Datsun 510 series Workshop Manual Download Page 12

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Summary of Contents for 510 series

Page 1: ...0 f j 1 1R1 1M o o 7 o I r t Jot I 0 4 V J 7 F 4 2 V y oomm llI IP c J ffi DRAKE PUBLlSHERS INC r ...

Page 2: ...ference source with which he perform normal ervice operations We ndeavor to rporato the late t manufacturing design changes nd upto date specifications at the time of publication While ryeffort made to attain cy the Publisher not be held Ipon ible for manufacturing changes typographical rors or omissions Upon ompiting the formation contained herein we have tried to be brief and impls elying on the...

Page 3: ...ISBN 87749 302 2 Published in 1973 by Dlake Publishers Inc 381 Palk Avenue South NewYolk N Y 10016 Dlake Publishels Inc 1973 Printed in the United States of America ...

Page 4: ...T DISTRIBUTOR 12 SPARK PLUGS 5 Cap and Rotor Head 12 Description 5 Point 12 Inspection 58 Phase Difference 12 Cleaning and Regap 58 TUNE UP GUIDE 14 TROUBLE SHOOTING IGNITION 58 TROUBLE SHOOTING 15 HEATER UNIT REMOVAL 59 TROUBLESHOOTING HEADLIGHT 62 TROUBLESHOOTINQ HORN 63 ENGINE RADIO 63 Removal 63 DESCRIPTION 22 TROUBLESHOOTING REMOVAL 23 SPEEDOMETER 64 INSTALLATION 24 TROUBLESHOOTING HEATER 65 ...

Page 5: ...ATIONS 97 Installation 79 THERMOSTAT 79 Removal and Installation 79 CLUTCH RADIATOR 79 Removal and Installation 9 REMOVAL 102 Inspection 80 RELEASE BEARING 102 REPAIR 103 Refacing Pressure Plate 103 ADJUSTMENT 104 BRAKES INSTALLATION 104 MASTER CYLINDER 105 MASTER CYLINDER 82 Removal 105 Removal 82 Disassembly 105 Installation 82 Inspection 106 FRONT DISC BRAKE 82 Assembly 106 Installation 106 Des...

Page 6: ...ion 116 MANUAL TRANSMISSION 12 Adjustment 11 CARBURETOR 131 TRUNK LID 11 CLUTCH 134 Removal and Installation 11 ENGINE TORQUE INFORMATION 136 Torsion Bar Removal TUNE UP 138 and Adjustment 117 LUBRICANTS SAE 138 CAPACITIES PRESSURES 139 AUTOMATIC TRANSMISSION 140 SPECIFICAliONS PROPELLER SHAFT 144 BRAKE CHASSIS WHEEL SfARTER 120 ALIGNMENT 146 DISTRIBUTOR 121 NOTES 14 a ...

Page 7: ...RESSION 7 Test Result 8 BATTERY 8 IGNITION TIMING 9 POINTS 9 CONDENSER 9 SPARK PLUGS 10 CARBURETOR 10 Idle Limiter Cap 11 CHECKING ADJUSTING DASH POT Automatic Transmission Only 11 Installed on Engine 11 DUAL POINT DISTRIBUTOR 12 Cap and Rotor Head 12 Point 12 Phase Difference 12 TUNE UP GUIDE 14 TROUBLE SHOOTING 15 I ...

Page 8: ...adjust as necessary Replace the camshaft cover using a new gasket if the old gasket appears tlattened or broken Run engine and check for leaks from the gasket Valve clearance Unit mOl in I Intake 0 20 0 008 Cold Exhaust 0 25 0 010 Intake 0 25 0 010 Warm Exhaust 0 30 0 012 Ag 1 Adjusting valve clearance 8 FAN BELT Check for cracks or damage Replace if necessary Adjust belt tension It is correct if ...

Page 9: ...m from rusting and corrosion The L LC does not contain any glycerine ethyl or alcohol It will not evaporate or boil away and can be used with either high or low temperature thermostats Itflows freely tran sfers heat eniciently and will not clog the passages in the cooling system The L L C must not be mixed with other product This coolant can be used throughout the seasons of the year Whenever any ...

Page 10: ...r in comhustion chambers can 1 11 from this trouhle nmpre ion prC Sl1re p i at rpm Standard 1 c 1350 Minimum 128 350 BATTERY Check electrolyte level in each batterv cell Unscrew each liller cap and inspect lluid level Ifthe lluid is low add distilled water to bring the level up approximately 0 394 to 0 787 in above the plates Do not overlill Measure the specitic gravity of battery elec trolyte Cle...

Page 11: ...Check the distributor breaker points for ab normal pitting and wear Replace if necessary Make sure they are in correct alignment for Fig 6 Adjusting ignition timing full contact and that point dwell and gap are correct Clean and apply distributor grease to the earn and wick Note Do not apply grease excessively Point gap 0 0177 to 0 0217 in Dwell angle 49 to 55 degrees CONDENSER Clean outlet of con...

Page 12: ... 1 in N range tor automatic transmission L EEOBO Fig 9 Checking spark plug point gap 10 Check ignition timing if neceesary adjust it to the specillcations 15 800 rpm retard sidel Adjust idle adjusting screw so that CO per centage is 1 5 0 5 Repeat the procedures as described in items 3 and 5 above so that CO percentage is 1 5 0 5 at 800 rpm Caution a On automatic transmission equipped model check ...

Page 13: ...T031 Fig 11 Setting idle limiter cap Fig 12 Dash pot adjustment CHECKING AND ADJUSTING DASH POT Automatic Transmission only Proper contact hetween throttle lever and dash pot stem provides normal dash pot per lonnance Adju tmenl of the proper contact can he made bv dash pot set screw If normal set can not be obtained between dash pot stem and throttle arm rotate dash pot to the proper position Ins...

Page 14: ...r tiOt or with oil slone At this time grease must be supplied to canHhaft and carn heel Do not applv ex cessively 1 When wear on each breaker point i noticeable replace points together with con tact an11 Fig 14 Checking of distributor breaker point gap 12 Point gap C018 to z in Dwell angle 49 to 550 If point gap IS adjusted by examining dwell angle install distributor on engine and proceed as foll...

Page 15: ...grees in terms of crank shaft angular displacement EEl38 Fig 18 Phase difference adjusting scale To correct further proceed as follows Referring to Figure 6 turn out adjuster plate set screw 12 to 2 turns The screw is located at contact set on retard side Using a notch in adjuster place as a hold turn adjuster plate as required until correct delay is ohtained Ignition is retarded when plate is tur...

Page 16: ...nlrol system lluottle switch operating angle L18 L16 t5tO Lib 620 AfT MfT AfT MfT degK e degree degree Thermo switchoperating temperature or OF Adjustment of operating pressure f a cO D R C 0 0 set pressure AfT MfT A T C Air cleaner A T C Valve opening temperature H mmHg inHg mmHg inHg Or OF 5 IB T O C 0 45100 5510 0177 toO 02t7 49 to 55 retard side 0 05 advance side 0 22 5 50 800 retard side 1 5 ...

Page 17: ...ive igmllon switch Defc tive st lrter oloL Repla c with proper grade il Charge ballery Replace Adjust Inspect Correcl n Repair Repair replace replace T ouble shooting procedure starting cin uil Switch on the starting motor with light ON When light goes off dims nsiderably Che k baltery b Check nnection and able Check s aller olur When light 51 s bright Che k wiring cllOn between h lttery nd Slarte...

Page 18: ... valve clearance Compression leak fromvaIve seat Sticky valve stem Weak defective alve springs Compression leak at cylinder head gasket Slicking or defective piston ing Worn piston ing cylinder Trouble shooting procedure Pour the engine iI from plug hole nd then measure cylinder compression Compression increases Compression does not change Check for loose terminal ordisconnection primary circuit C...

