J DAT5U N PICK UP 4 MODEL 521 SERIES r CHASSIS AND B ODY i r I NISSAN I f J J NISSAN MOT TOKYO r ev JJN 20023 99999 R CO JAPAN LTD
t f L R v I 41 0 OE Jljl QUI0J OA1 SUN UP p CK SERVICE t ttU MOOE ES 521 SER l lSStS 1001 i j il 1 1 1 It It 11 l t I po to N N SS tAQ10tlJAPAN tOKYO 10 IV 1
r FOREWORD This seroice manual has been of our prepared for distributors and dealers in providing effective seroice and maintenance proper customers this manual should be read for effective 1 utilization Explanations PleaJe refer se1 0e g seroice personnels and maintenance of are The carefully essential absolutely following satisfying our matters should be noted of this manuaL in this manual hand drive but will 2 of aJsisti series DA TSUN PICK PU model 521 Since the purpos
v SECTI ON GI GENERAL INFORMATION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I MODEL VARIATION GI 3 IDENTIFICATION NUMBER GI 3 GENERAL VIEWS GI 4 GENERAL SPECIFICATIONS GI a FINAL TRANSMISSION AND SPHDOMETER RATIO GI l0 RECOMMENDED LUBRICANTS AND PERIOD ICAL MAINTENANCE GI l0 I JACKING UP AND TOWING THE CAR GI la t NISSAN MOTOR CO TOKYO LTD JAPAN J
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ll GENERAL INFORMATION I t O Fig Gl l Short body pick up ft Fig 1 GI 2 Long body GI 1 pick up
r CHASSIS I I f Fig Gl 3 Double Fig GI 4 GI 2 pick Van up
GENERAL INFORMATION MODEL VARIATION Vehicle Engine model Pick up R H drive LH 521U LS2I L 4 R4W63 2 I 2 204 6 5 400 2 3 102 5000 300 6614 OtXl 4 F4W63 LS21T Plck up n 0 Pick up US2JU ULS21 VS21U VLS21 N521U NU21 JI3 5 881 8 4 R4W63 4 R4W63 4 R4W63 2 000 2 1 204 6 NU2lT 5 Rem ITkl drive Double V TIM speed Seating 3Plcity payload kg lb model F4W63 4 R4W63 4 R4W63 4 Double UNLS21 JlS 5 400 8 881 2 SOO 1 5 300 6614 Pick up VN521U V 102 3 NU21 PL5
Ill J IU U I U I en G 1 Z 1a o in mm MDe models 71 40 01 5012 81 I 1 I 1850172 IT Jb 6PR 14 0Q 1035 1 6 91 3 PL521TN PL521TU Indicates I 61 Unit II II II I I II J t f 13 gM 253019 4290168 4325170 j T 1 I 1 if Mark up pick body Short Ii B 0 710 28 iio In In Gl Fill
jj r M ci r Z oa or 0M 0 1 o in o II 71 I mm Unit 185146 2 I I oz I I Q m Z ma 88 I I II N I I I I I 2 40 IIII up 0M pick I I I I i I 1 I body Long ii 9 GI Fig Cl U
r CHASSIS Ir T 1 c E E 1 c o J 0 o I I 1 S o 9lE I M L 1 B B ii ai C M 0 M O Z9 OZE l N 1 I n r OJ oi 0 IB lS OVEl I I o 11 Q m o o IT q iaio I 00 t o O 00 r iXlOr O N ON NN J 1 11 ll GI 6
m Zm a r ZT1 o a oz r in N o mm Unit J1 0 I 1r e1 f I ON C bN OL N 00 I Oo tN e tC 1 rf I co I I I N I o 1111 Van l1 GI Fig in oN N Gl L
CHASSIS GENERAL SPECIFICATIONS 113 ENG lNE 52lU L521 Item L521T U52lU V52lU UL521 VL521 345 4 Ovralllenglh mrn in 4 Overall widlh mm in 1 575 62 0 1 570 Overall height mrn in 1 545 60 8 1 530 60 2 Wheel base mrn in 2 530 99 6 2 530 99 6 mrn in 1 850 72 8 325 3 170 1 171 618 1 c c g E 5 Length 830 32 7 65 0 is 40 9 1 0 0 Width c mrn 1430 in 1 3 56 320 52 0 Height mrn in 0 Front mrn in I 250 49 o f Rear mrn in 1 mrn in Minimum road c
GENERAL INFORMATION 115 ENGINE L16 ENGINE N521U NL521 NL521T UNL521 3 170 4 325 1 545 2 530 99 6 VNL52 I 4 345 1 575 62 0 60 8 1 618 530 60 2 2 530 99 6 1 850 728 830 32 7 3 56 400 1 157 320 52 0 420 1 650 1 040 65 0 40 9 GNL52 I LG521T 4 715 185 6 62 8 1 575 1 545 60 8 1 545 60 8 2 530 99 6 2 770 1 850 72 8 2 240 88 2 1 430 3 56 1 430 3 56 400 15 7 400 15 7 1 240 49 0 48 8 900 354 62 0 109 1 1 250 492 1 250 49 2 1250 49 2 I 250 492 1 267
jt r CHASSIS FINAL TRANSMISSION AND SPEEDOMETER RATIO L521T NL521T PL521TU LG521T GNL521T PL52ITN N52lU 52lU NL521 UNL521 L521 UL521 GN52lU VN52lU G521U V52lU GNL521 UNL521 LG521 VL521 Item 4 875 Final gear ratio 4 625 Control system f 4 875 375 4 R4W63 F4W63 Type S 4 625 375 4 4 625 R4W63 Column shift Column shift Floor shift U521 1st 3 657 4 243 5 000 2nd 2 177 2 558 3 014 3rd 1 419 589 1 1 685 4th 1 000 1000 1000 Reverse 3 638 u Speedometer
CmZm a rJ1 1oo s s 1 ZC1 C rc CD rJ o 3D SHEL SheUXIO MOBILE 3D Oil lOW Enco ES O 20 Supc MobilO BPSuperVl5Coda BP shclpuD 20 ex HD lOW 20W Lube 80 80 90 Lube Mobile Er Eocol u E 30 40 SO 3D MotrOiJ 40 20W 30 40 SO ES O HOEP 140 lOW 20W 30 40 SO Enco 80 90 u Oil E 90 140 RetinlA 1X Don Shel Shel IlD 80 90 140 MobilegrascP 140 GP E Mobile Bukcl 5W l Hydr Mulu 80 90 140 ex HD40 H Enco greas Esso purpo AtluJPcrmaGd Enco FlUid c oIHD Buke
l I s 1 Zt1 1Z INTERVAL I II I ct 36 72 24 48 X R 33 69 22 46 X X X X 30 66 20 44 X X X X 27 63 18 42 X X X X 24 60 16 40 X X X X 21 57 14 38 X X X X 18 54 gO 12 36 60 X X 15 51 87 10 34 58 X X X X 12 48 84 8 32 56 X X X X 9 45 81 6 30 54 X X X X 6 42 78 4 28 52 X X X X 39 75 50 X X X X X X X MAINTEC 26 2 3 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
z o0 mz F X r R 24 48 36 72 X r 33 69 X 20 44 30 66 38 14 57 36 60 12 JAI R E 34 58 10 87 51 15 X R 54 90 18 40 16 24 60 21 42 18 63 27 46 22 IN 32 56 8 12 48 134 NANnECE 45 81 9 42 78 I IAI llace Re 28 52 4 6 ent 30 54 6 26 SO 39 75 R X X X 2 3 6 0 1 leak lor eteilors l etc iles I nuts oi oi con ection d TS N l I Jsand too PO lOusand t oi oi CE J SER ber Nu ber Nu Wpe er oos distrbutor cartidge Jgs l1 ele NE ENG eJtcept ode
J v MAINTEC X 24 48 33 69 22 46 X 30 66 20 44 X 63 18 42 24 60 16 40 X 21 57 14 38 X 18 54 90 12 36 60 15 51 87 10 34 58 X 12 48 84 8 32 56 X g 45 81 6 30 54 6 42 78 4 28 52 X 26 50 X 27 INTERVAL X 36 72 39 75 X X X 2 3 JJ Vi X X X X X X X X X X X PL521TN PL521TU except els Al m X 0 POINTS kilometrs miles of of thousand thousand SERVICE of X X X X X BODY Number AS IS C Number X wear cylinders defcts X X
I m ZmQ 60 30 INTERVAL MAINTEC R X X X X R X X X X X 52 24 48 X X 21 45 X X 18 42 X X 15 39 X X 12 36 X X g 33 X X 6 X X 3 X X X R 54 Z r1 o Q X 27 57 r oz X X X X X X X r X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Replacmnt X X 6 0 necsary whicevr jf top miles level POINTS thousand of PL521TN PL521TU For LUBRICATNG oil diferntal months Number necsary gear or of A
r 60 30 27 51 57 X 24 48 INTERVAL MAINTEC R R X X X X X X X X X X R R X X X X X X X X X X X X X X X X 21 45 18 42 15 39 X X 12 36 R R g 33 X X 6 X X X 3 X X X 54 I C I IC C X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Replacmnt X X X 6 X 0 X X X X X X whicevr POINTS SE
5z Z n o0 r Cm Z m 10 I X 57 48 21 45 X X X X X 24 X X X X X X X X X 51 X X X X 30 27 X X X X 60 X X X X X X X X X X X X X X X X X INTERVAL MAINTE C X 18 42 15 39 12 9 X X X 54 X X X X X X 36 X X X X X X X X X X X X X 33 X X X X X 6 X X X X X 3 6 X X X X X X X 0 etc whicevr POINTS 8 For thousand of CHAS I wear hoses or BODY months first Number comes bolts pi ngs of SERVICE PL521TN PL521TU
CHASSIS LUBRICANTS CAPACITY sA U Liter 41 Fuel tank l I ai Imp measure measure gallon gallon 10 8 9 0 Without heater 6 0 58 1 32 1 With heater 6 6 74 1 45 1 5 MOO c Ul Coolant Without heater c 4 6 1 69 141 6 8 1 80 50 1 3 0 0 79 0 66 1 06 0 88 60 c lUl With heater 113 115 Engine Oil pan Ll6 Engine 4 0 113 0 63 0 17 0 14 0 7 0 19 0 15 20 53 0 0 44 115 Engine Oil filter Ll6 Engine Transmission case 33 0 Steering gear box Differential 0 83 case 0 087
GENERAL INFORMATION Supportable point The front supportable points are two places in frame side member The spring Fig CI 13 Rear rear supportable points are in front of the leaf of frame side member jacking point Garage jack Note When carrying out operations with the car jacked up be sure to support the car with stands When jacking up the front side front cross member or center apply garage jack to of suspension portion member When jacking up the rear side apply the ja
or CHASSIS Fig GI I8 Front towing point Fig GI I9 towing point 4T R SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN t or No PAGE No SUBJECT GI 20
SEen ON ER GI ENGINE REMOVAL INSTAllATION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD ENGINE REMOVAL AND INSTALLATION ER 1
lGIl El lE EtlG1tlE REMOi ll lSl Il l g tlOtl LLA ItlSfA At10 IlEfAOL II ER 3 CON1EN15 ENGINE REAR ENGINE RON ER HI RemoVal nstaHattOn l 110l 2 3 ING MOUN ING MOUN ER H it I I J 6 fig EJI 2 Engin tment comp EA 1 or th L16 ngin 4
CHASSIS Removal 12 Disconnect speedometer cable Disconnect flat attaching plug Scribe alignment marks on hood around hinges and from connector reverse lamp switch remove hood from hinges 2 drain coolant Completely engine and transmission 13 lubricant Disconnect remove 3 Remove blow by hose from cross shift rod and select rod shaft assembly by removing and then cross shaft bracket from side member rocker cover and air cleaner 14 4 Remove radiator 5 Disconnect battery cabl
ENGINE At this lifting lower jack gradually REMOVAL INSTAllATION placed under the transmission check draw offjack at adequate stage hoist up engine observing the tension of wire and adjusting the position of chain block so that engine tilts in order off body At this stage take on the care disconnecting parts for before positions actually disconnecting to make it cleared that accessories installed body side do not touch engine and transmission Installation Reverse the removal to parts
CHASSIS T T 2 6 to 3 2 kg 2 5 to 3 Okg m 181 to 21 7 ft Ib I m 1 O jj l l Fig ER 6 Sectional view for offront engine mounting the L t6 engine REAR ENGINE MOUNTING One type of with long rear extension T engine mounting is used for engine two For engines with short extension types of rear engine mounting for and L series engines are 33 to 3 8 kg m 123 9 to 27 5 ft Ib r T lIto 1 6 kg m 8 0 10 11 6 ft Ib Fig ER 7 Sectional view for of rear engine mounting the GN52t model 4
v ENGINE REMOVAL INSTALLATION i to kg m n 4 3 to 5 0 T 31 1 to 36 2 ft Ib I I i T 5 to 2 1 1 10 8 Fig kg m of rear engine mounting the U V N521 models I 3 3 to 3 8 kg 15 2 ft Ibl ER 8 Sectional view for T to lu iLn m 23 9 to 27 5 ft Ib d T j1 5 to 3 1 10 8 T 1 1 to 3 6 kg to J m 8 0 to 11 6 ft Ib Fig ER 9 Sectional view for Note Arrow marks means that engine kg of rear engine mounting the PL521 model removal carries out at this place ER 5 m 15 2 f
CHASSIS t1 lU rF JOURNAL DATE H ll l liR 1 REF or PAGE BULLETIN PH RW No SUBJECT No ER 6 rF REl
SECTION CL CLUTCH CD J DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD CLUTCH CL 1 CLUTCH CONTROL CL 5 SERVICE DATA AND SPECIFICATIONS CL10 TROUBLE DIAGNOSES AND CORRECTIONS CL 11
CLUTCH L CLUTCH I CONTENTS DESCRIPTION CL 1 Disc assembly CL 4 REMOVAL CL 2 Release bearing and sleeve CL 4 DISASSEMBLY CL 2 INSPECTION AND ADJUSTMENT CL 2 REASSEMBL Y 4 CL REINSTALLATION CL 3 Clutch assembly CL 4 Release mechanism CL 5 DESCRIPTION The clutch is of type a single dry disc diaphragm spring The major components plate diaphragm spring and provided with riveted springs arranged plales are wire on clutch cover engagement rings The clutch disc is to both sur
CHASSIS REMOVAL The clutch same 2 ass manner as mounting mbly is dimlounted the engine assembly the clutch assembly efer primarily Thus in the I release mechanism Remove dust cover from clutch housing Remove bearing when dis 2 the Section TM to Removing separate Transmission and other relative sections 3 return Remove release front from spring the withdrawal lever from cover and bearing remove sleeve and bearing sleeve and bearing sleeve from withdrawal lever from wi
CLUTCH Clutch 3 assembly Press the master gauge plate down exactly 7 8 307 0 1 etc Check clutch for excessive occurs on 2 cover diaphragm spring presswe plate crack and damage When noise wear clutch assembly replace Measuring and adjusting height of diaphragm spring in this first on Line up distance piece clutch assembly base plate special tool the height gauge plate is plate contacting clutch cover end with cover H from 7 8 nun The result indicates the distance by which in
CHASSIS Disc If facing is soiled with gIease I kerosene and dress facing with Jf a I clean off with oil Replace wire brush facing if required 2 Check disc for deflection and repair 2 or deflection at the outer circumference of replace if the facing withdrawal lever and hearing sleeve contact When point is worn in step When occurs on and sleeve bearing Release assembly grease replace sleeve bearing leaks from release or noise release bearing replace release bearing exceed
CLUTCH REINSTALLATION Withdrawal lever and bearing sleeve contact point lever Withdrawal ball pin and withdrawal lever Clean clutch pilot bushing contact surface and f1 it with multi purpose grease 2 Install disc assembly and clutch assembly by the of use a clutch aligning bar on flywheel special tool 00 ST20630 1 Withdrawal lever ball pin 3 Return 5pring 2 Withdrawal lever 4 Release bearing Fig CL 14 Position grease is 3 When grease is withdrawal lever on applied to
CHASSIS t I I I I I I Fig CL 16 Clutch control CLUTCH PEDAL Removal 1 Adjustment Remove return spring Adjust pedal pad height RH drive Loosen lock 2 nut of master cylinder push rod and selecting disconnect push rod end and applying shim Be sure to use shims s 545 in 138 5 mm to adjustment without stopper The is made for by having adequate thickness having same thickness for both upper and lower 3 Remove lock nut remove pedal and washer of pedal shaft and 153 2 Inspe
