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WORKSHOP MANUAL US VERSION RIGHT HAND MODEL EXP UBS PubNo. RV99_02-01.E

Manual de Isuzu trooper

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  1. 1. WORKSHOP MANUALUS VERSION RIGHT HAND MODEL EXP UBSPubNo. RV99_02-01.E
  2. 2. TOPWORKSHOP MANUAL 1998/1999UBS2000UBS2002UBS
  3. 3. HOMEPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS0AGeneral Information0BMaintenance and Lubrication
  4. 4. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS00SERVICE INFORMATION1AHEATING AND VENTILATION1BAIR CONDITIONING1DCOMPRESSOR OVERHAUL
  5. 5. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS00SERVICE INFORMATION2AFRONT END ALIGNMENT
  6. 6. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS3CFRONT SUSPENSION3DREAR SUSPENSION; COIL SPRING3EWHEELS AND TIRES
  7. 7. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.4A1CONTRNTS DIFFERENTIAL (FRONT)4A2ADIFFERENTIAL (Rear 220mm)4A2BDIFFERENTIAL (REAR 244mm)4B1DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)4B2DRIVELINE CONTROL SYSTEM (TOD)4CDRIVE SHAFT SYSTEM4D1TRANSFER CASE (STANDARD TYPE)4D2TRANSFER CASE (TOD)
  8. 8. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS5ABRAKE CONTROL SYSTEM5BANTI-LOCK BRAKE SYSTEM5CPOWER ASSISTED BRAKE SYSTEM5DPARKING BRAKES
  9. 9. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS: 6VD1 / 6VE1 SECTION No.CONTRNTS6AENGINE MECHANICAL6BENGINE COOLING6CENGINE FUEL6D1ENGINE ELECTRICAL6D2IGNITION SYSTEM6D3STARTING AND CHARGING SYSTEM6EENGINE DRIVEABILITY AND EMISSIONS6FENGINE EXHAUST6GENGINE LUBRICATION6HENGINE SPEED CONTROL SYSTEM6JINDUCTION
  10. 10. HOMEPAGE BACKPAGE NEXT 4JG2SECTION No.CONTRNTS00SERVICE INFORMATION6AENGINE MECHANICAL6A24JG2-NA / 4JG2-TURBO ENGINE6BENGINE COOLING6CFUEL SYSTEM6DENGINE ELECTRICAL6E-6FEXHAUST6G-4JX1 SECTION No.CONTRNTS6AENGINE MECHANICAL6BENGINE COOLING6CENGINE FUEL6DENGINE ELECTRICAL6EENGINE DRIVEABILITY AND EMISSIONS6FENGINE EXHAUST6GENGINE LUBRICATION6HENGINE SPEED CONTROL6JINDUCTION
  11. 11. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS7AAUTOMATIC TRANSMISSION (4L30-E)7A1TRANSMISSION CONTROL SYSTEM (4L30-E)7BMANUAL TRANSMISSION (AR-5)7BMANUAL TRANSMISSION (MUA)7CCLUTCH
  12. 12. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS8ALIGHTING SYSTEM8BWIPER / WASHER SYSTEM8CENTERTAINMENT8DWIRING SYSTEM8EMETER AND GAUGE8FBODY STRUCTURE8GSEATS8HSECURITY AND LOCKS8ISUN ROOF/CONVERTIBLE TOP8JEXTERIOR / INTERIOR TRIM
  13. 13. HOMEPAGE BACKPAGE NEXTTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No.CONTRNTS9ASEAT BELT SYSTEM9JSUPPLEMENTAL RESTRAINT SYSTEM (SRS)9J1RESTRAINT CONTROL SYSTEM
  14. 14. HOMEPAGE BACKTHIS MALUAL INCLUDES THE FOLLOWING SECTIONS:SECTION No. 10ACONTRNTS CRUISE CONTROL SYSTEM
  15. 15. SECTION GENERAL INFORMATION 0A1SECTION 0AGENERAL INFORMATION CONTENTS PAGE General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 2 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 3 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 6 Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A 8 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A10 Recommended Liquid Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A11 Recommended Thread Locking Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A11 Abbreviations Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A12Service 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 fasteners 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 specification. Following these instructions can help you avoid damage to parts and systems.
  16. 16. 0A2 GENERAL INFORMATIONGENERAL REPAIR INSTRUCTIONS 1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle. 2. Use covers on the vehicle body, seats, and floor to prevent damage and/or contaminations. 3. Disconnect the grounding cable from the battery before performing service operations. This will prevent cable damage or burning due to shortcircuiting. 4. Raise the vehicle with a jack set against the recommended lifting points (see Lifting instructions in this section). 5. Support the vehicle on chassis stands. 6. Handle brake fluid and antifreeze solution with great care. Spilling these liquids on painted surfaces will damage the paint. 7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe service operations. 8. Always use genuine ISUZU replacement parts. 9. Discard used cotter pins, gasket, plastic clips, O-rings, oil seals, lock washers, and selflocking nuts at disassembly. Normal function of these parts cannot be guaranteed if they are reused. 10. Keep the disassembled parts neatly in groups. This will facilitate smooth and correct reassembly.11. Keep fixing nuts and bolts separate. Fixing nuts and bolts vary in hardness and design according to installation positions. 12. Clean all parts before inspection or reassembly. 13. Clean the oil ports and other openings with compressed air to make certain that they are free of dirt and obstructions. 14. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation. 15. Use the recommended liquid gasket to prevent leakage. 16. Carefully observe all nut and bolt torque specifications. 17. When service operation is completed, make a final check to be sure service has been done properly and problem has been corrected. 18. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the following tools to recover and recycle the Refrigerant-134a (R-134a). For 134a: Use the R-134a Refrigerant Recovery/Recovery/ Recycling/Recharging/System (ACR4) or its equivalent to prevent the discharge of refrigerant into the air.
  17. 17. GENERAL INFORMATION 0A3HOW TO USE THIS MANUAL 1. Find the applicable section by referring to the table of contents on the introduction page of each manual. 2. In Service Information, an opening section of each manual, the troubleshooting, maintenance servicing, service data and/or information on special tools required for the service operations described in the next subsequent sections are arranged and compiled so concisely that you can see at a first glance. 3. Each section except the Service Information section is basically arranged in the following order of headings: General description On-vehicle service Unit repair4. The service operations are in two groups: one is the On-vehicle service where operations can be directly performed on the vehicle, and the other is the Unit repair where the operations are done on the work bench after removing the unit from the vehicle. 5. Each service operation section begins with a disassembled view of unit or equipment, which is useful to find relative components, service procedure, availability and contents of repair kits, etc.The number represents sequence of removal or disassembly Removal of unnumbered the parts (excluding bolts, nuts, washers, gaskets, cotter pins, etc.) is unnecessary unless replacement is needed. Where parts replacement requires specific information, instructions are given in Inspection and Repair. This frame is to be removed as a large disassembly with all the parts assembled in the frame. Each one of the parts in the frame is removed as a small disassembly. Parts to be removed or installed as a unit. 5 Parts contained in repair kit. 5 Indicates repair kit availability. When the installation (reassembly) procedure is the reverse order of the removal (disassembly) procedure, the sequence of service operation and the parts names will be omitted. Name of parts listed in sequence of service operation.
  18. 18. 0A4 GENERAL INFORMATION For illustrations where there are few items to be performed: The sequence of removal (disassembly) and the parts names will be given.6. After the illustration, the details of each operation are shown in the order the operations are carried out in the illustration. Refer to the explanations when checking importantinformation such as the notes in each operation, and places where special tools are to be used and their usage, and the specified service data.The symbol mark attached to the title indicates the action to be taken in the operations of each title. Example for this case; 1st step Reassemble pinion shaft The numbers given to the installation (assembly) procedure are the same as those given in the removal (disassembly) procedure in the illustration. Therefore, start with the larger number during reassembly. The titles of operations done in the illustration are given in bold letters. They are described in the order of the procedure of the operations. Special tools are identified with tool name and/or tool number. The drawing illustrates how the tool is used. Service data and specifications are listed in table. Important note. The action symbol indicates the step of service to be followed. Refer to the following paragraph for the meaning of each symbol.
  19. 19. GENERAL INFORMATION 0A5 7. In this manual, the following action symbols are used to indicate the type of service operations to be performed. ...Remove or disconnect...Adjust...Install or connect...Clean...Disassemble...Pay close attention - Important...Reassemble...Tighten to specified torque...Align the marks...Use special tool(s)...Correct direction...Lubricate with oil...Inspect...Lubricate with grease...Take measurement...Use liquid gasket8. The service standard is indicated in terms of Standard and Limit. The Standard means the assembly standard and standard range within which the parts areconsidered serviceable. Limit indicates the limit value (Correction or replacement is necessary when measurement is beyond this limit.)
  20. 20. 0A6 GENERAL INFORMATIONIDENTIFICATION VEHICLE IDENTIFICATION NUMBER (VIN) ISUZU MOTORS LTD.VINThis is the legal identification of the vehicle. It appears on the manufacturers Plate attached to the left of the engine compartment front end. VIN number is also stamped on the rear right side of the frame.VINJACUBS26GY7200001 Sequential Number Plant Code Model Year (Y: 2000) Wheel Base (D: Short, G: Long) Engine Type (26: 6VE1, 73: 4JX1) Vehicle Model World Manufacturer IdentifierENGINE SERIAL NUMBER The engine serial number is stamped on the left rear lower area of the cylinder block above the starter.4JX1 905RW0146VE1 905RW016
  21. 21. GENERAL INFORMATION 0A7 TRANSMISSION SERIAL NUMBER Manual: Stamped on the left side of the transmission intermediate plate.905RW015Automatic: Stamped on the identification plate, located on the left side of the transmission above the mode switch.HYDRAMATIC STRASBOURG MADE IN FRANCE SALG 20FPPART No.96 018 272 SERIAL No.0000 000 905RW018SERVICE PARTS IDENTIFICATION PLATEService parts ID plateThe 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.ISUZU MOTORS L T D. JAPAN V.I.N. M.D. ENGINE TRANS. GRADE TIRE BODY TYPE B. COLOR/TRIM OPTION905RW007
  22. 22. 0A8 GENERAL INFORMATIONLIFTING INSTRUCTIONS CAUTION: If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance.LIFTING POINTS AND SUPPORTABLE POINT LOCATIONSLong wheel Base ModelShort Wheel Base ModelLifting point Supportable point
  23. 23. GENERAL INFORMATION 0A9 LIFTING POINT; FRONT When using floor jack, lift on the center of the skid plate.SUPPORTABLE POINT; FRONT Position the chassis stands at the bottom of the frame sidemember, backward of front wheel.LIFTING POINT; REAR Position the floor jack at the center of the rear axle case when lifting the vehicle.SUPPORTABLE POINT; REAR Position the chassis stands at the bottom of the frame sidemember, just behind of the trailing link bracket.SUPPORTABLE POINT; REAR Position the chassis stands at the bottom of the rear axle case.
  24. 24. 0A10 GENERAL INFORMATIONTORQUE SPECIFICATIONS STANDARD BOLTS The torque values given in the following table should be applied where a particular torque is not specified. Nm (kgm / lbft) Nm kgcm / lbin Strength Class4.88.89.8Refined Bolt Identification84Bolt Diameter x Pitch (mm)Non-Refined89No markM 6x1.06 (60 / 527 (75 / 65M 8x1.2513 (130 / 11317 (175 / 15224 (240 / 208M10x1.2527 (2.8 / 20)37 (3.8 / 27)50 (5.1 / 37)M12x1.2561 (6.3 / 45)76 (7.8 / 56)95 (9.7 / 70)M14x1.596 (9.8 / 71)116 (11.9 / 86)142 (14.5 / 105)M16x1.5130 (13.3 / 96)170 (17.3 / 125)200 (20.4 / 148)M18x1.5188 (19.2 / 139)244 (24.9 / 180)287 (29.3 / 212)M20x1.5258 (26.3 / 190)337 (34.4 / 249)396 (40.4 / 292)M22x1.5332 (33.9 / 245)453 (46.3 / 335)530 (54.1 / 391)M24x2.0449 (45.8 / 331)570 (58.2 / 421)692 (70.6 / 511)*M10x1.526 (2.7 / 20)36 (3.7 / 27)48 (4.9 / 35)*M12x1.557 (5.8 / 42)71 (7.2 / 52)89 (9.1 / 66)*M14x2.089 (9.1 / 66)110 (11.2 / 81)133 (13.6 / 98)*M16x2.0124 (12.7 / 92)162 (16.5 / 119)191 (19.5 / 141)The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as casting, etc.FLARE NUTS Nm (kgm / lbft) Pipe diameter mm (in)TorquePipe diameter mm (in)Torque4.76 (0.187)16 (1.6 / 12)10.00 (0.394)54 (5.5 / 40)6.35 (0.250)26 (2.7 / 20)12.00 (0.472)88 (9.0 / 65)8.00 (0.315)44 (4.5 / 33)15.00 (0.591)106 (10.8 / 78)
  25. 25. GENERAL INFORMATION 0A11RECOMMENDED LIQUID GASKET TypeBrand NameManufacturerRemarksRTV* Silicon BaseThree Bond 1207B Three Bond 1207C Three Bond 1215 Three Bond 1280Three Bond Three Bond Three Bond Three BondFor Engine RepairsWater BaseThree Bond 1141EThree BondFor Engine RepairsSolventThree Bond 1104 Belco Bond 4 Belco Bond 401 Belco Bond 402Three Bond Isuzu Isuzu IsuzuFor Engine RepairsAnaerobicLOCTITE 515 LOCTITE 518Loctite LoctiteAllFor Axle Case Repairs. T/M* RTV: Room Temperature VulcanizerNOTE: 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 manufacturers 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 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 ColorLOCTITE 242BlueLOCTITE 262RedLOCTITE 270Red1. 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.GreenLOCTITE 271Application StepsApply LOCTITE to at least 1/3 of the bolts threaded area3. 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.
  26. 26. 0A12 GENERAL INFORMATIONABBREVIATIONS CHARTS LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUAL A Ampere(s) ABS Antilock Brake System A/C Air Conditioning ACCEL Accelerator ACC Accessary Adj Adjust A/F Air Fuel Ratio AIR Air Injection Reaction System ALDL Assembly Line Diagnostic Link Alt Altitude AMP Ampere(s) ANT Antenna APS Absolute Pressure Sensor ASM Assembly A/T Automatic Transmission/Transaxle ATDC After Top Dead Center Auth Authority Auto Automatic BARO Barometic Bat Battery Bat+ Battery Positive Terminal Bbl Barrel BCM Body Control Module BHP Brake Horsepower BP Back Pressure BTDC Before Top Dead Center C Degrees Celsius Cat. Conv. Catalytic Converter cc Cubic Centimeter CCC Computer Command Control CCOT Cycling Clutch Orifice Tube CCP Controlled Canister Purge CID Cubic Inch Displacement CL Closed Loop CLCC Closed Loop Carburetor Control CO Carbon Monoxide Coax Coaxial Conn Connector Conv Converter CP Canister Purge CPS Central Power Supply Crank Crankshaft CTS Coolant Temperature Sensor Cu.In. Cubic Inch CV Constant Velocity Cyl Cylinder(s) C3I Computer Controlled Coil Ignition DBM Dual Bed Monolith Diff Differential DIS Direct Ignition System Dist Distributor DOHC Double Overhead Camshaft DVM Digital Voltmeter (10 meg.) DVOM Digital Volt Ohmmeter DVDV Differential Vacuum Delay ValveEAC Electric Air Control EAS Electric Air Switching EBCM Electronic Brake Control Module ECC Electronic Climate Control ECM Electronic Control Module ECU Electronic Control Unit Engine Calibration Unit (PROM) EECS Evaporative Emission Control System EFE Early Fuel Evaporation EFI Electronic Fuel Injection EGR Exhaust Gas Recirculation EGR/TVS Exhaust Gas Recirculation/Thermostatic Vacuum Switch ELC Electronic Level Control ESC Electronic Spark Control EST Electronic Spark Control ETR Electronically Tuned Receiver EVRV Electronic Vacuum Regulator Valve (EGR) Exh Exhaust F Degrees Fahrenheit FF Front Drive Front Engine FL Fusible Link FLW Fusible Link Wire FRT Front FWD Front Wheel Drive 4WD Four Wheel Drive 4x4 Four Wheel Drive 4 A/T Four Speed Automatic Transmission/Transaxle Gal Gallon Gen Generator Gov Governor g Gram Harn Harness HC Hydrocarbons HD Heavy Duty HEI High Energy Ignition Hg Mercury HiAlt High Altitude HVAC Heater-Vent-Air Conditioning IAC Idle Air Control IC Integrated Circuit ID Identification Inside Diameter IDI Integrated Direct Ignition IGN Ignition ILC Idle Load Compensator INJ Injection IP Instrument Panel IPC Instrument Panel Cluster INT Intake J/B Junction Block km Kilometers km/h Kilometer per Hour kPa KiloPascals KV Kilovolts (thousands of volts) KW Kilowatts
  27. 27. GENERAL INFORMATION 0A13 L Liter lbft Foot Pounds lbin Inch Pounds LF Left Front LH Left Hand LR Left Rear LS Left Side LWB Long Wheel Base L-4 In-line Four Cylinder Engine MAF Mass Air Flow MAN Manual MAP Manifold Absolute Pressure MAT Manifold Air Temperature MEM-CAL Memory and Calibration Unit Max Maximum M/C Mixture Control Min Minimum mm Millimeter MPFI Multi-Port Fuel Injection MPG Miles per Gallon MPH Miles per Hour M/T Manual Transmission/Transaxle MV Millivolt NA Natural Aspirated NC Normally Closed Nm Newton Meters NO Normally Open NOx Nitrogen, Oxides of OD Outside Diameter O/D Over Drive OHC Overhead Camshaft OL Open Loop O2 Oxygen PAIR Pulse Air Injection Reactor System P/B Power Brakes PCV Positive Crankcase Ventilation PFI Port Fuel Injection PRESS Pressure PROM Programmable Read Only Memory P/N Park/Neutral P/S Power Steering PSI Pounds per Square Inch Pt. Pint Pri Primary PWM Pulse Width Modulated Qt Quart REF Reference RF Right Front RFI Radio Frequency Interference RH Right Hand RPM Revolutions per Minute RPO Regular Production Option RR Right Rear RS Right Side RTV Room Temperature Vulcanizing RVB Rear Vacuum Brake RVR Response Vacuum Reducer RWAL Rear Wheel Antilock Brake RWD - Rear Wheel DriveSAE Society of Automotive Engineers Sec Secondary SFI Sequential-port Fuel Injection SI System International SIR Supplemental Inflatable Restraint System SOHC Single Overhead Camshaft Sol Solenoid SPEC Specification Speedo Speedometer SRS Supplemental Restraint System ST Start Sw Switch SWB Short Wheel Base SYN Synchronize TAC Thermostatic Air Cleaner Tach Tachometer TBI Throttle Body Injection TCC Transmission/Transaxle Converter Clutch TCM Transmission/Transaxle Control Module TDC Top Dead Center Term Terminal TEMP Temperature TPS Throttle Position Sensor TRANS Transmission/Transaxle TURBO Turbocharger TV Throttle Valve TVRS Television & Radio Suppression TVS Thermal Vacuum Switch 3 A/T Three Speed Automatic Transmission/ Transaxle 2WD Two Wheel Drive 4x2 Two wheel Drive U-joint Universal Joint V Volt(s) VAC Vacuum VIN Vehicle Identification Number VRRRE Vehicle Refrigerant Recovery and Recycling Equipment V-ref ECM Reference Voltage VRV Vacuum Reducer Valve VSS Vehicle Speed Sensor VSV Vacuum Switching Valve V-6 Six Cylinder V Engine V-8 Eight Cylinder V Engine W Watt(s) w/ With w/b Wheel Base w/o Without WOT Wide Open Throttle
  28. 28. SECTION MAINTENANCE AND LUBRICATION 0B1SECTION 0BMAINTENANCE AND LUBRICATION CONTENTS PAGE Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B 2 Recommended Fluids, Lubricants and Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B 7 Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B10Service 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 fasteners 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 specification. Following these instructions can help you avoid damage to parts and systems.
  29. 29. 0B2 MAINTENANCE AND LUBRICATIONMAINTENANCE SCHEDULE GASOLINE ENGINE MODEL I: Inspect and correct or replace as necessary A: Adjust R: Replace or change T: Tighten to specified torque SERVICE INTERVAL: x 1,000 km 5 (Use odometer reading x 1,000 miles 3 or months whichever comes first) or months 6 GASOLINE ENGINE * Engine oil * Engine oil filter Oil leakage and contamination * Timing belt Spark plugs (For leaded fuel use) Spark plugs (Forunleaded fuel use) Exhaust system Radiator coolant concentration Cooling system for water leakage All hoses and pipes in engine compartment for clog or damage Fuel filter Fuel leakage Fuel tank * Air cleaner element Pre air cleaner Engine drive belt Valve clearance O2 Sensor (For leaded fuel use) O2 Sensor (For unleaded fuel use) CLUTCH Clutch fluid Clutch pedal travel and free play TRANSMISSION OR TRANSMISSION WITH TRANSFER CASE * Manual transmission with transfer case oil * AT Automatic transmission fluid leakage *(1) AT Automatic transmission fluid * AT Transfer case oil PROPELLER SHAFT Loose connections * Universal joints and splines for wear Universal joints and sliding sleeve (front and rear) FRONT AND REAR AXLE * Differential gear oil (Front and rear) Shift on the fly system gear oil Front axle shaft rubber boot for damage Axle case for distortion or damage Axle shafts for distortion or damage STEERING * Power steering fluid Oil leakage * Steering system for looseness or damage Power steering hose Steering wheel play Steering function Right and left turning radius Wheel alignment Joint ball for oil leakage or damage Joint ball rubber boot for damage SERVICE BRAKES Brake fluid Brake system for fluid leakage Brake function * Disc brake pads and discs wear Brake pedal travel and free play Pipes and hoses for loose connections or damageL: Lubricate 30 18 3635 21 4240 24 4845 50 27 30 54 6055 33 6660 36 7265 39 7870 42 8475 45 9080 85 90 95 100 48 51 54 57 60 96 102 108 114 12010 6 1215 9 1820 12 2425 15 30--R R R---------I I I----I I I I I ------I I--I I--I I--I I--I I---R I R--I I I--R I R--I I I--R I R--I I L--I I L--I I L--I I L----R I I I I--I I I I I--R I I I I--I I I I I---I I I I I I I I--I I I I I I I I I I--R I I I I I I I--I I I I I I I I I I--I I I I I I--I I I I I I--R I I I I I--I I I I I I--R R I--R------I I I--I I I I I R R R I I I I I I I I I I R I I R I I I I I I I I I (Check and adjust if necessary every 100,000 km or 60,000 miles) R (Replace every 150,000 km or 90,000 miles)---R-I I----I I I-I I II I L--I I L---R I I I I--I I I I I-I ---I I I R I I I I--R I I I I I I I I I----I I I I I I--R I I I I I--R R I (Replace (Replace I I I(1): Adjust or change automatic transmission fluid. *Marks:Under severe driving conditions, additional maintenance is required. Refer to Maintenance schedule under severe driving conditions.R R R R R R I I I every 165,000 km or 100,000 miles) R every 165,000 km or 100,000 miles) I I I I I I I I I -
  30. 30. MAINTENANCE AND LUBRICATION 0B3 GASOLINE ENGINE MODEL I: Inspect and correct or replace as necessary A: Adjust R: Replace or change T: Tighten to specified torque80 85 90 95 100 48 51 54 57 60 96 102 108 114 12010 6 1215 9 1820 12 2425 15 3030 18 3635 21 4240 24 4845 27 5450 30 6055 33 6660 36 7265 39 7870 42 8475 45 90--I I I--I I I--I I I--I I I--I I I--I I I----I--I--I--I--I--I----I I I I I I I--I I I I I I I--I I I I I I I--I I I I I I I--I I I I I I I--I I I I I I I----T I I I--T I R I I----T I I I--T I R I I----I ---I L----I ---I L--5 SERVICE INTERVAL: x 1,000 km (Use odometer reading x 1,000 miles 3 6 or months whichever comes first) or months PARKING BRAKE Parking brake function Parking brake lever travel Cables for looseness or damage and guide for damage Ratchet for wear or damage SUSPENSION Spring leaves for damage Mount for looseness or damage Shock absorbers for oil leakage Shock absorbers mount for looseness Rubber bushes of suspension wear or damage Spring action for loss of balance due to weakening Joint ball rubber boot for damage WHEELS Wheel pins Wheel disc for damage Hub bearinggrease Front and rear hub bearings for looseness Tire pressure and damage Tire rotation OTHERS Bolts and nuts on chassis and body Lube front free-wheeling hubsL: Lubricate*Marks:Under severe driving conditions, additional maintenance is required. Refer to Maintenance schedule under severe driving conditions.T T I I R I I I I (Rotate as required) I ---I L
  31. 31. 0B4 MAINTENANCE AND LUBRICATION DIESEL ENGINE MODEL I: Inspect and correct or replace as necessary A: Adjust R: Replace or change T: Tighten to specified torque30 18 3635 21 4240 24 4845 27 5450 30 6055 33 6660 36 7265 39 7870 42 8410 6 1215 9 1820 12 2425 15 30-R R I I I-R R I I I--I I-I I--I I-A I I-I I-I I-A I I-I I-I I-I I-I I-I I-I I-I I-I I--R R-I I I---R I R---I I I-I I L-I I L-I I L-I I L-I I L--R --I I I I I---R I I I I---I I I I I I I I-I I I I I I I I I I-I I I I I I I I-R I I I I I I I I I--I I I I I-I I I I I I-I I I I I-R I I I I I-5 SERVICE INTERVAL: x 1,000 km (Use odometer reading x 1,000 miles 3 6 or months whichever comes first) or m onths DIESEL ENGINE * Engine oil * Engine oil filter Oil leakage and contamination Idling speed and acceleration Fan belt tension and damage Timing belt Exhaust system All hoses and pipes in engine compartment for clog or damage Valve clearance * Air cleaner element Fuel filter Radiator coolant concentration Cooling system for water leakage CLUTCH Clutch fluid Clutch pedal travel and free play TRANSMISSION OR TRANSMISSION WITH TRANSFER CASE * Manual transmission with transfer case oil * AT Automatic transmission fluid * AT Transfer case oil PROPELLER SHAFT Loose connections * Universal joints and splines for wear Universal joints and sliding sleeve (front and rear) FRONT AND REAR AXLE * Differential gear oil (Front and rear) Shift on the fly system gear oil Front axle shaft rubber boot for damage Axle case for distortion or damage Axle shafts for distortion or damage STEERING * Power steering fluid Oil leakage * Steering system for looseness or damage Power steering hose Steering wheel play Steering function Right and left turning radius Wheel alignment Joint ball for oil leakage or damage Joint ball rubber boot for damage SERVICE BRAKES Brake fluid Brake system for fluid leakage Brake function * Disc brake pads and discs wear Brake pedal travel and free play Pipes and hoses for loose connections or damageL: LubricateR R I I I (Replace I I75 45 9080 85 90 95 100 48 51 54 57 60 96 102 108 114 120 R R I I I-R R I I I-R R I I II I-I I-I I-A R R I I-I I-I II I-I I-I I-I I---R I R---I I II I L-I I L-I I L-I I L-I I L-I I I I I---R I I I I---I I I I II I I I I I I I-I I I I I I I I I I-I I I R I I I I-R I I I I I I I I I-I I I I I I I I-I I I I I I I I I II I I I I-I I I I I I-I I I I I-R I I I I I-I I I I I-I I I I I IR R R R R R R R I I I I I I I I I I I I every 200,000 km or 125,000 miles) I I I I I I I INOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the left side of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back) cover for installation location of the sub (2nd) oil filter. *Marks:Under severe driving conditions, additional maintenance is required. Refer to Maintenance schedule under severe driving conditions.
