charging DATSUN 210 1979 Owner's Manual

Air

Conditioning

6
Loosen
the
connection

at
the

center

fitting
of

manifold

gauge
for
a

Clockwise
few
seconds
to

purge
air
inside

charg

ing
hose
See

Fig
AC
14

Counterclockwise

j

3

@

I

Can
tap
handle

2

ChlcginS
hose

3
Needle

4

Refrigerant
can

AC246

Fig
AC
13
Can

Top

Purging
air

R

12

To

L9w
pressure

service
valve
AC247

Fig
AC
14

Purging
Air

Ta

High
pressure

service
valve

f

r

AC181A

Fig
AC
15

Discharging
System

AC
ll
DISCHARGING
SYSTEM

The

pressurized
refrigerant

gas
in

side

system
must
be

discharged
to
a

pressure
approaching
atmospheric

pressure
prior
to

evacuating
refrigerant

inside

system
This

operation
should

be
also
made
to

pennit
safe
removal

when

replacing

system
components

A
Close

high
and
low

pressure

valves

of
manifold

gauge
fully

2

Connect
two

charging
hoses
of

manifold

gauge
to

their

respective

service
valves

WARNING

Securely
connect

high
pressure
dis

charge
service
valve
to
that
of

manifold

gauge
with
a
hose
also

connect
low

pressure
suction
serv

ice
valve
to
that
of
manifold

gauge

For

locations
of

high
and
low

pres

sure

discharge
and
suction
service

valves
see

Fig
AC
29

3

Open
both
manifold

gauge
valves

slightly
and

slowly
discharge
refriger

ant
from

system
See

Fig
AC
15

WARNING

Protect

fingers
with
cloth

against

frostbite

by
refrigerant
when
con

necting
the

charging
hose

to
the

service

valve
or

disconnecting
it

therefrom

Nole
Do

not
allow

refrigerant
to
rush

out
Otherwise

compressor
oil
will

be

discharged
along
with

refriger

ant

EVACUATING

SYSTEM

I

Connect

high
and
low

pressure

charging
hoses
of
manifold

gauge
to

their

respective
service
valves

of

sys

tem
and

discharge
refrigerant
from

system
Refer
to

Discharging
System

WARNING

Securely
connect

high
pressure
dis

charge
service
valve
to
that
of

manifold

gauge
with
a
hose
also

connect
low

pressure
suction

servo

ice

valve
to
that
of
manifold

gauge

For

locations
of

high
and

low

pres

sure

discharge
and
wction
service

valves

see

Fig
AC
29

Air

COl
ditioning

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
ftom

system
See

Fig
AC
16

5
When
low

pressure
gauge
reading

has

reached
to

approximately
500

nunHg
20

inHg
slowly

open
high

pressure
valve

First

step

To
Low

pressure

service
valve
To

High
pressure

service
valve

rtl

Second

step

To

Low

pressure

service
valve
To

High
pressure

service
valve

f

AC182A

Fig
AC
16

Evacuating
System
First

and
Second

Steps

AC

12
6
When

pressure
insill

system
h
as

dropped
to
710

mmHg
28

inHg

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

Note

a
The
low

pressure

gauge
reads
lower

by
25

mmHg
I

inHg
per
a

300
m

1

000
ft

elevation
Perfonn

evacu

alion

according
to
the

following

table

Elevation

m
ft

0
0

300

1
000

600
2
000

900
3
000
Vacuum
of

system

nunHg
inHg

710
28

685
27

660
26

635
25

Note

Values
show

reading
of
the

low
pressure
gauge

b
The
rate
of
ascension
of
the
low

pressure
gauge
should
be
less
than

25

mmHg
I

inHg
in
five

min

utes

If
the

pressure
rises
or
the

specified

negative

pressure
can

not
be
obtained

lhere
is
a

leak
in

the

system
In

this

case

immediately
charge
system
with

refrigerant
and

repair
the
leak

de

scribed
in

the

following

