air conditioning ISUZU TF SERIES 2004 Owner's Manual

6E–110 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Turn the ignition OFF.
2. Turn the air conditioning system OFF.
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition ON.
NOTE: The fuel pump will run for approx imately 2
seconds. Use the Scan Tool to command the fuel
pump ON.
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?283-376 kPa
(41-55 psi) Go to Step 3Go to Step 17
3 Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
NOTE: The fuel pressure will drop when the fuel
pump stops running, then it should stabilize and
remain constant.—Go to Step 4Go to Step 12
4 1. When the vehicle is at normal operating
temperature, turn the ignition ON to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Did the reading drop by the amount specified after the
engine was started?21-105 kPa
(3-15 psi) Go to Step 5Go to Step 9
5 Is fuel pressure dropping off during acceleration,
cruise, or hard cornering?—Go to Step 6Check for
improper fuel
6 Visually and physically inspect the following items for
a restriction:
The in-line fuel filter.
The fuel feed line.
Was a restriction found?—Verify repair Go to Step 7
7 Remove the fuel tank and visually and physically
inspect the following items:
The fuel pump strainer for a restriction.
The fuel line for a leak.
Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas?—Verify repair Go to Step 8
8 Replace the fuel pump.
Is the action complete?—Veri fy repai r—
9 1. Disconnect the vacuum hose from the fuel
pressure regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
Does the fuel pressure indicated by the fuel pressure
gauge drop by the amount specified?21-105 kPa
(3-15 psi) Go to Step 10Go to Step 11

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. When 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 movement for 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.

WORKSHOP MANUAL

TF SERIES




HEATING AND AIR CONDITIONING






SECTION 1

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 1- 3
Parts Location ................................................................................................................. 1- 5
Main Data and Specifications ......................................................................................... 1- 15
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 17
ON-Vehicle Service .......................................................................................................... 1- 26
Precautions For Replacement or repair of air conditioning parts .......................... 1- 26
Condenser ........................................................................................................................ 1- 36
Removal and Installation (4JA1-TC, 4JH1-TC).......................................................... 1- 36
Removal and Installation (Except 4JA1-TC, 4JH1-TC) ............................................. 1- 37
Condenser Fan Motor ...................................................................................................... 1- 38
Removal and Installation ............................................................................................ 1- 38
Receiver/drier ................................................................................................................... 1- 39
Removal and Installation ............................................................................................ 1- 39
Compressor...................................................................................................................... 1- 40
Removal and Installation (4J ENGINE) ...................................................................... 1- 40
Removal and Installation (6VE1) ................................................................................ 1- 42
Removal and Installation (C24SE) ............................................................................. 1- 44
Disassembly ................................................................................................................ 1- 50
Reassembly ................................................................................................................. 1- 52
Heater Unit........................................................................................................................ 1- 54
Removal and Installation ............................................................................................ 1- 54
Disassembly and Reassembly ................................................................................... 1- 56
Vent Unit (Without Heater) ............................................................................................. 1- 57
Removal and Installation ............................................................................................ 1- 57
Disassembly and Reassembly ................................................................................... 1- 59
Evaporator (With A/C)...................................................................................................... 1- 60
Removal and Installation ............................................................................................ 1- 60
Disassembly and Reassembly ................................................................................... 1- 61

1-2 HEATER AND AIR CONDITIONING
PAGE
Duct (Without A/C) ........................................................................................................... 1- 63
Removal and Installation ............................................................................................ 1- 63
Disassembly and Reassembly ................................................................................... 1- 64
Blower Unit Assembly ..................................................................................................... 1- 65
Removal and Installation ............................................................................................ 1- 65
Disassembly and Reassembly ................................................................................... 1- 67
Defroster Nozzle and Vent Duct ..................................................................................... 1- 68
Removal and Installation ............................................................................................ 1- 68
Rear Heater Duct.............................................................................................................. 1- 69
Removal and Installation ............................................................................................ 1- 69
Control Lever Assembly .................................................................................................. 1- 70
Removal and Installation ............................................................................................ 1- 70
Control Panel Illumination Bulb ..................................................................................... 1- 74
Removal and Installation ............................................................................................ 1- 74
Inspection and Repair................................................................................................. 1- 76
Troubleshooting .............................................................................................................. 1- 79
Special Service Tool ........................................................................................................ 1-104

HEATER AND AIR CONDITIONING 1-3
GENERAL DESCRIPTION
SYSTEM COOLING LINE










1.
Compressor 8.
Evaporator core
2.
Magnetic clutch 9.
Blower motor
3.
Receiver/Drier 10.
Heater unit
4.
Dual pressure switch or Trinary 11.
Mode (DEF/FOOT) control door

pressure switch (4J

-TC, 6VE1, 12.
Mode (VENT) control door
C24SE) 13.
Electronic thermostat
5.
Condenser 14.
Heater core
6.
Evaporator assembly
7.
Expansion valve

RTW310LF001001

1-4 HEATER AND AIR CONDITIONING
UNIT (only indoor parts)



This illustration is based on RHD model
RTW410LF000801

HEATER AND AIR CONDITIONING 1-5
PARTS LOCATION
RHD




RTW48AXF018801&RTW48AXF018901

1-6 HEATER AND AIR CONDITIONING
LHD




RTW48AXF019001&RTW48AXF019101

HEATER AND AIR CONDITIONING 1-7
WIRING DIAGRAM (4JA1-T(L) WITH A/C)



RTW48AXF003601