  32. 32. MAINTENANCE AND LUBRICATION 0B5 DIESEL ENGINE MODEL I: Inspect and correct or replace as necessary A: Adjust R: Replace or change T: Tighten to specified torque80 85 90 95 100 48 51 54 57 60 96 102 108 114 12010 6 1215 9 1820 12 2425 15 3030 18 3635 21 4240 24 4845 27 5450 30 6055 33 6660 36 7265 39 7870 42 8475 45 90---I I I---I I I---I I I---I I I---I I I---I---I---I---I---I-I I I I I I-I I I I I I I-I I I I I I-I I I I I I I-I I I I I I-I I I I I I I-I I I I I I-I I I I I I I-I I I I I I-I I I I I I I-T I I I-T I I I-T I R I I-T I I I-T I I I-T I I I-T I R I I-T I I I-I --I --I L-I --I --I --I L-I -5 SERVICE INTERVAL: x 1,000 km (Use odometer reading x 1,000 miles 3 6 or months whichever comes first) or months PARKING BRAKE Parking brake function Parking brake lever travel Cables for looseness or damage and guide for damage Ratchet for wear or damage SUSPENSION Spring leaves for damage Mount for looseness or damage Shock absorbers for oil leakage Shock absorbers mount for looseness Rubber bushes of suspension wear or damage Spring action for loss of balance due to weakening Joint ball rubber boot for damage WHEELS Wheel pins Wheel disc for damage Hub bearing grease Front and rear hub bearings for looseness Tire pressure and damage Tire rotation OTHERS Bolts and nuts on chassis and body Lube front free-wheeling hubsL: Lubricate*Marks:Under severe driving conditions, additional maintenance is required. Refer to Maintenance schedule under severe driving conditions.T T I I R I I I I (Rotate as required) -I --I L
  33. 33. 0B6 MAINTENANCE AND LUBRICATIONMAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS Severe driving conditions A: Repeated short trips B: Driving on rough roads C: Driving on dusty roads D: Driving in extremely cold weather and/or salted roads ItemIntervalCondition ABCDA+DEngine oilG D: Change every 5,000 km (3,000 miles) : Change every 5,000 km (3,000 miles)qqEngine oil filterG D: Replace every 10,000 km (6,000 miles) : Replace every 5,000 km (3,000 miles)qqAir cleaner elementG D: Replace every 20,000 km (12,000 miles) : Replace every 40,000 km (25,000 miles)qPower steering fluidReplace every 50,000 km (30,000 miles)qSteering system for looseness or damageInspect every 5,000 km (3,000 miles)qUniversal joints and sleevesInspect for wear and lubricate every 7,500 km (4,500 miles)qTransmission with transfer case oilMTChange every 20,000 km (12,000 miles) after changing at initial 10,000 km (6,000 miles)ATTransmission : Change every 32,000 km (20,000 miles)TFInspect every 5,000 km (3,000 miles)qTiming beltG: Replace every 120,000 km (75,000 miles)qqq qqq qEXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE Explanations of the services listed in the proceeding Maintenance Scheduled are presented in Service Information section of each manual.qqChange every 20,000 km (12,000 miles) after changing at initial 5,000 km (3,000 miles)Disc brake pads and discsqqTransfer: Change every 20,000 km (12,000 miles) after changing at initial 10,000 km (6,000 miles)Differential oilqReplace all questionable parts and note any necessary repairs as you perform these maintenance procedures.q
  34. 34. MAINTENANCE AND LUBRICATION 0B7RECOMMENDED FLUIDS, LUBRICANTS AND FUELS In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to select and use correctly best lubricants and diesel fuels. When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to the maintenance schedule for each vehicle model. The lubrication intervals in the maintenance schedule and the coverage and period of new vehicle warranty are based on the use of ISUZU genuine lubricants or recommended lubricants as given in the chart which will serve as a guide for selecting lubricants of proper brand name. LUBRICATIONDiesel engine crankcaseGasoline engine crankcaseManual transmission Transfer caseDifferential Shift on the fly system (GL-5 only)MAKEBRAND / TYPEGRADE APIISUZU GENUINE ISUZU GENUINE ISUZU GENUINE ISUZU GENUINE EXXON / ESSO EXXON / ESSO MOBIL CALTEX / CHEVRON SHELL ELF TOTALBESCO MULTI Z TYPE CE (10W-30) BESCO MULTI Z (10W-30) BESCO MULTI Z SUV (5W-30) BESCO S 3 (10W, 20W, 30, 40) ESSOLUBE XD-3+ (15W-40) ESSOLUBE XT331 (15W-40) DELVAC HP (15W-40, 20, 30, 40) DELO CXJ (15W-40, 30, 40) RIMURA D (15W-40, 30, 40 PERFORMANCE TROPHY (15W-40) RUBIA XT (15W-40)ISUZU GENUINE ISUZU GENUINE ISUZU GENUINE EXXON / ESSO EXXON / ESSO MOBIL CALTEX / TEXACO SHELL ELF TOTALBESCO RACING ACE (7.5W-30) BESCO MULTI ACE (7.5W-30) BESCO ACE (10W-30) ESSO SUPERFLO (15W-40, 15W-50, 20W-50) ESSO UNIFLO (15W-40, 15W-50, 20W-50) MOBIL SUPER XHP (15W-40, 15W-50, 20W-50) HAVOLINE FORMULA-3 (15W-40, 20W-50) HELIX SUPER (10W-30) SUPER SPORTI S (15W-40) QUARTZ 5000 (15W-40, 20W-50)ISUZU GENUINE EXXON / ESSO EXXON / ESSO MOBIL CALTEX / TEXACO SHELL ELF TOTALBESCO GEAR OIL TRANSAXLE (5W-30) ESSOLUBE XD-3+ (15W-40) ESSOLUBE XT331 (15W-40) MOBIL SUPER (10W-30) HAVOLINE FORMULA-3 (15W-40, 20W-50) RIMURA D (15W-40) SUPER SPORTI S (15W-40) QUARTZ 5000 (15W-40, 20W-50)ISUZU GENUINE ISUZU GENUINE EXXON / ESSO MOBIL CALTEX SHELL ELF TOTALBESCO GEAR OIL SH (80W-90, 90, 140) BESCO SHIFT ON THE FLY (75W-90) GEAR OIL GX (85W-90) MOBILUBE HD (80W-90, 85W-140) THURBAN GL-5 EP (80W-90, 85W-140) SPIRAX HD (90, 140) TRANSELF TYPE B (80W-90, 85W-140) TRANSMISSION TM (80W-90, 85W-140)GL-5 GL-5 GL-5 GL-5 GL-5 GL-5 GL-5 GL-5BESCO GEAR OIL LSD (140) GEAR OIL LSA (90) MOBILUBE HD LS (80W-90) GEAR OIL LSD (90) TRANSELF TYPE BLS (90) TRANSMISSION DA (85W-90)GL-5 GL-5 GL-5 GL-5 GL-5 GL-5ISUZU GENUINE EXXON / ESSO Differential MOBIL (Limited Slip Differential) CALTEX ELF TOTALCE CD CD CD CG4/CF CG-4/CF CF/CE CF CD/CF CE CF-4 SG SF SE SJ SJ SJ SJ SJ SG SJ SG CG-4/CF CG-4/CF SH SH CD/CF SG/CD SJ/CFACEAE2/B2 E2/B2E3 E2A2 A2 A3A2 E2/B2 E2/B2A2/B2
  35. 35. 0B8 MAINTENANCE AND LUBRICATIONLUBRICATIONMAKEBRAND / TYPEISUZU GENUINE EXXON / ESSO MOBIL CALTEX SHELL ELF TOTALBESCO ATF II, ATF III ESSO ATF D (DEXRON II-D) MOBIL ATF (DEXRON III) ATF HD (DEXRON II) SHELL DONAX TA (DEXRON II-D) ELFMATIC G3 (DEXRON III) TOTAL FLUID IID (DEXRON II-D)Propeller shaft sliding yoke, Universal joint Grease fitting (General purpose grease)ISUZU GENUINE EXXON / ESSO MOBIL CALTEX / TEXACO SHELL TOTALBESCO L-2 GREASE (No.2), L-3 GREASE (No.3) RONEX MP (No.2) MOBILGREASE HP 222 (No.2) STARPLEX-2 (No.2) SHELL RETINAX A (No.2) MULTIS EP2, EP3 (No.2, No.3)Propeller shaft sliding yoke Universal joint General purpose grease in MolybdenumISUZU GENUINE EXXON / ESSO EXXON / ESSO CALTEX TOTALONE LUBER MO GREASE BEACON Q2 (No.2) MULTIPURPOSE GREASE (Moly) (No.2) MOLYTEX GREASE EP2 (No.2) TOTAL MULTIS MS2 (No.2)ISUZU GENUINE TEXACO / CALTEXBESCO LLC SUPER TYPE E HAVOLINE EXTENDED LIFE ANTIFREEZE COOLANT HAVOLINE XLC EXTENDED LIFE COOLANT 6280Automatic transmission Power steering()Engine cooling systemFLUID Clutch and brake fluid reservoirTYPE Besco brake fluid (For light duty) Hydraulic brake fluid SAE J1703 FMVSS 116 DOT.3 gradeNOTE: When the recommended lubricants are specified in the workshop manual, follow them.GRADE APIACEA
