Page 1
WORKSHOP MANUAL
HOME
AXIOM
(UPR/S)
FOREWORD
This manual includes special notes, important points, service data,
precautions, etc. That a re needed for the maintenance, a djustments,
service, rem oval and insta llat i on 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 mater ial 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 edg e of the book below each se ction title.
These point to a more detailed table of contents preceding each
section.
This manual applies to 2002 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 Wh eel and Tire System
3F Intelligent Suspensio n System
DRIVELINE/AXLE
4A1 Differential (Front)
4A2 Differential (Rear)
4B1 Driveline Control System
4B2 Driveline Control System (TOD)
4C Drive Shaft System
4D2 Transfer Case (TOD)
BRAKE
5A Brake Co ntrol System
5B Anti-Lock Brake System
5C Power-Assisted Brake System
5D1 Parking Brake System (4×4 model)
5D2 Parking Brake System (4×2 model)
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
BODY AND ACCESSORIES
8A Lighting System
8B Wiper/Washer System
8C Entertainment
8D Wiring System
8E Me te r and Gauge
8F Body Structure
8G Seats
8H Security and Lo cks
8I Sun Roof/Convertible Top
8J Exterior/Interior Trim
RESTRAINTS
9A Seat Belt System
9J Supplemen tal Re st raint System ( A ir Ba g System)
9J1 Restraint Control System
CONTROL SYSTEM
10A Cruise Control System
Page 2
AXIOM
SECTION
GENERAL INFORMATION
General Information 0A. . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication 0B. . . . . . . . . . . . .
General Information
CONTENTS
CONTENTS
GENERAL INFORMATION
0A–1
General Repair Instruction 0A–1. . . . . . . . . . . . . . . .
Illustration Arrows 0A–2. . . . . . . . . . . . . . . . . . . . . . .
Identification 0A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard 0A–5. . . . . . . . . . . . . . . .
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.
Lifting Instructions 0A–9. . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications 0A–11. . . . . .
Abbreviations Charts 0A–12. . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate 0A–13. . . . . . . . . .
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 “K” or “M” for fifth digit of Vehicle
Identification Number.
Page 3
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
Arrow T ype Application
B Ambient/Clean air
flow
B Cool air flow
B Gas other than
ambient air
B Hot air flow
B Ambient air mixed
with another gas
B Can indicate
temperature change
Motion or direction
View Angle
Dimension (1:2)
Sectioning (1:3)
Lubrication point oil or
fluid
Lubrication point grease
Lubrication point jelly
Page 4
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.
GENERAL INFORMATION
0A–3
710RW003
Page 5
0A–4
GENERAL INFORMATION
Engine Serial Number
The gasoline engine serial number is stamped on the left
rear lower area of the cylinder block above the starter.
Automatic : Stamped on the identification plate, located
240R200014
on the left side of the transmission above the mode
switch.
240R200013
Page 6
Theft Prevention Standard
COMPONENT
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.
GENERAL INFORMATION
0A–5
Reference
Figure No.
0A-10 ENGINE 1– 6VE1 VIN plate
0A-11 TRANSMISSION 2– Automatic transmission VIN plate
0A-11 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
PRODUCTION SERVICE PARTS
Anti Theft Stamping/Plate/Label
STAMPING/PLATE LABEL
INDICATION
VIN label
PRODUCTION
SERVICE PARTS
Page 7
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
Automatic Transmission
901RW195
240R200012
Page 8
Body
GENERAL INFORMATION
0A–7
604R200007
Page 9
0A–8
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.
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.
901RW083
901RW084
Page 10
Lifting Instructions
CAUTION:
B 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.
Lifting Points and Supportable Point Locations
GENERAL INFORMATION
0A–9
B 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 Point: Front
B When using a floor jack, lift on the Convex portion of
the skid plate.
C00RX002
545RS001
Page 11
0A–10
GENERAL INFORMATION
Supportable Point: Front
B Position the chassis stands at the bottom of the frame
sidemember, behind the front wheel.
501RS003
Lifting Point: Rear
B Position the floor jack at the center of the rear axle
case when lifting the vehicle.
Supportable Point: Rear
B 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
B Position the chassis stands at the bottom of the rear
axle case.
420RS002
420RS001
Page 12
Standard Bolts Torque Specifications
Strength Class
The torque values given in the following table should be
applied where a particular torque is not specified.
GENERAL INFORMATION
0A–11
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
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 – 1 15 N·m (56 – 85 lb ft)
72 – 107 N·m (53 – 79 lb ft)
104 – 157 N·m (77 – 1 16 lb ft)
100 – 149 N·m (74 – 1 10 lb ft)
151 – 226 N·m (1 11 – 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)
8.8
Refined Non-Refined
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 – 71 1 N·m (318 – 524 lb ft)
9.8
–
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 – 1 14 N·m (56 – 84 lb ft)
72 – 107 N·m (53 – 79 lb ft)
1 14 – 171 N·m (84 – 126 lb ft)
107 – 160 N·m (79 – 1 18 lb ft)
160 – 240 N·m (1 18 – 177 lb ft)
153 – 230 N·m (1 13 – 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.
Page 13
0A–12
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 T erminal
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
LWB — 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
Page 14
GENERAL INFORMATION
0A–13
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 Vacuum 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.
905R200002
Page 15
AXIOM
SECTION
MAINTENANCE AND LUBRICATION
GENERAL INFORMATION
Maintenance and Lubrication
CONTENTS
0B–1
Maintenance Schedule List 0B–1. . . . . . . . . . . . . . .
Explanation of Complete Vehicle Maintenance
Schedule 0B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants 0B–8. . . .
Lubricant Viscosity Chart 0B–9. . . . . . . . . . . . . . . . .
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:
B to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
B to be driven on reasonable road surfaces within legal
operating limits;
B to be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
B to be driven on unleaded fuel
Unusual or severe operating conditions will require more
frequent vehicle maintenance, as specified in the
following sections.
ITEMS
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)
Recommended Liquid Gasket 0B–11. . . . . . . . . . .
Recommended Thread Locking Agents 0B–11. . .
Maintenance Service Data 0B–12. . . . . . . . . . . . . . . .
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:
B Towing a trailer, using a camper or car top carrier.
B Repeated short trips of less than 8 Km (5 miles) with
outside temperature remaining below freezing.
B Extensive idling and/or low speed driving for long
distances, such as police, taxi or door–to–door
delivery use.
B Operating on dusty, rough, muddy or salt spread
roads.
INTERVAL
Page 16
0B–2
MAINTENANCE AND LUBRICATION
Mileage Only Items
Page 17
Mileage/Months
MAINTENANCE AND LUBRICATION
0B–3
Page 18
0B–4
MAINTENANCE AND LUBRICATION
Page 19
MAINTENANCE AND LUBRICATION
0B–5
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.
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
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
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 whenever
increased engine noise is heard.
Tire Rotation
Rotate tires every 7,500 miles (12,000 km).
Front Wheel Bearings Lubricant
Replacement (Vehicles Produced Before
July/31/2001)
Clean and repack the front wheel bearings at 30,000
miles (48,000 km) intervals.
Refer to DRIVE SHAFT SYSTEM (SEC. 4C).
Front Wheel Bearings Check (Vehicles
Produced After Aug./1/2001)
Inspect hub unit bearing at every 60,000 miles (96,000
km).
If there is abnormal condition, replace hub unit bearing.
“Recommended Fluids and Lubricants” in this
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.
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.
Page 20
0B–6
MAINTENANCE AND LUBRICATION
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 operation. 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 TO
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
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).
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.
Page 21
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 .
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.
MAINTENANCE AND LUBRICATION
0B–7
Page 22
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
Brake system DOT-3 hydraulic brake fluid.
Power steering system DEXRON -III Automatic transmission fluid.
Automatic transmission DEXRON -III Automatic transmission fluid.
