wheel DATSUN PICK-UP 1977 Service Manual

General
Informa
ion

Fig
GI
I
Standord
wheelbase
model

Fig
GI

2
Delux
Cob

GI
2

General
Information
L

GENERAL
INFORMATION

CONTENTS

MOOEL
VARIATION
GI
3

APPROXIMATE
REFILL

CAPACITIES
GI
B

IDENTIFICATION
NUMBERS
GI
5

RECOMMENDED
FUEL
GI

B

LIFTING

POINTS
AND

TOWING
GI
B

RECOMMENDED
LUBRICANTS
GI

8

LIFTING
POINTS
GI

B
RECOMMENDED
SAE
VISCOSITY

SUPPORTABLE
POINTS
GI
7
NUMBER
GI
8

TOWING
GI
7
LUBRICANT
SPECIFICATIONS
GI
g

TIE
DOWN
GI
7

MODEL
VARIATION

Differential

Pay
load

Destination

Class
Model

Engine
Transmission
carrier
model

kg
Ob

and

gear
ratio

I
HL620TUV
F4W7lB

Standard

I
HL620FTUV
FS5W71
B

wheelbase

S

I
HL620KTUV
3N7lB

E

I
HLG620TUV
Ol

F4W7lB

u
0

0

E

Long
E

I
HLG620FTUV
0

FS5W71B

wheelbase

0

I
HLG620KTUV
8
a
3N7lB

0
Ol

0

u

I
KHL620TUV
Ol

F4W7lB

u

Deluxe

I
KHL620FTUV
FS5W7lB

Cab

KHL620KTUV
3N7lB
Hl90

500
1
1

00

L20B

4
375

u
i

0

HL620TU
F4W71
B

Standard

HL620FTU
FS5W7l
B

wheelbase

U

HL620KTU
3N7lB

S

0

I
HLG620TU
0

E
F4W7lB

0

8

Long

I
HLG620FTU
0

FS5W7lB

wheelbase

IHLG620KTU
Q
u

3N7lB

0
0

Z

KHL620TU
F4W71B

Deluxe

Q

KHL620FTU
FS5W7l
B

Cab

I
KHL620KTU
3N7lB

GI
3

r
General

Information

Differential

Pay
load

Destination
Class
Model

Engine
Transmission
carrier

model

kg
lb

and

gear
ratio

Standard
HL620TUN
F4W71B

wheelbase

HL620KTUN

3N71B

0

HLG620TUN

F4W7IB

Long
E

wheelbase
2

I
HLG620KTUN
Hl90

Canada

L20B

3N71B
500
1
100

4
375

I
KHL620TUN

F4W71B

0

Deluxe
Z

I
KHL620FTUN

Cab
FS5W7IB

I
KHL620KTUN

3N7J
B

Model
identification

KHLG620KTUV

I
I

L
U

V

N

T

K

F

0

G

o

H

K
I

Note

0
means
no
identification
Destined
for
U
s
A
and
Canada

California
model

Canada
model

Floor
shift
vehicle

Automatic
transmission

5

speed
manual
transmission

4

speed
manual

transmission

Long
wheelbase

Standard
wheelbase
and
Deluxe
Cab

Equipped
with
L20B

engine

Deluxe
Cab

GI
4

Fig
GI
9
Manual
trammiuion
number

location

Automatic

transmission

number

The
transmission

serial
number
is

attached
to
the

right
hand
side
of

transmission

case

Numbering
system

X
XXXXX

I

Serial
number

monthly

Month
of

manufacture

I
2

9
X
Y
Z

last

figure
of

year
of

manufacture

AT344

Fig
01
10
Automatic
trammi

sion

number
location

LIFTING
POINTS

AND
TOWING

LIFTING

POINTS

Screw

jack

Before

using
the

jack
proceed
a

follows
Generallnforml
ition

Apply

parking
brake

firmly
and

block
rear
wheels
if
the
front

of
the

vehicle
is
to

be
raised

Notes

a
Never

get
under
the
vehicle

while
it

is

supported
only
by
the

jack

Always
use

safety
stands
to

support

frame

or
rear
axle

case
when

you

have

to

get
beneath
the
vehicle

b
In
no
event
should
the

jack
be

applied
to

any
points

except
the

following
specified
portions

When

jacking
up
the
front
side

place
a
screw

jack
under
side
frame

about
520
nun

20
5
in
at
rear

of

front
axle
center

WT012

Fig
GI
ll
Front

lifting
point

When

jacking
up
the

rear
side

place

a
screw

jack
under
rear
axle
case
close

to
the
side

of
rear

spring

WH077

Fig
GI
12
Reor

lifting

point

Notes

a
When

the

yellow
mark

appean
on

the
screw

jack
it
indicates
the

maximum

permissible
height
Do

not

jack