  36. 36. MAINTENANCE AND LUBRICATION 0B9 DIESEL FUEL/APPLICABLE STANDARD JIS (JAPANESE INDUSTRIAL STANDARD) DIN (DEUTSCHE INDUSTRIE NORMEN) SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) BS (BRITISH STANDARD) NOTE: Use the applicable standard or equivalent for diesel fuels.Based on K2204 GAS OIL Based on EN590 : 1997 Based on SAE J-313C Based on BS EN590 : 1997
  37. 37. 0B10 MAINTENANCE AND LUBRICATIONOIL VISCOSITY CHART Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table.OIL VISCOSITY CHART FOR GASOLINE ENGINE APPLY GASOLINE ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE(Single grade)SAE 30SAE 20,20WSAE 10W25C 13F15C 5F0C 32F15C 60F38C 100F(Multi grade) SAE 5W-30SAE 10W-30SAE 15W-40,20W-40,20W-50 EG-01OIL VISCOSITY CHART FOR DIESEL ENGINE APPLY DIESEL ENGINE OIL(Multi grade)VISCOSITY GRADE - AMBIENT TEMPERATURESAE 5W-30SAE 10W-3025C 13F15C 5F10C 14F0C 32F15C 60F25C 30C 77F 86F 905RW017
  38. 38. MAINTENANCE AND LUBRICATION 0B11OIL VISCOSITY CHART FOR MANUAL TRANSMISSION AND TRANSFER CASE APPLY ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE(Single grade)SAE 40,50SAE 3025C 13F10C 14F5C 41F10C 50F20C 68F35C 95F(Multi-grade) SAE 5W-30SAE 10W-30SAE 15W-40,20W-40,20W-50 ET-12OIL VISCOSITY CHART FOR FRONT AXLE (Manual and Auto locking hub model) AND REAR AXLE APPLY GEAR OIL GEAR OIL VISCOSITY GRADE - AMBIENT TEMPERATURE (Single grade)SAE 140SAE 90SAE 80WSAE 75W25C 13F10C 14F0C 32F(Multi grade) SAE 75W-90SAE 80W-90SAE 80W-140 GA-0615C 59F30C 86F35C 95F
  39. 39. 0B12 MAINTENANCE AND LUBRICATIONOIL VISCOSITY CHART FOR FRONT AXLE (Shift on the fly model) APPLY GEAR OIL GEAR OIL VISCOSITY GRADE AMBIENT TEMPERATURE (Multi grade)SAE 75W 90SAE 80W 90, 80W 14025C10C0C15C30C35C13F14F32F59F86F95F
  40. 40. SECTION SERVICE INFORMATION 00 1SECTION 00SERVICE INFORMATION CONTENTS PAGE Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 3 Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052
  41. 41. 00 2 SERVICE INFORMATIONMEMO
  42. 42. SERVICE INFORMATION 00 3TROUBLESHOOTINGCONTENTS PAGE Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 4 Heating Cycle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 Fan Control Knob (Fan Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 Blower Motor Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 Blower Motor Does Not Run In Certain Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 Blower Motor Does Not Stop at OFF Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 Ceramic Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 Ceramic Heater Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 Ceramic Heater Does Not Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 Air Conditioning Cycle Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 Checking Refrigerant System with Manifold Gauge. . . . . . . . . . . . . . . . . . . . . . . . . 0024 Magnetic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 6VD1/6VE1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 4JG2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 4JX1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 Condenser Fan Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 Condenser Fan Does Not Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 Individual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041
  43. 43. 00 4 SERVICE INFORMATIONCIRCUIT DIAGRAM 6VD1/6VE1 (RHD) 8B / R+FL-1 80A MAINFL-4 30A CONDENSER FAN1.25 L/OP-2P-1 5WF-6 15A RR COOLER0.5 LG/YP-5P - 100.5 LG30BP-65W8B_5B70.5 BRFRAME5W0.5 BRENG.0.5 BRH-16H-14RELAY;STARTER (1)BODY0.5 BR1P-72 I-23A/C SW610130.5 LGI-23163W1 0.5 LGH-24H-510.85W/GH-26 0.5 LGH-13I-23 1 2B-36B-363 0.5 BR1RELAY ; HEATER AND A/CI-42 1ELECTRONIC THERMOSTAT16 0.5 P/GH-16I-42B-36342 C-20 10A AIR CON. 0.3 G/Y3L/RB-36I-423LC-19 25A BLOWER 0.3 G/Y20.3 G/Y0.3BB-5HEATER BEZEL ILLUMINATION3 2I-410.85 G/R2L/BH-20BLOWER RESISTORI-230.3 G/YRELAY ; TAIL (4)2L/B10.3 R/GB-52ILLUMINATION CONTROLLER (3)BLOWER MOTORM5 36 2 L/RI-41 6 I-411.25 L/O4 1 I-41I-1831I-18I-185 1.25 L/YI-414 I-18I-18 20.85 L/W2B1.25BI-23I-18 FAN SW12BH-20BODY-RHB-19BODY-LHB -1D08RY00128
  44. 44. SERVICE INFORMATION 00 50.5 LG20.5 LGH-51(IF EQUIPPED) 30.5 BRTRIPLE SWC-250.5 G/W 20.5 W/G5 H - 41 0.5G/B0.5G/B0.5BR/Y 7 H - 41 0.5BR/YPCM (E15)3PCM (B14)10.5 W/G X-6X-19471 X-19X-19536H-15C-391 1H-31 0.5LG/BMAGNETIC CLUTCHX-19X-6 3E-342 X-69H-6 0.5BR/Y1 X-60.5LG/BX-740.5LG/BX-76 H-412 H-42 0.5 BR1 X-7RELAY ; RR COOLER2 X-74RELAY; A/C COMPRESSOR1 0.5 G/O0.5 P/G0.5 BRRELAY ; A/C THERMOC-75 1H-50RR COOLER CONNECTORMH-50 0.5BRELAY; CONDENSER FANX-5H-51 0.5 BRX-530.5 BRX-50.5B3 X-52CONDENSER FANH-4141.25 L/O121.25LH-510.5 G/W0.5 LG/Y40.5 W/GC - 250.5 G/WC-250.3G/YC - 2520.5 BR1 0.5 LGPRESSURE SW (CONDENSER)3BC-75 2R-3BODY-RR1.25B3 H - 160.3 G/YFENDER-RHC - 391.25 B 1D08RY00129
  45. 45. 00 6 SERVICE INFORMATION6VD1/6VE1-(LHD)8B / R+FL-1 80A MAINFL-4 30A CONDENSER FAN1.25 L/OP-2 5W FL-2 50A KEY SWP-5_8B30BP-6P - 10FRAMEH-14P-7ENG.0.5LG/Y12H-14BODYF-1 15A RR COOLER5W3W/BP-15W5B3W/B 170.5 BR0.5 BRH-1642 B - 1114B - 11H - 260.5 LGB22 3WOFFACCIG2STIG1STARTER SWB10.5 BR3W/BI - 23A/C SW19 0.5LG0.5LGI - 23H-91 0.5 LGH - 510.5 LG1C-11 10A AUDIO(ACC),MIRROR 0.5O/G60.5 BR3L/BB-11I - 23 112B-36B-363 I-42RELAY ; HEATER AND A/C1ELECTRONIC THERMOSTAT21 0.5 P/GH-16I-42B-36342 C-20 10A AIR CON. C-19 25A BLOWER0.3 G/Y3L/RB-36I-423L0.3 G/Y1 0.3 G/Y0.5BB-5B-50.85 G/R2L/BHEATER BEZEL ILLUMINATION3 2 I-41BLOWER RESISTORI - 230.5 R/GFUSE F-1220.3G/YBLOWER MOTOR ILLUMINATION CONTROLLER (3)M5 I - 23 6 2 L/RI-411.25 L/O4 1 I-413 I - 18I - 18 20.85 L/W15I - 18 FAN SWBODY-LHB-19BODY-RH0.3G/Y1I - 18 51.25 L/YI-41I - 182B64 I - 18H - 482B1.25B3 I-41B-2D08RY00130
  46. 46. SERVICE INFORMATION 00 7(IF EQUIPPED) 2 0.5 LG0.5 LGH-510.5 BR30.5 LG/YC-250.5 W/R4312 H-41H-513X-52 X-52RELAY ; A/C THERMO0.5 W/R0.5 BR X-6X-60.5B0.5G/B397 C-3931 1H-31 C-75 1RR COOLER CONNECTORMH-50 0.5B1E-3X-1955H-50 PCM (B14)H-6X-194H-150.5LG/B5 H - 410.5BR/Y7 H - 410.5BR/Y31 X-191.25LX-74X-190.3G/YX-742 X-60.5LG/BX-71 X-60.5LG/B1X-70.5BR/YH-412RELAY ; RR COOLER46PCM (E15)0.5 BRX-5RELAY; A/C COMPRESSOR0.5 P/G10.5 G/OX-50.5 BRH-42RELAY; CONDENSER FAN0.5G/W2CONDENSER FAN4 H-511.25 L/O0.5G/W3BMAGNETIC CLUTCHC-75R-32 17 H - 12BODY-RR1.25B2C - 250.5 W/RC - 250.5G/W1DUAL PRESSURE SW or TRIPLE SW0.5 BR0.5 BRTRIPLE SWC-250.3 G/Y 2 FENDER-RHC-39D08RY00131
