clutch DATSUN 210 1979 Service Manual

DATSUN

210

SERVICE

MANUAL

Model

8310
Series

T

OfOUoW
lTY

INISSAN

N
OIlCOIIO

NISSAN
MOTOR

CO
LTD

17
1

Ginza
6
Chome

Chuo
ku

Tokyo
104

Japan
QUICK
REFERENCE

INDEX

GENERAL
INFORMATION

GI

ENGINE
TUNE
UP

ET

ENGINE
MECHANICAL
EM

ENGINE
LUBRICATION

SYSTEM
EL

COOLING
SYSTEM

CO

ENGI
NE
FUEL
EF

EMISSION
CONTROL
SYSTEM
EC

ENGINE
ELECTRICAL
SYSTEM
EE

ENGINE
REMOVAL
INSTALLATION
ER

CLUTCH

CL

lMr

MANUAL
TRANSMISSION
MT

AUTOMATIC
TRANSMISSION
AT

H

PROPELLER
SHAFT
OIFFERENTlAL
CARRIER
PO

FRONT
AXLE
FRONT
SUSPENSION
FA

10

REAR
AXLE
REAR
SUSPENSION
RA

BRAKE

SYSTEM
BR

WHEEL
A
NO

TI
RE
WT

0

STEERING
SYSTEM
ST

ENGINE
CONTROL
FUEL
EXHAUST
SYSTEMS
FE

BOOY
BF

BOOY
ELECTRICAL
SYSTEM
BE

AIR
CONOITIONING
AC

Erigine
crankcase

EI
gine
cooling
system

Transmission
case

Final
drive
case

housing

Steering
gear
box

Fuel
tank

Air

conditioning
system

Refrigerant

Compressor
oil

f
tl

It
J

4
i

1

protect
the

catalytic

cop
verter
froitr

contamination
t
n
General
Information

APPROXIMATE
REFILL
CAPACITIES

Without
oil
filter
AI4

Al5

w

Al5

M
T

AfT

MiL

A
T
Liter

US
measure

3
2
3

qt

2
8
3

qt

3

7

llLgt

33
3

qt

5
2
5

qt

5
0
5Y

qt

5
9
6
Y
at

57

6qt

1
3
2
Y

ot

1
2
2

pt

53
5

qt

0
9
1

pt

0
25

pt

50
13
Y
I

0
8
tol

Okg
1

8
to
2
2
1b

0
237

8
0
floz
Withoil

Without
heater

With

heatfr

MaDllal
soeed

5

spee

Automatic
1

1
Includes
2
7

liters
2

US

qt
2

Imp
qt
for

torque
converter

RECOMMENDED
FUEL

Use
an
unleaded
or
low
lead

gaso

line
with
a
minimum
octane

rating
of

91

RON
Research
Octane
Number
For

cars

equipp
d
with
the

Cataly

tic

converter
California
and
FU
mod

els
use

only
unleaded

gasoline
to

RECOMMENDED

Lubricant

GasOline
engine
oil

Gear
oil
Transmission

and

steering

Differential

Au
omatic

TIM
fluid

Multi

purpose
grease

Brake
and
clutch
fluid

Anti
freeze
L
NDED

LUBRICAN

COMMENDED

i

I
VISCOSITY
NUMBER

t1

NGON
0

L
J

I
j
H

I

IlL
I

t

l

I
lc
30
ItM
7

l
t

U

I
ItM
I

L
L
tJ

30

I

I
fu

JIl
inld

do

o

II

L
liOwl

1
I
I
1

10

I
I

I
I
t

I

I

j
r

I

I
J
1

21
l
1
I
71

c

DIUt
I2lItMOl
UGIIII
FI

R

NIl
I
01
a
Specifications
Remarks

APISE

API
GL4
Further
details
refer
to

recommended
SAE

viscosity
chart

API
GL
5

Type
DEXRON

NLGI
No
2
Lithium

soap
base

DOT
US
FMVSS
No
116

Ethylene
glycol
base

GI
5
Imp

meas4re

2

qt

2

qt

3Y

qt

2

it

4

qt

4

q

5Y

qt

5

qt

2Y

pt

2

pt

4

qt

I

pt

pt

II

gal

1
8
to
2
2
lb

83f1
oz

Ji

j

j

Condition

ABNORMAL

COMBUSTION

backfire
afterfire

run
on
etc

Improper
ignition
timing

Fuel

system
out
of

order

Feulty
cylinder
heed

etc

Others

EXCESSIVE
OIL

CONSUMPTION

Oilleek8111
Engine
Tune

up

Probable
cause

Surging
A
T
C
air

cleaner
vacuum
motor

Note
This
noise
will
be
hmnl
when
clutch

iI

disengaged

We
r
on
clutch

pilot

bushing

Not
e
This
noise
will
be
heared
when

utch
iI

disengaged

Improper
ignition
timing

Improper
heal

range
of

spark
plugs

Damaged
carburetor
or
manifold

gasket

backfire
aftedire

Clogged
