clock ISUZU TROOPER 1998 Service User Guide

1BÐ86 AIR CONDITIONING
Legend
(1) Out put Axis
(2) Motor
(3) Printed Circuit Board
(4) Sliding Contact
The mode and mix actuators are common actuators
with the built-in potentiometer. For the intake
actuator, the contact switch type is selected.
The potentiometer is a register assembled to the
printed circuit board of the mix and mode
actuators. It detects the air mix door position
specified by rotation of the output axis as a ratio of
the variable terminal (VM) voltage against the
reference voltage (VDD: 5V), then signals the value
to the automatic heater/air conditioner control unit.¥ Movement of Mix Actuator
Position of the air mix door is determined by the
controller on the automatic heater/air conditioner
control unit.
As the heat or cool side of the controller is
grounded, the transistor on the driver is activated
and, thus, the motor rotation is turned on. The
sliding contact connected to the motor sends the
position detection signal from the potentiometer
to the automatic heater/air conditioner control
unit. As the set temperature and interior
temperature are balanced, the controller returns
to the neutral and the motor rotation is stopped.
12
43
860RW026
C01RX016
M
N 3
2
7
6
8
98 43
65 21
7
Potentiometer
ConnectionPosition
Detection
Block Automatic Heater / Air
Conditioner Control Unit
Controller
Sliding Contact
Full Heate PositionTerminal PlateFull Cool PositionDriver
Cool Side Heat Side
C01RX005
Full cool
Full cool0 0 0.5 1.0
50 100%
Aperture of air mix doorVoltage ratio VM/VDD
Full heat Full heat
VDD
VM +
–
I-45 Rotation
(+) side (Ð) side direction Remarks
8 6 Clockwise Full heat side
6 8 Counter Full cool side
clockwise

AIR CONDITIONING 1BÐ87
¥ Movement of Mode Actuator
As target position of the mode door is decided on
the controller of the control unit, the control unit
reads the position detection signal from the
actuator to select the clockwise or counter
clockwise motor rotation direction.
Grounding the controller VENT or DEF side after
the direction selection activates the transistor on
the driver, thus turning on the motor rotation.
Accompanying the motor rotation, the sliding
contact rotates, too. When the target position is
reached, the controller on the control unit returns
to the neutral and the motor stops.¥ Movement of Intake Actuator
The controller on the automatic heater/air
conditioner control unit selects an intake mode to
be used.
As the Terminal No.5 is grounded via the
sliding contact on the terminal plate, the
transistor on the driver is activated, thus turning
on the motor rotation. Then, accompanying
move of the motor, the sliding contact rotates
until grounding of the Terminal No.5 is
removed, thus stopping the motor.I-49
I-49
DriverController
DEF side
VENT
side
Position
detection
block Control unit
Sliding
contact
Actuator side42
983
7
78910
HLHL
HHHL
HHLL
HHLH
HLLH
HLHH
LLHH
LHHH
LHLH 61
5
Interconnected
motor
VENTVENT
Mid point between VENT - B/L
B/L
Mid point between B/L - FOOT
FOOT
Mid point between FOOT - D/F
D/F
Mid point between D/F - DEF
DEFDEF
7
8
9
10 2 6
7
8
3
4
9
5
1
C01RX017
M
+6 1 2
65 4 3
REC
MIX
FRESH
Com1
2
5
3
4++
Ð
Terminal PlateAuto A/C
Control Unit (Actuator Side)
Driver Controller
Sliding Contact
Connected
C01RX006
Conducting pin Rotation
(+) side (Ð) side direction Remarks
5 1 Clockwise VENT to
DEF direction
1 5 Counter DEF to
clockwise VENT diction
Grounding Rotation
terminal direction Remarks
No.5 Clockwise RE-CIRCULA
TION
®MIX
®FRESH I-49

COMPRESSOR OVERHAUL 1D Ð 19
CAUTION: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of
the installer is held and the center screw is rotated,
the key will wedge and will break the clutch hub.7. Remove installer J-33013-B, check for proper
positioning of the shaft key (even or slightly above
the clutch hub).
8. Spin the pulley rotor by hand to see that the rotor is
not rubbing the clutch drive plate.
COMPRESSOR CLUTCH ROTOR AND/OR
BEARING
Removal
1. Remove the clutch plate and hub assembly as
described previously.
2. Remove rotor (1) and bearing assembly retaining
ring (2), using snap ring pliers.
3. Install pulley rotor and bearing puller guide J-33023-A
to the front head and install J-41552 pulley rotor and
bearing puller down into the inner circle of slots (1) in
the rotor. Turn the J-41552 puller clockwise in the
slots in the rotor.4. Hold the J-41552 puller in place and tighten the
puller screw against the puller guide to remove the
pulley rotor and bearing assembly.
Installation
1. With the compressor mounted to the J-34992
holding fixture, position the rotor and bearing
assembly on the front head.
2. Position the J-33017 pulley, rotor and bearing
installer and J-33023-A puller pilot directly over the
inner race of the bearing.
1
2 J-33013-B
901RW002
1
2
901RW003
J-41552
1
871RW007

1D Ð 22 COMPRESSOR OVERHAUL
COMPRESSOR SHAFT SEAL
Service Precaution
When replacing the shaft seal assembly, pressure relief
valve or control switches, it will be necessary to recover
the refrigerant. Other than clutch repair procedures, the
same holds true for any disassembly of the compressor.
A clean workbench covered with a sheet of clean
paper, and a place (clean trays, etc) for all parts being
removed and replaced is important, as is the use of
proper clean service tools.
CAUTION: Any attempt to use makeshift or
inadequate service tools or equipment may result
in damage and/or improper compressor operation.
All parts required for servicing the internal compressor
are protected by a preservative process and packaged
in a manner which will eliminate the necessity of
cleaning, washing or flushing of the parts. The parts
can be used in the internal assembly just as they are
removed from the service package. Seals and
protective packaging should be left intact until just
prior to installation.
If the compressor rear head, front head or cylinder and
shaft assembly is to be serviced or replaced, the oil in
the compressor must be drained, measured, recorded
and replaced.
Legend
(1) Suction Port
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve
(6) Mounting Boss
Seal Leak Detection
A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only
after actual refrigerant leakage is found using an
approved leak detector.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
Removal
1. Recover the refrigerant using Refrigerant Recovery
System.
2. Loosen and reposition compressor in mounting
brackets, if necessary.
3. Remove clutch plate and hub assembly from
compressor as described previously.
4. Remove the shaft seal retainer ring, using snap ring
pliers.
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the
seal, the retainer ring groove and the shaft itself.
Any dirt or foreign material getting into compressor
may cause damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J-23128-A into the recessed portion of the
Seal (1) by turning the handle clockwise. Remove
the Seal from the compressor with a rotary-pulling
motion.
Discard the seal. The handle must be hand-
tightened securely. Do not use a wrench or pliers.
1
2
3
456
871RW006
J-23128-A1
901RW008

COMPRESSOR OVERHAUL 1D Ð 23
7. Remove and discard the seal seat O-ring (2) from the
compressor neck using O-ring remover J-9553-01.
8. Recheck the shaft and inside of the compressor
neck for dirt or foreign material and be sure these
areas are perfectly clean before installing new parts.
Cleaning
Thoroughly clean O-ring seal groove in front head.
CAUTION: Seals should not be re-used. Always use
a new specification service seal on rebuild. Be sure
that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat
and seal are free of lint and dirt that could damage
the seal surface or prevent sealing.
Installation
1. Dip the new seal seat O-ring (1) in clean 525
viscosity refrigerant oil and assemble onto O-ring
installer J-33011.2. Insert the O-ring installer J-33011 into the
compressor neck until the installer "bottoms". Lower
the moveable slide of the O-ring installer to release
the O-ring into the seal O-ring lower groove (The
compressor neck top groove is for the shaft seal
retainer ring.) Rotate the installer to seat the O-ring
and remove the installer.
3. Dip the new seal in clean 525 viscosity refrigerant oil
and assemble seal to Seal Installer J-23128-A, by
turning handle clockwise. The stamped steel case
side of the lip seal must be engaged with knurled
tangs of installer so that flared-out side of lip seal is
facing and installed towards the compressor. Install
seal protector J-34614, in the seal lip and place over
the compressor shaft, and push the seal in place with
a rotary motion or place the seal protector J-34614
over end of compressor shaft, and slide the new seal
onto the shaft with a rotary motion until it stops. Take
care not to dislodge the O-ring. Be sure the seal (2)
makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer
J-23128-A and the seal protector J-34614.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
4. Install the new seal retainer ring with its flat side
against the Seal, using Snap-Ring Pliers. Use the
sleeve from O-ring installer J-33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J-39893 on rear head of compressor and connect
gage charging lines and Refrigerant Recovery
System. Pressurize suction and high-side of
compressor with R-134a Refrigerant. Temporarily
install (M9 ´1.25 thread on shaft) nut and, with the
compressor in horizontal position, rotate the
compressor shaft in normal direction of rotation
several times by hand. Leak test the seal area and
correct and leak found. Recover the refrigerant.
Remove shaft nut.
2 J-9553-01
901RW009
1
J-33011
901RW010
J-34614
2
J-23128-A
901RW011

00 – 14 SERVICE INFORMATION
STEERING WHEEL FREE PLAY
ADJUSTMENT
INSPECTION
1. Check the amount of steering wheel play by turning
the wheel in both directions until the tires begin to
move with the front wheels properly in the straight
ahead position.
NOTE:
The wheel free play should be checked with the engine
running.
Steering Wheel Free Play mm (in)
0 – 30 (0 – 1.18)
2. Also check the steering wheel for play and looseness
in mount by moving it back and froth and sideways.
While driving, check for hard-steering, steering
shimmy and tendency to pull to one side.
ADJUSTMENT
1. Align the front wheels properly in the straight ahead
position.
2. Loosen the lock nut on the adjusting screw of the
steering gear.
3. Turn the adjust screw clockwise to decrease free play
or counter-clockwise to increase.
4. After check of specified free play, tighten the lock nut
to specified torque.
Lock Nut Torque N·m (kg·m/lb·ft)
41 (4.2 / 30)

POWER STEERING 2A – 23
DISASSEMBLY
CAUTION:
Do not clamp the steering gear assembly in a vise by the
power cylinder housing.
1. Dust Cover
2. Retaining Ring
3. Back up RIng
4. Oil Seal
1) Clean the faces of the extended stub shaft.
2) Plug the hose fitting on the inlet side.
3) Remove the oil seal by blowing compressed air
through the hole in the outlet side.
5. Lock Nut
Remove the adjusting screw lock nut and turn the
adjusting screw counterclockwise to remove the
preload between the sector gear and the rack piston,
then remove the top cover bolts.
6. Top Cover Assembly
Holding the top cover stationary, turn the adjusting
screw clockwise to raise and free to cover, then
remove the cover.
7. O-ring
8. Sector Shaft
Bring the stub shaft into straight-ahead position. Do
not force the sector shaft off the gear box with a
hammer or other impact tools.

2A – 46 STEERING LINKAGE
OUTER TRACK ROD ASSEMBLY
Removal Steps
1. Nut and cotter pin, center track rod
2. Nut and cotter pin, knuckle arm
3. Lock nut, outer
4. Rod end assembly outer
5. Lock nut, inner
6. Rod end assembly, inner
The screw is threaded
counterclockwise.
Installation Steps
6. Rod end assembly, inner
5. Lock nut, inner
4. Rod end assembly outer
3. Lock nut, outer
2. Nut and cotter pin, knuckle arm
1. Nut and cotter pin, center track
rod These steps are based on the LHD model.

STEERING LINKAGE 2A – 47
REMOVAL
Preparation:
Remove wheel and tire assembly.
Refer to “Wheels and Tires” in section 3E.
1. Nut and Cotter Pin, Center Track Rod
Disconnect outer track rod assembly at the center
track rod.
Remover: 5-8840-2121-0 (J-36831)
CAUTION:
Be careful not to break the ball joint boot.
2. Nut and Cotter Pin, Knuckle Arm
Remove outer track rod assembly from the knuckle
arm.
Remover: 5-8840-2121-0 (J-36831)
CAUTION:
Be careful not to break the ball joint boot.
3. Lock Nut, Outer
NOTE:
In either outer rod, the screw on the right side of the
vehicle is threaded counterclockwise.
6. Rod End, Inner
Apply setting marks to ensure reassembly of the
parts in their original position.
4. Rod End Assembly, Outer
Apply setting marks to ensure reassembly of the
parts in their original position.
5. Lock Nut, Inner
NOTE:
In either outer rod, the screw on the right side of the
vehicle is threaded counterclockwise.

2A – 48 STEERING LINKAGE
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage, corrosion, bending, deteriorations or any other
abnormal condition are found through inspection.
Check the following parts.
•Rod end assembly
•Ball joint (Boot, screws and tapered surfaces)
INSTALLATION
6. Rod End, Inner
Align the setting marks applied during desassembly.
5. Lock Nut, Inner
Lock Nut Torque N·m (kg·m/lb·ft)
118 (12.0 / 87)
NOTE:
In either outer rod, the screw on the right side of the
vehicle is threaded counterclockwise.
4. Rod End Assembly, Outer
Align the setting marks applied during disassembly.
3 Lock Nut, Outer
Lock Nut Torque N·m (kg·m/lb·ft)
118 (12.0 / 87)
2. Nut and Cotter pin, Knuckle Arm
Tighten the nut to the specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.
Knuckle Arm Nut Torque N·m (kg·m/lb·ft)
98 (10.0 / 72)
1. Nut and Cotter Pin, Center Track Rod
Tighten the nut to the specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.
Track Rod Nut Torque N·m (kg·m/lb·ft)
98 (10.0 / 72)
NOTE:
If replacing the track rod, adjust the new track rod
length.
Rod Length (L) mm (in)
328.3 (12.93) : Wide Tread
299 (11.77) : Narrow Tread
NOTE:
Adjust the toe-in. Refer to “Front End Alignment” in
section 3A.