fuel tank removal DATSUN PICK-UP 1977 Service Manual

DESCRIPTION

FUEL

PUMP
TESTING

STATIC
PRESSURE
TEST

CAPACITY
TEST

DESCRIPTION

The
fuel

pump
transfers
fuel
from

the
tank
to
the
carburetor
in
sufficient

quantity
to
meet
the

engine
require

ments
at

any
speed
or

load

The
fuel

pump
is
a

pulsating
type

designed
for

easy
maintenance
It

con

sists
of
a

body
a

rocker
arm

assembly

a

fuel

diaphragm
a
fuel

diaphragm

spring
seal
inlet
and
outlet

valves

Figure
EF
19

shows
a
cross
sectional

view
of
the

pump

The
fuel

diaphragm
consists

of

specially
treated
rubber
which
is

not

affected

by

gasoline
and
held
in

place

by
two

metal
discs
and

a

pull
rod

FUEL

PUMP

TESTING

A
fuel

pump
is

operating

properly

when
its

pressure
is

within

specifica

tions

and
its

capacity
is

equal
to
the

engine
s

requirements
at
all

speeds

Pressure
and

capacity
must
be
deter

mined

by
two
tests
while
the

pump
is

still

mounted
on
the

engine
Be
sure

there
is
fuel
in

the
tank
when

carrying

out
the
tests
Engine
Fuel

MECHANICAL
FUEL
PUMP

CONTENTS

EF
9

EF
9

EF
9

EF
10
REMOVAL
AND
DISASSEMBLY

INSPECTION

ASSEMBL
Y
EF

10

EF
10

EF

11

1

1

Outlet
valve

2

Diaphragm

3

Diaphragm
spring

4
Inlet
valve

S
Rocker
ann
EF006

Fig
EF
19
Schematic
view

of
fuel
pump

STATIC
PRESSURE
TEST

The
static

pressure
test
should
be

made
as
follows

I
Disconnect
fuel
line
between
car

buretor
and
fuel

pump

2
Connect
a
rubber
hose
to
each

open
end
of
a
T
connector
and
con

nect
this
connector
hose

assembly
be

tween
carburetor
and
fuel

pump
Note
Locate
this
T
connector
as

close
to

carburetor
as

possible

3
Connect
a

suitable

pressure
gauge

to

the

opening
of
T
connector
and

fasten
hose
between
carburetor
and

T
connector
with

a

clip
securely

EF
9

854
co
in
in
one
minute
or
less

If
no

gasoline
or

only
a

little
flows

from

open
end
of

pipe
with

pump

operated
or
if

pump
does

not
work

perform
the

following
diagnosis

Notes

3
Do
not

connect
battery
in
reverse

polarity
which
if
left
for
a

long

time
would

damage
transitor

circuit
and
disable

pump
Engine
Fuel

b
Do
not
let
fall

pump
as
it

may

damage
electronic

components

c
Do
not

apply
overvoitage
max

l
8Y

Overvoltage
starting

by

quick
charge
or

tage
running

would
deteriorate
or

damage
elec

tronic

components

Fuel

pressure
maximum

0
32

kg
cm
4
6

psi

REMOVAL
AND
INSTALLATION

Flom
fuel
tank

Electric
fuel

pump
is
installed
on

bracket
with
two
bolts
This
bracket
is

located
on
R
H
side
member

adjacent

to
fuel
tank

I
Remove
inlet
hose
from
fuel

pump
Also
remove
outlet
hose
run

ning
to

engine
Receive
fuel

remaining

in
fuel
hose
in
a
suitable
container

2
Disconnect
harness
at

connector

3
Remove
bolts

securing
fuel

pump

to
bracket
and
detach
fuel

pump

4

Installation
is

the
reverse
order
of

removal

9

@

1
Cover

2

Magnet

3
Cover

gasket

4
Filter

5
Gasket

6

Spring
retainer

7
Washer
8
O

ring

9
Inlet
valve

10
Retutn

PIing

11
Plunger

12

Plunger
cylinder

13

Body
To
carburetor

1
Elecuic
fuel

pump

2

Mounting
bracket

3
Fuel
mter

EF72D

Fig
EF
23
Electric
fuel

pump

DISASSEMBLY

Do
not
disassemble
unless

pump
is

faulty

I
Remove

cover
with
wrench
and

take
out
cover
gasket
magnet
and

filter
from

pump
body

2
When

removing
plunger
take
out

spring
retainer
from

plunger
tube

3
Then
take
out
washer
O

ring

inlet
valve
return

spring
and

plunger

from
tube

Note
Do
not
disassemble
electronic

components
If

n

replace

with
new
ones

6

EF721

Fig
EF
24

Exploded
view

of
electric
fuel

pump

EF
12
ASSEMBLY

I

Before

assembly
clean
all

parts

with

gasoline
and

compressed
air

com

pletely

Notes

a
If

gask
t

an
d
fdterare

faulty
r

place

b
Clean

magnet
and
cover
for
fault

c
Take
care
not
to
defonn
thin
tube

d
Assemble

plunger
return

spring

inlet
valve
O

ring
washer
and
set

spring
retainer
in
that
order

e

Assemble
filter

gasket
and
cover

with

f

Tighten
cover
with
wrench
to
the

stopper

If

component
parts
are

dirty
after

disassembly
clean
as
follows

Wash
fIlter
and
strainer
with
clean

gasoline
and
blow
with

compressed

air
When

cleaning
parts
check

fllter
for
fault
If

faulty
replace

Wash

plunger
plunger
cylinder
and

inlet
valve
with
clean

gasoline
and

blow
dust
off

with

compressed
air

2
Check

c
v
m
lI

parts
for
wear

or

damage

If

they
are
found

faulty

replace

them

3

Insert

plunger
assembly
into

plunger
cylinder
of

body
and

apply

electric
current
to
it

Move
the

assembly

up
and
down

If
the

assembly
does
not
move
it

shows

that
the
electric

uuit
is

faulty

and
it
must
be

replaced

s

Install
tension

rod
at
rear
end

tighten
nut
to

make
the

distance
of

rubber

bushing
to
be
33
4
mm
1
315

in
and

torque
lock
nut
to
1

6
to
2
2

kg
m
12

to
16
ft
lb

6

Install
tension
rod
bracket

to

chassis

frame
bracket
and

torque
nut

to
1

6
to
2
2

kg
m

12
to
16
ft
lb

When

two
rubber

bushings
are
dif

ferent
in
size

arrange
adjusting
nut

Standard
dimension
is
11
0
mOl
0
433

in

as
shown
in

Figure
FA

16

Torque

lock
nut

to
1
6
to
2
2

kg
m

12
to
16

ft
lb

Il
0

11

0
0
433

t

lP

33
4
1
315

I

11
0

0
433
1
0
11
0

0

433

Adjusting
nut

Y
i

w

36
6
l
441

Unit
mm

in

FA235

Fig
FA
16
Tension
rod
detail

INSPECTION

I

Check
tension

rod
for
bend
and

the

thread
for

faulty
condition

Repair

or

replace
as

required

2

Check

bushing
rubber
for
wear

and
deterioration

Replace
if
neces

sary

TORSION

BAR

SPRING

REMOVAL
AND

INSTALLATION

Removal

1
Raise
vehicle
on
a
hoist
or
stands

2
Remove
wheel

3
Loosen
nuts
at

spring
anchor

bolt
Front
Axle
Front

Suspension

4
Remove
dust

cover
at
the
rear

end

of
torsion
bar

spring
and

detach

snap

ring

S
Withdraw
torsion
bar

spring
rear

ward

after

pulling
ou
t
anchor
arm

realWard

I

nstallalation

Install
torsion
bar

spring
in
the

reverse

sequence
of

removal

noting

the

following
instructions

I

Coat

grease
on
the
serrations
of

torsion
bar

spring
and
install
it

to

torque
arm

Note
Be

sure
to
install

right
and
left

torsion
bar

springs
correctly
They

can

be
identified
with
R

Right

and
L

Left
marked
on
the
end

surface

2
Install

anchor
arm
and

tighten

adjusting
nut
to

obtain
A
dimen

sion
See

Figure
F
A
17

When
anchor

arm
is

properly
adjusted
to
A

specification
upper
link
should
be
in

contact
with

rebound

bumper
rubber

See

Figure
FA
18
Install

snap
ring
and

dust
cover

Temporarily
tighten

adjust

ing
nut
until
B

specification
is

reached

I

I

I

FA236

Fig
FA
17

Installing
anchor
arm

Specifications
for
torsion
bar

spring

Diameter
x

length
mOl

in

Torsional

rigidity

kg
m

deg
ft
lb

deg

FA
9
Anchor
arm

setting
post
ion
A

ISt02Smm

0
59
to

0
98
in

Temporary
tightening
distance
B

60
to
70

mOl

2
36
to
2

76
in

UjPPje
Rebound

bumper

rubber

j

4W

Fig
FA

18

Setting
procedure

Notes

3
A

and
8

specifications
are

only
the

preliminary
rough
settings

directions
for

performing
the
final

adjustment
that

determines
the
ride

height
are
found
