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CRAKE PU3

IS1

RS

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lII

DATSUN 1200

RANGE

1971

1973

MAINTENANCE

REPAIR

BY

DRAKE AUTOMOTIVE EDITORS

Quick Referencelodel

MAINTENANCE

TUNE UP

ENGINEERING ELECTRICAL SYSTEM IGNITION SYSTEM FUEL SYSTEM COOLING SYSTEM

BRAKES

FRONT SUSPENSION

5

13

35

43

49

63

67

83

STEERING

89

REAR DRIVE

SUSPENSION

93

CLUTCH

99

TRANSMISSION

103

BODY WORK

111

SPECIFICATIONS

129

The purpose of this manual

IS to provide the automobile owner and mechanic with

a reference

source with which he can perform

normal service operations

We endeavor to lOcorporate the latest manufacturing design changes and up to date

specifications at the time of publication

While every effort IS made to attain accuracy

the Publisher cannot be held responsible for manufacturing changes typographical

errors or omiSSions

Upon compIling the information contained herein

Simple

relvlng on the combination of photographs

make thIS manual a useful tool

we have tried to

be brief and

Illustrations and text to

DRAKE

PUBLISHERS INC

361 PARK AVENUE SOUTH

NEW

YORK

NY 10016

ISBN 0 87 749 309

X

Pubhshed III 1973 by DRAKE PUBLISHERS INC

381 Park Avenue South New York N Y 10016

@Drake Pubhshers Inc 1973

Prmted m the Umted States of Amenca

able of Contents

MAINTENANCE

TUNE UP

DIsassembly

32

 

InspectIOn

RepaIr

33

VALVE

CLEARANCES

6

AdJustmg Regulator

33

ENGINE OIL

 

6

Assembly

33

OIL FILTER

7

COOLANT

7

COMPRESSION

 

7

ELECTRICAL SYSTEM

 

BATTERY

8

IGNITION TIMING

 

8

STARTER

36

DIstributor Breaker Pomt

9

Removal

37

Condenser

9

InstallatIOn

37

Spark Plugs

Carburetor

Idle LImIter Cap

Dash Pot

automatic transmISSIOn

model only Carburetor Return Sprmg Fuel Filter

ENGINE

DESCRIPTION

9

9

10

11

11

11

11

14

REMOVAL

14

INSTALLATION

14

CLEANING

INSPECTION

14

DISASSEMBL Y

14

INSPECTION

REPAIR

18

PreparatIOn

18

Cyltnder Head

18

Valve Assembly

Valve Spnng

Valve Rocker Shaft

Rocker Arm

Valve LIfter Push Rod

Camshaft

Camshaft Bearmg

Valve Tlmmg

Cyltnder Block

PIston Piston Pm

Plsto

LRmg

Connectmg Rod

Crankshaft

Bushmg

Bearing

Crankshaft Sprocket

Camshaft Sprocket Flywheel

ASSEMBL Y

PrecautIOn

Cyltnder Head

PIston

Engme

ConnectIng Rod

OIL PUMP

Removal Engme m vehicle

18

19

19

20

20

20

21

21

23

24

24

25

25

25

25

25

26

26

32

32

Trouble Shootmg

ALTERNATOR

Removal

InstallatIOn

REGULATOR

DeSCriptIOn

Trouble Shootmg

IGNITION SYSTEM

DISTRIBUTOR

ConstructIOn

Checkmg and Adjustment

SP ARK PLUGS

DeSCriptIOn

InspectIOn

Cleamng

Regap

FUEL SYSTEM

FUEL FILTER

DESCRIPTION

REMOVAL

INSTALLATION

FUEL PUMP

DeSCriptIOn

Testmg

Removal

InspectIOn

Assembly

DIsassembly

CARBURETOR

DeSCription

Adjustment

Removal

DIsassembly

Cleanmg

InspectIOn

Assembly

InstallatIOn

37

36

37

37

39

39

40

44

44

44

46

46

46

47

50

50

50

50

50

50

51

52

52

52

52

52

53

58

58

59

60

labl8 of Contents

Jets

TlOuble Shooting

COOLING SYSTEM

DESCRIPTION WATER PUMP Hemoval InstallatIOn THERMOSTAT Removal

InspectIOn

Installation

RADIATOR

Hemovdl

InspectIOn

InstallatIOn

BRAKES

FRONT DISC BRAKE BRAKE PAD

Replacement

InspectIOn

ReinstallatIOn

CALIPER

Removal

Disassembly

InspectIOn

Repmr

Reassembly

ReinstallatIOn

REAR BRAKE

Hemoval

Dlsdssembly

InspectIOn

Reassembly

HAND BRAKE

ReinstallatIOn

Removal

InspectIOn

RemstallatlOn

ADJUSTMENT

Front DI

c Brake

Rear Brake Brake Pedal HeIght Hand Brake

BLEEPIN

HYD

AULIC

SYs

r M

TROUBLE SHOOTING

60

FRONT SUSPENSION

60

 

DESCRIPTION RECOMMENDATIONS TROUBLE SHOOTING

64

STEERING

64

65

DESCRIPTION

65

RECOMMENDATIONS

65

TROUBLE SHOOTING

65

65

65

REAR DRIVE

66

SUSPENSION

66

66

REAR AXLE

Replacement

66

DIFFERENTIAL

REAR SUSPENSION REAR SHOCK ABSORBER

InspectIOn

RECOMMENDATIONS

68

68

68

CLUTCH

68

68

DESCRIPTION

70

CLUTCH PEDAL

70

Removal

71

InspectIOn

71

ReinstallatIOn

72

Adjustment

74

CLUTCH MASTER CYLINDER

74

Removal

74

DIsassembly

75

InspectIOn

75

Reassembly

75

RemstallatlOn

75

BLEEDING CLUTCH SYSTEM

76

77

78

TRANSMISSION

78

78

4 SPEED TRANSMISSION

78

3 SPEED TRANSMISSION

79

TROUBLE SHOOTING

79

iUIQM ATJ C TRANSMJSSIQ

80

RECOMMENDATIONS

85

90

90

91

94

94

95

96

96

97

97

fable of Contents

I

BODY WORK

HOOD

Removal

InstallatIOn

HOOD

LOCK

Removal

Adjustment

LubncatlOn TRUNK LID LOCK Removal

Adjustment

TRUNK LID TORSION BAR

DOOR CONSTRUCTION

WIRING DIAGRAMS

BULB SPECIFICATIONS

HEADLAMP THERMOMETER AND FUEL METER OIL PRESSURE AND IGNITION WARNING LAMPS

SPECIFICATIONS

112

112

112

112

112

112

114

116

116

116

116

117

118

120

121

122

126

SERVICE DATA

ENGINE

General SpeCificatIOn

Tlghtemng

Torque

SpeCIficatIOn

Coohng System

Fuel

System

Starter

Alternator

Regulator

Dlstnbutor

IgnItIOn Cot

CLUTCH

NOTES

130

134

134

134

135

139

140

142

143

144

145

145

146

174

I

I

t

I

aintenIDce

TUDe up

ainteDaDee

TUDe up

VAL VE CLEARANCES

Valve clearance

adjustment should be

made

while engme IS stationary

To adjust proceed as follows

Start engme and

run

It

until It

IS

heated to

operatIng temperature or at least more than

17S

of

engIne

011

temperature

engIne Rotate crankshaft to

bnng No

1

then stop

cylInder In

top dead center on ItS compressIOn stroke

Remove valve rocker cover to gaIn access to valve operatIng mechamsm

Adjust

valve

clearance

at

follOWing

four

pOints while engIne IS still hot

  • 1 Exhaust valve of No

1 cylinder

  • 2 Intake valve of No

1 cylinder

  • 3 Intake valve of No

2 cylinder

  • 5 Exham t valve of No 3 cylInder ote

Numbers

in

parenthesis agree with

those 10 accompanY1Og sketch

AgaIn rotate crankshaft one turn so that No

4

piston

IS

In

pressIOn stroke

top

dead

center

on

ItS

Adjust follOWIng valves

com

  • 4 Exhaust valve of No 2 cylinder

  • 6 3 cylinder

Intake

valve

of No

  • 7 4 cylInder

Intake

valve

of No

  • 8 Exhaust valve of No

4 cylinder

Adjustment should ue made

hot

After

all

valves

have

whIle engIne

IS

been

adjusted

correctly tighten lock nut firmly to secure the

adjustment

Checking and adjusting drive belt

Check for

a

cracked

Replace If defective

or

damaged

V belt

Adjust the belt tenSIOn

If

necessary

Belt

deflectIOn when thumb pressure of 220 Ib IS

applied

o 590 In

midway

between

pulleys

0394

to

ENGINE OIL

  • 011 capacity of engIne

IncludIng 011 filter

Capacity

MaXimum VB US gal

Imp gal

MInimum

5IB

US gal

III Imp gal

Make sure that engIne 011 IS not detenorated

With

cooling

water

or

gasolIne

DraIn

refill the 011 lf necessary

Notes

a

A

m1lky

011

indlcates

and

presence of cooling water

Valve clearance

Hot

Intake

Exhaust

0014 In

Rg

1 AdJustmg valve clearance

Fig

2 AdJustmg dnve belt tension

aintenIDce

une up

Find

the

cause

for

necessary

corrective

 

COOLANT

action

 
 

L L C

IS al ethylene glycol base product con

b

Oil

with

extremely

low

viscosity

in

tammg chemical

mhlbltors

to

protect

the

dicates dllutton with gasoline

 

coohng system from

rustmg

and

corrosIOn

Check 011 level

If found below

L

mark

refill

The

L I C

does

not

con tam

any

glycerme

to

H

mark on gauge

 

ethyl or methyl alcohol

It wIll not evaporate

 

OIL FILTER

 

or bOll away and can be used wIth either high or low temperature thermostat It flows freely transfers heat effiCiently and will not clog the

The 011 filter IS of a cartndge type

 

passages

m

the

coohng

wIth

system

The

other products

L L C

 

must not

be mIxed

ThiS

Check for 011 leaks through gasketed flange If

coolant can

be used throughout the seasons of

any leakage IS found

retIghten shghtly

If

the year

 

nece sary replaLe filter as an assembly

When mstalhng an 011 filter tIghten by hand

Whenever any coolant IS changed the coohng system should be flushed and refilled wIth a

Note

Do not overtighten 011 fIlter

or oil

new coolant Check the level

leakage may result

Fig 3 Checking engine 011 level I I Oc OF 0 121 20141 21 30 I
Fig
3 Checking engine 011 level
I
I
Oc
OF
0
121
20141
21
30
I
401401
5015BI
10
20
I
EGOQl
I

Fig 4 Protection concentration

COMPRESSION

Compression pressure test

Note To test cylinder compression

remove all spark plugs and hold tester fit

Percent

concen

tra lion

30

50

BOllIng pomt

09 kg cm2

Freeze

Sea level

coolmg sys

protectIon

tern pressure

2210F

2550F

50f

2280 F

2610F

31oF

ETO104

Fig 5 Testing compressIon pressure

aiDtenaDce

TUDe up

ting tightly m

der

spark plug hole

of a cylin

The

tester is

used

to

determme whether

cylinder

can

hold

compression

or

whether there IS

excessive

leakage past

rings etc

Test compressIOn wIth engme warm

all spark

plugs removed and throttle and choke valve

opened No cyhnder compressIOn should be

less than 80 of highest cyhnder s Excessive

variatIOn between cyhnders accompamed by

low speed missing of the cyllndel

usually 10

dlcates

blOken

a

valve

not

pIston

ring

properly

seating

Low

preSsures

or

a

even

though

umform

may

indIcate

worn

rings

ThIs

may

be

accompamed

by

excessive

011

consumptIOn

Test Conclusion

If one or more cyhnders read low Inject about

one tablespoon

of engine

011

on

top

of the

plstons

In

low

spark plug hole

these cy II nders

readmg

cyhnders

through

Repeat compressIOn check on

If compressIOn

Improves

rings

are defectIve

conSiderably

piston

If compressIOn does not Improve

valves are

stIcking or seatIng Improperly

If two

adjacent

cyhnders

mdlcate

low

com

pressIOn and mjectmg 011 on pistons does not

Increase

compreSSIOn

the

cause

may

be

a

cylInder head gasket leak between the cyhn

ders

Engine

011

and coolant In

result from this problem

cylInder could

CompressIOn pressure

178 to

206 pSI at 350 rpm

BATIERY

Check electrolyte level 10 each battery cell

Unscrew

each

filler

cap

level

If flUId level

IS low

Inspect add dIstilled water

and

flUId

to

bring level up to approximately 03937 to

07874 In above plates

Do not overfill

Mea ure

trolyte

P

illL gravlty of pattery

el

c

Clean

top of battery

and

terminals

With

a

solutIOn

of baking soda and water

Rinse off

and dry WIth compressed atr

The

top

of bat

tery must be clean to prevent current leakage

between terminals and from poSItive termlndl to hold down clamp

In additIOn to

current leakage

prolonged ac

cumulatIon of aCId and dirt on the top of bat tery may cause bhstenng of the material

covering

connector

straps

and

corrOSIOn

of

straps After tightening terminals coat them With petrolatum vasehnel to protect them

from corrosIOn

IGNITION TIMING

Check

spark

plugs

pOints for conditIon

and

dIstributor

breaker

Thoroughly wipe off dIrt and dust from tlmmg marks on crank pulley and front cover

I

I

j

Warm up engine suffiClently

Fngld chmates

TropIcal chmates

Other clunates

PermIssIble

value

Over

1

22

Over

I

18

Over

1

20

Full charge value

at 68OF

128

123

126

j J

I

ET002

Flg S Gheckmg

trolyte

the

speCific

gravity of

baltery

elec

f

l

aiDteDaDce

UDe up

Install a

timing lIght on No

1 cyhnder spark

plug WIre

and Install a tachometer

Set Idhng ipeed to approximately 800 rpm

Check 19mtlOn tImmg If It IS 50BTDC Before

Top

of Dead

hght

Center

by

the

use

If necessary

adjust It as follows

of tlmmg

Loosen

iet

screw

to

such

an

extent

that

dlstnbutor can be moved by hand

AdJuit

IgmtlOn tIming to 50BTDC

Lock

dlstnbutor

set

screw

and

make

that tlmmg IS correct

IgnitIOn tImmg

degreel

50

B T

DC

sure

Distributor Breaker Point Check dlstnbutor breaker pomts for abnormal pItting and wear Replace If necessary Make

wre they are In correct ahgnment for full con

tact and that pOint dwell and gap are correct Clean and apply dlstnbutor grease to cam and WIck

Note Do not apply grease excessively

  • Dl tI IbutOl

POint gap 0 018 to

0 022

In

Dwell angle 49 to 55 degrees

Condenser Clean outlet of condenser lead WIre

and check

for loose set screw Check condenber

meter

RetIghten If necessary

capacIty

With

a

capacity

Fig 7 Checking Igmllon timing

Condenser

msulatlOn

resistance

may

be also

checked usmg a tester by adjusting ItS range

to

measure large resIstance value

When con

denser IS normal

the

tester

pomter swmgs

largely and rapidly and moves gradually back

to the Infimte SIde When the pomter does not

stay

still

or

It

pomts

zero

m

replacement IS necessary

Condenser capacIty

022 J F

MIcro Farad

reSIstance

Condenser InsulatIOn resIstance

5

Mn

Mega ohms

Spark Plugs

Remove

and

clean

plugs

In

a

sand

blast

cleaner Inspect each spark plug

Make

iure

that they are of the specified heat range

In

ipect msulator for cracks and chIps Check both center and ground electrodes If they are

excessIVely

worn

replace

WIth

new

spark

plugs File center electrode flat Set the gap to

0031

to

0035 m

USIng the proper adjustIng

tool

Tighten plugs to

11

0 to

150

ft Ib torque

CARBURETOR

Idle mixture adjustment requIres the use

CO

meter

When

preparIng

to

adjust

of a

Idle

mixture

It

IS

essential

to

have

the

meter

thoroughly warmed and cahbrated

Warm up the engme suffiCiently

ContInue engIne operatIOn for one mmute un

der ldhng speed

ETOQ4

Fig 8 Checking dlstnbutor POint gap

aiDteDaDce

UDe up

Fig 9 Checking spark plug gap

Adjust throttle adjusting screw so that engme

speed

1S

800

rpm

m

N

automatic transmIssIOn

positIOn

for

Check IgnitIOn tlmmg

the specIficatIOns

If necessary adjust 1t to

IgnitIOn timing 50 800 rpm

Adjust Idle adjusting screw so that CO percen

tage IS

1

5t0

5ff

Repeat the adjustments as desctlbed In steps

3 above so that CO percentage IS 800 rpm

15t0

5ff

at

Cautions a On automatic transmission equipped model check must be done in

the

D

position

Be sure to apply parking

brake and to lock both front and rear wheels wIth wheel chocks

b Hold brake pedal while stepping down accelerator pedal Otherwise car will

on

rush out dangerously

On automatic transmISSIOn eqUIpped model make sure that the adjustment has been made wIth the selector lever In N posItion

And then

check the specificatIOns with the

lever In D posItion Insure that CO percent

and Idle speed are as follows

Idle rpm 650

CO percentage

with lever In

D

PoSitIOn

1

5t 0

5k

If necessary

adjust by progIesslvely turmng

throttle adJustlng screw

and

Idle

adJustmg

screw until correct adjustments are made

Throttle

sdJustlnl

screw

Idle adjust

Inlscrew Idle Itmlttc r

4

cap

Stopper

Fig

10

Throttle

screw

adjusting

screw

and

Idle

adjusting

CARB

STOPPER

Fig 11 Setting Idle limiter cap

Notes

a

Do not attempt to

screw

down

the

idle

adjusting

screw

completely

to

avoid damage to

the tip

to cause malfunctions

which will tend

b

After idle adjustment has been made

shift the level to

N

or

P

position for

automatic transmission

JI

I

c

Remove

the car

wheel chocks before startmg

Idle Limiter Cap

Do not

remove

this

Idle

necessary

necessary

If this

Unit

to

re adJust

It

hm1ter

cap

IS

removed

unless

It

IS

at the

time

of

In

I

stallatlon To adjust proceed as follows

Make sure that the percentage oLCO contents

satisfies the specifications

aiDtenuce

TUDe up

Fig

12 Fuel strainer

Install Idle hmlter cap m posItion makmg

sure that the adJustmg screw can further turn

rotatIOn m

the

CO RICH

d1rectlOn

Dash Pot Automatic Transmission Model Only Check operation of dash pot It should not be

cracked or bound

It IS also essenttal to check

w be certam that It IS m correct adjustment

Check to be sure that dash pot contacts

stop

per lever when engme speed reaches 1 900 to

  • 2 000 rpm

Engme should

be slowed down

from

3 000

to

  • 1 000 rpm within a few seconds

Readjust dash pot or replace It with a new one

lflt falls to meet the above condItions

Carburetor Return Spring

Check

throttle

return

sprmg

for

sign

of

damage

wear or squareness

Discard spring If

found

wIth

any

of above excessIvely

beyond

use

Fuel Filter

 

Check for a contammatlOn element water depoSIt and defection

All engmes use a cartridge type strainer If 1t

IS

found

to

assembly

be

defective

replace

as

an

r

 

u

IQgiDe

DESCRIPTION

The

A12

engme

IS

a

715 cu

m

In

I me over

head valve four cyltnder engine with 2874 m

bore

and

2 765

m

stroke

It feature

full opened

wedge

shaped

combustIOn

cham

ber

alummum

heads

and

fully

balanced

5 bearmg crankshaft

dependable power

to

turn

out

smooth

REMOVAL

Removmg hood

Open the hood

remove four mstallatlOn bolts

and remove the hood

Disconnect

mmal

the

battery cable

from

the

ter

Removmg radIator

Dram water from the radiator disconnect two radIator hoses remove four radIator m stallatlOn bolts and remove the radiator

Removmg cables and hoses

Disconnect the followmg cables hoses and

wires

High voltage cable

distributor

between Igmtton COlI and

Cable to the thermal transmitter

Cable to the 011 pressure sW1tch

Cable to the primary Side of the distributor

Cable to the startmg motor

Fuel hose

Cable to the alternator

Heater hose for model With heater only

It

Fig 13 Sectional view of A 12 Engine

I

Bngine

WIres

for

accelerator

operatIOn Will

be carned

and

choke

The

out

more

easily by

removing the a1r cleaner Lift up the engine toward the front

INSTALLA TION

Install

the

removal

engine

In

reverse

sequence

of

Disconnecting clutch wire on nght hand dnve

model On left hand dnve model disconnect hydraulIc line from the clutch slave cylInder

DIsconnect the clutch WIre at the JXlrtlOn of the wIthdrawal lever

Remove the exhaust front tube

Disconnect the the cable to the back up lamp SWItch

D1sconnect the speedometer cable

Remove the propeller shaft Remove four bolts used In the differential

carner SIde

and Withdraw the propeller shaft

Remove the shift lever

Model With remote control shIft lever

Disconnect the remote control rod at the JXlr

tlOn

of transmiSSIOn

outer lever

the remote control rod

and

remove

Model With floor Sh1ft lever

Remove the boot WIthdraw the lock pin and remove the lever The operatIOn IS carned out In the passenger compartment

Model With automatic transmiSSIOn

Remove pinS from both ends of the cross shaft and remove the shIft rod

Suspend the engine With wire Remove the front engine mounting installation

nuts

Remove the rear engine mounting installation

nuts

When

removing

the

engine

mounting

in

stallation nuts

be sure to apply a Jack beneath

the transmiSSIOn

CLEANING AND INSPECTION Clean the engine thoroughly before disassem bly Before cleaning the engine remove the

l

electncal

parts

and

plug

up the

carburetor

air horn to aVOid intrusIOn of foreign matter

The engine extenor Check the covers and

bolts for breakage

rust

damage and loss

CylInder block

Check

thoroughly the water

Jacket for cracks and breakage

Clutch hOUSing

Check for cracks

011 pan

Check for excessive rust

DISASSEMBLY

Mount engine assembly on engine stand

Remove

Side

the

engine

mounting

bracket

R H

Install the engine attachment

Mount the engine on the stand

Fig 14011 pump removal

Fig 15 Thermostat hOUSing removal

II

Bngine

Remove

the altel nator and engine mounting

bracket L H

slde

Remove the crankshaft pulley

Remove

filtel

the

011

pump

together

With

the 011

Remove the high tensIOn cable dlstnbutor cap on

Remove the spark plugs

wIth

the

Remove the dlstllbutor assembly

Remove the carburetor

Remove the rocker cover

Remove the Remove the manifolds

itat

thermo

houslllg

Remove the water pump

Remove the fuel pump

Remove

rods

the rocker

shaft assembly and push

Remove the cylInder head assembly

Invert the engine

Fig 18 Rocker shaft assembly removal

Fig

16 Manifolds removal

l r
l
r

I

7

I

Y

h

w

L

1

1

Fig 19 Cylinder head bolts removal sequence

Fig 17 Water pump removal

18

Fig 20 011 strainer removal

o

j

Bneine

Remove the 011 pan and 011 straIner

Remove

tenSlOner

the tImIng chaIn

cover and the chaIn

Remove

the

crankshaft

and

camshaft

sprockets together WIth the timing chaIn

Fig

21 Tlmmg cham cover removal

Rotate the engIne

a quarter turn and remove

the piston and connectIng rod

off the connectIng rod

assembly

Take

beatings at the same

tIme and keep them In order

Rotate the engIne a quarter turn and remove

the flywheel

Remove the maIn seal

bearIng cap and the rear 011

Remove the crankshaft

Remove the baffie plate and the

net

crank

case

Remove the camshaft after takIng off the cam

shaft plate

Remove the valve tfter

Remove the piston rIngs With a tlng remover

Press

out

the

piston

pIn

With

a

piston

pin

remover and an arbor press

Remove the valves USIng a valve tfter

Be careful not to lose valve sprIng seat 011 seal valve collet and valve rocker sprIng

I

FIg 22 PIston and connectmg rod assembly removal

FIg

24 Baffle plate and net removal

Fig 23 Rear 011 seal removal

Fig 25 Camshaft plate removal

Bogioe

0

WAI CI

o

o

WAIl Cl

Fig 26 Valve components

I

Fig 28 Checking the cylinder head surface

FIg 27 Cylinder head

Cyhnder head surface flatness

Al2 Engme

Standard

m

less than

o 0020

MaxImum

m

o 0039

INSPECTION AND REPAIR

Preparation

Check

the cyhnder

head and cylinder

block

for traces of water leaks before cleaning

Clean