ABS DATSUN PICK-UP 1977 Owner's Manual

REMOVAL

Referring
to

Figure
BR
29

remove

parts
in
numerical
order

enumerated

1

cD
2

BR17S

Fig
BR
29
Removal
method

of

Mcuter
Vae

DISASSEMBLY

When

disassembling
Master
Vac

ob

serve
the

following
instructions

a

Thoroughly
clean
mud
or
dust
from

Master
Vac

b
Extreme

care
should
be
taken
not

to
allow
dirt
dust
water
or

any

other

foreign
matter
into

any
com

ponent
parts

Be

sure
to

select
a
clean

place

before

disassembly
or
assembly

c
Mark

mating
joints
so
that

they

may
be
installed

exactly
in
their

original

positions

d

Keep
all
disassembled

parts

arranged
properly
so
that

they
may

readily
be
assembled

at

any
time

e
Clean
rubber

parts
and

synthetic

resin

parts
in

alcohol

f
Mter
all
disassembled

parts
are

cleaned
in
a

suitable
clean
solvent

place
on
a
clean
work
bench
Use

care
not
to
allow

dirt
and

dust
to

come
into

contact
with
these

parts

1
Install

spacer
on

rear
shell

spacer

temporarily
Place
Master
Vac
in
a

vise
Use
soft

jaws

2

Remove
clevis
and
lock
nut
De

tach
valve

body

guard

rW

ID

1

Clevis

2
Lock

nut
3
Valve

body

guard

BRD7S

Fig
BR

30

Removing
rear
hell
Brake

System

3

Identify
front
shell
and

rear
shell

clearly
so
that

they
may
be
reassem

bled
in
their

original

positions
from

which

they
were
withdrawn

Bolts

attached
on
dashboard
are

not
the

same
in

pitch

4

Using
Master
Vac
Wrench

ST08080000
remove
rear
shell
seal

assembly
and
disassemble

diaphragm

plate
assembly
front
shell

assembly

diaphragm
spring
and

push
rod

assem

bly

f

Q
BA076

Fig
BR
31

Removing
reor
shell

Rear
shell
seal

Pry
off
retainer
with

use
of

screw

driver

as
shown
and

detach

bearing

and
seal

Note
Do

not
disassemble
seal
assem

bly
unless

absolutely
necessary

Whenever
this
is
to
be

removed
use

care
not
to

damage
it

BRD7S

Fig
BR
32

Removing
retainer

Diaphragm
plate

Place

diaphragm
plate
assembly

on

a
clean
work
bench
Detach
dia

phragm
from

groove
in

plate
as
shown

BR
16
BA079

FlIf
BR

33

Separating

diaphragm

2

Using
a
screwdriver

as
shown

evenly
pry
air
silencer
retainer

until
it

is
detached
from

diaphragm
plate
as

sembly

Note
Never

use
a

hammer
to

remove

this
retainer
since
this
win
be
the

sure

y
of

damaging
it

BA322

Fig
BR
34

Removing
air
silencer

retainer

3
Pull

out
valve

plunger

stop
key

and
withdraw
silencer
and

plunger

assembly

Note
To

remove
valve

plunger

stop

key

properly
proceed
as

follows

With

key
hole

facing
down

lightly

push
valve

operating
rod
simulta

neously
while

applying
vibration
to

it

BA180

Fig
BR
35

Pulling
out

top
key

Condition

Wheel
wobbles

Unevenly
or

excessively
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
of
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

Damaged
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
start

and

improper
speed
due
to

rapid
acceleration

or

improper
brake

ap

plication

Improper
tire

pressure

Improper
front
wheel

alignment

Distorted
knuckle
or

suspension
link

WT
5
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

Conduct
tire

rotation

periodically

Measure
and

adjust

Balance

or

replace

Adjust

Align

Repair

replace
or
if

necessary
reinstall

Reduce

speed

Follow
correct
and

proper
driving
manner

Measure
and

adjust

Align

Repair
or

replace

Detail
A

Detail
D

REMOVAL
Engine
Control
Fuel

Exhaust

Systems

Detail
Bn
4

Detail
e

@

Detail
E

B

Fuel
tank
See

Figure
FE
a

I
Disconnect

battery

ground
cable

2
Remove
drain

plug
and
receive

the

remaining
fuel
into
a

suitable

container

3
Disconnect
filler
tube

fro
filler

hose

4
Remove

fuel
tank

securing
bolts

5
Disconnect

two
ventilation
hoses

fuel
return
hose
and
fuel
outlet
hose

from
fuel

tank

6
Disconnect
fuel
tank

gauge
unit

wires

at
connector

7
Remove

fuel
tank

Note

Plug
hose

and
tube

opening
l
to

prevent
entry
of
dust
or
dirt
while

removing

ReservoIr
tank

1

Disconnect

battery
ground
cable

2
Disconnect
two
ventilation
hoses

evaporation
hose
and
breather
hose

3
Remove
reservoir
tank

securing

bolts

and
remove
tank
with

protector
Note

Plug
hose
and
tube

opening
l
to

prevent
entry
of
dust
or

dirt
while

removing

Fuel

tank

gauge
unit

Disconnect

battery
ground
cable

2

Disconnect
wires

from
fuel
tank

gauge
unit

3

Remove
fuel

tank
For
details

refer
to
fuel
tank
removal

4

Unit

gauge
is
a

bayonet
type
and

can

be
removed

by

turning
it
counter

clockwise
with

screwdriver

Fuel

piping
See

Figure
FE
4

Fuel

tubes
are

serviced
as
an
as

sembly
so
that

replacement
of

fuel

tube
can

be

easily
done
However
do

not
disconnect

any
fuel
line
unless

absolu

tely

necessary

I

Drain
fuel
from
fuel
tank

2

Loosen
fuel

hose

clamps
and
dis

connect

fuel
tubes
on

each
end

Note

Plug
hose
and
tube

openings
to

FE

5
Detail
F
Detail

G

Detail
U

Detail
T

FE261

Fig
FE
4
Fuel

piping

prevent
entry
of

dust
or
dirt
while

removing

3
Unfasten

clips
that
hold
tube

on

under

body
and
remove
tube
from
the

vehicle

Fuel
filter

I
Disconnect
fuel
hoses
from
fuel

filter

by
removing
clamps
See

Figure

FE
5

FE18S

Fig
FE
S

Removing
fuel
filter
clamps

Body
Electrical

System

Room

lamp
and

engine
compartment
lamp
system

FUSE

BLOC
K

C
J
QA

C
J
CJ

CJ
CJ
1

100
I
2

I

I
t1

Wf

t
fi

FUSIBLE

LINK
ROOM
LAMP

t

I
6

I

II
lA

FUSE
o
C
1

BATTERY

I
I

DOOR

SWITCH
L
H
l
ENGINE

ROOM
LAMP

I
0

I

1

HOOD

SWITCt
f

I
c

I

DOOR
SWITCHIR
H

l

Fig
BE
5
Room

lamp
and

engine
compartment
lamp

system
BE852A

HEADLAMP

if

BE300

Fig
BE
6
Head
amp

HEADLAMP
BEAM

REPLACEMENT

I

Remove
radiator

grille
retaining

screws
and
remove
radiator

grille

2

Loosen
three

headlamp
retaining

ring
screws
I
t

may
be

unnecessary
to

remove
screws
Note
Do
not
disturb

aiming
adjust

screws

3
Remove

retaining
ring
by
rotating

it
clockwise

4
Remove

headlamp
beam
from

mounting
ring
and
disconnect

wiring

8E
5
connector
from

behind
beam

Note

Rubber
cover
is

installed
at

back
of

headlamp
beam
The
con

nector
is

located
in

the
cover

5

Change
headlamp
beam
and
con

nect

wiring
connector

to
new
beam

6
Place

headlamp
beam
in

position

so
that
three
location
tabs
behind

beam
fit
in

with
three
hollows
on

mounting
ring
Make
sure
that

sign

Top
of
beam
lens
i
i
on

upper
side

7
Install

headlamp
retaining
ring

and

tighten
retaining
screws

8
Place

radIator

grille
in

position

and

tighten

retaining
screws

AIMING

ADJUSTMENT

lJ

ii
i
tooi

1
Ji

Y
4
nnn

4
I

Horiz
tal

ad

justment

l

BE30l

Fig
BE
7

Aiming
adjustment

REFRIGERATION

SYSTEM

If

you
were
to

paint
your
finger

with
alcohol

your
finger
would
feel

cold
This
is
because
the

liquid
alcohol

takes
heat

away
from

your
finger

while
it

evaporates
If
a

quickly
evapo

rating

liquid
such
as
alcoliol
is

placed

in
a
container
inside
a
box
the
tem

f

Outside
air

U

Condenser

J6G1
i
i

1
1

t1

1

ilill
I
I

J

JJ
LlJ
i
l

7

U

Receiver

dryer

h

w

t

CONDENSER

The
condenser
is
installed
to
the

front
of
the
radiator

The
heated
and

compressed

refrigerant
gas
from
the
Air

Conditioning

perature
inside
the
box
will

drop
This

is
because
the

alcohol
is

evaporated

absorbing
the
heat
from
the
air

insidc

the
box
If
the

gaseous
alcohol
is

collected
and

cooled
with

cold
water

it
will
be

changed
back

into
a

liquid
by

absorption
of
its
heat

by
the
cold

water

The
cooler

operates
on
this

princi

Compressor

t

q
ttLJ

IrJ

Evaporator
It

J

1

J

f
9

d

lUr

I

Expansion
valve
V7777
J
High
pressure

lLLLLL
l

gas

I
I
High
pressure

liquid

t

u

compressor
condenses
to
a

liquid
by

being
cooled

by
air

passing
between

the
fins
of
the
condenser

1
GJ
7

vlmnn

iii

plI

d1i
1il

Ac459

Fig
AC

3
Condenser

AC3
pIe
The

liquid
used

is
the

refrigerant

R
12

The
heat
inside
the

passenger

compartment
is
absorbed

by

changing

the

refrigerant
from
a

liquid
to
a

gas

and
then

dissipated
to
the

outside

by

changing
the

refrigerant
from

a

gas

back
to
a

liquid

The

refrigeration
system
is

shown

in

Figure
AC
2

Low

pressurt

liquid

1

I
L2
Low

pressure

gas

Inside
air

li

r

L

Blower
motor

AC458

Fig
AC
2

Refrigeration
cycle

COMPRESSOR

The

compressor
is
installed
to
the

side

of
the

engine
and
is
driven

by

crank

pulley
through
a
belt
The

refrig

erant

gas
leaving
the

evaporator
is

forced
out
to
the
condenser

by
com

pressor
and
the
low

pressure
refrig

erant

gas
is

compressed
to
a

high

pressure
and

high

temperature

The

driving
force
is
transmitted

by

an
electrical
clutch
Because

engine

rpm
is

very
low

during
idling
the

clutch
will

not
transmit

the

driving

force
thus

ensuring
smooth

engine

idling

REFRIGERAi
H
R
12

COMPRESSOR
OIL

MAINTENANCE

PERIODIC
MAINTENANCE
AND

SEASON
IN

INSPECTION

GENERAL
SERVICE
INSTRUCTION

SAFETY

PRECAUTIONS

EV

ACUA
TlNG
AND

CHARGING
SYSTEM

HANDLING

MANIFOLD
GAUGE

HANDLING
SERVICE
VALVE

HANDLING
CAN
TAP

DISCHARGING
SYSTEM

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

This

refrigerant
is

usually
available

in
a
small
can
or
a

cylinder
In

either

case
it

is

liquefied
under

high
pressure

in
the
container

Refrigerant

evaporates
easily
has
a

low

evaporation
point
and
moreover

since
the
latent

heat
of
the

refrigerant

is

large
it

can
abSorb

a

large
amount

of
heat

wh

err
e

vaporating
Extreme

care
must
be
exercised
when

handling

the

refrigerant

COMPRESSOR
OIL

The
SUNISO
5GS
or
SUNISO

351

should
be
used
as

refrigeration

lubricant

Mixing
of
the

two
is

allowable

The

refrigeration
lubricant
should

be
used
to
assure
the
successful
com

pressor
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
lubrication

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
Air

Conditioning

GENERAL
SERVICE

CONTENTS

EVACUATING
SYSTEM

CHARGING
REFRIGERANT

CHECKING
FOR
LEAKS

HALIDE
LEAK

DETECTOR

ELECTRIC
LEAK

DETECTOR

REFRIGERANT
LEVEL
CHECK

SIGHT

GLASS

PERFORMANCE
TEST

COMPRESSOR
OIL
LEVEL
CHECK

PERFORMANCE
TEST

REFRIGERANT

LEAKS
AC
8

AC

8

AC
8

AC
8

AC
8

AC
9

AC
9

AC
9

AC10

AC

11

AC
12

MAINTENANCE

PERIODIC
MAINTENANCE

AND

SEASON
IN

INSPECTION

Both

periodic
maintenance
and

season
in

inspection
are

most
essential

to
enable
the
air

conditioner
to

give

full

performance

Perform
the

following
checks

Start

engine
and

check

refrigerant

level

through
sight
glass
on

receiver

dryer
For

details
refer
to

relative

topics
under

Refrigerant
Level

Check

2
Check
the
entire

sysiein
for

sign

of

refrigerant
leaks

Refer
to
relative

topics
under

Checking
for

Leaks

and

Refrigerant
Leaks

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

3
Check

compressor
drive
belts

for

proper
deflection

Season
off

Observe
the

following
maintenance

tips
to
allow

the
air

conditioner

to

operate

normally
in

the
next

season

I

Keep
the
entire

system
free
from

AC
8
AC12

AC

13

AC15

AC15

AC16

AC

16

AC16

AC
17

AC17

AC
17

AC18

refrigerant
leakage
by

periodically

checking
for

refrigerant
gas
leak

even

out
of
season

2

Turn
the

compressor
for
10

minutes

at
least
once
a
month

by

running
the

engine
at
1

500

rpm

c
ENERAL
SERVICE

INSTRUCTION

The

servicing
of
the
air
conditioner

should
be
carried
out

only
by
well

trained
servicemen
This

chapter
de

scribes
essential

points
of

servicing

Jf

a

Jarge
amount
of

dirt
and
sand

enter

the

system
they
will
be

carried
with

refrigerant
and

may

clog
the

system
or
scratch

rotating

parts
This

points
out
the
need
for

care
in

servicing
the

system
That

is

disconnecting

joints
should
be

carried
out

in
a
dean

place

Water
should
not
be
allowed
to

get

inside
the

system
The

refrigerant

does
not

readily
mix

with
water

However
the

presence
of
even
a

minute

amount
of

water
will
cause

a
chemical
reaction

at

high
tem

perature
which
will
in

turn

produce

hydrochloric
acid

HCl
Since

hydrochloric
acid
is

highly
corro

sive
to
metals
the
aluminum
and

copper
piping
etc
will
become

corroded
and
the

refrigeration

system
will
become

clogged

Water
in
the

system
will

ice
the

orifice
when
the

high
pressure
re

frigerant
is

changed
to
low

pressure

refrigerant
by

expansion
valve
etc

and
will
obstruct
the

refrigerant

flow

The

following
items

are

general

instructions
to
be

closely
observed
in

servicing
the

system

I
When
a

system
line
is

discon

nected

plug
the

opening
immediately

This
is

especially
necessary
to

prevent

moisture

condensation
from

forming

in
the
line
and
to

keep
out
dirt
and

dust
It
is
also

necessary
to

keep
the

line
at
and
above

surrounding
air

temperatures
at
all

times
When

con

necting
system
lines
do

not

attempt

to
remove
the

plug
from
the

opening

until

ready
for
immediate
use

2

Always
keep
the

working
place

clean
and

dry
and
free
from
dirt
and

dust

Wipe
water
off
with
a
clean

cloth

3
Have
all

necessary
tools
in

pre

paration
beforehand

and
have

tools

clean
and

dry

4
The

compressor
oil
will

easily

absorb
moisture
when

exposed
to
air

Immediateiy
close
the

opening
of
the

container
after
use
It
is
also

necessary

to
observe
the

following
notes

Notes

a
The
oil
should
not
be
transfused

from
a
container
into

another
as

the
failure

will

possibly
cause
mois

ture
to
mix

with
the
oil

b
The

used
oil
should
not
be

returned

into
a
container

c

The
oil

should
not

be
used
if
its

state
of

preservation
is

not
clear

enough

5
When

connecting
or

disconnect

ing
pipes
from
the

refrigeration
sys

tem
use
two

wrenches
One
wrench
is

used
for

holding
the

fixing
nut

in

place

while
the

other
for

turning
the

mating

flare

nut
Failure
to
do

so

may
result

in
a

twisted
tube
or

may
damage

connection

6
Also
use
care
not
to

give
scratches

to
the

seating
surface
at
connections

A

small
scratch
on

the

seating
surface
Air

Conditioning

may
be
the
cause
of

gas
leakage

Before

connecting
pipes
be
sure
to

give
coating
of

compressor
oil
to
the

sea

ting
surfaces

SAFETY

PRECAUTIONS

I

Since
direct

contact
of
the

liquid

refrigerant
with

your
skin
will
cause

frostbite

always
be
careful

when

handling
the

refrigerant
Wear

gloves

or

wrap
a

piece
of
cloth
around
service

valve

to

protect
your
fingers
against

frostbite

by

refrigerant
If

any
of
the

refrigerant
should

get
into

your
eyes

when

charging
the

refrigerant
splash

your
eyes
with

cool
water
to
raise

the

temperature
gradually
Apply
a

protec

tive

film
to

the

eye
to

avoid
infection

Do
not
rub

your
eyes
Consult
an

eye

specialist
Always
wear

goggles
or

glasses
to

protect
your
eyes
when

working
around
the

system
Should

refrigerant
strikes

your
body
splash

on
cool
water
and

apply
a

protective

film

2
The

refrigerant
service
container

has
a

safe

strength
However
if
han

dled

incorrectiy
it
wili

explode

Therefore

always
follow
the
instruc

tions
on
the

label
In

particular
never

stpre
it
in

a
hot

location
above

S20C

l250F
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

refrigerant
gas
is

heavier
than

air
and

will

lay
close
to
the
floor
be

especially
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

contacts
fire

and

special
care
is
therefore

required

when

checking
for

leaks
in

the

system

with

a
halide
torch

5

Do
not
steam

clean
on
the

sys

tern

especially
condenser
since
exces

sively
high
pressure
will
build

up
in

the

system
resulting
in

explosion
of
the

system

The

above

precautions
are
essential

in

handling
of

Refrigerant
l
2
and

their
strict
observation

requires
suffi

AC
9
dent

training
Therefore
it
is

of
first

importance
that

any
other

personnel

than
a
well
trained
serviceman
should

not
be

allowed
to
handle
the

refrig

erant

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

I

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

form

Consequently
the
effective

thermal

transmission
area

of
condenser

for

refrigerant
gas
will
be
red
uced
and

refrigerant
gas
to
be
condensed
will
be

red
ueed
The

pressure
rise
will
become

proportional
to

the
volume
of
the
air

in

system

2

When
air
and

refrigerant
are

mixed
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

shown
in

Figure
AC
13

When
valve
stem
is

fully
screwed

the
valve
is
front
seated
and
valve

path

and
the
center

path
are
blocked
When

valve
stem
is

backed
off
the

paths
are

opened