service DATSUN 210 1979 Manual Online

DATSUN
210
Model

8310
Series

F

BODY

CONSTRUCTION

BODY
ALIGNMENT

BUMPER

DESCRIPTION

INSPECTION

FRONT
BUMPER

REAR
BUMPER

BODY
FRONT
END

RADIATOR
GRILLE

FRONT
APRON

COWL
TOP
GRILLE

FRONT
FENDER

FENDER
PROTECTOR

HOOD

HOOD
LOCK
CONTROL

DOORS

FRONT
DOOR

REAR
DOOR
4
door
Sedan
and

Wagon

BODY
REAR
END

TRUNK
LID
Sedan

SAC
K
000
R
Hatchabck
BODY

CONTENTS

BF
2

BF
4

BF
5

BF
5

BF
6

BF
8

SF
8

BF
9

BF
9

BF
9

BF
10

BF
10

BF
10

BF
11

BF
11

BF
12

BF
12

BF
15

BF
16

BF
16

BF
18
TAILGATE

Wagon

WINDSHIELD
AND

WINDOW
GLASS

WINDSHIELD
GLASS

REAR
WINDOW
GLASS
Sedan
and

Hatchback

REAR
WINDOW
GLASS

Wagon

SIDE

WINDOW
GLASS
2
Door
Sedan

and
Hatchback

REAR
QUARTER
WINDOW
GLASS

Hatchback

REAR
SIDE
WINDOW
GLASS

Wagon

INTERIOR

INSTRUMENT
PANEL

CONSOLE
BOX

SEAT

SEAT
BELT

TRIM
AND

MOLDING

ROOF
TRIMMING

BODY
SIDE
TRIM
AND
MOLDING

SPECIAL
SERVICE

TOOLS
BF
20

8F
21

SF
21

BF
22

SF
23

BF
26

BF
26

BF
27

SF
29

BF
29

SF
30

BF
30

BF
31

SF
32

BF
32

BF
32

BF
34

Z
jJ

BF769B

Fig
BF
91

Removing
Screws

Attaching
Floor

Carpet

and

Clip

2
Release
lock
on
rear
seat
back

and
tilt

seat
back

approx
600

for

ward

3
Slide
rear

seat
back
backwards

and
draw
out
outside
seat
back

hinge

pin
from
bracket
on
car

body

BF770B

Fig
BF
92

Removing
Rear

Seat

Back

4

Slide
rear
seat
back
outwards

and
draw

out
inside
seat
back

hinge

from
bracket

on
car

body
and

remove

seat
back

S

Installation
is
in
the

reverse
order

of
removal

SEAT
BELT

DESCRIPTION

The

front
seat
belts
are
a

three

point

type
consisting
of

an
inner

lap

and
an
outer

lap
shoulder

belt

This

lap
shoulder
belt
is

provided

with

an

Emergency
Locking
Retractor

which

locks
the
belt

by
detecting
car
Body

deceleration

This

retractor
serves
to
restraint
the

belt

securely
in

case
of

emergency
as

in

a
collision
or
sudden

stop
of
the
car

thus

protecting
the
seat

occupant

against
serious

injury
Under
normal

condition
the
belt

can
be

freely

pulled

out

The
inner

lap
belt

is
combined
with

a
buckle
The
buckle
includes
a
switch

which
is

used
as
a
seat
belt

warning

device

The
rear
seat
belt

is
a
two

point

type
and
includes
an
automatic
belt

locking
retracting
device

CAUTION

1
In

conformity
with
MVSS
No
302

be
sure
to
remove
the
thin

poly

ethylene
covers
from
seat
belts
at

1
Pre

delivery
service

2

Parti

replacements

2
If
the
car
is
collided
or
ovarturned

replace
the
entire
belt

assembly

regardless
of
nature
of

accident

3
If
the
condition
of

any
component

of
a
seat
belt
is

questionable
do

not
have
seat
belt

repaired
but

raplaced
as
a
belt

assembly

4
If

webbing
is

cut

frayed
or
dam

aged
replace
belt

assembly

5
Do
not

spill
drinks
oil
etc
on

inner

lap
belt
buckla
Naver
oil

tongue
and
buckle

6
Use

only
a
NISSAN

genuina
seat

belt

assembly

REMOVAL
AND

INSTALLATION

I

Disconnect

battery
ground
cable

2
Loosen
bolt

attaching
inner

lap

belt

BF771B

Fig
BF
93

Removing
Inner
Lap
Belt

BF
31
3

On
driver
s
seat
disconnect
seat

belt
switch
and

remove
inner

lap
belt

4
Remove
bolt

securing
through

anchor

at
shoulder

portion
and
bolt

securing
anchor

at

lap
portion
from

lap
shoulder
belt

5

Remove
