2002 ISUZU AXIOM air conditioning

SECTION TABLE OF CONTENTS
GENERAL INFORMATION
0AGeneral Information
0BMaintenance and Lubrication
WORKSHOP MANUAL
HEATING, VENTILATION AND AIR
CONDITIONING
1AHVAC System
STEERING
2APower-Assisted System
AXIOM
(UPR/S)SUSPENSION
3CFront Suspension
3DRear Suspension
3EWheel and Tire System
3FIntelligent Suspension System
DRIVELINE/AXLE
4A1Differential (Front)
4A2Differential (Rear)
4B1Driveline Control System
4B2Driveline Control System (TOD)
4CDrive Shaft System
4D2Transfer Case (TOD)
FOREWORD
This manual includes special notes, impor tant points, service data,
precautions, etc. That are needed for the maintenance, adjustments,
service, removal and installation 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 material 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 edge of the book below each section title.
These point to a more detailed table of contents preceding each
section.BRAKE
5ABrake Control System
5BAnti-Lock Brake System
5CPower-Assisted Brake System
5D1Parking Brake System (4´4 model)
5D2Parking Brake System (4´2 model)
ENGINE
6AEngine Mechanical
6BEngine Cooling
6CEngine Fuel
6D1Engine Electrical
6D2Ignition System
6D3Starting and Charging System
6EDriveability and Emissions
6FEngine Exhaust
6GEngine Lubrication
6HEngine Speed Control System
6JInduction
TRANSMISSION
7AAutomatic Transmission
7A1Transmission Control System
BODY AND ACCESSORIES
8ALighting System
8BWiper/Washer System
This manual applies to 2002 models.8CEnter tainment
8DWiring System
8EMeter and Gauge
8FBody Structure
8GSeats
8HSecurity and Locks
8ISun Roof/Convertible Top
8JExterior/Interior Trim
RESTRAINTS
9ASeat Belt System
9JSupplemental Restraint System (Air Bag System)
9J1Restraint Control System
CONTROL SYSTEM
10ACruise Control System

0A±1
GENERAL INFORMATION
AXIOM
GENERAL INFORMATION
CONTENTS
General Information 0A. . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication 0B. . . . . . . . . . . . .
General Information
CONTENTS
General Repair Instruction 0A±1. . . . . . . . . . . . . . . .
Illustration Arrows 0A±2. . . . . . . . . . . . . . . . . . . . . . .
Identification 0A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard 0A±5. . . . . . . . . . . . . . . . Lifting Instructions 0A±9. . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications 0A±11. . . . . .
Abbreviations Charts 0A±12. . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate 0A±13. . . . . . . . . .
General Repair Instruction
1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, ªblockº front or rear
wheels, set jack against the recommended lifting
points (see ªLifting Instructionsº in this section), raise
vehicle and support with chassis stands and then
perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance of
cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and anti±freeze solution must be handled
with reasonable care, as they can cause paint
damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, O±rings, oil
seals, lock washers and self±locking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
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 ªSRS
Systemº 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. ªAIR BAGº warning light on the instrument
cluster.
2. A Code ªKº or ªMº for fifth digit of Vehicle
Identification Number.

0A±12
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A Ð Ampere(s)
ABS Ð Antilock Brake System
AC Ð Alternating Current
A/C Ð Air Conditioning
ACCEL Ð Accelerator
ACC Ð Accessory
ACL Ð Air Cleaner
Adj Ð Adjust
A/F Ð Air Fuel Ratio
AIR Ð Secondary Air Injection System
Alt Ð Altitude
AMP Ð Ampere(s)
ANT Ð Antenna
ASM Ð Assembly
A/T Ð Automatic Transmission/Transaxle
ATDC Ð After Top Dead Center
ATF Ð Automatic Transmission Fluid
Auth Ð Authority
Auto Ð Automatic
BARO Ð Barometric Pressure
Bat Ð Battery
B+ Ð Battery Positive Voltage
Bbl Ð Barrel
BHP Ð Brake Horsepower
BPT Ð Backpressure Transducer
BTDC Ð Before Top Dead Center

