fuel DATSUN PICK-UP 1977 Manual PDF

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

Manual
Transmission

I

TROUBLE
DIAGNOSES
AND
CORREGTIONS

Condition

Difficult
to

intel11lesh
gears

Causes
Jor
difficu
t

gear
shifting
are
classi

fied
to
troubles

concerning
control

system

and
transniissioo
When

gear
shift
lever
is

heavy
and
it
is
difficult
to
shift

gears
clutch

disengagement
may
also
be
unsmooth
First

make
sure
that

clutch

operates
correctly

and

inspect
transmissi
o

Gear
slips
out
of
mesh

In
most
cases
this
trouble
occurs
when

interlock
b
all
check
ball
and

or
spring
is

worn
or
weakened
or

when
control

system

is

faulty
In
this
case
the

trouble
cannot
be

corrected

by
replacing
gears
and
therefore

trouble

shooting
must
be

carried
out

care

fully
It
should
also
be

noted
that

gear
slips

out

of
mesh
due
to
vibration

generated
by

weakened
fron
t
and
rear

engine
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indicati90
that
th
e
noise
is

from
transmis

sion

t
Transmission

may
fa
ule

during
engine

idling

Check
air

fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gear
shaft
and
or

bearing

Insufficient

operating
stroke
due
to
worn
or

loose
sliding

part

Faulty
or

damaged
synchronizer

Worn
interlock
ball

Worn
check
ball

and
or

weakened
or
broken

spring

Wom
fork
rod
ball

groove

Wom
or
damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due

to

faulty
oil

seal
or

sealant

clogged

breather
etc

Worn

bearing

High
humming
occurs
at
a

high
speed

Damaged
bearing
Cyclic
knocking
sound

occurs
also
at
a

19W
speed

Worn

spline

Worn

bushing

j

MT
23
Corrective
action

Replace

pair
or
replace

Replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace

with

designated
oil

Clean
Of

replace

Replace

Replace

Replace

Replace

s

Install
tension

rod
at
rear
end

tighten
nut
to

make
the

distance
of

rubber

bushing
to
be
33
4
mm
1
315

in
and

torque
lock
nut
to
1

6
to
2
2

kg
m
12

to
16
ft
lb

6

Install
tension
rod
bracket

to

chassis

frame
bracket
and

torque
nut

to
1

6
to
2
2

kg
m

12
to
16
ft
lb

When

two
rubber

bushings
are
dif

ferent
in
size

arrange
adjusting
nut

Standard
dimension
is
11
0
mOl
0
433

in

as
shown
in

Figure
FA

16

Torque

lock
nut

to
1
6
to
2
2

kg
m

12
to
16

ft
lb

Il
0

11

0
0
433

t

lP

33
4
1
315

I

11
0

0
433
1
0
11
0

0

433

Adjusting
nut

Y
i

w

36
6
l
441

Unit
mm

in

FA235

Fig
FA
16
Tension
rod
detail

INSPECTION

I

Check
tension

rod
for
bend
and

the

thread
for

faulty
condition

Repair

or

replace
as

required

2

Check

bushing
rubber
for
wear

and
deterioration

Replace
if
neces

sary

TORSION

BAR

SPRING

REMOVAL
AND

INSTALLATION

Removal

1
Raise
vehicle
on
a
hoist
or
stands

2
Remove
wheel

3
Loosen
nuts
at

spring
anchor

bolt
Front
Axle
Front

Suspension

4
Remove
dust

cover
at
the
rear

end

of
torsion
bar

spring
and

detach

snap

ring

S
Withdraw
torsion
bar

spring
rear

ward

after

pulling
ou
t
anchor
arm

realWard

I

nstallalation

Install
torsion
bar

spring
in
the

reverse

sequence
of

removal

noting

the

following
instructions

I

Coat

grease
on
the
serrations
of

torsion
bar

spring
and
install
it

to

torque
arm

Note
Be

sure
to
install

right
and
left

torsion
bar

springs
correctly
They

can

be
identified
with
R

Right

and
L

Left
marked
on
the
end

surface

2
Install

anchor
arm
and

tighten

adjusting
nut
to

obtain
A
dimen

sion
See

Figure
F
A
17

When
anchor

arm
is

properly
adjusted
to
A

specification
upper
link
should
be
in

contact
with

rebound

bumper
rubber

See

Figure
FA
18
Install

snap
ring
and

dust
cover

Temporarily
tighten

adjust

ing
nut
until
B

