1979 DATSUN 210 length

CYLINDER
HEAD

I

Using
Valve
lifter
STl2070000

compress
valve

spring
and
remove

valve
collet

2

Release
Valve
Lifter
and
remove

spring
retainer

spring
oil
seal

spring

seat
and

valve

PREPARATION

FOR

INSPECTION

I

8efore

cleaning
check
for

signs

of
water

and
oille
s

2

Clean
oil
and

carbon

deposits

from
all

parts
They
should
be
clean

from

gaskets
and
sealant

3
Clean

all
oil
holes
with

solvent

and

dry
with

compressed
air

Make

sure

that

they
are
not

restricted

CYLINDER
HEAD

AND
VALVE

CHECKING

CYLINDER

HEAD
MATING
FACE

I

Make
a
visual
check
for
cracks

and

flaws

2

Measure
surface
of

cylinder
head

on

cylinder
block
sid
for

warpage

If

beyond

designated
limit

correct

s
rface
with

a
surface

grinder

Warpage
of
urfece

Less
than

0
1
mm
0
004
in

EM108

Fig
EM

IS
Checking

Cylinder
Head

Surface
Engine
Mechanical

EM462

Fig
EM

16
Removing
Value

3
Place
valve

components
in
order

INSPECTION
AND
REPAIR

Note

Surface

grinding
limit

The

grinding
limit

of

cylinder
head

is

determined

by
the

cylinder
block

grinding
in
an

engine

Depth
of

cylinder
head

grinding

is
A

Depth
of

cylinder
block

grinding

is

6B

The
limit
is
as

follows

A
B
0
2

mm
0
008
in

VALVE

i
Check
each
of

the
intake

and

exhaust
valve
for
worn

damaged
or

deformed
valve

caps
or
stems
Correct

or

replace
the
valve
that
is

faulty

For

standard
size
of
valve

refer
to

Service
Data

and

Specifications

2

Valve
face
or

valve
stem
end

surface
should
be

refaced

by
using
a

valve

grinder

Note
When
valve
head
has
been

worn

down
to
0
5

mm
0
020
in
in

thickness

replace
the
valve

Grinding
allowance
for
valve
stem

end
surface
is
0
5
mm
0
020
in
or

less

c

EM111

Fig
EM

19
Regrinding
Valve
Face

EM
5
C

vO@
lll@8

C
CQ8@
a

EM463

Fig
EM
17
Valve

Components

Note
Take
care
not
to
lose
valve

spring
seat
oil
seal
valve
collet

and
valve
rocker

guide

VALVE
SPRING

I

Check
valve

spring
for

squareness

using
a

steel

square
and

surface

plate

If

spring
is
out
of

square
S
more

than

specified
limit

replace
with

new

ones

Out

of

square
S

Less

than

1
6
mm

0
063
inl

L

1

EM296

Fig
EM
20

Measuring
Spring

Sguareness

2

Measure
the
free

length
and
the

tension

of
each

spring
If
the
measured

value
exceeds
the

specified
limit
re

place
spring

Refer

to
Service
Data
and

pecifica

tions

EMl13

Fig
EM
21

Measuring
Spring
Teruion

Note
If

cylinder
bore
has
worn

beyond
the
wear
limit
use

cylinder

liner

Undersize

cylinder
liners
are
avail

able
for
service

Interference
fit
of
cylinder
liner
in

cylinder
block
ahould
be
0
08
to

0
09
mm
0
003
I
to
0
0035
in

PISTON
PISTON
PIN

AND
PISTON
RING

I
Remove
carbon
from

piston
and

ring
grooves
with
a

carbon

scraper
and

a

curved
steel
wire

The
wire
will
be

useful
in

cleaning
bottom
land

of

ring

groove
Clean
out
oil
slots
in
bottom

land
of
oil

ring
groove

2

Check
for

damage
scratches
and

wear

Replace
if
fault
is
detected

3
Measure

side
clearance
of

rings
in

ring
grooves
as
each

ring
is
installed

If
side
clearance
exceeds
the

speci

fied
limit

replace

piston
together
with

piston
ring

Max
tolerance
of

side

clearance

0
1

mm
0
0039
in
Engine
Mechanical

u

EM482

Fig
EM
38

Measuring
Ring
Gap

Note

a
When

piston
ring
only
is
to
be

replaced
without

cylinder
bore
be

ing
corrected
measure
the

gap
at

the
bottom

of

cylinder
where
the

wear
is
minor

b

Oversize

piston
rings
are
available

for
service
0
5
mm
0
020
in
1

0

mm
0
039
in
oversize

5

Measure

piston
pin
hole
in
rela

tion
