2004 ISUZU TF SERIES section 1A

GENERAL INFORMATION 0A-3

NOTES ON THE FORMAT OF THIS MANUAL
1. Find the applicable Section by referring to the index at the front of the Workshop Manual binder.
2. The following technical service information is included in this Section:


Identification


Maintenance schedules


Recommended Iubricants


Recommended fuels


Oil viscosity charts
3. Individual Sections of this Workshop Manual are divided into the following categories:


Main data and specifications


Torque specifications


Recommended liquid gasket


Loctite application procedure


Servicing


Removal and installation


Disassembly


Inspection and repair


Reassembly


Troubleshooting
4. Each "Major Components" page of this Workshop Manual has an exploded view of the applicable area.
A brief explanation of the notation used follows:

MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
TABLE OF CONTENTS
PAGE
Maintenance Schedule (For GENERAL EXPORT) ......................................................... 0B- 2
Maintenance Schedule (For EUROPE) ........................................................................... 0B- 5
Severe Conditions Maintenance Schedule (For GENERAL EXPORT) ........................ 0B-11
Severe Conditions Maintenance Schedule (For EUROPE) .......................................... 0B-12
Recommended Fluids and Lubricants (For GENERAL EXPORT)................................ 0B-13
Recommended Fluids and Lubricants (For EUROPE).................................................. 0B-15
Oil Viscosity Chart ........................................................................................................... 0B-16

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

1-26 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.

1-28 HEATER AND AIR CONDITIONING

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.

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 or repair the compressor.

1-36 HEATER AND AIR CONDITIONING
CONDENSER
REMOVAL AND INSTALLATION (4JA1-TC, 4JH1-TC)

This illustration is based on RHD model RTW410LF000501
Removal Steps
1. Radiator grille
2. Front bumper fascia

Refer to SECTION 2A “FRONT
BUMPER”
3. Front bumper inpact support assembly

Refer to SECTION 2A “FRONT
BUMPER”
4. Air cleaner assembly
5. Inter cooler

Refer to SECTION 6A “INTER COOLER”
6. Engine hood lock
7. Engine hood front end stay
8. Pressure switch connector
9. Condenser fan connector
10. Refrigerant line
11. Refrigerant line
12. Receiver/drier bracket
13. Receiver/drier
14. Condenser assembly
Installation Steps
14. Condenser assembly
13. Receiver/drier
12. Receiver/drier bracket
11. Refrigerant line
10. Refrigerant line
9. Condenser fan connector
8. Pressure switch connector
7. Engine hood front end stay
6. Engine hood lock
5. Inter cooler

Refer to SECTION 6A “INTER COOLER”
4. Air cleaner assembly
3. Front bumper inpact support assembly

Refer to SECTION 2A “FRONT
BUMPER”
2. Front bumper fascia

Refer to SECTION 2A “FRONT
BUMPER”
1. Radiator grille

HEATER AND AIR CONDITIONING 1-47

Checking and Adjusting for Used Compressor
(1) Perform Oil return operation.
(Refer to "Oil Return Operation" in this section.)
(2) Discharge refrigerant and remove the compressor.


(3) Drain the compressor oil and measure the extracted oil with
a measuring cylinder.
(4) Check the compressor oil for contamination.
(Refer to "Contamination of Compressor Oil" in this
section.)
(5) Adjust oil level following the procedure below.

Type Collected Amount Charging Amount
more than 90 cm3
(3.0 fl.oz.) same as collected
amount
less than 90 cm3
(3.0 fl.oz.) 90 cm3 (3.0 fl.oz.) CR-14

(6) Install the compressor, then evacuate, charge and perform
oil return operation.
(7) Check system operation.


When it is impossible to perform oil return operation, the
compressor oil should be checked in the following order:
(1) Discharge refrigerant and remove the compressor.
(2) Drain the compressor oil and measure the extracted oil with
a measuring cylinder.
(3) Check the oil for contamination.
(4) If more than 90 cm
3 (3.0 fl.oz.) for CR-14 type is extracted
from the compressor, supply same amount of oil to the
compressor to be installed.
If the amount of oil extracted is less than 90 cm
3 (3.0 fl.oz.)
for CR-14 type recheck the compressor oil in the following
order:
(5) Supply 90 cm
3 (3.0 fl.oz.) for CR-14 type oil to the
compressor and install it onto the vehicle.
(6) Perform oil return operation.
(7) Remove the compressor and recheck the amount of oil.
(8) Adjust the compressor oil.