ESP DATSUN 210 1979 Owner's Guide

2

Tighten
adjusting
bar
lock
nut

with
cross
and
side
rods
installed
on

car

Note
Lock

adjusting
bar
lock
nut
so

that
ball

joint
on

outer
socket

knuckle
arm
side
is
86019
with

respect
to
that
on
inner

socket

cross

rod
side

INSPECTION
AND
REPAIR

Ball

Joint

1
When

ball
stud
is

worn
or

axial

play
exists

replace
side
rod

socket

with
a
new
one

2
When

dust
cover
is
broken

or
Steering
System

deformed
be

sure
to

replace
with
a

new
one

Initial

turning

torque

Ball

joint

5
to
25

kg
em

4
3
to
21
7
ft

Ibl

Note
Check
idler
side

joint
grease
at

recommended
intervals
and
renew

if

necessary
To

renew

grease

change
screw
with

grease
nipple
and

apply
recommended

grease
to

joint

through
grease
nipple
until

grease
is

forced
out
between
dust
seal
and

joint
socket

Idler
erm
8ssembly

Check
rubber

bushing
of
idler
arm

ST
11
for

breakage
wear
or

play
and
if

necessary
replace

Note

Apply
grease
to

idler
ann
as

sembly
when
disassembled

Cross
rod

and
side
rod

Check
side
rod

and
cross
rod
for

breakage
bend
or

crack
and

replace

with

a
new

one
if

necessary

Fixing
location

Check

fIxing
location
nuts
and

cotter

pins
for
looseness

play
or

breakage
When
looseness
or

play
is

found
check
for

wear
on

tapered

portion
of
ball
stud

gear
arm
or
idler

arm

ILLUMINATION
CONTROL
UNIT
Body
Electrical

System

8

GY
GW

AIMING

ADJUSTMENT

To

adjust
vertical

aim
use

adjusting

screw
on

upper
side
of

headlamp
and

to

adjust
horizontal
ailn

use

adjusting

screw
on
side
of

headlamp
BE1200

Fig
BE

I3
Illumination
Control
Unit

1

Vertical

adjustment

2

Horizontal

adjustment

BE1210

Fig
BE
14

Aiming

Ad
iusting
Screws

Note

Before

makiiIg
headlamp
aim

ing

adjustment
observe

the
follow

ing
instructions

a

Keep
all
tires
inflated
to
correct

pressures

b
Place

car
and
tester
on
one
and

BE
11
same

flat
surface

c
See

that
there
is

no
load
in
car

coolant

engine
oil

fIlled

up
to

correct
level
and
full
fuel
tank

other

than
the
driver
or

equivalent

weight
placed
in

driver
s

position

d

For
details
refer
to
SAE
J599d

When

performing
headlamp
aiming

adjustment
use

an

aiming
machine

aiming
wall
screen
or

headlamp
tester

For

operating
instructions
of

any

almer
it

should
be
in

good
repair

calibrated

and
used

accordi

g
to

respective
operation
manuals

supplied

with
the
unit

If

any
aimer
is

not
available

aiming

adjustment
can
be
done
as

follqws

Turn

headlamp
low
beam
on

H

Horizontal
center
line

of

headlamps

BE297D

Fig
BE
I5

Aiming
Adjustment
Unit

mm
in

Note

a

Adjust
headlamps
so

that

upper

edge
of
hot

spot
is

equal
in

height

to

headlamp
height
and
left

edge
of

hot

spot
is

equal
in

height
to
each

center
line
of

headlamps

b

Dotted
lines
in

illustration
show

center
of

headlamp

Seat
belt
wammg

timer
unit

1
Disconnect

battery
ground
cable

2
Remove
L

A
dash
side
finisher

3

Disconnect
b
arness
conn
ctor

4

Remove
timer
unit

attaching

screw

S
Install
timer
unit
in

the
everse

order
of

removal

BE1290

Fig
BE

27
Seat

Belt

Warning

Timer
Unit

Seat
belt
switch

I

Disconnect

battery
ground
cable

2

Slide
seat
all
the

way
forward

3

Disconnect
harness
connector

4

Remove
inner

seat
belt

by
re

moving

securing
bolt

5
Install
inner

seat
belt
in

the
re

verse
order
of
removal

BE31QC

Fig
BE
28
Driver
s
Inner

Seat

Belt
Body
Electrical

System

INSPECTION

Warning
buzzer

BE308C

Fig
BE

29
Warning
Buzzer

Seat
belt

warning
timer
unit

Seat
belt

warning
timer

unit

I
Y

o

j

r
tIT
I

Connect
terminal

j
to

negative

terminaI
of
DC
12
volt

power

supply

2
Connect

terminal
to

positive

terminal
of
DC
12
volt

power

supply

Buzzer

should
sound
intermit

tent

y

3

As
to

terminal

@
and

@
con

nect
to

positive
terminal
of
DC
12
volt

power
supply
respectively

Buzzer

should
sound
intermit

tently

Note
Make
sure
that

negative
termi

nal
of
DC
12

volt

power

supply
is

a1ways
connected
to
tenninal

CD

Q

e
Battery
t2V

Lamp
3
4W

BE312C

Fig
BE
30

Checking
Seat
Belt

Warning
Timer
Unit

Seat
belt

switch

Test

continuity
through
driver
s

seat
belt
switch
with
a

test

lamp
or

ohmmeter

There
should
be

continuity
be

BE

16
tween

two
terminals
when
the
seat

belt
is
unfastened

Conversely
there

should
not
be

continuity
when
fasten

ed

Speedometer

Condition

Neither

speedometer

pointer
nor
odometer

operates

Unstable

speedometer

pointer

Unusual
sound
occurs
in

response
to
increase
in

driving
speed

Inaccurate

speedometer

indication

Inaccurate
odometer

operation
Body
Electrical

System

Probable
cause

Loose

speedomeTer
cable
union
nut

Broken

speedometer
cable

Damaged
speedometer
drive

pinion
gear

Transmission

side

Faulty
speedometer

Improperly
tightened
or
loose

speedometer

cable
union
nut

Damaged

speedometer
cable

Faulty
speedometer

Excessively
bent
or
twisted

speedometer

cable
inner
wire
or
lack
of
lubrication

Faulty

speedometer

Faulty
speedometer

Improperly
meshed

second
and
third

gear
or

worn

gears

Faulty
feeding
due
to
deformed
odometer

and

pinion
carrier

BE
43
Corrective
action

Retighten

Replace

Replace

Replace

Retighten

Replace

Replace

Replace
or
lubricate

Replace

Replace

Replace
speedometer

Replace
speedometer

REFRIGERANT
R
12

The

refrigerant
used
in
the
air

conditioner
is

generally
called
Re

frigerant
12
R
12
No
other

refrig

erant
than
the
above

refrigerant
should

be
used

Note
Exercise

care
when

handling
re

frigerant
as
it
is

stored
under

high

pressure

COMPRESSOR
OIL

The

SUNISO
5GS

refrig
ration

lubricant
should
be
used
to
assure
the

successful

compressor
operation
Use

of
oils
other
than

recommended
or

mixing
of

the
oil
with

other
oils
would

cause
chemical
reaction

or
lead
to

lowered

viscosity
or

deficient
lubrica

tion

The
oil

absorbs
moisture

as
it
con

tacts
the
air

This

points
out
the
need

for

care
not
to

expose
it

to
atmos

phere
for

an
extended

period
of
time

MAINTENANCE

The

following
checks
and
main

tenance
are

especially
important
to
the

air
conditioner

I

Check

refrigerant
level

2
Check

refrigerant
leaks

3
Check

compressor
drive

belt
for

proper
deflection

4

Even
in

the
off
season
turn
the

compressor
for
10
minutes

at
least

once
a
month

by

running
the

engine
at

1

500

rpm

GENERAL

SERVICE

INSTRUCTIONS

If
dirt
water
or
air
enters

the
air

conditioner

system
it

will
be

seriously

affected
Be

sure
to
observe

the

following

I

Always
keep
the

working
place

clean

and

dry
and
free
from
dirt
and
Air

Conditioning

GENERAL
SERVICE

dust

Wipe
water
off
from
the
line

fittings
with
a

clean
cloth
before
dis

connecting

2

Have
all

necessary
tools

in

prepar

ation
beforehand

and
have
tools
clean

and

dry

3

Handling

plug
when

the

system

line
is

disconnected

4

Handling

compressor
oil

For
details
refer
to
each

descrip

tion
in
this

manual

SAFETY

PRECAUTIONS

WARNING

1
Since
direct
contact
of
the

liquid

refrigerant
with

your
skin

will

cause
frostbite

always
be
carelul

when

handling
the

refrigerant

Always
wear

goggles
to

protect

your

eyes
when

working
around

the

system

2
The

refrigerant
service
container

has
a
safe

strength
However
if

handled

incorrectly
it
will
ex

plode
Therelore

always
follow

the
instructions
On
the

label
In

particular
never
store
it
in
a
hot

location
above
520e

1260F

or

drop
it
