1979 DATSUN 210 check engine

INSPECTION

I

Disconnect

high
tension

cables

from

spark
plugs
by
pulling
on

boot

not
on
cable
itself

2

Remove

spark

plugs

3

Check
electrodes
and
inner

and

outer

porcelains
of

plugs
noting
the

type
of

deposits
and
the

degree
of

electrode
erosion

Refer
to

Fig
EE

76

Normal
Brown

to

grayish
Ian
de

posits
and

slighl
electrode
wear

indicate
correct

spark

plug
heat

range

Carbon
fouled

Dry
fluffy
carbon
de

posits
on
the
insulator
and
elec

trode
are

mostly
caused

by
slow

speed
driving
in

city
weak

ignition

too
rich
fuel
mixture

dirty
air

cleaner
etc

H
is
advisable
to

replace
with

plugs

having
hotter
heat

range

Oil
fouled

Wet
black

deposits
show

excessive

oil
entrance
into

comb
us

tion
chamber

through
worn

rings

and

pistons
or
excessive

clearance

between
valve

guides
and
stems
If

the
same
condition
remains
after

repair
use
a
hotter

plug

Overheating
White
or

light
gray
insu

lator
with
black
or

gray
brown

spots
and
bluish
burnt
electrodes

indicate

engine
overheating
More

over
the

appearance
results
from

incorrect

ignition
timing
loose

spark
plugs
low
fuel

pump
pres

sure

wrong
selection
of
fuel

a

hotter

range
plug
etc

H
is
advisable
to

replace
with

plugs

having
colder
heat

range

4
After

cleaning
dress
electrodes

with
a
smaU
fme
file
to
flatten
the

surfaces
of
both

center
and
side
elec

trodes
in

parallel
Set

spark
plug

gap
to

specification

5

Install

spark

plugs
and

torque

each

plug

6
Connect

spark
plug
wires

CLEANING

AND

REGAP

Clean

spark
plugs
in
a
sand
blast
Engine
Electrical

System

SPARK

PLUG

Conventional

type

Normal

Overheating

Multi

gap
type

Nonnal

Overheating

type
cleaner
Avoid
excessive

blasting

Clean
and
remove
carbon
or
oxide

deposits
but
do
not
wear

away
porce

lain
If

deposits
are
too
stubborn

discard

plugs

After

cleaning
spark

plugs
renew

firing
surface
of
electrodes
with
file

mentioned

above
Then
check

spark

plug
gap
with
wire

feeler

gauge
All

spark
plugs
new
or
used

should
have

the

gap
checked
and
reset

by
bending

ground
electrode

EEOSO

Fig
EE
77
Setting
Spark
Plug
Gap

Except
FU
model

EE
29
Carbon

fouled

EE079

Worn

Carbon

fouled

Worn

EE601

Fig
EE

76

Spark

Plug

EE586

Fig
EE
78

Setting
Spark
Plug

Gap
FU
models

Engine
Electrical

System

III

ALTERNATOR

Including
voltage
regulator

Condition

No

output

Excessive

output

Low

output

Noisy
alternator
Probable
cause

Sticking
brushes

Dirty
brushes
and

slip
rings

Loose
connections

or
broken
leads

Open
stator

winding

Open
rotor

winding

Open
diodes

Shorted
diodes

Shorted
rotor

Shorted
stator

Ground
BAT

terminal

Broken
fan
belt

Voltage
regulator
breakdown

Poor
connection
of
alternator

S
terminal

Open
diode

Loose
or
worn
fan
belt

Slicking
brushes

Low

brush

spring
tension

Voltage
regulator
breakdown

Dirty

slip
ring

Partial
hort

ground
or

open
in

stator

winding

Partially
shorted
or

grounded
rotor

winding

Open
or

damaged
diode

Loose

mounting

Loose
drive

pulley

Broken
ball

bearing

Improperly
seated
brushes

EE

36
Corrective
action

Correct
or

replace
bru
hes
and
brush

springs

Clean

Retigliten
or

older
connection

Replace
leads
if

necessary

Repair
or

replace
stator

Replace
rotor

Replace

