CONDENSER ISUZU KB P190 2007 Workshop Repair Manual

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description ........................................................................................................ 1- 3
Main Data and Specifications ......................................................................................... 1- 21
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 23
On-Vehicle Service .......................................................................................................... 1- 30
Precautions For Replacement or repair of air conditioning parts .......................... 1- 30
Condenser...................................................................................................................... .. 1- 40
Removal and Installation (4JH1-TC, 4JJ1-TC Standard Output)............................. 1- 40
Removal and Installation (4JJ1-TC High Output, 4JK1-TC High Output, 4JA1-T) ........................................ 1- 41
Removal and Installation (C24SE) ............................................................................. 1- 42
Condenser Fan Motor ..................................................................................................... 1- 43 Removal and Installation............................................................................................ 1- 43
Receiver/drier ................................................................................................................. . 1- 44
Removal and Installation............................................................................................ 1- 44
Compressor ..................................................................................................................... 1- 45
Removal and Installation (4JA1-T, 4JH1-TC) ............................................................ 1- 45
Removal and Installation (4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output) ......... 1- 47
Removal and Installation (C24SE) ............................................................................. 1- 49
Disassembly ................................................................................................................ 1- 55
Reassembly ................................................................................................................. 1- 57
Heater Unit .................................................................................................................... ... 1- 59
Removal and Installation............................................................................................ 1- 59
Disassembly and Reassembly................................................................................... 1- 61
Vent Unit (Without Heater) ............................................................................................. 1- 62 Removal and Installation............................................................................................ 1- 62
Disassembly and Reassembly................................................................................... 1- 64
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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-3
GENERAL DESCRIPTION
COOLING SYSTEM









1.
Compressor 8.
Evaporator core
2.
Magnetic clutch 9.
Blower motor
3.
Receiver/Drier 10.
Heater unit
4.
Triple pressure switch 11.
Mode (DEF/FOOT) control door
5.
Condenser 12.
Mode (VENT) control door
6.
Evaporator assembly 13.
Electronic thermostat
7.
Expansion valve 14.
Heater core



RTW 610LF000101

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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-21
MAIN DATA AND SPECIFICATIONS

COMPRESSOR

Model CR-14
Type 5 Vane rotary type
Displacement cm3 (lmp fl oz) 144 (4.03)
Oil type DH-PR
Oil capacity cm3 (lmp fl oz) 180 (5.07)
Magnetic clutch mm (in) Type: Dry single disc dia. 109 (4.3)

HEATING UNIT (VENT UNIT)

Type Reheat air mix
Core dimension mm (in) (L×H ×W ) 180 (7.09) × 182.3 (7.18) × 27 (1.06)
Capacity (kcal/h) 4200

BLOWER UNIT

Type Sirocco fan type

COOLING UNIT

Type Fin and tube evaporator
Evaporator element dimensions mm (in) (L×H ×W ) 222 (8.74) × 213 (8.39) × 56 (2.2)
Air volume / Heat absorption m3/H / W
300/3440
500/5140
• Expansion Valve type External pressure equalizer type
• Thermo Switch type (Cooler) Variable electronic thermostat
• Maximum Cool position °C ( °F) OFF 3± 0.5 (37.4 ±0.9)
DIFF 1.5 ±0.5 (34.7 ±0.9)
• Minimum Cool position °C ( °F)
OFF 11.6
±2 (52.9 ±3.6)
DIFF 2.9 ±2 (37.2 ±3.6)
• Thermo Switch type (A/C) °C ( °F) Fixed electronic thermostat
OFF 3 ± 0.5 (37.4 ± 0.9)
DIFF 1.5 ± 0.5 (34.7 ± 0.9)

CONDENSER
Type Aluminum louvered fins
Capacity kW (kcal/h) •
4JA1-T, 4JH1-TC, C24SE
14 (12300)
• 4JJ1-TC (Standard Output),
4JJ1- TC (High Output), 4JK1-TC (High Output),
17 (14620)

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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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HEATER AND AIR CONDITIONING 1-43
CONDENSER FAN MOTOR
REMOVAL AND INSTALLATION








RTW 710MF000701

Removal Steps
1. Radiator grille
2. Fan connector
3. Condenser fan motor

Installation Steps
3. Condenser fan motor
2. Fan connector
1. Radiator grille




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ISUZU KB P190 2007

1-54 HEATER AND AIR CONDITIONING
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.
W hen 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
W hen 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 (1.41 lmp fl oz)
Condenser 30 cm3 (0.84 lmp fl oz)
Receiver/drier 30 cm3 (0.84 lmp fl oz)
Refrigerant line (One piece) 10 cm3 (0.28 lmp 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.



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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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HEATER AND AIR CONDITIONING 1-91
RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Reduced or no air flow through
the condenser
•
Condenser clogged or dirty
• Radiator (condenser) fan
does not operate properly •
Clean
• Check cooling fan
operation
No bubbles in sight glass when
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
Discharge
(High)
pressure
gauge
abnormally
high
After stopping air conditioning,
pressure drops approx. 196 kPa
(2.0kg/cm
2 / 28psi) quickly •
Air in system
•
Evacuate and charge
refrigerant system
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
Low pressure gauge indicates
vacuum •
Clogged or defective
expansion valve •
Replace the
expansion valve
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pres-
sure gauge indicates vacuum •
Restriction caused by debris
or moisture in receiver/drier

•
Check system for
restriction and
replace receiver/drier

Discharge
(High)
pressure
gauge
abnormally
low
After turning off air conditioning,
high and low pressure gauge
balanced quickly
•
Compressor seal defective
• Poor compression due to
defective compressor
gasket •
Replace or repair
compressor
Low pressure gauge is lowered
after condenser is cooled by
water
•
Excessive refrigerant in
system

•
Discharge and
recover refrigerant
Recharge to specified
amount
Low pressure hose temperature
around the compressor refrigerant
line connector is lower than
around evaporator

•
Unsatisfactory valve
operation due to defective
temperature sensor of
expansion valve
• Expansion valve opens too
long •
Replace the
expansion valve




After turning off air conditioning,
high and low pressure gauge is
balanced quickly •
Compressor gasket is
defective
•
Replace


Suction
(Low)
pressure
gauge
abnormally
high
Air conditioning turns off before
passenger compartment is
sufficiently
cool •
Electronic thermostat
defective
•
Check the electronic
thermostat and
replace as necessary


* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING” in this section.

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ISUZU KB P190 2007