switch ISUZU TF SERIES 2004 Workshop Manual

HEATER AND AIR CONDITIONING 1-15
MAIN DATA AND SPECIFICATIONS

AIR 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 (5.04)
Magnetic clutch Type: Dry single disc dia. 109 mm (4.3 in.)

HEATING UNIT (VENT UNIT)

Type Rehead air mix
Core dimension mm (in.) (L

H

W) 180 (7.06)

182.3 (7.18)

27 (1.06)
Capacity (kcal./hr.) 4200

BLOWER UNIT

Type Sirocco fan type

COOLING UNIT

Type Fin and tube evaporator
Evaporator element dimensions mm (in.) (L

H

W) 230 (9.06)

212 (8.35)

74 (2.91)
Evaporator capacity (kcal./hr.) 2960/4420 kcal./hr. (300/500 m3/hr.)
* Expansion Valve type
External pressure equalizer type
* Thermo Switch type (Cooler)
Variable electronic thermostat

Maximum Cool position (
C)
OFF 3
0.5
DIFF 1.5
0.5

Minimum Cool position (
C)
OFF 11.6 2
DIFF 2.9 2
* Thermo Switch type (A/C) (
C)
Fixed electronic thermostat
OFF 3
0.5
DIFF 1.5
0.5
* Trinary Pressure Switch
Low pressure control and High pressure control are same
as Dual pressure switch
* Medium pressure control
OFF 1128  118 kpa (11.5  1.2 kg/cm
2G)
ON 1521  88 kpa (15.5  0.92 kg/cm2G)
CONDENSER
Type Aluminum louvered fins
Capacity (kcal./hr.) 12300 kcal./hr.

ELECTRIC FAN

Fan Dia
250
Motor Power (w) 90

1-16 HEATER AND AIR CONDITIONING
RECEIVER/DRIER

Capacity cc (cu in) 250 (15.3 cu in)
Assembly includes sight glass
and pressure sensitive device
(Dual pressure switch)
*Low pressure control
OFF: 18
3 (1.8
0.25kg/cm
2 G)
ON: 193 (1.90.3kg/cm2 G)
*High pressure control
OFF: 275
20N
m (28
0.2kg/cm
2 G)
ON: 59
20N
m (6
2kg/cm2 G)

REFRIGERANT
Type: HFC-134a Capacity: 0.65 kg (1.43 lbs.)

IDLE SPEED-UP CONTROL
Idle speed controlled by solenoid switch

HEATER AND AIR CONDITIONING 1-33
refrigerant container.


1) Make sure the evacuation process is correctly completed.
2) Connect the center-hose of the manifold gauge to the
refrigerant container.






Turn the charge valve handle counterclockwise to purge
to the charging line and purge any air exiting in the
center-hose of the manifold gauge.
3) Open the low-pressure hand valve and charge the
refrigerant about 200 g (0.44 lbs.).






Make sure the high-pressure hand valve is closed.






Avoid charging the refrigerant by turning the refrigerant
container upside down.
4) Close the low-pressure hand valve of the manifold gauge.






Check to ensure that the degree of pressure does not
change.
5) Check the refrigerant leaks by using a HFC-134a leak
detector.






If a leak occurs, repair the leak connection, and start all
over again from the first step of evacuation.
6) If no leaks are found, open the low-pressure hand valve of
the manifold gauge. Then continue charging refrigerant to
the system.






When charging the system becomes difficult:
(1) Run the engine at Idling and close the all vehicle
doors.
(2) A/C switch is "ON".
(3) Set the fan control knob (fan switch) to its highest
position.
(4) Set air soure selector lever to “RECIRC”



WARNING
BE ABSOLUTELY SURE NOT TO OPEN THE HIGH-
PRESSURE HAND VALVE. SHOULD THE HIGH-
PRESSURE HAND VALVE BE OPENED, THE HIGH-
PRESSURE REFRIGERANT GAS WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT
CONTAINER TO BURST.
7) When the refrigerant container is emptied, use the following
procedure to replace it with a new refrigerant container.
(1) Close the low-pressure hand valve.
(2) Raise the needle upward and remove the charge valve.
(3) Reinstall the charge valve to the new refrigerant
container.
(4) Purge any air existing in the center hose of the manifold
gauge.
8) Charge the system to the specified amount and then close
the low-pressure hand valve.
Refrigerant Amount g(lbs.)
720 (1.59)

HEATER AND AIR CONDITIONING 1-35
Reading Sight Glass

High and low
pressure pipe
temperature The high pressure
pipe is hot and the
low pressure pipe
is cold. There is a
distinct difference
in temperature
between them. The high pressure
pipe is warm and
the low pressure
pipe is cool. There
is no great
difference in
temperature
between them. There is little
difference in
temperature
between the high
pressure pipe and
the low pressure
pipe. The high pressure
pipe is hot and the
low pressure pipe
is slightly warm.
There is a
difference in
temperature
between them.
Sight glass
condition Almost transparent.
A flow of bubbles
can be seen, but
they disappear
when the throttle is
opened.

A flow of bubbles
always can be
seen. It appears
sometimes
transparent, and
sometimes frothy.
Something like fog
faintly can be seen.
Evan at idle with
the fan at "HI" (with
the window fully
open), the bubbles
cannot be seen.



Air conditioning
cycle condition
OK NG
(Not enough
refrigerant) NG
(Almost no
refrigerant) NG
(Too much
refrigerant)

The sight glass provides accurate diagnosis only under the following conditions.
If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the chart.
* Engine speed Idling
* A/C switch "ON"
* Blower fan operating at highest speed
* Air source selector lever at "RECIRC"
* Temperature control knob at coldest position
* Ambient temperature below 35
C (95
F) and humidity below 70% (See NOTE 1)
* High side pressure less than 1470 kPa (15 kg/cm
2 / 213 PSI) (See NOTE 2)

NOTE 1
If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass cannot be
used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified
amount of refrigerant. Then continue checking the system performance.

NOTE 2
If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue
checking system performance.

1-36 HEATER AND AIR CONDITIONING
CONDENSER
REMOVAL AND INSTALLATION (4JA1-TC, 4JH1-TC)

This illustration is based on RHD model RTW410LF000501
Removal Steps
1. Radiator grille
2. Front bumper fascia

Refer to SECTION 2A “FRONT
BUMPER”
3. Front bumper inpact 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 inpact support assembly

Refer to SECTION 2A “FRONT
BUMPER”
2. Front bumper fascia

Refer to SECTION 2A “FRONT
BUMPER”
1. Radiator grille

HEATER AND AIR CONDITIONING 1-37

REMOVAL AND INSTALLATION (EXCEPT 4JA1-TC, 4JH1-TC)



RTW410LF000701

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

HEATER AND AIR CONDITIONING 1-39
RECEIVER / DRIER
REMOVAL AND INSTALLATION



RTW410LF000601

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

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

HEATER AND AIR CONDITIONING 1-49

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.
When 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
When 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 (1.7 fl.oz.)
Condenser 30 cm3 (1.0 fl.oz.)
Receiver/drier 30 cm3 (1.0 fl.oz.)
Refrigerant line (One piece) 10 cm3 (0.3 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.

1-70 HEATER AND AIR CONDITIONING
CONTROL LEVER ASSEMBLY
REMOVAL AND INSTALLATION


This illustration is based on RHD model
RTW310MF000601

Removal Steps
1. Glove box

2. Instrument panel driver lower cover
3. Ash tray

4. Control cables

5. Center cluster
6. Attaching screw
7. A/C switch connector
8. Fan switch connector
9. Control lever assembly

Installation Steps


9. Control lever assembly
8. Fan switch connector
7. A/C switch connector
6. Attaching screw
5. Center cluster

4. Control cables
3. Ash tray
2. Instrument panel driver lower cover
1. Glove box

HEATER AND AIR CONDITIONING 1-77
D08R300070
Fan switch and Circuit board
Check for continuity between fan switch and A/C switch side
connector terminals.


B-13 B-57
Terminal
No.
SW.
position
1 2 3 4 5 6 2 3 10 11
OFF
1
2
3
(FAN SW.)
4
OFF CIRCUIT
BOARD
(A/C SW.)
ON


Electronic Thermostat
Check for continuity between electronic thermostat side
connector terminals.
(Cooler)



RTW410SH000201

(A/C)