1977 DATSUN PICK-UP lock

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

Engine
Mechanical

g
Piston

ring

Ring
height

Top
and

second

Side
clearance

Top

Second

Ring
gap

Top

Second

Oil
mm
in

mrn
in

mm
in

h
Cylinder
block

Cylinder
bore
inner
diameter
mm
in

Wear
limit
of
dittoed
inner

diameter

Cylinder
bore

taper
and
out
of
round

Difference
in

cylind
bore

Surface
flatness
mm
in

mm
in

mm
in

mm
in

i

Cylinder
head

Surface
flatness

mm
in

TIGHTENING
TORQUE

Cylinder
head

bolts

kg
m
fl
lb

Connecting
rod

big
end

nuts
kg
m
ft
Ib

Flywheel
fixing
bolts

kg
m
ft
Ib

Main

bearing
cap
bolts

kg
m
ft
lb

Camshaft
bracket
bolts

kg
m
ft
lb

Camshaft

sprocket
bolt

kg
m
ft
lb

Oil

pan
bolts

kg
m

ft
1b

Oil

pump
bolts

kg
m
ft
lb

Oil
strainer

bolts
kg
m

ft
lb

Oil

pan
drain

plug
kg
m
ft
lb

Rocker

pivot
lock
nuts

kg
m

ft
Ib

Camshaft

locating
plate
bolts

kg
m
ft
lb

Carburetor
nuts

kg
m

ft
lb

Manifold
bolts

kg
m
ft
lb

Fuel

pump
nuts

kg
m

ft
lb

Crank

pulley
bolt

kg
m
ft
lb

Water

pump
bolts

kg
m
ft
Ib

Front
cover
bolts

kg
m
ft

lb

EM

30
1
977
to
1
990
0

0778
to

0
0783

0
040
to
0
073
0
0016
to

0
0029

0

030
to
0

070
0
0012
to
0

0028

0
25
to

0
40
0
0098
to
0

0157

0

30
to
0

50
0
0118
to

0
0197

0
30
to
0

90
0

0118
to
0
0354

85
000
to
85
050

3
3465

to
3
3484

0
2

0
0079

om
5
0

0006

0
05
0
0020

less
than
0

05
0

0020

less
than
0
05

0
0020

6
5
to
8
5

47
to
61

4
5
to
5
5

33
to
40

14

to
16

101
to
116

4
5
to

5
5
33
to
40

1

8
to
2

0

13
to
15

12
to

16
87
to
116

0
6

to
0
9
4
3
to
6
5

I
J
to
1
5

8
0
to

10
8

0
8
to
1
1
5
8
to
8
0

2
0

to
3
0

14
to
22

5
0
to

6
0

36
to
43

0
6

to
0
9

4
3
to
6
5

0
5
to
1

0
3
6

to
7
2

1
2
to
1
6
8
7

to
11

6

1
2
to
1
8
8
7
to
13

0

12
to

16
87
to
116

0
4
to

0
5
2
9

to
3
6

8
mm
0
315
in

dia

6
mm
0

236
in
dia
1

0
to
1
3
7
2
to

9
4

0
4
to
0
6
2

9
to
4
3

Engine
Mechanical

SPECIAL
SERVICE
TOOL

No
Tool
number

tool
name
Description

Unit
mm
in

Engine
stand

assembly
This

engine
stand
assembly
is
used
for

disassembling
or

assembling
engine
block

or
differential
carrier

throughout

3600
in

all
directions
ST050lS000

ST050
11000

Engine
stand

ST050

12000

Base
For

use

on
Reference

page
or

Figure
No

All

Fig
EM
II

models

SE184

2
ST0526oo0l
This

engine
attachment
is
installed
to

engine
stand
Ll6

Fig
EM
II

ST0501S000
in

disassembling
or
assembling
engine
Ll8

Engine
attachment

L20B

Q

li

SE185

3
STl
0120000
Special
hollow
set
bolts
are
used
in

tightening
cylinder
heads
All

Fig
EM

18

in

L
series

engines
This
wrench
is
used
to

torque
cylinder
L
series

Cylinder
head
bolt

head
bolts
and
its
head
can
be
inserted
into
the

torque

1
rench

wrench

10
0
39
SE186

4
STl
064000
I
This
tool
is
used

togetller
with
a

torque
wrench
in

tightening
pivot
lock
nut
for
valve
clearance

adjustment

Pivot

adjuster

SE187

EM
33
All
Fig
EM
105

L
series

ENGINE
LUBRI
CATION
SYSTEM

Note

Pump
rotors
and

body
are
not

serviced

separately
If

pump
rotors

or
body
are

damaged
or
worn

replacement
of
the
entire
oil

pump

assembly
is

necessary

Tightening
torque

Oil

pump
mounting
bolts

Oil

pump
cover
bolts

Regulator
valve

cap
nut

Specifications

Oil

pressure
at

idling

Regulator
valve

spring

Free

length

Pressured

length

Regulator
valve

opening
pressure

OIL
FILTER

The
oil
filter
is
a

cartridge
type

The
oil
filter
element
should
be
reo

placed
