engine DATSUN 210 1979 Service Manual

Brake

System

INSPECTION

AND
ADJ
USTMENT

BRAKE
PEDAL

Free

height
h
mm
in
143
to

149

5

63
to
5

87

Free

play
at

pedal
pad
a
mm
in
I
to
5

0
04
to

0
20

Full
stroke

at

pedal
pad
s

With
brake
booster
mm
in
140
5
51

Depressed
height
d

mm
in

more
than

70
2
76

HAND
BRAKE

Pulling
force

Stroke
kg
lb

mm
in

Number

of
notches

MASTER

CYLINDER

Allowable
clearance
between

cylinder
and

piston

mm
in

BRAKE

BOOSTER

Maximum
vacuum

leakage
15

seconds
after

engine
is

stopped

mmHg
inHg

mm
in

mm
in
Push
rod

length
A

Operating
rod

length
8

I

c

tY

1I1

fF

I

BA290
d

IF

CHECK

VALVE

Maximum
vacuum

leakage
15

seconds
after
500

mmHg

19
69

inHg
pressure
is

applied
mmHg
inHg

BR

17
h

d
1

II

II

d
h

Free

play

V
Free

height

Depressed
height
aR002A

Full
stroke

20
44

93

to
106

3
66

to
4
17

7

to
8

less
than
0
15
0

0059

25

0
98

975
to
10
00
0
3839
to

0
3937

135
5
31

1

B

BR947

10

0
39

Steering
System

6
Reriiovebolt

Securing
worm
shaft

to
rubber

coupling

7
Remove
nut

and
lock

washer

se

curing
gear
arm
to
sector
shaft

Using

Steering
Gear
Arm

Puller

512902000
I

remove

steering
gear

arm

from
sector
shaft

Gear

housinif
I

0

Cearar
8
Remove

bolts

securing
steering

gear
housing
to

body
side
member

and
withdraw

steering
gear
housing

from

engine
compartment

n

ST289

Fig
ST

IB

Removing
Ste

i1l
Gear

Arm

Disassembly

f

Tightening
torque
of
bolts

and
nuts

kg
m
ft

Ib

@
2
0
to
3

0
14
to

22

@
2

0
to
3
0

14
to

22

@
7

0
to
8
0
51

to
58

@
2

0
to
3

0
14
to
22

ST864
1
Lock
nut

2
Filler

plug

3

Adjusting
shim

4

Adjusting
screw

5
Sector

shaft

bushing

6

Steering
gearhou
ing

7
Oil
seal

8
BaU

nut
9
Worm

shaft

10
Wonn

bearing

11
Wann

bearing
adjUsting

shim

12
Rear

cover

13
Oil
seal

14
Sector
shaft

Fig
ST

19

Steeri1l
Gear

SHi
Thoroughly
drail

steCring
gear
oil

by

removing
filler

plug
Place
steer

ing
gear
in

a
vise
with

Steering
Gear

Attachment
KV48100300
in

place

2

Loosen
lock
nut
and

remove
see

tor
shaft
cover

attaching
bolts
After

removing
sector
shaft
with
cover
re

move
cover
from
sector
shaft

by
turn

ing
screw
clockwise

1

Filler

plug

2
Lock

nut

3
Sector

shaft
cover

attaching

bolts

Fig
ST
20

Mounti1l

Steeri1l
Gear

in
a
Vue

3
Remove

rear
cover

securing
bolts

and
detach

rear
cover

4
Remove

bearing
adjusting

shim

s
and

steering
worm

assembly

ST
426

Fig
ST
21

Drawi1l
Steeri1l
Worm

A
em

b
y

DATSUN
210
Model

8310
Series

SECTIONFE

ENGINE
CONTROL
FUEL

EXHAUST
SYSTEMS

CONTENTS

ENGINE
CONTROL
SYSTEM

ACCELERATOR
CONTROL
SYSTEM

FUEL
SYSTEM

REMOVAL

INSPECTION
FE
2

FE
2

FE
4

FE
5

FE
5
INSTALLATION

EXHAUST
SYSTEM

REMOVAL

INSPECTION

INSTALLATION
FE

Ii

FE
7

FE
8

FE
9

FE
9

Engine
Control
Fuel
Exhaust

SYlltems

ENGINE
CONTROL
SYSTEM

ACCELERATOR
CONTROL
SYSTEM

@

s

1

Acce
i
ator

pedal

2
Accelerator

pedal
arm

3

Stopper
bolt

4

Stopper
lock
nut

S

Kickdown
switch
striker

Automatic
transmission

models

only

6
Accelerator
wire
outer
case

1
Accelerator
wire
socket

8
Accelerator

inner
wire

9

Accelerator

pedal
bracket

and
return

spring

10
Kickdown
switch

11
Accelerator

pedal
stopper
rubber

12
