torque ISUZU AXIOM 2002 Service Repair Manual

0A±1
GENERAL INFORMATION
AXIOM
GENERAL INFORMATION
CONTENTS
General Information 0A. . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication 0B. . . . . . . . . . . . .
General Information
CONTENTS
General Repair Instruction 0A±1. . . . . . . . . . . . . . . .
Illustration Arrows 0A±2. . . . . . . . . . . . . . . . . . . . . . .
Identification 0A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard 0A±5. . . . . . . . . . . . . . . . Lifting Instructions 0A±9. . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications 0A±11. . . . . .
Abbreviations Charts 0A±12. . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate 0A±13. . . . . . . . . .
General Repair Instruction
1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, ªblockº front or rear
wheels, set jack against the recommended lifting
points (see ªLifting Instructionsº in this section), raise
vehicle and support with chassis stands and then
perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance of
cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and anti±freeze solution must be handled
with reasonable care, as they can cause paint
damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, O±rings, oil
seals, lock washers and self±locking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.13. When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
system, be sure to use the Vehicle Refrigerant
Recovery and Recycling Equipment (VRRRE) to
recover and recycle Refrigerant±134a.
14. When a service operation is completed, make a final
check to be sure the service has been done properly
and the problem has been corrected.
15. SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System (SRS) ± Air Bags. This system is
not to be serviced without consulting the appropriate
service information. Consult Section 9J ªSRS
Systemº if work is to be done on the front of the
vehicle such as bumper, sheet metal, seats, wiring,
steering wheel or column. Also review SRS system
information if any arc welding is to be done on the
vehicle. The SRS system equipped vehicle can be
identified by:
1. ªAIR BAGº warning light on the instrument
cluster.
2. A Code ªKº or ªMº for fifth digit of Vehicle
Identification Number.

0A±11
GENERAL INFORMATION
Standard Bolts Torque Specifications
The torque values given in the following table should be
applied where a particular torque is not specified.
Strength Class4.88.89.8Strength ClassRefinedNon-Refined
Bolt
Identification
Bolt Diameter y
Pitch (mm)
M 6X1.0
M 8X1.25
M 10X1.25
* M10X1.5
M12X1.25
* M12X1.75
M14X1.5
* M14X2.0
M16X1.5
* M16X2.0
M18X1.5
M20X1.5
M22X1.5
M24X2.04 ± 8 N´m (3 ± 6 lb ft)
8 ± 18 N´m (6 ± 13 lb ft)
21 ± 34 N´m (15 ± 25 lb ft)
20 ± 33 N´m (14 ± 25 lb ft)
49 ± 74 N´m (36 ± 54 lb ft)
45 ± 69 N´m (33 ± 51 lb ft)
77 ± 115 N´m (56 ± 85 lb ft)
72 ± 107 N´m (53 ± 79 lb ft)
104 ± 157 N´m (77 ± 116 lb ft)
100 ± 149 N´m (74 ± 110 lb ft)
151 ± 226 N´m (111 ± 166 lb ft)
206 ± 310 N´m (152 ± 229 lb ft)
251 ± 414 N´m (185 ± 305 lb ft)
359 ± 539 N´m (265 ± 398 lb ft)5 ± 10 N´m (4 ± 7 lb ft)
12 ± 23 N´m (9 ± 17 lb ft)
28 ± 46 N´m (20 ± 34 lb ft)
28 ± 45 N´m (20 ± 33 lb ft)
61 ± 91 N´m (45 ± 67 lb ft)
57 ± 84 N´m (42 ± 62 lb ft)
93 ± 139 N´m (69 ± 103 lb ft)
88 ± 131 N´m (65 ± 97 lb ft)
135 ± 204 N´m (100 ± 150 lb ft)
130 ± 194 N´m (95 ± 143 lb ft)
195 ± 293 N´m (144 ± 216 lb ft)
270 ± 405 N´m (199 ± 299 lb ft)
363 ± 544 N´m (268 ± 401 lb ft)
431 ± 711 N´m (318 ± 524 lb ft) ±
17 ± 30 N´m (12 ± 22 lb ft)
37 ± 63 N´m (27 ± 46 lb ft)
36 ± 60 N´m (27 ± 44 lb ft)
76 ± 114 N´m (56 ± 84 lb ft)
72 ± 107 N´m (53 ± 79 lb ft)
114 ± 171 N´m (84 ± 126 lb ft)
107 ± 160 N´m (79 ± 118 lb ft)
160 ± 240 N´m (118 ± 177 lb ft)
153 ± 230 N´m (113 ± 169 lb ft)
230 ± 345 N´m (169 ± 255 lb ft)
317 ± 476 N´m (234 ± 351 lb ft)
425 ± 637 N´m (313 ± 469 lb ft)
554 ± 831 N´m (409 ± 613 lb ft)
The asterisk * indicates that the bolts are used for
female±threaded parts that are made of soft materials
such as casting, etc.

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.

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.

0B±11 MAINTENANCE AND LUBRICATION
Recommended Liquid Gasket
TypeBrand NameManufacturerRemarks
RTV*
Silicon Base
Three Bond 1207B
Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281Three Bond
Three Bond
Three Bond
Three Bond
Three BondFor Engine Repairs
For Axle Case
Repairs T/M
Repairs T/M
Water BaseThree Bond 1141EThree BondFor Engine Repairs
Solvent
Three Bond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 17430Loctite
Loctite
Loctite
All
* RTV: Room Temperature Vulcanizer
NOTE:
1. It is very important that the liquid gaskets listed above
or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacturer's instructions at all times.
3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
Recommended Thread Locking
Agents
LOCTITE TypeLOCTITE Color
LOCTITE 242Blue
LOCTITE 262Red
LOCTITE 271Red
Application Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
F00RW014
3. Tighten the bolts to the specified torque.
After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
NOTE: When the application procedures are specified in
this manual, follow them.

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)2
30'+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.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING 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 SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS 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.
Heating and Ventilation System
General Description
Heater
When the engine is warming up, the warmed engine
coolant is sent into the heater core. The heater system
supplies warm air into the passenger compartment to
warm it up.
Outside air is circulated through the heater core of the
heater unit and then into the passenger compartment. By
controlling the mixture of outside air and heater core air,
the most comfortable passenger compartment
temperature can be selected and maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature control
knob. This knob acts to open and close the air mix door,
thus controlling the amount of air passed through the
heater core.The air selector switch (Mode SW), with its different
modes, also allows you to select and maintain the most
comfortable passenger compartment temperature.
The air source select switch is used to select either
ªFRESHº for the introduction of the outside air, or ªCIRCº
for the circulation of the inside air. When the switch is set
to ªFRESHº, the outside air is always taken into the
passenger compartment. When setting the switch to
ªCIRCº position, the circulation of air is restricted only to
the inside air with no introduction of the outside air and the
air in the passenger compartment gets warm quickly.
However, the switch is normally set to ªFRESHº to
prevent the windshield from clouding.

1A±32
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Repair Of Refrigerant Leaks
Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the
connecting portion from twisting or becoming damaged.
852R200001When connecting the refrigerant line at a block joint,
securely insert the projecting portion of the joint portion
into the connecting hole on the unit side and secure with a
bolt. Apply the specified compressor oil to the O-rings
prior to connecting.
CAUTION: Compressor (PAG) oil to be used varies
according to the compressor model. Be sure to apply
oil specified for the model of compressor.
850RW002
O-rings (2) must be fitted in the groove (1) of refrigerant
line.
850RW003Insert the nut into the union.
First, tighten the nut by hand as much as possible, then
tighten the nut to the specified torque.
850RW004

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.