service DATSUN PICK-UP 1977 Service Manual

FOREWORD

This
service
manual
has
been

prepared
for
the

purpose
of

assisting
service

personnel
of

authorized
NISSAN
DATSUN
dealers
fu

providing
effective
service
and
maintenance
of

the

1977
Datsun
Pick

up

Since

proper
maintenance
and
service
are

absolutely
essential
fu

satisfying
the
Datsun

owners
this
inan
la1
should
be

kept
fu
a

handy
place
for

ready
reference
and
should
be

carefuny
studied

This
man
la1
fucludes

procedures
for
ma
futenance

ac
1justrnents
minor
service

operations

remowl
and
installation
and
for

disassembly
and

assembly
of

components

Some
of
these
service

operations
require
the

use
of

Special
Tools

especially
designed
for

effectiveperfonnance
of
service

operations

The

special
tools
are

presented
in
the
SE

section

As

you
read

through
the

maintenance

procedures
in
this
service
manual

you
will

occasionally
corne
across

paragraphs
headed
NOTE
or
CAUTION
A
NOTE
is

supplemental

infortl1ation
that
is

important
to
B

particular
procedure
CAUTION

warns
of

steps
that
must

be

fonowed
to

prevent
personal
injury
and
Qr

damage
to
some

part
of

your
DATSUN

The

Quick
Reference
Index
on
the
first

page
enables
the
user
to

quickly
locate
the

desired

section
At
the

beginning
of
each
individual
section
is
a
table
of
contents
which

gives
the

page
number
on
which
each

major
subject
begins
An
index
is

placed
at
the

beginning
of
each

major
subject
within
the
section

All
information
illustrations
and

specifications
contained
in
this
manual
are
based
on
the

latest

product
information
available
at
the
time
of

publication
approval
If

YOUT
DATSUN

model
differs
from
the

specifications
contained
in
this
manual
consult

your
NlSSAN

DATSUN
dealer
for
information

Rights
for

alteratiohat

any
time
of

specifications
and
methods
are

reserved

liability
for

any
personal
injury
or

property
damage
occasioned

by
the
use

of
this
service

man
la1
in

effecting
maintenance
or

repair
of

your
Datsun
is
in
no

way
assumed

by
Nissan

M9tor
Co
Ltd

Accordingly
anyone
using
a

service

procedure
or

tool
which
is

not

specifically
w

mended

by
Nissan
must
fust

completely
satisfy
himself

that
neither
his

safety
nor
the

vehicle
s

safety
wi11be

jeopardized
by
the
service

method
selected

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN

@
1976
N1SSAN
MOTOR
CO
LTD
Printed
in

Japan

IDENTIFICATION

NUMBERS

The
unit
and
vehicle
numbers
are

stamped
and

registered
at
the

factory

The

engine
and
vehicle
identifica

tion

numbers

are
used
on

legal
docu

ments
These
numbers
are
used
for

factory
communications
such

as

Technical

Reports
Warranty
Claims

Service
Journals
and
other
informa

tion

Vehicle
IdentHication

plate

The
vehicle
identification

plate
is

located
at
the
hood

ledge
in
the

engine

compartment

SP029

Fig
GI
3
Vehicle

identification
plat

location

Vehicle
serial
number

The
vehicle
serial
number
is

stamp

ed
on
the

upper
face
of
the

right
side

member
The
number
is
identified

by

the

follQwing
flgUres
as
a
serial

number

HL620
XXXXXX

I

Serial
number

Vehicle
model

j

e

G1268

Vehicle

serial
number

location
Fig
GI
4
General
Informa
tion

Engine
serllii
number

The

engine
serial
number
is

stamped
on
the
right
hand
side
of
the

cylinder
block

L20B
XXXXXX

I

Serial
number

Engine
model

k

Color
code
number

The
color
code
number
label
is

stuck
on
the
radiator

support

GI326

Fig
01
6
Color
code
number
label

location

M
V
S
S
c
rtlflcatlon
label

The
M
V

S
S
certification
label
is

located
at
the
driver
side
lock

pillar

Gl
5
tW

I

1

I

il

j

SP031

Fig
GI
7
M
V
S
S

certification

label
location

Vehicle
emission
control

Information
label

The
vehicle
emission
control
infor

mation
label
is
stuck
on
the

insicre
of

the

hood

panel

SP076

Fig
GI
B
Vehicle
emia
ion
control

information
label
location

Manual
transmission
number

The
transmission
serial
number
is

stamped
on
the
front

upper
face
of

transmission
case

Number
system

x
X
XXXXX

I

Serial
number

monthly

Month
of

manufacture

2
9
X
Y
Z

Line
code
of

manufacture

DATSUN
PICK
UP

MODEL

620
SERIES

I
NISSAN

I

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
ET

ENGINE

TUNE
UP

ENGINE
TUNE
UP
ET
2

BASIC
MECHANICAL
SySTEM
ET
7

IGNITION
AND

FUEL

SYSTEM

EMISSION
CONTROL
SYSTEM
ET

13

SERVICE
DATA
AND

ET

25

SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS
ET
9

H

27

Engine
Tune

up

BASIC
MECHANICAL
SYSTEM

ADJUSTING
INTAKE
AND
EXHAUST

VALVE
CLEARANCE

CHECKING
AND

ADJUSTING
DRIVE

BELT

RETIGHTENING
CYLINDER
HEAD
BOLTS

MANIFOLD
NUTS
AND
CARBURETOR

SECURING
NUTS

CHECKING
ENGINE
OIL

REPLACING
OIL
FILTER

CHANGING
ENGINE

COOLANT

ADJUSTING
INTAKE

AND

EXHAUST

VALVE
CLEARANCE

Note
After

tightening
cylinder
head

bolts

adjust
intake

and
exhaust

valve
clearances

Valve
clearance

adjustment
is

impossible
when
the

engine
is
in

oper

ation

1
Loosen

pivot
locking
nu
t
and

turn

pivot
screw
until
the

specified

clearance
is
obtained
while
cold

Using
service

tool

tighten
pivot

locking
nut

securely
after

adjustment

and
recheck
the
clearance

2
Warm

up
engine
for
at
least

several
minutes

and

stop
it
Measure

valve
clearance
while
hot
If
out
of

specifications
adjust

Unit
mm
in

Intake
0
20

0
008

Cold

Exhaust
0
25
0

010

Intake
0
25

OmO

Wann

I
Exhaust

0
30
0

012

STl
064000

I

ET009

Fig
ET

5

Adjusting
valve

clearance
CONTENTS

ET
7
PERMANENT
ANTI
FREEZE

COOLANT

CHECKING
COOLING
SYSTEM
HOSES

AND
CONNECTIONS

INSPECTION
OF

RADIATOR
CAP

COOLING
SYSTEM
PRESSURE
TEST

CHECKING
VACUUM

FITTINGS
HOSES

AND
CONNECTIONS

CHECKING
ENGINE
COMPRESSION

COMPRESSION
PRESSURE
TEST

TEST
RESULT
ET
7

ET7

ET
B

ET
B

ET
B

CHECKING
AND

ADJUSTING

DRIVE

BELT
ET

B

ET

B

ET
B

ET
B

ET

B

ET
9

ET
9

ET
9

2

Normal
drive
belt
deflection
is

8

to
12
mm

0
315
to
0
472

in
when

moderate
thumb

pressure
is

applied

midway
between

pulleys

1
Check
for

cracks
or

damage
Re

place
if

necessary

Compressor
pulley

8
to
12
mm
0
315
to
0
472
in

Idler

pulley

Water

pump
pulley

8
to
12
mm

0
315
to
0
472
in

Air

pump
pulley

Alternator

AC456

Fig
ET
6
Driue
belt
tension

RETIGHTENING

CYLINDER
HEAD

BOLTS
MANIFOLD

NUTS
AND

CARBURETOR

SECURING

NUTS
Tightening
torque

Cylinder
head
bolts

1st

turn

4

0

kg
m
29
ft
Ib

2nd
turn

6
0

kg
m

43
ft
Ib

3rd
turn

6
5
to

8
5

kg
m

47

to
61
ft
lb

Refer
to
the

following
tightening

torque
specifications

ET
7

r

connected

hose

to

prevent
dust

from

entering

To

air
check

valve

Fig
ET
17
Disconnect
air
hose

from
ojr
check
valve

6

Race

engine
1
500
to
2
000

rpm

two
or
three
times
under
no

load
then

run

engine
for
one
minute

at

idling

speed

7

Adjust
throttle

adjusting
screw

until

engine
is
at

specified
speed

Engine
speed

Manual
transmission

750

rpm

Automatic
transmission

in
D

position

650

rpm

8
Check

ignition

timing
If

neces

sary

adjust
it
to

specifications

This

operation
need
not
be
carried

out

at
1
600

Ian

1
000

miles
service

Ignition
timing

Manual

transmission

120
750

rpm
Non

California

100
750

rpm
California

Automatic
transmission

in
D

position

120

650

rpm

9
At
about
10

minutes
after

engine

is

run
at

idling
speed

adjust
idle

adjusting
screw
so

that
CO

percentage

is
at

specified
level

CO

percentage

Manual

transmission

2
t
I
at

750

rpm

Automatic
transmission

in
D

position

2
t
I
at
650

rpm

10

Repeat

procedures
as
described

in

steps
6
7

and
9
above
so
that
CO

percentage
is
at

specified
level
Check

ing
idle
CO
in

step
9
can
be
carried
out

right
after

step
7

11

Race

engine
I
500
to
2
000

rpm
two

or
three
times

under
no
load

and
make
sure
that

specified
CO

per

centage
is
obtained
Engine
Tune

up

12
Connect
air

hose
to
air
check

valve

If

engine
speed
increases

readjust
it

to
the

specified
speed
with

throttle

adjusting
screw

CO
Idle

adjustment
without

CO
meter

If
CO
meter
is
not

available
the

following
procedures

may
be
used

I

Check
carburetor

pipes
for

proper

connection

2
Wann

up
engine
until
water

tern

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

temperature

indicator

points
to
the
middle
Further

keep

engine

running
at
about

2
000

rpm
for

about
5
minutes

without

applying
load
to

engine
in
order
to

stabilize

engine
condition

Engine

hood
should

be

open

4

Run

engine
for
about

10
minutes

at

idling
peed

During
this
10

minutes

proceed
as
described
in

steps

5

to
9
below

5

Remove
air
hose
between
3

way

connector
5

way
connector
for
Cali

fornia

modeis
and
air

check
valve

shown
in

Figure
ET
17

Plug
the

dis

connected
hose

to

prevent
dust
from

entering

6
Race

engine
1

500
to
2

000

rpm

two
or
three

times
under

no
load
then

run

engine
for

one
minute

at

idling

speed

7

Adjust
throttle

adjusting
screw
so

that

engine
speeds
are
as
indicated

below

Engine
speed

Manual
transmission

815

rpm

Automatic
transmission

in
D

position

670

rpm

8
Check

ignition
timing
if
neces

sary
adjust
it

to
the

value

required
by

specifications
This

operation
need

not

be
carried
out
at
1

600
Ian

1
000

miles
service

9
At
about

10
minutes
after

engine

is
run
at

idling
speed
adjust
idle

adjusting
screw
until
maximum

rpm
is

obtained

ET
12
10

Repeat
procedures
as
described

in

steps
6
7
and

9
above

until

engine

speed
at
best
idle
mixture
is

815

rpm

for
manual
transmission

models
and

670

rpm
for
automatic

transmission

models
in
D

position

Adjustment

in

step
9

can
be

carried
out

right
after

step
7

II

Turn
the
idle

adjusting
screw

clockwise
until

engine
speed
drops
off

below

specified
rpm

Engine

speed
drops
off

Manual
transmission

60
to
70

rpm

Automatic
transmission

in
D

position

15
to
25

rpm

12
Connect
air
hose

to
air
check

valve

If

engine
speed
increases

readjust
it

to
the

specified
speed
with

throttle

adjusting
screw

IDLE
LIMITER
CAP

Do
not
remove
this
idle

limiter

cap

unless

necessary
If
this
unit

is

removed
it
is

necessary
to

readjust
it

at
the
time
of

installation
To

adjust

proceed
as
follows

1

After

adjusting
throttle
or

idle

speed
adjusting
screws
check
to
be

Sure

that
the
amount
of

CO
con

tained
in

exhaust

gases
meets
the

established
standard

2

Install
idle
limiter

cap
in

position

making
sure
that
the

adjusting
screw

further
turn
1

8
rotation
in
the

CO
RICH
direction

Carburetor

stopper

3lSo
ldle

limiter

cap

T

ET031

Fig
ET
18

Setting
idle
limiter

cap

CHECKING

CARBURETOR

RETURN

SPRING

Check
throttle

return

spring
for

cracks

squarene
s
or

defonnation

if

necessary

replace
with
a
new
one

Engine
Tune

up

SERVICE
DATA
AND

SPECIFICATIONS

Ignition
timing
and

idling

Manual
transmission

Automatic
transmission

in
D

position

Valve

clearance

Cold
Intake

Exhaust

Intake

Exhaust
Hot

Belt
tension

Fan

Air

pump

Air

coo

compressor

Pressure

Compression
pressure
at
350

rpm

Standard

Minimum

Radiator

cap
relief

pressure

Cooling
system

Leakage
testing
pressure

Battery
specific

gravity
at
200C
680F

Distribu
tor

Point

gap

Air

gap

Dwell

angle

Condenser

capacity

Condenser
insulation

resistance

Spark
plug

Gap
degree
rpm
120
B
T
D

C
j750
Non
Calif

models

100

B
T
D

C
j750
California
models

degree
rpm
l20B

T
D

C
j650

mm
in

mm
in

mm
in

mm
in
0
20
0
008

0
25

0
010

0
25
0
010

0
30
0
012

mm
in

mm
in

mm
in

kg

lb
8
to
12
0
315
to
0
472

8to
12
0
315

to
0
472

8

to
12
0
315
to

0
472

10
22
is

applied

kg
cm2

psi

kg
em2

psi

kg
em
2

psi
12
0

171

9
0
128

0
9

13

kg
cm2

Psi
1
6
23

1

26

mm
in

mm
in

degree

IF

Mil
0
45
to
0
55
0

018
to
0
022

0
2
to
0
4
0

008
to
0
016

490
to
550

0
20
to
0
24

5

mm

in
0
8
to
0
9
0
031
to
0
035

Breaker

points
type

1

0
to
1
1
0
039

to
0
043

Transistor
ignition
type

Checking
CO

percent
at

idling
speed
No
air

Manual
transmission
model

rpm

Automatic
transmission
model

rpm

Adjustment
of

operating
pressure
of
B

C
D
D

B
C
D
D

set

pressure

Manual
transmission

Automatic

transmission
2
1

1
750

2
1
1
650

mmHg
in

Hg

mmHg
in
Hg
510
to
550
20
1

to
21
7

490
to
530
19
3
to
20
9

ET
25

DATSUN
PICK
UP

MODEL

620
SERIES

lMlSSAN
I

oJ

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
EM

ENGINE

MECHANICAL

GENERAL
DESCRIPTION

ENGINE
DISASSEMBLY

INSPECTION
AND
REPAIR

ENGINE
ASSEMBLY

SERVICE
DATA
AND

SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS

SPECIAL
SERVICE
TOOLS
EM
2

EM
4

EM
8

EM
21

EM

2l

EM
31

EM

33

rr

ROCKER
ARM
AND

VALVE
ROCKER
PIVOT

Check

pivot
head
and
cam
contact

and

pivot
contact
surfaces
of
rocker

arm
for

damage
or
wear
If

damage
is

found

replace
them
A

faulty
pivot

must
be

replaced
together
with
its

corresponding
rocker
arm

VALVE
GUIDE

Measure
clearance
between

valve

guide
and
valve
stem
If
clearance

exceeds

designated
limit

replace
worn

parts
or
both

valve
and
valve

guide
In

this

case
it
is

essential
to
determine
if

such
a

clearance
has
been
caused

by
a

worn
or
bent
valve

stem
or
by
a
worn

valve

guide

Stem
to

guide
clearance

mm
in

Maximum
limit

of
above

clearance

mm
in
Engine
Mechanical

Exhaust
8
3
to
8
5
dia

0

327
to
0
335

4
1

3
0

I2
J
L

12

223

to
12
234

150

0
4812

to
0
4817

dia

1

P
Intake

I
I

J

10
8
0

425

S9
0

2
323
7

6
to
7

8

0
299

to
0
307
dia

1

Unit
mm

in

EM572

Fig
EM
41

Se11Jice
value

guide

In
take

valve
Exhaust

valve

0
020
to

0
053

0
0008
to
0

002

As
an

emergency
expedient
a

valve

can
be

pushed
into
valve

guide
and

moved
to
the

right
and

left
If

its

tip

deflects

about
0
2

mm
0
0079
in

or

more
it
indicates
that
the
clearance

between
stem
and

guide
exceeds
the

maximum
limit
of
0
1
mm
0
0039

in

Note
Valve
should
be
moved
in

paral

lel
with
rocker
arm

Generally
a

large
amount
of
wear
occurs
in

this

direction

Max
allowable
deflection

0
2
mm
0
0079

in

n
r

C1r
30mm
l
18Iin

r

EM115

Fig
EM

42
Mea

uring
clearance

between
valve

tern

and
valve

gu
ide
0

040
to

0
073

0
00
6
to

0
0029

0
1
0
0039
Replacement
of

valve

guide

I

To
remove
old

guides
use
a

drift

and

a

press
under

a
2
ton

pressure
or

a

hammer

Drive

them
out

from

combustion

chamber
side

toward
rocker

cover

Heated

cylinder
head
will
facilitate

the

operation

2

Ream

cylinder
head
side

guide

hole
at

room

temperature

10
6

E
e

417
5t

0

m3l
lj
10
6

O
fl

H

dl7

l
IV

II

Unit
mm
in

EM116

Fig
EM

43
Valve

guide
hole

Guide

hole
inner

diameter
an
mm
in
For

factory
standard

valve

guide
11

985
to
11

996

0
4718
to
0
4723

For
service

valve

guide

3

Carefully
press
new
valve

guide

into

valve
so
that
it
will
fit

smoothly

after

heating
cylinder
head

to
150
to

2000C

302
to

3920
F

Valve

guide
of
0
2
mm

0

0079
in

oversize

diameter
is

available
for

ser

vice

as
indicated
above

Interference
fit
of
valve

guide
to

guide
hole

0
027
to

0
049
mm

0
0011
to
0

0019
in

4

Ream
bore
with

valve

guide

press

ed
in

using
Valve
Guide

Reamer
Set

KVIOI039S0

EM
10
12

185
to
12
96

0
4797
to

0
4802

Reaming
bore

8

000
to
8

018
rnm

0
3150
to
0
3157
in

EM419

Fig
EM

44

Reaming
valve

guide

q

1

I

k

k
lO

i

I

37

9
to
38
1

eel
1
492
to
1
500
dis

co

q

0

45
