oil ISUZU TF SERIES 2004 Workshop Manual

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 1-27

REPAIR OF REFRIGERANT LEAKS
Refrigerant Line Connections


RTW410SH000101
Install new O-ring, if required. When disconnecting or
connecting lines, use two wrenches to prevent the connecting
portion from twisting or becoming damaged.


When connecting the refrigerant line at the block joint, securely
insert the projecting portion of the joint portion into the
connecting hole on the unit side and secure with a bolt.




Apply specified compressor oil to the O-rings prior to
connecting.

CAUTION:
Compressor (PAG) oil to be used varies according to
compressor model. Be sure to apply oil specified for the
model of compressor.



O-rings must be closely aligned with raised portion of
refrigerant line.

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.

1-46 HEATER AND AIR CONDITIONING

GENERAL REPAIR PROCEDURE
OIL SPECIFICATION

The HFC-134a system requires a synthetic (PAG)
compressor oil.

Compressor (PAG) oil varies according to compressor
model. Be sure to use oil specified for the model of
compressor.
Specified Compressor Oil
DH-PR



HANDLING OF OIL

The oil should be free from moisture, dust, metal powder,
etc.
 Do not mix with other oil.
 The water content in the oil increases when exposed to the
air. After use, seal oil from air immediately.

The compressor oil must be stored in steel containers, not
in plastic containers.

COMPRESSOR OIL CHECK
The Oil used to lubricate the compressor is circulating with the
refrigerant.
Whenever replacing any component of the system or a large
amount of gas leakage occurs, add oil to maintain the original
amount of. oil.

Oil Capacity

Capacity total in
system CR-14 180 cm3 (5.0 fl.oz.)
Compressor
(Service parts)
charging amount
CR-14
180 cm
3 (5.0 fl.oz.)

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.

1-48 HEATER AND AIR CONDITIONING

Checking and Adjusting for Compressor
Replacement
180 cm3 (5.0 lmp fl oz) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil from
the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the compressor.
3) Drain the compressor oil and measure the extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.

Amount of oil drained
From used compressor Draining amount of oil
From new compressor
less than
90 cm
3 (2.5 lmp fl oz) Some as drained
amount
more than
90 cm
3 (2.5 lmp fl oz) 90 cm
3 (2.5 lmp fl oz)

6) Evacuate, charge and perform oil return operation.
7) Check system operation.


CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even is the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
 The capacity of the oil has increased.
 The oil has changed color to red.

Foreign substances, metal powder, etc., are present in the
oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.

HEATER AND AIR CONDITIONING 1-49

OIL RETURN OPERATION
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the
refrigerant in the system.
When checking the amount of oil in the system, or replacing
any component of the system, the compressor must be run in
advance for oil return operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is "ON" and Set the fan
control knob at its highest position.
3) Run the compressor for more than 20 minutes between
800 and 1,000 rpm in order to operate the system.
4) Stop the engine.


REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply the following
amount of oil to the component parts to be installed.

Component parts to be installed Amount of oil
Evaporator 50 cm3 (1.7 fl.oz.)
Condenser 30 cm3 (1.0 fl.oz.)
Receiver/drier 30 cm3 (1.0 fl.oz.)
Refrigerant line (One piece) 10 cm3 (0.3 fl.oz.)

Refrigeration oil must be replenished if more than two parts
are removed at the same time. After installing these
components, check compressor oil.

1-50 HEATER AND AIR CONDITIONING
DISASSEMBLY


This illustration is based on the 4J engine model
871R300002

Disassembly Steps

1. Drive plate bolt
2. Plain washer

3. Drive plate
4. Snap ring

5. Pulley assembly

6. Snap ring
7. Thermo sensor and lead wire connector
8. Field coil
9. Compressor

Important Operations - Dissassembly


1. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from rotating, then remove the bolt.
Drive Plate Holder: 5-8840-4056-0 (J-37872)

1-52 HEATER AND AIR CONDITIONING
REASSEMBLY


This illustration is based on the 4J engine model
871R30003

Reassembly Steps
1. Compressor

2. Field coil
3. Thermo sensor and lead wire connector
4. Snap ring

5. Pulley assembly
6. Snap ring
7. Drive plate
8. Plain washer

9. Drive prate bolt

HEATER AND AIR CONDITIONING 1-53
Important Operation - Resassembly






2. Field Coil
Installation field coil.

Align the located portion (1) of the clutch coil and
compressor.


5. Pulley Asssembly
Using pulley installer and drive handle to install the pulley
assembly.
Pulley Installer: 5-8840-0118-0 (J-33940)
Drive Handle: 5-8840-0007-0 (J-8092)






9. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from
rotating.
Drive Plate Holder: 5-8840-4056-0 (J-37872)
Tighten the bolt to the specified torque.
N
m (kgf
m/Ib
in)

Torque 13 (1.3/113)
After tightening the bolt, check to be sure the pulley rotates
smoothly.