sensor ISUZU AXIOM 2002 Service Repair Manual

0A±12
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A Ð Ampere(s)
ABS Ð Antilock Brake System
AC Ð Alternating Current
A/C Ð Air Conditioning
ACCEL Ð Accelerator
ACC Ð Accessory
ACL Ð Air Cleaner
Adj Ð Adjust
A/F Ð Air Fuel Ratio
AIR Ð Secondary Air Injection System
Alt Ð Altitude
AMP Ð Ampere(s)
ANT Ð Antenna
ASM Ð Assembly
A/T Ð Automatic Transmission/Transaxle
ATDC Ð After Top Dead Center
ATF Ð Automatic Transmission Fluid
Auth Ð Authority
Auto Ð Automatic
BARO Ð Barometric Pressure
Bat Ð Battery
B+ Ð Battery Positive Voltage
Bbl Ð Barrel
BHP Ð Brake Horsepower
BPT Ð Backpressure Transducer
BTDC Ð Before Top Dead Center

C Ð Degrees Celsius
CAC Ð Charge Air Cooler
Calif Ð California
cc Ð Cubic Centimeter
CID Ð Cubic Inch Displacement
CKP Ð Crankshaft Position
CL Ð Closed Loop
CLCC Ð Closed Loop Carburetor Control
CMP Ð Camshaft Position
CO Ð Carbon Monoxide
Coax Ð Coaxial
Conn Ð Connector
Conv Ð Converter
Crank Ð Crankshaft
Cu. In. Ð Cubic Inch
CV Ð Constant Velocity
Cyl Ð Cylinder(s)
DI Ð Distributor Ignition
Diff Ð Differential
Dist Ð Distributor
DLC Ð Data Link Connector
DOHC Ð Double Overhead Camshaft
DTC Ð Diagnostic Trouble Code
DTM Ð Diagnostic Test Mode
DTT Ð Diagnostic Test Terminal
DVM Ð Digital Voltmeter (10 meg.)
DVOM Ð Digital Volt Ohmmeter
EBCM Ð Electronic Brake Control Module
ECM Ð Engine Control Module
ECT Ð Engine Coolant Temperature
EEPROM Ð Electronically Erasable Programmable
Read Only Memory
EGR Ð Exhaust Gas Recirculation
EI Ð Electronic Ignition
ETR Ð Electronically Tuned Receiver
EVAP Ð Evaporation EmissionExh Ð Exhaust

F Ð Degrees Fahrenheit
Fed Ð Federal (All States Except Calif.)
FF Ð Front Drive Front Engine
FL Ð Fusible Link
FLW Ð Fusible Link Wire
FP Ð Fuel Pump
FRT Ð Front
ft Ð Foot
FWD Ð Front Wheel Drive
4WD Ð Four Wheel Drive
4 x 4 Ð Four Wheel Drive
4 A/T Ð Four Speed Automatic Transmission/Transaxle
Gal Ð Gallon
GEN Ð Generator
GND Ð Ground
Gov Ð Governor
g Ð Gram
Harn Ð Harness
HC Ð Hydrocarbons
HD Ð Heavy Duty
Hg Ð Hydrargyrum (Mercury)
HiAlt Ð High Altitude
HO2S Ð Heated Oxygen Sensor
HVAC Ð Heater±Vent±Air±Conditioning
IAC Ð Idle Air Control
IAT Ð Intake Air Temperature
IC Ð Integrated Circuit / Ignition Control
ID Ð Identification / Inside Diameter
IGN Ð Ignition
INJ Ð Injection
IP Ð Instrument Panel
IPC Ð Instrument Panel Cluster
Int Ð Intake
ISC Ð Idle Speed Control
J/B Ð Junction Block
kg Ð Kilograms
km Ð Kilometers
km/h Ð Kilometer per Hour
kPa Ð Kilopascals
kV Ð Kilovolts (thousands of volts)
kW Ð Kilowatts
KS Ð Knock Sensor
L Ð Liter
lb ft Ð Foot Pounds
lb in Ð Inch Pounds
LF Ð Left Front
LH Ð Left Hand
LR ÐLeft Rear
LS Ð Left Side
LWB Ð Long Wheel Base
L±4 Ð In±Line Four Cylinder Engine
MAF Ð Mass Air Flow
MAN Ð Manual
MAP Ð Manifold Absolute Pressure
Max Ð Maximum
MC Ð Mixture Control
MFI Ð Multiport Fuel Injection
MIL Ð Malfunction Indicator Lamp
Min Ð Minimum
mm Ð Millimeter
MPG Ð Miles Per Gallon
MPH Ð Miles Per Hour
M/T Ð Manual Transmission/Transaxle
MV Ð Millivolt

