oil DATSUN PICK-UP 1977 Service Manual

7
After
the

specified
amount
of

refrigerant
has

been

charged
into

sys

tem
close
manifold

gauge
valves
Then

detach

charging
hoses
from
service

valves
of

system
Be
sure
to
install

valve

cap
to

service
valve

8

Confirm
that
there
are

no
leaks
in

system
by

checking
with
a
leak
detec

tor

Refer
to

Checking
for
Leaks

Note

Conducting
a
performance
test

prior
to

removing
manifold

gauge
is

a

good
sen
ice

operation
Refer
to

Performance

Test

CHECKING
FOR

LEAKS

Conduct
a

leak
test
whenever
leak

age
of
refrigerant
is

suspected
and

when

conducting
service

operations

which
are

accompanied
by
disassembly

Dr

loosening
of

connection
fittings
Air

Conditioning

Refrigerant
is
a

colorless
odorless

gas
and

leakage
from

system
is
diffi

cult
to
detect

Accordingly
the
use

of

a

leak
detector
facilitates

check
for

leaks

Two
methods
of

checking
are

available
one

employs
a
halide

leak

detector
which
burns

propane
gas
or

butane

gas
and
the
other

is
an
electric

type
leak

detector

HALIDE
LEAK
DETECTOR

Since
the

propane
leak
detector
and

butane
leak
detector

are
the

same
in

respect
to
their

operation
this

section

describes
the

operation
of
the

propane

leak
detector

The

copper
screen
is
heated

by
the

burning
of

propane
Refrigerant
gas

decomposes
to

color
the
flame
when

it

contacts
the
heated
screen
The

gas
to

be
checked
is
drawn
into

the

sampling

tube

and
sent
out
to
the
burner
A

refrigerant
leak
can

clearly
be
detected

by
variations
in
the
color
of
the
flame

Propane
type

NO
LEAK

SMALL

LEAK

LARGE
LEAK
Greenish

blue

Yellow

Purple
AC010
1

Copper
reaction

plate

2

Flame

adjusting
lines

3

Burner

4

Sampling
tube

5

Strainer

6

Gas
bomb

7
Flame

adjuster

Fig
A
C
25

Checking
for
leak

Butane

type

Pale
blue

Bright
blue

Vivid

green

AC
15
I

Discharge

refrigerant
in

one
or

two
seconds
to
ascertain

that

system

has
a

sufficient

pressure
needed
for

leak
detection

Charge
with
04

kg
I

lb
of

refrigerant
if

necessary

2

Light
leak
detector

Adjust
the

height
of

the
ilame
between

flame

adjusting
lines
at
the

top
and
bottom

of
combustion

tube
A

reaction

plate

will

immediately
become
red

hot

3

Place
the
end

of

sampling
tube

near
the

point
of
the

suspected
leak

in

system

Notes

a
Since

refrigerant
gas
is
heavier
than

air

small
leaks
can
b

easily
detect

ed

by

placing
sampling
tube
direct

ly
below
the
check

point

b
Suitable
ventilation
is

required
If

refrigerant

gas
is

mixed
with
the

surrounding
air
leak
detector
will

always
indicate
a

response
and

detection
of
the
actual
leak
will
be

difficult

c

Never
bold
leak
detector
at
an

angle

Cautions

a
Never

inhale
the
fumes

produced

by
combustion
of

refrigerant
gas

since

they
are
toxic

b
Never
use
halide
torch
in
a

place

where
combustible
or

explosive

gas

is

present

4
The

ilame
will
be
almost

colorless

when
there
is

no

refrigerant
gas
being

burned
When
there
is

a
small

refriger

ant

gas
leak
the
ilame

will
be

green
or

yellowgreen
When

refrigerant

gas
leak

age
is

large
the
ilame
will
be
brilliant

blue
or

purple
Since
the
color
of
the

ilame
will
be

yellow
when
dust
is

being
burned
Or
there
is

aging
scale
on

copper
reaction

plate
always
keep
the

strainer
of

sampling
tube
and
reaction

plate
clean

5

Major
check

points

I
Compressor

Compressor
shaft
seal

rotate
the

compressor
by
hand

Oil
filler

plug

Flexible
hose
connections

Rear
cover
and
side
cover

gaskets

Service
valve

2
Condenser

Condenser

pipe
fitting

Condenser
inlet
and
outlet

pipe

connections

I

Notes

a
The
bubbles
seen

through
the

sight

glass
are
influenced

by
the
ambient

temperature
Since
the
bubbles
are

hard
to
show

up
in

comparatively

low

temperatures
below
200C
6S0

F
it
is

possible
that

a

slightly

larger
amount
of

refrigerant
would

be
filled
if

supplied
according
to

the

sight
glass
Be

sure
to
recheck

the
amount
when
it

exceeds
200C

680F
In

higher
temperature
the

bubbles
are

easy
to

show

up

b

When
the

screen
in
the

receiver

dryer
is

clogged
the
bubbles
will

appear
even
if
the
amount
of

refrig

erant
is
normal
In
this
case
the

outlet
side

pipe
of
the
receiver

dryer
becomes

considerably
cold

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
is
within

the

specified

range
For
details
refer
to

Perform

ance

Test
described
later

Overcharging
will
show

up
in

higher

pressure
on
discharge
side

COMPRESSOR
OIL

LEVEL

CHECK