on

page
F
A
II

under

Adjustment

b
Discard
old

snap
ring
after

re

moving
it

Replace
with
new

one

during
reinstallation

3
Install
wheel
and

lower
vehicle

Adjust
vehicle

posture
at
curb

weight

full
fuel

tank
no

passengers
refer

ring
to

Adjustment

4

Torque
lock
nut
to
3
1
to
4
1

kg
m
22
to
30

ft
lb

INSPECTION

Check
torsion
bar

spring
for
wear

twist
etc
When

adjusting
vehicle

posture
replace
torsion
bar

spring

with
a
new
one
if
the

specified
height

can
not

be
obtained

All
models

21

9
x
830
0
862
x

32
68

3
74
27
I

DESCRIPTION

REMOVAL

DESCRIPTION

The
fuel
tank
is4Sliters
II

Ji
U
s

gal
9
Ji

Imper
gal
in

capacity
The

tank
unit
is

mounted
to

the

right
side

of
the
rear

floor

1
Fuel

tank

2
Drain

plug

3
Filler
tube

4

RescfYOir
tank

5
Filler
hose

6
Breather
hose

7
Ventilation
hose

8

Evaporation
hose

9
Fuel
outlet
hose
and
tube

10
Fuel

tank

gauge
unit

11

Protector

12
Bracket

13
Retainer

14
Return

tube
Engine
Control
Fuel
Exhaust

Systems

FUEL
SYSTEM

CONTENTS

FE
4

FE
5
INSPECTION

INSTALLATION
FE
6

FE
6

The
filler
shutter
is
installed
to

the

filler
tube
on
California
models

The
electric
fuel

pump
is

adopted

on
air

conditioner

equipped
models
For

the
electric
fuel

pump
refer
to

Section
EF

FE194

Fig
FE
3
Fuel
tank

FE
4

Detail
A

Detail
D

REMOVAL
Engine
Control
Fuel

Exhaust

Systems

Detail
Bn
4

Detail
e

@

Detail
E

B

Fuel
tank
See

Figure
FE
a

I
Disconnect

battery

ground
cable

2
Remove
drain

plug
and
receive

the

remaining
fuel
into
a

suitable

container

3
Disconnect
filler
tube

fro
filler

hose

4
Remove

fuel
tank

securing
bolts

5
Disconnect

two
ventilation
hoses

fuel
return
hose
and
fuel
outlet
hose

from
fuel

tank

6
Disconnect
fuel
tank

gauge
unit

wires

at
connector

7
Remove

fuel
tank

Note

Plug
hose

and
tube

opening
l
to

prevent
entry
of
dust
or
dirt
while

removing

ReservoIr
tank

1

Disconnect

battery
ground
cable

2
Disconnect
two
ventilation
hoses

evaporation
hose
and
breather
hose

3
Remove
reservoir
tank

securing

bolts

and
remove
tank
with

protector
Note

Plug
hose
and
tube

opening
l
to

prevent
entry
of
dust
or

dirt
while

removing

Fuel

tank

gauge
unit

Disconnect

battery
ground
cable

2

Disconnect
wires

from
fuel
tank

gauge
unit

3

Remove
fuel

tank
For
details

refer
to
fuel
tank
removal

4

Unit

gauge
is
a

bayonet
type
and

can

be
removed

by

turning
it
counter

clockwise
with

screwdriver

Fuel

piping
See

Figure
FE
4

Fuel

tubes
are

serviced
as
an
as

sembly
so
that

replacement
of

fuel

tube
can

be

easily
done
However
do

not
disconnect

any
fuel
line
unless

absolu

tely

necessary

I

Drain
fuel
from
fuel
tank

2

Loosen
fuel

hose

clamps
and
dis

connect

fuel
tubes
on

each
end

Note

Plug
hose
and
tube

openings
to

FE

5
Detail
F
Detail

G

Detail
U

Detail
T

FE261

Fig
FE
4
Fuel

piping

prevent
entry
of

dust
or
dirt
while

removing

3
Unfasten

clips
that
hold
tube

on

under

body
and
remove
tube
from
the

vehicle

Fuel
filter

I
Disconnect
fuel
hoses
from
fuel

filter

by
removing
clamps
See

Figure

FE
5

FE18S

Fig
FE
S

Removing
fuel
filter
clamps

Engine
Control
Fuel
Exhaust

Systems

2
Remove
fuel

filter

INSPECTION

Fuel

tanle

Check
fuel

tank
for

cracks
or

deformation
If

necessary
replace

2
Fuel
hose

Inspect
all
hoses
for
cracks

fatigue

sweating
or
deterioration

Replace
any

hose
that

is

damaged

3
Fuel
tube

Replace
any
fuel
tube
that
is

crack

ed
rusted

collapsed
or
deformed

Note

Inspect
hoses
and
tubes