carburetor

jet

Improper
function
of
the
float

Uneven

idling
Run
on

Improperly
adjusted
T
O
C
S
set

pressure

Except
FU

models

Malfunction
of
anti

dieseling
solenoid
valve

Malfunction
of
fuel
shut
off

system
FU

models

Malfunction

or
auto
hoke

Improper
y

adjusted
valve
clearance

Excess
carbon

in
combustion
chamber

Da
laged
alve

spring

backfire
after
he

Malfunction
of
A
T
C
air
cleaner

Inoperative
anti4lackfire
valve

Loose
oil

tain
plUI

ose
or

damaged
oil

pan
gasket

Loose
or

damaled
chain
cover

gasket

Wom
oil
seal
in
front

and
rear
of
crankshaft

Loo
or

damaged
locker

cover

gasket

Improper
lilhtening
of

oU
filter

Loose
or

damaled
oil

pressure
switch

ET
21
Corrective
action

Repair
or

replace

Renew
bush

and

adjust
drive
shaft

Adjust
ignition
liming

Use

specified
spark
plugs

Replace
them

with
new

parts

Disassemble
carburetor
and
check
it

Adjust
the
level
and
check
needle
valve

Adjust

Adjust

Check

or

replace

Check
fuel
shut
off

system

Adjust
or
re

place
necessary

Adjust

Adjust

Remove
head
and

get
rid
of
carbon

Replace
it
wit
a

new
one

Check
for
loose
vacuum
hoses

Replace
if

necessary

Replace

Tighten
it

Renew

lasket
or

tighten
iI

Renew

gasket
or

lighten
it

Renew
oil
seal

Renew

gasket
r

lighten
it
but

not
too

much

Renew

gasket
and

tighten
it
with
the

proper

torque

Renew
oil

pressure
switch
or

tighten
it

PRELIMINARY

CLEANING
AND

INSPECTION

Before

disassembling
engine
ob

serve
the
following
items

I

Prior
to

disassembling
check

outer

parts
for

sign
of
leak

past
their

gasketed
surfaces

2
Check
carburetor
and
fuel

pump

for
condition
fuel
hoses
for
deteriora

t
ion

cracks
or
otherwise

leakage
of

fuel

past
their

jointed
or

connected

surfaces

3

Wipe
dust
and
mud
off

engine

4

Inspect
outer

parts
for
visual

faults
and
broken
or

missing

parts
such

as
bolts
and

nuts

5
Check

piping
and
electrical
cir

cuits

for
deterioration
breakage

fittings
discontinuity
or
insulation

DISASSEMBLY

To

remove

engine
from
car
refer
to

Section
ER

for
Removal

1
Remove

starting
motor
then
re

move
transmission
from

engine

2
Remove
clutch
assembly

3
Remove

alternator
fan
belt
alter

nator
bracket
and
alternator
adjusting

bar

4
Remove

idler
pulley
air

pump

belt
and
idier

pulley
bracket

If
so

equipped

Note
Loosen
idler

pulley
nut
and

belt

adjusting
bolt
in
that
order

@

1

Idler

pulley
nut

2
Belt

adjusting
bolt

3
Air

pump
belt

4
Idler

pulley
bracket
EM527

Fig
EM
2

Removing
Idle

Pulley

Air

Pump
Belt
and
Idle

Pulley
Bracket
Engine
Mechanical

ENGINE
DISASSEMBLY

5

Remove
air

pump
pulley
air

pump
and
air

pump
bracket
If

so

equipped

6
Remove
fan
fan

spacer
and

pul

ley

7
Remove

oil
level

gauge

8
Remove

distributor

cap
and

high

tension

cables
as
an

assembly

9
Disconnect
distributor
vacuum

line
from
distributor
and
remove
dis

tributor

10
Disconnect

fuel
line
from

carbu

retor

II
Remove
fuel

pump
and
fuel
line

12
Remove
water
outlet
and

thermostat

13
Remove

engine
mounting
brack

et
R
H

14
