air conditioning ISUZU TF SERIES 2004 Manual PDF

1-48 HEATER AND AIR CONDITIONING

Checking and Adjusting for Compressor
Replacement
180 cm3 (5.0 lmp fl oz) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil from
the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the compressor.
3) Drain the compressor oil and measure the extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.

Amount of oil drained
From used compressor Draining amount of oil
From new compressor
less than
90 cm
3 (2.5 lmp fl oz) Some as drained
amount
more than
90 cm
3 (2.5 lmp fl oz) 90 cm
3 (2.5 lmp fl oz)

6) Evacuate, charge and perform oil return operation.
7) Check system operation.


CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even is the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
 The capacity of the oil has increased.
 The oil has changed color to red.

Foreign substances, metal powder, etc., are present in the
oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.

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.

1-50 HEATER AND AIR CONDITIONING
DISASSEMBLY


This illustration is based on the 4J engine model
871R300002

Disassembly Steps

1. Drive plate bolt
2. Plain washer

3. Drive plate
4. Snap ring

5. Pulley assembly

6. Snap ring
7. Thermo sensor and lead wire connector
8. Field coil
9. Compressor

Important Operations - Dissassembly


1. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from rotating, then remove the bolt.
Drive Plate Holder: 5-8840-4056-0 (J-37872)

HEATER AND AIR CONDITIONING 1-51


3. Drive Plate
Remove the drive plate.
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.






5. Pulley Assembly
Using pulley puller pilot and pulley puller to remove the
pulley assembly.
Pulley Puller Pilot: 5-8840-0121-0 (J-33943)
Pulley Puller: 5-8840-0111-0 (J-8433)
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive plate
should be replaced. The frictional surfaces of the pulley
assembly should be cleaned with a suitable solvent before
reinstallation.






6. Snap ring
Using snap ring pliers to remove the snap ring.

1-52 HEATER AND AIR CONDITIONING
REASSEMBLY


This illustration is based on the 4J engine model
871R30003

Reassembly Steps
1. Compressor

2. Field coil
3. Thermo sensor and lead wire connector
4. Snap ring

5. Pulley assembly
6. Snap ring
7. Drive plate
8. Plain washer

9. Drive prate bolt

HEATER AND AIR CONDITIONING 1-53
Important Operation - Resassembly






2. Field Coil
Installation field coil.

Align the located portion (1) of the clutch coil and
compressor.


5. Pulley Asssembly
Using pulley installer and drive handle to install the pulley
assembly.
Pulley Installer: 5-8840-0118-0 (J-33940)
Drive Handle: 5-8840-0007-0 (J-8092)






9. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from
rotating.
Drive Plate Holder: 5-8840-4056-0 (J-37872)
Tighten the bolt to the specified torque.
N
m (kgf
m/Ib
in)

Torque 13 (1.3/113)
After tightening the bolt, check to be sure the pulley rotates
smoothly.

1-54 HEATER AND AIR CONDITIONING
HEATER UNIT
REMOVAL AND INSTALLATION

This illustration is based on RHD model
RTW310LF000501-X

Removal Steps
1. Control cable

2. Instrument panel assembly and cross
beam
3. Electronic thermostat connector

4. Evaporator or duct
5. Heater unit

Installation steps
5. Heater unit
4. Evaporator or duct
3. Electronic thermostat connector

2. Instrument panel assembly and cross
beam
1. Control cable

HEATER AND AIR CONDITIONING 1-55
Important Operations – Removal
2. Instrument Panel Assembly and Cross Beam.
Refer to INSTRUMENT PANEL in CAB section.
4. Evaporator or Duct
Refer to “EVAPORATOR” or “DUCT” in this section.




Important Operation - Installation
2. Instrument Panel Assembly and Cross Beam
Adjust the heater control cables.
Refer to "CONTROL LEVER ASSEMBLY" in this section.

1-56 HEATER AND AIR CONDITIONING
DISASSEMBLY AND REASSEMBLY


This illustration is based on RHD model
RTW310LF001401
Disassembly Steps
1. Attaching screw
2. Main link-side
3. Sub link-side
4. Mode rod
5. Holder rod
6. Mode lever
7. DEF/FOOT-spring
8. VENT-spring
9. Heater box clip
10. Attaching screws
11. Foot duct
12. Fod H/Pipes seal
13. Heater core clamp
14. Heater core
15. Mix lever (2)
16. Mix lever (1)
17. Control cable clamp
18. Attaching screws
19. Upper case
20. Lower case
21. DEF/FOOT door
22. VENT door
23. Mix door
24. Control cable clamp
Reassembly Steps
24. Control cable clamp
23. Mix door
22. VENT door
21. DEF/FOOT door
20. Lower case
19. Upper case
18 Attaching screws
17. Control cable clamp
16. Mix lever (1)
15. Mix lever (2)
14. Heater core
13. Heater core clamp
12. Fod H/Pipes seal
11. Foot duct
10. Attaching screws
9. Heater box clip
8. VENT-spring
7. DEF/FOOT-spring
6. Mode lever
5. Holder rod
4. Mode rod
3. Sub link-side
2. Main link-side
1. Attaching screw

HEATER AND AIR CONDITIONING 1-57
VENT UNIT (WITHOUT HEATER)
REMOVAL AND INSTALLATION

This illustration is based on RHD model
860R300001-X

Removal Steps
1. Control cable

2. Instrument panel assembly and cross
beam
3. Electronic thermostat connector

4. Evaporator or duct
5. Vent unit

Installation steps
5. Vent unit
4. Evaporator or duct
3. Electronic thermostat connector

2. Instrument panel assembly and cross
beam
1. Control cable