Отопитель Кондиционер LGHAC-WE-0553

WORKSHOP MANUAL
N-SERIES
HEATING AND AIR CONDITIONING
SECTION 1
International Service & Parts

Tokyo, Japan
NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
All material contained in this Manual is based on latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model:
N-Series
This manual is applicable to 2005 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTENTS

00 SERVICE INFORMATION
1A HEATING AND VENTILATION
1B AIR CONDITIONING
1C —
COMPRESSOR OVERHAUL EXCEPT
1D1
TAIWAN
1D2 COMPRESSOR OVERHAUL FOR TAIWAN
SERVICE INFORMATION 00-1

SECTION 00
SERVICE INFORMATION
Contents
TROUBLESHOOTING .......................................... 00-2
Heating Cycle Troubleshooting ......................... 00-2
Fan Switch Troubleshooting .............................. 00-3
Air Conditioning Cycle Troubleshooting .......... 00-15
Magnetic Clutch Troubleshooting .................... 00-19
Compressor Troubleshooting .......................... 00-28
Individual Inspection ........................................ 00-29
MAIN DATA AND SPECIFICATIONS ................. 00-32
FIXING TORQUE................................................ 00-34
Refrigerant Line Fixing Torque (Except 4HK1-TC En-
gine Model For Australia) ................................ 00-34
Refrigerant Line Fixing Torque (4HK1-TC Engine
Model For Australia) ........................................ 00-35
Drive Plate / Field Coil Fixing Torque .............. 00-36
SPECIAL TOOLS................................................ 00-37
00-2 SERVICE INFORMATION
TROUBLESHOOTING
Heating Cycle Troubleshooting
TROUBLE POSSIBLE CAUSE CORRECTION

No heating or Insufficient 1. BIower motor does not run, or runs • Refer to “Fan Switch Troubleshooting”.
heating. improperly. • Check the engine coolant temperature
2. Engine coolant temperature is low. after warming up the engine and check
the thermostat. Replace as necessary.
3. Insufficient engine coolant.
• Add engine coolant as required.
4. Circulation volume of engine cool-
• Check if the water hose to the heater
ant is insufficient.
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.
5. Heater core clogged or collapsed. • Repair the temperature control link unit
6. The heater core is not provided with or mode doors.
air sent from the blower motor. • Repair or adjust the control cables.
7. Duct connections defective or un- • Repair or replace as necessary.
sealing.
Control knob moves but 1. Cable attaching clip is not correct. • Repair.
mode door does not oper- 2. Link unit of heater unit or blower as- • Repair.
ate. sembly defective.
The mode door cannot be 1. Link unit of heater unit or blower as- • Repair.
set to the mode selected. sembly defective.
2. Control cable is not adjusted. • Adjust.
Fan Switch Troubleshooting
Current flows to the blower motor through the heater & A/C relay X-12 to activate the rotation of the blower motor by
turning “ON” the fan switch.
Blower motor speed is controlled in stages by the resistor, by operating the switch from “LOW” to “HIGH.”
For 12 Volt (LHD Model)
RELAY;
FL-1 100A HEATER & A/C
2L MAIN 5 3L
30B/R 8B 8W 8W/B 3W/B X-12
H-6 X-12
2 1
P-3 P-1
2 FL-25 30A
P-4 P-2 RELAY; CHARGE (5) X-12 X-12
4
0.5W/R HEATER
4JH1
P-5
FRAME
2L
0.5B
2
B-14
BLOWER
MOTOR
B-14
1
2L/B
2B(4JH1)
1.25B
2L/B 2L/B 4
B-13 B-42
1 3
2
B-42 A/C SWITCH
1.25L/O 3
B-13 B-42
4 6
0.85L/Y
B-13 B-42
2 5 2
0.5L/W
B-13 B-42
3 4 1 OFF
BLOWER RESISTOR
3B
5B(4JH1) 3B 2B
HEADLIGHT BRACKET (LH) B-7
1
B-42
5B FAN SWITCH
FRAME-LH (FRONT) B-1
EXCEPT 4JH1
N1A0214E
For 12 Volt (RHD Model)
RELAY;
MAIN 5 3L
30B/R 2L 8B 8W/B 5W/B 3W/B X-12
H-6 X-12
2 1
P-3 P-1
2 FL-25 30A
4
0.5W/R HEATER
4JH1
P-5
FRAME
2L
0.5B
2
B-14
BLOWER
MOTOR
B-14
1
2L/B
A/C SWITCH
1
B-13
2L/B
0.5G/Y
4
2B
B-42
3 2
B-42
1.25L/O 3
B-13 B-42
4 6
0.85L/Y
B-13 B-42
2 5 2
2B
B-13 B-42
3 4 1
BLOWER RESISTOR
B-42
2B 2B 1
FAN SWITCH
3B 3B
5B
N1A0201E
FL-1 100A or 120A F-1 15A

2L AIR CON, HEATER
30B/R 8B MAIN 8W/B
P-1
8W/B
P-2
2
0.85L
H-6
3L
5W/B
P-3
BLOWER MOTOR
1
P-4 RELAY; B-14
3W/B
HEATER & A/C
5
1 X-12
X-12
B-14
X-12 X-12
2 4 2
P-5
0.5W/R
FRAME
RELAY; CHARGE (5)
0.85L/B
0.5B
1 3 4
B-13 B-42
0.85L/B 2
B-42 A/C SWITCH
4 6 3
B-13 B-42
0.5L/O
2 5
B-13 B-42
0.5L/Y 2
0.85B
3 4
B-13 B-42
0.5L/W 1 OFF
BLOWER RESISTOR
3B 2B 0.85B 1
HEADLIGHT BRACKET (LH) B-7 B-42

5B
FAN SW
N1A0216E
FL-1 100A or 120A F-1 15A

2L AIR CON, HEATER
30B/R 8B MAIN
P-1
8W/B
P-2
2
0.85L
H-6
3L
5W/B
P-3
BLOWER MOTOR
1
P-4 RELAY; B-14
3W/B
HEATER & A/C
5
1 X-12
X-12
B-14
X-12 X-12
2 4 2
P-5
0.5W/R
FRAME
0.85L/B
RELAY; CHARGE (1)
0.5B
A/C SWITCH
0.5G/Y
1 3 4
B-13 B-42
0.85L/B 2
B-42
4 6 3
B-13 B-42
*
2 5
B-13 B-42
0.5L/Y 2
2B
3 4
B-13 B-42
0.5L/W 1 OFF
BLOWER RESISTOR
3B 2B 0.85B 1

5B
FAN SW
EXCEPT 4HK1-TC ENGINE MODEL FOR AUSTRALIA: 0.85L/O

* 4HK1-TC ENGINE MODEL FOR AUSTRALIA: 0.5L/O
N1A0202E
For Taiwan
RELAY;
2L MAIN 5 3L
30B/R 8B 8W/B 5W 3W X-12
H-6 X-12
P-3 P-1 2 1
2 F-25 30A
4
0.85W/R HEATER
P-5
FRAME
2L
0.5B
2
B-14
BLOWER
MOTOR
B-14
1
2L/B
2
B-13
2L/R 4
2B
B-13 B-42
3 3
2
B-42 A/C SWITCH
1.25L/O 3
B-13 B-42 B-42
6 6 1
0.85L/Y
B-13 B-42
4 5 2
2B
0.5L/W
B-13 B-42
1 4 1 OFF
BLOWER RESISTOR FAN SWITCH

5B 3B 2B
N1A0215E
Connector List No. Connector Face
No. Connector Face
B-42 1 2 3
4 5 6
B-1 006-001
000-001
B-42
B-2 005-006
000-012
P-1
(12 V)
B-7 000-003
000-012
P-2
(12 V)
1 2
B-13 3 4 000-004
004-010
P-1
(24 V)
1 2 3
B-13 4 5 6 000-004
006-010
P-4
1
B-14 2 000-004
002-009
P-2
1 (24 V)
2 4
X-12
3
5
000-006
005-001
P-3
000-006
No. Connector Face
P-5
(12 V)
000-007
P-5
(24 V)
000-002
H-6
1 2 H-6 2 1
1 2 H-7 2 1
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14
N8A5489E
Blower Motor Does Not Run
Except Taiwan
N1A0207E
For Taiwan
N1A0208E
Blower Motor Does Not Run in Certain Position
Except Taiwan
N1A0209E
For Taiwan
N1A0124E
Blower Motor Does Not Stop at “OFF” Position
Except Taiwan
N1A0210E
For Taiwan
N1A0125E
Air Conditioning Cycle Troubleshooting
TROUBLE POSSIBLE CAUSE CORRECTION

No cooling or insufficient 1. Magnetic clutch does not run • Refer to “MAGNETIC CLUTCH
cooling TROUBLESHOOTING”
2. Compressor is not rotating property
• Drive belt loosened or broken • Adjust the drive belt to the specified
tension or replace the drive belt
• Magnetic clutch face is not clean • Clean the magnetic clutch face or re-
and slips place
• Incorrect clearance between mag- • Adjust the clearance (Refer to Section
netic drive plate and pulley 1D “COMPRESSOR OVERHAUL”)
• Compressor oil leaks from shaft • Replace the compressor
seal or shell
• Compressor seized • Replace the compressor
3. Insufficient or excessive charge of re- • Discharge and recover refrigerant.
frigerant Recharge to specified amount.
4. Leaks in the refrigerant system • Check refrigerant system for leaks
and repair as necessary.
Discharge and recover refrigerant.
Recharge to specified amount.
5. Condenser clogged or insufficient ra- • Clean the condenser or replace as
diation necessary
• Check radiator or condenser fan func-
tion
6. Temperature control link unit of the • Repair the link unit
heater unit defective
7. Unsteady operation due to foreign • Replace the expansion valve
substance in expansion valve
8. Poor operation of electronic thermo- • Check electronic thermostat and re-
stat place as necessary
Insufficient velocity of 1. Evaporator clogged or frosted • Check evaporator core and replace or
cooling air clean the core
2. Air leaking from cooling unit or air duct • Check evaporator and duct connec-
tion, then repair as necessary
3. Blower motor does not rotate properly • Refer to “FAN SWITCH TROUBLE-
SHOOTING”
* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY, RECY-
CLING, EVACUATION AND CHARGING” in section 1B.
Checking Refrigerant System with Manifold
Caution:
Gauge Vehicles that use Refrigerant-134a (R-134a) is used in
Conditions; the air conditioning system, be sure to use manifold
• Ambient temperature at approx. 30 — 35°C (86 — gauges, charging hoses and other air conditioning ser-
95°F) vice tools for R-134a when checking the refrigerant sys-
• Run the engine at 1,500 rpm tem. (Refer to “ON VEHICLE SERVICE” for Precautions
for R-134a Air Conditioning System in section 1B.)
• A/C switch is “ON”
• Run the blower motor at “4” (high) position
• Temperature control lever sets at “MAX COLD”
• Air source selector lever at “CIRC”
• Open then the all doors and engine hood
Normal pressures kPa (kg⋅cm2/PSl)
• Low-pressure side: Approx. 127 — 245 (1.3 — 2.5/
18 — 36)
• High-pressure side: Approx. 1373 — 1667 (14 —
17/199 — 242)
Connect the manifold gauge
Low-pressure hose (LOW) - Suction side (1)
High-pressure hose (HI) - Discharge side (2)
N1A0002E
Legend
1. Low side
2. High side
RESULT SYMPTOM TROUBLE CAUSE CORRECTION

Discharge (High) Reduced or no air flow through • Condenser clogged or dirty • CIean
pressure gauge the condenser • Radiator (condenser) fan • Check cooling fan op-
abnormally high does not operate properly eration
No bubbles in sight glass when • Excessive refrigerant in sys- • Check sight glass.
condenser is cooled by water tem (See “Reading Sight
(Insufficient cooling) Glass”)
• Discharge and recover
refrigerant.
Recharge to specified
amount
After stopping air conditioning, • Air in system • Evacuate and charge
pressure drops approx. 196 refrigerant system
kPa (2.0 kg⋅cm2/28 PSl) quickly
Discharge (High) Insufficient cooling and exces- • Insufficient refrigerant in • Check sight glass.
pressure gauge sive bubbles in the sight glass system (See “Reading Sight
abnormally low Glass”)
• Check for leaks
refrigerant.
amount
Low pressure gauge indicates • Clogged or defective expan- • Replace the expansion
vacuum sion valve valve
Frost or dew on refrigerant line • Restriction caused by de- • Check system for re-
before and after receiver/ drier bris or moisture in receiver/ striction and replace
or expansion valve, and low drier receiver/drier
pressure gauge indicates vac-
uum
After turning off air condition- • Compressor seal defective • Replace or repair com-
ing, high and low pressure • Poor compression due to pressor
gauge balanced quickly defective compressor gas-
ket
Suction (Low) Low pressure gauge is lowered • Excessive refrigerant in sys- • Discharge and recover
pressure gauge after condenser is cooled by tem refrigerant
abnormally high water Recharge to specified
amount
Low pressure hose tempera- • Unsatisfactory valve opera- • Replace the expansion
ture around the compressor tion due to defective tem- valve
refrigerant line connector is perature sensor of
lower than around evaporator expansion valve
• Expansion valve opens too
long
After turning off air condition- • Compressor gasket is de- • Replace
ing, high and low pressure fective
gauge is balanced quickly
Air conditioning turns off before • Electronic thermostat defec- • Check the electronic
passenger compartment is suf- tive thermostat and replace
ficiently cool as necessary
* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING, EVACUATION
AND CHARGING” in section 1B.
RESULT SYMPTOM TROUBLE CAUSE CORRECTION

Suction (Low) Condenser is not hot and • Insufficient refrigerant • Check sight glass.
pressure abnor- excessive bubble in sight glass (See “Reading Sight
mally low Glass”)
• Check for leaks
refrigerant.
amount
Frost on the expansion valve • Expansion valve clogged • Replace the expansion
inlet line valve
A distinct difference in temper- • Receiver/drier clogged • Replace the receiver/
ature between the inlet and drier
outlet refrigerant lines of the
receiver/drier
Expansion valve outlet refriger- • The temperature sensor of • Replace the expansion
ant line is not cold and low- the expansion valve is de- valve
pressure gauge indicates vac- fective, and the valve can-
uum not regulate the correct flow
of the refrigerant
Discharge temperature is low • Frozen evaporator core fins • Check electronic ther-
and air flow from vents is mostat and replace as
restricted necessary
Low-pressure gauge reading is • Clogged or blocked refriger- • Replace refrigerant line
low, or a vacuum reading may ant line
be shown
Suction (Low) No bubbles in sight glass after • Excessive refrigerant in sys- • Check sight glass.
and Discharge condenser is cooled by water tem (See “Reading Sight
(High) pressure (Insufficient cooling) Glass”)
abnormally high • Discharge and recover
refrigerant.
amount
Reduce air flow through con- • Condenser clogged • Clean
denser • Radiator (condenser) fan • Check cooling fan op-
does not rotate properly eration
Suction (Low) pressure hose is • Air in system • Evacuate and charge
not cold refrigerant
Suction (Low) Insufficient cooling and exces- • Insufficient refrigerant in • Check sight glass.
and Discharge sive bubbles in the sight glass system (See “Reading Sight
(High) pressure Glass”)
abnormally low • Check for leaks
refrigerant.
amount
Magnetic Clutch Troubleshooting while the engine is running. And it stops when either A/
C switch or fan switch is turned off.
The air conditioning is made up of the evaporator, con-
In addition to these switches, the air conditioning is also
denser, electronic thermostat, A/C switch, fan switch
stopped by turning off the magnetic clutch temporarily
and relays.
under the predetermined condition when the abnormal
The air conditioning starts its operation when both the A/
refrigerant pressure is sensed by pressure switch, or
C switch and the fan switch are turned on and the mag-
when the air temperature is sensed by electronic ther-
netic clutch gets engaged through the A/C thermo relay
mostat that prevents the evaporator core from freezing.
For 12 Volt (LHD Model Except 4JH1)
4JB1 / 4HG1 ENGINE ONLY

