engine ISUZU KB P190 2007 Workshop User Guide

MAINTENANCE AND LUBRICATION 0B-13
RECOMMENDED FLUIDS AND LUBRICANTS (For EUROPE)


In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly the best lubricants and diesel fuels.
W hen lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.

LUBRICATION/FLUID GRADE
API ACEA OTHER
Diesel engine crankcase B2/B3
E2/E3
Manual transmission
Transfer case B2/B3
E2/E3
Differential
Shift on the fly system
(GL-5 only)
GL-5

BESCO GEAR OIL SH (80W-90, 90, 140) (ISUZU GENUINE)
BESCO SHIFT ON THE FLY (75W-90) (ISUZU GENUINE)
THURBAN GL-5 EP (80W-90, 85W-140) (CALTEX)
SPIRAX A (140) (SHELL)
TRANSELF TYPE B (80W-90, 85W-140) (ELF)
TRANSMISSION TM (80W-90, 85W-140) (TOTAL)
EPX90 (90)(CASTROL)
DYNA DRIVE (80W-90) (CASTROL)
ENERGEAR HYPO (90) (BP)
ENERGEAR EP (80W-90) (BP)
Differential
(Limited Slip Differential)
(GL-5 only) GL-5

BESCO GEAR OIL LSD (140) (ISUZU GENUINE)
GEAR OIL LSD (90) (CALTEX)
SPIRAX A LS 90 (90) (SHELL)
TRANSELF TYPE BLS (90) (ELF)
TRANSMISSION DA (85W-90) (TOTAL)
HYPOY LSX (90) (CASTROL)
ENERGEAR LS-M (90) (BP)
Automatic transmission MOBIL ATF 3309
Power steering

DEXRON III
Propeller shaft sliding yoke
Universal joint
(General purpose grease in
Molybdenum) NLGI #2 or #3
multi purpose type grease
containing molybdenum disulfide
Engine cooling system Good quality ethylene glycol antifreeze or GM spec.
6033-M or equivalent

NOTE:
* If GL-5 Limited Slip Differential Lubricant is not available, use GL-5 Lubricant mixed with 1 bottle (118ml) of Limited
Slip Differential Lubricant additive (Parts No. 8-01052-358-0) or equivalent.



FLUID TYPE

Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade


DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD)
DIN (DEUTSCHE INDUSTRIE NORMEN)
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)
BS (BRITISH STANDARD) Based on K2204 GAS OIL
Based on EN590: 1997L
Based on SAE J-313C
Based on BS EN590: 1997

NOTE:
Use the applicable standard or equivalent for diesel fuels.



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0B-14 MAINTENANCE AND LUBRICATION
OIL VISCOSITY CHART
Lubricants should be carefully selected according to the lubrication chart. It is also important to select the viscosity
of lubricants according to the ambient temperature by referring to the following table.

OIL VISCOSITY CHART FOR DIESEL ENGINE
APPLY DIESEL ENGINE OIL
RTA7Z0SF000101



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MAINTENANCE AND LUBRICATION 0B-15

OIL VISCOSITY CHART FOR GASOLINE ENGINE APPLY GASOLINE ENGINE OIL
C24SE
(Multi grade)


HFV6




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1-30 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.
• W hen 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. W hen
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.
• W hen 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.
• W hen 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.


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HEATER AND AIR CONDITIONING 1-37
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. •
••
•
W hen 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 source 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) W hen 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.






