wheel alignment DATSUN PICK-UP 1977 Service Manual

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

Using
the

tester
check
the

two

black

yellow
BY
wires
from
the
in

hibitor
switch
in
the

ranges
N

and

I
and
the

tw
re
d

black

RBj
wir
s

in

the

range
R
for

continuity
Turn

range
select
lever
in
both

directions

from

each
lever
set

position
and
check

each

continuity

range
It

is
normal
if

the

electricity
is

on
while
the
lever
is

within
an

angle
of
about
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continl
ity

range
is
obvious

ly
unequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
of
the

range

selector
lever

and
two

fastening
bolts

of
the
switch

body
and
then
remove

the
machine
screw
under
the
switch

body
Adjust
the
manual
shaft
correct

ly
to
the

position
N

by
means
of
the

selector
lever

When
the

slot
of
the

shaft

becomes
vertical
the
detent

works
to

position
the
shaft

correctly

with
a

clicking
sound

MSlVe
the

switch

slightly
asj
Je
so

that
the
screw
hole
will
be

aligned

with
the

pin
hole
of
the
internal
rotor

combined
with
the
manual
shaft
and

check
their

alignment
by
inserting
a

1
5
mm
0
059
in
diameter

pin
into

the
holes
If

the

alignment
is
correct

fasten

the
switch

body
with
the
bolts

pull
out
the

pin
tighten

up
the
screw

in

the
hole
and
fasten
the
selector

lever
as
before
Check
the

continuity

again
with
the
tester
If

the
malfunc

tion
still

remains

replace
the
inhibitor

switch
Chcck
whether
the

reverse

lamp

and
the
starter
motor

operate
normal

ly
in
these

ranges
If
Ihere
is

any

lrouble

first
check
the

linkage
If

no

fault
is
found
in

the

linkage
check
the

inhibitor
switch

Separate
the
manual
lever
from
Ihe

remote
control
selector

rod
and
turn

the

range
selcct

lever
to

N

Note

In
the

position
N

the
slot
of

the

manual
shaft

is
vertical

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revolutions
of

the

engine
while
Automatic

Transmission

vehicle
is
held
in
a

stalled

condition

The
carburctor
is
in

full
throttle

opera

tion
with

the
selector
lever
in

ranges

f
2

and
I

respectively
Com

pare
the

measured
results
with
the

slandard

values

Components
to

be
tested

and

test

items

I
Clutches
brake

and
band
in
trans

mission
for

slipping

2

Torque
converter

for

proper
fune

tioning

3

Engine
for
overall

properly

STALL
TEST

PROCEDURES

Before

Icsting
c
heck
the

engine
oil

and

torque
converter

oil
warm

up
the

engine
cooling
water
to
suitable
tem

perature
by
running
at

1
200

rpm
with

the
selector
lever
in

the

range
P
for

several
minutes
Warm

up
the

torque

converter
oil
to
suitable

temperature

6010
1000C
140
to

2l20F

I

Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

fro

the
dri
er
s
seat
and

put
a
mark

on

specified
revolutions
on
the
meter

2

Secure
the
front
and
rear
wheels

with
chocks
and

apply
the
hand
brake

Be
sure
to

depress
the
brake

pedal

fumly
with
the
left
foot
before
de

pressing
the
accelerator

pedal

3
Throw
the
selector
lever
into

the

range
1

4

Slowly
depress
the
accelerator

pedal
until
the

throttle
valvc
is

fully

opened

Quickly
read
and
record
the

engine
revolution
when

the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5

Shift
the
selector
lever
to
N

and

operate
the

engine
at

approxi

mately
1
200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

ver
ter
oil

and
coolant

6

Make
similar
stall
tests
in

ranges

2
I
and
RIO

Note
The
stall
test

operation
as

speci

f
d
in
item
4

should
be

I
l3de

wiihin
five
seconds
If
it

takes
too

long
the
oil
deteriorates
an

the

clutches
brake

and
band
are
ad

versely
affected
Sufficient
cooling

time
should
be

given
between
each

AT
5O
test
for
the
four

ranges
0
2

I
and
R

JUDGEMENT

High
stall
revolution
more

than

standard
revolution

If
the

engine
revolution
in
stall

condition
is

higher
than
the
standard

values
it

indicates
that
one

or
more

clutches
in

the
transmission
are

slipping
and
therefore
no
further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High

rpm
in

all

ranges
low
Iine

pressure

High
rpm
in
D
2
and
I

and

normal

rpm
in
R
Rear
clutch

slipping

High
rpm
in
0

and

normal

rpm
in
I

clutch

slipping

High
rpm
in
R

only
Front

clutch
or
low
and
reverse

brake

slipping

To

determine
which
is

slipping

front
clutch
or
low

and
reverse
brake

a
road
test
is
nceded

If
whilc

coasting
after

starting

with
the
lever
in
1

range
engine

braking
does

not
work

properly
the

low
and

reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is

diffi

cult
to
ascertain

However
if
it

occurs

with
the
lever
in
2

range

engine

revolution
increases

Jp
to
thesarne

level
as
in

I

strange
It

is

impossible

to
check

it
in
the
stall
test
2
and

One

way

2
Standard
stall
revolution

If
the

engine
revolution
in

stall

condition
is
within

the
standard

values
the
control
elements
are

nor

mally

operating
in
the

ranges
0

2
I

and
R

Also

tIle

engine
and
one

way

clutch
of
the

torque
converter
are

normal
in

performance
and

operation

The
one

way
clutch
of

the

torque

converter
however
sometimes

sticks

This
is
determined
in

the
road
test

3
Lower
stall
revolution
than
stand

ard
revolution

If
the

engine
revolution
in
stall

condition
is

lower
than
the
standard

Front
Axle

Front

Suspension

FRONT
AXLE
AND

FRONT
SUSPENSION

CONTENTS

GENERAL
DESCRIPTION

FRONT
AXLE

REMOVAL
AND
INSTALLATION

WHEEL
BEARING
ADJUSTMENT

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

SHOCK
ABSORBER

REMOVAL
AND
INSTALLATION

INSPECTION

STABILIZER

REMOVAL
AND
INSTALLATION

INSPECTION

TENSION
ROD
FA
2

FA
3

FA
3

FA
4

FA
4

FA
5

FA
8

FA

8

FA
8

FA
8

FA
8

FA

8

FA
8
REMOVAL

AND
INSTALLATION

INSPECTION

TORSION
BAR

SPRING

REMOVAL
AND

INSTALLATION

INSPECTION

UPPER
AND
LOWER
LINKS

FjEMOVAL
AND

INSTALLATION

DISASSEMBLY

AND
ASSEMBLY

INSPECTION

ADJUSTMENT

VEHICLE
POSTURE

WHEEL

ALIGNMENT

STEERING
ANGLE

GENERAL
DESCRIPTION

uUl
FA

8

FA

9

FA

9

FA
9

FA

9

FA
10

FA
l0

FA
ll

FA
ll

FA
Il

FA
ll

FA

12

FA
12

FA224

Fig
FA
j
SectionallJiew

of
fronta
xle
and

fron
t

suspension

FA
2

WHEEL
ALIGNMENT

Correct
front
wheel

alignment

attains

proper
vehicle

handling
charac

teristics
and
the
least

steering
effort

with
a
minimum
amount
of
tire
wear

Before

adjusting
front
wheel

align

ment
make
sure
to

carry
out
a

pre

liminary
inspection
of
the
front
end

parts
for
the

following
conditions

1
Tire

pressure
and

balance

2
Wheel

bearings
and
nuts

3

Steering

gear
play

4

Steering
gear

housing
at
frame

S

Steering
linkage
and
connections

6
Shock
absorber
action

When

using
the

equipment
for
front

wheel

alignment
inspection
follow
the

inst

c
tions
furnished

with
the

equip

ment
Furthennore
the

inspection

should
be
made
with
the

vehicle
level

and
at

curb

weight

Camber
and

caster

Measure
camber
and
caster

and

adjust
them
in

accordance
with

the

following
procedures
if

necessary

Both
camber
and
caster

are
ad

justed
by
increasing
and

decreasing

thickness

of

adjust
shim

inserted
be

tween

upper
link

spindle
and

upper

link

mounting
bracket

To

adjust
caster

make
a

difference

between

thickness
of
front

and
rear

shims

By

adding
a
shim

I
mm
0

039

in

at
front
side

caster
will
be
de

creased

by
33

At
the

same
time

camber

will
also
be

decreased

by
6
S

To

adjust
camber
add
or
remove
an

equal
amount
of

shims
to
front

and

rear
sides

By

adding
a

pack
of
shims
I

mOl
0
039
in

thick
at
both

sides

camber

will

be
decreased

by
13

Shims

are
available
in
I

mm
0
039

in
2

mOl
0
079
in
and
4

mOl
0
157

in

thickness
Front
Axle
Front

Suspension

FA243

Fig
FA

25

Adjustingcamberand

cCJ
ter

Notes

a
Do
not
make
difference

between

front

and
rear
shims

in
thickness

beyond
2
mm

0
079
in
on
a

upper

link

spindle

b

Umit
shim
thickness
for

anyone

stack
within
6

nun
0

236
in

c
Do
not

use
shims
for

anyone
stack

more
the
2

sheets

Toe
in

Measure
toe
in

and

adjust
if
neces

sary
For

adjustment
carry
out
the

follOWIng
procedures

Turn

steering
wheel
to

straight

ahead

position
with
front
wheels
in

the
same

position
Then
check

steer

ing
gear
straight
ahead

position

Loosen
lock
nuts

@
left
hand

thread
and

ID
right
hand
thread

and
turn
cross
rod

CD
to

adjust
toe
in

Turn

cross
rod
to
forward

direction
as

shown

by
arrow
and
toe
in
is

reduced
When

cross
rod
is
turned
to

opposite

side
toe
in
is
increased

After

correct
toe
in
is

obtained

tighten
lock
nut

to
8

0
to
10

0

kg
m

S8
to

72
ft
Ib

r
J

r

CD

0

HI

r
I

e

f

FA244

Fig
FA

26

Adju6ting
toe
in

STEERING
ANGLE

Check

steering
angle
and
use
the

follow

ng
procedures
if

necessary

Loosen
lock
nut
at

stopper
bolt
and

adjust
steering
angle
with

stopper
bolt

Mter

obtaining
correct

steering

angle

secure
lock
nut

firmly

FA245

Fig
FA

27

Adjusting
steering
angle

Model
Item

All

models

mOl
in
1
2
to
3
0
079
to

0
118

Toe
in

degree
2

10
to
16

Camber

lOIS
Io

Caster
10SO

4S

I
60IS

Kingpin
inc

inal10n

I
Inner
wheel

360
10

Steering
angle

I
Outer
wheel

310
10

1
The

extreme
front
and

rear
of
the
tire

center

Unladen

2
The
total

angle
of

the
both
tires

FA
12

Front
Axle
Front

Suspension

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Vibration
shock
and

shimmy

ing
of

steering
wheeL

Vehicle

pulls
to
right
or
left
Probable
cause

Vibration
Too

much
backlash
of

steering

gear
wear

of
each

part
of

linkage
and
vibration
of
front

wheels
are
in

many
cases
transmitted
to
the

steering
wheel
This
is

Very
much
noticeable
when

traveJling
over
bad
roads
and
at

higher

speeds

Shock
When

the
front
wheels
are

travelling
over

bumpy
roads
the

play
of
the

steering
linkage
is

transmitted
to
the

steering
wheel
This
is

especially

noticeable
when

travelling
rough
road

Shimmy
Abnormal
vibrations
of
the
front

suspen

sion

group
and
the
whole

steering

linkage
which

occur
when

a

specific
speed
is
attained

Improper
air

pressure
of
tire

Unbalance
and
deformation
of
roadwheel

Unevenly
worn
tire
or

insufficient
tightening

Improperly
adjusted
or

worn
front
wheel

bearing

Faulty
wheel

alignment

Worn
or
loose

suspension
link
screw

bushing

Damaged
idler
arm

Insufficiently

tightened
steering
gear
housing

Worn

steering
linkage

Improper
steering
gear
adjustment
insufficient
back

lash

Faulty
shock
absorber
or
loose
installation

Unbalanced
vehicle

posture

When

driving
with
hands
off
the

steering
wheel

on
a

fiat
road
the
vehicle

gently
swerves
to

right
or

left

Note
A

faulty
rear

suspension
may
also
be
the
cause

of
this
condition
and
therefore
see
also
the

chapter
dealing
with
the
rear

suspension

Improper
air

pressure
of
tire

or
insufficient

