Isuzu Pick Up PICK UP 2000, Campo 2000, Trooper 2000 Workshop Manual

2000

WORKSHOP MANUAL

TROOPER

RODEO

AMIGO

TROOPER(UX)

CONTENTS

GENERAL INFORMA TION Section.0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

HEATING, VENTILA TION AND AIR CONDITIONING (HVAC) Section.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HVAC System 1A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING Section.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power–Assisted Steering System 2A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION Section.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Suspension 3C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Suspension 3D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel and Tire System 3E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVELINE/AXLE Section.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential (Rear) 4A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driveline Control System 4B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Shaft System 4C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Case 4D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKES Section.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Control System 5A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti–lock Brake System 5B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power-Assisted Brake System 5C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brakes 5D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE Section.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Charging System 6D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driveability and Emissions 6E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed Control System 6H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inducton 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION Section.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Transmission (4L30–E) 7A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Control System (4L30–E) 7A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission 7B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch 7C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION Section.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ligting System 8A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiper / Washer System 8B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entertainment 8C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring System 8D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Meter and Gauge 8E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Body Structure 8F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seats 8G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Security and Locks 8H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sunroof / Convertible Top 8I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior / Interior Trim 8J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESTRAINTS Section.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt System 9A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supplemental Restraint System (SRS) 9J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restraint Control System 9J1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL SYSTEM Section.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cruise Control System 10A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROOPER

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–10. . . . . . . . . . . . . . . . . . . . . . .

Standard Bolts Torque Specifications 0A–13. . . . . .

Abbreviations Charts 0A–14. . . . . . . . . . . . . . . . . . . .

Service Parts Identification Plate 0A–15. . . . . . . . . .

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 Bag.
This system is not to be serviced without consulting

the appropriate service information.
Consult Sections 9J1 and 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 panel.

2. A Code “J” or “K” for fifth digit of vehicle

Identification Number.

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 Detall

Arrow T ype Application

D Ambient/Clean air

flow

D Cool air flow

D Gas other than

ambient air

D Hot air flow

D Ambient air mixed

with another gas

D 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

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

905RY00002

F00RY00002

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.

F06RW001

Transmission Serial Number

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

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

240RW012

220RW084

Theft Prevention Standard

COMPONENT

The 11 major components listed below will be marked
with 17 digit V.I.N. 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 V.I.N. plate

0A-11 TRANSMISSION 2– Manual transmission

– Automatic transmission

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

V.I.N. plate

V.I.N. label

Anti Theft Stamping/Plate/Label

STAMPING/PLATE LABEL

INDICATION

PRODUCTION

SERVICE PARTS

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:
A. VIN plate locations for production.

B. Stamping locations for service parts.

Engine

Manual Transmission (AR–5)

901RW195

901RX021

Automatic Transmission (THM)

Body

GENERAL INFORMATION

0A–7

901RW197

Legend

(3) Engine Hood
(4) Front Door
(5) Rear Door

901RW113

(6) Fender
(7) Rear Quarfer Panel
(8) Front Bumper

0A–8

Body

GENERAL INFORMATION

Legend

(9) Back Door Left Side

901RW114

(10) Back Door Right Side

(11) Rear Bumper

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.

GENERAL INFORMATION

0A–9

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

901RY00057

0A–10

GENERAL INFORMATION

Lifting Instructions

CAUTION:

D 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.

D When jacking or lifting a vehicle at the frame side rail

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

Lifting Points and Supportable Point Locations

C00RW003

GENERAL INFORMATION

0A–11

Lifting Point; Front

D When using a floor jack, lift on the center of the skid

plate.

545RS001

Supportable Point; Front

D Position the chassis stands at the bottom of the frame

sidemember, behind the front wheel.

Lifting Point; Rear

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

case when lifting the vehicle.

420RS002

Supportable Point; Rear

D Position the chassis stands at the bottom of the frame

sidemember, just behind the trailing link bracket.

501RS003

501RW002

Legend

(1) Trailing Link Bracket

0A–12

GENERAL INFORMATION

Supportable Point; Rear

D Position the chassis stands at the bottom of the rear

axle case.

420RS001

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–13

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 (3—6)

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

77—115 N·m (56—85 lb ft)

72—107 N·m (53—79 lb ft)
104—157 N·m (77—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—711 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—114 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.

0A–14

GENERAL INFORMATION

Abbreviations Charts

List of automotive abbreviations which may be used
in this manual

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

Exh — Exhaust
° F — Degrees Fahrenheit
Fed — Federal (All States Except Calif.)
FF — Front Drive Front Engine
FL — Fusible Link
FLW — Fusible Link Wire
FP — Fuel Pump
FRT — Front
ft — Foot
FWD — Front Wheel Drive
4WD — Four Wheel Drive
4 x 4 — Four Wheel Drive
4 A/T — Four Speed Automatic Transmission/Transaxle
Gal — Gallon
GEN — Generator
GND — Ground
Gov — Governor
g — Gram
Harn — Harness
HC — Hydrocarbons
HD — Heavy Duty
Hg — Hydrargyrum (Mercury)
HiAlt — High Altitude
HO2S — Heated Oxygen Sensor
HVAC — Heater–Vent–Air–Conditioning
IAC — Idle Air Control
IAT — Intake Air Temperature
IC — Integrated Circuit / Ignition Control
ID — Identification / Inside Diameter
IGN — Ignition
INJ — Injection
IP — Instrument Panel
IPC — Instrument Panel Cluster
Int — Intake
ISC — Idle Speed Control
J/B — Junction Block
kg — Kilograms
km — Kilometers
km/h — Kilometer per Hour
kPa — Kilopascals
kV — Kilovolts (thousands of volts)
kW — Kilowatts
KS — Knock Sensor
L — Liter
lb ft — Foot Pounds
lb in — Inch Pounds
LF — Left Front
LH — Left Hand
LR —Left Rear
LS — Left Side
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

GENERAL INFORMATION

0A–15

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 — V acuum
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.

905RW007

TROOPER

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. . . .

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:

D to carry passengers and cargo within the limitations

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

D to be driven on reasonable road surfaces within legal

operating limits;

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

least several miles/kilometers;

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

ITEMS

REPLACE TIMING BELT Every 75,000 miles (120,000 km)
CHANGE ENGINE OIL AND OIL FIL TER Every 3,000 miles (4,800 km) or 3 months
CHANGE AUTOMATIC TRANSMISSION FLUID Every 20,000 miles (32,000 km)
CHANGE FRONT AND REAR AXLE OIL Every 15,000 miles (24,000 km)
CHANGE POWER STEERING FLUID Every 30,000 miles (48,000 km)

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

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

Recommended Thread Locking Agents 0B–12. . .

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

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:

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

outside temperature remaining below freezing.

D Extensive idling and/or low speed driving for long

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

D Operating on dusty, rough, muddy or salt spread

roads.

INTERVAL

0B–2

MAINTENANCE AND LUBRICATION

Mileage Only Items

Mileage/Months

MAINTENANCE AND LUBRICATION

0B–3

0B–4

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

0B–5

Explanation of Complete Vehicle Maintenance Schedule

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

Front and Rear Axle Lubricant
Replacement

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) or operation thereafter.

Manual Transmission Lubricant
Replacement

Replace the transmission lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000 miles (48,000 km) of operation thereafter.

