oil type ISUZU TF SERIES 2004 Repair 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

HEATER AND AIR CONDITIONING 1-47

Checking and Adjusting for Used Compressor
(1) Perform Oil return operation.
(Refer to "Oil Return Operation" in this section.)
(2) Discharge refrigerant and remove the compressor.


(3) Drain the compressor oil and measure the extracted oil with
a measuring cylinder.
(4) Check the compressor oil for contamination.
(Refer to "Contamination of Compressor Oil" in this
section.)
(5) Adjust oil level following the procedure below.

Type Collected Amount Charging Amount
more than 90 cm3
(3.0 fl.oz.) same as collected
amount
less than 90 cm3
(3.0 fl.oz.) 90 cm3 (3.0 fl.oz.) CR-14

(6) Install the compressor, then evacuate, charge and perform
oil return operation.
(7) Check system operation.


When it is impossible to perform oil return operation, the
compressor oil should be checked in the following order:
(1) Discharge refrigerant and remove the compressor.
(2) Drain the compressor oil and measure the extracted oil with
a measuring cylinder.
(3) Check the oil for contamination.
(4) If more than 90 cm
3 (3.0 fl.oz.) for CR-14 type is extracted
from the compressor, supply same amount of oil to the
compressor to be installed.
If the amount of oil extracted is less than 90 cm
3 (3.0 fl.oz.)
for CR-14 type recheck the compressor oil in the following
order:
(5) Supply 90 cm
3 (3.0 fl.oz.) for CR-14 type oil to the
compressor and install it onto the vehicle.
(6) Perform oil return operation.
(7) Remove the compressor and recheck the amount of oil.
(8) Adjust the compressor oil.

7B-2 MSG MODEL
MAIN DATA AND SPECIFICATIONS

Transmission type Fully synchronized 5-forward gears with a constant
mesh type reverse gear.

Transmission Control Direct control with the gear shift lever on the floor.

Gear ratio MSG5K
1st : 4.122
2nd : 2.493
3rd : 1.504
4th : 1.000
5th : 0.855
Rev : 3.720

Oil capacity lit. (US gal.) 1.55(0.41)

Weight ; approx. kg(lbs) 33.3(73.8)

MSG MODEL 7B-41

RTW47BSH000201
Important Operations
2. Rear Cover with Oil Seal
1)
Align the pins at the lower side of the rear cover with the
holes in the lower side of the intermediate plate.
2)
Apply recommended liquid gasket or its equivalent to the
rear cover fitting surfaces.
3) Install the rear cover to the intermediate plate.
4) Tighten the rear cover bolts to the specified torque.
Rear Cover Bolt Torque N
m(kgf
m/lb
ft)
37.2 (3.8 / 27.5)
Note:
Take care not to twist or puncture the oil seal during the
installation procedure.


RTW47BSH000301

3. Transmission Case
4. Bearing Snap Ring
1) Apply the engine oil to the transmission case top gear shaft
ball bearing fitting faces.
2)
Apply recommended liquid gasket or its equivalent to the
transmission case fitting surfaces.
3) Install the transmission case to the intermediate plate.
4) Pull the top gear shaft from the transmission case until the
ball bearing snap ring grove protrudes from the
transmission case front cover fitting faces.
5) Use a pair of snap ring pliers to install the snap ring to the
ball bearing.



6. Front Cover with Oil Seal
1) Clean and apply recommended liquid gasket or its
equivalent to the through bolt threads.
2) Install the new gasket and tighten the new cover bolt to the
specified torgue.
Front Cover Bolt Torgue N
m(kgf
m/lb.ft)
24.5 (2.5 / 18.1)









RTW47BSH000101
10. Shift Fork
Apply molybdenum disulfide type grease to the areas as
shown in the figure and install shift fork (Diesel engine).

MANUAL TRANSMISSION 7B1-21

7. Install the speedometer sensor (2).
Torque: 27 N




m (2.8 kg




m/20 lb




ft)
225R300001
8. Install top gear bearing snap ring (10) and counter
front bearing snap ring (8).


Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.


The snap rings must be fully inserted into the
bearing snap ring groove.
9. Front cover with oil seal (9).
Front Cover Oil Seal Replacement


Remove the oil seal from the front cover.


Apply engine oil to a new oil seal outer
circumference.


Apply recommended grease to the oil seal lip.


Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.

220R3000020
10. Install a new gasket and front cover (9) to the
transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:


After cleaning the bolt hole, dry it thoroughly with air.


After cleaning the screw face of a removed bolt or
new one, dry it thoroughly. Apply recommended
liquid gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six front cover bolts to the specified torque.
Torque: 25 N





m (2.6 kg





m/19 lb





ft)
11. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (7).
(Diesel engine, C24NE)
F07L100026

7B1-50 MANUAL TRANSMISSION

Main Data and Specifications
General Specifications
MUA 5G MUA 5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.357
2nd 2.301 2.502
3rd 1.427 1.501
4th 1.000 1.000
5th 0.828 0.809
Rev. 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"

MANUAL TRANSMISSION 7B1-79

5. Install top gear bearing snap ring (9) and counter
front bearing snap ring (7).


Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.


The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal (8).
Front Cover Oil Seal Replacement


Remove the oil seal from the front cover.


Apply engine oil to a new oil seal outer
circumference.

Apply recommended grease to the oil seal lip.


Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
220R3000020
8. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (6).
(Diesel engine, C24NE)
F07L100026
9. Install the fulcrum bridge to the transmission case.
(6VE1)
Torque: 38 N




m (3.9 kg




m/28 lb




ft)
RTW37ASH0002

Legend
(1) Fulcrum bridge

10. Apply molybdenum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
(6VE1)
11. Attach the shift fork to the fulcrum bridge and insert
the pin from below of the fulcrum bridge. (6VE1)

MANUAL TRANSMISSION 7B1-107

Main Data and Specifications
General Specifications

MUA5G MUA5S
Transmission type Fully synchronized forward and reverse gears
Control method Remote control with the gear shift lever on the floor.
Gear ratio: Transmission 1st 4.008 4.357
2nd 2.301 2.502
3rd 1.427 1.501
4th 1.000 1.000
5th 0.828 0.809
Rev. 3.651 3.970
Transmission oil capacity 2.95 lit. (3.12 US qt)
Type of lubricant Engine oil: Refer to the chart in "SECTION 0"

3B-4 POWER-ASSISTED STEERING SYSTEM

General Description
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering unit, a pressure hose
and a return hose.

Power Steering Unit

This illustration is based on the RHD model. 440R300001
The power steering unit is rack and pinion type.
The toe-in angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.

POWER-ASSISTED STEERING SYSTEM 3B-5

Hydraulic Pump
442R300004
The hydraulic pump is vane-type design. The
submerged pump has housing and internal parts tha
t
are inside the reservoir and operate submerged in oil.
There are two bore openings at the rear of the pump
housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly,
and end plate. The smaller opening contains the
pressure line union, flow control valve and spring.
The flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure.