warning DATSUN 210 1979 User Guide

The

charging
circuit
consists
of
a

battery
an

alternator

incorporating
an

IC

voltage
regulator
and

wiring
that

connects
these

parts

The

purpose
of

this

system
is
to

convert
mec
hanka

energy
from
the

engine
into
electrical

energy
which
is

used
to

operate
all

electrically
operat

ed
units
and
to

keep
the

battery

fully

charged

With
the

ignition
switch
in
ON
the

circuit
between

transistor
uTr

I
of
the

lC

voltage
regulator
and

ground
is

closed
Current
from
the

battery
then

flows

along
the
route

shown

by
the

arrOW
in

Fig
EE
26

turning
on
the

charge

warning
lamp
and

flowing
on

through
terminal
L

to
excite
the

rotor

When
the
alternator

begins
to

oper

ate
three

phase
alternating
current
is
ngine
Elect
ical

System

CHARGING
CIRCUIT

indicated

in
the
stator

coil
This
alter

nating
current
is

rectified

by
the

posi

tive
and

negative
silicon

diodes

When
the

voltage
at
terminal
8
is

higher
than

battery
voltage
current

produced
at
the

stator
flows

to
re

charge
the

battery
While
the

battery
is

being
re

charged
the

voltage
at
termi

nal
L

is

equal
to
that
of
terminal

8
At
this

point
there
is
no

voltage

differential
on
either
side
of
the

charge

warning
lamp
which
causes
the

charge

warning
lamp
to
turn
off
In

other

words
current
does

not
flow
from
the

battery
to
terminal
L

Accordingly

current
flow

through
the
rotor
as

shown
in

Fig
EE
27

is
taken
over

by

current

produced
at
the
stator
The

circuit
between
terminal
F
and

Tr
is

then
closed
See

Fig
EE
27

The
IC

voltage
regulator
monitors
generating
voltage
to
be

applied
to
the

battery
at
terminal
S
When
current

exceeds
the

specified
value
it
then

flows

through
the
zener
diode
ZD

closing
the

circ
it

consisting
of

transis

tor
Tr
and
resistor

R1
At
this

point
current
neither
flows

through

transistor
Tr

I
to

ground
nor
to
the

rotor

thereby

reducing
the

voltage

generated
at
the

stator
See

Fig

EE
28

When

voltage
generated
at
terminal

S
is

reduced
to
the

specified
value

transistor

allows
current
to
flow

through
the

rotor

increasing
the

generating
voltage

In

this
manner

output
voltage
from

the
alternator
does

not
rise
above
the

specified
value

by
the
ON
OFF

opera

tion

of
the

rotor
coil

through
the
IC

voltage
regulator

16

L

R
l
I

01
0

ls

CHARGE
LAMP

J
011

L

e
0

u

a

M
e

i
J

0

io
o
IGNITION

a

0

09

SWITC1
R2

El1
STATOR
COIL

04
0
R

F

1
BATTERY

8

ZD

ALTERNATOR

7
I

1
AJ

TI
3

IC
VOLTAGE
REGULATOR
Aa

E

1

7

EE760

Fig
EE
26

Simplified
Charging
Circuit
Initial
excitation

current

EE
10

FUSIBLE
LINK

FUSIBLE
LINK

f
BATTERY

@@

V

R

@@

G
G

FUSleLE

ImrnI
LI
NK

MTI

I
En

g
n
l
Electrical

Syst
lOl

IGNITION

SWITCH
FUSE

lOA

o
v

FUSE

lOA

C
V

L@@

BAT

f
L

S

BI

I

I

sl
fRO

L

I

I

F

I

EI

i
K
a

ALTERNATOR

lE
Ie

VOLTAGE

REGULATOR

I
I

L
WR

I
1

d

I

t
J

t
IGNITION

WR
SWITCH

BW

U
0

AUTO

CHOKE

RELAY
G
1

WR

J
I

00

00

gg
1

00

VR

1

E
lDID
I

@
O

BAT
mID

W

J
WR

W
FUSE

BLOCK

CHARGE

WARNING

LAMP

5J

BL

Note

@

V

@
California
models

Non
Qilifomo
18
models

FU
models

Fig
EE
29
Circuit
Dinrswr
EE742

mofCIuJ

Tg
ng
Sy
t
m

EE
12

Engine
Electrical

System

6

Tighten
through
bolts

rfl
Tightening
torque

Through
bolts

60
to
70

kg
cm

52
to
61
in
lb
ALTERNATOR
TEST

Before

conducting
an
alternator

test
make
sure
that
the

battery
is

fully

charged

A
30
Volt
voltmeter
and
suitable

INSPECTION
TABLE

With
alternator

aide
L
tenninal

grounded
internal

short
occurs

when
diode
is
short

circuited

@
test

probes
are

necessary
for
the

test

The
alternator

can
be

checked
easi

ly
by

referring
to
the

Inspection
Table

Bumed
out

bulb

Replace

and
Proceed

toUA

Ignition

switch

ON

Check

light

for

operation
Disconnect
Light
OFF

f

Light
OFF
connector
S

L

and

ground

L

lead
wire

Light
ON

Check

light

for

operation
Light
ON

I
Faulty
IC
RG

Replace
Connect
con

nector
S
L

and

ground
F

a1light
Light
OFF

I
FaultyA
C

G

I

Dim

light
for

operation

tf
i
rs

1
I
Faulty
A

C
G

I

Light
ON
I

Contact

positive
lead
of

voltmeter
on
B

lennina
and

negative
lead
to
L
tenninal
Light
ON

1

Engine
idling

Check

light

for

operation

Light
OFF

I
Engine
idling

Measure
the

voltage
across

B

and
L

terminals

Engine
speed

1

500

rpm

Ligh
tin

switch

ON

Check

light

for

operation
r
Dim

light

Light
OFF
Note

1
Use

fully
charged

battery

2

Light
Charge

warning
light

A

C
G
Alternator

parts
except
IC

regu
tor

IC
RG
IC
n

guJator

OK
IC
altemator
is
in

good
condition

3

When

reaching
Faulty
A
C
G
remove

alter

nator

from
car
and
disassemble

inspect
and

correct
or

replace
faulty
parts
Engine
speed

1
500

rpm

Measure
B

terminal
volt

sge

Make
sure
S

terminal
is

con

nected

correctly

4

Method
of

grounding
F

terminal

Contact

tip
of
wire
with

brush
and
attach

wire
to

alternator

body

Suitable
wire
I

Fig
EE
50

Grounding
F
Terminal

5
Terminals

S
L
BA
Tn

and
E
are

marked
on
rear
cover
of

alternator

EEl7
More

thanO
5V

I
Faulty
A
e

G

1

Less
thanO
5V

I
OK

T
Mon
than

15
5V

I
Z
C
RG

I

I3
to
15V

Engine
idling

Lighting

switch
ON

Check

light

for

operation

Light
ON

I
Faulty
A
C

G

I

Light
OFF

I
OK

DESCRIPTION

The

regulator
consists

essentially
of

in

egrated
circuits

incorporating
tran

sistors

These
transistors
int

errupt
and

admit

current
flow

to
the
alternator

rotor

coil
thus

maintaining
its

output

voltage
at
a
constant
value
Unlike
in
a

mechanical

type
regulator
an
electron

ic

relay
employing
transistors
is
uti

lized
These
transistors

are
enclosed
in

a

very
compact
sealed

case
The

electronic

relay
is

soldered
to
the

Brush

Ie

regulator

R

J

DIO

F

i
ZD

Tn
Engipe
Electrjcal
Syst
em

REGULATOR

brush

assembly
inside
the

alternator

Should

any

problem
with
the

relay

arise
it

should
be

replaced
together

with
the

brush

assembly
In
the

charge

warning
lamp
circuit
a
diode
is
at

tached
to
the
stator
coil
to

monitor

generating
voltage
at
the
stator

so
that

when
the

monitored

voltage
and

charging
voltage
are

equal
during
re

charging
the

charge

warning
lamp
is

turned
off

Accordingly
a

charge

warning
relay
is

not

employed
in

this

circuit

s

r
t

E

F
L
S
B

EE629

Fig
EE
51
lC

Voltage
RegultJtor

I

B

S

L

I

R

R

E
B
S
L

E
F
Terminal

R
Resistor

Rh
Thermistor

Tr
Transistor

ZD
Zener
diode

EE766

Fig
EE
52

Circuit
of
RegultJtor

EE
18
INSPECTION

To

check
the

IC

regulator
proceed

as
follows

Remove
IC

regulator
and

brushes
as

an

assembly
as
outlined
in

Disas

sembly
and

Assembly
section
under

the

heading
Alternator

CAUTION

When

performing
test

continuously

resistor

may
generate
heat
If

it
be

comes

high
temperature
stop
testing

for
a

while
to
avoid

burning

The

following
test

equipment
and

accessories
are

required

I
Resistor
R
10

ohms
20

watts
x
I

2

Variable
resistor

Rv
0
to
300

ohms
20
watts
x
I

3

Batteries
I

and
2
12

volts

x2

4
DC

voltmeter
0
to
30
volts

x
I

2
Connect

wiring
as
shown
in

Fig

EE
S3
and

perform
tests
as
follows

I

Measure

voltage

VI
at

battery
If

it
is

not
within

10
to
13

volts
re

charge
or

replace
battery
as

necessary

2
Disconnect
lead
wire

at
terminal

s

measure

voltage
V

2
between

terminals
F

and
E
If
it
is

below

2
0
volts

regulator
is

functioning

properly
Connect

lead
wire

to
termi

nalS

3

Measure

voltage
V

3
total
volt

age
of

batteries
I

and
2

If
it

is
not

within

20
to
26
volts
re

charge
or

replace
either
or

both
batteries

4

Gradually
decrease
resistance
of

variable
resistor

Rv
from
300
ohms

and
measure

voltage
V

2
between

terminals
En
and
F
As
resistance

DESCRIPTION

The

ignition
circuit
consists

of

igni

tion

switch
Ie

ignition
unit
dis

tributor

winng

ipark
plugs
and

battery

The

distributor
is

of
the

contactless

type
and
is

equipped
with
a

pick
up

coil
which

electrically
detects
the

igni

tion

timing
signal
in

place
of
the

ircuit

I
rea
r

of
the
conventional

distributor
The
IC

ignition
unit
is

a

new
addition

which

generates
the

signal
required
for
the

make
and
break

of
the

primary
current
for
the

ignition

coil

The

primary
current
is

supplied

by
the

battery
or
alternator
and

flows

through
the

primary
circuit

It
consists

of
the

ignition
switch

primary

winding
of
the

ignition
coil

IC

ignition
unit

and
all

connecting
low

tension

wiring

The

secondary
current
is

produced

by
the

ignition
coil
and
flows

through

the

secondary
circuit

resulting
in

high

voltage
spark
between

the
electrodes

of

the

spark

plugs
in

engine
cylinders

This
circuit

contains
the

secondary

winding
of
the

ignition
coil
distribu

tor

high
tension

cables
to

coil
and

spark

plugs
distributor

rotor
and

cap

When
the

ignition
switch
is

turned

on
and
the

distributor

reluctor
rotates

the

primary
current
flows

through
the

primary

winding
of
the

coil
and

through
IC

ignitionu
nit

to

ground

When
the

primary
circuit
is

opened

by
circuit

of
IC

ignition
unit

the

magnetic
field
built

up
in

the

primary

winding
of
the
coil

moves

through

the

secondary
winding
of
the

coil
in

ducing
high

voltage
This

high

voltage

is

produced

every
time

the

primary

circuit

opens
EngineElect
ical

System

IGNITfON

CIRCUIT

The

secondary
current

flows

through
the

high
tension

cable
to
the

distributor

cap
then

the
rotor

distributes
the
current
to

one
of
the

spark
plug
terminals
in
the

distrubutor

cap

Then
the

spark
occurs

while
the

secondary
current

jumps
the

gap
be

tween
the
insulated
electrode
and
the

ground
side
electrode
of
the

spark

plug
This

process
is

repeated
for
each

power
stroke

of
t

e

engine

The

spark
plug
should
be

inspected

cleaned
and

regapped
at

tune

up

Spark

plugs
should
also
be

replaced

periodically
as

specified
in

the

Maintenance
Schedule

The
remainder

of
the

ignition

component
parti
should
be

inspected

Battery

letink

Primary

winding

1

Ignition
coil

Secondary
winding
J
for

only
their

operation
air

gap
of

distributor

tightness
of

electrical

terminals
and

wiring
condition

Apply
grease
NLGI

consistency

No
I

containing
MaS
or

equivalent

to
distributor
rotor

shaft
as

required

WARNING

When
current
is

flowing
never

touch
with
bare

hand

high
tension

cables
or

any
other

parts
with

high

vollage
If

parts
are
moist

touching

them
could
cause
an
electric
shock

even
if

they
are
insulated

Always

wear

dry
well
insulated

gloves
or

wrap
affected

parts
with

dry
cloth

before

handling

To
starter

EE
20
Ro

or
head

Ul

J

r

Spark
plugs

EE743

Fig
EE
56

Ignition
System
Circuit

Diagram

REMOVAL

It
is
much
easier

to
remove

engine

and
transmission

as
a
single
unit
than

to

remove
alone
After
removal

engine

can
be

separated
from
the
transmission

assembly

WARNING

a
Place
wheel
chocks
in
fronl

of

front

wheels
and
in

rear
of

rear

wheels

b
Be
sure
to
hoist

engine
in
a
safe

manner

c
You
should
not
remove

engine

until
exhaust

system
has
com

pletely
cooled
off

Otherwise

you
may
burn

your

self
and
or
fire

may
break

out
in

fuel
line

Note
Fender
coven
should
be

used

to

protect
car

body

1
Disconnect

battery
ground
cable

from

battery
terminal
and
fusible
link

at
wire

connector

2
Remove
hood

as
follows

CAUTION

Have
an
assistant

help
you
so
as
to

prevent

damage
to

body

I
Mark
hood

hinge
locations
on

hood
to
facilitate
reinstallation

2

Support
hood

by
ltand
and
re

move
bolts

securing
it

to
hood

hinge

being
careful
not
to
let
hood

slip
when

bolts
are

removed
See

Fig
ER
2

3
Remove
hood
from
hood

hinge

f

Il

I

BF133A

Fig
ER
2

Removing
Hood

Remove

under
cover

Drain

radiator
coolant
and

engine
3

4

oil

5

Disconnect

upper
and
lower
hoses

from
radiator
and
disconnect
oil

cooler
hoses
automatic
transmission

only

6
Remove
four
bolts

securing
radia
Engine
Removal
Installation

tor

to

body
and
detach
radiator
after

removing
radiator
shroud

7

Remove
air
cleaner

assembly

from
carburetor
as
follows

1
Remove

fresh
air
duct
from
air

cleaner

2
Remove
hot
air
duct
from
air

cleaner

3

Loosen
air
cleaner
band
bolt

4
Disconnect
air

cleaner
to
air

pump
hose

at
air
cleaner

5

Disconnect
air
cleaner

ta
rocker

cover
hose

at
rocker
cover

6
Disconnect
air

cleaner
to
A
B

valve
hose
at
air

cleaner

7
Disconnect
air
cleaner
to
related

vacuum
hoses
at
air

cleaner

8
Disconnect
accelerator
control

wire
from
carburetor

9
Disconnect

the

following
cables

wires

and
hoses

Wire

to
auto
choke
heater

Wire
to

throttle

opener
cut
solenoid

or

throttle
switch

Wire

to
fuel
cut
solenoid

Wire
to

vacuum
switching
valve

High
tension

cable
between

igni

tion
coil
and
distributor

Battery
cable
to
starter
motor

Wire
to
distributor

Wire

to
thermal
transmitter

Wire

to
alternator

Engine
ground
cable
oil

pressure

switch
and

engine
harness
No
2

See

Fig
ER
3

o

1
Ground
cable

2

Engine
harness
No

2

3
Oil

pressure
switch

Fig
ER

3
EA368

Disconnecting
Cable
and

Wire

Fuel
hose

at
fuel

pump
and
fuel

return

hose
at
connection

Air

pump
air

cleaner
hose

Carbon
canister
hoses

Heater
inlet
and
outlet
hoses
if

so

equipped

ER
3
Vacuum
hose
of

brake
booster
at

intake
manifold

Air
conditioner

equipped

model

10
Remove

compressor
belt

To

remove
loosen
idler

pulley
nut

and

adjusting
bolt

1
Remove
air

pump

2
Remove

compressor
retaining

bolts
and
move

compressor
toward

fender
to
facilitate
removal
of

engine

Nole
Never

discharge
gas
from
com

pressor
while
work
is

being

per

formed

II

Compressor

EA478

Fig
ER
4

Location

of
Air

Compressor

3
Disconnect
vacuum
hose
of
air

conditioner
from
connector
of
intake

manifold

4
Remove

F
i

C
D

actuator
from

bracket

II
Remove
clutch

operating
cylin

der
from
clutch

housing
manual
trans

mission

only

dJ

Tightening
torque

Clutch

operating
cylinder

E
A3

to
clutch

housing

3
1

to
4
1

kg

22
to

30
ft
lbl

Fig
ER
5

Removing
Clutch

Operating

Cylinder

12

Disconnect

speedometer
cable

from
rear
extension

housing

13

Remove
transmission
control

linkage

I

For
cars

equipped
with
manual

transmission

remove

gear
shift
control

lever

Fig
ER
6

Removing
Gear
Shift

Control
Lever

2

For
cars

equipped
with
auto

matic
transmission
disconnect
selector

range
lever

e

a

EA163

Fig
ER

7
Di8connecting
Selector

Range
Lever

14

Disconnect
exhaust
front
tube

from

exhaust
manifold
and
exhaust

mounting
bracket
rom
transmission

I

liJ
Tightening
torque
I

ER370

Front
tube

to
exheust

manifold

1
9
to
2

5kg
m

14

to
18

ft
Ibl

Fig
ER
S

Disconnecting
E
chaust

Front
Tube
Engine
Remov
1
Installation

15

Hang
front
tube
end

with
a

suitable
thread
or
a
wire
to

prevent

tube
from

falling

J
6
Remove

propeller
shaft

Refer
to

Propeller
Shaft
Section

PO

for
removal

Plug
the

opening

end

of
rear
extension

housing
to

pre

vent
oil

leakage

P0315

liJ
Tightening
torque

Propeller
shaft
to

companion

flange

2
4
to
3
3

kg
m

17
to
24
ft
bl

Fig
ER
9

Removing

Propeller
Shaft

Note

Pul
me
tch
mark
on
both
shaft

and

companion
flange
so
that
shoft

can
be
reinstalled
in

original
posi

tion

17

Support
transmission
with

jack

18

Remove
bolts

securing
rear

engine
mounting
member
to
the

body

19
Attach

Engine
slinger

10006H7202
as
shown
in

Fig
ER
IO
Note

Use

slinger
only
wheo

engine
is

removed
from

or
installed
on
car

Be

sure
to
remove
it
efter
Ulle

This

slinger
is
listed
in

Parts
Cet

log

as
a
service

optiop

20

Connect

suitable
wire

or
chain

to

Engine

Slingers
and
raise

engine
a

little
to
take

weight
off
front
mount

ing
insulators

WARNING

For

sofety
in

subsequent

steps
ten

sion

of
wire
or
chain
should

be

slackened

against
engine

21
Remove

bolts

securing
front

engine

mounting
brackets
to
froni

engine
mounting
insulators

22
Reise

engine
and

transmission

and
remove
from

car
as

a

single
unit

See

Fig
ER
IO

CAUTION

a
Before

raising
engine
10gether
with

transmission
make
sure
that

all

hoses
and
wires
connected

thereto

are
disconnected
or
removed

b
When

raising
engine
be

especially

careful
not
to
knock
it

against

adjacent
parts

ER
4
EA225

Fig
ER
IO

Removing
Engine

BRAKE
PEDAL

a

a

Fr

play

h
Free

height

d

Depressed
height

Tightening
torque
Icg
m
ft
tb

@

@
Push
rod
or

operating
rod
lock

nut

1

6
to
2
2

12
to

16

Brake

lainp
switch
lock
nut

1
2
to

I
5
9
to
11

BR121A

Fig
BR
1

Adjusting
Broke
Pedal

I

Adjust

pedal
height
h
to
the

specifications
by
moving
brake

lamp

switch
and

operating
rod
if

equipped

with
brake
booster

Pedal

height
h

143
to
149
mm

5

63
to
5
87

inl

Then
secure
brake

lamp
switch
and

operating
rod

C
l
Tightening
tOlque

Blake

lamp
witch
lock
nut

1
2
to
1

5

kg
m

9
to
11
ft

lb

Operating
lad
lock
nut

1

6
to
2

2
kg
m

12

to
16
ft
b
Brake

System

ADJUSTMENT

2
With
brake

booster

Adjustment
is
not

necessary
under

normal
conditions
Check
pedal
free

play
If
it
exceeds
the
above

specifica

tion

adjust
push
rod

length
refer
to

brake
booster
for

adjustment
by
re

moving
master

cylinder
rerer
to
Mas

ter

Cylinder
for
removal

3
After

adjustment
is

completed

depress
brake

pedal
several
times
to

ensure
that
it

travels
over
its
entire

stroke

smoothly
without

squeaking

noise

twisting
or
interference

Pedal

depr
d

Might
d

more
than
70
mm
2
76

in

FRONT
DISC
BRAKE

Front
disc
brake
does
not

require

adjustment
under
normal
conditions

since

pad
to
rotor
clearance
is

auto

malically
adjusted
by
elasticity
of

piston
seal

REAR
BRAKE

Auto

edJuster
type

Adjustment
is
not

necessary
under

normal
conditions
since
brake
drum

t
shoe
clearance
is

automatically

compensated
for

by
operating
hand

brake

Wlien
brake
drum
to
shoe

clearance

is

correct

operating
noise

of

adjuster

is

not
heard
even
if
hand
brake
is

operated

HAND
BRAKE

I

Adjust
rear
brake
shoe

to
drum

clearance
before

adjusting
hand
brake

2
Turn

turnbuckle
so
that
when

hand
brake
control
lever
is

pulled

by
specified
force

lever
stroke
or

number
of
notches
is
as

follows

Pulling
fOil
20

kg
44
Ib

lever
stroke

93
to
106

mm

3
66
to
4

17
in

Numbel
of
notches
7
to
8

BR

2
f

BAQ05A

Fig
BR
2
Adjusting
Hand
Brake

Then

tighten
lock
nut

securely

3

After

returning
hand
brake
con

trol

lever
to
its

original
position

ensure
that

e
All
rear
brake

toggle
levers

return

to
their

original
positions

Rear
cables
are
not
slack

HAND
BRAKE
WARNING

LAMP
SWITCH

Bend
hand
brake

warning
lamp

switch

plate
down
so
that
brake

warn

ing
light
comes
on
when
ratchet
at

hand
brake
lever
is

moved
back
one

notch
and

goes
out
when
returned
to

its

original
position

BLEEDING

HYDRAULIC
SYSTEM

Hydraulic
brake

system
must
be

bled
whenever

any
line
has
been
dis

connected
or
air
has
in
some

way

entered

system

Spongy

pedal
action
is
an
indica

tion
that
air
has
entered
brake

system

Bleeding
hydraulic
system
deserves

much
attention
as
it
is
an
essential

element
in

regular
brake

servicing

Clean
all

dirt
around
master
cyl

inder
reservoir
remove
reservoir

cap

and

top
up
reservoir
with
recommend

edbrake
fluid

Note
Do
not
mix

two
different
brand

oils

2

Thoroughly
clean
mud
or
dust

from
bleeder
valve

so
that
outlet
hole

is
free
from

foreign
particles
Install
a

bleeder
hose
on
bleeder
valve

REMOVAL

I

Disconnect

wiring
to
brake
fluid

level

gauge

2
Disconnect
front
and
rear
brake

tubes
from
master

cylinder

CAUTION

When

removing
brake
tubes

use

suitable
tube

wrench

Never
use

open
end
or

edjustllble

wrench

Note
When

disconnecting
brake

tubes

be
sure
to
use
a
container

to
receive

draining
brake
fluid

Use
of

raga
is
also

suggested
to

keep
adjacent
perts
and
area

clean

3
Remove

master

cylinder
securing

nut
Master

cylinder
can
then
be
taken

out

DISASSEMBLY

1
Remove
reservoir

caps
and

filtern

and

drain
out
brake
fluid

2

Pry
off

stopper
ring
using
a

screwdriver

3
Remove

stopper
screw
and
take

out

stopper

primary
piston
assembly

spring
and

secondary
piston
assembly

in

the
order

shown

Note

Discard

caps
if

they
are
reo

moved
from

piston
assemblies
and

use

new
ones

4

Unscrew

pluga
to

gain
access
to

check
valve
for

disassembling

Note

a

Never
detach
reservoir
tanks

If

they
are
removed
for

any
reason

discard
them
and
install
new

ones

b
Do

not
remove
or
disassemble

brake
fluid
level

gauge

INSPECTION

Thoroughly
clean
all

parts
in
a

suitable
solvent
and
check
them
for

wear
or

damage
Replace
any

part
that

is

faulty
Brake

System

CAUTION

Use
brake
fluid

to
clean
Never

use

mineral
oil

I
Check

cylinder
and

pistons
for

evidence
of
abnonnal

wear
or

damage

Replace
if
found

faulty

2
Check

piston
to
cylinder
clear

ance
If
it

exceeds
the

specified
value

replace
either

piston
or

cylinder

Piston
to

cylinder
clearance

less
than
0
15

mm
0

0059
in

3

Check

springs
for
weakness

fatigue
or

damage
Replace
if
neces

sary

4
When

master

cylinder
is
disas

sembled
be

sure
to
discard

caps
and

valves

Replace
any
other

parts
which

show
evidence
of

deformation
wear
or

other

damage

S

Replace
damaged
oil
reservoirs

and

caps

ASSEMBLY

Assemble
master

cylinder
following

the
reverse

procedure
of

disassembly

paying
particular
attention

to
the
fol

lowing
note

Note

a

Replace
gaskets
and

packing
with

new
ones

b

Apply
brake
fluid

or
rubber

grease

to

sliding
contact
surface
of

parts

to
facilitate

assembly
of
master

cylinder

c
The
brake
master

cylinder
is

avail

able
in

both
NABCO
make
and

TOKICO
make
There
is

no
inter

changeability
of

repair
kits
or
com

ponent
parts
between

NABCO
and

TOKlCO
makes

When

replacing
the

repair
kit
or

component
parts
ascertain
the

brand
of
the
brake

master

cylinder

body
Be
sure

to
use

parts
of
the

same

make
as
the

fonner
ones

INSTALLATION

Install

master

cylinder

following

the
reverse

procedure
of
removal

After

installation
bleed
brake

system

BR
5
CAUTION

When

installing

Flare
Nut

6694310000
brake
tubes

use

Torque
Wrench

CiJ

Tightening
torque

Brake
master

cylinder

securing

nut

0
8
to
t
1

kg
m

5
8
to
8
0
ft
lb

Brake
tube
flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
b

BRAKE
FLUID

LEVEL
GAUGE

Inspection

I

Disengage
hand

brake
control

lever

2
Raise

cap
and

make
sure
that

hand

brake

warning
lamp

goes
on

when

float
comes
into
contact
with

stopper

BRAKE
LINE

REMOVAL

I
Remove
flare

nuts
on
both
ends

and

remove
retainers
and

clips

CAUTION

When

removing
brake
tubes
and

hoses
use
suitable
tube
wrench

Never
use

open
end
or

adjustable

wrench

2
To
remove
brake
hose

first
re

move
flare

nut

securing
brake
tube
to

brake
hose
and

withdraw
lock

spring

End
of
hose
can
then
be

removed
from

bracket
Next
remuve

brake
hose
Do

not
twist

brake
hose

INSPECTION

Check

brake
lines
tubes
and

hoses

for
evidence

of
cracks
deterioration
or

other

damage
Replace
any
faulty

parts

Remove
bias

ring
from

piston
A

S

Remove

retaining
rings
and
boots

at
the
end

of
both

pistons
A

and
B

I

Biuring

2

Boot

3

Retaining
ring

BA567

Fig
BR
15

Cylinder

Body
and
Pi
tan

6

Force
out

pistons
from

cylinder

by
feeding

compressed
air

gradually

WARNING

Gradually
increase
air

pressurs
10

that

piston
does
not

pop
out

7

Remove

piston
seals

CAUTION

Be
careful

not
to

damBlle
piston
and

cylinder
boily

8
Remove

yoke
spring
from

yoke

INSPECTION

Clean
au

parts
and
check
u
fol

lows

CAutiON

Use
brake

fluid
to

claan
Never

use

minersl

oil

Cylinder
bod

1

Check

inside
surface
of

cylinder

for
score
rust

wear

damage
or

pres

ence
of

foreign
substances
If

any

surface
fault
is
detected

replace
cyl

inder

body

2
Minor

damage
from
rust
of

foreign
substances

may
be
eliminated

by
polishing
surface

with
a
fme

emery

cloth
If

damage
is

major
cylinder

assembly
must
be

replaced
Brake

System

Yoke

Check
for
wear
cracks
or

other

damage

Replace
if

any
fault
is

de

tected

PIston

Check

piston
for
score
rust
wear

damage

orpresenco
of

foreign
sub

stances

Replace
if

any
fault
is

de

tected

CAUTION

Piston

sliding
surface
is

plated
00
not

polish
with

emery
peper
even
if

rust
or

foreign
matter

is
sticked
on

sliding

surface

PIston
seal
end
dust
seel

Replace
piston
seal
and
dust
seal
at

each

dis
mbly

ASSEMBLY

1

Apply
rubber

grease
to

cylinder

bore

and
install

piston
seal

2

Insert
bias

ring
into

piston
A
so

that
the

roundish

portion
of
it

faces

the
bottom
of

piston
A

bore

I

ID

J

if
C

jt

11

e

1

@

I

j
BA

I
Roundish

portion
3
Chamfer

2
Piston
A
4
Yoke

Fig
BR

16

A
embly
af
Bia

Ring

to
Piston

A

CAUTION

a

Be
careful
not
to

mistaka

piston
B

for

piston
A

b

Pistons
A

and
B
are

distinguished

from
each

other

by
a

dent
at
the

inner

bottom
of

piston
A

BR
8
Piston
A

Piston
B

BR41S

Fig
BR
17

Pisto
A
and
B

Note
Bias

ring
must

be
instaDed
on

the

original

position

3

Apply
rubber

grease
lightly
to
the

sliding

portions
of

pistons
and
insert

into

cylinder

Note

a
Insert

pistons
A

and
B

from

each

outside

b
When

inserting
pistons
be
careful

not

to
insert
too
far
Refer

to
Pad

Replacemeni

c
Install

piston
A

so
that

yoke

groove

of
bias

ring
of

piston
A
coincides

with

yoke
groove
of

cylinder

4

Instau

boot
and

retaining
ring

S
Install

yoke
springs
an

bias

ring

on

yoke

Front
face

1
1
0

Rear
face

BA416

1
Bias

Sprinl

2
Yoke

spring

Fig
BR
18
Yoke
with
Yoke

Spring