1968 DATSUN 510 seats

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

34

CHAPTER
SIX

Figure
4B
shows
the
crankshaft
and

piston
as

semblIes
m
an

exploded
VIew

PISTONS
AND
CONNECTING
RODS

The

pistons
shown
m

Figure
5
are

cast
alum

mum
With
concave
heads
The

piston
pms
are

hollow
steel
and
are
connected

to
the

pistons
m

a

full

floatmg
fit
Th

piston
pms
are

press
fitted

to
the

connectIng
rods

which
are
made
of

forged

steel

CD

l

o

o

o

CYLINDER
HEAD

The

cylInder
head

Figure
6A

is
an
aluminum

alloy
that

provides
added

coolmg
effiCiency
An

exploded
VIew
of
the

cylInder
head
and
asso

ciated

parts
is

given
in

Figure
6B

page
36

In

take
valve
seats

are
an
alummum
bronze

alloy

while
exhaust

valve
seats

are
cast
iron
All
seats

are
hot

press
fitted
mto
the
alummum

head

0A
CAMSHAFr

Figure
7
shows

the
cast
Iron

camshaft
located

inSide
the

rocker
arm
cover
Four
alummum

alloy
brackets

support
the
camshaft
m
the

cyl

mder
head

CD

VALVE
MECHANISM

Figure
8

page
37

IS
an

exploded
VIew
of
the

valve
camshaft
and

t1mmg
gear
mechanism

The
valve

system
has

pivot
type
rocker

arms

activated

directly
by
the
camshaft
mechanIsm

The
valves
are
fitted
with
dual

spnngs

CAMSHAFI

DRIVE

The
camshaft
IS
dnven

by
a
double

row
roller

cham
from
the
crankshaft
The
camshaft
dnve

mechanIsm
IS
shown
m

Figure
9
The

tensIOn

of
the
cham
IS
controlled

by
a
cham

tensioner

operated
by

spnng
and
oil

pressure
A
rubber

CD

190

CHAPTER
FOURTEEN

Master

Cylinder
Assembly
and
Installation

I
Assemble
the
master

cyhnder
m
the

reverse

order
of

dIsassembly

2
Pnor
to

assembly
soak

piston
cap
m
brake

flwd

Install

piston
so
that
It
seats

firmly
on
the

piston

cup

3
Coat
the

cyhnder
bore

and

pISton
assemblies

With
clean

brake
flwd
before

assembly

4
When

assembly
IS

complete
mount
master

cylmder
on
dash

wall
and
hook

connecting
rod

to
brake

pedal
Replace
return

sprmg
Fill
the

reservOir
With

clean
brake
flUid

5
If

aIr
has

seeped
mto
the
brake
Imes
bleed

the

brakes
as
descnbed
later
m
thIS

chapter

FRONT
DISC
BRAKES

SEDAN
AND

WAGON

Brake

Pad

Replacement

Pad
wear
should
be
checked

every
4
000

nuIes
Clearance
between

the

pad
and
the
rotor

IS

adjusted

automatIcally
and
therefore
IS
not
a

wear
mdlcator

Pad
thiCknesS
IS
checked

by
re

movmg
the
antI

rattle

clJp
When
the

pad
hning

becomes

worn
to

0
04

Imm
replace
all

pads
on
the

front
wheels

I
Remove

the
hub

cap
loosen
the
hub
nuts

jack

up
the
vehicle

support
with

stands
and

remove
the
front
wheels

2
Remove

the
antI
rattle

clJp
from

the

caliper

plate
as
shown
m

Figure
S

jty

3
Loosen
the
bleed
screw
Pull
the

calJper
plate

outward
4
Push
the

pISton
m

approximately
0
157
in

4mm

as
shown

m

Figure
6

5
The
outer

plate
should

be
loose

enough
to
be

removed
See

Figure
7

6

Dra
y
the

calJper
plate
rlfward

and
remove

the
inner

pad

7

Wipe
exposed
surface
of

piston
thoroughly

8
Push
the

piston
mto
the

cyhnder
bore
untJI

the

new

pads
can
be
mstalled
onto
the

calJper

plate

9
After

instl
llatIon
test
the
brakes
at
slow

speed
to
make
certam

they
are
fitted

properly

and
that

no
au
entered
the

hydraul1c
hnes
Bleed

the
brake

system
If

required

Front
Disc
