ServiceManual SectionI (87)

Repairs Air conditioning

andmaintenance

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 Volvos ar8 sold in vercions adapted for differsnt matksF.
These adaptions d€psnd on many factoB including legal,
taxationand mark€tr€ouir€m€nts.
Thb manual may thersforB show illustrctions and text
which do not applyto cars in your country.

Order No TP 30161/1
ThismanualsuD€rcedes:
IP 11633/1 24o Air conditioning
fP 1124A/1 260 Air conditioninq
fP 115A4/1 240 Air conditionina
{USA,/Canaoa,
TP 11412/2 260 Ait @Nitionins{USA,/Canada}

We ressrv€the right to make alter8rions

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 Contents
Operation Page

Specifications 2
Special tools 4
Generalrepairinstructions
D a m a q ecda u s ebdyd i r t m . o i s t u er et c . . . . . . . . . . . . . . . .
Receiver/Dryer.......... 6
Lubricating oil
l']srallirgnew system
1 e a k a s.e. . . . . . . . . . . . . . . 7
Safetyprecautions .... 7
Faulttracing
Modificatio ns th roug hout the years . . . .
't2
Draining refrigerant
Filling relrigerant B 1-21
Leadtest ............ a 22-27 21
York compressor (24O petrol/gasoline)
B 20 enqrnes c 1-3 23
B21engines......... c 4,12
Oillevelcheck 26
C l u t crhe p l a c e m (ernncr a r ) . . . . . . . . . . c 16-20 27
Disassemby assembly c2144 2A
Sankyo compressor {240 Diesel)
Removing fifling belladjusrmenr Dt 5 33
Replacement (compressor removed):
C'urch p .u l l e yc .a b o ns e a l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D 6-24 34
Bearing. ragnet D624 34
V a L v e p l a.t.e. . . . . . . . . . . D 26-29 39
Delco compressor {6-cyl. petrol/gasoline}
Femoving -fittrng - bek adjustmenl.. 40
Replacrng: clutch.pulley.bea ng. magnet E 4-5 41
Disassembly- asserbly .. E645 42
Evaporator, replacemem F 1-a 50
Evaporatorthermostat,replacement, modification ......... F9 - 1 5 52
I n s p e f l r o. .n. . . . . . . . . . . . . . . . . . . . F 16-20 54
Expansionvalve (nearevaporator),replacemem....... G 1-5 55
Expansionvalve - suction dischaagevalve on dryer, re-
pracemem........... Ht 5 56
Condenser,replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J14 57
Receiver/dryer,dryingage (desiccant)
replacement K]6 58
Eetrigerant hoses L'I 60
H e a t e rc o n t r ovl a l v e ,c h e c k i n g . . . . . . . . . . . . . . . . . . . . . 60
AC compensation {idle speed compensation)
C a r b u r e t et endg i n e s .............. N 1-5
I n j e c t e dn g i n e s .................. N6-16 63
\Mring diagrams:
240,1975-1977 68
260, t915 1517 69
70
240,260, t97I 11
2 4 0 , 2 6 0 ,1 9 8 0 72
2 4 0 ,2 6 0 ,1 9 8 1 - 13

Indexpage74

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 Group87 Air conditioning
Specifications

Specifications
test, seepage2l
Perfomance

Air conditioning24O
R e f r i g e r a tnytp, e . . . . . . . . R 12 (diclorodif luoromethanel
quantity 197F1978 1 . 1k g 2 . 4 l b s
1 9 7 9 -. . . . . . . . . . . . . . . 1 . 3k s 2 . 9 l b s
1980-.......... 1.3 ks 2.9 lbs

CompressorYork (Petrol/Gasolineengines)

Type(1975-1979) York A 209

No. cylinderc 2
Swepivolume.....,,,,,, 147cm3(9.0in3)
M a x .r e v . . . , l OOr,/s (6 OOOr,/min)
Lubricatngoil capacity 3oo cm3(0.64us pint)
Type {1979-} YorkA 21o
No. cylinderc 2
Sweplvolume........... 164 cm3(10 in3)
t M a xr.e v . . . . . . . . . . . . . . 100 r/s {6 ooo r,hin)
Lubncatingoil capacity 300 cm3{0.64 us pint)
Lubricalingoil. wpe compressor oil P,/N | 160048-3 or Suniso5,
BPEnergol LPT1OO,ShellClavus33, Tex6coCapella
E 500

Sankyocompressor(Diesel)

1980-1941 1942-
Type . . . . . . . . . . . . . . . . . . SankyoSD-508 SankyoSD5lO
N o .c y l i n d e. r. . . . . . . . . . . . 5 5
S w e p vi o | u m e . . . . . . . . . . . 138 cm3{8,4in3) 164cm3(10in3)
l ! 4 3 xr .e v . . . . . . . . . . . . . . . . l oo r,/s (6 000 r/min) 1oo r,/s (6 ooo r/min)
Lubricatingoil capaciry 135cm3{o.3uS pintt 135 cm3{0.3us pintl
Lub cating oil, typ€ Compressor oil P,/N1 160048 3 or Suniso5,
BP EneEolLPT100, Shellclavus33, Texaco
CapellaE 5OO

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 Group87 Air conditioning
Specificationt 240, 260

Tighteningtorques

Nm ft. lbs.
Pulleyse, n g i n ec r a n k s h a f{to u t e F i n n e 8
r )1 7 - B 2 3 . . . . . . . . . . . 6-10 4.4-7.4
Unions, expansionvalve pressurcequalizingpipe 't7
12.5
expans|onvalve 30 22
expansionvalve hose 30 22
evaporatorhose 30 22
c o n d e n s e '. . 11 12.5
r c c e i v e r / d r y e. .t . . . . 25 18
c o n p r e s s oYro A 2 0 9 , / 2 1 O. . . . . . . . . . 30 22
S a n k yS o D 5 O 8S . DsIO ........... 30 22
Compressor,{Yoft 2O9l21 0)
c y l i n d ebr l o c k . . . . . 20-30 15-22
bottom cover 20-30 15-22
rear beanngcover 20 15
conrcdbolts.... 20
o i lp r u g . . . . . . . . . . . . . . . . . 5 3.7
C o m p r c s s colru t c hc, e n r ebr o | t . . . . . . . . . . . . . . . 25-30 1822
Compressor, Sankyo
cyhnderblock 32 24
searerreta,ner..... 12
o i lp 1 u 9 . . . . . . . . . . . . . . . . . . . . 10 7.4
varve pdte ....... ....... 1l
C o m p r e s scol ru r c hu. e n r r b eo l l . . . . . . . . . . . 38 2A

Air conditioning260
Refrigerant, iype B 12 (diclorodifl
uoromethane)
1975-1978 1.1 kg 3.4 lbs.
1979- 1.5 kg 3.3 lbs.

CompressorDelco

Delco
6
Sweptvolume(1975-1977) 150.7cm3{9.2in3}
(1978-) 208cm3(12.7in3)
91.6r/s {5 500 r/min)
Lubricatingoil, volume 310cm3(0.65US pint)
Lubdcatingoil, type Compressoroil P/N 'l 160048-3or Suniso5,
BPEnergolLPT100,Shell Clavus,33,Texaco
Capella E 500

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 Gtoup 87 Air conditioning

Specifications260, Special tools

Tighteningtorques
ft. lbs.
Unions, co'1denser 1l
ev.porarorhose 30 22
'DWH hos. ftom conder 't7 12.5
hose (rhick)'DWH to evdporator 30 22
h o s el r h i n )e v d p o r a l orro D W F . . 24 t8
hose'DWH rc comprcsso 30 22
nose ec€ver'drye1 r 1979-) ... .. 24 18
e x p a n s o nv a r v ee q u d l DT p i p " . . . . . . . . 17 12.5
erPdnsronvalva 30 22
e x p a n s p rv d N en o s e . . . . . 30 22
c o f p r c s s o .r . . . . . 35 26
'DWH - Receiver./dryer incorporatingequalizing
vaMenousng
C o m p r e s s ocro, n r e c l i op1l a l e . . . .......... 1A-34 10-25
r c a ." y t , n d e5re a d . . . . . 26-34 19-25
c o m p r c s s co ur l c h .s h a f tn u t ............ 19 35 14 26
14-19 10-14

Specialtools

999

1801-3 Siandard handle

2261-9 PulleriSankyocompfessor
pulleY
5085-9 Presstool: nstalLing

5133'7 Counterhold:compressor
cluich
5134-5 pulley
Puller:DeLcocompressor
5!35-2 S p a c e rP
: ulley
5137-a orifr Puley
1801
5138-6 Drift: Installingpulleybeanng
5139-4 Putler;Ceramicsleeve
5140-2 Puller:Frontsea
5141-0 Adaptor:Compressor
5142-a Suppon:compressor
5143-6
5'lil4,4
5152-7
Fillingstation
Leakdetecror
Pre$ tool: c utch
encont€lner
5153-5 Nipple:ireo
o
seal
9175-4 Puller:compressor

2261

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 Gtoup 87 Air conditioning

Special tools

5140

f tri

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 Group 87 Air conditioning

General r epai insttuctions

Generalrepairinstructions

..-';.

I
240 1974- 2 260 1975-1978
3

Caution Fitting new air conditioningsystem

A I leaksmust be rectifiedas soon as possibleto prevent The compressorshould contaln oil. Other components
moistureor foreignparticleslrom enteringintothe system.
To r€ducethe risk of moistureingressduring reparNork,
keep surfacesdry and cLean.
9 i rs h o u l ob e s l o ' F dI n a 1 a i r
I n e c o - p r e s s o r. u b 1 c a r . r o lmportant
tight containerotherwiseit will absorbmoisturefrom the The air conditionlngsystem mlst be filledwith refiigerant
air. immedlatelyafterinstallationro m inimiz€the riskoi coro-
Do not rernovethe protedive plugson new pa.ts untiliust sion. For instruclionson how to fil the system see page
beforerhe part is to be fitled. Leaveone ofthe hose con_ 16.
nections unconnectedwhen fltting the component and f the air conditioningsystem has been left empty (in a
fllshthe completesystemwith refrige.antfor15-20 sec closed state) for more than 24 houls h mLrstbe fllshed
ondsbeforeconnectingit. This removesany impuit€s and tw ce with about2OOgmms (O.5lb) refrigerantbeforethe
mo sture. Do not howeverflushtoo stronglyotherwlseihe finalfill ng. The system must also be evacuatedfor about
lubncatingoil will be flushedout as well.
I n t h e e v e n t o f a c o l l i s i o n ,c h e c kv e r y c a r e f ul y e v e r y
c o m p o n e n tw , h i c h m a y h a v eb e e nd a m a g e d c. h e c kt h e
s o d e r e dj o i n t s e x t r ac a r e f u l l y D
. e f o r m e do r s p l i l p i p e s
10 minutesbetweenthe firstand secondflush. Following
the instructionson page 16.
o
nr!st not be repaired. Topping up with lubricatingoil
Note I Too mLrchoil causespoorcool ng. Too ittle will da
mage the compressor.
*Receiver/dryer
Top up the compressorafter repanng a leak or replacLng
The receiver/dryer,orthedryingagent,shouLdbe rcplaced one or more of the componentsin the system.
d f t e r- d . o r e p . t r . , n v o l v i r g l e d t a o "o r w l ' e r ' i n i r q 1 e w
components, or if moisture is suspected in ihe air
condltioningsystem.

* U S A : t o c o n f o r mw i t h W a r r a n t yp o l i c y ,t h e r e c e i v e r /
t i m e t h e s y s t e mi s o p e n e d .
d r y e r m u s tb e r e p l a c e d e a c h

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 Group 87 Air conditioning

Leakage safety precautions

Slow leakages(more than 24 hours) Ouickleakages(e.9.bursthose)

Normallythis does not involveany loss of lubicating oil. This usuallyinvolvesa loss of lubricatingoil.
When replacingcomponentsobserue:
The following volumesapply when fitting a new compo
Compressor
Drainandmeasure theoil fromthe old compressor. dl US pint
Alsodraintheoiifromthenewcompressor. Thenadd o.3
thesameamountof oil (new),aswasdrainedfromthe o.7 o.t5
old compressorto the new compressor.{At least 1 Drier o.5 o.1
dl=0.2US pint) 0.5 o.1
o.5 o.1
Other components
Drainand measurethe amountof oil. Add the rcquired
amountof oiito the new component
beforcflttingit.

Thisdoes not applyto air condirioningsystemswith

Yo'l compressors.In such casesallortrs addeddF
rectryto th€ compressor.

Safety precautions
Always wear tight tining safety Use tap water to remove refrigerant WARNING!
glasseswhen there is dangerof re-
frigerantloss. Gases lormed by heating refrigerant
are a serious health risk and can
cause serious lung damage.

Safetyglassesshouldalwaysbewom when wo*ing with
or nearrefrigerants.Rubber gloves should be worn and
allform of skin contactshould beavoidedsince refriger
ants causetrostbite. lf refrige.antshouldcontactthe eyes
or skin, splashthe eves or affectedarea with cold water
{preferablyfor15 min)andtreatthe injuryin thesame way
-,;"
G e t i n t o u c hw i t h a d o c t o ri f t h e i n j u r yd o e sn o t h e a l ,o r
s i g h t i s a f f e c t e d .A v o i d w o r k i n g n e a r n a k e d f l a m e s ,
cigarettesetc. High tem peratures causeth e refrigerante
t o l o r m p o i s o n o u sf u m e s w h i c h a r e t o x i c i n h i g h c o n -
NotelThe gasesca.| causeseriouslung darage eve.1in
low concenrrarronsThe symptoms may rol becomeevl
dentfor severalhourc or perhapseven a day later.

WARNING- EXPLOSION
RISK!
Do not sublect refrigerant coniainers to high

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 Group 87 Ai conditioning

Fault tacing, symptoms

Faulttracing
How to usethe FaultTracingtables
Findoutthe mostpossiblecauseofthe fault by checkingthe crosseson the left.Check
o
eachitem {startwithitemswhichareeasytocheck).Notethatthefaultsarenot listedin
order of orobabiliw.
lf it is not possibleto locatethe fault, pressuretest the systemto checkfor internal
faults,seepages10 & 11,

BrMnlus€
I checkflses
| lseewiin! didsram)
P@r(onnsctiororshor I ch€cf alccoles
l@mpr€ssordo€s nol opsBts)
coFpressor(oupl'ns bumt I R€ol6ca.oJphns rs"P secr'o1on Lorpr€ssoa
Fanmoror{blowarr.
do.s not op.rdr. I Checrcaolesanondor
Fan molor {blowor),poo. opoEtion Chock/Gpac€

Brck n or Doorconnectionin como4$or R.pl.c. cluich (see seci on oi conpressor)

clutchwindinq(clutchmwes in a^dour)
F6n motor scBgch€s orcontacG fan shroud I Ch€ck

D.ve belr roo l@5e or cra,red

rla5ra' contol valva od's n
II Ta.s'on o' '€pl.ce b€r
I CFscLvalv€. see pasp 60
Sse<scnon on.ompGsror o
an ducb blocl€d ch.ck 6ndclean
An inl6i in lrcnt of windscEenlshleld bock.d I Cheokand cl6an
Clutch baa ng wom or ofi-cente R6pac€ b€a ng. S€€ s6ctionon comprcssor.
corp,es{, wo- o, r@s. I F*-"h.- --pF*-, see secnonon conp,essor
tnw o'llav.l n (onprcssor{2501 | orair sysron. Medsu.edmoun
(warmlnd.healh) | Mustbe d Lea$1 5 dl 10.3US pift) rarhcompEssor,
repLacedryinsasenrin €c€iv€/dry.r andretksystem.

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 Group 87 Air conditioning

Fault tacing, symptoms

Symptom
--777)possib,ecause
Remedy

,/^.'/p94Y,/
/*"lc/,&/"*7
EvaForarorrhemosiardoesnotdisensasecompressor check/rcplac. thdrmostat See pag6 54
Expansion!a!e sruck in opan position

Top-op sysrem. Find eakaseand repan.

BLockedho.6 or component CheckJlow ihroush each componeni.

Add GfriseEni S.a pase 16
A r flow rh@ush condens6rbocked
Evaporatorblockadon an coo ing sid€
E6pofalo. lhomosrar ncorectly adjosidd Check lhemostat. See pag6 54.
nsufiicientretigerant iwhistli^g noisefrom evaporaror Drain and rafil system. See pag4 15 16
near erpanson valve, bubblesin sichi slass)

tupansionvalv€ capilary lube

Moisrurein syslem. C@lng c.pacnysdod atstan llew Drain.ysrem, replacoreceiverldryerordyins agent, fil
mnures)rhen poor. O. pooroparction ar hish ambienr wih retrlgeranr.See paq€ 15.

orarn system, rep ace raceiverldryeror dyins asem, litl

w th rerr se6nt. See pag6 15.

Su.lion discharQevalveseiz6d.Low pressuB n fronr ot Replace!a ves on r..everldryer SeepageS6

compressor,low suction {MoisruG in syslemJ

ce on evaporaioratrc@lnq sde {ihomosiar adjusted Check evapo€tor rhormosrar.See pago 54. Tesr wnh
tm ow or ran nor op6rarns)

Looseevaporatorrhermosrar Ch6ck/r6plrce See pa96 54

P@rcontactbetweonorpansionvalvecapI aryiob66nd
evaporaroroullel or poor insularon

T@ l6r€ea d fierencebelween ofiand on lor evaporator

Syfem d.rtull causes cr.shins noiso or vib€tions Dmii Sysiem Reft a.cod nO id pages j S j 6.
rrom h sh prcssurclines, ctckins nose trom compres
sori exdessivecompressorpr€ssuG and sucion pGs
suro, hissns nois€fbh expansionva ve, bubbtasorva
pour in sisht gla3s. ll conpr€ssor vatves damased by
derfillins, compr.ssor pressur. witbe loo low

Moislure in sysiem, c.n cause noso from expanson DEin r*em, rep4s4ecdwt
S e ep a a e 1 5 , t 6 5 a .

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 Group87 Coolingsystern
Farlt tacing. Ue66ureEsting

Fault tracing Pressuretesting

A s€paratepressuregaugekit or the pressuregaugeson lhe lillingstation(5143)shouldbe
ussd for ths following tests.
S€e n€xt pag€ for pr€ssur€s.

HiSh

1- Exp€mion valv. bl@k€d or 11. R€move blocl€96. R€pla@

6.iz€d in clos.d pcsition
2. ExpEBion €lv6 oplllary 12, R.pl6c6 sFNion v.lv., 55
tub€ damaqe - liqoid lc.

3. Moistu6 In 6vsi6m, ca!$t 3, DEinst€t.m. A.pllc€ 15,16

ico in dp8cio valv.. r€coiv.r/dry.r. Evaclaro B 1-26

1. Not mugh r€frig.Enl rl,DEin3yd€m,Ev€cu.t .nd 16.16 B1-26

ntl
2. O y 260 19t6-1977 2,Feplaceexpansion
valve,Fill 56 H 1-5
No bubbl6 in sisht sl.sr,
p@surs galgo rordhlF v€ry
lM. Posslblvno rdtdeamnrin

This can cao.o larg. l6.k€g3.

Erpansionutu€ crn b. bl@ksd or
seiz€din op.n pcilion-

Hish 1- Bl@k6€€in iocetver/dryer 1 Roplace R€md6 block6g€. 58

Hlgh 1, EtpaNion valv. s€iz.d in G14

2. Apamion v€ts 6il 6!6insr

4.poBrd dtrEr, r@s€4

3- Not .f,ouqh Efrig66nt, 3. Odin svsl€m, Ev.cu.t .nd filt. 15,15

Pcsilly bubbl* in 3isht sl.Bt. B 1-?6

1. R.pailGplac.. B.pla@ S€€3€ctionon compressor

High L DEinst$6m. Ewaaro andfll

Hlgh
2. No @ld .ir r.rch.. @nd€B.r
3. Bl@k8g. in high pBsuro sid€
4. Engin. €diator dsft.ar.d
5. An in sysr€n, P@r €vaclatio
End filling ol .sfigorant,
B 1-26
ch6ck cFling lan and b.lG-
6. DEin s'€tom. R.pl6c.
@co'vdldry€r. Ev&uat and fill B 1-26
accodino to imtrucrionr.

1. Moisturein sist€m, @c..iorl 1, Dr.insy.t.m. R.pl!c. 15,16

lom.rion ot i@. Low presuE @.iv.r/dry.r. Ev.cuar6and fll B 1-26
sido9@6!F v.ri6. c@ling .c6ding ro isrrudions
abilityOK in c6l @nditioB
blt pod or mn disronr h hot

musl bo r.pltc.d 6achliho the syslemk op€ned.

To contom with W.rsnly policv,lh. E@ivor/dryer

10

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 Group 87 Air conditioning

Fauktracing,prcssuretesting

Testconditions{24O,260l

1975-1978 1979-
Open Closed
Open Closed
Enginespeed 33 t/s (2 0OOr,/rnin) 33 r,/s {2 OOOr,hin)

CONTBOL
SETTINGS
3 (max) 3
Cool Cool
FLOOR Closed
DEF Closed Closed

aEc
Open Open
An conditioningswrrch On

240 Petrol/casoline1975-1978

Ambienttemp P.essureai pressurear

in lront of car compressorinlet compresso, Notel Pressuresrefer to sea level,and can vary ae
oC {oF) bar (psil outlet bar (psi} pendingon altitude,equipment,test conditionserc.

