1968 DATSUN 510 engine

ENGINE
39

Figure
11
Remove
the
clutch
return

spnng
from

Its

holdmg
bracket
and
the
clutch

operatmg

cylmder
from
the
clutch
withdrawal
lever

19
Disconnect
the

speedometer
cable
from
the

side
of
the
transnnsslOn
as
shown
m

Figure
12

20
Disconnect
the
flat

attachmg
plug
connector

from
the
reverse

lamp
sWitch
on
the

translDlSSlon

housing

21
At
the
transnnsslOn

housmg
disconnect
the

shIft

and
the
select
rods
Remove
the
cross
shaft

assembly
by
remOVIng
Its
bracket
from
the
Side

member

22
DISconnect
the
front
exhaust

pipe
from
the

exhaust
manIfold

by
remoVing
the
two
connect

mg
bolts

23
Disconnect
the
center
exhaust

pipe
from
the

rear
exhaust

pipe

24
Remove
the
front
exhaust

pipe
the

pre
muffler
and
the
center
exhaust

pipe
from
the

vehicle

25
Disconnect
the
dnve
shaft
from
the

matIng

flange
of
the

gear
carner

26
Insert
a

Jack
under
the
transmiSSIOn
and

jack
It

up
Just
a
little
to
remove
some
of
the

tension
from
the
rear
motor
mounts

CAUTION

Use
care
m
the

placement
of
the

lack

head
to

prevent
transmiSSIOn

housmg

damage
A
block

of
wood
can
be
m

serted

between
the

Jack
head
and

transmISSIOn

for

protection
The
block

of
wood
should
be

long
enough
to

span
the
transmiSSion

housmg

27
Remove
the
rear

engine
mountIng
cross

member

by
remoVing
the
bolts

holdmg
the
en

gine
mountIng
msulator
the

mountIng
cross

member
and
the
handbrake

clamp

28
Remove
the
bolts

secunng
the
front

engine

mountmg
msulators
to
the
front
cross
member

NOTE
At
thiS
time
all
Wires
hoses

and

lmkages
should
have
been
dIScon

nected

from
the

engme
and
transmIS

sIOn

Recheck
thiS
and

make
sure
that

no
loose

ends
Will

hamper
actual
en

gme
removal

29

RIg
a
cham

or
cable
hOist
to
the

lifting
eyes

stnngers
located

on
the

nght
front
and
left

rear

of
the

cylmder
head
Take

up
slack
m
the
hOist

30

Figure
13
shows
the

engme
bemg
lifted
Re

move
the

engine
slowly
by
lowenng
the

jack

beneath
the
transnnssion

gradually
until
It
can

@

40
CHAPTER
SIX

be
removed
Hoist
the

engme
off

Its
mounts
and

adjust
the
cham
or
cable
to
tIlt
the

engme
as

shown
in
the
illustration
ContInue
to

raIse

gradually

31
Once
the

engine
and
transmission
are
clear

of
the
vehIcle
lower
them
to
a
swtable

support

or
stand
and
dIsconnect
the
hOISt

32
The
transmISSIon
can
now
be
freed

by
re

movmg
the
bolts

holdIng
the
clutch

assembly
to

the

flywheel
housing
and

movmg
the
clutch

assembly
back
to

dIsengage
the
dnve
shaft

splmes

33
Witlltlie

engIne
removed

carefiillyinspect

the

mountIng
Insulators
for

SIgnS
of

damage
or

detenoratIon

Replace
them
1f

necessary

ENGINE
DISASSEMBLY

ThIS
sectIon
covers

dIsassembly
of
the

engine

once
It
has
been

removed
from
the
vehIcle
All

steps
would
be
followed
for
a

complete
engme

overhaul
But
smce

many
of
the

procedures
can

be
done
WIthout

removing
the

engIne
from
the

velucle
a

complete
course
of
actIon
should
be

decided
on
before
needless
removal
and
ms

assembly

Mount
the

engme
on
a
stand
or
other
sUItable

work
surface
before

msassembly
Thoroughly

clean
the
extenor
WIth
steam
or
solvent

CAUTION

Remove

the
alternator
starter
motor

carburetor
and
dIStributor

from
the

engine
before

cleaning
to

prevent

damage

Once
clean

mspect
the

engme
for

SIgnS
of

damage
or

mlssmg
parts
cracks
or
accumulated

rust
on
the
block

especIally
around
the
soft

plugs
cracks
In
the
clutch

housing
and
dents

or
cracks

In
the
oil

pan

DISassemble
as
follows

Alternator
Removal

1

Figure
14
shows
the

positIon
of
the
alternator

on
the

engme
and
a
VIew
of
the
alternator

mountIng
parts
Remove
the
two

bolts
lock

washers
and
shmls

holding
the
alternator
to
the

