1968 DATSUN 510 torque

2

CHAPTER

ONE

Sedan

Four

speed
Floor
Shift
P51O
UT
Pl5lO
T

Pl510

UT

P51O

UA
Pl5lO

A

Pl510
UA
AutomatIc
Three

speed

Wagon

Four

speed
Floor
Shift
WP510
UT
WPl510
T

WPL510
UT

WP510
UA
WPl5lO
A

WPL510
UA
AutomatIc
Three

speed

PIl
Il

up

Four

speed
Floor
Shift
Pl521
TU
Pl521
TN

CD
MAIN

SPECIFICATIONS
AND

DIMENSIONS

Table
1
covers

general
specIfications
and

dImensIOns
DetaIled

system
specIficatIOns
ill

cludmg
clearances
tolerances
and

torque
tlght

enrng
mformatlOn
are

presented
Wlthm
each

chapter

Parts

Replacement

When

you
order

parts
from
the
dealer
or
other

parts
dlstnbutor

always
order

by
engme
and

d

1

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

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

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

30
CHAPTER
FIVE

should
be
1
54
m
39mm
If
the

spnng
tension

is

accurate
the
rehef

valve
should

open
at
54
0

to
59
7
lb

1m
3

8
to
4
2

kg
cm

6
Reassemble
the
oil

pump
Make
certain
all

gaskets
are
mounted
flat

to
avoid
leaks

7
Install
the
dnve

spindle
and
the
oil

pump
to

the
front
cover

8
Install
the
distnbutor
in
the
same
relative

locallon
from
which
it
was
removed
If
the
num

ber
1

cyhnder
was
at

top
dead
center
on
the

compression
stroke
the

punch
mark
on
the
dnve

spindle
should
face
toward
the
front
of
the

engine

9
Install
the
front

splash
shield
and
the
front

stablhzer

10

Insert
the
drain

plug
in
the

pan
and
refill

the

engme

11
Oil

pressure
at
idle
should
be
142
to
17
1

lb

lin
1
0
to
1
2

kg
cm

12

Tlghtenmg
torque
values
for
the
oil

pump

mounting
bolts
is
10
8
to
152ft
lb
1
5
to
2
1

kg
m
and
21
69
to
25
31
ft
lb
3
0
to

25

kg
m

for
the
release

valve

cap
nut

Oil

Filter

The
oil
filter
is
mounted
on
the

nght
hand
side

of
the

cyhnder
block
It

IS
a

cartndge
type
with
built
m

gasket
and
threads
onto
the

mounting

spindle
The
filter
should
be

replaced
every

6
000
miles
as
follows

1
Dram
the

engme
oil
Walt
10
15
minutes

before

removmg
oil
filter

to
allow
It
to
dram

2

By
hand

or
with
the
aid
of

an
oil
filter

wrench

unscrew
the
filter
from
the

spmdle
as

shown

m

Figure
S

3

Cleanmg
of
the

oil
filter

IS
not
recommended

Rather

replace
It
as

reqUIred

4
Thread
the
new
oil
filter
onto
the

mounting

spindle
by
hand
Do
not

overtighten
or

leakage

nught
occur

ENGINE
53

the
mam

beanng
cap
and
the

cyhnder
block

beanng
recess
and

tighten
the

cap
bolts
to
the

proper
torque
WIth
a

torque
wrench

Tig
temng

torque

Main

bearings
506
to
57
8
It
Ib

70to80kg
m

195
to
23
9
It
Ib

27
to3
3

kg
m
Rod

beanngs

9
Loosen
the

cap
bolt
on
one
Side
and
measure

the
clearance

Figure
53
between
the

cap
and

block
Side
Clearance
should
be
WIthm
the
fol

lowmg
specmcatIons
Mam

beanngs
0

through

o

0024
m
0
to
0
06mm
rod

beanngs
00012

through
0
0032
m
0
030
to
0
0024mm

Weight
@

10
If

beanng
crush
IS
not
m
tolerance

replace

the

beanngs

Crankshaft
and
Camshaft

Sprockets

1
Check
for

damaged