Page 19: ...ol solenoid Sticked anti stall dash pot Ignition syltem trouble Incorrect ignition timing Defective spark plugs Defective distributor points Fuel system trouble Air ntake syltem in trouble Malfunction of choke system Clogged fuel pipe or floating valve Dirty or clogged fuel strainer Fuel pump will notwork properly Clogged carburetor jets Gagged air cleaner Air inhaling from manifold gasket or carb...

Page 20: ...e is accelerated Cause a misfue on each cylinder and if the noise deminiwi almost completely this crankshaft bearing generates the noise When you hear an overlapping metalic noise which increases its magnitude with the revolution of enaine and which decreases u engiIe is warmed up this noi3e is caused by piston and cylinder To locate the place cause amisfue on each cylinder Corrective action Reple...

Page 21: ...idling Run on Improperly adjusted valve clearance Excess carbon in combustion chamber DaJ llaged valve spring back fire after fire Loose oil drain plug Loose or damaged oil pan gasket Loose or damaged chain over gasket Defective oil seal in front and rear of crankshaft Loose or damaged locker cover gasket fmproper tightening of oil mter Loose or damaged oil pressure switch Corrective action This m...

Page 22: ...e switch Oil pressure decreases Defective quality or contamination of oil Defective air cleaner Overheat or overcoal Improper fuel mixture Decrease of oil pressure lnsufficient clearances Overheat Improper fuel mixture Corrective action Overhaul cylinder and new piston Remount piston ings Renew rings Repair or renew piston and cylinder Renew piston and piston ring Replace seal lip witha new one Re...

Page 23: ...CRIPTION REMOVAL INSTALLATION DISASSEMBLY Pistons and Connecting Rods Cylinder Head ASSEMBLY Cylinder Head Piston and Connecting Rods Engine OIL PUMP Removal Installation 22 23 24 24 27 27 27 28 29 30 36 36 37 21 ...

Page 24: ...er The cylinder block is cast in a single unit featuring deep skirting The L16 and L18 engines feature a H C valves wedge shaped combustion chamber alminum heads and fully balanced 5 bearing These engines are equipped with a single EM256 Fig 19 Cross section view 22 ...

Page 25: ...operating cylinder Disconnect thc fuel tube from the fuel pump If equippcd with heater remove its hoses at engine attachment Disconncct accelerator control linkage and choke wire at the carburetor side Disconnect the wirings for the starter alter n tor ignition coil oil pressure switch and thcrmaI transmitter Hemove the clutcb operating cylinder and its return spring Disconnect the speedometer cab...

Page 26: ...TION Reverse the removal procedure but do not con nect any parts to the engine steadily until the engine mounting insulators have been replaced and power unit weight is taken by them Fig 22 Engine on ngine stand Fig 23 Removing thermostat housing 24 DlSASSEMBL Y Remove transmission from engine Thoroughly drain engine oil and coolant by removing drain plugs Place engine assembly on the engine stand...

Page 27: ...r the convenience of cylinder head replacement special tool Chain Stopper STt742000I is prepared to sup port timing chain during the service operation By using this tool timing marks on crankshaft sprocket and timing EM095 Fig 26 Cylinder head bolt loosening sequence fig 29 Removing chain tensioner and timing chain j 1r Jp r k I W EM096 Fig 27 Supporting timing chain Fig 30 Removing chain drive sp...

Page 28: ...moving piston ring ST I 3030001 EM103 STl651S000 J EM099 Fig 33 Removing rear main bearing cap Fig 37 Removing piston pin I I Fig 34 Removing rear oil seal Fig 38 Removing rocker arm EM105 Fig 35 Removing buffle plate and net Fig 39 Removing camshaft 28 ...

Page 29: ...ith a ring remover Press all t piston pin Keep the disassembled parts in order STl2070000 EM106 Fig 40 Removing valve Cylinder Head Loosen valve rocker pivot lock nut and remove rocker arm by pressing down valve spnng Note Take care not to lose valve rocker guide Hemove camshaft Note At this time take care not to damage camshaft bearings and cam lohes Remove valves Take care not to lose valve spri...

Page 30: ... 42 Applying scalant Front cover and gasket 20 to 25 mm I I 7 to 0 984 in U 1 Points to be appl ed sealant all II E i EM151 S Fig 43 Applying sealant Main bearing cap and cylinder block 28 Using special tool Valve Lifter STt2070000 et valve spring seat in po ition and tit valve guide with oil seal Assemble valve in the order shown below alve inner and outer valve springs spring retainer valve coll...

Page 31: ...l No piston is at T D C on its compreHsion stroke Piston and Connecting Rod Assemnle pistons pist n pins and connecting rods to the designated cylinder Notes a Piston is pressed into connecting rod and fitting force is 0 5 to 15 tons and the aid of special tool Piston Pin Press Stand ST13030001 is necessary When pressing piston pin in connec ting rod apply engine oil to pin and small end of connec...

Page 32: ...as rear bearing No 5 The difference is that an oil hole is provided in the front bearing All bearings except No 1 bearing have an interchangeability between upper and lower bearings Applv engine oil to main bearing surfaces on hoth sides ofcylinder block and cap Install crankshaft Install main bearing cap and tighten bolts to pecitied torque Tightening tOlque 32 5 to 39 8 ft lb Notes Apply sealant...

Page 33: ...o rear main bearing cap Prior to installing applv sealant to these seals Install rear oil seal using special tool Crankshaft Rear Oil Seal Drift STt5310000 Applv a lithium grease to sealing lip of oil seal Install rear end plate Install tlywheel securely and tighten bolts to specitied torque Tightening torque 101 to 116 ft Ib Ij Pi r ction Fig 56 Installing piston rod assembly Fig 57 Piston ring d...

Page 34: ...o not apply sealant to any other part of cvlinder block and head surface Fig 59 Checking big end play 32 Turn crankshaft until No 1 piston is at T D C on its compression stroke Make sure that camshaft sprocket location notch and plate oblong groove are aligned at their correct positions When installing cylinder head make sure that all valves are apart from heads of pistons Do not rotate crankshatl...

Page 35: ...ver is disassembled I Fig 62 Installing chain tensioner Fig 63 Installing runt cover Instal1 front cover with gasket in place Notes Apply sealant to front side of cylinder block and front cover gasket as shown in Figure 42 Apply sealant only ta the top of front cover as shown in Figure 42 Install front cover with head gasket in place Check the height difference between cylinder block upper face an...

Page 36: ... if necessary retighten Install oil pump and distributor driving spin dle into front cover EM175 Fig 65 Installing crankshaft pulley and water pump 8 0 o A B 0 0 A B 0 0 B 8 0 o A B O 0 A EM176 FIg 66 Cylinder head bolts at Tightening torque 8 0 to 10 8 ft lb Notes Assemble oil pump and drive spindle making driving spindle mark face to oil pump hole Install oil pump together with drive spin dle so...

Page 37: ...several minutes finally adjust the clearance to the warm specifications Install rear engine slinger exhaust manifold and intake manifold Tightening torque 8 7 to 116 ft lb Install distributor assembly Install carburetor assembly and carburetor in sulator with stamp facing upward Tightening torque 3 6 to 7 2 ft lb Install fuel pipes and vacuum hose All pipes and hoses should be clamped securely bei...

Page 38: ...8 ETOO7 held within 0 315 to 0 472 in when thumb pressure is applied midway between pulleys A pressed force is about 22 0 lb Install engine mount bracket right hand oil filter oil pressure switch oil level gauge and water drain plug When installing an oil filter fasten it on cylinder block by hand Note Do not overtighten filter or oil Ieakage may occur Pour engine oil up to specified level OIL PUM...

Page 39: ... Figure 73 Using a new gasket install oil pump and drive spindle assembly so that the projection BDgine on its top is located in 11 25 a m position at this time the smaller bow shape will be placed toward the front as shown in Figure 74 Ascertain whether the engagement is order or not by checking the top of spindle through distributor fitting hole Tighten bolts securing oil pump to front cover 1 1...

Page 40: ...INKS 49 EMISSION CONTROL DIAGRAMS 50 DISTRIBUTOR 52 Construction 52 Disassembly 52 Assembly 53 IGNITION COIL 56 Construction 56 Description 57 SPARK PLUGS 57 Description 57 Inspection 58 Cleaning and Regap 58 TROUBLE SHOOTING IGNITION 58 HEATER UNIT REMOVAL 59 TROUBLESHOOTING HEADLIGHT 62 TROUBLESHOOTING HORN 63 RADIO 63 RerilQyal 63 TROUBLESHOOTING SPEEDOMETER 64 TROUBLESHOOTING HEATER 65 TROUBLE...

Page 41: ...s excited On the other hand current flows from the battery to ground through the ignition switch warning lamp voltage regulator L terminal lamp side contact point P4 movable contact point P5 and voltage regulator E terminal as shown by dotted line arrow marks Then the warning lamp lights When the alternator begins to operate three phase alternating current is induced in the stator coil This altern...

Page 42: ... decreased As the output voltage is decreased the movable contact point P2 and primary side contact PI comes into contact once again and the alternator voltage in creases Thus the rapid vibration of the movable contact point voltage constant When the alternator speed is further in creased or the voltage starts to rise ex cessively the movable contact point P2 r I I comes into contact with secondar...

Page 43: ...oor lubrication Fill in oil Worncommutator Disassemble motor Wornbrushes Replace brushes Starting motor Discharged battery Charge Or replace bartery cranks slowly l oose connection of terminal Clean and tighten terminal Worn brushes Replace brushes Locked brushes Inspect brush spring tension or repair brush holder Starting motor Dirty or worn commutator Clean nd epalf uanks slowly Armature rubs fi...

Page 44: ...RearcoVtr 8 Diode sel plate aittmb y 9 Diode over 10 Throu hbolts Rg 79 Exploded View of LT 150 58 LT 135 138 2 I P ulley ssemb y Front over J Front bearing 4 Rotor 5 Rear bearin 6 Stator 7 Diode set pbtc embly 8 Rear 9 Brush embl 10 Diode 11 Through bolts t J 9 o Rg 80 Exploded View of LT 160 19 a ...

Page 45: ...6 Brush holder ssembly 7 DiOde eE121 Flg 82 Sectional View of L T 160 19 Loosen adjusting bolt Remove alternator drive belt Remove parts associated with alternator from engine Remove alternator from vehicle Installation Installation is the reversal of removal VOLTAGE REGULATOR Description The regulator consists basically of a voltage regulator and a charge relay The voltage ...

Page 46: ...ge with regulator mounted on vehicle it is necessary to rotate engine at high speed Connect DC voltmeter 05 30Vl DC ammeter 15 30Al battery and resistor 0 25 ohms with cables as shown Check to be sure that all electrical loads such as lamps air conditioner radio etc are discon nected Before starting engine be sure to make short circuit with a cable between fuse side ter minal of resistor 0 250 and...

Page 47: ...w SA reading over SA FuUy charged battery available Fully charged battery not available I Replace with fuUy charged battery I Connect a 0 25 ohm resistor in series 2 Check to see ifcurrent falls below SA I 1 Current falls below SA Current does nol fall below SA Recharge battery and see if current falls below SA T I Reduce engine speed to idling and then raise it to 2 500 rpm while observing needle...

Page 48: ...ew 4 CIOsshead screwdriver Ag 86 Adjusting Core Gap Adjustment As the result of above measurement when regulating voltage is deviated from rated value adjust regulator in accordance with the following instructions 1 Inspect contact surface and if rough lightly polish surface with fine emery paper 500 or 600 2 Measure each gap and adjust ifnecessary Adjust core gap and point gap in that order No ad...

Page 49: ...t lamp remains lit Pilot lamp emainslit tween N terminals of l Check fan belt tension Pilot lamp relay Oil ontact gulator and alternator If reet remove egulator points Qui of rdef Alternator circuit defective od adjust as necessary Replace regul 1tor if continuity exists Over 5 2 Valls Pilot lamp does 001 lit Pilot lamp clay assembly is in good odition TROUBLE DIAGNOSES AND CORRECTIONS Including a...

Page 50: ...ted or grounded rotor winding Replace rotor Open or defective diode Replace diode Noisy alternator Loose mounting Retighten mounting bolts Loose drive puUey Retighten pulley correctly Defective ball bearing Replace bearing Improperly seated brushes Seat brushes correctly Alternator Fuses and Fusible Links E tIi Iu r tor N r Qo wt Lou M La t P re O lp t C ftlor N br A p L320 Engine compartment 1 LS...

Page 51: ...LUTOt PEDAL CARSURfTDR MTCH DETECTING CLOSE THIIOTTLE IlO5lnON Datsun emission control system manual transmission IGNITION WITOI BATTERY l AUTOMATIC TRANSMISSION TO OISTRIJUTOfI ICHITlON COIL DUAL IIOINT OISTRI8UTOII R TAROED Pat KE swtTQt DETlCTING DI CftN nfROTTU POSlnON SWITCH DETECTING CL CIS THROTTLE POSITION Datsun emission control system with automatic transmission 50 ...

Page 52: ...lSptem 1 FROM CARBURETOR AIR CLEANER FROM FUEL TANK 2 TO CllAHKCAlI VAPOR VENT LINE FLOW GUIDE VALVE The v lv opan when the pr Ie Ie over 0 4 in Hg CV lIE FUEL TANK Datsun evaporative emission control system 51 ...

Page 53: ...ed Two breaker points which consists of ad vance and retard breakers are placed in par a1Iel with each other in the primary ignition circuit The retard breaker point works when the relay is switched ON and the advance breaker point works when the relay is swit ched OFF See Fig 91 12 fig 90 External View of Distributor The distributor follows the conventional de sign except for the dual points i e ...

Page 54: ...out and disconnect collar to remove the entire rotating parts 1 Advanced breaker point 2 Ret rded breaker pomt 3 Phase difft rence Assembly Assemblv can be made in reverse sequence of disassembly Refer to Figure 101 for replacement and reassembly of governor spring and cam In assembling distributor use caution so that rotor head positioning tip at cam is set on governor spring circular hook side T...

Page 55: ...mbly 8 Breaker assembly 9 Contact set 10 Connector assembly II Vacuum control assembly 12 Screw 13 Condensor assembly for Advanced point 14 Screw 15 Distributor cap assembly 16 Carbon point assembly 17 Fixing plate 18 Bolt 19 Condensor assembly for Retarded point 20 Screw 21 Lead wire as embly for Advanced point 22 Lead wire assembly for Retarded point 23 Earth wire assembly iE1 ...

Page 56: ...pring A is in slit in cam plate with a clearance between the two at beginning and end ofgovernor operation Meanwhile weight pin on opposite side comes in short rectangular hole Fig 95 Unscrewing Breaker Sets Screws Fig 99 Removing Carn Q i EE141 Ag 96 Removing Contact Breaker Fog 100 Exploded View EE073 Fig fJ11 Removing Knock Pin EE075 s b 5 ...

Page 57: ...ction 18 I Governor Ieighl 2 Clearance fOl slart and end of advancin angle 3 Rectangular hook 4 Governor printt R 5 am plate 6 Weight pin 7 Circular hook 8 Gm ernuT spring A 9 Rotor positioning tip l rillliJr lnitlal Sl l ndary It Tmin 1 C Jp 4 Sprln 5 Side h 7 8 9 III II Primary III S n dar In uhllllr HI il l nlcr Segment Case ...

Page 58: ...lug gap The cap is made of alkyd resin which offers high resistance to electric arc and increased insulation Normal Overheating The resistor in the ignition coil circuit helps produce strong sparks from starting to high speed full power operation The internal resistor limits to a maximum safe flow of the primary current through the coil and distributor contact points Thus it protects the contact p...

Page 59: ... timing loose spark plugs low fuel pump pressure wrong selection of fuel a hotter plug etc It is advisable to replace with plugs having colder heat range After cleaning dress electrodes with a small fine file to flatten the surfaces of both center and side electrodes in parallel Set spark plug gap to specification Install spark plugs and torque each plug to 11 to 15 ft lb Connect spark pi ug wires...

Page 60: ...breakage of governor spring A pin or a hole of governor portion worn out Burnt too much Improper and etarded timing Defective function of governor Dirty point Point gap too narrow Dirty After cleaning spark plugs renew firing sur face of electrodes with file mentioned above Then gap spark plugs to 0 0276 to 0 0315 in using a round wire feeler gauge All spark plugs new or used should have the gap c...

Page 61: ... I II S III J I i 1 11 c 1 Q l II ilt I yl I C ti II l f 1 I 1 1 1 JSI I m s3iiLI INi 1J lc 1t 1 1 l II I l i II I IIr fiF o II II I I I 1 I i Illi i m nnmm 1 J2l t l l 1 1 I I I IIiI I lI c A 1 C 1 L t Itti1nT f rt III dJ r o 1 J e lW I III IC Ii i 11 I 0 C r W T I I l III i I J Ii c I Ji3r J I Ii Xrf F l I l J il rs r o r I e 0 hill IF it 111 5 u I t I 0 I aft 0 il 4 u c o E il ii c E z c 0 E is...

Page 62: ...IleCtricalSystem Q 0 P 1 1 8 iii aa o 8 CD a t 1J l a c z a 1 rraa 1 Il ir t lf1l g or c 1l g c o E c E E cS c E is 8 dl It 81 ...

Page 63: ...g and replace or producing momentary short tape damaged wires Lights burn cut High oltage regulator setting Adjust voltage regulator frequently Loose cOIUlections in lighting Check circuitCor loose connections circuit LIght will not Discharged battery Recharge battery and correct light cause Loose connections in lighting Tighten connections circuit Burned out bulbs Replace bulbs or sealed beam uni...

Page 64: ...battery Improper contact of horn relay Correct point Open circuit or rong ground coo Replace or repair horn nection of horn interior Wear of horn point Adjust adjusting screw Low volume Improper contact of fuse or 000 Correct contact improper tone nector Open circuit of harness Repair Improper contact of horn point Correct horn point Wear of horn point Adjust adjusting screw Crack in diaphragm Rep...

Page 65: ...ctive speedometer Replace speedometer f Unsteady pointer Improper setting of speedometer Correct setting cable union nut Defective speedometer cable Replace cable Defective speedometer Replace speedometer Strange sound Excessive bend lack of lubricant Replace or lubricate cable eyncbronized and twist of meter cable inner wire witbrunning Defective speedometer Replace speedometer speed Inaccurate R...

Page 66: ...removed Bend or break of defroster hose Looseness of heater BUpport Looseness of each fixing screw TROUBLE SHOOTING RADIO IIectricalSpteJD Corrective action Check and repair wiring harness Replace switch Replace motor Clean fin Replace motor Repai r Repair water pump Check or clean piping Repair Purge air out of hose Replace thermostat Replace water hose Retighten clip Replace gasket Solder leakin...

Page 67: ...e will not p Connect with bond wire between engine and ignition coil locating area of body Secure ground of ignition coil Distributor Secure contact of carbon electric pole and rotor Eliminate excessive tips at rotor pole or cap pole scrubbing by driver Check stagger bet veen rotor and starter Charging system Sound of alternating current Alternator Set 0 5 F condenser at charging present terminal ...

Page 68: ...RATURE SENSOR 69 Removal 69 Installation 69 FUEL PUMP 69 Removal and Disassembly 69 Inspection 70 Assembly 70 CARBURETOR 73 Removal 73 Disassembly 73 Float Chamber 74 ANTI DIESEUNG SOLENOID 74 Removal 74 Installation 74 BOOST CONTROLLED DECELERATION DEVICE 74 Assembly and Installation 74 Cleaning and Inspection 74 JETS 75 81 ...

Page 69: ...s and reaches above 480C 11S0Fl the air control valve completely opens to prevent the entrance of hot air and allows under hood air alone to be introduced into the carburetor See Figure 111 AIR CONTROL VALVE The air control valve acts in the manner described previously and the temperature of s c i n ir a I L he sensor is always kept at about 430C II10oFl When the engine is operating under heavy lo...

Page 70: ...dle engine operation The idle compensator thermostatic valve par tially opens at 650C l490F and fully opens at 750C l670F Never attempt to disassemble this unit since it is sealed for tightness and properly adjusted for valve timing TEMPERATURE SENSOR Removal Flatten tabs ofclip with pliers Pull off hoses Note Note the respective positions of hoses from which they were removed Take off sensor and ...

Page 71: ...mage diaphragm or oil seal Drive out rocker arm pin by using a press or hammer Inspection Check upper body and lower body for cracks Check val ve assembly for wear on valve and valve spring Blow valve assembly with breath to examine its function Check diaphragm for small holes cracks or wear Check rocker arm for wear at the portion in contact with camshaft Check rocker arm pin for wear A worn pm m...

Page 72: ... rocker arm by hand If fuel is drawn up soon after rocker arm is released fuel pump is functioning properly 1 Fuel pump cap 2 Cap gasket 3 Valve packing Ass y 4 Fuel pump valve Ass y 5 Valve retainer 6 Diaphragm Ass y 7 Diaphragm spring 8 PUU rod 9 Lower body seal washer 10 Lower body seal 11 Inlet connector 12 Outlet connector 13 Rocker arm spring 14 Rocker arm 15 Rocker arm side pin 16 Fuel pump...

Page 73: ...ed 7 Primary emulsion tube 8 P I st slow air bleed 9 P 2nd gOW air bleed 10 P slow jet II P bypass hole 12 P throttle valve t 3 S main nozzle 14 S small venturi 15 S main air bleed 16 S slow jet 17 S slow air bleed 18 S emulsion tube 19 S main jet 20 S bypass hole 21 S throttle valve Fig 119 Sectional View of Carburetor ...

Page 74: ... Remove throttle return spring from primary side 1 Ventui 2 Main air bleed 3 Emuleion take Rg 120 Removing Thermostat ET038 4 Secondary 5 Primary 1 2 ET039 fig 121 Removing Diaphragm Chamber Remove pump lever and pump rod Remove cam connecting rod Remove thermostat cover by unscrewing three set screws 1 Needle valve 2 Stopper plate 3 Filter 4 Filter l screw S Nipple o11 ET040 Fig 122 Removing Filt...

Page 75: ...hen torque screws to 30 to 48 in lb R After inotalling anti dieseling solenoid leave carburetor more than 12 hours without operation After replacement is over start engine and check to be sure that fuel is not leaking and that anti dieseling solenoid is in good con dition Notes a Do not allow adhesive getting on valve Failure to follow this caution would result in improper valve performance or clo...

Page 76: ...ment Inspect gaskets to see if they appear hard or brittle or if edges are torn or distorted Ifany such condition is noted they must be replaced Check filter screen for dirt or lint Clean and if it is distorted or remains plugged replace Check linkage for operating condition Inspect operation of accelerating pump Pour fuel into float chamber and make throttle lever operate And check condition of f...

Page 77: ...aoUDI Sptem DRAINING FLUSHING WATER PUMP Removal Dis ssembly Inspection Installation THERMOSTAT Removal and Installation RADIATOR Removal and Installation Inspection 78 78 78 79 79 79 79 79 79 79 80 1 1 ...