center

kicking
plate

Sedan
or
rear
side
finisher
Hatch

back

6
Remove

securing
bolts
and
re

move

lap
shoulder
belt
with

Emergen

cy
Locking
Retractor

attached

BF311B

Fig
BF

94
Removing
Lop
Shoulder

Belt

7

Removing
rear
seat
belts

Remove

seat
cushion
and
seat
back

Then
loosen
bolts

attaching
rear
seat

belts
and

remove
rear
seat
belts

BF772B

Fig
BF

95

Removing
Rear
Seat
Belt

8
Install
front
and
rear
seat
belts
in

the
reverse
order
of
removal

iil
Tightening
torque

Anchor

bolt

2
4
to
3
2

kg
m

17
to

23
ft

Ibl

Body

WAGON

6

I

Da
h
side
fInisher

2
Front

pillar
garnish

3

Body
front
side
welt

4
Center

pillar
garnish

5

Body
rear
side
welt

6

Luggage
side

upper
f

misher
7
Front

IticIting
plate

8
Rear

kicking
plate

9

Luggage
side
lower
rmi
Jher

10
Rear
window

welt

II

Luggage
rear
fini3her

12

Drip
center
and
rear

moldins

13
Air
outlet

grille

14

Rear
Cender

moldins

15

Luggage
floor
board

16

Front

pillar
moldins

8F7748

Fig
BF

IOO

Body
Side
Trim
and

Molding

SPECIAL
SERVICE
TOOLS

I
Kent

Moore
No

I
Kent
Moore
No

Tool
number

tool
name
Reference

page
or

Fis
No
Tool
number

tool
name
Reference

page
or

FiB
No

ST08800000

Sucker

ST088
10000

Caulking
hand

gun

cf0
FIg
BF
55

Fig
BF
67

Page
BF
22

Page
BF
23
Fig
BF
70

BF
34

DESCRI

PTI
ON

Cabl
are
covered
with

color
coded

vinyl
for

easy
identification
In
the

wiring
diagram
olors
are

indicated

by

one
or
two

alphabetical
letters

It
is
recommended
that
the

battery

be

disconnected
before

performing

any
electrical
service

other
than

bulb

or

fuse

replacement

In

addition
to

fuses
a
fusible

link

has
been

installed
to

protect

wiring

Circuit

system

Starting
and

ignition
system

Charging
system

Lighting
system

Signal
system

Instrument

system

Others

Grounding
system

The
main
cable

of
each

system
is

generally
coded
with
a

single
color

These

colors
are

represented
by
such

letters
as
G
W
or
Br
Minor
items
of

each
circuit
s

terminal
are
coded

with

a
two
tone
color

as
follows

BW
Black
with
white

stripe

LgR

Light
green
with
red

stripe
Body
ectrical

System

BODY
ELECTRICAL

WIRING

The

fusible
link

functions

almost
the

same

as
a

fuse

though
its

characteris

tics
are

slightly
different
than

normal

fuses

CABLE
COLORS

Cable
colors
are

generally
used

as

shown
in

the

following
table

Color

B

Black

W

White

R

Red

G

Green

y

Yellow

L
Br

Lg

Blue
Brown

Light
green

B

Black

INSPECTION

Inspect
all

electrical
circuits

Ie

Terring
to

wiring
or
circuit

diagrams

Circuits
should
be

tested
for
continui

ty
or

short
circuit
with
a
conventional

test

lamp
or

low

reading
voltmeter

Before

inspecting
circuit
ensure
that

I

Each
electrical

component
part
or

cable
is

securely
fastened
to
its
con

nector

or
tenninal

2

Each
connection
is

fIrmly
in

place

and

free
from
rust

and
dirt

BE

2
3
No

cable

covering
shows

any
evi

dence
of

cracks

deterioration
or
other

damage

4

Each
terminal
is
at
a
safe
distance

3
Vay
from

any
adjacent
metal

parts

5

Each
cable
is
fastened
to

its

proper
connector
or

terminal

6

Each

grounding
bolt
is

fumly

planted

7

Wiring
is

kept
away
from

any

adjacent

parts
with

sharp
edges
or

high

temperature
