1968 DATSUN 510 ECU

110

CHAPTER

NINE

Points

Figure
S8

gives
details
of
the

sIngle

pomt

system
The

pomts
should
be

Inspected
penod

Ically
for
condItIon
and

wear
At
the

same
tlme

the

pOInt
gap
should
be
checked

and
reset
1f

necessary
Pomts
should
be
checked

at
least

every
2
500
mIles

SET
SCREW

PRIMARY

LEAD

TERMINAl

@

1
Unhook
the
two

clamps
holdmg
the

distnbu

tor

cap
to
the
dIStrIbutor

2
Remove
the
dlstnbutor

cap
and

pull
the
rotor

off
of
the
center

shaft

3

Carefully
note
or
mark
the

pOSItIon
of
the

dIStrIbutor

relatIve
to
the

fixmg
plate
at

the

bottom

of
the

distrIbutor

4
Loosen
the

hold
down
bolt
at
the
bottom
of

the
dlstnbutor

and
rotate
the
dIStnbutor

untIl

the

rubbmg
arm
that
rests
on
the
dIStrIbutor

cam

IS
at
a

high
pomt
of
the

cam
At

that

pomt
the

pomts
should
have

a

gap
between
them

5

Inspect
the

general
condItion

of
the

pomts

for
wear

pIttIng
and
smoot1mess

Pomts
that
are

worn

excessIvely
or
are

badly
pItted
must
be

replaced
Pomts
In

good
condItIon
can
be

re

surfaced

With
a

pOInt
file
number

600
sand

paper
or
WIth
a
small
whetstone

6
To

replace
or

remove
the

pomts
from
the

dIStrIbutor
loosen
the

screws
at
the
contact
arm

and

pnmary
lead

connectIOn
Do
not
remove
the

screw
Pull

up
on
the

primary
lead

to

dISc
onnect

the

termmal
from
the
contact
arm

7
Loosen
the
screw

holdmg
the

ground
WIre
to

the

pOInt
assembly
and

remove
it

S
Loosen
and

rell
ove
the
screws

holdIng
the

pomt

assembly
to
the

dIStnbutor
breaker

plate
Remove
the

pOInt
assembly
from
the
dIStrIbutor

Inspect
condItIon
of
the

pOInts
and

reconditIon

or

replace
as

reqUIred

9

Replace
the

points
Make
certain

to
recon

nect
the

ground
WIre
and
the

pnmary
lead

Apply

3

trace
of
cam

lubncatlng

grease
to
the
cam

upon

reassembly

10
WIth
the

pOInts
open
adjust

gap
It
should

be
between
00177

to
00217
In
045
to
055

mm

11
Install
the
rotor

put
the

cap
on
the
dIStribu

tor
secure
the

clamps
and
return
the
dtstrIbutor

to
its

onginal
pOSItIon
TIghten
the
hold
down

bolt

CONDENSER

PeriodJcally
check

the
condenser
electrIcal

lead

wire
and

the
set
screw
connectIon
As
a

matter
of

good
practIce
replace
the
condenser

whenever
the

pomts
are

replaced

DISTRIBUTOR

DISASSEMBLY

1
Take
off
the
dIstrIbutor

cap
and

remove
the

rotor

2
DIsconnect
the

vacuum
me
from
the
vacuum

con
troller

3
Mark
the

pOSItIon
of
the
distrIbutor
relative

to
the

housmg
remove
the
bolts
and
lIft
the

dIstrIbutor

off

4

Take
off
the
vacuum
controller
as
shown
m

F1gDre
S9

@

J

I

v

o

o
o

o

5
Remove
the
contact

pOInt
assembly
as

pre

VIously
descnbed

6
Remove
the

c01Jtact
breaker

assembly
Figure

60

by

remOVIng
the

clIps
that

hold
It
m

place

Be
careful

not
to
lose
the
steel
balls
located
be

tween
the
breaker

plate
and
breaker

springs

122

CHAPTER
TEN

1
Start
the

engIne
and

bnng
It

up
to
normal

