1968 DATSUN 510 compression ratio

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

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
FOUR

ENGINE
AND
IGNITION
TUNE
UP

For
best

performance
and

economy
care

must
be
taken
in

perfornnng
tune

ups
While

accuracy
is

required
the
task
IS
not
d1flicult
if

the

steps
m
tlus

chapter
are
followed

carefully

Cars
used

pnmarily
m

CIty
stop
and

go
dnv

ing
WIll

reqwre
attention
more

frequently
than

those
used

on

highways
ThIs
is
because
the

engme
does
not
reach
full

operatIng
temperature

ConsequentlY
valves
tend
to
stick

compression

drops
and

engme
operatIon
becomes

rough

A
tune

up
IS
adVISable

every
6
000
miles
or

sooner

dependmg
on

type
of

driving
Every

12
000
nu1es
the

spark
plugs
and

ignitIon
break

er

pomts
should
be

replaced
not

Just
cleaned

and

adjusted

A
mmor
tune

up
consISts
of

checking
battery

condItIon

cleanmg
gapping
or

replacmg
spark

plugs
and
dIstnbutor
breaker

pomts
adjustIng

dIStnbutor
dwell

angle
adjusting
IgnitIon
tun

mg
and

settIng
the
carburetor
Idle
mixture
and

idle

speed
A

major
wne

up
includes
the
above

items

plus
igllltIon
compressIOn
valve
clear

ance
carburetor
emISsion
control
deVIce
and

electncal
checks
and

adjustments

Tune

up
Equipment
Required

The

follOWIng

eqUIpment
IS

required
Chap

ter
Two

provides
a

bnef

descnption
of
the
test

eqwpment
I
Voltmeter
ammeter
and
ohmmeter

2

Hydrometer

3

CompressIOn
tester

4
Vacuum

gauge

s
Dwell
meter

6
Tachometer

7
I

StrobOSCOpIC
tmung
lIght

8
Feeler

gauges

9

Torque
wrench

10
Assorted
hand

tools

Connection
of
Tune

up
Equipment

Follow
the

manufacturer
s
recommendations

for
the
use
of
test

eqwpment
If

pOSSible
Figme

1
IS
a
basiC
schematic

diagram
applicable
to

CD

10
Battery

I
TIm1Illbght

T
8Ier

spa
k
plup

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

60
SIX

Table
1
ENGINE
SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Cylinder
Arrangement

