Isuzu 1999 RODEO Workshop Manual

Page 1

WORKSHOP MANUAL

RODEO

(UE)

FOREWORD

This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of vehicle components.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication.

All rights are reserved to make changes at any time without notice.

Arrangement of the material is shown in the table of contents on the right-hand side of this page. A black spot on the first page of each section can be seen on the edge of the book below each section title. These point to a more detailed table of contents preceding each section.

This manual applies to 1999 models.

SECTION TABLE OF CONTENTS

GENERAL INFORMATION

0A General Information 0B Maintenance and Lubrication

HEATING, VENTILATION AND AIR CONDITIONING

1A HVAC System

STEERING

2A Power-Assisted System

SUSPENSION

3C Front Suspension 3D Rear Suspension 3E Wheel and Tire System

DRIVELINE/AXLE

4A1 Differential 4A2 Differential 4B Driveline Control System 4C Drive Shaft System 4D Transfer Case

BRAKE

5A Brake Control System 5B Anti-Lock Brake System 5C Power-Assisted Brake System 5D1 Parking Brake System (4x4 model) 5D2 Parking Brake System (4x2 model)

HEC ENGINE

6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel 6D1 Engine Electrical 6D2 Ignition System 6D3 Starting and Charging System 6E Driveability and Emissions 6F Engine Exhaust 6G Engine Lubrication 6H Engine Speed Control System 6J Induction

TRANSMISSION

7A Automatic Transmission 7A1 Transmission Control System 7B Manual Transmission 7C Clutch

BODY AND ACCESSORIES

8A Lighting System 8B Wiper/Washer System 8C Entertainment 8D Wiring System 8E Meter and Gauge 8F Body Structure 8G Seats 8H Security and Locks 8I Sun Roof/Convertible Top 8J Exterior/Interior Trim

RESTRAINTS

9A Seat Belt System 9J Supplemental Restraint System (Air Bag System) 9J1 Restraint Control System

CONTROL SYSTEM

10A Cruise Control System

6VD1

6A 6B 6C 6D1 6D2 6D3 6E 6F 6G 6H 6J

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0A–1

GENERAL INFORMATION

RODEO

GENERAL INFORMATION

CONTENTS

General Information 0A. . . . . . . . . . . . . . . . . . . . .

Maintenance and Lubrication 0B. . . . . . . . . . . . .

General Information

CONTENTS

General Repair Instruction 0A–1. . . . . . . . . . . . . . . .

Illustration Arrows 0A–2. . . . . . . . . . . . . . . . . . . . . . .

Identification 0A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theft Prevention Standard 0A–5. . . . . . . . . . . . . . . .

Lifting Instructions 0A–10. . . . . . . . . . . . . . . . . . . . . . .

Standard Bolts Torque Specifications 0A–12. . . . . .

Abbreviations Charts 0A–13. . . . . . . . . . . . . . . . . . . .

Service Parts Identification Plate 0A–14. . . . . . . . . .

General Repair Instruction

1.If a floor jack is used, the following precautions are recommended.

Park vehicle on level ground, “block” front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions” in this section), raise vehicle and support with chassis stands and then perform the service operations.

2.Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting.

3.Use a cover on body , seats and floor to protect them against damage and contamination.

4.Brake fluid and anti–freeze solution must be handled with reasonable care, as they can cause paint damage.

5.The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs.

6.Use genuine Isuzu parts.

7.Used cotter pins, plastic clips, gaskets, O–rings, oil seals, lock washers and self–locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused.

8.To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation.

9.Clean the parts before inspection or reassembly . Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions.

10.Lubricate rotating and sliding faces of the parts with oil or grease before installation.

1 1.When necessary, use a sealer on gaskets to prevent

leakage.

12. Carefully observe all specifications for bolt and nut torques.

13.When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant–134a.

14.When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected.

15.SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental

Restraint System (SRS) – Air Bags. This system is not to be serviced without consulting the appropriate service information. Consult Section 9J “SRS System” if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by:

1. “AIR BAG” warning light on the instrument

cluster.

2. A Code “J” for fifth digit of Vehicle Identification

Number.

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0A–2

GENERAL INFORMATION

Illustration Arrows

Arrows are designed for specific purposes to aid your understanding of technical illustrations.

Arrow T ype

Application

Front of vehicle

Up Side

Task Related

View Detail

View Angle

Dimension (1:2)

Sectioning (1:3)

Arrow T ype Application

f Ambient/Clean air

flow

f Cool air flow

f Gas other than

ambient air

f Hot air flow

f Ambient air mixed

with another gas

f Can indicate

temperature change

Motion or direction

Lubrication point oil or fluid

Lubrication point grease

Lubrication point jelly

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0A–3

GENERAL INFORMATION

Identification

Vehicle Identification Number (VIN)

This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle.

710RW003

F00RX002

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0A–4

GENERAL INFORMATION

Engine Serial Number

f 6VD1 Engine

The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter.

F06RW001

f X22SE Engine

The gasoline engine serial number is stamped on the rear end raised area of the cylinder block left side.

035RW022

Transmission Serial Number

Manual : Stamped on the left side of the transmission intermediate plate.

220RS025

Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode switch.

240RW019

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0A–5

GENERAL INFORMATION

Theft Prevention Standard

The 11 major components listed below will be marked with 17 digit VIN at the stage of production. In addition its service parts will be marked with manufacturer’s trade mark, “R” mark and “DOT” mark.

Reference

INDICATION

Figure No.

COMPONENT

PRODUCTION SERVICE PARTS

0A-10 ENGINE 1– 6VD1

– X22SE

VIN plate

0A-1 1 TRANSMISSION 2– Manual transmission

– Automatic transmission

VIN plate

0A-1 1 BODY 3– Engine hood

4– Front door 5– Rear door 6– Fender 7– Rear Quarter panel 8– Front bumper 9– Back door left side 10– Back door right side 11– Rear bumper

VIN label

Anti Theft Stamping/Plate/Label

STAMPING/PLATE LABEL

PRODUCTION

SERVICE PARTS

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0A–6

GENERAL INFORMATION

Anti Theft Stamping/Label/Plate Location

The stamping, label and plate locations are indicated by arrows in the illustration below.

NOTE:

1.VIN plate locations for production.

2.Stamping locations for service parts.

Engine (6VD1)

901RW080

Engine (X22SE)

035RW025

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0A–7

GENERAL INFORMATION

Manual Transmission (TREMEC T5)

240RW020

Manual Transmission (MUA)

901RW081

Page 9

0A–8

GENERAL INFORMATION

Automatic Transmission (THM)

901RW082–1

Body

604RW023

Page 10

0A–9

GENERAL INFORMATION

Body Label Instructions

Do not peel off the masking tape until completion of paint work when replacing these parts, as the tape is affixed on the label attached to service parts for body of the anti–theft component.

NOTE: Be sure to pull off the masking tape after paint work has been completed.

Do not attempt to remove this label for any reason.

901RW083

Precautions in pulling off the masking tape

1.Use only your finger nail or a similar blunt instrument to peel off the masking tape. Use of a sharp object will damage the underlying anti–theft label.

2.Be careful not to damage the paint around the label.

901RW084

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0A–10

GENERAL INFORMATION

Lifting Instructions

CAUTION:

f If a lifting device other than the original jack is

used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage.

f When jacking or lifting a vehicle at the frame side

rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance.

Lifting Points and Supportable Point Locations

C00RX002

Lifting Point: Front

f When using a floor jack, lift on the Convex portion of

the skid plate.

545RS001

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0A–11

GENERAL INFORMATION

Supportable Point: Front

f Position the chassis stands at the bottom of the frame

sidemember, behind the front wheel.

501RS003

Lifting Point: Rear

f Position the floor jack at the center of the rear axle

case when lifting the vehicle.

420RS002

Supportable Point: Rear

f Position the chassis stands at the bottom of the frame

sidemember, just behind the trailing link bracket.

501RW002

Legend

(1) Trailing Link Bracket

Supportable Point: Rear

f Position the chassis stands at the bottom of the rear

axle case.

420RS001

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0A–12

GENERAL INFORMATION

Standard Bolts Torque Specifications

The torque values given in the following table should be applied where a particular torque is not specified.

4.8

8.8

9.8

Strength Class

Refined Non-Refined

Bolt Identification

Bolt Diameter × Pitch (mm)

M 6X1.0

M 8X1.25

M 10X1.25

* M10X1.5 M12X1.25

* M12X1.75

M14X1.5

* M14X2.0

M16X1.5

* M16X2.0

M18X1.5 M20X1.5 M22X1.5 M24X2.0

4 – 8 N·m (3 – 6 lb ft)

8 – 18 N·m (6 – 13 lb ft) 21 – 34 N·m (15 – 25 lb ft) 20 – 33 N·m (14 – 25 lb ft) 49 – 74 N·m (36 – 54 lb ft) 45 – 69 N·m (33 – 51 lb ft)

77 – 115 N·m (56 – 85 lb ft)

72 – 107 N·m (53 – 79 lb ft) 104 – 157 N·m (77 – 116 lb ft) 100 – 149 N·m (74 – 110 lb ft)

151 – 226 N·m (111 – 166 lb ft) 206 – 310 N·m (152 – 229 lb ft) 251 – 414 N·m (185 – 305 lb ft) 359 – 539 N·m (265 – 398 lb ft)

5 – 10 N·m (4 – 7 lb ft)

12 – 23 N·m (9 – 17 lb ft) 28 – 46 N·m (20 – 34 lb ft) 28 – 45 N·m (20 – 33 lb ft) 61 – 91 N·m (45 – 67 lb ft) 57 – 84 N·m (42 – 62 lb ft)

93 – 139 N·m (69 – 103 lb ft)

88 – 131 N·m (65 – 97 lb ft)

135 – 204 N·m (100 – 150 lb ft)

130 – 194 N·m (95 – 143 lb ft) 195 – 293 N·m (144 – 216 lb ft) 270 – 405 N·m (199 – 299 lb ft) 363 – 544 N·m (268 – 401 lb ft) 431 – 711 N·m (318 – 524 lb ft)

– 17 – 30 N·m (12 – 22 lb ft) 37 – 63 N·m (27 – 46 lb ft) 36 – 60 N·m (27 – 44 lb ft)

76 – 114 N·m (56 – 84 lb ft)

72 – 107 N·m (53 – 79 lb ft) 114 – 171 N·m (84 – 126 lb ft) 107 – 160 N·m (79 – 118 lb ft)

160 – 240 N·m (118 – 177 lb ft)

153 – 230 N·m (113 – 169 lb ft) 230 – 345 N·m (169 – 255 lb ft) 317 – 476 N·m (234 – 351 lb ft) 425 – 637 N·m (313 – 469 lb ft) 554 – 831 N·m (409 – 613 lb ft)

The asterisk * indicates that the bolts are used for female–threaded parts that are made of soft materials such as casting, etc.

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0A–13

GENERAL INFORMATION

Abbreviations Charts

List of automotive abbreviations which may be used in this manual

A — Ampere(s) ABS — Antilock Brake System AC — Alternating Current A/C — Air Conditioning ACCEL — Accelerator ACC — Accessory ACL — Air Cleaner Adj — Adjust A/F — Air Fuel Ratio AIR — Secondary Air Injection System Alt — Altitude AMP — Ampere(s) ANT — Antenna ASM — Assembly A/T — Automatic Transmission/Transaxle ATDC — After Top Dead Center ATF — Automatic Transmission Fluid Auth — Authority Auto — Automatic BARO — Barometric Pressure Bat — Battery B+ — Battery Positive Voltage Bbl — Barrel BHP — Brake Horsepower BPT — Backpressure Transducer BTDC — Before Top Dead Center ° C — Degrees Celsius CAC — Charge Air Cooler Calif — California cc — Cubic Centimeter CID — Cubic Inch Displacement CKP — Crankshaft Position CL — Closed Loop CLCC — Closed Loop Carburetor Control CMP — Camshaft Position CO — Carbon Monoxide Coax — Coaxial Conn — Connector Conv — Converter Crank — Crankshaft Cu. In. — Cubic Inch CV — Constant Velocity Cyl — Cylinder(s) DI — Distributor Ignition Diff — Differential Dist — Distributor DLC — Data Link Connector DOHC — Double Overhead Camshaft DTC — Diagnostic Trouble Code DTM — Diagnostic Test Mode DTT — Diagnostic Test Terminal DVM — Digital Voltmeter (10 meg.) DVOM — Digital Volt Ohmmeter EBCM — Electronic Brake Control Module ECM — Engine Control Module ECT — Engine Coolant Temperature EEPROM — Electronically Erasable Programmable Read Only Memory EGR — Exhaust Gas Recirculation EI — Electronic Ignition ETR — Electronically Tuned Receiver EVAP — Evaporation Emission

Exh — Exhaust ° F — Degrees Fahrenheit Fed — Federal (All States Except Calif.) FF — Front Drive Front Engine FL — Fusible Link FLW — Fusible Link Wire FP — Fuel Pump FRT — Front ft — Foot FWD — Front Wheel Drive 4WD — Four Wheel Drive 4 x 4 — Four Wheel Drive 4 A/T — Four Speed Automatic Transmission/Transaxle Gal — Gallon GEN — Generator GND — Ground Gov — Governor g — Gram Harn — Harness HC — Hydrocarbons HD — Heavy Duty Hg — Hydrargyrum (Mercury) HiAlt — High Altitude HO2S — Heated Oxygen Sensor HVAC — Heater–Vent–Air–Conditioning IAC — Idle Air Control IAT — Intake Air Temperature IC — Integrated Circuit / Ignition Control ID — Identification / Inside Diameter IGN — Ignition INJ — Injection IP — Instrument Panel IPC — Instrument Panel Cluster Int — Intake ISC — Idle Speed Control J/B — Junction Block kg — Kilograms km — Kilometers km/h — Kilometer per Hour kPa — Kilopascals kV — Kilovolts (thousands of volts) kW — Kilowatts KS — Knock Sensor L — Liter lb ft — Foot Pounds lb in — Inch Pounds LF — Left Front LH — Left Hand LR —Left Rear LS — Left Side L WB — Long Wheel Base L–4 — In–Line Four Cylinder Engine MAF — Mass Air Flow MAN — Manual MAP — Manifold Absolute Pressure Max — Maximum MC — Mixture Control MFI — Multiport Fuel Injection MIL — Malfunction Indicator Lamp Min — Minimum mm — Millimeter MPG — Miles Per Gallon MPH — Miles Per Hour M/T — Manual Transmission/Transaxle MV — Millivolt

