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IES

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AI2

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SEDAN

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SCIENTIFIC

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DATSI

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ProCarManuals.com

seIE

IFIe

PUBLICATIONS

WORKSHOP

MANUAL

SERIES

DATSUN

1000

1200

SERIES OIO

0110

SEDAN

WAGON

PICK

AUTOMATIC

and

MANtJAL

TRANSMISSIONS

With

Speelfieations

Repair

and

Maintenanee

Data

SCIIL C

PUBUCADONS

MELBOURNE

ProCarManuals.com

Published

Scientific

Publications

Ply

Ltd

142

Oarence

Street

Sydney

2000

New

South

Wales

Printed

Kenmure

Press

Ply

Ltd

New

South

Wales

Scientific

Publications

Pty

Ltd

Registered

at GPO

Sydney

for

transmission

post

book

First

Edition

January

1972

National

Library

Australia

Registry

Number

SBN

85566 038

OWLt

Scientific

Publications

wishes

thank

Nissan

Motor

Corp

USA

and

Borg

Warner

Lid

Fairfield for

help

aspects

preparing

this

manual

ProCarManuals.com

EXGIXE

COOLING

SYSTEM

FUEL

SYSTEM

CLUTCH

MANUAL

TRANS1UISSION

AUTOMATIC

TIlANSMISSION

REAR

AXLE

STEERING

FRONT

SUSPENSION

BRAKES

ELECTRIC

SYSTE

BODY

WHEEL

AXD

TYRES

LUHIUCATION AND

MAINTENANCE

EMISSIOX

CONTROL

SYSTI

IXDEX

GLOSSARY

TERMS

ROAD

TEST

103

126

131

148

184

195

200

211

lIlt

217

ProCarManuals.com

OTHER

TITLES

THE

SCIENTIFIC

PUBUCATIONS

NUAI

SERIES

Bool

Pag

IDo

Price Book

Pages

Dlu

Price

Car

Text

Indiom

Aus

Car

Text

trntiollS

AusLt

Austin

A40

Devon

106

Lawn

Mowers

Vieta

Stroke

Austin

A40

Somerset

Kirby

Stroke

100

utoServ

294

Morris

Minor

142

161

Complete

BMC

Mini

Morris

Minor

1000

96 96

1100 1800

431

315

Morris Austin

Mini

Datsun

1000 1200

224

208

Cooper

and

Datsun

510

1300

Mini

1100

Moke

236

187

1400

1600

256

241

Morris Austin

1100

145

106

Dodge

ASM

106

464

517

Morris

Austin

1800

Ford

Capri

1600

138

and

1600

173 108

Morris Austin

1800

Ford

Consul

Zephyr

66a 224

174

1951

153

Midget

Series

106

Ford

ConsulZephyr

Series

TC TD

1956

184

124

MGA

MGB

304 204

Ford

Cortina

1200

Peugeot

403 404

121

171

1500 1600

288

192

Renault

750f760

33 79 98

Ford

Customline

Renault

Dauphine

133 158

Custom

1949

166

193

Renault

and

RIO

164

Ford

Customline

OHV

121 107

Rootes

Group

Hillman

Ford

Escort

100

Humber

Husky

Cob

BOO 1300

184

172

1958

390

399

Ford

Falcon

Simca

Aronde

Elysee

cyl

290

188

Ford

Falcon

1200 1300

113

121

238

155

Standard

Ford

and

1939

46 40

81 51

Mercury

1932

122 132

Standard

1955

58 41

147

134

Hillman

Hunler

Standard

Space

Arrow

188

121

master

Series

125 105

Holden

1948

53 FJ

Standard

Vanguard

III

184

149

Toyota

Corolla

00 73

176

107

HD HR

286

128

Toyota

Corolla

1200

Holden

80 82

Toyota

Corona

224

175

Holden

Series

Triumph

TR2

167

130

and

cyt

287

197

Valiant

Holden

Engine

174

Engine

272 215

Valiant

AP5

Holden

AP6

VC VE

cyl

Engine

224

188

Engine

279

145

Holden Torana

Vauxhall Viva

1969

Brabham

191 120

200

140

Trucks

437 657

Volkswagen

1500

IHC

Trucks

line

173

245

1600

224 160

IHC

Trucks

line

595

1040

Volkswagen

1100

1200

Jaguar

Mks

VII

VIII

1200A 1300

1500

224 204

IX XK

140

Volkswagen

150

274

237

Transporter

256 202

Jaguar

24 34

Mks

Wolseley

1500

100

and

3 8

274

281

Production

Jaguar

3 8

202

124

Recommended

retail

price

in Australia

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South

Africa

Central

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Agency

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United

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Distributors

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America

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California

91503

Repco

Auto

Parts

Doylestown

Penn

Angeles

Calif

Toronto

Ontario

Vancouver

ProCarManuals.com

Type

Bore

Stroke

AIO

engine

Capacity

engine

Compression

ratio

AIO

engine

Bhp

Maximum

AIO

engine

Maximum

torque

engine

Firing

order

Idling

speed

CYLINDER

HEAD

Type

Gasket

face

distortion

limit

Valve

seat

material

Inlet

Exhaust

Valve

seat

