DATSUN 210 1979 Workshop Manual

9
Make
SUre
there
is

proper
end

play
at

crankshaft

Crankshaft

end

play

0
05toO
15mm

0
OO20
to
0

0059
in

laJlk
h
end

play

J

EM486

Fig
EM

63

Checking
Crank

luJft

End

Play

10

Install
rear

oil
seal

using
suitable

drift

Fig
EM

64
n

talling
Rear
Oil
Seal

II
Install
rear

plate

12
Install

flywh
el

secwely
and

tighten
bolts
to

specified
torque

dl
Tightening
torque

Flywheel
and
drive

plate

A
14

engine
fixing
bolts

8
0

to
9

0

kg
m

58
to

65
ft
Ib

Drive

plate
A
15

engine

fixing
bolts

8
5

to
9
5

kg
m

61
to
69
ft
b

Fig
EM
65
n

talling
Flywheel

13

Rotate

engine
quarter
turn

and

install

piston
rod

assembly
using
Pis
Engine
Mechanical

ton

Ring
Compressor
EM03470000

EM497

Fig
EM
66

tolling
Platon
Rod

Assem

bly

Note

a

Insert

pistons
in
L

r
nding
cyl

inders

b

Apply
engine
oil

to

sliding
parts

c

Arrange
pistons
so
number

stamped

on

piston
head
faces
to
front
of

engine

d
Before

installing
piston
piston
rings

should
be

positioned
as
shown
in

Fig
EM
67

Second

ring

Oil

ring
lower
rail

EM49B

Fig
EM
67

Positioning
Piston

Ring

Gap

14

Apply

engine
oil
to

bearing

surfaces

dl
Tighte
ning
torque

Connecting
rod

cap
nuts

3

2
to
3

8

kg
m

23
to
27
ft
b

EM499

Fig
EM

68

Tightening
Connecting

Rod

Cap

Note

Am11
connecting
rods
and

connecting
rod

caps
so

cylinder

numben
face
in
same
direction

EM
14
I

S
Make
sure
there

exists

proper

end

play
at

connecting
rod

big
end

See

Fig
EM41

Big
end

play

0
1
to
0
2

mm

0
004
to
0
008
in

16

Insert
crank

sprocket
keys
in

keyways
of
crankshaft

Install
cam

shaft
and

crankshaft

sprockets

tempo

rarily
for

adjustment
of
tooth

height

by
using
adjusting
washers

Height
dif

Less1
h
l11

0

5
mm
0

020
in

Adjusting
washer

thickness

0
5
mm

10
020

in

EM500

Fig
EM
69

Adju
ting
Sprocket

Tooth

Height

17
Install

tinting
chain
and
cam

shaft

sprocket
with
their

markings

properly
aligned
See

Fig
EM
70

Then
set
No
I

piston
at
T
D
C
on

compression
stroke
See

Fig
EM
71

Oil

sprocket
teeth
and
chain
with

engine
oil

Match
mark

Key
groove

EM501

Fig
EM
70

Aligning
Markinga

Note
Make
sure
camshaft

sprocket

dowel
hole
and
crankshaft

sprocket

key
are

in
line
and
both
dowel
hole

and

key
are
located
downward

m
k

camSM9tJ
down
hole

Key
groove

EM767

Fig
EM
11

Setting
No

I
Piston

atT
D
C

18

Tighten
camshaft

sprocket
bolt

ifl

Tightening
torque

Camshaft

sprocket
bolt

4
to
4
8

kg
m

29

to
35
fHbl

EM502

Fig
EM
72

Tightening
Camshaft

Sprocket
Bolt

19
Install
chain
tensioner
and

tight

en
tensioner

attaching
bolts

ifl

Tightening
torque

Tensioner

enaching
bolt

0
6
to
0
8

kg
m

14
3

to
5
8
ft
b

EM503

Fig
EM
73

Installing
Chain

Tensioner

20
Check

projection
L
of
ten

sioner

spindle

If

projection
L
exceeds
the

speci

fied
limit

replace
chain
Engine
Mechanical

Correct

projection
L

Less

than

15
mm
0
59
inl

lEM504

Fig
EM
74

Checking
Projection
of

Tf

nsioner

Spindle

21

Correctly
install
oil
thrower
in

front
of
camshaft

sprocket

22
Press
new
oil
seal
in

timing
chain

cover
F
ran
t

cover
oil
seal
should
be

replaced
when
front
cover
is

disassem

bled

23
Install

timing
chain
cover
with

gasket
in

place

Note
When

inatalling
oil
seal

apply

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and
fold

ed

lip
Also

apply
coating
of
oil
to

periphery
of
oil
seal

ifl
Tightening
torque

Timing
chain

cover
bolts

0
5
to
0
7

kg
m

3
6
to
5
1
ft
Ib

Z5

1
o

j

I

t
f

4

EM455

Fig
EM
75

Installing
Timing
Chain

Covtr

24
Install
water

pump
with

gasket

in

place

ifl
Tightening
torque

Water

pump
attaching
bolts

0

9
to
1
4

kg
m

16
5
to
10
1
ft
bl

25
Install
crank

pulley
then
con

firm
and
set
No
I

piston
at
T

D
C
on

compression
stroke

EM
15
ifl
Tightening
torque

Crank

pulley
nut

15to
20

kg
m

108
to
145
ft
b

26
Invert

engine
Install
oil
stniiner

and
oil

pan
using
new
gasket
and

oil

seal

Note
Give

coating
of
sealant
to
seam

between
oil

pan
gasket
and
oil

pan

oil
seal

ifl
Tightening
torque

Oil

pan
bolts

0
4
to
0
6

kg
m

12
9
to
4
3
ft
lb

27
Install

gasket
and

cylinder
head

Note
Do
not

apply
sealant
to

any

other

part
of

cylinder
block

and

head
surface

28

Tighten
cylinder
head
bolts

ifl

Tightening
torque

Cylinder
head
bolts

7
0
to
7
5

kg
m

51
to
54
ft

IM

Note

a
One

of

cylinder
head
bolts
is
smal

ler

in
diameter
than
others
and
has

a
hollow
head
It
should
be
install

ed
on

right
side
center
of

cylinder

head

b

Tightening
should
be
made
in

two

or
three

steps
finally
torquing
to

specification

c

Retighten
cylinder
head
bolt
after

engine
has
been
warmed

up

Refer
to
Carburetor
Idle
R
P
M

and
Mixture
Ratio
EF
Section
for

Adjustment
and

Inspection

EM505

Fig
EM
76
Cylinder
Head
Bolt

Tightening
Sequence

29

Apply
engine
oiho
both
ends

of

push
rods
and
insert
in

proper
se

quence

30

Apply

engine
oil
to

valve
stem

end
and

rocker
arm
contact

surfaces

Position
rocker
shaft

assembly
on

cyI

inder
head

31

Tighten
rocker
shaft
bracket

bolts
to

specified
torque

fJ

Tightening
torque

Rocker
shaft
bracket
bolts

2
0
to
2
5

kg
m

14
to
18
ft

b

Note

Tightening
should
be
done

in

two
or
three

stages
outwardly
from

center
bracket

EM506

Fig
EM

77
Rocker

Shaft
Bolt

Tightening
Sequence

32

Adjust
valve

clearance
to

speci

fied
value

Note

a
First

set
clearance
to
0

25

mm

0
0098

in
when

engine
iscold

b
After

engine
has
been
assembled

warm
it

up
for
at
least
several

minutes

finally

adjust
clearance
to

specification
For
details
refer
to

Adjusting
Intake
and
Exhaust
Valve

Clearance
in
ET

Section

EM507
or

Wrench

2
Screwdriver

3
Feeler

gauge

Fig
EM
78

Adjusting
Value

Clearance
Engine
Mechanical

Valve

clearance

Intake
and

exhaust

hot

0
35
mm
0
014
in

cold

0

25
mm
0
010
in

fJ

Tightening
torque

Velve
rocker

adjusti
g
nut

1
6
to
2
2

kltm

12
to
16
ft
b

33

Install
rocker

cover

34

Install
intake
and

exhaust
mani

folds

fJ

Tightening
torque

Manifold
nuts

1
5
to
2
0

kg
m

11
to
14

fHb

Note

When

installing
intake
and
ex

haust

manifolds
locate
bolt

in

center
of

fitting
hole

EM528

Fig
EM
79

Installing
Manifolds

35
Install
E
G
R
control

valve

36

Install
baffle

plate
and

carbure

tor

fJ
Tightening

torque

Carburetor
nuts

0
4

to
0
6

kg
m

2
9
to
4
3
ft

Ibl

37
Install
vacuum

control
valve
as

sembly
and
bracket

38
Install

air
cleaner

bracket
and
air

cleaner

39

Connect
air

vacuum
and

blow

by
hoses
to
air

cleaner

40
Install

pipe
connector
to
control

valve
hose
and

engine

mounting
brack

etLR

41

Install

distributor

EM

16
CAUTION

a
8e
sure
to
set
No
1

piston
to

LD
C
of

compression
stroke

b
Before

instaliation
return
distribu

tor
rotor

approximately
30

degrees

from
its
correct

position
Insert

distributor

meshing
distributor

drive

gear
and
driven

gear

c
After
installation
distributor
rotor

should

align
with

mark
on
rotor

cap

J

No
1

mark

EM508

Fig
EM

80
Cornct
P05ition

of

Rotor

42

Dismount

engine
from

Engine

Stand

ST0501S000
and

place
it

on

suitable

engine
stand

Re

move

Engine
Attachment

KVlOI
2500

43

Install

spark
plugs
and

engine

mounting
bracket
R
H

44

Install
oil

pump
and
ftIter

assem

bly

45
Install
thermostat

and
water

outlet

46
Install
fuel

pump
and
fuel

lines

Do
not

forget
to

install

spacer
and

gasket

47

Install
distributor
vacuum
line

48
Install
distributor

cap
and

high

tension

cables
as
an

assembly
Connect

high
tension

cables

49
Insert

oil
level

gauge

50

Install
fan
fan

pulley
and
fan

spacer

Lock
bolt

by
bending
lock

washers

51

Install
alternator
bracket

adjust

ing
bar
water

pump

pulley
alternator

and
fan
belt

Be

sure
that
belt
deflection
is
held

within

specified
range
when
moderate

force
is

applied
midway
between

pul

leys

Belt
deflection

8t012mm

0

31
to
0
47
in

Force

10

kg
22Ib

Deflection
Fan

pulley

f

Crank

pulley
Alternator

pulley

EM768

Fig
EM
81
Fan
Belt
Temion

52
Install
air

pump
bracket
air

pump
and
air

pump
pulley
If

so

equipped
Engine
Mechanical

53
Install
idler

pulley
bracket
air

pump
belt
and

idler

pulley
If

so

equipped
See

Fig
EM
2

Be
sure
deflection
of
air

pump
belt

is

same
as
that
of
fan
belt

Belt
deflection

8
to
12
mm

0
31
to
0
47
in

Force

10

kg
22Ib

Deflection

10

kg
22Ib

Fig
EM
82
Air

Pump
Belt
Tension

EM
17
54

Install
clutch
and
cover
assem

bly
using
Clutch

Aligning
Bar

STI0610000

For

details
refer
to
Installation
in

CL
Section

Fig
EM
83

Installing
Clutch

Assembly

Engin
Mechanical

SERVICE
DATA
AND
8PECIRCATION8

GENERAL
SPECIFICATIONS

Engine
model
AI5

Cylinder
arrangement
4

in
line

Displacement
cc
cu
in

1
397
85
24

I
488
90
80

Bore
and

Stroke
mm
in
76
0
x
77
0
76
0
x
82

0

2
992
x

3
031
2
992
x

3
228

Valve

arrangement
OR
V

Firing
order
I

3
4
2

Compression
2

Number
of

piston
rings

Oil

Number
of

main

bearings
5

Compression
ratio

California
and
FU
model

of
Non
California

Non
California

except
FU
model

and
Canada

EM

18
8
9

8
5

Engine
Mechanical

INSPECTION
AND
ADJUSTMENT

CYLINDER
HEAD
AND
VALVE

Cylinder
head
Unit
mm
in

Standard
Limit

Head
surface
flatness
Less
than

0
05
0
0020
0
1
0

004

Valve
Unit
mm

in

j
I
Hot

Valve
clearance

I
Cold
Intake
valve
Exhaust
valve

0
35
0
014

0
25
0

010

Valve
lift
7

91
0
3114
8
22
0
3236

H
37
0
to
37

2

1
457

to
1

465
30
0
to

30
2

1
181
to
1
189
D
L
Valve
head

diameter

a

H
Valve

length

L
103
6
to
104

0

4
079
to
4

094

D
7

970
to
7
985

0
3138
to

0
3144
7
945
to
7
960

0

3128
to
0
3134
Valve
stem
diameter

EM769

Valve
seat

angle

a
45030

Valve

spring

Free

height
mm
in
46
5
1

831

Compressed
height

mm
kg
in
lb
30
2
22
2

to
25
6

valve

open
1
189

49
0
to
56
4

Assembled

height

mm

kg
in
lh
38
7
544
to
62
6

valve
closed
1
524
120
0

to
138
0

Out
of

square
S
mm
in
Less

than
1
6

0
063

EM

19

Valve

guide
senice

INTAKE

f

D21
Dl

I

r

I
I

I
d
18
5

0

728

L

EXHAUST

II
3
