1979 DATSUN 210 brake rotor

with
the

pin
hole
of
the
internal

rotor

combined
with
the
manual

shaft
and

check
their

alignment
by

inserting
a

1
5
mm
0
059
in
diameter

pin
into

the

holes
If
the

alignment
is

correct

fasten
the
switch

body
with
the
bolts

pull
out
the

pin
tighten
up
the
screw

in

the
hole
and
fasten

the
selector

lever
as
before
Check

the

continuity

pin
with
the
lesler
If

Ihe
malfunc

tion
still
remains

replace
the
inhibitor

switch

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission
and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revoiutions
o
the

cngine
while

vehicle
is
held
in

a
stalled

condition

The
carburetor
is
in

fullthrollle

opera

tion
with
the
selector
lever
in

ranges

1
2
and
I

respectively
Com

pale
the
measured

results
with
the

standard

values

Components
to
be
tested
and

test
itelJUl

I

Clutches
brake
and
band
in
trans

mission
for

slipping

2

Torque
converter
for

proper
func

tioning

3

Engine
for
overall

properly

STAU

TEST
PROCEDURES

Before

testing
check
the

engine
oil

and

torque
converter

oil
warm

up
the

engine

cooling
w

ter
to

suitable
tem

perature
by

running
at
1
200

rpm
with

the

selector
lever
in
the

range
P

for

sevcral
minutes

Warm

up
the

torque

converter
oil

to
suitable

temperature

60
to
lOOoC

140
to
2120F

I

Mount
the

engine

tachometer
at
a

location
that

allows

good
visibility

from

the
driver

s
seat
and

put
a
mark

on

specified
revolutions

on
the

meter

2

Secure
the
front
and
rear
wheels

with
chocks

and

apply
the
hand

brake

Be
SIIre

to

depress
the
brake

pedal

firmly
with
the
left
foot
before
de

pressing
the

accelerator

pedal

3
Throw
the

selector
lever
into
the

range
11

4

Slowly

depress
the

accelerator

pedal
until
the

throttle
valvc
is

fully
Automatic

Transmission

opened
Quickly
read
and

record

the

engine
revolution

when
the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5
Shift
the
selector
lever

