ECU DATSUN PICK-UP 1977 Owners Manual

Body
Frame

Removal
and
installation

assembly

2
To
install

seat
reverse
above
re

moval

procedure
1
Remove

four
bolts

retaining
seat

slide

assembly
to

floor
take

out
seat

SEPARATE
SEAT

1

Head
re5traint

2
Seat
assembly

3

Reclining
device

4

Seat
slide
outer

5
eat
slide
inner
s

J

j

BF0358

Fig
BF

49

Separate
seat

Removal
and
installation

I

Remove
two

nuts

attaching
front

of
seat
slide
to
floor

2

Remove
two
bolts

attaching
rear

of

seat
slide
to
floor
3
Then

remove
seat
with

seat
slides

from
the

vehicle

4

Installation
is
the
reverse
order
of

removal

SEAT
BELT

1
Inner
belt

2

Tongue
stopper

3

Emergency
locking
retractor

4

Outer
anchor

plate

5

Lap
shoulder
belt

6
Shoulder

through
anchor
BF036B

Fig
BF
50

Seat
belt

BF

20
DESCRIPTION

The
seat
belt
is
a
three

point
type

consisting
essentiaily
of
a

lap
shoulder

belt
and
an
inner

lap
belt

The

lap
shoulder
belt

is
fitted
with

an

emergency
locking
retractor
which

senses
the

speed
at
which
the

webbing

is

being
pulled
and

the
deceleration
of

the
vehicle

The
inner

lap
belt
has
a
buckle
The

buckle
of
the
driver

s
seat
belt
includes

a
switch
which
functions
as
a
seat
belt

warning
device

CAlJI10NS

a
In

conformity
with
M
V

S
S
No

302
be
sure
to

remove
the
thin

polyethylene
covers
from
seat

belts

at
the
time
of

I
Pre
delivery
service

2
Parts

replacement

b
If

the
vehicle
has

overturned
or

been
in
a
collision

replace
the

entire

belt

assembly
regardless
of

nature
of
accident

c

If
the
condition

of

any

component

of
a

seat
belt
is

questionable
have

entire
belt

assembly
replaced
rather

than

attempting
to

repair
seat
belt

d
If

webbing
is
cut

frayed
or
dam

aged

replace
belt

assembly

e
Do
not

spill
drinks
oil
etc

on

inner

lap
belt
buckle
Never
oil

tongue
and
buckle

f

Use

only
a

genuine
Nissan
seat
belt

assembly

REMOVAL
AND

INSTAUATION

I

Disconnect

battery
ground
cable

2
Disconnect
buckle
switch
harness

at
connector
under
seat

3
Loosen

bolt

retaining
inner

lap

belt
and
remove
inner

lap
belt

4

Remove
bolt

securing
emergency

locking
retractor

5

Remove
shoulder
anchor
bolt

and
remove

lap
shoulder
belt
assem

bly

6
Installation
is

the
reverse
order
of

removal

Tightening
torque

Anchor
bolts

2
5
to
3
0

kg
m

18
to
22
ft
lb

DESCRIPTION

Cables
are
covered
with
color

coded

vinyl
for

easy
identification
In

the

wiring
diagram
colors
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

The
fusible
link
functions
almost
the

same
as
a

fuse

though
its
eharac

teristics

are
slightly
different
than

normal
fuses

CABLE
COLORS

Cable
colors
are

indicated

by
one
or

two

alphabetical
letters

B

Black
Be
Brown

G
Green

L
Blue

Lg
Light

green

R

Red
W
White
Y
Yellow

The
main

cable
is

generally
coded

with

a

single
color
The

others
are

coded
with
a

two
tone
color
as

follows

BW

Black
with
white

stripe

gR

Light
green
with
red

stripe

INSPECTION

Inspect
all

electrical

circuits
refer

ring
to

wiring
or

circuit

diagrams

Circuits

should
be

tested
for
conti

nuity
or

short