Remove

oil

pump
and
filter
as

sembly

EL043

Fig
EM

3

Removing
Oil

Pump

15

Remove

spark
plugs

16

Install

Engine
Attachment

KVlOI02500
to

cylinder
block

using

engine

f1
ounling
bracket

R
H
attach

ing
studs
fuel

pump
attaching
studs

and
alternator

bracket

attaching
bolt

holes

17
Mount

engine
on

Engine
Stand

ST050I
SOOO

Fig
EM
4

EM
3
18
Remove

engine
mounting
brack

et

L
H

19
Disconnect

air
vacuum
and

blow

by
hoses
from
air

cleaner

20
Remove
air
cleaner
and
air

cleaner
brackets

21

Remove
vacuum
control
valve

assembly
and
bracket

as
a
unit

22
Remove
carburetor
and
baffle

plate

23

Remove
E
G
R
control
valve

24

Remove
intake
and
exhaust

manifold
assemblies

EM528

Fig
EM
5

Removing
Manifold

25
Remove
P
C
V

hose

pipe
con

nector
to
control
valve

26
Remove

rocker
cover

27
Loosen
valve
rocker

adjusting

nut
and
turn

adjusting
screws
out
to

disengage
push
rods
Then

evenly

loosen
rocker
shaft
bolts

28
Remove
rocker
shaft

assembly

EM453

Fig
EM
6
Removing
Rocker

Shaft

Assembly

29
Withdraw

push
rods
and

keep

them
in

correct
order
1

30
Loosen

cylinder
head
bolts

a

little
at
a
time

in
the

sequence
shown

in

Fig
EM
and
remove

cylinder

head

EM142

Fig
EM
48

Measuring
Bearing

Clearance

6
If
clearance
exceeds
the

specified

value

replase
bearing
with
an
under

size

bearing
and

grind
crankshaft

journal
adequately

Max
tolerance
of
main

bearing
clearance

0
10

mm
0
0039
in

MEASURING

CONNECTING

ROD
BEARING

CLEARANCE

I
Measure

connecting
rod

bearing

clearance
in
same
manner
as
above

tfl
Tightening
torque

Connecting
rod

cap
nuts

3
2
to
3
8

kg
m

23
to
27
fHb

2
If

clearance
exceeds
the

specified

value

replace
bearing

with
an
under

size

bearing
and

grind
the
crankshaft

journal
adequately

Max
tolerance
of

connecting

rod

bearing
clearance

0
10

mm
0
0039
in

Note
Since

bearings
are

precision

insert

type
it
is
not

necessary
to

file

bearing
caps
or
to

grindbeari

surfaces
with
an

emery
cloth
to

correct

bearing
clearance

MISCELLANEOUS

COMPONENTS

CRANKSHAFT
SPROCKET

AND

CAMSHAFT
SPROCKET

I

Check
tooth
surface
for
flaws
or

wear

Replace
sprocket
if
fault
is
Engine
Mechanical

found

2

Install
camshaft

sprocket
in

posi

tion

and
check
for
runout

If
runout
exceeds
the

specified

limit

replace
camshaft

sprocket

Runout

Total
indicator

reading

Less
than
0

1
mm
0
004

in

EM309

Fig
EM
49

Checking
Cam

haft

Sprocket
Runout

CHAIN
AND

CHAIN

TENSIONER

I

Check
chain
for

stepped
wear

scratches
or
other

problems
on

roller

links

Replace
if

necessary

2
Check
chain
tensioner
for
wear

breakage
or

any
other
fault
which

would

interfere
with

proper
chain

function

Replace
if

necessary

FLYWHEEL

I

Check

ring
gear
If
worn
or
dam

aged
excessively
replace

2

Clutch

contacting
face
of

fly

wheel

should
be
smooth
If

worn

damaged
or

roughened
beyond
limits

repair
or

replace

3
Before

disassembling
and
after

re

assembling
check

flywheel
run
out

with
a

dial

gauge
This
check
is

made

by
rotating
flywheel