Replace

Replace
rotor

Replace

Replace
insulator

Replace

Check

regulator

operation
and

repair
or

replace
a

required

Correct

Replace

Retighten
or

replace

Correct
or

replace
brushes
and

springs
if

necessary

Replace
brush

spring

Check

regulator
operation
and

repair
or

replace
as

required

Clean

Replace
tator

Replace
rotor

Replace
diode

Retighten
bolts

Retighten

Replace

Seat

correctly

Engine
Electrical

System

IV
IGNITION
CIRCUIT

When

engine
does
not

start

If

there
is
no

problem
in
fuel

system

ignition
system
should
be

checked
This
can
be

easily
done

by

detaching
a

high
tension
cable
from

distributor

starting
engine
and
ob

serving
oondition
of

spark
that

occurs
between

high
tension
cable
and

engine

block
After

checking
this

repair
as

necessary
tery
and
anti
dieseliilg
wlenoid

valve
connector
to
cuI
off

supply

of
fuel
10

engine
Then
observe
the

condition
of

sparks
while
starter

motor
is
in

operation

Note
Turn

ignilion
switch
off
and

disconnect
ground
cable
from
bat

Condition
Location

Probable
cause
Corrective
action

No

spark
at
all
Distributor

Breakage
of
lead
wire
on
low
tension

side

Repair

Poor
insulation
of

cap
and
rotor
head

Replace

Open
pick
up
coil

Replace

Air

gap
wider
than

specification
Adjust

Ignition
coil
Wire

breakage
or
short
circuit

of
coil

Replace
with
new
one

High
tension
cable
Wire

coming
off

Repair

Faulty
insulation

Replace

IC

ignition
unit

Faulty
IC

ignition
unit

Replace

Breakage
of
circuit

Replace

Detached
connection

Repair

Spark
length
Spark
plugs
Spark
plug

gap
too

wide
Correct
or

replace

More
than
6

mm

Too

much
carbon
Clean
or

replace

0
24
in

Broken
neck

of
insulator
Replace

Expiration
of

plug
life

Replace

Distributor
Air

gap
too
wide

Correct

IC

ignition
unit

Faulty
IC

ignition
unit

Replace

Breakage
of
circuit

Replace

Detached
connection

Repair

EE
37

INSTALLATION

Install
in
the

reverse
order

of
re

moval

observing
the

following

Note

When

inslal1ing
be
sure
to

check
thaI
electrical
harnesses

are

connected
ly

1
When

installing
first
secure
rear

engine
mounting
member
to

body

2
Refer
to

applicable
section
when

installing
and

adjusting
any
parts

Adjust
clutch

pedal
free
travel
Re

fer

to
Clutch
Pedal
Free
Travel

Section
CL
for
installation
and

adjustment

Adjust
accelerator
control

system

Refer
to

Engine
Control

System

Section
FE
for

adjustment

For

installation
of
air
conditioner

compressor
and
belt

adjustment

Refer
to
Idler

Pulley
and
Com

pressor
Drive
Belt

for

adjustment

of
belt
tension

3
When

installing
exhaust
front

tube
on
exhaust
manifold
be
sure
to

use
new

gasket

4

When

installing
hood

following

engine
installation
be
sure
that

it
is

properly
centered
and
that
hood

lock

operates
securely
Refer
to
Hood

See

tion
BF

for

adjustment
Engine
Removal
Installation

ENGINE
MOUNTING

INSULATOR

FRONT
INSULATOR

Removal

Disconnect

battery
ground
cable

2

Suspend
engine
with
wire

or

chain

3

Remove
front

engine
mounting

insulator

lower
and

upper
nuts
on

both
sides

4
Make

sure
that
wire

or
chain
used

to

suspend
engine
is

positioned

prqper

ly
so
that
no
load
is

applied
to

insulators
and
remove
nuts

complete

ly

5

Lift

up
engine
and

separate
in

sulators

from

