1968 DATSUN 510 transmission

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

CHAPTER
ELEVEN

CLUTCH
TRANSMISSION
AND
DRIVESHAFf

CLUTCH

i
es

ription

Datsun
uses
a

single
dry
dtsc
clutch
with

dIaphragm
spring
The

major
components
are

clutch
cover

pressure
plate
dIaphragm

spring

and
WIre

nngs
The
clutch
dISC
has
riveted

plates

on
both
surfaces
and
coll

spnngs
arranged
in
a

link
The
coll

springs
absorb

shock
to
soften
and

smooth
clutch

engagement
Figure
1
next

page

is
an

exploded

diagram
of

the
clutch

assembly

Clutch
Removal

The
transmIssion
must
be

separated
from
the

engme
to
remove
tlte
clutch

assembly
This
can

be
done

by
removmg
the
transmISSIon
and

engme

from
the
vehicle
as
a
umt
or

by
remoVIng
the

transmiSSIon

separately
Removal
of
the

engine

and
transmissIOn
IS
descnbed
In

Chapter
Six

Removal
of
the
transmISSIon

only
IS
descnbed

later
in
tills

chapter

Outcb

Disassembly

1

Separate
clutch

assembly
from

flywheel

Loosen
and

remove
bolts

dIagonally
and

gradu

ally
as
shown
m

Figure
2

2
Remove
dust
cover
from
clutch

housmg

3
Remove
return

spnng
from

beanng
sleeve

Separate
the
Withdrawal
lever
from

bearing

sleeve
w

1

4
Remove
release

bearmg
and

bearing
sleeve

from
front
cover
Remove
wIthdrawal
lever

ball

pm
Figure
3

CD

1
Withdrawal
lever

ball

pin

2
Withdrawal
lever

3
Return

spnng

4
Release

beanng
4

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
129

scratches
on
the

pressure
plate
may
be

removed

with

crocus
cloth

If
the
source
of
clutch
trouble
IS
still
not
evl

dent
take
the

pressure
plate
and
disc
to
a

compe

tent

garage
to
check
the

pressure
plate
finger

release

height
and
nmout
Never

attempt
to
ad

just
the

fingers
or
dismantle
the

pressure
plate

Without

proper
tools
and

experience

Check
the
release

bearing
by
holdmg
the
Inner

race
and

rotatmg
the
outer
race
With

hght
pres

sure

applied
If
the

bearing
is

rough
or

noisy

replace
it

CAUTION

Never
clean
the
release

bearing
In

solvent
It
IS

prelubriCflted
at

the

fac

tory
Simply

wipe
with
a
Unt

free
cloth

If
the
release

bearing
shows

any
signs
of
loss

of

lubncant
install
a
new

bearing
Replace
the

sleev
lu
SignS
of
wear
are
evident

Clutch

Reassembly

1
Be

sure

your
hands
are
clean
for
the
initIal

assembly

2

Inspect
the
clutch

facings
pressure
plate
and

flywheel
to
be
sure

they
are
free
from

grease
oil

and
other

foreIgn
material

3

TIghtly
fit
release

bearmg
onto
the

bearing

sleeve
When

beanng
IS
mstalled
turn

bearmg

With

a

finger
to
make
sure
It

operates
smoothly

4

Apply
multI

purpose
grease
to
the

bearmg

sleeve
InSIde

groove
See

Figure
5

CD
Ji

rot

Pac
thiS
r

r
r

1
1i

QI
ecess

5

Apply
multi

purpose
grease
to
the

WIth

drawallever
and

bearing
sleeve
contact

point
and
to
the
Withdrawal
lever
ball

pm
and
with

drawallever
contact

point

f

6
Clean
the
clutch

pllot
bushmg
and
fill
It

With
multi

purpose
grease

7
Mount
the
WithdraWal
lever
release

bearing

and

bearing
sleeve
to
the
clutch

housing
Install

dust
cover
on
clutch

housing
and
connect
return

spring
to
WithdraWal
lever

8
Place
the

pressure
plate
and
clutch
disc
in

positIon
on
the

flywheel
Make
certain
the

pres

sure

plate
is
In
the
same

positIon
