Opel Frontera 2000 Workshop Manual

Page 1

WORKSHOP MANUAL

FRONTERA

(UE)

FOREWORD

This manual includes special notes, important points, service data, precautions, etc. That a re needed for the maintenance, a djustments, service, rem oval and insta llat i on of vehicle components.

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

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

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

This manual applies to 1999 models.

SECTION TABLE OF CONTENTS

GENERAL INFORMATION

0A General Information 0B Maintenance and Lubrication

HEATING, VENTILATION AND AIR CONDITIONING

1A HVAC System

STEERING

2A Power-Assisted System

SUSPENSION

3C Front Suspension 3D Rear Suspension 3E Wh eel and Tire System

DRIVELINE/AXLE

4A1 Differential (Front) 4A2 Differential (Rear)

4B Driveline Control System 4C Drive Shaft System 4D Transfer Case

BRAKE

5A Brake Co ntrol System 5B Anti-Lock Brake System 5C Power-Assisted Brake System 5D Parking Brake System

HEC 6VD1 ENGINE

6A 6A Engine Mechanical 6B 6B Engine Cooling

6C 6C Engine Fuel 6D1 6D1 Engine Electrical 6D2 6D2 Ign iti on Sy st em 6D3 6D3 Starting and Charging System 6E1 6E2 Driveability and Emissions

6F 6F Engine Exhaust

6G 6G Engine Lubrication

6H 6H Engine Speed Control System

6J 6J Induction

TRANSMISSION

7A Automatic Transmission 7A1 Transmission Control System

7B Manual Transmission

7C Clutch

BODY AND ACCESSORIES

8A Lighting System

8B Wiper/Washer System

8C Entertainment

8D Wiring System

8E Me te r and Gauge

8F Body Structure

8G Seats

8H Security and Lo cks

8I Sun Roof/Convertible Top

8J Exterior/Interior Trim

RESTRAINTS

9A Seat Belt System

9J Supplemen tal Re st raint System ( A ir Ba g System)

9J1 Restraint Control System

CONTROL SYSTEM

10A Cruise Control System

Page 2

GENERAL INFORMATION

SECTION

CONTENTS

General Information....................................... 0A - 1

Meintenance and Lubrication......................... 0B - 1

GENERAL INFORMATION

CONTENTS

GENERAL INFORMATION 0A–1

General Repair Instruction............................. 0A - 1

Illustration Arrows .......................................... 0A - 2

Identification................................................... 0A - 3

Lifting Instructions.......................................... 0A - 5

General Repair Instruction

1. If a floor jack is used, the following precautions are recommended. Park vehicle on level ground, “block" front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions" in this section), raise vehicle and support with chassis stands and then perform the service operations.

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

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

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

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

6. Use genuine Isuzu parts.

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

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

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

10. Lubricate rotating and sliding faces of the parts with

Standard Bolts Torque Specifications............ 0A - 8

Abbreviations Charts ..................................... 0A - 9

Service Parts Identification Plate................... 0A - 11

oil or grease before installation.

11. When necessary , use a sealer on gaskets to prevent leakage.

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

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

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

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

1. “AIR BAG" warning light on the instrument cluster.

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

Page 3

0A–2 GENERAL INFORMATION

Illustration Arrows

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

Arrow Type Application

• Ambient/Clean air flow

Front of vehicle

Up Side

Task Related

• Cool air flow

• Gas other than

• Hot air flow

• Ambient air mixed with

• Can indicate

ambient air

another gas

temperature change

View Detail

View Angle

Dimension (1:2)

Sectioning (1:3)

Motion or direction

Lubrication point oil or fluid

Lubrication point grease

Lubrication point jelly

Page 4

Identification

Vehicle Identification Numbe r (VIN)

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

GENERAL INFORMATION 0A–3

F00RX018

F00RX017

Page 5

0A–4 GENERAL INFORMATION Engine Serial Number

• 6VD1 Engine The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter.

F06RW001

• X22SE Engine The gasoline engine serial number is stamped on the rear end raised area of the cylinder block left side.

Transmission Serial Number

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

220RS025

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

035RW022

240RW019

Page 6

Lifting Instructions

Lifting Points and Supportable Point Locations

4 Door Model

GENERAL INFORMATION 0A–5

C00RX002

Page 7

0A–6 GENERAL INFORMATION

2 Door Model

Lifting Point: Front

• When using a floor jack, lift on the Convex portion of the skid plate.

545RS001

C00RX001

Supportable Point: Front

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

501RS003

Page 8

GENERAL INFORMATION 0A–7

Lifting Point: Rear

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

420RS002

Supportable Point: Rear

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

Supportable Point: Rear

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

420RS001

Legend

(1) Trailing Link Bracket

EndOFCallout

501RW002

Page 9

0A–8 GENERAL INFORMATION

Standard Bolts Torque Speci fications

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

Strength Class

Bolt Identification

Bolt Diameter Pitch (mm)

M 6X1.0

M 8X1.25

M 10X1.25

* M10X1.5 M12X1.25

* M12X1.75

M14X1.5

* M14X2.0

M16X1.5

* M16X2.0

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

4.8 8.8 9.8 Refined Non-Refined

××××

4 – 8 N·m (3 – 6 lb ft)

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

77 – 115 N·m (56 – 85 lb ft)

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

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

5 – 10 N·m (4 – 7 lb ft)

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

93 – 139 N·m (69 – 103 lb ft)

88 – 131 N·m (65 – 97 lb ft)

135 – 204 N·m (100 – 150 lb ft)

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

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

36 – 60 N·m (27 – 44 lb ft) 76 – 114 N·m (56 – 84 lb ft) 72 – 107 N·m (53 – 79 lb ft)

114 – 171 N·m (84 – 126 lb ft)

107 – 160 N·m (79 – 118 lb ft) 160 – 240 N·m (118 – 177 lb ft) 153 – 230 N·m (113 – 169 lb ft) 230 – 345 N·m (169 – 255 lb ft) 317 – 476 N·m (234 – 351 lb ft) 425 – 637 N·m (313 – 469 lb ft) 554 – 831 N·m (409 – 613 lb ft)

–

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

Page 10

GENERAL INFORMATION 0A–9

Abbreviations Charts

List of automotive abbreviations which may be used in this manual

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

EEPROM — Electronically Erasable Programmable Read Only Memory EGR — Exhaust Gas Recirculation EI — Electronic Ignition ETR — Electronically Tuned Receiver EVAP — Evaporation Emission Exh — Exhaust ° F — Degrees Fahrenheit Fed — Federal (All States Except Calif.) FF — Front Drive Front Engine FL — Fusible Link FLW — Fusible Link Wire FP — Fuel Pump FRT — Front ft — F o ot FWD — Front Wheel Drive 4WD — F our Wheel Drive 4 x 4 — Four Wheel Drive 4 A/T — Four Speed Automatic Transmission/Transaxle Gal — Gallon GEN — Generator GND — Ground Gov — Governor g — Gram Harn — Har ness HC — Hydrocarbons HD — Heavy Duty Hg — Hydrargyrum (Mercury) HiAlt — High Altitude HO2S — Heated Oxygen Sensor HVAC — Heater–Vent–Air–Conditioning IAC — Idle Air Control IAT — Intake Air Temperature IC — Integrated Circuit / Ignition Control ID — Identification / Inside Diameter IGN — Ignition INJ — Injection IP — Instrument Panel IPC — Instrument Panel Cluster Int — Intake ISC — Idle Speed Control J/B — Junction Block kg — Kilograms km — Kilometers km/h — Kilometer per Hour kpa — Kilopascals kV — Kilovolts (thousands of volts) kW — Kilowatts KS — Knock Sensor L — Liter lb ft — Foot Pounds lb in — Inch Pounds LF — Left Front LH — Left Hand LR — Left Rear LS — Left Side LWB — Long Wheel Base L–4 — In–Line Four Cylinder Engine MAF — Mass Air Flow MAN — Manual

Page 11

0A–10 GENERAL INFORMATION

MAP — Mani fold Absolute Pressure Max — Maximum MC — Mixture Control MFI — Multiport Fuel Injection MIL — Malfunction Indicator Lamp Min — Minimum mm — Millimeter MPG — Miles Per Gallon MPH — Miles Per Hour M/T — Manual Transmission/Transaxle MV — Millivolt N — Newtons NA — Natural Aspirated NC — Normally Closed N·M — Newton Meters NO — Normally Open NOX — Nitrogen, Oxides of OBD — On-Board Diagnostic OD — Outside Diameter O/D — Over Drive OHC — Overhead Camshaft OL — Open Loop O2 — Oxygen O2S — Oxygen Sensor PAIR — Pulsed Secondary Air Injection System P/B — Power Brakes PCM — Powertrain Control Module PCV — Positive Crankcase Ventilation PRESS — Pressure PROM — Programmable Read Only Memory PNP — Park/Neutral Position P/S — Power Steering PSI — Pounds per Square Inch PSP — Power Steering Pressure Pt. — Pint Pri — Primary PWM — Pulse Width Modulate Qt. — Quart REF — Reference RF — Right Front RFI — Radio Frequency Interference RH — Right Hand RPM — Revolutions Per Minute RPM Sensor — Engine Speed Sensor RPO — Regular Production Option RR — Right Rear RS — Right Side RTV — Room Temperature Vulcanizing RWAL — Rear Wheel Antilock Brake RWD — Rear Wheel Drive SAE — Society of Automotive Engineers Sec — Secondary SFI — Sequential Multiport Fuel Injection SI — System International SIR — Supplemental Inflatable Restraint System SOHC — Single Overhead Camshaft Sol — Solenoid SPEC — Specification Speedo — Speedometer SRS — Supplemental Restraint System

ST — Start / Scan Tool Sw — Switch SWB — Short Wheel Base SYN — Synchronize Tach — Tachometer TB — Throttle Body TBI — Throttle Body Fuel Injection TCC — Torque Converter Clutch TCM — Transmission Control Module TDC — Top Dead Center Term — Ter minal TEMP — Temperature TOD— Torque On Demand TP — Throttle Position TRANS — Transmission/Transaxle TURBO — Turbocharger TVRS — Television & Radio Suppression TVV — Thermal Vacuum Valve TWC — Three Way Catalytic Converter 3 A/T — Three Speed Automatic Transmission/ Transaxle 2WD — Two Wheel Drive 4 x 2 — Two Wheel Drive U–joint — Universal Joint V — Volt(s) VAC — Vacuum VIN — Vehicle Identification Number VRRRE — V ehicle Refrigerant Recov ery and Recycling Equipment V–ref — ECM Reference Voltage VSS — Vehicle Speed Sensor VSV — Vacuum Switch Valve V–6 — Six Cylinder “V" Engine V–8 — Eight Cylinder "V" Engine W — Watt(s) w/ — With w/b — Wheel Base w/o — Without WOT — Wide Open Throttle

Page 12

Service Parts Identification Plate

The V ehicle Inf ormation 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.

GENERAL INFORMATION 0A–11

905RT013

Page 13

MAINTENANCE AND LUBRICATION 0B–1

SECTION

GENERAL INFORMATION

MAINTENANCE AND LUBRICATION

CONTENTS

Maintenance Schedule List............................ 0B - 1

Service and Maintenance ..................... ....... .. 0B - 2

Recommended Fluids and Lubricants........... 0B - 9

Lubricant Viscosity Chart............................... 0B - 10

Maintenance Schedule List

Normal Vehicle Use

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

• to carry passengers and cargo within the limitations specified on the tire placard located on the inside of the glove compartment door;

• to be driven on reasonable road surfaces within legal operating limits;

• to be driven on a daily basis, as a general rule, for at least several mi les/kilometers;

• to be driven on unleaded fuel

Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following sections.

Recommended Liquid Gasket .................... 0B - 12

Recommended Thread Locking Agents ..... 0B - 13

Maintenance Service Data............................. 0B - 14

Page 14

0B–2 MAINTENANCE AND LUBRICATION

Service a nd Maintenance

Page 15

MAINTENANCE AND LUBRICATION 0B–3

Page 16

0B–4 MAINTENANCE AND LUBRICATION

Page 17

MAINTENANCE AND LUBRICATION 0B–5

Page 18

0B–6 MAINTENANCE AND LUBRICATION

Page 19

MAINTENANCE AND LUBRICATION 0B–7

Page 20

0B–8 MAINTENANCE AND LUBRICATION

Page 21

MAINTENANCE AND LUBRICATION 0B–9

Recommended Fluids and Lubricants

USAGE FLUID/LUBRICANT

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

chart on the following page for proper viscosity) Engine coolant Brake system DOT-3 hydraulic brake fluid.

Power steering system DEXRON® II-E Automatic transmission fluid. Automatic transmission DEXRON® -III Automatic transmission fluid. MUA Type Manual transmission & Transfer case Engine oil

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

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

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

Mixture of water and good quality ethylene glycol base

type antifreeze.

(See oil chart on following page for proper viscosity)

GL-5 Limited slip differential gear lubricant together with

limited slip differential lubricant additive (Part No.

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

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

proper viscosity)

Engine oil

Page 22

0B–10 MAINTENANCE AND LUBRICATION

Lubricant Viscosity Chart

Lubricants should be carefully selected according to the

Oil Viscosity Chart for Gasoline Engine

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

905RT011

Page 23

MAINTENANCE AND LUBRICATION 0B–11

Oil Viscosity Chart for Manual Transmission and Transfer Case

Oil Viscosity Chart for Front Axle

B00RW002

B00RW003

Page 24

0B–12 MAINTENANCE AND LUBRICATION Oil Viscosty Chart for Rear Axle

Recommended Liquid Gasket

Type Brand Name Manufacturer Remarks

Three Bond 1207B

RTV* Silicon Base

Water Base Three Bond 1141E Three Bond For Engine Repairs

Solvent

Anaerobic

* RTV: Room Temperature Vulcanizer NOTE:

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

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

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

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

LOCTITE 515 LOCTITE 518 LOCTITE 17430

Three Bond Three Bond Three Bond Three Bond Three Bond

Three Bond Isuzu Isuzu Isuzu

Loctite Loctite Loctite

3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket. The connecting surfaces must be perfectly dry.

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

For Engine Repairs For Axle Case

Repairs T/M Repairs T/M

For Engine Repairs

All

B00RW004

Page 25

Recommended Thread Locking Agents

LOCTITE Type LOCTITE Color

LOCTITE 242 Blue LOCTITE 262 Red LOCTITE 271 Red

Application Steps

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

2. Apply LOCTITE to the bolts.

MAINTENANCE AND LUBRICATION 0B–13

F00RW014

3. Tighten the bolts to the specified torque. After tightening, be sure to keep the bolts free from vibration and torque for at least an hour until LOCTITE hardens.

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

Page 26

0B–14 MAINTENANCE AND LUBRICATION

Maintenance Service Data

Service Data and Specifications

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

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

CLUTCH Clutch pedal free play 5-15 mm (0.20-0.59 in) BRAKE Brake pedal free play 6-10 mm (0.24-0.39 in)

Parking brake travel 6-7 notches

WHEEL ALIGNMENT Toe-in (Front) 0±2 mm (0±0.08 in)

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

PROPELLER SHAFT Flange torque 63 N·m (46 lbft) WHEEL AND TIRES Size 235/75R15

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

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

Approximate Capacities

Items Metric Measure U.S. Measure

Fuel tank 80 L 21.1 Gal. * Crankcase (V6–3.2L ENGINE) Oil Change with Filter 4.7 L 5.0 Qt

Oil Change without Filter 4.0 L 4.2 Qt

* Crankcase (L4–2.2L ENGINE) Oil Change with Filter 4.5 L 4.8 Qt

Oil Change without Filter 4.2 L 4.4 Qt

Coolant M/T (V6–3.2L ENG) 11.0 L 11.6 Qt

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

Transmission Manual (V6–3.2L ENG) 2.95 L 3.1 Qt

Manual (L4–2.2L ENG) 2.13 L 2.25 Qt

Automatic 8.6 L 9.1 Qt Transfer 1.45 L 1.5 Qt Axle Rear 1.77 L 1.87 Qt

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

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

Page 27

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–1

SECTION

HEATING, VENTILATION AND AIR

CONDITIONING (HVAC)

HVAC SYSTEMS

CONTENTS

Service Precaution. . . . . . . . . . . . . . . . . . . . . 1A–3

Heating and Ventilation System. . . . . . . . . . . 1A–3

General Description . . . . . . . . . . . . . . . . . . 1A–3

Heater and Ventilation Associated Parts . . 1A–4

Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–5

Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 1A–8

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

Individual Inspection. . . . . . . . . . . . . . . . . . 1A–13

Heater Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–15

Heater Unit and Associated Parts . . . . . . . 1A–15

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–15

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1A–16

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Blower Assembly and Associated Parts . . . 1A–20

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

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

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

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

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

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

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

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

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

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

Rear Heater Duct, Defroster Nozzle

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

Rear Heater Duct, Defroster Nozzle,

Ventilation Duct and Associated Parts . . . 1A–24

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

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

Control Lever Assembly and / or Control Cable 1A–25

Control Lever Assembly, Control

Cable and Associated Parts . . . . . . . . . . . 1A–25

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

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

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

Control Panel Illumination Bulb and

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

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

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

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

Resistor and Associated Parts . . . . . . . . . . 1A–28

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

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

Air Conditioning System . . . . . . . . . . . . . . . . 1A–29

General Description . . . . . . . . . . . . . . . . . . 1A–29

Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 1A–36

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–38

Individual Inspection. . . . . . . . . . . . . . . . . . 1A–46

General Repair Procedure . . . . . . . . . . . . . 1A–47

Leak Check. . . . . . . . . . . . . . . . . . . . . . . . . 1A–48

Compressor Assembly. . . . . . . . . . . . . . . . . . 1A–54

Compressor Assembly and Associated

Parts (6VD1). . . . . . . . . . . . . . . . . . . . . . . 1A–54

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

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

Compressor Assembly and Associated

Parts (X22SE). . . . . . . . . . . . . . . . . . . . . . 1A–56

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

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

New Compressor Installation . . . . . . . . . . . 1A–57

Condenser Assembly. . . . . . . . . . . . . . . . . . . 1A–58

Condenser Assembly and Associated Parts 1A–58

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

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

Condenser Fan Motor . . . . . . . . . . . . . . . . . . 1A–59

Condenser Fan Motor and Associated Parts 1A–59

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

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

Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . 1A–60

Receiver / Drier and Associated Parts . . . . 1A–60

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

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

Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . 1A–61

Pressure Switch and Associated Parts. . . . 1A–61

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

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

Evaporator Assembly. . . . . . . . . . . . . . . . . . . 1A–62

Evaporator Assembly and Associated Parts 1A–62

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

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

Page 28

1A–2 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Electronic Thermostat, Evaporator Core

and/or Expansion Valve. . . . . . . . . . . . . . . . 1A–64

Disassembled View . . . . . . . . . . . . . . . . . . 1A–64

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

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

Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . 1A–66

Refrigerant Line and Associated Parts . . . . 1A–66

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–66

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1A–67

Main Data And Specifications. . . . . . . . . . . 1A–68

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–71

Service Precaution . . . . . . . . . . . . . . . . . . . 1A–71

General Description . . . . . . . . . . . . . . . . . . 1A–71

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–72

Magnetic Clutch Assembly (DKV-14D Type). 1A–73

Parts Location View . . . . . . . . . . . . . . . . . . 1A–73

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–73

Inspection and Repair. . . . . . . . . . . . . . . . . 1A–75

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

Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . 1A–77

Oil Specification . . . . . . . . . . . . . . . . . . . . . 1A–77

Handling of Oil . . . . . . . . . . . . . . . . . . . . . . 1A–77

Compressor Oil Check . . . . . . . . . . . . . . . . 1A–77

Checking and Adjusting Oil Quantity for

Used Compressor. . . . . . . . . . . . . . . . . . . 1A–77

Checking and Adjusting for Compressor

Replacement. . . . . . . . . . . . . . . . . . . . . . . 1A–78

Contamination of Compressor Oil . . . . . . . 1A–78

Oil Return Operation. . . . . . . . . . . . . . . . . . 1A–78

Replacement of Component Parts . . . . . . . 1A–78

Main Data and Specifications. . . . . . . . . . . 1A–79

Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A–81

Automatic Air Conditioning System . . . . . . . . 1A–82

General Description . . . . . . . . . . . . . . . . . . 1A–82

Automatic Air Conditioner Parts

Configuration . . . . . . . . . . . . . . . . . . . . . . 1A–82

Refrigerant Line and Associated Parts . . . . 1A–83

Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 1A–84

Functions and Features . . . . . . . . . . . . . . . 1A–90

Automatic Air Conditioner Block Diagram. . 1A–91

Control Panel Layout . . . . . . . . . . . . . . . . . 1A–92

Air Control Functions . . . . . . . . . . . . . . . . . 1A–93

Operation and Functions of Control Panel

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–94

Overview of Construction, Movement and

Control of Major Parts of Automatic Air

Conditioner System . . . . . . . . . . . . . . . . . 1A–97

Overview of Automatic Control of Automatic

Air Conditioner . . . . . . . . . . . . . . . . . . . . . 1A–100

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 1A–104

Troubleshooting, Its Overview and

Procedures . . . . . . . . . . . . . . . . . . . . . . . . 1A–104

Auto Air Co nditioner Control Unit Power

Supply Diagnosis . . . . . . . . . . . . . . . . . . . 1A–105

Performance and Movement checklist for

Automatic Air Conditioner Related Parts . 1A–107

Troubleshooting With Self-Diagnosis

Function . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–109

Inspection By Failed Location . . . . . . . . . . . . 1A–113

Inspection of the Sensors. . . . . . . . . . . . . . 1A–113

Inspection of the Intake Actuator System . 1A–117

Inspection of the Mix Actuator System . . . . 1A–120

Inspection of the Mode Actuator System . . 1A–123

Inspection of the Fan Motor System. . . . . . 1A–126

Inspection of the Magnetic Clutch System . 1A–130

Condenser Fan Diagnosis . . . . . . . . . . . . . 1A–133

Individual Inspection. . . . . . . . . . . . . . . . . . 1A–136

On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1A–140

Power Transistor. . . . . . . . . . . . . . . . . . . . . 1A–140

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–140

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–140

Automatic Heater/Air Conditioner Control Unit 1A–140

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–140

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–140

Interior Temperature Sensor (Aspirator). . . 1A–141

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–141

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–141

Outside Air Temperature Sensor . . . . . . . . 1A–141

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–141

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–141

Solar Radiation Sensor. . . . . . . . . . . . . . . . 1A–142

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–142

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–142

Electronic Thermostat. . . . . . . . . . . . . . . . . 1A–142

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–142

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–142

Mode Actuator . . . . . . . . . . . . . . . . . . . . . . 1A–143

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–143

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–143

Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . 1A–143

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–143

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–143

Intake Actuator . . . . . . . . . . . . . . . . . . . . . . 1A–144

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–144

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 1A–144

Page 29

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–3

Service Precaution

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

Heating and Ventilation System

General Description

Heater

When the engine is warming up, the warmed engine coolant is sent out into the heater core. The heater system supplies warm air into the passenger compartment to warm it up. Outside air is circulat ed 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.

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 threa d lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may dama ge the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

The air selector knob, with its different modes, also allows you to select and maintain the most comfortable 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 out side air i s 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 compar tment gets warm qui ckly. However, the lever is normally s et to “FRESH" to prevent the windshield from clouding.

Page 30

1A–4 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater and Ventilation Associated Parts

Legend

(1) Ventilation Duct (2) Defroster Nozzle (3) Lap Vent Duct (4) Rear Heater Duct

EndOFCallout

840RX007

(5) Ventiration Lower Duct (6) Heater Unit (7) Duct (W/O A/C) (8) Evaporator Assembly (With A/C) (9) Blower Assembly

Page 31

Ventilation

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–5

Setting the air so urce select lever to “FRESH" position allows the heating system to work with sending the fresh air from outside.

The blower fan also serves to deliver fresh outside air to the passenger compartment to assure adequate ventilation.

810RW319

Page 32

1A–6 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Lever Assembly

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

Legend

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

The fan control is used to contr ol the a mount of air sen t out by the resistor at four levels from “LOW" to “HIGH".

865RW006

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

EndOFCallout

Air Source Select Lever

The intake of outside air and the circu lation of ins ide air are controlled by sliding this lever left or right.

Fan Control Lever

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

1. Low

2. Medium Low

3. Medium High

4. High

Temperature Control Knob

When the temperature control knob is in the “COLD" position, the air m ix door closes to block the flow air to the heater core. When the temperature control knob is in the “HOT" position, the air mix door opens to allow air to pass through the heater core and heat the passenger compartment. Placing the knob in a inter mediate positi on will cause a lesser or greater amou nt a ir to reac h the heater core. In this mode the passenger compartment temperature can be regulated.

Page 33

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–7

Flow of Each Position of the All Select Dials

Air Select Knob

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

Vent

– In this position, air is discharged from the upper air outlet. A ir quan tity is contr olled by the fan control lever.

Bi-Level

– In this position, air flow is divided between the upper air outlets and the floor air outlets, with warmer air delivered to the floor outlets than the air delivered to th e upper air outlets whe n the temp lever is in middle position.

C01RX001

Foot

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

Def/Foot

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

Defrost

– In this position, most of the air is delivered to the windshield and a s mal l a mou nt i s del ivered 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.

Page 34

1A–8 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Circuit Diagram

D08RX149

Page 35

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–9

Diagnosis

Heating Cycle diagnosis

Condition Possible cause Correction

No heating or insufficient heating. Blower motor does not run or runs

improperly. Engine coolant temperature is low. Check the engine coolant

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

is insufficient.

Heater core clogged or collapsed. Clean or replace as neces sa ry. The heater cores is not provided

with air sent from the blower motor. Duct connections defective or

unsealing.

Control lever moves but mode door does not operate.

The mode door cannot be set to the mode selected.

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

assembly defective. Link unit of heater unit or blower

assembly defective. Control cable is not adjusted. Adjust.

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

temperature after warming up the engine and check the th er m ostat. Replace as necessary.

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

Repair the temperature control link unit or mode doors.

Repair or replace as necessary.

Repair

Repair.

Page 36

1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Fan Control Lever (Fan Switch) Diagnosis

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

Condition Possible cause Correction

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

— Refer to Chart B, C, D and E

position (s). Blower moto r do es no t st op at “OFF "

— Refer to Chart F

position.

D08RX250

Page 37

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–11

Chart “A" Blower Motor Does Not Run

Step Action Yes No

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

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

2. Turn fan control lever “ON".

3. Check to see if battery voltage is present at chassis side connector terminal No. B5-2

Is there a battery voltage?

Poor ground or

open circuit either

between chassis

side connector

terminal No. B5-1

and No. B3-2 or

No. I23-1 and body

ground (No. B-8).

Replace control

lever assembly.

Open circuit

between No. F-4

(20A) fuse and No.

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

B5-2.

Step Ac tion Yes No

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

between chassis

side connector

terminal No. B3-1

and No.I23-2.

Replace control

lever assembly.

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

Step Action Yes No

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

between the chassis side

connector terminal

No. B3-4 and No.

I23-3.

Replace control

lever assembly.

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

Step Action Yes No

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

between chassis

side connector

terminal No. B3-6

and No. I23-4.

Replace control

lever assembly.

Page 38

1A–12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart “E" Blower Motor Does Not Run At High Position

Step Action Yes No

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

between Chassis

side connector

terminal No. B3-3

and No. I23-5.

Replace control

lever assembly.

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

Step Action Yes No

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

between chassis

side connector

terminal No.B5-1

and

No.B3-2,No. B3-3

and No.I23-5,

No.B3-6 and

No.I23-4, No.B3-4

and No.I23-3 or

No.B3-1 and

No.I23-2

Replace control

lever assembly.

Page 39

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–13

Individual Inspection

Blower Motor

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

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

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

Resistor

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

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

873RW008

840RX013

Legend

(1) Resi st e r As sembly (2) Connector Terminal (Resister Side) (3) Position Switch

EndOFCallout

Page 40

1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Fan Control Lever (Fan Switch)

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

Heater Relay

1. Disconnect the heater relay (X-6).

• When removing the connector for relay, unfasten the tank lock of the connector by using a screwdriver, then pull the relay (1) out.

Legend

(1) Control Lever Connector Terminal (Control

Lever Side)

(2) Position Switch

EndOFCallout

825RX046

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

D08RX157

901RX071

Page 41

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–15

Heater Unit and Associated Parts

Heater Unit

Legend

(1) Instrument Panel Assembly (2) Resistor Connector (3) Heater Hose (4) Heater Unit Assembly (5) Duct (W/O A/C)

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Drain the engine coolant.

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

• Refer to Refrigerant Recovery in this section.

4. Remove the Instrument panel assembly.

• Refer to Instrument Panel Ass embly in Body an d

Accessories section.

5. Remove instrument panel bracket.

• Refer to Cross Beam Assembly in Body and

Accessories section.

6. Cross Beam Assembly .

• Refer to Cross Beam Assembly in Body and

840RX006

(6) Evaporator Assembly (With A/C) (7) Lap Vent Duct (8) Rear Heater Duct

(9) Ventilation Lower Duct (10) Instrument Panel Bracket (11) Cross Beam Assembly

Accessories section.

7. Disconnect resistor connector.

8. Re move duct.

9. Re move evaporator assembly (A/C only).

• Refer to Evaporator Assembly in this section.

10. Remove driver lap vent duct.

11. Re move ventilation lower duct.

12. Remove rear heater duct.

• Remove foot rest, carpet and 3 clips.

13. Remove heater unit assembly.

• Disconnect heater hoses at heater unit.

Page 42

1A–16 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Installation

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

1. When handling the PCM and the control unit, be careful not to make any impr oper connectio n of the connectors.

Heater Core and / or Mode Door

Disassembled View

2. Adjust the control cables.

• Refer to Control Lever Assembly in this section.

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

4. After putting engine coolant in remove the air well and confirm the quantity of coolant.

Legend

(1) Heater Unit (2) Case (Temperature Co ntrol) (3) Heater Core

EndOFCallout

Removal

1. Disconnect the battery ground cable.

860RX002

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

2. Drain the engine coolant.

Page 43

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–17

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

• Refer to Refrigerant Recovery in this section.

4. Remove heater unit.

• Refer to Heater Unit in this section.

