oil change DATSUN PICK-UP 1977 Owner's Manual

P
ROPELLER
SHAFT
DIFFERENTIAL
CARRIER

c
Flank
oontact

Adjust
in

the
same
manner
as
in

b

cV

t

PD195

Fig
PD
25
Flank
contact

d
Face
contact

Adjust
in
the

same
manner
as
in

a

P0196
t

Fig
PD
26
Face

contact

e
Correct
tooth
contact

Fig
PD
27
Correct

contact

Note

Change
in
thickness
of

adjWll

ing
washer
is

accompanied
by

change
in
backlash
Oled
it
when

instaIIi
gear
INSTALLATION

Installing
can
be

done
in
the
reverse

order
of
removal

Tightening
torque

Gear
carrier
to
rear
axle
case

1
7

to
2
5

kg
m

12
to
18
ft
lb

Drain
and
filler

plug

6
0
to
10
0

kg
m

43
to
72
ft
lb

Gear
oil

capacity
1
0
liter

2
US

pt
I
Y

Imp
pt

REPLACEMENT
OF

FRONT
OIL
SEAL

Replacement
of
front
oil

seal
with

d
ifferential
carrier

assembly
installed

on
the
vehicle

When

replacing
front
oil
seal

do
as

follows

1
Drain

gear
oil

2
Raise

the
rear
end
of

vehicle

and

support
it
with

safety
stands

3
Detach

propeller
shaft
from
com

panion

flange
of
carrier

4

R
1
ove
drive

pinion
n
t

holding

companion
flange
with
Drive
Pinion

Flange
Wrench

ST31S30000
P0238

Fig
PD

29
Removing
companion

flange

6
Remove
oil
seal

7
Set

new
oil
seal
in

position
using

Oil
Seal

Fitting
Tool

KV38102SS0

Apply
grease
in
between
seal

lips

8
Fit

companion
flange
and
flat

w

sher
on
drive

pinion
and
secure

them
in

position
by
tightening
nut
to

the

given

torque
confirming
specified

preload
using
Drive
Pinion

Flange

WrencliST31530000

Tightening
torque

14
0

to
17
0

kg

101
to
123
ft
Ib

Pinion

bearing
preload

with
oil
seal

11
0
to
14
0

kg
cm

9
5
to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4

o
g

6
8
8
8Ib

Notes

a
Preioad
of
old

bearing
is
the
same

value
as
that
of

a
new
bearing

b
If
the
desired
nut

tightening
torque

P0237
can
ot
be
obtained
renew
nut
and

readjust

Fig
PD
28
R

moving
drive

pinion

nut

S
Extract

companion
flange

using
a

standard

puller

PD
13
8
Reinstall

propeller
shaft
and
fill

up
differential
carrier

with

gear
oil

Note
When

installing
fulcrum

pin

insert
it

from
rearward

of
vehicle

12

Install

tension
rod
shock
ab

sorber

I
stabilizer
torsion

bar

spring

and

knuckle
arm

referring
to
the

related

paragraphs

13

Install
brake
disc

to
knuckle

spindle
and

torque
securing
bolt
to
4
2

to
5

0

kg
m
30

to
36
ft
Ib

14

Install
wheel
and
brake

drum
as

an

assembly
and

torque
knuckle

spin

dle

nut
to
8
0

to
9
0

kg
m
58
to
65

ft
Ib

DISASSEMBLY

AND

ASSEMBLY

Upper
link

I

Detach

upper
link

spindle
from

upper
links
and

remove

clamp
dust

cover
and
dust
seal
Secure

upper
link

in
a
vise
and

loosen
screw

bushing

Assemble
link

spindle
in
reverse

sequence
to

disassembling
noting
the

following
instructions

2

Torque
screw

bushing
on

upper

link
to
3S
to

55

kg
m
253
to

398

ft
Ib

Install
new
dust
seal
and
dust

cover
and
secure
them
with

clamp

3

Coat

grease
to

screw

bushing
in

side
and
the
thread

portion
of

upper

link

spindle

liberally
Screw
front
and

rear
links
to

upper
link

spindle
in
the

same

length
so
as
to
obtain

the

speci

fied

figures
as
shown
in

Figure
FA

23

Unit
mm
in

I

44

6
1
156
FA2

Upper
link

and

upper
link

spindle
Fig
FA
23
Front
Axle
Front

Suspension

4

Make
sure