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±1
AXIOM
HEATING, VENTILATION AND AIR
CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution 1A±3. . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System 1A±3. . . . . . . . . . .
General Description 1A±3. . . . . . . . . . . . . . . . . . . . .
Heater Unit 1A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts 1A±6. . . . . . . .
Removal 1A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door 1A±7. . . . . . . . . .
Disassembled View 1A±7. . . . . . . . . . . . . . . . . . . .
Removal 1A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit 1A±9. . . . . . . . . . . .
Disassembled View 1A±9. . . . . . . . . . . . . . . . . . . .
Removal 1A±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit 1A±11. . . . . .
Disassembled View 1A±11. . . . . . . . . . . . . . . . . . . .
Removal 1A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly 1A±12. . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts 1A±12. .
Removal 1A±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door 1A±13. . . . . . .
Disassembled View 1A±13. . . . . . . . . . . . . . . . . . . .
Removal 1A±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor 1A±15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts 1A±15. . . . . .
Removal 1A±15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle and
Ventilation Duct 1A±16. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts 1A±16. . .
Removal 1A±16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System 1A±18. . . . . . . . . . . . . . . . . .
General Description 1A±18. . . . . . . . . . . . . . . . . . . . .
Diagnosis 1A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System 1A±31. . . . . . . . . . . . . . . . . . Individual Inspection 1A±31. . . . . . . . . . . . . . . . . . . . .
General Repair Procedure 1A±31. . . . . . . . . . . . . .
Leak Check 1A±33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Assembly 1A±38. . . . . . . . . . . . . . . . . . .
Compressor Assembly and Associated
Parts (6VE1) 1A±38. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation 1A±39. . . . . . . . . . . .
Condenser Assembly 1A±40. . . . . . . . . . . . . . . . . . . .
Condenser Assembly and Associated
Parts 1A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor 1A±42. . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor and Associated
Parts 1A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier 1A±43. . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts 1A±43. . . .
Removal 1A±43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch 1A±44. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts 1A±44. . .
Removal 1A±44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly 1A±45. . . . . . . . . . . . . . . . . . . .
Evaporator Assembly and Associated
Parts 1A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor, Evaporator Core and/or
Expansion Valve 1A±47. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 1A±47. . . . . . . . . . . . . . . . . . . .
Removal 1A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line 1A±49. . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts 1A±49. . . .
Removal 1A±49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications 1A±51. . . . . . . . . . . . .

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.

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±22
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Duct Sensor
The duct sensor is the sensor to detect temperature
change of the side of evaporator blower coming by fresh
recirculation of intake door or ªonº ªoffº of compressor.
The temperature is converted to resistant rate.
And it works as thermostat to control to prevent freezing
of evaporator.
This sensor is installed in the upper case of evaporator.
874R200010
Legend
(1) Sensor Part
(2) Evaporator Core
(3) Duct Sensor Assembly
(4) Evaporator Assembly
Refrigerant Line
Restriction in the refrigerant line will be indicated by:
1. Suction line Ð A restricted suction line will cause low
suction pressure at the compressor, low discharge
pressure and little or no cooling.
2. Discharge line Ð A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line Ð A liquid line restriction will be evidenced
by low discharge and suction pressure and
insufficient cooling.
Refrigerant flexible hoses that have a low permeability to
refrigerant and moisture are used. These low
permeability hoses have a special nylon layer on the
inside.
852RS001
Legend
(1) Reinforcement Layer (Polyester)
(2) External Rubber Layer
(3) Internal Rubber Layer
(4) Resin Layer (Nylon)

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±27
ConditionPossible causeCorrection
Discharge (High Gauge) Pressure
Abnormally High
Condenser clogged or dirty.Clean the condenser fins
Abnormally HighCooling fan does not operate
properly.Check the cooling fan operation.
Discharge (High Gauge) Pressure
Abnormally High.
Insufficient cooling.Excessive refrigerant in system.Discharge and recover refrigerant.
Recharge to specified amount.
Discharge (High Gauge) Pressure
Abnormally High.
High pressure gauge drop. (After
stopping A/C, the pressure drops
approx. 196 kPa (28 psi) quickly)Air in system.Evacuate and charge refrigerant
system.
Discharge (High Gauge) Pressure
Abnormally Low.
Insufficient coolingInsufficient refrigerant in system.Check for leaks. Discharge and
recover the refrigerant. Recharge to
the specified amount.
Discharge (High Gauge) Pressure
Abnormally Low.
Low pressure gauge indicates
vacuum.Clogged or defective expansion
valve.Replace the expansion valve.
Discharge (High Gauge) Pressure
Abnormally Low.
Frost or dew on refrigerant line
before and after the receiver/drier or
expansion valve, and low pressure
gauge indicates vacuum.Restriction caused by debris or
moisture in the receiver/drier.Check system for restriction and
replace the receiver/drier.
Discharge (High Gauge) Pressure
Abnormally Low.Compressor seal defectiveRepair or replace the compressor.
High and low pressure gauge
balanced quickly. (After turned off
A/C)Poor compression due to a defective
compressor gasket.Repair or replace the compressor.
Suction (Low Gauge) Pressure
Abnormally High.
Low pressure gauge (Low pressure
gauge is lowered after condenser is
cooled by water.)Excessive refrigerant in system.Discharge and recover refrigerant
Recharge to specified amount.
Suction (Low Gauge) Pressure
Abnormally High.
Low pressure hose temperature.
(Low pressure hose temperature
around the compressor refrigerant
Unsatisfactory valve operation due
to defective temperature sensor of
expansion valve.Replace the expansion valve.
around the com ressor refrigerant
line connector is lower than around
evaporator.)Expansion valve opens too long.Replace the expansion valve.
Suction (Low Gauge) Pressure
Abnormally High.
High and low pressure gauge
balanced quickly. (After turned off
A/C)Compressor gasket is defective.Repair or replace the compressor.
Suction (Low Gauge) Pressure
Abnormally Low.
Insufficient cooling.Insufficient refrigerant in system.Check for leaks. Discharge and
recover the refrigerant. Recharge to
specified amount.
Suction (Low Gauge) Pressure
Abnormally Low.
Frost on the expansion valve inlet
lineExpansion valve clogged.Replace the expansion valve.

1A±28
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condition CorrectionPossible cause
Suction (Low Gauge) Pressure
Abnormally Low
Receiver/drier inlet and outlet
refrigerant line temperature. (A
distinct difference in temperature
develops.)Receiver/Drier clogged.Replace the receiver/drier.
Suction (Low Gauge) Pressure
Abnormally Low.
Expansion valve outlet refrigerant
line. (Not cold and low pressure
gauge indicates vacuum.)Expansion valve temperature sensor
is defective.Replace the expansion valve.
Suction (Low Gauge) Pressure
Abnormally Low.
When the refrigerant line is clogged
or blocked, the low pressure gauge
reading will decrease, or a vacuum
reading may be shown.Clogged or blocked refrigerant line.Replace refrigerant line.
Suction (Low Gauge) Pressure
Abnormally Low.
Evaporator core is frozen.Thermo switch defective.Replace thermo switch.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
High.Excessive refrigerant in system.Discharge and recover the
refrigerant, the Recharge to the
specified amount.
Insufficient cooling.Condenser clogged or dirty.Clean the condenser fin.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
High.
Suction (Low) pressure hose (Not
cold).Air in system.Evacuate and charge refrigerant.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
Low.
Insufficient coolingInsufficient refrigerant in system.Check for leaks. Discharge and
recover refrigerant. Recharge to
specified amount.
A/C Ð Air Conditioning

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.