WORKSHOP MANUAL

TBR SERIES

HEATING AND AIR CONDITIONING

SECTION 1
 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 the latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
 HEATING AND AIR CONDITIONING 1-1

SECTION 1
HEATING AND AIR CONDITIONING

TABLE OF CONTENTS

PAGE
General Description............................................................................................................ 1- 2
Main Data and Specifications ............................................................................................ 1- 9
Special Parts Fixing Nuts and Bolts ................................................................................. 1- 10
Servicing.............................................................................................................................. 1- 13
Precautions For Refrigerant-134a (R-134a) Air Conditioning system ....................... 1- 13
General Repair Procedure............................................................................................. 1- 17
Condenser ........................................................................................................................... 1- 27
Removal and Installation............................................................................................... 1- 27
Receiver Dehydrator........................................................................................................... 1- 28
Removal and Installation............................................................................................... 1- 28
Compressor......................................................................................................................... 1- 29
Removal and Installation............................................................................................... 1- 29
Disassembly and Reassembly ...................................................................................... 1- 31
Front Cooler Assembly ...................................................................................................... 1- 35
Removal and Installation............................................................................................... 1- 35
Disassembly and Reassembly ...................................................................................... 1- 36
Control Lever Assembly..................................................................................................... 1- 38
Removal and Installation............................................................................................... 1- 38
Inspection and Repair.................................................................................................... 1- 39
Rear Cooler Unit ................................................................................................................. 1- 40
Disassembly and Reassembly ...................................................................................... 1- 40
Rear Cooler Overhead Duct ............................................................................................... 1- 42
Disassembly and Reassembly ...................................................................................... 1- 42
Troubleshooting ................................................................................................................. 1- 43
1-2 HEATING AND AIR CONDITIONING

GENERAL DESCRIPTION
SYSTEM COMPONENTS

T
ON
FR
 HEATING AND AIR CONDITIONING 1-3

SYSTEM COOLING LINE

,,,,,,
Condenser
Rear cooler unit

,,,,,,
,,,,,
,,,,,,
Compressor

y
,
Front cooler unit

,,
Expansion

yy
,,
Valve

High Pressure Vapor

,,
High Pressure Liquid
Receiver-
Low Pressure Liquid Dehydrator
with Pressure
Low Pressure Vapor Switch

FRONT COOLER UNIT

NT
O
FR
1-4 HEATING AND AIR CONDITIONING

WIRING DIAGRAM

MAIN RR COOLER
EB-3 E-14
60A 20A
8B/R 2L/R

P-1 A/C
RELAY ; A/C
BATT E-12
P-6 IGN 3 10A
X-1
EB-2 5 3L/R 0.5BR
40A X-1
3W 1
X-1 FT COOLER
E-13
2 4
30B/Y

X-1 X-1 20A

5B/Y

9B/Y

21

0.5LG/R
H-1
3W/B

P-8 P-9 P-7

2L/W
P-7 : EARTH ; BODY
P-8 : EARTH ; FRAME
1
P-9 : EARTH ; ENGINE

BLOWER(FRT)
B-17
1 19 6
SW ; ER-16 H-1 H-3 M
STARTER
B-17
B
0.85R/B
0.85B

2
2L/B

2L/B
(M/T)
(A/T)

ST IG ACC B-16
4 10
RESISTOR(FRT)

H-6 H-4
ER-16
3
1
B-16
3B/Y
TURN,BACK

0.5LG
15A
C-5

B-16 21 9 13 14
3 H-7 H-7 H-9 H-9
0.85B

0.5LG/Y
1.25L/O
0.85R/B

2L/B

7 6 3 4
0.5LG/R

I-6 I-6 I-6 I-6

1 15
I-6 H-7
TURN,BACK UP LAMP

5
I-6
2
8 I-6
I-6

OFF LO Me HI
0.5G/R
0.5B

VAR. BEZEL
FAN SW (FRT)
VOL. ILLUMI.
2B

FUSE E-11
(TAIL.LIGHT)

0.85B 0.85B
EARTH ; E/R (RH) ER-11
2B 2B
EARTH ; BODY (LH) I-2
0.85B 0.85B
EARTH ; E/R (LH) B-9
2B
 HEATING AND AIR CONDITIONING 1-5

22 2L/R 1 2L/R
H-1 H-13

0.5BR

2
14
AR-3

BLOWER(RR)
H-1

M
0.5BR

0.5BR
AR-3
8
1
B-18 A/C AMP.