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1-38 HEATER AND AIR CONDITIONING
8) Charge the system to the specified amount and then close the low-pressure hand valve.
Refrigerant Amount g(lbs)
4JA1-T, 4JH1-TC, C24SE 720 (1.59)
4JJ1-TC (Standard Output)
4JJ1-TC (High Output)
4JK1-TC (High Output)
650 (1.43)

9) Check for refrigerant leaks by using a HFC-134a leak detector.
• A fully charged system is indicated by the sight glass on
the receiver/drier being free of any bubbles (Refer to
"Reading Sight Glass").
• Check the high and low pressure value of the manifold
gauge. (Refer to “CHECKING REFRIGERANT SYSTEM
W ITH MAINFOLD GAUGE” in SERVICE
INFORMATION.)
Immediately after charging refrigerant, both high and low
pressures are slightly high and to the left of the gauge, but they
settle down to the guide pressure valves as shown below:
• Ambient temperature; 30 ∼35 °C (86 ∼95 °F)
• Guide pressure
High-pressure side;
Approx. 1373 ∼1670 kPa (14 ∼17 kg/cm
2 / 199 ∼242 psi)
Low-pressure side;
Approx. 127 ∼245 kPa (1.3 ∼2.5 kg/cm
2 / 18 ∼36 psi)
10) Close the low pressure hand valve and charge valve of the refrigerant container.
11) Stop the air conditioning and the engine.
12) Disconnect the high and low pressure hoses from the manifold gauge fittings.





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HEATER AND AIR CONDITIONING 1-39
Reading Sight Glass

High and low
pressure pipe
temperature The high pressure
pipe is hot and the
low pressure pipe
is cold. There is a
distinct difference
in temperature
between them. The high pressure
pipe is warm and
the low pressure
pipe is cool. There
is no great
difference in
temperature
between them. There is little
difference in
temperature
between the high
pressure pipe and
the low pressure
pipe. The high pressure
pipe is hot and the
low pressure pipe
is slightly warm.
There is a
difference in
temperature
between them.
Sight glass
condition Almost transparent.
A flow of bubbles
can be seen, but
they disappear
when the throttle is
opened.

A flow of bubbles
always can be
seen. It appears
sometimes
transparent, and
sometimes frothy.
Something like fog
faintly can be seen.
Even at idle with
the fan at "HI" (with
the window fully
open), the bubbles
cannot be seen.



Air conditioning
cycle condition
OK NG
(Not enough refrigerant) NG
(Almost no
refrigerant) NG
(Too much
refrigerant)

The sight glass provides accurate diagnosis only under the following conditions.
If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the chart.
* Engine speed Idling
* A/C switch "ON"
* Blower fan operating at highest speed
* Air source selector lever at "RECIRC"
* Temperature control knob at coldest position
* Ambient temperature below 35 °C (95 °F) and humidity below 70% (See NOTE 1)
* High side pressure less than 1470 kPa (15 kg/cm
2 / 213 psi) (See NOTE 2)

NOTE 1
If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass cannot be
used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified
amount of refrigerant. Then continue checking the system performance.

NOTE 2
If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue
checking system performance.



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1-40 HEATER AND AIR CONDITIONING
CONDENSER
REMOVAL AND INSTALLATION (4JH1-TC, 4JJ1-TC Standard Output)

13
12
8
10
11
14
10
9
6
7
5
2
3
1
41410
4JH1-TC 4JJ1-TC
Standard Output
(RHD)
14
10
4JJ1-TC
Standard Output
(LHD)
9

This illustration is based on RHD model


RTW 710LF001401
Removal Steps
1. Radiator grille
2. Front bumper fascia • Refer to SECTION 2A “FRONT
BUMPER”
3. Front bumper impact 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 impact support assembly • Refer to SECTION 2A “FRONT
BUMPER”
2. Front bumper fascia • Refer to SECTION 2A “FRONT
BUMPER”
1. Radiator grille


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HEATER AND AIR CONDITIONING 1-41

REMOVAL AND INSTALLATION (4JJ1-TC High Output, 4JK1-TC High Output, 4JA1-T)




This illustration is based on RHD model


RTW 710LF001501

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


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1-42 HEATER AND AIR CONDITIONING

REMOVAL AND INSTALLATION (C24SE)




This illustration is based on RHD model


RTW 710LF004101

Removal Steps
1. Radiator grille
2. Engine hood lock
3. Engine hood front end stay
4. Triple 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

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