engine
mounting
rack

ets

Inspection

If
there
is

damage
deterioration
or

separation
of
bounded
surface
re

place

Installation

Install
front
insulators
in

reverse

sequence
of
removal

noting
the
fol

lowing

1
Do
not
confuse

right
and

left

insulators
R

right
side
or

L

left
side
identification
mark
is

stamp

ed
on
each
insulator

2
Install
front
insulator
so
that

ER
5
position
pin
is

projected
upward

3

Tighten
the

bolts
and

nut
correct

ly
and

securely
See

Fig
ER
I

REAR

INSULATOR

Removal

l

Support
transmission

weight
with

ajack

2
Remove

nuts

securing
rear

engine

mounting
insulator
to

mounting
mem

ber

3
Remove

bolts

connecting
rear
en

gine
mounting
insulator
to
transmis

sion

reaf
extension

housing

4

Jack

up
the

transmission
a
little

and

remove
insulator

Inspection

If
there
is

damage
deterioration
or

separation
of

mating
surface

replace

Installation

Install
rear

engine
mounting
mem

ber
and

insulator
in

reverse
order

of

removal

noting
the

following

I

Install
insulator
in

place
so

that

direction
of
mounted

insulator
is

same

as
that
in

Fig
ER

2

Tighten
nuts
and

bolts

correctly

and

securely
As
for

tightening
torque

see

Fig
ER
l

CLUTCH
DISC
AND

COVER

REMOVAL

1
Remove
transmission
from
en

gine
Refer
to

Removal
Section
MT

2

Insert
Clutch

Aligning
Bar

ST20610000
4

speed
tranSmission
or

KV30100IOO
5

speed
transmission

into

clutch
disc
hub

until
it

will
no

longer
gd
It
is

important
to

support

weight
of

clutch
disc
in
the

steps
that

follow

ST20610000

4

peed

transmission

KV30100100

S

peed

transmission

S

cL194

Fig
CL
W

Supporting
Clutch

Assembly
Clutch

CLUTCH
UNIT

n

j

3

Loosen
bolts

attaching
clutch

cover
to

flywheel
one
turn

each
at
a

time
until

spring

pressure
is
released

Be
sure
to
turn
them

out
in

a
crisscross

fashion

4
Remove
clutch
disc
and
cover

assembly

INSPECTION

Wash
all
disassembled

parts
except

disc

assembly
in
suiiable

cleaning
sol

vent
to
remove
dirt
and

grease
before

making
inspection
and

adjustment

FI
1
and

pressure
plate

Check
friction
surface
of

flywheel

and

pressure
plate
for

scoring
or

roughness
Slight
roughness
may
be

smoothed

by
using
fine

emery
cloth
If

surface
is

deeply
scored
or

grooved

the

part
should
be

replaced

Clutch
disc
sembi

Inspect
clutch
disc
for
worn
or

oily

facings
loose
rivets

and
broken
or

loose

torsional

springs

CL
7
1

Clutch
disc

assembly

2

Clutch
cover

assembly

3
ReleaJe

bearing

4

Bearing
sleeve

S

Withdrawal
lever

6

Withdrawa11ever
ball

pin

7
Return

spring

CL370

Fig
CL
9
Clutch
Unit

I
If

facings
are

oily
disc
should
be

replaced
In

this
case

inspect
transmis

sion

front
cover
oil
seal

pilot
bushing

engine
rear
oil
seals
and
other

points

for
oil

leakage

2
The

disc
should
also
be

replaced

when

facings
are
worn

locally
or
worn

down
io
ihe

specified
limit

Wear
limit
of

facing
A

Les
than
0
3
mm
0
012
in

9111

I

A

M

m

C
L336

Fig
CL
ll

M
asur

ng
Clutch

Facing

Wear

Condition

Clutch

slips

Clutch

drags
Clutch

TROUBLE

DIAGNOSES
AND

CORRECTIONS

Probable

cause
and

testing
Corrective
action

Slipping
of
clutch

may
be
noticeable

when

any
of
the

following
symptoms
is

encountered

during
operation

I
Car
will
not

respond
to

erigine
speed
during
acceleration

2
Insufficient

car

speed

3
Lack
of

power

during
uphill

driving

Some
of
the

above
conditions

may
also
be
attributable
to

engine
problem
First
determine

whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear

and
or

overheating
will
occur
on
clutch

facing
to
such

an
extent
that
it
is

no

longer
serviceable

TO

TEST
FOR
SLIPPING
CLurCH

proceed
as
follows

During
upgrade
havelling
run

engine
at

about
40
to
50

km
h
25
to
31
MPH

with

gear
shift

lever
in

3rd
speed
position
shift
into

highest

gear
and
t
the
same
time

rev

up
engine
If
clutch

is

slipping
car
willnot

readily
respond
to

depression
of
accelerator

pedal

Clutch

facing
warn

excessively

Oil
or

grease
on
clutch

facing

Warped
clutch

cover
or

pressure
plate
Replace

Replace

Repair
or

replace

Dragging
clu

tch
is

particularly
noticeable

when

shifting

gears
especially
into

low

gear

TO
TEST
FOR

DRAGGING
CLurCH

proceed
as
follows

I
Start

engine

Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine

speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is
heard
when

shifting

gears
from
Neutral
into

Reverse

2

Stop
engine
and
shift

gears
Conduct
this
test
at
each

gear
position

3
In

step
2

gears
are
shifted

smoothly

except
1st

speed
position
at

idling

a
If

dragging
is

encountered

at
the
end
of

shifting
check
condition
of

synchro

mechanism
in

transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4

Push

change
lever
toward
Reverse
ide

depress
pedal
to
check
for
free

travel
of

pedal

a
If

pedal
can
be

depressed
further
check
clutch
for

condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5

below

5
Check

clutch
control

pedal
height
pedal
free

play
free

travel
withdrawal
lever

play
etc

If

any
abnormal

condition
does
not
exist
and
if

pedal
cannot
be

depressed
further
check

clutch
for

condition

Clutch
disc

runout
or

warped

Wear
or
rust

on
hub

splines
in

clutch

disc

Diaphragm
spring
toe

height
out
of

adjustment
or
toe

tip
worn

Worn

or

improperly
installed

parts
Replace

Clean
and
lubricate

with

grease
or

replace

Adjust
or
replace

Repair
or

replace

CL12

I
ht
2nd

fork
r

2

3rd

top
fork
rod

3
Reverse
fork
rod

4

Retaining

pin

5
I
t

2nd
shift

fork

6
3rd

top
shift
fork

7

Checking
ball

plug

8

Check
ban

spring

9
Check
ball

10
Interlock

plunger

11

S

topper
ring

12

Shift
rod
A
bracket

13
Reverse

shift
fork

14
Lock

pin

15

Striking
lever
Manual
Transmission

16

Striking
rod

17
Return

spring
plug

18
Reverse

check

spring

19
Return

pring

20

Plunger

21
D

ring

22
Stopper
pin
bolt

23

Striking
guide
assembly

24

Striking
guide
oil
seal

REMOVAL

To

dismount
transmission

from
the

car

proceed
as
follows

Disconnect

battery
ground
cable

2

Remove
console
box

and
detach

rubber
boots
if

so

equipped

3

Place
transmission
control
lever

in

neutral

position
and
remove
it

m

TM781

Fig
MT
4

Removing
Control
Lever
@

@

25
Control
lever

bushing

26

Expansion
plug

27
Control

pin
bushing

28
Control
arm

pin

29
Control
lever
o

Tightening
torque
kg
m
ft
lb

@
0
5
to

0
8
3

6
tn
5
8

@
1
3
to
1
7

9
to
12

Fig
MT
3
F4W60L
Tra11lmiBSion

Shift
Control

Components
TM094A

4
Jack

up
the

car
and

support
its

weight
on

safety
stands
Use
a

hy

draulic
hoist
or

open
pit
if
available

Make

sure
that

safety
is

insured

5

Disconnect
front
exhaust
tube

and

remove
bolt

securing
exhaust

mounting
bracket
from

exhaust
front

tube

side

6

Disconnect
wires
from

reverse

back

up
lamp
switch

7

Disconnect

speedometer
cable

from
rear
extension
At

the
same
time

removey

top
detecting
switch
if
so

equipped

8
Remove

propeller
shaft

Refer
to
Removal
Section
PO

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from
flow

ing
out

MT
3
9

Remove
clutch

operating
cylinder

from
transmission
case

10

Support
engine
by
placing
a

jack

under
oil

pan
with
a
wooden

block

used
between
oil

pan
and

jack

CAUTION

00
not

place
the

jack
under
the

oil

pan
drain

plug

11

Support
transmission
with
a

transmission

jack

12

Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

V

Synchronizers

I
Remove

spread

springs

j
and

take

out

shifting

inserts@

2

Separate
coupling
sleeve

@
from

synchro
hub

@

0
t
j

@

O
LJ

J
1

ID

4

Synchro
hub

S
Baulk

ring
1

Spread

spring

2

Shifting
insert

3

Coupling
sleeve

TMSOl

Fig
MT
30
Synchronjzer

Assembly

ADAPTER
PLATE

DISASSEMBLY

1
Remove
reverse
idler
shaft

snap

ring
using
snap

ri
1g
pliers
and

draw

out
reverse
idler
shaft

by
lightly

tap

ping
the
shaft

end
with
a

soft
hammer

k

Fig
MT
31

Removing
Reverse

Idler

Shaft
Snap

Ring

REAR

EXTENSION

DISASSEMBLY

I

Remove
lock

pin
nut
and

lock

pin

from

striking
1

lever

Remov

str

iking

lever

TM803

Fig
MT
32

Removing
Lock
Pin

Nut
Manual

Transmission

2

Remove

striking
rod
and

stiking

guide
from
rear

end
of
rear

extension

j

1
Lock

pin

2

Striking
lever

3
Return

spring
plug

4

Con
trollevcr

5

Striking
rod

6

Striking
fod

guide

7
Control
Ie
o
eI

pin

8

Stopper
pin
bolt

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and

check
for
wear

damage
or

other

faulty
conditions

CAUTION

a
Be
careful
not

to

damage
any

parts

with

scraper

b
Do
not
clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE
AND

REAR
EXTENSION

I
Check

for
cracks
which

might

cause
oil
leak
or
other

faulty
condi

tions

2

Check

mating
surface
of
case
to

engine
or

adapter
plate
for
small
nicks

projection
or

sealant

Remove
all

nicks

projection
or

sealant
with
a

fine
stone

3
If
rear
ext

nsion

bushing
is
worn

or
cracked

replace
it

as
an

assembly
of

bushing
and
rear
extension

BEARING

Thoroughly
clean

bearing
and

dry

with

compressed
air

2

When
race
and
ball
surfaces

are

MT
9
Note
Do

not
remove
rear
extension

bushing
from
rear
extension

@

TM804

Fig
MT
33
Shifting
Mechanism

worn
or
rough
or
when
balls
are

out
of
round
or

rough
replace
bearing

TM372

Fig
MT
34
In

pecting
Ball

Bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND
SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or

cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
or

worn

spline
if

necessary

replace

3
It
is

necessary
to

measure
end

play
before

disassembling
mainshaft

and
after

reassembling
rnainshaft

Tighten
mainshaft
lock
nut
to

speci

fied
limit
and
measure
end

play
to
in

sure
that
it
is

within

specified
limit

If
end

play
is
not
within

specified

limit
disassemble
and
check

parts
for

condition

Replace
any

part
which
is

worn
or

damaged