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0A–14

GENERAL INFORMATION

N — Newtons NA — Natural Aspirated NC — Normally Closed N·M — Newton Meters NO — Normally Open NOX — Nitrogen, Oxides of OBD — On-Board Diagnostic OD — Outside Diameter O/D — Over Drive OHC — Overhead Camshaft OL — Open Loop O2 — Oxygen O2S — Oxygen Sensor PAIR — Pulsed Secondary Air Injection System P/B — Power Brakes PCM — Powertrain Control Module PCV — Positive Crankcase Ventilation PRESS — Pressure PROM — Programmable Read Only Memory PNP — Park/Neutral Position P/S — Power Steering PSI — Pounds per Square Inch PSP — Power Steering Pressure Pt. — Pint Pri — Primary PWM — Pulse Width Modulate Qt. — Quart REF — Reference RF — Right Front RFI — Radio Frequency Interference RH — Right Hand RPM — Revolutions Per Minute RPM Sensor — Engine Speed Sensor RPO — Regular Production Option RR — Right Rear RS — Right Side RTV — Room Temperature Vulcanizing RWAL — Rear Wheel Antilock Brake RWD — Rear Wheel Drive SAE — Society of Automotive Engineers Sec — Secondary SFI — Sequential Multiport Fuel Injection SI — System International SIR — Supplemental Inflatable Restraint System SOHC — Single Overhead Camshaft Sol — Solenoid SPEC — Specification Speedo — Speedometer SRS — Supplemental Restraint System ST — Start / Scan Tool Sw — Switch SWB — Short Wheel Base SYN — Synchronize Tach — Tachometer TB — Throttle Body TBI — Throttle Body Fuel Injection TCC — Torque Converter Clutch TCM — Transmission Control Module TDC — Top Dead Center Term — Terminal TEMP — Temperature TOD— Torque On Demand TP — Throttle Position TRANS — Transmission/Transaxle TURBO — Turbocharger

TVRS — Television & Radio Suppression TVV — Thermal V acuum Valve TWC — Three Way Catalytic Converter 3 A/T — Three Speed Automatic Transmission/T ransaxle 2WD — Two Wheel Drive 4 x 2 — Two Wheel Drive U–joint — Universal Joint V — Volt(s) VAC — Vacuum VIN — Vehicle Identification Number VRRRE — Vehicle Refrigerant Recovery and Recycling Equipment V–ref — ECM Reference Voltage VSS — Vehicle Speed Sensor VSV — V acuum Switch Valve V–6 — Six Cylinder “V” Engine V–8 — Eight Cylinder ”V” Engine W — Watt(s) w/ — With w/b — Wheel Base w/o — Without WOT — Wide Open Throttle

Service Parts Identification Plate

The Vehicle Information Plate (Service Parts ID plate) is provided on all vehicle models. It is located on the center dash wall inside the engine compartment. The plate lists the VIN (Vehicle Identification Number), paint information and all production options and special equipment on the vehicle when it was shipped from the factory.

905RT013

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0B–1

MAINTENANCE AND LUBRICATION

RODEO

GENERAL INFORMATION

Maintenance and Lubrication

CONTENTS

Maintenance Schedule List 0B–1. . . . . . . . . . . . . . .

Explanation of Complete Vehicle Maintenance

Schedule 0B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Fluids and Lubricants 0B–8. . . .

Lubricant Viscosity Chart 0B–9. . . . . . . . . . . . . . . . .

Recommended Liquid Gasket 0B–11. . . . . . . . . . .

Recommended Thread Locking Agents 0B–12. . .

Maintenance Service Data 0B–13. . . . . . . . . . . . . . . .

Maintenance Schedule List

Normal Vehicle Use

The maintenance instructions in this Maintenance Schedule are based on the assumption that the vehicle will be used as designed:

f to carry passengers and cargo within the limitations

specified on the tire placard located on the inside of the glove compartment door;

f to be driven on reasonable road surfaces within legal

operating limits;

f to be driven on a daily basis, as a general rule, for at

least several miles/kilometers;

f to be driven on unleaded fuel Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following sections.

Severe Driving Conditions

If the vehicle is usually operated under any of the severe driving conditions listed below , it is recommended that the applicable maintenance services be performed at the specified interval shown in the chart below.

Severe driving conditions:

f Towing a trailer, using a camper or car top carrier. f Repeated short trips of less than 8 Km (5 miles) with

outside temperature remaining below freezing.

f Extensive idling and/or low speed driving for long

distances, such as police, taxi or door–to–door delivery use.

f Operating on dusty, rough, muddy or salt spread

roads.

ITEMS

INTERVAL

CHANGE ENGINE OIL AND OIL FILTER Every 3,000 miles (4,800 km) or 3 months CHANGE AUTOMATIC TRANSMISSION FLUID Every 20,000 miles (32,000 km) CHANGE REAR AXLE OIL Every 15,000 miles (24,000 km) REPLACE TIMING BEL T Every 75,000 miles (120,000 km) REPLACE AIR CLEANER FIL TER See explanation of service, page 0B–5 CHANGE POWER STEERING FLUID Every 30,000 miles (48,000 km)

Page 17

0B–2

MAINTENANCE AND LUBRICATION

Mileage Only Items

F00RX004

Page 18

0B–3

MAINTENANCE AND LUBRICATION

Mileage/Months

F00RX006

Page 19

0B–4

MAINTENANCE AND LUBRICATION

F00RX013

Page 20

0B–5

MAINTENANCE AND LUBRICATION

Explanation of Complete Vehicle Maintenance Schedule

Brief explanations of the services listed in the preceding Maintenance Schedule are presented below. Replace all questionable parts and note any necessary repairs as you perform these maintenance procedures.

Front and Rear Axle Lubricant Replacement

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary . Replace the front and rear axle lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.

Manual Transmission Lubricant Replacement (MUA Type)

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary . Replace the transmission lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.

Transfer Case Lubricant Replacement

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary . Replace the transfer case lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.

Air Cleaner Element Replacement

Replace the air cleaner under normal operating conditions every 30,000 miles (48,000 km). Operation of the vehicle in dusty areas will necessitate more frequent replacement.

Spark Plug Replacement

Replace the plugs at 100,000 miles (160,000 km) intervals with the type specified at the end of this section.

Cooling System Service

Drain, flush and refill system with new engine coolant. Refer to “Recommended Fluids and Lubricants” in this section, or ENGINE COOLING (SEC.6B).

Timing Belt Replacement

Replacement of the timing belt is recommended at every 100,000 miles (160,000 km). Failure to replace the timing belt may result in serious damage to the engine.

Valve Clearance Adjustment (V6, 3.2L ENG)

Incorrect valve clearance will result in increased engine noise and reduced engine output. Retorque the camshaft bracket bolts before checking and adjusting the valve clearance.

Check and adjust the valve clearance every 60,000 miles (100,000 km).

Tire Rotation

Rotate tires every 7,500 miles (12,000 km).

Spark Plug Wire Inspection

Check the spark plug wires at 60,000 mile (96,000 km) intervals.

Front Wheel Bearings Lubricant Replacement

Clean and repack the front wheel bearings at 30,000 miles (48,000 km) intervals. Refer to DRIVE SHAFT SYSTEM (SEC. 4C).

Radiator Core and Air Conditioning Condenser Cleaning

Clean the front of the radiator core and air conditioning condenser, at 60,000 miles (96,000 km) intervals.

Fluid Level Check

A fluid loss in any system (except windshield washer) may indicate a problem. Repair the system at once.

Engine oil level

Check level and add if necessary . The best time to check the engine oil level is when the oil is warm. After stopping the engine with the vehicle on a level surface, wait a few minutes for the oil to drain back to the oil pan. Pull out the oil level indicator (dipstick). Wipe it clean and push the oil level indicator back down all the way . Pull out the oil level indicator, keeping the tip down, and look at the oil level on it.

Add oil, if needed, to keep the oil level above the “ADD” mark and between the “ADD” and “FULL” marks in the operating range area. Avoid overfilling the engine since this may cause engine damage. Push the oil level indicator back down all the way after taking the reading. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level.

Engine coolant level and condition

Check engine coolant level in the coolant reservoir and add engine coolant if necessary. Inspect the engine coolant and replace it if dirty or rusty.

Windshield washer fluid level

Check washer fluid level in the reservoir and add if necessary.

Power steering system reservoir level

Check and keep at the proper level.

Brake master cylinder reservoir level

Check fluid. Keep fluid at proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced.

Hydraulic clutch system

Check fluid level in the reservoir. Add fluid as required.

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0B–6

MAINTENANCE AND LUBRICATION

Battery fluid level

Check fluid level in the battery.

Fluid Leak Check

Check for fuel, water, oil or other fluid leaks by looking at the surface beneath the vehicle after it has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice gasoline fumes or fluid at any time, locate the source and correct it at once.

Engine Oil and Oil Filter Replacement

Always use API SE, SF, SG, SH or ILSAC GF–1 quality oils of the proper viscosity. When choosing an oil, consider the range of temperatures the car will be operated in before the next oil change. Then, select the recommended oil viscosity from the chart. Always change the oil and the oil filter as soon as possible after driving in a dust storm.

Engine Cooling System Inspection

Inspect the coolant/anti–freeze. If the coolant is dirty or rusty , drain, flush and refill with new coolant. Keep coolant at the proper mixture for proper freeze protection, corrosion inhibitor level and best engine operating temperature. Inspect hoses and replace if cracked, swollen or deteriorated. Tighten the hose clamps if equipped with screw–type clamps. Clean outside of radiator and air conditioning condenser. Wash filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and the cap is also recommended.

Exhaust System Inspection

Visually inspect the exhaust pipes, muffler, heat shields and hangers for cracks, deterioration, or damage. Be alert to any changes in the sound of the exhaust system or any smell of fumes. These are signs the system may be leaking or overheating. Repair the system at once, if these conditions exist. (See also “Engine Exhaust Gas Safety” and “Three Way Catalytic Converter” in the Owner’s manual.)

Fuel Cap, Fuel Lines, and Fuel Tank Inspection

Inspect the fuel tank, the fuel cap and the fuel lines every 60,000 miles (96,000 km) for damage which could cause leakage. Inspect the fuel cap and the gasket for correct sealing and physical damage. Replace any damaged parts.

Drive Belt Inspection

Check the serpentine belt driving for cracks, fraying, wear, and correct tension every 30,000 miles (48,000 km). Replace as necessary .

Wheel Alignment, Balance and Tires Operation

Uneven or abnormal tire wear, or a pull right or left on a straight and level road may show the need for a wheel alignment. A vibration of the steering wheel or seat at

normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are “cold” (include the spare). Maintain pressure as shown in the tire placard, which is located on the driver’s door lock pillar.

Steering System Operation

Be alert for any changes in steering action. An inspection or service is needed when the steering wheel is harder to turn or has too much free play, or if there are unusual sounds when turning or parking.

Brake Systems Operation

Watch for the “BRAKE” light coming on. Other signs of possible brake trouble are such things as repeated pulling to one side when braking, unusual sounds when braking or between brake applications, or increased brake pedal travel. If you note one of these conditions, repair the system at once. For convenience, the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, bindings, leaks, crack, chafing etc. Inspect disc brake pads for wear and rotors for surface condition. Inspect other brake parts, including parking brake drums, linings etc., at the same time. Check parking brake adjustment.

Inspect the brakes more often if habit or conditions result in frequent braking.

Parking Brake and Transmission Park Mechanism Operation

Park on a fairly steep hill and hold the vehicle with the parking brake only. This checks holding ability. On automatic transmission vehicles, shifting from “P” position to the other positions cannot be made unless the brake pedal is depressed when the key switch is in the “ON” position or the engine is running.

WARNING: BEFORE CHECKING THE STARTER SAFETY SWITCH OPERA TION BELOW , BE SURE T O HAVE ENOUGH ROOM AROUND THE VEHICLE. THEN FIRMLY APPLY BOTH THE PARKING BRAKE AND THE REGULAR BRAKE. DO NOT USE THE ACCELERATOR PEDAL. IF THE ENGINE STARTS, BE READY TO TURN OFF THE KEY PROMPTLY. TAKE THESE PRECAUTIONS BECAUSE THE VEHICLE COULD MOVE WITHOUT WARNING AND POSSIBLY CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.

Starter Safety Switch Operation (Automatic Transmission)

Check by trying to start the engine in each gear while setting the parking brake and the foot brake. The starter should crank only in “P” (Park) or “N” (Neutral).

Starter Safety Switch Operation (Manual Transmission)

T o check, place the shift lever in “Neutral”, push the clutch pedal halfway and try to start. The starter should not

Page 22

0B–7

MAINTENANCE AND LUBRICATION

crank. The starter should crank only when the clutch pedal is fully depressed.

Accelerator Linkage Lubrication

Lubricate the accelerator pedal fulcrum pin with chassis grease.

Steering and Suspension Inspection

Inspect the front and rear suspension and steering system for damaged, loose or missing parts or signs of wear. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc.

Body and Chassis Lubrication

Lubricate the key lock cylinders, the hood latch, the hood and door hinges, the door check link, the parking cable guides, the underbody contact points, and the linkage.

Propeller Shaft Inspection and Lubrication

Check the propeller shaft flange–to–pinion bolts for proper torque to 63 N•m (46 lb ft) for front and rear propeller shaft.

Automatic Transmission Fluid Replacement

Under harsh operating conditions, such as constant driving in heavy city traffic during hot weather , or in hilly or mountainous terrain, change the transmission fluid and service the sump filter after every 20,000 miles (32,000 km) of operation. More over, the remaining life percentage of ATF can be estimated by using TECH–II as an auxiliary tool to judge the right time for ATF replacement. The remaining life percentage is calculated from ATF’S heat history. When it is close to 0%, ATF replacement is recommended.

Auto Cruise Control Inspection

Check to see if the clearance between cruise link and accelerator link is normal. Also check that the connected properly .

Clutch Lines and Hoses Inspection

Check lines and hoses for proper attachment, binding, leaks, cracks, chafing, deterioration, etc. Any questionable parts should be replaced or repaired at once. When abrasion or wear is evident on lines or hoses, the cause must be corrected.

Clutch Control Lubrication

Lubricate the clutch pedal bushing, the clevis pin, and pedal spring every 15,000 miles (24,000 km) or 6 months. If a squeaking noise arises from around the bushing or the clevis pin at the clutch pedal arm when the clutch pedal is depressed, lubricate them.

Clutch Pedal Free Play Inspection

Note the clutch pedal free play . It should be 5 – 15 mm (0.2 – 0.6 in). Adjust clutch control when there is little or no free play .

Accelerator Linkage Inspection

Inspect for interference, binding, and damaged or missing parts. Check accelerator pedal for smooth operation and even pedal effort. Replace parts as needed.

Page 23

0B–8

MAINTENANCE AND LUBRICATION

Recommended Fluids and Lubricants

USAGE FLUID/LUBRICANT

Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil

chart on the following page for proper viscosity)

Engine coolant

Mixture of water and good quality ethylene glycol base

type antifreeze. Brake system DOT-3 hydraulic brake fluid. Power steering system DEXRON II-E Automatic transmission fluid. Automatic transmission & T5 Type Manual Transmis-

sion

DEXRON -III Automatic transmission fluid.