0.5LG/W 5
B-18

2L/B
PRESS SW
1
4 0.5G/W 1 2 0.5G/B
B-18 B-6 B-6
B-11
15
THERMISTOR

H-1
3

2
X-3

X-3

2
RELAY ; A/C COMP

B-11
AR-2
2
0.5BR

RESISTOR(RR)
0.5LG/B 6 1
B-18 AR-2
X-3

X-3

1
B-18
1
5

2 7 0.5B/R 16
B-18 B-18 H-1
AR-2

1.25L/O

2L/B
B-18
0.5G (A/T)

3
9
0.85L/W
1

1 2
X-9

X-9
RELAY ; A/C CUT

AR-1 AR-1

4
AR-1
X-9

X-9
0.5B/R
0.5B

3
AR-1
5
4
1.25BR/Y (M/T)

1.25BR/Y (A/T)

0.5O

11 OFF LO Me HI
H-1
FAN SW (RR)
2B

0.5O
12
0.5BR/Y

H-5 2
H-13
1 1 1
SW ; THERMO(A/C CUT)
ER-6

TE-9
B-5
VSV ; FICD
MAGNET
CLUTCH

2B

0.85B

2B
1-6 HEATING AND AIR CONDITIONING

WIRING HARNESS CONNECTOR LIST

No. CONNECTOR FACE No. CONNECTOR FACE

AR-1 ER-11

AR-2 ER-16

AR-3 H-1

B-6 H-3

B-9 H-4

B-11 H-6

B-16 H-7

B-17 H-9

B-18 H-13

ER-6 I-2
 HEATING AND AIR CONDITIONING 1-7

WIRING HARNESS CONNECTOR LIST

No. CONNECTOR FACE No. CONNECTOR FACE

I-6

P-1

P-6

P-7

P-8

P-9

X-1

X-3
1-8 HEATING AND AIR CONDITIONING

VENTILATION

Center and Side Outlet Rr. Cooler Outlet

Outside Air

Vent Duct

Outside Air
FT Cooler Unit

Cooler core
 HEATING AND AIR CONDITIONING 1-9

MAIN DATA AND SPECIFICATIONS

AIR COMPRESSOR
Type 10PA15
Displacement cc 155.3
Oil Type ND-8
Oil Capacity cc 160
Magnetic clutch mm φ140

Fr COOLING UNIT
Type Plate Fin Evaporator
Evaporator element dimension mm (L×H×W) 300×90×140
Evaporator capacity W 2600
Fan Type Sirocco fan type
Resistor Resistance Ω Lo-Hi 2.7
Me-Hi 0.6
CONDENSER
Type NCS condenser
Capacity W AT:11400
MT:9450

RECEIVER-DRYER
Capacity cc 300
Desiccant Material ZEOLITE

R-134a g Single AT: 600

Single MT: 530
Dual AT: 870
Dual MT: 790

IDLE SPEED-UP CONTROL Idle speed controlled by VSV

Rr COOLING UNIT
Type Plate Fin Evaporator
Evaporator element dimension mm (L×H×W) 230×90×140
Evaporator capacity W 2150
Fan Type Sirocco Fan Type
Resistor Resistance Ω Lo-Hi 1.21
Me-Hi 0.39
1-10 HEATING AND AIR CONDITIONING

SPECIAL PARTS FIXING NUTS AND BOLTS

COMPRESSOR ASSEMBLY
N⋅m(kgf⋅m/Ib⋅ft)

13.2 (1.35 / 9.76)

 HEATING AND AIR CONDITIONING 1-11

REFRIGERATION SYSTEM (FRONT)

N⋅m(kgf⋅m/Ib⋅ft)

19.7-24.5(2.0-2.5/14.5-18.1)

29.4-34.4(3.0-3.5/21.7-25.4)

EVAPORATOR
29.4-34.3(3.0-3.5/21.7-25.3)

C A
B

D
7.8-11.8(0.8-1.2/5.8-8.7)
11.8-14.7(1.2-1.5/8.7-10.8)

3.9-6.9(0.4-0.7/2.9-5.1)

7.8-11.8(0.8-1.2/5.8-8.7)

D
AR
RW
FO
 11.8-14.7 (1.2-1.5 / 8.7-10.8)

11.8-14.7 (1.2-1.5 / 8.7-10.8)

F

E
1-12 HEATING AND AIR CONDITIONING

REFRIGERATION SYSTEM (REAR)

29.4-34.4 (3.0-3.5 / 21.7-25.4)

29.4-34.4 (3.0-3.5 / 21.7-25.4)

11.8-14.7 (1.2-1.5 / 8.7-10.8)

11.8-14.7 (1.2-1.5 / 8.7-10.8)

29.4-34.4 (3.0-3.5 / 21.7-25.4)

C
29.4-34.4 (3.0-3.5 / 21.7-25.4)
D
AR
RW
FO
N⋅m(kgf⋅m/Ib⋅ft)
 HEATING AND AIR CONDITIONING 1-13

SERVICING
PRECAUTIONS FOR
REFRIGERANT-134a (R-134a) AIR
CONDITIONING SYSTEM

R-12 and R-134a systems require different types of lubricating

oil. Components designed solely for use with one refrigerant
and oil type must never be interchanged with components
designed solely for use with another refrigerant and oil type.

R-134a Refrigerant:
• R-134a differs entirely from R-12 in its composition and,
therefore, the two should never be mixed. Always 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 compressor
model. Be sure to use oil specified for the model of
compressor.

Oil Specification ND-OIL8

• The PAG compressor oil for the R-134a system tends to

Evaporator absorb moisture more quickly than mineral oil. When air
conditioning parts are removed for servicing, all the open
ends of parts and components must be sealed with caps to
keep out contaminants.
• The PAG compressor oil must be stored in metal containers,
not in plastic containers.

Refrigerant line Cap

1-14 HEATING AND AIR CONDITIONING

Service charge valve:

• The diameter of the service charge valve for the R-134a
Removal system is made larger than that for the R-12 system to
prevent cross-contamination. In addition, the screw-in type
joint of the R-12 system is replaced with a quick joint type in
the R-134a system.
• To prevent refrigerant from escaping during installation and
Connection removal of charging hoses from the service charge valves,
quick-joint type fittings are used.
Connection : Push on firmly until locked (a "click" will be
heard).
Removal : Hold the grip-ring and pull to remove.
• Air conditioning manifold gauges, charging hoses and other
service tools designed exclusively for the R-134a system
must be used with this vehicle.
 HEATING AND AIR CONDITIONING 1-15

No. R-134a
1 M12 x 1.75
2 M10 x 1.5 Manifold gauge
3 M14 x 1.25
4 Quick joint type
1

(Low side) Charging hose

(High side)
Quick joint
Quick joint (High side)
(Low side)

4
1

2 2
2

Charge valve handle

3 3

Refrigerant container
Vacuum pump

• Do not use the same vacuum pump for evacuating the R-

134a and R-12 systems interchangeably (The vacuum pump
hose fitting is a M10×1.5).
• R-134a vacuum pumps must have a positive shutoff valve.

CAUTION
Never use the same vacuum pump for both R-134a and R-
12 systems, as cross contamination of compressor oil
may occur.
1-16 HEATING AND AIR CONDITIONING

Refrigerant Recovery, Recycling and Charging

• Avoid releasing the R-134a into the atmosphere.
4
Use the ACR (R-134a Refrigerant Recovery/Recycling/
Recharging/System) or equivalent to recover and recycle R-
4
134a. Note that the ACR (or equivalent) is not
interchangeable between the R-134a and R-12 systems.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)

Refrigerant Leak Inspection

• The flame type gas leak detector for the R-12 system cannot
be used with the R-134a system.
• The electric leak detector for the R-12 cannot be used with
the R-134a system as the R-134a particles are far smaller
than the R-12 molecules and, therefore, may not be always
detected. Use leak detectors designed exclusively for the R-
134a system.
 HEATING AND AIR CONDITIONING 1-17

General Repair Procedure

There are certain procedures, practices and precautions that
should be followed when servicing air conditioning systems:
• Keep your work area clean.
• Always wear safety goggle and protective gloves when
working on refrigerant systems.
• Beware of the danger of carbon monoxide fumes caused by
running the engine.
• Beware of discharged refrigerant in enclosed or improperly
ventilated garages.
• Always disconnect the negative battery cable and discharge
and recover the refrigerant whenever repairing 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 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.
• 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 require
discharging the refrigerant circuit, the operations described
in this section must be performed in the following sequence:

4
1) Using the ACR (R-134a Refrigerant Recovery/Recycling/
Recharging/System) or equivalent to thoroughly discharge
and recover the refrigerant.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
2) Remove and replace the defective part.
3) After evacuation, charge the air conditioning system and
check for leaks.
1-18 HEATING AND AIR CONDITIONING

REPAIR OF REFRIGERANT LEAKS

Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the connecting
portion from twisting or becoming damaged.

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 oil specified for the
model of compressor.

O-rings must be closely aligned with raised portion of

refrigerant line.
O-ring

Insert nut into union. First tighten nut by hand as much as

possible. Then, tighten nut to specified torque.
(Refer to "Special Parts Fixing Nuts and Bolts" in this section)

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.
• Be sure to apply specified compressor oil to the new O-
rings.
5) Retighten the refrigerant line fitting to the specified torque.
• Use two wrenches to prevent twisting and damage to the
line.
6) Evacuate, charge and retest the system.
 HEATING AND AIR CONDITIONING 1-19

LEAK IN THE HOSE

If the compressor inlet or outlet hose is leaking, the entire 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.
5) Evacuate, charge and test the system.

COMPRESSOR LEAKS
If leaks are located around the compressor shaft seal or shell,
replace the compressor.

REPLACEMENT OF COMPONENT PARTS

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

Note:
Refill with HFC134a (R134a) compressor oil. Oil is
available in a 40cc container for refill.

cc (Imp fl oz)
Component parts to be installed Amount of oil
1 Evaporator 40 (1.4)
2 Condenser 40 (1.4)
3 Receiver/drier 10 (0.3)
4 Refrigerant line 10 (0.3) per line
5 Compressor Refer following procedure

Compressor
COMPRESSOR OIL CHECK
New compressor
to replace The new compressor is filled of compressor oil. Therefore, in
case the compressor is replaced, extract the excessive oil
(quantity of A - B as illustrated) after replacing the compressor.