The
oil

used
to
lubricate

compres

sor
circulates
into

system
from
the

oil

sump
while

c9mpressor
is

operating

The

efore
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

fa

cilitates
to
return
oil
to

compressor

I

Operate
compressor
at

engine

idling
speed
1
000

rpm
or

below

with
controls
set

for
maximum

cooling
Air

Conditionin
j

and

high
blower

speed
for
10
to

15

minutes
in

order
to
return

compressor

oil
to

compressor

2

Stop
the

engine
and

discharge

refrigerant
of

system
and
then

remove

compressor
from

the
vehicle

3
Remove

compressor
fIller

plug

Drain

compressor
oil
from

compres

sor
oil

sump
and

measure
the

amount

4

Compressor
oil
is

satisfactory
if

the

following
amount
of
oil

remains
in

the

compressor

Residual
oil

S5
to
128

gr
3
to
4
oz

5
Check
the
cleanliness
of
the
oil
If

the
oil
contains

chips
or

other

foreign

material
clean
oil

5ump
with
new

oil

6
Discard
the

used
oil
and

fili
with

the
same
amount
of
new
oil
Add

oil
if

found
less
than
above
amount

Fig
AC
27

Filler

plug

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

complet

ed
recheck
oil
level
drain
oil
to

correct
level
if

level
is

excessively
high

PERFORMANCE
TEST

The
cooling

performance
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

guide

in

checking
for

problems

I

Park
the
vehicle
indoors
or
in
the

shade

AC
17
2

Open
all
the
windows
of
the

vehicle
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

Ga

uge

5

Set
fan
control
lever
to
maxi

mum

6
Set

temperature
control
lever

to

max
cool

position

7
Start
the

engine
and
hold

engine

speed
at
1
500

rpm

S
After
the
air

conditioner
has
been

operated
for
about
10
minutes

measure

system

pressures
at

high
pres

sure

discharge
side
and
low

pressure

suction
side

9
Measure
the

temperature
of
dis

charge
air
at

outlet

grille

10
Measure
the

temperature
of

capin

11
Measure
ambient

temperature

and

humidity
one
meter
3
3
ft

away

from
condenser
front
Be

careful
not

to

expose
dry
buib

and
wet
bulb

to

direct

sunlight

12
Check
for

any
abnormalities

by

comparing
the
test

results
with
stand

ard

pressure
in
Performance

Chart

Notes

a
The

pressure
will

change
in
the

followi

g
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
by
reference
to

the
Trouble

Diagnoses
and
Cor

rections

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

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

2

R

C7

c

L

PJJ

I

8

INSTALLATION

a
c
J

l
i
rp

To
install

compressor
reverse
the

order
of
removal
Observe
the

follow

ing
nhlJo
e
trorf
1001

vom
R

i
n3

Wheliqli
liiAniitg

fiil
l
in

pt
l

witlil
tiiel
sam
efuouiitITof

b11
1fasitlult

used

previously
v
d
rnl

2

Oil

capacity
new

compressor

O
910
1

owt
llllt
blj
f
H
w
s
013
5

rlT
s

0
111
boc

19
bB1rllo

bi2

qqll
no

e

l
bffik
kuanM
mpdi

x
of

Jli
oln

L
il
m
1IlffiiOrb

fler
ot
oldm

F
n

Cheo

f
undeF
r
n
al

1
aQ

r1tIU
Jt
t31
HClJI1
t
JIVU

i
rlUI

1o
ifm
ft
q
t

VI
31U
S
ltlod

bnM
UfO
l
W

kldf

CJiJi
ti

WIf
nl

L
llil
g

ncn
d

oressor

M
et

illpuntinl
botts
if

l9Wul
fb

i
l
fI
I
l

1Ttio
l

qqlJ

necessary
re

Ighten

I

d
210
Air

Conditioning

Tightening

torque

Flexible
hose
to

compressor

dl

t
kg
J
l

IQ

1

Tf
es

oriti
ra

Lbolts

IbP
fo
o15g

m
J

r
f6i
o
20
i
il

f

J

rt
I

r

aGket
engine

Dons
1
1

0

1
1
3
16

5

l11fd
1l

V

f

42
3
3U
llif

Yl

I
u

y
j

3
D
not

remove

IJgs
orflexibie

1i6
e
before

ready
for
immediate
use

4l
di

Wheniiinstallingccomptess
i
turn

it
serWfiPtiffies
SlOt

5
When

connecting
flexible

hose
to

9mPr
ssor

apD
v

a
coat
of
Hfresh

JU
UI

l1Il
t
2
JIUU
uOHltl
r
fl

compressor
0
1

to

fs
aHn
lurfaces
of

1n
1l11
JJ

J
f
PJU

Ht
UlUJ
jJ

joints

AC

26
5

1

Compressor
attachment

2

Compressor

3

Compressor
bracket

4
AHernator

5
Idler

pulley
bracket

AC745

Fig
AC
31

Removing
compressor

6
Evacuate

cooling
system
then
re

charge
with

refrigerant
Refer

to

Evacuating
and

Charging
System
under

l
r

Gen
efal

Servic
ectioo

f
iI
t

7
F

Whenever
remoV
J

compres
r

be
su
J

t8

C6itiu
t
Ua
t
st
make

idie

mV
i
1rJ

adjustril
rit
and

adjwt
beJf
tension

yv

1

r
Y

N
o
s

9

r
h

v

a

For

compressor
diive
belt

and

tOoling
fan
belt
tensions
refer

to

1
Ildlet

Yt
j
WI
c
S
t
q

b

Cheok

refrigerant

leakage
if

neces

sary
correct

dO
I
wl
Tw
l
rt

f
r2

iVl
2
i
l
n

U
l

bnu
1
1Z
2

gf

ign
rb

nojJ

2

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

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