to

operate
upper
link

spindle
smoothly
after

installation

5

Replace
filler

plug
with

grease

nipple
and

pack
grease
until

grease

comes
out
from

dust
cover

Reinstall
f1ller

plug

Lower
link

When

installing
torque
arm
on

lower
link

tighten
it

to
the

following

specifications

Serration
boss

1
8

to
2

6

kg
m

13
to

19
ft

Ib

Arm

head

2
7

to
3
7

kg
m

20
to

27
ft
tb

INSPECTION

Upper
link

spindle
fulcrum

pin

and
screw

bushing

Apply
screw

bushing
to

upper
link

spindle
or
fulcrum

pin
and
measure

axial
end

play
between

them

When
the
end

play
exceeds
0
35

mm
0

0138
in

replace

upper
link

spindle
or
fulcrum

pin
together
with

screw

bushings

Condition

Vehicle

empty
no

payload

Vehicle
loaded

Notes

a
Vehicle

empty
no

payload
consists

of
the

following
conditions

I
Full

tank
of

gasoline
radiator

f1lled
and

engine
oil
level
full

2

Spare
tire
wheel

jack
and

jack

handle
in

design
position

b
Vehicle
loaded
consists
of
the
fol

lowing
conditions

For
all
models
2

persons
and
SIlO

leg
I
103lb

payload

FA
Check
the
screw
of

upper
link

spindle
fulcrum

pin
and
screw
bush

ing
and

repair
or

replace
if

necessary

Note

Discard
dust
cover
and

dust
seal

when
disassembled

ADJUSTMENT

VEHICLE
POSTURE

Vehicle

posture
may
be
incorrect

due

to
weakened

spring
or

other

faulty

condition
The

following
procedures

are

necessary
when

adjustment
is

Ie

quired

That
is

the
vehicle

posture
can
be

adjusted
by

obtaining
only
the

speci

fied
H

dimension

changing
the

length
of
anchor
bolt

I

Raise
front
of
vehicle

on
stands

2

Adjust
H

dimension
with

turn

ing
nut

adjusting
anchor
bolt
H

dimension

changes
approximately
3
5

mm
0

J38
in

vertically
when

adjust

nut
is
turned

one

complete
turn

3
To

make
the
best

vehicle

posture

H
dimension
must
be
in
the
follow

ing
range

H

dimension
mOl

in

All
models

79
to

84
3

11
to
3
31

54
5
2

15

o
i

Fig
FA

24
FA242

Dimension

for
standard

vehicle

postl4re

DISASSEMBLY

AND

ASSEMBLY

1

00
11I

1

Reservoir

cap

2
Oil
mter

3
Oil

reservoir

4

Packing

5
Valve

cap
Brake

System

00

oC
1

O

b
0
1

r
r

L

BA927

6

Secondary
piston

stopper

7

Bleeder
screw

8

Secondary
return

spring

9

Secondary
piston

10

Primary
return

spring
11

Primary
piston

12
Piston

stopper

13
Piston

stopper
ring

1
Remove
reservoir

cap
and
filter

and
drain
out
brake
fluid

2

Pry
off

stopper
ring
using
a

screwdriver

3
Remove

stopper
screw
and

take

out

stopper
primary
piston
assembly

spring
and

secondary
piston

assembly

in
the

order
shown

Note
Discard

piston
cup
if
it
is
re

moved
from

piston
sembly
and

use
a
new

one

4

Unscrew

plugs
to

gain
access
to

check

valve
for

disassembling

Note
Never
detach
reservoir
tank
U

it
is
removed
for

any
reason
dis

canI
it

and
install
a
new
one

S
Assemble
master

cylinder
in

the

reverse

sequence
of

disassembly
pay

ing
particular
attention
to
the

follow

ing
notes
Fig
BR
10
Master

cylinder

Tightening
torque

Valve

cap

T
okico

8

t09

kg
m

S8
to
6S
ft
Ib

Nabco

2
5
to
3
S

kg
m

18
to
2S

ft
Ib

Bleeder

0
7

to
0

9

kg
m

S
to

7
ft
lb

Notes

a

Replace
gaskets
and

packings
with

new
ones

b

Apply
brake
fluid
or
rubber

grease

to

sliding
contact
surfaces
of

parts