ac

cording
to
the

periodic
mainte

nance
schedule

4

Fuel
filter

Replace
fuel
filter

according
to

the

periodic
maintenance
schedule
or

when

it
is

clogged
or
restricted

DESCRIPTION

REMOVAL

DESCRIPTION

The
exhaust

systems
installed
on

the
non
California
models
differ
in

specifications
from
those
installed
on

the
California
models
Fuel
filter
is

of
a

cartridge
type

and
cannot
be
cleaned

Always

replace

with
a
new
one

5
Fuel
tank

gauge
unit

Check

gauge
unit

for
rust
deforma

tion
or

deterioration
If

necessary

replace

INSTALLATION

To
install
reverse
the
order
of

removal
Observe
the

following

I

Install
hose

clamps
securely
Do

not

tighten
excessively
to

avoid

damaging
hoses

2
Fasten

clips
holding
fuel
tube
on

under

body
securely
Failure
to
follow

this
caution

could
result
in

damage
to

the
surface

of
fuel

tube

3
Do
not
kink

or
twist

hose
and

tube
when

they
are
routed

EXHAUST
SYSTEM

CONTENTS

FE
6

FE

8
INSPECTION

INSTAllATION

Non
California
models

The
exhaust

system
consists

of
a

front
exhaust
tube
a
main

muffler

assembly
with
rear

tube

mounting

hangers
brackets
and
a
heat

insulator

FE
6
4
Install
fIller
hose
after
fuel

tank

has
been
mounted
in

place
Failure

to

follow
this
caution
could
result
in

leakage
from

around
hose
connections

5
When

installing
fuel
tank

gauge

unit

align
the

projection
of

tank

gauge

unit
with
the

notch
in
fuel

tank
and

tighten
it

securely
Be

sure
to
install

gauge
unit

with
O

ring
in

place

6
Run

engine
and
check
for
leaks
at

connections

Tightening

torque

Drain

plug

5

0
to
6
0

kg
m

36

to
43

ft
Ib

Fuel
tank

securing
bolt

0
8
to
1
I

kg
m

6
to
8
ft
Ib

Reservoir

tank

securing

bolt

032
to
0
44

kg
m

2

to
3

ft
Ib

FE
8

FE
8

California
models

The
exhaust

system
cOllsists
of

a

front
exhaust

tube
a

catalytic
conver

ter

assembly
a
center
tube
a

main

muffler

assembly
with
rear
tube

mounting
hangers
brackets
and
heat

insulators

The

catalytic
converter
is
COD

nected
to
the
front

tube
and
the

center

tube
with
bolts
and
nuts

Body
Frame

30

For
installation

reverse
above

steps
However
observe

the

following

instructions

i
If
the
cab

body
is

to
be

replaced

note

position
and

location
of
insula

tors
and
washers
used

See

Figure

BF
4

2

Adjust
hand

brake
stroke

pro

perly

3

Air
bleed
brake

and
clutch

system

thorougWy

Cab

body
to
frame

mounting

bolt

torque

1

6
to
2
2

kg
m

12

to
16
ft
Ib
o
i

k

q

1Q
j

b

crru
V

J
8F630

rr

1

4
n
Fig
BF
5

Lifting

up
cab

body

REAR

BODY

1

Bolster

2

Shim
B

3
Bolster

4

Shim
A

5

Frame

6
Rubber
washer

7
Plain
washer

BF664

Fig
BF
6
Rear

body
mountings

REAR
BODY

REMOVAL

AND

INSTALLATION

The
rear

body
is

securely
fastened

to
the
frame
at

eight
places
It

should

be
hoisted
after
the
fuel
tank
is

re

moved
from

the
rear

body

Use

the

following
procedures
as
a

guide
when
removal
or

installation

of

rear

body
is

necessary

I

Apply

parking
brake

2

Disconnect
cables
from

battery

3

Disconnect
rear

combination

lamp
wiring
harness
at
connectors

4
Disconnect
fuel

hoses
from
fuel
tank
Remove
fuel
tank

from
rear

body
5

Remove

eight
rear

body

attaching

bolts

BF665

Fig
BF
7

Rear

body
mountings

BF
5

REMOVAL
AND

INSTALLATION

I

Disconnect

battery
ground
cable

2

Working
through
meter

openings

of

cluster
lid
remove

three
screws

retaining
cluster

lid
to
instrument

panel

3

From
underneath
instrument

panel
remove
one
screw

retaining
me

