window DATSUN PICK-UP 1977 Service Manual

DESCRIPTION

DOOR

REMOVAL
AND
INSTALLATION

ALIGNMENT

DOOR
TRIM
AND
SEAL

REMOVAL
AND
INSTALLATION

GLASS
RUN

REMOVAL
AND
INSTALLATION

DOOR
VENTILATOR
WINDOW

Optional

REMOVAL
AND
INSTALLATION

j
Body
Frame

DOOR

CONTENTS

BF12

BF
12

BF
12

BF12

BF12

BF12

BF13

BF
13

BF13

BF13
DOOR
GLASS
AND
REGULATOR

REMOVAL
AND
INSTALLATION

ADJUSTMENT

DOOR
LOCK

REMOVAL

AND
INSTALLATION

ADJUSTMENT

DOOR
LOCK
STRIKER

WEATHERSTRIP

DESCRIPTION

REMOVAL
AND
INSTALLATION
BF14

BF14

BF14

BF
14

BF15

BF
15

BF
15

BF
15

8F
15

BF
15

CD

CV

CID
@

@

@

1
Door

sash

2
Window
outside

weatherstrip

3
Wmdow
inside

weatherstrip

4
Door

weatherstrip

5
Rear

glass
run
rubber

6
Door

finish
holder

7
Rear
lower
sash

8
Seal
screen

9
Door

weatherstrip
clip

10
Front

glass
run
rubber

11
Lower

door

hinge

12

Upper
door

hinge

13
Front

lower
sash

14

Door

glass

15

Glazing
rubber

16
Door

glass
bottom
channel

BF030B

Fig
BF
21
Door
without
ventilator
window

BF
11

@

I

r

L

c

@

DESCRIPTION

The

door
consists

of
inner

and

outer

panels
welded

together
to

form
a

rigid
structure

The
curved

glass
provides
greater

shoulder
room

A
door

that

incorporates
a

ventila

tor

window
is
also
available

as
an

option

The

weatherstrip
is
inserted
into

the

groove
on
the

door
sash
side
and
is

attached

by
clips
on
the
door

side

DOOR

REMOVAL
AND

INSTALLATION

I
With
door
in
full

open
position

place
a

garage
jack
or
stand
beneath

door
to

support
its

weight
when
bolts

are
removed
Place

rag
between
door

and

jack
or
stand
to

avoid
damaging

painted
surface
Body
Frame

CD

1

@

@

ID

@

AJ

@

@

@
1

Door
sash

2

Window
outside

weatherstrip

3

Window
inside

weatherstrip

4

Door

atherstrip

5
Rear

glass
run

rubber

6
Door
finish
holder

7
Rear
lower

sash

8
Seal
screen

9
Door

weatherstrip
clip

10
Front

glass
run

rubber

11
Lower
door

hinge

12

Upper
door

hinge

13

Front
lower

sash

14
Door

glass

15

Glazing
rubber

16
Door

glass
bottom
channel

11

Lower

support

18

Upper
support

19
Door
ventilator

assembly

BF031B

Fig
BF
22
Door
with
ntilator
window

Optional

BF023

Fig
BF
23

Supporting
door

2

Separate
lower
door

hinge
hole

cover
from
dash

side
trim

3

While

supporting
door
as
above

back
off

body
to

upper
and
lower

hinge

attaching
bolts
accessible

from

inside
cab
three
each
Door

can
now

be
taken
out
from
cab

body

I
t

I

l
f
p1

1
W
JJ

i

Sl
j

Fig
BF

24

Removing
door

hinge

bolt

8F
12
4

To

install
reverse

removal

pro

cedure

ALIGNMENT

Elongated
holes
three
each
in

door

hinge
and
door

lock
striker

pro

vide
for

up
and

down
forward
and

backward
and
or

sideways
adjustment

to

assure

proper
door

fit

to
door

opening

To

adjust
door

alignment
loosen

bolts
and
move
door
to

desired

posi

lion

to
obtain
a

parallel

space
between

door
sides

and
door

opening
Also

check
to

be
certain

that

weatherstrip

contacts

body
opening

evenly
to

pre

vent

entry
of
mud
and
water

DOOR
TRIM
AND

SEAL

REMOVAL
AND

INSTALLATION

1

Remove
screw

securing
inside

door
handle

escutcheon
remove
es

cutcheon

2

Remove

screws
which
hold

pull

handle
and
arm
rest
in

position
Pull

handle
and

arm
rest
can
then
be

taken

out

3

Pull

retaining
spring
off

regulator

handle
Take

out

regulator
handle

and

seat
washer

BF640

4

When

removing
door
finish
it
is

important
that
inside

door

panel
and

door

finish

are
not

damaged

With
a

screwdriver

pry
off
re

taining
clips
exercising
care
not
to

damage

clips

I

a
I

II
I
L

jl

ld

II

Fig
BF
26

Removing
door

finish

5

Separate
water
seal

screen
from

inside

door

panel

6
To
install

reverse
removal

pro

cedure

However
observe
the
follow

ing
instalJation
notes

i
When

water
seal

screen
is
to
be

replaced
be
Sure
to

cement
it
back

into

position
securely
to
ensure
a

water
sealed
door
This

can
be

done

by

evenly

applying
adhesive

to

grooves
in

inside
door

panel

Broken
screen
Or

one

suspected
to

be

leaking
must
be

replaced
with
a

new
one
Body
Frame

1

3
Seat

washer

Regulator
handle

Retaining
spring

Fig
BF
25

Removing
regulator
handle

Adhesive

I
i

f
f

nil

Section
A

A
Ii

ir
coil

IIIII
I

J
J

iif
J

lUJ

A

A
J

J

BF641

Fig
BF
27
Adhesive

for
seal
screen

2
With
door

glass

up
set

regulator

handle

at
an

angle
shown
in

Figure

BF
28

d

1

J

900
Spring

l

BF462

Fig
BF
28
Installation

angle
of

regulator
handle

GLASS
RUN

REMOVAL
AND

INSTALLATION

I

With
door
in
full
out

position

lower

glass
all
the

way

2

Remove

pull
handle
arm
rest
and

regulator
handle

3
Remove
door
fmish
and
water

seal
screen

4
Remove
outer
and
inner

weather

strips
from
door

BF
13
5

Remove
door

glass

6

Remove

glass
run
rubbers

from

front
and
rear
lower
sashes

and
from

those
of
fixed
door

Use
caution

to
avoid

damaging

rubbers

during
removal

operation

7
Remove

front
and
rear
lower

door

sashes
when
ventilator
window

is

not

provided

8

On
vehicles

equipped
with
venti

lator
window
remove

ventilator

window

frame
and
rear

lower
door

sash

9

To
install

reverse
removal

pro

cedure
However

observe
the

follow

ing
notes

I

Before

applying
adhesive
clean

the
inside
of
door

sash

2

Apply
adhesive

to
glass
run

rubber
on
door
sash

contacting
face

and
fit

it

correctly
Particularly
care

should
be

taken
at
corners
and

contact

face

to
assure
a

good
fit

CD

CID

BF641

1
Door
sash

2

Glass
run
rubber

3
Adhesive

Fig
BF

29

Applying
adhesive
to

glass
run
ru
bber

DOOR
VENTILATOR

WINDOW

Optional

REMOVAL
AND

INSTALLATION

I

Remove
five
ventilator
window

frame

attaching
bolts
Lift
frame
out

of
door
For

detailed

procedure
refer

to
relative

topic
under
Door
Glass

and

Regulator

2
Remove
nuts
and

spring
securing

lower
end
of

ventilator
window
to

frame

3
Work
off
rivets

which
hold

upper

end
of
ventilator
window
to
frame

take
out
window

4
To

install
reverse
removal

pro

cedure

Body
Frame

DOOR
GLASS
AND
REGULATOR

CD

REMOVAL
AND

INSTALLATION

L

Open
door
lower
glass
all
the

way

2
Remove
iflllide
door
handle
es

cutcheon

3
Remove

pull
handle

4

Remove
arm
rest

5
Remove
regulator
handle

6
Remove
door
finish

7
Peel
off
water
seal
screen

8
Work
off

outer
and
inner
weath

erstrips
from
door
being
sure
not
to

scratch
door

paint
during
operation

Use
a
suitable

plain
screwdriver
or

similar
flat
bladed
tool
io

remove
and

place
a

piece
of

rag
between
screw

driver
and
door

panel

BF643
1
Outet

weatherstrip

2
Screwdriver

3
Piece
of

rag

Fig
BF
31

Removing
outer

weather

trip

9

Remove
three
door

glass
bottom

channel

attaching
bolts
Remove
door

glass
by

lifting
it

straight

up
Fig
BF
30
Door

gl
and

regulator

10
On
door

equipped
with
venti

lator

remove
three
bolts

securing
door

glass
bottom
channel
then

let

glass
go

to

the
bottom
of
door

Remove
ventilator
frame

attaching

bolts
and
lift
frame

straight
up
out
of

door
Remove
door

glass
by
lifting
it

straight
up

11

Back
off
the
five

guide
channel

to

regulator
base

attaching
screws

Take
out

regulator
assembly

through

large
access
hole
in
inside
door

panel

DOOR
LOCK

1
Escutcheon