operatIng
temperature

2

Inspect
all
hoses
and
connectIons
for
leaks

and
detenoratIon
Shut
off
the

engme
Replace

any
defectIve
hoses

3
Remove
the
hose
attached
to
the
check

valve

4

VIsually
Inspect
the

posItIon
of
the
valve

plate
InsIde
the

valve

body
See

Figure
10
It

should

be

lIghtly
posItIoned
agaInst
the

valve

seat

away
from
the
aIr
dlstnbutor
manifold

5
Insert
a

probe
Into
the
valve
connectIon
on

the
check
valve

Depress
the
valve

plate
It

should
return

freely
agaInst
the
valve
seat
when

released

6
Leave
the
hose
dISconnected
and
start
the

engme

7

Slowly
Increase

engine
speed
to
1
500

rpm

Watch
for
exhaust

gas
leakage
at
the
check

valve
There
should

not
be

any
The
valve

may

flutter

or
VIbrate
at
Idle

speeds
ThIS
IS
normal

Replace
the
valve
u

defecuve

Anti
Backfire
Valve

1
Start
the

engme
and

bnng
to

operating

temperature

2

Inspect
all
hoses
and
hose
connectIons
for

leaks
and
detenoratIon

Replace
as

required

3
DIsconnect
the
hose
at
the
antI
backfire

valve

leading
to
the
Intake

manuold
Insert
a

plug
ill

the

hose
and
fasten

securely

4

Open
and
close
the
throttle
valve

rapidly
See

Figure
11
Place
a

finger
over
the
valve
outlet
to

the

m
take
manuold
If

arr
flow
IS
felt
for

one
to
two
seconds
the
valve
IS

functIonIng

properly

If
there
s
no
aIr
or
If
the
flow
is
felt
for
more

than
two
seconds
the
valve
IS
defectIve
and
must

be

replaced

5
Connect
the
alr
hose
to
the
mtake
manuold

after

remOVIng
the

plug

6
DIsconnect
the
aIr
mlet
hose
from
the
air

pump
at
the
antI
backfire
valve
If
the

engine

Idle

speed
changes
excessIvely
the
valve
is
de

fectIve
and
must
be

replaced

Air

Pump

1
Check
the
atr

InjectIon
pump
belt
tension

DeflectIon
of
the
belt
should
be
0
5
In
when

pushed
In

by
thumb

pressure
Adjust
belt
u

necessary

2

Operate
the

engme
untIl
normal

temperature

IS
reached

3

Inspect
all
hoses
hose

connectIons
and
the

arr

gallery
for

SIgnS
of

leaks
or
detenoratIon

Replace
as

required

4
DIsconnect
the
air

supply
hose
at
the
check

valve

5
Insert
the

open
pipe
end
of
a

pressure
test

gauge
adapter
Into
the
air

supply
hose
See

Fig

ure
12

Clamp
the

adapter
firmly
to
the
hose

Install
the

pressure
test

gauge
to

the

adapter

PosItIon
the

adapter
and
test

gauge
so
that
the

alr
blast
emitted

through
the
dnlled

pipe
plug

Will
be

harmlessly

dislppated

6
Install
a
tachometer

on
the

engme
WIth
the

engIne
speed
set
to

1
500

rpm
observe
the

pres

sure

readmg
AIr

pressure
should
be
0
47
m

Hg

16mm
Hg

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
139

@
1
Re
erse

gear

2
Re
erse
shaft

3
Reverse

gear

4

Snep
nng

5
Thrust
washer

6
Reverse

gear
needle

beanng

7
Counter

gear

8
Counter
shaft

9
Counter

spacer

10
Needle
bearing
assembly

11
Thrust
washer

12
Thrust
washer
J

f

I

I

I

I

I

I

I

I

I

I

J

I

I

i

I
f

4
rm

9
13
MaIO
dnve

gear

14
MaIO
