1979 DATSUN 210 checking oil

I

powder
and
oil

applied
sp
hingly
to

all

ring
gear
teeth

For
the
tooth

contact

pattern
see

paragraph
dealing
with
tooth
contact

pattern
adjustl1ll
nt

DISASSEMBLY

FINAL
DRIVE
ASSEMBLY

I
Put

match
marks

on
side

bearing

caps
and

carrier
and
remove
side

bearing
caps
and

take
out
differential

case

assembly

using
Slide
Hammer

HTI2400000

PD266

Fig
PD

5

Removing

Diffe
ntial

Ca
e

A
embly

Note
Care
should
be
taken

not
to

confWle
the

left
end

right
hand

bearing
caps
and

bearing
outer

races

so
that

reassembly
will
be

easily

carried
out
with
the
same

parts
in

the

original
position

2

Rel
love
drive

pinion
nut

using

Drive
Pinion

Flange
Wrench

ST31530000
and

pull
off

companion

flange
using
a
standard

puller

Fig
PD

6
Removing
Drive
Pinion

Nut

3
Extract
drive

pinion
assembly
to

the
rearwards

by

tapping
the

front
end
Propeller
Shaft
Differential
Carrier

of

drive

pinion
with
a
soft
baminet

Drive

pinion
can
be
taken
out

together

with
rear

bearing
inner

race

collapsi

ble

spacer
and
washer

4

Remove
oil
seal
and
take
out

front

bearing
inner

race

Note

Oil
seal

must
not
be
reused

5

Hold
rear

bearing
inner

race
with

Drive

Pinion
Rear

Bearing
Inner
Race

Puller
ST30031000
and
extract
from

drive

pinion
with

a

press

STJ0031000

r

1

i
9

PD205

Fig
PD
7

Removing
Pinion

Rear

Bearing
I
nfUr
Race

6

To
remove
outer
races

of
both

front

and
rear

bearings
apply
a
brass

drift
to

race
side
surface
and

with

draw

them

by
tapping
the

top
of

drift

with

a
hammer

PD268

Fig
PD

B
Removing
Pinion
Front

and
Rear

Bearing
Outer
Race

DIFFERENTIAL
CASE

I

When

replacing
side

Wle
Differenliai

Side

Puller
ST3305
1001

and

ST33052000
bearing

Bearing

Adapter

PD
4
Fig
PD
9
Removing
Side

Bearing

Note

a

Puller
should
be
bandlOd
with
care

in

catching
the

edge
of

bearing

inner
race

b
Be
careful
not
to
confuse
left
and

right
band

parts

2

Rel
love
ring
gear
by
sp
readJ
lg

out
lock

straps
and

loosening

ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate
shaft
lock

pin
from

ring
gear
side

using
Solid

Punch
KV3810Ig00

KV3810I800

PD319

Fig
PD
I0
Removing
Lock
Pin

Note
Lock

pin
is
slaked
et

pin
hole

mouth
on
differential

case
Do
not

punch
it
off

forcibly
without

checking
how
it
is

staked

4

Draw
out

pinion
mate
shaft
and

remove

pinion
ID3
tes
side

gears
and

thrust
washers

Note

Put
mams
on

gear
end
thrust

waaher
so
that

they
can
be
re

installed
in
their

origiital
positions

from
which

they
were
removed

INSPECTION

Thoroughly
clean
all
disassembled

parts
and

examine
them
to
see

that

Front
Axle
Front

Suspension

Condition

Instability
of
car

Stiff

steering
wheel

Checking
up
procedure

Jack

up
front
wheels
detach
the

steering

gear
arm

and

operate
the

steering
wheel

and

If
it
is

light
check

steering
linkage
and

suspension
parts

If
it
is

heavy
check

steering
gear
and

steering
column

parts

Excessive

steering
wheel

play

Noises
Probable

cause

Improper
tire

pressure

Worn
rubber

bushings
for
transverse
link
and

tension
rod

Incorrect
wheel

alignment

Worn

or
deformed

steering
linkage
and

suspension
link

Incorrect

adjustment
of

steering
gear

Deformed
or

unbala
1ced
wheel

Improper
tire

pressure

Insufficient
lubricants
or

mixing
impurities

in

steering
gear
box
or

excessively
worn

steering
linkage

Stiff
or
damaged

suspension
ban

joint
or

lack
of

grease

Worn

or

incorrectly
adjusted
wheel

bearing

Worn
or

damaged
steering
gear
and

bearing

Incorrectly
adjusted
steering
gear

Deformed

steering
linkage

Incorrect
wheel

alignment

Damaged
strut

mounting
bearing

Damaged
or
stiff

piston
or
shock
absorber

piston
rod

in
the
strut

Interference
of

steering
column
with

turn

signal
switch

Incorrectly
adjusted
steering
gear
housing

Worn

steering
linkage

Improperly
fitted

gear
housing

Incorrectly

adjusted
wheel

bearing

Worn
transverse
link

and
tension
rod

bushings

Improper
tire

pressure

Insufficient

lubricating
oil
and

grease
for

suspension
ball

joint
and

steering
linkage
or

their

breakage

Loose

steering
gear
bolts
linkage
and
sus

pension
parts

Faulty
shock
absorber

inside
the
strut

Faulty
wheel

bearing

Worn

steering

linkage
and

steering
gear

Worn
transverse
link
and
tension
rod

bushings

Broken

or

collapsed
coil

spring

FA
17
Corrective
action

Adjust

Replace

Adjust

Replace

Adjust

Correct
or

replace

Adjust

Replenish
grease
or

replace
the

part

Replace

Replace
or

adjust

Repalce

Adjust

Replace

Adjust

Replace

Replace

Adjust

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish
lubri

cating
oil
and

grease

or

replace

Retighten

Replace

Replace

Replace

Replace

Replace

BRAKE

BOOSTE
R

INSPECTION
OF

OPERATION

Checking
vecuum

pressure

I

Connect
a

vacuum

gauge
in
the

tine
between
check
velve

and
brake

booster

1
Check
valVe

2

Vacuum
gauge

BA942

Fig
BR
26
Air

Tighte
Te
Set

Up

Probable
cause

Air

leakage
at

check
valve

2
Air

leakage
at

push
rod

seal

3
Air

leakage
between
valve

body
and

seal

4
Air

leakage
at
valve

plunger
seat

5

Damaged
piping
or

joints

Air

tight
test
Under
loed

Fifteen

seconds
after

engine
is

stopped
and

brake

fully

applied
ob

serve
the
rate

of

drop
in
air

pressure

registered
by
vacuum

gauge
If

vacuum

Probable
cause

Air

leakage
at
check
valve

2

Damaged
diaphragm

3
Reaction

disc

dropped
off

4

Air

leakage
at

poppet
assembly
seat

and
valve

body

Inspec
tinK
chec
k
valve

Remove

clip
and
disconnect
hoses
Brake

System

2
Start

engine
end
merease

engine

speed
Stop

engine
when

vacuum

gauge
indicates
500

mmHg
l9
69

inHg

Air

tiKht
test

No
load

Fifteen
seconds
after

engine
is

stopped
observe
the
rate

of

drop
in
air

pressure
registered
by
vacuum

gauge

If
vacuum

pressure
drop
below
the

specified
value
refer
to

the

following

chart
to
determine
the

cause
of

failure

Maximum
vacuum

leakage

25

mmHg
0
98

inHgl

Corrective
action

Replace
check
valve

Replace
brake
booster
as
an

assembly

Repair
or

replace

pressure
drops
below
the

specified

value
refer
to
the

following
chart

to
determine
the
cause
of
failure

Maximum

vacuum

leakage

25
mmHg
0
98

inHgl

Corrective
action

Replace
check
valve

Replace
brake
booster
as
an

assembly

at
connections
The
check
valve
can

now
be
removed

BR
12
JQeL

i
l
f

