manualshive.com logo in svg

Datsun 1200 1973, Repair Manual

The Datsun 1200 1973 Repair Manual is a comprehensive and invaluable resource for any owner or enthusiast. This manual covers everything from routine maintenance to complex repairs, providing step-by-step instructions and diagrams. Easily downloadable for free at manualshive.com, it's a must-have for DIY enthusiasts and professionals alike.

Share
Download
background image

Summary of Contents for 1200 1973

Page 1: ...J J l P Otl l J X 4 t t h r 3 f f 510 1200 1973 610 1973 76 710 1974 77 810 1977 78 8210 1974 78 2005 1977 78 f10 197778 510 1978 R4 speCltlC oo lt ourselt tlAalote r J J ...

Page 2: ...J spARK PLUli ENGINE 7 rAR8 J J ...

Page 3: ...ok Company president and chief executIve officer WILLIAM A BARBOUR Chilton Way executIve vice president RICHARD H GROVES vice president Radnor Pa 19089 and general manager JOHN P KUSHNERICK managing editor KERRY A FREEMAN S A E senior editor RICHARD J 215 687 8200 RIVELE editor ROBERT F KING CHILTON BOOK COMPANY RADNOR PENNSYLVANIA ...

Page 4: ...Irs TIus book outlmes prreedures for servIcmg and rep31nng vehIcles usmg nfe effechve methods The procedures contain many NOTES CAUTIONS and WARNINGS wh ch should be followed along Wlth standard safety procedures to eltm10ate the poSSlblltty of personal Injury or Improper serVIce whICh could damage the vehicle or compromise Its safety It IS Important to note that repaIr procedures and techmques to...

Page 5: ...e 62 General Engme SpeCifications 63 Crankshaft and Connectmg Rod Speclfi catIons 64 Piston and Rmg SpeCifications 65 Valve SpeCificatIons 65 Torque SpeCificatIons 66 Engme Removal and Installatlon all en gmes except FIO 66 Engme Removal and Installatlon FI0 67 Cylmder Head 68 Intake Mamfold 72 Exhaust Mamfold 73 Timmg Cham Cover 73 Tlmmg Cham and Camshaft 75 Tlmmg Cham and TenslOner 76 Camshaft 7...

Page 6: ...apter 9 Brakes Brake System 187 Adjustment 187 HydraulIc System 187 Master Cylmder 187 System B1eedmg 190 Front DISC Brakes 191 DISC Brake Pads 191 Chapter 10 Body Doors 201 Door Panels 202 Appendix Wmdshleld WIper Motor and Lmkage 139 Instrument Cluster 140 Headhghts 144 Fuse LocatIons 144 145 Clutch Slave Cylmder 153 B1eedmg the Clutch Hydrauhc System 155 AutomatIc TransmIssIOn 155 Axle Shaft 16...

Page 7: ...e speCific procedure ThiS wIll give you the overall view of what Will be reqUIred as far as tools supplies and you There IS nothing more frustrating than haVing to walk to the bus stop on Monday mornmg because you were short one metric bolt during your Sunday afternoon repair So read ahead and plan ahead The sections begm With a briefdiSCUS sIOn of the system and what It Involves Adjustments andor...

Page 8: ...chometer 8 Torque wrench ThiS assures proper tightening of Important fasteners and aVOids costly thread strlppmg too tight or leaks too loose 9 011 can filler spout 10 011 filter strap wrench Makes re moval of a tight filter much Simpler Never use to mstall filter 11 Pair ofchannel lock plIers Always handy to have 12 Two sturdy jackstands cmder blocks brIcks and other makeshift sup ports are Just ...

Page 9: ...y the engme model code EngIne senal number Routine Maintenance AIR CLEANER All Datsuns covered m this gUIde are eqUIpped With a disposable paper car tndge au cleaner element At every tune up or sooner If the car IS operated m a dusty area undo the wmgnut remove the housmg top and Withdraw the element Check the element Replace the filter If It IS extremely duty Loose dust can some times be removed ...

Page 10: ...to the mtake mamfold to be burned With the normal aIr fuel mixture The PCV valve should be replaced every 24 000 miles Make sure that all PCV don nectIons are tIght Check that the con nectmg hoses are clear and not clogged Replace any bnttle or broken hoses To replace the valve whICh IS located m the mtake mamfold dIrectly below the carburetor 1 Squeeze the hose clamp With phers and remove the hos...

Page 11: ... apply aIr pressure to the fuel tank Side of the valve The aIr should Fuel filler cap With vacuum rebef valve Carbon canister How through the valve and eXit the crank case Side of the valve If the valve does not operate as outlined above replace It 2 Apply aIr pressure to the crankcase Side of the valve AIr should not pass to either ofthe other two outlets 3 When aIr pressure IS apphed to the carb...

Page 12: ...y the alternator out With a bar such as a ratchet handle or broom handle and then tIghten the alternator bracket nuts Checlnng belt deflectIon 4 Recheck the tensIOn The alternator dnve belt also operates the water pump It might be good msur ance to carry an extra belt m the trunk NOTE The optional aIr condItIOning dnve belt is adjusted In a S1mllarfash IOn Loosen the alternator bracket nuts to adj...

Page 13: ...onous gas In the presence offlame Do not open or dIsconnect any part of the air condlttOmng system Sight Glass Check You can safely make a few Simple checks to determme If your aIr condltlon mg system needs service The tests work best Ifthe temperature IS warm about 700 F 1 Place the automatic transmiSSIOn In Park or the manual transmiSSIOn m Neutral Set the parkmg brake 2 Run the engme at a fast ...

Page 14: ...w mOIsture to enter and cause a very expensIVe rust problem NOTE ExerCise the air conditIOner for a feu minutes every two ueeks or so dunng the cold months ThiS aVOids the pOSSibilIty of the compressor seals drying out from lack of lubncatlOn FLUID LEVEL CHECKS Engine Oil The best tImeto check the engme OlliS before operatIng the engme or after It has been slttmg for at least 10 mmutes m order to ...

Page 15: ...IOn IS not hot shift Into Dnve Low then Neutral or Park Set the handbrake and block the wheels Remove the dipstick wipe It clean then Add automatIc transmiSSion flUid through the dip stIck tube reinsert It firmly Remove the dipstick and check the flUid level on the appropn ate scale The level should be at the Full mark If the level IS below the Full mark add Type A or Dexron lP type automatic tran...

Page 16: ...ncant m the Check the rubber gasket on the cap when checkmg coolant level steering gear every 12 000 miles If the level IS low check for leakage An Oily film IS not considered a leak solId grease must be present Change the lubncant every 36 000 miles Use steering gear lu bncant The lubricant IS added and checked through the filler plug hole In the top of the steenng gear Battery The battery IS loc...

Page 17: ... 118 725 710 wagon 1976 78 38 34 27S 36 118 18 115 625 B210 1976 45 40 425 118 I 75 2 2 145 1375 725 610 wagon wagon 197677 45 40 425 118 275 1325 11 8 725 710 wagon 1977 78 60 525 36 118 2 75 2 2 159 145 II 810 wagon wagon 1977 78 36 32 49 49 106 7 FIO 1977 78 45 40 36 118 275 159 79 200SX 1978 45 40 36 36 118 275 132 94 510 jelly or chaSSIS grease after c1eanmg them TIRES Check the au pressure m...

Page 18: ...that radial tIres are better all around per fonners givmg longer wear and better handhng An added benefit whICh you should consider when purchasmg tIres IS that radials have less rolhng resistance and can give up to a 10 mcrease m fuel economy over a bias ply tIre n y lXflxl iI ill IOII IOII TlIe rotation patterns TIres of different constructIon should never be mixed Always replace tIres m sets of...

Page 19: ...er Under the claSSifica tion system adopted by the American Pe troleum Institute API In May 1970 SE IS the highest deSignation for pas senger car use The S stands for pas senger car and the second letter denotes a more peclfic apphcatlon SA Oil for Instance contains no additIves and IS SUitable only for very hght duty usage 011 deSignated MS motor severe may also be used Since thiS was the highest...

Page 20: ...oosen the dram plug Turn the plug out by hand By keepIng an Inward The 01 filter on Lsenesengmes IS eastly located on the nght hand SIde of the block pressure on the plug as you unscrew It 011 won t escape past the threads and you can remove It Without beIng burned by hot 011 5 Allow the 011 to dram completely and then mstall the dram plug Don t D e r i 1 Jf I n I 1Io l y I A strap wrench w lI mak...

Page 21: ...ecure It With the attachmg screws tlghtenmg them to 3 5ft Ibs 3 Pour the same amount of Type A Dexron ll automatic transmiSSIOn flUId which was dramed from the Oil pan m through the filler pipe Make sure that the funnel contamer hose or any other Item used to assist m fillIng the transmis sIOn IS clean 4 Start the engine Do NOT race It Allow the engine to Idle for a few mm utes 5 Place the selecto...

Page 22: ...tIveand pOSltI ve to posItIve or you stand a chance ofdam aging the electrical systems of both cars Keep the engme runnmg 10 the donor car If the car stIll falls to start call a garag ontmual gnndmg on the starter Will overheat the umt and make repaIr or replacement necessary Jacking Never use the tIre changmg jack for anythmg other than that Ifyou mtend to use thiS tool to perform your own mamte ...

Page 23: ...ks de tenoratlng radiator or heater hoses loose andor frayed fan belt etc These httle Items have the tendency to develop mto major headaches so don t overlook any thmg w At i t 1 i I A or r AI r l d r J Pull on the spark plug boot not the wne SPARK PLUGS A typical spark plug consists of a metal shell surroundmg a ceramic msulator A metal electrode extends downward through the center of the msulato...

Page 24: ...73 1200 BP 5ES o 032 49 55 0020 5B 5B NA 700 600 0010 15 0 0036 700 600 cold cold C 0014 0014 t l l hot hot 1973 610 BP 6ES o 028 49 55 0018 5B 5B 26 800 650 0008 0010 15 S 0031 0022 800 6 0 34 cold cold 0010 0012 0 hot hot 0 1974 610 B6ES o 028 49 5 0017 12B 12B 3 38 750 650 0010 0012 3 I 0031 0022 750 6 0 hot hot 1974 710 B6ES o 028 49 55 0017 12B 12B 26 800 650 0010 0012 15 0031 0022 800 6 0 34...

Page 25: ...1 49 55 0018 12B 12B 38 750 650 0010 0012 20 1976 610 110 Z Federal 0035 0022 hot ot t 12B 38 750 650 0010 0012 20 19 16 610 110 BY 6ES 0031 Elec 12B 0 Cahiorn a 0035 trOn1C hot hot 1971 B210 BP 5ES o 039 49 55 0018 lOB 8B 38 700 650 0014 0014 20 d Federal 0043 0022 hot hot 1917 13210 13P 5ES o 039 E ec lOB lOB 38 700 650 0014 0014 20 CaMorn a 0043 tron C hot hot 1977 710 BP 6ES 0031 49 55 0018 12...

Page 26: ...ederal 0043 10 10 36 700 650 0010 0012 10 0 5 1977 810 lI6ES o 039 Ele d 78 0043 trontC hot hot Ca 1 0008 0010 I co d co d 0 1978 510 lIP 6ES 0039 E ec 9 12 38 600 600 0010 0012 10 0043 hot hot I federal tron1C I 1977 2005 llP 6ES o 039 E ec 9 12 38 600 600 0010 0012 10 78 Ca lforn1a 0043 tron1C hot hot 1978 510 lIP 6ES 0039 E ec 10 12 38 600 600 0010 0012 10 a Cahfornm 0043 trOn1C hot hot Z 1n E ...

Page 27: ...ORT Insulator Tip Fast Heat Transfer LOWER Heat Range COLD PLUG Spark plug heat range loads In severe cases the heat may be come high enough to start the fueVau mllrture burnmg throughout the combus tion chamber rather than just to the front ofthe plug as m normal operation At thiS time the piston IS nsmg m the cylmder makmg ItS compressIOn stroke The burn mg mass IS compressed and an explOSIOn re...

Page 28: ...r cap and COli Replace any damaged wmng Ifno phYSI cal damage IS obVIOUS the WIres can be checked With an ohmmeter for excessive resistance Remove the dlstnbutor cap and leave the WIres connected to the cap Connect one lead of the ohmmeter to the correspondmg electrode mSlde the cap and the other lead to the spark plug ter mmal remove It from the spark plug for the test Replace any WIre whICh show...

