DATSUN PICK-UP 1977 Service Manual

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

Body
Frame

Note
Vertical

adjustment
should
be

carried
out
after
hood
lock
male

and
female

adjustment
has

been

completed

3

To
correct
hood
lock

alignment

loosen

two
hood
lock
male
attaching

bolts
and

move
hood

lock
male
and

female
in

the
lateral
and
fore

and
aft

directions
as

required
D

1r

r

BF642A

Fig
BF
16

Adjusting
hood
lock

male

Tightening

torque

Male
and
female

attaching
bolts

0
45

to
0
60

kg
m

3
3

to
4
3

ft
Ib
4
Dove
tail
bolt
at

hood
lock
male

provides
for
vertical

adjustment
in

aligning
hood

to
make
it
flush
with

fender

To
correct
loosen

lock
nut
on

dove
tail

bolt
and
turn
dove
tail
bolt
in

or
out

as

necessary
to
obtain
a

correct

height

HOOD
LOCK
CONTROL

JI

I

i
I

r

lPP

J
jJ
J

Sr

aj
I

I
I

J

f
ifry
ff
I
ii1iiilliii
j
iW

r
U

I

j
Y

f
7

j

1

JJ
J

8F
9
5

Tighten
lock

nut
firmly
while

holding
dove
tail
bolt
with
a

screw

driver

to
secure

adjustment

Tightening

torque

Lock

nut
of

dove
tail

1
9

to
2
6

kg
m

14

to
19
ft
lb

BF643A

1
Lock

nut

2
Hood
lock

male
3

Safety
catch

Fig
BF

17
Doue
tail
bolt

height

adjustment

1
Dove
tail
bolt

seat

2

Lock
nut

3
Cushion
rubber

4

Spring

5

Spring
retainer

6
Dove
tail
bolt

7

Clamp

8

Clamp

9
Hood
lock

female

10
Control
cable

assembly

BF644A

Fig
BF
18
Hood
lock
and
control
cable

REMOVAL
AND

INSTALLATION

I

Remove
hood
lock
male

by
re

moving
two

attaching
bolts

2
To
remove
hood
lock
female
first

remove
radiator

grille
Back
off
two

bolts

securing
hood
lock
female

in

position
Hood
lock
female

can
now

be
taken
out

3
Remove

two
bolts

attaching
hood

lock
handle

assembly
to
dash
side

paneL

Disconnect
cable
at
hood
lock

female
and
remove
cable

clamps
Pull

cable
out
into

cab

4

To
install
hood
lock
male
and

female
reverse
removal

procedure

Mter
installation
check
to
insure
that

they
are

properly
aligned

5
To

install
hood
lock
handle

as

sembly
reverse

steps
observing
the

following
notes

I
Check
to
be
certain
that

cable

clamps
are

tight
and
secure

2
Install
hood
lock
handle
bracket

in

place
by

using
two
of
four
holes

See

Figure
BF
19
Body
Frame

@

1

Hood
tock
handle

2

Hood
lock
handle

bracket
BF645A

3

Clamp

4

Hole

5

Attaching
bolt

Fig
BF

19

1MtalIing
hood
lock
handle

brocket

ADJUSTMENT
AND

INSPECTION

I
If
hood
lock
handle

is

heavy
turn

dove
tail
bolt
of
hood
lock
male
coun

terclockwise
to
reduce
tension
of

hood

lock

spring

Lock
nut
of
dove
tail
bolt
should

fust
be
loosened

If
looseness
is
noticed
hood
is

not

tight
and
will
vibrate
To
correct
this

turn
bolt
clockwise
and
recheck

2
Check
hood
lock
mechanism
as

follows

BF
10
I
Check

safety
catch

lever
and

spring
for
deformation

fatigue
or

rusting

2
Check

female
lever
and

return

spring
for
deformation

fatigue
or
rust

ing

Improper
operation
of
female

lever

may
cause

disengagement
be

tween
female
lever

and
dove
tail
bolt

3
Make
sure
that

safety
catch

hooks

engine
hood

properly
when

hood
latch
has
been

disengaged

0l

11
mm

I
nun
BF409A

0
433
in

0
3t5
in

Fig
BF
20

Safety
catch
lever
to

radiator

upper

support

acVu5tment

Lubrication

When

checking
or

adjusting
the

hood

lock
lubricate
the

pivot
catcher

and

return

spring
of

secondary
latch

thoroughly
Also
lubricate
the
lever
of

the
hood
lock
female
for

smooth
and

correct

operation

DESCRIPTION

DOOR

REMOVAL
AND
INSTALLATION

ALIGNMENT

DOOR
TRIM
AND
SEAL

REMOVAL
AND
INSTALLATION

GLASS
RUN

REMOVAL
AND
INSTALLATION

DOOR
VENTILATOR
WINDOW

Optional

REMOVAL
AND
INSTALLATION

j
Body
Frame

DOOR

CONTENTS

BF12

BF
12

BF
12

BF12

BF12

BF12

BF13

BF
13

BF13

BF13
DOOR
GLASS
AND
REGULATOR

REMOVAL
AND
INSTALLATION

ADJUSTMENT

DOOR
LOCK

REMOVAL

AND
INSTALLATION

ADJUSTMENT

DOOR
LOCK
STRIKER

WEATHERSTRIP

DESCRIPTION

REMOVAL
AND
INSTALLATION
BF14

BF14

BF14

BF
14

BF15

BF
15

BF
15

BF
15

8F
15

BF
15

CD

CV

CID
@

@

@

1
Door

sash

2
Window
outside

weatherstrip

3
Wmdow
inside

weatherstrip

4
Door

weatherstrip

5
Rear

glass
run
rubber

6
Door

finish
holder

7
Rear
lower
sash

8
Seal
screen

9
Door

weatherstrip
clip

10
Front

glass
run
rubber

11
Lower

door

hinge

12

Upper
door

hinge

13
Front

lower
sash

14

Door

glass

15

Glazing
rubber

16
Door

glass
bottom
channel

BF030B

Fig
BF
21
Door
without
ventilator
window

BF
11

@

I

r

L

c

@

DESCRIPTION

The

door
consists

of
inner

and

outer

panels
welded

together
to

form
a

rigid
structure

The
curved

glass
provides
greater

shoulder
room

A
door

that

incorporates
a

ventila

tor

window
is
also
available

as
an

option

The

weatherstrip
is
inserted
into

the

groove
on
the

door
sash
side
and
is

attached

by
clips
on
the
door

side

DOOR

REMOVAL
AND

INSTALLATION

I
With
door
in
full

open
position

place
a

garage
jack
or
stand
beneath

door
to

support
its

weight
when
bolts

are
removed
Place

rag
between
door

and

jack
or
stand
to

avoid
damaging

painted
surface
Body
Frame

CD

1

@

@

ID

@

AJ

@

@

@
1

Door
sash

2

Window
outside

weatherstrip

3

Window
inside

weatherstrip

4

Door

atherstrip

5
Rear

glass
run

rubber

6
Door
finish
holder

7
Rear
lower

sash

8
Seal
screen

9
Door

weatherstrip
clip

10
Front

glass
run

rubber

11
Lower
door

hinge

12

Upper
door

hinge

13

Front
lower

sash

14
Door

glass

15

Glazing
rubber

16
Door

glass
bottom
channel

11

Lower

support

18

Upper
support

19
Door
ventilator

assembly

BF031B

Fig
BF
22
Door
with
ntilator
window

Optional

BF023

Fig
BF
23

Supporting
door

2

Separate
lower
door

hinge
hole

cover
from
dash

side
trim

3

While

supporting
door
as
above

back
off

body
to

upper
and
lower

hinge

attaching
bolts
accessible

from

inside
cab
three
each
Door

can
now

be
taken
out
from
cab

body

I
t

I

l
f
p1

1
W
JJ

i

Sl
j

Fig
BF

24

Removing
door

hinge

bolt

8F
12
4

To

install
reverse

removal

pro

cedure

ALIGNMENT

Elongated
holes
three
each
in

door

hinge
and
door

lock
striker

pro

vide
for

up
and

down
forward
and

backward
and
or

sideways
adjustment

to

assure

proper
door

fit

to
door

opening

To

adjust
door

alignment
loosen

bolts
and
move
door
to

desired

posi

lion

to
obtain
a

parallel

space
between

door
sides

and
door

opening
Also

check
to

be
certain

that

weatherstrip

contacts

body
opening

evenly
to

pre

vent

entry
of
mud
and
water

DOOR
TRIM
AND

SEAL

REMOVAL
AND

INSTALLATION

1

Remove
screw

securing
inside

door
handle

escutcheon
remove
es

cutcheon

2

Remove

screws
which
hold

pull

handle
and
arm
rest
in

position
Pull

handle
and

arm
rest
can
then
be

taken

out

3

Pull

retaining
spring
off

regulator

handle
Take

out

regulator
handle

and

seat
washer

BF640

4

When

removing
door
finish
it
is

important
that
inside

door

panel
and

door

finish

are
not

damaged

With
a

screwdriver

pry
off
re

taining
clips
exercising
care
not
to

damage

clips

I

a
I

II
I
L

jl

ld

II

Fig
BF
26

Removing
door

finish

5

Separate
water
seal

screen
from

inside

door

panel

6
To
install

reverse
removal

pro

cedure

However
observe
the
follow

ing
instalJation
notes

i
When

water
seal

screen
is
to
be

replaced
be
Sure
to

cement
it
back

into

position
securely
to
ensure
a

water
sealed
door
This

can
be

done

by

evenly

applying
adhesive

to

grooves
in

inside
door

panel

Broken
screen
Or

one

suspected
to

be

leaking
must
be

replaced
with
a

new
one
Body
Frame

1

3
Seat

washer

Regulator
handle

Retaining
spring

Fig
BF
25

Removing
regulator
handle

Adhesive

I
i

f
f

nil

Section
A

A
Ii

ir
coil

IIIII
I

J
J

iif
J

lUJ

A

A
J

J

BF641

Fig
BF
27
Adhesive

for
seal
screen

2
With
door

glass

up
set

regulator

handle

at
an

angle
shown
in

Figure

BF
28

d

1

J

900
Spring

l

BF462

Fig
BF
28
Installation

angle
of

regulator
handle

GLASS
RUN

REMOVAL
AND

INSTALLATION

I

With
door
in
full
out

position

lower

glass
all
the

way

2

Remove

pull
handle
arm
rest
and

regulator
handle

3
Remove
door
fmish
and
water

seal
screen

4
Remove
outer
and
inner

weather

strips
from
door

BF
13
5

Remove
door

glass

6

Remove

glass
run
rubbers

from

front
and
rear
lower
sashes

and
from

those
of
fixed
door

Use
caution

to
avoid

damaging

rubbers

during
removal

operation

7
Remove

front
and
rear
lower

door

sashes
when
ventilator
window

is

not

provided

8

On
vehicles

equipped
with
venti

lator
window
remove

ventilator

window

frame
and
rear

lower
door

sash

9

To
install

reverse
removal

pro

cedure
However

observe
the

follow

ing
notes

I

Before

applying
adhesive
clean

the
inside
of
door

sash

2

Apply
adhesive

to
glass
run

rubber
on
door
sash

contacting
face

and
fit

it

correctly
Particularly
care

should
be

taken
at
corners
and

contact

face

to
assure
a

good
fit

CD

CID

BF641

1
Door
sash

2

Glass
run
rubber

3
Adhesive

Fig
BF

29

Applying
adhesive
to

glass
run
ru
bber

DOOR
VENTILATOR

WINDOW

Optional

REMOVAL
AND

INSTALLATION

I

Remove
five
ventilator
window

frame

attaching
bolts
Lift
frame
out

of
door
For

detailed

procedure
refer

to
relative

topic
under
Door
Glass

and

Regulator

2
Remove
nuts
and

spring
securing

lower
end
of

ventilator
window
to

frame

3
Work
off
rivets

which
hold

upper

end
of
ventilator
window
to
frame

take
out
window

4
To

install
reverse
removal

pro

cedure

Body
Frame

DOOR
GLASS
AND
REGULATOR

CD

REMOVAL
AND

INSTALLATION

L

Open
door
lower
glass
all
the

way

2
Remove
iflllide
door
handle
es

cutcheon

3
Remove

pull
handle

4

Remove
arm
rest

5
Remove
regulator
handle

6
Remove
door
finish

7
Peel
off
water
seal
screen

8
Work
off

outer
and
inner
weath

erstrips
from
door
being
sure
not
to

scratch
door

paint
during
operation

Use
a
suitable

plain
screwdriver
or

similar
flat
bladed
tool
io

remove
and

place
a

piece
of

rag
between
screw

