air conditioning ISUZU AXIOM 2002 Service Service Manual

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±35
Refrigerant Recycling
Recycle the refrigerant recovered by J-39500
(ACR4:HFC-134a Refrigerant Recovery / Recycling /
Recharging / System) or equivalent.
For the details of the actual operation, follow the steps in
the ACR
4(or equivalent) Manufacturer's Instructions.
Evacuation of The Refrigerant System
901R100023
Legend
(1) Low Side
(2) High Side
NOTE: Explained below is a method using a vacuum
pump. Refer to the ACR4(or equivalent) manufacturer's
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture thor-
oughly from the system.
1. Connect the gauge manifold.

High-pressure valve (HI) Ð Discharge-side.

Low-pressure valve (LOW) Ð Suction-side.
2. Discharge and recover the refrigerant.
3. Connect the center hose of the gauge manifold set to
the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves.
5. When the low-pressure gauge indicates
approximately 750 mmHg (30 inHg), continue the
evacuation for 5 minutes or more.
6. Close both hand valves and stop the vacuum pump.
7. Check to ensure that the pressure does not change
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 confirming that the
gauge manifold pressure is at 750 mmHg (30 inHg),
close both hand valves.
9. Close positive shutoff valve. Stop the vacuum pump
and disconnect the center hose from the vacuum
pump.
Charging The Refrigerant System
There are various methods of charging refrigerant into the
air conditioning system.
These include using J-39500 (ACR
4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure

ACR
4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer's instruction.
901R100022
Legend
(1) Low Side
(2) High Side

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.

1A±36
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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.
901R100021
Legend
(1) Low Side
(2) High Side
(3) Refrigerant Container
(4) Weight Scale
5. Place the refrigerant container(3) up right on a weight
scale(4).
Note the total weight before charging the refrigerant.
a. Open the refrigerant container valve.
b. Open the low side vale on the manifold gauge set.
Refer to the manufacturer's instructions for a
weight scale charging station.
901RS144
6. Perform a system leak test:

Charge the system with approximately 200 g
(0.44 lbs) 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. If no leaks are found, continue charging refrigerant to
the air conditioning system.

Charge the refrigerant until the scale reading
decreases by the amount of the charge specified.
Specified amount: 700 g (1.54 lbs)

If charging the system becomes difficult:
1. Run the engine at idle and close all the vehicle
doors.
2. Turn A/C switch ªONº.
3. Set the fan switch to its highest position.
4. Set the air source selector lever to ªCIRCº.
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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±37
8. When finished with the refrigerant charging, close the
low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System
1. Run the engine and close all the vehicle doors.
2. Turn A/C switch ªONº, set the fan switch to its highest
position.
3. Set the air source switch to ªCIRCº, set the
temperature switch to the full cool position.
4. Check the high and low pressure of the manifold
gauge.

Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:

The ambient temperature should be between
25±30
C (77±86
F).

The pressure guideline for the high-pressure side is
approximately 1372.9±1863.3 kPa (199.1±270.2
psi).

The pressure guideline for the low-pressure side is
approximately 147.1±294.2 kPa (21.3±42.7 psi).

If an abnormal pressure is found, refer to
Checking
The Refrigerant System With Manifold Gauge in
this section.
5. Put your hand in front of the air outlet and move the
temperature switch of the control panel to different
positions. Check if the outlet temperature changes as
selected by the control switch.

1A±38
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor Assembly
Compressor Assembly and Associated Parts (6VE1)
852R100002
Legend
(1) Compressor Bracket
(2) Magnetic Clutch Harness Connector
(3) Compressor
(4) O-ring(5) To Evaporator
(6) Suction Line (Low-Pressure Hose)
(7) Discharge Line (High-Pressure Hose)
(8) To Condenser
(9) Serpentine Belt
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.

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±40
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser Assembly
Condenser Assembly and Associated Parts
875R200022
Legend
(1) Refrigerant Line
(2) Pressure Switch Connector
(3) Condenser & Receiver Tank Assembly
(4) Condenser Air Guide
(5) Front Bumper Assembly(6) Engine Hood Front End W/Engine Hood Lock
& Bumper Stay
(7) Front Center Bumper Retainer
(8) Front Side Bumper Retainer (RH)
(9) Head Light (R/LH)
(10) Front Side Turn Signal Light (R/LH)
(11) Horn (R/LH)
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.

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

Refer to the
Front Bumper in Body Structure
section.
4. Remove front center bumper retainer.
5. Remove front side bumper retainer (RH).
6. Remove condenser air guide.
7. Remove engine hood front end with engine hood lock
& bumper stay.

Apply setting mark to the engine hood lock fixing
position before removing it.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±41
8. Remove horn (R/LH).
9. Remove front side turn signal light (R/LH).
10. Remove head light (R/LH).
11. Disconnect pressure switch, ambient sensor and
condenser fan connector.
12. Disconnect refrigerant 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.
13. Remove condenser & receiver tank assembly.

Handle with care to prevent damaging the
condenser or radiator fin.
Installation
1. Install condenser & reciver tank assembly.

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

Tighten the condenser fixing bolts to the specified
torque.
Torque: 6 Nwm (52 lb in)
2. Connect refrigerant line.

Tighten the inlet line connector fixing bolt to the
specified torque.
Torque: 15 Nwm (11 lb ft)

Tighten the outlet line connector fixing bolt to the
specified torque.
Torque: 6 Nwm (52 lb in)

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

Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
3. Connect pressure switch, ambient sensor and
condenser fan connector.
4. Install head light (R/LH).
5. Install front side turn signal light (R/LH).
6. Install horn (R/LH).
7. Install engine hood front end with engine hood lock &
bumper stay.

Align the setting mark when installing.
8. Install condenser air guide.
9. Install front side bumper retainer (RH).
10. Install front center bumper retainer.
11. Install front bumper assembly.

1A±42
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser Fan Motor
Condenser Fan Motor and Associated Parts
875R200016
Legend
(1) Condenser Fan Assembly
(2) Condenser Air Guide
(3) Front Bumper Assembly(4) Condenser Fan Motor
(5) Shroud
(6) Fan
(7) Horn (RH)
Removal
1. Disconnect the battery ground cable.
2. Remove the front bumper assembly.

Refer to the
Front Bumper in Body Structure
section.
3. Remove the condenser air guide.
4. Remove the horn (RH).
5. Remove the condenser fan assembly.

Disconnect the fan motor connector and remove
the 3 fixing bolts.
6. Remove the shroud.

Remove the 3 fixing nuts.

Loosen the condenser fixing nut and disconnect the
fan motor connector from bracket.
7. Remove the fan.

Remove the fan fixing C-ring and plate.
8. Remove the condenser fan motor.
Installation
To install, follow the removal 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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±43
Receiver / Drier
Receiver / Drier and Associated Parts
875R200019
Legend
(1) Front Side Turn Signal Light (LH)
(2) Refrigerant Line
(3) Head Light (LH)
(4) Front Bumper Assembly
(5) Receiver / Drier
(6) Pressure Switch Connector
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.

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

Refer to the
Front Bumper in Body Structure
section.
4. Remove front side turn signal light (LH).
5. Remove head light (LH).
6. Disconnect pressure switch connector.
7. Disconnect refrigerant 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.
8. Remove receiver/drier.

Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. If installing a new receiver/drier, be sure to add 30cc
(1.0 fl. 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 Nwm (52 lb in)
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 the refrigerant line.

1A±44
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Pressure Switch
Pressure Switch and Associated Parts
875R200021
Legend
(1) Pressure Switch Connector
(2) Front Side Turn Signal Light (LH)
(3) Head Light (LH)
(4) Front Bumper Assembly
(5) Pressure Switch
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.

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

Refer to the
Front Bumper in Body Structure
section.
4. Remove the front side turn signal light (LH).
5. Remove the head light (LH).
6. Disconnect pressure switch connector.
7. 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.
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
Torque: 13 Nwm (113 lb in)