1968 DATSUN 510 alternator

II

CHAPTER
SIX

ENGINE

Cylmder
block

Crankshaft

PistOns
and

connectmg
rods

Cyhnder
head

Camshaft

Valve
mechamsm

Camshaft
dnve

Mamfolds

011

pump

Fuel

pump
Carburetor

Emission
control
devIces

Engme
removal

Engme
dISassembly

Pistons
and

connectmg
rods

Cyhnder
head

Engme
mspectIon
and

replllr

Engme
reassembly

Service
data
and

speCifications

CHAPTER
SEVEN

FUEL
SYSTEM

Air
cleaner

Fuel
strlllner

Fuel

pump
Carburetor

Fuel
tank

1
CHAPTER

EIGHT

COOLING

SYSTEM

DescnptIon

Water

pump

Fan
clutch
Thermostat

Radiator

CHAPTER
NINE

ENGINE

ELECTRICAL
SYSTEM

Starter

Overrunmng
clutch

assembly

ChargIng
ClrcUlt

Alternator

Alternator

output

Voltage
regulator
DIstrIbutor

Condenser

Igrntlon
cod

SpeCifications

Spark
plugs

CHAPTER

TEN

EMISSION

CONTROL

SYSTEM

Exhaust
emiSSIOn

control

Crankcase

emission
control

Air

mJectlon
system
Engme
modifications

Evaporative
emiSSion
control

Exhaust

system

CHAPTER
ELEVEN

CLUTCH

TRANSMISSION
AND
DRIVESHAFT

Clutch

TransmissIon

Master

cyhnder
TransmissIon
data
and

speCIfications

Operating
cyhnder
Dnveshaft

Withdrawal
lever

adjustment
Dnveshaft
data
and

speCIfications

Clutch

system

bleedmg
Automatic
transmIssIon
checks

Clutch
data

and

speCIfications
31

62

84

91

114

127

PERIODIC

MAINTENANCE

7

Table
1
ENGINE

LUBRICATION
AND
MAINTENANCE

FREQUENCY
EVERY

E
E
E

E

E
E

E
Eo
00
00

00
00
00

00

00

gq
00

00

00

NO

t
r61li
0

CD

Check

engine
011
level

top
up
If

required
X

Change
engine
011
X

Lubricate

carburetor

hnkage
X

Lubricate
distributor
rotor
shaft
and
ann
shaft
X

Apply
grease
to
distributor
cam
heel
X

Check

radiator
coolant
level
X

Change
radIator
coolant
X

Change
radiator
coolant
additive

X

Check

battery

electrolyte
level
X

Check

specific
gravity
of

battery
X

Check

engine
starting
exhaust
color
X

Tighten

cyhnder
head

manifolds
and

pipe
flanges
X

Adjust
valve
clearance

X

Check

Ignition
timing
X

Tighten
carburetor

fittings
X

Check
fan
belt
tension
X

Check
for
011

pan
leakage
X

Tighten
engine
mounts
X

Check
fuel
strainer
X

Replace
fuel
strainer
X

Check
for
fuel
leaks
X

Replace
011
filter
X

Check

spark
plugs
X

Replace
spark
plugs
X

Check
dlstnbutor

cap
rotor
and

POints
X

Adjust
engine
Idle

speed
X

Check

air
cleaner

fittings
X

Clean
011
filler

cap
X

Clean

battery
cables
and
terminals

X

Check
alternator
and

voltage
regulator
function

X

Check

starter
motor
function

X

Replace
aIr
cleaner
element

X

Check
fuel

pump
function

X

Check

cyhnder

compressIon
X

Clean
carburetor

Jets
and
float
chamber

X

Check
dlstnbutor
condenser

X

Check
crankcase
ventilation
control
valve
X

12
CHAPTER
THREE

13
IMPROPER
IDLE

MIXTURE

Roats

slowly
between

13
17
14
SMALl
SPARK

GAP
or
DEFECTIVE

POINTS

Slight
float
between

14
16

ignItIOn
switch
If
the
starter
still
fails
to
crank

properly
remove
the
starter
and
test
it

2
Starter
turns
but
does
not

engage
with

engine

This
trouble
is

usually
a
defective

pInion
or
sole

noid

shlfting
fork

It

may
also
be
that
the
teeth

on
the

pInion
flywheel
ring
gear
or
both
are

worn
down