specification
is

reached

I

I

I

FA236

Fig
FA
17

Installing
anchor
arm

Specifications
for
torsion
bar

spring

Diameter
x

length
mOl

in

Torsional

rigidity

kg
m

deg
ft
lb

deg

FA
9
Anchor
arm

setting
post
ion
A

ISt02Smm

0
59
to

0
98
in

Temporary
tightening
distance
B

60
to
70

mOl

2
36
to
2

76
in

UjPPje
Rebound

bumper

rubber

j

4W

Fig
FA

18

Setting
procedure

Notes

3
A

and
8

specifications
are

only
the

preliminary
rough
settings

directions
for

performing
the
final

adjustment
that

determines
the
ride

height
are
found
on

page
F
A
II

under

Adjustment

b
Discard
old

snap
ring
after

re

moving
it

Replace
with
new

one

during
reinstallation

3
Install
wheel
and

lower
vehicle

Adjust
vehicle

posture
at
curb

weight

full
fuel

tank
no

passengers
refer

ring
to

Adjustment

4

Torque
lock
nut
to
3
1
to
4
1

kg
m
22
to
30

ft
lb

INSPECTION

Check
torsion
bar

spring
for
wear

twist
etc
When

adjusting
vehicle

posture
replace
torsion
bar

spring

with
a
new
one
if
the

specified
height

can
not

be
obtained

All
models

21

9
x
830
0
862
x

32
68

3
74
27
I

DATSUN
PICK
UP

MODEL
620
SERIES

l
NISSAN

I

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
FE

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

ENGINE

CONTROL
SYSTEM

FUEL
SYSTEM

EXHAUST

SYSTEM
FE
2

FE
4

FE
6

Engine
Control

Fuel
Exhaust

Systems

ENGINE

CONTROL
SYSTEM

CONTENTS

DESCRIPTION

REMOVAL
AND

INSTAllATION
INSPECTION

ADJUSTMENT
FE
2

FE
3

DESCRIPTION

The

accelerator
control

system
is
of

flexible

cable

type
so

that
the

linkage
operates
smoothly
and
the

system
is

not
affected

by

engine
vibration

u

l

f
L

4
@

Arrow

B

E
78
mm
3
07
in

T
2
to
4
mm

0
08
to

0
16
in

MUlti

purpose

grease
FE

3

FE
3

The
choke

system
is

automatically

controlled

i

p
@

I
@
@

CV

j

I

Accelerator

pedal
II

Screw

2

Accelerator

pedal
bracket
12

Pedal

stopper
bolt

and

return

spring
13

Kickdown
switch

striker

3
Accelerator

pedal
arm

Automatic
transmission

4

Pedal

stopper
lock

nut

models

only

5
S

pring
clamp
14

Kickdown

switch

6
Lock

nut

Automatic
transmission

7

Adjust
nut

models

only

8
Wire
holder

15
Switch

stopper
nu

t

9

Accelerator
wire

16
Carburetor

10

Accelerator
wire
outer
case

FE

2
FE260

Fig
FE
l
Accelerator
control

sy
t
m

Engine
Control
Fuel
Exhaust

Systems

REMOVAL
AND

INSTALLATION

Accelerator

wire

I

Remove
air
cleaner

assembly

2

Disconnect
accelerator
wire

from

carburetor

3

Loosen
lock

nut
and
disconnect

accelerator
wire
outer
case
from
wire

holder
See

Figure
FE
I

4

Remove

spring
clamp
and

discon

nect
accelerator
wire

from
accelerator

pedal
arm

S

Remove
two

screws

securing
ac

celerator
wire
outer
case
to

body
and

detach
accelerator
wire

6
To

install
reverse
the
order

of

removal

Apply
recommended
multi

purpose
grease
slightly
to

portion

MG
shown
in

Figure
FE
I

Accelerator

pedal
assembly

I
Remove

spring
clamp
then
dis

connect
accelerator
wire
from

tip
of

pedal
ann

2
Remove

two
screws

securing
ac

celerator

pedal
bracket

to

body

3
Remove

accelerator

pedal
from

dash

panel
See

Figure
FE
I

4
To
install
reverse
the
order
of

removal

INSPECTION

I
Check
accelerator

pedal
return

spring
for

rust

fatigue
or

damage

Replace
if

necessary

2

Check
accelerator
wire

cases
and

fastening
locations
for
rust

damage
or

looseness

Repair
or

replace
if

necessary

ADJUSTMENT

Accelerstor

pedal
and
wire

Adjust
pedal

stopper
bolt

Section
A

so
as
to
obtain

specifi

ed

height
E
as
shown
in

Figure

FE
I

Secure

pedal
stopper
bolt
with

stopper
lock
nut
Refer

to
Figure

FE
I
E

78
mOl
3
07

in

Tightening
