1979 DATSUN 210 Service Manual

rt

ASSEMBLY

1

Press

bearings
into
V

pulley
with

Bearing
Installer
5T0237
1000

51
02371000

AC503

Fig
AC
47

In

talling
Bearing

2
Install
outer

snap
ring
in

groove

of
V

pulley

3

Using
Installer
KV99l
0061
0

and

Stopper
ST33061000

press
clutch

wheel
into
V

pulley

4
Install
inner

snap
ring
in

groove

of
clutch
wheel

u

Installer

KV99100610

2

Stopper

ST33061000

AC504

Fig
AC
48

Installing
Clutch
Wheel

INSPECTION

I
Check
friction
surface
of
clutch

for

damage
due
to

excessive
heat
or

excessive

grooving
due
to

slippage
If

neceSS3I

replace
clutch
wheel
and

V

pulley
as
a
set
Air

Conditioning

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

3
Oil
or
dirt

on
friction
surfaces
of

clutch
wheel
and
V

pulley
should
be

cleaned
with
a
clean
Iint

free
clot

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

Fig
AC
49

Grounding
Point

01
Coil

S

If

clutch

assembly
must
be
re

placed
remember
that
break
in

opera

tion
is

neceSS3I
The
break
in

opera

tion
consists

of

engaging
and
disen

gagingthe
clutch
some

tirty
tlines

SHAFT
SEAL

The
shaft

seal

assembly
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
car
for

shaft

seal

replacement

I
Remove

oil
filler

plug
with
O

ring

and
drain
the

compressor
oil

AC

28
AC393

Fig
AC

50
Removing
Filler

Plug

2
Remove
clutch
Refer
to
Com

pressor
Clutch
for
removal

3
Remove
shaft

key
from
crank

shaft

L

IJ
C

I

0

ACS07

Fig
AC
51

Removing
Shott

Key

4
Remove

seal

plate

J

e

I

@

IR
n

1
j

AC866

Fig
AC
52

Removing
Seal
Plote

5
With

Compressor
Seal
Puller

pull

out
seal

gland
and
discard

CAUTION

a
iscard
all

parts
of
he

seal
in

cluding
tha

O
ring

b

00
not

use
a

screwdrivel
to

pry

shaft
seal
from
shaft
as

damage
to

shaft

may
result

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

REMOVAL

1
Remove
each
screw

securing
dis

charge
and
suction
connectors

using

TOD
Driver
Bit

2
Pull
out
each

discharge
and

suc

tion
connector

Note
Memorize
mounted
direction
of

discharge
and
suction
connectors
to

ensure
correct

reassembling

a@

AC873

Fig
AC
63

Removing
Discharge
and

Suction
Connectors
Air
Conditioning

INSTALLATION

I

Attach
new
O

ring
to
each

cy

lindrical

portion
of

discharge
and
suc

tion
valves

Note

Apply
clean
lubricant
to
O

ring

so

that
it
can
be

fitted

tightly
to

cylindrical
portion
and

crankcase

hole

AC
31
2
Insert
each

discharge
and

suction

valves
into

correct
valve

port
in

crank

case

by
matching
it

with
mark
on

cylinder
head

3

Set
each
valve
in

the
same

posi

tion

as
it
was
before

removal
and

tighten
screws
with

specified
torque

cD

Tightening
torque

Discharge
and
suction

connectors

2
1
to
3

2

kg
m

15

to
23
ft
b

Com
pressor
OFF
I

I

Blower
makes

noise
Repair
or
re

place
blower

Bearings
of
com

pressor
clutch
or

idler
pulley

make
noise

Replace

C
l
W
Noisy
Compressor
itself
makes

noise
Repair
or

replace
com

pressor
Belt
is
loose

Adjust
belt

Suction
pressure
is
low

Strainer
in
pipe

Line
Is
restricted

Replace
strainer

Pipe
at
receiver

drier
outlet
has

low
temperature

Receiver
drier
is

restricted
Replace

receiver
drier
I

Fin
and
tube
of

evaporator
or

laminated
evapo

rator
have
some

dents
Replace
or
repair

evaporator

Expansion
valve
is

close
excessively

or
gas
leakage
from

thermo
bulb

Replace
expansion

valve
Compressor
ON
J

I

When
engine

rpm
is
changed

there
are
reso

nant
sounds

Retighten
com

pre
ssor
bracket

bolts
Piping
is
reso

nating
Add

clamp
Insufficient
cooling

Bubbles
in
sight
glaS

Check
refrigeration
line

for
gas
leaks
and
repair

leaks
if
any
Charge
re

frigerant
to
correct

level
In
case
of
too

many
leaks
stop
com

pressor
discharge
the

system
evaCUate
and

recharge
the
system

As
necessary
replace

receiver
drier

Air
in
system
may

cause
bubbles
in
sight

glass

System
pressure
and
temperature
of
discharge
air
llre

abnormal
Refer
to
Performance
Test
Diagnoses

for
detail

Suction
pres

sure
is
high

Expansion

valve
is
open

excessively
Replace
ex

pansion
valve
Discharge
pressure
is

high

Overcharge
of
refrigerant

Discharge
some
of
refrig

erani
to
correct
level

Air
is
mixed
in
Discharge

system
and
replace
drier

Evacuate
and
recharge

system
Condenser
s
fin
is
dented

or
clogged
with
dust

Clean
exterior
surface

with
water
No
bubbles
in

sight
glass

With
manifold
gauge

check
system
pres

sures
Measure
tem

perature
of
discharge

air
Refer
to
Perform

ance
Test
Blower
does
not

rotate
Refei
to
Blower

Motor
Diagnoses

Temperature
of
discharge

air
is
abnormal
but
system

pres5ure
is
normal

Suction
pressure
iJ

high
while
dis

charge
pressure
is

low
Valve
or
gasket

of
compressor
is

damaged
Repair
or
replace

compreuor
Check
air
flow

system
Refer
to
Air

Conditioner
Operation
Chart
Compressor
does
not
run

Refer
to
Com

pressor
Diagnoses

Check
grommets

on
car
s
dash

panel
for
air

leaks
check

other
seal
of

car

Air

Conditioning

BLOWER
MOTOR
DIAGNOSES

I
Blower
motor
inoperative

I
Check
20

ampere
fuse
in
air
conditioner
harness

Fuse
blown
Fuse

OK

Locate
short
circuited

spot
and

repair

or

replace
faulty

parts
Ground
one
of
lead
wires

Black
blue
3

speed
Black
white
2

speed

Black

yellow
l

speed
1eading
to
fan

switch

Blower
runs
Blower
does

not
run

Check

ground
circuit
and

lead
wire
con

oeetion
When
no

problem
is
found

replace
blower

switch
Ground
black
wire

of
blower
motor

i

Blower

runs
Blower
does
not

run

Check
resistor
for
connection
When

no

problem
is
found

replace
resistor
Connect
12
volt

test

light
to
white
wire

leading
to

blower
motor

Light
ON
Light
OFF

Check
lead
wire
for
connection

When

no

problem
is
found

replace
blower
motor
Check
for

presence
of

voltage
at
main

relay

No
Yes

Check
for

presence
of

voltage
at
air

conditioner
harness
Check

lead
wire
for
connection

When
no

problem
is
found

replace
relay

AC
33

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