adjustIng
bar
and
the

adjustIng
bar
to
the

engme

block

2
Remove
the
two
bolts
and
lockwashers

hold
ing
the
alternator
to
lower

mounting
bracket

3
Remove
the
alternator
and

mountmg
brack

ets

Starter
Motor
Removal

1
Remove
two

mountIng
bolts
and
lockwashers

holdmg
starter
motor
to
clutch

housmg

2
Pull
starter

assembly
toward
front
of

engme

and

remove

Distributor
Removal

1
Scnbe

ahgnment
marks
on
the
mstrlbutor

shaft
tl
ie

ihsthDutor
mountmg
oracket
anihlfe

front
cover
so
that
the
dIStnbutor
can
be
re

placed
accurately
later

2
Remove
two
bolts
and
lockwashers

holdIng

the
dlstnbutor

mountmg
housmg
to
the

front

cover

3
Pull

up
on
the
dlstnbutor
and
remove
it

as

a
unit

Carburetor
Removal

1
Remove
the
four
nuts
and
lockwashers

join

mg
the
carburetor
and
mtake
manifold
then

remove
carburetor

Oil

Pump
Removal

1
Remove
the
four

mountIng
bolts
and
lock

washers

2
WIthdraw
the
011

pump
assembly
from
tht

front
cover
as
shown
m

Figure
15

@

Air

Pump
Removal

1
Remove
the
bolt

passmg
through
the
slot
on

ENGINE

@
41

I
t

43

44

45
46

49

48

47
46
45
43
44

38
39

37
Alternator
bracket

38
Hex
bolt

39
Hex
bolt

40
Lock

spring
washer

41
Bracket
shim

42
Adjusbng
bar

43
Hex
bolt
44
Hex
bolt

45
Lock

spnng
washer

46
Rat
washer

47
Voltage

regulator

48

Phillips
screw

49

Spring
washer

4Z
CHAPTER
SIX

the

adJustmg
bar
mto
the

mountmg
flange
of
the

arr

pump

2
Remove
the
bolt

lInking
the

arr

pump
to
the

mountmg
bracket
and
remove

pump

3
The
bracket
has
four
bolts
to
the

engme
the

adJustmg
bar
mounts
on
the
front
cover
WIth
two

bolts
Remove
these

to
free
the
front
cover

Water

Pump
Removal

I
Remove
the
bolts
and
lockwashers

Jommg

the
water

pump
to
the
front
cover
The
number

of
bolts
vanes
from

year
to

year
due
to

pump

aesign
clianges
Remove
water

pump

Fuel

Pump
Removal

I
Remove
the
two
nuts
and
lockwashers
secur

mg
fuel

pump
to
the

engIne
and
remove

pump

Rocker
Arm
COYer
Removal

I
Remove
SIX
bolts

holdmg
rocker
arm
cover

to
head
and
lIft
off
cover

Intake
and
Exhaust
Manifold
Removal

I
Remove
eleven
nuts
and
lockwashers
that

secure
the
mtake
and
exhaust
manIfolds

2
Remove
mtake
and
exhaust
manIfolds
as

shown
in

Figure
16

Thermostat
and
Water
Inlet

Housings

1
Remove
two
bolts
and
lockwashers

secunng

thermostat

housmg
to
head
Remove

housmg
as

shown
m

Figure
17
@

2
Remove
two
nuts
and
lockwashers
from

top

of
thermostat

housmg
to

gam
access
to
thermo

stat

3
Remove
two
bolts
and
lockwashers
that
hold

water
mlet

housmg
to
front
cover
and
lIft
off

housing

Front
Cover
Removal

1
Remove
bolt
and

washer
from
center
of
crank

pulley
Pulley
tool
Will
be

necessary
for
removal

from
crankshaft

2
Remove
nme
bolts
and
lockwashers

holdmg

front
cover
to

cylInder
block
then
remove
cover

as

shown
m

Figure
18

@

Chain
Tensioner
and
Drive
Chain
Removal

I

Figure
19
shows
the
camshaft
dnve

mechan

Ism
Remove
the
two
bolts
and
lockwashers
010

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

ENGINE
45

@

@

10
Remove
the
baffle

plate
and
steel
net
as

shown
in

Figure
30

11

Carefully
remove
the

connecting
rods
and

pIStons
from
the

cyhnders
by
pulling
them
out

of
the
bottom
of
the

cyhnder
block
@

12

Inspect
all

parts
for

signs
of

damage
or

wear

Repau
or

replace
as

reqUIred

PISTON
AND

CONNECI1NG

ROD
DISASSEMBLY

1
Remove
the

piston
nngs
from
the

pistons
as

shown
m

Figure
31

t
p

t

r
d

2
Removal
of
the

pISton
pms
from
the

pIStonS

and

connecting
rods

requires
the
use
of

a

press

and
tool
ST4484000D

CYLINDER
HEAD

DISASSEMBLY

I
Remove
the
valve
rocker

springs
that
are

looped
over
the

top
of
the
rocker
arms

2
Loosen
the
valve
rocker

pivot
lock