with
dial

gauge

finger
resting
on
the
farthest

point

from
center
of

flywheel
If
it

exceeds

the

specified
limit

replace
it

EM
II
Runout

Total
indicator

reading

Less

then

0
15
mm
0
0059
in

Fig
EM
50
Checking
Flywheel
Runout

Note
Removal
and
installation
of

ring

gear
requires
use
of

hydraulic

press
It
is

also
necessary
to
heat

ring

gear
to
180
to
2000C
356

to

3920F
thus
facilitating
removal

and
installation
Do
not
heat

ring

gear
to
more
than
3000C
5nOF

To
do
so
could
result
in

impaired

hardness
of

ring

gear

CRANKSHAFT

FRONT
AND

REAR
OIL

SEAL

First
check
front
and
rear
oil

seals

for
worn
or
folded
over

sealing
lip
or

oil

leakage
If

necessary
replace
with
a

new
seal
When

installing
a
new
seal

pay
attention

to

mounting
direction

Note
It
is

good
practice
to

renew
oil

seal
whenever

engine
is
overhauled

Front

u
Front

Rear

EM487

Fig
EM

51
Cranhhaft
Oil
Seal

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

Tool

number
tool
name

EM03470000
Piston

ring
compressor
Engine
Mechanical

Kent
Moore
No

Reference

page
or

Fig
No

Fig
EM
66

EM
35
Tool

number
tool

name

ST20610000
Clutch

aligning
bar
Kent

Moore
No

Reference

page
or

Fig
No

125673

Fig
EM
83

1

Servo

diaphragm
4

Stopper

2
Bracket
5
Link

3
Lock
nut
6
Carburetor

EF732

Fig
EF
56

Adjusting
Seroo

Diaphragm

Adjwting
Screw

FUEL

SHUT
OFF

SYSTEM

Precautions

a

Before

checking
make
sure

engine

is

warmed

up
and
choke
wive
is

fully
open

b

On
air
conditioner

equipped
mod

els
turn
off

air
conditioner
switch

in

steps
I

through
12

c

Keep
clutch

pedal
held
down
with

your
foot
while

depressing
accele

g

f
J

1
Engine
Fuel

rator

pedllI
when
shift
leVer
ISm

any
position
other
than

neutral

Otherwise
car
will

surge
forward

abruptly

Note
Do

not
attach
test
leads
of
a

circuit
tester
to
terminals
other

than
those

designated

Run

engine
at

idling

speed

2
Disconnect

anti
dieseling
solenoid

valve
connector
and
make

sure
that

engine

stops
If

not

replace
anti

dieseling
solenoid
valve

assembly

EF856

Fig
EF

57

Checking
Function

of

Anti
die

eling
Solenoid
Valve

31
A

t

CID

@

V

II
l

To

distributor

T
n

l1on
coon
o

1

Ignition
switch

2
Fuse

3

Anti
dieseling
solenoid

4

Neu
tral

detecting
switch
5
Throttle
valve
swltch

6

Engine
revolution
switch

7

Transistor

ignition
unit

8
Function
test
connector

Fig
EF
58

Checking
Fuel
Shut
off

System
Operation
with
Function

Test
Connector
EF436A

EF
22
3
Conilect
anti

ieselingsolenoid

valve
connector

4
Restart

engine

5
Connect

circuit
tester

as
shown
in

Fig
EF
S8

6

Depress
clutch

pedal
and

shift

gears
into
5th

position

7

Depressing
clutch

pedal
increase

engine
speed
to

about
3

000

rpm
by

depressing
accelerator

pedal
Then

quickly
close
throttle
wIve

by
re

leasing
accelerator

pedal

8
At
this
time
check

for

presence

of

voltage
across
A

and
B

I
If

voltmeter

reading
i
ero
dur

ing
acceleration
and
is
12V

during

deceleration
fuel
shut
off

system
is

functioning

2
If

voltmeter

reading
is

zero
or

l2V
in

both

engine
operations
fuel

shut
off

system
is

malfunctioning

In

any
case
continue
with
the

following
items

9

Shift
lever
to
neutral

then
in

crease

engine
speed
and

quickly
close

throttle
valve

If

voltmeter

reading
is

zero
in
both

engine
operations
and
results
of
test

i
tern

8
are
correct
neutral

detecting

switch
is

functioning
properly
If
not

check
neutral

detecting
switch
harness

and
connections

Replace
if

necessary

10
Turn

off

ignition
switch

II

Disconnect
throttle
valve
switch

connector
and
connect

circuit
tester

to
throttle
valve
switch
connector

12

Run

engine
under

no
load
In

crease

engine

speed
slowly
and
make

sure

engine
speed
is
within
the

speci

fied

range
when
throttle
valve
switch
is

turned
on

Then

decrease

engine
speed
slowly

and
make
sure

engine
speed
is
within

the

specified
range
when
throttle
valve

switch
is
turned

off

If
not

adjust
throttle
valve

switch

13
In
air

conditioner

equipped

models

proceed
as
follows

I
Check
F
l
C
D

rpm
and
correct

if

necessary

2
With

air
conditioner
in
ON

F
l
C
D
is
actuated
increase

engine

speed
slowly
then
decrease
it
And

make

sure
throttle
valve

operates

Click
sOund
is
heard
or

continuity

turns
to
OFF
when

engine
speed

decreases
to

idling

If
not

adjust
throttle
valve
switch

Fig
EF

59

Adjusting
Throttle

Valve
Switch
Eng
ine
Fuel

If
throttle
valve
switch
cannot
be

adjusted
to

specification
replace

Engine
operation
Throttle
valve
switch

continuity
Engine
speed

rpm

When

engine
speed

increases
OFF
ON
1
150

t200

When

engine
speed

decreases
ON

OFF
I
000
t
200

Inspecting
engine
revolution

switch

Note
Before

checking
the

engine

revolution
switch

make
sure

the

functions
of
other

components
are

correct
in
accordance

with
the

items

described
above

Disconnect
throttle
valve

switch

connector
2
Connect
circuit
tester

3
Run

engine
at

idling
speed

4

Depress
clutch

pedal
and
shift

gear
into
5th

position

5

Depressing
clutch

pedal
increase

engine
speed
slowly
Make

sure

engine

speed
is
within
the

specified
range

when
voltmeter

goes
from
OV
to
l2V

Then
decrease

engine

speed
slowly

and
make

sure

engine
speed
is
within

the

specified
range
when
voltmeter

goes
from
12V

to
OV

EF
23
MAJOR
SERVICE

OPERATION

The

perfectly
adjusted
carburetor

deliver
the

proper
fuel
and
air
ratios

at
aD

speeds
for
the

particular
engine

for
which
it

was

designed
By
com

pletely
disassembling
at
re
ular
inter

vals
which
will
allow

cleaning
of
all

parts
and

passages
the
carburetor
can

be
maintained
in
its

original
condition

and
will

continue
to
deliver
the

proper

ratios

To
maintain
accurate
carburetion

of

passages
and

discharge
holes
ex

treme
care
must
be
taken
in

cleaning

Use

only
carburetor
solvent
and

compressed
air

to
clean
all

passages

and

discharge
holes
Never

use
wire

or

other

pointed
instrument
to
clean
or

carburetor
calibration
will
be
affected

REMOVAL

Remove
carburetor
from

engine

taking
sufficient

care
to
the

following

Precautions

a
When

disconnecting
fuel
lines
do

not

spill
fuel
from
fuel

pipe

b
When

removing
carburetor

do
not

drop

any
nut

or
bolt
into

intake

manifold

c
Be

careful
not
to
bend
or
scr
tch

any

part

d
Link

system
of
carburetor
differ

between
models
for
U
S
A

and

Canada
For
details
see

Figure
EF

60
which
is
based
on
Canadian

models

Vacuumswltching
valve

The
vacuum

switching
valve

changes
the

vacuum

passage
by
the

electrical
signa

The
solenoid
installed
in
the
valve

moves
the
needle

valve
and
controls

vacuum
signal
in

order
to

change
the

vacuum
advance

I
c

III

J

IL
jll
J

EC164A

Fig
EC
82
Vacuum

Switching
Valve

Thermal
vacuum
valve

3

port
type

U
S
A
modele

except

FU
model

The
thermal
vacuum
valve
detects

engine
cooling
water

temperature
and

controls
the
vacuum
signal
for
distrib

utor
vacuum
advance
mechanism

This
3

port
type
thermal
vacuum

valve
is

a
2

stage
action

type

That
is

when
the
water

temperature
is
too

low

or

high
the
acuum
signal
is
transmit

ted
to
the
distributor

ffi2
To
air

cleaner

From
B
PT

valve

From
distributor

EC156A

Fig
EC
83
Thermal
Vacuum
Valve

3

port
type

Top
detecting
switch

For
M
T
models

The

top
detecting
switch
for
M
T

models
is
located

on
the
side
face
of

the
transmission

gear
box

A

plunger
of
the
switch
detects
the

position
of
the

striking
rod
and
Emission
Control

System

changes
the

continuity
between

two

lead
wires

EC165A

Fig
EC
84

Top
Detecting
Switch

Top
detecting
switch

For
Celifornla
AfT
model

The

top
detecting
switch
for

Arr

models
is

installed
as
a

plug
for
t
e

governor
feed
line

pressure
take
out

port
for
service

This
switch
detects
the
line

pressure

for
the
band

servo
release
side
and

front
clutch
and

changes
the
continui

ty
between
lead
wires
to
the

switch

body

EC166A

Fig
EC
85

Top
Detecting
Switch

AfT
model

Vacuum

delay
valve

The
vacuum

delay
valve
prevents
a

rapid
vacuum

change
in
the
distributor

vacuum
advance
line
This
valve
is

designed
for

one

way
operation
and

consists
of
a
one

way
umbrella
valve

and
a

sintered
steel
fluidic
restrictor

B

P
T
valve
side

J

l

1

Sintered
metric
disc

2
One

way
unbreUa
valve

EC860

Fig
EC
86
Vacuum

Delay
Value

EC

29
In
line
orifice

Some
orifices
are
installed
in
the

midway
at

the
vacuum
line
The
size

of
the

orifice
is

important
to
control

vacuum
advance

Therefore

pay
attention

not
to
lose

them

and
install
a

proper
part
when

replacing

Orifice

EC167A

Fig
EC
87
In
line

Orifice

REMOVAL
AND

INSTALLATION

f
Vacuum

switching
valve

The

vacuum

switching
valve
is

located
on
the

rear
end
of
the

intake

manifold

I
Disconnect

a

pair
of

lead
wires

from
valve
and

two
rubber
tubes

2
Loosen
two

screws

securing
valve

to
intake
manifold

Vacuum

switching

valve
can
then
be
taken
out

3
Installation
is
in
the
reverse

s

quence
of

removal

EC16BA

Fig
EC
88

Removing
Vacuum

Switching
Valve

Top
detecting
switch

For
M
T
models

The

top
detecting
switch
is

located

on
the

side
face
of

the
transmission