clutch DATSUN 210 1979 Manual PDF

Air

Conditioning

4

1
Control
wire

2
Control
rod

3
Intake
actuator

4
Vacuum

switch

5

Check
valve

6
Intake

return

spring

7
Intake
door

AC268A

Fig
AC
9
Intake
Actuator

AC
7
ELECTRICAL
CIRCUIT

DESCRIPTION

The

following
wiring

diagram
pro

vides
a

complete
description
of
the

whole

circuit
When

both
the

ignition

switch
and
fan

switch
are
tu
ned
on

the
main

relay
is

actuated
and

electric

power
is

supplied
to
the

blower
motor

and
electric
clutch
of
the

compressor

The
blower
motor

speed
is
controlled

by
the

fan
switch

with
the

aid
of

resistors
The

compressor
clutch
is

actuated

by
the

thermostat
A

fuse
is

part
of
the
air

conditioner
harness

Air

Conditioning

Ale
position

Main

relay

Blower

motor

Fan
switch

Fusible

r
link

o
c

Fuse

This

fuse
is
built

into
air

con
harnes
s
I

L
RW
B
5
d

2nd

I
I
olst

Resistor
1

Battery
Ignition
Fuse

1
switch

Micro
switch

Low

pressure
switch

0

Thermost

T
I

CompreSsor

clutch

roo
h

Magnet
valve

AC269A

VENT
8

L
HEAT
DEF
and
REC
HEAT

position

Main

relay

Blower
motor

Fusible

1
link

0
O
C

Fuse

This
fuse
is
built

into
air
coil
harness
RW
o
Fan
switch

Ignition

switch
r
o

Fuse
5
d

2nd

olsl

I

Resistor

0
1

Micro
switch

j

Battery

Low

pressure
switch

0

J

The
most

T
tr
r

I

Compressor

clutch

Magnet
valve

AC270A

Fig
AC
IO
Electrical
Circuit

Ac
a

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

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

Com
pressor
OFF
I

I

Blower
makes

noise
Repair
or
re

place
blower

Bearings
of
com

pressor
clutch
or

idler
pulley

make
noise

Replace

C
l
W
Noisy
Compressor
itself
makes

noise
Repair
or

replace
com

pressor
Belt
is
loose

Adjust
belt

Suction
pressure
is
low

Strainer
in
pipe

Line
Is
restricted

Replace
strainer

Pipe
at
receiver

drier
outlet
has

low
temperature

Receiver
drier
is

restricted
Replace

receiver
drier
I

Fin
and
tube
of

evaporator
or

laminated
evapo

rator
have
some

dents
Replace
or
repair

evaporator

Expansion
valve
is

close
excessively

or
gas
leakage
from

thermo
bulb

Replace
expansion

valve
Compressor
ON
J

I

When
engine

rpm
is
changed

there
are
reso

nant
sounds

Retighten
com

pre
ssor
bracket

bolts
Piping
is
reso

nating
Add

clamp
Insufficient
cooling

Bubbles
in
sight
glaS

Check
refrigeration
line

for
gas
leaks
and
repair

leaks
if
any
Charge
re

frigerant
to
correct

level
In
case
of
too

many
leaks
stop
com

pressor
discharge
the

system
evaCUate
and

recharge
the
system

As
necessary
replace

receiver
drier

Air
in
system
may

cause
bubbles
in
sight

glass

System
pressure
and
temperature
of
discharge
air
llre

abnormal
Refer
to
Performance
Test
Diagnoses

for
detail

Suction
pres

sure
is
high

Expansion

valve
is
open

excessively
Replace
ex

pansion
valve
Discharge
pressure
is

high

Overcharge
of
refrigerant

Discharge
some
of
refrig

erani
to
correct
level

Air
is
mixed
in
Discharge

system
and
replace
drier

Evacuate
and
recharge

system
Condenser
s
fin
is
dented

or
clogged
with
dust

Clean
exterior
surface

with
water
No
bubbles
in

sight
glass

With
manifold
gauge

check
system
pres

sures
Measure
tem

perature
of
discharge

air
Refer
to
Perform

ance
Test
Blower
does
not

rotate
Refei
to
Blower

Motor
Diagnoses

Temperature
of
discharge

air
is
abnormal
but
system

pres5ure
is
normal

Suction
pressure
iJ

high
while
dis

charge
pressure
is

low
Valve
or
gasket

of
compressor
is

damaged
Repair
or
replace

compreuor
Check
air
flow

system
Refer
to
Air

Conditioner
Operation
Chart
Compressor
does
not
run

Refer
to
Com

pressor
Diagnoses

Check
grommets

on
car
s
dash

panel
for
air

leaks
check

other
seal
of

car

J
COnlp
reSSOI
clutch
is
not
J

engaged
c
00

ha
voltage
decreased

to
es
thall
lO
5V

Lead
wire
or
com

pressor
clutch
is

dead
I
Ground
terminal
of
coil

is
poor
a
t
connection

Repair
connection

Refer
to
CompreSior

Clutch
Diagnoses
J
J

r
In
c
e
Clutch
is
not
en

gaged
yet
replace

compressor
dutch

lr1

vetChatgO
of
Ief
ge1ant

I

I
e
refrigotant
gas
10
n
o
t
cnt
j

that
sight
gla
ss
of
receiver
drier
has

onlY
a
few
bubble

Engine5peed
l
OOrpm

i
l

r
Check
for
dis

charge
pressure

OK
if
dbcnarge

pres
ure
is

reduced
Discharge
pres

sure
is
not

reduced
l
Compressor
clutch
is
engaged
but
compre
sor

doe
not
IUn

Cbeck
and
re

adjust
gap
of

clutch
Clea
Il
oil
OJ
dust

on
contact
sur

face
of
clutch

if
slipping
con

ti
n
ues
rCPlaO
J

compressor
clutch
Check
belt
teMion

and
adjust
it

lfbelt
bwor
l
out

or
damaged
ie

pl
ce
iI

Air
in
refrigeration
System

J

Discharge
system
ftom
service

valve
on
discharge
side

Evacuate
a
nd
rech
arge
the

Lystem
J

When
torque
is
stm
grellt
repair

or
rtV1ace
compressor

j
T

son
rod
l

mp
teSSOI

j
Internal
problem

in
cornpre
sor
cyl

inder
Check
y
tem

Repau
or
replace

nece
tY
J
r
Compte
r
oille
ing
J

Air
blOW
on
spot
whcre
oil
leak
e
vidence
is

round
Then
check
for
refrigerant
leakS
us
n

leak
detectof

Refrigerant
leaking

Repau
01
replace

compttUOr
I

NO
teftig

lea
ing

Wipe
clean
oil

wi
h
Jag

L
Noisy
onlY
when

clutch
is
engaged

Check
for
oo
c

comprenor
mount

ing
Dolts

Retighten
bolts

Compressor
drive

belt
islOosc
Adjust

belt
ttM1on

If
cotTlpre
sor
is

noisY
yet
repair

or
replace
compres

sor
Noisy
when
clutch

is
not
engaged

Remove
cQm1JressOt

belL
Turn
pulley
of

compressot
clutch
by

hand
and
check
for

noise
If
noisC
is

MaId
repair
com

preM
or
clutCh

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o
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a
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