engine DATSUN PICK-UP 1977 Service Manual

Air

Conditioning

PERFORMANCE
TEST
DIAGNOSES

Condition

Discharge
air
too
warm

a
Both

discharge
and
suction

pres

sure
too

high

b
Both

discharge
and
suction

pres

sure
too
low

c
Discharge

pressure
too

high
and

suction

pressure
too
low

d
Suction

pressure
too

high
and

discharge

pressure
too
low

e

Discharge

pressure
normal
and

suction

pressure
too

high

t
Discharge

pressure
normal
and

luction

pressure
too
low

g
Suction

pressure
normal
and

discharge
pressure
too

high

h
Both

discharge
and
suction

pres

sure
normal

Air

conditioning
is

operating

properly

Discharge
air
normal

or
too
cold

a

Discharge
pressure
normal
and

suction

pressure
too
low
Probable
cause

Air

mixed
with
refrigerant
in

system

Overcharge
of

refrigerant

Loose
fan
belt
or

engine
over

heating

Obstructed
or

dirty
condenser
fins

Insufficient

refrigerant
charge

Over

filling
of

compressor
oil

Damaged
compressor
valve
or

pack

ing

Loose

compressor
drive
belt

Clutch

slippage

Faulty
expansion
valve

Clogged
expansion
valve
strainer

Water
has
frozen
at

expansion

valve

Faulty
expansion
valve

Faults
of
both

a
and
h
exist

Air
leaks
from

engine
com

partment

Restricted
air
flow

through
evapo

ratof

Slow
blower
motor

speed

AC
21
Corrective
action

Evacuate
and

charge
system

Discharge
some
of

refrigerant
to

correct
level

Adjust
fan
belt
or
check

cooling

system

Clean
exterior

surface
with
water

Add

refrigerant

Drain
oil
and
correct
oil
level

Refer

to

Compressor
oil
level

check

Repair
or

replace
compressor
Refer

to

Compressor

Adjust

Repair
Refer
to

Compressor

Reinstall

sensing
bulb
correctly
to

keep
it

tight
to

pipe

Replace

Clean
strainer

Evacuate
and

charge
system

Replace

Correct

sealing

Clean

evaporator
fins

Check
and

repair
blower
motor
and

wiring

Air

Conditioning

NOISE
DIAGNOSES

NOISY

I

I

I
Set
fan

switch
on

2

Change
the

engine
rpm

frequently

Detect

the
source
of

noise

I

From

engine
compartment
From
cabin

Cooling
unit

j

Check
the

resonant
sound
when
the

engine
rpm
is

changed

I

I

No

resonant
sound

Compressor
itself
makes
noise
j

Blower
motor

makes
noise

Replace
or

repair
blower

Resonant

sound

Repeat
compressor
clutch
ON
and

OFF

This

checking
can
be

performed
by
changing

engine
rpm
while

fan
switch
is

set
at

ON
Retighten
compressor
bracket
bolt

If

piping
is

resonating
add

clip

Noisy
only
when
clutch
is

engaged
Noisy
when

clutch
is
not

engaged

I

Check
drive
belt
for

slackness

Check
for
loose

compressor
mounting
bolts

I

I
Remove

compressor
belt
then
turn

compressor

pulley

by
hand
If
noise
is
heard

repair
com

pressor
clutch

If

OK

If
loose

Compressor
itself
makes
noise

Repair
or

replace
compressor
Retighten
or

adjust

Nl1

2

R

C7

c

L

PJJ

I

8

INSTALLATION

a
c
J

l
i
rp

To
install

compressor
reverse
the

order
of
removal
Observe
the

follow

ing
nhlJo
e
trorf
1001

vom
R

i
n3

Wheliqli
liiAniitg

fiil
l
in

pt
l

witlil
tiiel
sam
efuouiitITof

b11
1fasitlult

used

previously
v
d
rnl

2

Oil

capacity
new

compressor

O
910
1

owt
llllt
blj
f
H
w
s
013
5

rlT
s

0
111
boc

19
bB1rllo

bi2

qqll
no

e

l
bffik
kuanM
mpdi

x
of

Jli
oln

L
il
m
1IlffiiOrb

fler
ot
oldm

F
n

Cheo

f
undeF
r
n
al

1
aQ

r1tIU
Jt
t31
HClJI1
t
JIVU

i
rlUI

1o
ifm
ft
q
t

VI
31U
S
ltlod

bnM
UfO
l
W

kldf

CJiJi
ti

WIf
nl

L
llil
g

ncn
d

oressor

M
et

illpuntinl
botts
if

l9Wul
fb

i
l
fI
I
l

1Ttio
l

qqlJ

necessary
re

Ighten

I

d
210
Air

Conditioning

Tightening

torque

Flexible
hose
to

compressor

dl

t
kg
J
l

IQ

1

Tf
es

oriti
ra

Lbolts

IbP
fo
o15g

m
J

r
f6i
o
20
i
il

f

J

rt
I

r

aGket
engine

Dons
1
1

0

1
1
3
16

5

l11fd
1l

V

f

42
3
3U
llif

Yl

I
u

y
j

3
D
not

remove

IJgs
orflexibie

1i6
e
before

ready
for
immediate
use

4l
di

Wheniiinstallingccomptess
i
turn

it
serWfiPtiffies
SlOt

5
When

connecting
flexible

hose
to

9mPr
ssor

apD
v

a
coat
of
Hfresh

JU
UI

l1Il
t
2
JIUU
uOHltl
r
fl

compressor
0
1

to

fs
aHn
lurfaces
of

1n
1l11
JJ

J
f
PJU

Ht
UlUJ
jJ

joints

AC

26
5

1

Compressor
attachment

2

Compressor

3

Compressor
bracket

4
AHernator

5
Idler

pulley
bracket

AC745

Fig
AC
31

Removing
compressor

6
Evacuate

cooling
system
then
re

charge
with

refrigerant
Refer

to

Evacuating
and

Charging
System
under

l
r

Gen
efal

Servic
ectioo

f
iI
t

7
F

Whenever
remoV
J

compres
r

be
su
J

t8

C6itiu
t
Ua
t
st
make

idie

mV
i
1rJ

adjustril
rit
and

adjwt
beJf
tension

yv

1

r
Y

N
o
s

9

r
h

v

a

For

compressor
diive
belt

and

tOoling
fan
belt
tensions
refer

to

1
Ildlet

Yt
j
WI
c
S
t
q

b

Cheok

refrigerant

leakage
if

neces

sary
correct

dO
I
wl
Tw
l
rt

f
r2

iVl
2
i
l
n

U
l

bnu
1
1Z
2

gf

ign
rb

nojJ

2

IDLER

PULLEY

FAN
BELT
TENSION

ADJUSTMENT

The

standard

compressor
drive

belt

tension
is
between

8
and
12

mm

AC480

Note
Be

sure
to

loosen

locking
nut

before

turning

adjusting
bolt
Re

tighten
it

after

adjustment

REMOVAL
AND

INSTALLATION

Remove
drive

belt

To
do
this
loosen

locking
nut

before

loosening

adjusting
bolt
Drive

belt
will
then
be
detached

2

Remove
idler

pulley
from
bracket

by
r

J1e

vM
or
king
nut

jiwT
9ff
t

llil
reverse
the

order
of

rerr
oval
jldJ
1
t

Jldr

J
I

INSPECTiON

Oheck
idler

pulley
for

smooth
rota

tion

G
0

llfHt
H
Y

d
H

u
t
1
W

n
l

ot
Jrk
H
l

Check
i

ler

pulley
bracket
for

cracks

Replace
arts
iffound

damaged

c

f
lOJ

gD
IlI
J
l

gtt
flvlnv

nOj
IH

q
g

cll
dE
m
J

COOLING
UNIT

REMOVAL
AND
oM1

INSTALl
A

1lIONI
gnillslUli
n

dW
C

19qm91
crft

llU2
3

6rn
f01
Gl0ql

pj

nDiScoimecprlY
i

ferY
lgroUR
hable

2

Disbhargiou
y
tem

iRefrflsll
Qis

chargingrSystemiillidenGeneral
S

ervicel

sectiom5qiq
10
2
9
fl
1U
n
1Ii
2

oj
liD
Air

Conditioning

0
32
and
0
47
in

when

depressed

with
thumb

pressure
midway
between

the
crankshaft

and

compressor
pulleys

If

necessary
turn

adjusting
bolt

to

move
idler

pulley
up
or
down

until

belt

tension
is

correct

Idler

pulley

Crankshaft

pulley

AC456

Fig
AC
32

Adjustment
of
bolt
tension

3

Connect
low

and

high
pressure

pipes
to
their

proper
positions
in

engine
compartment

Notes

3
Be
sure

to
use
two

wrenches
when

connecting

pipe
joints

b

Plug
pipe

opening

immediately

after

pipe
disconnection

c
Be

careful
not
to

break

expansion

valve
This
valve
is

wrapped
with

heat

insulating
tape

0

J
JWu

J
1
2
ld

m

bm
Ufl

J51
8

I

1

lEldgJ
v
Jwm
j

y
d
n
l2u

1
C765

X

fIlO
1i

qJ
j

gnjlcfu2fIJ
lc
rf

1551

1UJ

flip
1h
tqnPfffi2n
Wfi

i
V1c
ip

j

at
3duJ

lsIliqr
J

wlr
v
n

irWfiqX
ani

qiq

4q
v
Remo
e

tworgromll
ets
from

dash

panel
lots
n

5
lRemove

glovelbox
lBl
n1

