Isuzu Trooper 2002 User Manual

WORKSHOP MANUAL

US VERSION

RIGHT HAND MODEL

EXP UBS

PubNo. RV99_02-01.E

WORKSHOP MANUAL

TOP

1998/1999

UBS

2000

UBS

2002

UBS

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

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0A

0B

SECTION No. CONTRNTS

0A General Information
0B Maintenance and Lubrication

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00

1D

1B

1A

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

00 SERVICE INFORMATION
1A HEATING AND VENTILATION
1B AIR CONDITIONING
1D COMPRESSOR OVERHAUL

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00

2A

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

00 SERVICE INFORMATION
2A FRONT END ALIGNMENT

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3C

3D

3E

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

3C FRONT SUSPENSION
3D REAR SUSPENSION; COIL SPRING
3E WHEELS AND TIRES

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4A1

4A2A

4A2B

4B1

4B2

4C

4D1

4D2

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

4A1 DIFFERENTIAL (FRONT)
4A2A DIFFERENTIAL (Rear 220mm)
4A2B DIFFERENTIAL (REAR 244mm)

4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON

THE FLY)

4B2 DRIVELINE CONTROL SYSTEM (TOD)

4C DRIVE SHAFT SYSTEM
4D1 TRANSFER CASE (STANDARD TYPE)
4D2 TRANSFER CASE (TOD)

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5A

5B

5C

5D

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

5A BRAKE CONTROL SYSTEM

5B ANTI-LOCK BRAKE SYSTEM

5C POWER ASSISTED BRAKE SYSTEM

5D PARKING BRAKES

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6A

6B

6C

6D1

6D2

6D3

6E

6F

6G6H6J

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

6VD1 / 6VE1

SECTION No. CONTRNTS

6A ENGINE MECHANICAL

6B ENGINE COOLING

6C ENGINE FUEL
6D1 ENGINE ELECTRICAL
6D2 IGNITION SYSTEM
6D3 STARTING AND CHARGING SYSTEM

6E ENGINE DRIVEABILITY AND EMISSIONS

6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL SYSTEM

6J INDUCTION

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00

6A

6A2

6B

6C

6D6E6F

6G

6A

6B

6C

6D

6E

6F

6G

6H

6J

4JG2

SECTION No. CONTRNTS

00 SERVICE INFORMATION
6A ENGINE MECHANICAL

6A2 4JG2-NA / 4JG2-TURBO ENGINE

6B ENGINE COOLING
6C FUEL SYSTEM
6D ENGINE ELECTRICAL
6E -

6F EXHAUST
6G -

4JX1

SECTION No. CONTRNTS

6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E ENGINE DRIVEABILITY AND EMISSIONS

6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL

6J INDUCTION

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7A

7A1

7B

7B

7C

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

7A AUTOMATIC TRANSMISSION (4L30-E)

7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)

7B MANUAL TRANSMISSION (AR-5)
7B MANUAL TRANSMISSION (MUA)
7C CLUTCH

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8A

8B

8C

8D8E8F

8G8H8I

8J

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

8A LIGHTING SYSTEM
8B WIPER / WASHER SYSTEM
8C ENTERTAINMENT
8D WIRING SYSTEM
8E METER AND GAUGE

8F BODY STRUCTURE
8G SEATS
8H SECURITY AND LOCKS

8I SUN ROOF/CONVERTIBLE TOP

8J EXTERIOR / INTERIOR TRIM

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9A

9J

9J1

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

9A SEAT BELT SYSTEM

9J SUPPLEMENTAL RESTRAINT SYSTEM

(SRS)

9J1 RESTRAINT CONTROL SYSTEM

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10A

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

10A CRUISE CONTROL SYSTEM

GENERAL INFORMATION 0A–1

SECTION 0A

GENERAL INFORMATION

CONTENTS

PAGE

General Repair Instructions ...............................................0A– 2

How To Use This Manual .................................................0A– 3

Identification ...........................................................0A– 6

Lifting Instructions ......................................................0A– 8

Torque Specifications ....................................................0A–10

Recommended Liquid Gasket .............................................0A–11

Recommended Thread Locking Agents .....................................0A–11

Abbreviations Charts ....................................................0A–12

Service Precaution

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

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

SECTION

GENERAL REPAIR INSTRUCTIONS

1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle.

2. Use covers on the vehicle body, seats, and
floor to prevent damage and/or
contaminations.

3. Disconnect the grounding cable from the
battery before performing service operations.
This will prevent cable damage or burning due
to shortcircuiting.

4. Raise the vehicle with a jack set against the
recommended lifting points (see “Lifting
instructions” in this section).

5. Support the vehicle on chassis stands.

6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.

7. The use of the proper tool(s) and special tool(s)
where specified is essential to efficient,
reliable, and safe service operations.

8. Always use genuine ISUZU replacement parts.

9. Discard used cotter pins, gasket, plastic clips,
O-rings, oil seals, lock washers, and self­locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.

10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct
reassembly.

11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and
design according to installation positions.

12. Clean all parts before inspection or
reassembly.

13. Clean the oil ports and other openings with
compressed air to make certain that they are
free of dirt and obstructions.

14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
installation.

15. Use the recommended liquid gasket to prevent
leakage.

16. Carefully observe all nut and bolt torque
specifications.

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

18. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the
following tools to recover and recycle the
Refrigerant-134a (R-134a).

For 134a:

Use the R-134a Refrigerant Recovery/Recovery/
Recycling/Recharging/System (ACR4) or its
equivalent to prevent the discharge of
refrigerant into the air.

0A–2 GENERAL INFORMATION

GENERAL INFORMATION 0A–3

HOW TO USE THIS MANUAL

1. Find the applicable section by referring to the
table of contents on the introduction page of
each manual.

2. In “Service Information”, an opening section of
each manual, the troubleshooting, maintenance
servicing, service data and/or information on
special tools required for the service operations
described in the next subsequent sections are
arranged and compiled so concisely that you
can see at a first glance.

3. Each section except the Service Information
section is basically arranged in the following
order of headings:

General description
On-vehicle service
Unit repair

4. The service operations are in two groups: one is
the “On-vehicle service” where operations can
be directly performed on the vehicle, and the
other is the “Unit repair” where the operations
are done on the work bench after removing the
unit from the vehicle.

5. Each service operation section begins with a
disassembled view of unit or equipment, which
is useful to find relative components, service
procedure, availability and contents of repair
kits, etc.

The number represents sequence of
removal or disassembly

Removal of unnumbered the parts
(excluding bolts, nuts, washers,
gaskets, cotter pins, etc.) is
unnecessary unless replacement is
needed.
Where parts replacement requires
specific information, instructions are
given in “Inspection and Repair”.

This frame is to be removed as a
large disassembly with all the parts
assembled in the frame. Each one of
the parts in the frame is removed as
a small disassembly.

Parts to be removed or installed as a
unit.

★ Parts contained in repair kit.

★ Indicates repair kit availability.

When the installation (reassembly)
procedure is the reverse order of the
removal (disassembly) procedure,
the sequence of service operation
and the parts names will be omitted.

Name of parts listed in sequence of
service operation.

For illustrations where there are few items to
be performed:

The sequence of removal
(disassembly) and the parts names
will be given.

The symbol mark attached to the title
indicates the action to be taken in the
operations of each title.
Example for this case;

1st step – Reassemble pinion shaft

The numbers given to the installation
(assembly) procedure are the same
as those given in the removal
(disassembly) procedure in the
illustration. Therefore, start with the
larger number during reassembly.

The titles of operations done in the
illustration are given in bold letters.
They are described in the order of
the procedure of the operations.

Special tools are identified with tool
name and/or tool number.
The drawing illustrates how the tool
is used.

Service data and specifications are
listed in table.

Important note.

The action symbol indicates the step
of service to be followed.
Refer to the following paragraph for
the meaning of each symbol.

information such as the notes in each operation,
and places where special tools are to be used
and their usage, and the specified service data.

0A–4 GENERAL INFORMATION

6. After the illustration, the details of each
operation are shown in the order the operations
are carried out in the illustration. Refer to the
explanations when checking important

GENERAL INFORMATION 0A–5

7. In this manual, the following action symbols
are used to indicate the type of service
operations to be performed.

. . . Remove or disconnect . . . Adjust

. . . Install or connect . . . Clean

. . . Disassemble . . . Pay close attention - Important

. . . Reassemble . . . Tighten to specified torque

. . . Align the marks . . . Use special tool(s)

. . . Correct direction . . . Lubricate with oil

. . . Inspect . . . Lubricate with grease

. . . Take measurement . . . Use liquid gasket

8. The service standard is indicated in terms of
“Standard” and “Limit”.
The “Standard” means the assembly standard
and standard range within which the parts are

considered serviceable.
“Limit” indicates the limit value (Correction or
replacement is necessary when measurement
is beyond this limit.)

VEHICLE IDENTIFICATION NUMBER (VIN)

This is the legal identification of the vehicle.
It appears on the manufacturer’s Plate attached to the left
of the engine compartment front end. VIN number is also
stamped on the rear right side of the frame.

VIN

VIN

ISUZU MOTORS LTD.

JAC UBS 26 G Y 7 200001

Sequential Number
Plant Code
Model Year (Y: 2000)
Wheel Base (D: Short, G: Long)
Engine Type (26: 6VE1, 73: 4JX1)
Vehicle Model
World Manufacturer Identifier

ENGINE SERIAL NUMBER

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

4JX1

0A–6 GENERAL INFORMATION

IDENTIFICATION

905RW014

905RW016

6VE1

GENERAL INFORMATION 0A–7

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.

96

0000 000

018

PART No.

SERIAL No.SAL

HYDRAMATIC
STRASBOURG

MADE IN FRANCE

G 20

272

FP

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.

Service parts ID plate

ISUZU MOTORS LT D. JAPAN

V.I.N.
M.D.
ENGINE
GRADE

TRANS.
TIRE

BODY TYPE

B. COLOR/TRIM

OPTION

905RW015

905RW018

905RW007

0A–8 GENERAL INFORMATION

LIFTING INSTRUCTIONS

CAUTION:

• 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.

• 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

Long wheel Base Model

Short Wheel Base Model

Lifting point

Supportable point

GENERAL INFORMATION 0A–9

LIFTING POINT; FRONT

When using floor jack, lift on the center of the skid plate.

SUPPORTABLE POINT; FRONT

Position the chassis stands at the bottom of the frame
sidemember, backward of front wheel.

LIFTING POINT; REAR

Position the floor jack at the center of the rear axle case
when lifting the vehicle.

SUPPORTABLE POINT; REAR

Position the chassis stands at the bottom of the frame
sidemember, just behind of the trailing link bracket.

SUPPORTABLE POINT; REAR

Position the chassis stands at the bottom of the rear axle
case.

TORQUE SPECIFICATIONS

STANDARD BOLTS

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

0A–10 GENERAL INFORMATION

N·m (kg·m / lb·ft)
N·m kg·cm / lb·in

Strength

Class

4.8 8.8 9.8

Refined Non-Refined

Bolt

Identifi-

cation

Bolt
Diameter x
Pitch (mm)

M 6x1.0 6 (60 / 52 7 (75 / 65 –
M 8x1.25 13 (130 / 113 17 (175 / 152 24 (240 / 208
M10x1.25 27 (2.8 / 20) 37 (3.8 / 27) 50 (5.1 / 37)
M12x1.25 61 (6.3 / 45) 76 (7.8 / 56) 95 (9.7 / 70)
M14x1.5 96 (9.8 / 71) 116 (11.9 / 86) 142 (14.5 / 105)
M16x1.5 130 (13.3 / 96) 170 (17.3 / 125) 200 (20.4 / 148)
M18x1.5 188 (19.2 / 139) 244 (24.9 / 180) 287 (29.3 / 212)
M20x1.5 258 (26.3 / 190) 337 (34.4 / 249) 396 (40.4 / 292)
M22x1.5 332 (33.9 / 245) 453 (46.3 / 335) 530 (54.1 / 391)

M24x2.0 449 (45.8 / 331) 570 (58.2 / 421) 692 (70.6 / 511)
*M10x1.5 26 (2.7 / 20) 36 (3.7 / 27) 48 (4.9 / 35)
*M12x1.5 57 (5.8 / 42) 71 (7.2 / 52) 89 (9.1 / 66)
*M14x2.0 89 (9.1 / 66) 110 (11.2 / 81) 133 (13.6 / 98)
*M16x2.0 124 (12.7 / 92) 162 (16.5 / 119) 191 (19.5 / 141)

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

FLARE NUTS

N·m (kg·m / lb·ft)

Pipe diameter mm (in) Torque Pipe diameter mm (in) Torque

4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)

6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)

8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)

4

No mark

8

8

9

GENERAL INFORMATION 0A–11

RECOMMENDED LIQUID GASKET

* RTV: Room Temperature Vulcanizer

NOTE:

1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.

2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.

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

the liquid gasket.

The connecting surfaces must be perfectly dry.

4. Do not apply LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greater

than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

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

Type Brand Name Manufacturer Remarks

RTV* Three Bond 1207B Three Bond For Engine Repairs

Silicon Base Three Bond 1207C Three Bond

Three Bond 1215 Three Bond For Axle Case
Three Bond 1280 Three Bond Repairs. T/M

Water Base Three Bond 1141E Three Bond For Engine Repairs

Three Bond 1104 Three Bond
Belco Bond 4 Isuzu

Solvent

Belco Bond 401 Isuzu

For Engine Repairs

Belco Bond 402 Isuzu
LOCTITE 515 Loctite

Anaerobic

LOCTITE 518 Loctite

All

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242 Blue

LOCTITE 262 Red

LOCTITE 270 Green

LOCTITE 271 Red

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.