MUA Type Manual transmission & Transfer case Engine oil

(See oil chart on following page for proper viscosity) Rear axle and front axle GL-5 gear lubricant (Standard differential)

GL-5 Limited slip differential gear lubricant together

with limited slip differential lubricant additive (Part No.

8-01052-358-0) or equivalent (If equipped with optional

limited slip differential) (See oil chart in this section for

proper viscosity) Clutch system a. Pivot points Chassis grease b. Clutch fork joint Chassis grease c. Master cylinder DOT-3 hydraulic brake fluid Hood latch assembly a. Pivots and spring anchor Engine oil b. Release pawl Chassis grease Hood and door hinges Engine oil Chassis lubrication Chassis grease Parking brake cables Chassis grease Front wheel bearings Multipurpose grease Shift on the fly system GL-5 gear lubricant (SAE 75W-90) Body door hinge pins and linkage, fuel door hinge, rear

compartment lid hinges

Engine oil

Windshield washer solvent Washer fluid Key lock cylinder Synthetic light weight engine oil (SAE 5W-30) Accelerator linkage Chassis grease

Page 24

0B–9

MAINTENANCE AND LUBRICATION

Lubricant Viscosity Chart

Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table.

Oil Viscosity Chart for Gasoline Engine

905RT011

Page 25

0B–10

MAINTENANCE AND LUBRICATION

Oil Viscosity Chart for Manual Transmission and Transfer Case (Except T5 Type)

B00RW002

Oil Viscosity Chart for Front Axle

B00RW003

Page 26

0B–11

MAINTENANCE AND LUBRICATION

Oil Viscosty Chart for Rear Axle

B00RW004

Recommended Liquid Gasket

Type Brand Name Manufacturer Remarks

RTV* Silicon Base

Three Bond 1207B Three Bond 1207C Three Bond 1215 Three Bond 1280 Three Bond 1281

Three Bond Three Bond Three Bond Three Bond Three Bond

For Engine Repairs For Axle Case

Repairs T/M Repairs T/M

Water Base Three Bond 1141E Three Bond For Engine Repairs

Solvent

Three Bond 1104 Belco Bond 4 Belco Bond 401 Belco Bond 402

Three Bond Isuzu Isuzu Isuzu

For Engine Repairs

Anaerobic

LOCTITE 515 LOCTITE 518 LOCTITE 17430

Loctite Loctite Loctite

All

* RTV: Room Temperature Vulcanizer NOTE:

1.It is very important that the liquid gaskets listed above

or their exact equivalent be used on the vehicle.

2.Be careful to use the specified amount of liquid

gasket. Follow the manufacturer’s instructions at all times.

3.Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket.

The connecting surfaces must be perfectly dry.

4. Do not apply LOCTITE 17430, LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result.

Page 27

0B–12

MAINTENANCE AND LUBRICATION

Recommended Thread Locking Agents

LOCTITE Type LOCTITE Color

LOCTITE 242 Blue LOCTITE 262 Red LOCTITE 271 Red

Application Steps

1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

2.Apply LOCTITE to the bolts.

F00RW014

3.Tighten the bolts to the specified torque. After tightening, be sure to keep the bolts free from

vibration and torque for at least an hour until LOCTITE hardens.

NOTE: When the application procedures are specified in this manual, follow them.

Page 28

0B–13

MAINTENANCE AND LUBRICATION

Maintenance Service Data

Service Data and Specifications

ENGINE

Valve clearance (cold): only V6–3.2L ENG Intake 0.28±0.05 mm (0.011±0.002 in)

Exhaust 0.3±0.05 mm (0.012±0.002 in) Spark plug type K16PR-P11/PK16PR11/RC10PYP4 Spark plug gap 1.05 mm (0.04 in)

CLUTCH Clutch pedal free play 5-15 mm (0.20-0.59 in) BRAKE

Brake pedal free play 6-10 mm (0.24-0.39 in) Parking brake travel 6-7 notches

WHEEL ALIGNMENT

Toe-in (Front) 0±2 mm (0±0.08 in) Toe-in (Rear) 0±5 mm (0±0.2 in) Camber (Front) 0°±30’ Camber (Rear) 0°±1° Caster (Front) 2° 30’±45’ Toe–Axis (Rear) ±1°

PROPELLER SHAFT Flange torque 63 N·m (46 lb ft) WHEEL AND TIRES

Size P215/75R15,

P235/75R15

P245/70R16

Wheel nut torque 118 N·m (87 lb ft) Tire inflation pressure (Front) 200 kPa (29 psi) 180 kPa * Tire inflation pressure (Rear) 200 kPa (29 psi) 180 kPa

* Unless otherwise specified on tire information label on the vehicle.

Approximate Capacities

Items Metric Measure U.S. Measure

Fuel tank 80 L 21.1 Gal. * Crankcase (V6–3.2L ENGINE)

Oil Change with Filter 4.7 L 5.0 Qt Oil Change without Filter 4.0 L 4.2 Qt

* Crankcase (L4–2.2L ENGINE)

Oil Change with Filter 4.5 L 4.8 Qt Oil Change without Filter 4.2 L 4.4 Qt

Coolant

M/T (V6–3.2L ENG) 11.0 L 11.6 Qt M/T (L4–2.2L ENG) 6.9 L 7.3 Qt A/T 11.1 L 11.7 Qt

Transmission

Manual (V6–3.2L ENG) 2.95 L 3.1 Qt Manual (L4–2.2L ENG) 2.13 L 2.25 Qt

Automatic 8.6 L 9.1 Qt Transfer 1.45 L 1.5 Qt Axle

Rear 1.77 L 1.87 Qt

Front 1.25 L 1.33 Qt Shift on the fly system 0.12 L 0.13 Qt Power steering 1.0 L 1.1 Qt Air conditioning (R-134a) 0.6 L 1.32 Qt

*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.

Page 29

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–1

RODEO

HEATING, VENTILATION AND AIR

CONDITIONING (HVAC)

HVAC SYSTEMS

CONTENTS

Service Precaution 1A–2. . . . . . . . . . . . . . . . . . . . . .

Heating and Ventilation System 1A–2. . . . . . . . . . .

General Description 1A–2. . . . . . . . . . . . . . . . . . . .

Wiring Diagram 1A–6. . . . . . . . . . . . . . . . . . . . . . .

Diagnosis 1A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Individual Inspection 1A–11. . . . . . . . . . . . . . . . . . .

Heater Unit 1A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Unit and Associated Parts 1A–13. . . . . . . .

Removal 1A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Core and / or Mode Door 1A–14. . . . . . . . . .

Disassembled View 1A–14. . . . . . . . . . . . . . . . . . . .

Removal 1A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection 1A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Mode Control Link Unit 1A–16. . . . . . . . . . . .

Disassembled View 1A–16. . . . . . . . . . . . . . . . . . . .

Removal 1A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Temperature Control Link Unit 1A–17. . . . . .

Disassembled View 1A–17. . . . . . . . . . . . . . . . . . . .

Removal 1A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Assembly 1A–18. . . . . . . . . . . . . . . . . . . . . . . .

Blower Assembly and Associated Parts 1A–18. .

Removal 1A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Link Unit and / or Mode door 1A–19. . . . . . .

Disassembled View 1A–19. . . . . . . . . . . . . . . . . . . .

Removal 1A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Motor 1A–21. . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Motor and Associated Parts 1A–21. . . . . .

Removal 1A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Heater Duct, Defroster Nozzle and

Ventilation Duct 1A–22. . . . . . . . . . . . . . . . . . . . . . . . .

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts 1A–22. . .

Removal 1A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Lever Assembly and / or Control

Cable 1A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Lever Assembly, Control Cable and

Associated Parts 1A–23. . . . . . . . . . . . . . . . . . . . . .

Removal 1A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Illumination Bulb 1A–26. . . . . . . . . . . .

Control Panel Illumination Bulb and

Associated Parts 1A–26. . . . . . . . . . . . . . . . . . . . . .

Removal 1A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistor 1A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistor and Associated Parts 1A–26. . . . . . . . . .

Removal 1A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning System 1A–27. . . . . . . . . . . . . . . . . .

General Description 1A–27. . . . . . . . . . . . . . . . . . . . .

Diagnosis 1A–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Individual Inspection 1A–44. . . . . . . . . . . . . . . . . . . . .

General Repair Procedure 1A–45. . . . . . . . . . . . . .

Leak Check 1A–47. . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Assembly 1A–52. . . . . . . . . . . . . . . . . . .

Compressor Assembly and Associated

Parts 1A–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–53. . . . . . . . . . . . . . . . . . . . . . . . . . . .

New Compressor Installation 1A–53. . . . . . . . . . . .

Condenser Assembly 1A–54. . . . . . . . . . . . . . . . . . . .

Condenser Assembly and Associated

Parts 1A–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–54. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condenser Fan Motor 1A–55. . . . . . . . . . . . . . . . . . . .

Condenser Fan Motor and Associated

Parts 1A–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–55. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiver / Drier 1A–56. . . . . . . . . . . . . . . . . . . . . . . . .

Receiver / Drier and Associated Parts 1A–56. . . .

Removal 1A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Switch 1A–57. . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Switch and Associated Parts 1A–57. . .

Page 30

1A–2

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Removal 1A–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–57. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaporator Assembly 1A–58. . . . . . . . . . . . . . . . . . . .

Evaporator Assembly and Associated

Parts 1A–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–59. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Thermostat, Evaporator Core

and/or Expansion V alve 1A–59. . . . . . . . . . . . . . . . .

Disassembled View 1A–59. . . . . . . . . . . . . . . . . . . .

Removal 1A–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–60. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Line 1A–61. . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Line and Associated Parts 1A–61. . . .

Removal 1A–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–62. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Data And Specifications 1A–62. . . . . . . . . . . . .

Compressor 1A–65. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Precaution 1A–65. . . . . . . . . . . . . . . . . . . .

General Description 1A–65. . . . . . . . . . . . . . . . . . . . .

Diagnosis 1A–66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Clutch Assembly (DKV-14D Type) 1A–67

Parts Location View 1A–67. . . . . . . . . . . . . . . . . . . .

Removal 1A–67. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Repair 1A–68. . . . . . . . . . . . . . . . . .

Installation 1A–69. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Oil 1A–70. . . . . . . . . . . . . . . . . . . . . . . . .

Oil Specification 1A–70. . . . . . . . . . . . . . . . . . . . . . .

Handling of Oil 1A–70. . . . . . . . . . . . . . . . . . . . . . . .

Compressor Oil Check 1A–70. . . . . . . . . . . . . . . . .

Checking and Adjusting Oil Quantity

for Used Compressor 1A–70. . . . . . . . . . . . . . . . . .

Checking and Adjusting for Compressor

Replacement 1A–71. . . . . . . . . . . . . . . . . . . . . . . . .

Contamination of Compressor Oil 1A–71. . . . . . . .

Oil Return Operation 1A–71. . . . . . . . . . . . . . . . . . .

Replacement of Component Parts 1A–71. . . . . . .

Main Data and Specifications 1A–72. . . . . . . . . . . . .

Special Tools 1A–74. . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

Heating and Ventilation System

General Description

Heater

When the engine is warming up, the warmed engine coolant is sent out into the heater core. The heater system supplies warm air into the passenger compartment to warm it up. Outside air is circulated through the heater core of the heater unit and then back into the passenger compartment. By controlling the mixture of outside air and heater core air, the most comfortable passenger compartment temperature can be selected and maintained. The temperature of warm air sent to the passenger compartment is controlled by the temperature control knob. This knob acts to open and close the air mix door, thus controlling the amount of air passed through the heater core.

The air selector knob, with its different modes, also allows you to select and maintain the most comfortable passenger compartment temperature. The air source select lever is used to select either “FRESH” for the introduction of the outside air, or “CIRC” for the circulation of the inside air. When the lever is set to “FRESH”, the outside air is always taken into the passenger compartment. When setting the lever to “CIRC” position, the circulation of air is restricted only to the inside air with no introduction of the outside air and the air in the passenger compartment gets warm quickly. However, the lever is normally set to “FRESH” to prevent the windshield from clouding.

Page 31

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–3

840RW002

Legend

(1) Defroster Nozzle (2) Ventilation Duct (3) Blower Assembly (4) Evaporator Assembly (With A/C)

(5) Duct (W/O A/C) (6) Heater Unit (7) Ventilation Lower Duct (8) Lap Vent Duct (9) Rear Heater Duct

Page 32

1A–4

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Control Lever Assembly

The control lever assembly has some cables to control the mode and temperature of the heater unit and the mode door for the air source of the blower assembly.

The fan control is used to control the amount of air sent out by the resistor at four levels from “LOW” to “HIGH”.

865RW006

Legend

(1) Air Source Select Lever (2) Air Select Knob (3) Fan Control Lever (Fan Switch)

(4) Air Conditioning (A/C) Switch (W/ A/C) (5) Temperature Control Knob (6) Middle Position

Ventilation

Setting the air source select lever to “FRESH” position allows the heating system to work with sending the fresh air from outside. The blower fan also serves to deliver fresh outside air to the passenger compartment to assure adequate ventilation.

Air Select Knob

The air select knob allows you to direct heated air into the passenger compartment through different outlets.

1.Vent – In this position, air is discharged from the upper air outlet. Air quantity is controlled by the fan control lever.

2.Bi-Level – In this position, air flow is divided between the upper air outlets and the floor air outlets, with warmer air delivered to the floor outlets than the air delivered to the upper air outlets when the temp lever is in middle position.

3.Foot – In this position, air flow is delivered to the foot, while sending a small amount of air to the windshield.

4.Def/Foot – In this position, air flow is delivered to the foot, while sending approx. 40% of total amount of air to the windshield.

Selecting this mode allows air conditioning system to work while the fan switch is turned to on position, even if the A/C switch is off.

5.Defrost – In this position, most of the air is delivered to the windshield and a small amount is delivered to the side windows.

Selecting this mode allows air conditioning system to work while the fan switch is turned to on position, even if the A/C switch is off.

Moving the air source select lever to the “CIRC” position provides quickest heat delivery by closing the blower assembly mode door. In this position, outside air is not delivered to the passenger compartment.

Page 33

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–5

C01RW001

Air Source Select Lever

The intake of outside air and the circulation of inside air are controlled by sliding this lever left or right.

Fan Control Lever

This lever controls the blower motor speed to regulate the amount of air delivered to the defrost, foot, and ventilation ducts:

1.Low

2.Medium Low

3.Medium High

4.High

Temperature Control Knob

When the temperature control knob is in the “COLD” position, the air mix door closes to block the flow air to the heater core. When the temperature control knob is in the “HOT” position, the air mix door opens to allow air to pass through the heater core and heat the passenger compartment. Placing the knob in a intermediate position will cause a lesser or greater amount air to reach the heater core. In this mode the passenger compartment temperature can be regulated.

