1968-1973 Datsun 510 and PL 521 Pick-Up Service & Repair Manual

j y 1 10 2 and 4 doOt and i ftUSt eI C I II I L u l c lDQ I 1 to 1913 091 3 CU n o

Datsun Owners Workshop Manual by J H Haynes ASSOCIate Member of the GUIld of Motorrng WrIters and B L Chalmers Hunt TEng eEl AMIMI AMIRTE AMVBRA Models covered UK Datsun 1300Saloon 1296ee Datsun 1400 Saloon 1428 ee Datsun 1600 Saloon and Estate 1595 ee USA Datsun PL 510 2 door Sedan 97 3 eu In Datsun PL 5104 door Sedan 97 3 eu In Datsun WPL510 Wagon 97 3 eu In Datsun PL 521 Pickup 11 1 Hustler 97 3 eu In ISBN 0 85696 123 X @ J H Haynes and Company Limited 1974 All roghts reserved No part of thIS book may be reproduced or transmitted on any form or by any means electronle or mechanoeal oneludlng photOCOPYIng recording or by any information storage or retrieval system Without permission In wtltong from the copy tight holder Pnnted In England e J H HAYNES AND COMPANY LIMITED SPARKFORD YEOVIL SOMERSET ENGLAND dlltrlbuted on the USA by HAYNES PUBLICATIONS INC 9421 WINNETKA AVENUE CHATSWORTH LOS ANGELES CALIFORNIA 91311 USA

Acknowledgements Our thanks must go to the Nossan Motor Company LImIted of Japan for the use of some of their techmcallllustratlons About this manual Castrol LImIted and ehamplon L mIted gave their usual help WIth lubncatlon and spark plugs respectIvely Stanley Randolph page edIted the text The 81m of tillS book IS to help you get the best value from your car It can dO so In two ways Forst It can help you deCIde what wotk must be done even should you ehoose to have It done by a garage the routIne maintenance and the doagnoSls and coune of actIon when random faults occur But it IS hoped that you will also use the second and fuller purpose by taCkling the work yourself ThIS can gIVe you the satIsfactIon of dOIng the Job younelf On the SImpler JObs It may even be qUICker than booking the car Into a garage and goIng thera twice to leave and collect It Perhaps most Important much money can be saved by avoIding the costs a garage must charge to cover theIr labour and overheads The book has draWings and descriptIons to show the functIon of the various components so that theIr layout can be under stood The tasks are described In a step by step sequenee so that even a novIce can cope with complICated work Sueh a peroon IS often the very one to buy a car needing repair yet be unable to afford garage costs The JObs are descrobed assuming only normal spanners are avadable and not specIal tools But a reasonable OUtfIt of tools WIll be a worthwhile Investment Many specoal workshop tools produced by the manufacturer merely speed the work and In lhese cases guIdance is gIVen as to how to do the Job WIthout them the often quoted example being the use of a large hose elJp to compress the pIston ron9S for insertIon In the cylonder But on a very few occaSIons the specIal tool IS essentl8l to prevent damage to components then theor use os descnbed Though It mIght be poSSIble to borrow the tool sueh work may have to be entrusted to the offICIal Datsun dealer To avoId labour costs a garage WIll often gIve a cheaper repaIr by fl ng dltloned assembly T o e mech n Il helped by thos book to dIagnose the fault and make a repair uSing only 8 mrnor spare part The claSSIC case IS repalrmg a non functIoning starter motor by fitting new brushes The manufacturer s offlel8l workshop manuals arewrItten for theor traIned staff and so assume specIal knowledge detaIl os left out Thos book IS written for the owner and so goes Into such detaIl The book IS dIVIded Into twelve ehapters Each ehapter IS dIVIded Imo numbered sectIons whIch are headed In bold type between horozontal lines Each sectIon consists of rlally numbered paragraphs illustratIons are numbered according to ehapter and sequence of oceurrence In that ehaptar Procedures once descrIbed In the text are not normally repeated If It IS necessary to refer to another Chapter the reference WIll be glV8n In ehapter number and SectIon number thus ehapter 1 16 If It IS consodered necessary to refer to a partIcular paragraph In another Chapter the reference IS e g Chapter 1 5 5 eross references gIVen Without the use of the word ehapter apply to sectIons In the same ehapter e g see SectIon 8 means also In thIS ehapter When the left or roght SIde of a car IS mentioned It IS as If lookIng forward Great effort has been made to ensure that thos book os complete and up to dot The manufacturers continually modIfy theor cars even In retrospect Whilst every care os taken to ensure that the informatIon In thIS manual os eorrect no liabIlity can be accepted by the authors or publishers for loss damage or Injury caused by any errors In or omISSions from th mfor

3 r r l r W Datsun 1600 Estate North American version

Introduction to the Datsun The range of vehleles dealt wIth In thIS manual IS called the 510 S8roes In Nonh Ameroca and the 1300 1400 or 1600 on the Unrted Kingdom dependmg on Its individual engine size Throughout thIS manual therefore the carS are SImply known as the 510 seroes but are dIfferentIated by body style and engine capacity as and when necessary An anolysls of the range IS falrlv simple for both markets v e have obvIOusly found It poSSIble to onclude both Nonh Amenean specification cars and UK cars 10 the same book Without difficulty such IS their baSIC similarity Series Model number Sanal prefIX Body style Transmission 510 091 PL510 2 door saloon Manual 510 092 PL510 2 door saloon AutomatiC 510 094 PL510 4 door saloon Manual 510 095 PL510 4 door saloon Automatic 510 194 PL510 Wagon Estate Manual 510 195 PL510 Wagon Estate Autcmatlc 521 395 PL521 PIck up Manual The 510 saloon was flfst ontroduced to both markets late In 1968 but was not actually avaIlable In the UK untIl early the follOWIng year Produetlon has stopped of all models except for the 2 door saloon Ion USA and the p ek Jp now called LBl Hustler although It IS thought that the 510 saloon WIll soon stOp The series has been phenomenally successful 10 North Amenca because the total package was nght As they were Introduced on the UK before any deep market penetratIon had taken place by Datsun UK they were less of a success In numerical terms although they have paved the way for the now current 610 160 and 180 senes Simple In concept and conventional In construction they have a reputatlon of strength and economy they also have some performance too If their racing success In Amenca IS anvthlng to go by Some models are not available In both markets the 1400 saloon IS UK only whilst the estate and pick up are North Amencan only

Use of Enghsh 5 As thIS book has been wtlnen m the URlted K mgdom It uses the approproate EnglISh eomponent names Some of these dIffer from those used m America Normally thIS cause no d ff eulty But to make sure a glossary IS prmted below Glossary EnglISh AntI roil bar Bonnet engine coved Boot luggage eompartmentl Bottom gear Bulkhead Clearance erownwheel Cateh Camfollower or tappet Cat s eye e rcllp Drop arm Drop head eoupe Dynamo Earth electrical Estate car Exhaust maRlfold Fault fmdmg Free play Free wheel Gudgeon pm Gearchange Gearbox Hood Hard top Half shaft Hotspot Leading shoe of brake Layshaft of gearbox Mudguard or wing Motorway Paraffin Petrol Reverse Saloon Split cotter for valve spring cap Split pm Sump Silencer Steen og arm S de light S de marker light Spanner Tappet Tab washer Top gear Transmission Trallmg shoe of brake Track rod of steering Wmdscreen Am lean StablllSer or sway bar Hood Trunk 1st gear Forewall Lash Rmg gear of dIfferentIal Lateh Valve lifter or tappet Road reflectmg lane marker Snap ring Pitman arm ConvertIble Generator DC Grou nd StatIon wagon Header Trouble shootmg Lash Coast Piston Pin or Wrist pm ShIft TransmIssIon Soft top Hard top Axle shaft Heat riser Prnnary shoe Cou oter shaft Fender Freeway turnpike ete Kerosene Gas Back up Sedan Lock for valve spring retamer Cotter pm Oil pan Muffler Spmdle arm Parkmg lIght Cat s eye Wrench Valve lIfter Tang lock HIgh Whole drove Ime from clutch to axle shaft Secondary shoe Tie rod or connecting rod Wmdshleld Miscellaneous pOints An 0 1 seal IS fitted to components lubricated by grease I A Damper 1 a Shock absorber It damps out bounCing and absorbs shocks of bump Impact Both names are correct and both are used haphazardly Note that Bntlsh drum brakes are different from the BendiX type that IS common In Amenca so different deSCriptive names result The shoe end furthest from the hydraulic wheel cylinder IS on a pivot interconnection between the shoes as on BendiX brakes IS most uncommon Therefore the phrase Primary or Secondary shoe does not apply A shoe IS said to be Leading or Trailing A iLeadmq shoe ISone on whIch a JXIlnt On the drum as It rotates forward reaches the shoe at the end worked by the hydrauliC cylinder before theanchor end The opposite IS a trailing shoe and thiS one has no self seNO from the wrapping effect of the rotating drum The word Tuning has a narrower meanmg than 10 Amenca and applies to that engme servicing to ensure full power The words Service Or Maintenance are used where an Amencan would say Tune up

MetriC ConwrIlon Tables 7 Spanner size equivalents AF Whit Fits Metne MerrIe SIze A F Inch EquIValent A F EquIValent 4BA 0248 9 64 63 7 0276 2BA 032 3116 81 8 0315 9 0 35 10 0 39 7116 044 1 4UNF 112 11 0413 045 3116 1 4 BSF 114 12 047 1 2 050 516 UNF 127 13 051 053 1 4 516 BSF 135 9 16 056 318 UNF 142 14 055 0604 516 318 BSF 153 15 0 59 5 8 063 7 16 Bolt 16 16 063 17 067 11 16 069 7 16 Some nuts 175 072 318 7 16 BSF 183 18 071 314 076 1 2 UNF 193 19 075 20 079 13116 082 20 8 083 7 16 1 2 BSF 211 21 0 83 7 8 088 9 16 Some nuts 224 22 087 093 1 2 9 16 BSF 236 23 0 91 15 16 094 58 UN F 23 8 24 0 945 25 0 985 I 101 256 102 9 16 5 8 BSF 259 26 1 02 11 16 107 58 Heavy UNF 272 27 106 111 58 11 16 BSF 282 28 tl0 1 1 8 113 314 UNF 287 29 114 30 118 121 11 16 314 BSF 307 31 122 11 4 126 314 Heavy UNF 320 32 126 1 31 314 7 8 8SF 333 33 1 3 15 16 132 7 8 UNF 335 34 134 35 138 149 7 8 1 BSF 378 36 142 37 146

Contents Chapter SectIon Paga Section Page Use of Englosh 5 Routine mamtenance 10 MetriC conversion tables 6 Lubrication chart 13 Ordenng spare parts 9 1 EngIne General descrtptlon 20 Reassembly 36 Removal 20 RefItting 41 Dlsmantlmg 24 Start up after overhaul 42 Decarbonlsatlon 30 Fault dIagnoSIs 42 2 Cooling system DrainIng flushing flllong 45 Water pump 47 RadIator 46 Fan belt adjustment 50 Thermostat 47 Fault diagnOSIs 51 3 Carburet on and exhaust emISSIOns A If cleaner 54 Exhaust emiSSion control 66 Fuel pump 54 Dual contact breaker pOint distributor 70 Carburettor 56 EvaporatIVe control system 71 Fuel tank 62 Fault dIagnoSIs 73 4 IgnotlOn system Contact breaker po lOts 75 Tlmmg 80 Condenser 75 Spark plugs 81 Dlstnbutor 79 Fault diagnOSIs 83 5 Clutch Bleeding 86 Master cylinder 91 Adjustment 86 Slave eylonder 92 Removal and refItting 89 Fault dIagnoSIs 93 6 Gearbox and automatic transmISSion Removal and replacement 97 Automatic transmiSSion 113 Dismantling 99 Fault diagnoSIs automat e 116 Reassembly 103 Fault diagnoSIs manuaU 119 7 Propeller shaft Removal and replacement 122 Universal Jomts 122 8 Rear axle FlRal dnve and dIfferentIal 126 Rear axle removal and replacement 131 Pinion 011 seal 129 Dlfferent al assembly 133 9 BrakIng system Adjustment 136 Wheel cylrnder 141 Bleeding 136 Master cylonder 145 DISC face 137 Vacuum servo umt 148 Drum shoes 139 Fault dIagnoSIs 149 10 ElectrIcal system Battery 160 SWItches 169 Alternator 161 Horn 172 Starter motor 163 Windscreen wiper 172 LIghts 165 Fault diagnOSIs 179 11 SuspensIon and steerong Front wheel hub 194 Steenng gearbox 210 Front suspension 197 Steerong wheel 215 Rear suspension 204 Steering column 215 Drove shaft 206 Fault diagnOSIs 217 12 Bodywork and underfreme Maintenance 218 Bonnet 223 Repairs 219 Boot lid 224 Bumpers 219 Doors 224 Wmdscreen 221 Heater and ventilator 232 LIst of Illustrations 238 Inde 244

Ordenng spare parts Buy genuine Datsun spares from a Datsun dealer direct If you can If you go to an authorlsed dealer genuine parts can usually be supplied from stock Always have details of the car Its serial and engine numbers available when ordering parts If you can take along the part to be renewed It IS helpful Modifications were continually being made and many were not pubhclsed A storemsn In a parts department IS qUite Justified In saYing that he cannot guarantee the correctness of a part unless these relevant numbers are available The car Identification plate IS attached to the centre of the top of the bulkhead and ISvISIble when the bonnet IS fully open The car number IS stamped on a plate which also IS attached to the top of the bulkhead The engine number 1 located on the rear fight hand Side of the cylinder block When obtaining new parts remember that some assemblies may be exchanged ThiS IS very much cheaper than buymg them outfight and thrOWing the old part away Before handIng baek an Item m exchange always clean It to remove dirt and 011 Engme number location ear dentlf eatlon plate

1968-1973 Datsun 510 and PL 521 Pick-Up Service & Repair Manual

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