relative
to

fly

wheel
as
when
removed
Use
a
clutch

alIgning

bar

Special
Tool
ST20630000

FIgDfe
6
to

alIgn
the
clutch
dISc

splIne
to
the

pllot
bearing

CD

NOTE

If
the

special
tool
is
not
avail

able

cut
an

input
shaft
from
a

Junk

transmission

9
Install
the

pressure
plate
mounting
bolts

Tighten
the
bolts

dIagonally
opposite
each
other

one
turn
at
a
time
to

prevent
warpmg
Torque

the
bolts
to
10
8
to
15
9
ft
lbs
1
5
to
2
2

kg
m
Remove

durmny
shaft

10
Install
the
clutch

housing
to
the

engme

Clutch
ntrol

Datsuns
have
a

hydraulic
clutch
control

system
It
consISts
of
a

pendant
clutch

pedal

CLUTCH
TRANSMISSION
AND
DRlVESIIAFI
133

C
8

Q@J

@

C

Operating
Cylinder
Reassembly

1
Soak

pISton
cup
m
brake
flUid
and
Install
It

In
the
same

pOSitIOn
as
before
removal

2

Apply
brake
flUid

to
the

cylInder
and

pIston

before

mstalImg
piston

3

Replace
all

parts
m
the
reverse
order
of

removal

Operating
Cylinder
Installation

1
RemstallatIon
IS
the
reverse
of
removal

2
Bleed
aIr
from
the

hydraulIc
system

3

Adjust
the

pushrod
so
that
withdrawal
lever

end

play
IS
0
0787
to
0
1181
In
2

0
to
3
Omm

Procedures
for

the

adjustment
are

given
below

WITHDRAWAL
LEVER
AD
JUSTMENT

Correct

adjustment
of
the
clutch
withdrawal

lever
IS
essentIal
InsufficIent
free
travel
between

the
release

bearmg
and

dIaphragm
fingers
can

cause
the
clutch
to

slIp
ExceSSIve
free
travel
can

prevent
full

dISengagement
of
the
clutch
Refer

to

Figure
11

1
Loosen
lock
nut

2
SCrew
In
the

pushrod
fully
with
the

adjustmg

nut

3
Unscrew

adJustmg
nut
1
turns

TIghten

lock
nut

J

4
Check
the
end

play
of
the
wIthdrawal
lever

End

play
should
be
0
0787
to
0
0906
in
2
0
to

2
3mm
The
correct
end

play
will

give
a
clear

ance
of
0
0512
m

1
3mm
between
the
release

bearmg
and

diaphragm
fingers
@

1
Lock
nut

2

AdJustmg
nut

3
Wrthdrawal
ever

4
Release
beer

ng

5

Diaphragm
spnng
20
to
30

0
079
to
0
11

B

Unit
mm
m

5
If
the
above

adjustment
does
not
result
in

satIsfactory
clutch

operatIon
the
clutch
dISC
is

probably
worn

excessIvely
and
will

reqUire
re

placement
as

preVIously
dIScussed

BLEEDING
CLUTCH
SYSTEM

AIr
In
the
clutch

hydraulIc
system
makes
shIft

Ing
gears
extremely
difficult
1f
not

impOSSIble

To
bleed
the

system
proceed
as
follows

1
Remove
the
bleed
screw
dust

cap
from
the

operating
cylInder

2
Attach
a
bleeder
hose
to
the

bleed
screw

Immerse
the
other
end
of
the
hose
m
a
container

f

hydraulIc
brake
fluid

3
Check
to
see
that
clutch
master

cylInder

reservoir
IS
full
of
brake
flUid

ReplenISh
if

necessary

4

Open
the
bleeder
screw

three
quarters
of
a

tlIrn
and
have
an
assistant

pump
the
clutch

pedal
slowly
Pump
the
clutch
until
the

flUid

entenng
the

contatner
is
clean
and
free
from

bubbles

5

TIghten
bleed
screw

Replace
dust

cap
Refill

the
flUid

reservoir

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
DRIVESIIAFI
135

stands
If

possible
the
use
of
an

open
pit
or

hydraulIc
hOISt
IS
recommended

3

Figure
13
shows
the
underside
of
the

sedan

and
statIon

wagon
Figure
14
IS
the

pick
up

4
DIsconnect

negatIve
battery
cable
from

termInal

r

j

7T
@

r

1
Cross
shall

2
Back
up

lamp
sWitch

cable
3

Speedometer
dn
e
cable

4
Exhaust
manifold

5

Propeller
shall