1968 DATSUN 510 fuel cap

ENGINE
59

2
Coat

the

pan
gasket
on
both
sides
With

gasket

compound
and
attach
the

oil

pan
to
the

cyhnder

block

Torque
as

specIfied

Manifold
and
Carburetor
Installation

1
Install
the
mtake
and
exhaust
manIfolds
WIth

associated

gasket
to
the

cylmder
head

2
Mount
the
carburetor
and

gasket
to
the
mtake

manIfold

2

Adjust
all
mtake
and
exhaust
valves
to
the

specIfied
clearance
for
a
cold

engme

Clutch

Assembly
Installation

CAUTION

Take

extreme
care
not
to

get
grease

or
011
on
the

clutch
or

flywheel
frlc

hon
contact

surfaces

1
Place
the
clutch
disc

assembly
on
the

flywheel

With
the

longer
chamfered

splmed
end
of
the
dISC

toward
the
transmISSion

2

Visually
align
or
use
a

dummy

splmed
dnve

shaft
to

ahgn
the
diSC

assembly
With
the

flywheel

pilot
beanng

3
Install
and

tighten
the
SIX
bolts

holdmg
the

clutch
cover

assembly
to
the

flywheel
Tighten

the
bolts
a
turn
each
tune

by
diagonal
pattern

until

they
are

tight
Tlghtenmg
torque
should
be

174

to
188ft
lbs
24
to
2
6

kg
m

NOTE
There
are
two
dowels
on

the

flywheel
to

locate
the
clutch
cover

4
Remove

dummy
shaft
If
used

after
the

above
bolts
are

fully
tightened

5
Refit
the
release

bearing
and
translI11Ssion

case
Miscellaneous
Installation

1
Connect
the
fuel
hose

on
the
front

part
of
the

engme
to
the
fuel

pump
and
to
the
carburetor

2

Gap
the

spark
plugs
and
mstall
them

usmg

new

gaskets

3
Coat
the
rocker
arm
cover

gasket
With
sealer

and

position
It
on
the

cylmder
head

4
Install
the
rocker
arm
cover
and

tighten
the

two
thumb

screws
that
hold
it

m

place

5
Install
distrIbutor

makmg
certam
that
the

notch

on
the
distributor
shaft

assembly
mates

With
the
drive

spmdle
Ahgn
the
location
marks

made

dunng
disassembly
so
that
the
distrIbutor

is

positioned
as
before

6

Install
and

tighten
the
bolts
which
hold
the

dIStributor

to
the
front

cover

7
Install

pomts
condenser
and
rotor

8

Replace
distrIbutor

cap
and
attach

spark
plug

Wires
m
the
correct

sequence
Make
certain
that

all
wires
are

firmly
seated
m
the
distrIbutor

cap

and
attached

securely
to
the

spark
plugs

9
HOISt
the

engme
assembly
from
the
work

stand

10
Install
the
alternator
bracket
alternator

and

engme
mounts
to
the
block

11
Install
the

IgnItIon
coil
oil
filter
oil

pressure

SWitch

dipstick
and

water
drain

plug

12
Connect
the

vacuum
Ime
between
the
dis

trIbutor
and
carburetor

13
Connect
the
transIDlSSlOn
to
the

engine
prior

to
mstallatIon
m
the
vehicle

Engine
Installation

Installation
is
the

reverse
of
the

procedures

followed
m

removal
Be
certaIn
thatlall

battery

connections
are
made

that
water
hoses

are
se

cured

wmng
IS
connected

properly
and
that
all

required
bolts
and
mounts
are
mstalled
and

tightened
Replace
the
radiator
fan
belts
and

radiator
shroud
Fill
the

engme
With
the

proper

grade
of
oil
and
the
radiator
With

recommended

coolant
Install
the
hood

to
the

hInges
according

to
the
marks
made

dUrIng
removal

SERVICE
DATA
AND
SPECIFICATIONS

Table
1
covers
servIce
data
and

engme
Speci

fications

FUEL
SYSTEM
6S

CD

2
Remove
the
fuel
stramer
from
Its

mountlng

clIp

3

Replace
the
fuel
stramer
as

reqUIred

4
Reconnect
the
mtake
and
outlet
fuellmes

FUEL
PUMP

The
fuel

pump
conSISts
of
a

body
rocker
arm

and
lmk

assembly
dIaphragm

dIaphragm

spring
seal
and
mlet
and
outlet
valves
The
l
r

t

1
9

l

F
r

fl

rocker
arm
IS
dnven

by
a

pump
cam
mounted

on
the
catnShaft
In
the
front

part
of
the
rocker

arm
front
cover

assembly

Figure
S
shows
the
fuel

pump
for
all