C Ð Degrees Celsius
CAC Ð Charge Air Cooler
Calif Ð California
cc Ð Cubic Centimeter
CID Ð Cubic Inch Displacement
CKP Ð Crankshaft Position
CL Ð Closed Loop
CLCC Ð Closed Loop Carburetor Control
CMP Ð Camshaft Position
CO Ð Carbon Monoxide
Coax Ð Coaxial
Conn Ð Connector
Conv Ð Converter
Crank Ð Crankshaft
Cu. In. Ð Cubic Inch
CV Ð Constant Velocity
Cyl Ð Cylinder(s)
DI Ð Distributor Ignition
Diff Ð Differential
Dist Ð Distributor
DLC Ð Data Link Connector
DOHC Ð Double Overhead Camshaft
DTC Ð Diagnostic Trouble Code
DTM Ð Diagnostic Test Mode
DTT Ð Diagnostic Test Terminal
DVM Ð Digital Voltmeter (10 meg.)
DVOM Ð Digital Volt Ohmmeter
EBCM Ð Electronic Brake Control Module
ECM Ð Engine Control Module
ECT Ð Engine Coolant Temperature
EEPROM Ð Electronically Erasable Programmable
Read Only Memory
EGR Ð Exhaust Gas Recirculation
EI Ð Electronic Ignition
ETR Ð Electronically Tuned Receiver
EVAP Ð Evaporation EmissionExh Ð Exhaust

F Ð Degrees Fahrenheit
Fed Ð Federal (All States Except Calif.)
FF Ð Front Drive Front Engine
FL Ð Fusible Link
FLW Ð Fusible Link Wire
FP Ð Fuel Pump
FRT Ð Front
ft Ð Foot
FWD Ð Front Wheel Drive
4WD Ð Four Wheel Drive
4 x 4 Ð Four Wheel Drive
4 A/T Ð Four Speed Automatic Transmission/Transaxle
Gal Ð Gallon
GEN Ð Generator
GND Ð Ground
Gov Ð Governor
g Ð Gram
Harn Ð Harness
HC Ð Hydrocarbons
HD Ð Heavy Duty
Hg Ð Hydrargyrum (Mercury)
HiAlt Ð High Altitude
HO2S Ð Heated Oxygen Sensor
HVAC Ð Heater±Vent±Air±Conditioning
IAC Ð Idle Air Control
IAT Ð Intake Air Temperature
IC Ð Integrated Circuit / Ignition Control
ID Ð Identification / Inside Diameter
IGN Ð Ignition
INJ Ð Injection
IP Ð Instrument Panel
IPC Ð Instrument Panel Cluster
Int Ð Intake
ISC Ð Idle Speed Control
J/B Ð Junction Block
kg Ð Kilograms
km Ð Kilometers
km/h Ð Kilometer per Hour
kPa Ð Kilopascals
kV Ð Kilovolts (thousands of volts)
kW Ð Kilowatts
KS Ð Knock Sensor
L Ð Liter
lb ft Ð Foot Pounds
lb in Ð Inch Pounds
LF Ð Left Front
LH Ð Left Hand
LR ÐLeft Rear
LS Ð Left Side
LWB Ð Long Wheel Base
L±4 Ð In±Line Four Cylinder Engine
MAF Ð Mass Air Flow
MAN Ð Manual
MAP Ð Manifold Absolute Pressure
Max Ð Maximum
MC Ð Mixture Control
MFI Ð Multiport Fuel Injection
MIL Ð Malfunction Indicator Lamp
Min Ð Minimum
mm Ð Millimeter
MPG Ð Miles Per Gallon
MPH Ð Miles Per Hour
M/T Ð Manual Transmission/Transaxle
MV Ð Millivolt

0B±5 MAINTENANCE AND LUBRICATION
Explanation of Complete Vehicle
Maintenance Schedule
Brief explanations of the services listed in the preceding
Maintenance Schedule are presented below.
Replace all questionable parts and note any necessary
repairs as you perform these maintenance procedures.
Front and Rear Axle Lubricant
Replacement
Check the lubricant level after every 7,500 miles (12,000
km) of operation and add lubricant to level of filler hole if
necessary.
Replace the front and rear axle lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000 miles (48,000 km) of operation thereafter.
Air Cleaner Element Replacement
Replace the air cleaner under normal operating
conditions every 30,000 miles (48,000 km).
Operation of the vehicle in dusty areas will necessitate
more frequent replacement.
Spark Plug Replacement
Replace the plugs at 100,000 miles (160,000 km)
intervals with the type specified at the end of this section.
Cooling System Service
Drain, flush and refill system with new engine coolant.
Refer to
ªRecommended Fluids and Lubricantsº in this
section, or ENGINE COOLING (SEC.6B).
Timing Belt Replacement
Replacement of the timing belt is recommended at every
100,000 miles (160,000 km).
Failure to replace the timing belt may result in serious
damage to the engine.
Valve Clearance Adjustment
Incorrect valve clearance will result in increased engine
noise and reduced engine output.
Retorque the camshaft bracket bolts before checking and
adjusting the valve clearance.
Check and adjust the valve clearance whenever
increased engine noise is heard.
Tire Rotation
Rotate tires every 7,500 miles (12,000 km).
Front Wheel Bearings Lubricant
Replacement (Vehicles Produced Before
July/31/2001)
Clean and repack the front wheel bearings at 30,000
miles (48,000 km) intervals.
Refer to DRIVE SHAFT SYSTEM (SEC. 4C).
Front Wheel Bearings Check (Vehicles
Produced After Aug./1/2001)
Inspect hub unit bearing at every 60,000 miles (96,000
km).
If there is abnormal condition, replace hub unit bearing.
Radiator Core and Air Conditioning
Condenser Cleaning
Clean the front of the radiator core and air conditioning
condenser, at 60,000 miles (96,000 km) intervals.
Fluid Level Check
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine oil level
Check level and add if necessary. The best time to check
the engine oil level is when the oil is warm. After stopping
the engine with the vehicle on a level surface, wait a few
minutes for the oil to drain back to the oil pan. Pull out the
oil level indicator (dipstick). Wipe it clean and push the oil
level indicator back down all the way. Pull out the oil level
indicator, keeping the tip down, and look at the oil level on
it.
Add oil, if needed, to keep the oil level above the ªADDº
mark and between the ªADDº and ªFULLº marks in the
operating range area. Avoid overfilling the engine since
this may cause engine damage. Push the oil level
indicator back down all the way after taking the reading.
If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level.
Engine coolant level and condition
Check engine coolant level in the coolant reservoir and
add engine coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Windshield washer fluid level
Check washer fluid level in the reservoir and add if
necessary.
Power steering system reservoir level
Check and keep at the proper level.
Brake master cylinder reservoir level
Check fluid. Keep fluid at proper level. A low fluid level can
indicate worn disc brake pads which may need to be
serviced.
Hydraulic clutch system
Check fluid level in the reservoir. Add fluid as required.
Battery fluid level
Check fluid level in the battery.
Fluid Leak Check
Check for fuel, water, oil or other fluid leaks by looking at
the surface beneath the vehicle after it has been parked
for a while. Water dripping from the air conditioning
system after use is normal. If you notice gasoline fumes or
fluid at any time, locate the source and correct it at once.
Engine Oil and Oil Filter Replacement
Always use API SE, SF, SG, SH or ILSAC GF±1 quality
oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the next oil
change. Then, select the recommended oil viscosity from
the chart.

0B±6MAINTENANCE AND LUBRICATION
Always change the oil and the oil filter as soon as possible
after driving in a dust storm.
Engine Cooling System Inspection
Inspect the coolant/anti±freeze. If the coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep coolant
at the proper mixture for proper freeze protection,
corrosion inhibitor level and best engine operating
temperature. Inspect hoses and replace if cracked,
swollen or deteriorated. Tighten the hose clamps if
equipped with screw±type clamps. Clean outside of
radiator and air conditioning condenser. Wash filler cap
and neck. To help ensure proper operation, a pressure
test of both the cooling system and the cap is also
recommended.
Exhaust System Inspection
Visually inspect the exhaust pipes, muffler, heat shields
and hangers for cracks, deterioration, or damage.
Be alert to any changes in the sound of the exhaust
system or any smell of fumes. These are signs the system
may be leaking or overheating. Repair the system at
once, if these conditions exist. (See also ªEngine Exhaust
Gas Safetyº and ªThree Way Catalytic Converterº in the
Owner's manual.)
Fuel Cap, Fuel Lines, and Fuel Tank
Inspection
Inspect the fuel tank, the fuel cap and the fuel lines every
60,000 miles (96,000 km) for damage which could cause
leakage.
Inspect the fuel cap and the gasket for correct sealing and
physical damage. Replace any damaged parts.
Drive Belt Inspection
Check the serpentine belt driving for cracks, fraying,
wear, and correct tension every 30,000 miles (48,000
km). Replace as necessary.
Wheel Alignment, Balance and Tires
Operation
Uneven or abnormal tire wear, or a pull right or left on a
straight and level road may show the need for a wheel
alignment. A vibration of the steering wheel or seat at
normal highway speeds means a wheel balancing is
needed. Check tire pressure when the tires are ªcoldº
(include the spare).
Maintain pressure as shown in the tire placard, which is
located on the driver's door lock pillar.
Steering System Operation
Be alert for any changes in steering operation. An
inspection or service is needed when the steering wheel
is harder to turn or has too much free play, or if there are
unusual sounds when turning or parking.
Brake Systems Operation
Watch for the ªBRAKEº light coming on. Other signs of
possible brake trouble are such things as repeated pulling
to one side when braking, unusual sounds when braking
or between brake applications, or increased brake pedaltravel. If you note one of these conditions, repair the
system at once.
For convenience, the following should be done when
wheels are removed for rotation: Inspect lines and hoses
for proper hookup, bindings, leaks, crack, chafing etc.
Inspect disc brake pads for wear and rotors for surface
condition.
Inspect other brake parts, including parking brake drums,
linings etc., at the same time. Check parking brake
adjustment.
Inspect the brakes more often if habit or conditions
result in frequent braking.
Parking Brake and Transmission Park
Mechanism Operation
Park on a fairly steep hill and hold the vehicle with the
parking brake only. This checks holding ability. On
automatic transmission vehicles, shifting from ªPº
position to the other positions cannot be made unless the
brake pedal is depressed when the key switch is in the
ªONº position or the engine is running.
WARNING: B E F O R E C H E C K I N G T H E S TA R T E R
SAFETY SWITCH OPERATION BELOW, BE SURE TO
HAVE ENOUGH ROOM AROUND THE VEHICLE.
THEN FIRMLY APPLY BOTH THE PARKING BRAKE
AND THE REGULAR BRAKE. DO NOT USE THE
ACCELERATOR PEDAL. IF THE ENGINE STARTS,
BE READY TO TURN OFF THE KEY PROMPTLY.
TAKE THESE PRECAUTIONS BECAUSE THE
VEHICLE COULD MOVE WITHOUT WARNING AND
POSSIBLY CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
Starter Safety Switch Operation
Check by trying to start the engine in each gear while
setting the parking brake and the foot brake. The starter
should crank only in ªPº (Park) or ªNº (Neutral).
Accelerator Linkage Lubrication
Lubricate the accelerator pedal fulcrum pin with chassis
grease.
Steering and Suspension Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts or signs of
wear. Inspect power steering lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc.
Body and Chassis Lubrication
Lubricate the key lock cylinders, the hood latch, the hood
and door hinges, the door check link, the parking cable
guides, the underbody contact points, and the linkage.
Propeller Shaft Inspection and Lubrication
Check the propeller shaft flange±to±pinion bolts for
proper torque to 63 Nwm (46 lb ft) for front and rear
propeller shaft.

0B±12MAINTENANCE AND LUBRICATION
Maintenance Service Data
Service Data and Specifications
ENGINEValve clearance (cold)Intake 0.28+0.05 mm (0.011+0.002 in)
Exhaust 0.3+0.05 mm (0.012+0.002 in)
Spark plug typeK16PR-P11/PK16PR11/RC10PYP4
Spark plug gap1.05 mm (0.04 in)
BRAKEBrake pedal free play6±10 mm (0.24±0.39 in)
Parking brake travel6±7 notches
WHEEL ALIGNMENTToe-in (Front)0 to +2 mm (0 to +0.08 in)
Toe-in (Rear)0+5 mm (0+0.2 in)
Camber (Front)0
+30'
Camber (Rear)0
+1

Caster (Front)2
30'+45'
Toe±Axis (Rear)+1

PROPELLER SHAFTFlange torque63 N´m (46 lb ft)
WHEEL AND TIRESSizeP235/65R17
Wheel nut torque118 N´m (87 lb ft)
Tire inflation pressure (Front)180 kPa (26 psi)
* Tire inflation pressure (Rear)180 kPa (26 psi)
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
ItemsMetric MeasureU.S. Measure
Fuel tank74 L19.5 Gal.
* CrankcaseOil Change with Filter4.7 L5.0 Qt
Oil Change without Filter4.0 L4.2 Qt
CoolantA/T11.1 L11.7 Qt
TransmissionAutomatic8.6 L9.1 Qt
Transfer1.35 L1.4 Qt
AxleRear1.77 L1.87 Qt
Front1.25 L1.33 Qt
Shift on the fly system0.12 L0.13 Qt
Power steering1.0 L1.1 Qt
Air conditioning (R-134a)0.6 L1.32 Qt
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±1
AXIOM
HEATING, VENTILATION AND AIR
CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution 1A±3. . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System 1A±3. . . . . . . . . . .
General Description 1A±3. . . . . . . . . . . . . . . . . . . . .
Heater Unit 1A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts 1A±6. . . . . . . .
Removal 1A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door 1A±7. . . . . . . . . .
Disassembled View 1A±7. . . . . . . . . . . . . . . . . . . .
Removal 1A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit 1A±9. . . . . . . . . . . .
Disassembled View 1A±9. . . . . . . . . . . . . . . . . . . .
Removal 1A±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit 1A±11. . . . . .
Disassembled View 1A±11. . . . . . . . . . . . . . . . . . . .
Removal 1A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly 1A±12. . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts 1A±12. .
Removal 1A±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door 1A±13. . . . . . .
Disassembled View 1A±13. . . . . . . . . . . . . . . . . . . .
Removal 1A±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor 1A±15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts 1A±15. . . . . .
Removal 1A±15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle and
Ventilation Duct 1A±16. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts 1A±16. . .
Removal 1A±16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System 1A±18. . . . . . . . . . . . . . . . . .
General Description 1A±18. . . . . . . . . . . . . . . . . . . . .
Diagnosis 1A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System 1A±31. . . . . . . . . . . . . . . . . . Individual Inspection 1A±31. . . . . . . . . . . . . . . . . . . . .
General Repair Procedure 1A±31. . . . . . . . . . . . . .
Leak Check 1A±33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Assembly 1A±38. . . . . . . . . . . . . . . . . . .
Compressor Assembly and Associated
Parts (6VE1) 1A±38. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation 1A±39. . . . . . . . . . . .
Condenser Assembly 1A±40. . . . . . . . . . . . . . . . . . . .
Condenser Assembly and Associated
Parts 1A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor 1A±42. . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor and Associated
Parts 1A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier 1A±43. . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts 1A±43. . . .
Removal 1A±43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch 1A±44. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts 1A±44. . .
Removal 1A±44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly 1A±45. . . . . . . . . . . . . . . . . . . .
Evaporator Assembly and Associated
Parts 1A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor, Evaporator Core and/or
Expansion Valve 1A±47. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 1A±47. . . . . . . . . . . . . . . . . . . .
Removal 1A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line 1A±49. . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts 1A±49. . . .
Removal 1A±49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications 1A±51. . . . . . . . . . . . .

