1977 DATSUN PICK-UP check engine

q

1

I

k

k
lO

i

I

37

9
to
38
1

eel
1
492
to
1
500
dis

co

q

0

45
597
to
45
613

1
795
to
1
796
dia
5
Correct

valve
seat
surface
with

new
valve

guide
as
the
axis

VALVE

SEAT
INSERTS

Check
valve
seat
inserts
for

any

evidence

of

pitting
at
valve
contact

surface

and
reseat
or
replace
if
worn

excessively

Valve
seat
insert
of
0
5
mm
0
0197

in
oversize
is
available
for

service
as

shown
below

Intake

Unit
mm
in
Engine
Mechanical

Fig
EM
45

Correcting
valve
seat

EM573

0

32

6
1

2835
dia

Exhaust

I
I

30

U81
dia
17
5
0
295

Unit
mm

in
37
580
to
37

596
1
4795
to
1
4802
dia

Cylinder
head
rece
diameter

For

factory
standard

insert

Intake

For
service
insert

For

factory
standard

insert

Exhaust

I
For
service
insert

Interference

fit

mm
in
Intake

Exhaust
Fig
EM
46
Seroice
valve
seat
dimensions

Unit

mm

in

45
000
to

45
016
1

7717
to
1

7723

45
500
to
45
516
1

7913
to

I
7920

37
000
to
37
016
1

4567
to
I
4573

37
500
to
37
516
1

4764
to
I
4770

0
081
to
0
113
0
0032
to
0
0044

0
064
to
0
096
0
0025
to
0
0038

EM
11
Replacln
valve
eat
In
ert

1
Old
insert
can
be
removed

by

boring
it
out
until
it

collapses
The

machine

depth
stop
should
be

set

so

that

boring
cannot
continue
beyond

the
bottom
face
of
the
insert

recess
in

cylinder
head

2

Select
a
suitable
valve
seat
insert

and

check
its
outside
diameter

3
Machine

cylinder
head
recess
to

the
concentric
circles
in

valve

guide

center
so
that
insert

will
have
the

correct
fit

4
Heat

cylinder
head
to
a

tempera

ture
of
150
to
2000C
302
to
3920
F

5
Fit
insert

ensuring
that
it
beds
on

the

bottom
face
of
its

recess
and

caulk
more
than
4

points

6

Newly
fitted
valve
seats
should
be

cut
or

ground
at
the

specified
dimen

sions

as
shown
in

Figure
EM
47

7

Apply
small
amount
of
fine

grind

ing
compound
to
valve

contacting
face

and

put
valve
into

guide
Lap
valve

against
its
seat
until

proper
valve
seat

ing
is
obtained
Remove
valve
and
then

clean
valve
and

valve
sea
1

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

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

Engine
Mechanical

Standard

Wear
limit

Inner
diameter
85
000

to
85
050

0

2
0
0079

3
3465
to
3
3484

Cylinder
bore

mm
in
Out
of
round
O
ot5
0
0006

Taper
0
015
0
0006

Difference
in

cylinder
bore

0
05
0
0020

0
2
0
0079

mm
in

CYLINDER

BORING

I
When

any
cylinder
needs

boring

all
other

cylinders
must
also
be
bored

at
the

same
time

Oversize

pistons

spec
Hic
etlons

Piston
diameter
mm
in

Servioe
standard

0
50
0
0197

Oversize

1
00

0
0394

oversize

3
The
size

to
which

cylinders
must

be

honed
is

determined

by

adding

piston

to
cylinder
clearance
to
the

largest
piston
diameter
at

piston
skirt

in

thrust
direction

EM126

Fig
EM
54

Measuring
piston
diamet
r
2

Determine

piston
oversize
ac

cording
to
amount
of
wear
of

cylinder

84
985
to
85
035

3
3459

to
3
3478

85
465
to
85
515

3
3648
to
3

3667

85

965
to
86
015

3
3844
to
3

3864

Standard
clearance

ffim
in

Feeler

gauge
mm

in

Extracting
force

kg
Ib

Notes

a

To

prevent
strain
due
to

cutting

heat
bore
the

cylinders
in
the
order

of

2
4
1

3

b

Before

boring
any
cylinder
install

main

bearing
caps
in

place
and

tighten
to
the

specification
so
that

the
crankshaft

bearing
bores
will

not
become
distorted

from
the
bor

ing
operation

4

Do
not
cut

too
much
out
of

cylinder
bore

at
a
time
Cut

only
0
05

mm
0
0020
in

or
so
in
diameter

at
a

time

EM
14
L

7
A

aboull
6
m

o
7323in

r

127

Fig
EM
55

MeCUJlJring
piston
skirt

diameter

Rebored
size

calculation

o
A
B
C
A
0
005
to

0
Q25
mm

0
0002
to
0
0010
in

where

D
Honed

diameter

A

Skirt
diameter
as
measured

B
Piston
to
wall

clearance

C

Machining
allowance
0
02
mm

0
0008
in

0
025

to
0

045
0

0010
to
0
0018

0
04
0

0016

0
2

to
1

5
O

44
to

3
31

5

Measurement

of
a

just
machined

cylinder
bore

requires
utmost
care

since
it

is

expanded
by

cutting
heat

6

As
a
final

step
cylinders
should

be

honed
to
size

7

Measure
the

finished

cylinder

bore
for

out
of
round
or

tapered
part

8
Measure

piston
to

cylinder
clear

ance

This

clearance
can
be
checked

easily
by
using
a
feeler

gauge
and
a

spring
balance
hooked

on
feeler

gauge

measuring
the
amount
of
force

re

quired
to

pull

gauge
out
from

between

piston
and

cylinder

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

r

Piston

pin
outside
diameter

Piston

pin
hole
diameter

Piston

pin
to

piston
clearance

I

Interference
fit
of

piston

pin
to

connecting
rod

CONNECTING

ROD

I
If
a

connecting
rod
has

any
flaw

on
either
side
of
the
thrust
face
or
the

large
end

correct
or

replace
it

EM133

Fig
EM
61
Ch

cking
rod

alignment

Connecting
rod

bend

or
torsion

per
100
mm

or
3
94
in

length

mm
in

3

When

replacing

connecting
rod

select
rod

so
that

weight
difference

between
new
and
old

ones
is

within
7

gr
0
25
oz

Do

not
use

a
combination
of
new

and

former

connecting
rod

big
end

nuts
and

connecting
rod
bolts
which

affect

specified
weight
variations

4
Install

connecting
rods
with

bear

ings
on
to

corresponding
crank

pins

and

measure
thrust
clearance

Ifmeas

ured

value
exceeds

limit

replace
Engine
Mechanical

Unit

mm
in

20
993
to
20
998
0

8265
to

0
8267

21

001
to
21
008
0

8268
to
0
8271

0
003
to
0
015

0
0001
to

0
006

0
015

to
0
035
0

0006
to
0
0014

2
Check

connecting
rod
for
bend
or

torsion

using
a

connecting
rod

aligner

If
bend
or
torsion
exceeds
the

limit

q
rrect
or

replace

Standard

Maximum

0
03
0

0012
0
05

0
0020

Fig
EM
62

Checking
big
end

play

Standard

Maximum

Big
end

play
mm

in
0
2

to
0
3

0

0079
to
0
01
18
0
6
0
0236

EM

16
CRANKSHAFT

1

Whenever
crankshaft
is
removed

from

engine
it

should
be

cleaned

thoroughly
in

a
suitable

solvent

After

cleaning
check

crankshaft

journal
and

crank

pin
Jor
score
bias

wear
or

cracks

Rep
air

or

replace
as

required

If

damage
is
minor

dress
with
fine

crocus
cloth

2

Check

journals
and
crank

pins
for

taper
and

out
of

round
with
a
micro

meter

Measurement
should
be
taken

along
journals
for

taper
and
around

journals
for

out
of
round

See

Figure

EM
63
for

detailed
information

If

journals
or
crank

pins
are

tapered

or
out
of
round

beyond
limits

replace

with
a

new
shaft

A
B

Out
of

round

X
Y

Taper
A
B

Unit
mm
in

19
5

0
768

tt
30
27

32

181
1
06
1
260

43

O
l
69

I

E
1

All

main

journa

59
942
to
59
955
All
crank

pm

2

3599
l
2

3604
49
961
to
49

974

o

1
9670
to
1

9675

EM424

Fig
EM
63

Crankshaft
and

journal

dimensions

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