models

through
1970

Figure
6
illustrates
the

fuel
pump

for
1971
and
later
models

Fuel

pump
Testing

Fuel

pump
pressure
and
fuel

pump
capacity

testlng
are

performed
m
tests
descnbed
below

Both
tests
are

performed
With
the
fuel

pump

mounted
to
the

engme

Static
Pressure
Test

1
DIsconnect
the
carburetor
fuel
lme
at
the

carburetor

2
Install
an

adapter
and
a
tee

fittmg
to
the

fuel
lIne
and
attach

a
SUItable

pressure
gauge

3
Connect

adapter
to
carburetor

4
Start
and
run

engine
at

varymg

speeds

5
The

gauge
reading
IS
static
fuel

pressure
It

should
remam
between
256
and
341
Ib
m
2

018
to
0
24

kg
cm2
Pressure
below
thelower

lImIt
mdlcates
extreme
wear
on
one

part
or

gen

eral

wear
on
several

pump
parts
Pressure
above

the

upper
hrmt
indIcates

an

excessIvely
strong

diaphragm

spnng
or
a

dIaphragm
that
is
too

tIght
Both
condItIons

require
the

removal
of
the

fuel

pump
for

necessary
repaIr
or

replacement

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

8
1
Fuel
tank
Bssembly

2
Fue
tank
fixing
bolt

3
Fuel
tank
lock
washBr

4
Plain
washer

5
Filler
neck

6
Screw

7
Fuel
tank
filler
hOS8

8
Filler
cap
Bssembly
9
Packing

11
Floor
plug

12
BrBather
tube

13
Connector

14
T
tube

15
Clip

16
Fuel
tank
gauge
umt
17
Fuel
gaUgB
O
nng

18
Fuel
gauge
lock
plate

19
Hose
clamp

20
Earth
plate
mounting
bracket

21
Shim

22
Rubber
plug

23
Rubber
grommB

7

13
Id
@
t
I
l

I
1

23
19
21
20
I
13

11

12
I
14

L
1

A
21

I

26

TO
CRANK
CASE
@

1
Fuel
tank
assembly

2
Drain
plug

3
Drain
packing

4
Fuel
tank
filler
neck

5
Screw

6
Fuel
tank
filler
hose

7
Hose
clamp

8
Hose
clamp

9
Filler
cap
assembly

10
Filler
cap
packing

11
Fuel
tank
gauge
umt

12
0
ring

13
Fuel
geuge
loc
l
plate

14
H
bolt

15
Plain
washer

16
Spnng
wesher

17
Fuel
gauge
earth
plale

18
Rubber
plug

19
Tank
reseNOlr
essembly

20
H
bolt
With
washer

21
Plein
washer

22
Breather
tube

23
Breather
tube

24
Breether
tube

25
Nylon
clip

26
Rubber
grommet

27
Shim
QD
g

j

QO

@

15

I
1
Fuellank
assembly

17
8
2
Fuel
tank
drain
plug

3
Packing

4
Weld
nul

5
Plain
washer

6
Spllng
washer

7
Hex
bolt

33
8
Upper
filler
tube
assembly

9
Filler
hose
assembly

10
Hex
nut

11
Plain
washer

U
12
Spllng
washer

25
13
Machine
screw

rt
41
40
14
Hose
clamp

2i
15
Filler
cap
assembly

27
J
16
Filler
cap
packing

L
1
17
Filler
neck
packing

21

35
20
Fuel
gauge
O
lIng

20
21
Fuel
tank
gauge
Unit

23
Tank
reservoll
assembly

24
Spllng
washer

25
Screw

26
Breather
tube

27
Breather
tube

28
Breather
lube

29
Breather
tube

30
Breather
tube

31
Breather
tube

32
Breather
tube

33
Breather
tube
assembly

34
flexible
hose

35
Flexible
hose

36
flexible
hose

37
Fuel
tank
to
crankcase
tube
a

39
Reservoll
pipe
assembly

TO
CR
CASE
I
Y
40
Hose
clamp

41
Hose
clamp

I
42
Hose
clamp

37
30
1
43
Machine
screw

44
Spllng
washer
rIJ

45
Rubber
grommet

I
fi

j

82

CHAPTER
SEVEN

Removal

Pick

up

The
fuel
tank

IS
mstalled

along
With
the

vapor

liqUid
separator
A

cover
m
front
of
the
left

rear

wheel

protects
the

vapor
lIqUid

separator
from

damage
Figure
23
shows
the

cover
mstalled

and

Figure
24
shows
It
removed

I
Remove
dram

plug
from
bottom
of
fuel

tank

and
dram
the
fuel
mto
sUitable

safe
contamer

2
Disconnect
wire

leadmg
to
fuel

gauge
unIt

3
Disconnect
and

remove
fuel
Inlet
tube

4
Disconnect
rubber

tubes
of
fuel
outlet
and

fuel

return
lInes
5
Disconnect
tube

leadmg
to

vapor
liqUid

separator

6
Remove

fixmg
bolts

holdmg
tank

In

place

7
Remove
fuel

tank
from
vehIcle

Inspection

Inspect
the
fuel
tank
d

connectIng
lInes
for

SIgn
of

damage
or
leaks
If
dIrt

IS
found

In
the

carbl
relor
r
fuel

pump

upon
dlsassemb

y
blo

out
the
fuel

lines

usmg
compressed
air

Repair

Fuel
tank

leaks

may
be

repaired
by
soldering

or

brazmg
the
fuel
tank

WARNING

A

fuel
tank
IS
a

potential
bomb

capable

of

klllmg
anyone

nearby
should

It
ex

plode
Always
observe
the

followmg

safety
precautions
when

repairing
the

fuel
tank

1
Remove
all
fuel
and
have
the

tank
steam

cleaned

InSIde
and
out

2
F1l1
the
tank
WIth
Inert

gas
such
as
carbon

diOXide
or

mtrogen
or
WIth
water

3
Have
a

properly
rated
fire

extIngUisher

handy
and
never
work
near
the
vehicle

After
the

repair
IS
made

pour
the
water
out

or
release
the

gas
then

put
about

a

quart
of

gasolme
In

the
tank
and
slosh
It
around
Pour

the

gasolme
out
blow
the

tank
out
WIth
com

pressed
aIr
then

replace
tank
In

vehIcle

Installation

To
mstall
the

f
iel
tank

reverse
the

p
rocedur

used

dUring
removal
After
InstallatIon
check

carefully
for
leaks

Choke

and
Accelerator

Linkages

Figure
25
IS
an

exploded
VIew
of
the

lInkages

used
on
the

accelerator
and
choke
controls
To

disassemble

replace
and
mstall
the

lInkages

refer

to
the
IllustratIon
and

proceed
as

reqUIred

INDEX

237

2

7

30

28
WIrIng
diagrams

WIrIng
harnesses

Electncal

system
engme

Alternator

Chargmg
ClfCUlt

Dlstnbutor

IgmtlOn
coIl

Spark
plugs

Starter

Voltage
regulator

Emission

control
crankcase

DescnptIon

General

mspectIon

SchematIc
vIew

VentIlatIOn

control
valve

EmIssIOn

control
exhaust

AIr

pump

AntI
backfire
valve

Check
valve

DescnptlOn

Engme
modificatIons

system

Exploded
and
schematIc
vIews

Mamtenance
and

testIng

Troubleshootmg

Emission
control

system

evaporatIve

Engme

Camshaft

and

beanngs

Camshaft

sprocket

Component
descnptIons

Componenl

reassembly
and
mstallatIon

CompressIOn

testmg

Connectmg
rod

beanngs

Connectmg
rods

Crankshaft

Crankshaft
and

tImmg
cham

Crankshafl

sprocket

Cylmder
block

CylInder
head

DescnptlOn

Disassembly

Exploded
view

Flywheel

InstallatIOn

LubncatIon

MaIO

bearmgs

PIston

nngs

Pistons
and

connectmg
rods

PiStOns
and

piston
pms

Reassembly

Removal

SectIonal

views

ServIce
data

SpeCificatIons

Troubleshootmg

Valve
rocker

PIvot

Valves

Engme
lubncatlon

DescnptIon
217
222

205
207

98

104

98

105
111

111

112
113

9197

104

122

122

121

38
114

123

115
120

114

15

123

48
54

53

31

38

5759

24

52

51
54

51

57

53

49
55

46
56

31

40

33

53

59

27
30

52

50

45

50
54

53

38

32

60
61

60
61

13

54

47
53
114

114

121

114
LubncatlOn
ClfCUlt

011
filter

011

pump

Engme
tune

up

Checks

miscellaneous

Compression
testIng

DIstributor

Dwell

angle

EqUIpment
usage

ReqUIred
eqUIpment

Spark
plugs

Tlmmg

Tlmmg
dual

pomt
dlstnbutor

Valve
clearances

Exhaust

systems

Exploded
views

InspectIon

InstallatIOn

Removal

pickup

Removal
sedan
and

wagon

F

Fan
clutch

DIsassembly
and

reassembly

OperatIon
and

mspectlon

Flywheel

Fuel

pump

Capacity
test

DescnptlOn

Exploded
views

InspectIOn

InstallatIOn

Reassembly

Removal
an

assembly

StatIc

pressure
test

Fuel
stramer

Fuel

system

Air
cleaner

Carburetor

Fuel

pump

Fuel

stramer

Fuel
tank

Troubleshootmg

Fuel
tank

DescnptIon

Exploded
Views

InspectIOn
and

repaIr

Installation

Removal

sedan

Removal

pick
up

Removal

wagon

Fuses

G

27
General

mformatIon
25

24

21

24

20

20

21

23

24

25

124
126

126

126

126

123

l

89

89

53

68

37
65

66
67

68

58

68

42
68

65

1
2v

62

69

65

68
l

6

7

1
l

76

78
81

82

82

76

82

7
6

2

1

F