insert

recess

diameter

head

Inlet

standard

insert

Inlet

replacement

insert

Exhaust

standard

insert

Exhaust

replacement

insert

Cylinder

head

bore

diameter

for

valve

guide

tandard

guide

ENGINE

SPECIFIC

TIO

cylinder

line

OHV

73mm

874

59mm

323

70mm

756

988

cm3

in3

1171

in3

6000

rpm

6000

rpm

4000

rpm

@4000

rpm

3600

rpm

3600

rpm

4 2

600

Aluminium

alloy

IOmm

004

Aluminium

bronze

Cast

iron

016

37 00

14573

14567

516

14770

14763

016

2998

2992

516

3350

3195

3190

011

4728

4724

Replacement

guide

211

200

4807

4800

450

Valve

seat

angle

Valve

seat

width

Inlet

0512

80mm

p709

Exhaust

Valve

seat

insert

outer

diameter

standard

Inlet

080

096

459

460

iri

080

096

302

303

Exhaust

Valve

seat

insert

inner

diameter

Inlet

Exhaust

1181

004in

26mm

023

2362

2323

064

096

0025

0038

ALVES

GUIDES

AND

SPRINGS

Valve

seat

insert

depth

Inlet

and

exhaust

Insert

interference

fit

head

Valves

Head

diameter

inlet

35mm

378

29mm

142

3426

3430

103

104

0750

40984

015

045

0006

0018

040

070

0016

0028

exhaust

Stem

diameter

Overall

length

Stem

guide

clearance

Inlet

Exhaust

Valve

lift

A10

engine 7

3071

2953

engine

Valve

guide

Inner

diameter

015

000

3155

3150

044

033

4740

4737

022

044

00009 0

0017

53mm

087

Outside

diameter

Interference

fit

head

Length

ProCarManuals.com

Engine

Fitted

height

above

spring

seat

Valve

spring

Free

length

Fitted

length

and

load

Number

effective

coils

Wire

diameter

Coil diameter

Rocker

arm

valve

stem

clearance

Hot

18mm

709

7992

516

@66

llb

276

1693

224

0 0324

0138

0098

PISTONS

PISTON

RINGS

AND

GUDGEON

PINS

Cold

Pistons

Type

Piston

fit

Skirt

diameter

standard

oversize

2nd oversize

3rd

oversize

4th

oversize

100

nun

oversize

125

6th

oversize

150

nun

Piston

cylinder

bore

clearance

Piston

rings

Width

compression

oil

con

trol

Side

clea

ance

grpove

Ung

gap

GUDGEON PIN

Gudgeon

Diame

Slipper

skirt

cast

aluqlinium

alloy

Selective

967

nun

8727

8747

217

267

nun

8826

8845

467

517

8924

8944

717

767

nun

9022

9042

967

017

riun

9121

9140

217

297

nun

92 19

9239

467

517

nun

9318

9337

023

043

nun

00009 0

0017

0787

1575

0016

0027

0079

0ll8

17447

17452mm

6869

6871

Clearance

piston

006

008

0002

0003

Interference

fit

connecting

rod

017

034

0007

Length

65 23

6548

5681

5779

With

pistolJ

temperature

200C

680F

CRAN

SHAFT

AND

MAIN

BEARINGS

Crankshaft

Main

journal

diamet

964

957

9671

9668

0012

020

062

nun

0008

0024

5mm

0059

015

050

nun

0006

0020

0 15

0020 0 0059

0118

835

827

0722

00719

974

961

7706

7701

0012

CONNECTING

ROD

AND

BIG

END

BEARING

Journal

taper

ovality

wear limit

Main

ring

clear

Clearance

wear

CrankShaft

run

out

End

float

End

float

wear

limit

Main

bearing

thickness

rankpin

diameter

Crankpin

taper

ovality

wear

limit

Connecting

rod

Lergth

engine

116

117

9051

6188

121

7822

7846

500

508

0591

0 0594

0079

0012

016

020

050

0008

0 0020

010

mrn

0020

0039

CAMSHAFT

AND

BEARINGS

AI2

engine

Big

end

bearing

thickness

Big

end end

float

End

float

wear

limit

Big

end

bearing

clearance

crankpin

Connec

ing

rod bent

misalignment

Camshaft

bearing

journal

diameter

793

806

7241

7246

283

296

7040

7046

ProCarManuals.com

Camshaft

run

out

Journal

bearing

clearance

Bearing

inner

diameter

LUBRICATION

Type

Oil

pump

type

Filter

type

Oil

pump

Side

clearance

inner

and

outer

rotors

Clearance

outer

rotor

and

body

Clearance

rotor

end

cover

Relief

valve

spring

Free

leilgth

Fitted

length

Relief

pressure

783

796

6844

6849

IiI

283

296

rom

6647

6652

218

231

6228

6233

IOmm

0004

0039

024

065

0009

0026

843

833

17261

17257

333

323

7060

7050

846

836

6868

6865

333

323

nim

6667

6663

268

258

6247

6243

Full

pressure

Eccentric

motor

trochoid

Full

flow

065

0020

6047

0 21

0059

0083

12mm

0492

4349

3030

26 kg cm2

54 0 59 70

psi

Engine

Capacity

With

new

filter

litre

Imp

qts

US qts

litre

Imp

qts

US qts

Less

filter

TORQUE

WRENCH

SETTING

MAXIMUM

Comiecting

rod

nuts

Cylinder

head

bolts

Flywheel

bolts

A10

engine 3

Al2

engine 7

5420