to
facilitate

assembly
of
master

cylinder

c
The
blllke
master

cylinder
is
avail

able
in
both
NABCO
make
and

TOKlCO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between
NABCO
and

TOKlCO
JIIlkes
When

replacing

the

repair
kit

or

component

parts

BR
6
ascertain
the
brand
of
the
brake

master

cylinder
body
Be

sure
to

use

parts
of
the

same
make
as
the

former
ones

INSPECTION

Thoroughly
clean
all

parts
in

a

suitable
solvent
and
check
for
WOol
or

damaged
parts
Replace
any

part
that

is

faulty

Note
Do

not
clean
robber

parts
with

minerai
oil
since
this
will
be
the

sure

way
of

deteriolllting
parts
Use

brake
fluid
or
alcohoL
When

alco

hol
is
used
for

leaning
these

parts

do
not

immerse
them

in
it

longer

than
30

seconds
After

parts
are

cIeaned

dry
with

compressed
air

I
Check

cylinder
and

position
for

evidence
of
abnonnaI

wear
or

damage

Replace
if
found

faulty

2

Check

piston
to

cylinder
clear

ance
If
it
is

more
than

O
IS

mm

0
OOS9
in

replace
either

piston
or

cylinder

Master

cylinder
inner
diameter

19
0S
mm
Yoin

3
Check
for
weakened

fatigued
or

damaged
springs
and

replace
if
neces

sary

4
When
master

cylioder
is

disassem

bled
be
sure
to

discard

cups
and

valves

Replace

any
other

part
which

shows

evidence
of
deformation
wear

or

damage

S

Replace
damaged
oil
reservoirs

and

caps

INSTALLATION

Install
master

cylinder
in
the

re

verse

sequence
of
removal

Bleed
air

out
of
master

cylinder
by

loosening
bleeder
screw
after
it
is

installed
in

its

original
position

Tightening
torque

Brake
master

cylinder

attaching

nut

0
8
to
1
1

kg
m

6
to
8
ft
Ib

Brake
tube
connector

I
S
to
1
8

kg
m

II

to
13
ft
Ib

Ibove
mentioned

st
is
available
when
op

the

FRONT
BRAKE
Brake

System

entire
brake

system
except

N

L
S
V
is

correctly

adjusted

After
shoe
return

spring

Adjuster
assembly

8

Adjuster
head

9

Adjuster
head
shim

10
Lock
spring

11

Adjuster
housing

12

Adjuster
wheel

13

Adjuster
screw

14

Retaining
spring

15
Lock

plate

16

Adjuster
shim

17
Rubber
boot
1
Brake

disc

2
Brake

shoe
assembly

3
Wheel

cylinder
assembly

4

Brake
shoe

upper
return

spring

5
Brake
shoe
lower

return

spring

REMOVAL

I
Jack

up
front
of
vehicle

just
high

enough
to
remove
tire
and

support
it

with

safety
stands

2

Remove
wheel

and
brake
drum
If

brake
drum
cannot
be

easily
removed

return
brake

adjuster
install
two
bolts

M8
x
1
25
in
holes
on
the

flange
face

of
brake
drum

and

tighten
bolts
even

ly
until
brake
drum
is
driven
out

3
In
order
to

ease

operation
re

move
hub

assembly
from
knucRle

spindle
Refer
to
Front
Axle

4

Unhook

upper
lower
and
after

shoe
return

springs
and
then
remove

brake
shoe
assemblies

S
Disconnect
brake
hose
from

wheel

cy
linder

6
Loosen

securing
nut
and
remove

wheel

cylinder

7
Remove
rubber
boot

adjuster

shim
lock

plate
and

retaining
spring

and
then
remove

adjuster
assembly

from
brake
disc
Fig
BR
I

6
Front
brake

1
Brake
hose

2
Wheel

cylinder
attaching

bolt

BA312

3
Rubber
boot

Fig
BR
17

Removing
wheel

cylinder

DISASSEMBLY
AND

ASSEMBLY

Wheel
cylinder

@

rr
l

@

t

a

Wheel

cy
linder

housing

2
Piston

3
Piston

cup

4
Dust

cover

5
Retainer
BR649

6
Connector

7

Packings

8
Connector
bolt

9
Bleeder

screw

10

Bleeder

cap
Wheel
cylinder
can
be

disassembled

simply
by
the

following
procedures

described
below

Remove
retainer
and
dust
cover

and
take
out

piston
from
wheel
cyl

inder
Be

careful
not
to

damage

sliding

part
of

piston
and

piston
cup

Thoroughly
wa
sh

u
disassembled

parts
in

brake
fluid
or
alcohol

Note
Do

not
wash
rubber

parts
with

mineral
oil

since
they
are
deterio

rated

When
alcohol
is
used
however
do

not
immerse
rubber

parts
in
alcohol

longer
than
30
seconds
After

parts

are
cleaned

dry
them
with
com

pressed
air

Assemble
wheel

cylinder
in

reverse

sequence
of

diassembly

When

securing
connector
bolt
in

sert
its
location

tip
to
the
hole
of

wheel

cylinder
firmly
and

tighten
it

securely

Carry
out

operations
carefully
so

that

component
parts
are
not
damaged

or
no
dust
and
other

foreign
materials

enter

cylinder

Note

The
brake
wheel

cylinder
is

available

in
both
NABCO
make
and

TOKICO
make
There
is

no
inter

changeability
of

repair
kits
or
com

ponent
parts
between
NABCO
and

TOKICO
makes

When

replacing
the

repair
kit
or

ent

parts
ascertain
the

brand

of
the
brake
wheel

cylinder

body
Be
sure
to
use

parts
of
the

same
make
as
the
former
ones

INSPECTION

Brake
drum

I

Replace
brake
drum
whose
dia

meter
is

beyond
the
limit
of

1
5
mm

0
OS9
in
with

respect
to
the

standard

inner
diameter
of
2S4
0
rom
10
00

SR
tO
Fig
BR
18
Front
wheel

cylinder
in

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

DISCHARGING
SYSTEM

The

pressurized
refrigerant
gas
Ul

side

system
must
be

discharged
to
a

pressure
approaching
atmospheric

pressure
prior
to

evacuating
refrigerant

inside

system
This

operation
should

be
made
to

permit
safe
re
oval
when

replacing
system
components

I

Close

high
and
low

pressure

valves
of
manifold

gauge
fully

2

Connect
two

charging
hoses
of

manifold

gauge
to

their

respective

service
valves

3

Open
both
manifold

gauge
valves

slightly
and

slowly
discharge
refriger

ant
from

system
See

Figure
AC
17

Note

Do
not
allow

refrigerant
to
rush

out
Otherwise

compressor
oil
will

be

discharged
along
with
re

frigerant

AC735

Fig
AC

17
Discharging

system

Caution
Protect

fingers
with
cloth

against
frostbite

by
refrigerant

when

connecting
the

charging
hose

to

the
service
valve

or

disconnecting

it
therefrom
Air

Conditioning

EVACUATING
SYSTEM

1
Connect

high
and
low

pressure

charging
hoses
of

manifold

gauge
to

their

respective
service

valves
of

sys

tern

and
d

ischarge

refrigerant
from

system
Refer
to

Discharge
System

2

When

refrigerant
has
been

dis

charged
to

a

pressure
approaching
at

mospheric
pressure
connect
center

charging
hose
to
a

vacuum

pump

3
Close
both
valves
of
manifold

gauge
fully
Then
start

vacuum

pump

4

Open
low

pressure
valve
and
suck

old

refrigerant
from

ystem
See

Figure
AC
18

S

When
low

pressure
gauge
reading

has

reached
to

approximately
500

mm

Hg
20
in

Hg
slowly
open
high

pressure
valve

See

Figure
AC
19

6
When

pressure
inside

system
has

dropped
to

710
mm

Hg
28
in

Hg

fully
close
both
of

valves
of
manifold

gauge
and

stop
vacuum

pump
Let

stand
it

for
5

to
10
minutes
in

this

state

and
confirm
that
the

reading

does
not
rise

Notes

a
The
low

pressure
gauge
reads
lower

by
2S

mm

Hg
I

in

Hg

per
a
300

m

1
000
ft
elevation
Perform

evacu

ation

according
to
the

following

table

Elevation

m
ft
Vacuum
of

system

mm

Hg
in

Hg

0

0

300

I
000

600
2
000

900
3

000
710
28

68S
27

660
26

635
25

Note
Values
show

readings
of
the

low

pressure
gauge

AC

12
b
The
rate
of
ascension
of
the
low

pressure
gauge
should
be
less
than

2S
mm
Hg
I

in

Hg
in
five

min

utes

If
the

pressure
rises
or
the

specified

negative

pressure
can
not
be
obtained

there
is
a

leak
in
the

system
In
this

case
immediately
charge

system
with

refrigerant
and

repair
the
leak
de

scribed
in
the

following

I
Confirm
that
both
valves
of

manifold

gauge
are

fully
closed
and

then
disconnect
center

charging
hose

from

vacuum

pump

2
Connect
center
hose
to
can

tap

in

place
of
vacuum

pump
Attach

refrigerant
can
to

can

tap
and

pass

refrigerant
to
manifold

gauge

3

Loosen
the
connection
of
center

fitting
of
manifold

gauge
to

purge
air

from

center
hose

4

Open
low

pressure
valve
of
mani

fold

gauge
and

charge
refrigerant
into

system
After
one
can
about
0
4

kg
I

Ib
of

refrigerant
has
been

charged

into

system
close
low

pressure
valve

5

Check
for

refrigerant
leakage

with
a
leak
detector

Repair
any
leak

ages
found
Refer
to

Checking
for

Leaks
and

Refrigerant
Leaks

6
Confirm
that
both
valves
of

manifold

gauge
are

fully
closed
and

then

change
center

charging
hose
from

can

tap
to
vacuum

pump

7

Open
high
and
low

pressure

valves
and

operate
vacuum

pump
to

suck

refrigerant
from

system
When

the

pressure
in

system
has

dropped
to

710

mm

Hg
28
in

Hg
fully
close

both
valves
of
manifold

gauge

7

The
above

operation
completes

evacuation
of

system
Next

charge

refrigerant
Refer
to

Charging
Refrig

erant

Notes

a
The
bubbles
seen

through
the

sight

glass
are
influenced

by
the
ambient

temperature
Since
the
bubbles
are

hard
to
show

up
in

comparatively

low

temperatures
below
200C
6S0

F
it
is

possible
that

a

slightly

larger
amount
of

refrigerant
would

be
filled
if

supplied
according
to

the

sight
glass
Be

sure
to
recheck

the
amount
when
it

exceeds
200C

680F
In

higher
temperature
the

bubbles
are

easy
to

show

up

b

When
the

screen
in
the

receiver

dryer
is

clogged
the
bubbles
will

appear
even
if
the
amount
of

refrig

erant
is
normal
In
this
case
the

outlet
side

pipe
of
the
receiver

dryer
becomes

considerably
cold

PERFORMANCE
TEST

Check
for
the
amount
of

refrigerant

in
the

system
can
be

made

by
meas

uring

pressure
on

discharge
side

The

correct
amount
of

refrigerant
is

in
the

system
if

pressure
on
the

discharge
side
is
within

the

specified

range
For
details
refer
to

Perform

ance

Test
described
later

Overcharging
will
show

up
in

higher

pressure
on
discharge
side

COMPRESSOR
OIL

LEVEL

CHECK

The
oil

used
to
lubricate

compres

sor
circulates
into

system
from
the

oil

sump
while

c9mpressor
is

operating

The

efore
to

correctly
measure
com

pressor
oil
the

amount
of
oil

flowing

to

system
must
be

considered
If
a

considerable
amount
of

leakage
of

refrigerant
gas
happens
the

leakage
of

compressor
oil
is
also
considered

There

will
be

no

compressor
oil
leak

age
from
a

completely
sealed

