1968 DATSUN 510 brake

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

TWELVE

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
149

DIfferentIal

Rear
axle
and

suspension

Codspnng

Shock
absorber

Rear

suspensIOn
arm

Rear
axle

shaft
Wheel

beanngs

Seals

Rear

spnng

Axle
case

SpecificatIons

CHAPTER
THIRTEEN

FRONT

AXLE
FRONT
SUSPENSION
AND
STEERING
168

Wheel
hub
and

bearmg

StabilIzer

TenSion
rod

Spnng
and
strut

assembly

Transverse
lInk

Lower
ball

Jomt
Front

suspension
adjustment

Wheel

alignment

Posture

adJustment

Steenng
system

SpeCificatIons

CHAPTER
FOURTEEN

BRAKES
187

Brake

pedal

Master

cylInder

Front
diSC
brakes

Rear
brakes

Front
drum
brakes
Wheel

cylInders

Brake

system
bleedIng

Handbrake

Service
data
and

speCificatIons

CHAPTER
FIFTEEN

BODY
ELECTRICAL
SYSTEM

Wmng

SWitches
and
fuses

Instrument

meters
and

panels

Heater
205

Wmdshleld

wipers

Wmdslueld
washers

Headlamps

WIrIng
diagrams

CHAPTER

SIXTEEN

BODY

223

Front

body
trIm

Bumpers

Hood
lock
control

Doors
Door
locks
and

regulators

Trunk
lId
and

rear

bumper

Seats

Tad

gate

INDEX

235

I

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

CHAPTER
TWO

PERIODIC
MAINTENANCE

To
ensure

good
performance
dependability

and

safety
regular
penodlc
maintenance
is

necessary
TIns

chapter
outlInes
routine

and

penodlc
mamtenance
for
the

average
dnver

Under

heavy
usage
semcmg
mtervals
will
be

shortened

Regular
routme
mamtenance
will

help
aVOId

expensive
repaIrs

ROUTINE
CHECKS

The

followlDg
checks
should
be

performed
at

each
fuel

stop

1
Check

engme
oil
level

Top
up
as

requrred

2
Check
radiator
coolant
level

Top
up
as
re

qwred

3
Check

battery
electrolyte
The

battery
case

IS
marked
With

upper
hrmt
and
lower
lnmt
lInes

Level
should
be
maID
tamed

between
the
IIDes

4
Check
that
the
master

cylInder
brake
flwd

reservOir
level
IS
between
the
max
and
mm

lInes
marked
on
the

plastic
case

S

Check
the

plastic
clutch

cyhnder
reservoir

level
Level
should
be
between
the
max
and

mm
lInes

6
Check
the
windsh1eld
washer
flwd
reservoir

Top
up
as

required
7
Check
tire

pressures
when
the
tIres
are
cold

Front
and
rear
tire

pressures
should
be
24

pounds
under
normal

dnving
conditions
TIre

pressure
should
be
28

pounds
for

h1gh
speed

dnvmg
conditions

8
Check
the

engIne
for

general
conditIon

Check
for

leaky
or
cracked
hoses
and
loose

wmng

9
Check
condition
of
wmdshleld

wiper
blades

PERIODIC
CHECKS

Table

1

prOVIdes
penodIc
checks
and
main

tenance
that
should
be

performed
on
a
set

schedule
Table
2

gIves
recommended
lubncants

and
Table
3

specIfies
the

grades
of
oil
that
should

be
used
Procedures
for

performmg
the
semces

are

presented
ID
vanous

chapters
of
tlus
manual

Table
3
RECOMMENDED
GRADES
OF
OIL

Temperature
Engine
on

MS

Above
32
C
90

F
average
SAE
30
IOW
30

32
to
0
C
90

to
32

F
mlmmum
SAE
20
20W
IOW
30

O
to
12
C
32
tolO

F
mlRlmum
SAE
IOW
IOW
30

Below
12
C
10
F
mlmmum
SAE
lOW
IOW
30

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

TROUBLESHOOTING

15

5

Stumbling
when

acceleratmg
from
Idle

Check

accelerator

pump
diaphragm
and
Idle

speed
adjustment

6

Engine
mISses
at

hIgh

speed
or
lacks

power

This
mdlcates

pOSSible
fuel
starvatIon
Check

fuel

pump
pressure
and

capacIty
Clean
main

Jet

and
float
needle

valve

7
Black
exhaust
smoke

Black
exhaust
smoke
means
a

badly
ovemch

nuxture
Check
Idle

mIXture
and
Idle

speed
ad

Justment
Check
for
excessive
fuel

pump
pres

sure
or
blocked
return
hne
from
carburetor

to

fuel
tank
Check
for

leaky
float
or
worn
needle

valve

8
ExceSSIve

fuel

consumptIOn

ThIS

may
be
another
mdIcatIon
of

an
ovemch

fuel
mixture
Check
that
automatIc
choke

oper

ates

If
so

eqUIpped
or
that
the
manual
choke

contraIlS
not

being
left
out
Check
Idle
mIXture

and
Idle

speed
Check
for
excessIve
fuel

pump

pressure
leaky
float

or
worn
needle

valve
Make

certam
that

jets
are
the

proper
SIZe

Fuel

Pump
Pressure

Testing

1
Install
a
T

fittmg
m
the
fuel
hue

close
to
the

carburetor

2
Connect
a
fuel

pressure

gauge
to
the

fittmg

WIth
a
short
tube

3
Check
fuel

pump
pressure
as
described

in
the

Fuel

System
chapter

EXHAUST
EMISSION
CONTROL

The

followmg
symptoms
as
ume

you
have
ad

justed
the

Ignition
and
carburetor

to

specdicatIon

and
that

you
have
checked

the
results
on
an

accurate
exhaust

gas
anajyzer

1
CO

content
too
low

Make

sure
Idle

speed
IS
not
too
low
Check
Idle

mIXture

adjustment
too
lean
Check
carbu

retor

Jets
and

channels
Clean
and
or

replace
as

necessary
Check

engme
condition
With
a
com

pressIOn
and
vacuum
test

2
CO
content
too

hIgh

Check
Idle
mixture

adjustment
too

nch
Check

for

dIrty
air
cleaner

and
defectIve

automatIc

choke
If
so

equipped
Check
carburetor

Jets
and
channels
Clean
and
or

replace
as

necessary

Check

engme
condItIon
WIth

compression
and

vacuum
test

3

Hydrocarbon
level
too

hIgh

Check
that

Idle

speed
and
mIXture

adjustments

are

to

specIfication
Check

spark
plug
condItIon

and

gap
Check
breaker

pomts
Check

IgnItIon

tnumg
too

early
Check
mtake

mamfold
for

leaks
Check

valve
clearance
too

small
Check

condItIon

of
valves
With

compressIOn
test

MANUAL
CLUTCH

1

SlIppage

ThiS

is
most

noticeable
when

acceleratIng
m
a

hIgh
gear
at

relatIvely
slow

speed
To

check

slip

page
park
the
car
on

a
level
surface

WIth
the

handbrake

set
ShIft
to
2nd

gear
and
release
the

clutch

as
If

drlVing
off
If
the

clutch
is

good
the

engme
will
slow
and
stall
If
the

clutch

shps
con

tInued

engme
speed
will

gIve
It

away

CAUTION

ThIS
IS
a
severe

test

Perform

only

when

slippage
IS

suspected
not

penodlcally

Shppage
results
from
IDSufliclent
clutch

pedal

free

play
all
or

grease
on
the

clutch
disc

worn

pressure
plate
or
weak

sprmgs
Also
check
for

bIndIng
m
the
clutch
cable

and
lever
arm
which

may

prevent
full

engagement

2

Drag
or

failure
to
release

ThIS

problem

usually
causes
dIfficult

shIftIng
and

gear
clash

espeCially
when

downshIftmg
The

causes

may
be
excessive
clutch

pedal
free

play

warped
or
bent

pressure
plate
or
clutch
dISC
ex

cessive
clutch
cable

guide
sag
and
broken
or

loose
clutch

lmings
Check
conditIOn
of

mam

shaft

splines

3
Chatter
or

grabbing

A
number
of

thmgs
can
cause

tIns
Check

cable

gUIde
sag
and

tIghtness
of
transnusslOn
to
frame

and

engme
to
transmlSslon

mountIng
bolts

Check
for

worn
or

mISaligned
pressure
plate
and

misalIgned
release

plate

4

Other
nOIses

NOISe

usually
mdlcates
a

dry
or
defective
release

bearIng
Check
the

beanng
and

replace
If
neces

16

CHAPTER

TIlREE

sary
Also
check
all

parts