Automatic Transmission Fluid
Replacement

Check the fluid leakage at 15,000 miles (24,000 km) and
30,000 miles (48,000 km) and after every 15,000 miles
(24,000 km) or operation thereafter.
Replace the transmission fluid at 120,000 miles (192,000
km) of operation thereafter.

Transfer Case Lubricant Replacement

Replace the transfer case lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000 miles (48,000 km) of operation thereafter.

Extension Lubricant Level Check (2WD
only)

Check oil level at 15,000 miles (24,000 km) and 30,000
miles (48,000 km) and after every 30,000 miles (48,000
km) or operation thereafter.

Air Cleaner Element Replacement

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

Spark Plug Replacement

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

Cooling System Service

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

Timing Belt Replacement

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

Valve Clearance Adjustment

Incorrect valve clearance will result in increased engine
noise and reduced engine output.
Retorque the camshaft bearing cap bolts before checking
and adjusting the valve clearance.
Check and adjust the valve clearance if noise occurs.

Tire Rotation

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

Front Wheel Bearings Lubricant
Replacement

Clean and repack the front wheel bearings at 30,000
miles (48,000 km) intervals.
Refer to FRONT DRIVING AXLE (SEC. 4C).

Radiator Core and Air Conditioning
Condenser Cleaning

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

Fluid Level Check

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

Engine oil level

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

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

Engine coolant level and condition

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

Windshield washer fluid level

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

Power steering system reservoir level

Check and keep at the proper level.

Brake master cylinder reservoir level

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

Hydraulic clutch system

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

0B–6

MAINTENANCE AND LUBRICATION

Battery fluid level

Check fluid level in the battery.

Fluid Leak Check

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

Engine Oil and Oil Filter Replacement

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

Engine Cooling System Inspection

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

Exhaust System Inspection

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

Fuel Cap, Fuel Lines, and Fuel Tank
Inspection

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

Drive Belt Inspection

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

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

Steering System Operation

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

Brake Systems Operation

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

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

Parking Brake and Transmission Park
Mechanism Operation

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

WARNING: BEFORE CHECKING THE STARTER
SAFETY SWITCH OPERA TION BELOW, BE SURE 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
(Automatic Transmission)

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

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

Starter Safety Switch Operation (Manual
Transmission)

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

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

Accelerator Linkage Lubrication

Lubricate the accelerator pedal fulcrum pin with chassis
grease.

Steering and Suspension Inspection

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

Body and Chassis Lubrication

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

Propeller Shaft Inspection and Lubrication

Except TOD model : yoke and universal joints with grease
containing MOS2 (disulfide molybdenum type grease) at
the interval shown in the Maintenance Schedule.
All models : check for play in normal direction of rotation of
sliding yoke and universal joints. Also check the propeller
shaft flange–to–pinion bolts for proper torque to 63 N•m
(46 lb ft) for front and rear propeller shaft.

MAINTENANCE AND LUBRICATION

0B–7

Auto Cruise Control Inspection

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

Clutch Lines and Hoses Inspection

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

Clutch Control Lubrication

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

Clutch Pedal Free Play Inspection

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

Accelerator Linkage Inspection

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

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.
Manual transmission Engine oil

Rear axle and front axle GL-5 gear lubricant (Standard differential)

Clutch system
a. Pivot points Engine oil
b. Clutch fork joint Chassis grease
c. Master cylinder DOT-3 hydraulic brake fluid
Hood latch assembly
a. Pivots and spring anchor Engine oil
b. Release pawl Chassis grease
Hood and door hinges Engine oil
Chassis lubrication Chassis grease
Parking brake cables Chassis grease
Front wheel bearings Wheel bearing grease
Shift on the fly system GL-5 gear lubricant
Transfer Case (Except TOD and 2WD model) SAE40 (Areas where ambient temperatures of 32°C

TOD system DEXRON -III Automatic transmission fluid.
Extension assembly DEXRON -III Automatic transmission fluid.
Propeller shafts (Except TOD model) Grease containing MoS2 or multipurpose type grease

Sliding yoke and Univeral joint
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.

(See oil chart on following page for proper viscosity)

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 diferential) (See oil chart in this section for

proper viscosity)

(90°F) and higher are regularly encountered.)

SAE5W–30SF (Other areas)

NLGI No.2

Engine oil

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

905RT011

0B–10

MAINTENANCE AND LUBRICATION

Oil Viscosity Chart for Manual Transmission and Transfer Case

Oil Viscosity Chart for Front Axle

B00RW002

B00RW003

Oil Viscosty Chart for Rear Axle

MAINTENANCE AND LUBRICATION

0B–11

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

* 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.

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

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.

For Engine Repairs
For Axle Case Repairs. T/M

Repairs. T/M

For Engine Repairs

All

B00RW004

0B–12

MAINTENANCE AND LUBRICATION

Recommended Thread Locking Agents

LOCTITE Type LOCTITE Color

LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red

Application Steps

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

The surfaces must be perfectly dry.

2.Apply LOCTITE to the bolts.

F00RW014

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

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

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

Maintenance Service Data

Service Data and Specifications

MAINTENANCE AND LUBRICATION

0B–13

ENGINE

CLUTCH Clutch pedal free play 5-15 mm (0.197-0.591 in)
BRAKE

WHEEL ALIGNMENT

PROPELLER SHAFT Flange torque 63 N•m (46 lb ft) (Except TOD model)

WHEEL AND TIRES

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

Valve clearance (cold) Intake 0.28±0.05 mm (0.011 in)

Exhaust 0.3±0.05 mm (0.015 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
Toe-in 0±2 mm (0±0.08 in)
Camber
Caster 2° 10’±45’

Wheel nut torque 118 N•m (87 lb ft)
Tire inflation pressure (Front) 210 kPa (30 psi)
* Tire inflation pressure (Rear)

6-7 notches

0°±30’

43 N•m (32 lb ft) (TOD model)

240 kPa (35 psi)

Approximate Capacities

Items Metric Measure U.S. Measure

Fuel tank 85 L 22.5 Gal.
* Crankcase

Coolant

Transmission

Transfer 1.45 L 1.5 Qt
Transfer with TOD 1.9 L 2.0 Qt
Extention 0.185 L 0.195 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 Kg 1.32 Ibs

*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 4.3 Qt
M/T 8.5 L 9.0 Qt
A/T 8.8 L 9.3 Qt
Manual 2.7 L 2.86 Qt
Automatic 8.6 L 9.1 Qt

Rear 3.0 L 3.2 Qt
Front (4WD vehicle only) 1.4 L 1.5 Qt

TROOPER

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. . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 1A–8. . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis 1A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Individual Inspection 1A–12. . . . . . . . . . . . . . . . . . . . .

Heater Unit 1A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Unit and Associated Parts 1A–14. . . . . . . .

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

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

Heater Core and / or Mode Door 1A–16. . . . . . . . . .

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

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

Inspection 1A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Heater Mode Control Link Unit 1A–18. . . . . . . . . . . .

Disassembled View 1A–18. . . . . . . . . . . . . . . . . . . .

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

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

Heater Temperature Control Link Unit 1A–19. . . . . .

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

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

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

Blower Assembly 1A–20. . . . . . . . . . . . . . . . . . . . . . . .

Blower Assembly and Associated Parts 1A–20. .

Removal 1A–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Blower Link Unit and / or Mode door 1A–21. . . . . . .

Disassembled View 1A–21. . . . . . . . . . . . . . . . . . . .

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

Installation 1A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Motor 1A–23. . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Motor and Associated Parts 1A–23. . . . . .

Removal 1A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Rear Heater Duct, Defroster Nozzle and

Ventilation Duct 1A–24. . . . . . . . . . . . . . . . . . . . . . . . .

Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts 1A–24. . .

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

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

Center and / or Drive Side Vent 1A–25. . . . . . . . . . .

Center Vent, Drive Side Vent and

Associated Parts 1A–25. . . . . . . . . . . . . . . . . . . . . .

Removal 1A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Control Lever Assembly and / or Control

Cable 1A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Lever Assembly, Control Cable

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

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

Installation 1A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Illumination Bulb 1A–28. . . . . . . . . . . .

Control Panel Illumination Bulb and

Associated Parts 1A–28. . . . . . . . . . . . . . . . . . . . . .

Removal 1A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistor 1A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistor and Associated Parts 1A–29. . . . . . . . . .

Removal 1A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning System 1A–30. . . . . . . . . . . . . . . . . .

General Description 1A–30. . . . . . . . . . . . . . . . . . . . .

Diagnosis 1A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Individual Inspection 1A–47. . . . . . . . . . . . . . . . . . . . .

General Repair Procedure 1A–48. . . . . . . . . . . . . .

Compressor Assembly 1A–55. . . . . . . . . . . . . . . . . . .

Compressor Assembly and Associated

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

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

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

Condenser Assembly 1A–57. . . . . . . . . . . . . . . . . . . .

Condenser Assembly and Associated Parts 1A–57

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

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

Receiver / Drier 1A–58. . . . . . . . . . . . . . . . . . . . . . . . .

Receiver / Drier and Associated Parts 1A–58. . . .

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

Installation 1A–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Switch 1A–59. . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Switch and Associated Parts 1A–59. . .

Removal 1A–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Evaporator Assembly 1A–60. . . . . . . . . . . . . . . . . . . .

Evaporator Assembly and Associated Parts 1A–60

1A–2

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

Installation 1A–61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Thermostat, Evaporator Core

and/or Expansion Valve 1A–61. . . . . . . . . . . . . . . . .

Disassembled View 1A–61. . . . . . . . . . . . . . . . . . . .

Removal 1A–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Air Conditioning Switch and Illumination Bulb 1A–63

Air Conditioning Switch, Illumination Bulb

and Associated Parts 1A–63. . . . . . . . . . . . . . . . . .

Removal 1A–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–63. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Line 1A–64. . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Line and Associated Parts 1A–64. . . .

Removal 1A–64. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–65. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Data And Specifications 1A–66. . . . . . . . . . . . .

Compressor 1A–68. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Precaution 1A–68. . . . . . . . . . . . . . . . . . . .

General Description 1A–68. . . . . . . . . . . . . . . . . . . . .

Metric Thread Size Information 1A–70. . . . . . . . . . . .

Compressor Clutch Plate and Hub Assembly 1A–70

Removal 1A–70. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–70. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Clutch Rotor and/or Bearing 1A–71. . .

Removal 1A–71. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Clutch Coil 1A–72. . . . . . . . . . . . . . . . . .

Removal 1A–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–73. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Shaft Seal 1A–74. . . . . . . . . . . . . . . . . .

Service Precaution 1A–74. . . . . . . . . . . . . . . . . . . . . .

Seal Leak Detection 1A–74. . . . . . . . . . . . . . . . . . .

Removal 1A–74. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning 1A–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–75. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Pressure Relief Valve 1A–76. . . . . . . .

Removal 1A–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–76. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Oil 1A–76. . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Oil Check 1A–76. . . . . . . . . . . . . . . . .

Checking and Adjusting Oil Quantity for

Used Compressor 1A–76. . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting for Compressor

Replacement 1A–76. . . . . . . . . . . . . . . . . . . . . . . . .

Contamination of Compressor Oil 1A–77. . . . . . . .

Oil Return Operation 1A–77. . . . . . . . . . . . . . . . . . .

Replacement of Component Parts 1A–77. . . . . . .

Compressor Leak Testing (External and

Internal) 1A–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 1A–79. . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Air Conditioning System 1A–81. . . . . . . .

General Description 1A–81. . . . . . . . . . . . . . . . . . . . .

Full Automatic Air Conditioner Parts

Configuration 1A–81. . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Line and Associated Parts 1A–82. . . .

Circuit Diagram 1A–83. . . . . . . . . . . . . . . . . . . . . . . . .

Functions and Features 1A–88. . . . . . . . . . . . . . . . . .

Automatic Air Conditioner Block Diagram 1A–89. . .

Control Panel Layout 1A–90. . . . . . . . . . . . . . . . . . . .

Air Control Functions 1A–91. . . . . . . . . . . . . . . . . . . .

Operation and Functions of Control Panel

Switches 1A–92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Construction, Movement and
Control of Major Parts of Automatic Air

Conditioner System 1A–94. . . . . . . . . . . . . . . . . . . . .

Overview of Automatic Control of Automatic

Air Conditioner 1A–98. . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 1A–102. . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting, Its Overview and

Procedures 1A–102. . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Air Conditioner Control Unit Power

Supply Diagnosis 1A–103. . . . . . . . . . . . . . . . . . . . .

Performance and Movement checklist for

Automatic Air Conditioner Related Parts 1A–105.

Troubleshooting With Self-Diagnosis

Function 1A–107. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection By Failed Location 1A–111. . . . . . . . . . . . .

Inspection of the Sensors 1A–111. . . . . . . . . . . . . . .

Inspection of the Intake Actuator System 1A–115.

Inspection of the Mix Actuator System 1A–118. . . .

Inspection of the Mode Actuator System 1A–121. .

Inspection of the Fan Motor System 1A–124. . . . . .

Inspection of the Magnetic Clutch System 1A–129

Individual Inspection 1A–132. . . . . . . . . . . . . . . . . . .

On-Vehicle Service 1A–135. . . . . . . . . . . . . . . . . . . . . .

Power Transistor 1A–135. . . . . . . . . . . . . . . . . . . . . .

Removal 1A–135. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–135. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Heater/Air Conditioner Control

Unit 1A–135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–135. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–135. . . . . . . . . . . . . . . . . . . . . . . . . . . .

In Car Sensor 1A–136. . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–136. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–136. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient Sensor 1A–136. . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–136. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–136. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sun Sensor 1A–137. . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–137. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–137. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Thermostat 1A–137. . . . . . . . . . . . . . . . . .

Removal 1A–137. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–137. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mode Actuator 1A–138. . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–138. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–3

Installation 1A–138. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mix Actuator 1A–138. . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–138. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–138. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Intake Actuator 1A–139. . . . . . . . . . . . . . . . . . . . . . . .

Removal 1A–139. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1A–139. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Heater

When the engine is warming up, the warmed engine
coolant is sent out into the heater core. The heater system
supplies warm air into the passenger compartment to
warm it up.
Outside air is circulated through the heater core of the
heater unit and then back into the passenger
compartment. By controlling the mixture of outside air and
heater core air, the most comfortable passenger
compartment temperature can be selected and
maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature control
knob. This knob acts to open and close the air mix door,
thus controlling the amount of air passed through the
heater core.
The air selector knob, with its different modes, also allows
you to select and maintain the most comfortable
passenger compartment temperature.
The air source select lever is used to select either
“FRESH” for the introduction of the outside air, or
“RECIRC” for the circulation of the inside air. When the
lever is set to “FRESH”, the outside air is always taken
into the passenger compartment. When setting the lever
to “RECIRC” position, the circulation of air is restricted
only to the inside air with no introduction of the outside air
and the air in the passenger compartment gets warm
quickly . However , the lever is normally set to “FRESH” to
prevent the windshield from clouding.