CLUTCH Adjusting Part number 30611 shim Thickness 27260 16 0 0630 30612 27260 0 8 0 0315 30613 27260 0 5 0 0197 Item model R H drive L H drive 8 Fig CL 17 Pedal height adjustment CL18 Sectional view of clutch CL 7 master mm in 126 4 96 117 4 61 Multi purpose grease CLUTCH MASTER CYLINDER Fig 2 1 Applied cylinder in mm mm in 33 s 5 13S 150 0 5 91
r CHASSIS Removal Reinstallation Disconnect 2 Disconnect clutch line from master cylinder pum rod from clutch Reinstall 1 pedal the master cylinder assembly sequence of removal and adjust follo Adjust pedal height by changing push Remove securing bolts and 2 remove rod length Bleed air out of the hydraulic system cylinder master reverse and drain fluid 3 s in assembly from vehicle OPERATING CYLINDER Removal Disassembly Remove return spring 1 Remove riller cap and drain flui
CLUTCH Reassembly Reassemble operating cylinder in reverse sequence of disassem ly noting the following matters Soak piston cup in fluid before reassembly 1 piston cup carefully so that it is faced Apply brake fluid sufficiently 2 to Install correctly cylinder and piston and assemble them Reinstallation Reinstall the operating cylinder in reverse sequence of removal I Bleed air out of the hydraulic system 2 Adjust push 2 0 to 3 0 the following rod so that withdrawal lever end
CHASSIS SERVICE DATA AND SPECIFICATIONS All 521 series Clutch cover type Diaphragm MF200K Clu tch release lever Withdrawal lever end play mm in 2 0 to 3 0 0 0787 to O 1l81 Diaphragm spring to flywheel height mm in 43 to 45 1 693 to U72 Clutch disc Single dry disc 20OCBL Type Facing size Outer dia x Inside dia x Thickness cm2 Total friction area in 200 sq in 362 mm 130 x x 3 5 7 87 3386 0 to x 5 12 56 I Thickness of disc assembly Free in mm Compressed 6 8 in mm t
CLUTCH TROUBLE DIAGNOSES AND CORRECTIONS Probable Condition damaged Noises audible on Excessively pedal depression cated release bearing worn Corrective action cause or lubri poorly be cannot bearing and diaphragm spring Seized release the Replace out Insufficient pedal or broken clutch return and control springs Weakened broken or drawal lever return Excessive drive shaft pedal Set contact unhooked clutch with in springs weakened faces with felt polishers or the R
CHASSIS Condition C lu1ch drags Probable Corrective action cause Insufficient push rod length Excessive Adjust the push free travel pedal Adjust Warped clutch disc Set level of clutch disc if possible Roughened linings Repolish loose broken or lining diaphragm to spring with linings Replace linings clenched with damaging bearing 5 0 run out a 0 0197 in mm metal brush or them if necessary replace Incorrect release length correctly free travel correctly Maximum plate
CLUTCH Condition Abnormal lining Probable Corrective action cause Insufficient pedal free travel Adjust clutch pedal free travel correctly wear Driver steps unnecessarily lining causes wear on pedal and damage to this release bearing Advise driver to discontinue wrong practice and step clutch pedal only when on ne cessary Weakened or snapped Check pressure springs for tension pressure springs fied and replace springs if they as speci are un serviceable Incorrectly insta
CHASSIS a Probable Condition Worn ij or Corrective action cause Replace linings burned disc linings Overloaded master cylinder d to a stricted transfer port re Overhaul piston the master cup if swollen cylinder replace the or damaged and clean the transfer port bleed the system SERVICE JOURNAL OR BULLETIN REFERENCE I JOURNAL or PAGE No DATE BULLETIN iO SUBJECT No 1 I J f I i 1 I l I 1 CL 14
I SECTION TM t TRANSMISSION em l DATSUN PICK UP MODEL 521 SERIES CHASSIS I BODY NlsSAN I NISSAN MOTOR CO TOKYO JAPAN LTD 1 TRANSMISSION TM TYPE F4W63 TRANSMISSION TM 12 TRANSMISSION GEAR CONTROL COLUMN SHIFT CONTROL SYSTEM TM 15 SERVICE DATA AND SPE CIFICATlONS TM 18 TROUBLE DIAGNOSES AND CORRECTIO N S TM 21
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TRANSMISSION TRANSMISSION CONTENTS DESCRIPTION TM l Gear and shaft TM 8 SPECIFICATIONS TM l Balk TM 8 REMOVAL TM 3 Shifting TM 8 DISASSEMBl Y TM 4 Oil seal TM 9 INSPECTION TM 7 Rear TM 9 9 ring insert engine mounting insulator Transmission case and rear extension TM 7 REASSEMBLY AND ADJUSTMENT TM Bearing TM 7 REINSTAllATION TM 12 DESCRIPTION 521 Datsun forward F4W63 Both series vehicles adopt type column shift I reverse 4 forward I reverse the type R4W6
CHASSIS l J 1 2 J 3 Extension Applied housing type short model GN521U GN521 G521U LG521 N521U NL521 UNL52l VN521U VNL521 2 long 3 short 521U L521 52IU VL521 L521T Fig TM j LG521T NL521T GNL521T PL521TU PL52lTN R4lV56 and F4lV56 transmissions TM 2 U521U UL521
TRANSMISSION REMOVAL For transmission dismounting applies Refer to Section ER the following procedure Engine Removal of this Manual I Disconnect battery cable from terminal 2 Remove du tch starting housing to motor and bolts used to attach engine Jack up vehicle and support it with four stands 3 Recommend a hydraulic hoist or open pit be utilized Fig if available 4 Disconnect 6 Disconnect front lamp exhaust tube from exhaust mani fold 1M 3 7 Detaching propeller shaf
CHASSIS 4 Remove 14 bottom cover bottom 5 cover Remove securing bolts and remove from transmission speedometer pinion and remove rear exten sion Note When rear extension cannot lightly tap it with Fig TM 5 Dismounting a plastic be removed easily or wooden mallet transmission DISASSEMBLY For transmission applies The casings careful not to disassembly the following procedure are damage made of aluminum alloy metal Be it 1 Drain gear oil from transmission 2 Remove dust cover
I I I i I I I I I I I I I I I I I I I J I I I I I TRANSMISSION p with a drift using a fork rod pin punch Removing ear fork pull ST23510 0 tool special out rod I I I I I fnt I I I I I i r I I I I I II i I I I J I I I I I I I Fig I I 12 I TM 12 Driving out retaining pin Remove main shaft assembly from rear side and main drive gear from front side Note I When main cannot I shaft assembly and be removed easily case with or main drive
CHASSIS 13 and @ 14 Remove snap ring 4th 3rd remove See Figure from main shaft front side @ synchro assembly Remove main shaft lock nut viously and and 3rd gear @ TM 14 for part identification numbers remove reverse @ loosened pre gear and sleeve Fig Fig IS TM 15 Removing map When removing main shaft gear of 1st gear to bearing puller special and withdraw bearing retainer washer @ j Removing bushing ring apply the front end tool ST22130000 j and 1st gear simultaneousl
TRANSMISSION Push out counter shaft from 8 or rear to front with a drift using a fork rod pin punch Removing fork pull other proper tool and take out counter gear Fig 12 jJ special tool ST235IOOOO out rod 1M 12 Dril1ingoutretainingpin Remove main shaft assembly from rear side and main drive gear from front side Note When main shaft assembly and or main drive gear cannot case Fig 9 front Remove e rever 10 TM l0 be removed easily lightly tap transmission with asticor wood mallet
r CHASSIS 13 and @ 14 from main shaft fron t side Remove soap ring remove See Figure and and 3rd gear @ TM 14 for part identification numbe Remove viously synchroassembly 4th 3rd main shaft lock nut remove reverse @ loosened pre gear and sleeve Fig Fig 15 TM 15 Removing map When removing main shaft gear of 1st gear to and withdraw washer @ bearing puller special bearing retainer @i Removing bushing ring apply the front end tool ST22130000 1st gear simultaneously by
TRANSMISSION INSPECTION Thoroughly cJ and check clean all disassembled parts with solvent them for and other defective damage wear conditions @ Transmission o 18 9 1 Coupling 2 Shifting insert Fig sleeve TM J 9 cr case and extension rear Clean them with solvent thoroughly crack which may cause oil leaking and check for and other defective conditions 3 Synchro hub 4 Spread spring When bur joint repair Synchronizer disassembled To disassemble main drive gear remove snap
CHASSIS Gear and shaft End 5 plays of I st 2nd range from 005 to 0 15 I Check gear replace 2 as for damage and wear crack or and shaft soap for crack wear and worn 0 0020 to 0 0059 in the end play is deviated from this range required Check and 3rd gears should be in mm When select proper ring again spline Replace if required 3 Check main shaft for straightness Replace main shaft with new one 0 15 mm 0 0059 in end exceeds maximum l Maximum out run if a out run a
TRANSMISSION Oil seal Replace snap ring Rear is if lip is deformed dropped worn or cracked or when off engine mounting insulator Replace if weakened deteriorated or cracked REASSEMBLY ADJUSTMENT Reassemble When assembly transmission in reverse sequence reassembling note the following of dis 3 Main shaft and gear When drift to Note 1 Snap ring 4 1st gear 2 4th 3rd 5 Thrust washer and ball assembly 6 Main shaft Ist 2nd synchronizer 7 Main 3 synchronizer 1M 28 Fig
JfIl CHASSIS 5 disassembly To lock main shaft install main shaft in transmis sion double case with the rated to 79 5 lb ft intermesh gears tightening torque 8 0 tighten lock to 11 0 kg m For shown in the nut proper thrust 57 8 0 05 and fIrmly bend lock washer side tluust washer five types available are Select washer so that counter gear end 0 15 to rear following table mm 0 0020 0 0059 to in play as a is when assembled Note Install thrust washer 132225 A0900 Part numb
TRANSMISSION Shift fork and operating lever i l Rear view o 3 J Forward 1 c 1 @ Operating lever ass 3 y Reverse shift fork 41st Reverse check Fig TM 31 shift rod 2nd shift fork 5 shift rod 6 3rd 4th shift Operating Layout ofshift fork and operating fork ver ass shift rod y lever Install each fork rod and shift fork Note shift fork 8 Pay attention b Be sure that there is to no installing direction gap between fork rod and shift fork 2 Install each fork rod tog
I f I f 0 CHASSiS REINSTALLATION Remount transmission in reverse sequence ofdis mounting Q JwaSherl 2JCross slirlt Fig TM 33 Installing fLockPin cross shaft TYPE F4W63 TRANSMISSI ON CONTENTS DESCRIPTION TM 12 INSPECTION REMOVAL TM 13 ASSEMBLY TM 14 TM 13 Shift fork TM 14 AND INSTALLATION DISASSEMBLY DESCRIPTION The tion is the type F4W63 transmission is used especially for Thus floor shift type vehicle Generally however the construe same as in this TM 34 yp T REPAIR F4W63
TRANSMISSION REMOVAL AND INSTALLATION Remove speedometer pinion assembly drive procedures for removal and installation of Primarily the F4W63 transmission mission 6 are 7 the same as R4W63 trans For the F4W63 transmission however removal and Remove eight rear extension remove rear extension housing securing housing Disengage s bolts iking rod from fork rod gates and installation of shift lever are required DISASSEMBLY Drain transmission gear oil Remove dust cover 2 spring remov
CH ASSIS 13 Remove bearing four bolts used to secure main shaft retainer to transmiSsion case Fig 15 TM 40 Drawing out main slraft assembly Draw out main drive shaft INSPECTION AND REPAIR Fig 1M 39 RemovingmainslraftbNring retiD For detailed procedure for inspection and repair refer to the section Service covering the type R4W63 data and specifications transmission are shown in page TM 18 14 Draw out main shaft assembly from transmission ASSEMBLY case The transmission is
l TRANSMISSION I Install shift forks 1st 2nd and 4th 3rd on sleeves and apply 1st 2nd fork rod 2 Place 4th 3rd interlock plunger in Place interlock 3 coupling reverse the position and fit plunger in the position and assemble shift fork and fork rod Secure each fork to fork rod with retaininjfpin rp 4 fork rod r TRANSMISSION GEAR CONTROL COLUMN SHIFT CONTROL SYSTEM CONTENTS REMOVAL TM 16 ADJUSTMENT TM 17 INSPECTION AND REPAIR TM 17 Shift linkage TM 17 INSTALLATION TM 17
r CHASSIS REMOVAL Remove steering wheel assembly o Snap ring 0 Fig 4J TM Fig 2 Remove Removing sleering steering column shell w cover I TM 46 Withdrawing C washer hand lever Remove C washel 4 turn l Controllcver pivot pin signal and lighling switch Fig 44 TM Removing sleering column slrea I Lock 2 Select lever and select rod 3 Lower bracket pin and lock wire co 47 7M Fig 4 Shift lever and shift rod 5 Select lever boss Separating ever and rod lever from shift rod 5
TRANSMISSION The individual Note joints use small washers and snap When rings Before removing check them for reinstalling apply chassis installing grease to the following parts sequence and direction I Select lever pivot bolt bushing 2 Select lever boss select lever guide unit 3 Reverse check unit 4 Insert and change lever units in upper portion of INSPECTION AND REPAIR Check all sliding parts and other components for and defective other conditions Replace as wear required cont
CH ASSIS SERVICE DATA AND SPECIFICATIONS CONTENTS General specifications TM 18 Specifications TM 18 General TIGHTENING TORQUE TM 20 specifications Type Con trol system Synchromesh type F4W63 R4W63 R4W63 Floor shift Column shift Column shift Warner Warner Warner Gear ratio 1st 3 657 4 243 5 000 2nd 2 177 558 2 3 014 3rd 1419 1 587 1 685 4th 000 1 1 000 1 000 Rev Speedometer gear 3 638 ratio 19 5 Final gear ratio Extension 18 5 4 875 4 625 housing Oil capaci ty
TRANSMISSION Model F4W63 R4W63 Item Each gear standard end play For aU gears mm 0 05 to 0 15 in 0 0020 to 0 0059 Balk ring cone clearance StMdard clearance mm 2 to 1 6 1 in 0 0472 to 0 0630 Replacement 4th 3rd standard 0 8 mm in 0 0315 adjusting shim Part number 32263 14600 Main drive gear adjusting Reverse idler gear 40 1 shim in 0 0551 to 0 0571 32263 1460 I 1 45 to 1 50 0 0571 to 0 0591 32263 14602 1 50 to 1 55 0 0591 to 0 0610 32263 14603 55 1 0 0610 to 0 0630 322
1 i CHASSIS Model R4W63 F4W63 Item Counter gear thrust washer Thickness Part number in mm 32225 A0900 2 35 to 40 2 0 0925 to 0 0945 32225 A090 I 2 40 to 45 2 0 0945 to 0 0965 32225 A0902 45 2 to 2 50 0 0965 to 0 0984 32225 A0903 50 2 to 2 55 0 0984 to 0 1004 2 55 to 2 60 0 1004 to 0 1024 32225 A0904 Tightening torque kg Transmission proper Engine Front 2 4 to 2 8 transmission installation bolt cover 08 transmission installation bolt tightening nut Companion fla
TRANSMISSION Select lever pivot bolt 0 5 to 0 8 3 6 to 5 8 Lower support bracket 0 6 to 1 0 3 to 4 7 2 Steering wheel tightening Transmission gear control nut 7 0 to 5 7 50 6 to 54 2 floor shift Control lever installation bolt 1 9 to 2 2 13 7 to 15 9 TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable Corrective action cause Difficult to Causes for difficult gear shifting intermesh gears and transmission are classified to troubles concerning the control system When the gear s
fI CHASSIS Probable Condition Noise When noise occurs noise occurs while Insufficient or Corrective action cause under engine idling and stops while the clutch is shifting gears it may be judged Add oil or improper lubricant Oil leaking due to defective oil seal and disengaged Clean or at a Replace Damaged bearing Cyclic knocking sound Replace occurs replace high speed occun also at a low speed Worn each spline Replace Worn each bushing Replace SERVICE JOURNAL OR JOURNA
SECTION PD PROPELLER SHAFT DIFFERENTIAL CARRIER CI DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD PROPELLER SHAFT AND UNIVERSAL JOINT PD 1 DIFFERENTIAL CARRIER PD 5
7 1 C
PROPELLER SHAFT DIFFERENTIAL CARRIER PROPELLER SHAFT AND UNIVERSAL JOINT CONTENTS DESCRIPTION PO ASSEMBL Y REMOVAL PD 3 SERVICE PO 4 DISASSEMBL Y PD 3 TROUBLE INSPECTION PD 3 CORRECTIONS PD 4 AND SPECIFICATIONS DATA DIAGNOSES AND PD 5 @ @ Fig PO I Propella shaft for UV N 521 and except Floor Shift vehicles DESCRIPTION Three GN 521 types and 52 IT series vehicles These of are vehicle are counter balanced within propeller shafts for UV N 52l cm gr The used tapped co
CHASSIS f rA 6 u Fig PD 2 Fig Propeller shaft for PD3 G NJ521 series vehicles Propeller shafr for Floor shift vehicles PD 2
DIFFERENTIAL CARRIER PROPELLER SHAFT REMOVAL N UV S21 Remove except propeller transmission side Floor shifl vehicles shaft carefully spline and rear oil G N S21 and Floor shift vehicles Remove so differential gear not to damage seal 3 joint mounting bolts from both and remove case as transmission and bearing mounting brackets DISASSEMBLY Primarily is balanced are required do not disassemble as an When assembly however the propeller shaft because and disassembly it Fig re
1 CHASSIS is CD 4 When snap ring 5 When bearing oil seal ring damaged deformed replace or Propeller shaft installation bolt 2 5 to 3 0 is @ 6 damaged or When sleeve damaged 18 5 to 22 m Jb ft yoke and main shaft splined portions replace sleeve yoke and I are main shaft is propeller shaft tube surface dented Direction slackness or replace cracked When center 8 kg and or needle roIler replace worn or worn When 7 @ bearing is worn or damaged replace ASSEMBLY Assembl
PROPELLER SHAFT DIFFERENTIAL CARRIER TROUBLE DIAGNOSES AND CORRECTIONS Condition Vibration tion Probable Vibra occurs Worn haft at medium during or the Unbalance due to bent and high speed vibration transmitted needle damaged universal joint Replace bearing on propeller or Corrective action cause or dented propeller Repair or replace shaft i Loose propeller shaft installation to Retighten l body I Worn transmission rear extension t r Damaged Knocking sound during
CHASSIS ID @ 1 j I j I @ j @ Qt @ I Companion nange 2 Front 3 Spacer 4 Pinion bearing height adjust shim 8 Side bearing IS Drive gear 9 Bearing 16 Lock 17 Adjust shim 18 Thrust block 19 Side gear 20 Pinion mate shaft cap 10 Differential 1 Oil case 81 5 Pinion mate gear 12 6 Pinion mate gear 13 Drive pinion 7 Side gear thruit washer 14 Rear bearing 8 Cross secaonal view P Fig Adjust washer pin of differential carrier REMOVAL When removing gear
PROPElLER SHAFT DIFFERENTIAL CARRIER DISASSEMBLY Note Be sure to segregate left lright anc side bearings together with shims Inspectio before 1 In order to obtain the oil assembly for disassembly cause leakage of trouble and measure tooth pinion When tooth contact and backlash are incorrect measure backlash and torque Unbend diagonal drive gear and pinion contact 4 correctly check lock washer loosen installation bolts in and separate drive gear sequence of drive S Pull
f CHASSIS Be sure to replace it with Note new one when rein Apply bearing seized damaged are adapter an to race s side surface and withdraw O Put removed pinion height adjust oil seal P marily replace 6 Gear carrier Differential replace mate gear thrust washers excessively replace weakened is damaged or replace oil seal whenever disassembled worn or cracked replace worn or cracked case When sliding part is 8 pinion or worn When sliding part is 7 noise occurs se
PROPELLER SHAFT DIFFERENTIAL CARRIER Side gear thrust washer Thickness Part number mm in ST3321 0000 38424 25660 0 76 to 0 81 0 0299 to 0 0319 38424 32200 0 81 to 0 86 0 0319 to 0 0339 38424 32201 0 86 to 0 91 0 0339 to 0 0358 38424 32202 101 to 1 06 0 0398 to 0 0417 38424 32203 1 06 to l ll 0 0417 to 0 0437 Fig PD 16 Installing side bearing Adjusting pinion height Install pinion on specified preload measure differentia1 7 to 10 carrier temporarily apply 1 to 8 9 in lb 6
CHASSIS 2 drive Apply bearing pinion carrier to and install front Remove drive 6 install shim cone pinion the on from back of differential carrier and bearing rear cup When adjusting preload check pinion height again 3 and tighten companion flange Install 7 to 10 specified preload nut so 6 2 to 8 9 in Ib kgem that can be obtained drive Adjusting 4 Install gauge ferential carrier and and drive tool measure clearance between gauge end pinion end surface ST31100000
PROPELLER SHAFT DIFFERENTIAL CARRIER i Pinion bearing adjust washer Thickness 38135 09400 2 43 00957 38136 09400 2 41 0 0949 0 1004 38137 09400 2 39 0 0941 53 2 0 0996 38139 09400 37 2 0 0933 51 2 0 0988 38140 09400 35 2 0 0925 2 49 0 0980 38140 09400 2 33 0 0917 38141 09400 31 2 0 0909 Thickness 38127 09400 59 2 38128 09400 57 2 38129 09400 55 2 38130 09400 09400 38131 38132 09400 4 Part number Part number mm 0 1020 1012 0 38133 09400 47 2 0 0972 38134 09400
F O 3 T 1 I CHASSIS When the width is insufficient 8 Side bearing shim Part number Thickness 38453 61200 0 05 mm in 9 add shim Measure drive gear and drive pinion backlash When backlash is less than standard value it from left to move 0 0020 right Move from right to left when excessive Q7 0 0028 0 38454 61200 38455 61200 0 12 0 0047 38456 61200 0 25 0 0098 38457 61200 50 0 0 0197 Standard backlash 0 13 to 0 18 mm 0 0051 to 0 0071 in 5 Coincide marks on and install be
DIFFERENTIAL CARRIER PROPELLER SHAFT Inspecting and repairing drive TOE tooth contact gear l I Put red lead Minium evenly three to four teeth of drive gear on both surfaces of turn drive gear to both directions several times by hand and check drive gear for tooth contact 2 When tooth contact is incorrect shim adjust Be sure to wipe completion of adjustment a readjust off red lead HEEL SIDE thickness of completely upon Fig c Heel contact When surface is insufficient contact dam
CHASSIS e Correct contact shim is accompanied by change in backlash Check When proper tooth contact is obtained lead from ilear face A correct contact pattern that it lies in the range of 2 3 when no load is wipe off to 3 4 from it when red installing gear means INSTALLATION tip of tooth applied Install differential in carrier reverse removal Lubricate gears with gear oil upon Note Change in the thickness of adjusting washer sequence completion of installation or SERVICE DATA
PROPELLER SHAFT DIFFERENTIAL CARRIER Tightening torque 122 9 Drive pinion nut kg m ft lb 14 to 17 Drive gear bolts kg m ft Ib 4 8 to 5 34 7 to 39 8 Side bearing cap bolts kg m ft Ib 4 2 to 4 8 4 to 34 7 30 kg m ft Ib kg m ft Ib 2 101 to Differential carrier to axle housing fIx nuts Companion flange to propeller on drive 11 6 to 174 5 to 3 0 18 1 to 2 7 21 DIAGNOSES AND CORRECTIONS Condition Noise 4 2 shaft ftx nuts mOUBLE 16 to Probable Shortage C aerective acti
n 7 J CHASSIS Noise on rom Corrective action Probable cause Condition Loosen clamp bolts and nuts holding drive Retighten gear side torque bearing etc Side gear jammed in differential Pinion gears Worn or too Replace side gear thrust washer damaged designated tightening Replace defective parts case their shaft tigh t on them to the as required Replace and pinion thrust washer backlash bwtween drive gear and Excessive Incorrect backlash drive pinion Replace Worn different
SECTION FA FRONT AXLE FRONT SUSPENSION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD FRONT AXlE FA FRONT SUSPENSION fA 9 SERVICE DATA SPECIFICATION S FA 19 TROUBLE DIAGNOSES AND CORRECTIONS FA 21 1
r lit
FRONT AXLE FRONT SUSPENSION FRONT AXLE CONTENTS Inspection FA 3 FA 2 Reinstallation FA 7 FA 2 Wheel DESCRIPTION FA FRONT AXLE Removal 8 FA bearing adjustment DESCRIPTION Fig The knuckle spindle FA l Cross sectional view is installed on the knuckle spindle parts support through the king pin The king pin bushing is placed between the knuckle spindle and of ront king pin sliding arm FA l Knuckle spindle Inner wheel 3 Outer wheel bearing 4 Oil 5 Wheel hub 6 Washer 7 Spin
CHASSIS knuckle the operated the knuckle secured on supported is with two is lightly wheel bearings spindle and brake drum and wheel are With this the wheel hub with hub bolts construction spindle spindle the knuckle round king pin axis wneel hub The on arm moves wheels lightly rotate round the knuckle axis FRONT AXLE Removal I Jack up vehicle and support it with stands 2 Remove hub nuts and wheeL Fig 11 Remove brake hose from wheel hole cylinder 5 6 Remove brake drum 5
FRONT AXLE Tap spindle lightly with 13 a copper FRONT SUSPENSION Clearance limit 0 15 lead hammer or 0 0059 in mm and detach it from knuckle spindle support Be careful not to i Standard dimensions drop thrust bearing King pin r outer diameter 19 979 to 20 000 mm inner diameter Bushing 0 7866 to 0 7874 in when filled 20 010 to 20 035 mm 0 7878 to 0 7888 in if ldf 2 1 tI Fig Lightly tap 14 by applying race a FA 6 brass bar circumference with and remove from wheel hub When
CHASSIS Visual Serviceability Standard for Wheel Bearing INNER RACE SUR FACE OUTER RACE FITTED SURFACE COLLAR SURFACE OUTER RACE SURFACE INNER RACE FITTED SURFACE ROLLER ROLLING SURFACE INNER RACE SMALL COLLAR LARGE COLLAR ROLLER SUPPORTER OUTER RACE Unserviceable x when minor May be used Judgement 0 emery paper Rust should be removed with Race and roller Cause s t O O atU 8 Flaking l l 15o l l ii Service life due to rolling fatigue x before the service life The However this fo
FRONT AXLE FRONT SUSPENSION I Race and roller i 1 l g o Cause l a 0 0 0 0 0 Seizure l l ro 00 l u x x In x the most discoloring Scratch 6 6 or wear 6 6 foreign removal of result other handling or Recess made 6 6 by Poor lubricant 6 bit foreign grown scar due to quality matter deteriorated lubricant or Intrusion of dust Fitted surface is Wear due to excessive preliminary pressure 6 6 6 Excessive preliminary pressure Fretting 6 6 6 The fitted part is
17 CHASSIS Inner RoUer race Recess Cracked roller bit flaking Cracked inner inner race made on Recess by foreign matter race on auter race made by bit foreign matter III Recess bit 4 on foreign roller made by matter Spindle Check 5 spindle for exploration or dyeing test When bearing inner spindle with a crack new one by means of a race slips against spindle When thread is Check front hub for crack by magnetic and replace if cracked Fr nt hub exploration or dy
FRONT AXLE or it does not rotate smootWy or noise occurs FRONT SUSPENSION U Spindle nut when thread is Repair or replace as side utilize upper side as reaming reaming guide and upper side center damaged both When reaming upper side bushings 7 from Perform reaming lower utilize lower when reaming lower and guide to align the line correctly Bushing inner when fitted diameter 20 010 to 20 035 0 7878 to 0 7888 in mm Reinstallation 2 Reinstall front axle in noting the follow
CHASSIS 6 Fill wheel hub and hub cap with MIL G2108 Figure 10924 or up to 1lurpose multi grease J Wheel bearing adjustment the described level See I FA 9 Tighten spindle nut to the specified tightening torque Tightening torque 2 to 3 4 3 kg m 1 to 24 6 ft b 23 Fig 7 FA 9 Filling space between heel Fill space between wheel bearing rolle seal lip pocket with multi purpose grease bearing and grease MIL G2108 Fig or FA 11 heel Tightening bearing lock nut 10924 complet
FRONT SUSPENSION FRONT AXLE Note Wheel bearing rotation starting torque New bearing and seal 15 Used bearing and seal 7 Spring balance indication New bearing and seal Used bearing and seal Correctly measure tiar direction starting against hub force toward tangen bolt 13 0 in Ib orless em kg 1 in Ib 6 em kg or b less No slackness should exist toward axial direc tion at hub bolt 2 1 kg 4 6 Ib 1 0 kg 8 or less 5 2 2Ib or less Apply cotter pin spindle to secure nut and in
CHASSIS The front suspension is double wishbone type in a which uses torsion bar dependent suspension Both the upper and lower links bracket secured on the upper and lower links frame by are means swing through spring installed on the of welding The screw bushing and rubber bushing respectively Top and bottom of installed respectively link and screw the knuckle through bushing on spindle support rubber bushing on are upper lower link The tension rod is installed tension rod
FRONT AXLE 8 RemOve nuts tension rod D from the front and rear FRONT SUSPENSION ends of Remove bracket bolts @ from the front end of tension rod and then detach tension rod together with bracket Fig Fig FA 16 Tension rod 12 FA 18 Removingcotterpin Drive out fulcrum pin with a drift and detach knuckle spindle support from lower link Remove dust cover Remove fulcrum bolt after 9 detach knuckle loosening spindle support from its nut and upper link Fig J Fulcrum bolt Fig 2 S
CHASSIS Remove lower link 17 arm CD bolt and separate torque torque arm arm @ and torque link from lower f Fig 15 Twist and spindle FA 20 separate upper link and remove dust cover separated upper link on a I Upper link spindk from upper link and dust seal vise and remove screw Secure bushings FA 23 Lower link and torque Fig ann r 18 t Using bushing special a tap it with bushing from a tool to lower link ST36070000 hammer and drive out lower link bracket r J t I
FRONT SUSPENSION FRONT AXLE replace if necessary Specifications for Shock Absorber Check dust seal for wear and Max Min 12 4 315 mm length 205 mm 8 1 in 110 mm 3 in 4 Stroke and replace damage as in length required Check threaded part of upper link spindle fulcrum pin and screw bushing and repair or replace if necessary force Damping Rebound 110 Compression 55 kg kg 5 Ib 242 3 3lb I21 Lower link bushing upper link bushing I O 3m Check rubber 0 98 ft sec sec bushin
1 CHASSIS 1 I Lower link bushing which lower link bushing mounting bracket is inserted and bushing 5 kg 9 m 615 to 68 7Ib ft Upper link 3 When collar interior of lower link along 5 to 8 Tightening torque Reinstallation Tighten I seal and dust bushing screw on upper link Install grease cover exterior are rusted remove rust with emery paper 24 to 25 kg Tightening torque 2 Apply disassembly hammer tool special a to lower link and fit lower ST36070000 bushing link tap
FRONT SUSPENSION FRONT AXLE 2 Install dust seal knuckle on 5 spindle support Remove f1ller grease until 3 Coincide of notch direction for cotter pin on plug install grease and nipple inject grease comes out from dust cover Reinstall f1l1er plug fulcrum pin with direction of pin hole of knuckle spindle fulcrum and drive support support with into hole into knuckle pin spindle copper or lead hammer Insert cotter a tighten lock 6 pin Upon installation make sure that fulcru
or r CHASSIS 3 Make the distance of rubber bushings to be 36 6 1441 in mm nut on the front eod of by tightening tension rod When adjust rubber bushings are compressed unequally position of adjusting nut the I Lock nut tightening torque 5 to 2 1 kg 1 m 10 8 to 15 2 ft Ib Bracket bolt tightening torque 1 5 to 2 1 10 8 to kg E m E 15 2 ft Ib Fig Bracket bolt 1 5 to 2 1 4 mm 33 FA 32 Stabilizer instJJUation tightening torque kg m 10 8 to 15 8 Torsion bar spring Grease serration
FRONT AXLE FRONT SUSPENSIO t 3 Jack up applied spring tighten Figure FA 33 nut anchor which anchor bolt is dimension that so meets the standard dimension Jack up vehi and support it with stands e shown in and secure lock nut A 68 5 dimension mm 2 697 in A dimension Short body 98 3 86 Long body 92 3 62 Van 75 2 95 Double cabin 75 2 95 Option 90 3 54 mm in P @1 t@ fii 4to 5 kg m 28 9 to 36 2 ft Ib 2 Check vehicle for posture and adjust if necessary 4 See Adjustm
CHASSIS Thoroughly check all 2 componenV parts and repair and suspension systems of steering replace defective OT Short Toein 1 r mm parts before starting wheel alignment v D Cabin Van Long 2 t03 2 t03 2t03 0 0787 to 0 1181 0 0787 to 0 1181 0 0787 to 0 1181 in CambeT 1015 lOIS 1020 Caster 1050 2015 1055 King pin inclination 6015 6015 6010 Inner wheel 360 360 360 Outer wheel 310 310 310 Steering angle Toe in I f Measure ment the 2 in toe and adjust as F OT
FRONT AXLE Adj osting shim FRONT SUSPENSION 1 J I Thi kness Part number 5454204101 1 I li 11 mm in I IAJ t i rr 1 r o 1 rro I J 0 0394 t V 5454304101 2 0 0787 J Standard thickness J 1 54544 04101 0 1575 4 r t r t j 1 1 J II To adjust caster make a difference of front shim and that of thickne increases approximately 33 rear caster per I between thickness shim When front shim reduces mm t Caster changes 0 0394 in of shim Fig FA 37 Adjusting cambe
r CHASSIS When at readjusted in Ib cm kg r 6 1 7 less than the hub bolt When both bearing and seal When are new readjusted than 2 1 4 6 less than 10 2 2 1b kg less Ib kg resistance kg m ft lb less than 5 0 3 6 sliding resistance kg m ft Ib less than 5 0 3 6 Brake hose connecting nut kg m ft Ib Wheel bearing lock nut kg m ft Ib 3 2 to 3 4 23 1 to 24 6 Brake disc kg m ft Ib 4 0 to 5 4 28 9 to 39 0 Upper link sliding Lower link Tightening torque fixing bolt 7
FRONT AXLE FRONT SUSPENSION 1 I TROUBLE DIAGNOSES AND CORRECTIONS V v Condition Probable Corrective action cause shock and shimmying of steer Vibration ing wheel Vibration ing Too much backlash of steer abrasion of each part of linkage gear vibration and of front wheels wheel This is very much noticeable when travelling over air pressure of tire Unbalance ar d Adjust deformation of road in are transmitted to the steering many cases Improper bad roads and at higher wheel
I v CHASSIS Probable Condition 9frective cause action L Worn loose or suspension link screw Replace bushing of Deforrned steering and linkage suspension Correct the unbalance Unbalanced vehicle level Instability of vehicle Improper Worn Replace link Adjust air pressure of tire loose or suspension link screw Replace bushing Adjust Incorrect wheel alignment Worn or deforrned steering linkage and Replace suspension link Incorrect adjustment of steering gear Adjust Corr
FRONT AXLE Cfdi e o FRONT SUSPENSION tIOn Excessive steering wheel play Probable Corrective action cause I 7 v Incorrectly adjusted steering Worn steering linkage idler gear housing Worn or loose wheel Retighten bearing suspension I Replace arm Improperly fitted of gear box Incorrectly adjusted Adjust link Adjust screw Replace bushing Noise Improper air pressure of tire Adjust Insufficient lubricating oil and grease for Replenish lubricating suspension ball joint and ste
1 CHASSIS Probable Condition Excessively or partially Corrective action cause worn tire Improper Adjust air pressure of tire Incorrect wheel Adjust alignment Defective wheel bearing Replace Incorrect brake adjustment Adjust Improper tire shifting Adjust rotation Rough and improper driving manner Drive more SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE BULLETIN No PAGE No SUBJECT FA 24 gently
SECTION RA 1 REAR AXLE REAR SUSPENSION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NI55AN MOTOR CO TOKYO JAPAN LTD REAR AXLE RA 1 REAR SUSPENSION RA 4
REAR AXLE J V 1 J REAR AXLE t CONTENTS DESCRIPTION RA l INSPECTION R 2 REMOVAL RA l INSTALLATION RA 3 J @ 1 12 Axle shaft 3 Wheel bearing 4 Plain washer 5 Lock washer 6 Lock nut 7 Oil sea1 8 Bearing 9 Shim 10 Fig RA l Cross sectionallliew 3 DESCRIPTION The housing in rear is a axle is pressed weight and is any torsional and The rear of a steel semi cage Grease seal 11 Bnkedrum 12 Wheel nut ax Remove brake shoe and disconnect hand brake wire float
CHASSIS 4 Remove four nuts used to install brake end to axle and disconnect brake line Fig RA J 8 p RemoPing A lQck Remove RARemoPing loci nut Withdraw axle shaft 9 Note Be careful notto damage oil seal in axle case side 6 Use axle stand axle on vise special tool ST07630000 and Withdraw axle bearing together with brake disc and bearing cage by using RA 7 Remove oil Seal Fig RA 4 seal again because Secwring axle in cup from Unbend lock washer with a screw a tool puRer special
REAR AXLE t i surface rust on roUer or 4 other defective condition Coincide washer tightening 4 Be to sure removed oil seal and lock washer replace lip with nut groove nutand bend washer carefully so correctly by lip that is not maged with new ones Note When no Fit bearing cup and grease seal with a grease 2 MIL G2108 or rubber evenly while fitting brass hammer cone with a to cage Fill Tap 5 lip with on axle Fit oil seal to tube end MIL G2108 and fit or a set
CHASSIS Install other parts in 1 Fig RA ll reverse sequence to removal MClJSUring clearance toward tDCW direction I REAR SUSPENSION CONTENTS DESCRIPTION RA 5 SUSPENSION ASSEMBLY RA 5 Removal SPRING Removal AXLE CASE RA 5 Removal RA 5 RA 5 INSPECTION RA 5 ASSEMBL Y RA 6 RA 5 SPEC I FICA TIONS RA 6 AND REPAIR RA 6 U YO i c @ Ofr ff l 4 1 2 3 4 5 Spring helper rubber Qiprcar spring Pin rear spring front Pad rear spring lower R H L U Assy shackle rear spring outer 6 7 8
REAR AXLE DESCRIPTION The which and rear parallel a Banjo is a suspension rear uses ends of the spring type rigid suspension leaf spring Both front elliptic semi are secured on the frame with rubber bushings and the shock absorber is installed cross the member from the spring lower pad The suspension is an under type on slung type SUSPENSION ASSEMBLY Removal Fig I RA H Removing suspension assembly Jack up vehicle and support it with stands Remove road wheel SPRING 2 Disconnec
1 I CHASSIS rubber and bushings 4 replace Shock absorber If repl leaking noise or reduced damping force is detected ce ASSEMBLY Rear suspension assembling is carried sequence to I out disassembly by noting the following When installing rubber bushings in reverse items coat soap water on them slightly RA 15 Pig Removing Ie case 2 following Shackle pin Spring When the is spring cracked broken or rubber bushing under no weakened I 1 5 to 13 Spring pin 5 to 13 11 m 83 2
REAR AXLE N 521 PL52 3 04 Spririg constant kg mm bfin lb kg 170 0 to 20 1 N G 5 2 0 44 292 20 195 0 to 430 1 0 to J V 144 257 to 521 95 9 9 544 than 5 8 1142 U N 521 112 95 to 2 209 to 430 4 5 252 than mo mo U 521 N Option N 52t 277 6 I more 1 112 0 100 to 200 220 to 441 J 5 3 297 than 500 1102 th mo 1 500 1102 Camber Free mm Loaded in 127 5 00 143 5 63 170 in 35 38 1 11 43 0 33 30 650 1433 500 102 70 6 6 69 69 with specified load mm lb
CHASSIS t E JOURNAL UR RViJ JOURNAL DATE BULLETIN 6UL ETli l lRECFEEHEi or No PAGE No SUBJECT f fi 1 B RA
SECTION BR BRAKE j i DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS r I NIS J NI l ArJf NISSAN MOTOR CO TOKYO LTD BR BRAKE JAPAN w 1
1 VA tf
BRAKE BRAKE CONTENTS DESCRIPTION BR Inspection BRAKE BR Reassembly Removal BR REAR BRAKE BR 8 Inspection BR Removal and BR 9 Reinstallation BR 1 BR 9 BR 2 Reassembly Removal BR 2 HAND BRAKE Disassembly BR 3 I nspecti on BR 3 Inspection Reassembly BR 3 Installation Reinstallation BR 3 BR 4 Bra k BR 4 Brake shoe clearance BR 4 Hand brake BR 4 BR 5 SERVICE BR 6 TROUBLE MASTER BRAKE PEDAL CYLINDER LINES Removal Inspection Reinstallati FRONT m
CHASSIS 3 Tightening torque steering wheels Fulcrum pin For vehicles with both left 3 5 to 4 0 kg m and right hand MASTER CYLINDER 1 Valve cap 2 Valve cap 3 Check valve 4 Check valve 5 Oil reservoir cap 6 gasket spring Reservoir 7 Reservoir band 8 Packing 9 Stopper 15 bolt Primary piston cup 16 Secondary piston cup 17 Stopper ring 10 Piston return tt Spring 18 Snap ring 12 Spring 19 Rubber boot 13 Valve 20 Push rod 14 Piston spring scat Fig BR 2 Master
BRAKE Disassembly In I Drain brake fluid 2 Remove stopper bolt 3 Remove rubber boot remove 4 principle replace piston cup gasket and valves with whenever master cylinder is disasSembled new ones 5 Check piston return springs for damage other defective conditions and replace snap ring and stopper ring and 6 Replace others if deformed out piston and other related wear and necessary damaged push rod Take as oLdefective from parts cylinder 5 Remove valve cap and then remove
CHASSIS BRAKE LINES I Brake 2 Brake tube 3 Brake 4 Front 4 way hose tube connector 5 Brake tube 6 Brake tube 7 Brake hose 8 Connector 9 Brake tube 10 Vinyl 11 Brake tube 12 Brake hose 13 Rear 3 way cover connector Fig BR4 BTaJe 14 Brake tube 15 Brake tube lines Removal 1 Disconnect brake tube both ends and remove by turning flare nuts on the clips used to secure brake tube on the panel Fig BR 6 Rear J WdY ConnectoT Inspection Thoroughly clean brake Fig 2 Di
BRAKE other parts parts so that brake lines do not interfere with other 4 way connector to 1 7 to 2 brake tube during driving due to vibrati on Connector to brake tube 2 Apply brake fluid to threaded part of brake tube 12 0 3 to 14 5 17 to 2 0 3 12 17 to 2 0 3 to 14 5 12 to 5 14 Wheel cylinder to flare nut correctly engage threads and tighten flare nul brake hose Wheel cylinder to 3 Install brake hose Install front brake hose being sure not to twist particularly carefully so
CHASSIS r Removal and disassembly round lf Out Jack up vehicle and support it with stands I 254 mm Inner diameter 10 00 in Less than 0 02 mm 0 0008 in 2 Remove wheel and brake druOL When brake drum cannot be removed 3 In order to return brake easily operation ease Umit ofrebored drum JD remove hub assembly 2 brake shoe When seated Unhook upper lower and after shoe return springs sive and then remove brake shoe assemblies unevenly heating linings 10 04 in Disconnect brake hos
i BRAKE 1 1 12 4488 dla 810 5039 die u 11 4 11 1111 II IU ENGTH FR 136 r r 515 371 F Unit Fig BR 8 mm H 134 515 301 Unit in Upper return spring BR 9 Lower return Fig 5 Check brake disc for distortion 6 Wheel cylinder mm in spring f fl @ @ 1 Wheel cylinder housing 2 Piston 3 Piston cup 4 Dust 5 Snap ring 6 Connector 7 Packing 8 Connector bolt 9 Bleeder BR I0 Front wheel cylinder I 1 Wheel cylinder can following procedure be disassembled simply by t
CHASSIS Apply rubber grease to piston cup and other rubber parts slightly and brake lIuid Reassembly Reassemble sequence to to piston and cylinder bore and reinstallation and reinstall brake front in Note the disassembly and removal reverse following matters I When to grease adjuster assembling adjuster adjuster housing assembly bore adjuster apply brake wheel and screw When installing adjuster assembly to brake disc Fig apply BR l1 Greasing points on ront brake brake grea
k BRAKE if 8 disassembly Remov al and Disconnect brake tube at wheel cylinder by loosening flare nut J Jack up vehicle and support with stands 2 Remove wheel and brake drum 9 Remove wheel cylinder from brake disc by loosening installation nuts 10 spring plate lock plate and from brake disc assembly adjuster Remove rubber boot shim and remove 1 Inspection For the rear brake inspection refer to the instructions for front brake I Fig BR tJ Rear b ake Brake drum Refer to the para
CHASSIS 1 J Upper Wire diameter x free length in mm mm 2 0 in return x 0 079 175 x spring 2 3 32 5 6 89 spring Lower return 0 091 32 5 6 22 x 14 x 83 2 30 158 x After shoe return spring 0 055 30 5 27 3 28 x 27 5 turns 12 Load kg lb x length mm x 473 0 in FREE LENGTH 19 184 x 0 748 7 24 x LENGTH 1010 L 3941dia Unit mm 99 x 0 188 6 93 FREE 1U BR 15 5 4 176 17516 69 ll 1 Fig x x 3 90 56 I 111 12 610 504 Unit in Upper return spring Fig
1 c v d Wheel cylinder 64 20 3 ifUler diameter mm 13116 cover For piston assembly Wheel cylinder and pull piston out head and inspection and reassembly refer apply Before installing brake shoe assemblies grease to the following in 1 Remove dust t BRAKE brake places Brake shoe installing grooves of adjuster and wheel cylinder to 2 Extension link installing grooves 3 Lower surface of spring seat 4 Contact surfaces between brake disc and brake shoe offront brake assembly Si
r I CHASSIS HAND BRAKE @ I Control bracket 6 Set spring 11 Inner lever 15 Equalizer 2 Control lever 7 Front lever 12 Arm spring 16 Rear cable Lock plate Cable spring 3 Control stem 8 Front cable 13 Center link rod 17 4 Control guide 9 Outer lever 14 Equalizer link 18 5 Control yoke 10 Center cable Fig BR 19 Hand brake construction Front cable center cable Removal Completely loosen hand Control stem 2 1 Completely 2 Remove loosen hand brake clevis pins D a
1 BRAKE Rear cable 2 Replace if ratchet pawl ly or unusually I Completely 2 Remove clevis pin and disconnect equalizer from loosen hand brake 3 or and teeth are worn excessive damaged Check springs for weakness and replace if required link equalizer Installation 3 Remove lock plate CD and cable spring @ Reinstall hand brake in reverse sequence of removal Grease G2108 or sliding parts with multi purpose grease MIL GI0924 JUSTMENT AD Brake pedal height Loosen stopper up to su
r CHASSIS i Rear drum brake Part No Thickness mm in With hand brake fully released For clearance 3061 I 27260 16 00630 30612 27260 0 8 0 0315 30613 27260 5 0 0 0197 Note When having the Screw in 5 135 mm sure to refer rear brake brake shoe Front drum upper and shim lower installation bolts stopper so that height of brake pedal head 5 33 in procedure rear to brake adjusting use for thickn same cylinder m 3 be adjusting the adjust is and tighten lock from da
BRAKE when control stem is 44 1 to 66 llb pulled Lock with adjust force of 20 to 30 kg a screw other end of hose in container a containing some brake fluid with lock nut Normal stroke 80 to 100 3 3 15 to 3 94 in mm Limited stroke Less than 144 Note mm 5 67 in 4 H nd brake must operate smoothly pulled and released noise Depress brake pedal Make dragging twisting sure that while being or With brake pedal screw 5 when stroke exceed 7 Bleeding hydraulic system essentia
CHASSIS Brake lining Dimension width x front thickness Total friction rear x length 4 5 x x 244 18 x 0 2 440 68 2 sq in em area 45 in rom Wheel cylinder Front rom in 20 64 13 16 Rear rom in 20 64 13 16 Master cylinder diameter rom 19 05 3 4 in Service data Master Cylinder push At brake rod pedal height rom in rom in 138 5 545 Brake pedal Brake pedal height 5 135 33 5 Wheel cylinder Allowable maximum clearance between cylinder and piston Master rom in
BRAKE Tightening torque Fulcrum pin kg m lb ft 5 to 4 0 3 Master cylinder kg m lb ft 2 1 to 2 5 m kg lb ft 6t09 Master cylinder valve cap 3 to 28 9 25 15 2 to 18 1 4 to 65 1 43 4 way connector kg m ftIb 10 to 15 7 23 to 10 85 3way connector kg m ft lb 10 to 15 7 23 to 10 85 Front brake Wheel cylinder kg m lb ft 4 2 to 5 2 Connector bolt kg m lb ft 1 7 to 2 0 Brake disc kgm lb ft 4 0 to 5 4 kg lb ft 5 to 18 1 10 1 7 to 2 0 123 30 4 to 37 6 3 12 5 14 to 28 9
CHASSIS Condition Spongy pedal Probable Deteriorated brake shoe lining face Replace Worn brake shoe lining Replace Oogged brake line Inspect and clean Air in brake lines Bleed Swollen hose due to deterioration use of Replace hose and bleed system Use prescribed brake fluid Use of a brake fluid boiling poin t of which is Change too low bleed system reservoir filler cap vent hole This promotes a vacuum that sucks in air through slight or thoroughly poor quality brake fluid Oogged
BRAKE Condition Probable Worn or damaged Corrective action cause rust other than brake Repair or replace Repair or replace Adjust and Apply brake grease drum Defective wheel Faulty cylinder operation brake shoe sliding Faulty adjuster sliding plate installation bolt Loose back Deformed back plate Replace Improperly adjusted wheel bearing Readjust wheel Improper Brake drags or replace Readjust alignment Inspect and clean Loose leaf spring U oolt Retighten Insufficient
CHASSIS Condition Squeal Probable Corrective action cause Deteriorated brake shoe lining face Correct by means of polishing or replace Deteriorated brake shoe lining face Correct by means of polishing or replace Worn brake shoe lining Replace Improper brake shoe and lining contact Replace Excessive friction between brake shoe and Oean and apply brake grease brake disc Foreign brake drum sliding sur Oean deflection of drum sliding sur Rebore or replace matter on face Damag
BRAKE SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT BA 21
CHASSIS E JOURI l SERVi JOURNAL DATE OR ET j k3UU I EFEI1E Il E or PAGE BULLETIN L No SUBJECT No BA 22
SECTION WT WHEEL AND TIRE DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I 1 Jc NI SSANMOTOR CO TOKYO JAPAN LTD WHEEL AND TIRE WIl TROUBLE DIAGNOSES AND CORRECTIONS WT 5
WHEEl AND TIRE WHEEL AND TIRE CONTENTS DESCRIPTION WT 2 Tire rotation WT2 TIRE SIZE INSPECTION WT2 I nflation of tires WT 2 Wheel WT 2 CHECKING WHEELS AND JACKING UP WT3 in Front 6 00 Rear 6 00 146PR LT Front 6 00 146PR L T Rear 6 00 14 8PR 6PR 14 LT PL52l G N 521 Series LT 6 00 146PR LT L521 TU Only U N V Front 50 5 Rear 50 5 t 146PR LT 521 TIRE INFLATION PRESSURE To be measured when tires are 6PR 14 LT cold Unit Under 100 km h 60 MPH Over 100 km h kg lb cm2
CflASSIS Tighten DESCRIPTION wheel nuts to a torque of 5 to 10 0 kg 8 m 61 5 to 72 3 ft Ib Inflation of tires Tire rotation improve riding comfort and Tires with proper pressure the steering stability reduce driving sound and extend To equalize the service life in the checked for proper pressure The tires should be monthly bassis conditions 5 0 rises pressure frequently depending or more while the tires 7 Ib kg cm in2 tires should be rotated as shown diagram on driving on Ord
WHEEL AND TIRE izontal axes Figure WT 3 the at 15 are the points indicated by mm 0 06 in or more asterisk in replace wheel Fig 2 Fig WT 3 Wheel rim run out Jacking WT 4 Place jack under rear spring added car is jacked up damage tear condition of flange of rim welded deformed and for deformation unit and damaged other Front seat Rear apply parking brakes and as precaution against moving place block under the front Check the spare tire up Place jack under low
CHASSIS 3 5 Remove wheel cap Change when Fig 4 WT 7 Removing wheel 6 Loosen wheel nuts When loosening turn nuts counterclockwise WT B Loos ing wheel Remove sure to WT 9 jack wheel by wheel a 4 WT temporarily nuts follow the order shown in figure ing Tighl order of wheel and tightening wheel following the above mentioned order nut wrench Fig tighling be Fig cap and tighten tire nul nut properly
WHEEL AND TIRE TROUBLE DIAGNOSES AND CORRECTIONS Possible Condition Wheel wobbles Corrective actions causes Improper tire pressure Measure and Damaged tire Repair or distorted wheel rim or Unbalanced wheel Balance Loosen wheel n ills Retighten or damaged wheel bearing cessive play of wheel bearing Worn or ex Improper front wheel alignment Worn or link damaged steering ball Correct adjust correctly replace correctly play or replace Adjust joint and Replace bushing Excessi
I CHASSIS Condition Tire Possible squeals Improper tire pressure Improper front wheel Distorted knuckle C DATE or Measure and adjust correctly alignment y BULLETIN Realign correctly suspension pnV CE JOURN AL yn JOURNAL Corrective actions causes link Repair 01 UU 1 J lE P J or replace if nesessary n i n t RI lr t or PAGE No No SUBJECT WT 6
SECTION ST STEERING DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN I LTD STEERING ST STEERING LINKAGE ST 6 SERVICE DATA AND SPECIfiCATION ST 8 TROUBLE DIAGNOSES AND CORRECTIONS ST 9 I
STEERING STEERING CONTENTS DESCAIPTION ST 1 INSPECTION AND REPAI A REMOVAL ST 2 ASSEMBLY AND ADJUSTMENT DISASSEMBL Y ST 3 INSTALLATION 4 ST 4 ST ST 6 fr DESCRIPTION 1 J Steering column 7 Cross rod Steering column jacket 8 Cross rod socket 3 Steering wheel 9 Idler arm assembly 4 Column clamp 10 5 Post grommet 11 6 Steering gear 1 2 Side rod Steering gear assembly ann P g ST l Structural view CT 1 of steering r1Jechanism
v CHASSIS The steering gear is of gear ratio is 19 8 IThe rod tie rods one on link as the front recirculating ball type a steering linkage each side of the wishbone type These side rods pitman the and idler arm left and wheel Steering motion in arm side At the same through is remove steering post control is attached to steering colunan jacket even gear I Detach gear lever 2 Disconnect shift lever from shift rod and select lever and from select rod at the steering c
if STEERING Remove 10 steering 12 housing installation bolts gear Detach transmission control parts from steering column jacket 11 Remove steering gear assembly toward engine com partment DISASSEMBLY JID @ I @ 6 D 1 3 1 Sector shaft 2 Filler 3 Sector shaft 4 Sector shaft adjusting Gear housing 5 adjusting screw plug cover screw shim Fig 6 Sector 11 Column jacket 7 Oil seal 12 Steering column 8 Gear housing bushing 13 Column jacket bushing 9 Worm 14 10 Wo
CHASSIS Pull sector shaft 3 from gear screw with sector shaft together cover sector shaft housing Disassemble Remove column 7 jacket bushing adjusting INSPECTION AND REPAIR and shims from the cover Wash all in parts solvent clean and dry them thoroughly I Sector shaft Check sector shaft tooth surface for pitting exfoliation or c other damage and replace sector shaft and or necessary contact surface is gear housing bushing Yhen replace as bushing as damaged Check necessar
STEERING 1 6 to 18 Tightening torque 116 Standard Install sector haft adjusitng 5 kg m and selected shim in the slot of sector shaft to 13 0 ft Ib bearing shim thickness worm lj Measure end clearance 1 5 mm 0 0591 in adjusting mm Worm bearing adjusting Part No 4 screw mm 48029 71200 0 762 0 0300 48030 71200 0 254 0 0100 48031 71200 0 127 0 0050 48032 71200 0 050 0 0020 of worm t shim so a proper sector shaft that end clearance is 0 01 to 0 03 0 0004 to 0 0012 in shim
CHASSIS Sector shaft cover 9 tightening torque m 116 to 13 0 kg 1 6 to 1 8 adjusting lb ft lock Note Be sure to use preventing agent surface of surface of 3 on steering gasket and apply oil the sector shaft cover gear housing and nut and leak nut sector shaft tighten when temporarily slowly shaft Connect gear several times 8 to ensure Set gear arm to sector shaft it turns to neutral move Pour gear oil position and with ball measure nut Approximately liter 0 70 US pts
STEERING REMOVAL AND DISASSEMBLY I Jack up the front 7 of vehicle and support it with pins and Remove cotter ends of cross and idler arm rod nuts from ball studs in both and separate cross rod from gear arm stands 2 pins and Remove cotter ball studs from knuckle nuts and detach side rod INSPECTION AND REPAIR in both sides arms I Side rod ball joint and When ball cross rod stud is wo n and direction is excesSive replace with Fig 3 Remove shaft and used nut remove pulle
CHASSIS Side rod ball stud Knuckle Gear arm arm or 6 to 7 side idler kg 6 to 7 kg side arm 4 to 50 6 43 m lb ft m o 434 to 50 6 ft Ib @ Idler assembly arm 3 2 to 3 7 kg I m 1 to 26 8 ft b 23 A Cross rod lock nut 9 to 12 kg m 1 to 86 8 ft lb 65 ST 15 Cross sectional view Fig When 2 adjust cross cross rod socket an cross ro are rod length correctly I multi purpose grease Apply to threaded Standard cross rod length 516 mm 20 3 in Adjust toe in and 2 outline
STEERING SERVICE DATA Standard thickness of Worm shims bearing adjusting in mm 15 0 059 t Initial turning torque of steering column New worm bearing kgm Used bearing kgm in Ib worm in Ib 4 0 to 6 0 3 5 to 5 2 2 4 to 2 1 to 3 8 4 End clearance of sector shaft adjusting screw Backlash at the gear arm top end Oil capacity ann mm in 0 01 to 0 03 o to 0 1 mm in mm in mm in 33 0 0 0004 to 0 0012 0 to 0 004 0 70 0 58 0 1 to 5 0 0 004 to 0 020 dimension A 8 ST Refer
CHASSIS SERViCE JOURNAL OR BUllETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT r J ST 10
SECTION FE ENGINE CONTROL FUEL EXHAUST SYSTEM DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS I NISSAN I GI t i t NISSAN MOTOR CO TOKYO JAPAN LTD ENGINE CONTROL SYSTEM FE 1 FUEL AND EXHAUST PIPINGS FE 5
EN GINE CONTROL FUEL EXHAUST SYSTEM ENGINE CONTROL SYSTEM 1 CONTENTS DESCRIPTION FE 3 Play of accelerator wire ADJUSTMENT FE 3 Pedal stopper FE 3 4 FE height f L1 I Open Angle Operating I Close Hitach 81 Nikki 82 C A Nut B Adjust C Lock nut B A nut Unit Fig FE 1 Accelerator contTol syst fE for RH drive mm in
CHASSIS GP l Clearance 0 to 1 0 to 0 0394 Unit Fig FE 2 Accelerator control system for LH drive rnm in mm in except model PL521 it E3 Unit Fig FE 3 Accelerator control system FE 2 for LH drive PL521 model
ENGINE CONTROL EXHAUST SYSTEM FUEL half turns DESCRIPTION so to 0 08 in The accelerator is system light The constructed so and the smootWy is linkage is system Tighten accelerator control the that in part linkage A nut C B to lock nut mm Nut 0 04 B is of carburetor side outer case operates affected by engine not that accelerator wire play is I to 2 Throttle Valve Operating Angle vibration 0 AD USTMENT RH drive I I FE I Fully screw nut bracket and adjust can A
CHASSIS Pedal stopper height RH drive wire Upon completion of accelerator accelerator pedal and adjust stopper plate between ance pedal I mm proximately arm and 0 04 in stopper play so depress that clear is plate when throttle valve is opened Secure stopper plate with a lock ap fully screw Unit Fig 18St FE 8 Adjusting ped41 hight for LH drive PL521U method is the Adjusting ever Unit FE 7 in 83 3 Fig stopper mm mm same as for lR drive How pedal stroke differs in Adj
ENGINE CONTROL FUEl EXHAUST SYSTEM FUEL AND EXHAUST PIPINGS CONTENTS EXHAUST PIPE AND MUFFLEA FE 5 FUEL TANK Description FE 7 Difference of part by model FE 7 Precautions for removal and installation FE 9 AND PIPINGS FE 9 Description FE 9 Removal FE 11 I nspection and repair FE 11 EXHAUST PIPE AND MUFFER N521 Model Series l GN521 Model Series t Note Front and are Fig FE tO Exhaust construction rear tubes of the GN521 model series longer than those of the N521 model se
I I CHASSIS VN521 Model Series UN521 Model Series Note Aear tube of the UN521 model series diffen from that of the VN521 model Fig ies FE l1 Exhaust constructi01l for VN521 and UN521 models G521 Model Series 521 Model Series Note L Rear tube of the V521 model series diffen from that of the 521 model b ies of the G521 model Muffl that of the 521 model series Fig FE 12 Exhaust construction FE 6 for 521 a11d V521 models ies is than long
ENGINE CONTROL FUEL EXHAUST SYSTEM e i 1 i l11l I Fig FE 13 Exhaust constTUction Description fOT tube Exhaust piping consists of front tube muffler and Difference of part by PL521 model These components are clamped clips rear model Front tube Muffler Rear tube 52tU 20010 14800 20100 00100 2040t N52tU 20010 83000 20100 B2000 20401 B2000 521 1 20010 20600 20100 00 100 2040t 00301 52 IT 1 20010 t 4800 20100 BOIOO 20401 NL521 20010 B3600 20100 B2000 20401 B2000 52IT
CH ASSIS PL521 N521 521 SERISE EXHAUST PIPINGS 1887 74 3 N521 serise CD 1193147 01 A 2127183 71 0 @ b GN521 serise N L521 serise @ A A A 5 @ b GNL521 serise A B 3 1638 5 164 51 206147 3 JiS 3P c @ 511 521 serise G521 serise @ 37tI54 0 1653165 11 @ c A A @ 15e21 1 59 L521 serise 9 1 GL521 serise 1973 3 77 71 PL521 serise D Unit FE S mm in
FUEL ENGINE CONTROL EXHAUST SYSTEM Precaution for removal and installation I Remove mount bolts A B and C See through muffler are embossed FE1O FEB 2 Remove 3 Remove installation tube FigUres Muffler side of front tube and rear tube side of on clamps manifold L E J J B and D bolts used to secure and disconnect exhaust exhaust tube from EMBOSSMENT manifold Fig b FE 15 Clearance should be 55 FE 14 Fig NOlll a When connecting tube to muffler cenlllr Removing of Muffler
C CHASSIS Three types of fuel tank fuel tank for the 521 G521 N521 and GN521 UN521 fuel tank for the V521 and fuel tank for the PL521 U are Tank capacity is 41 liters VN521 and all fuel tanks available e Fig Fig FE 18 F l tank FE 19 Fuel tank for VN521 for 521 FE 19 r V521 and UN521 G521 G521 and GN521 10 8 US gal 9 0 Imp gal for
ENGINE CONTROL FUEL EXHAUST SYSTEM rY To CAANK CASE V A i Fig FE 20 F 1 tank FE ll rfoT PL521 U
CFlASSIS Removal I 521 and GN521 models I Remove drain 2 Loosen hand brake 3 Remove plug and drain fuel hole inspection completely cover from body rear Through inspection hole disconnect unit gauge wiring and disconnect outlet tube and breather tube 4 Loosen filler hose 5 Remove front and and then 2 remove clips clip rear tank support bracket bolts fuel tank UVN521model Procedures for the 521 However and GN521 that breather tube position and note Fig models apply suppor
ENGINE CONTROL FUEL EXHAUST SYSTEM SERVICE JOURNAL OR BUllETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT y 11 3
CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE BULLETIN No PAGE No SUBJECT CJ FE 14
SECTION BF BODY DATSUN PICK UP MODEL 521 SEPIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD FRAME BF 1 BODY BF 3 HOOD BF 1 FRONT END AND FRONT FENDER BF 8 DOOR BF 13 DOUBLE PICK UP AND VAN BF 18 WINDSHIELD AND REAR WINDOW BF 21 INSTRUMENT PANEL BF 23 SEAT BF 25 ROOM TRIM BF 26 a
BODY fRAME DESCRIPTioN The ladder shape frame members and six cross consists of left and members right the frame as side This frame with in condition long as the vehicle is used under the standard When the vehicle comes into a hard collision or creased bending stress and torsional strength sufficiently is driven with an excessive load on withstands against heavy load and high speed however broken and or The engine springs are cab mounted body on rear severe use body shock ab
p BODY 5 ts stlOIOI 6 h E E lOS IlII os I n Uh c I iJ c J m Q r I Q Tg Ig COVlill l EO It all o j Il II m t o uml r u E llOtoS rtl I c 3 u 21 10 iE9 Q o I E ij r E l I s 20 IO ill E tLlSl IE l1 2 Q it u l b ijo f 1M t alii BF 2 a
BODY BODY CONTENTS MAIN CAB CAOSS SECTIONS BODY AEAA OF CAB BODY MOUNTING BODY MOUNTING BF 3 DETACHING BFA DETACHING CAB BODY AEAA BODY BF 5 BF 6 BFA MAIN CROSS SECTIONS OF CAB BODY Fig BF J Crosssecticm of cab body 1 li Fig 4 Cross secticm BF BF 3 of cab body 2
I 10 BODY CAB BODY MOUNTING Jute 0 LA S O C c lif S C 0 Body mounting jute Body mounting bracket Aubber washe Body mountmg b 0 I t 3rd b Plain washer y mountmg rubber r A bber washu et o Washe is 1st body mounting Body mounting bolt J Plain washer rubber Special I washer Body mounting bottom rubber ock nut Plain washer Mounting bolt Unless otherwi details are MCtion Crosssection A A Cross section B B Fig BF 5 Cab the specially notBd same as those in 8J B Cross
BODY DETACHING CAB BODY I Disconnect battery terminal from battery 2 Disconnect speedometer cable 3 Remove steering mechanism steering wheel steering post assembly and remote control system BF 9 Disconnect brake tube Fig 5 6 Disconnect hand brake partment linkage harness body and engine Fig 4 BF 7 7 Removing steering post clamp bolts front lever and cable joint engine controls Disconnect accelerator at such choke wire as heater hose etc rear engine com instrument harness
BODY Fig 4 Apply Fig BF ll up cab Taking kg body since radiator radiator grille before core or to rear body lift chain block up rear and dismount support or lifting not to scar or body while scratch cab lifting and be body Slightly body weight long body Approximately 140 309lb cab portion near rear rear body rearward while lifting Aear to detach hqist Carefully baiance pull sure hanger body Lifting careful Be body mounting body Note 9 wire or rope the us
BODY HOOD CONTENTS Adjusting SF 7 ADJUSTMENT Centering hood lock Adjusting hood lock control lever operating force hood tightness AEMOVAl AND SF 7 SF S SF S INSTAllATION SF S Removal SF S Installation SF S ADJUSTMENT CD 2 9 I r 0 0 t 1 @ f I 1 Fig @ in 5 Dove 4 Safety catch 2 Dove tail bolt retaining nut 5 Female 3 Spring 6 Spring tail bolt Fig Adjusting The female hood lock is 4 I BF 15 adjusting stroke toward mal hood locks with provided the front or a
I i BODY Loosen installation bolts and align the correctly center Disconnect windshield washer hose at nozzle 3 Cover hood lock control lever Adjusting operating force to When the hood Jock control lever cannot be operated lightly 2 loosen dove tail bolt retaining nut protect cowl area with cloth or other proper material them from dama ng increase dove tail bolt installation length and reduce securing force of spring hood Adjusting tightness When the hood is closed and is slack redu
BODY BUMPER @ Fig SF 1 Front bumper 2 Bumper day 18 Front 3 Front member bumper Removal I 2 Remove installation bolts from both ends of bumper Front bumper Fig BF 19 bumper stays Bumper stays both ends of front apron G Detach G Front are installed at on engine compartment side frame with four bolts apron Removing bumper bolt Fig BF 9 BF 20 Removing bumper bolt
BODY 3 Pull forward and remove bumper together Installation with bumper stays 4 Install front Remove four installation bolts When installing and separate bumper that stays from bumper GRItE GRILLE SURROUNDINGS L are Radiator grille and headlamp sequence of removal so and clearance between bumper and AND HEADLAMP RIM @ BF 2J reverse uniform 1 Fig in align position carefully and correctly bumper height front apron RADIATOR bumper Upper radiator grille surrounding 2 Radiator
BODY FRONT APRON 1 3 Fig Front 3 Front apron bumper BF 23 Front apron Removal Detach front Bumper stay 2 Removal bumper See Figure BF 18 Remove apron to fender attaching bolts and I remove Clean fender attaching removing screws bolts and nuts by dirt from them apron downward 2 Disconnect side marker FRONT FENDERS 3 lamp wirings for headlamp and lamp at their Remove radiator BF 24 Front fender assemblies from the vehicle Fig BF l1 flasher grille grille surroundings and h
ODY 8 front side attaching bolts from headlamp Remove 4 Remove front fender 7 rear side attaching bolts installing parL Pig BF26 lt 7 Pr ft j 4 Jchf rg att boJts Pig 5 Remove apron to BP 29 Fender rear side attaching bolts fender attaching bolts from both sides 8 Remove attaching bolt from bottom of front rear fender 9 Pull left or right front fender toward front left right direction and detach Pig 6 BF 27 Apron to fender attaching or it bolt Remove front fender t
BODY DOOR CONTENTS ADJUSTMENT SF 13 DOOR LOCK MECHANISM Door lock striker SF 13 Removal Door SF 14 Installation hinge REMOVAL SF 14 Fig DOOR SF 15 SF 15 SF GLASS AND AEGULATOA 1 Door 2 Door window ventilator 3 Door window 4 Glass run 5 Door window weather 6 Door ou tside handle 7 Door lock 8 Door lock and remote control Ass y 9 Door panel assem bly strip key cylinder window regulator I nside 11 Regulator 12 Door 13 Scaling screen 14 Sealing screen 15 Sea
