oil pressure ISUZU AXIOM 2002 Service Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2002, Model line: AXIOM, Model: ISUZU AXIOM 2002Pages: 2100, PDF Size: 19.35 MB
Page 20 of 2100
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.
Page 26 of 2100
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)230'+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.
Page 45 of 2100
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 0C
(32F).
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.
Page 57 of 2100
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±31
Air Conditioning System
Individual Inspection
Triple Pressure Switch (V6, A/T)
1. Disconnect the connector and check for continuity
between pressure switch side connector terminals (1)
and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminals (3) and (4) and the
fan operates.
875RY00010
Condenser Fan
1. Disconnect the condenser fan connector.
2. Connect the battery positive terminal to the
condenser fan side connector terminal No.C-16-1
and negative to the No.C-16-2.
3. Check that condenser fan is rotating correctly.
875R200002
General Repair Procedure
Precautions For Replacement or Repair of
Air Conditioning Parts
There are certain procedures, practices and precautions
that should be followed when servicing air conditioning
systems:
Keep your work area clean.
Always wear safety goggles and protective gloves
when working on refrigerant systems.
Beware of the danger of carbon monoxide fumes
caused by running the engine.
Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts
are reconnected or installed.
When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
Always install new O-rings whenever a connection is
disassembled.
Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1. Use the J-39500 (ACR
4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover the
refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning
system and check for leaks.
Page 59 of 2100
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.
Page 67 of 2100
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.
Page 69 of 2100
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.
Page 70 of 2100
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)
Page 76 of 2100
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.
Page 79 of 2100
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