torque
01
nut

0
38

to
0
4S

kg
m

2

7
to
3
2

ft
b

2

Release
auto

choke
effect
since

throttle
lever
is

opened
by
fast
idle

earn
until

engine
warms

up

I

Keep
choke
valve

fully
open

with

fingers

2

Pull
throttle
lever

up
by
hand

1

Adjust
nut

2
Lock
nut

3
Accelerator
wire

4
Dust
co

r

5
After

completing
the

adjustment

as

previously
explained
check
the

following

I

Make
sure

that
accelerator

system
functions

smoothly
and

quietly

without

disturbing
any
adjacent

parts

2

Depress
accelerator

pedal
down

until

throttle
valve

fully

opens
Make

sure
that

the
clearance
T
between

accelerator

pedal
reverse
side
and
dash

floor
is
2
to
4
mm
0
08
to

0
16
in

without
floor

mat

Adjust
pedal

stop

per
bolt
and
lock
nut
if

beyond
limits

3

Check
throttle

lever
if
it

returns

to
the

original
position
as
soon
as

accelerator

pedal
is

released

FE
3
then
automatic

choke
effect
will

be

released

3

Set
throttle
valve
to

completely

closed

position
and
with
wire

suf

ficiently
slackened

lighten

adjust
nut

until
throttle
lever
is
about
to
move

Accelerator

pedal
play
is

zero

at
this

lime
See

Figure
FE

2

4

Unscrew

adjust
nut

approxi

mately
two
and
a

half
turns
so
that

accelerator

pedal
play
is
3
mOl

0
012

in

Tighten
lock
nut

securely
See

Figure
FE
2

1

I

1

CD
@

FE184

Fig
FE72

AdjU6ting
accelerator
wire

play

4

Apply
recommended
multi

purpose
grease
slightly
on
the

portion

as
shown
in

Figure
FE
I
Also
refer

to

the

periodic
maintenance
schedule

Kickdown
switch
Automatic

transmission
models
only

Kickdown
switch

adjustment
is

cor

rect
if
it
is

actuated

by
kickdown

switch
striker
when

accelerator

pedal

is

fully

depressed

Always
tighten
switch

stopper
nut

securely
after

proper
adjustment
is

obtained

DESCRIPTION

REMOVAL

DESCRIPTION

The
fuel
tank
is4Sliters
II

Ji
U
s

gal
9
Ji

Imper
gal
in

capacity
The

tank
unit
is

mounted
to

the

right
side

of
the
rear

floor

1
Fuel

tank

2
Drain

plug

3
Filler
tube

4

RescfYOir
tank

5
Filler
hose

6
Breather
hose

7
Ventilation
hose

8

Evaporation
hose

9
Fuel
outlet
hose
and
tube

10
Fuel

tank

gauge
unit

11

Protector

12
Bracket

13
Retainer

14
Return

tube
Engine
Control
Fuel
Exhaust

Systems

FUEL
SYSTEM

CONTENTS

FE
4

FE
5
INSPECTION

INSTALLATION
FE
6

FE
6

The
filler
shutter
is
installed
to

the

filler
tube
on
California
models

The
electric
fuel

pump
is

adopted

on
air

conditioner

equipped
models
For

the
electric
fuel

pump
refer
to

Section
EF

FE194

Fig
FE
3
Fuel
tank

FE
4

Detail
A

Detail
D

REMOVAL
Engine
Control
Fuel

Exhaust

Systems

Detail
Bn
4

Detail
e

@

Detail
E

B

Fuel
tank
See

Figure
FE
a

I
Disconnect

battery

ground
cable

2
Remove
drain

plug
and
receive

the

remaining
fuel
into
a

suitable

container

3
Disconnect
filler
tube

fro
filler

hose

4
Remove

fuel
tank

securing
bolts

5
Disconnect

two
ventilation
hoses

fuel
return
hose
and
fuel
outlet
hose

from
fuel

tank

6
Disconnect
fuel
tank

gauge
unit

wires

at
connector

7
Remove

fuel
tank

Note

Plug
hose

and
tube

opening
l
to

prevent
entry
of
dust
or
dirt
while

removing

ReservoIr
tank

1

Disconnect

battery
ground
cable

2
Disconnect
two
ventilation
hoses

evaporation
hose
and
breather
hose

3
Remove
reservoir
tank

securing

bolts

and
remove
tank
with

protector
Note

Plug
hose
and
tube

opening
l
to

prevent
entry
of
dust
or

dirt
while

removing

Fuel

tank

gauge
unit

Disconnect

battery
ground
cable

2

Disconnect
wires

from
fuel
tank

gauge
unit

3

Remove
fuel

tank
For
details

refer
to
fuel
tank
removal

4

Unit

gauge
is
a

bayonet
type
and

can

be
removed

by

turning
it
counter

