Operating cylinder DATSUN 210 1979 Service Manual

pl
ice
mter
as

an

assembly

2

When

installing
oil
mter

tighten

by
hand

Note
Do
not

overtighten
oil
filter

lest

leakage
shoUld
occur

CHANGING
ENGINE

COOLANT

PERMANENT

ANTI
FREEZE

COOLANT

Note

The

permanent
anti

freeze

coolant
is
an

ethylene
glya
l
base

product

containing
chemical
in

hibitors
to

protect
the

cooling

system
from

rusting
and
corrosion

The
anti

freeze
does
not
cOntain

any
glycerine
or

ethyl
alcohol
It

will
not

evaporate
or
boil
a

ay
and

can
be

ilsed
with
either

high
or
low

temperature
thermostats
It

flows

freely
transfers
heat

efficiently

and
will
not

clog
the

passages
in

the

cooling

system
The
anti
freeze

must
not
be
mixed

with
other

product
This
coolant
can
be
used

throughout
the
seasons
of
the

year

Whenever
coolant
is

changed
the

cooling

system
must
be
flushed
and

refilled
with
a
new
coolant
Check
the

coolant
level

See
instructions

attached
to

the

anti
freeze
container
for

mixing
ratio

of
anti
freeze

to
water

CHECKING
COOLING

SYSTEM
HOSES

AND
CONNECTIONS

Check
hoses
and

fittings
for
loose

connections

or
deterioration
Re

tighten
or

replace
if

necessary

INSPECTION
OF
RADIATOR

CAP

Apply
reference

pressure
0

9

kgj
cm2
13

psi
to

radiator

cap
by

means
of
a

cap
tester
to

see
if
it
is

satisfactory
Replace

cap
assembly
if

necessary
I

j
ngine
Tune

up

ET012

Fig
ET

3

Testing
Radiator

Cap

COOLING
SYSTEM

PRESSURE
TEST

Witli
radiator

cap
removed

apply

reference

pressure
1
6

kgfcm2
23

psi
to
the

cooling
system
by
means

0

no

Fig
ET
4

Water

capacity
M
Tmodelsl

Without
heater

5
2
liten

5
1f
US

qt
4

Imp
qt

With
heeter

5
9
Iiten

6
4
US

qt
5

Y

Imp
qt

Water

capacity
AfT
modelsl

Without
heater

5
0
liters

5

y
US

qt
4

Imp

qt

With
heater

5
7
liten

6
US

qt
5

Imp
ill

CHECKING
ENGINE

COMPRESSION

Note

a
To
check

cylinder

compression
it
is

essential

to
remove
all

spark
plugs

The

purpose
of
this
test
is
to

ET
4
determine
whether
there
is
exces

sive

leakage

past
piston
rings
head

gasket
etc
To
test

engine
should

be
heated
to
the

operating
t
M

ture
and
throttle
valve

opened

b

Cylinder
compre
on
in

Cylinders

should
not
be
less

than
llO
of
the

highest
reading
Different

compres

sion

in
two
ore
more

cYlinder
usual

ly
indicates
an

improperly
seated

valve
or
broken

piston
ring

c
Low

compression
in

cylinders
am

result
from
worn

piston

rings
This

trouble

may
usuaDy
be
accom

panied
by
ex
ssive
fuel

consump

tion

I

Warm

up
engine
sufficiently

2

Disconnect

aU

spark

plugs

3
Disconnect
anti
dieseling

solenoid

valve
connector

4

Properly
attach
a

compression

tester
to

spark

plug
hole
in

cylinder

being
tested

FiI
ET
S
ET529

Testing
Compre
sion

Pr
s8ure

5

Depress
accelenit6r

pedal
to

open

throttle
and
choke

valves

Note
Do
not

pump
pedal

6
Start

engine
as

quickly
as

pos

sible

Compression
pressllre

kg
cm2
ii
at

rpm

Standard
13

5
192

350

Minimum
12
5

1781
350

If

cylinder

compression
in
o
e

or

more
cylinders
is
low

pour
a

small

quantity
of

engine
oil
into

cylinders

through
the

spark

plug
holes
and
retest

compression

I

If

addingoil
helps
the

compres

1l

I

I

1J

1

Diaphragm
spring

2

Diapliragm

3
Valve
shaft

4
Valve

5
ValVe

seat

6
Valve
chamber

EC231

Fig
EC
64
E
G
R
Control
Value

Thermal
vacuum
valve

2

port

type

FU
and
Canada
models

The
2

port

type
thermal
vacuum

valve
is
mounted
on
the

engine

thermostat

housing
It

detects

engine

coolant

temperature
by
means
of
a

built
in

bi
metal
and

opens
or
closes

the
vacuum

passage
in
the

thermal

vacuum
valve

When
the
vacuum

passage
is

open

the

carburetor
vacuum

signal
is

applied

to
the

diaphragm
of
the
E
G
R
con

trol

valve
to
actuate
the

taper
valve

connected
to
the

diaphragm

1

Spring

2

Bi
metal

3
O

ring

EC232

Fig
EC
65
Thermal
Vacuum
Valve

2

port
type
Emission
Control

System

Thermal
vacuum
valve

3

port
type

U
S
A
models

except

FU

model

The
3

port
type
thermal

vacuum

valve
is
located

on
the
rear

end
of
the

cylinder
head

It

defects

engine
coolant

tempera

ture

by
means
of
wax

expansion
and

opens
or
closes
the
air

passage
from

the
air

cleaner

When

the
air

passage
is
closed
the

carburetor
vacuum
signal
is

applied
to

the

diaphragm
of
the
E
G
R

control

valve
to
actuate
the

taper
valve
con

nected
to
the

diaphragm
This
valve
is

also
co
used
as
a

component
for
the

Spark
Timing
Control

System

JiI2
To
air
cleaner

From
B
P
T

valve

From
distributor

EC156A

Fig
EC
66
Thermal
Vacuum
Valve

3

port
type

B
P
T
valve

The
B
P

T
valve
monitors
exhaust

pressure
to
activate
the

diaphragm

controlling
intake

manifold
vacuum

applied
to
the
E
G
R

control
vaNe
In

other
words
the

amount
of
recirculat

ed
exhaust

gas
vari

s
with
the

position

of
the
E
G
R

valve

regulated
by
the

operating
condition
of
the

engine

EC
23
To
E

G
R

control
valve
Vacuum
nal
Curce

Air
bleed
1

Exhaust

pressure

EC310A

Fig
EC
67
B
P
T
Value

REMOVAL
AND

INSTALLATION

E
G
R
control
valve

I
Disconnect

vacuum
hose
and
re

move
nuts

securing
E
G
R

control

valve
to
E

G
R

passage
The
E

G
R

control
valve

can
then
be
taken
out

Fig
EC

68

Remouing
E
G
R

Control
Valve

CAUTION

Pay
attention

not
to

give
damage
to

packing
of
E
G
R

control
valve

2

Installation
is
in

the
reverse
se

quence
of
removal

Note
In

installing
new
E
G
R

control

valve
confirm
that

the
model

num

ber
and

identification
marks
at

the

top
of
valve
are

as
follows

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

Engine
Removal
Installation

SERVICE
DATA
AND
SPECIFICATIONS

TIGHTENING

TORQUE

Front

engine
mounting
bracket
to

engine

Front
insulator
to

engine
mounting

bracket

Front
insulator
to

suspension
member

Rear
insulator
to
rear

engine
mounting

member

Rear

engine
mounting
member
to

body

Rear
insulator
to
trailsmission

Clutch

operating

cylinder
to
clutch

housing

Front

tube
to
exhaust
manifold

Propeller
shaft
to

companion
flange

Emaust

mounting
bracket
to
tranSmission
kg
rn
ft
lb

kg
rn
ft
Ib

gem
ft
Ib

g
m
ft
lb

g
m

ft
Ib

g
m
ft
Ib

kg
m
ft
Ib

g
m
ft
lb

kg
m
ft
lb

g
m
ft
Ib

ER
6
1

6
to
2
1

12
to
IS

1
6
to

p
12
0
I

3
2
to
4
3
23
to
31

0
9

to
1
2

6
5
to
8
7

3
2
to

4
3
23
to
31

0
9
to

q
6
5
to
8
7

3
1

to
4
1
22

to
30

1
9

to
2
5

14
to
18

2
4

to
3
3

17
to
24

0
8
to
1
2
5
8

to
8

7

DATSUN
210
Model
8310
Series

SECTIONCL

CLUTCH

CONTENTS

ADJUSTMENT

CLUTCH
PEDAL
HEIGHT

CLUTCH
PEDAL
FREE

TRAVEL

BLEEDING
CLUTCH
SYSTEM

CLUTCH
CONTROL

CLUTCH
PEDAL

CLUTCH
MASTER
CYLINDER

OPERATING
CYLINDER

CLUTCH
LINE

CLUTCH
UNIT

CLUTCH
DISC
AND

COVER
CL
2

CL
2

CL
2

CL
2

CL
3

CL
3

CL
4

CL
5

CL
6

CL
7

CL
7
RELEASE

BEARING

PILOT
BUSHING

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPEctiON
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