RELAY; PRESSURE
F-1 10A A/C THERMO SWITCH
AIR CON 5 0.85G/W 2 0.85G/W 1 2 0.85G/O
RELAY; 3L 0.5BR 1 X-10 H-5 J-6 J-6
X-10
HEATER & A/C
2 4
FL-25 30A X-10 X-10
0.85G/O
1.25LG/B
HEATER
6
H-14
4
0.5BR
B-17
0.5P/G
DIODE
0.85G/O
B-17
3
1.25L
2L
1
0.5LG E-5
3 1
1 2 B-15 B-15
THERMOSTAT
ELECTRONIC
B-39 B-39
MAGNETIC CLUTCH
(COMPRESSOR)
BLOWER A/C SWITCH B-39 B-15
MOTOR 3 2
0.5G/Y
0.5G/Y
2
B-42
3
1 OFF
3B 3B 2B
1
B-42
5B
FAN SWITCH
N1A0203E
For 12 Volt (LHD Model 4JH1/Taiwan)
RELAY; PRESSURE
F-1 10A A/C THERMO SWITCH
AIR CON 5 0.85G/W 2 0.85G/W 1 2 0.85G/O
RELAY; 3L 0.85BR 1 X-10 H-5 J-6 J-6
X-10
HEATER & A/C
2 4 RELAY;
X-10 X-10
F-25 30A A/C COMPRESSOR
1.25LG/B
HEATER 0.85G/Y 1
X-24 2
X-24
2 1
0.85BR
B-17 H-14
0.5P/G
DIODE
0.85G/Y
B-17
1
1.25L
2L
0.5LG
1
3 1 E-5
ELECTRONIC THERMOSTAT
1 2 B-15 B-15
BLOWER B-39 B-39
MOTOR
MAGNETIC
A/C SWITCH B-39 B-15 CLUTCH
3 2 (COMPRESSOR)
0.5G/Y
0.5G/Y
2
B-42
3
B-42
1
2
2B
1 OFF
FAN SWITCH
5B 3B 2B
TAIWAN
N1A0218E
RELAY;
F-1 10A A/C THERMO
AIR CON 5 0.85G/W 2 0.85G/W
RELAY; 3L 0.85BR 1 X-10 H-5
X-10
HEATER & A/C
2 4 1
X-10 X-10
FL-25 30A J-6
1.25LG/B
HEATER PRESSURE
SWITCH
4 J-6
2
0.85BR
B-18
0.5P/G
0.85G/O
DIODE
B-18
3
2
1.25L
2L
X-24
0.5LG
RELAY;
3 1 A/C
COMPRESSOR
ELECTRONIC THERMOSTAT
1 2 B-15 B-15
X-24
BLOWER B-39 B-39
MOTOR 1
0.85G/Y
A/C SWITCH B-39 B-15 7 1
3 2 H-14 H-14
0.5G/Y 4JH1
0.5G/Y
0.85G/Y(4JH1)
0.85G/O(4JB1)
0.5G/O(4JG2)
4
1
2
B-42 E-5
3
MAGNETIC
CLUTCH
1
(COMPRESSOR)
3B 3B 2B 2B
1
B-42
5B FAN SWITCH
N1A0219E
PRESSURE
F-1 15A SWITCH
AIR CON, HEATER 0.85G/W 2 0.85G/W 1 2 0.85G/O
RELAY; 0.85BR 0.85BR X-10 5 H-5 J-6 J-6
X-10
HEATER & A/C 1
2 4
X-10 X-10
0.5LG/B
RELAY;
0.85G/O
A/C THERMO
4
B-17
DIODE
0.85BR
0.5P/G
B-17
3 6
H-14
0.5LG
0.5LG
BLOWER 1 2 3 1
MOTOR B-39 B-39 B-15 B-15
0.85G/O
ELECTRONIC
THERMOSTAT
B-15
B-39
A/C SW 2
3 1
0.5G/Y
E-5
0.5G/Y
MAGNETIC
CLUTCH
4
2
B-42
3
1 OFF
3B 2B 1
0.85B
5B
FAN SW
N1A0205E
PRESSURE
F-1 15A SWITCH
AIR CON, HEATER
RELAY;
HEATER & A/C
0.85BR 0.85BR
1
X-10
X-10 5
0.85G/W
H-5
2 0.85G/W 1
J-6 J-6
2
*
2 4
X-10 X-10
0.5LG/B
0.85BR
RELAY;
0.85L
A/C THERMO
*
(FOR NKR66, NKR71 ENG.)
0.5P/G
2 3
NQR71 ENG.)
NQR66, NPR71,
(FOR NPR66,
B-18 X-33
6
H-14
B-18 X-33 X-33

BLOWER
MOTOR 1 10 11
*
0.5LG
0.5LG
1 2 3 1
1
B-39 B-39 B-15 B-15
E-5
ELECTRONIC
THERMOSTAT
B-15
B-39
A/C SW 2 MAGNETIC
3 CLUTCH
0.5G/Y
(COMPRESSOR)
0.5G/Y 0.5G/Y
4
2
B-42
3
1 OFF
3B 2B 0.85B 1 B-42
5B
EXCEPT 4HK1-TC ENGINE MODEL FOR AUSTRALIA: 0.85G/O
FAN SW
* 4HK1-TC ENGINE MODEL FOR AUSTRALIA: 0.5G/O
N1A0220E
Connector List No. Connector Face
No. Connector Face
B-42 1 2 3
4 5 6
B-1 006-001
000-001
E-5 1
B-7 001-013
000-012
E-5 1
B-17 1 2 3 4
001-014
004-004
1 2 3 4
5 6 7 8 9
H-14 10 11 12 13 14
15 16
B-18 1 2 3 4
016-003
004-004
4 3 2 1
9 8 7 6 5
H-14
14 13 12 11 10
16 15
B-15 1 2 3 016-004
003-009
J-6 1 2
1
2 4
X-10
3
5
002-032
005-001
1 2 3 4
5 6 7 8
H-14 9 10 11 12
13 14 15 16
1
B-39 2 3 016-001
003-019
4 3 2 1
8 7 6 5
H-14 12 11 10 9
16 15 14 13
016-002
H-5
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 14 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
N8A5488E
Magnetic Clutch Does Not Operate
N1A0211E
N1A0127E
Compressor Troubleshooting
ITEM TROUBLE POSSIBLE CAUSE CORRECTION

1 Noise from compressor 1. Defective Piston Replace cylinder and shaft assembly
2. Defective bearing Replace cylinder and shaft assembly
3. Defective shaft Replace cylinder and shaft assembly
2 Noise from magnetic 1. Defective bearing Replace magnetic clutch
clutch face 2. Defective clutch Replace magnetic clutch
3. Clearance between drive plate Adjust the clearance or replace mag-
and pulley is not standard netic clutch
3 Insufficient cooling 1. Defective gasket Replace gasket
2. Defective reed valve Replace valve plate
3. Defective suction valve Replace suction valve
4 Not rotating 1. Defective piston Replace cylinder and shaft assembly
2. Defective shaft Replace cylinder and shaft assembly
3. Rotating parts seized due to in- Replace compressor
sufficient oil
5 Oil and/or gas leakage 1. Defective seal Replace shaft seal
2. Defective O-ring Replace
Individual Inspection For Taiwan
Blower Motor
1. Disconnect the blower motor connector from the
blower motor.
2. Connect the battery positive terminal to the No. 1
(No. 2; RHD) terminal of the blower motor and neg-
ative to the No. 2 (No. 1, RHD).
3. Be sure to check to see if the blower motor oper-
ates correctly.
N1A0006E
Fan Switch
Check for continuity between fan switch and A/C switch
side connector terminals.
N1A0005E
Resistor
1. Disconnect resistor connector.
2. Check for continuity and resistance between the
terminals of the resistor.
Except Taiwan
1
N1A0007E
1 4 2 3
2 4 3 1
2 3
1 2 3 4
1 24V
1 9.3
2 4.0
3 1.2
4
N1A0132E
Legend
1. SW position
2. Terminal No.
3. Resistance value
Heater & A/C and A/C Thermo Relay
Check for continuity between relay side connector termi-
nal.
3 — 5 --- Continuity
1 — 5 --- No Continuity
When battery voltage is applied between 2 — 4
3 — 5 --- No Continuity
1 — 5 --- Continuity
N1A0010E
Pressure Switch
Disconnect the connector and check for continuity be-
tween pressure switch side connector terminal.
Terminal No. Control Continuity

1—2 Magnetic CIutch Continuity
N1A0008E
For GCC
A/C Switch
Check for continuity between A/C switch side connector
terminals.
N1A0009E
2 1
Magnetic Clutch
1. Disconnect the magnetic clutch harness connec-
tors.
2. Apply battery voltage to the clutch side connector
terminal, check to see if the magnetic clutch is at- N1A0011E
tracted to the pulley.
For Australia Electronic Thermostat
1. With the air select lever set to “VENT” and the air
source select lever to “CIRC”, start the air condi-
tioning.
2. While shifting the temperature control lever from
“FULL COOL” through the “FULL HOT”, check to
see if the magnetic clutch turns on and off.
(*Note that the time required to reach the “OFF”
point depends on the warm or cold air at 3.5 ±
0.5°C at the electronic thermostat thermo sensor).
3. While the magnetic clutch is turning “ON” and
“OFF”, measure the voltage between chassis side
connector terminal No. 1 and No. 2.
Terminal No. Magnetic CIutch Voltage

ON 0V
1—2
OFF Battery voltage
N1A0157E
For Taiwan
N1A0013E
N1A0012E
MAIN DATA AND SPECIFICATIONS
HEATER UNIT
Temperature control Reheat mix system
Capacity kW (kcal) 4.30 (3,700)
Air flow (m3 /hr) 280
HEATER CORE
Type Fin & tube type
EVAPORATOR ASSEMBLY
Capacity kW (kcal) 4.47 (3,850)
Air flow (m3/hr) 420
EVAPORATOR CORE
Type AI-laminate louver fin type
EXPANSION VALVE
Type External pressure equalizer type
THERMOSTAT SWITCH
Type Electronic thermostat
°C (°F) OFF: Below 3.5 ± 0.5 (38.3 ± 0.9)
ON: Above 5.0 ± 0.5 (41.0 ± 0.9)
CONDENSER
Type Parallel flow
Radiator performance kW (kcal) 11.0 (9,500) - NPR, NKR (for GCC)
5.1 (4,400) - NKR (for Taiwan), NPR (for Australia)
RECEIVER/DRIER
Internal volume cc (lmp. fl oz) 300 (8.5) - NKR (for Taiwan), NPR (for Australia)
250 (7.1) - NKR, NPR (for GCC)
PRESSURE SWITCH
Type Dual pressure switch (for GCC and Taiwan)
2
kPa (kg/cm / PSI) • Low pressure control (for GCC)
ON: 206 ± 30 (2.1 ± 0.3 / 30 ± 4)
OFF: 177 ± 25 (1.8 ± 0.2 / 26 ± 3)
• High pressure control (for GCC)
ON: 2350 ± 200 (24.0 ± 2.0 / 341 ± 29)
OFF: 2940 ± 200 (30.0 ± 2.0 / 426 ± 29)
• Low pressure control (for Taiwan)
ON: 221 ± 20 (2.25 ± 0.2 / 32 ± 3)
OFF: 196 ± 20 (2.0 ± 0.2 / 28 ± 3)
• High pressure control (for Taiwan)
ON: 2350 ± 200 (24.0 ± 2.0 / 341 ± 29)
OFF: 2940 ± 200 (30.0 ± 2.0 / 426 ± 29)
Triple pressure switch (for Australia)

• Low pressure control
ON: 206 ± 30 (2.1 ± 0.3 / 30 ± 4)
OFF: 177 ± 25 (1.8 ± 0.2 / 26 ± 3)
• Medium pressure control
ON: 1470 ± 100 (15 ± 1.0 / 213 ± 14)
OFF: 1079 ± 120 (11 ± 1.2 / 156 ± 17)
• High pressure control
ON: 2350 ± 200 (24.0 ± 2.0 / 341 ± 29)
OFF: 2940 ± 200 (30.0 ± 2.0 / 426 ± 29)
REFRIGERANT g (lbs) R-134a / 450 (0.99) (for GCC)
Type/Specified amount R-134a / 600 (1.32) (for Australia, Taiwan)
COMPRESSOR
Model DKS-15-D (except Taiwan)
DKS-13CH (for Taiwan)
Swash plate type (except Taiwan)
Number of cylinder 10
Bore mm (in) 30.5 (1.2)
Stroke mm (in) 21.4 (0.8)
Displacement cc (lmp fl oz) 156 (4.4)
Swash plate type (for Taiwan)
Number of cylinder 6
Bore mm (in) 36 (1.42)
Stroke mm (in) 21.4 (0.84)
Displacement cc (lmp fl oz) 131 (3.7)
Maximum speed (rpm) 7,000 (up to 8,400)
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (lmp fl oz) ZXL-100PG / 180 (5.0)
(ISUZU PART NO. 8-97101-338-0)
Shaft seal Lip type
Weight kg (lbs) 4.4 (9.7) (except Taiwan)
4.1 (9.0) (for Taiwan)
MAGNETIC CLUTCH
Type Electromagnetic single-plate dry clutch
Rated voltage 12 (24) Volts D.C.
Starting torque N⋅m (kg⋅m / lb⋅ft) 49 (5.0 / 36)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs) 2.1 (4.6)
FIXING TORQUE
Refrigerant Line Fixing Torque (Except 4HK1-TC Engine Model For Australia)
15 (1.5/11)
6 (0.6/4)
25 (2.5/18)
15 (1.5/11)
15 (1.5/11)
N1A0014E
Refrigerant Line Fixing Torque (4HK1-TC Engine Model For Australia)
N.m (kg.m / lb.ft)
25 (2.5 / 18)
15 (1.5 / 11) 6 (0.6 / 4)
15 (1.5 / 11)
15 (1.5 / 11)
6 (0.6 / 4)
N1A0196E
Drive Plate / Field Coil Fixing Torque
5 (0.5/44)
15 (1.5/11)
N1A0015E
SPECIAL TOOLS
Tool Number /
Tool Number / Illustration
Illustration Description / Remarks
Description / Remarks
5-8840-0629-0 (J-39500-
A) / ACR4 (115V 60Hz)
5-8840-0120-0 (J-33942)
5-8840-0630-0 (J-39500-
/ Shaft seal remover and
220A) / ACR4 (220-240V
installer
50/60Hz)
5-8840-0631-0 (J-39500-
220ANZ) / ACR4 (220-
5884001200
240V 50/60Hz Australian

model)
5884006290
ACR4: R-134a Refriger- 5-8840-0368-0 (J-34614)
ant Recovery/ Recycling / Shaft seal guide
/ Recharging / System
5884003680
5-8840-0117-0 (J-33939)
/ Drive plate holder
5-8840-0118-0 (J-33940)
/ Pulley installer
5884001170
5884001180
5-8840-0122-0 (J-33944-
A) / Drive plate puller
5-8840-0007-0 (J-8092) /
Drive handle
5884001220
5884000070
5-8840-0621-0 (J-33944)
/ Forcing screw
5884006210
5-8840-0121-0 (J-33943)
/ Pulley puller pilot
5884001210
5-8840-0111-0 (J-8433) /
Pulley puller
5884001110
HEATING AND VENTILATION 1A-1

