1977 DATSUN PICK-UP alternator belt

Engine
Tune

up

BASIC
MECHANICAL
SYSTEM

ADJUSTING
INTAKE
AND
EXHAUST

VALVE
CLEARANCE

CHECKING
AND

ADJUSTING
DRIVE

BELT

RETIGHTENING
CYLINDER
HEAD
BOLTS

MANIFOLD
NUTS
AND
CARBURETOR

SECURING
NUTS

CHECKING
ENGINE
OIL

REPLACING
OIL
FILTER

CHANGING
ENGINE

COOLANT

ADJUSTING
INTAKE

AND

EXHAUST

VALVE
CLEARANCE

Note
After

tightening
cylinder
head

bolts

adjust
intake

and
exhaust

valve
clearances

Valve
clearance

adjustment
is

impossible
when
the

engine
is
in

oper

ation

1
Loosen

pivot
locking
nu
t
and

turn

pivot
screw
until
the

specified

clearance
is
obtained
while
cold

Using
service

tool

tighten
pivot

locking
nut

securely
after

adjustment

and
recheck
the
clearance

2
Warm

up
engine
for
at
least

several
minutes

and

stop
it
Measure

valve
clearance
while
hot
If
out
of

specifications
adjust

Unit
mm
in

Intake
0
20

0
008

Cold

Exhaust
0
25
0

010

Intake
0
25

OmO

Wann

I
Exhaust

0
30
0

012

STl
064000

I

ET009

Fig
ET

5

Adjusting
valve

clearance
CONTENTS

ET
7
PERMANENT
ANTI
FREEZE

COOLANT

CHECKING
COOLING
SYSTEM
HOSES

AND
CONNECTIONS

INSPECTION
OF

RADIATOR
CAP

COOLING
SYSTEM
PRESSURE
TEST

CHECKING
VACUUM

FITTINGS
HOSES

AND
CONNECTIONS

CHECKING
ENGINE
COMPRESSION

COMPRESSION
PRESSURE
TEST

TEST
RESULT
ET
7

ET7

ET
B

ET
B

ET
B

CHECKING
AND

ADJUSTING

DRIVE

BELT
ET

B

ET

B

ET
B

ET
B

ET

B

ET
9

ET
9

ET
9

2

Normal
drive
belt
deflection
is

8

to
12
mm

0
315
to
0
472

in
when

moderate
thumb

pressure
is

applied

midway
between

pulleys

1
Check
for

cracks
or

damage
Re

place
if

necessary

Compressor
pulley

8
to
12
mm
0
315
to
0
472
in

Idler

pulley

Water

pump
pulley

8
to
12
mm

0
315
to
0
472
in

Air

pump
pulley

Alternator

AC456

Fig
ET
6
Driue
belt
tension

RETIGHTENING

CYLINDER
HEAD

BOLTS
MANIFOLD

NUTS
AND

CARBURETOR

SECURING

NUTS
Tightening
torque

Cylinder
head
bolts

1st

turn

4

0

kg
m
29
ft
Ib

2nd
turn

6
0

kg
m

43
ft
Ib

3rd
turn

6
5
to

8
5

kg
m

47

to
61
ft
lb

Refer
to
the

following
tightening

torque
specifications

ET
7

r

I

I

PRELIMINARY
CLEANING
AND

INSPECTION

DISASSEMBL
Y

PRELIMINARY

CLEANING
AND

INSt

ECTION

Before

disassembling

engine
note

the

following

I
Fuel

oil
or
water

may
leak

past

cylinder
head
and
block
Prior
to

disassembling
check

cylinder
head

1
1ltermal
vacuum
valve

2
Check

valve

3
Altitude

compensator

in

air
cleaner

4
Air

gallery
pipe

S

Auto
choke

6
Automatic

temperature

control
air

cleaner

7
Anti
8ackfire
valve
A
B

valve

8
Boost
Controlled

Deceleration

Device
Bee
D
D

9
P
c
v

valve

to
Air
relief
valve

11
E

G
R

control
valve

12
B
C
D
D

control
valve
and

solenoid
valve

13

Emergency
air

relief
valve

14
Air

pump
air
cleaner

IS
Carbon
canister

16
Air
control

valve

11
Air

pump
Engine
Mechanical

ENGINE

DISASSEMBLY

CONTENTS

EM
4

EM
4
PISTONS
AND
CONNECTING
RODS

CYLINDER

HE
AD
EM
7

EM
7

front
chain

cover
oil

pan
and
oil

filter

gaskets
lInd
crankshaft
and
water

pump
seals
for

signs
of

leakage
past

their

gasketed
surfaces

2
Check
carburetor
and

fuel

pump

for
condition
fuel
hoses
for

deteriora

tion
cracks

or

leakage
of
fuel

past

their

jointed
or
connected

surfaces

Fig
EM

0
Emiuion
control
devic
s

California
mod
18
E
T366

3
Remove

carburetor
air

cleaner

Remove
fresh

air
duct

Disconnect
hot
air
duct
from

air

cleaner

Disconnect
air

cleaner
to
air

pump

hose
at
air

cleaner

Disconnect
air

cleanef
to
rocker

cover

hose
at
rocker
cover

Disconnect

air
cIeaner

to
air

con

trol

valve
hose
at
air

cleaner
Cali

fornia

models

only
Disconnect
air

cleaner
to
A

B
valve

hose
at
air

cleaner

Disconnect
air

cleaner
to

related

part
vacuum
hoses
at
air

cleaner

Loosen
air

cleaner
band
bolt
and

remove
carburetor
air

cleaner
as

sembly
from

carburetor

4

Plug
up
carburetor
air

horn

to

prevent
entry
of

foreign
matter

5

Remove

alternator
drive

belt

alternator
and

alternator
bracket

EM
4
6

Remove
air

pump
drive

belt
cool

er

compressor
and
idler

pulley
if

so

equipped

7
Remove
starter
motor
from
trans

mission

8

Visually

inspect
cylinder
head

cylinder
block
rocker
C
Ner

front

chain
cover
oil

pan
and
all
other
outer

parts
for
oil
water
and
fuel
leaks

breakage
or

missing
parts
such

as
bolts

and
nuts

9

Check

piping
and
electrical
cir

cuits
for
deterioration

breakage
fit

tings
discontinuity
or
insulation

DISASSEMBLY

To

remove

engine
from
vehicle

refer
to

the
instructions
under
the

Engine
Removal

and
Installation

ER
section

I

Remove
transmission
from

en

gine

2
Remove

clutch

assembly
from

flywheeL

3

Thoroughly
drain

engine
oil
and

coolan
t

by

removing
drain

plugs

Store

engine
oil
and

coolant
if

they

are

to
be

used

again

4
Place

engine
assembly
on

engine

stand

I

Remove

cooling
fan

2

Remove

right
engine

mounting

bracket

3

Remove
oil
filter
with
Oil

Filter

Wrench
STI9320000

4

Remove
oil

pressure
swi

tch

5

Install

engine
attachment
to

cylinder
block

utilizing
bolt

holes
in

alternator

bracket
and

water
drain

hole

6
Set

engine
on
stand

Engine
Attachment

ST05260001

Engine
Stand

ST050I

SOOO

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

The

pump
shaft
is

supported
by
a

double
row

of
ball

bearings

press
fit
in

an
aluminum
die
cast

pump
body
The

bearings
are

permanently
lubricated

and
sealed

to

prevent
loss
of
lubricant

and

entry
of

dirt

The

pump
is

provided
with
an

impeller
which
turns
on
a
steel

shaft

The

steel
shaft
rotates

together
with

the

torque

coupling
wheeL
The
volute

chamber
is
built
in
the

engine
front

cover

assembly

The
inlet
of
the

pump
is

connected

to

the
radiator
s
lower
tank

by
a
hose

i

o

CQ047

Fig
CO
2
Water

pump
and

engine

front
cover

REMOVAL
AND

INSTALLATION

Removal

in
to
a
clean

con

assembly

I

CQ048

Fig
CO
3
Removing
water

pump

Installation

1
Be

sure
to
clean
the

gasket
sur

faces
in
contact
with

pump
and
front

cover

Always
use
new

gaskets
when

installing

pump
assembly
Be
sure
to

tighten
bolts
Cooling
System

Tightening

torque

0
4
to
0
5

kg
m

3
0
to
3
6
ft
lb

2

Fill

cooling
system
and
check
for

leaks
at

pump

3

Install
fan
blade
and

tighten
at

taching
bolts

securely
Install
belt
and

adjust
for

specified
tension

4

Operate
the

engine
at
fast

idling

and
recheck
for
leaks

5
Install
fan
shrouds

Note
Ensure
that
clearance
between

shroud
and
Can
is

even
at

any

place

DISASSEMBLY

Water

pump
is

made
of
aluminum

and
its

bearing
outer
race
is
of
a

press

fit

type
For
this

reason
water

pump

should
not
be
disassembled

INSPECTION
AND

ADJUSTMENT

Inspection

Inspect
pump
assembly
for
the

fol

lowing
conditions
and

replace
if
nee

essary

1

Badly
rusted
or
corroded

body
as

sembly
and

vane

2

Excessive
end

play
or

roughness
of

bearings
in

operation

3
Reduced

cooling
efficiency
due
to

deteriorated
silicone
oil

4
Oil

leakage
in

torque
coupling
Adjustment

Fan

belt
should
be

properly
ad

justed
at
all
times
A

tight
belt
causes

wear
of

alternator
and
water

pump

bearings
A
loose
belt

brings
about

improper
cooling
fan
water

pump

and
alternator

operation

Check
the
belt
slack
between
alter

nator
and
fan

pulley
by
force
of
10

kg

22
lb

Slackness
of
fan
belt

8
to
12

mm

0
31
to
0
47
in

If

adjustment
is

necessary
loosen

bolt

retaining
alternator

adjusting
bar

to
alternator
Move

alternator
toward

or

away
from

engine
until
the
correct

tension
is
obtained

TORQUE
COUPLING

Except
air

conditioner

equipped

models

The

torque
coupling
keeps
the
fan

speed
at
2
500

rpm
rated
or
below

to

conserve
horsepower
at

high
engine

speed
It
also

helps
reduce
fan
noise
to

a
minimum

during
high
speed
opera

tion

This
unit
is
filled
with
a

special

silicone
oil
used
as
a

fluid

coupling

which
controls
the

fan

speed
Silicone

oil

can
not
be

replenished

1

Torque
coupling
wheel

2

Torque
coupling
cover

3

Torque
coupling
bearing

4
Pulley

5
Water

pump

C0060

Fig
CO
4
Sectional
view
of

torque
coupling
and
water

pump

00
3

REMOVAL

1
Disconnect

negative
battery
ter

minaL

2

Disconnect
two
lead
wires

and

connector
from
alternator

3
loosen

adjusting
bolt

4

Remove
alternator
drive
belt

5
Remove

parts
associated
with

alternator
from

engine

6

Remove
alternator
from

vehicle

DISASSEMBLY

1
Remove

pulley
nut
and

pulley

assembly

11

C

@@@
EE033

Fig
EE
27

Removing
pulley
ond

fan

2
Remove
brush
holder

fIxing

screws
and
remove
brush
holder

cover
Pull
brush
holder
fOIWard

and

remove
brushes

together
with
brush

holder

Note
Do
not

disconnect
N
tenninaJ

from
stator

coil
lead
wire

EE346

1
N
terminal

2
Brush

holder

3
Brush
holder

co
r

Fig
EE
28

Remouing
brush
Engine
Electrical

System

3
Remove

through
bolts

Separate

front
cover
with

rotor
from
rear
cover

with
stator

by
lightly

tapping
front

bracket
with
a

wooden
mallet

J

J

4

C

EE035

Fig
EE
29

Separating
front
cover

with

rotor

from
rear

cover

4
Remove
three
set

screws
from

bearing
retainer

and

separate
rotor

from
front
cover

DO
Q
EE036

Fig
EE
3D

Removing
rotor

5

Pull

rear

bearing
out
from
rotor

assembly
with

a

press
or

bearing

puller

L

I
EE037

Fig
EE
3I

Pulling
out

of
roar

bearing

EE
16
6
Remove
diode

cover

fIXing
screw

and

remove
diode

cover
Disconnect

three
stator

coil
lead
wires
from

diode

terminal

with
a

soldering
iron

7
Remove

A
tenninaJ
nut
and
diode

installation

nut
and

remove

diode

assembly

CD

AJ

f
e

ecA

O

1
Diode

assembly

o

2
Diode
cover
o

EE039

Fig
EE
32

Removing
diode

088embly

Note
Use
care

in

assembly
to

on
it
handling
diode

an

undue

st

INSPECTION
AND

REPAIR

Remove

alternator
from
car

and

connect
a
circuit
tester
between
F

tenninal
and
E
terminal

When
the
resistance

is

approxi

mately
5il
the
condition
of

brush
and

fIeld
coil
is

satisfactory
When
no

continuity
exists
in
brush
or
fIeld

coil
or

when
resistance
differs

significantly
between
those

parts
dis

assemble
and

inspect

A

o
E

O

1

ld

Q

EE040

Fig
EE
33

Inspecting
alternator

ADJUSTMENT

VOLTAGE
REGULATOR

When
regulating
voltage
as
meas

ured
above
deviates

from
rated
value

adjust
regulator
in

accordance
with
the

following
instructions

I

Inspect
contact
surface
and
if

rough
lightly
polish
with
fine

emery

paper
1
500
or
600

2
Measure
each

gap
and

adjust
if

necessary
Adjust
core

gap
and

point

gap
in
that
order
No

adjustment
is

required
for

yoke

gap

3

Adjusting
core

gap

Loosen
screw
4
mm
0
157
in

diameter
which
is
used
to
secure

contact
set
on

yoke
and
move
contact

upward
or
downward

properly
See

Figure
EE
49

Core

gap

0
6

to
1
0
mm

0
024
to
0
039
in

EE398

I
Contact

set

2
ThicknesJ
gauge

3
4

mm
0
157
in
dia
screw

4

Crosshead
Jcrewdriver

Fig
EE
49

AdjUJJting
core
gap
Engine
Electrical

System

4

Adjusting

point
gap

Loosen
screw
3

mm
O
lIS
in

diameter
used
to
secure

upper
con

tact
and
move

upper
contact

upward

or
downward
as

necessary
See

Figure

EE
50

Point

gap

035

to
0
45
mm

0
014

to
O
D1S
in

EE399

I
Thicknes

gauge

2
3
mm

0
118
in
dia

screw

3
Cro
Sshelld

screwdriver

4

Upper
contact

Fig
EE
50
Adjusting

point
gap

5

Adjusting
voltage

Adjust
regulating
voltage
as

follows

Loosen
lock
nut

securing

adjusting

screw
Turn
this
screw
clockwise
to

increase
or
counterclockwise
to

decrease

regulating
voltage
See

Figure
EE
5

J
CD

EE400

I

Wrench

2

Crosshead
screwdriver

3

Adjusting
screw

4
l
ock

nut

Fig
EE
51

AdjUJJting
rel
Ulating
voltage

CHARGE
RELAY

Nonna

relay
operating
voltage
is
S

to
IOV
as
measured
at
alternator
A

tenninal

Relay
itself
however

oper

ates
at
4
to
5V

Use
a
DC
voltmeter
and
set

up
a

circuit

as
shown
in

Figure
EE
52

Adjust
charge

relay
in

the
same

manner
as
that
for

voltage
regulator

L

Connect

positive
tenninal
of
voltmeter
to

regulator
lead
connector
N
tenninal
with

negative
terminal

grounded

2
Start

engine
and

keep
it

idle

3
Take
voltmeter

reading

o
Volt

I
Check
for

continuity
be

tween
terminals
of
re

gulator
and
alternator

2
Alternator
circuit

inopera

tive
if

continuity
exists
Below
5
2
Volts

Charge
warning
lamp
on

I
Check
fan
belt
tension

2
If
correct
remove

regulator

and

adjust
as

necessary
Over
5

2
Volts

Charge
warning
lamp
on

Charge
relay
coil
or
contact

points
out
of
order

Replace
regulator

Over
5
2
Volts

Charge
warning
lamp
off

Charge
relay
assembly
is
in

good
condition

EE
23

Engine
Electrical

System

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Including
alternator

Condition
Probable
cause

No

output
Sticking
brushes

Dirty
brushes
and

slip
rings

Loose
connections

or
broken
leads

Open
sta
tor

winding

Open
rotor

winding

Open
diodes

Shorted
rotor

Shorted
stator

Grounded
A

terminal

Broken

fan
belt

Excessive

output
Broken
neutral

wire
COIOf
of
wire
is

yellow

Voltage
fegulator
breakdown

Poor

grounding
of
alternator
and

voltage

regulator
En

terminal

Broken

ground
wire

color
of
wire
is
black

Low

output
Loose

or
worn
fan
belt

Sticking
brushes

Low

brush

spring
tension

Voltage
regulator
breakdown

Dirty

slip
rings

Partial
short

ground
or

open
in

stator

winding

Partially
shorted

or

grounded
rotor

winding

Open
or
damaged
diode

Noisy
alternator
Loose

mounting

Loose
drive

pulley

Broken
ball

bearing

Improperly
seated
brushes

EE

25
Corrective
action

Correct
or

replace
brushes
and
brush

springs

Clean

Retighten
or
soldef

connections

Replace
leads
if

necessary

Repair
Of

replace
stator

Replace
rotor

Replace

Replace
rotor

Repair
or

replace

Replace
insulator

Replace

Replace

Check

regulator
operation
and

repair
or

replace
as

required

Retighten
terminal
connection

Replace

Retighten
or

replace

Correct
or

replace
brushes
and

springs
if

necessary

Replace
brush

springs

Check

regulator
OpefatiOn
and

repair
or

replace
as

required

Clean

Replace
stator

Replace
rotor

Replace
diode

Retighten
bolts

Retighten

Replace

Seat

correctly