DATSUN 210 1979 Service Manual

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

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

0

@
o
s
xl
m
u
U
0
0

xJ
l

1
I
9

0
I
K
s

0
0

en
o
o
l

me
0

r

U
0
I

@
0
0

Tightening
torque
kg
m
ft
Ib

I
Clutch
wheel
bearing
10
Valve
pla
te
assembly

2
Snap
ring
11
Cylinder
gasket
@
i
1
to
3
2
IS
to
23

C
l
3
Clutch
wheel
alsembly
12
Cylinder
head
assembly
@
O
to
1
0
5
1
to
7
2

0
4
Magnetic
coil
13
B
plate
gasket
@
1
5
11

5
Shaft
seal
assembly
14
Bale
plate
@
0
7
5
1

6
Connector
IS
a
ting

7
O
ring
16
au
filler
plug

i
8
Cylindet
head
17
Clutch
assembly

o
Q
9
CyUhder
head
gasket
18
Compreslor
assembly

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

rt

ASSEMBLY

1

Press

bearings
into
V

pulley
with

Bearing
Installer
5T0237
1000

51
02371000

AC503

Fig
AC
47

In

talling
Bearing

2
Install
outer

snap
ring
in

groove

of
V

pulley

3

Using
Installer
KV99l
0061
0

and

Stopper
ST33061000

press
clutch

wheel
into
V

pulley

4
Install
inner

snap
ring
in

groove

of
clutch
wheel

u

Installer

KV99100610

2

Stopper

ST33061000

AC504

Fig
AC
48

Installing
Clutch
Wheel

INSPECTION

I
Check
friction
surface
of
clutch

for

damage
due
to

excessive
heat
or

excessive

grooving
due
to

slippage
If

neceSS3I

replace
clutch
wheel
and

V

pulley
as
a
set
Air

Conditioning

2
The
clearance
between
V

pulley

and
clutch
wheel
should
be
0
4

to
0
6

mm
0
016
to
0

024
in

If
not

replace
clutch

wheel
assem

bly

3
Oil
or
dirt

on
friction
surfaces
of

clutch
wheel
and
V

pulley
should
be

cleaned
with
a
clean
Iint

free
clot

or

suitable
solvent

4
Check
coil
for
shorted
or

opened

lead
wire

Pay

particular
attention

to

grounding

part
of
coil
If
there
is
no

continuity
replace
electromagnetic

coil

Fig
AC
49

Grounding
Point

01
Coil

S

If

clutch

assembly
must
be
re

placed
remember
that
break
in

opera

tion
is

neceSS3I
The
break
in

opera

tion
consists

of

engaging
and
disen

gagingthe
clutch
some

tirty
tlines

SHAFT
SEAL

The
shaft

seal

assembly
of
this

compressor
is

of
a

simplified
design

yet
tight
sealing
and

long

lasting

REMOVAL

It
is
recommended
that
the
com

pressor
be

removed
from

the
car
for

shaft

seal

replacement

I
Remove

oil
filler

plug
with
O

ring

and
drain
the

compressor
oil

AC

28
AC393

Fig
AC

50
Removing
Filler

Plug

2
Remove
clutch
Refer
to
Com

pressor
Clutch
for
removal

3
Remove
shaft

key
from
crank

shaft

L

IJ
C

I

0

ACS07

Fig
AC
51

Removing
Shott

Key

4
Remove

seal

plate

J

e

I

@

IR
n

1
j

AC866

Fig
AC
52

Removing
Seal
Plote

5
With

Compressor
Seal
Puller

pull

out
seal

gland
and
discard

CAUTION

a
iscard
all

parts
of
he

seal
in

cluding
tha

O
ring

b

00
not

use
a

screwdrivel
to

pry

shaft
seal
from
shaft
as

damage
to

shaft

may
result

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