ground clearance DATSUN PICK-UP 1977 Service Manual

L

0
5
to
0
8
mm

71j

Correct

2

Inspect
soldered
connection
of

armature
lead

and
commutator
If

loose
connection
is
found
solder
it

using
resin

flux

3

Armature
test
for

ground

Using
a
circuit
tester

place
one

test

probe
onto
armature
shaft
and
other

onto
each
commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

EE022

Fig
EE

16

Testing
annature
for

ground

4

Check
armature
for
short

by

placing
it
on
armature
tester

growler

with
a

piece
of
iron

over
armature

core

rotating
armature
If
the

plate

vibrates
armature

is
shorted

j
l

EE023

Fig
EE

17

Testing
annature

for

ahort
Engine
Electrical

System

L

File
l

0

Commutator

Segmen
t

IWMica

Incorrect

EE021

Fig
EE
15

Undercutting
i118ulating
mica

5
Check

armature
for

continuity
by

placing
probes
of

tester
on
two

seg

ments
side

by
side
If
tester
shows
no

continuity
the
circuit
is

open

OVERRUNNING
CLUTCH

ASSEMBLY

Inspect
pinion
assembly
and
screw

sleeve
Screw
sleeve

must
slide

freely

along
armature
shaft

splines
If

damage
is
found
or
resistance
is
felt

when

sliding
it
must
be

repaired

Inspect

pinion
teeth
If
excessive
rub

bing
is
found
on
teeth

replace

Flywheel

ring
gear
also
must
be
in

spected

l

EE278

Fig
EE
18

Overrunning
clutch

auem

bly

BRUSH

HOLDER
TEST

FOR

GROUND

Using
a
circuit
tester

place
one
test

probe
onto

negative
side

of
brush

holder

and
another
onto

positive
side

If

tester
shows

continuity
brush

holder
is

shorted
to

ground

Replace

brush

holder

EE
9
Ee026

Fig
EE
19

Testing
brush

for

round

BEARING
METAL

Inspect
bearing
metal
for
wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm
0
0079
in

