length DATSUN 510 1968 Service Repair Manual

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

28

CHAPTER
FIVE

011

gallery
supphes
011
to
the
crankshaft
mam

beanngs
Dnlled

passages
m
the
crankshaft

direct
oil
from
the

mam

bearings
to
the

con

nectmg
rod

beanngs
011

mJected
from

jet
holes

in
the

connectIng
rods

IS
directed

to
the

cylmder

walls
and

piston
pins
0U
dlstnbuted
from
the

mam

gallery
enters
the
cham
tensioner
The

pad

IS
held

against
the
cham

by
011

pressure
and

spnng
tension
The

tmung
chain
receives
011

through
the

Jet
located
near
It

LubncatIon
IS

supphed
to
the

cyhnder
head

mam
011

gallery
through
the
crankshaft
center

beanngs
Camshaft

beanngs
on
the

cyhnder

head

are
fed

directly
from
the

cyhnder
head

mam

gallery
The
rocker

arms
and
valves
are

lubncated

intermittently

by
the
camshaft
011

gallery
and
the

small
channel
at
the
base
CIrcle

portIon
of
each
cam
OllIS

supphed
to
the
cam

shaft
011

gallery
through
the
No
2
and
No
3

camshaft

bearings

OIL
PUMP

The
011

pump
IS
mstalled
m
the
bottom
of

the

front
cover
as
shown
in
2
The

pump
is

held
m

place
by
four
bolts
to
the
front
cover
It

IS
a
rotor

type
dnven

by
the
011

pump
spmdle

whIch
IS
dnven
off
of
the
crankshaft
Pressure
IS

regulated
by
a
valve
shown

m

Figure
3
A
slot

at
the

top
of
the
dnve
rotor

engages
a

dog
clutch

at
the
lower
end
of
the
distnbutor
dnve
shaft

assembly
The

011

pressure
rehef
valve

IS
not

adjustable
In
the
released

pOSition
the
valve

pernnts
011
to
be

by
passed
through
a

passage
on

the

pump
cover
to
the
mlet
Side
of

the

pump

CD
CD

Oil

Pump
Removal

1
Remove
the
dIStnbutor
from
the

top
of
the

front

cover
Make
certam
to
mark
the

posItIon

of
the

dtstnbutor
relative
to
the

front
cover
so

that

It
can
be

replaced
m
the

same

posItIon

2
Drain
the

engme
od

3
Remove
the
front
stabIhzer
from
the
bottom

front
of
the

engme
compartment

4
Remove
the
front

splash
shIeld
from
the
bot

tom
front
of
the

engine
compartment

5
Remove
the
bolts

holdmg
the
oil

pump
to

the

front
cover
Remove
011

pump
and
drive

gear

spmdle
from
the
front
cover

Disassembly
Inspection
Repair
and

Assembly

Figure
4
IS
an

exploded
VIew
of
the
011

pump

assembly
Refer
to
the

figure
and
the

accom

panymg
index

1

Separate
the

body
cover
from
the

011

pump

body
by

unscreWIng
the

secunng
bolt

2
Remove
the

pump
dnve
mechamsm
and

dnver

gear
from
the

pump
body
Clean
the
dIS

assembled

parts
m
a
suitable
solvent

3

Inspect
for

Signs
of
wear
or

damage
Reparr

or

replace
as

necessary

4

Inspect
the
drive
rotor
shaft
for

excessive

wear
or

sconng
Check
the

followmg
clearances

a
Side

clearance
between
mner
and
outer

rotor
00020
to
00047
m
005
to

0
12mm

b

Tip
clearance
0
0492

m
0
12mm

c
elearance
between

outer
rotor
and

body

00059

to
0
0083
in
015
to
0
21mm

5
Check
the
relief
valve

spring
dtmenslOn
to

ensure
that
It
has
not
lost
tension

Free

length

should
be
2
24

m
57mm

Compressed

length

ENGINE
47

allowable

warpage
IS
0
0039
in
0
I
mm

Standard
should
be
less
than
0
0012
in

O
03mm
In
the
event
the
measurements
are

out
of
tolerance
the

cylmder
head
surface

should
be
milled

or
resurfaced

3

Verify
that
all
water
and
011

passages
are
free

of

foreign
matena

Use

compressed
aIr
to
clean

passages
after

scraping

4
Note
the
condition
of
all
studs
in
the

cylinder

head

Replace
damaged
ones

Valve

Assembly

I
Check
intake
and
exhaust
valve
assembhes

for
worn

damaged
or
deformed
valve

caps
and

stems
Correct
or

replace
the
valve
If
excessive

defects
exist

2
Measure
valve
stem
diameter
WIth
a
micro

meter
as
shown
in

Fignre
36

Figure
37

gives

cnncal
drmensions

@

@

Y

lm

1

0
515

r

3
Reface
the
valve
face
and
valve
stem

using
a

valve

grinder
as
18
shown
in

Fignre
38
NOTE

When
the
valve
head

1uzs

been
reduced
to
00197
in
0
Smm

or
less
In
thIckness

replace
the
valve

Grinding
allowance

for
the
valve
stem

end

surface
is
00197
In
0
Smm
or

less

4
Measure
the
free

length
and
tension
of
each

valve

spring
If
the
measured
values
exceed
the

hnuts

specified
below

replace
the

spring

SPRING
SPECIFICATIONS

Free
Length
Outel

Spring

Inner

Spring

Outer

Spring
2
0472
10

52
Omm

1
765710
44
85mm

153m
at6393
331Ib

389mm
at290

15kg

138m
at
2712
154lb

35mm
at12
3
0
7

kg

121
10
at
105
38
5
29
Ib

30
7mm
at
47
8
2
4
kg

09610
at5621
2871b

245mm
at

25
5
13

kg
Valve
Closed

I
nner

Spring

Outer

Spnng

Valve

Open

Inner
Spnng

5
Check
the

deformation
of
each

spnng
with
a

square
Replace
any
spnng
WIth
a
deflection
of

o
063
in
I

611lID
or
more

6
Check
all

workmg
surfaces
of
the
rocker
arms

for

damage
or
wear
If
defects

or

apparent
ex

cessIve
wear

are
found

replace
them
A
defective

PIvot
reqwres
It
S

replacement
along
WIth
the

correspondIng
rocker
ann

7
Measure
the
clearance
between
the

valve

gwde
and
the
valve
stem
If
the
clearance
ex

ceeds
hnuts

replace
the
worn

parts
or
both

50

CHAPTER
SIX

3
Pull

up
on
the

spnng
scale
If
the

force
re

qurred
to

pull
the
feeler

gauge
out
IS
more
than

3
3

lbs
or
less
than
0
44
Ibs

the

piston
skirt

IS
either

too

large
or
small
for
the

cyhnder
and

must
be

replaced
With

a

pISton
of
the

proper
size

EIther
that

or
the

cyhnder
must
be

rebored
or

a
new

cyhnder
hner

mstalled

Piston

Piston
Pin
and
Piston

Ring

1

Inspect
all

parts
carefully
for

signs
of

clups

cracks
and

general
wear

2
Measure
the
side
clearance
oLeac

ring
in

It
S

appropnate
groove
as
shown
in

Figure
45

Clearances
should
be
witlun
the

following
tol

erances

Top
Ring
00018

through
00031
In

0045

through
0
078mm

00012

through
0
0025
In

0030

through
0063mm

00010

through
0
0025
In

0025

through
0063mm
Middle

Ring

011

Ring
bottom

@

3
Check
the

gap
of
each

nng
by
mserting
it

about
1
mch
down
the
bore

squanng
it

With
the

wall

by
tappmg
It
WIth

an
mverted

pIston
and

measunng
the

gap
between
the
two
ends
of
the

ring
Figure
46
In
the
event
the

cyhnders
are

not

being
rebored
measure
the

nng
gap
toward

the
bottom
of
the
bore

where
the

least
wear