from
a

high
height

3
The

refrigerant
gas
is
odorless

and
colorless
and

breathing

may

become
difficult
due
to
the
lack

of

oxygen
Since
the

relrigerant

gas
is
heavier
than
air
and

will

lay
close

to
the
floor

be

espe

cially
careful
when

handling
it
in

small
confined

spaces

4
The

refrigerant
itself

is
nonflam

mable
However

a
toxic

gas

phosgene
gas
is

produced
when

it

contacu
fire
and

special
care
is

therefore

required
when
check

ing
for

leaks
in
the

system
with
a

halide
torch

5
Do
not
steam
clean
On
the

sys

tem

especially
condenser
since

excessively
high
pressure
will

build

up
in
the

system
resulting

in

explosion
of
the

system

The

above

precautions
are
essen

tial

in

handling
of

Refrigerant

12
and
their
strict
observation

AC
9
requires
sufficient

training

Therefore
it
is
of
first

impor

tance
that

any
other

personnel

than
a
well
trained
serviceman

should
not
be

allowed
to
handle

the

refrigerant

EVACUATING
AND

CHARGING

SYSTEM

During

servicing
use
caution
to

keep
air

from

getting
into

refrigerant

When
air

enters
the

system
all

refriger

ant
must
be
evacuated

from

system

prior
to

charging
new

refrigerant
Air

in

refrigerant
has
the

following
delete

rious
effects

1
Since
the
condensation

tempera

ture
of

the
air
is

extremely
low
the
air

will
not

be
condensed
when

refrigerant

gas
is
condensed
in
the
condenser

and

the
air

will
thus
remain
in

gaseous

fonn

Consequently
the
effective

thermal
transmission
area
of
condenser

for

refrigerant
gas
will

be
reduced
and

refrigerant
gas
to
be

condensed
will

be

reduced
The

pressure
rise
will
become

proportional
to
the
volume

of
the
air

in

system

2
When
air
and

refrigerant
are

r
tixed
in

system
a

chemical
reaction

will
be

produced
and

hydrochloric

acid
which
will

adversely
affect
the

aluminum

copper
iron
and
other

materials
in

system
may
be

generated

HANDLING
MANIFOLD

GAUGE

The

pressure
at
the

high
and
low

sides
of

system
should
be
measured

when

evacuating
and

charging

refrig

erant
and
when

diagnosing
trouble
in

the

system
The
manifold

gauge
is
used

for
these

purposes
A

manifold

gauge

has
two

pressure

gauges
a
low

pressure

gauge
and
a

high
pressure

gauge
These

gauges
are

connected
to
the

high
and

low
side
service

valves
of

system

through
flexible

charging
hoses
The

construction

of
manifold

gauge
is

Air

Conditioning

6
Loosen
the
connection

at
the

center

fitting
of

manifold

gauge
for
a

Clockwise
few
seconds
to

purge
air
inside

charg

ing
hose
See

Fig
AC
14

Counterclockwise

j

3

@

I

Can
tap
handle

2

ChlcginS
hose

3
Needle

4

Refrigerant
can

AC246

Fig
AC
13
Can

Top

Purging
air

R

12

To

L9w
pressure

service
valve
AC247

Fig
AC
14

Purging
Air

Ta

High
pressure

service
valve

f

r

AC181A

Fig
AC
15

Discharging
System

AC
ll
DISCHARGING
SYSTEM

The

pressurized
refrigerant

gas
in

side

system
must
be

discharged
to
a

pressure
approaching
atmospheric

pressure
prior
to

evacuating
refrigerant

inside

system
This

operation
should

be
also
made
to

pennit
safe
removal

when

replacing

system
components

A
Close

high
and
low

pressure

valves

of
manifold

gauge
fully

2

Connect
two

charging
hoses
of

manifold

gauge
to

their

respective

service
valves

WARNING

Securely
connect

high
pressure
dis

charge
service
valve
to
that
of

manifold

gauge
with
a
hose
also

connect
low

pressure
suction
serv

ice
valve
to
that
of
manifold

gauge

For

locations
of

high
and
low

pres

sure

discharge
and
suction
service

valves
see

Fig
AC
29

3

Open
both
manifold

gauge
valves

slightly
and

slowly
discharge
refriger

ant
from

system
See

Fig
AC
15

WARNING

Protect

fingers
with
cloth

against

frostbite

by
refrigerant
when
con

necting
the

charging
hose

to
the

service

valve
or

disconnecting
it

therefrom

Nole
Do

not
allow

refrigerant
to
rush

out
Otherwise

compressor
oil
will

be

discharged
along
with

refriger

ant

EVACUATING

SYSTEM

I

Connect

high
and
low

pressure

charging
hoses
of
manifold

gauge
to

their

respective
service
valves

of

sys

tem
and

discharge
refrigerant
from

system
Refer
to

Discharging
System

WARNING

Securely
connect

high
pressure
dis

charge
service
valve
to
that
of

manifold

gauge
with
a
hose
also

connect
low

pressure
suction

servo

ice

valve
to
that
of
manifold

gauge

For

locations
of

high
and

low

pres

sure

discharge
and
wction
service

valves

see

Fig
AC
29

4

Wfefrlgerant

charging
speed
slows

down

charge
it
while

running
the

compressor
for

ease
of

charging
After

having
taken

the

steps
up
to

3
above

proceed
with

charging
in
the

following

order

1
Shut

off

high
pressure
valve
of

manifold

gauge

2
Run

the

engine
at

idling

speeds

below
1

500

rpm

3
Set
the

Temperature
lever
and

Fan

switch
at
maximum
cool
and

maximum

speed
respectively

To

Lpw
pressure

service

valve

t
Air

Conditioning

4

Charge

efiigerani
while
con

trolling
low

pressure
gauge
reading
at

2
8

kg
cm2

40

psi
or

less

by
turning

in

or
out
low

pressure
valve
of
mani

fold

gauge
See

Fig
A

20

WARNING

Never

charge
refrigerant

through

high

pressure
side

discharge
side

of

system
since
this
will

force
re

frigerant
back
into

refrigerant
can

and
can

may
explode

To

High
pressure

service
valve

A

5
When

refrigerant
can
is

empty

fully
close
both
valves

of
manifold

gauge
and

replace

refrigerant
can
with

a
new

ot
e

Before

opening
manifold

gauge

valve
to

charge

refrigerant
from
new

can
be

sure
to

purge
air

from
inside

charging
hose

6

Charge
the

specified
amount
of

refrigerant
into

system
by
weighing

charged

refrigerant
with

scale
Over

charging
wiU

cause

discharge
pressure

to
rise
AC380A

Fig
AC
20
Charging
Refrigeront

Measure
the
amount

of

charged
refrigerant

with
a

scale

Make
a
note

of
the

amount

charged
from

can

AC252

Fig
AC
21

Chorging
Refrigeront

Refrigerant
capacity

Unit

kg
lb

Refrigerarit
Minimum

Maximum

R
12

0
8
1
8

1
0
2
2

AC14
Note
The

p
Ce
of
btibble
hi

sight
glass
of
receiver
drier
is

an

unsuitable

method
of

checking
the

amount
of

refrigerant

charged
in

system
The
state
of
the
bubbles

iJt

sight
glass
should

only
be
used
ior

checking
whether
the
amount
of

charged

refrigerant
is
small
or

not

The
amount
of

charged

refrigerani

can
be

correcdy

judged
by
means

of

discharge
pressure
Refer
to
Re

frigerant
Level
Check

7
After

the

specified
amount
of

refrigerant
has
been

charged
intosys

tern
close
manifold

gauge
valves
Then

detach

charging
hoses
from
service

valves
of

system
Be

sure
to
install

valve

cap
to
service

valve

8

Confirm
that

there
are
no
leaks
in

system
by
checking
with
a
leak
detec

tor

Refer

to

Checking
for

Leaks

Note

Conducting
8

performance
test

prior
to

removing
manifold

gauge
is

8

good
service

operation
Refer
to

Performance

Test

CHECKING
FOR

LEAKS

Conduct
a
leak
t
st
whenever
leak

age
of

refrigerant
is

suspected
and

when

conducting
service

operations

which
are

accompanied
by

disassembly

or

loosening
of
connection

fittings

Refrigerant
is

a
colorless
odorless

gas
and

leakage
from

system
is

diffi

cult
to
detect

Accordingly
the
use
of

a
leak
detector
facilitates
check
for

leaks
Two

methods
of

checking
are

available
one

employs
a

halide
leak

detector
which
bums

propane

gas
or

butane

gas
and
the
other
is

an
electric

type
leak

detector

If

any
trace
of
oil
is

noted
at
and

around
connection

fittings
it
is

a
sure

indication
that

refrigerant
is

leaking

This
condition
can
be
corrected

easily

by

retightening
the

joints
If

any

joint

on
line
is

suspected
of
small
amount
of

leakage
use
a
leak
detector
to
locate

leaking
points

HALIDE
LEAK
DETECTOR

Since
the

propane
leak
detector
and

butane
leak
detector
are
the
same
in

respect
to
their

operation
this
section

describes
the

operation
of
the

propane

leak
detector

The

copper
screen
is
heated

by
the
Air

Conditioning

burning
of

propane
Refrigerant
gas

decomposes
to
color
the

flame
when
it

contacts
the
heated

screen
The

gas
to

be
checked
is
drawn
into
the

sampling

tube
and

sent
out
to
the
burner
A

refrigerant
leak
can
clearly
be

detected

by
variations
in
the
color
of
the

flame

1

Copper
reaction

plate

2
Flame

adjusting
lines

3
Burner

4

Sampling
tube

5
Strainer

6
Gas
bomb

7

Flame

adjuster

AC010

Fig
AC
22
Checking
for
Leaks
4

The
flame
will
be

almost
colorless

when
there
is
no

refrigerant
gas
being

burned
When
there
is

a
small

refriger

ant

gas
leak
the
flame
will
be

green
or

yellowgreen
When

refrigerant
gas
leak

age
is

large
the
flame

will
be
brilliant

blue
or

purple
Since
the

color
of
the

flame
will
be

yellow
when
dust
is

being
burned

or
there
is

aging
scale
on

copper
reaction

plate
always
keep
the

strainer

of

sampling
tube
and
reaction

plate
clean

5

Major
check

points

l
Compressor

Compressor
shaft
seal

rotate
the

compressor
by
hand

Flexible
hose

connections

Front
and
rear

head

gaskets

Service
valve

2
Condenser

Condenser

pipe
fitting

Condenser
inlet
and

outlet

pipe

connections

3
Refrigerant
lines

Flared
section
of

high

pressure
and

low

pressure
flexible
hoses

Une

connections

4

Evaporator
housing

Inlet
and
outlet
line
connections

Expansion
valve

Propane
type
Butane

type

ELECTRIC
LEAK
DETECTOR

NO
LEAK

Greenish
blue
Pale

blue

For
the

operational
procedures

SMALL
LEAK
Yellow

Bright
blue
refer

to
the
instructions
furnished
with

LARGE
LEAK

Purple
Vivid

green
each
electric
leak
detector

Discharge
refrigerant
in
one
or

two
seconds

to
ascertain

that

system

has

a
sufficient

pressure
needed
for

leak
detection

Charge
with
0
4

kg
0
9

Ib
of

refrigeranl
if

necessary

2

Light
leak
detector

Adjust
the

height
of
the
flame
between

flame

adjusting
lines
at
the

top
and
bottom

of
combustion
tube

A
reaction

plate

will

immediately
become
red
hot

3
Place
the
end
of

sampling
tube

near
the

point
of
the

suspected
leak
in

system

Note

a
Since

refrigerant
gas
is

heavier
than

air
small
leaks

can
be

easily
detect

ed

by

placing
sampling
tube
direct

ly
below
the
check

point
b
Suitable
ventilation
is

required
If

refrigerant
gas
is

mixed
with
the

surrounding
air
leak
detector
will

always
indicate
a

response
and

detection
of
the
actual
leak
will
be

difficult

c
Never

hold
leak
detector
at
an

angle

WARNING

a
Never
inhale
the
fumes

produced

by
combustion

of

refrigerant
gas

since

they
are
toxic

b
Never
use
halide
torch
in
a

place

where
combustible
or

explosive

gas
is

present

AC
15
REFRIGERANT

LEVEL
CHECK

SIGHT

GLASS

Sight
glass
is

provided
at
the

top
of

receiver

drier
One

guide
for
whether

there
is

enough
refrigerant
in

syst
m
is

given
by
observing
refrigerant
flow

through
sight
glass
However
this

method
is
unsuitable
for

judging
the

aJTlount
of

refrigerant
The
correct

refrigeranl
level
can
be

judged
by

measuring
the

system
pressures
in

ac

cordance
with
the

procedures
as
de

scribed
in
Performance
Test

1

Start
the

engine
and
hold

engine

speed
al
1

500

rpm

2

Set
AIR
lever
to

AlC

position