I

ECTIONS

SPECIAL

SERVICE
TOOLS
CL
8

CL
9

CL
10

CL
10

CL10

CL
11

CL
12

CL
14

CLUTCH
PEDAL

HEIGHT

I

Adjust
clutch

pedal
height
H
to

the

specified
range
with

pedal
stopper

adjusting
nut
Then

tighten
lock
nut

CD

2

Adjust
clutch

pedal
free

play
A

to
the

specified
range
at

pedal

pad

with
clutch
master

cylinder
push
rod

Then

tighten
lock
nut

@

Note

a

Pedal
free

play

appeared
due
to

clearance

among
pedal
hole

push

rod
and

piston
should
be

measured

on

top
face
of

pedal
pad

b

Depress
and
release
clutch

pedal

over
its
entire
stroke
to
ensure
that

the
clutch

linkage

operates
smooth

ly
without

squeak
noise

inter

ference
and

binding

I

I

Lock
nut

2

Lock
nut

Cl325

Fig
CL
I

AdjlUting
Clutch

Pedal

Height

Pedal

height
H

143

to
149

mm
5

63
to
5
87
in

Pedal
free

play
An

1

to
5
mm

0
04

to
0

20
in
Clutch

ADJUSTMENT

tfl
Tightening
torque

Lock
nut

CD

0
8

to
1
2

kg
m

5
8
to
8
7

ft
Ib

Lock
nut

@

0
8
to
1

Icll
m

5
8
to
8
7
ft

lbl

CLUTCH
PEDAL

FREE
TRAVEL

Adjust
clutch

pedal
free
travel

whenever
clutch
does
not

disengage

properly
or
whenever
new

clutch

parts
are

i
lslalled

I
Loosen
lock

nut
and

push
nut

djust
length
of

push
rod

by
turning

p
lsh
rod
with

open
end
wrench

until

release

bearing
lightly
touches
clutch

dia

phragm

spring

2

Then
turn

push
rod
back

approxi

mately
I

4
turns
so
that
withdrawal

lever

play
B

clearance
between

withdrawal
lever

push
nut
and
with

drawal
lever

is
within
the

specified

range

V

@

1
B

I

Lock

nut

2
Push
nut

3

Withdrawallcver

CL327

Fig
CL

2

AdjlUting
Clutch

Pedal

Free

Trauel

3

Tighten
lock
nut

against
push

nut

being
careful
not
to
disturb
the

adjustment

4

Depress
and
release
clutch

pedal

several
times

then
recheck

with

drawal

lever

play
B

Readjust
if

necessary

5

Finally
measure

pedal
free
travel

C
at
center
of

pedal
pad

CL
2
Withdrawalle

er
play
nBn

clearance
between
withdrawal

I
er

push
nut
and
withdrawal

le
erl

1
0

to
2
0

mm

0

039
to

0
079
in

Clutch

pedal
free

tr
el
en

at
center
of

pedal
pad

16to33
mm

0
63
to
1
30
in

BLEEDING
CLUTCH

SYSTEM

The

hydraulic
clutch

system
must

be
bled
whenever

clutch
line
has
been

disconnected
or
air
has
entered
it

When

pedal
action
has
a

spongy

feeling
it
is
an
indication
that
air
has

entered
the

system

Bleeding
clutch

system
is

an
essen

tial

part
of

regular
clutch
service

I
Remove

cap
of
reservoir
and

top

up
with
recommended
brake
fluid

2

Thoroughly
clean
mud
and
dust

from
bleeder
screw
of

operating
cyl

inder

so
that
outlet
hole

is
free
from

any

foreign
material
Install
bleeder

hose

vinyl
hose
on
bleeder
screw

Place
the
other
end
of
it
in

a

container

filled
with
brake
fluid

3
Have

a
co
worker

depress
clutch

pedal
two
or

three
times

With
clutch

pedal
depressed
fully
loosen
bleeder

screw

to
bleed
air
out
of
clutch

sys

tem

4
Close
bleeder

screw
quickly
as

clutch

pedal
is
on
down
stroke

5
Allow
clutch

pedal
to
return

slowly
with
bleeder

screw
closed

6

Repeat
steps
3

through
5
until
no

air

bubble
shows
in

the

vinyl
hose

tfl

Tightening
torque

Bleeder
screw

0
7

to
0
9

kg
m

5
1

to
6
5
ft

lbl

7

Depress
and
release

clutch

pedal

several
times
then

check
for

external

hydraulic
leaks
at

connections

Note

a
Brake
fluid

conlaining
air
is

white

and
has

visible
air
bubbles

b

Brake
fluid

containing
no
air

runs

out

of
bleeder
screw
in
a
1lO6d

stream
without
air

bubbles

c

Pay
close
attention
to

clutch
fluid

level

in
reservoir

during
bleeding

operation
Clutch

d

Pour
brake
fluid
into

reServoir

up

to

the

specified
level

CLUTCH
CONTROL

Clutch
ma5ter
cylinder

2

Clutch
disc

assembly

3
Clutch
cover

assembly

4

Release

bearing
and
sleeve

assembly

5

Return

spring

6
Clutch
line

7

Clutch

pedal

8

Operating
cylinder

9
Withdrawal
lever

10
Withdrawal
lever
ball

pin
CAUTION

a
00
not

re
use
brake
fluid

drained

during

bleeding
operation

b

Exercise
care
not
to

splash
brake

fluid
on
exterior
finish
as
it
will

damage
the

paint

e
When

tightening
flare
nut
use
Flal
ll

Nut

Torque
Wrench

GG94310000

CLUTCH
PEDAL

REMOVAL

l

JF

j

1

Clevis

pin

2
Master

cylinder

push
rod

3

Snap
pin

4

E

ring

5

Bushfug

6
autch

pedal

7

Return

spring

j
CL351

Fig
CL
4

Clutch
Pedal

C
L369

Fig
CL

3

Hydraulic
Clutch

Control

System

CL
3
I

Remove

snap
pin
from

end
of

clevis

pin
Separate
master

cylinder

push
rod
from
clutch

pedal

2

Remove
E

ring
from

tip
of
ful

crum

pin
and

take

out
clutch

pedal

and
return

spring

are

clean
and
free
from

foreign
matter

Cearance
between

cylinder

bore
and

piston

Leu
than
0
15

mm

0
0059
in

ASSEMBLY

Assemble
clutch
master

cylinder
in

the
reverse
order
of

disassembly
Ob

serve
the
following

I

Dip
piston
cup
in
brake

fluid

before

installing
Make
sure
that

it
is

correctly
faced
in

position

1
Return

spring

2

Supply
valve
rod

3
Piston

4

Secondary

cup
5

Spring
seat

6
Valve

spring

7

Primary
cup

8
Push
rod

CL283

Fig
CL
7
Piston

Asaembly

2

Apply
a

coating
of
brake
fluid
to

cylinder
and

piston
when

assembling

if
Tightening
torque

Reservoir
band

0
25
to
0
4

kg
m

11
8
to
2
9
ft
lb

Supply
valve

stopper

0
15
to
0
3

kg
m

1
1
to
2
2
ft
Ib

INSTALLATION

Install
clutch
master

cylinder
in
the

reverse
order
of
removal
Observe
the

following

I

Bleed
air

out
of

hydraulic
system

Refer
to

Bleeding
Clutch

System
for

bleeding

2

Adjust
pedal
height
and

pedal

free

travel
Refer
to

Clutch
Pedal

Height
and
Clutch
Pedal
Free

Travel

for

adjustment
Clutch

if
Tightening
torque

Master

cylinder
to
dash

panel

securing
nut

0
8
to
1
2

kg
m

5
8
to
8
7
ft

Ib

Clutch
tube
flare
nut

1
5
to
1
8

kg
m

11

to
13
ft
lb

CAUTION

When

connecting
clutch
tube

use

F

lere
Nut

Torque
Wrench

GG94310000

Note
When

tightening
flare
nut
hold

pipe
by
hand
to

r
it

from

twilling

OPERATING

CYLINDER

REMOVAL

I
Disconnect
clutch
tube
from

clutch
hose
at
the

bracket
on

side

member

CAUTION

When

disconnecting
clutch
tube

use

suitable
flare
nut
wrench

Never
use
an

open
end
wrench
or

adjustable
wrench

2
Remove
lock

spring
then
dis

engage
hose
from
bracket

3
Remove
clutch
hose
from

oper

ating
cylinder

4
Remove

operating
cylinder

DISASSEMBLY

Remove

push
rod
and
dust

cover

2

Remove

piston
and

piston
cup
as

an

assembly

Note

Discard

piston
cup
and
dust

cover

3
Remove
bleeder
screw

Cl
5
1

4

v

I
Bleeder
screw

2

Cylinder
body

3
Piston

cup

4
Piston
5
Dust
cover

6
Push
rod

7
Lock
nut

8

Push
nut

CL203

Fig
CL
B

Operating
Cylinder

INSPECTION

Visually

inspect
all
disassembled

parts
and

replace

parts
which
are
worn

or

damaged
too

badly

beyond
specifi

cations

CAUTION

To
clean
or
WISh
all

parts
of

operating

cylinder
dean
brake
fluid
must
be

Used

Never

use
mineral
oils
such
as

gasoline

and
kerosene
It
will
ruin
the
rubber

parts
of
the

hydraulic
system

I

Check

cylinder
bore
and

piston

for
score
or
rust
and
if
found

replace

2
Check

cylinder
bore
and

piston

for
wear
If
clearance

between

cylinder

bore
and

piston
i5
more

than
the

specified
value

replace
piston
or

oper

ating
cylinder
assembly

3

Check
condition
of

piston

cup

and
dust
cover

Always

replace
them

after

disassembly

4
Check
bleeder
hole
to

be
sure

that
it
is

clean

Clearance
between

cyliniler
bore

and

piston

less
than
0
15
mm
0
0059
in

ASSEMBLY

Assemble

operating
cylinder
in

the

reverse
order
of

disassembly
Observe

the

following

t

Prior
to

lWembly

dip
a
new

piston
cup
in
clean

brake
fluid
To

install

piston
cup
on

piston
pay
par

ticular
auention
to
its

direction

2

Dip
cylinder
and

piston
in

clean

brake

fluid
before

assembly

INSTALLATION

Install

operating
cylinder
in
the

reverse
order
of

removal
Observe

the

following

1

Bleed
air

thoroughly
from
clutch

hydraulic
system
Refer
to

Bleeding

Clutch

System
for

bleeding

2

Adjust
clutch

pedal
free
travel

Refer
to

Clutch
Pedal
Free

Travel
for

adjustment

Note

a

Use
new

gasket

b
When

operating
cylinder
is
removed

from
or

instaUed
on
clutch
haus

ing
without

disconnecting
clutch

hose
from

operating
cylinder
loos

en
bleeder

screw
so
that

push
rod

mo

lightly

c
E
xer

e

care
not
to

p
or
wist

clutch
hose
Be

sure
to
install

clutch
hose

away
from

exhaust

tube

d
When

tightening
flare

nut
hold

pipe
by
hand
to

prevent
it
from

twisting

CAUTION

When

connecting
dutch
tuhe

uSe

Flare

Nut

Torque
Wrench

G694310000

@
Tightening
torque

Bleeder

screw

0
7
to
0
9

kg
m

5
1
to
6
5
ft
Ihl
Clutch

o

cylinder
to
clutch

housing
securing
bolts

3
1
to
4
1

kg
m

22
to
30
ft
lbl

Clutch
hose
to

operating

cyli
nder

1
7
to
2
0

kg
m

12
to
14
ft

lbl

Flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
Ibl

CLUTCH
LINE

INSPECTION

Check
clutch
lines
tube

and
hose

for
evidence
of
cracks
deterioration
or

other

damage

Replace
if

necessary

If

leakage
occurs
at
or

around

joints
retighten
and
if

necessary
re

place
damaged

parts

REMOVAL

CAUTION

When

disconnecting
clutch
tube

use

suitable
flare

nut
wrench

Never

use
an

open
end
wrench
or

adjustable
wrench

1

Qisconnect
clutch
tube
from

clutch

hose
at
bracket
on
side
mem

ber

2
emove
lock

spring
then
disen

gage
hose
from
bracket

3

Remove
clutch
hose
from

oper

ating
cylinder

4

Disconnect
clutch
tube
from
mas

ter

cylinder

5

Remove

clamp
fIxing
clutch
tube

to
dash

panel
and
side

member

CL
6
INSTALLAnOlll

Wipe
the

opening
ends
of

hydraulic

line

to
remove

any
foreign
matter

before

malting
connections

I
Connect
clutch
tuhe
to

master

cylinder
with
flare
nut

2
Fix
clutch
tube
to
dash

panel

and
side

member
with

clamp

3
Then

tighten
flare

nut

@

Tightening
torque

Flar
nut

1
5
to
1
8

kg
m

11
to

13
ft

Ibl

2
InstaU
clutch
hose
on

operating

cylinder
with
a

gasket
in

place

Note

Use
new

gaslcet

@
Tightening
torque

1
7
to
2
0

kg
m

12
to
14ft
lbl

3

Engage
opposite
end
of

hose
with

bracket
InstaU
lock

spring
fIxing
hose

to
bracket

Note

a
When

tightening
flare

nut
hold

pipe
by
hand
to

prevent
it
from

twisting

b
Exercise
care
not
to

warp
or
twist

clu1ch
hose

4

Connect
clutch
tube
to

hose
with

flare
nut
and

tighten
it

5
Check
distance

between
clutch

line
and

adjacent
parts

especially
be

tween
hose
and
exhaust
tube

6

Bleed
air
out
of

hydraulic
system

Refer
to

Bleeding
Clutch

System

for

bleeding

CAUTION

When

tightening
flare

nut
use

Flare

Nut
Wrench

G
G9431
0000

Clutch

SERVICE
DATA
AND

SPECIFICATIONS

ENERALSPECIFICATIONS

Clutch
control

system

Type
of
clutch
control

Clutch
master

cylinder

Diameter

Clutch

operating
cylinder

Type

Diameter

Clutch
disc

Type

Facing
size

Outer
dia

x
Inner
dia

x
Thickness

Thicmess
of
disc

assembly

Free

Installed

Number
of
torsion

springs

Clutch
cover

Type

FuU
load
Hydraulic

mill
in
15
88

mm
in
Adjustable

1746

180CBL

mrn
in
180
x
125
x
3
5

7
09
x
4

92
x
0
138

mm
in

mm
in
8
5
to
9
2
0
335
to
0
362

7

6
to
8
0
0
299
to
0
315

6

kg

Ob
CI80S

335
to
385
739
to
849

INSPECTION
AND
ADJUSTMENT

Clutch

pedal

Pedal

height
H

Pedal
free

play
A

Withdiawallever

play
B

Pedalfree
travel
C

Clutch
master

cylinder

Maximum
clearance
between

cylinder
bore
and

piston

Clutch

operating
cylinder

Maximum
clearance
belween

cylinder
bore
and

piston

Clutch
disc

Wear
liinit
of

facing

Depth
of
rivet

head
below

facing
surface

Runoullimit

Distance
of

runout

checking
point

from
the
hub

center

Maximum
backlash

of

spline

at
outer

edge
of

disc
mm
in

mm
in

mm
in

mm
in
143
to
149
5

63
to

5
87

1

to
5

0
04
to
0

20

1

0
to
2

0
0
039
to
0
079

16
to
33
0
63
to
1
30

mm
in

Less
than
0
15
0
0059

mm
in

Less
than
0
15
0
0059

mm
in

mm
in
0

3
0
012

0
5
0
020

mm
in
85

3
35

mm
in

0
4
0
016

CLIO