1977 DATSUN PICK-UP air condition

DESCRIPTION

INSPECTION

CLEANING
AND
REGAP

DESCRIPTION

The

spark
plugs
are
of
the

conven

tional

type
having
14
mm
0

551
in

threads
The

spark
plug
gaps
are
1
0
to

1
1
mm
0
039
to
0
043
in
on
Cali

fomia
models
and
0
8

to
0
9
mm

0
031
to

0
035
in
on
non
California

models
The

inspection
and

cleaning

should
be
made
every
suitable
mainte

nance

period
If
necessary
replace

Note
All

spark

plugs
installed
on
an

engine
must
be

of
the
same
brand

and
the

same
number
of
heat

range

INSPECTION

L
Remove

spark
plug
wire

by

pulling
on

boot
not
on
wire
itself

2
Remove

spark
plugs

3

Check
electrodes
and
inner

and

outer

porcelains
of

plugs
noting
the

type
of

deposits
and
the

degree
of

electrode
erosion

Refer
to

Figure

EE
96

Normal
Brown
to

grayish
tan
de

posits
and

slight
electrode
wear

indicate
correct

spark
plug
heat

range

Carbon
fouled

Dry
fluffy
carbon

deposits
on
the
insulator
and

electrode
are

usually
caused

by

slow
speed
driving
in

city
weak

ignition
too
rich
fuel
mixture

dirty
air
cleaner
etc

It
is

advisable
to

replace
with

plugs

having
hotter
heat

range

Oil
fouled
Wet
black

deposits
indi

cate
excessive
oil
entrance
into

combustion
chamber

through
worn

rings
and

pistons
or
excessive
clear

ance
between
valve

guides
and

stems
If
the
same
condition
re

mains
after

repair
use
a
hotter

plug
Engine
Electrical

System

SPARK
PLUG

CONTENTS

EE
4B

EE
47

EE
47

EE
47
SERVICE
DATA
AND
SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS
EE
4B

