heater ISUZU TF SERIES 2004 Service Manual

ENGINE DRIVEABILITY AND EMISSIONS 6E–163
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT
(BANK 1 SENSOR 1)
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
Heated ox ygen sensors are used to minimize the
amount of time required for “Closed Loop” fuel control
operation and to allow accurate catalyst monitoring. The
ox ygen sensor heater greatly decreases the amount of
time required for fuel control sensors Bank 1 HO2S 1 1
to become active. Ox ygen sensor heaters are required
by catalyst monitor sensors Bank 1 HO2S 2 to maintain
a sufficiently high temperature which allows accurate
ex haust ox ygen content readings further from theengine.
The engine control module (ECM) will run the heater
test only after a cold start (determined by engine coolant
and intake air temperature at the time of start-up) and
only once during an ignition cycle. When the engine is
started the ECM will monitor the HO2S voltage. When
the HO2S voltage indicates a sufficiently active sensor,
the ECM looks at how much time has elapsed since
start-up. If the ECM determines that too much time was
required for the Bank 1 HO2S 1 to become active, a
Diagnostic Trouble Code P0135 will set.
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P0135 A O
2 Se nsorHea ter Circuit (Bank 1 Sen-
sor 1)1. No DTC re lating to MAP senso r a nd ECT
se nsor.
2. Engine coolant temperature is more than
60 de g. C.
3. Engine run time is longer than 20 seconds.
4. MAP se nso r o utput is mo re tha n 70kPa .
5. O
2 se nsor ba nk 1 hea te r current mo re tha n
10mA.No fail-safe function.

6E–164 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM - Inspect harness
connectors for backed-out terminals, improper
mating, broken locks, improperly formed or damagedterminals, and poor terminal-to-wire connection.
Damaged harness - Inspect the wiring harness for
damage; shorts to ground, shorts to battery positive
and open circuits.
Diagnostic Trouble Code (DTC) P0135
O
2 Sensor Heater Circuit (Bank 1 Sensor 1)
Step A ction Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0:
Diagnostic Trouble Code”.
Is the DTC P0135 stored as “Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”.
2. Select “Clear DTC Information” with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed
This Ignition” in “F2: DTC Information”.
Was the DTC P0135 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Check for poor/faulty connection at the O
2 sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
—Verify repair Go to Step 5
5 Visually check the O
2 sensor.
Was the problem found? —Go to Step 11Go to Step 6
6 Using the DVM and check the O
2 sensor.
1. Ignition “Off”, engine “Off”.
2. Disconnect O
2 sensor connector
3. Measure the resistance of heater.
Was the tester indicated specified value?
Approx imately
12.5
at 20°CGo to Step 7Go to Step 11
3431
C56(J2) E77
3 4
1234
O2 Sensor

ENGINE DRIVEABILITY AND EMISSIONS 6E–165
7 Using the DVM and check the heater power supply
circuit for the affected cylinder.
1. Ignition “On”, engine “Off”.
2. Disconnect the O
2 sensor connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10 - 14.5V Go to Step 9Go to Step 8
8 Repair the open or short to ground circuit between the
“O
2 Sensor” fuse (10A) and O2 sensor.
Is the action complete?—Veri fy repai r—
9 Using the DVM and check the heater ground circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Refer to 6E-88 page.
3. Disconnect the O
2 sensor connector.
4. Check the circuit for open or short to ground
circuit.
Was the problem found?
Breaker box is not available:
1. Ignition “Off”, engine “Off”.
2. Disconnect the O
2 sensor connector and ECM
connector.
3. Check the circuit for open or short to ground
circuit.
Was the problem found?
—Repair faulty
harness and
verify repair Go to Step 10 Step A ction Value(s) Yes No
4
V
E77
J2-31Breaker BoxE-77





331E56(J2) E77

6E–166 ENGINE DRIVEABILITY AND EMISSIONS
10 Using the DVM and check the heater ground circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the O
2 sensor connector.
3. Check the circuit for short to voltage circuit.
Was the DVM indicated voltage?
—Repair faulty
harness and
verify repair Go to Step 12
11 Replace the O
2 sensor.
Was the problem solved?—Verify repair Go to Step 12
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step A ction Value(s) Yes No
3
V
E77

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