compression ratio ISUZU TROOPER 1998 Service Repair Manual

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.

1B Ð 4 AIR CONDITIONING
The refrigeration cycle includes the following four
processes as the refrigerant changes repeatedly
from liquid to gas and back to liquid while
circulating.
EVAPORATION
The refrigerant is changed from a liquid to a gas
inside the evaporator. The refrigerant mist that
enters the evaporator vaporizes readily. The liquid
refrigerant removes the required quantity of heat
(latent heat of vaporization) from the air around the
evaporator core cooling fins and rapidly vaporizes.
Removing the heat cools the air, which is then
radiated from the fins and lowers the temperature
of the air inside the vehicle.
The refrigerant liquid sent from the expansion valve
and the vaporized refrigerant gas are both present
inside the evaporator and the liquid is converted to
gas.
With this change from liquid to gas, the pressure
inside the evaporator must be kept low enough for
vaporization to occur at a lower temperature.
Because of that, the vaporized refrigerant is sucked
into the compressor.
COMPRESSION
The refrigerant is compressed by the compressor
until it is easily liquefied at normal temperature.
The vaporized refrigerant in the evaporator is
sucked into the compressor. This action maintains
the refrigerant inside the evaporator at a low
pressure so that it can easily vaporize, even at low
temperatures close to 0¡C (32¡F).
Also, the refrigerant sucked into the compressor is
compressed inside the cylinder to increase the
pressure and temperature to values such that the
refrigerant can easily liquefy at normal ambient
temperatures.
CONDENSATION
The refrigerant inside the condenser is cooled by
the outside air and changes from gas to liquid.
The high temperature, high pressure gas coming
from the compressor is cooled and liquefied by the
condenser with outside air and accumulated in the
receiver/drier. The heat radiated to the outside air
by the high temperature, high pressure gas in the
compressor is called heat of condensation. This is
the total quantity of heat (heat of vaporization) the
refrigerant removes from the vehicle interior via the
evaporator and the work (calculated as the quantity
of heat) performed for compression.
EXPANSION
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize.
The process of lowering the pressure to encourage
vaporization before the liquefied refrigerant is sent
to the evaporator is called expansion. In addition,
the expansion valve controls the flow rate of the
refrigerant liquid while decreasing the pressure.
That is, the quantity of refrigerant liquid vaporized
inside the evaporator is determined by the quantity
of heat which must be removed at a prescribed
vaporization temperature. It is important that the
quantity of refrigerant be controlled to exactly the
right value.
COMPRESSOR
The compressor performs two main functions:
It compresses low-pressure and low-temperature
refrigerant vapor from the evaporator into high-
pressure and high-temperature refrigerant vapor to
the condenser. And it pumps refrigerant and
refrigerant oil through the A/C system.
6VD1/6VE1 engine on RHD model is equipped with
an invariable capacity five-vane rotary compressor
(DKV-14D Type).
The compressor sucks and compresses refrigerant
by the rotation of the vane installed to the shaft,
and always discharges a fixed amount of refrigerant
independent of the load of refrigerant.
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 is abnormally high.
·OFF ....... 160 ±5¡C (320.0 ±41¡F)
·ON ........ 135 ±5¡C (275.0 ±41¡F)
Diesel Engine models and 6VD1/6VE1 engine on
LHD model are equipped with a swash plate type
compressor
Swash plate compressors have a swash (slanted)
plate mounted on the shaft. When the shaft turns,
the rotation of the swash plate is converted to
reciprocating piston motion which sucks in and
compresses the refrigerant gas.
Shaft seal (Lip type) is installed between the valve
plate and shaft & cylinder head to prevent
refrigerant gas leaks. A specified amount of
compressor oil is contained in the oil pan.
This oil is supplied to the cylinders, bearings, etc.,
by an oil pump which is connected to the swash
plate shaft.

COMPRESSOR OVERHAUL 1D Ð 3
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
car, except as noted. They have been prepared in
order of accessibility of the components. When the
compressor is removed from the car for servicing,
the oil remaining in the compressor should be
discarded and new refrigerant oil added to the
compressor.
Magnetic clutch assembly repair procedures require
that the system be discharged of refrigerant. (Refer
to Section 1B for ÒREFRIGERANT RECOVERYÓ.)
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
compressor is seized. Low discharge pressure may
be due to a faulty internal seal of the compressor,
or a restriction in the compressor. Low discharge
pressure 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.
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.
6VD1 engine is equipped with an invariable
capacity five-vane rotary compressor (DKV-14D
Type).
The compressor sucks and compresses refrigerant
by the rotation of the vane installed to the shaft,
and always discharges a fixed amount of refrigerant
independent of the load of refrigerant.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 ±5¡C (320.0 ±9.0¡F)
·ON ..... 135 ±5¡C (275.0 ±9.0¡F)
4JG2 Engine are provided with a swash plate type
compressor (DKS-15CH Type)
Swash plate compressors have a swash (slanted)
plate mounted on the shaft. When the shaft turns,
the rotation of the swash plate is converted to
reciprocating piston motion which sucks in and
compresses the refrigerant gas.
Shaft seal (Lip type) is installed between the valve
plate and shaft & cylinder head to prevent
refrigerant gas leaks. A specified amount of
compressor oil is contained in the oil pan.
This oil is supplied to the cylinders, bearings, etc.,
by an oil pump which is connected to the swash
plate shaft.
With some compressors the differential between
the intake pressure and discharge pressure
generated while the compressor is operating is
used for lubrication instead of an oil pump.
Three pistons are arranged at 120g intervals around
the center of the swash plate shaft. These pistons
are connected to the ends of the swash plate
through shoe disks and balls.
The rotation of the swash plate causes
reciprocating movement of the piston inside the
cylinders, with each piston operating as two
cylinders. Because of that, the compressor operates
as though it has 6 cylinders.
The specified amount of the compressors oil is
150cc (4.2 Imp fl oz).
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.

5A±39 BRAKE CONTROL SYSTEM
Diagnostic Trouble Codes
Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
ItemDiagnosisChart No.
12Start CodeNormalÐ
14EHCU FunctionAbnormality in input/output, operational and
control circuitsB-2
15Power Voltage DropB-3
16CLASS±2 Communication Line Ab-
normalityB-4
21G-sensorWiring disconnectionB-5
23Transmission InputInput abnormalityB-6
24Transfer MonitorB-7
32Motor & Motor RelayShorted or disconnected coilB-8
35Valve RelayShorted or disconnected coil/wiringB-9
41FL Holding Solenoid ValveShorted or disconnected coil/wiringB-10
42FL Decompression Solenoid ValveShorted or disconnected coil/wiringB-11
43FR Holding Solenoid ValveShorted or disconnected coil/wiringB-12
44FR Decompression Solenoid ValveShorted or disconnected coil/wiringB-13
45Rear Holding Solenoid ValveShorted or disconnected coil/wiringB-14
46Rear Decompression Solenoid ValveShorted or disconnected coil/wiringB-15
51FL Wheel Speed SensorDisconnected coil/wiringB-16
52FR Wheel Speed SensorDisconnected coil/wiringB-17
53RL Wheel Speed SensorDisconnected coil/wiringB-18
54RR Wheel Speed SensorDisconnected coil/wiringB-19
61FL Wheel Speed SensorShorted coil/wiringB-20
62FR Wheel Speed SensorShorted coil/wiringB-21
63RL Wheel Speed SensorShorted coil/wiringB-22
64RR Wheel Speed SensorShorted coil/wiringB-23
65Sensor Signal InputWrong number of teethB-24

POWER ASSISTED BRAKE SYSTEM 5C – 31
•Operation
1) Outline
When the L.S.P.V. (Load Sensing Proportioning
Valve) detects a change in load weight, the load
sensing lever moves. Its reaction force is
transmitted to the bottom of the load sensing
valve to secure an optimum rear wheel cylinder
fluid pressure break point in proportion to the
actual load weight.
Besides, if the front brake system should fail, the
devices is designed to prevent the master cylinder
fluid pressure from decreasing and to apply it
directly to the rear wheel cylinder to obtain a
sufficient braking performance.
From rear
master cylinder
2) Operation
(1) When the fluid pressure is under the break point.
The fluid pressure of the rear master cylinder
passes through a clearance between the valve
seal and the piston and acts on the rear wheel
cylinder. At this moment, a downward force is
applied to the piston. However, the compression
spring force and reaction force of the load sensing
lever keep the piston in the upper position by
pushing upwards. (See the left figure.)To rear
wheel cylinder
(2) When the fluid pressure is equal to the break
point.
As the rear wheel cylinder pressure increases, it
surpasses the compression spring force and
reaction force of the load sensing lever, causing
the pistion to move downwards, so that the
pistion butts against the valve seal to shut off the
fluid line between the master cylinder and rear
wheel cylinder. (See the left figure.)
(3) When the fluid pressure is over the break point.
When the fluid pressure increases further, the
piston moves upwards. The moment the piston
comes apart from the valve seal, fluid pressure is
applied to the rear wheel cylinder and the piston
moves downwards so that the fluid line is shut off
again. This process goes on repeatedly to control
the fluid pressure to the rear wheel cylinder.
C05RW024 C05RW021 C05RW025

6A±3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.

A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.

Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.

At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.

Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:

When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick±up unit.

The 12±volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.

Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die±cast casting
for 75
V±type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent±roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V±type design. The ports are cross±flow
type.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast±iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid±type oil pump driven by
the crankshaft is fed through full±flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A±79
ENGINE MECHANICAL
015RV014The size mark (1) for piston outside diameter is
represented as shown in illustration below.
Outside Diameter
Size Mark A : 93.360 mm±93.370 mm
(3.6756 in±3.6760 in)
Size Mark B : 93.371 mm±93.380 mm
(3.6760 in±3.6764 in)
Size Mark C : 93.381 mm±93.390 mm
(3.6764 in±3.6768 in)
015RS025Measure the cylinder bore inside diameter (refer to
ªCylinder Blockº in this manual).
012RS002
Piston Rings (8)
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement

Insert the piston ring into the bore.

Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
diameter is the smallest.

Measure the ring end gap.
Compression Ring
1st ring
Standard:
0.300 mm±0.400 mm
(0.0118 in±0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
Standard:
0.450 mm±0.600 mm
(0.0177 in±0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
Standard:
0.150 mm±0.450 mm
(0.0059 in±0.0177 in)
Limit: 1.05 mm (0.0413 in)

6A±80
ENGINE MECHANICAL
015RS026

Positioning mark (1) is painted as shown in the
illustration.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027
2. Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds the
specified limit, the piston must be replaced.
Compression Ring Clearance
Standard : 0.016 mm±0.038 mm
(0.0006 in.±0.0015 in)
Limit : 0.15mm (0.0059 in)
015RS028
Piston Pin (9)
NOTE: Do not reuse the old piston pin.
1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three different
positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Standard : 0.023 mm±0.038 mm (0.0009
in±0.0015 in)
015RS029
3. Insert the new pin into the piston and rotate it. If the
pin rotates smoothly with no backlash, the clearance
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.
Clearance
Standard : 0.010 mm±0.017 mm
(0.0004 in.±0.0007 in)
Limit : 0.040 mm (0.0016 in)

6A±90
ENGINE MECHANICAL
Main Data and Specification
General Specification
ItemSpecificationsItem6VD16VE1
Engine type, number of cylinders and arrangementWater cooled, four cycle V6
Form of combustion chamberPent roof type
Valve mechanism4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner typeCasted in cylinder drive
Total piston displacement3165 cc3494 cc
Cylinder bore x stroke93.4mm x 77.0mm93.4mm x 85.0mm
(3.6772 in x 3.0315 in)(3.6772 in x 3.3465 in)
Compression ratio9.1 : 1
Compression pressure at 300rpm14.0 Kg/cm

Engine idling speed rpmNon adjustable (750)
Valve clearanceIntake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12in)
Oil capacity5.3 liters
Ignition timingNon adjustableNon adjustable
16
BTDC at idle rpm)(20
BTDC at idle rpm)
Spark plugK16PR±P11, PK16PR11, RC10PYP4
Plug gap1.0 mm±1.1 mm(0.0394 in ± 0.0433 in)

6E±264
ENGINE DRIVEABILITY AND EMISSIONS
Hard Start Symptom

 
StepNo Ye s Value(s) Action
121. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to
Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 13
131. Check for a loose ignition coil ground.
Refer to
Electronic Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 14
141. Remove the ignition coils and check the ignition
coils for cracks or carbon tracking.
2. If a problem is found, replace affected coil(s) as
necessary.
Was a problem found?
ÐVerify repairGo to Step 15
151. Check IAC operation. Perform the procedure in the
DTC P0506, Step 6 diagnostic table.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 16
161. Check for the following engine mechanical
problems (refer to
Engine Mechanical):

Low compression

Leaking cylinder head gaskets

Worn or incorrect camshaft

Camshaft drive belt slipped or stripped
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 17
171. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection

Tech 2 data

Freeze Frame data/Failure Records buffer

All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repair
Contact
Technical
Assistance