circuit

with
a

conven

tional
test

lamp
or

low

reading
volt

meter
Before

inspection
of

circuit

ensure
that

I
Each
electrical

component

part
or

cable
is

securely
fastened
to

its
con

nector
or
terminal

2
Each
connection

is

firmly
in

place

and

free
from
rust
and
dirt

3

No
cable

covering
shows

any

evidence
of
cracks

deterioration

or

other

damage

4

Each
terminal

is
at

a
safe

distance

away
from

any
adjacent
metal

parts

5
Each

cable
is
fastened

to
its

proper
connector
or
terminal
Body
Electrical

System

BODY
ELECTRICAL

WIRING

6

Each

grounding
bolt
is

firmly

pbnted

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
ftxed

portions

and

moving
parts
are

long
enough
to

withstand
shocks
and

vibratory
forces

Notes

a
Before

starting
to

inspect
and

repair

any
part
of
electrical

system
or

other

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
sure
to
clean
terminals

with
a

rag
Fasten

cable
at

positive

terminal
and
then

ground
cable

at

negative
terminal

Apply

grease
to

top
of
these

terminals
to

prevent
rust
from

developing
on

them

b
Never

use
a

screwdriver
or
senrice

tool
to
conduct

a

continuity
test

Use
test
leads

c
Never

ground
an

open
circuit
or

circuits
under
no
load
Use

a
test

lamp
12V
3W

or
circuit
tester
as
a

load

FUSE
AND

FUSIBLE

LINK

DESCRIPTION

The
fuse
and
fusible
link

are

protec

tive

devices
used
in

an
electrical
cir

cuit

When
current

increases

beyond

rated

amperage
fusible
metal

melts

and

the

circuit
is

broken

BE
2
MAINTENANCE

INSTRUCTIONS

Fuse

The
fuse

block
is
installed

under

the
instrument

panel
on
the
left

hand

drive

vehicle

BE848A

Fig
BE
1

Fuse
block

When
for
one
reason

or
another

fuse

has
melted
use

systematic
pro

cedure
to
check
and
eliminate
cause
of

problem
before

installing
new
fuse

Notes

a
If
fuse
is

blown
be
sure
to
elimi

nate
cause
of

problem
before
in

stalling
new
fuse

b
Use

fuse
of

specified

rating
Never

use
fuse
of
more
than

specified

rating

Co

Check
condition
of

fuse
holders
If

much

rust
or
dirt
is
found

thereon

clean

metal

parts
with
fine

grained

sandpaper
until

proper
metal
to

metal
contact
is
made

Poor

contact
in

any
fuse
holder
will

often
lead
to

voltage
drop
or

heating
in
the
circuit
and
could

result
in

improper
circuit

operation

Fusible

link

Fusible
link

protects

lighting

starting
charging
and

accessory
cir

cuits

Body
Electrical

System

Horn
switch

The
horn
switch
is

integral
with

the

turn

signal
and
dimmer
switch
as

sembly
Remove
switch

assembly
as

outlined
in
Turn

Signal
and
Dimmer

Switch

IGNITION
SWITCH
BE861A

Fig
BE

3
I

Removing
ignition
switch

REMOVAL
AND

INSTALLATION

I
Disconnect

battery
ground
cable

from

battery

2
Unscrew
and
remove
escutcheon

from
the
front
of

ignition
switch

3
Withdraw

ignition
switch
and

wiring
assembly
with

spacer
from

shell
cover
as
shown
in

Figure
BE
3

4

Disconnect
wiring
connector

from
the
back
of

ignition
switch

5

Replace
ignition
switch
with
a

new
one

6
Connect

ignition
switch
to

wiring

connector

7

Position

ignition
switch
to