SECTION 1A
HEATING 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
GENERAL DESCRIPTION ................................... 1A-2
Heater................................................................ 1A-2
Control Lever Assembly .................................... 1A-3
Ventilation.......................................................... 1A-4
Air Select Lever ................................................. 1A-4
Air Source Select Lever..................................... 1A-4
Fan Switch Lever............................................... 1A-4
Temperature Control Lever ............................... 1A-5
ON-VEHICLE SERVICE ....................................... 1A-6
Heater Unit/Heater Core.................................... 1A-6
Heater Temperature Control Link Unit/Air Mix Door .. 1A-8
Heater Mode Control Link Unit/Mode Door ....... 1A-9
Blower Assembly ............................................. 1A-10
Blower Link Unit/Mode Door............................ 1A-13
Blower Motor ................................................... 1A-14
Blower Filter..................................................... 1A-16
Ventilation Grille .............................................. 1A-17
Defroster Nozzle/Ventilation Duct.................... 1A-19
Control Lever Assembly .................................. 1A-20
Control Panel Illumination Bulb ....................... 1A-23
Resistor ........................................................... 1A-24
1A-2 HEATING AND VENTILATION
GENERAL DESCRIPTION
Heater
When the engine warming up, the warmed engine coolant is sent out into the heater core. The heater system supplies
warm air into the passenger compartment to warm it up.
Outside air is circulated through the heater core of the heater unit and then back into the passenger compartment. By
controlling the mixture of outside air and heater core air, the most comfortable passenger compartment temperature
can be selected and maintained.
The temperature of warm air sent to the passenger compartment is controlled by the temperature control lever. This
lever acts to open and close the air mix door, thus controlling the amount of air passed through the heater core.
The air select lever, with its different modes, also allows you to select and maintain the most comfortable passenger
compartment temperature.
The air source select lever is used to select either “FRESH” for the introduction of the outside air, or “CIRC” for the
circulation of the inside air. When the lever is set to “FRESH”, the outside air is always taken into the passenger com-
partment.
When setting the lever to “CIRC” position, the circulation of air is restricted only to the inside air with no introduction
of the outside air and the air in the passenger compartment gets warm quickened. However, the lever is normally set
to “FRESH” to prevent the windshield from clouding.
N1A0016E
Legend
1. Side defroster nozzle (LH) 7. Duct
2. Ventilation duct (LH) 8. Blower assembly
3. Defroster nozzle 9. Evaporator assembly (W/A/C)
4. Side defroster nozzle (RH) 10. Heater unit
5. Ventilation duct (Center) 11. Control lever assembly
6. Ventilation duct (RH) 12. A/C switch
Control Lever Assembly

The vehicle has cable-control-type to control by cable the mode and temperature of the heater unit and the mode door
for the air source of the blower assembly.
The fan control is used to control the amount of air sent out by the resistor at four levels from “LOW” to “HIGH”.
N1A0017E
Legend
1. Air select lever 4. A/C switch (W/A/C)
2. Air source select lever 5. Temperature control lever
3. Fan switch lever
Ventilation
Set “AIR SOURCE SELECT LEVER” to “FRESH” position and turn on the blower fan. Heating can be done in this
lever position, sending in fresh air from outside.
The blower fan also serves to deliver fresh outside air to the vehicle interior to assure adequate ventilation.
N1A0018E
Air Select Lever Air Source Select Lever

The air selector lever allows you to direct heated air into The intake of outside air and the circulation of inside air
the passenger compartment through different outlets. are controlled by sliding this lever left or right.
1. Vent - In this position, air is discharged from the Moving the air source select lever to the “CIRC” position
upper air outlet. Air quantity is controlled by the fan provides quickest heat delivery by closing the blower as-
control knob. sembly mode door. In this position, outside air is not de-
2. Bi-Level - In this position, air flow is divided be- livered to the passenger compartment.
tween the upper air outlets and the foot air outlets,
Fan Switch Lever
with warmer air delivered to the floor outlets than
the air delivered to the upper air outlets. This lever controls the blower motor speed to regulate
the amount of air delivered to the defrost, foot, and ven-
3. Foot - In this position, air flow is delivered to the
tilation ducts:
foot only.
1. Low
4. Def/Foot - In this position, air flow is delivered to
the foot, while sending approx, 30% of total amount 2. Medium Low
of air to the windshield. 3. Medium High
5. Defrost - In this position, most of the air is deliv- 4. High
ered to the windshield and a small amount is deliv-
ered to the side windows.
Temperature Control Lever
When the temperature control lever is in the “COLD” position, the air mix door closes to block the flow of air to the
heater core.
When the temperature control lever is in the “HOT” position, the air mix door opens to allow air to pass through the
heater core and heat the passenger compartment.
Placing the lever in an intermediate position will cause a lesser or greater amount of air to reach the heater core. In
this mode the passenger compartment temperature can be regulated.
N1A0019E
Legend
1. Heater unit 4. Cold air
2. Air mix door 5. Hot air
3. Heater core 6. Temperature controlled air
ON-VEHICLE SERVICE
Heater Unit/Heater Core
N1A0020E
Legend
1. Instrument panel assembly 7. Water hose
2. Defroster nozzle and ventilation duct 8. Bolt (Panel - Heater unit)
3. Heater control cable 9. Bolt (Heater unit - Reinforce)
4. Foot duct 10. Heater unit
5. Duct (NPR only) 11. Heater core
6. Front grille
Removal
Preparation:
Disconnect the battery ground cable.
1. Instrument Panel Assembly
Refer to Section 2 “CAB AND FRAME” for Instru-
ment Panel Assembly removal procedure.
2. Defroster Nozzle and Ventilation Duct
Refer to “DEFROSTER NOZZLE / VENTILATION
DUCT” removal procedure in this section.
3. Heater Control Cable
Disconnect the cables from the heater unit.
4. Foot Duct
5. Duct (NPR only)
6. Front Grille
7. Water Hose
• Loosen the water hose clips and disconnect the
N1A0022E
water hoses from the heater unit.
• Put caps to the openings of the heater unit and
the water hoses to prevent a lot of engine cool- Legend
ant from spilling out of them. 1. Pin
8. Bolt (Panel - Heater Unit) 2. Reinforce
3. Fixing bolt (Heater unit - Reinforce)
11. Heater Core
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Adjust the heater control cable.
Refer to “CONTROL LEVER ASSEMBLY” installa-
tion procedure in this section.
2. When installing the heater unit, defroster nozzles
and ventilation ducts, be sure that proper seal is
made, without any gap between them.
3. Check the engine coolant level. When the level is
below the specified amount, replenish engine cool-
ant to the proper level.
N1A0021E
Legend
1. Water hose clip
2. Bolt
9. Bolt (Heater Unit - Reinforce)

10. Heater Unit
• Drop the heater unit positioning pins from the
reinforce, and remove the heater unit while slid-
ing the engaged section between the evapora-
tor and the heater unit.
Heater Temperature Control Link Unit/Air Mix Door
N1A0023E
Legend
1. Heater unit 6. Air mix door
2. Rod 7. Mix sub lever
3. Door lever 8. Mode door
4. Foot duct 9. Heater core
5. Upper case
Removal 5. Upper Case

Preparation: Separate two halves of the upper case.
Disconnect the battery ground cable. 6. Air Mix Door
1. Heater Unit 7. Mix Sub Lever
Refer to “HEATER UNIT” removal procedure in this Press the tab of the sub lever inward, and take out
section. the sub lever.
2. Rod Installation
3. Door Lever
To install, follow the removal steps in the reverse order.
Pull out the door lever while raising up the catch of
the door lever.
4. Foot Duct
Heater Mode Control Link Unit/Mode Door
N1A0024E
Legend
1. Heater unit 6. Foot duct
2. Screw 7. Upper case
3. Washer and mode main lever 8. Mode door
4. Rod 9. Mode sub lever
5. Door lever 10. Heater core
Removal Pull out the door lever while raising up the catch of
Preparation: the door lever.
Disconnect the battery ground cable. 6. Foot Duct
1. Heater Unit 7. Upper Case
Refer to “HEATER UNIT” removal procedure in this 8. Mode Door
section. 9. Mode Sub Lever
2. Screw Press the tab of the sub lever inward, and take out
3. Washer and Mode Main Lever the sub lever.
4. Rod Installation
5. Door Lever
Blower Assembly
N1A0025E
Legend
1. Evaporator assembly (A/C only) 9. Bolt (Blower assembly - Reinforce)
2. Under cover (Without A/C) 10. Blower assembly
3. Glove box (Without A/C) 11. Floor panel
4. Duct (Without A/C) 12. Headlight grill cover
5. Washer tank (Without A/C) 13. Headlight assembly and combination light (RH)
6. Washer tank bracket 14. Front side panel
7. Blower control cable 15. Outside mirror cover
8. Bolt (Panel-Blower assembly) 16. Mirror stay cap
Removal • Remove the ground point bolts of headlight
Preparation: bracket (RH) (3) and right frame (front).
Disconnect the battery ground cable. • Remove the grommet (2) provided at the lower
Discharge and recover refrigerant (A/C only). right side of the blower assembly (1), and pull
1. Glove Box (Without A/C) in the harness to the room through the blower
Open the glove box and remove the fixing screws. hole.
2. Under Cover (Without A/C) 13. Bolt (Panel - Blower Assembly)
While pulling the under cover (1) with care, remove
the clips (2) on the backside of the cover.
N1A0027E
N1A0026E
3. Washer Tank (Without A/C)

Remove the washer tank fixing three bolts (Upper:
two, Lower: one) and disconnect the connector.
4. Washer Tank Bracket
Disconnect the harness connection connector and
remove the fixing bolts.
5. Blower Control Cable
Disconnect the blower control cable from the blow-
er assembly.
6. Evaporator Assembly
Refer to Section 1B “AIR CONDITIONING” for
Evaporator Assembly removal procedure.
7. Duct (Without A/C)
8. Mirror Stay Cap
Spread the stay fixing part by fingers to remove the N1A0028E
mirror stay cap. Be careful not to break the two in-
side claws.
9. Outside Mirror Cover Legend
Insert a screwdriver to the front ends of cover to re- 3. Headlight bracket (RH)
move the outside mirror cover. 4. Bolt (Panel-Blower assembly)
10. Front Side Panel
Remove five clips and a bolt.
11. Headlight Grill Cover
Remove the headlight grill cover from the claw part
of headlight assembly at first, and then remove a
clip.
12. Headlight Assembly and Combination Light (RH)
• Refer to Section 8 “CAB AND CHASSIS ELEC-
TRICAL” for Headlight removal procedure.
14. Bolt (Blower Assembly - Reinforce)
N1A0029E
Legend
1. Bolt (Blower assembly - Reinforce)
2. Fuse box
3. Pin
15. Blower Assembly

• Remove the blower fixing bolts.
• Drop the blower positioning pins from the rein-
force to remove them.
Installation
noting the following point.
1. Adjust the blower control cable.
Refer to “CONTROL LEVER ASSEMBLY” installa-
tion procedure in this section.
Blower Link Unit/Mode Door
N1A0030E
Legend
1. Blower assembly 5. Upper case
2. Blower filter 6. Mode door
3. Door lever 7. Mode sub lever
4. Lower case
Removal 5. Upper Case

Preparation: Separate two halves of the upper case.
Disconnect the battery ground cable. 6. Mode Door
1. Blower Assembly 7. Mode Sub Lever
Refer to “BLOWER ASSEMBLY” removal proce- Press the tab of the sub lever inward, and take out
dure in this section. the sub lever.
2. Blower Filter Installation
3. Door Lever
Pull out the door lever while raising up the catch of
the door lever.
4. Lower Case
Blower Motor
N1A0031E
Legend
1. Under cover 6. Fan
2. Washer tank 7. Blower motor
3. Washer tank bracket 8. Harness connection connector
4. Blower motor assembly 9. Blower motor connector
5. Clip
Removal
Preparation:
1. Under Cover
the clips (2) on the back side of the cover.
N1A0026E
2. Washer Tank
Remove the washer tank fixing three bolts (Upper:
two, Lower: one) and disconnect the connector.
3. Washer Tank Bracket
Disconnect the harness connection connector and
remove the fixing bolts.
4. Blower Motor Assembly
Disconnect the motor connector.
5. Clip
6. Fan
7. Blower Motor
Installation
Blower Filter
N1A0033E
Legend
1. Glove box 3. Slit
2. Blower filter
Removal
1. Glove Box
Open the glove box and remove the fixing screws.
2. Blower Filter
Pull out the blower filter from the blower upper slit.
Installation
Ventilation Grille
N1A0034E
Legend
[Driver Side] [Passenger Side]
1. Meter cluster 1. Instrument panel assembly
2. Ventilation grille 2. Ventilation duct
3. Ventilation grille
Removal
Preparation:
[Driver Side]
1. Meter CIuster
Refer to Section 2 “CAB AND FRAME” for Meter
Cluster removal procedure.
2. Ventilation Grille
Push the catches of the grille on the backside of
the cluster to the inside, and remove the ventilation
grille.
N1A0035E
[Passenger Side]
ment Panel removal procedure.
2. Ventilation Duct
3. Ventilation Grille
Installation
Defroster Nozzle/Ventilation Duct
N1A0036E
Legend
1. Instrument panel assembly 6. Defroster nozzle (It is not installed on the vehicle with
2. Ventilation duct (RH) forged air ventilation as an optional equipment.)
3. Ventilation duct (CTR) 7. Side defroster nozzle (It is not installed on the vehicle
4. Ventilation duct (LH) with forged air ventilation as an optional equipment.)
5. Reinforcement stay
Removal
Preparation:
ment Panel removal procedure.
2. Ventilation Duct (RH)
3. Ventilation Duct (CTR)
4. Ventilation Duct (LH)
5. Reinforcement Stay
6. Defroster Nozzle
7. Side Defroster Nozzle
Installation
Control Lever Assembly
N1A0037E
Legend
1. Glove box 7. Control lever assembly
2. Center cluster 8. Fan switch connector
3. Knob 9. A/C switch connector
4. Control panel bezel 10. Illumination bulb connector
5. Control cable 11. Clip
6. A/C switch (A/C only)
Removal 6. A/C Switch
Preparation: Push the catches at both sides of the A/C switch to
Disconnect the battery ground cable. the inside, and remove the A/C switch by pulling it
out.
1. Glove Box
Open the glove box and remove the fixing screws.
2. Center Cluster
• While pulling the cluster with care, remove the
upper and the back side clips (1) of the cluster.
• Disconnect the cigar lighter and illumination
connectors.
N1A0038E
3. Knob
N1A0040E
4. Control Panel Bezel
Push the four catches at both sides of the bezel to
the inside, and remove the illumination bulb (1) Legend
from the bezel (2). 1. A/C switch
2. Control lever
3. Catch
7. Control Lever Assembly

• Remove the lever fixing bolts and pull the lever
assembly out.
• Disconnect the A/C switch connector clip and
fan switch connector from the lever assembly.
• Remove the control cable fixing clip.
Installation
noting the following points:
1. Adjust the control cables.
Air source control cable
1) Slide the control lever to the left (“CIRC” posi-
tion).
N1A0039E
2) Connect the control cable at the “CIRC” posi-
5. Control Cable tion of the link unit of blower assembly and fix it
Disconnect the control cables from the heater and with the clip.
blower units. Temperature control cable
1) Slide the control lever to the left/right (“MAX
COLD”/“MAX HOT” position).
2) Connect the control cable at the “COLD”/“HOT” 2) Connect the control cable at the “DEFROST”
position of the temperature control link of the position of the mode control link of the heater
heater unit and fix it with the clip. unit and fix it with the clip.
Air select control cable 2. Check control cable operation.
1) Slide the control lever to the right (“DEFROST”
position).
N1A0041E
Control Panel Illumination Bulb
N1A0042E
Legend
1. Control panel bezel 3. Socket
2. Control panel illumination bulb
Removal
Preparation:
1. Control Panel Bezel
Refer to “CONTROL LEVER ASSEMBLY” removal
procedure.
2. Control Panel Illumination Bulb
Pull the bulb from the bulb socket.
Installation
Resistor
N1A0043E
Legend
1. Under cover 3. Resistor
2. Resistor connector 4. Washer tank
Removal
Preparation:
1. Under Cover
the clips (2) on the backside of the cover.
N1A0026E
2. Resistor Connector
3. Resistor
Installation
AIR CONDITIONING 1B-1

SECTION 1B
AIR CONDITIONING
Caution:
Contents
GENERAL DESCRIPTION ................................... 1B-2
Air Conditioning Refrigerant Cycle Construction ... 1B-2
Compressor ....................................................... 1B-3
Magnetic Clutch................................................. 1B-4
Condenser ......................................................... 1B-4
Receiver/Drier.................................................... 1B-4
Dual Pressure Switch (for GCC and Taiwan) .... 1B-5
Triple Pressure Switch (for Australia) ................ 1B-5
Evaporator ......................................................... 1B-6
Expansion Valve................................................ 1B-6
Electronic Thermostat........................................ 1B-7
Refrigerant Line ................................................. 1B-7
Service Charge Valves ...................................... 1B-7
Air Conditioning Parts........................................ 1B-8
ON-VEHICLE SERVICE ..................................... 1B-10
Precautions for Refrigerant -134a (R-134a) Air Condi-
tioning System ................................................. 1B-10
Precautions for Replacement or Repair of R-134a Air
Conditioning Parts ........................................... 1B-12
Compressor ..................................................... 1B-20
New Compressor Installation........................... 1B-21
Condenser Assembly (Except 4HK1-TC Engine Mod-
el For Australia) ............................................... 1B-22
Condenser Assembly (4HK1-TC Engine Model For
Australia) ......................................................... 1B-23
Receiver / Drier (Except 4HK1-TC Engine Model For
Australia) ......................................................... 1B-24
Receiver / Drier (4HK1-TC Engine Model For Austra-
lia).................................................................... 1B-25
Pressure Switch............................................... 1B-26
Evaporator Assembly ...................................... 1B-27
Evaporator Core / Expansion Valve (LHD Model)... 1B-30
Evaporator Core / Expansion Valve (RHD Model) .. 1B-32
A/C Switch ....................................................... 1B-34
Refrigerant Line (Except 4HK1-TC Engine Model For
Australia) ......................................................... 1B-36
Refrigerant Line (4HK1-TC Engine Model For Austra-
lia).................................................................... 1B-37
1B-2 AIR CONDITIONING
GENERAL DESCRIPTION
Caution:
This Vehicle is equipped with Refrigerant-134a (R-134a) air conditioning system.
R-134a and A-12 systems require different types of lubricating oil. Components designed solely for use with one re-
frigerant and oil type must never be interchanged with components designed solely for use with another refrigerant
and oil type. Refer to “ON-VEHICLE SERVICE” for Precautions for R-134a Air Conditioning system in this section.
Air Conditioning Refrigerant Cycle Construction
N1A0045E
Legend
A. High pressure, high temperature gas 6. Evaporator assembly
B. High pressure, high temperature mixture of gas 7. Expansion valve
and liquid 8. Temperature sensor
C. High pressure, medium temperature liquid 9. Evaporator core
D. Low pressure, low temperature mixture of liquid 10. Blower motor
and gas 11. Heater unit
E. Low pressure, low temperature gas 12. Heater core
1. Compressor 13. Temp. control door (Air mix door)
2. Magnetic clutch 14. MODE (DEF) control door
3. Receiver / Drier 15. MODE (VENT) control door
4. Pressure switch 16. MODE (HEAT) control door
5. Condenser 17. Electronic thermostat
The refrigeration cycle includes the following four pro- The high temperature, high pressure gas coming from
cesses as the refrigerant changes repeatedly from liquid the compressor is cooled and liquefied by the condenser
to gas and back to liquid while circulating. with outside air and accumulated in the receiver/drier.
The heat radiated to the outside air by the high temper-
Evaporation ature, high pressure gas in the compressor is called
The refrigerant is changed from a liquid to a gas inside heat of condensation. This is the total quantity of heat
the evaporator. The refrigerant mist that enters the (heat of vaporization) the refrigerant removes from the
evaporator vaporizes readily. The liquid refrigerant re- vehicle interior via the evaporator and the work (calcu-
moves the required quantity of heat (latent heat of va- lated as the quantity of heat) performed for compres-
porization) from the air around the evaporator core sion.
cooling fins and rapidly vaporizes.
Removing the heat cools the air, which is then radiated Expansion
from the fins and lowers the temperature of the air inside The expansion valve lowers the pressure of the refriger-
the vehicle. ant liquid so that it can easily vaporize.
The refrigerant liquid sent from the expansion valve and The process of lowering the pressure to encourage va-
the vaporized refrigerant gas are both present inside the porization before the liquefied refrigerant is sent to the
evaporator and the liquid is converted to gas. evaporator is called expansion. In addition, the expan-
With this change from liquid to gas, the pressure inside sion valve controls the flow rate of the refrigerant liquid
the evaporator must be kept low enough for vaporization while decreasing the pressure.
to occur at a lower temperature. That is, the quantity of refrigerant liquid vaporized inside
Because of that, the vaporized refrigerant is sucked into the evaporator is determined by the quantity of heat
the compressor. which must be removed at a prescribed vaporization
temperature. It is important that the quantity of refriger-
Compression ant be controlled to exactly the right value.
The refrigerant is compressed by the compressor until it
is easily liquefied at normal temperature. Compressor
The vaporized refrigerant in the evaporator is sucked The compressor performs two main functions:
into the compressor. This action maintains the refriger- It compresses low-pressure and low-temperature refrig-
ant inside the evaporator at a low pressure so that it can erant vapor from the evaporator into high-pressure and
easily vaporize, even at low temperatures close to 0°C high-temperature refrigerant vapor to the condenser.
(32°F). And it pumps refrigerant and refrigerant oil through the
Also, the refrigerant sucked into the compressor is com- A/C system.
pressed inside the cylinder to increase the pressure and This vehicle is equipped with a swash plate type com-
temperature to values such that the refrigerant can eas- pressor (DKS-15 D Type, DKS-13 CH Type for Taiwan
ily liquefy at normal ambient temperatures. only).
Swash plate compressors have a swash (slanted) plate
Condensation mounted on the shaft. When the shaft turns, the rotation
The refrigerant inside the condenser is cooled by the of the swash plate is converted to reciprocating piston
outside air and changes from gas to liquid. motion which sucks in and compresses the refrigerant
gas.
Shaft seal (Lip type) is installed between the valve plate
and shaft a cylinder head to prevent refrigerant gas
leaks. A specified amount of compressor oil is contained
in the oil pan.
This oil is supplied to the cylinders, bearings, etc., by an A condenser (1) may malfunction in two ways: it may
oil pump which is connected to the swash plate shaft. leak, or it may be restricted. A condenser restriction will
With some compressors the differential between the in- result in excessive compressor discharge pressure. If a
take pressure and discharge pressure generated while partial restriction is present, the refrigerant expands af-
the compressor is operating is used for lubrication in- ter passing through the restriction.
stead of an oil pump. Thus, ice or frost may from immediately after the restric-
The specified amount of compressor oil is 180cc (5.0 tion. If air flow through the condenser or radiator is
Imp fl oz). blocked, high discharge pressures will result. During
The oil used in the R-134a system compressor differs normal condenser operation, the refrigerant outlet line
from that used in R-12 systems. will be slightly cooler than the inlet line.
Also, compressor oil to be used varies according to the The vehicle is equipped with the condenser of the paral-
compressor model. Be sure to avoid mixing two or more lel flow type condenser. A larger thermal transmission
different types of oil. area on the inner surface of the tube allows the radiant
If the wrong oil is used, lubrication will be poor and the heat to increase and the ventilation resistance to de-
compressor will seize or malfunction. crease.
(Refer to “ON-VEHICLE SERVICE” for Precautions for
R-134a Air Conditioning System in this section)
The magnetic clutch connector is a waterproof type.
Magnetic Clutch
The compressor (1) is driven by the drive belt from the
crank pulley of the engine. If the compressor is activated
each time the engine is started, this causes too much
load to the engine. The magnetic clutch (2) transmits the
power from the engine to the compressor and activates
it when the air conditioning is “ON”. Also, it cuts off the
power from the engine to the compressor when the air
conditioning is “OFF”. (Magnetic clutch repair procedure
can be found in Section 1D) 1
N1A0047E
2
Receiver/Drier
1
The receiver/drier performs four functions;
• As the quantity of refrigerant circulated varies de-
pending on the refrigeration cycle conditions, suffi-
cient refrigerant is stored for the refrigeration cycle
to operate smoothly in accordance with fluctua-
tions in the quantity circulated.
• The liquefied refrigerant from the condenser is
mixed with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles is sent to the ex-
pansion valve, the cooling capacity will decrease
N1A0046E
considerably. Therefore, the liquid and air bubbles
are separated and only the liquid is sent to the ex-
Condenser pansion valve.
The condenser assembly in front of the radiator, which • The receiver/drier utilizes a filter and dryer to re-
carry the refrigerant and cooling fins to provide rapid move the dirt and water mixed in the cycling refrig-
transfer of heat. erant.
Also, it functions to cool and liquefy the high-pressure A receiver/drier may fail due to a restriction inside the
and high-temperature vapor sent from the compressor body of the unit. A restriction at the inlet to the receiver/
by the radiator fan or outside air. drier will cause high pressures.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum For Taiwan
with a smaller tank. It has 250cc (7.1 Imp fl oz) refriger-
ant capacity.
Dual Pressure Switch (for GCC and Taiwan)

The dual pressure switch (1) is installed on the upper
part the receiver/drier (2), to defect excessively high
pressure (high pressure switch) and prevent compres-
sor seizure due to the refrigerant leaking (low pressure
switch), switching the compressor “ON” or “OFF” as re-
quired.
The pressure switch connector is water proof type.
R-134a refrigerant pressure characteristics differ from
those of R-12. Thus, the dual pressure switch operation
for R-134a systems has been changed from R-12.
• Low-pressure control (for GCC) kPa (kg/cm2 / PSI)
Compressor
– ON: 206±30 (2.1±0.3 / 30±4)
– OFF: 177±25 (1.8±0.2 / 26±3) N1A0049E
• High-pressure control (for GCC)

Compressor
Triple Pressure Switch (for Australia)
– ON: 2,350±200 (24.0±2.0 / 341±29) The triple pressure switch (1) is installed on the upper
part of the receiver/drier (2). This switch is constructed
– OFF: 2,940±200 (30.0±2.0 / 426±29) with a unitized type of two switches. One of them is a low
• Low-pressure control (for Taiwan) and high pressure switch (Dual pressure switch) to
Compressor switch “ON” or “OFF” the magnetic clutch as a result of
– ON: 221±20 (2.25±0.2 / 32±3) irregularly high-pressure or low-pressure of the refriger-
– OFF: 196±20 (2.0±0.2 / 28±3) ant. The other one is a medium pressure switch (Cycling
switch) to switch “ON” or “OFF” the condenser fan by
• High-pressure control (for Taiwan) sensing the condenser high side pressure.
Compressor
• Low-pressure control kPa (kg/cm2 / PSI)
– ON: 2,350±200 (24.0±2.0 / 341±29) Compressor
– OFF: 2,940±200 (30.0±2.0 / 426±29) – ON: 206±30 (2.1±0.3 / 30±4)
For GCC
– OFF: 177±25 (1.8±0.2 / 26±3)
• Medium-pressure control
Condenser fan
– ON: 1,470±100 (15±1.0 / 213±14)
– OFF: 1,079±120 (11±1.2 / 156±17)
1 • High-pressure control
Compressor
– ON: 2,350±200 (24.0±2.0 / 341±29)
– OFF: 2,940±200 (30.0±2.0 / 426±29)
2
N1A0048E
Expansion Valve
This expansion valve is external pressure type and it is
installed at the evaporator intake port.
The expansion valve converts the high pressure liquid
1
refrigerant sent from the receiver/drier to a low pressure
liquid refrigerant by forcing it through a tiny port before
sending it to the evaporator.
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring adjust-
ment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure.
It then transmits these to the top chamber of the dia-
phragm.
The refrigerant pressure is transmitted to the dia-
phragms bottom chamber through the external equaliz-
ing pressure tube.
2
N1A0212E The ball valve is connected to the diaphragm. The open-
ing angle of the expansion valve is determined by the
Evaporator force acting on the diaphragm and the spring pressure.
The evaporator (1) cools and dehumidifies the air before The expansion valve regulates the flow rate of the refrig-
the air enters the vehicle. High-pressure liquid refriger- erant. Accordingly, when a malfunction occurs to this ex-
ant flows through the expansion valve into the low-pres- pansion valve, both discharge and suction pressures
sure area of the evaporator.The heat in the air passing get low, resulting in insufficient cooling capacity of the
through the evaporator core is lost to the cooler surface evaporator.
of the core, thereby cooling the air. For R-134a air conditioning, the expansion valve cali-
As heat is lost between the air and the evaporator core bration has been changed from R-12 to match the R-
surface, moisture in the vehicle condenses on the out- 134a characteristics.
side surface of the evaporator core and is drained off as
water.
When the evaporator malfunctions, the trouble will show
up as inadequate supply of cool air. The causes is typi-
cally a partially plugged core due to dirt, or a malfunc-
tioning blower motor.
The evaporator core with a laminate louver fin is a sin-
gle-sided tank type where only one tank is provided un-
der the core.
N1A0051E
Legend
1. Expansion valve
2. Insulator
3. Evaporator core
N1A0050E
Electronic Thermostat
The thermostat consists of the thermosensor (1) and
thermostat unit (2) which functions electrically to reduce
the noises being generated while the system is in oper-
ation.
The electronic thermosensor is mounted at the evapora-
tor core outlet and senses the temperature of the cool air
from the evaporator, Temperature signals are input to
the thermostat unit. This information is compared by the
thermo unit and the results in output to operate the A/C
thermo relay and turn the magnetic clutch “ON” or “OFF”
to prevent evaporator freeze-up.
A characteristic of the sensor is that the resistance de-
creases as the temperature increases and the resis-
tance increases as the temperature decreases.
N1A0053E
Legend
1. Reinforcement layer (Polyester)
2. External rubber layer
3. Internal rubber layer
4. Resin layer (Nylon)
Service Charge Valves