to
the

outer
diameter
of

pin
If

wear

exceeds
limit

replace
piston
pin

together
with

piston
on
which
it
is

installed

Piston

pin
to

piston
clearance

O
OOS
to
0
012
mm

0

0003
to
0
0005
in

Note

Determine
the

fitting
of

piston

pin
into

piston
pin
hole

to
such
an

extent
that
it
can
be

pressed

smoothly

by
fmger
at
room
tem

perature
This

piston
pin
must
be
a

tight
press
fit
into

connecting
rod

EM481

Fig
EM
37
Me

suring
Piston

Ring

Side
Clearance

4

Measure

ring
gap
with
a
feeler

gauge
placing
ring

squarely
in

cyl

inder

Ring
should
be

placed
to
diameter

at

upper
or
lower

limit
of

ring
travel

If

ring

gap
exceeds
the

specified

limit

replace
ring

Max
tolerance
of

ring

gap

1
0
mm
0
039
in
EM131

Fig
EM
39
Piston
Pin

Fitting

CONNECTING
ROD

1
If
a

connecting
rod
has

any
flaw

on
either
side
of

thrust
face
and

large

end
correct
or

replace
it

Bend
and
torsion

per
100
mm
3

94
in

length

Less
than

0
05
mm
0
0020
in

EM

9
EM133

Fig
EM

40
Checking
Rod

Alignment

2
Check

connecting
rod

for
bend
or

torsion

using
a

connecting
rod

aligner

If
bend

or
torsion

exceeds
limit
cor

rect

or

replace

3
When

replacing
connecting
rod

select
rod

so

weight
difference
be

tween
new
and
old
ones
is
within
5

gr

0
180z

4
Install

connecting
rods
with
bear

iogs
on
to

corresponding
crank

pins

and
measure

thrust
clearance
If
meas

ured

value
exceeds
limit

replace
con

necting
rod

Max
tolerance
of

big
end

play

0
4
mm
0
016
in

l
Big
end

play

l

t

t

EM483

Fig
EM
41
Checking
Big
End

Pwy

CRANKSHAFT

I

Repair
or

replace
as

required
If

faults
are
minor

correct
with

fine

crocus
cloth

2
Check
with
a
micrometer

journals

and
crank

pins
for

taper
and
out
of

round
Measurement
should
be
taken

along

journals
for

taper
and

around

journals
for
out
of

round

If
out
of
round

or

taper
exceeds

the

specified
limit

replace
or

repair

Engine
Mechanical

INSPECTION
AND
ADJUSTMENT

CYLINDER
HEAD
AND
VALVE

Cylinder
head
Unit
mm
in

Standard
Limit

Head
surface
flatness
Less
than

0
05
0
0020
0
1
0

004

Valve
Unit
mm

in

j
I
Hot

Valve
clearance

I
Cold
Intake
valve
Exhaust
valve

0
35
0
014

0
25
0

010

Valve
lift
7

91
0
3114
8
22
0
3236

H
37
0
to
37

2

1
457

to
1

465
30
0
to

30
2

1
181
to
1
189
D
L
Valve
head

diameter

a

H
Valve

length

L
103
6
to
104

0

4
079
to
4

094

D
7

970
to
7
985

0
3138
to

0
3144
7
945
to
7
960

0

3128
to
0
3134
Valve
stem
diameter

EM769

Valve
seat

angle

a
45030

Valve

spring

Free

height
mm
in
46
5
1

831

Compressed
height

mm
kg
in
lb
30
2
22
2

to
25
6

valve

open
1
189

49
0
to
56
4

Assembled

height

mm

kg
in
lh
38
7
544
to
62
6

valve
closed
1
524
120
0

to
138
0

Out
of

square
S
mm
in
Less

than
1
6

0
063

EM

19

Valve

guide
senice

INTAKE

f

D21
Dl

I

r

I
I

I
d
18
5

0

728

L

EXHAUST

II
3
0
118

t

81
o

8
5
327
to
0
335

Combustion
chamber
ide

Valve

guide
length
L

D

Valve

guide

Outer
diameter

D2

Valve

guide

Inner

diameter

Finished
size
d

Cylinder
head
valve

guide

hole
diameter
a

Interference
fit
of
valve

guide

In

Stem
to

guide
clearance

Ex
Engine
Mechanical

1

Unit
mm

in

EM770

Intake
for
Non
California

except
FU

Exhaust

49
1
93
EM171

Unit
mm
in

Intake
for

California

Canada

FU
model
for
Non

California

53
2

09

12

0331012
044

0

4737
to
0
4742

12

233
to
12
244

0
4816

to
0
4820

8

000
to
8
015

0
3150
to

0
3156

12
200
to

12
211

0
4803
to
0

4807

0

022
to

0
044

0
0009
to
0
0017

Standard

0
Q15

to
0
045

0
0006
to
0
0018

0
040
to
0
070

0

0016
to

0
0028

EM

20
Unit