0
118

t

81
o

8
5
327
to
0
335

Combustion
chamber
ide

Valve

guide
length
L

D

Valve

guide

Outer
diameter

D2

Valve

guide

Inner

diameter

Finished
size
d

Cylinder
head
valve

guide

hole
diameter
a

Interference
fit
of
valve

guide

In

Stem
to

guide
clearance

Ex
Engine
Mechanical

1

Unit
mm

in

EM770

Intake
for
Non
California

except
FU

Exhaust

49
1
93
EM171

Unit
mm
in

Intake
for

California

Canada

FU
model
for
Non

California

53
2

09

12

0331012
044

0

4737
to
0
4742

12

233
to
12
244

0
4816

to
0
4820

8

000
to
8
015

0
3150
to

0
3156

12
200
to

12
211

0
4803
to
0

4807

0

022
to

0
044

0
0009
to
0
0017

Standard

0
Q15

to
0
045

0
0006
to
0
0018

0
040
to
0
070

0

0016
to

0
0028

EM

20
Unit

mm
in

Max
tolerance

0
1
0
004

Engine
Mechanical

Valve
seat

Intake
valve
insert
service

Non
California
Unit
mm

in

California

9anada
FU

model

H
L

I

I
D

D

1
02

1
1

1
J

Ol
I

I

D

38
580
to
38
596
1
5189
to

1
5195

D2
31

9
to
32
1
1
256

to
1
264

D3
36
5
to

36
7

I
437
to
I
445

H
5
9
to

6
0
0

232
to

0
236

L
1
3
to
2
3
0

051
to

0
091

0
600

O2
200

Do
38

500
to
38
516
1

5157
to

1
5164
D2
EM772

38
580
to
38

596

1
5189

to
1
5195

31
9
to
32
1
1
256
to

1
264

35
5

to
35
7
1
398

to
I
406

5
8
to
5

9
0
228
to
0
232

1
3
to
2
3
0
051
to
0
091

600

200

38
500
to
38
516
1
5157

to
1
5164

Do
Cylinder
head
valve
insert
hole
diameter

Exhaust

valve
insert
service

D

D
D2

I
D2

I
I
H

H

I
I
l

I
C

Do

C

EM773

EM
21
Unit
mm
in

33

580
to
33
596

1
3220
to
1
3227

26
85

to
27
15

1
0571
to
1

0689

5
9

to
6
0
0

232
to

0
236

0
8
to
1
0

0
031
to
0
039

33
500
to
33

516
1

3189
to

1
3195

Engine
Mechanical

Finished
size
of
service
valve

insert
cutter

Intake

Exhaust
Unit
mm
in

For
Non
Clilifornia

except
FU
model
For

California
Canada
FU
model
for

Non
California

T
fil

@
Lr

I

I

JII

I
I
I
I

I

I
Dl

I

D

EM774
EM775

D

D2
36
5

to
36
7
1437
to
I
445
36
5
to
36
7
1

437
to

1
445

34
4

to
34
6
1
354
to
1
362

Unit
mm
in

All
models

j

III
900

C

WII
L

I

I

EM776

D

C
29
5
to
29
7

1
161
to
1
169

1

8
0
071

EM
22

Engine
Mechanical

Valve
rocker
arm
and
shaft
Unit
mm
in

Rocke
shaft
outer
diameter
19
979

to
20
000

0
7866
to

0
7874

Rocker
arm

to
rocker
shaft

clearance
0
020
to
0

054

0
0008
to
0

002

Rocker
ann
bore
diameter
20
020
to
20
033

0
7882
to
0
7887

Valve
lifter
and

push
rod
Unit

mm
in

Standard
Wear

limit

Valve
lifter
lifter
hole
clearance
0
02
to
0

05

0
0008
to

0
0020
0
15

0
0059

CAMSHAn

Camshaft

journal
and

bearing
specifications
Standard

Camshaft

bearing
Camshaft

journal
Camshaft

journal

Bearing
Size

inner
diameter
diameter
to

bearing
clearance

No
I
43

833
to

43
843
43
783
to
43

796
0

037
to

0
060

I

7257
to
I
7261
1

7237
to
I
7242

0
0015
to
0
0024

No
2
43
323
to
43
333
43

283
to
43

296
0
027
to
0
050

1
7056
to
1
7060
I

7041
to
I

7046
0
0011
to
0

0020

Standard
No
3
42
836
to
42
846
42
783
to
42
796
0
040
to
0
063

1
6865
to
1

6868
1

6844
to
1
6849
0
0016
to
0

0025

No
4
42
323
to
42
333
42

283
to
42
296
0
027
to
0
05

1
6663
to
1

6667
1

6647
to
1

6652
0
00
II

to
0

0020

No
5
41
258
to
41

268
41
208
to
41
221
0
037
to
0
060

1
6243

to
1
6247
1
6224
to
1
6229
0
0015
to
0

0024

EM

23
Unit

mm
in

Camshaft

journal

to

bearing
clear

ance
wear
limit

0
15
0
0059