Page 29: ...es on IS controlled by a relay whICh In turn IS connected to throt tle pOSItion temperature and transmls Pull the rotor straIght off to remove It Carefully check the pomt contact surfaces slOn SWitches The dual pOints are ad justed With a feeler gauge In the same manner as the Single pOint distributor Inspection of the Points 1 Disconnect the high tenSIOn wue from the top of the distributor and th...

Page 30: ...er set the pomt gap now or later after you have remstalled the dlstnbutor 6 On dual pOint models mstall the distributor makmg sure the marks made earher are hned up Note that the slot for the 011 pump dnve IS tapered and Will only fit one way 7 On smgle pomt dlstnbutors shp the new set ofpomts onto the locatmg dowel and mstall the screws that hold the as sembly onto the plate Don t tighten them al...

Page 31: ...e 7 Rotor 1 S Dlstnbutor cop 23 Ground Wire 8 Breaker plate 16 Corbon pOint assembly crease or decrease the gap to the proper settmg 5 Tighten the adjusbnent lockscrew and recheck the contact gap to make sure that It didn t change when the lockscrew was tIghtened 6 Replace the rotor and distributor cap and the high tensIOn WIre whICh connnects the top of the distributor and the COli Make sure that...

Page 32: ...Shaft assembly ahgned With notch In the shaft Ahgn the tab In the base of the distributor cap With the notch In the distributor body Make sure that the cap IS firmly seated on the 13 Vacuum control assembly 14 Terminal assembly 15 Clamp 16 Retaining plate 17 Gear set dlstnbutor and that the retainer chps are In place Make sure that the end of the high tensIOn WIre IS firmly placed In the top of th...

Page 33: ... lead wlre odvanced pOints Primary lead wire retarded pOints 5 Primary lead Wife set serew 6 Set Icrew advonced pOints 7 Set screw retarded pOints 8 Adluster plate set screws 9 Breaker plate set screws After setting the pOint gap to speCifica tion With a feeler gauge as descnbed above check the dwell angle With a meter Attach the dwell meter according to the manufacturer s instruction sheet A typi...

Page 34: ...ect readIng IS obtaIned disconnect the dwell meter 7 Check the adjustment of the Igm tlon timing DUAL POINT DISTRIBUTOR Adjust the pOInt gap ofa dual POInt diS tributor With a dwell meter as follows 1 Disconnect the wmng harness of the distributor from the engIne wmng harness 2 USIng a jumper Wire connect the black wue of the engine Side of the harness to the black wire of the distribu tor Side of...

Page 35: ...IS at tached to the dlstnbutor shaft and has one tooth for each cylInder In the engmefour teeth for four cyllnder engines and SIX teeth for sIx cylinder engines When the teeth of the rotating reluctor approach the magnetIc pickup COlI whICh IS attached to the dlstnbutor base plate they mduce a voltage whICh tells the externally mounted amplifier to turn the COlI pnmary off A tIming CIrCUIt In the ...

Page 36: ...tment proce dures on the electromc Igmtlon system are somewhat simpler than on a conven tional system Smce there are no pomts and condenser to replace at tune uptime a number of steps have been elimmated Also smce dwell IS electromcally con trolled the Igmtlon hmmg should never need adjustment However Datsun still recommends checkmg the tlmmg at 12 000 mile mtervals The electromc con trol umt Itse...

Page 37: ...ll Air gap 5 Pole piece 6 Adluster plate 7 Reludor IS adjustment of the aIr gap between the reluctor and the pickup COlI ThiS should be checked and adjusted If necessary at the normal tune up Intervals Au gap adjustment 1 Remove the dIstnbutor cap and rotor 2 USing a non magnetic feeler gauge check the gap between the pICkup COli and the reluctor One of the reluctor teeth and the coil must be alig...

Page 38: ... second for the spark plug to Ignite the mIXture m the cylmder the spark plug must fire a httle before the piston reaches TDC Otherwise the mixture will not be com pletely Igmted as the piston passes TDC and the full power of the explOSIOn will not be used by the engine The tlmmg measurement IS given m degrees of crankshaft rotation before the piston reaches TDC BTDC If the set ting for the Igniti...

Page 39: ...g hght clear of the fan 14 With the timing hght aimed at the pulley and the marks on the engine turn the distributor In the dlTectIon ofrotor ro tatIOn to retard the spark and In the op posite dlTectIon of rotor rotation to ad vance the spark Ahgn the marks on the pulley and the engine With the flashes of the timing hght Tighten the hold down bolt VALVE LASH Valve adjustment determines how far the...

Page 40: ...after first removmg no 1 plug untIl the piston AdJustmg 1200 B210 and FI0 valve clearance IS at the top ofItS stroke and the TOC tIm mg mark on the crankshaft pulley IS m ahgnment With the tImmg mark pomter At thiS pomt the valves for no 1 should be closed 5 With no 1 piston at TOC of the compressIOn stroke check the clearance on valves Nos 1 2 3 and 5 counting from the front to the rear 6 To adju...

Page 41: ...mark on the crankshaft pulley IS hned up approxI mately as It would be when the No 1 spark plug fires 4 Adjust the No 1 cylmder mtake valve to 0 008 m 0 20 mm FlfSt loosen the pivot lockmg nut and then msert the feeler gauge between the cam and cam follower Adjust the pivot screw until there IS a shght pull on the gauge when It IS mserted straight between the cam and follower Then tighten the lock...

Page 42: ... been done check and adjust the Igmtlon tlmmg to the proper setting 4 Turn off the engme and connect a tachometer to the engme 5 Remove the au cleaner and start the engme With the transmiSSIOn m Neutral check the Idle speed on the ta chometer Ifthe readmg on the tachome ter IS correct continue on to Step 6 IfIt IS Throttle adJustlll1 screw Idle adJust InIlCrew 3 Idle hnl1tter cap 4 Stopper Carbure...

Page 43: ...rs Warm the engIne to nOTmal temperature and hook up a tachometer Automatic trans miSSIOn cars are adjusted wIth selector m Dnve so be sure that parkmg IS on and the wheels blocked for safety AdJust the speed to speCifications u mg the adJust mg crew The Idle speed adJustmg screw IS located m the throttle chamber near the dlstnbutOT Idle mixture cannot be set without the use ofa CO meter 810 Idle ...

Page 44: ...rlnp Worn connectlnr rod bearlnga Fuel octane too low wom onnect ng rod bearlnp Loose plflton pin CollapMd r sticky valve lifter 6 C eYlve alve clearance exceulve end play In rotatlnl shaft Fan belt contacting stationary surface SU elednc fuel pump normal Generator brushes breaded fan bel Improperly tensioned tan belt Steam esc aplq throu ba leak In the coohnr J7Si em or the radI atorover1lowvent ...

Page 45: ...a screwdnver be tween the battery post and the cable clamp Turn the headlIghtson high beam and ob serve them as the screwdriver IS gently twisted to ensure good metal to metal contact Testing battery cable connecbans uslnl a acnrwdrlver 14 If case IScracked replace battery If the case IS mtact remove corrosion WIth a solution of bakmg soda and water CAU TION do not get t 1 solut Dn nto the bat ter...

Page 46: ... 31 23 2 3 Check the IgnItIon SWItch start posItIon Connect a 12V test lamp between the starter post of the solenOId or relay and ground Turn the 19mtlOn SWItch to the start pOSItIOn and JIggle the key sr TER RELAY Checking the Ignition switch shirt posrtlon If the lamp doesn t lIght when the SWItch IS turned check the IgnItIOn SWitch for loose connectIOns cracked msulatlOn or broken wIres RepaIr ...

Page 47: ...nor mal Rotate the crankshaft untIl the contact heel rests on a hIgh pOint of the dlstnbutor cam and adjust the pOint gap to specIfi catIons Replace the resIstor or the resIstance wIre If the resIstance ISzero If the breaker pOints are Intact clean the contact surfaces With fine emery cloth and adjust the pOint gap to speCIficatIOns If pItted or worn replace the pOints and con denser and adjust th...

Page 48: ...esistance Results and lndtcatums CoIls utIlIZing ballast resIstors or reSIstance wires should have approximately 1 on re sIstance coIls WIth Internal reSIstors should have approximately 4 on reSIstance If values far from the above are noted re place the coIl If no spark IS eVident If spark ISgood In somecylInders If spark IS good In all cylInders If the spark ISgood and consIstent If the spark IS ...

Page 49: ...r Normal wear IS md cated byap proximately 001 wear per 1000 mIles Clean and regap the spark plug If wear IS not ex ceSSIVe Replace the spark plug If excessIVely worn 47 Carbon foulIng black dry fluffy depOSIts Test the hIgh tension leads Check the valve train Clean and regap the plugs In eIther case If present on most or all Check the fuel system 5 1 plugs Overly nch fuel mIxture due to restnct e...

Page 50: ...Iently Fuel mIxture too lean Poor compressIOn Fuel grade too low Replace With plugs of the proper heat range Adjust tImmg to specIfica tIons Clean the spark plug seat and check the coolIng system Check the fuel system Check compressIOn Use hIgher octane fuel Proceed to 47 82 51 47 47 47 82 111 5 1 61 47 Test and Procedure Re fUlt8 and IndtcatIons Proceed to 47 Determme the statIc IgmtlOn tImIng Us...

Page 51: ...me to the tank WIth low pressure compressed aIr untIl bubbhng IS heard from the fuel filler neck Also blowout the carburetor fuel lme both ends dIsconnected If no suction IS eVIdent replace or repair the fuel pump NOTE Repeated otl foultng of the spark plugs or a no start condItIOn could be the re81ut of a ruptured vacuum booster pump dtaphragm through whtch 011 or gasoltne Lq beIng drawn Into the...

Page 52: ...er the not start Inspect for droplets or perature tank must be dramed and the a layer of water changes fuel lInes blown out With com pressed aIr Te8t and Procedure Resndt8 and IndtCatt07Ul Proceed to 61 Test engine compresSIon Remove all spark plugs Insert a compres sion gauge mto a spark plug port crank the engine to obtam the maximum readmg and record Testing compression Chevrolet DIY G M Corp C...

Page 53: ... md1cated NOTE A Jumped ttmtng cham 18 often tn dtcated by dt fjU ult crankmg See below 71 See below Readmg Steady from 17 22 m Hg Indtcatw7Ul Proceed to Normal 81 Low and steady Late IgnItIon or valve tImmg or low compres SIOn 61 Very low Vacuum leak 72 Needle fluctuates as engine IgmtIon mISS blown cylInder head gasket speed mcreases leakmg valve or weak valve spnng 6 1 83 Gradual drop In readmg...

Page 54: ...e vacuum hose s to the dIstrIbutor If speCI fied start the engme and observe the timIng marks at the speCIfied engIne speed 8 3 Check the operation of the distrI butor advance mechanism s To test the mechanical advance dIS connect all but the mechanical ad vance and observe the tImmg marks WIth a tlmmg lIght as the engIne speed IS mcreased from Idle If the mark moves smoothly WIth out heSItatIOn I...

Page 55: ...p perSISts remove and replace the bft er MetallIc tap through the stetho Collapsed valve lIfter scope able to push the rocker arm lIfter sIde down by hand Remove and replace the lIfter 101 101 ErratIc Irregular motIon of the valve stem StIckmg valve burned RecondItIon the valve and or valve valve gUIde t Next Chap ter EccentrIc motion of the pushrod at Bent pushrod the rocker arm Replace the pushr...

Page 56: ...ately 1h play at Its mId pOint under thumb pressure 11 2 Check the flUId level of the cooling system 11 3VISually InSpect the external por tIons of the coolIng system radia tor radIator hoses thermostat el bow water pump seals heater hoses etc for leaks If none are found pressunze the cooling sys tem to 14 15 pSI Replace or tIghten the fan belt as necessary Checkmg the fan belt tension Nlssan Moto...

Page 57: ...tor cap and Insert a thermometer Into the radIator Allow the engine to Idle After a short whIle there WIll be a sudden rapId Increase In coolant temperature The temperature at whIch thIS sharp nse stops IS the thermostat opemng temperature If the thermostat opens at or about the specI fied temperature If the temperature doesn tIncrease If the temperature Increases slowly and gradually replace the ...

