air condition DATSUN PICK-UP 1977 Service Manual

Inspection

Check

continuiry
in
fan
switch

circuit
with
a
test
lamp
or

an
ohm

meter

I

011
I
2
3

ICD

Tt

tt

AC772

Fig
AC
45
Fan
switch

RESISTOR
FOR
FAN
SWITCH

Removal
and
Installation

I

Disconnect
battery

ground
cable

2
Remove

glove
box

3
Remove

cooling
unit
Refer
to

Removal
and
Installation
under

Cooling
Unit

4

Disconnect
resistor
lead
wires
at

connector

@

O
sn
I
3n

CD
00
@

AC492

Fig
AC

46
Resistor

for
fan
switch
Air

Conditioning

5

Remove
resistor

assembly
from

upper
side
of

cooling
unit

Resistor
is

inserted
into

case

6
To
install

res
istor
for
fan
switch

reverse
the

order
of
removaL

Inspection

Test

continuity
between
resistor

and
fuse

THERMO
SWITCH

Removal
and
installation

1
Disconnect

battery

ground
cable

2

Remove

glove
box

3
Remove

duct
from

cooling
unit

4

Disconnect
thermo
switch
control

cable
and
lead
wires

5

Remove
thermo
switch

Note

Capillary
lube
is
fitted
into

groove
in
cooler
unit

6
To

install
thermo
switch
reverse

the

order
of
removal

I

I

AC773

Fig
AC
47

Removing
thermo
switch

AC

32
Inspection

I

Fully
move
thermo
swirch
lever

to
COLD

2

Test

continuity
between

ter

minals
with
a
test

tamp
or

an
ohm

meter

Continuity
should
exist

3

Dip
capillary
tube
end

into
ice

water
Test
continuity
between
ter

minals

Continuity
should
not
exist

4

Replace
if
switch
is

found
dam

aged

F
I
C
D
SOLENOID
VALVE

Removal
and
installation

I

Disconnect
battery
ground
cable

2
Disconnect
lead
wires
and
vacu

um

tube

3

Remove
two
screws
securing
sole

noid

valve
and
remove
solenoid
valve

AC77
4

Fig
AC

48
Removing
F
l
C
D

solenoid
valve

4
To
install
solenoid
valve
reverse

the
order
of
removal

Inspection

1
Test

continuity
in
solenoid
valve

circuit
with

a
test

lamp
or
an
ohm

meter

2
Turn
both
fan
switch
and
thermo

switch
on

3
Run

engine
at
idle
and
check
to

be
sure
that
vacuum
is

present
in
line

between
solenoid
valve
and

diaphragm

DESCR

IPTIDN

COMPRESSOR
CLUTCH

REMOVAL

INSTAllATION

DISASSEMBLY

ASSEMBLY

INSPECTION

DESCRIPTION

Model
CF206
is
a
crank

type

compressor
specially
designed
with

minimum
size
and

light
weight
for

use

on

compact
vehicles

The

compressor
crankshaft
is

driven

by
a
belt
from
the
crankshaft

pulley

through
the

electromagnetic
clutch

Two

pistons
positioned
in

line
are

actuated

by
connecting
rods
coo

nected
to
the
crankshaft

Discharge
and
suction
valves
are

mounted
in
the

valve
liner
between
the

crankcase
and

cylinder
head

As
a
lubricant

SUNlSO
NO
5
is

used

Simplified
positive
pressure

lubrication
utilizes

existing
pressure

differential
between
suction

intake

and
crankcase
to

provide
a
film
of

lubricating
oil
to

bearings
All
internal

components
have
been

designed
to

provide
more
than

adequate
lubrica

tion
to

cylinder
walls

connecting
rod

bearings
and
seal

assembly
The
result

is

improved
lubrication
lower

seal

temperatures
reduced
oil

pumping

and
a

reduction
in
the
number

of

moving
parts
Air

Conditioning

COMPRESSOR

AC33

AC34

AC34

AC34

AC35

AC
35

AC35
CONTENTS

SHAFT
SEAL
ASSEMBLY

REMOVAL

INSTAllATION

INSPECTION

CYLINDER
HEAD
AND
VALVES

REMOVAL

INSTAllATION
AC36

AC36

AC36

AC37

AC37

AC37

AC37

AC728

Fig
AC
49
Sectional
view

of
compressor

AC33

Air

Conditioning

1foo

1t
1

t7
LV

I
1
Clutch
wheel

bearing

2

Snap
ring

3

Clutch
wheel

assembly

4

Magnet
coil

5

Shaft
seal

assembly

6

Service
valve

7

Flange
valve

O

ring

8

Cylinder
head

9

Cylinder
head

gasket

10

Cylinder
gasket

11
Valve

plate
assembly

12
Base

plate
gasket

13
Base

plate

14
O

ring

15
Oil
filler

plug

16
Clutch

assembly

17

Compressor
assembly

COMPRESSOR

CLUTCH

The
most

likely
source
of

problem

is
clutch

slippage
Factors
are
listed

here

Exercise

ample
care

I

Clearance
between
clutch

hub

and

pulley
should
be
0
4

to
0
6
mm

0
016
to

0
024
in

at
all

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
IO
5V

REMOVAL

I

Using
Clutch

Spanner
Wrench

hold
clutch
hub
With
suitable

socket

wrench
remove
bolt

retaining
clutch

hub
to
crankshaft
H

@
@

AC776

Fig
AC
51

Remouing
bolt

2
Then

using
Clutch

Removing

Bolt
remove
clutch

assembly
from

cmnkshaft

Fig
AC
52

Removing
clutch

AC34
AC775

Fig
A
C
50

Exploded
view

of

compressor

3

Loosen
four

electromagnetic
coil

mounting
screws
Coil

assembly
can

then
be

taken
out

easily

Fig
A
C
53

Removing
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

kg
m
5
1

ft
Ib

2
Install
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

Tightening

torque

Clutch
hub

securing
bolt

1
5

kg
m

II
ft
lb

DISASSEMBLY

1
Remove
two

snap
rings
retaining

bearing
They
are

located
inside
of

clutch
wheel

AC500

Fig
AC
54

Removing

snap
rings

2

Using
Clutch
Wheel

Remover

KV99100700
and
conventional

puller

remove
V

pulley
with

bearings
from

clutch
wheel

KV99100700

AC501

Fig
A
C
55

Removing
clutch
wheel

bearings

3

Using
Bearing
Remover

ST33061000

press
clutch
wheel
bear

ings
out
from
clutch
wheel
Air

Conditioning

9

AC502

Fig
AC
56

Removing
V

pulley
from

clutch

ASSEMBLY

I

Press

bearings
into
V

pulley
with

Bearing
Installer
ST02371000
ST02371000

AC503

Fig
A
C
57

Installing
bearin

2

Install
outer

snap
ring
in

groove

of
V

pulley

3

Using
Installer
KV99100610
and

Stopper
ST33061000

press
clutch

wheel
into
V

pulley

4

Install
inner

snap
ring
in

groove

of
clutch
wheel

t

INSPECTION

Check
friction
surface
of
clutch

for

damage
due
to
excessive
heat
or

excessive

grooving
due
to

slippage
If

necessary
replace
clutch
wheel
and

V

pulley
as
a
set

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

AC
35
Installer

KV99100610

2

Stopper

ST33061000

AC504

Fig
AC
58
Installing
clutch
wheel

3
Oil

or
dirt
on
friction
surfaces
of

clutch
wheel
and
V

pulley
should
be

cleaned
with
a

clean
lint
free
cloth
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

AC506

Fig
AC

59

Grounding
point

of
coil

5

If
clutch

assembly
must
lie
re

placed
remember
that

break
in

opera

tion
is

necessary
The
break
in

opera

tion

consists
of

engaging
and

disengag

ing
the

clutch

some

tirty
times

SHAFT

SEAL

ASSEMBLY

The

shaft
seal

assembley
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

vehicle

for

shaft
seal

replacement

I
Remove

oil
filler

plug
with
D

ring

and
drain

the

compressor
oil

Fig
AC

60

Removing
filler
plug

2
Remove

clutch
Refer
to

Com

pressor
Clutch

Removal

3

Remove

shaft

key
Air

Conditioning

jpL

Y
L

I
i
0

I
I

0

Ace07

Fig
AC
61

Removing
s
wft

key

4

Remove
seal

plate

AC80e

Fig
AC

62

Removing
seal

plate

5

With
the

Compressor
Seal

Puller

pull
out

seal

gland
and
discard

Notes

a

Discard
all

parts
of
the
seal

includ

ing
the
O

ring

b
Do

not
use
a

screwdriver
to

pry

shaft
seal
from
shaft

as

damage
to

shaft

may
result

AC809

Fig
A
C

63
Removing
s
wft
eal

INSTALLATION

1
Clean

shaft
and
seal

cavity
with

clean

lint
free
cloth

2

Dip
seal

gland
in

clean

refrigerant

oil

AC
36
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

1

I

Fig
AC
64

Inserting
wft
al

ass

mbly

5

Place
carbon

ring
in

ring
retainer

so
lapped
surface
is

facing
outward

Note

The
indentions
in
outside

edge

of
carbon

ring
must

engage

driving

lugs
and
be

firmly
seated
in

re

tainer

6
Install
new
D

ring
in

groove
of

seal

plate

Note

Use

refrigeration
oil
to

make
it

adhere
to
surface

7

Space
seal

plate
with

equal
clear

ance
around

shaft
and

insert

cap

screws

8

Tighten
these

screws

evenly

Tightening

torque

Seal

plate
securing

cap
screws

0
7
to
1

0

kg
m

5
to
7
ft

Ib

AC811

Fig
AC
65

8p
cing
01

plate
and

tightening
cap
screws

9

Install

clutch
Refer
to
Com

pressor
Clutch
Installation

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

CYLINDER
HEAD

AND
VALVES

Insufficient

refrigerant