  47. 47. 00 8 SERVICE INFORMATION4JG2 (RHD) 8B / R+FL-1 80A MAINFL-4 30A CONDENSER FAN1.25 L/OP-2P-1 5WF-6 10A RR COOLER0.5 LG/YP-5_70.5BR8B30B5W0.5 BR5B0.5 BRH-162I-23A/C SW1 H-14P-7 FRAME6 I-2313 0.5LG0.5LG0.5 LGH-240.5 LGENG.0.5BRP - 101 H-510.5 BR5WP-6 BODYI-231C-251RELAY ; CHARGE (1)PRESSURE SW (CONDENSER) 3W1016C-250.85W/G0.5 G/WH-2610 H-410.5 G/W2 B-36RELAY ; A/C THERMO43C-20 10A AIR CON.I-42C-19 25A BLOWERX-5 1ELECTRONIC THERMOSTAT16 0.5 P/GI-42H-16X-5 30.5 P/G3LI-42H-41 0.5G/O0.3G/YB-5BLOWER MOTORI-230.5G/OILLUMINATION CONTROLLER (3)0.5G/OMAGNETIC CLUTCH0.85 G/R2L/B3 BLOWER RESISTOR1 E-30.3G/YHEATER BEZEL ILLUMINATION2 H-200.3 R/G2L/BRELAY ; TAIL (4)121H-5B-5I-4146 22M2 X-50.5 G/O31X-5B-36 3L/RB-360.3G/YRELAY ; HEATER AND A/C0.5 LG10.5 G/WH-51B-360.3B2 40.5 BRH-135 I-23I-41 4 I-411.25B11.25L/O 1.25L/Y 0.85L/W4 I-180.3GYI-18312B6I-416 2L/RI-180.5 G/O3 I-41C-69I-185 I-1812 I-18 FAN SWVSV; FICD1 H-20C-69BODY-RHB-19BODY-LHB-10.5 B2B27 FENDER-LHC-16D08RY00124
  48. 48. SERVICE INFORMATION 00 9(IF EQUIPPED) 2 0.5 LGH-510.5 LG3 TRIPLE SWC-250.5 LG/YC-250.5 W/R41.25 L/O30.5 W/RH-512X-19X-6X-194361 1 C-75 1H-50 RR COOLER CONNECTORM0.5BH-50 2CONDENSER FAN0.5LG/BH-310.5B1X-195H-15C-391 X-191.25L0.5B0.5LG/BX-6 342 X-6RELAY; CONDENSER FAN0.5 W/G 1X-60.5LG/BRELAY ; RR COOLER0.5 BRH-423BC-75 2BODY-RR1.25BR-37 C-39 FENDER-RH3 C-39 D08RY00125
  49. 49. 00 10 SERVICE INFORMATION4JG2 (LHD)8B / R+FL-1 80A MAINFL-4 30A CONDENSER FAN1.25 L/OP-2 5W FL-2 50A KEY SWP-5_8B30BP-6P - 10H-14P-7ENG.0.5LG/Y12H-14BODYF-1 15A RR COOLER5W3W/BP-1FRAME5W5B3W/B 14170.5 BRH - 260.5 BRH-163W/B 40.5 LG0.5 BR 2 3WOFFACCIG2B2STB1IG1B - 11STARTER SW2 B - 11I - 23A/C SW60.5 BR1C-11 10A AUDIO(ACC),MIRROR 0.5O/G19 0.5LGI - 230.5LGH-91 0.5 LGH - 510.5 LG3L/BB-11I - 23 112B-36B-363 I - 42RELAY ; HEATER AND A/C1ELECTRONIC THERMOSTAT21 0.5 P/GH - 16I - 42B-36343L/RB-36I - 422 C-20 10A AIR CON. C-19 25A BLOWER3L0.3 G/Y1 0.5BB-50.3 G/YBLOWER MOTOR ILLUMINATION CONTROLLER (3)M B-52L/BHEATER BEZEL ILLUMINATION0.85 G/R2L/BH - 48 4 3 2 I - 41BLOWER RESISTORI - 230.5 R/GFUSE F-1225 36 2 L/R6 I - 411.25 L/O4 1 I - 41I - 183 I - 18I - 18 20.85 L/WI - 1815 FAN SWBODY-LHB-19BODY-RH0.3G/Y1I - 18 51.25 L/YI - 414 I - 182BI - 41H - 48 2B1.25BI - 23B-2D08RY00126
  50. 50. SERVICE INFORMATION 00 11(IF EQUIPPED) 2 0.5 LG0.5 LGH-510.5 BR3 TRIPLE SWC-250.5 BRC-250.5 W/R0.5 LG/Y 1031X-5H-512 X-52RELAY ; A/C THERMO420.5BE-331.25L1 10.5LG/BH-31 C-75 1RR COOLER CONNECTOR C-69X-1955H-50VSV;FICDMH-50 2C-75 3B0.5 G/O 11 X-190.3B2C-69X-194H-15C-39 1MAGNET CLUTCHX-60.5B0.5 G/O1X-19X-6 3H-542 X-60.5LG/B0.5 G/OH-411 X-60.5LG/B60.5B0.5 P/GX-5RELAY ; RR COOLER30.5 G/OX-50.5 W/RH-42RELAY; CONDENSER FANH-41CONDENSER FAN0.5G/W1.25 L/O4 H-5123 C-16R-3BODY-RR1.25B0.5G/W0.5 W/R2C - 250.5 BRC - 250.5G/W1DUAL PRESSURE SW or TRIPLE SW42 FENDER-RHC-39D08RY00127
  51. 51. 00 12 SERVICE INFORMATION4JX1 (RHD)8B / R+FL-1 80A MAINFL-3 40A C/HEATER3W/LP-25WP-1P-5 70.5 BR0.5BRH-1615W2C-25 1ENG.FRAMEPRESSURE SW (CONDENSER) C-2516X-2113 H-242CHARGE RELAY(1)A/C SW 0.5BR0.5LG0.5 G/W0.85W/G12 H-412 B-36 I-23HEATER & A/C RELAY1X-5I-42X-5 I-42H-163LI-42X-5 340.5 P/GX-1270.5 Y/G DIODE0.5G/OBLOWER RESISTORI-23B-4422 0.5 G/W FULL HOT SW4 H-17B-49522L/R 6I-41 4 I-41 11.25L/O 1.25L/Y 0.85L/WI-18I-1831I-18I-1850.3 G/Y0.3G/Y0.3G/Y8 H-261 1B-48E-27I-18CERAMIC HEATER2 2BI-4140.5G/O6B-49ECM (JI-31)0.5G/O1I-23 315 H-133W/G31.25B1H-60.3G/Y0.85 G/R2L/BH-20ILLUMINATION CONTROLLERHEATER BEZEL ILLUMINATION20.3 R/G2L/BTAIL RELAY (4)1I-414B-44B-5I-41X-12H-15H-41BLOWER MOTOR2X-123 110.3G/YB-52X-1222 0.3B16 0.5 P/G0.5G/O1ELECTRONIC THERMOSTAT0.3G/YC-19 25A BLOWERM13C-20 10A AIR CON.H-41X-5CERAMIC HEATER RELAY452A/C THERMO RELAYB-3633L/RB-36ECM (J1-23)0.5G/B 10.5 LGB-3636 I-2310.5 LG3W2 I-23H-13X-2140.5 G/WH-2610THRMO SW RELAY0.5 G/YBODYH-14X-210.5 G/BP-70.5BRP - 105WP-61X-213W/G5B0.5 LG30B8B_I-18B-48FAN SW122B2BH-20MAGNETIC CLUTCHBODY-RHB-19BODY-LHB-2D08RY00132
  52. 52. SERVICE INFORMATION 00 13THERMO SW 0.5G/B2 C-741190.5G/WC-74H-90.5G/W4 ENGINE WARMING SWI-25 2 I-25 I-25I-25 5315 H-16160.5BH-422 H-5ECM (J2-11)50.5BH-261.25B1 0.3R/G0.5 L/PILLUMINATION CONTROLLERH-160.5 L/PTAIL RELAY(4)I-256 0.85G/R0.5 L/P14 0.85G/RD08RY00133
  53. 53. 00 14 SERVICE INFORMATION4JX1 (LHD)8B / R+FL-1 80A MAINFL-3 40A C/HEATER3W/LP-25WP-1P-5 170.5 BR0.5BRH-1615W2C-25 1ENG.FRAMEC-2514X-2119 H-92STARTER SW (ACC) 0.5 LG3W2 I-2312 H-410.5LG2 B-361X-5X-50.3G/Y1 ELECTRONIC THERMOSTAT16 0.5 P/GI-42H-133LI-42X-5 340.5 P/GX-1270.5 Y/G DIODE0.5G/O I-23ILLUMINATION CONTROLLER2 0.3 G/W 1 ECM (JI-31)B-494 H-17FULL HOT SW B-4952I-23 6 2L/R 6 I-41 4 I-41 11.25L/O 1.25L/Y 0.85L/WI-18I-1831I-18I-1850.3G/Y0.3G/Y10 H-26 1 B-481 E-27I-18CERAMIC HEATER2 2BI-4140.5G/O35 H-133W/G3 BLOWER RESISTORB-4420.5G/O0.85 G/R2L/BH-481.25B1H-60.3G/YHEATER BEZEL ILLUMINATION40.3 R/G2L/BTAIL RELAY (4)2I-414B-44B-5I-41X-12H-12H-41BLOWER MOTOR2X-123 140.3G/YB-52X-1221 0.5BCERAMIC HEATER RELAYI-42C-19 25A BLOWERM13C-20 10A AIR CON.H-41X-50.5G/O3L/R452A/C THERMO RELAYB-363ECM (J1-23)0.5G/B 10.5 LGI-23HEATER & A/C RELAY B-3636 0.5 G/W0.5O/G0.5BRA/C SWI-23B-36X-2140.5 G/WH-261THERMO SW RELAYPRESSURE SW (CONDENSER)0.5 G/YBODYH-14X-210.5 G/BP-70.5BRP - 105WP-61X-213W/G5B0.5 LG30B8B_I-18B-48FAN SW1522B2BH-48MAGNETIC CLUTCHBODY-LHB-19BODY-RHB-2D08RY00134
  54. 54. SERVICE INFORMATION 00 15THERMO SW 0.5G/B2 C-7410.5G/WC-7417 H-240.5G/W4 ENGINE WARMING SWI-25 2 I-25 I-25I-25 5315 H-16160.5BH-422 H-5ECM (J2-11)16 H-250.5B1 0.3R/G1.25BILLUMINATION CONTROLLERH-160.5 L/PTAIL RELAY(4)I-256 0.85G/R0.5 L/P6 0.85G/RD08RY00135
  55. 55. 00 16 SERVICE INFORMATIONHEATING CYCLE TROUBLESHOOTING TROUBLE No heating or Insufficient heating.1. 2.3. 4.POSSIBLE CAUSE Blower motor does not run, or runs improperly. Engine coolant temperature is low.Insufficient engine coolant. Circulation volume of engine coolant is insufficient. 5. 6.7. 8. Control knob moves but mode door does not operate.1.The mode door cannot be set to the mode selected.1.2.2.Heater core clogged or collapsed. The heater core is not provided with air sent from the blower motor. Duct connections defective or unsealing. Ceramic heater defective. CORRECTION Refer to FAN CONTROL KNOB (FAN SWITCH) Troubleshooting. Check the engine coolant temperature after warming up the engine and check the thermostat. Replace as necessary. Add engine coolant as required. Check if the water hose to the heater core is clogged, collapsed or twisted. Repair or replace as necessary. Check water pump function. Repair or replace as necessary. Clean or replace as necessary. Repair the temperature control link unit or mode doors. Repair or adjust the control cables. Repair or replace as necessary.Refer to CERAMIC HEATER Troubleshooting.Cable attaching clip is not correct. Link unit of heater unit or blower assembly defective.Repair.Repair.Link unit of heater unit or blower assembly defective Control cable is not adjusted.Repair.Adjust.