TOD SYSTEM (TOD system model only) DEXRON -IIE or DEXRON -III Automatic transmis-
Rear axle and front axle GL-5 gear lubricant (Standard differential)
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
Windshield washer solvent Washer fluid
Key lock cylinder Synthetic light weight engine oil (SAE 5W-30)
Accelerator linkage Chassis grease
Mixture of water and good quality ethylene glycol base
type antifreeze.
sion fluid.
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)
Engine oil
Page 23
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
MAINTENANCE AND LUBRICATION
0B–9
Oil Viscosity Chart for Front Axle
905RT011
B00RW003
Page 24
0B–10
MAINTENANCE AND LUBRICATION
Oil Viscosty Chart for Rear Axle
B00RW004
Page 25
MAINTENANCE AND LUBRICATION
Recommended Liquid Gasket
Type Brand Name Manufacturer Remarks
Three Bond 1207B
RTV*
Silicon Base
Water Base Three Bond 1141E Three Bond For Engine Repairs
Solvent
Anaerobic
Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281
Three Bond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
LOCTITE 515
LOCTITE 518
LOCTITE 17430
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
Isuzu
Isuzu
Isuzu
Loctite
Loctite
Loctite
For Engine Repairs
For Axle Case
Repairs T/M
Repairs T/M
For Engine Repairs
All
0B–11
* 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.
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 26
0B–12
MAINTENANCE AND LUBRICATION
Maintenance Service Data
Service Data and Specifications
ENGINE
BRAKE
WHEEL ALIGNMENT
PROPELLER SHAFT Flange torque 63 N·m (46 lb ft)
WHEEL AND TIRES
* Unless otherwise specified on tire information label on the vehicle.
Valve clearance (cold) 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)
Brake pedal free play 6–10 mm (0.24–0.39 in)
Parking brake travel 6–7 notches
Toe-in (Front) 0 to +2 mm (0 to +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°
Size P235/65R17
Wheel nut torque 118 N·m (87 lb ft)
Tire inflation pressure (Front) 180 kPa (26 psi)
* Tire inflation pressure (Rear) 180 kPa (26 psi)
Approximate Capacities
Items Metric Measure U.S. Measure
Fuel tank 74 L 19.5 Gal.
* Crankcase
Coolant A/T 11.1 L 11.7 Qt
Transmission Automatic 8.6 L 9.1 Qt
Transfer 1.35 L 1.4 Qt
Axle
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.
Oil Change with Filter 4.7 L 5.0 Qt
Oil Change without Filter 4.0 L 4.2 Qt
Rear 1.77 L 1.87 Qt
Front 1.25 L 1.33 Qt
Page 27
AXIOM
SECTION
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
HEATING, VENTILATION AND AIR
CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
1A–1
Service Precaution 1A–3. . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System 1A–3. . . . . . . . . . .
General Description 1A–3. . . . . . . . . . . . . . . . . . . . .
Heater Unit 1A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts 1A–6. . . . . . . .
Removal 1A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door 1A–7. . . . . . . . . .
Disassembled View 1A–7. . . . . . . . . . . . . . . . . . . .
Removal 1A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit 1A–9. . . . . . . . . . . .
Disassembled View 1A–9. . . . . . . . . . . . . . . . . . . .
Removal 1A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit 1A–11. . . . . .
Disassembled View 1A–11. . . . . . . . . . . . . . . . . . . .
Removal 1A–1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly 1A–12. . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts 1A–12. .
Removal 1A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door 1A–13. . . . . . .
Disassembled View 1A–13. . . . . . . . . . . . . . . . . . . .
Removal 1A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor 1A–15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts 1A–15. . . . . .
Removal 1A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle and
Ventilation Duct 1A–16. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts 1A–16. . .
Removal 1A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System 1A–18. . . . . . . . . . . . . . . . . .
General Description 1A–18. . . . . . . . . . . . . . . . . . . . .
Diagnosis 1A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System 1A–31. . . . . . . . . . . . . . . . . .
Individual Inspection 1A–31. . . . . . . . . . . . . . . . . . . . .
General Repair Procedure 1A–31. . . . . . . . . . . . . .
Leak Check 1A–33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Assembly 1A–38. . . . . . . . . . . . . . . . . . .
Compressor Assembly and Associated
Parts (6VE1) 1A–38. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation 1A–39. . . . . . . . . . . .
Condenser Assembly 1A–40. . . . . . . . . . . . . . . . . . . .
Condenser Assembly and Associated
Parts 1A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor 1A–42. . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor and Associated
Parts 1A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier 1A–43. . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts 1A–43. . . .
Removal 1A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch 1A–44. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts 1A–44. . .
Removal 1A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly 1A–45. . . . . . . . . . . . . . . . . . . .
Evaporator Assembly and Associated
Parts 1A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor, Evaporator Core and/or
Expansion Valve 1A–47. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 1A–47. . . . . . . . . . . . . . . . . . . .
Removal 1A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line 1A–49. . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts 1A–49. . . .
Removal 1A–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications 1A–51. . . . . . . . . . . . .
Page 28
1A–2
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor 1A–53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution 1A–53. . . . . . . . . . . . . . . . . . . .
General Description 1A–53. . . . . . . . . . . . . . . . . . . . . .
Diagnosis 1A–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Clutch Assembly (DKV-14G Type) 1A–55
Parts Location View 1A–55. . . . . . . . . . . . . . . . . . . .
Removal 1A–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 1A–57. . . . . . . . . . . . . . . . . .
Installation 1A–57. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil 1A–59. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specification 1A–59. . . . . . . . . . . . . . . . . . . . . . .
Handling of Oil 1A–59. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check 1A–59. . . . . . . . . . . . . . . . .
Checking and Adjusting Oil Quantity for
Used Compressor 1A–59. . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting for Compressor
Replacement 1A–60. . . . . . . . . . . . . . . . . . . . . . . . .
Contamination of Compressor Oil 1A–60. . . . . . . .
Oil Return Operation 1A–60. . . . . . . . . . . . . . . . . . .
Replacement of Component Parts 1A–60. . . . . . .
Main Data and Specifications 1A–61. . . . . . . . . . . . .
Special Tools 1A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System 1A–64. . . . . . . .
General Description 1A–64. . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioner Parts
Configuration 1A–64. . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram 1A–65. . . . . . . . . . . . . . . . . . . . . . .
Functions and Features 1A–70. . . . . . . . . . . . . . . .
Automatic Air Conditioner Block Diagram 1A–71.
Control Panel Layout 1A–72. . . . . . . . . . . . . . . . . . .
Air Control Functions 1A–73. . . . . . . . . . . . . . . . . . .
Control Panel Switch Operation 1A–74. . . . . . . . .
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System 1A–77. . . . . . . . . . . . . . . . . . .
Overview of Automatic Control of Automatic
Air Conditioner 1A–81. . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System 1A–82. . . . . .
Troubleshooting 1A–86. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting, Its Overview and
Procedures 1A–86. . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Air Conditioner Control Unit Power
Supply Diagnosis 1A–87. . . . . . . . . . . . . . . . . . . . .
Performance and Movement checklist for
Automatic Air Conditioner Related Parts 1A–89.
Troubleshooting With Self-Diagnosis
Function 1A–91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection By Failed Location 1A–97. . . . . . . . . . . . .
Inspection of the Sensors 1A–97. . . . . . . . . . . . . . .
Inspection of the Intake Actuator System 1A–101.
Inspection of the Mix Actuator System 1A–104. . . .
Inspection of the Mode Actuator System 1A–107. .
Inspection of the Fan Motor System 1A–110. . . . . .
Inspection of the Magnetic Clutch System 1A–115
Individual Inspection 1A–118. . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1A–121. . . . . . . . . . . . . . . . . . . . . .
Power Transistor 1A–121. . . . . . . . . . . . . . . . . . . . . .
Removal 1A–121. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Heater/Air Conditioner Control
Unit 1A–121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–121. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In Car Sensor 1A–122. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–122. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–122. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor 1A–122. . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–122. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–122. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sun Sensor 1A–123. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–123. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–123. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor 1A–123. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–123. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–123. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Actuator 1A–124. . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–124. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix Actuator 1A–124. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–124. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Actuator 1A–125. . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A–125. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A–125. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 29
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–3
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.
Heating and Ventilation System
General Description
Heater
When the engine is warming up, the warmed engine
coolant is sent 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 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.
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.
The air selector switch (Mode SW), with its different
modes, also allows you to select and maintain the most
comfortable passenger compartment temperature.
The air source select switch is used to select either
“FRESH” for the introduction of the outside air, or “CIRC”
for the circulation of the inside air. When the switch is set
to “FRESH”, the outside air is always taken into the
passenger compartment. When setting the switch 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 switch is normally set to “FRESH” to
prevent the windshield from clouding.
Page 30
1A–4
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Legend
(1) Defroster Nozzle
(2) Ventilation Duct
(3) Blower Assembly
840R200007
(4) Evaporator Assembly
(5) Ventilation Lower Duct
(6) Heater Unit
(7) Rear Heater Duct
Page 31
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–5
Air Source Select Switch
Press this button to select either Fresh Air Intake or CIRC
(inside air circulation). There is an indicator light inside the
button. This light indicates that the CIRC mode is “ON”.
Fresh Air Intake is the default setting for both DEFROST
and FOOT/DEFROST.
Fan Control Switch
This switch controls the blower motor speed to regulate
the amount of air delivered to the defrost, foot, and
ventilation ducts:
1.L0
2.M1
3.M2
4.M3
5.HI
C01RW001
Temperature Control Switch
When the temperature control switch is in the “18°C
(65°F)” position, the air mix door closes to block the air
flow to the heater core.
When the temperature control switch is in the “32°C
(90°F)” position, the air mix door opens to allow air to pass
through the heater core and heat the passenger
compartment.
Selecting the desired temperature will control the air flow
through the heater core, allowing control of the cabin
temperature.
Page 32
1A–6
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Heater Unit and Associated Parts
Heater Unit
Legend
(1) Instrument Panel Assembly
(2) Cross Beam Assembly
(3) Instrument Panel Bracket W/Suspension
Control Unit
(4) Ventilation Lower Duct
Removal
1.Disconnect the battery ground cable.
2.Drain the engine coolant.
3.Discharge and recover refrigerant (with air
conditioning).
B Refer to
4.Remove the Instrument panel assembly.
B Refer to
Accessories section.
5.Remove instrument panel bracket w/suspension
control unit.
B Refer to
Accessories section.
6.Cross Beam Assembly.
B Refer to
Accessories section.
Refrigerant Recovery in this section.
Instrument Panel Assembly in Body and
Cross Beam Assembly in Body and
Cross Beam Assembly in Body and
840R200008
(5) Rear Heater Duct
(6) Evaporator Assembly
(7) Heater Unit Assembly
(8) Heater Hose
(9) Power Transistor Connector
7.Disconnect power transistor connector.
8.Remove evaporator assembly.
B Refer to
9.Remove ventilation lower duct.
10.Remove rear heater duct.
B Remove foot rest, carpet and 3 clips.
11.Disconnect mode/mix actuator connector.
12.Remove heater unit assembly.
B Disconnect heater hoses at heater unit.
Evaporator Assembly in this section.
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.
Page 33
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
2.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
1A–7
Legend
(1) Heater Core
(2) Case (Temperature Control)
(3) Heater Unit
(4) Mix Actuator
860R200001
(5) Mode Door
(6) Duct
(7) Mode Actuator
(8) Case (Mode Control)
Page 34
1A–8
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Removal
1.Disconnect the battery ground cable.
2.Drain the engine coolant.
3.Discharge and recover refrigerant (with air
conditioning).
B Refer to
4.Remove heater unit.
B Refer to
5.Remove duct.
6.Remove mix actuator.
7.Remove mode actuator.
8.Remove case (Mode control) and do not remove link
unit at this step.
9. Remove case (Temperature control) separate two
halves of core case.
Refrigerant Recovery in this section.
Heater Unit in this section.
11.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.
10.Remove heater core (1).
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1.Check that each mode door operates properly.
860RS002
860RS003
Page 35
Disassembled View
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Heater Mode Control Link Unit
1A–9
Legend
(1) Case (Mode Control)
(2) Heater Unit
(3) Mode Sub-lever
(4) Clip
Removal
1.Disconnect the battery ground cable.
2.Drain engine coolant.
3.Discharge and recover refrigerant (with air
conditioning)
B Refer to
4.Remove heater unit.
B Refer to
5.Remove mode actuator.
6.Remove the case (Mode control) from heater unit.
7.Remove washer and the mode main lever.
8.Remove rod.
9.Press the tab of the sub-lever inward, and take out the
sub-lever.
Refrigerant Recovery in this section.
Heater Unit in this section.
860R200002
(5) Door Lever
(6) Rod
(7) Mode Actuator
(8) Washer and Mode Main Lever
860RS006
Page 36
1A–10
10.Pull out the door lever while raising up the catch of the
11.Remove clip.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
door lever.
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.
Page 37
Heater Temperature Control Link Unit
Disassembled View
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–11
Legend
(1) Case (Temperature control)
(2) Door Lever
(3) Clip
(4) Rod
Removal
1.Disconnect the battery ground cable.
2.Drain engine coolant.
3.Discharge and recover refrigerant (with air
conditioning).
B Refer to
4.Remove heater unit.
B Refer to
5.Remove mix actuator.
6.Remove the case (Temperature control) from the
heater unit.
7.Remove rod.
8.Remove sub-lever.
9.Pull out the door lever while raising up the catch of the
door lever.
10.Remove clip.
Refrigerant Recovery in this section.
Heater Unit in this section.
860R200003
(5) Clip
(6) Sub-lever
(7) Mix Actuator
(8) Heater Unit
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.
Page 38
1A–12
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Blower Assembly
Blower Assembly and Associated Parts
Legend
(1) Instrument Panel Assembly
(2) Blower Assembly
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant (with air
conditioning).
B Refer to
3.Remove instrument panel assembly.
B Refer to
Accessories section.
4.Disconnect power transistor connector.
5.Remove evaporator assembly.
B Refer to
Refrigerant Recovery in this section.
Instrument Panel Assembly in Body and
Evaporator Assembly in this section.
873R200004
(3) Evaporator Assembly
(4) Heater Unit
6.Disconnect blower motor/intake actuator connector.
7.Remove blower assembly.
Installation
To install, follow the removal steps in the reverse order.
Page 39
Disassembled View
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Blower Link Unit and / or Mode door
1A–13
Legend
(1) Blower Assembly
(2) Upper Case
(3) Mode Door
(4) Lower Case
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant (with air
conditioning).
B Refer to
3.Remove blower assembly.
B Refer to
4.Remove intake actuator.
5.Remove max high relay.
6.Remove lower case.
7. Separate the upper case and slit the lining parting
face with a knife.
Refrigerant Recovery in this section.
Blower Assembly in this section.
873R200001
(5) Max High Relay
(6) Intake Actuator
(7) Sub Lever
(8) Door Lever
873RS002
Page 40
1A–14
8.Pull out the mode door while raising up the catch of
9.Remove sub-lever.
10.Remove door lever.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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.
Page 41
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Blower Motor
Blower Motor and Associated Parts
1A–15
Legend
(1) Blower Motor Connector
(2) Blower Motor Assembly
(3) Clip
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.
873RS004
(4) Fan
(5) Blower Motor
(6) Attaching Screw
Installation
To install, follow the removal steps in the reverse order.
Page 42
1A–16
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Rear Heater Duct, Defroster Nozzle and Ventilation Duct
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
Legend
(1) Defroster Nozzle
(2) Cross Beam Assembly
(3) Center Ventilation Duct and Side Defroster
Duct
Removal
1.Disconnect the battery ground cable.
2.Remove instrument panel assembly.
B Refer to
Accessories section.
3. Remove center ventilation duct and side defroster
duct.
B Remove 5 screws.
Instrument Panel Assembly in Body and
840R200009
(4) Instrument Panel Bracket W/Suspension
Control Unit
(5) Instrument Panel Assembly
(6) Rear Heater Duct
(7) Ventilation Lower Duct
4.Remove instrument panel brackets w/suspension
control unit.
B Refer to
Accessories section.
5.Remove cross beam assembly.
B Refer to
Accessories section.
6.Remove ventilation lower duct.
Cross Beam Assembly in Body and
Cross Beam Assembly in Body and
Page 43
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
7.Remove rear heater duct.
B Remove foot rest carpet and 3 clips.
8.Remove defroster nozzle.
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.
1A–17
Page 44
1A–18
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Air Conditioning System
General Description
Air Conditioning Refrigerant Cycle Construction
Legend
(1) Duct Sensor
(2) Evaporator Core
(3) Evaporator Assembly
(4) Temperature Sensor
(5) Blower Motor
(6) Expansion Valve
(7) Pressure Switch
(8) Receiver/Drier
The refrigeration cycle includes the following four
processes as the refrigerant changes repeatedly from
liquid to gas and back to liquid while circulating.
C01RY00013
(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
Page 45
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–19
Evaporation
The refrigerant is changed from a liquid to a gas inside the
evaporator. The refrigerant mist that enters the
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.
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.
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 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
clutch repair procedure.
Compressor in this section for magnetic
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:
871RX026
Legend
(1) Magnetic Clutch
(2) Magnetic Clutch Connector
(3) Compressor
Condenser
The condenser assembly 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.
Page 46
1A–20
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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.
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.
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.
Triple Pressure Switch (V6, A/T)
Triple pressure switch 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
Low-pressure
control
High-pressure
control
ON
(kPa/psi)
206.0±30.0
(29.8±4.3)
2353.6±196.1
(341.3±28.4)
OFF
(kPa/psi)
176.5±24.5
(25.6±3.6)
2942.0±196.1
(426.6±28.4)
875R200015
Legend
(1) Pressure Switch
(2) Receiver Drier
(3) Condenser & Receiver Tank Assembly
(4) Condenser Fan
Receiver / Drier
The receiver/drier performs four functions:
B 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.
B 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.
B The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.
Condenser fan
Medium-pressure
control
ON
(kPa/psi)
1471.0±98.1
(213.3±14.2)
OFF
(kPa/psi)
1078.7±117.7
(156.4±17.1)
Expansion Valve
This expansion valve 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.
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.
Page 47
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–21
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure decreases, resulting in insufficient cooling
capacity of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.
874R200003
Legend
(1) Expansion Valve
(2) Evaporator Assembly
The evaporator core with a laminate louver fin is a
single-sided tank type where only one tank is provided
under the core.
874RY00015
Legend
(1) Evaporator Core
(2) Expansion Valve
Evaporator
The evaporator cools and dehumidifies the air before the
air enters the passenger compartment. High-pressure
liquid refrigerant flows through the expansion valve into
the low-pressure area of the evaporator. The heat in the
air passing through the evaporator core 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.
Page 48
1A–22
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Duct Sensor
The duct sensor is the sensor to detect temperature
change of the side of evaporator blower coming by fresh
recirculation of intake door or “on” “off” of compressor.
The temperature is converted to resistant rate.
And it works as thermostat to control to prevent freezing
of evaporator.
This sensor is installed in the upper case of evaporator.
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.
Legend
(1) Sensor Part
(2) Evaporator Core
(3) Duct Sensor Assembly
(4) Evaporator Assembly
874R200010
852RS001
Legend
(1) Reinforcement Layer (Polyester)
(2) External Rubber Layer
(3) Internal Rubber Layer
(4) Resin Layer (Nylon)
Page 49
Air Conditioning Parts
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–23
Legend
(1) Liquid Line (High-Pressure Pipe)
(2) Clip
(3) Discharge Line (High-Pressure Hose)
(4) Pressure Switch
(5) Receiver/Drier
852R200008
(6) Condenser Air Guide
(7) Condenser & Receiver Tank Assembly
(8) Condenser Fan
(9) Compressor
(10) Suction Line (Low-Pressure Hose)
(1 1) Evaporator Assembly
Page 50
1A–24
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
Air Conditioning Cycle Diagnosis
Condition Possible cause Correction
No cooling or insufficient cooling.
Insufficient velocity of cooling air.
Magnetic clutch does not run. Refer to
Compressor is not rotating properly.
Drive belt is loose or broken.
Compressor is not rotating properly.
Magnetic clutch face is not clean and
slips.
Compressor is not rotating properly.
Incorrect clearance between
magnetic drive plate and pulley.
Compressor is not rotating properly.
Compressor oil leaks from the shaft
seal or shell.
Compressor is not rotating properly.
Compressor is seized.
Insufficient or excessive charge of
refrigerant.
Leaks in the refrigerant system. Check the refrigerant system for
Condenser is clogged or insufficient
radiation.
Temperature control link unit of the
heat unit is defective.
Unsteady operation due to a foreign
substance in the expansion valve.
Poor operation of the electronic
thermostat.
Evaporator clogged or frosted. Check the evaporator core and
Air leaking from the cooling unit or air
duct.
Blower motor does not rotate
properly.
“Magnetic Clutch Diagnosis”
in this section.
Adjust the drive belt to the specified
tension or replace the drive belt.
Clean the magnetic clutch face or
replace.
Adjust the clearance. Refer to
Compressor in this section.
Replace the compressor
Replace the compressor
Discharge and recover the
refrigerant. Recharge to the
specified amount.
leaks and repair as necessary.
Discharge and recover the
refrigerant. Recharge to the
specified amount.
Clean the condenser or replace as
necessary.
Repair the link unit.
Replace the expansion valve.
Check the electronic thermostat and
replace as necessary.
replace or clean the core.
Check the evaporator and duct
connection, then repair as
necessary.
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.
Page 51
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:
B Run the engine at idle
B Air conditioning switch is “ON”
B Run the blower motor at “HIGH” position (5 positions)
B Temperature control set to “MAX COLD” (65°F)
B Air source selector at “CIRC”
B Open the engine hood
B Close all the doors
Normal Pressure:
B At ambient temperature: approx. 25–30°C
(77–86°F).
B At low-pressure side: approx. 147.1–294.2 kPa
(21.3–42.7 psi).
B 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.
1A–25
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
Page 52
1A–26
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Connect The Manifold Gauge
Low-pressure hose (LOW) — Suction side
High pressure hose (HI) — Discharge side
Legend
(1) Low Side
(2) High Side
901R100020
Page 53
Condition Possible cause Correction
Ab
h
around the com ressor refrigerant
Discharge (High Gauge) Pressure
normally Hig
Discharge (High Gauge) Pressure
Abnormally High.
Insufficient cooling.
Discharge (High Gauge) Pressure
Abnormally High.
High pressure gauge drop. (After
stopping A/C, the pressure drops
approx. 196 kPa (28 psi) quickly)
Discharge (High Gauge) Pressure
Abnormally Low.
Insufficient cooling
Discharge (High Gauge) Pressure
Abnormally Low.
Low pressure gauge indicates
vacuum.
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.
Discharge (High Gauge) Pressure
Abnormally Low.
High and low pressure gauge
balanced quickly. (After turned off
A/C)
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser clogged or dirty. Clean the condenser fins
Cooling fan does not operate
properly.
Excessive refrigerant in system. Discharge and recover refrigerant.
Air in system. Evacuate and charge refrigerant
Insufficient refrigerant in system. Check for leaks. Discharge and
Clogged or defective expansion
valve.
Restriction caused by debris or
moisture in the receiver/drier.
Compressor seal defective Repair or replace the compressor.
Poor compression due to a defective
compressor gasket.
Check the cooling fan operation.
Recharge to specified amount.
system.
recover the refrigerant. Recharge to
the specified amount.
Replace the expansion valve.
Check system for restriction and
replace the receiver/drier.
Repair or replace the compressor.
1A–27
Suction (Low Gauge) Pressure
Abnormally High.
Low pressure gauge (Low pressure
gauge is lowered after condenser is
cooled by water.)
Suction (Low Gauge) Pressure
Abnormally High.
Low pressure hose temperature.
(Low pressure hose temperature
p
line connector is lower than around
evaporator.)
Suction (Low Gauge) Pressure
Abnormally High.
High and low pressure gauge
balanced quickly. (After turned off
A/C)
Suction (Low Gauge) Pressure
Abnormally Low.
Insufficient cooling.
Suction (Low Gauge) Pressure
Abnormally Low.
Frost on the expansion valve inlet
line
Excessive refrigerant in system. Discharge and recover refrigerant
Recharge to specified amount.
Unsatisfactory valve operation due
to defective temperature sensor of
expansion valve.
Expansion valve opens too long. Replace the expansion valve.
Compressor gasket is defective. Repair or replace the compressor.
Insufficient refrigerant in system. Check for leaks. Discharge and
Expansion valve clogged. Replace the expansion valve.
Replace the expansion valve.
recover the refrigerant. Recharge to
specified amount.
Page 54
1A–28
Suction (Low Gauge) Pressure
Abnormally Low
Receiver/drier inlet and outlet
refrigerant line temperature. (A
distinct difference in temperature
develops.)
Suction (Low Gauge) Pressure
Abnormally Low.
Expansion valve outlet refrigerant
line. (Not cold and low pressure
gauge indicates vacuum.)
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.
Suction (Low Gauge) Pressure
Abnormally Low.
Evaporator core is frozen.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
High.
Insufficient cooling.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
High.
Suction (Low) pressure hose (Not
cold).
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
Low.
Insufficient cooling
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condition CorrectionPossible cause
Receiver/Drier clogged. Replace the receiver/drier.
Expansion valve temperature sensor
is defective.
Clogged or blocked refrigerant line. Replace refrigerant line.
Thermo switch defective. Replace thermo switch.
Excessive refrigerant in system. Discharge and recover the
Condenser clogged or dirty. Clean the condenser fin.
Air in system. Evacuate and charge refrigerant.
Insufficient refrigerant in system. Check for leaks. Discharge and
Replace the expansion valve.
refrigerant, the Recharge to the
specified amount.
recover refrigerant. Recharge to
specified amount.
A/C — Air Conditioning
Page 55
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.
1A–29
Condition Possible cause Correction
Condenser fan does not run.
D08R200041
– Refer to “Chart A”.
– Refer to “Chart B”.
Page 56
1A–30
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart “A” Condenser Fan Does Not Run
Step Action Yes No
1 Are 30A fuse normal? Go to
2 Is relay (X-16) normal? Go to
3 Is pressure switch normal?
4 Is fan motor normal? Go to
5 1. Disconnect condenser fan relay (X-16).
2. Check to see if battery voltage is present at the chassis side
relay terminal NO. X16-5.
Is there a battery voltage?
6 1. Reconnect condenser fan relay (X-16).
2. Check to see if battery voltage is present at chassis side
connector terminal No.C21-3.
Is there a battery voltage?
7 Check to see if continuity between chassis side relay terminal
No.X16-2 and the chassis side connector terminal No.C21-4.
Is there a continuity?
8 Check to see if continuity between chassis side connector
terminal No. C16-1 and chassis side relay terminal No.X16-1.
Is there a continuity?
Poor ground or
between chassis
side connector
No.C16-2) and
Step 2
Step 3
Go to
Step 4
Step 5
Go to
Step 6
Go to
Step 7
Go to
Step 8
open circuit
terminal
No.X16-4 (or
body ground
(No.C10).
Replace
Replace
Switch defective
or insufficient
refrigerant.
Replace
Repair open
circuit between
Condenser Fan
fuse (30A) and
No.X16-5.
Repair open
circuit between
fuse (10A) and
C21-3.
Repair open
circuit.
Repair open
circuit.
Chart “B” Condenser Fan Does Not Stop
Step Action Yes No
1 1. Disconnect the triple pressure connector.
Does condenser fan stop?
Replace the triple
pressure switch.
Replace the
condenser fan
relay.
Page 57
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Air Conditioning System
1A–31
Individual Inspection
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.
875RY00010
Condenser Fan
1.Disconnect the condenser fan connector.
2.Connect the battery positive terminal to the
condenser fan side connector terminal No.C-16-1
and negative to the No.C-16-2.
3.Check that condenser fan is rotating correctly.
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:
B Keep your work area clean.
B Always wear safety goggles and protective gloves
when working on refrigerant systems.
B Beware of the danger of carbon monoxide fumes
caused by running the engine.
B Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
B Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
B When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
B 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.
B When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
B Always install new O-rings whenever a connection is
disassembled.
B Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
B 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
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.
4
: HFC-134a Refrigerant
875R200002
Page 58
1A–32
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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.
852R200001
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.
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.
850RW002
850RW004
Page 59
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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?
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.
Repair refrigerant
system.
Go to
Compressor
operation to be
confirmed.
1A–33
Step 2
Inspection Steps
Check the components of air–conditioner to see if there
occurs any refrigerant leak along the flow of refrigerant.
NOTE:
B To avoid refrigerant leak detection error, avoid
refrigerant vapor and cigarette smoke presence when
performing the inspection. Also, select a location that
is not susceptible to wind, in case refrigerant vapor is
found it will not be blown off.
B 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.
B It is possible to visually check the leak from inside the
cooling unit. Follow the method below when
performing the inspection. Remove the drain hose or
resistor of the cooling unit, and insert a leak detector
to see if there are signs of leakage.
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
B Pipe connection
B Sealing section of shaft
B Mating section or cylinder
Condenser
B Pipe connection
B Welds of condenser body
Receiver driver
B Pipe connection
B Attaching section of pressure switch
B Section around the sight glass
Evaporator unit (cooling unit)
B Pipe connections
B Connections of expansion valve
B Brazed sections of evaporator
NOTE:
B 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
B Pipe connection
B Caulking section of the hose
B Hose (cracks, pinholes, flaws)
Pipe
B Pipe connection
B Pipe (cracks, flaws)
Charge valve
NOTE:
B 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.
B Use two wrenches to prevent twisting and damage
to the line.
B Do not over tighten.
2.Perform a leak test on the refrigerant line fitting.
Page 60
1A–34
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
3.If the leak is still present, discharge and recover the
refrigerant from the system.
4.Replace the O-rings.
B O-rings cannot be reused. Always replace with new
ones.
B Be sure to apply the specified compressor oil to the
new O-rings.
5. Retighten the refrigerant line fitting to the specified
torque.
B 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.
B Cap the open connections at once.
4.Connect the new hose assembly.
B Use two wrenches to prevent twisting or damage to
the hose fitting.
B Tighten the hose fitting to the specified torque.
5.Evacuate, charge and test the system.
WARNING:
B SHOULD HFC-134A CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.
B 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.
B 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
4
(or equivalent) as shown below.
ACR
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.
B Always wear safety goggles and protective gloves.
B Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
B 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.
B If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
passenger compartment.
B 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.
B HFC-134a and R-12 should never be mixed as their
compositions are not the same.
B HFC-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oil and, therefore, should
be handled more carefully.
B Keep HFC-134a containers stored below 40°C
(104°F).
901R100022
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.
Page 61
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–35
Refrigerant Recycling
Recycle the refrigerant recovered by J-39500
4
:HFC-134a Refrigerant Recovery / Recycling /
(ACR
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
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
4
B ACR
(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer’s instruction.
