1977 DATSUN PICK-UP torque

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

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

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

Service

Equipment

CHAssis
AND
BODY
TOOL

Applied
Ser
17
620NA

No
Tool
Number
Tool
Name

vehic
1e
Newly

Class
Remarks

added

or
unit
KYOO
1
02000

Clutch

5Tl
66
1000
I

Pilot

bushing
puller
All
X
3
610
710
530

KV30100200
Clutch

aligning
bar
All
X
2

610
710
530

5T200500
10
Base

plate
All
X
5

B210
610
710
530

5T20050100
Distance

piece
All
X
5

B210
610
710
530

5T20050051
5et
bolt
All
X
5

B210
610
710
530

5TZ0050240

Diaphragm
adjusting
wrench
All
X
5

B210
610
710
530

GG943
10000
Flare
nut

torque
wrench
All
X
2
FIO
B210
610
710

530

2
Manual

transmission

5TZ2360002
DriftC
All
X
2

B21O
530

5T23540000
Fork
rod

pin
punch
All
X
2
FIO
B210
610
710

530

5T23800000
Transmission

adapter
All
X
2
FIO
B210
610
710

530

5T23810001

5etting
plate
adapter
All
X
5
530

5T22520000
Wrench
All
X
2

B2iO
530

5T23860000
Counter

gear
drift
All
X
2
530

KV311
00400
Transmission

press
stand
All
X
5
530

5T30031000

Bearing
puller
All
X

2
FIO
B210
610
710

530

KV32101330

Bearing
puller
FSSW71B
X
X
2
B21O
530

3
Differential

ST063
I
0000
Diff

attachment
All
X
5

610

ST31530000
Drive

pinion
flange
wrench
All
X
2

B210
610
710
S30

ST3306S001
Diff
side

bearing
puller
All
X
2
610
S30

ST33051001
Puller

ST3306
I
000

Adapter

ST3090S000
Orive

pinion
rear

bearing
inner

race

All
X
2
610
S30

replacer

ST30031000
Puller

ST3090
1000
Base

ST33230000
Diff
side

bearing
drift
All
X
2
610

ST3194S000
Drive

pinion
setting
gauge
ass

y
All
X

2
610

ST3l941000

Height
gauge

5T3l942000

Dummy
shaft

SE
4

Service

Equipment

Applied
Ser
77
620NA

Newly

No
Tool
Number
Tool

Name
vehicle
Class
Remarks

added

or

unit
KVOO
102000

ST31970000
Collar
All
X
2

610

ST30611000
Drive

pinion
outer
race
drift
bar
All
X
2

610

ST30613000
Drive
pinion
outer
race
drift

adapter
All
X
2

610

ST3062
1000
Drive

pinion
outer
race
drift

adapter
All
X
2

610

KV311
00300
Solid

punch
All
X
2

610
710
S30

ST3127S000
Preload

gauge
All
X
2
B21O
610
710
S30

KV381025S0
Oil
seal

fitting
tool
All
X
2
610

4

Front
axle

ST35380000
Kingpin
bushing
drift
All
X
2

HT56802000

Kingpin
bushing
reamer
All
X
2

ST36070000
Transverse
link

bushing
replacer
All
X
2

ST35390000
Kingpin

grease
seal
drift
All
X
2

5

Rear
axle

ST38020000

Bearing
lock
nut
wrench
All
X
2

KV40101000
Rear

axle
stand
All
X
2
B210

610
710
S30

ST36230000

Sliding
hammer
All
X
5

B210
610
710
S30

HT72480000
Rear

axle
shaft

bearing
puller
All
X
2

B210
610
710
S30

6

Steering

ST2902000
I
Pitman

arm

puller
All
X
2

B210
610
710
S30

ST27
180001

Steering
wheel

puller
All
X
2
FIO
B210
610
710

S30

HT72520000
Ball

joint
remover
All

X
2
FIO
B210
610
710

S30

ST3127S000
Preload

gauge
All
X
FlO
B210
610
710

S30

7

Brake

GG943
10000
Brake

pipe
torque
wrench
All
X
2

B210
610
710
S30

ST08060000
Master
Vac
oil
seal
retainer
drift
All
X
3

B210
610
710
S30

ST08080000
Master
Vac
wrench
All
X
3
B210
610
710
S30

SE
5