to

exhaust
manifold

hot

air
duct

2

Air
c1eaner
to
air

pump
hose

3

Air
cleaner
to
rocker

cover
hose

4

Air
cleaner

to
air
control
valve

hose

5

6

48
Install

spark
plugs
in

place

49
Connect
all
distributor

high
ten

sion

cables
to

spark
plugs

50
Install
air

pump
drive
belt
cool

er

compressor
and
idler

pulley

51

Install
left

engine
mounting

bracket

52
Install
clutch

assembly
on

flywheel
with
Clutch

Aligning
Bar

KV30100200
Air

cleaner
to
A
B

valve

hose

Other
vacuum
hoses

Tightening
torque

1
2
to
2
2

kg
m

8

7
to
15
9

ft
lb

EM
26
I

I

KV30100200

EM440

Fig
EM
I07
In

talling
clutch
embly

53

Using
an
overhead
hoist
and

lifting
cable
hoist

engine
away
from

engine
stand
and

then
down
onto

engine
carrier

54
Install

right
engine
mounting

bracket
oil
filter
oil

pressure
switch

oil

level

gauge
and
water

drain

plug

When

installing
oil

filter
fasten
it
to

cylinder
block

by
hand

Note
Do
not

overtighten

flit
or
oil

leakage
may
occur

55
Install
alternator
bracket

adjust

ing
bar
alternator

cooling
fan

and

belt

56

Adjust
the
deflection
of
drive

belts
when

thumb

pressure
is

applied

midway
between

pulleys
A

pressed

force
is
above
10

kg
22
0
lb

Deflection

of
drive
belts

8
to
12
mm

0
315

to
0
472
in

EM613

Fig
EM
lOB
Fan
belt
tension

57
Fill

engine
oil

up
to

specified

level

DESCRIPTION

COOLANT
LEVEL

DRAINING
AND
FLUSHING
THE

COOLING
SYSTEM

WATER
PUMP

REMOVAL
AND

INSTALLATION

DISASSEMBLY

INSPECTION
AND
ADJUSTMENT

TORQUE
COUPLING

REMOVAL
AND

INSTALLATION

DESCRIPTION

The

cooling
system
is
of
the
con

ventional

pressure
type
A

centrifugal

pump
installed
on

the

timing
chain

cover
serves
to
circulate
the

coolant

The

pressure
type
radiator
filler

cap

installed
on
the
radiator

operates
the

cooling
system
at

higher
than

atmos

pheric
pressure

The

higher

pressure
raises
the

boiling
point
of
the

coolant
and
in
Cooling
System

COOLING
SYSTEM

CONTENTS

CO
2

CO
2
OISASSEMBL
Y

INSPECTION

TEM
COUPLlNG

INSPECTION

THERMOSTAT

REMOVAL
AND

INSTALLATION

INSPECTION

RADIATOR

REMOVAL
AND

INSTALLATION

INSPECTION
CO
2

CO
2

CO
3

CO
3

CO
3

CO
3

CO
4

creases
the

cooling
efficiency
of

the

radiator

When
the

thermostat
is
closed

the

coolant
remains
in
the

cylinder
head

and

block
for
swift

warming
up
of
the

engine
After
it
reaches

normal

oper

ating

temperature
the

coolant
circu

lates

through
the
radiator

The

cooling
fan

drive
is
of
a

coupling
type

COOLANT

LEVEL

The

coolant
level
should

be
check

ed

and
maintained
at
SO

mm
1
97
in

below

the

upper
face
of
filler

neck

when
the

engine
is
cold
C0055

Fig
CO

I
Cooling

ry
lem

Caution

To
avoid
serious

personal

injury
never
remove
I3diator

cap

quickly
when

engine
is
hot
Sudden

release
of

cooling

system
pressure
is

very

dangerous

CO
2
CO
4

CO
4

CO
4

CO
5

CO
5

CO
5

CO
5

CO
5

CO
5

CO
6

If
it
is

necessary
to
remove
radiator

cap
wben
radiator
is
hot
turn

cap

slowly
counterclockwise

to
the
r

step
After
all

pressure
in
the
cool

ing
system
is
released
tom

cap

passing
the

stop
and
remove
it

DRAINING

AND
FLUSHING

THE

COOLING

SYSTEM

To
drain

the

cooling
system
re

move
radiator

cap
release
drain

cock

at
the
bottom

of
radiator
and
drain

plug
on

the

right
side
of

cylinder

block
If
the

heater

system
is
installed

set
heater

temperature
control
valve
to

open
position
After
the

coolant
is

drained

completely
close
drain

cock

and

plug
and
refill
the

system
with

clean
soft
water

WATER
PUMP

The

water

pump
cooling
fan

pulley

and

torque

coupling
are

a
unitized

construction

The
water

pump
is
of

a

centrifugal

type
which

is
mounted
on
the

engine

front
cover

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

REMOVAL
AND

INSTALLATION

To

replace
the

torque

coupling

follow
the

same

procedure
as
in
the

water

pump
The

torque
coupling
can

not
be

separated
from
the
water

pump
Cooling
System

DISASSEMBLY

The

torque
coupling
is

so

designed

that
it

can
not
be

disassembled
INSPECTION

Inspect

torque
coupling
for
oil

leakage
If

necessary

replace

TEM

COUPLl
G

For
air
conditioner

equipped
models

Tem
coupling
is

a

type
of
fan

coupling
which
is

provided
with
a

temperature
control

system

The
conventional

coupling

always

slips
the
fan
at

a
high

speed
under

a

constant
ratio

regardless
of

the

engine

cooling

requirement

The

slipping
ratio

of
the
Tern

coupling
however

is

properly
changed

with
the

cooling
requirement

ON
denotes

that

cooling
is
re

quired
and
the
fan

operates
up
to

about

2
150

rpm
When

high

cooling
is

not

required

during
cold
season
with

the

engine
warmed

up
etc
the

oper
w

6
I

1
Bi
metal

thermostat

2

Slide
valve

3
Reserve
chamber

for
OFF

4

Bearing

5

Driving
chamber
for

ON

6

ouplingpart
labyrinth

coon

Fig
CO
5
CrQM
sectional
view

of
Tem
coupling

ation
is

placed
under

OFF
condition

and
the
fan

slips
at
about

1
650

rpm

The
coiled
bimetal
thermostat

installed
on

the
front
center

portion
of

the
Tem

coupling
detects

temperature

of
air

passing

through
the

radiator

The
air

temperature
is

directly

relative
to
the

engine
coolant

tempera

ture
and
the
inside

slide
valve
is

opened
or
closed

as

required
and
thus

the
ON
OFF

control
is

performed

When
the
air

temperature
rises

the

bimetal
is

expanded
and
the

valve
is

opened
silicon
oil
is
forwarded

to
the

groove
that
transmits

torque
and
the

CO
4
system
is

placed
under
ON

con

dition

When
the

valve
closes
silicone
oil
is

not

supplied
to
the

driving
chamber

oil
in

the

driving
chamber
is

accumu

lated
on

periphery
due
to
the

centrif

ugal
force
and
led

into
the
reserve

chamber
Now

oil
is

eliminated
from

the

driving
chamber

and
the

system
is

placed
under
OFF
condition

With
this

system
when
fan

cooling

is
not

required
the

output
loss
is

minimized

and
noise

can
be
far

reduced

Underhood
air

I

@
Dr

Underhood
air

I
Engine
Fuel

f
f
l

l

ID
s

6

Cif

Ittl
ID
Air
inlet

pipe

Air
con
trol
valve

Hot
air

pipe

Diaphragm

Vacuum
hose

Diaphragm
spring

Air
bleed
valve

closed

Temperature
sensor

assembly
Holair

EF114

Fig
EF
2
Hota
r

delivery
mode

During
cold

engine
operation

7

To
manifold
Small

vacuum

1
Air
inlet

pipe

2
Air
con
trol

valw

3
Hot
air

pipe

4

Diaphnp

S
V
leuum
hoses

6

Diaphragm
prinl

7
Air

bleed
valve

closed

II

Temperature
senSOr

assembly

EF20S

Fig
EF
3
Cold
air

delivery
mode

During
cold

engine
operation

f
1

J
liP

omanifold
2

@
Air
inlet

pipe

Air

control
valve

Hot
air

pipe

Diaphragm

Vacuum
hoses

Diaphragm
spring

Air
bleed
valve

fully
open

8

Temperature
sensor

assembly

EF715

Fig
EF
4
Cold
air

delivery
mode

During
hot

engine
operation

ID

@
f

fjr

R
lfl
ow

2

underh
r
5

rv

Itti
ID

Hot
air
Air
inlet

pipe

Air
control
valve

Hot
air

pipe

Diaphragm

Vacuum
hose

Diaphragm
spring

Air
bleed
valve

partially
opened

8

Temperature
sensor

assembly

EF716

Fig
EF
5

Regulating
air

delivery
mode

EF
4
A
T
C
AIR
CLEANER

COLD
AIR
OPERATION

I

When
under
hood
air

temperature

is
low

The
sensor
air
bleed

valve
remains

in

the
closed

position
and
vacuum

passage
is

established
between
the
in

take
manifold
and

the
vacuum
motor

and
the
intake
manifold

vacuum
is

applied
to
the

vacuum
motor
dia

phragm
When
the

vacuum
is

small
or

when
the

engine
is

operating
under

eavy

1004
the
air

control
valve

opens

widely

irrespective
of
the

temperature

around
the

sensor
to
introduce
the

under
hood
air

cold
air

for
increased

power
of
the

engine

2

When
under

hood
air

temperature

is

high

The

sensor
air

bleed
valve

opens

fully
to
shut
off

the
vacuum

passage

between

the
intake
manifold
and
the

vacuum
motor
Due
to
the
force
of
the

vacuum
motor

diaphragm
spring
the

air

control
valve

closes
the
hot
air

pipe

of
the
air

cleaner
and

introduces
the

under

hood
air

cold
air

A
T
C
AIR
CLEANER

COLD

AND
HOT

AIR
OPERATION

When
the
sensor
air

bleed
valve
is

partially
opened
opening
of

the
air

control
valve
varies

with
the
vacuum

of
the

intake
manifold
With
the
air

control
valve
half
open

the
cold
air

and
hot
air
are
sucked

together
and

mixed
for

controlling
of
the
air

tem

perature
of
the
air

to
be
introduced
to

the
air

cleaner

to

facilitate
smooth

operation
of
air

control
valve

If
the
above
test
reveals

any
prob

lem

in
the

operation
of
air

control

valve

carry
out
the

following
test

4
Remove
air

cleaner
cover
Set

temperature
sensing
element
of
ther

mistor
or

thermometer
to
a

position

where

temperature
around
sensor
can

be

measured
In

this
case
fIx

wiring
of

thermistor
or

thermometer
on
the

bottom

surface
of
air

cleaner
with

adhesive

tape
in

such
a
manner
that

the

set

position
of

temperature
sensing

DESCRIPTION

OPERATION

DESCRIPTION

The
idle

compensator
is

basically
a

thermostatic
valve

which
functions
to

introduce
the
air

directly
from
the
air

cleaner
to
the

intake
manifold
to

compensate
for
abnormal
enrichment

of
mixture
in

high
idle

temperature

The
bi
metal

attached
to
the
idle

compensator
detects

the

temperature

of
intake
air
and

opens
or
closes
the

valve
Two

idle

compensators
having

different

temperature
characteristics

are

installed
one

opens
at
an
intake
air

temperature
of

60
to
700C
140
to

l580F

and
the
other
at
70

to
900C

158
to
1940F

OPERATION

The
construction
of
the
idle

com

pensator
is

shown
in
the

following
Engine
Fuel

element
will
not
be
affected

by
air

flow

Then
install
air
cleaner
cover

Fig
EF
13

Checking
temperature

sensor

IDLE
COMPENSATOR

CONTENTS
5

Carry
out
test
as
described
in

steps
I
2
and
3
above
When
air

control
valve

begins
to

open
to
under

hood
air
inlet
side
several
minutes

after

engine
starting
read
the

indica

tion

of
thermistor
or

thermometer
If

reading
falls
within
the

working
tern

perature

range
of

temperature
sensor

the
sensor
is

normal
If

reading
ex

ceeds
the

range

replace
the

sensor

with
new
one

Note
Before

replacing
temperature

sensor
check

idle

compensator
as

described
in

Idle

compensator

EF
7

EF
7
REMOVAL
AND
INSTALLATION

INSPECTION
EF

B

EF

8

q

EF222
1

Orifice

2
Bi
metal

3
Rubber
valve

Fig
EF

14
Structure

of
idle

compensator

Bi

metal
Intake
air

temperature

No

1
Below
