1968 DATSUN 510 fuel tank removal

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
SEVEN

FUEL
SYSTEM

The
fuel

system
mcludes
the

fuel

tank

straIner

pump
carburetor
arr
cleaner
and

necessary
lines

Inspect
components
for
leaks

and
deterioratIOn
whenever
mamtenance
is

done
The
fuel
stramer
should
be

mspected
peri

odIcally
and
cleaned

AIR
CLEANER

The
au
filter
element
is
viscous

paper
and

does
not

require
cleanmg
Replace
It

every

24
000
mlles
or
more

frequently
under
harsh

condItIons

Several
mInor
differences
exist
between

vehicles

dependmg
on
the

type
of
emisSIOn
con

trol
device
used

Figure
1
shows
location
of
the

air
cleaner
on
the

engme
and

parts
compnsing

the
cleaner

system
on
model

years
through
1969

Figure
2
shows
the

changes
for
1970
and
later

Warm
air
is

supplIed
to
the
air
cleaner
from
the

exhaust
mamfold
to

prevent
carburetor

Icmg

AIR
CLEANER
REMOVAL

AND
REPLACEMENT

1
Unthread
the

WIng
nut

atop
the
cleaner

assembly

2
Remove
the
two
bolts

holdIng
the
air
cleaner

to
the

support

3

Disconnect
the

aIr
cleaner
duct
from

the
base

of
the
cleaner
intake
throat
4
LIft
off
the
aIr
cleaner

body
and
remove
the

aIr
filter
as
shown
m

Figure
3

To
remove
the
arr
cleaner

proceed
as
follows

1
Perform

steps
1

through
4
above

2
Unscrew
the
band
bolt
at
the
base
of
the

air
cleaner

3
DIsconnect
all
hoses

leadmg
to
the
air

cleaner

4
Pull

up
on
the

body
of
the
air
cleaner
and

remove
from
carburetor

5

Except
for
the

au
filter

element
thoroughly

clean
all

parts

6
Reverse
the

steps
above
for

reassembly

FUEL
STRAINER

The
fuel
stramer

IS
located
on
the

nght
hand

side
of
the

engme
compartment
Figure
4
shows

the
fuel
stratner
hoses

clamps
and
the
mount

Ing
clIp
that
holds
the
fuel
stramer
In

place
The

fuel
stramer
IS
of
the

cartrIdge
type
and
uses
a

fiber
mat
and

nylon
as

strainer
elements
The

fuel
stramer
should
be

mspected
frequently
for

foreIgn
material
and

replaced
at
least

every

24
000
rmles

1
DIsconnect
the
inlet

and
outlet
hoses
from

the
fuel
stratner
Make
certatn
that
the
mlet
hose

bottom
IS
not

permItted
to
fall
below
the
level

of
the
fuel
tank

or

leakage
wIll
occur

68
CHAPTER
SEVEN

Capacity
Test

Perform
the

capacity
test

only
when
the
statIc

pressiue
test
IS
withm

acceptable
lirmts

1

D
sconnect
the
fuellme

at
the
carburetor

2
Place
a
sUItable
container
at

the
end
of
the

fuellme

3

St
lrt
the

engm
and

run
at
OOO

rpm

4
The
fuel

pump
should
delIver
fuel
into
the

co
ntainer
at
a
rate

slightly
over
two

pints
per

minute

If

no

gasolme
or

only
a
lIttle

appears
the
fuel

lme
is

clogged
or
thefuel

pump
defectIve
Bef

removmg
the
fuel

pump
remove
the

gas
tank

filler

cap
dtsconnect
the
mlet
and

outlet
fuel

lmes
and

qlow
through
them
With

compressed

air
to
make
certam

they
are
clear
Reconnect
the

fuellmes
and
retest
the
flow
If
stIll

insufficient

the
fuel

p
mp
requires
servicmg
or

replacement

Fuel

Punip
Removal
and

Disassembly

1
Unscrew
the

two

mountIng
nuts

hOldmg
fuel

pump
to
the

cylmder
head

2
Disconnect
the
inlet
and
outlet
lines

3
Remove
the
fuel

pump
from
the

cylmder

head

4
Place
the

pump
on
a
work
bench
and
remove

the
screws

jommg
the

upper
and
lower

bodIes

5
Remove
the

cap
and

gasket
by
removing
the

cap
screws

6
Unscrew
the
elbow
and
connector

7
Remove
the
valve
retamer

by
unscrewmg
the

two
valve
retamer
screws
The
two
valves
are

then

easily
removed

8
To
remove
the

dIaphragm
spring
lower

body

seal
washer
and
lower

body
seal
from
the
lower

body
