1979 DATSUN 210 service

REFRIGERANT
LINES
Air

Conditioning

@

I

J

L

S

r
Z
S
t

@

See

Fig
AC
29
When

replacing

flexible
hose
and
tube
observe
the

following

1

Before

starting
work
be

sure
to

discharge
system

2

When

disconnecting
tubes
be

sure
to

use
two

wrenches
on
both

tubes

3

After
discon

ecting
tubes

plug

all

openings
immediately
to

prevent

entrance
of
dirt
and
moisture

4

Compressed
air
must
never
be

used
to
clean

dirty
line
Clean
with

refrigerant

gas

5
In

connecting
tubes
be
sure
to

apply
compressor
oil
to

seating
surface

and
then

tighten
tubes
to

specified

tightening
torque
See

Fig
AC
30

Be

sure
to
use
two
wrenches
when

tightening
a
flare

nut
of
tube

Coat
seat
surfaces
with
com

pressor
oil
and
then

tighten

AC263

Fig
AC

30
Line
Connection
CD

6
Make
sure

refrigerant
line
is

clamped
securely
Start

engine
and

raise

engine
speed
to

inspect
if
there
is

vibration
or
unusual
noise

7

Conduct
leak
t
st
and
make
su
e

that
there
is
no
leak

from
connections

8
Refer
to

General
Service
for

evacuating
and

charging
system

COOLING
UNIT

REMOVAL

I

Disconnect

battery
ground
cable

2

Discharge

refrigerant
from

sys

tern
Refer
to
General
Service

3
Loosen

flare
nuts
at
each
con

nection
of
inlet

and
outlet

pipes
of

evaporator

AC
21
1

High
pressure
discharge
service

valve

2
Low

pressure
suction
service
valve

3

Compressor

4

Condenser

5
Receiver

drier

6

Cooling
unit

7

Low

pressure
switch

lightening
torque

kg
m
ft
lb

@
4

5
to

5
0
33
to
36

@
3
0
to
3
5
22
to
25

AC385A

Fig
AC
29

Refrigerant
Lines

CAUTION

Immediatelv
plug
up
all

openings

to

prevent
entrance
of

dirt
and

moisture

4
Remove
instrument
under

cover

5
Remove

glove
box

6
Disconnect

wiring
harness

con

nectors
from

compressor
relay
and

thermostat

7
Remove

upper
and
lower

attach

ing
bolts
and

remove

cooling
unit

AC386A

Fig
AC
31
Removing
Cooling
Unit

to

DISASSEMBLY

AND
ASSEMBLY

y
1

7
1
r

II

l

1

Using
a
knife
cut

packings
at

upper
and
lower
case
fit
in

portion

2
Remove

clips
fixing
upper
case
to

lower

case

3

Separate
upper
case
from
lower

case

by

pulling
it

upward

4
Withdraw

evaporator
assembly

out
oflower
case

5
Remove
thermostat
from

upper

case

by
removing

attaching
screWs

CAUTION

Capillary
tube
should
not
be
bent

too

sharply

6
To
assemble
reverse
the

order
of

disassembly
Be

sure
to

join
mating

surfaces
of

packings
at

upper
and

lower
case
fit
in

portion
with
an
adhe

sive

substance

Note

When

installing
thermostat

in

sert

capillary
tube
in
same

place
as

it

was
before
removal
Be
sure
to

insert

capillary
tube
end
about

50

em
19
7

in
from

evaporator
core

INSPECT

ON

In

case

evaporator
core
or

expan

sion

valve
have

gas

leaking
repair
or

replace
it
with

a
new
one
as

necessary

Dirt
and

nicotine
accumulation

on

evaporator
case
will

go
b
d
and
smell
Air

Conditioning

1

Mainrelay

2

Thermostat

3

Upper
case

4

Expansion
valve

5

Evaporator
assembly

6

Lower
case

ID

AC387A

Fig
AC
32

Cooling
Unit

This
means
that

you
have
to

remove

them
from
time

to
time
to
assure

healthful
fresh
air
inside

car

INSTAllATION

Install

evaporator
in
the
reverse

order

of
removal

observing
the
follow

ing

I
When

replacing

evaporator
with

new

one

charge
compressor
with

same
amount
of
new
oil
as
was
drained

before

2

Evaporator
case
should

be
in

stalled
as

close
s

possible
to

heater

unit

3
Refer
to

Fig
AC
29
for

tighten

ing

torque
of
flare
nuts

4
Refer
to
General
Service

for

evacuating
and

charging
system

5
Conduct
leak
test
and
ensu
e

that

there
is

no

gas
leak
from