20 168) 1 . 72 . a \ 2 4 2 A 1 1 0 1 3 ( 1 3 91 8 1 )
30 (86) 2 . 2 - 2 . 7l 3 1 4 a t 1 3 _ 1 6( 1 S 1 _ 2 2 3 )
40 (104) 3 V3 414247) 1A 22 Q\O 3a7)

260 Petrol/Gasoline1 975-1 97?

24O Petrol/casoline1979-
Ambienttemp Evaporator Pressureat
Ambiemtemp Pressurear Pressureat in ftont oI car pressureat c.mpressor
in front of car compressorinler comDressor feliefvalve
'c fF) bar tpsil ourtetbar (psil (low pressurel
'c {'F) bar (psi} outlet bar {psi)
20 (68) 1 . 2 2 6 1 1 73 6 ) 6 . 5 9 . 0( 9 1 1 2 5 )
30 {86) 20 (68) 19-2.0\26-28) 913(125 181)
1.4-2.6 9-36) 8.O_12.0
30 (86) 2 . 2 - 2 . 1B 1 3 A l 1 5 - 1 8 ( 2 0 9 2 5 1 )
(111_167)
40 (to4) (18) 40 (104) 2 8-3.5(39-49) 19 231265_3211
1.3 14.8 (206)

2/tODiesel198G- 260 1978-Petrol/Gasoline

Ambienttemp Pressureat Pressureat Ambienttemp Pressureat Pressurear

in front of car compressorinlet compressor in front of car compressorinlet compressor
'C {.F) bar (psi} ourletbar (psi} 'ceF) bar (psil outlet bar {psi)
1 . 4 - 2 . 7\ 1 4 - 3 7 t 6 . 7 1 O . 9( 9 3 - r 5 2 ) 20 ( 6 8 ) 1 . 02 . 4( 1 4 - 3 3 ) 6 . 5 9 . 3 1 9 0 - 1 3 0 )
1 . O2 . 7 1 1 4 - 3 7 1 9 . 4 - 1 4 . 1 30 (86) 1 . O - 2 . 31 1 4 , 3 2 t A 1 - 1 3 . 5
(131-196) ( r2 1 _ 1 8 8 )
14 (19) 1 80 (2s1) (104) 1.2 2.2111-31) 10.5 16.7
(146_2331

1t

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 Group87 Ah conditioning
Modilications

Modifications

1976 modelyear
New evapoEtor housing covel
Butyl taps usedto seal evaporatoroutl€t, coverand eva-

valvemustnot be insulated.
NOTEIExpansion

'l 1978 modelyear

Receive/dryer relocated
movedto lront panelnextto engineradi-
Receiv€r/dry€r
us€don 240 and260 seies.
6tor.Samereceiver/dryer

240 expansion valve and thermostat

fitted on 260.
Expansion anddischarge pressursvalveson2 60 wersdis-
continued in 1978. Thevalves,whichw€rs incoporated
in the r€ceiver/dryer,havebsen replacedby the 24o ex-

Samethemostat{B) is usedfor 24O and 260 series.

Compressordoes not opsrateconstantlybut only when
temperatursof evaporatorexce€dsa predeterminedlevel.

't2

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 Gtoup 87 Ah conditioning

Modificatlons

1979 model year

Adjustable
thermostat
Prevlouslythethermostatcouldbe switchedon by means
oi a rocker switch, and the temperatureadjusteo oy a
lever. 1979- modes now have an adjustableknoo.
The capillarytube now leadsfrom the themostat io the
evaporatorouter. The function of the thermostat is rhe

Notel The orange secton beyond MAX shoutd onry oe

usedwhen quick coolingis required,.nd in exrretrreoon-
ditionssuch as drivingin desen regions,otheNise warer
which has condensedon the evaporatorw I freeze and
obstructrhe passageof air.

p
240
Rubbermountedcompressor{apptiesto vehicteswmour

Largercapacity compressor1240 petrol,/gasolreon,y,.

Y o r kA 2 1 0 . C a p a c i t y1 6 4 c m 3 ( 1 Oi n 3 )( p r e v i o u s tiy4 7
c m J ( 9 . Oi n r ) .

Refrigerantvolume increasedaccordingty:
2 4 O : 1 . 3k s ( 2 . 9 l b s )
2 6 0 : 1 . 5k g ( 3 . 3 t b s )

Newtype ot AC compensationfor engine

Operates n principleby supplyingexrrafuelair (caburet-
ted enginesor air(injectedengines)toenginewhen com-

The system comprisesa solenoidvalve, a vacuum valve

See AC compensarion,pages61-67

t3

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 Gnup 87 Ai conditioning

1980 modelyear
260 compressor
(mm)threads
[4illimetfe bolts,pre'
usedfor mounting 0)

Diesel 0
Sankyocompressorused, m m threads
Notel Dieselenginesdo not have an AC compensation
system (idlespeed compensation)

Delayed engagement of compressor

Delayrelayiitted to 1I8G- vehicles.engagescompressor
approx. 10 secondsafter enginesrdr ard relay receiv's

1981 model year

Cut-outswitch on receiver/dryer
(USA only)
Sensesthe rcceiver,/dryer prcssure.lfthis is too low, the
switch cuts offthe curenttothe compressot,thus preven_
rmg oamage.

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 Gtoup87 At conditioning
Drciningrcfigennt

A. Drainingrefrigerant
Specialtool:5143

Readthe safety precautionson page 7.

TheAC systemmustbe drainedif the refrigerant

circuitis disconnected
or ifone or moreof the components
is replaced.
Thepressure
gaugesetonfillingstation15143)shouldbe used;makesurethatthepressure gaugesareclosedbeforecon-

Connections
Nipplesshouldbe fingerrightonly.
Disconnectthe batterynegativelead.

240 Pet.ol/gasoline
and diesel
Removethe cover nuts and connectthe btue hoseto the
compressor"suction" side and the red hoseto the outtet
side marked"disch .

A2
2601975-1977
Remove rheredhose(high
the covernutsandconnect
pressure)tothe (small
compressor pipe)andthebtuehose
llow pressure)ro the equallsrngvalve on the suspensron

A3
260 1978-
Removethe cover nuts and connectthe red hose (high
pressure)tothe compressor(smallpipe)a nd the bluehose
{low pressure)to the compressor(largepipe).

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 Gtoup 87 Ah conditioning

A4
The short centre hoseshouldbe placedin an exhaustgas
extraclorhose as a safety precaunon.
Openthe gaugevalvesand lhe valveson the components.
Openthevalveonthe centrehosevery carefullysothatthe
refrigerantslowlYflows o!t.
0
CautionI lf the relrigerant flows out too quick ly
lubricating oilwill be drawn out of the system

Closethe valveswhen the gaugesIndcate zero.

0 (

B. Fillingrefrigerant
Specialtools:5143,5144,5153,9942
0 (

Beadthe safety precauiionson page 7.

Equipment required 0)
Fillingstation 5143

I Ii
5144
Nipple 5153
9942
Rubbersloves, safery slasses.

0
5143
0
Evacuating system,
filling measuringcylinder
Bl
Disconnectthe battery negativelead.
Check that:
- hosesand pressuregaugesarc coftecnyconnected
allvalves arc closed
- venr screw on vacuum pump ]s ooseo.
Makesurethat spacersarefitted to the endsofthe hoses.
The spacers,which open lhe valves,should be placed in
the nipplesat the end of each hose.

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 Gtoup 87 Ai conditioning

B2
connect hosesto component
S e e p a g e1 5 .

B3
Connectcentreshon hoseto vacuumDumD

B4
Make surethat measuringcylinderis empty
This can be checkedat the liquidindicatorin the centreof
the cylinder.lf empty. it must be evacuatedat the same

Method:
Openthe outlet valve on the measu ng cylinder,see fig.

o Cautionl Do not open the valve until the cylinderis

B5
Fully open gaugevalves and valves at compo-
nents

B6
Sun vacuumpump

B7
Openthe vacuumpumpvalveslowly (the cente valvebe-
low the pressuregaugesl.

1l

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 Gtoup 87 Ah conditioning

B8
Turnvent screwon vacuumpumponeturn clock-

L e a v e t h ep u m p o n 1 , / 2 - 1 m i n u l ea n d t h e nc l o s e t h ev e n t {,

This sperformedto renrovemoisturefromthe system and

from the oil in the pump. A hlgherdepressioncan be ob

B9
(
Evacuatesystem until low pressure gauge (on
left) indicatesnearly- l bar (-14 psi), then run
vacuumpumpfor a further 30 minutes,
Note! lf the temperatureis below 3OoC {86oFl the vac
uum pump shouldbe left runningfor a further 20 minuies, (
all together 50 minules.

TheabovevaluesarevaLidai (orcloseto)sealevel.
Pressurcsshouldbe reducedby 0.034 bar (O.47
psl)forevery3OOmetres984 ft abovesealeve

E.s. 1 5OO metres (4 920 ft) above sea evel

=5xO.034+O.17 bar (2.37 osi) reducedpres
su'e+ aop'o\.- 0.82 b"
6
Bto
C l o s et h e v a c u u mp u m p v a l v e a n da l s o t h eo u t l e t v a l v o
en
the measuringcylinder(if evacuated).
Switch off the vacuum pump.
lf the specifieddepressioncannotbe obtainedor if it drops
on closingthe valves,there is a leak in the systern.
Find and coffect the leak and evacuat€the system once ei (

0 I
Btl
The following procedures only apply iI the
measudng cylinder has been evacuated or ifthere
is less than 1 600, 1 800 or 2 000 grammesrre-
frigerant in it (depends on year and vehicle type).
In othercasesproceedto leaktesting,816
6 0 0 s = 3 . 6 l b s ,1 8 O O s = 4 l b s , 2 O O O g = 4 . 5

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 Group 87 Air conditioning

Bt2
Open

I - valve on refrigerantcontainer
- valvefor input refrigeranton measuringcylinder

Bt3
Open the upper valve above the measurlngcy inder and
transferaf€w hundredgrammesof refrigerant.Cose the

B t4
Record pressure and set scale on measuring
cylinder.
T u r ni h e s c a L e
{ m a r k e dR 1 2 ) t o t h e s a m ep r e s s u r a
es l n
dicatedon the pressure9auge.
E.g. pressuregauge shows 4.9 Set the measLringcyl-
inderwith the 4.9 scale abovethe refrigeranlindicaror.

Open upper valve on measuring cylinder and rransfer

1600 {3.6 lbsl, 18OO (4 lbsl or 2ooo {4.5 lbsl
srammes refriseranr (dependinson modelyear and ve-
hicle type).
1 1O0 {2.5 lbs), I3OO (2.9 bs) or 15oo (3 4 lbs)
g€mmes n system p !s 200 grammesfor eak test and
moisture remov3l.The rest is necessaryto prevent the
meas!.ingcy indersfromdra ningcomp erelywh ch would
3 necesstate evac!aringthe cylnder beforethe next filllng
Close valve.

B t5
Close
- va ve for input refilgerant
va ve on reirigerantcontain€r

Bt6

Leak test
Openthe ouiletvalveon the measuringcyl nderand trans_
fer 2oo grammes (O.4 lb) of refrigerantto the system

:c
t9

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 Gtoup87 Air conditioning
Fi ing refrigercnt

Bt7
Checkall connectionswith leak detector5144
field(buzzes
Setthe detectorto the mostsensitive nearlv
allthetime).Rectit anyleaksandperfoma newleaktest

Bt8

Filling
Beforeaddingrcf gerantto the system,the refrigerant
usedfor the lsak test must be drainedand the system

Method:
hosefrcmthevatuumpumpandplacethe
Disconnectthe
endofthehosein an exhaustgas {safetyprecau-
extractor

Openthevalveonthe centrehoseverycarefullysothatthe
refrigeEntslowly flows out.
flowsouttooquicklylubricating
Note!lf the refrigerant oil
will be drawnout of the compressor.
Closethe valvewhenthe gaugesindicateapproxamately

Bt9
cente hoseto vacuumpump.
Reconnect
Switchon the vacuumpumpand openthe pumpvalve

Leavethe pump runningfor 10 minutesafterthe low

pressuregaugeindicatesnearly-1 bar ( 14 psi).

820
Closevacuum pumpvalve
pump
Switch off vacuum
821
Fill refrigerant
Opentheoutlelvalveonthe measuring cylinder andtlans-
fer 1 1OO,1 30Oor 1 50Ogrammesof refrigerant to the
system.{Amountdepends on modelyearandvehiclerype,
seepages2-4).
Switchon the heaterunitforthe cylinderif it is difficultto
seethe last30MOO grammes.
Note!lfthe measuringcylinderis drained it
completely
must be evacuatedbeforethe next filling,
Closeboththegaugevalvesandmakesurethattheother
valvesareclosed.Reconnectthe batteryearthlead.
Testthe system,seenextpage.

