check oil ISUZU KB P190 2007 Workshop Repair Manual

0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Raise the vehicle with a jack set against the axle or the frame.
3. Support the vehicle on chassis stands.
4. Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5. Disconnect the grounding cable from the battery before performing service operations.
This will prevent cable damage or burning due to short circuiting.
6. Handle brake fluid and antifreeze solution with great care.
Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups. This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate. Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. W hen removing or replacing parts that require refrigerant to the discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the aim of the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.


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0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Replace the fuel filter (**Mark) when the fuel filter indicator light is lit.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
ENGINE
Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I (DIESEL) I I I I I I I R I I I I I I I R I I I I * Engine oil (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - R - R - R - R - R - R - R - R - R - R

(4JA1-T) R R R R R R R R R R R R R R R R R R R R * Engine oil filter (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination (GASOLINE) - I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage
I I - I - I - I - I - I - I - I - I - I Fuel tank - - - I - - - I - - - I - - - I - - - I O2 Sensor (C24SE) Replace every 160,000km (HFV6)
MIL diagnostic Indicates O2 Sensor Valve clearances (6VE1) Check and adjust if noisy (4JH1-TC, 4JA1-T) A - - A - - - A - - - A - - - A - - - A (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - A - - - - - - - A - - - -
Spark plugs (C24SE) (for leaded fuel
use) - R - R - R - R - R - R - R - R - R - R
Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
Spark plugs
(HFV6) Replace every 120,000km Spark plug wire - - - - - - - - - - - - - - - - - - - I Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R (4JH1-TC, 4JA1-T) - - R - - R - - R - - R - - R - - R - - ** (4JJ1 (Standard Output),
4JJ1 (High Output)) Replace the fuel filter when the fuel filter indicator light is lit.
Fuel pump in fuel tank
(4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - I - - - - - - - I - - - -
Engine / Accessory drive belt
(C24SE) - - - - - - - - - I - - - - - - - - - I

(HFV6) Replace every 100,000km Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system
I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (HFV6) - I - I - I - I - I - I - I - I - I - R (C24SE) - I - I - I - I - R - I - I - I - I - R (DESEL) - I - I - I - I - I - I - I - I - I - I Engine coolant
(4JJ1 (Standard Output),
4JJ1 (High Output)) Change every 2 years
Cooling system for water leakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
Timing belt
(C24SE) - - - - - - - - - - - - - - - I - - - - Replace every 120,000km Timing belt (6VE1) Replace every 160,000km

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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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1-32 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.

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HEATER AND AIR CONDITIONING 1-51

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.
W henever 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 cm
3 (5.07 lmp fl oz)
Compressor
(Service parts)
charging amount
CR-14
180 cm3 (5.07 lmp fl oz)



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1-52 HEATER AND AIR CONDITIONING
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
(2.53 lmp fl oz) same as collected
amount
less than 90 cm3
(2.53 lmp fl oz) 90 cm3
(2.53 lmp 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 (2.53 lmp 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 (2.53 lmp
fl oz) for CR-14 type recheck the compressor oil in the
following order:
(5) Supply 90 cm
3 (2.53 lmp 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.


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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-53
Checking and Adjusting for Compressor
Replacement
180 cm3 (5.07 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 (2.53 lmp fl oz) Some as drained
amount
more than
90 cm
3 (2.53 lmp fl oz) 90 cm
3 (2.53 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.


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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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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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HEATER AND AIR CONDITIONING 1-81
INSPECTION AND REPAIR



840R300005-X

Resistor
As for air-conditioning model, fixed on left (RHD) / right (LHD)
side of the evaporator unit.
As for heater only model, fixed on left (RHD) / right (LHD) side
of the duct placed between blower unit and heater unit.
Replace the resistor with a new on if the coil is found to be
open or if the resistance value deviates from the specified
range.




Terminal Resistance
3 – 2 2.04 Ω
3 – 4 0.88 Ω
3 – 1 0.31 Ω



Blower motor
Check blower motor for smooth rotation.
Connect the battery positive terminal to the No.1 terminal of the
blower motor and negative to the No.2.
Be sure to check to see if the blower motor operates correctly.


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