press
the

diaphragm
down
Wh1le

domg

thIS
cant
the

dIaphragm
so
that
the

rectangular

part
m
the
lower
end
of
the

pull
rod

unhooks

from
the
rocker

arm
lmk
ThIS
action
IS
shown

mFigure7

9
Drive
out
the
rocker
arm

pm
by
usmg
a
dnve

dnft
nd
hammer

Fuel

Pump
Inspection

1

Check
the

upper
and
lower
bodIes
for

cracks

2

Check
the
valve

assembly
for
wear
on
valves

and

springs
CD

3
Check
the

diaphragm
for
small
holes
cracks

and
wear

4
Check
the
rocker
arm
for
wear
where
It
con

tacts
the
camshaft

5
Check
the
rocker
arm

pin
for

wear
A
worn

pin
may
cause
011

leakage

6
Check
all
other

parts
for
abnormalItIes
or

defects

Replace
With
new

parts
as

reqUlred

Reparr
kIts
are
available
from
Datsun
dealers

and

parts
outlets

Fuel

Pump
Assembly

1

Assembly
of
the
fuel

pump
is
the
reverse
of

dlsassembly

2
Use
new

gaskets
durmg
assembly
and

mstanatIon

3
Lubncate
the
rocker
arm
the
rocker
arm

link
the
rocker
arm

pm
and
the
lever

pin
before

mstallatIon

4
To
test
the

operatIon
ohhe
fuel

pump
before

remstallatlOn
connect
a
three
foot

pIece
of
fuel

lme
or
hose
betweentbe
fuel
filter
and
the
fuel

pump
Hold
the
fuel

pump
at
the
end
of
the
fuel

lme

conSIderably
above
the
level
of
the
fuel

stramer

Operate
the
rocker
arm

by
hand
If
fuel

IS
drawn

up
to
the

pump
soon
after
the

pumpmg

actIon
IS
started
the

pump
IS

satIsfactory

5
Install
the
fuel

pump
to
the

cylmder
head
and

secure
the

mounting
nuts
to

the
studs

6
Reconnect
the
mlet
and
outlet
fuellmes

7
Check
the

operatIon
of
the
fuel

pump
by

runnmg
pressure
capaCIty
tests
as
descnbed

preVIously

76
CHAPTER
SEVEN

Carburetor

Assembly

Assembly
is
the
reverse
of

dISassembly
Make

certam
all

gaskets
are
mounted
flat

Be
careful

not
to
use
force
In

assembly
Make
certam
that

all
Interlock
lInks

operate
smoothly

FUEL
TANK

Description

FIgures
15
16
17
and
18
are

exploded
views

of
the
fuel
tanks
used
on
the
sedan
and

wagons

Figure
15
IS
for
sedans

through
model

year
1969

Figure
16

applIes
to
sedans
from
1970
With

evaporative
control

system
F

q
nre
17
shows
the

statIon

wagon
through
1969

Figure
18

applIes

to
the

statIon

wagon
WIth

evaporative
control

system
f

m
1970
The
fuel
tank
for
the

pIck
up

is
shown
m

Figure
19

A
fuel
return

system
from
the
carburetor
to

the
fuel
tank

keeps
fuel
from

becommg
over

heated
m
the
carburetor
float
chamber
When

the
normal
level
m
the
float
chamber

IS
exceeded

a

pressure
valve

opens
and
returns
the
excess

fuel

to
the
tank

Removal
Sedans

1
Remove
drain

plug
m
bottom
of
fuel
tank
and

drain
the
fuel
into
a

suitable
safe
contamer

2
Detach
rear
seat
and
seat
back
See

Figure
20

3

Open
trunk
lId
and
remove
the
trunk
finISh

mg
board
4
DIsconnect
wire

leadmg
to
fuel

gauge
umt

5
DIsconnect
and
remove
the
fuel
inlet
tube

See

Figure
21

6
DIsconnect
rubber
tubes
of
fuel
outlet
and

fuel

return
lInes
from
the
tank

7
Remove
four

fixmg
bolts
and
lock
washers

from

edge
of
fuel
tank

8
Remove
fuel
tank
from
vehicle

Removal

Wagon

1
Remove
draIn

plug
from
bottom
of
fuel
tank

and
dram
the
fuel
mto

swtable
safe
contatner

2
Disconnect
WIre

leadIng
to
fuel

gauge
unit

3
Disconnect
and
remove
fuel
mlet
tube

4
DISconnect
rubber
tubes
of
fuel
outlet
and

fuel
return
lInes

5
Refer
to

Figure
22
Remove
four

fixing
bolts

holdmg
tank
in

place

6
Remove
fuel
tank
from
veh1c1e

82

CHAPTER
SEVEN

Removal

Pick

up

The
fuel
tank

IS
mstalled

along
With
the

vapor

liqUid
separator
A

cover
m
front
of
the
left

rear

wheel

protects
the

vapor
lIqUid

separator
from

damage
Figure
23
shows
the

cover
mstalled

and

Figure
24
shows
It
removed

I
Remove
dram

plug
from
bottom
of
fuel

tank

and
dram
the
fuel
mto
sUitable

safe
contamer

2
Disconnect
wire

leadmg
to
fuel

gauge
unIt

3
Disconnect
and

remove
fuel
Inlet
tube

4
Disconnect
rubber

tubes
of
fuel
outlet
and

fuel

return
lInes
5
Disconnect
tube

leadmg
to

vapor
liqUid

separator

6
Remove

fixmg
bolts

holdmg
tank

In

place

7
Remove
fuel

tank
from
vehIcle

Inspection

Inspect
the
fuel
tank
d

connectIng
lInes
for

SIgn
of

damage
or
leaks
If
dIrt

IS
found

In
the

carbl
relor
r
fuel

pump

upon
dlsassemb

y
blo

out
the
fuel

lines

usmg
compressed
air

Repair

Fuel
tank

leaks

may
be

repaired
by
soldering

or

brazmg
the
fuel
tank

WARNING

A

fuel
tank
IS
a

potential
bomb

capable

of

klllmg
anyone

nearby
should

It
ex

plode
Always
observe
the

followmg

safety
precautions
when

repairing
the

fuel
tank

1
Remove
all
fuel
and
have
the

tank
steam

cleaned

InSIde
and
out

2
F1l1
the
tank
WIth
Inert

gas
such
as
carbon

diOXide
or

mtrogen
or
WIth
water

3
Have
a

properly
rated
fire

extIngUisher

handy
and
never
work
near
the
vehicle

After
the

repair
IS
made

pour
the
water
out

or
release
the

gas
then

put
about

a

quart
of

gasolme
In

the
tank
and
slosh
It
around
Pour

the

gasolme
out
blow
the

tank
out
WIth
com

pressed
aIr
then

replace
tank
In

vehIcle

Installation

To
mstall
the

f
iel
tank

reverse
the

p
rocedur

used

dUring
removal
After
InstallatIon
check

carefully
for
leaks

Choke

and
Accelerator

Linkages

Figure
25
IS
an

exploded
VIew
of
the

lInkages

used
on
the

accelerator
and
choke
controls
To

disassemble

replace
and
mstall
the

lInkages

refer

to
the
IllustratIon
and

proceed
as

reqUIred

EMISSION
CONTROL
SYSTEM
123

7
If
the

pressure
does
not
meet

reqwrements

dISconnect
the

aIr

supply
hose
to
the
antI

backfire
valve

Clamp
a

plug
mto
the
hose
and

repeat
the

pressure
test

8
If
the
air

mJection
pump
does
not
meet
the

pressure
specIfication
It
should
be

replaced

NOTE

Repair
of
the
air

injection

pump
is

possible
but
have
the

lob

done

by
your
dealer

9
Close
the
hole
of
the
test

gauge
by
finger
With

the

engme
runnmg
at
1
500

rpm
See

Figure
13

If
a

leakIng
sound
is
heard

or

leakIng
air
is
felt

at
the
relIef
valve
the
relIef
valve

IS
defectIve

RepaIr
or

replace
as

reqUIred
ENGINE
MODIFICATIONS
SYSTEM

Testlng
and
mamtenance
of
the
sWitches

relays
and
solenOIds

comprismg
the

engine

modIficatIons

reqwres
SpecIal
knowledge
and

test

eqUIpment
If
the
mechanic

suspects
that

troubles
eXist
In
these

parts
check
With

a
dealer

Mamtenance
of
the
dIstrIbutor
breaker

points

and

tImmg
of

engines
is
covered

m

Chapter

Four

EVAPORATIVE
EMISSION

y
CONTROL
SYSTEM

f

Detailed
informatIon

on
the
fuel

tank
and

connecting
fuel
lines

IS

given
In

Chapter
Seven

EXHAUST

SYSTEM

Figures
14
next

page
15

page
125
and
16

page
126

are

exploded
VIews
of
the
exhaust

systems
Figure
14

applIes
to
the
sedan

FIgure

15

to
the

wagon
and

FIgure
16
to
the

pIck
up

The

system
in
sedans
and

wagons
consists
of

the
front
tube

pre
muffier
center
tube
rear

tube
mam
muffier
and
tail

pipe
The

pick

up

exhaust

system
mcludes
the
front
tube
muffier

and
rear
tube

Removal
Sedan
and

Wagon

1
Loosen

clamps
at
the
front
tube
center
tube

and
mam
muffier
connectIons
See

Figure
17

2
DIsconnect
front
tube
and
exhaust

manifold

flange
connection

3
Remove
units
from

vehicle

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