1968 DATSUN 510 maintenance

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
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

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

PERIODIC

MAINTENANCE

7

Table
1
ENGINE

LUBRICATION
AND
MAINTENANCE

FREQUENCY
EVERY

E
E
E

E

E
E

E
Eo
00
00

00
00
00

00

00

gq
00

00

00

NO

t
r61li
0

CD

Check

engine
011
level

top
up
If

required
X

Change
engine
011
X

Lubricate

carburetor

hnkage
X

Lubricate
distributor
rotor
shaft
and
ann
shaft
X

Apply
grease
to
distributor
cam
heel
X

Check

radiator
coolant
level
X

Change
radIator
coolant
X

Change
radiator
coolant
additive

X

Check

battery

electrolyte
level
X

Check

specific
gravity
of

battery
X

Check

engine
starting
exhaust
color
X

Tighten

cyhnder
head

manifolds
and

pipe
flanges
X

Adjust
valve
clearance

X

Check

Ignition
timing
X

Tighten
carburetor

fittings
X

Check
fan
belt
tension
X

Check
for
011

pan
leakage
X

Tighten
engine
mounts
X

Check
fuel
strainer
X

Replace
fuel
strainer
X

Check
for
fuel
leaks
X

Replace
011
filter
X

Check

spark
plugs
X

Replace
spark
plugs
X

Check
dlstnbutor

cap
rotor
and

POints
X

Adjust
engine
Idle

speed
X

Check

air
cleaner

fittings
X

Clean
011
filler

cap
X

Clean

battery
cables
and
terminals

X

Check
alternator
and

voltage
regulator
function

X

Check

starter
motor
function

X

Replace
aIr
cleaner
element

X

Check
fuel

pump
function

X

Check

cyhnder

compressIon
X

Clean
carburetor

Jets
and
float
chamber

X

Check
dlstnbutor
condenser

X

Check
crankcase
ventilation
control
valve
X

CHAPTER
TEN

EMISSION

CONTROL
SYSTEM

ThIs

chapter
covers
emission

control
and

exhaust

systems
The
emission

devices
used
in

clude
crankcase
ermssion

controls
an
exhaust

ermssion

system
and

evaporative
emission
con

trols

EXHAUST
EMISSION

CONTROL
SYSTEM

Two
methods
of
exhaust
emission

control
are

used

on
the
Datsun

One
is

an
aIr

injection

system
the
other
consists

of

engine
modifica

tIons
Datsuns

were

equipped
With
the
air

injec

tIon

system
only
through
1970
SInce
then
all

models

have
combined
aIr

mjection
with

engine

modIficatIons
EmisSIon

servicing
IS

complex

and

should
be
left
to

qualIfied

professionals

Figure
1

Illustrates
the

system
used

through

model

year
1969

Figure
2
IS
the

system
used

after
1970

Figures
3

through
7
offer
detaIls
of

various

emission

components

Maintenance
and

Testing

Penodlc

mspection
and
service

should
be

done

every
12
months

or
12
000
miles
The

engine
must
be

in

good
working
order
to
main

tain

a
low

level
of
harmful
emissions
There

fore

perform
a

general
tune

up
as

spec1fied
in

Chapter
Four
before

followmg
the

procedures

below
CRANKCASE
EMISSION

CONTROL
SYSTEM

The
crankcase

emission
control

system
is

shown
in

FlgDre
8
It
IS
a
closed

system
that

pre

vents
crankcase

gases
from

escaping
to
the
at

mosphere

Blowby
gases
are
dIrected

to
the

intake

manifold

through
the
ventilation

control

valve

Normally
capacity
of
the

valve
is

suffi

cient
to
handle
the

blowby

gas
plus
a
small

amount
of

ventIlating
air
drawn
from
the

air

cleaner

through
a
tube

leading
to
the
crankcase

Under
fun

throttle
condItIons
manifold
vacuum

is

Insufficient
to
draw
the

blowby
through
the

valve
When
this

happens
b10wby
flows

through

the

system
In
the
reverse
dIrection

General

1
Start
the

engine
and

bring

up
to

operating

temperature

2
Check

hoses
and
hose
connections
for

leaks

3

Examine
the
hoses
for

signs
of

cracks
or
de

terioraoon

Replace
as

required

Crankcase

Ventilation

Control
Valve

1
Start
the

engme

2
Remove

the
ventIlator
hose
from
the
crank

case
ventilatIon
control
valve
A

htssmg
nOISe

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

MAINTENANCE
LOG

DATE
TYPE
OF
SERVICE
COST
REMARKS

j

h

duhl
book
lor

Jour
bike
I

r
r

r

t

lIIi
r

1J
COMBl

IlUIUOfIIOHl
0

1

2
I
K
NDA

1BMCf
lwaocll

so

OIft
I

i

I
J

I
A

Clymer
s

completely
new

professionally
written

motorcycle
servlcejman

I
uals
a
must
for

all
bike
ownersl

Expert
text
and
hundreds
of

photos
glve

i
model

by
model
serVice

repair
and

troubleshooting
Information
Jobs
for

I
the

amateur
are

fully
detailed
When
to
call
n
a

pro
IS
also

mad
e
c1eai

The
books
listed
below
offer

full
maintenance
information
for
rtI
re

than
200

separate
models

They
are
available

through
local
bo
kstores

motorcycle
dealers
automotive
accessories
outlets
or

postpaid
dU

3d
from

Clymer
Publications
I

I

BSA
TWINS

6SO
1963
1972

BULTACO
SINGLES
125
25Occ

All
Vear

HODAKA
SINGLES
90

lOCk
1964
1972

I

HONDA

SINGLES
SO

9O
1963
1971

HONDA
SINGLES
100
250cc
1970
1972

HONDA

TWINS
l125
350cc
1964
1972

HONDA

SCRAMlnERI
250
305cc
All
Year

HONDA

TWINSI4SO
1965
1973

HONDA

FOURShso

500
1972

HONDA

FOURS

7SO
19691972

HUSQVARNA
51

GLES
125
450cc

1966
1972
MJ02

5
SO

MJ03
7
SO

MJ07

6
SO

MJ10
S
SO

MJ15

5
SO

MJ20
S
SO

M330
4
SO

MJ33
5
SO

MJ32

5
SO

MJ41

5
50

M423
7
SO
KAWASAKI
SINGLES
90
350

1966
1972

KAWASAKI
TWINS
250
35O

c
1966
1971

KAWASAKI
TRIPLES
S50

7SO
1969
19n

MONTESA
125
360

1965
1972

OSSA
125
250
1971
1972

SUZUKI
SINGLES
50
UlCk
19U
1972

SUZUKI
TWINS
125
500cc
1964
1972

SUZUKI
TRIPLES
1971
1972

TRIUMPH
TWINS
500

6SO
1963
1971

YAMAHA
ROTARY
SINGLES
50

73
1963
1971

YAMAHA

ENDURO
SINGLES
90
360

1968
19n

YAMAHA
TWINS
9O
350cc
1965
1972

YAMAHA
TWINS
650

1970
1973

RIDE
AND
STAY
AlIVEu
The

complete
book

of
motorcycle
baSICS
defenSive

dmg
wet

weather

safety
tipS

signaling
efe
X910
2

95
M350
5
SO

MJ5
2
5
SO

M3531
5
SO

M356
7
SO

MJ62
7
50

M365
S
SO

M366
5
SO

MJ68
5
50

MJa2
5
SO

M3aa

4
50

M40a

4
50

MJ9a
4
SO

M403
5
SO
I

I

t

r

r

r

r

1
l

I

June
1973

publlcatlonY

@j
CLYMEIt
IONS

j

222
NORTH
VIRGIL
AVENUE
LOS
ANGELES
CALIF
90004

t

i