BR119A

Fis
BR
27
Location

of
Check
Valllt

2

Using
a
brake

booster
testel

apply
a
vacuum

pressure
of
500

mmHg

19
69

inHg
to
the

port
of
check

valve
on
the
brake
booster
side
If

vacuum

pressure
drops
below
the

specified
value
in
15

seconds

replace

check
valve
with
a
new
one

Maximum

vacuum

leakage

01
eheck
valn

10

mmHg
0
39

inHgl

3
When

pressure
is

applied
to
the

b

rake
booster
side
of
check
valve
and

valve
does
not

open
replace
check

valve
with
a

new
one

I

0

tLLiJ

Manifold
side
Brake
booster
side

1

Spring

2

Valve
BR963

Fig
BR
28

Check
Value

4
When

installing
check

valve
be

careful
to
avoid

incorrect
connectiolU

See

Fig
DR
28

Operetlns
test

1
Connect

an
oil

pressure
gauge
to

brake

ine
at
connection

on
master

cylinder

2
Install

a

pedal
force

gauge
on

brake

pedal

3
Start

engine
end

increase

engine

speed
until
a
vacuum

pressure
of

500

mmHg

19
69

inHg
is

registered
on

vacuum

pressure
gauge
With

a

steady

vacuum

pressure
of
500

mmHg
19
69

inHg
measure
oil

pressure
with
res

pect
to
each

pedal

operating
force

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

COMPRESSOR

OIL
LEVEL
CHECK

The
oil
used
to
lubricate

compres

sor
circulates
into

system
from
the
oil

sump
while

compressor
is

operating

Therefore
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

facio

litates
to

return
oil
to

compressor

1

Operate
compressor
at

engine

idling
speed
I
OOO

rpm
or
below

with

controls
set
for

maximum

cooling

and

high
blower

speed
for
10
to
15

minutes
in
order

to
return
com

pressor

oil
to

compressor

2

Stop
the

engine
and

discharge

refrigerant
of

system
and
then

remove

compressor
from
the

car

3

Remove

compressor
filler

plug

Drain

compressor
oil
from

compres

sor
oil

sump
and
measure
the
amount

AC742

Fig
AC
23
Filler
Plug

4

Compressor
oil
is

satisfactory
if

the

following
amount
of
oil
remains
in

the

compressor

Residual
oil

140
to
220
cc

4
7

to
7
4
US
fl
oz

4
9
to
7
7

Imp
fl
oz
Air

Conditioning

5
Check
the

cleanliness
of
the

oil
If

the
oil
contains

chips
or
other

foreign

material
clean

oil

sump
with
new
oil

6
Discard
the
used
oil
and
fill
with

the
same

amount
of

new
oil
Add

oil
if

found
less

than
above
amount

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

com

pleted
recheck

oil
level
drain
oil

to

correct
level

if
level
is

excessively
high

CAUTION

a
The
oil
should
not
be
transfused

from
a
container
into
another
as

the
failure
will

possibly
cause

moisture
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

PERFORMANCE
TEST

The

cooling

per
ormance
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

guiqe

in

checking
for

problems

1
Park
the

car
indoors
or
in
the

shade

2

Open
all
the
windows

of
the
car

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

Gauge

5

Set
air
lever
to

AIC

position

6
Set

temperature
lever
to
maxi

mum
cold

position

7

Set
blower
to
its

highest

speed

8
Start
the

engine
and
hold

engine

speed
at
1
500

rpm

9
After
the
air
conditioner
has
been

operated
for
about
10
minutes
meas

ure

system
pressures
at

high
pressure

discharge
side
and
low

pressure
suc

tion

side

10
Measure
the

temperature
of
dis

AC
17
charge
air
at
the

center
outlet

grille

11
Measure

the

temperature
and

humidity
of
the

evaporator
in
take
air

at

the

recirculating
air
inlet

of
the

evaporator

12
Measure
the

temperature
and

humidity
of
the
ambient
air
at
a

point

I
m
3
3
ft

front
of

condenser

However
a

dry
bulb

and
wet
bulb

must
not
be

placed
in

direct
sunlight

13

Check
for

any
abnormalities
by

comparing
the
test
results

with
stand

ard

pressure
Refer
to

Performance

Chart

Note

a

The

pressure
will

change
in
the

following
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
Refer
to
Trouble

Diagnoses
and
Corrections

REFRIGERANT

LEAKS

If
leaks
are

noticeable
leaky
parts

should
be

repaired
Then
system

should

be
fIlled
with

refrigerant

CAUTION

00

not

operate
compressor
with

refrigerant
level

excessively
low

If
this
caution
is

neglected
a
burnt

compressor
will
result
since

heavy
loss

of

refrigerant
usually
indicates

heavy

loss
of

compressor
liil

I

f

system
has
been

exposed
to

atmosphere
for

an
extended

period
of

time

I
receiver

drier
must
be

replaced

If
leaks
are

slight
and

no
air
is

present

in

system
add

refrigerant
as

necessary

To
detect
leaks

refer
to

Checking

AC867

Fig
AC
53

Removing
Shaft
Seal

INSTALLATION

1
Clean
shaft

and
seal

cavity
with

clean
lint
free
cloth

2

Dip
seal

gland
in
clean

refrigerant

oil

3
Push
seal

assembly
except
carbon

ring
over
end

of
shaft
with

carbon

ring
retainer

facing
out

4
Move

seal

assembly
into

position

on
shaft

ACB68

Fig
AC

54

1merting
Shaft
Seal

Assembly

5
Place
carbon

ring
in

ring
reta
iner

so

lapped
surface
is

facing
outward

Note
The
indentions
in
outside

edge

of
carbon

ring
must

engage
driving

lugs
and
be

rmnly
seated

in
re

tainer

6
Install
new
Q

ring
in

groove
of

seal

plate

Note
Use

refrigeration
oil
to

make
it

adhere
to

surface
Air

Conditioning

7

Space
seal

plate
with

equal
clear

ance
around
shaft
and
insert

cap

screws

Tighten
these
screws

evenly

IiJ
Tightening
torque

Seal

plate
securing

cap
screws

0
7
to
1
0

kg
m

5
1
to
7
2
ft
Ibl

AC869

Fig
AC

55
Spacing
Seal
Plate
and

Tightening
Cap
Screws

8
Install
clutch
Refer
to

Compres

sor
Clutch
for
installation

9

Charge
lubricant

To

Low

pressure

service
valve
10
Install
oil
filler

plug
together

with
O

ring

CAUTION

Use
new
O

ring
when

installing
oil

filler

plug

INSPECTION

Check
for

gas
leakage
as
follows

I

Plug
high
and
low

pressure
joints

on

compressor
with
blind

caps

2

Connect

charging
hoses
in
lines

between
manifold

gauge
and

high
and

low

pressure
service
valves

Connect

refrigerant
can
to
middle

hose
of
manifold

gauge

3

Open
valve

of
can

tap
and

charge

refrigerant
Loosen
oil
filler

plug
at

side
of

compressor
to

purge
air
out
of

compressor

4
Turn

shaft
5
or
6
turns
Then

confIrm
that

pressure
does
not

decrease
on
low

pressure
gauge
If

gauge
indicates
a

pressure
decrease

there
is

a
leak
Conduct
a
leak
test

Under
such
a
condition
remove
and

then
install

parts
again

To

High
pressure

service
valve

Low

r

fi

IZl

AC
29
High

AC183A

Fig
AC
56

Checking
for
Gas

Leakage