2004 ISUZU TF SERIES air condition

MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SCHEDULE (For EUROPE)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
Diesel Engine model (ACEA B2 specification engine oil)

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
DIESEL ENGINE * Engine oil (4JH1-TC) - R - R - R- R- R- R- R - R - R- R* Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * Engine oil filter(4JH1-TC) - R - R - R- R- R- R- R - R - R- R* Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - I I I I I I I I I I I I I I I I I I I
Valve clearance (4JH1-TC) - - - A - - - A - - - A - - - A - - - A Valve clearance (4JA1-TC) - - A - - A - - A - - A - - A - - A - - * Air cleaner element (4JH1-TC) I I I I I I I R I I I I I I I R I I I I * Air clearance element (4JA1-TC) - - I I I I I I R I I I I I I I I R I I Fuel filter (4JH1-TC) - - R - - R - - R - - R - - R - - R - - Fuel filter (4JA1-TC) - - - - - - - - R - - - - - - - - R - - Engine coolant concentration (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Engine coolant concentration
(4JA1-TC) - - I - - I - - I - - I - - I - - I - - Cooling system for water leakage
(4JH1-TC) - I - I - I - I - I - I - I - I - I - I Cooing system for water leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - CLUTCH Clutch fluid (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Clutch fluid (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Clutch pedal travel and play (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play (4JA1-TC) - - I - - I - - I - - I - - I - - I - - TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
* Manual transmission with fluid (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * Manual transmission with fluid
(4JA1-TC) - - R - - I - - R - - I - - R - - I - - * Transfer case oil (4JH1-TC) - - - I - - - I - - - I - - - I - - - I * Transfer case oil (4JA1-TC) - - R - - I - - R - - I - - R - - I - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Gear control mechanism for
looseness (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness (4JA1-TC) - - - - - - - - I - - - - - - - - I - I * AT Automatic transmission fluid
(4JH1-TC) - - - I - - - I - - - I - - - I - - - I * AT Automatic transmission fluid (4JA1-TC) - - - - - - - - I - - - - - - - - I - I * AT Transfer case oil (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * AT Transfer case oil (4JA1-TC) - - R - - I - - R - - I - - R - - I - -

MAINTENANCE AND LUBRICATION 0B-11
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
G : Gasoline engine
B : Driving on rough roads
4JA1-T : 4JA1-T Diesel engine
C : Driving on dusty roads
4JA1-TC : 4JA1-TC Diesel engine
D : Driving in extremely cold weather and/or on salted roads
4JH : 4JH1-TC Diesel engine
E : Towing trailer or climbing mountain frequently
D
: Diesel engine
MT : Manual transmission

AT : Automatic transmission

4WD
Four wheel drive


Condition
A B C D E A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month4JA1-T : Change every 2,500 km (1,500 miles) 4JA1-TC : Change every 5,000 km (3,000 miles) 4JH : Change every 7,500 km (4,500 miles)



G Replace every 5,000 km (3,000 miles) or 3 month



Engine oil filter
D Replace every 5,000 km (3,000 miles)




Exhaust system Inspect every 5,000 km (3,000 miles)







Air cleaner element Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)


Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)



Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000
miles)



Transmission or transfer case
oil MT Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


AT Transmission:
Change every 20,000 km (12,000 miles)






4WD Transfer:
Change every 20,000 km (12,000 miles)


Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and discs Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)






Interval Item

0B-12 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)


Severe driving conditions
4JA1-TC : 4JA1-TC Diesel engine
A: Repeated short trips
4JH : 4JH1-TC Diesel engine
B: Driving on rough roads
D : Diesel engine
C: Driving on dusty roads
MT : Manual transmission
D: Driving in extremely cold weather and/or on salted roads
AT : Automatic transmission
E: Towing trailer or climbing mountein frequently
4WD : Four wheel drive


Condition
Item Interval
A B C D A+D
Engine oil 4JH : Change every 5,000 km (3,000 miles) 4JA1-TC : Change every 7,500 km (4,500 miles)



Engine oil filter 4JH : Replace every 5,000 km (3,000 miles) 4JA1-TC : Replace every 7,5000 km (4,500 miles)




Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)





Air cleaner element Replace every 20,000 km (12,000 miles)



Steering system for looseness or
damage Inspect every 5,000 km (3,000 miles)




Universal joints and sleeves Inspect for wear and lubricate every 10,000 km (6,000 miles)



Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)



AT
Transmission:
Inspection every 20,000 km (12,000 miles)





4WD Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 miles)



Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and discs Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum wear Inspect every 5,000 km (3,000 miles)

WORKSHOP MANUAL

TF SERIES




HEATING AND AIR CONDITIONING






SECTION 1

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 1- 3
Parts Location ................................................................................................................. 1- 5
Main Data and Specifications ......................................................................................... 1- 15
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 17
ON-Vehicle Service .......................................................................................................... 1- 26
Precautions For Replacement or repair of air conditioning parts .......................... 1- 26
Condenser ........................................................................................................................ 1- 36
Removal and Installation (4JA1-TC, 4JH1-TC).......................................................... 1- 36
Removal and Installation (Except 4JA1-TC, 4JH1-TC) ............................................. 1- 37
Condenser Fan Motor ...................................................................................................... 1- 38
Removal and Installation ............................................................................................ 1- 38
Receiver/drier ................................................................................................................... 1- 39
Removal and Installation ............................................................................................ 1- 39
Compressor...................................................................................................................... 1- 40
Removal and Installation (4J ENGINE) ...................................................................... 1- 40
Removal and Installation (6VE1) ................................................................................ 1- 42
Removal and Installation (C24SE) ............................................................................. 1- 44
Disassembly ................................................................................................................ 1- 50
Reassembly ................................................................................................................. 1- 52
Heater Unit........................................................................................................................ 1- 54
Removal and Installation ............................................................................................ 1- 54
Disassembly and Reassembly ................................................................................... 1- 56
Vent Unit (Without Heater) ............................................................................................. 1- 57
Removal and Installation ............................................................................................ 1- 57
Disassembly and Reassembly ................................................................................... 1- 59
Evaporator (With A/C)...................................................................................................... 1- 60
Removal and Installation ............................................................................................ 1- 60
Disassembly and Reassembly ................................................................................... 1- 61

1-2 HEATER AND AIR CONDITIONING
PAGE
Duct (Without A/C) ........................................................................................................... 1- 63
Removal and Installation ............................................................................................ 1- 63
Disassembly and Reassembly ................................................................................... 1- 64
Blower Unit Assembly ..................................................................................................... 1- 65
Removal and Installation ............................................................................................ 1- 65
Disassembly and Reassembly ................................................................................... 1- 67
Defroster Nozzle and Vent Duct ..................................................................................... 1- 68
Removal and Installation ............................................................................................ 1- 68
Rear Heater Duct.............................................................................................................. 1- 69
Removal and Installation ............................................................................................ 1- 69
Control Lever Assembly .................................................................................................. 1- 70
Removal and Installation ............................................................................................ 1- 70
Control Panel Illumination Bulb ..................................................................................... 1- 74
Removal and Installation ............................................................................................ 1- 74
Inspection and Repair................................................................................................. 1- 76
Troubleshooting .............................................................................................................. 1- 79
Special Service Tool ........................................................................................................ 1-104

HEATER AND AIR CONDITIONING 1-3
GENERAL DESCRIPTION
SYSTEM COOLING LINE










1.
Compressor 8.
Evaporator core
2.
Magnetic clutch 9.
Blower motor
3.
Receiver/Drier 10.
Heater unit
4.
Dual pressure switch or Trinary 11.
Mode (DEF/FOOT) control door

pressure switch (4J

-TC, 6VE1, 12.
Mode (VENT) control door
C24SE) 13.
Electronic thermostat
5.
Condenser 14.
Heater core
6.
Evaporator assembly
7.
Expansion valve

RTW310LF001001

1-4 HEATER AND AIR CONDITIONING
UNIT (only indoor parts)



This illustration is based on RHD model
RTW410LF000801