clockwise
with

screwdriver

Fuel

piping
See

Figure
FE
4

Fuel

tubes
are

serviced
as
an
as

sembly
so
that

replacement
of

fuel

tube
can

be

easily
done
However
do

not
disconnect

any
fuel
line
unless

absolu

tely

necessary

I

Drain
fuel
from
fuel
tank

2

Loosen
fuel

hose

clamps
and
dis

connect

fuel
tubes
on

each
end

Note

Plug
hose
and
tube

openings
to

FE

5
Detail
F
Detail

G

Detail
U

Detail
T

FE261

Fig
FE
4
Fuel

piping

prevent
entry
of

dust
or
dirt
while

removing

3
Unfasten

clips
that
hold
tube

on

under

body
and
remove
tube
from
the

vehicle

Fuel
filter

I
Disconnect
fuel
hoses
from
fuel

filter

by
removing
clamps
See

Figure

FE
5

FE18S

Fig
FE
S

Removing
fuel
filter
clamps

Engine
Control
Fuel
Exhaust

Systems

2
Remove
fuel

filter

INSPECTION

Fuel

tanle

Check
fuel

tank
for

cracks
or

deformation
If

necessary
replace

2
Fuel
hose

Inspect
all
hoses
for
cracks

fatigue

sweating
or
deterioration

Replace
any

hose
that

is

damaged

3
Fuel
tube

Replace
any
fuel
tube
that
is

crack

ed
rusted

collapsed
or
deformed

Note

Inspect
hoses
and
tubes
ac

cording
to
the

periodic
mainte

nance
schedule

4

Fuel
filter

Replace
fuel
filter

according
to

the

periodic
maintenance
schedule
or

when

it
is

clogged
or
restricted

DESCRIPTION

REMOVAL

DESCRIPTION

The
exhaust

systems
installed
on

the
non
California
models
differ
in

specifications
from
those
installed
on

the
California
models
Fuel
filter
is

of
a

cartridge
type

and
cannot
be
cleaned

Always

replace

with
a
new
one

5
Fuel
tank

gauge
unit

Check

gauge
unit

for
rust
deforma

tion
or

deterioration
If

necessary

replace

INSTALLATION

To
install
reverse
the
order
of

removal
Observe
the

following

I

Install
hose

clamps
securely
Do

not

tighten
excessively
to

avoid

damaging
hoses

2
Fasten

clips
holding
fuel
tube
on

under

body
securely
Failure
to
follow

this
caution

could
result
in

damage
to

the
surface

of
fuel

tube

3
Do
not
kink

or
twist

hose
and

tube
when

they
are
routed

EXHAUST
SYSTEM

CONTENTS

FE
6

FE

8
INSPECTION

INSTAllATION

Non
California
models

The
exhaust

system
consists

of
a

front
exhaust
tube
a
main

muffler

assembly
with
rear

tube

mounting

hangers
brackets
and
a
heat

insulator

FE
6
4
Install
fIller
hose
after
fuel

tank

has
been
mounted
in

place
Failure

to

follow
this
caution
could
result
in

leakage
from

around
hose
connections

5
When

installing
fuel
tank

gauge

unit

align
the

projection
of

tank

gauge

unit
with
the

notch
in
fuel

tank
and

tighten
it

securely
Be

sure
to
install

gauge
unit

with
O

ring
in

place

6
Run

engine
and
check
for
leaks
at

connections

Tightening

torque

Drain

plug

5

0
to
6
0

kg
m

36

to
43

ft
Ib

Fuel
tank

securing
bolt

0
8
to
1
I

kg
m

6
to
8
ft
Ib

Reservoir

tank

securing

bolt

032
to
0
44

kg
m

2

to
3

ft
Ib

FE
8

FE
8

California
models

The
exhaust

system
cOllsists
of

a

front
exhaust

tube
a

catalytic
conver

ter

assembly
a
center
tube
a

main

muffler

assembly
with
rear
tube

mounting
hangers
brackets
and
heat

insulators

The

catalytic
converter
is
COD

nected
to
the
front

tube
and
the

center

tube
with
bolts
and
nuts

Engine
Control
Fuel
Exhaust
S
t

ys
ems

Non
Califomia
model

Qf

@
Si
tr
l

Qf

Si
tIJ

i
Qf

I

l
j

l
tr
l

r
Qf

Si
i
l

l

t
1

I
tr
l

9
r

8

1Bi
1
Front
tube

2
Exhaust

tube

clamp

3
Rear

tube

assembly

4
Muffler

assembly

5

Rear
tube

mounting

6
Front

tube
mounting

California
model

6

@@
8

Qf

@
fit
J
0

I

1

2

I

7
Front
tube

Catalytic
converter

Center
tube

Muffler

assembly

Diffuser

Rear
tube

mounting

Front
tube

mounting

FE390

Fig
FE
6
E
r

ha
t

system

FE
7