too
far
to

engage

properly

3
Starter

engages
but
will
not

dISengage
when

IgmtlOn
switch
IS
released

TIns
trouble
is

usually
caused

by
a

sticking
sole

nOid
but

occasionally
the

pmlOn
can

jam
on
the

flywheel
With
manual
transmissions
the

pinion

can
be

temporanly
freed

by
rockmg
the
car
in

high

gear
Naturally
this
IS
not

poSSible
in
auto

matics
the
starter
must
be
removed

4
Loud

grinding
noISes
when
starter
runs

TIns

usually
means
the
teeth
on
the

pinion

and
or

flywheel
are
not

meshing
properly
It

may
also
mean
the
over

running
clutch
IS
broken

In
the
first
case
remove
the
starter
and

examine

the

gear
teeth
In
the
latter
remove
the
starter

and

replace
the

pmion
dnve

assembly

CHARGING
SYSTEM

Charging
system
troubles

may
be
in
the
alter

nator

voltage
regulator
or
fan
belt
The
follow

ing
symptoms
are

typical

1
Alternator

warning

lamp
does
not
come
on

when

IgmtlOn
is

turned
on

This

may
indicate
a
defective

ignition
switch

battery
voltage

regulator
or

lamp
Frrst

try
to
15
HEAD
GASKET

LEAK

Roats
between
5
19
16
RESTRICTm

EXHAUST
SYSTEM

Normal
when
first

started

Drops
to
0
as

rpm
Increases

May

eventually
rrse
to

about
16

start
the
car
If
it
doesn
t
start
check

the

igllltlon

sWitch
and

battery

If
the
car
starts
find
the

voltage
regulator
and

disconnect
the
wlute
red
Wire
this
is
the

lamp

wire
Ground
the

wire
If
the

lamp
hghts
the

voltage
regulator
is
defective
not

properly

grounded
try
tightening
the

mounting
screws

or
the
alternator
brushes
are
not

contactmg
the

commutator
If
the

lamp
does
not

light
when
the

wire
IS

grounded
the

lamp
is

probably
burned

out

replace
It

2
Alternator

warning
lamp
comes
on
and

stays
on

This

usually
mdicates
that
no

chargmg
is

takmg

place
Frrst
check
the
fan
belt

tension
and

adlust

if

necessary
Check
the

battery
condition
with

the

hydrometer
and
check
all
electrical
connec

tions
m
the

chargmg
system
Fmally
isolate
the

trouble
to
the
alternator
or

voltage
regulator

3
Alternator

warmng

lamp
flashes
erratically

This

usually
indicates
the

chargmg
system
is

workmg
intermittently
Check
the
fan
belt
ten

sion
and
all
electncal
connections
m
the

charg

ing
system
Check
alternator
brushes
and
cODlh

tlon
of
the
commutator

4

Baltery
reqUires
frequent
additiOns

of
water

or

lamps
require
frequent

replacement

The
alternator
IS

probably
overchargmg
the
bat

tery
The

voltage
regulator
is

probably
faulty

check
it

using
the

procedures
given
in

Chaper

Nme

5
ExceSSive

noISe

from
he
alternator

Check
for
loose
alternator

mountmg
The

TROUBLESHOOTING
13

trouble

may
also
be
worn

bearings
Remove
the

alternator
and

repair

ENGINE

These

procedures
assume
the
starter
cranks

the

engme
over

normally
If
not
refer
to
Starter

section
m
this

chapter

1

Engme
won
t
start

Could
be

caused

by
the

IgOltlon
or
fuel

problems

First
determine
If

high
voltage
to

spark
plug

occurs
To
do
thiS
dISconnect
one
of
the

spark

plug
wires
Hold
the

exposed
wrre
termlOal
y
to

Y2
lOch
from

ground
any
metal
in

engine
com

partment
With
an
msulated
screwdriver
Crank

the

engme
over