Page 34

1A–6

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Wiring Diagram

D08RW060

Page 35

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–7

Diagnosis

Heating Cycle diagnosis

Condition Possible cause Correction

No heating or insufficient heating.

Blower motor does not run or runs improperly.

Refer to “FAN CONTROL LEVER (FAN SWITCH) DIAGNOSIS”.

Engine coolant temperature is low. Check the engine coolant

temperature after warming up the engine and check the thermostat.

Replace as necessary. Insufficient engine coolant. Add engine coolant as required. Circulation volume of engine coolant

is insufficient.

Check if the water hose to the heater

core is clogged, collapsed or twisted.

Repair or replace as necessary. Heater core clogged or collapsed. Clean or replace as necessary. The heater cores is not provided with

air sent from the blower motor.

Repair the temperature control link

unit or mode doors. Duct connections defective or

unsealing.

Repair or replace as necessary.

Control lever moves but mode door

Cable attaching clip is not correct. Repair

oes not operate.

Link unit of heater or blower assembly defective.

Repair

The mode door cannot be set to the mode selected.

Link unit of heater unit or blower assembly defective.

Repair.

Control cable is not adjusted. Adjust.

Page 36

1A–8

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Fan Control Lever (Fan Switch) Diagnosis

Current flows to the blower motor through the heater relay (X-6) to activate the rotation of the blower motor by turning “ON” the fan control knob (fan switch). Blower motor speed is controlled in stages by the resistor, by operating the switch from “LOW” to “HIGH”. For the inspection of the relays, switches and units in each table, refer to “INDIVIDUAL INSPECTION” in this section.

D08RW059

Condition Possible cause Correction

Blower motor does not run. — Refer to Chart A Blower motor does not run in certain

position (s).

— Refer to Chart B, C, D and E

Blower motor does not stop at “OFF” position.

— Refer to Chart F

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Chart “A” Blower Motor Does Not Run

Step

Action

Yes No

1 Is relay (X-6) OK? Go to Step 2 Replace 2 Is fuse EB-4 (20A) OK? Go to Step 3 Replace 3 Is resistor OK? Go to Step 4 Replace 4 Is fan control lever OK?

Go to Step 5

Replace control

lever assembly . 5 Is blower motor OK? Go to Step 6 Replace 6 1. Turn the ignition switch “ON”.

2. Turn fan control lever “ON”.

3. Check to see if battery voltage is present at chassis side connector terminal No. B5-1

Is there a battery voltage?

Poor ground or

open circuit either

between chassis

side connector

terminal No. B5-2

and No. B3-2 or

No. I23-1 and

body ground (No.

B-8).

Open circuit

between No.

EB-4 (20A) fuse

and No. B5-1.

Chart “B” Blower Motor Does Not Run At Low Position

Step

Action

Yes No

1 Is resistor OK? Go to Step 2 Replace 2 Is fan control lever (Fan Switch) OK? Open circuit

between chassis

side connector

terminal No. B3-1

and No.I23-2.

Replace control lever assembly .

Chart “C” Blower Motor Does Not Run At Medium Low Position

Step

Action

Yes No

1 Is resistor OK? Go to Step 2 Replace 2 Is fan control lever (Fan Switch) OK? Open circuit

between the chassis side

connector

terminal No. B3-4

and No. I23-3.

Replace control lever assembly .

Chart “D” Blower Motor Does Not Run At Medium High Position

Step

Action

Yes No

1 Is resistor OK? Go to Step 2 Replace 2 Is fan control lever (Fan Switch) OK? Open circuit

between chassis

side connector

terminal No. B3-6

and No. I23-4.

Replace control lever assembly .

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Chart “E” Blower Motor Does Not Run At High Position

Step

Action

Yes No

1 Is resistor OK? Go to Step 2 Replace 2 Is fan control lever (Fan Switch) OK? Open circuit

between Chassis

side connector

terminal No. B3-3

and No. I23-5.

Replace control lever assembly .

Chart “F” Blower Motor Does Not Stop In The “OFF” Position

Step

Action

Yes No

1 Is the fan control lever (Fan Switch) OK? Short circuit

between chassis

side connector

terminal No. B5-2

and

No. B3-2,No. B3-

3 and No. I23-5,

No. B3-6 and

No. I23-4,

No. B3-4 and

No. I23-3 or

No. B3-1 and

No. I23-2

Replace control lever assembly .

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Individual Inspection

Blower Motor

1. Disconnect the blower motor (B-5) connector from the blower motor.

2. Connect the battery positive terminal to the No. 1 terminal of the blower motor and the negative to the No. 2.

3.Be sure to check to see if the blower motor operates correctly .

873RW002

Resistor

1.Disconnect the resistor (B-3) connector.

2.Check for continuity and resistance between the terminals of the resistor.

840RS001

Fan Control Lever (Fan Switch)

1.Check for continuity between the terminals of the fan switch.

D08RW058

Heater Relay

1.Disconnect the heater relay (X-6). f When removing the connector for relay, unfasten

the tank lock of the connector by using a screwdriver, then pull the relay (1) out.

825RS001

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

2.Check for continuity between the heater relay (X-6) terminals.

825RS179

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Heater Unit

Heater Unit and Associated Parts

840RW003

Legend

(1) Instrument Panel Assembly (2) Cross Beam Assembly (3) Instrument Panel Bracket (4) Ventilation Lower Duct (5) Rear Heater Duct

(6) Driver Lap Vent Duct (7) Evaporator Assembly (A/C only) (8) Duct (9) Heater Unit Assembly

(10) Heater Hose

(1 1) Resistor Connector

Removal

1.Disconnect the battery ground cable.

2.Drain the engine coolant.

3.Discharge and recover refrigerant (with air conditioning).

f Refer to Refrigerant Recovery in this section.

4.Remove the Instrument panel assembly. f Refer to Instrument Panel Assembly in Body and

Accessories section.

5.Remove instrument panel bracket. f Refer to Cross Beam Assembly in Body and

Accessories section.

6.Cross Beam Assembly . f Refer to Cross Beam Assembly in Body and

Accessories section.

7.Disconnect resistor connector.

8.Remove duct.

9.Remove evaporator assembly (A/C only). f Refer to Evaporator Assembly in this section.

10.Remove driver lap vent duct. 1 1.Remove ventilation lower duct.

12.Remove rear heater duct.

f Remove foot rest, carpet and 3 clips.

13.Remove heater unit assembly .

f Disconnect heater hoses at heater unit.

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Installation

To install, follow the removal steps in the reverse order, noting the following points:

1. When handling the PCM and the control unit, be careful not to make any improper connection of the connectors.

2.Adjust the control cables. f Refer to Control Lever Assembly in this section.

3.When installing the heater unit, defroster nozzle and center vent duct, be sure that the proper seal is made, without any gap between them.

Heater Core and / or Mode Door

Disassembled View

860RW001

Legend

(1) Heater Core (2) Case (Temperature Control) (3) Heater Unit

(4) Mode Door (5) Duct (6) Case (Mode Control)

Removal

1.Disconnect the battery ground cable.

2.Drain the engine coolant.

3.Discharge and recover refrigerant (with air conditioning).

f Refer to Refrigerant Recovery in this section.

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4.Remove heater unit. f Refer to Heater Unit in this section.

5.Remove duct.

6.Remove case (Mode control) and do not remove link unit at this step.

7. Remove case (Temperature control) separate two halves of core case.

860RS002

8.Remove heater core (1).

860RS003

9.Pull out the mode door while raising up the catch of the door lever.

860RS004

Inspection

Check for foreign matter in the heater core, stain or the core fin defacement.

Installation

To install, follow the removal steps in the reverse order, noting the following point:

1.Check that each mode door operates properly.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater Mode Control Link Unit

Disassembled View

860RW002

Legend

(1) Case (Mode Control) (2) Heater Unit (3) Mode Sub-lever

(4) Clip (5) Door Lever (6) Rod (7) Washer and Mode Main Lever

Removal

1.Disconnect the battery ground cable.

2.Drain engine coolant.

3.Discharge and recover refrigerant (with air conditioning)

f Refer to Refrigerant Recovery in this section.

4.Remove heater unit. f Refer to Heater Unit in this section.

5.Remove the case (Mode control) from heater unit.

6.Remove washer and the mode main lever.

7.Remove rod.

8.Press the tab of the sub-lever inward, and take out the sub-lever.

860RS006

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1A–17

9.Pull out the door lever while raising up the catch of the door lever.

10.Remove clip.

Installation

To install, follow the remove steps in the reverse order, noting the following points:

1.Apply grease to the mode sub-lever and to the abrasive surface of the heater unit.

2.After installing the link unit, check to see if the link unit operates correctly.

Heater Temperature Control Link Unit

Disassembled View

860RS007

Legend

(1) Case (Temperature control) (2) Clip (3) Door Lever

(4) Clip (5) Heater Unit (6) Rod (7) Sub-lever

Removal

1.Disconnect the battery ground cable.

2.Drain engine coolant.

3.Discharge and recover refrigerant (with air conditioning).

f Refer to Refrigerant Recovery in this section.

4.Remove heater unit. f Refer to Heater Unit in this section.

5.Remove the case (Temperature control) from the heater unit.

6.Remove rod.

7.Remove sub-lever.

8.Pull out the door lever while raising up the catch of the door lever.

9.Remove clip.

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Installation

To install, follow the removal steps in the reverse order, noting the following points:

1. Apply grease to the sub-lever and to the abrasive surface of the heater unit.

2.After installing the link unit, check to see if the link unit operates correctly.

Blower Assembly

Blower Assembly and Associated Parts

873RW004

Legend

(1) Instrument Panel Assembly (2) Blower Assembly

(3) Evaporator Assembly (A/C only) (4) Duct (5) Heater Unit

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant (with air conditioning).

f Refer to Refrigerant Recovery in this section.

3.Remove instrument panel assembly . f Refer to Instrument Panel Assembly in Body and

Accessories section.

4.Disconnect resistor connector.

5.Remove duct.

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6.Remove evaporator assembly (A/C only). f Refer to Evaporator Assembly in this section.

7.Disconnect blower motor connector.

8.Remove blower assembly .

Installation

To install, follow the removal steps in the reverse order, noting the following point:

1.Adjust the control cables. f Refer to Control Lever Assembly in this section.

Blower Link Unit and / or Mode door

Disassembled View

873RS001

Legend

(1) Upper Case (2) Mode Door (3) Lower Case

(4) Sub Lever (5) Door Lever (6) Blower Assembly

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant (with air conditioning).

f Refer to Refrigerant Recovery in this section.

3.Remove blower assembly . f Refer to Blower Assembly in this section.

4.Remove lower case.

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5. Separate the upper case and slit the lining parting face with a knife.

873RS002

6.Pull out the mode door while raising up the catch of door lever.

7.Remove sub-lever.

8.Remove door lever.

Installation

To install, follow the removal steps in the reverse order, noting the following points:

1. Apply grease to the door lever and to the abrasive surface of the upper case.

2. Apply an adhesive to the parting face of the lining when assembling the upper case.

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Blower Motor

Blower Motor and Associated Parts

873RW001

Legend

(1) Attaching Screw (2) Blower Motor Connector (3) Blower Motor Assembly

(4) Clip (5) Fan (6) Blower Motor

Removal

1.Disconnect the battery ground cable.

2.Remove blower motor connector.

3.Remove attaching screw.

4.Remove blower motor assembly .

5.Remove clip.

6.Remove fan.

7.Remove blower motor.

Installation

To install, follow the removal steps in the reverse order.

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Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts

840RW008

Legend

(1) Defroster Nozzle (2) Cross Beam Assembly (3) Center Ventilation Duct and Side Defroster

Duct

(4) Instrument Panel Bracket (5) Instrument Panel Assembly (6) Rear Heater Duct (7) Lap Ventilation Duct (8) Ventilation Lower Duct

Removal

1.Disconnect the battery ground cable.

2.Remove instrument panel assembly . f Refer to Instrument Panel Assembly in Body and

Accessories section.

3. Remove center ventilation duct and side defroster duct.

f Remove 5 screws.

4.Remove lap ventilation duct.

5.Remove instrument panel brackets. f Refer to Cross Beam Assembly in Body and

Accessories section.

6.Remove cross beam assembly . f Refer to Cross Beam Assembly in Body and

Accessories section.

7.Remove ventilation lower duct.

8.Remove rear heater duct. f Remove foot rest carpet and 3 clips.

9.Remove defroster nozzle.

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Installation

To install, follow the removal steps in the reverse order, noting the following point:

1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching.

Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts

865RW004

Legend

(1) Control Cable (2) Control Lever Assembly (3) Meter Cluster Assembly

(4) Glove Box (5) Instrument Panel Driver Lower Cover

Assembly

(6) Fan Switch Air Conditioning Switch Connector

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Removal

1.Disconnect the battery ground cable.

2.Remove instrument panel driver lower cover assembly.

3.Remove meter cluster assembly. f Refer to Instrument Panel Assembly in Body and

Accessories section.

4.Remove glove box.

5.Remove the control lever attaching screws.

6.Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors.

865RW001

7.Remove control level assembly .

8.Disconnect control cables at each unit side.

865RW002

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Installation

To install, follow the removal steps in the reverse order, noting the following points:

1.Adjust the control cable.

865RW005

f Air source control cable.

1. Slide the control lever to the left (“CIRC” position).

2. Connect the control cable at the “CIRC” position of the link unit of the blower assembly and secure it with the clip.

f Temperature control cable.

1. Turn the control knob to the left (“MAX COLD” position).

2. Connect the control cable at the “COLD” position of the temperature control link of the heater unit and secure it with the clip.

f Air select control cable

1. Turn the control knob to the right (“DEFROST” position).

2. Connect the control cable at the “DEFROST” position of the mode control link of the heater unit and secure it with the clip.

2.Check the control cable operation.

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Control Panel Illumination Bulb

Control Panel Illumination Bulb and Associated Parts

865RW003

Legend

(1) Control Lever Assembly (2) Bulb Socket (3) Illumination Bulb

Removal

1.Disconnect the battery ground cable.

2.Remove control lever assembly . f Refer to Control Lever Assembly in this section.

3.Pull out the bulb socket from the panel by turning it counterclockwise.

4.Pull the illumination bulb from the socket.

Installation

To install, follow the removal steps in the reverse order.

Resistor

Resistor and Associated Parts

840RW001

Legend

(1) Duct (Heater only) (2) Resistor (3) Resistor Connector (4) Glove Box

Removal

1.Disconnect the battery ground cable.

2.Remove glove box.

3.Remove resistor connector.

4.Remove duct (heater only).

5.Remove resistor.

Installation

To install, follow the removal steps in the reverse order.

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Air Conditioning System

General Description

Air Conditioning Refrigerant Cycle Construction

C01RS003

Legend

(1) Electronic Thermostat (2) Evaporator Core (3) Evaporator Assembly (4) Temperature Sensor (5) Expansion Valve (6) Blower Motor (7) Pressure Switch or Pressure Sensor (8) Receiver/Drier

(9) Condenser

(10) Compressor

(1 1) Magnetic Clutch (12) Mode (HEAT) Control Door (13) Temp. Control Door (Air Mix Door) (14) Heater Core (15) Mode (VENT) Control Door (16) Heater Unit (17) Mode (DEF) Control Door

The refrigeration cycle includes the following four processes as the refrigerant changes repeatedly from liquid to gas and back to liquid while circulating.

Evaporation

The refrigerant is changed from a liquid to a gas inside the evaporator. The refrigerant mist that enters the

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evaporator vaporizes readily. The liquid refrigerant removes the required quantity of heat (latent heat of vaporization) from the air around the evaporator core cooling fins and rapidly vaporizes. Removing the heat cools the air, which is then radiated from the fins and lowers the temperature of the air inside the vehicle. The refrigerant liquid sent from the expansion valve and the vaporized refrigerant gas are both present inside the evaporator as the liquid is converted to gas. With this change from liquid to gas, the pressure inside the evaporator must be kept low enough for vaporization to occur at a lower temperature. Because of that, the vaporized refrigerant is sucked into the compressor.

Compression

The refrigerant is compressed by the compressor until it is easily liquefied at normal temperature. The vaporized refrigerant in the evaporator is sucked into the compressor. This action maintains the refrigerant inside the evaporator at a low pressure so that it can easily vaporize, even at low temperatures close to 0°C (32°F). Also, the refrigerant sucked into the compressor is compressed inside the cylinder to increase the pressure and temperature to values such that the refrigerant can easily liquefy at normal ambient temperatures.

Condensation

The refrigerant inside the condenser is cooled by the outside air and changes from gas to liquid. The high temperature, high pressure gas coming from the compressor is cooled and liquefied by the condenser with outside air and accumulated in the receiver/drier. The heat radiated to the outside air by the high temperature, high pressure gas in the compressor is called heat of condensation. This is the total quantity of heat (heat of vaporization) the refrigerant removes from the vehicle interior via the evaporator and the work (calculated as the quantity of heat) performed for compression.

Expansion

The expansion valve lowers the pressure of the refrigerant liquid so that it can easily vaporize. The process of lowering the pressure to encourage vaporization before the liquefied refrigerant is sent to the evaporator is called expansion. In addition, the expansion valve controls the flow rate of the refrigerant liquid while decreasing the pressure. That is, the quantity of refrigerant liquid vaporized inside the evaporator is determined by the quantity of heat which must be removed at a prescribed vaporization temperature. It is important that the quantity of refrigerant be controlled to exactly the right value.

Compressor

The compressor performs two main functions: It compresses low-pressure and low-temperature refrigerant vapor from the evaporator into high-pressure and high-temperature refrigerant vapor to the condenser. It pumps refrigerant and refrigerant oil through the air conditioning system.

This vehicle is equipped with a five-vane rotary compressor (1). The specified amount of the compressor oil is 150cc (5.0 fl. oz.). The oil used in the HFC-134a system compressor differs from that used in R-12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction. The magnetic clutch connector is a waterproof type.

Magnetic Clutch

The compressor is driven by the drive belt from the crank pulley of the engine. If the compressor is activated each time the engine is started, this causes too much load to the engine. The magnetic clutch (3) transmits the power from the engine to the compressor and activates it when the air conditioning is ON. Also, it cuts off the power from the engine to the compressor when the air conditioning is OFF. Refer to Compressor in this section for magnetic clutch repair procedure.

871RX001

Condenser

The condenser assembly (6) is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins. Also, it functions to cool and liquefy the high-pressure and high-temperature vapor sent from the compressor by the radiator fan or outside air. A condenser may malfunction in two ways: it may leak, or it may be restricted. A condenser restriction will result in excessive compressor discharge pressure. If a partial restriction is present, the refrigerant expands after passing through the restriction.

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Thus, ice or frost may form immediately after the restriction. If air flow through the condenser or radiator is blocked, high discharge pressures will result. During normal condenser operation, the refrigerant outlet line will be slightly cooler than the inlet line. The vehicle is equipped with the parallel flow type condenser. A larger thermal transmission area on the inner surface of the tube allows the radiant heat to increase and the ventilation resistance to decrease. The refrigerant line connection has a bolt at the block joint, for easy servicing.

852RW007

Receiver / Drier

The receiver/drier (5) performs four functions:

f As the quantity of refrigerant circulated varies

depending on the refrigeration cycle conditions, sufficient refrigerant is stored for the refrigeration cycle to operate smoothly in accordance with fluctuations in the quantity circulated.

f The liquefied refrigerant from the condenser is mixed

with refrigerant gas containing air bubbles. If refrigerant containing air bubbles. If refrigerant containing air bubbles is sent to the expansion valve, the cooling capacity will decrease considerably. Therefore, the liquid and air bubbles are separated and only the liquid is sent to the expansion valve.

f The receiver/drier utilizes a filter and drier to remove

the dirt and water mixed in the cycling refrigerant.

f The sight glass, installed atop the receiver/drier,

show the state of the refrigerant. A receiver/drier may fail due to a restriction inside the body of the unit. A restriction at the inlet to the receiver/drier will cause high pressure. Outlet restrictions will be indicated by low pressure and little or no cooling. An excessively cold receiver/drier outlet may indicate a restriction. The receiver/drier of this vehicle is made of aluminum with a smaller tank. It has a 300cc refrigerant capacity. The refrigerant line connection has a bolt at the block joint, for easy servicing.

852RW007

Dual Pressure Switch (V6,M/T)

The pressure switch (Dual pressure switch) (2) is installed on the upper part of the receiver/drier, to detect excessively high pressure (high pressure switch) and prevent compressor seizure due to the refrigerant leaking (low pressure switch), so that the compressor is able to be turned “ON” or “OFF”.

Compressor

(kPa/psi)

OFF

(kPa/psi)

Low-pressure

control

205.9±29.4 (29.9±4.3)

176.5±19.6 (25.6±2.8)

High-pressure

control

2059.4±196.1 (341.3±28.4)

2942.0±196.1 (426.6±28.4)

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Triple Pressure Switch (V6, A/T)

Triple pressure switch (2) is installed on the upper part of the receiver/drier. This switch is constructed with a unitized type of two switches. One of them is a low and high pressure switch (Dual pressure switch) to switch “ON” or “OFF” the magnetic clutch as a result of irregularly high–pressure or low pressure of the refrigerant. The other one is a medium pressure switch (Cycling switch) to switch “ON” or “OFF” the condenser fan sensing the condenser high side pressure.

Compressor

(kPa/psi)

OFF

(kPa/psi)

Low-pressure

control

186.3±29.4 (27.0±4.3)

176.5±24.5 (25.6±3.6)

High-pressure

control

2353.6±196.1 (341.3±28.4)

2942.0±196.1 (426.6±28.4)

Condenser fan

(kPa/psi)

OFF

(kPa/psi)

Medium-pressure

control

1471.0±98.1 (213.3±14.2)

1078.7±117.7 (156.4±17.1)

Pressure Sensor

The pressure sensor (2) is installed on the upper part of the receiver/drier. This sensor converts high pressure detection of refrigerant to an electrical voltage signal and supplies it to the ECM. The ECM controls switching compressor idle speed and cooling fan operation by the electrical voltage signal.

875RW007

Expansion Valve

This expansion valve (3) is an external pressure type and it is installed at the evaporator intake port. The expansion valve converts the high pressure liquid refrigerant sent from the receiver/drier to a low pressure

liquid refrigerant by forcing it through a tiny port before sending it to the evaporator (4). This type of expansion valve consists of a temperature sensor, diaphragm, ball valve, ball seat, spring adjustment screw, etc. The temperature sensor contacts the evaporator outlet pipe, and converts changes in temperature to pressure. It then transmits these to the top chamber of the diaphragm. The refrigerant pressure is transmitted to the diaphragm’s bottom chamber through the external equalizing pressure tube. The ball valve is connected to the diaphragm. The opening angle of the expansion valve is determined by the force acting on the diaphragm and the spring pressure. The expansion valve regulates the flow rate of the refrigerant. Accordingly, when a malfunction occurs to this expansion valve, both discharge and suction pressure get low, resulting in insuf ficient cooling capacity of the evaporator. The calibration has been changed to match the characteristics of HFC-134a.

874RX003

Evaporator

The evaporator cools and dehumidifies the air before the air enters the passenger compartment. High-pressure liquid refrigerant flows through the expansion valve (2) into the low-pressure area of the evaporator. The heat in the air passing through the evaporator core (1) is lost to the cooler surface of the core, thereby cooling the air. As heat is lost between the air and the evaporator core surface, moisture in the vehicle condenses on the outside surface of the evaporator core and is drained off as water . When the evaporator malfunctions, the trouble will show up as an inadequate supply of cool air. The cause is typically a partially plugged core due to dirt, or a malfunctioning blower motor.

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The evaporator core with a laminate louver fin is a single-sided tank type where only one tank is provided under the core.

874RX002

Electronic Thermostat

The thermostat consists of the thermo sensor (3) and thermostat unit (5) which functions electrically to reduce the noises being generated while the system is in operation. The electronic thermo sensor (3) is mounted at the evaporator core (2) outlet and senses the surface temperature of the evaporator core (4). Temperature signals are input to the thermostat unit. This information is compared by the thermo unit and results in the output to operate the A/C thermostat relay and turn the magnetic clutch ON or OFF to prevent evaporator freeze-up. A characteristic of the sensor is that the resistance decreases as the temperature increases and the resistance increases as the temperature decreases.

874RX005

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Refrigerant Line

Restriction in the refrigerant line will be indicated by:

1.Suction line — A restricted suction line will cause low suction pressure at the compressor, low discharge pressure and little or no cooling.

2. Discharge line — A restriction in the discharge line generally will cause the discharge line to leak.

3.Liquid line — A liquid line restriction will be evidenced by low discharge and suction pressure and insufficient cooling.

Refrigerant flexible hoses that have a low permeability to refrigerant and moisture are used. These low permeability hoses have a special nylon layer on the inside.

852RS001

Legend

(1) Reinforcement Layer (Polyester) (2) External Rubber Layer (3) Internal Rubber Layer (4) Resin Layer (Nylon)

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Air Conditioning Parts

852RX002

Legend

(1) Liquid Line (High-Pressure Pipe) (2) Clip (3) Discharge Line (High-Pressure Hose) (4) Pressure Switch

(5) Receiver/Drier (6) Condenser Assembly (7) Compressor (8) Suction Line (Low-Pressure Hose) (9) Evaporator Assembly

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Wiring Diagram

D08RX001

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Diagnosis

Air Conditioning Cycle Diagnosis

Condition Possible cause Correction

No cooling or insufficient cooling.

Magnetic clutch does not run. Refer to “Magnetic Clutch Diagnosis”

in this section.

Compressor is not rotating properly. Drive belt is loosened or broken.

Adjust the drive belt to the specified tension or replace the drive belt.

Compressor is not rotating properly. Magnetic clutch face is not clean and slips.

Clean the magnetic clutch face or replace.

Compressor is not rotating properly. Incorrect clearance between magnetic drive plate and pulley.

Adjust the clearance. Refer to Compressor in this section.

Compressor is not rotating properly. Compressor oil leaks from the shaft seal or shell.

Replace the compressor

Compressor is not rotating properly. Compressor is seized.

Replace the compressor

Insufficient or excessive charge of refrigerant.

Discharge and recover the refrigerant. Recharge to the specified amount.

Leaks in the refrigerant system. Check the refrigerant system for

leaks and repair as necessary. Discharge and recover the refrigerant. Recharge to the specified amount.

Condenser is clogged or insufficient radiation.

Clean the condenser or replace as necessary.

Temperature control link unit of the heat unit is defective.

Repair the link unit.

Unsteady operation due to a foreign substance in the expansion valve.

Replace the expansion valve.

Poor operation of the electronic thermostat.

Check the electronic thermostat and replace as necessary.

Insufficient velocity of cooling air.

Evaporator clogged or frosted. Check the evaporator core and

replace or clean the core.

Air leaking from the cooling unit or air duct.

Check the evaporator and duct connection, then repair as necessary.

Blower motor does not rotate properly.

Refer to Fan Control Lever (Fan Switch) Diagnosis in this section.

*For the execution of the charging and discharging operation in the table above, refer to Recovery, Recycling, Evacuating and Charging in this section.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Checking The Refrigerant System With Manifold Gauge

Since Refrigerant-134a (HFC-134a) is used in the air conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air conditioning service tools for HFC-134a when checking the refrigerant system.

Conditions:

f Run the engine at Idling f Air conditioning switch is “ON” f Run the blower motor at “HIGH” position f Temperature control lever set to “MAX COLD” f Air source selector lever at “CIRC” f Open the engine hood f Close all the doors

Normal Pressure:

f At ambient temperature: approx. 25–30°C

(77–86°F).

f At low-pressure side: approx. 147.1–294.2 kPa

(21.3–42.7 psi).

f At high-pressure side: approx. 1372.9–1863.3 kPa

(199.1–270.2 psi).

Refer to the table on the refrigerant pressure-temperature relationship.

HFC-134a Pressure-Temperature Relationship

Pressure Temperature

(kPa) (psi) (°C) (°F)

36 5.3 –20 –4.4

67 9.7 –15 5 104 15 –10 14 147 21 –5 23 196 28 0 32 255 37 5 41 314 45 10 50 392 57 15 59 471 68 20 68 569 82 25 77 677 98 30 86 785 114 35 95 912 132 40 104

1059 154 45 113 1216 176 50 122

Connect The Manifold Gauge

Low-pressure hose (LOW) — Suction side High pressure hose (HI) — Discharge side

901RS180

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1A–37

Legend

(1) Low Side (2) High Side

Condition Possible cause Correction

Discharge (High Gauge) Pressure

Condenser clogged or dirty. Clean the condenser fins

normally Hig

Cooling fan does not operate properly.

Check the cooling fan operation.

Discharge (High Gauge) Pressure Abnormally High.

Insufficient cooling.

Excessive refrigerant in system. Discharge and recover refrigerant.

Recharge to specified amount.

Discharge (High Gauge) Pressure Abnormally High.

High pressure gauge drop. (After stopping A/C, the pressure drops approx. 196 kPa (28 psi) quickly)

Air in system. Evacuate and charge refrigerant

system.

Discharge (High Gauge) Pressure Abnormally Low.

Insufficient cooling

Insufficient refrigerant in system. Check for leaks. Discharge and

recover the refrigerant. Recharge to the specified amount.

Discharge (High Gauge) Pressure Abnormally Low.

Low pressure gauge indicates vacuum.

Clogged or defective expansion valve.

Replace the expansion valve.

Discharge (High Gauge) Pressure Abnormally Low.