Brake
Removal

I
Jack

up
the
vehicle

place
It
on
stands
and

remove
the
wheels

P

CHAPTER
SIXTEEN

ThIS

chapter
provides
infOrnl8tion
and

pro

cedures
for
removal

adJustment
and
or
re

placement
of
various

body
components
in

cluded
are
the

hood
front
trinl
doors
seats

locks

bumpers
tail

gates
and
door
and
window

controls
The
illustrations

given
are

typical
of

the
sedan
the
station

wagon
IS
similar
Details

on
the

pick
up
are

given
in

separate
illustrations

Other

body
repairs
require
special
knowledge

CD
L

BODY

and
tools
and
should
be

referred
to

your
Datsun

dealer
or
local

body
shop

FRONT
BODY
TRIM
AND

BUMPERS

Figure
1
next

page
is

an

exploded
diagram

of
the

body
tnm
and

bumper
for
the
sedan

Figure
2
shows
the
front

bumper
on
the

pick
up

Refer
to
the
illustratIons
and

remove
and

replace

1
Front

bumper

2

Bumper
stay

3
Front
member

228

CHAPTER
SIXTEEN

1
lock
knob

2
lock
installation
bolt

3
Bell
crank
installation
bolt

4
Door
lock
remote

control

assembly

5
Door

lock

assembly

6
OutsIde

handle
lever

7
InSide
lock
knob
IOstallatJon

bolt
CD

CD

D

00

TRUNK
LID

AND
BUMPER

Figure
10

page
230
shows
the
constructIon

details
of
the
sedan

trunk
lid
and

bumper
Figure

11

page
231
Illustrates
the

wagon
bumper

assembly

SEATS

Fre
12

page
232

IS
an

exploded
View
of

the
front

seat
and

mountIng
brackets
used
m
the
1
Door

panel
assembly

2
Door
Window
ventJlator

assembly

3
Door
Window

glass

4
Glass
run

5
Door
wmdow

weather

stnp

6
Door
outsIde
handle

7
Door
lock

key
cylinder

8
Door
lock
and

remote
control

assembly

9
Door
WIndow

regulator

10
InSIde

handle

11

Regulator
handle

12
Door
fimsh

13

Sealing
screen

14

Sealing
screen

15

Sealing
screen

16

Support
cushIon

@

FRONT
SEAT

FOR
PICK

UP

four
door
sedan
The
front

seats
and

mountmg

brackets
for

the
two
door
sedan
and
station

wagon
are
the
same

Figure
13
shows
the
seat

for

the

pIck
up

TAIL
GATE

Refer
to

Figure
14

page
233
for
details
of

the

statIon

wagon
tail

gate

INDEX

A
Inspection
and

repair
191

Air
cleaner
Pad

replacement
190

Exploded
views
63
64
Piston
seal

replacement
193

Removal
and

replacement
62
Reassembly
and
installation
193

Removal
190

Air

pump
40

Brakes
front

pick
up

Alternator

Brushes
104
Adjustment
201

Diode
103
Exploded
View
195

Disassembly
98
ServiCing
194

SpecdicatIons
194
203
204

Exploded
Views
41
99

Brakes
rear

pick
up

Inspection
and

repair
101

Adjustment
202

Output
checks
104

Exploded
View
195

Reassembly
104

Servicing
194

Removal
40
98

Brakes
rear
sedan
and

wagon

Rotor
102

Adjustment
202

Stator
102

Exploded
view
194

Axle
removal

pick
up
175

Inspection
and

repair
193

Reassembly
194

B
Removal
and

disassembly
193

Breaker

points
110

Ball

JOint
lower
sedan
and

wagon
174
Bumpers

Battery
Exploded
view
front

pick
up
223

Inspecllon
aiii
I

servicing
21
Exploded
View
front
sedan
and

wagon
224

SpeCific
gravity
21
Exploded
view
rear
sedan
230

Body
Exploded
view
rear

wagon
231

Body
Irlm
and

bumpers
223
224

Door
lock
and

regulator
225

C

Doors
225

Hood
lock
control
225
Camshaft

Seats
228

DeSCription
34

Tail

gate
228

Exploded
view
37

Trunk
hd
and

bumper
228

Inspection
48

Brake

pedal
Reassembly
54

Inspection
and

repair
187

Sprocket
53

Installation
188

Tlmmg
chain
57

Removal
187
Carburetor

Brakes
Cleaning
and

inspection
75

Adjustment
201
202
Dash

pot
adjustment
71

Bleeding
196

DesCription
37
69

Brake

pedal
187
Disassembly
71

Front
diSC
sedan
and

wagon
190
193

Exploded
Views
74
75

Front
drum

pick
up
194
Fuel
level

adjustment
69

Handbrake
197
201

Idhng
adjustment
69

Master

cyhnder
188
Interlock
valve
70

Rear

pick
up
194

Reassembly
76

Rear

sedan
and

wagon
193
Removal
40
71

SpeCifications
and
service
data
203
204
Sectional
view
69

Troubleshooting
16

Throttle
valve
70

Wheel

cyhnders
pIck
up
196
Charging
system

Brakes
front
diSC
sedan
and

wagon
Troubleshooting
12

Adjustment
201
Choke
and
accelerator

Disassembly
191

Disassembly
and

installation
82

Exploded
view
192

Exploded
view
83

l

INDEX
239

Rear

suspensIOn
wagon
Removal
40
92

Servlcmg
161
Termmals
94

Tightening
torques
162
Test

diagnosIs
97

Testmg
96

Troubleshootmg
10

5

Steenng
also
see

Suspension
front

I

Exploded
views
182
185
L

Seats

SpecIfications
186

DescnptIon
228

Troubleshooting
16

Exploded
View
front
4
door
sedan
232

SuspensIOn
front

pick
up

Exploded
VIew
front

pick
up
228

Axle
removal
175

Service
hmts
4

Inspection
and

repair
179

Shock
absorbers
sedan
154

Installation
179

Shock
absorbers

wagon
162

Posture

adjustment
181

Spark
plugs
Removal
177

CondlllOn
chart
21

Wheel

abgnment
182

InspectIon
and

servlcmg
21

Wheel

bearmg
adjustment
177

Recommended

types
112

Suspension
front
sedan
and

wagon

SpecificatIOns
and
tables

Inspection
and

repair
176

Adjustment
and
wheel

alignment
175

InstallatIOn
177

Brake
service
data
203
204

Lower
ball

Jomt
174

Brakes
203
204

Spnng
and
strut

assembly
173

Camshaft

beanngs
48

Stabilizer
173

Caster
and
camber
sedan
and

wagon
175

TenSIOn
rod
173

Clutch
134

Transverse
bnk
174

Clutch
service
data
134

Wheel

beanngs
177

Connectmg
rod

beanng
underslzes
52

Wheel
hubs
and

bearmgs
168
173

Dlstnbutor
112

SWItches

Dnveshaft
147

DescnptIon
205

Dnveshaft
service
dala
147

Exploded
View

through
1969
208

Engme
60
61

Exploded
view
1970
1972
207

Engme
service
data
60
61

General
4

Mam

bearmg
underslzes
52

T

Piston

rmg
gap
50

Rear

suspenSIOn
pick
up
167
Tail

gate
228
233

Rear

suspensIOn
torques
wagon
162

TenSIOn
rod
sedan
and

wagon
173

Steermg
186
Thermostat

TransmiSSion
manual
144

DescnptIon
89

TransmiSSion
service
data
manual
144

Inspection
and

replacement
89

Valve

spnng
47

Removal
89

Sprmg
and

strut

assembly
sedan
and

wagon
173
Tires

Spnngs
sedan
154
Wear

analYSIS
17

Stabilizer
sedan
and

wagon
173

TransmiSSion
automatic

Starter
Downshift

solenOid
147

Armature
95
Inhlbllor
SWItch
148

Beanngs
96
Kick
down
SWitch
147

Brush
holder
96

Lmkage
mspectIon
and

adjustment
148

Brushes
and
lead
WIre
95
011
checks
147

Cleaning
mspectIon
and

repair
94
Oil

leakage
147

Construcllon
92
TransmiSSion
manual

Disassembly
92

DescnptIon
134

Exploded
View
93

Disassembly
138

Field
COIl
94

Exploded
view
138

Magnetic
SWItch
96
Gear

assembly
exploded
view
139

Magnetic
SWItch

assembly
test
97

Inspection
and

repair
141

Operation
91
Installation
143

Overrunnmg
clutch

96

Reassembly
and

adjustment
142

Reassembly
96
Removal
134