check DATSUN PICK-UP 1977 Service Manual

REFRIGERANT

LEAKS

If
leaks
are

noticeable

leaky
parts

should

be

repaired
Then

system

should
be

filled
with

refrigerant
Do

not

operate
compressor
with

refriger

ant

level
e

cessively
low

If
this
caution
is

neglected
a
burnt

compressor
will

result
since

heavy
loss

of

refrigerant
usually
indicates

heavy

loss
of

compressor
oil

If

system
has

been

exposed
to

atmosphere
for
an

extended

period
of
Air

Condition

ing

time

receiver

dryer
must

be

replaced

If
leaks
are

slight
and
no
air
is

present

in

system
add

refrigerant
as

necessary

To

detect
leaks
refer
to

relative

topics
under

Checking
for

Leaks

Here
is

how
leaks
are

stopped

I

Check

torque
on
the

connection

fitting
and

if
too
loose

tighten
to

the

proper

torque
Check
for

gas

leakage

with

a
leak

detector

2
If

leakage
continues

even
after

AC
18
the

fitting
has
been

retightened
dis

charge

refrigerant
from

system
discon

nect
the

fittings
and
check
its

seating

face
for

damage
Always

replace
even

if

damage
is

slight

3
Check

compressor
oil

and
add
oil

if

required

4

Charge

refrigerant
and
recheck

for

gas
leaks
If
no
leaks

are
found

evacuate

and

charge

system

Air

Conditioning

TROUBLE
DIAGNOSES
AND
CORRECTION

CONTENTS

COOLING
DIAGNOSES

FUNCTION
TEST

STANDARD
PERFORMANCE

PERFORMANCE

TEST
DIAGNOSES
AC19

AC
20

AC
20

AC21
COMPRESSOR

DIAGNOSES

NOISE

DIAGNOSES

BLOWER
MOTOR

DIAGNOSES
AC
22

AC23

AC24

COOLING
DIAGNOSES

INSUFFICIENT
COOLING

I

I

Check
amount
of

discharged
air

j

If
OK
No
or
insufficient

discharged
air

Performance
test

Refer
to

performance

test
on
the

following

page
1

ChecK
blower

I

I

I
If
OK

I

I

Repair
cooling

unit
Blower

stops
Check

sight
glass
for
bubbles

I

I

Many
bubbles

I

I
No
or

few
bubbles

Check
refrigeration
line

for

leakage

Note
If
there

are
too

many
bubbles

stop
compressor
and

check
for

leaks

Then

evacuate
and

recharge

system
Refer
to

Blower
motor

diagnoses

I

If

OK
lfleaks

Discharge
the

system

Evacuate

and

recharge
Repair
leaks
and

recharge

AC
19

Air

Conditioning

PERFORMANCE
TEST
DIAGNOSES

Condition

Discharge
air
too
warm

a
Both

discharge
and
suction

pres

sure
too

high

b
Both

discharge
and
suction

pres

sure
too
low

c
Discharge

pressure
too

high
and

suction

pressure
too
low

d
Suction

pressure
too

high
and

discharge

pressure
too
low

e

Discharge

pressure
normal
and

suction

pressure
too

high

t
Discharge

pressure
normal
and

luction

pressure
too
low

g
Suction

pressure
normal
and

discharge
pressure
too

high

h
Both

discharge
and
suction

pres

sure
normal

Air

conditioning
is

operating

properly

Discharge
air
normal

or
too
cold

a

Discharge
pressure
normal
and

suction

pressure
too
low
Probable
cause

Air

mixed
with
refrigerant
in

system

Overcharge
of

refrigerant

Loose
fan
belt
or

engine
over

heating

Obstructed
or

dirty
condenser
fins

Insufficient

refrigerant
charge

Over

filling
of

compressor
oil

Damaged
compressor
valve
or

pack

ing

Loose

compressor
drive
belt

Clutch

slippage

Faulty
expansion
valve

Clogged
expansion
valve
strainer

Water
has
frozen
at

expansion

valve

Faulty
expansion
valve

Faults
of
both

a
and
h
exist

Air
leaks
from

engine
com

partment

Restricted
air
flow

through
evapo

ratof

Slow
blower
motor

speed

AC
21
Corrective
action

Evacuate
and

charge
system

Discharge
some
of

refrigerant
to

correct
level

Adjust
fan
belt
or
check

cooling

system

Clean
exterior

surface
with
water

Add

refrigerant

Drain
oil
and
correct
oil
level

Refer

to

Compressor
oil
level

check

Repair
or

replace
compressor
Refer

to

Compressor

Adjust

Repair
Refer
to

Compressor

Reinstall

sensing
bulb
correctly
to

keep
it

tight
to

pipe

Replace

Clean
strainer

Evacuate
and

charge
system

Replace

Correct

sealing

Clean

evaporator
fins

Check
and

repair
blower
motor
and

wiring

Air

Conditioning

COMPRESSOR

DIAGNOSES

I
COMPRESSOR

TROUBLE

Turn
the

compressor
dutch
wheel

by
hand

I

I

If

OK
j

Will
not
turn

Apply
12V
direct

current
to

compressor
clutch

Then
check
clutch

engagement

I

j

If
OK
I

Internal

problem
in

compressor
cylinder

Repair
or

replace
compressor

Check

voltage
oflead
wire

for

compressor
on

cooler
cable

I

I

If
OK
I
Clutch
does
not

engage

I

Clutch
is

damaged

Repair
or

replace
dutch

assembly

No

voltage

I

Internal

problem
in

compressor

Repair
or

replace

compressor
Check
or

repair
wiring
system
for

compressor

clutch

AC
22

Air

Conditioning

NOISE
DIAGNOSES

NOISY

I

I

I
Set
fan

switch
on

2

Change
the

engine
rpm

frequently

Detect

the
source
of

noise

I

From

engine
compartment
From
cabin

Cooling
unit

j

Check
the

resonant
sound
when
the

engine
rpm
is

changed

I

I

No

resonant
sound

Compressor
itself
makes
noise
j

Blower
motor

makes
noise

Replace
or

repair
blower

Resonant

sound

Repeat
compressor
clutch
ON
and

OFF

This

checking
can
be

performed
by
changing

engine
rpm
while

fan
switch
is

set
at

ON
Retighten
compressor
bracket
bolt

If

piping
is

resonating
add

clip

Noisy
only
when
clutch
is

engaged
Noisy
when

clutch
is
not

engaged

I

Check
drive
belt
for

slackness

Check
for
loose

compressor
mounting
bolts

I

I
Remove

compressor
belt
then
turn

compressor

pulley

by
hand
If
noise
is
heard

repair
com

pressor
clutch

If

OK

If
loose

Compressor
itself
makes
noise

Repair
or

replace
compressor
Retighten
or

adjust

Nl1

Air

Conditioning

BLOWER
MOTOR
DIAGNOSES

Blower
motor

inoperative

Check
fuse

In
fuse
block

15A
W

Single
fuse
15A
at

cooling
unit

I

j

If
OK

Check
the

continuity
and

fitting
of
fan
switch

I

I

If
OK

I

I

Connect
fan
switch
to

wiring
harness

2

Turn
the

ignition
switch
ON
IG

3
Set
fan
switch
at
ON
1
2
or
3

position

Check
the

voltage
for
blower
motor

Blue
lead
wire
is

poweI
source

Blue
wire

with
white

stripe
is

for

grounding

I

I
Voltage

I

I

Check
the

continuity
and

fitting
of
resistance
on

cooling
unit

I

I
If
OK
If

damaged

I
I

Replace
blower
motor
Replace
resistance

AC

24
mown
fuse

Replace
fuse

j

If

damaged

I

I

Replace
fan
switch

No

voltage

Replace
main
relay

IDLER

PULLEY

FAN
BELT
TENSION

ADJUSTMENT

The

standard

compressor
drive

belt

tension
is
between

8
and
12

mm

AC480

Note
Be

sure
to

loosen

locking
nut

before

turning

adjusting
bolt
Re

tighten
it

after

adjustment

REMOVAL
AND

INSTALLATION

Remove
drive

belt

To
do
this
loosen

locking
nut

before

loosening

adjusting
bolt
Drive

belt
will
then
be
detached

2

Remove
idler

pulley
from
bracket

by
r

J1e

vM
or
king
nut

jiwT
9ff
t

llil
reverse
the

order
of

rerr
oval
jldJ
1
t

Jldr

J
I

INSPECTiON

Oheck
idler

pulley
for

smooth
rota

tion

G
0

llfHt
H
Y

d
H

u
t
1
W

n
l

ot
Jrk
H
l

Check
i

ler

pulley
bracket
for

cracks

Replace
arts
iffound

damaged

c

f
lOJ

gD
IlI
J
l

gtt
flvlnv

nOj
IH

q
g

cll
dE
m
J

COOLING
UNIT

REMOVAL
AND
oM1

INSTALl
A

1lIONI
gnillslUli
n

dW
C

19qm91
crft

llU2
3

6rn
f01
Gl0ql

pj

nDiScoimecprlY
i

ferY
lgroUR
hable

2

Disbhargiou
y
tem

iRefrflsll
Qis

chargingrSystemiillidenGeneral
S

ervicel

sectiom5qiq
10
2
9
fl
1U
n
1Ii
2

oj
liD
Air

Conditioning

0
32
and
0
47
in

when

depressed

with
thumb

pressure
midway
between

the
crankshaft

and

compressor
pulleys

If

necessary
turn

adjusting
bolt

to

move
idler

pulley
up
or
down

until

belt

tension
is

correct

Idler

pulley

Crankshaft

pulley

