clutch ISUZU AXIOM 2002 Service Repair Manual

0A±13
GENERAL INFORMATION
N Ð Newtons
NA Ð Natural Aspirated
NC Ð Normally Closed
N´M Ð Newton Meters
NO Ð Normally Open
NOX Ð Nitrogen, Oxides of
OBD Ð On-Board Diagnostic
OD Ð Outside Diameter
O/D Ð Over Drive
OHC Ð Overhead Camshaft
OL Ð Open Loop
O2 Ð Oxygen
O2S Ð Oxygen Sensor
PAIR Ð Pulsed Secondary Air Injection System
P/B Ð Power Brakes
PCM Ð Powertrain Control Module
PCV Ð Positive Crankcase Ventilation
PRESS Ð Pressure
PROM Ð Programmable Read Only Memory
PNP Ð Park/Neutral Position
P/S Ð Power Steering
PSI Ð Pounds per Square Inch
PSP Ð Power Steering Pressure
Pt. Ð Pint
Pri Ð Primary
PWM Ð Pulse Width Modulate
Qt. Ð Quart
REF Ð Reference
RF Ð Right Front
RFI Ð Radio Frequency Interference
RH Ð Right Hand
RPM Ð Revolutions Per Minute
RPM Sensor Ð Engine Speed Sensor
RPO Ð Regular Production Option
RR Ð Right Rear
RS Ð Right Side
RTV Ð Room Temperature Vulcanizing
RWAL Ð Rear Wheel Antilock Brake
RWD Ð Rear Wheel Drive
SAE Ð Society of Automotive Engineers
Sec Ð Secondary
SFI Ð Sequential Multiport Fuel Injection
SI Ð System International
SIR Ð Supplemental Inflatable Restraint System
SOHC Ð Single Overhead Camshaft
Sol Ð Solenoid
SPEC Ð Specification
Speedo Ð Speedometer
SRS Ð Supplemental Restraint System
ST Ð Start / Scan Tool
Sw Ð Switch
SWB Ð Short Wheel Base
SYN Ð Synchronize
Tach Ð Tachometer
TB Ð Throttle Body
TBI Ð Throttle Body Fuel Injection
TCC Ð Torque Converter Clutch
TCM Ð Transmission Control Module
TDC Ð Top Dead Center
Term Ð Terminal
TEMP Ð Temperature
TODÐ Torque On Demand
TP Ð Throttle Position
TRANS Ð Transmission/Transaxle
TURBO Ð TurbochargerTVRS Ð Television & Radio Suppression
TVV Ð Thermal Vacuum Valve
TWC Ð Three Way Catalytic Converter
3 A/T Ð Three Speed Automatic Transmission/Transaxle
2WD Ð Two Wheel Drive
4 x 2 Ð Two Wheel Drive
U±joint Ð Universal Joint
V Ð Volt(s)
VAC Ð Vacuum
VIN Ð Vehicle Identification Number
VRRRE Ð Vehicle Refrigerant Recovery and Recycling
Equipment
V±ref Ð ECM Reference Voltage
VSS Ð Vehicle Speed Sensor
VSV Ð Vacuum Switch Valve
V±6 Ð Six Cylinder ªVº Engine
V±8 Ð Eight Cylinder ºVº Engine
W Ð Watt(s)
w/ Ð With
w/b Ð Wheel Base
w/o Ð Without
WOT Ð Wide Open Throttle
Service Parts Identification Plate
The Vehicle Information Plate (Service Parts ID plate) is
provided on all vehicle models.
It is located on the center dash wall inside the engine
compartment. The plate lists the VIN (Vehicle
Identification Number), paint information and all
production options and special equipment on the vehicle
when it was shipped from the factory.
905R200002

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.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A±18
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Air Conditioning System
General Description
Air Conditioning Refrigerant Cycle Construction
C01RY00013
Legend
(1) Duct Sensor
(2) Evaporator Core
(3) Evaporator Assembly
(4) Temperature Sensor
(5) Blower Motor
(6) Expansion Valve
(7) Pressure Switch
(8) Receiver/Drier(9) Condenser
(10) Compressor
(11) Magnetic Clutch
(12) Mode (HEAT) Control Door
(13) Temp. Control Door (Air Mix Door)
(14) Heater Core
(15) Mode (VENT) Control Door
(16) Heater Unit
(17) Mode (DEF) Control Door
The refrigeration cycle includes the following four
processes as the refrigerant changes repeatedly from
liquid to gas and back to liquid while circulating.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±19
Evaporation
The refrigerant is changed from a liquid to a gas inside the
evaporator. The refrigerant mist that enters the
evaporator vaporizes readily. The liquid refrigerant
removes the required quantity of heat (latent heat of
vaporization) from the air around the evaporator core
cooling fins and rapidly vaporizes. Removing the heat
cools the air, which is then radiated from the fins and
lowers the temperature of the air inside the vehicle.
The refrigerant liquid sent from the expansion valve and
the vaporized refrigerant gas are both present inside the
evaporator as the liquid is converted to gas.
With this change from liquid to gas, the pressure inside
the evaporator must be kept low enough for vaporization
to occur at a lower temperature. Because of that, the
vaporized refrigerant is sucked into the compressor.
Compression
The refrigerant is compressed by the compressor until it is
easily liquefied at normal temperature.
The vaporized refrigerant in the evaporator is sucked into
the compressor. This action maintains the refrigerant
inside the evaporator at a low pressure so that it can
easily vaporize, even at low temperatures close to 0
C
(32
F).
Also, the refrigerant sucked into the compressor is
compressed inside the cylinder to increase the pressure
and temperature to values such that the refrigerant can
easily liquefy at normal ambient temperatures.
Condensation
The refrigerant inside the condenser is cooled by the
outside air and changes from gas to liquid.
The high temperature, high pressure gas coming from the
compressor is cooled and liquefied by the condenser with
outside air and accumulated in the receiver/drier. The
heat radiated to the outside air by the high temperature,
high pressure gas in the compressor is called heat of
condensation. This is the total quantity of heat (heat of
vaporization) the refrigerant removes from the vehicle
interior via the evaporator and the work (calculated as the
quantity of heat) performed for compression.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize.
The process of lowering the pressure to encourage
vaporization before the liquefied refrigerant is sent to the
evaporator is called expansion. In addition, the expansion
valve controls the flow rate of the refrigerant liquid while
decreasing the pressure.
That is, the quantity of refrigerant liquid vaporized inside
the evaporator is determined by the quantity of heat which
must be removed at a prescribed vaporization
temperature. It is important that the quantity of refrigerant
be controlled to exactly the right value.
Compressor
The compressor performs two main functions:It compresses low-pressure and low-temperature
refrigerant vapor from the evaporator into high-pressure
and high-temperature refrigerant vapor to the condenser.
It pumps refrigerant and refrigerant oil through the air
conditioning system.
This vehicle is equipped with a five-vane rotary
compressor.
The specified amount of the compressor oil is 150cc
(5.0 fl. oz.).
The 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.
The magnetic clutch connector is a waterproof type.
Magnetic Clutch
The compressor is driven by the drive belt from the crank
pulley of the engine. If the compressor is activated each
time the engine is started, this causes too much load to
the engine. The magnetic clutch transmits the power from
the engine to the compressor and activates it when the air
conditioning is ON. Also, it cuts off the power from the
engine to the compressor when the air conditioning is
OFF. Refer to
Compressor in this section for magnetic
clutch repair procedure.
871RX026
Legend
(1) Magnetic Clutch
(2) Magnetic Clutch Connector
(3) Compressor
Condenser
The condenser assembly is located in front of the radiator.
It provides rapid heat transfer from the refrigerant to the
cooling fins.
Also, it functions to cool and liquefy the high-pressure and
high-temperature vapor sent from the compressor by the
radiator fan or outside air.

1A±20
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
A condenser may malfunction in two ways: it may leak, or
it may be restricted. A condenser restriction will result in
excessive compressor discharge pressure. If a partial
restriction is present, the refrigerant expands after
passing through the restriction.
Thus, ice or frost may form immediately after the
restriction. If air flow through the condenser or radiator is
blocked, high discharge pressures will result. During
normal condenser operation, the refrigerant outlet line will
be slightly cooler than the inlet line.
The vehicle is equipped with the parallel flow type
condenser. A larger thermal transmission area on the
inner surface of the tube allows the radiant heat to
increase and the ventilation resistance to decrease.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
875R200015
Legend
(1) Pressure Switch
(2) Receiver Drier
(3) Condenser & Receiver Tank Assembly
(4) Condenser Fan
Receiver / Drier
The receiver/drier performs four functions:

As the quantity of refrigerant circulated varies
depending on the refrigeration cycle conditions,
sufficient refrigerant is stored for the refrigeration
cycle to operate smoothly in accordance with
fluctuations in the quantity circulated.

The liquefied refrigerant from the condenser is mixed
with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles. If refrigerant
containing air bubbles is sent to the expansion valve,
the cooling capacity will decrease considerably.
Therefore, the liquid and air bubbles are separated
and only the liquid is sent to the expansion valve.

The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the
receiver/drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum
with a smaller tank. It has a 300cc refrigerant capacity.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
Triple Pressure Switch (V6, A/T)
Triple pressure switch is installed on the upper part of the
receiver/drier. This switch is constructed with a unitized
type of two switches. One of them is a low and high
pressure switch (Dual pressure switch) to switch ªONº or
ªOFFº the magnetic clutch as a result of irregularly
high±pressure or low pressure of the refrigerant. The
other one is a medium pressure switch (Cycling switch) to
switch ªONº or ªOFFº the condenser fan sensing the
condenser high side pressure.
Compressor
ON
(kPa/psi)OFF
(kPa/psi)
Low-pressure
control206.0+30.0
(29.8+4.3)176.5+24.5
(25.6+3.6)
High-pressure
control2353.6+196.1
(341.3+28.4)2942.0+196.1
(426.6+28.4)
Condenser fanON
(kPa/psi)OFF
(kPa/psi)
Medium-pressure
control1471.0+98.1
(213.3+14.2)1078.7+117.7
(156.4+17.1)
Expansion Valve
This expansion valve is an external pressure type and it is
installed at the evaporator intake port.
The expansion valve converts the high pressure liquid
refrigerant sent from the receiver/drier to a low pressure
liquid refrigerant by forcing it through a tiny port before
sending it to the evaporator.
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring
adjustment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure. It
then transmits these to the top chamber of the
diaphragm.
The refrigerant pressure is transmitted to the diaphragm's
bottom chamber through the external equalizing pressure
tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
the force acting on the diaphragm and the spring
pressure.

1A±24
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
Air Conditioning Cycle Diagnosis
ConditionPossible causeCorrection
No cooling or insufficient cooling.Magnetic clutch does not run.Refer to ªMagnetic Clutch Diagnosisº
in this section.
Compressor is not rotating properly.
Drive belt is loose or broken.Adjust the drive belt to the specified
tension or replace the drive belt.
Compressor is not rotating properly.
Magnetic clutch face is not clean and
slips.Clean the magnetic clutch face or
replace.
Compressor is not rotating properly.
Incorrect clearance between
magnetic drive plate and pulley.Adjust the clearance. Refer to
Compressor in this section.
Compressor is not rotating properly.
Compressor oil leaks from the shaft
seal or shell.Replace the compressor
Compressor is not rotating properly.
Compressor is seized.Replace the compressor
Insufficient or excessive charge of
refrigerant.Discharge and recover the
refrigerant. Recharge to the
specified amount.
Leaks in the refrigerant system.Check the refrigerant system for
leaks and repair as necessary.
Discharge and recover the
refrigerant. Recharge to the
specified amount.
Condenser is clogged or insufficient
radiation.Clean the condenser or replace as
necessary.
Temperature control link unit of the
heat unit is defective.Repair the link unit.
Unsteady operation due to a foreign
substance in the expansion valve.Replace the expansion valve.
Poor operation of the electronic
thermostat.Check the electronic thermostat and
replace as necessary.
Insufficient velocity of cooling air.Evaporator clogged or frosted.Check the evaporator core and
replace or clean the core.
Air leaking from the cooling unit or air
duct.Check the evaporator and duct
connection, then repair as
necessary.
Blower motor does not rotate
properly.Refer to Fan Control Lever (Fan
Switch) Diagnosis in this section.
*For the execution of the charging and discharging
operation in the table above, refer to
Recovery,
Recycling, Evacuating and Charging in this section.

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

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