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 Group 87 Air conditioning

Performancetest
822
C Testcondition
s l24O,260l
197+1978 1979-
Open Closed
Open Closed
s3 t/s \2 00O l-rlinl 33 t/s l2ooo l[]'in)
C O N T R O LS E T T I N G S
3 (max) 3
Cool Cool

o
FLOOR Closed Closed
DEF Closed Closed

Open Open
Air conditioningswitch On

Recordedoperatingconditions24O
Appliesto vehices equippedwith a viscouscouplingfan.

Note I Pressuresreferio sea level,and can vary depend

ing on altitude,equipment,test conditionsetc.

823
240 Petrol/Gasoline
1975-1978
Ambienttemp in front of car oC (oF) 20 {68)

824
24O Petrol/Gasoline
1979-

Ambient temp in front ot car oC (oF) 20 1681 30 (86) 40 {104}

Air temp at panelvents oC (oF) 9 12 {48-54) 9-12 (48-54) 9-12l4e-541
Prcssure
at compressorinlet
(large
connedion)MPa .... o.t24.26 o.t44.26 o.13
p s i. . . . . . 11-31 20-37 18
Pressure
at compressor
outlet
(small
connection)
MPa..... o.65-O.90 o.80-1.20 1.48
psr...... 92 128 114 111 210

21

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 Group87 Air conditioning
Momance test,Diesel,260

240 Diesel198G

Ambisnt temp in tront of car oC {oF) 20 1681 30 (86) /tO (lO4)

Air tempat panelventsoc {oF) 8-12 {46-54) U12@6-541 8-t2|.46-541

Pressureat compressorinlet
{large MPa ....
connection) o.14.27 o.14.27 0.14
p s i. . . . . . 14-38 ft44 20

Pressure outlet
at compressor
MPa.....
connection}
{small o.67-1.09 o.94-1.41 1.4
psi ....-. 95-155 134-200

Recordedoperatingconditions260
fan
with a viscouscoupling
Appliesto vehiclesequipped

NoteI Pressures referto sealevel,andcanvarydepend-

ingon aftitude,€quipment, etc.
test conditions

826
@
1975-1978
260 Petrol/Gasoline

Ambient temp in front of car oC (oF) 20168t 30 (86) 40 (1()4)

Airtemp at panelvents oC (oFl 8-r2 (46-54) 14-20 {57-68) 20-28 {68-€2

Evaporatorpressureat reliefvalve MPa 0.1s-o.20 o.224.27 o.2g-0.35

p s i. . . 27-24 31-38 40-50

Highpressure MPa .
at compressor o.9-1.3 1 . 5 - 1. I 1.9-2.3
p s i. . . 130-185 2 to-256 270-320

260 1979- Petrol/Gasoline

Ambient temo in front of car oC (oF) 20 {68) 30 {s6) iro (1o4)

Air tempar panelventsoC(8oFl 9-12 {48-54) 9-12 @a-541 9-12 (48-54}

P.essure
at comprcssorinlet
MPa ....
connection)
{large 0.10-o.24 o.10-o.23 o.124.22
p s r' . . . . 14-34 17-32

Pressureat compressoroutlet
(small
connection)MPa..... o.65-O.93 0.87-'t.35 1.0F1.67
psi ...... 92-132 124-192 149237

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 Group 87 Air conditioning

York compressor B 20 engine

Q
C. York compressor- B 2O engine
Removing- fitting - belt adiustment
Notel Checkoil levelbeforefitting a new or reconditionedcompressor,see page 26.

o Removing
Drainrefrigemnt
from system,seepage15.
CI

Disconnectlrom compressorl

- refrigerant
hoses{plusendsimmediately).
Detachthe compressorfromthe mountlngblacket

c2
(|
4 Fitting
Posltionthe compressor,do nottightenthe retainingbolts

Fit the stay betweenthe centre and lower brackets.

1 Tightenthe bohs in the order indicaiedadjacent
Tighteningtorques:
Compressor boltsmax.30 Nm (22 ft. lbs)
Remainlnsbolts33-41 Nm (24-30ft. lbs.)

o
C3

Fit belt
Adjustthe behtensonby meansofthe air pump,/roller.
It sho!ldnotbe posslble
to depressthe beltby morerhan
6 8 mm (measured betweenair pump compressor).
Connectthe refrigerant
hoses.UsenewO rings,smeared

Tishteningtorque30 Nm (22 ft. lbs).

rf Replacereceiver/dryer
Add refrigerant
or dryingagent.See page58.
to the svstem,seepageI6.

23

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 Gtoup87 Air conditioning

Yo comprcssor- 817-B 23 engines

0
York compressor- B 17-B 23 engines
Bemoving- fitting - cleaning
Notel Checkoil levelbeforcfitting a new or reconditionedcompressor,see page 26.

*$t (

Removing
fromsystem,seepage15.
Dminrefrigerant
Cars with power deering
Detachthepowerpumpandhangitfrcm thewheelhous-
I
ins.

Carswith twin drive belts

c5
a
Uft off the drive belts by removingthe crankshaftpulley.

c6
All cars:
Disconnect f rcm compre$sor: (

- rcfrigeGnt
hoses(plugsendsimmedeitely).

andmountingbracket.
Removethe compressor

Fitting
o (

c7
Carswithout power steering
anddrivebelt(s).
Fitthecompressor
Reconne€,t hoses.Use new Orings,
the refrigerant
smearedwith compressotoil.
Tightening torqle 30 Nm {22 ft. lbs)
Set belt tensionby moving the compressot.lt should not
be possibleto depressthe belt by more than $-1O mm

or dryingagent, see
Replacethe receiver/dryer o"n' o)
Add rcf gerantto the system,seepage16.

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 Group 87 Air conditioning
- B 174 23
Yotkcomprcssor

c8
Carswith power steeringand twin drive belts

0 Fitthe compressor,

c9
Fit:
I studs oppositeeach other
2 - inner pulley

4 compressordrive belt and outer pulley

6 - screws and nuts.

Note!The crankshaftshouldbe rotatedwhilst tight-

eningthe pullevbohs.and alsowhen lrttrngrhe belr.
(2-3 tulns).

ct0
Check belt tension: lt should not be possjbleto depress
t h e b e l tb y m o r et h a n3 - l 0 m m ( O . 1 2 - O . 4i n ) , ( 8 O 1 0 0
N=l8 22 lbs).

VA Incorrect belt tension

Placewasher (s) betweenthe pulleyhalvesto slackenthe

p
belts. Removewasher(s)to tighten the belts.
Onewasheraltersthe belttensionby about5 mm {0-2 in).
Reconnect the refrigelant hoses. Use new O-nngs,
smearedwiih comprcssoroil.
Tightenins torque 30 Nm (22 ft. lbs.)
Heplacerhe receiver/dryeror drying agent. See page
54.
Add refrigerantto the s)€tem, see page 16.

cll
Carswith powersteeringandonedrivebelt

ct2
Fit drive b€lt
Fit the belt ovef the crankshaft. and power
compressor

Tightenthe belt by moving the power pump.

Checkthe belt tensionas follows:
Attachtool5l9T to the beltbetweenthecrankshaftpulley

The belt tensionshould be 17-18 units.

Reconnect the refrigerant hoses. Use new O-rings,
smearedwathcompressoroil.
Tightenins torque 30 Nm (22 {t. lbs.}.
Replace the receiver/dryeror drying agent. See page

Add refrigerantto the system,see page 16.

25

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 Group 87 Ah conditioning

Yo* comprcssot - oil level check

Oil levelcheck- York compressor

ct3
Normaly t is not necessaryto check lhe oil level on in (
{
staLl€dcompressors,but new or reconddonedunits musl
be checkedbefore instalalion and refrigerantis added
New compressoBare chargedwith oil durins manufac

@r I
W AR NI NG
lfihe ol levelin an instaled compressoris checked
it is mportantthatthe refigerant is drainedfromthe
systembeforethe oi plug is !nscrewed. lf this pre
A d pstick can be made to measurethe levelof oil in the
cauton is not fo owed the reftgerant wil sprayoll
compressor.The dlpstickcan be shapedfrom a 3 mm dF
of hole,taking the oil in the compressoralong with
ameter brasswire, and graduatedwlh 1Ox3 mm ma*s
it
as 5hown above Tdch dvisior cotrespondsto dpp'ori
m a t e l yO . 0 3 d m 3 , / ( O . 0 6U S p i n t )
0
ct4

Checking
T h e g r a d u a t e dp a r t o f t h e d i p s t i c ks h o u l d b e h e d a t (
r i g h t a n g l e st o t h e b o t t o r no f l h e c o m p r e s s o rT. h e c o r
r e c t o i l e v e l f o r n e w c o m p r e s s o r si s 2 8 2 9 m m ( 0 . 3d m 3
= 0 . 0 6U S p i n 0 .
On installedcompressorswhich have been run, so some
of the olLwillhave beencirculatedin the system and con-
sequentlythe levelof oil in the compressorwill be consider
a b l y l o w e r { 2 02 5 m m = 0 . 8 - l . O i n ) t h a ns p e c i f i eadb o v e .
0 (

f t h e l e v e ls l e s st h a n2 0 m m ( O . 8i n ) t o p u p t o 2 0 m m

ct5

Adding oil
Only compressoroils may be used to top up the system,

Beforeunscrewingthe oil p ug checkthat lhe Oiing is in-

tad and that the sealingsurfaceson the plug and crank
caseare unclamaged.The o pllg shoud be tightenedto
approximatey5 Nm (4 tt. lbs.)
0

26

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 Group87 Ah conditioning
York compressor, clutch reDlacement

Q
York compressor,clutch replacement(on car)
(Not necessaryto d@inrcfrigetant)

ct6
Removing
Lock clutch and remove pulley centre bolt
Turn on the ignitionto engagethe electrcmagneticclutch
a nd counterholdthe pulleywith the drivebelt. Removethe
bolt and free the pulley from the shaft by screwing in a
5,/8" UNC (A) bolt in the centre.

ct7
Remove magnet
lead(2).
Disconnect

- fourbolts(1).
magnet(3).

c/8
Fitting
Fit the magnetwith the lead turned upward, and connect
t h e c a b l eM
. akesurethatthekeyislocatedcoiiectlyinthe
groove.Attach the pulley.

ct9
Fit centreboh
Tum on the ignition and counterholdthe pulley with the
d ve belt when tighteningthe bolt.
Tigttening torque 25-30 Nm (18-€O tt. lbs.)
Turn the pulleyand make surethat it does not contactthe

c20
andpage25 for 821.
Seepase24 for 820 engines,

21

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 Group 87 Air conditioning

Yo* comprcssor,disassembly

York compressor
Disassembling
Off car)
t, (

Not€ lThe valveplateisonlyavarlableas a complete

unrr Includrngvalves.and can be replacedwrthout
removlng the compressorfrom the vehicle. See
ope'atronsC24-25. C38. lr ,s however necessary
to drain the rcfrigeranlfrom lhe system, see page

c2l
Remove clutch and magnet
Lockthe clutch by connectinga battery.Counte old the
0 I
pulleyas illustmtedand removethe centre boll.
Screw in a 5,/8' UNC bolt and removethe pulley.
Lift out the magnet.
I

c22
Remove kev and end washer

c23
Remove seal
Carefullylift out the seal with the aid of a sreelwirc. Make
surethatthere are no burrsorscoreson the shaft, and that
0r I
the innersealingsufaces are clean.

f' (
D]
c24
Removeseruicevalvesand boltsretainingcom-
pressofrcp

Removecompressortop

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 Group 87 Ait conditioning

York comprcssor, disassembly

c25
,D Remove:
- guide pin
- valveplate(ifnecessarytapthesideslighnywith a plastic

Carefu yscrapeoffpiecesofgasket(ifany)f rom the crank-

*--.--'
Valve plate replacement only, see page 3l operation
c3B.

c26
ljnscrew and remove bottom cover and clean
crankcaseand covermatingsurfaces,
c27
ldentify con rods and caps

c28
Removecon rod bolts. lift oft cap and pressout
con rod and pistonthroughcylinder.

(f
c29
Remove bearing cover plate
Cleananddrythecrankcase
andshaftto removealltraces

c30
Removecrankshaftbearing
Heatthecrankcase (300'F)in an oven.
to 150"C
( T h i s m a k e s i t e a s i e r t o r e m o v e t h e c r a n k s h a f ta n d
bearing.)
lfthe crankshaftis undamaged,and only the bearingis to
be replaced,clampthe centresectionofthe shaft in a vice
and Leveroff the bearingwith two screwdriverc.

rf

29

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 Group87 Ah conditioning

YorkcomprcssoLassembly

AssemblingYork compressor

c31
Fit cEnkshaftrear bearing
Fitthebeangbyexsrtingpressure
ontheinnerrace.

'lF:'
c32
Fit crankshatt front bearing
Ivlakesurethatthebearingseatisfreefrombunsandclin.
Heatthe crankcase to l50oc {3oooF)in an oven.
Pressin the bearing.

c33
Fit crankshaft
Afterthe crankcase hascooledplaceit in a pressas illus
trated restingthe front end on a support.
Insertthecrankshaft itin relationto the
andcarcfullyalign
bearinginnerrace.
Pressin the shaftuntilthebeainginnerracecontactsthe

a
lmpoftam lf the crankshaft
doesnot contactthe
bearinginnerrace,damagewill result.

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 Group 87 Air conditioning

Yotk compressoL assembly

c34
Fit new rubbersealto rearcoverDlate

0
c35
Lightlypressoncoverplateandtightenallscrews
Tightento a torque of 20 Nm (15 ft. lbs.).

0 Fit pistons and con rods

c36

NotelThe lockpin (A) in thegudgeonpin must point

towards the cenlre of the compressor.

Assemble con rods and caps and tighten to alorque of

20 Nm {15 ft. lbs.l.
Checkfor smooth operationby turning the shaft a few

c37
Fit bottom cover whh new gasket and tighten
if crosswise to 20-30 Nm (15-30 ft. lbs.)

c38

D Fit valve cover and top cover

Smearcompressoroilonto the crankcase,valvecoverand
top coversea ing surfaces.
Fit the crankcaseguide pins,
P l a c ea n e w g a s k e t o n t h ec r a n k c a s e a nm
d a k es u r ew h e n
fining the valve plate that the nuts point upwards.
Placea newgasketbetweenthe valvecoverandtop cover.
SmearthesealingsLrrfacesoftheseruicevalveswth com
pressoroil and place new sealsin the top cover.
Securethe valveswlth the four long bolts and tighten the
remainingbolts in theoder indic.ted adjacenttoa torque
o f 2 G 3 0 N m ( 1 5 - 3 Of t . l b s . ) .

31

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 I
Gtoup 87 Ah conditioning

Yotk compressoa assembly

c39
Check new seal
Compress seala few times.
(1)
The lugs mustbe ableto movein andout of the re
I

Fit seal
c40
0 (

oll andpresst on to the

lmmercethe sealin compressor

Placethe
f.ce {A)facins
upward.
finelygroundsur
plstonringin itsholderwiththe

c4l
0 (

Press down seal with end washer

i.t c42
::, '
Fit end washer
.'.,
.l &, Fita newsealunderthe washer'Oilthe sealingsurfaces
wnh compressoroil andcentreit beforetightenlng

c43
Fit cover washer
Thewashercanbe pressed on by hand.lt shdesonto the
wher ll_eLlLlchis
pocrl.on
shatrdrd rakesup theco-recl
f,tted.
@

d',
q
Fit clutch
Tightenthe centreboltto 25-30 Nm (18-22 ft. lbs l

c45
Add 30o cm3 {0.6 Us pintl compressor
oil
Seepase26 for oil levelcheck.

32

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 igroup87 Ait conditloning
Sankyo compressor on diesel engines

D. SankyocompressorSD S08, b1O

Removing- fitting - belt adjustment

D1
Removing
Drainrefrigerant,
seepage15.
Disconnectf rcm compressor:

- rcfrigerant
hoses(plugendsimmediatety).

D2
Slackenthe mountingbolts,arowed.

D3
Lift off the d ve belt, removethe mounting botts and lift
away the compressot

D4
Fitting - belt adjustment
lf the compressorhasbeenrcplacedor repairedrhe oil level

Mdhod:
Drainthe old compressofoilinto a measuringcylinderand

Add the sameamountof new oilto the comprcssorbeforc

insralljngit.
The a mountof oil addedmust be morethan 40 cm3 (0.08
US pint).
Smearthe plugO ring with compressoroil and tightenthe
p l u st o a t o r q u eo f 1 0 i 2 N m ( 7 . 4 1 1 . 5 f t . l b s . l .
lf for instancea hose has burst and refrigeranthas been
lost very quickly,add 135 cm3 oilto the compressor.

D5
Atach the compressorloosely. Adjustthe behtensionand
tightenthe mountingbolts-ltshould notbe possibleto de
pressthe belt by more than 5-10 mm (O.2-O.4 in).

Reconnect the refdgerant hoses. lJse new O-rings,

smearedwith compressoroil.

0 Tighteningtorque 30 Nm (22 ft. lbs.)

Replace receiver/dryeror drying agent, see page 58.
Fill refrige€nt, see page 16.

33

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 Gtoup 87 Air conditioning

Sankyo compressoL parts replacement

Clutch replacement,SankyocompressorSD 5O8, 51O

Includesreplacementof pulley,carbonseal,bearings(2x),magnet
Specialtools: 1801,2261,5137,
5142,9175

Disassembly
0' (

D6
Mount compressorin vice
Use protectivejaws to avoid damagingthe compressor.
@r (

D7
Removenut (19 mm) from clutch
U s e a h o o k w r e n c h t o c o u n t e r h o i dl h e c l u t c l , .

o, o)
Pull off clutch
A$ach puller22Sl with 3 x 1,/4" x l bolts and pulloff

@rI

0 I
D9
Remove retainer and felt seal

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 Gtoup 87 Ah conditioning

Sanlcfo comprcssor. parts replacement

Dt0
Remove:

I
- Oiing.

I Dtl
Bemovecarbonseallrom shaft
Usepuller
9175.

I Dt2
Remove inner circlip

D
I
Dt3
Removepulley
Usea universa
puler.
Remov€the circlipsecuringthe bearing

i0

35

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 Gtoup 87 Air condhioning

SankyocompressoLparts replacement

Dt4
Pressout bearings
Supportthepulleyon block5142. Pressoutthetwo bear_
ingswithdriftl gor and5137. NOTETherearetwobeaF
ings.

Remove magnet

Removethe scrcwsandlift out the magnet-

o)
Assembly
Specialtools:at085,5142 and9175

Fit magnet
Securethe lead to the clamp.

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 Group87 Air conditioning
SankyocompressoLpans replacement

Dt7
Pressin bearings

! Usepresstool5095andblock5142.
Fit the bearingsone at a time.

D t8
Fit circlip

D19
Attach pulley to compressor
Useblock5142.

o
5142
Carefullytapthe
pulleyinto position
witha ptasric
ma er_

D20
Fit innercirclip

t D2l
Fit carbon seal
Firstattachthe seattotoot9175.

D22
SmearO-ringwith compressoroil beforeplacing
in compressor
{Raised
section
of O-rinsupward.)

(D

37

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 Gtoup 87 Air conditioning

Sanll/ocomprcssoaparts replacement

D23
Fit:
- circlip
{
felt sealandretainer

*
,I
t

D24 (

Fit clutch
5142 Alignthe clutchto the keyway.
Carefullytapon theclutchwitha plasticmalletuntilone
two of the threadsarevisible.Useblock5142.
Fit nut
or
CI(
torque3a Nm {29 ft. lbs.)
Tiqhtening
seePage33.
Fit compressor,

I
(

ll
{

38

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 Gtoup 87 Ai conditioning

Sankyo compressoL valve plate rcplacement

0
Valve plate on Sankyocompressor,replacement
(Oft cat)

lF
i
I
Removing

t Mount compressorin vice

(valvecoverup.)
D25

M a r k t h e p o s i t i o no f t h e c o v e r .

D26
Bemovescrewsand cover
Carefullyleveroff the cover wllh a screwdriver.

D27
Free valve plate
Carefullyleveroff the valve platewithout scoringthe sur-

I Cleanthe compressorbody and valve plate.

Fifting
D28
Place new gasket and valve plate on bod,,
Makesurethat the guidepin fits in to ihe coffecthole,
otheMisethe retaining
screwswillnot fit propeny.

I
D29
Placenew gasketbetweenvalveplateand cover
I Positionthe coveraccodingto the indenrificatton
marks.
Tightenthe boltscrosswise.
\
I Tightening torque15 2 Nm (lltl.5 ft. tbs.l.

N O T E I fo i l h a s b e e ns p i l t d u r i n gt h e r e p a i r , t h eo i l
plug should be removed and the compressor
o i l d r a i n e d i n t o a m e a s u r i n gc y l i n d e r .C o n e c t
a m o u n r = 1 3 5 c m 3 .( 0 . 3U S p i n r ) .
R e t u r nt h e o i l a n d t i g h i e n i h e o i l p t u g t o 1 0 N m
(7.4 ft. lbs.).

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 Gtoup 87 Air conditioning

Delcocomprcssoton 827, 828 engines

E. Delco compressor
Removing- fitting - belt adjustment
Specialtool514l
I
h is not necessarytodischargeref gerantfrcm the
system ifthe compressoris only moved to one sde
to obtain accesstothe enginevalvese.t.c. In such
a casefollow E2 and hangthe compressorfromthe
bonnet hinge

EI
Removing
Drain ref gerantfrcm the system, see page 1 5.
Disconnectthe connectionplatefor rhe compressorhoses.
'fl

6,1
Fit:
protecuveplugs on plate
- adaptor5141 to compressor.

{ l
E2
Removecompressor
Disconnecr
the lead.
Moveasidethe upperradiatorhoseandte it to a suitabte
CI)
a
- mountinsbolts{4 x)

Lft awaythe compressor. 0)l

E3
Fifting - belt adiustment
Positionthe comp.essorand drive belt.
Adjusl the belt tension and tighten the coi,pressor
m o u n l i n gb o l t s .l t s h o u l d n o t b e p o s s i b t e t od e p r e s st h e
b e l t b y m o r e t h a n 5 - 1 0 m m ( 0 . 2 - 0 . 4i n ) .

Remove adaptor 5 14 1 and fit the connecrionplate.

