1987 MAZDA 626 Workshop Manual

16 OUTLINE
Safety Precautions
1. The R-12 liquid refrigerant is highly volatile. A drop
of it on the skin of your hand could result in local-
ized frostbite. When handling the refrigerant, be
sure to wear gloves.
2. If the refrigerant splashes into your eyes, wash
them with clean water immediately. It is standard
practice to wear goggles or glasses to protect your
eyes, and gloves to protect your hands.
3. The R-12 container is a highly pressurized vessel.
Never leave it in a hot place, and check to be sure
that the temperature where it is stored is below
52°C (126°F).
4. A halide leak detector is often used to check the
system for refrigerant leakage. Remember that
R-12, upon coming into contact with flame (this de-
tector burns like propane to produce a small flame),
produces phosgene, a toxic gas.
69G16X020
V/^V
Connection
LZl
jvmi
Refrigerant Container Service Valve
1. Before connecting the valve to the refrigerant con-
tainer, turn the handle fully counterclockwise.
2. Turn the disc counterclockwise until it reaches its
highest position.
3. Connect the center hose to the valve fitting. Turn
the disc fully clockwise by hand.
4. Turn the handle clockwise to make a hole in the
sealed tap.
5. Turn the handle fully counterclockwise to fill the
center hose with air. Do not open the high- and
low-pressure manual valves.
6. Loosen the center hose nut connected to the cen-
ter fitting of the manifold gauge.
Allow air to escape for a few seconds, then tight-
en the nut.
69G16X-021
16-10

OUTLINE 16
Leak-Testing the System
After finishing the evacuation of the system, check
it for leaks.
1. Install the refrigerant container valve.
2. Open the high-pressure manual valve to charge
the system with refrigerant gas.
3. When the low-pressure gauge reads 98.1 kPa (1
kg/cm2, 14.2 psi), close the high-pressure man-
ual valve.
4. Using a halide gas leak detector, propane torch,
or electric leak detector, check the system for leaks.
If a leak is found, repair the faulty component or
connection, then evacuate the system.
76G16X-632
Charging the System
1. Close both the high- and low-pressure manual
valves completely after the system is evacuated.
2. Install the refrigerant container service valve.
3. Open the low-pressure manual valve and charge
the system with refrigerant gas.
4. When charging the system becomes difficult, run
the engine at fast idle and operate the air condi-
tioner.
Caution
Be sure to keep the container in the upright
position to prevent liquid refrigerant from be-
ing charged into the system through the suc-
tion side and possibly damaging the
compressor.
5. Charge the system to the specified amount, then
close the low-pressure manual valve.
Specified amount: 800 g (28.24 oz)
Note:
If the sight glass on the receiver-drier is free
of bubbles, the system is fully charged.
6. Close the low-pressure manual valve and the ser-
vice valve of the refrigerant container.
7. Stop the air conditioner and the engine.
8. Quickly disconnect both hoses from the gauge
fittings.
9. Put the cap nuts on the gauge fittings.
16—11

16 OUTLINE
Thermometer (Dry)
Thermometer
(Dry & Wet)
76G16X-633
69G16X-024
DETERMINING THE RELATIVE HUMI-DITY: Read the temperatures of the dry- and v^et-bulb thermometers at the air inlet (evapo-rator inlet). Then bring them into mutual relation on the chart and determine the intersection, which is the relative humidity^ For exampie, if the dry-bulb temperature^ is 90° F. and the wet-bulb temper- ^ ature is 78° F, the relative humidity is ^ 60%.
DRV BUL8 TEMPERATURE
Performance Test
After finishing repairs, be sure to conduct a perfor-
mance test of the air conditioning system as follows.
Procedure
1. Connect the manifold gauge set. (Refer to page
16-8)
2. Run the engine and keep the engine speed at
1750 rpm.
3. Operate the air conditioner at MAX COOLING.
4. Open all windows and doors.
5. Insert a dry-bulb thermometer in the center of the
ventilator outlet.
6. Place a dry and wet thermometer close to the in-
let of the blower inlet.
7. The high pressure should be within 1374—1569
kPa (14.0—16.0 kg/cm2, 200—227 psi).
Note:
If the pressure is too high, pour water on the
condenser; if it is too low, cover the front sur-
face of the condenser.
8. The dry-bulb thermometer at the inlet should be
within 25—35°C (77—95°F).
Operate the air conditioning system in this condi-
tion until the conditions of the high and low pres-
sure gauges and thermometers are stabilized.
Reading the standard performance curve
1. Read the inlet temperature an get the relative hu-
midity from the psychrometric chart.
2. Read the cool air temperature at the air outlet.
3. Determine the difference between the inlet and out-
let dry-bulb temperature.
4. For example, when the difference is 17°C (30.6°F)
and the relative humidity is 60%:

If
the closing point is the upper part of the line, cool-
ing performance is satisfactory.
76G16X-634
READING THE GRAPH: After reading the temperatures of the wet-and dry-bulb thermometers at the evapo-rator air inlet, the relative humidity (%} can be determined Example: If the dry- and wet-bulb temperatures at the evaporator air inlet are 25°
C
and 19 5°C respectively, find the point of intersection of the dotted lines in the graph, which is

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16—12

COMPRESSOR 16
69G16X-026
M10X1.25^45
Low-pressure x pressure
hose hose Compressor
COMPRESSOR
ON-VEHICLE INSPECTION
1. Connect the manifold gauge set.
2. Run the engine at 1,500 rpm.
3. Check the compressor flow:
a) High pressure is not low and low pressure is not
higher than normal.
b) Metallic sound.
c) Check to be sure that the high-pressure and low-
pressure gauges show the same value immedi-
ately after the air conditioner is switched OFF.
If both gauges show the same value immediate-
ly, it can be assumed that the gasket or the valve
inside the compressor is damaged.
4. Stop the engine.
5. Check the shaft seal and others for leakage.
6. Inspect the drive plate pulley magnetic clutch for
signs of oil.
7. Check the clearance between the drive plate and
pulley. (Refer to page 16—21.)
If any of the above checks reveal faults, repair the
compressor or magnetic clutch.
76G16X-635
Bracket No.2 Adjusting Bolt Bracket

, ,shaft

' stay _ M8XI. 25^20 MIO X 1.25 Compressor
69G16X-028
REMOVAL OF COMPRESSOR
1. Perform the Oil Return Operation. (See below.)
2. Disconnect the battery ground cable.
3. Disconnect the clutch lead wire from the wiring
harness.
4. Discharge the refrigerant from the refrigeration
system.
5. Disconnect the two flexible hoses. Plug the open
fittings immediately to keep moisture out of the
system.
6. Loosen the drive belt.
7. Remove the compressor mounting bolts and the
compressor.
Bracket No.1 M
to* 1.25

^Compressor
MIOxl. 25^110 MIOxl. 25^125
Oil Return Operation
1. If the refrigerant level is low, charge the system to
the specified amount.
2. Run the engine and air conditioner at idle and at
maximum cooling for at least 20 minutes.
76G16X-636
16—13

16 COMPRESSOR
1. Bolt
2. Drive plate
3. Shim
4. Snap ring
5. Cover
6. Pulley assembly
7. Screw
8. Coil
9. Felt
10. Shaft seal cover
11. Front cylinder head
12. Seal seat
13. Shaft seal
14. O-ring
15. Gasket
16. Valve plate
17. Suction valve
18. O-ring
19. Oil filler plug
20. O-ring
21. Drain plug
22. Plate
23. Bolt
24. Gasket
25. Bolt
69G16X-030

(f''
(
(f''
( 1 49 9201 010 H
/
flSt^
ISSP
, —*
76G16X-605
DISASSEMBLY OF MAGNETIC CLUTCH
1. Using the SST to prevent drive plate rotation, re-
move the center bolt.
2. Using the SST, remove the drive plate.
3. Remove the shims from either the drive shaft or
the drive plate.
76G16X-606
16—14

COMPRESSOR 16
4. Using external snap ring pliers, remove the snap
ring and then the cover.
69G16X-033
7.
8.
69G16X-035
Place the SST on the hub of the front head and
use it to remove the pulley assembly.
Note:
To keep it from changing shape, hook the pul-
ley puller's hook onto the V-pulley section.
Remove the coil lead wire from the wire holder on
the compressor.
Remove the coil by removing the screws.
Note:
Do not suspend the coil by holding the lead
wire.
Inspection
a) Drive plate
If the frictional surface shows signs of damage
due to excessive heat, the drive plate and pul-
ley should be replaced.
b) Pulley assembly
Check the appearance of the pulley assembly.
If the frictional surface of the pulley shows signs
of excessive grooving due to slippage, both the
pulley and drive plate should be replaced. The
frictional surfaces of the pulley assembly should
be cleaned with a suitable solvent before rein-
stallation.
c) Coil
Check the coil for a loose connector or cracked
insulation.
Remove the felt.
16—15

16 COMPRESSOR
DISASSEMBLY OF COMPRESSOR
Shaft Seal Assembly
1. Using the SST, remove the shaft seal cover as fol-
lows: attach the remover hook to the shaft seal cov-
er hook and draw the cover out slowly.
76G16X-608
Compressor Oil
1. Remove the drain plug and the oil filler plug, then
drain out the oil.
2. Measure the drained oil with a measuring cylinder.
3. Check the drained oil for any of the following con-
ditions:
a) Whether the opacity of the oil has increased.
b) Whether the oil color has changed to red.
c) Whether foreign matter, such as metal filings,
etc., is present in the oil.
Note:
If the oil drained from the compressor is as
described above, replaced it with new oil.
69G16X-037
16—16

COMPRESSOR 16
4. Remove the six screws.
69G16X-038
5. Alternately tap two projections on the circumfer-
ence of the front head with a screwdriver and plas-
tic mallet, and remove the front head.
69G16X-039
6. Using the SST, remove the shaft seal.
49 9201 060
76G16X-609
49 H061 004

i i
76G16X-610
7. Using the SST, remove the seal seat.
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16-17