Accelerator

pedal
stopper
bracket

H

109
mm
4
29
in

REMOVAL
AND

INSTALLATION

Accelerator
wI
e

I
Disconnect
accelerator
wire
from

carburetor

2
Remove

snap
pin
from

tip
of

pedal
arm
then
disconnect
wire

from

accelerator

pedal
arm

3
Remove

accelerator

pedal

stopper

bracket
from
dash

panel
and

pull
into

driver

compartment

4

To
install
reverse
order
of
Ie

moval

Accelerator

pedal
a

embly

I

Disconnect
accelerator
wire
at

tip

of
accelerator

pedal
arm

2

Remove
screws

securing
accel

erator

pedal
bracket

to

body

3

Remove
accelerator

pedal
from

dash

panel

4

To
install

reverse
order
of
re

moval
I
IJ

1

II

I

V

J

v

I

@

INSPECTION

I
Check

accelerator

pedal
return

spring
for
rust

fatigue
or

damage

Replace
if

necessary

2

Check

accelerator
wire

cases

socket
and

fastening
locations
for
rust

damage
or
looseness

Repair
or

replace

if

necessary

ADJUSTMENT

Accelerator
IInka
e

I
Connect
accelerator
wire
to
car

buretor
and
accelerator

pedal
arm

2

Adjust
dilnension
H
with

stop

per
bolt

as
shown
in

Fig
FE
I

Dimension
H

109mm
4
29
in

FE
2
F
E558

Fig
FE
I

Accelerator
Control

System

Note
After

adjustment
securely

tighten

stopper
bolt
lock
nut

3
Pull

outer
case
to
uP
direction

making
sure
that

throttle
lever
is
re

turned
to

idle

position
Move
back

outer
case
I

mm
0
04
in
from

a

position
where
throttle

lever
starts

moving
and
fasten

outer
case

securely

with

clamp

Q4t

1

Clamp

2
Outer
case

FE1
1

Fig
FE
2

Adju

ting
Accolerator

Linkage

Engine
Control
Fuel
Exhaust

Systems

4
When
accelerator

pedal
is

fully

depressed
make
sure
that
throttle

valve

opens
fuUy

5
After
above

adjustments
have

been
made
make
sure
that
accelerator

linkage

operates
smoothly
without

dragging
Make
sure
that
throttle
lever
returns

securely
to
idle

position
as

soon
as

accelerator

pedal
is
released

K1ckdown
switch

On
the
automatic
transmission

models
it
is
also

necessary
to

adjust

kickdown
switch
The
kickdown

FE
3
switch

adjustment
is
correct
if
kick

down
switch
is
actuated

by
the

stop

per
located

on
the

tip
end
of

pedal

arm
when
accelerator

pedal
is
de

pressed

fuUy
Always
tighten
lock
nut

securely
when

proper
adjustment
is

obtained

Engine
Control
Fuel
Exhaust

Systems

REMOVAL

WARNING

When

replacing
fuel
line

parts
be

sure
to
observe
the

following

a
Put
a
CAUTION
INFLAM

MABLE

sign
in

workshop

b
Be

sure
to
furnish

workshop

with
In

asphyxiator

c
Be
sure
to
disconnect

battery

ground
cable
before

conducting

operations

d
Put
drained
fuel
in
an

explosion

proof
container
and

put
on
lid

securely

FUEL
TANK

Sedan

I

Disconnect
battery
ground
cable

2
Drain
fuel
from
fuel
tank

then

disconnect
fuel
hose

3
Remove

filler
hose

protector

and

inspection
cover
in

luggage
com

i
tl

f

I

Filler
hose

protector

2

Inspection
cover

FE561

Fig
FE
4

Removing
Filler
Hose

Protector
and
Inspection

Cover

4
Disconnect
fuel
filler
hose

vent

hoses
and
fuel
tank

gauge
unit
wire

connector

I

JI

I

2
FE562

3

Fig
FE

5
Di

connecting
Ho
e
and

Connector
5
Remove
fuel
tank

protector

6
Remove
fuel
tank

Hatchback
and

Wagon

I
Disconnect

battery

ground
cable

2
Drain

fuel
from
fuel
tank

then

disconnect
fuel
hose

3

Remove

luggage
carpet
luggage

board

inspection

covef
and
side
finish

er

4
Disconnect
fuel
filler
hose

vent

hoses
and
fuel
tank

gauge
unit
wire

connector
See

Fig
FE

5

5
Remove

fuel
tank

protector

6
Remove
fuel
tank

FUEL
TANK
GAUGE
UNIT

Sedan

1
Remove

inspection
cover
in

lug

gage
compartment
See

Fig
FE
3

2

Disconnect
fuel
tank

gauge
unit

wire
connector

3
Remove
fuel
tank

gauge
unit

Hatchback
and

Wagon

I
Remove

luggage
carpet
luggage

board
and

inspection
cover

2

Disconnect
fuel
tank

gauge
unit

wire

connector

3
Remove
fuel
tank

gauge
unit

CHECK
VALVE

Sedan

I
Remove

inspection
cover
and
fuel

filler
hose

protector
in

luggage
com

partment

2
Remove
check
valve

Hatchback

I
Remove

luggage
carpet
luggage

board
and

luggage
side
finisher

2
Remove
check
valve

Wagon

I
Remove

rear
side
finisher
in

luggage
compartment

2
Remove
check
valve

FE
5
FUEL
TUBE

Fuel
tubes
are
serviced

as
an
assem

bly
so
that
the

replacement
of
fuel

tube

can
be

easily
done
However

do

not
disconnect

any
fuel
line
unless

absolutely
necessary

Drain

fuel
from
fuel
tank

2

Loosen
fuel
hose

clamps
and
dis

connect
fuel
tube

at
each
end

Note

Plug
hose
and
tube

openings
to

prevent
entry
of
dust
or
dirt
while

removing

3
Unfasten

clips
that

hold
tube
on

underbody
and

remove
tube

from
the

car

FUEL

FILTER

I
Disconnect
fuel
hoses
from
fuel

filter

by

removing
clamps

2

Take
out
fuel
strainer
and
discard

it

INSPECTION

FUEL
TANK

Check
fuel
tank
for

cracks
or
defor

mation

If

necessary
replace

FUEL
HOSE

Inspect
all
hoses
for
cracks

fatigue

sweating
or
deterioration

Replace
any
hose
that
is

damaged

FUEL
TUBE

Replace
any
fuel
tube
that

is
crack

ed
rusted

collapsed
or
deformed

FUEL
FILTER

Replace
fuel
filter
at
the

specified

maintenance
interval
or

if
it

becomes

clogged
or
restricted

Fuel
filter
is
of
a

cartridge
type
and

cannot
be
cleaned

Always
replace

with

a
new
one

CHECK
VALVE

1
Blow
air

through
connector

on

fuel
tank
side

A
considerable
resistance
should
be

felt
at
the
mouth
and
a

portion
of
air

Engine
Control

f1lel
Exhaust

Systems

flow
be
directed
toward

atmosphere

side

2

Blow
air

tluough
connector
on

atmosphere
side
Air

flow
should
be

smoothly
directed
toward

fuel
tank

3
If

cbeck
valve
is

suspected
of
not

being
properly
functioning
in

steps
I

and
2
above

replace

To

fuel
tank

FE477
Pressure
valve

Vacuum
valve

Return

spring

Fig
FE
6

Checking
Check
Valve

INSTALLATION

Install

any
parts
of
the
fuel

system

in

the
reverse
order
of

removal
Ob

serve

the

following
notes
Note

a

Install
hose

clamps
securely
Do

not

tighten
excessively
to
avoid

dam

aging
hoses

b
Fasten

clips
holding
fuel
tube
on

underbody
securely
Failure
to
fol

low

this
caution
could
result

in

damage
to
the
surface
of
fuel
tube

c
Do

not
kink
or
twist
hOse
and
tube

when

they
are

routed

d
Run

the

engine
and
check
for

leaks

at
connections

FUEL

TANK

Not

InstaU
fuel
filler
hose
after
fuel

tank
has

been
mounted
in

place

Failure
to
foUow

this
rule
could

result
in

leakage
from
around
hose

connections
Do
not

twist
or
smash

vent
hoses
when

they
are
routed

Be

sure
to
retain
them
with

clips

securely

FE
6
@
Tightening

torque

Drain

plug

1
6

to
2
4

kg
m

112
tn
17
ft
bl

Fuel

tank

0
8

to
1
2

kll
m

15
8
to
8
7

ft
Ibl

FUEL

TANK
GAUGE
UNIT

Note
When

installing
fuel
tank

gauge

unit

aJign
the

projection
of
tank

gauge
unit

with
the
notch
in

fuel

tank
and

tighten
it

securely
Be
sure

to
instaU

tank

gauge
unit
with

O

ring
in

place

CHECK

VALVE

Note
When

installing
check
valve
be

careful
of
its

designated
direction

See

Fig
FE

Engine
Control

fuel
Exhaust

Systems

Non
California
models

except
FU

model

Automatic
transmission

equipped
models

@

REMOVAL

CALIFORNIA

MODELS

AND
FU

MODEL

I

Remove

catalytic
converter
shel

ter
and
rear
exhaust
tube
shelter

2

Temporarily
loosen
bolts

securing

exhaust

mounting
insulator
to

body

and

remove
bolts

securing
muffler

lower

clamp
imd
muffler
to
muffler

upper
clamp

Note
Take
care
Dot
to

drop
muffler

heat
insulator

3

Remove
rear
exhaust
tube
from

catalytic
converter
and
remove
it

from

car
as
follows

I
Remove
bolts

securing
exhaust

mounting
insulator
to

body
and

put

rear
exhaust

tube
on
rear
axle
case

as

shown
in

Fig
FE
9
1

Front
tube

assembly

2

Pre
muff1er

3

Exhaust
tube

clip

4
Momer

wembly

5
Muffler

clamp
ring
rubber

6
Rear

tube

7
Exhaust

mounting
insulator

8
Exha
st
tail

mounting
bracket

9
Exhaust

mounting

1
ttacket
8@

@

4

wp

8

@

Tightening
torque

kg
m
ft
lb

@
2
0
to
2

6

14
to
t9

@
0
8

to
1
2

5
8
to
8
7

@
3
2
to

4
3
23
to
31

FE629

Fig
FE
B
E
haust

System
Non

California
mode
e

cept
FU
modet

FE639

Fig
FE

9

Putting
Rear
E
halUt

Tube

2

Pull
rear
exhaust
tube

assembly

forward

to

place
as
shown
in

Fig

FE
IO
Then

pull
it

further
while

swaying
rear

exhaust
tube

assembly

clockwise

and
counterclockwise

FE

B
II

F

E640

Fig
FE
IO

Removing
Rear

E
xhault

Tube

Assembly

4

Remove
catalytic
converter
from

front

exhaust
tube

5

Temporarily
loosen
nuts

securing

f

root
exhaust
tube

to
exhaust
mani

fold

6
Remove
front
exhaust
tube
from

exhaust

mounting
bracket

7

Remove
bolt

securing
V
bolt

housing

clamp
to

gusset

Engine
Control
Fuel

Exhaust

Systems

8

Remove
front

exhaust
tube

from

exhaust
manifold

NON
CALIFORNIA
MODELS

EXCEPT
FU
MODEL

I

Temporarily
loosen
nuts

securing

front
exhaust
tube

assembly
to

ex

haust
manifold

2
Remove

front
exhaust
tube

as

sembly
from
exhaust

mounting
brack

et

3

Temporarily
loosen
bolts

securing

exhaust

mounting
insulator

to

body

and
remove
bolts

securing
muffler

lower

clamp
and
muffler
to

muffler

upper
clamp

4
Remove
exhaust
tube

clip

5
Break
sealant
off
the
front

tube

to

rear
tube
connection

Note
A

sealant
is

applied
to
the

tube

connections
to
eliminate
the
leak

age
of
exhaust

gases
Observe
the

procedures
outlined
later
in
this

section
as
a

guide

6
Remove
front
tube
from
exhaust

manifold

then
remove
rear
tube

from

car
Refer
to

California
Models
and
FU

Model
for

removal

When

disconnecting
the

exhaust

tube
connections
observe
the

follow

ing
parts

I
Break
old

sealant
off
the

con

nection

by
lightly
tapping
around
the

tube

with
a

hammer
and

twisting

muffler

F

E630

Fig
FE
11

Breaking
Sealant

Fig
FEd
2
2

Using
a
rubber
hammer

tap
on

the

front
end
of
the
muffler
while

pushing
it

toward
rear
The
muffler

assembly
can
then
be
taken
out

FE632

Fig
FE
13

Tapping
Muffler
with

a
Rubber
Hammer

INSPECTION

I
Check

pre
muffler
muffler

as

sembly
and
tubes
for

cracks

damage

or
corrosion

Replace
if

necessary

2

Replace
bracket
and

mounting

rubber
that

are
cracked

fatigued
or

sweated

INSTALLATION

Install
exhaust

system
which
has

been
removed
as
an

assembly
in
re

verse
order
of
removal
Observe
the

following

CALIFORNIA

MODELS

AND
FU
MODEL

1Jl

Tightening
torque

Exhaust
manifold
to

front
tube
nuts

2
0
to
2
6

kg
m

14
to
19
fHb

U
bolt

housing
clamp
to

gusset
bolt

3
2

to
4
3

kg
m

23
to
31
ft
bl

U
bolt

clamp
securing
nuts

1
6
to
2
1

k
l
m

12
to
15
ft

bl

Exhaust

mounting
bracket
to

transmission

nuts

0
8
to

1
2

kg
m

5
8
to
8
7
ft

Ibl

Exhaust

mounting
bracket
to

front
tube
bolt

3
2
to
4
3

k
l
m

23
to
31
ft
Ib

FE
9
CatalytiC
converter
to
front

tube
bolts

3
2
to
4
3

kg
m

23

to
31
ft

Ibl

Catalytic
converter
to

rear

tUbe
bolts

3
2
to
4
3

kg
m

23
to
31
ft

Ibl

Exhaust
tail

mounting
bracket

to

body
bolts

0
8
to
1
2

kg
m

5
B
to
8
7
ft
Ibl

Exhaust

mounting
insulator

to
exhaust
tail

mounting

bracket
nut

0

8
to
1
2

kg
m

5
8
to
8
7
ft
Ib

Exhaust

mounting
insulator
to

rear
tube
nut

O
B
to
1
2

kg
m

5
8
to
8
7
ft
Ib

Catalytic
converter
shelter
bolts

O
B

to
1
2

kg
m

5
8
to
B
7
ft
Ib

Rear
exhaust
tube
shelter
bolts

0
3

to
0
5

kg
m

2
2
to
3
6

ft
bl

Installation

precautions

I

When

assembling
be
careful
not

to
let

gas
leak
from
around
connec

tions
of

exhaust

system
components

Evenly
tighten
nut

securing
exhaust

manifold
to
front
exhaust
tube

2

Always
maintain
sufficient
clear

ance
between
heat
shield
insulators

and

adjacent
parts
See

Fig
FE

I7

3
Be
sure
to
install
new

gaskets
and

bolts
after

removing
following
parts

Front
tube

Catalytic
converter

Rear
tube

4
Install

mounting
parts
as
sub

assembly
on
car

body

I

Always
locate
mounting
rubbers

in
such

way
that

preload
applied
to

them
is

kept
to
minimum

f

Do
not

apply
excessive
load

I

F

E289

Fig
FE
J4

Mounting
Rubbe

Engine
Control
Fuel
Exhaust

Systems

2
For

inStallation
of

inounting
in

sulator

refer
to

Figs
FE
15

and
FE
16

D

l

FE600
2
t
2

mm

0
08
to
0
08

in

Fig
FE
IS

lrutalling
Mounting

lruulator
1
Front

2
to
8
mm

FE501

oS
to
0
31
in

Fig
FE
I6

l
tolling
Mounting

lmulator

2

o

t
J
1

Section
A

A

Oearance
mm

in

1
20
to
30
0
79
to
1
18

2
13
5
to
19
5
0
531
to
0
768

3
20
5
to
26
5

0
807
to
1
43

4
23

to
33
0
91
to
1
30

5
20
to
30
0
79
to

1
18
Note
Aft
instaDation

check
that

mOlmting
brackets

mounting
rub

bers

and

mounting
insoIator
are

free
from
undue

str

If

oYof
liboft

part
is

DOtinstalled

r
r
i
excessM
noises
or
wbra

tions

may
be

transmitted
to
car

body

b
Check
all
tube

colll1ections
for
ell

hanst

gas
leaks
and
entire

system

for
unusual

noises
witb

engine
run

ning

B

A
6

@

Section
B
B

6
Exhaust
fmisher

equipped
models

except

Wagon

20
to
30

0
79
to
1
18

Other
models

22
to
32

0
87
to
1
26

FE633

Fig
FE

I
7

Proper
Clea
nce

for
E
r
Must

System
Californw
models
and
FU
model

FE
tO