HVAC Systems: Removal & Installation Isuzu Axiom I

REMOVAL

1. Disconnect the battery ground cable.
2. Drain the engine coolant.
3. Discharge and recover refrigerant (with air conditioning). Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
4. Remove the Instrument panel assembly. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
5. Remove instrument panel bracket w/suspension control unit. Refer to step 23 under «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
6. Cross Beam Assembly. Refer to step 23 under «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
7. Disconnect power transistor connector.
8. Remove evaporator assembly. Refer to «EVAPORATOR ASSEMBLY»(ref-194286-S35491389522005092700000) .
9. Remove ventilation lower duct.
10. Remove rear heater duct. Remove foot rest, carpet and 3 clips.
11. Disconnect mode/mix actuator connector.
12. Remove heater unit assembly. Disconnect heater hoses at heater unit. Refer to «HEATER UNIT»(ref-194286-S16389916832005092700000) .

INSTALLATION

To install, follow the removal steps in the reverse order, noting the following points

1. When handling the PCM and the control unit, be careful not to make any improper connection of the connectors.
2. When installing the heater unit, defroster nozzle and center vent duct, be sure that the proper seal is made, without any gap between them.

Scheme 51

Scheme 52

Scheme 53

1. Disconnect the battery ground cable.
2. Drain the engine coolant.
3. Discharge and recover refrigerant (with air conditioning). Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
4. Remove heater unit. Refer to «HEATER UNIT»(ref-194286-S16389916832005092700000) .
5. Remove duct.
6. Remove mix actuator.
7. Remove mode actuator.
8. Remove case (Mode control) and do not remove link unit at this step.
9. Remove case (Temperature control) separate two halves of core case.
10. Remove heater core (1).
11. Pull out the mode door while raising up the catch of the door lever.

Scheme 54

To install, follow the removal steps in the reverse order, noting the following point

1. Check that each mode door operates properly.

Scheme 55

Scheme 56

1. Disconnect the battery ground cable.
2. Drain engine coolant.
3. Discharge and recover refrigerant (with air conditioning) Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
4. Remove heater unit. Refer to «HEATER UNIT»(ref-194286-S16389916832005092700000) .
5. Remove mode actuator.
6. Remove the case (mode control) from heater unit.
7. Remove washer and the mode main lever.
8. Remove rod.
9. Press the tab of the sub-lever inward, and take out the sub-lever.
10. Pull out the door lever while raising up the catch of the door lever.
11. Remove clip.

To install, follow the remove steps in the reverse order, noting the following points

1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit.
2. After installing the link unit, check to see if the link unit operates correctly.

Scheme 57

1. Disconnect the battery ground cable.
2. Drain engine coolant.
3. Discharge and recover refrigerant (with air conditioning). Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
4. Remove heater unit. Refer to «HEATER UNIT»(ref-194286-S16389916832005092700000) .
5. Remove mix actuator.
6. Remove the case (Temperature control) from the heater unit.
7. Remove rod.
8. Remove sub-lever.
9. Pull out the door lever while raising up the catch of the door lever.
10. Remove clip.

To install, follow the removal steps in the reverse order, noting the following points

1. Apply grease to the sub-lever and to the abrasive surface of the heater unit.
2. After installing the link unit, check to see if the link unit operates correctly.

Scheme 58

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant (with air conditioning). Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove instrument panel assembly. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
4. Disconnect power transistor connector.
5. Remove evaporator assembly. Refer to «EVAPORATOR ASSEMBLY»(ref-194286-S35491389522005092700000) .
6. Disconnect blower motor/intake actuator connector.
7. Remove blower assembly.

To install, follow the removal steps in the reverse order.

Scheme 59

Scheme 60

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant (with air conditioning). Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove blower assembly. Refer to «BLOWER ASSEMBLY»(ref-194286-S14882460812005092700000) .
4. Remove intake actuator.
5. Remove max high relay.
6. Remove lower case.
7. Separate the upper case and slit the lining parting face with a knife.
8. Pull out the mode door while raising up the catch of door lever.
9. Remove sub-lever.
10. Remove door lever.

To install, follow the removal steps in the reverse order, noting the following points

1. Apply grease to the door lever and to the abrasive surface of the upper case.
2. Apply an adhesive to the parting face of the lining when assembling the upper case.

Scheme 61

1. Disconnect the battery ground cable.
2. Remove blower motor connector.
3. Remove attaching screw.
4. Remove blower motor assembly.
5. Remove clip.
6. Remove fan.
7. Remove blower motor.