5. Remove duct.

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

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

9. P ull out the mod e door while raisin g up the catch o f the door lever.

860RX004

Legend

(1) Mode Door (2) Door Lever

Legend

(1) Heater Core (2) Core Case

EndOFCallout

8. Remove heater core.

860RW021

EndOFCallout

Inspection

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

Installation

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

1. Check that each mode door operates properly.

Legend

(1) Heater Core

EndOFCallout

860RW020-1

Page 44

1A–18 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater Mode Control Link Unit

Disassembled View

Legend

(1) Heater Unit (2) Case (Mode Control) (3) Washer and Mode Main Lever

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Drain engine coolant.

3. Discharge and recover refrigerant (with air conditioning)

• Refer to Refrigerant Recovery in this section.

4. Remove heater unit.

• Refer to Heater Unit in this section.

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

6. Remove washer and the mode main lever.

7. Remove rod.

8. P ress the tab of the su b-lever inward, and take out the sub-lever.

860RW017

(4) Rod (5) Mode Sub Lever (6) Door Lever (7) Clip

860RW018

Page 45

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–19

9. P ull out the door lever while raising up the catch o f the door lever.

10. Remove clip.

Heater Temperature Control Link Unit

Disassembled View

Installation

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

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

2. A fter installing the link u nit, check to see if the link unit operates correctly.

Legend

(1) Heater Unit (2) Case (Temperature control) (3) Door Lever

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Drain engine coolant.

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

• Refer to Refrigerant Recovery in this section.

4. Remove heater unit.

• Refer to Heater Unit in this section.

860RX001

(4) Sub Lever (5) Clip (6) Rod (7) Clip

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

6. Re move rod.

7. Re move sub-lever.

8. P ull out the door lever while raising up the catch o f the door lever.

9. Re move clip.

Page 46

1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Installation

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

Blower Assembly

Blower Assembly and Associated Parts

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

2. A fter installing the link u nit, check to see if the link unit operates correctly.

Legend

(1) Instrument Panel Assembly (2) Heater Unit

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant (with air

840RX005

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

conditioning).

• Refer to Refrigerant Recovery in this section.

3. Remove instrument panel assembly .

• Refer to Instrument Panel Assembly in Body

Page 47

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–21

structure section.

4. Disconnect resisto r connector.

5. Remove duct.

6. Remove evaporator assembly (A/C only).

• Refer to Evaporator Assembly in this section.

7. Disconnect blower motor connector.

8. Remove blower assembly.

Blower Link Unit and / or Mode door

Disassembled View

Installation

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

1. Adjust the control cables.

• Refer to Control Lever Assembly in this section.

Legend

(1) Blower Assembly (2) Door Lever (3) Sub Lever

EndOFCallout

Removal

1. Disconnect the battery ground cable.

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

• Refer to Refrigerant Recovery in this section.

3. Remove blower assembly.

• Refer to Blower Assembly in this section.

4. Remove lower case.

873RX002

(4) Lower Ca s e (5) Mode Door (6) Upper Case

Page 48

1A–22 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

873RW006

6. P ull out the mo de door while raisin g up the catch of door lever.

7. Remove sub-lever.

8. Remove door lever.

Installation

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

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

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

Page 49

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–23

Blower Motor

Blower Motor and Associated Parts

Legend

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

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Remove blower motor connector.

3. Remove attaching screw.

4. Remove blower motor assembly.

5. Remove clip.

6. Remove fan.

7. Remove blower motor.

873RX001

(4) Cli p (5) Fan (6) Blower Motor

Installation

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

Page 50

1A–24 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Rear Heater Duct, Defroster Nozzle and Ventilation Duct

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

Legend

(1) Cross Beam Assembly (2) Defroster Nozzle (3) Ventilation Lower Duct (4) Lap Ventilation Duct

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Remove instrument panel assembly.

• Refer to Instrument Panel Assembly in Body

Structure section.

3. Remove center ventilation duct and side defroster

840RX004

(5) Rear Heater Duct (6) Instrument Panel Assembly (7) Instrument Panel Bracket (8) Center Ventilation Duct and Side Defroster

duct.

• Remove 5 screws.

4. Remove lap ventilation duct.

5. Remove instrument panel brackets.

• Refer to Cross Beam Assembly in Body Structure section.

6. Re move cross beam assem bly.

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HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–25

• Refer to Cross Beam Assembly in Body Structure section.

7. Remove ventilation lower duct.

8. Remove rear heater duct.

• Remove foot rest carpet and 3 clips.

9. Remove defroster nozzle.

Installation

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

1. Co nnect each duct and nozzle secur ely leaving no clearance between them and making no improper matching.

Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts

Legend

(1) Control Cable (2) Control Lever Assembly

EndOFCallout

865RX009

(3) Meter Cluster Assembly (4) Instrument Panel Driver Lower Cover Assembly (5) Glove Box

Page 52

1A–26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Removal

1. Disconnect the battery ground cable.

2. Remove instrument panel driver lower cover assembly.

3. Remove meter cluster assembly.

• Refer to Instrument Panel Assembly in Body

Structure section.

4. Remove glove box.

5. Remove the control lever attaching screws.

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

7. Remove control level assembly.

8. Disconnect control cables at each uni t side.

865RX012

865RX010

Page 53

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–27

Installation

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

1. Adjust the control cable.

• Air source control cable.

1 Slide the control lever to the left (“CIRC"

position).

2 Connect the control cable at the “CIRC"

position of the link unit of the blower assembly and secure it with the clip.

• Temperature control cable.

1 Turn the control knob to the left (“MAX COLD"

position).

2 Connect the control cable at the “COLD"

position of the tempe rature control link of th e heater unit and secure it with the clip.

• Air select contr ol cable

1 Turn the control knob to the right

(“DEFROST" position).

2 Connec t the contr ol cable at the “DEFROST"

position of the mode con trol l ink of the heater unit and secure it with the clip.

2. Check the control cable operation.

865RX013

Page 54

1A–28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Control Panel Illumination Bulb

Control Panel Illumination Bulb and Associated Parts

865RX011

Legend

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

Removal

1. Disconnect the battery ground cable.

2. Re move control lever assembly.

• Refer to Control Lever Assembly in this section.

3. P ull out the bulb socket from the panel by tur ning it counterclockwise.

4. Pull the illumination bulb from the socket.

Installation

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

EndOFCallout

Resistor and Associated Parts

Legend

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

Resistor

Removal

1. Disconnect the battery ground cable.

2. Re move glove box.

3. Re move resistor co nne cto r.

4. Remove duct (heater only).

5. Re move resistor.

Installation

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

840RX016

EndOFCallout

Page 55

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–29

Air Conditioning System

General Description

Air Conditioning Refrigerant Cycle Construction

Legend

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

EndOFCallout

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

C01RX004

(9) Condenser (10) Compressor (11) Magnetic Clutch (12) Mode (HEAT) Control Door (13) Temp. Control Door (Air Mix Door) (14) Heater Core (15) Mode (VENT) Control Door (16) Heater Unit (17) Mode (DEF) Control Door

Evaporation

The refrigerant is changed from a liquid to a gas ins ide

Page 56

1A–30 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

the evaporator. The refrigerant mist that enters the evaporator vaporizes readily. The liquid refrigerant removes the required quantity of heat (latent heat of vaporization) from the air around the evaporator core cooling fins and rap idly vaporizes. Removing the heat cools the air, which is then radiated from the fins and lowers the temperature of the air inside the vehicle. The refrigerant liq uid se nt fr om the expansion valve and the vaporized refrigerant gas are both present inside the evaporator as the liquid is converted to gas. With this change from l iquid to gas, the pressure insid e the evaporator must be kept low enough for v aporization to occur at a lower temperature. Because of that, th e vaporized refrigerant is sucked into the compressor.

Compression

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

Condensation

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

Compressor

The compressor performs two main functions: It compresses low-pressure and low-temperature refrigerant vapor from the evaporator into high-pres sure and high-temperature refrigerant vapor to the condenser. It pumps refrigerant and refrigerant oil through the air conditioning system. This vehicle is equipped with a five-vane rotary compressor. The specified amount of the compressor oil is 150cc (5.0fl.oz.). The oil used in the HFC-134a system compressor differs from that used in R-12 systems. Also, compressor oil to be used varies ac cording to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is us ed, lubrica tion will be poor an d the compressor will seize or malfunction. The magnetic clutch connector is a waterproof type.

Magnetic Clutch

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

Expansion

The expansion valve lowers the pressure of the refrigerant liquid so that it can easily vaporize. The process of lowering the pressure to encourage vaporization before the liquefied refrigerant is sent to the evaporator is called expansion. In addition, the expansion valve controls the flow rate of the refrigerant liquid while decreasing the pressure. That is , th e q ua n ti ty of re f rigerant liquid vaporiz ed in si de the evaporator is determined by the quantity of heat which must be removed at a prescribed vaporization temperature. It is important that the quantity of refrigerant be controlled to exactly the right value.

871RX009

Legend

(1) Magnetic Clutch

(2) Connector: Magnetic Clutch

(3) Compressor

EndOFCallout

Page 57

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–31

Condenser

The condenser assembly is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins. Also, it functions to cool and liquefy the high-pressure and high-temperature vapor sent from the co mpressor by the radiator fan or outside air. A condenser may malfun ction in two ways: it may leak, or it may be restricted. A condenser restriction will result in excessive compressor discharge pressure. If a partial restriction is present, the refrigerant expands after passing through the restriction. Thus, ice or frost may form immediately after the restriction. I f air flow through the condenser or radiator is blocked, high discharge pressures will res ult. During normal condenser operation, the refrigerant outlet line will be slightly cooler than the inlet line. The vehicle is equipped with the parallel flow type condenser. A larger thermal transmission area on the inner surface of the tube allows the radiant heat to increase and the ventilation resistance to decrease. The refrigerant line connection has a bolt at the block joint, for easy servicing.

• The liquefied refr ige rant from the cond enser i s mixed with refrigerant gas containing air bubbles. If refrigerant containing air bubbles. If refrigerant containing air bubbles is se nt to the expansio n valve, the cooling capacity will decrease considerably. Therefore, the liquid and air bubbles are separated and only the liquid is sent to the expansion valve.

• The receiver/drier uti lizes a filter and dri er to remove the dirt and water mixed in the cycling refrigerant.

• The sight glass, installed atop the receiver/drier, show the state of the refrigerant.

A receiver/drier may fail due to a restricti on inside the body of the unit. A rest r iction at t he inle t to the rece iver/ drier will cause high pressure. Outlet restr ictions will be ind icated by low pressure and little or no cooling. An excessively cold receiver/drier outlet may indicate a restriction. The receiver/drier of thi s vehicle is made of alu minum with a smaller tank. It has a 300cc refrigerant capacity. The refrigerant li ne connection has a bolt at the block joint, for easy servicing.

Dual Pressure Switch (V6,M/T)

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

875RX003

Legend

(1) Pressure Switch (2) Receiver/Drier (3) Condenser & Receiver Tank Assembly (4) Condenser Fan (6VD1 A/T)

EndOFCallout

Receiver / Drier

The receiver/drier performs four functions:

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

Compressor

Low-pressure

control

High-pressure

control

(kPa/psi)

186.3±29.4 (27.0±4.3)

2350.4±196.1 (340.7±28.4)

OFF

(kPa/psi)

176.5±19.6 (25.6±2.8)

2942.0±196.1 (426.6±28.4)

Triple Pressure Switch (V6, A/T)

Triple pressure switch is installed on the upper part of the receiver/drier. This switch is constructed with a unitized type of two switches. One of them is a low and high pressure switch (Dual pressure switch) to switch “ON" or “OFF" the magnetic clutch as a result of irregularly high-pressure or low pressure of the refrigerant. The o ther one is a mediu m pressure switch (Cycling switch) to switch “ON" or “OFF" the co ndenser fan sensing the condenser high side pressure.

Compressor

Low-pressure

control

High-pressure

control

(kPa/psi)

186.3±29.4 (27.0±4.3)

2353.6±196.1 (341.3±28.4)

OFF

(kPa/psi)

176.5±24.5 (25.6±3.6)

2942.0±196.1 (426.6±28.4)

Page 58

1A–32 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

the force acting on the diaphragm and the spring

Condenser fan

Medium-pressure

control

(kPa/psi)

1471.0±98.1

(213.3±14.2)

OFF

(kPa/psi)

1078.7±117.7 (156.4±17.1)

Pressure Sensor

The pressure sensor is installed on the upper part of the receiver/drier. This sensor converts high pressure detection of refrigerant to an electrical voltage signal and supplies it to th e PC M. The PCM co ntr ol s switchin g compressor idle sp eed an d coolin g fan operation by the electrical voltage signal.

pressure. The expansion valve regulates the flow rate of the refrigerant. Accordingly, when a malfunction occurs to this expansion valve, both discharge and suction pressure get low, resulting in insufficient cooling capacity of the evaporator. The calibration has been changed to match the characteristics of HFC-134a.

875RX002

Legend

(1) Pressure Switch (2) Receiver Drier

EndOFCallout

Expansion Valve

This expansion valve is an external pressure ty pe and it is installed at the evaporator intake port. The expansion valve converts the high pressure l iquid refrigerant sent from the receiver/drier to a low pressure liquid refrigerant by forcing it through a tiny por t before sending it to the evaporator. This type of expansion valve consists of a temperature sensor, diaphragm, ball valve, ball seat, spring adjustment screw, etc. The temperature sensor cont acts the evaporator outlet pipe, and converts changes in tempe rature to pressur e. It then transmits these to the top chamber of the diaphragm. The refrigerant pressure is transmitted to the diaphragm's bottom chamber through the external equalizing pressure tube. The ball valve is connected to the diaphragm. The opening angle of the expansion valve is deter mined by

874RX009

Legend

(1) Expansion Valve (2) Evaporator Assembly

EndOFCallout

Evaporator

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

Page 59

Legend

(1) Evaporator Core (2) Expansion Valve

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–33

874RX007

EndOFCallout

Electronic Thermostat (With Manual A/C)

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

874RX008

Legend

(1) Ther mo Sen so r (2) Evaporator Core (3) Thermostat Unit

EndOFCallout

Page 60

1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line

Restriction in the refrigerant line will be indicated by:

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

2. D ischarge line — A restricti on in the discharge line generally will cause the discharge line to leak.

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

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

Legend

(1) Reinforcement Layer (Polyester) (2) Exter na l Rubber Layer (3) Internal Rubber Layer (4) Resin Layer (Nylon)

EndOFCallout

852RS001

Page 61

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–35

Refrigerant Line Associated Parts

Legend

(1) Evaporato r Assembly (2) O-Ring (3) Drain Hose (4) Liquid Line (High Pressure Pipe) (5) Suction Line (Low – Pressure Hose)

EndOFCallout

852RX008

(6) Platform Seal (7) Condense r As se mbly (8) Receiver Drier

(9) Pressure Switch (10) Discharge Line (High Pressure Hose) (11) Compressor

Page 62

1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Circuit Diagram

D08RX151

Page 63

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–37

D08RX150

Page 64

1A–38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Diagnosis

Air Conditioning Cycle Diagnosis

Condition Possible cause Correction

No cooling or insufficient cooling. Magnetic clutch does not run. Refer to “Magnetic Clutch

Diagnosis" in this section.

Compressor is not rotating pr operly. Drive belt is loosened or broken.

Compressor is not rotating pr operly. Magnetic clutch face is not clean and slips.

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

Compressor is not rotating pr operly. Compressor oil leaks fr om the shaft seal or shell.

Compressor is not rotating pr operly. Compressor is seized.

Insufficient or excessive charge of refrigerant.

Leaks in the refrigerant system. Check the refrigerant system for

Condenser is clog ged or insu fficient radiation.

Temperature control link unit of the heat unit is defective.

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

Poor operation of the electronic thermostat.

Insufficient velocity of cooling air. Evaporator clogged or frosted. Check the evaporator core and

Air leaking from the cooling unit or air duct.

Blower motor does not rotate properly.

Adjust the drive belt to the spec ified tension or replace the drive belt.

Clean the magnetic clutch face or replace.

Adjust the clearance. Refer to Compressor in this section.

Replace the compressor

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

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

Clean the condenser or replace as necessary.

Repair the link unit.

Replace the expansion valve.

Check the electronic ther m ostat and replace as necessary.

replace or clean the core. Check the evaporator and duct

connection, then repair as necessary.

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

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

Page 65

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–39

Checking The Refrigerant System With Manifold Gauge

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

Conditions:

• Run the engine at Idling

• Air conditioning switch is “ON"

• Run the blower motor at “HIGH" position

• Temperature control lever set to “MAX COLD"

• Air source selector lever at “CIRC"

• Open the engine hood

• Close all the doors

• At ambient temperature: approx. 25–30°C (77–86°F).

Normal Pressure:

• At low-pressure side: approx. 147.1–294.2 kPa (21.3–42.7 psi).

• At high-pressure side: approx. 1372.9–1863.3 kPa (199.1–270.2 psi).

Refer to the table on the refrigerant pressure-temperature re lat ion sh ip.

HFC-134a Pressure-Temperature Relationship

Pressure Temperature

(kPa) (psi) (

36 5.3 –20 –4.4

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

1059 154 45 113 1216 176 50 122

C) (

°°°°

Page 66

1A–40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Connect The Manifold Gauge

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

Legend

(1) High Side

EndOFCallout

901RX060

(2) Low Side

Page 67

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–41

Condition Possible cause Correction

Discharge (High Gauge) Pressure Abnormally High

Discharge (High Gauge) Pressure Abnormally High. Insufficient cooli ng.

Discharge (High Gauge) Pressure Abnormally High. High pressure gauge dr op. (After stopping A/C, the pressure drops approx. 196kPa (28psi) quickly)

Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooli ng

Discharge (High Gauge) Pressure Abnormally Low. Low pressure gauge indicates vacuum.

Discharge (High Gauge) Pressure Abnormally Low. Frost or dew on refrigerant line before and after the receiver/dr ier o r expansion valve, and low pressure gauge indicates vacuum.

Discharge (High Gauge) Pressure Abnormally Low. High and low pressure gauge balanced quickly. (After tur ned off A/ C)

Suction (Low Gauge) Pressure Abnormally High. Low pressure gauge (Low pressure gauge is lowered after con denser is cooled by water.)

Suction (Low Gauge) Pressure Abnormally High. Low pressure hose temperature. (Low pressure hose temperature around the compressor refrigerant line connector is lower than around evaporator.)

Suction (Low Gauge) Pressure Abnormally High. High and low pressure gauge balanced quickly. (After tur ned off A/ C)

Suction (Low Gauge) Pressure Abnormally Low. Insufficient cooli ng.

Suction (Low Gauge) Pressure Abnormally Low. Frost on the expansion valve inlet line

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

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

Air in system. Evacuate and charge refrigerant

Insufficient refrigerant in system. Check for leaks. Discharge and

Clogged or defective expansion valve.

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

Compressor seal defective Repair or replace the compressor. Poor compression due to a defective

compressor gasket.

Excessive refrigerant in system. Discharge and recover refrigerant

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

Expansion valve opens too long. Replace the expansion valve.

Compressor gasket is defective. Repair or replace the compressor.

Insufficient refrigerant in system. Check for leaks. Discharge and

Expansion valve clogged. Replace the expansion valve.

Check the cooling fan operation.

Recharge to specified amount.

system.

recover the refrigerant. Recharge to the specified amount.

Replace the expansion valve.

Check system for restriction and replace the receiver/drie r.

Repair or replace the compressor.

Recharge to specified amount.

Replace the expansion valve.

recover the refrigerant. Recharge to specified amount.

Page 68

1A–42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condition Possible cause Correction

Suction (Low Gauge) Pressure Abnormally Low Receiver/drier inlet and outlet refrigerant line temperature. (A distinct difference in temperature develops.)

Suction (Low Gauge) Pressure Abnormally Low. Expansion valve outlet refrigerant line. (Not cold and low pressure gauge indicates vacuum.)

Suction (Low Gauge) Pressure Abnormally Low. When the refrigerant line is clogged or blocked, the low pressure gauge reading will decrease, or a vacuum reading may be shown.

Suction (Low Gauge) Pressure Abnormally Low. Evaporator core is frozen.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Insufficient cooli ng.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Suction (Low) pressure hose (Not cold).

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooli ng

Receiver/Drier clogged. Replace the receiver/drier.