nut

and

remove
the

rocker
arm

by
pressing
down
the

valve

spnngs
on
each
valve
Take
care
not
to

lose
the
valve
rocker

gwdes
located
between
the

end
of
the
valve
stem
and
the
rocker
arm

46

CHAPTER

SIX

CAUTION

When

removing
camshaft
use
ex

treme
care
not

to
scratch

the
cam

bushings
Be
certam
to

leave
the
cam

shaft

bushings
Intact
so
as

not
to

get

them
out

of
al

gnment

3

Remove
camshaft
from
the

cylmder
head

by

carefully
pullmg
It

out
of

the
camshaft

beanng

housmgs
as
shown

m

Figure
32

@

4
Use
a
valve

hfter
as
shown
in

Figure
33

to

compress
the
valve

spnngs
so
that
the

valve

collects

located
at
the

tops
of
the
valve

stems

can

be
wIthdrawn
Once
the

collets
are

out
all

parts
of
the
valve

mechamsm
can
be
removed

from
the

cylmder
head

@

The
valves
are
removed

by

pullmg
them
out

the

bottom
SIde
of
the

cylinder
head

IdentIfy

each

upon
removal
to

permit
remstallation
in

the
same

posItion

Figure
34
Illustrates

the
var
@

o

o

IOUS

components
of
the
camshaft
and

valve

assembly

ENGINE

INSPECTION
AND

REPAIR

Once
the

engme
has

been

dIsassembled
clean

and

mspect
all

parts
to
determme
theIr
condi

tIon

CntIcal
dunenslOns
are
hsted
in
each

sec

tion
below

Cylinder
Head

CAUTION

Use
care
when

handling
the

cylinder

head

to
make
certam

that
the

cam

shaft

beanngs
are

not
removed

or

dIsplaced

1
Clean
all

foreign
matenal
from
the

cylmder

head

Pay

partIcular
attentIon
to

removal
of
car

bon
from

the
combustIon
chambers

Scrape
off

as
much
as

pOSSIble
and
remove
the
rest
with
a

wire

wheel
on
an
electric

dn11

2
Measure
the
machIned

surface
of
the
head

for

warpmg
FIgUre
35
covers
the

procedure
Use

a

StraIght
edge
and
feeler

gauge
Maxunum

@

ENGINE
47

allowable

warpage
IS
0
0039
in
0
I
mm

Standard
should
be
less
than
0
0012
in

O
03mm
In
the
event
the
measurements
are

out
of
tolerance
the

cylmder
head
surface

should
be
milled

or
resurfaced

3

Verify
that
all
water
and
011

passages
are
free

of

foreign
matena

Use

compressed
aIr
to
clean

passages
after

scraping

4
Note
the
condition
of
all
studs
in
the

cylinder

head

Replace
damaged
ones

Valve

Assembly

I
Check
intake
and
exhaust
valve
assembhes

for
worn

damaged
or
deformed
valve

caps
and

stems
Correct
or

replace
the
valve
If
excessive

defects
exist

2
Measure
valve
stem
diameter
WIth
a
micro

meter
as
shown
in

Fignre
36

Figure
37

gives

cnncal
drmensions

@

@

Y

lm

1

0
515

r

3
Reface
the
valve
face
and
valve
stem

using
a

valve

grinder
as
18
shown
in

Fignre
38
NOTE

When
the
valve
head

1uzs

been
reduced
to
00197
in
0
Smm

or
less
In
thIckness

replace
the
valve

Grinding
allowance

for
the
valve
stem

end

surface
is
00197
In
0
Smm
or

less

4
Measure
the
free

length
and
tension
of
each

valve

spring
If
the
measured
values
exceed
the

hnuts

specified
below

replace
the

spring

SPRING
SPECIFICATIONS

Free
Length
Outel

Spring

Inner

Spring

Outer

Spring
2
0472
10

52
Omm

1
765710
44
85mm

153m
at6393
331Ib

389mm
at290

15kg

138m
at
2712
154lb

35mm
at12
3
0
7

kg

121
10
at
105
38
5
29
Ib

30
7mm
at
47
8
2
4
kg

09610
at5621
2871b

245mm
at

25
5
13

kg
Valve
Closed

I
nner

Spring

Outer

Spnng

Valve

Open

Inner
Spnng

5
Check
the

deformation
of
each

spnng
with
a

square
Replace
any
spnng
WIth
a
deflection
of

o
063
in
I

611lID
or
more

6
Check
all

workmg
surfaces
of
the
rocker
arms

for

damage
or
wear
If
defects

or

apparent
ex

cessIve
wear

are
found

replace
them
A
defective

PIvot
reqwres
It
S

replacement
along
WIth
the

correspondIng
rocker
ann

7
Measure
the
clearance
between
the

valve

gwde
and
the
valve
stem
If
the
clearance
ex

ceeds
hnuts

replace
the
worn

parts
or
both