1968 DATSUN 510 Service Repair Manual

52

CHAPTER
SIX

@

1oI
DlA

IlIA

AU
Al

I
2
1I
a

1I
1
6
L

us

MAIN
BEARING
UNDERSIZE

Beanng
Beanng
top
Crank

Journal

sIZe

thickness

diameter

1
I000mm
mm
In

mm
In

STD
1
822
les5
54
942
54
955

0
0717
0
0722
2
1631
3
1636

25
1947
1960
54
692

54
705

Undersize
0
0767
0
0772

2
1532
2

1537

50
2072
2085

54
442
54
455

UndersIZe
00816

0
0821
2
1434
2
1439

75

2197
2
210
54
192
54
205

UndersIZe

0
0865
0
0870
2
1335
2
1341

100
2
322
2
335

53
942
53
955

UndersIZe
00914

0
0919

2
1237
2
1242

CONNECTING
ROD
BEARING

UNDERSIZE

Beanng
Beanng
top
Crank

pin

SIZe
thickness

diameter

l
loo0mm
mm
In

mm
In

STD
1493
1506
49961
49
974

0
0588
0
0593
1
9670
1
9675

6
1523
1536
49901

49
914

Undersize
0
0600
0
0605

1
9646
1
9651

12
1553
1566

49841
49
854

UndersIZe

00611
0
0617

1
9622
1
9628

25
1
618
1
631
49
711
49
724

UndersJZ8
0
0637
0
0642

1
9571
1
9576

50
1743
1756

49461
49
474

UndersIZe
00686

00691
1
9473
1
9478

75

1868
1881
49
211
49
224

UndelSlZ8
00735
0
0741
1
9374
1
9379

100
1993
2006
48
961

48
974

UndersIZe

0
0785
0
0790
1
9276
1
9281
5
Install
the
crankshaft
m
the

cylinder
block

and
measure
end

play
WIth
a
feeler

gauge
Figure

52
Allowable
IS
between
0
0020
and
0
0059
in

005
and
0
15mm

6

Replace
the
center
shIm
If
the
above

specified

value

IS
exceeded

by
0
0118

m
0
3mm

7
Check
the
main
dnve
shaft

puot
bearing
at

the

rear
of
the
crankshaft

for
wear
and

damage

Replace
It
If

any
defects
are
found

Main
and

Connecting
Rod

Bearings

1
Check
all

beanngs
for
seIZUres

meltIng
scor

mg
and
burrs

2
Measure
rod
and
main

bearings
clearances

WIth

PlastIgage
as
outhned

below

3
Insert
the

bearings
m
the

connecting
rod
rod

caps
main

beanng
caps
and
holders

4
Cut
a

pIece
of

PlastIgage
to
the
width
of
the

beanng
to
be
measured
and

place
It

m

parallel

with
the
crank

pm
as
shown
10

Figure
52
Make

certain
the

PlastIgage
does
not
cover
the
ou
hole

5
Install

bearings
and

caps
Main

bearings

should
be

tIghtened
to
32
5

through
398ft
lbs

45
to
55

kg
m
and

rod

beanngs
to
19
5

through
23
9
ft
lbs
2
7
to
3
3

kg
m

6
Remove
the

cap
and
measure
the
WIdth
of
the

PlastIgage
to
determine
clearance

7

Mam

beanng
readIngs
should
be
between

o
0008
and
0
0028
m
0
020
to
O
072mm
Rod

beanng
clearance
should
be
between
0
0006
and

0
0026
m
0014
to
0
066mm

8
To
check

beanng
crush
set
the

beanng
on

ENGINE
53

the
mam

beanng
cap
and
the

cyhnder
block

beanng
recess
and

tighten
the

cap
bolts
to
the

proper
torque
WIth
a

torque
wrench

Tig
temng

torque

Main

bearings
506
to
57
8
It
Ib

70to80kg
m

195
to
23
9
It
Ib

27
to3
3

kg
m
Rod

beanngs

9
Loosen
the

cap
bolt
on
one
Side
and
measure

the
clearance

Figure
53
between
the

cap
and

block
Side
Clearance
should
be
WIthm
the
fol

lowmg
specmcatIons
Mam

beanngs
0

through

o

0024
m
0
to
0
06mm
rod

beanngs
00012

through
0
0032
m
0
030
to
0
0024mm

Weight
@

10
If

beanng
crush
IS
not
m
tolerance

replace

the

beanngs

Crankshaft
and
Camshaft

Sprockets

1
Check
for

damaged
teeth

Replace
sprocket

1f

necessary

2
Install
the

camshaft

sprocket
and
check
for

runout
as
shown
m

Figure
54
If
over
0
04331

m
0
Imm

replace
the

sprocket
Check
for

thrust
deViation
at
the
same
tIme
Thrust
deVia

tIOn

should
be
between
0
0031
and
0
0150
m

008
to
0
38mm

3
Check
the
chain
for

damage
severe
wear

and
stretch
at
the
roller
hnks

Replace
the
cham

1f
defects
or
exceSSIve
stretch
IS
found

4
Check
the
cham
tenslOner
and
the
cham

gwdes
for
wear
and

damage

Flywheel

1
Check
the
clutch
disc
contact
surface
of
the

flywheel
for
wear
and

damage
@

2

Measure
deviation
of
the
clutch
disc
contact

surface

usmg
a
dial

gauge
If
deVIation
exceeds

004331
m
O
lmm

replace
the

flywheel

3
Check

flywheel
teeth
for

damage
Consult
a

dealer

Or
machIne

shop
1f
m
doubt

ENGINE
ASSEMBLY

This
section
covers

assembly
of
the

engme

after
corrective
mamtenance
has
been
com

pleted
SpecificatIons
and

torque
informatIon

are

given
at
the
end
of
the
sectIon
The

followmg

general
precautions
should
be
followed
m

assembhng
the

engme

1
Make
certam

all

parts
are

thoroughly
clean

and
that
all
011
and
water

passages
are
free
from

foreign
matenal

2
All

parts
that

slIde
mto
or

through
other

parts

should
be
coated
With
a
thm
film
of
new

engme

011
before

assembly

3
Don
t
reuse

gaskets
packIng
and
011
seals

Complete
lats
are
aVlUlable
for
the
entire

engme

and
for
the

cyhnder
head
and
block
assemblIes

4

Keep
tools
and
work
benches
clean
to
aVOid

contammatlon
of
delIcate

parts

5
Be

sure
to
follow

specmed
torque
tIghtenmg

values
and
order

of

tlghtenmg
where

given

6

Unless

complete
rebwld

of
the

engme
has

been
done
valves
and
associated

parts
bear

ings
pistons
and

connectIng
rods
should
be

remstalled
where

they
were
taken
from

CYLINDER

HEAD

Valve
and
Valve

Spring
Assembly

1
Insert
valve
from
bottom
of
block

54

CHAP1ER
SIX

2
Set
the
valve

spnng
seat

m

position
on
the

top
of
the
block
and

over
the

valve
stem

3
Place
the
oil
seal
over
the

valve
stem

4
Place
the

mner
and

outer
valve

spnngs
over

the
valve
stem

S

Place
the

spnng
retamer

over
the

springs

compress
spnngs
With

spring
compressor
Figure

55
and
mstall
valve
collets
around
valve
stem

so
that

they
lock
onto
stem

6
Release

spnng
compressor
If
collets
are
firm

ly
locked
onto
the

groove
m
the

valve
stem

assembly
IS

complete

7
Install
the
rocker

guIde
on

top
of
the

valve

stem
when

assemblmg
the
rocker

pivot
assembly

VaIve
Rocker
Pivot

Assembly

1
Thread
lock
nut
onto
valve
rocker

pivOt
and

place
rocker
retaIner
over
the
valve
rocker

pivOt

2
Thread
the
above

assembly
mto
the
rocker

bushIng
protrudIng
from
the

head

Camshaft

Assembly

1
Mount
the

locatIng
plate
on
the
front
of
the

head
as

shown
m

FJgIlI
1
56

2
From
the
back
of
the
head

carefully
InSert

the
camshaft

through
the

four
camshaft

beanngs

being
ca
efu1
not
to
move
or

damage
the
bear

ings

NOTE
Install
the

CQJ7IShaft

sprocket

onto
the

camshaft
so
that

the
three

locating
holes
are

at
the

top
left
and

bottom
h

1
3

Install
the

camshaft

sprocket
and
fuel

pump

cam
onto

the
front
of
the

camshaft
and

torque

to

specificatIon

4
Check
the
camshaft
for
end

play
using
a

feeler

gauge
as

preViously
described

Rocker
Pivot

Assembly

1
Push
down
on
valve

spnng
with
screwdriver

and
insert
rocker

piVOt
arm
between
camshaft

and
valve
stem

Insert
rocker
valve

guide
onto

top
of

valve
stem

at
this
time

2
Install
valve

rocker

springs
over

top
of
rocker

pivot
arm

Piston
and

Connecting
Rod

Assembly

1

Assemble
the
four

pistons

pms
and
connect

mg
rods
Secure

piston

pm
The

connecting
rod

IS

press
fitted
onto
the

pISton
pin
With
from
1
to

3
tons
of
force

NOTE
The

pistons
are

marked
with

an
F
which

should

point
toward
the

front
of
the

engine
The

connecting

rods

must
be
installed
so

that
the
011

Jet
In
the

large
end

IS

positioned
to

ward
the

right
Side

of
the

tnglne
The

center

of
the

piston
pin
IS

oD
set
In

relation
to
the

center

of
the

piston
so

correct

assembly
is
cntical

2
Use
a

nng
expander
to
install
the

rings
onto

the

pistons
Install
the

top
and
rmddle

nngs

with
the
marks

up

3

Lubncate
the

rod

bearings
hghtly
and
mstall

them
into

their

respective

connectIng
rods
and

rod

caps

ENGINE
55

Cylinder
Block

Assembly

1
PositIon
all
crankshaft

parts
on
a
work
bench

ThIS
mcludes
the
crankshaft
main

beanngs

rear
011

seal
woodruff

keys
crankshaft

gear

011

pump
gear
011
thrower
bolts
and

bearing

caps
Figure
57
shows
the

arrangement

@

2
Insert
maIO

beanngs
mto

appropnate
cy1m

der
block
holders

NOTE
The
center
No
3

beanng
IS

the

only
flanged
type
of
thrust
bear

Ing
Bearings
No
2
and
No
4
are

Identical
No
1
and
No
5

Jaring
ap

pear
identical
but
No
1
as
an
011

hole
All

bearings
except
No
1
are

Interchangeable
as
to

upper
and
lower

half

3

LIghtly
lubncate
the

crankshaft
and

beanng

matmg
surfaces
then
mstall

beanngs
10
mam

beanng
caps

4
Install
the
crankshaft

5
Install
mam

beanng
caps
over

crankshaft

msert
mam

cap
bolts
and

tighten
hghtly
The

mam

beanng
caps
have
an
arrow
marked
on

each
one
These
must

pomt
to
the
front
of
the

engme

6

Gently
move
the
crankshaft
10
an
aXIal
drrec

don

toward
the
front
of
the

engme
to

venfy
that

the
mam

beanng
caps
are

properly
alIgned
and

seated
7
Use
a

torque
wrench
to

tighten
the

cap
bolts

to
the
hmlts

speCIfied
The

t1ghtenmg
operatIon

should
be
done

gradually
10
three

or
four

sep

arate

stages
starting
10
the
center
and

workmg

outward

to
each
end

8
Rotate
the
crankshaft
to
make
certain
it
isn
t

bmding

9
Use
a
feeler

gauge
to
check
the
end

play
at

the
center

No
3

beanng
Figure
58

10
Install
the
SIde
oll
seals
into
the
rear
mam

cap
and

cy1mder
block
as
shown
10

Figure
59

@

11
Install
the
rear
011
seal
WIth
Datsun
tool

ST49370000
or

equIvalent

12
Install
the
rear
end

plate

13
Install
the

flywheel
WIth

proper
bolts
and

lock
washers
and

torque
as

specified

56

CHAPTER
SIX

NOTE
Lubncate
the

cylinder
walls

with
new

engine
oil

prior
to
insertIOn

of
pistOns
Make

certain
that
the

ring

gaps
are
not
In
line

wIth
one
another

Place

the

gaps
180

degrees
from
each

other

and
not

posltloned
either

front

to
back
or

dIrectly
in
line
with

the

piston
pIns

CAUTION

Use
extreme
care
when

Inserting
pzs

tons
so
as
to
avoId

crankshaft

damage

14
With
the
aid
of

a

nng
compressor
illStaIl

the

pISton
and

connectmg
rod
assembhes
into

the

cyhnder
block

as
shown
in

Figure
60
Make

certain
the

proper
piston
IS
mserted
mto
the

proper
hner
and
the
F
on
each

pISton
faces

forward

@

15
Install

beanngs
mto
the

connectIng
rod

caps

after

lubncatmg
them

hghtly

16

Gently
push
connecting
rods
With

beanngs

installed
down
the

cyhnder
until
contact

IS
made

with
the
crankshaft

17
Set

connectIng
rod

caps
over
crankshaft
and

insert

COnnectIng
rod
bolts
Make
certam
that
the

numbers
on
the
rods

and
the
rod

caps
face
in

the
same
direction

18

Tighten
rod
bolts
to
the

proper
torque
speci

ficatIon

as
shown

m

Figure
61

I
J

@v

N

i

19
Check
the

connecting
rod
end

play
With
a

feeler

gauge
as

previously
described

Cylinder
Head
Installation

1

Spread
a
suitable

gasket
seahng
agent
on
the

top
of
the

cylinder
block
and

position
a
new
head

gasket

2

Spread
seahng
agent
on

top
of
the

gasket

CAUTION

PositIon
the

crankshaft
so
that
no

pzston
IS
at

top
dead
center

Before

installing
head

point
the

keys
on
the

camshaft
and

crankshaft

straight
up

Once

the
head
zs

Installed
do
not

rotate
the

camshaft
and

crankshaft

separately
as

damage
to
the

piston

tops
might
result

3
Place
the

cyhnder
gently
onto
the
head

gask
et

NOTE
Three

dIfferent

types
of
bolts

are
used

to
hold
down
the
head

Make

certain
the

proper
ones
are
used

In

the

proper
places

4
Insert
head
bolts

through
holes
ill
head
and

thread
them
mto
the

cyhnder
block

5

Refemng
to

Figure
62

use
a

torque
wrench

and
Datsun
tool
ST49010000
or

equivalent
to

tIghten
the
head
bolts
to

specIficatIon
Tighten

them

gradually
m
three
or
four

stages
wlnle
fol

lOWIng
the

sequence
diagram
Torque
values
are

hsted

m
the

specIfication
table

ENGINE

57

@
L
13
and

L
16

engme

000000
8

4
2

6
10

7

3
1

5
9

o
0

0
0

0
Front

Crankshaft
and

Timing
Chain

Assembly

1

Insert
a
woodruff

key
mto
the
crankshaft

key

way
and
slide
the
crankshaft

sprocket
mto

place

2
Insert
a
woodruff

key
m
the

Illiddle
crank

shaft

keyway
and
slide
the

dIstnbutor
dnve

gear

mto

place

3
FIt
the
oil
thrower

to
the
crankshaft

as
shown

m

Figure
63

NOTE
Make
certam
that
the
crank

shaft
and

camshaft

keys
are

polntlng

upwards

4
Install
the

tmung
chain

over
the
crankshaft

and
camshaft

sprockets
Figure
64
shows
the

proper
relatIonslnp
of
the

tIming
marks
on
the

camshaft

sprocket
the

tmung
cham
and
the

crankshaft

sprocket
There
should
be
42
hnks

of
cham
from

tmung
mark
to

tmung
mar
k

5
Install
the
cham

gwdes
and
cham
tensIoner

NOTE

If
the
stretch

of
the
cham

roller
links
IS
extreme

adJust
the

cam

shaft

sprocket
location

by
tranfernng

the

camshaft
set

pOSltlon
of
the

cam

shaft

sprocket
to
No
2
or
No
3
hole

Procedures
to
make

thIS

adJustment

are

gIVen
m

steps
6

through
II

below
@

1
Fuel

pump
drive

eam

2
Cham

gUide

3
Cham

tensloner

4
Crank

sprocket

5
Cam

sprocket

6
Cham

gUide

6
Set
N
1

pISton
at

top
de

8
n
r
on

f

compressIon
stroke

7
Refer
to

Figures
65
and
66

Figure
65
is
a

dIagram
of
the
camshaft
locate

piate
an
d
FI

1

66
shows
the
front
side
of
the
camshaft

sprOcKee5
r

11
r

If

8
Examme
whether
the
camshaft
locatIon
hole

y

on

the
camshaft

sprocket
com
ff
llii
sl
ff
end

foI

tri4o

of
the

oblong
groove
in
the
camshaft

locate
E
1litc

If
the
locatIon
hole
IS
off
the
end
of
the

groove

the
stretch
of
the
cham
is

beyond
limit

9
Remove
the
bolt

holding
the
oil

pwp
p
cam

and
camshaft

sprocket
Move
the
camshaft

sprocket
mto

posItIon
so
that
No

2
hole
coin

Cides
With
the

oblong

groove
No
2
hole
should

be
on
the

right
end
of
the

oblong
groove

10
If
the
locatIon

hole

posItIon
still
isn
t
cor

rect
rotate
the
camshaft

sprocket
to
hole
No
3

which
should
be
on
the

nght
end
of
the

oblong

groove

@

58

CHAPTER
SIX

Notch
for

t1mmg
check

Camshaft

locatmg
hole

Timmg

mark

11
Should

none
of
the
above

adjustments
be

adequate
return
the
camshaft

sprocket
to
the

No
1
hole
and

replace
the
Oll

pump
cam
and

bolt
Under
these
conditIons
the

cham
must
be

replaced

Front
Cover
Crankshaft

Polley

And
Water

Pomp
InstaDation

1
Press
a
new
Oll
seal
into
the
front
cover

2

Apply
gasket

seahng
compound
to
both
sides

of
the
left
hand

and

nght
hand
front

cover

gaskets
Mount
the

gaskets
and

front
cover
to

the
block
With
bolts
and
lockwashers
Check

the
seal
of
the
head

gasket
at
the

top
of
the
front

cover
Make
certam
to
attach
bolts
at
that

locatlon

3

Insert
woodruff

key
into
crankshaft
and
slide

crankshaft

pulley
onto
crankshaft

4
Install
crankshaft
bolt
and
washer
then

torque
as

per
the

speclficatlon
table

5
Coat
water

pump
gasket
on
both
sides
With

gasket
compound
and
mount
the
water

pump
to

the
front
cover
as
shown

m

Figure
67

Oil

Pump
Installation

1
With
No
1

cyhnder
at

top
dead
center
on
Its

compressIOn
stroke
mstall
the

packing
for
the

Oll

pump
and
distnbutor
dnve

spmdle
mto
the

front
cover

2
Install
the
Oll

pump
and
distnbutor
drive

spmdle
Refer
to

Figure
68
and
make
certain

that
the
dnve

spmdle

top
IS
located

m
the
11
25
@

a
m

position
The
smaller

portion
of
the

spmdle

should
be
toward
the
front
of
the

engme

Fuel

Pomp
Water
Inlet
Elbow
lbermostat

Housing
and
Water
Outlet
Elbow
InstliJIation

1
Install
the
fuel

pump
with
associated

gasket

2
Install
the
water
mlet
elbow
front
thermo

stat

housmg
thermostat
and
water
outlet
elbow

along
With
associated

gaskets

3
Bolt
the
front
and
rear

hftmg
eyes
to
the

right

front
and
left

rear
of
the

cyhnder
block

4
Install

gasket
and
front

cover
on
the
front
of

the
head

Oil
Strainer
and
Oil
Pan
Installation

1
Mount
the
011
stramer
With

gasket
to
the
bot

tom
of
the

cyhnder
block

Torque
to

specifica

tion

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