1979 DATSUN 210 Operating cylinder

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

Clutch

Clutch
cover

Diaphragm
spring
height
mm
in

Unevenness
of

diaphragm
spnng
toe

height
mm
in
29
0

to
31

0
1
142
to
1
220

Less
than
O
5
0
020

TIGHTENING
TORQUE

Pedal

stopper
lock
nut

Master

cylinder
push
rod
lock

nut

Operating
cylinder
push
rod

lock
nut

Operating
cylinder
bleeder
screw

Master

cylinder
to

dash

panel
securing

nut
kg
m
ft
lb

Clutch
tube
flare
nut

kg
m

ft
Ib
kg
m
ft
b

kg
m

ft
Ib

kg
m

ft
b

kg
m
ft
b
0
8

to
1
2
5

8
to
8

7

0
8
to
1
2
5

8
to
8
7

0
8

to
1
2
5
8
to
8
7

0

7
to
0
9
5
1

to
6
5

0
8

to
1
2
5

8
to
8
7

1
5

to
1
8
11
to

13

Operating
cylinder
to
clutch

housing

securing
bolt

Qutch
hose
to

operating
cylinder

Qutch
cover
bolt
kg
m
ft

lb

kg
m
ft
Ib

kg
m

ft
Ib
3
1

to
4
1
22
to
30

17

to
2
0

12
to
14

1

6
to
2
1

12
to
15

CL
11

I
ht
2nd

fork
r

2

3rd

top
fork
rod

3
Reverse
fork
rod

4

Retaining

pin

5
I
t

2nd
shift

fork

6
3rd

top
shift
fork

7

Checking
ball

plug

8

Check
ban

spring

9
Check
ball

10
Interlock

plunger

11

S

topper
ring

12

Shift
rod
A
bracket

13
Reverse

shift
fork

14
Lock

pin

15

Striking
lever
Manual
Transmission

16

Striking
rod

17
Return

spring
plug

18
Reverse

check

spring

19
Return

pring

20

Plunger

21
D

ring

22
Stopper
pin
bolt

23

Striking
guide
assembly

24

Striking
guide
oil
seal

REMOVAL

To

dismount
transmission

from
the

car

proceed
as
follows

Disconnect

battery
ground
cable

2

Remove
console
box

and
detach

rubber
boots
if

so

equipped

3

Place
transmission
control
lever

in

neutral

position
and
remove
it

m

TM781

Fig
MT
4

Removing
Control
Lever
@

@

25
Control
lever

bushing

26

Expansion
plug

27
Control

pin
bushing

28
Control
arm

pin

29
Control
lever
o

Tightening
torque
kg
m
ft
lb

@
0
5
to

0
8
3

6
tn
5
8

@
1
3
to
1
7

9
to
12

Fig
MT
3
F4W60L
Tra11lmiBSion

Shift
Control

Components
TM094A

4
Jack

up
the

car
and

support
its

weight
on

safety
stands
Use
a

hy

draulic
hoist
or

open
pit
if
available

Make

sure
that

safety
is

insured

5

Disconnect
front
exhaust
tube

and

remove
bolt

securing
exhaust

mounting
bracket
from

exhaust
front

tube

side

6

Disconnect
wires
from

reverse

back

up
lamp
switch

7

Disconnect

speedometer
cable

from
rear
extension
At

the
same
time

removey

top
detecting
switch
if
so

equipped

8
Remove

propeller
shaft

Refer
to
Removal
Section
PO

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from
flow

ing
out

MT
3
9

Remove
clutch

operating
cylinder

from
transmission
case

10

Support
engine
by
placing
a

jack

under
oil

pan
with
a
wooden

block

used
between
oil

pan
and

jack

CAUTION

00
not

place
the

jack
under
the

oil

pan
drain

plug

11

Support
transmission
with
a

transmission

jack

12

Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

V

Manual
Transmission

S

R

o

o

D
l

@

@

l

@

l

25
Control
lever
boot

26
Control

pin
bushing

27
Control
arm

pin

28
Control
lever

29
Control
lever
knob
1

2nd
3rd
fork
rod
9
4th

5th
shift
fork
17

Shift
arm
bracket

2

Retaining

pin
10
2nd
3rd
shift
fork
18
Arm
bracket
O

ring

3

Checking
ball

plug
11
Ist
reverse
shift

fork
19
Arm
bracket

plain
washer

4
Check
ball

spring
12

Striking
rod
20
O

ring

5
Check
ball
13
Striking
lever
21

S

lriking
guide

6
ht
reverse
fork
rod
14
Lock

pin
22

Striking
guide
oil
seal

7
Interlock

plunger
15
Striking
pin
23

Expansion
plug

8

4th
5th
fork
rod
16
Shift
arm
24
Control
lever

bushing
Tightening
torque
kg
m

fHb

@
0

9
to
1
2
6
5

to
8
7

@
8
2
to
to
O
59

to
72

TM229A

Fig
MT
68
FS5W60L
Transmission

Shift
Control

Components

REMOVAL
4

Jack

up
the

car
and

supporl
its

weight
on

safety
slands
Use
a

hy

draul

c
hoist
or

open

pit
if
available

Make

sure
that

safety
is

insured

S
Disconnect
front

exhaust
tube

and

remove
bolt

securing
exhaust

mounting
bracket
from
exhaust
front

tube
side

6
Disconnect
wires

from
reverse

back

up
lamp
switch

7

Disconnect

speedometer
cable

from
rear
extension
At
the
same
time

remove

top
detecting
switch
if

so

equipped

8
Remove

propeller
shaft

Refer
to

Removal
Section
PD
To

dismount
transmission

from
the

car

proceed
as
follows

Disconnect

battery

ground
cable

2
Remove
console
box
and

detach

rubber
boots
if
so

equipped

3
Place

transmission
control
lever

in

neutral

position
and

remove
it

CJi
J

TM781
Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from

flow

ing
out

Fig
MT
69

Removing
Control
Lever

MT
17
9
Remove

clutch

operating

cylinder

from
transmission
case

10

Support
engine
by
placing
a

jack

under
oil

pan
with

a
wooden

block

used
between

oil

pan
and

jack

CAUTION

Do
not

place
the

jack
under
the
oil

pan
drain

plug

II

Support
transmission
with
a

transmission

jack

12
Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

CV

TIGHTENING

TORQUE

Ball

pin

Striking
lever

lock
nut

S
llft
arm
bracket

Mainshaft

bearing
retainer

screw

Mainshaft

lock
nut

Rear
extension

installation
bolt

Stopper

pin
bolt

Front

cover
installation

bolt

Speedometer
sleeve
lock

ing
plate
bolt

Top
detecting
switch

Reverse

lamp
switch

Neutral
switch

Return

spring
plug

Gear
oil

filler

plug

Gear
oil
drain

plug

Transmission
to

engine

installation
bolt

Tr

msmissiori
to

engihe

rear

plate
installation
bolt

Transmission

to

gusset

installation
bolt

Starting
motor
to

trans

inissi
n
installation
bolt

Rear

mounting
insulator
to

transmission
installation
bolt

Crossmember

mounting

bolt

Rear

engine
mount

installation
bolt

Clutch

operating
cylinder

installation
bolt

Propeller
shaft
to

differential
carrier

Control
lever

pin

installation
nut

Exhaust

mounting
bracket

to
exhaust
front
tube

FU
model

only
Manual
Transmission

F4W60L

2
0
to
3
0

14
to
22

0
9

to
1
2

6
5
to
8
7

0
7
to

1
0
5
1
to
7
2

1
6
to
2
2
12
to
16

0
5
to
0

8
3
6
to
5
8

1
0

to
1

6
7

to
12

0
3
to
0
5
2
2
to

3
6

2
0
to
3
5
14
to
25

2

0
to

3
5
14
to
25

0
5
to

1
0
3
6
to
7
2

2
5
to

4
0
18
to

29

2
5

to
4

0

18
to

29

1

6
to
2
2

12Jo
16

1

6
to
2
2
12

t
16

4
6
to

6
1
33

to
44

3

0
to
4
0
22
to
29

0
9

to
1

2
6
5
to
8
7

3
2

to
4
3
23

to
31

0
9

to
1
2
6
5
to

8
7

3
1

to
4
1

22
to
30

2
4

to
3
3

17
to
24

1
3

to
1
7
9

to
12

3
2

to
4
3
23
to
31

MT33
Unit

kg
m
ft
lb

FS5W60L

2
0

to
3

0
14
to
22

0
9
to

1
2
6
5
to
8
7

8
2

to
10

0
59
to

72

0
8
to
1
3
5
8
to
9

4

10
0

to
11
0
72
to
80

1
6
to
2
2
12
to
16

1

0
to
1

6
7
to
12

0
3
to
0
5
2
2
to
3

6

2

0
to

3
5
14
to
25

2
0

to
3
5

14
to
25

2
0

to
3
5

14
to
25

0
5
to
1
0
3
6
to
7
2

2
5
to
4
0
18
to
29

i
5
to
4

0

18
to
29

1

6
to
2
2
12
to
16

1

6
to
2

2
12
to
16

4

6
to
6
1
33
to
44

3
0

to
4

0
22
to
29

0
9
to
1
2
6
5
to
8
7

3
2
to
4
3

23
to
31

0

9
to
1
2

6
5
to
8
7

3
1
to
4
1
22
to
30

2
4
to

3
3
17
to
24

1
3
to
1
7
9
to

12

3
2
to

4
3
23
to
31

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