1977 DATSUN PICK-UP oil pressure

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

ManifolJ
nuts

I

2
to
1
6

kg
m

8
7
to
I

6
ft
lb

Carburelor
nuls

0
5
to
1
0

kg
m

3
6
to
7
2
fl
tb

Fig
ET
7
Tightening
s

quence

CHECKING
ENGINE

OIL

Check
if
oil
is
diluled
with
water

or

gasoline
Drain
and
refill
oil
if

necessary

Notes

a
A

milky
oil
indicates
the

presence

of

cooling
water
Isolate
the
cause

and
take
corrective
measure

b
An
oil
with

extremely
low

viscosity

indicates
dilution
with

gasoline

2
Check
oil
level
If
below
the

specified
level

raise
it

up
10
the
H

level

Engine
oil

capacity

including
oil

filter

Maximum
H
leven

4
3
liters

4

MUS
qt
3
Y

Imp
qt

Minimum
L

level

3
3
liters

3
f
US

qt
2
U

Imp
ql

REPLACING
OIL

FILTER

The
oil
mter
is

a

cartridge
type
and

can
be
removed

using
Oil
Filter

Wrench
STI9320000

I
Check
for
oil
leaks

past
gasketed

flange
If

leakage
is

found

retighten

just
enough
to

stop
leakage
If

retight

ening
is

no

longer
effective

replace

mter
as
an

assembly
Engine
Tune

up

2
When

installing
oil

filter

tighlen

by
hand

Note
Do
not

overtighten
oil

flIt

lest

leakage
should
occur

CHANGING
ENGINE

COOLANT

PERMANENT
ANTI
FREEZE

COOLANT

Permanent
anti

freeze
coolant
is
an

ethylene
glycol
base

producl
conlain

ing
chemical
inhibilors
10

protect
the

cooling
system
against
corrosion

The
anti
freeze
does
not
contain

any

glycerine
ethyl
or
methyl
alcohol

It
will
not

evaporate
or
boil

away
and

can
be
used
with
either

high
or
low

temperaturethennoslat

It

flows

freely
transfers
heat
effi

ciently
and
will

not

clog
passages
in

the

cooling
system

The
anti
freeze
must
not
be
mixed

with
other

products

This
coolant
can
be
used

through

out

the
seasons
of
the

year

Whenever
coolant
is

changed
the

cooling

syslem
should
be
flushed
and

refilled
with
a

new
coolant

Check
the
level
See
the
instruc

lions
furnished

by
the
manufacturer

for
the
mixture
ratio

of
anti
freeze
10

water

CHECKING

COOLING

SYSTEM
HOSES

AND
CONNECTIONS

Check
hoses
and

fittings
for
loose

connections
or
deterioration
Re

tighten
or

replace
if

necessary

INSPECTION
OF

RADIATOR

CAP

Apply
reference

pressure
0
9

kg
cm2
13

psi
1
to
radiator

cap
by

means
of

a

cap
tester
to
see
if
it
is

satisfactory
Replace
cap
assembly
if

necessary

ET
8
Fig
ET
fJ

Teltill
l
rod
ioto

cop

COOLNG
SYSTEM

PRESSURE
TEST

With
radiator

cap
removed

apply

reference

pressure
1

6

kg
cm2
23

psi
to
the

cooling
system
by
means

of
a
lesler
to
detect

any
leakage

Water

capacity

Without
heater

7
4
liters

7
U
US

qt
6
f

Imp
qt

With
heater

8
0
liters

8
f
US

qt
7

Imp
qt

CHECKING
VACUUM

FITTINGS
HOSES

AND
CONNECTIONS

Check
the
condition
of

filtings
and

hoses

Retighten
or

replace
if
neces

sary

All
vacuum
hoses
can
be
identified

by
colors

White
line

Vacuwn
tube
to
carburetor
E

G
R

Tube

Vacuum
tube
to
thermal
vacuum

valve

Thennal
vacuum
valve
to
E
G
R

control
valve

Yellow

line

Spark
delay
valve
to

distributor

Spark
delay
valve
to
vacuum
tube

Distributor

to
vacuum
tube

Vacuum
tube
to
carburetor

Vacuum
tube
to
canister

Green
line

Anti

backfire
valve
to
intake
mani

fold

Air

control
valve
to

emergency
air

relief
valve

Intake
manifold
to
vacuum
hose

connector

Intake

manifold
to
canister

CHECKING
ENGINE

COMPRESSION

COMPRESSION
PRESSURE

TEST

I
Warm

up
engine
sufficiently

2
Disconnect

all

spark
plugs

3
Disconnect
anti

dieseling
solenoid

valve
connector

4

Properly
attach
a

compression

tester
to

spark

plug
hole
in

cylinder

being
tested
Engine
Tune

up

I

ET010
Different

compression
in
two
or

more

cylinders
usually
indicates

an

improperly
seated
valve
or
broken

piston
ring

9
Low

compression
in

cylinders
can

result
from
worn

piston
rings
This

condition

may
usually
be

accompanied

by
excessive

fuel

consumption

TEST
RESULT

If

compression
in

one
or
more

cylinders
is
low

pour
a
small

quantity

of

engine
oil
into

cylinders
through

the

spark
plug
holes
and
retest
com

pression

I

If

adding
oil
increases
the
com

pression
pressure
the
chances
are
that

rings
are

faulty

2

If

pressure
stays
low

probable

cause
is

that
valve
is

sticking
or

seating

improperly

3
If

cylinder
compression
in

any

two

adjacent
cylinders
is

low
and
if

adding
oil
does
not

help
the

compres

sian
there
is

leakage
past
the

gasket

surface

Oil
and
water
in

combustion
cham

bers

can
result
from

leakage

IGNITION
AND

FUEL
SYSTEM
Fig
ET
10

Teding

compression

pressure

5

Depress
accelerator

pedal
to

open

throttle
and
choke
valves

Note
Do

not

pump
pedal

6
Start

engine
as

quickly
as

pos

sible

7

Compression
pressure

kg
cm2

psi
at

rpm

Standard

12
0

171
350

Minimum

9

0
128
350

8

Cylinder
compression
in

cylinders

Should
not
be
less
than

80
of

highest

reading

CONTENTS

CHECKING
BATTERY
ET
9

CHECKING
DISTRIBUTOR
CAP
ROTOR

CHECKING
AND

ADJUSTING
IGNITION
AND
CONDENSER
ET
11

TIMING
ET
10

CONDENSER
ET
11

ADJUSTING
IGNITION
TIMING
ET10

ADJUSTING
CARBURETOR
IDLE
RPM

CHECKING
AND
REPLACING
SPARK
PLUG
ETlO
AND
MIXTURE
RATIO
ET

11

CHECKING
DISTRIBUTOR
OPERATING
IDLE

LIMITER
CAP
ET
12

PARTS
AND

IGNITION
WIRING
ETlO
CHECKING
CARBURETOR
RETURN
SPRING
ET

12

BREAKER
POINTS

lNon
California
models

ET
10
CHECKING
CHOKE
MECHANISM

AI
R

GAP
lCalifornia
models
ET11
Choke

plate
and

linkage
ET13

DISTRIBUTOR
ET
11
CHECKING
FUEL

LINES

IGNITION
WIRING

ET
11
Hoses

pipings
connections
etc

ET
13

REPLACING
FUEL
FILTER
ET
13

CHECKING
BATTERY

Check

electrolyte
level
in

each
bat

tery
cell
I
Unscrew

each
filler

cap
and

inspect
fluid
level
If
the
fluid
is
low

add
distilled
water
to

bring
the
level

up
approximately
10
to
20
mm
0
39

H
9
to
0
79

in
above
the

plates
Do
not

overfill

2
Measure
the

specific
gravity
of

battery
electrolyte

Fresh
air

Blow

by
gas

CHECKING

VENTILATION

HOSE

1

Check
hoses
and
hose
connec

tions
for
leaks

2
Disconnect
all
hoses
and
blow

them
out
with

compressed
air

If

any
hose

cannot
be
free
of

obstructions

replace

Ensure
that
flame

arrester
is

surely

inserted
in
the

hose
between
air

cleaner
and
rocker
cover

CHECKING
EXHAUST

MANIFOLD
HEAT

CONTROL
VALVE

Run

engine
and

visually
check

counterweight
to
see

if
it

operates

properly

I
For

some
time

after

starting

engine
in
cold

weather

counterweight

turns

counterclockwise
until

it
comes

into

contact
with

stopper

pin
installed

to

exhaust
manifold

Counterweight

gradually
moves

down

clockwise

as

engine
warms

up

and
ambient

temperature
goes
higher

around
exhaust
manifold

2

When

engine
speed
is

increased

discharge
pressure
of
exhaust

gases

causes

counterweight
to
move
down

ward

clockwise
Engine
Tune

up

CoOl
1

Oil
level

gauge

2

8affle

pia
te

3

Flame
arrester

4

Filter

5
P
C
V
valve

6

Steel
net

7

Baffle

plate

1fiI

o

EC716

Fig
ET
20
Crankcaae
emi
ion

control8
tem

3
When
heat

control
valve
is
in
the

full

open

position
counterweight

moves
further

clockwise

exceeding
the

position
described

in
1

1
above
and

stops

again
coming
into

contact
with

stopper

pin

ct

t

C

EC245

1

Counterwe
ht

2

Stopper
pin

3

Heat
control

valve

Fig
ET
21
Cold

operation
of
counte

weigh
t

EC246

1

Counterweight

2

Stopper
pin

3
Heat
control
valve

Fig
ET

22
Hot

operation
of
counter

weight

ET

14
2
With

engine

stopped
visually

check

E
F
E

system
for
the

following

items

I
Thermostat

spring
for
dismount

ing

2

Stopper

pin
for

bend
and
count

er

weight
stop
position
for

dislocation

3

Check
heat
control

valve
for

malfunction

due
to
break
of

key
that

locates

counterweight
to
valve

shaft

4

Check
axial
clearance

between

heat
control

valve
and
exhaust
mani

fold
Correct
clearance
is
0
7
to
1
5

mm
0
028
to

0
059
in

5

Check
welded

portion
of

heat

control

valve
and

valve
shaft
for

any

indication
of
crack

or

flaking

6
Rotate
heat

control
valve

shaft

with
a

fmger
and

check
for

binding

between

shaft
and

bushing
in

closing

and

opening
operation
of
heat
control

valve
If

any
binding
is
felt
in

rotating

operation
move
valve
shaft
in

the

rotation
direction
several
times
If

this

operation
does
not

correct

binding

condition
it
is
due

to
seizure
between

shaft
and

bushing
and

exhaust
mani

fold

should
be

replaced
as
an
assem

bly

CHECKING
SPARK

TIMING
CONTROL

SYSTEM

This

system
is

installed
on
non

California
automatic
transmission

models

SPARK
DELAY
VALVE

Automatic
transmission

models

only

This
valve

delays
vacuum

spark

advance

during
rapid
acceleration
it

also
cuts

off
the

vacuwn

spark
advance

imme

iately
upon
deceleration

The

valve
is

designed
for
one

way
opera

tion

and
consists

of
a
one

way
umbrel

la
valve
and
sintered
steel
fluidic

restrictor

Condition

ENGINE
POWER
NOT

UP
TO
NORMAL

Low
compression

Ignition
system
out
of

order

Fuel

system
out

of

order

Air
intake

system
out

of
order

Emission
control

Overheating

O

cooIing

Others
Engine
Tune

up

Probable
cause

Incorrect

iSnition
timing

Damaged

spark
plugs

Worn
distributor

points

Malfunction
of
choke

system

Clogged
fuel

pipe
or

floating
valve

Dirty
or

clogged
fuel
strainer

Fuel

pump
will
not
work

properly

C10ssed
carburetor

jets

Malfunction
of
altitude

compensator

CIOJBed
air
cleaner

Ail

inhaling
from
manifold

gasket
or

carburetor

gasket

Malfunction
of

E
G
R
valve

Stick
E
F
E

valve
shaft

Insufficient
coolant

Loose
fan
belt

Worn
or
oiled
fan
belt

Inoperative
thermostat

Worn
water

pump

Clogged
or

leaky
radiator

Worn
radiator
filler

cap

Ail

in

cooling
system

Improper
engine
oil

grade

Incorrect

ignition
timing

Clossed
carburetor
lean
mixture

Disconnected
altitude

compensator
hOlle

Inoperative
thermostat

Improper
octane
fuel

L

j
tire

pressure

Dragging
brake

Clutch

slipping

ET

30
Corrective
action

Previously
mentioned

Adjust

Clean

adjust
or

replace
plull

Dress

or

replace
points
Also
check

condenser

Adj
lst

Clean

Replace

Repair
or

replace

Disassemble
and
clean

Check
and

replace

Replace
element

Replace
gasket

Check
and
replace

Repair

Replenish

Adjust
fan
belt

Replace

Replace

Replace

Flush

repair
or

replace

Replace

Retighten
each

part
of

cooling
system

Replace
with

proper
grade
oil

Adjust

Overhaul
carburetor

Connect

Replace

Replace
with

specified
octane
fuel

Inflate

to

specified

pressure

Adjust

Adjust

Except
transistor

ignition
system

Condition

ABNORMAL

COMBUSTION

backfue
afterflre

run
on
etc

Improper

ignition
timing

Fuel

system
out
of

order

Faulty
cylinder
head
etc

Others

EXCESSIVE
OIL

CONSUMPTION

Oilloak

Excessi
lo
oil

consumption

Others
Engine
Tune

up

probable
cause

Improper
ignition
timing

Improper
heat

range
of

spark
plugs

Damaged
carburetor

or
manifold

gasket

backfue
afterfire

Clol
l
ed
carburetor

jet

Improper
function
of

the
float

Uneven

idling
Run
on

Improperly
adjusted
B

C
D
D

set

pressure

Malfunction
of
anti

dieseling
solenoid
valve

Malfunction
of
auio
choke

Improperly
adjusted
valve
clearance

Excess
carbon
in

combustion
chamber

Damaged
valve

spring
backfire
afterflre

Malfunction
of

A
T
C

air
cleaner

Inoperative
ariti
backfue
valve

Loose
oil
drain

plug

Loose

or
damaged
oil

pan
gasket

Loose
or

damaged
chain
cover

gasket

Worn
oil
seal
in
front
and
rear
of
crankshaft

Loose
or

damaged
locker
cover

gasket

Improper
tightening
of
oil
filter

Loose
or

damaged
oil

pressure
switch

Cylinder
and

pioton
wear

Improper
location
of

piston
ring

gap
or

reversely
assembled

piston
ring

Damage
piston
rings

Worn

piston
ring
groove
and

ring

Fatigue
of
valve
oil
seal

lip

Worn
valve

stem

Inadequate
quality
of

engine
oil

Engine
overheat

ET32
Corrective
action

Adjust
ignition
timing

Use

specified
spark
plugs

Replace
them
with
new

parts

Disassemble
carburetor
and
check
it

Adjust
the
level
and
check
needle
valve

Adjust

Adjust

Check
or

replace

Adjust

Adjust

Remove
head
and

get
rid
of
carbon

Replace
it
with
a
new
one

Check
for
loose
vacuum
hoses

Replace
if

necessary

Replape

Tighten
it

Renew

gasket
or

tighten
it

Renew

gasket
or

tighten
it

Renew
oil
seal

Renew

gasket
or

tighten
it
but
not
too

much

Renew

gasket
and

tighten
it
with
the

proper

torque

Renew
oil

pressure
switch
or

tighten
it

Overhaul

cylinder
and
renew

piston

Remoun
t

piston
rings

Renew

rings

Repair
or
renew

piston
and

cylinder

Renew

piston
and

piston
ring

Replace
seal

lip
with
a

new
one

Renew
valve
or

guide

Use
the

designated
oil

Previously
mentioned

Condition

POOR
FUEL
ECONOMY

Se
the

xplanation

of
the
pow
r

dec

Oth
n

PROBLEM
IN

OTHER

FUNCTIONS

D
cr
d

oil

p
ssure

Excessive
wear
on
the

sliding

parts

Scuffing
of

sliding

parts

Floor

temperature
too

high
California

only
Engine
Tune

up

Probable
cause

Exceeding
idling
revolution

Inoperative
acceleration
recovery

Fuel

leakage

Malfunction
of
B

C
D
D

Malfunction
of
A
r
C
air

cleaner

Inadequate
oil

quality

Overheat

Worn

oil

pump
regulator
valve

Functional
deterioration
of
oil

pump

Blocked
oil
f1lter

Increased
clearance
in
various

sliding
parts

Blocked
oil
strainer

Inoperative
oil

gauge
pressure
switch

Oil

pressure
decreases

Improper

quality
or
contamination
of

oil

Damaged
air
cleaner

Overheat
or
overcoal

Improper
fuel
mixture

Decrease
of
oil

pressure

Insufficient
clearances

Overhea
t

Improper
fuel

mixture

Problem
in

fuel

system
Refer
to

Inspec

tion
of
Fuel

System

Problem
in

ignition
system
Refer
to
In

spection
of

Ignition
System

ET33
Corrective
action

Adjust
it

to
the

designated
rpm

Adjust
it

Repair
or

tighten
the
connection
of

fuel

pipes

Adjust

Check
and

replace

Use
the

designated
oil

Previously
mentioned

Disassemble