901R100023
Legend
(1) Low Side
(2) High Side
NOTE: Explained below is a method using a vacuum
4
pump. Refer to the ACR
instructions when evacuating the system with a ACR
(or equivalent) manufacturer’s
4
(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.
B High-pressure valve (HI) — Discharge-side.
B 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.
B If the pressure changes, check the system for
leaks.
B If leaks occur, retighten the refrigerant line
connections and repeat the evacuation steps.
901R100022
Legend
(1) Low Side
(2) High Side
B 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.
Page 62
1A–36
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.
901R100021
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:
B Charge the system with approximately 200 g
(0.44 lbs) of HFC-134a.
B Make sure the high pressure valve of the manifold
gauge is closed.
B Check to ensure that the degree of pressure does
not change.
B Check for refrigerant leaks by using a HFC-134a
leak detector.
B 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.
B Charge the refrigerant until the scale reading
decreases by the amount of the charge specified.
Specified amount: 700 g (1.54 lbs)
B 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.
Page 63
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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 switch to “CIRC”, set the
temperature switch to the full cool position.
4. Check the high and low pressure of the manifold
gauge.
B Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:
B The ambient temperature should be between
25–30°C (77–86°F).
B The pressure guideline for the high-pressure side is
approximately 1372.9–1863.3 kPa (199.1–270.2
psi).
B The pressure guideline for the low-pressure side is
approximately 147.1–294.2 kPa (21.3–42.7 psi).
B If an abnormal pressure is found, refer to
The Refrigerant System With Manifold Gauge in
this section.
5.Put your hand in front of the air outlet and move the
temperature switch of the control panel to different
positions. Check if the outlet temperature changes as
selected by the control switch.
Checking
1A–37
Page 64
1A–38
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor Assembly
Compressor Assembly and Associated Parts (6VE1)
Legend
(1) Compressor Bracket
(2) Magnetic Clutch Harness Connector
(3) Compressor
(4) O-ring
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant
B Refer to
3.Disconnect magnetic clutch harness connector.
Refrigerant Recovery in this section.
852R100002
(5) To Evaporator
(6) Suction Line (Low-Pressure Hose)
(7) Discharge Line (High-Pressure Hose)
(8) To Condenser
(9) Serpentine Belt
Page 65
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–39
4.Remove serpentine belt.
B Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
Legend
(1) Auto Tensioner
(2) Idle Pulley
(3) Cooling Fan Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
5.Disconnect refrigerant line connector.
B 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.
850RY00005
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.
B Take care not to let the compressor oil flow out.
B Inspect O-rings and replace if necessary.
871RX033
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
)
Installation
1.Install compressor.
B Tighten the compressor fixing bolts to the specified
torque.
Torque: 19 N•m (14 lb•ft)
2.Connect refrigerant line connector.
B Tighten the refrigerant line connector fixing bolts to
the specified torque.
Torque: 15 N•m (11 lb•ft)
B O-rings cannot be reused. Always replace with new
ones.
B Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
3.Install serpentine belt.
B Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
871RX035
Page 66
1A–40
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser Assembly
Condenser Assembly and Associated Parts
Legend
(1) Refrigerant Line
(2) Pressure Switch Connector
(3) Condenser & Receiver Tank Assembly
(4) Condenser Air Guide
(5) Front Bumper Assembly
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant.
B Refer to
3.Remove front bumper assembly.
B Refer to the
section.
Refrigerant Recovery in this section.
Front Bumper in Body Structure
875R200022
(6) Engine Hood Front End W/Engine Hood Lock
& Bumper Stay
(7) Front Center Bumper Retainer
(8) Front Side Bumper Retainer (RH)
(9) Head Light (R/LH)
(10) Front Side Turn Signal Light (R/LH)
(11) Horn (R/LH)
4.Remove front center bumper retainer.
5.Remove front side bumper retainer (RH).
6.Remove condenser air guide.
7.Remove engine hood front end with engine hood lock
& bumper stay.
B Apply setting mark to the engine hood lock fixing
position before removing it.
Page 67
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
8.Remove horn (R/LH).
9.Remove front side turn signal light (R/LH).
10.Remove head light (R/LH).
11.Disconnect pressure switch, ambient sensor and
condenser fan connector.
12.Disconnect refrigerant line.
B When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line.
13.Remove condenser & receiver tank assembly.
B Handle with care to prevent damaging the
condenser or radiator fin.
Installation
1.Install condenser & reciver tank assembly.
B If installing a new condenser, be sure to add 30cc
(1.0 fl. oz.) of new compressor oil to a new one.
B Tighten the condenser fixing bolts to the specified
torque.
Torque: 6 N•m (52 lb in)
2.Connect refrigerant line.
B Tighten the inlet line connector fixing bolt to the
specified torque.
Torque: 15 N•m (11 lb ft)
B Tighten the outlet line connector fixing bolt to the
specified torque.
Torque: 6 N•m (52 lb in)
B O-rings cannot be reused. Always replace with new
ones.
B Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
3.Connect pressure switch, ambient sensor and
condenser fan connector.
4.Install head light (R/LH).
5.Install front side turn signal light (R/LH).
6.Install horn (R/LH).
7.Install engine hood front end with engine hood lock &
bumper stay.
B Align the setting mark when installing.
8.Install condenser air guide.
9.Install front side bumper retainer (RH).
10.Install front center bumper retainer.
11.Install front bumper assembly.
1A–41
Page 68
1A–42
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser Fan Motor
Condenser Fan Motor and Associated Parts
Legend
(1) Condenser Fan Assembly
(2) Condenser Air Guide
(3) Front Bumper Assembly
Removal
1.Disconnect the battery ground cable.
2.Remove the front bumper assembly.
B Refer to the
section.
3.Remove the condenser air guide.
4.Remove the horn (RH).
5.Remove the condenser fan assembly.
B Disconnect the fan motor connector and remove
the 3 fixing bolts.
6.Remove the shroud.
B Remove the 3 fixing nuts.
B Loosen the condenser fixing nut and disconnect the
fan motor connector from bracket.
7.Remove the fan.
B Remove the fan fixing C-ring and plate.
8.Remove the condenser fan motor.
Front Bumper in Body Structure
875R200016
(4) Condenser Fan Motor
(5) Shroud
(6) Fan
(7) Horn (RH)
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.
Page 69
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Receiver / Drier
1A–43
Receiver / Drier and Associated Parts
875R200019
Legend
(1) Front Side Turn Signal Light (LH)
(2) Refrigerant Line
(3) Head Light (LH)
(4) Front Bumper Assembly
(5) Receiver / Drier
(6) Pressure Switch Connector
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.
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant.
B Refer to
3.Remove front bumper assembly.
B Refer to the
section.
4.Remove front side turn signal light (LH).
5.Remove head light (LH).
6.Disconnect pressure switch connector.
7.Disconnect refrigerant line.
B 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.
8.Remove receiver/drier.
B Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
Refrigerant Recovery in this section.
Front Bumper in Body Structure
Page 70
1A–44
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Pressure Switch
Pressure Switch and Associated Parts
875R200021
Legend
(1) Pressure Switch Connector
(2) Front Side Turn Signal Light (LH)
(3) Head Light (LH)
(4) Front Bumper Assembly
(5) Pressure Switch
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)
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant.
B Refer to
3.Remove the front bumper assembly.
B Refer to the
section.
4.Remove the front side turn signal light (LH).
5.Remove the head light (LH).
6.Disconnect pressure switch connector.
7.Disconnect pressure switch.
B 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.
“Refrigerant Recovery in this section.
Front Bumper in Body Structure
Page 71
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Evaporator Assembly
Evaporator Assembly and Associated Parts
1A–45
Legend
(1) Refrigerant Line
(2) Drain Hose
(3) Dash Side Trim Panel
(4) Power Transistor and Duct Sensor Connector
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant.
B Refer to
3.Remove glove box.
4.Disconnect power transistor (2) and duct sensor
connector (1).
5.Remove sill plate.
6.Remove dash side trim panel.