  56. 56. SERVICE INFORMATION 00 17FAN CONTROL KNOB (FAN SWITCH) Current flows to the blower motor through the Heater & A/C relay (B-36) to activate the rotation of the blower motor by turning ON the fan controlknob (fan switch). Blower motor speed is controlled in stages by the resistor, by operating the switch from LOW to HIGH.B-36 RELAY; HEATER & ACC-19 25A BLOWERB-5B-5 RHD12 BLOWERM MOTOR 21I-18 2 FAN SW.63365421BLOWER RESISTOROFFI-411B-1 B-2B-1B-2I-411 42 5B-53 61 2(RHD) BODY-LH (LHD) BODY-RHB-361234I-181 42 53 6D08RY00167
  57. 57. 00 18 SERVICE INFORMATIONBLOWER MOTOR DOES NOT RUN IS BLOWER RELAY (B-36) OK?YESNO IS NO. C-19 (25A) FUSE OK?REPLACEYESNO IS RESISTOR OK?REPLACEYESNO IS FAN CONTROL KNOB (FAN SWITCH) OK?REPLACEYESNO IS BLOWER MOTOR OK?REPLACE CONTROL LEVER ASSEMBLYYESNO TURN THE IGNITION SWITCH ON (ENGINE IS RUNNING) FAN CONTROL KNOB (FAN SWITCH) ONREPLACE CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. B5-1 (NO. B5-2; RHD)YESPOOR GROUND OR OPEN CIRCUIT EITHER BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. B5-2 (NO. B5-1; RHD) AND NO. I-41-2 OR NO. I18-1 AND BODY GROUND NO. B-2 (NO. B-1; RHD)NOOPEN CIRCUIT BETWEEN NO. C-19 (25A) FUSE AND NO. B5-1 (NO. B5-2; RHD)
  58. 58. SERVICE INFORMATION 00 19BLOWER MOTOR DOES NOT RUN IN CERTAIN POSITION 1 : (LOW) 2 : (MEDIUM LOW) C 3 : (MEDIUM HI) D 4 : (HIGH) * CHECKING IS PERFORMED ONLY WHEN IN THE MALFUNCTION MODE. ABLOWER MOTOR DOES NOT RUN ATBPOSITION IS RESISTOR OK?YESNO IS FAN CONTROL KNOB (FAN SWITCH) OK?REPLACEYESNOCONDITION: OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. I41-1 AND NO. I18-2 B CONDITION: OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. I41-4 AND NO. I18-5 C CONDITION: OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. I41-6 AND NO. I18-3 D CONDITION: OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. I41-3 AND NO. I18-6REPLACE CONTROL LEVER ASSEMBLYABLOWER MOTOR DOES NOT STOP AT OFF POSITION IS FAN CONTROL KNOB (FAN SWITCH) OK?YESNOSHORT CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. B5-2 (NO. B5-1 : RHD) AND NO. I41-2 (OR) NO. I41-3 AND NO. I18-6 (OR) NO. I41-6 AND NO. I18-3 (OR) NO. I41-4 AND NO. I18-5 (OR) NO. I41-1 AND NO. I18-2REPLACE CONTROL LEVER ASSEMBLY
  59. 59. 00 20 SERVICE INFORMATIONCERAMIC HEATER When the fan control knob (fan switch) turns on with the temperature control knob set to FULL HOT (full hot switch ON), the ceramic heater in the heater unit turns on and the blow temperature goes up. When the ceramic heater turns on, FICDstarts to operate at the same time. When either one of the fan switch, the full hot switch or the thermo switch (which turns on when the coolant temperature gets below 80C (176F) turns off, the ceramic heater also turns off.X-21 B-36 FL-3 40A C/HEATER12 1FL-1 80A MAIN4C-20 10A A/CECM (J1-23)33RELAY; THERMO SW2 4RELAY; HEATER A/CX-12 B-19 1 3RELAY; CERAMIC HEATERB-48 2 41 CERAMIC HEATER2I-18 1 4DIODE 4FAN SW.321B-442 11 FULL HOT SW. 2B-49 (RHD)B-1(LHD)B-2B-1B-18B-2B-481 2B-36X-121234X-21B-4912 1I-18B-441 2 3 41 221 42 53 6D08RWD66
  60. 60. SERVICE INFORMATION 00 21CERAMIC HEATER DOES NOT OPERATE ARE NO. FL-3 (40A) AND NO. C-20 (10A) OK?YESNOREPLACEARE A/C AND CERAMIC HEATER RELAYS OK?YESNOREPLACEARE BLOWER MOTOR AND FAN SW. OK?YESNOREPLACEIS FULL HOT SW. OK?YESNOREPLACEDOES TEMP. CONTROL LINK (HEATER UNIT) OPERATE CORRECTLY?YESNOIS THERMO RELAY OK?DOES CONTROL LEVER CABLE OPERATE CORRECTLY?NOYESADJUST OR REPLACEREPAIR OR REPLACE TEMP. CONTROL UNITYESNO TURN THE IGNITION SW. ON (ENGINE IS RUNNING) CERAMIC HEATER ONREPLACECHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. B48-1YESNOOPEN CIRCUITCHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. B48-2YESNOCERAMIC HEATER DEFECTIVECHECK THE CERAMIC HEATER OR CERAMIC HEATERRELATED HARNESS FOR A POOR GROUND AND REPAIR IT AS NECESSARY
  61. 61. 00 22 SERVICE INFORMATIONCERAMIC HEATER DOES NOT STOP WHEN THE IGNITION SW. OFF, DOES CERAMIC HEATER STOP?YES SHORT CIRCUIT BETWEEN CHASSIS SIDE RELAY TERMINAL NO. X12-3 AND CHASSIS SIDE CONNECTOR TERMINAL NO. B49-1NO CERAMIC HEATER RELAY DEFECTIVE
  62. 62. SERVICE INFORMATION 00 23AIR CONDITIONING CYCLE TROUBLESHOOTING TROUBLEPOSSIBLE CAUSECORRECTION1. Magnetic clutch does not runRefer to MAGNETIC CLUTCH troubleshooting2. Compressor is not rotating properly Drive belt loosened or brokenNo cooling or insufficient coolingAdjust the drive belt to the specified tension or replace the drive belt Clean the magnetic clutch face or replace Adjust the clearance (Refer to Section 1D COMPRESSOR OVERHAUL Replace the compressorMagnetic clutch face is not clean and slips Incorrect clearance between magnetic drive plate and pulleyCompressor oil leaks from shaft seal or shell Compressor seized 3. Insufficient or excessive charge of refrigerant 4. Leaks in the refrigerant system5. Condenser clogged or insufficient radiation6. Temperature control link unit of the heater unit defective 7. Unsteady operation due to foreign substance in expansion valve 8. Poor operation of electronic thermostat 1. Evaporator clogged or frostedReplace the compressor Discharge and recover refrigerant. Recharge to specified amount. Check refrigerant system for leaks and repair as necessary Discharge and recover refrigerant. Recharge to specified amount. Clean the condenser or replace as necessary Check radiator or condenser fan function Repair the link unitReplace the expansion valve2. Air leaking from cooling unit or air duct 3. Blower motor does not rotate properlyCheck electronic thermostat and replace as necessary Check evaporator core and replace or clean the core Check evaporator and duct connection, then repair as necessary Refer to Section 00 for FAN CONTROL KNOB (FAN SWITCH) troubleshooting Insufficient velocity of cooling air * For the execution of the charging and discharging operation in the table above, refer to the RECOVERY, RECYCLING, EVACUATING AND CHARGING in section 1B.
  63. 63. 00 24 SERVICE INFORMATIONCHECKING REFRIGERANT SYSTEM WITH MANIFOLD GAUGE Conditions; Ambient temperature at approx. 25 30C (77 86F) Run the engine at Idling A/C switch is ON Run the blower motor at 4 (high) position Temperature control knob sets at MAX COLD Air source selector lever at CIRC Close the all doors Normal pressures kpa (kgcm2 / PSI); Low-pressure side: Approx. 147 294 (1.5 3.0 / 21 43) High-pressure side: Approx. 1373 1863 (14 19 / 199 270 ) Connect the manifold gauge Low-pressure hose (LOW)Suction side High-pressure hose (HI)Discharge side(Low side)(High side)
  64. 64. SERVICE INFORMATION 00 25 RESULT Discharge (High) pressure gauge abnormally highSYMPTOMTROUBLE CAUSEReduced or no air flow through the condenser Condenser clogged or dirty Radiator (condenser) fan does not operate properly Clean Check cooling fan operationNo bubbles in sight glass when condenser is cooled by water (Insufficient cooling) Excessive refrigerant in system Check sight glass.After stopping air conditioning, pressure drops approx. 196 kPa (28 PSI) quickly Discharge (High) pressure gauge abnormally lowCORRECTION Air in systemInsufficient cooling and excessive bubbles in the sight glass Insufficient refrigerant in system(See Reading Sight Glass) Discharge and recover refrigerant. Recharge to specified amount Evacuate and charge refrigerant system Check sight glass. (See Reading Sight Glass) Check for leaks Discharge and recover refrigerant. Recharge to specified amountLow pressure gauge indicates vacuum Restriction caused by debris or moisture in receiver/drier Check system for restriction and replace receiver/drierAfter turning off air conditioning, high and low pressure gauge balanced quickly Low pressure gauge is lowered after condenser is cooled by water Compressor seal defective Poor compression due to defective compressor gasket Excessive refrigerant in system Replace or repair compressorLow pressure hose temperature around the compressor refrigerant line connector is lower than around evaporator Unsatisfactory valve operation due to defective temperature sensor of expansion valve Expansion valve opens too long Replace the expansion valveAfter turning off air conditioning, high and low pressure gauge is balanced quickly Compressor gasket is defective ReplaceAir conditioning turns off before passenger compartment is sufficiently cool* Replace the expansion valveFrost or dew on refrigerant line before and after receiver/ drier or expansion valve, and low pressure gauge indicates vacuumSuction (Low) pressure gauge abnormally high Clogged or defective expansion valve Electronic thermostat defective Check the electronic thermostat and replace as necessary Discharge and recover refrigerant Recharge to specified amountFor the charging and discharging operations in the table above, refer to RECOVERY, RECYCLING, EVACUATION AND CHARGING in this section.
  65. 65. 00 26 SERVICE INFORMATION RESULTSYMPTOMTROUBLE CAUSECORRECTION Insufficient refrigerant Check sight glass.(See Reading Sight Glass) Check for leaks Discharge and recover refrigerant. Recharge to specified amount Expansion valve clogged Replace the expansion valveA distinct difference in temperature between the inlet and outlet refrigerant lines of the receiver/drier Receiver/drier clogged Replace the receiver/drierExpansion valve outlet refrigerant line is not cold and low-pressure gauge indicates vacuum The temperature sensor of the expansion valve is defective, and the valve cannot regulate the correct flow of the refrigerant Replace the expansion valveDischarge temperature is low and air flow from vents is restricted Frozen evaporator core fins Check electronic thermostat and replace as necessaryLow-pressure gauge reading is low, or a vacuum reading may be shown Suction (Low) and Discharge (High) pressure abnormally highCondenser is not hot and excessive bubble in sight glassFrost on the expansion valve inlet lineSuction (Low) pressure abnormally low Clogged or blocked refrigerant line Replace refrigerant lineNo bubbles in sight glass after condenser is cooled by water (Insufficient cooling) Excessive refrigerant in system Check sight glass.(See Reading Sight Glass) Discharge and recover refrigerant. Recharge to specified amountReduce air flow through condenser Clean Check cooling fan operationSuction (Low) pressure hose is not cold Suction (Low) and Discharge (High) pressure abnormally low Condenser clogged Radiator (condenser) fan does not rotate properly Air in system Evacuate and charge refrigerantInsufficient cooling and excessive bubbles in the sight glass Insufficient refrigerant in system Check sight glass. (See Reading Sight Glass) Check for leaks Discharge and recover refrigerant. Recharge to specified amount
  66. 66. SERVICE INFORMATION 00 27MAGNETIC CLUTCH When the A/C switch and the fan control knob (fan switch) are turned on with the engine running, current flows through the thermostat and the compressor relay to activate the magnetic clutch. The air conditioning can be stopped by turning off the A/C switch or the fan control knob (fan switch). However, even when the air conditioning is in oper-ation, the electronic thermostat, the pressure switch or the PCM (6VD1/6VE1 Engine) is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of the vehicle, etc.6VD1/6VE1 ENGINE Pin number with ( BATTERYRELAY; A/C B-36FL-1 80A MAIN); RHDC-25C-20 10A A/C1 PRESSURE SW. 22 2 4 6 1RELAY; THERMOSTAT(3) 1 (1) 3A/C SW.X-5I-23C-3PCM (E15)42 4FAN SW.3RELAY: A/C COMPRESSOR4121OFF 13I-18 B-1 (RHD)X-7B-2C-1(LHD)PCM (B14)31MgMAGNETIC CLUTCH1ELECTRONIC THERMOSTATE-3 2I-42B-1B-2I-42B-36X-5X-711 2 323C-25411 234 23 2 1 W/ CONDENSER FANE-3I-181 4112 5C-1I-233 61 42 5C-3A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F163 6D08RY00295
  67. 67. 00 28 SERVICE INFORMATION MAGNETIC CLUTCH DOES NOT RUN TURN THE STARTER SWITCH ON AND START THE ENGINE. TURN THE FAN SWITCH ON. DOES THE BLOWER MOTOR RUN?YESNO IS THE FUSE C-20 (10A) NORMAL?REFER TO THE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR DOES NOT RUN.YESNO DISCONNECT THE A/C SWITCH CONNECTOR AND REMOVE THE A/C SWITCH. IS THE A/C SWITCH NORMAL?REPLACE THE FUSE.YESNO IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR I23-2?REPAIR OR REPLACE THE SWITCH.YESNO REINSTALL THE A/C SWITCH AND DISCONNECT THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) CONNECTOR C25. TURN THE A/C SWITCH ON. IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR C25-1?REPAIR AN OPEN CIRCUIT BETWEEN THE FUSE C-20 AND I23-2.YESNO IS THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) NORMAL?REPAIR AN OPEN CIRCUIT BETWEEN I23-6 AND C25-1.YESNO RECONNECT THE CONNECTOR C25 AND DISCONNECT THE A/C THERMO RELAY CONNECTOR X5. IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR C25-2 AND X5-1?REPLACE THE SWITCH.YESNO
  68. 68. SERVICE INFORMATION 00 29 IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR X5-2?REPAIR AN OPEN CIRCUIT.YESNO IS THE A/C THERMO RELAY NORMAL?REPAIR AN OPEN CIRCUIT BETWEEN THE FUSE C-20 AND X5-2.YESNO DISCONNECT THE ELECTRONIC THERMOSTAT CONNECTOR I42. IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR I42-3?REPLACE THE RELAY.YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR X5-3 AND I42-1?REPAIR AN OPEN CIRCUIT BETWEEN I23-6 AND I42-3.YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR I42-2 AND THE GROUND?REPAIR AN OPEN CIRCUIT.YESNO DISCONNECT THE PCM CONNECTORS. IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR X5-4 AND PCM C3-E15?REPAIR AN OPEN CIRCUIT.YESNO RECONNECT X5 AND I42. IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR PCM C3-E15?REPAIR AN OPEN CIRCUIT.YESNO DISCONNECT THE A/C COMPRESSOR RELAY CONNECTOR X7. IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR X7-1 AND X7-2?REPLACE THE ELECTRONIC THERMOSTAT.
  69. 69. 00 30 SERVICE INFORMATIONYESNO DIS CONNECT THE MAGNETIC CLUTCH CONNECTOR E3. CONNECT THE BATTERY WITH MAGNETIC CLUTCH SIDE CONNECTOR E3-1. DOES THE MAGNETIC CLUTCH WORK?REPAIR AN OPEN CIRCUIT BETWEEN THE FUSE C-20 AND X7-1 (OR X7-2).YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR X7-4 AND E3-1?REPAIR OR REPLACE THE MAGNETIC CLUTCH.YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR X7-3 AND PCM C1-B14?REPAIR AN OPEN CIRCUIT.YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR X5-4 AND PCM C3-E15?REPAIR AN OPEN CIRCUIT.YESNOREPLACE THE PCM.REPAIR AN OPEN CIRCUIT.