Page 78: ...ntrifugal type which is mounted on the engine front cover The fan and pulley are bolted at the pulley hub The pump shaft is supported by a double row ball bearing press fit in an aluminum die cast pump body The bearings are permanently lubricated and sealed to prevent loss of lubricant and entry of dirt 78 The pump contains an impeller that turns on a steel shaft which rotates in the ball bearings...

Page 79: ...t predetermined temperatures and if not opemting properly should be removed and tested as listed below Removal and Installation Drain coolant partially Disconnect upper radiator hose at water outlet fig 127 Removing Thermostat Loosen two securing nuts and remove water outlet gasket and thermostat from ther mostat housing After checking thermostat satisfactorily in stall replacing with a new housin...

Page 80: ...ll radiator in reverse sequense of removal Inspection I adiator cap should be checked for pressure at regular tune up intervals First check rubber seal Oil cap for tears cracks or deterioration after cleaning it Then install radiator cap on a te ter If cap docs not hold pressure or will not release at thp proper pressure replace cap Also in pect radiator for water leakage using a cap tester unde a...

Page 81: ...on FRONT DISC BRAKE Description Removal Disassembly Inspection and Repair Piston Seal Replacement Assembly and Installation Pad Replacement REAR BRAKE Removal and Disassembly Inspection Assembly 82 82 82 82 82 82 84 84 85 85 86 86 86 87 88 II ...

Page 82: ...force F These forces cause rotating moment which increases reac tion force F This is called self energizing ac tion In this SC brake it is around 50 As pad wears movement of piston is in creased and when seal is deflected more than its elastic deformation piston wiil slide out ward causing slip between seal and piston thus assuring constant clearance between pad and disc Removal Jack up the vehicl...

Page 83: ...tional View ot Front Disc Brake 6 Brakes 1 Cylinder 2 Pi ton eal 3 Wiper eal 4 Eletainer 5 Piston 6 Clip 7 Shim 8 Pad 9 Caliper plate 10 Torsion ipring 11 Cotter pin 12 Nut 13 Washer 14 Support bracket 15 Hold down pin 16 Pivot pin 17 Mounting bracket 18 Spring 83 ...

Page 84: ... and wiper seal and then it can be easily taken out Inspection and Repair Check the cylinder assembly for oil leakage and any damage and replace the cylinder assembly if any abnormal condition is detec ted on it Note Unlike the wheel cylinder cup of drum brakes the piston seal of SC type disc brake has three important functions sealing retracting piston and automatic adjusting If pistonseal is dam...

Page 85: ...to the cylindcr hol Fig 136 Measuring Runout of Disc Clean the piston Check that no damage exists on piston surface Insert the piston Take care that the relieved position of the piston faces pivot pin Insert fin t two inches gently avoiding tilting Assembly and Installation Clean the mounting surface and disc surface Attacb the disc to thc hub Install tbc bub to tbe knucklc pindle lnsc t the pisto...

Page 86: ... and thereafter Pad thickness is easily checked by removing the anti rattle clip When linings become worn to less than 0 04 in in thickness not in cluding the metal backing plate replace all pads Note Always replace the pads in full sets of four using genuine parts Remove the road wheel Remove the anti rat tie clip from the caliper plate Fig 138 Removing Anti Rattle Clip 88 Loosen the bleed screw ...

Page 87: ...e brake disc The wheel cylinder is easily disassembled by removing the snap ring and dust cover Remove the adjuster assembly Remove the brake disc Inspection Drums If they show score excessive out of roundness and so forth reconditioning by machining is required Drum inside out of roundness below 0 0020 in Nominal inner diameter of the drum is 8999 in Limit ofreconditioning in diameter is 9 040 in...

Page 88: ...for wear sign of rust and damage If the clearance between the cylinder and the piston exceeds 0 0059 in replace them 88 When the wheel cylinder is overhauled it is recommendable to replace cups even if ap parently they are in satisfactory conditions and they must be replaced if deformed due to damage crack corrosion and ageing Assembly Assemble in the reverse order of disassembly Be careful not to...

Page 89: ...oss member 5 St bilizer 6 Tension rod 7 Transverse link 8 Steering knuckle ann Ag 143 Front Suspension Assembly 6 7 RECOMMENDATIONS U to the need for a large number of special lonl and alignment equipment it is recom 80 mended that repairs to the front end be left to a completely equipped shop ...

Page 90: ...Steering STEERING GEAR COMPONENTS 92 RECOMMENDATIONS 92 ASSEMBLY 93 STEERINGLINKAGE 93 81 ...

Page 91: ...0 Ass y nut ball 3 Cover sector shaft 7 Camp jacket column II Assfy column steering 4 Screw adjurting roller shaft 8 Ass y bearing column Fig 144 Steering Gear Components RECOMMENDATIONS Due to the nepd for a large number of special tooJ and al ignment equipment it is recom mended that repairs to the steering com pOllenb be left to a completely equipped shop 82 ...

Page 92: ... the th ball hit ch ther 3 Lock the adjult ew with the lock mporarily 4 Move the gear for Ie ra imel from the ide of the Beu arm E nd mak smoothly 5 After this t backl uh OIl the op of the s ar arm should be brtweeD 0 O 1 mm 0 0 0039 the uual point 6 If the backlash more tban O 1 mm 0 0039 I ew th adjust 5Crew funher IIId peat the th proce es of 2 5 til ome within the ndard figure 7 Finally the ad...

Page 93: ...Bear Drive Suspension SHOCK ABSORBERS Remvval Inspection Installation DRIVE SHAFT RECOMMENDATIONS 96 96 96 96 97 97 85 ...

Page 94: ...nisher assembly Remove the double nuts which fasten the up per end ofthe rear shock absorber to the body Remove the shock absorber from its lower mounting bracket on the axle housing Inspection Test the shock absorber and replace if necessary Check for oil leakage and cracks Also check the shaft for straightness Inspect the rubber bushings for damage cracks and deformation Replace the parts if nec...

Page 95: ...Sleeve yoke 13 Needle bearing 4 Drive shaft stopper 9 Sleeve yoke plug 14 Snap ing 5 Rubber boot 10 Spider journal Rg 149 Drive Shaft RECOMMENDATIONS Due to the large number of special tools required and the advanced knowledge necessary it is recommended that the overhaul of the differential be left to a properly equipped shop 87 ...

Page 96: ...02 RELEASE BEARING 102 REPAIR 103 Refacing Pressure Plate 103 ADJUSTMENT 104 INSTALLATION 104 MASTER CYLINDER 105 Removal 105 Disassembly 105 Ins pection 106 Assembly 106 Installation 106 BLEEDING CLUTCH SYSTEM 106 81 ...

Page 97: ...ing sleeve 2 Clutch cover assembly with plate 9 Clutch elease bearing 3 10 Bearing sleeve bolder spring 4 Bolt 11 Dust cover 5 Lock washer t2 Return spIing 6 Clutch withdrawal lever 13 Withdrawal lever push 7 Retainer spring t4 Lock nut Rg 150 Outch Diaphragm Spring Type ...

Page 98: ...h eleue bearing 4 Pre SUre plate t2 Release lever support 20 Bearing deeve holder spring S Prelllure plate bolt 13 Retaining spring 21 Dun cover 6 Eye bolt pin 14 Bolt 22 Return pring 7 Pre sure fpring IS Lock washer 23 Lock nut 8 PreJ rlU e spring retainer 16 Clutch withdrawal lever 24 Withdrawal lever push nut F1g 151 Clutch Coil Spring Type Olutch 101 ...

Page 99: ...ure is relieved II E E E E 0 N N i i o 0 I E E E E E E o i01 r4H1 7 Bmm mm 52 m Remove the screws completely and lift the clutch assembly away from the flywheel Note Be sure not to soil with grease or oil the surface of the disc RELEASE BEARING Replace if there is rough spot or wear on the release lever control surface or if the inside wear causes too much play Ifit is judged that the remaining gr...

Page 100: ...94 in from specified standard di mension Ifit needs to be cut more than 1 0 mm 0 0394 in the unit must be replaced After refacing the out of flatness should be less than 0 1 mm 0 0039 in Refacing Pressure Plate The pressure plate can be refaced if the sur face is rough or has uneven wear In this case the tension of clutch springs working on the pressure plate will be weakened 103 ...

Page 101: ...the highest point on the tip of the release lev r Ag 156 Adjusting Release Lever Height 104 Replace the height finger and pillar by the clutch actuating mechanism and actuate the clutch several times by operating the handle Note This will enable the parts to settle down on their knife edges Replace the height linger and recheck the height of the release levers checked for run out as near the edge ...

Page 102: ...bolts are fully tightened Tightening torque should be 11 to 16 lb ft Remove the clutch aligning bar Irelease lever stopperl Refit the release bearing and transmission case Note In assembling a clutch disc be sure to apply small amount of Multipurpose grease MILG 2108 or 10924 to the disc splines Neglecting this caution will result in clutch slippage MASTER CYLINDER Removal Remove the clevis pm ins...

Page 103: ...ld be replaced Piston spring and inlet valve spring must also be replaced when they are broken or weak Replace clutch hose and tube if any abnormal signs of damage or deformation are found 108 Assembly This is accomplished by reversing the disassembling procedure but the following points should be observed Prior to assembly piston cup should be soaked in brake fluid Install piston cup taking care ...

Page 104: ...TraDsmissioD REMOVAL INSTALLATION 4 SPEED TRANSMISSION Removal and Installation RECOMMENDATIONS J09 III 113 113 113 lO l ...

Page 105: ...TraDsmissioD 11 I I Ii I Fig 159 3Forward Speed Transmission C I Ll Fig l60 4Forward Speed Transmission 108 ...

Page 106: ...nnect the hand brake wire at the equalizer pivot as shown in Figure 163 Loosen the two exhaust center pipe clamps and turn the premuffier complete with center pipe to the left as shown in Figure 164 This will allow sufficient room for the propeller shaft to be removed Remove the propeller shaft by disconnecting the four securing bolts at the companion flange of the gear carrier Seal the end of the...

Page 107: ...on extension housing See Fig 165 Disconnect the lower shift rods from the shift levers and remove the cross shaft assembly from the transmission case See Fig 166 Remove the clutch operating cylinder from the clutch housing Support the engine with a jack placed under the oil pan Do not locate the jack under the Fig 166 Disconnecting Remote Control Linkage Fig 167 Detaching Clutch Operating Cylinder...

Page 108: ...ection This will allow sufficient room for the transmission to be removed Remove the starting motor and the bolts at taching the clutch housing to the engine Lower the jack gradually and withdraw the transmission INSTALLATION Installation of the transmission is the reversal of the procedure given for removal However attention should be given to the following points Notes a Fill the transmission wi...

Page 109: ...d brake 14 Oil pan 29 to 36 ft Ib 14 to 18 f Ib 5 Rear clutch 15 Control valve T 14 to 16 kg m h 1 3 to 18 kg m 6 Front planetary gear 16 Input shaft 101 to 116 ft Ib 9 4 to 13 ft lb 7 Rear planetary gear 17 Torque converter T 0 6 to 0 8 kg m T 0 55 to 0 75 kg m 8 One way clutch t8 Converter housin1 4 3 to 5 8 ft Ib 4 0 to 5 4 ft Ib 9 Low Reverse brakC 19 Drive plate T 0 25 to 0 35 kg m 10 Oil dis...

Page 110: ...overing the 3 forward speed transmission it will be necessary to remove the shift lever from the control lever bracket On the 4 speed transmission the rear engine mounting sup port is securely placed between the upper sup port plate and rubber insulator on one hand and the lower support plate and rubber in sulator on the other RECOMMENDATIONS Due to the complexity of setting up a disassembled tran...

Page 111: ...Bod Work FRONT FENDER Removal and Installation HOOD Removal and Installation Adjustment TRUNK LID Removal and Installation Torsion Bar Removal and Adjustment 116 116 116 116 117 117 117 117 U5 ...

Page 112: ...n for removal Fig 171 Removing the Fender fill 172 Removing the Hood U8 HOOD Removal and Installation Open hood and place a protective cover over the front fenders to prevent damage to pain ted areas Scribe Ipenci the location of the hinge straps on under surface of hood Replace the bolts attaching the hinge to the hood With the aid of a helper remove the hood Fig 173 Removing the Hood Support Rod...

Page 113: ...lid and place a cover over the rear fenders and rear panel to protect them from damage to painted area With the aid of a helper remove the trunk lid attaching bolts and remove trunk lid See Fig 174 Torsion Bar Removal and Adjustment Remove torsion bar fixing wire then using a screw driver as shown in Fig 175 remove the torsion bar The tension of the torsion bar can be adjusted by changing the loca...

Page 114: ... 1 z 3 Fig 177 Window Regulator U8 1 Froot door glass 2 Bottom channel 3 Front egulator ass y 4 Regulater handle S RaUer guide 6 Stopper 7 Connecting clip 8 Nyloo washer 9 Rear docx glass 10 Rear egulater ass y ...

Page 115: ...OIL PUMP 122 GENERAL 123 ELECTRICAL 123 MANUAL TRANSMISSION 127 CARBURETOR 131 CLUTCH 134 ENGINE TORQUE INFORMATION 136 TUNE UP 138 LUBRICANTS SAE 138 CAPACITIES PRESSURES 139 AUTOMATIC TRANSMISSION 140 PROPELLER SHAFT 144 BRAKE CHASSIS WHEEL ALIGNMENT 146 NOTES 147 D8 ...

Page 116: ...han 60 amps 12 Volts No load starter revolution pm More than 7 000 More than 6 000 Shift type of pinion gear Magnetic shift Number of teeth on pinion gear 9 Number of teeth on ring gear 120 Weight g lb 5 1 10 42 5 8 12 8 SPECIFICATIONS AND SERVICE DATA Specifications Model Item LTI50 o58 LTI6019 LTlJ5 1J8 AppliLable to 510 and 610 models except 510 and 610 models 620 model for Canada for Canada Ma...

Page 117: ...9177 to 0 02 7 AJvauccd ld Retarded side cqll llly 0 50 to 0 65 I 1010 I 43 r 430 to I 440 0 41 94 to 0 48 8 450 to 4Ml 0 4402 to 0 4 09 001 In O G3R 0 0004 h 0 00 5 0 0 11 0003 I 0005 00002 H O JI50 1 O t1l4 0 0006 H 000 It x 1115 lUISO ltl 0 1 156J 0015 II J fi 9 D002 tu 0 0 11 4 972 104 990 0 1959100 1 5 5 000 10 5 018 0 1 9 to 0 1976 0 01 tnO 046 0 0004 tv O OOI Point gap mm in Point pTt ssure...

Page 118: ...gth lI6 In 114 9 to 115 2 4 524104 535 L mm in LIB Ex 115 7 to 116 0 4 555 104 567 Valve stem diameter lI6 In 7 965 to 7 980 0 3136 to 0 3142 D mm in LIB Ex 7 945 107 960 0 3128 100 3134 a Valve seat angle In Ex 45030 OIL PUMP I i lth ning turque Oil pump mounting bolts Oil pump cover bolts Cap nut regulator alve kg m ftIb kg m flIb kg m fl Ib 1 1 to 15 8 010 II 0 7101 0 5 1 to 7 2 4 to 5 29 to 26...

Page 119: ... 1 114 103 1 912 Hlt chl 1 5 1 1 5 1t4 122 71 72 HII ehl 15 1 42 S 114 1I7L N pi DWtrilu lorCr1Iln p 1 v AtI u S t 1 JI t1 oJ IltaTt E ND fIjq O HD J Hitachi 50 11 15 3 9 47 69 411 53 2 400 13 4 LI6 Hitachi 4 1O 5 9 9 0 1lh5ll 1 500 12 4 L2 Hitachi 4 6 J 9 5 5 D60652 1 000 9 6 At2 Hitachi 550 12 5 9 8 65 1 412 63 2 100 13 8 C lllrlr II IAd Dnu1 VD U AdII Pol t Dw n srlnll y M I DI trlbut 0 AIIIII ...

Page 120: ...s AC Regulator i CACTI trul Rd V tA6 R 4IM c s Ai 1 CouG Go A i G P d R I OI G G p G Gap rfJ i i J Yoolt i J i i i G fiuubishi 0 32 044 U 12 J 48 032 044 028 036 032 040 012 016 N A RLA l litsum hi 032 043 o32 147 032 043 028 035 032 039 012 01614 15 RL2220B5 R Mit uhishi 032 043 032 047 032 043 028 035 032 035 012 015 14 15 RL 2B U20 liIslIhishi 035 047 030 043 030 043 0 32 047 032 043 012 01613 ...

Page 121: ... plate 8 Interior B Interior light 5 Backup 25 Warning lights 1 5 L521 Headlights 37 5 50 Instrument 5 PLS21 37 5 SPL310 HeadliRhts 50 Front turn parking 25 B Front parking turtI 25 5 TilU top 25 B Tail stop 2 l6 Irtun 25 LictrlIeplate 8 B clcup 25 In rior 6 Interior 6 Instrumr nll warning 15 L seplate 8 Inspection lamp B PL5lO Headlights 37 5 50 Radio I WPLSlO 37 5 PUll Headlighu 31 5 50 Front pa...

Page 122: ...wion JIr r 11 l II I t COLOIlCODE G II n jllll t4 L 11 I iil 1 i I cnm w 111 JlI 1 7 1 V Jfrdll i 1 11111 I n IF I II IJ I r i I l I i j r i r r III l o I I i I d 71 a r 1rtJ e f 3 l u J o J l r c 11 7lI tl II L L A l f I l a f DPTlONAL EQU PMEm 1 10 ltomatic trarumission 126 ...

Page 123: ... JNL510S lot 3 263 19 5 4 375 Column shift P510 SlV PL510 Sl 2nd IS45 1715 3 900 Warner type synchromesh 3rd 1000 WP510U WPL510 Rev 3 355 17 5 3 S99 f F4W63L P510 S TV JNL510 S T lot 3382 PL510 S T 2nd 2 013 IS 5 3 700 N510TU 3rd 1312 P510TKU PL510TK 4th 1000 4 Fmw ro peed I RPL510SWTV PL510TV Rev 3 364 FloofS uft Warner type synchromesh F4W63L ht 3657 WP510TU 2nd 177 16 5 3 700 WPL510T 3 d 1 419 ...

Page 124: ...13 1312 1000 None 3 365 SPL311 PL510 SPJ 110 3 515 2 140 1 328 1000 None 5 l7 SRL311 2 957 1858 1311 1000 65 2 922 PL510 3 657 2 177 1 419 1 000 None 3 638 3 382 2 013 1312 1000 None 3 634 3 382 2 013 1312 1000 N 3 634 HLS30 3 549 2 197 1 420 1 000 None 3 164 2 957 1 857 1 311 1 000 852 922 LHllO KLBllO 3 757 2 169 1 404 1 000 None 3 640 CD L60 transfer cue ratiOl 2 264 1 nd I I 1 Condition Probab...

Page 125: ... em in lb withoutoil seal with oil seal At ompanion flange bolt hole kg Ib without oil seal withoil seal 7 to 10 6 1 to 8 7 S to 11 7 0 to 9 6 2 0 to 2 9 4 4 to 6 4 2 3 to 3 2 5 1 to 7 1 Thickness of pinion height adjusting washer mm in 3 09 0 1217 3 12 0 1228 3 15 0 1240 3 18 0 1252 3 21 0 1264 3 24 0 127S 3 27 0 12S7 3 30 0 1299 3 33 0 1311 3 3S 0 1323 3 39 0 1335 3 42 0 134S 3 45 0 135S 3 48 0 ...

Page 126: ...n mate Thickness of side gear thrust washer mm in Q to 0 80 0 0295 to 0 03151 0 80 to 0 85 0 0315 to 0 03351 0 85 to 0 90 0 0335 to 0 03541 Backlash in pinion mate and side gear or clearance between ide gear and thrust washer mm in 0 1 to 0 2 0 0039 to 0 0079 Ring ar Backlash between ring gear and drivepinion mm in 0 1 to 0 2 O 0039 to 0 0079 Runnut of reat ide of iog gear gear mm in Thickness of ...

Page 127: ... control L52ll L501 R 1 1 950 R with 23 M 39 with Jrl emisrion 38W 5 M 70 95 i control with 38W 6 U20 87 SU 950 UOO s M nll t Sole U20 32 N i1with 8 87 with emi uion 46W 5 N 25 950 with 46W 7 LIB 071 87 PL510 95 D LIe 071 87 ISO withemwion 95 13 lrol L24 23 N 21 rrT wth 079 950 emialon control HLS30 At2 71 with 78CD emission control UllO nJlllO From SOIt chamber topto fuelleYel 131 ...

Page 128: ...9B 80 B 100 55 14 PUlO kakl 1 81 1 024 115 ec BO el 48 I 220 2D3OCE 2nd dual 120 thrOlltdowndl1lft El Nlhonkl 1 102 827 96 BO B 100 55 14 1 320 kat 1 81 1 024 1151C1C 60 tS ec 220 2D3OC 2nd dUlll 120 throatdowndraft J Nihooki 1 022 788 90 B 0 45 14 1 520 hln 1 180 1 06 14 ICf 48 sec D2630A M dUIlI thm t downdraft J Nihonlia 1 022 788 92 60 48 100 40 024 14 PlAll blu LlSO 1 06 140 sec 60 4Hlt 2 40 ...

Page 129: ...itachi 1 605 100 4 5 with HJG46W 5 emlDmncontrol HJC46W 7 StI type Ildedraft 1 16 Hitachi 1 l 2 945 35 ll5 240 46 180 16 puna DAF328 1 200 U02 155 120 18 100 dual C C f C C see C throat downdraft 1 16 Hitachi 1 101 900 155 1I1 240 255 071 48 ISO 020 16 with DAF328 8 1 260 1 I01 1969 I 118 16 100 emiSSIOn auto c 1 5 C cont DAF328 6 1970 itd DAF328 10 PL521 CD 1 24 Hitachi L811 A with HJG46W P enull...

Page 130: ...0 for RUll PlAlllrRIAll SPL310 i1 169 178 2 04 7 87 X 333 e 012 020 6 10 JIO spring J 1 56 2 011 S 76 X 8 60 80 2 17 13 SPL311 diaphr gm N A 7 81 X N A N A 012 020 N A I l SRL311 spring 5 12X 2 1 1 PUIO il 92 6 101 4 1 91 1 87 X 339 e 012 020 8 lts 98 WPL510 pring 1 1S 2 01 5 UX 31 4 2 00 1 510 diaphragm I 7 87 X 339 B 012 020 B 15 98 WPL510 sprina 1 77 5 12X 31 4 1 1 5IO LS21 roll 161 179 1 98 7 ...

Page 131: ...ree Compressed 7 H7 362 120 x O I tO in 12 6 11 i02 Material Number of torsion spring Allowable min depth of rivet head from facing surface Allowable facing ron out Allowable free play of spline 8 6 9 0 nm 0 J 38G O 1 in 7 6 7 9 IllIl1 0 3012 O 31 lU in I HITACHI HT50S 17 AKEBOXO A50 G 0 3 mm 0 Ollb in O mm 0 0197 in 0 4 rom 0 0157 in Pressure platlll Allowable refacing limit 1 0 mm 0 0394 in Clut...