Expansion valve temperature sensor is defective.

Clogged or blocked refrigerant line. Replace refrigerant line.

Thermo switch defective. Replace thermo switch.

Excessive refrigerant in system. Discharge and recover the

Condenser clogged or dirty . Clean the condenser fin. Air in system. Evacuate and charge refrigerant.

Insufficient refrigerant in system. Check for leaks. Discharge and

Replace the expansion valve.

refrigerant, the Recharge to the specified amount.

recover refrigerant. Recharge to specified amount.

A/C — Air Conditioning

Page 69

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–43

Magnetic Clutch Diagnosis

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

current flows through the thermostat and the

D08RX249

compressor relay to activate the magnetic clutch.

Page 70

1A–44 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

The air conditioning can be stopped by turning of the air conditioning switch or the fan control knob (fan switch). However, even when the air conditi oni ng is i n o peration, the electronic thermostat, the pressure switch or the Powertrain Control Module (PCM;V6-3.2L)/ Engine Control Module (ECM;L4-2.2L) is used to stop the air conditioning tempora rily by turning off the ma gnetic

Magnetic Clutch Does Not Run

Step Action Value(s) Yes No

1 Is the fuse No. F-5 normal? — Go to Step 2 Replace the

2 Are the relay No.X-6 (heater relay). No.X-5

(Thermostat relay) and No.X-4 (compressor relay) normal?

3 Is pressure switch normal? — Go to Step 4 Place the

4 Are the air conditioner switch and the fan control

switch normal?

5 1. Turn the ignition switch “ON" (the engine is run).

2. Turn the air conditioner switch and the fan control switch on.

Is the battery voltage applied between harness side connector terminal No.E3-1 and ground?

6 Repair an open circuit between compressor side

terminal and ground or replace compressor. Is the action complete?

7 Is there continuity between harness side connector

terminal No.X4-1 and No.E3-1?

8 Re pair an open circuit b etween terminal No.X4-1 and

No.E3-1. Is the action complete?

9 Is the battery voltage applied between har ness side

connector ter minal No.X4-2 and ground, No.X4-5 and ground?

10 Repair and open circuit between terminal No.X4-2 and

No.F-5 fuse, No.X4-5 and No.F-5 fuse. Is the action complete?

11 Is there continuity between harness side connector

terminal No.X4-4 and No.C1-B14?

12 Repair an open circ uit between ter minal No.X4-4 and

No.C1-B14. Is the action complete?

13 Is the battery voltage applied between harness side

connector terminal No.I24-2 and ground?

14 Repair an op en circuit between ter minal No.I24-2 and

No.F-5 fuse. Is the action complete?

15 Is the battery voltage applied between harness side

connector terminal No.B4-3 and ground?

clutch in the prearranged conditions to reduce the engine load which is being caused by the rise in the engine coolant te mperature, and the a ccel eration of the vehicle, etc. For the inspection of the relays, switches and units in the table, refer to “Individual Inspection" in this section.

— Go to Step 3 Replace the

pressure

— Go to Step 5 Replace the A/

C switch and

fan control

Approx.12V Go to Step 6 Go to Step 7

—Varify repair —

— Go to Step 9 Go to Step 8

— Go to Step 7 —

Approx.12V Go to Step 11 Go to Step 10

— Go to Step 9 —

— Go to Step 13 Go to Step 12

— Go to Step 11 —

Approx.12V Go to Step 15 Go to Step 14

— Go to Step 13 —

Approx.12V Go to Step 17 Go to Step 16

fuse

relay

switch.

switch

Page 71

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–45

Magnetic Clutch Does Not Run (Cont’s)

Step Action Value(s) Yes No

16 Repair an open circ uit between ter minal No.B4-3 and

No.I24-1. Is the action complete?

17 Is there continuity between harness side connector

terminal No.I23-6 and No.B-2?

18 Repair an op en circuit between ter minal No.I23-6 and

No.B4-2. Is the action complete?

19 Is there continuity between harness side connector

terminal No.I23-1 and ground (No.B-8)?

20 Repair an op en circuit between ter minal No.I23-1 and

No.B-8. Is the action complete?

21 Is the battery voltage applied between harness side

connector terminal No.C11-1 and ground?

22 Repair an open circuit between terminal No.C11-1

and No.F-5 fuse. Is the action complete?

23 Is the battery voltage applied between harness side

connector terminal No.X5-2 and ground?

24 Repair an open circ uit between ter minal No.X5-2 and

No.C11-2. Is the action complete?

25 Is the battery voltage applied between harness side

connector terminal No.B4-1 and ground?

26 Repair an open circ uit between ter minal No.B4-1 and

No.X5-4. Is the action complete?

27 Is there continuity between harness side connector

terminal No.X5-1 and No.C3-E15?

28 Repair an open circ uit between ter minal No.X5-1 and

No.C3-E15. Is the action complete?

29 Replace the PCM.

Is the action complete?

— Go to Step 15 —

— Go to Step 19 Go to Step 18

— Go to Step 17 —

— Go to Step 21 Go to Step 20

— Go to Step 19 —

— Go to Step 23 Go to Step 22

— Go to Step 21 —

— Go to Step 25 Go to Step 24

— Go to Step 23 —

— Go to Step 27 Go to Step 26

— Go to Step 25 —

— Go to Step 29 Go to Step 28

— Verify repair —

CAUTION: There are condition whitch air conditioner system dose not operate except trouble as follows.

1. The throttle is greater than 90%.

2. The ignition voltage is below 10.5 volts.

3. Th e engine speed is greater than 4500 RPM for 5 seconds or 5400 RPM.

4. The engine coolant temperature (ECT) is greater than 125°C (257°F).

5. The intake air temperature (IAT) is less than 5°C (41°F).

6. Th e power steering pressure switch signa ls a high pressure condition.

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1A–46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Individual Inspection

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

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

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

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

• For handling of these relays, refer to Heater Relay

in this section.

Legend

(1) A/C Switch Connector (switch side) (2) Fan Switch Connector (switch side)

EndOFCallout

901RX071

Pressure Switch

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

D08RX254

875RX010

Page 73

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–47

General Repair Procedure

Precautions For Replacement or Repair of Air Conditioning Parts

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

• Keep your work area clean.

• Always wear safety goggle and protective gloves when working on refrigerant systems.

• Beware of the danger of carbon monoxide fumes caused by running the engine.

• Beware of discharged refrigerant in enclosed or improperly ventilated garages.

• Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system.

• When discharging and recovering the refrigerant, do not allow refrigerant to discha rge too fast; it will draw compressor oil out of the system.

• Keep moisture and contaminants out of the system . When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately. Never remove the caps or plugs until the lines or parts are reconnected or installed.

• When disconnecting or reconnecting the lines, use two wrenches to support the line fitting, to prevent from twisting or other damage.

• Always install new O-rings whenever a connection is disassembled.

• Before connecting any hoses or lines, apply new specified compressor oil to the O-rings.

• When removing and replacing any parts which require discharging the refrigerant circuit, the operations described in this section must be performed in the following sequence:

1 Use the J-39500 (ACR

Recovery / Recycling / Recharging / System) or equivalent to thoroughly discharge and recover

the refrigerant. 2 Remove and replace the defective part. 3 After evacuation, charge the air conditioning

system and check for leaks.

: HFC-134a Refrigerant

Repair Of Refrigerant Leaks

Refrigerant Line Connections

Install new O-ring s, if required. W hen discon necting or connecting lines, use two wrenches to prevent the connecting portion from twisting or becoming damaged.

852RS003

When connecting the refrigerant line at a block joint, securely inser t the pr ojecting portion of the jo int por t ion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-rings prior to connecting.

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

850RW002

Page 74

1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

850RW003

Leak Check

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

Inspection of refrigerant leak

Refrigerant leak may cause an ad verse effect not only on the performance and durability of each component of the air-conditioner, but also on the global atmosphere. Therefore, it is most impor tant to re pair refrigerant l eak when there is any leak found.

Inspection flow of refrigerant leak

Step Action Yes No

1 1. Evacuate the refrigerant system.

2. Charge the refrigerant.

Is there any refrigerant leak?

2 1. Operate the com presso r for more than 5 minutes to raise the

pressure on the high pressure side.

Is there any refrigerant leak at high pressure components?

Inspection Steps

Check the components of a ir-conditioner t o see if th ere occurs any refrigerant leak along the flow of refrigerant.

• To avoid an error in the detection of refr igerant leak, make sure of there being no refrigerant vapor or cigarette smoke around the vehicle before conducting the inspection. Also, select a location where the refrigerant vapor will not get blown off with wind.

• Inspection should be conducted chiefly on the pipe connections and sections where a marked oil contamination is found. When refrigerant is leaking, oil inside is also leaking at the same time.

• It is possible to visually check the leak from inside the cooling unit. Follow the method below when checking. Remove the drain hose or resistor of the

cooling unit, and insert a leak detecto r to see if there occurs any leak.

High Pressure Side

1. Discharger section of compressor.

2. Inlet/outlet section of condenser.

3. Inlet/outlet section of receiver driver.

4. Inlet section of cooling unit.

Low Pressure Side

1. Outlet section of cooling unit.

2. Intake section of compressor.

Repair refrigerant

system. Go to Step 2.

Compressor

Repair refrigerant

system.

operation to be

confirmed.

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HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–49

Major Checking Points of Refrigerant Leak

Compressor

• Pipe connection

• Sealing section of shaft

• Mating section or cylinder

Condenser

• Pipe connection

• Welds of condenser body

Receiver driver

• Pipe connection

• Attaching section of pressure switch

• Section around the sight glass

Evaporator unit (cooling unit)

• Pipe connections

• Connections of expansion valve

• Brazed sections of evaporator

• The evaporator and expansion valve are contained in the case. Remove the drain hose or the resistor of the cooling unit and insert a leak detecto r wh en checking for any leak.

Flexible hose

• Pipe connection

• Caulking section of the hose

• Hose (cracks, pinholes, flaws)

Pipe

• Pipe connection

• Pipe (cracks, flaws)

Charge valve

• The charge valve, which is used to connect the gauge manifold, is normally provided with a resin cap. When the valve inside gets deteriorated, refrigerant will leak out.

Leak at Refrigerant Line Connections

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

• Use two wrenches to prevent twisting and

damage to the line.

