1968 DATSUN 510 air condition

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

FUEL
SYSTEM
75

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11
1
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1
1
l
l
l
l
l
l
lC

lC
lC
l
and
delIcate
Therefore
do
not

attempt
to
force

It

Improper
handlmg
WIll
cau
e
dIstortIOn

10
In

assemblIng
the
bImetal

place
the
ther

mostat

cover

gaSket
gently
In

place
and
mstall

the
thermostat
cover
after

makmg
sure
that
the

lever
on
which
the
bImetal

hangs
moves

smoothly

11
After

ughtenmg
completely
bend
and
ad

Just
the
bImetal
rod
so
that
the

upSIde
of
the

bImetal
case
IS
level
withm
0
02
m
O
5mm
of

the
slIt
on
the
bImetal
rod
Be
sure
the
bImetal

rod

operates
smoothly

12

Adjust
the
choke
valve

opening
to
00709

m

1
8mm

by
bendIng
the

connecting
rod

Carburetor

Cleaning
and

Inpection

Dirt

gum
water
or
carbon
contammation
of

cntIcal

parts
IS
often

responsIble
for
unsatlsfac

tory
carburetor

performance
Careful

cleanmg

and

InspectIon
IS
therefore
essential

1
After

disassembly
submerge
all

parts
In
a

specIal
carburetor
cleaner
Be
certam
to
follow

the
mmufacrurer
s
instructions
In

usmg
the

cleaner

2
After

cleanmg
blow
all

passages
and
cast

mgs
With

compressed
aIr
Make
certam
all

parts

are

completely
dry

3

Carefully
mspect
parts
for

SIgnS
of
wear

VISIble
wear
IS
suffiCIent
cause
to

replace
a

part

4

Pay
speCIal
attentIon
to
condItIon
of
the
float

seat
and
needle
the
throttle
and
choke
shaft

bores
In
the
throttle

body
and
cover

castIngs
and

to
the
Idle

adjustIng
needles

5

Inspect
all

gaskets
to
see
IT

they
are
hard

or

bnttle
or
IT
the

edges
are
tom
or
dIstorted
It

IS

sound

practIce
to

replace
them
whenever
the

carburetor
is
dIsassembled

6
Check
the
filter
screen
for
dIrt
or
lint
If
after

cleanmg
It
IS
not

completely
clean

replace
It

7
Check
all

lInkages
for
smooth

operatIon

Correct
as

reqUIred

8
Check

operation
of
the
acceleration

pump
by

puttIng
gas
m
the
float
chamber
and

operatIng

the
throttle
lever

by
hand
Fuel
should
be

pumped
from
the

acceleration
nozzle
IT
the
unIt

IS

satlsfactory

9

Carefully
InSpect
the

dIaphragm
for
holes
or

leaks

Replace
IT
defective
il

CHAPTER
EIGHT

COOLING
SYSTEM

The

coolIng
system
IS
of
the
closed

pressure

type
Coolant
flows

through
passages
In
the

cyl

mder
head
and
block
and
is
cooled

by
the

radIator
water

pump
and
thermostat

Figure
1

mdlcates
normal
flow

The
radIator
is

a

corrugated
fin

type
wh1le

the
thermostat

IS
a

pellet
desIgn
The
water

pump

IS

centnfugal
and
has

an
alummum
dlecast

body

CD
Several

changes
have
been
made
in
the
water

pump
assembly
over
the

years
pnmanly
be

cause
of

changmg
ennSSlon
cootrol

require

ments
The
diSCUSSIOn
and

procedures
that
fol

low
cover
1970
and
1971

models
However

complete
IllustratIve
material

IS

given
for
all

model

years
so
that

dIfferences
can

readIly
be

identIfied
In
the
models
With
aIr

conditionmg

ENGINE
ELECI
RICAL

SYSTEM

113

i

Normal

plug
appearance
noted

by
the
brown

to

graYlsll
lan

depOSits
and

slight
eleclrode

wear
This

plug
indicates
the
correct

plug
heal

range
and

proper
air
fuel

ratio

jI

Jo

t
Ql
i

Carbon

fouhng

distinguished
by

dry
fluffy
black

carbon

depOSits
which

may
be
