lock ISUZU TF SERIES 2004 Workshop Manual

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)

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 1-37

REMOVAL AND INSTALLATION (EXCEPT 4JA1-TC, 4JH1-TC)



RTW410LF000701

Removal Steps
1. Radiator grille
2. Engine hood lock
3. Engine hood front end stay
4. Pressure switch connector
5. Condenser fan connector
6. Refrigerant line
7. Refrigerant line
8. Receiver/drier bracket
9. Receiver/drier
10. Condenser assembly

Installation Steps
10. Condenser assembly
9. Receiver/drier
8. Receiver/drier bracket
7. Refrigerant line
6. Refrigerant line
5. Condenser fan connector
4. Pressure switch connector
3. Engine hood front end stay
2. Engine hood lock
1. Radiator grille

1-40 HEATER AND AIR CONDITIONING
COMPRESSOR
REMOVAL AND INSTALLATION (4J ENGINE)





852R300006
Removal Steps
1. Air duct
2. Magnetic clutch harness connector
3. Lock nut
4. Tension adjustment bolt
5. Drive belt
6. Refrigerant line
7. Bolt; compressor to bracket
8. Compressor assembly

Installation Steps
8. Compressor assembly

7. Bolt; compressor to bracket

6. Refrigerant line
5. Drive belt
4. Tension adjustment bolt
3. Lock nut
2. Magnetic clutch harness connector
1. Air duct

HEATER AND AIR CONDITIONING 1-75
Important Operation - Removal
1. Control lever assembly
Refer to “CONTROL LEVER ASSEMBLY” in this section.

2. Illumination Bulb
To remove the illumination bulb, insert an ordinary screwdriver
into the slot (B) at the back of the bulb. Turn the bulb
counterclockwise and pull it free.

1-86 HEATER AND AIR CONDITIONING

RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Suction
(Low)
pres-sure
abnormally
low
Condenser is not hot and
excessive bubble in sight glass







Insufficient refrigerant








Check sight
glass.(See “Reading
Sight Glass”)


Check for leaks


Discharge and
recover refrigerant.
Recharge to specified
amount
Frost on the expansion valve inlet
line

Expansion valve clogged


Replace the
expansion valve

A distinct difference in
temperature between the inlet and
outlet refrigerant lines of the
receiver/drier

Receiver/drier clogged




Replace the receiver/
drier


Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum



The temperature sensor of
the expansion valve is
defective, and the valve
cannot regulate the correct
flow of the refrigerant

Replace the
expansion valve



Discharge temperature is low and
air flow from vents is restricted

Frozen evaporator core fins


Check electronic
thermostat and
replace as necessary
Low-pressure gauge reading is
low, or a vacuum reading may be
shown

Clogged or blocked
refrigerant line


Replace refrigerant
line
Suction
(Low) and
Discharge
(High)
pressure
abnor-
mally
high
No bubbles in sight glass after
condenser is cooled by water
(Insufficient cooling)





Excessive refrigerant in
system






Check sight
glass.(See “Reading
Sight Glass”)


Discharge and
recover refrigerant.
Recharge to specified
amount
Reduce air flow through con-
denser


Condenser clogged

Radiator (condenser) fan
does not rotate properly

Clean

Check cooling fan
operation
Suction (Low) pressure hose is
not cold

Air in system

Evacuate and charge
refrigerant
Suction
(Low) and
Discharge
(High)
pres-sure
abnor-
mally
low
Insufficient cooling and excessive
bubbles in the sight glass

Insufficient refrigerant in
system


Check sight glass.
(See “Reading Sight
Glass”)


Check for leaks

Discharge and
recover refrigerant.
Recharge to specified
amount

MSG MODEL 7B-3
GENERAL DESCRIPTION


The MSG type transmission is fully synchronized 5-speed unit with blocking ring type synchronizers and a constant
mesh type reverse gear.
The unit consists principally of a case with an integral clutch housing, intermediate plate, rear cover and gears.
The top of the rear cover is a quadrant box containing the transmission control mechanism.
The case and rear cover are cast aluminum alloy to reduce weight.

MSG MODEL 7B-15
DISASSEMBLY
MAJOR COMPONENTS




RTW47BLF000301

Disassembly Steps
1. Clutch shift block and release bearing
2. Clutch shift fork
3. Speedometer sensor
4. Speedometer driven gear assembly
5. Gear control box assembly


6. Front cover with oil seal



7. Counter gear snap ring


8. Bearing snap ring
9. Rear cover with oil seal
10. Transmission case
11. Intermediate plate with gear assembly

MSG MODEL 7B-17
MAJOR COMPONENT

INTERNAL PARTS




Disassembly steps
1. Detent assembly
2. Shift fork assembly & interlock pin
3. Rev. and 5th gear assembly

4. Counter gear shaft assembly
5. Top & main gear shaft assembly