1968 DATSUN 510 brake light

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

CHAPTER
TWELVE

DIFFERENTIAL
REAR
AXLE

AND
REAR
SUSPENSION

The
dIfferential
rear
axle
and
rear

suspen

sIon
dIffer
for
the
various
models
ThIS

chapter

deals
WIth
each

separately

Due

to
the
need
for

SpecIal
tools
and

exper

Ience
to
dIsassemble
and

repaIr
these
unItS
the

followmg
procedures
generally
cover
removal

InspectIon
and

replacement
only
If
mechanIcal

dIfficultIes

eXIst
WIthIn
the
dIfferentIal
and
rear

axle

components
refer
servIce
and

repair
to
a

Datsun
dealer
or

competent
garage

DIFFERENTIAL

SEDAN

The
cast
Iron
dIfferentIal

assembly
used

in

the
sedan
is
shown
in

Figure
1
next

page

Proper
lubncatlOn
of
the

gear
housmg
IS
essen

tIal
Check
lubncant

every
3
000
mlles
and
re

plenISh
as

necessary
Drain
and
refill
lubncant

at
least

every
30

000
miles

Differential
Removal
Sedan

1
DISconnect
handbrake
rear
cable
dnve

shaft

and
axle
dove
shafts

by
removing
bolts
shown

by
arrows
of

Figure
2

2

Place
a

Jack
under
the
dIfferential
and

lift

slIghtly
Remove
nuts
on
both
ends

of
dtfferentIal

mountlng
member
See

Figure
3

3
Remove
four

fixIng
bolts
that
hold
dIfferentIal

to
the

suspensIon
member

BRAKES
193

Front
Disc
Brake
Piston
Seal

Replacement

If
oil

leakage
is
detected
around
the

piston

seal
It
should
be

replaced
as
follows

I
Rinse
the

cyhnder
bore
With
brake
flwd
In

sert
new
seal
into
the

groove
taking
care
not
to

damage
It
Attach
the

wiper
seal
Lubricate

cylinder
bore

lightly
With
brake
fluid

2
Clean
the

piston
Inspect
the

pISton
for
scor

ing
or
other

damage
before

inserting
It
Make

sure
that
the
relieved

portion
of
the

pISton
faces

the

pivot
pin
Prevent

tilting
of
the

piston
when

It
IS
mserted
mto
the

cyhnder
Refer
to

Figure
13

@

4

Front
Disc
Brake

Assembly
and
Installation

I
Clean
the

mounting
surface
and
disc
surface

Attach
the
disc
to
the
hub

2
Install
the
hub
to
the
knuckle

spindle

3
Insert
the

piston
into
the

cylinder
untIl
its

face
is
almost
flush
With
the
face
of
the

wiper

seal
retamer

4
Install
the

cyhnder
mto
the

caliper
plate
and

secure
with
the
torsion

spnngs

5

Assemble
the
hold
down

pm
spring
washer

and

nut
to
the

support
bracket

6

Insert
cotter

pin
into
the
nut

7
Assemble

mounting
bracket
and

calJper
plate

with

pivot
pm
washer

spring
and
nut

Tighten

nut

completely
and
insert
cotter

pin

8

Pry
up
the
hold
down
bracket
with
a
screw

dnver
Hook
it

to
the

upper
end
of
the

mounting

bracket
Turn
the

cal1per
plate
to
make
sure
it

slides

smoothly

9
Install
the

caliper
assembly
to
the

knuckle

flange
10
Attach
shun
to
inner

pad

I
I
Insert
the
inner
dIsc

pad
Pull

the

caliper

plate
outward
and
insert
the
outer
disc

pad

12
Attach
the
anti
rattle

plate

13

Replace
wheel
and
remove
stands

REAR
BRAKE
SEDAN
AND

WAGON

Figure
14
IS
an

exploded
view
of
the
rear

brake

assembly
used
m
the
sedan
and

wagon

Rear
Brake
Removal
and

Disassembly

1
Jack

up
the
rear
of
the
vehicle
and

support
It

on
stands
Remove
the
wheels

2
Release
the

parkIng
brake
DISConnect
the

cross
rod
from
the
lever
of
the
ie
wheel

cylinder

3
Remove
the
brake
drum

4
Remove
the
return

springs
and
take
out
the

brake
shoe
assemblies

5
Disconnect
the
brake
tube
from
the
wheel

cylinder

6
Remove
the
wheel

cylinder
by
removing
dust

cover

plates
and

adJusting
shIms

7
DISassemble
the
wheel

cylinder
by
removing

the
dust
cover
and

snap
nng

8
Remove
the

adJuster
assembly

Rear
Brake

Inspection
d

Repair

Sedan
and

Wagon

I

Inspect
the
brake

druf
1s
for

scoring
signs
of

excessive
heat
and
out
of
round

Repair
or
re

place
the
drums
as

reqUIred
The

following

specificatIons
apply

Drum
Out
of
Round

Inner
Olameter

MaXImum
Diameter
after

IlI1ndmg
Less
than
0
0020
In
0
05mm

8
999
m
228
6mm
1

9040
In
229
6mm

2

Inspect
brake

limngs
for
wear

signs
of
oil
or

grease
and
cracks
If

any
of
these
conditions
are

found

replace
the

linmgs
Have

a
brake

special

ISt
arc
the

limngs
to
match
the
diameter
of
the

drums
after

replacement
If
the