Tishrening torque 12F34 Nm {10-25 ft. tbs.}
Replace receiver/dryeror drying agem, see page 58.
0 ) l
Fill reirigerant,see page 16.

40

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 Grcup87 Air conditioning

Delcocomprcssor,parts replacement

0
Clutch replacement,Delco compressor

Includesreplacementof pulley,bearing.magnet

E4
oblain accessto clutch
Disconnectthe negativeteadfrom the batrery.
Detachthe compressorfrom the mountingbracketsand

Bend the upper radiatorhose underthe compressorand

placea pieceof wood abovethe hoseto supportrhecom

t E5
For removalof components,see pages42-43, E7-13.
Forfitting of solenoid,see page48, E36-39.
For fining the remainingcomponents,see pages49-50,
E40-45.

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 Gtoup 87 Air condhioning

Delcocomprcssor, disassembly

{ ) {
DisassemblingDelcocompressor
Specialtools:1801,5132,5133,5134,5135,5137,5139,5140,5142
(Off cat)

MountJixture5132 in vice
E6 cl
Supportthe compressorin the fixture.

E7
@ l
9/16"
Remove clutch nut
Cou.terholdtheclutchwith5133 andremovethenutwith
a 9,/16" socket.

{) (
FB

- circlip

E9
Withdraw clutch
Usepuller5134.

ol
E|0
Remove:

- circlip
- sleeve(leverout with screwdiver)

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 Group 87 Ai conditioning

Delcocomprcssoadisassemw

Pull ofi pulley

0 Usea suitablepuller.
Usetool5135 to supportthe centrcspindteof the purer.

Et2
Removepulleycirclipand driveout bearhrg
80t+5t37 Usedrift513?andhandle
1a01.
Placesupport5142 beneaththe pulley.

I Et3
Remove magnet
ldentifythe positionof rhe magnet.

- rrlagnet.

Et4
Bemove circlip and ceramic sleeve
Bemovethe circlipandfrcntcollar.
Withdrawthe sleevewith puller5139.

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 Gtoup 87 Air conditioning

Delco comprcssor, disassembly

Et5
RemoveO-ring
Use a pieceo{ steelwiro, shapedas illustrated.

Et6 @t,
I
Removesealwith 5140
Pressthe toolagainstthe sealandtum it untilthe lug grips

Pull out the tool and seal. o)e

Et7
Turn compressorand fixture so that bottom end
o a
porntsup
Bemovethe safety valve, O-dngsand rcar cover.

@)a

ldentify location of oil pump gear and collar

outerO r ng.

Et9
Lift off rearvalve housingand valve plate
U s ea p a i r o fl o c k i n gp l i e l sa n d g r i p t h et w o d r i t t e dh o t e si n
the housing. o

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 Grcup 87 Ai conddoning
D elco compressor, disassembly

E20
Remove oil pump suction pipe and O-ring

I E2l
Detach compressorfrom fixture
Supportcompressor
on 5142, fronr end up

E22
Lift off outer housing {rom cylinder unit

0 E23
Pull out front end O-ring

E24
Lift off front section

E25
Removelront valvehousingand valveplatefrom
cylinder unit

E26
Clean and check all parts

E27
Replace seals and worn parts
0
f*." t* "*."** ir"t "in
ararat'te
asa c.-neresna*
l

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 Group87 Air condhioning

Delco compressor, assembly

{)

AssemblingDelcocompressor
Specialtools:1801,5132,5133.5138.5139,5144,5/ 42,5152

F2B
Support cylinder unit on 5142 and fit lront valve
0,e
plate and valve housing

trTl-"i:1rrT111.il l O' f

5142

829 r), t
Fit {ront sectionand O-ringon valve housing
Smear the O-ing with compressoroil.

0e
0)a
E30
Position outer housing above cylinder unit
Turnthehousingsothatthe holein theplateabovethe oil
sumpalignswith thesuctionpipehoLein thecylinderunt.

{)a

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 Group 87 Ai conditioning

Delco compressor, assembly

E3l
Moum compressorin tixtures5132 as illustrated
0 and fit suctionpipeand O-ring
Thecylinderunitshoutd
rhenberurned
sothatthesucnon
prpe|s centredin the hole jn the ojtsump ptate_

E32
Fit rear valve plate
Alignthe pl6tewith the cytinderunit.

I E33
Fiti

- O{ing
oil pump(alisnidenrification
ma*s).

Fit sieve in rear section

0
47

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 Gtoup87 Air conditioning
Delcoconprcssor, assembly

E35
Fit rear section

Note The locationof the two guide pins.

Tighteningtorquefornuts= 2&-34 Nm {l9-25ft. lbs.)

Fit:
- satetyvalve,tighteningroque = I 4-1 I N m ll (Fl 4 ft
lbs.l
- O-ringsfor hoseconnections.

E36
Fit magnet
Fitth€ magnetaccordingtothepreviouslymadeidentifica

NOTETheplugfor the etectricleadsshouldpoint to

10 o clockwhen the serviceplateon the
comDressor Dointsto 12 o clock.

Thefixtureshouldbe heldin thevicewiththefrontend

facingup.

E37 O
Fit circliptor magnet

E38
Fit shaft seal
Attachthe s€alto 5140.
Insertthetoolinthefrontendcollarandtum
ituntiltheseal

Th€nprsssdownthe springandtum the tool anti-clock

wiseto releasethe sealfiomthe tool.

E39

- O-ringin innergroovein collar

- ceramicrjng(usepuller5139)
circlipfor ceramicdng.

o
48

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 Group 87 Ah conditioning

D elco compressor, assembly

Fit bearing and circlip on pulley

rN Used ft 513a andhandle 1a01.

E4l
Fit pulley
Used ft 5138andhandle
r8O1.

0 E42
Fhl

I
E4s
Fit:
- new sleevefor felt seal
- key in shaft key\,vay.

(f

49

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 -
II
GroupB7 Ah conditioning
Evaporctor,rcplacement

E44
Fit clutchwith presstool 5152
T t ' e t h r L s t b e a r r g m . s r b e l o - r r e o o e r w F e n r h e c r u r c h dnn o
5152 v
NOTEDo not ovenightenthe cl|rtchotherwiselt will con

Fit:
E45 @e
- washer and circlipin clr.rtchcentre
- n u t ( m a c h i n e de n d f a c i n g w a s h e d .

Tightenthe nut:
0)a
Tishteningtorque 19-35 {14-26 tt. lbs.l
Use a 9,/16" socket and countefiold with 5133.

0,, {

F. Evaporator,replacement 0De
0te
Removing

Disconnectthe battery negativelead.

Drain refrigerantfrcm the sysiem, see page 15.

- g l o v ec o m p a r t m e n t
- p a n e b e n e a t hg l o v e c o m p a d m e n t
s i d e p a n e ln e x t t o h e a t e r .
Removethe rlght defrostervent and air duct.
(

50

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 Group 87 Ai conditioning
EvaporctoL rcplacement

Remove thermostat {rom cover

0 Applies to 24O | 975-1978)

N o t e t h a t t h e p o s i t i o no f t h e t h e r m o s t a t{ 1 ) c a n
v a r y a n d t h a t t h e c a p i l l a r y t L r boen 1 9 7 9 -m o d e l s
i s m o u n t e d o n t h e e v a p o r a t o rp i p e .

cover (2).
F3

I Unscrew conneqtions and carefully pull out eva-

porator

Fifting

Frt:
- new evaporatorseal

0 Fit (as applicable):

F5

0 Connect refrigerant hoses

Usenew O rings,smearedwith compressor
o.

e\, Tightenins
torque30 Nm {22 ft. lbs.)
Replacereceiver/dryer
Frllsystem
or dryinsagerr, seepase 58.
with ref gerantandteakrest,seepage16.

Insulatehosesand connecttons

NOTE The expansionvatvemusr not be ins!tated.

- glovecompartmenr

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 Grcup 87 Ar condiion;ng

Evaporatot thermostat, replacement

Evaporatorthermostat,replacement c 0
Thermostatlocationvarieswith modeltype and year

The folowins variationsoccur:

24O 1975-197A,260 !978: The thermostatis locatedin the evaporatorcovera nd
the caDlllarvtube {heat sensod is insertedin the evaporator.
26O 1975-1977: No themostatfitted. The temperatureofthe refrigerantlsregulated
For replacement
insteadby a suctiondlschargevalve,incorporatedin rhe receiver,/dryer'
s e e p a g e5 6 , o p € G t i o nH 1 - 5 .
240,260 1979 earlytypes: Adiustablethermostatlocatedon the controlpanel.The
0)a
caoilLarv tube is insertedin the evaporator.lf prcbLemsarise, e.g iregul.r cvcling,the
thermostat should be replacedand lhe capillarytub€ placed on the evaporatoroutlet
( s a m ea s f o r L a t eW p e s ) I. h e r m o s t a tP , / N 1 2 5 9 6 1 7 7 .
240 , 260 1 97 9 late types : Adjlslable thermosratlocatedon the controlpanel The
caDilarvtube is mounted on the evaporatoroullet.
0)e
to changeto the adlustable
On replacingthermostatson old rype models it is advisabLe
tvpe, see instructionsbelow A specialkLtP/N 1129O90-5 is availabLe

Fitting new type adtustablethermostat 0ll f

F s0 e
- glove compartment
panel beneathglove compartment
- side panelsnear heater.
0a
Ft0
Loosenthermostat. cut off capillary tube
tubein evaporator.
Leaverestof capillary

Clean evaporator outlet

6) I
52

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 Group87 Air condhioning
Evaporator them ostat rcpIacement

Connect thermostat across AC rclay and @m-

pEssor solenoid
105 Compressor sol€noid
106 Solenoid
107 Thermostat+ switch
129AC relay

107 129

Ft3
Attach thermostat to comrol oanel

Bend capillary tube and attach h to evafrorator

outlet
Bendthscapillarylubeapproximately40 mm{1.5 in)trom
its endarounda 10 mm (O.4in) diam€terpipe.
Attach the tubs to the evaporatoroutlet pipe with two
clampslP,/N944267-4).

Insulateevaporator outlet
Useinsulation tapeP,/N591235-7.
R€fit parts removed.

53

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 Gtoup87 Air conditioning
EvaDorctor thermostat inspection

Evaporatorthermostat, inspection
Allvehiclss,apartfrom 260197F1977models,areequipp€dwith ovaporatorthermo-
stats.The purposeoftheth€rmostatisto cycleli.e.engage/disengage)
the compress-
or, A defectivethermostatcanusuallycaus€ths evaporatortoiceup which blocksthe
air flow and consequently€uses poor cooling.
The tvDeand locationof the thermostatvariesas follows:

240 197+1974.260
Adjustable tlpe mounted on evaporator cover.
24O,260 1579-t Non adjustablethermostatmountedon dashboad controlpanel.

Fl6
Inspectthermostat as follows: DASHBOARDCONTBOLSETTING
TESTCONDITIONS
- Bonnet{hood)open. Doorsand windows closed - Temperature
controlat COOL
- Enginespeedapprox.33 r/s (2,000/min) - FloorandDEFshuttersclosed(pushbuttonsout)
-An additionalfanmustbe usedto coolthecondenser. - REC(recirculation)
buttondepr€ssed
- An-condswitchON (1975-1978)
- 1979- modelswith adjustabl€
typethermostarset ad-
justerknobto blues€ction.

Fl7
Check that compre5aorcrycles the compressor
doesnot cyclee.g. becauseof higham-
checkthatthethermostat
After5-1Ominoperation cycles bienttemperatures,
a roadtestshouldbe carriedout.See
clutch.lf
the mov€msntof the compressor
by obseruing F 18.

Ft8
Boad test Notethe lowesttemp€rature
at whichthethermostatdis-
(Ambient temperature should not exceod 25oC = engagesthe compressor,This should be 5o-8oc
77OFJ (41o-46oF)dependins
on the temperature
of the coolins
an.
Drivethevehiclsarapproximatsly50 km,/h(3o mph)and
measurethetemperatur€ ofthe air fiom the cen-
releas€d

Ft9 F20
lf temperature b allove 8'C (46oF) It temperatureis lower than soc (41oF)
240 1975- 1978,260 1978: 240 1975 - 1978, 260 1978
Removethe soundproofing and panelon the sid€of the and panelon the sideof the
Removethe soundproofing

Turn the thermostatscrew slightlyclockwise. Tumthe thermostatscrewslightlyanticlockwise.

240, 260 1979- 240,2601979-

Thethermostatcannotbe adiust€d6nd mustthereforebe Thethemostatcannotbe adjusted
andmuntherefor€be

54

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 Group 87 Ai conditioning

Expansion valve rcplacement

G. Expansionvalve (nearevaporator),replacement
( 2 4 0 a n d2 6 0 1 9 7 8 - m o d e s )
on 260 1s75 1977 modelsthe expansionvalve is incorporatedwith a dischargeprcssurevatve and is mounteclon the
receiver,/dwer.see oveneaf.

t Removing

Disconnectthe battery negativelead.

0 Drain .efrigerantfrcm the system, see page 15.

Remove:
- soundproofingpanel

G2
Removel

- evaporatoroutler ins!lation

NOTE Thermostatlocationvarieswith model type

0 G3
Fit new expansion valve
Usenew O-ings,smearedwith compressoroil.
Tightenins
torque30 Nm {22 ft. lbs.}.

G4
Fit:

Insulatethe evaporator
outletpipe.

NOTE Do not insulatethe expansionva ve.

G5
Replacereceiver/dryer
or dryingagent,see page
58.
Fillsystem with refrgerant,see page 16.
Refit side panels and soundproo{ing.

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 Group87 Ah condhioning
Eryansionvafue- suctiondischaryevalve,rcplacement

H, Expansion
valve,sustiondischargevalve in receiver/dryeJ
, re-
placement
Onlvfifted to 260 1975-1977models

Removing
Disconnectthe batterynegativetead.
Drainrefrigerantfrom tho system,see page 1 5 .
Ivlarkpositionof valve body cov6r.

H2
Bemove:
- retainingbolts

-Gring.

H3
Remove:
- bolts and lock washsrs

- expansion
valveO-ring.

Smearnew O-ringswith compressor oil.

Fittwo O-dngsto expansionvalveand oneto suctiondis-

PlaceoneO-ringin expansion
valveseatin valvebody.

H5
Fit:

- lockwashersandmountingbolts
- coverO-ring(oil fitst)
- covor,according to proviously
mademarks.

Replacedryingagent,s€epage59, operationK3.
seepage16.
Fillsystemwith refdgerant,
56

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 Group 87 Ait conditianing

Condenser.replacement

c
J. Condenser,
replacement

Removing
Disconnectthe baltery negativelead.
Dra n refigerant from the system,see page 15.
J2
i0 obtain accessto compressor

- radialorgrilleand headamp frames

- r g h t h e a da m p , 2 6 0 a n d 2 4 O 1 9 7 9

- electnccoo n9 fan (if fitted)

Disconnectrefrgerant hoses(plug ends mmedtarety).
Remove condenser

0
Fitting
J3

Fit condenser

i0 Reconnecrreftigeranthoses.
Us€new O rings,smearedwlh compressor
o
Tghtening
torque17 Nm {12 ft. tbs_).

Q
Beplacereceiver/dryeror drying agent, see next page.
Fill system with refrigerant,see page I6.

51

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 Group87 Ah conditioning
Receiver/ dryeL replacement

Receiver/dryer.replacement
NOTEThe receiver/dryer containsa desiccant(dryingagent)thepurposeofwhich is to absorbanv moisturein the
is not exposedto air (moisture).
refrigerantcircuit.Becauseof this it is very importantthat the receiver/dryer
Receive/dryerlocationand type varieswith enginetype and model

NOTEFollowing anyreparrswhichinvolveinleF
rupringthe.eirigersnlcircuilor if moistureis
suspectedin the system,the receive/dryeror
desiccant(dryingagenl)must be replaced.

KI
Replacingreceive/dryer
240. | 975-t 977
24, 260 1978-
Disconnect leadfromthobattery.
thenegative
fromthe syslem,seepage15.
Drainrefrigerant
Disconnectthe hosss(plugendsimmediately)-
refrigerant
Replace receiver/dryer
NoTE Measurethe amountof oil in the receiver,/dryer.
Thesameamountof newoilmustbeaddedtothereplac*.
ment receiver,/dryer(260 and Diesel)or York compressor
(240).

240 1975-1977
K2 o
Fitting
lvlakesurethattheevaporator
hoseis connected
to the
OUTconnection on the rcceivet/dryet.
Reconnectthe refrigeranthoses. Use new O-rings
smearedwith compressor oil.
Tishteninstorque25 Nm (18 ft lbs.l.
Add r€frig€rantto the system, seepage I 6, Reconnect

240, 260 1978-

Replacingdrying agent
K3
260 1975-1977
Removing
Disconnectthe batterynegativelead.
Drainrcf gerantfrom the system.seepage15.

Disconnectre"frigeranthoses{plug endsimmediately as
wellas in valvebody)
ldentifyvalvebodyposition
in relation
10mounting
bracket.
Ot

58

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 1
Group87 Air conditioning
Beceiver/dryeLreplacement

K4
Removereceiver/drver
(ldeftify the position of the body first. )

K5
Removethe O-rings.Cleanthe sieveandremoverneDag
containing
the dryingagent.
Smearthe new O-ringswith compressor oitbeforefitting.
Place new bag oI drying agent in receiver/dryer.

K6
Fit receiver/dryer
Reconnectthe refrigeranthoses. Use new O-rings,
smearedwith compressor oit.
Tishtening torque,seofig. (41 Nm = 30ft. tbs.24 Nm =
18 ft. lbs,17 Nm = 12 ft. tbs)
Add refrigerantto the system,seepage16.
Beconnect the battery.

59

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 Gtoup 87 Air conditioning

Refrigercnt hoset heater control valve

L. Refrigeranthoses,replacement
l f o n e o r m o r e o l t h e r e f r i g e r a n th o s e s h a s b u r s t ,c a u s i n gr a p i d l o s s o f t h e r e f r i g e r a n t i,t i s v e r y p r o b a b l et h a t
c o m p r e s s o ro i l h a s b e e n l o s t . T h i s o i l m u s i b e r e p a c e dw i t h n e w o i l - S e e p a g e 7 .
I n p r i n c i pe t h e m e t h o df o r r e p l a c i n gh o s e s i s t h e s a m e f o r a l l l y p e s . l t s h o u l db e n o t e dh o w e v e r t h a t t h eh o s e sa r e o f
v a r y i n g l e n g t h a n d t h a t e a c h h o s e i s i n t e n d e df o r a s p e c i a lp a r t o f t h e r e f r i g e r a ncl i r c u i l .

LI
Replacement
Disconnectthe battery negativeLead.
Drain refrigerantfrom the system, see page 15.
Replacethe defectivehose.
lf necessary,add new comprcssoroil (does not apply to
systems with York compressor). Use new O rinss,
smearedwith compressoroil. Tighten all connecnonsto
toque, see specificationson page 2 4.
Replacereceiver/dryef or drying agent, see page 58.
Add refrigerantto the system, see page I6.
Reconnectthe battery.

M. Inspectionof mechanicalheatercontrolvalve
s!€tem is unableto keeppassengercompartmentcool in hot weather,the heaterconlrolvalveshould
tfthe air condirioning be

oa
'COOL i
inspectedand if necessaryadjusted.The problemmay be due to the valvenot closingwhen the heatercontrolis at

Inspectionand adjustment
Remove:
- soundproofingpanel beneathsteeing wheel
- side panelsnext to heater
o{|
Warm up the engine.
Move rhe heatercontrolto ofi (closed)andcheckthat the
input hose from the engineto the heater control valve is
cold. lf not. tum the adjusterscrew (arrcwed)3,/4 tum

Checkthat the hose coos down after a few minuteswith

the engineidling.
Aso check that the heater control valve lever boftoms
"COOL'
when ihe temperaturecontrcl is set to
Apply sealerto the adjusterscrew.
Refit side panel and soundproofing.
0 (

60

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 Group 87 Ait conditioning

AC compensatian.cafturrcted engines

N. AC compensation- idle speed compensation

0 T h e p u r p o s eo f t h e A c c o m p e n s a t i o n s v s t e mi s r o c o u n t e r a clrh e r n c r e a s e tdo a do n r h ee n g i n ea l r d e s p e e d s w h e nt h e
c o m o r - e s s oi sr e n g a g e o .l r f J r c t i o n s I n p r i r L i p t €o y s r , o p t y1 g a d d i l r o l d t, u e t - a. r r i " r r r e i c a
o u . r e t e oe n q i n e s ro r a . r
U l j e c r e oe r g r r e s j o a s tt h e l h . o t r ' Fv d t v ew h e l r t , ec o m p . e q s o ri s e r g a g e d .
An alternative c o m p e n s a t i n gs v s t e mi s f i t t e dr o c e r r a i nv e h i c t e s( 8 2 j A 8 2 - s w e d e n ,A u s t r ai a ,c a n a d a ) a , n df u n c t i o n s
b y a d v a n c i n gt h e i g n i t i o nw h e n r h e c o m p r e s s o ri s e n g a g e d .

Carburretedengines

All 1975-1 978 modets

ldle speed s kepr constanrwhen th€ compressoris en-
gagedby nreansof a solenoidvalve mounied on rhe caF

0 Wher rhe romp.-.ror s "rqageo t." tocd or tre "r9rr"

rncreases. On sensingthis ihe sotenoidvatveopensaoo al
l o w sa n a d d i to n a l a m o u not f f u e ta i r m x l u r et o b y p a s sr h e
lhrottle valve and maintaina consta.r ide speeo
The solenoidvalve closes rhe bypass channetwnen me
compressor|s drsengaged.

0
(0
-,o)
4-cylinder1979-
{ E x c lS. w e d e n ,A u s i r a l i aC, a n a d a8, 2 t A 1 9 8 2 _ )
The compressor,when engaged, acrualesthe soenoo
v a l v e( 1 ) w h i c hi nt u r no p e n st h e v a c u u m
v a v el 2 ) d o w r n s
mofe fuelair mixtureto bypassthethrort e vatve The id €
speed s Increasedby a pproxinrarely3 5 r,/s (2OOr,/min)

r l e " o t a c p l r i l l u s r r " r , oc n
l-"*' *1.'" '"" h*-. *" I
L o - ' n d c l e d . I h e F io c .utr l o o f r r - - o s " , , m a v r o w - |
P v e rb F d , f - r . r ,
I

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 Group87 Air condi[oning
AC comparsation, carbutetEd engines

N3
B21A'1982 - (Sweden, Austlalia, Canada)
Theidlespeedcompensationsystemfunctionsby aclvan-
cingthe ignitionwhenthe compressor is engaged.
Compr€ssordis€ngaged:The depressionin front of the
throttlevalveis low andconsequentlvthe distributoris not

Compr€ssorengaged: The depressionafter the thmttle

andidlespeedis kept
valveishigh,theignitionis advanced

Theadjacent showswhsrethehosesare
illustration
theexactroutingof thehosesmayhow-
connecled,

827A,824A 1979- N5
1 Oelayvalve
2 Solenoidvalve.Only'1979-with AC
3 Checkvalve(Whitesidef8cinsinletmanitold)

62

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 Group87 Air conditioning
AC compensatioainiectedenginesBl9-823

AG Gompensation- injectedengines819-823

N6
8 1 9 E ,8 2 1E , B 2 1 F .1 9 7 5 - 1 9 7 8
Asolenoidvalveopensa bypasschannelallowingmore air
toflow pasr rhe throttlevalvewhen the compressorrs en
gagedand the engine is idling.

B 1 9 E ,8 2 1E , B 2 3 E 1 9 7 9 -
B21F 1979-1981

NOTE821FCalifornia 1981andall821F 1982

modelsarefittedwith constantidlesDeedsvstem

Thesolenoidvalveoperatesin coniunctionwith a vacuum

valvewhich opensa channelallowingmo.e ai.to bypass
the throftle valve,thereby increasingthe idle speed.

N8
8 2 1E T 19 8 1 -
(Shown adjacent)

821FTis fitted with constantidle speedsystem

(ClS)and thereforedoes not requireAC com-

63

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 Group 87 Ah conditioning

AC compensation
827E,B28E

827 E 1975-1974

N9
The solenoidvalve opens when the compressoris en
gaged,and morc air bypassesthe throttle valve.

B 2 7 E1 9 7 9 - 1 9 8 0 ,B 2 8 E1 9 8 1 -
(Excl.SwedenandAustralia) Nto

64

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 Gtoup 87 Air conditioning

AC compensation 827E, B2BE

B27E 1979 Sweden and Australia

',0

(l

1 . D e l a yv a l v e . C e r t a . m o d e s o n y 5. Charcoallilter A!sralraonlv
2. Solenoid valve. Only cars wrth AC 6.'EGR valve
7. An inletfor lilter
4 Vacuum valve. A!sralia o.lv L V a c u u ma m p l i f i e r
' E x h a ! s tg a s r e c t r c ua l i o n

B27E 1980. B2aE 1981 - Sweden and Australia

N12

1 . D e l a yv a l v e . C e r r a i nm o d e l so n y
2. Sol.noid valve OnLycars wirh AC

6. Charcoal liller. Ausva a on y

65

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 Group87 Ai conditioning
B27F
AC compensation,

827 1975-1978
Nt3

The solenoidvalve opens when the compressor|s enga

ged, and more air bypassesthe throttle valve.

827 F 1979

I
2
3

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 Gtoup 87 Air conditioning

AC compensation,
B28F

B28F 1980 (all marketsl

B28F 1981 USA Federaland Canada

Nt5

1
2
3 Controlpressureregulator

Nt6

B28F 1981 USA, Californiaand Japan

A B28F 1982-
Thesevehiclesarefittedwith constanridlespeedsrsrem(cts)

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 Group87 Ah conditioning
Wiing diagram

Air conditioning24O
1975-1977
a

F Conpressorsol€noidvalve

Reversing(Back-up)light
Airconditioning
windows(relay)1977 only
Electric
Glovecompartment light

Air conditionins engag€d

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 Group 87 Air conditaning
Wiing diagrcm

Air conditioning
26O
1975-1977

B
c Air conditioningswitch
D
E
Compressorsolenoid
G

Clove compartment
light
Revercins (Back-up)
lighr

An @ndhioning engaged

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 Gtoup87 Air conditioning
Wting diagnm

Air conditioning240, 260

1978

Comp.6ssorsolenoid

Fus€ no. 2
Horn

Reversing (Back-up)light
Air conditionins
Elect.icwindows (relay)

Ai condit_|oning€ngaged

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 Group87 At conditioning
Wiringdiagrcm

Air conditioning 240, 260

19 7 9

O Adjustablethermoslar cofirol

F Compressorsolenoid

Fuseno. 3

Fus€no. 12
(Back-up)
Revelsing tighr
Electric
windows(rctay)

E
and adjostabte theno$ar ON. lgnition, fan swirch 6nd adjustabte lgnirionand fan switch ON
thermostat, ON Adjunabb thermo$at OFF

71

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 Group87 Air conditioning
W ng diagrcm

Air conditioning240, 260 B

1980 c
o Adjustablethermosrai
E

G Delay relay (engages1O

sec afteralternatorvoltage

H Chargingindicatorlamp

Fuseno. 12
(Backup) lisht
Reversing

Electricwindows(relayl

Fuseno. 13

Combinedinstruments
lgnhionON, engineOFF
{altehator not ch8lginsl

Enginerunning,adjustablethermostatON Enginerunning.adjustablethermostat Enginorunning,fan switch ON

and ian switch ON Adjustablethemostat OFF

a
12

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 Group 87 Ait conditioning

Whing diagtam

Air conditioning240, 260

1981-

B
c M crcswitchlClS vehicles

B D
&
\)ry
E solenoid valve (ercl. Cls

G Delay relay (engaOes10

secafteraLternalorvoltage
D+61)
Chargingindicatoilamp
K
L
cor oul swltch(locatedon
receiver,/dryer)
USA only

(Backup)light
Reversing

Electc windows(relay)

Fuseno. 13

Combined
instrument

lgnition ON (engine OFF alterna, Enginerunning,adjustabterher- Enginerunning,adjunablerheF

tor nor charginq) mosratON (Ac ONI mostatOFF (AC OFF)

l3

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 Group 87 Ait conditioning

W ng diagrcm

)onditioning24O, 260
1981-

B
c Microswirch 1C S vehlcles

D
E Solenod valve {excl.CIS

G D e L a yr e a y ( e n g a g e s1 0
sec afler ahernatorvohaqe
at D+61)
C h a f g i n gi n d c a t o r a m p

L
M CLr oLi swnch llocared on
receiver/dryer)USA on y
S8
GR = grey

BN
R e v e G i n s{ B a c ku p ) l i s h t

E ectric windows (re ay)

B
GN
OR
VO
Combinedinstrument

= withoutpotential

= potential lower than

Engine runnang,adiustable theF
rtON{Ac oNl mo$ar oFF (AC OFF)

13

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 Group 87 Ait conditioning

Index
12
carburelted engines,
a l l1 9 7 5 - 1 9 7 8 N1 61
N2-4 61
fiting.. ... ... 6
4 cyl 1979- . . . . . . . . . . . . . . . . . . .
6 c y l1 9 7 9 - . . . . . . . . , . . . . . . . . . .N 5 62
244,197a 1911 .. .. ... .. K1-2 5a
2 4 4 , 2 6 01 9 i A - . . . . . . . . . . . . . . K1-2 58
4 c y l1 9 7 5 - 1 9 7.8. . . . . . . . . . N6 63
4 c y l1 9 7 9. . . . . . . . . . . . . . . . . . N7-8 63
2 6 Q ,1 9 7 5 - 1 9 7 7. . . . . . , . . . . . . K3-6 58
6 c y lE 1 9 7 5 - 1 9 7 .8. . . . . . . . . N9 64
6 cyE l 1 9 7 9 .-. . . . . . . . . . . . . . . N10-12 64 filling (charging) B1-24
6 c y l F1 9 7 51 9 7 8. . . . . . . . . . N13 66 d r a i n i n. .g. . . . . . . . . . . . . . . . . . . . 15
6 c y l1 9 7 9 - . . . . . . . . . . . . . N14 66
Chargingsystem B1-24 l6 r e p l a c e m, e. .n l . . . . . . ., L1 60
Clut6hreplacement,seerespective
compressor Safety precautions 7
Compressor,seerospective
manufacturer Sankyo conpressor (Diesel)
removingfiiiing beh adjustment D1-5 33
repacemenr clulch, pulley, carbon seal,
r e p l a c e m e.n. t. . . . . . . . . . . . . . D6-24 34
Delco comp.essor {827, 828)
bearlng,solenoid, roplacement D6-24 34
removlng filting beh adtustmenl E1-3 40 v a l v ep l a t e ,r e p l a c e m e n t. . . . . . o25 29 39
cl!tch, pulley, bearing, solenod d i s a s s e m b |.y. . . . . . . . . . . . . . . . E6-15 34
r e p | a c e m e.n. t. . . . . . . . . . . . . . . 845 41 a s s e n b l .y. . . . . . . . . . . . . . . . . . . . o1v24 36
d i s a s s e m b.l y. . . . . . . . . . . . . E6-27 42
S p e c i a l t o o l s. . . 4
a s s e m b r. y. . . . . . . . . . . . . . . . . . . . E28-45 46
Desiccant {see dryins aqent)
2 4 0( + D i e s e l l. . . . . . . . . . . .. . . .. . . . . . .. . . . . . . . 2
6 2 6 0 . . .. . . .. . . . . . . . . . .. . .. . . 3
Suctiondischargevalve - expan'

r e p L a c e m e. .n.t. . . . . . . . . . . . . . F 18 2 6 0 1 9 7 5 19 7 7 o n l y . . . . . . . . . H1 - 5 56

Evaporator thermostat
replacemenm t , o d f i c a r i o n. . . . . . F9-15 52 240 822-25 21
n s p e c t i o n, . . . . F 1 62 0 54 260 822, 22
826 27
240 19-75- .. G15 Thermosrat,see eveporator
2 6 0 1 9 7 8 -. . . . . . . . . . . . . . . . Gl 5 55
2 260 1975 1977 ... ... .... . H1 - 5 56
Evacuatinq system B1 - 1 0 16 240.................... 3
2 6 0 . . .. . . .. . .
s y m p t o m .s. . . . . . . . . . . . . . . . . .
pressLreresrng 1o 2 4 0 ,1 9 7 5 1 9 7 7 . . . . . . . .. 6a
Freon, see refrigeranr 2 6 0 ,1 9 7 5 - 1 9 7 7. . . . . . . . . . 69
240,260 1974 70
ldle speed compensation. see AC
2 4 . 2 6 4 1 9 7 9. . . . . . . . . . . . . . 71
2 4 o ,2 6 0 1 9 8 0+ D i e s e. . . . . . 72
2 4 0 , 2 6 01 9 8 1 + O e s e l . . . .
l n s p e c t i o na, d j u s i m e n .t . . . . . . M1 60
-7 Yolk comp.essorlB2O, 817-823)
L e a k a g e. . . . . removngJ nlnq belt adjustmenl,
L e a k t e s. t. . . . . . . . .. . . . . . . . . . . . B1 6 - 17 19 820 23
817 823 c4-12
tubricaring oil 6
c r u t c hf e p r a c e m e n t . . . . . . . . c16-20 27
oi l6v€l check, c 1 31 5 26
f o r r e f r i g e r a n. .t . . . . . . . . . . . . . . . B 14 d i s a s s e m b. l.y. . . . . . . . . . . . . . . . c21 20 2a
a s s e m o r y. . . . . . c31-45 30

74

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 VOI-VOSUPPOBTS VOI-UIITARY
lrlECHAlllC
CEBTlFlCAT|0ll
8YtflE [.1.4.S.E.

l U S A o ny )

Your
nrostitlportant
spectal tool

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