teeth

Replace
sprocket

1f

necessary

2
Install
the

camshaft

sprocket
and
check
for

runout
as
shown
m

Figure
54
If
over
0
04331

m
0
Imm

replace
the

sprocket
Check
for

thrust
deViation
at
the
same
tIme
Thrust
deVia

tIOn

should
be
between
0
0031
and
0
0150
m

008
to
0
38mm

3
Check
the
chain
for

damage
severe
wear

and
stretch
at
the
roller
hnks

Replace
the
cham

1f
defects
or
exceSSIve
stretch
IS
found

4
Check
the
cham
tenslOner
and
the
cham

gwdes
for
wear
and

damage

Flywheel

1
Check
the
clutch
disc
contact
surface
of
the

flywheel
for
wear
and

damage
@

2

Measure
deviation
of
the
clutch
disc
contact

surface

usmg
a
dial

gauge
If
deVIation
exceeds

004331
m
O
lmm

replace
the

flywheel

3
Check

flywheel
teeth
for

damage
Consult
a

dealer

Or
machIne

shop
1f
m
doubt

ENGINE
ASSEMBLY

This
section
covers

assembly
of
the

engme

after
corrective
mamtenance
has
been
com

pleted
SpecificatIons
and

torque
informatIon

are

given
at
the
end
of
the
sectIon
The

followmg

general
precautions
should
be
followed
m

assembhng
the

engme

1
Make
certam

all

parts
are

thoroughly
clean

and
that
all
011
and
water

passages
are
free
from

foreign
matenal

2
All

parts
that

slIde
mto
or

through
other

parts

should
be
coated
With
a
thm
film
of
new

engme

011
before

assembly

3
Don
t
reuse

gaskets
packIng
and
011
seals

Complete
lats
are
aVlUlable
for
the
entire

engme

and
for
the

cyhnder
head
and
block
assemblIes

4

Keep
tools
and
work
benches
clean
to
aVOid

contammatlon
of
delIcate

parts

5
Be

sure
to
follow

specmed
torque
tIghtenmg

values
and
order

of

tlghtenmg
where

given

6

Unless

complete
rebwld

of
the

engme
has

been
done
valves
and
associated

parts
bear

ings
pistons
and

connectIng
rods
should
be

remstalled
where

they
were
taken
from

CYLINDER

HEAD

Valve
and
Valve

Spring
Assembly

1
Insert
valve
from
bottom
of
block

54

CHAP1ER
SIX

2
Set
the
valve

spnng
seat

m

position
on
the

top
of
the
block
and

over
the

valve
stem

3
Place
the
oil
seal
over
the

valve
stem

4
Place
the

mner
and

outer
valve

spnngs
over

the
valve
stem

S

Place
the

spnng
retamer

over
the

springs

compress
spnngs
With

spring
compressor
Figure

55
and
mstall
valve
collets
around
valve
stem

so
that

they
lock
onto
stem

6
Release

spnng
compressor
If
collets
are
firm

ly
locked
onto
the

groove
m
the

valve
stem

assembly
IS

complete

7
Install
the
rocker

guIde
on

top
of
the

valve

stem
when

assemblmg
the
rocker

pivot
assembly

VaIve
Rocker
Pivot

Assembly

1
Thread
lock
nut
onto
valve
rocker

pivOt
and

place
rocker
retaIner
over
the
valve
rocker

pivOt

2
Thread
the
above

assembly
mto
the
rocker

bushIng
protrudIng
from
the

head

Camshaft

Assembly

1
Mount
the

locatIng
plate
on
the
front
of
the

head
as

shown
m

FJgIlI
1
56

2
From
the
back
of
the
head

carefully
InSert

the
camshaft

through
the

four
camshaft

beanngs

being
ca
efu1
not
to
move
or

damage
the
bear

ings

NOTE
Install
the

CQJ7IShaft

sprocket

onto
the

camshaft
so
that

the
three

locating
holes
are

at
the

top
left
and

bottom
h

1
3

Install
the

camshaft

sprocket
and
fuel

pump

cam
onto

the
front
of
the

camshaft
and

torque

to

specificatIon

4
Check
the
camshaft
for
end

play
using
a

feeler

gauge
as

preViously
described

Rocker
Pivot

Assembly

1
Push
down
on
valve

spnng
with
screwdriver

and
insert
rocker

piVOt
arm
between
camshaft

and
valve
stem

Insert
rocker
valve

guide
onto

top
of

valve
stem

at
this
time

2
Install
valve

rocker

springs
over

top
of
rocker

pivot
arm

Piston
and

Connecting
Rod

Assembly

1

Assemble
the
four

pistons

pms
and
connect

mg
rods
Secure

piston

pm
The

connecting
rod

IS

press
fitted
onto
the

pISton
pin
With
from
1
to

3
tons
of
force

NOTE
The

pistons
are

marked
with

an
F
which

should

point
toward
the

front
of
the

engine
The

connecting

rods

must
be
installed
so

that
the
011

Jet
In
the

large
end

IS

positioned
to

ward
the

right
Side

of
the

tnglne
The

center

of
the

piston
pin
IS

oD
set
In

relation
to
the

center

of
the

piston
so

correct

assembly
is
cntical

2
Use
a

nng
expander
to
install
the

rings
onto

the

pistons
Install
the

top
and
rmddle

nngs

with
the
marks

up

3

Lubncate
the

rod

bearings
hghtly
and
mstall

them
into

their

respective

connectIng
rods
and

rod

caps

ENGINE
55

Cylinder
Block

Assembly

1
PositIon
all
crankshaft

parts
on
a
work
bench

ThIS
mcludes
the
crankshaft
main

beanngs

rear
011

seal
woodruff

keys
crankshaft

gear

011

pump
gear
011
thrower
bolts
and

bearing

caps
Figure
57
shows
the

arrangement

@

2
Insert
maIO

beanngs
mto

appropnate
cy1m

der
block
holders

NOTE
The
center
No
3

beanng
IS

the

only
flanged
type
of
thrust
bear

Ing
Bearings
No
2
and
No
4
are

Identical
No
1
and
No
5

Jaring
ap

pear
identical
but
No
1
as
an
011

hole
All

bearings
except
No
1
are

Interchangeable
as
to

upper
and
lower

half

3

LIghtly
lubncate
the

crankshaft
and

beanng

matmg
surfaces
then
mstall

beanngs
10
mam

beanng
caps

4
Install
the
crankshaft

5
Install
mam

beanng
caps
over

crankshaft

msert
mam

cap
bolts
and

tighten
hghtly
The

mam

beanng
caps
have
an
arrow
marked
on

each
one
These
must

pomt
to
the
front
of
the

engme

6

Gently
move
the
crankshaft
10
an
aXIal
drrec

don

toward
the
front
of
the

engme
to

venfy
that

the
mam

beanng
caps
are

properly
alIgned
and

seated
7
Use
a

torque
wrench
to

tighten
the

cap
bolts

to
the
hmlts

speCIfied
The

t1ghtenmg
operatIon

should
be
done

gradually
10
three

or
four

sep

arate

stages
starting
10
the
center
and

workmg

outward

to
each
end

8
Rotate
the
crankshaft
to
make
certain
it
isn
t

bmding

9
Use
a
feeler

gauge
to
check
the
end

play
at

the
center

No
3

beanng
Figure
58

10
Install
the
SIde
oll
seals
into
the
rear
mam

cap
and

cy1mder
block
as
shown
10

Figure
59

@

11
Install
the
rear
011
seal
WIth
Datsun
tool

ST49370000
or

equIvalent

12
Install
the
rear
end

plate

13
Install
the

flywheel
WIth

proper
bolts
and

lock
washers
and

torque
as

specified