oil

pump
and

repair
or
renew
it

Repair
or

replace
it

with
a

new
one

Renew
it

Disassemble
and

replace
the
worn

parts
with

new
ones

Oeanit

Replace
it
with
a
new
one

Previousiy
mentioned

Exchange
the
oil
with

proper
one
and

change
element

Change
elemen
t

Previously
mentioned

Check
the
fuel

system

Previously
mentioned

Readjust
to
the

designated
clearances

Previously
mentioned

Check
the
fuel

system

Check
and

repair

Check
and

repair

Fig
EM

3

Crankshafl

PISTON

AND

CONNECTING
ROD

The

pistons
are

of
a

special
alumi

num

casting
and
have

struts
to
control

thermal

expansion
two

compression

rings
and

one
combined
oil

ring
The

piston
heads

are
slightly
dished

The

piston
pil1S
are
a

special
hollow

steel

shaft

They
are
full

floating
fit
to
the

piston
and

press
fit
to
the

connecting

rods

The

connecting
rods
are
of
a

special

forged
steel
Oil
is

sprayed
to
the

connecting
rod
small
ends

through

drilled

passages
in

the

large
ends
of

rod

Oil
holes
in

the

connecting
rods

are
located
so
as
to
insure

optimum

lubrication
under

heavy
load

0
50
1

o

E

Moao

Fig
EM
4

Piston
and

connecting
rod

CYLINDER
HEAD

The

cylinder
head
is

made
of
a

light
strong
aluminum

alloy
with

good

cooling
efficiency
it
contains

wedge

type
combustion
chambers
A

special

aluminum
bronze
valve
seat
is

used
on

the
intake
valve
while
a
heat
resistant

steel
valve
seat
is
installed

on
the

exhaust
valve
These

parts
are

all
hot

press
fitted

EM407

Fig
EM
S

Cylinder
head
Engine
Mechanical

CAMSHAFT

The
camshaft
is

made
of
a

special

cast
iron
and
is
loca
ted
inside
the

rocker
cover
Four
aluminum

alloy

brackets

support
it
Camshaft

bearings

are
lubricated
from
oil
holes
which

lead
to
the

main
oil

gallery
of
the

cylinder
head

Concentric

passages
are
drilled
in

the

front
and

rear

parts
of
the

earn

shaft

Oil
to
each
earn
lobe
is

supplied

through
an
oil

hole
drilled
in
the
base

circle
of
each
lobe
Lubricant
is

sup

plied
to
the
front
oil

gallery
from
the

2nd
camshaft

bearing
and
to
the

rear

oil

gallery
from
the

3rd
camshaft

bearing
These

holes
on
the
base

circle

of
the

lobe

supply
lubricant
to
the

earn

pad
surface
of
the
rocker
arm

and

to
the
valve

tip
end
The
cams
feature

a

long
overlap
profile
to
reduce
NOx

emission

Fig
EM
6

Camshafl

VALVE
MECHANISM

The
valve

system
has
the

pivot
type

rocker

arms
that

are
activated

directly

by
the
earn
mechanism

this
has
made

its

moving

parts
considerably
lighter

and

provides
ideal

high
speed
perform

ance

Dual

type
valve

springs
are
in

stalled

h

@l

if

Exhaust

Intake
EM084

Fig
EM
7
Valve
mechanism

EM

3
CAMSHAFT
DRIVE

The
camshaft
is
driven

by
a
double

row
roller
chain
driven

by
the

crank

shaft
The
tension
of
the

chain
is

controlled

by
a

chain
tcosioner

which

is

operated
by
spring
and
oil

pressure

The
rubber
shoe

type
tensioner

damps

vibration

of
the

chain
and
controls
its

tension

EM537

Fig
EM

8
Chain

driving

aystem

MANIFOLDS

The
intake
manifold
is
of
an
alumi

num
cast

alloy

The
exhaust
manifold
is

of
a
dual

design
and

incorporates
a
heat
control

valve
in
it
The

heal
control
valve
is

used
to

warm
the
intake
manifold

A

plate
is
installed
on
the
outer

face
of
the
manifold
to
draw
hot

intake
air

out

through
it
The
exhaust

pipe
is
connected
to
the

flanged
sur

face
of
the
exhaust
manifold

Fig
EM

9
Intak
and
exhaust

manifolds