ECU DATSUN 510 1968 Service User Guide

68
CHAPTER
SEVEN

Capacity
Test

Perform
the

capacity
test

only
when
the
statIc

pressiue
test
IS
withm

acceptable
lirmts

1

D
sconnect
the
fuellme

at
the
carburetor

2
Place
a
sUItable
container
at

the
end
of
the

fuellme

3

St
lrt
the

engm
and

run
at
OOO

rpm

4
The
fuel

pump
should
delIver
fuel
into
the

co
ntainer
at
a
rate

slightly
over
two

pints
per

minute

If

no

gasolme
or

only
a
lIttle

appears
the
fuel

lme
is

clogged
or
thefuel

pump
defectIve
Bef

removmg
the
fuel

pump
remove
the

gas
tank

filler

cap
dtsconnect
the
mlet
and

outlet
fuel

lmes
and

qlow
through
them
With

compressed

air
to
make
certam

they
are
clear
Reconnect
the

fuellmes
and
retest
the
flow
If
stIll

insufficient

the
fuel

p
mp
requires
servicmg
or

replacement

Fuel

Punip
Removal
and

Disassembly

1
Unscrew
the

two

mountIng
nuts

hOldmg
fuel

pump
to
the

cylmder
head

2
Disconnect
the
inlet
and
outlet
lines

3
Remove
the
fuel

pump
from
the

cylmder

head

4
Place
the

pump
on
a
work
bench
and
remove

the
screws

jommg
the

upper
and
lower

bodIes

5
Remove
the

cap
and

gasket
by
removing
the

cap
screws

6
Unscrew
the
elbow
and
connector

7
Remove
the
valve
retamer

by
unscrewmg
the

two
valve
retamer
screws
The
two
valves
are

then

easily
removed

8
To
remove
the

dIaphragm
spring
lower

body

seal
washer
and
lower

body
seal
from
the
lower

body
press
the

diaphragm
down
Wh1le

domg

thIS
cant
the

dIaphragm
so
that
the

rectangular

part
m
the
lower
end
of
the

pull
rod

unhooks

from
the
rocker

arm
lmk
ThIS
action
IS
shown

mFigure7

9
Drive
out
the
rocker
arm

pm
by
usmg
a
dnve

dnft
nd
hammer

Fuel

Pump
Inspection

1

Check
the

upper
and
lower
bodIes
for

cracks

2

Check
the
valve

assembly
for
wear
on
valves

and

springs
CD

3
Check
the

diaphragm
for
small
holes
cracks

and
wear

4
Check
the
rocker
arm
for
wear
where
It
con

tacts
the
camshaft

5
Check
the
rocker
arm

pin
for

wear
A
worn

pin
may
cause
011

leakage

6
Check
all
other

parts
for
abnormalItIes
or

defects

Replace
With
new

parts
as

reqUlred

Reparr
kIts
are
available
from
Datsun
dealers

and

parts
outlets

Fuel

Pump
Assembly

1

Assembly
of
the
fuel

pump
is
the
reverse
of

dlsassembly

2
Use
new

gaskets
durmg
assembly
and

mstanatIon

3
Lubncate
the
rocker
arm
the
rocker
arm

link
the
rocker
arm

pm
and
the
lever

pin
before

mstallatIon

4
To
test
the

operatIon
ohhe
fuel

pump
before

remstallatlOn
connect
a
three
foot

pIece
of
fuel

lme
or
hose
betweentbe
fuel
filter
and
the
fuel

pump
Hold
the
fuel

pump
at
the
end
of
the
fuel

lme

conSIderably
above
the
level
of
the
fuel

stramer

Operate
the
rocker
arm

by
hand
If
fuel

IS
drawn

up
to
the

pump
soon
after
the

pumpmg

actIon
IS
started
the

pump
IS

satIsfactory

5
Install
the
fuel

pump
to
the

cylmder
head
and

secure
the

mounting
nuts
to

the
studs

6
Reconnect
the
mlet
and
outlet
fuellmes

7
Check
the

operatIon
of
the
fuel

pump
by

runnmg
pressure
capaCIty
tests
as
descnbed

preVIously