Frost or dew on refrigerant line before and after the receiver/drier or expansion valve, and low pressure gauge indicates vacuum.

Restriction caused by debris or moisture in the receiver/drier.

Check system for restriction and replace the receiver/drier.

Discharge (High Gauge) Pressure Abnormally Low.

Compressor seal defective Repair or replace the compressor.

High and low pressure gauge balanced quickly. (After turned off A/C)

Poor compression due to a defective compressor gasket.

Repair or replace the compressor.

Suction (Low Gauge) Pressure Abnormally High.

Low pressure gauge (Low pressure gauge is lowered after condenser is cooled by water.)

Excessive refrigerant in system. Discharge and recover refrigerant

Recharge to specified amount.

Suction (Low Gauge) Pressure Abnormally High.

Low pressure hose temperature. (Low pressure hose temperature

Unsatisfactory valve operation due to defective temperature sensor of expansion valve.

Replace the expansion valve.

around the com ressor refrigerant

line connector is lower than around evaporator.)

Expansion valve opens too long. Replace the expansion valve.

Suction (Low Gauge) Pressure Abnormally High.

High and low pressure gauge balanced quickly. (After turned off A/C)

Compressor gasket is defective. Repair or replace the compressor.

Suction (Low Gauge) Pressure Abnormally Low.

Insufficient cooling.

Insufficient refrigerant in system. Check for leaks. Discharge and

recover the refrigerant. Recharge to specified amount.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condition CorrectionPossible cause

Suction (Low Gauge) Pressure Abnormally Low.

Frost on the expansion valve inlet line

Expansion valve clogged. Replace the expansion valve.

Suction (Low Gauge) Pressure Abnormally Low

Receiver/drier inlet and outlet refrigerant line temperature. (A distinct difference in temperature develops.)

Receiver/Drier clogged. Replace the receiver/drier.

Suction (Low Gauge) Pressure Abnormally Low.

Expansion valve outlet refrigerant line. (Not cold and low pressure gauge indicates vacuum.)

Expansion valve temperature sensor is defective.

Replace the expansion valve.

Suction (Low Gauge) Pressure Abnormally Low.

When the refrigerant line is clogged or blocked, the low pressure gauge reading will decrease, or a vacuum reading may be shown.

Clogged or blocked refrigerant line. Replace refrigerant line.

Suction (Low Gauge) Pressure Abnormally Low.

Evaporator core is frozen.

Thermo switch defective. Replace thermo switch.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High.

Excessive refrigerant in system. Discharge and recover the

refrigerant, the Recharge to the specified amount.

Insufficient cooling.

Condenser clogged or dirty. Clean the condenser fin.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High.

Suction (Low) pressure hose (Not cold).

Air in system. Evacuate and charge refrigerant.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally Low.

Insufficient cooling

Insufficient refrigerant in system. Check for leaks. Discharge and

recover refrigerant. Recharge to specified amount.

A/C — Air Conditioning

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1A–39

Magnetic Clutch Diagnosis

D08RX002

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

When the air conditioning switch and the fan control knob (fan switch) are turned on with the engine running, current flows through the thermostat and the compressor relay to activate the magnetic clutch. The air conditioning can be stopped by turning of the air conditioning switch or the fan control knob (fan switch). However, even when the air conditioning is in operation, the electronic thermostat, the pressure switch or the

Powertrain Control Module (PCM;V6-3.2L)/ Engine Control Module (ECM;L4-2.2L) is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of the vehicle, etc. For the inspection of the relays, switches and units in the table, refer to “Individual Inspection” in this section.

Magnetic Clutch Does Not Run

Step Action Yes No

1 Are No. EB-5 (10A) fuse and No. EB-4 (20A) fuse OK? Go to Step 2 Replace 2 Are heater (X-6), thermostat (X-5), and compressor (X-4) relays

OK?

Go to Step 3 Replace

3 Is pressure switch OK?

Go to Step 4

Switch defective

or insufficient

refrigerant. 4 Are air conditioning switch and fan control lever (Fan Switch) OK? Go to Step 5 Replace 5 1. Turn the ignition switch “ON” (Engine is running).

2. Air conditioning switch and fan control lever (Fan Switch) “ON”.

3. Check to see if battery voltage is present at chassis side connector terminal No. E3-1.

Is there a battery voltage?

Go to Step 6 Go to Step 7

6 Check to see if continuity between compressor side connector

terminal No. E3-1 and the magnetic clutch side connector terminal.

Is there a continuity?

Magnetic clutch

defective.

Compressor

defective.

7 Check to see it battery voltage is present at chassis side

connector terminal No.I24-2. Is there a battery voltage?

Go to Step 8

Open circuit

between No.EB-5

(10A) fuse and

No. I24-2.

8 Check to see if battery voltage is present at chassis side

connector terminal No. C11-1 Is there a battery voltage?

Go to Step 9

Open circuit

between No.I24-1

and No. C11-1.

9 1. Disconnect thermostat relay (X-5).

2. Check to see if battery voltage is present at the chassis side relay terminal NO. X5-5

Is there a battery voltage?

Go to Step 10

Open circuit

between No.

EB-5 and C1 1-2

(10A) fuse and

No.X5-5.

10 Check to see if voltage (approx. 10V) is present between chassis

side relay terminal No. X5-2 and No. X5-4. Is there a battery voltage?

Go to Step 11 Go to Step 17

11 1. Reconnect thermostat relay and disconnect compressor relay

(X-4).

2. Check to see if battery voltage is present at the chassis side relay terminal No. X4-5.

Is there a battery voltage?

Go to Step 12

Open circuit

between No.

EB-5 (10A) fuse

and No. X4-5.

12 Check to see if continuity between chassis side relay terminal No.

X4-1 and the chassis side connector terminal No. E3-1. Is there a continuity?

Go to Step 13 Open circuit.

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Magnetic Clutch Does Not Run (Cont’d)

Step NoYesAction

13 Check to see if battery voltage is present between chassis side

relay terminal No. X4-2 and No. X4-4. Is there a battery voltage?

Go to Step 14 Go to Step 15

14 Check to see if battery voltage is present at chassis side relay

terminal No. X4-2. Is there a battery voltage?

Go to Step 16

Open circuit

between No.

EB-5 (10A) fuse

and No. X4-2.

15 Check to see if battery voltage is present at chassis side

connector terminal No. C1-B14. Is there a battery voltage?

Power train

control module

(PCM) defective.

Refer to

Driveability and

Emissions in

Engine section.

Open circuit

between No.

X4-4 and No.

C1-B14.

16 Check to see if continuity between chassis side relay terminal No.

X5-1 and chassis side connector terminal No. C3-E15. Is there a continuity?

Power train

control module

(PCM) defective.

Refer to

Driveability and

Emissions in

Engine section.

Open circuit

17 Check to see if battery voltage is present at chassis side relay

terminal No.X5-2. Is there a battery voltage?

Go to Step 18

Open circuit

between No.X5-2

and C1 1-2.

18 1. Reconnect thermostat relay.

2. Check to see if battery voltage is present at chassis side connector terminal No.B4-3.

Is there a battery voltage?

Go to Step 19

Open circuit

between No.I24-1

and No.B4-3.

19 Check to see if battery voltage (appox 10V) is present at chassis

side connector terminal No. B4-1. Is there a battery voltage?

Go to Step 20

Open circuit

between No.

X5-4 and No.

B4-1.

20 Check to see if continuity between chassis side connector

terminal No. B4-2 and No.I23-6. Is there a continuity?

Electronic

thermostat

defective.

Open circuit

between No.

B4-2 and

No.I23-6 or poor

ground (Fan

Switch Ground

Circuit).

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condenser Fan Diagnosis

While the air conditioning is ON, the cycling switch in the triple pressure switch senses the refrigerant pressure, and activates the condenser fan to improve the cooling capacity of the condenser when the refrigerant pressure

exceeds a set pressure value. The condenser fan stops when the air conditioning is turned “OFF” or when the pressure goes down below the set pressure value.

D08RW062

Condition Possible cause Correction

Condenser fan does not run.

– Refer to “Chart A”. – Refer to “Chart B”.

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Chart “A” Condenser Fan Does Not Run

Step Action Yes No

1 Are 30A fuse OK? Go to Step 2 Replace 2 Is relay (X-9) OK? Go to Step 3 Replace 3 Is pressure switch OK?

Go to Step 4

Switch defective

or insufficient

refrigerant. 4 Is air conditioning switch OK? Go to Step 5 Replace 5 Is fan motor OK? Go to Step 6 Replace 6 1. Disconnect condenser fan relay (X-9).

2. Check to see if battery voltage is present at the chassis side relay terminal NO. X9-5

Is there a battery voltage?

Go to Step 7

Open circuit

between EB-17

fuse (30A) and

No.X9-5.

7 1. Reconnect condenser fan relay (X-9).

2. Air conditioning switch “ON”.

3. Check to see if battery voltage is present at chassis side connector terminal No.C11-3.

Is there a battery voltage?

Go to Step 8

Open circuit

between I-24-1

and C1 1-3.

8 1. Air conditioning switch “OFF”.

2. Check to see if continuity between chassis side relay terminal No.X9-2 and the chassis side connector terminal No.C11-4.

Is there a continuity?

Go to Step 9 Open circuit.

9 Check to see if continuity between chassis side connector

terminal No. C24-1 and chassis side relay terminal No.X9-1. Is there a continuity?

Poor ground or

open circuit

between chassis

side connector

terminal No.X9-4

(or No.C24-2)

and body ground

(No.C36).

Open circuit.

Chart “B” Condenser Fan Does Not Stop

Step Action Yes No

1 1. Air conditioning switch “OFF”.

Does condenser fan stop?

Triple pressure

switch defective.

Condenser fan

relay (X9) defective.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Individual Inspection

Fan Control Knob (Fan Switch) And Air Conditioning (A/C) Switch

1.Check for continuity between the fan switch and the A/C switch side connector terminals.

D08RW061

Heater (X-6), Thermostat (X-5), Condenser Fan (X-9) And Compressor (X-4) Relay

1.Disconnect relays and check for continuity and resistance between relay terminals.

f For handling of these relays, refer to Heater Relay

in this section.

825RS179

Pressure Switch

1.Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals (1) and (2).

875RW003

Triple Pressure Switch (V6, A/T)

1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2).

2.Reconnect the connector to activate the A/C switch, and check to see if there is continuity between the chassis side connector terminals (3) and (4) and the fan operates.

875RW013

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Condenser Fan

1.Disconnect the condenser fan connector.

2.Connect the battery positive terminal to the condenser fan side connector terminal No.C-24-1 and negative to the No.C-24-2.

3.Check that condenser fan is rotating correctly.

875RW010

General Repair Procedure

Precautions For Replacement or Repair of Air Conditioning Parts

There are certain procedures, practices and precautions that should be followed when servicing air conditioning systems:

f Keep your work area clean. f Always wear safety goggle and protective gloves

when working on refrigerant systems.

f Beware of the danger of carbon monoxide fumes

caused by running the engine.

f Beware of discharged refrigerant in enclosed or

improperly ventilated garages.

f Always disconnect the negative battery cable and

discharge and recover the refrigerant whenever repairing the air conditioning system.

f When discharging and recovering the refrigerant, do

not allow refrigerant to discharge too fast; it will draw compressor oil out of the system.

f Keep moisture and contaminants out of the system.

When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately.

Never remove the caps or plugs until the lines or parts are reconnected or installed.

f When disconnecting or reconnecting the lines, use

two wrenches to support the line fitting, to prevent from twisting or other damage.

f Always install new O-rings whenever a connection is

disassembled.

f Before connecting any hoses or lines, apply new

specified compressor oil to the O-rings.

f When removing and replacing any parts which

require discharging the refrigerant circuit, the operations described in this section must be performed in the following sequence:

1. Use the J-39500 (ACR

: HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent to thoroughly discharge and recover the refrigerant.

2. Remove and replace the defective part.

3. After evacuation, charge the air conditioning system and check for leaks.

Repair Of Refrigerant Leaks

Refrigerant Line Connections

Install new O-rings, if required. When disconnecting or connecting lines, use two wrenches to prevent the connecting portion from twisting or becoming damaged.

852RS003

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

When connecting the refrigerant line at a block joint, securely insert the projecting portion of the joint portion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-rings prior to connecting.

CAUTION: Compressor (PAG) oil to be used varies according to the compressor model. Be sure to apply oil specified for the model of compressor.

850RW002

O-rings (2) must be fitted in the groove (1) of refrigerant line.

850RW003

Insert the nut into the union. First, tighten the nut by hand as much as possible, then tighten the nut to the specified torque.

850RW004

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Leak Check

Inspection of refrigerant leak

Refrigerant leak may cause an adverse effect not only on the performance and durability of each component of the air–conditioner, but also on the global atmosphere. Therefore, it is most important to repair refrigerant leak when there is any leak found.

Inspection flow of refrigerant leak

Step Action Yes No

1 1. Evacuate the refrigerant system.

2. Charge the refrigerant. Is there any refrigerant leak?

Repair refrigerant

system.

Go to Step 2.

2 1. Operate the compressor for more than 5 minutes to raise the

pressure on the high pressure side.

Is there any refrigerant leak at high pressure components?

Repair refrigerant

system.

Compressor

operation to be

confirmed.

Inspection Steps

Check the components of air–conditioner to see if there occurs any refrigerant leak along the flow of refrigerant.

NOTE:

f To avoid an error in the detection of refrigerant leak,

make sure of there being no refrigerant vapor or cigarette smoke around the vehicle before conducting the inspection. Also, select a location where the refrigerant vapor will not get blown off with wind.

f Inspection should be conducted chiefly on the pipe

connections and sections where a marked oil contamination is found. When refrigerant is leaking, oil inside is also leaking at the same time.

f It is possible to visually check the leak from inside the

cooling unit. Follow the method below when checking. Remove the drain hose or resistor of the cooling unit, and insert a leak detector to see if there occurs any leak.

High Pressure Side

1.Discharger section of compressor.

2.Inlet/outlet section of condenser.

3.Inlet/outlet section of receiver driver.

4.Inlet section of cooling unit.

Low Pressure Side

1.Outlet section of cooling unit.

2.Intake section of compressor.

Major Checking Points of Refrigerant Leak

Compressor

f Pipe connection f Sealing section of shaft f Mating section or cylinder

Condenser

f Pipe connection

f Welds of condenser body

Receiver driver

f Pipe connection f Attaching section of pressure switch f Section around the sight glass

Evaporator unit (cooling unit)

f Pipe connections f Connections of expansion valve f Brazed sections of evaporator

NOTE:

f The evaporator and expansion valve are contained in

the case. Remove the drain hose or the resistor of the cooling unit and insert a leak detector when checking for any leak.

Flexible hose

f Pipe connection f Caulking section of the hose f Hose (cracks, pinholes, flaws)

Pipe

f Pipe connection f Pipe (cracks, flaws)

Charge valve

NOTE:

f The charge valve, which is used to connect the gauge

manifold, is normally provided with a resin cap. When the valve inside gets deteriorated, refrigerant will leak out.

Leak at Refrigerant Line Connections

1.Check the torque on the refrigerant line fitting and, if too loose, tighten to the specified torque.

f Use two wrenches to prevent twisting and damage

to the line.

f Do not over tighten.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

2.Perform a leak test on the refrigerant line fitting.

3.If the leak is still present, discharge and recover the refrigerant from the system.

4.Replace the O-rings. f O-rings cannot be reused. Always replace with new

ones.

f Be sure to apply the specified compressor oil to the

new O-rings.

5. Retighten the refrigerant line fitting to the specified torque.

f Use two wrenches to prevent twisting and damage

to the line.

6.Evacuate, charge and retest the system.

Leaks In The Hose

If the compressor inlet or outlet hose is leaking, the entire hose must be replaced. The refrigerant hose must not be cut or spliced for repair.

1.Locate the leak.

2.Discharge and recover the refrigerant.

3.Remove the hose assembly . f Cap the open connections at once.

4.Connect the new hose assembly . f Use two wrenches to prevent twisting or damage to

the hose fitting.

f Tighten the hose fitting to the specified torque.

5.Evacuate, charge and test the system.

Compressor Leaks

If leaks are located around the compressor shaft seal or shell, replace or repair the compressor.

Recovery, Recycling, Evacuation and Charging of HFC-134a

Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury.

f Always wear safety goggles and protective gloves. f Always work in a well-ventilated area. Do not weld or

steam clean on or near any vehicle-installed air conditioning lines or components.

f If HFC-134a should come in contact with any part of

the body , flush the exposed area with cold water and immediately seek medical help.

f If it is necessary to transport or carry any container of

HFC-134a in a vehicle, do not carry it in the passenger compartment.

f If it is necessary to fill a small HFC-134a container

from a large one, never fill the container completely. Space should always be allowed above the liquid for expansion.

f HFC-134a and R-12 should never be mixed as their

compositions are not the same.

f HFC-134a PAG oil tends to absorb moisture more

quickly than R-12 mineral oil and, therefore, should be handled more carefully.

f Keep HFC-134a containers stored below 40°C

(100°F).

WARNING:

f SHOULD HFC-134A CONTACT YOUR EYE(S),

CONSULT A DOCTOR IMMEDIATELY.

f DO NOT RUB THE AFFECTED EYE(S). INSTEAD,

SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT.

f OBTAIN PROPER MEDICAL TREATMENT AS

SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREA TED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN.

Refrigerant Recovery

The refrigerant must be discharged and recovered by using the J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent before removing or mounting air conditioning parts.

1.Connect the high and low charging hoses of the ACR

(or equivalent) as shown below.

901RS181

Legend

(1) Low Side (2) High Side

2.Recover the refrigerant by following the Manufacturer’s Instructions.

3.When a part is removed, put a cap or a plug on the connecting portion so that dust, dirt or moisture cannot get into it.

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Refrigerant Recycling

Recycle the refrigerant recovered by J-39500 (ACR

:HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent. For the details of the actual operation, follow the steps in the ACR4(or equivalent) Manufacturer’s Instructions.

Evacuation of The Refrigerant System

901RS182

Legend

(1) Low Side (2) High Side

NOTE: Explained below is a method using a vacuum pump. Refer to the ACR

(or equivalent) manufacturer’s

instructions when evacuating the system with a ACR

(or

equivalent). Air and moisture in the refrigerant will cause problems in

the air conditioning system. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system.

1.Connect the gauge manifold.

f High-pressure valve (HI) — Discharge-side. f Low-pressure valve (LOW) — Suction-side.

2.Discharge and recover the refrigerant.

3.Connect the center hose of the gauge manifold set to the vacuum pump inlet.

4. Operate the vacuum pump, open shutoff valve and then open both hand valves.

5.When the low-pressure gauge indicates approximately 750 mmHg (30 inHg), continue the evacuation for 5 minutes or more.

6.Close both hand valves and stop the vacuum pump.

7.Check to ensure that the pressure does not change after 10 minutes or more.

f If the pressure changes, check the system for

leaks.

f If leaks occur, retighten the refrigerant line

connections and repeat the evacuation steps.

8.If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the gauge manifold pressure is at 750 mmHg (30 inHg), close both hand valves.

9.Close positive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump.

Charging The Refrigerant System

There are various methods of charging refrigerant into the air conditioning system. These include using J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent and direct charging with a weight scale charging station.

Charging Procedure

f ACR

(or equivalent) Method

For the charging of refrigerant recovered by ACR4(or equivalent), follow the manufacturer’s instruction.

901RS183

Legend

(1) Low Side (2) High Side

f Direct charging with a weight scale charging

station method

1.Make sure the evacuation process is correctly completed.

2.Connect the center hose of the manifold gauge to the weight scale.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

3.Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle.

4.Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle.

901RS184

Legend

(1) Low Side (2) High Side (3) Refrigerant Container (4) Weight Scale

5.Place the refrigerant container(3) up right on a weight scale(4).

Note the total weight before charging the refrigerant. a. Open the refrigerant container valve.

b. Open the low side vale on the manifold gauge set.

Refer to the manufacturer’s instructions for a weight scale charging station.

901RS144

6.Perform a system leak test: f Charge the system with approximately 200 g

(0.44 lbs) of HFC-134a.

f Make sure the high pressure valve of the manifold

gauge is closed.

f Check to ensure that the degree of pressure does

not change.

f Check for refrigerant leaks by using a HFC-134a

leak detector.

f If a leak occurs, recover the refrigerant. Repair the

leak and start all over again from the first step of evacuation.

7.If no leaks are found, continue charging refrigerant to the air conditioning system.

f Charge the refrigerant until the scale reading

decreases by the amount of the charge specified.

Specified amount: 650 g (1.43 lbs)

f If charging the system becomes difficult:

1. Run the engine at idle and close all the vehicle doors.

2. Turn A/C switch “ON”.

3. Set the fan switch to its highest position.

4. Set the air source selector lever to “CIRC”.

5. Slowly open the low side valve on the manifold gauge set.

WARNING: BE ABSOLUTELY SURE NOT TO OPEN THE HIGH PRESSURE VALVE OF THE MANIFOLD GAUGE. SHOULD THE HIGH PRESSURE VALVE BE OPENED, THE HIGH PRESSURE REFRIGERANT WOULD FLOW BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT CONT AINER TO BURST.

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8.When finished with the refrigerant charging, close the low pressure valve of the manifold gauge and container valve.

9.Check for refrigerant leaks.

Checking The A/C System

1.Run the engine and close all the vehicle doors.

2.Turn A/C switch “ON”, set the fan switch to its highest position.

3.Set the air source lever to “CIRC”, set the temperature lever to the full cool position.

4. Check the high and low pressure of the manifold gauge.

f Immediately after charging refrigerant, both high

and low pressures might be slightly high, but they settle down to the pressure guidelines shown below:

f The ambient temperature should be between

25–30°C (77–86°F).

f The pressure guideline for the high-pressure side is

approximately 1372.9–1863.3 kPa (199.1–270.2 psi).

f The pressure guideline for the low-pressure side is

approximately 147.1–294.2 kPa (21.3–42.7 psi).

f If an abnormal pressure is found, refer to Checking

The Refrigerant System With Manifold Gauge in this section.

5.Put your hand in front of the air outlet and move the temperature control lever of the control panel to different positions. Check if the outlet temperature changes as selected by the control knob.

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Compressor Assembly

Compressor Assembly and Associated Parts

871RX004

Legend

(1) Magnetic Clutch Harness Connector (2) Refrigerant Line Connector

(3) Compressor (4) Serpentine Belt

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant f Refer to Refrigerant Recovery in this section.

3.Disconnect magnetic clutch harness connector.

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4.Remove serpentine belt. f Move serpentine belt tensioner to loose side using

wrench then remove serpentine belt.

850RW001

Legend

(1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Serpentine Belt

5.Disconnect refrigerant line connector. f When removing the line connector, the connecting

part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

6.Remove compressor.

Installation

1.Install compressor. f Tighten the compressor fixing bolts to the specified

torque.

Torque: 19 N•m (14 lb•ft)

2.Connect refrigerant line connector. f Tighten the refrigerant line connector fixing bolts to

the specified torque.

Torque: 15 N•m (11 lb•ft)

f O-rings cannot be reused. Always replace with new

ones.

f Be sure to apply new compressor oil to the O-rings

when connecting refrigerant lines.

3.Install serpentine belt. f Move serpentine belt tensioner to loose side using

wrench, then install serpentine belt to normal position.

4.Connect magnetic clutch harness connector.

New Compressor Installation

The new compressor is filled with 150cc (5.0fl.oz.)of compressor oil and nitrogen gas. When mounting the compressor on the vehicle, perform the following steps;

1.Gently release nitrogen gas from the new compressor.

f Take care not to let the compressor oil flow out. f Inspect O-rings and replace if necessary.

871RX005

2.Turn the compressor several times by hand and release the compressor oil in the rotor.

3. When installing on a new system, the compressor should installed as it is. When installing on a used system, the compressor should be installed after adjusting the amount of compressor oil. (Refer to Compressor in this section)

871RX003

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Condenser Assembly

Condenser Assembly and Associated Parts

875RW008

Legend

(1) Engine Hood Lock (2) Pressure Switch Connector (3) Refrigerant Line

(4) Radiator Grille (5) Engine Hood Front End Stay (6) Condenser Assembly

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. f Refer to Refrigerant Recovery in this section.

3.Remove radiator grille.

4.Remove engine hood front end stay.

5.Remove engine hood lock. f Apply setting mark to the engine hood lock fixing

position before removing it.

6.Disconnect pressure switch connector.

7.Disconnect refrigerant line. f When removing the line connector, the connecting

part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

8.Remove condenser assembly . f Handle with care to prevent damaging the

condenser or radiator fin.

Installation

1.Install condenser assembly . f If installing a new condenser, be sure to add 30cc

(1.0 fl. oz.) of new compressor oil to a new one.

f Tighten the condenser fixing bolts to the specified

torque.

Torque: 6 N•m (52 lb in)

2.Connect refrigerant line. f Tighten the inlet line connector fixing bolt to the

specified torque.

Torque: 15 N•m (11 lb ft)

f Tighten the outlet line connector fixing bolt to the

specified torque.

Torque: 6 N•m (52 lb in)

f O-rings cannot be reused. Always replace with new

ones.

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f Be sure to apply new compressor oil to the O-rings

when connecting the refrigerant line.

3.Connect pressure switch connector.

4.Install engine hood lock.

5.Install engine hood front end stay.

6.Install radiator grille.

Condenser Fan Motor

Condenser Fan Motor and Associated Parts

875RW009

Legend

(1) Condenser Fan Assembly (2) Condenser Fan Motor

(3) Radiator Grille (4) Shroud (5) Fan

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. f Refer to Refrigerant Recovery in this section.

3.Remove radiator grille.

4.Remove condenser fan assembly . f Disconnect the fan motor connector and remove

the 4 fixing bolts.

5.Remove shroud.

f Remove the 3 fixing nuts. f Loosen the condenser fixing nut and disconnect the

fan motor connector from bracket.

6.Remove fan. f Remove the fan fixing C-ring and plate.

7.Remove condenser fan motor.

Installation

To install, follow the removal steps in the reverse order, noting the following point.

1.Route the fan motor harness in its previous position, and fix it securely with clip and bracket.

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Receiver / Drier

Receiver / Drier and Associated Parts

875RW011

Legend

(1) Pressure Switch Connector (2) Refrigerant Line (3) Radiator Grille (4) Receiver / Drier (5) Bracket Bolt

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. f Refer to Refrigerant Recovery in this section.

3.Remove radiator grille.

4.Disconnect pressure switch connector.

5.Disconnect refrigerant line. f When removing the line connected part, the

connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

6.Remove bracket bolt.

7.Remove receiver/drier. f Loosen the bolt, then, using care not to touch or

bend the refrigerant line, carefully pull out the receiver/drier.

Installation

To install, follow the removal steps in the reverse order, noting the following points:

1.If installing a new receiver/drier, be sure to add 30cc (1.0 fl. oz.) of new compressor oil to a new one.

2.Put the receiver/drier in the bracket and connect with the refrigerant line. Check that no excessive force is imposed on the line. Fasten the bracket bolt to the receiver/drier.

3.Tighten the refrigerant line to the specified torque.

Torque: 6 N•m (52 lb in)

4.O-rings cannot be reused. Always replace with new ones.

5.Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line.

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Pressure Switch

Pressure Switch and Associated Parts

875RW012

Legend

(1) Pressure Switch Connector (2) Pressure Switch (3) Radiator Grille

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. f Refer to “Refrigerant Recovery in this section.

3.Remove radiator grille.

4.Disconnect pressure switch connector.

5.Disconnect pressure switch. f When removing the switch connected part, the

connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

Installation

To install, follow the removal steps in the reverse order, noting the following point:

1.O-ring cannot be reused. Always replace with a new one.

2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch.

3.Tighten the pressure switch to the specified torque.

Torque: 13 N•m (113 lb in)

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Evaporator Assembly

Evaporator Assembly and Associated Parts

874RW007

Legend

(1) Resistor and Electronic Thermostat Connector (2) Drain Hose

(3) Refrigerant Line (4) Glove Box (5) Evaporator Assembly

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. f Refer to Refrigerant Recovery in this section.

3.Remove glove box.

4.Disconnect resistor (2) and electronic thermostat connector (1).

840RS005

5.Disconnect drain hose.

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6.Disconnect refrigerant line. f Use a back-up wrench when disconnecting and

reconnecting the refrigerant lines.

f When removing the refrigerant line connected part,

the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

7.Remove evaporator assembly .

Installation

To install, follow the removal steps in the reverse order, noting the following points:

1.To install a new evaporator assembly, add 50cc (1.7 fl. oz.) of new compressor oil to the new core.

2.Tighten the refrigerant outlet line to the specified torque.

T orque: 25 N•m (18 lb ft)

3.Tighten the refrigerant inlet line to the specified torque.

T orque: 15 N•m (11 lb ft)

4.O-rings cannot be reused. Always replace with new ones.

5.Be sure to apply new compressor oil to the O-rings when connecting lines.

Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View

874RX001

Legend

(1) Lining (2) Expansion Valve (3) O-ring (4) Evaporator Assembly (5) Lower Case

(6) Clip (7) Attaching Screw (8) Evaporator Core (9) Electronic Thermostat

(10) Upper Case

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Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. f Refer to Refrigerant Recovery in this section.

3.Remove evaporator assembly . f Refer to Evaporator Assembly in this section.

4.Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly.

5.Remove clip.

6.Remove attaching screw.

7.Remove upper case.