2
Inside

handle

3
Spring

4

Door
lock
knob

5
Knob

grommet

6
Outside
handle

7
Outside
handle
rod
j

f

ffi
I

Fig
BF
32
BF035

Removing
door

glass

12
To
install
reverse
removal

pro

cedure

ADJUSTMENT

I

In
and
out
and
fore
and
aft
ad

justment
can
be
made

by
moving

front

or
rear
sash
and

guide
channel

as

required

The
ease
with
which
window
assem

bly
raises
and
lowers

depends
on
ad

justment
of
rear

lower
sash
Rear

lower
sash
should
be

parallel
with

front
lower
sash

2

Fore
and
aft

adjustment
is

deter

mined

by
position
of

guide
channel

and
front
lower
sash

Moving
front

lower
sash
backward
reduces

play
in

window

assembly

j

CID

@

8
Nylon
nut

9

Locking
plate
ring

10
LOcking

plate

11
Door

lock
cylinder

12

Door
lock

13

Stopper

BF

14
BF410A

Fig
BF
33
Door
lock
mechonillm

WINDSHIELD
GLASS

DESCRIPTION

The

windshield

glass
is
retained
in

the

body
glass
opening
through
the

weatherstrip
There
are
twelve

water

drain
holes
one
on
each

side
of
the

bottom
of
the

glass
opening
and
ten

along
the

length
of
the

weatherstrip

1

Weatherstrip

2
Windshield

glass

3

Water
drain
hole

Fig
BF
35
Windshield

glass
and

weatherstrip
BF473A

REMOVAL

1
Place

protective
covers
over
en

gine
hood
front
fender
seat
and
in

strument

panel

2
Remove
inside
rearview
mirror

and
sun
visor

3
Remove
windshield

mouldings
if

so

equipped

4

Using
a

putty
knife
or
similar

flat
bladed
tool

pry
lips
of
weather

strip
out
of

place
from

top
and
side

flanges
of

body
opening

If

weatherstrip
is

to
be
reused
it
is

important
that
it

not
be

damaged

during
this

operation

BF041

Fig
BF
36

Removing
weatherstrip
Body
Frame

WINDSHIELD
GLASS

5

Working
from
inside
vehicle

push

windshield

glass
out

of

body

opening

by
hand

starting
at

right
and
left

upper
COIners
and

working
out
toward

ends

6
After

removing
weatherstrip
from

top
and
sides
of

body
opening
lift

glass

up
sufficiently
to

permit
removal

of

weatherstrip
from
bottom

flange

pry
weatherstrip
out
of

position

This

operation

requires
two
men

INSPECTION

Prior
to

installing
windshield

glass

make
the

following
checks
on
body

glass

opening
and

weatherstrips

I
Clean

weatherstrip
channels
re

placing
those
found
with

cracks
or

signs
of
deterioration

2
Clean

body
openings
noting
if

these
are
distorted
or
corroded

INSTALLATION

L

Fit

weatherstrip
on

glass

making

sure
it
is

properly
seated
and

posi

tioned
Adhesive
need
not
be

applied

0

BF641

Fig
BF

37

Fitting
weatherstrip
on

glass

2

Insert
a
draw
cord

completely

around

weatherstrip
outer
channel

Q
i

I

dYii

1

Windshield

glass

2
Draw
cord

3

Weatherstrip

Fig
BF

38
In8erting
draw
cord
around

weatherstrip
outer
channel
8F648

BF
16
3

With
aid
of
a

helper
press
wind

shield

assembly
against
body
opening

from
outside

being
sure
weatherstrip

lip
aligns
ith

body
opening
flange

4

Slowly

pull
cord
ends
from
inside

to

overlap
weatherstrip
channel
on

body
opening

flange
starting
at
center

top
and

working
out
toward
ends
This

operation
should
be
done
while
one

man
pushes

glass
against
body
opening

from
outside

The

same

technique
should
be

ap

plied
to

right
left
and
bottom

wea
th

erstrips

Fig
BF
39

Fitting
weatherstrip

top

BF650

Fig
BF

40

Fitting
weatherstrip

bottom

5
Install

windshield

moldings
on

weatherstrip
if
so

equipped

6
Install
inside
rearview
mirror
and

sun
visor

BACK
WINDOW

GLASS

AND
SIDE

WINDOW

GLASS

Refer
to
relative

topics
under
Re

moval

Inspection
and
Installa

tion
of
windshield

glass

Body
Frame

INTERIOR
TRIM

AND
CENTER
