1977 DATSUN PICK-UP radiator

Body
Frame

BODY
FRONT
END

1
Hood

2
Hood

support
rod
@

3
Hood

bumper

4
Fender

@

5

Bumper
bracket
shim

6
Bumper
side
bracket

7
Bumper

8

Bumper
stay

9
Front

apron

10
Radiator

grille

FRONT
BUMPER

REMOVAL
AND

INSTALLATION

L
Remove

bumper
to
fender
at

taching
bolts

2
Remove
four

bumper
stay
to

side

frame
front

attaching
bolts
Pull
bum

per
assembly

straight
forward

3
For
installation
reverse
above

steps
Align
bumper
with
front
fender

and

apron
then

tighten
them

up

RADIATOR
GRILLE

REMOVAL
AND

INSTAUATION

I

Remove
radiator

grille
by
re

moving

attaching
screws
six

on

top

and
two
on
both
ends

Remove
ornament
on
radiator

grille
by
removing
nuts
from
behind

radiator

grille
4

ZID

@

7

BF029B

Fig
BF
11

Body
front
end

FRONT
APRON
3

For
installation
reverse
above

steps
observing
the

following

I
Check
to
be
certain

that
six

guide
studs
enter
holes
in
radiator

support
lower
frame
before

tightening

top
screws

CD

@
REMOVAL
AND

INSTALLATION

I

Remove
front

bumper

2
Remove

radiator

grille

3

Disconnect
front
turn

signal
wire

harness
a
t
connector

4

Remove
front

apron
by
removing

attaching
bolts

S
For
installation
reverse
above

steps

B

632

1
Radiator

grille

2
Guide
stud

3
Guide

stud
hole

4
Radiator

support
lower

frame

Fig
BF
12
Radiator

grille
guide

studs

2

Align
grille
with
head

lamps
and

fenders

BF
7

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

REMOVAL
AND

INSTALLATION

I

Remove
hood
lock
male

by
re

moving
two

attaching
bolts

2
To
remove
hood
lock
female
first

remove
radiator

grille
Back
off
two

bolts

securing
hood
lock
female

in

position
Hood
lock
female

can
now

be
taken
out

3
Remove

two
bolts

attaching
hood

lock
handle

assembly
to
dash
side

paneL

Disconnect
cable
at
hood
lock

female
and
remove
cable

clamps
Pull

cable
out
into

cab

4

To
install
hood
lock
male
and

female
reverse
removal

procedure

Mter
installation
check
to
insure
that

they
are

properly
aligned

5
To

install
hood
lock
handle

as

sembly
reverse

steps
observing
the

following
notes

I
Check
to
be
certain
that

cable

clamps
are

tight
and
secure

2
Install
hood
lock
handle
bracket

in

place
by

using
two
of
four
holes

See

Figure
BF
19
Body
Frame

@

1

Hood
tock
handle

2

Hood
lock
handle

bracket
BF645A

3

Clamp

4

Hole

5

Attaching
bolt

Fig
BF

19

1MtalIing
hood
lock
handle

brocket

ADJUSTMENT
AND

INSPECTION

I
If
hood
lock
handle

is

heavy
turn

dove
tail
bolt
of
hood
lock
male
coun

terclockwise
to
reduce
tension
of

hood

lock

spring

Lock
nut
of
dove
tail
bolt
should

fust
be
loosened

If
looseness
is
noticed
hood
is

not

tight
and
will
vibrate
To
correct
this

turn
bolt
clockwise
and
recheck

2
Check
hood
lock
mechanism
as

follows

BF
10
I
Check

safety
catch

lever
and

spring
for
deformation

fatigue
or

rusting

2
Check

female
lever
and

return

spring
for
deformation

fatigue
or
rust

ing

Improper
operation
of
female

lever

may
cause

disengagement
be

tween
female
lever

and
dove
tail
bolt

3
Make
sure
that

safety
catch

hooks

engine
hood

properly
when

hood
latch
has
been

disengaged

0l

11
mm

I
nun
BF409A

0
433
in

0
3t5
in

Fig
BF
20

Safety
catch
lever
to

radiator

upper

support

acVu5tment

Lubrication

When

checking
or

adjusting
the

hood

lock
lubricate
the

pivot
catcher

and

return

spring
of

secondary
latch

thoroughly
Also
lubricate
the
lever
of

the
hood
lock
female
for

smooth
and

correct

operation

Body
Electrical

System

Room

lamp
and

engine
compartment
lamp
system

FUSE

BLOC
K

C
J
QA

C
J
CJ

CJ
CJ
1

100
I
2

I

I
t1

Wf

t
fi

FUSIBLE

LINK
ROOM
LAMP

t

I
6

I

II
lA

FUSE
o
C
1

BATTERY

I
I

DOOR

SWITCH
L
H
l
ENGINE

ROOM
LAMP

I
0

I

1

HOOD

SWITCt
f

I
c

I

DOOR
SWITCHIR
H

l

Fig
BE
5
Room

lamp
and

engine
compartment
lamp

system
BE852A

HEADLAMP

if

BE300

Fig
BE
6
Head
amp

HEADLAMP
BEAM

REPLACEMENT

I

Remove
radiator

grille
retaining

screws
and
remove
radiator

grille

2

Loosen
three

headlamp
retaining

ring
screws
I
t

may
be

unnecessary
to

remove
screws
Note
Do
not
disturb

aiming
adjust

screws

3
Remove

retaining
ring
by
rotating

it
clockwise

4
Remove

headlamp
beam
from

mounting
ring
and
disconnect

wiring

8E
5
connector
from

behind
beam

Note

Rubber
cover
is

installed
at

back
of

headlamp
beam
The
con

nector
is

located
in

the
cover

5

Change
headlamp
beam
and
con

nect

wiring
connector

to
new
beam

6
Place

headlamp
beam
in

position

so
that
three
location
tabs
behind

beam
fit
in

with
three
hollows
on

mounting
ring
Make
sure
that

sign

Top
of
beam
lens
i
i
on

upper
side

7
Install

headlamp
retaining
ring

and

tighten
retaining
screws

8
Place

radIator

grille
in

position

and

tighten

retaining
screws

AIMING

ADJUSTMENT

lJ

ii
i
tooi

1
Ji

Y
4
nnn

4
I

Horiz
tal

ad

justment

l

BE30l

Fig
BE
7

Aiming
adjustment

To

adjust
vertical
aim

use

adjusting

screw

on

upper
side

of

headlamp
and

to

adjust
horizontal
aim

use

adjusting

screw

on
side

of
head

lamp

Notes

Before

making
headlarnp
aiming
ad

justment
observe
the

foUowing
in

structions
Body
Electrical

System

a

Keep
aU

tires
inflated
to
correct

pressures

b
Place

vehicle
and
tester

on
the

same

flat
surface

c

See
that
there

is
no
load
in
vehicle

I
Gasoline
radiator
and

engine
oil

pan
filled

up
to

correct
levels

2
Without

passenger
When

performing
headlamp
aiming

adjustment
use
an

aiming
device

aiming
wall
screen
or

headlamp
tester

For

operating
instructions
of

any

aimer

refer
to

respective
operation

manuals

supplied
with
the
unit

DRIVING
BEAM
HIGH

BEAM

L

wt

H
G

hi
i

iiI

PASSING
BEAM
LOW
BEAM
10
m
32
8
ft

W2

H2
10
m

02
8
n

d

20

h2
I

02

I

I

f
10
m

32
8
ft

Driving
beam

High
beam

Passing
beam
Low

beam

HI

WI
01

mm
mm

CO

in
in

I
715
780

48

All
models

28
15
30

71
hI

H2
W2

h2

O2
d

mm
mm
mm

in

in
in
0

140

I
715

11
160

12018
5
51
28

15
45

67
mm
mm

in
in

392
349

is
43
13
74

BE302

Fig
BE
8

Aiming
adjustment

BE

6

OUTLINE
OF
AIR
CONDITIONER

REFRIGERATION

SYSTEM

CONDENSER

COMPRESSOR

RECEIVER
DRYER

COOLING
UNIT

ELECTRICAL
CIRCUIT

OUTLINE
OF
AIR

CONDITIONER

The

air
conditioner
consists

es

sentially
of
a

cooling
unit

compressor

condenser
receiver

dryer
and

piping

The

cooling
unit

secured
with

three

brackets
is
a

ttached
to
the

location

occupied
by
the

package

tray

in
the
dash

panel

The

cooled
air
from
the
duct

is

directed
into
the

passenger
compart
Air

Conditioning

DESCRIPTION

CONTENTS

AC
2

AC3

AC
3

AC3

AC4

AC4

AC
5
DESCRIPTION

MAIN

RELAY

FAN
SWITCH

THERMO

SWITCH

PRESSURE
SWITCH

COMPRESSOR
RELAY

F
I
C
D

SOLENOID
VALVE
AC
5

AC
7

AC
7

AC
7

AC
7

AC
7

AC
7

ment

through
the
three

outlets
at

the

instrument

panel

The

compressor
serves
to

compress

the

vaporized
refrigerant
and
is
attach

ed

through
the
bracket
to
the
loca

tion

occupied
by
the

mechanical
fuel

pump
on
the

engine

The
condenser
cools
the

compres

sed

refrigerant
vapor
sent

by
the
com

pressor
and
is

located
on

the
front
of
the
radiator
in

the

engine
compart

ment

The
receiver

dryer

serving
as
a

reservoir

for

storage
of
the

liquid
sent

by
the
condenser
is

located
on
the

right
in
the

engine
compartment

The

piping
consists
of

two
flexible

hoses

and
five

copper
tubes
which

connect
various

components
of
the

air

conditioning
system

I

Cooling
unit

2

Expansion
valve

3
Receiver

dryer

4

Comressor
5

Condenser

6
Duct

@
Flexible
hose

@
Copper
tube

AC
2
AC724

Fig
AC
1

Cooling
system

REFRIGERATION

SYSTEM

If

you
were
to

paint
your
finger

with
alcohol

your
finger
would
feel

cold
This
is
because
the

liquid
alcohol

takes
heat

away
from

your
finger

while
it

evaporates
If
a

quickly
evapo

rating

liquid
such
as
alcoliol
is

placed

in
a
container
inside
a
box
the
tem

f

Outside
air

U

Condenser

J6G1
i
i

1
1

t1

1

ilill
I
I

J

JJ
LlJ
i
l

7

U

Receiver

dryer

h

w

t

CONDENSER

The
condenser
is
installed
to
the

front
of
the
radiator

The
heated
and

compressed

refrigerant
gas
from
the
Air

Conditioning

perature
inside
the
box
will

drop
This

is
because
the

alcohol
is

evaporated

absorbing
the
heat
from
the
air

insidc

the
box
If
the

gaseous
alcohol
is

collected
and

cooled
with

cold
water

it
will
be

changed
back

into
a

liquid
by

absorption
of
its
heat

by
the
cold

water

The
cooler

operates
on
this

princi

Compressor

t

q
ttLJ

IrJ

Evaporator
It

J

1

J

f
9

d

lUr

I

Expansion
valve
V7777
J
High
pressure

lLLLLL
l

gas

I
I
High
pressure

liquid

t

u

compressor
condenses
to
a

liquid
by

being
cooled

by
air

passing
between

the
fins
of
the
condenser

1
GJ
7

vlmnn

iii

plI

d1i
1il

Ac459

Fig
AC

3
Condenser

AC3
pIe
The

liquid
used

is
the

refrigerant

R
12

The
heat
inside
the

passenger

compartment
is
absorbed

by

changing

the

refrigerant
from
a

liquid
to
a

gas

and
then

dissipated
to
the

outside

by

changing
the

refrigerant
from

a

gas

back
to
a

liquid

The

refrigeration
system
is

shown

in

Figure
AC
2

Low

pressurt

liquid

1

I
L2
Low

pressure

gas

Inside
air

li

r

L

Blower
motor

AC458

Fig
AC
2

Refrigeration
cycle

COMPRESSOR

The

compressor
is
installed
to
the

side

of
the

engine
and
is
driven

by

crank

pulley
through
a
belt
The

refrig

erant

gas
leaving
the

evaporator
is

forced
out
to
the
condenser

by
com

pressor
and
the
low

pressure
refrig

erant

gas
is

compressed
to
a

high

pressure
and

high

temperature

The

driving
force
is
transmitted

by

an
electrical
clutch
Because

engine

rpm
is

very
low

during
idling
the

clutch
will

not
transmit

the

driving

force
thus

ensuring
smooth

engine

idling

INSPECTION

Evaporator

Check

evaporator
for

leakage
or

damage
If

damaged
replace

Expansion
valve

Check

expansion
valve
for

leakage

or

clogging
If

clogged
clean
filter
in

expansion
valve
If

damaged

replace

RECEIVER
DRYER

AND

PIPING

REMOVAL
AND

INSTAUATION

Receiver
dryer

I
Disconnect

battery
ground
cable

2

Discharge
system
Refer
to

Dis

charging
System
under
General
Service

section

3

Disconnect

compressor
lead
wire

at

connector

4

Disconnect

cooling
pipes
at

joints

Acno

Fig
AC
39

Diaconnecting
coo

ing

pipes

Notes

a

Plug
all

piping

joints
immediately

after

pipe
disconnection
to

prevent

entry
of
dust
or
moisture
laden
air

into

receiver

dryer
or
air
aJOdi

tioning
system

b
Use

two
wrenches
when
dIsconnect

ing
cooling
pipes

5

Remove
four
screws

securing

receiver

dryer
bracket

to
vehicle

body

and
detach

compressor
relay
and

pres

sure
switch
as
an

assembly

6
To

install
receiver

dryer
and

piping
reverse
the
order
of
removal
Air

Conditioning

Notes

a

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when
con

necting
cooling

pipes

b
Use
two
wrenches
when

connecting

cooling
pipes

c

Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Checking

System
under
General
Service

sec

tion

d
Check

refrigerant

leakage
if
neces

sary
repair

Refer
to

Evacuating
and

Charging

System
under

General
Service
See

tion

Condenser

Disconnect

battery

ground
cable

2

Discharge

system
Refer

to
Dis

charging
System
under
General

Service

section

3
Drain

engine
coolant

4

Remove
radiator

grille

5

Remove

radiator

shroud
and

radiator

On
automatic
transmission

models

disconnect
both

torque
converter
oil

hoses

Note

While

cooling
water
is
hot

take

precautions

against
scalding

6
Disconnect
two

pipes
from

con

denser
remove
two

screws

securing

condenser

Condenser

can
now
be

removed

AC485

Fig
AC

40

Removing
conden
er

Notes

a
Use

two
wrenches
when
disconnect

ing
pipe

joints

b

Plug
openings
immediately
after

disconnecting
pipes

7

To
install

reverse
the
order
of

removal

AC

29
Tightening
torque

Flare
nut
for

copper
tube

from

compressor

2
5
to
4
0

kg
m

i8
to
29
ft
Ib

Flare
nut

for

copper
tube

to
receiver

dryer

2
5

to
3
5

kg
m

i8
to
25
ft
lb

Notes

a
When

disconnecting
and

connecting

cooler

pipes
be
sure
to

use
two

wrenches

b

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when

con

necting
cooler

pipes

c

To

prevent

possibility
of

explosion

due
to

high

pressure
within

cooling

system
do

not
clean
condenser

with
steam

Always
use
cold
water

or

cold

compressed
air

d
Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Charging

System
under
General

Service
sec

tion

e
Check

refrigerant
leakage
if
neces

sary
repair
Refer
to

Checking
for

Leaks
under
General
Service

sec

tion

INSPECTION

RecelYer

dryer

Check
for

refrigerant
leakage
or

damage

Check
for

proper
connection
of

two

lead
wires

running
to

pressure

switch

If

any
component

part
is
found

damaged
replace
receiver

dryer
and

pressure
switch
as

an

assembly

Condenser

I

Check

inlet
and
outlet

pipe
joints

and

sealing
surfaces
for

damage
Re

place
parts
if

damaged
or

leaky

2

Clogged
condenser
fins
or

air

pas

sages
may
reduce

cooling
efficiency
of

condenser
Clean
these

areas
with

dry

compressed
air

Piping

Check

piping
for

leakage
If

leakage

occurs
at
connections

retighten

connecting
nuts

Replace
if

leakage

persists