parts
such
as
exhaust

pipe

8

Wiring
is

kept
away
from

any

rotating
or

working
parts
fan

pulley

fan
belt
etc

9
Cables
between
fIXed

portions

and

moving

parts
are

long
enough
to

withstand
shocks
and

vibratory
forces

Note

a
Before

starting
to

inspect
and

repair

any

part
of
electrical

system
or

oth
parts
which

may
lead
to

a

short
circuit
disconnect
cables
at

battery
terminals
as
follows

Disconnect
cable
at

negative

terminal

and
then
disconnect
cable

at

positive
terminal

Before

connecting
cables
to

battery

terminal
be

s
1
to
clean
tenninals

with
a

rag
Fasten
cable
at

positive

t
minal
and
then

ground
cable

at

negative
tenninal

Apply

grease
to

top
of
these
terminals
to

prevent
rust
from

developing
on

them

b
Ne
use
a

screwdriver
or
service

tool
to
oonduct
a

oontinuity
test

Use
test
leads

Co

Nev
ground
an

open
circuit

or

circuits
under
no
lood
Use
a

test

lamp
I2V

3W
or

circuit
tester
as
a

lood

FUSE
AND

FUSIBLE
LINK

MAINTENANCE

INSTRUCTIONS

Fuse

The
fuse

block
is
installed

under

the

instrument

panel
on

driver
s
side

DATSUN

210
Model

8310
Series

SECTIONAC

AIR
CONDITIONING

CONTENTS

DESCRIPTION

OUTLINE
OF
AIR
CONDITIONER

REFRIGERATION
SYSTEM

AIR
FLOW

VACUUM
SYSTEM

ELECTRICAL
CIRCUIT

GENERAL
SERVICE

REFRIGERANT
R
12

COMPRESSOR
OIL

MAINTENANCE

GENERAL
SERVICE
INSTRUCTIONS

SAFETY
PRECAUTIONS

EVACUATING
AND

CHARGING
SYSTEM

CHECKI
NG
FOR
LEAKS

REFRIGERANT
LEVEL
CHECK

COMPRESSOR
OIL
LEVEL
OHECK

PERFORMANCE
TEST

REFRIGERANT

LEAKS

SERVICE
PROCEDURES

FAST
IDLE
ACTUATOR

IDL
E
PULLEY
AND
COMPRESSOR

DRIVE
BELT

COMPR
ESSOR

CONDENSER

RECEIV
ER

DRIER

REFRIGERANT
LINES
I

COOLING
UNIT

EXPANSION
VALVE

THERMOSTAT

MAIN
RELAY

HEATER
UNIT

WATER
COCK
AC
2

AC
2

AC
3

AC
5

AC
6

AC
7

AC
9

AC
9

AC
9

AC
9

AC
9

AC
9

AC

1

AC14

AC15

AC
17

AC17

AC17

AC18

AC1B

AC19

AC19

AC
20

AC
20

AC
21

ACc21

AC
22

AC
22

AC
23

AC
23

AC
23
BLOWER
MOTOR

RESISTOR

AIR
CONDITIONER

CONTROL

FAN
SWITCH

MICROSWITCH

LOW
PRESSURE
SWITCH

MAGNET
VALVE

FUSE

REPLACEMENT

VACUUM
HOSE
DIAGRAM

WIRING
DIAGRAM

COMPRESSOR
MODEL
SC206

PRELIMINARY
CLEANING

COMPRESSOR
CLUTCH

SHAFT
SEAL

CYLINDER
HEAD

AND
VALVE
PLATE

DISCHARGE
AND
sU
CTiON

CONNECTORS

TROUBLE
DIAGNOSES
AND

CORRECTIONS

AIR

CONDITIONER
DIAGNOSES

BLOWER
MOTOR
DIAGNOSES

COMPRESSOR
DIAGNOSES

COMPRESSOR
CLUTCH
DIAGNOSES

VACUUM
SYSTEM
DIAGNOSES

PERFORMANCE
TEST

DIAGNOSES

PERFORMANCE
CHART

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPECTION
AND
ADJUSTMENT

TIGHTENING
TORQUE

SPECIAL
SERVICE
TOOLS
AC
23

AC
23

AC
23

AC
23

AC23

AC
24

AC
24

AC24

AC
24

AC
25

AC
26

AC
27

AC
27

AC
28

AC30

AC30

AC32

AC
32

AC
33

AC34

AC35

AC36

AC37

AC
41

AC
42

AC
42

AC
42

AC
43

AC
44

REFRIGERANT
R
12

The

refrigerant
used
in
the
air

conditioner
is

generally
called
Re

frigerant
12
R
12
No
other

refrig

erant
than
the
above

refrigerant
should

be
used

Note
Exercise

care
when

handling
re

frigerant
as
it
is

stored
under

high

pressure

COMPRESSOR
OIL

The

SUNISO
5GS

refrig
ration

lubricant
should
be
used
to
assure
the

successful

compressor
operation
Use

of
oils
other
than

recommended
or

mixing
of

the
oil
with

other
oils
would

cause
chemical
reaction