Apply LOCTITE to at least 1/3 of the
bolt’s threaded area

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.

ABBREVIATIONS CHARTS

LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUAL

A – Ampere(s)
ABS – Antilock Brake System
A/C – Air Conditioning
ACCEL – Accelerator
ACC – Accessary
Adj – Adjust
A/F – Air Fuel Ratio
AIR – Air Injection Reaction System
ALDL – Assembly Line Diagnostic Link
Alt – Altitude
AMP – Ampere(s)
ANT – Antenna
APS – Absolute Pressure Sensor
ASM – Assembly
A/T – Automatic Transmission/Transaxle
ATDC – After Top Dead Center
Auth – Authority
Auto – Automatic

BARO – Barometic
Bat – Battery
Bat+ – Battery Positive Terminal
Bbl – Barrel
BCM – Body Control Module
BHP – Brake Horsepower
BP – Back Pressure
BTDC – Before Top Dead Center

°C –Degrees Celsius
Cat. Conv. – Catalytic Converter
cc – Cubic Centimeter
CCC – Computer Command Control
CCOT – Cycling Clutch Orifice Tube
CCP – Controlled Canister Purge
CID – Cubic Inch Displacement
CL – Closed Loop
CLCC – Closed Loop Carburetor Control
CO – Carbon Monoxide
Coax – Coaxial
Conn – Connector
Conv – Converter
CP – Canister Purge
CPS – Central Power Supply
Crank – Crankshaft
CTS – Coolant Temperature Sensor
Cu.In. – Cubic Inch
CV – Constant Velocity
Cyl – Cylinder(s)
C3I – Computer Controlled Coil Ignition

DBM – Dual Bed Monolith
Diff – Differential
DIS – Direct Ignition System
Dist –Distributor
DOHC – Double Overhead Camshaft
DVM – Digital Voltmeter (10 meg.)
DVOM – Digital Volt Ohmmeter
DVDV – Differential Vacuum Delay Valve

EAC –Electric Air Control
EAS – Electric Air Switching
EBCM – Electronic Brake Control Module
ECC – Electronic Climate Control
ECM – Electronic Control Module
ECU – Electronic Control Unit

– Engine Calibration Unit (PROM)
EECS – Evaporative Emission Control System
EFE – Early Fuel Evaporation
EFI – Electronic Fuel Injection
EGR – Exhaust Gas Recirculation
EGR/TVS – Exhaust Gas Recirculation/Thermostatic

Vacuum Switch
ELC – Electronic Level Control
ESC – Electronic Spark Control
EST – Electronic Spark Control
ETR – Electronically Tuned Receiver
EVRV – Electronic Vacuum Regulator Valve (EGR)
Exh – Exhaust

°F – Degrees Fahrenheit
FF – Front Drive Front Engine
FL – Fusible Link
FLW – Fusible Link Wire
FRT –Front
FWD – Front Wheel Drive
4WD – Four Wheel Drive
4x4 – Four Wheel Drive
4 A/T – Four Speed Automatic Transmission/Transaxle

Gal – Gallon
Gen – Generator
Gov – Governor
g – Gram

Harn – Harness
HC – Hydrocarbons
HD –Heavy Duty
HEI – High Energy Ignition
Hg – Mercury
HiAlt – High Altitude
HVAC – Heater-Vent-Air Conditioning

IAC – Idle Air Control
IC – Integrated Circuit
ID – Identification

– Inside Diameter
IDI – Integrated Direct Ignition
IGN – Ignition
ILC – Idle Load Compensator
INJ –Injection
IP – Instrument Panel
IPC – Instrument Panel Cluster
INT – Intake

J/B – Junction Block
km – Kilometers

km/h – Kilometer per Hour
kPa – KiloPascals
KV – Kilovolts (thousands of volts)
KW – Kilowatts

0A–12 GENERAL INFORMATION

SAE – Society of Automotive Engineers
Sec – Secondary
SFI – Sequential-port 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
Sw – Switch
SWB – Short Wheel Base
SYN – Synchronize

TAC – Thermostatic Air Cleaner
Tach – Tachometer
TBI – Throttle Body Injection
TCC – Transmission/Transaxle Converter Clutch
TCM – Transmission/Transaxle Control Module
TDC – Top Dead Center
Term – Terminal
TEMP – Temperature
TPS – Throttle Position Sensor
TRANS – Transmission/Transaxle
TURBO – Turbocharger
TV – Throttle Valve
TVRS – Television & Radio Suppression
TVS – Thermal Vacuum Switch
3 A/T – Three Speed Automatic Transmission/

Transaxle
2WD – Two Wheel Drive
4x2 – Two wheel Drive

U-joint – Universal Joint
V – Volt(s)

VAC – Vacuum
VIN – Vehicle Identification Number
VRRRE – Vehicle Refrigerant Recovery and Recycling

Equipment
V-ref – ECM Reference Voltage
VRV – Vacuum Reducer Valve
VSS – Vehicle Speed Sensor
VSV – Vacuum Switching 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

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
MAT – Manifold Air Temperature
MEM-CAL – Memory and Calibration Unit
Max – Maximum
M/C – Mixture Control
Min – Minimum
mm – Millimeter
MPFI – Multi-Port Fuel Injection
MPG – Miles per Gallon
MPH – Miles per Hour
M/T – Manual Transmission/Transaxle
MV – Millivolt

NA – Natural Aspirated
NC – Normally Closed
N·m – Newton Meters
NO – Normally Open
NOx – Nitrogen, Oxides of

OD – Outside Diameter
O/D – Over Drive
OHC – Overhead Camshaft
OL – Open Loop
O2– Oxygen

PAIR – Pulse Air Injection Reactor System
P/B – Power Brakes
PCV – Positive Crankcase Ventilation
PFI – Port Fuel Injection
PRESS – Pressure
PROM – Programmable Read Only Memory
P/N – Park/Neutral
P/S – Power Steering
PSI – Pounds per Square Inch
Pt. – Pint
Pri – Primary
PWM – Pulse Width Modulated

Qt – Quart
REF – Reference

RF – Right Front
RFI – Radio Frequency Interference
RH – Right Hand
RPM – Revolutions per Minute
RPO – Regular Production Option
RR – Right Rear
RS – Right Side
RTV – Room Temperature Vulcanizing
RVB – Rear Vacuum Brake
RVR – Response Vacuum Reducer
RWAL – Rear Wheel Antilock Brake
RWD - Rear Wheel Drive

GENERAL INFORMATION 0A–13

MAINTENANCE AND LUBRICATION 0B–1

SECTION 0B

MAINTENANCE AND LUBRICATION

CONTENTS

PAGE

Maintenance Schedule ...................................................0B– 2

Recommended Fluids, Lubricants and Fuels .................................0B– 7

Oil Viscosity Chart.......................................................0B–10

Service Precaution

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

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

SECTION

0B–2 MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE

GASOLINE ENGINE MODEL

I: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate

SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months

5
3
6

10

6

12

15

9

18

20
12
24

25
15
30

30
18
36

35
21
42

40
24
48

45
27
54

50
30
60

55
33
66

60
36
72

65
39
78

70
42
84

75
45
90

80
48
96

85
51

102

90
54

108

95
57

114

100

60

120

GASOLINE ENGINE
* Engine oil
* Engine oil filter

Oil leakage and contamination

* Timing belt

Spark plugs (For leaded fuel use)
Spark plugs (For unleaded fuel use)
Exhaust system
Radiator coolant concentration
Cooling system for water leakage
All hoses and pipes in engine compartment

for clog or damage
Fuel filter
Fuel leakage
Fuel tank

* Air cleaner element

Pre air cleaner
Engine drive belt
Valve clearance
O

2

Sensor (For leaded fuel use)

O

2

Sensor (For unleaded fuel use)

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R

(Replace every 165,000 km or 100,000 miles)
(Replace every 165,000 km or 100,000 miles)

(Check and adjust if necessary every 100,000 km or 60,000 miles)

(Replace every 150,000 km or 90,000 miles)

CLUTCH

Clutch fluid

Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid leakage
*

(1)

Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT

Loose connections

*

Universal joints and splines for wear

Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)

Shift on the fly system gear oil

Front axle shaft rubber boot for damage

Axle case for distortion or damage

Axle shafts for distortion or damage

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­STEERING
* Power steering fluid

Oil leakage

* Steering system for looseness or damage

Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage

SERVICE BRAKES

Brake fluid
Brake system for fluid leakage
Brake function

* Disc brake pads and discs wear

Brake pedal travel and free play
Pipes and hoses for loose connections or damage

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(1): Adjust or change automatic transmission fluid.
*Marks:Under severe driving conditions, additional maintenance is required.

Refer to “Maintenance schedule under severe driving conditions”.

AT
AT
AT

MAINTENANCE AND LUBRICATION 0B–3

GASOLINE ENGINE MODEL

I: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate

SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months

5
3
6

10

6

12

15

9

18

20
12
24

25
15
30

30
18
36

35
21
42

40
24
48

45
27
54

50
30
60

55
33
66

60
36
72

65
39
78

70
42
84

75
45
90

80
48
96

85
51

102

90
54

108

95
57

114

100

60

120

PARKING BRAKE

Parking brake function
Parking brake lever travel
Cables for looseness or damage and guide for

damage

Ratchet for wear or damage

SUSPENSION

Spring leaves for damage
Mount for looseness or damage
Shock absorbers for oil leakage
Shock absorbers mount for looseness
Rubber bushes of suspension wear or damage
Spring action for loss of balance due to weakening
Joint ball rubber boot for damage

WHEELS

Wheel pins
Wheel disc for damage
Hub bearing grease
Front and rear hub bearings for looseness
Tire pressure and damage
Tire rotation

OTHERS

Bolts and nuts on chassis and body
Lube front free-wheeling hubs

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(Rotate as required)

*Marks:Under severe driving conditions, additional maintenance is required.

Refer to “Maintenance schedule under severe driving conditions”.

0B–4 MAINTENANCE AND LUBRICATION

DIESEL ENGINE MODEL

I: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate

SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months

5
3
6

10

6

12

15

9

18

20
12
24

25
15
30

30
18
36

35
21
42

40
24
48

45
27
54

50
30
60

55
33
66

60
36
72

65
39
78

70
42
84

75
45
90

80
48
96

85
51

102

90
54

108

95
57

114

100

60

120

DIESEL ENGINE
* Engine oil
* Engine oil filter

Oil leakage and contamination

Idling speed and acceleration

Fan belt tension and damage

Timing belt
Exhaust system
All hoses and pipes in engine compartment

for clog or damage

Valve clearance

* Air cleaner element

Fuel filter
Radiator coolant concentration
Cooling system for water leakage

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NOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the left

side of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back)
cover for installation location of the sub (2nd) oil filter.

(Replace every 200,000 km or 125,000 miles)

*Marks:Under severe driving conditions, additional maintenance is required.

Refer to “Maintenance schedule under severe driving conditions”.

CLUTCH

Clutch fluid

Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT

Loose connections
* Universal joints and splines for wear

Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)

Shift on the fly system gear oil

Front axle shaft rubber boot for damage

Axle case for distortion or damage

Axle shafts for distortion or damage

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STEERING
* Power steering fluid

Oil leakage

* Steering system for looseness or damage

Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage

SERVICE BRAKES

Brake fluid
Brake system for fluid leakage
Brake function

* Disc brake pads and discs wear

Brake pedal travel and free play
Pipes and hoses for loose connections or damage

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-

-

-

-

R

I
I
I
I
I
I
I
I
I

R

I
I
I
I
I

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

I
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-

­I
I

­I
I
I
I
I

-

-

-

-

-

-

-

-

-

-

-

-

-

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I
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I
I
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I
I
I

I
I
I
I
I
I

AT
AT

MAINTENANCE AND LUBRICATION 0B–5

DIESEL ENGINE MODEL

I: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate

SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months

5
3
6

10

6

12

15

9

18

20
12
24

25
15
30

30
18
36

35
21
42

40
24
48

45
27
54

50
30
60

55
33
66

60
36
72

65
39
78

70
42
84

75
45
90

80
48
96

85
51

102

90
54

108

95
57

114

100

60

120

PARKING BRAKE

Parking brake function
Parking brake lever travel
Cables for looseness or damage and guide for

damage

Ratchet for wear or damage

SUSPENSION

Spring leaves for damage
Mount for looseness or damage
Shock absorbers for oil leakage
Shock absorbers mount for looseness
Rubber bushes of suspension wear or damage
Spring action for loss of balance due to weakening
Joint ball rubber boot for damage

WHEELS

Wheel pins
Wheel disc for damage
Hub bearing grease
Front and rear hub bearings for looseness
Tire pressure and damage
Tire rotation

OTHERS

Bolts and nuts on chassis and body
Lube front free-wheeling hubs

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

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I
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T

I

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I

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-

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-

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-

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-

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-

-

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­I
I

I

-

-

-

-

-

-

-

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-

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-

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-

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T

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L

-

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-

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I

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-

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L

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I

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-

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I

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-

-

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I
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L

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I
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I

T

I

­I
I

I

-

(Rotate as required)

*Marks:Under severe driving conditions, additional maintenance is required.

Refer to “Maintenance schedule under severe driving conditions”.

0B–6 MAINTENANCE AND LUBRICATION

Item Interval

Condition

ABCD A+D

Engine oil G : Change every 5,000 km (3,000 miles)

D : Change every 5,000 km (3,000 miles)

●●

Engine oil filter G : Replace every 10,000 km (6,000 miles)

D : Replace every 5,000 km (3,000 miles)

●●

Air cleaner element G : Replace every 20,000 km (12,000 miles)

D : Replace every 40,000 km (25,000 miles)

●

Power steering fluid Replace every 50,000 km (30,000 miles) ●●
Steering system for looseness

or damage

Inspect every 5,000 km (3,000 miles) ●

Universal joints and sleeves Inspect for wear and lubricate every 7,500 km (4,500 miles) ●●
Transmission with MT Change every 20,000 km (12,000 miles)

transfer case oil after changing at initial 10,000 km (6,000 miles)

●

Transmission :

AT

Change every 32,000 km (20,000 miles)

●●● ●

Transfer:

TF Change every 20,000 km (12,000 miles)

after changing at initial 10,000 km (6,000 miles)

●

Differential oil Change every 20,000 km (12,000 miles)

after changing at initial 5,000 km (3,000 miles) ●
Disc brake pads and discs Inspect every 5,000 km (3,000 miles) ●●●
Timing belt G : Replace every 120,000 km (75,000 miles) ●●

EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE

Explanations of the services listed in the proceeding
Maintenance Scheduled are presented in “Service
Information” section of each manual.

Replace all questionable parts and note any
necessary repairs as you perform these
maintenance procedures.

MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS

Severe driving conditions

A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads

MAINTENANCE AND LUBRICATION 0B–7

RECOMMENDED FLUIDS, LUBRICANTS

AND FUELS

In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very
important to select and use correctly best lubricants and diesel fuels.

When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below,
according to the maintenance schedule for each vehicle model.

The lubrication intervals in the maintenance schedule and the coverage and period of new vehicle warranty
are based on the use of ISUZU genuine lubricants or recommended lubricants as given in the chart which
will serve as a guide for selecting lubricants of proper brand name.

LUBRICATION MAKE BRAND / TYPE

GRADE

API ACEA

ISUZU GENUINE BESCO MULTI – Z TYPE CE (10W-30) CE
ISUZU GENUINE BESCO MULTI – Z (10W-30) CD
ISUZU GENUINE BESCO MULTI – Z SUV (5W-30) CD
ISUZU GENUINE BESCO S – 3 (10W, 20W, 30, 40) CD

Diesel engine crankcase EXXON / ESSO ESSOLUBE XD-3+ (15W-40) CG4/CF E2/B2

EXXON / ESSO ESSOLUBE XT331 (15W-40) CG-4/CF E2/B2
MOBIL DELVAC HP (15W-40, 20, 30, 40) CF/CE
CALTEX / CHEVRON DELO CXJ (15W-40, 30, 40) CF
SHELL RIMURA D (15W-40, 30, 40 CD/CF
ELF PERFORMANCE TROPHY (15W-40) CE E3
TOTAL RUBIA XT (15W-40) CF-4 E2

ISUZU GENUINE BESCO RACING ACE (7.5W-30) SG
ISUZU GENUINE BESCO MULTI ACE (7.5W-30) SF
ISUZU GENUINE BESCO ACE (10W-30) SE

EXXON / ESSO ESSO SUPERFLO (15W-40, 15W-50, 20W-50) SJ A2
Gasoline engine EXXON / ESSO ESSO UNIFLO (15W-40, 15W-50, 20W-50) SJ A2
crankcase MOBIL MOBIL SUPER XHP

(15W-40, 15W-50, 20W-50)

SJ A3
CALTEX / TEXACO HAVOLINE FORMULA-3 (15W-40, 20W-50) SJ
SHELL HELIX SUPER (10W-30) SJ
ELF SUPER SPORTI S (15W-40) SG
TOTAL QUARTZ 5000 (15W-40, 20W-50) SJ A2

ISUZU GENUINE BESCO GEAR OIL TRANSAXLE (5W-30) SG

EXXON / ESSO ESSOLUBE XD-3+ (15W-40) CG-4/CF E2/B2
EXXON / ESSO ESSOLUBE XT331 (15W-40) CG-4/CF E2/B2

Manual transmission MOBIL MOBIL SUPER (10W-30) SH
Transfer case CALTEX / TEXACO HAVOLINE FORMULA-3 (15W-40, 20W-50) SH

SHELL RIMURA D (15W-40) CD/CF
ELF SUPER SPORTI S (15W-40) SG/CD
TOTAL QUARTZ 5000 (15W-40, 20W-50) SJ/CF A2/B2

ISUZU GENUINE BESCO GEAR OIL SH (80W-90, 90, 140) GL-5
ISUZU GENUINE BESCO SHIFT ON THE FLY (75W-90) GL-5

Differential

EXXON / ESSO GEAR OIL GX (85W-90) GL-5

Shift on the fly system

MOBIL MOBILUBE HD (80W-90, 85W-140) GL-5

(GL-5 only)

CALTEX THURBAN GL-5 EP (80W-90, 85W-140) GL-5
SHELL SPIRAX HD (90, 140) GL-5
ELF TRANSELF TYPE B (80W-90, 85W-140) GL-5
TOTAL TRANSMISSION TM (80W-90, 85W-140) GL-5

ISUZU GENUINE BESCO GEAR OIL LSD (140) GL-5

EXXON / ESSO GEAR OIL LSA (90) GL-5

Differential MOBIL MOBILUBE HD LS (80W-90) GL-5
(Limited Slip Differential) CALTEX GEAR OIL LSD (90) GL-5

ELF TRANSELF TYPE BLS (90) GL-5
TOTAL TRANSMISSION DA (85W-90) GL-5

0B–8 MAINTENANCE AND LUBRICATION

FLUID TYPE

Clutch and brake fluid reservoir Besco brake fluid (For light duty)

Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade

LUBRICATION MAKE BRAND / TYPE

GRADE

API ACEA

ISUZU GENUINE BESCO ATF II, ATF III

EXXON / ESSO ESSO ATF D (DEXRONII-D)
Automatic transmission MOBIL MOBIL ATF (DEXRONIII)
Power steering CALTEX ATF HD (DEXRONII)

SHELL SHELL DONAX TA (DEXRONII-D)

ELF ELFMATIC G3 (DEXRONIII)

TOTAL TOTAL FLUID IID (DEXRONII-D)

ISUZU GENUINE

BESCO L-2 GREASE (No.2), L-3 GREASE (No.3)

Propeller shaft sliding EXXON / ESSO RONEX MP (No.2)
yoke, Universal joint MOBIL MOBILGREASE HP 222 (No.2)
Grease fitting CALTEX / TEXACO STARPLEX-2 (No.2)
(General purpose grease)

SHELL SHELL RETINAX A (No.2)

TOTAL MULTIS EP2, EP3 (No.2, No.3)
Propeller shaft sliding ISUZU GENUINE ONE LUBER MO GREASE

yoke EXXON / ESSO BEACON Q2 (No.2)
Universal joint EXXON / ESSO MULTIPURPOSE GREASE (Moly) (No.2)

General purpose grease

CALTEX MOLYTEX GREASE EP2 (No.2)

(

in Molybdenum

)

TOTAL TOTAL MULTIS MS2 (No.2)

ISUZU GENUINE BESCO LLC SUPER TYPE E

TEXACO / CALTEX HAVOLINE EXTENDED LIFE ANTIFREEZE
Engine cooling system COOLANT

HAVOLINE XLC
EXTENDED LIFE COOLANT 6280

NOTE:
When the recommended lubricants are specified in the workshop manual, follow them.

MAINTENANCE AND LUBRICATION 0B–9

NOTE:
Use the applicable standard or equivalent for diesel fuels.

DIESEL FUEL/APPLICABLE STANDARD

JIS (JAPANESE INDUSTRIAL STANDARD) Based on K2204 GAS OIL
DIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590 : 1997
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE J-313C
BS (BRITISH STANDARD) Based on BS EN590 : 1997

0B–10 MAINTENANCE AND LUBRICATION

OIL 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

APPLY GASOLINE ENGINE OIL

SAE 30

SAE 5W-30

SAE 15W-40,20W-40,20W-50

SAE 10W-30

SAE 20,20W

SAE 10W

EG-01

(Multi grade)

(Single grade)

VISCOSITY GRADE - AMBIENT TEMPERATURE

−25˚C

−13˚F

−15˚C
5˚F

38˚C

100˚F

15˚C
60˚F

0˚C

32˚F

OIL VISCOSITY CHART FOR DIESEL ENGINE

APPLY DIESEL ENGINE OIL

VISCOSITY GRADE - AMBIENT TEMPERATURE

(Multi grade )

SAE 5W-30

SAE 10W-30

–25°C –15°C0°C–10°C15°C25°C30°C

–13°F5°F32°F14°F60°F77°F86°F

905RW017

MAINTENANCE AND LUBRICATION 0B–11

OIL VISCOSITY CHART FOR MANUAL TRANSMISSION AND TRANSFER CASE

APPLY ENGINE OIL

SAE 5W-30

SAE 15W-40,20W-40,20W-50

SAE 10W-30

SAE 40,50

ET-12

(Multi-grade)

(Single grade)

VISCOSITY GRADE - AMBIENT TEMPERATURE

SAE 30

−25˚C

−13˚F

−10˚C
14˚F

35˚C

95˚F

20˚C

68˚F

5˚C

41˚F

10˚C

50˚F

OIL VISCOSITY CHART FOR FRONT AXLE (Manual and Auto locking hub model)

AND REAR AXLE

APPLY GEAR OIL

SAE 75W-90

SAE 80W-140

SAE 80W-90

GA-06

(Multi grade)

(Single grade)

GEAR OIL VISCOSITY GRADE - AMBIENT TEMPERATURE

−25˚C

−13˚F

30˚C

86˚F

−10˚C
14˚F

35˚C

95˚F

15˚C

59˚F

0˚C

32˚F

SAE 80W

SAE 75W

SAE 140

SAE 90

0B–12 MAINTENANCE AND LUBRICATION

OIL VISCOSITY CHART FOR FRONT AXLE (Shift on the fly model)

APPLY GEAR OIL

GEAR OIL VISCOSITY GRADE – AMBIENT TEMPERATURE

(Multi grade)

SAE 80W – 90, 80W – 140

SAE 75W – 90

–25°C
–13°F14°F32°F59°F86°F95°F

–10°C15°C30°C35°C0°C

SECTION 00

SERVICE INFORMATION

CONTENTS

PAGE

Troubleshooting ........................................................00– 3

Main Data and Specifications .............................................00–45

Fixing Torque...........................................................00–48

Special Tools ...........................................................00–52

SERVICE INFORMATION 00 – 1

SECTION

00 – 2 SERVICE INFORMATION

MEMO

SERVICE INFORMATION 00 – 3

TROUBLESHOOTING

CONTENTS

PAGE

Circuit Diagram .........................................................00– 4

Heating Cycle Troubleshooting ............................................00–16

Fan Control Knob (Fan Switch) ............................................00–17

Blower Motor Does Not Run ............................................00–18

Blower Motor Does Not Run In Certain Position............................00–19

Blower Motor Does Not Stop at “OFF” Position............................00–19

Ceramic Heater .........................................................00–20

Ceramic Heater Does Not Operate .......................................00–21

Ceramic Heater Does Not Stop ..........................................00–22

Air Conditioning Cycle Troubleshooting.....................................00–23

Checking Refrigerant System with Manifold Gauge.........................00–24

Magnetic Clutch ........................................................00–27

6VD1/6VE1 Engine ....................................................00–27

4JG2 Engine .........................................................00–31

4JX1 Engine..........................................................00–34

Condenser Fan..........................................................00–37

Condenser Fan Does Not Run ...........................................00–38

Condenser Fan Does Not Stop ..........................................00–39

Compressor Troubleshooting .............................................00–40

Individual Inspection.....................................................00–41

00 – 4 SERVICE INFORMATION

CIRCUIT DIAGRAM

6VD1/6VE1 (RHD)

0.5 LG

0.5 LG

B -1

BODY-RH

BODY-LH

FRAME

ENG.

5B

BODY

8B / R

8 B

+

_

P - 6

30B

P - 1

P - 5

P - 10

P - 7

P - 2

FL-1
80A MAIN

FL-4
30A CONDENSER FAN

F-6
15A RR COOLER

I-23

2

I-23

6

A/C SW

BLOWER
MOTOR

0.3 G/Y

I-42

I-42

I-42

1

3

2

16

0.5 LG

1

5W

B-19

0.5 BR

0.5 BR

0.5 P/G

H-24 H-51

13 1

H-16

7

H-16

2 L/R

I-41

I-18

I-18

I-18

I-18

1.25 L/O

1.25 L/Y

0.85 L/W

3

3

6

5

2

4

1

6

FAN SW

HEATER BEZEL

ILLUMINATION

I-23

I-23

I-18

I-18

3

5

4

1

0.3 R/G

0.85 G/R

ILLUMINATION

CONTROLLER (3)

RELAY ; TAIL (4)

H-20

1

2 B

2

BLOWER
RESISTOR

I-41

I-41

I-41

I-41

2L/B

2 B

1.25B

M

B-5

2

1

B-5

B-361B-36

B-36B-36

2

34

I-23

1

0.85W/G

3L/R

3L

C-19
25A BLOWER

0.3B

ELECTRONIC
THERMOSTAT

5W3W

0.5 BR

1.25 L/O

0.5 LG/Y

0.3 G/Y 0.3 G/Y

RELAY ;
HEATER AND
A/C

C-20 10A
AIR CON.

0.5 BR0.5 BR

RELAY;STARTER (1)

5W

H-14

16

H-26

2L/B

2

H-20

H-13

10

0.3 G/Y

0.5 LG

D08RY00128

SERVICE INFORMATION 00 – 5

D08RY00129

0.5 LG

X - 5 X - 5

X - 5X - 5

14

RELAY ;
A/C THERMO

32

0.5 P/G

0.3 G/Y

1.25 B

X - 7 X - 7

X - 7X - 7

43

21

H - 41

7

H - 41

5

H - 6

9

E - 3

1

0.5BR/Y0.5BR/Y

0.5G/B0.5G/B

0.5BR/Y

0.5 BR

PCM (E15)

PCM (B14)

0.5 G/O

0.5

G/W

0.5

G/W

0.5

G/W

RELAY;

A/C COMPRESSOR

MAGNETIC CLUTCH

0.5 LG

0.5 BR

C - 25 C - 25

PRESSURE SW
(CONDENSER)

2

H-41

12

C - 39FENDER-RH

1

1

H-51

6

H-15

1

1

H-31

2

H-50

7

C-39

0.5 LG/Y

0.5 BR

0.5 BR

0.5 BR

0.5 BR

0.5 LG

0.5B

0.5B3B 0.5LG/B0.5LG/B0.5LG/B

R - 3

BODY-RR

X - 6 X - 6

X - 6

H-50

RR COOLER

CONNECTOR

X - 6

RELAY ; RR COOLER

12

X-19 X-19

5334

C-25

3

TRIPLE SW

4

H-51

0.5 W/G
3

H-42

0.5 W/G
2

0.5 W/G
4

X-191X-19

C-75

1.25L

1

H - 16

3

0.3G/Y

M

2

C-75

1.25B

(IF EQUIPPED)

RELAY; CONDENSER FAN

CONDENSER FAN

1.25 L/O

C-25

H-41

6

4

H-51

2

00 – 6 SERVICE INFORMATION

6VD1/6VE1-(LHD)

0.5 LG

H - 26

14

B - 2

BODY-LH

BODY-RH

FRAME

ENG.

5B

BODY

8B / R

8 B

+

_

P - 6

30B

P - 1

P - 5

P - 10

P - 7

P - 2

FL-1
80A MAIN

I - 23

2

I - 23

I - 23

6

1

A/C SW

BLOWER
MOTOR

0.3 G/Y

I-42

I-42

I-42

1

3

2

21

0.5LG

H-14

1

5W

B-19

0.5 BR

B

OFF

ST

IG2

ACC

STARTER SW

IG1

B

2

1

4

2

5W

FL-2
50A KEY SW

H-14

2

3W/B

B-11

0.5 BR

0.5 P/G

H - 9 H - 51

19 1

H-16

17

H-16

0.5LG

0.5 LG

0.5 LG

0.3G/Y

2 L/R

I-41

I - 18

I - 18

I - 18

I - 18

1.25 L/O

1.25 L/Y

0.85 L/W

3

3

6

5

2

4

1

6

FAN SW

HEATER BEZEL
ILLUMINATION

I - 23

I - 23

I - 18

I - 18

3

5

4

1

0.5 R/G

0.85 G/R

ILLUMINATION

CONTROLLER (3)

FUSE F-12

H - 48

15

2 B

2

BLOWER
RESISTOR

I-41

I-41

I-41

I-41

2L/B

2 B

0.3G/Y

1.25B

M

B - 5

1

2

C-11 10A
AUDIO(ACC),MIRROR

B - 5

B-361B-36

B-36B-36

2

34

3L/B 0.5O/G

3L/R3L

C-19
25A BLOWER

0.5B

ELECTRONIC
THERMOSTAT

5W3W

3W/B

3W/B

0.3 G/Y

1

RELAY ;
HEATER AND
A/C

C-20 10A
AIR CON.

0.5 BR

0.5 BR

B - 11 B - 11

FL-4
30A CONDENSER FAN

F-1
15A RR COOLER

1.25 L/O

0.5LG/Y

0.3 G/Y

D08RY00130

SERVICE INFORMATION 00 – 7

D08RY00131

0.5BR/Y

5

0.5BR/Y

H - 41

5

H-15

1

1

H-31

2

H-50

7

C-39

X - 5 X - 5

X - 5X - 5

14

RELAY ;
A/C THERMO

32

H-41

6

0.5 P/G

0.5 BR0.5 G/O

0.5 BR

0.5 LG/Y

0.5 BR

0.5 BR

0.5 BR

X - 7 X - 7

X - 7X - 7

43

21

H - 41

7

H - 6

9

E - 3

1

0.5BR/Y

0.5G/B

0.5B

0.5B3B 0.5LG/B0.5LG/B0.5LG/B

R - 3

BODY-RR

PCM (B14)

PCM (E15)

X - 6 X - 6

X - 6

H-50

RR COOLER

CONNECTOR

X - 6

RELAY ; RR COOLER

12

RELAY;

A/C COMPRESSOR

MAGNETIC CLUTCH

0.5G/W

0.5G/W

0.5G/W

H-51

0.5 BR

C - 25 C - 25

DUAL PRESSURE SW

or

TRIPLE SW

2

H-41

121

H-51

4

X-19 X-19

5334

C-25

3

TRIPLE SW

4

H-51

0.5 W/R
3

H-42

0.5 W/R
2

0.5 W/R
4

X-191X-19

C-75

1.25L

1

H - 12

17

0.3G/Y

M

2

C-75

1.25B

(IF EQUIPPED)

RELAY; CONDENSER FAN

CONDENSER FAN

1.25 L/O

C-25

C-39

FENDER-RH

2

0.3 G/Y

0.5 LG0.5 LG

2

00 – 8 SERVICE INFORMATION

4JG2 (RHD)

D08RY00124

BODY-RH

BODY-LH

8 B

P - 6

BODY

B-19

B-1

8B / R

+

P - 1

P - 5

_

5B

30B

P - 10

P - 7

FRAME

ENG.

RELAY ; CHARGE (1)

10

H-13

0.85W/G

B-361B-36

34

0.3B

1.25B

P - 2

B-36B-36

3L

B-5

M

B-5

H-20

I-41

2

3L/R

2

1

2L/B

2

2L/B

2

FL-1
80A MAIN

5W

5W

H-14

5W

3W

RELAY ;
HEATER AND
A/C

C-19
25A BLOWER

BLOWER
MOTOR

BLOWER
RESISTOR

I-41

I-41

I-41

I-41

1

C-20 10A
AIR CON.

3

6

4

1

FL-4 30A
CONDENSER FAN

F-6 10A
RR COOLER

I-23

0.5BR

I-23

16

H-26

0.3G/Y

2L/R

1.25L/O

1.25L/Y

0.85L/W

0.5BR

2

1

6

3

5

2

A/C SW

6

0.5LG

I-23

ELECTRONIC
THERMOSTAT

HEATER BEZEL

ILLUMINATION

I-18

I-18

I-18

I-18

0.5 BR

I-42

FAN SW

0.5 LG

3

I-42

0.5LG

0.3G/Y

1

0.5 P/G 0.5 P/G

I-42

2

3

I-23

5

I-23

4

I-18

1

I-18

2B

H-20

2 B

1.25 L/O

0.5 LG/Y

7

H-16

13

0.5 LG

H-24

PRESSURE SW
(CONDENSER)

RELAY ;
A/C THERMO

16

H-16

RELAY ; TAIL (4)

ILLUMINATION

CONTROLLER (3)

0.85 G/R

0.3 R/G

0.3GY

1

FENDER-LH

0.3G/Y

0.5

0.5

C-16

0.5
H-51

0.5

C-25

C-25

H-51

H-41

0.5

LG

1

BR

1

2
4

G/W

0.5 BR

10

G/W

G/W

1 2

X-5 X-5

X-5X-5

34

0.5 G/O
6

H-41

0.5G/O
1

H-5

0.5G/O
1

E-3

MAGNETIC CLUTCH

7

0.5 BR

0.5G/O0.5 G/O

1

C-69

VSV; FICD

C-69

2

0.5 B

SERVICE INFORMATION 00 – 9

D08RY00125

6

H-15

1

1

H-31

2

H-50

1

C-39

0.5 LG/Y

0.5 BR

0.5B

0.5B3B 0.5LG/B0.5LG/B0.5LG/B

R - 3

BODY-RR

X - 6 X - 6

X - 6

H-50

RR COOLER

CONNECTOR

X - 6

RELAY ; RR COOLER

12

H-51

X-19 X-19

5334

C-25

3

TRIPLE SW

4

H-51

0.5 W/R
3

H-42

0.5 W/R
2

0.5 W/G
4

X-191X-19

C-75

1.25L

1

0.5B

M

2

C-75

1.25B

(IF EQUIPPED)

RELAY; CONDENSER FAN

CONDENSER FAN

1.25 L/O

C-25

C-39

FENDER-RH

3

C-39

7

0.5 LG0.5 LG

2

00 – 10 SERVICE INFORMATION

4JG2 (LHD)

D08RY00126

BODY-LH

BODY-RH

+

_

8 B

P - 6

BODY

2

B - 11 B - 11

B

IG1

STARTER SW

RELAY ;
HEATER AND
A/C

B-19

B - 2

P - 1

P - 5

P - 10

ENG.

3W/B

1

30B

ST

8B / R

5B

FRAME

IG2

B-11

B-361B-36

P - 2

P - 7

3W/B

4

B

2

OFF

ACC

1

3L/B 0.5O/G

C-11 10A
AUDIO(ACC),MIRROR

2

B-36B-36

34

3L/R3L

C-19
25A BLOWER

1

B - 5

0.5B

M

B - 5

2

2L/B2L/B

H - 48

4

2

I - 41

1.25B

FL-1
80A MAIN

BLOWER
MOTOR

BLOWER
RESISTOR

5W

FL-2
50A KEY SW

3W/B

2

H-14

C-20 10A
AIR CON.

3

I - 41

6

I - 41

4

I - 41

1

I - 41

H-14

5W

5W3W

1

0.5 BR

2 L/R

1.25 L/O

1.25 L/Y

0.85 L/W

FL-4
30A CONDENSER FAN

F-1
15A RR COOLER

14

H - 26

0.5 BR

2

I - 23

I - 23

1

6

3

5

2

A/C SW

I - 23

I - 18

I - 18

I - 18

I - 18

6

HEATER BEZEL

ILLUMINATION

FAN SW

0.5 BR

0.3 G/Y

ELECTRONIC
THERMOSTAT

3

I - 23

5

I - 23

4

I - 18

1

I - 18

FUSE F-12

0.85 G/R

0.3G/Y

H - 48

1.25 L/O

0.5LG/Y

H-16

0.5LG

0.5 LG

I - 42

ILLUMINATION

CONTROLLER (3)

0.5 R/G

2 B

15

2 B

17

0.5LG

3

I - 42

2

0.3 G/Y

I - 42

H - 9

1

0.5 BR

19

0.5 P/G

0.5 LG

0.5 LG

H - 16

1

H - 51

21

SERVICE INFORMATION 00 – 11

D08RY00127

5

H-15

1

1

H-31

2

H-50

2

C-39

X - 5 X - 5

X - 5X - 5

34

RELAY ;
A/C THERMO

12

H-41

6

0.5 P/G

0.5 BR0.5 G/O

0.5 G/O

0.5 G/O

0.5 G/O

0.5 LG/Y

0.5 BR

H - 5

1

E - 3

C-16

1

0.5B

0.5B3B 0.5LG/B0.5LG/B0.5LG/B

R - 3

BODY-RR

X - 6 X - 6

X - 6

H-50

RR COOLER

CONNECTOR

X - 6

RELAY ; RR COOLER

12

MAGNET CLUTCH

0.5G/W

0.5G/W

0.5G/W

H-51

0.5 BR

C - 25 C - 25

DUAL PRESSURE SW

or

TRIPLE SW

2

H-41

101

H-51

4

X-19 X-19

533

3

0.5B

C-69

C-69

VSV;FICD

1

2

4

C-25

3

TRIPLE SW

4

H-51

0.5 W/R
3

H-42

0.5 W/R
2

0.5 W/R
4

X-191X-19

C-75

1.25L

1

0.3B

M

2

C-75

1.25B

(IF EQUIPPED)

RELAY; CONDENSER FAN

CONDENSER FAN

1.25 L/O

C-25

C-39

FENDER-RH

2

0.5 LG0.5 LG

2

00 – 12 SERVICE INFORMATION

4JX1 (RHD)

D08RY00132

P - 6

BODY

FL-1

P - 2

10

2

HEATER &
A/C RELAY

B-36B-36

34

3L/R

C-19
25A BLOWER

3L

2

B-5

BLOWER

M

MOTOR

80A MAIN

5W

5W

H-14

5W

3W

8B / R

+

P - 1

P - 5

_

5B

30B

8 B

P - 10

P - 7

ENG.

FRAME

CHARGE

RELAY(1)

H-13

0.85W/G

B-361B-36

0.3B

1

FL-3
40A C/HEATER

C-20 10A
AIR CON.

H-26

0.5BR

3W/L

13

3

I-42

0.3G/Y

7

H-16

1

0.5 P/G 0.5 P/G

I-42

2

0.5BR

PRESSURE SW
(CONDENSER)

A/C THERMO
RELAY

16

H-16

1

C-25

C-25

2

0.5 G/W

12

H-41

0.5 G/W

12

X-5 X-5

34

H-41

X-5X-5

0.5G/O0.5G/O

7

THRMO SW
RELAY

21

X-21 X-21

X-21X-21

43

0.5 G/Y

ECM

(J1-23)

0.5 G/B

0.5G/B

12

X-12 X-12

RELAY

H-15

0.5
B-44

Y/G

X-12X-12

34

11

1

CERAMIC HEATER

5

H-41

0.5 BR

0.5BR

16

2

I-23

A/C SW

I-23

I-23

1

ELECTRONIC
THERMOSTAT

0.3G/Y

H-24

6

0.5LG

0.5 LG 0.5 LG0.5 LG

I-42

BODY-RH

BODY-LH

B-19

B-2

1.25B

B-5

H-20

I-41

2L/B

2L/B

FULL HOT
SW

8

H-26

MAGNETIC
CLUTCH

DIODE

ECM

(JI-31)

CERAMIC
HEATER

B-44

2

15

H-13

0.5

G/W

1

B-49

3W/G 3W/G

B-49

2

0.3

G/Y

1

B-48

B-48

2

2B

1

6

3

5

2

I-18

I-18

I-18

I-18

HEATER BEZEL

ILLUMINATION

FAN SW

I-23

I-23

I-18

I-18

TAIL RELAY (4)

3

0.85 G/R

5

4

0.3G/Y

1

2B

1

H-20

2 B

ILLUMINATION

CONTROLLER

0.3G/Y

0.3 R/G

2

2

BLOWER
RESISTOR

I-41

I-41

I-41

I-41

3

6

4

1

2L/R

1.25L/O

1.25L/Y

0.85L/W

H-6

0.5G/O

H-17

0.3G/Y

0.5G/O

E-27

2

4

1

SERVICE INFORMATION 00 – 13

D08RY00133

ECM

(J2-11)

0.5 L/P0.5 L/P

I-25

I-25

3

I-25

2

I-25

6

I-25

5

4

1

H-16

14

0.3R/G

0.85G/R0.85G/R

ILLUMINATION

CONTROLLER

TAIL RELAY(4)

ENGINE
WARMING
SW

1.25B 0.5B

C-74 C-74

12

THERMO SW

H-9

19

0.5G/W 0.5G/W

0.5 L/P

0.5G/B

H-26

5

H-42

16

H-5

2

0.5B

H-16

15

00 – 14 SERVICE INFORMATION

4JX1 (LHD)

D08RY00134

8 B

P - 6

BODY

+

P - 1

P - 5

_

30B

P - 10

ENG.

STARTER SW

8B / R

5B

P - 7

FRAME

(ACC)

0.5O/G

B-361B-36

0.5B

FL-1
80A MAIN

P - 2

2

HEATER &
A/C RELAY

B-36B-36

34

3L/R

C-19
25A BLOWER

3L

1

B-5

BLOWER

M

MOTOR

H-14

FL-3
40A C/HEATER

5W

5W

1

0.5BR

C-20 10A
AIR CON.

14

H-26

I-23

0.5BR

I-23

0.3G/Y

5W

3W

2

A/C SW

I-23

1

ELECTRONIC
THERMOSTAT

3W/L

19

3

I-42

0.3G/Y

17

H-16

1

0.5 P/G 0.5 P/G

I-42

2

0.5BR

PRESSURE SW
(CONDENSER)

A/C THERMO
RELAY

16

H-13

1

C-25

C-25

2

0.5 G/W

12

H-41

0.5 G/W

12

X-5 X-5

34

H-41

X-5X-5

0.5G/O0.5G/O

7

THERMO
SW
RELAY

21

X-21 X-21

X-21X-21

43

0.5 G/Y

ECM

(J1-23)

0.5 G/B

0.5G/B

12

X-12 X-12

RELAY

H-12

0.5
B-44

Y/G

X-12X-12

34

14

1

CERAMIC HEATER

5

H-41

0.5 BR

H-9

6

0.5LG

0.5 LG 0.5 LG0.5 LG

I-42

BODY-LH

BODY-RH

B-19

B-2

1.25B

B-5

H-48

I-41

2L/B

2L/B

FULL HOT
SW

MAGNETIC
CLUTCH

DIODE

ECM

(JI-31)

H-26

CERAMIC
HEATER

B-44

2

5

H-13

0.3

G/W

1

B-49

3W/G 3W/G

B-49

2

10

1

B-48

B-48

2

2B

2

6

3

5

2

I-18

I-18

I-18

I-18

HEATER BEZEL

ILLUMINATION

FAN SW

I-23

I-23

I-18

I-18

TAIL RELAY (4)

3

0.85 G/R

5

4

0.3G/Y

1

2B

15

H-48

2 B

ILLUMINATION

CONTROLLER

0.3G/Y

0.3 R/G

4

2

BLOWER
RESISTOR

I-41

I-41

I-41

I-41

3

6

4

1

2L/R

1.25L/O

1.25L/Y

0.85L/W

H-6

0.5G/O

H-17

0.5G/O

E-27

2

4

0.3G/Y

1

SERVICE INFORMATION 00 – 15

D08RY00135

ECM

(J2-11)

0.5 L/P

I-25

I-25

3

I-25

2

I-25

6

I-25

5

4

1

H-16

6

0.3R/G

0.85G/R0.85G/R

ILLUMINATION
CONTROLLER

TAIL RELAY(4)

ENGINE
WARMING
SW

1.25B 0.5B

C-74 C-74

12

THERMO SW

H-24

17

0.5G/W 0.5G/W

0.5 L/P

0.5G/B

H-25

16

H-42

16

H-5

2

0.5B

H-16

15

00 – 16 SERVICE INFORMATION

TROUBLE POSSIBLE CAUSE CORRECTION

HEATING CYCLE TROUBLESHOOTING

No heating or
Insufficient heating.

• Refer to “FAN CONTROL KNOB (FAN
SWITCH)” Troubleshooting.

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

• Add engine coolant as required.

• Check if the water hose to the heater

core is clogged, collapsed or twisted.
Repair or replace as necessary.

• Check water pump function. Repair or
replace as necessary.

• Clean or replace as necessary.

• Repair the temperature control link unit

or mode doors.

• Repair or adjust the control cables.

• Repair or replace as necessary.

• Refer to “CERAMIC HEATER”

Troubleshooting.

• Repair.

• Repair.

• Repair.

• Adjust.

1. Blower motor does not run, or
runs improperly.

2. Engine coolant temperature is
low.

3. Insufficient engine coolant.

4. Circulation volume of engine
coolant is insufficient.

5. Heater core clogged or
collapsed.

6. The heater core is not provided
with air sent from the blower
motor.

7. Duct connections defective or
unsealing.

8. Ceramic heater defective.

1. Cable attaching clip is not
correct.

2. Link unit of heater unit or
blower assembly defective.

1. Link unit of heater unit or
blower assembly defective

2. Control cable is not adjusted.

Control knob moves
but mode door does
not operate.

The mode door
cannot be set to the
mode selected.

SERVICE INFORMATION 00 – 17

FAN CONTROL KNOB (FAN SWITCH)

Current flows to the blower motor through the
Heater & 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.”

12
3

4

B-36B-1 B-2

1 2 3
4 5 6

1
2

1 23
456

I-41 B-5 I-18

1

2

B-36

RELAY;
HEATER & AC

C-19
25A
BLOWER

2

3

6

4

1

6

3

5

2

1

M

BLOWER
MOTOR

2

1

RHD

OFF

B-5 B-5

I-18

BLOWER
RESISTOR

FAN SW.

I-41

B-1
B-2

(LHD) BODY-RH

(RHD) BODY-LH

D08RY00167

00 – 18 SERVICE INFORMATION

BLOWER MOTOR DOES NOT RUN

• IS NO. C-19 (25A) FUSE OK?

• IS BLOWER RELAY (B-36) OK?

YES NO

REPLACE

NO

REPLACE

NO

REPLACE

NO

REPLACE CONTROL LEVER ASSEMBLY

NO

REPLACE

NO

OPEN CIRCUIT BETWEEN NO. C-19
(25A) FUSE AND NO. B5-1 (NO. B5-2;
RHD)

YES

• IS RESISTOR OK?

YES

• IS FAN CONTROL KNOB (FAN SWITCH) OK?

YES

• IS BLOWER MOTOR OK?

YES

• TURN THE IGNITION SWITCH “ON” (ENGINE IS
RUNNING)

• FAN CONTROL KNOB (FAN SWITCH) “ON”

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT

AT CHASSIS SIDE CONNECTOR TERMINAL NO. B5-1
(NO. B5-2; RHD)

YES

POOR GROUND OR OPEN CIRCUIT EITHER BETWEEN
CHASSIS SIDE CONNECTOR TERMINAL NO. B5-2
(NO. B5-1; RHD) AND NO. I-41-2 OR NO. I18-1 AND BODY
GROUND NO. B-2 (NO. B-1; RHD)

SERVICE INFORMATION 00 – 19

BLOWER MOTOR DOES NOT RUN IN CERTAIN

POSITION

A 1 : (LOW)

BLOWER MOTOR DOES

B 2 : (MEDIUM LOW)

NOT RUN AT

C 3 : (MEDIUM HI)

POSITION

D 4 : (HIGH)

* CHECKING IS PERFORMED ONLY WHEN IN

THE MALFUNCTION MODE.

• IS RESISTOR OK?

YES

• IS FAN CONTROL KNOB (FAN SWITCH) OK?

YES

A CONDITION:

• OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR
TERMINAL NO. I41-1 AND NO. I18-2

B CONDITION:

• OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR
TERMINAL NO. I41-4 AND NO. I18-5

C CONDITION:

• OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR
TERMINAL NO. I41-6 AND NO. I18-3

D CONDITION:

• OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR
TERMINAL NO. I41-3 AND NO. I18-6

NO

REPLACE

NO

REPLACE CONTROL LEVER
ASSEMBLY

BLOWER MOTOR DOES NOT STOP AT “OFF”

POSITION

• IS FAN CONTROL KNOB (FAN SWITCH) OK?

YES

SHORT CIRCUIT BETWEEN CHASSIS SIDE
CONNECTOR TERMINAL

• NO. B5-2 (NO. B5-1 : RHD) AND NO. I41-2
(OR)

• NO. I41-3 AND NO. I18-6
(OR)

• NO. I41-6 AND NO. I18-3
(OR)

• NO. I41-4 AND NO. I18-5
(OR)

• NO. I41-1 AND NO. I18-2

NO

REPLACE CONTROL LEVER
ASSEMBLY

00 – 20 SERVICE INFORMATION

CERAMIC HEATER

When the fan control knob (fan switch) turns on
with the temperature control knob set to “FULL
HOT” (full hot switch “ON”), the ceramic heater in
the heater unit turns on and the blow temperature
goes up. When the ceramic heater turns on, FICD

starts to operate at the same time. When either one
of the fan switch, the full hot switch or the thermo
switch (which turns on when the coolant tempera­ture gets below 80°C (176°F) turns off, the ceramic
heater also turns off.

FL-3
40A

C/HEATER

RELAY;
HEATER A/C

ECM
(J1-23)

24

13

C-20
10A
A/C

FL-1

80A

MAIN

B-18B-1

B-36

1

3

X-12

2

4

1

3

X-21

2

4

1

2

1

2

4

1

3

2

4

1

1

2

CERAMIC
HEATER

FAN SW.

B-19

B-48

I-18

B-44

B-49

RELAY;
THERMO
SW

RELAY;
CERAMIC
HEATER

DIODE

FULL HOT
SW.

B-1

B-48

1
2

1
2

2

1

12

B-49

I-18

213
546

12
3

4

B-36 X-12 X-21

1 2 3 4

B-44

(RHD)

B-2

(LHD)

B-2

D08RWD66

SERVICE INFORMATION 00 – 21

CERAMIC HEATER DOES NOT OPERATE

• ARE NO. FL-3 (40A) AND NO. C-20 (10A) OK?

YES NO

REPLACE

REPLACE

REPLACE

REPLACE

• ARE A/C AND CERAMIC HEATER RELAYS OK?

YES NO

• ARE BLOWER MOTOR AND FAN SW. OK?

YES NO

• IS FULL HOT SW. OK?

• DOES TEMP. CONTROL LINK (HEATER UNIT)

OPERATE CORRECTLY?

YES NO

REPLACE

•

TURN THE IGNITION SW. “ON” (ENGINE IS RUNNING)

• CERAMIC HEATER “ON”

•

CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT
CHASSIS SIDE CONNECTOR TERMINAL NO. B48-1

YES NO

OPEN CIRCUIT

•

CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT
CHASSIS SIDE CONNECTOR TERMINAL NO. B48-2

YES NO

CERAMIC HEATER DEFECTIVE

• CHECK THE CERAMIC HEATER OR CERAMIC HEATER­RELATED HARNESS FOR A POOR GROUND AND REPAIR
IT AS NECESSARY

YES NO

• DOES CONTROL LEVER CABLE OPERATE CORRECTLY?• IS THERMO RELAY OK?

YES NO

NO YES

ADJUST OR REPLACE

REPAIR OR REPLACE
TEMP. CONTROL UNIT

00 – 22 SERVICE INFORMATION

CERAMIC HEATER DOES NOT STOP

WHEN THE IGNITION SW. “OFF”, DOES CERAMIC HEATER
STOP?

YES NO

CERAMIC HEATER RELAY DEFECTIVE

•

SHORT CIRCUIT BETWEEN CHASSIS SIDE RELAY TERMINAL
NO. X12-3 AN

D CHASS

IS SIDE CONNECTOR TERMINAL

NO. B49-

1

SERVICE INFORMATION 00 – 23

AIR CONDITIONING CYCLE TROUBLESHOOTING

No cooling or insuffi­cient cooling

Insufficient velocity
of cooling air

1. Magnetic clutch does not run

2. Compressor is not rotating properly

• Drive belt loosened or broken

• Magnetic clutch face is not

clean and slips

• Incorrect clearance between
magnetic drive plate and pulley

• Compressor oil leaks from shaft
seal or shell

• Compressor seized

3. Insufficient or excessive charge of
refrigerant

4. Leaks in the refrigerant system

5. Condenser clogged or insufficient
radiation

6. Temperature control link unit of the
heater unit defective

7. Unsteady operation due to foreign
substance in expansion valve

8. Poor operation of electronic thermo­stat

1. Evaporator clogged or frosted

2. Air leaking from cooling unit or air
duct

3. Blower motor does not rotate prop­erly

• Refer to “MAGNETIC CLUTCH”
troubleshooting

• 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
Section 1D “COMPRESSOR OVER­HAUL”

• Replace the compressor

• Replace the compressor

• Discharge and recover refrigerant.

Recharge to specified amount.

• Check refrigerant system for leaks
and repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.

• Clean the condenser or replace as
necessary

• Check radiator or condenser fan
function

• Repair the link unit

• Replace the expansion valve

• Check electronic thermostat and

replace as necessary

• Check evaporator core and replace
or clean the core

• Check evaporator and duct connec­tion, then repair as necessary

• Refer to Section 00 for “FAN
CONTROL KNOB (FAN SWITCH)”
troubleshooting

* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY,

RECYCLING, EVACUATING AND CHARGING” in section 1B.

TROUBLE POSSIBLE CAUSE CORRECTION

00 – 24 SERVICE INFORMATION

CHECKING REFRIGERANT SYSTEM
WITH MANIFOLD GAUGE

Conditions;

• Ambient temperature at approx. 25 ∼ 30°C (77
∼ 86°F)

• Run the engine at Idling

• A/C switch is “ON”

• Run the blower motor at “4” (high) position

• Temperature control knob sets at “MAX COLD”

• Air source selector lever at “CIRC”

• Close the all doors

Normal pressures kpa (kg·cm2/ PSI);

Low-pressure side:

Approx. 147 – 294 (1.5 – 3.0 / 21 – 43)

High-pressure side:

Approx. 1373 – 1863 (14 – 19 / 199 – 270 )

Connect the manifold gauge

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

(Low side) (High side)

RESULT SYMPTOM TROUBLE CAUSE CORRECTION

SERVICE INFORMATION 00 – 25

Reduced or no air flow through
the condenser

No bubbles in sight glass when
condenser is cooled by water
(Insufficient cooling)

After stopping air conditioning,
pressure drops approx. 196 kPa
(28 PSI) quickly

Insufficient cooling and excessive
bubbles in the sight glass

Low pressure gauge indicates
vacuum

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

After turning off air conditioning,
high and low pressure gauge
balanced quickly

Low pressure gauge is lowered
after condenser is cooled by
water

Low pressure hose temperature
around the compressor refriger­ant line connector is lower than
around evaporator

After turning off air conditioning,
high and low pressure gauge is
balanced quickly

Air conditioning turns off before
passenger compartment is suffi­ciently cool

• Condenser clogged or dirty

• Radiator (condenser) fan

does not operate properly

• Excessive refrigerant in
system

• Air in system

• Insufficient refrigerant in

system

• Clogged or defective expan­sion valve

• Restriction caused by debris
or moisture in receiver/drier

• Compressor seal defective

• Poor compression due to

defective compressor gasket

• Excessive refrigerant in

system

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

• Expansion valve opens too
long

• Compressor gasket is defec­tive

• Electronic thermostat defec­tive

• Clean

• Check cooling fan

operation

• Check sight glass.
(See “Reading Sight

Glass”)

• Discharge and
recover refrigerant.
Recharge to speci­fied amount

• Evacuate and
charge refrigerant
system

• Check sight glass.
(See “Reading Sight
Glass”)

• Check for leaks

• Discharge and

recover refrigerant.
Recharge to speci­fied amount

• Replace the expan­sion valve

• Check system for
restriction and
replace
receiver/drier

• Replace or repair
compressor

• Discharge and
recover refrigerant
Recharge to speci­fied amount

• Replace the expan­sion valve

• Replace

• Check the electronic

thermostat and
replace as neces­sary

Discharge
(High) pres­sure gauge
abnormally
high

Discharge
(High) pres­sure gauge
abnormally
low

Suction
(Low) pres­sure gauge
abnormally
high

* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,

EVACUATION AND CHARGING” in this section.

RESULT SYMPTOM TROUBLE CAUSE CORRECTION

Suction
(Low) pres­sure abnor­mally low

Suction
(Low) and
Discharge
(High) pres­sure abnor­mally high

Suction
(Low) and
Discharge
(High) pres­sure abnor­mally low

00 – 26 SERVICE INFORMATION

• Check sight

glass.(See “Reading
Sight Glass”)

• Check for leaks

• Discharge and

recover refrigerant.
Recharge to speci­fied amount

• Replace the expan-

sion valve

• Replace the receiv-

er/drier

• Replace the expan-

sion valve

• Check electronic

thermostat and
replace as necessary

• Replace refrigerant

line

• Check sight

glass.(See “Reading
Sight Glass”)

• Discharge and

recover refrigerant.
Recharge to speci-

fied amount

• Clean

• Check cooling fan

operation

• Evacuate and charge

refrigerant

• Check sight glass.

(See “Reading Sight
Glass”)

• Check for leaks

• Discharge and

recover refrigerant.
Recharge to speci­fied amount

• Insufficient refrigerant

• Expansion valve clogged

• Receiver/drier clogged

• The temperature sensor of

the expansion valve is defec­tive, and the valve cannot
regulate the correct flow of
the refrigerant

• Frozen evaporator core fins

• Clogged or blocked refriger-

ant line

• Excessive refrigerant in
system

• Condenser clogged

• Radiator (condenser) fan

does not rotate properly

• Air in system

• Insufficient refrigerant in

system

Condenser is not hot and exces­sive bubble in sight glass

Frost on the expansion valve inlet
line

A distinct difference in tempera­ture between the inlet and outlet
refrigerant lines of the
receiver/drier

Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum

Discharge temperature is low and
air flow from vents is restricted

Low-pressure gauge reading is
low, or a vacuum reading may be
shown

No bubbles in sight glass after
condenser is cooled by water
(Insufficient cooling)

Reduce air flow through con­denser

Suction (Low) pressure hose is
not cold

Insufficient cooling and excessive
bubbles in the sight glass

SERVICE INFORMATION 00 – 27

MAGNETIC CLUTCH

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

ation, the electronic thermostat, the pressure switch
or the PCM (6VD1/6VE1 Engine) 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.

1 23
456

RELAY; A/C

B-36

C-20
10A

A/C

FL-1
80A

MAIN

1

2

B-2

C-25

2

4

X-5

1

3

(3)

(1)

4

1

3

2

4

1

A/C SW.

FAN SW.

I-23

PRESSURE
SW.

RELAY;
THERMOSTAT

B-2

X-7 C-25

C-1

C-3

E-3 I-23

BATTERY

X-7

RELAY: A/C
COMPRESSOR

1

E-3

MAGNETIC
CLUTCH

Mg

OFF

I-18

2

6

1

321

123

12
3

4

12

1

1

213
546

I-18

X-5

B-1

(LHD)(RHD)

B-1

1
2

34

W/ CONDENSER

FAN

2

4

1

3

C-3

PCM (E15)

C-1

PCM (B14)

3

1

2

ELECTRONIC
THERMOSTAT

I-42

I-42 B-36

Pin number with ( ); RHD

A1 A2 A3 A4 A5 A6 A7 A8 A9

A10A11A12 A13A14 A15 A16

B1 B2 B3 B4 B5 B6 B7 B8 B9

B10 B11 B12 B13 B14 B15 B16

E1 E2 E3 E4 E5 E6 E7 E8 E9

E10 E11 E12 E13 E14 E15 E16

F1 F2 F3 F4 F5 F6 F7 F8 F9

F10 F11 F12 F13 F14 F15 F16

6VD1/6VE1 ENGINE

D08RY00295

00 – 28 SERVICE INFORMATION
MAGNETIC CLUTCH DOES NOT RUN

• TURN THE STARTER SWITCH ON AND START THE
ENGINE.

• TURN THE FAN SWITCH ON.

• DOES THE BLOWER MOTOR RUN?

YES NO

REFER TO THE DIAGNOSIS PROCEDURE FOR
“BLOWER MOTOR DOES NOT RUN”.

• IS THE FUSE C-20 (10A) NORMAL?

YES NO

REPLACE THE FUSE.

• DISCONNECT THE A/C SWITCH CONNECTOR AND
REMOVE THE A/C SWITCH.

• IS THE A/C SWITCH NORMAL?

YES NO

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND I23-2.

•

REINSTALL THE A/C SWITCH AND DISCONNECT THE DUAL
PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) CON­NECTOR C25.

• TURN THE A/C SWITCH ON.

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR C25-1?

YES NO

REPLACE THE SWITCH.•

RECONNECT THE CONNECTOR C25 AND DISCONNECT THE
A/C THERMO RELAY CONNECTOR X5.

•

IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNEC­TOR C25-2 AND X5-1?

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN I23-6
AND C25-1.

•

IS THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE
SWITCH) NORMAL?

YES NO

REPAIR OR REPLACE THE SWITCH.• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR I23-2?

SERVICE INFORMATION 00 – 29

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR X5-2?

REPAIR AN OPEN CIRCUIT.

YES NO

• IS THE A/C THERMO RELAY NORMAL?

REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND X5-2.

YES NO

• DISCONNECT THE ELECTRONIC THERMOSTAT CONNEC-

TOR I42.

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR I42-3?

YES NO

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-

NECTOR X5-3 AND I42-1?

REPAIR AN OPEN CIRCUIT BETWEEN I23-6
AND I42-3.

YES NO

• DISCONNECT THE PCM CONNECTORS.

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-

NECTOR X5-4 AND PCM C3-E15?

REPAIR AN OPEN CIRCUIT.

YES NO

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-

NECTOR I42-2 AND THE GROUND?

REPAIR AN OPEN CIRCUIT.

YES NO

• DISCONNECT THE A/C COMPRESSOR RELAY CONNEC-

TOR X7.

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR X7-1 AND X7-2?

REPLACE THE ELECTRONIC THERMOSTAT.

YES NO

• RECONNECT X5 AND I42.

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR PCM C3-E15?

REPAIR AN OPEN CIRCUIT.

REPLACE THE RELAY.

00 – 30 SERVICE INFORMATION

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND X7-1 (OR X7-2).

• DIS CONNECT THE MAGNETIC CLUTCH CONNECTOR E3.

• CONNECT THE BATTERY WITH MAGNETIC CLUTCH SIDE

CONNECTOR E3-1.

• DOES THE MAGNETIC CLUTCH WORK?

YES NO

NO

REPAIR OR REPLACE THE MAGNETIC CLUTCH.

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON­NECTOR X7-4 AND E3-1?

YES

REPAIR AN OPEN CIRCUIT.

REPAIR AN OPEN CIRCUIT.

REPAIR AN OPEN CIRCUIT.

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON­NECTOR X7-3 AND PCM C1-B14?

YES NO

NO

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON­NECTOR X5-4 AND PCM C3-E15?

YES

REPLACE THE PCM.

SERVICE INFORMATION 00 – 31

4JG2 ENGINE

1 23
456

RELAY; A/C

B-36

C-20

(LHD)

10A

A/C

FL-1
80A

MAIN

1

2

B-2

C-25

2

4

X-5

1

3

4

1

3

2

4

1

A/C SW.

FAN SW.

I-23

PRESSURE
SW.

RELAY;
THERMO

B-2

C-25 E-3 I-23

BATTERY

3

1

2

ELECTRONIC
THERMOSTAT

1

E-3

MAGNETIC
CLUTCH

Mg

OFF

I-18

2

6

1

321

123

12
3

4

12

1

213
546

I-18

X-5

B-1

(LHD)

(RHD)

B-1

1
2

34

W/ CONDENSER

FAN

I-42

I-42 B-36

D08RY00169

00 – 32 SERVICE INFORMATION

MAGNETIC CLUTCH DOES NOT RUN

• ARE NO. C-20 (10A) FUSE AND NO. C-19 (25A) FUSES OK?

YES NO

REPLACE

• ARE HEATER & A/C (B-36) AND THERMOSTAT (X-5)
RELAYS OK?

YES NO

REPLACE

• IS PRESSURE SWITCH (DUAL PRESSURE SWITCH) OK?

YES NO

SWITCH DEFECTIVE OR INSUFFICIENT REFRIGERANT

• ARE A/C SWITCH AND FAN CONTROL KNOB (FAN
SWITCH) OK?

YES NO

REPLACE

• TURN THE IGNITION SWITCH “ON” (ENGINE IS
RUNNING)

• A/C SWITCH AND FAN CONTROL KNOB (FAN SWITCH
“ON”

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT
CHASSIS SIDE CONNECTOR TERMINAL NO. E3-1

NO YES

MAGNETIC CLUTCH DEFECTIVE

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT
CHASSIS SIDE CONNECTOR TERMINAL NO. C25-1

YES NO

OPEN CIRCUIT BETWEEN NO. C-20 (10A) FUSE AND
NO. C25-1

• DISCONNECT THERMO RELAY (X-5)

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT

CHASSIS SIDE RELAY TERMINAL NO. X5-2

YES NO

OPEN CIRCUIT BETWEEN NO. C25-2 AND NO. X5-2

• CHECK TO SEE IF VOLTAGE (APPROX. 10V) IS PRESENT
CHASSIS SIDE RELAY TERMINAL NO. X5-1 AND
NO. X5-3

CONTINUED NEXT PAGE

SERVICE INFORMATION 00 – 33

CONTINUED PREVIOUS PAGE

NO YES

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT

CHASSIS SIDE RELAY TERMINAL NO. X5-1

OPEN CIRCUIT BETWEEN NO. X5-4 AND NO. E3-1

YES NO

• RECONNECT THERMO RELAY

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT

CHASSIS SIDE CONNECTOR TERMINAL NO. I42-3

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT
CHASSIS SIDE CONNECTOR TERMINAL NO. I23-2

NO YES

OPEN CIRCUIT BETWEEN
NO. C-20 (10A) FUSE AND
NO. I23-2

OPEN CIRCUIT BETWEEN
X5-1 AND NO. I23-6

NO YES

• CHECK TO SEE IF BATTERY VOLTAGE (APPROX. 10V)
IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL
NO. I42-1

YES NO

• CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT
CHASSIS SIDE CONNECTOR TERMINAL NO. I42-2

OPEN CIRCUIT BETWEEN NO. X5-3 AND NO. I42-1

YES NO

• OPEN CIRCUIT BETWEEN NO. I42-2 AND NO. I18-4 OR
POOR GROUND (FAN SWITCH GROUND CIRCUIT)

ELECTRO THERMO DEFECTIVE

OPEN CIRCUIT BETWEEN
NO. I23-6 AND NO. I42-3

00 – 34 SERVICE INFORMATION

4JX1 ENGINE

1 23
456

RELAY; A/C

B-36

C-20

10A

A/C

FL-1

80A

MAIN

1

2

B-2

C-25

2

4

X-5

1

3

4

1

3

2

4

1

A/C SW.

FAN SW.

I-23

PRESSURE
SW.

RELAY;
THERMO

B-2

C-25 I-23

BATTERY

1

E-27

MAGNETIC
CLUTCH

Mg

OFF

I-18

2

6

1

321

123

12
3

4

12

213
546

I-18

X-5

B-1

(LHD)

(RHD)

3

1

2

ELECTRONIC
THERMOSTAT

I-42

B-1

1
2

34

W/ CONDENSER

FAN

I-42 B-36

E-27

1

1

D08RY00170

SERVICE INFORMATION 00 – 35

MAGNETIC CLUTCH DOES NOT RUN

• TURN THE STARTER SWITCH ON AND START THE
ENGINE.

• TURN THE FAN SWITCH ON.

• DOES THE BLOWER MOTOR RUN?

YES NO

REFER TO THE DIAGNOSIS PROCEDURE FOR
“BLOWER MOTOR DOES NOT RUN”.

• IS THE FUSE C-20 (10A) NORMAL?

YES NO

REPLACE THE FUSE.

• DISCONNECT THE A/C SWITCH CONNECTOR AND
REMOVE THE A/C SWITCH.

• IS THE A/C SWITCH NORMAL?

YES NO

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND I23-2.

•

REINSTALL THE A/C SWITCH AND DISCONNECT THE DUAL
PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) CON­NECTOR C25.

• TURN THE A/C SWITCH ON.

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR C25-1?

YES NO

REPLACE THE SWITCH.•

RECONNECT THE CONNECTOR C25 AND DISCONNECT THE
A/C THERMO RELAY CONNECTOR X5.

•

IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNEC­TOR C25-2 AND X5-1?

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN I23-6
AND C25-1.

•

IS THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE
SWITCH) NORMAL?

YES NO

REPAIR OR REPLACE THE SWITCH.• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR I23-2?

00 – 36 SERVICE INFORMATION

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR X5-2?

REPAIR AN OPEN CIRCUIT.

YES NO

• IS THE A/C THERMO RELAY NORMAL?

REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND X5-2.

YES NO

• DISCONNECT THE ELECTRONIC THERMOSTAT CONNEC-

TOR I42.

• IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE

CONNECTOR I42-3?

YES NO

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-

NECTOR X5-3 AND I42-1?

REPAIR AN OPEN CIRCUIT BETWEEN I23-6
AND I42-3.

YES NO

REPAIR AN OPEN CIRCUIT.

YES NO

• IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-

NECTOR I42-2 AND THE GROUND?

REPAIR AN OPEN CIRCUIT.

REPLACE THE RELAY.

• DIS CONNECT THE MAGNETIC CLUTCH CONNECTOR E27.

• CONNECT THE BATTERY WITH MAGNETIC CLUTCH SIDE

CONNECTOR E27-1.

• DOES THE MAGNETIC CLUTCH.

YES NO

REPAIR OR REPLACE THE MAGNETIC CLUTCH.

• REPAIR AN OPEN CIRCUIT BETWEEN X5-4 AND E27-1.

SERVICE INFORMATION 00 – 37

CONDENSER FAN

When the cycling switch, which controls the
condenser fan of the triple pressure switch while
the A/C switch is on, senses the refrigerant pressure

and the condenser fan turns on, the motor operates
via the condenser fan relay.

1 23
456

4

1

3

2

4

1

FAN SW.

B-2

OFF

I-18

I-18

B-1

(LHD)

(RHD)

X-19

1
3
4
5

RELAY;
CONDENSER
FAN

4

TRIPLE
PRESSURE
SWITCH

3

1

CONDENSER
FAN

2

M

C-75

C-39

C-25

FL-4
30A

CONDENSER FAN

FL-1

80A

MAIN

2
6
1

I-23

RELAY; A/C

A/C SWITCH

2

C-39 C-75C-25

I-23 X-19

1234
5678

43

8726

1

5

12

12

1
2

34

213
546

12
3

4

D08RWD70

00 – 38 SERVICE INFORMATION

CONDENSER FAN DOES NOT RUN

YES NO

• DOES A/C SYSTEM OPERATE CORRECTLY?

• IS FL-4 (30A) FUSE OK?

CHECK A/C SYSTEM AND REPAIR AS NECESSARY

YES NO

• IS CONDENSER FAN RELAY (X-19) OK?

REPLACE

REPLACE

YES NO

• IS TRIPLE PRESSURE SWITCH (CYCLING SWITCH SIDE)

OK?

REPLACE

YES NO

• IS CONDENSER FAN MOTOR OK?

REPLACE

YES NO

• CHECK TO SEE IF CONTINUITY BETWEEN FL-4 (30A)

FUSE AND CHASSIS SIDE RELAY TERMINAL NO. X19-1.

REPLACE

YES NO

• CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE

CONNECTOR TERMINAL NO. I23-6 AND NO. C25-3.

OPEN CIRCUIT

YES NO

• CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE

CONNECTOR TERMINAL NO. C25-4 AND CHASSIS SIDE
RELAY TERMINAL NO. X19-4.

OPEN CIRCUIT

YES NO

• CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE

RELAY TERMINAL NO. X19-5 AND CHASSIS SIDE
CONNECTOR TERMINAL NO. I18-4.

OPEN CIRCUIT

YES NO

SERVICE INFORMATION 00 – 39

• CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE
RELAY TERMINAL NO. X19-3 AND CHASSIS SIDE
CONNECTOR TERMINAL NO. C75-1.

YES NO

OPEN CIRCUIT

POOR GROUND OR OPEN CIRCUIT BETWEEN CHASSIS
SIDE CONNECTOR TERMINAL NO. C75-2 AND BODY
GROUND (NO. C39-7)

CONDENSER FAN DOES NOT STOP

• IS CONDENSER FAN RELAY (X-19) OK?

YES NO

REPLACE

TRIPLE PRESSURE SWITCH (CYCLING SWITCH SIDE)
DEFECTIVE

REPLACE TRIPLE PRESSURE SWITCH

00 – 40 SERVICE INFORMATION

1. Defective rotor/piston

2. Defective bearing (DKS-15CH)

3. Defective shaft

1. Defective bearing

2. Defective clutch

3. Clearance between drive plate
and pulley not standard

1. Defective gasket

2. Defective rotor/reed valve

3. Defective trigger valve/suction
valve

1. Defective rotor/piston

2. Defective shaft

3. Rotating parts seized due to
insufficient oil

1. Defective seal

2. Defective O-ring

Replace compressor/cylinder and
shaft assembly
Replace cylinder and shaft assembly
Replace compressor/cylinder and
shaft assembly

Replace magnetic clutch
Replace magnetic clutch
Adjust the clearance or replace
magnetic clutch

Replace compressor/gasket
Replace compressor/valve plate
Replace compressor/suction valve

Replace compressor/cylinder and
shaft assembly
Replace compressor/cylinder and
shaft assembly
Replace compressor

Replace compressor/shaft seal
Replace

Noise from compressor

Noise from magnetic
clutch face

Insufficient cooling

Not rotating

Oil and/or gas leakage

1

2

3

4

5

ITEM PROBLEM POSSIBLE CAUSES CORRECTION

COMPRESSOR TROUBLESHOOTING

SERVICE INFORMATION 00 – 41

I-18 I-23

123456126

OFF

1

FAN SW. 2

3
4

OFF

A/C SW.

ON

FAN CONTROL KNOB (FAN SWITCH) AND A/C
SWITCH

INDIVIDUAL INSPECTION

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

2
6543

1

3
62514

<Connector terminal>

I-23 I-18

I-23 I-18

5

A/C SW.

BEZEL
ILLUMI­NATION

FAN SW.

OFF

1

2

3

4

32 6 1

253641

HEATER & A/C, THERMOSTAT, COMPRESSOR,
CONDENSER FAN AND CERAMIC HEATER RELAY

Check for continuity between the relay terminals.

2 – 4 ..... No continuity

(When battery voltage is applied between 1 – 3)

2 – 4 ..... Continuity

2

2

1

1

4

4

3

3

Terminal

No.

SW.
position

DUAL PRESSURE SWITCH

2

1

Disconnect pressure switch connector and check for
continuity between pressure switch side connector
terminals.

00 – 42 SERVICE INFORMATION

TRIPLE PRESSURE SWITCH (W/CONDENSER FAN)

43

1 2

1) Disconnect the connector and check for continuity
between pressure switch side connector terminal.

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

[A/C OFF]

[A/C ON]

Terminal No. Control Continuity

1 - 2 Magnetic Clutch Continuity
3 - 4 Condenser Fan No Continuity

Terminal

Refrigerant Pressure Continuity Fan

No.

1079±98 kPa No

OFF

(11.0±1.0 kg·cm2/ 156±14 psi) Continuity

3 - 4

1471±98 kPa

Continuity ON

(15.0±1.0 kg·cm2/ 213±14 psi)

BLOWER MOTOR

1

2

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

2) Connect the battery positive terminal to the No. 1
(NO.2; RHD) terminal of the blower motor and
negative to the No. 2 (NO. 1; RHD).

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

Terminal Normal
SW. No.12346 Operating
position Resistance

2.4Ω

0.90Ω

0.28Ω
–

1
2
3
4

RESISTOR

14263

2

Motor

3 6 4 1

432

(SW.position)

(Connector
terminal)

1

1) Disconnect resistor (I-41) connector.

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

SERVICE INFORMATION 00 – 43

CONDENSER FAN

12

THERMO SWITCH (ENGINE)

12

1) Disconnect the condenser fan connector (C-75).

2) Connect the battery positive terminal to the No. 1
terminal and negative to No. 2.

3) Be sure to check to see if condenser fan operates
correctly.

With the environmental temperature of the switch set to
the following conditions, check to see if there is any
continuity between the switch side connector terminals.

Ambient Terminal

Continuity

Temperature No.

Above 77 – 83°C

1 – 2 No Continuity

(170.6–181.4°F)

CERAMIC HEATER

1

2

Ceramic heater

Disconnect the ceramic heater connector and check for
continuity between ceramic heater side connector
terminals.

Connector No. B-48
Terminal 1 2
Continuity

00 – 44 SERVICE INFORMATION

FULL HOT SWITCH

2 1

Temperature
control link

Full hot switch

1) With the temperature control knob set to the full hot
position, check to see visually if the temperature
control link of the heater unit operate correctly and if
the link contacts securely with the full hot switch.

2) Disconnect the full hot switch connector.

3) With the full hot switch contacted, check to see if
there is any continuity between the switch side
connector terminals.

B-49

Terminal
Full No. 1 2
hot switch

FREE
CONTACT

SERVICE INFORMATION 00 – 45

HEATER UNIT

Temperature control Reheat air mix system
Capacity (Kcal./hr.) 3,700
Air flow (m3/hr.) 280

HEATER CORE

Type Fin & tube type
Element dimension mm (in.) 161 (6.3) × 163 (6.4) × 45 (1.8)
Radiating area m

2

Approx. 2.1

EVAPORATOR ASSEMBLY

Capacity (Kcal./hr.) 4,200
Air flow (m3/hr.) 470

EVAPORATOR CORE

Type Al-laminate louver fin type
Element dimension mm (in.) 235 (9.3) × 224 (8.8) × 74 (2.9)

EXPANSION VALVE

Type External pressure equalizer type

THERMOSTAT SWITCH

Type Electronic thermostat

°C (F) OFF: 3.5 ± 0.5 (38.3 ± 0.9)

ON: 5.0 ± 0.5 (41.0 ± 0.9)

CONDENSER

Type Parallel flow
Radiation performance (Kcal./hr.) 11,500

RECEIVER/DRIER

Type Assembly includes sight glass with dual (triple)

pressure switch

Internal volume cc (Imp. fl oz) 300 (8.5)

PRESSURE SWITCH

Type Dual pressure switch

kPa (kg·cm2/ PSI) • Low pressure control

ON: 205.9 ± 30 (2.1 ± 0.3 / 29.9 ± 4)

(Except 6VD1 / 6VE1, LHD model)
186 ± 30 (1.9 ± 0.3 / 27 ± 4)
(only for 6VD1/ 6VE1, LHD model)

OFF: 176 ± 20 (1.8 ± 0.2 / 26 ± 3)

• High pressure control
ON: 2354 ± 196 (24.0 ± 2.0 / 341 ± 28)
OFF: 2942 ± 196 (30.0 ± 2.0 / 427 ± 28)

Triple pressure switch (W/Condenser fan)

• Low pressure control
ON: 186 ± 30 (1.9 ± 0.3 / 27 ± 4)
OFF: 176 ± 20 (1.8 ± 0.2 / 26 ± 3)

• Medium pressure control
ON: 1471 ± 98 (15.0 ± 1.0 / 213 ± 14)
OFF: 1079 ± 98 (11.0 ± 1.0 / 156 ± 14)

• High pressure control
ON: 2354 ± 196 (24.0 ± 2.0 / 341 ± 28)
OFF: 2942 ± 196 (30.0 ± 2.0 / 427 ± 28)

REFRIGERANT

Type/Specified amount g (lbs) HFC-134a / 750 (1.65)

MAIN DATA AND SPECIFICATIONS

00 – 46 SERVICE INFORMATION

COMPRESSOR

Model DKV-14D
Type Vane rotary (Invariable)
Number of vanes 5
Rotor diameter mm (in.) 64 (2.52)
Stroke mm (in.) 8.75 (0.34)
Displacement cc (Imp fl oz) 140 (3.9)
Maximum speed (rpm) 7,000 (up to 8,400)
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (Imp fl oz) ZXL-200PG, 150 (4.2)

ISUZU PART NO.

8-97101-336-0
Refrigerant g (lbs.) HFC-134a, 750 (1.65)
Shaft seal Lip type
Weight kg (lbs.) 3.6 (7.94)

MAGNETIC CLUTCH

Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption (A) 3.7
Starting torque N·m 39 (4.0 / 30)

(kg·m / lb·ft)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs.) 2.2 (4.9)

6VD1/6VE1 (RHD) & 6VD1 (LHD) (SAUDI/PHILIPPINE)

6VD1/6VE1 (LHD) Except SAUDI/PHILIPPINE

COMPRESSOR

Model HD6
Type Vane rotary (Invariable)
Number of vanes 6
Rotor diameter mm (in.) 64 (2.52)
Stroke mm (in.) 24 (0.94)
Displacement cc (Imp fl oz) 164 (4.59)
Maximum speed (rpm) 9,000
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (Imp fl oz) SD2-231, 150 (4.2)
Refrigerant g (lbs.) R-134a, 750 (1.65)
Shaft seal Lip type
Weight kg (lbs.) 6.8 (14.99)

MAGNETIC CLUTCH

Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption (A) 3.7
Starting torque N·m 39 (4.0 / 30)

(kg·m / lb·ft)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs.) 2.2 (4.9)

SERVICE INFORMATION 00 – 47

4JG2/4JX1

COMPRESSOR

Model DKS-15CH
Type Swash plate type
Number of cylinder 6
Bore mm (in.) 36 (1.4)
Stroke mm (in.) 24 (0.94)
Displacement cc (Imp fl oz) 147 (4.1)
Maximum speed (rpm) 7,000 (up to 8,400)
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (Imp fl oz) ZXL-100PG, 150 (4.2)

ISUZU PART NO.

8-97101-338-0
Refrigerant g (lbs.) HFC-134a, 750 (1.65)
Shaft seal Lip type
Weight kg (lbs.) 4.1 (9.0)

MAGNETIC CLUTCH

Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption (A) 3.7
Starting torque N·m 49 (5.0 / 36)

(kg·m / lb·ft)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs.) 2.3 (5.1)

00 – 48 SERVICE INFORMATION

FIXING TORQUE

N·m (kg·m / lb·ft)

25(2.5/18)

15(1.5/11)

15(1.5/11)

13(1.3/113in)

6.0(0.6/52in)

6(0.6/52in)

38(3.9/28)

19(1.9/14)

19(1.9/14)

15(1.5/11)

25(2.5 / 18)

27(2.8 / 20)

40(4.1/30)

40(4.1/30)

20(2.0/14)

15(1.5/11)

25(2.5/18)

27(2.8/20)

4JX1

4JG2

6VD1/6VE1, RHD

19(1.9/14)

40(4.1/30)

19(1.9/14)

27(2.8/20)

6VD1/6VE1, LHD

19(1.9/14)

15(1.5/11)

E01RY00001

SERVICE INFORMATION 00 – 49

15(1.5/11)

5(0.5/43in)

14(1.4/122in)

22(2.2/16)

DKV-14D TYPE

N·m (kg·m / lb·in)

13(1.3/113)

5(0.5/43)

DKS-15CH TYPE

N·m (kg·m / lb·ft)

871RY00027

871RY00026

00 – 50 SERVICE INFORMATION

Legend

1. Clutch Driver

2. Rotor Bearing Retainer

3. Pulley Rotor and Bearing
Assembly

4. Clutch Coil Assembly

5. Connector

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

Caution

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.

HEATING, VENTILATION AND AIR CONDITIONING(HVAC)

1

2

3

4

5

6

8

9

7

10

11

871RW002

SERVICE INFORMATION 00 – 51

Metric Thread Size Information

Compressor to mounting bracket bolts(Front)
M10×1.5 – 6H
Compressor to mounting bracket bolts(Rear)
M8×1.25 – 6H
Suction-discharge port screw
M10×1.5 – 6H
Compressor shaft
M9×1.25 – 6H
Internal hub-clutch drive assembly
M22×1.5 – 6H

00 – 52 SERVICE INFORMATION

HFC-134a

SPECIAL TOOLS

ILLUSTRATION PARTS NO. PARTS NAME

5-8840-0629-0

ACR4(115V 60Hz)

(J-39500-A)

5-8840-0630-0

ACR4(220-240V 50/60Hz)

(J-39500-220A)

5-8840-0631-0 ACR4(220-240V 50/60Hz
(J-39500-220ANZ) Australian model)

ACR4:

HFC-134a Refrigerant Recovery / Recycling

/Recharging / System

SERVICE INFORMATION 00 – 53

ILLUSTRATION PARTS NO. PARTS NAME

5-8840-2007-0

Drive plate holder

(J-7624)

5-8840-0122-0

Drive plate puller

(J-33944-A)

5-8840-0621-0

Forcing screw

(J-33944-4)

5-8840-0620-0

Pulley puller pilot

(J-38424)

5-8840-0111-0

Pulley puller

(J-8433)

5-8840-0622-0

Pulley puller leg

(J-24092-2)

5-8840-0118-0

Pulley installer

(J-33940)

5-8840-0007-0

Drive handle

(J-8092)

DKV-14D TYPE

901RX056

00 – 54 SERVICE INFORMATION

ILLUSTRATION PARTS NO. PARTS NAME

5-8840-2007-0

Drive plate holder

(J-7624)

5-8840-0122-0

Drive plate puller

(J-33944-A)

5-8840-0621-0

Forcing screw

(J-33944-4)

5-8840-0121-0

Pulley puller pilot

(J-33943)

5-8840-0111-0

Pulley puller

(J-8433)

5-8840-120-0

Shaft seal remover and installer

(J-33942)

5-8840-0368-0

Shaft seal guide

(J-34614)

5-8840-0118-0

Pulley installer

(J-33940)

5-8840-0007-0

Drive handle

(J-8092)

DKS-15CH TYPE

901RX056

SERVICE INFORMATION 00 – 55

ILLUSTRATION TOOL NO. TOOL NAME

5-8840-2610-0

Hub and Clutch Drive Plate Asm. remover

(J-33013-B)

5-8840-2615-0

Compressor Holding Fixture

(J-33026)

5-8840-2612-0

Puller Pilot

(J-33023-A)

5-8840-2617-0

Pulley Puller

(J-41552)

5-8840-2611-0

Pulley and Bearing Assembly Installer

(J-33017)

5-8840-0111-0

Puller Bar

(J-8433-1)

5-8840-0111-0

Forcing Screw

(J-8433-3)

5-8840-2614-0

Clutch Coil Installer Adapter

(J-33025)

5-8840-2613-0

Clutch Coil Installer Adapter

(J-33024)

5-8840-2629-0

Seal Seat Remover and Installer

(J-23128-A)

5-8840-2630-0

O-Ring Remover

(J-9553-01)

DELPHI Harrison HD6/HDT6 Special Tools

901RW012

901RW013

901RW015

901RW016

901RW017

901RW018

901RW019

901RW020

901RW021

901RW024

901RW025

00 – 56 SERVICE INFORMATION

ILLUSTRATION TOOL NO. TOOL NAME

5-8840-2609-0

O-Ring Installer

(J-33011)

5-8840-0368-0

Shaft Seal Protector

(J-34614)

5-8840-2616-0

Pressure Testing Connector

(J-39893)

901RW026

901RW027

901RW032

CAUTION

When fasteners are removed, always
reinstall them at the same location from
which they were removed. If a fastener
needs to be replaced, use the correct part
number fastener for that application. If the
correct part number fastener is not available,
a fastener of equal size and strength (or
stronger) may be used.

Fasteners that are not reused, and those
requiring thread locking compound, will be
called out. The correct torque values must
be used when installing fasteners that
require it. If the above conditions are not
followed, parts or system damage could
result.

HEATING AND VENTILATION 1A – 1

SECTION 1A

HEATING AND VENTILATION

CONTENTS

PAGE

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

Heater...............................................................1A– 2

Control Lever Assembly ................................................1A– 3

Ventilation ...........................................................1A– 3

Air Select Knob .......................................................1A– 4

Air Source Select Lever ................................................1A– 4

Fan Control Knob .....................................................1A– 4

Temperature Control Knob .............................................1A– 4

Ceramic Heater .......................................................1A– 5

On-Vehicle Service ......................................................1A– 6

Heater Unit ..........................................................1A– 6

Heater Core and/or Mode Door..........................................1A– 8

Heater Mode Control Link Unit ..........................................1A–10

Heater Temperature Control Link Unit ....................................1A–12

Blower Assembly .....................................................1A–14

Blower Link Unit and/or Mode Door......................................1A–16

Blower Motor ........................................................1A–18

Rear Heater Duct, Defroster Nozzle and Ventilation Duct ....................1A–20

Center and/or Side Vent ...............................................1A–22

Control Lever Assembly and/or Control Cables ............................1A–24

Control Panel Illumination Bulb..........................................1A–27

Resistor .............................................................1A–28

Ceramic Heater and/or Full Hot Switch ...................................1A–30

SECTION

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

1A – 2 HEATING AND VENTILATION

GENERAL DESCRIPTION

HEATER

Side def hose

Vent box

Upper center vent duct

Lower center
vent duct

Blower assembly

Control lever assembly

Evaporator
assembly

W/A/C

W/O A/C

Duct

Heater unit

Lap vent nozzle

Vent box

Side def hose

Defroster nozzle

Rear heater duct

A/C - Air Conditioning

This illustration is based on LHD

This illustration is based on LHD

Temperature control knob

A/C switch (W/A/C)

TEMP

A/C

Fan control knob(Fan switch)

Air source select lever Air select knob

HEATING AND VENTILATION 1A – 3

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

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

CONTROL LEVER ASSEMBLY

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.

1A – 4 HEATING AND VENTILATION

AIR SELECT KNOB

The air selector 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 foot 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% of total
amount of air to the windshield

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

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.

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

TEMPERATURE CONTROL KNOB

When the temperature control knob is in the
“COLD” position, the air mix door closes to block
the flow of air to the heater core.

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

Heater core

Heater unit

TO VENT OUTLET

Air mix door

VENT MODE

TO FOOT

TO VENT OUTLET

BI-LEVEL MODE

FOOT MODE

TO FOOT OUTLET

TO DEF OUTLET(LHD)

DEF/FOOT MODE

TO FOOT OUTLET

TO DEF OUTLET

DEF MODE

TO DEF OUTLET

: COLD AIR

: HOT AIR

: TEMP.CONTROLLED AIR

Full hot switch

Ceramic heater

Heater unit

HEATING AND VENTILATION 1A – 5

CERAMIC HEATER

When the fan control knob (fan switch) turns on with the temperature control knob set to “FULL HOT” (full
hot switch “ON”), the ceramic heater in the heater unit gets hot, thus causing the heater blow temperature
of diesel vehicle to get high to improve the heating performance (Since the engine coolant temperature of
diesel vehicle is low, its blow temperature is also low.).

Glow plug

Full hot switch

Fan switch

Thermo switch

Less than 80°C (177.8°F)

CERAMIC HEATER

“ON”

CERAMIC HEATER

“OFF”

OFF

ON

OFF

OFF

OFF

ON

ON

ON

This illustration is based on RHD