Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual — part 7
0B–11
MAINTENANCE AND LUBRICATION
Recommended Liquid Gasket
Type
Brand Name
Manufacturer
Remarks
RTV*
Silicon Base
Three Bond 1207B
Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
For Engine Repairs
For Axle Case
Repairs T/M
Repairs T/M
Water Base
Three Bond 1141E
Three Bond
For Engine Repairs
Solvent
Three Bond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 17430
Loctite
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 Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 271
Red
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–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)
BRAKE
Brake pedal free play
6–10 mm (0.24–0.39 in)
Parking brake travel
6–7 notches
WHEEL ALIGNMENT
Toe-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 SHAFT
Flange torque
63 N·m (46 lb ft)
WHEEL AND TIRES
Size
P235/65R17
Wheel nut torque
118 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
Items
Metric Measure
U.S. Measure
Fuel tank
74 L
19.5 Gal.
* Crankcase
Oil Change with Filter
4.7 L
5.0 Qt
Oil Change without Filter
4.0 L
4.2 Qt
Coolant
A/T
11.1 L
11.7 Qt
Transmission
Automatic
8.6 L
9.1 Qt
Transfer
1.35 L
1.4 Qt
Axle
Rear
1.77 L
1.87 Qt
Front
1.25 L
1.33 Qt
Shift on the fly system
0.12 L
0.13 Qt
Power steering
1.0 L
1.1 Qt
Air conditioning (R-134a)
0.6 L
1.32 Qt
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
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
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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