1A–4

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Legend

(1) Side Defroster Hose
(2) Vent Box
(3) Upper Center Vent Box
(4) Lower Center Vent Box
(5) Blower Assembly
(6) Control Lever Assembly
(7) Evaporator Assembly

840RS004

(8) Duct
(9) Heater Unit

(10) Rear Heater Duct

(11) Lap Vent Nozzle
(12) Vent Box
(13) Side Defroster Hose
(14) Defroster Nozzle

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Control Lever Assembly

The vehicle has cable-type-control to control the mode
and temperature of the heater unit and the mode door for
the air source of the blower assembly.

Legend

(1) Air Source Select Lever
(2) Air Select Knob

1A–5

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

865RW007

(3) Fan Control Knob (Fan Switch)
(4) Air Conditioning (A/C) Switch (W/ A/C)
(5) Temperature Control Knob

1A–6

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Ventilation

Set “AIR SOURCE SELECT LEVER” to “FRESH”
position and turn on the blower fan. Heating can be done
in this lever position, sending in fresh air from outside.

The blower fan also serves to deliver fresh outside air to
the vehicle interior to assure adequate ventilation.

C01RS001

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Air Select Knob

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

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

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

3.Foot – In this position, air flow is delivered to the foot
while sending approx 30% op total amount air to the
wind shield.

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

1A–7

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

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

Moving the air source select lever to the “CIRC” position
provides quickest heat delivery by closing the blower
assembly mode door. In this position, outside air is not
delivered to the passenger compartment.
Selecting this mode allows air conditioning system to
work when the fan switch is turned to on position, even if
the A/C switch is off.

Air Source Select Lever

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

Fan Control Knob

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

1.Low

2.Medium Low

3.Medium High

4.High

C01RW001

Temperature Control Knob

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

1A–8

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Wiring Diagram

D01RS005

Diagnosis

d

Heating Cycle diagnosis

Condition Possible cause Correction

No heating or insufficient heating.

Control lever moves but mode door

oes not operate.

The mode door cannot be set to the
mode selected.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Blower motor does not run or runs
improperly.

Engine coolant temperature is low. Check the engine coolant

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

is insufficient.

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

air sent from the blower motor.
Duct connections defective or

unsealing.
Cable attaching clip is not correct. Repair
Link unit of heater or blower

assembly defective.
Link unit of heater unit or blower

assembly defective.
Control cable is not adjusted. Adjust.

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

temperature after warming up the
engine and check the thermostat.
Replace as necessary.

Check if the water hose to the heater
core is clogged, collapsed or twisted.
Repair or replace as necessary.

Repair the temperature control link
unit or mode doors.

Repair or replace as necessary.

Repair

Repair.

1A–9

1A–10

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Fan Control Lever (Fan Switch) Diagnosis

Current flows to the blower motor through the heater and
the A/C relay (B-36) to activate the rotation of the blower
motor by turning “ON” the fan control knob (fan switch).
Blower motor speed is controlled in stages by the resistor,
by operating the switch from “LOW” to “HIGH”.

For the inspection of the relays, switches and units in
each table, refer to “INDIVIDUAL INSPECTION” in this
section.

Condition Possible cause Correction

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

— Refer to Chart B, C, D and E

position (s).
Blower motor does not stop at “OFF”

— Refer to Chart F

position.

D01RS004

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart “A” Blower Motor Dose Not Run

1A–11

Step

1 Is relay (B-36) OK? Go to Step 2 Replace
2 Is fuse C-19 (25A) OK? Go to Step 3 Replace
3 Is resistor OK? Go to Step 4 Replace
4 Is fan control knob OK?

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

2. Turn fan control knob “ON”.

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

Is there a battery voltage?

Action

open circuit either

terminal No. B5-2

Yes No

Go to Step 5

Poor ground or

between chassis

side connector

and No. B3-2 or

No. I18-1 and

body ground (No.

B-2).

Replace control
lever assembly.

Open circuit

between No.

C-19 (25A) fuse

and No. B5-1.

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

Step

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

Action

terminal No. B3-1

Yes No

between chassis

side connector

and No.I18-2.

Replace control
lever assembly.

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

Step

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

Action

terminal No. B3-4

Yes No

between the
chassis side

connector

and No. I18-5.

Replace control
lever assembly.

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

Step

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

Action

terminal No. B3-6

Yes No

between chassis

side connector

and No. I18-3.

Replace control
lever assembly.

1A–12

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

Step

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

Action

terminal No. B3-3

Yes No

between Chassis

side connector

and No. I18-6.

Replace control
lever assembly.

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

Step

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

Action

terminal No. B5-2

Yes No

between chassis

side connector

and

No. B3-2,No. B3-

3 and No. I18-6,

No. B3-6 and

No. I18-3,

No. B3-4 and

No. I18-5 or

No. B3-1 and

No. I18-2

Replace control
lever assembly.

Individual Inspection

Blower Motor

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

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

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

Resistor

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

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

840RS001

873RS005

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–13

Fan switch

position

Resistor terminals

with continuity

Resistance

1 1 — 2 2.4 W
2 2 — 4 0.90 W
3 2 — 6 0.28 W
4 2 — 3 —

Fan Control Knob (Fan Switch)

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

825RS001

2.Check for continuity between the heater and the A/C
relay (B-36) terminals.

Fan switch

position

Switch connector terminals with con-

tinuity

OFF No continuity

1 1 – 2 – 4
2 1 – 4 – 5
3 1 – 3 – 4
4 1 – 4 – 6

Heater & A/C Relay

1.Disconnect the heater and the A/C relay (B-36).
D When removing the connector for relay, unfasten

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

865RS001

Condition

Normal 1 – 3 (Approx 85–105W)

When battery voltage is

applied between 1 – 3

825RS002

Relay terminals with

continuity

2 – 4

1A–14

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater Unit and Associated Parts

Heater Unit

Legend

(1) Instrument Panel Assembly
(2) Instrument Panel Center Bracket
(3) Resistor
(4) Duct
(5) Evaporator Assembly (A/C only)
(6) Rear Heater Duct

Removal

1.Disconnect the battery ground cable.

2.Drain the engine coolant.

3.Discharge and recover refrigerant (with air
conditioning)

D Refer to Refrigerant Recovery in this section.

860RY00005

(7) Heater Unit Assembly
(8) Center Ventilation Lower Duct
(9) Driver Lap Vent Nozzle

(10) Water Hose

(11) Electro Thermo Connector (With A/C)

(12) Resistor Connector

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

Accessories section.

5.Disconnect the water hoses at the heater unit.

6.Disconnect resistor connector.

7.Remove duct.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

9.Remove instrument panel center bracket.
D Refer to Cross Beam Assembly in Body and

Accessories section.

10.Remove rear heater duct.

11.Remove heater unit assembly.

12.Remove driver lap vent nozzle.

13.Remove center ventilation lower duct.

Installation

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

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

2.Adjust the control lever assembly cables.
D Refer to Control Lever Assembly in this section.

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

1A–15

1A–16

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Disassembled View

Heater Core and / or Mode Door

Legend

(1) Case (Temperature Control)
(2) Mode Door
(3) Duct

Removal

1.Disconnect the battery ground cable.