R-134a service charge valve shapes is different from the
charge valves used in the R-12 system. The charging
hoses have a quick-joint type fitting, to reduce refriger-
ant loss during removal and installation. This type of
valve also eliminates the possibility of cross charging R-
N1A0052E 12 and R-134a systems when using approved service
equipment.
Refrigerant Line
Restrictions in the refrigerant line will be indicated by:
1. Suction line; A restricted suction line will cause low
suction pressure at the compressor, low discharge
pressure and little or not cooling.
2. Discharge line; A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line; A liquid line restriction will be evidenced
by low discharge and suction pressure and insuffi-
cient cooling.
Refrigerant flexible hoses that have a low permeability
to refrigerant and moisture are used.
These low permeability hoses have a special nylon layer
on the inside.
N1A0054E
Air Conditioning Parts
Except 4HK1-TC Engine Model For Australia
4
7
N1A0055E
Legend
1. Evaporator 5. Refrigerant suction line
2. Compressor bracket 6. Receiver / drier
3. Compressor 7. Pressure switch
4. Refrigerant liquid line 8. Condenser
4HK1-TC Engine Model For Australia
8
4
6
5
2 3
N1A0197E
Legend
1. Evaporator 5. Refrigerant suction line
2. Compressor bracket 6. Receiver / drier
3. Compressor 7. Pressure switch
4. Refrigerant liquid line 8. Condenser
ON-VEHICLE SERVICE
Precautions for Refrigerant -134a (R-134a)
Legend
Air Conditioning System 1. Refrigerant line
This vehicle is equipped with Refrigerant-134a (R-134a) 2. Cap
air conditioning system. 3. Evaporator
R-134a and R-12 systems require different types of lu-
bricating oil. Components designed solely for use with Service charge valve:
one refrigerant and oil type must never be interchanged • The diameter of the service charge valve for the R-
with components designed solely for use with another 134a system is made larger than that for the R-12
refrigerant and oil type. system to prevent cross-contamination. In addi-
R-134a Refrigerant: tion, the screw-in type joint of the R-12 system is
• R-134a differs entirely from R-12 in its composition replaced with a quick joint type in the R-134a sys-
and, therefore, the two should never be mixed. Al- tem.
ways charge the specified amount of R-134a.
• The pressure characteristics of R-134a differ from
those of R-12. The low pressure is lower, and the
high pressure is higher.
R-134a Compressor oil:
• The R-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires
a mineral compressor oil. The two oils must never
be mixed.
• Compressor (PAG) oil varies according to com-
pressor model. Be sure to use oil specified for the
model of compressor.
Oil Specification
ZXL-100PG (ISUZU PART No. 8-97101-338-0)
• The PAG compressor oil for the R-134a system
tends to absorb moisture more quickly than mineral
oil. When air conditioning parts are removed for
servicing, all the open ends of parts and compo- N1A0057E
nents must be sealed with caps to keep out con-

taminants. • To prevent refrigerant from escaping during instal-
lation and removal of charging hoses from the ser-
• The PAG compressor oil must be stored in metal vice charge valves, quick-joint type fittings are
containers, not in plastic containers. used.
Connection: Push on firmly until locked (a “click”
will be heard).
Removal: Hold the grip-ring and pull to remove.
N1A0056E
N1A0058E
• Air conditioning manifold gauges, charging hoses and other service tools designed exclusively for the R-134a
system must be used with this vehicle.
N1A0059E
Legend
1. Manifold gauge 5. Charge valve handle
2. Quick joint (Low side) 6. Vacuum pump
3. Charging hose 7. Service container
4. Quick joint (High side)
• Do not use the same vacuum pump for evacuating
the R-134a and R-12 systems interchangeably
(The vacuum pump hose fitting is a M10X1.5).
• R-134a vacuum pumps must have a positive shut-
off valve.
N1A0061E
Refrigerant Leak Inspection

• The flame type gas leak detector for the R-12 sys-
tem cannot be used with the R-134a system.
N1A0060E
• The electric leak detector for the R-12 cannot be
used with the R-134a system as the R-134a parti-
cles are far smaller than the R-12 molecules and,
Legend therefore, may not be always detected. Use leak
1. M10 × 1.5 (Hose fitting) detectors designed exclusively for the R-134a sys-
tem.
Caution:
Never use the same vacuum pump for both R-134a and Precautions for Replacement or Repair of
R-12 systems, as cross contamination of compressor oil R-134a Air Conditioning Parts
may occur. There are certain procedure, practices and precautions
Refrigerant Recovery, Recycling and Charging that should be followed when servicing air conditioning
systems:
• Avoid releasing the R-134a into the atmosphere.
Use the ACR4 (R-134a Refrigerant Recovery/ Re- • Keep your work area clean.
cycling/ Recharging/ System) or equivalent to re- • Always wear safety goggle and protective gloves
cover and recycle R-134a. Note that the ACR4 (or when working on refrigerant systems.
equivalent) is not interchangeable between the R • Beware of the danger of carbon monoxide fumes
134a and R-12 systems. caused by running the engine.
ACR4 (115V 60Hz): 5-8840-0629-0 (J-39500-A)
• Beware of discharged refrigerant in enclosed or im-
ACR4 (220-240V 50/60Hz): 5-8840-0630-0 (J-
properly ventilated garages.
39500-220A)
ACR4 (220-240V 50/60Hz Australian model): 5- • Always disconnect the negative battery cable and
8840-0631-0 (J-39500-220ANZ) discharge and recover the refrigerant whenever re-
pairing the air conditioning system.
• When discharging and recovering the refrigerant,
do not allow refrigerant to discharge too fast; it will
draw compressor oil out of the system.
• Keep moisture and contaminants out of the sys-
tem. When disconnecting or removing any lines or
parts, use plugs or caps to close the fittings imme-
diately.
Never remove the caps or plugs until the lines or
parts are reconnected or installed.
• When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
• Always install new O-rings whenever a connection
is disassembled.
• Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
• When removing and replacing any parts which re-
quire discharging the refrigerant circuit, the opera-
tions described in this Section must be performed
in the following sequence:
1. Using the ACR4 (R-134a Refrigerant Recovery/
Recycling/ Recharging/ System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR4 (115V 60Hz): 5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz): 5-8840-0630-0 (J-
39500-220A)
ACR4 (220-240V 50/60Hz Australian model): 5-
8840-06311-0 (J-39500-220ANZ)
N1A0062E
When connecting the refrigerant line at the block joint,

securely insert the projecting portion of the joint portion
into the connecting hole on the unit side and secure with
a bolt.
N1A0061E
2. Remove and replace the defective part.

3. After evacuation, charge the air conditioning sys-
tem and check for leaks.
Repair of Refrigerant Leaks

N1A0063E
Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the con- Legend
necting portion from twisting or becoming damaged. 1. O-ring
2. Block joint
Apply specified compressor oil to the O-rings prior to

connecting.
Caution:
Compressor (PAG) oil to be used varies according to
compressor model. Be sure to apply specified oil for the
N1A0064E N1A0066E
O-rings must be closely aligned with raised portion of re-

frigerant line. Legend
1. Union
2. Nut
3. Damage
Leak at Refrigerant Line Connections

1. Check the torque on the refrigerant line fitting and,
if too loose, tighten to the specified torque.
• Use two wrenches to prevent twisting and damage
to the Line.
• Do not over tighten.
2. Perform a leak test on the refrigerant line fitting.
3. If the leak is still present, discharge and recover the
refrigerant from the system.
4. Replace the O-rings.
• O-rings cannot be reused. Always replace with
new ones.
N1A0065E
• Be sure to apply specified compressor oil to the
new O-rings.
Legend 5. Retighten the refrigerant line fitting to the specified
1. O-ring torque.
2. Raised portion • Use two wrenches to prevent twisting and damage
to the line.
Insert nut into union. First tighten nut by hand as much
as possible. Then, tighten nut to specified torque. 6. Evacuate, charge and retest the system.
(Refer to “SERVICE INFORMATION” for Fixing Torque Leak in The Hose
in section 00)
If the compressor inlet or outlet hose is leaking, the en-
tire hose must be replaced. Refrigerant hose must not
be cut or spliced for repair.
1. Locate the leak.
2. Discharge and recover the refrigerant.
3. Remove the hose assembly.
• Cap the open connections at once.
4. Connect the new hose assembly.
• Use two wrenches to prevent twisting or damage to
the hose fitting.
• Tighten the hose fitting to the specified torque. ACR4 (220-240V 50/60Hz Australian model): 5-88410-
5. Evacuate, charge and test the system. 0631-0 (J-39500-220ANZ)
Compression Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling, Evacuation and Charging

Handling Refrigerant-134a
Air conditioning systems contain R-134a.
This is a chemical mixture which requires special han-
dling procedures to avoid personal injury.
• Always wear safety goggles and protective gloves.
• Always work in a well-ventilated area. Do not weld
or steam clean on or near any vehicle-installed air
conditioning lines or components.
• If R-134a should come in contact with any part of
the body, flush the exposed area with cold water
and immediately seek medical help.
• If it is necessary to transport or carry any container
of R-134a in a vehicle, do not carry it in the passen-
ger compartment.
• If it is necessary to fill a small R-134a container
from a large one, never fill the container complete-
ly. Space should always be allowed above the liq-
uid for expansion.
• R-134a and R-12 should never be mixed as their
compositions are not the same.
N1A0067E
• R-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oil and, therefore, should 1. Connect the high and low charging hoses of the
be handled more carefully. ACR4 (or equivalent) as shown.
• Keep R-134a containers stored below 40°C 2. Recover the refrigerant by following the ACR4
(100°F). Manufacture’s Instructions.
Warning:
WARNING: 3. When a part is removed, put a cap or a plug on the
• SHOULD R-134a CONTACT YOUR EYE(S), connecting portion so that dust, dirt or moisture
CONSULT A DOCTOR IMMEDIATELY. cannot get into it.
• DO NOT RUB THE AFFECTED EYE(S). IN- Refrigerant Recycling
STEAD, SPLASH QUANTITIES OF FRESH
COLD WATER OVER THE AFFECTED AREA TO Recycle the refrigerant recovered by ACR4 or equiva-
GRADUALLY RAISE THE TEMPERATURE OF lent.
THE REFRIGERANT ABOVE THE FREEZING For the details of the actual operation, follow the steps
POINT. in the ACR4 Manufacture’s Instructions.
ACR4 (115V 60Hz): 5-8840-0629-0 (J-39500-A)
• OBTAIN PROPER MEDICAL TREATMENT AS
ACR4 (220-240V 50/60Hz): 5-8840-0630-0 (J-39500-
SOON AS POSSIBLE. SHOULD THE R-134a
220A)
TOUCH THE SKIN, THE INJURY MUST BE
ACR4 (220-240V 50/60Hz Australian model): 5-8840-
TREATED THE SAME AS SKIN WHICH HAS
0631-0 (J-39500-220ANZ)
BEEN FROSTBITTEN OR FROZEN.
Evacuation of The Refrigerant System
Refrigerant Recovery
The refrigerant must be discharged and recovered by Notice:
using ACR4 (R-134a Refrigerant Recovery/ Recycling/ Explained below is a method using a vacuum pump. Re-
Recharging/ System) (1) or equivalent before removing fer to ACR4 (or equivalent) manufacture’s instructions
or mounting air conditioning parts. when evacuating the system with ACR4 (or equivalent).
ACR4 (115V 60Hz): 5-8840-0629-0 (J-39500-A)
Air and moisture in the refrigerant will cause problems in
ACR4 (220-240V 50/60Hz): 5-8840-0630-0 (J-39500-
the air conditioning system.
220A)
Therefore, before charging the refrigerant, be sure to
evacuate air and moisture thoroughly from the system.
Charging The Refrigerant System
There are various methods of charging refrigerant into
the air conditioning system.
These include using ACR4 (R-134a Refrigerant Recov-
ery/ Recycling/ Recharging/ System) or equivalent and
direct charging with a manifold gauge charging station.
ACR4 (115V 60Hz): 5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz): 5-8840-0630-0 (J-39500-
220A)
ACR4 (220-240V 50/60Hz Australian model): 5-8840-
0631-0 (J-39500-220ANZ)
Charging procedure
• ACR4 (or equivalent) method
For the charging of refrigerant recovery by ACR4
(1), follow the manufacture’s instruction.
N1A0068E
1. Connect the gauge manifold.

• High-pressure valve (HI) — Discharge-side
• Low-pressure valve (LOW) — Suction-side
2. Discharge and recover the refrigerant.
3. Connect the center hose of the gauge manifold set
to the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves.
5. When the low-pressure gauge indicates approx.
750 mmHg (30 inHg), continue the evacuation for
5 minutes or more.
6. Close both hand valves and stop the vacuum
pump.
N1A0067E
7. Check to ensure that the pressure does not change
after 10 minutes or more.
• If the pressure changes, check the system for
leaks.
• If leaks occur, retighten the refrigerant line connec-
tions and repeat the evacuation steps.
8. If no leaks are found, again operate the vacuum
pump for 20 minutes or more. After confirming that
the gauge manifold pressure is at 750 mmHg(30
inHg), close both hand valves.
9. Close positive shutoff valve.
Stop the vacuum pump and disconnect the center
hose from the vacuum pump.
N1A0070E
Legend
1. Charge valve handle 3. Vacuum pump
2. Service container
• Direct charging with a manifold gauge charging 5. Tighten the plate nut sufficiently by hand. Then turn
station method the charge valve handle clockwise to lower the
Handling the charging valve handle when installing needle and bore a hole in the refrigerant container.
refrigerant container. 6. Turn the charge valve handle counterclockwise to
1. Before attaching the charge valve to the refrigerant raise the needle. The refrigerant in the refrigerant
container, turn the charge valve handle (1) coun- container is charged into the air conditioning sys-
terclockwise until the needle (2) is fully retracted. tem by the operation of the manifold gauge.
2. Turn the plate nut (3) counterclockwise until it • Be absolutely sure not to reuse the emptied refrig-
reaches its highest position relative to the charge erant container.
valve.
3. Install the charge valve onto the refrigerant con-
tainer (4).
4. Turn the plate nut clockwise and connect the cen-
ter hose of the manifold gauge to the charge valve
(5).
7. When the refrigerant container is emptied, use the
following procedure to replace it with a new refrig-
erant container.
1) Close the low pressure hand valve.
2) Raise the needle upward and remove the
charge valve.
3) Reinstall the charge valve to the new refriger-
ant container.
4) Purge any air existing in the center hose of the
manifold gauge.
8. Charge the system to the specified amount and
then close the low-pressure hand valve.
Refrigerant Amount g (lbs.)

450 (0.99) GCC, 600 (1.32) Australia & Taiwan
N1A0071E
• A fully charged system is indicated by the sight
glass on the receiver/drier being free of any bub-
1. Make sure the evacuation process is correctly bles (Refer to “Reading Sight Glass”).
completed. • Check the high and low pressure value of the man-
2. Connect the center-hose of the manifold gauge to ifold gauge.
the refrigerant container. • Check for refrigerant leaks by using a R-134a leak
• Turn the charge valve handle counterclockwise to detector.
purge the charging line and purge any air existing Immediately after charging refrigerant, both high
in the center-hose of the manifold gauge. and low pressures are slightly high and to the left
3. Open the low-pressure hand valve and charge the of the gauge, but they settle down to the guide
refrigerant about 200 g (0.44 lbs.). pressure valves as shown below:
• Make sure the high-pressure hand valve is closed. • Ambient temperature; 30 — 35°C (86 — 95°F)
• Avoid charging the refrigerant by turning the refrig- • Guide pressure
erant container upside down. High-pressure side;
Approx. 1373 — 1667 kPa (14 — 17 kg/cm2 / 199
4. Close the low-pressure hand valve of the manifold
— 242 PSI)
gauge.
Low-pressure side;
• Check to ensure that the degree of pressure does Approx. 127 — 245 kPa (1.3 — 2.5 kg/cm2 / 18 —
not charge. 36 PSl)
5. Check the refrigerant leaks by using a R-134a leak 9. Close the low pressure hand valve and charge
detector. valve of the refrigerant container.
• If a leak occurs, repair the leak connection, and 10. Stop the air conditioning and the engine.
start all over again from the first step of evacuation. 11. Disconnect the high and low pressure hoses from
6. If no leaks are found, open the low-pressure hand the manifold gauge fittings.
valve of the manifold gauge. Then continue charg-
ing refrigerant to the system.
• When charging the system becomes difficult:
1) Run the engine at 1,300 — 1,500 rpm and open
the all vehicle doors.
2) A/C switch is “ON”.
3) Set the fan control knob (fan switch) to its high-
est position.
Warning:
WARNING:
BE ABSOLUTELY SURE NOT TO OPEN THE HIGH-
PRESSURE HAND VALVE. SHOULD THE HIGH-
PRESSURE HAND VALVE BE OPENED, THE HIGH-
PRESSURE REFRIGERANT GAS WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE REFRIG-
ERANT CONTAINER TO BURST.
Reading Sight Glass
High The high pressure pipe The high pressure pipe There is little difference The high pressure pipe
and low is hot and the low pres- is warm and the low in temperature between is hot and the low pres-
pressure pipe is cold. There pressure pipe is cool. the high pressure pipe sure pipe is slightly
sure is a distinct difference in There is no great differ- and the low pressure warm. There is a differ-
pipe temperature between ence in temperature pipe. ence in temperature
temper- them. between them. between them.
ature
Sight Almost transparent. A A flow of bubbles Something like fog Even at idle with the fan
glass flow of bubbles can be always can be seen. It faintly can be seen. at “HI” (with the window
condi- seen, but they disap- appears sometimes fully open), the bubbles
tion pear when the throttle is transparent, and some- cannot be seen.
opened. times frothy.
N1A0072E N1A0073E N1A0074E N1A0075E
Air con-
ditioner
NG NG NG
cycle OK
(Not enough refrigerant) (Almost no refrigerant) (Too much refrigerant)
condi-
tion
The sight glass provides accurate diagnosis only under

the following conditions.
If the vehicle can be tested under these conditions,
check the sight glass appearance and compare to the
chart.
• Engine speed 1,500 RPM
• A/C switch “ON”
• Blower fan operating at highest speed
• Air source selector lever at “RECIRC”
• Temperature control knob at coldest position
• Ambient temperature below 35°C (95°F) and hu-
midity below 70%
Notice:
If the vehicle cannot be moved to a testing location that
meets these specifications, then the sight glass cannot
be used for diagnosis. You must discharge and recover
the refrigerant, then recharge the system with the spec-
ified amount of refrigerant. Then continue checking the
system performance.
• High side pressure less than 1667 kPa (17 kg⋅cm2
/ 242 PSI)
Notice:
If the high side pressure is greater than stated, the sight
glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system
with the specified amount of refrigerant.
Then continue checking system performance.
Compressor
3
4
N1A0076E
Legend
1. Magnetic clutch harness connector 4. Compressor
2. Drive belt 5. O-ring
3. Refrigerant line
Removal
Preparation:
1. Magnetic clutch harness connector
2. Drive Belt
Loosen the tension pulley center nut (1) and ten-
sion adjustment bolt (2), then remove the drive belt
(3).
N1A0077E
3. Refrigerant line
When removing the line connector, the connecting Legend
part should immediately be plugged or capped to 1. A/C compressor
prevent foreign matter from being mixed into the 2. Pulley
line. 3. Center nut
4. Compressor 4. Drive belt
5. Adjustment bolt
Installation 6. Crank pulley
1. Compressor 7. Tension pulley
Tighten the compressor fixing bolts to the specified 8. Generator
torque.
4. Magnetic Clutch Harness Connector
Tighten:
Compressor Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft). New Compressor Installation
2. Refrigerant Line The new compressor is filled with 180cc (5.0 lmp fl oz)
• Tighten the refrigerant line fixing bolt to the speci- of compressor oil and nitrogen gas. When mounting the
fied torque. compressor on the vehicle, perform the following steps;
Tighten:
Refrigerant Line Bolt to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft).
• O-ring cannot be reused. Always replace with new
ones.
• Be sure to apply new specified compressor oil to
the O-rings when connecting refrigerant lines.
3. Drive Belt
Push the drive belt with the force of 10 kg (22 lbs)
and adjust the drive belt tension by tightening idle
pulley tension adjustment bolt, until the 8 — 12 mm
(0.31 — 0.47 in) deflection of the belt is obtained.
Then tighten the pulley center nut.
Tighten:
Idle Pulley Center nut to 39 N⋅m (4.0 kg⋅m/29 lb⋅ft).
N1A0079E
1. Gently release nitrogen gas from the rear head of

the new compressor.
• Take care not to let the compressor oil flow out.
• Inspect O-rings and replace if necessary.
2. Turn the compressor several times by hand and re-
lease the compressor oil in the cylinder.
3. When installing on a new system, the compressor
should be installed as it is. When installing on a
used system, the compressor should be installed
after adjusting the amount of compressor oil. (Re-
fer to Section 1D “COMPRESSOR OVERHAUL”
for General Information.)
N1A0078E
Condenser Assembly (Except 4HK1-TC Engine Model For Australia)
"
#
!
N1A0199E
Legend
1. Refrigerant line 4. Condenser assembly
2. Pressure switch 5. Refrigerant line fixing clamp
3. Receiver / drier
Removal 4. Condenser assembly

Preparation: • Remove the radiator stay before condenser
Disconnect the battery ground cable. (GCC).
Installation
1. Pressure switch connector
2. Refrigerant line fixing clamp 1. Condenser Assembly
3. Refrigerant Line • If installing a new condenser, be sure to add 30cc
(0.8 Imp fl oz) of new specified compressor oil to a
• Use a back up wrench when disconnecting and re-
new one.
connecting the refrigerant lines.
• Tighten the condenser bolt to the specified torque.
• When removing the line, the connecting part
2. Refrigerant Line
should immediately be plugged or capped to pre-
vent foreign matter from being mixed into the line. • Tighten the inlet line to the specified torque.
• O-rings cannot be reused. Always replace with
Tighten: new ones.
Inlet line to 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
• Tighten the outlet line to the specified torque. the O-rings when connecting refrigerant line.
Tighten: 3. Refrigerant Line Fixing Clamp
Outlet line to 6 N⋅m (0.6 kg⋅m/4 lb⋅ft) 4. Pressure Switch Connector
Condenser Assembly (4HK1-TC Engine Model For Australia)
N1A0198E
Legend
1. Refrigerant line 3. Receiver / drier
2. Pressure switch 4. Condenser assembly
Removal • When removing the line, the connecting part

Preparation: should immediately be plugged or capped to pre-
Disconnect the battery ground cable. vent foreign matter from being mixed into the line.
Discharge and recover refrigerant. 2. Condenser assembly
1. Refrigerant Line
Installation
Tighten:
1. Condenser Assembly Inlet line to 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
• If installing a new condenser, be sure to add 30cc • Tighten the outlet line to the specified torque.
(0.8 Imp fl oz) of new specified compressor oil to a
new one. Tighten:
• Tighten the condenser bolt to the specified torque. Outlet line to 6 N⋅m (0.6 kg⋅m/4 lb⋅ft)
2. Refrigerant Line • O-rings cannot be reused. Always replace with
• Tighten the inlet line to the specified torque. new ones.
the O-rings when connecting refrigerant line.
Receiver / Drier (Except 4HK1-TC Engine Model For Australia)
N1A0080E
Legend
Receiver / Drier (4HK1-TC Engine Model For Australia)
N1A0198E
Legend
Removal 3. Receiver / Drier

Preparation: • Loosen the fixing bolt and carefully pull out the re-
Disconnect the battery ground cable. ceiver/drier.
Installation
1. Pressure Switch Connector
2. Refrigerant line
1. If installing a new receiver/drier, be sure to add 30
connecting the refrigerant line.
cc (0.8 Imp fl oz) of new specified compressor oil to
• When removing the line connected part, the con- a new one.
necting part should immediately be plugged or 2. Put the receiver/drier in the bracket, and connect
capped to prevent foreign matter from being mixed with the refrigerant line. Check that no excessive
into the line. force is imposed on the line. Fasten the fixing bolt
to the receiver/drier.
3. Tighten the line to the specified torque. 4. O-rings cannot be reused. Always replace with
new ones.
Tighten:
Refrigerant Line to 6 N⋅m (0.6 kg⋅m/4 lb⋅ft) 5. Be sure to apply new specified compressor oil to
the O-rings when connecting refrigerant line.
Pressure Switch
1
1
for GCC for Australia
for Taiwan
N1A0213E
Legend
1. Receiver / drier 3. Triple pressure switch
2. Dual pressure switch 4. Pressure switch connector
Removal Installation
Preparation: To install, follow the removal steps in the reverse order,
Disconnect the battery ground cable. noting the following points:
Discharge and recover refrigerant. 1. O-ring cannot be reused. Always replace with a
1. Pressure Switch Connector new one.
2. Pressure Switch 2. Be sure to apply new specified compressor oil to
• Turn the pressure switch counterlockwise to re- the O-ring when connecting pressure switch.
move it. 3. Tighten the pressure switch to the specified torque.
• When removing the switch connected part, the Tighten:
connecting part should immediately be plugged or Pressure switch to 10 N⋅m (1.0 kg⋅m/7.4 lb⋅ft)
capped to prevent foreign matter from being mixed
into the line.
Evaporator Assembly
2 7
12
4
11
5
10
N1A0083E
Legend
1. Electronic thermostat connector 7. Drain hose
2. Temperature control cable 8. Under cover
3. Front grille 9. Evaporator assembly
4. Duct (NPR only) 10. Washer tank
5. Center cluster 11. Glove box
6. Refrigerant line 12. Resistor connector
Removal 5. Temperature Control Cable
Preparation: Disconnect the temperature control cable of the
Disconnect the battery ground cable. control lever assembly from the heater unit.
Discharge and recover refrigerant. 6. Duct (NPR only)
1. Glove Box 7. Front Grille
Open the glove box and remove the fixing screws. After removing the grille, remove the grille fixing
2. Under Cover clip (RH).
the clips (2) on the back side of the cover.
N1A0086E
N1A0026E Legend
1. Panel
3. Washer Tank 2. Clip
• Remove the washer tank fixing three bolts (Upper:
two, Lower: one) and disconnect the connector. 8. Refrigerant Line
• Do not disconnect the washer tank tube. • Use a back up wrench when disconnecting and re-
4. Center Cluster connecting the refrigerant line.
• While pulling the cluster with care, remove the up- • When removing the refrigerant line connected part,
per and back side clips (1) of the cluster. the connecting part should immediately be plugged
or capped to prevent foreign matter from being
• Disconnect the cigar lighter and illumination con- mixed into the line.
nectors.
• Disconnect the resistor and thermostat connec-
tors.
• Disconnect the drain hose.
N1A0038E
N1A0087E
Legend
1. Evaporator
2. Grommet
3. Drain hose
Installation
1. To install a new evaporator assembly, add 50cc
(1.4 lmp fl oz) of new specified compressor oil to a
new core.
2. Tighten the refrigerant outlet line to the specified
torque.
Tighten:
Outlet line to 28 N⋅m (2.8 kg⋅m/21 lb⋅ft)
3. Tighten the refrigerant inlet line to the specified
torque.
Tighten:
Inlet line to 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
4. O-rings cannot be reused. Always replace with
new ones.
5. Be sure to apply new specified compressor oil to
the O-rings when connecting lines.
Evaporator Core / Expansion Valve (LHD Model)
N1A0088E
Legend
1. Evaporator assembly 7. Thermo sensor
2. Electronic thermostat 8. Lining
3. Upper case 9. Lower case
4. Insulator and under cover 10. Lining
5. Evaporator core 11. Insulator
6. Expansion valve
Removal 4. To install a new evaporator core, add 50cc (1.4
Preparation: Imp. fl oz) of new specified compressor oil to a new
Disconnect the battery ground cable. core and install the thermostat sensor to the evap-
Discharge and recover refrigerant. orator core specified position with the clip where it
was before.
Refer to “EVAPORATOR ASSEMBLY” removal 5. Tighten the refrigerant lines to the specified torque.
procedure in this section. Tighten:
2. Electronic Thermostat • Refrigerant line 1 to 10 N⋅m (1.0 kg⋅m/7 lb⋅ft)
• Remove the sensor fixing clip. • Refrigerant line 2 to 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
• Pull out the grommet from the upper case to re- • Refrigerant line 3 to 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
move the thermostat.
3. Upper Case
• Separate the upper and lower case.
• Slit the case parting face with a knife since the lin-
ing is separated.
4. Insulator and Under Cover
5. Evaporator Core
Pull up the core from the lower case.
6. Expansion Valve
• Tear off the insulator (1) carefully.
• Remove the sensor fixing clip.
• Use a back up wrench when disconnecting all re-
frigerant pipes, and remove the expansion valve
(2).
N1A0090E
6. Apply an adhesive to parting face of lining when

assembling evaporator assembly.
7. The thermostat sensor (1) is installed on the core
with the clip (2) and it must not interfere with the
core.
N1A0089E
Installation
1. O-rings cannot be reused. Always replace new
ones.
the O-rings when connecting lines. N1A0091E
3. Be sure to install the expansion valve sensor and
the insulator on the place where it was before.
Evaporator Core / Expansion Valve (RHD Model)
N1A0193E
Legend
1. Evaporator assembly 7. Evaporator core
2. Upper case 8. Pipe assembly
3. Lining 9. Lower case
4. Clip 10. Expansion valve
5. Amplifier & Thermistor 11. Insulator and cover
6. Thermo sensor
Removal
Preparation:
Refer to “EVAPORATOR ASSEMBLY” removal
procedure in this section.
2. Amplifier & Thermistor
• Remove the sensor fixing clip.
• Pull out the grommet from the upper case to re-
move the thermostat.
3. Upper Case
• Separate the upper and lower case.
• Slit the case parting face with a knife since the lin-
ing is separated.
4. Insulator and Cover N1A0194E
5. Evaporator Core
Pull up the core from the lower case.
6. Expansion Valve
Take off two installation bolts and subsequently re-
move pipe assembly and expansion valve sequen-
tially.
Installation
1. Tighten the expansion valve to the specified
torque.
Tighten:
Installation bolts to 5 N⋅m (0.5 kg⋅m/3.7 lb⋅ft)
ones.
the O-rings when connecting lines.
4. To install a new evaporator core, add 50cc (1.4
Imp. fl oz) of new specified compressor oil to a new
core.
5. Apply an adhesive to parting face of lining when
assembling evaporator assembly.
6. Install the amplifier & thermistor sensor (2) surely
to the evaporator core specified position with the
clip (1) where it was before.
A/C Switch
N1A0092E
Legend
1. Center cluster 3. Control panel bezel
2. Knob 4. A/C switch
Removal
Preparation:
1. Center Cluster
• While pulling the cluster with care, remove the up-
per and backside clips (1) of the cluster.
• Disconnect the cigar lighter and illumination con-
nectors.
N1A0038E
N1A0040E
2. Knob
3. Control Panel Bezel Legend
Push the four catches at both sides of the bezel to 1. A/C switch
the inside, and remove the illumination bulb (1) 2. Control lever
from the bezel (2). 3. Catch
Installation
N1A0039E
4. A/C Switch
Push the catches at both sides of the A/C switch to
the inside, and remove the switch by pulling it out.
Refrigerant Line (Except 4HK1-TC Engine Model For Australia)
4
N1A0096E
Legend
1. Refrigerant line (Compressor — Condenser) 4. Front grille
2. Refrigerant line (Receiver / Drier — Evaporator) 5. Refrigerant line (Compressor — Evaporator)
3. Clamp / Clip
Refrigerant Line (4HK1-TC Engine Model For Australia)
6
1
N1A0195E
Legend
1. Refrigerant line (Compressor — Condenser) 4. Front grille
2. Refrigerant line (Receiver / Drier — Evaporator) 5. Band clip
3. Refrigerant line (Compressor — Evaporator) 6. Band clip
Removal
Preparation:
1. Front grille
2. Clamp / Clip (Except 4HK1-TC Engine Model For
Australia)
3. Band clip (4HK1-TC Engine Model For Australia)
4. Refrigerant line (Compressor — Condenser)
5. Refrigerant line (Compressor — Evaporator)
6. Refrigerant line (Receiver / Drier — Evaporator)
• Use a back-up wrench when disconnecting and re-
• When removing the refrigerant line connecting
part, the connecting part should immediately be
plugged or capped to prevent foreign matter from
being mixed into the line.
Installation
ones.
the O-rings when connecting refrigerant lines.
3. If installing a new refrigerant line, be sure to add 10
cc (0.3 lmp fl oz) of new specified compressor oil to
a new one.
4. Tighten the refrigerant line to the specified torque.
(Refer to “SERVICE INFORMATION” for FIXING
TORQUE in section 00.)
COMPRESSOR OVERHAUL EXCEPT TAIWAN 1D1-1