conne
tion

EXPANSION
VALVE

Expansion
valve
malfunctions
such

as
valve

stuck

open
valve
stuck

close

refrigerant
leakage
and

improper
in

stall
tion

of

sensing
bulb
are
de

scribed

The
first
two
conditions

require

replacement
of

expansion
valve

When
both
water

and

refrigerant

AC

22
are
circulated

in
the

system
frost
cwill

form

near
the
ball
of

expansion
alve

and

block
the
flow
of

refrigerant
In

this
case

however

operation
of
the

valve

can
be
returned
to

normal

by

heating
the
valve

Expansion
valve
is

equipped
with

an

adjusting
screw
However
since

the

screw
is
set

properly
at

the

factory

adjustment
is

unnecessary
If

expan

sion

valve
is

damaged

replace
with

new
one

RIEMOV
L
AND

INSTALlATION

See

Fig
AC
32

Disconnect

baltery
ground
cable

2
Remove
ev

porator
Refer
to

Cooling
Unit
for

removal

3

Remove
heat
insulator

covering

expansion
valve

assembly

4
Remove

clamp
attaching
sensing

bulb

5

Loosen
flare
nuts
and
remove

expansion
valve
from

evaporator
and

inlet

pipe

CAUTION

Plug
all

openings
to

prevent
entrance

of
dirt
and
moisture

6

Installation
is
ill
the
reverse
order

of

removal

THERMOSTAT

REMOVAL
AND

INSTALlATION

See

Fig
AC
32

Remove

cooling
unit

2
Remove

screws

attaching
thenno

stat
and
then

remove
thermostat

CAUTION

Capillary
tube
should
not
be
bent

too

sharply

3
Installation
is
in

the
reverse
order

of
removal

LOW
PRESSURE

SWITCH

REMOVAL

AND

INSTALLATION

I
Disconnect

battery
ground
cable

2

Discharge

refrigerant
from

sys

tem

Refer
to

General
Service

3
Disconnect

connector
to
low

pressure
switch

4
Remove
low

pressure
switch

by

turning
the
switch

5

Installation
is
in
the
reverse

order

of

removal

INSPECTION

Using
a
circuit

tester
make
sure

that
low

pressure
switch
exhibits
con

tinuity
when

gas
pressure
of

refriger

ant
in

system
is
normal
and
that
low

pressure
switch

does
not
exhibit
con

tinuity
when

gas
pressure

drops
below

2
2

kg
cm2

31

p
i

MAGNET

VALVE

REMOVAL
AND

INSTALLATION

I
Disconnect

battery
ground
cable

2
Disconnect

magnet
valve
lead

wires
and

vacuum
hoses

3

Remove

magnet
valve

securing

screws
and
then
remove

magnet

valve

i

i

WrE

AC389A

Fig
AC

36

Removjng
Magnet
Valve

4

Installation
is
in

the

reverse
order

of
removal

INSPECTION

I
rest

continuity
with

ohmmeter

2

Apply
D

C
12
volts
across
termi
Air

Conditioning

031

under
this
state

orally
blow

through
one
vacuum

port
to
ensure

that
there

is
air
flow
at

the
other

FUSE
REPLACEMENT

REPLACEMENT

A

20

ampere
in

line
fuse
is

part
of

air

conditioner
harness
located
behind

glove
box
J
Disconnect

batiery

ground
cable

2

Remove
instrument

under
cover

3

Remove

glove
box

4
Take
out
fuse

holder
from
air

conditioner
harness
and

replace
fuse

with
a
new
one

CAUTION

If

fuse
is

blown
be
sure

to
climi

nate
the

cause
befure

installing
new

fuse
in

position

r

AC276A

Fig
AC
37

Fu
e

Replacement

VACUUM
HOSE
DIAGRAM

u

CJ

Magnet

valve

Al

1

From
intake

manifold

AC
24
Fast
idle

actuator
Check

valve

Vacuum

switch
Intake

actuator

I

0

0

2

S

1l

AC27BA

Fig
AC
38
Vacuum
Hose

Diagram

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

r

CYLINDER
HEAD

AND
VALVE

PLATE

Insufficient

refrigerant
v

p
sion

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
cylinder
head

securing

bolts

Fig
AC

57
Removing
Cylinder
Head

2
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

CAUTION

00

not
hit
or

llIp
head
to

separate

head
and
valve

plate
because

damage

to
head

may
result

AC871

Fig
AC
58

Removing
Volve
Plate

and
Head

3
When

removing
the

gaskets
use
a

sharp
edged
knife
Air

Conditioning

CAUTION

a
In

removing
head

gasket
be

very

careful
not

to

damage
machined

sealing
surface

b
00
not
reuse

gaskets

AC815

Fig
AC
59

Removing
Gasket

INSTALLATION

Valves
and
valve

plates
are
furnish

ed

only
as
a

complete
assembly

8

AC872

Fig
AC

60
Valve
Plate

Assembly

I

Apply
a
thin
mm
of
clean
refri

geration
oil
on
area
of
crankcase
to
be

covered

by
cylinder
gasket

Fig
AC
61

Applying
Clean

Refrigeration
Oil

AC
30
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
flim
of
clean
refri

geralion
oil
to

top
and
bottom
valve

plate
areas
to
be
covered

by
gaskets

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

AC817

Fig
AC
62

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
mm
of
clean
refri

geration
oil
on
the

machined
surface

of

cylinder
head
which
matches
head

gasket

7

Place
head
on

cylinder
head

gas

ket
so
dowel

pins

go
into

dowel

pin

holes
in
head

8

Tighten
screws
to

specified
limit

iil

Tightening
torque

Cvlinder
head
screws

2
1
to
3
2

kg
m

15
to
23
ft
Ibl

DISCHARGE
AND

SUCTION

CONNECTORS

Discharge
and
suction
connectors

are
located

on
rear
side
of

compressor

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

01
o
B
0
a
Ut
Ut
o
a
a
i
o
Ut
A
o
l
Cl
o
l
l

tC

Air

Conditioning

COMPRESSOR
CLUTCH
DIAGNOSES

Compressor
clutch
is

not

engaged

Check
20

arnpere
fuse
in
air
conditioner

harness

Fuse
blown

Fuse
OK

Locate
short

circuited

spot
and

repair
or

replace
damaged
parts
Connect
12
volt
test

light
to

compressor

clutch
lead
wire
Ground
the
other
end
of

test

light
Set
air
control
lever

to
A
C

posi

tion

Light
ON
Light
OFF

I

Check
low

pressure
switch
for

continuity

L
H
drive

only
Check
lead

wire
and

ground
wire
of

compres

sor
clutch
for
connection
When
there
is

nothing
wrong
with
them

replace

compressor

clutch

No

I
Yes

Measure

pressure
in

system
If
there
is
a

leak
service

system
If

pressure
is
normal

check
low

pressure
switch
as
a

part
reo

place
if

necessary
Connect
12
volt
test

light
to
terminal
of

blue

green
wire

leading
to
thermostat

Ground
the
other

end
of
test

light

Light
ON
Light
OFF

Check

ground
circuit
and
make

sure
of

proper
connection

Further

check
lead
wire
connection

and
when

no

problem
is

found

replace
air
conditioner

harness
or
main

harness
Connect
12

volt
test

light
to
blue
white
wire

of
microswitch
Ground
the
other
end
of

test

light

I

Light
ON

I
Light
OFF

I

Check
lead
wire
connection

When
no

problem
is
found

replace
thermostat
Check
for
current
flow
in

lead
wire
to
main

relay

Yes

I
I
No

Check
lead
wire

for
connection

When
no

problem
is

found

replace

microswitch
or
main

relay
Check

power

supply

AC
35

r

Air

Conditioning

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

Compressor

Model

Type

Displacement

Cylinder

Bore
x

stroke
cc
ell
in

rev
SC206

Yoke

100
6
10

mm
in

47

6
x
28
1

1
874
x
1
106

Clock
wise

View
from
drive
end
Direction
of
rotation

Lubrication

oil

Type

Capacity
in

refrigeration

system
cc
US
11

OZ

Imp
11
oz
SUNISO
5GS

237
8
0
8
3

Refrigerant

Type

Capacity
kg

lb
R
12

0
8
to
1
0
1

8
to
2
2

INSPECTION

AND
ADJUSTMENT

Belt

tension

mm
in

kg

lb

Fan

belt

applied
pressure
8
to
12

0
31
to
0
47

10
22

8
to
12

0
31
to
0
47

10
22
A
C

compressor
belt

applied
pressure

F
I
C
D

adJustment

Automatic
700

rpm

650

rpm

at
Du

position
When

AlC
is

ON

F

LC
D
is

actuated

800

rpm

800

rpm

at
Nu

position
Engine
model
Transmission
When

AlC
OFF

Manual

AI4
AI5

Clutch
hub
to

pulley
clearance
mm
in

0
4
to
0

6
0

016
to
0
024

AC
42