To install, follow the removal steps in the reverse order.

Scheme 62

1. Disconnect the battery ground cable.
2. Remove instrument panel assembly. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
3. Remove center ventilation duct and side defroster duct. Remove 5 screws.
4. Remove instrument panel brackets w/suspension control unit. Refer to step 23 under «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
5. Remove cross beam assembly. Refer to step 23 under «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
6. Remove ventilation lower duct.
7. Remove rear heater duct. Remove foot rest carpet and 3 clips.
8. Remove defroster nozzle.

To install, follow the removal steps in the reverse order, noting the following point

1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching.

Scheme 63

The refrigeration cycle includes the following four processes as the refrigerant changes repeatedly from liquid to gas and back to liquid while circulating.

PRECAUTIONS FOR REPLACEMENT OR REPAIR OF AIR CONDITIONING PARTS

There are certain procedures, practices and precautions that should be followed when servicing air conditioning systems

1. Keep your work area clean.
2. Always wear safety goggles and protective gloves when working on refrigerant systems.
3. Beware of the danger of carbon monoxide fumes caused by running the engine.
4. Beware of discharged refrigerant in enclosed or improperly ventilated garages.
5. Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system.
6. When discharging and recovering the refrigerant, do not allow refrigerant to discharge too fast; it will draw compressor oil out of the system.
7. Keep moisture and contaminants out of the system. When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately.

Never remove the caps or plugs until the lines or parts are reconnected or installed.

1. When disconnecting or reconnecting the lines, use two wrenches to support the line fitting, to prevent from twisting or other damage.
2. Always install new O-rings whenever a connection is disassembled.
3. Before connecting any hoses or lines, apply new specified compressor oil to the O-rings.
4. When removing and replacing any parts which require discharging the refrigerant circuit, the operations described in this section must be performed in the following sequence

1. Use the J-39500 (ACR 4 : HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent to thoroughly discharge and recover the refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning system and check for leaks.

1. Install compressor. Tighten the compressor fixing bolts to the specified torque. Torque: 19 N.m (14 lb.ft)
2. Connect refrigerant line connector. Tighten the refrigerant line connector fixing bolts to the specified torque. Torque: 15 N.m (11 lb ft) O-rings cannot be reused. Always replace with new ones. Be sure to apply new compressor oil to the O-rings when connecting refrigerant lines.
3. Install serpentine belt. Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position.
4. Connect magnetic clutch harness connector.

NEW COMPRESSOR INSTALLATION

The new compressor is filled with 150cc (5.0 fl.oz.) of compressor oil and nitrogen gas. When mounting the compressor on the vehicle, perform the following steps

Scheme 64

1. Gently release nitrogen gas from 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 release the compressor oil in the rotor.
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. (Refer to «COMPRESSOR ASSEMBLY»(ref-194286-S04922934792005092700000) )

Scheme 65

Scheme 66

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove front bumper assembly. Refer to «FRONT BUMPER»(ref-194310-S39754406142005092700000) .
4. Remove front center bumper retainer.
5. Remove front side bumper retainer (RH).
6. Remove condenser air guide.
7. Remove engine hood front end with engine hood lock & bumper stay. Apply setting mark to the engine hood lock fixing position before removing it.
8. Remove horn (R/LH).
9. Remove front side turn signal light (R/LH).
10. Remove head light (R/LH).
11. Disconnect pressure switch, ambient sensor and condenser fan connector.
12. Disconnect refrigerant line. When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.
13. Remove condenser & receiver tank assembly. Handle with care to prevent damaging the condenser or radiator fin.

1. Install condenser & receiver tank assembly. If installing a new condenser, be sure to add 30cc (1.0 fl. oz.) of new compressor oil to a new one. Tighten the condenser fixing bolts to the specified torque. Torque: 6 N.m (52 lb in)
2. Connect refrigerant line. Tighten the inlet line connector fixing bolt to the specified torque. Torque: 15 N.m (11 lb ft) Tighten the outlet line connector fixing bolt to the specified torque. Torque: 6 N.m (52 lb in) O-rings cannot be reused. Always replace with new ones. Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line.
3. Connect pressure switch, ambient sensor and condenser fan connector.
4. Install head light (R/LH).
5. Install front side turn signal light (R/LH).
6. Install horn (R/LH).
7. Install engine hood front end with engine hood lock & bumper stay. Align the setting mark when installing.
8. Install condenser air guide.
9. Install front side bumper retainer (RH).
10. Install front center bumper retainer.
11. Install front bumper assembly.

