TOP

(INDEX)

2008-2011MY

WORKSHOP MANUAL

HEATING, VENTILATION
AND AIR CONDITIONING

No.MGHAC-WE-0871
69209_MGHAC-WE-0871_Maegaki 2011.5.19 4:37 PM ページ 1

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
1L Power Take-Off (PTO)
2 SUSPENSION 2A1 Air Suspension Control System
2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4 BRAKES 4A2 Brake Control System (Air Over)
4A3 Brake Control System (Full Air)
4B2 Brake (Air Over)
4B3 Brake (Full Air)
4C Anti-Lock Brake (ABS)
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
4F Speed Retarder System
4G Trailer Brake
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G Power Take-Off (PTO)
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME AND FRAME ACCESSORIES 11A Frame
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MGHAC-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-1

HVAC
Heating and Ventilation
TABLE OF CONTENTS
Heater and Ventilation System. . . . . . . . . . . . . . . 7A-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-31
Description of Function and Operation . . . . . . . 7A-2 Blower Resistor . . . . . . . . . . . . . . . . . . . . . . . . . 7A-33
Components Location Diagram. . . . . . . . . . . . . 7A-9 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-33
Functional Inspection: Heater Cycle System . 7A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-33
Functional Inspection: Fan Switch System . . . 7A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-34
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7A-13
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-15
Blower Motor Relay . . . . . . . . . . . . . . . . . . . . . . 7A-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-16
Blower ASM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-18
Blower Link Unit and Intake Door. . . . . . . . . . . . 7A-19
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-19
Inside Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-20
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-20
Outside Air Filter . . . . . . . . . . . . . . . . . . . . . . . . 7A-21
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-21
Heater Unit (Heater and Evaporator Unit) . . . . . 7A-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-23
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-24
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-25
Air Mix Door and Mode Door . . . . . . . . . . . . . . . 7A-26
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-27
Vent Grille. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-28
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-28
Defroster Nozzle and Ventilation Duct . . . . . . . . 7A-29
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-29
Control Lever ASM. . . . . . . . . . . . . . . . . . . . . . . 7A-30
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-30
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7A-2 Heating and Ventilation

Heater and Ventilation System

Description of Function and Operation Control Lever ASM
Heater The control lever ASM enables the cable to select the
air outlet for the heater unit, adjust the temperature and
After the engine warms up, the heater system uses the
switch between inside and outside air for the blower
warm engine coolant to supply warm air to the vehicle
ASM. The fan control controls the outlet air volume in 4
cabin.
levels from "LOW" to "HIGH" via the blower resistor.
Outside air is supplied to the vehicle cabin through the
heater core of the heater unit.
The temperature inside the vehicle is optimally
adjusted by controlling the mixture of air between the
outside air and the heater core.
The opening/closing angle of the air mix door of the
heater unit is adjusted by operating the temperature
control knob or the temperature control dial (automatic
A/C), controlling the amount of air that passes through
the heater core. This in turn controls the temperature
inside the vehicle.
The air outlet inside the vehicle can be selected
arbitrarily by changing the mode of the outlet selector
knob or the outlet selector switch (automatic A/C).
The air selector lever or the air selector switch
(automatic A/C) is a lever (switch) used for selecting
"outside air intake" or "inside air recirculation". When it
is set to "FRESH", it enables intake of the outside air at
all times. (Inside air is also partially mixed.) When it is
set to "RECIRC", it enables for inside air recirculation
without intake of the outside air. It speeds up heating of
the vehicle cabin, but it is better to use "FRESH" in
order to ventilate and prevent fogging of the windshield,
etc.
Control Lever ASM

1 2 3

5 4
LNW77ASF000101

Legend
1. Outlet Selector Knob 4. Air Conditioning Switch (A/C Switch)
2. Air Selector Lever 5. Fan Speed Control Knob (FAN Switch)
3. Temperature Control Knob
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Heating and Ventilation 7A-3

Control Panel ASM (Vehicle with Automatic A/C)
The control panel ASM enables the actuator to select
the air outlet for the heater unit, adjust the temperature
and switching between inside and outside air for the
blower ASM. The fan control controls the outlet air
volume in 8 levels (when in manual mode) via the BLC
(blower module assembly).
Control Panel ASM (Automatic A/C)
1 2 3 4 5

10 9 8 7 6
LNW77CSF000201

Legend
1. Automatic Air Conditioning Switch (AUTO 6. Outlet Selector Switch (MODE Switch)
Switch) 7. Air Conditioning Switch (A/C Switch)
2. Fan Speed Control Dial (FAN Switch) 8. Defroster Switch
3. Display Panel Indication 9. Air Selector Switch
4. Outside Air Temperature Display Switch 10. Automatic Air Conditioning Off Switch (OFF
(OUTSIDE Switch) Switch)
5. Temperature Control Dial

Fan Speed Control Knob (Dial)

The blower motor rotation is controlled by this knob via
the blower resistor, thereby adjusting the amount of air
blow from the air outlet.
The knob has the following 4 setting positions.
1. LOW
2. MEDIUM LOW
3. MEDIUM HIGH
4. HIGH
For vehicles with automatic A/C, the rotations of the
blower motor are controlled in 8 levels by the fan speed
control dial via the blower motor assembly (when in
manual mode).

Air Selector Lever (Switch)

By sliding this lever to the left or right, either "FRESH"
(outside air intake) or "RECIRC" (inside air
recirculation) can be selected.
For vehicles with automatic A/C, "FRESH" (outside air
intake) and "RECIRC" (inside air recirculation) are
toggled by pressing the switch.
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7A-4 Heating and Ventilation

Ventilation
When the air selector lever (switch) is set to "FRESH"
(outside air intake), intake of outside air is enabled at all
times. (In order to enhance the heating performance,
inside air is partially mixed through the inside air mix
door of the blower ASM.)
The blower fan has a function to maintain proper
ventilation by intake of the outside air into the vehicle
cabin.
When the air selector lever (switch) is set to "RECIRC"
(inside air recirculation), inside air is recirculated
without intake of the outside air.

FRESH (Outside air ventilation)

4 Inside air
5
6 1

Outside air

To Heater and
evaporator unit
2
3

RECIRC (Inside air recirculation)

Inside air
4
1
5

To Heater and
evaporator unit

3 2

MFW87ALF000101

Legend
1. Blower Motor 4. Inside Air filter
2. Blower Fan 5. Intake Door
3. Outside Air Filter 6. Inside Air Mix Door
MGHAC-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後４時１分
Outlet Selector Knob (Switch)
The air outlet to send air can be selected by this knob
(switch).
The air outlet to send air is selected by adjusting the
position of 2 types of rotary mode door inside the
heater unit. This mode door adjusts the opening range
of each outlet of the heater unit, blocks the opening
sections and passes air through the inside of the door,
enabling selection of 6 blowing patterns.
For vehicles with automatic A/C, "DEFROST" can be
selected by pressing the defroster switch (the air
conditioner is automatically turned "ON" when the
defroster switch is pressed.)
• FACE: Setting to this position supplies air to the
vehicle cabin through the ventilation ducts (1 and
2). The amount of air is controlled by the fan speed
control knob (dial).
4 4
3
2
2
1
1
This illustration is based on RHD.
Heating and Ventilation 7A-5
• BI-LEVEL: Setting to this position divides the air
into two groups in the heater unit, after which it is
supplied to the vehicle cabin through the
ventilation ducts (1 and 2) and the foot duct (5).
When the temperature control knob is set to the
center position, air that is supplied to the feet
through the foot duct (5) is set to a higher
temperature than the air that is supplied through
the ventilation ducts (1 and 2).
• FOOT: Setting to this position supplies the entire
amount of air to the feet through the foot duct (5).
• DEF/FOOT-1: Setting to this position supplies a
smaller amount of air to the feet (5) than the
"FOOT" mode, and a small amount of air is
supplied for defrosting (3 and 4).
• DEF/FOOT-2: Setting to this position increases the
amount of air for defrosting (3 and 4) compared to
the "DEF/FOOT-1" mode, and decreases the
amount of air to be supplied to the feet (5).
• DEFROST: Setting to this position supplies a large
proportion of the air to the windshield (4) and a
small amount of air to the side windows (3).
4
3
MFUB50MF000301
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7A-6 Heating and Ventilation

Mode Door Operation Diagram (When Air Mix Door = MAX COOL)

FACE BI-LEVEL FOOT

1
5

DEF / FOOT-1 DEF / FOOT-2 DEFROST

LNW87ALF000201

Legend
1. Mode Door (for DEF/FOOT) 4. Evaporator Core
2. Heater Core 5. Mode Door (for FACE)
3. Air Mix Door
MGHAC-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-7

Mode Door Structural Drawing (DEF/FOOT-2 Mode)

To Defroster nozzle
To Ventilation duct

5
1

From Blower To Foot duct

4
3
LNW87AMF000101

Legend
1. Mode Door (for DEF/FOOT) 4. Evaporator Core
2. Heater Core 5. Mode Door (for FACE)
3. Air Mix Door
MGHAC-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-8 Heating and Ventilation

Temperature Control Knob (Dial)
This knob (dial) is used to control the air temperature
blown from the air outlet. When the knob (dial) is set to
the "MAX COLD" (18°C (64°F)) position, the air mix
door is closed and the air flow into the heater core is
blocked. When the knob (dial) is set to the "MAX HOT"
(32°C(90°F)) position, the air mix door is fully opened
to pass all the air through the heater core to heat the
vehicle cabin.
When the knob (dial) is set to the center position
(middle temperature), the air flow into the heater core is
increased or decreased to adjust the temperature
inside the vehicle cabin.
When Set to "MAX HOT" (FACE Mode)

5
1

Cold air

Hot air

3 2

LNW87ASF000101

Legend
1. Mode Door (for DEF/FOOT) 4. Air Mix Door
2. Heater Core 5. Mode Door (for FACE)
3. Evaporator Core
MGHAC-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-9

Components Location Diagram

1 2

3
11

4
10
5

9 8 7 6
MFWB7AMF000101

Legend
1. Defroster Nozzle 7. Foot Duct (LH)
2. Side Defroster Nozzle (RH) 8. Air Duct
3. Ventilation Duct (RH) 9. Blower ASM
4. Control Lever ASM 10. Ventilation Duct (LH)
5. Foot Duct (RH) 11. Side Defroster Nozzle (LH)
6. Heater and Evaporator Unit

This illustration is based on RHD.

MGHAC-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後４時１分
7A-10 Heating and Ventilation
Functional Inspection: Heater Cycle System
Condition
No or insufficient heating
The control knob moves but the mode
door does not operate.
The mode door cannot be set to a
specified mode.
Possible Cause
The blower motor does not operate or is
malfunctioning.
The engine coolant temperature is low.
The level of the engine coolant is
insufficient.
The amount of the engine coolant in
circulation is insufficient.
The heater core is clogged or damaged.
The air mix door is defective.
Damage or insufficient airtightness of
duct connection.
The cable attachment lock clamp is
defective or detached.
The heater unit or the blower ASM's link
unit is defective.
The heater unit or the blower ASM's link
unit is defective.
The control cable is maladjusted.
Correction
Refer to "Functional Inspection: Fan
Switch System" in this section.
Warm up the engine and inspect the
engine coolant temperature.
Inspect the thermostat and replace it as
necessary.
Replenish the engine coolant as
necessary.
Inspect the water hose that is
connected to the heater core for
clogging, damage or twist. Repair or
replace it as necessary.
Inspect the water pump and the
thermostat.
Clean or replace it as necessary.
Repair or adjust the control cable of the
temperature control link unit.
Repair or adjust the control cable.
Repair or replace it as necessary.
Repair.
Repair.
Repair.
Adjust.
MGHAC-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後４時１分
Functional Inspection: Fan Switch System
• Refer to "Heater and Air Conditioning (Manual)"
and "Connector List" in section 9D Wiring System.
The blower motor does not operate regardless of
the switch position
Prior confirmation and visual inspection
• Check that the battery voltage is normal.
If the battery voltage is not normal, recharge or
replace the battery.
• Check that the fuses are normal.
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short etc.)
before replacing the fuse.
• Check that the ground connections are normal.
If the ground connection is defective (due to
incorrect installation or being considerably dirty),
repair and clean.
• Check that the harness and the connector are
normal.
Check the connector for connection faults and the
harness for defect such as abrasion or bends.
Check that the wire inside the harness has not
come loose and caused a short-circuit.
• Check the effect of the post-mounted electrical
components (radio and lights etc.).
Turn off or remove the post installed electrical
components so that they do not affect the
inspection or the operation.
Structural components inspection
• Check the blower motor fuse (F30).
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short circuit,
etc.) before replacing the fuse.
• Check the blower motor relay.
Perform a continuity inspection of the blower motor
relay and replace it if any abnormality is found.
• Check the blower resistor.
Perform a continuity inspection of the blower
resistor and replace it if any abnormality is found.
• Check the fan switch.
Perform a continuity inspection of the fan switch
and replace it if any abnormality is found.
• Check the blower motor.
Inspect the blower motor and replace it if any
abnormality is found.
Circuit inspection
• Check the following circuits for disconnections,
short circuits (power supply and GND), or high
resistance.
If any defects are discovered, repair or replace the
circuit.
(Each terminal No. indicates the connector
terminal at the chassis harness side.)
Heating and Ventilation 7A-11
- Between blower motor relay terminal No.5 and
fan switch terminal No.8
- Between blower motor relay terminal No.1 and
blower motor terminal No.2
- Between fan switch terminal No.1 and GND
Blower motor does not function at the 1 (LOW)
position
Prior confirmation and visual inspection
• Check that the battery voltage is normal.
If the battery voltage is not normal, recharge or
replace the battery.
• Check that the fuses are normal.
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short etc.)
before replacing the fuse.
• Check that the ground connections are normal.
If the ground connection is defective (due to
incorrect installation or being considerably dirty),
repair and clean.
• Check that the harness and the connector are
normal.
Check the connector for connection faults and the
harness for defect such as abrasion or bends.
Check that the wire inside the harness has not
come loose and caused a short-circuit.
• Check the effect of the post-mounted electrical
components (radio and lights etc.).
Turn off or remove the post installed electrical
components so that they do not affect the
inspection or the operation.
Structural components inspection
• Check the blower resistor.
Perform a continuity inspection of the blower
resistor and replace it if any abnormality is found.
• Check the fan switch.
Perform a continuity inspection of the fan switch
and replace it if any abnormality is found.
Circuit inspection
• Check the following circuit for disconnections,
short circuits (power supply and GND), or high
resistance.
If any defects are discovered, repair or replace the
circuit.
(Each terminal No. indicates the connector
terminal at the chassis harness side.)
- Between blower resistor terminal No.1 and
GND (RHD)
- Between blower resistor terminal No.4 and
GND (LHD)
MGHAC-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後４時１分
7A-12 Heating and Ventilation
Blower motor does not function at the 2 (MEDIUM
LOW) position
Prior confirmation and visual inspection
• Check that the battery voltage is normal.
If the battery voltage is not normal, recharge or
replace the battery.
• Check that the fuses are normal.
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short etc.)
before replacing the fuse.
• Check that the ground connections are normal.
If the ground connection is defective (due to
incorrect installation or being considerably dirty),
repair and clean.
• Check that the harness and the connector are
normal.
Check the connector for connection faults and the
harness for defect such as abrasion or bends.
Check that the wire inside the harness has not
come loose and caused a short-circuit.
• Check the effect of the post-mounted electrical
components (radio and lights etc.).
Turn off or remove the post installed electrical
components so that they do not affect the
inspection or the operation.
Structural components inspection
• Check the blower resistor.
Perform a continuity inspection of the blower
resistor and replace it if any abnormality is found.
• Check the fan switch.
Perform a continuity inspection of the fan switch
and replace it if any abnormality is found.
Circuit inspection
• Check the following circuit for disconnections,
short circuits (power supply and GND), or high
resistance.
If any defects are discovered, repair or replace the
circuit.
(Each terminal No. indicates the connector
terminal at the chassis harness side.)
- Between blower resistor terminal No.3 and fan
switch terminal No.6 (RHD)
- Between blower resistor terminal No.2 and fan
switch terminal No.6 (LHD)
Blower motor does not function at the 3 (MEDIUM
HI) position
Prior confirmation and visual inspection
• Check that the battery voltage is normal.
If the battery voltage is not normal, recharge or
replace the battery.
• Check that the fuses are normal.
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short etc.)
before replacing the fuse.
• Check that the ground connections are normal.
If the ground connection is defective (due to
incorrect installation or being considerably dirty),
repair and clean.
• Check that the harness and the connector are
normal.
Check the connector for connection faults and the
harness for defect such as abrasion or bends.
Check that the wire inside the harness has not
come loose and caused a short-circuit.
• Check the effect of the post-mounted electrical
components (radio and lights etc.).
Turn off or remove the post installed electrical
components so that they do not affect the
inspection or the operation.
Structural components inspection
• Check the blower resistor.
Perform a continuity inspection of the blower
resistor and replace it if any abnormality is found.
• Check the fan switch.
Perform a continuity inspection of the fan switch
and replace it if any abnormality is found.
Circuit inspection
• Check the following circuit for disconnections,
short circuits (power supply and GND), or high
resistance.
If any defects are discovered, repair or replace the
circuit.
(Each terminal No. indicates the connector
terminal at the chassis harness side.)
- Between blower resistor terminal No.2 and fan
switch terminal No.5 (RHD)
- Between blower resistor terminal No.3 and fan
switch terminal No.5 (LHD)
Blower motor does not function at the 4 (HI)
position
Prior confirmation and visual inspection
• Check that the battery voltage is normal.
If the battery voltage is not normal, recharge or
replace the battery.
• Check that the fuses are normal.
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short etc.)
before replacing the fuse.
• Check that the ground connections are normal.
If the ground connection is defective (due to
incorrect installation or being considerably dirty),
repair and clean.
• Check that the harness and the connector are
normal.
Check the connector for connection faults and the
harness for defect such as abrasion or bends.
Check that the wire inside the harness has not
come loose and caused a short-circuit.
MGHAC-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後４時１分
• Check the effect of the post-mounted electrical
components (radio and lights etc.).
Turn off or remove the post installed electrical
components so that they do not affect the
inspection or the operation.
Structural components inspection
• Check the blower resistor.
Perform a continuity inspection of the blower
resistor and replace it if any abnormality is found.
• Check the fan switch.
Perform a continuity inspection of the fan switch
and replace it if any abnormality is found.
Circuit inspection
• Check the following circuit for disconnections,
short circuits (power supply and GND), or high
resistance.
If any defects are discovered, repair or replace the
circuit.
(Each terminal No. indicates the connector
terminal at the chassis harness side.)
- Between blower motor terminal No.1 and fan
switch terminal No.4
Blower motor does not stop
Prior confirmation and visual inspection
• Check that the battery voltage is normal.
If the battery voltage is not normal, recharge or
replace the battery.
• Check that the fuses are normal.
If a fuse is faulty (because it is blown, etc.),
investigate/repair the cause (harness short etc.)
before replacing the fuse.
Specifications
Item
Heater Unit Temperature control system
Heat discharge
Air supply
Fan motor (rated voltage)
Heater Core Type
Effective core dimension
Heat dissipation area
Heating and Ventilation 7A-13
• Check that the ground connections are normal.
If the ground connection is defective (due to
incorrect installation or being considerably dirty),
repair and clean.
• Check that the harness and the connector are
normal.
Check the connector for connection faults and the
harness for defect such as abrasion or bends.
Check that the wire inside the harness has not
come loose and caused a short-circuit.
• Check the effect of the post-mounted electrical
components (radio and lights etc.).
Turn off or remove the post installed electrical
components so that they do not affect the
inspection or the operation.
Structural components inspection
• Check the fan switch.
Perform a continuity inspection of the fan switch
and replace it if any abnormality is found.
Circuit inspection
• Check the following circuits for short circuits.
If any defects are discovered, repair or replace the
circuit.
(Each terminal No. indicates the connector
terminal at the chassis harness side.)
- Between fan switch terminal No.1 and No.8
(line-to-line short circuit)
- Between fan switch terminal No.8 and blower
motor relay terminal No.5 (short circuit with
GND)
Specifications
Reheat air mix system
4100 kcal./h (4.8 kW)
290 m3/h
24 V
Fin-and-tube type
284.7 x 100 x 27 mm (11.2 x 3.9 x 1.1 in)
Approximately 2.1 m2
MGHAC-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-14 Heating and Ventilation

Blower Motor
Components

MFWB7AMF000301

Legend
1. Knee Bolster Panel (Passenger Side) 2. Blower Motor ASM

This illustration is based on RHD. 2. Inspect whether the blower motor operates
correctly.

Removal
1. Remove the knee bolster panel (on the passenger
side).
• Refer to “Instrument Panel” in section
9K,Exterior/Interior Trim.
2. Remove the blower motor ASM.
• Disconnect the connector of the blower motor. 2 1
• Remove the mounting screw of the blower
motor.

Inspection
Blower motor
1. Connect the (+) side of the battery voltage to
terminal No.2 of the blower motor and the (–) side
to terminal No.1.
LNW77ASH000901
MGHAC-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-15

Installation
Perform installation in the reverse order of the removal.
MGHAC-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-16 Heating and Ventilation

Blower Motor Relay

Removal 2. Disconnect the blower motor relay (2).
1. Fuse and Relay Box (Cab Junction Block) Position

2 1

LNW77BSH000301

Legend
1
1. Blower Motor Fuse
2. Blower Motor Relay

3. Inspect the continuity between the terminals at the

relay side.
2

5 4
4
3
1 1 2
5 3
2
3
LNW77BLH000101

Legend
1. Relay Box Lid
2. Relays
3. Fuses MFW87ASH000201

This illustration is based on RHD. 1 - 4--------------- continuity

1 - 2--------------- no continuity
(When battery voltage is applied between 3 - 5)
1 - 4--------------- no continuity
1 - 2--------------- continuity

Installation
Perform installation in the reverse order of the removal.
MGHAC-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-17

Blower ASM
Components

1
2

MFWA7AMF001101

Legend
1. Knee Bolster Panel (Passenger Side) 2. Blower ASM

This illustration is based on RHD. 5. Open the front lid and remove the mounting bolts
(outside the vehicle cabin) (1) for the blower ASM.

Removal
1. Remove the knee bolster panel (on the passenger
side).
• Refer to “Instrument Panel” in section
9K,Exterior/Interior Trim.
2. Disconnect the air source control cable.
• Disconnect the air source control cable from the
blower ASM.
• If the vehicle has automatic A/C, disconnect the
connector for the intake actuator.
3. Disconnect the connector of the blower motor.
4. Disconnect the connector for the blower resistor
(or the BLC if the vehicle has automatic A/C).

1
MFW77ASH000201

6. Remove the mounting bolt, nut and screw (inside

the vehicle cabin) for the blower ASM.
7. Remove the blower ASM.
MGHAC-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-18 Heating and Ventilation

• Remove it together with the blower ASM
mounting stay (bottom side).

Installation
Perform installation in the reverse order for removal
while paying attention to the following items.
1. Adjust the air source control cable.
• Refer to "Control Lever ASM" in this section.
MGHAC-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-19

Blower Link Unit and Intake Door

Components

4
1 2

4 3

MFW77AMF000401

Legend
1. Lower Case 4. Upper Case
2. Air Duct 5. Intake Sub Lever and Door Lever
3. Blower Motor ASM 6. Intake Door

This illustration is based on RHD. Installation

Perform installation in the reverse order for removal
Removal while paying attention to the following items.
1. Confirm that the intake door is mounted to the
1. Remove the blower ASM.
proper position, and then tighten the screw of the
• Refer to "Blower ASM" in this section. upper case.
2. Remove the outside air filter. 2. Apply grease on the sliding surface of each lever.
3. Remove the inside air filter. 3. After installation, check that the intake door
4. Remove the lower case. operates correctly.
• Remove the mounting screw of the lower case.
5. Remove the intake sub lever.
• Remove the mounting screw of the intake sub
lever.
• If the vehicle has automatic A/C, remove the
intake actuator and the rod.
6. Remove the door lever.
7. Split the upper case into two.
• Remove the mounting screw of the upper case.
8. Remove the intake door.
MGHAC-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-20 Heating and Ventilation

Inside Air Filter

Components

MFW77AMF000501

Legend
1. Inside Air Filter

Removal
1. Open the front lid.
2. Remove the inside air filter.
• Pull out the filter from the slit at the top of the
blower.

Installation
Perform installation in the reverse order for removal
while paying attention to the following items.
• Firmly fit the filter into the slit.
• Firmly fit the claw of the filter into the lock at the
blower side.
MGHAC-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-21

Outside Air Filter

Components

1
MFW77AMF000601

Legend
1. Outside Air Filter

Removal
1. Open the front lid.
2. Remove the outside air filter.

Installation
Perform installation in the reverse order for removal
while paying attention to the following item.
• Firmly fit the claw of the filter into the lock at the
blower side.
MGHAC-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-22 Heating and Ventilation

Heater Unit (Heater and Evaporator Unit)

Components

4 3

7
5

6 MFWB7AMF000501

Legend
1. Meter Cluster 5. Foot Duct (RH)
2. Knee Bolster Panel (Driver Side) 6. Heater and Evaporator Unit
3. Fuse and Relay Box (Cab Junction Block) 7. Foot Duct (LH)
4. Junction Block

This illustration is based on RHD. • If the vehicle has automatic A/C, disconnect the
connectors for each actuator and the coolant
temperature sensor.
Removal 6. Disconnect the connector for the electronic
1. Remove the blower ASM. thermostat.
• Refer to "Blower ASM" in this section. • If the vehicle has automatic A/C, disconnect the
2. Remove the meter cluster. connector of the fin sensor (evaporator
• Pull the meter cluster towards you and temperature sensor).
disconnect the clip on the back side. 7. Lift the junction block from the reinforcement.
• Disconnect each connector. • Remove the installation nut from the junction
3. Remove the knee bolster panel (on the driver block.
side). 8. Lift the fuse and relay box (cab junction block) from
• Remove the mounting bolts and resin clips for the reinforcement.
the knee bolster panel (driver side), and pull the • Remove the installation nut from the fuse and
panel towards you to disconnect the clips on relay box.
the back side. 9. Drain the engine coolant.
4. Remove the foot duct (RH and LH). 10. Remove the heater hose.
5. Disconnect each control cable.
MGHAC-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-23

• Remove the heater hose clip (3) to disconnect
the hose from the heater and evaporator unit.
(when doing so, make sure to plug the heater
hose and the heater and evaporator unit to
prevent excessive leakage of the coolant.)
11. Drain the A/C refrigerant.
• Refer to "Manual Air Conditioning System" in
section 7B Manual Air Conditioning.
12. Remove the fitting of the A/C pipe.
• Remove the A/C pipe connecting bolt (1).
• After disconnecting each pipe, put a cap or a
cover on the joint section to prevent the foreign
matter from getting into the air conditioning
cycle.
13. Remove the mounting bolt (2) of the heater and
evaporator unit.

3
MFW77ASH000301

14. Remove the mounting bolt and nut (inside the

vehicle) of the heater and evaporator unit.
15. Remove the heater and evaporator unit.

Installation
Perform installation in the reverse order for removal
while paying attention to the following items.
1. Do not re-use the A/C pipe O-ring. Always replace
it with a new one. (apply compressor oil on the O-
ring.)
2. Tighten the joint section of the A/C pipe at the
specified torque.
Tightening torque = 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
3. Adjust each control cable.
• Refer to "Control Lever ASM" in this section.
4. After feeding the engine coolant, thoroughly
remove air and check the water level.
MGHAC-WE-0871.book 24 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-24 Heating and Ventilation

Heater Core
Components

3
LNW77AMF001501

Legend
1. Heater and Evaporator Unit 3. Coolant Temperature Sensor (vehicle with
2. Heater Core automatic A/C)
4. Pipe Cover

Removal • Use a flat-blade screwdriver, etc., to remove the

heater pipe from the connecting section (1).
1. Remove the blower ASM.
• Refer to "Blower ASM" in this section.
2. Remove the coolant temperature sensor (vehicle
with automatic A/C).
1
• Remove the clamp of the coolant temperature
sensor.
3. Remove the heater pipe from the heater core. (Do
not re-use the heater core.)

1
LNW77ASH001401
MGHAC-WE-0871.book 25 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-25

4. Remove the pipe cover.
• Remove the mounting screw of the pipe cover.
5. Remove the heater core.
• Pull out the heater core from the heater and
evaporator unit.

If the heater core is to be re-used, remove the heater

and evaporator unit and slowly pull out the core with
the heater pipe connected to it.

Installation
1. Install the heater core.
• Slowly insert the heater core into the heater
and evaporator unit.
2. Attach the heater pipe.
• Insert the pipe into the heater core and fasten it
with the C clip.
3. Attach the pipe cover.
4. Install the blower ASM.
MGHAC-WE-0871.book 26 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-26 Heating and Ventilation

Air Mix Door and Mode Door

Components

11

10

2
3

4
8
6
7

LNW77BMF000301

Legend
1. Evaporator Core 7. Mix Lever
2. Heater and Evaporator Unit Case (LH) 8. Fin Sensor Cover
3. Heater Core 9. Mode Main Lever
4. Mode Door (for DEF/FOOT) 10. Door Lever
5. Air Mix Door 11. Mode Door (for FACE)
6. Heater and Evaporator Unit Case (RH)

This illustration is based on RHD. 6. Remove the door lever.

7. Split up the heater and evaporator unit case.
Removal • Remove the mounting screw of the heater and
evaporator unit case.
1. Remove the heater and evaporator unit.
• Split carefully without straining the heater core
• Refer to "Heater Unit (Heater and Evaporator and the evaporator core.
Unit)" in this section.
• Be careful so that the sensor connector is not
2. Remove the fin sensor cover and push the sensor caught in the unit.
connector into the unit.
8. Remove each mode door.
3. Remove each lever to which the air selection and
9. Remove the air mix door.
the temperature control cables were connected.
• If the vehicle has automatic A/C, remove each
actuator.
4. Disconnect the mix lever.
5. Remove the mode main lever.
• Remove the mounting screw of the mode main
lever.
MGHAC-WE-0871.book 27 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-27

Installation
Perform installation in the reverse order for removal
while paying attention to the following items.
1. Confirm that each mode door and the air mix door
are mounted to the proper position and then
tighten the screw of the unit.
2. Apply grease on the sliding surface of each lever.
3. After the installation, check that each mode door
and the air mix door operate correctly.
MGHAC-WE-0871.book 28 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-28 Heating and Ventilation

Vent Grille
Components

1
1
1
1

3 2

MFW87ASF000101

Legend
1. Vent Grille 3. Side Trim Panel
2. Meter Cluster

This illustration is based on RHD.

Removal
1. Remove the meter cluster.
• Pull the meter cluster towards you and
disconnect the clip on the back side.
• Disconnect each connector.
2. Remove the side trim panel.
• Remove the resin clip of the side trim panel and
pull the panel towards you to disconnect the
clip on the back side.
3. Remove each vent grille.
• Lift and remove the claw (1) at the back side of
the meter cluster. 1
• Remove the grille at the side trim panel side in
LNW77ASH000201
the same way.

Installation
Perform installation in the reverse order of the removal.
MGHAC-WE-0871.book 29 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-29

Defroster Nozzle and Ventilation Duct

Components

4 5 1

MFWB7AMF000201

Legend
1. Side Defroster Nozzle (RH) 4. Side Defroster Nozzle (LH)
2. Ventilation Duct (RH) 5. Defroster Nozzle
3. Ventilation Duct (LH)

This illustration is based on RHD. Installation

Perform the installation in the reverse order of the
Removal removal while paying attention to the following
instruction.
1. Remove the instrument panel ASM.
1. Firmly fix the connecting section of each duct so
• Refer to "Instrument Panel" in section 9K, that there are no gaps.
Exterior/Interior Trim.
2. Remove the side defroster nozzle (LH).
• Remove the mounting screw of the side
defroster nozzle (LH). (then remove the
mounting screw for each nozzle and duct in
order.)
3. Remove the side defroster nozzle (RH).
• If the vehicle has automatic A/C, remove the
harness clip from the solar radiation sensor.
4. Remove the defroster nozzle.
5. Remove the ventilation duct (RH).
6. Remove the ventilation duct (LH).
MGHAC-WE-0871.book 30 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-30 Heating and Ventilation

Control Lever ASM

Components

3
4
5

9 7
6
5
8

MFWB7AMF000601

Legend
1. Meter Cluster 6. A/C Switch
2. Control Lever ASM 7. Instrument Panel ASM
3. Control Panel Bezel 8. Cluster Compartment
4. Lever Knob 9. Control Cables
5. Knobs

This illustration is based on RHD.

