2002 ISUZU AXIOM clutch

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±39
4. Remove serpentine belt.

Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RY00005
Legend
(1) Auto Tensioner
(2) Idle Pulley
(3) Cooling Fan Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
5. Disconnect refrigerant line connector.

When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line.
6. Remove compressor.
Installation
1. Install compressor.

Tighten the compressor fixing bolts to the specified
torque.
Torque: 19 Nwm (14 lbwft)
2. Connect refrigerant line connector.

Tighten the refrigerant line connector fixing bolts to
the specified torque.
Torque: 15 Nwm (11 lbwft)

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.
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.
871RX033
2. Turn the compressor several times by hand and
release the compressor oil in the rotor.
3. When installing on a new system, the compressor
should installed as it is. When installing on a used
system, the compressor should be installed after
adjusting the amount of compressor oil. (Refer to
Compressor in this section)
871RX035

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±53
Compressor
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT LOCATION VIEW IN ORDER TO
DETERMINE WHETHER YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR
THE SRS WIRING. WHEN YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR
THE SRS WIRING, REFER TO THE SRS ON-VEHICLE
SERVICE INFORMATION. FAILURE TO FOLLOW
CAUTIONS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important
for proper service. The compressor connections and the
outside of the compressor should be cleaned before any
ºOn±Vehicleº repair, or before removal of the
compressor. The parts must be kept clean at all times and
any parts to be reassembled should be cleaned with
Trichloroethane, naphtha, kerosene, or equivalent
solvent, and dried with dry air. Use only lint free cloths to
wipe parts.
The operations described below are based on bench
overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When the compressor is
removed from the vehicle for servicing, the oil remaining
in the compressor should be discarded and new
compressor oil added to the compressor.
Compressor malfunction will appear in one of four ways:
noise, seizure, leakage or low discharge pressure.
Resonant compressor noises are not cause for alarm;
however, irregular noise or rattles may indicate broken
parts or excessive clearances due to wear. To check
seizure, de±energize the magnetic clutch and check tosee if the drive plate can be rotated. If rotation is
impossible, the compressor is seized. Low discharge
pressure may be due to a faulty internal seal of the
compressor, or a restriction in the compressor. Low
discharge pressure may also be due to an insufficient
refrigerant charge or a restriction elsewhere in the
system. These possibilities should be checked prior to
servicing the compressor. If the compressor is
inoperative, but is not seized, check to see if current is
being supplied to the magnetic clutch coil terminals.
The compressor oil used in the HFC±134a system
compressor differs from that used in R±12 systems.
Also, compressor oil to be used varies according to the
compressor model. Be sure to avoid mixing two or more
different types of oil.
If the wrong oil is used, lubrication will be poor and the
compressor will seize or malfunction.
DKV-14G Type Compressor
DKV±14G is equipped with five±vane rotary compressor.
These vanes are built into a rotor which is mounted on a
shaft.
When the shaft rotates, the vanes built into the cylinder
block assembly are operated by centrifugal force.
This changes the volume of the spare formed by the rotor
and cylinder, resulting in the intake and compression of
the refrigerant gas. The discharge valve and the valve
stopper, which protects the discharge valve, are built into
the cylinder block assembly. There is no suction valve but
a shaft seal is installed between the shaft and head; a
trigger valve, which applies back pressure to the vanes, is
installed in the cylinder block and a refrigerant gas
temperature sensor is installed in the front head.
The specified quantity of compressor oil is contained in
the compressor to lubricate the various parts using the
refrigerant gas discharge pressure.
871RX002

1A±54
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
ConditionPossible causeCorrection
Noise from compressionDefective rotor/pistonReplace compressor/cylinder and
shaft assembly
Defective shaftReplace compressor/cylinder and
shaft assembly
Noise from magnetic clutchDefective bearingReplace magnetic clutch
Defective clutchReplace magnetic clutch
Clearance between drive plate and
pulley not standardAdjust the clearance or replace
magnetic clutch
Insufficient coolingDefective gasketReplace compressor/gasket
Defective rotor/reed valveReplace compressor/valve plate
Defective trigger valve/suction valveReplace compressor/suction valve
Not rotatingDefective rotor/pistonReplace compressor/cylinder and
shaft assembly
Defective shaftReplace compressor/cylinder and
shaft assembly
Rotating parts seized due to
insufficient oilReplace compressor
Oil and/or gas leakageDefective sealReplace compressor/shaft seal
Defective O-ringReplace

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±55
Magnetic Clutch Assembly (DKV-14G Type)
Parts Location View
871RX025
Legend
(1) Drive Plate bolt
(2) Drive Plate
(3) Snap Ring(4) Pulley Assembly
(5) Field Coil
(6) Shim (s)
(7) Lead Wire
Removal
1. Using drive plate holder J-33939 (1) to prevent the
drive plate from rotating, then remove the drive plate
bolt.
871RX029
2. Remove drive plate by using drive plate puller
J-33944-A (2) and forcing screw J-33944-4 (1).
871RX023
3. Remove shim (s).

