ECU DATSUN 210 1979 Service Manual

REFRIGERANT
LINES
Air

Conditioning

@

I

J

L

S

r
Z
S
t

@

See

Fig
AC
29
When

replacing

flexible
hose
and
tube
observe
the

following

1

Before

starting
work
be

sure
to

discharge
system

2

When

disconnecting
tubes
be

sure
to

use
two

wrenches
on
both

tubes

3

After
discon

ecting
tubes

plug

all

openings
immediately
to

prevent

entrance
of
dirt
and
moisture

4

Compressed
air
must
never
be

used
to
clean

dirty
line
Clean
with

refrigerant

gas

5
In

connecting
tubes
be
sure
to

apply
compressor
oil
to

seating
surface

and
then

tighten
tubes
to

specified

tightening
torque
See

Fig
AC
30

Be

sure
to
use
two
wrenches
when

tightening
a
flare

nut
of
tube

Coat
seat
surfaces
with
com

pressor
oil
and
then

tighten

AC263

Fig
AC

30
Line
Connection
CD

6
Make
sure

refrigerant
line
is

clamped
securely
Start

engine
and

raise

engine
speed
to

inspect
if
there
is

vibration
or
unusual
noise

7

Conduct
leak
t
st
and
make
su
e

that
there
is
no
leak

from
connections

8
Refer
to

General
Service
for

evacuating
and

charging
system

COOLING
UNIT

REMOVAL

I

Disconnect

battery
ground
cable

2

Discharge

refrigerant
from

sys

tern
Refer
to
General
Service

3
Loosen

flare
nuts
at
each
con

nection
of
inlet

and
outlet

pipes
of

evaporator

AC
21
1

High
pressure
discharge
service

valve

2
Low

pressure
suction
service
valve

3

Compressor

4

Condenser

5
Receiver

drier

6

Cooling
unit

7

Low

pressure
switch

lightening
torque

kg
m
ft
lb

@
4

5
to

5
0
33
to
36

@
3
0
to
3
5
22
to
25

AC385A

Fig
AC
29

Refrigerant
Lines

CAUTION

Immediatelv
plug
up
all

openings

to

prevent
entrance
of

dirt
and

moisture

4
Remove
instrument
under

cover

5
Remove

glove
box

6
Disconnect

wiring
harness

con

nectors
from

compressor
relay
and

thermostat

7
Remove

upper
and
lower

attach

ing
bolts
and

remove

cooling
unit

AC386A

Fig
AC
31
Removing
Cooling
Unit

LOW
PRESSURE

SWITCH

REMOVAL

AND

INSTALLATION

I
Disconnect

battery
ground
cable

2

Discharge

refrigerant
from

sys

tem

Refer
to

General
Service

3
Disconnect

connector
to
low

pressure
switch

4
Remove
low

pressure
switch

by

turning
the
switch

5

Installation
is
in
the
reverse

order

of

removal

INSPECTION

Using
a
circuit

tester
make
sure

that
low

pressure
switch
exhibits
con

tinuity
when

gas
pressure
of

refriger

ant
in

system
is
normal
and
that
low

pressure
switch

does
not
exhibit
con

tinuity
when

gas
pressure

drops
below

2
2

kg
cm2

31

p
i

MAGNET

VALVE

REMOVAL
AND

INSTALLATION

I
Disconnect

battery
ground
cable

2
Disconnect

magnet
valve
lead

wires
and

vacuum
hoses

3

Remove

magnet
valve

securing

screws
and
then
remove

magnet

valve

i

i

WrE

AC389A

Fig
AC

36

Removjng
Magnet
Valve

4

Installation
is
in

the

reverse
order

of
removal

INSPECTION

I
rest

continuity
with

ohmmeter

2

Apply
D

C
12
volts
across
termi
Air

Conditioning

031

under
this
state

orally
blow

through
one
vacuum

port
to
ensure

that
there

is
air
flow
at

the
other

FUSE
REPLACEMENT

REPLACEMENT

A

20

ampere
in

line
fuse
is

part
of

air

conditioner
harness
located
behind

glove
box
J
Disconnect

batiery

ground
cable

2

Remove