CONSOLE

HEADLINING

DESCRIPTION

The

headlining
assembly
is
of
a

suspension
type
which
is
held
in

place

ct

I

2

3

4

5

6

7

8

9

REMOVAL

1
Remove
two
inside
rearview
mir

ror

attaching
screws
and
detach
rear

view
mirror

2
Remove
three
sun
visor

attaching

screws
and
detach
sun
visor

3

Remove
two
assist

rail

attaching

screws
and

detach
assist

rail

4

Remove
room

lamp

5

Open
doors
and
remove

body
side

welts
on
each
side

6
Remove
windshield

glass
and

weatherstrip

7

Remove
back
window
and
weath

erstrip

8
Remove

garnish
securing
the
end

of

headlining
to
rear

pillar
by
listing
wires

The

design
is

quite

similar
to
that
used
in
a

passenger
car

A

BF648A

Fig
BF
43
Headlining

CD
r
h
i

r

J

I

I

I

II

CID

BF661

1

Headlining
cloth
4

Door

glass

2

Clip

5

Back
window

glass

3
Garnish

Fig
BF
44

Removing
gami8h

9
Detach

all

cemented

edges
of

headlining
from

flanged
portion
of

roof

rail

10

Disengage

listing
wires
from
roof

rail

and
detach

headlining

INSTALLATION

I

Apply
adhesive
cement
to
the

outer
surface
of

flange
and

headlining

attaching
surface

evenly

8F
18
2

Install

listing
wires
in

place
on

roof
rail

3

First
attach
front

headlining
to

the

flanged
portion
of
roof
rail

Secondly
attach
the
rear

edges
of

headlining
in

place
while

pulling
the

headlining
material
to
avoid
wrinkles

4

Attach
the

right
and
left

edges
of

headlining
material
to

the

flanged
por

tions

using
care
to
avoid
wrinkles

5
Cut
excess

headlining
material
ex

cept
for
that
at
the

upper
areas
of

front
center
and
rear

pillars
not

covered

by
body
side
welt
The

edges

of

headlining
ma
terial
at
these

areas

should
be
so
cut
that
it
can
be
folded

properly
in

place

6
Install

garnish
on
the
extreme
end

of

headlining
at

rear

pillar

7
Drill
a

hole
in

headlining
where

room

lamp
is
located

Install
room

lamp

8

Install

body
side
welts

9
Install
windshield

glass

10
Install
back
window

glass

11

Install
assist

rail
sun
visor
and

inside
rearview
mirror

BACK
TRIM
AND

BACK

INSIDE

FINISHER

DELUXE
CAB

REMOVAL
AND

INSTALLATION

Back
trim

I
Move
floor

carpet
aside

2
Remove

four
bolts

attaching
back

trim

to
floor

3
Remove
five
trim

clips
and
detach

back
trim

4
Installation
is
the
reverse
order
of

removal

Back
Inside
finisher

I
Remove
seat
belt
retractor

2
Remove
five
trim

clips
and
detach

back

inside
fmisher

3
Installation
is
the
reverse
order
of

removal

Notes

a
The
bubbles
seen

through
the

sight

glass
are
influenced

by
the
ambient

temperature
Since
the
bubbles
are

hard
to
show

up
in

comparatively

low

temperatures
below
200C
6S0

F
it
is

possible
that

a

slightly

larger
amount
of

refrigerant
would

be
filled
if

supplied
according
to

the

sight
glass
Be

sure
to
recheck

the
amount
when
it

exceeds
200C

680F
In

higher
temperature
the

bubbles
are

easy
to

show

up

b

When
the

screen
in
the

receiver

dryer
is

clogged
the
bubbles
will

appear
even
if
the
amount
of

refrig

erant
is
normal
In
this
case
the

outlet
side

pipe
of
the
receiver

dryer
becomes

considerably
cold

PERFORMANCE
TEST

Check
for
the
amount
of

refrigerant

in
the

system
can
be

made

by
meas

uring

pressure
on

discharge
side

The

correct
amount
of

refrigerant
is

in
the

system
if

pressure
on
the

discharge
side
is
within

the

specified

range
For
details
refer
to

Perform

ance

Test
described
later

Overcharging
will
show

up
in

higher

pressure
on
discharge
side

COMPRESSOR
OIL

LEVEL

CHECK

The
oil

used
to
lubricate

compres

sor
circulates
into

system
from
the

oil

sump
