We call it simply… - The Datsun Roadster Book

You can kiss it goodbye!
The “original” – out with the old…..
In 1987- 88 we first published the manual shown above.
We sold slightly more than 230 copies. We’ve spent the
last 10 months revising it, re-typing it, expanding it,
adding photos and illustrations, and improving
everything that was provided in “the original”.
Announcing the Biggest, Most Informative Datsun
Roadster Book Ever!
The “new” standard has been completed and will be
Available May 1, 2006
We call it simply…
The Datsun Roadster Book™
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
So big it’s in 2 parts! Over 650 pages!
A summary of what’s in store…..
Part I – “The Parts Book”
Pages
Words
Paragraphs
Illustrations, photos, and ads
Sections in the parts manual
Exploded parts diagrams
Part listings
Service interval recommendations
Remember When!
Miscellaneous tech tips
336
119530
4430
62
47
7 subsections
46
2672
127
11
20
Part II – “Technical and Service Manual”
Pages
Words
Paragraphs
Technical specs, etc
Wiring diagrams
Service and repair sections
Owner’s manual reprints
Illustrations, photos, and ads
Vintage magazine articles
Vintage Datsun Competition bulletins
342
59800
1690
5 pages
6 pages
80 pages – 21 sections
5 (all years)
71
11
5
Quantities may change slightly in final editing
Available as a 2-volume set or as separate volumes.
The new manual(s) will be permanently bound rather than in 3-ring binders.
Read on to see a sampling of items included!
Please note that font and picture size for the examples have been reduced or
cropped to fit more information into this flyer. Most illustrations are full page
width and most font is Arial 10 pt. minimum. All exploded diagrams are full-page
views.
In other words, all these examples are smaller than the actual items in the
manuals.
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Part I
The Parts Manual
by
Scott Sheeler
Model Years 1966 – 1970
An Assortment of Parts Listings, Part Numbers, How Things
Work, Vintage Invoices, and Miscellaneous Historical
Information
Traditional Information for Traditional Owners
Look at the Table of Contents! Where else can you get all this info in one
place?
Table of Contents
THE FAIRLADY STORY ............................................................................................................................................1
THE TIMELINE OF FAIRLADY SP AND SR .............................................................................................................7
WHO ARE WE AND WHY SHOULD YOU CARE? ...................................................................................................8
WHY PART NUMBERS? .........................................................................................................................................14
WHY ARE SOME PARTS MISSING?......................................................................................................................15
WHAT AM I DRIVING? ............................................................................................................................................16
1966 ...................................................................................................................................................... ……16
1967 ............................................................................................................................................................. 17
1967 ½......................................................................................................................................................... 17
1968 ............................................................................................................................................................. 17
1969 ............................................................................................................................................................. 18
1970 ............................................................................................................................................................. 18
PARTS MANUAL .....................................................................................................................................................19
2000 Block, Pistons, and Crankshaft........................................................................................................ 20
1600 Block, Pistons, and Crankshaft........................................................................................................ 28
2000 Head, Camshaft, and Valve Train..................................................................................................... 36
1600 Head, Camshaft, and Valve Train..................................................................................................... 46
Solex Carburetors (New and Old), Linkage, and Intake Manifold .......................................................... 54
“Old” (original) Style Solex Carburetors ......................................................................................... 54
“New” Style Solex Carburetors........................................................................................................ 58
1600/2000 SU Carburetors, Linkage, and Intake Manifold ...................................................................... 66
2000 SU’s ........................................................................................................................................... 66
1600 SU’s ........................................................................................................................................... 70
Fuel Tank, Pump, and Filter ...................................................................................................................... 80
Fuel Pipes, Connectors, and Hoses – (1966 – 1967) ............................................................................... 83
Fuel Pipes, Connectors, and Hoses – (1968 – 1970) ............................................................................... 84
Oil Pump and Filter .................................................................................................................................... 90
Exhaust Manifold, Exhaust Pipes, Clamps, and Hangers....................................................................... 98
1600 / 2000 Exhaust Manifold.................................................................................................................. 100
Water Pump, Radiator, Fan Shroud, and Hoses.................................................................................... 106
1600 Water Pump, Fan, and Fan Belt............................................................................................. 106
2000 Water Pump, Fan, and Fan Belt............................................................................................. 108
1600 / 2000 Radiator, Shroud, and Hoses ..................................................................................... 110
Distributor, Spark Plugs, Ignition Coil, and Battery Brackets.............................................................. 116
Air Filter and Filter Elements .................................................................................................................. 126
Accelerator, Throttle, and Choke Cables ............................................................................................... 129
Engine/Transmission Mounting and Brackets ...................................................................................... 134
Emission Control System........................................................................................................................ 140
Brake Master Cylinders ........................................................................................................................... 146
Clutch Master Cylinder and Pedals ........................................................................................................ 147
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Brake Lines, Hoses, and Pipes ............................................................................................................... 155
Front Suspension, Hub, Wheel, and Brakes .......................................................................................... 160
Rear Suspension, Brakes, and Handbrake ............................................................................................ 170
Rear Axle, Differential, and Drive Shaft.................................................................................................. 179
Transmission Cases, Gaskets, Seals ..................................................................................................... 186
Shift Linkage............................................................................................................................................. 190
Clutch, Operating Cylinder, Pipe, and Hose .......................................................................................... 198
5-Speed Transmission ............................................................................................................................. 204
4-Speed Transmission ............................................................................................................................. 216
Starter........................................................................................................................................................ 228
Alternator .................................................................................................................................................. 234
Steering Box and Linkage ....................................................................................................................... 240
Steering Wheel and Column.................................................................................................................... 241
Wiring Harness and Cables..................................................................................................................... 250
Instruments and Cables........................................................................................................................... 254
Lights and Reflectors – Head, Tail, Parking, License ........................................................................... 256
Lights and Reflectors – Backup, Side, Interior...................................................................................... 257
Switches and Knobs - 1966-67................................................................................................................ 268
Switches and Knobs – 1968 .................................................................................................................... 269
Switches and Knobs – 1969-70 ............................................................................................................... 270
Relays, Voltage Regulators, Horn, and Fuse Box - Misc. Electrical Parts .......................................... 271
Windshield Washer, Hoses, and Nozzles............................................................................................... 272
Windshield Wiper Motor, Arms, and Blades .......................................................................................... 275
Heater, Hoses, Ducts, and Controls ....................................................................................................... 277
Door, Vent Window, and Window Glass................................................................................................. 279
Door Lock, Handles, and Window Winders ........................................................................................... 281
Upholstery, Convertible Tops, Hard Tops, Tonneau Covers, Roll Bars and Car Covers................... 283
BODY PARTS – DATSUN COLLISION ESTIMATING MANUAL .........................................................................291
APPENDIX A - 1971 DATSUN COMPETITION PARTS CATALOG REPRINT ....................................................300
An English translation of “The Fairlady Story”!
Translated by Aki Hatahira
The Fairlady Story
This is a direct, literal translation of the Japanese text from Fairlady I (Neko
Boutique 1977) without editing or modifications to “Americanize” it. We hope you
find it interesting.
It may be inelegant to write in detail about a beautiful and noble lady. However, people who have
been attracted to the beautiful name, appearance, and everything are addicted to her. The
sadness by loving her creates inelegant desire. I want to know everything about her, past,
present, and any little detail of her, and set it in my heart. That is how “The Fairlady Story” has
been written.
Chapter 1 - The Fairlady I Before Dawn – Dutsun Sports
The history of the Fairlady is all about the history of Japanese sports cars. The debut of the
sports car named as the Fairlady in the world was 1961. It was Dutsun Fairlady SPL212……
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Exploded parts diagrams!
2000 Block, Pistons, and Crankshaft
Parts listings with NISSAN part numbers including “unlisted” items as of
NISSAN’s January 2006 price list!
Parts Listing – 2000 Block, Pistons, and Crankshaft
MAJOR COMPONENTS
PART NUMBER
01 2000 cylinder block assembly w/freeze plugs
02 Crankshaft (requires 4 #92 plugs)
03 Flywheel with ring gear
04 Ring gear only
05 Timing cover with seal
06 Steel oil pan
07 Aluminum oil pan (7 qt. / 6.36 l.)
08 Connecting rod with cap (4 req'd)
09 Crankshaft timing gear
10 Oil slinger
11 Crankshaft pulley
12 Crankshaft pulley shims (qty. as req'd)
11010-25500 NL
12200-A7400
12310-25500
12312-19G00
13500-25501
11110-12200 NL
11110-25500
12100-25500 NL
13021-20100
12302-20100
12303-25500
12299-32200
“NL” = not listed
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
In-depth discussion of the individual vehicle systems in simple terms!
BACKGROUND
The 2000 engine block comes in one configuration; a one-piece cast iron unit that weighs about
97 pounds (44.10 kg). There are 5-main bearings in all 2000 blocks. The debut of the 2000
block coincided with the 5-main 1600 block in mid-1967. Both blocks are very similar in many
ways. The main bearing caps are separate castings that are machined to fit, bolted on, and then
line-bored in place to assure a straight saddle for the crankshaft. The block is very sturdy in the
main bearing area because the casting includes diagonal buttresses at each main bearing that
support the bearing caps and crankshaft by transferring loads into the sides of the block. The
main bearings sizes are exactly the same as the 5-main 1600. The crankshaft dimensions are
almost identical; the primary differences being that the 2000 crankshaft has a longer stroke and a
longer front “nose” due to the overhead camshaft timing mechanism………..
Service interval recommendations! Miles and Kms!
KEY SERVICE INTERVALS
Every
Change oil
Change oil filter
Drop oil pan and clean inside
3,000 miles / 4830 km
3,000 miles / 4830 km
24,000 miles / 38640 km
Historical parts invoices – a trip down memory lane!
Remember When!
Check the price for the bumpers, over riders, and factory antenna.
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Vintage NISSAN publications!
End of Part I – “The Parts Book”
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Part II
Technical and Service Manual
by
Scott Sheeler
Model Years 1966 – 1970
An Assortment of Technical Specifications, Service Instructions,
Owner’s Manual Reprints, and Miscellaneous Historical
Information
Another comprehensive Table of Contents!
THE FAIRLADY STORY ............................................................................................................................................1
THE TIMELINE OF FAIRLADY SP AND SR .............................................................................................................7
WHO ARE WE AND WHY SHOULD YOU CARE? ...................................................................................................8
WHAT AM I DRIVING? ............................................................................................................................................14
1966 ............................................................................................................................................................. 14
1967 ............................................................................................................................................................. 15
1967 ½......................................................................................................................................................... 15
1968 ............................................................................................................................................................. 15
1969 ............................................................................................................................................................. 15
1970 ............................................................................................................................................................. 16
TECHNICAL SPECIFICATIONS AND WIRING DIAGRAMS ..................................................................................17
General Specifications............................................................................................................................... 18
TECHNICAL SPECIFICATIONS AND DIMENSIONS .............................................................................................21
Some Valuable Conversion Factors ......................................................................................................... 23
Torque Settings for Fasteners .................................................................................................................. 24
Wiring Diagrams......................................................................................................................................... 25
1967 SPL and SRL 311 .....................................................................................................................................25
1968 SPL and SRL 311 .....................................................................................................................................26
1969 SPL and SRL 311 (USA) ..........................................................................................................................27
1969 SPL and SRL 311 (non-USA) ..................................................................................................................28
1970 SPL311 .....................................................................................................................................................29
1970 SRL311 .....................................................................................................................................................30
Some Technology and the Datsun Roadster ........................................................................................... 31
Silicone brake fluid...........................................................................................................................................31
Synthetic motor oil ...........................................................................................................................................31
Cryogenic treatment of parts ..........................................................................................................................31
SERVICE AND REPAIR MANUAL ..........................................................................................................................33
SPECIAL TOOLS THAT ARE NEEDED IN EVERY ROADSTER TOOL BOX:.......................................... 33
SRM 01 - Engine Removal / Reinstallation - R-16 and U-20.................................................................... 34
SRM 02 – Disassembly of the U20 Engine ............................................................................................... 38
SRM 03 – Reassembly of the U20 Engine ................................................................................................ 42
SRM 04 – Disassembly of the R16 Engine ............................................................................................... 50
SRM 05 – Reassembly of the R16 Engine ................................................................................................ 54
SRM 06 – Disassembly of the 5-Speed Gearbox ..................................................................................... 62
SRM 07 – Reassembly of the 5-Speed Gearbox ...................................................................................... 66
SRM 08 – Disassembly of the 4-Speed Gearbox ..................................................................................... 70
SRM 09 – Reassembly of the 4-Speed Gearbox ...................................................................................... 74
SRM 10 - SU Carburetor - Remove - Disassemble – Rebuild - Replace 1600/2000............................... 78
SRM 11 – Distributor Remove, Repair, Replace ...................................................................................... 84
SRM 12 – Front Suspension and Brakes.................................................................................................. 88
SRM 13 – Front Brake, Hubs, and Wheel Bearings ................................................................................. 92
SRM 14 – Disassembly and Repair of Brake Cylinders .......................................................................... 94
SRM 15 – Remove and Replace Brake Pads and Shoes......................................................................... 98
SRM 16 - 1966 - 70 Seat Cover Removal and Replacement.................................................................. 102
SRM 17 – Remove and Replace 1968 – 70 Dashboard.......................................................................... 106
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
SRM 18 – Remove and Replace Points, Plugs, Condenser .................................................................. 110
SRM 19 – The R20 Engine ....................................................................................................................... 112
SRM 20 – Rebuild Fuel Pump.................................................................................................................. 114
SRM 21 – Installing an AC Delco Alternator on 1968-70 Cars .............................................................. 115
APPENDIX A – OWNER’S MANUAL REPRINTS .................................................................................................118
1966 and 1967 SPL311............................................................................................................................. 119
1967½ SPL and SRL311........................................................................................................................... 144
1968 SPL and SRL311.............................................................................................................................. 166
1969 SPL and SRL311.............................................................................................................................. 188
1970 SPL and SRL311.............................................................................................................................. 211
APPENDIX B - VINTAGE ADS AND ARTICLES REPRINTS ...............................................................................235
Part I - The Rob Beddington (www.fairlady.org) Collection ................................................................. 236
Part II - The Greg Valazza (www.Datsun.org) Collection....................................................................... 250
Part III – Vintage Magazine Articles ........................................................................................................ 266
APPENDIX C - VINTAGE ROADSTER COMPETITION BULLETINS REPRINTS................................................306
Technical specs compiled from over a dozen separate publications!
Technical Info
General Specifications
SPL311
1966-1967
SPL311
1968-1970 (smog)
SRL311
SRL311
1967 Solex
1967 SU
SRL311
1968-1970
(smog)
Engine
Displacement
Displacement
cu in
Bore/Stroke in.
3.267
Compression Ratio
Compression Press.
PSI @ 350 RPM
R-16
1595cc
97.33 cu in
R-16
1595cc
97.33 cu in
U-20
1982cc
121 cu in
U-20
1982cc
121 cu in
U-20
1982cc
121
3.433 x 2.630
3.433 x 2.630
3.433 x 3.267
3.433 x 3.267
3.433 x
9.0 : 1
9.0 : 1
9.5 : 1
9.5 : 1
9.5 : 1
181 PSI
181 PSI
166 PSI
166 PSI
166 PSI
Technical Specifications and Dimensions
Single value in center column denotes same value for all models
R-16 3-Main
R-16 5-Main
U-20
PISTON
Cylinder bore
Standard
st
1 oversize .010”
nd
2 oversize .020”
rd
3 oversize .030”
th
4 oversize .040”
th
5 oversize .060”
Piston to bore
Clearance
3.4323 – 3.4342”
3.4413 – 3.4433”
3.4512 – 3.4531”
3.4610 – 3.4630”
3.4709 – 3.4728”
3.4905 – 3.4925”
.001 - .0017”
.001 - .0017”
.0012 - .0020”
.0374 - .0414”
.8657 - .8661”
.0374 - .0414”
.8657 - .8661”
.0392 - .0396”
.8655 - .8660”
PISTON PIN
Hole offset
Piston pin diameter
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Complete torque specs in U.S. and metric values!
