clutch ISUZU KB P190 2007 Workshop User Guide

1-58 HEATER AND AIR CONDITIONING
Important Operations - Reassembly

RTW 510SH001001





2. Field Coil
Installation field coil. • Align the located portion (1) of the clutch coil and
compressor.




RTW 510SH001101
4. Pulley Assembly
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)




RTW 510SH000701




8. 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.




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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-89
AIR CONDITIONING CYCLE TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE CORRECTION
1. Magnetic clutch does not run
•
Refer to “MAGNETIC CLUTCH”
troubleshooting in this section
2. Compressor is not rotating properly
• Drive belt loosened or broken •
Adjust the drive belt to the specified
tension or replace the drive belt
• Magnetic clutch face is not clean and
slips •
Clean the magnetic clutch face or replace

• Incorrect clearance between magnetic
drive plate and pulley •
Adjust the clearance (Refer to
“COMPRESSOR OVERHAUL”)
• Compressor oil leaks from shaft seal or
shell •
Replace the compressor

• Compressor seized • Replace the compressor
3. Insufficient or excessive charge of
refrigerant •
Discharge and recover refrigerant.
Recharge to specified amount.
4. Leaks in the refrigerant system


•
Check refrigerant system for leaks and
repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
5. Condenser clogged or insufficient radiation

•
Clean the condenser or replace as
necessary
• Check radiator or condenser fan function
6. Temperature control link unit of the heater
unit defective •
Repair the link unit
7. Unsteady operation due to foreign
substance in expansion valve •
Replace the expansion valve

No cooling or
insufficient
cooling
8. Poor operation of electronic thermostat
•
Check electronic thermostat and replace
as necessary
1. Evaporator clogged or frosted
•
Check evaporator core and replace or
clean the core
2. Air leaking from cooling unit or air duct
•
Check evaporator and duct connection,
then repair as necessary
Insufficient
velocity
of cooling air
3. Blower motor does not rotate properly
• Refer to “FAN CONTROL KNOB (FAN
SW ITCH)” troubleshooting in this section

* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY,
RECYCLING, EVACUATING AND CHARGING” in this section.



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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-93
MAGNETIC CLUTCH
W hen the A/C switch and the fan control knob (fan switch) are turned on with the engine running, current flows
through the thermostat and the compressor relay to activate the magnetic clutch.
The air conditioning can be stopped by turning off the A/C switch or the fan control knob (fan switch).
However, even when the air conditioning is in operation, the electronic thermostat, the pressure switch or the ECM
is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to
reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of
the vehicle, etc.


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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-95
MAGNETIC CLUTCH DOES NOT RUN (4JA1-T)



Replace
YES
• Are the A/C thermo (X-15) and heater & A/C (X-11)
relay OK?
• Are the No. SBF-6 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES
• Is the pressure switch (C-24) OK?
YES
• Are the A/C switch (B-57) and the fan switch (B-13)
OK?
NO
YES
• Turn the ignition switch "ON" (Engine is running)
• A/C switch and fan control knob (fan switch) "ON"
NO
Replace
NO
Defective switch or insufficient
refrigerant
NO
NO
Does the magnetic clutch
operate?
YES
Replace
• Disconnect the magnetic clutch connector.
• Is there battery voltage between the engine room harness
connector terminal No.1 (E-3) and ground?
Defective compressor
YESNO
Defective magnetic clutch
• Is the electronic thermostat (C-55) OK?
YES
Replace
NO
• Disconnect the A/C thermo relay.
• Is there continuity between the engine room harness
connector terminal No.1 (E-3) and engine room harness
connector terminal No.1 (X-15)?


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ISUZU KB P190 2007

1-100 HEATER AND AIR CONDITIONING
MAGNETIC CLUTCH DOES NOT RUN (4JH1-TC)



Replace
YES
• Are the A/C thermo (X-15) and heater & A/C (X-11)
and A/C compressor (X-14) relay OK?
• Are the No. SBF-6 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES
• Is the pressure switch (C-24) OK?
YES
• Are the A/C switch (B-57) and the fan switch (B-13)
OK?
NO
YES
• Is there continuity between the engine harness
connector terminal No.1 (E-3) and the engine room
harness connector terminal No.2 (X-14)?
• Disconnect the A/C compressor relay.
• Turn the ignition switch "ON" (Engine is running)
• A/C switch and fan control knob (fan switch) "ON"
NO
Replace
NO
Defective switch or insufficient
refrigerant
NO
NO
Does the magnetic clutch
operate?
YES
Replace
• Disconnect the magnetic clutch connector.
• Is there battery voltage between the engine room harness
connector terminal No.1 (E-3) and ground?
Defective compressor
YESNO
Defective magnetic clutch
• Is the electronic thermostat (C-55) OK?
YES
Replace
NO


