section 8 ISUZU TF SERIES 2004 Workshop Manual

HEATER AND AIR CONDITIONING 1-69
REAR HEATER DUCT
REMOVAL AND INSTALLATION


This illustration is based on RHD model
RTW410LF001301

Disassembly Steps
1. Front seat assembly (RH/LH)
 Refer to SECTION 10 “FRONT SEAT”
2. Rear floor console

Refer to SECTION 10 “FLOOR
CONSOLE”
3. Front floor console (A/T, M/T Model)

Refer to SECTION 10 “FLOOR
CONSOLE”
4. Sill plate (RH/LH)
 Refer to SECTION 10 “INTERIOR
TRIM PANELS”
5. Dash side trim cover (RH/LH)
6. Carpet
7. Clip
8. Rear Heater duct (RH/LH)
9. Rear Heater duct center

Reassembly Steps
9. Rear heater duct center
8. Rear heater duct (RH/LH)
7. Clip
6. Carpet
5. Dash side trim cover (RH/LH)
4. Sill plate (RH/LH)

Refer to SECTION 10 “INTERIOR
TRIM PANELS”
3. Front floor console (A/T, M/T Model)
 Refer to SECTION 10 “FLOOR
CONSOLE”
2. Rear floor console

Refer to SECTION 10 “FLOOR
CONSOLE”
1. Front seat assembly (RH/LH)

Refer to SECTION 10 “FRONT SEAT”

HEATER AND AIR CONDITIONING 1-71
Important Operation - Removal
2. Instrument Panel Driver Lower Cover
Refer to “INSTRUMENT PANEL” in CAB section.


RTW310SH000101

4. Control Cables
Disconnect control cables at each unit side.


5. Center Cluster
Refer to “INSTRUMENT PANEL” in CAB section.

HEATER AND AIR CONDITIONING 1-75
Important Operation - Removal
1. Control lever assembly
Refer to “CONTROL LEVER ASSEMBLY” in this section.

2. Illumination Bulb
To remove the illumination bulb, insert an ordinary screwdriver
into the slot (B) at the back of the bulb. Turn the bulb
counterclockwise and pull it free.

HEATER AND AIR CONDITIONING 1-83

AIR CONDITIONING CYCLE TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE CORRECTION
No cooling or
insufficient
cooling
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

8. Poor operation of electronic thermostat


Check electronic thermostat and replace
as necessary
Insufficient
velocity
of cooling air

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

3. Blower motor does not rotate prop-erly


Refer to “FAN CONTROL KNOB (FAN
SWITCH)” 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.

HEATER AND AIR CONDITIONING 1-85

RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Discharge
(High)
pressure
gauge
abnormally
high 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
After stopping air conditioning,
pressure drops approx. 196 kPa
(2.0kg/cm
2 / 28 PSI) quickly

Air in system


Evacuate and charge
refrigerant system
Discharge
(High)
pressure
gauge
abnormally
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
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

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
Suction
(Low)
pressure
gauge
abnormally
high 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


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.

WORKSHOP MANUAL

TF SERIES




MANUAL TRANSMISSION
(MSG MODELS)





SECTION 7B

MSG MODEL 7B-1
SECTION 7B
MANUAL TRANSMISSION
(MSG MODELS)
TABLE OF CONTENTS
PAGE
Main Data and Specifications .................................................................................... 7B - 2
General Description.................................................................................................... 7B - 3
Torque Specification .................................................................................................. 7B - 4
Repair Kit .................................................................................................................... 7B - 6
Removal and Installation ........................................................................................... 7B - 7
Disassembly ............................................................................................................... 7B - 15
Inspection and Repair ............................................................................................... 7B - 25
Reassembly ................................................................................................................ 7B - 29
Special Service Tool .................................................................................................. 7B - 42

MSG MODEL 7B-7
REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before
you begin.





Important Operations - Removal
Battery Cable
Disconnect the negative (-) cable from the battery terminal.

Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.



Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.



Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.




Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.

WORKSHOP MANUAL

TF SERIES




MANUAL TRANSMISSION
(MUA MODELS)





SECTION 7B1

MANUAL TRANSMISSION 7B1-1

SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA
CONTENTS
PAGE
MUA (4





2)
Service Precaution .......................................................................................................... 7B1 – 3
General Description ........................................................................................................ 7B1 – 4
Rear Oil Seal (4




2) ........................................................................................................... 7B1 – 5
Transmission (4




2) ......................................................................................................... 7B1 – 7
Disassembled View ..................................................................................................... 7B1 – 7
Removal ....................................................................................................................... 7B1 – 8
Installation ................................................................................................................... 7B1 –12
Transmission Case .......................................................................................................... 7B1 –18
Major Component ........................................................................................................ 7B1 –18
Disassembly ................................................................................................................ 7B1 –19
Reassembly ................................................................................................................. 7B1 –20
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 –23
Disassembled View ..................................................................................................... 7B1 –23
Disassembly ................................................................................................................ 7B1 –24
Inspection and Repair ................................................................................................. 7B1 –25
Reassembly ................................................................................................................. 7B1 –26
Reverse Gear and 5th Gear ............................................................................................ 7B1 –27
Disassembled View ..................................................................................................... 7B1 –27
Disassembly ................................................................................................................ 7B1 –29
Inspection and Repair ................................................................................................. 7B1 –31
Reassembly ................................................................................................................. 7B1 –31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 –38
Disassembled View ..................................................................................................... 7B1 –38
Disassembly ................................................................................................................ 7B1 –40
Inspection and Repair ................................................................................................. 7B1 –42
Reassembly ................................................................................................................. 7B1 –45
Main Data and Specifications ......................................................................................... 7B1 –51