1979 DATSUN 210 engine oil

2

Install

piston
rings

Install
so
that

stamped
mark
on

ring
faces

upward

Note

a
There
are
two

types
of

top
rings

One
is
conventional

special
cast

iron

ring
the
other
is
steel

ring

which

is
called

a

high
power

ring

b

Second

ring
has

larger
taper
surface

than

top
ring

c
In
combined
oil

ring

upper
rail
is

same
as
lower

one

I
lnT

10

EM158

Fig
EM

57
Installing
Piston

Ring

3

Fix

bearings
on

connecting
rod

and

connecting
rod

cap

VALVE
ROCKER
SHAFT

ASSEMBLY

Install

parts
as
shown

in

Fig

EM
58
in

place
on
rocker
shaft

@

EM491

Fig
EM
58
Valve
Rocker

Shaft

As

embly

ENGINE

ASSEMBLY

I
The
first

step
in

engine
assembly

is

to
bolt

Engine
Attachment

KV
10
102500
to

right
hand
side

of

cylinder
block
In
succession
install

block
in

Engine
Stand

ST0501S000

with

engine
bottom

up

2

Apply
a

light
coat
of

engine
oil
to
Engine
Mechanical

sliding
surfaces
of
valve
lifters
insert

lifters
in

holes
in

cylinder
block

3

To
install
camshaft
be
sure
to

coat
sliding
surfaces
of
camshaft
bush

ings
with

a
light
coat
of

engine
oil

Insert
camshaft
in

cylinder
block
from

front
side
of

engine
exercising
care

not
to

damage
camshaft

bushings

4

Install
camshaft

locating
plate

and

tighten
bolts
to

specified

torque

i
l

Tightening
torque

Camshaft

locating
plate

0
4
to
0

5

kg
m

2
9
to
3
6
ft

Ibl

Note
Set

locating
plate
so
as
the

Lower
mark
comes
to

engine

bottom
side

Fig
EM
59

Installing
Camshaft

Locating
Plate

5

Install
baffle

plate
and
steel
net

6
Set
main

bearings
at

proper
por

tion
of

cylinder
block
and

caps

No
1
2
3

0

0
0

0
0
0

I
I

J

upperW

r

Lower
J

EM492

Fig
EM
60
Main

Bearings
and

Caps

Note

a
Center

bearing
No
3
is

a

flanged

type
for
thrust
force

b
Two
internal

bearings
No
2
and

No
4
are
of
the

same

type

c
Front

bearing
No
I
is
the

same

type
as
rear

bearing
No
5

EM

13
d
All

bearings

except
No
2
and
No
4

are
not

interchangeable
between

upper
and
lower

bearings

7

Apply
engine
oil
to
main

bearing

surfaces
on
both
sides
of

cylinder

block
and

cap

Install

crankshaft

8

Install
main

bearing
cap
and

tight

en

bolts
to

specified
torque

lil

Tightening
torque

Main

bearing
cap

5
0

to
6
0

kg
m

36

to
43

ft
lb

Note

a

Apply
seal
to
each
rear
main
bear

ing
contact
comer
of

cylinder
block

as
shown
in
F
EM

61

EM493

Fig
EM
6

Applying
Sealant

b

Arrange

parts
so
arrow
mark

on

bearing
cap
faces
toward
front
of

engine

c

Prior
to

tightening
bearing
cap

bolts

place
bearing
cap
in

proper

position
by

shifting
crankshaft
in

axial
direction

d

Tighten
bearing
cap
bolts

gradually

in
two
to
three

stages
outwardly

from
center

bearing
in
the

sequence

shown
in

Fig
EM
62

e
After

securing
bearing

cap
bolts

ascertain
that
crankshaft
turns

smoothly

@I

EM494

Fig
EM

62
Torque
Sequence
of

Cap
Bolts

9
Make
SUre
there
is

proper
end

play
at

crankshaft

Crankshaft

end

play

0
05toO
15mm

0
OO20
to
0

0059
in

laJlk
h
end

play

J

EM486

Fig
EM

63

Checking
Crank

luJft

End

Play

10

Install
rear

oil
seal

using
suitable

drift

Fig
EM

64
n

talling
Rear
Oil
Seal

II
Install
rear

plate

12
Install

flywh
el

secwely
and

tighten
bolts
to

specified
torque

dl
Tightening
torque

Flywheel
and
drive

plate

A
14

engine
fixing
bolts

8
0

to
9

0

kg
m

58
to

65
ft
Ib

Drive

plate
A
15

engine

fixing
bolts

8
5

to
9
5

kg
m

61
to
69