FUEL
SYSTEM
71

Dash
Pot

Adjustment

The

adjustment
of
the
dash

pot
IS
done

by

warmmg
up
the

engme
properly
and

checkIng
If

the
throttle
lever
touches
th
dash

pot
stem
as

the

engine
reaches
1
800
and
2
000

rpm
under

no
load
conditIons

Proper
contact
between
the

throttle
lever
and
the
dash

pot
stem

produces
a

normal
dash

pot
performance
Should
a
normal

mcrease
m

engme
speed
not
occur

adjust
the

dash

pot
as
follows

1
Loosen
the
dash

pot
locknuts

2
Rotate
the
dash

pot
nght
and
then
left

3

Adjust
the
dash

pot
so
that
the
throttle
lever

hIts
the
stem
between
1
800
and
2
000

rpm

4
Fasten
the
lock
nuts

securely

5
The
clearance
between
the
throttle
valve
and

the
throttle
chamber
wall
should
be
0
0709
m

0
8mm

or
10

degrees
In
throttle
valve

angle

MAJOR
CARBURETOR

SERVICE
PROCEDURES

A
carburetor
m

good
operatIng
condition
will

delIver
the

pr
per
gasolme
and
aIr
ratIos
for
all

engme
runnmg
speeds
A

gradual
declme
In

smoothness

response
and

power
Will
occur
as

the
carburetor

slIps
from

adjustment
and
Its
delI

cate

parts
become

dirty
and
worn
Overhaul

should

only
be

attempted
by
an

expenenced

mechanic

Accurate
calIbratIon
of

passages
and
dIS

charge
hole

reqUIre
that

extreme
care
be
taken

In

dISassembly
cleanmg
and

reassembly
Use

only
a

hIgh
grade
carburetor
cleaner
and
com

pressed
arr
to
clean

parts
and

passages
Never

use
wire
or
other

pOInted
Instruments
for
clean

ing
CalIbratIon
of
the
carburetor
will
be
af

fected
The

procedures
below
are

generally
true

for
all
models
As
an
aId

Figures
13
and
14
are

typIcal
examples
of
the
carburetors
used

Carburetor
Removal

1
Remove
the
au
cleaner

by
dIsconnectIng
all

hoses
attached
to
It

remoVmg
the
two
bolts

holdmg
the

aIr
cleaner
to
the

support
and

loos

enmg
the
band
bolt
at
the
base
of
the
aIr
cleaner

2
DIsconnect
fuellme
vacuum
Ime
and
choke

wire
u

eqUIpped
from
the
carburetor
3
Remove
the
throttle
lever

4
Remove
four
nuts
and
washers

holdmg
car

buretor
to
manIfold

5
Lift
carburetor
off
of
manuold

6
Remove
and
dIscard
carburetor
to
manuold

gasket

7
Place
carburetor
on
clean
workbench

Carburetor

Disassembly

1
The
maIn

Jets
slow

Jets
and
needle
valves
on

both
the

pnmary
and

secondary
systenIS
are

accessIble
from
outsIde
the
carburetor
Refer
to

FIgures
13
and
14
for
locatI
n

2
The
choke
chamber
can
be
detached

by
re

mOVIng
the

connectIng
rod

pump
connectIng

rod
return

sprmg
stop
pm
and
the

set
screws

I

that
hold

It
in

place

3
The

pnmary
and

secondary
emulSIon
tubes

can
be
disassembled

by
remOVIng
the
mam
air

bleeds

on
the

respectIve
SIdes

4

To
check
the
accelerator

pump
remove
the

cylInder
cover
Be
careful
not
to
lose
the

return

spnng
and
Inlet
valve
at
the
lower

part
of
the

pIston
durmg
dIsassembly

5
Detach
the
throttle
chamber
from
the
float

chamber

by
remOVIng
the
rod

lInkIng
the
dia

phragm
WIth
the

secondary
throttle
valve
and

the
four
screws
that
hold
It
However
It
IS

preferable
to
leave
the
throttle