Torque Settings for Fasteners
Single value in center column denotes same value for all models
R-16 3-Main
R-16 5-Main
U-20
Engine Tightening
Torques
Cylinder head bolts
st
1 step
33 ft. lb. (4.56 kg/m)
nd
2 step
48 ft. lb. (6.64 kg/m)
rd
3 step
50 ft. lb. (6.92 kg/m)
Main bearing caps
80 ft. lb (11.1 kg/m)
Connecting rod bolts
45 ft. lb. (6.22 kg/m)
Flywheel bolts
50 ft. lb (6.92 kg/m)
Rocker bracket bolts
35 ft. lb. (4.84 kg/m)
Crank pulley bolt
120 ft. lb. (16.60 kg/m)
kg/m)
Cam / jackshaft screw
Overhead cam bolts
NA
OHC cam bearing cap nuts
8mm stud
NA
6mm stud
NA
Oil pan nuts / bolts
33 ft. lb. (4.46 kg/m)
48 ft. lb (6.64 kg/m)
50 ft. lb (6.92 kg/m)
80 ft. lb. (11.1 kg/m)
45 ft. lb (6.22 kg/m)
50 ft. lb. (6.92 kg/m)
35 ft. lb. (4.84 kg/m)
120 ft. lb. (16.60 kg/m)
43 ft. lb. (6.36 kg/m)
63 ft. lb. (8.72 kg/m)
65 ft. lb. (8.99 kg/m)
65 ft. lb. (8.99 kg/m)
65 ft. lb. (8.99 kg/m)
58 ft. lb. (8.02 kg/m)
NA
145 ft. lb. (20.06
4 ft. lb. (.55 kg/m)
NA
13 ft. lb. (1.80 kg/m)
NA
NA
4 ft. lb. (.55 kg/m)
13 ft. lb. (1.80 kg/m)
5 ft. lb. (.69 kg/m)
Service and repair steps for major systems!
SRM 01 - Engine Removal / Reinstallation - R-16 and U-20
Since most people using this manual are driving cars with a couple of generations of miles under
their wheels, the first step of the engine removal process is to visit the local “U-do it” car wash.
Thoroughly cover the engine with a degreaser such as Gunk and have at it with the high pressure
hose. Cover the distributor and air filter with plastic or you may have to push it home. A
distributor full of moisture is a misfire waiting to happen. Clean the engine, transmission, frame,
and engine compartment. Any dirt you get off now is less dirt to get on you when you start
working on it.
The design of the 1600 / 2000 sports car drive train and chassis is such that the engine and
gearbox are removed as an assembly from the engine compartment. Any attempt to disprove
this law of mechanics will result in unbelievable amounts of extra work.
REMOVAL OF ENGINE / GEARBOX FROM CHASSIS
1)
Park the car on a smooth, level, and solid surface that won’t allow your jack stands to
sink into the ground. Be sure you have access to all four sides of the car without crowding. Extra
space is needed at the front so you can maneuver an engine crane if you use one. Allow at least
one extra car length in front to place the engine, gearbox, and crane. If you are using an
overhead hoist on a beam, allow at least one car length behind the car so you can push the car
backward from under the engine / gearbox while it is suspended on the hoist.
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Complete Owner’s manual reprints – 5 volumes cover years 1966-70!
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Vintage magazine articles and advertisements!
Reprinted with permission of Road & Tack magazine
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
Classic press photos, brochures, and publications!
End of Part II – “Technical and Service Manual”
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.
And finally, to close the deal…………..
We have tried to offer the most comprehensive, complete collection of information
about all areas of roadster ownership to assist you with basic maintenance and
operation of your car including parts information to help with the increasingly
difficult parts search.
We believe that we have improved both quality and quantity of a publication that
has been highly regarded since it was originally published 18-years ago.
Look over these examples and rest assured that the contents of both manuals are
even better than what we’ve shown you here. Not only better in total content, but
spelled “kurecktly”, too (unlike the original 18 years ago)!
We hope you’ve enjoyed your sample of our books and place an order for your
own copies.
Permanently bound with soft covers, each book has over 300 pages without any
full, blank pages. You get information – not blank paper!
Available as individual volumes, Part I and Part II are priced at
$54.88 each
which includes delivery via USPS Media Mail.
Also available as a two-volume set
for $88.88 the set,
which also includes delivery via USPS Media Mail.
P.S. – if you opt for a single volume and decide to get the second volume in
a separate transaction the individual volume price applies.
Sales tax is only added for books shipped or delivered to addresses in Georgia.
Send your check (we hold until cleared) or money order to:
TheDatsunRoadsterBook, LLC
5380 Overbend Trail
Suwanee, GA 30024
Send questions to: [email protected]
Thanks for your time.
All items copyright 1987 – 2006 The DatsunRoadsterBook, LLC All rights reserved.