1968 DATSUN 510 wheel

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

60
SIX

Table
1
ENGINE
SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Cylinder
Arrangement

DIsplacement

Bore
and
Stroke

Valve

Arrangement

MaxImum
Brake

Horsepower

MaxImum
Gross

Torque

Firing
Order

Engme
dle

Smgle
POint

Dual
Pomt

CompressIon
RatIo

Engme
Idle
Mamfold
at
Idle

rpm

011
Pressure
hot

@
2
000

rpm

i
TIGHTENING

TORQUE
ft
Ib

kg
m

Cylinder
Head
Bolts

1st
turn

2nd
turn

Flywheel

Flxmg
Bolts

M
In

Beanng
Cap
Bolts

Camshaft
Gear

Bolt

I
011
Pan

1
1

fF
I

011

Pump

QII
Stramer

F

I
Crank

Pulley
Bolt

SPECIFICATIONS
In
mm

Valve
Mechamsm

Valve
Clearance
Hot

Valve
Clearance
Cold

Valve
Head
DIameter
Intake

Valve
Head
DIameter
Exhaust

Valve
Stem

DIameter
Intake

Valve
Stem
DIameter

Exhaust

Valve

Length
Intake

Valve

Length
Exhaust

Valve

LIft

Valve

Spring
Free

Length
Outer

Valve

Sprmg
Free
Length
Inner

Vaiv

Spnng
Loaded

Length
Outer

Valve

Spring
Loaded

Length
Inner

Valve

Sprmg
Assembllld

HeIght
Outer

Valve

Spnng
Assembled

Helght
Inner

Valve

Spnng
Effective
Turns
Outer

Valve

Sprmg
EffectIve
Turns

Inner

Valve
GUIde

Length
Intake

Valve
GUIde

Length
Exhaust

Valve

GUIde

HeIght
from
Head
Surface

Valve
GUIde
Inner
DIameter
Intake

Valve
GUIde
Inner
DIameter
Exhaust

Va
Ive
GUIde

Outer
Dlam
eter
Intake

Valve
GUIde
Outer

DIameter
Exhaust

Valve
GUIde
to

Stem
Clearance
Intake

Valve

GUIde
to
Stem
Clearance
Exhaust

Valve
eat

W
dth
Intake

Valve

SEtat
WIdth
Exhaust
4
m

Ilnil

97
3
cu
m
1595cc

3
2677
x
2
9016
In
83
x
73

7mm

Overhead
Camshaft

96

@
5
600

rpm

110
ft
Ib
13
8
kg
m

@
3
600

rpm

1
3
4
2
r

600

rpm

700

pm

85
1

i7
7
In

Hg
450mm

Hg

54
to
60
Ib
m
2

3
8
tQ
4
2

Iig
cm

325
4
5

39
8
5
5

68
No
75
9
9
50

to
1039

325

to
39
8
4
5

to
5
5

362
to
43
4
50
to
60

2
9
to
5
1
0
4
to
0
7

108
to
15
2
1
5
to
2
1

58t087
08to
12

1157
to
130
1
160
to
180

o
118
0
30

o

0C
98

0
25

1
50
38

0

1
30
33
0

031
80

031
80

456
1159

4
57
116
O

03937
100

2
05
52
0

1
77
44
96

1
21

@
1054
Ib
3
07

@
47
8

kg

o
96

@
56
Ib
24
5

@
25
5

kg

1
53

@
63
9

Ib
38
9

@
29

0
kg

1
38

@
27
1
Ib
35

@
123

kg

45
I

55

2
32
59
0

2
32
59
0

0409

to
0
417
104

to
106

0315

to
03154
80

to
8018

0315
to
03154
80
to
8
Oi8

04718
to
04723
11
985
to
11
996

04718
to

04723
11
985
to
11
996

00006
to
00018
0
015

to
0
045

00016
to
00028
0040

to
0070

o
055

to
0
071
1
4

to
1
8

0063
to
0079
1
6
to
20

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

CHAPTER

NINE

ENGINE
ELECTRICAL
SYSTEM

The
electrIcal

system
has

undergone
slIght

yearly
changes
the
most

SignIficant
being
ill
the

distrIbutor
Some
models
have
a

smgle
contact

pomt
whIle
others
have

a
dual

pomt
system
De

talls

are
covered

m
the
dIstrIbutor
sectlon
The

electrIcal

system
IS
a
12
volt

negatIve
type

OPERATION

Figure
1
shows
the

starter
motor
When
the

Ignltlon
sWItch

IS
turned

to
the

start

pOSItIon

current
flows

through
the

senes
and
shunt
colis

of
the

magnetIc
SWitch
and

magnetizes
It
The

plunger
IS

pulled
mto
the

sWItch

operatlng
the

shIft
lever
to

engage
the
dnve

pmlon
with

the

flywheel
rmg
gear
and
to
close
the

magnetIc

SWitch

CD
Figure
2
shows
the
starter
motor
CIrcUIt
Clos

ing
of
the

statlonary
and
movable
contacts
cause

the
motor
to
crank
the

engme
and
cut
out
the

series
coIl
of
the

magnetic
switch
The

magnetic

pull
of
the
shunt
coll

IS
suffiCIent
to
hold
the

pmIOn
m
mesh
With
the

flywheel
nng
gear
after

meshing
has
occurred
After
the

engme
starts

and
the

Ignition
key
IS
released
to
the
on

POSI

1

CD

12
11
10

1

Stationary
contact
8
ShIlt
le
er

2
Sene
coli
9
Orne

pinion

3

IgmtlOn
SWitch
10

Ring

gear

4
Solenoid
11
Plmon
slee
e

spllng

5

Shunt
COil
12
Armature

6

Plunger
13
Movable
contact

7
Return

spllng
14

Battery

91
CHAPTER
NINE

bon
the
serIes
coll

demagnetizes
agatnst
the

shunt
cOIl
The
return

spnng
causes
the

plunger

to
return
to
the

origmal
posItIon
stoppmg
the

starter
The

overrunnmg
clutch

provIdes
for

positIve
meshmg
and

unmeshmg
of
the

pmlOn

gear
and

flywheerrmg
gear
and

perinitStlie

pmlon
to
overrun
the
armature
after
the

engme

has
started

CONSTRUCIlON

A

typical
Datsun
starter
motor

is
shown
m

Figure
3
The

example
is
for

1971
models
but

about
the

only
dIfferences

existing
between
It
and

other
models
are
the
number
of
elements
used
in

the
dust
cover
and
the
number
of
thrust
washers

Removal

1
DIsconnect
the

battery
ground
cable

2
Disconnect

the
black

yellow
wire
from
the

magnetIc
sWitch
tennmal
on
the
solenoid

3
Disconnect
the
black

battery
cable
and
red

wire
from
the

battery
tennmal
on
the
solenOId

4
Remove
two
bolts

holdmg
the

startmg
motor

to

flywheel
hOUSIng
The

battery
ground
cable
is

attached
to
the

flywheel
hOUSIng
bottom
bolt

5
Pull
starter
motor
toward
front
of

engme
and

remove

Disassembly

1
Remove
the

nut

holdIng
the
electrIc
WIre
to

the

magnetIc
sWItch
M
tennmal
DIsconnect
the

WIre

2
Remove
three
screws

securmg
magnetic

switch

assembly
to

yoke
Remove

magnetic

sWItch

assembly
and
dust
cover
s

Figure
4

3
Remove
two

through
bolts
and
brush
cover

assembly
as
shown

m

Figure
5

4
Remove
the

yoke
assembly
by
tappmg
lIghtly

as
In

Figure
6

5
Remove
bolt

nut
and
washers
at
base
of

yoke
to
free
shut
lever
WIthdraw
the
armatlIre

and
shut
lever
as
shown
m

Figure
7

6
Remove
the

pInIOn
stop
nng
located
at
the

end
of
the
armature
shaft
To
remove
the

stop

nng
push
the

stop
nng
to
the
clutch
SIde
remove

the

snap
nng
and
Withdraw
the

stop
nng
and
CD

c

0
I

CD

Ml

ml

CD

a
I

II

0

l

g
I

o

96

CHAFTER
NINE

@

EK
lle

Correct

Incorrect

ground
As
shown
m

Figure
i
7

place
one
test

probe
onto
the
armature
shaft
and
the
other

probe
onto
each
commutator
bar

ContInuity

IndICates
a

groundt
and
the
armature
must
be

replaced

@

6
Check
the

armature
for
shorts

by
placmg
It

on
a

holdmg
fixture

holdmg
a
hack
saw
blade

over
the
core
and

rotatIng
the
armature
If
the

saw
blade
VIbrates
the
armature

Is
shorted
and

must
be

replaced

7
Check
for

contInuity
by
placmg
the

probes

of
a
tester
on
two
sIde

by
slde

segments
of
the

armature
No

current

passage
mdlcates

an

open

CIrcUIt
The

armature
must
be

replaced
If
read

mgs
are

InCOnslste
t

replace
the
armature

OVERRUNNING
CLUTCH
ASSEMBLY

1

Inspect
the

plmon
assembly
and

screw
leeve

The

screw
sleeve

must
slIde

freely
along
the

armature
shaft
If

damage
IS
detected
or
1f
It
does

not
move

freely
replace
It

Inspect
the

pmion

teeth
for

damage
and
wear

Replace
1f

required

2

Inspect
the
teeth

on
the

flywheel

nng
gear
for

mlssmg
or

damaged
teeth

If
defective
the

fly

wheel

must
be

replaced
BRUSH
HOLDER

1

Usmg
a
CirCUIt
tester

as
shown

In

Figure
18

place
one
test

probe
on
the

rear
cover
and
the

other

on
the

posltlve
SIde

of
the

brush
holder
If

the
tester
shows
conduction
the
brush
holder
IS

shorted
to

ground
or
the
msulator
IS
defective

Replace
the
brush
holder

@

STARTER

MOTOR
BEARINGS

1

Inspect
the

bearmgs
at
eIther
end
of
the
rear

cover
and
the

gear
case

assembly
If

they
show

SignS
of

sconng
or
other

damage
replace
them

Check
the

clearance
of
the
armature
shaft

to
the

bearmgs
It
should
be
less
than
0
0079

In

0
2mm

2
If
the

bearings
are

replaced
new

bearing

clearance
should
be
00012
to
00039

In
0
03

to
0
10mm

MAGNETIC
SWITCH
ASSEMBLY

1

Inspect
the

magnetic
sWItch
contacts
for
de

fects

and

damage
replace
1f

necessary

ASSEMBLY

To
reassemble
the
starter
motor

reverse
the

procedures
used

dUring
disassembly
When

as

sembly
has
been

completed
perform
the

follow

mg
tests

Testing

The
starter

motor
should
be

subjected
to
a

no
load
test
and
a
lock

torque
test

follOWIng

overhaul
to
ensure
that
Its

performance
will
be

satIsfactory
when
mstalled

on
the

engme
These

tests

are
also

helpful
In

detennmIng
the
cause

of

problems
before

dIsassembly

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