replace

metal

MAGNETIC
SWITCH

ASSEMBLY

1

Using
a
circuit
tester

l
check

con

tinuity
between
S
terminal
of

mag

netic

switch
and
switch

body
metal
If

continuity
does
not
exist
shunt

coit
is

opened

Replace
switch

assembly

2
In
the

same
manner
as
above

check

continuity
between
terminals

S
and
M

If

continuity
does
not

exist
series

coil
is

opened

Replace
switch

assembly

ASSEMBLY

Reassemble

starting
motor
in

re

verse

sequence
of

disassembly

When

assembling
be

sure
to

apply

grease
to

gear
case
and

rear
cover

bearing
metal

and

apply
oil

lightly
to

pinion

TEST

PERFORMANCE
TEST

Starter
motor
should
be

subjected

to
a
no
load

test
whenever
it
has

been
overhauled
to
ensure
that

its

performance
will
be

satisfactory
when

installed
on

engine
Starter
motor

should
also
be

subjected
to

the
test

when
the
cause
of
abnormal

operation

is

to
be
determined

A
brief
outline
of

the
test
is

given
below

No
load
test

Connect

starting
motor
in

series

with

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Starter
motor

Diagnoses
of
test

1
Low

speed
with

no
load
and

high

current
draw

may
result
from
the

following

1

Tight
dirty
or
worn

bearings

2

Bent
armature
shaft
or
loosened

field

probe

3
Shorted
armature

Check
armature
further

4

A

grounded
armature
or
field

a
Remove

input
tenninal

b

Raise
two

negative
side
brushes

from
commutator

c

Using
a
circuit
tester

place
one

probe
onto

input
tenninal
and
the

other
onto

yoke

d
I

f
tester
indicates

continuity

raise
the

other
two
brushes
and
check

field
and
armature

separately
to

determine
whether
field
or
armature
is

grounded

2
F

allure
to

operate
with

high

current
draw

may
be

caused

by
the
Engine
Electrical

System

Specified
current

draw
and

revolu

tion
in

these
test
are

shown
in

Specifications

Switch

6
Battery

Et

Voltmeter
Ammeter

Ee026

Fig
EE
20
No
load

l
ting

following

I
A

grounded
or

open
field
coil

Inspect
the
connection
and
trace

circuit
with

a
circuit
tester

2
Armature
coil
does
not

operate

Inspect
commutator
for
excessive

burning
In
this
case
arc

may
occur
on

damaged
commutator
when
motor
is

operated
with
no
load

3
Burned
out
commutator
bar

Weak
brush

spring
tension
broken

brush

spring
rubber
bush
thrust
out

of
mica
in

commu
tat
or
or
a
loose

contact
between
biush
and
com

mutator
would

cause
commutator
bar

to
burn

3
Low

current
draw
and
low

no
load

speed
would

cause

high

internal
resistance

due
to
loose
con

nections

damaged
leads

dirty
corn

mutator
and
causes
listed
on
item

2

3

EE10
MAGNETIC
SWITCH

ASSEMBLY
TEST

Switch

o

Fv
IB
I

I

D

Battery
Starter
motor

EE351

FiN
EE

21
Circuit

ofmagndic
awitch

assembly
ted

If
the

starting
motor
check
is

OK
check

magnetic
switch
as

sembly
Connect
cables

between

negative
battery
tenninal

and
start

ing
motor
M
terminal

positive

battery
terminal
and

starting
motor

S
terminal

connecting
a
switch
in

series
as

shown
in

Figure
EE

21

With
the
switch
on

push

pinion

back
to

remove
all
slack
and

measure

the
clearance
l
between

pinion

front

edge
and

pinion
stopper
The

clearance
should
be

held
within
0
3
to

1
5
mm

0
012
to
0

059
in

If
neces

sary
adjust
it

by
changing
or

adding

adjusting

washer
s

Adjusting
washers

are
available
in

to
two

different
sizes

0
5
mm
0

020
in

and
O
S

mm
0
031

in

0
3
to
I
S
rom

0
012
to
0
059
in

l

EE029

Fig
EE
22
MeO

uring
clearance

t

2
The
allowable
maximum

out
of

round
of
brake
drum
is
0
02

mm

0

0008
in

Re

condition
or

replace
brake
drum

if

specified
limit
is
exceeded

3

Measure
for

tapered
brake
drum

If

specified
limit
of
0

02
mm
0

0008

in
is

exceeded
as
measured
at

a

position
where
the
distance
of
4S
mm

177
in
is

kept
away
from
inlet

re
condition
or

replace
brake
drum

4

Contact
surface
with
which

linings
come
into

contact
should
be

finished
to

such
an
extent
that
it
is

ground
by
a
No
120
to
150
sand

paper

S

Using
a
drum

racer
finish
brake

drum

by
machining
if
it

shows

any

sign
of
score
marks

partial
wear
or

stepped
wear
on
its
contact
surface

Note
After
brake
drum
is

completely

re
conditioned
or
renewed
check

drum
and
shoes
for

proper
contact

pattern

Brake

assembly

I
When
brake
shoe

linings
are

cracked

incompletely
seated
uneven

Iy
worn

andlor
deteriorated
due
to

excessive

heating
or
soiled
with

oil

grease
and
