1977 DATSUN PICK-UP lock

Standard

Camshaft
bend

mm
in
0

02
0
0008

CAMSHAFT

ALIGNMENT

I
Check
camshaft
camshaft

journal

and
earn
surface
for
bend
wear

or

damage
If

damage
is

beyond
limits

replace
affected

parts

2
A
bend
value
is
one
half
of
the

reading
obtained
when
camshaft
is

turned
one
full
revolution
with
a
dial

gauge

applied
to
2nd

and
3rd

journals

Standard

height

of
tam
mm
in
I
Intake

1
Exhaust

Wear

limit
of
earn

height
mm
in

Allo
able
difference
in

diam
ter

betweim
max
worn

and
min

mm
in

worn

parts
of
c

mshaft

journal
Engine
Mechanical

Bend
limit

0
05
0
0020

I

Fig
EM

50
Checking
camMa
t
bend

40
30
to
40
35

1

5866
to
1
5886

0
25
0

0098

0
05
0
0020

Maximum
tolerance
in

j01
irri

mm
in
0
1

0
0039

diameter

CamShaft
end

play
mm
in
0
08
to
0
38

0
0031
to
0
0150

Standard

Surface
flatness

mm
in
less
than

0
05
0
0020

Cy
LlNDER
BLOCK

I

Visually
check

cylinder
block
for

cracks
or
flaws

2
Measure

top
of

cylinder
block

cylinder
head

mating
face
for

warp

age
If

warpage
exceeds
limits
correct

it
Maximum
tolerance

0
10
0

0039

EM540

Fig
EM
51

Cheching
cylinder
block

au
rface

EM
13
j

Using
a
bore

gauge
measure
cyl

inder

bore
for
out
of
round
or

taper
If

out
of

round
or

taper
is
excessive

re

bore

cylinder
walls
with
a

boring

machine
Measuremen
t
should
be

taken

along
bores
for

taper
and
around

bores
for

out
of
round
See

Figure

EM
52

Qu
t
of
round

Taper
X

Y

A

B

M12

Fig
EM

52

Measuring
cylinder
bore

diameter

4
When
wear

taper
or

out
of

round

is
minor
and
within
limits

remove

step

at

topmost
portion
of

cylinder
using

a

ridge
reamer
or

other
similar
tool

HOW
TO
MEASURE

CYLINDER
BORE

A

bore

gauge
is
used
Measure

cylind
r
bore

at

top
middle
and
bot

tom

positions
toward
A
and
B
direc

tions

as
shown
in

Figure
EM
53

and

record
the
measured
values

A
I

120
0
79

IlL

60
2
36

lll

B

100
3
94

el
1

Unit
mm
m

EM
22

r

Fig
EM
53

Cylinder
bort
me08Uring

positions

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

Fig
EM
68
P14stigage

Note
Do

not
tum
crankshaft
while

plastigage
is

being
inserted

5
Remove

cap
and

compare
width

of
the

plastigage
at
its
widest

part
with

the
scale

printed
in

plastigage
enve

lope

Fig
EM

69

Measuring
bearing

clearance

MEASUREMENT
OF

CONNECTING
ROD

BEARING

CLEARANCE

I

Measure

connecting
rod

bearing

clearance
in
the

same
manner
as
above

Tightening
torque

4
5

to
5
5

kg
m
33

to
40
ft
lb
Engine
Mechanical

Bearing
011
clearance

Standard
Wear
limit

Main

bearing
clearance

mm
in
0
020
to

0
062

0
0008
to
0
0024
0
12
0
0047

Connecting
rod

bearing

clearance
mm
in
0

025
to
0
055

0
0010
to
0
0022
0

12
0
0047

2
If

clearance
exceeds

specified

value

replace
bearing
with
an
under

size

bearing
and

grind
crankshaft

jour

nal

adequately

FiniNG
BEARINGS

Bearings
are
manufactured
with

crush
to

make

bearing
snug
down
into

its

bore
To

measure
this

proceed
as

follows

I
Set
main

bearing
in
main

bearing

cap
recess
or

cylinder
block

bearing

recess

correctly

2
Lock
one
side
of

bearing
and

press
other
side
until

bearing
back

surface
touches
the
recess

Bearing
crush

All
main

bearings
mm
in

All

connecting
rod

bearings
mm
in

4

Handle

connecting
rod

bearing
in
3
Then

measure

bearing
crush
H

with
a
feeler

gauge
See

Figure
EM
70

The
standard

bearing
crush