Scheme 67

1. Disconnect the battery ground cable.
2. Remove the front bumper assembly. Refer to «FRONT BUMPER»(ref-194310-S39754406142005092700000) .
3. Remove the condenser air guide.
4. Remove the horn (RH).
5. Remove the condenser fan assembly. Disconnect the fan motor connector and remove the 3 fixing bolts.
6. Remove the shroud. Remove the 3 fixing nuts. Loosen the condenser fixing nut and disconnect the fan motor connector from bracket.
7. Remove the fan. Remove the fan fixing C-ring and plate.
8. Remove the condenser fan motor.

To install, follow the removal steps in the reverse order, noting the following point.

1. Route the fan motor harness in its previous position, and fix it securely with clip and bracket.

Scheme 68

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove front bumper assembly. Refer to «FRONT BUMPER»(ref-194310-S39754406142005092700000) .
4. Remove front side turn signal light (LH).
5. Remove head light (LH).
6. Disconnect pressure switch connector.
7. Disconnect refrigerant line. When removing the line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.
8. Remove receiver/drier. Loosen the bolt, then, using care not to touch or bend the refrigerant line, carefully pull out the receiver/drier.

To install, follow the removal steps in the reverse order, noting the following points

1. If installing a new receiver/drier, be sure to add 30cc (1.0 fl. oz.) of new compressor oil to a new one.
2. Put the receiver/drier in the bracket and connect with the refrigerant line. Check that no excessive force is imposed on the line. Fasten the bracket bolt to the receiver/drier.
3. Tighten the refrigerant line to the specified torque. Torque: 6 N.m (52 lb in)
4. O-rings cannot be reused. Always replace with new ones.
5. Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line.

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove the front bumper assembly. Refer to «FRONT BUMPER»(ref-194310-S39754406142005092700000) .
4. Remove the front side turn signal light (LH).
5. Remove the head light (LH).
6. Disconnect pressure switch connector.
7. Disconnect pressure switch. When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

To install, follow the removal steps in the reverse order, noting the following point

1. O-ring cannot be reused. Always replace with a new one.
2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch.
3. Tighten the pressure switch to the specified torque. Torque: 13 N.m (113 lb in)

Scheme 69

Scheme 70

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove glove box.
4. Disconnect power transistor (2) and duct sensor connector (1).
5. Remove sill plate.
6. Remove dash side trim panel.
7. Remove passenger lower bracket.
8. Disconnect drain hose.
9. Disconnect drain hose.
10. Disconnect refrigerant line. Use a back-up wrench when disconnecting and reconnecting the refrigerant lines. When removing the refrigerant line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.
11. Remove evaporator assembly.

To install, follow the removal steps in the reverse order, noting the following points

1. To install a new evaporator assembly, add 50cc (1.7 fl. oz.) of new compressor oil to the new core.
2. Tighten the refrigerant outlet line to the specified torque. Torque: 25 N.m (18 lb ft)
3. Tighten the refrigerant inlet line to the specified torque. Torque: 15 N.m (11 lb ft)
4. O-rings cannot be reused. Always replace with new ones.
5. Be sure to apply new compressor oil to the O-rings when connecting lines.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove evaporator assembly. Refer to «EVAPORATOR ASSEMBLY»(ref-194286-S35491389522005092700000) .
4. Remove the duct sensor fixing clip. Pull the sensor from the evaporator assembly.
5. Remove clip.
6. Remove attaching screw.
7. Remove upper case.
8. Remove lower case. Slit the case parting face with a knife since the lining is separated when removing the evaporator. Lift to remove the upper case.
9. Remove evaporator core.
10. Remove expansion valve. Tear off the insulator carefully. Remove the sensor fixing clip. Use a back-up wrench when disconnecting all refrigerant pipes.

To install, follow the removal steps in the reverse order, noting the following points

Scheme 75

1. The sensor is installed on the core with the clip.
2. The sensor must not interfere with the evaporator core.
3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration.
4. O-rings cannot be reused. Always replace with new ones.
5. Be sure to apply new compressor oil to the O-rings when connecting lines.
6. Be sure to install the sensor and the insulator on the place where they were before.
7. To install a new evaporator core, add 50cc (1.7 fl. oz.) of new compressor oil to the new core.
8. Tighten the refrigerant lines to the specified torque. Refer to «MAIN DATA AND SPECIFICATIONS»(ref-194286-S40042491182005092700000) .
9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly.