valve
mtact
unless

absolutely
reqUired
If

It
IS

necessary
to
dlS

assemble
the
valve
It
should
be
Installed
so
that

the

secondary
throttle
valve
will
be

gap
free

OtherwIse
stable
Idle
and

good
slow

speed

performance
will
suffer

is
To
check
the
float
the
float
chamber
cover

must
be
removed

I

7
The

dIaphragm
IS
dIsassembled

by
removing

the
set
screws

holdmg
the

dIaphragm
chamber

cover
In

reassemblIng
the

diaphragm
be
careful

not
to
turn
the

edge
of
the

dIaphragm
up

8
In

dlsassemblmg
and

reassembling
the
mter

lockIng
lInks
take
care
so
that
each

lInkage
has

a
smooth
actIon
and
that

parts
are
not
forced

mto

pOSItIon

9
For
vehIcles

equipped
With
an
automatIc

choke
remove
the
brmetal

case

by
releasmg
the

set
screws
The
bimetal

1l
extremely
senSItIve

COOLING
SYSTEM
8S

and

In
those
with
exhaust
and

evaporatIve
emIS

sion
control
devIces
a
fan
clutch
IS
combIned

WIth
the
thermostat
to
detect

temperature
m
the

engme
compartlnent
When
the

temperature

nses
the
thermostat
detects
the

change
an
the

fan
clutch

engages
thereby
helpmg
to
cool
the

engme

WATER
PUMP

Figure
2

page
86
IS
an

exploded
drawmg
of

the
water

pump
and
fan

assembly
for
1970
to

1971
The

top
half
of
the
IllustratIon

applIes
to

those
models
WIth
exhaust
and

evaporatIve

emiSSIOn
control

systems
The
bottom
half
covers

models
WIth
a
crankcase

emiSSIon
control
deVIce

only

Figure
3

page
87

IS
an

exploded
drawmg
of

the
water

pump
and
fan

assembly
for
1968

models
Without
exhaust

or

evaporatIve
controls

Figure
4

page
88
shows
the
1968
model
With

emISSIon
control
deVIce
As

can
be
seen
from
the

illustratIons
most
dIfferences
eXISt
withIn
the

fan
clutch

assembly

Water

Pump
Removal

1
Remove

upper
and

lower
radIator
hoses
from

the
thermostat

housmg
and

cylmder
block
re

spectIvely
Dram
coolant
from
rad1ator
and

cylInder
block

2
Loosen
the
alternator

mountlng
bolt
and
the

adjustIng
bolt
on
the
alternator

mountIng

bracket

3
Move
the
alternator
toward
the

cylinder

block
untIl
slack
IS
eVIdent
10

the
fan
belt
Re

move
fa
belt
fro
alternator
water

pump
and

crankshaft

pulley

4
It
IS
difficult
to
remove
the
water

pump
from

the
front

housmg
With
the
radiator
and

top

shroud
10

place
so
remove
them

5
Remove
the
bolts

holdmg
the
fan

assembly

to
the
water

pump
and
remove
the
fan

assembly

6
Remove
the
bolts

holdmg
the
water

pump
to

the
front

housmg
as
shown
In

Figure
S

Water

Pump
Disassembly
Repair
and

Assembly

Disassembly
or

attempted
repaIr
of
the
water

pump
assembly
IS
not
recommended
If
the

pump
assembly
IS
corroded
the

vanes
are
dam
aged
or
the

bearmgs
are

nOISY

replace
the

entIre
umt

1

Inspect
the
water

pump
assembly
and

replace

If

reqUIred

2

If
the
water

pump
assembly
IS
stIll
serVIce

able
clean
It

thoroughly
before
mstallatIon

3
Assemble
the
water

pump
assembly
m
the

front
cover
10
the
reverse
order
for

disassembly

Do
not
reuse
old

gaskets

4

Replace
the
fan

assembly
on
the

water

pump

and
mstall
the
radiator
and

top
shroud

5

Inspect
the

fan
belt

carefully
for

SIgnS
of

wear

or
cracks
DIscard

It
If
10
doubt

6
Install
the
fan
belt
around
the
crankshaft

pulley
water

pump
pulley
and
the
alternator

pulley

7

Adjust
the
alternator
on
Its
bracket

so
there

IS
no
more
than
0
5
10

deflection
of
the
fan

belt
when

pushed
10

by
thumb

pressure

8

TIghten
alternator
bracket

adjustIng
bolt
and

alternator

mountmg
bolt

securely

9
Install
the

upper
and
lower
rad1ator
hoses

and

tIghten
securely

10
Refill
the
radIator
and

coolmg
system
With

approved
coolant

or
water

NOTE
Because

of
the

many
aluml

num

parts
In
the

engine
a

hIgh
qualIty

antI

freeze

compound
should
be
used

In
the

cooling
system

11
Start
the

engme
and
run
untIl

operatIng

temperature
IS
reached
or
untIl

you
re
sure
the

thermostat
has

opened
and
coolant
IS

CIrCulatIng

throughout
the
entIre

coolIng
system
Top
up

radIator
as

reqUIred

90

CHAPTER

EIGHT

degrees
C
The
maXImum
WIdth
of
the
thermo

stat

openIng
should
be
0315
In
8mm

3
If
the
thermostat
IS
defectIve
or
If

you
have

an
doubts
about
It
mstall
a
new

one

4
When

Installmg
the
thermostat
m
the
hous

Ing
be
certaIn
to

place
the

spnng
end
down

Coat
both
SIdes
of
the

gasket
WIth
sealer
to

pre

vent
leaks
and

tIghten
the

mountlng
nuts

securely

RADIATOR

The
radIator
IS
of
conventional

desIgn
A

draIn
cock
IS

proVIded
at
the
bottom
back
to

perrmt
drainIng
The

system
IS

pressurized
and

the
rehef
valve

incorporated
In
the
filler

cap

mamtains
the

pressure
at

approximately
12
8

Ib
in
0
9

kg
cm
Coolant

capacity
is
1
691

gallons
6

4
lIters

Figure
8
shows
radIator
com
ponents
Note
that
vehicles

equIpped
WIth
auto

matIc
transmISSIon
have

provlSlons
for
connect

Ing
the
011
cooler
lInes
to
the
bottom
of
the

radiator

Radiator

Removal
Inspection

and

Replacement

1
Remove
the

upper
and
lower
radIator
hoses

to
draIn

coolant

2
Remove
four

machme
screws

securmg
radIa

tor
shroud

3
Remove
four

hex
bolts

secunng
rad1ator
to

mountlng
bracket

4
Remove
shroud
and

radIator
from
vehIcle

5

Inspect
radIator
for

SignS
of
leaks

RepaIr
or

replace
as

required

6
InstallatIon

IS
the

OppOSIte
of
removal

CD
14
1
Radiator

assembly
10
Plain
washer

2
Radiator

assembly
11
Plain
washer

automal1c
12
Hose

clamp

3
RadIator

cap
assembly
13
Hose

clamp

4
Drain
cock
handle
14
Radiator

shroud

5
Drain
cock

packing
15
Machine
screw

6

Upper
hose
16
Plain
washer

7
Lower
hose
17

Spring
washer

8
Hex
bolt
18
Hex
nut

9
Hex
nut
19
011
cooler
hoses

Automatic

only

2

i

7

1213

91
CHAPTER
NINE

bon
the
serIes
coll

demagnetizes
agatnst
the

shunt
cOIl
The
return

spnng
causes
the

plunger

to
return
to
the

origmal
posItIon
stoppmg
the

starter
The

overrunnmg
clutch

provIdes
for

positIve
meshmg
and

unmeshmg
of
the

pmlOn

gear
and

flywheerrmg
gear
and

perinitStlie

pmlon
to
overrun
the
armature
after
the

engme

has
started

CONSTRUCIlON

A

typical
Datsun
starter
motor

is
shown
m

Figure
3