has
occured

4

Ring

gap
should

be
as
follows
Top
Ring
00091

through
0
0150
In

0
23

through
o
38mm

o
0059

through
0
0118
In

0
15

through
0
30mm

o
0059

through
0
0118
In

0
15

through
0
30mm
Middle

Rmg

0
1

Rmg
bottom

@

fJ
t

1

v

5
Measure
the

pIston
pm
hole
on
both
SIdes
of

the

pIston
Measurement
should
be
between

08268
and
0
8271
m
21
001
and
21
008mm

6
Measure

pISton
pin
outsIde
dIameter
With

a

nucrometer
as
shown

m

Figure
47
The
mea

surement
should
be
between

0
8265
and
0
8267

in
20
993
and

20
998mm

7
Measure

pIston
pm
length
It
should
be

between

2
835
and
2
844
m
72
00
and

72
25mm

ENGINE
51

8

Figure
48
shows
the

pm
bemg
mserted
to

make
certam
that

It
can
be

pressed
m
at
room

temperature
by
hand
Piston

pm
clearance
to

piston
pm
should
be
between
0
0003
and
0
0004

m
0008
and
0
01Omm

NOTE
The

piston
pin
IS

fitted
to
the

connecting
rod
with
a

fitting
force
of

from
1
to
3
tons

of

pressure

Connecting
Rod

1

Inspect
all

connectmg
rods
for
flaws
or

obVIOUS

damage

2
Check
for

proper
alignment
as
shown

m

Fig

ure
49

RealIgn
as

necessary
ThIS
can
be
done

by
an
automotive
maclune

shop
Maxrmum

allowable
bend

m
the

connecting
rods
IS
0
0020

m
0
05mm

per
3
94

m
of

connecting
rod

length

@
3
Defects
m
the

piston
pm
hole

reqwre
replace

ment

of
the

connectmg
rod
Select
new
ones
so

that

weight
dIfference
between
new
and
old
IS

wlthm
0212
oz
6

gr

4
Install

beanngs
m
the
crankshaft
end
of
all

rods
Mount
the
rods
on
the
crankshaft
and

replace
beanngs
and
rod

caps
Install
bolts
and

tighten
Use
a
feeler

gauge
to
measure
end

play

between
the

connecting
rods
and
the
crankshaft

Figure
50
The
standard
measurement
should

be
between
00079
and
0
0118
m
02
and

0
3mm
Maximum
allowable
wear
IS
00118
m

0
3mm

Crankshaft

1
Check
the
crankshaft

journal
and
crank

pm

1
1

for
cracks
obVIOUS
wear
and
scratcheS

Repair

or

replace
defective

parts
I

2
Check
the
crankshaft
for
bend
If
the
bend

at
the
center

Journal
exceeds
0
0020

m

0
05mm
have
the
crankshaft

prOfeSSIOnally

straightened
or

replace
It

3
Check
crankshaft

Journals
and
crank

pms
for

out
of
round
and

taper
Figure
51
lIsts

speci

fications

Regnnd
the
crankshaft
1f
the

specIfica

tions
are
exceeded

by
more
than
00012

m

0
03mm

4

Replace
the

connecting
rod
and
mam
bear

mgs
With

proper
undersIZe

beanngs
If
the
crank

shaft
IS

reground
The

followmg
table

prOVides

data
for

beanng
replacement
based

on
the

final

sIZe
of
the
crankshaft

Journals
and
crank

pIllS

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

ENGINE
ELECI
RlCAL
SYSTEM
9S

@

@

4
Test
the
COIls
for
shorts

by
unsoldermg
the

connectIons
of
each
coIl
and

repeatlng
the
test

given
m

step
3
If

a
defectIve
coil
IS
found
It

must
be

replaced

BRUSHES
AND
BRUSH
LEAD
WIRE

1
Check
condItIon
of
the
brush
contact
surface

and

general
wear
of
the
brush
If
the
brush
is

worn
to
under
02362
In

60mm
m

length

replace
It

Inspect
all
connectIons

carefully
for

looseness

or
cracks

Replace
or

reparr
as
re

qUIred

2
Check
the
connectIon
of
the
lead

clIp
and

WIre

3
Check
brush
holders
and

sprmg
clIps
for

damage
Replace
1f

they
will
not
hold
the
brushes

agaInst
the
commutator

properly
Clean
all

brushes
aIld
brush
holders

thoroughly

4
Check
brush

sprmg
tenSIon
WIth
a

spnng

scale
as
shown
m

Figure
14
The

reading
should

be
1
76
Ibs
0
8

kg
Replace
the

spnng
if
the

tenSIon
IS
under
1
54
Ibs
0
7

kg
@

ARMATURE
ASSEMBLY

1
Check
external

appearance
of
the
armature

and
commutator

2
Use
a

dIal

gauge
Figure
15
to
measure
the

armature
shaft
for
bend

Replace
the
armature

shaft
1f
the
bend
exceeds
0
001
in
0
08mm

@

3

Inspect
the
commutator
If
the
surface
IS

rough
sand

It
With
No
500

emery
paper
untIl

smooth
Use
a
dIal

gauge
to
check
the

commu

tator
If
out
of
round

IS
more
than
00079

In

0
2mm
or
the

depth
of
the

Insulatlng
mica
is

less
than
0
0079
In
0
2mm
from
the
commu

tator
surface
the
commutator
should
be
turned

on
a
lathe
Out
of
round
should
be
less
than

o
0020
in
0
05mm

Insulatmg
mica

should
be

undercut
as
shown

m

Figure
16

to
a

depth
of

from
0
0197
to
0
0315
in

0
5
to
0
8mm

4

Inspect
the

soldered
connectIon
of
the

arma

ture
lead
and
the
commutator
If
the
connection

is
loose
resolder
It

5

Usmg
a
clrcmt
tester
test
the
armature
for

130

CHAPTER

ELEVEN

master

cylInder

operatlng
cylinder
and
with

drawal
lever

Figure
7
shows
all

components

whlle

Figures
8
and
9
are

exploded
VIews
of
the

master

cylmder
and

operatIng
cylinder
for

models
smce
1970
Prior
models

are

similar
In

construction

MASTER

CYLINDER

Master

Cylinder
Removal

Sedans
and

Wagons

1
Remove
cleVIS

pin
mstalled
at
the

pushrod

2

Disconnect
clutch
hose

from
the
master

cylin

der
and
dram
flwd

3

Remove
bolts
to
free

master

cylinder

Master

Cylinder
Removal

Pick
up

1
DIsconnect

pushrod
from
clutch

pedal

2
DIsconnect
clutch
hose
from
master

cylInder

and
drain
fluid

3
Remove
bolts
to
free
master

cylInder

Master

Cylinder
Disassembly

1
Remove
filler

cap
and
drain
fluid

2
Pull
back
dust
cover
and

remove

snap
ring

3
Remove

stopper
pushrod
piston
assembly

cup
and
return

spnng

CD

i
Master

Cylinder
Inspection

1
Clean
all

parts
thoroughly
In
clean
brake

flwd

2
Check

cylInder
and

pISton
for

wear
or
dam

age
Replace
as

required

3
Check
the

clearance
between

cylInder
and

pIston
If
clearance
is

larger
than

0
005
in

0

13mm

replace
the

cylinder

4

Replace
the

pISton
cup
whenever
it
is
re

moved
from

the

cylInder
or
when
It
shows

SIgnS

of

wear
or

damage

5
Check
all
other

parts
for
wear
or

damage

and

replace
as

required

Master

Cylinder
Assembly

1
Soak

piston
cup
m
brake
fluid

2
Install

pIston
cup

3
Coat
the

cylinder
and

pIston
thoroughly
WIth

brake
flwd
and
assemble

4

Replace
other

parts
in
the

reverse
order
of

removal

Master

Cylinder
Installation

1
Bolt
the
master

cylInder
into

pOSItion

2

Adjust
clutch

pedal
heIght
by
adjusting
the

pushrod
length
Pedal

heIght
from
floorboard

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