while

c9mpressor
is

operating

The

efore
to

correctly
measure
com

pressor
oil
the

amount
of
oil

flowing

to

system
must
be

considered
If
a

considerable
amount
of

leakage
of

refrigerant
gas
happens
the

leakage
of

compressor
oil
is
also
considered

There

will
be

no

compressor
oil
leak

age
from
a

completely
sealed

system

When

system
operates
under

satisfying

condition
the

compressor
oil
level

check
is

unnecessary

When

checking
the
level

of
com

pressor
oil
or

when

replacing
any

component
part
of
the

system
use
the

following
service

procedure
This

fa

cilitates
to
return
oil
to

compressor

I

Operate
compressor
at

engine

idling
speed
1
000

rpm
or

below

with
controls
set

for
maximum

cooling
Air

Conditionin
j

and

high
blower

speed
for
10
to

15

minutes
in

order
to
return

compressor

oil
to

compressor

2

Stop
the

engine
and

discharge

refrigerant
of

system
and
then

remove

compressor
from

the
vehicle

3
Remove

compressor
fIller

plug

Drain

compressor
oil
from

compres

sor
oil

sump
and

measure
the

amount

4

Compressor
oil
is

satisfactory
if

the

following
amount
of
oil

remains
in

the

compressor

Residual
oil

S5
to
128

gr
3
to
4
oz

5
Check
the
cleanliness
of
the
oil
If

the
oil
contains

chips
or

other

foreign

material
clean
oil

5ump
with
new

oil

6
Discard
the

used
oil
and

fili
with

the
same
amount
of
new
oil
Add

oil
if

found
less
than
above
amount

Fig
AC
27

Filler

plug

If

compressor
is

inoperative
due
to

faulty
compressor
or

heavy
loss
of

refrigerant
remove

compressor
and

repair
as

necessary
Then

pour
oil

up

to
correct
level
and
install
on

engine

After
above

steps
have
been

complet

ed
recheck
oil
level
drain
oil
to

correct
level
if

level
is

excessively
high

PERFORMANCE
TEST

The
cooling

performance
of
the
air

conditioner

changes
considerably
with

changes
in

surrounding
conditions

Testing
must
be

performed
using
the

correct
method
This

test
is
used
to

judge
whether

system
is

operating
cor

rectly
and

can
also
be
used

as
a

guide

in

checking
for

problems

I

Park
the
vehicle
indoors
or
in
the

shade

AC
17
2

Open
all
the
windows
of
the

vehicle
fully
However

close
the

doors

3

Open
the
hood

4

Connect
manifold

gauge
to

high

and
low
side
service
valves
of
the

system
Refer
to

Handling
Manifold

Ga

uge

5

Set
fan
control
lever
to
maxi

mum

6
Set

temperature
control
lever

to

max
cool

position

7
Start
the

engine
and
hold

engine

speed
at
1
500

rpm

S
After
the
air

conditioner
has
been

operated
for
about
10
minutes

measure

system

pressures
at

high
pres

sure

discharge
side
and
low

pressure

suction
side

9
Measure
the

temperature
of
dis

charge
air
at

outlet

grille

10
Measure
the

temperature
of

capin

11
Measure
ambient

temperature

and

humidity
one
meter
3
3
ft

away

from
condenser
front
Be

careful
not

to

expose
dry
buib

and
wet
bulb

to

direct

sunlight

12
Check
for

any
abnormalities

by

comparing
the
test

results
with
stand

ard

pressure
in
Performance

Chart

Notes

a
The

pressure
will

change
in
the

followi

g
manner
with

changes
in

conditions

When

blower

speed
is

low
dis

charge

pressure
will

drop

When
the
relative

humidity
of
in

take
air
is
low

discharge
pressure

will

drop

b

The

temperature
will

change
in
the

following
manner
with

changes
in

conditions

When
the
ambient
air

temperature

is

low
the
outlet
air

temperature

will
become
low

If
the
test
reveals
that
there
is

any

abnormality
in

system
pressure
isolate

the

cause
and

repair
by
reference
to

the
Trouble

Diagnoses
and
Cor

rections