system

When

system
operates
under

satisfying

condition
the

compressor
oil
level

check
is

unnecessary

When

checking
the
level

of
com

pressor
oil
or

when

replacing
any

component
part
of
the

system
use
the

following
service

procedure
This

fa

cilitates
to
return
oil
to

compressor

I

Operate
compressor
at

engine

idling
speed
1
000

rpm
or

below

with
controls
set

for
maximum

cooling
Air

Conditionin
j

and

high
blower

speed
for
10
to

15

minutes
in

order
to
return

compressor

oil
to

compressor

2

Stop
the

engine
and

discharge

refrigerant
of

system
and
then

remove

compressor
from

the
vehicle

3
Remove

compressor
fIller

plug

Drain

compressor
oil
from

compres

sor
oil

sump
and

measure
the

amount

4

Compressor
oil
is

satisfactory
if

the

following
amount
of
oil

remains
in

the

compressor

Residual
oil

S5
to
128

gr
3
to
4
oz

5
Check
the
cleanliness
of
the
oil
If

the
oil
contains

chips
or

other

foreign

material
clean
oil

5ump
with
new

oil

6
Discard
the

used
oil
and

fili
with

the
same
amount
of
new
oil
Add

oil
if

found
less
than
above
amount

Fig
AC
27

Filler

plug

If

compressor
is

inoperative
due
to

faulty
compressor
or

heavy
loss
of

refrigerant
remove

compressor
and

repair
as

necessary
Then

pour
oil

up

to
correct
level
and
install
on

engine

After
above

steps
have
been

complet

ed
recheck
oil
level
drain
oil
to

correct
level
if

level
is

excessively
high

PERFORMANCE
TEST

The
cooling

performance
of
the
air

conditioner

changes
considerably
with

changes
in

surrounding
conditions

Testing
must
be

performed
using
the

correct
method
This

test
is
used
to

judge
whether

system
is

operating
cor

rectly
and

can
also
be
used

as
a

guide

in

checking
for

problems

I

Park
the
vehicle
indoors
or
in
the

shade

AC
17
2

Open
all
the
windows
of
the

vehicle
fully
However

close
the

doors

3

Open
the
hood

4

Connect
manifold

gauge
to

high

and
low
side
service
valves
of
the

system
Refer
to

Handling
Manifold

Ga

uge

5

Set
fan
control
lever
to
maxi

mum

6
Set

temperature
control
lever

to

max
cool

position

7
Start
the

engine
and
hold

engine

speed
at
1
500

rpm

S
After
the
air

conditioner
has
been

operated
for
about
10
minutes

measure

system

pressures
at

high
pres

sure

discharge
side
and
low

pressure

suction
side

9
Measure
the

temperature
of
dis

charge
air
at

outlet

grille

10
Measure
the

temperature
of

capin

11
Measure
ambient

temperature

and

humidity
one
meter
3
3
ft

away

from
condenser
front
Be

careful
not

to

expose
dry
buib

and
wet
bulb

to

direct

sunlight

12
Check
for

any
abnormalities

by

comparing
the
test

results
with
stand

ard

pressure
in
Performance

Chart

Notes

a
The

pressure
will

change
in
the

followi

g
manner
with

changes
in

conditions

When

blower

speed
is

low
dis

charge

pressure
will

drop

When
the
relative

humidity
of
in

take
air
is
low

discharge
pressure

will

drop

b

The

temperature
will

change
in
the

following
manner
with

changes
in

conditions

When
the
ambient
air

temperature

is

low
the
outlet
air

temperature

will
become
low

If
the
test
reveals
that
there
is

any

abnormality
in

system
pressure
isolate

the

cause
and

repair
by
reference
to

the
Trouble

Diagnoses
and
Cor

rections