or
lead
to

lowered

viscosity
or

deficient
lubrica

tion

The
oil

absorbs
moisture

as
it
con

tacts
the
air

This

points
out
the
need

for

care
not
to

expose
it

to
atmos

phere
for

an
extended

period
of
time

MAINTENANCE

The

following
checks
and
main

tenance
are

especially
important
to
the

air
conditioner

I

Check

refrigerant
level

2
Check

refrigerant
leaks

3
Check

compressor
drive

belt
for

proper
deflection

4

Even
in

the
off
season
turn
the

compressor
for
10
minutes

at
least

once
a
month

by

running
the

engine
at

1

500

rpm

GENERAL

SERVICE

INSTRUCTIONS

If
dirt
water
or
air
enters

the
air

conditioner

system
it

will
be

seriously

affected
Be

sure
to
observe

the

following

I

Always
keep
the

working
place

clean

and

dry
and
free
from
dirt
and
Air

Conditioning

GENERAL
SERVICE

dust

Wipe
water
off
from
the
line

fittings
with
a

clean
cloth
before
dis

connecting

2

Have
all

necessary
tools

in

prepar

ation
beforehand

and
have
tools
clean

and

dry

3

Handling

plug
when

the

system

line
is

disconnected

4

Handling

compressor
oil

For
details
refer
to
each

descrip

tion
in
this

manual

SAFETY

PRECAUTIONS

WARNING

1
Since
direct
contact
of
the

liquid

refrigerant
with

your
skin

will

cause
frostbite

always
be
carelul

when

handling
the

refrigerant

Always
wear

goggles
to

protect

your

eyes
when

working
around

the

system

2
The

refrigerant
service
container

has
a
safe

strength
However
if

handled

incorrectly
it
will
ex

plode
Therelore

always
follow

the
instructions
On
the

label
In

particular
never
store
it
in
a
hot

location
above
520e

1260F

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

relrigerant

gas
is
heavier
than
air
and

will

lay
close

to
the
floor

be

espe

cially
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

contacu
fire
and

special
care
is

therefore

required
when
check

ing
for

leaks
in
the

system
with
a

halide
torch

5
Do
not
steam
clean
On
the

sys

tem

especially
condenser
since

excessively
high
pressure
will

build

up
in
the

system
resulting

in

explosion
of
the

system

The

above

precautions
are
essen

tial

in

handling
of

Refrigerant

12
and
their
strict
observation

AC
9
requires
sufficient

training

Therefore
it
is
of
first

impor

tance
that

any
other

personnel

than
a
well
trained
serviceman

should
not
be

allowed
to
handle

the

refrigerant

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

1
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

fonn

Consequently
the
effective

thermal
transmission
area
of
condenser

for

refrigerant
gas
will

be
reduced
and

refrigerant
gas
to
be

condensed
will

be

reduced
The

pressure
rise
will
become

proportional
to
the
volume

of
the
air

in

system

2
When
air
and

refrigerant
are

r
tixed
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

Fig
AC
I
I

When

valve
stem
is

fully
screwed

the
valve
is

front
seated
and
valve

path

Low

pressure

gauge

Compound
pressure
gauge
Air

Conditioning

and
the
tenter

path
are
blocked
When

valve

stem
is
backed
off
the

paths
are

opened

High
pressure
gauge

Back
seated

Full
counter

clockwise

I

VA

l

C
f

f
f
J

l
r

To
low
side
To
vacuum

pump
01

To

high
side

service
valve

refrigerant
can
service
valve

Fig
AC
II
Manifold

Gauge

ConnectIon
to

service
valve

I

Fully
close
both
valves
of

mani

fold

gauge
Connect

high
and

low

pressure
charging
hoses
to
manifold

gauge

2
Remove

caps
from
service
valves

Connect
high
and

low

pressure
charg

ing
hoses
to
service
valves
in

system

The

refrigerant
gas
will
be

discharged

since
check
valve
is

open
when

pressing
charging
hose

onto
service

valve

3

Next
loosen
the
connection
fit

ting
of

charging
hose
at
manifold

gauge
side
for
2
to
3
seconds
to

purge

any
air
inside

charging
hose

by
the

pressurized
gas
in

system

DIsconnection
from

servIce
val
ve

I

Fully
close
both
valves
of
mani

fold

gauge

2
Disconnect

two

charging
hoses

from
service
valves
At

this
time

the

gas
will

be

discharged
until
check
valve

is

closed
Therefore
disconnect
hose

quickly

WARNING

Work
with

fingers

protecte
with

cloth

against
frostbite

by
reo

frigerant
FronHeated

Fun

clockwise

r

AC243

HANDLING
SERVICE
VALVE

An
automatic

check
valve
is

built

into
service

valve
When
this
valve

presses
against
the
connection

fiUing

that
is

when

charging
hose

is
con

nected
to
service

valve
the
valve
is

open
When

charging
hose
is

discon

nected
the
valve
is
closed
auto

matically
Always
observe
the
follow

ing

usage
precautions

1ts

Close

I

Cap

2
Service
valve

3

Charging
hose
ir

Open

4

Packing

5
Check
valve

AC244

Fig
AC
12
Service
Valve

I

Always
install
valve

cap
after

using
service
valve

When

high

speed
operation
is

per

AC
I0
formed
without
valve

cap
a

negative

pressure
will

gradually
build

up
at

the

low

pressure
side
of

system
and
air

may
be
sucked
in
In
addition
dirt

and

dust
will

easily
enter
the
valv
result

ing
in

foreign
matter

entering
the

system

CAUTION

00
not
over

tighten
valve

cap

2
Check
valve
wiJI
be
half

opened

during
connection
and

disconnection

of

charging
hoses
and

refrigerant
will

be

forcefully
discharged
Therefore

connect
and
disconnect

charging
hoses

quickly
while

pressing
flare
nut
of

charging
hose

against
service

valve

WARNING

Work
with

fingers
protected
with

cloth

against
frostbite

by
reo

frigerant

3

Since
close
contact
between
the

thread
of
valve

cap
and
the
thread
of

service

valve
will

prevent
gas
leakage

keep
these
areas
clean
and

free
of

scratches
and

damage

4

Since

packing
of

charging
hose

will
be
lost

during
long
use

always

check

packing
prior
to

installing
charg

ing
hose

HANDLING
CAN
TAP

A

wide

variety
of
can

taps
are

available
The

following
procedures

apply
to

conventional
can

taps

For

the
correct

usage
refet
to

the

manufacturer

s
instructions

I

Connect

charging
hose
to
the

center

fitting
of
manifold

gauge
At

this
time
confirm
that

both
stems
are

fully
turned
in

frontoSeated

2
Turn

can

tap
handle

fully
coun

terlockwise
so
that
the
needle
is

pulled
up

3

Attach
can

tap
to

refrigerant
can

firmly

4

Turn
can

tap
handle

fully
clock

wise

to
make
a

hole
in

refrigerant

can
See

Fig
AC
13

5
Turn

the
handle

fully
counter

clockwise
to
raise
the
needle

Refriger

ant

gas
will
flow

up
to
the
center

fitting
of
manifold

gauge
See

Fig
AC

14

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