ter

assembly
to
lower

panel
of
instru

ment

4

Withdraw
cluster
lid

slightly
For

ccess
to
switches
knobs
etc
follow

the

procedures

given
in

each
section

5

From
behind

combination
meter

disconnect

speedometer
cable

at

speedometer
head
and

multiple
con

nector
instrume

nt
wire

assembly

from

printed
circuit

6
On
vehicle
with
clock

disconnect

wires

at
each
connection

on
meter

printed
circuit

7
Remove
four
screws

retaining

me
ter

assembly
to
cluster
lid

8

Remov
combination
meter

as

sembly

9
When

installing
combination

me

ter

assembly
follow

the
reverse
se

quence
of
removal

Fig
BE

23

Removing
eluster
lid

SPEEDOMETER

REMOVAL
AND

INSTALLATION

1

Remove
combination
meter

as

sembly
Follow
the

procedures
under

Removal
and
Installation
in
Combina

tion

Meter
Body
Electrical

System

2
Remove
meter
front
cover
and

shadow

plate
by

removing
clips
and

screws

3

Remove
screws

retaining
speed

ometer
to

printed
circuit

housing
and

remove

speedometer

4
Install

speedometer
in
the

reverse

sequence
of
removal

ODOMETER
SWITCH

REMOVAL

AND

INSTALLATION

I
Remove

speedometer
as
outlined

under

Speedometer

2
Remove
odometer

retaining

screws

3
Install
odometer
in
the
reverse

sequence
of
removal

BE342A

Fig
BE

24
Odometerswitch

FUEL

GAUGE

AND
WATER

TEMPERATURE

GAUGE

DESCRI

PTION

The
fuel

gauge
consists

of
a

tank

unit

located
in
the

fuel
tank

and
fuel

gauge
The
tank

unit

detects
fuel
level

with
its

float

converts
fuel
level
varia

tion
to
a
resistance

of
slide
resistor

installed

on
the
float
base
and

thus

controls

current

flowing
to
the
fuel

gauge

BE16
The
water

temperature
gauge
con

sists
of
a

gauge
and
thermal
transmit

ter
located
in
the

engine
block
The

thermal
transmitter
is

equipped
with

a

thermistor
element

which
converts

cooling
water

temperature
variation

to

a
resistance
and
thus
the
thermal

tr

t
c

rtrols
cUfTent
flowing
to

the

gauge

The

fuel

gauge
and

water

tempera

ture

gauge
are

provided
with
a
bi
metal

arm
and
heater
coil
When
the

ignition

switch
is

set
to
ON
current
flows
to

the
heat
coil
and
the
heat
coil
is

heated
With
this
heat
the
bi
metal

arm
is

bent
and
thus
the

pointer

connected
to
the
bi
metal

arm
is

oper

ated
The
characteristics

of
both

gauges
are
the

same

A
tolerance

may
occur
on
the

water

temperature
gauge
or
fuel

gauge
due
to

source

voltage
fluctuation
The

voltage

regulator
is
used
to

supply
a

constant

voltage
so
that

the
water

temperature

gauge
and
fuel

gauge
operate
correctly

The

operating
part
of
the

regulator

consists
of
a
bi

metal

arm
and

a
heater

coil
When
the

ignition
switch
is

turned
on
the
bi
metal

arm
is
heated

and
bent

by
the
coil

opening
the

contact

Consequently
current
to

the

coil
is

interrupted
As

the
bi
metal

cools
the

contact
closes
The

repeti

tion

of
this

operation

produces
a

pulsating
voltage
of
8
volts
which
is

applied
to
the

water

temperature
and

fuel

gauges

If
both
the
water

temperature

gauge
and
fuel

gauge
become

faulty
at

the

same
time
this

may
be
attributed

to

problem
in
the

voltage
regulator

REMOVAL
AND

INSTALLATION

1
Remove

combination
meter
as

sembly
Follow
the

procedures
under

Removal

and
Installation
in
Combina

tion

Meter

2

Remove
meter
front
cover
and

shadow

plate
by

removing
clips
and

screws

3
Remove

retaining
nuts
at
the

back
side
of
combination

meter
as

sembly
and
remove

meter

4

Install
meter
in

the
reverse
se

quence
of

removal