cooling ISUZU AXIOM 2002 Service User Guide

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±29
Condenser Fan Diagnosis
While the air conditioning is ON, the cycling switch in the
triple pressure switch senses the refrigerant pressure,
and activates the condenser fan to improve the cooling
capacity of the condenser when the refrigerant pressure
exceeds a set pressure value. The condenser fan stops
when the air conditioning is turned ªOFFº or when the
pressure goes down below the set pressure value.
D08R200041
ConditionPossible causeCorrection
Condenser fan does not run.±Refer to ªChart Aº.
±Refer to ªChart Bº.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±33
Leak Check
Inspection of refrigerant leak
Refrigerant leak may cause an adverse 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 important to repair refrigerant leak
when there is any leak found.
Inspection flow of refrigerant leak
StepActionYe sNo
11. Evacuate the refrigerant system.
2. Charge the refrigerant.
Is there any refrigerant leak?
Repair refrigerant
system.
Go to Step 2
21. Operate the compressor for more than 5 minutes to raise the
pressure on the high pressure side.
Is there any refrigerant leak at high pressure components?
Repair refrigerant
system.
Compressor
operation to be
confirmed.
Inspection Steps
Check the components of air±conditioner to see if there
occurs any refrigerant leak along the flow of refrigerant.
NOTE:

To avoid refrigerant leak detection error, avoid
refrigerant vapor and cigarette smoke presence when
performing the inspection. Also, select a location that
is not susceptible to wind, in case refrigerant vapor is
found it will not be blown off.

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
performing the inspection. Remove the drain hose or
resistor of the cooling unit, and insert a leak detector
to see if there are signs of leakage.
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.
Major Checking Points of Refrigerant Leak
Compressor

Pipe connection

Sealing section of shaft

Mating section or cylinder
Condenser

Pipe connection

Welds of condenser bodyReceiver 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
NOTE:

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 detector when 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
NOTE:

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.

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

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

1A±70
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Functions and Features
Automatic air conditioning control unit
The control unit features a prominent control and display
panel that clearly shows air conditioner operational
settings (delivered air volume, air outlet location,
inside/outside air circulation, and set temperature).
Desired temperature can be set in ±17
C (1
F)
increments. The current setting appears on the digital
display.
Automatic temperature control
Vehicle interior temperature is maintained at the set level.
It is unaffected by changes in vehicle speed, outside air
temperature, and number of passengers.
Maximum cooling and heating
Moving the switch to the 18
C (65
F) position provides
maximum cooling. Moving the switch to the 32
C (90
F)
position provides maximum heating.
Automatic air flow control
Air flow is automatically and precisely regulated in
response to set temperature change and/or changes in
heater unit mixing door aperture.
Automatic air outlet selection
Appropriate air outlets (VENT, BE-LEVEL, FOOT, or
DEF) are selected in response to changes in outlet
temperatures. The mode switch permits manual selection
of the desired air outlet.
Air source (Fresh air intake from outside the
vehicle or recirculation of the air inside the vehicle)
selection
Automatic switching between outside air (FRESH),
recirculated inside air (RECIRC), or a combination of the
two (MIX) occurs in response to changes in outlet
temperatures.The intake switch permits manual
selection of the air source (FRESH or RECIRC). Mixing
of the two sources is not possible during manual
operation. When the defrost mode switch (DEF) is
pressed, the system automatically switches to outside air
intake.
Cooler start-up control
When the vehicle is parked in a hot area for an extended
period of time, the evaporator becomes hot. When the
cooler is turned on, hot air is blown into the vehicle until
the evaporator cools down. The cooler start-up control
prevents blower operation until the evaporator is able to
provide cool air.
Heater start-up control
When the vehicle is parked in a cold area for an extended
period of time, the heater core becomes cold. When the
heater is turned on, cold air is blown into the vehicle until
the heater core heats up. The heater start-up control
prevents blower operation to the air outlets until the
heater core is able to provide warm air. Air is delivered
through the defrost outlets.
Solar radiation offset
The sun sensor uses a photodiode to precisely determine
the amount of solar radiation affecting the vehicle. The
cooler operates in response to this radiation to quickly
correct the vehicle interior temperature.Switch position memory
Current switch positions are stored in memory when the
ignition switch is turned off. When the ignition switch is
turned on again, the switches automatically return to the
position they were in when the ignition switch was turned
off. This simplifies the restarting procedure.
Self-diagnosis function
The self-diagnosis switches on the control panel permit
easy system troubleshooting. Refer to ªSelf-Diagnosisº
later in this Section.

1A±76
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
I
Pressing the intake switch permits manual control of air intake and/
or recirculation.
I
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t
a
k
e

S
w
i
t
c
h
If the intake switch is pressed during manual DEF or D/F, the intake
switch LED briefly turns on. However, outside air intake (FRESH)
continues.
T
e
m
p
e
r
a
t
u
r
e

C
o
n
t
r
o
l
S
w
i
t
c
hThe display panel temperature setting can be set from 18
C (65
F)
to 32
C (90
F).
Pressing and immediately releasing the  switch increases the
temperature setting in -17
C (1
F) increments. If the switch is
pressed and held, the temperature setting increases rapidly.
Pressing and immediately releasing the
switch decreases the
temperature setting in -17
C (1
F) decrements. If the switch is
pressed and held, the temperature setting decreases rapidly.
When the temperature setting is at 32
C (90
F), the unit is set to
maximum heat mode.
When the temperature setting is at 18
C (65
F), the unit is set to
maximum cooling mode.

6A±1
ENGINE MECHANICAL (6VE1 3.5L)
AXIOM
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System 6D3. . . . . . . . . . . . Driveability and Emissions 6E. . . . . . . . . . . . . . . .
Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System 6H. . . . . . . . . . . .
Induction 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL (6VE1 3.5L)
CONTENTS
Service Precaution 6A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 6A±3. . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis 6A±4. . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH 6A±19. . . . . . . . . . . . . . . . .
Removal 6A±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH 6A±21. . . . . . . . . . . . . . . . .
Removal 6A±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber 6A±22. . . . . . . . . . . . . . . . . . . . . .
Removal 6A±22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH 6A±24. . . . . . . . . . . . . . . . . . . . .
Removal 6A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH 6A±25. . . . . . . . . . . . . . . . . . . .
Removal 6A±25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley 6A±26. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A±32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A±35. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring
and Valve Guide 6A±37. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod 6A±38. . . Removal 6A±38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A±40. . . . . . . . . . . .
Removal 6A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal 6A±45. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A±46. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A±49. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts 6A±49. . . . .
Disassembly 6A±50. . . . . . . . . . . . . . . . . . . . . . . . . .
Clean 6A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±50. . . . . . . . . . . . . . . . . .
Reassembly 6A±51. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide 6A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide and Associated Parts 6A±53. . . . . . . . . . . .
Disassembly 6A±53. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±54. . . . . . . . . . . . . . . . . .
Reassembly 6A±57. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A±60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts 6A±60. . . . . . . . .
Disassembly 6A±60. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±61. . . . . . . . . . . . . . . . . .
Reassembly 6A±63. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 6A±67. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts 6A±67. . . . . . . .
Disassembly 6A±67. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair for Bearings 6A±68. . . . . .
Inspection and Repair for Crankshaft 6A±70. . . . .
Reassembly 6A±71. . . . . . . . . . . . . . . . . . . . . . . . . .

6A±11
ENGINE MECHANICAL (6VE1 3.5L)
Condition CorrectionPossible cause
Engine overheatingLevel of Engine Coolant too lowReplenish
Fan clutch defectiveReplace
Incorrect fan installedReplace
Thermostat defectiveReplace
Engine Coolant pump defectiveCorrect or replace
Radiator cloggedClean or replace
Radiator filler cap defectiveReplace
Level of oil in engine crankcase too
low or wrong engine oilChange or replenish
Resistance in exhaust system
increasedClean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrectReplace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shortedCorrect or replace
Cylinder head gasket damagedReplace
Engine overcoolingThermostat defectiveReplace (Use a thermostat set to
open at 82
C (180
F))
Engine lacks compressionÐÐÐÐRefer to Hard Start
OthersTire inflation pressure abnormalAdjust to recommended pressures
Brake dragAdjust
Clutch slippingAdjust or replace
Level of oil in engine crankcase too
highCorrect level of engine oil
Exhaust Gas Recirculation Valve
defectiveReplace

6A±26
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Driver Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 N´m (123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 N´m (16 lb ft) for fan pulley and fan
bracket.
Torque : 7.5 N´m (66.4 lb in) for fan and clutch
assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A±27
ENGINE MECHANICAL (6VE1 3.5L)
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley remove
center bolt, then the pulley.11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014R100020
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm (1.1811 in).
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.