Page 132: ...S CRANKSHAFT BEARINGS I h lI End 0 I d B lnlll I I i I Motna rlng h ck Inch I M r I I hto 1 Y CI I C 01 Shott 8 in Shoff Il n h t Shft I 101111 h ck I Jilek tn CI o cI 01 Cl u h i Inch Inch B I 1 N Inch 966 i I ooa 67 1 1 1 0 1 9n 0005 1 0131 013 002 001 T 1 2 04 2 360 001 0016 010 012 0027 01 a 012 U 20 0012 T 1 2045 0013 2 47 1 010 012 0024 0021 I 012 016 a 012 1 121 L I I 001 1 12 1 7 a 2 161 1...

Page 133: ... r ll Dltpl nm1I1 I Ce I Ma T Cl Ne fn l Inch C 1e Inch R l 8 k H P fl t OIlP un I ce plll pm nd I j Enlllneh t 196 6 I 1 0 196661 71 1 2 j 1200 1972 1 16 l 1 4 1200 ENGINE GENERAL SPECIFICATIONS 2 174 J OSS 19 21 7 5200 I n 2100 I 2040 n n S 1299 2 4U 2 30 97 22 0 6000 I 103 4000 5 0 17 3 6 9 U9S 2 433 3 261 U 0 92 SU b I 00 I 3040 17 2 n 09 U 125 6000 5 1 b 131 100 150 000 2 2 902 97 I 9 00 I 10...

Page 134: ...61 MI hI ltlt IS 11 1 4 1 1 55 I 1 4 2 1 55 11 3 4 2 t 35 41 I 3 6 2 vlley It I vll vlley n 7 n pvn 75 ADJUSTMENT OF IDLING Adjust the ngine at normal idling setting Engine idling Idlin liming 0 1 rpm ldeg e relard side M Tvehicle 800 5 1 BlOC 15 0 5 A Tvehicle 650 io D mge 511 BTlX 15 0 5 Recommended Lubricants SAE T r U4 T Or o tI IOW 30 lOW W 20 IOW 10 IOW O lOW 1lI 30 IOW 10 lOW 40 IOW 40 20 2...

Page 135: ...N A 4 6 S1 11 1 1 A 4 3 4 6 2 0 11 4 8 3 4 4 6 Slt1 111 1 3 5 4 2 0 111 9 0 3 4 4 3 13 S I 111 11 7 5 5 4 2 0 114 9 0 3 4 4 3 13 ithtwlJ twin I hoke rhuretors L 12O 1 8 3 2 4 3 18 9 3 5 7 N A N A L i20 L521 3 8 3 2 4 2 1 7 10 8 5 9 2 1 2 5 6 1 L51O 5 2 4 4 6 4 IL4 1 1 1l9 6 8 1 6 3 4 13 7 2 with heater WlL51D 5 2 4 6 4 IIA 2 1 119 6 8 2 6 3 4 1 1 7 2 with heater PL521 4 3 6 4 2 1 7 10 8 6 8 2 6 3 ...

Page 136: ...hifl 0 7 6 2 18 0 410 17 0 1 40 0 02761 0 24411 1 614 0 669 3 1 ud 3rd timing 0 7 5 5 15 0 32 5 27 0 0 55 0 01761 0 2165 1280 1063 12 Throttle k Ip 0 8 6 5 14 0 36 0 18 8 192 10 0315 10 2559 1417 0 740 4 2 Sulenoid downshift 0 55 5 0 12 0 22 0 12 5 0 60 10 0217 0 1969 0866 0 492 1 3 Se und lo k 0 55 5 0 16 0 33 5 21 0 0 60 0 0217 0 1969 1 319 0 827 1 3 Throttle elief 0 9 5 6 14 0 26 8 19 0 2 19 0 ...

Page 137: ...18 P ParkJ The transmission shaft is fixed Thl Backward The transmission slarlc4 Up or downshillS ltom lIil tlly hI nd and lOp Fixed at ld Fixed allow downshifls tWill plal cd llo lIlr IL Till 19inc illl bl qarku llpl R Reverse N Neutral t utral TI1 I ill b o Drive IU tr llll bl 2 d lock I Lock up J 11Ilernally I termeshing 11 l1 pl ar pUlllp AUlOlllath transmissiOll fluid Dl rull IYlk 5 5 liters ...

Page 138: ...449 116 0 457 Rear clutch Number of drive plates Number of driven plates Clearance Thickness of retaining plate mm in mm in 4 4 1 0 to 1 5 0 039 to 0 059 4 8 0 189 It tW reverse hrake Number of drive plattos Number of driven plates Clearance Thickn s of retaining plate mm in mm in 4 4 0 80 to 105 0 031 to 0 041 118 0 465 12 0 0 472 12 2 0 4S0 12 4 0 488 t2 6 0 496 12 8 0 504 Brake band Piston size...

Page 139: ...ft lock ut lock nut for oil cooler pipe connector to transmission case Oil cooler pipt onnecting nut Test plug oil pressure inspection hole Suppor actuator parking rod inserting position to extension Oil charging pipe to ase Dust ver to converter housing Selector range lever to manual shaft Selector rod lock nut Control lever boll Control lever bracket to floor COfltlOj lever knob to evel 14 0 to ...

Page 140: ...e spline to mainshaft Spline lash wear limit Maximum run out of propeller shaft Spider journal diameter wear limit Pennissible unbalance Dynamic 35 gr cm 0 486 in oz at 5 800 p m Thickness of available snap rings Standard Oversize white yellow I green blue brown colorless pink 2 00 mm 0 0787 in 2 02 mm 0 0795 2 04 mm 0 0803 in 2 06 mm O OSll in 2 08 mm 0 0819 in 2 10 mm 0 0827 in 2 12 mm 0 0835 in...

Page 141: ...shaftfix bolt Oil dram nd filler plug 17 to 20 122 9 to 144 6 7 to S 50 S to 57 8 0 9 to 1 2 6 5 to S 7 1910 2 6 13 7 10 18 8 19 to 2 6 13 710 lS S 6 to 8 43 410 57 S 5 to 7 3S 2 10 50 6 5 to 6 36 2 to 43 4 7 to 10 50 6 to 72 3 2 0 to 2 7 14 5 to 19 5 4 to 6 28 9 to 43 4 Oil Ipal i y ahOllO liter D S qt Imper qt 0 8 7 8 3 4 djll tiltg ethods Variation umbers o pressed by mm G O Oummv shaft u I I I...

Page 142: ... T KilO W Pi i o bd R U ill lio 1 0 g Wltul w 1 Ru r q B JIII f f S d t ll Ii UlO M 54 B 55 3 30 1 30 12 166 45 2S 25 32 7 15 WL60 98 4 54 B 55 3 130 1 30 12 16 6 45 2S 25 32 7 15 PUlO 93 8 47 5 47 0 1030 1030 00 13 6030 3B 28036 5PL310 89 8 47 8 4 7 1 1030 1026 06 13 6034 38 28036 PUll 93 7 7 5 47 2 0 1045 06 136015 38 28036 RU11 93 7 47 5 47 2 0 1045 13 6015 3B 28036 5P1 311 89 8 50 47 2 1 30 10...

Page 143: ...s b r o ...

Page 144: ...ej l8iring adjustment and di oslJm1Jtho s for theimtomobile Qwner anll theprofessionaI mechanic r t dj lC s c 1nditi o b e reIease signals cigare li Hters eIe c ic cloc s tum sign l mdl at ii p w r t power wmdow lifts speedqmeters and wmdshi eId Y sl1ers a nd Wipers There 1 4 eve1 a s sl 9tl n 11 voted to controls for the handicapped l JD SB l87749 128 3 paper 1 9 i 1b S N 87749 129 1 3 95 ij ELEC...

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Datsun 510 series, Workshop Manual

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Summary of Contents for 510 series

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