oil DATSUN 210 1979 Service Manual

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

If

leakage
oCcurs

at
end
around

joints
re

tighten
Of

if

necessary
re

place
faulty

parts

INSTALLATION

Pay
particular
attention
to
follow

ing
instructions
when

installing
brake

lines

I
Leave
a
sulfident

space
between

brake
lines
and

adjacent
parts
so
that

brake
lines
are

completely
free
from

vibration

during
driving

2
Be
careful
not
to

warp
or
twist

brake

lines

3
When

installing
brake
tube

keep

a
certain

distance
between
tube
and

adjacent

parts
as

follows

Tube
to

rotating
parts

30

mm
1
18
in

Tube
to

moving
parts

10
mm
10
39
in

Tube
to
other

palls

5

mm
10
20
in

4

Always
fasten
brake
tubes
with

mounting

clips
where

necessary

On
rear
axle

case
are
two

double

dips
which

should
be
used
to

secure

brake
tubes

in

manner
described
be

low

Bend
short

clip
straight
up
With

brake
tube

on

long
clip
bend

clip

up

and
around
tube

Finally

wrap
short

clip
around
tube
to

secure
the
in

slallation

f
J

i

2

BA141

Fig
BR
7

Fastening
Brake
Tube

Securely
with
Double

Clip

5

Do

not

tighten
brake
line
mount

ing
flare
nut

excessively

CAUTION

When

installing

Fla
e
Nut

6694310000
brake
tubes

use

Torque
Wrench
Brake

System

t
D
Tightening

torque

Brake
tube
flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
lb

Brake
hose
connector

1
7
to
2
0

kg
m

112
to

14
ft
lb

J

way
connector
bolt

0
8
to

1
1

kltm

5
8
to
8
0
ft

Ib
NP

VALVE

Front
wheel

cylinder

Front
wheel

cylinder
Master

cylinder

front
jde

6

Upon
completion
of

installation

of

brake
lines

bleed
air
out
of

brake

lines
Rear
wheel

cylinder

BR114A
Master

cylinder

rear
side

Fig
BR
B
NP
Valve

FRONT

DISC
BRAKE

9
ilJ

I

Bias
s

pring

2
Yoke

3
Bleeder

4

Piston
seal

5
Piston
B
11
Piston
A

12

Cylinder
body

13
Pad

spring

14
Pad

15
Pin
6
Boot

7

Retaining
ring

8
Clip

9
Yoke

spring

10
Bias

ring

BR123A

Fig
BR
9
Di
c
Broke

PAD
REPLACEMENT
Note
Check
to
ensure
that

pad

springs
rebound

easily

3
Detach

pads
from

caliper
assem

bly
with

pliers
Removal

I
Jack

up
front
of
car
and

support

it
on

safety
stands
Remove
wheel

2
Remove

clips
and

pull
out

pins

extracting
coil

spring
and

pad
springs

by
hand
CAUTION

After

removing
pads
do
not

depress

brake

pedal
or

piston
will

jump
out

BR

INSTALLATION
INSTRUCTIONS

Typical
Glrllng
B
ake
Pad

SYIlem

Girling
disc
brakes
are

very
similar
to
ATE
disc
brakes

except
that
the

piston
seal
does

not

pul
the

piston
and
brake
pads

away
from
the
rotor
In
the

Girling
System
with

the

pistons
i

the

relaxeilposition
the

pad
just
touches
the

rotor

Ped
Removal

1
Raise
the
car

alid
removiHire
and
wheel

2

Girling
disc
brake

pads
ere
held
in

piece
either

by
a
retainer

plates
or
b
retainer

pins
Retainer

plates
are
boiled
to

the
caliper
housing
and

need

only
to

be
loosened

and

roteted
out
of
the

way
Some
models
use
anti
raWe

springs
which
must

be

replaced
whenever
new

pads
ere
installed
The
retainer

pins
are

held
in

place
by

hairpin
type
spring
clips
There
are
two

types
of
breke

pads
used
with
the