SECTION 1D1
COMPRESSOR OVERHAUL EXCEPT TAIWAN
Caution:
Contents
GENERAL DESCRIPTION .................................1D1-2
GENERAL INFORMATION.................................1D1-3
Compressor Oil................................................1D1-3
SERVICE PROCEDURES ..................................1D1-5
Compressor Overhaul .....................................1D1-5
1D1-2 COMPRESSOR OVERHAUL EXCEPT TAIWAN
GENERAL DESCRIPTION
N1A0097E
When servicing the compressor, keep dirt or foreign ma- Swash plate compressors have a swash (slanted) plate
terial from getting on or into the compressor parts and mounted on the shaft. When the shaft turns, the rotation
system. Clean tools and a clean work area are important of the swash plate is converted to reciprocating piston
for proper service. The compressor connections and the motion which sucks in and compresses the refrigerant
outside of the compressor should be cleaned before any gas.
“On-Vehicle” repair, or before removal of the compres- Shaft seal (Lip type) is installed between the valve plate
sor. The parts must be kept clean at all times and any and shaft a cylinder head to prevent refrigerant gas
parts to be reassembled should be cleaned with Trichlo- leaks. A specified amount of compressor oil is contained
roethane, naphtha, kerosene, or equivalent solvent, and in the oil pan.
dried with dry air. Use only lint free cloths to wipe parts. This oil is supplied to the cylinders, bearings, etc., by an
The operations described below are based on bench oil pump which is connected to the swash plate shaft.
overhaul with compressor removed from the car, except With some compressors the differential between the in-
as noted. They have been prepared in order of accessi- take pressure and discharge pressure generated while
bility of the components. When the compressor is re- the compressor is operating is used for lubrication in-
moved from the car for servicing, the oil remaining in the stead of an oil pump.
compressor should be discarded and new refrigerant oil Three pistons are arranged at 120 degree intervals
added to the compressor. around the center of the swash plate shaft. These pis-
Magnetic clutch assembly repair procedures require tons are connected to the ends of the swash plate
that the system be discharged of refrigerant. (Refer to through balls.
Section 1B for “REFRIGERANT RECOVERY”.) The rotation of the swash plate causes reciprocating
Compressor malfunction will appear in one of four ways: movement of the piston inside the cylinders, with each
noise, seizure, leakage or low discharge pressure. Res- piston operating as two cylinders. Because of that, the
onant compressor noises are not cause for alarm; how- compressor operates as though it has 6 cylinders.
ever, irregular noise or rattles may indicate broken parts The specified amount of the compressors oil is 180 cc
or excessive clearances due to wear. To check seizure, (5.0 Imp fl oz).
de-energize the magnetic clutch and check to see if the The oil used in the R-134a system compressor differs
drive plate can be rotated. If rotation is impossible, the from that used in R-12 systems.
compressor is seized. Low discharge pressure may be Also, compressor oil to be used varies according to the
due to a faulty internal seal of the compressor, or a re- compressor model. Be sure to avoid mixing two or more
striction in the compressor. Low discharge pressure different types of oil.
may also be due to an insufficient refrigerant charge or If the wrong oil is used, lubrication will be poor and the
a restriction elsewhere in the system. These possibilities compressor will seize or malfunction.
should be checked prior to servicing the compressor. If (Refer to Section 1B “ON-VEHICLE SERVICE” for Pre-
the compressor is inoperative, but is not seized, check cautions for R-134a Air Conditioning System in this
to see if current is being supplied to the magnetic clutch manual.)
coil terminals.
This vehicle is provided with a swash plate type com-
pressor.
GENERAL INFORMATION
Compressor Oil
Oil specification
a mineral compressor oil.
The two oils must never be mixed.
Specified Compressor Oil
ZXL-100PG (ISUZU PART NO. 8-97101-338-0)
Handling of oil
• The oil should be free from moisture, dust, metal
powder, etc.
• Do not mix with other oil.
• The water content in the oil increases when ex-
posed to the air. After use, seal oil from air imme- N1A0140E
diately.
(R-134a PAG Compressor Oil absorbs moisture 4. If the amount of oil drained is much less than 90 cc
very easily than R-12.) (2.5 Imp fl oz), some refrigerant may have leaked
• The compressor oil must be stored in steel contain- out. Conduct leak tests on connections of each
ers, not in plastic containers. system, and if necessary, repair or replace faulty
parts.
Compressor oil check 5. Check the compressor oil for contamination.
The oil used to lubricate the compressor is circulating (Refer to “Contamination of Compressor Oil” in this
with the refrigerant. section.)
Whenever replacing any component of the system or a 6. Adjust oil level following the procedure below.
large amount of gas leakage occurs, add oil to maintain
the original amount of oil. Collected Amount Charging Amount
Oil Capacity more than 120 cc
same as collected amount
Capacity total in system 180 cc (5.0 Imp fl oz) (3.4 Imp fl oz)
Compressor (Service less than 120 cc

180 cc (5.0 Imp fl oz) 120 cc (3.4 lmp fl oz)
parts) charging amount (3.4 lmp fl oz)
Checking and Adjusting for Used Compressor 7. Install the compressor, then evacuate, charge and
perform oil return operation.
1. Perform Oil return operation.
(Refer to “Oil Return Operation” in this section.) 8. Check system operation.
When it is impossible to perform oil return
2. Discharge refrigerant and remove the compressor.
operation, the compressor oil should be checked in
3. Drain the compressor oil and measure the extract- the following order:
ed oil with a measuring cylinder.
1. Discharge refrigerant and remove the compressor.
2. Drain the compressor oil and measure the extract-
3. Check the oil for contamination.
4. If more than 120 cc (3.4 lmp fl oz) of oil is extracted
from the compressor, supply same amount of oil to
the compressor to be installed.
If the amount of oil extracted is less than 120 cc
(3.4 lmp fl oz), recheck the compressor oil in the
following order:
5. Supply 120 cc (3.4 lmp fl oz) of oil to the compres-
sor and install it on to the vehicle.
6. Perform oil return operation.
Checking and Adjusting for Compressor Replace- Replacement of component parts
ment When replacing system component parts, supply the fol-
180 cc (5.0 lmp fl oz) of oil is charged in compressor lowing amount of oil to the component parts to be in-
(service parts). So it is necessary to drain the proper stalled.
amount of oil from the new compressor.
1. Perform oil return operation. Component parts to be installed Amount of oil
2. Discharge refrigerant and remove the compressor. Evaporator 50 cc (1.4 lmp fl oz)
Condenser 30 cc (0.8 Imp fl oz)
ed oil.
4. Check the compressor oil for contamination. Receiver/drier 30 cc (0.8 Imp fl oz)
5. Adjust oil level as required. Refrigerant line (One piece) 10 cc (0.3 Imp fl oz)
Amount of oil drained Draining amount of oil

from used compressor from new compressor
less than 180 cc
Same as drained amount
(3.4 Imp fl oz)
more than 180 cc
180 cc (3.4 lmp fl oz)
(3.4 Imp fl oz)
6. Evacuate, charge and perform oil return operation.

7. Check system operation.
Contamination of compressor oil

Unlike engine oil, no cleaning agent is added to the com-
pressor oil. Even if the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
N1A0141E
conditions:
• The capacity of the oil has increased.
• The oil has changed color to red.
• Foreign substances, metal powder, etc., are
present in the oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor
oil is discovered, the receiver/drier must be re-
placed.
Oil return operation

There is close affinity between the oil and the refriger-
ant. During normal operation, part of the oil recirculates
with the refrigerant in the system.
When checking the amount of oil in the system, or re-
placing any component of the system, the compressor
must be run in advance for oil return operation. The pro-
cedure is as follows:
1. Open the all doors and engine hood.
2. Start the engine and A/C switch is “ON”. Set the fan
control knob at its highest position.
3. Run the compressor for more than 20 minutes be-
tween 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
SERVICE PROCEDURES
Compressor Overhaul
4
2
3
N1A0142E
Legend
1. Drive plate bolt 5. Pulley assembly
2. Drive plate 6. Lead wire connector
3. Shim(s) 7. Field coil
4. Snap ring
Disassembly
1. Drive Plate Bolt
Using drive plate holder to prevent the drive plate
from rotating, then remove the bolt.
Drive Plate Holder: 5-8840-0117-0 (J-33939)
5-8840-0117-0
N1A0145E
6. Pulley Assembly
Using pulley puller pilot and pulley puller to remove
the pulley assembly.
Pulley Puller Pilot: 5-8840-0121-0 (J-33943)
N1A0143E Pulley Puller: 5-8840-0111-0 (J-8433)
2. Drive Plate Check the appearance of the pulley assembly. If
Using drive plate puller and forcing screw to re- the frictional surface of the pulley shows signs of
move the drive plate. excessive grooving due to slippage, both the pulley
and drive plate should be replaced. The frictional
Drive Plate Puller: 5-8840-0122-0 (J-33944-A)
surfaces of the pulley assembly should be cleaned
Forcing Screw: 5-8840-0621-0 (J-33944-4) with a suitable solvent before reinstallation.
If the frictional surface shows signs of damage due
to excessive heat, the drive plate and pulley should
be replaced.
5-8840-0111-0
5-8840-0621-0
5-8840-0122-0
5-8840-0121-0
N1A0146E
7. Lead Wire Connector

N1A0144E Remove the lead wire from lead wire fixing bush.
8. Field Coil
3. Shim(s) Loosen three screws and remove the field coil with
4. Snap Ring lead wire.
5. Cover (If so equipped) Check coil for loose connector or cracked insula-
Using snap ring pliers to remove the snap ring. tion.
5-8840-0007-0
5-8840-0118-0
N1A0147E N1A0149E
Reassembly 4. Cover (If so equipped)

1. Field Coil 5. Snap Ring
2. Lead Wire Connector Install the snap ring with the inside indented portion
Install the field coil to the compressor. facing out.
Lead wire must be facing up.
Tighten the field coil fixing screws to the specified
torque.
Tighten:
Field coil screw to 5 N⋅m (0.5 kg⋅m / 44 lb⋅ft)
N1A0119E
6. Shim(s)
7. Drive Plate
Install the drive plate to the compressor drive shaft
together with the original shim(s).
N1A0148E
Press the drive plate by hand.
3. Pulley Assembly
Using pulley installer and drive handle to install the
pulley assembly.
Pulley Installer: 5-8840-0118-0 (J-33940)
Drive Handle: 5-8840-0007-0 (J-8092)
N1A0150E N1A0152E
8. Drive Plate Bolt

from rotating.
Tighten the bolt to the specified torque.
Tighten:
Drive plate bolt to 15 N⋅m (0.5 kg⋅m / 11 lb⋅ft)
5-8840-0117-0
N1A0143E
After tightening the bolt, check to be sure the pulley

rotates smoothly.
Check to be sure that the clutch clearance is be-
tween 0.3 — 0.6 mm (0.01 — 0.02 in).
If necessary, install adjusting shim(s).
Adjusting shims are available in the following thick-
ness.
0.1 mm (0.0039 in)

Thickness 0.3 mm (0.0118 in)
0.5 mm (0.0197 in)
COMPRESSOR OVERHAUL FOR TAIWAN 1D2-1

SECTION 1D2
COMPRESSOR OVERHAUL FOR TAIWAN
Caution:
Contents
GENERAL DESCRIPTION .................................1D2-2
GENERAL INFORMATION.................................1D2-3
Compressor Oil................................................1D2-3
SERVICE PROCEDURES ..................................1D2-5
Compressor Overhaul .....................................1D2-5
1D2-2 COMPRESSOR OVERHAUL FOR TAIWAN
GENERAL DESCRIPTION
N1A0097E
When servicing the compressor, keep dirt or foreign ma- Swash plate compressors have a swash (slanted) plate
terial from getting on or into the compressor parts and mounted on the shaft. When the shaft turns, the rotation
system. Clean tools and a clean work area are important of the swash plate is converted to reciprocating piston
for proper service. The compressor connections and the motion which sucks in and compresses the refrigerant
outside of the compressor should be cleaned before any gas.
“On-Vehicle” repair, or before removal of the compres- Shaft seal (Lip type) is installed between the valve plate
sor. The parts must be kept clean at all times and any and shaft a cylinder head to prevent refrigerant gas
parts to be reassembled should be cleaned with Trichlo- leaks. A specified amount of compressor oil is contained
roethane, naphtha, kerosene, or equivalent solvent, and in the oil pan.
dried with dry air. Use only lint free cloths to wipe parts. This oil is supplied to the cylinders, bearings, etc., by an
The operations described below are based on bench oil pump which is connected to the swash plate shaft.
overhaul with compressor removed from the car, except With some compressors the differential between the in-
as noted. They have been prepared in order of accessi- take pressure and discharge pressure generated while
bility of the components. When the compressor is re- the compressor is operating is used for lubrication in-
moved from the car for servicing, the oil remaining in the stead of an oil pump.
compressor should be discarded and new refrigerant oil Three pistons are arranged at 120 degree intervals
added to the compressor. around the center of the swash plate shaft. These pis-
Magnetic clutch assembly repair procedures require tons are connected to the ends of the swash plate
that the system be discharged of refrigerant. (Refer to through balls.
Section 1B for “REFRIGERANT RECOVERY”.) The rotation of the swash plate causes reciprocating
Compressor malfunction will appear in one of four ways: movement of the piston inside the cylinders, with each
noise, seizure, leakage or low discharge pressure. Res- piston operating as two cylinders. Because of that, the
onant compressor noises are not cause for alarm; how- compressor operates as though it has 6 cylinders.
ever, irregular noise or rattles may indicate broken parts The specified amount of the compressors oil is 180 cc
or excessive clearances due to wear. To check seizure, (5.0 Imp fl oz).
de-energize the magnetic clutch and check to see if the The oil used in the R-134a system compressor differs
drive plate can be rotated. If rotation is impossible, the from that used in R-12 systems.
compressor is seized. Low discharge pressure may be Also, compressor oil to be used varies according to the
due to a faulty internal seal of the compressor, or a re- compressor model. Be sure to avoid mixing two or more
striction in the compressor. Low discharge pressure different types of oil.
may also be due to an insufficient refrigerant charge or If the wrong oil is used, lubrication will be poor and the
a restriction elsewhere in the system. These possibilities compressor will seize or malfunction.
should be checked prior to servicing the compressor. If (Refer to Section 1B “ON-VEHICLE SERVICE” for Pre-
the compressor is inoperative, but is not seized, check cautions for R-134a Air Conditioning System in this
to see if current is being supplied to the magnetic clutch manual.)
coil terminals.
This vehicle is provided with a swash plate type com-
pressor.
GENERAL INFORMATION
Compressor Oil
Oil specification
a mineral compressor oil.
The two oils must never be mixed.
Specified Compressor Oil
ZXL-100PG (ISUZU PART NO. 8-97101-338-0)
Handling of oil
• The oil should be free from moisture, dust, metal
powder, etc.
• Do not mix with other oil.
N1A0098E
• The water content in the oil increases when ex-
posed to the air. After use, seal oil from air imme- 4. If the amount of oil drained is much less than 90 cc
diately. (2.5 Imp fl oz), some refrigerant may have leaked
(R-134a PAG Compressor Oil absorbs moisture out. Conduct leak tests on connections of each
very easily than R-12.) system, and if necessary, repair or replace faulty
• The compressor oil must be stored in steel contain- parts.
ers, not in plastic containers. 5. Check the compressor oil for contamination.
(Refer to “Contamination of Compressor Oil” in this
Compressor oil check
section.)
The oil used to lubricate the compressor is circulating 6. Adjust oil level following the procedure below.
with the refrigerant.
Whenever replacing any component of the system or a Collected Amount Charging Amount
large amount of gas leakage occurs, add oil to maintain
more than 120 cc
the original amount of oil. same as collected amount
(3.4 lmp fl oz)
Oil Capacity
less than 120 cc
Capacity total in system 180 cc (5.0 Imp fl oz) 120 cc (3.4 lmp fl oz)
(3.4 lmp fl oz)
Compressor (Service
180 cc (5.0 Imp fl oz) 7. Install the compressor, then evacuate, charge and
parts) charging amount
perform oil return operation.
Checking and Adjusting for Used Compressor 8. Check system operation.
1. Perform Oil return operation. When it is impossible to perform oil return
(Refer to “Oil Return Operation” in this section.) operation, the compressor oil should be checked in
2. Discharge refrigerant and remove the compressor. the following order:
3. Drain the compressor oil and measure the extract- 1. Discharge refrigerant and remove the compressor.
ed oil with a measuring cylinder. 2. Drain the compressor oil and measure the extract-
3. Check the oil for contamination.
4. If more than 120 cc (3.4 lmp fl oz) of oil is extracted
from the compressor, supply same amount of oil to
the compressor to be installed.
If the amount of oil extracted is less than 120 cc
(3.4 lmp fl oz), recheck the compressor oil in the
following order:
5. Supply 120 cc (3.4 lmp fl oz) of oil to the compres-
sor and install it on to the vehicle.
6. Perform oil return operation.
Checking and Adjusting for Compressor Replace- Replacement of component parts
ment When replacing system component parts, supply the fol-
180 cc (5.0 lmp fl oz) of oil is charged in compressor lowing amount of oil to the component parts to be in-
(service parts). So it is necessary to drain the proper stalled.
amount of oil from the new compressor.
1. Perform oil return operation. Component parts to be installed Amount of oil
2. Discharge refrigerant and remove the compressor. Evaporator 50 cc (1.4 lmp fl oz)
Condenser 30 cc (0.8 Imp fl oz)
ed oil.
4. Check the compressor oil for contamination. Receiver/drier 30 cc (0.8 Imp fl oz)
5. Adjust oil level as required. Refrigerant line (One piece) 10 cc (0.3 Imp fl oz)
Amount of oil drained Draining amount of oil