ft
b

Fig
EM
65
n

talling
Flywheel

13

Rotate

engine
quarter
turn

and

install

piston
rod

assembly
using
Pis
Engine
Mechanical

ton

Ring
Compressor
EM03470000

EM497

Fig
EM
66

tolling
Platon
Rod

Assem

bly

Note

a

Insert

pistons
in
L

r
nding
cyl

inders

b

Apply
engine
oil

to

sliding
parts

c

Arrange
pistons
so
number

stamped

on

piston
head
faces
to
front
of

engine

d
Before

installing
piston
piston
rings

should
be

positioned
as
shown
in

Fig
EM
67

Second

ring

Oil

ring
lower
rail

EM49B

Fig
EM
67

Positioning
Piston

Ring

Gap

14

Apply

engine
oil
to

bearing

surfaces

dl
Tighte
ning
torque

Connecting
rod

cap
nuts

3

2
to
3

8

kg
m

23
to
27
ft
b

EM499

Fig
EM

68

Tightening
Connecting

Rod

Cap

Note

Am11
connecting
rods
and

connecting
rod

caps
so

cylinder

numben
face
in
same
direction

EM
14
I

S
Make
sure
there

exists

proper

end

play
at

connecting
rod

big
end

See

Fig
EM41

Big
end

play

0
1
to
0
2

mm

0
004
to
0
008
in

16

Insert
crank

sprocket
keys
in

keyways
of
crankshaft

Install
cam

shaft
and

crankshaft

sprockets

tempo

rarily
for

adjustment
of
tooth

height

by
using
adjusting
washers

Height
dif

Less1
h
l11

0

5
mm
0

020
in

Adjusting
washer

thickness

0
5
mm

10
020

in

EM500

Fig
EM
69

Adju
ting
Sprocket

Tooth

Height

17
Install

tinting
chain
and
cam

shaft

sprocket
with
their

markings

properly
aligned
See

Fig
EM
70

Then
set
No
I

piston
at
T
D
C
on

compression
stroke
See

Fig
EM
71

Oil

sprocket
teeth
and
chain
with

engine
oil

Match
mark

Key
groove

EM501

Fig
EM
70

Aligning
Markinga

Note
Make
sure
camshaft

sprocket

dowel
hole
and
crankshaft

sprocket

key
are

in
line
and
both
dowel
hole

and

key
are
located
downward

m
k

camSM9tJ
down
hole

Key
groove

EM767

Fig
EM
11

Setting
No

I
Piston

atT
D
C

18

Tighten
camshaft

sprocket
bolt

ifl

Tightening
torque

Camshaft

sprocket
bolt

4
to
4
8

kg
m

29

to
35
fHbl

EM502

Fig
EM
72

Tightening
Camshaft

Sprocket
Bolt

19
Install
chain
tensioner
and

tight

en
tensioner

attaching
bolts

ifl

Tightening
torque

Tensioner

enaching
bolt

0
6
to
0
8

kg
m

14
3

to
5
8
ft
b

EM503

Fig
EM
73

Installing
Chain

Tensioner

20
Check

projection
L
of
ten

sioner

spindle

If

projection
L
exceeds
the

speci

fied
limit

replace
chain
Engine
Mechanical

Correct

projection
L

Less

than

15
mm
0
59
inl

lEM504

Fig
EM
74

Checking
Projection
of

Tf

nsioner

Spindle

21

Correctly
install
oil
thrower
in

front
of
camshaft

sprocket

22
Press
new
oil
seal
in

timing
chain

cover
F
ran
t

cover
oil
seal
should
be

replaced
when
front
cover
is

disassem

bled

23
Install

timing
chain
cover
with

gasket
in

place

Note
When

inatalling
oil
seal

apply

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and
fold

ed

lip
Also

apply
coating
of
oil
to

periphery
of
oil
seal

ifl
Tightening
torque

Timing
chain

cover
bolts

0
5
to
0
7

kg
m

3
6
to
5
1
ft
Ib

Z5

1
o

j

I

t
f

4

EM455

Fig
EM
75

Installing
Timing
Chain

Covtr

24
Install
water

pump
with

gasket

in

place

ifl
Tightening
torque

Water

pump
attaching
bolts

0

9
to
1
4

kg
m

16
5
to
10
1
ft
bl

25
Install
crank

pulley
then
con

firm
and
set
No
I

piston
at
T

D
C
on

compression
stroke

EM
15
ifl
Tightening
torque

Crank

pulley
nut

15to
20

kg
m

108
to
145
ft
b

26
Invert

engine
Install
oil
stniiner

and
oil

pan
using
new
gasket
and

oil

seal

Note
Give

coating
of
sealant
to
seam

between
oil

pan
gasket
and
oil

pan

oil
seal

ifl
Tightening
torque

Oil

pan
bolts

0
4
to
0
6

kg
m

12
9
to
4
3
ft
lb

27
Install

gasket
and

cylinder
head

Note
Do
not

apply
sealant
to

any

other

part
of

cylinder
block

and

head
surface

28

Tighten
cylinder
head
bolts

ifl

Tightening
torque

Cylinder
head
bolts

7
0
to
7
5

kg
m

51
to
54
ft

IM

Note

a
One

of

cylinder
head
bolts
is
smal

ler

in
diameter
than
others
and
has

a
hollow
head
It
should
be
install

ed
on

right
side
center
of

cylinder

head

b

Tightening
should
be
made
in

two

or
three

steps
finally
torquing
to

specification

c

Retighten
cylinder
head
bolt
after

engine
has
been
warmed

up

Refer
to
Carburetor
Idle
R
P
M

and
Mixture
Ratio
EF
Section
for

Adjustment
and

Inspection

EM505

Fig
EM
76
Cylinder
Head
Bolt

Tightening
Sequence

29

Apply
engine
oiho
both
ends

of

push
rods
and
insert
in

proper
se

quence

30

Apply

engine
oil
to

valve
stem

end
and

rocker
arm
contact

surfaces

Position
rocker
shaft

assembly
on

cyI

inder
head

31

Tighten
rocker
shaft
bracket

bolts
to

specified
torque

fJ

Tightening
torque

Rocker
shaft
bracket
bolts

2
0
to
2
5

kg
m

14
to
18
ft

b

Note

Tightening
should
be
done

in

two
or
three

stages
outwardly
from

center
bracket

EM506

Fig
EM

77
Rocker

Shaft
Bolt

Tightening
Sequence

32

Adjust
valve

clearance
to

speci

fied
value

Note

a
First

set
clearance
to
0

25

mm

0
0098

in
when

engine
iscold

b
After

engine
has
been
assembled

warm
it

up
for
at
least
several

minutes

finally

adjust
clearance
to

specification
For
details
refer
to

Adjusting
Intake
and
Exhaust
Valve

Clearance
in
ET

Section

EM507
or

Wrench

2
Screwdriver

3
Feeler

gauge

Fig
EM
78

Adjusting
Value

Clearance
Engine
Mechanical

Valve

clearance

Intake
and

exhaust

hot

0
35
mm
0
014
in

cold

0

25
mm
0
010
in

fJ

Tightening
torque

Velve
rocker

adjusti
g
nut

1
6
to
2
2

kltm

12
to
16
ft
b

33

Install
rocker

cover

34

Install
intake
and

exhaust
mani

folds

fJ

Tightening
torque

Manifold
nuts

1
5
to
2
0

kg
m

11
to
14

fHb

Note

When

installing
intake
and
ex

haust

manifolds
locate
bolt

in

center
of

fitting
hole

EM528

Fig
EM
79

Installing
Manifolds

35
Install
E
G
R
control

valve

36

Install
baffle

plate
and

carbure

tor

fJ
Tightening

torque

Carburetor
nuts

0
4

to
0
6

kg
m

2
9
to
4
3
ft

Ibl

37
Install
vacuum

control
valve
as

sembly
and
bracket

38
Install

air
cleaner

bracket
and
air

cleaner

39

Connect
air

vacuum
and

blow

by
hoses
to
air

cleaner

40
Install

pipe
connector
to
control

valve
hose
and

engine

mounting
brack

etLR

41

Install

distributor

EM

16
CAUTION

a
8e
sure
to
set
No
1

piston
to

LD
C
of

compression
stroke

b
Before

instaliation
return
distribu

tor
rotor

approximately
30

degrees

from
its
correct

position
Insert

distributor

meshing
distributor

drive

gear
and
driven

gear

c
After
installation
distributor
rotor

should

align
with

mark
on
rotor

cap

J

No
1

mark

EM508

Fig
EM

80
Cornct
P05ition

of

Rotor

42

Dismount

engine
from

Engine

Stand

ST0501S000
and

place
it

on

suitable

engine
stand

Re

move

Engine
Attachment

KVlOI
2500

43

Install

spark
plugs
and

engine

mounting
bracket
R
H

44

Install
oil

pump
and
ftIter

assem

bly

45
Install
thermostat

and
water

outlet

46
Install
fuel

pump
and
fuel

lines

Do
not

forget
to

install

spacer
and

gasket

47

Install
distributor
vacuum
line

48
Install
distributor

cap
and

high

tension

cables
as
an

assembly
Connect

high
tension

cables

49
Insert

oil
level

gauge

50

Install
fan
fan

pulley
and
fan

spacer

Lock
bolt

by
bending
lock

washers

51

Install
alternator
bracket

adjust

ing
bar
water

pump

pulley
alternator

Engin
Mechanical

SERVICE
DATA
AND
8PECIRCATION8

GENERAL
SPECIFICATIONS

Engine
model
AI5

Cylinder
arrangement
4

in
line

Displacement
cc
cu
in

1
397
85
24

I
488
90
80

Bore
and

Stroke
mm
in
76
0
x
77
0
76
0
x
82

0

2
992
x

3
031
2
992
x

3
228

Valve

arrangement
OR
V

Firing
order
I

3
4
2

Compression
2

Number
of

piston
rings

Oil

Number
of

main

bearings
5

Compression
ratio

California
and
FU
model

of
Non
California

Non
California

except
FU
model

and
Canada

EM

18
8
9

8
5

Engine
Mechanical

Piston

ring

Unit
mm
in

Standard
Wear
limit

Top
0
04

to
0
07

0

0016
to

0
0028

0
10
0
0039

Side
clearance

2nd
0
03
to

0
06

0
0012
to
0
0024

Oil
Combined

Top
0
20

to
0
35

0
0079

to
0

0138

Ring
gap
2nd
0
15
to
0
30

1

00
0
0394

0

0059
to

0
0118

Oil
0
30
to
0
90

rail

ring
0

0118
to
0

0354

Piston

pin
Unit

mm
in

Interference
fit
of

piston

pin
to

connecting
rod
18

995
to
19
000

0

747
to

0
748

63

00
to

63
25

2
480
to
2
490

19
003
to
19

012

0
748
to
0

749

0

008
to

0
012

0

0003
to

0
0005

0
017

to
0

035

0

0006
to
0
0013
Piston

pin
diameter

Piston

pin
length

Piston

pin
hole
diameter

Piston

pin
to

piston

clearance

CONNECTING
ROD

Unit
mm

in

Standard
Repair
replace

limit

Center
distance
132
97
to
133
03

5

2350
to
5
2374

Bend

per
100
mm
or

3

94
in

length
Less
than

0
05
0
0020

0
10

0
0039

Torsion

per
100
mm
or

3
94
in

length

Big
end

play
Less
than

0
07
0
0028

0
1
to
0
2

0
004
to
0

008
0
4
0
016

EM
27

Engine
Mechanical

CRANKSHAFT

1

Q
I

j
s

l

s

A
B
AI4

AI5
Unit
mm
in

Journal

diameter
A

c
r
49
951
to
49

964

h9666
to
1
967
1

Pin
diameter
8
44
961

to
44

974

I
7701
to
1

7706

EM777
8
38
45

to
38
55

1
5138
to
1
5177

Standard

Out
of
round
X
Y

Taper
A
B

Taper
and
out
of
round

of

Less
than

A
B
journal
and

crank

pin

0
005
0
0002

0
A
B
X
Y

Crankshaft
bend
Less
than

0
025
0
0010

Crankshaft
free
end

play
0
05
to
0
15

EM715
0
0020
to

0
0059

BEARING

Bearing
oil
clearance

Unit

mm
in

Standard

Wear
limit

Main

bearing
clearance
0
026
to
0
090

0
0010
to

0
035

0
10
0
0039

CO
llecting
rod

bearing

clearance
0

030
to
0
079

0
0012
to
0
0031

EM
28
40
95
to
41

05

1
6122
to
1

6161

Unit
mm

in

Wear
limit

0
03

0
0012

0
05
0
0020

0
30
0
0118

t
IGHTENING

TORQUE

Cylinder
head
bolt

Rocker
shaft
bracket
bolt

ain

bearing
cap
bolt

Flywheel
fixing
bolt

Drive

plate
fixing
bolt
Al4

AlS

Connecting
rod

cap
nut

Camshaft

sprocket
bolt

Locating
plate
bolt

Valve
rocker

adjusting
nut

Oil
strainer
bolt

Oil

pan
bolt

Oil

pan
drain

plug

Timing
chain

cover
bolt

Crank

pulley
bolt

Water

pump
bolt

Fuel

pump
bolt

Spark
plug

Engine
mounting
securing
bolt
Engine
Mechanical

Unit

kg
iii

ft
lb

7

0
to

7
5
51

to
54

2
0t02
5

14to
18

5

0
to

6
0
36

to
43

8

0
to
9
0
58
to

65

8
0
to
9
0

58
to

65

8
5
to
9
5
61
to
69

3
2
to
3

8
23
to

27

4
0

to
4
8

29
to

35

0

5
to

0
8

3
6
to
5
8

1
6
to
2
2
12to

16

0
9
to
I
4

6
5
to

10
1

0
4

to
0

6
2

9
to
4
3

2

0
to
3

0
14
to
22

0
5
to
0
7
3

6
to
5
1

15to
20

l08
to
145

0
9
to
I
4

6
5
to

1O
l

0
9
to
I
4
6
5
to

10
1

1
5
to
2

0
11

to
14

1
9
to
2
5
14to

18

EM
30