instrument

under
cover

3

Remove

glove
box

4
Take
out
fuse

holder
from
air

conditioner
harness
and

replace
fuse

with
a
new
one

CAUTION

If

fuse
is

blown
be
sure

to
climi

nate
the

cause
befure

installing
new

fuse
in

position

r

AC276A

Fig
AC
37

Fu
e

Replacement

VACUUM
HOSE
DIAGRAM

u

CJ

Magnet

valve

Al

1

From
intake

manifold

AC
24
Fast
idle

actuator
Check

valve

Vacuum

switch
Intake

actuator

I

0

0

2

S

1l

AC27BA

Fig
AC
38
Vacuum
Hose

Diagram

PRELIMINARY

CLEANING

Before

starting
work
remove
dirt

from
outside

the
detached

compressor

Clean
the

workbench
tool
and

your

hands

COMPRESSOR

CLUTCH

The

most

likely
source
of

problem

is
clutch

slippage
Factors
are

listed

here
Exercise

ample
care

1

Clearance
between
clutch

hub

and

pulley
should
be
0
4
to
0
6

mm

0
016
to
0
024
in
at
aU

peripheral

points

2

Make
sure
that
there
is
no
oil

or

dirt
on
friction
surfaces
of
clutch
disc

clutch
hub
and

pulley
Remove
oil
or

dirt
with
clean
lint
free
cloth

3
Make

sure
that
terminal

voltage
at

magnetic
coil
is

above
10
5V

REMOVAL

I

Using
Clutch

Spanner
Wrench

hold
clutch
hub
With
suitable

socket

wrench
remove
bolt

retaining
clutch

hub

to
crankshaft

AC391A

Fig
AC
41

Removing
Bolt

2
Then

using
Clutch

Removing

Bolt
remove
clutch

assembly
from

crankshaft

CAUTION

Be
careful
not
to

demage
key
on

compressor
crankshaft
Air

Conditioning

AC392A

Fig
AC

42

Removing
Clutch

Assembly

3
Loosen
four

electromagnetic
coil

mounting
screws
Coil

assembly
can

then
be
taken
out

easily

AC869

Fig
AC
43
R

mouing
Magnetic

Clutch

INSTALLATION

Locate
the

electromagnetic
coil
at

the
correct

position
on

compressor

housing
Then
secure
four

electro

magnetic
coil

mounting
screws

@

Tightening
torque

Electromagnetic
coil

mounting

screws

0
7

kltm
5
1
ft
Ibl

2
InstaU
the
clutch

assembly
on
the

crankshaft

Note

Key
should
be
set
on

crank

shaft
before

installing
clutch

assem

bly

3

Using
Clutch

Spanner
Wrench

hold
clutch
hub
With
socket

wrench

secure
clutch
hub

securing
bolt

iJJ

Tightening
torque

Clutch

hub

securing
bolt

1
5

kg
m
11
ft
Ib

AC
27
DISASSEMBLY

1

Remove
two

snap
rings
retaining

bearing
They
are
located

inside
of

clutch
wheel

I

AC500

Fig
AC
44

Removing
Snap
Ring

2

Using
Clutch
Wheel
Remover

KV99100700
and
conventional

puller

remove
V

pulley
with

bearings
from

clutch
wheel

KV99100100

AC501

Fig
AC

45

Removing
V

Pulley

from
Clutch

Assembly

3

Us
i
n

g
Bearing
Remover

ST33061000

press
clutch
wheel
bear

ings
out

from
clutch
wheel

ST33061000

I

Jiffi
I

ACSD2

Fig
AC
46

Removing
Clutch

Wheel

Bearing

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

r

CYLINDER
HEAD

AND
VALVE

PLATE

Insufficient

refrigerant
v

p
sion

is

likely
to
be
caused

by
damaged
head

gasket
or

damaged
valves

Prior

to

servicing
the

head
and
valve

plate
both
service

valves
should
be

opened
to
free

any
gas
pressure
which

may
be
in
the

compressor

REMOVAL

I

Remove
cylinder
head

securing

bolts

Fig
AC

57
Removing
Cylinder
Head

2
Remove
valve

plate
and
head

from

cylinder
by

prying
or

tapping

under
the
ears
which

extend
from

valve

plate

If

head
and
valve

