DATSUN 510 1968 Service Manual PDF

56

CHAPTER
SIX

NOTE
Lubncate
the

cylinder
walls

with
new

engine
oil

prior
to
insertIOn

of
pistOns
Make

certain
that
the

ring

gaps
are
not
In
line

wIth
one
another

Place

the

gaps
180

degrees
from
each

other

and
not

posltloned
either

front

to
back
or

dIrectly
in
line
with

the

piston
pIns

CAUTION

Use
extreme
care
when

Inserting
pzs

tons
so
as
to
avoId

crankshaft

damage

14
With
the
aid
of

a

nng
compressor
illStaIl

the

pISton
and

connectmg
rod
assembhes
into

the

cyhnder
block

as
shown
in

Figure
60
Make

certain
the

proper
piston
IS
mserted
mto
the

proper
hner
and
the
F
on
each

pISton
faces

forward

@

15
Install

beanngs
mto
the

connectIng
rod

caps

after

lubncatmg
them

hghtly

16

Gently
push
connecting
rods
With

beanngs

installed
down
the

cyhnder
until
contact

IS
made

with
the
crankshaft

17
Set

connectIng
rod

caps
over
crankshaft
and

insert

COnnectIng
rod
bolts
Make
certam
that
the

numbers
on
the
rods

and
the
rod

caps
face
in

the
same
direction

18

Tighten
rod
bolts
to
the

proper
torque
speci

ficatIon

as
shown

m

Figure
61

I
J

@v

N

i

19
Check
the

connecting
rod
end

play
With
a

feeler

gauge
as

previously
described

Cylinder
Head
Installation

1

Spread
a
suitable

gasket
seahng
agent
on
the

top
of
the

cylinder
block
and

position
a
new
head

gasket

2

Spread
seahng
agent
on

top
of
the

gasket

CAUTION

PositIon
the

crankshaft
so
that
no

pzston
IS
at

top
dead
center

Before

installing
head

point
the

keys
on
the

camshaft
and

crankshaft

straight
up

Once

the
head
zs

Installed
do
not

rotate
the

camshaft
and

crankshaft

separately
as

damage
to
the

piston

tops
might
result

3
Place
the

cyhnder
gently
onto
the
head

gask
et

NOTE
Three

dIfferent

types
of
bolts

are
used

to
hold
down
the
head

Make

certain
the

proper
ones
are
used

In

the

proper
places

4
Insert
head
bolts

through
holes
ill
head
and

thread
them
mto
the

cyhnder
block

5

Refemng
to

Figure
62

use
a

torque
wrench

and
Datsun
tool
ST49010000
or

equivalent
to

tIghten
the
head
bolts
to

specIficatIon
Tighten

them

gradually
m
three
or
four

stages
wlnle
fol

lOWIng
the

sequence
diagram
Torque
values
are

hsted

m
the

specIfication
table

ENGINE

57

@
L
13
and

L
16

engme

000000
8

4
2

6
10

7

3
1

5
9

o
0

0
0

0
Front

Crankshaft
and

Timing
Chain

Assembly

1

Insert
a
woodruff

key
mto
the
crankshaft

key

way
and
slide
the
crankshaft

sprocket
mto

place

2
Insert
a
woodruff

key
m
the

Illiddle
crank

shaft

keyway
and
slide
the

dIstnbutor
dnve

gear

mto

place

3
FIt
the
oil
thrower

to
the
crankshaft

as
shown

m

Figure
63

NOTE
Make
certam
that
the
crank

shaft
and

camshaft

keys
are

polntlng

upwards

4
Install
the

tmung
chain

over
the
crankshaft

and
camshaft

sprockets
Figure
64
shows
the

proper
relatIonslnp
of
the

tIming
marks
on
the

camshaft

sprocket
the

tmung
cham
and
the

crankshaft

sprocket
There
should
be
42
hnks

of
cham
from

tmung
mark
to

tmung
mar
k

5
Install
the
cham

gwdes
and
cham
tensIoner

NOTE

If
the
stretch

of
the
cham

roller
links
IS
extreme

adJust
the

cam

shaft

sprocket
location

by
tranfernng

the

camshaft
set

pOSltlon
of
the

cam

shaft

sprocket
to
No
2
or
No
3
hole

Procedures
to
make

thIS

adJustment

are

gIVen
m

steps
6

through
II

below
@

1
Fuel

pump
drive

eam

2
Cham

gUide

3
Cham

tensloner

4
Crank

sprocket

5
Cam

sprocket

6
Cham

gUide

6
Set
N
1

pISton
at

top
de

8
n
r
on

f

compressIon
stroke

7
Refer
to

Figures
65
and
66

Figure
65
is
a

dIagram
of
the
camshaft
locate

piate
an
d
FI

1

66
shows
the
front
side
of
the
camshaft

sprOcKee5
r

11
r

If

8
Examme
whether
the
camshaft
locatIon
hole

y

on

the
camshaft

sprocket
com
ff
llii
sl
ff
end

foI

tri4o

of
the

oblong
groove
in
the
camshaft

locate
E
1litc

If
the
locatIon
hole
IS
off
the
end
of
the

groove

the
stretch
of
the
cham
is

beyond
limit

9
Remove
the
bolt

holding
the
oil

pwp
p
cam

and
camshaft

sprocket
Move
the
camshaft

sprocket
mto

posItIon
so
that
No

2
hole
coin

Cides
With
the

oblong

groove
No
2
hole
should

be
on
the

right
end
of
the

oblong
groove

10
If
the
locatIon

hole

posItIon
still
isn
t
cor

rect
rotate
the
camshaft

sprocket
to
hole
No
3

which
should
be
on
the

nght
end
of
the

oblong

groove

@

58

CHAPTER
SIX

Notch
for

t1mmg
check

Camshaft

locatmg
hole

Timmg

mark

11
Should

none
of
the
above

adjustments
be

adequate
return
the
camshaft

sprocket
to
the

No
1
hole
and

replace
the
Oll

pump
cam
and

bolt
Under
these
conditIons
the

cham
must
be

replaced

Front
Cover
Crankshaft

Polley

And
Water

Pomp
InstaDation

1
Press
a
new
Oll
seal
into
the
front
cover

2

Apply
gasket

seahng
compound
to
both
sides

of
the
left
hand

and

nght
hand
front

cover

gaskets
Mount
the

gaskets
and

front
cover
to

the
block
With
bolts
and
lockwashers
Check

the
seal
of
the
head

gasket
at
the

top
of
the
front

cover
Make
certam
to
attach
bolts
at
that

locatlon

3

Insert
woodruff

key
into
crankshaft
and
slide

crankshaft

pulley
onto
crankshaft

4
Install
crankshaft
bolt
and
washer
then

torque
as

per
the

speclficatlon
table

5
Coat
water

pump
gasket
on
both
sides
With

gasket
compound
and
mount
the
water

pump
to

the
front
cover
as
shown

m

Figure
67

Oil

Pump
Installation

1
With
No
1

cyhnder
at

top
dead
center
on
Its

compressIOn
stroke
mstall
the

packing
for
the

Oll

pump
and
distnbutor
dnve

spmdle
mto
the

front
cover

2
Install
the
Oll

pump
and
distnbutor
drive

spmdle
Refer
to

Figure
68
and
make
certain

that
the
dnve

spmdle

top
IS
located

m
the
11
25
@

a
m

position
The
smaller

portion
of
the

spmdle

should
be
toward
the
front
of
the

engme

Fuel

Pomp
Water
Inlet
Elbow
lbermostat

Housing
and
Water
Outlet
Elbow
InstliJIation

1
Install
the
fuel

pump
with
associated

gasket

2
Install
the
water
mlet
elbow
front
thermo

stat

housmg
thermostat
and
water
outlet
elbow

along
With
associated

gaskets

3
Bolt
the
front
and
rear

hftmg
eyes
to
the

right

front
and
left

rear
of
the

cyhnder
block

4
Install

gasket
and
front

cover
on
the
front
of

the
head

Oil
Strainer
and
Oil
Pan
Installation

1
Mount
the
011
stramer
With

gasket
to
the
bot

tom
of
the

cyhnder
block

Torque
to

specifica

tion

ENGINE
59

2
Coat

the

pan
gasket
on
both
sides
With

gasket

compound
and
attach
the

oil

pan
to
the

cyhnder

block

Torque
as

specIfied

Manifold
and
Carburetor
Installation

1
Install
the
mtake
and
exhaust
manIfolds
WIth

associated

gasket
to
the

cylmder
head

2
Mount
the
carburetor
and

gasket
to
the
mtake

manIfold

2

Adjust
all
mtake
and
exhaust
valves
to
the

specIfied
clearance
for
a
cold

engme

Clutch

Assembly
Installation

CAUTION

Take

extreme
care
not
to

get
grease

or
011
on
the

clutch
or

flywheel
frlc

hon
contact

surfaces

1
Place
the
clutch
disc

assembly
on
the

flywheel

With
the

longer
chamfered

splmed
end
of
the
dISC

toward
the
transmISSion

2

Visually
align
or
use
a

dummy

splmed
dnve

shaft
to

ahgn
the
diSC

assembly
With
the

flywheel

pilot
beanng

3
Install
and

tighten
the
SIX
bolts

holdmg
the

clutch
cover

assembly
to
the

flywheel
Tighten

the
bolts
a
turn
each
tune

by
diagonal
pattern

until

they
are

tight
Tlghtenmg
torque
should
be

174

to
188ft
lbs
24
to
2
6

kg
m

NOTE
There
are
two
dowels
on

the

flywheel
to

locate
the
clutch
cover

4
Remove

dummy
shaft
If
used

after
the

above
bolts
are

fully
tightened

5
Refit
the
release

bearing
and
translI11Ssion

case
Miscellaneous
Installation

1
Connect
the
fuel
hose

on
the
front

part
of
the

engme
to
the
fuel

pump
and
to
the
carburetor

2

Gap
the

spark
plugs
and
mstall
them

usmg

new

gaskets

3
Coat
the
rocker
arm
cover

gasket
With
sealer

and

position
It
on
the

cylmder
head

4
Install
the
rocker
arm
cover
and

tighten
the

two
thumb

screws
that
hold
it

m

place

5
Install
distrIbutor

makmg
certam
that
the

notch

on
the
distributor
shaft

assembly
mates

With
the
drive

spmdle
Ahgn
the
location
marks

made

dunng
disassembly
so
that
the
distrIbutor

is

positioned
as
before

6

Install
and

tighten
the
bolts
which
hold
the

dIStributor

to
the
front

cover

7
Install

pomts
condenser
and
rotor

8

Replace
distrIbutor

cap
and
attach

spark
plug

Wires
m
the
correct

sequence
Make
certain
that

all
wires
are

firmly
seated
m
the
distrIbutor

cap

and
attached

securely
to
the

spark
plugs

9
HOISt
the

engme
assembly
from
the
work

stand

10
Install
the
alternator
bracket
alternator

and

engme
mounts
to
the
block

11
Install
the

IgnItIon
coil
oil
filter
oil

pressure

SWitch

dipstick
and

water
drain

plug

12
Connect
the

vacuum
Ime
between
the
dis

trIbutor
and
carburetor

13
Connect
the
transIDlSSlOn
to
the

engine
prior

to
mstallatIon
m
the
vehicle

Engine
Installation

Installation
is
the

reverse
of
the

procedures

followed
m

removal
Be
certaIn
thatlall

battery

connections
are
made

that
water
hoses

are
se

cured

wmng
IS
connected

properly
and
that
all

required
bolts
and
mounts
are
mstalled
and

tightened
Replace
the
radiator
fan
belts
and

radiator
shroud
Fill
the

engme
With
the

proper

grade
of
oil
and
the
radiator
With

recommended

coolant
Install
the
hood

to
the

hInges
according

to
the
marks
made

dUrIng
removal

SERVICE
DATA
AND
SPECIFICATIONS

Table
1
covers
servIce
data
and

engme
Speci

fications

60
SIX

Table
1
ENGINE
SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Cylinder
Arrangement

DIsplacement

Bore
and
Stroke

Valve

Arrangement

MaxImum
Brake

Horsepower

MaxImum
Gross

Torque

Firing
Order

Engme
dle

Smgle
POint

Dual
Pomt

CompressIon
RatIo

Engme
Idle
Mamfold
at
Idle

rpm

011
Pressure
hot

@
2
000

rpm

i
TIGHTENING

TORQUE
ft
Ib

kg
m

Cylinder
Head
Bolts

1st
turn

2nd
turn

Flywheel

Flxmg
Bolts

M
In

Beanng
Cap
Bolts

Camshaft
Gear

Bolt

I
011
Pan

1
1

fF
I

011

Pump

QII
Stramer

F

I
Crank

Pulley
Bolt

SPECIFICATIONS
In
mm

Valve
Mechamsm

Valve
Clearance
Hot

Valve
Clearance
Cold

Valve
Head
DIameter
Intake

Valve
Head
DIameter
Exhaust

Valve
Stem

DIameter
Intake

Valve
Stem
DIameter

Exhaust

Valve

Length
Intake

Valve

Length
Exhaust

Valve

LIft

Valve

Spring
Free

Length
Outer

Valve

Sprmg
Free
Length
Inner

Vaiv

Spnng
Loaded

Length
Outer

Valve

Spring
Loaded

Length
Inner

Valve

Sprmg
Assembllld

HeIght
Outer

Valve

Spnng
Assembled

Helght
Inner

Valve

Spnng
Effective
Turns
Outer

Valve

Sprmg
EffectIve
Turns

Inner

Valve
GUIde

Length
Intake

Valve
GUIde

Length
Exhaust

Valve

GUIde

HeIght
from
Head
Surface

Valve
GUIde
Inner
DIameter
Intake

Valve
GUIde
Inner
DIameter
Exhaust

Va
Ive
GUIde

Outer
Dlam
eter
Intake

Valve
GUIde
Outer

DIameter
Exhaust

Valve
GUIde
to

Stem
Clearance
Intake

Valve

GUIde
to
Stem
Clearance
Exhaust

Valve
eat

W
dth
Intake

Valve

SEtat
WIdth
Exhaust
4
m

Ilnil

97
3
cu
m
1595cc

3
2677
x
2
9016
In
83
x
73

7mm

Overhead
Camshaft

96

@
5
600

rpm

110
ft
Ib
13
8
kg
m

@
3
600

rpm

1
3
4
2
r

600

rpm

700

pm

85
1

i7
7
In

Hg
450mm

Hg

54
to
60
Ib
m
2

3
8
tQ
4
2

Iig
cm

325
4
5

39
8
5
5

68
No
75
9
9
50

to
1039

325

to
39
8
4
5

to
5
5

362
to
43
4
50
to
60

2
9
to
5
1
0
4
to
0
7

108
to
15
2
1
5
to
2
1

58t087
08to
12

1157
to
130
1
160
to
180

o
118
0
30

o

0C
98

0
25

1
50
38

0

1
30
33
0

031
80

031
80

456
1159

4
57
116
O

03937
100

2
05
52
0

1
77
44
96

1
21

@
1054
Ib
3
07

@
47
8

kg

o
96

@
56
Ib
24
5

@
25
5

kg

1
53

@
63
9

Ib
38
9

@
29

0
kg

1
38

@
27
1
Ib
35

@
123

kg

45
I

55

2
32
59
0

2
32
59
0

0409

to
0
417
104

to
106

0315

to
03154
80

to
8018

0315
to
03154
80
to
8
Oi8

04718
to
04723
11
985
to
11
996

04718
to

04723
11
985
to
11
996

00006
to
00018
0
015

to
0
045

00016
to
00028
0040

to
0070

o
055

to
0
071
1
4

to
1
8

0063
to
0079
1
6
to
20

ENGINE
61

SPECIFICATIONS
In
mm
continued

Valve
Seat
Interference

Fit
Intake

Valve
Seat
Interference
Flt
Exh

ust

Valve
GUide
Interference
fit

I

Camshaft
and

Timing
Chain

Ca
mshaft
End

Play

Camshaft
Lobe
LIft

Camshaft
Journal
Diameter

Camshaft
Bend

Camshaft

Bearing
Inner
Diameter

Camshaft
Journal
to

B

arlng
Clearance

Rocker
Arm
Lever
Ratio

Connecting
Rod

Center
Distance

Standard

Bearing
Thickness

Big
End

Play

Connectmg
Rod

Beanng
Clearance

Connecting
Rod
Bend

per
3
937
In
100mm

Crankshaft
and
Main

Beanng

Journal
Diameter

Journal

Taper
and
Out
ot
Round

Crankshaft
Free
End

Play

Crank
Pin
Diameter

Crank
Pin

Taper
and
Out
ot
Round

Main

Bearing
Thickness

Main

Beanng
Clearance

Crankshaft
Bend

Piston

Standard
Diameter

Ellipse
Difference

Ring
Groove

Top

Second

011

Piston
to
Bore
Clearance

Piston
Pm
Hole
Offset

Piston
Pin

Piston
Pin
Diameter

Piston
Pin

Length

Piston
Pin
to
Piston
Clearance

Interference
Fit
ot
Piston
Pin
to

Connecting
Rod

Bushing

Piston

Ring

Ring
Height

Top

Second

011

Side
Clearance

Top

Second

011

Ring
Gap

Top

Second

011
Table
1
ENGINE
SERVICE
DATA
AND
SPECIFicATIONS
continued

00031
to
0
0043
0
OB

to
0
11

00024
to
0
0039
006
to
0
10

00011
to
00019
0027
to
0049

00031
to
0
0150
0
08
to
0
38

o
261
6
63

18877
to

1
8883
47
949
to
47
962

o
0020
0
05

1
8898
to
1
8904
48

0
to
48
016

00015
to
0
0026
0038
to
0
076

15

5
507
to
5
509
139
87
to

139
93

o
0588
to
0
0593
1
493
to
1
506

00079
to
0
0118
0
20
to
030

o
0006
to
0
0022
0
014
to
0
056

o
0012
003

2
1631
to
2
1636
54
942
to
54
955

less
than
00012
003

o
002
to
0
0059
0
05

to
0
15

1
9670
to
1
9675
49961
to
49
975

less
than
0
0012
0
03

o
0717
to
0
0722
1

822
to
1
835

o
0008
to
0
0028
0
020
to
0
072

00019
005

3267

to
3
269
8299
to
83
04

0013

to
0014
032
to
035

008
20

o
08
2
0

o
16
4

0

00010
to
0
0018
0
025
to
0
045

00394
0
0020
1
O
0
05

o
8266
to
0
8268
20
995
to
21
0
0

2
8346

to
2
8445
72
00
to
72

251

o
0003

to
0
0004
0
OOS
to
0
OlD

00006
to
0
0013
0015
to
0
033

o
0787
2
0

o
0787
2
0

o
1575
40

00018
to
00031
0
045
to
0
078

00012

to
0
0025
0030
to
0
063

00010
to
00025
0025
to
0
063
i
J

I

n

T

00091
to
0
0150
023
to
038

00059
to
0
0118
0
15
to
0
30

00059

to
0
0118
0
15

to
0
30

CHAPTER
SEVEN

FUEL
SYSTEM

The
fuel

system
mcludes
the

fuel

tank

straIner

pump
carburetor
arr
cleaner
and

necessary
lines

Inspect
components
for
leaks

and
deterioratIOn
whenever
mamtenance
is

done
The
fuel
stramer
should
be

mspected
peri

odIcally
and
cleaned

AIR
CLEANER

The
au
filter
element
is
viscous

paper
and

does
not

require
cleanmg
Replace
It

every

24
000
mlles
or
more

frequently
under
harsh

condItIons

Several
mInor
differences
exist
between

vehicles

dependmg
on
the

type
of
emisSIOn
con

trol
device
used

Figure
1
shows
location
of
the

air
cleaner
on
the

engme
and

parts
compnsing

the
cleaner

system
on
model

years
through
1969

Figure
2
shows
the

changes
for
1970
and
later

Warm
air
is

supplIed
to
the
air
cleaner
from
the

exhaust
mamfold
to

prevent
carburetor

Icmg

AIR
CLEANER
REMOVAL

AND
REPLACEMENT

1
Unthread
the

WIng
nut

atop
the
cleaner

assembly

2
Remove
the
two
bolts

holdIng
the
air
cleaner

to
the

support

3

Disconnect
the

aIr
cleaner
duct
from

the
base

of
the
cleaner
intake
throat
4
LIft
off
the
aIr
cleaner

body
and
remove
the

aIr
filter
as
shown
m

Figure
3

To
remove
the
arr
cleaner

proceed
as
follows

1
Perform

steps
1

through
4
above

2
Unscrew
the
band
bolt
at
the
base
of
the

air
cleaner

3
DIsconnect
all
hoses

leadmg
to
the
air

cleaner

4
Pull

up
on
the

body
of
the
air
cleaner
and

remove
from
carburetor

5

Except
for
the

au
filter

element
thoroughly

clean
all

parts

6
Reverse
the

steps
above
for

reassembly

FUEL
STRAINER

The
fuel
stramer

IS
located
on
the

nght
hand

side
of
the

engme
compartment
Figure
4
shows

the
fuel
stratner
hoses

clamps
and
the
mount

Ing
clIp
that
holds
the
fuel
stramer
In

place
The

fuel
stramer
IS
of
the

cartrIdge
type
and
uses
a

fiber
mat
and

nylon
as

strainer
elements
The

fuel
stramer
should
be

mspected
frequently
for

foreIgn
material
and

replaced
at
least

every

24
000
rmles

1
DIsconnect
the
inlet

and
outlet
hoses
from

the
fuel
stratner
Make
certatn
that
the
mlet
hose

bottom
IS
not

permItted
to
fall
below
the
level

of
the
fuel
tank

or

leakage
wIll
occur

13
8

t

12
i

l

2
cover
packIng

3
Co
er
packIng
n

4
VISCOUS
paper
eleme
23

filter

5
Band

6
Insuletor
OWer
body
pecking

1
Element
pac
l
lng
liL
J
J
4

9
Grommet

10
Grommet

11
Band
bolt
lll
i
8

12
WIng
nut
packing

13
Wing
nut
AV
T

14
support

15
Ilolt

19
I
Il
cleaner
cover

22
ExhaUst
manIfold

23
Ilolt

24
I
Il
cleaner
duct
i
9
10

S
e
l

ci
r
C

t
f
J

14
IS

13
1
0
lot

1
Air
cleaner

3
Co
er
paclung

4
Viscous
paper
element

FIlter

5
Band

6
Insuletor

7
Lower
body
packmg

8
Element
peclllng

10
Grommet

11
Band
bolt

16
Compensator
assembly

17
Idle
compensator
connectmg

tube
l

1
1
@

5
11
10
I
13
12
G
3
4
7
0
g
l
i

FUEL
SYSTEM
6S

CD

2
Remove
the
fuel
stramer
from
Its

mountlng

clIp

3

Replace
the
fuel
stramer
as

reqUIred

4
Reconnect
the
mtake
and
outlet
fuellmes

FUEL
PUMP

The
fuel

pump
conSISts
of
a

body
rocker
arm

and
lmk

assembly
dIaphragm

dIaphragm

spring
seal
and
mlet
and
outlet
valves
The
l
r

t

1
9

l

F
r

fl

rocker
arm
IS
dnven

by
a

pump
cam
mounted

on
the
catnShaft
In
the
front

part
of
the
rocker

arm
front
cover

assembly

Figure
S
shows
the
fuel

pump
for
all
models

through
1970

Figure
6
illustrates
the

fuel
pump

for
1971
and
later
models

Fuel

pump
Testing

Fuel

pump
pressure
and
fuel

pump
capacity

testlng
are

performed
m
tests
descnbed
below

Both
tests
are

performed
With
the
fuel

pump

mounted
to
the

engme

Static
Pressure
Test

1
DIsconnect
the
carburetor
fuel
lme
at
the

carburetor

2
Install
an

adapter
and
a
tee

fittmg
to
the

fuel
lIne
and
attach

a
SUItable

pressure
gauge

3
Connect

adapter
to
carburetor

4
Start
and
run

engine
at

varymg

speeds

5
The

gauge
reading
IS
static
fuel

pressure
It

should
remam
between
256
and
341
Ib
m
2

018
to
0
24

kg
cm2
Pressure
below
thelower

lImIt
mdlcates
extreme
wear
on
one

part
or

gen

eral

wear
on
several

pump
parts
Pressure
above

the

upper
hrmt
indIcates

an

excessIvely
strong

diaphragm

spnng
or
a

dIaphragm
that
is
too

tIght
Both
condItIons

require
the

removal
of
the

fuel

pump
for

necessary
repaIr
or

replacement