thickness
of
the

limng
is
under
0
0591
m
1
5mm

replace
it

3
Check
the

adjusting
cams
for
smooth

opera

tion

Replace
as

reqUIred

4
Check
the

spnngs
If

they
appear
weak
or

uneven
m
tension

replace
them

BRAKES

ZOI

Cross
Rod

Removal

Wagon

I
Remove
the

pull
off

spnngs
at
each
end
of

the

cross
rods

2

RelI
ove
clevis

pms
and

cross
rods

Rear
Cable

Removal

Pick
op

1
Remove

cleVIS

pm
and

disconnect

equalizer

from

equal1zer
link

2
Remove
lock

plate
1
and
cable

spring
2

as
shown

ill

Figure
24

3
Remove
both

rear
brake
drums
DISConnect

rear
cable
from

toggle
lever
3

Separate
cable

connecting
flange
4
from
brake
dIsc
See

Figure
25

4
Remove
rear
cable

Handbrake

Inspection
and

Repair

1

Inspect
all

cables
and

parts
for

damage
ex

cessive

elongation
and

general
wear

Replace
as

reqUlred
I

2

Inspect
ratchet

pawl
and
teeth
on

control

stem
for
excessive

wear

Replace
as

reqUIred

3
Check

springs
for

weakness

Replace
as

reqUIred

Handbrake

Installation

I

Install

parts
of
the
handbrake

system
m
the

reverse
of

removal
Make
certam
all

connections

are

tight

2
Lubncate
all

slIdmg
parts
With

muItl

purpose

grease

Front
Brake

Adjustment
Sedan
and

Wagon

AdJustment
of
the

front
dIsc
brake
units
18

not

reqwred
as
it

18
made

automatIcally
Re

place
the
front
dISC
brake

pads
and
rebwld
the

pISton
assemblJes
If
the

brakes
are

defective

Front
Brake

Adjustment
Pick

up

I
Refer
to

Figure
26
Jack

up
vehicle
to
lIft

wheel

requiring

adJustment

2

Remove
rubber
boot

from

brake
disc

3

Lightly
tap
adJuster

housmg
and
move
It
for

ward
Turn

adJuster
wheel

with
a
screwdriver

and

spread
brake
shoes

Stop
turnmg
adJuster

wheel
when

a

considerable

drag
is

felt
on
brake

drum

NOTE
For

both

left
and

right
brakes

brake
shoes

spread
when

adJuster

wheelIS

turned
downward

4
Return

adJuster
wheel
12
ratchet
teeth
to

obtam
correct
clearance

between
brake
drum

and

shoes

5

Turn

brake
drum
to
make

sure
that
drum

turns
Without

draggmg
If

draggmg
exists

readJust

138

INDEX

H
OIl

pump

Descnptlon
36

Handbrake

Exploded
view

29

Adjustment
202

Inspection
and

repaIr
28

Cable
removal

front
sedan
and

wagon
197

Installation

58

Cable
removal
rear

pick
up
201

Removal

28
40

Cable
removal
rear
sedan

and

wagon
197

Cross
rod

removal

wagon
201

Exploded
views

198
200

p

Inspection
and

repair
201

Installation

201

Penodlc

mamtenance

Headlights

MaIntenance

mtervals
chart

7

Bulb

replacement
210

Penodlc

checks
6

Descnptlon
210

Recommended
lubncants
8

Exploded
view

219

Routine

checks
6

HeatIng
system

Piston

nngs

Descnptlon
210

Exploded
view

pick
up
213
Inspection
50

Exploded
VIews
sedan
and

wagon
214
215
Removal

45

Hood

lock
control
RIng
gap
50

Exploded
View

pick
up
225
Pistons

Descnptlon
34

Exploded
VIew
sedan
and

wagon
226

Inspection
50

Reassembly
54

Igmtlon
coil

111

R

Igmtlon

system

Tlmmg
23
Radiator

Troubleshooting
13

Exploded
view
90

Instrument

meters
and

panels
Removal
and

replacement
90

Descnptlon
210
Rear
axle

pick
up

Exploded
View

pick
up
213
Axle

case

166

Exploded
view
sedan
and

wagon
Inspection
and

mstalIatlon
164

1970
1972

212

Removal

164

Exploded
view

sedan
and

wagon
Sectional

view

163

through
1969

211
Rear

axle

wagon

Intake
manifold

Disassembly
158

Descnptlon
36

Exploded
view

158

Removal

42

Inspection
and

reassembly
160

InstallatIOn

160

Removal

158

M
Rear
axle
and

suspenSion
sedan

Exploded
view

152
153

Mam

beanngs
52

Inspection
and

repaIr
154

MaIntenance

penodlc
6
8

InstalIatlon
154

Master

cylInder
Removal

151

Exploded
vIew

smgle
188
Rear

spnngs
pick
up
166

Exploded
view
tandem

189
Rear

spnngs
wagon
161

Inspection
and

repllIr
188
Rear
axle
shaft
sedan

155
156

Reassembly
and
InstalIatlon

190
Rear

suspension
arm
sedan

155

Removal
and

disassembly
188
Rear

suspenSion
pick
up

Modelldentdicatlon

1

Exploded
view

166

Inspection
and

repllIr
167

InstalIatlon

167

0
Rear

spnngs
166

Removal

165

011

filler

30

Spnngs
166

d

43

Torques
67