8.Remove lower case. f Slit the case parting face with a knife since the lining

is separated when removing the evaporator.

874RS006

f Lift to remove the upper case.

874RW001–1

9.Remove evaporator core.

874RW002–1

10.Remove expansion valve.

f Tear off the insulator carefully. f Remove the sensor fixing clip.

f Use a back-up wrench when disconnecting all

refrigerant pipes.

Installation

To install, follow the removal steps in the reverse order, noting the following points:

1.The sensor is installed on the core with the clip.

2. The sensor must not interfere with the evaporator core.

3.When installing the new evaporator core, install the thermo sensor (2) to the evaporator core (1) specified position with the clip in the illustration.

874RX004

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4.O-rings cannot be reused. Always replace with new ones.

5.Be sure to apply new compressor oil to the O-rings when connecting lines.

6.Be sure to install the sensor and the insulator on the place where they were before.

7.T o install a new evaporator core, add 50cc (1.7 fl. oz.) of new compressor oil to the new core.

8.Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications in this section.

9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly.

Refrigerant Line

Refrigerant Line and Associated Parts

852RX001

Legend

(1) Clip and Clamp (2) Liquid Line (High-Pressure Pipe)

(3) Discharge Line (High-Pressure Hose) (4) Radiator Grille (5) Suction Line (Low-Pressure Pipe)

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Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section.

3.Remove radiator grille.

4.Remove clip and clamp.

5.Disconnect liquid line (High-pressure pipe).

6.Disconnect suction line (Low-pressure pipe) using a back-up wrench.

7.Disconnect suction line (Low-pressure hose) using a back-up wrench.

8.Disconnect discharge line (High-pressure hose) using a back-up wrench.

D Use a backup wrench when disconnecting and

reconnecting the refrigerant lines.

D When removing the refrigerant line connecting part,

the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

Installation

To install, follow the removal steps in the reverse order, noting the following point:

1.O-rings cannot be reused. Always replace with new ones.

2.Be sure to apply new compressor oil to the O-rings when connecting lines.

3.Tighten the refrigerant line to the specified torque. Refer to Main Data and Specifications for Torque

Specifications in this section.

Main Data And Specifications

General Specifications

Heater Unit

Temperature control Reheat air mix system Capacity 3,700 Kcal./hr. Air flow 280 m#/h

HEA TER CORE

Type Fin and tube type Element dimension 167 mm (6.6 in.) × 151 mm (5.9 in.) × 35 mm (1.4 in.) Radiating area Approx. 2.4 m@

EV APORATOR ASSEMBL Y

Capacity 4,100 Kcal./hr. Air flow 430 m#/hr

EV APORATOR CORE

Type Al-laminate louver fin type Element dimension 235 mm (9.3 in.) × 224 mm (8.8 in.) × 60 mm (2.4 in.)

EXP ANSION VALVE

Type External pressure equalizer type

THERMOSTAT SWITCH

Type Electronic thermostat

OFF: Below 0.5 ± 0.5 °C (32.9 ± 0.9 °F) ON: Above 4.5 ± 0.5 °C (40.1 ± 0.9 °F)

CONDENSER

Type Parallel flow type Radiation performance 9,400 Kcal./hr

RECEIVER/DRIER

Type Assembly includes sight glass with dual (triple) pres-

sure switch (V6) or pressure sensor (L14)

Internal volume 300 cc (10 fl.oz.)

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PRESSURE SWITCH

Type

Dual pressure switch Low pressure control

ON: 205.9±29.4 kPa (29.9±4.3 psi) OFF: 176.5±24.5 kPa (25.6±3.6 psi)

High pressure control

ON: 2353.6±196.1 kPa (341.3±28.4 psi)

OFF: 2942.0±196.1 kPa (426.6±28.4 psi) Triple pressure switch (V6, A/T) Low pressure control

ON: 196.3±29.4 kPa (27.0±4.3 psi)

OFF: 176.5±19.6 kPa (25.6±2.8 psi) Medium pressure control

ON: 1471.0±98.1 kPa (213.3±14.2 psi)

OFF: 1078.7±1 17.7 kPa (156.4 ±17.7 psi) High pressure control

ON: 2353.6±196.1 kPa (341.3±28.4 psi)

OFF: 2942.0±196.1 kPa (426.6±28.4 psi)

REFRIGERANT

Type HFC-134a Specified amount 650 g (1.43 lbs.)

Torque Specifications

852RX003

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874RX006

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Compressor

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS ON-VEHICLE SERVICE INFORMATION. FAILURE TO FOLLOW CAUTIONS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

General Description

When servicing the compressor, keep dirt or foreign material from getting on or into the compressor parts and system. Clean tools and a clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any ”On–Vehicle” repair, or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichloroethane, naphtha, kerosene, or equivalent solvent, and dried with dry air. Use only lint free cloths to wipe parts. The operations described below are based on bench overhaul with compressor removed from the vehicle, except as noted. They have been prepared in order of accessibility of the components. When the compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be discarded and new compressor oil added to the compressor. Compressor malfunction will appear in one of four ways: noise, seizure, leakage or low discharge pressure. Resonant compressor noises are not cause for alarm; however, irregular noise or rattles may indicate broken parts or excessive clearances due to wear. To check seizure, de–energize the magnetic clutch and check to

see if the drive plate can be rotated. If rotation is impossible, the compressor is seized. Low discharge pressure may be due to a faulty internal seal of the compressor, or a restriction in the compressor. Low discharge pressure may also be due to an insufficient refrigerant charge or a restriction elsewhere in the system. These possibilities should be checked prior to servicing the compressor. If the compressor is inoperative, but is not seized, check to see if current is being supplied to the magnetic clutch coil terminals. The compressor oil used in the HFC–134a system compressor differs from that used in R–12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction.

DKV-14G Type Compressor

DKV–14G is equipped with five–vane rotary compressor. These vanes are built into a rotor which is mounted on a shaft. When the shaft rotates, the vanes built into the cylinder block assembly are operated by centrifugal force. This changes the volume of the spare formed by the rotor and cylinder, resulting in the intake and compression of the refrigerant gas. The discharge valve and the valve stopper, which protects the discharge valve, are built into the cylinder block assembly . There is no suction valve but a shaft seal is installed between the shaft and head; a trigger valve, which applies back pressure to the vanes, is installed in the cylinder block and a refrigerant gas temperature sensor is installed in the front head. The specified quantity of compressor oil is contained in the compressor to lubricate the various parts using the refrigerant gas discharge pressure.

871RX002

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Diagnosis

Condition Possible cause Correction

Noise from compression

Defective rotor/piston Replace compressor/cylinder and

shaft assembly

Defective shaft Replace compressor/cylinder and

shaft assembly

Noise from magnetic clutch

Defective bearing Replace magnetic clutch Defective clutch Replace magnetic clutch Clearance between drive plate and

pulley not standard

Adjust the clearance or replace magnetic clutch

Insufficient cooling

Defective gasket Replace compressor/gasket Defective rotor/reed valve Replace compressor/valve plate Defective trigger valve/suction valve Replace compressor/suction valve

Not rotating

Defective rotor/piston Replace compressor/cylinder and

shaft assembly

Defective shaft Replace compressor/cylinder and

shaft assembly

Rotating parts seized due to insufficient oil

Replace compressor

Oil and/or gas leakage

Defective seal Replace compressor/shaft seal Defective O-ring Replace

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Magnetic Clutch Assembly (DKV-14D Type)

Parts Location View

871RW009

Legend

(1) Drive Plate bolt (2) Drive Plate (3) Snap Ring

(4) Pulley Assembly (5) Field Coil (6) Shim (s) (7) Lead Wire

Removal

1. Using drive plate holder J-33939 (1) to prevent the drive plate from rotating, then remove the drive plate bolt.

871RW014

2.Remove drive plate by using drive plate puller J-33944-A (2) and forcing screw J-33944-4 (1).

871RW013

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3.Remove shim (s).

4.Remove snap ring (1) by using snap ring pliers.

871RW016

5.Remove pulley assembly by using pulley puller pilot J-38424, pulley puller J-8433 and pulley puller leg J-24092-2.

871RS009

6.Loosen screw and disconnect the coil lead wire connector.

871RS010

7.Loosen three screws and remove the field coil.

871RS011

Inspection and Repair

Drive Plate

If the frictional surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced.

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 reinstallation.

Coil

Check coil for loose connector or cracked insulation.

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Installation

1.Install field coil. f Align the located portion (1) of the field coil and

compressor.

871RW017

f Tighten the mounting screw to the specified torque.

Torque: 5N·m (44 lb in)

2.Connect the lead wire connector with the rubber hold and tighten the screw.

3.Install pulley assembly by using pulley installer J-33940-A and drive handle J-8092.

871RS013

4.Install snap ring.

5.Install shim (s).

6. Install the drive plate to the compressor drive shaft together with the original shim(s)(1). Press the drive plate by hand.

871RW012

7. Install drive plate bolt by using drive plate holder J-33939 (1) to prevent the drive plate from rotating.

871RW014

f Tighten the drive plate bolt to the specified torque.

Torque: 13 N·m (113 lb in)

f After tightening the drive plate bolt, check to be sure

the pulley rotates smoothly.

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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

f Check to be sure that the clutch clearance is

between 0.3-0.6 mm (0.01-0.02 in.)

871RW011

f If necessary, install adjusting shim(s). f Adjusting shims are available in the following

thickness.

Thickness

f 0.1 mm (0.0039 in.) f 0.3 mm (0.0118 in.) f 0.5 mm (0.0197 in.)

Compressor Oil

Oil Specification

f The HFC-134a system requires a synthetic (PAG)

compressor oil whereas the R-12 system requires a mineral compressor oil. The two oils must never be mixed.

f Compressor (PAG) oil varies according to

compressor model. Be sure to use oil specified for the model of compressor.

f Always use HFC-134a Vane Rotary Type

Compressor Oil (AIPDN Part No.2-90188-301-0)

Handling of Oil

f The oil should be free from moisture, dust, metal

powder, etc.

f Do not mix with other oil. f The water content in the oil increases when exposed

to the air. After use, seal oil from air immediately. (HFC-134a Vane Rotary Compressor Oil absorbs moisture very easily.)

f The compressor oil must be stored in steel

containers, not in plastic containers.

Compressor Oil Check

The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil.

Oil Capacity Capacity total in system: 150cc (5.0 fl.oz) Compressor (Service parts) charging amount:

150 cc (5.0 fl.oz)

Checking and Adjusting Oil Quantity for Used Compressor

1.Perform oil return operation. Refer to Oil Return Operation in this section.

2. Discharge and recover refrigerant and remove the compressor.

3.Drain the compressor oil and measure the extracted oil with a measuring cylinder.

4.If the amount of oil drained is much less than 90 cc (3.0 fl. oz.), some refrigerant may have leaked out. Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts.

5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil in this section.)

6.Adjust the oil level following the next procedure below.

(Charging Amount)

(Collected Amount)

more than 90cc (3.0 fl.oz)

same as collected amount

less than 90 cc (3.0 fl.oz) 90cc (3.0 fl.oz)

7. Install the compressor, then evacuate, charge and perform the oil return operation.

8.Check system operation.

When it is impossible to preform oil return operation, the compressor oil should be checked in the following order:

1. Discharge and recover refrigerant and remove the compressor.

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2.Drain the compressor oil and measure the extracted oil with a measuring cylinder.

3.Check the oil for contamination.

4.If more than 90 cc (3.0 fl. oz.) of oil is extracted from the compressor, supply the same amount of oil to the compressor to be installed.

5.If the amount of oil extracted is less than 90 cc (3.0 fl. oz.), recheck the compressor oil in the following order.

6.Supply 90 cc (3.0 fl. oz.) of oil to the compressor and install it onto the vehicle.

7. Evacuate and recharge with the proper amount of refrigerant.

8.Perform the oil return operation.

9.Remove the compressor and recheck the amount of oil.

10.Adjust the compressor oil, if necessary. (Collected Amount) (Charging Amount)

more than 90 cc (3.0 fl.oz)

same as collected amount

less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

Checking and Adjusting for Compressor Replacement

150 cc (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor.

1.Perform oil return operation.

2.Discharge and recover the refrigerant and remove the

compressor.

3.Drain the compressor oil and measure the extracted

oil.

4.Check the compressor oil for contamination.

5.Adjust the oil level as required. (Amount of oil drained

from used compressor)

(Draining amount of oil from new compressor)

less than 90 cc (3.0 fl.oz) Same as drained

amount

more than 90 cc (3.0 fl.oz)

90 cc (3.0 fl.oz)

6.Evacuate, charge and perform the oil return

operation.

7.Check the system operation.

Contamination of Compressor Oil

Unlike engine oil, no cleaning agent is added to the compressor oil. Even if the compressor runs for a long period of time (approximately one season), the oil never becomes contaminated as long as there is nothing wrong with the compressor or its method of use.

Inspect the extracted oil for any of the following conditions:

f The capacity of the oil has increased.

f The oil has changed to red. f Foreign substances, metal powder, etc., are present

in the oil.

If any of these conditions exists, the compressor oil is contaminated. Whenever contaminated compressor oil is discovered, the receiver/drier must be replaced.

Oil Return Operation

There is close affinity between the oil and the refrigerant. During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return operation. The procedure is as follows:

1.Open all the doors and the engine hood.

2.Start the engine and air conditioning switch to “ON” and set the fan control knob at its highest position.

3.Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.

4.Stop the engine.

Replacement of Component Parts

When replacing the system component parts, supply the following amount of oil to the component parts to be installed.

(Component parts to be installed)

(Amount of Oil)

Evaporator 50 cc (1.7 fl. oz.) Condenser 30 cc (1.0 fl. oz.) Receiver/dryer 30 cc (1.0 fl. oz.) Refrigerant line (one

piece)

10 cc (0.3 fl. oz.)

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Main Data and Specifications

General Specifications

COMPRESSOR

Model DKV-14G Type Vane rotary type Number of vanes 5 Rotor diameter 64 mm (2.52 in.) Stroke 8.75 mm (0.34 in.) Displacement 140 cc (47.3 fl.oz.) Maximum speed 7,000 rpm (up to 8,400 rpm) Direction of rotation Clockwise (Front-side view) Lubrication system Pressure differential type Lubricant R-134a Vane Rotary Type Compressor Oil

(AIPDN Part No.2-90188-301-0)

150 cc (5.0 fl.oz.) Refrigerant Refrigerant-134a (R-134a), 650 g (1.43 lbs.) Shaft seal Lip type Weight 3.0 kg

MAGNETIC CLUTCH

Type Electromagnetic single-plate dry clutch Rated voltage 12 Volts D.C. Current consumption 3.7 A Starting torque 49 N·m (36 lb·ft) Direction of rotation Clockwise (Front-side view) Weight 2.4 kg (5.3 lbs.)

Isuzu 1999 RODEO Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual