air condition ISUZU TROOPER 1998 Service User Guide

SERVICE INFORMATION 00 Ð 27
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 com-
pressor 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 oper-ation, the electronic thermostat, the pressure switch
or the PCM (6VD1/6VE1 Engine) is used to stop the
air conditioning temporarily by turning off the mag-
netic clutch in the prearranged conditions to reduce
the engine load which is being caused by the rise in
the engine coolant temperature, and the accelera-
tion of the vehicle, etc.
123
45 6
RELAY; A/C
B-36C-20
10A
A/C FL-1
80A
MAIN
1
2
B-2
C-25
2
4
X-5
1
3 (3)
(1)
4
13
24
1
A/C SW.
FAN SW.
I-23
PRESSURE
SW.
RELAY;
THERMOSTAT
B-2
X-7 C-25
C-1C-3E-3I-23
BATTERY
X-7
RELAY: A/C
COMPRESSOR
1
E-3
MAGNETIC
CLUTCHMg
OFF
I-18
2
6
1
321123
12
3412
11
213
5 46
I-18
X-5
B-1(LHD) (RHD)
B-1
1
2 34
W/ CONDENSER
FAN
2
4
1
3
C-3PCM (E15)
C-1PCM (B14)
3
1
2
ELECTRONIC
THERMOSTAT
I-42
I-42B-36
Pin number with ( ); RHD
A1 A2 A3 A4 A5 A6 A7 A8 A9A10 A11 A12 A13 A14 A15 A16B1 B2 B3 B4 B5 B6 B7 B8 B9B10 B11 B12 B13 B14 B15 B16E1 E2 E3 E4 E5 E6 E7 E8 E9E10 E11 E12 E13 E14 E15 E16F1 F2 F3 F4 F5 F6 F7 F8 F9F10 F11 F12 F13 F14 F15 F16
6VD1/6VE1 ENGINE
D08RY00295

00 Ð 50 SERVICE INFORMATION
Legend
1. Clutch Driver
2. Rotor Bearing Retainer
3. Pulley Rotor and Bearing
Assembly
4. Clutch Coil Assembly
5. Connector
6. Shaft Seal Parts
7. Pump Assembly
8. High Pressure Relief Valve
9. Shipping Cap
10. Special 134a Suction Port
11. Special 134a Discharge Port
Caution
The operations described below are based
on bench overhaul with the compressor
removed from the vehicle, except as noted.
They have been prepared in order of
accessibility of the components. When a
compressor is removed from the vehicle for
servicing, the amount of PAG lubricant
remaining in the compressor should be
drained, measured and recorded. This PAG
lubricant should then be discarded and an
equal amount of new PAG lubricant added to
the compressor.
The service compressor is shipped without
PAG oil. When service procedures require,
use only Isuzu approved PAG oil.
HEATING, VENTILATION AND AIR CONDITIONING(HVAC)
1
2
3
4
5
68
97
10
11
871RW002

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 correct torque values must
be used when installing fasteners that
require it. If the above conditions are not
followed, parts or system damage could
result.
HEATING AND VENTILATION 1A Ð 1
SECTION 1A
HEATING AND VENTILATION
CONTENTS
PAGE
General Description.....................................................1AÐ 2
Heater...............................................................1AÐ 2
Control Lever Assembly................................................1AÐ 3
Ventilation...........................................................1AÐ 3
Air Select Knob.......................................................1AÐ 4
Air Source Select Lever................................................1AÐ 4
Fan Control Knob.....................................................1AÐ 4
Temperature Control Knob.............................................1AÐ 4
Ceramic Heater.......................................................1AÐ 5
On-Vehicle Service......................................................1AÐ 6
Heater Unit..........................................................1AÐ 6
Heater Core and/or Mode Door..........................................1AÐ 8
Heater Mode Control Link Unit..........................................1AÐ10
Heater Temperature Control Link Unit....................................1AÐ12
Blower Assembly.....................................................1AÐ14
Blower Link Unit and/or Mode Door......................................1AÐ16
Blower Motor........................................................1AÐ18
Rear Heater Duct, Defroster Nozzle and Ventilation Duct....................1AÐ20
Center and/or Side Vent...............................................1AÐ22
Control Lever Assembly and/or Control Cables............................1AÐ24
Control Panel Illumination Bulb..........................................1AÐ27
Resistor.............................................................1AÐ28
Ceramic Heater and/or Full Hot Switch...................................1AÐ30

When the engine warming up, the warmed engine
coolant is sent out into the heater core. The heater
system supplies warm air into the passenger
compartment to warm it up.
Outside air is circulated through the heater core of
the heater unit and then back into the passenger
compartment. By controlling the mixture of outside
air and heater core air, the most comfortable
passenger compartment temperature can be
selected and maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature
control knob. This knob acts to open and close the
air mix door, thus controlling the amount of air
passed through the heater core.The air select knob, with its different modes, also
allows you to select and maintain the most
comfortable passenger compartment temperature.
The air source select lever is used to select either
ÒFRESHÓ for the introduction of the outside air, or
ÒCIRCÓ for the circulation of the inside air. When
the lever is set to ÒFRESHÓ, the outside air is always
taken into the passenger compartment. When
setting the lever to ÒCIRCÓ position, the circulation
of air is restricted only to the inside air with no
introduction of the outside air and the air in the
passenger compartment gets warm quickened.
However, the lever is normally set to ÒFRESHÓ to
prevent the windshield from clouding.
1A Ð 2 HEATING AND VENTILATION
GENERAL DESCRIPTION
HEATER
Side def hose
Vent box
Upper center vent duct
Lower center
vent ductBlower assembly
Control lever assembly Evaporator
assembly W/A/C
W/O A/C
Duct Heater unit
Lap vent nozzle Vent box Side def hoseDefroster nozzle
Rear heater duct
A/C - Air Conditioning This illustration is based on LHD

HEATING AND VENTILATION 1A Ð 7
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. When handling the ECM and the control unit, be
careful not to make any improper connection of the
connectors.
2. Adjust control lever assembly cables.
Refer to ÒCONTROL LEVER ASSEMBLYÓ installation
steps in this section.
3. When installing the heater unit, defroster nozzle and
center vent duct, be sure that proper seal is made,
without any gap between then.
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Drain engine coolant
·Discharge and recover refrigerant (W/A/C)
(Refer to Section 1B ÒREFRIGERANT RECOVERYÓ)
1. Instrument Panel Assembly
Refer to Section 10 ÒBODYÓ for INSTRUMENT PANEL
ASSEMBLY removal procedure.
2. Water Hose
Disconnect water hoses at heater unit.
3. Resistor Connector
4. Duct
4a. Evaporator Assembly
Refer to Section 1B ÒAIR CONDITIONINGÓ for
Evaporator Assembly removal procedure.
5. Instrument panel center bracket
6. Rear Heater Duct
7. Heater Unit
8. Lap vent nozzle
9. Center ventilation lower duct

HEATING AND VENTILATION 1A Ð 15
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Discharge and recover refrigerant (W/A/C)
(Refer to Section 1B ÒREFRIGERANT RECOVERYÓ)
1. Instrument Panel Assembly
Refer to Section 10 ÒBODYÓ for INSTRUMENT PANEL
ASSEMBLY removal procedure.
2. Resistor Connector
3. Duct
3a. Evaporator Assembly (A/C only)
Refer to Section 1B ÒAIR CONDITIONINGÓ for
EVAPORATOR ASSEMBLY removal procedure.
4. Kick panel
5. Blower Motor Connector
6. Blower Assembly
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following point:
1. Adjust Control Lever Assembly Cables
Refer to ÒCONTROL LEVER ASSEMBLYÓ installation
procedure in this section.

1A Ð 24 HEATING AND VENTILATION
Removal Steps
1. Center console assembly
2. Lower cluster assembly
3. Glove box
4. Instrument panel passenger lower
cover assembly
5. Instrument panel driver lower cover
assembly
6. Meter cluster assembly
7. Attaching screws
8. Fan switch and air conditioning switch
connector
9. Control lever assembly
10. Control cable
CONTROL LEVER ASSEMBLY AND/OR CONTROL CABLES
6
1
5
2
10
7
7
88
910
To Mode control linkTo Temp control linkTo Blower assembly
4
3
Installation Steps
To install, follow the removal steps in
the reverse order.
This illustration is based on LHD

AIR CONDITIONING 1B Ð 1
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 correct torque values must
be used when installing fasteners that
require it. If the above conditions are not
followed, parts or system damage could
result.
SECTION 1B
AIR CONDITIONING
CONTENTS
PAGE
General Description.....................................................1BÐ 3
Air Conditioning Refrigerant Cycle Construction...........................1BÐ 3
Compressor.........................................................1BÐ 4
Magnetic Clutch......................................................1BÐ 5
Receiver/Drier.......................................................1BÐ 5
Dual Pressure Switch.................................................1BÐ 6
Triple Pressure Switch................................................1BÐ 6
Expansion Valve......................................................1BÐ 6
Evaporator..........................................................1BÐ 7
Electronic Thermostat.................................................1BÐ 7
Refrigerant Line......................................................1BÐ 7
Service Charge Valve..................................................1BÐ 7
Air Conditioning Parts.................................................1BÐ 8
On-Vehicle Service......................................................1BÐ 13
Precautions For Replacement or Repair of Air Conditioning Parts.............1BÐ 13
Compressor Assembly and Associated Parts..............................1BÐ 23
Condenser Assembly (LHD V6 without Condenser Fan).....................1BÐ 33
Condenser Fan Motor.................................................1BÐ 35
Receiver/Drier.......................................................1BÐ 37
Pressure Switch......................................................1BÐ 39
Evaporator Assembly.................................................1BÐ 42
Evaporator Core and/or Expansion Valve.................................1BÐ 44
Electronic Thermostat.................................................1BÐ 47
A/C Switch and Illumination Bulb.......................................1BÐ 48
Refrigerant Line......................................................1BÐ 49
Rear Cooler Parts.....................................................1BÐ 51

1B Ð 2 AIR CONDITIONING
Full Automatic Air Conditioning System....................................1BÐ 60
General Description.....................................................1BÐ 60
Full Automatic Air Conditioner Part Configuration.........................1BÐ 60
Circuit Diagram......................................................1BÐ 62
Function and Features.................................................1BÐ 74
Full Automatic Air Conditioner Block Diagram.............................1BÐ 75
Air Conditioning Parts.................................................1BÐ 76
Control Panel Layout..................................................1BÐ 80
Air Control Functions.................................................1BÐ 81
Operation and Function of Control Panel Switches.........................1BÐ 82
Overview of Construction, Movement and Control of Major Parts of Full Automatic
Air Conditioner System................................................1BÐ 84
Overview of Automatic Control of Full Automatic Air Conditioner............1BÐ 88
Troubleshooting........................................................1BÐ 92
Troubleshooting, Its Overview and Procedures............................1BÐ 92
Performance and Movement Checklist for Automatic Air Conditioner Related
Parts...............................................................1BÐ 95
Troubleshooting with Self-Diagnosis Function............................1BÐ 97
Inspection by Failed Location.............................................1BÐ100
Inspection of the Sensors..............................................1BÐ100
Inspection of the Intake Actuator System.................................1BÐ104
Inspection of the Mix Actuator System...................................1BÐ107
Inspection of the Mode Actuator System.................................1BÐ110
Inspection of the Fan Motor System.....................................1BÐ113
Inspection of the Magnet Clutch System.................................1BÐ118
Inspection of the Air Conditioner Room Temperature Setup System..........1BÐ123
Individual Inspection..................................................1BÐ124
On-Vehicle Service......................................................1BÐ126
Power Transistor.....................................................1BÐ126
Automatic Air Conditioner Control Unit..................................1BÐ126
In Car Sensor........................................................1BÐ127
Ambient Sensor......................................................1BÐ127
Sun Sensor..........................................................1BÐ128
Electronic Thermostat.................................................1BÐ128
Mode Actuator.......................................................1BÐ129
Mix Actuator.........................................................1BÐ129
Intake Actuator......................................................1BÐ130

AIR CONDITIONING 1B Ð 3
AIR CONDITIONING REFRIGERANT CYCLE CONSTRUCTION




 

 













 

 
 
 
 

 
 


 












 

 
 
 
 
 
 





1514
11
12
13
1610
177
34
5
2
18
96
13 Side vent
Lap ventOutside air
EngineSide vent
Cooling air
High pressure, high temperature gas
High pressure, high temperature
mixture of gas and liquid
Low pressure, low temperature
mixture of liquid and gas
Low pressure, low temperature gas High pressure, medium temperature liquidSide defrost Side defrostDefrost Center vent
GENERAL DESCRIPTION
1. Compressor
2. Magnetic clutch
3. Receiver/Drier
4. Dual pressure switch
5. Condenser
6. Evaporator assembly
7. Expansion valve
8. Temperature sensor
9. Evaporator core10. Blower motor
11. Heater unit
12. Heater core
13. Temp. control door (Air mix door)
14. Mode (DEF) control door
15. Mode (VENT) control door
16. Mode (HEAT) control door
17. Electronic thermostat