597
to
45
613

1
795
to
1
796
dia
5
Correct

valve
seat
surface
with

new
valve

guide
as
the
axis

VALVE

SEAT
INSERTS

Check
valve
seat
inserts
for

any

evidence

of

pitting
at
valve
contact

surface

and
reseat
or
replace
if
worn

excessively

Valve
seat
insert
of
0
5
mm
0
0197

in
oversize
is
available
for

service
as

shown
below

Intake

Unit
mm
in
Engine
Mechanical

Fig
EM
45

Correcting
valve
seat

EM573

0

32

6
1

2835
dia

Exhaust

I
I

30

U81
dia
17
5
0
295

Unit
mm

in
37
580
to
37

596
1
4795
to
1
4802
dia

Cylinder
head
rece
diameter

For

factory
standard

insert

Intake

For
service
insert

For

factory
standard

insert

Exhaust

I
For
service
insert

Interference

fit

mm
in
Intake

Exhaust
Fig
EM
46
Seroice
valve
seat
dimensions

Unit

mm

in

45
000
to

45
016
1

7717
to
1

7723

45
500
to
45
516
1

7913
to

I
7920

37
000
to
37
016
1

4567
to
I
4573

37
500
to
37
516
1

4764
to
I
4770

0
081
to
0
113
0
0032
to
0
0044

0
064
to
0
096
0
0025
to
0
0038

EM
11
Replacln
valve
eat
In
ert

1
Old
insert
can
be
removed

by

boring
it
out
until
it

collapses
The

machine

depth
stop
should
be

set

so

that

boring
cannot
continue
beyond

the
bottom
face
of
the
insert

recess
in

cylinder
head

2

Select
a
suitable
valve
seat
insert

and

check
its
outside
diameter

3
Machine

cylinder
head
recess
to

the
concentric
circles
in

valve

guide

center
so
that
insert

will
have
the

correct
fit

4
Heat

cylinder
head
to
a

tempera

ture
of
150
to
2000C
302
to
3920
F

5
Fit
insert

ensuring
that
it
beds
on

the

bottom
face
of
its

recess
and

caulk
more
than
4

points

6

Newly
fitted
valve
seats
should
be

cut
or

ground
at
the

specified
dimen

sions

as
shown
in

Figure
EM
47

7

Apply
small
amount
of
fine

grind

ing
compound
to
valve

contacting
face

and

put
valve
into

guide
Lap
valve

against
its
seat
until

proper
valve
seat

ing
is
obtained
Remove
valve
and
then

clean
valve
and

valve
sea
1

Engine
Mechanical

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Engine
model
L20B

Cylinder
arrangement

Displacemen
t

Bore
and
stroke
4
in

line

cc
co
in

mm
in
1

952

J
19
1

85
x

86
3

35
x
3
39

O
H

C

I

3
4
2
Valve

arrangement

Firing
order

Engine
idle
rpm

Manual
transmission

Automatic
transmission
in
D

range
750

650

8
5

Compression
ratio

Oil

pressure
Warm
at
2

000

rpm

kg
cm2

psi
3
5
to
4
0
50

to
57

SPECIFICATIONS

a
Valve
mechanism

Valve

clearance
Warm

Intake

Exhaust

Valve
clearance
Cold

Intake

Exhaust

Valve
head
diameter

Intake

Exhaust

Valve
stem
diameter

Intake

Exhaust

Valve
length

Intake

Exhaust

Valve
lift

Intake
and
exhaust
mm
in

0
25
0
010

0
30
0
012

mmOn

0
20
0
008

0
25
0
010

mm
in

42
0
to
42
2
1
654

to
1

661

35

0
to
35
2
1

378
to
1
386

mm
in

7

965
to
7
980
0
3136
to

0
3142

7
945
to
7
960
0
3128
to

0
3134

mmOn

114
9
to
115
2
4
524
to
4
535

115
7
to
116
0
4
555
to
4

567

mmOn

Valve

spring
out

of

square
mm
in
10
5
0
413

less
than
1

6
0
063

Valve

spring
free

length
mm
in

Intake
and
exhaust
Outer

Inner
49
98
1
968

44

85
J
766

EM
27