charging ISUZU TROOPER 1998 Service Repair Manual

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
6VD1 / 6VE1
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D1 ENGINE ELECTRICAL
6D2 IGNITION SYSTEM
6D3 STARTING AND CHARGING SYSTEM
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL SYSTEM
6J INDUCTION

GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle.
2. Use covers on the vehicle body, seats, and
floor to prevent damage and/or
contaminations.
3. Disconnect the grounding cable from the
battery before performing service operations.
This will prevent cable damage or burning due
to shortcircuiting.
4. Raise the vehicle with a jack set against the
recommended lifting points (see ÒLifting
instructionsÓ in this section).
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.
7. The use of the proper tool(s) and special tool(s)
where specified is essential to efficient,
reliable, and safe service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, plastic clips,
O-rings, oil seals, lock washers, and self-
locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct
reassembly.11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and
design according to installation positions.
12. Clean all parts before inspection or
reassembly.
13. Clean the oil ports and other openings with
compressed air to make certain that they are
free of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
installation.
15. Use the recommended liquid gasket to prevent
leakage.
16. Carefully observe all nut and bolt torque
specifications.
17. When service operation is completed, make a
final check to be sure service has been done
properly and problem has been corrected.
18. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the
following tools to recover and recycle the
Refrigerant-134a (R-134a).
For 134a:
Use the R-134a Refrigerant Recovery/Recovery/
Recycling/Recharging/System (ACR
4) or its
equivalent to prevent the discharge of
refrigerant into the air.
0AÐ2 GENERAL INFORMATION

SERVICE INFORMATION 00 Ð 23
AIR CONDITIONING CYCLE TROUBLESHOOTING
No cooling or insuffi-
cient cooling
Insufficient velocity
of cooling air1. Magnetic clutch does not run
2. Compressor is not rotating properly
·Drive belt loosened or broken
·Magnetic clutch face is not
clean and slips
·Incorrect clearance between
magnetic drive plate and pulley
·Compressor oil leaks from shaft
seal or shell
·Compressor seized
3. Insufficient or excessive charge of
refrigerant
4. Leaks in the refrigerant system
5. Condenser clogged or insufficient
radiation
6. Temperature control link unit of the
heater unit defective
7. Unsteady operation due to foreign
substance in expansion valve
8. Poor operation of electronic thermo-
stat
1. Evaporator clogged or frosted
2. Air leaking from cooling unit or air
duct
3. Blower motor does not rotate prop-
erly·Refer to ÒMAGNETIC CLUTCHÓ
troubleshooting
·Adjust the drive belt to the specified
tension or replace the drive belt
·Clean the magnetic clutch face or
replace
·Adjust the clearance (Refer to
Section 1D ÒCOMPRESSOR OVER-
HAULÓ
·Replace the compressor
·Replace the compressor
·Discharge and recover refrigerant.
Recharge to specified amount.
·Check refrigerant system for leaks
and repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
·Clean the condenser or replace as
necessary
·Check radiator or condenser fan
function
·Repair the link unit
·Replace the expansion valve
·Check electronic thermostat and
replace as necessary
·Check evaporator core and replace
or clean the core
·Check evaporator and duct connec-
tion, then repair as necessary
·Refer to Section 00 for ÒFAN
CONTROL KNOB (FAN SWITCH)Ó
troubleshooting
* For the execution of the charging and discharging operation in the table above, refer to the ÒRECOVERY,
RECYCLING, EVACUATING AND CHARGINGÓ in section 1B.
TROUBLEPOSSIBLE CAUSECORRECTION

RESULT SYMPTOM TROUBLE CAUSE CORRECTION
SERVICE INFORMATION 00 Ð 25
Reduced or no air flow through
the condenser
No bubbles in sight glass when
condenser is cooled by water
(Insufficient cooling)
After stopping air conditioning,
pressure drops approx. 196 kPa
(28 PSI) quickly
Insufficient cooling and excessive
bubbles in the sight glass
Low pressure gauge indicates
vacuum
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pres-
sure gauge indicates vacuum
After turning off air conditioning,
high and low pressure gauge
balanced quickly
Low pressure gauge is lowered
after condenser is cooled by
water
Low pressure hose temperature
around the compressor refriger-
ant line connector is lower than
around evaporator
After turning off air conditioning,
high and low pressure gauge is
balanced quickly
Air conditioning turns off before
passenger compartment is suffi-
ciently cool·Condenser clogged or dirty
·Radiator (condenser) fan
does not operate properly
·Excessive refrigerant in
system
·Air in system
·Insufficient refrigerant in
system
·Clogged or defective expan-
sion valve
·Restriction caused by debris
or moisture in receiver/drier
·Compressor seal defective
·Poor compression due to
defective compressor gasket
·Excessive refrigerant in
system
·Unsatisfactory valve opera-
tion due to defective temper-
ature sensor of expansion
valve
·Expansion valve opens too
long
·Compressor gasket is defec-
tive
·Electronic thermostat defec-
tive·Clean
·Check cooling fan
operation
·Check sight glass.
(See ÒReading Sight
GlassÓ)
·Discharge and
recover refrigerant.
Recharge to speci-
fied amount
·Evacuate and
charge refrigerant
system
·Check sight glass.
(See ÒReading Sight
GlassÓ)
·Check for leaks
·Discharge and
recover refrigerant.
Recharge to speci-
fied amount
·Replace the expan-
sion valve
·Check system for
restriction and
replace
receiver/drier
·Replace or repair
compressor
·Discharge and
recover refrigerant
Recharge to speci-
fied amount
·Replace the expan-
sion valve
·Replace
·Check the electronic
thermostat and
replace as neces-
saryDischarge
(High) pres-
sure gauge
abnormally
high
Discharge
(High) pres-
sure gauge
abnormally
low
Suction
(Low) pres-
sure gauge
abnormally
high
* For the charging and discharging operations in the table above, refer to ÒRECOVERY, RECYCLING,
EVACUATION AND CHARGINGÓ in this section.

