1979 DATSUN 210 check engine light

3
way
connector

ck

Air

@
Manometer

Carbon
canister
Emission
Control

System

400
mmH20
15
75

inH20

Check
valve

Fuel

filler
cap

r

EC091A

Fig
EC
I09

Checking
Evaporative
Emiuion
Control

Syatem

FUEL
CHECK
VALVE

I
Blow
air

through
connector
on

fuel
tank
side

A

considerable
resistance

should
be

felt
at
the
mouth
and
a

portion
of
air

flow
be
directed
toward
the

engine

2
Blow
air

through
connector
on

engine
side

Air
flow
should
be

smoothly
direct

ed
toward
fuel
tank

3
If
fuel
check
valve

is

suspected
of

not

being

properly
functioning
in

steps

I

and
2
above

replace

Engine
side
Fuel
tank

side

Q

Evaporative
fuel
flow

Fresh
air

flow

EC090A

Fig
EC
110

Checking
Fuel
Check

Valve
CARBON
CANISTER
PURGE

CONTROL
VALVE

Check
for
fuel

vapor
leakage
in
the

distributor

vacuum
line

at

diaphragm

of
carbon
canister

purge
control
valve

To
check
for

leakage

proceed
as

follows

I
Disconnect
rubber
hose
in
the

line
between
T

connector
and
carbon

canister
at
T
connector

2

Inhale
air
into

the

opening
of

rubber
hose

running
to
vacuum
hole
in

carbon
canister

and
ensure
that
there

is

no
leak

ET349

Fig
EC
lll

Checking
Carbon
Canister

Purge
Control
Valve

EC37
3
If
there
is
a
leak
remove

top

cover
from

purge
control
valve
and

check
for
dislocated
or
cracked
dia

phragm
If

necessary
replace
dia

phragrrt
kit
which
is
made

up
of
a

retainer

diaphragm
and

spring

i

ii

1
Cover

2

Diaphragm

3
Retainer

4

Diaphragm
spring

ET350

Fig
EC
112

Carbon
Canister

Purge

Control
Valve

FUEL
TANK
VACUUM

RELIEF
VALVE

Remove
fuel
filler

cap
and
see
it

functions

properly

I

Wipe
clean
valve

housing
and
have

it
in

your
mouth

2
Inhale
air
A

slight
resistance

ac

companied
by
valve
indicates
that

valve
is
in

good
mechanical
condition

Note
also
that

by
further
inhaling
air

the
resistance
should
be

disappeared

with
valve
clicks

3
If
valve
is

clogged
or
if

no
resist

ance
is

felt

replace
cap
as
an
assem

bled
unit

O

ET500

Fig
EC

1l3
Fuel
Filler

Cap

TERMINAL

Check
terminal
for

damage
and

wear
and

replace
magnetic
switch

assembly
if

necessary

FIELD
COIL

Check
field
coil
for
insulation
If

the
insulation
of
oil
is

damaged
or

worn
it
should
be

replaced

Testing
field
coil
for

continuity

Connect
the

probe
of
a
circuit

tester
or
an
ohmmeter
to
field
coil

two

positive
terminal
of

positive
brush

holder

If
tester
shows
no

continuity
field

circuit

or
coil
is

open

Replace
it

Fig
EE

13

Testing
Field
Coil

for
Continuity

Testing
field

coli
for

ground

Place
one

probe
of
circuit
tester

onto
yoke
and
the
other

of
to
field

coil
lead

positive
terminal

If

very
little
resistance
is

read
field

coil
is

grounded

Replace
it

I

EE017

Fig
EE
14

Testing
Field
Coil

for
Ground
Engine
Electrical

System

BRUSHES
AND
BRUSH

LEAD
WIRE

Check
the
surface
condition
of

brush
contact
and
wear
of
brush
If
a

loose

contact
is
found
it
should
be

replaced

If
brush
is

worn
so
that
its
length
is

less
than

specified
value

replace

Minimum

length
of
brush

Non
reduction

gear
type

12
mm
0
47
in

Reduction

gear
type

11
mm
0
43
in

Check
the
connection

of
lead

clip

and
lead
wire

Check
brush
holders
and

spring
clip

to
see
if

they
are
not
deformed
or

bent
and
will

properly
hold
brushes

against
the
commutator

If

brushes
or
brush
holders
are

dirty
they
should
be
cleaned

BRUSH
SPRING
TENSION

Check
brush

spring
tension

by
a

spring
scale

as
shown
in

Fig
EE
l
5

If
it
is

faulty
replace
it

Spring
tension

Non
reduction

geaf
type

1
4
to
1
8

kg
3
1
to
4
0
Ib

Reduction

gear
type

1
6
to

2
0

kg
3
5
to
4
4
Ib

I

r

4
1

0
5

to
0
8
rom

O

iO

Correct

EE
7
ARMATURE
ASSEMBLY

Check
external

appearance
of

arma

ture
and