2.Drain the engine coolant.

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

D Refer to Refrigerant Recovery in this section.

860RS001

(4) Heater Unit
(5) Case (Mode Control)
(6) Heater Core

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

5.Remove duct.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–17

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

860RS002

8.Remove heater core (1).

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

860RS004

Inspection

Check for foreign matter in the heater core, stains or core
fin damage.

860RS003

Installation

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

1.Check that each mode door operates properly.

1A–18

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Disassembled View

Heater Mode Control Link Unit

Legend

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

Removal

1.Disconnect the battery ground cable.

2.Drain engine coolant.

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

D Refer to Refrigerant Recovery in this section.

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

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

6.Remove washer and the mode main lever.

7.Remove rod.

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

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

860RS005

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

10.Remove clip.

860RS006

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–19

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.

Heater Temperature Control Link Unit

Disassembled View

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

Legend

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

Removal

1.Disconnect the battery ground cable.

2.Drain engine coolant.

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

D Refer to Refrigerant Recovery in this section.

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

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

6.Remove rod.

7.Remove sub-lever.

860RS007

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

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

9.Remove clip.

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.

1A–20

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Blower Assembly

Blower Assembly and Associated Parts

Legend

(1) Electro Thermo Connector
(2) Blower Motor Connector
(3) Resistor Connector
(4) Dash Side Trim Panel (RH)

Removal

1.Disconnect the battery ground cable.

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

D Refer to Refrigerant Recovery in this section.

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

Accessories section.

873RY00003

(5) Blower Assembly
(6) Duct
(7) Evaporator Assembly (A/C only)
(8) Heater Unit
(9) Instrument Panel Assembly

4.Disconnect resistor connector.

5.Remove duct.

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

7.Remove dash side trim panel (RH).

8.Disconnect blower motor connector.

9.Remove blower assembly.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Installation

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

1.Adjust the control lever assembly cables.
D Refer to Control Lever Assembly in this section.

Blower Link Unit and / or Mode door

Disassembled View

1A–21

Legend

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

Removal

1.Disconnect the battery ground cable.

873RS001

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

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

D Refer to Refrigerant Recovery in this section.

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

1A–22

4.Remove lower case.

5. Separate the upper case and slit the lining parting

6. Pull out the mode door while lifting up the catch of

7.Remove sub-lever.

8.Remove door lever.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

face with a knife.

873RS002

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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Blower Motor

Blower Motor and Associated Parts

1A–23

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.

1A–24

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) Center Defroster Nozzle
(2) Side Defroster Nozzle
(3) Side Ventilation Duct
(4) Center Ventilation Upper Duct
(5) Center Ventilation Lower Duct

Removal

1.Disconnect the battery ground cable.

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

Accessories section.

3.Remove center ventilation upper duct.

4.Remove side ventilation duct.

5.Remove center ventilation lower duct.

874RS017

(6) Center Console
(7) Rear Heater Duct
(8) Driver Lap Duct
(9) Cross Beam Assembly

(10) Instrument Panel Assembly

6.Remove driver lap duct.

7.Remove center console.

8.Remove rear heater duct.
D Refer to Consoles in Body and Accessories

section.

9.Remove cross beam assembly.
D Refer to Cross Beam Assembly in Body and

Accessories section.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

10.Remove side defroster nozzle.

11.Remove center 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.

Center and / or Drive Side Vent

Center Vent, Drive Side Vent and Associated Parts

1A–25

Legend

(1) Center Vent
(2) Meter Cluster Assembly
(3) Lower Cluster Assembly

Removal

1.Disconnect the battery ground cable.

2.Remove front console assembly.

3.Remove lower cluster assembly.

4.Remove instrument panel driver lower cover
assembly.

5.Remove meter cluster assembly.
D Refer to Instrument Panel Assembly in Body and

Accessories section.

740RS003

(4) Front Console Assembly
(5) Instrument Panel Driver Lower Cover

Assembly

(6) Side Vent

6.Remove screws and the center vent from center
cluster while prying up the center vent catch portions.

7. Remove screws and the side vent from the center
cluster while prying up the vent catch portions.

Installation

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

1A–26

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts

Legend

(1) Instrument Panel Passenger Lower Cover

Assembly
(2) Glove Box
(3) Fan Switch and Air Conditioning Switch

Connector
(4) Temp Control Link Connection
(5) Control Cable
(6) Blower Assembly Connection

Removal

1.Disconnect the battery ground cable.

2.Remove front console assembly.

3.Remove lower cluster assembly.

4.Remove glove box.

865RS011

(7) Attaching Screws
(8) Control Lever Assembly
(9) Mode Control Link Connection

(10) Front Console Assembly

(1 1) Lower Cluster Assembly

(12) Instrument Panel Driver Lower Cover

Assembly

(13) Meter Cluster Assembly

5.Remove instrument panel passenger lower cover
assembly.

6.Remove instrument panel driver lower cover
assembly.

7.Remove meter cluster assembly.
D Refer to Instrument Panel Assembly in Body and

Accessories section.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

8.Remove attaching screws.
D Remove the four attaching screws.

865RS010

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

1A–27

865RS009

10.Remove control lever assembly.

11.Remove control cable.

Installation

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

1.Adjust the control cable.

865RY00013

1A–28

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D Air source control cable.

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

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

D Temperature control cable.

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

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

D Air select control cable

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

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

2.Check the control cable operation.

Control Panel Illumination Bulb

Control Panel Illumination Bulb and Associated Parts

Legend

(1) Control Lever Assembly

Removal

1.Disconnect the battery ground cable.

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

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

4.Pull the illumination bulb from the socket.

Installation

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

865RS007

(2) Bulb Socket
(3) Illumination Bulb

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Resistor and Associated Parts

1A–29

Resistor

Legend

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

Removal

1.Disconnect the battery ground cable.

2.Remove front console.

3.Remove lower cluster.

4.Remove glove box.

5.Remove instrument panel passenger lower cover
assembly.

D Refer to Instrument Panel Assembly in Body and

Accessories section.

6.Remove resistor connector.

7.Remove duct (heater only).

8.Remove resistor.

874RW005

(5) Front Console
(6) Lower Cluster
(7) Instrument Panel Passenger Lower Cover

Assembly

Installation

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

1A–30

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Air Conditioning System

General Description

Air Conditioning Refrigerant Cycle Construction

Legend

(1) Electronic Thermostat
(2) Evaporator Core
(3) Evaporator Assembly
(4) Temperature Sensor
(5) Expansion Valve
(6) Blower Motor
(7) Dual 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.

C01RS003

(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

Evaporation

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–31

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.

This vehicle is equipped with six-cylinder axle plate
compressor (1).
The specified amount of the compressor oil is 240cc
(8.0 fl. oz.).
The oil used in the HFC-134a system compressor differs
from that used in R-12 systems.
Also, compressor oil to be used varies according to the
compressor model. Be sure to avoid mixing two or more
different types of oil.
If the wrong oil is used, lubrication will be poor and the
compressor will seize or malfunction.
The magnetic clutch connector is a waterproof type.

Magnetic Clutch

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

Condensation

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

Expansion

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

Compressor

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

852RW002

Condenser

Also, it functions to cool and liquefy the high-pressure and
high-temperature vapor sent from the compressor by the
radiator fan or outside air.
A condenser may malfunction in two ways: it may leak, or
it may be restricted. A condenser restriction will result in
excessive compressor discharge pressure. If a partial
restriction is present, the refrigerant expands after
passing through the restriction.
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.

1A–32

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

The refrigerant line connection has a bolt at the block
joint, for easy servicing.
The condenser assembly (6) is located in front of the
radiator. It provides rapid heat transfer from the
refrigerant to the cooling fins.

875RW004

Receiver / Drier

The receiver/drier (5) performs four functions:

D 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.

D The liquefied refrigerant from the condenser is mixed

with refrigerant gas 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.

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

the dirt and water mixed in the cycling refrigerant.

D The sight glass, installed on top of the receiver/drier,

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

875RW004

Pressure Switch

The pressure switch (Dual pressure switch) (4) is
installed on the upper part of the receiver/drier, to detect
excessively high pressure (high pressure switch) and
prevent compressor seizure due to the refrigerant leaking
(low pressure switch), so that the compressor is able to be
turned “ON” or “OFF”.
The pressure characteristics of HFC-134a refrigerant
differ from those of R-12. Thus, the pressure switch
operation for HFC-134a systems has been changed from
R-12.

Compressor

Low-pressure

control

High-pressure

control

ON

(kPa/psi)

186.3±29.4
(27.0±4.3)

2353.6±196.1
(341.3±28.4)

OFF

(kPa/psi)

176.5±19.6
(25.6±2.8)

2942.0±196.1
(426.6±28.4)

875RW004

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–33

Expansion Valve

This expansion valve (1) 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 (2).
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring
adjustment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure. It
then transmits these to the top chamber of the
diaphragm.
The refrigerant pressure is transmitted to the diaphragm’s
bottom chamber through the external equalizing pressure
tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
the force acting on the diaphragm and the spring
pressure.
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure get low, resulting in insuf ficient cooling capacity
of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.

Evaporator

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

874RY00003

874RY00007

Electronic Thermostat

The thermostat consists of the thermo sensor (1) and
thermostat unit (4) which functions electrically to reduce
the noises being generated while the system is in
operation.
The electronic thermo sensor (1) is mounted at the
evaporator core (2) outlet and senses the temperature of
the cool air from the evaporator (3). Temperature signals
are input to the thermostat unit. This information is
compared by the thermo unit and results in the output to
operate the A/C thermostat relay and turn the magnetic
clutch ON or OFF to prevent evaporator freeze-up.

1A–34

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

A characteristic of the sensor is that the resistance
decreases as the temperature increases and the
resistance increases as the temperature decreases.

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.

874RX022

852RW011

Legend

(1) Pressure Resistance Layer (Polyester Braid)
(2) Moisture Resistance AND Outer Protector

Layer
(3) Heat Resistance Layer
(4) Heat Resistance Core Layer (Neoprene)
(5) Low Permeation Layer (Nylon Barner)

Air Conditioning Parts

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–35

Legend

(1) Liquid Line (High-Pressure Pipe)
(2) O-ring
(3) Compressor
(4) Discharge Line (High-Pressure Hose)
(5) Pressure Switch
(6) Receiver Drier

852RW009

(7) Condenser Assembly
(8) Drive Belt
(9) Relay

(10) Drain Hose

(11) Suction Line (Low-Pressure Hose)
(12) Evaporator Assembly
(13) A/C Switch

1A–36

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Wiring Diagram

D08RW254

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–37

D08RX003

1A–38

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D08RW256

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 “Magnetic Clutch Diagnosis”

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.

1A–39

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 Knob (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.

1A–40

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:

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

Normal Pressure:

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

(77–86°F).

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

(21.3–42.7 psi).

D 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 in this section.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Ab

h

Connect The Manifold Gauge

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

1A–41

Legend

(1) Low Side
(2) High Side

Condition Possible cause Correction

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.

901RS137

Condenser clogged or dirty. Clean the condenser fins
Cooling fan does not operate

Check the cooling fan operation.

properly.
Excessive refrigerant in system. Discharge and recover refrigerant.

Recharge to specified amount.

Air in system. Evacuate and charge refrigerant

system.

Insufficient refrigerant in system. Check for leaks. Discharge and

recover the refrigerant. Recharge to
the specified amount.

Clogged or defective expansion

Replace the expansion valve.

valve.

1A–42

around the com ressor refrigerant

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)

Condition CorrectionPossible cause

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 system for restriction and
replace the receiver/drier.

Repair or replace the compressor.

Suction (Low Gauge) Pressure
Abnormally High.

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

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
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.

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.

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.

Replace the expansion valve.

recover the refrigerant. Recharge to
specified amount.

Replace the expansion valve.

Condition CorrectionPossible cause

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

A/C — Air Conditioning

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Excessive refrigerant in system. Discharge and recover the

refrigerant, the Recharge to the

specified amount.
Condenser clogged or dirty. Clean the condenser fins.
Air in system. Evacuate and charge refrigerant.

Insufficient refrigerant in system. Check for leaks. Discharge and

recover refrigerant. Recharge to

specified amount.

1A–43

1A–44

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Magnetic Clutch Diagnosis

When the air conditioning switch and the fan control knob
(fan switch) are turned on with the engine running, current

D08RX004

flows through the thermostat and the compressor relay to
activate the magnetic clutch.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–45

The air conditioning can be stopped by turning off the air
conditioning switch or the fan control knob (fan switch).
However, even when the air conditioning is in operation,
the electronic thermostat, the pressure switch or the
Powertrain Control Module (PCM) is used to stop the air
conditioning temporarily by turning off the magnetic clutch

in the prearranged conditions to reduce the engine load
which is being caused by the rise in the engine coolant
temperature, and the acceleration of the vehicle, etc.
For the inspection of the relays, switches and units in the
table, refer to “Individual Inspection” in this section.

Magnetic Clutch Does Not Run

Step Action Yes No

1 Are No. C-20 (10A) fuse and No. C-19 (25A) fuse OK? Go to Step 2 Replace
2 Are heater and A/C (B-36), thermostat (X-5), and compressor

(X-7) relays OK?

3 Is pressure switch (dual pressure switch) OK?

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

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

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

Is there a battery voltage?

6 Check to see if continuity between compressor side connector

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

Is there a continuity?

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

connector terminal No. C25-1
Is there a battery voltage?

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

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

Is there a battery voltage?

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

side relay terminal No. X5-1 and No. X5-3.
Is there a battery voltage?

10 1. Reconnect thermostat relay and disconnect compressor relay

(X-7).

2. Check to see if battery voltage is present at the chassis side
relay terminal No. X7-2.

Is there a battery voltage?

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

X7-4 and the chassis side connector terminal No. E3-1.
Is there a continuity?

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

relay terminal No. X7-1 and No. X7-3.
Is there a battery voltage?

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

terminal No. X7-1.
Is there a battery voltage?

Go to Step 3 Replace

Switch defective

or insufficient

Go to Step 4

Go to Step 6 Go to Step 7

Magnetic clutch

defective.

Go to Step 8

Go to Step 9

Go to Step 10 Go to Step 16

Go to Step 11

Go to Step 12 Open circuit.

Go to Step 13 Go to Step 14

Go to Step 15

refrigerant.

Compressor

defective.

Open circuit

between No.C-20

(10A) fuse and

No. C25-1.

Open circuit

between No.

C25-2 and

No.X5-2.

Open circuit

between No.

X5-4 and No.

Open circuit

between No.