shell

cover

opening
install
and

tighten

escutcheon
and
secure
ignition
switch

to
shell
cover
R
terminal

1G
terminal

ST
terminal

B
terminal

8E

22
1

Voltage

regulator

2
Horn

relay

3

Headlamp
relay

4

Ignition
relay
California

only

5

Auto
choke
heater

relay

6

Compressor
relay

Au
conditioner

equipped
model

7

Floor
sensor

relay
California

only

8
Inhibitor

relay
Automatic

tran5mission

only

INSPECTION
BE683B

Fig
BE
30

ContInuity
test

Test

continuity

through
ignition

switch

by
using
test

lamp
or
ohm

meter

C

A
terminal
TERMINAL
0

F

F

B

IG

ST

A

R
KEY

FOSITlON

t

1

o

j
u

u

I

I
A

C

C

Fig
BE

32

Ignition
witch
BE6848

RADIO

REMOVAL
AND

INSTALLATION

Radio

Removal

Pull
radio
knobs
offradio
control

shafts
Body
Electrical

System

2
Remove
radio

holding
nuts
and

washer
from
radio

control
shafts

3
Remove
radio

bezel
from
the

front

of
radio

4

From
under
instrument

panel

disconnect
antenna
cable
and
lead

wires

power
lead
and

speaker
lead

5

Remove
radio

from
instrument

panel

Installation

Fr
m
behind
instrument

panel

position
radio

to
instrument

panel

2
Install
radio
bezel
to
the

front
of

radio

3
Install
washers
and
nuts
on

radio

control
shafts
and

tighten
them
secure

ly
Then
install
control
knobs

4
Connect
antenna
cable
and
lead

wires

power
lead
and

speaker
lead

Antenna
and

antenna
cable

Removal

From
behind
instrument

panel

disconnect
antenna
cable
at
conne
tor

2
Remove

plug
on
antenna
base
and

remove
antenna
base

retaining
screw

3
Remove

antenna
and
cable
as

sembly
from
fr
ont

pillar

4
Unscrew
antenna

clip
from
front

pillar
if

necessary
aE323

Fig
BE

41
Radio

Installation

Remove
rubber

plugs
that
cover

antenna

mounting
opening
in
front

pillar
when

installing
radio
antenna

on
vehicle
that
is
not

equipped
with

radio

2
Thread

mounting
stud
of
antenna

clip
into

upper
antenna

mountins

opening

3
Insert

antenna
cable
into

lower

antenna

mounting
opening
and

place

ant
nna

base
in

position

4

Install
antenna
base

retaining

screw

5
Route
antenna
cable

along
upper

dash

panel
to
radio

6

Connect
antenna
cable
at
con

nector

BE
25
t

BEB67
A

Fig
BE
42
Radio
ant

nna

ADJUSTMENT

Antenna
trimmer

When
a
new

radio
receiver
antenna

or
antenna
feeder
is
installed
antenna

trimmer

should
be

adjusted

Extend
antenna

completely

2
Tune
in
the

weakest
station
be

tween
12
and
16
1

200
to
1
600KC

on
dial

Noise

may
be

generated
but
dis

regard
it

3
Turn

antenna
trimmer
to

right

and
left

slowly
and
set
it
at
a

position

where

receiving
sensitivity
is

highest

SE133

Fig
BE
43

Adjwting
antenna
trimmer

CLOCK

REMOVAL

Remove

battery

ground
cable

2
Remove
cluster
lid

following

instructions
in

steps
I

to
4

of
Removal

in

Combination
Meter

3

Disconnect
three
wire
connectors

of
clock
from
combination
meter

printed
circuit

and
instrument
harnes

wiring

4
Remove
three
s
rews
and
remove

clock
from
cluster
lid

HEATER
UNIT
ASSEMBLY

Removal

L
Disconnect

battery
ground
cable

2

Drain

engine
coolant

3

Remove
defroster
hoses

4

Remove
three

cable

retaining