J
Charge
system
with
a
can
of

refrigerant
about
0
4

kg
0
9Ib
Re

fer
to

Charging
Refrigerant

2
Check
for

refrigerant

leakige

with
a
leak
detector

Repair
any
leak

ages
found
Refer
to

Checking
for

Leaks

3

Discharge
refrigerant
again
and

then
evacuate

system

CHARGING
REFRIGERANT

I
Install
manifold

gauge
to

system

Refer
to

Handling
Manifold

Gauge

WARNING

Securely
connect

high
pressure
dis

charge
service
valve
to
that
of

manifold

gauge
with
a
hose
also

connect
low

pressure
suction
serv

ice
valve
to
that
of
manifold

gauge

For
locations
of

high
and
low

pres

sure

discharge
and
suction
service

valves

see

Fig
AC
29

CAUTION

a
Be
sure
to

purge
air
from
the

high

and
low

pressure
charging
hoses

b
If
air
is
mixed
with

refrigerant
gas

in

system
evacuation
of

system

should
be

performed
Refer
to

Evacuating
System

2
Attach

center

charging
hose

of

manifold

gauge
to

refrigerant
can

through
can

tap
Break
seal
of

refriger

ant
can
to

allow

refrigerant
to
enter

manifold

gauge
Loo

en

charging
hose

at
the
center

fitting
of
manifold

gauge

and

purge
air
from
inside

charging

hose
Refer
to

Handling
Can

Tap

3

Open
high
and
low

pressure

valves
of
manifold

gauge
and

charge

refrigerant
into

system
See

Fig

AC
17

Note
When

refrigerant
charging
speed

is

slow
immerse

refrigerant
can
in

water
heated

to
a

temperature
of

about
400C
1
040

F
for

a
short

time

See

Fig
AC
18

WARNING

a
Under

any
circumstances
the

re

frigerant
can
must
not
be
warm

ed
in

water
heated
to
a

temper

ature
of

over
520C
1260F

b

A
blow
toreh
or
stove
must

never
be
used

to
warm

up
the

can
Air

Conditioning

To
Low

pressure

service
valve

t

R
12
t

@
I
J
To

High
pressure

service
valve

t

t

AC183A

Fig
AC
17

Charging
Refrigerant

p
CAUTION

When

charging
liquefied
refrigerant

into
the

system
with
the
can
turned

upside
down
to
reduce

charging
time

charge
it

only
through
high
pressure

discharge
service
valve
but
not

through
low

pressure
suction
service

valve
See

Fig
AC
19
After

comple

tion
of

charging
the

compressor

should

always
be
turned
several
times

manually
lmmene
in
water

heated
to
about

400C
1040F

for
a

hort
time

AC184A

Fig
AC
18
Charging
Refrigerant

To
Low

pressure

service

valve
To

High
pressure

service
valve

t

r

J

AC
13
Low

t

AC185A

Fig
AC
19

Chorging
Liquefied
Refrigerant

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

I

I

3
Set

temperature
lever
to
max

imum

cold

position
Air

Conditioning

4

Sefblower
to
maximum

speed

S

Check

sight
glass
after

the

lapse

Almost
no

refrigerant

Check
item

Temperature
of

high
prenure

and
low

pressure
lines
Almost
no
difference

between

high
presswc

and

lowpressufC
side

temperature

State
in

sight
gl
ltS3
Bubbles
flow
continu

ously
Bubbles
will

disappear
and
some

thing
like

mist
wiD

flow
when

rerrigel
l
llt

is

nearly

gone

AC256

Pressure
of

system
High
pressure
side
is

abnormally
low

Repair
Stop
compressor
and

conduct
an

overall

check

Note

a
The
bubbles
seen

tbrough
the

sight

glass
are
influenced

by
the
ambient

tempemture
Since
the
bubbles
are

bard
to
show

up
in

comparatively

low

tempemtures
below
200C
680

F
it
is

possible
that
a

slightly

larger
amouot
of

refrigemot
would

be
filled
if

supplied
according
to

tbe

sight
glass
Be

sure
to
recheck

the
amount
when
it

exceedS
20
C

680F
In

higher
tempemture
tbe

bubbles
are

easy
to
show

up
Insufficient

High
pressure
side
is

warm
and

low

pressure

side
is

fairly
cokt

The
bubbles
are
seen

at
intervals
of
1
2

seconds

AC257

Both

pressures
on

high

and
low

pressure
sides

are

slightly
low

Check
for
gas

leakage

repair
as

required
re

plenish
and

chaxge

system

b
Wben
the
screen
in
tbe
receiver

drier
is

clogged
tbe
bubbles
wiD

appear
even
if
the
amount
of

refrig

erant
is

nonnaL
In
this
case
tbe

outlet
side

pipe
of
tbe
receiver
drier

becomes

considembly
cold

AC
16
of

abOut
five
rilintJtes

Jullgeaccording

to
the

following
table

Suitable
Too
much

refrigerant

High
pressure
side
is

hot
and
low

pressure

side

is
cold
High
pressure
side
is

abnormally
hot

Almost
transparent

Bubbles

may
appear

when

engine
speed
is

raised
and
lowered
No
bubbles
can
be
seen

No
clear
difference
exists
these
two

conditions

nl

AC258

Both

pre55ures
on

high

and
low

pressure
sides

are

normal
Both

pressures
on

high

and
low

pressure
sides

are

abnonnally
high

Discharge
refrigerant

from
service
valve
of

low

pressure
side

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
i
within
the

specified

range
For
details
refer
to
Trouble

Diagnoses
and
Corrections
for

per

fannance
test

Overcharging
will
show

up
in

higher

presstJre
on

discharge
side

Air

Conditioning

IDLER
PULLEY
AND

COMPRESSOR
DRIVE
BELT

ADJ
USTMENT
OF
BELT
TENSION

Idler

pulley

Alternator

Crankshaft

pulley

Unit

mm
in

Idler

pulley

Fig
AC
25

Belt
Tension

Specified
compressor
belt

tension
is

8

to
12
mm
0
31
to
0
47

in
when

thumb

pressure
of
10

kg
22

Ib
is

applied
midway
between
idler

pulley

and

compressor
pulley

1
Loosen

idler

pulley
lock

nut
and

then

adjust
pulley
by
turning
adjusting

bolt

2

After

adjustment
tighten
idler

pulley
lock
nut
bolt

3
Remove
idler

pulley

4
Install

pulley
in
the

reverse

order
of
removal

5

Adjust
compressor
belt
tension

REMOVAL
AND

INSTALLATION

1

Jack

up
front

of
car
and
remove

under
cover

2
Remove
idler

pulley
lock
nut

and
loosen
belt
tension

adjusting
Fig
AC26
AC382A

Idler

Pulley

TIghtening
torque

@
3
7
to

5
1

kg
m
27
to
37
ft

lb

AC383A

Fig
AC
27

Compressor
and
Bracket

AC
19
REMOVAL

I

Operate

compressor
if

possible

at

engine
idling
speed
with
air
condi

tioner

controls
set
for
maximum
cool

ing
and

high
blower

speed
for20
to

30

minutes
with
all

windows

open
to

return

oil
into

compressor

2
Disconnect

battery
ground
cables

and

compressor
lead
wire
at
con

nector

3

Discharge
refrigerant
from

cool

ing
system
Refer
to

Discharging
Sys

tem

4

Jack

up
front
of
car
and

remove

under
cover

5
Loosen
idler

pulley
lock
nut
and

loosen
tension

adjusting
bolt

fully

Remove

compressor
drive
belt

See

Fig
AC
26

6
Remove

high
and
low
flexible

hoses
from

compressor

WARNING

Gradually
loosen

discharge
side

hose

fitting
and
remove
it
after

remaining
pressure
has
been
re

leased

CAUTION

Be
sure
to

immediately
put
plug
in

flexible
hose
and

compressor
open

ings

7
Remove
bolts

securing
lower

part

of

compressor

8
Remove
bolts

securing
upper
part

of

compressor
Hold

compressor
with

one
hand
when

removing
bolts
and

then
remove

compressor

With

compressor
clutch

up
lift

compressor
out
with

both
hands

CAUTION

00
not

attempt
to
leave
the
com

pressor
on
its
side
or

upside
down

for
more
than
10
minutes
as
the

compressor
oil
will
enter
the
low

pressure
chambers
If
under
that

condition

compressor
should
be

oper

ated

suddenly
internal

damage
would

result
To

expel
oil
from
chambers

hand
crank

compressor
several
times

in
its
installed
condition

INSTA
L1ATION

InstaU
in
the
reverse

order
of

removal

observing
the

following

I

When

installing
add

required

amount
Of

compressor
oil
Refer
to

Compressor
Oil
Level
Check

2

Apply
a

coat
of
fresh

compressor

oil
to

sealing
surfaces
of

pipe
joints

3
Check

tightening
torque
of
com

pressor
mounting
bolts

compressor

mounting
bracket

mounting
bolts
and

refrigerant
line
See
Figs
AC
27

and

AC
29

4

DO
not
remove
plugs
from

com

pressor
and
flexible
hose
before

connecting
hoses

S
Turn

compressor
several
times

before

installing

6

Adjust
compressor
drive

belt

tension

See

Fig
AC
2S

7
Evacuate

and

recharge
system

Refer
to

General
Service

for

evacuating
system
and

charging
re

frigerant

8
Conduct
leak
test
and
make
sure

that
there
is

no
leak
from
connections

CONDE
NSER

REMOVAL

Disconnect

battery
ground
cable

2

Discharge
system
Refer
to

Gen

eral
Service
for

discharging
system

3
Remove

radiator

grille

4
Remove

center

stay

5
Disconnect

refrigerant
lines
from

condenser

CAUTION

8
Use
wrench
to
fix
union
on
con

denser
and
then
loosen
flare
nut
of

refrigerant
line
with
another

wrench

b

Plug

up
all

openings
in
condenser

and

system
Air

COl1ditioning

6

Remove

mounting
bolts
ihen

remove
condenser

from
car

1a

11

AC384A

Fig
AC
28

Removing
Condenser

INSPECTION

Inspect

joints
of
inlet

and
outlet

pipes
for
cracks
and
scratches

Upon

finding
any

problem
which

may
cause

gas
to
leak

repair
or

replace
con

denser

Condenser
fins
or
air

passages
clog

ged
with
dirt

insects

or
leaves
will

reduce

cooling

effiCiency
of
con

denser
In

such
a
case

clean
fms
or

air

passages
with

compressed
air

CAUTION

Do
not
clean
condenser
with
ste8m

Be

sure
to

use
cold
water
or
com

pressed
air

INSTALLATION

Install
condenser

in
the
reverse

order
of
removal

observing
Ihe
follow

ing

I

When

replacing
condenser
add

same
amount

of
oil
as

was
drained

from

previous
condenser
to
com

pressor

AC

20
2

Keep
piugsin

place
until
im

mediately
before

connecting
work
is

started

3
Refer
to

Refrigerant
Line

for

tightening

torque
on

line
connec

tions

4

Refer
to
General
Service
for

evacuating
and

charging
system

5
Conduct
leak
test
and
make

sure

that
there
is

no
leak
from
connections

RECEIVER

DRIER

REMOVAL
AND

INS

ALLATION

See

Fig
AC
29

Disconnect

battery
ground

2

Discharge
system
Refer

to
Gen

eral
Service
for

discharging
system

3

Disconnect

refrigerant
lines

from

receiver
drier

CAUTION

Plug
all

openings
to

prevent
entrance

of
dirt
and

moisture

4

Remove
receiver

drier

mounting

screws
Remove

receiver
drier

5
Install

receiver
drier
in

the
reverse

order
of
removal
With

plugs
taken
off

immediately
before

connecting
work

is

started
connect
line
and
receiver

drier

Refer
to

Refrigerant
Une

for

tighten

ing

torque

6
Refer

to
General
Service
for

evacuating
and

charging
system

7

Conduct

leak
test
and
make
sure

that

there
is

no
leak
from
connections

INSPECTION

Check

receiver
drier

for
leaks

or

damage
If

necessary
replace

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

to

DISASSEMBLY

AND
ASSEMBLY

y
1

7
1
r

II

l

1

Using
a
knife
cut

packings
at

upper
and
lower
case
fit
in

portion

2
Remove

clips
fixing
upper
case
to

lower

case

3

Separate
upper
case
from
lower

case

by

pulling
it

upward

4
Withdraw

evaporator
assembly

out
oflower
case

5
Remove
thermostat
from

upper

case

by
removing

attaching
screWs

CAUTION

Capillary
tube
should
not
be
bent

too

sharply

6
To
assemble
reverse
the

order
of

disassembly
Be

sure
to

join
mating

surfaces
of

packings
at

upper
and

lower
case
fit
in

portion
with
an
adhe

sive

substance

Note

When

installing
thermostat

in

sert

capillary
tube
in
same

place
as

it

was
before
removal
Be
sure
to

insert

capillary
tube
end
about

50

em
19
7

in
from

evaporator
core

INSPECT

ON

In

case

evaporator
core
or

expan

sion

valve
have

gas

leaking
repair
or

replace
it
with

a
new
one
as

necessary

Dirt
and

nicotine
accumulation

on

evaporator
case
will

go
b
d
and
smell
Air

Conditioning

1

Mainrelay

2

Thermostat

3

Upper
case

4

Expansion
valve

5

Evaporator
assembly

6

Lower
case

ID

AC387A

Fig
AC
32

Cooling
Unit

This
means
that

you
have
to

remove

them
from
time

to
time
to
assure

healthful
fresh
air
inside

car

INSTAllATION

Install

evaporator
in
the
reverse

order

of
removal

observing
the
follow

ing

I
When

replacing

evaporator
with

new

one

charge
compressor
with

same
amount
of
new
oil
as
was
drained

before

2

Evaporator
case
should

be
in

stalled
as

close
s

possible
to

heater

unit

3
Refer
to

Fig
AC
29
for

tighten

ing

torque
of
flare
nuts

4
Refer
to
General
Service

for

evacuating
and

charging
system

5
Conduct
leak
test
and
ensu
e

that

there
is

no

gas
leak
from
conne
tion

EXPANSION
VALVE

Expansion
valve
malfunctions
such

as
valve

stuck

open
valve
stuck

close

refrigerant
leakage
and

improper
in

stall
tion

of

sensing
bulb
are
de

scribed

The
first
two
conditions

require

replacement
of

expansion
valve

When
both
water

and

refrigerant

AC

22
are
circulated

in
the

system
frost
cwill

form

near
the
ball
of

expansion
alve

and

block
the
flow
of

refrigerant
In

this
case

however

operation
of
the

valve

can
be
returned
to

normal

by

heating
the
valve

Expansion
valve
is

equipped
with

an

adjusting
screw
However
since

the

screw
is
set

properly
at

the

factory

adjustment
is

unnecessary
If

expan

sion

valve
is

damaged

replace
with

new
one

RIEMOV
L
AND

INSTALlATION

See

Fig
AC
32

Disconnect

baltery
ground
cable

2
Remove
ev

porator
Refer
to

Cooling
Unit
for

removal

3

Remove
heat
insulator

covering

expansion
valve

assembly

4
Remove

clamp
attaching
sensing

bulb

5

Loosen
flare
nuts
and
remove

expansion
valve
from

evaporator
and

inlet

pipe

CAUTION

Plug
all

openings
to

prevent
entrance

of
dirt
and
moisture

6

Installation
is
ill
the
reverse
order

of

removal

THERMOSTAT

REMOVAL
AND

INSTALlATION

See

Fig
AC
32

Remove

cooling
unit

2
Remove

screws

attaching
thenno

stat
and
then

remove
thermostat

CAUTION

Capillary
tube
should
not
be
bent

too

sharply

3
Installation
is
in

the
reverse
order

of
removal

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