value
is

listed
below

Weight

H

Fig
EM
70

Checking
bearing
crum

o
to
0
03
0
to

0
0012

0
015
to
0
045
0
0006
to

0
0018

the
same
manner
as
above

Main

bearing
undersize

Unit
mm
in

Bearing
top
thickness
Crank

journal
diameter

1

827
to

1
835
59
942
to

59
955

SID

0
0719
to

0
0722
2

3599
to
2

3604

0
25
0
0098

1
952
to
1
960

59
692
to

59
705

Undersize
0
0769
to
0
0772
2

3501
to
2
3506

0
50
0
0197
2
077
to

2
085
59442
to
59
455

Undersize
0

0818
to
0

0821
2
3402
to

2
3407

0
75
0
0295
2
202
to
2
210

59
192

to
59
205

Undersize
0
0867
to
0
0870

2
3304
to
2
3309

EM

18

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

5
Install
rocker
arms

by

pressing

valve

springs
down
with
a
screwdriver

6
Install
valve
rocker

springs

7
After

assembling
cylinder
head

turn
camshaft
until
No
I

piston
is
at

T
D
C
on
its

compression
stroke

EM1S5

Fig
EM
83

A
embling
cylinder
head

PISTON
AND

CONNECTINGROD

1

Assemble

pistons
piston
pins
and

connecting
rods

on
the
de
ignated

cylinder

STl3030001

EM156

Fig
EM
84
Installing
piston
pin

EM157

Fig
EM
85
Assembling
piston
and

connecting
rod

Notes

a
Piston

is

pressed
into

connecting

rod
with

fitting
force
of
0
5
to
5

tons
aid
of
Piston
Pin
Press

Stand
STl303000
I
is

necessary

When

pressing
piston
pin
into
con

necting
rod

apply
engine
oil
to

pin

and
small
end
of

connecting
rod
Engine
Mechanical

b

Arrange
so
that
oil

jet
of
connect

ing
rod
big
end
is
directed
toward

right
side
of

eylinder
block

c

Be
sure
to
install

piston
in

cylinders

with
notch
mark
of

piston
head

toward
front
of

engine

2

Install

piston
rings

InstalI

top
and
second

rings
in

right

position
with
marked
side

up

Notes

a

Top
ring
is

chromium

plated
on

liner

contacting
face

b
Second

ring
has

larger
taper
surface

than

top
ring

c
In
the
combined
oil

ring
upper
rail

is
the
same
as

lower
one

j

c6J

EM158

Fig
EM
86

lalling
pidon
rings

3

Fix

bearings
on

connecting
rod

and

connecting
rod

cap

Note
Clean
back
side
of

bearing
care

fully

ENGINE
ASSEMBLY

The
first

step
in

engine
assembly

is

to
bolt

Engine
Attachment

ST0526000
I

to

right
hand
ide
of

cylinder
block
Next
install
block
on

another

Engine
Stand
ST0501S000

with

engine
bottom

up

2

Set
main

bearings
at

the

proper

portion
of

cylinder
block

Rear
Front

III
III

m
It
IlL

D

D

D
D
D

1
5
1
4
1
3
1
2
1
1

EM159

Fig
EM
87
Main

bearings

EM
22
3
Install
baffle

plate
including

cyl

inder
block
net

Notes

a

Only
center

bearing
No
3

is
a

flanged
type

b
All
inter
bearings
No
2

and
No
4

are
the
same

type

c
Front

bearing

No
I
is

also
the

same

type
as
rear

bearing
No
5

The
difference
is

that
an
oil
hole
is

provided
in
the
front

bearing

d
All

upper
and
lower

bearings
are

interchangeable

4

Apply
engine
oil

to
main

bearing

surfaces
on
both
sides
of

cylinder

block
and

cap
and
then
install
crank

shaft

5
Install
main

bearing

cap
and

tight

en

bolts
to

specified

torque

Tightening
torque

4
5
to
5
5

kg
m
33

to
40
ft
lb

Notes

a

Apply
sealant
to
each
side
of
rear

main

bearing
cap
and
each
comer

of

eylinder
block
as
shown
in

Figure
EM
79

b

Arrange
parts
so
arrow
mark
on

bearing
cap
faces
toward
front
of

engine

c

Prior
to

tightening
bearing
cap

bolts

place
bearing
cap
in

proper

position
by
shifting
crankshaft
in

the
axial
direction

d

Tighten
bearing
cap
bolts

gradually

in
two
to
three

stages
outwardly

from
center

bearing
in
the

sequence

as
shown
in

Figure
EM
88

e
After

securing
bearing

cap
bolts

ascertain
that
aankshaft
turns

smoothly

@

i

d

l

j
1

@EM543

Fig
EM
8S
Torque

sequence
0

cap
bolt

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

2
Turn
crankshaft
until
No
I

pis

ton
is
at
T
D
C

on
its

compression

stroke

3
Make

sure
thai
camshaft
sprock

et
location
notch
and

plate
oblong

groove
are

aligned
at
their
correct

positions

4

When

installing
cylinder
head

make
sure

that
all
valves
are

apart

from
heads
of

pistons

5
Do

not
rotate
crankshaft
and

camshaft

separately
or
valves
will
hit

heads
of

pistons

6

Temporarily
tighten
two
bolts

CD

V
sJiown

in
Fig

re
EM
96

Tightening
torque

2

kg
m

14
ft
b

15
Install
crankshaft

sprocket
and

oil

pump
drive

gear
and
fit
oil

thrower

Note
Make
sure
lhat

maling
marks
of

crankshaft

sprocket
face
10
Cront

16
Install

timing
chain

Noles

a
Make

sure
that
crankshaft
and
cam

shaft

keys
point

upwards

Fuel

pump
drive

earn

2
Chain

guide

3

Chain
tensioner

4

Crank

sprocket

5
earn

sprocket

6
Chai

guide

EM439

b
Set

timing
chain

by

OOgning
its

mating
marks
with
those
oC
crank

shaft

sprocket
and
camshaft

sprock

et
at
the

right
hand
side
There
are

forty
four
chain
links
between
two

mating
marks
of

timing
chain

c
NO
2
hole
is

Cactory

adjusted

When
chain
stretches

excessively

adjust
camshaft

sprocket
at

No
3

hole

d
Use
a

set
of

timing
marks
and

location
hole

numbers
Engine
Mechanical

17
Install
chain
slack
side

guide
to

cylinder
block

18
Install
chain
tensioner

Note

Adjust
protrusion
oC
chain
ten

sioner

spindle
to
0
mm
0
in

Fig
EM
98

lmtalling
chain
tensioner

19
Press
new
oil
seal
in

front
cover

Notes

a
Front

cover
oil
seal
should
be
reo

placed
when
Cront
cover
is

disas

sembled

b
BeCore

pressing
oil
seal
into
Cront

cover

give
coating
of

engine
oil
to

periphery
of
oil
seal

c
This
oil
seal
is
a
threaded
seal

type

which
has

improved
sealing
charac

teristics
Do
not

apply
grease
to

sealing

lip

20
Install
front
cover
with

gasket
in

place

1

Timing
mark

2

Timing
mark

EM545

Fig
EM

99

Installing
fronl
COlHlr

Notes

a

Apply
sealant
to
Cront
cover
and

corners
oC

upper
section
of

cylinder

block

as
shown

in

Figure
EM
78

EM
24
b
Install
Cront
cover
with
head

gasket

in

place

c

Check

height
diCCerence
between

cylinder
block

upper
Cace
and
Cront

cover

upper
Cace
DifCerence
must

be
less
than
0
15

mm
0
0059
in

d

Note
that
difCerent

types
oC
bolts

are
used

e

Before

installing
front
cover
on

cylinder
block

apply

coating
oC

engine
oil
10

sealing
lip
of
oil

seal

EMS11

Fig
EM
lOD
Front

cover
bolts

Tightening
torque

Size
M8
0
315
in

1
0
to
1
3

kg
m
7

2
to
9
4

ft
lb

Size
M6
0
236
in

0
4
to
0
6

kg
m
2

9
to
4

3
ft
lb

21
Install
crankshaft

pulley
and

water

pump
assembly
then
set
No
I

piston
at
ToO
C
on
its

compression

stloke

Crankshaft

pulley
nu
I

tightening
torque

12
to
16

kg
m
B7
to
116
ft

lb

EM546

Fig
EM
Ol

lnstallingcran
haft

pulley
and

water

pump

22

Finally

tighten
head

bolts
to

the

specified
torque
in

three

steps

according
to
the

lightening
sequence

shown
in

Figure
EM
96

Note
thai
Iwo

types
of
bolts

are

used

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