Scheme 76

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove the front bumper assembly. Refer to «FRONT BUMPER»(ref-194310-S39754406142005092700000) .
4. Remove the condenser air guide.
5. Remove the front side turn signal light (LH).
6. Remove the head light (LH).
7. Remove clip and clamp.
8. Disconnect liquid line (High-pressure pipe).
9. Disconnect suction line (Low-pressure pipe) using a back-up wrench.
10. Disconnect suction line (Low-pressure hose) using a back-up wrench.
11. Disconnect discharge line (High-pressure hose) using a back-up wrench. Use a backup wrench when disconnecting and reconnecting the refrigerant lines. 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.

To install, follow the removal steps in the reverse order, noting the following point

1. O-rings cannot be reused. Always replace with new ones.
2. Be sure to apply new compressor oil to the O-rings when connecting lines.
3. Tighten the refrigerant line to the specified torque. Refer to «MAIN DATA AND SPECIFICATIONS»(ref-194286-S40042491182005092700000) .

CHECKING AND ADJUSTING FOR COMPRESSOR REPLACEMENT

150 cc (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor.

1. Perform oil return operation, refer to «OIL RETURN OPERATION»(ref-194286-S09525754172005092700000) .
2. Discharge and recover the refrigerant and remove the compressor.
3. Drain the compressor oil and measure the extracted oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required. OIL LEVEL ADJUSTMENT Amount Of Oil Drained From Used Compressor Draining Amount Of Oil From New Compressor Less Than 90 cm 3 (3.0 fl.oz) Same As Drained Amount More Than 90 cm 3 (3.0 fl.oz) 90 cm 3 (3.0 fl.oz)
6. Evacuate, charge and perform the oil return operation.
7. Check the system operation.

REPLACEMENT OF COMPONENT PARTS

When replacing the system component parts, supply the following amount of oil to the component parts to be installed.

OIL LEVEL ADJUSTMENT

1. Remove the glove box.
2. Remove the MAX-HI relay.
3. Disconnect the power transistor connector.
4. Remove the power transistor.

To install, follow the removal step in the reverse order.

Scheme 77

1. Disconnect the battery ground cable.
2. Remove the knee pad (R/LH).
3. Remove the center cluster upper.
4. Remove the center cluster.
5. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
6. Disconnect the six connectors.
7. Remove the automatic air conditioner control unit.

To install, follow the removal step in the reverse order.

Scheme 78

1. Disconnect the battery ground cable.
2. Remove the meter cluster. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
3. Remove the in car sensor.

To install, follow the removal step in the reverse order.

Scheme 79

1. Disconnect the battery ground cable.
2. Remove the horn (LH).
3. Disconnect the ambient sensor connector.
4. Remove the ambient sensor.

To install, follow the removal step in the reverse order.

1. Disconnect the battery ground cable.
2. Remove the center cluster upper.
3. Disconnect the sun sensor connector.
4. Remove the sun sensor.

To install, follow the removal step in the reverse order.

Scheme 80

1. Disconnect the battery ground cable.
2. Remove the evaporator assembly. Refer to «EVAPORATOR ASSEMBLY»(ref-194286-S35491389522005092700000) .
3. Remove the duct sensor assembly.

To install, follow the removal step in the reverse order.

Scheme 81

1. Disconnect the battery ground cable.
2. Remove the instrument panel driver lower cover assembly.
3. Remove the driver knee bolster assembly. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
4. Remove the actuator rod.
5. Remove the mode actuator.

To install, follow the remove step in the reverse order.

Scheme 82

1. Disconnect the battery ground cable.
2. Remove the knee pad (R/RH).
3. Remove the center cluster upper.
4. Remove the center cluster. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-194310-S41043073612005092700000) .
5. Disconnect the six connectors.
6. Remove the Audio & Switch Assembly.
7. Remove the actuator rod.
8. Remove the mix actuator.

To install, follow the remove step in the reverse order.

Scheme 83

1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant. Refer to «REFRIGERANT RECOVERY»(ref-194286-S07511965142005092700000) .
3. Remove the evaporator assembly. Refer to «EVAPORATOR ASSEMBLY»(ref-194286-S35491389522005092700000) .
4. Disconnect the intake actuator connector.
5. Remove the intake actuator.

To install, follow the remove step in the reverse order.