dn
e

beanng

15
MaIO
drl
e

spacer

16
MelO
drl
e

snap
ring

17
MaIO
shaft

18
steel
ball

19
Thrust
washer

20
MaIO
shaft
needle
bearing

21
Meln
shaft

bushlOg

22
MaIO
shaft
flm

gear

23
Baulk

nng

24
Sh

ftlOg
Insert

25

Spread
sprlOg

9

1
Remove
the
drain

plug
and
dram
the
trans

rmSSlon

gear
011
Into

a
SUItable
container

2
Remove
the
dust
cover
and
release
the

re

tainer

spring
securing
the

Withdrawal
lever
Re

move
the
lever
and
release

bearing
from
the

clutch

housmg

3
Remove
the

pIn
securing
the

strikmg
rod
to

the
control
lever
and
remove
the
control
lever

4
Remove
five
front
cover

securing
bolts
and

the
front

cover

i

j

5
Remove
14
hex
bolts

and
washers
from
bot

tom
cover
Remove
bottcifu
cover
from
trans
I

I

I

I

I

I

i

i

J
34

34
26
Synchronize
hub

27
CoupllOg
slee
e

28
MaIO
shaft
needle

beanng

29
Second

gear
assembly

30
MaIO
shaft
needle

beanng

31
Third

speed
gear

32
Baulk

nng

33

ShlftlOg
IOsert

34

Spread
spring

35

Synchro
hub

36
Slee
e

coupllOg

37

Snep

nng

38
MaIO
shaft

pilot
beanng

39
Main
shaft

bearing

40
MaIO
shaft

snap
ring

41
Re
erse
maIO

gear
and
hub
set

42
Rwerse
hub
maIO
shaft

43

Speedometer

gear

44
Steel
ball

45
MaIO
sheft
loc
l
washer

46
MaIO
shaft

nut

28
iy

25

25

21

rmssion
case

Figure
25
shows
the
tranSmISSIon

With
the
bottom
cover
removed

6
Remove

speedometer
dnve

pmion
assembly

7
Remove
hex
bolts

holdmg
rear
extension

housmg
to
transmISSIon
case
Remove
rear
ex

tenSIon

housing
as
shown
m

Figure
26

8

fDlsengage
stnkmg
rod
from
fork
rod

gates

9
Unscrew
three
check
ball

plugs
and
remove

sprmgs
and
balls

10
Drive
out

retatnmg
pms
used
to
secure
forks

to
fork
rods
and
remove
rods
and
forks

11
Move
the
1st
2nd

and
3rd
4th

coupling

140

CHAPTER

ELEVEN

@

sleeve
into

gear
at

the
same
tune
This
will
lock

the
mam
shaft

Release
the
main

shaft
nut

12

Withdraw
the

counter
shaft
and
remove
the

counter

gear
with

the
two
needle
roller

bearings

and

spacers

13

Refer
to

Figure
27

Release
reverse
idler

gear
snap
ring
Remove
reverse

idler

gears
and

shaft

@
14
Remove

four
bolts

holding
maIn
shaft
bear

Ing
retainer
to
transmissIOn

case
as
shown
in

Figure
28

@

15

Withdraw
the
main
shaft

assembly
from

transmIssion
case
See

Figure
29

16
Release
the

snap
ring

securing
the
3rd
4th

synchronizer
and
hub

Remove
the
hub

com

plete
With

couplIng
sleeve

17

Remove
the

300

speed
gear
and

needle
roller

bearings
from

maIn

shaft

18

Unscrew
the
main
shaft

nut
and

remove
the

nut

and

locking
plate

19
Remove
the

speedometer
drive

gear
and

steel
ball

20
WIthdraw
the

main
shaft

reverse

gear
and

hub

21
Press
off
the
main
shaft

bearmg

complete

With
the

bearing
retainer

DIFFERENTIAL
REAR

AXLE
AND
REAR

SUSPENSION
155

i

I

I

I

REAR
SUSPENSION
ARM

SEDAN

Rear

Suspension
Arm
Removal
Sedan

1
Jack

up
the
rear
of
the
vehIcle
and

support