to
N

and

operate
the

engine
at

approxi

mately
1
200
rpm
for
more
than
one

minute
to
cool

down
the

torque
con

verter
oil
and
coolant

6
Make
similar
staU
tests
in

ranges

2
I
and
R

CAUTION

The

dill
test

operstion
81

specified
in

i18m
4

should
be

I118de
within

fiv

lIeonds

If
it
tBkes
too

long
the

oil

If

and
the
cluti
hn
blllke

and
b
nd

elll

ly
I
Suf

ficient

cooling
time
should

be

given

r

eech
test
for
the
four

IlInges

0
Z
1
end
R

JUDGEMENT

High
stall
revolution

more
than

staitdard
revolution

If
the

engine
levolulion
in

stall

condi
ion
is

higher
than
the
standard

values
it
indicates

that
onc
or
more

clutches
in
the

transmission
are

slipping
and
therefore
no

further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High
rpm
in

all

ranges
low
line

pr
ssure

High
rpm
in
0

2
and
I

and

normal

rpm
in
6R

Rear
clutch

slipping

High
rpm
in
D

and
2
and

normal

rpm
in

One

way

clutch

slipping

High
Ipm
in
R

only
Front

clutch
or
low

and
reverse
brake

slipping

To

determine
which
is

slipping

front

clutch
or
low
and
reverse

brake

a
road

test
is

needed

If
while

coasting
after

starting

with
the
levcr
in
I

range
engine

braking
does
not

work

properly
the

low

and
reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is
diffi

cuJt
to
ascertain

However
jf
it

occurs

with

the
lever
in
1

range
engine

AT
41
revolution
increases

up
to
the
same

level

as
in
1st

range
It

is

impossible

to

check
it
in
the

stall
test

2
Standard
stall
rnoluiion

If
the

engine
revoluiion
in

stall

ondition
is
within

he
standard

values
the
control
elements
are

nOf

mally

operating
in

the

ranges
D

2n
I

and
R

Also
the

engine
and
one

way

clutch
of
the

torque
converter
are

norinal
in

performance
and

operation

The

one

way
clutch

of
the

torque

converter

however
sometimes

sticks

This
is
determined

in
the
road

test

3

Lower

stall
revolution
than
lIand

ard

revolution

If

the

engine
revolution
in

stall

condition
is

lower
than
the

standard

values
it

indicates
that
the

engine
is
in

abnormal

condition
or
the

torque
con

verter
s
one

way
clutch
is

slipping

4
O
hers

I
If

the

accelerating
performance

is

poor
until
vehicle

speed
of

approxi

mately
SO

kmfh
30
MPH
is
attained

and
then
normal

beyond
that

speed
it

can
be

judged
that
the

torque
con

verte
c

s
one

way
clutch
is

slipping

2

If
the

torque
converter

sane

way
dutch
sticks

vehicle

speed
can

not

exceed

approximately
80

kmfh

SO
MPH
in
the

road
tesl

In
such

a

case
the

torque
converter

oil
tem

perature
rises

abnormally
and
so

special
care
is

required

3
If
the

transmission
does
not

op

erate

properly
at
all
vehicle

speeds
it

indicates

poor
engine
performance

ROAD

TEST

An

accurate

knowledge
of
the
au
to

matic

transmission
is

required
for
an

exact

diagnosis

II
is

recommended
that
a

diagnosis

guide
chart
with
the
standard

vehicle

speeds
for
each

stage
of

the

up
and

down

shiftings
be

prepared
Measured

vehicle

speeds
are
to

be
filled
in

the

adjoining
column
after
each

testing

Also
it

is
advisable
to

mount

a

stopper
for

positioning
the
throttle

opening

Turning
engie
of
front

wheel

Inner
wheel
380
to

42

Outel
wheel
31
0

to
35
0

Tightening
torque
of
bolts

and
nuts

kg
m

ft
lb

@
3

9
to
5
3
28
to
38

@
3
0
to
3
5

22
to
25

@
5
5
to
10
0
40
to
72

@
7
3
to
9

9
53
to

72

@
5
1
to
6
1
371044

ear
wheels
with
chocks

fron
t

of
car
and

support
Front
Axle
Front

Suspension

FA125

Fig
FA

6
AdjU

ting
Steering

Angle

FRONT

AXLE

1
Grease
seal

2
Inner
wbeel

bearin

3

Wheel
hub

4

Outer
wheel

bearins

5
Wheel

bearing
washer

6
Wheel

bearing
nut

7

Adjusting
cap

8
O

ring

9
Hub

cap

10

Disc
brake
rotor

FA803

Fig
FA
7
Front
Axle

it
with

safety
stands

3
Remove
wheel
and
tire

assembly

4

Remove
brake
tube
brake

caliper

assembly

referring
to

Section
DR

FA
4
4
After

adjustment

l
ck

adju

ment
nut

Note

Turning
angle
of
outer
wheel

will

automatically
be
Set

by

adjust

ing
turning
angle
ofin

f
U
wheel
to

specified
values

FA726

Fig
FA
8

RemouingBroke
Caliper

5
Work

off
hub

cap
from

hub

using

t

n
screwdrivers
as
shown
below

If

necessary
tap
around
it

with
a
soft

hammer
while

removing

cap

F
A386

Fig
FA
9

Remouing
Hub

Cap

Note

During
operation
be
careful
to

avoid

deinaging
O
ring

6

Pry
off
cotter

pin
take
out
ad

justing
cap
and

wheel

bearing
lock
nut

7

Remove
wheel
hub
with
disc

brake
rotor
from

spindle
with

bearing

installed

FA199

Fig
FA
10

Removing
Wheel
Hub

Note
Be
careful

not
to

drop
outer

bearing
DOne
out
of
hub
when

removing
hub
from
knuckle

spin

dle

8
Remove
outer

bearing
cone

9
Loosen
four

bolts

securing
brake

disc
remove

disc
brake

rotor
from

wheel
hub

assembly

Fig
FA
11

Removing
Due
Broke

Rotor

Loosen
screws

securing
baffle

plate

take
out
baffle

plate

10
Remove
inner

earing
cone
after

prying
out

grease
seaL
Discard

grease

seaL

11

If
it
is

necessary
to

replace

earing
outer
race
drive
it
out
from

hub
with

a
brass
drift
and
mallet

Evenly

tap
bearing
outer
race
through

two

grooves
inside
hub
Front
Axle

Front

Suspension

Fig
FA

12
Removing
Bearing
Outer

Race

INSPECTION

WHEEL
BEARING

Thoroughly
clean

grease
and
dirt

from
wheel

bearing
with

cleaning
sol

vent
and

dry
with

compressed
air
free

from
moisture
Check
wheel

bearing
to

see
that
it

rolls
freely
and
is
free
from

noise
crack

pitting
or
wear

WHEEL
HUB

Check
wheel
hub
for

crack

by

means
of

a

magnetic
exploration
or

dyeing
test
and

replace
if
cracked

INSTALLATION

Install
front
axle
in
the

reverse

order
of
removal

noting
the
fol

lowing

I
Install

bearing
outer
race
with

Front
Wheel

Bearing
Drift

Inner
ST35321000
Front
wheel

Bearing
Drift
Outer
ST35322000

and

Drift
Bar
ST35325000

until
they

seat
in

hub

2

Pack
hub
and
hub

cap
with

re

commended
multi

purpose
grease
up

to

shaded

portions

fA261

Fig
FA
13

LubriCating
Points

of

Wheel

Hub

FA
5
3
Coat
each

bearing
DOne
with
rec

ommended
multi

purpose
grease

FA781

Fig
FA

14

Coating
Bearing
Cone

with
Grease

4

Place
inner

bearing
cone
in
hub

and
install

a
new

grease
seal

coating

sealing
lips
with
recommended
multi

purpose
grease

5

Concerning
installation
of

brake

parts
refer
to

Section
BR

i
l
Tightening
tOlque

Disc
brake

Rotor
to

hub

3
9
to
5
3

kg
m

28
to
38
ft

lbl

6

Install
hub
with
rotor
and
outer

bearing
cone

7

Sparingly
apply
recommended

multi

purpose
grease
to
threaded

por

tion
of

spindle
and

bearing
washer
to

bearing
contacting
face
Then

install

washer
and
wheel

bearing
nut

Adjust
wheel

bearing
nut
as
de

scribed
in

Adjustment
in
this
section

Note

a
In

order
to
assure
DOrrect

bearing

starting

torque
and

to
extend
serv

ice

nfe
of
wheel

bearings
be
sure

to

avoid
dirt
and

foreign
particles
get

ting
iIi

bearings
grease
seal
Washer

bearing
nut
etc

b

Grease
should
be

changed
at
each

disassembly
end
in

aa
ordance
with

Periodic

Maintenance
Schedule

8

Install
O

ring
on

hub

cap
and

install
hub

cap
on
hub

9
Install
brake

caliper
assembly
re

ferring
to

Section
BR

10
Install
wheel
and
lire

WHEEL

BEARING

Wheel

bearing
axial

play

Wheel

bearing
nut

tightening

torque

Return

angle

Rotation

starting

torque

With
new

grease
seal

With

used

grease
seal

At

wheel
hub

bolt

With
new

grease
seal

With
used

grease
seal

SUSPENSIONBA
JOINT

Turning
torque

New

parts

Used

parts

TIGHTENIN

TORQUE

LOWERBAl
L
JOINT

Ball

joint
socket

to
lower

arm

Ball

joint
to
knuckle

arm
Stud
nut

STRUT

Steering
knuckle

arm
to
strut

Strut
to

hoodledge

Piston
rod
self

locking
nut

Gland

packing

DISC
BRAKE

Rotor
to

hub

SIDE
ROD

Side
rod
ball

jOIDt
to
knuckle
arm

LOWER
ARM

Lower
arm
bolt
nut

Side
rod

adjusting
nut

TENSION
ROD

Tension
rod

bushing
installation
nut

Tension

rod
to
lower
arm

Tension

rod
bracket
to

body
Frpn
Axle

Front

Suspension

mm
in

0
0

kg
m
ft
lb

degree
3
0

to
3
5
22
to
25

900

kg
cm
in

lbr

kg
em
in
Ib
Less
than
7
0
6
1

1
0
to
4
5
0

9
to

3
9

kg
lb

kg
lb
Less
than
1
2
2

6

0
1
7
to
0

79
0
37
to
1
74

kg
cm
in

Ib

kg
cm
in

Ib
40
to
100
35
to
87

More
than
20
17

kg
m
ft
Ib

5
1
to
6
1

37
to
44

5
5

to
10
0
40

to
72

7
3
to
9
9

53
to
72

2
5
to
3
5

18
to

25

6
0

to
7
5
43
to
54

8
0
to
11
0

58
to
80

3
9
to
5
3
28

to
38

3
0

to
7
0
22
to
51

3
9
to
5

0
2810
36

8
0

to
10
0
58
to
72

4
5
to

5
1
33
to
37

5
1
to

6
1
37
to
44

3
2

to
4
3
23
to
31

FA
14

DATSUN
2

0
Model
83
0
Series

SECTIONBR

BRAKE
SYSTEM

CONTENTS

ADJUSTMENT

BRAKE
PEDAL

FRONT
DISC
BRAKE

REAR

BRAKE

HAND

BRAKE

BLEEDING
HYDRAULIC
SYSTEM

SERVICE
BRAKE

BRAKE
PEDAL

MASTER
CYLINDER

BRAKE
FLUID
LEVEL

GAUGE

BRAKE
LINE

NP
VALVE

FRONT
DISC
BRAKE
BR
2

BR
2

BR
2

BR
2

BR
2

BR
2

BR
3

BR
3

BR
4

BR
5

BR
5

BR
6

BR
6
ROTOR

REAR

BRAKE

BRAKE
BOOSTER

HAND
BRAKE

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPECTION
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

CORRECTIONS

SPECIAL
SERVICE
TOOL
BR

9

BR

l0

BR
12

BR
14

BR
16

BR
16

BR
17

BR
18

8R
19

8R
22

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

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

FOREIGN
DISC
PAD
INSTALLATION
INSTRUCTIONS

Typical
Ate
Teves

System

Removel

1

Drain
about
half

of
the

brake
fluid
out
of
the

master

cylinder
prior
to

replacing
the

disc
brake

pads
This
will
allow
sufficient

expansion
room

for
the
brake
fluid
in
the

lines
when
the

pistons
are
pushed
back

into
their
bores
to
make
room
for
the
added

Ihickness
of
the
new

pad
linings

2

Reise
the
car
and
lemove
tire
and
wheel

3
The
breke

pads
can

be
removed
without

lemovinll
the

caliper
from
the
car

4
The
brake

pad
reteining
pins
are

held
in

plaCe
bY
lock
rinlls
in
Ihe
inner

caliper

housing
The

pins
must
be
knocked
out
with

e
hammel
end

punch
from
theoulllide

5
Remove

spreader
spring
which
is

positioned
under
the

pins

6
A

special
tool
is
available
flom
the
car

manufacturer
forremoving
pads
from
caliper

or

pliers
can
be
used
to

pull
them
oul
be
careful
not
to

damage
the
rotor

7
Push
Ihe
brake

pistons
back
into

their
boros
If

you
encounter

difficulty
in

pushingil

he

pistofls
back
lhere

may
very
weIL
Wr9Jl
l

ern
in
lh

e
caliper
that
calls
for
more

attention
than

simplY
replecing
worn
out

pads
IUhe
pistons
are

eticking
or
If
the

seals
are

leaking
you
should
disassembl
the

caliper
and

repair
il

8

Lift
out
old

pads
from

Ihe

caliper

9
Remove
O

Ring
from
inside

caliper

Inslallatlon

II

1

Apply
silicone
lubricanl
to
Ihe

O

Rings
ana
to

grooveS
inside
each

caliper

2
Assemble
an
O

Ring
in

each

groove

3
Position
innor

pads
in

caliper

4
Position

oulpad
in

caliper

5

Replacespreadet
spring

8

ReplaceiPtnsaM
lighter

7
Install
wheel
and
lire

l

Final

Checl

A
Iter
Ihe
new

padS
have
been
installed
on

bolh
front

wheel
check
the

master

cylinder

fluid
level
Rlllhe

reservoiril

necessary
Depress
Ihe
brake

pedal
firmly
severaUlmes

to
sellhe
new

pads
on
he
rotor

i

See
Inst
ctionsOnBat
k
of
Box
For
rr

l8ge
of

EMP

l
iL
1
f

J

TypIcal
Ale

System

New
Brake
Division
Boston
MA
02135
Commerce
CA
90040
Fort
Worth
TX
76106