1968 DATSUN 510 automatic transmission

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

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

4

CHAPTER
ONE

chassIs

number
Write
the
numbers
down
and

carry
them
ill

your
wallet

Service
Hints

Throughout
thIs

manual
keep
two
conven

bons

ill
mmd
Front
refers
to
the
front
of
the

vehicle
The
left
and

nght
sides
of
the

ve

hicle
refer
to
a

person
sittIng
ill
the

car

facing

forward
For

example
the

steenng
wheelIS

on

the
left
hand
Side
All
dimensIOns
and

capacities

are
expressed

ill
units
fanuhar

to
a
Umted

States

mechaniC
such
as
illches
and

pounds
Metric

measurements

are
also

given
Metnc

tools
are

reqUITed
to
work

on
the
Datsun
CD

DATSUN

IENGINE
CAPACITY

IMAX
HP
RPM

IWHEELBASE

IENGINE
NUMBER

FAR
NO

NlSSAN

MOTOR

co
LTD

YOKOHAMA
JAPAN
TYPEI
510

1595
cc

961P
6600

rpm

mm

L

1
00988

P61
l
O
1
l
M

Table
1
MAIN
SPECIFICATIONS

AND
DIMENSIONS

r
ITEM
Sedan

Wagon
Plm

up

EnglDe
Type
L16

L16
L16

Valve

Arrangement
Overhead

Cam
Overhead
Cam
Overhead
Cam

Bore
3
26n
ID
83mm

3
2677
ID
83mm
3
2677
ID
83mm

Stroke
2902
ID

73
7mm
2
902
ID

73
7mm
2
902
In

73
7mm

Displacement
97
3
cu
ID

l595cc
97
3
cu
In

l595cc
97
3
cu
ID
1595cc

CompressIOn
Ratio
851

851
851

MaXimum
SAE

Hompower
96

@
5

600

rpm
96

@
5
600

rpm
96

@
5
600

rpm

MaXimum
SAE

Torque
998ft
Ib
138

kg
m
998ft
Ib
138

kg
m

9911
ft
Ib
138

kg
m

Fuel
Octane
85

85
85

Lengtb
1622
ID

4
12Omm
163
2
ID
4
I45mm
168
9
ID
4
290mm

Width

61
4
ID

l
560mm
61
4
ID
1
560mm
62
8
In

Cl
595mm

Height
55
lID
1
400mm
565
ID

Cl
435mm
60
8
ID

Cl
545mm

Wheelbase

95
3
ID

2
42Omm

95
3
ID

2
420mm
99
6
In

2
530mm

Room

Space

Inner

Length
63
3
In
1
61Omm
673
ID

1
710mm
72
8
ID

1
850mm

Inner
Width

499
ID
1
27Omm

507
ID

1
29Omm
563
In

1
430mm

Inner

Height
44
4
In
1
130mm

44
61D
1
135mm
15
7
ID

399mm

Tread

Front

50
4
ID

28Omm
502
In
1
275mm
492
In
1
250mm

Rear
504
In

1
280mm
496
In

Cl
260mm
499
ID
1
267mm

Road

Clearance
741n

l88mm
64
ID
l63mm
787
ID
200mm

Weight

4

Speed
2
0611b
935

kg
2
138
Ib

970

kg
2
127
Ib
965

kg

Automatic

2
114Ib
959

kg
2
182
Ib
990

kg

Minimum

Turning
RadiUS
157ft
48m

157ft
48m
171
ft
52m

Seating

Capaaty
5

5
2

Battery

Volt

12

12
12

Capacity
400rSOAH

400r50AH
40
or
60
AH

Connection

Negative
ground
Negative
ground
Negative
ground

Fuel

Tank

Capaaty
11

9

gal
45
liter
11
9

gal
45
liter
108

gal

41J
r

011

Pan

Capacity
42

qts
40

liter
4
2

qb
40
liter

1
06

gal
40
Iller

011
Filter

Capaaty
74

ql
07
liter
74

ql
0
7
liter
1
48

Pint
0
7
liter

Transmission

Capaaty
1
8

ql
1
7
liter

18

ql
1
7
Iller
2
11

qt
20
Iller

Dlflerenbal

Capaaty
85

ql
80
liter
11

ql
1
0
liter
87

ql
0
83
lIter

Coolant

Capaaty
7
2

ql
6
8
liter
7
2

ql
6
8
lIter
7
2

qt
6
8
Iller

Clutch

Type

Dry
Single
diSC

Dry
slDgle
diSC

Dry
slDgle
diSC

Draphragm
spnng
Diaphragm

spnng
Diaphragm

spnng
l

GENERAL
INFORMATION
5

Table
1
MAIN

SPECIFICATIONS
AND
DIMENSIONS
continued

Suspension
Rear
Sedan
Wagon
Pick

up

Manual
Automatic
Manual
Automatic
Manual

HypoJd
Hypoid
Hypold

ReCIrculating
ball
ReCIrculating
ball
ReCirculating
ball

DIsc
DIsc
Drum

Drum
Drum
Drum

Mechanical
rear
wheels
Mechanical
rear
wheels
Mechanical
rear
wheels

Independent
strut

type
Independent
strut

type
Independent
torsion
bar

with
tension
rods
and
with
tension
rods
and

stabilizer
stabilIZer

Independent
semi

trailing
Semi

elliptiC
leaf

spring
Semi

elliptic
leaf

spnng

arms
wrtII
coli

springs
and

shock
absorbers

5
6O
13
4PR
5
6O
13
4PR
600
14
6PRLT
ITEM

Transmission

Type

Final
Gear

Type

Steering
Gear

Type

Brake

Front

Rear

Parking
Brake

Suspension
Front

Tires

6
2
Q
1
C
S

PA
l
PlLlU

EN
4
1
AJ
E

Dt7
A

1
1
1

2
A
ru
r
f
f
A

I
III

r
c

o
I
pP
D

LA
I
tV
r
IL

c

W

L
L
l
G

ftiv
TJ

dE
IJ
S
prlc
I

u

F
l
e

p
f
vi
Ii

ftl
1
3

l

1t
J
p7
5

PrlV

B4dc
u
11
1

S
t
f
PT

f
L
UJ
ff
zr
F

T
ff

lfo

1oo

4

t

M

0

IY
AJ
to
BTOL

@
OD

2

lP

S

PAtl
pI
c

5
IN
G

ex
Sf

0103
I
D
0
3
O

j

oo

0
0
0
to

l
c

o

0
0

2
JP
t
UE

SEIT
A

C
1

J

P

r
OVll

t
ate

I
l
h
l
JlA

ye
I
o

ctg
fI

O
0

I
d

1e
d
c

Ji
uo
JJ

cb
c
s
rlr
I

l
4

c
1
2

24

CHAPTER
FOUR

block

and
should
be
used
as
the
reference

point

m

II
1akmg

adjustments

6
With
a

piece
of
white
chalk
mark

a
hne
down

the
center
of
the

pomter
and
mark
the

timing

groove
on
the
crankshaft

pulley
which

IS
to
be

used
m

tImmg
the

engine
SpecIficatIon
for
tun

ing
reqUIres
trlhmg
at
10

degrees
before

top

dead
center
wluch
would
be
the

fourth
mark

from
the
left
end
of
the

row
of
marks

7
Loosen
the
hold
down
bolt
at
the
base
of
the

dlstnbutor

8
Locate
the
slow

speed
1
Ile

adjustIng
screw
on

the
carburetor

so
that
Ile

speed
can
be

adjusted

whIle

runnmg
Also
locate
throttle

adJustmg

screw

9
Start

engme
and

adjust
speed
With
the

adJust

ing
screws
to
the

readmgs
below

Smgle
pomt
dIStributor
600

rpm

Dual

pomt
trlbutor
700

rpm

10
Alternate

adjustment
of
the
two
screws

untIl
the
smoothest
Idle
at
the

proper
speed
IS

achieved

11
Pomt
the

tlIrung
lIght
at
the

stationary

pomter
When
the

lIght
flashes
the

timmg
mark

n
the
crankshaft

pulley
should

hne

up
With
the

mark
on
the

stationary
pomter
If
It
does
not

exactly
Ime

up
rotate

the
dlstnbutor

gradually

untIl
the
marks

align
mdlcatlng
correct

timmg

12
Shut
off
the

engme
remove
the

tmung
lIght

and
tachometer

tighten
the
hold
down
bolt
on

the
dlStnbutor
and
connect
the
vacuum
advance

hne
to
the
tli
tnbutor

IGNITION
TIMING

IDLE

SPEED
IDLE

MIXTURE

DUAL
POINT
DISTRIBUTOR

ONLY

The

followmg
applies
to
velucles
With
dual

pomt
distributor
and
an
exhaust
emission
con

trol
deVice
If
these

procedures
are
followed

ha
ul
exhaust

emisSion
should
be
below
the

maximum
allowable
level

1
Locate
the
Idle

and
throttle

adJustmg
screws

on
the
carburetor

2
Warm

up
the

engine
thoroughly

3
Connect

tachometer
and

tmung
light

4
Set
the

Id
le
speed
at
700

rpm
With
the
Idle

adjust
screw
5

Adjust

IgnltJ
on

tuning
at
10

degrees
before

top
dead

center

6
Increase
the

speed
of
the

engme
to
2
000

rpm

With
the
accelerator

or
throttle

hnkage
and
hold

for
about

15
seconds

7
Return
to
Idle
for
one
mmute

8
Set
the

engme
to
best
Idle
at
750

rpm
770

rpm
for
automatJ
c
transIDlsslOn
With
the
Idle

and
throttle

adJustmg
screws

9
Re

uce

engme
speed
at
700

rpm
720

rpm

for

automatic
transmission

by
turnmg
the
Idle

adJustmg
screw
clockWise
for
a
leaner
IlliXture

10
Connect
a
wife
lead
between
the
advance

ami
retard
Side
tenrunals
See

Figure
4

Speed

should

drop
from
100
to
150

rpm

11
Check

IgIl1tIon
tmung
With

tImmg
light
It

should
now
be
at

top
d
ad
center

12
If
the

tlmmg
IS

nSJt
correct

stop
the

engme

and

adjust
the
retarded
breaker

pomt

13
Start
the

engme
and
reclieck
ili

tmung
If

l

incorrect
reset
the
retarded
breaker

pomt
until

it
IS
correct

Repeat
s
nece

s

14
Disconnect
the
wife

bet
reen
the
advance

and
retard
termmals

15
Recheck

tmung
It
should

be
10

degrees

before

top
dead

center

16
If
mcorrect

repeat
the
above

procedures

un
tIl

satIsfactory

17

T
he
Idle

speed
of
automatic
transnllsslOn

vehicles
should

be
about
575

rpm
With
the

gear

j

selector

m
the

dhve

poSltlon
c

t

DWELL
ANGLE
SETIING

1
Connect

the
dwell

angle
meter

2

PLoJust
dwell

angle
to
49

to
55

degrees

OMPRESSION
TEST

I

A

compressIOn
test
IS

performed
to
check
for

worn

piston
nngs
or
to
detect
the

cause
of

a

low

speed
miss
Before

undertaking
the

test

el
llmate
the

pOSSibility
of

sticky
valves

by
usmg

one
of
the

oil
additives

deSigned
for
the

purpose

With
valves
free
test

compressIOn
as

follows

1
Run
the

engme
for
15
to
20
mmutes
untIl

normal

operating

temperatures
are
obtained

2
Shut
off

engme
remove
arr
cleaner
and

I
Piston
with
pin

2
Piston
nng
set

3
Piston
nng
set

4
Connecting
rod

5
Connecting
rod
bolt

6
Connecting
rod
nut

7
Connecting
rod
bushing

8
Crankshaft

9
011
gallery
plug

10
Bushing

11
Woodruff
key

12
Crank
gear

13
011
pump
gear

14
OJlthrower

15
Pulley
washer

16
Crank
pulley
bolt

17
Crank
pulley
shaft

18
Crank
bushing
set

19
Flywheel
assembly

20
Flywheel
nng
gear

21
Flywheel
to
clutch
dowel

22
Flywheel
bolt
4

23
Converter
pilot

24
Dnve
plate

25
Crankshaft
plate

26
Dnve
plate
bolt
13
I

14

17

15
2
3

l
L
4
8
9
6
19
1
J
21

2
24
8
ICD
I

For
automatic
transmission
W

lit

ENGINE

37

CD

4

11lL

8

311
@
2S

10

32
@
@
24

33
Q
23

1
21

rl
qp

12
26

27

19
34

30

31
1
25

@
24

W
32
@

30

33
0

21

28
tJ

2S
ctJ5J

27

20

II

27

Inner
valve
seat

spnng

1
Camshaft

10
Camshaft
cham
19
Intake
valve

28
Valve
011
seal

2
Camshaft
dowel

11
Chain
tensloner
20
Exhaut
valve

29
Valve
rocker

4
Cam

locating
plate
12
Hex
bolt
21
Valve

spnng
30
Valve
rocker
WIth

pad

5

Spnng
washer

13

Spnng
washer
22
Valve

spnng
31
Valve
rocker

Pivot

6
Hex
bolt

14
Chain
tension
Side

gUide
23
Valve

retamer
32
Pivot
ICICk

nul

7
Cam
sprocket
15
Chain
tension
slack

gUide
24
Valve
collet

33
Rocker

retainer

8
Cam

gear
bolt
16

Spnng
washer
25
Rocker

valve
guide
34
Rocker

valve

spnng

9
Fuel

pump
earn

assembly
17
Hex
bolt
26

Valve
seat
35

Rocker

bushing

vious

chapter
for

specmcaoons
and
mamten

ance
CARBURETOR

The
carburetor

IS
a

smgle
two
barrel
down

draft

type
From
1968

through
1971
the
car

buretor

on
manual
transmissIOn
models

has
a

hand
choke

control
1972
models
are

eqUIpped

With
an
automatic
choke
much
the

same
as
has

been

used
on
all

automaoc
transmISSion
models
FUEL
PUMP

The
fuel

pump
IS
on
the
front

right
hand
Side

of
the

engme
Just
below
the
rocker
arm
cover

It

IS
a

diaphragm
type
dnven

by
the
camshaft

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