horn DATSUN PICK-UP 1977 Service Manual

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

Emission
Control

System

C
bur
tor

I

EC284

When

installing
this
valve

ensure

that
it

properly
oriented
Tlus
valve

shuuld
be

replaced
periodically
Refer

to
Maintenance
Schedule

Note
Carburetor
side
Black

DisInDutor
side

Brown

horn
distributor

To

carburetor

TOdi

ribUI0
carburClor

EC
lCiJr

Fig
EC

9
Operation
01

park
delay

value

INSPECTION

Remove

spark
delay
valve

2
Blow

air

through
port
on
carbure

tor

side
then

through
the

other

port

on
distributor
side

Spark
delay
valve
Distributor
side

1
One
way
umbrella
valve

2
Sintered
metal

disc

Fig
EC
8

Spark
delay
valve

is
in

good
condition
if
when

finger
is

placed
over

port
on
distributor
side

air

flow
resistance
is

greater
than
that

on
the

other
side
See

Figur
ET
lO

3
If
a

considerable
air
flow
resist

ance
is

fell
at

port
on
distributor
side

in

step
2

above
and
if

the
condition
of

spark
delay
valve
is

questionable
dip

port
on
carburetor
side
into
a

cup

filled
with

water
Blow
air

through
the

other

port
Small
air
bubbles
should

appear

Carburetor
side

Distributor
side

EC346

Fig
EC
IO

Checking
park
delay
valve

EC
8
EC219

Fig
EC

11

Checking
spark
d

tay
valve

Note
Be
careful
to
avoid

entry
of
oil

or
dirt
into
valve

AIR
INJECTION

SYSTEM

DESCRIPTION

The
Air

Injection

System
A

LS
is

aeSigiieino

iiiject
coin

pressed
air
sec

ODllary
air

corning
from
the
air

pump

into
the
exhaust
manifold
to
reduce

hydrocarbons
and
carbon
monoxide
in

exhaust
lri
s

through
re
combustion

There

are
two

types
of
A

I

S
One

type
is
mounted
on
California
models

and
the
other
is
on
non
California

models
The
non
California

type
con

sists
of
an
air

pump
air

cleaner
an
air

pump
a
relief

valve
a
check
valve
an

anti

backfIre
valve
an
air

gallery
and

hoses
The
California

type
has
in

addition
to
the

components
of
the

non
California

type
an
air
control

valve
and

an

emergency
air
relief
valve

These
valves

prevent
ahnonnal
tem

perature
rise
of
the

catalytic
converter

Air

pump

I

Operate
engine
until
it
reaches

normal

operating
temperature

2

Inspect
all
hose
hose
connec

tions
and
air

gallery
for
leaks
and

correct
if

necessary
before

checking

air

injection

pump

3
Check
air

injection
pump
belt

tension
and

adjust
to

specifications
if

necessary

4

Disconnect
air
supply
hose
at

check
valve

5

Disconnect
vacuum
hose
from
the

air

control
valve
California

type

only

6
Insert

open
pipe
end
of
Air

Pump

Test

Gauge

Adapter
STl9870000
in

air

supply
hose

Clamp
hose

securely

to

adapter
to

prevent
it
from

blowing

out
Position

adapter
and
test

lli
uge
so

that
air
blast
emitted

through
drilled

pipe
plug
will
be

harmlessly

dissipated

7
Install

a
tachometer

on

engine

With

engine
speed
at
2

600

rpm
ob

serve

pressure
produced
at

test

gauge

Air

pressure
should
be
100

mmHg

3

94

inHg
or
more

8
If
air

pressure
does

not
meet

above

specifications
proceed
as
fol

lows

I

Repeat
2
and
3

above

2
Disconnect
air

supply
hose
at

anti
backfire
valve

Plug
air

hose

open

ing
and

screw
with
a

clamp
Repeat

pressure
test

3
With

engine

speed
at
1

500

rpm

close
hole
of
test

gauge
with

finger
If

a

leaking
sound

is
heard
or

leaking
air

is
felt

by
ftnger
at