caused

by
an

over

rich

alr
lue
mixture
excessive
hand

choking

clogged
air

filler
or
excessl
e

Idling

t
I

j
if

r
l

1

tfc
ji

0
1

fouling
indicated

by
wet

o
ly
depOSits
caused

by
011

pumping
past
worn

rings
or
down
the
Intake

valve

gUIdes
A
hotter

plug

temporanly
reduces

011

depOSits
but
a

plug
that
IS

too
hot
leads

to

pre

Ignition
end

possible

engine
damage
@

Red
brown

yellow
and
white

coatings
caused

by

luel
and
011
addltl

es
These

depOSits
are

not
harm

ful
If

they
remain
In
a

powdery
lorm

pr

11

L
J

J

S

C

ShinY
yellow

glaze
on
Insulalor
cone
IS

caused
when

the

powdery

depOSits
from
fuel

and
011
addltl
es

melt

Melting
occurs

during
hard

acceleration
alter

prolonged
Idling
This

glaze
conducts

electnclty

and

shorts
out
the

plug

e

1

A
I

A

I

7

Overheated

plug
indIcated

by
burned

or
blistered

Insulator

tiP
and

badly
worn
electrodes
ThiS
condl

J

tlon

may
be

caused

by
pre
Ignition

cooling
system

defects
lean
alr

luel
ratiOS
low
octane
luel

or
o
er

advanced

Ignition
timing

Spark
plUI
condition

photos
courtesy
of
AC

SPIr1l
Plug
Olv
s
on

Gene
MolDrs

Corporlllon

CHAPTER
TEN

EMISSION

CONTROL
SYSTEM

ThIs

chapter
covers
emission

control
and

exhaust

systems
The
emission

devices
used
in

clude
crankcase
ermssion

controls
an
exhaust

ermssion

system
and

evaporative
emission
con

trols

EXHAUST
EMISSION

CONTROL
SYSTEM

Two
methods
of
exhaust
emission

control
are

used

on
the
Datsun

One
is

an
aIr

injection

system
the
other
consists

of

engine
modifica

tIons
Datsuns

were

equipped
With
the
air

injec

tIon

system
only
through
1970
SInce
then
all

models

have
combined
aIr

mjection
with

engine

modIficatIons
EmisSIon

servicing
IS

complex

and

should
be
left
to

qualIfied

professionals

Figure
1

Illustrates
the

system
used

through

model

year
1969

Figure
2
IS
the

system
used

after
1970

Figures
3

through
7
offer
detaIls
of

various

emission

components

Maintenance
and

Testing

Penodlc

mspection
and
service

should
be

done

every
12
months

or
12
000
miles
The

engine
must
be

in

good
working
order
to
main

tain

a
low

level
of
harmful
emissions
There

fore

perform
a

general
tune

up
as

spec1fied
in

Chapter
Four
before

followmg
the

procedures

below
CRANKCASE
EMISSION

CONTROL
SYSTEM

The
crankcase

emission
control

system
is

shown
in

FlgDre
8
It
IS
a
closed

system
that

pre

vents
crankcase

gases
from

escaping
to
the
at

mosphere

Blowby
gases
are
dIrected

to
the

intake

manifold

through
the
ventilation

control

valve

Normally
capacity
of
the

valve
is

suffi

cient
to
handle
the

blowby

gas
plus
a
small

amount
of

ventIlating
air
drawn
from
the

air

cleaner

through
a
tube

leading
to
the
crankcase

Under
fun

throttle
condItIons
manifold
vacuum

is

Insufficient
to
draw
the

blowby
through
the

valve
When
this

happens
b10wby
flows

through

the

system
In
the
reverse
dIrection

General

1
Start
the

engine
and

bring

up
to

operating

temperature

2
Check

hoses
and
hose
connections
for

leaks

3

Examine
the
hoses
for

signs
of

cracks
or
de

terioraoon

Replace
as

required

Crankcase

Ventilation

Control
Valve

1
Start
the

engme

2
Remove

the
ventIlator
hose
from
the
crank

case
ventilatIon
control
valve
A

htssmg
nOISe

128

CHAPTER
ELEVEN

1
Clutch
disc

assembly

2
Clutch
cover

3
Hex
bolt

4
Lock
washer

5
Withdrawal
lever

6
Withdrawal
lever

ball

pin

7
Lock
washer

8
Retainer

spnng

9
Clutch
sleeve

10
Release

bearing

11
Holder

spring

12
Dust
cover

13
Return

spring

14
Push
nut

15
Hex
nut
CD

9

11

8

6

7

1
Release

beanng
2

Beanng
sleeve
2

5
13

12

15

14

Clutch

Inspection
and

Repair

1

Thoroughly
clean
all
dISassembled

parts
ex

cept
for
the

dISc

assembly
and
release

bearmg

In
a
SUItable
solvent

2
Check

all

parts
carefully
for
wear
cracks

and
other
defects

3
Check
the
clutch
disc
for
oil
soaked

or

cracked

faCIngs

warpmg
loose
nvets

exceSSIve

wear
and
broken

spnngs

4
Check
the

pressure
plate
for

sconng
bum

marks
blue
tlnted
areas
and
cracks

If

any
of

the
above
condItIons
are
found

re

place
the
clutch
dISC
and
or
the

pressure
plate

Replace
dISC

assembly
1f

facmg
IS
worn
so
that

the

facmg
heIght
above
the

nvet
IS
less
than

00118m
03mm

Very
mmor
bum

marks
and

CLUTCH
TRANSMISSION
AND
DRlVESHAFI
141

22
Remove
the
thrust
washer
and
mam
shaft

1st

speed
gear
complete
With
needle
roller
bear

mg
Be
careful
not
to
lose
the
small
steel
ball

which
locates
the
thrust
washer
Remove
main

shaft
1st

gear
bushmg

23
Remove
the
mam
shaft
2nd

speed
gear
and

needle
roller

bearmg

24
To
dISassemble

synchronizer
assembly
re

move

sprmgs
from
both
ends

Figure
30
shows

the

synchronIZer
dIsassembled

@

d

@

n

9
cr

1

Coupling
slee
e

3

Synchro
hub

2

Shlftmg
msert
4

Spread
spnng

25
DIsassemble
the
mam
dnve

gear
by
remov

mg
the

snap
nng
Use

snap
nng
phers

26
Remove
mam
dnve

gear
bearmg
With
bear

Ing
puller
and
arbor

press

Transmission

Inspection
and

Repair

1

Thoroughly
clean
all
dtsassembled

parts
With

solvent
Check
all

parts
carefully
for
wear
dam

age
or
other
defects

2
Check
the

mountIng
faces

carefully
for

pittIng

or
burrs
that
could
cause
011
leaks
Make
certatn

to
clean
off
all
old

gaskets
and

gasket
adhesive

3

RepaIr
or

replace
dowel

pm
if
bent
or
dam

aged

4

Inspect
rear
extensIon

bushing
for

SIgnS
of

mtenor
wear

Replace
as

reqUIred

5

Inspect
ball

bearmgs
for

SIgnS
of

damage
to

inner
or
outer
race
Rotate
the
ball

bearmg
and

feel
for

SIgnS
of
fnctIon
or

draggmg
If
ball
bear

mgs
are
defectIve
In

any
way
replace
them

6

Replace
needle

bearIngs
1f
wom
or

damaged

7
Check
the
mam
shaft
and

gears
for
wear
damage
or
cracks

Replace
defectIve

parts
as

required
Check
the
maIn
shaft
for

straIghtness

WIth
a

measurmg
gauge
as
shown
m

Figure
31

MaxImum

runpulls
0
0059
m
0
15mm

@

8
Measure
the
backlasH
of
each

gear
See

Fig

nre
32
Standard
backlash
is
0
0020
to
0
0039

In
0
05
to
0
10mm
Gear
wear
hrmt
IS
0
0079

In
0
20mm
If
the

gears
are
worn

beyond
limtt

both
the
dnve
and
dnven

gears
should
be
re

placed
as
a
set

@

9
Check
the
end

play
of
all

gears
WIth
a
feeler

gauge
End

play
should
be
between
0
0020
to

0
0059

m
005
to
0
15mm
If
end

play
IS
not

correct
Sh1nIS
of
vanous
thicknesses
are
avail

able
to
correct
the
condItIon

10
Check
balk

nngs
for
wear

plttmg
and

burrs

Replace
1f
defective

11
Place
balk

rmg
in

pOSItion
on
cone
of
each

gear
Push
the
balk

rmg
onto
the

gear
and
check

gap
between
balk

nng
end
face
and
clutch
tooth