• Do not over tighten.

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

3. I f the l eak i s still presen t, disch arge and rec over the refrigerant from the system.

4. Replace the O-rings.

• O-rings cannot be reused. Always replace with

new ones.

• Be sure to apply the specified compressor oil to the new O-rings.

5. Re tighten the refrigerant line fitting to the specified torque.

• Use two wrenches to prevent twisting and

damage to the line.

6. Evacuate, charge and retest the system.

Leaks In The Hose

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

1. Locate the leak.

2. Discharge and recover the refrigerant.

3. Re move the hose assembly.

• Cap the open connections at once.

4. Connect the new hose assembly.

• Use two wrenches to prevent twisting or damage

to the hose fitting.

• Tighten the hose fitting to the specified torque.

5. Evacuate, charge and test the system.

Compressor Leaks

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

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

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

• Always wear safety goggles and protecti ve gloves.

• Always work in a well-ventilated area. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components.

• If HFC-134a should come in cont act with any par t of the body, flu sh the exposed area with cold water and immediately seek medical help.

• If it is necessary to transport or carry any container of HFC-134a in a vehicle, do not carry it in the passenger compartment.

• If it is necessar y to fill a small HFC-134a container from a large one, never fill the container completely. Space should always be allowed above the liquid for expansion.

• HFC-134a and R-12 should never be mixed as their compositions are not the same.

• HFC-134a PAG oil tends to absorb moisture more quickly than R-12 mineral oil and, therefore, should be handled more carefully.

• Keep HFC-134a containers stored below 40°C (100°F).

Page 76

1A–50 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

WARNING:

• SHOULD HFC-134A CONTACT YOUR EYE(S), CONSULT A DOCTOR IMMEDIATELY.

• DO NOT RUB THE AFFECTED EYE(S). INSTEAD, SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT.

• OBTAIN PROPER MEDICAL TREATMENT AS SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREATED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN.

Refrigera nt Recovery

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

1. Connect the high and low charging hoses of the

ACR

(or equivalent) as shown below.

:HFC-134a Refrigerant

3. W hen a part is removed, put a cap or a pl ug on the connecting portion so that dust, dirt or moisture cannot get into it.

Refrigerant Recycling

Recycle the refrigerant recovered by J-39500

(ACR

:HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent. For the details of the actual operation, follow the steps in the ACR

(or equivalent) Manufacturer's Instructions.

Evacuation of The Refrigerant System

901RX057

Legend

(1) High Side (2) Low Side

EndOFCallout

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

901RX058

Legend

(1) High Side (2) Low Side

EndOFCallout

Explained below is a method using a vacuum pump. Refer to the ACR instructions when evacuating the system with a ACR

(or equivalent) manufacturer's

(or equivalent). Air and moisture in the refrigerant will cause problems in the air conditioning sys tem. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system.

1. Connect the gauge manifold.

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

• Low-pr essure va lve (LOW) — Suction-side.

2. Discharge and recover the refrigerant.

3. Co nnect the center ho se of the gauge manifold set to the vacuum pump inlet.

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

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

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

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HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–51

7. C heck to ensure that th e pressure does not ch ange after 10 minutes or more.

• If the pressure changes, check the system for

leaks.

• If leaks occur, retighten the refrigerant line

connections and repeat the evacuation steps.

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

9. C lose p ositive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump.

Charging The Refrigerant System

There are various meth ods of charging refrigerant into the air conditioning system. These include using J-39500 (ACR Refrigerant Recovery/Re cycling/Rechargi ng/System) or equivalent and direct charging with a weight scale charging station.

Charging Procedure

ACR

•

(or equivalent) Method

For the charging of refrige rant recovered by ACR equivalent), follow the manufacturer's instruction.

:HFC-134a

(or

Direct charging with a weight scale charging

•

station method

1. Make sure the evacuation process is correctly completed.

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

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

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

Legend

(1) High Side (2) Low Side

EndOFCallout

901RX057

901RX059

Legend

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

EndOFCallout

5. P lace the refrige rant container up right on a weight scale. Note the total weight before charging the refrigerant.

a Open the refrigerant container valve. b Open the low side vale on the mani fol d gauge

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

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1A–52 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

6. Perform a system leak test:

• Charge the system with approximately 200g (0.44lbs) of HFC-134a.

• Make sure the high pressure valve of the manifold gauge is closed.

• Check to ensure that the degree of pressure does not change.

• Check for refrigerant leaks by using a HFC-134a leak detector.

• If a leak occurs, recover the refrigerant. Repair the leak and start all over again from the first step of evacuation.

7. I f no leaks are found, continue charging r efrigerant to the air conditioning system.

• Charge the refrigerant until the scale reading

decreases by the amount of the charge specified.

Specified amount: 650g (1.43lbs)

• If charging the system becomes difficult:

1 Run the engine at idle and close all the

vehicle doors. 2 Turn A/C switch “ON". 3 Set the fan switch to its highest position. 4 Set the air source selector lever to “CIRC". 5 Slowly open the low side valve on the

manifold gauge set.

WARNING: Be absolutely sure not to open the high pressure valve of the manifold gauge. Should the high pressure valve be opened, the high pressure refrigerant would flow backward, and this may cause the refrigerant container to burst.

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

9. Check fo r refrigerant leaks.

Checking The A/C System

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

• If an abnormal pressure is found, refer to Checking The Refrigerant Sy stem With Manifold Gauge in this section.

5. P ut your hand in front o f the air o utlet an d move the temperature control lever of the control panel to different positions. Check if the outlet temperature changes as selected by the control knob.

Reading Sight Glass

The sight glass provides accurate diagnos is only under the following conditions. If the vehicle can be tested under these conditions, check the sight glass a ppearance and compare to the chart bel ow.

• Engine speed idle

• A/C switch “ON"

• Blower fan operating at highest speed

• Air source selector lever at “RECIRC"

• Temperature control lever at coldest position

• Ambient temperature below 30°C (86°F) and humidity below 70% (See NOTE 1)

• High side pressure less tha n 1667.1 kPa (241.7 psi) (See NOTE 2)

NOTE: 1. If the vehicle c annot be moved to a testing location that meets the se specifications, then the sight glass cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue checking the system performance.

NOTE: 2. If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue checking system performance.

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

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

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

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

• Immediately after char ging refrigerant, both high

and low pressures might be slightl y hig h, but they settle down to the pressure guidelines shown below:

• The ambient temperature should be between 25–

30°C (77–86°F).

• The pressure gu id eli ne for the hig h- pr essu re s id e

is approximately 1372.9–1863.3kPa (199.1–

270.2 psi).

• The pressure guideline for the low-pressure side

Page 79

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–53

High and low pressure pipe temperature

Slight glass condition Almost transparent. A

Air condi tioni ng c yc le condition

The high pressure pipe is hot and the low pressure pipe is cold. There is a distinct difference in temperature between them.

flow of bubbles can

be seen, but they

disappear when the

throttle is opened.

OK NG

The high pressure pipe is warm and the low pressure pipe is cool. There is no great difference in temperature between them.

A flow of bubbles

always can be seen.

It appears sometimes

transparent, and

sometimes frothy.

(Not enough

refrigerant)

There is litttle difference in temperature between the high pressure pipe and the low pressure pipe.

Something like fog

faintly can be seen.

NG (Almost no refrigerant)

The high pressure pipe is hot and the low pressure pipe is slightly warm. There is a defference in temperature between them.

Even at idle with the

fan at “HI” (with the window fully open),

the bubbles cannnot

be seen.

(Too much

refrigerant)

Page 80

1A–54 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor Assembly

Compressor Assembly and Associated Par ts (6VD1)

Legend

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

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant

• Refer to Refrigerant Recovery in this section.

3. Disconnect magnetic clutch harness connector.

4. Remove serpentine belt.

• Move serpentine belt tensioner to loose side using wrench then remove serpentine belt.

871RX021

(3) Compressor (4) Serpentine Belt

Page 81

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–55

Legend

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

850RX003

Installation

1. Install compressor.

• Tighten the compressor fixing bolts to the specified torque.

Torque: 19N•m (14lb•ft)

2. Connect refrigerant line connector.

• Tighten the refr igerant line connector fixing bol ts to the specified torque.

Torque: 15N•m (11lb•ft)

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

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

3. Install serpentine belt.

• Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position.

4. Connect magnetic clutch harness connector.

EndOFCallout

5. Disconnect refrigerant line connector.

• When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

6. Remove compressor.

Page 82

1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor Assembly and Associated Par ts (X22SE)

Legend

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

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant

• Refer to Refrigerant Recovery in this section.

3. Disconnect magnetic clutch harness connector.

871RX022

(3) Compressor (4) Serpentine Belt

Page 83

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–57

4. Remove serpentine belt.

• Move serpentine belt tensioner to loose side using wrench then remove serpentine belt.

Legend

(1) Power Steering Oil Pump (2) Air Conditioner Compressor (3) Tensioner (4) Crankshaft Pulley (5) Power Steering Oil Pump (6) Air Conditioner Compressor (7) Crankshaft Pulley (8) Generator

EndOFCallout

5. Disconnect refrigerant line connector.

• When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

6. Remove compressor.

• Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position.

4. Connect magnetic clutch harness connector.

New Compressor Installation

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

1. Gently release nitrogen gas from the new compressor.

• Take care not to let the compressor oil flow out.

• Inspect O-rings and replace if necessary.

850RX006

871RX008

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

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

Installation

1. Install compressor.

• Tighten the compressor fixing bolts to the specified torque.

Torque: 19N•m (14lb•ft)

2. Connect refrigerant line connector.

• Tighten the refr igerant line connector fix ing bolts to the specified torque.

Torque: 15N•m (11lb•ft)

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

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

3. Install serpentine belt.

871RX013

Page 84

1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condenser Assembly

Condenser Assembly and Associated Parts

Legend

(1) Engine Hood Lock (2) Pressure Switch Connec to r (3) Refrigerant Line

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Remove engine hood front end stay.

5. Remove engine hood lock.

• Apply setting mar k to the engi ne hood lock fixin g position before removing it.

6. Disconnect pressure switch connector.

7. Disconnect refrig erant line.

• When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

875RW008

(4) Radiator Grille (5) Engine Hood F ront End Stay (6) Condense r As se mbly

8. Re move condenser asse mbly.

• Handle with care to prevent damaging the condenser or radiator fin.