The

example
is
for

1971
models
but

about
the

only
dIfferences

existing
between
It
and

other
models
are
the
number
of
elements
used
in

the
dust
cover
and
the
number
of
thrust
washers

Removal

1
DIsconnect
the

battery
ground
cable

2
Disconnect

the
black

yellow
wire
from
the

magnetIc
sWitch
tennmal
on
the
solenoid

3
Disconnect
the
black

battery
cable
and
red

wire
from
the

battery
tennmal
on
the
solenOId

4
Remove
two
bolts

holdmg
the

startmg
motor

to

flywheel
hOUSIng
The

battery
ground
cable
is

attached
to
the

flywheel
hOUSIng
bottom
bolt

5
Pull
starter
motor
toward
front
of

engme
and

remove

Disassembly

1
Remove
the

nut

holdIng
the
electrIc
WIre
to

the

magnetIc
sWItch
M
tennmal
DIsconnect
the

WIre

2
Remove
three
screws

securmg
magnetic

switch

assembly
to

yoke
Remove

magnetic

sWItch

assembly
and
dust
cover
s

Figure
4

3
Remove
two

through
bolts
and
brush
cover

assembly
as
shown

m

Figure
5

4
Remove
the

yoke
assembly
by
tappmg
lIghtly

as
In

Figure
6

5
Remove
bolt

nut
and
washers
at
base
of

yoke
to
free
shut
lever
WIthdraw
the
armatlIre

and
shut
lever
as
shown
m

Figure
7

6
Remove
the

pInIOn
stop
nng
located
at
the

end
of
the
armature
shaft
To
remove
the

stop

nng
push
the

stop
nng
to
the
clutch
SIde
remove

the

snap
nng
and
Withdraw
the

stop
nng
and
CD

c

0
I

CD

Ml

ml

CD

a
I

II

0

l

g
I

o

24
21

TO
oto
25
1
17
18
19
o
15

16

20
@

1
IgnItIon
coIl

2
Ignlllon
COIl
resls
Ol

3
p
II
lS
sere
ll

4
spnng
lles1
Br

5
PlaIn
wesner

6
illstl
OUtor
assembly

1
illstllbu
Ol
sUP
rt

II
sere
ll

9
spnng
wesner

10
0
ling

11
Ills
nbutor
gasket

12
llolt

13
VaCUum
control
tube

14
Vecuum
tube
grommet

IS
spar
plug
IIeslIer

1
sperll
plug

11
111gb
tenSIon
cable

18
IIlglllenSIOn
cable

19
lI
gll
tensIon
cable

20
IIlgII
tensIon
cable

ii
lIlgII
tenSion
cable

22
Ceble
older

23
Cable
c1emp

24
cable
clempllOlder

25
Ceble
clemp
J

110

CHAPTER

NINE

Points

Figure
S8

gives
details
of
the

sIngle

pomt

system
The

pomts
should
be

Inspected
penod

Ically
for
condItIon
and

wear
At
the

same
tlme

the

pOInt
gap
should
be
checked

and
reset
1f

necessary
Pomts
should
be
checked

at
least

every
2
500
mIles

SET
SCREW

PRIMARY

LEAD

TERMINAl

@

1
Unhook
the
two

clamps
holdmg
the

distnbu

tor

cap
to
the
dIStrIbutor

2
Remove
the
dlstnbutor

cap
and

pull
the
rotor

off
of
the
center

shaft

3

Carefully
note
or
mark
the

pOSItIon
of
the

dIStrIbutor

relatIve
to
the

fixmg
plate
at

the

bottom

of
the

distrIbutor

4
Loosen
the

hold
down
bolt
at
the
bottom
of

the
dlstnbutor

and
rotate
the
dIStnbutor

untIl

the

rubbmg
arm
that
rests
on
the
dIStrIbutor

cam

IS
at
a

high
pomt
of
the

cam
At

that

pomt
the

pomts
should
have

a

gap
between
them

5

Inspect
the

general
condItion

of
the

pomts

for
wear

pIttIng
and
smoot1mess

Pomts
that
are

worn

excessIvely
or
are

badly
pItted
must
be

replaced
Pomts
In

good
condItIon
can
be

re

surfaced

With
a

pOInt
file
number

600
sand

paper
or
WIth
a
small
whetstone

6
To

replace
or

remove
the

pomts
from
the

dIStrIbutor
loosen
the

screws
at
the
contact
arm

and

pnmary
lead

connectIOn
Do
not
remove
the

screw
Pull

up
on
the

primary
lead

to

dISc
onnect

the

termmal
from
the
contact
arm

7
Loosen
the
screw

holdmg
the

ground
WIre
to

the

pOInt
assembly
and

remove
it

S
Loosen
and

rell
ove
the
screws

holdIng
the

pomt

assembly
to
the

dIStnbutor
breaker

plate
Remove
the

pOInt
assembly
from
the
dIStrIbutor

Inspect
condItIon
of
the

pOInts
and

reconditIon

or

replace
as

reqUIred

9

Replace
the

points
Make
certain

to
recon

nect
the

ground
WIre
and
the

pnmary
lead

Apply

3

trace
of
cam

lubncatlng

grease
to
the
cam

upon

reassembly

10
WIth
the

pOInts
open
adjust

gap
It
should

be
between
00177

to
00217
In
045
to
055

mm

11
Install
the
rotor

put
the

cap
on
the
dIStribu

tor
secure
the

clamps
and
return
the
dtstrIbutor

to
its

onginal
pOSItIon
TIghten
the
hold
down

bolt

CONDENSER

PeriodJcally
check

the
condenser
electrIcal

lead

wire
and

the
set
screw
connectIon
As
a

matter
of

good
practIce
replace
the
condenser

whenever
the

pomts
are

replaced

DISTRIBUTOR

DISASSEMBLY

1
Take
off
the
dIstrIbutor

cap
and

remove
the

rotor

2
DIsconnect
the

vacuum
me
from
the
vacuum

con
troller

3
Mark
the

pOSItIon
of
the
distrIbutor
relative

to
the

housmg
remove
the
bolts
and
lIft
the

dIstrIbutor

off

4

Take
off
the
vacuum
controller
as
shown
m

F1gDre
S9

@

J

I

v

o

o
o

o

5
Remove
the
contact

pOInt
assembly
as

pre

VIously
descnbed

6
Remove
the

c01Jtact
breaker

assembly
Figure

60

by

remOVIng
the

clIps
that

hold
It
m

place

Be
careful

not
to
lose
the
steel
balls
located
be

tween
the
breaker

plate
and
breaker

springs

122

CHAPTER
TEN

1
Start
the

engIne
and

bnng
It

up
to
normal

operatIng
temperature

2

Inspect
all
hoses
and
connectIons
for
leaks

and
detenoratIon
Shut
off
the

engme
Replace

any
defectIve
hoses

3
Remove
the
hose
attached
to
the
check

valve

4

VIsually
Inspect
the

posItIon
of
the
valve

plate
InsIde
the

valve

body
See

Figure
10
It

should

be

lIghtly
posItIoned
agaInst
the

valve

seat

away
from
the
aIr
dlstnbutor
manifold

5
Insert
a

probe
Into
the
valve
connectIon
on

the
check
valve

Depress
the
valve

plate
It

should
return

freely
agaInst
the
valve
seat
when

released

6
Leave
the
hose
dISconnected
and
start
the

engme

7

Slowly
Increase

engine
speed
to
1
500

rpm

Watch
for
exhaust

gas
leakage
at
the
check

valve
There
should

not
be

any
The
valve

may

flutter

or
VIbrate
at
Idle

speeds
ThIS
IS
normal

Replace
the
valve
u

defecuve

Anti
Backfire
Valve

1
Start
the

engme
and

bnng
to

operating

temperature

2

Inspect
all
hoses
and
hose
connectIons
for

leaks
and
detenoratIon

Replace
as

required

3
DIsconnect
the
hose
at
the
antI
backfire

valve

leading
to
the
Intake

manuold
Insert
a

plug
ill

the

hose
and
fasten

securely

4

Open
and
close
the
throttle
valve

rapidly
See

Figure
11
Place
a

finger
over
the
valve
outlet
to

the

m
take
manuold
If

arr
flow
IS
felt
for

one
to
two
seconds
the
valve
IS

functIonIng

properly

If
there
s
no
aIr
or
If
the
flow
is
felt
for
more

than
two
seconds
the
valve
IS
defectIve
and
must

be

replaced

5
Connect
the
alr
hose
to
the
mtake
manuold

after

remOVIng
the

plug

6
DIsconnect
the
aIr
mlet
hose
from
the
air

pump
at
the
antI
backfire
valve
If
the

engine

Idle

speed
changes
excessIvely
the
valve
is
de

fectIve
and
must
be

replaced

Air

Pump

1
Check
the
atr

InjectIon
pump
belt
tension

DeflectIon
of
the
belt
should
be
0
5
In
when

pushed
In

by
thumb

pressure
Adjust
belt
u

necessary

2

Operate
the

engme
untIl
normal

temperature

IS
reached

3

Inspect
all
hoses
hose

connectIons
and
the

arr

gallery
for

SIgnS
of

leaks
or
detenoratIon

Replace
as

required

4
DIsconnect
the
air

supply
hose
at
the
check

valve

5
Insert
the

open
pipe
end
of
a

pressure
test

gauge
adapter
Into
the
air

supply
hose
See

Fig

ure
12

Clamp
the

adapter
firmly
to
the
hose

Install
the

pressure
test

gauge
to

the

adapter

PosItIon
the

adapter
and
test

gauge
so
that
the

alr
blast
emitted

through
the
dnlled

pipe
plug

Will
be

harmlessly

dislppated

6
Install
a
tachometer

on
the

engme
WIth
the

engIne
speed
set
to

1
500

rpm
observe
the

pres

sure

readmg
AIr

pressure
should
be
0
47
m

Hg

16mm
Hg

134

CHAPTER

ELEVEN

CLUTCH
SERVICE
DATA

AND

SPECIF1CATIONS

Table
1

proVIdes
serVIce
data

and

specifica

tIons
for
the
clutch

system

TRANSMISSION

Description

Datsuns
are

eqUIpped
with
either

an
auto

matic
or
manual
transrmSSIOn

Due
to
the
com

pleXity
of
the
unIt
and

the
need
for

special
tools

and

knowledge
overhaul

of
the
automatic
trans

mISSIon
is
not

covered
In
thIS
manual
Auto

matIc
transmISSIOn

checks
and

adjustments
are

given
later
m
thIS

chapter
Reparr
and
mainte

nance

should
be
referred
to

a
Datsun
dealer

or

qualIfied
mechamc

The
manual
transmission
is

a
four
forward

Table
1
speed
unlt
controlled
With
a
floor

mounted
lever

It
consIsts
of
transrmSSIOn

case
rear
extensIOn

housing
and

gear
assembly
The
clutch

housmg

and
transmissIOn

case
are
a

sIngle
unIt
The

rear

extension

housmg
is

detachable

Figure
12
shows

the
4
forward

speed
transmission

Transmission

Removal

Removal
of
the

transmIssion
from
dIfferent

models

Varles

accordmg
to
the

dIfferent
struc

ture
Involved
The

following
procedures

gen

erally

apply
to
all

types

Important
dIfferences

are
noted

1
Prom

InsIde
the
vehicle

remove
the
floor

covenng
around
the

gear
shift

so
that
the
shIft

lever
can
be
removed

2
Jack

up
the
vehIcle
and

support
it
with
four

CLUTCH
SERVICE
DATA
AND
SPECIFICATIONS

Pressure

Spring

Free

length

Fitted

length
and
load

Out
of

rlght

angle

MInimum

sprmg
force

Clutch
Release
Lever

Release

bearlng
to

dlaphragm
clearance

Diaphragm
sprlng
to

flywheel
height

Release

lever
to

flywheel
height

Clutch
DISC

FaCing
size

Outer

dIameter
x
inSide
diameter

x
thlckness

Thickness

Free

Compressed

Number
of

tOrslO
1
springs

Minimum

depth
of
rivet
head

from

faCing
surface

Allowable

facmg
runout

Allowable

spline
free

play

Pressure

Plate

Allowable

refacmg
limit

Clutch
Pedal

Height
when
not

depressed

Free
stroke
of

pedal
head

Pressmg
strength
at
full

stroke

Clutch
Master

Cylinder

Diameter

MaXimum

clearance
between

cylinder
and

pIston

Tightening

Torque

Clutch

assembly

securing
bolt
2
059
In
52
3mm

1
149
In
197
4
4
Ib
29
2mm
44
2

kg

o
1968

per
3
937
In
5

per
100mm

15

00472
to
0
0551
In

1
2
to
1
4mm

1732
0
0394
m

44
O
1

Omm

1
988

0
0197
In

505
0
05mm

787
X

5
120
x
0
0140
In
200
x
130
x
3
5mm

o
3386
to
0
3543
m
8
6
to
9
Omm

03012
to
0
3130
m
765

to
7
95mm

6

00118
In
03mm

o
097
In
0
5mm

00157
m
04mm

o
0394

In
1
Omm

8
150
m
207mm

o
984
m
25mm

33
Ib
15

kg

0625
m

15
87mm

00051
m
0
13mm
J

i

r

174
to
188ft
Ib
24

to
2

6

kg
m

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
139

@
1
Re
erse

gear

2
Re
erse
shaft

3
Reverse

gear

4

Snep
nng

5
Thrust
washer

6
Reverse

gear
needle

beanng

7
Counter

gear

8
Counter
shaft

9
Counter

spacer

10
Needle
bearing
assembly

11
Thrust
washer

12
Thrust
washer
J

f

I

I

I

I

I

I

I

I

I

I

J

I

I

i

I
f

4
rm

9
13
MaIO
dnve

gear

14
MaIO
dn
e

beanng

15
MaIO
drl
e

spacer

16
MelO
drl
e

snap
ring

17
MaIO
shaft

18
steel
ball

19
Thrust
washer

20
MaIO
shaft
needle
bearing

21
Meln
shaft

bushlOg

22
MaIO
shaft
flm

gear

23
Baulk

nng

24
Sh

ftlOg
Insert

25

Spread
sprlOg

9

1
Remove
the
drain

plug
and
dram
the
trans

rmSSlon

gear
011
Into

a
SUItable
container

2
Remove
the
dust
cover
and
release
the

re

tainer

spring
securing
the

Withdrawal
lever
Re

move
the
lever
and
release

bearing
from
the

clutch

housmg

3
Remove
the

pIn
securing
the

strikmg
rod
to

the
control
lever
and
remove
the
control
lever

4
Remove
five
front
cover

securing
bolts
and

the
front

cover

i

j

5
Remove
14
hex
bolts

and
washers
from
bot

tom
cover
Remove
bottcifu
cover
from
trans
I

I

I

I

I

I

i

i

J
34

34
26
Synchronize
hub

27
CoupllOg
slee
e

28
MaIO
shaft
needle

beanng

29
Second

gear
assembly

30
MaIO
shaft
needle

beanng

31
Third

speed
gear

32
Baulk

nng

33

ShlftlOg
IOsert

34

Spread
spring

35

Synchro
hub

36
Slee
e

coupllOg

37

Snep

nng

38
MaIO
shaft

pilot
beanng

39
Main
shaft

bearing

40
MaIO
shaft

snap
ring

41
Re
erse
maIO

gear
and
hub
set

42
Rwerse
hub
maIO
shaft

43

Speedometer

gear

44
Steel
ball

45
MaIO
sheft
loc
l
washer

46
MaIO
shaft

nut

28
iy

25

25

21

rmssion
case

Figure
25
shows
the
tranSmISSIon

With
the
bottom
cover
removed

6
Remove

speedometer
dnve

pmion
assembly

7
Remove
hex
bolts

holdmg
rear
extension

housmg
to
transmISSIon
case
Remove
rear
ex

tenSIon

housing
as
shown
m

Figure
26

8

fDlsengage
stnkmg
rod
from
fork
rod

gates

9
Unscrew
three
check
ball

plugs
and
remove

sprmgs
and
balls

10
Drive
out

retatnmg
pms
used
to
secure
forks

to
fork
rods
and
remove
rods
and
forks

11
Move
the
1st
2nd

and
3rd
4th

coupling