1977 DATSUN PICK-UP Service Manual

DATSUN
PICK
UP

MODEL

620
SERIES

I
NISSAN

I

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION

BF

BO
DY
FRAME

CAB

BODY
AND
FRAME

REAR
BODY

BODY
FRONT
END

HOOD

DOOR

WINDSHIELD

GLASS

INSTRUMENT
PANEL

INTERIOR
TRIM
AND

CENTER
CONSOLE

SEAT
BF
2

BF
5

BF

7

BF

8

BF
11

BF
16

BF
17

BF

18

BF

19

Body
Frame

CAB

BODY
AND

FRAME

On
the
620

series
models

chassis

frames
are

classified
into
three

types

the
standard
wheelbase

model

long

wheelbase

model
and

Deluxe

Cab
The
frame
consists
of

right
and
left

side
members
which
are
linked

to

gether
with
crossmembers
to

form
a

rigid
structure
that
can

withstand
heavy
loads

The
second

crossmember

is

located
somewhat
to

the
rear
to

permit
individual

replacement
of
the

transmissiol

FRAME
ALIGNMENT

STANDARD
WHEELBASE
MODEL

f
r1
1

587
5

J
I

1

X
62
50

I

b
q

J

A
1

7
I
b

9

9

8

I
1

e

t
r

0
ij
e

6

rd

r
r
1sol

1

1
9ClS

1

085

42

721
Cl

H
1

I

11
OO

l
1

i11
175

6
89

1

069
4
42

10

942
5
37
11

1007
39
65

I

284

295

11
18
11

61
00

d

M

o
8
r

r

c

8

o
r

T
L

BF025B

Fig
BF

I
Underbody
dime1l8ion
Standard
whee

b
e

SF
2

Body
Frame

LONG
WHEELBASE
MODEL

In
4
l1

1

873
8

Ir
mrn

0

IN

bi

1
b

v
p
v
M

r
y
M

t

c
I

f

G

0
v

D
c

IS

S

t

I

y
r
M
J

1
0
10

9

V
raj
p

N

78

1

085

42

72
1
350

Ii

I

1

20
63

d3
1

U

n
L
II

t

I
T

r
r

J

M

o

C

M

o
e
I
I

o

M

0

So

I

I

Fig
BF
2

Underbody
dimensions
Long
wheelbase
BF0268

DELUXE
CAB

17

1

C

y
0
l

r
r

M
2
V

d

J

JSO

r

S

1

085

42

72

I

I
I
li4

1
069
4

42
10
942
5

37
11

284

11
18
Jr
t
r

iO

u
b
P

tl
b

c

N
0

l

f

t
0

M

00
I
0

0

0
o

1
00
N

It

1
b

t
8Qa

3
o

OS

A

b
U

n

j

1

007
39
65

1

11
61

1

M

o
bu
c
r

I
T

I

I

M

8

R
It
o

BF
3
Fig
BR

3
Underbody
dimensiom

Delu
Cab
BF027B

CAB
BODY
Body
Frame

Ist

mounting
2nd

mounting

1
Bolt

2

Plain

washer

3
Rubber
washer

4

Upper
rubber

5
Bottom

rubber

6
Plain
w

er

7

Upper
washer

8

Lower
washer

1st

mounting

REMOVAL

AND

INSTALLATION

Remove

battery
from

engine

compartment

2

Disconnect
oil
cooler
hoses
from

radiator
automatic
transmission

model

only

3

Disconnect
air
conditioner

tubes

from

condenser
if
so

equipped

4

Drain
water
from

cooling
system

completely
and
remove
radiator

and

condenser
if
so

equipped

5

Remove

engine
hood
from
hood

hinges
after

scribing
hood
for
rein

stallation

6
Remove

bumper
stay
from
frame

and
remove
front

bumper

7
Remove

radiator

grille

8
With
the

aid
of

Steering
Wheel

Puller

ST27
180001
remove

steering

wheel
from

steering
shaft

9

Remove

steering

gear
arm
from

steering
sector
shaft

using
suitable

puller

10

Remove
screws

securing

steering

shaft
dust

seat
and
insulator
in

posi

tion
2nd

mounting

3rd

mounting

II

Remove

steering
gear

housing

from
frame
and

pull
it
out
into

engine

compartment

12

Disconnect

speedometer
cable
at

transmission

1
3

Disconnect

carbon
canister

hoses

between

canister
to

vacuum

gallery
and
canister

to
intake

manifold

at
canister

14

Disconnect
air

pump
to
air

pump
air

cleaner
hose
at
air
cleaner

15

Disconnect
air
conditioner

hoses

from

compressor
if
so

equipped

16

Disconnect
air
cleaner

duct
from

body

17

Disconnect

Master
Vac
vacuum

hose
at
intake

manifold

18
Remove

snap
ring
and
control

lever

pin
from
transmission

striking

guide
and

remove
control
lever

19
Disconnect
fuel

hoses
at
fuel

strainer

20
Disconnect
fuel

return
hose

and

evaporation
hose
at
connectors

21
Disconnect
brake
and
clutch

tubes

from
each

master

cylinder

22
Remove

all

clips
securing
fuel

tubes
brake

tubes
and
clutch
tube
at

cab

body

BF
4
BF472A

Unit
mm
in

Fig
BF
4
Cab

body
mountings

23
Loosen
hand
brake
control
cable

at
brake
control
lever

Then
discon

nect
cable
from
dash

panel

Note

Place
blocks

against
front
and

rear
wheels
to

prevent
vehicle
from

rolling
off

accidentally

24
Free

accelerator
wire
from

car

buretor

25
Disconnect

heater
hoses
at

engine
side

26
Disconnect
wire
harnesses
from

related

engine
electrical

parts

27
Disconnect

engine
and

chassis

harnesses
at
their
connection

on

right

sidemember
near

rear

engine
mounting

member

28
Remove
six

bolts

securing
body

to
frame

29
With
the
use
of
suitable

ropes

and
an
overhead
hoist
lift
cab

body

straight
up

slowly
and

place
it
on
a

level
surface

Note
In

lifting
up
cab

body
use

care

not
to

dash
it

against

engine
or
rear

body
Cab

body

weighs
approxi

mately
220

kg
485
Ib

Body
Frame

30

For
installation

reverse
above

steps
However
observe

the

following

instructions

i
If
the
cab

body
is

to
be

replaced

note

position
and

location
of
insula

tors
and
washers
used

See

Figure

BF
4

2

Adjust
hand

brake
stroke

pro

perly

3

Air
bleed
brake

and
clutch

system

thorougWy

Cab

body
to
frame

mounting

bolt

torque

1

6
to
2
2

kg
m

12

to
16
ft
Ib
o
i

k

q

1Q
j

b

crru
V

J
8F630

rr

1

4
n
Fig
BF
5

Lifting

up
cab

body

REAR

BODY

1

Bolster

2

Shim
B

3
Bolster

4

Shim
A

5

Frame

6
Rubber
washer

7
Plain
washer

BF664

Fig
BF
6
Rear

body
mountings

REAR
BODY

REMOVAL

AND

INSTALLATION

The
rear

body
is

securely
fastened

to
the
frame
at

eight
places
It

should

be
hoisted
after
the
fuel
tank
is

re

moved
from

the
rear

body

Use

the

following
procedures
as
a

guide
when
removal
or

installation

of

rear

body
is

necessary

I

Apply

parking
brake

2

Disconnect
cables
from

battery

3

Disconnect
rear

combination

lamp
wiring
harness
at
connectors

4
Disconnect
fuel

hoses
from
fuel
tank
Remove
fuel
tank

from
rear

body
5

Remove

eight
rear

body

attaching

bolts

BF665

Fig
BF
7

Rear

body
mountings

BF
5

6
Attach

lifting
ropes
to
hooks
in

rear
body
as
shown
in

Figure
BF
8

and
lift

up
rear
body
slowly
and

carefully

Notes

a
When

lifting
rear

body
make
sure

that
it
is
in
a

good
balanced
cond

ition

b
While

lifting
use
care
not
to
allow

rear

body
to
hit

against
cab

body
or

any
adjacent
parts

c
The
rear

body
weighs

approxillll
te

Iy
130

kg
286
Ib

BF0288

Fig
BF

8

Lifting
up
rear

body

7
To
install
rear
body
reverse
the

order
of
removal

Carefully
observe

the
following
instructions

Make
sure
that

spacers
and
shims

used
with
bolts
are

properly
placed

in
their

original
positions
Refer
to

Figure
BF
6
for

the
location
of
these

parts

The
rear

body
to
frame

attaching

bolts
should
be

torqued
to
3
3
to
4
2

kg
m
24
to
30
ft
Ib
Body
Frame

REAR
GATE

00

REMOVAL
AND
INSTAllATION

1

W

@

BF661

I

Open
rear

gate

2

Remove
rear

gate
chain
from
ear

gate

3
Remove

rear

gate
hinge
attaching

bolts
and

take
out
rear

gate
and
rear

gate
hinge
shims

4

To
install
rear

gate
reverse
the

order
of
removal

ALIGNMENT

The
rear

gate
should

be

adjusted
so

that
there
exists

an

equal
clearance

between

body
and
the

periphery
of

rear

gate
There
should
be
no

stepped

portion
at

any
points

I

To

adjust
the

height
of

rear

gate

add
or
remove
shims
at
rear

gate
hinge

Two
sizes
of
shim
are
available
in

thickness
1
6
mm
0
0630
in
and
0
8

rom
0
0315
in

rr

r

f

r

@

C
L

i

BF
6
1
Rear

gate
chain

2
Rear
gate
chain

bolt

3
Rear

body

4
Shim

S
Hook
handle

6
Reargate

Fig
BF
9
Rear
gate

2
To

adjust
rear

gate
in

the
left
and

right
directions
loosen
rear

gate
hinge

attaching
bolts
and

move
rear

gate
as

required

3
To

adjust
rear

gate
hook
loosen

two

attaching
bolts
and
move
rear

gate

hook

up
down
or
left

right
in
elon

gated
holes
as

required

GUARD
FRAME

Optional

REMOVAL
AND

INSTAUATION

The

guard
frame
is
furnished
as
an

optional
equipment

I

Remove
nine

guard
frame
at

taching
bolts
and

detach

guard
frame

2

To
install

optional
guard
frame

reverse
the
order
of
removal

s

SF673

Fig
BF

lO
Guard

frame

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