relief

valve
relief

valve
is

malfunctioning
Relief
valve

should

be

replaced
or

repaired

4

If
air

injection
pump
does
not

meet
minimum

requirement
of

pres

sure
test
it

should
be

replaced

Control
valve

The

following
procedures
are
reo

commended
for

checking
and
or
as

certaining
that
the
various

components

of
the
exhaust
emission
con
Irol

system

are

operating

properly

The

engine
and
all

components

must

be
at
normal

operating
tempera

tures
when
the

tests
are

performed

Prior

to

performing
any
extensive

diag

nosis

of
the
exhaust
control

system
it
Emission
Control

System

must
be
determined
that

the

engine
as

a
unit
is

functioning
properly

Check
valva

Warm

up
engine
thoroughly

2

Disconnect
hose

leading
to
check

valve
from
air

hose
COJUlector

3

Check
hose

opening
for

any
indi

cation
of
exhaust

gas
leaks
Ifleaks
are

detected

replace
check
valve

4

Race
the

engine

lightly
at
about

2
000

cpm
and
then

return
it
to

idling
VisuaDy
check
the
hose
for

any

indication
of
exhaust

gas
leaks
before

the

engine
returns
to

idling

speed
If

leaks
are
detected

replace
check
valve

EC310

Fig
EC
43

Checking
check
valve

Air

pump
raIle
valve

After

completing
inspection
of
air

pump
check
air

pump
relief
valve
in

the

following
steps

J

Disconnect
hoses

leading
to
check

valve
and
air
control

valve
from
air

hose

connector
and

install
blind

cap

to
the

connector

2
With

engine
running
at

about

3
000

rpm
under
no
load

place
your

hand
on
the
air

outlet
of
air

pump

relief
valve
to
check
for

discharged
air

If
no
air

is
felt

replace
the
air

pump

relief

valve

EC311

Fig
EC
44

Checking
air

pump
relief

valve

EC

18
Air
control
valve

C
U
ornla
models

I
Warm

up
engine
thoroughly

2
Before

checking
air
control

valve

check
all
hoses

for
loose
connection

leaks
etc
and

repair
or

correct
if

necessary

3

With

engine
idling
disconnect
the

outlet
side
hose
of

the
air
control

valve
and

place

your
hand
on
the
air

hose
outlet
to
check
for
air
If
no
air
is

felt

replace
the
air

control
valve

4

Pull
vacuum
hose
off
from
air

con
trol
valve
If

discharge
of
air
from

air
hose

stops
the
air
con
trol
valve

is

normaL
If

discharge
is
still
felt

replace

the
valve

Plug
up
the

removed

vacuum
hose

to

stabilize

engine
running

EC312

Fig
EC
45

Checking
air
control
valve

Emarsancy
air
rella
valve

E
A
R
Valve

lCalHornla
models

L
Warm

up
engine
thoroughly

2

Before

checking
air

control
valve

check
all
hoses
for
loose
connection

leaks
etc
and

repair
or
correct
if

necessary

3
Race

engine
approximately

2
000

rpm
under
no
load
Place

your

hand
on
air

outlet
of
E

A
R
valve
to

check
for

presence
of

discharged
air
If

no
air

is
felt

E
A

R
valve
is
normal

4

Disconnect
vacuum
hose
from

B
A

R
valve
as
shown
in

Figure
EC

46

STEERING
GEAR

Removal
and

installation

Removal

I
Disconnect

battery
ground
cable

from
the
terminal

2
Remove

horn

pad
by

unscrewing

two
bolts
from
the
rear
side
of

steering

wheel
bar

Note
Be

sure
to

punch
mark
with

0
on
the

top
of

steering
column

shaft

Fig
ST

3
R

moving
horn

pad
STEERING
SYSTEM

A

@

@l
@

J
i

u
p

I

1

jj

ST199

Sector
shaft

adjusting

screw

2

Filler

plug

3
Sector
shaft
cover

4

Sector
shaft

adjusting

screw
shim

5

Gear

housing

6
Sector
shaft

