brake DATSUN 210 1979 Manual PDF

1
Control
lever

2

Front
cable

3
Rear

cable

adjuster

4

Rear
cable

S

Strap

6

Oevis

1

Return

spring

REMOVAL

Removal
of
control
lever
and

front
ceble

Disconnect

terminal
from

hand
Brake
System

HAND
BRAKE

BA120A

Fig
BR
34
Hand

Broke

3
Remove
lock

plate
Disconnect

cable

adjuster

brake

warning
switch

2
Remove

bolts

securing
hand

brake
lever
to
floor

@
BR005A

Fig
BR

36

Removi1l
1
Front
Cable

1
Hand
brake

warning
switch

2

Terminal

3
Bolt

4
Pin
4

Pull
front
cable
out
into
driver

s

compartment
and

remove
it

together

with
control

assembly

5

If

necessary

separate
front
cable

from
hand
brake
lever

by

breaking
pin

and

replace
front
cable

B
R036A
CAUTION

Be
careful

not
to
deform
or

damage

control
lever

Fig
BR
35

Hand
Brake
Lever

BR
14

Note
Front

cable
clevis

pin
and

cotter

pin
are
available
as

service

parts

Removal
of
eer
ceble

I
Disconnect
cable

adjuster
CD

from
front
cable

2
Remove

lock

plate
@
and

strap
00
at
axle
case

1

I
Rear
cable

adjuster

2
Lock

plate

3

Strap
BR037A

Fig
BR
37
Removing
Rear
Cable
Brake

System

3

Pull
off
return

spring
CD
and

disconnect
rear

cable
from

lever

by

removing
clevis

pin
@

@

I
Return

spring

2

Clevis

pin

6R122A

Fig
BR
38

Removing
Rear
Cable

BR
15
INSPECTION

I
Check
control
stem
and

lever
for

wear
or
other

damage
Replace
if

necessary

2

Replace
worn
or

fatigued

sprin

3
Check
wires
for

discontinuity
or

deterioration

Replace
ifheces

ary

4

Replace
malfunctioning
warning

light
or
switch

5

Check

parts
at
each

connection

and
if

found
defonned
or

damaged

replace

INSTALLATION

Install
hand
brake

assembly
in
the

reverse

procedure
of
removal

Brake

System

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

SERVICE
BRAKE

Type

Front

Rear

Pad
or

lining
dimension

Width
x
thickness
x

length

Front

Rear
Disc
AN20

Drum

LT20
Auto

rnm
in

Pad

41
2
x

10
0
x
61
4

1
622
x
0394
x
2
417

Lining

35
0
x
4
8

x
195

0

1
378
x
0
189
x
7

68
mm
in

Rotor
outer
diameter
or

drum
inner
diameter

Front

Rear

Wheel

cylinder
inner
diameter

Front

Rear

Master

cylinder
inner
diameter

Brake

booster

Type

Diaphragm
diameter

NP
valve

split
point
x

reducing
ratio

Type
of

adjusting
shoes
rnm
in

rnm
in
245
0
9
65

203
2
8
00

rnm
in

mm
in

rnm
in
51
1
2
012

20
64
13

16

20
64

13
16

mm
in

kg
cm
2

psi
M60

152
4
6

20
x

0
4
284
x

0
4

BR
16

Brake

System

INSPECTION

AND
ADJ
USTMENT

BRAKE
PEDAL

Free

height
h
mm
in
143
to

149

5

63
to
5

87

Free

play
at

pedal
pad
a
mm
in
I
to
5

0
04
to

0
20

Full
stroke

at

pedal
pad
s

With
brake
booster
mm
in
140
5
51

Depressed
height
d

mm
in

more
than

70
2
76

HAND
BRAKE

Pulling
force

Stroke
kg
lb

mm
in

Number

of
notches

MASTER

CYLINDER

Allowable
clearance
between

cylinder
and

piston

mm
in

BRAKE

BOOSTER

Maximum
vacuum

leakage
15

seconds
after

engine
is

stopped

mmHg
inHg

mm
in

mm
in
Push
rod

length
A

Operating
rod

length
8

I

c

tY

1I1

fF

I

BA290
d

IF

CHECK

VALVE

Maximum
vacuum

leakage
15

seconds
after
500

mmHg

19
69

inHg
pressure
is

applied
mmHg
inHg

BR

17
h

d
1

II

II

d
h

Free

play

V
Free

height

Depressed
height
aR002A

Full
stroke

20
44

93

to
106

3
66

to
4
17

7

to
8

less
than
0
15
0

0059

25

0
98

975
to
10
00
0
3839
to

0
3937

135
5
31

1

B

BR947

10

0
39

FRONT

DISC
BRAKE

Pad

wear
limit

Minim
urn
thickness

Rotor

repair
limit

Runout

Parallelism

Thickness

DRUM
BRAKE

Lining
wear
limit

Minimum
thickness

Drum

repair
limit

Maximum
inner

diameter

Initial

stage
203
2

nun
8
in

Out
of
roundness

Radial
cunout

Taper

Wheel

cylinder

repair
limit

Piston
to
cylinder
clearance

TIGHTENING

TORQUE

Master

cylinder
to
brake
booster

Brake
booster
to

body

Brake

tube
flare
nut

Brake

hose
connector

Air
bleeder
valve

3

way
connector

mounting
bolt

Brake

warning
lamp
switch
lock
nut

Caliper
fixing
bolt

Rotor

fixing
bolt

Rear
brake
wheel

cylinder

mounting

bolts

Front
brake
baffle

plate
fixing
bolts

Rear
brake
disc

fixing
bolts

BRAKE
BOOSTER

Brake
booster
to

body

Operating
rod

lock
nut

Flange
io

shell
cover

Push
rod

adjusting
nut
nun
in

nun
in

nun
in

mm
in

nun
in

nun
in

mm
in

nun
in

mm
in

nun
in

kg
m

ft
lb

kg
m
ft
lb

kg
m
ft
Ib

kg
m

ft
lb

kg
m

ft
Ib

kg
m
ft
lb

kg
m
ft

Ib

kg
m
ft
lb

kg
m
ft

Ib

kg
m
ft

lb

kg
m

ft
Ib

kg
m
ft
Ib

kg
m
ft

lb

kg
m
ft
lb

kg
m

ft
lb

kg
m
ft
lb
Brake

System

BR

1B
1
6
0

063

less

than
0
12

0
0047

less
than

0
03
0
0012

more
than
8
4

0
331

1
5

0
059

204
5
8

05

less
than
0
02
0
0008

less
than
0
1
0
004

less
than

0
02
0
0008

less
than
0
15
0
0059

0
8

to
1
1
5
8
to
8

0

0
8

to
1
1
5
8
to
8
0

1
5

to
1
8
II

to
13

1
7
to

2
0

12
to
14

0
7

to
0
9
5
1

to
6
5

0

8
to

1
1
5
8
to
8
0

l
2
to
1
5
9

to
II

7
3

to
9

9
53
to
72

3
9

to
5
3

28
to

38

0
6

to
0
8
4
3
to
5
8

0
34

to
0
44
2
5

to
3
2

2
2
to
2
7

16
to

20

0
8
to

1
1
5
8
to
8

0

1
6
to
2
2

12
to

16

0
8

to
1
1
5
8
to
8

0

1
6
to
2
2
12

to
16

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

Condition

Unbalanced
brakes

Brakes
fade

Brakes

drag
Brake

System

Probable

cause

Improper
tire
inflation

Improp
r

adjustment
of
shoe
to
drum
clear

ance

Grease
oil
mud
or
water
on

linings
or

pads

Mud
in
brake
drum

Deterioration

oflinings
or

pads

Excessi
wear
of

linings
or

pads

Wheel

cylinder
in

poor
condition

Poor

sliding
condition
of
brake
shoe

Looseness
of

cylinder
body
or

back

plate

securing
bolts

Scored
or

out
f
round

drums

Sticking
wheel
cylinder

cups

Deformation
of
back

plate

Incorrect

adjustment
of
wheel

bearings

Incorrect

adjustment
of
wheel

aligoment

Looseness
of
leaf

spring
securing
U
bolts

Brake
fluid

has
too

low

boiling
point

Use
of

improper

linings
or

brake

linings
are

contaminated

Brake
drums
are

out
f

round

Hydraulic
connections
master

cylinder
and

wheel

cylinders
are
corroded
or

damaged

Bleed
screw
is

open

Pedal

linkage
is

binding
or

push
rod

adjust

ment
is
too

long

Master

cylinder

compensator
part
is

ob

structed

Seized
master

cylinder

piston

Poor
shoe
condition

Poor
wheel

cylinder
condition

Deformation
of

piston

cups

Poor
condition
of

caliper
because
of

faulty

piston
seals

Excessive
runaut
of
rotor

Hand
brake

will
not
return

Clogged
m

ter

cylinder
return

port

BR
20
Corrective
action

Inflate

to
correct

pressure

Readjust

Clean
brake
mechanism
and

check
for

cause

of

problem
Replace

linings
or

pads

Clean

Replace

Replace

Repair
or

replace

Adjust

F
ten
or

replace

Recondition
or

replace
brake
drum
as
re

quired
Check
for

improper

lining
contact

with

dflllll
and

grind
lining
if

necessary

Recondition
or

replace
cylinder

Replace

Adjust
or

replace

Adjust

Tighten
or

replace

Drain
and
fill

system
with

appr
d
fluid

Replace
linings

Repair
or

replace
as

necessary