for

mlSaltgnment
and

uneven
wear

TRANSMISSION

1

Difficult
to
mesh

gears

Make
certam
the

clutch

pressure
plate
and
re

lease

beanng
are
m

good
condItion
The
trouble

can
be

caused

by
worn

gears
shaft
and
or
bear

mgs
DISassemble
and

repaIr
as

requIred
Also

can
be
caused

by
msufficlent

operatmg
stroke

due

to
worn
or
loose

sltdmg
parts
or
a
defective

synchronIZer
DIsassemble

carefully

InSpect
and

replace
as

requIred

2
Gears

slip
out

of
mesh

Generally
thIS
trouble
occurs
when

the
mterlock

plunger
check
ball
and

or

spnng
IS
weakened

or
worn
The
trouble
can

also
be
caused

by
worn

fork
rod
ball

groove

damaged

bearings
or
dam

aged

gears
DIsassemble

carefully
mspect
and

replace
as

required

3
NOIse

If
nOISes
are
heard

wIth
the

engme
idlmg
and
the

clutch

disengaged
the
nOIse
IS

probably

conung

from
the

transmISSIOn
Several
Items

can
cause

nOISes

either

smgly
or
m
combmatIon

Check
the

qualIty
and

quantity
of
lubrIcant

in
the
trans

mISSIon

Replace
or

replenISh
as

necessary
Worn

bearIngs
wIll

usually
produce
a

lugh
humming
at

hIgh
speed
and

a

cycltc
knockIng
sound
at
low

speed
Worn

or

damaged
splInes
and

bushmgs

will
also
cause

nOIse

BRAKES

1
Brake

pedal

goes
to

floor

There

are
numerous
causes
for
thIS

includIng

excessIvely
worn

Itnmgs
aIr
in
the

hydraultc

sys

tem

leaky
brake
lmes

leaky
wheel

cylmders
or

leaky
or
worn

master

cylmder
Check
for
leaks

and
thIn
brake

linmgs
Bleed
and

adjust
the

brakes
If

thIS
doesn
t
cure
the
trouble

rebwld

wheel

cylmders
a
nd
or
master

cylmder

2

Spongy

pedal

Normally
caused

by
aIr
m
the

system
blee
d
and

adjust
the
brakes

3

Brakes

pull

Check

brake

adjustment
Also
check
for
contam
inated

brake

Itmngs
from
leaks

leaky
wheel

cyltnders
loose

caltpers
frozen

or
seIZed

pIstons

and
restrIcted
brake
lmes

or
hoses
In
addItion

check
front
end

alignment
and

suspensIOn
dam

age
such
as
broken
front

or
rear

sprmgs
shocks

etc
Check
condItIon

of
tIres

4
Brakes

squeal
or
chatter

Check
brake

lmmg
thickness

and
brake
drum

roundness
Ensure

that
the
shoes
have
cham

ferred
ends

and
are
not
loose

Inspect
the
condI

tion
of

the
rotors
on
the
front
wheel
dISC

brakes

to
make

certain

they
are
not
scored

or

damaged

Clean

away
all
dIrt
on
shoes

pads
rotors

or

drums

5

Draggmg
brakes

Check

brake

adjustment
includmg
handbrake

Check
for
broken
or

weak
shoe
return

springs

swollen
rubber

parts
due
to

unproper
brake
flUId

or
other
contammatIon

Clean
or

replace
de

fectIve

parts

6
Hard

pedal

Check
brake

linmgs
for

contammation
Also

check
for

restrIcted
brake
lines

and
hoses

7

High
speed
fade

Check

for
dIstorted
or
out
of
round
drums

and

contamInated
brake

lmmgs
Make

certam
the

recommended
brake
flUId
IS

used
Dram
entIre

system
and
refill
If
In
doubt

8

Pulsatmg
pedal

Check
for
dIStorted
or
out
of
round
drums

or

rotors
Check
for

excessIVe
brake

dISC
run
out

STEERING
AND

SUSPENSION

NOTE
Unusual

steermg
pullmg
or

wandermg
IS

usually
caused

by
bent

or
otherwise

mIsaligned

suspenszon

parts
Because

of
the

speCialized
equIp

ment

reqUired
to
evaluate
and

correct

these

faults
It
IS
recommended

t
tat

servIce
to

the

steermg
and

suspension

system
be

referred
to

your
Datsun

dealer

oca

quallfied
specrallst
m

thiS

field

1
VibratIOn

felt
m

steermg
wheel

VIbratIon
can
be
caused

by
several

thmgs
includ

ing
lll1proper
aIr

pressure
m
tIres

uneven
wear

TROUBLESHOOTING
17

of
tIre
loose
wheels

unproper
adjustment
or

wear
of
front
wheel

bearIngs
faulty
wheel

align

ment
or
wear
of
transverse
lInk
and
tension
rod

bushings
Inspect
all

parts
carefully
for
wear
or

damage

Replace
or

replUI
parts
as

required

2
Shock

transmltled

through
steering
wheel

This
is

usually
most
noticeable
when

traveling

over
bad
roads
at

relatively
high
speeds
Causes

Include

damage
to
the
idler
ann
insuffiCient

tIghtening
of

steenng
gear
box
wear
of
the
steer

Ing
linkage
and
wear
of
the

suspension
ball

joint

Inspect
all

parts
for
wear
or

damage
Refer
to

Chapter
ThIrteen
for
service
or

repair
you
can

perform
and
for

procedures
which
should
be

referred
to

your
deal
r

3

Shlmmymg

This
is

usually
most
noticeable
when
a

specIfic

speed
IS
attained
and
will

normally
repeat
at
that

speed
Causes
are

generally
unbalanced
wheels

unproper
adjustment
of

steenng
gear
insuffi

cient
backlash
malfunction
of
the
shock
ab

sorbers
or
loose
bolts
for
the
strut

mountIng

Reparr
or

replace
defective

parts
as

required

Refer
to

Chapter
Thirteen

4

Wandermg
of
car
m
one
dlrectlOnl

This

problem
can
be
caused

by
improper
air

pressure
loose
wheel

nuts
difference
in
tire
tread

wear
from
left

to

right
side
Incorrect

adjustment

of
wheel

bearings
defectIve
wheel

beanngs

collapsing
or

twistIng
of
front

spnng
or
Incorrect

wheel

alignment
Also

binding
of
the
brake

shoes
worn

bushings
in
the
transverse
link
or
the

tension
rod
and
deformation
of
s

enng

lInkage

and

suspension
link
can
cause
wander

Carefully

iuspect
all

parts
for
looseness
and
wear
and
re

place
or

repaIr
as

required
In
some
c
ases
a
de

fective
rear

suspension
may
also
cause
the

vehicle
to
wander

5

InstabIlity

Instability
can

be
caused

by
unproper
tIre

pres

sures
worn

bushings
in
the
transverse
link
and

tension
rod
mcorrect
wheel

alignment
worn

steenng
linkage
Incorrect

adjustment
of
steer

ing
gear
and
unbalanced
wheels

Inspect
all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required
6

Heavy
feelmg
m

steering

This
can
be
caused

by
improper
tIre

pressures

insuffiCient
or
contamInated
lubncant
in

gear

box

damage
or
insuffiCient

grease
In

suspeuslon

ball

Joint
damaged
or

badly
adjusted
wheel

bearIngs
worn
or

damaged
steermg
gear
dam

age
of

upper
strut

bearing
and
mterference
of

steenng
column
With
turn

signal
SWitch

Inspect

all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required

7
ExceSSIve

play
m

steermg
wheel

This
is

usually
caused

by
Incorrect

adjustment
of

the

steenng
gear
worn

bushings
in
the

steering

linkage
or
Idler
arm
mcorrect

adjustment
of
the

front
wheel

bearings
worn

bushIngs
in
the
trans

verse
lInk
and
tension
rod

Carefully
inspect
all

parts
for
wear
or

damage
Adjust
repair
or
re

place
as

reqUIred

TIRE
WEAR
ANALYSIS

Abnormal
tIre
wear
should

always
be
ana

lyzed
to
deternune
the

cause
The
most
common

are
Incorrect
tIre

pressure
improper
dnving

overloading
and

Incorrect
wheel

ahgDment

Figures
2A

through
2F

identify
wear

patterns

and
mdicate

likely
causes

Of

I

1

l

D

1

Undennflatlon
Worn
more
on
Sides
than
In

center