I BODY 2 Align door position correctly before adjusting door by adjusting Loosen gently 3 to align striker against Open Door attaching striker door and door and apply a jack or rigid rack door striker Note 2 open beneath door to support it striker It should be noted however that door sag cannot be corrected Fully and close screws When applying jack or cloth between door and door latch mechanism tighten striker attaching a rigid rack apply piece of jaek or rack to protect
BODY DOOR LOCK MECHANISM Door lock is provided with a lock knob and is of door is open an unlock type in which lock knob does not lower while 6 D @ o l @ @ Fig I 2 Detach inside handle and regulator handle an ordinary Be careful not to scar or remove screw scratch panel and Detach damaged driver Lock 3 Bell crank 4 Door lock remote control 5 Door lock 6 Outside handle lever 7 Inside lock knob installation bolt installation bolt installation bolt assembly assembly seal
BODY 4 Remove door lock with remote control together DOOR GLASS AND REGULATOR assembly through work opening Detach door lock assembly door finish and sealing screen I 2 Remove installation bults and remove door window support cushion I a 1 I I Do i I r Fig BF J9 b Removing door lock 1 c Installa tion 1 Install door lock mechanism in reverse Fig sequence of BF 41 Sealing screen and bolts removal 2 Upon completion of installation make A sure between outside handle
BODY 4 Remove four installation screws from upper portion of door sash Fig Fig 5 Removing fouT installation Detach side window weather screw driver carefully so as not to strip with Removing door ventilator 8 Pull door glass upward and 9 Remove four door window regulator assembly in stallation BF 43 BF 45 remove it screws SCTewS an ordinary damage it Fig BF 46 Door window regulator instaLtion screws 10 Remove service Fig 6 opening weatherstrip Remove two door window
BODY DOUBLE PICK UP AND VAN CONTENTS BF18 SIDE WINDOW TAIL GATE AND Double pick up BF 18 Double pick up Van BF 18 Van SIDE BF 19 LIFT GATE BF 19 BF 20 WINDOW Double pick up CROSS SECTION A A Fig When installing be sure to BF 48 Side window double pick up apply sealing agent between body panel and weather strip Van Fig BF lB BF 49 Side window van
BODY Remove set weather strip remove screws toward side window sash detach luggage compartment side and side window assembly toward outside When installing be weather from sure to apply sealing agen t between strip and panel G Roof Side window sash Fig BF 50 Removing side window TAIL GATE AND LIFT GATE Double pick up Tail gate lock r ll 1 Side lock T G RH assembly 4 Clip 2 Side lock T G LH assembly 5 Thrust 3 Remote control assembly Fig and Remove tail gate inside
I I J B Van Tail gate lock @ II 1 Tail gate lock body assembly 2 Shaft 3 Lock lever 4 8 j Fig Detach tail gate inside cover and remove right tail gate side lock installation BF 52 Tail gate lock both left and screws CD r Strike spring assembly 5 Lift gate side lock assembly 7 Push lever 8 Lock lever 9 Stopper A 10 Pull lever 11 Keylcrer 12 Tail gate 13 Lift gate lock ide lock assembly 14 Striker assembly 15 Clip 16 Key cylinder 17 Outside 18 Pull handle l
BODY 3 When lock does not operate check grease lightly and smoothly lever sliding parts for lubrication as and apply required Uft gate Remove lift gate support installation Fig BF 55 screws Removing lock Upon completion of reinstallation I Make sure that both side locks and two locks on tail gate top operate correctly 2 When both side claw strokes are unbalanced at remote control adjuster so adjust that both claws engage evenly Fig Apply a piece BF 57 Lift gate of cloth between ro
BODY windshield REMOVAL Place protective a panel instrument cover over and front front fenders hood The glass method which below procedure may be used to check ou the tlines the windshield opening seat I Check 2 Remove rear view mirror support ularities 3 Remove windshield wiper 2 t On inside of body loosen the lip of rubber channel arm assembly channel rubber windshield for Cle n off old sealer around windshield anyirreg and opening check entire b dy opening flan
BCJDY r t CD Weather With the aid of center windshield Note Do Glass BF 59 Draw cord installed Fig 4 2 strip a assembly notposition helper in Fig carefully position and 7 body opening glass by tapping or BF 60 Sectional view of rubber channel Reinstall all previously removed parts and remove protective coverings hammering any time t l f WATERLEAK CORRECTION at H11 iH t l In many instances minor waterleaks around windshield may be corrected by performing the t
BODY Fig BF 61 Removing instrument panel REMOVAL I Disconnect battery terminal 2 Disconnect heater control strun1mtharnessfengine wirings for 3 jwishienld BF 62 wire from compartment harness wP Remove steering pOst Fig 4 lever screws from the top of instrument panel and two from both sides in connector 5 panel instrument PulJ rearward and separate it from body toward left rietc clamp Remove four set insiallation bolts Removing steerifJg post clamp bolts Fig RF 4 BF 6
BODY SEAT square shape pipe frame and Sshape and and vinyl leather are used for and urethane springs Rear seat Seat uses steel van seat cover REMOVAL Front seat and pick up double pick up van J@ a Fig Fig Remove four riser Seat can be Rear seat BF 64 Front seat installation nuts Remove screwed against seat double pick front side hinge installation remove rear seat as Seat cushion Fig G screws separate an assembly up SEAT BELT Q an seat back from brackets in both side
BODY ROOM TRIM OVERHEAD LINING Removal o Insert a spatula and withdraw o between roof panel and roof rail end of overhead lining one Peel off overhead lining from roof panel from the t withdrawn end to the other end eAi e j Installa tion o Thoroughly remove lining remained foreign matter o Adhere overhead apply adhesive is and to roof other panel front side to rear side completely Providing circumference with a OVERHEAD LINING stretched sufficient space so folded into roof
SECTION BE BODY ELECTRICAL DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO JAPAN LTD WIRING BE 1 FUSE BE 7 LIGHTING SYSTEM BE 8 HORN BE 15 METER AND GAUGES BE l B WINDSHIELD WIPER AND WASHER BE 26 IGNITION SWITCH AND STEERING LOCK BE 3D RADIO BE 32 CLOCK BE 35 HEATER BE 36 a
BODY ELECTRICAL WIRING CONTENTS WIRING Engine HAANESS BE 1 compartment harness BE 1 WIRING BE 2 INSPECTION Instrument harness Body harness DIAGRAM BE 2 BE 4 BE 7 WIRING HARNESS Engine compartment harness t Fig BE 1 E gi compartment harness BE 1
BODY Instrument harness Body harness Fig BE 2 Instrument hamess Fig BE 3 B09Y BE 2 ham s 521
600 BodY l EtECJR C t n J 4 t I 1 JN harness C bt j S DC C f L t 1 j i r 1 4 BE fi codY rness lO V521 h f f t lt l rne55 Fg BE 5 Bod BE 3 0521
BODY WIRING DIAGRAM w g r c s c a ta m CI i c m o 0 a J OCO t lI I i I 8 i cO 03 g i eT if f n J r r I I 01 4 o o o g 0 o g a i c IIl 8 8 l I l I l J 3 3 1 r eve Fig I 6 Wiring BE dillgram BE 4 common countms 3i J C1
BODY ELECTRICAL w c o0 U OE a o 6m J lQOII J t3S lJi i 0 i j io a H i II u lRi Jj Q LJ w G O 0j I 1 Ji J i f l1 a 5d a j d diagram Fig BE 7 Wiring BE 5 U S A Canada 8 lP o l ct Q3 a a l c J
BOPY w 9 a r CD c og I CD iL M i 5 V Ii t C I 1 CD U J n i c J Ii 1 i i t J Q J i 6 i Ifi I i i ii Iil I 1 j I I I 8 11 1 1 E t 1t ii l l 2 gf t I f tit Fig 8 Wiring diagram BE 6 BE Van Double cabin Q 12 tl CI Ca a o I i lP 0 IJ CC J O
BOOYELE TRICAL INSPECTION Cables 6 should be into contact with Referring to wiring diagram check wiring harness for connection with electrical connection and harness note the Connected equipment and installation following When f i connector checking wiring matters unit should not be loose rusted ed or cover should not be tion bolts pletely so are bolts should be or that Cables 7 continuity is body should be at sections of unit where vibration which current No
BODY LIGHTING SYSTEM CONTENTS SIGNAL AND DIMMEA BE 8 TUAN Sealed beam unit replacement BE 8 COMBINATION SWITCH Headlamp adjustment BE 8 HEADLAMP SIGNAL AEAA SIDE BE COMBINATION LAMPS LICENSE PLATE LAMPS MAAKEA 9 BE 11 SWITCH LIGHTING LAMP FLASHEA BE 11 Removal PAAKING AND TUAN FAONT BE 11 Removal DIAGNOSES AND BE 10 TROUBLE BE 10 COAAECTIONS BE 12 BE 12 Headlamp ILLUMINATION LAMP BE 10 BULB SPECIFICATIONS BE 10 Turn BE 13 signal lamps Tail lamp stop lamp lice
BODY ELECTRICAL When adjusting low beam adjust aiming of low beam head lamps at the outside adjusting high beam cover at the outside with cover and then beam head lamps High adjust aiming of high at the inside Vertical adjusting 1 low beam head lamps 1 screw Horizontal adjusting screw Fig Aiming head lamp BE 12 Low beam beam t f I r r c i J 1 n When t 10m 32 lIftl i J r I f in Hmm 521 N521 741 G521 GN521 738 U521 UN521 715 V521 720 VN521 M 132 I Gfll h mm
BODY 2 Remove connector from wire harness 3 Remove lamp housing installation REAR COMBINATION LAMP nuts and remove When removing bulb toward socket lamp assembly turn with lens removed push bulb bulb counterclockwise and withdraw bulb When 2 removing lamp housing I Remove connector from wire harness 2 Loosen lamp installation nuts and remove lamp assembly 1 SIDE FLASHER MARKER Remove if i 1 i side flasher lamp installation nut from the inside of fender Of and and lamp h
BODY ELECTRICAL TURN SIGNAL AND DIMMER ring and steering wheel 2 Remove horn 3 Remove shell cover 4 Unscrew two screws used to secure switch on COMBINATION SWITCH Removal Disconnect combination switch from wire harness at connector column plug steering jucket and column remOve jacket steering switch from locating hole Now remove switch on completely LIGHTING SWITCH Removal Fig BE 16 Removing turn I Remove connector from the back of lighting switch 2 Remove 3 Remove nut 4
v BODY T LIGHT TCH CUXK IL iz It I TO USf r TO rUSE H Fig BE iS Circuit diagram for lighting system CtUUJdU S A TROUBLE DIAGNOSES AND CORRECTIONS Headlamp Condition The not headlamp does light Probable Blown off fuse or Corrective action cause faulty contact for both Check fuse for When fused Faulty lighting switch or light relay or vice versa is defective Conduct Defective dimmer switch cause then or replace continuity switch is defective be switched to lower b
BODY ELECTRICAL Condition Headlamps dim Probable Corrective action cause Defective light circuit Check the headlight circuit for cable being about to break and faulty contact or check fuse for faulty contact Repair Headlamps dim Partly discharged battery or with engine Charge battery if required operated under idling speed Headlamps replace if required Measure specific gravity of electrolyte when the engine is stopped or still dim Defective battery Replace battery beam unit
BODY Condition All turn Probable Corrective actions causes Defective flasher unit signal Replace the flasher unit lainps do not go out Flashing cycle is A to low lamp having wattage specified wattage more than the flashing cycle Faulty contact one is used Defective flasher unit Turn signal lamp Replace with the specified Replace flasher in circuit Repair as unit necessary is too A high lamp having wattage less than the spe Replace with the specified one cified wattage
ELECTRICAL BODY Tail license lamp stop lamp back up lamp lamp Condition Probable Both left and right lamps do not Blown offfuse or Corrective action cause faulty Check fuse for fusing and faulty contact contact When fuse is blown off detect and correct light cause Defective stop lamp switch or backup lamp switch or faulty Stop lamps and and replace fuse When two lead wires of switch are contact neeted and the backup lamp only circuit are normal Replace switch or lamp lights
BODY JUSTMENT AD Note When adjust screw Clockwise I Secure horn in power 2 a vise and connect horn cables to is turned Current decreases Counterclockwise Current increases supply See Figure BE 19 Set power supply switch to and make ON sure 4 that voltmeter indicates 12 to 12 5V Upon completion of above adjustment make sure that horn sounds correctly with 14 to 15V generated by alternator AMMETER 110 to 15Al HORN Sound VOLTAGE METER 115 to 20VI Fig 3 for hum adjustment B
BODY ELECTRICAL TROUBLE DIAGNOSES AND CORRECTIONS Probable cause Condition Horn does not Excessively discharged battery operate Corrective action Measure specific gravity of Charge Blown off fuse if required Check fuse for fusing and improper contact Replace Improper electrolyte horn button contact or repair if required In this case the horn sounds relay terminal S is though horn grounded Check and repair horn button Defective horn relay Horn sounds though the horn relay termi nals
I BODY METERS AND GAUGES CONTENTS COMBINATION METEA BE lB OIL PAESSUAE WAANING Description BE 1B IGNHlON WARNING LAMP BE 21 Replacement BE 19 BULB SPECIFICATION BE 21 BE 19 TAOUBLE BE 19 COAAECTIONS SPEEDOMETEA Replacement FUEL METEA AND THERMOMETEA LAMP BE 21 DIAGNOSES AND BE 22 BE 19 Speedometer BE 22 Description BE 19 Thermometer and fuel meter BE 23 Replacement BE 20 Oil pressure and ignition BE 25 warning lamps COMBINATION METER Description The combination fuel sp
