DATSUN 510 1968 Service Repair Manual
Manufacturer: DATSUN, Model Year: 1968, Model line: 510, Model: DATSUN 510 1968Pages: 252, PDF Size: 12.2 MB
Page 1 of 252
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Fust
Pnntmg
June
1972
Second
Pnntmg
September
1972
Thm
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1973
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COPYrIght
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1972
Clymer
Pubhcahons
All
rlghts
reserved
No
part
of
thIs
publicatIOn
may
be
reproduced
stored
In
a
retrleval
system
or
trans
nlltted
m
any
form
or
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any
means
electronic
mechanical
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recordmg
or
otherwIse
without
the
prlor
written
permIssIon
of
Clymer
PublrcatlOns
J
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Pnnted
In
USA
Page 2 of 252
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Page 3 of 252
CON1EN1S
CHAPTER
ONE
GENERAL
INFORMATION
Introduction
Model
Identification
CHAPTER
TWO
PERIODIC
MAINTENANCE
RoutIne
checks
Pen
odic
checks
CHAPTER
THREE
TROUBLESHOOTING
EqUIpment
Starter
ChargIng
system
EngIne
Igmtlon
system
Fuel
system
Exhaust
emIssIon
control
CHAPTER
FOUR
ENGINE
AND
IGNITION
TUNE
UP
EqUIpment
Battery
Spark
plugs
DIstrIbutor
Igmtlon
timIng
CHAPTER
FIVE
ENGINE
LUBRICATION
SYSTEM
Descnptlon
Lubncation
cIrcuIt
SpecIficatiOns
and
dImensIons
EngIne
lubncation
and
maIntenance
Recommended
lubncants
Clutch
TransmIssiOn
Brakes
Steenng
and
suspension
TIre
wear
analysIs
Wheel
balancIng
Idle
speed
and
Idle
mIXture
Dwell
angle
setting
CompressIon
test
Valve
clearance
adjustment
AddlllOnal
checks
Oil
pump
I
6
t
1
4
V
9
t
1
20
27
Page 4 of 252
II
CHAPTER
SIX
ENGINE
Cylmder
block
Crankshaft
PistOns
and
connectmg
rods
Cyhnder
head
Camshaft
Valve
mechamsm
Camshaft
dnve
Mamfolds
011
pump
Fuel
pump
Carburetor
Emission
control
devIces
Engme
removal
Engme
dISassembly
Pistons
and
connectmg
rods
Cyhnder
head
Engme
mspectIon
and
replllr
Engme
reassembly
Service
data
and
speCifications
CHAPTER
SEVEN
FUEL
SYSTEM
Air
cleaner
Fuel
strlllner
Fuel
pump
Carburetor
Fuel
tank
1
CHAPTER
EIGHT
COOLING
SYSTEM
DescnptIon
Water
pump
Fan
clutch
Thermostat
Radiator
CHAPTER
NINE
ENGINE
ELECTRICAL
SYSTEM
Starter
Overrunmng
clutch
assembly
ChargIng
ClrcUlt
Alternator
Alternator
output
Voltage
regulator
DIstrIbutor
Condenser
Igrntlon
cod
SpeCifications
Spark
plugs
CHAPTER
TEN
EMISSION
CONTROL
SYSTEM
Exhaust
emiSSIOn
control
Crankcase
emission
control
Air
mJectlon
system
Engme
modifications
Evaporative
emiSSion
control
Exhaust
system
CHAPTER
ELEVEN
CLUTCH
TRANSMISSION
AND
DRIVESHAFT
Clutch
TransmissIon
Master
cyhnder
TransmissIon
data
and
speCIfications
Operating
cyhnder
Dnveshaft
Withdrawal
lever
adjustment
Dnveshaft
data
and
speCIfications
Clutch
system
bleedmg
Automatic
transmIssIon
checks
Clutch
data
and
speCIfications
31
62
84
91
114
127
Page 5 of 252
CHAPTER
TWELVE
DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
149
DIfferentIal
Rear
axle
and
suspension
Codspnng
Shock
absorber
Rear
suspensIOn
arm
Rear
axle
shaft
Wheel
beanngs
Seals
Rear
spnng
Axle
case
SpecificatIons
CHAPTER
THIRTEEN
FRONT
AXLE
FRONT
SUSPENSION
AND
STEERING
168
Wheel
hub
and
bearmg
StabilIzer
TenSion
rod
Spnng
and
strut
assembly
Transverse
lInk
Lower
ball
Jomt
Front
suspension
adjustment
Wheel
alignment
Posture
adJustment
Steenng
system
SpeCificatIons
CHAPTER
FOURTEEN
BRAKES
187
Brake
pedal
Master
cylInder
Front
diSC
brakes
Rear
brakes
Front
drum
brakes
Wheel
cylInders
Brake
system
bleedIng
Handbrake
Service
data
and
speCificatIons
CHAPTER
FIFTEEN
BODY
ELECTRICAL
SYSTEM
Wmng
SWitches
and
fuses
Instrument
meters
and
panels
Heater
205
Wmdshleld
wipers
Wmdslueld
washers
Headlamps
WIrIng
diagrams
CHAPTER
SIXTEEN
BODY
223
Front
body
trIm
Bumpers
Hood
lock
control
Doors
Door
locks
and
regulators
Trunk
lId
and
rear
bumper
Seats
Tad
gate
INDEX
235
I
Page 6 of 252
CHAPTER
ONE
GENERAL
INFORMATION
This
manual
provides
maintenance
informa
tIon
on
the
Datsun
510
Series
and
521
Series
of
vehlcles
The
510
Series
includes
the
two
door
sedan
four
door
sedan
and
station
wagon
The
521
Senes
IS
the
pIck
up
truck
Coverage
is
from
1968
through
1972
models
All
models
use
the
L16
engme
a
96
horse
power
four
cylmder
overhead
camshaft
design
The
510
has
a
fully
synchronized
four
speed
manual
or
three
speed
automatic
transmisSIon
The
521
has
a
four
speed
manual
transmission
only
In
1972
horsepower
ratIng
was
lowered
to
92
horsepower
due
to
changes
m
emission
control
device
requirements
Figure
1
is
an
over
all
view
of
the
four
door
sedan
Figure
2
shows
the
station
wagon
and
Figure
3
illustrates
the
pick
up
truck
Over
the
years
the
510
and
521
series
have
remained
essentIally
the
same
with
the
excep
tion
of
changes
to
the
emISsion
control
systems
and
overall
body
stylmg
In
this
manual
every
effort
has
been
made
to
pinpoint
significant
c
if
ferences
between
model
years
The
use
of
SpecIal
tools
and
test
equipment
has
been
avoided
wherever
possible
When
necessary
special
tools
and
test
equipment
are
illustrated
either
in
actual
use
or
alone
A
well
equipped
mecharuc
may
find
he
can
substitute
similar
tools
or
make
his
own
to
fulfill
a
e
Ii
ment
Recommendations
are
occasionally
made
to
refer
servIce
or
mamtenance
to
a
Datsun
dealer
or
a
SpecIaliSt
in
a
specIfied
field
In
these
cases
work
WIll
probably
be
done
more
qUlckly
and
economIcally
than
if
the
mecharuc
performs
them
himself
MODEL
IDENTIFICATION
Body
Number
Plate
The
body
number
IS
stamped
on
the
fire
wall
in
the
engine
compartment
The
numbers
give
the
chasSIS
model
and
serial
number
Model
Identification
Plate
The
model
Identification
plate
Figure
4
is
mounted
WIthin
the
engine
compartment
TIns
plate
gIves
engine
number
and
veh1cle
number
Engine
Identification
The
engine
identrlicatlon
marking
is
stamped
on
the
right
hand
SIde
of
the
cylinder
block
just
below
the
third
and
fourth
sp8l
k
plugs
Model
Identification
Numbel
ll
The
following
numbers
have
been
assigned
to
the
510
and
52
I
Series
vehicles
oj
Page 7 of 252
2
CHAPTER
ONE
Sedan
Four
speed
Floor
Shift
P51O
UT
Pl5lO
T
Pl510
UT
P51O
UA
Pl5lO
A
Pl510
UA
AutomatIc
Three
speed
Wagon
Four
speed
Floor
Shift
WP510
UT
WPl510
T
WPL510
UT
WP510
UA
WPl5lO
A
WPL510
UA
AutomatIc
Three
speed
PIl
Il
up
Four
speed
Floor
Shift
Pl521
TU
Pl521
TN
CD
MAIN
SPECIFICATIONS
AND
DIMENSIONS
Table
1
covers
general
specIfications
and
dImensIOns
DetaIled
system
specIficatIOns
ill
cludmg
clearances
tolerances
and
torque
tlght
enrng
mformatlOn
are
presented
Wlthm
each
chapter
Parts
Replacement
When
you
order
parts
from
the
dealer
or
other
parts
dlstnbutor
always
order
by
engme
and
d
1
Page 8 of 252
GENERAL
INFORMATION
3
CD
i
J
x
CD
Page 9 of 252
4
CHAPTER
ONE
chassIs
number
Write
the
numbers
down
and
carry
them
ill
your
wallet
Service
Hints
Throughout
thIs
manual
keep
two
conven
bons
ill
mmd
Front
refers
to
the
front
of
the
vehicle
The
left
and
nght
sides
of
the
ve
hicle
refer
to
a
person
sittIng
ill
the
car
facing
forward
For
example
the
steenng
wheelIS
on
the
left
hand
Side
All
dimensIOns
and
capacities
are
expressed
ill
units
fanuhar
to
a
Umted
States
mechaniC
such
as
illches
and
pounds
Metric
measurements
are
also
given
Metnc
tools
are
reqUITed
to
work
on
the
Datsun
CD
DATSUN
IENGINE
CAPACITY
IMAX
HP
RPM
IWHEELBASE
IENGINE
NUMBER
FAR
NO
NlSSAN
MOTOR
co
LTD
YOKOHAMA
JAPAN
TYPEI
510
1595
cc
961P
6600
rpm
mm
L
1
00988
P61
l
O
1
l
M
Table
1
MAIN
SPECIFICATIONS
AND
DIMENSIONS
r
ITEM
Sedan
Wagon
Plm
up
EnglDe
Type
L16
L16
L16
Valve
Arrangement
Overhead
Cam
Overhead
Cam
Overhead
Cam
Bore
3
26n
ID
83mm
3
2677
ID
83mm
3
2677
ID
83mm
Stroke
2902
ID
73
7mm
2
902
ID
73
7mm
2
902
In
73
7mm
Displacement
97
3
cu
ID
l595cc
97
3
cu
In
l595cc
97
3
cu
ID
1595cc
CompressIOn
Ratio
851
851
851
MaXimum
SAE
Hompower
96
@
5
600
rpm
96
@
5
600
rpm
96
@
5
600
rpm
MaXimum
SAE
Torque
998ft
Ib
138
kg
m
998ft
Ib
138
kg
m
9911
ft
Ib
138
kg
m
Fuel
Octane
85
85
85
Lengtb
1622
ID
4
12Omm
163
2
ID
4
I45mm
168
9
ID
4
290mm
Width
61
4
ID
l
560mm
61
4
ID
1
560mm
62
8
In
Cl
595mm
Height
55
lID
1
400mm
565
ID
Cl
435mm
60
8
ID
Cl
545mm
Wheelbase
95
3
ID
2
42Omm
95
3
ID
2
420mm
99
6
In
2
530mm
Room
Space
Inner
Length
63
3
In
1
61Omm
673
ID
1
710mm
72
8
ID
1
850mm
Inner
Width
499
ID
1
27Omm
507
ID
1
29Omm
563
In
1
430mm
Inner
Height
44
4
In
1
130mm
44
61D
1
135mm
15
7
ID
399mm
Tread
Front
50
4
ID
28Omm
502
In
1
275mm
492
In
1
250mm
Rear
504
In
1
280mm
496
In
Cl
260mm
499
ID
1
267mm
Road
Clearance
741n
l88mm
64
ID
l63mm
787
ID
200mm
Weight
4
Speed
2
0611b
935
kg
2
138
Ib
970
kg
2
127
Ib
965
kg
Automatic
2
114Ib
959
kg
2
182
Ib
990
kg
Minimum
Turning
RadiUS
157ft
48m
157ft
48m
171
ft
52m
Seating
Capaaty
5
5
2
Battery
Volt
12
12
12
Capacity
400rSOAH
400r50AH
40
or
60
AH
Connection
Negative
ground
Negative
ground
Negative
ground
Fuel
Tank
Capaaty
11
9
gal
45
liter
11
9
gal
45
liter
108
gal
41J
r
011
Pan
Capacity
42
qts
40
liter
4
2
qb
40
liter
1
06
gal
40
Iller
011
Filter
Capaaty
74
ql
07
liter
74
ql
0
7
liter
1
48
Pint
0
7
liter
Transmission
Capaaty
1
8
ql
1
7
liter
18
ql
1
7
Iller
2
11
qt
20
Iller
Dlflerenbal
Capaaty
85
ql
80
liter
11
ql
1
0
liter
87
ql
0
83
lIter
Coolant
Capaaty
7
2
ql
6
8
liter
7
2
ql
6
8
lIter
7
2
qt
6
8
Iller
Clutch
Type
Dry
Single
diSC
Dry
slDgle
diSC
Dry
slDgle
diSC
Draphragm
spnng
Diaphragm
spnng
Diaphragm
spnng
l
Page 10 of 252
GENERAL
INFORMATION
5
Table
1
MAIN
SPECIFICATIONS
AND
DIMENSIONS
continued
Suspension
Rear
Sedan
Wagon
Pick
up
Manual
Automatic
Manual
Automatic
Manual
HypoJd
Hypoid
Hypold
ReCIrculating
ball
ReCIrculating
ball
ReCirculating
ball
DIsc
DIsc
Drum
Drum
Drum
Drum
Mechanical
rear
wheels
Mechanical
rear
wheels
Mechanical
rear
wheels
Independent
strut
type
Independent
strut
type
Independent
torsion
bar
with
tension
rods
and
with
tension
rods
and
stabilizer
stabilIZer
Independent
semi
trailing
Semi
elliptiC
leaf
spring
Semi
elliptic
leaf
spnng
arms
wrtII
coli
springs
and
shock
absorbers
5
6O
13
4PR
5
6O
13
4PR
600
14
6PRLT
ITEM
Transmission
Type
Final
Gear
Type
Steering
Gear
Type
Brake
Front
Rear
Parking
Brake
Suspension
Front
Tires
6
2
Q
1
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