service ISUZU TROOPER 1995 Owner's Manual

COMPRESSOR OVERHAUL 1 D - 1
SECTION 10
COMPRESSOR OVERHAUL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . 1 D-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D-2
General Information . . . . . . . . . . . . . . . . . . . . 1 D-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . 1 D-3
Service Procedures . . . . . . . . . . . . . . . . . . . . . 1D-5
Magnetic Clutch Assembly . . . . . . . . . . . . . 1 D-5
Main Data and Specifications . . . . . . . . . . . . . 1 D-8
General Specifications . . . . . . . . . . . . . . . . . 1 D-8
Torque Specifications . . . . . . . . . . . . . . . . . 1 D-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9
GENERAL DESCRIPTION
When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor
parts and system. Clean tools and a clean work area
are
important for proper service. The compressor
connections and the outside of the compressor
should be cleaned before any "On-Vehicle" repair,
or before removal of the compressor. The parts must
be kept clean at all times and any parts to be
reassembled
should be cleaned with Trichloro­
ethane, naphtha, kerosene, or equivalent solvent,
and
dried with dry air. Use only lint free cloths to
wipe parts.
The
operations described below are based on bench
overhaul
with compressor removed from the
vehicle, except as noted. They have been prepared
in
order of accessibility of the components. When
the compressor is removed from the vehicle for
servicing, the oil remaining in the compressor
should be discarded and new compressor oil added
to the compressor.
Magnetic clutch assembly repair procedures require
that the system be discharged of refrigerant. (Refer
to Section 1 B for "REFRIGERANT RECOVERY".)
Compressor malfunction will appear in one of four
ways: noise, seizure, leakage or low discharge
pressure. Resonant
compressor noises are not
cause for alarm; however, irregular noise or rattles
may indicate broken parts or excessive clearances
due to wear. To check seizure, de-energize the
magnetic clutch and check to see if the drive plate
can be rotated.
If rotation is impossible, the com­
pressor is seized. Low discharge pressure may be
due to a faulty internal seal of the compressor, or a
restriction in the compressor.
Low discharge pres­
sure
may also be due to an insufficient refrigerant
charge
or a restriction elsewhere in the system.
These possibilities
should be checked prior to
servicing the compressor. If the compressor is
inoperative,
but is not seized, check to see if current
is being supplied to the magnetic clutch coil
terminals.
This vehicle is equipped with five-vane rotary com­
pressor.
The
compressor has vanes built into a rotor which is
mounted on a shaft.
When the shaft rotates, the vanes built into the
cylinder block assembly are opened by centrifugal
force.
This changes the volume of the space formed by the
rotor and cylinder, resulting in the intake and
compression of the refrigerant gas. The discharge
valve and the
valve stopper, which protects the
discharge valve, are
built into the cylinder block
assembly. There is no suction valve but a shaft seal
is
installed between the shaft and head; a trigger
valve, which applies back pressure to the vanes, is
installed in the cylinder block and a refrigerant gas
temperature sensor is installed in the front head.
The specified
quantity of compressor oil is contained
in
the compressor to lubricate the various parts
using
the refrigerant gas discharge pressure.
The thermo sensor is installed to the front head of
the compressor to protect it by stopping its
operation when the refrigerant gas is insufficient or
when the temperature get abnormally high.
•OFF ..... 160 ±soc (320.0 ± 9.0°F)
•ON ..... 135 ±soc (275.0 ± 9.0°F)
The oil used in the HFC-134a system compressor
differs from that used in R-12 systems.
Also, compressor
oil to be used varies according to
the compressor model. Be sure to avoid mixing two
or more different types of oil.
If the wrong oil is used, lubrication will be poor and
the compressor will seize or malfunction.
The specified
amount of the compressor oil is
150cc (5.0 fl.oz.).

COMPRESSOR OVERHAUL 10-3
GENERAL INFORMATION
COMPRESSOR OIL
OIL SPECIFICATION
• The HFC-134a system requires a synthetic
(PAG) compressor oil whereas the R-12 system
requires a
mineral compressor oil. The two oils
must never be mixed.
• Compressor (PAG) oil varies according to com­
pressor model. Be sure to use oil specified for
the model of compressor.
• Always use HFC-134a Vane Rotary Type Com­
pressor Oil
(AIPDN Part No. 2-90188-301-0)
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.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)
•
The compressor oil must be stored in steel
containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is circul­
ating 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 system 150cc (5.0 fl.oz.)
Compressor (Service
parts)
charging amount 15 0cc (5
·0
fl.oz.)
Checking and Adjusting for Used Compressor
1. Perform Oil return operation.
(Refer to "Oil Return Operation" in this section.)
2. Discharge and recover refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the
extracted oil with a measuring cylinder (Fig. 1 D-
2).
Fig. 1D-2
4. If the amount of oil drained is much less than
90cc (3.0 fl.oz.), some refrigerant may have
leaked out. Conduct leak tests on connections of
each system, and if necessary, repair or replace
faulty parts.
5. Check the compressor oil for contamination.
(Refer to "Contamination of Compressor Oil" in
this section.)
6. Adjust oil level following the procedure below
(Fig. 1 D-3).
Collected Amount
more than 90cc
(3.0 fl.oz.)
Charging Amount
same as collected amount
less than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
7. Install the compressor, then evacuate, charge
and
perform oil return operation.
8. Check system operation.
When it is impossible to perform oil return oper­
ation, the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove
the compressor.
2. Drain the compressor oil and measure the
extracted oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90cc (3.0 fl.oz.) of oil is extracted
from the compressor, supply same amount of
oil to the compressor to be installed.
If
the amount of oil extracted is less than 90cc
(3.0 fl.oz.),
recheck the compressor oil in the
following order:
5. Supply 90cc (3.0 fl.oz.) of oil to the compressor
and install it onto the vehicle.

