2004 ISUZU TF SERIES charging

6E–204 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The engine control module (ECM) monitors the system
voltage on the ignition feed terminals to the ECM. A
system voltage Diagnostic Trouble Code will setwhenever the voltage is above a calibrated value.Diagnostic Aids
Check for a faulty charging system components.
Diagnostic Trouble Code (DTC) P0563 Sy stem Voltage High
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P0563 A System Voltage High Battery voltage is above 16V. No fail-safe function.
Step A ction Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check

ENGINE DRIVEABILITY AND EMISSIONS 6E–205
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0:
Diagnostic Trouble Code”.
Is the DTC P0563 stored as “Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”.
2. Select “Clear DTC Information” with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed
This Ignition” in “F2: DTC Information”.
Was the DTC P0563 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate correct ignition voltage? Less than 16V Go to Step 5Check the
charging
system and Go
to Step 5
5 Is the battery jamp start cable incorrectly connecting?
—Verify
procedure Go to Step 6
6 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 7
7 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step A ction Value(s) Yes No

1-26 HEATER AND AIR CONDITIONING
ON-VEHICLE SERVICE

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:

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:

1) Using the ACR
4 (HFC-134a Refrigerant Recovery/
Recycling/Recharging/System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR
4 (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4 (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3)
After evacuation, charge the air conditioning system and
check for leaks.

HEATER AND AIR CONDITIONING 1-29

RECOVERY, RECYCLING, EVACUATION
AND CHARGING
Handling Refrigerant-134a (HFC-134a)
Air conditioning systems contain HFC-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 HFC-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 HFC-
134a in a vehicle, do not carry it in the passenger
compartment.
 If it is necessary to fill a small HFC-134a container from a
large one, never fill the container completely. Space should
always be allowed above the liquid for expansion.

Keep HFC-134a containers stored below 40
C (104
F).


WARNING





SHOULD HFC-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 HFC-134a TOUCH THE SKIN,
THE INJURY MUST BE TREATED THE SAME AS SKIN
WHICH HAS BEEN FROSTBITTEN OR FROZEN.

F06R300012


REFRIGERANT RECOVERY
The refrigerant must be discharged and recovered by using
ACR4 (HFC-134a Refrigerant Recovery/Recycling/Recharging/
System) or equivalent before removing or installing air
conditioning parts.
ACR
4 (115V 60Hz) :5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4 (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
1) Connect the high and low charging hoses of the ACR
4 (or
equivalent) as shown.
2) Recover the refrigerant by following the ACR
4
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.

1-30 HEATER AND AIR CONDITIONING

REFRIGERANT RECYCLING
Recycle the refrigerant recovered by ACR4 or equivalent.
For the details of the actual operation, follow the steps in the
ACR
4 Manufacturer's Instructions.
ACR4 (115V 60Hz) :5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4 (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)

F06R300014


EVACUATION OF THE REFRIGERANT
SYSTEM
NOTE:
Explained below is a method using a vacuum pump. Refer
to the ACR
4 (or equivalent) Manufacturer's Instructions
when evacuating the system with ACR4 (or equivalent).

Air and moisture in the refrigerant will cause problems in the air
conditioning system.
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. 100kPa
(750 mmHg/30 inHg), continue the evacuation for 5 minutes
or more.
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 100 kPa (750 mmHg/30 inHg), close
both hand valves.
9) Close positive shutoff valve.
Stop the vacuum pump and disconnect the center hose
from the vacuum pump.

HEATER AND AIR CONDITIONING 1-31
CHARGING THE REFRIGERANT SYSTEM
There are various methods of charging refrigerant into the air
conditioning system.
These include using the ACR
4 (HFC-134a Refrigerant
Recovery/ Recycling/Recharging/System) or equivalent and
direct charging with a manifold gauge charging station.
ACR
4 (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4 (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
F06R300012
Charging procedure





ACR4 (or equivalent) method
For the charging of refrigerant recovered by ACR4, follow the
Manufacturer's Instruction.

1-32 HEATER AND AIR CONDITIONING
F06R300013








Direct charging with a manifold gauge charging
station method.
Handling the charging 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

HEATER AND AIR CONDITIONING 1-33
refrigerant container.


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
to 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 HFC-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 Idling and close the all vehicle
doors.
(2) A/C switch is "ON".
(3) Set the fan control knob (fan switch) to its highest
position.
(4) Set air soure selector lever to “RECIRC”



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.
8) Charge the system to the specified amount and then close
the low-pressure hand valve.
Refrigerant Amount g(lbs.)
720 (1.59)