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BACK TO MAIN INDEX ISUZU KB P190 2007
TO MODEL INDEX
HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description ........................................................................................................ 1- 3
Main Data and Specifications......................................................................................... 1- 21
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 23
On-Vehicle Service .......................................................................................................... 1- 30
Precautions For Replacement or repair of air conditioning parts.......................... 1- 30
Condenser........................................................................................................................ 1- 40
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Removal and Installation (4JH1-TC, 4JJ1-TC Standard Output)............................. 1- 40
Removal and Installation
(4JJ1-TC High Output, 4JK1-TC High Output, 4JA1-T) ........................................ 1- 41
Removal and Installation (C24SE)............................................................................. 1- 42
Condenser Fan Motor ..................................................................................................... 1- 43
Removal and Installation............................................................................................ 1- 43
Receiver/drier .................................................................................................................. 1- 44
Compressor ..................................................................................................................... 1- 45
Removal and Installation (4JA1-T, 4JH1-TC) ............................................................ 1- 45
Removal and Installation
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output) ......... 1- 47
Removal and Installation (C24SE)............................................................................. 1- 49
Disassembly................................................................................................................ 1- 55
Reassembly................................................................................................................. 1- 57
Heater Unit ....................................................................................................................... 1- 59
Disassembly and Reassembly................................................................................... 1- 61
Vent Unit (Without Heater) ............................................................................................. 1- 62
BACK TO CHAPTER INDEX ISUZU KB P190 2007
TO MODEL INDEX
1-2 HEATER AND AIR CONDITIONING
PAGE
Evaporator (With A/C) ..................................................................................................... 1- 65
Duct (Without A/C)........................................................................................................... 1- 68
Blower Unit Assembly..................................................................................................... 1- 70
Defroster Nozzle and Vent Duct ..................................................................................... 1- 73
Rear Heater Duct ............................................................................................................. 1- 74
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Control Lever Assembly ................................................................................................. 1- 75
Control Panel Illumination Bulb ..................................................................................... 1- 79
Inspection and Repair ................................................................................................ 1- 81
Troubleshooting .............................................................................................................. 1- 85
Special Service Tool........................................................................................................ 1-119
TO MODEL INDEX
GENERAL DESCRIPTION
COOLING SYSTEM
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1. Compressor 8. Evaporator core
2. Magnetic clutch 9. Blower motor
3. Receiver/Drier 10. Heater unit
4. Triple pressure switch 11. Mode (DEF/FOOT) control door
5. Condenser 12. Mode (VENT) control door
6. Evaporator assembly 13. Electronic thermostat
7. Expansion valve 14. Heater core
RTW610LF000101
TO MODEL INDEX
COMPONENTS (CHASSIS SIDE)

(4JA1-T RHD MODEL)
line
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RTW710LF001901
TO MODEL INDEX
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output RHD MODEL)
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RTW710LF002001
TO MODEL INDEX
(C24SE RHD MODEL)
Evaporator
Refrigerant liquid line
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Refrigerant
suction line
Receiver/drier
Condenser
Refrigerant discharge line
RTW710LF002101
TO MODEL INDEX
(4JA1-T, 4JH1-TC LHD MODEL)

(4JH1-TC)
•
Refrigerant suction line

(4JA1-T)
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Refrigerant liquid line
RTW710LF002201
TO MODEL INDEX
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output LHD MODEL)
Refrigerant suction line Evaporator

(4JJ1 ·TC High Output,4JK1 ·TC High Output)
Refrigerant suction line

(4JJ1 ·TC Stand ard Output)
iI
o
Refrigerant line
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Ref';9''''''\ liquid line
Condenser
High Output)
RTW710LF002301
TO MODEL INDEX
(C24SE LHD MODEL)
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Condenser
Receiver/drier
RTW710LF002401
TO MODEL INDEX
COMPONENTS (INSIDE CAB)

Side def hose LH
Defroster nozzle
Vent duct assist side

Side def hose RH
Blower unit
Center vent duct
Heater unit or Vent unit

Vent duct driver side
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Evaporator or Duct
Rear heater duct
Control lever assembly
This illustration is based on RHD model

RTW710LF001301
TO MODEL INDEX
VENTILATION
-------------1
U I
I
I
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("--I
TO VENT OUTLET
TO DEF OUTLET
'------------'-, -~ - -
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DEF/FOOT MODE DEF MODE

RTW710MF000601 & RTW410MF000301

TO MODEL INDEX
WIRING DIAGRAM (4JA1-T)
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TO MODEL INDEX
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TO MODEL INDEX
(4JH1-TC)
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TO MODEL INDEX
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output RHD MODEL)
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RTW78AXF012101
TO MODEL INDEX
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output LHD MODEL)
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RTW78AXF028001
TO MODEL INDEX
C24SE (A/C WITH HEATER)

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RTW780XF013701
TO MODEL INDEX
C24SE (COOLER WITHOUT HEATER)

ISBF-11100A
MAIN
B B/R
~20A ~30A
CONDENSER BLOWER
FAN
BODY ENGINE
1.25
L/O
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VV/R
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1.25
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ROOM-RH ROOM-LH
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RTW680XF012401
TO MODEL INDEX
CONNECTOR LOCATION (RHD MODEL)

(EUROPE)
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lIEX 1_Xl$ RELAY
XI6. X17 DIODE
E61-E616 FUSE
S6F1-SBF9 SLOW BLOW FUSE
RTW78AXF039101&RTW78AXF045301
TO MODEL INDEX
(LHD MODEL)
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..
RTW78AXF039201&RTW78AXF045401
TO MODEL INDEX
MAIN DATA AND SPECIFICATIONS
COMPRESSOR
Model CR-14
Type 5 Vane rotary type
3
Displacement cm (lmp fl oz) 144 (4.03)
Oil type DH-PR
3
Oil capacity cm (lmp fl oz) 180 (5.07)
Magnetic clutch mm (in) Type: Dry single disc dia. 109 (4.3)
HEATING UNIT (VENT UNIT)

Type Reheat air mix
Core dimension mm (in) (L×H×W) 180 (7.09) × 182.3 (7.18) × 27 (1.06)
Capacity (kcal/h) 4200
BLOWER UNIT
Type Sirocco fan type
COOLING UNIT
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Type Fin and tube evaporator
Evaporator element dimensions mm (in) (L×H×W) 222 (8.74) × 213 (8.39) × 56 (2.2)
3
Air volume / Heat absorption m /H / W 300/3440
500/5140
• Expansion Valve type External pressure equalizer type
• Thermo Switch type (Cooler) Variable electronic thermostat
• Maximum Cool position °C (°F) OFF 3±0.5 (37.4±0.9)
DIFF 1.5±0.5 (34.7±0.9)
• Minimum Cool position °C (°F) OFF 11.6±2 (52.9±3.6)
DIFF 2.9±2 (37.2±3.6)
• Thermo Switch type (A/C) °C (°F) Fixed electronic thermostat
OFF 3 ± 0.5 (37.4 ± 0.9)
DIFF 1.5 ± 0.5 (34.7 ± 0.9)
CONDENSER
Type Aluminum louvered fins
Capacity kW (kcal/h) • 4JA1-T, 4JH1-TC, C24SE
14 (12300)
• 4JJ1-TC (Standard Output),
4JJ1- TC (High Output),
4JK1-TC (High Output),
17 (14620)
TO MODEL INDEX
RECEIVER/DRIER
Capacity cc (cu in) 250 (15.3)
Assembly includes sight glass
and pressure sensitive device
(Dual pressure switch)

• Low pressure control
2
kPa (kg/cm /psi) OFF: 177±26 (1.8±0.25/26±4)
2
kPa (kg/cm /psi) ON: 186±30 (1.9±0.3/27±4)
• High pressure control
2
kPa (kg/cm /psi) OFF: 2746±196 (28±2/398±28)
2
kPa (kg/cm /psi) ON: 588±196 (6±2/85±28)
(Triple pressure switch)

• Low pressure control
2
kPa (kg/cm /psi) OFF: 177±26 (1.8±0.25/26±4)
2
kPa (kg/cm /psi) ON: 186±30 (1.9±0.3/27±4)
• Medium pressure control
2
kPa (kg/cm /psi) OFF: 1128±118 (11.5±1.2/164±17)
2
kPa (kg/cm /psi) ON: 1521±88 (15.5±0.9/220±13)
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• High pressure control
2
kPa (kg/cm /psi) OFF: 2746±196 (28±2/398±28)
2
kPa (kg/cm /psi) ON: 588±196 (6±2/85±28)
ELECTRIC FAN
Fan Dia ∅250
Motor Power (w) 90
REFRIGERANT
Type
HFC-134a
Capacity kg (lbs)
• 4JA1-T, 4JH1-TC, C24SE
0.72 (1.59)
• 4JJ1-TC (Standard Output),
4JJ1-TC (High Output),
4JK1-TC (High Output)
0.65 (1.43)
Idle speed controlled by solenoid switch (4JA1-T only)

IDLE SPEED-UP CONTROL
TO MODEL INDEX
SPECIAL PARTS FIXING NUTS AND BOLTS

FIXING TORQUE
(COMPRESSOR ASSEMBLY) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
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RTW510MF000501
TO MODEL INDEX
(4JA1-T RHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
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RTW710LF003301
TO MODEL INDEX
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output RHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
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RTW710LF003401
TO MODEL INDEX
(C24SE RHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
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RTW710LF003501
TO MODEL INDEX
(4JA1-T, 4JH1-TC LHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
11-19(1_1I95in-1_91168in)
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RTW710LF003601
TO MODEL INDEX
(4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output LHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
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RTW710LF003701
TO MODEL INDEX
(C24SE LHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)
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RTW710LF003801
TO MODEL INDEX
ON-VEHICLE SERVICE
PRECAUTIONS FOR REPLACEMENT OR
REPAIR OF AIR CONDITIONING PARTS
There are certain procedures, practices and precautions that
should be followed when servicing air conditioning systems:
• Keep your work area clean.
• Always wear safety goggle and protective gloves when
working on refrigerant systems.
• Beware of the danger of carbon monoxide fumes caused by
running the engine.
• Beware of discharged refrigerant in enclosed or improperly
ventilated garages.
• Always disconnect the negative battery cable and discharge
and recover the refrigerant whenever repairing the air
conditioning system.
• When discharging and recovering the refrigerant, do not
allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
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• Keep moisture and contaminants out of the system. When
disconnecting or removing any lines or parts, use plugs or
caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts are
reconnected or installed.
• When disconnecting or reconnecting the lines, use two
wrenches to support the line fitting, to prevent from twisting
or other damage.
• Always install new O-rings whenever a connection is
disassembled.
• Before connecting any hoses or lines, apply new specified
compressor oil to the O-rings.
• When removing and replacing any parts which require
discharging the refrigerant circuit, the operations described
in this section must be performed in the following sequence:
4
1) Using the ACR (HFC-134a Refrigerant Recovery/
Recycling/Recharging/System) or equivalent to
thoroughly discharge and recover the refrigerant.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
ACR (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3) After evacuation, charge the air conditioning system and
check for leaks.
TO MODEL INDEX
REPAIR OF REFRIGERANT LEAKS

Refrigerant Line Connections
Install new O-ring, if required. When disconnecting or
connecting lines, use two wrenches to prevent the connecting
portion from twisting or becoming damaged.
RTW410SH000101
When connecting the refrigerant line at the block joint, securely

insert the projecting portion of the joint portion into the
connecting hole on the unit side and secure with a bolt.
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Apply specified compressor oil to the O-rings prior to
connecting.
CAUTION:
Compressor (PAG) oil to be used varies according to
compressor model. Be sure to apply oil specified for the
model of compressor.
O-rings must be closely aligned with raised portion of

refrigerant line.
TO MODEL INDEX
Insert nut into union. First tighten nut by hand as much as

possible. Then, tighten nut to specified torque.
(Refer to "Special Parts Fixing Nuts and Bolts" in this section)
LEAK AT REFRIGERANT LINE

CONNECTIONS
1) Check the torque on the refrigerant line fitting and, if too
loose, tighten to the specified torque.
• Use two wrenches to prevent twisting and damage to the
Line.
• Do not over tighten.
2) Perform a leak test on the refrigerant line fitting.
3) If the leak is still present, discharge and recover the
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refrigerant from the system.
4) Replace the O-rings.
• O-rings cannot be reused. Always replace with new
ones.
• Be sure to apply specified compressor oil to the new O-
rings.
5) Retighten the refrigerant line fitting to the specified torque.
• Use two wrenches to prevent twisting and damage to the
line.
6) Evacuate, charge and retest the system.
LEAK IN THE HOSE

If the compressor inlet or outlet hose is leaking, the entire hose
must be replaced. Refrigerant hose must not be cut or spliced
for repair.
1) Locate the leak.
2) Discharge and recover the refrigerant.
3) Remove the hose assembly.
• Cap the open connections at once.
4) Connect the new hose assembly.
• Use two wrenches to prevent twisting or damage to the
hose fitting.
• Tighten the hose fitting to the specified torque.
5) Evacuate, charge and test the system.
COMPRESSOR LEAKS
If leaks are located around the compressor shaft seal or shell,
replace or repair the compressor.
TO MODEL INDEX
RECOVERY, RECYCLING, EVACUATION

AND CHARGING
Handling Refrigerant-134a (HFC-134a)
Air conditioning systems contain HFC-134a.
This is a chemical mixture, which requires special handling
procedures to avoid personal injury.
• Always wear safety goggles and protective gloves.
• Always work in a well-ventilated area. Do not weld or steam
clean on or near any vehicle-installed air conditioning lines
or components.
• If HFC-134a should come in contact with any part of the
body, flush the exposed area with cold water and
immediately seek medical help.
• If it is necessary to transport or carry any container of HFC-
134a in a vehicle, do not carry it in the passenger
compartment.
• If it is necessary to fill a small HFC-134a container from a
large one, never fill the container completely. Space should
always be allowed above the liquid for expansion.
• Keep HFC-134a containers stored below 40°C (104°F).
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WARNING
• SHOULD HFC-134a CONTACT YOUR EYE(S), CONSULT
A DOCTOR IMMEDIATELY.
• DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER OVER
THE AFFECTED AREA TO GRADUALLY RAISE THE
TEMPERATURE OF THE REFRIGERANT ABOVE THE
FREEZING POINT.
• OBTAIN PROPER MEDICAL TREATMENT AS SOON AS
POSSIBLE. SHOULD THE HFC-134a TOUCH THE SKIN,
THE INJURY MUST BE TREATED THE SAME AS SKIN
WHICH HAS BEEN FROSTBITTEN OR FROZEN.
REFRIGERANT RECOVERY
The refrigerant must be discharged and recovered by using
4
ACR (HFC-134a Refrigerant Recovery/Recycling/Recharging/
System) or equivalent before removing or installing air
conditioning parts.
4
ACR (115V 60Hz) :5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
: 5-8840-0631-0 (J-39500-220ANZ)
4
1) Connect the high and low charging hoses of the ACR (or
equivalent) as shown.
4
2) Recover the refrigerant by following the ACR
Manufacturer's Instructions.
F06R300012
3) When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture cannot get
into it.
TO MODEL INDEX
REFRIGERANT RECYCLING
4
Recycle the refrigerant recovered by ACR or equivalent.
For the details of the actual operation, follow the steps in the
4
ACR Manufacturer's Instructions.
4
ACR (115V 60Hz) :5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
: 5-8840-0631-0 (J-39500-220ANZ)
EVACUATION OF THE REFRIGERANT

SYSTEM
NOTE:
Explained below is a method using a vacuum pump. Refer
4
to the ACR (or equivalent) Manufacturer's Instructions
4
when evacuating the system with ACR (or equivalent).
Air and moisture in the refrigerant will cause problems in the air
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Therefore, before charging the refrigerant, be sure to evacuate
air and moisture thoroughly from the system.
1) Connect the gauge manifold.
• High-pressure valve (HI) - Discharge-side
• Low-pressure valve (LOW) - Suction-side
2) Discharge and recover the refrigerant.
3) Connect the center hose of the gauge manifold set to the
vacuum pump inlet.
4) Operate the vacuum pump, open shutoff valve and then
F06R300014 open both hand valves.
5) When the low-pressure gauge indicates approx. 100kPa
(750 mmHg/30 inHg), continue the evacuation for 5 minutes
or more.
6) Close both hand valves and stop the vacuum pump.
7) Check to ensure that the pressure does not change after 10
minutes or more.
• If the pressure changes, check the system for leaks.
• If leaks occur, retighten the refrigerant line connections
and repeat the evacuation steps.
8) If no leaks are found, again operate the vacuum pump for
20 minutes or more. After confirming that the gauge
manifold pressure is at 100 kPa (750 mmHg/30 inHg), close
both hand valves.
9) Close positive shutoff valve.
Stop the vacuum pump and disconnect the center hose
from the vacuum pump.
TO MODEL INDEX
CHARGING THE REFRIGERANT SYSTEM

There are various methods of charging refrigerant into the air
4
These include using the ACR (HFC-134a Refrigerant
Recovery/ Recycling/Recharging/System) or equivalent and
direct charging with a manifold gauge charging station.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
: 5-8840-0631-0 (J-39500-220ANZ)
Charging procedure
• ACR (or equivalent) method
4
4
For the charging of refrigerant recovered by ACR , follow the
Manufacturer's Instruction.
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F06R300012
TO MODEL INDEX
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F06R300013
• Direct charging with a manifold gauge charging

station method.
Handling the charging valve handle when installing refrigerant
container.
1) Before attaching the charge valve to the refrigerant
container, turn the charge valve handle counterclockwise
until the needle is fully retracted.
2) Turn the plate nut counterclockwise until it reaches its
highest position relative to the charge valve.
3) Install the charge valve onto the refrigerant container.
4) Turn the plate nut clockwise and connect the center hose of
the manifold gauge to the charge valve.
5) Tighten the plate nut sufficiently by hand. Then turn the
charge valve handle clockwise to lower the needle and bore
a hole in the refrigerant container.
6) Turn the charge valve handle counterclockwise to raise the
needle. The refrigerant in the refrigerant container is
charged into the air conditioning system by the operation of
the manifold gauge.
• Be absolutely sure not to reuse the emptied
TO MODEL INDEX
refrigerant container.
1) Make sure the evacuation process is correctly completed.
2) Connect the center-hose of the manifold gauge to the
• 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.
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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 source 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.
TO MODEL INDEX
8) Charge the system to the specified amount and then close

the low-pressure hand valve.
Refrigerant Amount g(lbs)
4JA1-T, 4JH1-TC, C24SE 720 (1.59)
4JJ1-TC (Standard Output)
4JJ1-TC (High Output) 650 (1.43)
4JK1-TC (High Output)
9) Check for refrigerant leaks by using a HFC-134a leak

detector.
• A fully charged system is indicated by the sight glass on
the receiver/drier being free of any bubbles (Refer to
"Reading Sight Glass").
• Check the high and low pressure value of the manifold
gauge. (Refer to “CHECKING REFRIGERANT SYSTEM
WITH MAINFOLD GAUGE” in SERVICE
INFORMATION.)
Immediately after charging refrigerant, both high and low
pressures are slightly high and to the left of the gauge, but they
settle down to the guide pressure valves as shown below:
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• Ambient temperature; 30∼35°C (86∼95°F)
• Guide pressure
High-pressure side;
2
Approx. 1373∼1670 kPa (14∼17 kg/cm / 199∼242 psi)
Low-pressure side;
2
Approx. 127∼245 kPa (1.3∼2.5 kg/cm / 18∼36 psi)
10) Close the low pressure hand valve and charge valve of the
11) Stop the air conditioning and the engine.
12) Disconnect the high and low pressure hoses from the
manifold gauge fittings.
TO MODEL INDEX
Reading Sight Glass
High and low The high pressure The high pressure There is little The high pressure
pressure pipe pipe is hot and the pipe is warm and difference in pipe is hot and the
temperature low pressure pipe the low pressure temperature low pressure pipe
is cold. There is a pipe is cool. There between the high is slightly warm.
distinct difference is no great pressure pipe and There is a
in temperature difference in the low pressure difference in
between them. temperature pipe. temperature
between them. between them.
Sight glass Almost transparent. A flow of bubbles Something like fog Even at idle with
condition A flow of bubbles always can be faintly can be seen. the fan at "HI" (with
can be seen, but seen. It appears the window fully
they disappear sometimes open), the bubbles
when the throttle is transparent, and cannot be seen.
opened. sometimes frothy.
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Air conditioning NG NG NG
cycle condition OK (Not enough (Almost no (Too much
refrigerant) refrigerant) 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)
2
* High side pressure less than 1470 kPa (15 kg/cm / 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.
TO MODEL INDEX
CONDENSER
REMOVAL AND INSTALLATION (4JH1-TC, 4JJ1-TC Standard Output)
10
10
10
13
11
12
14
4JJ1-TC
9 Standard Output
(LHD)
14
4JJ1-TC
9 Standard Output
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(RHD)
14 7
10
4
4JH1-TC
6
1
RTW710LF001401
Removal Steps Installation Steps

1. Radiator grille 14. Condenser assembly
2. Front bumper fascia 13. Receiver/drier
• Refer to SECTION 2A “FRONT 12. Receiver/drier bracket
BUMPER” 11. Refrigerant line
3. Front bumper impact support assembly 10. Refrigerant line
• Refer to SECTION 2A “FRONT 9. Condenser fan connector
BUMPER” 8. Pressure switch connector
4. Air cleaner assembly 7. Engine hood front end stay
5. Inter cooler 6. Engine hood lock
• Refer to SECTION 6A “INTER COOLER” 5. Inter cooler
6. Engine hood lock • Refer to SECTION 6A “INTER COOLER”
7. Engine hood front end stay 4. Air cleaner assembly
8. Pressure switch connector 3. Front bumper impact support assembly
9. Condenser fan connector • Refer to SECTION 2A “FRONT
10. Refrigerant line BUMPER”
11. Refrigerant line 2. Front bumper fascia
12. Receiver/drier bracket • Refer to SECTION 2A “FRONT
13. Receiver/drier BUMPER”
14. Condenser assembly 1. Radiator grille
TO MODEL INDEX
REMOVAL AND INSTALLATION (4JJ1-TC High Output, 4JK1-TC High Output, 4JA1-T)
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RTW710LF001501

2. Engine hood lock 9. Receiver/drier
3. Engine hood front end stay 8. Receiver/drier bracket
4. Pressure switch connector 7. Refrigerant line
5. Condenser fan connector 6. Refrigerant line
6. Refrigerant line 5. Condenser fan connector
7. Refrigerant line 4. Pressure switch connector
8. Receiver/drier bracket 3. Engine hood front end stay
9. Receiver/drier 2. Engine hood lock
TO MODEL INDEX
REMOVAL AND INSTALLATION (C24SE)
cardiagn.com
RTW710LF004101

2. Engine hood lock 9. Receiver/drier
3. Engine hood front end stay 8. Receiver/drier bracket
4. Triple pressure switch connector 7. Refrigerant line
5. Condenser fan connector 6. Refrigerant line
6. Refrigerant line 5. Condenser fan connector
7. Refrigerant line 4. Pressure switch connector
8. Receiver/drier bracket 3. Engine hood front end stay
9. Receiver/drier 2. Engine hood lock
TO MODEL INDEX
CONDENSER FAN MOTOR
REMOVAL AND INSTALLATION
cardiagn.com
RTW710MF000701

1. Radiator grille 3. Condenser fan motor
2. Fan connector 2. Fan connector
3. Condenser fan motor 1. Radiator grille
TO MODEL INDEX
RECEIVER / DRIER
cardiagn.com
RTW710LF000801

1. Radiator grille 5. Receiver/drier
2. Pressure switch connector 4. Bracket bolt
3. Refrigerant line 3. Refrigerant line
4. Bracket bolt 2. Pressure switch connector
5. Receiver/drier 1. Radiator grille
TO MODEL INDEX
COMPRESSOR
REMOVAL AND INSTALLATION (4JA1-T, 4JH1-TC)
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852R300006

1. Air duct 8. Compressor assembly
2. Magnetic clutch harness connector 7. Bolt; compressor to bracket
3. Lock nut 6. Refrigerant line
4. Tension adjustment bolt 5. Drive belt
5. Drive belt 4. Tension adjustment bolt
6. Refrigerant line 3. Lock nut
7. Bolt; compressor to bracket 2. Magnetic clutch harness connector
8. Compressor assembly 1. Air duct
TO MODEL INDEX
Important Operations - Installation
7. Bolt; Compressor to Bracket

N⋅m (kgf⋅m/lb⋅ft)
Torque 44 (4.5/33)
6. Refrigerant Line
N⋅m (kgf⋅m/lb⋅in)
Torque 11∼19 (1.1/95∼1.9/168)
5. Drive Belt
Refer to SECTION 6A “COOLING SYSTEM”.
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TO MODEL INDEX
REMOVAL AND INSTALLATION (4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output)
cardiagn.com
RTW510MF000201

1. Magnetic clutch harness connector 5. Compressor assembly
2. Drive belt ▲ 4. Bolt; compressor to bracket
3. Refrigerant line ▲ 3. Refrigerant line
4. Bolt; compressor to bracket ▲ 2. Drive belt
5. Compressor assembly 1. Magnetic clutch harness connector
TO MODEL INDEX

Torque 44 (4.5/33)
3. Refrigerant Line
Torque 11∼19 (1.1/95∼1.9/168)
2. Drive Belt
Refer to SECTION 6A “INTAKE MANIFOLD”.
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TO MODEL INDEX
REMOVAL AND INSTALLATION (C24SE)
cardiagn.com
RTW310MF000401

1. Magnetic clutch harness connector 5. Compressor assembly
2. Drive belt 4. Bolt; compressor to bracket
3. Refrigerant line 3. Refrigerant line
4. Bolt; compressor to bracket 2. Drive belt
5. Compressor assembly 1. Magnetic clutch harness connector
TO MODEL INDEX

Torque 44 (4.5/33)
3. Refrigerant Line
Torque 11∼19 (1.1/95∼1.9/168)
2. Drive Belt
Refer to SECTION 6A “V-BELT TENSION OF
ALTERNATER”.
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TO MODEL INDEX
GENERAL REPAIR PROCEDURE

OIL SPECIFICATION
• The HFC-134a system requires a synthetic (PAG)
compressor oil.
• Compressor (PAG) oil varies according to compressor
model. Be sure to use oil specified for the model of
compressor.
Specified Compressor Oil
DH-PR
HANDLING OF OIL
• The oil should be free from moisture, dust, metal powder,
etc.
• Do not mix with other oil.
• The water content in the oil increases when exposed to the
air. After use, seal oil from air immediately.
• The compressor oil must be stored in steel containers, not
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in plastic containers.
COMPRESSOR OIL CHECK

The Oil used to lubricate the compressor is circulating with the
refrigerant.
Whenever replacing any component of the system or a large
amount of gas leakage occurs, add oil to maintain the original
amount of. oil.
Oil Capacity
Capacity total in 3
CR-14 180 cm (5.07 lmp fl oz)
system
Compressor
3
(Service parts) CR-14 180 cm (5.07 lmp fl oz)
charging amount
TO MODEL INDEX
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
3
more than 90 cm same as collected
(2.53 lmp fl oz) amount
CR-14 3 3
less than 90 cm 90 cm
(2.53 lmp fl oz) (2.53 lmp fl oz)
(6) Install the compressor, then evacuate, charge and perform

oil return operation.
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(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.
3
(4) If more than 90 cm (2.53 lmp fl oz) for CR-14 type is
extracted from the compressor, supply same amount of oil
to the compressor to be installed.
3
If the amount of oil extracted is less than 90 cm (2.53 lmp
fl oz) for CR-14 type recheck the compressor oil in the
following order:
3
(5) Supply 90 cm (2.53 lmp 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.
TO MODEL INDEX
Checking and Adjusting for Compressor

Replacement
3
180 cm (5.07 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 Draining amount of oil
From used compressor From new compressor
less than Some as drained
3
90 cm (2.53 lmp fl oz) amount
3
more than 90 cm (2.53 lmp fl oz)
3
90 cm (2.53 lmp fl oz)
6) Evacuate, charge and perform oil return operation.
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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.
TO MODEL INDEX
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
3
Evaporator 50 cm (1.41 lmp fl oz)
3
Condenser 30 cm (0.84 lmp fl oz)
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3
Receiver/drier 30 cm (0.84 lmp fl oz)
3
Refrigerant line (One piece) 10 cm (0.28 lmp 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.
TO MODEL INDEX
DISASSEMBLY
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This illustration is based on the 4J engine model
RTW510MF000301
Disassembly Steps
1. Drive plate bolt
2. Plain washer
3. Drive plate
4. Snap ring
5. Pulley assembly
6. Snap ring
7. Field coil
8. Compressor
Important Operations - Disassembly

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)
RTW510SH000701
TO MODEL INDEX
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
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RTW510SH000801
reinstallation.
6. Snap ring
Using snap ring pliers to remove the snap ring.
RTW510SH000901
TO MODEL INDEX
REASSEMBLY
cardiagn.com
This illustration is based on the 4J engine model
RTW510MF000401
Reassembly Steps
1. Compressor
2. Field coil
3. Snap ring
4. Pulley assembly
2. Snap ring
3. Drive plate
7. Plain washer
8. Drive prate bolt
TO MODEL INDEX
Important Operations - Reassembly

2. Field Coil
Installation field coil.
• Align the located portion (1) of the clutch coil and
compressor.
RTW510SH001001
4. Pulley Assembly
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)
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RTW510SH001101
8. 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

RTW510SH000701
smoothly.
TO MODEL INDEX
HEATER UNIT
cardiagn.com
RTW710LF001601
Removal Steps Installation steps

1. Control cable 5. Heater unit
2. Instrument panel assembly and cross 4. Evaporator or duct
beam 3. Electronic thermostat connector
3. Electronic thermostat connector 2. Instrument panel assembly and cross
4. Evaporator or duct beam
5. Heater unit 1. Control cable
TO MODEL INDEX
Important Operations – Removal

2. Instrument Panel Assembly and Cross Beam.
Refer to SECTION 10 “INSTRUMENT PANEL”.
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.
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TO MODEL INDEX
DISASSEMBLY AND REASSEMBLY
cardiagn.com
RTW310LF001401
Disassembly Steps Reassembly Steps

1. Attaching screw 24. Control cable clamp
2. Main link-side 23. Mix door
3. Sub link-side 22. VENT door
4. Mode rod 21. DEF/FOOT door
5. Holder rod 20. Lower case
6. Mode lever 19. Upper case
7. DEF/FOOT-spring 18. Attaching screws
8. VENT-spring 17. Control cable clamp
9. Heater box clip 16. Mix lever (1)
10. Attaching screws 15. Mix lever (2)
11. Foot duct 14. Heater core
12. FOD H/Pipes seal 13. Heater core clamp
13. Heater core clamp 12. FOD H/Pipes seal
14. Heater core 11. Foot duct
15. Mix lever (2) 10. Attaching screws
16. Mix lever (1) 9. Heater box clip
17. Control cable clamp 8. VENT-spring
18. Attaching screws 7. DEF/FOOT-spring
19. Upper case 6. Mode lever
20. Lower case 5. Holder rod
21. DEF/FOOT door 4. Mode rod
22. VENT door 3. Sub link-side
23. Mix door 2. Main link-side
24. Control cable clamp 1. Attaching screw
TO MODEL INDEX
VENT UNIT (WITHOUT HEATER)

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RTW710LF002801
Removal Steps Installation steps

1. Control cable 5. Vent unit
2. Instrument panel assembly and cross 4. Evaporator or duct
beam 3. Electronic thermostat connector
3. Electronic thermostat connector 2. Instrument panel assembly and cross
4. Evaporator or duct beam
5. Vent unit 1. Control cable
TO MODEL INDEX
Important Operations - Removal

2. Instrument Panel Assembly and Cross Beam.

Refer to “CONTROL LEVER ASSEMBLY” in this section.
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TO MODEL INDEX
cardiagn.com
RTW610LF000701

2. Main link-side 15. VENT door
3. Sub link-side 14. DEF/FOOT door
4. Mode rod 13. Lower case
5. Holder rod 12. Upper case
6. Mode lever 11. Heater core clamp
7. DEF/FOOT-spring 10. Heater box clip
8. VENT-spring 9. FOD H/pipes seal
9. FOD H/pipes seal 8. VENT-spring
10. Heater box clip 7. DEF/FOOT-spring
11. Heater core clamp 6. Mode lever
12. Upper case 5. Holder rod
13. Lower case 4. Mode rod
14. DEF/FOOT door 3. Sub link-side
15. VENT door 2. Main link-side
TO MODEL INDEX
EVAPORATOR (WITH A/C)

cardiagn.com
RTW710LF003001

1. Glove box 6. Evaporator assembly
2. Passenger lower bracket 5. Refrigerant line
3. Electronic thermostat connector 4. Drain hose
4. Drain hose 3. Electronic thermostat connector
5. Refrigerant line 2. Passenger lower bracket
6. Evaporator assembly 1. Glove box
TO MODEL INDEX
cardiagn.com
RTW710MF000901

1. Packing cooler outlet 15. Grommet : A/C pipe
2. Packing cooler inlet 14. Evaporator assembly W/Expansion valve
3. Seal FOD cooler 13. Packing drain
4. Filter cover assembly 12. Drain hose
5. Air filter 11. Insulator : case lower
6. Electronic thermostat 10. Case : cooler lower
7. Clip heater 9. Case : cooler upper
8. Attaching screws 8. Attaching screws
9. Case : cooler upper 7. Clip heater
10. Case : cooler lower 6. Electronic thermostat
11. Insulator : case lower 5. Air filter
12. Drain hose 4. Filter cover assembly
13. Packing drain 3. Seal FOD cooler
14. Evaporator assembly W/Expansion valve 2. Packing cooler inlet
15. Grommet : A/C pipe 1. Packing cooler outlet
TO MODEL INDEX
Important Operation -Reassembly

6. Electronic Thermostat
1) Install the electronic thermostat to the evaporator core
specified position with the clip.
2) Sensor part must not interfere with the evaporator core.
RTW710SH000901
cardiagn.com
TO MODEL INDEX
DUCT (WITHOUT A/C)

cardiagn.com
RTW710LF003901

1. Glove box 3. Evaporator assembly
2. Passenger lower bracket 2. Passenger lower bracket
3. Evaporator assembly 1. Glove box
TO MODEL INDEX
cardiagn.com
RTW710MF001001

1. Packing cooler outlet 8. Grommet
2. Packing cooler inlet 7. Packing drain
3. Seal FOD cooler 6. Case : cooler lower
4. Clip heater 5. Case : cooler upper
5. Case : cooler upper 4. Clip heater
6. Case : cooler lower 3. Seal FOD cooler
7. Packing drain 2. Packing cooler inlet
8. Grommet 1. Packing cooler outlet
TO MODEL INDEX
BLOWER UNIT ASSEMBLY

cardiagn.com
RTW710LF001801

1. Control cable 7. Blower unit assembly or intake box
2. Instrument panel assembly and cross assembly
beam 6. Blower motor connector
3. Electronic thermostat connector 5. Resistor connector
4. Evaporator or duct 4. Evaporator or duct
5. Resistor connector 3. Electronic thermostat connector
6. Blower motor connector 2. Instrument panel assembly and cross
7. Blower unit assembly or intake box beam
assembly 1. Control cable
TO MODEL INDEX


Refer to “CONTOROL LEVER ASSEMBLY” in this section.
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TO MODEL INDEX
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2. Intake link 12. Bell mouth
3. Intake lever 11. Mode door
4. Intake packing 10. Lower case
5. Attaching screws 9. Upper case
6. Blower motor assembly 8. Flat resistor
7. Attaching screw 7. Attaching screw
8. Flat resistor 6. Blower motor assembly
9. Upper case 5. Attaching screws
10. Lower case 4. Intake packing
11. Mode door 3. Intake lever
12. Bell mouth 2. Intake link
TO MODEL INDEX
DEFROSTER NOZZLE AND VENT DUCT

cardiagn.com
RTW710MF000201

1. Instrument panel assembly and cross beam 5. Center vent duct
2. Side def hose RH/LH 4. Vent duct driver side and assist side
3. Defroster nozzle 3. Defroster nozzle
4. Vent duct driver side and assist side 2. Side def hose RH/LH
5. Center vent duct 1. Instrument panel assembly and cross beam
Important Operation - Removal

TO MODEL INDEX
REAR HEATER DUCT

cardiagn.com
RTW710LF004301

1. Front seat assembly (RH/LH) 9. Rear heater duct center
• Refer to SECTION 10 “FRONT 8. Rear heater duct (RH/LH)
SEAT”. 7. Clip
2. Rear floor console 6. Carpet
• Refer to SECTION 10 “FLOOR 5. Dash side trim cover (RH/LH)
CONSOLE”. 4. Sill plate (RH/LH)
3. Front floor console (A/T, M/T Model) • Refer to SECTION 10 “INTERIOR
• Refer to SECTION 10 “FLOOR TRIM PANELS”.
CONSOLE”. 3. Front floor console (A/T, M/T Model)
4. Sill plate (RH/LH) • Refer to SECTION 10 “FLOOR
• Refer to SECTION 10 “INTERIOR CONSOLE”.
TRIM PANELS”. 2. Rear floor console
5. Dash side trim cover (RH/LH) • Refer to SECTION 10 “FLOOR
6. Carpet CONSOLE”.
7. Clip 1. Front seat assembly (RH/LH)
8. Rear Heater duct (RH/LH) • Refer to SECTION 10 “FRONT
9. Rear Heater duct center SEAT”.
TO MODEL INDEX
CONTROL LEVER ASSEMBLY

cardiagn.com
RTW710MF000801

1. Glove box 9. Control lever assembly
2. Instrument panel driver side lower cover 8. Fan switch connector
3. Ash-tray 7. A/C switch connector
4. Control cables 6. Attaching screw
5. Center cluster 5. Center cluster
6. Attaching screw 4. Control cables
7. A/C switch connector 3. Ash-tray
8. Fan switch connector 2. Instrument panel driver side lower cover
9. Control lever assembly 1. Glove box
TO MODEL INDEX

2. Instrument Panel Driver Lower Cover
Refer to SECTION 10 “INSTRUMENT PANEL” .
4. Control Cables
Disconnect control cables at each side of the unit.
RTW710SH000601
5. Center Cluster
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TO MODEL INDEX

9. Control Lever Assembly
Air source control cable
RHD
1) Slide the control lever to the left (“CIRC” position).
2) Connect the control cable at the "CIRC" position of the link
unit of blower assembly and fix it with the clip.
LHD
1) Slide the control lever to the right (“FRESH” position).
2) Connect the control cable at the "FRESH" position of the
link unit of blower assembly and fix it with the clip.
Temperature control cable

RHD
1) Turn the control knob to the right (“FULL HOT” position).
2) Connect the control cable at the “FULL HOT” position of the
mix lever of the heater unit and fix it with the clip.
LHD
1) Turn the control knob to the left (“FULL COLD” position).
2) Connect the control cable at the “FULL COLD” position of
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the mix lever of the heater unit and fix it with the clip.
Air select control cable

RHD
1) Turn the control knob to the left (“VENT” position).
2) Connect the control cable at the “VENT” position of the
mode control link of the heater unit and fix it with the clip.
LHD
1) Turn the control knob to the right (“DEF” position).
2) Connect the control cable at the “DEF” position of the mode
control link of the heater unit and fix it with the clip.
4. Control Cables
Check control cable operation
TO MODEL INDEX
TEMPERATURE CONTROL CABLE AIR SELECTOR CABLE
f\\
AIR SOURCE SELECT CABLE
~
J1rnjdi
~ )VJ
@
RHO
r1
l:.~
COLD
HOT
FRESH
LHO
cardiagn.com
COLD VENT DEF
HOT
RTW410MF000201
TO MODEL INDEX
CONTROL PANEL ILLUMINATION BULB

cardiagn.com
RTW710MF000401

1. Control lever assembly 2. Illumination bulb
2. Illumination bulb 1. Control lever assembly
TO MODEL INDEX

1. Control lever assembly
Refer to “CONTROL LEVER ASSEMBLY” in this section.
2. Illumination Bulb
To remove the illumination bulb, insert a pliers (long nose) into
the cap at the back of the bulb. Turn the bulb counterclockwise
and pull it free.
RTW710MH000101
cardiagn.com
TO MODEL INDEX
INSPECTION AND REPAIR

Resistor
As for air-conditioning model, fixed on left (RHD) / right (LHD)
side of the evaporator unit.
As for heater only model, fixed on left (RHD) / right (LHD) side
of the duct placed between blower unit and heater unit.
Replace the resistor with a new on if the coil is found to be
open or if the resistance value deviates from the specified
range.
840R300005-X
Terminal Resistance
3–2 2.04 Ω
3–4 0.88 Ω
3–1 0.31 Ω
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Blower motor
Check blower motor for smooth rotation.
Connect the battery positive terminal to the No.1 terminal of the
blower motor and negative to the No.2.
Be sure to check to see if the blower motor operates correctly.
TO MODEL INDEX
Fan switch and A/C switch

Check for continuity between fan switch and A/C switch side
connector terminals.
(A/C (4JA1-T, 4JJ1-TC Standard Output, 4JJ1-TC High
Output, 4JK1-TC High Output))
B-13 B-57
Terminal
No.
SW.
1 2 3 4 5 6 2 3 1 5 6
position
RTW710SH000801
OFF
1
(FAN SW.) 2
3
4
OFF
(A/C SW.)
ON
(A/C (4JH1-TC, C24SE)).
cardiagn.com
B-13 B-57
Terminal
No.
SW.
1 2 3 4 5 6 1 5 6
position
OFF
1
(FAN SW.) 2
3
RUW710SH000501
4
OFF
(A/C SW.)
ON
(Cooler)
B-13 B-57
Terminal
No.
SW.
1 2 3 4 5 6 2 3 10 11
position
OFF
1
(FAN SW.) 2
3
4
D08R300070
OFF
(A/C SW.)
ON
TO MODEL INDEX
Electronic thermostat
Check for continuity between electronic thermostat side
connector terminals.
(A/C)
RTW410SH000201
(Cooler)
cardiagn.com
TO MODEL INDEX
Triple Pressure switch

Disconnect pressure switch connector and check for continuity
between pressure switch side connector terminal.
RTW4A0SH000201
Heater and thermo switch relay.

Check for continuity between the relay terminals.
1 - 5 ⋅⋅⋅⋅⋅ No continuity
(When battery voltage is applied between 2 - 4 )
1 - 5 ⋅⋅⋅⋅⋅ Continuity
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825r300045
Check for continuity between the relay terminals.

1 - 2 ⋅⋅⋅⋅⋅ No continuity
(When battery voltage is applied between 3 - 4 )
1 - 2 ⋅⋅⋅⋅⋅ Continuity
825r300023
TO MODEL INDEX
TROUBLESHOOTING
FAN CONTROL KNOB (FAN SWITCH)
Current flows to the blower motor through the Heater & A/C relay (X-11) to activate the rotation of the blower motor
by turning “ON” the fan control knob (fan switch). Blower motor speed is controlled in stages by the resistor, by
operating the switch from “LOW” to “HIGH.”
~EXC~PT
SBF-6 C24SE
ISSF.aIC2<SE IX-11 I
~ )=
~ ftELAY,
.~. ~U.TU'''IC
rf-<~
~ r-- r- l£ '
-
1------ c W<o)ill
I- F ';;
7 ,7
-_.
11 , , ft£SlSTCf!
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I r-
I 1/ •
, ,
"
I '" ~~-
L ______ c '~
~ ~
~ ~ [i]j ~ 16-131
~ eI,j, I,j ~ ~
u.K1lu
ill' I:D'-I"
t I
RTW710LF004201
TO MODEL INDEX
BLOWER MOTOR DOES NOT RUN
• Is heater & A/C relay (X-11) OK?
YES NO
• Is No.SBF-6 (30A) (except C24SE) or No.SBF-8

(30A) (C24SE) slow blow fuse OK? Replace
YES NO
• Is resistor OK? Replace
YES NO
• Is fan control knob (Fan switch) OK? Replace
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YES NO
• Is blower motor OK? Replace control lever

assembly
YES NO
• Turn the ignition switch "ON" (Engine is running) Replace

• Fan control knob (Fan switch) "ON"
• Check to see if battery voltage is present at

chassis side connector terminal No.C105-1 is there a
battery voltage?
YES NO
Open circuit between
Open circuit either between chassis side connector No.SBF-6 (30A) (except
terminal No.C105-2 and No.C104-3 or No.B13-1 and C24SE) or No.SBF-8 (30A)
body ground No.C-109. (C24SE) slow blow fuse and
No.C105-1.
TO MODEL INDEX
BLOWER MOTOR DOES NOT RUN IN CERTAIN POSITION
A1: (Low)
Blower motor does not 2: (Medium Low) Position
B
run at C 3: (Medium Hi)
D 4: (High)
* Checking is performed only when in the malfunction
mode.
• Is resistor OK?
YES NO
• Is fan control knob (Fan switch) OK? Replace
YES NO
cardiagn.com
A Condition: Replace control lever
assembly
• Open circuit between chassis side connector
terminal No. C104-2 and No. B13-3
BCondition :
CCondition:
DCondition:
TO MODEL INDEX
BLOWER MOTOR DOES NOT STOP AT “OFF” POSITION
• Is fan control knob (Fan switch) OK?
YES
NO
Check the circuit between chassis side connector terminals
for short to GND Replace control lever assembly
• No. C105-2 and No. C104-3
(or)
• No. C105-2 and No. B13-4
(or)
• No. C104-1 and No. B13-5
(or)
• No. C104-4 and No. B13-6
(or)
• No. C104-2 and No. B13-3
cardiagn.com
TO MODEL INDEX
AIR CONDITIONING CYCLE TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE CORRECTION

No cooling or 1. Magnetic clutch does not run • Refer to “MAGNETIC CLUTCH”
insufficient troubleshooting in this section
cooling 2. Compressor is not rotating properly • Adjust the drive belt to the specified
• Drive belt loosened or broken tension or replace the drive belt
• Magnetic clutch face is not clean and • Clean the magnetic clutch face or replace
slips
• Incorrect clearance between magnetic • Adjust the clearance (Refer to
drive plate and pulley “COMPRESSOR OVERHAUL”)
• Compressor oil leaks from shaft seal or • Replace the compressor
shell
• Compressor seized • Replace the compressor
3. Insufficient or excessive charge of • Discharge and recover refrigerant.
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
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necessary
• Check radiator or condenser fan function
6. Temperature control link unit of the heater • Repair the link unit
unit defective
7. Unsteady operation due to foreign • Replace the expansion valve
substance in expansion valve
8. Poor operation of electronic thermostat • Check electronic thermostat and replace
as necessary
Insufficient 1. Evaporator clogged or frosted • Check evaporator core and replace or
velocity clean the core
of cooling air 2. Air leaking from cooling unit or air duct • Check evaporator and duct connection,
then repair as necessary
3. Blower motor does not rotate properly • 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.
TO MODEL INDEX
CHECKING REFRIGERANT SYSTEM

WITH MANIFOLD GAUGE
Conditions;
• Ambient temperature at approx. 30∼35°C (86∼95°F)
• Run the engine at Idling
• A/C switch is “ON”
• Run the blower motor at “4” (high) position
• Temperature control knob sets at “MAX COLD”
• Air source selector lever at “CIRC”
• Close the all doors
2
Normal pressures kPa (kg/cm /psi);
Low-pressure side:
Approx. 127 – 245 (1.3 – 2.5 / 18 – 36)
High-pressure side:
Approx. 1373 – 1670 (14 – 17 / 199 – 242)
Connect the manifold gauge
Low-pressure hose (LOW) ∼ Suction side
High-pressure hose (HI) ∼ Discharge side
f06r300014
cardiagn.com
TO MODEL INDEX
RESULT SYMPTOM TROUBLE CAUSE CORRECTION

Discharge Reduced or no air flow through • Condenser clogged or dirty • Clean
(High) the condenser • Radiator (condenser) fan • Check cooling fan
pressure does not operate properly operation
gauge No bubbles in sight glass when • Excessive refrigerant in • Check sight glass.
abnormally condenser is cooled by water system (See “Reading Sight
high (Insufficient cooling) Glass”)
• Discharge and
recover refrigerant.
Recharge to specified
amount
After stopping air conditioning, • Air in system • Evacuate and charge
pressure drops approx. 196 kPa refrigerant system
2
(2.0kg/cm / 28psi) quickly
Discharge Insufficient cooling and excessive • Insufficient refrigerant in • Check sight glass.
(High) bubbles in the sight glass system (See “Reading Sight
pressure Glass”)
gauge • Check for leaks
abnormally • Discharge and
low recover refrigerant.
amount
• •
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Low pressure gauge indicates Clogged or defective Replace the
vacuum expansion valve expansion valve
Frost or dew on refrigerant line • Restriction caused by debris • Check system for
before and after receiver/ drier or or moisture in receiver/drier restriction and
expansion valve, and low pres- replace receiver/drier
sure gauge indicates vacuum
After turning off air conditioning, • Compressor seal defective • Replace or repair
high and low pressure gauge • Poor compression due to compressor
balanced quickly defective compressor
gasket
Suction Low pressure gauge is lowered • Excessive refrigerant in • Discharge and
(Low) after condenser is cooled by system recover refrigerant
pressure water Recharge to specified
gauge amount
abnormally Low pressure hose temperature • Unsatisfactory valve • Replace the
high around the compressor refrigerant operation due to defective expansion valve
line connector is lower than temperature sensor of
around evaporator expansion valve
• Expansion valve opens too
long
After turning off air conditioning, • Compressor gasket is • Replace
high and low pressure gauge is defective
balanced quickly
Air conditioning turns off before • Electronic thermostat • Check the electronic
passenger compartment is defective thermostat and
sufficiently replace as necessary
cool
* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING” in this section.
TO MODEL INDEX
RESULT SYMPTOM TROUBLE CAUSE CORRECTION

Suction Condenser is not hot and • Insufficient refrigerant • Check sight
(Low) excessive bubble in sight glass glass.(See “Reading
pressure Sight Glass”)
abnormally • Check for leaks
low • Discharge and
recover refrigerant.
amount
Frost on the expansion valve inlet • Expansion valve clogged • Replace the
line expansion valve
A distinct difference in • Receiver/drier clogged • Replace the receiver/
temperature between the inlet and drier
outlet refrigerant lines of the
receiver/drier
Expansion valve outlet refrigerant • The temperature sensor of • Replace the
line is not cold and low-pressure the expansion valve is expansion valve
gauge indicates vacuum defective, and the valve
cannot regulate the correct
flow of the refrigerant
Discharge temperature is low and • Frozen evaporator core fins • Check electronic
air flow from vents is restricted thermostat and
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replace as necessary
Low-pressure gauge reading is • Clogged or blocked • Replace refrigerant
low, or a vacuum reading may be refrigerant line line
shown
Suction No bubbles in sight glass after • Excessive refrigerant in • Check sight
(Low) and condenser is cooled by water system glass.(See “Reading
Discharge (Insufficient cooling) Sight Glass”)
(High) • Discharge and
pressure recover refrigerant.
abnor- Recharge to specified
mally amount
high Reduce air flow through con- • Condenser clogged • Clean
denser • Radiator (condenser) fan • Check cooling fan
does not rotate properly operation
Suction (Low) pressure hose is • Air in system • Evacuate and charge
not cold refrigerant
Suction Insufficient cooling and excessive • Insufficient refrigerant in • Check sight glass.
(Low) and bubbles in the sight glass system (See “Reading Sight
Discharge Glass”)
(High) • Check for leaks
pres-sure • Discharge and
abnor- recover refrigerant.
mally Recharge to specified
low amount
TO MODEL INDEX
MAGNETIC CLUTCH
When the A/C switch and the fan control knob (fan switch) are turned on with the engine running, current flows
through the thermostat and the compressor relay to activate the magnetic clutch.
The air conditioning can be stopped by turning off the A/C switch or the fan control knob (fan switch).
However, even when the air conditioning is in operation, the electronic thermostat, the pressure switch or the ECM
is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to
reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of
the vehicle, etc.
cardiagn.com
TO MODEL INDEX
4JA1 – T
RELAY:HEATER
SBF-1 SBF-G
~
," """
~
~ 'M r- - - - - - -l
Me
"""'" '" , ::
I PRESSURE
- I SN
STARTER SoN
~ 1-0 ' ,
.- - - -
..;;::- •
I
I
(~ERCN..Y) "
I '--
~ ' =- =---
, r- , ~ """""'"
--
~ :
, ,
SN. "': Il - ~,
,
'-- ~ ---
• ~
----- "=-B - ' .=- iiXiXii<
,
r-~
,
1[- , , ELECTR(X<IIC
cardiagn.com
n-ERMOSTAT
,
ANSoN. I'? :2
'--
'-,- -JAt
--
I <?
l--'- 0 0
~> ~
0 OfF
- §.
_0
~
","c
C><
r0-f'-
_ _
OIODE I'-~ 1 -
L___ ~ ~ ,
G
=
I C-1OP I , ~~'
,O>XEcm.
000"'
RONLY)
8
10-79 1 le.24I @]~ I e-551
6~ I 3 4 ~ em
~ IX·ll I IX.'5 1 Ix.16 1
9 ~ I r; IWI!]
RTW710XF000201
TO MODEL INDEX
MAGNETIC CLUTCH DOES NOT RUN (4JA1-T)
• Are the No. SBF-6 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES NO
• Are the A/C thermo (X-15) and heater & A/C (X-11) Replace
relay OK?
YES NO
• Is the pressure switch (C-24) OK? Replace
YES NO
• Is the electronic thermostat (C-55) OK? Defective switch or insufficient

refrigerant
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YES NO
• Are the A/C switch (B-57) and the fan switch (B-13) Replace
OK?
YES NO

• A/C switch and fan control knob (fan switch) "ON"
• Disconnect the magnetic clutch connector.
• Is there battery voltage between the engine room harness

connector terminal No.1 (E-3) and ground?
NO YES
Does the magnetic clutch

• Disconnect the A/C thermo relay.
operate?
YES NO
• Is there continuity between the engine room harness
connector terminal No.1 (E-3) and engine room harness
connector terminal No.1 (X-15)? Defective compressor
Defective magnetic clutch

TO MODEL INDEX
YES NO
• Is there continuity between the engine room Open circuit between the engine room
harness connector terminal No.2 (X-15) and harness connector terminal No.1 (X-
ground? 15).
YES NO
• Is there battery voltage between the engine room Open circuit between the engine room
harness connector terminal No.3 (X-15) and harness connector terminal No. 2 (X-
ground? 15).
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YES NO
• Disconnect the pressure switch. Open circuit between the No. EB-13
fuse and the engine room harness
• Is there continuity between the engine room connector terminal No. 3 (X-15).
harness connector terminal No. 5 (X-15) and the
engine room harness connector terminal No. 2 (C-
24)?
YES NO
• Disconnect the condenser fan relay connector Open circuit between the engine room
condenser fan. harness connector terminal No. 5 (X-
15) and the engine room harness
• Is there continuity between the relay terminal connector terminal No. 2 (C-24).
No.3 (X-13)and engine room harness connector
terminal No.3 (C-24)?
YES NO
• Is there battery voltage between the engine room Open circuit between the condenser
harness connector terminal No.4 (C-24) and fan relay No. 3 (X-13) and engine
ground? room harness connector terminal No.3
(C-24).
TO MODEL INDEX
NO
Open circuit between the No. EB-13

fuse and engine room harness
connector terminal No. 4 (C-24).
YES
• connect the A/C thermo relay connector.

• Disconnect the electronic thermostat.
• Is there continuity between the engine room

harness connector terminal No. 2 (C-55) and the
engine room harness connector terminal No. 1
(C-24)?
YES NO
• Is there battery voltage between the engine Open circuit between the engine room
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room harness connector terminal No.3 (C-55) harness connector terminal No. 2 (C-
and ground? 55) and the engine room harness
YES NO
• Is there continuity between the engine room Open circuit between the No. EB-13
harness connector terminal No.1 (C-55) and the fuse and the engine room harness
chassis side harness connector terminal No.5 connector terminal No. 3 (C-55).
(B-57) ? or (cooler only) the short connector
terminal No.3 (B-79) and the chassis side
harness connector terminal No.5 (B-57)?
YES NO
• Is there continuity between the engine room Open circuit between the engine room
harness connector (cooler only) terminal No. 4 harness connector terminal No. 1 (C-
(C-55) and the chassis side harness connector 55) or (cooler only) the short
terminal No. 11 (B-57)? connector No. 3 (B-79) and the
chassis side harness connector
terminal No.5 (B-57).
TO MODEL INDEX
YES NO
• Is there battery voltage between the chassis side Open circuit between the engine room
harness connector terminal No. 10 (B-57) and ground? harness connector (cooler only) terminal
No. 4 (C-55) and the chassis side harness
connector terminal No. 11 (B-57).
YES NO
• Disconnect the A/C switch. Open circuit between the chassis side
harness connector No. 1 (B-79) and the
chassis side harness connector terminal
• Is there battery voltage between the chassis side No. 10 (B-57).
harness connector terminal No. 6 (B-57) and ground (C-
109)?
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YES NO
• Defective ECM Open circuit between the No. EB-13 fuse

and the chassis side harness connector
No. 6 (B-57).
TO MODEL INDEX
4JH1 – TC
RELAY;HEATER
STARTER SW'-l~j------=!
~
, - - - - -r- _
, ' ~j-
,
1 , ,o-J-f--
RELAY;
THERMO
we ON. ,
1
! (~~
1 L ' ++--+--I
, ----- ~ -
G , ---
~I
,
- ,
,r- ~
.- ,+-
ELECTRONIC
cardiagn.com
THERMOSTAT
I~ o-J---,c---t+-t---j-o ,
- - _J
FAASW. 2
'--
I 2 0 0
l--'- 0 Off
~
~
-
,",
,
- - - -1
,
I
RELAY
,1
, Me
COMPRESSOR
j-o , , 1
1
'-- ~ '--- _J
~
ECM(n)
ECM(38)
~
~
=
~
16-13 1 16-571 I C-24I ~ IC-551
rJ!hl I34 ~ em
IC-$ I [IT] IX-11 1 IX-14 l lx-15 1
9 ~ I RTW710XF000301
TO MODEL INDEX
MAGNETIC CLUTCH DOES NOT RUN (4JH1-TC)
(10A) fuses OK?
YES NO
• Are the A/C thermo (X-15) and heater & A/C (X-11) Replace
and A/C compressor (X-14) relay OK?
YES NO
YES NO

refrigerant
cardiagn.com
YES NO
OK?
YES NO

• Is there battery voltage between the engine room harness

connector terminal No.1 (E-3) and ground?
NO YES
• Disconnect the A/C compressor relay. Does the magnetic clutch

operate?
• Is there continuity between the engine harness

connector terminal No.1 (E-3) and the engine room YES NO
harness connector terminal No.2 (X-14)?
Defective compressor

TO MODEL INDEX
YES NO
Open circuit between the engine

• Is there battery voltage between the engine room harness connector terminal No.1 (E-3)
harness connector terminal No.1 (X-14) and and the engine room harness
ground? connector terminal No.2 (X-14).
YES NO
• Disconnect the A/C thermo relay. Open circuit between the No. EB-13
connector terminal No.1 (X-14).
harness connector terminal No.3 (X-14) and No.2
(X-15)?
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YES NO
• Disconnect the ECM harness connector. Open circuit between the engine room
harness connector terminal No.2 (X-
• Is there continuity between the ECM harness 15) and the engine room harness
connector terminal No.38 (C-56) and the engine connector terminal No. 3 (X-14).
room harness connector terminal No.5 (X-14)?
YES NO
• Is there continuity between the ECM harness Open circuit between the ECM
connector terminal No.33 (C-56) and the engine harness connector terminal No.38 (C-
room harness connector terminal No.1 (X-15)? 56) and the engine room harness
connector terminal No. 5 (X-14).
YES NO
• Is there battery voltage between the engine room Open circuit between the ECM
harness connector terminal No.3 (X-15) and harness connector No. 33 (C-56) and
ground? the engine room harness connector
terminal No. 1 (X-15).
YES NO
• Disconnect the pressure switch? Open circuit between the No. EB-13
24)?
TO MODEL INDEX
YES NO
• Disconnect the condenser fan relay connector Open circuit between the engine room
condenser fan. harness connector terminal No. 5 (X-
No. 3 (X-9) and engine room harness connector
YES NO
• Is there battery voltage between the engine Open circuit between the condenser
room harness connector terminal No.3 (C- fan relay No.3 (X-9) and the engine
24) and ground? room harness connector terminal No.
4 (C-24).
cardiagn.com
NO

YES


(C-24)?
YES NO
YES NO
harness connector terminal No.1 (C-55) and fuse and the engine room harness
ground (C-109) ? connector terminal No. 3 (C-55).
TO MODEL INDEX
NO
Open circuit between the engine room

harness connector terminal No. 1 (C-55)
and ground (C-109).
YES
• Disconnect the A/C switch.
• Is there battery voltage between the chassis side

harness connector terminal No. 6 (B-57) and ground (C-
109)?
cardiagn.com
YES NO
• Defective ECM Open circuit between the No. EB-13 fuse

No. 6 (B-57).
TO MODEL INDEX
4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output RHD MODEL
RELAY:HE.llTER
Sal'-' S8~ ~
BATTERY ~ ~
, '"""" ~---l
L ~i MAIN
,-----< r -" ,
6LCM€R
,-__+ , COll-~~
- ' PRESSURE
1.. $TARTER&N=j;~j----cO-~ , j-<> , oft-- - I, ON.
.~---=-----tfO ,;;: !-I---+I,+j-<> : - !

I~ " o-J-+ - - - II L =- ,=. ___ J
;~.ERCN..Y) ~NSER FAN RELAY(3) r-;.;-l
rt---t-+<
~,c --1 L:::...J
1++---1-+ ' nll-~~~

L j-<> ,
'-Nv--JI< • o-j-f-+-~+-
~4---+ '
~-=- L-
~
___ J'
_____ C -
, ,=- r---- l
~ 4-~~--r~ ,
H+-I----J-o '
I[-j=:-Q-W----+-+
I,
I!r- ~
ELECTRONIC
cardiagn.com
Tf£RMOSTAT
I
F~&N. 20-+-----,
I 2 0 0
0 ~,
l--'- -
~
--1
I '
nll-;;--".J I RELAY
,
, I '"
COMPRESSOR
j-<> ,
~ -=- L-
~
___ J I ,
ECM(4)
8 ' - - - _ ECM(55)~
r.:= L - - - - - - , 1 ,
, ~~;: ,-"-"".,,CTOR
(CXXllEROM.Y)
~
RTW710XF000401
TO MODEL INDEX
MAGNETIC CLUTCH DOES NOT RUN (4JJ1-TC Standard Output, 4JJ1-TC

High Output, 4JK1-TC High Output RHD MODEL)
(10A) fuses OK?
YES NO
• Are the A/C thermo (X-15), heater & A/C (X-11) and Replace
A/C compressor (X-14) relay OK?
YES NO
YES NO
cardiagn.com
refrigerant
YES NO
OK?
YES NO

• Is there battery voltage between the engine room

harness connector terminal No.1 (E-3) and ground?
NO YES

operate?


TO MODEL INDEX
YES NO
• Is there battery voltage between the engine room Open circuit between the engine
harness connector terminal No.1 (X-14) and harness connector terminal No.1 (E-3)
ground? and the engine room harness
YES NO
harness connector terminal No.3 (X-14) and the
engine room harness connector terminal No.1 (X-
15).
cardiagn.com
YES NO
YES NO
connector terminal No.4 (C-58) and the engine harness connector terminal No.55 (C-
YES NO
harness connector terminal No.2 (X-15) and harness connector terminal No. 4 (C-
ground? 58) and the engine room harness
YES NO
24)?
TO MODEL INDEX
YES NO
• Disconnect the condenser fan relay. Open circuit between the engine room
harness connector terminal No. 5 (X-
YES NO
room harness connector terminal No.3 (C- fan relay No.3 (X-9) and the engine
4 (C-24).
cardiagn.com
NO

YES


(C-24)?
YES NO
YES NO
ground (C-109) ? or (cooler only) the short connector terminal No. 3 (C-55).
connector terminal No.3 (B-79) and ground (C-
109)?
TO MODEL INDEX
YES NO
• Is there continuity between the engine room harness Open circuit between the engine room
connector (cooler only) terminal No. 4 (C-55) and the harness connector terminal No. 1 (C-55) or
chassis side harness connector terminal No. 11 (B-57)? (cooler only) the short connector No. 3 (B-
79) and ground (C-109).
YES NO
• Is there battery voltage between the chassis side Open circuit between the engine room
harness connector terminal No. 10 (B-57) and ground? harness connector (cooler only) terminal
No. 4 (C-55) and the chassis side harness
connector terminal No. 11 (B-57).
cardiagn.com
YES NO
• Disconnect the A/C switch. Open circuit between the chassis side
harness connector No. 1 (B-79) and the
chassis side harness connector terminal
• Is there battery voltage between the chassis side No. 10 (B-57).
harness connector terminal No. 6 (B-57) and ground?
YES NO
• Is the electronic thermostat OK? Open circuit between the No. EB-13 fuse
No. 6 (B-57).
YES NO
• Defective ECM Replace electronic thermostat

TO MODEL INDEX
4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output LHD MODEL
RELAY;HEATER
S61'-1 S6R5
~ ~
BATIERY /IJA
MAIN
:no.
BLOv..€R ,
--=-~ --- l
,-if-" , - - -i-< ' COll-~-.-,
~ $TAATER~ON:~=~~--~ , j-o' l ,'I PRESSURE
ON
- ~ I-+-+--J-o ' -
"--;=---- ---IF. - I, j-o·
1
,
Lr-: II L =-,=. ___ J
~N$ER FAN RELAY(3) r-;.;-l
~ ,"
rt---t-+o
--1 L.:::...J
1++--1+ ' o.I!-~~~ RELAY;

L j-o , THERMO
!-44---~' '
~ -"- -'---- ___ J
'-NV'--I\< • 0++---1--1 ~
_____ C -
_ _~
" ::- ,-------l,
G L---I~
+++----\-0 ' ojj-- - ,

1
,r- ~
.- -
,+-
ELECTRONIC
cardiagn.com
THERMOSTAT
FAASN. I~ 20+- - - ~
,: =-'-___
1:*1J !
I 2 0 0
l--'- 0 Off
- ~
L\----\-o~ , :: ----1
~
.
-::l r + - - -j-o , oll-o-o..J
I '
r0-1E
RELAY
1 0+-_-+_-"1 , ---~, _/1--",,,,,

1
Me
MAGNETIC "'II I'
COMPRESSOR
CLUTa-I ~ r IV"
- 0 rL~ -"-'
,
- ___ J
'
ECM(4)
~
~ L--_ECM($5)~
~ Ic.s51
•W ~
Ix-11 1
em
IX-14 1Ix-15 1
9 ~ I RTW710XF000501
TO MODEL INDEX
MAGNETIC CLUTCH DOES NOT RUN (4JJ1-TC Standard Output, 4JJ1-TC

High Output, 4JK1-TC High Output LHD MODEL)
(10A) fuses OK?
YES NO
• Are the A/C thermo (X-15), heater & A/C (X-11) and Replace
A/C compressor (X-14) relay OK?
YES NO
YES NO
cardiagn.com
refrigerant
YES NO
OK?
YES NO


NO YES

operate?


TO MODEL INDEX
YES NO
Open circuit between the engine

• Is there battery voltage between the engine room harness connector terminal No.1 (E-3)
harness connector terminal No.1 (X-14) and and the engine room harness
ground? connector terminal No.2 (X-14).
YES NO
harness connector terminal No.3 (X-14) and the
engine room harness connector terminal No.1 (X-
15)?
cardiagn.com
YES NO
YES NO
connector terminal No.4 (C-58) and the engine harness connector terminal No.55 (X-
YES NO
harness connector terminal No.2 (X-15) and harness connector terminal No. 4 (C-
ground? 58) and the engine room harness
YES NO
24)?
TO MODEL INDEX
YES NO
• Disconnect the condenser fan relay. Open circuit between the engine room
YES NO
room harness connector terminal NO.3 (C- fan relay No.3 (X-9) and the engine
4 (C-24).
cardiagn.com
NO

YES


(C-24)?
YES NO
YES NO
ground (C-109)? connector terminal No. 3 (C-55).
TO MODEL INDEX
YES NO
• Disconnect the A/C switch. Open circuit between the engine room
harness connector terminal No. 1 (C-55)
and ground (C-109).

YES NO
• Is the electronic thermostat OK? Open circuit between the No. EB-13 fuse
cardiagn.com
No. 6 (B-57)
YES NO

TO MODEL INDEX
C24SE
RELAY; HEATER
BATTE RY
SBF-1 SBF-8
30A
~ EB-13
100A
~IN BLOWER
10A
AlC ...-- -~
- ---l
r~-~ r-v
I
2 c> I
~
STARTERSW ~
1-01 I PRESSURE
I SW
c Lro --C;::,.- -=-

3 u-
4
I
o .~ 11
11-0
'-- =-L ___ J
I
(COOLER o~iY) CONDENSER FAN RELAY(3) ~

1 0 -I - - ...---
- ----l
ltec
2
I
5
10- f-
-o'+-o-~
I RELAY;
AlC SW
"----- 1-0 4 u-
I THERMO
~~
I
3 I
6 '-- =-'- ___ J

-------~ - ~
...-- -'(COGLER ONLYjl
B 4-
3
I
I
I
ELECTRONIC
r-~-
cardiagn.com
2 0- THERMOSTAT
I 1 I
I!
I
1 0- f-
FANSW
2 S'
Z
0
'-- =-'- ___ J
~
I 2 0 0
l___~_ OFF _
t:e
W
B
c5
0
~
...---
1
- ----l
I
rG--f' J
2 0- - RELAY
I
I
AlC
I
MAG COMPRESSOR
3 u-
"enG
CLU TCH
I
-=- ~f-o I
'-- =--
4
~ ___ J
~
ECM(14)~ C24SE
ECM(31) ECM(26) ECM(11)~ 6VE1
:~D
--
~ ~ SHORT
6VE1 C24SE
) CONNECTOR
~
6l%; I ~
~
RTW610XF000501
TO MODEL INDEX
MAGNETIC CLUTCH DOES NOT RUN (C24SE)

• Are the No. SBF 8 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES NO
• Are the A/C thermo (X-15), heater & A/C (X-11) Replace
and A/C compressor (X-14) relay OK?
YES NO
YES NO

refrigerant
cardiagn.com
YES NO
OK?
YES NO

• A/C switch and fan control knob (fan switch "ON")

NO YES

operate?


TO MODEL INDEX
YES NO
• Is there battery voltage between the engine room Open circuit between the engine harness
harness connector terminal No.1 (X-14) and connector terminal No.1 (E-2) and the
ground? engine room harness connector terminal
No.2 (X-14).
YES NO
• Is there battery voltage the engine room harness connector terminal No.1 (X-14).
connector terminal No.3 (X-14) and ground?
YES NO
• Disconnect the ECM harness connector. Open circuit between the No. EB-13
cardiagn.com
• Is there continuity between the ECM harness connector terminal No. 3 (X-14).
connector terminal C24SE No. 14 (C-56) and the
engine room harness connector terminal No.4
(X-14)?
YES NO
connector terminal C24SE No. 26 (C-56) and the harness connector terminal C24SE
engine room harness connector terminal No. 1 No.14 (C-56) and the engine room
(X-15)? harness connector terminal No. 4 (X-
14).
YES NO
harness connector terminal No. 2 (X-15) and harness connector terminal C24SE
ground? No. 26 (C-56) and the engine room
15).
YES NO
• Disconnect the pressure switch? Open circuit between the No. EB-13
24).
TO MODEL INDEX
YES NO
• Disconnect the condenser fan relay connector condenser Open circuit between the engine room
fan. harness connector terminal No.3 (X-15)
and the engine room harness connector
terminal No. 1 (C-24).
• Is there continuity between the relay terminal No. 3 (X-
10) and engine room harness connector terminal No.4
(C-24)?
YES NO
• Is there battery voltage between the engine room Open circuit between the condenser fan
harness connector terminal NO. 3 (C-24) and ground? relay No.3 (X-10) and engine room harness
cardiagn.com
NO
Open circuit between the No. EB-13 fuse

and engine room harness connector
YES NO
• Disconnect the pressure switch. Open circuit between the No. EB-13 fuse
• Is there continuity between the engine room harness terminal No. 2 (X-15).
connector terminal No. 4 (X-15) and the engine room
harness connector terminal No. 1 (C-24).
YES NO
• Connect the A/C thermo relay connector. Open circuit between the engine room
harness connector terminal No. 4 (X-15)
• Disconnect the electronic thermostat. and the engine room harness connector
• Is there continuity between the engine room harness
connector terminal No. 2 (C-55) and the engine room
harness connector terminal No. 2 (C-24)?
TO MODEL INDEX
YES NO
• Is there battery voltage between the engine room Open circuit between the engine room
harness connector terminal No. 3 (C-55) and ground? harness connector terminal No. 2 (C-24)
YES NO
• Is there continuity between the engine room harness Open circuit between the No. EB-13 fuse
connector terminal No. 1 (C-55) and ground (C-109)? and the engine room harness connector
cardiagn.com
YES NO
• Disconnect the A/C switch. Open circuit between the engine room
harness connector No. 1 (C-55) and ground
(C-109).
YES NO
• Is the electronic themostat OK? Open circuit between the No. EB-13 fuse
No. 6 (B-57).
YES NO

TO MODEL INDEX
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME
5-8840-0629-0
(J-39500-A)
5-8840-0630-0
(J-39500-220A)
5-8840-0631-0
(J-39500-220ANZ)
cardiagn.com
5-8840-4056-0
(J-37872) Drive plate holder
5-8840-0121-0
(J-33943) Clutch pulley puller pilot
5-8840-0111-0
(J-8433) Clutch pulley puller
5-8840-0118-0
(J-33940) Clutch pulley installer
5-8840-0007-0
(J-8092) Driver handle

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BACK TO MAIN INDEX ISUZU KB P190 2007

COMPONENTS (CHASSIS SIDE)

(C24SE RHD MODEL)

Refrigerant liquid line

Refrigerant discharge line

(4JA1-T, 4JH1-TC LHD MODEL)

Refrigerant discharge line

Refrigerant discharge line

Refrigerant suction line Evaporator

Refrigerant suction line

(C24SE LHD MODEL)

COMPONENTS (INSIDE CAB)

Vent duct assist side

Center vent duct

Heater unit or Vent unit

Rear heater duct

Control lever assembly

This illustration is based on RHD model

VENT MODE BI-LEVEL MODE FOOT MODE

TO DEF OUTLET TO DEF OUTLET

~ : TEMP CONTROLLED AIR

DEF/FOOT MODE DEF MODE

RTW710MF000601 & RTW410MF000301

WIRING DIAGRAM (4JA1-T)

VSoI fICO DIODE

'J.1 di"~ ~I ':~ll[p "

$ 158I'~1_ ISBFe I XlO.

C24SE (A/C WITH HEATER)

'" '" RESIS TER

~8~ 'rt.;,--------,-;S-' 0.'

C24SE (COOLER WITHOUT HEATER)

CONNECTOR LOCATION (RHD MODEL)

MAIN DATA AND SPECIFICATIONS

HEATING UNIT (VENT UNIT)

(Dual pressure switch)

(Triple pressure switch)

Idle speed controlled by solenoid switch (4JA1-T only)

SPECIAL PARTS FIXING NUTS AND BOLTS

(4JA1-T RHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)

(C24SE RHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)

(4JA1-T, 4JH1-TC LHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)

(C24SE LHD MODEL) N⋅⋅m (kgf⋅⋅m/lb⋅⋅in)

REPAIR OF REFRIGERANT LEAKS

When connecting the refrigerant line at the block joint, securely

O-rings must be closely aligned with raised portion of

Insert nut into union. First tighten nut by hand as much as

LEAK AT REFRIGERANT LINE

LEAK IN THE HOSE

RECOVERY, RECYCLING, EVACUATION

EVACUATION OF THE REFRIGERANT

CHARGING THE REFRIGERANT SYSTEM

• Direct charging with a manifold gauge charging

8) Charge the system to the specified amount and then close

9) Check for refrigerant leaks by using a HFC-134a leak

Reading Sight Glass

REMOVAL AND INSTALLATION (4JH1-TC, 4JJ1-TC Standard Output)

Removal Steps Installation Steps

Removal Steps Installation Steps

REMOVAL AND INSTALLATION (C24SE)

Removal Steps Installation Steps

CONDENSER FAN MOTOR

REMOVAL AND INSTALLATION

Removal Steps Installation Steps