Page 58: ... over nor underfull and that the pIckup In the sump IS In the proper posItion and free from sludge 12 5Inspect the 011 pump dnve and the 011 pump FIll ordrain the crankcase to the proper capa cIty and clean the pIckup screen In solvent If necessary If no Improvement IS noted If the pump dnve or the 011 pump appear to be defectIve service as necessary and retest per 12 1 If the pump dnve and pump a...

Page 59: ... as It was pomted ongInally This Will be done automatIcally If the marks on the engme and the distributor are lmed up With the rotor 2 Install the distrIbutor hold down bolt and clamp Leave the screw loose enough so that you can move the distrib utor WIth heavy hand pressure 3 Connect the pnmary wife to the COli Install the dlstnbutor cap on the diS tributor housmg Secure the distributor cap With ...

Page 60: ...r IS correctly m stalled the breaker pomts should be m such a posItion that they are Just ready to break contact With each other ThiS IS ac comphshed by rotatmg the distributor body after It has been mstalled m the engine Once agam lme up the marks that you made before the distrIbutor was removed from the engine 7 Install the distrIbutor hold down bolt 8 Install the spark plug mto the No 1 spark p...

Page 61: ...2 Front cover 6 Stator 10 Diode cover 3 Front bearing 7 Rear cover 11 Through bolt 4 Rotor 8 Brush assembly cb l IJ 1 I II Il 1 J Exploded v ew of alternator used on 510 610 710 and 200SX 1 Pulley assembly 2 Front cover 3 Front bearing 4 Rotor 5 Rear bearing 6 Brush assembly 7 Rear cover 8 Diode set plate assembly 9 Diode cover 10 Through bolt ...

Page 62: ...lternator attachmg bolts and remove the alternator from the vehICle 5 Install the alternator m the reverse order of removal REGULATOR Removal and Installation NOTE I9Z8 models are equlpped wfth mtegral regulator alternators Smce the regulator IS part of the alter nator no adjustments are possIble or necessary 1 Disconnect the negative battery ter mmal 2 Disconnect the electrical lead con nector of...

Page 63: ...S used to secure the contact set on the yoke and move the contact up or down as neces sary RetIghten the screw The gap should be 0 024 0 039 m 2 AdJust the pomt gap of the voltage regulator coIl by loosemng the screw used to secure the upper contact and AdJustmg the core gap 1 Contacts 2 Feeler gauge 3 Adlustlng screw Phillips screwdriver 8 Brush assembly 9 Ie voltage regulator 10 Rear cover 11 Th...

Page 64: ... be be tween 143153 volts at 680 F STARTER Removal and Installation 1 Disconnect the negative battery cable from the battery 2 Disconnect the starter wlflng at the Note the wIre locatIons before removmg the starter starter takmg note of the pOSItIons for correct remstallatlon 3 Remove the bolts attachmg the 4 Exploded v1ew 1978 non reductIOn gear starter 1 Magnetic sWitch assembly 9 Through bolt 1...

Page 65: ... 10 Thrust wosher 11 Stop washer 12 Stop clop 13 Pinion retainer 14 Pinion 15 Overunnln9 clutch 16 Field Call Exploded v ewof 510 610 and 710 starter CD l Exploded v ew of 1200 and B210 starter 1 End housing 8 Armature 15 Overrunning clutch 2 Dust cover 9 Thrust wosher 16 field Call 3 lever 10 Bushing 17 Yoke 4 Dust cover 1 Stop washer 18 Brush cover 5 Pin 12 Stop clip 19 Brush 6 Solenoid 13 PInio...

Page 66: ...ttery LOCK TE H Amp NO LOAD TEST Hour Torque Year Model Capaclly Amps Volts lrfIn Amps Volt RPM 1973 510 50 60 420 60 79 60 12 7 000 1973 1200 NA 420 63 65 60 12 7 000 All 610 NA 430 60 63 60 12 7 000 710 MT 540 50 60 60 2 6 000 AT Brush M mmum Spnng Bnuh Temwn Length oz m 62 028 62 037 49 64 047 4964 047 All 200SX NA Not Recommended 60 12 7 000 4964 047 All B210 NA Not Recommended 60 12 7 000 49 ...

Page 67: ...head The A12 A13 and A14 senes of engmes are used m the 1200 the B210 and the FIO The maJor difference be tween these engmes IS the mcreased diS placement of the A13 and the A14 achieved through a longer stroke All the A senes engmes are overhead valve engmes The camshaft IS placed high m the cylmder block allowmg short pushrods therefore valve tram recipro cating weight IS reduced and higher engm...

Page 68: ...the extra two cylmders the maJor difference IS that the L24 engme IS fuel mJected while the others are carbureted Like the others the 1 24 utIhzes a cast non block and an alummum cyhnder head Engines are referred to by model des Ignation codes throughout thiS book Use the Engme Identification chart for IdentificatIon of engmes by model number of cylInders dIsplacement and camshaft location Engine ...

Page 69: ...o p 1973 OHC4 973 Dual throat 96 100 327 x 2 90 85 1 54 57 510 1600 Sedan LI6 1595 downdraft 5 600 3 600 1973 OHV4 715 Dual throat 69 70 2 87 x 2 76 85 1 54 60 1200 Sedan A12 1171 downdraft 6 000 4 000 1200 Coupe 1973 OHC4 1080 Dual throat 100 100 335x3307 85 1 50 57 610 1800 Sedan L18 1770 downdraft 5 600 3 600 610 1800 Hardtop 610 1800 Wagon 197475 OHC4 1191 Dual throat 112 108 335x339 85 1 50 5...

Page 70: ...50 FI0 A14 1397 downdraft 6 000 3 600 1976 OHC4 1191 Dnal throat 112 108 335x339 85 1 50 57 610 L20B 1952 downdraft 5 600 3 600 1976 77 OHC4 1191 Dual throat 100 100 3 35 x 3 39 85 1 50 57 710 L20B 1952 downdraft 5 600 5 600 1977 78 OHC4 1191 Dual throat 97 102 335x339 85 1 50 57 200SX L20B 1952 downdraft 5 600 3 200 1978 OHC4 1191 Dual throat 97 102 335 x 3 39 85 1 50 57 510 L20B 1952 downdraft 5...

Page 71: ...ompreuwn Control LI6 o 001 002 0009 0015 00060012 o 006 0 012 o 002 0 003 o 001 003 o 001 003 A12 o 001 002 0008 0014 0008 0014 00100014 o 002 0 003 o 002 0 003 o 002 0003 L18 o ool 002 0014 0022 0012 0020 o 012 0035 o 002 0 003 o 002 0 003 o 002 0 003 A13 o 001 002 o 008 0 010 o 008 0 010 o 010 0030 o 002 003 o 002 0 003 L20B o ool 002 o 010 0 020 o 010 0 020 o 010 0020 o oo2 003 o 002 0 003 L20B...

Page 72: ...968 1766 o 00080 002 00016 0002 Yes 1975 78 A14 45 1975 78 129 119 1831 o 0006 0 002 00016 0003 Yes ENGINE REMOVAL AND INSTALLATION ALL ENGINES EXCErr F10 move the battery from models With the L16 engme 3 Dram the coolant and automatic transmiSSIOn flUId 4 Remove the gnlle on 510 610 and 710 models Remove the radIator after dIsconnectmg the automatic transmiSSIOn coolant tubes 5 Remove the au clea...

Page 73: ... pm and remove the lever from mSlde the car 12 Detach the exhaust pipe from the exhaust mamfold Remove the front sec tion of the exhaust system 13 Mark the relationship ofthe dnve shaft flanges and remove the dnveshaft 14 Place a Jack under the transmIs SIOn Remove the rear crossmember On 1200 and B210 models remove the rear engine mounting nuts 15 Attach a hOist to the IIftmg hooks on the engme a...

Page 74: ...e the slave cyhnder from the clutch housmg 7 Unhook the speedometer cable from the transmiSSIOn and remove the shift hnkage from the transmiSSIOn 8 Unbolt the exhaust pipe from the exhaust mamfold There are three bolts which attach the pipe to the mamfold and two bolts whICh attach the pipe support to the engme 9 Unbolt the axle shafts from the dif ferential 10 Remove the left and nght buffer rods...

Page 75: ...gether Rap the head With a mallet to loosen It from the block Remove the head and discard the gasket 8 Remove the pushrods keepIng them In order To replace the cylmder head on OHV engines 1 Make sure that head and block sur faces are clean Check the cylinder head surface With a straightedge and a feeler gauge for flatness Ifthe head IS warped more than 0 003 m It must be trued If thiS IS not done ...

Page 76: ...on the timing cham 1 Crank the engme until the No I piston I TDC ofthe compressIOn stroke and disconnect the negatIve battery cable dram the coolmg system and re move the aircleaner and attending hoses 2 Remove the alternator o o 4 3 o o 2 1 o o 6 5 o o 10 9 o L ene he lel torque hghtenmg equen e 4 vlll1 de 3 Disconnect the carburetor throttle Imkage the fuellme and any other vac uum lmes or elect...

Page 77: ... 20 Install and assemble the remammg components of the engme m the reverse order of removal Wedge thecham With a wooden block arrow Ifyou don t you lI be fishmg fur the cham m the crankcase DimenSIOns for fabricating wooden wedge used to hold ham m place L24 OVERHEAD CAMSHAFT ENGINE NOTE Any of the followmg proce dures that involve removmg or dlS turbmg the tlmmg chain on the over head cam en6lne ...

Page 78: ... 3 1 5 000 o 0 10 14 9 13 o 0 L24 head torque equenlt 14 Imtall a new head ga ket and place the head m pO ltlon on the block 15 Imtall the head bolt 111 their ongl nallocatIon 16 Torque the head bolts m three stage first to 29 ft lb then to 43 ft Ib then to 62 ft lb 17 Remstall the calmh lft procket 111 It ongm ll locatIon The ch un I m talled at the ame tIme 1 the procket Make ure the m lrh you m...

Page 79: ...ottle hnk age 3 Remove the B P T valve control tube from the mtake mamfold Remove the EGR hoses 4 DIsconnect all electncal wlflng to the fuel mJectIon Unit Note the location of the wues and mark them m some man ner to faclhtate re1l1stallatIon 5 Make sure all Wires hoses hnes etc are removed Unbolt the mtake mam fold Keep the bolts 111 order smce they are of two different sizes 6 InstallatIon IS t...

Page 80: ... Remove the OIl pump attachmg screws and take out the pump and ItS dnve spmdle 5 Remove the coolmg fan and the fan pulley together With the dnve belt 6 Remove the water pump 7 Remove the crankshaft pulley bolt and remove the crankshaft pulley 8 Remove the bolts holdmg the front cover to the front of the cylInder block the four bolts whICh retam the front ofth OIl pan to the bottom of the front cov...

Page 81: ...been removed It may be necessary to remove the 011 pan to reach the hfters for removal 8 The camshaft bearmgs can be pressed out and replaced They are avail able m underslzes should It be necessary to regrmd the camshaft Journals 9 Remstall the camshaft Ifthe locat mg plate has an Oil hole It should be to the nght ofthe engme The locatmg plate IS marked With the word LOWER and an arrow Locating pl...

Page 82: ...t to be re used markmg It IS useless 5 Unbolt the camshaft sprocket and remove the sprocket along with the cham As you remove the cham hold It where the cham tenslOner contacts It When the cham ts removed the ten SlOner IS gomg to come apart Hold on to It and you won t lose any of the parts There IS no need to remove the cham gUIde unless It IS bemg replaced 6 Install the tImmg cham and the camsha...

Page 83: ...e Ifthe notch m the sprocket IS to the left of the groove m the retammg plate then the cham IS stretched and needs ad Justmg CDto I to 3 2 Remove the camshaft sprocket together With the cham and remstall the sprocket and cham With the locatmg dowel on the camshaft mserted mto ei ther the no 2 or 3 hole of the sprocket dependmg on whether the engme IS a four or SIX cylmder The tlmmg mark on the tlm...

Page 84: ...tons With engme OIl 9 Turn the top compressIOn nng to bnng ItS gap to about the 1 30 0 clock posItIon Set the remammg nngs so that thelf gaps are posItioned 1800 apart around the piston The OIl nng gap w1l1 be dIrectly under the top compreSSIOn nng gap 10 Turn the crankshaft untIl the rod Journal of the particular cylInder you are workmg on IS brought to the TDC POSI tion 11 With the piston and nn...