  70. 70. SERVICE INFORMATION 00 314JG2 ENGINE RELAY; A/C B-36FL-1 80A MAINBATTERYC-25C-20 10A A/C1 PRESSURE SW. 2(LHD)22 4 RELAY; THERMO6 1A/C SW. 13X-5I-23 43 4FAN SW.3ELECTRONIC THERMOSTAT1122OFF 1I-42I-18B-2(LHD)B-1(RHD)1MgMAGNETIC CLUTCHE-3B-1B-2I-42B-36X-511 2 33 2 1C-25E-311 234 21234I-181 42 5I-233 61 42 53 6W/ CONDENSER FAN D08RY00169
  71. 71. 00 32 SERVICE INFORMATIONMAGNETIC CLUTCH DOES NOT RUN ARE NO. C-20 (10A) FUSE AND NO. C-19 (25A) FUSES OK?YESNOREPLACEARE HEATER & A/C (B-36) AND THERMOSTAT (X-5) RELAYS OK?YESNOREPLACEIS PRESSURE SWITCH (DUAL PRESSURE SWITCH) OK?YESNOSWITCH DEFECTIVE OR INSUFFICIENT REFRIGERANTARE A/C SWITCH AND FAN CONTROL KNOB (FAN SWITCH) OK?YESNOREPLACETURN THE IGNITION SWITCH ON (ENGINE IS RUNNING) A/C SWITCH AND FAN CONTROL KNOB (FAN SWITCH ON CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. E3-1NOYESMAGNETIC CLUTCH DEFECTIVECHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. C25-1YESNODISCONNECT THERMO RELAY (X-5)OPEN CIRCUIT BETWEEN NO. C-20 (10A) FUSE AND NO. C25-1CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE RELAY TERMINAL NO. X5-2YESNOOPEN CIRCUIT BETWEEN NO. C25-2 AND NO. X5-2CHECK TO SEE IF VOLTAGE (APPROX. 10V) IS PRESENT CHASSIS SIDE RELAY TERMINAL NO. X5-1 AND NO. X5-3CONTINUED NEXT PAGE
  72. 72. SERVICE INFORMATION 00 33CONTINUED PREVIOUS PAGENOYESOPEN CIRCUIT BETWEEN NO. X5-4 AND NO. E3-1CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE RELAY TERMINAL NO. X5-1YESNORECONNECT THERMO RELAYCHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. I42-3CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. I23-2NO NOYES OPEN CIRCUIT BETWEEN NO. I23-6 AND NO. I42-3YESOPEN CIRCUIT BETWEEN NO. C-20 (10A) FUSE AND NO. I23-2OPEN CIRCUIT BETWEEN X5-1 AND NO. I23-6CHECK TO SEE IF BATTERY VOLTAGE (APPROX. 10V) IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. I42-1YESNOOPEN CIRCUIT BETWEEN NO. X5-3 AND NO. I42-1CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT CHASSIS SIDE CONNECTOR TERMINAL NO. I42-2YESNOELECTRO THERMO DEFECTIVEOPEN CIRCUIT BETWEEN NO. I42-2 AND NO. I18-4 OR POOR GROUND (FAN SWITCH GROUND CIRCUIT)
  73. 73. 00 34 SERVICE INFORMATION4JX1 ENGINERELAY; A/C B-36FL-1 80A MAINBATTERYC-25C-20 10A A/C1 PRESSURE SW. 22 2 4 RELAY; THERMO6 1A/C SW. 13X-5I-23 414 FAN SW.3MgMAGNETIC CLUTCH1E-272 OFF 1I-18B-1B-2(RHD)(LHD)3 ELECTRONIC THERMOSTAT1 2I-42B-1B-2I-42B-36X-511 2 3I-1811 234 2143 2 1E-27C-252311 42 5I-233 61 42 53 6W/ CONDENSER FAND08RY00170
  74. 74. SERVICE INFORMATION 00 35 MAGNETIC CLUTCH DOES NOT RUN TURN THE STARTER SWITCH ON AND START THE ENGINE. TURN THE FAN SWITCH ON. DOES THE BLOWER MOTOR RUN?YESNO IS THE FUSE C-20 (10A) NORMAL?REFER TO THE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR DOES NOT RUN.YESNO DISCONNECT THE A/C SWITCH CONNECTOR AND REMOVE THE A/C SWITCH. IS THE A/C SWITCH NORMAL?REPLACE THE FUSE.YESNO IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR I23-2?REPAIR OR REPLACE THE SWITCH.YESNO REINSTALL THE A/C SWITCH AND DISCONNECT THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) CONNECTOR C25. TURN THE A/C SWITCH ON. IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR C25-1?REPAIR AN OPEN CIRCUIT BETWEEN THE FUSE C-20 AND I23-2.YESNO IS THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) NORMAL?REPAIR AN OPEN CIRCUIT BETWEEN I23-6 AND C25-1.YESNO RECONNECT THE CONNECTOR C25 AND DISCONNECT THE A/C THERMO RELAY CONNECTOR X5. IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR C25-2 AND X5-1?REPLACE THE SWITCH.YESNO
  75. 75. 00 36 SERVICE INFORMATION IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR X5-2?REPAIR AN OPEN CIRCUIT.YESNO IS THE A/C THERMO RELAY NORMAL?REPAIR AN OPEN CIRCUIT BETWEEN THE FUSE C-20 AND X5-2.YESNO DISCONNECT THE ELECTRONIC THERMOSTAT CONNECTOR I42. IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE CONNECTOR I42-3?REPLACE THE RELAY.YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR X5-3 AND I42-1?REPAIR AN OPEN CIRCUIT BETWEEN I23-6 AND I42-3.YESNO IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNECTOR I42-2 AND THE GROUND?REPAIR AN OPEN CIRCUIT.YESNO DIS CONNECT THE MAGNETIC CLUTCH CONNECTOR E27. CONNECT THE BATTERY WITH MAGNETIC CLUTCH SIDE CONNECTOR E27-1. DOES THE MAGNETIC CLUTCH.REPAIR AN OPEN CIRCUIT.YESNO REPAIR AN OPEN CIRCUIT BETWEEN X5-4 AND E27-1.REPAIR OR REPLACE THE MAGNETIC CLUTCH.
  76. 76. SERVICE INFORMATION 00 37CONDENSER FAN When the cycling switch, which controls the condenser fan of the triple pressure switch while the A/C switch is on, senses the refrigerant pressureand the condenser fan turns on, the motor operates via the condenser fan relay.X-19 FL-1 80A MAINFL-4 30A CONDENSER FAN 1 RELAY; CONDENSER FAN3 RELAY; A/C4 52 6 1A/C SWITCHTRIPLE PRESSURE SWITCH4 34 4 FAN SW.31C-25I-2312 OFFCONDENSER FANM12I-18 2 B-2 B-1C-39(LHD) (RHD)C-75C-25C-391 312I-232367482 5217652 1X-191 1 438454C-753 64I-1823121 42 53 6D08RWD70
  77. 77. 00 38 SERVICE INFORMATIONCONDENSER FAN DOES NOT RUN DOES A/C SYSTEM OPERATE CORRECTLY?YESNOCHECK A/C SYSTEM AND REPAIR AS NECESSARYIS FL-4 (30A) FUSE OK?YESNOREPLACEIS CONDENSER FAN RELAY (X-19) OK?YESNOREPLACEIS TRIPLE PRESSURE SWITCH (CYCLING SWITCH SIDE) OK?YESNOREPLACEIS CONDENSER FAN MOTOR OK?YESNOREPLACECHECK TO SEE IF CONTINUITY BETWEEN FL-4 (30A) FUSE AND CHASSIS SIDE RELAY TERMINAL NO. X19-1.YESNOREPLACECHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. I23-6 AND NO. C25-3.YESNOOPEN CIRCUITCHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. C25-4 AND CHASSIS SIDE RELAY TERMINAL NO. X19-4.YESNOOPEN CIRCUITCHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE RELAY TERMINAL NO. X19-5 AND CHASSIS SIDE CONNECTOR TERMINAL NO. I18-4.YESNO OPEN CIRCUIT
  78. 78. SERVICE INFORMATION 00 39CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE RELAY TERMINAL NO. X19-3 AND CHASSIS SIDE CONNECTOR TERMINAL NO. C75-1.YES POOR GROUND OR OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO. C75-2 AND BODY GROUND (NO. C39-7)NOOPEN CIRCUITCONDENSER FAN DOES NOT STOP IS CONDENSER FAN RELAY (X-19) OK?YESNOTRIPLE PRESSURE SWITCH (CYCLING SWITCH SIDE) DEFECTIVEREPLACEREPLACE TRIPLE PRESSURE SWITCH
  79. 79. 00 40 SERVICE INFORMATIONCOMPRESSOR TROUBLESHOOTING ITEMPROBLEM1Noise from compressorPOSSIBLE CAUSES 1. Defective rotor/piston 2. Defective bearing (DKS-15CH) 3. Defective shaftCORRECTION Replace compressor/cylinder and shaft assembly Replace cylinder and shaft assembly Replace compressor/cylinder and shaft assembly2Noise from magnetic clutch face1. Defective bearing 2. Defective clutch 3. Clearance between drive plate and pulley not standardReplace magnetic clutch Replace magnetic clutch Adjust the clearance or replace magnetic clutch3Insufficient cooling1. Defective gasket 2. Defective rotor/reed valve 3. Defective trigger valve/suction valveReplace compressor/gasket Replace compressor/valve plate Replace compressor/suction valve4Not rotating1. Defective rotor/pistonReplace compressor/cylinder and shaft assembly Replace compressor/cylinder and shaft assembly Replace compressor2. Defective shaft 3. Rotating parts seized due to insufficient oil 5Oil and/or gas leakage1. Defective seal 2. Defective O-ringReplace compressor/shaft seal Replace
  80. 80. SERVICE INFORMATION 00 41INDIVIDUAL INSPECTION FAN CONTROL KNOB (FAN SWITCH) AND A/C SWITCH I-23I-185 3 2 6 12 5 3 6 4 1Check for continuity between fan switch and A/C switch side connector terminals. I-181OFFBEZEL ILLUMINATIONSW. position3Terminal No.1234I-23 561FAN SW.I-23FAN SW.I-181 3 66 5 4 32 51 4A/C SW.OFF 1 2 3 4 OFF ONHEATER & A/C, THERMOSTAT, COMPRESSOR, CONDENSER FAN AND CERAMIC HEATER RELAY2Check for continuity between the relay terminals. 42 1424A/C SW.222 4 ..... No continuity (When battery voltage is applied between 1 3)3 32 4 ..... Continuity1DUAL PRESSURE SWITCH Disconnect pressure switch connector and check for continuity between pressure switch side connector terminals. 216
  81. 81. 00 42 SERVICE INFORMATION TRIPLE PRESSURE SWITCH (W/CONDENSER FAN) 1) Disconnect the connector and check for continuity between pressure switch side connector terminal. 2) Reconnect the connector to activate the A/C switch, and check to see if there is continuity between the chassis side connectors and the fan operates. [A/C OFF] Terminal No.Continuity1-2Magnetic ClutchContinuity3-43Control Condenser FanNo Continuity[A/C ON]4Terminal Continuity Fan No.Refrigerant Pressure 107998 kPa (11.01.0 kgcm2 / 15614 psi) 147198 kPa (15.01.0 kgcm2 / 21314 psi) 13-4No OFF Continuity Continuity ON2BLOWER MOTOR21) Disconnect the blower motor (B-5) connector from the blower motor. 2) Connect the battery positive terminal to the No. 1 (NO.2; RHD) terminal of the blower motor and negative to the No. 2 (NO. 1; RHD). 3) Be sure to check to see if the blower motor operates correctly.1RESISTOR 1) Disconnect resistor (I-41) connector. 2) Check for continuity and resistance between the terminals of the resistor.1(Connector terminal) 2436Motor 4314121(SW.position)0.28420.9036Normal Operating Resistance 2.423SW. positionTerminal No.12346
  82. 82. SERVICE INFORMATION 00 43 CONDENSER FAN 1) Disconnect the condenser fan connector (C-75). 2) Connect the battery positive terminal to the No. 1 terminal and negative to No. 2. 3) Be sure to check to see if condenser fan operates correctly.21THERMO SWITCH (ENGINE) With the environmental temperature of the switch set to the following conditions, check to see if there is any continuity between the switch side connector terminals.21Ambient Temperature Above 77 83C (170.6181.4F)Terminal No.Continuity12No ContinuityCERAMIC HEATER Disconnect the ceramic heater connector and check for continuity between ceramic heater side connector terminals.Ceramic heater 1 2Connector No. Terminal ContinuityB-48 12
  83. 83. 00 44 SERVICE INFORMATION FULL HOT SWITCHTemperature control link Full hot switch 2 1B-49 Terminal Full No. hot switch FREE CONTACT121) With the temperature control knob set to the full hot position, check to see visually if the temperature control link of the heater unit operate correctly and if the link contacts securely with the full hot switch. 2) Disconnect the full hot switch connector. 3) With the full hot switch contacted, check to see if there is any continuity between the switch side connector terminals.