mm
in

Max
tolerance

0
1
0
004

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

Not

Pump
rotors
and

body
are
not
serv

iced

separatdy
If

pump
rotors
or

body
are

damaged
or

worn

replace

ment
of
the
entire
oil

pump
assembly

isnecessary

OIL
PRESSURE

REGULATOR
VALVE

The
oil

pressure
regulator
valve
is

not

adjustable
At
the
released

posi

tion
the
valve

permits
the
oil
to

by

pass
through
the

passage
in
the

pump
cover
to
the
inlet
side
of

the

pump
Check

regulator
valve

spring
to

ensure

that

spring
tension
is
correct

no

1

Regulator
valve

2
Relief

valve

3
Valve

spring
E
L045

Fig
EL
5

Regulator
and
Reli
Vatv
Engine
Lubrication
System

8Peciflcatlons

Oil

pressure

At

idling

more
than

O

Blrg
an2
11

psi

At

3
000

rpm

3
B
to
5
2lrg

an2

54
to
74

psi

Regulator
ai

spring

Free

length

43
49
rom
1
7122
in

InstoJlod
l

ngth
load

30
3
mm
3
67

kg

1
193

inJB
09lbl

Regulator
val

o

ning
pressur

3

8
to
4
2

lrg
an2

54
1060

psi

OIL
PRESSURE

RELIEF
VALVE

The
relief
valve
located
in

the
oil

pump
cover

by
passes
the

oil
into
the

main
oil

gallery
when

the
oil
filter

elem
nt
is

exCessively
clogged
With

regula
tor
valve
removed
check
valve

for

operation
See

Fig
EL
5

OIL
FILTER

tEMOVAL

Place
a
suitable
container
under
the

f1lter

Unscrew
f1lter
from
oil

pump
cover

flange
using
Oil
Filter
Wrench

STl9320000

EL
4
Fig
EL
6

Removing
Oil
Filter

INSTALLAnON

I
Coat

the

packing
on
the
new

f1lter
with

oil
Position
the

f1lter
on

the
oil

pump
cover

flange
Hand

tight

en
the
f11ter
until
the

packing
contacts

the

cover

flange
then
advance
it

2
3

tum

Note
Do
not

overtighten
the
fiIter

or

oil
leak

may
occur

2

Operate
the

engine
at
fast
idle

and
check
for
oil
leaks
Check
the
oil

level
and
add
oil
if

necessary

OIL
PRESSURE

WARNING

SWITCIt

The
oil

pressure
warning
switch
is

located

on
the

oil

pump
cover
and

wired
to

an
instrument

cluster
See

Fig
EL
6

The

warning

light
glows
whenever

the

oil

pressure
drops
below
0

2
to
0
4

kg
cm1
2
8
to
5
7

psi

Prior
to

installing
a
switch
to
cover
I

be

sure
to

apply
a
conductive
sealer

to

threads
of

switch

Engine
Lubrication

System

SERVICE
DATA
AND
SPECIFICATIONS

Oil

pump
Standard
Wear
limit

Rotor
side
clearance
nun
in
0
04
to
0
08
0
20
0
0079

Rotor

to
bottom
cover

0

0016
to
0

0031

Rotor

tip
clearance
mm
in
less
than

0
20
0
0079

0
12

0
0047

Outer
rotor
to

body
clearance
nun
in
0

15
to
0
21

0
50
0
0197

0
0059

to
0
0083

Oil

pressure
regulator
valve

Oil

pressure
a
t

idling

Oil

pressure
at
3

000

rpm

Regulator
valve

spring

Free

length

Installed

length
load
kg
cm2

psi

kg
cm2

psi
more

than
0
8
II

3
8

to
5
2
54

to
74

nun
in

nun

kg
in

lb
43
49
I

7122

30
3
3
67
1
193

8
09

Tightening
torque

Oil

pump
securing
bolts

Oil

pump
cover
bolt

Regulator
valve

cap
nut
kg
m
ft
lb

kg
m
ft

lb

kg
m
ft
lb
0
9
to

I
4

6
5
to
10
1

0
39
to
0

52
2
8

to
3

8

4

0
to
5
0
29

to
36

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition
Probable
cause
Corrective
action

Oil

leakage
Damaged
or
cracked

body
cover

Oil

leakage
from

gasket

Oil

leakage
from

regulator
valve

Oil

leakage
from
blind

plug
Replace

Replace

Tighten
or

replace

Replace

Decreased
oil

pressure
Leak
of
oil
in

engine
oil

pan

Dirty
oil
strainer

Damaged
or
worn

pump
rotors

Faulty
regulator

Used
of

poor
quality
engine
oil
Correct

Clean
or

replace

Replace

Adjust
or

replace

Replace

Noise
Excessive
backlash
in

pump
rotors
Replace

EL
5

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