oommutator

I

Inspect
commutator
If
the

sur

face
of
commutator
is

rough
it
must

be
sanded

lightly
with
No
500

sand

paper
If

the

depth
of

insulating
mica

is

less
than
0
2
mm
0
008
in
from

commutator
surface

insulating
mica

should
also
be
undercut

so
that
its

depth
is
0
5

to
0

8
mm
0

020
to

0
031
in

The

wear
limit
of
commutator
dia

meter
is
I

mm
0
04
in
If
the

diameter
of
commutator

is
less
than

specified
value

replace
armature

assembly

Diameter
limit

Non
reduction

gear
type

32

mm
1
26
in

Reduction

gear
type

29
mm
1
14

in

I
@

EE018

Fig
EE

15
Inspecting
Bnah

Spring

Tension

c

I

File

Commutator

nt

I

1

11
Mica

Incorrect

EE021

Fig
EE
16

Undercutting
Imulating
Mica

2

Inspect
silldered
conneetibn
of

armature

lead
and

commutator
If

loose
connection
is
found

solder
it

using
resin
flux

3
Armature
test

for

ground

Using
a

circuit
tester

place
one
test

probe
onto
armature
core
or
shaft
and

other
onto
each

commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

L
L

I

EE022

F
EE
17

Teating
Armature

for

Ground

4
Check

armature
for
short

by
plac

ing
it
on

armature
tester

growler

with
a

piece
of
iron

over
arma
t
ure

core

rotating
armature
If
the

plate

vibrates
armature
is

shorted

jeBel

EE023

Fig
EE

18

Testing
Armature
or

Short

5

Check
armature
for

continuity
by

placing
probes
of
tester
on
two

seg

ments
side

by
side
If
tester
shows
no

continuity
the
circuit

is

open

OVERRUNNING
CLUTCH

ASSEMBLY

Inspect
pinion
assembly
and
screw

sleeve
or

reduction

gear
Screw
sleeve

must
slide

freely
along
armature
shaft

splines
or

pinion

gear
shaft
must
slide

freely
through
reduction

gear
If

dam

age
is
found
or
resistance

except
nor

mal
resistance
due
to

spring
felt

when

sliding
it

must
be

repaired

Inspect

pinion
teeth
If
excessive

rubbing
is

found
on

teeth

replace
Flywheel
ring

gear
also
must
be

inspected
Engine
Electrical

System

@

ll

EE278

Fig
EE
19

Overrunning
Clutch

Assembly

1
Pinion

gear

2

Reduction

gear

EE617

Fig
EE
20
Pinion
and

Reduction

Gear

Overrunni11C
Clutch

AS5em

bly

BRUSH
HOLDER
TEST

FOR

GROUND

Using
a

circuit
tester

place
one
test

probe
onto

negative
side
of
brush

holder
and
another
onto

positive
side

If

tester
shows

continuity
brush
hold

er

is
shorted
to

ground
Replace
brush

holder

EE025

Fig
EE

21

Testing
Brush

for

Ground

BEARING
METAL

Non
reduction

gear
type

spect
bearing
metal
for

wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm

0
008
in

replace

metal

EE

8
BAI
L

BEARING

Reduction

gear
type

Holding
outer
race
with

finger

rotate

bearing
to
see
if
there
is

any

play
or
bind
If

necessary
replace

bearing

MAGNETic

SWITCH

ASSEMBLY

I

Using
a
circuit
tester

check
con

tinuity
between
S

terminal
of

mag

netic
switch
and

switch

body
metal

If

continuity
does
not
exist

shunt
coil
is

opened

Replace
switch

assembly

2
In
the

same
manner
as
above

check

continuity
between
terminals

S
and
M

If

continuity
does
not

exist
series
coil
is

opened

Replace
switch

assembly

ASSEMBLY

Reassemble

starting
motor
in
re

verse

sequence
of

disassembly

When

assembling
be
sure
to

apply

grease
to

gear
case

and
rear
cover

bearing
metal
and

apply
oil

lightly
to

pinion

TEST

PERFORMANCE
TEST

Starter
motor
should
be

subjected

to
a
no
load
test
whenever
it

has

been

overhauled

to
ensure
that

its

perfo
rmance
will
be

satisfactory
when

installed
on

engine
Starter
motor

should
also
be

subjected
to
the
test

when
the

cause
of
abnormal

operation

is

to
be
determined
A
brief
outline
of

the
test
is

given
below

No

loadtest

Connect

starting
motor
in
series

willi

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Specified
current
draw
and
rev6lu

tion
in
this
test
are
shown
in

Sp
ci

Cications

REMOVAL

1

Disconnect

battery

negative

cable

2

Disconnect
two

lead
wires
and

oonnector
from
alternator

3

Loosen

adjusting
bolt

4

Remove
alternator
drive

belt

5

Remove

parts
associated
with

alternator
from

engine

6
Remove
alternator

from
car

DISASSEMBLY

I
Remove

through
bolts

Separate

front
cover
with
rotor

from
rear
cover

with
stator

by
lightly

tapping
front

bracket
with
a

wooden
mallet

rnJ

J

i

EE525

Separating
Front

COI
T

Fig
EE

31

2

Place
rear
cover
side
of

rotor
in
a

vise

with
soft

jaw
and

remove

pulley

nuts
Then
remove

pulley
and
fan

from
rotor
shaft

3

Remove

setscrews
from

bearing

retainer
and

separate
rotor
from
front

EE526

Fig
EE
32

Removing

Pulley
and
Fan

tr

s

0
27

Fig
EE
33
Removing
Rotor
Engine
Electrical

System

4
Pull

rear

bearfug
off
rotor

assem

bly
with
a

bearing
puller
or

press

EE037

Fig
EE
34

Pressing
Out

Rear

Bearing

I

EO

Fig
EE

35
Pulling
Out
Rear

Bearing

5

When

removing
IC

regulator

only

proceed
as
follows

I

Using

soldering
iron

disconnect

wire

connecting
diode

set

plate
to

brush
at
brush

terminal

2

Remove

bolt

securing
diode
set

plate
to
rear
cover
side
face

3

Remove
nut

securing
battery

terminal
bolt

4

To
facilitate
removal

s1ighly
lift

stator

coil

together
with
diode
set

plate
from

re
r
cover
Then
remove

screw

connecting
diode
set

plate
with

brush

5

Separate
stator
coil
and
diode

together
with

rear
cover
and

remove

brush
and

IC

regulator

6
Disconnect
stator

coil
lead
wires

from
diode
terminals
with

a

soldering

iron

Remove

screws

securing
brush
re

move
stator
from

rear
cover

EE648

Fig
EE
36

Removing
Stator

Coil

EE
14
7

Disconnect
wire
from
diode
tor

minal
at
brush
terminal
with

soldering

iron

Remove

brush

assembly
with
IC

regulator
by
loosening
screws

8
Remove
diode

holder

by
loosen

ing
screws

acefii
li

E
E649

Fig
EE

37

Removing
Diode
Holder

INSPECTION
AND

REPAIR

ROTOR
INSPECTION

I

Continuity
test
of
rotor
coil

Apply
tester
between

slip

rings
of

rotor
If

there
is

no

continuity
field

coil
is

open

Replace
rotor

assembly

Fig
EE

38

Continuity
Test

of

Rotor
Coil

2

Ground
test
of
rotor
coil

Check

continuity
between

slip
ring

and

rotor
core
If

continuity
exists

replace
rotor

assembly
because
rotor

coil

or

slip
ring
may
be

grounded

EE532

Fig
EE
39
Te

ting
Rotor
Coil

for
Ground

Engine
Electrical

System

6

Tighten
through
bolts

rfl
Tightening
torque

Through
bolts

60
to
70

kg
cm

52
to
61
in
lb
ALTERNATOR
TEST

Before

conducting
an
alternator

test
make
sure
that
the

battery
is

fully

charged

A
30
Volt
voltmeter
and
suitable

INSPECTION
TABLE

With
alternator

aide
L
tenninal

grounded
internal

short
occurs

when
diode
is
short

circuited

@
test

probes
are

necessary
for
the

test

The
alternator

can
be

checked
easi

ly
by

referring
to
the

Inspection
Table

Bumed
out

bulb

Replace

and
Proceed

toUA

Ignition

switch

ON

Check

light

for

operation
Disconnect
Light
OFF

f

Light
OFF
connector
S

L

and

ground

L

lead
wire

Light
ON

Check

light

for

operation
Light
ON

I
Faulty
IC
RG

Replace
Connect
con

nector
S
L

and

ground
F

a1light
Light
OFF

I
FaultyA
C

G

I

Dim

light
for

operation

tf
i
rs

1
I
Faulty
A

C
G

I

Light
ON
I

Contact

positive
lead
of

voltmeter
on
B

lennina
and

negative
lead
to
L
tenninal
Light
ON

1

Engine
idling

Check

light

for

operation

Light
OFF

I
Engine
idling

Measure
the

voltage
across

B

and
L

terminals

Engine
speed

1

500

rpm

Ligh
tin

switch

ON

Check

light

for

operation
r
Dim

light

Light
OFF
Note

1
Use

fully
charged

battery

2

Light
Charge

warning
light

A

C
G
Alternator

parts
except
IC

regu
tor

IC
RG
IC
n

guJator

OK
IC
altemator
is
in

good
condition

3

When

reaching
Faulty
A
C
G
remove

alter

nator

from
car
and
disassemble

inspect
and

correct
or

replace
faulty
parts
Engine
speed

1
500

rpm

Measure
B

terminal
volt

sge

Make
sure
S

terminal
is

con

nected

correctly

4

Method
of

grounding
F

terminal

Contact

tip
of
wire
with

brush
and
attach

wire
to

alternator

body

Suitable
wire
I

Fig
EE
50

Grounding
F
Terminal

5
Terminals

S
L
BA
Tn

and
E
are

marked
on
rear
cover
of

alternator

EEl7
More

thanO
5V

I
Faulty
A
e

G

1

Less
thanO
5V

I
OK

T
Mon
than

15
5V

I
Z
C
RG

I

I3
to
15V

Engine
idling

Lighting

switch
ON

Check

light

for

operation

Light
ON

I
Faulty
A
C

G

I

Light
OFF

I
OK

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

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

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