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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-105
MAGNETIC CLUTCH DOES NOT RUN (4JJ1-TC Standard Output, 4JJ1-TC
High Output, 4JK1-TC High Output RHD MODEL)



Replace
YES
• Are the A/C thermo (X-15), heater & A/C (X-11) and
A/C compressor (X-14) relay OK?
• Are the No. SBF-6 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES
• Is the pressure switch (C-24) OK?
YES
• Are the A/C switch (B-57) and the fan switch (B-13)
OK?
NO
YES
• Is there continuity between the engine harness
connector terminal No.1 (E-3) and the engine room
harness connector terminal No.2 (X-14)?
• Disconnect the A/C compressor relay.
• Turn the ignition switch "ON" (Engine is running)
• A/C switch and fan control knob (fan switch) "ON"
NO
Replace
NO
Defective switch or insufficient
refrigerant
NO
NO
Does the magnetic clutch
operate?
YES
Replace
• Disconnect the magnetic clutch connector.
• Is there battery voltage between the engine room
harness connector terminal No.1 (E-3) and ground?
Defective compressor
YESNO
Defective magnetic clutch
• Is the electronic thermostat (C-55) OK?
YES
Replace
NO


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ISUZU KB P190 2007

1-110 HEATER AND AIR CONDITIONING
MAGNETIC CLUTCH DOES NOT RUN (4JJ1-TC Standard Output, 4JJ1-TC
High Output, 4JK1-TC High Output LHD MODEL)



Replace
YES
• Are the A/C thermo (X-15), heater & A/C (X-11) and
A/C compressor (X-14) relay OK?
• Are the No. SBF-6 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES
• Is the pressure switch (C-24) OK?
YES
• Are the A/C switch (B-57) and the fan switch (B-13)
OK?
NO
YES
• Is there continuity between the engine harness
connector terminal No.1 (E-3) and the engine room
harness connector terminal No.2 (X-14)?
• Disconnect the A/C compressor relay.
• Turn the ignition switch "ON" (Engine is running)
• A/C switch and fan control knob (fan switch) "ON"
NO
Replace
NO
Defective switch or insufficient
refrigerant
NO
NO
Does the magnetic clutch
operate?
YES
Replace
• Disconnect the magnetic clutch connector.
• Is there battery voltage between the engine room
harness connector terminal No.1 (E-3) and ground?
Defective compressor
YESNO
Defective magnetic clutch
• Is the electronic thermostat (C-55) OK?
YES
Replace
NO


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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-115
MAGNETIC CLUTCH DOES NOT RUN (C24SE)

Replace
YES
• Are the A/C thermo (X-15), heater & A/C (X-11)
and A/C compressor (X-14) relay OK?
• Are the No. SBF 8 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES
• Is the pressure switch (C-24) OK?
YES
• Are the A/C switch (B-57) and the fan switch (B-13)
OK?
NO
YES
• Is there continuity between the engine harness
connector terminal No.1 (E-2) and the engine room
harness connector terminal No.2 (X-14)?
• Disconnect the A/C compressor relay.
• Turn the ignition switch "ON" (Engine is running)
• A/C switch and fan control knob (fan switch "ON")
NO
Replace
NO
Defective switch or insufficient
refrigerant
NO
NO
Does the magnetic clutch
operate?
YES
Replace
• Disconnect the magnetic clutch connector.
• Is there battery voltage between the engine room
harness connector terminal No.1 (E-2) and ground?
Defective compressor
YESNO
Defective magnetic clutch
• Is the electronic thermostat (C-55) OK?
Replace
NOYES


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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-119
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME


5-8840-0629-0 (J-39500-A)




5-8840-0630-0
(J-39500-220A)




5-8840-0631-0
(J-39500-220ANZ)


5-8840-4056-0 (J-37872)

Drive plate holder


5-8840-0121-0 (J-33943)

Clutch pulley puller pilot

5-8840-0111-0 (J-8433)

Clutch pulley puller


5-8840-0118-0 (J-33940)

Clutch pulley installer


5-8840-0007-0 (J-8092)

Driver handle



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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-53
FRONT HUB AND DISC
(4 ×
××
×
4 Manual Locking Hub Model)
DISASSEMBLY
Refer to SECTION 3E “WHEELS AND TIRES” for wheel removal procedure




RTW 440LF00030 1

Disassembly Steps

1 . Bolt
2. Cover assembly
3. Snap ring and shim
4. Body assembly
5. Lock washer

6. Hub nut

7. Hub and disc assembly
8. Outer bearing
9. Oil seal
10. Inner bearing
11. ABS sensor rotor

1 2. Bolt

13. W heel pin




1 4. Clutch assembly
15. Snap ring
16. Knob
17. Compression spring
18. Follower

1 9. Retaining spring
20. X-ring
2 1. Snap ring
22. Inner assembly
23. Snap ring
24. Ring
25. Spacer



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ISUZU KB P190 2007