1 BODY ELECTRICAL The illumination board with clips lamp sockets they can are secured on the back be removed and reinstallation 4 Loosen speedometer cable cable from speedometer union nut and remove speedometer head easily The fuel meter and thermometer The regulator use meter regulator minimize indication error due to fluctuation and therefore the meters are voltage Install combination meter in s reverse sequence to removal very reliable SPEEDOMETER Replacement I Replace
J BODY The consists thermometer thermaltransmitter of in located thermometer and a the thermaltransmitter is equipped with engine a block The current bimetal arm ON the provided current flows to the heat coil pointer connected the to with tolerance may occur on are ann and arm on a voltage fluctuation supply a constant If both Consequently defective the thermometer of fuel applied the at trouble in the the a to the time coil the contact closes The a pulsati
BODY ElECTRICAL When the ignition switch is circuit is closed warning ignition switch through the generator current to ON the ignition the warning lamp bulb and to ground regulator When the engine is started and the comes opposes in lamp set and current flows from the into effect it the generator output operation flowing from the warning the current breaks the warning circuit ground connection and the lamp goes out Ignition switch r Fig BE 26 8 Removing thermometer c 0 5 co
rr BODY mOUBLE DIAGNOSES AND CORRECTIONS Speedometer Condition Probable Corrective action cause Speedometer pointer and Improperly tightened speedometer odometer do not operate union nut cable Broken speedometer cable union nut correctly Replace Damaged speedometer drive pinion Speedometer pointer Retighten gear Replace Defective speedometer Replace Rapidly bent speedometer cable Correct drive or pinion gear replace deflects widely Damaged speedometer drive pinion gear Defec
BODY ElECTRICAL Thermometer and fuel meter Probable Condition Both thermometer and Blown off fuse or Corrective action cause improper connection Check fuse for fusing and improper contact fuel meter do not Replace after correcting operate Correct contact Defective fused or voltage regulator Damaged cause if fused Replace open contact Both thentlometer and Defective voltage fuel meter indicate wire inaccurately grounding seized regulator contact and Broken heat or improper
v BODY Condition Probable Improper cable Corrective action cause If thermometer indicates contact a temperature slightly lower than the actual temperature check cable from thermometer transmitter for cable poor contact and to thermal being about to break faulty grounding and repair if necessary Fud meter Fuel meter does not Defective tank unit Replace tank yellow tank unit operate Defective fuel meter unit if Replace fuel pointer does pointer deflects when cable is grounded wit
BODY ElECTRICAL Oil pressure and ignition warning lamps Condition Probable Corrective action cause Oil pressure warning lamp Lamp does light not Blown offfuse or faulty Check fuse for contact fusing and faulty contact when ignition switch Replace after correcting is set to necessary ON Broken lamp bulb filament or faulty cable contact cause or repair as If oil pressure switch yellow black cable is grounded and warning lamp does not light check bulb for burnt out fIlament a
rl BODY WINDSHIELD WIPER AND WASHER CONTENTS DESCRIPTION AEMOVAl AND INSTAllATION Wiper motor Wiper motor linkage BE 26 Wiper switch BE 27 Washer nozzle BE 27 BE 27 Caution for windshield washer BE 27 Specifications BE 28 adjustment operation BE 28 BE 28 DESCRIPTION The windshield mechanism wiper wiper arms consists of wiper motor and blades The wiper motor unit consists of a motor and auto stop mechanism motor is of a The the 2 wiper engine electrically operated windshield wa
BODY ELECTRICAL REMOVAL AND INSTALLATION Wiper motor linkage Removing wiper I arm from pivot shaft Raise wiper blade from windshield glass of wiper 2 ann and remove Separate wiper wiper motor ann raise the base from pivot shaft drive shaft arm from con 25mm 0 984 in necting rod Fig Wiper BE J 1 Wiper arm installation motor Disconnect connector from wire harness 2 Separate wiper drive shaft motor arm from con necting rod Fig BE 30 Wiper motor linkage Fig 3 and 4 Lo
J BODY Caution for windshield washer 3 Remove installation nut 4 Remove wiper switch from the back of instrument plain washer and spacer operation panel Do not operate windshield washer continuously Washer nozzle than 30 seconds adjustment often When washer nozzle is installed not is sprayed properly adjust sprayed or when washer fluid is without improper windshield Norrnally nozzle direction so that fluid in proper range See causes or applying windshield more washer fluid This
BODY ElECTRICAL Probable Condition Corrective action cause Power supply Blown off fuse due to trouble of other Check and cable part in windshield wiper circuit correct trouble Loose open Check wiring or broken wiring for other part near operation and motor and terminal for connection connector I Correct if necessary Erroneous wiring Check each connecting cord for cord color and correct Switch Improper grounding Correct Improper switch Connect L Blue B Black and contact mo
5 r BODY Condition Probable Corrective action causes Windshield Windshield wiper blade sticks wiper blade shield on wind Raise arm without glass and operate applying windshield wiper load Oean windshield glass and or replace wiper blade Windshield wiper speed Motor Low high speed differs from I cannot be considerably ratio 14 Windshield wiper is operated under the changed correctly same or speed at both low and high speeds windshield wiper does not operate at eith
BODY ELECTRICAL Removal IGNITION SWITCH Remove ring nut from ignition switch I Description plain The ignition switch controls the engine ignition system and most of electrical The terminal 2 Terminal equipment is for power I to ON is connected to 3 magnetic switch on switch is set to START switch supply power The terminal S terminal of the by STEERING LOCK the stater motor When the ignition current flows to the pass line so resistor of is for radio magnetic 5 only Descriptio
r BODY 2 Now remove steering lock proper from sleering jackel tube 3 When tighten installing a new lwo new self ear steering lock type screws be sure to proper 10 shear off their heads I Ignition 2 5 Lock spindle Key cylinder part 6 S leering 3 Steering jactet tube 7 Self shear type 4 Lock collar 8 Attaching switch put rb haft screw SCJeW Fig BE 34 Steering lock RADIO CONTENTS INSTAllATION BE 32 ADJUSTING BE 33 ANTENNA TRIMMER Noise prevention INSTALLATI
l BODY ELECTRICAL L InslaII mounting brackel on InslaII anlenna 7 radio proper and lead anlenna cable to Ihe back of instrument panel 2 Remove mask for radio from instrument 3 Fit radio inlo inslrument panel by applying il from panel 8 the back of inslrumenl 4 panel Tighten plain washer Connect anlenna cable and speaker cable 10 lead cables from radio Connecl radio power source cable 10 blue cable of inslrumenl harness spring washer and nul on adjusl shaft Note Blue cable of instr
f BODY Noise prevention chart Run engine raise antenna set volume to maximum and sel dial al medium point withoul catching a Condition casting wave broad Probable Corrective action cause Ignition system Noise occurs when is engine High tension code tension High operaled code may be disregarded because noise suppressor is used coil Ignitio wire from Apart choke as ignilion coil as far possible Install 5 fJ F capacilor in primary side 0 a lerminal of ignition coil Note Be car
BODY ElECTRICAL Condition Probable Noise presenls when Corrective action cause Horn Noise presents when turn signallarnps a 0 terminal or Inslall horn is blown Flasher unit InslaII lF capacilor 5 5 pF 0 a on horn relay horn switch capacitor are operated Note a Be sure to locate capacitor most near position completely of noise source and connect in parallel b Cut lead wire as short as possible c Ground wire should be placed d e on the body Make installation and con
rr BODY HEATER @ CD J @ Fig I Inlet hose 2 Outlet 3 Air duct 4 Defroster hose hose 5 Hose connector 6 Defroster 7 Heater control lever 8 Air control 9 Clamp nozzle lever 10 Room healer unit 11 Heater control cable BE 40 Heatl T unit Installation I Remove instrumenl panel 2 Install heater unil proper on dash panel Connecl to blue cable wire harness of blue cable from molor healer unil Secure black cable on heater unil with 10 screw ground Fil heater hoses 10 hol
BODY ELECTRICAL 4 Install air intake duct G Air intake duct Fig 5 42 BE on dash G Installing InslaII defroster nozzle on panei and heater unit 1 Defroster nozzle 2 Heater control lever Heater unit Fig BE 43 3 Defroster Air control lever nozzle and heater and air control levers heater unit 9 the back of inslrumenl Connecl healer conlrol cable 10 healer conlrollever panel 6 InslaII healer switch on inslrumenl panel 7 Install heater conlrol lever and air control lever on 10 I
JI BODY TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable Corrective cause actiQp Hol air does nol come out Molor does nol Open or shorl circuil of feed harness Check and repair wiring harness operate Defective swilch Conducl continuity tesl and replace switch if necessary Defective motor Fan cannol be rotaled smoothly by Replace Molor journal is out oflubricant or hand Hot air does Dol come stick motor Lubricatejoumal Replace motor Slow rolation offan Replace molor Loose f
SECTION SE SERVICE EQUIPMENT DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO JAPAN LTD SPECIAL SERVICE TOOL SE 18
SERVICE EQUIPMENT SPECIAL SERVICE TOOL Tool number Tool M reference S Figure name mm Applied Description in model page See Fig No Clutch tool For centering lhe c1ulch disc ST20630000 521 Fig CIA 5 130 Clulch aligning PA30 bar G l J S30 j ST20051000 Clutch base For measuring the diaphragm 521 spring height 130 Use with the distance assembly @ plale piece Sf20058001 Fig CL6 C30 S30 510 41 C24 C80 For measuring the ST20058001 q diaphragm 521 Fig CL6 130 spring
r CHASSfS M reference S Applied Figure Tool number Description Toolnarne mm in page model See Fig No Transmission tool For ST23620000 supporting the inter lock ball when inslalling Ihe fork Fork rod page TM II rod guide ST23510000 Fork rod All For removing Ibe fork rod 521 Page relaining pins CIO TM 5 510 pin punch C30 n I ST22 I 30000 For removing the main shaft 521 bearing 780 For removing the drive shaft 521 bearing C30 Fig TM 16 Bearing replacer 0 ST30030000
2 E EQUIPMENL SERVI jl 1 j L j Tool number tl Applied Tl r9 Lnarrie mm Description page model in See No Fig H r S M reference 1 Figure 1 ST23g00000 I l Ie l n For inslalling the main shaft 521 bearing 130 1 Transmission If q 0 r1 d Uifferen tial carrier tool 3tl 1 t l Setting Iool of Ihe ST07320000 I gear carrier 521 s 4L PD IO J stand e J lfl nj 1r jn in lJtbs rlgf Hi tt li1 ST33010000 Fig 130 Differential carrier dl Cl 1 ijL adapter J Fig i
CHASSIS S M reference Figure Tool number Tool Descriplion mm name For removing the drive pinion rear pinion model in ST3003000ll Drive Applied bearing Fig PD 16 PO I7 S30 inner race C30 rear bearing inner 521 page See Fig No CIO II race replacer 510 @ ST33210000 For assembling the side 521 bearing CIO PD 16 Fig PO 18 V510 Differential side bearing drift Fig V For ST31IOOOO heighl adjustmenl of the drive 521 130 pinion V510 Drive pinion arrangemenl gauge For me
SERVICE EQUIPMENT S M reference Tool number Tool Figure name Applied Description mm See For measuring the distance ST321 10000 belween side bearing caps Front axle and 521 Fig No Fig PD 22 130 V510 DifferenliaI side bearing cap gauge page model in n suspension tool For removing the ST35380000 king pin bush New Page 521 FA 7 King pin bush drift r For correcling the king pin HT56802000 521 Page FA 7 bush King pin bush reamer ST36070000 Lower link bush drift SE 5 For
f e CHASSIS Tool number M referenc S Figure Tool name mm Description in Applied model page See Fig No Rear axle and suspension tool ST38020000 Rear axle For loosening the rear axle and tighlening bearing 521 Fig 6 RA lock nul bearing lock nul wrench ST07630000 Fig RA4 For removing the rear axle sbafl Rear axle stand Use with sliding hammer ST36230000 C r II ST3623WQO Use as hammer by sliding the weighl Sliding All Fig 4 RA hammer I f ST37 I 40000 For remov
n SERVICr EtlJJPMENT S M reference Figure Tool number Tool name mm Appjied Descriplion in IfV 10 1 page model I v See Fig i 1 J l Il I I No I u I ST38220000 for inslalling the 521 raft bearing and collar u Jl ear axle axle rear i Fig RA 8 I 130 shaft bearing collar insert l f 1 I u 1 to I I Steering I tool t ST27140000 r gear Steering gear 521 For removing the sleering arm 130 arm 510 I l p L Fig T4 i i BIIO 1 J k o L f I r r q I J I
r V CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or BULLETIN No SUBJECT PAGE No E R
INISSANl Issuro Date 25th August 1970 U105501 Publication No 10E s 0521GO