retainer

pins
One
is

cut

away
for
the

pin
end
the
other
is
drilled
These

padS
ere

definitely

not

interchengeable

3
Remove
the
reteiner

4

Lift

padS
up
and
out
of
the

celiper

Pad

Installation

1
Attach

a

piece
of
hose
to
the
bleeder
screw
and

place
the

hose
into
a
container

2

Open
bleeder
screw
one
turn
and
with
even

pressure
push
the

pistons
down

to
the

bottom
of
the

caliper
bores

3
Tighten
the
bleeder
screw
and
remove
the

piece
o
hose
This

procedure
makes

room
for
the

added
thickness
of
the

new

linings

4

Reposition
the

pad
retainer
and
the
anti
rattle

spring
i

used
and

tighten
the
bolts

or

replace
the

retaining
pins
and
screw
them
with
the

hairpin
Iips

5
Check
to
be
sure

you
have

a

high
hard

pedal
then
test
the
car

See
Instructions
On
Back
of
Ball
For
Correct

Usage
of
EMP

Gh11ng
dlac
brall

Ilmple
to
art
lc

Depending
III

ppU

aUon
atalnln

pilla
nd

clip

may
blt

placed
by
larga
QU

pin

Form
No
91

BR563

Fig
BR
10

Removing
Pad

Inspection

Clean

pads
with

cleaning
solvent

CAUTION

Use
brake
fluid
to
clean
Never
use

mineral
oil

2
When

pads
are

heavily
fouled

with
oil
or

grease
or
when

pad
is

deteriorated

or
deformed

replace
it

3
If

pad
is
worn
to
less
than
the

specified
value

replace

Pad
wear

limit

Minimum
thickness

t
6

mm
0
063
in

Note

Always
replace
pads
in

pad
kit

four

pads
two

clips
four

pad
pins

and
four

pad
springs

4
Check
rotor

referring
to
Rotor

for

inspection

Installetlon

I
Clean

and

apply
P
RC

grease
on

yoke
guide
groove
of

cylinder

body

sliding
contact

portions
of

yoke
and

end
surface
of

piston

Note

a
Do
not

use
common
brake

grease

b

Be
careful
not
to

get
brake

grease

on
rotor
and

pads

2
Loosen
air
bleeder

and

push
pis

ton
B

outer

piston
in

cylinder
until

end
surface
of

piston
B

coincides
with

end
surface
of

retaining
ring
on
boot

Then

inner

pad
can
be

installed
Brake

System

BR564

Fig
BR
11

Pushing
Piston

CAUTION

Piston
can
be

easily
pushed
in

by

hand
but
if

pushed
too
far

groove
of

piston
will

go
inside
of

piston
seal
as

shown
in

Fig
BR
12

At
this

point
if

piston
is

pressured
or
moved

piston

seal
will
be

damaged
If

piston
has

been

pushed
in
too
far

remove
brake

assembly
and
disassemble
it
Then

push

piston
out
in
the

direction
shown

by
arrow

Assemble
it

again
referring
to
follow

ing
section

00

I
Normal

I

position

L

BR409

Fig
BR
12
Position

for
Pushing
Piston

3
Push

piston
A
inner

piston
in

cylinder
by

pulling
yoke
as
shown

The

outer

pad
can
then

be
installed

BRS6S

Fig
BR
13

Pulling
in
Piston
A

BR
7
4

After
installing

pads
depress

brake

pedal
several
times
and

pads

will
settle
into

proper
position

Note

When
worn
out

pads
are
re

placed
with
new
ones
brake
fluid

may
overflow
reservoir
While
re

placing
pads
keep

loosening
bleeder

to
release
brake
fluid

5
Install

wheels
and
lower
car
to

ground

REMOVAL

I
Remove

pads
Refer
to
Pad
Re

placement

2

Remove
brake

tube
from

caliper

assembly

CAUTION

When

removing
brake
tube
use
suit

able
tube

wrench
Never
use

open
end

or

adjustable
wrench

Note

Plug
up
hole
in