from used compressor from new compressor
less than 180 cc
Same as drained amount
(3.4 Imp fl oz)
more than 180 cc
180 cc (3.4 lmp fl oz)
(3.4 Imp fl oz)
6. Evacuate, charge and perform oil return operation.

7. Check system operation.
Contamination of compressor oil

Unlike engine oil, no cleaning agent is added to the com-
pressor oil. Even if the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
N1A0099E
conditions:
• The capacity of the oil has increased.
• The oil has changed color to red.
• Foreign substances, metal powder, etc., are
present in the oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor
oil is discovered, the receiver/drier must be re-
placed.
Oil return operation

There is close affinity between the oil and the refriger-
ant. During normal operation, part of the oil recirculates
with the refrigerant in the system.
When checking the amount of oil in the system, or re-
placing any component of the system, the compressor
must be run in advance for oil return operation. The pro-
cedure is as follows:
1. Open the all doors and engine hood.
2. Start the engine and A/C switch is “ON”. Set the fan
control knob at its highest position.
3. Run the compressor for more than 20 minutes be-
tween 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
SERVICE PROCEDURES
Compressor Overhaul
N1A0100E
Legend
1. Drive plate bolt 14. Front cylinder head
2. Drive plate 15. O-ring
3. Shim(s) 16. Gasket
4. Snap ring 17. Front valve plate
5. Cover (If so equipped) 18. Front suction valve
6. Pulley assembly 19. Rear cylinder head
7. Lead wire connector 20. O-ring
8. Field coil 21. Gasket
9. Felt (If so equipped) 22. Rear valve plate
10. Shaft seal cover (If so equipped) 23. Rear suction valve
11. Snap ring 24. Cylinder and shaft assembly
12. Shaft seal assembly 25. Key
13. Through bolt with gasket 26. Oil drain plug
Disassembly
1. Drive Plate Bolt
from rotating, then remove the bolt.
N1A0103E
Legend
1. Cover
N1A0101E
6. Pulley Assembly
Using pulley puller pilot and pulley puller to remove
2. Drive Plate the pulley assembly.
Using drive plate puller and forcing screw to re- Pulley Puller Pilot: 5-8840-0121-0 (J-33943)
move the drive plate. Pulley Puller: 5-8840-0111-0 (J-8433)
Drive Plate Puller: 5-8840-0122-0 (J-33944-A) Check the appearance of the pulley assembly. If
Forcing Screw: 5-8840-0621-0 (J-33944-4) the frictional surface of the pulley shows signs of
If the frictional surface shows signs of damage due excessive grooving due to slippage, both the pulley
to excessive heat, the drive plate and pulley should and drive plate should be replaced. The frictional
be replaced. surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.
N1A0102E
N1A0104E
3. Shim(s)
4. Snap Ring 7. Lead Wire Connector
Remove the lead wire from lead wire fixing bush.
5. Cover (If so equipped)
Using snap ring pliers to remove the snap ring.
8. Field Coil
Loosen three screws and remove the field coil with
lead wire.
Check coil for loose connector or cracked insula-
tion.
N1A0105E
9. Felt (If so equipped)

10. Shaft Seal Cover (If so equipped)
Using shaft seal remover to remove the shaft seal N1A0106E
cover (1).
Engage the remover hook with the shaft seal cover 11. Snap Ring
groove and slowly draw the shaft seal cover out. Using snap ring pliers to remove the snap ring.
Shaft Seal Remover: 5-8840-0120-0 (J-33942)
N1A0107E
12. Shaft Seal Assembly
Using shaft seal remover to remove the shaft seal
assembly.
Engage the remover hook with the shaft seal as-
sembly groove and slowly draw the shaft seal as-
sembly out.
Shaft Seal Remover: 5-8840-0120-0 (J-33942)
The shaft seal (1) is precision-machined and its
critical parts are finished to extremely close toler-
ances. The assembly must be handled with great
care, it slips face demanding particularly careful
handling.
The shaft seal can not be reused. Install a new
shaft seal at reassembly.
Take care not to scratch or otherwise damage the
shaft seal face.
Keep the shaft seal free from lint and dirt. N1A0109E
16. Gasket
17. Front Valve Plate
18. Front Suction Valve
Check the front valve plate for scratching and
bending.
Check the front valve plate and the front cylinder
head for nicks and burrs on the sealing surface.
Buff or replace the valve plate and cylinder head if
nicks and burrs are present.
Check that the front valve plate passage is free
from obstructions.
Check the front valve plate and the cylinder head
for cracks.
Replace the valve plate and cylinder head if cracks
are present.
N1A0108E 19. Rear Cylinder Head
20. O-ring
13. Through Bolt with Gasket Alternately tap the projections on the circumfer-
14. Front Cylinder Head ence of the rear cylinder head with a screwdriver
15. O-ring and a plastic hammer to remove the rear cylinder
Alternately tap the projections on the circumfer- head.
ence of the front cylinder head with a screwdriver
and a plastic hammer to remove the front cylinder
head.
N1A0110E
21. Gasket
Notice:
22. Rear Valve Plate Do not mix up the front and rear valve plates.
23. Rear Suction Valve
4. Gasket
24. Cylinder and shaft assembly
Apply a coat of new compressor oil to the new gas-
Check the rear valve plate for scratching and bend-
ket.
ing.
Install the gasket to the valve plate.
Check the rear valve plate and the rear cylinder
head for nicks and burrs on the sealing surface. 5. O-ring
Buff or replace the valve plate and cylinder head if 6. Rear Cylinder Head
nicks and burrs are present. Apply a coat of new compressor oil to the new O-
ring.
Check that the rear valve plate passage is free
from obstructions. Install the O-ring to the rear cylinder head.
Check the rear valve plate and the cylinder head Install the rear cylinder head.
for cracks. Tap the rear cylinder head into place with a plastic
Replace the valve plate and cylinder head if cracks hammer.
are present.
Reassembly
1. Cylinder and Shaft Assembly
Clamp the cylinder shaft assembly in a vise. The
rear side of the cylinder shaft assembly must be
facing up.
2. Rear Suction Valve
Apply a coat of new compressor oil to the new suc-
tion valve.
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.
N1A0112E
Legend
1. Rear cylinder head
2. Gasket
3. O-ring
4. Valve plate
5. Suction valve
7. Front Suction Valve

Set the cylinder shaft assembly with the front side
facing up.
N1A0111E Apply a coat of new compressor oil to the new suc-
tion valve.
Legend Install the suction valve by aligning it with the
1. Escape groove spring pin and the cylinder valve relief grooves.
2. Suction valve
3. Piston
3. Rear Valve Plate

Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by align-
ing it with the spring pin.
11. Front Cylinder Head
Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head.
Install the front cylinder head.
Tap the front cylinder head into place with a plastic
hammer.
Notice:
When installing the cylinder head, be careful that the
end of the drive shaft does not damage the shaft seal
assembly surface in the cylinder head.
12. Through Bolt with Gasket
Gaskets cannot reused. Always replace new ones.
Tighten the bolts to the specified torque a little at a
time in the sequence shown in the illustration.
N1A0111E Tighten:
Through bolt to 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
Legend
1. Escape groove
2. Suction valve
3. Piston
8. Front Valve Plate

Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by align-
ing it with the spring pin.
Notice:
Do not mix up the front and rear valve plates.
N1A0114E
Rotate the compressor drive shaft two or three

times to make sure that it moves smoothly.
13. Shaft Seal Assembly
CIean the sealing portion of the compressor and
shaft seal (1).
Install the shaft seal guide onto the end of the drive
shaft.
Shaft Seal Guide: 5-8840-0368-0 (J-34614)
Apply new compressor oil to the shaft seal guide.
Install the shaft seal onto the compressor drive
shaft head by using shaft seal installer.
N1A0113E
Shaft Seal Installer: 5-8840-0120-0 (J-33942)
9. Gasket
Apply new compressor oil to the new gasket.
Install the gasket to the valve plate by aligning it
with the spring pin.
10. O-ring
N1A0115E N1A0116E
14. Snap Ring

Using snap ring pliers to install the snap ring. Legend
1. Shaft seal cover
15. Shaft Seal Cover (If so equipped)
2. Felt
16. Felt (If so equipped)
Clean the sealing portion of the compressor and 17. Field Coil
shaft seal cover.
18. Lead Wire Connector
Install the shaft seal guide onto the end of the drive
Install the field coil to the compressor.
shaft.
Lead wire must be facing up.
Shaft Seal Guide: 5-8840-0368-0 (J-34614)
Tighten the field coil fixing screws to the specified
Apply new compressor oil to the shaft seal guide. torque.
Install the shaft seal cover onto the drive shaft by
using shaft seal installer. Tighten:
The installation position of the shaft seal cover is Field coil screw to 5 N⋅m (0.5 kg⋅m / 44 lb⋅ft)
shown in the illustration.
Shaft Seal Installer: 5-8840-0120-0 (J-33942)
N1A0117E N1A0119E
19. Pulley Assembly 22. Shim(s)

Using pulley installer and drive handle to install the 23. Drive Plate
pulley assembly. Install the drive plate to the compressor drive shaft
Pulley Installer: 5-8840-0118-0 (J-33940) together with the original shim(s).
Drive Handle: 5-8840-0007-0 (J-8092) Press the drive plate by hand.
N1A0118E N1A0120E
20. Cover (If so equipped) 24. Drive Plate Bolt

21. Snap Ring Using drive plate holder to prevent the drive plate
Install the snap ring with the inside indented portion from rotating.
facing out. Drive Plate Holder: 5-8840-0117-0 (J-33939)
Tighten the bolt to the specified torque.
Tighten:
Drive plate bolt to 15 N⋅m (0.5 kg⋅m / 11 lb⋅ft)
N1A0101E
After tightening the bolt, check to be sure the pulley

rotates smoothly.
Check to be sure that the clutch clearance is be-
tween 0.3 — 0.6 mm (0.01 — 0.02 in).
If necessary, install adjusting shim(s).
Adjusting shims are available in the following thick-
ness.
0.1 mm (0.0039 in)

Thickness 0.3 mm (0.0118 in)
0.5 mm (0.0197 in)
N1A0122E
LGHAC-WE-0553
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all

countries except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition February, 2006

No.LGHAC-WE-0553 PRINTED IN JAPAN

Отопитель Кондиционер LGHAC-WE-0553

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WORKSHOP MANUAL

HEATING AND AIR CONDITIONING

International Service & Parts

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on latest product

This manual is applicable to 2005 year model.

SECTION No. CONTENTS

HEATING AND AIR CONDITIONING

TROUBLE POSSIBLE CAUSE CORRECTION

FL-1 100A or 120A F-1 15A

RELAY; CHARGE (5)

FRAME-LH (FRONT) B-1

FL-1 100A or 120A F-1 15A

FRAME-LH (FRONT) B-1

EXCEPT 4HK1-TC ENGINE MODEL FOR AUSTRALIA: 0.85L/O

BLOWER RESISTOR FAN SWITCH

No. Connector Face

No. Connector Face

TROUBLE POSSIBLE CAUSE CORRECTION

RESULT SYMPTOM TROUBLE CAUSE CORRECTION

RESULT SYMPTOM TROUBLE CAUSE CORRECTION

4JB1 / 4HG1 ENGINE ONLY

B-18 X-33 X-33

No. Connector Face

ITEM TROUBLE POSSIBLE CAUSE CORRECTION

Terminal No. Control Continuity

Terminal No. Magnetic CIutch Voltage

MAIN DATA AND SPECIFICATIONS

Triple pressure switch (for Australia)

N.m (kg.m / lb.ft)

15 (1.5 / 11) 6 (0.6 / 4)

240V 50/60Hz Australian

HEATING AND AIR CONDITIONING

Control Lever Assembly

Air Select Lever Air Source Select Lever

11. Heater Core

9. Bolt (Heater Unit - Reinforce)

Removal 5. Upper Case

3. Washer Tank (Without A/C)

15. Blower Assembly

Removal 5. Upper Case

7. Control Lever Assembly

HEATING AND AIR CONDITIONING

Air Conditioning Refrigerant Cycle Construction

Dual Pressure Switch (for GCC and Taiwan)

• High-pressure control (for GCC)

Service Charge Valves

nents must be sealed with caps to keep out con-

Refrigerant Leak Inspection

When connecting the refrigerant line at the block joint,

2. Remove and replace the defective part.

Repair of Refrigerant Leaks

Apply specified compressor oil to the O-rings prior to

O-rings must be closely aligned with raised portion of re-

Leak at Refrigerant Line Connections

Recovery, Recycling, Evacuation and Charging

1. Connect the gauge manifold.

Refrigerant Amount g (lbs.)

N1A0072E N1A0073E N1A0074E N1A0075E

The sight glass provides accurate diagnosis only under

1. Gently release nitrogen gas from the rear head of

Removal 4. Condenser assembly

Condenser Assembly (4HK1-TC Engine Model For Australia)