plate
adhere
hold

head
and

tap
valve

plate
ears

away

from
head

with
a
soft
hammer

CAUTION

00

not
hit
or

llIp
head
to

separate

head
and
valve

plate
because

damage

to
head

may
result

AC871

Fig
AC
58

Removing
Volve
Plate

and
Head

3
When

removing
the

gaskets
use
a

sharp
edged
knife
Air

Conditioning

CAUTION

a
In

removing
head

gasket
be

very

careful
not

to

damage
machined

sealing
surface

b
00
not
reuse

gaskets

AC815

Fig
AC
59

Removing
Gasket

INSTALLATION

Valves
and
valve

plates
are
furnish

ed

only
as
a

complete
assembly

8

AC872

Fig
AC

60
Valve
Plate

Assembly

I

Apply
a
thin
mm
of
clean
refri

geration
oil
on
area
of
crankcase
to
be

covered

by
cylinder
gasket

Fig
AC
61

Applying
Clean

Refrigeration
Oil

AC
30
2

Place

cylinder

gasket
in

position

on

cylinder
so
dowel

pins
in

crankcase

go

through
dowel

pin
holes
in

cylinder

gasket

3

Apply
a
thin
flim
of
clean
refri

geralion
oil
to

top
and
bottom
valve

plate
areas
to
be
covered

by
gaskets

4

Place
valve

plate
in

position
on

cylinder
gasket
so

discharge
valve
as

semblies

I
e

smaller
diameter
assem

blies
with

restrainer
over
valve
reed

are

facing
up
and

locating
dowel

pins

go
through
dowel

pin
holes

in
valve

plate

AC817

Fig
AC
62

Placing
Valve
Plate

5
Place
head

gasket
in

position
on

valve

plate
so
dowel

pins
go
through

dowel

pin
holes
in

gasket

6

Apply
a
thin
mm
of
clean
refri

geration
oil
on
the

machined
surface

of

cylinder
head
which
matches
head

gasket

7

Place
head
on

cylinder
head

gas

ket
so
dowel

pins

go
into

dowel

pin

holes
in
head

8

Tighten
screws
to

specified
limit

iil

Tightening
torque

Cvlinder
head
screws

2
1
to
3
2

kg
m

15
to
23
ft
Ibl

DISCHARGE
AND

SUCTION

CONNECTORS

Discharge
and
suction
connectors

are
located

on
rear
side
of

compressor

REMOVAL

1
Remove
each
screw

securing
dis

charge
and
suction
connectors

using

TOD
Driver
Bit

2
Pull
out
each

discharge
and

suc

tion
connector

Note
Memorize
mounted
direction
of

discharge
and
suction
connectors
to

ensure
correct

reassembling

a@

AC873

Fig
AC
63

Removing
Discharge
and

Suction
Connectors
Air
Conditioning

INSTALLATION

I

Attach
new
O

ring
to
each

cy

lindrical

portion
of

discharge
and
suc

tion
valves

Note

Apply
clean
lubricant
to
O

ring

so

that
it
can
be

fitted

tightly
to

cylindrical
portion
and

crankcase

hole

AC
31
2
Insert
each

discharge
and

suction

valves
into

correct
valve

port
in

crank

case

by
matching
it

with
mark
on

cylinder
head

3

Set
each
valve
in

the
same

posi

tion

as
it
was
before

removal
and

tighten
screws
with

specified
torque

cD

Tightening
torque

Discharge
and
suction

connectors

2
1
to
3

2

kg
m

15

to
23
ft
b

Air

Conditioning

TIGHTENING

TORQUE

Compressor
bracket
to

cylinder
block
kg
m
ft

lb

3
7
to
5
1

27
to

37

37
to
5
1
27
to

37
Compressor
to

compressor
bracket

Refrigerant
line
connection

3

8
in
diameter
tube

1
2
in

diameter
tube
3
0
to
3

5
22
to
25

4

5
to
5

0
33

to
36

Compre
or

Electromagnetic
coil
kg
m
ft

lb

2
1
to
3
2

15
to

23

0
7

to
1
0

5
1
to
7

2

1
5

11

0
7
5
1
Cylinder
head

and
connector

Seal

plate
securing
cap

Clutch
hub

AC
43

olIIl