oil capacity ISUZU KB P190 2007 Workshop Repair Manual

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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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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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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REAR AXLE 4B-3
MAIN DATA AND SPECIFICATIONS
REAR AXLE
Ring gear size mm (in)φ194 (7.94) φ220 (8.66)
Rear axle type Banjo, semi-floating
Rear axle capacity N (kg/lb)18140 (1850/4079)
Rear axle case
Axle tube section

Outside diameter mm (in)80 (3.15)
Thickness mm (in)4.5 (0.118)
Final drive type Single speed
Final gear type Hypoid
Drive pinion bearing preload N⋅m (kgf ⋅cm/lb ⋅in)
Starting torque (At drive pinion flange nut) 0.6-1.1 (6.5-11.5/5.6-10.0) 0.7-1.3 (7.0-13.0/6.1-11.3)
Preload adjusting method Collapsible
Final gear backlash mm (in) 0.13-0.18 (0.005-0.007) 0.15-0.20 (0.006-0.008)
Differential carrier assembly
W eight (Dry) kg/lb22.0/48.5 29.0/63.9
Lubrication
Specified gear oil (APL grade) GL5 GL5 (STD), GL5LSD (LSD)
Oil capacity liter (US/UK gal) 1.6 (0.42/0.35) 2.4 (0.63/0.53)


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4B-8 REAR AXLE
SERVICING
Rear Axle Oil Replacement
Oil Capacity liters (US/UK gal.)

Specified gear oil GL5 (API grade)(STD)
GL5LSD (LSD)

φ220mm 2.4 (0.63/0.53)
φ194mm 1.6 (0.42/0.35)
Filler Plug and Drain Plug Torque N ⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0/58)

Axle Shaft Roller Bearing Endplay
Inspection
1. Raise and suitably support vehicle.
2. Remove the wheel and brake drum.
3. Inspect the axle shaft roller bearing endplay using dial gauge.
Endplay mm (in
)
Standard 0 ~ 0.2 (0 ~ 0.008)
If the endplay exceeds 0.2mm (0.008 in), replace the
axle shaft roller bearings.
Refer to Rear Axle Reassembly.

RTW 34BSH000101


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FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) φ
φφ
φ
194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 3.583, 3.727, 3.909, 4.100, 4.300, 4.555, 4.777, 5.125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.31)
Axle shaft type Constant velocity joint (Barfield joint type and double offset joint).


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SHIFT ON THE FLY SYSTEM 4C2-11






5. Actuator • Clean the actuator contact surface with the housing.
•
Apply liquid gasket to the contact surface on the
actuator side.
• Align shift arm with the groove of sleeve and install the
actuator.

4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N⋅m (kgf ⋅m/lb ⋅in)
9 (0.9/78)














3. Front Axle Drive Shaft (LH side)
2. Bolt • Install front axle drive shaft and mounting bracket.
• Tighten fitting bolts to specified tightening torque.
Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
116 (11.8/85)
1. Filler Plug • Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal) 0.12 (0.03/0.03)
• Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque N⋅m (kgf ⋅m/lb ⋅ft)
78 (8.0/58)



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6 – 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop. Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn ON ? Go to
section
6E “On Board Diagnostic
(OBD) System Check" Go to Step 2
2 The battery fluid level and the
gravity Was the problem found? Re-charge the
battery or
replace the battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil,
vacuum and fuel piping) Was the problem found? Return normal
condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or replace Go to Step 8
8 Go to section 6E “On Board
Diagnostic (OBD) System
Check” Was the problem found?
Verify repair Go to Step 9
9 Go to mechanical
troubleshooting chart Was the problem found?
Verify repair —


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TROUBLESHOOTING 6 – 17
14-3 Battery Under Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there intermittent contact between the brush
and the slip ring? —
Repair or
replace the
brush holder assembly. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there a short circuit in the rotor coil? —
Repair or
replace the rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit on the
stator coil? —
Repair or
replace the stator coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? —
Replace the
rectifier Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Was the electrical load excessive? — Replace more
higher capacity generator. Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

14-4 Battery Unstable Charging Current
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? —
Repair or
replace the
brush and/or the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there the short circuit or an open circuit in the
rotor coil? —
Repair or
replace the rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit in the
stator coil? —
Repair or
replace the stator coil. Go to Step 5
5 Inspect the connection between the rectifier and
stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ? —

Repair the loose
connection. Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved


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6A – 6 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JH1TC
Engine type
Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type
Timing gear train system Dry type, chrome plated
Gear drive
No. of cylinders-bore × stroke mm (in) 4 – 95.4 × 104.9 (3.76 × 4.13)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement liter
Compression ratio (to 1) 2,999
18.3
Compression pressure MPa (kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb)MT: Approximately 249 (549)
AT: Approximately 236 (520)
Fuel injection order 1 – 3 – 4 - 2
Specified fuel type JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm
700 ± 25 (A/C OFF)
800 ± 25 (A/C ON)
Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system
Injection pump type 0.4 (0.016)
0.4 (0.016) 24.5
55.5
54.0
26.0
BOSCH distributor VP44 type
Injection nozzle type
Injection nozzle opening pressure
MPa (kg/cm
2/psi) Hole with 5 orifices

1st 19.5 (199/2,828)
2nd (Reference) 34.3 ∼35.8 (350 ∼365/4,980 ∼5,197)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)
Oil pump type
Oil filter type Gear
Cartridge paper element
Oil capacity lit (US/UK gal)
6.2 (1.64/1.36) (For 4
× 2)
7.0 (1.85/1.54) (For 4 × 4)
Oil cooler type W ater cooled

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