1968 DATSUN 510 automatic transmission

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

FUEL
SYSTEM
69

CARBURETOR

The
carburetor
IS
an
Hltach1

Type
DAF328

Several
varIations
are
used

dependmg
on
the

model

year

type
of
transmissIOn
and
the
emIS

SIon
control

system
The
dIfferent
models
are

the
same
as
far
as
basiC

operation
IS
concerned

Therefore
the

followmg
dISCUSSIon
covers
a

typIcal
carburetor
The

automatIc
choke
IS
used

on
automatIc
transmISSIon
and
1972
models

only
All
other
chokes
are
manual

Refer
to

Figure
8
The
carburetor
conSIsts
of

a

pnmary
system
used
m
normal

runnmg
and
a

secondary
system
used
for

hIgh
speed
or

heavy

load

operatIons

CARBURETOR
ADJUSTMENT

Idling
Adjustment

Idle

adjustment
IS
made

by
the
throttle

adjust

and
Idle

adjust
screws
both
of
wh1ch
are
located

at
the
bottom
of
the
carburetor

1

Screw
the
Idle

adjust
screw
all
the

way
in

to

the

fully
closed

pOSItIon
Do
not
over

tIghten

CD

6
2
Unscrew
the
Idle

adjust
screw

approXImately

three

cor
nplete
turns

3
Screw
m
the
throttle

adjust
screw
two
or
three

turns
and
start
the

engui
e

4
Screw
out
the
throttle

adjust
screw

slowly

until
the
onset

roughness
followmg
a

gradu81

speed
drops

5
Screw
m

the
Idle

aOJust
screw
untIl
the

engme

runs

smoothly
at
the

hIghest

speed

6

Readjust
the
throttle
screw
to

drop
the

engme

speed
Repeat
these

adjustments
untIl
a
smooth

engme
speed
at
the

proper
Idle

rpm
IS
ach1eved

Refer
to
the
tune

up
chapter
for

proper
rpm

Fuel
Level

Adjustment

Constant
fuel
level
IS
mamtamed

by
the
float

and
the
needle
valve

Figure
9
sb
ws
the
fuel

level

system
wlthm
the
carburetor
If
the
level
IS

at
the
lIne
on
the

f
lel
reservOir
level
is

properly

set
If
not

adjust
It

by
bendmg
the
float
seat

Adjust
the

gap
between
the
valve
stem
and
the

float
seat
to
00591
m

1
5mm
with
the
float

fully
luted

up
by
bendmg
the
float

stopper

1213141516

20

I

h

r

1
Secondary
main

nozzle

2
Secondary
small
venturi
10

Secondary
bypass
hole
18

Primary
slow
air
bleed

3

Secondary
main
air
bleed
11

Secondary
throttle
valve
19
Air
vent

4

Secondary
slow

Jet
12
Choke
valve
20
Level

gauge

5

Secondary
slow
air
bleed
13

Primary
main
air
bleed
21

Primary
main

Jet

6
Needle
valve
14

Primary
main
nozzle
22
Idle
limit
screw

7
Float
15
Economizer
bleed
23
Idle
hole

8

Secondary
emulSion
tube
16

Primary
slow

let
24

Bypass
hole

9

Secondary
main

Jet
17

Primary
economizer
25

Primary
throttle
valve

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

EMISSION
CONTROL
S
IS
TEM
SEDAN
AND
SlATION

YfAGON
Yfl
tH
AUTOMATIC
TRANSMISSION
TO
DISTRIBUTOR

IGNITION
COIL

IGNITION
SWITCH

tnE
RETARDED
BREAKER
POINT
1

SPEED
SWITCH
THROTTLE
SWITCH
SWITCH
DETECTING
WIDE
OPEN

THROTTLE
POSITION

SWITCH
DETECTING
CLOSE

THROTTLE
POS
iION
Q
Z
S

e
l

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
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

BODY

ELECTRICAL

SYSTEM

217

bulb

socket
must

be

pulled
out
from
the
back

of

the
unit

and
then
the
bulb
can
be

replaced
Care

fully

mspect
the
unit
that

reqUIres
bulb

replace
ment
and
follow
the

appropriate

procedure

Make

certain

you

replace
the
bulb

with
one

rated
at
the
same

voltage
amperage
and
watt

age
Examples
of

units
that

might

require
bulb

replacement
are
the
front

park
and

directional

lamps
rear

combination

lamp
side

marker

lamps
interior
room

lamps
license

plate
lamps

and

engine

compartment
lamps

Fuse

Replacement

Whenever

a
fallure
occurs

m

any

part
of

the

electrical

system
always
check
the

fuse
box
to

see
1f

a
fuse
has
blown
The
fuse

box
is
located

on
the

firewall
within
the

engine

compartment

If
a
fuse
has
blown
It
will
be
eVident

by
bIacken

mg
of
the
fuse
or

by
a
break
of
the

metal
element

Within
the
fuse

The

wiring
diagrams
below

mdIcate

the
cir

cuits

that
are
connected

to
each
fuse

Before

replacing
a
fuse

always
detenIlIDe
what
caused

it
to
blow
and
correct
the

trouble

Never

replace

a
fuse
With
one
of

a

higher

amperage
ratIng
than

originally
used
Never

use
tmfOll
or
other
ma

tenal
to

Jump
across
fuse

tenIlIDals

Failure
to

follow
these

basic
rules

could
result
in

fire
or

damage
to

major
components

WIRING

DIAGRAMS

The

following
figures

provide
wiring
diagrams

for
the
sedan

wagon
and

pick
up
Figure
20

page
220

applies
to
the
sedan
and
station

wagon
with

manual
transmission

Figure
21

page
221
covers
the
sedan
and

station

wagon

With
automatic
transmission

Figure
22

page

222
is
for
the

pick
up
I

l

INDEX
239

Rear

suspensIOn
wagon
Removal
40
92

Servlcmg
161
Termmals
94

Tightening
torques
162
Test

diagnosIs
97

Testmg
96

Troubleshootmg
10

5

Steenng
also
see

Suspension
front

I

Exploded
views
182
185
L

Seats

SpecIfications
186

DescnptIon
228

Troubleshooting
16

Exploded
View
front
4
door
sedan
232

SuspensIOn
front

pick
up

Exploded
VIew
front

pick
up
228

Axle
removal
175

Service
hmts
4

Inspection
and

repair
179

Shock
absorbers
sedan
154

Installation
179

Shock
absorbers

wagon
162

Posture

adjustment
181

Spark
plugs
Removal
177

CondlllOn
chart
21

Wheel

abgnment
182

InspectIon
and

servlcmg
21

Wheel

bearmg
adjustment
177

Recommended

types
112

Suspension
front
sedan
and

wagon

SpecificatIOns
and
tables

Inspection
and

repair
176

Adjustment
and
wheel

alignment
175

InstallatIOn
177

Brake
service
data
203
204

Lower
ball

Jomt
174

Brakes
203
204

Spnng
and
strut

assembly
173

Camshaft

beanngs
48

Stabilizer
173

Caster
and
camber
sedan
and

wagon
175

TenSIOn
rod
173

Clutch
134

Transverse
bnk
174

Clutch
service
data
134

Wheel

beanngs
177

Connectmg
rod

beanng
underslzes
52

Wheel
hubs
and

bearmgs
168
173

Dlstnbutor
112

SWItches

Dnveshaft
147

DescnptIon
205

Dnveshaft
service
dala
147

Exploded
View

through
1969
208

Engme
60
61

Exploded
view
1970
1972
207

Engme
service
data
60
61

General
4

Mam

bearmg
underslzes
52

T

Piston

rmg
gap
50

Rear

suspenSIOn
pick
up
167
Tail

gate
228
233

Rear

suspensIOn
torques
wagon
162

TenSIOn
rod
sedan
and

wagon
173

Steermg
186
Thermostat

TransmiSSion
manual
144

DescnptIon
89

TransmiSSion
service
data
manual
144

Inspection
and

replacement
89

Valve

spnng
47

Removal
89

Sprmg
and

strut

assembly
sedan
and

wagon
173
Tires

Spnngs
sedan
154
Wear

analYSIS
17

Stabilizer
sedan
and

wagon
173

TransmiSSion
automatic

Starter
Downshift

solenOid
147

Armature
95
Inhlbllor
SWItch
148

Beanngs
96
Kick
down
SWitch
147

Brush
holder
96

Lmkage
mspectIon
and

adjustment
148

Brushes
and
lead
WIre
95
011
checks
147

Cleaning
mspectIon
and

repair
94
Oil

leakage
147

Construcllon
92
TransmiSSion
manual

Disassembly
92

DescnptIon
134

Exploded
View
93

Disassembly
138

Field
COIl
94

Exploded
view
138

Magnetic
SWItch
96
Gear

assembly
exploded
view
139

Magnetic
SWItch

assembly
test
97

Inspection
and

repair
141

Operation
91
Installation
143

Overrunnmg
clutch

96

Reassembly
and

adjustment
142

Reassembly
96
Removal
134