DIsplacement

Bore
and
Stroke

Valve

Arrangement

MaxImum
Brake

Horsepower

MaxImum
Gross

Torque

Firing
Order

Engme
dle

Smgle
POint

Dual
Pomt

CompressIon
RatIo

Engme
Idle
Mamfold
at
Idle

rpm

011
Pressure
hot

@
2
000

rpm

i
TIGHTENING

TORQUE
ft
Ib

kg
m

Cylinder
Head
Bolts

1st
turn

2nd
turn

Flywheel

Flxmg
Bolts

M
In

Beanng
Cap
Bolts

Camshaft
Gear

Bolt

I
011
Pan

1
1

fF
I

011

Pump

QII
Stramer

F

I
Crank

Pulley
Bolt

SPECIFICATIONS
In
mm

Valve
Mechamsm

Valve
Clearance
Hot

Valve
Clearance
Cold

Valve
Head
DIameter
Intake

Valve
Head
DIameter
Exhaust

Valve
Stem

DIameter
Intake

Valve
Stem
DIameter

Exhaust

Valve

Length
Intake

Valve

Length
Exhaust

Valve

LIft

Valve

Spring
Free

Length
Outer

Valve

Sprmg
Free
Length
Inner

Vaiv

Spnng
Loaded

Length
Outer

Valve

Spring
Loaded

Length
Inner

Valve

Sprmg
Assembllld

HeIght
Outer

Valve

Spnng
Assembled

Helght
Inner

Valve

Spnng
Effective
Turns
Outer

Valve

Sprmg
EffectIve
Turns

Inner

Valve
GUIde

Length
Intake

Valve
GUIde

Length
Exhaust

Valve

GUIde

HeIght
from
Head
Surface

Valve
GUIde
Inner
DIameter
Intake

Valve
GUIde
Inner
DIameter
Exhaust

Va
Ive
GUIde

Outer
Dlam
eter
Intake

Valve
GUIde
Outer

DIameter
Exhaust

Valve
GUIde
to

Stem
Clearance
Intake

Valve

GUIde
to
Stem
Clearance
Exhaust

Valve
eat

W
dth
Intake

Valve

SEtat
WIdth
Exhaust
4
m

Ilnil

97
3
cu
m
1595cc

3
2677
x
2
9016
In
83
x
73

7mm

Overhead
Camshaft

96

@
5
600

rpm

110
ft
Ib
13
8
kg
m

@
3
600

rpm

1
3
4
2
r

600

rpm

700

pm

85
1

i7
7
In

Hg
450mm

Hg

54
to
60
Ib
m
2

3
8
tQ
4
2

Iig
cm

325
4
5

39
8
5
5

68
No
75
9
9
50

to
1039

325

to
39
8
4
5

to
5
5

362
to
43
4
50
to
60

2
9
to
5
1
0
4
to
0
7

108
to
15
2
1
5
to
2
1

58t087
08to
12

1157
to
130
1
160
to
180

o
118
0
30

o

0C
98

0
25

1
50
38

0

1
30
33
0

031
80

031
80

456
1159

4
57
116
O

03937
100

2
05
52
0

1
77
44
96

1
21

@
1054
Ib
3
07

@
47
8

kg

o
96

@
56
Ib
24
5

@
25
5

kg

1
53

@
63
9

Ib
38
9

@
29

0
kg

1
38

@
27
1
Ib
35

@
123

kg

45
I

55

2
32
59
0

2
32
59
0

0409

to
0
417
104

to
106

0315

to
03154
80

to
8018

0315
to
03154
80
to
8
Oi8

04718
to
04723
11
985
to
11
996

04718
to

04723
11
985
to
11
996

00006
to
00018
0
015

to
0
045

00016
to
00028
0040

to
0070

o
055

to
0
071
1
4

to
1
8

0063
to
0079
1
6
to
20

INDEX

237

2

7

30

28
WIrIng
diagrams

WIrIng
harnesses

Electncal

system
engme

Alternator

Chargmg
ClfCUlt

Dlstnbutor

IgmtlOn
coIl

Spark
plugs

Starter

Voltage
regulator

Emission

control
crankcase

DescnptIon

General

mspectIon

SchematIc
vIew

VentIlatIOn

control
valve

EmIssIOn

control
exhaust

AIr

pump

AntI
backfire
valve

Check
valve

DescnptlOn

Engme
modificatIons

system

Exploded
and
schematIc
vIews

Mamtenance
and

testIng

Troubleshootmg

Emission
control

system

evaporatIve

Engme

Camshaft

and

beanngs

Camshaft

sprocket

Component
descnptIons

Componenl

reassembly
and
mstallatIon

CompressIOn

testmg

Connectmg
rod

beanngs

Connectmg
rods

Crankshaft

Crankshaft
and

tImmg
cham

Crankshafl

sprocket

Cylmder
block

CylInder
head

DescnptlOn

Disassembly

Exploded
view

Flywheel

InstallatIOn

LubncatIon

MaIO

bearmgs

PIston

nngs

Pistons
and

connectmg
rods

PiStOns
and

piston
pms

Reassembly

Removal

SectIonal

views

ServIce
data

SpeCificatIons

Troubleshootmg

Valve
rocker

PIvot

Valves

Engme
lubncatlon

DescnptIon
217
222

205
207

98

104

98

105
111

111

112
113

9197

104

122

122

121

38
114

123

115
120

114

15

123

48
54

53

31

38

5759

24

52

51
54

51

57

53

49
55

46
56

31

40

33

53

59

27
30

52

50

45

50
54

53

38

32

60
61

60
61

13

54

47
53
114

114

121

114
LubncatlOn
ClfCUlt

011
filter

011

pump

Engme
tune

up

Checks

miscellaneous

Compression
testIng

DIstributor

Dwell

angle

EqUIpment
usage

ReqUIred
eqUIpment

Spark
plugs

Tlmmg

Tlmmg
dual

pomt
dlstnbutor

Valve
clearances

Exhaust

systems

Exploded
views

InspectIon

InstallatIOn

Removal

pickup

Removal
sedan
and

wagon

F

Fan
clutch

DIsassembly
and

reassembly

OperatIon
and

mspectlon

Flywheel

Fuel

pump

Capacity
test

DescnptlOn

Exploded
views

InspectIOn

InstallatIOn

Reassembly

Removal
an

assembly

StatIc

pressure
test

Fuel
stramer

Fuel

system

Air
cleaner

Carburetor

Fuel

pump

Fuel

stramer

Fuel
tank

Troubleshootmg

Fuel
tank

DescnptIon

Exploded
Views

InspectIOn
and

repaIr

Installation

Removal

sedan

Removal

pick
up

Removal

wagon

Fuses

G

27
General

mformatIon
25

24

21

24

20

20

21

23

24

25

124
126

126

126

126

123

l

89

89

53

68

37
65

66
67

68

58

68

42
68

65

1
2v

62

69

65

68
l

6

7

1
l

76

78
81

82

82

76

82

7
6

2

1

F