ISUZU AXIOM 2002 Service Manual PDF

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±45
Evaporator Assembly
Evaporator Assembly and Associated Parts
874R200015
Legend
(1) Refrigerant Line
(2) Drain Hose
(3) Dash Side Trim Panel
(4) Power Transistor and Duct Sensor Connector(5) Passenger Lower Bracket
(6) Sill Plate
(7) Evaporator Assembly
(8) Glove Box
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.

Refer to
Refrigerant Recovery in this section.
3. Remove glove box.
4. Disconnect power transistor (2) and duct sensor
connector (1).
5. Remove sill plate.
6. Remove dash side trim panel.
7. Remove passenger lower bracket.
8. Disconnect drain hose.
874R200005

1A±46
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
9. Disconnect drain hose.
10. Disconnect refrigerant line.

Use a back-up wrench when disconnecting and
reconnecting the refrigerant lines.

When removing the refrigerant line connected part,
the connecting part should immediately be plugged
or capped to prevent foreign matter from being
mixed into the line.
11. Remove evaporator assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. To install a new evaporator assembly, add 50cc
(1.7 fl. oz.) of new compressor oil to the new core.
2. Tighten the refrigerant outlet line to the specified
torque.
Torque: 25 Nwm (18 lb ft)
3. Tighten the refrigerant inlet line to the specified
torque.
Torque: 15 Nwm (11 lb ft)
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting lines.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±47
Duct Sensor, Evaporator Core and/or Expansion Valve
Disassembled View
874R200012
Legend
(1) Lining
(2) Expansion Valve
(3) O-ring
(4) Evaporator Assembly
(5) Lower Case(6) Clip
(7) Attaching Screw
(8) Evaporator Core
(9) Duct Sensor
(10) Upper Case
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 duct 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.
874RS006

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

Lift to remove the upper case.
874R200007
9. Remove evaporator core.
874R200008
10. Remove expansion valve.

Tear off the insulator carefully.

Remove the sensor fixing clip.

Use a back-up wrench when disconnecting all
refrigerant pipes.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. The sensor is installed on the core with the clip.
2. The sensor must not interfere with the evaporator
core.
3. When installing the new evaporator core, install the
duct sensor (2) to the evaporator core (1) specified
position with the clip in the illustration.
874RY00016
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting lines.
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. Tighten the refrigerant lines to the specified torque.
Refer to
Main Data and Specifications for Torque
Specifications in this section.
9. Apply an adhesive to the parting face of the lining
when assembling the evaporator assembly.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±49
Refrigerant Line
Refrigerant Line and Associated Parts
852R200007
Legend
(1) Clip and Clamp
(2) Liquid Line (High-Pressure Pipe)
(3) Discharge Line (High-Pressure Hose)
(4) Condenser Air Guide(5) Front Bumper Assembly
(6) Front Side Turn Signal Light (LH)
(7) Head Light (LH)
(8) Suction Line (Low-Pressure Pipe)
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.

Refer to
Refrigerant Recovery in this section.
3. Remove the front bumper assembly.

Refer to the
Front Bumper in Body Structure
section.
4. Remove the condenser air guide.5. Remove the front side turn signal light (LH).
6. Remove the head light (LH).
7. Remove clip and clamp.
8. Disconnect liquid line (High-pressure pipe).
9. Disconnect suction line (Low-pressure pipe) using a
back-up wrench.
10. Disconnect suction line (Low-pressure hose) using a
back-up wrench.

1A±50
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
11. 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 connecting part should immediately be plugged
or capped to prevent foreign matter from being
mixed into the line.
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. O-rings cannot be reused. Always replace with new
ones.
2. Be sure to apply new compressor oil to the O-rings
when connecting lines.
3. Tighten the refrigerant line to the specified torque.
Refer to
Main Data and Specifications for Torque
Specifications in this section.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±51
Main Data And Specifications
General Specifications
Heater Unit
Temperature controlReheat air mix system
Capacity4.3 kw (3700 Kcal./hr.)
Air flow280 m
/h
HEATER CORE
TypePlate and corrugate fin
Element dimension167 mm (6.6 in.) y 151 mm (5.9 in.) y 35 mm (1.4 in.)
Radiating areaApprox. 2.4 m
EVAPORATOR ASSEMBLY
Capacity4.8 kw (4100 Kcal./hr.)
Air flow430 m
/hr
EVAPORATOR CORE
TypeAl-laminate louver fin type
Element dimension235 mm (9.3 in.) y 224 mm (8.8 in.) y 60 mm (2.4 in.)
EXPANSION VALVE
TypeInternal pressure equalizer type
CONDENSER
TypeParallel flow type
Radiation performance14.8 kw (12,700 Kcal./hr.)
CONDENSER FAN
Air flow850 m3/h
Fan size
261
RECEIVER/DRIER
TypeAssembly includes triple pressure switch
Internal volume300 cc (10 fl.oz.)
PRESSURE SWITCH
TypeTriple pressure switch
Low pressure control
ON: 206.0+30.0 kPa (29.8+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
TypeHFC-134a
Specified amount700 g (1.54 lbs.)

1A±52
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Torque Specifications
852R200009
874R200013

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