Note:
Extract the
excessive oil Compressor oil for HFC134a (R134a) tends to absorb
(A–B) moisture easily. Therefore, seal the container immediately
A B
after use.
1-20 HEATING AND AIR CONDITIONING

RECOVERY, RECYCLING, EVACUATION AND

CHARGING
Handling Refrigerant-134a
Air conditioning systems contain R-134a.
This is a chemical mixture which requires special handling
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 passenger
compartment.
• If it is necessary to fill a small R-134a container from a large
one, never fill the container completely. Space should
always be allowed above the liquid for expansion.
• R-134a and R-12 should never be mixed as their
compositions are not the same.
• R-134a PAG oil tends to absorb moisture more quickly than
R-12 mineral oil and, therefore, should be handled more
carefully.
• Keep R-134a containers stored below 40°C (100°F).

WARNING
• SHOULD R-134a CONTACT YOUR EYE (S), CONSULT A
DOCTOR IMMEDIATELY.
• DO NOT RUB THE AFFECTED EYE (S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER OVER
THE AFFECTED AREA TO GRADUALLY RAISE THE
TEMPERATURE OF THE REFRIGERANT ABOVE THE
FREEZING POINT.
• OBTAIN PROPER MEDICAL TREATMENT AS SOON AS
POSSIBLE. SHOULD THE R-134a TOUCH THE SKIN,
THE INJURY MUST BE TREATED THE SAME AS SKIN
WHICH HAS BEEN FROSTBITTEN OR FROZEN.
 HEATING AND AIR CONDITIONING 1-21

REFRIGERANT RECOVERY
The refrigerant must be discharged and recovered by using the
ACR 4 4
ACR (R-134a Refrigerant Recovery/Recycling/Recharging/
System) or equivalent before removing or installing air
conditioning parts.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
(High side)
4
1) Connect the high and low charging hoses of the ACR (or
equivalent) as shown
(Low side)
4
2) Recover the refrigerant by following the ACR
Manufacturer’s Instructions.
3) When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture cannot get
into it.

REFRIGERANT RECYCLING
4
Recycle the refrigerant recovered by the ACR or equivalent.
For the details of the actual operation, follow the steps in the
4
ACR Manufacturer’s Instructions.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-0A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)

EVACUATION OF THE REFRIGERANT SYSTEM

Note:
Explained below is a method using a vacuum pump. Refer
4
to the ACR (or equivalent) Manufacturer’s Instructions
4
when evacuating the system with ACR (or equivalent).

Air and moisture in the refrigerant will cause problems in the air
(Low side)
conditioning system.
(High side)
Therefore, before charging the refrigerant, be sure to evacuate
air and moisture thoroughly from the system.
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 In.Hg), continue the evacuation for 5 minutes or
more.
1-22 HEATING AND AIR CONDITIONING

6) Close both hand valves and stop the vacuum pump.

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 connections
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 In.Hg), close both
hand valves.
9) Close positive shutoff valve.
Stop the vacuum pump and disconnect the center hose
from the vacuum pump.

CHARGING THE RERIGERANT SYSTEM

There are various methods of charging refrigerant into the air
ACR 4
conditioning system.
4
These include using the ACR (R-134a Refrigerant Recovery/
Recycling/Recharging/System) or equivalent and direct
charging with a manifold gauge charging station.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
(High side) : 5-8840-0630-0 (J-39500-220A)

(Low side) Charging procedure

• ACR (or equivalent) method
4

4
For the charging of refrigerant recovered by ACR , follow the
Manufacturer's Instruction.
 HEATING AND AIR CONDITIONING 1-23

Manifold gauge

(Low side) Charging hose

(High side)

Charge valve handle

Vacuum pump

Refrigerant container

• Direct charging with a manifold gauge charging station

method
Handling the charge valve handle when installing refrigerant
container.
1) Before attaching the charge valve to the refrigerant
container, turn the charge valve handle counterclockwise
until the needle is fully retracted.
2) Turn the plate nut counterclockwise until it reaches its
highest position relative to the charge valve.
3) Install the charge valve onto the refrigerant container.
4) Turn the plate nut clockwise and connect the center
hose of the manifold gauge to the charge valve.
5) Tighten the plate nut sufficiently by hand. Then turn the
charge valve handle clockwise to lower the needle and
bore a hole in the refrigerant container.
6) Turn the charge valve handle counterclockwise to raise
the needle. The refrigerant in the refrigerant container is
charged into the air conditioning system by the operation
of the manifold gauge.
• Be absolutely sure not to reuse the emptied
refrigerant container.
1-24 HEATING AND AIR CONDITIONING

1) Make sure the evacuation process is correctly completed.

2) Connect the center-hose of the manifold gauge to the
refrigerant container.
• Turn the charge valve handle counterclockwise to purge
the charging line and purge any air exiting in the center-
hose of the manifold gauge.
3) Open the low-pressure hand valve and charge the
refrigerant about 200 g (0.44 lbs.).
• Make sure the high-pressure hand valve is closed.
• Avoid charging the refrigerant by turning the refrigerant
container upside down.
4) Close the low-pressure hand valve of the manifold gauge.
• Check to ensure that the degree of pressure does not
change.
5) Check the refrigerant leaks by using a R-134a leak
detector.
• If a leak occurs, repair the leak connection, and start all
over again from the first step of evacuation.
6) If no leaks are found, open the low-pressure hand valve of
the manifold gauge. Then continue charging 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 highest
position.

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 REFRIGERANT CONTAINER TO
BURST.

7) When the refrigerant container is emptied, use the

following procedure to replace it with a new refrigerant
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 refrigerant
container.
(4) Purge any air existing in the center hose of the
manifold gauge.
 HEATING AND AIR CONDITIONING 1-25

8) Charge the system to the specified amount and then close

the low-pressure hand valve.
Refrigerant Specified Amount g(lbs.)
• SINGLE A/C 550 ± 50 (1.21 ± 0.11)
• TWIN A/C 700 ± 50 (1.54 ± 0.11)
• A fully charged system is indicated by the sight glass on
the receiver/drier being free of any bubbles (Refer to
"Reading Sight Glass").
• Check the high and low pressure value of the manifold
gauge.
• Check for refrigerant leaks by using a R-134a leak
detector.

Immediately after charging refrigerant, both high and low

pressures are slightly high and to the left of the gauge, but they
settle down to the guide pressure valves as shown below:
• Ambient temperature; 30-35°C (86-95°F)
• Guide pressure
High-pressure side;
2
Approx. 1373-1667 kPa (14-17 kg⋅cm /199-242 psi)
Low-pressure side;
2
Approx. 127-245 kPa (1.3-2.5 kg⋅cm /18-36 psi)
9) Close the low pressure hand valve and charge valve of the
refrigerant container.
10) Stop the air conditioning and the engine.
11) Disconnect the high and low pressure hoses from the
manifold gauge fittings.
1-26 HEATING AND AIR CONDITIONING

Reading Sight Glass

High and low The high pressure The high pressure There is little The high pressure
pressure pipe pipe is hot and the pipe is warm and the difference in pipe is hot and the
temperature low pressure pipe is low pressure pipe is temperature between low pressure pipe is
cold. There is a cool. There is no the high pressure slightly warm.
distinct difference in great difference in pipe and the low There is a difference
temperature between temperature between pressure pipe. in temperature
them. them. between them.
Sight glass Almost transparent. A A flow of bubbles Something like fog Even at idle with the
condition flow of bubbles can always can be seen. faintly can be seen. fan at "HI" (with the
be seen, but they It appears sometimes window fully open),
disappear when the transparent, and the bubbles cannot
throttle is opened. sometimes frothy. be seen.

Air conditioning NG NG NG
cycle condition OK (Not enough (Almost no (Too much
refrigerant) refrigerant) refrigerant)

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 lever at coldest position
* Ambient temperature below 35°C (95°F) and humidity below 70% (See NOTE 1)
2
* High side pressure less than 1667 kPa (17 kg⋅cm /242 PSI) (See NOTE 2)

NOTE 1
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 specific
amount of refrigerant.
Then continue checking the system performance.

NOTE 2
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.
The continue checking system performance.
 HEATING AND AIR CONDITIONING 1-27

CONDENSER

REMOVAL AND INSTALLATION

3
4

2
5

Removal Steps Installation Steps

1. Radiator grille To install, follow the removal procedure in
2. Engine hood front end stay reverse order.
3. Engine hood lock
4. Refrigerant line
5. Condenser
1-28 HEATING AND AIR CONDITIONING

RECEIVER DEHYDRATOR

REMOVAL AND INSTALLATION

Removal Steps Installation Steps

1. Radiator grille To install, follow the removal procedure in
2. Dual pressure switch connector reverse order.
3. Refrigerant line
4. Bracket bolt
5. Receiver dehydrator
 HEATING AND AIR CONDITIONING 1-29

COMPRESSOR

REMOVAL AND INSTALLATION

EVAPORATOR

RR COOLER
3

RR COOLER
6

D
AR
RW
FO

Removal Steps Installation Steps

1. Nut; idler pulley 6. Compressor assembly
2. Bolt; idler pulley tension ▲ 5. Bolt; compressor to bracket
3. Belt ▲ 4. Compressor flex/hose
4. Compressor flex/hose ▲ 3. Belt
5. Bolt; compressor to bracket 2. Bolt; idler pulley tension
6. Compressor assembly 1. Nut; idler pulley
1-30 HEATING AND AIR CONDITIONING

Important Operations -Installation

5. Bolt; Compressor to Bracket

N⋅m(kgf⋅m/Ib⋅ft)
54.0-64.0 (5.5-6.5/39.8-47.2)

4. Compressor Flex/Hose
N⋅m(kgf⋅m/Ib⋅ft)
6.0-9.0 (0.6-0.9/4.4-6.6)

3. Belt
Check the drive belt tension.
Depress the drive belt mid-portion with a 10 kg (22 lb/98N)
force.
Standard deflection mm(in.)
10 (0.4)
 HEATING AND AIR CONDITIONING 1-31

DISASSEMBLY AND REASSEMBLY

4 10

Disassembly Steps Reassembly Steps

1. Screw 10. Compressor assembly
2. Bracket 9. Plate washer
3. Bolt ▲ 8. Magnet clutch stator
▲ 4. Magnet clutch hub 7. Snap ring
5. Snap ring ▲ 6. Magnet clutch rotor
▲ 6. Magnet clutch rotor 5. Snap ring
7. Snap ring ▲ 4. Magnet clutch hub
▲ 8. Magnet clutch stator 3. Bolt
9. Plate washer 2. Bracket
10. Compressor assembly 1. Screw
1-32 HEATING AND AIR CONDITIONING

Disassembly Steps
4. Magnet Clutch Hub
1) Using vise pliers to prevent the clutch hub from
rotating.
Caution:
Take care not to scratch the clutch hub.

2) Remove the bolt.

3) Remove the clutch hub and washer. Washer is for
adjustment; therefore number is not fixed.

6. Magnet Clutch Rotor

1) Using snap ring expander remove the snap ring.
Caution:
Take care not to scratch the bearing seal cover when
removing.

2) Remove the rotor.

8. Magnet Clutch Stator

1) Using snap ring expander remove the snap ring.
2) Remove the wire harness, then remove the stator.
 HEATING AND AIR CONDITIONING 1-33

Reassembly Steps
8. Magnet Clutch Stator
1) Align the pin of the stator with cooler compressor as
shown in the figure, then install.

2) Install the stator, then install the wire harness clamp

and earth wire.
3) Using snap ring expander install the new snap ring
facing its chamfered side upward.
Caution:
Take care not to excessively widen the snap ring.

6. Magnet Clutch Rotor

1) Install the rotor.
2) Using snap ring expander install the new snap ring
facing its chamfered side upward.
Caution:
• Take care not to excessively widen the snap ring.
• Take care not to scratch the bearing seal cover
when installing.

4. Magnet Clutch Hub

1) Install the plate washer.
2) Install the magnet clutch hub, then using vise pliers to
prevent the clutch hub from rotating.
Caution:
Take care not to scratch the clutch hub.

3) Tighten the bolt to the specified torque.

Magnet Clutch Bolt Torque N⋅m(kgf⋅m/lb⋅ft)
13.2 (1.35/9.76)
1-34 HEATING AND AIR CONDITIONING

Magnet Clutch Air Gap Inspection

1) Set the dial gauge vertically to the magnet clutch hub.
2) Connect the battery negative cable to the magnet clutch
connector and battery positive cable to the compressor.
Measure the air gap when switching the magnet clutch ON
and OFF.
Air Gap Specification mm (in)
0.5±0.15 ( 0.02±0.006)
If not as specified, remove the magnet clutch hub and
adjust with the adjusting shim(s).
Adjusting shims are available in the following thickness.
0.1mm (0.0039in)
Parts No.: 1-83579-890-0
0.3mm (0.0118in)
Thickness Parts No.: 1-83579-891-0
0.5mm (0.0197in)
Parts No.: 1-83579-892-0
 HEATING AND AIR CONDITIONING 1-35

FRONT COOLER ASSEMBLY

REMOVAL AND INSTALLATION

Removal Steps Installation Steps

1. Instrument panel assembly To install, follow the removal procedure in
2. Cooler assembly reverse order.
1-36 HEATING AND AIR CONDITIONING

DISASSEMBLY AND REASSEMBLY

3
21

17

18

23
20
2

10
1
9

19

16

24

25
11

22 7

13
14

15
6

14
5
12

22

7
 HEATING AND AIR CONDITIONING 1-37

Disassembly Steps Reassembly Steps

1. Evaporator sub-assembly 15. Holding spring To reassembly, follow the
2. Cooling unit case 16. Packing disassembly procedure in reverse
3. Cooling unit case 17. Packing order.
4. Blower case sub-assembly 18. Packing
5. Blower case 19. Packing
6. Motor assembly 20. Packing
7. Blower fan 21. Packing
8. Expansion valve 22. Nut
9. Thermistor assembly 23. Packing
10. Net 24. Liquid tube
11. Blower resistor 25. Suction tube
12. Pipe
13. Packing
14. Washer
1-38 HEATING AND AIR CONDITIONING

CONTROL LEVER ASSEMBLY

REMOVAL AND INSTALLATION

6
7
5
3

Removal Steps Installation Steps

1. Cluster assembly To install, follow the removal procedure in
2. Control knob reverse order
3. Control panel case
4. Binding taping screw
5. Crossrecess pan screw
6. Bracket
7. Wiring
 HEATING AND AIR CONDITIONING 1-39

INSPECTION AND REPAIR

Resistor
As for air-conditioning model, fixed on right side of the
evaporator unit.
Replace the resistor with a new one if the coil is found to
be open or if the resistance value deviates from the
specified range.

Air-conditioning model
Me-Hi 0.6Ω
Hi Lo-Me 2.1Ω
0.6 2.1

Me

Lo Hi Me Lo

Blower motor
Check blower motor for smooth rotation.
Connect the battery positive terminal to the No. 1 terminal of
the blower motor and negative to the No. 2.
Be sure to check to see if the blower motor operates correctly.

0.5WR Fan switch

0.5W (RESISTOR S/W) Check for continuity between switch connector terminals.
(RESISTOR S/W)
0.5RG
0.5WL (LAMP)
(BLOWER C) 0.5GR (WIRE)
(LAMP) B C L Me Hi
OFF
1
(MODE)
1.25WB 1.25LR 2
(B) 0.85LY (BLOWER Hi)
(BLOWER Me) 3
1-40 HEATING AND AIR CONDITIONING

REAR COOLER UNIT

DISASSEMBLY AND REASSEMBLY

6 2

10

11

9
 HEATING AND AIR CONDITIONING 1-41

Disassembly Steps Reassembly Steps

1. Liquid tube To reassembly, follow the disassembly
2. Suction tube procedure in reverse order.
3. Drain hose
4. Blower resistor
5. Cooling unit case
6. Evaporator sub-assembly
7. Expansion valve
8. Cooling unit case
9. Cooling unit case
10. Blower fan
11. W/Fan motor assembly
1-42 HEATING AND AIR CONDITIONING

REAR COOLER OVERHEAD DUCT

DISASSEMBLY AND REASSEMBLY

4
4

Disassembly Steps Reassembly Steps

1. Rear cooler switch To reassemble, follow the disassembly
2. Air duct parts procedure in reverse order.
3. Air duct parts
4. Air outlet grille assembly
 HEATING AND AIR CONDITIONING 1-43

TROUBLESHOOTING
Refer to the appropriate troubleshooting from the following symptoms. Each flow chart is followed below.
1. Trouble of Fan Control System
1-A Front blower motor would not rotate totally
1-B Front blower motor does not rotate in certain position
1-C Front blower motor does not stop at "OFF" position.
1-D Rear blower motor would not rotate totally
1-E Rear blower motor does not rotate in certain position
1-F Rear blower motor does not stop at "OFF" position.

2. Trouble of Air-Conditioning System

2-A Magnetic clutch would not engage
2-B Refrigeration system defective
2-C Rear cooler does not cool
1-44 HEATING AND AIR CONDITIONING

1-A FRONT BLOWER MOTOR WOULD NOT ROTATE TOTALLY

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

• Is Cooler fuse (20A) OK?

YES NO

• Is resistor OK? Replace

YES NO

• Is front fan control knob (Fan switch) Replace

OK?

YES NO

• Is blower motor OK? Replace control lever assembly

YES NO

• Turn the ignition switch "ON" (Engine is Replace

running)
• Front fan control knob (Fan switch)
"ON"

• Check to see if battery voltage is

present at chassis side connector
terminal No. 1 B-17

YES NO

Poor ground or open circuit either Open circuit between cooler

between chassis side connector terminal fuse (20A) and No. 2 B-17
No. 2 B-17 and No. 2 B-16 or No. 8 I-6
and body ground
 HEATING AND AIR CONDITIONING 1-45

1-B FRONT BLOWER MOTOR DOES NOT ROTATE IN CERTAIN POSITION

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

Blower motor does not A. Lo: (Low)

run at B. Me: (Medium) Position
C. Hi: (High)
* Checking performed only when in
manufaction mode.

• Is resistor OK?

YES NO

• Is fan control knob (Fan switch) OK? Replace

YES NO

A. Condition: Replace control lever assembly

• Open circuit between chassis side connector
terminal No. 3 B-16 and No. B-9
B. Condition:
• Open circuit between chassis side connector
terminal No. 1 B-16 and No. 7 I-6
C. Condition:
• Open circuit between chassis side connector
terminal No. 2 B-17 and No. 6 I-6
1-46 HEATING AND AIR CONDITIONING

1-C FRONT BLOWER MOTOR DOES NOT STOP AT "OFF" POSITION

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

• Is fan control knob (Fan switch) OK?

YES NO

Short circuit between chassis side connector terminal Replace control lever assembly
• No. 2 B-17 and No. 2 B-16
(Or)
• No. 2 B-16 and No. 7 I-6
(Or)
• No. 3 B-16 and No. B-9
 HEATING AND AIR CONDITIONING 1-47

1-D REAR BLOWER MOTOR WOULD NOT ROTATE TOTALLY

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

• Is rear cooler fuse (20A) OK?

YES NO

• Is resistor OK? Replace

YES NO

• Is rear fan control knob (Fan switch) Replace

OK?

YES NO

• Is blower motor OK? Replace control lever assembly

YES NO

• Turn the ignition switch "ON" (Engine is Replace

running)
• Rear fan control knob (Fan switch)
"ON"

• Check to see if battery voltage is

present at chassis side connector
terminal No. 2 AR-3

YES NO

Poor ground or open circuit either Open circuit between cooler

between chassis side connector terminal fuse (20A) and No. 2 AR-3
No. 1 AR-3 and No. 2 AR-2 or No. 3
AR-1 and body ground
1-48 HEATING AND AIR CONDITIONING

1-E REAR BLOWER MOTOR DOES NOT ROTATE IN CERTAIN POSITION

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

Blower motor does not A. Lo: (Low)

run at B. Me: (Medium) Position
C. Hi: (High)
* Checking performed only when in
manufaction mode.

• Is resistor OK?

YES NO

• Is fan control knob (Fan switch) OK? Replace

YES NO

A. Condition: Replace control lever assembly

• Open circuit between chassis side connector
terminal No. 3 AR-2 and No. 4 AR-1
B. Condition:
• Open circuit between chassis side connector
terminal
C. Condition:
• Open circuit between chassis side connector
terminal No. 1 AR-2 and No. 1 AR-1
 HEATING AND AIR CONDITIONING 1-49

1-F REAR BLOWER MOTOR DOES NOT STOP AT "OFF" POSITION

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

• Is fan control knob (Fan switch) OK?

YES NO

Short circuit between chassis side connector terminal Replace control lever assembly
• No. 1 AR-3 and No. 2 AR-2
(Or)
• No. 1 AR-2 and No. 1 AR-1
(Or)
• No. 3 AR-2 and No. 4 AR-1
1-50 HEATING AND AIR CONDITIONING

2-A MAGNETIC CLUTCH WOULD NOT ENGAGE

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

• Turn the ignition switch "ON" (Engine is running)

• Thermo switch and fan switch "ON"

• Check to see if battery voltage is present at magnetic

clutch chassis side connector terminal

NO YES

• Stop the engine Magnetic clutch deffective

• Are A/C (10A) and cooler (20A) fuses OK?

YES NO

• Are A/C and A/C cut relays OK? Replace

YES NO

• Is pressure switch (Dual pressure switch) OK? Replace

YES NO

• Are thermo switch and fan control knob (Fan switch) Switch defective or insufficient refrigerant
OK?

YES NO

• Is thermo switch OK? Replace

YES NO

• Check to see if continuity between chassis side Replace

connector terminal No. 8 I-6 and ground

YES NO

Check the A/C related harness and repair it as necessary Poor ground or open circuit
 HEATING AND AIR CONDITIONING 1-51

2-B REFRIGERATION SYSTEM DEFECTIVE

Checkpoint Trouble Cause Countermeasure

First turn engine (with engine

speed of about 1000 rpm) and
thermo switch on, and set fan
switch to be at 1-3 position

Sight glass for being clear or NG The system is charged Charge the system with
not unsufficiently refrigerant gas

OK
Check to see if bubbles come
out within 5 seconds after NG Adjust the refrigerant gas
turning the thermo switch off The system is over-charged
quantity
from 5 minutes running

OK
(Thermo switch on again)
Check to see if the pressure of NG
high pressure side is 16kg/cm
2 Condenser is fouled or clogged Clean or replace the condenser
2
(228psi/15.7×10 kPa) or lower.

NG Purge air from the refrigeration

Air exists in the system
system

NG
Pipe line is clogged Clean or replace the pipe line

NG Clean or replace the expansion

Expansion valve is clogged
valve

Continued on the next page

1-52 HEATING AND AIR CONDITIONING

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Check to see if the pressure of NG Repair or replace the

low pressure side is about Compressor is faulty
2 2 compressor
2.1kg/cm (30psi/2.1×10 kPa)

NG
Expansion valve is difective Replace the expansion valve
 HEATING AND AIR CONDITIONING 1-53

2-C REAR COOLER DOES NOT COOL

(Refer to "WIRING HARNESS TERMINAL POSITIONS" in this section.)

• Is magnetic clutch operation normal?

YES NO

• Is rear cooler (20A) fuse OK? Check magnetic clutch circuit

(See chart A)

YES NO

• Turn the ignition switch "ON" (Engine is running) Replace rear cooler (20A) fuse
• Front fan switch "ON"

• Rear fan switch "ON". (HI)

• Check to see if battery voltage is present at rear fan
switch chassis side connector terminal No. 2 AR-1

NO YES

• Is rear cooler relay OK? Replace rear fan switch

YES NO

• Is magnetic switch OK? Replace

YES NO

• Check to see if continuity between chassis side Switch defective or insufficient

connector terminal No. 3 X-1 and ground refrigerant

YES NO

Check the rear cooler related harness and repair it as Poor ground or open circuit
necessary
 TBHAC-WE-0065 IN

You are requested to order this manual using the

manual number that is shown above.

This manual is applicable for vehicles in Indonesia.

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 June, 2000

No. TBHAC-WE-0065 IN