up
further

b

When
the

jack
is
at
lower
llinit
do

not

add

large
force
downward

GI
6
YeDow
mark

WHOSO

Fig
GI

13

Warning

ogai
t

over
stroke

Garage

Jack

Note
When

carrying
out

operntions

with
a

garage

jack
be
sure
to

support
the
vehicle
withstands
in

a
safe
manner

When

jacking
up
the
front
end

apply
garage
jack
to
front
cross

member
or
center

portion
of
sus

pension
member

When

jacking
up
the
rear
end

apply
the

jack
to
rear
axle
case

r
J

uc

I

GI075
n9

Fig
GI

14
Front

lifting
point

GI076

Fig
GI
15
Rear

lifting

point

SUPPORTABLE
POINTS

The
front

supportable
points
are

under
frame

side
member

The
rear

supportable
points
are

under
rear

axle
case

Fig
GI

16
Front

supportable
points

v

GI078

Fig
GI
17
Rear

supportable
points

TOWING

When
the
vehicle
is
to
be

towed

forward
connect

a

rope
securely
to

the
hook
under
the
1st

CrosSIn
ember

Before

towing
make
sure
the

parking

brake
is

released
General
Information

To
tow
another
car
connect
t1ie

rope
to
rear
leaf

spring
shackle

Notes

a
A

towing
rope
should
not
be
con

nected
to

any
position
other
than

as
described
above

b
Avoid

applying
load

suddenly
to
a

towing
rope
as
it

may
cause
dam

age

WH131

Fig
Gl
18

Fronttowing
point

Fig
01
19
Rear
towing
point

GI
7
Manual
transmission

Before

towing
make
sure

the
trans

mission
is
in
neutral

gear

If
the
rear
axle
or
transmission
is

inoperative
the
vehicle
should
be

towed
with
its

rear
wheels
off
the

ground
or
the

propeller
shaft
must
be

re
l1oved

Automatic
transmission

When
the
vehicle
is
towed
on
its

rear
wheels
make
sure
the
trans

mission
is
in
N

Neutral
position

Don
t
exceed
30
km
h
20

MPH
and
a

distance
of
Hi
kin

6
miles
If
the
rear

axle
or
transmission
is

inoperative
or

if
the

speed
exceed
the
above
condi

tions

the
vehicle
must
be
towed
with

its

rear
wheels
off
the

ground
or
the

propeller
shaft
must
be
removed

Note
When
the
vehicle
is
towed
with

its
front
wheels
on
the

ground
the

steering
wheel
shouId
be
secured

to

maintain
a

straight
ahead

position

TIE
DOWN

The
front
two
tie

down
hooks

are

located
under

the
1st
crosSInember

The
hook
is

available
as
a

towing

hook
For
rear
tie
down
the
rear
leaf

spring
shackle
be
used
lIDs

point
is

also
used
as
a

towing
point

EE322

Fig
ET
15
Checking
diltribu
tor

point

gap

AIR
GAP

California
models

For

inspection
procedures
and

reference
data
refer

to
the

topic
Air

Gap
in

Section
EE

page
EE
29

DISTRIBUTOR

Check

centrifugal
advance
unit
for

loose
connection
or

improper
opera

tion
If
it
is
not

operating
properly

the

problem
may
be

due
to
a

sticky

spring
or
excessively
worn

parts
This

operation
needs
a
distributor
tester

For

inspection
procedures
and

ref

erence
data
refer
to

relative

topic

under
Distributor
in

Section
EE

If
vacuum
advance
mechanism
does

not

properly
operate
check
for
the

following
items
and

correct
the

prob

lem

as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
connection
If

necessary

retighten
or

replace

2

Check
vacuum
diaphragm
for
air

leak

If

necessary
replace
diaphragm

3

Inspect
breaker

plate
for
smooth

movement

If

plate
does
not
move
smoothly

this
condition
could
be
due

to

sticky

steel
balls
If

necessary
replace
break

er
plate
assembly

IGNITION
WIRING

Use

an
ohmmeter
to
check
resist

ance
of

secondary
cables
Disconnect

cables
from

spark

plugs
and
install
a

proper
adapter
between
cable
and

spark
plug
Remove

distributor
cap

and
secondary
cables
as
an

assembly

Do
not
remove
cables
from

cap

Check
resistance
of
one
cable
at
a

time

Connect
ohmmeter
between

spark

plug
adapter
and

corresponding
elec

trade
inside
cap
If
resistance
is
more

than
30
000
ohms
remove
cable
from
Engine
Tune

up

cap
and
check
cable
resistance

only
If

resistance
is
still
more
than

30
000

ohms

replace
cable

assembly

EF125

Checking
high
tension

cable

CHECKING

DISTRIBUTOR
CAP

ROTOR
AND

CONDENSER

Note
This

operation
is

to
be

per

formed
while

checking
distributor

points
Inspect
distributor

cap
for

cracks
and

flashover

External
surfaces
of
all

parts
of

secondary
system
must
be
cleaned
to

reduce

possibility
of

voltage
loss
All

wires
should
be
removed
from
distrib

utor

cap
and
coil
so
that
terminals

can

be

inspected
and
cleaned
Burned
or

corroded
terminals
indicate
that
wires

are
not

fully
seated
which

causes

arcing
between
end
of
wire
and
ter

minal
When

replacing
wires
in

ter

minai
be

sure
they
are

fully
seated

before

pushing
rubber

nipple
down

over
tower
Check
distributor
rotor
for

damage
and
distributor
cap
for

cracks

CONDENSER

I
Clean

outlet
of
condenser
lead

wire

and
check
for

loose
setscrew

Retighten
if

necessary

2
Check

condenser
with
a
con

denser
tester

Condenser

capacity

0
20
to
0
24

IF

Micro
Farad

Condenser
insulation
resistance

5Mn

Mega
ohms

ADJUSTING

CARBURETOR
IDLE

RPM
AND
MIXTURE

RATIO

Cautions

a
On
automatic
transmission

equip

T
11
ped
models
check
should
be

per

fonned
in

the
D

position

Be
sure

to

engage
parking
brake
and

to
lock
both
front
and
rear

wheels

with
wheel
chocks

b

Keep
your
foot
down
on
the
brake

pedal
while

depressing
the
accelera

tor

pedal
Otherwise
vehicle

surges

forward

dangerously

Notes

a
Do
not

attempt
to
screw
the
idle

adjusting
sc
ew
down

completely

Doing
so
could
cause

damage
to

tip

which
in

turn
will
tend
to
cause

malfunctions

b

If
idle
limiter

cap
obstructs

proper

adjustment
remove
it

To
install
idle
limiter

cap
refer
to

Idle
Limiter

Cap

c

After
idle

adjustment
has

been

made
shift
the
lever
to
the
N
or

P

position
for
automatic
trans

mission

d
When

measuring
CO

percentage
in

sert

probe
into

tail

pipe
more
than

40
em
15
7
in

CO
idle

adjustment
with

CD
meter

Idle
mixture

adjustment
requires

the
use
of
a

CO
meter

especially
for

California
models
When

preparing
to

adjust
idle
mixture
it
is

essential
to

have
the
meter

thoroughly
warmed

up

and
calibrated

I
Check
carburetor

pipes
for

proper

connection

2

Warm

up
engine
until
water
tem

perature
indicator

points
to
the
middle

of

gauge
The

procedure
to
warm

up

engine
is
not

specifically
recom

mended
Either

driving
vehicle
or

oper

ating
engine
at

no
load
will
be

good

3
Make

sure
that
water
tempera

ture
indicator

points
to

the
middle

Further

keep
engine
running
at
about

2

000

rpm
for
about
5
minutes
with

out

applying
load
to

engine
in

order
to

stabilize

engine
condition
Engine

hood
should
be

open

4
Run

engine
for

about
10
minutes

at
idling
speed
During
this
10

minutes

proceeq
as
described
i

steps

5

to
9
below

5
Remove
air
hose
between
3

way

connector
5

way
connector
for
Cali

fornia
models
and
air

check
valve
as

shown
in

Figure
ET
17

Plug
the

dis

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

r

28
Remove

cylinder
head

assembly

Use

Cylinder
Head
Bolt
Wrench

STl0120000
to

remove

cylinder
head

bolts
Loosen
bolts

from

CD
to

@
as

shown
in

Figure
EM
18

Fig
EM
IS

Cylinder
head
bolt

loosening
equence

Notes
When

removing
cylinder
heao

from

engiJJe
installed

on
car
follow

the

instructions
below

a
Turn
crankshaft

until
No
I

pilton

is
at
T
D
C

on
its

compression

stroke

b
Remove

rocker
Cover
and
fuel

pump

c
To
facilitate

assembling
o
tion

scribe
8
mark

on

timing
c
8in

and

camshaft

sprocket
with

paint
be

fore
removal

d
Loosen
camshaft
bolt

and
remove

fuel

pump
drive
earn

e

Support
timing
chain

by

utilizing

Chain

Stopper
STl7420001
bet

ween

timiilg
chains
as
shown
in

Figure
EM
19

This
0

peration
eliminates

the

prob

lem
of

realigning

timing
marks

on

timing
chain
and
crankshaft

sprocket

EM538

Fig
EM
19

Supporting
timing
chain

f

Remove
camshaft

sprocket

g
Loosen

cylinder
head
bolts

and

remove

cylinder
head
Engine
Mechanical

29
Invert

engine

30

Remove
oil

pan
and

oil
strainer

EM094

Fig
EM
20

Removing
oil
traintir

and
oil

pump

31

Remove
oil

pump
and
its
drive

spindle
See

Figure
EM
20

32
Remove
front
cover

33

Remove
chain
tensioner

and

chain
slack
side

guide

EM095

Fig
EM
21

Removing
chain
ten
ioner

and
tim

ing
chain

34
Remove

timing
chain

See

Figure
EM
2l

35
Remove

oil
thrower
crankshaft

wonn

gear
and

chain
drive

sprocket

Fig
EM
22

Removing
chain
drive

Proc
et

EM
6
36
Remove

piston
and

connecting

rod

a

mbly
Extract

connecting
rod

bearings
keeping
them
in
order

I

Fig
EM
23

Removing

pilton
and

connecting
rod
aat
m
b

y

37

Remove

flywheel
and

rear

plate

Be

careful
not

to

drop
them

EM415

Fig
EM

24

Removing
flywheel

38
Remove
main

bearing
caps

Use
Crankshaft

Main

Bearing

Cap

Puller
KVIOI04ISO

to
remove
center

and
rear

main

bearing

caps
Keep
them

in
order

KVIOI04IS0

EM539

Fig
EM
25

Removing
rear

main

bearing

cap

39

Remove
two
side
seals
from

rear

main

bearing
ca

p

40
Remove
rear
oil

seal

r

Engine
Mechanical

INSPECTION
AND
REPAIR

PREPARATION
FOR
INSPECTION

CYLINDER
HEAD
AND
VALVE

CHECKING
CYLINDER
HEAD
MATING

FACE

VALVE
ASSEMBLY

VALVE
SPRING

ROCKER
ARM
AND
VALVE

ROCKER

PIVOT

VALVE
GUIDE

VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARING

CAMSHAFT

BEARING
CLEARANCE

VALVE
TIMING

CAMSHAFT
ALIGNMENT

CYLINDER
BLOCK

HOW
TO
MEASURE

CYLINDER
BORE

CYLINDER

BORING

PREPARATION
FOR

INSPECTI
N

I

Before

cleaning
check

for

signs

of
water

and
oil
leaks
in

cylinder
block

and

head

2
Clean
oil
carbon

deposits
and

sealant
from
an

parts
Remove

gasket

3
Clean
all

oil
holes
with
solvent

and

dry
with

compressed
air

Make

sure
that

they
are

not
restricted

CYLINDER
HEAD

AND
VALVE

CHECKING
CYLINDER

HEAD

MATING
FACE

EM407

Fig
EM

34
Cylinder
head
CONTENTS

EM
8

EM
B

EM
8

EM
8

EM
9

EM
lO

EM
l0

EM
11

EM

12

EM
12

EM
12

EM
13

EM

13

EM
13

EM
14
PISTONS
PISTON
PINS
AND

PISTON
RINGS

CONNECTING
ROD

CRANKSHAFT

BUSHING
AND
BEARING

MEASUREMENT

OF
MAIN

BEARING

CLEARANCE

MEASUREMENT
OF

CONNECTING
ROD

BEARING
CLEARANCE

FITTING

BEARINGS

MISCELLANEOUS
COMPONENTS

CRANKSHAFT
AND

CAMSHAFT

SPROCKETS

CHAIN

TENSIONER
AND
CHAIN

GUIDE

FLYWHEEL

FRONT
COVER
AND

REAR
OIL
SEAL

Note

Never

remove
camshaft
bear

ings
unless

you
have
a

Suitable

machine

or

boring
Camshaft
bear

ing
in
line
If

you
once
remove

camshaft

bearings
bearing
centers

will
come
out

o

alignment
reo

conditioning
is

very
difficult
with

out
center

borings

L
Make

a
v

isual
check
for
cracks

and
flaws

2

Measure
the
surface
of

cylinder

head
on

cylinder
block

side
for

warpage
If
it
is

found
to
be

beyond

the
limit

designated
below

regrind
the

affected
surface

with
a
surface

grinder

Fig
EM
35

Checking
cylinder
head

8JJrface

EM
8
Head
surface
flatnes

Standard

less
than
0
05

mm
0
0020
in
O
lmm

0
0039
in
EM
15

EM
16

EM
16

EM
17

EM
17

EM
1B

EM
18

EM
19

EM
19

EM
20

EM
20

EM
20

Maximum

VALVE
ASSEMBLY

Check
each
intake

and
exhaust

valve
for
worn

damaged
or
deformed

valve

caps
or
stems

Correct
or

replace

any
valve
that
is

faulty

2
Valve

face
or
valve
stem
end

surface

should
be
refaced
with
a
valve

grinder

10

L
I
I

I

EM109

Fig
EM
36
Intak
and

exhaust
valve

dimensions

I
Turn

engine
until
No

I

piston
is

at
T
D
C
on

its

compression
stroke

Determine

whether
camshaft

sprocket

location
notch
comes

off
the
left
end

of
the

oblong
groove
on
camshaft

locating
plate
If
the
location
notch

is

off
the

left
end
of
the

oblong
groove

chain

stretch
is

beyond
limits

40150

EMl46

Fig
EM
74

Camshafllocating
plate

2

Turn

engine
until
No

I

piston
is

at
T
D

C

on
its

compression
stroke

setting
camshaft
on

No
2
location

hole
in

camshaft

sprocket
This
No
2

notch

should
then
be

on
the

right
end

of
the

oblong

groove
When
No
2
hole

is

used
NO
2

timing
mark
must
also

be
used

The
amount

of
the

modifica

tion
is
a

40
rotation

of
crankshaft

3

When
modification
becomes
im

possible
even

by
transferring
camshaft

location

hole

replace
chain

assembly
Engine
Mechanical

CHAIN

TENSIONER
AND

CHAIN
GUIDE

Check
for

wear
and

breakage
Re

place
if

necessary

r

I

L

EM147

Fig
EM
75
Cam

haft
dri
mechanilm

FLYWHEEL

I

Check
clutch
disc

contact
surface

with

flywheel
for

damage
or
wear

Repair
or

replace
if

necessary

2

Measure
runout
of
clutch
disc

contact
surface

with
a
dial

gauge
fit

exceeds
0
15

mm
0
0059
in

total

indicator

reading

replace
it

EM
20
EM426

Fig
EM

76
Checking
flywheel

deviation

3

Check

tooth
surfaces
of

ring
gear

for
flaws

or
wear

Replace
if

necessary

FRONT

COVER
AND

REAR
OIL
SEAL

First
check

front
cover

an
rear
oil

seal
for

worn
or
folded
over

sealing
lip

or
oil

leakage
If

necessary
install
a

new
seal
When

installing
a
new

seal

pay
attenti
on
to

mounting
direction

Note
It
is

good
practice
to

replace
oil

seal
whenever

engine
is

overhauled

Frant
t
r

r

J
I

Front

Real

EM150

Fig
EM

77
Oil

eals

of
crank

haft