7

Oil
l

8
Gear

housing
bushing

3
Remove

steering
wheel
with

Steering
Wheel
Puller

ST27I80001

after

backing
off

steering
wheel

fIXing

nut

Fig
ST
4

Removing
teering
wheel

Note
Be
sure
not
to
hammer
the

special
tool
while

removing

4

Remove

upper
and
lower

steering

column
shell

covers

S
Remove
turn

signal
switch
as

sembly

ST3
9
Worm

assembly

ball

nut
assembly

10
Worm

bearing
adjusting

shim

11
Column

jacket

12

Steering
column
shaft

13
Column

jacket
bushing

14

ring

15
Worm

bearing

Fig
ST
2
Sectional
view

of
steering

gear

6
Remove
column

clamp
fixing

bolts

c
@

I

f
c

I

1
I

1

i

T201

Fig
ST
5
Removing
column

clamp

7
Remove
four
bolts

securing
steer

ing
post
grommet
to
dash

panel

8
Remove
nut

securing

gear
arm
to

sector
shaft
and
then
withdraw

gear

arm
with
the
use
of
Pitman
Arm
Puller

ST2902000I

Body
Electrical

System

ELECTRICAL
ACCESSORIES

CONTENTS

HORN

DESCRIPTION

REMOVAL
AND
INSTALLATION

IGNITION
SWITCH

REMOVAL
AND
INSTALLATION

INSPECTION

WINDSHIELD
WIPER
AND
WASHER

REMOVAL
AND
INSTALLATION

INSPECTION

RADIO

REMOVAL
AND
INSTALLATION

ADJUSTMENT

CLOCK

REMOVAL

I
NST
ALLA
TION

HEATER

DESCRIPTION

AIRFLOW

HEATER
UNIT
ASSEMBLY
BE
21

BE
21

BE
21

8E
n

BE
22

BE
22

BE
23

BE
23

BE
23

BE
25

BE
25

BE
25

BE
25

BE
25

BE
26

BE
26

BE
26

BE
28

BE
29

HORN

DESCRIPTION

The

horn
circuit
includes

a
horn

relay
Current
from
the

battery
flows

through
the
fusible
link
and
fuse
to

the
horn

relay
terminal
B

where
it
is

shunted

by
the
two
circuits
In
one

circuit
terminal
S
the
current
flow
is

supplied
through
the
solenoid
and

Fusible
link

Qi
att
Fu

H

I
HIBQ

t
J

JJI

L
J

Hornrelay

Qm
HEATER
CORE

FAN

MOTOR

CONTROL
ASSEMBLY

ADJUSTMENT

SPECIFICATIONS

TACHOMETER

REPLACEMENT

8UL8
REPLACEMENT

SEAT
8ELT
WARNING

SYSTEM

DESCRIPTION

REMOVAL
AND
INSTALLATION

WARNING
LAMP
BULB
REPLACEMENT

INSPECTION

TROUBLE
DIAGNOSES
AND

CORRECTIONS

HORN

WINDSHIELD
WIPER
AND
WASHER

RADIO

Horn
button

BE859A

Fig
BE

29
Circuit

diagram
of
horn

sy
tem
horn
button

to
the

ground
In

the

other
circuit
terminal
H
the
current

flow
is

supplied
through
the

relay

contacts
and
horn

Horn
bracket

serves
as
a

grounding

When
the
horn
button
is

pressed

current
from
the

battery
energizes
the

solenoid
As
the
solenoid
is

energized

the

relay
contacts
are
closed
This

allows
the
current
to
flow
to
the
horn

BE
21
REMOVAL
AND

INSTALLATION

Horn
8E
29

BE
29

BE
29

8E
29

BE
30

BE
30

BE
30

8E
30

8E
31

BE
31

BE
31

8E
31

8E
31

BE
33

8E
33

8E

34

BE
35

I

Disconnect

battery
ground
cable

2
Disconnect
horn
wire
at
terminal

on
horn

body

3
Remove
horn

retaining
bolt

4
Install
horn
in
the
reverse
se

quence
of
removal

Horn

relay

The
horn

relay
is
installed
on
the

hoodIedge
on
the

right
side
of
the

engine
compartment

I
Disconnect

battery
ground
cable

2
Disconnect
horn
relay
wire
con

nector
at
terminals
on
horn
relay

3
Remove

retaining
screws

4
Install
horn

relay
in
the
reverse

sequence
of
removal

Body
Electrical

System

Horn
switch

The
horn
switch
is

integral
with

the

turn

signal
and
dimmer
switch
as

sembly
Remove
switch

assembly
as

outlined
in
Turn

Signal
and
Dimmer

Switch

IGNITION
SWITCH
BE861A

Fig
BE

3
I

Removing
ignition
switch

REMOVAL
AND

INSTALLATION

I
Disconnect

battery
ground
cable