Repair
as

necessary

Close
screw

and
bleed

system

Lubricate

linkage
check

pedal
return

spring

for
condition
and

adjust
push
rod
as
neces

sary

Blowout

foreign
matter
with

compresSed

air

Disassemble

master

cylinder
and

replace

piston
Bleed

system

Clean
and

repair

Repair
or

replace

Replace

Replace
piston
seals

Turn
rotor
on
lathe
or

replace

Check
and

repair

Clean

Condition

Brakes

drag

Brake
chatters

Brake

squeals

Pedal

pulsates

Rear

lock

under

light
brake

pedal
force

Rear

lock

under

heavy
brake

pedal
force
Brake

System

Probable
cause

Clogged
brake
lines

Incorrect

adjustment
of
wheel

bearings

Improper
shoe
to
drum
clearance

Weak
shoe
return

springs

No

free
travel
in

brake
shoe
return

Groove

or
out
of
round
brake
drum

or
rotor

Loose

or
bent

support
plate

Distorted

brake

shoes
or

pads

Grease
or

brake
fluid
on

linings

Dirty
or
scored

brake
drums

Distorted
brake
shoes

or
bent

support
plate

Weak
or
broken
brake
shoe

retaining
spring

or
return

spring

Glazed
or

contaminated
brake

lining

Out
of
round
or
off
center
drum

On

disc
brakes
lateral
runout
of
brake

rotor

is

excessive

Excessive
variation
in

thickness
of
brake

rotor
surfaces

Improper
tire

pressures

Excessive

wear
of

tires

Faulty
NP
valve

Improper
tire

pressures

Excessive
wear
of
tires

Poor

front

braking
effect

Grease
oil
mud

or
water
on

linings

or

pads

Excessive
wear

of

linings
or

pads

Local
fit
of

linings
or

pads

Master

cylinder
or

wheel

cylinder
in

poor

condition

BR
2t
Corrective
action

Check
and
clean

Adjust
or
repair

Adjust

Replace

Adjust

pedal
height

Grind
or
replace
as

required

Tighten
support
plate
bolts
to

specified

torque
or

replace

plate

Replace
as

necessary

Replace
linings

Blowout

assembly
with

compressed
air

or

refinish
drum

Replace
faulty
unit

Replace
if

faulty

Cam

ground
lining
to
elilninate

glaze
If
it

doesn
t

replace
linings

Turn
drum
or

replace
as

necessary

Check
with
dial
indicator

turning
disc

by

hand
If
runout
exceeds

specifications
re

place
disc

Measure
around
disc
face
with
micrometer

Replace
disc
as

required

Check
and

adjust

Check
and

replace

Replace

Check
and

adjust

Check
and

replace

Clean
or

replace

Replace

Shave
or

replace

Repair
or

replace

t

MAINTEN
NCE

TIRE
INFLATION

Correct
tire

pressure
is

very
impor

tant
for

steering
ease
and

riding
com

fort
Correct

pressure
also
makes
for

a

quieter
ride

and
extends
tire
life

If

all
tires

are

inspected
frequently

and
maintained

at
correct

pressure

any

sharp
objects
in
tread
can
be

quickiy
detected
nd
abnormal

wear

which
invites
serious

problems
can
be

avoided

After

inflating
tires
valves

should

be
checked
for

leakage
Without

valve

caps
leakage
will
occur

due
to
dirt
and

water

resulting
in

underinflation
Ac

cordingly
whenever
tire

pressure
is

checked
be
sure
to

tighten
vaive

caps

firmly
by
hand

JW

Sri

in

1
II

I

i

I
1
I
1

1
I

I

I
II

I
I
I

i

M
I

l
1

14
nl

01
I

II

Toe

in
or

toe
out
wear

I
J

I

I
p

rt
i

Ilnl
lll

11111
IllIlI

Shoulder
wear

Toe
in
or
toe
out

wear

When
the
front

wheels
are
aligned

in

an
excessive

toe
in
or

toe
out
condi

tion

the
tires

will
tend
to

scrape
the

tread
rubber
off
and
the
tread
will

de

elop
a

feathered

edge

Center
wear

Center
wear
is
caused

by
overinfla

tion
of
the
tire
Wheel
and

Tire

WHEEL
AND

TIRE

TIRE
WEAR

Tread
ar
Indicator

Tires
are

provided
with

tr
lad
wear

indicator
at

six

places
around
tire

circumference

indicating
1
6

mm

J

in
tread

depth
When
tires
wear
and

then

marks

appear
replace
them

wtth

new
ones

Tread
wear
indicator

Tire
tread

L
1
c

WH024

Fig
WT
l
Tread
WearJndicator

n

1

ii

J
J

f
J

I

h
I

me

1111

Center
wear

j

I

1II
mnr

I

j
n

Ii

Ii

i

I
Jil

111

lie

Uneven
wear
WT004

Fig
WT

2
A
bnormal
Tire
Wtor

Shoulder
wear

This
wear

may
be
caused

by
under

inflation
incorrect
wheel
camber
or

continued
excessive

speed
around

curves
In

general
the
first
two
causes

are
the

most
common
Underinflation

causes
wear
on
both
sides
of
treads

while

camber
causes
wear
on

only
one

side
of
tread

WT
2
Uneven
wear

Uneven
wear
is

caused

by
incorrect

camber
or
caster

malfunctioning
sus

pension
unbalanced
wheel
out
of

round
brake
drum
or
other
mechani

cal
conditions
To

stop
this
abnormal

wear
correct
the
above

faulty
parts

TIRE
REPLACEMENT

CAUTION

Different

types
of
tires
sucb
as
bias

bias
belted
and
radial

tireS
must

not

be
mixed

except
in
an

emergancy

Mixed

use
of
different

types
of
tires

can

adversely
affect
car

ilndlilig
and

may
cause
driver
to
lose
control

Note

a
Be

sure
to
check
the
wheel

nut

torque
after
the
wheel
has
been

run
for

the
rust
I
000
km
600

miles
also
in

cases
of

repairing
fiat

tires
tire
rotation
etc

and
every

10
000
km

6
000
miles
thereafter

Retighten
if

necessary

b
It
is

recommended
that
new
tires
be

installed
in

pairs
on
the
same
axle

When

replacing
only
one
tire
it

should
be

paired
with
the
most

tread
to

equalize
braking
tl1lction

c

When

replacing
original
tires
with

those
tires
of
an

optional
recom

mended
site
and
of

diff
rent
diam

eter
the

speedometer
must
be
reo

calibrated

I

To

replace
a
tire

with
a

jack
in
a

safe
manner
refer
to

Lifting
Points

and

Towing
Section
GI
for

jacking

up

WARNING

Never

get
under

car
whila

it
is

supported

only
by
jack

Always
use

Il
fety
stands
to

suppon

side
member
of

body
construction

when

you
must

get
berreatb
car

Condition

Wheel
wobbles

Unevenly
or
exces

sively
worn
tire

Tire

squeals
Wheel
and
Tire

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Probable
cause

Improper
tire

pressure

Damaged
tire
or
distorted
wheel

rim

Unbalanced
wheel

Loose

wheel
nuts

Worn
or

damaged
wheel

bearing
or
excessive

play
in
wheel

bearing

Improper
front
wheel

alignment

Worn

or

damaged
ball

joint

Excessive

steering
linkage
play
or
worn

steering
linkage

Loose

steering
linkage
connection

Broken

suspension
spring

Faulty
shock
absorber

Improper
tire
rotation

Improper
tire

pressure

Unbalanced
wheel

Improperly
adjusted
brake

Improper
wheel

alignment

Excessively
distorted
or

improperly
installed

suspension
link

High
speed
on
curves

Sudden
starts
and

improper
speed
due
to

rapid
acceleration
or

improper
brake

ap

plication

Improper
tire

pressure

Improper
front

wheel

alignment

Distorted
knuckle
or

suspension
link

WT7
Corrective
action

Measure
and

adjust

Repair
or

replace

Balance

Tighten

Correct

play
or

replace
wheel

bearing

Align

Replace

Adjust
or
replace

Tighten
nuts
to
rated

torque
or
replace

worn

parts
if

any

Replace

Replace

Rotate
tires

periodically

Measure
and

adjust

Balance
or

replace

Adjust

Align

Repair

replace
or
if

necessary
reinstall

Reduce

speed

Drive
in

a

proper
manner

Measure
and

adjust

Align

Repair
or
replace