1968 DATSUN 510 spark plugs

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Page 3 of 252

DATSUN 510 1968 Service Repair Manual
CON1EN1S

CHAPTER
ONE

GENERAL
INFORMATION

Introduction

Model
Identification

CHAPTER
TWO

PERIODIC

MAINTENANCE

RoutIne
checks

Pen
odic
checks

CHAPTER
THREE

TROUBLESHOOTING

EqUIpment

Page 4 of 252

DATSUN 510 1968 Service Repair Manual
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
c

Page 12 of 252

DATSUN 510 1968 Service Repair Manual
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
01

Page 18 of 252

DATSUN 510 1968 Service Repair Manual
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

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

Page 19 of 252

DATSUN 510 1968 Service Repair Manual
14

CHAPTER
THREE

I
No

spark
to
one

plug

The

only

possible
causes
are
a
defective
dlStri

butor

cap
or

spark
plug
wrre
Examme
the
dis

tnbutor

cap
for
mOisture
drrt
or
ca

14

CHAPTER
THREE

I
No

spark
to
one

plug

The

only

possible
causes
are
a
defective
dlStri

butor

cap
or

spark
plug
wrre
Examme
the
dis

tnbutor

cap
for
mOisture
drrt
or
carbon
track

ing
caused

by
flashover
cracks
etc

2
No

spark
to

any

plug

ThlS
could
mdicate
trouble
in
the

prImary
or

secondary
Circuits
Frrst

remove
the
coil
wire

from
the
center

post
of
the
dlStributor

Hold
the

Wire
end
about
1
1
mch
from

ground
With
an

msulated
screwdrIver

Crank
the

engme
H

sparks
are

produced
the
trouble
is
m
the
rotor

or
distributor

cap
Remove
the

cap
and
check

for
burns

mOisture
dirt
carbon

trackmg

cracks
etc
Check
the
rotor
for
excessive
burn

mg
pittmg
or
cracks

Replace
both
rr

necessary

H
the
cod
does
not

produce
any
spark
check

the

secondary
Wire
for

opens
H
the

wrre
is

good

turn
the

engme
over

so
the

breaker

pomts
are

open
Examme
the

points
for
excessIVe

gap

burmng

pittmg
and
looseness

Replace
and
ad

Just
rr

necessary
With
the

points
open
check

voltage
to

ground
at
the
cod
with
a
voltmeter
or

test

lamp
If

voltage
is

present
the
cOlllS

prob

ably
bad
Have
it
checked
or

substitute
a
known

good
one

If

voltage
is
not

present
check
wrre
connec

tions
to
cOll
and
distrIbutor

Temporanly
dIs

connect
the
Wire
from
the
distrIbutor

to
the
cOll

and
measure
from
the
coli

to

ground
If

voltage

is

present
the
distnbutor

lS
shorted

Examme

the
breaker

pomts
and

connecting
WIres
care

fully
If

voltage
is
still
not

present
check
the

other
coli
termmal
for

ground
Voltage
at
thiS

termmal
but
not
at
the
other
mdicates
a
defecnve

cOll
No

voltage
at
tlus

termmal
mdicates
an

open
Wire
between
the

termmal
and
the

battery

3
Weak

spark

If
the

spark
lS
so
small
it

cannot

Jump
from
the

wrre
to

ground
check

battery
condinon
Other

causes

are
bad
breaker

points
condenser
m

correct
breaker

pomt
gap
dirty
or
loose
con

necnons
m
the

pnmary
crrcuit
or

dirty
or
burned

rotor
or
distnbutor
Also
check

for
worn
dis

tnbutor
cam
lobes

4

Mlssmg

ThiS
is

usually
caused

by
fouled
or

damaged

plugs

plugs
of
the

wrong
heat

range
or
mcorrect
plug
gap
Clean
and

regap
the

spark
plugs
flus

trouble
can
also
be

caused

by
weak

spark
see

symptom
3
or
mcorrect

igmnon
tlIDing

5

Spark
polarity

Less

voltage
is

requrred
to
cause
electron
flow

from

a

relatively
hot
electrode
to
a
cooler
elec

trode

Smce
the
center
electrode
is
hottest
this

electrode
should
be

negative
Electron
flow
lS

then
from
the
center
electrode
to
the
outer
elec

trode
From
20
to
40

percent
more

voltage
is

requrred
to
cause
electron
flow
from

the
outside

electrode
to
the
hotter

center
electrode
This

occurs
when
the

spark

voltage
is

positive
The

cOll
wrres
must
be

connected

correctly

FUEL
SYSTEM

Fuel

system
troubles
must
be
iSolated

at
the

carburetor
fuel

pump
or
fuellrnes
These

pro

cedures
assume
that
the

igmtlon
system
has

been

checked
and

properly
adjusted

I

Engme
Will

not
start

Frrst
detenmne
that
fuellS

reachIng
the
carbu

retor
Remove
the

au
cleaner
look
into
the

carburetor
throat

and

depress
the
accelerator

several
tlIDes

There
should
be
a
stream
of
fuel

from
the

discharge
tube
each
time
the
accelerator

lS

depressed
If
not
the
fuel

pump
lS
not
dehver

mg
fuel
to
the
carburetor
or
the
float

system
m

the
carburetor
lS
not

workmg
Make

certam

there
is
fuel
m
the
fuel
tank
Check
the

automatic

choke
rr
so

equipped
to
make

certain
it
is
not

stuck
If

necessary
rebudd

the
fuel

pump
or

overhaul
the
carburetor

whichever
lS
determmed

to
be

faulty

2

Engme
runs

at

fast
Idle

Usually
thiS
is
caused

by
misadJustment
of
the

carburetor
idle

setting
Readjust
as

required

3

Rough
Idle

or

engme
miss
with

frequent

stallmg

Check
idle
miXture

and
idle

speed
adjustments

Inspect
the

overall
conchtlOn
of
the
carburetor

for

foreign
material
and
clean

or
overhaul

as

required

4

Engme
diesels

contmues
to
run

after

engme
IS
turned

off

Check
idle
IDlXture

and
idle

speed
adjustments

Page 25 of 252

DATSUN 510 1968 Service Repair Manual
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
i

Page 26 of 252

DATSUN 510 1968 Service Repair Manual
ENGINE
AND
IGNITION
TUNE
UP
21

many
types
of
test

eqUipment
and

may
be
used

as
a

gUide
If
the
manufacturer

s

mstructioQs
are

not
aVailable
Connections
shown
in

Figure
1

ENGINE
AND
IGNITION
TUNE
UP
21

many
types
of
test

eqUipment
and

may
be
used

as
a

gUide
If
the
manufacturer

s

mstructioQs
are

not
aVailable
Connections
shown
in

Figure
1

are
as
follows

1
Voltmeter

a
PosItive
lead
to
resistor
side
of
COli

b

Negative
1
ead
to

ground

2

Tlmmg
Light

a
PosItive
lead
to

posItive
battery
termmal

b

Tngger
lead
to
number
1

spark
plug

c

Negative
lead
to

ground

3
Tachometer

a
PosItive

lead
to
dlstnbutor
Side
of
coil

b

Negative
lead
to

ground

4
Dwell
Meter

a

PosItive
lead
to
dlstnbutor
Side
of
COlI

b

Negative
lead
to

ground

BAlTERY
INSPECTION
AND
SERVICE

1
Check
the
level
of
the

electrolyte
m

battery

cells
If

necessary
replemsh
with
distilled
water

Do
not
overfill

2

Measure
the

speCific
gravity
of
the

battery

electrolyte
Refer
to
the

followmg
table
2
Use
the

proper
size
socket
and
wrench
to

remove

spark
plugs
from
the

cyhnder
head

Make
certam
that
the

gaskets
are
removed
from

the

spark
plug
holes

3

Wipe
off
the
msulator
With
a
clean

rag
to

remove

grease
and
dirt

4

Carefully

mspect
the
msulator
and

body
of

each

plug
for

signs
of

cracks
or

chips

Replace

If

faulty

5

Inspect
spark
plug
threads
and
electrodes
for

damage
or
excessive
wear

Replace
as

requrred

Figure
2
shows
the

cond1t
J
on
of

normal
and
de

fectIVe

spark
plugs
along
with

an

explanation

of
the

causes
of

the
abnormal
conditions

6
If
the

spark
plugs
are
still
serviceable
clean

them

thoroughly
With
a

stiff
brush
or

preferably

With
a
sand

blasting
type
of
cleaner

7
File
the

center
electrode

so
that

It
has

a
fiat

surface

8
File
the
surfaces
of
the
outer
electrode

so
that

all
surfaces

are
fiat
and
smooth

9

Usmg
a
feeler

gauge
adjust
clearance
be

tween
the
electrodes
to
0
031
to
0
035
m
0
8

to
0
9mm
as
shown
m

Figure
3

Full

Charge
Value

CD
68

degrees
F

PermiSSIble
Value
20

degrees
C
3

Frigid
chmates

Tropical
chmates

Other
climates
Over
1
22

Over
118

Over
1
20
128

123

126

3
Clean

top
of

battery
and
termmals
With
a

solutIOn
of

bakmg
soda
and
water
Rmse
off
and

dry
thoroughly
Top
of

battery
must
be
clean
to

prevent
current

leakage
between
termmal
and

from

pOSitive
termmal
to
hold
down

clamp
Pro

longed
accumulatIOn
of
aCid
and
dirt
on

top
of

battery
may
cause

blIstenng
of
the
matenal
cov

enng
on
the
connector

straps
and
detenoration

of
the

straps
themselves

4

Tighten
the
cable

connectors
to
the
termmal

securely

5
Coat
the
termmals

lIghtly
With

petrolatum
to

protect
them
from
corrosion

SPARK
PLUGS
INSPECTION

AND
SERVICE

1
Remove

spark
plug
WIres
Mark
them
to
fi

sure
correct

replacement
J

J

I

I

j

j

10
Remstall

spark
plugs
Make
certam
to
use

a
new

gasket
for
each

plug
Use
a

torque
wrench

to

tighten
spark
plugs
from
11
0
to
150
ft
lb

1
5
to
2
0

kg
m

11
Remstall
WIres

DISTRIBUTOR
INSPECTION

AND
SERVICE

Dependmg
on
the
model

year
velucles
have

a

smgle
pomt
or
a
dual

pomt
dlstnbutor

system

Page 30 of 252

DATSUN 510 1968 Service Repair Manual
ENGINE
AND
IGNITION
TUNE
UP
4

25

block
the
throttle
and
choke
m
the
WIde

open

position

3
Remove
all
four

spark
plugs

4

Sequentially
press
a

compressIOn
test

gauge

mto
e

ENGINE
AND
IGNITION
TUNE
UP
4

25

block
the
throttle
and
choke
m
the
WIde

open

position

3
Remove
all
four

spark
plugs

4

Sequentially
press
a

compressIOn
test

gauge

mto
each
of
the

spark
plug
holes
and
crank
the

engme
for
at
least
four
strokes
Record
the
com

pressIOn
readmg
for
each

cylmder
Standard

compressIOn
readmg
IS
171
Ibs
m
12
0

kg
cm
Mmlmum

acceptable
readmg
IS
159

lbs
m
2

11
5

kg
cm

5
No

readmg
should
be
less
than
80
of
the

highest
cylmder
reading
ExceSSive

vanatiC
ns

between

cylmders
accompanied
by
low

speed

mlssmg
of
the

cyhnder
or

cylmders
that
read

low

usually
mdlcates

a
valve
not

properly
seat

mg
or
a
broken

piston
ring

Low

pressures
even

though
uniform

may

mdicate

worn

nngs
ThIS

IS

especlall
true
1f
ex

cessive
011

cQIlsumptlon
has
been
noticed
If
one

or
more

cylmders
read
low

or
uneven

inject

about
a

tablespoon
of

engine
ail

on

top
of
the

piston
of

that

cylinder
and
crank
the

engine

several
tlmes

noting
the

compressIOn
reading

If

compressIOn
has
nsen
the

piston

nngs
or

cylmders
are
worn
and
should

befserviced
If

compressIOn
has
not

unproved
after

addmg
oil

the
valves
are

Stlcking
or
are
not

seating

prop

erly

If
two

adjacent
cylmders
have
low

compres

sion
and

mjectmg
01

9es
not
increas
the
read

mg
the
head

gasket
between
the

cylmders
IS

probably
leaking

VALVE
CLEARANCE
ADJUSTMENT

Valve

adjustment
should
be
done
in
two

steps
first
With
the

engme
cold
and
then
at

operatmg
temperature
Refer
to

Figure
6

and

proceed
as
follows

1
Remove

arr
liter

2
Remove
rocker

arm
cover
Take

care
not
to

damage
the

gasket

3
Remove
the

spark
plugs
and

rotate
the
en

gine
unt1l
number
1

cylinder
IS
at

top
dead
center

o
l
the

compressIOn
stroke
This
can
be
de

tepnmed
w
hen
the

top
dead
center
mark
on

the
crankshaft

pulley
is

m

alignment
With
the

statIOnary

pomter
and
both
valves
for

number

1

cylmder
are
closed

I
4

Counting
from
the
front
of
the

engme
ad

Just
valves
1
2
3

and
5
as
follows
Loosen
the

pivot
lockmg
nut
and
turn
the

pivot
screw
unt1l

clearance
between
the

pivot
screw
and
the
rock

er
ann
IS
0
0079

m
0
200mm
for
the
mtake

valves
and

0
0098
in
0
25mm
for
the

exhaust

valves
Check

clearances
With

a
feeler

gauge
as

shawn
When
correct

tlghten
the

pivot
locking

nut

l

1

5
Rotate
the
crankshaft
unt1l
the
number
4

pISton
IS
at

top
dead

center
an
the

compressIOn

stroke
This

IS
one

complete
revolution
of
the

crankshaft

Agam
the
0

degree
mark
should

align
With
the

pomter
and
both

valves
on
num

ber
4

cylinder
should
be
closed

6

Adjust
valves
4
6
7
and
8

as
above

i

I

7

Replace
spark
plugs
Ignition
WIres

r
ick
r

1

arm
cover

gasket
and
air
filter

8
Start

engine
and

run
it
unt1l

operating
tem

perature
IS
reached

9
Remove
rocker

ann
cover
and

repeava
iius

ment
Clearances
should
be

0
0098

m
0

25fumj

for
the

mtake
valves
and
00Il8
m
0
30mi

for
the
exhaust
valves
Check
clearances
before

loosening
the

pivot
lockmg
nuts
as

they

may

already
be

properly
set
If

not

adjust
as
re

quir
l

ADDmONAL

CHECKS

l

Qunng
tune

ups
check
the

followmg
Ite

far

SignS
of
defects

or
excessive
wear
I

i

1

Inspect
the
carburetor
for

buildup
of

foreign

matenal

Pay
Special
attention
to
the

throat
and

linkages
Clean
or
overhaul
as

required
Det8
1ls

for
carburetor
mamtenance
are

given
in

Chapter

seven

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