key DATSUN 510 1968 Service Repair Manual

I
Piston
with
pin

2
Piston
nng
set

3
Piston
nng
set

4
Connecting
rod

5
Connecting
rod
bolt

6
Connecting
rod
nut

7
Connecting
rod
bushing

8
Crankshaft

9
011
gallery
plug

10
Bushing

11
Woodruff
key

12
Crank
gear

13
011
pump
gear

14
OJlthrower

15
Pulley
washer

16
Crank
pulley
bolt

17
Crank
pulley
shaft

18
Crank
bushing
set

19
Flywheel
assembly

20
Flywheel
nng
gear

21
Flywheel
to
clutch
dowel

22
Flywheel
bolt
4

23
Converter
pilot

24
Dnve
plate

25
Crankshaft
plate

26
Dnve
plate
bolt
13
I

14

17

15
2
3

l
L
4
8
9
6
19
1
J
21

2
24
8
ICD
I

For
automatic
transmission
W

lit

ENGINE

43

@

0
00

o

mg
the
cham

tenslOner
to

the
block
to

free
the

sprIng
loaded

tenslOner

assembly

2
Remove
the
four

bolts

and

lockwashers
hold

mg
the
left
and

rIght
sIde

cham

guides
to
the

cylmder
block

Remove
the

guIdes

3
On

the
front

of
the
camshaft

remove

the
bolt

and

lockwasher

holdIng
the
fuel

pump
cam
as

sembly
and
the

eam

sprocket
to
the
eam

4
LIft

the
drIve

chaIn
asIde

and

remove
the

earn

sprocket
and
fuel

pump
cam
from
the

cam

shaft

as
shown

In

Figure
20

5

Remove
the
dnve
cham
from
the
crankshaft

drIve

spr6cket

Cylinder
Head
Removal

NOTE
Removal

of
the

cylinder
head

requires
a

special
tool

identified
as

DatsunST49010000
and
is

shown
In

FIGURE
21
@

I

USIng
the

specIal
tool
or

eqUIvalent
remove

ten
bolts
and

washers

holdIng
cylinder
head
to

cyhnder
block

See

Figure
22

2

Remove
head
from

block
and
dtscard

gasket

Oil
Pan
and
Strainer
Removal

I
Invert
the

engme
remove
22
bolts
and
wash

ers

secunng
pan
to
block

and
remove
011

pan

On

automatIc
transmission

models

tpe
pan
bolts

also
hold
the

oIl
cooler
hose
and
tube

clamps
in

place
DISCard

011

pan
gasket

3

Figure
23

shows
the
oIl
stramer

mOlJ
lted
m

the
block

Remove
two
bolts
and
washers

for

dISassembly

Crankshaft
Removal

I
Use
a

gear
puller
as

shown
III

Figure
24

to

pull
the
oIl
thrower

crankshaft
worm

gear
and

drive
cham

sprocket
from

the
crankshaft

The

above

parts
are
held
In

place
by
three

woodruff

keyS

2

DISconnect
the

pIston
and

connectrng
rod

assemblIes

from

the
crankshaft

by

removing
the

ENGINE
55

Cylinder
Block

Assembly

1
PositIon
all
crankshaft

parts
on
a
work
bench

ThIS
mcludes
the
crankshaft
main

beanngs

rear
011

seal
woodruff

keys
crankshaft

gear

011

pump
gear
011
thrower
bolts
and

bearing

caps
Figure
57
shows
the

arrangement

@

2
Insert
maIO

beanngs
mto

appropnate
cy1m

der
block
holders

NOTE
The
center
No
3

beanng
IS

the

only
flanged
type
of
thrust
bear

Ing
Bearings
No
2
and
No
4
are

Identical
No
1
and
No
5

Jaring
ap

pear
identical
but
No
1
as
an
011

hole
All

bearings
except
No
1
are

Interchangeable
as
to

upper
and
lower

half

3

LIghtly
lubncate
the

crankshaft
and

beanng

matmg
surfaces
then
mstall

beanngs
10
mam

beanng
caps

4
Install
the
crankshaft

5
Install
mam

beanng
caps
over

crankshaft

msert
mam

cap
bolts
and

tighten
hghtly
The

mam

beanng
caps
have
an
arrow
marked
on

each
one
These
must

pomt
to
the
front
of
the

engme

6

Gently
move
the
crankshaft
10
an
aXIal
drrec

don

toward
the
front
of
the

engme
to

venfy
that

the
mam

beanng
caps
are

properly
alIgned
and

seated
7
Use
a

torque
wrench
to

tighten
the

cap
bolts

to
the
hmlts

speCIfied
The

t1ghtenmg
operatIon

should
be
done

gradually
10
three

or
four

sep

arate

stages
starting
10
the
center
and

workmg

outward

to
each
end

8
Rotate
the
crankshaft
to
make
certain
it
isn
t

bmding

9
Use
a
feeler

gauge
to
check
the
end

play
at

the
center

No
3

beanng
Figure
58

10
Install
the
SIde
oll
seals
into
the
rear
mam

cap
and

cy1mder
block
as
shown
10

Figure
59

@

11
Install
the
rear
011
seal
WIth
Datsun
tool

ST49370000
or

equIvalent

12
Install
the
rear
end

plate

13
Install
the

flywheel
WIth

proper
bolts
and

lock
washers
and

torque
as

specified

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

CHAPTER

NINE

ENGINE
ELECTRICAL
SYSTEM

The
electrIcal

system
has

undergone
slIght

yearly
changes
the
most

SignIficant
being
ill
the

distrIbutor
Some
models
have
a

smgle
contact

pomt
whIle
others
have

a
dual

pomt
system
De

talls

are
covered

m
the
dIstrIbutor
sectlon
The

electrIcal

system
IS
a
12
volt

negatIve
type

OPERATION

Figure
1
shows
the

starter
motor
When
the

Ignltlon
sWItch

IS
turned

to
the

start

pOSItIon

current
flows

through
the

senes
and
shunt
colis

of
the

magnetIc
SWitch
and

magnetizes
It
The

plunger
IS

pulled
mto
the

sWItch

operatlng
the

shIft
lever
to

engage
the
dnve

pmlon
with

the

flywheel
rmg
gear
and
to
close
the

magnetIc

SWitch

CD
Figure
2
shows
the
starter
motor
CIrcUIt
Clos

ing
of
the

statlonary
and
movable
contacts
cause

the
motor
to
crank
the

engme
and
cut
out
the

series
coIl
of
the

magnetic
switch
The

magnetic

pull
of
the
shunt
coll

IS
suffiCIent
to
hold
the

pmIOn
m
mesh
With
the

flywheel
nng
gear
after

meshing
has
occurred
After
the

engme
starts

and
the

Ignition
key
IS
released
to
the
on

POSI

1

CD

12
11
10

1

Stationary
contact
8
ShIlt
le
er

2
Sene
coli
9
Orne

pinion

3

IgmtlOn
SWitch
10

Ring

gear

4
Solenoid
11
Plmon
slee
e

spllng

5

Shunt
COil
12
Armature

6

Plunger
13
Movable
contact

7
Return

spllng
14

Battery

ENGINE
ELECfRlCAL
SYSTEM
99

2

3

r

I

J

20

2
Rotor
aS5em

bly

3
Ball

beanng

5
Rear
cover

assembly

6
Diode
assembly

7
Diode

8
Diode
assembly

9
Diode

10
Terminal
A
assembly

11
Terminal
B
assembly

14
Brush

15
Brush
holder

17
Brush
co
er

18
Screw

19
Sa
ew
@

8

Front
cover

assembly

Packing
retainer

Ball
beanng

Beanng
retainer
29
Screw

30
Screw

31

Spacer

32
Bolt
33

Pulley
assembly

34

Key

35

Pulley
nut
assembly

36
Bolt
set
20
Wire
leads

21
Screw

22
Screw

24
Insulator

@
@

148

CHAPTER

ELEVEN

1

Insert

key
in

IgnItion
switch
and
turn
to
first

posltlon

2

Depress
accelerator

pedal
fully
LISten
for

the
solenOId

to
click
If

a
clIck
is
heard
the

solenoid
is

operating
correctly

3

Replace
solenoid
if
click

IS
not
heard
Before

replacing
solenoid
dram

apprOlumately
2

pInts
of
transmission
011
from
tranSmISsion
Re

fill
when
solenoid

replacement
is

complete

4
If
solenoId
IS

operatlng
correctly
but
trouble

persISts
check
WIres
for

continuity
With
electri

cal
tester

Linkage
Inspection
and

Adjustment

To

inspect
and

adjust
the

linkage
on
the

transmission

proceed
as
follows

Figure
4
j

shows
the

linkage
for
column
shift
models
and

Figure
47
shows
the

lInkage
for
floor
shift

models

1
Move
selector
from
P
to
1
and
back

again

several

tImes
If
the

lInkage
is

correct
a

slight

click
sh
uld
be
felt

and
heard
when

the
selector

is

set
at
each

position

2
If
the
lever

position
is

mcorrect
adjust
the

lin

age
in

t
ie
ngin
C
Q1I1

lT
me
t

s9

mat

f46

OSIoI0mm

00197
to

mJ

r2
oN

k
@
FRONT

tion
D
of
the
detent
manual
valve

alignS
with

posItion
D
of
the

pOSItIon
plate
as
shown
in

the
illustrations

Inhibitor
Switc
h

Checks

and

Adjustment

The
inhibItor

SWitch

lights
the
reverse

lamp

and

enables
the
starter
motor
to

operate
in
the

neutral
and

park
positIons
Figure
48
shows
the

construction
and

mountlng
of
the
InhibItor

SWitch
To
check
the
mhIbltor
switch

proceed

as
follows

r

I
5

1
InhIbitor
switch

2
Menual
shalt

3
Washer

4
Nut
5
Manual

plate

6
Washer

7
Nut

8
Inhibitor

switch

9

Range
select
Iner

1
Move
selector
lever
to
reverse

position
and

clieck
that
reverse

lamp
bun

lignts
If

not
in

spect
bulb
and

replace
1f
defectlve
If
bulb
is
all

right
replace
mhibItor
switch

2
Check
for

proper
operation
of
starter
motor

in

neutral
and

park
positions
If
abnormal
check

to

see
that

lInkage
IS
correct
If

linkage
IS
cor

rect
replace
Inhibitor
SWitch

110
CHAPTER
FIFTEEN

FOR
MANUAL

IGNITION
KEY

i

I
MADV
Nf
D

BRAKE
POINT

v
sa

tS

57

51
Th
rottle
sWItch

52
Speed
sWItch

relay

53
Speed
detector

assembly
Q
FOR

AUTOMATIC

IGNITION
KEY

AOVANEO

BRAKE
POINT

I
SPEED

DETECTOR

SPEED
SWITCH

I
RELAY
MJsr
I

IQ

52

SOLENOID

VALVE

54

Relay

55
Screw

56
Clutch
sWItch

assembly
57

Relay
assembly

58
Screw

INSTRUMENT
METERS
AND

PANELS

Figure
9
Illustrates
the
instrument

panel
and

gauges
used
on
the
sedan
and

wagon
models

untIl
1970

Figure
10

page
212
shows
the
m

strument

panel
and

gauges
smce
1970

Figure
11

page
213
shows
the
lDstrument

panel
and

gauges
used
on
the

pick

up

HEATER

Figures
12

page
214
and
13

page
215
are

exploded
Views
of
the
heaters
used

on
the
sedan

and

wagon
FigDre
14

page
213
shows
the

heater
used
on
the

pick
up

WINDSHIELD
WIPER

Figure
15

page
216
illustrates
the
wind

shield

Wiper
system
used
on
the
sedan
and

wagon

smce
1969
Earlier
models

were
slrmlar

Figure

16

page
217
shows
the

wiper
motor
wlule

Figure
17

page
2
I
7
shows
the

Wiper
motor

Imkage
on
the

pick
up
WINDSHIELD
WASHER

Figure
18

page
218
is

an

exploded
View
of

the
WindshIeld
washer

system
used
on
the
sedan

and

wagon
smce
1969
The
washer
used
on
the

pick
up
IS
SImilar

HEADLAMP

The

headlamp
units
used
on
the
sedan

wagon

and

pick
up
are
all
similar
to
that
shown
m

Figure
19

page
219

Replacement
of

the
sealed

beam
UnIts

reqwres
that
the

headlamp
trim
be

removed
so
that
the
sealed
beam
unit
can
be

withdrawn

AdJustment
of
the

headlamps
should

be
referred
to

a

qualified
electrical

shop

Lamp
Bulb

Replacement

Bulb

replacement
consIsts
of

removmg
the

retamer

nng
and
lens
from
the
unit

removmg

the
bulb
and

replacmg
It
In
some
cases
the