1 D-4 COMPRESSOR OVERHAUL
6. Perform oil return operation.
7. Remove the compressor and recheck the
amount of oil.
8. Adjust the compressor oil, if necessary.
Collected Amount
more than 90cc
(3.0
fl.oz.)
Charging Amount
same as collected amount
less than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
Checking and Adjusting for Compressor
Replacement
150cc (5.0 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 and recover refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the
extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust oil level as required.
Amount of oil drained
from used compressor
less than 90cc
(3.0
fl.oz.)
Draining amount of oil
from new compressor
Same as drained
amount
more than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
6. Evacuate, charge and perform oil return oper­
ation.
7. Check system operation.
CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor
oil. Even if 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 com­
pressor
oil is discovered, the receiver/dryer must
be
replaced.
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 com­
pressor
must be run in advance for oil return oper­
ation. The procedure is as
follows:
1. Open the all doors and engine hood.
2. Start the engine and air conditioning switch is
"ON" and Set the fan control knob at its hig­
hest position.
3. Run the compressor for more than 20 minutes
between
800 and 1,000 rpm in order to operate
the system.
4. Stop the engine.
REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply
the following
amount of oil to the component parts
to be installed.
Component parts to be installed Amount of oil
Evaporator 50cc
(1.7
fl.oz.)
Condenser 30cc
(1.0 fl.oz.)
Receiver/dryer 30cc
(1.0 fl.oz.)
Refrigerant line (one piece) 1 Occ (0.3 fl. oz.)
Fig. 1 D-3
•

COMPRESSOR OVERHAUL 1 D-5
SERVICE PROCEDURE
MAGNETIC CLUTCH ASSEMBL V
2
Fig. 10-4
1••1 REMOVAL
1. Drive plate bolt
liC\1 • Using drive plate holder (J-33939) to prevent
~ the drive plate from rotating, then remove
the drive
plate bolt (Fig. 1 0-5).
2. Drive plate
liC\1 • Using drive plate puller (J-33944-A) and
~ forcing screw (J-33944-4) to remove the
drive
plate (Fig. 1 0-6).
3. Shim(s)
4. Snap ring
• Using snap ring pliers to remove the snap
ring (Fig 10-7).
5. Pulley assembly
liC\1 • Using pulley puller pilot (J-38424), pulley
~ puller (J-8433) and pulley puller leg
(J-24092) to remove the pulley assembly
(Fig. 1 0-8).
6. Lead wire connector
• Loosen screw and disconnect the coil lead
wire connector (Fig. 1 0-9).
7. Field coil
• Loosen three screws and remove the field
coil
(Fig. 10-1 0). Removal
steps
1. Drive
plate bolt
2. Drive plate 3. Shim(s)
4. Snap ring
5. Pulley assembly
6. Lead wire connector
7. Field
coil
Installation
steps
To install, follow the removal
steps in the reverse order.
J-33939
Fig. 1 D-5
Fig. 1 D-6

BUMPERS 28-1
SECTION 28
BUMPERS
NOTE:
Fasteners are important attaching parts in that they could affect the performance of vital components and
systems,
and/or could result in major repair expense. They must be replaced with one ofthe same part number
or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser or
substitute design. Torque values must be used as specified during reassembly to assure proper retention of
these parts. Refer to Torque Value Chart in the general information of Section "OA".
CONTENTS
General Description ................................ 2B-1 Front Bumper ....................................... 2B-2
On-Vehicle Service ................................. 2B-2
Rear Bumper ........................................ 2B-4
GENERAL DESCRIPTION
This section describes how to remove and install front
and rear bumpers. Each bumper is installed with two
fixing bolts used on either side to fasten backbar to
the frame, a slider is used to fasten the bumper fascia
tothe fender panel. The bumpers can be removed by
taking them out forward or backward after removing
the two fixing bolts on either side.

28-2 BUMPERS
FRONT BUMPER
ON-VEHICLE SERVICE
Removal steps 1. Front fog llght connector 2. Front bumper fixing bolts 3. Front bumper assembly 4. Front fog light garnish
5. Bumper fascia lower bolts 6. Front bumper retainer 7. Reinforce lower bolt 8. Reinforce assembly
9. Back bar fixing bolt
10. Front fog light assembly 11. Front bumper slider
Fig. 2B-1
Installation steps To install, follow the removal steps in the reverse order.
•

SHEET METAL 2C-1
SECTION 2C
SHEET METAL
NOTE:
Fasteners are important attaching parts in that they could affect the performance of vital components and
systems,
and/or could result in major repair expense. They must be replaced with one of the same part number or
with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly to assure proper retention of these
parts. Refer
to Torque Value Chart in the general information of Section "OA".
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . 2C-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 2C-2
Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Engine Hood Hinge . . . . . . . . . . . . . . . . . . 2C-4
Engine Hood Lock .................... 2C-5
Radiator Grill and Front end
Lower Panel
....................... 2C-6
Front Fender Panel ................... 2C-7
Body Mounting ...................... 2C-9
GENERAL DESCRIPTION
This section includes items of front end sheet metal
that are attached by bolts, screws
or clips and related
accessory components.
Anti-corrosion materials have been applied to the
interior surfaces
of some metal panels to provide rust resistance.
When servicing these panels, areas on
which this material has been disturbed should
be
properly recoated with service-type anti-corrosion
material.

2C-2 SHEET METAL
COWL COVER
Removal steps
1. Front wiper arms
2.
Cowl cover brackets 3. Cowl cover
4. Cowl cover seals 5. Front window lower molding 6. Cowl cover stoppers
Installation steps
To install, follow the removal steps in the reverse order.
ON-VEHICLE SERVICE
4
Fig. 2C-1
•

FRONT END ALIGNMENT 3A-1
SECTION3A
FRONT END ALIGNMENT
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were removed. If
a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out. The correcttorque value
must be used when installing fasteners that require it. If the above conditions are not followed, parts or
system damage could result.
CONTENTS
General Description ................................ 3A-1
Camber Adjustment ............................. 3A-4
Definition of Terms .............................. 3A·2 Toe-in Adjustment ............................... 3A-5
On-Vehicle Service ................................. 3A-3 Maximum Steering Angle Adjustment ....... 3A-5
Inspection ......................................... 3A-3 Main Data and Specifications ..................... 3A-6
Trim Height Adjustment ........................ 3A-3 General Specifications .......................... 3A-6
Caster
Adjustment ............................... 3A-3 Torque Specifications ........................... 3A-6
GENERAL DESCRIPTION
"Front End Alignment" refers to the angular
relationship between the front wheels, the front
suspension attaching parts and the ground.
Proper front end alignment must be maintained in
order to insure efficient steering, good directional
stability and to prevent abnormal tire wear.
The
most important factors of front end alignment are
wheel toe-in, wheel camber and axle caster.

FRONT END ALIGNMENT 3A-3
ON-VEHICLE SERVICE
INSPECTION
Before making any adjustments affecting caster,
camber or toe-in, the following front end inspection
should be made.
I L•IINSPECT
1. Tires for proper inflation pressure. Refer to
"Wheels and Tires" in section 3E.
2. Front wheel bearings for proper adjustment.
Refer to "Front Wheel Drive" in section 4C.
3. Ball joints, tie rod ends and relay rods. If
excessive looseness is noted, correct before
adjusting. Refer
to "Steering Linkage" in section
3B3.
4. Wheel and tires for run-out. Refer to "Wheels
and Tires" in section 3E.
5. Trim height. If not within specifications, the
correction
must be made before adjusting caster.
6. Steering gear for looseness at the frame.
7. Shock absorbers for leaks or any noticeable
noise.
Refer
to "Front Suspension" in section 3C.
8. Control arms or stabilizer bar attachment for
looseness. Refer to "Front Suspension" in section
3C.
9. Alignment equipment. Follow the manufacturer's
instructions.
10. Level of the vehicle. The vehicle must be on a
level surface.
TRIM HEIGHT ADJUSTMENT
Adjust the trim height by means of the adjusting bolt
on the height control arms (Fig. 3A-4 and 5).
W CAUTION:
When adjusting front end alignment, be sure to
begin with trim height as trim height adjustment
may change other adjusted alignments.
1. Check and adjust the tire inflation pressures.
2. Park the vehicle on a level ground and move the
front of the vehicle up and down several times to
settle the suspension.
3. Make necessary adjustment with the adjusting
bolt on the height control arms.
WHEEL
ALIGNMENT SPECIFICATION
Trim height (Z) 129 mm (5.08 in)
Lower
ball joint
B
Fig. 3A-4
Fig. 3A-5
CASTER ADJUSTMENT
Level ground
The caster angle can be adjusted by means of the
caster shims installed between the chassis frame and
fulcrum pins (Fig. 3A-6 and 7).
WHEEL
ALIGNMENT SPECIFICATION
LWB
Caster angle
SWB
W CAUTION:
Left and right side to be equal within 30'
NOTE:
Difference of the caster shim front/rear thickness shall
be 3.6
mm (0.142 in) or less. Overall thickness of caster
shim and camber shim shall be 10.8 mm (0.425 in) or
less.