7.Remove passenger lower bracket.
8.Disconnect drain hose.
Refrigerant Recovery in this section.
874R200015
(5) Passenger Lower Bracket
(6) Sill Plate
(7) Evaporator Assembly
(8) Glove Box
874R200005
Page 72
1A–46
9.Disconnect drain hose.
10.Disconnect refrigerant line.
11.Remove evaporator assembly.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
B Use a back-up wrench when disconnecting and
reconnecting the refrigerant lines.
B 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.
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.
Torque: 25 N•m (18 lb ft)
3.Tighten the refrigerant inlet line to the specified
torque.
Torque: 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.
Page 73
Duct Sensor, Evaporator Core and/or Expansion Valve
Disassembled View
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–47
Legend
(1) Lining
(2) Expansion Valve
(3) O-ring
(4) Evaporator Assembly
(5) Lower Case
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant.
B Refer to
3.Remove evaporator assembly.
B Refer to
4.Remove the duct 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.
B Slit the case parting face with a knife since the lining
is separated when removing the evaporator.
Refrigerant Recovery in this section.
Evaporator Assembly in this section.
874R200012
(6) Clip
(7) Attaching Screw
(8) Evaporator Core
(9) Duct Sensor
(10) Upper Case
874RS006
Page 74
1A–48
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
B Lift to remove the upper case.
9.Remove evaporator core.
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
duct sensor (2) to the evaporator core (1) specified
position with the clip in the illustration.
874R200007
10.Remove expansion valve.
B Tear off the insulator carefully .
B Remove the sensor fixing clip.
B Use a back-up wrench when disconnecting all
refrigerant pipes.
874R200008
874RY00016
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.To 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.
Page 75
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Refrigerant Line
Refrigerant Line and Associated Parts
1A–49
Legend
(1) Clip and Clamp
(2) Liquid Line (High-Pressure Pipe)
(3) Discharge Line (High-Pressure Hose)
(4) Condenser Air Guide
Removal
1.Disconnect the battery ground cable.
2.Discharge and recover refrigerant.
B Refer to
3.Remove the front bumper assembly.
B Refer to the
section.
4.Remove the condenser air guide.
Refrigerant Recovery in this section.
Front Bumper in Body Structure
852R200007
(5) Front Bumper Assembly
(6) Front Side Turn Signal Light (LH)
(7) Head Light (LH)
(8) Suction Line (Low-Pressure Pipe)
5.Remove the front side turn signal light (LH).
6.Remove the head light (LH).
7.Remove clip and clamp.
8.Disconnect liquid line (High-pressure pipe).
9.Disconnect suction line (Low-pressure pipe) using a
back-up wrench.
10.Disconnect suction line (Low-pressure hose) using a
back-up wrench.
Page 76
1A–50
11.Disconnect discharge line (High-pressure hose)
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
using a back-up wrench.
B Use a backup wrench when disconnecting and
reconnecting the refrigerant lines.
B 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
Specifications in this section.
Main Data and Specifications for Torque
Page 77
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Main Data And Specifications
General Specifications
Heater Unit
Temperature control Reheat air mix system
Capacity 4.3 kw (3700 Kcal./hr.)
Air flow 280 m#/h
HEATER CORE
Type Plate and corrugate fin
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 ASSEMBLY
Capacity 4.8 kw (4100 Kcal./hr.)
Air flow 430 m#/hr
EVAPORATOR CORE
Type Al-laminate louver fin type
Element dimension 235 mm (9.3 in.) × 224 mm (8.8 in.) × 60 mm (2.4 in.)
EXPANSION V ALVE
Type Internal pressure equalizer type
CONDENSER
Type Parallel flow type
Radiation performance 14.8 kw (12,700 Kcal./hr.)
CONDENSER FAN
Air flow 850 m3/h
Fan size W261
RECEIVER/DRIER
Type Assembly includes triple pressure switch
Internal volume 300 cc (10 fl.oz.)
PRESSURE SWITCH
Type
REFRIGERANT
Type HFC-134a
Specified amount 700 g (1.54 lbs.)
Triple pressure switch
Low pressure control
ON: 206.0±30.0 kPa (29.8±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±117.7 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)
1A–51
Page 78
1A–52
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Torque Specifications
852R200009
874R200013
Page 79
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor
1A–53
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
Page 80
1A–54
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
Condition Possible cause Correction
Noise from compression
Noise from magnetic clutch
Insufficient cooling
Not rotating
Oil and/or gas leakage
Defective rotor/piston Replace compressor/cylinder and
shaft assembly
Defective shaft Replace compressor/cylinder and
shaft assembly
Defective bearing Replace magnetic clutch
Defective clutch Replace magnetic clutch
Clearance between drive plate and
pulley not standard
Defective gasket Replace compressor/gasket
Defective rotor/reed valve Replace compressor/valve plate
Defective trigger valve/suction valve Replace compressor/suction valve
Defective rotor/piston Replace compressor/cylinder and
Defective shaft Replace compressor/cylinder and
Rotating parts seized due to
insufficient oil
Defective seal Replace compressor/shaft seal
Defective O-ring Replace
Adjust the clearance or replace
magnetic clutch
shaft assembly
shaft assembly
Replace compressor
Page 81
Magnetic Clutch Assembly (DKV-14G Type)
Parts Location View
Legend
(1) Drive Plate bolt
(2) Drive Plate
(3) Snap Ring
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
(4) Pulley Assembly
(5) Field Coil
(6) Shim (s)
(7) Lead Wire
1A–55
871RX025
Removal
1. Using drive plate holder J-33939 (1) to prevent the
drive plate from rotating, then remove the drive plate
bolt.
2.Remove drive plate by using drive plate puller
J-33944-A (2) and forcing screw J-33944-4 (1).
871RX023
3.Remove shim (s).
871RX029
Page 82
1A–56
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
4.Remove snap ring (1) by using snap ring pliers.
871RY00029
5.Remove pulley assembly by using pulley puller pilot
J-38424 (2), pulley puller J-8433 (1) and pulley puller
leg J-24092-2 (3).
6.Loosen screw and disconnect the field coil wire
connector.
871RY00030
7.Loosen three screws and remove the field coil.
871RY00033
871RY00034
Page 83
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–57
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.
Installation
1.Install field coil.
B Align the located portion (1) of the field coil and
compressor.
3.Install pulley assembly by using pulley installer
J-33940-A (2) and drive handle J-8092 (1).
871RY00032
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.
871RY00035
B 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.
871RY00031
Page 84
1A–58
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
7. Install drive plate bolt by using drive plate holder
J-33939 (1) to prevent the drive plate from rotating.
871RX029
B Tighten the drive plate bolt to the specified torque.
Torque: 13 N·m (113 lb in)
B After tightening the drive plate bolt, check to be sure
the pulley rotates smoothly.
B Check to be sure that the clutch clearance is
between 0.3-0.6 mm (0.01-0.02 in.)
871RY00028
Legend
(1) Dial Gauge
(2) Pulley Assembly
(3) Field Coil Wire Connector
B If necessary, install adjusting shim(s).
B Adjusting shims are available in the following
thickness.
Thickness
B 0.1 mm (0.0039 in.)
B 0.3 mm (0.0118 in.)
B 0.5 mm (0.0197 in.)
Page 85
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor Oil
1A–59
Oil Specification
B 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.
B Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for the
model of compressor.
B Always use HFC-134a Vane Rotary Type
Compressor Oil (AIPDN Part No.2-90188-301-0)
Handling of Oil
B The oil should be free from moisture, dust, metal
powder, etc.
B Do not mix with other oil.
B 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.)
B 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)
more than 90cc (3.0
fl.oz)
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.
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)
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
(Collected Amount)
same as collected
amount
same as collected
amount
Page 86
1A–60
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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)
less than 90 cc (3.0 fl.oz) Same as drained
more than 90 cc (3.0
fl.oz)
6.Evacuate, charge and perform the oil return
operation.
7.Check the system operation.
(Draining amount of oil
from new compressor)
amount
90 cc (3.0 fl.oz)
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)
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)
(Amount of Oil)
10 cc (0.3 fl. oz.)
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:
B The capacity of the oil has increased.
B The oil has changed to red.
B 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.
Page 87
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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), 700 g (1.54 lbs.)
Shaft seal Lip type
Weight 3.5 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 3.0 kg (6.6 lbs.)
1A–61
Page 88
1A–62
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Torque Specifications
871RX028
Page 89
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Special Tools
1A–63
ILLUSTRATION
TOOL NO.
TOOL NAME
J-33939
Drive plate holder
J-33944-A
Drive plate puller
J-33944-4
Forcing screw
ILLUSTRATION
TOOL NO.
TOOL NAME
J-33940-A
Pulley installer
J-8092
Drive handle
J-38424
Pulley puller pilot
J-8433
Pulley puller
J-24092-2
Pulley puller leg
Page 90
1A–64
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Automatic Air Conditioning System
General Description
Using a variety of sensors, this automatic air conditioner
accurately senses outside air temperature, solar
radiation quantity , evaporator’s blowing temperature, and
interior temperature, then enters these data to the
automatic air conditioner control unit (equipped with the
built-in micro-computer). The data provided to the control
unit enables to automatically control blow temperature
and blow air quantity, turn on or off the compressor and
switch the blow port as well as switching between the
fresh air intake and interior air circulation.
Resetting the automatic function allows you to switch to
the manual control mode.
The self-diagnoisis function of the automatic air
conditioner control unit (with the built-in micro-computer)
allows the unit to access and diagnose a failed part easier
and quicker.
Automatic Air Conditioner Parts Configuration
Legend
(1) In Car Sensor
(2) Sun Sensor
(3) Ambient Sensor
(4) Intake Actuator
(5) Blower Unit
(6) Max – High Relay
(7) Display
865R200050
(8) Audio & Switch Assembly
(9) Evaporator Assembly
(10) Duct Sensor
(11) Mix Actuator
(12) Heater Unit
(13) Automatic Air Conditioner Control Unit
(14) Mode Actuator
Page 91
Circuit Diagram
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–65
D01R200010
Page 92
1A–66
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
D01R200011
Page 93
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–67
D01R200003
Page 94
1A–68
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
D01R200004
Page 95
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–69
D01R200009
Page 96
1A–70
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Functions and Features
Automatic air conditioning control unit
The control unit features a prominent control and display
panel that clearly shows air conditioner operational
settings (delivered air volume, air outlet location,
inside/outside air circulation, and set temperature).
Desired temperature can be set in –17°C (1°F)
increments. The current setting appears on the digital
display.
Automatic temperature control
Vehicle interior temperature is maintained at the set level.
It is unaffected by changes in vehicle speed, outside air
temperature, and number of passengers.
Maximum cooling and heating
Moving the switch to the 18°C (65°F) position provides
maximum cooling. Moving the switch to the 32°C (90°F)
position provides maximum heating.
Automatic air flow control
Air flow is automatically and precisely regulated in
response to set temperature change and/or changes in
heater unit mixing door aperture.
Automatic air outlet selection
Appropriate air outlets (VENT, BE-LEVEL, FOOT, or
DEF) are selected in response to changes in outlet
temperatures. The mode switch permits manual selection
of the desired air outlet.
Air source (Fresh air intake from outside the
vehicle or recirculation of the air inside the vehicle)
selection
Automatic switching between outside air (FRESH),
recirculated inside air (RECIRC), or a combination of the
two (MIX) occurs in response to changes in outlet
temperatures.The intake switch permits manual
selection of the air source (FRESH or RECIRC). Mixing
of the two sources is not possible during manual
operation. When the defrost mode switch (DEF) is
pressed, the system automatically switches to outside air
intake.
Cooler start-up control
When the vehicle is parked in a hot area for an extended
period of time, the evaporator becomes hot. When the
cooler is turned on, hot air is blown into the vehicle until
the evaporator cools down. The cooler start-up control
prevents blower operation until the evaporator is able to
provide cool air.
Heater start-up control
When the vehicle is parked in a cold area for an extended
period of time, the heater core becomes cold. When the
heater is turned on, cold air is blown into the vehicle until
the heater core heats up. The heater start-up control
prevents blower operation to the air outlets until the
heater core is able to provide warm air. Air is delivered
through the defrost outlets.
Solar radiation offset
The sun sensor uses a photodiode to precisely determine
the amount of solar radiation affecting the vehicle. The
cooler operates in response to this radiation to quickly
correct the vehicle interior temperature.
Switch position memory
Current switch positions are stored in memory when the
ignition switch is turned off. When the ignition switch is
turned on again, the switches automatically return to the
position they were in when the ignition switch was turned
off. This simplifies the restarting procedure.
Self-diagnosis function
The self-diagnosis switches on the control panel permit
easy system troubleshooting. Refer to “Self-Diagnosis”
later in this Section.
Page 97
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Automatic Air Conditioner Block Diagram
1A–71
F01R200004
Page 98
1A–72
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Control Panel Layout
Legend
(1) Temperature Control Switch
(2) Auto Switch
(3) DEF Mode Switch
(4) Rr DEF Mode Switch
865R200006
(5) Intake Switch
(6) Mode Switch
(7) Air Conditioning Switch
(8) Fan Switch
(9) Off Switch
Page 99
Air Control Functions
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–73
Legend
(1) DEF Door
(2) Air Mix Door
(3) Evaporator Core
(4) Fresh Air Intake
(5) Interior Air Intake
(6) Blower Unit
C01R200013
(7) Evaporator Unit
(8) Heater Core
(9) Heater Unit
(10) Sub Air Mix Door
(11) FOOT Door
(12) VENT Door
Page 100
1A–74
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Control Panel Switch Operation
Switch Name Panel Display Switch Operation
A
u
t
o
S
w
i
t
c
h
O
f
f
S
w
i
t
c
h
F
a
n
Y
·
B
S
w
i
t
c
h
M
o
d
e
S
w
i
t
c
h
During manual outside air intake (FRESH), pressing the AUTO
switch cancels manual outside air intake. The display panel shows
the current set temperature, the current air outlet(s), and the blower
speed. The intake switch LED shows the current air source. The
A/C switch LED is on.
Air volume, air outlet operation, and air source are controlled
automatically. The compressor is on.
During manual inside air recirculation (REC), pressing the AUTO
switch does not cancel inside air recirculation. The intake switch
LED is on.
When the OFF switch is pressed, the display panel clears except
for the air outlet indication. Blower and compressor operation stop.
The air source switches from automatic to outside air.
During manual inside air recirculation (REC), pressing the OFF
switch does not cancel inside air recirculation. The intake switch
LED is on.
When the fan switch is pressed, air outlet volume (fan speed) can
be manually controlled. Other control switches are unaffected. The
display panel clears AUTO indication.
1. FAN switch is pressed during automatic fan control (AUTO)
Fan control (AUTO)→Press Y fan switch→Fan speed increases
from automatic set speed to HI
Fan control (AUTO)→Press B fan switch→Fan speed decreases
from automatic set speed to LO
2. Fan switch is pressed when the fan is off.
Fan (OFF)→Press Y fan switch→The fan operates at LO speed
Fan (OFF)→Press B fan switch→The fan operates at LO speed
3. Fan switch is pressed when the fan is in manual operation.
Manual (LO)→Press Y fan switch→Manual operation
(LO)→ (M1)→(M2)→(M3)→(HI)
Manual (HI)→Press B fan switch→Manual operation
(HI)→(M3)→(M2)→(M1)→(LO)
Press the mode switch to manually select the air outlet(s). Each
time the switch is pressed, the air outlets change in the progression
shown below.
Mode switch (Automatic control of air
outlets)→VENT→BI-LEVEL→FOOT→DEF/FOOT
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