clips
and
disconnect
control
cables

from
valves
and
water

cock

5

Disconnect
two

fan
motor
lead

wires
from
each
connector

6
Disconnect
two
resistor

lead
wires

from
each
connector

7

Disconnect
water
hoses
from
core

and
water
cock

8

Remove
three

heater
housing

mounting
bolts
and

dismount
heater

unit
from
vehicle

Installation

1

Position
heater
unit
under
instru

ment

panel
and
install
three
heater

unit

securing
bolts

2

Install
water
hoses

3
Position
heater

control
cables
to

room
valve
air
intake
valve
and
water

cock

4

Adjust
control
cable

length
for

proper
operation
as

outlined
in

Adjust

ment

5
Connect
fan
motor
wires
and

resistance
wires

to
each
connector

plug

6

Install
defroster
hoses

7

Connect

battery
ground
cable

8
Fill

cooling

systeIT

9
Run

engine
at
2
000

rpm
with

AIR

lever
in

the
HOT

position

Make
sure
that

engine
coolant
is
fIlled

up
to
correct
level

HEATER
CORE

Removal
and
installation

L

Drain

engine
coolant

2
Remove
defroster
hoses

3
Disconnect
water
hoses
from
inlet

and
outlet

pipes
of
heater
core

4

Remove
four

clips
and
front

cover
Body
Electrical

System

BE869A

Fig
BE
48

Removing
front
cov
r

S

Withdraw
heater
core
from
heater

housing

BE870A

Fig
BE
49

Removing
heater
core

6

Install
heater
core
in

the
reverse

sequence
of

removal

FAN
MOTOR

Removal
and
Installation

L
Dismount
heater
unit

assembly

from
vehicle

as
outlined
in
Removal
of

Heater
Unit
Assembly

2
Remove
nine

spring
clips
and

disassemble
heater

housing

3
Remove
fan
from
fan
motor

4
Remove
fan

motor

retaining

screws
and
fan
motor

S
Assemble
heater

housing
and
in

stall
heater
unit

to
vehicle
in
the

reverse

sequence
of
removal

as
out

lined
in

Installation
of

Heater
Unit

Assembly

I

CONTROL
ASSEMBLY

Removal
and
Installation

I
Remove
three
cable

retaining

clips
and
disconnect
control
cables

from
valves
and
cock

BE
29
2

Disconnect
three
lead
wires

from

each
connector

plug

3

Remove
radio
bezel
from
the

front
of
radio

following
instructions

in

steps
I

to
3
in

Removal
of
Radio

4

Remove
heater
control
knobs
and

heater

bezel

5

Remove
two

retaining
bolts
and

heater
control

assembly

6
Install
control

assembly
in
the

reverse

sequence
of

removal
When

connecting
control
cables

to
valves
and

cock

adjust
control
cable

length
as

outlined
in

Adjustment

ADJUSTMENT

AIR
lever

L
Move
AIR
lever
to
the
DEF

position

2

Open
air
intake

valve
and

connect

control

cable
to
air
intake
valve

3

Clip
control
cable
with
cable

re

taining
clip

Fig
BE
50
A
iT
intake
valve

4
Pull
room
valve

upward
and
con

nect
control
cable
to
room
valve

5

Clip
control
cable
with

cable
re

taining
clip

BE871A

Fig
BE
51

Room
valve

SEAT
BELT

WARNING
SYSTEM

DESCRIPTION

Except
Canada

When

the

ignition
switch
is
turned

to
the
ON

position
the

warning

lamp
comes
on

and
remains
on
for
4

to
8

seconds
The

warning
buzzer

sounds
for
4

to
8
seconds
intermittent

ly
if
the
driver
s
seat
belt
is

not

fastened

properly

The
seat
belt

warning
system
con

sists
of
a
driver
s
belt
switch
a

warning

buzzer
a

warning
lamp
a
timer
unit

and
an

ignition
switch

For
Canada

When
the

ignition
switch
is
turned
Body
Electrical

System

to
the

ON

position
the

warning

lamp
comes
on
and
the

warning
buz

zer
sounds
if
the
driver

s
seat
belt
is

not

fastened

properly

The
seat
belt

warning
system
con

sists
of

a
driver
s

belt
switch

a

warning

buzzer

a

warning
lamp
and
an

igni

tion
switch

REMOVAL
AND

INSTALLATION

Ignition
switch

Refer
to

page
BE
22

for
Removal

and
Installation

Timer
unit

Timer
unit
is
fIXed

on
a
reinforce

ment
behind

glove
box

BE688B

I
Disconnect

battery
ground
cable

2
Remove

glove
box

3
Disconnect
timer
unit

connector

4
Remove
two
screws

retaining

timer
unit
on
reinforcement
Timer

unit
can
then
be
taken

out

S

Installation
is
in
the
reverse
se

quence
of
removal

Warning
buzzer

Warning
buzzer
is
fIxed

on
a
re

inforcement
behind

glove
box

Refer
to
the

preceding
timer
unit

for
Removal
and
Installation
BE282B

Fig
BE
54
Timer
unit

BE967A

Fig
BE
55
Warning
buzzer

Driver
s
seat
belt
switch

I
Remove
seat
belt

ecuring
bolt

2
Disconnect
belt
switch
lead
wire

at
connector

3

Seat
belt
can
then
be
taken
out

4

Installation
is
in
the

reverse
se

quence
ofremoval

BE
31
Warning
lamp
body

Warning

lamp
is

located
on
instru

ment

panel

I
Remove

cluster
lid

2
Disconnect

lead
wire

at
connee

tor

3
Remove

two
screws

retaining

lamp
body

4

Installation
is
in
the

reverse
se

quence
of
removal

WARNING
LAMP
BULB

REPLACEMENT

I
Remove
cluster

lid

2
Twist

warning
lamp
socket

Socket
with
bulb

can
then
be
taken

out

3

Pick

up
bulb

from
socket

4
Install
new
bulb
in
the
reverse

sequence
of
removal

Bulb

wattage

Seat
belt

warning
lamp
I
7W

INSPECTION

Warning
buzzer

Apply
12V

direct
current
between

CD
and

@
and
check
whether
buzzer

sounds
or
not

The
buzzer

must
sound
when

CD

and

@
are
connected
to

power

circuit
See

Figure
BE
55
for

warning

buzzer

Note
Make

sure
that

negative

terminal
of

power
circuit
is

always

connected

to

@
terminal

Timer
unit

Turn

ignition
key
to
the

ON

position
The

voltage
between

@
and

ground
must
be
12V
for
4

to
8

seconds
and
then

go
out
See

Figures

BE
54
and
BE
56

Belt
switch

Test

continuity
between
two
lead

wires
from
seat
belt
switch
with
ohm

meter
or
test

lamp

Body
Electrical

System

RADIO

Noise

prevention

Position
vehicle
in
an

open
area

away
from
steel

buildings
run

engine
extend
antenna
to
its
maximum

length
set
volume

control

to
maximum
and
set
dial
at
a
medium

point
without

catching
broadcasting
wave

Condition

Ignition

system

Noise
occurs
when

engine
is

op

erated

Charging
system

Sound
of

alternating
current

pre

sents

When

accelerator

pedal
is

depressed

or

released
noise

presents

Supplement
equipment

When

engine
starts
noise

presents

Noise

still

presents
even
after

stop

ping
engine

Notes

a
Be
sure
to
locate

capacitor
as

close

as
to

noise
source
and
connect
in

parallel
Probable
cause
Corrective
action

High
tension
wire

Install
new

high
tension
wire

Ignition
coil
Install
a
0

51lF

capacitor
to

primary
side

terminal
of

ignition
