air bleeding DATSUN 210 1979 Service Manual

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

FA070

FA071

Fig
FA

26
Air
Bleeding
from
Strul

9
Place
Strut

Steering
Gear

Housing
Attachment
KV48100300
in

jaws
of
a
vise

10

Before

proceeding
with
further

steps
pull
piston
rod
all

the

way
out

to
the
limit
of

its
stroke
install
bound

bumper
rubber
in

place
to

prevent

piston
rod

from
falling

by
its

own

weight

11

Compress
spring
with

Spring

Compressor
ST35651001

ST35651001

r
l

I

FA665

Fig
FA

27
Compressing
Spring

Note
To

prevent
interference
be

tween

upper
spring
seat
and

special

tool
leave

upper
2
5
to
3
turns
of

spring
coils
free

compress
spring

and
assemble
to
strut

12
Lubricate
dust
seal
indicated

by

arrow
in

Fig
FA
28

with
recommend

ed
multi

purpose
grease
Front
Axle
Front

Suspension

I

1

i
I
FA671

Fig
FA
28
Grea

ing
Point

13
Install
dust

cover

upper
spring

seat

dust
seal

mounting
bearing
and

insulator
in
this
written

order

Note

a
Be

careful
to
avoid

damaging
piston

rod

during
disassembly
and
assem

bly
Do

not
use

pliers
or
the
like
in

an
effort
to
extract

piston
rod

b
InstaU
thrust

bearing
so
that
it

points
in
correct

direction

Fig

FA

28

14

Tighten
new

piston
rod

self

locking
nut

fil
Tightening
torque

Pi
ton
rod
elf

Iocking
nut

6
0
to
7
5

kg
m

43
to
54

ft
lbl

Note

a

Temporarily
tighten
self

locking

nut
on

tip
of

piston
rod
After

installing
piston
rod
on
car

tighten

self

locking
nut
to

specification

b

Replace
self

locking
nut
whenever

strut

is
disassembled

15
To

prevent
entry
of

water
and

dust

apply
a
thick

coat
of

recom

mended

multi

purpose
grease
to

points

indicated

by
arrows
in

Fig
F
A

28

16
After

placing

spring
in

position

between

upper
and

lo
er

spring
seats

release

compressor
graduaUy

I
J

k

1
jt
r
end

FA074

Fig
FA
29

talling
Front

Spring

FA
9
17

Raise
bound

bumper
rubber

10

u

per
spring
seal

I

STALLATION

Install
strut
and

spring
assembly
in

reverse
order
of
removaL

fil

Tightening
torque

Strut

to

hoodledge

2
5
to
3
5

kg
m

18

to
25

ft
Ib

Steering
knuckle

arm
to
strut

7
3
to
9
9

kg
m

53

to
72
ft
lb

Note

a

Make
sure
brake
hose
is

secure
and

not
tw

ted

b
When

installing
steering
knuckle

ann
to
the
bottom

of
strut
as

sembly

epply
the
suitable

sealing

material
to
the
indicated

portion
so

as
to

prevent
ball
stud
from
rust

FA660

Fig
FA
30
Applying
Sealant

TENSION
ROD
AND

STABILIZER
BAR

REMOVAL

I

Jack

up
the
front
of
car
and

support
it
with

safety
stands
remove

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

L

@
fl
JJ

l

f
m

ff
v
1

II
2

I

I
II

B

s1

r
Dip
other
end

of
hose
into
brake

fluid
bled
in

a
container

3

Pepress
brake

pedal
two
or
three

times
and
then

keep
pedal
fully
de

pressed

4

With
brake

pedal
fully
depressed

open
bleeder
valve

to
exhaust
air

Note

a
Carefully
monitor
brake
fluid
level

at
master

cylinder
during
bleeding

operation

BRAKE
PEDAL

REMOVAL

I

Remove

snap
pin
installed
at
the

end

of
clevis

pin
Draw
out

clevis

pin

and

separate
push
rod
or

operating
rod

from
brake

pedal

2
Remove
bolt
and
E

ring
securing

fulcrum

pin
and
draw
out
fulcrum

pin

Then
brake

pedal
can
be
taken
out

along
with
return
coil

spring
Brake

System

b
Do
not
reuse

brake
fluid
drained

during
bleeding
operation

c
Bleed
air
in
the

following

sequence

Master

cylinder
Rear

wheel

front
wheel

d

Be
careful
not
to

splash
brake
fluid

on

painted
areas

5

Close
bleeder
valve

quickly
as

brake

pedal
is

on
down
stroke

6
Allow
brake

pedal
to
return
slow

ly
with
bleeder
screw
closed

SERVI
CE

BRAKE

fJ

Brake

lamp
switch

Lock

nut

Fulcrum

pin

Brake

push
rod
or

operating
rod

Snap

pin

Bolt

E

ring

Tightening
torque
kg
m
ft
Ib

@
1

6
to
2
2

12
10
16

@
1
2
to

l
S
9
to

II

BROS8A

Fig
BR
3
Broke
Pedal

INSPEctioN

Check
brake

pedal
for

the

following

items

servicing
as

necessary

I
Check
brake

pedal
for
bend

2
Check
return

springs
for

fatigue

3
Check

clevis
for

deformation
and

crack
at
welded

part

BR
3
7

Repeat
bleeding
operations
until

no
air

bubbles
show
in

hose

Note

a

Brake
fluid

containing
air
is

white

and
contalns
air
bubbles

b
Brake
fluid

containing
no
air

rons

out
of
bleeder
valve
in
a
solid

stream
free
of
air

bubbles

8

Repeat
steps
above
on

remaining

brake
line
to

expel
air

INSTALLATION

Install
brake

pedal

following
the

reverse

procedure
of
removal

paying

attention
to
the

following
items

I

Apply
coating
of
recommended

multi

purpose
grease
to

sliding
portion

and
return
coil

spring

BA113A

Fit
BR

4
Lubricating
Point

2
Be

sure
to

install
E

ring
and
bolt

securely

3
Insert
CleviS

pin
through
brake

pedal

4

Adjust
brake

pedal
after

installa

tion
Refer
to
Blake
Pedal
for

adjust

ment

j
Tightening

torque

Push
rod

or
op8leting
rod

lock
nut

1
6
to

2
2

kltm

12
to
16
ft

Ibl

Brake

lamp
switch
lock
nut

1
2
to
1
5

kltin

9
to
11
ft
lb