  84. 84. SERVICE INFORMATION 00 45MAIN DATA AND SPECIFICATIONS HEATER UNIT Temperature control Capacity Air flow(Kcal./hr.) (m3/hr.)Reheat air mix system 3,700 280HEATER CORE Type Element dimension Radiating areamm (in.) m2Fin & tube type 161 (6.3) 163 (6.4) 45 (1.8) Approx. 2.1EVAPORATOR ASSEMBLY Capacity Air flow(Kcal./hr.) (m3/hr.)EVAPORATOR CORE Type Element dimensionmm (in.)EXPANSION VALVE Type THERMOSTAT SWITCH TypeCONDENSER Type Radiation performanceC (F)Electronic thermostat OFF: 3.5 0.5 (38.3 0.9) ON: 5.0 0.5 (41.0 0.9)(Kcal./hr.)Parallel flow 11,500cc (Imp. fl oz)Assembly includes sight glass with dual (triple) pressure switch 300 (8.5)PRESSURE SWITCH Type kPa (kgcm2 / PSI)REFRIGERANT Type/Specified amountAl-laminate louver fin type 235 (9.3) 224 (8.8) 74 (2.9) External pressure equalizer typeRECEIVER/DRIER Type Internal volume4,200 470g (lbs)Dual pressure switch Low pressure control ON: 205.9 30 (2.1 0.3 / 29.9 4) (Except 6VD1 / 6VE1, LHD model) 186 30 (1.9 0.3 / 27 4) (only for 6VD1/ 6VE1, LHD model) OFF: 176 20 (1.8 0.2 / 26 3) High pressure control ON: 2354 196 (24.0 2.0 / 341 28) OFF: 2942 196 (30.0 2.0 / 427 28) Triple pressure switch (W/Condenser fan) Low pressure control ON: 186 30 (1.9 0.3 / 27 4) OFF: 176 20 (1.8 0.2 / 26 3) Medium pressure control ON: 1471 98 (15.0 1.0 / 213 14) OFF: 1079 98 (11.0 1.0 / 156 14) High pressure control ON: 2354 196 (24.0 2.0 / 341 28) OFF: 2942 196 (30.0 2.0 / 427 28)HFC-134a / 750 (1.65)
  85. 85. 00 46 SERVICE INFORMATION6VD1/6VE1 (RHD) & 6VD1 (LHD) (SAUDI/PHILIPPINE) COMPRESSOR Model Type Number of vanes Rotor diameter Stroke Displacement Maximum speed Direction of rotation Lubrication system LubricantRefrigerant Shaft seal Weight MAGNETIC CLUTCH Type Rated voltage Current consumption Starting torque Direction of rotation Weightmm (in.) mm (in.) cc (Imp fl oz) (rpm)cc (Imp fl oz)g (lbs.) kg (lbs.)(A) Nm (kgm / lbft)DKV-14D Vane rotary (Invariable) 5 64 (2.52) 8.75 (0.34) 140 (3.9) 7,000 (up to 8,400) Clockwise (Front-side view) Pressure differential type ZXL-200PG, 150 (4.2) ISUZU PART NO. 8-97101-336-0 HFC-134a, 750 (1.65) Lip type 3.6 (7.94)Electromagnetic single-plate dry clutch 12 Volts D.C. 3.7 39 (4.0 / 30) Clockwise (Front-side view) 2.2 (4.9)kg (lbs.)6VD1/6VE1 (LHD) Except SAUDI/PHILIPPINE COMPRESSOR Model Type Number of vanes Rotor diameter Stroke Displacement Maximum speed Direction of rotation Lubrication system Lubricant Refrigerant Shaft seal Weight MAGNETIC CLUTCH Type Rated voltage Current consumption Starting torque Direction of rotation Weightmm (in.) mm (in.) cc (Imp fl oz) (rpm)cc (Imp fl oz) g (lbs.) kg (lbs.)(A) Nm (kgm / lbft) kg (lbs.)HD6 Vane rotary (Invariable) 6 64 (2.52) 24 (0.94) 164 (4.59) 9,000 Clockwise (Front-side view) Pressure differential type SD2-231, 150 (4.2) R-134a, 750 (1.65) Lip type 6.8 (14.99)Electromagnetic single-plate dry clutch 12 Volts D.C. 3.7 39 (4.0 / 30) Clockwise (Front-side view) 2.2 (4.9)
  86. 86. SERVICE INFORMATION 00 474JG2/4JX1 COMPRESSOR Model Type Number of cylinder Bore Stroke Displacement Maximum speed Direction of rotation Lubrication system LubricantRefrigerant Shaft seal Weight MAGNETIC CLUTCH Type Rated voltage Current consumption Starting torque Direction of rotation Weightmm (in.) mm (in.) cc (Imp fl oz) (rpm)cc (Imp fl oz)g (lbs.) kg (lbs.)(A) Nm (kgm / lbft) kg (lbs.)DKS-15CH Swash plate type 6 36 (1.4) 24 (0.94) 147 (4.1) 7,000 (up to 8,400) Clockwise (Front-side view) Pressure differential type ZXL-100PG, 150 (4.2) ISUZU PART NO. 8-97101-338-0 HFC-134a, 750 (1.65) Lip type 4.1 (9.0)Electromagnetic single-plate dry clutch 12 Volts D.C. 3.7 49 (5.0 / 36) Clockwise (Front-side view) 2.3 (5.1)
  87. 87. 00 48 SERVICE INFORMATIONFIXING TORQUE Nm (kgm / lbft) 25(2.5/18) 6VD1/6VE1, RHD19(1.9/14) 15(1.5/11)15(1.5/11)13(1.3/113in) 15(1.5/11) 6.0(0.6/52in)38(3.9/28)15(1.5/11) 19(1.9/14)6(0.6/52in) 40(4.1/30) 6VD1/6VE1, LHD40(4.1/30)25(2.5 / 18) 19(1.9/14) 27(2.8 / 20) 4JG225(2.5/18) 19(1.9/14) 27(2.8/20)27(2.8/20) 15(1.5/11) 20(2.0/14) 40(4.1/30)19(1.9/14) 4JX116141A E01RY00001
  88. 88. SERVICE INFORMATION 00 49DKV-14D TYPENm (kgm / lbin)13(1.3/113) 5(0.5/43)871RY00027DKS-15CH TYPENm (kgm / lbft) 5(0.5/43in)15(1.5/11)14(1.4/122in)22(2.2/16) 871RY00026
  89. 89. 00 50 SERVICE INFORMATIONHEATING, VENTILATION AND AIR CONDITIONING(HVAC)1273 89 10 4 11 5 6871RW002Legend 1. Clutch Driver 2. Rotor Bearing Retainer 3. Pulley Rotor and Bearing Assembly 4. Clutch Coil Assembly 5. Connector 6. Shaft Seal Parts 7. Pump Assembly 8. High Pressure Relief Valve 9. Shipping Cap 10. Special 134a Suction Port 11. Special 134a Discharge PortCaution The operations described below are based on bench overhaul with the compressor removed from the vehicle, except as noted. They have been prepared in order of accessibility of the components. When a compressor is removed from the vehicle for servicing, the amount of PAG lubricant remaining in the compressor should be drained, measured and recorded. This PAG lubricant should then be discarded and an equal amount of new PAG lubricant added to the compressor. The service compressor is shipped without PAG oil. When service procedures require, use only Isuzu approved PAG oil.
  90. 90. SERVICE INFORMATION 00 51 Metric Thread Size Information Compressor to mounting bracket bolts(Front) M101.5 6H Compressor to mounting bracket bolts(Rear) M81.25 6H Suction-discharge port screw M101.5 6H Compressor shaft M91.25 6H Internal hub-clutch drive assembly M221.5 6H
  91. 91. 00 52 SERVICE INFORMATIONSPECIAL TOOLS ILLUSTRATIONPARTS NO.PARTS NAME5-8840-0629-0 (J-39500-A)HF C- 13 4aACR4 (115V 60Hz)5-8840-0630-0 (J-39500-220A)ACR4 (220-240V 50/60Hz)5-8840-0631-0 (J-39500-220ANZ)ACR4 (220-240V 50/60Hz Australian model)ACR4 : HFC-134a Refrigerant Recovery / Recycling /Recharging / System
  92. 92. SERVICE INFORMATION 00 53DKV-14D TYPE ILLUSTRATIONPARTS NO.PARTS NAME5-8840-2007-0 (J-7624)Drive plate holder5-8840-0122-0 (J-33944-A)Drive plate puller5-8840-0621-0 (J-33944-4)Forcing screw5-8840-0620-0 (J-38424)Pulley puller pilot5-8840-0111-0 (J-8433)Pulley puller5-8840-0622-0 (J-24092-2)Pulley puller leg5-8840-0118-0 (J-33940)Pulley installer5-8840-0007-0 (J-8092)Drive handle901RX056
  93. 93. 00 54 SERVICE INFORMATIONDKS-15CH TYPE ILLUSTRATIONPARTS NO.PARTS NAME5-8840-2007-0 (J-7624)Drive plate holder5-8840-0122-0 (J-33944-A)Drive plate puller5-8840-0621-0 (J-33944-4)Forcing screw5-8840-0121-0 (J-33943)Pulley puller pilot5-8840-0111-0 (J-8433)Pulley puller5-8840-120-0 (J-33942)Shaft seal remover and installer5-8840-0368-0 (J-34614)Shaft seal guide5-8840-0118-0 (J-33940)Pulley installer5-8840-0007-0 (J-8092)Drive handle901RX056
  94. 94. SERVICE INFORMATION 00 55DELPHI Harrison HD6/HDT6 Special Tools ILLUSTRATIONTOOL NO.TOOL NAME5-8840-2610-0 (J-33013-B)Hub and Clutch Drive Plate Asm. remover5-8840-2615-0 (J-33026)Compressor Holding Fixture5-8840-2612-0 (J-33023-A)Puller Pilot5-8840-2617-0 (J-41552)Pulley Puller5-8840-2611-0 (J-33017)Pulley and Bearing Assembly Installer5-8840-0111-0 (J-8433-1)Puller Bar5-8840-0111-0 (J-8433-3)Forcing Screw5-8840-2614-0 (J-33025)Clutch Coil Installer Adapter5-8840-2613-0 (J-33024)Clutch Coil Installer Adapter5-8840-2629-0 (J-23128-A)Seal Seat Remover and Installer5-8840-2630-0 (J-9553-01)O-Ring Remover901RW012901RW013901RW015901RW016901RW017901RW018901RW019901RW020901RW021901RW024901RW025
  95. 95. 00 56 SERVICE INFORMATIONILLUSTRATIONTOOL NO.TOOL NAME5-8840-2609-0 (J-33011)O-Ring Installer5-8840-0368-0 (J-34614)Shaft Seal Protector5-8840-2616-0 (J-39893)Pressure Testing Connector901RW026901RW027901RW032 901RW032
  96. 96. SECTION HEATING AND VENTILATION 1A 1SECTION 1AHEATING AND VENTILATION CAUTION When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.Fasteners that are not reused, and those requiring thread locking compound, will be called out. The correct torque values must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.CONTENTS PAGE General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 2 Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 2 Control Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 3 Air Select Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 4 Air Source Select Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 4 Fan Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 4 Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 4 Ceramic Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 6 Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 6 Heater Core and/or Mode Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A 8 Heater Mode Control Link Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A10 Heater Temperature Control Link Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A12 Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A14 Blower Link Unit and/or Mode Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A16 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A18 Rear Heater Duct, Defroster Nozzle and Ventilation Duct . . . . . . . . . . . . . . . . . . . . 1A20 Center and/or Side Vent . . . . . . . . . . . . . . . . . . . . . . . . . . .

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