00 Ð 52 SERVICE INFORMATION
HFC-134a
SPECIAL TOOLS
ILLUSTRATION PARTS NO. PARTS NAME
5-8840-0629-0
ACR
4(115V 60Hz)
(J-39500-A)
5-8840-0630-0
ACR
4(220-240V 50/60Hz)
(J-39500-220A)
5-8840-0631-0 ACR
4(220-240V 50/60Hz
(J-39500-220ANZ) Australian model)
ACR
4: HFC-134a Refrigerant Recovery / Recycling
/Recharging / System

AIR CONDITIONING 1B Ð 7
EVAPORATOR
The evaporator cools and dehumidifies the air
before the air enters the vehicle. High-pressure
liquid refrigerant flows through the expansion valve
(1) into the low-pressure area of the evaporator (2).
The heat in the air passing through the evaporator
core is lost to the cooler surface of the core, thereby
cooling the air.
As heat is lost between the air and the evaporator
core surface, moisture in the vehicle condenses on
the outside surface of the evaporator core and is
drained off as water.
When the evaporator malfunctions, the trouble will
show up as inadequate supply of cool air. The
cause is typically a partially plugged core due to
dirt, or a malfunctioning blower motor.
The evaporator core with a laminate louver fin is a
single-sided tank type where only one tank is
provided under the core.
ELECTRONIC THERMOSTAT
The thermostat consists of the thermosensor (1)
and thermostat unit (4) which functions electrically
to reduce the noises being generated while the
system is in operation.
The electronic thermosensor (1) is mounted at the
evaporator core (2) outlet and senses the
temperature of the cool air from the evaporator (3).
Temperature signals are input to the thermostat
unit. This information is compared by the thermo
unit and the results in output to operate the A/C
Thermostat relay and turn the magnetic clutch
ÒONÓ or ÒOFFÓ to prevent evaporator freeze-up.
A characteristic of the sensor is that the resistance
decreases as the temperature increases and the
resistance increases as the temperature decreases.
REFRIGERANT LINE
Restrictions in the refrigerant line will be indicated by:
1. Suction line; A restricted suction line will cause
low suction pressure at the compressor, low
discharge pressure and little or not cooling.
2. Discharge line; A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line; A liquid line restriction will be
evidenced by low discharge and suction
pressure and insufficient cooling.
Refrigerant flexible hoses that have a low
permeability to refrigerant and moisture are used.
These low permeability hoses have a special nylon
layer on the inside.
SERVICE CHARGE VALVES
The charging hoses have a quick-joint type fitting,
to reduce refrigerant loss during removal and
installation.
12
3
4
Reinforcement layer(Polyester) Resin layer(Nylon)
Internal rubber layer
External rubber layer
1
2
874RY00003874RX022

AIR CONDITIONING 1B Ð 13
ACR41) Using the ACR4(HFC-134a Refrigerant Recovery/
Recycling/ Recharging/ System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(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.
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF
AIR CONDITIONING PARTS
There are certain procedure, 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.
·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:
ON-VEHICLE SERVICE

AIR CONDITIONING 1B Ð 15
COMPRESSOR LEAKS
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
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).
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
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.

1B Ð 16 AIR CONDITIONING
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 ACR4(HFC-134a Refrigerant Recovery/ Recycling/
Recharging/ System) or equivalent before removing or
mounting air conditioning parts.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
1) Connect the high and low charging hoses of the ACR
4
(or equivalent) as shown
2) Recover the refrigerant by following the ACR4
ManufactureÕs Instructions.
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.
ACR4
(Low side) (High side)
HFC 134a
REFRIGERANT RECYCLING
Recycle the refrigerant recovered by ACR4or equivalent.
For the details of the actual operation, follow the steps in
the ACR
4ManufactureÕs Instructions.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)

AIR CONDITIONING 1B Ð 17
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 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. Air and moisture in the refrigerant will cause problems in
the air conditioning system.
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) Ð Discharge-side
·Low-pressure valve (LOW) Ð 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 open both hand valves.
5) When the low-pressure gauge indicates approx. 750
mmHg (30 inHg), continue the evacuation for 5
minutes or more.
6) Close both hand valves and stop the vacuum pump.
EVACUATION OF THE REFRIGERANT SYSTEM
NOTE:
Explained below is a method using a vacuum pump. Refer
to ACR
4(or equivalent) manufactureÕs instructions when
evacuating the system with ACR4(or equivalent)
(Low side) (High side)