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
147

SERVICE
DATA
AND
SPECIFICATIONS

Table
3

gives
the
service
data
and

specIfica

tIons
for
the

dnveshaft

AUTOMATIC
TRANSMISSION

CHECKS
AND
ADJUSTMENTS

Whlle
removal
and

repair
of
the
automatic

transmisSIOn
IS
not

recommended
the

follo
VlIlg

checks
and

adjustments
should

help
prevent

costly
repatrs

Transmission
Oil
Check

Check
the
automatIc
transmission
oil
level
at

least

every
3
000
mlles

Replemsh
With

hIgh

qualIty
automatIc
transmISSIon
flUId
as

reqUIred

Be
careful
not
to
overfill
as

damage
to
the
seals

can
result
To
check
the
011
level

proceed
as

follows

1
Start
the

engme
and

nm
it
untIl
normal

oper

atrng
temperature
IS
reached

2

Apply
brakes
and

move
the
transmission

shut
lever

through
all
drive

pOSItions
and

place

lever
In

park
position

3
WIth

engme
running
remove
tranSmISSIon

dIp
StIck
clean
It
WIth
a
lInt
free
cloth
or

paper

and
return
it
to
the
transmission

4
Remove

dIp
stIck

agam
and
examine
level
on

dIp
stIck

gauge
It
should
be
between
the
low

and
full
marks

Replenish
as

necessary

5

VIsually
InSpect
the
color
and
condItIon
of

the
OIl
on
the

dIp
stIck
Normal
color
of
the
OIl

IS
red
If
the
color
IS
abnormal
dram
and

re

place
If
the
011
has
detenorated

to
a
vamlsh

lIke

qualIty
It

may
cause
the
control
valve
to

stIck
Blackened
oil

may
mdlcate
a
burned

clutch
or
brake
band
6
Should
the
above
condItIons

exist
refer

mamtenance
to
a
transmISSIon

specIalIst

Transmission
Oil

Leakage
Check

011

leakage
may
occur
at
the

Junction
of
the

transmissIon
and
rear
extensIon
011
tube
con

nectors
011

pan
OIl

pressure
mspectIon
holes

downshIft
solenoid
or
breather

pipe

Abnormal
OIl

usage
usually
mdlcates
leaks

that
should
be

stopped
before
severe

damage
IS

done
To

mspect
for
011
leaks

proceed
as

follows

1
LIft
car

up
on
hOISt
or

Jack
up
and

place
on

stands

2
Clean
outsIde
of
transmISSIon
case
With

cleanIng
solvent
to
remove
dIrt
and
011

accumu

latIons

3
Start

engme
and
nm
untIl

operating
temper

ature
is
reached

4
ShIft

gear
lever
to
dnve
to
Increase
011

pres

sure
and
CIrculatIon
WIthin
tranSmISsion

5

Inspect
pOInts
mentIoned
above
for

SIgnS
of

leakage
Leakage
of
transrmSSIOn
011

IS
dIStrnC

tIve

by
its
reddISh
color

6
If
leaks
are
detected
refer
servIce
and

reparr

to

qualIfied
transrmssion

specialISt

Kick
down
Switch

and
Downshift
Solenoid

Checks
and

Adjustment

When
ktck
down

operatIon
IS
not
correct
or

the

speed
changmg
pomt
IS
too

high
check
the

klck
down
SWItch
downshIft
solenOId
and
the

wlDng
between
them

Figure
45
shows
the
loca

tIOn
of
these

parts
To
check

operatIon
proceed

as
follows

Table
3
J

DRIVESHAFT
SERVICE
DATA
AND
SPECIFICATIONS

SpeCifications

Axial

play
of

spider
Journal

Sleeve

yoke
spltne
to
malnshaft

Spline
lash
wear
Itmlt

MaXimum
drive
shaft
runout

Journal
diameter
wear
limit

Penmlsslble

dynamiC
unbalance
at
4
000

rpm

Tightening
Torque

Flange
yoke
to

compaRlon
flange
nuts

CompaRlon
flange
center

bearing
nut
pick

up

Bearing
mounting
bracket
installation
bolt
00315
In
008mm

OtoO
0031
In
OtoO
08mm

00197
In

0
5mm

00236
In
06mm

00059
In

0
15mm

0278
In
oz

15

gr
cm

2893
to

615ft
Ib
40
to
8
5

kg
m

74
to
111
ft
Ib
10
to
15
kg
m

18

to
20
ft
Ib
24
to
2
7

kg
m