Installation

1. Install condenser assembly.

• If installing a new condenser, be sure to add 30cc (1.0fl.oz.) of new compressor oil to a new one.

• Tighten the condenser fixing bolts to the specified torque.

Torque: 6N•m (52lb in)

2. Connect refrigerant line.

• Tighten the inlet li ne connector fixing bolt to the specified torque.

Page 85

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–59

Torque: 15 N•m (11 lb ft)

• Tighten the outlet line c onnector fi xing bolt to the specified torque.

Torque: 6 N•m (52 lb in)

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

3. Connect pressure switch connector.

4. Install engine hood lock.

5. Install engine hood front end stay.

6. Install radiator grille.

Condenser Fan Motor

Condenser Fan Motor and Associated Parts

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

Legend

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

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Remove condenser fan assembly.

• Disconnect the fan motor connec tor and remove the 4 fixing bolts.

5. Remove shroud.

• Remove the 3 fixing nuts.

875RW009

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

• Loosen the conde nser fixing nut and disc onnect the fan motor connector from bracket.

6. Re move fan.

• Remove the fan fixing C-ring and plate.

7. Remove condenser fan motor.

Installation

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

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

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1A–60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Receiver / Drier

Receiver / Drier and Associated Parts

875RX001

Legend

(1) Pressure Switch Connec to r (2) Pressure Switch (3) Refrigerant Line (4) Radiator Grille (5) Receiver / Drier (6) Bracket Bolt

Installation

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

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

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

3. Tighten the refrigerant line to the specified torque.

Torque: 6 N•m (52 lb in)

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

5. B e sure to apply new compressor oil to t he O-rings when connecting the refrigerant line.

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Disconnect pressure switch connector.

5. Disconnect refrig erant line.

• When removing the line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

6. Remove bracket bolt.

7. Remove receiver/drier.

• Loosen the bolt, the n, using care not to touch or bend the refrigerant line, carefully pull out the receiver/drier.

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HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–61

Pressure Switch

Pressure Switch and Associated Parts

875RX001

Legend

(1) Pressure Switch Connec to r (2) Pressure Switch (3) Refrigerant Line (4) Radiator Grille (5) Receiver / Drier (6) Bracket Bolt

Installation

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

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

2. B e sure to apply new compress or oil to the O-ring when connecting pressure switch.

3. Tighten the pressure switch to the specified torque.

Torque: 13 N•m (113 lb in)

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to “Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Disconnect pressure switch connector.

5. Disconnect pressure switch.

• When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

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1A–62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Evaporator Assembly

Evaporator Assembly and Associated Parts

Legend

(1) Refrigerant Line (2) Drain Hose (3) Resistor and Electronic Thermostat Connector (4) Evaporato r Assembly

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to Refrigerant Recovery in this section.

3. Remove glove box.

874RX010

(5) Bolt: Evaporator Fix (6) Glove Box (7) Sill Plate (8) Pad: Dash Side Trim (9) Reinforcement: Inst Panel Lower

Page 89

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–63

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

840RW019

5. Disconnect drain hose.

6. Disconnect refrig erant line.

• Use a back-up wrench when disconnecting and

reconnecting the refrigerant lines.

• When removing the refrigerant line connected

part, the conn ecting part should immediately be plugged or capped to p revent foreign matter from being mixed into the line.

7. Remove e vaporator assembly.

Installation

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

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

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

Torque: 25 N•m (18 lb ft)

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

Torque: 15 N•m (11 lb ft)

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

5. B e sure to apply new compressor oil to t he O-rings when connecting lines.

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1A–64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View

Legend

(1) Lining (2) Upper Case (3) Electronic Thermostat (4) Evaporator Core (5) Lining: Case

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to Refrigerant Recovery in this section.

3. Remove evaporator assembly.

• Refer to Evaporator Assembly in this section.

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

5. Remove clip.

6. Remove attaching screw.

7. Remove upper case.

8. Remove lower case.

• Slit the case parting face with a knife since the

lining is separated when removing the evaporator.

874RX011

(6) Attaching Screw (7) Clip (8) Lower Ca s e

(9) Evaporator Assembly (10) O-ring (11) Expansion Valve

874RW034

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HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–65

• Lift to remove the upper case.

9. Remove evaporator core.

Installation

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

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

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

3. W hen installing the new evaporator core, install the thermo sensor to the evaporator core specified position with the clip in the illustration.

874RX013

10. Remove expansion valve.

• Tear off the insulator carefully.

• Remove the sensor fixing clip.

• Use a back-up wrench when disconnecting all refrigerant pipes.

874RX012

874RX014

Legend

(1) Evaporator Core (2) Ther mo Sen so r (3) Lower Ca s e (4) Upper Case

EndOFCallout

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

5. B e sure to apply new compressor oil to t he O-rings when connecting lines.

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

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

8. Ti ghten the refri gerant lines to the spec ified torque. Refer to Main Data and Specifications for Torque Specifications in this section.

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

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1A–66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Refrigerant Line

Refrigerant Line and Associated Parts

Legend

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

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Discharge and recover refrigerant.

• Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Remove clip and clamp.

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

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

852RX009

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

back-up wrench.

7. Di sconnect suction line (Low-pressure h ose) using a back-up wrench.

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

• Use a backup wrench when disconnecting and

reconnecting the refrigerant lines.

• When removing the refrigerant line connecting

part, the co nnecting part should immediately be

Page 93

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–67

plugged or capped to p revent foreign matter from being mixed into the line.

Installation

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

1. O -rings ca nnot be reused. A lways replace with new ones.

2. B e sure to apply new compres sor oil to the O-r ings when connecting lines.

3. Tighten the refrigerant line to the specified torque. Refer to Main Data and Specifications for Torque Specificat ions in this secti on.

Page 94

1A–68 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Main Data And Specifications

General Specifications

Heater Unit

Temperature control Reheat air mix system Capacity 3,700 Kcal./hr.

Air flow 280 m

HEATER CORE

Type AUTO A/C Plate and corrugate-fin type

MANU A/C Fin and tube type

Element dimension MANU A/C 161 mm (6.3) × 163 mm (6.4 in.) × 45 mm (1.8 in.)

A UTO A/C 171 mm (6.7) × 161 mm (6.3 in.) × 25 mm (1 in.)

Radiating area MANU A/C Approx. 2.1 m

AUTO A/C Approx. 1.3 m

EVAPORATOR ASSEMBLY

Capacity AUTO A/C 4,100 Kcal./hr.

MANU A/C 4,200 Kcal./hr.

Air flow AUTO A/C 430 m

MANU A/C 470 m

EVAPORATOR CORE

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

EXPANSION VALVE

Type Internal pressure equalizer type

THERMOSTAT SWITCH

Type Electronic thermostat

CONDENSER

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

RECEIVER/DRIER

Type Assembly includes sight glass with dual (triple) pressure

switch (V6) or pressure sensor (L14)

Internal volume 300 cc (10 fl.oz.)

2 2

/hr

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

Page 95

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–69

PRESSURE SWITCH

Type Dual pressure switch

Low pressure control

ON: 186.3±29.4 kPa (27.0±4.3 psi) OFF: 176.5±24.5 kPa (25.6±3.6 psi)

High pressure control

ON: 2353.6±196.1 kPa (341.3±28.4 psi)

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

ON: 196.3±29.4 kPa (27.0±4.3 psi)

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

ON: 1471.0±98.1 kPa (213.3±14.2 psi)

OFF: 1078.7±117.7 kPa (156.4±17.7 psi) High pressure control

ON: 2353.6±196.1 kPa (341.3±28.4 psi)

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

REFRIGERANT

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

Page 96

1A–70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Torque Specifications

E06RX006

E06RX007

Page 97

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–71

Compressor

Service Precaution

WARNING: This vehicle has a Supplemental Restraint System (SRS). Refer to the SRS Component Location View in order to determine whether you are performing service on or near the SRS components or the SRS wiring. When you are performing service on or near the SRS components or the SRS wiring, refer to the SRS On-Vehicle Service Information. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SRS sys tem repairs.

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

General Description

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

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

DKV-14D Type Compressor

DKV-14D is equipped with five-vane rotary compressor. These vanes are built into a rotor which is mounted on a shaft. When the shaft rotates, the vanes built into the cylind er block assembly are operated by centrifugal force. This changes the volume of the spare formed by the rotor and cylinder, resulting in the intake and compression of the refrigerant gas. The discharge valve and the valve stopper, which protects the discharge valve, are built into the cylinder block assembly. There is no suction valve but a shaft seal is installed bet ween the shaft and h ead; a trigge r valve, which applies back pressure to the vanes, is inst alled in the cylinder block and a refrig erant gas temperatu re sensor is in stalled in the front head. The specified quanti ty of compres sor oil is con tained in the compressor to lub ricate the various pa rts usin g the refrigerant gas discharge pressure.

A01RS003

Page 98

1A–72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Diagnosis

Condition Possible cause Correction

Noise from compression Defective rotor/piston Replace compressor/cylinder and

shaft assembly

Defective shaft Replace compressor/cylinder and

shaft assembly

Noise from magnetic clutch Defective bearing Replace magnetic clutch

Defective clutch Replace magnetic clutch Clearance between drive plate and

pulley not standard

Insufficient cooling Defective gasket Replace compressor/gasket

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

Not rotating Defective rotor/piston Replace compressor/cylinder and

Defective shaft Replace compressor/cylinder and

Rotating parts seized due to insufficient oil

Oil and/or gas leakage Defective seal Replace compressor/shaft seal

Defective O-ring Replace

Adjust the clearance or replace magnetic clutch

shaft assembly

shaft assembly Replace compressor

Page 99

Magnetic Clutch Assembly (DKV-14D Type)

Parts Location View

Legend

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

HEATING, VENTILATION AN D AIR COND IT IONING (HVAC) 1A–73

871RX012

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

EndOFCallout

Removal

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

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

871RX016

901RX055

Page 100

1A–74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

3. Remove shim (s).

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

871RW016

5. R emove pulley assembly by using pu lley puller pilot J-38424, pulley puller J-8433 and pulley puller leg J-24092-2.

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

871RS010

7. Loosen three screws and remove the field coil.

871RS009

871RS011

Opel Frontera 2000 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual