1987 MAZDA 626 charging

16 OUTLINE
Sight glass
REFRIGERATION SYSTEM
Checking the Refrigerant Charge
1. Run the engine at idle.
2. Operate the air conditioner at maximum cooling
for a few minutes.
3. Check the amount of refrigerant by observing the
sight glass on the receiver-drier. (Refer to follow-
ing table.)
76G16X-005
Item Symptom Amount of refrigerant Remedy

1 Bubbles present
in
sight glass. Insufficient refrigerant. Check
for
leakage with
a gas

leak tester.
2 No bubbles present
in
sight
glass.
No
(or
insufficient) refrigerant. Refer
to
items
3
and
4.

3 No temperature difference
be-
tween compressor inlet and outlet.
System
is
empty
or
nearly empty. Evacuate and charge the sys-tem. Then check
for
leakage with
a
gas leak tester.
4 Temperature between compres-sor inlet and outlet
is
noticeably different.
Proper amount
of (or
too much) refrigerant. Refer
to
items
5
and
6.

5 Immediately after the
air
condi-tioner
is
turned off, refrigerant
in
sight glass stays clear.
Too much refrigerant. Discharge the excess refrigerant
(to the specified amount).
6 When the
air
conditioner
is

turned off, refrigerant foams and
then stays clear.
Proper amount
of
refrigerant. Refrigerant amount
is
normal.

Installation of the Manifold Gauge Set
Note:
Fittings for attaching the manifold gauge set
are on the high and low pressure pipes.
1. Close both hand valves of the manifold gauge set.
2. Install the charging hoses in the gauge set to the
fittings.
Connect the low-pressure hose to the low-pressure
gauge fitting and the high-pressure hose to the
high-pressure gauge fitting.
Tighten the hose nuts by hand.
69G16X-017
16-8

OUTLINE 16
Discharging the Refrigeration System
1. Connect the manifold gauge set to the system.
2. Place the free end of the center hose on a shop
towel.
3. Slowly open the high pressure manual valve to ad-
just the refrigerant flow. Open the valve only slightly.
Caution
If refrigerant is allowed to escape too fast, the
compressor oil will be drawn out of the
system.
4. Check the shop towel to make sure no oil is being
discharged.
If oil is present, partially close the manual valve.
5. After the manifold gauge reading drops below 343
kPa (3.5 kg/cm2, 50 psi), slowly open the low
pressure manual valve.
6. As the system pressure drops, gradually open both
the high- and low-pressure manual valves until both
gauges read 0 kPa (0 kg/cm2, 0 psi).
76G16X-631
Evacuation of the Refrigeration System
Whenever the air-conditioning system has been ex-
posed to the atmosphere, it must be evacuated.
1. Connect the manifold gauge set.
2. Connect the center hose of the gauge set to the
vacuum pump inlet.
3. Operate the vacuum pump, then open both man-
ual valves.
4. When the low pressure gauge indicates approxi-
mately 710 mmHg (28 inHg), close both manual
valves and stop the vacuum pump.
5. Check to be sure that the degree of pressure does
not change after 10 minutes or more in this condi-
tion.
If
the pressure changes, check the system for
leaks, and repair if necessary.
6. If no leaks are found, once again operate the vacu-
um pump and open both manual valves to obtain
760 mmHg (30 inHg).
7. Close both manual valves, and stop the vacuum
pump.
Disconnect the hose from the vacuum pump.
69G16X-019
16-9

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 COMPRESSOR
Installation of Shaft Seal Cover
1. Install the guide shaft seal on the drive shaft end.
2. Using the SST, install the shaft seal cover.
Direction of the cover is shown in the figure.
76G16X-613
69G16X-048
Compressor Oil
Compressor Oil: FREOL DS-83P
1. Tighten the oil drain plug using a new O-ring.
Tightening torque: 13—15 N-m
(1.3—1.5 m-kg, 9.4—10.8 ft-lb)
2. Remove the oil filler plug and supply new oil
through the filler.
The charging amount is as follows:

Collected amount Charging amount
More than
60 cc
Same
as
collected amount
Less than
60 cc
60
cc
3. Tighten the oil filler plug, using a new O-ring.
Tightening torque: 13—15 N-m
(1.3—1.5 m-kg, 9.4—10.8 ft-lb)
ASSEMBLY OF MAGNETIC CLUTCH
Verify that the felt is installed on the front cylinder
head.
1. Install the coil onto the compressor (with the lead
wires on top) and tighten the mounting screws.
Tightening torque: 3.9—5.9 N-m
(0.4—0.6 m-kg, 2.9—4.3 ft-lb)
2. Insert the head wire into the wire holder on the com-
pressor.
16—20