from

battery

2
Unscrew
and
remove
escutcheon

from
the
front
of

ignition
switch

3
Withdraw

ignition
switch
and

wiring
assembly
with

spacer
from

shell
cover
as
shown
in

Figure
BE
3

4

Disconnect
wiring
connector

from
the
back
of

ignition
switch

5

Replace
ignition
switch
with
a

new
one

6
Connect

ignition
switch
to

wiring

connector

7

Position

ignition
switch
to
shell

cover

opening
install
and

tighten

escutcheon
and
secure
ignition
switch

to
shell
cover
R
terminal

1G
terminal

ST
terminal

B
terminal

8E

22
1

Voltage

regulator

2
Horn

relay

3

Headlamp
relay

4

Ignition
relay
California

only

5

Auto
choke
heater

relay

6

Compressor
relay

Au
conditioner

equipped
model

7

Floor
sensor

relay
California

only

8
Inhibitor

relay
Automatic

tran5mission

only

INSPECTION
BE683B

Fig
BE
30

ContInuity
test

Test

continuity

through
ignition

switch

by
using
test

lamp
or
ohm

meter

C

A
terminal
TERMINAL
0

F

F

B

IG

ST

A

R
KEY

FOSITlON

t

1

o

j
u

u

I

I
A

C

C

Fig
BE

32

Ignition
witch
BE6848

Body
Electrical

System

TROUBLE
DIAGNOSES
AND
CORRECTIONS

HORN

Condition

Horn

does
not

operate

Horn

sounds

continuously

Reduced
volume

and
or
tone

quality
Probable
cause

Discharged
battery

Measure
specific
gravity
of

electrolyte

Burnt

fuse

Faulty
horn
button

contact

Horn
sounds
when

horn

relay
terminal
s

is

grounded

Inoperative
horn

relay

Horn

sounds
when
B
and

H
horn

relay

tenninals
are
connected
with
a
test
lead

Damaged
horn
or
loose
horn

terminal
con

nection

Short
circuited
horn

button
and
or
horn

button

lead
wire

When
light
green
lead
wire
is

disconnected

from
horn

relay
terminal
s

horn

stops
to

sound

Inoperative
horn

relay

Loose
or

poor
connector
contact

Fuse
relay
horn
and
or
horn

button

Damaged
horn

BE
33
Corrective
action

Recharge
or

replace
battery

Correct
cause
and

replace
fuse

Repair
horn
button

Replace
horn

relay

Correct
horn
te
inal
onnection
or

replace

horn

Repair
horn
button
or
its

wiring

Replace
horn

relay

Repair

Replace

CD
m
Cl
@
D
@

I

j

1
To
instrument
harness
IS
To
battery
30
To
check
connector

2
To
full
transistor
amplifier
16
To
fusible
link
3t
To
headlamp
L
U
type
2

California
models
only
17
To
engine
harness
No
2
32
To
sido
marker
lamp
L
B

3
To
hood
switch
18
To
alternator
33
To
front
combination
lamp
L
H

4
To
engine
compartment
lamp
1
9
To
front
combination
lamp
R
n
34
To
horn
Low

ll
l
S
To
washer
motor
20
To
headlamp
R
H
type
2
3S
To
horn
High

l
l
0
6
To
auto
choke
heater
relay
1
To
side
marker
lamp
R
n
36
To
B
C
D
D
cut
olenoid
California
models

7
To
detector
dri
e
counter
22
To
headlamp
R
B
type
1
only

Non
Califunia
model
except
for
Canada
23
To
ground
37
To
block
tcrminal
distributor
California

8
To
ignition
relay
California
models
only
i4
To
thermal
transmitter
models
only

9
To
floor
sensor
relay
California
modeb
only
is
To
distributor
Non
California
models
only
38
To
ignition
coil
Non
California
models
only

n
10
To
inhibitor
relay
A
T
only
26
To
8
C
D
D
cut
solenoid
Non
California
39
To
condenser

t
II
To
head
lamp
relay
models
only
40
To
ignition
coil
and
resistor
@

12
To
horn
relay
27
To
fuel
cut
solenoid
California
models
only

OJ
v

m
13
To
voltage
regulator
28
To
auto
choke
heater

g
e
14
To
cooler
cable
29
To
headlamp
L
R
type
1

OJ
to

o
Q
m
r0

C
1
i

Ql
CIl
Il
l
3