radiator ISUZU KB P190 2007 Workshop Repair Manual

0A-6 GENERAL INFORMATION
IDENTIFICATION




CHASSIS NUMBER
The chassis number is stamped on the right-hand side of the
chassis side member under the right door.



RTW 50ASH000201

VEHICLE IDENTIFICATION PLATE
The vehicle identification plate is attached to the upper face of
the radiator sill in the engine compartment.



BODY AND OPTION IDENTIFICATION
PLATE
The body and option plate shows body style, body serial
number, paint and trim colour combination, paint number,
engine transmissions, axle ratio options and built date. The
built date is defined as 'the date of manufacture' by the
calendar month and year in which the body shell and power
train sub-assemblies are co-joined or moved from the
production line.


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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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

1-44 HEATER AND AIR CONDITIONING
RECEIVER / DRIER
REMOVAL AND INSTALLATION



RTW 710LF000801

Removal Steps
1. Radiator grille
2. Pressure switch connector
3. Refrigerant line
4. Bracket bolt
5. Receiver/drier

Installation Steps
5. Receiver/drier
4. Bracket bolt
3. Refrigerant line
2. Pressure switch connector
1. Radiator grille


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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 1-91
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

1-92 HEATER AND AIR CONDITIONING
RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Condenser is not hot and
excessive bubble in sight glass





•
Insufficient refrigerant






•
Check sight
glass.(See “Reading
Sight Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount
Frost on the expansion valve inlet
line •
Expansion valve clogged
•
Replace the
expansion valve
A distinct difference in
temperature between the inlet and
outlet refrigerant lines of the
receiver/drier •
Receiver/drier clogged


•
Replace the receiver/
drier


Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum

•
The temperature sensor of
the expansion valve is
defective, and the valve
cannot regulate the correct
flow of the refrigerant •
Replace the
expansion valve



Discharge temperature is low and
air flow from vents is restricted
•
Frozen evaporator core fins

•
Check electronic
thermostat and
replace as necessary
Suction
(Low)
pressure
abnormally
low

Low-pressure gauge reading is
low, or a vacuum reading may be
shown •
Clogged or blocked
refrigerant line
•
Replace refrigerant
line
No bubbles in sight glass after
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
Reduce air flow through con-
denser
•
Condenser clogged
• Radiator (condenser) fan
does not rotate properly •
Clean
• Check cooling fan
operation
Suction
(Low) and
Discharge
(High)
pressure
abnor-
mally
high

Suction (Low) pressure hose is
not cold •
Air in system • Evacuate and charge
refrigerant
Suction
(Low) and
Discharge
(High)
pres-sure
abnor-
mally
low 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

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ISUZU KB P190 2007

2A-2 FRAME AND BUMPER
FRONT BUMPER (A TYPE)
REMOVAL AND INSTALLATION

8
8
9
2
1
7
5
4
43
3
6
RTW 72ALF000501

Removal Steps

1. Radiator grille
2. Front bumper fascia
3. Bezel (W /O fog light)
4. Fog light
5. Bumper seal
6. Front bumper impact support assembly
7. Front bumper impact bar assembly
8. Fascia support side bracket
9. Fascia support lower bracket

Installation Steps

9. Fascia support lower bracket
8. Fascia support side bracket
7. Front bumper impact bar assembly
6. Front bumper impact support assembly
5. Bumper seal
4. Fog light
3. Bezel (W /O fog light)
2. Front bumper fascia
1. Radiator grille



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ISUZU KB P190 2007