It

on
stands

2
Remove
wheel
and
brake
drum

3
DIsconnect
dnve
shaft
from
axle
shaft

4
Remove
handbrake
cable
from
lever
attached

to
wheel

cylInder

5

Plug
brake
tube
to

prevent
loss
of
brake
flwd

6
Remove
wheel

beanng
lock
nut
rear
axle

shaft
wheel

beanngs
and
OIl
seal
Remove
rear

brake

assembly
from

suspensIOn
arm

7
Place

Jack
under

suspenSIon
arm
remove

shock
absorber
from
lower
bracket
lower

Jack

gradually
remove
coll

spnng
spnng
seat
and

bumper
assembly

8
Remove
two
bolts

secunng
suspensIOn
arm
to

suspensIOn
member
and
remove

suspensIOn
arm

See

Figure
14
9
Remove
rubber

bushmg
from

suspensIon
arm

usmg
a

bushmg
remover
as
shown
In

Figure
15

@

Rear

SllSpension
Arm

Inspection

Repair
and

Installation
Sedan

1
Examme

suspensIOn
arms
for

damage
dents

and
cracks

Replace
tf
defectIve

2
Check
rubber

bushmgs
carefully
for
wear

damage
and

general
condItIon

3
Install

suspensIOn
arm
m
reverse
of
removal

When

Installmg
suspensIOn
arm
to

suspensIOn

member
re

tIghten
the
bolts
after
the
vehIcle

IS

removed
from
stands

Change
self

lockmg
nuts

every
tIme

they
are
removed

dunng
semcmg

REAR
AXLE
SHAFf
WHEEL

BEARINGS
AND
SEALS
REMOVAL

AND
DISASSEMBLY

SEDAN

1
Jack

up
the
rear
of
the
vehIcle
and

support
It

on
stands

2
Remove
wheel
and
brake
drum

3
DIsconnect
dnve
shaft
from
axle
shaft

4
Remove
wheel

bearmg
lock

nut

usmg
axle

shaft

flange
wrench
to
hold
the

companIOn

flange
See

Figure
16

5
Use

a
slIde
hammer
to
Withdraw
the
axle
shaft

assembly
Refer
to

Figure
17

6
Remove
011
seal
and

Inner

bearmg
usmg
rear

axle
shaft

bearmg
dnft
as
shown
In

Figure
18

162

CHAPTER
TWELVE

14
Coat
the
front
bracket

pm
and

bushmg
and

shackle

pm
and

bushing
With
a

soap
solution

pnor
to

assembly

15
The
front

pm
secunng
nut
and
shock
ab

sorber
lower
end

securmg
nut
should
be

re

tightened
after

the
vehicle

is

sittmg
on
the

ground

16

Make
certaJn
the
shackle

bushmg
flange
is

clamped
evenly
on
both
Sides

SHOCK
ABSORBER

REMOVAL
INSPECTION
AND

INSTALLATION

WAGON

1
Jack

up
the

center
of
the
rear
axle
and

sup

port
th
e
axle

housmg
With
stands

2
Reinove
the

lower
end
of
the
rear
shock

absorber
from

spring
seat

3
Loosen
the
four
bolts

secunng
the

upper

bracket
to

body
Remove
shock
absorber
and

upper
bracket

4
Check
shock
absorber
for
leaks
and

cracks

Check
the
shaft
for

straighmess

Replace
1f

defective

5

Inspect
rubber

bushmgs
for

damage
cracks

and

general
condition

Replace
1f
defective

6
Install
the
shock
absorber

by
reversing
the

procedure
used

durmg
removal

DIFFERENTIAL

pICK
UP

The
dlfferenl1al

carner
IS
made

up
of
alum

mum

alloy
and
uses
a

hyp01d
bevel

gear

Proper

lubncatIon
IS
essenl1al
Check
and

replemsh
the

lubncant

every
3
000

mlles
Drain
and
refill

every
30
000
inlles

Figure
30
IS
a
cross
sectional

View
of
the

pick

up
dIfferential
Difterential
Removal

Pick

up

1
