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

. . . . . . . . . . . . . 

SECTION

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . .