width DATSUN 210 1979 Service Manual

VALVE

GUIDE

Measure
the

clearance
between

valve

guide
and
valve

stern
If

the

clearance
exceeds
the

specified
limit

replace
the
worn

parts
or
both
valve

and
valve

guide
In
this

case
it
is

essential
to
determine
if
such
a
clear

ance
has

been
caused

by
a
worn
or

bent
valve
stem

or

by
a
worn
valve

guide

Determining
clearance

Precise
measurement
of
clearance

between
valve

stem
and

valve

guide

needs
the

aid
of
a
micrometer

and
a

telescope
hole

gauge
By
using
these

gauges
check
the
diameter
of
valve

stem
in

three

places
top
center
and

bottom

EM030

Fig
EM
22

Checking
Valve
Stem

Diameter

Insert

telescope
hole

gauge
in

valve

guide
bore

measuring
at
center

Subtract
the

highest
reading
of

valve
stem
diameter
from
valve

guide

bore
to
obtain
the
stem
to

guide

clearance

As

an

expedient
a
valve
is

pushed

in

valve

guide
and
moved
to
the

right

and
left
If
its

tip
deflects

beyond
the

specified
limit
there
it
will
be
known

that
the
clearance
between
stem
and

guide
exceeds
the
maximum
limit

Max
allowabl

deflection

0
2

mm
0
008
in

Max
tolerance

Stem
to

guide
clearance

0
1

mm
10
004
in

ote
Valve
sbould
be
moved
in

paraIlel
with
rocker
ann
General

ly
a

large
amount
of
wear
occurs
in

this
direction
Engine
Mechanical

Max
deflection
limit

Unit

mm
in

EM467

Mea6uring
Clearance

between
Valve
Stem

and
Valve
Guide
Fig
EM
23

Replacement
of
valve

julde

I
To
remove
old

guides
use
a
drift

and

a

pie
and
drive
them
out
of

rocker

cover
side
toward
combustion

chamber

Heating
cylinder
head
to
I

SO

to
200
C
302
to
392
F
will
facili

tate

operation

T11033000

EM468

1
II

Fig
EM

24

Driving
Valve
Guide
out

of

Cylinder
Head

2

Ream
cylinder
head
valve

guide

hole

using
Reamer
STlI081000

12
2

mrn
0
480
in

dia
at
room

tempera

ture

3

Carefully
press
service

Valve

guide

into

cylinder
head

guide
hole
It
will

fit

smoothly
after

heating
cylinder

head
to
ISO
to
200
302
to
392

F

4
Ream

bore
with
valve

guide
press

ed

in

using
Reamer
STll0320000
8

mm
0
31
in
dia

Reaming
bore

8
000

to
8
015

mm

0
3150
to
0
3156
in

EM
6
EM470

Fig
EM
25

Reaming
Valve
Guide

5

Correct
va1ve
seat
surface
with

new
valve

guide
as
the
axis

VALVE
SEAT

Check

valve
seat
for
evidence
of

pitting
at
valve

contact
surface

and

reface
or

replace
if
worn

excessively

Valve
seat
insert

of
0
5

mm
0
020

in
oversize

is
available
for
service

Refaclng
valve
seat

When
width
of
valve
seat
is

wide
or

narrow

beyond

specifications
it

should
be
refaced
with
valve
seat
with

cutter
or

grinding
stone

iIT11670000

EM411

Fig
EM
26

Refacing
Valve

Seat
with

Valve

Seat
Cutter

Replaclna
valve
seat
Insert

I

Old
insert
can
be

removed

by

boring
out
until
it

collapses
Machine

depth
stopper
should
be
set
So
that

boring
cannot
continue

beyond
the

bottom
face
of
the
insert
recess
in

cylinderhead

2
Machine

cylinder
head
recess
in

concentric
circles
to
valve

guide
center

so
that
insert
will
have
correct
fit

3
Ream

cylinder
head
recess
at

room

temperature

4
Heat

cylinder
head
to

tempera

ture
of
150
to
200

C
302
to
3920F

Out
of
ound
X
Y

Less
than
0
03

mm
10
0012
in

Taper
A
B

Less
than
0
03
mm

0
0012
in

Out
of
round
X
Y

Taper
A
B

B

o

r

EM716

Fig
EM
42
Mea6Urement
Point

3
After

regrinding
crankshaft
fmish

it

t
1
t
1e
necessary

s
ize
indicated
in

the

chart
under
Service
Data

and

Specifi

cations

by
using

Ill
adequate
u
dersize

bearing
according
to
the
extent
of

required
repair

4
Crankshaft
can
be
checked
for

bend

by
placing
it

on
V

blocks
and

using
a
dial

gauge
with
its

indicating

finger
resting
on
center

journal

If
bend
exceeds
the

specified
limit

replace
or

repair

Bned
Total

indicator

reading

Less
than
0

10

mm
0

0039
in

EM137

Fig
EM
43

Checking
Crankshaft

Bend

5

Measure

crankshaft
end

play
as

shown
in

Fig
EM
44
If

beyond
the

specified
limit

replace
main

bearing

Max

tolerance
of
end

play

0
3

mm
10
012

in
Engil
e

Mechllpjcal

Crsnk5haf
end

play

EM486

Fig
EM
44

Checking
Crankshaft
End

Play

6
To

replace
crankshaft
rear

pilot

bushing
proceed
as
follows

1
Pull
out

bushing
using
Pilot

Bushing
Puller
KvloI02800

Fig
EM
45

Pulling
Out
Pilot

Bushing

2

Before

installing
a
new

bushing

thoroughly
clean

bushing
hole

3

Insert

pilot

bushing
until
dis

tance
between

flange
end
and

pilot

bushing
is
the

specified

diJ1l
nce
A

Distance
A

Approximetely

2
8
mm
0

110
in

Do
not
oil

bushing

A

Pilot

bushing

EM719

Fig
EM
46

Installing
Pilot

Bushing

Note
When

installing

pilot
bushing

be
careful
not
to

damage
edge
of

EM

l0
pilot
C

snd
not
to

imat

1

1
1

BEARING

MEASURING
MAIN

BEARING
CLEARANCE

I

Thoroughly
clean
all

bearings

Check
for
scratches
melt
score
or

wear

Replace
bearings
if
fault
is

detected

2
Crankshaft

journals
and

bearings

should
be
clean
and
free
from
dust

and

dirt
before
oil
Clearance
is
meaSured

Plastigage

EM
141

Fig
EM
47

Plastigage

3
Set

main

b
e1lfing
on

cap
block

4
Cut
a

plastigage
to
width
of
bear

ing
and

place
it

in

parallel
with
crank

pin
clear
of
oil
hole
Install

cap
on

assembly
and

tighten
them

together
to

specified

torque

fj
Tightening
torque

Main

bearing
cop
bolt

5
0
to
6
0

kg
m

36

to
43
fHb

Note

Do
not
turn
crankshaft
while

plastigage
is

being
inserted

5

Remove

cap
and

compare
width

of

plastigage
at
widest

part
with
scale

printed
in

plastigage
envelope

they
are
worn

damaged
or
otherwise

faulty
and
how

they
are
affected
Re

pair
or

replace
all

faulty

parts
which

ever
is

necessary

1
Check

gear
teeth

for

scoring

cracking
or

chipping
and
make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault

is
evident

replace

parts
as

required

Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a

set

therefore
should
either

part
be

damaged

replece
as
a
set

2
Check

pinion
shaft
and

pinion

mates
for
scores
and

signs
of
wear

and

replace
as

required

F
oUow
the
same

procedure
for
side

gear
and
their
seats
on
differential

case

3

Inspect
all

bearing
races
and
roU

ers
for

scoring
chipping
or
evidence
of

excessive
wear

They
should
be
in

tiptop
condition
such
as
not
worn
and

with
mirror

like
surfaces

Replace
if

there
is
a

shadow
of

doubt
on
their

efficiency
as
an

incorrect

bearing
op

eration

may
result
in
noises
and

gear

seizure

4

Inspect
thrust
washer
faces
SmaU

faults
can
be

corrected
with

sand

paper
If

pinion
mate
to
de

gear

backlash
exceeds

specified
value
re

place
thrust

washers

Pinion

mate
to
side

gear
backlash

0
10
to
0
20
mm

0
0039
to
0
0079
in

5

Inspect
gear
carrier
and
differ

ential
case
for
cracks
or
distortion
If

either

condition
is
evident

replace

Jaulty

parts

6
As
a

general
rule
oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY
AND

ADJUSTMENT

Assembly
can
be
done
in
the

reverse
order
of

disassembly
The

foUowing
directions
for

adjustment

and

usage
of

special
tools
enable
to

obtain
a

perfect
differential

operation
Propeller
Shaft
Differential
Carrier

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
washers
and

the

like
to
install
them

correctly

2

Thoroughly
clean
the

surfaces
on

which
shims

washers

bearings
and

bearing
caps
are
installed

3

Apply
gear
oil
when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

ASSEMBLY
OF

DIFFERENTIAL
CASE

1

Assemble

pinion
mates
side

gears

and
thrust
washers
in
differential
case

2
Fit

pinion
shaft
to
differential

case

so
that
it

meets
lock

pin
hole

3

Adjust
pinion
mate

to
ide

gear

backlash
or
the
clearance
between
the

rear
face
of
side

gear
and

thrust

washer
to
the

specified
value

by

selecting
side

gear
thrust
washer

Pinion
mate
to
side

gear
backlash

0
10
to
0
20

mm

10
0039
to
0
0079
in

PD023

Fig
PD

l1
Measuring
Clearance

Side

gear
thrust

washer

Thickness
mm
in

0
785
0
0309

0
835
0

0329

0

885
0
0348

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it
is

secured
into

place

5

Apply
oil

to

gear
tooth
surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6

Place

ring

gear
on
differential
case

and
install
bolts
and
lock

straps
Tor

que
bolts
to

specification
and
bend

up

lock

straps

PO
5
tiJ
Tightening
torque

Ring
gear
bolt

6
0
to
7
0

kg
m

43
to
51
ft
Ib

CAUTION

e
Use

only
genuine
ring
gear
bolts

end
new
lock

straps

b

Tighten
bolts
in
criss
crilss
fashion

lightly

tapping
around
bolt
heads

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
Side
Bear

ing
Adjust
Weight
ST3250S000

Weight
mock
ST3250
I

000
and

Master

Gauge
ST325020oo
or
suit

able

standard

gauge
17
5
nun
0
689

in

thickness
and

a

weight
block
2
5

kg
5
5
Ib

prior
to
installation

Standald

bearing
width

17
5
mm
10
689
in

y

ST32501000

8
Select
side

bearing
shims
re

ferring
to

Adjustment
of
Side

Bearing

Shims

9
Press
fit
side

bearing
cone
into

differential
case

using
Gear
Carrier

Side

Bearing
Drift
ST33220oo0
and

Adapter
ST33052000

w

I
ST33220000

PD244
1000

ST33052000

Fig
PD
13

lnatalling
Side

Bearing

Cone

drive

pinion
arid

lubricate

pinion
rear

bearing
with

gear
oil

4
Insert

companion
flange
into
oil

seal
and
hold
it

firmly
against
pinion

front
bearing
cone
From
the

rear
of

the

gear
carrier
insert

drive

pinion

into

companion
flange

5
Ascertain
that

threaded

portion

of
drive

pinion
and
new

drive

p
ion

nut
are
free
from
oil
or

grease

6

Holding

companion
flange
with

Drive
Pinion

Flange
Wrench

STJ1530000

tighten
nut
and
then

pull
drive

pinion
into

front

bearing

cone
and
into

flange

As
drive

pinion
is

pulled
into
front

bearing
cone
drive

pinion
end

play
is

reduced
While
there
is

still
end

play
in

drive

pinion
companion
flange
and

cone
will
be
fell

to
bottom
out
This

indicates
that

bearing
cone
and
com

panion
flange
have
bottomed
on

col

lap
ible

spacer

From
this

point
a

much
greater

torque
must
be

applied
to
turn

pinion

nut
since

spacer
must
be

collapsed

Also
from
this

point
nut

hould
be

tightened
very
slowly
and
drive

pinion

end

play
checked
often
0
that

pinion

bearing
preload
does

not
exceed
the

limits

When

the
drive

pinion
end

play
has

been
eliminated
the

specified
preload

i

being
approached

CAUTION

00
not
decrease

preload
by
loosen

ing
pinion
nut
This
will
remove

compression
between

pinion
front

end
rear

bearing
cones
and

collapsibla

spacer
and

may
permit
front
bear

ing
cone
to
turn
on
drive

pinion

Moreover
nut
becomes
loose

7
Turn
drive

pinion
in

both
direc

lions
several
times

to
set

bearing

rollers

Then

adjust
bearing
preload
to

specification
using
Preload

Gauge

STJ127S000

iil
Tightening
tOlque

Pinion
nut

14
to

30

kg
m

101
to
217
ft
lb

D

iY8

pinion
preload

with

oil
seal

6
0
to
8
0

kg
cm

5
2

to
6
9
in
Ib
Propeller
Shaft
Differential
Carrier

P0447

Fig
PD

17

Measuring
Pinion

Preload

If
this

specification
is

exceeded

replace
collapsible
spacer

Note
Preload
of
used

bearing
is
the

same
value
as

that
of
new

bearing

ADJUSTMENT

OF
SIDE

BEARING
SHIMS

I

If

hypoid

gear
set

gear
carrier

differential
case
or

side

bearing
ha

been

replaced
adjust
the
ide

bearing

preload
with

adjusting
him

The

required
thickness
of

adjusting

shim
can
be
calculated

by
the

follow

ing
formulas

T
A

C
D
H

xO
OI

020
E

T2
B
D
H
xO
Ol
0

20

F

Where

T

Required
thickness
of
left

side

bearing

adjusting
shim

mm

T

2
Required
thickness
of

right

side

bearing
adjusting
shim

mm

A

Figure
marked
on
the
left

side

bearing

housing
of

gear

carrier

B

Figure
marked

on
the

right

side

bearing
housing
of

gear

carrier

C

D

Figures
marked
on
the
dif

ferential
case

E
F

These
are
differences
in

width

of
left

or

right
side

bearing

against
the
tandard
width

mm

H

Figure
marked
on
the

ring

gear

PD
7
Figures
for
A
B
C
D
and
H
are

dimensional
variations
in
units

of

1
100
mm

against
each
standard

measurement

F

MarkS

MarkC
D

L

P0214

Fig
PD
18

Thickness

of
Shim
on

Left
and

Right
Sides

PD190

Fig
PD
19
Variation
Number
on

Ring
Gear

Examples
of
calculation

EX
1

A
I
B

2
C
2
D
3

E
0
02

mm
F
0
01
mm

H
2

Left
side

T
A

C
D
H
xO

OI

0
20
E

I
2
3
2
x

0
01

0
20
0
02
0
26

rnm

The
correct

shims
are
0
05

plus

three

pieces
of
0
07
mm
thick

Right
side

T2
B

D
W
xO
QI

0
20
F

2
3
2
x

0
01

0
20
0
01
0
16

mm

The
correct

shims
are
0
10

plus

0
07
mm
thick

Propeller
Shaft
Differential
Carrier

SERVICE
DATA

Drive

pinion

Preload

with
oil
seal

Thickness
of

pinion
height

adjusting

washer

Side

gear
and

pinion
mate

Thickness

of
side

gear
thrust
washer

Pinion
mate
to
side

gear
backlash

clearance
between
side

gear
and

thrust
washer

Ring
gear

Ring
gear
to
drive

pinion
backlash

Thickness
of
side

bearing

adjusting

shint

Side

bearing
standard
width

L

dimension

Oil

capacity

TIGHTENING

TORQUE

Drive

pinion
nut

Ring

gear
bolt

Side

bearing
cap
bolt

Companion
flange
to

propener

shaft

fixing
bolt

Gear
carrier

to
rear
axle
case

fixing
bolt

Oil
drain
and
ftller

plugs
kg
cm
in

lb
6
0

to
8
0
5

2
to
6
9

mm
em
2
74

0
1079

2
77
0

1091

2
80
0
1102

2
g3
0
1114

2
86
0
1126

2

89
0

1138

2
92
0
1150

2

95
0
1161

2
98
0

1173

3
01
0

1185

3
04

0
1197

3

07
0
1209

3
10
0
1220

3
13
0
1232

3
16
0
1244

3
19
0
1256

3
22
0
1268

3
25
0

1280

mm
in

0
785
0

0309

0
835
0

0329

0
885
0

0348

0
10

to
0
20

0
0039

to
0

0079
mmOn

mm
in

0
10
to
0
15

0
0039

to
0
0059

mm
in

0
05

0
0020

0
Q7
0
0028

0
10

0
0039

0
20

0
0079

0

50
0
0197

17
5
0
689

153
40
to
153
45
6
0394
to
6
0413
mm
in

mm
in

liter

US
pt
Imp
pt
approximately

0
9

I
U
I

kg
m

ft
Ib

kg
m
ft
Ib

kg
m
ft
lb
14to30
IOI
t0217

6
0
to
7
0
43
to
51

5
0
to
6
0
36
to
43

kg
m
ft
Ib

kg
m
ft
b

kg
m
ft

lb
2
4
to
3
3
17
to
24

1
7
to
2
4

12
to
17

6
to
10
43
to
72

PD
ll

V

CD

l

t

177t

ID
@
A

5

Adjust
gap
c

between
recess

of
rear
axle
tube
and

rear
axle

bearing

by
selecting
shinto

Gap
e

o
to
0
1
mm
0
to
0
004
in

Gap
c
can
be

calculated

by

c
a
b
d

where
a
Distance

from
rear

axle

tube
end

to
recess

b

Bearing
width

c

Gap
c

d
Shint
thickness

RA559

Fig
RA
15

Gap
C

Rear
axle
case
end
shim

Thickness
mm
in

om5
0
0030

0
1
50

0
0059

0
225
0

0089

0
300

0
0118

6
Measure

axial
end

play
of
axle

shaft
with
dial

indicator

Axial
end

plav

0
10
to
0

45
mm

0
0039
to
0
0177
in
Rear
Axle
Rear

Suspension

1
Rear
axle

shaft

2
Rear
axle
shaft

guide

3
Rear
axle
case

4
Oil
seal
I

ill

A
70
to

90
mm

2
76

to
3
54
in

A

A560

Fig
RA
14
Installing
Rear
Axle

Slwft

R
550

Fig
RA
16

Measuring
End

Play

CAUTION

When

installing
brake
1ubes
use
Flare

Nul

Torque
Wrench
GG94310000

ifl
Tightening
torque

Brake
disc

fixing
nut

1
5
to
2
0

kg
m

11
to
14
ft
lb

Brake
tube
flare

nut

1
5
to
1
8

kg
m

11
to
13
ft
lb

Wheel
nut

8
0
to
10

kg
m

58
to
72
ft
lb

REAR
AXLE
CASE

Remove

I
Raise
rear
of
car
and

securely

support
under

body
member
on

both

sides
Refer
to
Rear

Axle

Assembly

for
removal

2

Drain
differential

gear
oil

3
Remove
rear
axle
shaft
assemblies

on
both
sides
Refer
to
Rear

Axle

RA
5
Shaft
and
Wheel

Bearing
for
removal

and

remove
rear
axle
assemblies

Refer

to
Rear

Axle

Assembly
for

removal

4
Remove

differential
carrier
assem

bly
from
rear
axle

case

5

Remove

brake
tube
and
rear

cable

Inspection

Check
axle
case
for

yield
deforma

tion
or
cracks
and

replace
if

necessary

Installetion

Install
axle

case
in
the

reverse
order

of
removal

Note

Change
oil
seal
and

gasket
at

each
ove

haul

ifl

Tightening
tOlque

Differential
carrier

fixing

bolt

1
6

to
2
4

kg
m

12
to
17
ft

lbl

Oil
drain

and
filler

plug

6
0
to
10
0

kg
m

43
to
72
ft

lbl

Blake
connector

fixing
bolt

0
8
to
1
1

kg
m

5
8
to
8
0
ft
Ibl

REAR
SUSPENSION

SHOCK
ABSORBER

Removal

1
Remove
nuts
secu

ng
shock

absorber

upper
end
to
wheel
house

paneL

RA551

Fig
RA

17
Shock
Absorber

Upper

End
Sedan

Brake

System

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

SERVICE
BRAKE

Type

Front

Rear

Pad
or

lining
dimension

Width
x
thickness
x

length

Front

Rear
Disc
AN20

Drum

LT20
Auto

rnm
in

Pad

41
2
x

10
0
x
61
4

1
622
x
0394
x
2
417

Lining

35
0
x
4
8

x
195

0

1
378
x
0
189
x
7

68
mm
in

Rotor
outer
diameter
or

drum
inner
diameter

Front

Rear

Wheel

cylinder
inner
diameter

Front

Rear

Master

cylinder
inner
diameter

Brake

booster

Type

Diaphragm
diameter

NP
valve

split
point
x

reducing
ratio

Type
of

adjusting
shoes
rnm
in

rnm
in
245
0
9
65

203
2
8
00

rnm
in

mm
in

rnm
in
51
1
2
012

20
64
13

16

20
64

13
16

mm
in

kg
cm
2

psi
M60

152
4
6

20
x

0
4
284
x

0
4

BR
16