coil

Note
Be

careful
not
to
install

capacitor
to

secondary
or

primary
breaker
side
other

wise

engine
becomes

improper

Install
bond

strap

Distributor
Secure
contact
of
carbon
electric

pole
and

rotor

Eliminate

sharp
tip
on

rotor

pole
or

cap
pole

by

scrubbing
with
a

screwdriver

Check

stagger
between
rotor

and
stator

Alternator
Install
a
0

51lF
capacitor
to

charging
termi

nalA

Note
Do

not

use
a
larger
capacitor

If

capacitor
is

installed
to
terminal
F

alternator
coil
will
be

damaged

Regulator
Install
a
0

51lF
capacitor
to
IGN
terminal

of

voltage
regulator

Operative
noise
of
water
tem

perature
and
fuel

gauges
Install
O

IIlF
capacitor
between
terminal
and

ground
wire

Note
If

a

capacitor
having
a

larger
capacity

is
used
indication
of

gauge
will
be
de

viated

b
Cut
lead
wire

as
short
as

possible

c

Ground
wire
should
be
attached
on

the

body

completely

d
Make
installation
and
connection
securely

e

Carefully
identify

or
OUT

mark
IN

BE
35

OUTLINE
OF
AIR
CONDITIONER

REFRIGERATION

SYSTEM

CONDENSER

COMPRESSOR

RECEIVER
DRYER

COOLING
UNIT

ELECTRICAL
CIRCUIT

OUTLINE
OF
AIR

CONDITIONER

The

air
conditioner
consists

es

sentially
of
a

cooling
unit

compressor

condenser
receiver

dryer
and

piping

The

cooling
unit

secured
with

three

brackets
is
a

ttached
to
the

location

occupied
by
the

package

tray

in
the
dash

panel

The

cooled
air
from
the
duct

is

directed
into
the

passenger
compart
Air

Conditioning

DESCRIPTION

CONTENTS

AC
2

AC3

AC
3

AC3

AC4

AC4

AC
5
DESCRIPTION

MAIN

RELAY

FAN
SWITCH

THERMO

SWITCH

PRESSURE
SWITCH

COMPRESSOR
RELAY

F
I
C
D

SOLENOID
VALVE
AC
5

AC
7

AC
7

AC
7

AC
7

AC
7

AC
7

ment

through
the
three

outlets
at

the

instrument

panel

The

compressor
serves
to

compress

the

vaporized
refrigerant
and
is
attach

ed

through
the
bracket
to
the
loca

tion

occupied
by
the

mechanical
fuel

pump
on
the

engine

The
condenser
cools
the

compres

sed

refrigerant
vapor
sent

by
the
com

pressor
and
is

located
on

the
front
of
the
radiator
in

the

engine
compart

ment

The
receiver

dryer

serving
as
a

reservoir

for

storage
of
the

liquid
sent

by
the
condenser
is

located
on
the

right
in
the

engine
compartment

The

piping
consists
of

two
flexible

hoses

and
five

copper
tubes
which

connect
various

components
of
the

air

conditioning
system

I

Cooling
unit

2

Expansion
valve

3
Receiver

dryer

4

Comressor
5

Condenser

6
Duct

@
Flexible
hose

@
Copper
tube

AC
2
AC724

Fig
AC
1

Cooling
system

Air

Conditioning

REMOVAL
AND
INSTALLATION

COMPRESSOR

REMOVAL

INSTALLATION

IDLER
PULLEY

FAN
BELT

TENSION
ADJUSTMENT

REMOVAL
AND
INSTALLATION

INSPECTION

COOLING
UNIT

REMOVAL
AND
INSTALLATION

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

RECEIVER
DRYER
AND
PIPING

COMPRESSOR

REMOVAL

I
Remove

battery

2

Disconnect

compressor
lead
wire

at
connector

3
Loosen
idler

pulley
lock

nut
then

adjusting
bolt
Remove

compressor

drive
belt

from

compressor
pulley

AC477

Fig
AC
28

Removing
drive
belt

4

Discharge
system
Refer
to
Dis

charging
System
under
General
Service

section
CONTENTS

AC
25

AC25

AC26

AC
27

AC
27

AC27

AC
27

AC27

AC
27

AC
2B

AC
29

AC
29
REMOVAL

AND
INSTALLATION

INSPECTION

WIRING

HARNESS
AND

COMPONENTS

WIRING
DIAGRAM

MAINTENANCE

MAIN
RELAY

COMPRESSOR

RELAY

FAN
SWITCH

RESISTOR
FOR
FAN
SWITCH

THERMO
SWITCH

F
I

C
D
SOLENOID
VALVE
AC29

AC29

AC30

AC30

AC31

AC31

AC31

AC31

AC32

AC32

AC
32

5
Remove
flexible
hose

fixing
plate

and
disconnect
low
and

high
pressure

flexible
hoses
from

compressor

Notes

a
Use
two

wrenches
when
disconnect

ing
pipe

joints

b

Plug
flexible
hose
and

compressor

joint
openings
immediately
after

disconnection
to

prevent
entry
of

dust
moisture
laden
air
etc

Fig
AC
29

Disconnecting
ftexible

hoses

from
compressor

6
Remove

bolts

securing
fuel
tube

to

compressor
attachment

AC
25
Y
1

L

AC744

7
Remove
four
bolts

securing
com

pressor
to
its
bracket

Compressor
and

attachment

can
now
be
detached
as
an

assembly

Notes

a
There
are
a

total
of
four
bolts
two

on

upper
side
of
bracket
and
two

on
lower
side
of

compreSsor

Loosen

upper
bolts
and
remove

lower
bolts
When

removing
upper

bolts

securely
hold

compressor

with
one
hand

b
When

installing
temporarily
tighten

upper
bolts
then

tighten
lower

bolts

I

o

Fig
AC
37

Disconnectirt
connector
3

DISASSEMBLY
AND
ASSEMBLY

I
Remove
bracket
and
lead
wire

connector
main

relay
thermo
switch

resistor

motor
etc
from

cooling

unit

2

Remove
five
screws
and
duct

3
Remove
main

relay

4

Remove
thermo
switch

5

Remove
three
screws
and
five

springs
securing

upper
case
lower
case

and

rear
bracket

6
Unfasten

fittings
securing
inlet

and
outlet

pipes
Air

Conditioning

11
To
install

cooling
unit
reverse

the
order
of
removal

Notes

a

Apply
a
coat
of

fresh

compressor

oil
to

sealing
surfaces
when
COD

necting
pipe
joints

b
Use
two
wrenches
when
connecting

cooling
pipes

c
Evacuate
cooling

system
then
re

chaJge
with

refrigerant

Refer
fo

Evacuating
and

Charging

System
under
General
Service
see

tion

9

7

Upper
and
lower
cases
can
now

be

separated

8
Remove
motor
and
fan
as
an

assembly
Also
remove

evaporator

9
Peel
heat

insulating
tape
from

ex

pansion
valve
and
unfasten

clip
secur

ing
expansion
valve

capillary
tube
to

pipe

Remove

expansion
valve
from

evap

orator

10
To
install
reverse
the
order
of

removal

AG
28
d
Check

refrigerant
leakage
if
neces

sary
repair
Refer
to

Checking
for

Leaks
under
General
Service
sec

tion

Tightening
torque

Copper
tube

joint
nut

High

pressure
side
3

8
in

2
5
to
3
5

kg
m

18
to
25
ft
lb

Low

pressure
side
I

2
in

2
5
to
4
0

kg
m

18
to
29
ft
lb

00

L

1

Motor

2

Fan

3
Lower
case

4

Cooler
duct

5

Evaporator

6

Expansion
valve

7

Upper
case

8
Resistor

9
Main

relay

10
Thermo
switch

11
Cable
c

mp

12
Cable

3
Harness

AC725

Fig
A
C
38

Disassembling
cooling
unit

Expansion
valve

tightening

torque

5

kg
m
36
ft
Ib

Notes

a
When

installing
expansion
valve
on

evaporator
make
sure
that

temper

ature
oensing

capillary
tube
is
in
its

proper
position
on
outlet
side

b

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
of

pipes