Main

bearing

cap

bolts

30 kg

3830

Camshaft

sprocket

bolt

Camshaft

locating

plate

bolts

Sump

bol

Oil

pump attachment

bolis

Oil

strainer

bolts

Crankshaft

pulley

bolt

16kg

116

Timing

chain

tensioner

bolts

klilm

Rocker

pedestal

bolts

Mainfolct

bolts

Pump

release

valve

plug

DES

RIP

lON

The

four

cylinder

overhead

valve

engine

has

cast

iron

the

comi

cting

rod

and

this

the

only

means

retaining

the

alloy

cylinder

block

and

crankcase

The

cylinder

head

gudgeon

the

assembly

cast aluminium

alloy

with

replaceable

valve

guides

Each

The

crankshaft

counter

balanced

and

funs

three

valve

has its

individual

port

and

operated

tappet

push

AIO

five

AI2

steel

backed

copper

lead

split

shell

rod

and

rocker

arm

from

the

camshaft

main

bearings

Crankshaft

end

float

taken

the

centre

main

bearing

Connectirig

rod

big

end

bearings

are

split steel

backed

copper

lead

replaceable

shells

Pistons

are

marked

the

crown

with

code

number

the

cylinder

bore

size

which

must

the

front

the

engine

Pistons

are

slipper

skirt

aluminium

alloy

type

with

two

compression

rings

and

orie

oil

ring

The

lower

compression

ring

taper

faced

and

eoil

ring

comprises

upper

and

lower

chrome

faced

steel

segment

with

spacer

between

The

gudgeon

interference

fit

the

smail

end

ProCarManuals.com

Engine

Driven

Side

View

1000

Series

Engine

and

Automatic

Transmission

Typical

Also

1200

Series

Connecting

rods

and

big

end

bearing

caps

are

numbered

The

big

ends

the

connecting

rods

are

bored

oil

squirt

hole

the

thrust

side

The

oil

pump

the

trocoid

gear

internal

rotor

type

and

driven

the

camshaft

provide

full

pressure

the

engine

Oil

passes

through

drilling

the

centre

rocker

pedestal

provide

lubrication

the

rocker

armS

and

shaft

Oil

pressure

maintained

at a

pre

detennined

maximum

spring

loaded

relief

valve

situated

within

the

pump

body

The

lubricating

oil

passes

through

full

flow

oil

filter

moun

ted

externally

the

oil

pump

REMOVE

AND

INSTAL

mNE

AND

TRANSMISSION

Drain

the

cooling

system

and

the

gearbox

Disconnect

the

battery leads

the

battery

and

remove

the

battery

and

battery

Hay

Release

the

retaining

clips

and

remove

the

upper

and

lower

radiator

hoses

Remove

the

air

cleaner

Where

fitted

release

the

retaining

clips

and

disconnect

the

heater

hoses

the

engine

Disconnect

the

high

and

low

tension

leads

the

coil

and

distributor

Disconnect

the

alternator

leads

the

alternator

and

the

starter

leads

the

starter

solenoid

Disconnect

the

oil

gauge

and

temperature

gauge

wires

the

eng

Disconnect

the

choke

and

throttle

con

rrollinkage

the

carburettor

Disconnect

the

fuel

inlet

pipe

the

fuel

pump

Remove

the

flange

nuts

and

disconnect

the

exhaust

outlet

pipe

the

manifold

Raise

the

car

sufficiently

take

out

the

split

pins

and

disconnect

the gear

change

links

the

levers

the

side

the

gearbox

Unscrew

the

ferrule

and

disconnect

the

speedometer

drive

cable

assembly

the

gearbox

rear

extension

Disconnect

the

earth

strap

the

starter

motor

mounting

bolt

Disconnect

the

handbrake

rod

support

the

gearbox

Take

out

the

four

bolts

disconnect

the

rear

universal

joint

flange

from

the

pinion

flange

the

rear

and

withuraw

the

pC0peller

shaft

from

the

rear

ufthc

gearbox

1000

model

Slacken

the

lock

nut

the

adjuster

end

the

clutch

control

cable and

unscrew

the

cable

adjuster

bolt

from

the

end

the

cable

1200

model

Slacken

the

adjustment

the

upper

end

ofth

cable

case

and

unhook

the

lower

end

the

cable

off

the

clutch

release

throwout

lever

Remove

clutch

cable

casing

bracket

attaching

bolt

and

withdraw

the

cable and

bracket

clear

the

engine

and

gearbox

assembly

models

with

hvdraulic

clutch

operation

ProCarManuals.com

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Datsun 200SX Bedienungsanleitung

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Datsun 1981 200SX Bedienungsanleitung

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Datsun 510 series Gebrauchsanweisung

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