Page 85: ...e the engine and transmis sIOn assembly from the vehicle 2 Remove the transmiSSIOn from the engme 3 Remove the clutch from the fly wheel 4 Remove the flywheel from the crankshaft 5 Remove the rear mam bearmg cap together With the beanng cap SIde seals 6 Remove the rear mam OIl seal from around the crankshaft 7 Apply lIthIUm grease around the sealmg IIp of the OIl seal and mstall the seal around th...

Page 86: ...ew gasket placed over the dnve spmdle mstall the OIl pump and dove spmdle assembly so that the proJec bon on the top of the dnve spmdle IS located m the 11 25 0 clock poslbon PosItion of distributor dnve spmdle L senes en gmes 9 Install the dlstnbutor With the metal tip of the rotor pomtlng toward the No 1 spark plug tower of the distributor cap 10 Assemble the remammg compo nents m the reverse or...

Page 87: ...engIne water pump removal 2 Loosen the four bolts retammg the fan shroud to the radiator and remove the shroud 3 Loosen the belt then remove the fan and pulley from the water pump hub 4 Remove the five bolts retammg the pump and remove the pump together With the gasket from the front cover 5 Remove all traces of gasket matenal and mstall the water pump m the reverse order With a new gasket and sea...

Page 88: ...s and remove the water outlet gasket and the thermostat from the thermostat housmg 4 Install the thermostat In the reverse order ofremoval usmg a new gasket WIth sealer and with the thermostat spnng to ward the mSlde of the engme ALL ENGINES 1 Dram the engme coolant mto a clean contamer so that the level IS below the thermostat housmg Thermostat removal ...

Page 89: ...ng process Starred Procedures that should be performed to ensure maximum performance and en gine lIfe Double starred Proce dures that may be performed to Increase enllne performance and relIabIlIty These procedures are usually reserved for extremely heavy duty or competItIOn usage In many cases a chOIce of methods IS also prOVIded Meth ods are Identified In the same manner as procedures The chOice...

Page 90: ...or anti seize com pounds before mstallatIon to prevent seIzure Never over torque bolts or spark plugs m alummum threads Should strlppmg occur threads can be restored accordmg to the followmg procedure usmg Heh COlI thread mserts Tap drIll the hole WIth the strIpped threads to the specIfied sIze see chart Usmg the specI fied tap NOTE Belt Cotl tap zes refer to the SIze thread be mq replaced rather ...

Page 91: ...nd number the valve faces front to rear usmg a permanent felt tIp marker Remove the rocker arms Valve Identification Remove the rocker arms With shaft s or balls and nuts WIre the sets of rockers balls and nuts together and IdentIfy accordmg to the correspondmg valve Remove the valves and sprIngs Usmg an appropnate valve spnng compressor dependmg on the configuration of the cyl mder head compress ...

Page 92: ...both dIago nals along the longitudinal centerlIne and across the cylInder head at several points If warpage exceeds 003 In a 6 span or 006 over the total length the cylinder head must be resurfaced NOTE If warpage ex ceeds the manufacturers maztmum toler ance for materzal removal the cyl1nder head must be replooed When mIlling the cylInder heads of V type engines the Intake manI fold mounting posI...

Page 93: ...With a machmlSt ReplaCing the valve guides OTE Valve guuks s undd only be replaced If dam aged or If an over8lZe valve stem ts not avatlo ble A VALVE GUIDE 10 B SLlGHnV SMALLER THAN VALVE GUIDE 0 0 Valve guide remonl tool A VALVE C UIDE I 0 B LAAGEA THAN THE VALVE GUIDE 0 0 Dependmg on the type of cylInder head valve guIdes may be pressed hammered or shrunk In In cases where the guides are shrunk ...

Page 94: ...t WIth a pIlot of the correct SIze InstalI the ptlot Into the valve gUIde and uSing steady pressure turn the reamer clockWIse CAUTION Do not turn the reamer counter clockwISe Remove only as much material as necessary to clean the seat Check the concentricIty of the seat see below If the dye method IS not used coat the valve face WIth Prusslan blue dye in stall and rotate It on the vahe seat USing ...

Page 95: ...s changing POSI tIon and hftlng the tool often to prevent grooving Lap the valve untIl a smooth pol Ished seat IS eVIdent Remove the valve and tool and nnse away all traces of grinding compound Fasten a suctIOn cup to a pIece of drill rod and mount the rod In a hand dnll Proceed as above uSing the hand drIll as a lapping tool CAUTION Due to the hIgher speeds In volved when u8Ing the hand dTtll car...

Page 96: ...pnng Installed height LubrIcate the valve stems and mstall the valves In the cylInder head as numbered LubrIcate and pOSItIOn the seals IT used see above and the valve spnngs Install the spring retainers compress the spnngs and Insert the keys using needlenose plIers or a tool desIgned for thiS purpose NOTE Re tam the keys unth wheel beanng grease dunng mstallaturn Measure the dIstance between the...

Page 97: ...ooth and square remov Ing as lIttle matenal as pOSSible Replace the rocker arm If exceSSively worn If a rocker stud shows SignS of wear It must be re placed see below If a rocker nut shows stress cracks replace It If an exhaust ball IS galled or burned substItute the Intake ball from the same cylInder If it IS Intact and Install a new Intake ball NOTE Avotd USIng new rocker baIl 071 ezhaust valves...

Page 98: ...qual Measure the length of the pushrods com pare to specIficatIOns and replace as neces sary Inspect the valve lIfters i Checking the lifter face Remove lIfters from theIr bores and remove gum and varnIsh uSing solvent Clean walls of lIfter bores Check lIfters for concave wear as Illustrated If face IS worn concave re place lIfter and carefully Inspect the cam shaft LIghtly lubrIcate lIfter and In...

Page 99: ...ed If bearing or Journal appear defectIve cause of fa1lure should be deter mined before replacement noUl AnUtI Remove crankshaft from block see below Measure the main bearing Journals at each end tWIce 90 apart uSing a mIcrometer to determine dIameter Journal taper and ec centricIty If Journals are Within tolerances reinstall beanng caps at theIr speCified torque USing a telescope gauge and mI cro...

Page 100: ...Remo e the rIdge from the top of the cylIn der RIDGE CAUSED BY CYLINDER WEAR Cylinder bore ridge RemOVIng the pIston and connectIng rod In order to faclhtate removal of the pIston and connecting rod the rIdge at the top cf the cylInder unworn area see Illustration must be removed Place the pIston at the bottom of the bore and cover It WIth a rag Cut the rIdge away USIng a ndge reamer exercIsing ex...

Page 101: ...block Ha e the block hot tanked to remove grease corrOSIOn and scale from the water Jackets NOTE COlls lt the operator to determme whether the cam ha It beanngs Ill be dam aged dUTlng the hot tall process Check the block for cracks VIually Inspect the bloc for cracks or chIps The most common locations are as follows Adjacent to freeze plugs Between the cylInders and water Jack ets AdJacent to the ...

Page 102: ...n oversize piS ton Installed If the measurements are WIth In specifications the cylInder may be used as IS WIth only finish hOning see below NOTE Prtor to submttttng the block for bcmng perform the follounng operatton s Check the bore dIameter and surface 2 3 PIston skirt selz ure re sulted In thiS pattern Engme must be rebored 4 Piston skirt and all ng seizure caused thiS damag Engine must be reb...

Page 103: ...eeds 005H the deck heIght should be corrected NOTE Block deck he ght and warpage should be corrected concurrently Check the cyl1n 1er block bearing alIgn ment Checkmg maIO beanng saddle alignment Remove the upper bearing Inserts Place a straightedge In the beanng saddles along the centerlIne of the crankshaft If clear ance eXIsts between the straIghtedge and the center saddle the block must be ahg...

Page 104: ...xceSSIVe try to obtain a slIghtly larger pIston to bnng clearance WIthin specIfications Where this IS not pOSSible obtain the first oversIze piS ton and hone or If necessary bore the cylInder to size A semble the pIstons and connecting rods SlJl Installing piston pmlock rings Inspect pIston pin connectIng rod small end bushing and pIston bore for gallIng scor mg or excessive wear If eVIdent replac...

Page 105: ...l typical If excessIve wear IS indIcated or If the engine IS being completely rebUIlt camshaft bear Ings should be replaced as folIows DrIve the camshaft rear plug from the block As semble the removal puller WIth its shoulder on the bearing to be removed GradualIy tighten the puller nut until beanng IS re moved Remove remaining bearlngs leavlng the front and rear for last To remove front and rear ...

Page 106: ... file Hold the ring In the groove and measure Side clearance If necessary correct as indICated above NOTE Always tnstaU any addtttonal spacers above the ptS ton nng The nng groove must be deep enough to allow the nng to seat below the lands see IllustratIOn In many cases a gono go depth gauge WIll be provided With the pIston rings Shallow grooves may be corrected by recutting while deep grooves re...

Page 107: ...eat the seal Hold the pIpe In pOSI tion and tnm the ends of the seal flush if reqUIred Install the crankshaft Satfna the rear m11ln aeal L J Home made belnng roll out pin PRY FORWARD PRY CRANKSHAfT FORWARD Thoroughly clean the mainbeanng saddles and caps Place the upper halves of the beanng Inserts on the saddles and press Into posi tion NOTE Ensure that the 011 holes alIgn Press the correspondlnV...

Page 108: ...unt a dIal indIcator stand on the front of the block With the dIal indICator stem rest Ing on the nose of the crankshaft parallel to the crankshaft aXIs Pry the crankshaft the extent of Its travel rearward and zero the indIcator Pry the crankshaft forward and record crankshaft end play NOTE Crankshaft end play also may be measured at the thrust beanng ll81ng feeler gauges see IllustratIon j Checki...

Page 109: ...to protect the crankshaft Journals Installing a piston Check connecting rod Side clearance Determine the clearance between the Sldes of the connecting rods and the crankshaft us Ing feeler gauges If clearance is below the m1mmum tolerance the rod may be ma chined to provide adequate clearance If clearance IS exceSSIve substItute an unworn rod and recheck If clearance ISstili outside specifications...

Page 110: ...ushing In the crankshaft If the bushing IS excessIvely worn remove It WIth an expand Ing puller and a slIde hammer and tap a new bushing Into place PosItIon the engine cylInder head Side up LubrIcate the lIft ers and Install them Into theIr bores InstaIt the cylInder head and torque It as specified In the car sectIOn Insert the pushrods where applIcable and Install the rocker shaft s If so eqUIp p...

Page 111: ...tIOn of the gases whICh are formed m tern IS the PCV valve ThiS vacuum con the combustion chamber durmg combus trolled valve regulates the amount of tlon leak by the piston nngs and enter the gases whICh are recycled mto the com crankcase Smce these gases are under bustIon chamber At low engme speeds pressure they tend to escape from the the valve IS partIally closed hmltIng the crankcase and ente...

Page 112: ...eby Moon AirtempcrllUftSCDSOr Droppullrau1or Overall VIew of 810 emISSIons control system Crank Collie ventilation control valve 2 name Jrre tcr 3 Scaled flllcr cap 4 Baffle plate S Od levcl pugc 6 O rmg 7 Od para tor 8 BJffle plate 9 namc anc tcI Crankcase ventIlatIOn system schematIc ...

Page 113: ...heIr own way out of the crankcase This alternate route IS usually a weak OIl seal or gasket m the engme As the gas escapes by the gasket It also creates an OIl leak BeSides causmg OIl leaks a clogged PCV valve also allows these gases to remam m the crankcase for an extended penod of time promotmg the formation of sludge m the engme The above explanatIon and the trouble shooting procedure whIch fol...

Page 114: ...Side and the fuel tank or crankcase be comes 2 m Hg the rehef valve opens and allows ambient au from the au cleaner mto the fuel tank or the engme crankcase ThiS ambient au replaces the vapor wlthm the fuel tank or crankcase bnngmg the fuel tank or crankcase back mto a neutral or posItive pressure range EvaporatIve ernlSSlOn control system schematIc 1 Carbon canister 2 Vacuum SIgnal line 3 Camster...

Page 115: ...tarded POInts CIrCUIt the advanced set of pomts con trols the pnmary CIrCUIt The retarded set of pomts IS activated as follows The retarded set of pomts IS actIvated only whIle the throttle IS partially open the temperature IS above 500 F and the transmiSSIon IS m any gear but Fourth gear NOTE When the ambIent tempera ture IS below 300 F the retarded set of pomts IS removed from the Igmtlon CIrcuI...

Page 116: ...CE 1 Disconnect the WIrmg harness of the distributor from the engme harness 2 Connect the black WIre of the engme harness to the black WIre of the dlstnbutor harness With a Jumper WIre ThiS connects the advanced set ofpomts 3 With the engme Idlmg adJust the Ignition tImmg by rotating the distrIbu tor 4 DIsconnect the Jumper WIre from the black WIre of the dIstributor harness and connect It to the ...

Page 117: ...ting prevents the complete combustion ofthe air fuel mIXture because of the reduced amount of au ThiS condition Will result m a large amount of HC emiSSIOn Ennchmg the au fuel mixture for a short time dunng the high vacuum condition Will reduce the emiSSIOn of HC However ennchmg the au fuel mix ture With only the mixture adJustmg screw Will cause poor engine Idle or m vlte an mcrease m the carbon ...

Page 118: ...e BCDD IS lower than the mtake mamfold vaC lum when the throttle IS suddenly released the engine speed wIll not lower to Idle speed To adJust the set operatmg pressure of the BCDD remove the adJustmg screw 1 BCDD adJusting screw 2 Cover cover from the BCDD mechamsm mounted on the Side of the carburetor On 810 models the BCDD system IS m stalled under the throttle chamber The adJusting screw IS a l...

Page 119: ...side under hood aIr to be drawn mto the engme Testing When the au around the temperature sensor ofthe umt mounted Inside the au cleaner housmg reaches 100 F the sen sor should block the How of vacuum to the au control valve vacuum motor When the temperature around the tem perature sensor IS below 1000 F the sen sor should allow vacuum to pass onto the au valve vacuum motor thus blockmg off the au ...

Page 120: ...ated and blocks the vacuum Ime lead mg to the EGR valve thus preventIng exhaust gas reclIculatIon When the tem perature of the engme coolant reaches operating temperature the solenOId IS deactIvated and vacuum IS allowed to act upon the EGR valve diaphragm and ex haust gas reclIculatlon takes place Testing Check the operatIOn of the EGR sys tem as follows 1 VIsually mspect the entire EGR control s...

Page 121: ...powered test hght to the two electrical leads of the sWitch g Heat the con tamer of water h The sWitch should conduct cur rent when the water temperature IS below 770 F and stop conducting cur rent when the water reaches a tempera ture somewhere between 880 1060 F Replace the SWItch If It functions other wise TRANSMISSION CONTROLLED SPARK SYSTEM The TransmissIOn Controlled Spark System TCS was mtr...

Page 122: ...of the pump body vanes and rotor for wear If the rotor has abnormal wear replace the aIr pump 3 Check the needle roller beanng for wear and damage Ifthe bearmgs are de fective the aIr pump should be replaced 4 Check and replace the rear Side seal Ifabnormal wear or damage IS notIced 5 Check and replace the carbon shoes holdmg the vanes If they are found to be worn or damaged 6 A depOSIt of carbon ...

Page 123: ...mmg from the pump The au pump rehef valve should vent the pres sunzed au to the atmosphere IfIt IS work mg properly NOTE When performmg this test do not completely block the discharge lme of the aIr pump as damage may result If the reltef valve falls to func tlOn properly AIR INJECTION NOZZLES Check around the aIr mamfold for au leakage WIth the engme runmng at 2 000 rpm If au IS leakmg from the e...

Page 124: ...o the at mosphere NOTE Only unleaded fuel must be used wIth catalytic converters lead In fuel will qUIckly pollute the catalyst and render It useless The emergency aIr rehef valve IS used as a catalyst protection deVIce When the temperature of the catalyst goes above maximum operating temperature the temperature sensor sIgnals the sWItchmg module to actIvate the emergency aIr re hef valve ThiS sto...

Page 125: ...mp mount mg nuts and remove the fuel pump as sembly from the sIde of the engme 3 Install the fuel pump m the reverse order of removal usmg a new gasket and sealer on the matmg surface FUEL PUMP HO The 810 smce It IS fuel mJected utJ hzes an electnc fuel pump mounted near Fuel pump locahon L senes fours I Packmg 2 Valve assembly 3 Retamer 4 Screw 5 Diaphragm assembly 6 DIaphragm spnng 7 Retamer 8 D...

Page 126: ... the engme stalls for some reason the fuel pump IS cut off even though the IgmtIon sWitch remams m the on posItIon Fuel Pump Removal and Installation 810 ReleaSing pressure at the cold start valve 1 Disconnect the negative battery cable 2 Locate and disconnect the cold start valve harness connector See the Illustra tion for the locatIon 3 Usmg two Jumper WIres from the battery energize the cold st...

Page 127: ...etors discussed m thiS book are two stage type carburetors On thiS type of carburetor the engme A II 1 Secondary throttle lmkage adJustment 1 Roller 2 Connecting lever 3 Return plate Adlust plote 5 Throttle chamber 6 Throttle valve Carburetor used on later L senes engInes rum on the pnmary barrel most of the tIme With the secondary barrel bemg used for acceleration purposes When the throttle valve...

Page 128: ...ould be 0 0374 m With a manual trans mISSIOn and 0 0461 m With an automatic transmiSSIOn 2 Install the carburetor on the engme 3 Start the engme and measure the fast Idle rpm With the engme at operatmg temperature ThiS should be about 2 000 rpm WIth a manual transmiSSIOn and 2 400 rpm With an automatic transmis sIOn 4 To adJust the fast Idle speed turn the fast Idle adJustIng screw coun terclockWi...

Page 129: ...tle and choke shaft wash all parts except diaphragms elec bores for wear or an out of round condl tnc choke umts pump plunger and any tlon Damage or wear to the throttle ann other plastic leather fiber or rubber shaft or shaft bore Will often reqUIre re parts m clean carburetor solvent Do not placement of the throttle body These leave parts III the solvent any longer than parts reqUIre a close tol...

Page 130: ...wer valve 12 Secondary maIn all bleed 13 Pnmary mam all bleed 14 InJector weIght IS Pnmary slow all bleed 16 AcceleratIng pump 17 Plug 18 Pnmary slow Jet 19 Needle valve 20 Float 21 Anll dleselmg solenOId valve 22 Primary mam Jet 23 Secondary mam Jet 24 Idle hm1ter cap 25 Idle adJust screw 26 Spnng 27 Throttle adJust screw 28 Spnng 29 Pnmary and secondary throttle valve 30 Acceleratmg pump rod 31 ...

Page 131: ... 38 DlIphr chamber parts 39 Idle lImiter ap 40 Idle adjUst SClew 41 Idle adjUst screw SP Ull 42 Throttle adjust screw 43 Throttle adjust screwsplll1l 44 Primary nd secondary throttle 1 45 BCD 0 for Cabfonu3 46 Vacuum ntrollOlenold valve 47 BCD D except C bromta Note Do not remove the parts marked With steruk r Exploded vIew of 1975 710 carburetor earher models 610 and 510 are stnular not the other...

Page 132: ...u seats but do not overtighten as the tIps Will be distorted Tighten all screws gradually m rotatIon Do not tighten needle valves mto theu seats uneven Jetting Will result Always use new gas kets Be sure to adJust the float level when reassemblmg ELECTRONIC FUEL INJECTION SYSTEM The electromc fuel inJectIon svstem used on the L24 engme In the 810 IS a Bosch L Jetromc umt bUIlt under hcense m Japan...

Page 133: ...r temperature sensor tempera ture of mtake au 6 Startmg sWitch signals that starter IS operatmg 7 Altitude sWitch used on Cahfornla i cars to signal changes m atmo phenc pressure The sensors provIde the mput to the control UnIt whICh determmes the amount of fuel to be mJected by ItS preset program The L JetronIc fuel mJectIon system IS a highly complex UUlt All repair or ad Justment should be left...

Page 134: ... the passage of current when It IS the electncal component IS mounted turned off Smce the sWitch IS a part of Perhaps the easiest way to vlsuahze the CIrcle necessary for a complete CH thiS IS to thmk of connectmg a hght bulb CUlt It operates to leave an opemng In With two WIres attached to It to your car the CirCUIt and thus an mcomplete or battery The battery m your car has two open CIrCUIt when...

Page 135: ...A Similar thmg happens on a smaller scale when the power supply wire to a component or the electncal component Itself becomes grounded before the normal ground con nectIon for the CIrCUIt To prevent dam age to the system the fuse for the CIrCUIt blows to mterrupt the CIrCUlt protectmg the components from damage Because groundmg a WIre from a power source makes a complete circUIt less the reqUIred ...

Page 136: ... IS defective NOTE Never substttute the Jumper WIre for the bulb as the bulb IS the component reqUIred to use the power from the pother source 5 If the bulb In the test hght goes on then the current IS gettmg to the bulb that IS not workmg m the car ThIS elImmates the first ofthe three pOSSible causes Con nect the power supply wife andconnect a Jumper wire from the bulb to a good metal ground Do t...

Page 137: ... sure that the system IS filled With coolant 1977 78200SX 1 Disconnect the battery cable 2 Dram the engme coolant and re move the heater hose from the engme Side 3 Inside the pas enger com part ment disconnect the lead wires from the heater umt to the m trument harness 4 At thiS pomt the mstrument panel must be removed m order to remove the heater assembly To remove the panel proceed as follows 5 ...

Page 138: ...e mlet and outlet hoses 6 Remove the heater duct and re move the defroster hoses from the as sembly 7 Remove the au mtake door control cable 8 Disconnect the wlflng harness to the heater 9 Remove the retammg bolts and re move the heater umt 10 Installation IS m the reverse order of removal 1977 78 FIO 1 Disconnect the battery ground cable 2 Dram the engme coolant and re move the heater hoses 3 Rem...

Page 139: ...ater sWitch 11 Heater hose outlet 7 Heater control 12 Defroster nozzle l H 8 Heater case R H 13 Defroster dud l H 9 Heater COre 10 Heater case L H CD 1 S de outf t 2 Cooler dud 3 Defroster naule Heater assembly 1978 510 Defroste duct 7 Side defroster connector 5 Heater unl 8 Center ventilation duct 6 S de defroster center duct ...

Page 140: ...lve 9 Control Wile heater control to water cock 10 Control rod heater control to shut valve 11 Heater cock 1200 heater I Defroster nozzle 2 Oer ro ter hose 3 Air Intake box 4 Hcater box L H 5 ClIp 6 He ater core 7 Ventilatorvalve 8 Re lstOJ 9 Heater bo R H 10 Fan and fan motor 1 t Healer cock 12 Heater control 13 Center ventilator 14 Knob 15 Hedt valve B210 heater ...

Page 141: ...Remove the heater assembly as de scnbed earher 2 Remove the seahng sponges Unfas ten the seven chps that hold the heater case together 3 Remove the heater core from the cases 4 InstallatIOn IS the reverse of re moval 1977 78200SX I Remove the heater assembly as de scnbed earher 2 Remove the heater controls from the heater body 3 Remove the connectIng rod from the au mIx door 4 UnclIp the five clIp...

Page 142: ...ll out the radIO SWItch knobs 3 In order to remove the mstrument panel first remove the steenng wheel and cover 4 Remove the control knobs on the In strument panel by pushIng In on them and turnmg them counterclockwIse Once the knobs are removed remove the nuts 5 Remove the Instrument panel screws See the IllustratIon for theIr loca tIon 6 DIsconnect the SWItch WIres after notIng theIr locatIon an...

Page 143: ...er of removal 1978 510 1 DIsconnect the battery ground cable 6 Defroster nante 7 Instrument garmsh 8 RodJO 9 Speaker 10 Ventllohon duct 11 Package trQY 12 Glove box 13 Glove box I d 14 Ash troy 15 Outer case 2 Remove the steenng column covers and dIsconnect the hazard warn mg sWItch connector 3 Loosen the wIper sWItch attachmg screws and remove the wIper sWItch 4 Pull out the ash try and the heate...

Page 144: ...0 mstrument cluster 1978 510 Imtrument panel removal pomts L Cluster lad A 2 Cluster lid 8 3 Instrument panel 4 FInisher A 0 Cluster lid B securing Cluster lid A securing screw posItions screW positions I l Wiper motor 1978 510 ...

Page 145: ...ots to the body Remove the aIr mtake grIlle for access 3 Open the hood and unscrew the motor from the firewall 4 DIsconnect the wumg connector and remove the wIper motor WIth the Imkage 5 Reverse the procedure for mstalla tIon Wmdshleld wiper motor and hnkage 710 NOTE If the wIpers do not park cor rectly adjust the pOSItIOn of the auto matIc stop cover on the wIper motor 1200 B21o AND FlO The wIpe...

Page 146: ...clockWIse to remove 3 From the rear dIsconnect the lIghter wue Turn and remove the lIghter outer case 4 Remove the radIO and heater knobs 5 Remove the shell cover from the steenng column 6 Remove the screws whICh hold the Instrument cluster to the Instrument panel Pull out the cluster 7 DIsconnect the wumg connector 1200 mstrument cluster removal DIsconnect the speedometer cable by unscrewmg the n...

Page 147: ...ents may now be readIly replaced 12 Reverse the procedure for mstalla bon 1 Meter 2 RadiO 3 Glove box 4 Speaker 5 Instrument panel 6 Slay Escutcheon 5 Wiper SWitch knob 6 RadiO knob 7 Cigarette lIghter 8 Gauges 9 Light SWitch 1 0 Tachometer 11 Wiper SWitch 12 RadiO 13 Clock FlO 1 DIsconnect the battery ground cable 2 DI connect the speedometer cable from the back of the speedometer 3 Remove the pa...

Page 148: ...ble 2 Remove the steenng column cov ers 3 DIsconnect the speedometer cable and the radIO antenna 4 DIsconnect all the WIres from the back of the panel after notIng theIr loca tIon and markmg them 5 Remove the bolts whIch secure the steermg column clamp Remove the package tray 6 Unbolt the panel from the brackets on the left and nght hand SIdes 7 Remove the nght slde wmdshleld pIllar tnm and remove...

Page 149: ...nob 13 Speaker harness 4 Gauges 9 light control sWitch 14 illumination bulb 5 light monator 10 Cluster cover 15 Instrument panel f1 200SX Instrument panel 1 Cluster lid 2 Meter assembly 3 Instrument mounting lower bracket Instrument pad S Ventilation grille 6 Defroster nozzle 7 Instrument garmsh 8 Radio 9 Speaker 10 Ventilation duct 11 Package tray 12 Glove box 13 Glove box lId 14 Ash troy 15 Oufe...

Page 150: ...all the gnlle If It was removed from the car Fuses Model Fu e Bo Location FlUe Lank LocatIOn 1973 510 Engme compartment rIght rear Between battery and alternator 1973 1200 78 Under mstrument panel rIght of steermg column 610 710 Under mstrument panel Between battery and alternator behmd wmd shIeld washer tank B21O FI0 Below hood release knob Adjacent to battery posItIve ternunal 810 KKk panel rIgh...

Page 151: ... now be fully downward 4 Increase the mltIal clearance A by 8 mm 031 In 5 Push lever 4 fully upward Now tIghten nut I untIl It makes contact WIth trunmon 7 Then back the nut offone full mrn and tIghten It WIth nut 2 FIVE SPEED MODELS 1 Loosen locknuts 1 2 3 and 4 2 Make sure shIft lever 5 IS pushed completely Into the transmISSIOn case then move It back 8 mm 031 m 3 Place the car m thIrd gear 4 Pu...

Page 152: ... 4 speed transmISSIon j 8 For S speed tnnSml5l10n FI0 shIft hnkage assembhes 1 Select lewr E 2 Shift lever E 3 Shift rod Shift lever 5 Select rod 6 Select lever 7 Radius link 8 Control rod 9 Hand lever 8mm 031 In Four speed Imkage FI0 ...

Page 153: ...ght sWItch 5 Remove the shIft lever 6 Remove the clutch operatmg cylm der from the clutch housmg 7 Support the engme WIth a large 1200 and B21O hsconnect the back up hght SWitch I speedometer cable 2 clutch slave cy hnder 3 rear engme mount bolts 4 crossmem ber bolts 5 11 O Disconnect speedometer and back up hght sWitch wood block and a Jack under the 011 pan 8 Unbolt the transmISSIOn from the cro...

Page 154: ...peed transmiSSiOn used m the 710 Remove the clutch slave eylmder 510 610 and 710 erossmember bolts 9 Lower the rear of the engIne to allow clearance 1978 510 erossmember removal 10 Remove the starter NOTE On 610 and 710 unbolt the support gussets from the engine and transmISSIOn 11 Unbolt the transmISSIOn Lower and remove It to the rear 12 Reverse the procedure for rem stallabon Check the clutch h...

Page 155: ...eased thIS spnng IS convex that IS It IS dIshed outward toward the transmls slOn Pushmg m the clutch pedal achIates the slave cylmder Connected to the other end ofthe slave cyhnder rod IS the throwout beanng fork The throwout beanng IS attached to the fork When the clutch pedal IS depressed the slave cyl mder pushes the fork and beanng for ward to contact the dIaphragm spnng of the pressure plate ...

Page 156: ... Clutch cover aso embly 8 Operatmg cylinder 4 Release beanng and eeve ll mbly 9 Wllhdrawallever 5 Return spring 10 Wtthdrawallever ball pm 510 610 and 710 clutch control system I Clutch pedal 2 Clutch master cyhnder 3 Clutch plpmg 4 OperaUQI cyhnder S WIthdrawal lever 6 Release beanlll 7 Clutch co r 8 Clutch disc 9 Return spnng 10 Push rod ...

Page 157: ...eeve the con tact surface of the lever ball pIn and lever Replace the release mechamsm 5 Install the dISC ahgmng It WIth a splIned dummy shaft Tlghtenmg the pressure plate bolts The dummy shaft keeps the plate m alIgnment 6 Install the pressure plate and torque the bolts to 17 18 ft Ibs on L16 engInes and 11 16 ft Ibs on all other engmes 7 Remove the dummy shaft 8 Replace the transmISSIOn FlO Beca...

Page 158: ...ver from the upper sectIon of the clutch housmg 3 Remove the SIX bolts whIch secure the clutch cover The easIest way to turn the engIne over to reach all the bolts IS to Jack up the nght front wheel place the Removmg clutch cover bolts L Removmg prImary dnve gear transmISSIOn In hIgh gear and rotate the wheel by hand 4 Remove the InspectIon hole cover on the nght SIde wheel housmg 5 Remove the thr...

Page 159: ...d scores and replace the parts as necessary LIght scor mg and glaze can be removed WIth crocus cloth soaked m brake flUId 7 Generally the cup seal should be replaced each tIme the master cylmder IS dIsassembled Check the cup and replace It IfIt IS worn fatIgued or damaged 8 Check the clutch flUId reservOIr filler cap dust cover and the pIpe for dIS tortIon and damage and replace the parts as neces...

Page 160: ...roken CID I ft Jf V I Bleeder screw 2 Cylinder body 3 PISton cup 4 Plslon 5 Dust cover 6 Push rod 7 Lock nut 8 Push nut Exploded vIew of 510 610 and 710 slave cylmder 8 Lubncate all of the new parts m clean brake flUId and reassemble m the reverse order of dIsassembly takmg note of the foIIowmg a Use care when reassembhng the pIston cup to prevent damagmg the hpped portIOn of the pIston cup b FIll...

Page 161: ...Jack up the front ofthe car and sup port It safely on stands 2 SlIde a dram pan under the trans mISSIOn Loosen the rear 011 pan bolts first to allow most ofthe flUId to dram off WIthout makmg a mess on your garage floor 3 Remove the remammg bolts and drop the pan 4 DIscard the old gasket clean the pan and remstall the pan WIth a new gasket 5 TIghten the retammg bolts In a cnss cross pattern startm...

Page 162: ... lInkage 3 Detach the shIft Imkage 4 DIsconnect the neutral safety sWItch and downshIft solenoId wmng 5 Remove the dram plug and dram the torque converter If there IS no con verter dram plug dram the transmISSIOn Dlsconnectmg torque converter bolts through access hole If there IS no transmIssIOn dram plug remove the pan to dram Replace the pan to keep out dIrt 6 Remove the front exhaust pIpe 7 Rem...

Page 163: ...Iversal JOInts one at each end and a slIp yoke at the front of the assembly whICh fits Into the back of the transmISSIOn The 610 810 and 200SX Incorporate an addItIonal umver sal JOInt at the center of the dnveshaft WIth a support bearmg The FlO does not use a dnveshaft III the conventIonal sense Instead power IS transmItted to the front wheels through a paIr of axle 1 Sleeve yoke 2 Spider With fo...

Page 164: ... bracket 5 Center bearing support 6 Center bearing 7 Companion flange 8 Flange yoke 9 Rear drlveshaft Exploded view of 810 dnveshaft Exploded view of 200SX manual transmISSIOn dnveshaft 1 Front drlveshaft 2 Real drlveshoft 3 Dust seal 4 Snap r1 n9 5 Boll bearing 6 Cushion 1 Center bearing Insulator ...

Page 165: ...t be dIsassembled for lubncatIon at 24 000 mIle mtervals The splmes are lubncated by transmISSIOn 011 1 Release the handbrake 2 Loosen the 510 muffler and rotate It out of the way 3 On the 510 remove the handbrake rear cable adjustIng nut and dIsconnect the left handbrake cable from the ad Juster 4 Unbolt the rear flange 5 Pull the dnveshaft down and back 6 Plug the transmISSIOn extensIOn housmg 7...

Page 166: ...tly speakmg they are not dnve shafts but dnve axles A specIal puller IS necessary to remove the axles The tool IS Illustrated here 1 Jack up the car and support It WIth safety stands 2 Remove the wheel and tue 3 Pull out the cotter pm and then re move the wheel beanng nut You ll have to hold the wheel hub stIll somehow whIle you do thIS 4 Remove the bolts whICh secure the dnvesha to the transaxle ...

Page 167: ... the brake backIng plate 4 Attach a slIde hammer to the axle shaft and remove It Use the shde ham mer and a two pronged puller to remove the 011 seal from the hOUSIng NOTE If a slide hammer IS not aVail able the axle can sometimes be pned out uSing pry bars on opposmg Sides of the hub If end play IS found to be exceSSIve the bearIng should be replaced ShIm mIng the beanng IS not recommended as thI...

Page 168: ...rease Coat the seal hp also 9 Remstall the wheel beanngs In Pack with wheel bearmg grease MP2 or MP3 at each overhaul 1 Grease seal 3 Distance pIece 2 Wheel bearmg Inner Cutaway of wheel beanng stall the outer beanng on the axle shaft so that the sIde WIth the seal WIll be toward the wheel Always press or dnve on the mner beanng race 10 The dIstance pIece may be reused If It IS not collapsed or de...

Page 169: ...6 In 14 If the turnIng torque or axle shaft play IS Incorrect dIsassemble the umt and Install a new dIstance pIece The axle dnveshafts must be removed and dIsassembled to lubncate the ball splInes every 30 000 mIles Handle the dnveshaft carefully It IS eaSIly damaged No repaIr parts for the dnveshafts are Fadener Torque It lb Wheel nut Axle dnveshaft Bange nuts Beanng locknut Axle shaft mner Bange...

Page 170: ...ose the balls and spacer 5 Pack about 10 grams 035 oz of grease mto the ball grooves Also pack about 35 grams I 23 oz ofgrease mto the other area 6 TWlsbng play between the two shaft halves should not exceed 0 004 10 Check play WIth the dnveshaft completely com pressed 7 WhIle reassemblmg adjust the U Jomt sIde play to 0001 m or less by se lectmg sUItable snap nngs Four dIf ferent thIcknesses are ...

Page 171: ...ensIOn rods whICh attach to the chaSSIS STRUT Removal and Installation 1 Jack up the car and support It safely Remove the wheel 2 DIsconnect and plug the brake hose Remove the brake cahper as out hned In Chapter 9 Remove the dISC and hub as descnbed In thIS chapter 3 DIsconnect the tensIOn rod and sta blhzer bar from the transverse lInk 4 Unbolt the steenng arm Pry the control ann down to detach I...

Page 172: ... 7 Tension rod 8 Transverse link 9 Lower ball lOin 200SX front suspenSIOn Strut mounting Insulator Strut mounhng beanng Upper spring leat Bumper rubber Dust cover 6 Platon rod 7 Front prlng 8 Strut assembly 9 Hub auombly 10 Splndlo 11 8alllo n 12 Transverse link 13 TenSion rod 14 Stabilizer 15 Suspension member 1200 and B210 front suspensIOn 3 ...

Page 173: ...lOin Transverse lank 5 Sub frame 6 Drlveshaft 7 Stabilizer FI0 front suspensIon 6 7 510 610 and 710 front suspenSIon 1 tnIt mounting lulator 2 COlI spring 3 Stmt assembly 4 SuspenSlon ross member 5 Stabilizer 6 Tenslon rod 7 Transverse link 8 Steenng knuckle arm 1 ...

Page 174: ... relYIng Instead on a method of determInIng the force In Inch pounds reqUIred to keep Pry the control arm down to separate the strut from the ball JOInt rurnIng ThIS method IS not the knuckle very helpful to the backyard mechanIC SInce It Involves removmg the ball JOInt whICh IS what we are tryIng to aVOId In 8 Reverse the procedure to Install The self lockIng nuts holdIng the top of the strut mus...

Page 175: ...l beanngs are m good shape and properly adjusted As a double check on thIS have someone watch the ball Jomt whIle you move the tue up and down WIth the bar Ifyou can see conSIderable play beSIdes feelIng play at the top of the wheel the ball Jomt needs replacmg Removal and Installation 1 RaIse and support the car so that the wheels hang free Remove the wheel 2 Unbolt the tensIOn rod and stabl hzer...

Page 176: ...d replace It 1 Steenng gear arm 2 Crossrod 3 Stde rod 4 Side rod outer socket 5 Side rod lOner socket 6 Idler ann assembly Use a brass dnft to remove the beanng races 10 Replace the cahper brake hose and wheel Lower the vehICle FI0 Hub Assembly Removal and Installation I Jack up the car and support It wIth Jackstands 2 Remove the wheel and tIre as sembly Detach the brake Ime and plug It to prevent...

Page 177: ... OtherwIse undue force may be applIed to the dnveshaft 6 InstallatIon IS In the reverse order of removal Hub removal FRONT END ALIGNMENT Caster and camber angles cannot be adjusted except by replaCIng worn or bent parts SuspensIOn heIght IS adjusted by replaCIng the front spnngs Vanous spnngs are avaIlable for adjustment Toe In IS adjusted by changmg the length of the steerIng sIde rods The length...

Page 178: ......

Page 179: ...to 1 IS o 04 0 12 8 OS 9 3S 40 42 33 30 3S 30 S 1 35 004 0 12 7 4S 9 IS 40 42 33 30 3S 30 SO 2 20 o 20 0 28 J IS 1O 4S 36 30 31 34 bIBS 39 30 ply tire 0 0 79 radIalply tire 200SX All I OS 2 3S 810 All I 10 2 40 S10 Sedan I OS 2 3S Hatchback 1978 S10 Station Wagon SS 2 2S 1978 FI0 All 20 1 SO Information not appllcahle trldtrld Ztrl oz Zt l trl0 3 l C Z l ...

Page 180: ... er 7 Torque orrette S Handbrake cable 9 Srake hase 10 Baund bumper 8 7 3 2 6 5 1 SUJpenslon member 2 Su pen lon arm 3 Member mounting Insulator A Ddt renttal mounting lnaulator 5 COil prlng 6 Bumper rubber 7 Spring at S Shock absorber 9 Drive haft 10 O ft ntlol mountu 9 member 11 Differential corrler 510 and 610 rear suspensIOn except stabon wagon ...

Page 181: ... whICh are dnven 7 Brake hose S Handbrake cable by separate axle shafts COli spnngs are used along wIth hydraulIc shock absorb ers The 1978510 sedans and hatchbacks are eqUIpped wIth a four hnk type sohd rear axle whICh utIlIzes COli spnngs The 810 sedans use a semI traIlIng arm In dependent rear suspensIOn whICh IS qUIte SImIlar to the early 510 suspensIOn The FlO sedan and hatchback use traIl In...

Page 182: ...Rear arm bolt 1978510 sedan rear suspensIon 9 Rear axle bearing 10 Beanng spacer 11 Rear axle shaft 12 Shock absorber lower end bolt 13 Shock absorber assembly 14 Special wash r 15 Shock absorber mounting bushIng A 16 Shock absorber mounting bush ng B 17 Bound bumper cover 18 Bound bumper rubber 19 Shock absorber mounting Insulator 20 COli spring 21 Upper link bushing bolt 22 Upper link bushIng Fl...

Page 183: ...g seating pad 11 Reor axle shaft 20 Rear sprang assembly 12 Shock absorber assembly 21 location plate 13 Special washer 22 Reor axle bumper 14 Shock absorber bushing 23 U bolt Spnng clip 15 Front pm assembly 24 Shackle pm assembly 16 Spnng bushing 2S Shackle 17 Front pin outer plate 26 Torque arrester 18 lower spring seat 1 Axle lube S Shackle 2 U bolt 6 5pn n9 sea 3 Shock absorber 7 leaf spring B...

Page 184: ... Differential mounhng member 10 Differential mounting plate Exploded vlew 8lO sedan rear suspensIOn 11 Suspension arm assembly 12 Shock absorber 13 SpeCIal washer 14 Shock absorber mounting bushing A 15 Shock absorber mounting 16 Sprang seat rubber 17 Shock absorber mounhng bushing B 18 Bumper cover 19 Dust cover 20 Bumper 21 Call spring 22 Suspension orm bushing 23 D fferential mounting spacer 2 ...

Page 185: ...n Wagon and All 710 and 200SX Models I RaIse the rear axle untIl the wheels hang free Support the car on stands Sup port the rear axle WIth a floor Jack 2 Remove the spare tIre 3 Unbolt the bottom end of the shock absorber 4 Unbolt the axle from the spnng leaves 5 Unbolt the front spong bracket from the body Lower the spnng end and bracket to the floor 6 Unbolt and remove the rear shackle 7 Unbolt...

Page 186: ...e spnng 6 Lower the Jack slowly and remove the sprmg Removmg shock absorber lower nut and U bolts 810 Spnng shackle bolts 7 InstallatIon IS In the reverse order of removal FlO Station Wagon I Jack up the car and support It WIth safety stands 2 Remove the wheel and tIre 3 Remove the nuts from the lower portIOn of the shock absorber 4 Remove the nuts from the U bolts and detach the bumper rubbers an...

Page 187: ...Ion IS In the reverse order of removal 1978510 Sedan and Hatchback Models 1 RaIse the car and support It WIth Jackstands 2 Support the center of the dIfferen tIal WIth a Jack or other SUItable tool 3 Remove the rear wheels 4 Remove the bolts secunng the lower ends of the shock absorbers 5 Lower the Jack under the dIfferen tIal slowly and carefully and remove the COIl spnngs after they are fully ex...

Page 188: ...val m thIS chapter DIsas sembly of the sprIngshock umt requues a spnng compressor It IS recommended that you leave thIS Job to a profeSSIOnal ALL LEAF SPRING MODELS I RaIse the rear ofthe car and support It wIth Jackstands Rear shock retammg nuts1978 510 2 DIsconnect the lower end of the shock absorber by remOVIng the nut at the spnng seat It IS a good Idea to spray the nut wIth penetratIng 011 fi...

Page 189: ...he SIde The warnmg buzzer whIch sounds when the dnver s door IS opened WIth the steenng unlocked IS located behmd the mstrument panel Steenng lock secunng screws 200SX others simi lar STEERING GEAR Removal and Installation 510 610 710 1 Remove the steenng shaft U Jomt clamp bolt 2 Remove the smd nut and pull the steenng rod ball Jomt from the steenng arm 3 Unbolt the steenng gear box from the fram...

Page 190: ...ng the worm shaft to the rubber couplIng 2 Remove the nut and the lock washer whIch secure the gear arm to the sector shaft Removmg the steermg gear arm With a puller 3 USIng a puller remove the steenng gear arm from the sector shaft 4 Unbolt the front exhaust pIpe from the exhaust manIfold 5 Remove the bolts secunng the gear box to the frame and remove the gearbox 6 InstallatIon IS In the reverse...

Page 191: ... steenng assembly 1 Sector haft 2 Steenng gear housing 3 locknut 4 F U r plug 5 Sector ihaft cover 6 Sedor shaft ad lust n9 shim 7 Sector shaft adluliitlng screw 8 Worm bearing 9 Ball nut 10 Worm shoft 11 Steering worm assembly 12 O ring 13 Worm beanng shim 14 Rear cover 5 Rubber coupling 6 Steering gear 7 Gear arm 8 Cross rod 9 Side rod 10 Idle arm ...

Page 192: ...ssembly 2 Steenng column cover 3 Upper clamp 4 Lower clamp FI0 steenng assembly 5 Steering gear boot 6 Steenng clip 7 Column lower 10lnt assembly 8 Steenng column assembly 9 Column hole cover assembly 10 Steering gear assembly 11 Side rod assembly I ...

Page 193: ... back off untIl the wheelIS free ofdrag Repeat the procedure on the other adjuster bolt on the same wheel Some models may have only one adjuster bolt per wheel Bolt Adjuster With ClIck Arrangement 1973 510 The adjuster IS located on the backIng plate The adjustment proceeds m clIcks or notches The wheel WIll often be locked temporanly as the adjuster passes over center for each clIck Thus the ad J...

Page 194: ...Stopper ring 4 Stopper screw 5 Stopper 6 PnmarY Plston assembly 7 PrImary piston return spring 8 Secondary piston assembly 9 Secondary piston return spnng 10 Plug II Check vdive 12 Reservolf Exploded view of 1200 and B210 master cyhnder pm need not be removed on models WIth the vacuum booster Unbolt the master cylInder from the firewall and remove The adjustable pushrod IS used to adjust brake ped...

Page 195: ...S 189 1 Reservoir cap 2 Filter 3 Reservoir tank 4 Stopper ring assembly 9 51 10 S opper screw econda 11 Plug ry return spring 12 Check valve cOle v U Jf D 9 e 7 r g Explod d e vIew of 810 master cyhnder 1 Reservoir cop 2 Strainer Stopper nng Stopper screw 5 Stopper 6 Primary piston 7 Spring 8 Second 9 S ary piston pring 10 Plug 11 Check valve ...

Page 196: ...es 2 The usual procedure IS to bleed at the po1Ots farthest from the master cylm der first 3 FIt a rubber hose over the bleeder screw Submerge the other end of the hose m clean brake flUId 10 a clear glass con tamer Loosen the bleeder screw 4 Slowly pump the brake pedal sev eral tImes UlltIl flUId free of bubbles IS dIscharged An assIstant IS requIred to pump the pedal 5 On the last pump10g stroke...

Page 197: ...up the car and remove the wheel 2 Remove the clIp s retaInIng pInS and anti squeal chps Remove the COli sprIng 3 Usmg phers pull out the pads and antI squeal shIms 4 Thoroughly clean the exposed end of each pIston and the calIper assembly Check the rotor dISC for SCOrIng If It IS badly scored It must be removed for re surfacIng or replacement 5 Before Instalhng the new pads the pIstons must be pus...

Page 198: ...ng A Innor pIston 4 PISton 5 Piston seal JCI 9 r1 CI p 6 Brake pad 2 Spring 7 Air bleeder 3 Pin 8 Retaining flng 4 Sh m fro t brake caliper fI200and B210 n Exploded view 0 9 Boot 10 Piston B 11 CylInder 12 Piston A 13 Blcs ring 14 Yoke spung 15 Yak ...

Page 199: ...ub on the spmdle and adjust the wheel beanng 10 Insert a new seal m the cyhnder groove and attach the wIper seal Lubn cate the cyhnder bore WIth brake flUId Insert the pIston cautIously untIl the PIS ton head IS almost flush WIth the wIper seal retamer The reheved part ofthe PIS ton must face the PIvot pm 11 Install the cylInder mto the cahper plate and secure It WIth the tensIOn spnngs 12 Install...

Page 200: ...unded rmg portIOn comes to the bottom of the pIston PIston A has a small depreSSIOn mSlde whIle B does not 13 Lubncate the pIstons wIth clean brake flUId and msert mto the cyhnder Install the boot and retammg nng The yoke groove of the bIaS nng of pIston A Piston A Inner piston Piston B Ouler piston PIston comparIson mner and outer must ahgn WIth the yoke groove of the cylInder 14 Install the yoke...

Page 201: ...val and Installation 510 610 710 810 AND 200SX I RaIse the vehICle and remove the wheels 2 Release the parkmg brake DIscon nect the cross rod from the lever of the brake cylInder Remove the brake drum Place a heavy rubber band around the cylmder to prevent the pIston from com mg out 3 Remove the remrn sprIngs and shoes 4 Clean the backmg plate and check the wheel cyhnder for leaks To remove the wh...

Page 202: ... Bleeder 10 Lock plate A II Lock plate B 12 Lock plate C and D 13 Dusl cover 14 Brake shoe assembly after Exploded view of 510 610 and 710 rear bralce o 5 Exploded view of FI0 rear drum bralce 1 Dust cover 6 Shoe fixing spring 10 Piston 2 Shoe fixing pin 7 Return spring 11 Dust cover 3 lever assembly 8 Wheel cyhnder body 12 Adlust nut Shoe 9 Piston cup 13 Broke disc 5 Return spring ...

Page 203: ...shoe assembly 9 Spring seat 4 Return spring 10 Anti rattle spring 5 Adluster o ssembly 11 RetOlner 6 Stopper pin RldI shoe Lining IS high 1 Brake diSC 2 Adluster 3 lover 4 Brake shoe assembly 5 Return spring 6 Wheel cyhnder 7 Anti rattle pin 8 Spring sea 9 Anti rattle spring 10 Retainer 11 Stopper assembly Adluster location hole Front of car Front shoe Lmmg IS low Exploded vIew of 810 sedan rear d...

Page 204: ...r to prevent the pIston from commg out 4 Clean the backmg plate and check the wheel cylInder for leaks To remove the wheel cylmder remove the brake 1 Hand broke lever 2 Cable 3 Clop 4 lack plato 5 Turn buckle Hand brake adlUtter 6 Cable 7 Cable a Hanger strop 9 Return sprang 10 Cable shank 11 Hand broke leyer cover lIne dust cover plates and adJusbng shIms Clearance between cyhnder and pIston shou...

Page 205: ...compensate for cable stretchmg 1 Control slem 2 Control slem bracket 3 Front cable 4 Cable lock plate 5 Center lever 6 Return spnng 7 Rear cable adJusler 8 Balance lever 9 Rear cdble 10 levIs 510 and 610 except stahon wagon parkmg brake assembly a 1 Control tem 2 Control stem br lcket 3 hont Ldble 4 Ret urn sprang 5 Rear cable 6 P ukmg return spnng 7 Swmg arm 8 B ll lnlC lL er 9 Cro rod 610 stabon...

Page 206: ...1 00047 90 904 9055 0079 0059 1200 B210 5 0750 0331 o 0039 80 804 8051 0063 0059 710 58 65 0750 0331 o 0047 90 904 9055 0079 0059 FI0 5 0750 0339 o 0047 80 804 8051 0063 0039 810 5 08125 0413 o 0059 90 904 9055 0079 0059 1978 510 58 65 o 8125 0331 o 0047 90 904 9055 0079 0059 200SX 5 0750 0331 o 0047 90 904 9055 0079 0059 NOTE Minimum lining th okness IS as recommended b1 the manufacturer Because ...

Page 207: ... bumper valance panel windshJeld Wlper blades cowl top gnlle and sdl moldmg 2 Remove the package tray 3 Remove the hmge access hole cover from the dash SIde trIm on 1200 models 4 Open the door and support It wIth a Jack 5 Remove the hmge bolts at the body SIde and remove the door I rronl door 2 Support Door removal 6 Reverse the removal procedure to mstall the door CD I Upper hmge 2 Rear door 3 Lo...

Page 208: ...ully pull the panel to ward you and release the chps 4 To mstall the panel reverse the re moval procedure Hood adjustment Hood Trunk and Tailgate Alignment All ofthese panels should be alIgned m theIr openmg by adjustIng the hmge po sltIonmg and lock posltIomng Trunk adjustment StatIon wagon t lgate updown and slde to Slde ad justment Bolts StatIon wagon taIlgate fore and aft adjustment Fuel Tank ...

Page 209: ...BODY 203 r I if 15 j l l l oIIl c5c i N Dt OO ll E tl a B Qj E 0 l 8 fj I fj o o ...

Page 210: ...l Ime from the tank Sedan aM Hardtop 6 DIsconnect the fuel gauge wues from the tank 7 Remove the rear seat cushIOn and back Remove the front mounong bolts 8 Remove the other two retammg bolts and hft out the tank 9 InstallatIOn IS the reverse of re moval B210 COUPE 1 DIsconnect the battery ground cable 2 Remove the fimsh panel from the rIght sIde of the trunk 3 Place a pan under the dram plug and ...

Page 211: ... bolts secunng the fuel tank and remove the tank 6 InstallatIon IS m the reverse order of removal FlO WAGON The removal procedure IS the same as that for the sedan and hatchback How ever when removmg the fuel tank bolts It IS easIer Ifyou start at the three bolts at the front ofthe tank 200SX 1 DIsconnect the battery ground cable 2 Remove the rubber plug located on the floor panel above the left S...

Page 212: ...n ose 6 Evopora I 7 Filler hose 8 F lIe cap For Sport Wagon 9 Separator 10 ltmlt valve 11 Vent cleaner J8 1 Dram plug 2 Fuel outlet hose 3 Filler hOle hose Ventilation 5 FIller tube 6 FIUer neck 7 Filler cap 8 Breather hose r heck valve 9 fue C e unit 10 Fuel goug hose 1 Evaporation 12 Fuel tank 1 t to hose 3 Fuel re u 1 I tank tray 14 Fue 15 Nylon clamp 200SX fuel tank ...

Page 213: ...e ventIla tIon hose evaporatIon hose and outlet hose 5 Remove the tIre stopper DIscon nect the wmng from the gauge 6 Remove the four bolts secunng the fuel tank and remove the tank 7 InstallatIon IS m the reverse order of removal 1978 510 SEDAN 1 DIsconnect the battery ground cable 2 Remove the back seat tnm III the luggage compartment 3 Dram the fuel m the fuel tank 4 DIsconnect all the hoses and...

Page 214: ... Fuel pump 7 Fuel outlet tube a Fuel return tube 9 Fuel strainer 10 Carbon canls er v II 810 sedan fuel tank 1 Fuel filler hose 2 Check valve 3 Vapor liquid separator 4 Ventilation hose 5 Fuel tank Unit gauge 6 Fuel tank 7 Fuel pump 8 Fuel outlet tube 9 Fuel return tube 10 Fuel strOlner 810 statIon wagon fuel tank ...

Page 215: ...DY 209 Fuel tonk 2 Fuel gauge tonk unit 3 Vent hose 4 Check valve 5 Fuel filler hose 6 Grommet 7 Fuel strainer 8 I uel return tube 9 Fuel outlet tube 10 evaporative tube 1978 510 sedan fuel tank and hnes ...

Page 216: ...rotector 9 Fuel s rol ner 10 Fuel outlet tube 11 Fuel return tube 12 Evoporatlve tube 1978510 hatchback fuel tank and hnes 1 Fuel tank 2 fuel gauge tank unl 3 Vent hose Check volve S Fuel filler hose grommet 6 Fuel filler hose 7 Fuel stromer 8 Fuel ou let tube 9 Fuel return tube 10 Evaporative tube I 1978 510 statIon wagon fuel tank and hnes ...

Page 217: ...8 020 II 32 344 873 43 64 672 1707 1 64 016 040 23 64 359 913 II 16 6118 1746 1 32 031 079 3 8 375 953 45 64 J700 1786 3 64 047 1 19 25 64 391 992 23 32 719 1826 1 16 063 159 13 32 406 1032 47 64 734 1865 5 64 078 198 27 64 422 1072 3 4 750 1905 3 32 094 238 7 16 438 II II 49 64 766 1945 7 64 109 2 78 29 64 453 II 51 25 32 781 1984 1 8 125 318 15 32 469 II 91 51 64 797 2024 9 64 141 357 31 64 484 ...

Page 218: ...7 400 50 1 968 500 80 3149600 150 5905 500 400 15748000 21 826 770 51 2 007 870 81 3 188 970 155 6102350 500 19685000 22 866 140 52 2 047 240 82 3 2211 340 180 6 299 200 600 23 622 000 23 905 510 53 2086610 83 3267 710 165 6 496 050 700 27 559 000 24 944880 54 2 125 980 84 3 307 080 170 6 692 900 SOO 31 496 000 25 984 250 55 2165 350 85 3 346 450 175 6 889 750 900 35 433 000 26 1 023 620 56 2 204 ...

Page 219: ...0390 J4 1110 7 tolO 60 0400 JJ 1130 6 2040 Sf 0410 32 1160 5 2055 51 O4to 31 1200 4 2090 S7 0430 JO IllS 3 mo 56 0465 29 1360 2 ttlO 55 O5to 11 1405 2210 54 O5SO 27 1440 Decimal Equivalent Size of the Letter Drills l n D lOoI l nlf D at llntr Dllmal DnI I DnO 1 llll oIon DnO 1 01 6 2M J t77 S 341 I I 211 T m c 242 I to U 361 D 246 ttS 377 I 250 I J02 31i f m D 316 I 397 261 r m 404 I 266 D m Z 413...

Page 220: ... II II 14 If 11 11 11 7 I I I 11 II It It 11 11 I 4 I I II II II for capocltles under 10 quarn multiply true capacity by 3 fInd quarts An l freeu for the tnpled volume and dIVIde by 3 for quarts to add To Increase the Freesing totection of Anti Freeze Solutions Already In alled 0 Qoorh oIUHYIINI GlYCOI Im 1 s m fr M fl 111 O f I I If 10 O I II 10 41 II 10 10 a I JI 2 I t t I t t JY 1 I t II I t t ...

Page 221: ...11 4 ltf t 4 rft p t f r lV ...

Page 222: ...g specI fically to the Datsun make tune ups brake Jobs general maintenance and hundreds of other repairs routrne Ten logically divided chapters provide all the Information you need J Chapter 1 General Information and Maintenance Chapter Tune Up and TJQubleshootlng Chapter 3 Engine and Engine Rebuilding D Chapter 4 EmiSSion Controls and Fuel C Chapter 5 ChaSSIS Electncal f t I Chapter 6 Clutch anI ...

Reviews:

No comments

Related manuals for 1200 1973

Yakima K1188 Instructions Manual preview
K1188
Brand: Yakima Pages: 12
JEHNERT SOUND DESIGN 65400 Assembly Instruction Manual preview
65400
Brand: JEHNERT SOUND DESIGN Pages: 8
Rainbow Experience Series Installation Manual preview
Experience Series
Brand: Rainbow Pages: 19
Yakima K1006 Instructions Manual preview
K1006
Brand: Yakima Pages: 12
Dometic PERFECTVIEW CAM80AHD Installation And Operating Manual preview
PERFECTVIEW CAM80AHD
Brand: Dometic Pages: 196
Yuasa SmartShot Automatic 12V 1.5 Amp 5 Stage Technical Manual preview
SmartShot Automatic 12V 1.5 Amp 5 Stage
Brand: Yuasa Pages: 44
Toyota 4Runner 2019 Quick Reference Manual preview
4Runner 2019
Brand: Toyota Pages: 52
DriveRight 8156OBD Installation Manual preview
8156OBD
Brand: DriveRight Pages: 16
Vangear Woody-Pod Instruction Manual preview
Woody-Pod
Brand: Vangear Pages: 5
Safe Fleet FRC SafeTrack Hardware Installation Manual preview
FRC SafeTrack
Brand: Safe Fleet Pages: 20
v.link VL2-MBN2 Manual preview
VL2-MBN2
Brand: v.link Pages: 12
Honda 2006 Accord Owner'S Manual preview
2006 Accord
Brand: Honda Pages: 569
Havis-Shields Telescoping Computer Base C-TCB-34 Install Instructions preview
Telescoping Computer Base C-TCB-34
Brand: Havis-Shields Pages: 1
PEUGEOT 106 2001 Owner'S Manual preview
106 2001
Brand: PEUGEOT Pages: 107
Rydeen BSS2 Owner'S Manual preview
BSS2
Brand: Rydeen Pages: 14
Griffin Technology iTrip Bluetooth User Manual preview
iTrip Bluetooth
Brand: Griffin Technology Pages: 6
Mitsubishi Pajero Pinin 1999 Workshop Manual preview
Pajero Pinin 1999
Brand: Mitsubishi Pages: 919
Volvo XC70 - ANNEXE 808 Quick Manual preview
XC70 - ANNEXE 808
Brand: Volvo Pages: 8

Brands by name

Popular brands

Load more brands