caliper
so
that

brake
fluid
does

not
flow
out
from

cylinder
body

3
Loosen
bolts

securing
cylinder

body
to
knuckle

spindle
and

remove

caliper
assembly
from
strut

DISASSEMBLY

I
Drain
brake
fluid
from

top
hole

of

cylinder
body

2
Push
both

pistons
A
and
B
into

cylinder
Refer
to

Pad

Replacement

3

Tap
cylinder
body
lightly
with

a

plastic
hammer
Cylinder
will

then

separate
from

yoke

BR115A

Fig
BR
14

Tapping
Cylinder
Block

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

REAR
BRAKE

1
Brake
disc

2
Wheel

cylinder
assembly

3
Brake
shoe
assembly

4
Return

spring

5

Adjuster
assembly

6

Stopper

1

Stopper
pin

8

Anti
rattle

pin

9
Spring
se
t

10
Anti
rattle

spring

11
Retainer

REMOVAL

L
Jack

up
rear
of

car
and

support
it

with

safety
stands

2

Remove
wheel
and

brake
drum

I

Engage
hand
brake
lever

2
Pull

pin
out
and
remove

stopper

from

toggle
lever

3

Disengage
hand
brake
lever

If
brake
drum

cannot
be

easily

removed
install
two

baIts
8
mm

diameter
I
25
mm

pitch
to
drive
it

out

3
Disconnect
brake

tube
flare
nut

Install
a
brake

line

plug
in

open
end
of

brake
tube

CAUTION

When

removing
brake
tube
use

suitable
tube
wrench
Never
use

open
end
or

adjustable
wrench

4
Remove
hand
brake
return

spring

and

pull
out

clevis

pin
to

separate

hand

brake
cable
and
lever

5
Remove
anti

rattle

spring
and

pin

6
Remove
return

spring
and
brake

shoes
Brake

System

Dueetio
of
ro

tiO

Front
of
car

7
Remove
dust

cover
and

toggle

lever
with

adjuster
assembly

8
Remove

wheel

cylinder

DISASSEMBLY
AND

ASSEMBLY

Wheel

cylinder

BR909
I
Dust
cover

2
Piston

3
Piston

cup

4

Wheel

cylinder
body

5

Spring

6
Bleeder

1
Bleeder

cap

Fig
BR
23
Wheel

Cylinder

Remove

dust
cover
and

parts
will

BR
l0
Tightening

torque
kg
m

ft
lb

@
0
6
to
0
8
4

3
ro
5
8

@
2
2
to
2
7

16
to
20

BR116A

Fig
BR
22
Rear
Broke

be
disassembled

Thoroughly
wash
all

parts
Assem

ble
wheel

cylinder
in

reverse
order

of

disassembly

CAUTION

Use
brake
fluid
to
clean
Never
use

mineral
oil

Note

a

Apply
a

coating
of

brake
fluid

to

piston
cliP
at

assembly

b

Charge
with

genuine
Nissan
disc

brake

grease
KR60900010

or

equivalent
before

installing
dust

cover

c
The
brake
wheel

cylinder
is
avail

able
in

both
NABCO
make
and

TOKlCO
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
wheel

cylinder

body
Be
sure
to
use

parts
of

the

same
make

as
the
fonner
ones

INSPECTION

Brake
drum

I
Check
inner
diameter
of
brake

drum
to
make
sure

it
is

properly
round

and

tapered
If

it
is
not

repair
or

replace
brake

drum

Inner
diameter

Standard
diametel

203
2
mm
8

in

Maximum
diameter

204
5

mm
8
05
in

Out
of
loundness

ellipticity

less
than

0
02
mm
0
0008
in

Radial
runout

less
than
0
1
mm
0

004
in

Total
indicator

reading

Taper

less
than

0
02
mm
0
0008
in

Measured

at
a

point
40

mm

1
57
in
flam
inlet

2

Contact
surface
with

which
lin

ings
come
into

contact

should
be

fine
finished
with

No
120

to
150

sandpaper

3

Using
a
drum
racer
finish
brake

drum

by

machining
if
it
shows

any

sign
of

score
marks

partial
wear

or

stepped
wear
on
its

contact
surface

Note

After
brake
drum
has

been

completely
re
conditioned

or
re

placed
check
drum
and
shoes
for

proper
contact

pattern

Brake
e

embly

1

Replace
any
linings
which
are

cracked
worn

or
oil
stained

2
If

lining
is
worn

to
less
than
the

specified
value

replace

Lining
wear
limit

Minimum

thickness

1
5

mm
0
059

in

3

Replace
any
shoe
return

springs

which
are

broken
or

fatigued

4

Replace

fatigued
anti

rattle

spring

damaged
pin
and
or
retainer

Wheel

cylinder

I

Replace
any
cylinder
or

piston

which
is

scratched

scored
or

worn
on

its

sliding
contact
surface
Brake

System

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
limit

Piston
ta

cylinder
clearance

less
than
0
15
mm
0

0059
in

3

Replace
any
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

5

Replace
any
damaged
dust
cover

fatigued
piston
spring
or

faulty
thread

ed

parts

6

Replace
any
tube
connector

which
is

worn
on
its

threaded

portion

INSTALLATION

Install
rear
brake
in
reverse
order

of

removal

closely

observing
the
follow

ing

1

Tighten
following

parts
to

speci

fied

torque

CAUTION

When

installing
brake
tube

use
Flare

Nut

Torque
Wrench

6694310000

ifl

Tightening
torque

Flared
nut

1
5
to
1
8

kg
m

11
to
13
fHb

Ail
bleedel

0
7
to
0
9

kg
m

15
1
to
6
5
ft
Ib

Wheel

cylinder

mounting
bolt

0

6
to

0
8

kg
m

4
3

to
5
8
ft
b

2
There
are

two

types
of

adjusters

which
have

right
thread
or
left
thread

R
H
brake

Right
thread

adjuster

L
H

brake

Left
thread

adjuster

3

Sparingly

apply
a
coat
of
brake

grease
to
the

following
points

Lubricating
points

e

Adjuster
nut
and
rod
threads

Mating
surfaces

between

adjuster

and

toggle
lever
and

pin
and

roller

BR

ll
0

J

o

BR
117
A

Fig
BR
24

Lubricating
Points

of

Adju
ter

4

Referring
to

Fig
BR

25
for

locations
of

lubricating
points
apply
a

coat
of
brake

grease
to
these

points

Exercise

care
not
to
allow

grease
to

come
into

contact
with

lining
or
ad

juster
screws

Lubricating

points

e

Contact
areas

between
wheel

cyl

inder
anchor
block
and
brake
shoe

e

Mating
surfaces
between
brake
shoe

and

brake
disc

Contact
areas

between
hand
brake

adjuster
and
brake

shoe

Contact
areas
between
brake

disc

brake

shoe
and

toggle
lever

Contact
areas
between

anti
rattle

pin

spring
retainer
and

brake
shoe

Fig
BR
25

Lubricating
Points

5

To

prevent
water
from

entering

brake
drum

apply
dry
sealant
to

brake

disc

mounting
surfaces
of
the

follow

ing

parts

Wheel

cylinder

Anti
rattle

spring

6
Make

sure
that

entire
brake

shoe

fits
in

place

7

Make
sure
that

adjuster
operates

properly

8
After
installation
is

completed

check
and

adjust
shoe

to
drum
clear

ance

by
operating
hand
brake
several

times

9

Bleed
brake

system

BRAKE

BOOSTE
R

INSPECTION
OF

OPERATION

Checking
vecuum

pressure

I

Connect
a

vacuum

gauge
in
the

tine
between
check
velve

and
brake

booster

1
Check
valVe

2

Vacuum
gauge

BA942

Fig
BR
26
Air

Tighte
Te
Set

Up

Probable
cause

Air

leakage
at

check
valve

2
Air

leakage
at

push
rod

seal

3
Air

leakage
between
valve

body
and

seal

4
Air

leakage
at
valve

plunger
seat

5

Damaged
piping
or

joints

Air

tight
test
Under
loed

Fifteen

seconds
after

engine
is

stopped
and

brake

fully

applied
ob

serve
the
rate

of

drop
in
air

pressure

registered
by
vacuum

gauge
If

vacuum

Probable
cause

Air

leakage
at
check
valve

2

Damaged
diaphragm

3
Reaction

disc

dropped
off

4

Air

leakage
at

poppet
assembly
seat

and
valve

body

Inspec
tinK
chec
k
valve

Remove

clip
and
disconnect
hoses
Brake

System

2
Start

engine
end
merease

engine

speed
Stop

engine
when

vacuum

gauge
indicates
500

mmHg
l9
69

inHg

Air

tiKht
test

No
load

Fifteen
seconds
after

engine
is

stopped
observe
the
rate

of

drop
in
air

pressure
registered
by
vacuum

gauge

If
vacuum

pressure
drop
below
the

specified
value
refer
to

the

following

chart
to
determine
the

cause
of

failure

Maximum
vacuum

leakage

25

mmHg
0
98

inHgl

Corrective
action

Replace
check
valve

Replace
brake
booster
as
an

assembly

Repair
or

replace

pressure
drops
below
the

specified

value
refer
to
the

following
chart

to
determine
the
cause
of
failure

Maximum

vacuum

leakage

25
mmHg
0
98

inHgl

Corrective
action

Replace
check
valve

Replace
brake
booster
as
an

assembly

at
connections
The
check
valve
can

now
be
removed

BR
12
JQeL

i
l
f

BR119A

Fis
BR
27
Location

of
Check
Valllt

2

Using
a
brake

booster
testel

apply
a
vacuum

pressure
of
500

mmHg

19
69

inHg
to
the

port
of
check

valve
on
the
brake
booster
side
If

vacuum

pressure
drops
below
the

specified
value
in
15

seconds

replace

check
valve
with
a
new
one

Maximum

vacuum

leakage

01
eheck
valn

10

mmHg
0
39

inHgl

3
When

pressure
is

applied
to
the

b

rake
booster
side
of
check
valve
and

valve
does
not

open
replace
check

valve
with
a

new
one

I

0

tLLiJ

Manifold
side
Brake
booster
side

1

Spring

2

Valve
BR963

Fig
BR
28

Check
Value

4
When

installing
check

valve
be

careful
to
avoid

incorrect
connectiolU

See

Fig
DR
28

Operetlns
test

1
Connect

an
oil

pressure
gauge
to

brake

ine
at
connection

on
master

cylinder

2
Install

a

pedal
force

gauge
on

brake

pedal

3
Start

engine
end

increase

engine

speed
until
a
vacuum

pressure
of

500

mmHg

19
69

inHg
is

registered
on

vacuum

pressure
gauge
With

a

steady

vacuum

pressure
of
500

mmHg
19
69

inHg
measure
oil

pressure
with
res

pect
to
each

pedal

operating
force

Relationship
between
oil

pressure

and

pedal
operating
force
is

illustrated

in

Fig
BR

29
If
test

results
are
not

as

specified
in

Fig
BR

29
check
brake

booster
for
condition
in
manner
des

cribed
under

Inspection
before
re

moval
of

this
unit

REMOVAL
M60

120
1
710

AA
I
1

1

110
1
560
1
v

e
100

1
420
I

90
1

280
I
1

1

80
1
140
I
Z

I
t

70
1

000
i

60
850

I

o
50
710
d

40
570

g
i

gl

j
ll
10

140

J
0

1
0

2
0

221
441

Rod

operating
force

kg
lb
Brake

System

Also

check
brake
line
for

evidence

of
fluid

leakage

Note

Detennine
whether
source
of

problem
is
in
brake
booster
or

check
valve
Before

you
reach

a

fmal
conclusion

always

inspect

check
valve
first

o
10
20

30
40
50

22
44

66
88
110

Pedal

operating
force

kg
lb

BA121A

Fig
BR
29

Performance

Diagram
of
Brake
Booster

Remo

parts
in

numerical
order

enumerated

BR593
ti

J

Fig
BR
30
Procedures

for
Removing

Brake
Booster

ADJUSTMENT

I

Adjust
the

length
of

push
rod
to

the

value
indicated
below

Length
ad
justment
of

push
rod
is

made
at
the

tip

of

push
rod

Length
A

9
75
to
10
00
mm

0
3839

to
0
3937
in

j
f

Irl

I

l
if

L
J

BA290

Fig
BR
31

Length
A

BR
13
BR288

Fig
BR
32

Adjusting
Push
Rod

Length

2

Install

clevis

Adjust
length
of

operating
rod
to

specified
value

length
B

135
mm
5
31
in

c
f

lIJ
t

t

B

BR947

Fig
BR
33

Length
B

INSTALLATION

Install

in
the

reverse

sequence
of

removaJ

IiJ
Tightening

torque

Master

cylinder
to
brake
booster

0
8
to

1
1

kg
m

5
8

to
8
0
ft
Ib

Brake
booster
to

body

0
8

to
1
1

kg
m

5
8

to
8

0
ft

lbl

Note

After
brake
boOster
is

properly

installed
in

car
conduct
an
air

tight

and

op
rational
tests
as

previously

described

Brake

System

TROUBLE

DIAGNOSES

AND
CORRECTIONS

Condition

Excessive

pedal
travel

Spongy
pedal

Poor

braking
effect
Probable
cause

Low
brake
fluid

level
or

empty
master

cyUnder
reservoir

Leakage
in

master

cylinder

Deteriorated

check
valve

Air
in

system

Faulty
brake

adjustment

Excessive
lateral

play
on
disc
caused

by

loose
or
worn
wheel

bearings
or

steering

parts

Low

fluid
level
in
master

cylinder

Air
in

system

Faulty
brake

adjustment

Reservoir
fIller

cap
vent
hole

clogged

Swollen
hose
due

to
deterioration

or
use
of

poor
quality
hose

Distored

brake
shoes
or

excessively
worn

or

cracked
brake
drum

Soft
or
swollen

caliper
seals

Use
of
a

brake
fluid

with
too
low

boiling

point

Fluid

leakage
in
brake
lines

Low

brake
fluid
level
or

empty
master

cylinder
reservoir

Air
in
brake

lines

Excessive
shoe

to
d
rum
clearance

Grease

oil
mud
or
water
on

linings
or

pads

Deterioration
of

linings
or

pads

Local
fit

of

linings
or

pads

Linings
or

pads
excessively
worn

Master

cylinder
or

wheel

cylinders
in

poor

condition

Frozen
or

seized

caliper
pistons
on
disc

brakes

Finding
mechanical

linkage
at
brake

pedal

and
shoes

BR
19
Corrective
action

Fill
and

bleed
as

necessary
Test

for
source

of

leakage

by
examining
all
lines

connec

tions
and
wheel

cylinder

Overhaul
master

cylinder

Replace
check

valve
and
bleed

system

Bleed

system

Adjust
shoe
to
drum
clearance

Inspect

auto

adjuster
operation

Replace
or

adjust

faulty
parts

Top
with
fluid
and

inspect
for

leakage

Correct
as

necessary

Adjust
shoe
to
drum
clearance

Inspect

auto

adjuster
operation

Clean
and
bleed

system

Replace
hose
and
bleed

system

Replace
faul

ty
parts

Drain

hydraulic

system
flush
with
alcohol

and

replace
all
seals

Replace
with

specified
brake
fluid
and

bleed

system

Check
master

cylinder
p
pmg
and

wheel

cylinder
for
leaks
and

repair

Fill
and
bleed

as

necessary

Bleed

system

Adjust

Clean
brake
mechanism
and
check
for

cause

of

problem
Replace

linings
or

pads

Replace

Shave
or

replace

Replace

Repair
or

replace

Disassemble

caliper
and
free

up
as

required

Free

up
as

required