Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 533
0B–12
MAINTENANCE AND LUBRICATION
Maintenance Service Data
Service Data and Specifications
ENGINE
Valve 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 type
K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap
1.05 mm (0.04 in)
CLUTCH
Clutch pedal free play
5–15 mm (0.20–0.59 in)
BRAKE
Brake pedal free play
6–10 mm (0.24–0.39 in)
Parking brake travel
6–7 notches
WHEEL ALIGNMENT
Toe-in
0
±
2 mm (0
±
0.08 in)
Camber
0
°±
30’
Caster
2
°
10’
±
45’
PROPELLER SHAFT
Flange torque
63 N·m (46 lb ft) (Except TOD model)
43 N·m (32 lb ft) (TOD model)
WHEEL AND TIRES
Size
P245/70R16
Wheel nut torque
118 N·m (87 lb ft)
Tire inflation pressure (Front)
210 kPa (30 psi)
* Tire inflation pressure (Rear)
240 kPa (35 psi)
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
Items
Metric Measure
U.S. Measure
Fuel tank
85 L
22.5 Gal.
* Crankcase
Oil Change with Filter
4.7 L
5.0 Qt
Oil Change without Filter
4.0 L
4.2 Qt
Coolant
M/T
8.5 L
9.0 Qt
A/T
8.8 L
9.3 Qt
Transmission
Manual
2.7 L
2.86 Qt
Automatic
8.6 L
9.1 Qt
Transfer
1.45 L
1.5 Qt
Transfer with TOD
1.9 L
2.0 Qt
Extention
0.185 L
0.195 Qt
Axle
Rear
3.0 L
3.2 Qt
Front (4WD vehicle only)
1.4 L
1.5 Qt
Shift on the fly system
0.12 L
0.13 Qt
Power steering
1.0 L
1.1 Qt
Air conditioning (R-134a)
0.8 L
1.76 lb
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–1
TROOPER
HEATING, VENTILATION AND AIR
CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution
1A–3
. . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System
1A–3
. . . . . . . . . . .
General Description
1A–3
. . . . . . . . . . . . . . . . . . . . .
Wiring Diagram
1A–8
. . . . . . . . . . . . . . . . . . . . . . .
Diagnosis
1A–9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Inspection
1A–12
. . . . . . . . . . . . . . . . . . .
Heater Unit
1A–14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts
1A–14
. . . . . . . .
Removal
1A–15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–15
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door
1A–16
. . . . . . . . . .
Disassembled View
1A–16
. . . . . . . . . . . . . . . . . . . .
Removal
1A–16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
1A–17
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–17
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit
1A–18
. . . . . . . . . . . .
Disassembled View
1A–18
. . . . . . . . . . . . . . . . . . . .
Removal
1A–18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–19
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit
1A–19
. . . . . .
Disassembled View
1A–19
. . . . . . . . . . . . . . . . . . . .
Removal
1A–19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–19
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly
1A–20
. . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts
1A–20
. .
Removal
1A–20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–21
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door
1A–21
. . . . . . .
Disassembled View
1A–21
. . . . . . . . . . . . . . . . . . . .
Removal
1A–21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–22
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor
1A–23
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts
1A–23
. . . . . .
Removal
1A–23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–23
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle and
Ventilation Duct
1A–24
. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts
1A–24
. . .
Removal
1A–24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–25
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center and / or Drive Side Vent
1A–25
. . . . . . . . . . .
Center Vent, Drive Side Vent and
Associated Parts
1A–25
. . . . . . . . . . . . . . . . . . . . . .
Removal
1A–25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–25
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Lever Assembly and / or Control
Cable
1A–26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Lever Assembly, Control Cable and
Associated Parts
1A–26
. . . . . . . . . . . . . . . . . . . . . .
Removal
1A–26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–28
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Illumination Bulb
1A–29
. . . . . . . . . . . .
Control Panel Illumination Bulb and
Associated Parts
1A–29
. . . . . . . . . . . . . . . . . . . . . .
Removal
1A–29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–29
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor
1A–30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor and Associated Parts
1A–30
. . . . . . . . . .
Removal
1A–30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–30
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System
1A–31
. . . . . . . . . . . . . . . . . .
General Description
1A–31
. . . . . . . . . . . . . . . . . . . . .
Diagnosis
1A–39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Inspection
1A–47
. . . . . . . . . . . . . . . . . . .
General Repair Procedure
1A–48
. . . . . . . . . . . . . .
Compressor Assembly
1A–56
. . . . . . . . . . . . . . . . . . .
Compressor Assembly and Associated
Parts (6VE1)
1A–56
. . . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–56
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–57
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation
1A–57
. . . . . . . . . . . .
Condenser Assembly
1A–58
. . . . . . . . . . . . . . . . . . . .
Condenser Assembly and Associated Parts
1A–58
Removal
1A–58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–58
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier
1A–59
. . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts
1A–59
. . . .
Removal
1A–59
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–59
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch
1A–60
. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts
1A–60
. . .
Removal
1A–60
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–60
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly
1A–61
. . . . . . . . . . . . . . . . . . . .
1A–2
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Evaporator Assembly and Associated Parts
1A–61
Removal
1A–61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–62
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Thermostat, Evaporator Core and/or
Expansion Valve
1A–62
. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
1A–62
. . . . . . . . . . . . . . . . . . . .
Removal
1A–63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–63
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Switch and Illumination
Bulb
1A–64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Switch, Illumination Bulb
and Associated Parts
1A–64
. . . . . . . . . . . . . . . . . .
Removal
1A–64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–64
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line
1A–65
. . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts
1A–65
. . . .
Removal
1A–65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–66
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications
1A–67
. . . . . . . . . . . . .
Compressor
1A–70
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
1A–70
. . . . . . . . . . . . . . . . . . . .
General Description
1A–70
. . . . . . . . . . . . . . . . . . . . . .
Diagnosis
1A–71
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Clutch Assembly (DKV-14G Type)
1A–72
Parts Location View
1A–72
. . . . . . . . . . . . . . . . . . . .
Removal
1A–72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
1A–74
. . . . . . . . . . . . . . . . . .
Installation
1A–74
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil
1A–76
. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specification
1A–76
. . . . . . . . . . . . . . . . . . . . . . .
Handling of Oil
1A–76
. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check
1A–76
. . . . . . . . . . . . . . . . .
Checking and Adjusting Oil Quantity for
Used Compressor
1A–76
. . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting for Compressor
Replacement
1A–76
. . . . . . . . . . . . . . . . . . . . . . . . .
Contamination of Compressor Oil
1A–77
. . . . . . . .
Oil Return Operation
1A–77
. . . . . . . . . . . . . . . . . . .
Replacement of Component Parts
1A–77
. . . . . . .
Main Data and Specifications
1A–78
. . . . . . . . . . .
Special Tools
1A–80
. . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System
1A–81
. . . . . . . .
General Description
1A–81
. . . . . . . . . . . . . . . . . . . . .
Full Automatic Air Conditioner Parts
Configuration
1A–81
. . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts
1A–82
. . . .
Circuit Diagram
1A–83
. . . . . . . . . . . . . . . . . . . . . . .
Functions and Features
1A–88
. . . . . . . . . . . . . . . .
Automatic Air Conditioner Block Diagram
1A–89
.
Control Panel Layout
1A–90
. . . . . . . . . . . . . . . . . . .
Air Control Functions
1A–91
. . . . . . . . . . . . . . . . . . .
Operation and Functions of Control Panel
Switches
1A–92
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System
1A–94
. . . . . . . . . . . . . . . . . . .
Overview of Automatic Control of Automatic
Air Conditioner
1A–98
. . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
1A–102
. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting, Its Overview and
Procedures
1A–102
. . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Air Conditioner Control Unit Power
Supply Diagnosis
1A–103
. . . . . . . . . . . . . . . . . . . . .
Performance and Movement checklist for
Automatic Air Conditioner Related Parts
1A–105
.
Troubleshooting With Self-Diagnosis
Function
1A–107
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection By Failed Location
1A–111
. . . . . . . . . . . . .
Inspection of the Sensors
1A–111
. . . . . . . . . . . . . . .
Inspection of the Intake Actuator System
1A–115
.
Inspection of the Mix Actuator System
1A–118
. . . .
Inspection of the Mode Actuator System
1A–121
. .
Inspection of the Fan Motor System
1A–124
. . . . . .
Inspection of the Magnetic Clutch System
1A–126
Condenser Fan Diagnosis
1A–129
. . . . . . . . . . . . . .
Individual Inspection
1A–132
. . . . . . . . . . . . . . . . . . .
On-Vehicle Service
1A–135
. . . . . . . . . . . . . . . . . . . . . .
Power Transistor
1A–135
. . . . . . . . . . . . . . . . . . . . . .
Removal
1A–135
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–135
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Heater/Air Conditioner Control
Unit
1A–135
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–135
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–135
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In Car Sensor
1A–136
. . . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–136
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–136
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor
1A–136
. . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–136
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–136
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sun Sensor
1A–137
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–137
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–137
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor
1A–137
. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–137
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–137
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Actuator
1A–138
. . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–138
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–138
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix Actuator
1A–138
. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–138
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–138
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Actuator
1A–139
. . . . . . . . . . . . . . . . . . . . . . . .
Removal
1A–139
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1A–139
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 out 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 back 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 knob, with its different modes, also allows
you to select and maintain the most comfortable
passenger compartment temperature.
The air source select lever is used to select either
“FRESH” for the introduction of the outside air, or
“RECIRC” for the circulation of the inside air. When the
lever is set to “FRESH”, the outside air is always taken
into the passenger compartment. When setting the lever
to “RECIRC” 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 lever is normally set to “FRESH” to
prevent the windshield from clouding.
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