periodically
with

the
use
of
Oil

Filter
Wrench
ST19320000

When

installing
an
oil
filter
fasten

it
to

cylinder
block

by
hand

Note
Do
not

overtighten
filter
or
oil

leakage
may
occur
OIL
PRESSURE

REGULATOR
VALVE

The
oil

pressure
regulator
valve
is

not

adjustable
At
the
released

position
the
valve

permits
the
oil

to

by
pass
through
the

passage
in

the

pump
cover
to
the
inlet
side
of
the

pump
Check

regulator
valve

spring
to

ensure
that

spring
tension
is

correct

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
lb

kg
cm2

psi

mm
in

mm
in

kg
em
2

psi

RELIEF

VALVE

The
relief
valve
located
at
the

center

portion
securing
oil
fIlter
to

the

cylinder
block

by

passes
the
oil

into
the
main

gallery
when
the
oil

fIlter
element
is

excessively

clogged

STl9320000

EL015

Fig
EL
9

Removing
oil

filter

EL
4
EL014

Fig
EL
B

Regulator
value

l
l

to
1
5
8
0
to
11

0
7
to

1
0
5
Ito
7
2

4

to
5
29
to
36

0
8
to
2
8

II
to
40

52
5
2
067

34
8

1
370

35
to
5
0
50
to
71

With
oil
fIlter
removed
check

valve
unit
for

operation
Inspect
for
a

cracked
or
broken
valve
If

replace

ment
is

necessary
remove
valve

by

prying
it

out
with
a
screwdriver

Install
a
new
valve
in

place
by

tapping
it

EL016

Fig
EL
JO
Relief
lJOlue

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

Condition

Loss

of
water

Poor
circulation

Corrosion

Overheating

Overcooling
Cooling
System

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Probable
cause

Damaged
radiator
seams

Leaks
at
heater
connections
or

plugs

Leak
at

water

temperature
gauge

Loose

joints

Damaged
cylinder
head

gasket

Cracked

cylinder
block

Cracked

cylinder
head

Loose

cylinder
head

bolts

Restriction
in

system

Insufficient
coolant

Inoperative
water

pump

Loose

fan
belt

Inoperative
thermostat

Excessive

impurity
in

water

Infrequent
flushing
and

draining
of

system

Inoperative
thermostat

Radiator
fin
choked
with
mud
chaff
etc

Incorrect

ignition
and
valve

timing

Dirty
oil
and

sludge
in

engine

Inoperative
water

pump

Loose
fan
belt

Restricted
radiator

Inaccurate

temperature
gauge

Impurity
in

water

Inoperative
thermostat

Inaccurate

temperature
gauge

CO
7
Corrective
action

Repair

Repair

Tigh
ten

Tighten

Replace

Check

engine
oil
for
contamination
and
refill

as

necessary

Replace

Check

engine
oil
in
crankcase
for

mixing

with

water

by
pulling
oil
level

gauge

Replace

Tighten

Check
hoses

for

crimps
and

clear
the

system

of
rust
and

sludge
by
flushing
radiator

Replenish

Replace

Adjust

Replace

Use
soft
clean
water
Rain

water
is
satis

factory

Cooling

system
should
be

drained
and

flushed

periodically
Permanent
anti
freeze

Ethylene
glycol
base
can
be

used

through

out
the

seasons
of
the

year
and

change

periodically
at
intervals
recommended

Replace

Clean
out

air

passage
thoroughly
by
using
air

pressure
from

engine
side
of
radiator

Adjust

Refill

Replace

Adjust

Flush
radiator

Replace

Use
soft
clean
water

Replace

Replace

r

AIR
CLEANER

1
Loosen

bolts

securing
air
cleaner

to
air
cleaner
bracket

2
Loosen
air

cleaner
lock
bolt
and

remove
air

cleaner
from
carburetor

Disconnect
the

following
hoses
when

dismounting
air

cleaner

Under
hood
air
inlet

hose

Hot
air
inlet

hose

Vacuum

hose
Sensor
to
intake

manifold

Vacuum
hose
Sensor
to
vacuum

motor

Vacuum
hose

Idle

compensator
to

intake
manifold

Hose
Air

pump
to
air
cleaner

Hose
AB
valve

to
air
cleaner

Hose
Carburetor
to
air

cleaner

Blow

by
hose
Air

cleaner
to

rocker

cover

Hose
Air

control
vaive
to
air

cleaner
California

models

only

3
To

install

reverse
the
removal

procedure

INSPECTION

1
AIR
CLEANER

ELEMENT

Viscous

paper
type
air
cleaner

ele

ment
does
not

require
any
cleaning

operation
until
it

is

replaced
periodi

cally
Brushing
or

blasting

operation

will
cause

clogging
and

result
in
enrich

ment

of
carburetor
mixture

and

should
never
be

conducted
For

reo

placement
interval
of
air

cleaner
ele

ment
refer
to
Maintenance
Sched

ule

2
HOT

AIR

CONTROL
SYSTEM

In

warm
weather
it
is

difficult
to

find

out
malfunction
of
hot
air
control

system
In

cold
wea
thee

however

malfunction
of
air
control
valve

due
to

disconnection
or

deterioration
of

vacu

um

hose
between
intake
manifold
and

vacuum
motor
and

insufficient
dura

bility
of
air
control
valve

will
cause

insufficient
automatic
control

opera

tion

for
intake
air
and

result
in

engine

disorder

including

I

Stall

or
hesitation
of

engine

oper

ation

2

Increase
in

fuel

consumption

3

uck
of

power
Engine
Fuel

These

phenomena
reveal
malfunc

tion
of
hot
air
control

system
If
these

phenomena
should
occur
check
hot

air
control

system
as

described
in
the

following
before

carrying
out

inspec

tion

of
carburetor

2
1
Vacuum

hose

Intake
manifold
to
3

way
connec

tor
3

way
connector
to

temperature

sensor
3

way
connector
to

idle
com

pensator
temperature
sensor
to
vacu

um

motor

I

Check
that

vacuum
hoses
are

se

curely
connected
in

correct

postion

2

Check
each
hose
for

cracks
or

distortion

hose

clip
for

condition

Note

Vacuum
hose

position
R
H

side
of
Nissan

mark
on
the

top
of

sensor
is
for

intake
manifold
L
U

side
of

the
mark

is
for

vacuum

motor

2
2
Vacuum

motor

I

With

engine
stopped
disconnect

fresh
air

duct

Place
a
mirror

at
the
end
of
air

cleaner
inlet

pipe
as
shown
and

check

to

see
if
air

con
trol
valve

is
in

correct

position

EF213

Fig
EF
11

Inspecting
valve

position

Air

control
valve
is
in

correct

posi

tion
if
its
under
hood
air

inlet
is

open

and
hot
air
inlet
is

closed
Check
air

control
valve

linkage
for

condition

2

Disconnect

vacuum
motor
inlet

vacuum
hose
and
connect

another

hose
to
the
inlet
to

apply
vacuum
to

vacuum
motor
Vacuum
can
be

ap

plied
by
breathing
in
the

hose
end

as

shown

Place
a
mirror

at
the

end
of
air

cleaner
inlet

pipe
and

check
to

see
if

air

control
valve

is
in
correct

position

EF
6
EF217

Fig
EF
12

Inspecting
valve

position

Correct

position
of
air

control
valve

is

the
reverse
of

paragraph
J
above
Air

control
valve
is
in
correct

position
if

under
hood
air
inlet
is

closed
and
hot

air

inlet
is

open

3
With

hot
air

inlet
in

open
posi

tion

as
described
in

paragraph
2

above

pinch
vacuum
hose
with

fingers

and
cut
off
air

from
vacuum
hose
In

this
condition
check
that
air

control

valve

maintains
the

condition
de

scribed
in

step
2

for
more
than
30

seconds
and
that
hot
air

inlet
is

open

If

diaphragm
spring
actuates
the
air

control
valve

by
its

spring
force
to

open
under
hood
air
inlet

within
30

seconds

replace
vacuum
motor
as
an

assembly
since
this

may
be

resulted

from

air
leak
at
vacuum
motor
dia

phragm

2
3
Temperature
ensor

Check

temperature
sensor
for
func

tion

by

proceeding
as
follows
Be

sure

to

keep
engine