Removal
1. Remove the meter cluster.
• Pull the meter cluster towards you and
disconnect the clip on the back side.
• Disconnect each connector.
2. Remove each cluster compartment.
• Remove the mounting screw of the cluster
compartment.
3. Remove the lever knob and each knob.
4. Remove the control panel bezel (2) from the
control lever ASM (1).
MGHAC-WE-0871.book 31 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-31

• Lift the 4 claws of the control panel bezel (2) Inspection
and remove it together with the A/C switch. Fan Switch
1. Inspect the continuity between the connector
terminals at the switch side while operating the fan
switch according to the connection table below.
1 Night
illumination
+ -
3 2 1
8 7 6 5 4

2 SW position
LNW77BSH001601
5. Disconnect each control cable.
• Disconnect each control cable from the link
section of the heater and evaporator unit and
the blower ASM.
• Disconnect each control cable from the lock
clamp.
6. Remove the control lever ASM.
• Remove the mounting screw and pull the
control lever ASM towards you to disconnect
the connectors of the A/C switch and the fan
switch.
7. Remove the control lever ASM.
8. Remove the control panel illumination valve.
• Remove the illumination valve (2) from the
mounting section (1) at the back side of the
control lever ASM by turning it to the left.
1 "COOL" position on the left.
2
LNW77ASH002501
Terminal No.
8 6 5 4 1
OFF
1
2
3
4
LNW71ASH002501
Installation
Perform installation in the reverse order for removal
while paying attention to the following items.
1. Adjust the control cable.
• Air selector control cable:
- Set the air selector lever to "RECIRC"
position on the left.
- Set the blower ASM link (mode door)
position to "RECIRC", connect the control
cable and fasten it to the lock clamp.
• Temperature control cable:
- Set the temperature control knob to the
- Set the temperature control link of the
heater unit (air mix door) to the "COOL"
position, connect the control cable and
fasten it to the lock clamp.
• Outlet selector control cable:
- Set the outlet selector knob to the "FACE"
position.
- Set the mode control link of the heater unit
(mode door) to the "FACE" position, connect
the control cable and fasten it to the lock
clamp.
2. Make sure that the control cable is firmly fastened
to the original position at the lock clamp.
3. After installation, inspect the operation of the
control lever ASM.
MGHAC-WE-0871.book 32 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-32 Heating and Ventilation

RECIRC
CE
CO
OL FA
EL
LEV
BI-
FR

FOOT
ES
H

DEF/
FOOT
DE -1
F/F
OO
T-2
T
HO

DE
F
LNW77AMF001301

This illustration is based on RHD.

MGHAC-WE-0871.book 33 ページ ２０１１年５月１９日　木曜日　午後４時１分

Heating and Ventilation 7A-33

Blower Resistor
Components

LNW77AMF001101

Legend
1. Blower ASM 2. Blower Resistor

Removal
1. Remove the knee bolster panel (on the passenger
side).
• Refer to “Instrument Panel” in section
9K,Exterior/Interior Trim.
2. Disconnect the blower resistor connector.
3. Remove the blower resistor.
• Remove the mounting screw of the blower
resistor.
MGHAC-WE-0871.book 34 ページ ２０１１年５月１９日　木曜日　午後４時１分

7A-34 Heating and Ventilation

Inspection
Blower Resistor
1. Disconnect the blower resistor connector.
2. Inspect the conduction and the resistance value
between the terminals at the blower resistor side
based on the connection table below.
RHD

2 1 1

4 3
4 2 3 1

Resistance
Terminal No.
value ( )
1 2 3 4
SW position 24V

1 8.4

2 4.5

3 1.8

LNW87ASH000201

Legend
1. Pin No.

LHD

2 1 1

4 3
1 3 2 4

Resistance
Terminal No.
value ( )
1 2 3 4
SW position 24V

1 8.4

2 4.5

3 1.8

LNW87ASH000101

Legend
1. Pin No.

Installation
Perform installation in the reverse order of the removal.
69209_MGHAC-WE-0871_奥付 2011.5.9 10:13 AM ページ 1

Published: May, 2011 All rights reserved.

Eighth Edition

WORKSHOP MANUAL
HEATING, VENTILATION
AND AIR CONDITIONING
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
69209_MGHAC-WE-0871_奥付 2011.5.9 10:13 AM ページ 2
 2008-2011MY

WORKSHOP MANUAL

HEATING, VENTILATION
AND AIR CONDITIONING

No.MGHAC-WE-0871