Overheating
White
or

light

gray
in

sulator
with
black
or

gray
brown

spots
and
bluish
burnt
electrodes

indicate

engine
overheating
More

over
the

appearance
results
from

incorrect

ignition
timing
loose

Normal

Overheating

EE079

4
After
cleaning
dress
electrodes

with
a
smaU
fine
file
to
flatten
the

surfaces
of
both
center
and
side

electwdes
in

parallel
Set

spark
plug

gap
to

specification

5
InstaU

spark
plugs
and

torque

each

plug
to
L5

to
2
0

kg
m

11
to
14

ft
Ib

6
Connect

spark

plug
wires

CLEANING

AND
REGAP

Clean

spark
plugs
in

a
sand
blast

type
cleaner
Avoid
excessive

blasting

Clean
and
remove
carbon
or
oxide

deposits
but
do
not

wear
away

porcelain
If

deposits
are
too
stubborn

EE
47
spark
plugs
low
fuel

pump
pres

sure

wrong
selection
of
fuel
a

hotter

plug
etc

It
is
advisable
to

replace
with

plugs

having
colder
heat

range

Ir

i

Carbon
fould

Worn

Fig
EE
96

Spark
plug

discard

plugs

After

cleaning
spark
plugs
renew

firing
surface
of
electrodes
with
me

mentioned
aboVe
Then

gap
spark

plugs
to

specified
values
with
a
round

wire
feeler

gauge
All

spark
plugs
new

or
used
should
have
the

gap
checked

and
reset

by
bending
ground
electrode

EEOBO

Fig
EE
97

Setting
park
plug
gap

Engine
Electrical

System

SERVICE
DATA
AND
SPECIFICATIONS

California

models
Non

California

models

For
Canada

except
for

Canada

BP6ES
ll
BP6ES

BPR6ES
Standard

L45PW
ll
L45PW

BP4E
ll
BP5ES
ll
BP4E

BP5ES
BPR4ES

Type
Hot

type

L46PW
ll

L47PW
ll

L46PW
L47PW
BPR5ES

Cold

type
BP7ES
ll

BP7ES

BPR7ES

LMPW
ll
LMPW

1
0
to
l
l
0
8
to
0

9
0
8
to
0
9

Plug

gap
mm

in

0

039
to
0
043
0

031
to
0
D35
0
031
to
0

035

Tightening
torque
kg
m
ft
Ib

I
1
5
to
2

0
11
to
14

TROUBLE

DIAGNOSES

AND

CORRECTIONS

When

engine
does
not
start

If
there
is

no

problem
in

fuel

system
ignition
system
should
be

checked
This
can
be

easily
done

by

detaching
a

high
tension
wire

from
spark

plug
starting

engine
and

ob

serving
condition
of

spark
that

occurs

between

high
tension

wire
and

spark

plug
terminal

After

checking
this

repair
as

necessary
Note
On
California
models

disc
on

nect
anti

dieseling
solenoid

valve

connector
to

cut
off

supply
of
fuel

to

engine
and

then
observe

the

condition

of

spaIks
while
starter

motor
is

in

operation

Condition
Location

Probable

cause
Corrective
action

No

spark
at
all

Distributor

Faulty
insulation
of
condenser

Non
Cali

Replace

fomia

models

Breakage
of
lead
wire
on
low
tension
side

Repair

Poor
insulation
of

cap
and
rotor
head

Replace

Seized

points
Non
California

models

Repair

Open
pick
up
coil
California
models

Replace

Air

gap
wider
than

specification
Cali

Adjust

fornia

models

Ignition
coil

Wire

breakage
or
short
circuit

of
coil

Replace
with
new
one

High
tension
wire

Wire

coming
off

Repair

Faulty
insulation

Replace

Transistor

ignition
Faulty
transistor

ignition
unit

Replace

unit

California

models

EE
4B

Condition

Spark
length

I

to
2
rnm
0
039

to
0
079
in
Of

irregular

More

than
6
rnm

0
236
in
Engine
Electrical

System

Location
Probable
cause

Distributor
Point

gap
too
wide
Non
California
mo

dels

Oil

on
point
Non
California
models

Burned

points
Non

California
models

Spark

plugs
Spark

plug
gap
too
wide

Too
much
carbon

Broken
neck
of
insulator

Expiration
of

plug
life

Air

gap
too
wide
California
models

Distributor

Transistor

ignition

unit
California

models
Faulty
transistor
ignition
unit
Corrective
action

Correct

Clean

Replace

Correct
or

replace

Clean
or
replace

Replace

Replace

Correct

Replace

2

Engine
rotates
but
does
not
run

smoothly

This

may
be

caused

by
the

ignition
system
or
other

engine
condi
Hons
not

related
to

ignition
Therefore
first
a
complete
inspection
of

ignition
system

should
be

carried
out

Condition

Engine
misses
Location
Probable

cause

Distributor
Dirty
point
Non
California
models

Foreign
mattef
on

pick
up
coil
California

models

Improper
point

gap
Non
California
mo

dels

Impropef
air

gap
California
models

Leak
of

electricity
at

cap
and
rotor
head

Damaged
insulation
of
condenser

Non

California
models

Malfunctioning
contact
arm
Non
Cali

fornia
models

Faulty
contact
arm

spring
Non
Cali

fornia
models

Breakage
of
lead
wire
Non
California

models

Breakage
of

pick
up
coil
lead
wire
Cali

fornia
models

Worn

or
shaky
breaker

plate

Worn
or
shaky
distributor

driving
shaft

Layer
short
circuit
or
inferior

quality

coil
Ignition
coil

High
tension
wire
Deterioration
of
insulation
with
con

sequent
leak
of

electricity

EE
49
Corrective
ac
ion

Clean

Clean

Correct

Correct

Repair
or

replace

Replace

Oil
shaft

Replace

Replace

Replace

Replace
assembly

Replace
assembly

Replace
with

good
one

Replace

Condition

Engine
causes

knocking
very

often

Engine
does

not

deliver

enough

power
Location

Spark

plugs

Transistor

ignition

unit

California

models

Distributor

Spark

plugs

Distributor

Spark

plugs
Engine
Electrical

System

Probable
cause

Fouled

Leak
of

electricity
at

upper
porcelain

insulator

Faulty
transistor

ignition
unit

Improper
ignition

timing
too

advanced

Coming
off

or

breakage
of

governor

spring

Worn

pin
or
hole
of

governor

Burnt

too
much

Improper
ignition
timing
too

retarded

Improper
functioning
governor

Point

gap
too

narrow

Non
California

models

Foreign
particles
stuck
in

air

gap
Cali

fornia
models

Fouled

EE

50
Corrective
action

Clean

Repair
or

replace

Replace

Correct

Correct

or

replace

Replace

Replace

Correct

Replace
assembly

Correct

Oean

Oean

Engine
Removal

Installation

ENGINE

REMOVAL
AND
INSTAllATION

REMOVAL

INSTALLATION

ENGINE
MOUNTING
INSULATORS

REMOVAL

It
is
much
easier

to
remove

engine

and
transmission

as
a

single
unit

than

to

remove
them

separately
After
re

moval

engine
can
be

separated
from

transntission

assembly

Notes

a
Be

sure
to
hoist

engine
and

jack
up

transmission
in
a
safe
manner

b
Use

fender
cove
to

protect
vehicle

body

1
Remove

battery

2
Scribe

hood

hinge
location
for

proper
reinstallation
and
remove

hood

Note
Have

an
assistant

help
you
so
as

to

prevent
damage
to

body

3
Drain

radiator
coolant

4

Disconnect

upper
and
lower

radiator
hoses

from

engine

5

Remove

two
oil
cooler
hoses

from
lower

end
of
radiator
Auto

ma
tic
transmission

models

only

6
Remove

radiator

shroud

7

Remove
four

bolts

securing
radia

tor
and

detach
radiator

Note

Always
tighten
securing
bolt
at

upper
right
hand
side

together
with

body
harness

terminal

8

Remove
carburetor
air

cleaner
as

follows

Remove
fresh
air

duct

Remove

hot
air

duct

Loosen
air

cleaner
band

bolt
and
air

cleaner

supporting
bolts

Disconnect
air

cleaner
ta
air

pump

hose

Disconnect
air
cleaner

to
rocker

cover
hose
at

rocker

cover

Disconnect
air

cleaner

to
air

control

valve
hose
California

models

only
CONTENTS

ER
2

ER
3

ER
3
FRONT

INSULATOR

REAR

INSULATOR

TIGHTENING

TORQUE
ER
4

ER
4

ER
4

Disconnect
air

deaner
to

A
B
valve

hose

Disconnect
air

cleaner
ta

vacuum

hoses

Note

Protect
carburetor
from
dust

and

foreign
matter

by

placing
cover

over
air
inlet

opening

9

Disconnect

fuel

pump
to
fuel

fdter
hose
and
return

hose

10

Disconnect
carbon
canister

hose

on

engine
side

II

Disconnect
air

pump
air

C1eaner

to
al

p

p
hose

12

Disconnect

following
cables

wires

and
hoses

Engine
ground
cable

Accelerator
wire
at

carburetor

High
tension

cable
between

ignition

coil

and
distributor

Wire

to
distributor
at

body
ter

minal

Wire
to

oil

pressure
switch

Wires
to
thermal

transmitter

Wires
to

B
C

p
D
cut
solenoid

Non
California

models

only

auto

choke
heater
and

anti

dieseling

solenoid

Wires

to
alternator

Wires
to
starter

motor

Heater
inlet
and
outlet

hoses
if
so

equipped

Vacuum
hose
of

Master
Vac
at
in

taJce
manifold

Wires
for

back

up

lamp
switch

Cable
to

speedometer

13

Remove
transmission

control

linkage
from

transmission

Manual

transmission
models

I

Detach
rubber
boot

2
Remove
E

ring
and
control

lever

pin
from

transmission

striking
rod

guide
and

remove
control
lever

ER
2
Fig
ER
l

Automatic

transmission
models

I

Disconnect

selector

range
lever

from
manual
shaft

2
Disconnect
wires

at
inhibitor

switch
and

down
shift
solenoid

14
Air

conditioner

equipped

models
need

following

procedures

1
After

removing
flexible

hose

support
remove
four

comi
ressor

se

curing
bolts

Then
move
the

com

pressor
to

battery

support

2

Remove

vacuum
hoses
of

F
LC
D
solenoid
valve

3
Remove
F
LC

D
actuator

15
Remove
two
bolts

securing

clutch

operating
cylinder
Then
dis

connect

operating
cylinder
and

flexi

ble
tube

as
an

assembly

Manual

transmission

models

only

16
Disconnect
front

exhaust
tube

from
exhaust
manifold

17
Remove

propeller
shaft

I

Disconnect

propeller
shaft

center

bearing
bracket
from

third

crossmember

2

Disconnect

propeller
shaft
from

companion
flange
of
differential

carrier

3
Remove

propeller
shaft
from

transmission

and

plug

up
rear
end
of

extension

housing
of

transmission
to

prevent
oil

leakage

18
Attach
a
suitable
wire

or
chain

to
lift

engine

19
Remove

front

engine
mounting

bolts

at

engine
mounting
front

sup

port

CLUTCH

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Probable
cause
and

testing

Clutch

slips
Corrective
action

Slipping
of
the

clutch

may
be

noticeable
when

any
of
the

following
symptoms
is

encountered

during
operation

I
Vehicle
will

not

respond
to

engine

speed
during
acceleration

2
Insufficient
vehicle

speed

3
Lack
of

power
during
uphill
driving

Some
of
the

above
conditions
are
also

experienced
when

engine

problem
is

oc

urring
First

de
tennine
whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear
and
or

overheating
will
occur
on
clutch

facing
until
it
is

no

longer
serviceable

TO
TEST
FOR
SLIPPING
CLlJfCH

proceed
as
follows

During
upgrade
travelling
run

engine
at

about
40
to
50
km

h
25
to
31

MPH
with

gear
shift

lever
in

3rd

speed
position
shift
into

highest
gear
and
at
the
same
time

rev

up
engine
If
clutch

is

slipping
vehicle
will
not

readily

respond
to

depression
of
accelerator

pedal

Clutch

facing
worn

excessively

Oil
or

grease
on
clutch

facing

W

r
d
clut
h
cov
r

pressure
plat
Replace

Replace

tpa
o
e
lace

Dragging
clutch
is

particularly
noticeable
when

shifting
gears
especially
into

low

gear

TO
TEST
FOR
DRAGGING
CLlJfCH

proceed
as
follows

I
Start

engine
Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine
speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is

heard
when

shifting
from
Neutral
into

Reverse
Clutch

drags

2

Stop
engine
and
shift

gear
Conduct
this
test
at
each

gear
position

3
Gears

are
smoothly
shifted
in

step
2
but

drag
when

shifting
to
1st

speed
position
at

idling

a
If

dragging
is
encountered
at
the
end
of

shifting
check
condition
of

synchro

mechanism
in
transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4
Push

change
lever
toward
Reverse
side

depress
pedal
to
check
for
free
travel

a

If

pedal
can
be

depressed
further
check
clutch
condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5
below

5
Check
clutch
control

pedal
height
pedal
free
travel
withdrawal
lever

play
etc

If
no
abnonnal

condition
exists
and
if

pedal
cannot
be

depressed
further
check
clutch

condition

Clutch
disc
runout
or

warped

Wear

or
rust

on
hub

splines
in
clutch
disc

Diaphragm
spring
toe

height
out
of
ad

justment
or
toe

tip
worn

Worn
or

improperly
installed

parts

CL10
Repair
or

replace

Clean
and
lubricate
with

grease
or

replace

Adjust
or

replace

Repair
or

replace

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
CLUTCH

Probable
cause
and

testing
Corrective
action

Clutch

chattering
is

usually
noticeable
when
vchicle
is

just
rolled
off
with
clutch

partially

engaged

Weak
or
broken
clutch
disc
torsion

spring

Oil
or

grease
on
clutch
facing

Clutch

facing
out
of

proper
contact
or

clutch
disc

runout

Loose
rivets

Warped

pressure
plate
or
clutch
cover

surface

Unevenness
of

diaphragm
spring
toe

height

Loose

engine
mounting
or
deteriorated

rubber

A
noise
is
heard
after
clutch
is

disengaged

Damaged
release

bearing

A
noise
is

heard
when
clutch
is

disengaged

Insufficient

grease
on
the

sliding
surface

of

bearing
sleeve

Clutch
cover
and

bearing
are
not
installed

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or
replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
vehicle
is

suddei11y
staited
off
with
clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
vehicle
will
not
start
off

smoothly
from
a

standing
start
or

clutch
is

engaged
before
clutch

pedal
is

fully

depressed

Oil
or

grease
on
clutch

facing

Clutch

facing
worn
or
loose
rivets

Wear
or
rust
on

splines
in

drive
shaft
and

clu
tch
disc

Warped
flywheel
or

pressure
plate

Loose
mountings
for

engine
or

power

train
units

CLll
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be
careful

not
to

damage
any

parts

with

scraper

b

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
pecting
ball

bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND

SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4
Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0
0126
to
0
0154
in

2nd

gear

0
12
to

0
19
mm

0
0047

to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to
0

0146
in

TM374

Fig
MT

29

Measuring
end

play