cold
before

starting

test

I

With

engine
off

check
air

control

valve
for
condition
In

this
case
under

hood
air

inlet
is

open
Use
a
mirror

for

inspection
as
2
2
1

above

2

Start

engine
and

keep
idling

Immediately
after

engine
starting

check
air
control
valve
for

correct

position
as
described
above
In

this

case
correct

position
of

air
control

valve

is
the
reverse
of
2
2
I

under

hood
air

inlet
is

closed
and
hot

air

inlet
is

open

3
Check
that
air
control
valve

grad

ually
opens
to
under
hood
air

inlet

side
as

engine
warms

up
When
en

vironmental

temperature
around
tern

perature
sensor
is

low

spend
more

time

for

engine
warming
up
operation

4

Run
the

engine
at

varying
speeds

5

The

pressure
gauge
indicates

static
fuel

pressure
in
the
line

The

gauge
reading
should
be

within
the

following
range

0
21
to
0

27

kg
em2

3
0

to
3

8

psi

Note
If

the
fuel
in
carburetor
float

chamber
has
run
out

and

engine
has

stopped
clip
and

pour
fuel

into

carburetor
Fasten

clip
secure

ly
and

repe
1
static

pressure
test

Pressure
below
the
lower
limit
indi

cates
extreme
wear
on
one

part
or

a

small
amount
of
wear
on
each

working

part
It

also
indicates

ruptured
dia

phragm
worn

warped
dirty
or

gum

ming
valves
and
seats
or
a
weak

diaphragm
return

spring
Pressure

above
the

upper
limit
indicates
an

excessively
strong
tension
of
dia

phragm
return

spring
or
a

diaphragm

that
is
too

tight
Both
of
these
condi

tions

require
the
removal
of

pump

assembly
for

replacement
or

repair

CAPACITY
TEST

The

capacity
test
is

made

only

when
static

pressure
is
within
the

specifications
To

make
this
test

pro

ceed

as
follows

1

Disconnect

pressure
gauge
from

T
connector
and
in
its
vacant

place

install
a

suitable
container

as
a
fuel

sump

2
Run

engine
at
1

000

rpm

3
The

pump
should

deliver
1
000

cc

2
11

US

pt
of
fuel
in

one
minute
or

less

If
little

or
no
fuel
flows
from
the

open
end
of

pipe
it
is
an

indication

that
fuel
line
is

clogged
or

pump
is

malfunctioning

REMOVAL
AND

DISASSEMBLY

Remove
fuel

pump
assembly
by

unscrewing
two

mounting
nuts
and

disassemble
in

the

following
order

1

Separate

upper
body
and
lower

body
by

unscrewing
body
set
screws
Engine
Fuel

2

Take
off

cap
and

cap
gasket
by

removing
cap
screws

3
Unscrew
elbow

and
connector

4
Take
off
valve

retainer

by
un

screwing
two
retainer

screws
and
re

move
two
valves

5
To
remove

diaphragm

press

down
its

center

against
spring
force

With

diaphragm
pressed
down

tilt
it

until
the
end
of

pull
rod
touches
the

inne

wall
of

body
Then
release

diaphragm
to
unhook

push
rod
Be

careful

during
this

operation
not
to

damage
diaphragm
or
oil
se
L

i
J

EFOO7

Fig
EF

20
Remouing
pull
rod

6
Drive
rocker
arm

pin
out
with
a

press
or
hammer

8

o

6

7

8

@

INSPECTION

I

Check

upper
body
and
lower

body
for
cracks

EF
10
I
fuel

pump
cap

2

Cap
gasket

3
Valve

packing

4

fuel

pump
val
e

assembly

S
Valve
retainer

6

Diaphragm
assembly

7

Diaphragm
spring

8
PuRro

9

Lower
body
seal

washer

10
Lower
body
seal

11
Inkl
connector

12
Outlet
connector

13
Rocker
arm

spring

14
Rocker
arm

I
S
Rocker

artyl
side

pin

16
Fuel
pump
packing

17

Spacer
fuel

pump

fo
cylinder
block

EF510

Fig
EF
21
Slruc
ure
of
fuel

pump

2
Check

valve
assembly
for
wear
on

valve
and
valve

spring
Blow
valve

assembly
with
brea
th
to
examine
its

function