oT
0

6

Detach

cooling
unit

cover

Icyom
n

AC

ZA
AC766

Fig
AC
34

Removing
cooling
unit

cover

7

Remove
three
ducts

from

cooling

unit

i

j

l

I

11

AC767

Fig
A
C
35

Removing
cooler
ducts

8
Remove
thermo

switch
control

cable
from

conne
ctor

9
Remove

cooling
unit

and
bracket

as
an

assembly

J

t

AC768

F

lIJAh
Cr
P

3
6
R
1

7
fi
vorr

l
l51
r

Ig

emo
vmg
coo

mg
um

r

n
I1iBITJ
0HJ
Jl
t

rbtivl2

Ofm
IIfj

wom
51
f

H

f
L

ol

IJgjjJpn
1I
SH
tc

vehicle
bn

y
with
five
rews

q

2tl
G

i
O

r
Jv
a8f1l1

J
a

I
ld
1

51
b
nc

IOJni

QisconnecEf
twonleadliwif
eUcon
1

nectars
from

cooling
unitqiq
s
iuo
UHf

INSPECTION

Evaporator

Check

evaporator
for

leakage
or

damage
If

damaged
replace

Expansion
valve

Check

expansion
valve
for

leakage

or

clogging
If

clogged
clean
filter
in

expansion
valve
If

damaged

replace

RECEIVER
DRYER

AND

PIPING

REMOVAL
AND

INSTAUATION

Receiver
dryer

I
Disconnect

battery
ground
cable

2

Discharge
system
Refer
to

Dis

charging
System
under
General
Service

section

3

Disconnect

compressor
lead
wire

at

connector

4

Disconnect

cooling
pipes
at

joints

Acno

Fig
AC
39

Diaconnecting
coo

ing

pipes

Notes

a

Plug
all

piping

joints
immediately

after

pipe
disconnection
to

prevent

entry
of
dust
or
moisture
laden
air

into

receiver

dryer
or
air
aJOdi

tioning
system

b
Use

two
wrenches
when
dIsconnect

ing
cooling
pipes

5

Remove
four
screws

securing

receiver

dryer
bracket

to
vehicle

body

and
detach

compressor
relay
and

pres

sure
switch
as
an

assembly

6
To

install
receiver

dryer
and

piping
reverse
the
order
of
removal
Air

Conditioning

Notes

a

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when
con

necting
cooling

pipes

b
Use
two
wrenches
when

connecting

cooling
pipes

c

Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Checking

System
under
General
Service

sec

tion

d
Check

refrigerant

leakage
if
neces

sary
repair

Refer
to

Evacuating
and

Charging

System
under

General
Service
See

tion

Condenser

Disconnect

battery

ground
cable

2

Discharge

system
Refer

to
Dis

charging
System
under
General

Service

section

3
Drain

engine
coolant

4

Remove
radiator

grille

5

Remove

radiator

shroud
and

radiator

On
automatic
transmission

models

disconnect
both

torque
converter
oil

hoses

Note

While

cooling
water
is
hot

take

precautions

against
scalding

6
Disconnect
two

pipes
from

con

denser
remove
two

screws

securing

condenser

Condenser

can
now
be

removed

AC485

Fig
AC

40

Removing
conden
er

Notes

a
Use

two
wrenches
when
disconnect

ing
pipe

joints

b

Plug
openings
immediately
after

disconnecting
pipes

7

To
install

reverse
the
order
of

removal

AC

29
Tightening
torque

Flare
nut
for

copper
tube

from

compressor

2
5
to
4
0

kg
m

i8
to
29
ft
Ib

Flare
nut

for

copper
tube

to
receiver

dryer

2
5

to
3
5

kg
m

i8
to
25
ft
lb

Notes

a
When

disconnecting
and

connecting

cooler

pipes
be
sure
to

use
two

wrenches

b

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when

con

necting
cooler

pipes

c

To

prevent

possibility
of

explosion

due
to

high

pressure
within

cooling

system
do

not
clean
condenser

with
steam

Always
use
cold
water

or

cold

compressed
air

d
Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Charging

System
under
General

Service
sec

tion

e
Check

refrigerant
leakage
if
neces

sary
repair
Refer
to

Checking
for

Leaks
under
General
Service

sec

tion

INSPECTION

RecelYer

dryer

Check
for

refrigerant
leakage
or

damage

Check
for

proper
connection
of

two

lead
wires

running
to

pressure

switch

If

any
component

part
is
found

damaged
replace
receiver

dryer
and

pressure
switch
as

an

assembly

Condenser

I

Check

inlet
and
outlet

pipe
joints

and

sealing
surfaces
for

damage
Re

place
parts
if

damaged
or

leaky

2

Clogged
condenser
fins
or

air

pas

sages
may
reduce

cooling
efficiency
of

condenser
Clean
these

areas
with

dry

compressed
air

Piping

Check

piping
for

leakage
If

leakage

occurs
at
connections

retighten

connecting
nuts

Replace
if

leakage

persists

Inspection

Check

continuiry
in
fan
switch

circuit
with
a
test
lamp
or

an
ohm

meter

I

011
I
2
3

ICD

Tt

tt

AC772

Fig
AC
45
Fan
switch

RESISTOR
FOR
FAN
SWITCH

Removal
and
Installation

I

Disconnect
battery

ground
cable

2
Remove

glove
box

3
Remove

cooling
unit
Refer
to

Removal
and
Installation
under

Cooling
Unit

4

Disconnect
resistor
lead
wires
at

connector

@

O
sn
I
3n

CD
00
@

AC492

Fig
AC

46
Resistor

for
fan
switch
Air

Conditioning

5

Remove
resistor

assembly
from

upper
side
of

cooling
unit

Resistor
is

inserted
into

case

6
To
install

res
istor
for
fan
switch

reverse
the

order
of
removaL

Inspection

Test

continuity
between
resistor

and
fuse

THERMO
SWITCH

Removal
and
installation

1
Disconnect

battery

ground
cable

2

Remove

glove
box

3
Remove

duct
from

cooling
unit

4

Disconnect
thermo
switch
control

cable
and
lead
wires

5

Remove
thermo
switch

Note

Capillary
lube
is
fitted
into

groove
in
cooler
unit

6
To

install
thermo
switch
reverse

the

order
of
removal

I

I

AC773

Fig
AC
47

Removing
thermo
switch

AC

32
Inspection

I

Fully
move
thermo
swirch
lever

to
COLD

2

Test

continuity
between

ter

minals
with
a
test

tamp
or

an
ohm

meter

Continuity
should
exist

3

Dip
capillary
tube
end

into
ice

water
Test
continuity
between
ter

minals

Continuity
should
not
exist

4

Replace
if
switch
is

found
dam

aged

F
I
C
D
SOLENOID
VALVE

Removal
and
installation

I

Disconnect
battery
ground
cable

2
Disconnect
lead
wires
and
vacu

um

tube

3

Remove
two
screws
securing
sole

noid

valve
and
remove
solenoid
valve

AC77
4

Fig
AC

48
Removing
F
l
C
D

solenoid
valve

4
To
install
solenoid
valve
reverse

the
order
of
removal

Inspection

1
Test

continuity
in
solenoid
valve

circuit
with

a
test

lamp
or
an
ohm

meter

2
Turn
both
fan
switch
and
thermo

switch
on

3
Run

engine
at
idle
and
check
to

be
sure
that
vacuum
is

present
in
line

between
solenoid
valve
and

diaphragm

GENERAL

DESCRI
PTION

Special
Tools

play
very
important

role
in

the
maintenance

of
vehicles

These
are

essential
to
the
safe

accu

rate
and

speedy
servicing

The

working
times
listed
in
the
col

umn
under
FLAT
RATE

TIME
in

FLAT
RATE
SCHEDULE
are
com

puted
based
on

the
use
of

Special

Tools

The
identification
code
of
mainte

nance
tools
is

made

up
of
2

alpha

betical
letters
and

8

digital
figures

The

heading
two
letters

roughly

classify
tools
or

equipment
as
fol

lows

STOOOOOOOO

KVOOOOOOOO
Special
Tool

Special
Tool

Recently
established

Engine
Overhauling

Machine

General

Gauge

Hand
Tool
EMOOOOOOOO

GGOOOOOOOO

HTOOOOOOOO

HOW
TO
READ

SPECIAL
TOOL
LIST

APPLIED
VEHICLE
OR
UNIT

In
this

column
word
All
is

given

for
tools

applicable
to
all
vehicle
mod

els
and
unit

types
treated
in

this
manu

al
for
tools

applicable
only
to

particu

lar
models
or
units

those
vehicle

models
or
unit

types
are
indicated

NEWLY
ADDED

X

put
in
this
column
shows

newly
added
tools
Service

Equipment

SERVICE
EQUIPMENT

CLASS

Indicated
in
this
column
are

classi

fication

ftg1ll
es
in

accordance
with

Classification
of

Speciai
Tool
REMARKS

As

regards

special
tools
which
are

also

applicable
to
models
other
than

those
dealt
ith
U

this
m
inual
this

coluITUl
names
those
other
models

CLASSIFICATION
OF
SPECIAL

TOOL

I

Inspection
and
minor

repairs

11
General

disassembly
and

assembly

Ill

Special
disassembly
and

assembly

A

Important

a
Exclusive
with

no
alternative

b

Parts
will
be

damaged
if

repaired

without

special
tool

c

Gauges

B

General

To
facilitate

servicing

I

Inspection
and
minor

repairs

a

Inspection
and
maintenance

b
Unit

replacement

c
Minor

unit

disassembly

SPECIAL
TOOL
SET

See

attached
tool
list

The
set
is

available
for
new

and

other
dealers
who

must

go
through

initial

preparation

SET
77
620NA

KV00102000

This
set
is

designed
for
the

chassis

and

body
of
the

620
models
without

regard
to
their
destination

SE
2
Classification

Important
General

2

3
4

5

6

11

General

disassembly
and

assembly

General

disassembly
such
as

engine

transmission
and

differential

111

Special
disassembly
and

assembly

a

Disassembly
of

exclusive

parts

such
as
automatic
transmission

and

electrical
accessories

b

Special
work
such

as

boring
and

welding

c

Work

very
rarely
required

SET
3N71B
KV0010l000

This
set
is

designed
for
use

on
the

3N71B
automatic

transmission
It
con

sists

of
the
same
service
tools
as
those

previously
available

separately

Service

Equipment

TOOL
LIST

ENGINE
TOOL

Tool
Number
Tool
Name

Newly
added
Class
Remarks

ST050
I

SODa

Engine
stand

assembly
5
FIO
B2iO
610
710

S30

tST05011000
Engine
stand

ST050
I

2000
Base

ST05260001

Engine
attachment
5
610
710

STlOl20000

Cylinder
head
bolt
wrench
2

610
710
S30

STl
0640001
Pivot

adjuster
I
610
710
S30

KVIOI039S0

Valve
guide
reamer
set
3
FiO

B210
610
710

S30

STl1081
000
Reamer
12
2
mffi
0
480
in

dia

J

STl1032000
Reamer
8
0
mffi

0
315
in
dia

STl1320000
Drift

STll650001
Valve
seat
cutter
set
2

610
710
S30

STl2070000
Valve
lifter
5

B210
610
710

S30

STl3030001
Piston

pin
press
stand
2
610
710

S30

STl53
10000
Crankshaft
rear

oil
seal
drift
2
610
710
S30

KVI01041S0
Crankshaft
main

bearing
cap
puller
2

610
710

S30

KVIOI04110
Crankshaft
main

bearing
puller

STl6512001

Adapter

STl6701001
Adapter

STl6610001
Pilot

bushing
puller
3
610
710
S30

STl7420001
Chain

stopper
2
610
710
S30

STl9320000
Oil
filter
wrench
FIO

B210
610
710

S30

STl9870000
Air

pump
test

gauge
FI0
B210
610
710

STl98
10000

Hexagonal
wrench
3
FIO
B2iO
610
710

STl9890000
Rotor

adapter
2

FIO
B210
610
710

STl9900000

Dummy
shaft
2
FIO
B210
610

710

STl99
10000

Bearing
drift
2
FIO
B210
610
710

STl9920000
Rotor
stand
2

FIO
B210
610
710

STl9930000

Bearing
adapter
2
FIO

B210
610
710

ST
I

9940000

Bearing
pressing
tool
3
FIO
B210
610
710

EM03470000
Piston

ring
compressor
2
FIO
B210
610
710

S30

SE
3