brake
fluid

replace

2

Replace
linings
if
the
thickness
is

worn
down
to
less
than
1
0
mm
0
039

in

Note

When
brake
shoe

lining
is
in

stalled

grind
brake
shoe

lining
face

to
diameter

equal
to
that
of
brake

drum

lining
dimension

Width
x
Thickness
x

Length

4S
x

4
S
x

244
mm

1
77
x
0

177
x

9
61
in

3

Check

adjuster
for
smooth

oper

ation

4

Replace
shoe
return

springs
which

are
broken
or

fatigued
Brake

System

Standard
dimensions
of
shoe

springs

Free

length
Dia

of

spring
No
of
Installed

Item

lengthlload

mOl

in
mOl
in

coils

mm

kg
in
lb

Upper
136
5

2
0
0

079
37
IS9
S
14

to
16

S

37
6
28
31

to
3S

Lower
134
S

2
3
0
091
35
IS9
5
21

to
23

5
30
6
28
46
to

Sl

After
shoe
83
2

1
4
O
OSS
27
S
99
4

to
S

3
28
3

90
9
to
II

Wheel

cylinder

I

Replace

any
cylinder
or

piston

which
is
scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS
mm

0
OOS9
in

Wheel

cylinder
inner
diameter

19
0S
mOl

Y
in

3

Replace
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

S

Replace

damaged
dust
cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its

threaded

portion

INSTALLATION

Install
front
brake
in
the

reverse

sequence
of
removal

paying
particular

attention
to
the

following
instructions

I

When

assembling
adjuster
assem

bly

apply
brake

grease
to

adjuster

housing
bore

adjuster
wheel
and
ad

juster
screw

When
installing
adjuster

assembly

to
brake
disc

apply
brake

grease
to

disc

adjuster
and

retaining
spring
slid

ing
surfaces

to
slide

adjuster
smoothly

Measure

adjuster
sliding
resistance

Adjust
by
adjuster
shim
when

sliding

resistance
is

in
rrect

BR
ll
Adjuster
sliding
resistance

S
to

12

kg
II
to
261b

2

When

installing
wheel

cylinder
be

sure
to
secure
the

cylinder
with
R

mark

to
right
hand
disc
and
the
one

with
L
mark
to

left
hand
disc

Otherwise
brake
hoses

may
interfere

with
other

adjacent
parts
As

to
the

connecting
instructions

of
brake
hose

no
twist
or

contact
is
existed
on

brake

hose

referring
the

related

topic
Brake

line

Tightening

torque

Wheel

cylinder

SA
to

6
6

kg
m

39
to
48
ft

lb

Connector
bolt

1
9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
hose

1
7
to
2

0

kg
m

12
to
14
ft
lb

Air
bleeder

0
7

to
0
9

kg
m

5
to
7
ft

Ib

Brake
disc

4
2

to
S
O

kg
m

30

to
36
ft
lb

3

Before
installing
brake
shoe
as

semblies

apply
brake

grease
to
wheel

cylinder
and

adjuster
brake
shoe
in

stalling
grooves
and
brake
disc
and

brake
shoe

assembly
contact
faces

two

places
Exercise

care
not
to

allow

grease
to

come
into
contact
with

linings
and

adjuster

2
Install
the
clutch

assembly
on
the

crankshaft

Note

Key
should
be

set
on
crank

shaft
before

installing
clutch
assem

bly

3

Using
Clutch

Spanner
Wrench

hold
clutch
hub
With

socket
wrench

secure
clutch
hub

securing
bolt

Tightening

torque

Clutch
hub

securing
bolt

1
5

kg
m

II
ft
lb

DISASSEMBLY

1
Remove
two

snap
rings
retaining

bearing
They
are

located
inside
of

clutch
wheel

AC500

Fig
AC
54

Removing

snap
rings

2

Using
Clutch
Wheel

Remover

KV99100700
and
conventional

puller

remove
V

pulley
with

bearings
from

clutch
wheel

KV99100700

AC501

Fig
A
C
55

Removing
clutch
wheel

bearings

3

Using
Bearing
Remover

ST33061000

press
clutch
wheel
bear

ings
out
from
clutch
wheel
Air

Conditioning

9

AC502

Fig
AC
56

Removing
V

pulley
from

clutch

ASSEMBLY

I

Press

bearings
into
V

pulley
with

Bearing
Installer
ST02371000
ST02371000

AC503

Fig
A
C
57

Installing
bearin

2

Install
outer

snap
ring
in

groove

of
V

pulley

3

Using
Installer
KV99100610
and

Stopper
ST33061000

press
clutch

wheel
into
V

pulley

4

Install
inner

snap
ring
in

groove

of
clutch
wheel

t

INSPECTION

Check
friction
surface
of
clutch

for

damage
due
to
excessive
heat
or

excessive

grooving
due
to

slippage
If

necessary
replace
clutch
wheel
and

V

pulley
as
a
set

2
The

clearance
between
V

pulley

and
clutch
wheel
should
be
0
4
to
0
6

mm
0

016
to
0
024
in

If
not

replace
clutch
wheel
assem

bly

AC
35
Installer

KV99100610

2

Stopper

ST33061000

AC504

Fig
AC
58
Installing
clutch
wheel

3
Oil

or
dirt
on
friction
surfaces
of

clutch
wheel
and
V

pulley
should
be

cleaned
with
a

clean
lint
free
cloth
or

suitable
solvent

4

Check
coil
for
shorted
or

opened

lead
wire

Pay
particular
attention

to

grounding
part
of

coil
If
there
is
no

continuity
replace
electromagnetic

coil