driver
and
door

panel

BF643
1
Outet

weatherstrip

2
Screwdriver

3
Piece
of

rag

Fig
BF
31

Removing
outer

weather

trip

9

Remove
three
door

glass
bottom

channel

attaching
bolts
Remove
door

glass
by

lifting
it

straight

up
Fig
BF
30
Door

gl
and

regulator

10
On
door

equipped
with
venti

lator

remove
three
bolts

securing
door

glass
bottom
channel
then

let

glass
go

to

the
bottom
of
door

Remove
ventilator
frame

attaching

bolts
and
lift
frame

straight
up
out
of

door
Remove
door

glass
by
lifting
it

straight
up

11

Back
off
the
five

guide
channel

to

regulator
base

attaching
screws

Take
out

regulator
assembly

through

large
access
hole
in
inside
door

panel

DOOR
LOCK

1
Escutcheon

2
Inside

handle

3
Spring

4

Door
lock
knob

5
Knob

grommet

6
Outside
handle

7
Outside
handle
rod
j

f

ffi
I

Fig
BF
32
BF035

Removing
door

glass

12
To
install
reverse
removal

pro

cedure

ADJUSTMENT

I

In
and
out
and
fore
and
aft
ad

justment
can
be
made

by
moving

front

or
rear
sash
and

guide
channel

as

required

The
ease
with
which
window
assem

bly
raises
and
lowers

depends
on
ad

justment
of
rear

lower
sash
Rear

lower
sash
should
be

parallel
with

front
lower
sash

2

Fore
and
aft

adjustment
is

deter

mined

by
position
of

guide
channel

and
front
lower
sash

Moving
front

lower
sash
backward
reduces

play
in

window

assembly

j

CID

@

8
Nylon
nut

9

Locking
plate
ring

10
LOcking

plate

11
Door

lock
cylinder

12

Door
lock

13

Stopper

BF

14
BF410A

Fig
BF
33
Door
lock
mechonillm

REMOVAL
AND

INSTALLATION

I

Open
door

2

Remove
inside

door
handle
es

cutcheon

3

Remove

pull
handle

4

Remove
arm
rest

5

Remove

regulator
handle

6

Remove
door
finish

7

Peel
off
water
seal
screen

8
Raise

door

glass
to
full

up
posi

tion

9
Remove
inside
door
lock
knob

10

Remove
rear
lower
sash
attach

iog
bolts

11

Disconnect
remote
control

rod

from

key
cylinder
and

outside
door

handle

12

Remove
three
door
lock
assem

bly

attaching
screws

13

Remove
two
inside
door
handle

attaching
screws

14

Together
with
inside
door

handle
take

out
door
lock
as
an

assembly
through
large
access
hole
in

door

panel

15

Remove
two
outside
door

handle

attaching
nuts
Outside
door

handle
can
then
be

taken
out

16

Remove
lock

plate
from

key

cylinder
and

detach

key

cylinder

17

To
install
door

lock

assembly

outside
and
inside
door
handles
and

key
cylinder
reverse
removal

pro

cedure

18
Lubricate
door
lock
with

grease

which
meets

the

requirements
of
MIL

G
I0924B
or

equivalent
as

listed

below

ALVANIA
GREASE

RA
SHELL

BEACON
325

ESSO

MOBILE
GREASE
22

MOBIL
Body
Frame

ADJUSTMENT

OutsIde
door
handle

Adjustment
of

play
in
outside

door

handle
is

controlled

by
play
adjust

ment
of

nylon
nut
on
threaded

end
of

outside
door
handle
rod

Correct

play
is
1
0

mm
0
039
in

or
below

as
measured
between

nylon

nut

and

locking
plate

Inside
door

handle

Elongated
hole
in
inside
door

handle

provides
for

play

adjustment
of

inside
door
handle

Correct

play
is
1
0

mm
0

039
ill

or
below
as
measured
at
control
rod

A

L
A

I

1

rB

I

B

REMOVAL
AND

INSTAUATION

I

Open
door

2
Free

weatherstrip
from

door
sash

clamp

BF
15
DOOR
LOCK

STRIKER

Adjustment
of
door
lock
striker

should

be
made

after
door