C-20 (10A) fuse

and No. X7-1.

X7-2.

1A–46

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Magnetic Clutch Does Not Run (Cont’d)

Step NoYesAction

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

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

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

X-54 and chassis side connector terminal No. C3-E15.
Is there a continuity?

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

terminal No. X5-1.
Is there a battery voltage?

17 1. Reconnect thermostat relay.

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

Is there a battery voltage?

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

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

19 Check to see if continuity between chassis side connector

terminal No. B4-2 and No. I18-4.
Is there a continuity?

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

connector terminal No. I23-2.
Is there a battery voltage?

Power train

control module

(PCM) defective.

Refer to

Driveability and

Emissions in

Engine section.

Power train

control module

(PCM) defective.

Refer to

Driveability and

Emissions in

Engine section.

Go to Step 17 Go to Step 20

Go to Step 18

Go to Step 19

Electronic

thermostat

defective.

Open circuit
between X5-1
and No.I23-6.

Open circuit

between No.

X7-3 and No.

C1-B14.

Open circuit

Open circuit

between No.I23-6

and No.B4-3.

Open circuit

between No.

X5-3 and No.

B4-1.

Open circuit

between No.

B4-2 and No.

I18-4 or poor

ground (Fan

Switch Ground

Circuit).

Open circuit

between No.

C-20 (10A) fuse

and No.I23-2.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–47

Individual Inspection

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

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

Heater And A/C (B-36), Thermostat (X-5)
And Compressor (X-7) Relay

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

D For handling of these relays, refer to Heater &A/C

Relay in this section.

Fan swtich

position

OFF No continuity

1 1 – 2 – 4
2 1 – 4 – 5
3 1 – 3 – 4
4 1 – 4 – 6

A/C switch

position

OFF 1 – 6

ON 1 – 2 – 6

Fan switch connector terminals with

continuity

A/C switch connector terminals with

continuity

865RS002

Condition

Normal 1 – 3 (Approx 85–105W)

When battery voltage is

applied between 1 – 3

825RS003

Relay terminals with

continuity

2 – 4

1A–48

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Pressure Switch

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

875RW003

D 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

4

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

2. Remove and replace the defective part.

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

Repair Of Refrigerant Leaks

Refrigerant Line Connections

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

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:

D Keep your work area clean.
D Always wear safety goggles and protective gloves

when working on refrigerant systems.

D Beware of the danger of carbon monoxide fumes

caused by running the engine.

D Beware of discharged refrigerant in enclosed or

improperly ventilated garages.

D Always disconnect the negative battery cable and

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

D When discharging and recovering the refrigerant, do

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

D 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.

D When disconnecting or reconnecting the lines, use

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

D Always install new O-rings whenever a connection is

disassembled.

D Before connecting any hoses or lines, apply new

specified compressor oil to the O-rings.

When connecting the refrigerant line at a block joint,

852RS003

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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–49

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

850RW002

O-rings (2) must be closely aligned with the raised portion
(1) of refrigerant line.

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

850RW004

850RW003

1A–50

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 Step 2

Compressor

operation to be

confirmed

Inspection steps

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

NOTE:

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

make sure there is no refrigerant vapor or cigarette
smoke around the vehicle before conducting the
inspection.

Also, select a location where the refrigerant vapor will
not be blown off by wind.

D 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.

D It is not possible to visually check the leak from inside

the cooling unit. Follow the method below when
checking.

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

High pressure side

1.Discharger section of compressor

2.Inlet/outlet section of condenser

3.Inlet/outlet section of receiver driver

4.Inlet section of cooling unit

Low pressure side

1.Outlet section of cooling unit

2.Intake section of compressor

Major checking points of refrigerant leak
Compressor

D Pipe connection
D Sealing section of shaft
D Mating section of cylinder

Condenser

D Pipe connection

D Welds of condenser body

Receiver drier

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

Evaporator unit (cooling unit)

D Pipe connection
D Connections of expansion valve
D Brazed sections of evaporator

NOTE:

D 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

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

Pipe

D Pipe connection
D Pipe (cracks, flaws)

Charge Valve

NOTE:

D 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.

D Use two wrenches to prevent twisting and damage

to the line.

D Do not over tighten.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–51

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

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

ones.

D Be sure to apply the specified compressor oil to the

new O-rings.

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

D 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.
D Cap the open connections at once.

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

the hose fitting.

D Tighten the hose fitting to the specified torque.

5.Evacuate, charge and test the system.

WARNING:

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

CONSULT A DOCTOR IMMEDIATELY.

D 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.

D 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.

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

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

D 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.

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

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

D 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.

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

compositions are not the same.

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

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

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

(100°F).

901RS141

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.

1A–52

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

D ACR

(or equivalent) Method

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

901RS142

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.

D High-pressure valve (HI) — Discharge-side.
D 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.

D If the pressure changes, check the system for

leaks.

D If leaks occur, retighten the refrigerant line

connections and repeat the evacuation steps.

901RS141

Legend

(1) Low Side
(2) High Side

D 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.

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.

901RS143

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.

1A–53

901RS144

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

(0.44 lbs) of HFC-134a.

D Make sure the high pressure valve of the manifold

gauge is closed.

D Check to ensure that the degree of pressure does

not change.

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

leak detector.

D 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.

D Charge the refrigerant until the scale reading

decreases by the amount of the charge specified.

Specified amount: 600 g (1.32 lbs)

D 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.

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

9.Check for refrigerant leaks.

1A–54

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Checking The A/C System

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

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

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

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

D Immediately after charging refrigerant, both high

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

D The ambient temperature should be between

25–30°C (77–86°F).

D The pressure guideline for the high-pressure side is

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

D The pressure guideline for the low-pressure side is

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

D If an abnormal pressure is found, refer to Checking

The Refrigerant System With Manifold Gauge in
this section.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor Assembly

Compressor Assembly and Associated Parts

1A–55

Legend

(1) Compressor Bracket
(2) Seal Washer

Removal

1.Disconnect the battery ground cable.

852RW010

(3) Refrigerant Line Connector
(4) Compressor
(5) Drive Belt

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

3.Disconnect magnetic clutch harness connector.

1A–56

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

4.Remove drive belt.
D Move drive belt tensioner to loose side using

wrench then remove drive belt.

Legend

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

4.Connect magnetic clutch harness connector.

850RY00001

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

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

6.Remove compressor.

Installation

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

torque.

Torque: 19 N•m (14 lb•ft)

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

the specified torque.

Torque: 15 N•m (11 lb•ft)

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

ones.

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

when connecting refrigerant lines.

3.Install drive belt.
D Move serpentine belt tensioner to loose side using

wrench, then install serpentine belt to normal
position.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condenser Assembly

Condenser Assembly and Associated Parts

1A–57

Legend

(1) Refrigerant Line
(2) Pressure Switch Connector
(3) Front Bumper Assembly

Removal

1.Disconnect the battery ground cable.

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

3.Remove radiator grille.

4.Remove front bumper assembly.
D Refer to Bumpers in Body and Accessories section.

5.Remove engine hood front end stay.

6.Disconnect pressure switch connector.

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

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

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

condenser or radiator fin.

875RY00005

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

Installation

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

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

D Tighten the condenser fixing bolts to the specified

torque.

Torque: 6 N•m (52 lb•in)

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

specified torque.

Torque: 15 N•m (11 lb•ft)

D Tighten the outlet line connector fixing bolt to the

specified torque.

Torque: 6 N•m (52 lb•in)

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

ones.

1A–58

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

when connecting the refrigerant line.

3.Connect pressure switch connector.

Receiver / Drier

Receiver / Drier and Associated Parts

4.Install engine hood front end stay.

5.Install front bumper assembly.

6.Install radiator grille.

Legend

(1) Pressure Switch Connector
(2) Refrigerant Line

Removal

1.Disconnect the battery ground cable.

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

3.Remove radiator grille.

4.Disconnect pressure switch connector.

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

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

6.Remove bracket bolt.

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

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

875RY00004

(3) Receiver / Drier
(4) Radiator Grille
(5) Bracket Bolt

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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Pressure Switch

Pressure Switch and Associated Parts

Legend

(1) Pressure Switch Connector

1A–59

875RY00006

(2) Pressure Switch
(3) Radiator Grille

Removal

1.Disconnect the battery ground cable.

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

3.Remove radiator grille.

4.Disconnect pressure switch connector.

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

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

Installation

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

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

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

3.Tighten the pressure switch to the specified torque.

Torque: 13 N•m (113 lb•in)

1A–60

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Evaporator Assembly

Evaporator Assembly and Associated Parts

Legend

(1) Resistor and Electronic Thermostat Connector
(2) Drain Hose
(3) Refrigerant Line
(4) Passenger Knee Bolster Reinforcement

Assembly

Removal

1.Disconnect the battery ground cable.

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

3.Remove front console assembly.

4.Remove lower cluster assembly.

5.Remove glove box.

6.Remove instrument panel passenger lower cover
assembly.

7.Remove passenger knee bolster reinforcement
assembly.

D Refer to Instrument Panel Assembly in Body and

Accessories section.

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

874RT002

(5) Instrument Panel Passenger Lower Cover

Assembly
(6) Glove Box
(7) Front Console Assembly
(8) Lower Cluster Assembly
(9) Evaporator Assembly

874RY00009

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–61

9.Disconnect drain hose.

10.Disconnect refrigerant line.
D Use a back-up wrench when disconnecting and

reconnecting the refrigerant lines.

D 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.

11.Remove evaporator assembly.

Installation

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

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

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

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.

Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View

Legend

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

Removal

1.Disconnect the battery ground cable.

874RX017

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

(10) Upper Case

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

1A–62

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

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

5.Remove clip.

6.Remove attaching screw.

7.Remove upper case.

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

is separated when removing the evaporator.

874RY00006

10.Remove expansion valve.

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

D Use a back-up wrench when disconnecting all

refrigerant pipes.

D Lift to remove the upper case.

9.Remove evaporator core.

874RS006

874RY00005

Installation

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

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

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

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

874RX021

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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–63

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

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

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

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

Air Conditioning Switch and Illumination Bulb

Air Conditioning Switch, Illumination Bulb and Associated Parts

Legend

(1) Control Lever Assembly

Removal

1.Disconnect the battery ground cable.

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

3.Lift up the catch portion (1) of the switch and remove
the air conditioning switch (2) while pushing it toward
the outside.

865RS003

(2) Illumination Bulb
(3) A/C Switch

4.Turn the illumination bulb counterclockwise to
remove.

Installation

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

865RS004

1A–64

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Refrigerant Line

Refrigerant Line and Associated Parts

Legend

(1) Clip and Clamp
(2) Suction Line (Low Pressure Hose)
(3) Liquid Line (High-Pressure Pipe)

Removal

1.Disconnect the battery ground cable.

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

3.Remove radiator grille.

4.Remove air cleaner.

5.Remove clip and clamp.

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

852RY00013

(4) Discharge Line (High Pressure Hose)
(5) Air Cleaner
(6) Radiator Grille
(7) Suction Line (Low-Pressure Pipe)

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

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

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

D Use a backup wrench when disconnecting and

reconnecting the refrigerant lines.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D When removing the refrigerant line connecting part,

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

Installation

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

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

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

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

Specifications in this section.

1A–65

1A–66

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Main Data And Specifications

General Specifications

HEATER UNIT

Temperature control Reheat air mix system
Capacity 4.3 kw (3,700 Kcal./hr.)
Air flow 280 m#/hr

HEATER CORE

Type Plate and corrugate fin type
Element dimension 171 mm (6.7 in.) × 161 mm (6.3 in.) × 25 mm (0.98 in.)
Radiating area Approx. 0.75 m@

EV APORATOR ASSEMBL Y

Capacity 4.9 kw (4,200 Kcal./hr.)
Air flow 470 m#/hr

EVAPORATOR CORE

Type Al-laminate louver fin type
Element dimension 235 mm (9.3 in.) × 225.3 mm (8.9 in.) × 60 mm (2.4 in.)

EXPANSION V ALVE

Type Internal pressure equalizer type

THERMOSTAT SWITCH

Type Electronic thermostat

OFF: Below 3.5 ± 0.5 °C (38.3 ± 0.9 °F)
ON: Above 5.0 ± 0.5 °C (41.0 ± 0.9 °F)

CONDENSER

Type Parallel flow
Radiation performance 15.9 kw (13,700 Kcal./hr.)

RECEIVER/DRIER

Type Assembly includes sight glass with dual pressure

switch

Internal volume 300 cc (10 fl.oz.)

PRESSURE SWITCH

Type

REFRIGERANT

Type HFC-134a
Specified amount 600 g (1.32 lbs.)

Dual pressure switch
Low pressure control

ON: 186.3±29.4 kPa (27.0±4.3 psi)
OFF: 176.5±19.6 kPa (25.6±2.8 psi)

High pressure control

DIFF: 2353.6±196.1 kPa (341.3±28.4 psi)
OFF: 2942.0±196.1 kPa (426.6±28.4 psi)

Torque Specifications

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–67

852RW004

874RX016

1A–68

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor

Service Precaution

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

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

General Description

The HD6/HT6 Automotive Conditioning Compressor and
Clutch Assembly is a light weight, six cylinder axial design
consisting of three double ended pistons and weighs

5.8 kg (12.7 lbs.)
Although this compressor is the same for all vehicle
applications, there are differences in installations,
mounting brackets, pulleys, torque cushions and
switches, none of which will affect the following overhaul
procedures.

This compressor has a clutch driver design without torque
cushion (1).

871RW001

Service compressors are supplied with either the control
switches assembled in the rear head or a plug may be
found where a control switch is required. If the service
compressor requires control switches, the plug may be
removed from the appropriate rear head switch cavity of
the replaced compressor and assembled as prescribed in
this manual.
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” repairs, 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 solvent, and
dried with dry air. When necessary to use a cloth on any
part, it should be of a non-lint producing type

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A–69

Legend

(1) Clutch Driver
(2) Rotor Bearing Retainer
(3) Pulley Rotor and Bearing Assembly
(4) Clutch Coil Assembly
(5) Connector

The operations described below are based on bench
overhaul with the compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When a compressor is
removed from the vehicle for servicing, the amount of
PAG lubricant remaining in the compressor should be
drained, measured and recorded. This PAG lubricant
should then be discarded and an equal amount of new
PAG lubricant added to the compressor.
The service compressor is shipped without PAG oil.
When service procedures require, use only Isuzu
approved PAG oil.

871RW002

(6) Shaft Seal Parts
(7) Pump Assembly
(8) High Pressure Relief Valve
(9) Shipping Cap

(10) Special 134a Suction Port

(11) Special 134a Discharge Port