tightening

of
wheel
nu
ts

Difference
in

height
of

right
and
left
tire
treads

Incorrect

adjustment
or
abrasion
of
front
wheel

bearing

Weakened
front
torsion

spring
or
deviation
from

standard

specification

Improper
wheel

alignment

Worn

or
loose

suspension
link

screw

bushing

FA
14
Corrective
action

Adjust

Correct
the
unbalance

or
re

place

Replace
or
tighten

Adjust
or

replace

Adjust

Replace

Replace

TIghten

Replace
ball

joint

Adjust

Replace
or

tighten

Adjust

Adjust
or

tighten

Replace
tires

Adjust
or

replace

Replace

Readjust

Replace

Condition

Vehicle

puBes
to

right
or
left

Instability
of
vehicle

Stiff

steeirng
wheel

Excessive

steering
wheel

play

Noise
Front
Axle

Front

Suspension

Probable
cause

Deformed
of

steering

linkage
and

suspension
link

Unbalanced

vehicle
level

Improper
air

pressure
of
tire

Worn
or

loose

suspension
link
screw

bushing

Incorrect
wheel

alignment

Worn
or
deformed

steering

linkage
and

suspension

link

Incorrect

adjustment
of

steering
gear

Deformed
unbalanced
wheel

Check

and
correct
in
the

following
manner

Jack

up
front

wheels
detach
the

steering
gear
and

operate
the

steering
wheel
and

a

If
it
is

light
check

steering
linkage
and

suspension

groups

b
If
it
is

heavy
check

steering

gear
and

steering

column

groups

Improper
air

pressure
of
tire

Insufficient
lubricants
or

mixing
impurities
in

steering

linkage
or

excessively
worn

steering

linkage

Insufficient
lubricant
in

gear
box
or
contaminated

lubricant

Unsmooth

king
pin
damaged
part
Or
insufficient

lubrication

Worn

or

incorrectly
adjusted
wheel

bearing

Worn

damaged

steering
gear
and

bearing

Incorrectly
adjusted

steering
gear

Deformed

steering
linkage

Incorrect
wheel

alignment

Interference
of

steering
column
with
turn

signal

switch

Incorrectly
adjusted
steering
gear

Worn

steering
linkage
idler

arm

Improperly
fitted
of

gear
box

Incorrectly
adjusted
wheel

bearing

Worn
or
loose

suspension
link

screw
bushing

Improper
air

pressure
of
tire

Insufficient

lubricating
oil
and

grease
for

suspension

link
screw

bushing
and

steering
linkage
or
their

breakage

FA

15
Corrective
action

Replace

Correct

the
unbalance

Adjust

Replace

Adjust

Replace

Adjust

Correct

or

replace

Adjust

Replenish
grease
or

replace

the

part

Add

or

replace
gear
oil

Replace

Replace
or

adjust

Replace

Adjust

Replace

Adjust

Adjust

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish
lubricating
oil
and

grease
or

replace

Condition

Noise

Grating
tire
noise

Jumping
of

disc
wheeL

Excessively
or

partially
worn

tire
Front
Axle
Front

Suspension

Probable
cause

Loose

steering
gear
bolts

linkage
and

suspension

groups

Faulty
shock
absorber

Damaged
wheel

bearing

Worn

steering
linkage
and

steering
gear

Worn
of
loose

suspension
link
screw

bushing

Improper
air

pressure
of
lire

Incorrect
wheel

alignment

Deformed
knuckle

spindle
and

suspension
linkage

Rough
driving

Improper
air

pressure
of
tire

Unbalanced
wheels

Faulty
shock
absorber

Worn
tire

Deformed
wheel
rim

Improper
air

pressure
of
tire

Incorrect
wheel

alignment

Damaged
wheel

bearing

Incorrect
brake

adjustment

Improper
tire

shifting
rotation

Rough
and

improper
wiving
manner

FA
16
Corrective
action

Retighten

Replace

Replace

Replace

Replace

Adjust

Adjust

Replace

Avoid

rough
driving

Adjust

Adjust

Replace

Replace

Replace

Adjust

Adjust

Replace

Adjust

Adjust

Drive
more

gently

Condition

Pedal

yields
under

slight
pressure
Brake

System

Probable

cause

Wheel

cylinder
in

poor
condition

Poor

sliding
condition
of
brake
shoe

Looseness
of

cylinder
body
or

back

plate

securing
bolts

Scored
or
out

of
round
drums

Sticking
wheel

cylinder

cups

Deformation
of
back

plate

Incorrect

adjustment
of
wheel

bearings

Incorrect

adjustment
of
wheel

alignment

Looseness
of
leaf

spring
securing
U

bolts

Faulty
N
L

S
V

Deteriorated
check
valve

Ex

ternalleaks

Leakage
on
master

cylinder

BR
24
Corrective
action

Repair
or

replace

Adjust

Fasten
or

replace

Recondition
or

replace
brake

drum
as
reo

quired
Check
for

improper
lining
contact

with
drum
and

grind
lining
if

necessary

Recondition
or

replace
cylinder

Replace

Adjust
or

replace

Adjust

Tighten
or

replace

Replace

Replace
check
valve
and
bleed

system

Check
master

cylinder

piping
and

wheel

cylinder
for
leaks
and

repair

Overhaul
master

cylinder

Condition

Wheel
wobbles

Unevenly
or

excessively
worn

tire

Tire

squeals
Wheel
and
Tire

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Probable

cause

Improper
tire

pressure

Damaged
tire

or
distorted
wheel

rim

Unbalanced
wheel

Loose
wheel
nuts

Worn
or

damaged
wheel

bearing
or
excessive

play
of
wheel

bearing

Improper
front
wheel

alignment

Worn

or
damaged
ball

joint

Excessive

steering
linkage

play
or
worn

steering

linkage

Loose

steering
linkage
connection

Broken

suspension
spring

Damaged
shock

absorber

Improper
tire

rotation

Improper
tire

pressure

Unbalanced
wheel

Improperly
adjusted
brake

Improper
wheel

alignment

Excessively
distorted
or

improperly
installed

suspension
link

High
speed
on

curves

Sudden
start

and

improper
speed
due
to

rapid
acceleration

or

improper
brake

ap

plication

Improper
tire

pressure

Improper
front
wheel

alignment

Distorted
knuckle
or

suspension
link

WT
5
Corrective
action

Measure
and

adjust

Repair
or

replace

Balance

Tighten

Correct

play
or

replace
wheel

bearing

Align

Replace

Adjust
Or

replace

Tighten
nuts
to
rated

torque
or

replace

worn

parts
if

any

Replace

Replace

Conduct
tire

rotation

periodically

Measure
and

adjust

Balance

or

replace

Adjust

Align

Repair

replace
or
if

necessary
reinstall

Reduce

speed

Follow
correct
and

proper
driving
manner

Measure
and

adjust

Align

Repair
or

replace

STEERING
SYSTEM

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Steering
wheel
moves

heavily

Steering
wheel
turns

but

sluggishly

Vehicle

pulls
to
one

side
Probable
cause

Wheel

alignment
out
of

specifications
or
air

pressure
in
tires

too
low

Steering

linkage
out
of

adjustment

Steering
column
out
of

alignment

Wheels
out
of

alignment
or
air

pressure
in

tires

too
low

Damaged
steering
linkage

Wheels
out

of

proper
alignment

Wheel

bearing
out
of

adjustment

Damaged

steering
linkage

ST
9
Corrective
action

Align
or

inflate
tires

to
correct

pressure

Adjust
and

see
relative

topic
under
Front

Suspension

Repair

Repair
or
inflate
tires

to
correct
air

pressure

Replace
and
see
relative

topic
under
Front

Suspension

Align

Adjust

Replace
and

see
relative

topic
under
Front

Suspension