Jack

up
the
rear
wheels
and

support
vehicle

With
stands

2
DIsconnect
dnve

pmlOn
companlOn
flange

to

yoke
connectIon

3
Remove

rear
axles

as
descnbed
later
m
thIS

chapter

4
Remove
dlfferenl1al

gear
assembly

Difterential

Inspection
Pick

up

The

followmg

mspection
can
be
done
Without

disassembly
of

the
d1fferenl1al
If
abnormahties

or

damage
eXiSts
refer
further
serVice
and

reparr

to

your
dealer

1
Check
the

tooth
contact

pattern
WIth
lead

OXide
at
two
or
three

pomts
after

remoVlDg
rear

cover
Refer
to

FIgure
5
for

correct
contact

pattern
If
the

pattern
IS

faulty
disassembly
and

adJustment
of
the
dIfIerentialIs

required

2
Measure
backlash
between
dnve

gear
and

pmlOn
With
a
dial
mdlcator
Backlash
should

be

00051
to
0
0071

m
013

to
0
18mm

3
Rotate
the

gears
and
lISten
for

SignS
of
bear

mg
noise

4

Inspect
gear
teeth
for

SIgnS
of

damage
or

cracks

Difterential
Installation

Pick

up

Install
the
differential

by
reversmg
the

pro

cedures
used

dunng
removal

REAR
AXLE
AND

SUSPENSION

pICK
UP

The

rear
axle

IS
of
the

semi

floatIng
type
The

rear
wheels

use

tapered
roller

beanngs
Figure

31

IS
a
cross
sectional
view
of
the
rear
axle

REAR
SUSPENSION

TORQUE
TIGHTENING

SPECIFICATIONS
WAGON

Shock

absorber

upper
bracket
to

body
bolts

Shock
absorber
to

upper
bracket

lock
nuts

Shock
absorber

to
lower
bracket
lock
nuts

Rear

spnng
U
bolt
nuts

Shackle
nuts

Front

pm
nuts

Front
bracket

flxmg
nuts

Brake
dISC
to
rear

housmg
bolts

DifferentIal
carner

to
axle

housmg
bolt

Dnve
shaft

flange
nuts
11
to
18
ft
Ib
1

5
to
2
5

kg
m

12

to
16

ft
db
17
to
2
2

kg
m

25
to
33
ft
Ib
35
to
45

kg
m

43

to
47
ft
Ib
60
to
6
5

kg
m

32
to
36
ft
Ib
45
to
50

kg
m

32
to

36
ft
Ib
45
to
5
0

kg
m

13
to
17
ft
Ib
18
to
23

kg
m

20
to

28
ft
Ib
28

to
3
9

kg
m

14
to
16
ft
Ib
20
to
2
2

kg
m

20
to
28
ft
Ib
28

to
3
9

kg
m

164

CHAPTER

TWELVE

Rear
Axle
Removal

Pick

up

1
Jack

up
the
vehicle
and

support
It
With

stands

2
Remove
wheels

and
brake
drum

3
Remove
brake
shoe

and
chsconnect
hand

brake
WIre
See

Figure
32

4
Remove
four
nuts

holding
brake
end
to
axle

Disconnect

brake
hne
Refer
to

Figure
33

@

5
WIthdraw

axle
shaft
Be
careful
not
to
dam

age
01l
seal
ill
axle
case
SIde

6
Secure

axle
m

holdmg
fixture

or
secure

WIth

vise

7
Unbend
lockwasher
With
screwdnver

as

shown
m

FIgure
34

Do
not
reuse
lockwasher

replace
With

new
one

8
Remove
lock

nut
With
a
wrench
or

special

tool
shown

m

Figure
35

9
WIthdraw
axle

beanng
brake
disc
and
bear

mg
cage
by
usmg
a

puller
or

SpecIal
tool
shown

m

Figure
36
@

10

Remove
011
seal
as

required
Do
not

reuse

011
seal

agaJn
replace
It
With

a
new
one

t

11
To
remove

bearmg

cup
from

cage
remove

seal

apply
a
brass
bar
and

tap
It

evenly
With
a

hammer

Rear
Axle

Inspection
nnd

Installation

Pick
up

1
Check

the
axle
for
bends
and
cracks

Replace

1f

damaged