600C
1400F

60
to
70
C

140
to
l580F

Above
700C

158
OF

Below
700C

1580F

70
to
900C

158
to
1940F

Above
900C
1940F
No
2

EF
7
The
idle

compensator

operates
in

response
to
the

under
hood
air

temper

ature

as
shown
below

Idle

compensator
operation

Fully
closed

Close
to

open

Fully

open

Fully
closed

Close
to

open

Fully

open

3
Check

diaphragm
for

small
holes

carcks
or
wear

4

Check

rocker
arm
for
wear
at
the

mating
portion
with

camshaft

5

Check
rocker
arm

pin
for
wear
A

worn

pin
may
cause
oil

leakage

6
Check
all

other

components
for

any
abnormalities
and

replace
if
neces

sary

DESCRIPTION

INSPECTION

REMOVAL
AND

INSTALLATION

DESCRIPTION

The
electric
fuel

pump
is

adopted

on
air

conditioner

equipped
models
Engine
Fuel

ASSEMBLY

Reverse

the
order
of

disassembly

Closely
observe
the

following
instruc

tions

L

Use
new

gaskets

2

Lubricate
rocker
ann
rocker
arm

link
and

rocker
arm

pin
before
installa

tion
3

To
test
the

function

proceed
as

follows

Position
fuel

pump
assembly
about

I

meter
3
3
ft

above
fuel
level
of

fuel

strainer
and
connect
a

pipe
from

strainer
to
fuel

pump

Operate
rocker

arm
by
hand
If

fuel

is

drawn

up
soon
after
rocker
arm
is

released

fuel

pump
is

functioning

properly

ELECTRIC
FUEL
PUMP

CONTENTS

EF
11

EF
11

EF
12
DISASSEMBL
Y

ASSEMBL
Y

TROUBLE

DIAGNOSES
AND

CORRECTIONS
EF
12

EF
12

The
silicon
transistor

type
fuel

pump

consists
of

a
transistor
diodes
a

sole

I
Tr

lOsistor

6
Ou
tIet
valve

2

Plunger

7
Return

spring

3

Diaphragm

8
Filter

4

Diode

9

Magnet

5

Magnet
coil

10
Inlet
valve

INSPECTION

I
Disconnect
fuel
hose
at

pump

outlet

2

Connect

a
suitable
hose

approxi

mately
6

mm
0

24
in
inner

dia

meter
to

pump
outlet
ev
J

J

Note
If
diameter
is
too
small
the

following

proper
delivery

capacity

cannot
be
obtained
even
if

pump

functions

properly

EF
11
EF
13

noid
a

pump
mechanism
and
filter

parts

I
T
nsistor

2

Re
ist
f
I

3
Dinde

4

Signal
coil

5
Main
coil

6
Resistor
3

7
Zener
dlOdl

8

Resistor
2

EF719

Fig
EF
22
Construction

of
electric

fuel

pump

3

With
hose
outlet
in
a

higher
posi

tion

than

pump

operate
pump
and

check

delivery
capacity
for
more
than

15

seconds

4

The

capacity
should
be
I
400

cc

Engine
Fuel

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Fuel

pump
fails
to

operate

Fuel

pump
fails
to

discharge
sufficient

flow

Insufficient
fuel

discharge
during

high
speed
travelling

Low
float
level

at

idling

Fuel

pump
is
actuated

more

frequently
than

under
normal
condi

tion

Rattling
noise
Probable
cause

Terminals
or
connections
loose

Rust
on
terminals
or

grounding
metal

Frozen

liquid
in

plunger
or

pump

Clogged
filter

Insufficient
fuel

Air
in

fuel
hose

through
connections

Hose
necked
down
or
bent

Fuel
tank
breather
tube
bent
or
necked

down

Weakened
return

spring

Air
sucked

through
connection
fuel
hose

and
fuel

pump
joint

Fuel
hose
on
suction
side
bent

Clogged
fIlter

Mounting
bolts
loose

EF
13
Corrective
action

Retighten

Clean

Clean

plunger
assembly

Replace
pump
if

plunger
is

stuck
or
seized

Clean

pump
interior
Clean
and

if

necessary

replace
fIlter

Replenish

Apply
a

coating
of
end
sealing

compound
to

connections
and

retighten

Check
and
correct

Check
and
correct

Replace

Apply
a

coating
of
end

sealing
compound
to

connection
and

retighten

Check
and
correct

Clean
or

replace
fIlter

Retighten