1A±58
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
7. Install drive plate bolt by using drive plate holder
J-33939 (1) to prevent the drive plate from rotating.
871RX029

Tighten the drive plate bolt to the specified torque.
Torque: 13 N´m (113 lb in)

After tightening the drive plate bolt, check to be sure
the pulley rotates smoothly.
Check to be sure that the clutch clearance is
between 0.3-0.6 mm (0.01-0.02 in.)871RY00028
Legend
(1) Dial Gauge
(2) Pulley Assembly
(3) Field Coil Wire Connector

If necessary, install adjusting shim(s).

Adjusting shims are available in the following
thickness.
Thickness

0.1 mm (0.0039 in.)

0.3 mm (0.0118 in.)

0.5 mm (0.0197 in.)

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±61
Main Data and Specifications
General Specifications
COMPRESSOR
ModelDKV-14G
TypeVane rotary type
Number of vanes5
Rotor diameter64 mm (2.52 in.)
Stroke8.75 mm (0.34 in.)
Displacement140 cc (47.3 fl.oz.)
Maximum speed7,000 rpm (up to 8,400 rpm)
Direction of rotationClockwise (Front-side view)
Lubrication systemPressure differential type
LubricantR-134a Vane Rotary Type Compressor Oil
(AIPDN Part No.2-90188-301-0)
150 cc (5.0 fl.oz.)
RefrigerantRefrigerant-134a (R-134a), 700 g (1.54 lbs.)
Shaft sealLip type
Weight3.5 kg
MAGNETIC CLUTCH
TypeElectromagnetic single-plate dry clutch
Rated voltage12 Volts D.C.
Current consumption3.7 A
Starting torque49 N´m (36 lb´ft)
Direction of rotationClockwise (Front-side view)
Weight3.0 kg (6.6 lbs.)

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±115
Inspection of the Magnetic Clutch System
6VE1 Engine
D08R200037

1A±116
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
ConditionPossible causeCorrection
Magnetic clutch does not workÐRefer to Chart A
Chart A: Magnetic Clutch Does Not work
StepActionValue(s)Ye sNo
1Is the fuse No.F±7 normal?
ÐGo to Step 2
Replace the
fuse
2Is the relay No.X±2 (compressor relay) No.X±8 (A/C
thermo relay) and No.X±1 (heater relay) normal?
ÐGo to Step 3
Replace the
relay
3Is there continuity between the pressure switch side
connector terminal No.C21±1 and No.C21±2?
ÐGo to Step 5Go to Step 4
4Pressure switch defective or refrigerant pressure
improper.
Pressure switch replaced or refrigerant pressure
adjusted?
ÐGo to Step 3Ð
51. Turn the ignition switch on. (the engine is run.)
2. Turn the air conditioner switch on.
Is the battery voltage applied between the harness side
connector terminal No.E2±1 and the ground?
ÐGo to Step 7Go to Step 6
6Magnetic clutch defective or earth defective.
Magnetic clutch replaced or earth replaced?
ÐGo to Step 5Ð
7Is there continuity between the harness side connector
terminal No.X2±1 and No.E2±1?
ÐGo to Step 9Go to Step 8
8Repair an open circuit between terminal No.X2±1 and
No.E2±1.
Is the action complete?
ÐGo to Step 7Ð
9Is the battery voltage applied between the harness side
connector terminal No.X2±5 and ground, No.X2±2 and
ground?
ÐGo to Step 11Go to Step 10
10Repair an open circuit between terminal No.X2±5 and
fuse No.F±7, No.X2±2 and fuse No.F±7.
Is the action complete?
ÐGo to Step 9Ð
11Is the battery voltage applied between the harness side
connector terminal No.I20±18 and ground?
ÐGo to Step 13Go to Step 12
12Repair an open circuit between terminal No.I20±18 and
No.X2±4.
Is the action complete?
ÐGo to Step 11Ð
13Is the battery voltage applied between the harness side
connector terminal No.C21±2 and ground?
ÐGo to Step 15Go to Step 14
14Repair an open circuit between terminal No.C21±2 and
fuse No.F±7.
Is the action complete?
ÐGo to Step 13Ð
15Is the battery voltage applied between the harness side
connector terminal No.X8±5 and ground, No.X8±2 and
ground?
ÐGo to Step 17Go to Step 16
16Repair an open circuit between terminal No.X8±5 and
No.C21±1, No.X8±2 and fuse No.F±7.
Is the action complete?
ÐGo to Step 15Ð