air condition DATSUN 210 1979 Service Manual

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

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

for
Leaks
Here
is

how
leaks

are

stopped

I

Check

torque
on

the
connection

fitting
and
if
too
loose

tighten
to
the

proper
lorque
Check
for

gas
leakage

with
a
leak
detector
Air

Conditioning

2
If

leakage
continues

ven
after

the

fitting
has
been

retightened
dis

charge
refrigerant
from

system
disc
on

net

the

fittings
and

check
its

seating

face

for

damage

Always
replace
even

if

damage
is

slight
J

Check

compressor
6il

and
add
oil

if

required

4

Charge

refrigerant
and
recheck

for

gas
leaks

If

no
leaks
are
found

evacuate

and

charge
system

SERVICE
PROCEDURES

FAST
IDLE

ACTUATOR

ADJUSTMENT
OF

IDLE
SPEED

Engine
model

Transmission
When

A
C
is
OFF
When
A
C
is
ON

F

LCD
is

actuated

Manual

700

rpm
800

rpm

A14
A15

Automatic
650

rpm
800

rpm

at
D

position
at
N

position

The
fast
idle

control
device
is
used

on

cars

equipped
with

an
air

condi

tioner
to
raise
the

idle

speed
auto

matically

Use
the

following
procedures
when

adjusting

1
Run

engine
until
it

reaches

oper

ating

temperature

2

With
air
conditioner
in

OFF

when

compressor
is
not

operated

make

sure
that

clearance
e
between

levers
A
and

8
is

more
than

J
mm

0
12
in

If
clearance
C
is

less
than

J

mm
0
12
in

loosen
cable
lock

screw
and

push
down

on
lever
A

so

that
clearance
C
is

more
than
J
mm

0
12
in

3
Make
sure

that

engine
is
at
cor

rect
idle

speed

4

With
air

conditioner
in

ON
when

F

LC
D
is
actuated

set

engine
speed

to
800

rpm
using

following
procedures

as
a

guide

I
Turn

adjusting
screw
until
en

gine
speed
is
800

rpm

On
cars

equipped
with
automatic

transmission

make
this

adjustment

with
shift
control
lever
in

N

posi

tion
2
If

engine
speed
cannot
be

adjust

ed

properly
with

adjusting
screw

check
and

adjust
clearance
e

again

3

Depress
and
release
accelerator

pedal
several
times
and
make

sure
that

engine

speed
reduces
to
800

rpm
as

pedal
is

released

If
correct

adjustment
is
not
made

repeat

steps
I
to
3
above
until

engine
speed
is

800

rpm
at

idling

1

FlCD

adjusting
screw

2
Lever
A

3
Lever
B

4

Cable
lo
k

screw
Clearance

e

AC381
A

Fig
AC
24
Fast
Idle
Actuotor

AC
18
REMOVAL
AND

INSTALLATION

Remove

vacuum
hose
from
actua

tor

2

Remove
air

cleaner

assembly

3

Remove
cotter

pin
and

pin
and

disconnect

actuator
from
F

LC
D

lever
connected

to
throttle
shaft

4

Remove

actuator

attaching
nuts

then
remove
actuator

5
Install

actuator
in

the
reverse

order
of
removal

6
After

installing
adjust
actuator

Refer
to

Adjustment
of

Idle

Speed

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

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

Note
When

installing
thermostat
in

sert

capillary
tube

in
same

place
as

it
was

before
removal

Be
sure
to

insert

capillary
tube
end
about
SO

em

19
7
in
from

evaporator
core

INSPECTION

1
Test

continuity
between
two

switch
terminals

with
test

lamp
or

ohmmerter

Continuity
should
exist

2
With

capillary
tube
end

dipped

into
ice

salt
water
maintained
to
I

oc

300
F
test

continuity
between
two

switch

terminals

Continuity
should

not
exist

3
If

switch
is

found

damaged
re

place

MAIN
RELAY

REMOVAL

AND

INSTALLATION

I
Disconnect

battery
ground
cable

2
Remove

glove
box

3
Disconnect

connector
from
main

relay

4

Remove
screw

retaining
main

relay
to

cooling
unit
then
remove

main

relay

5

Installation
is
in
the
reverse

order

of

removal

INSPECTION

Test

continuity
of

relay
with
ohm

meter
or
test

lamp
In

testing
main

relay
there
must
be

continuity
be

tween

CD
and

CV

When
l2Y

direct

current
is

applied

to

CD

CV
CID

@
normally
close

ti

I

I
6

i

i
f

i

f

Fig
AC
33
Air

Conditioning

HEATER
UNIT

Refer
to
Heater
Unit

Section
BE

WATER
COCK

Refer

to
Water
Cock
Section
BE

BLOWER
MOTOR

Refer
to
Blower

Motor
Section

BE

RESISTOR

Refer

to
Resistor

Section
BE

MICROSWITCH

CV

REMOVAL
AND

INSTALLATION

1
Remove
air

conditioner
control

assembly
Refer

to
Heater
Control

Assembly
Section
BE

2

Remove
screws

attaching
micro

switch
and

then
remove
rnicroswitch

3

Install
rnicroswitch
in
the
reverse

order

of
removal

I

NSPECTI
ON

Make

sure
that

continuity
exists
in

AC
23
AIR

CONDITIONER

CONTROL

Refer
to
Heater
Control

Assembly

for
Air

Conditioner
Section
BE

Note
When

adjusting
AIC
control

cable

and
rod

keep
in
mind
that

OFF

on
front

panel
is
used
as

A

C
for
air

conditioning
sys

tem

FAN

SWITCH

Refer
to

Fan
Switch
Section
BE

1
Microswitch

2
Fan
switch

AC19SA

Fig
AC

34
Microswitch

rnicroswitch
when

its

protruding
part

is

pushed

w

AC199A

Fig
AC

35
Microswitch

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

WIRING
DIAGRAM

CIRCUIT
DIAGRAM

Air

conditioner
system

G
DD

w

FUSIBLE

LINK

I
BATTERY

LG
Lr

LG
c
J

LW
J

I
THERMOSTAT

W

W

r
B

B
8

ALTERNATOR

IGNITION

SWITCH

il

W

LB

LLG

J

LOW
PRESSURE

SWITCH

L
c
J

L
c
J

l

J
MAGNET

VALVE

L

c
J
CJ
C

COMPRE
SOR

CLUTCH

LIT

IACC

15A

L1

3
E
FUSE
BLOCK
Air

Conditioning

W

1
8
t
FUSE

20A

MAIN

RELAY

J
rn

W
I

fJ
RESISTOR

Dt
J

M
BLOWER

MOTOR

W

c
J
c
J
C

r

BvM

LW

LY
I

MICRO

SWITCH

B

AC404A

Fig
AC
39
Circuit

Diagram

of
Air
Conditioner

I

AC

25

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