1968 DATSUN 510 ECO mode

CON1EN1S

CHAPTER
ONE

GENERAL
INFORMATION

Introduction

Model
Identification

CHAPTER
TWO

PERIODIC

MAINTENANCE

RoutIne
checks

Pen
odic
checks

CHAPTER
THREE

TROUBLESHOOTING

EqUIpment

Starter

ChargIng
system

EngIne

Igmtlon

system

Fuel

system

Exhaust

emIssIon
control

CHAPTER

FOUR

ENGINE
AND
IGNITION
TUNE
UP

EqUIpment

Battery

Spark
plugs

DIstrIbutor

Igmtlon

timIng

CHAPTER
FIVE

ENGINE
LUBRICATION
SYSTEM

Descnptlon

Lubncation

cIrcuIt
SpecIficatiOns
and
dImensIons

EngIne
lubncation
and

maIntenance

Recommended
lubncants

Clutch

TransmIssiOn

Brakes

Steenng
and

suspension

TIre
wear

analysIs

Wheel

balancIng

Idle

speed
and
Idle

mIXture

Dwell

angle
setting

CompressIon
test

Valve
clearance

adjustment

AddlllOnal
checks

Oil

pump
I

6

t
1

4

V

9
t

1

20

27

CHAPTER
ONE

GENERAL
INFORMATION

This
manual

provides
maintenance
informa

tIon
on
the
Datsun
510
Series
and
521
Series
of

vehlcles
The
510
Series
includes
the
two
door

sedan
four
door
sedan
and
station

wagon
The

521
Senes
IS
the

pIck

up
truck

Coverage
is
from

1968

through
1972
models

All
models
use
the
L16

engme
a
96
horse

power
four

cylmder
overhead
camshaft

design

The
510
has
a

fully
synchronized
four

speed

manual
or
three

speed
automatic
transmisSIon

The
521
has
a
four

speed
manual
transmission

only
In
1972

horsepower
ratIng
was

lowered

to
92

horsepower
due
to

changes
m
emission

control
device

requirements
Figure
1
is

an
over

all
view
of
the
four
door
sedan

Figure
2
shows

the

station

wagon
and

Figure
3
illustrates
the

pick
up
truck

Over
the

years
the
510
and
521
series
have

remained

essentIally
the
same
with
the

excep

tion
of

changes
to
the

emISsion
control

systems

and
overall

body
stylmg
In
this
manual

every

effort
has
been
made
to

pinpoint
significant
c
if

ferences
between
model

years

The
use
of

SpecIal
tools
and
test

equipment

has
been
avoided
wherever

possible
When

necessary
special
tools
and
test

equipment
are

illustrated
either
in
actual
use
or
alone
A
well

equipped
mecharuc

may
find
he
can

substitute
similar
tools
or
make
his

own
to
fulfill
a
e

Ii

ment

Recommendations
are

occasionally
made
to

refer
servIce
or
mamtenance
to
a
Datsun
dealer

or
a

SpecIaliSt
in
a

specIfied
field
In
these
cases

work
WIll

probably
be
done
more

qUlckly
and

economIcally
than
if
the
mecharuc

performs

them
himself

MODEL
IDENTIFICATION

Body
Number
Plate

The

body
number
IS

stamped
on
the
fire
wall

in
the

engine
compartment
The
numbers

give

the
chasSIS
model
and
serial
number

Model
Identification
Plate

The
model
Identification

plate
Figure
4
is

mounted
WIthin
the

engine

compartment
TIns

plate
gIves
engine
number
and
veh1cle

number

Engine
Identification

The

engine
identrlicatlon

marking
is

stamped

on
the

right
hand
SIde
of
the

cylinder
block

just

below
the
third
and
fourth

sp8l
k

plugs

Model
Identification
Numbel
ll

The

following
numbers
have
been

assigned
to

the
510
and
52
I
Series

vehicles

oj

FUEL
SYSTEM
6S

CD

2
Remove
the
fuel
stramer
from
Its

mountlng

clIp

3

Replace
the
fuel
stramer
as

reqUIred

4
Reconnect
the
mtake
and
outlet
fuellmes

FUEL
PUMP

The
fuel

pump
conSISts
of
a

body
rocker
arm

and
lmk

assembly
dIaphragm

dIaphragm

spring
seal
and
mlet
and
outlet
valves
The
l
r

t

1
9

l

F
r

fl

rocker
arm
IS
dnven

by
a

pump
cam
mounted

on
the
catnShaft
In
the
front

part
of
the
rocker

arm
front
cover

assembly

Figure
S
shows
the
fuel

pump
for
all
models

through
1970

Figure
6
illustrates
the

fuel
pump

for
1971
and
later
models

Fuel

pump
Testing

Fuel

pump
pressure
and
fuel

pump
capacity

testlng
are

performed
m
tests
descnbed
below

Both
tests
are

performed
With
the
fuel

pump

mounted
to
the

engme

Static
Pressure
Test

1
DIsconnect
the
carburetor
fuel
lme
at
the

carburetor

2
Install
an

adapter
and
a
tee

fittmg
to
the

fuel
lIne
and
attach

a
SUItable

pressure
gauge

3
Connect

adapter
to
carburetor

4
Start
and
run

engine
at

varymg

speeds

5
The

gauge
reading
IS
static
fuel

pressure
It

should
remam
between
256
and
341
Ib
m
2

018
to
0
24

kg
cm2
Pressure
below
thelower

lImIt
mdlcates
extreme
wear
on
one

part
or

gen

eral

wear
on
several

pump
parts
Pressure
above

the

upper
hrmt
indIcates

an

excessIvely
strong

diaphragm

spnng
or
a

dIaphragm
that
is
too

tIght
Both
condItIons

require
the

removal
of
the

fuel

pump
for

necessary
repaIr
or

replacement

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

FUEL
SYSTEM
71

Dash
Pot

Adjustment

The

adjustment
of
the
dash

pot
IS
done

by

warmmg
up
the

engme
properly
and

checkIng
If

the
throttle
lever
touches
th
dash

pot
stem
as

the

engine
reaches
1
800
and
2
000

rpm
under

no
load
conditIons

Proper
contact
between
the

throttle
lever
and
the
dash

pot
stem

produces
a

normal
dash

pot
performance
Should
a
normal

mcrease
m

engme
speed
not
occur

adjust
the

dash

pot
as
follows

1
Loosen
the
dash

pot
locknuts

2
Rotate
the
dash

pot
nght
and
then
left

3

Adjust
the
dash

pot
so
that
the
throttle
lever

hIts
the
stem
between
1
800
and
2
000

rpm

4
Fasten
the
lock
nuts

securely

5
The
clearance
between
the
throttle
valve
and

the
throttle
chamber
wall
should
be
0
0709
m

0
8mm

or
10

degrees
In
throttle
valve

angle

MAJOR
CARBURETOR

SERVICE
PROCEDURES

A
carburetor
m

good
operatIng
condition
will

delIver
the

pr
per
gasolme
and
aIr
ratIos
for
all

engme
runnmg
speeds
A

gradual
declme
In

smoothness

response
and

power
Will
occur
as

the
carburetor

slIps
from

adjustment
and
Its
delI

cate

parts
become

dirty
and
worn
Overhaul

should

only
be

attempted
by
an

expenenced

mechanic

Accurate
calIbratIon
of

passages
and
dIS

charge
hole

reqUIre
that

extreme
care
be
taken

In

dISassembly
cleanmg
and

reassembly
Use

only
a

hIgh
grade
carburetor
cleaner
and
com

pressed
arr
to
clean

parts
and

passages
Never

use
wire
or
other

pOInted
Instruments
for
clean

ing
CalIbratIon
of
the
carburetor
will
be
af

fected
The

procedures
below
are

generally
true

for
all
models
As
an
aId

Figures
13
and
14
are

typIcal
examples
of
the
carburetors
used

Carburetor
Removal

1
Remove
the
au
cleaner

by
dIsconnectIng
all

hoses
attached
to
It

remoVmg
the
two
bolts

holdmg
the

aIr
cleaner
to
the

support
and

loos

enmg
the
band
bolt
at
the
base
of
the
aIr
cleaner

2
DIsconnect
fuellme
vacuum
Ime
and
choke

wire
u

eqUIpped
from
the
carburetor
3
Remove
the
throttle
lever

4
Remove
four
nuts
and
washers

holdmg
car

buretor
to
manIfold

5
Lift
carburetor
off
of
manuold

6
Remove
and
dIscard
carburetor
to
manuold

gasket

7
Place
carburetor
on
clean
workbench

Carburetor

Disassembly

1
The
maIn

Jets
slow

Jets
and
needle
valves
on

both
the

pnmary
and

secondary
systenIS
are

accessIble
from
outsIde
the
carburetor
Refer
to

FIgures
13
and
14
for
locatI
n

2
The
choke
chamber
can
be
detached

by
re

mOVIng
the

connectIng
rod

pump
connectIng

rod
return

sprmg
stop
pm
and
the

set
screws

I

that
hold

It
in

place

3
The

pnmary
and

secondary
emulSIon
tubes

can
be
disassembled

by
remOVIng
the
mam
air

bleeds

on
the

respectIve
SIdes

4

To
check
the
accelerator

pump
remove
the

cylInder
cover
Be
careful
not
to
lose
the

return

spnng
and
Inlet
valve
at
the
lower

part
of
the

pIston
durmg
dIsassembly

5
Detach
the
throttle
chamber
from
the
float

chamber

by
remOVIng
the
rod

lInkIng
the
dia

phragm
WIth
the

secondary
throttle
valve
and

the
four
screws
that
hold
It
However
It
IS

preferable
to
leave
the
throttle
valve
mtact
unless

absolutely
reqUired
If

It
IS

necessary
to
dlS

assemble
the
valve
It
should
be
Installed
so
that

the

secondary
throttle
valve
will
be

gap
free

OtherwIse
stable
Idle
and

good
slow

speed

performance
will
suffer

is
To
check
the
float
the
float
chamber
cover

must
be
removed

I

7
The

dIaphragm
IS
dIsassembled

by
removing

the
set
screws

holdmg
the

dIaphragm
chamber

cover
In

reassemblIng
the

diaphragm
be
careful

not
to
turn
the

edge
of
the

dIaphragm
up

8
In

dlsassemblmg
and

reassembling
the
mter

lockIng
lInks
take
care
so
that
each

lInkage
has

a
smooth
actIon
and
that

parts
are
not
forced

mto

pOSItIon

9
For
vehIcles

equipped
With
an
automatIc

choke
remove
the
brmetal

case

by
releasmg
the

set
screws
The
bimetal

1l
extremely
senSItIve

76
CHAPTER
SEVEN

Carburetor

Assembly

Assembly
is
the
reverse
of

dISassembly
Make

certam
all

gaskets
are
mounted
flat

Be
careful

not
to
use
force
In

assembly
Make
certam
that

all
Interlock
lInks

operate
smoothly

FUEL
TANK

Description

FIgures
15
16
17
and
18
are

exploded
views

of
the
fuel
tanks
used
on
the
sedan
and

wagons

Figure
15
IS
for
sedans

through
model

year
1969

Figure
16

applIes
to
sedans
from
1970
With

evaporative
control

system
F

q
nre
17
shows
the

statIon

wagon
through
1969

Figure
18

applIes

to
the

statIon

wagon
WIth

evaporative
control

system
f

m
1970
The
fuel
tank
for
the

pIck
up

is
shown
m

Figure
19

A
fuel
return

system
from
the
carburetor
to

the
fuel
tank

keeps
fuel
from

becommg
over

heated
m
the
carburetor
float
chamber
When

the
normal
level
m
the
float
chamber

IS
exceeded

a

pressure
valve

opens
and
returns
the
excess

fuel

to
the
tank

Removal
Sedans

1
Remove
drain

plug
m
bottom
of
fuel
tank
and

drain
the
fuel
into
a

suitable
safe
contamer

2
Detach
rear
seat
and
seat
back
See

Figure
20

3

Open
trunk
lId
and
remove
the
trunk
finISh

mg
board
4
DIsconnect
wire

leadmg
to
fuel

gauge
umt

5
DIsconnect
and
remove
the
fuel
inlet
tube

See

Figure
21

6
DIsconnect
rubber
tubes
of
fuel
outlet
and

fuel

return
lInes
from
the
tank

7
Remove
four

fixmg
bolts
and
lock
washers

from

edge
of
fuel
tank

8
Remove
fuel
tank
from
vehicle

Removal

Wagon

1
Remove
draIn

plug
from
bottom
of
fuel
tank

and
dram
the
fuel
mto

swtable
safe
contatner

2
Disconnect
WIre

leadIng
to
fuel

gauge
unit

3
Disconnect
and
remove
fuel
mlet
tube

4
DISconnect
rubber
tubes
of
fuel
outlet
and

fuel
return
lInes

5
Refer
to

Figure
22
Remove
four

fixing
bolts

holdmg
tank
in

place

6
Remove
fuel
tank
from
veh1c1e

COOLING
SYSTEM
8S

and

In
those
with
exhaust
and

evaporatIve
emIS

sion
control
devIces
a
fan
clutch
IS
combIned

WIth
the
thermostat
to
detect

temperature
m
the

engme
compartlnent
When
the

temperature

nses
the
thermostat
detects
the

change
an
the

fan
clutch

engages
thereby
helpmg
to
cool
the

engme

WATER
PUMP

Figure
2

page
86
IS
an

exploded
drawmg
of

the
water

pump
and
fan

assembly
for
1970
to

1971
The

top
half
of
the
IllustratIon

applIes
to

those
models
WIth
exhaust
and

evaporatIve

emiSSIOn
control

systems
The
bottom
half
covers

models
WIth
a
crankcase

emiSSIon
control
deVIce

only

Figure
3

page
87

IS
an

exploded
drawmg
of

the
water

pump
and
fan

assembly
for
1968

models
Without
exhaust

or

evaporatIve
controls

Figure
4

page
88
shows
the
1968
model
With

emISSIon
control
deVIce
As

can
be
seen
from
the

illustratIons
most
dIfferences
eXISt
withIn
the

fan
clutch

assembly

Water

Pump
Removal

1
Remove

upper
and

lower
radIator
hoses
from

the
thermostat

housmg
and

cylmder
block
re

spectIvely
Dram
coolant
from
rad1ator
and

cylInder
block

2
Loosen
the
alternator

mountlng
bolt
and
the

adjustIng
bolt
on
the
alternator

mountIng

bracket

3
Move
the
alternator
toward
the

cylinder

block
untIl
slack
IS
eVIdent
10

the
fan
belt
Re

move
fa
belt
fro
alternator
water

pump
and

crankshaft

pulley

4
It
IS
difficult
to
remove
the
water

pump
from

the
front

housmg
With
the
radiator
and

top

shroud
10

place
so
remove
them

5
Remove
the
bolts

holdmg
the
fan

assembly

to
the
water

pump
and
remove
the
fan

assembly

6
Remove
the
bolts

holdmg
the
water

pump
to

the
front

housmg
as
shown
In

Figure
S

Water

Pump
Disassembly
Repair
and

Assembly

Disassembly
or

attempted
repaIr
of
the
water

pump
assembly
IS
not
recommended
If
the

pump
assembly
IS
corroded
the

vanes
are
dam
aged
or
the

bearmgs
are

nOISY

replace
the

entIre
umt

1

Inspect
the
water

pump
assembly
and

replace

If

reqUIred

2

If
the
water

pump
assembly
IS
stIll
serVIce

able
clean
It

thoroughly
before
mstallatIon

3
Assemble
the
water

pump
assembly
m
the

front
cover
10
the
reverse
order
for

disassembly

Do
not
reuse
old

gaskets

4

Replace
the
fan

assembly
on
the

water

pump

and
mstall
the
radiator
and

top
shroud

5

Inspect
the

fan
belt

carefully
for

SIgnS
of

wear

or
cracks
DIscard

It
If
10
doubt

6
Install
the
fan
belt
around
the
crankshaft

pulley
water

pump
pulley
and
the
alternator

pulley

7

Adjust
the
alternator
on
Its
bracket

so
there

IS
no
more
than
0
5
10

deflection
of
the
fan

belt
when

pushed
10

by
thumb

pressure

8

TIghten
alternator
bracket

adjustIng
bolt
and

alternator

mountmg
bolt

securely

9
Install
the

upper
and
lower
rad1ator
hoses

and

tIghten
securely

10
Refill
the
radIator
and

coolmg
system
With

approved
coolant

or
water

NOTE
Because

of
the

many
aluml

num

parts
In
the

engine
a

hIgh
qualIty

antI

freeze

compound
should
be
used

In
the

cooling
system

11
Start
the

engme
and
run
untIl

operatIng

temperature
IS
reached
or
untIl

you
re
sure
the

thermostat
has

opened
and
coolant
IS

CIrCulatIng

throughout
the
entIre

coolIng
system
Top
up

radIator
as

reqUIred

J

188

CHAPTER
FOURTEEN

Brake
Pedal
Installation

1

Apply
pedal
grease
to
the

pedal
shaft
sleeves

and

push
rod
cleVIS

pm

2
Installation
is
the

reverse
of

removal

3

Torque
the
fulcrum

pm
to

25
3
to

28
9
ft
lb

3
5
to

4
0

kg
m

MASTER
CYLINDER

FIgure
3
is

an

exploded
view
of
the
tandem

master

cyhnder
used
on
the
sedan
and

wagon

starting
m
1969
Earher
models
are
sinnlar

Figure
4
IS
an

exploded
View
of
the
master

cyhn

der
used
on
the

pIck
up

Master

Cylinder
Removal

1
Remove
reservOIr

cap
and
drain
brake
f1wd

2
DISconnect
brake

pedal
return

spring

3
Disconnect
brake
tube
from
master

cyhnder

4
Remove
two
bolts

holdmg
master

cyhnder
to

front
dash

assembly

5
Remove
master

cylinder

Master

Cylinder
Disassembly

1
Remove

dust
cover
and

piston
stopper
screw

2
Remove

snap
nng
and

stopper
ring
then

pllShrod
3
Remove
the

piston
and
related

parts
from

cyhnderbody

4
Remove

valve

cap
gasket
check
valve
and

check
valve

spring

NOTE
DISassemble
master

cylmder

carefully
Don
t

damage
the

slldmg

surfaces

of
pISton
and

pISton

cup
Do

not
remove

flUId
reservOlT

unless
ab

solutely
necessary
Remove

pISton
cup

only
If

pISton
must
be

replaced

r

Master

Cylinder
Inspection
nnd

Repair

1
Clean

all

parts
thoroughly
with
clean
brake

fiwd

2
Check

cyhnder
and

piston
for
abnormal
side

wear
and

damage
Replace
as

reqUIred

3
Check
all

spnngs
for
weakness
and

damage

Reparr
as

reqUIred

4
As
a
matter
of
sound

practIce
replace
all

cups
and
valves
whenever
the
master

cyhnder
is

dISassembled

DefinItely
replace
them
1f

they
are

deformed
due
to

swellmg
wear
and

age

5

Inspect
all
other

parts
Replace

any
that

are

defective

CD
1
Valve

cap

2
Valve
cap

gasket

3
Check
valve

4
Check
valve

spnng

5
011

reservoIr

cap

6
Reservoir

7
ReservOir
band

8

Paclang

9

Stopper
bolt

10

PIston
return

spnng
11

Sprmg
seat

12

Spnng

13
Valve

14
PIston

15

Pnmary
pIston
cup

16

Secondary
piston

cup

17

Stopper
nng

18

Snap
nng

19
Rubber
boot

20
Push
rod