AC456

Fig
AC
32

Adjustment
of
bolt
tension

3

Connect
low

and

high
pressure

pipes
to
their

proper
positions
in

engine
compartment

Notes

3
Be
sure

to
use
two

wrenches
when

connecting

pipe
joints

b

Plug
pipe

opening

immediately

after

pipe
disconnection

c
Be

careful
not
to

break

expansion

valve
This
valve
is

wrapped
with

heat

insulating
tape

0

J
JWu

J
1
2
ld

m

bm
Ufl

J51
8

I

1

lEldgJ
v
Jwm
j

y
d
n
l2u

1
C765

X

fIlO
1i

qJ
j

gnjlcfu2fIJ
lc
rf

1551

1UJ

flip
1h
tqnPfffi2n
Wfi

i
V1c
ip

j

at
3duJ

lsIliqr
J

wlr
v
n

irWfiqX
ani

qiq

4q
v
Remo
e

tworgromll
ets
from

dash

panel
lots
n

5
lRemove

glovelbox
lBl
n1

oT
0

6

Detach

cooling
unit

cover

Icyom
n

AC

ZA
AC766

Fig
AC
34

Removing
cooling
unit

cover

7

Remove
three
ducts

from

cooling

unit

i

j

l

I

11

AC767

Fig
A
C
35

Removing
cooler
ducts

8
Remove
thermo

switch
control

cable
from

conne
ctor

9
Remove

cooling
unit

and
bracket

as
an

assembly

J

t

AC768

F

lIJAh
Cr
P

3
6
R
1

7
fi
vorr

l
l51
r

Ig

emo
vmg
coo

mg
um

r

n
I1iBITJ
0HJ
Jl
t

rbtivl2

Ofm
IIfj

wom
51
f

H

f
L

ol

IJgjjJpn
1I
SH
tc

vehicle
bn

y
with
five
rews

q

2tl
G

i
O

r
Jv
a8f1l1

J
a

I
ld
1

51
b
nc

IOJni

QisconnecEf
twonleadliwif
eUcon
1

nectars
from

cooling
unitqiq
s
iuo
UHf

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

INSPECTION

Evaporator

Check

evaporator
for

leakage
or

damage
If

damaged
replace

Expansion
valve

Check

expansion
valve
for

leakage

or

clogging
If

clogged
clean
filter
in

expansion
valve
If

damaged

replace

RECEIVER
DRYER

AND

PIPING

REMOVAL
AND

INSTAUATION

Receiver
dryer

I
Disconnect

battery
ground
cable

2

Discharge
system
Refer
to

Dis

charging
System
under
General
Service

section

3

Disconnect

compressor
lead
wire

at

connector

4

Disconnect

cooling
pipes
at

joints

Acno

Fig
AC
39

Diaconnecting
coo

ing

pipes

Notes

a

Plug
all

piping

joints
immediately

after

pipe
disconnection
to

prevent

entry
of
dust
or
moisture
laden
air

into

receiver

dryer
or
air
aJOdi

tioning
system

b
Use

two
wrenches
when
dIsconnect

ing
cooling
pipes

5

Remove
four
screws

securing

receiver

dryer
bracket

to
vehicle

body

and
detach

compressor
relay
and

pres

sure
switch
as
an

assembly

6
To

install
receiver

dryer
and

piping
reverse
the
order
of
removal
Air

Conditioning

Notes

a

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when
con

necting
cooling

pipes

b
Use
two
wrenches
when

connecting

cooling
pipes

c

Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Checking

System
under
General
Service

sec

tion

d
Check

refrigerant

leakage
if
neces

sary
repair

Refer
to

Evacuating
and

Charging

System
under

General
Service
See

tion

Condenser

Disconnect

battery

ground
cable

2

Discharge

system
Refer

to
Dis

charging
System
under
General

Service

section

3
Drain

engine
coolant

4

Remove
radiator

grille

5

Remove

radiator

shroud
and

radiator

On
automatic
transmission

models

disconnect
both

torque
converter
oil

hoses

Note

While

cooling
water
is
hot

take

precautions

against
scalding

6
Disconnect
two

pipes
from

con

denser
remove
two

screws

securing

condenser

Condenser

can
now
be

removed

AC485

Fig
AC

40

Removing
conden
er

Notes

a
Use

two
wrenches
when
disconnect

ing
pipe

joints

b

Plug
openings
immediately
after

disconnecting
pipes

7

To
install

reverse
the
order
of

removal

AC

29
Tightening
torque

Flare
nut
for

copper
tube

from

compressor

2
5
to
4
0

kg
m

i8
to
29
ft
Ib

Flare
nut

for

copper
tube

to
receiver

dryer

2
5

to
3
5

kg
m

i8
to
25
ft
lb

Notes

a
When

disconnecting
and

connecting

cooler

pipes
be
sure
to

use
two

wrenches

b

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when

con

necting
cooler

pipes

c

To

prevent

possibility
of

explosion

due
to

high

pressure
within

cooling

system
do

not
clean
condenser

with
steam

Always
use
cold
water

or

cold

compressed
air

d
Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Charging

System
under
General

Service
sec

tion

e
Check

refrigerant
leakage
if
neces

sary
repair
Refer
to

Checking
for

Leaks
under
General
Service

sec

tion

INSPECTION

RecelYer

dryer

Check
for

refrigerant
leakage
or

damage

Check
for

proper
connection
of

two

lead
wires

running
to

pressure

switch

If

any
component

part
is
found

damaged
replace
receiver

dryer
and

pressure
switch
as

an

assembly

Condenser

I

Check

inlet
and
outlet

pipe
joints

and

sealing
surfaces
for

damage
Re

place
parts
if

damaged
or

leaky

2

Clogged
condenser
fins
or

air

pas

sages
may
reduce

cooling
efficiency
of

condenser
Clean
these

areas
with

dry

compressed
air

Piping

Check

piping
for

leakage
If

leakage

occurs
at
connections

retighten

connecting
nuts

Replace
if

leakage

persists

MAINTENANCE

Replace
any
wiring
harness
which
is

cracked
deteriorated
or

poorly
in

sulated

Always
replace
wire
with
those
of

the

same
diameter
Do

not
use
wire
of

smaller
diameter

Where

necessary
securely
retain

wire
harnesses
with

clips
or

tapes
so

that

they
will
not
be

frayed
or
worn

by
vibration

Notes

a

Repair
or

replace
any
electrical

part

which
is

questionable
or
likely
to

cause
a
short
circuit

When
disconnecting
battery
cables

always
disconnect

ground
cable
be

fore

positive
cable
Clean
battery

and
terminals
before

connecting

cables
then
connect

positive
cable

and

ground
cable
in

that
order

Apply
a
coat
of

grease
to
terminals

to

prevent
rust
formation

b
Do
not

attempt
to
conduct
a
con

tinuity
test
with
a

screwdriver
or

service
tools

always
use
test
lead

wires

c
Do
not

ground
terminals
when

circuits
are

open
or
unloaded

always
use

a
test

lamp
12V
3W

or
circuit
tester
as
a

load

MAIN
RELAY

Removal
and
Installation

The
main

relay
is
attached
to
the

cooling
unit

I

Disconnect

battery

ground
cable

2

Disconnect
main

relay
lead
wires

at
connector

3

Remove

cooling
unit

assembly

Refer
to
Removal
and
Installation

under

Cooling
Unit

4
Remove
the
screw

securing
main

relay
to

cooling
unit

and
detach
main

relay

5

To
install
main

relay
reverse
the

order

of
removal

Inspection

To

check

continuity
in

relay

circuit
use
a

test

lamp
or
an
ohm

meter

Continuity
between

points
3

and
4
should
exist
Air

Conditioning

When
a
12

volt
d
c
is

applied
across

points
3
and
4

continuity
between

points
I
and
2

should
also
exist

CD

00

COMPRESSOR
RELAY

Removal
and
installation

Disconnect

compressor
relay
lead

wires

at
connector

2
Remove

two
screws
securing
com

pressor
relay
to
receiver

dryer
and

detach

compressor
relay

3
To
install

compressor
relay
reo

verse
the
order
of
removal
@

I
ul

CDe
JOO

ID
IDe

@e

L

AC465

Fig
AC
42
Main

relay

Inspection

Using
a
test

lamp
or

an
ohmmeter

make

sure
that

compressor
relay
con

tacts

open
and

close
con

tinuously

Continuity
always
exists
between

points
3
and
4
When

current
flows

through

points
3

and
4

points
1

and
2
close
This

causes
current
to

flow

through
1
and
2

FAN
SWITCH

Removal
and
installation

1
Disconnect

battery
ground
cable

2
Remove

screws

securing
console

box
Withdraw
console
box
forward

and
disconnect
lead
wire
connector

3
Detach
switch
knob

4
From
rear
side
of
console
box

remove
screws

securing
switch
and

remove
switch

5
To
install
fan
switch
reverse
the

order
of
removal

AC
31
i
t
v

J

AC489

Fig
A

C
43
Compressor
relay

AC771

Fif
AC

44
Removing
fan
switch