1A±2
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor 1A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution 1A±53. . . . . . . . . . . . . . . . . . . .
General Description 1A±53. . . . . . . . . . . . . . . . . . . . . .
Diagnosis 1A±54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Clutch Assembly (DKV-14G Type) 1A±55
Parts Location View 1A±55. . . . . . . . . . . . . . . . . . . .
Removal 1A±55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 1A±57. . . . . . . . . . . . . . . . . .
Installation 1A±57. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil 1A±59. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specification 1A±59. . . . . . . . . . . . . . . . . . . . . . .
Handling of Oil 1A±59. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check 1A±59. . . . . . . . . . . . . . . . .
Checking and Adjusting Oil Quantity for
Used Compressor 1A±59. . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting for Compressor
Replacement 1A±60. . . . . . . . . . . . . . . . . . . . . . . . .
Contamination of Compressor Oil 1A±60. . . . . . . .
Oil Return Operation 1A±60. . . . . . . . . . . . . . . . . . .
Replacement of Component Parts 1A±60. . . . . . .
Main Data and Specifications 1A±61. . . . . . . . . . . . .
Special Tools 1A±63. . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System 1A±64. . . . . . . .
General Description 1A±64. . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioner Parts
Configuration 1A±64. . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram 1A±65. . . . . . . . . . . . . . . . . . . . . . .
Functions and Features 1A±70. . . . . . . . . . . . . . . .
Automatic Air Conditioner Block Diagram 1A±71.
Control Panel Layout 1A±72. . . . . . . . . . . . . . . . . . .
Air Control Functions 1A±73. . . . . . . . . . . . . . . . . . .
Control Panel Switch Operation 1A±74. . . . . . . . .
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System 1A±77. . . . . . . . . . . . . . . . . . .
Overview of Automatic Control of Automatic
Air Conditioner 1A±81. . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System 1A±82. . . . . .
Troubleshooting 1A±86. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting, Its Overview and
Procedures 1A±86. . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Air Conditioner Control Unit Power
Supply Diagnosis 1A±87. . . . . . . . . . . . . . . . . . . . . Performance and Movement checklist for
Automatic Air Conditioner Related Parts 1A±89.
Troubleshooting With Self-Diagnosis
Function 1A±91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection By Failed Location 1A±97. . . . . . . . . . . . .
Inspection of the Sensors 1A±97. . . . . . . . . . . . . . .
Inspection of the Intake Actuator System 1A±101.
Inspection of the Mix Actuator System 1A±104. . . .
Inspection of the Mode Actuator System 1A±107. .
Inspection of the Fan Motor System 1A±110. . . . . .
Inspection of the Magnetic Clutch System 1A±115
Individual Inspection 1A±118. . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1A±121. . . . . . . . . . . . . . . . . . . . . .
Power Transistor 1A±121. . . . . . . . . . . . . . . . . . . . . .
Removal 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Heater/Air Conditioner Control
Unit 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In Car Sensor 1A±122. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor 1A±122. . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sun Sensor 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Actuator 1A±124. . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix Actuator 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Actuator 1A±125. . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±125. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±125. . . . . . . . . . . . . . . . . . . . . . . . . . . .