If

sparks
do
not

Jump
to

ground

or
the

sparks
are

very
weak
the
trouble

may
be

10
the

IgnitIOn
system
See

Ignition
System
Trou

bleshootmg
to
further
check
If

sparks
occur

properly
the
trouble

may
be
10
the
fuel

system

See
Fuel

System
Troubleshootmg

2

Engme
misses

steadily

Remove
one

spark
plug
wrre
at
a
tune
and

ground
the
wrre
If

engme
mISs
increases
that

cyhnder
was
work

109
properly
Reconnect
the

wire
and
check
the
others
When
a
wire

IS
dIs

connected
and

engme
miss
remams
the
same

that

cylinder
IS
not

finng

Check

spark
as
descnbed
10

Step
1
If
no

spark

occurs
for
one

cyhnder
only
check
dlStnbutor

cap
wrre
and

spark
plug
If

spark
occurs

prop

erly
check

compressIOn
and
mtake
maOlfold

vacuum
to
ISolate
the
trouble

3

Engme
misses

erratlcally
at
all

speeds

Interrmttent
trouble
can
be
difficult
to
find
It

could
be
ill
the

Ignition
system
exhaust

system

or
fuel

system
Follow

troubleshooting
proce

dures
for
these

systems
carefully
to
isolate
the

trouble

4

Engme
misses

at
Idle

only

Trouble
could
exist

anywhere
ill

IgOltlon
system

Follow

Ignition
TroubleshootlOg
procedure
care

fully
Trouble
could
also
eXist
10
the
carburetor

Idle
crrcult
Check
Idle
mIXture

adjustment
and

check
for
restnctions
m
the
idle
crrcUlt

5

Engme
misses
at

high
speed
only

Problems
could
be
ill
the
fuel
or

IgOltlon
systems
heck
accelerator

pump
operation
fuel

pump

dehvery
fuel
hnes
etc
as
descnbed
under
Fuel

System
Troubleshootillg
Also
check

spark
plugs

and
wrres

6
Low

performance
at
all

speeds
poor

acceleratIOn

Trouble

usually
ill

IgOltlon
or
fuel

system
Check

each
With
the

appropnate
troubleshooting
pro

cedure

7
ExceSSive

fuel
consumptIOn

Could
be
caused

by
a

Wide

variety
of

seemmgly

unrelated
factors
Check
for
clutch

shppage

brake

drag
defective
wheel

beanngs
or

poor

front
end

alignment
Check

IgOltlOn
system
and

fuel

system

8
011

pressure
lamp
does
not

light
when

IgmtlOn

switch

IS
on

Check
the
alternator

warning
lamp
If
it
ISn
t
on

either

go
to

Step
1

Chargmg
System
Trouble

shootlOg
If

only
the
oil

pressure
lamp
IS
off

open

the

englOe
compartment
hd
and
locate
the
oil

pressure
sender
on
the
block
near
the
oil
filter

Make
sure
the
wrre
is
connected
to
the
sender

and

makmg
good
contact
Pull
the
wrre
off
and

ground
it
If
the

lamp
hghts
replace
the
sender

If
the

lamp
does
not

light
replace
the

lamp

9
011

pressure
lamp
lights
or

flickers
when

engme
IS

runmng

Indicates
low

or

complete
loss
of
oil

pressure

Stop
the

englOe
unmedmtely
coast
to
a

stop
With

the
clutch

dISengaged
Tlus

may

simply
be

caused

by
a
low
oil
level
or
an

overheatmg
en

glOe
Check
the
oil
level
and
fan
belt
tensIOn

Check
for
a
shorted
oil

pressure
sender
with
an

ohmmeter
or
a

contlOulty
tester
Remove
and

clean
the
oil

dipstick
and
check
oil
level
and

condition

RepleOlsh
or

replace
the
oil

as
re

qurred
Listen
for
unusual
nOISes

mdlcatmg
dam

aged
beanngs
etc
Do
not
re
start
the

engine

until

you
know

why
the

hght
went
on
and

are

sure
that
the

problem
has
been
corrected

IGNITION
SYSTEM

This

procedure
assumes
the

battery
IS
ill

good

enough
condition
to
crank
the

engme
at
a

normal
rate

26

CHAPTER

FOUR

2
Check
all
belts
hoses
and
fuellmes

Replace

If

reqUIred
Check
the
tensIon
of
the
belts
for

the
au

pump
and
the
alternator

Adjust
as
re

qUIred
Normal
deflection
of
the
belts
when
pushed
m

by
hand
should
be

approXImately
0
5

m

13mm
as
shown
m

Figure
7

3

Inspect
the
011
filter
for
leaks

TIghten
or
re

place
as

necessary
The
filter
should

replaced

at
least

every
6
000
mIles

4

Inspect
the

lIlr
cleaner

for
excessIve
accumu

latIon
of
dIrt

Replace
at

least

every
24
000
miles

under
normal

operatmg
cornhtIons

5

Carefully

mspect
the

water

pump
and

the

radIator
for

SIgnS
of

leaks

Repair
as

necessl
i
y

6
Check
the
emissIoo
control
deVice
If

so

eqwpped
Refer

to

Chapter
Ten
for

checks
and

tests

to
be
made

c

1

7
Check

engine
oIl

Replems
9
or

replace
as

reqUIred

8
Check
the

level
of
the
brake

fluid
m

the
brake

and

clutcJ1
master

cylmder
reservOirs

ReplenISh

as

necessary

ii
t

d

fl

tlJ

l

CHAPTER
SIX

ENGINE

Datsun
510
and
521
veJucles
use
the
L16

engme
Over
the

years
the

deSign
remamed

essentIally
the
same
with
nunor

changes
made

to
accommodate
drlIerent
elIDSSlon
control
de

VIces

The
Ll6
IS
a
four
cylmder

overhead
cam

shaft

engme
With
a
97
3
cubic
mch
1595cc

dISplacement
Cylmder
bore
IS
3
2677
in

83mm
stroke
IS
2
9016
m
73
7mm

Output

IS
96

horsepower
1972
mode1s
92
horse

power
at
5
600

rpm
Compression
ratIo
is
8
5

to
1

Equipment
includes
a

single
two
barrel

Hltaclu
carburetor
an
HItachi
alternator
an

HItachi
starter
motor
and
either
a

smgle
point

or
dual

pomt
distnbutor

Figure
1
next

page
IS

an
overall
view

of
the

engme
Figure
2
next

page
is
a
sectIonal
view
The

following

para

graphs
describe
and
illustrate
the

major
com

ponents
of
the

engine
and

provide
detaIled

InStructIons
on
the

removal
disassembly
inspec

tIon

reparr
and

reassembly
of
the

engine

CYLINDER
BLOCK

The

cylmder
block
is
shown
in

Figure
3A

Figure
3B

page
33
IS
an

exploded
view
of
the

block
and
associated

parts
CRANKSHAFI

The
crankshaft
F

JgUre
4A
is
made
of

forged

steel
and
has
a

high
capacity
balance

weight

Figure
4B
shows
the
crankshaft
and

pISton
as

semblies
m
an

exploded
VIew

DA

38

CHAPTER
SIX

EMISSION

CONTROL
DEVICES

All

Datsuns
have
a
sealed

type
of
crankcase

emISSion
control
device
and
an
exhaust
emISsion

control
deVice
Models
sold

m
Cahfornla

smce

1970
also
have
an

evaporative
emisSion

control

deVice
An

rmportant
part
of
the

exhaust
control

device
is
the
air

pump
located

at
the

bottom
left

hand
side
of
the

engme
It

IS
dnven

by
a
belt
off

of
the
crankshaft

pulley
and

supphes
air
to
the

exhaust

system
In
1972

an
electric
blower
in

corporated
m
the

air
cleaner

replaced
the

mechanical

pumI

ENGINE
REMOVAL

Expenence
has

shown
It
IS
easier

to
remove

the

engine
and

the
transmission

as
a

smgle
UnIt

than

to
remove
the

engme
alone
Once

the
en

gine
and

transmiSSIon
are

out
of

the
vehIcle
the

tranSmIssion
can
be

detached
from
the

engme

To
remove
the

engme
transmISsion

proceed

as
follows

1
Scribe

ahgnment
marks
on
the
hood

around

the

hmges
ThIS

will
make
remstallatlon

eaSIer

2
Remove
the

two
bolts
that
secure

each

hInge

and

remove
the
hood

It
is

not

necessary
to
re

move
the
hood

support
from

the

engme
firewall

3

DISconnect
the
lower

radIator
hose

from
the

right
hand
SIde
of
the

engine
and
at
the
bottom

of
the
radIator
ThIS
will

pernnt
coolant
to
dram

from
the

engme
and
the

radIator

4

Remove
the
draIn

plugs
from
the

engine

pan

and
translIDSsIon

and

completely
dram
lubn

cants
Into
suitable

contamers

5
DISconnect

the

battery
cables
from

the
bat

tery
loosen

the
two
hold
down

clamps
and

re

move

the

battery

NOTE

The
location
and

number

of

hoses

to
be
removed

from
the
air

cleaner
varies

from
model
to

model

It
IS

normally
easier
to
remove

the

hoses

from
the
sources
rather

than

try

to

dISconnect

them

from

yndemeath

the

air

cleaner
The
1972
model

Will

requlre
dlsconnectlOn

of
the
electrica1

cirCUit

In
the
air

cleaner

system
wing
nut
from
the

top
of
the
air
cleaner
and

remove
the

aIr
cleaner

7
DIsconnect
the

upper
radiator
hose
from
the

radiator
and
the
thermostat

housmg
Remove

the
hose

8
Disconnect
the
two
heater

hoses
from

the

nght
hand
side
of
the

engme
TIe
these
bac
so

they
won
t
interfere
with

removal
of
the

engme

9
Remove
the
radIator

grille

by
unscrewing
all

mountmg
screws

10
Remove
the
four

mounting
screws

holding

the
fan
shield
to
the
backside

of
the

radiator

11
Remove
the
four

mountmg
bolts

holdIng
the

radiator

In

place
In
automatic
tranSmISsion

models
dISconnect

the
two
transnnsslOn
oIl

cooler

lInes
from

the
bottom
of
the
radiator

Pull
the

radiator

straight
up
to
remove
Remove

the
fan

shield

12
Loosen

the

adjustment
and

mounting
bolts

from

the

retamIng
brackets
on
the
alternator

and

air

pump
If
so

eqwpped
The

alternator
is
lo

cated
at
the
bottom

nght
hand
Side
of
the

engme

and
the
air

pump
on
the

lower
left
hand
Side

13
Loosen
tenSIon

on
the

two
dnve
belts

re

move
the
belts
from

the
alternator
and
air

pump

and
then
from
the

fan

pulleys

14
Remove
the
bolts

holdIng
the
fan
and

pulley

to
the
water

pump
assembly
and
remove
the

fan
and

pulley

15

DISconnect
the
fuel
hne
from
the
fuel

pump

16
DIsco

ect
accelerator

control

linkage
and

choke

WIre
at
the
carburetor

17
Disconnect

the

wiring
from

the
starter

motor
alternator

Ignition
coIl
oIl

pressure

switch

and

temperature

transmItting
unit

NOTE
The

following

steps
are

per

formed

from
under
the
car
lack

up

the

front
of
the

car
and

position

stands
under

the

front
support

points

to

proVide

working
room

under

the

vehicle

WARNING

Never

climb
under
a
vehicle
that
is

supported
by
the

lack
only
If
stands

are

not
avflllable

sturdy
wooden

blocks
can

be
U3ed

6
Disconnect
all
hoses

that
lead
to
the

air

cleaner

remove
two

bolts
that
hold
the
air

cleaner
to

its

mountmg
bracket

unscrew
the
18
Remove
two
bolts

holdIng
the
clutch

operat

Ing
cylInder
to
the

flywheel
hOUSIng
shown

m

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