compression

is

likely
to
be
caused

by

damaged
head

gasket
or

damaged
valves

Prior

to

servicing
the
head
and
valve

plate
both
service

valves
should
be

opened
to
free

any
gas

pressure
which

may
be
in

the

compressor

REMOVAL

I

Remove
the
bolts

from

flanged

type
service

valves

using
Torx
Driver

Bit

Note
The
direction
of

flanged
type

service
valves

should
be
noted
for

reinstallation

AC812

Fig
AC
66

Removing
service
valves

2
Remove
the

remaining
bolts
in

the
head
Air

Conditioning

AC813

Fig
A
C
6
7
Removing

cylinder
head

bolts

3
Remove

valve

plate
and
head

from

cylinder
by
prying
or

tapping

under
the
ears
which
extend
from

valve

plate

If
head
and
valve

plate
adhere
hold

head
and

tap
valve

plate
ears

away

from

head
with
a

soft
hammer

Note
Do

not
hit
or

tap
head
to

separate
head
and
valve

plate
be

3use

damage
to
head

may
result

Fig
AC
68
Removing
valve

plate

and
head

4
When

removing
the

gaskets
use
a

sharp
edged
knife

Notes

a
In

removing
head

gasket
be

very

careful
not
to

damage
machined

sealing
surface

b
Do

not
reuse

gaskets

AC815

Fig
A
C
69
Removing
gasket

AC37
INSTALLATION

Valves
and
valve

plates
are
furnish

ed

only
as
a

complete
assembly

I

Apply
a
thin

film
of
clean

refrig

eration

oil
on
area
of
crankcase
to
be

covered

by
cylinder
gasket

2
Place

cylinder
gasket
in

position

on

cylinder
so
dowel

pins
in
crankcase

go
through
dowel

pin
holes
in

cylinder

gasket

3

Apply
a
thin

film
of
clean

refrig

eration

oil
to

top
and
bottom
valve

plate
areas
to
be
covered

by
gaskets

AC816

Fig
A
C
70
Applying
clean

refrigeration
oil

4
Place
valve

plate
in

position
on

cylinder

gasket
so

discharge
valve
as

semblies
i

e
smaller
diameter
assem

blies
with
restrainer

over
valve
reed

are

facing
up
and

locating
dowel

pins

go
through
dowel

pin
holes
in
valve

plate

Fig
A
C
71
Placing
valve

plate

5
Place
head

gasket
in

position
on

valve

plate
so
dowel

pins
go
through

dowel

pin
holes
in

gasket

6

Apply
a
thin
film
of
clean

refrig

eration

oil
on
the
machined
surface
of

cylinder
head
which

matches
head

gasket

7

Place
head
on

cylinder
head

gasket
so
dowel

pins
go
into
dowel

pin

holes
in

head
Air

Conditioning

8

Apply
a

thin
fihn
of
clean

refrig

eration
oil

to
service

valve

flanges

9
Place

flange
valve
O

ring
in

posi

tion

on

cylinder
head

10
Place
service
valves
in

position

on

proper
service
valve

ports
suction

or

discharge
and
insert

two

longer

screws

through
service
valve

mountiing

pads
head
valve

plate
and

into
crank

AC
38
case

11

Insert

remammg
head

screws

and

run
in

all
screws
until
the

heads

make

contact

Tightening
torque

Head
and

service
valve

screws

2
1

to
3
2

kg
m

15
to
23

ft
lb

Air

Conditioning

SPECIAL
SERVI
CE
TOOLS

Unit
mm
in
For

use

on
Reference

page
or

Figure
No
No
Tool
number

tool
name
Description

KV99100700

Clutch
wheel

remover
To

remove
clutch
wheel
from
V

pulley
620

Fig
AC
55

BE436

2

KV991006S0
To
install
clutch
wheel
into
V

pulley
620

Fig
AC
58

Clutch
wheel

38

1
50

1

installer
set

KV99100610

Installer

ST33061000

Stopper

BE437

3
ST33061000
To

remove
clutch
wheel

bearing
from
V

pulley
620

Fig
AC
56

Bearing

remover
38
1
50

BE438

4
ST02371000
To
install
clutch
wheel

bearing
into
V

pulley
620
Fig
AC
57

Bearing

installer
50
1
96

Co

tJ
BE439

AC
39

Air

Conditioning

Tool
number

For
Reference

No
Description

use

page
or

Remarks

tool
name

Unit
mm
in
on

Figure
No

5
Clutch

To
hold
clutch

wheel
when

removing
clurch

wheel
620

Fig
AC
51

124878
1

spanner
wrench

6
Clutch

removing

bolt

7

Compressor
seal

puller

8

Torx
driver
bit

9

Oil

dip
stick
To

remove
V

pulley
from
crankshaft

To

remove
shaft
seal
from

crankshaft

To
remove

flange
bolts

To

inspect
oil
level

AC
40
BE440

BE441

BE442

B

E443

BE434
620

620

620

620
Fig
AC
52
126344

Fig
AC
63
J

10549

Fig
AC
66
124392

110545