hinge
has

been

adjusted
correctly

Elongated
holes
three

provide
for

up
and
down
or

fore
and
aft

adjust

ment
to
establish

proper
engagement

between
door
lock
striker

and
door

lock
latch

WEATHERSTRIP

DESCRIPTION

The

weatherstrip
is
retained

by

clamp
to
the
door
sash
and

by
19

clips

to
the
door

panel
No

adhesive
is

used

to
retain

the

weatherstrip
to

door

Section
A

A

j

Section
B
B

BF645

Fig
BF
34

Door

weatheratrip

3

Pry
off

clips
from

door

panel

remove

weatherstrip

4

To

instaH
reverse
removal

pro

cedure

WINDSHIELD
GLASS

DESCRIPTION

The

windshield

glass
is
retained
in

the

body
glass
opening
through
the

weatherstrip
There
are
twelve

water

drain
holes
one
on
each

side
of
the

bottom
of
the

glass
opening
and
ten

along
the

length
of
the

weatherstrip

1

Weatherstrip

2
Windshield

glass

3

Water
drain
hole

Fig
BF
35
Windshield

glass
and

weatherstrip
BF473A

REMOVAL

1
Place

protective
covers
over
en

gine
hood
front
fender
seat
and
in

strument

panel

2
Remove
inside
rearview
mirror

and
sun
visor

3
Remove
windshield

mouldings
if

so

equipped

4

Using
a

putty
knife
or
similar

flat
bladed
tool

pry
lips
of
weather

strip
out
of

place
from

top
and
side

flanges
of

body
opening

If

weatherstrip
is

to
be
reused
it
is

important
that
it

not
be

damaged

during
this

operation

BF041

Fig
BF
36

Removing
weatherstrip
Body
Frame

WINDSHIELD
GLASS

5

Working
from
inside
vehicle

push

windshield

glass
out

of

body

opening

by
hand

starting
at

right
and
left

upper
COIners
and

working
out
toward

ends

6
After

removing
weatherstrip
from

top
and
sides
of

body
opening
lift

glass

up
sufficiently
to

permit
removal

of

weatherstrip
from
bottom

flange

pry
weatherstrip
out
of

position

This

operation

requires
two
men

INSPECTION

Prior
to

installing
windshield

glass

make
the

following
checks
on
body

glass

opening
and

weatherstrips

I
Clean

weatherstrip
channels
re

placing
those
found
with

cracks
or

signs
of
deterioration

2
Clean

body
openings
noting
if

these
are
distorted
or
corroded

INSTALLATION

L

Fit

weatherstrip
on

glass

making

sure
it
is

properly
seated
and

posi

tioned
Adhesive
need
not
be

applied

0

BF641

Fig
BF

37

Fitting
weatherstrip
on

glass

2

Insert
a
draw
cord

completely

around

weatherstrip
outer
channel

Q
i

I

dYii

1

Windshield

glass

2
Draw
cord

3

Weatherstrip

Fig
BF

38
In8erting
draw
cord
around

weatherstrip
outer
channel
8F648

BF
16
3

With
aid
of
a

helper
press
wind

shield

assembly
against
body
opening

from
outside

being
sure
weatherstrip

lip
aligns
ith

body
opening
flange

4

Slowly

pull
cord
ends
from
inside

to

overlap
weatherstrip
channel
on

body
opening

flange
starting
at
center

top
and

working
out
toward
ends
This

operation
should
be
done
while
one

man
pushes

glass
against
body
opening

from
outside

The

same

technique
should
be

ap

plied
to

right
left
and
bottom

wea
th

erstrips

Fig
BF
39

Fitting
weatherstrip

top

BF650

Fig
BF

40

Fitting
weatherstrip

bottom

5
Install

windshield

moldings
on

weatherstrip
if
so

equipped

6
Install
inside
rearview
mirror
and

sun
visor

BACK
WINDOW

GLASS

AND
SIDE

WINDOW

GLASS

Refer
to
relative

topics
under
Re

moval

Inspection
and
Installa

tion
of
windshield

glass