ISUZU TROOPER 1998 Service Repair Manual

AIR CONDITIONING 1BÐ125
Power Transistor
1. Remove the power transistor connector (I-47)
from the evaporator assembly.
2. Check the conduction between the power
transistor side terminals.
MAX HI Relay
1. Remove the MAX HI relay connector (B-64) from
the blower assembly.
2. Check the conduction between the MAX HI relay
side terminals.In Car Sensor
1. Turn on the ignition switch (the engine is
started). Start the air conditioner in "Full Auto".
2. Make sure that the in car sensor suctions
cigarette smokes and such.
3. Dismount the in car sensor from the automatic
heater/air conditioner control unit. Connect (+)
end and (-) end of the battery to the aspirator
motor side terminals No.1 and No.2
, respectively, then
check if the motor runs normally.I-34
I-34














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43
3 41
2 21
No continuity between terminals (2) and (4).
Continuity between terminal (2) and (4) when battery
voltage is applied between (1) and (3).
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1
2
3
Terminal
No.Conduction
Conducted (50½ maximum)
Conducted (100½ maximum)
Conducted (220½ maximum) Not conducted
Not conducted 1
µ23
Testing
rod
µ
µ
µ
µ
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1BÐ126 AIR CONDITIONING
ON-VEHICLE SERVICE
Power Transistor
Legend
(1) Evaporator Assembly
(2) Passenger Knee Bolster Reinforcement
(3) Lower Cluster
(4) Front Console
(5) Glove Box
(6) Instrument Panel Passenger Lower Cover
(7) Power Transistor Connector
(8) Power Transistor
Removal
1. Remove front console.
2. Remove lower cluster.
3. Remove glove box.
4. Remove instrument panel passenger lower
cover.
5. Remove passenger knee bolster reinforcement.
6. Disconnect the power transistor connector.
7. Remove power transistor.
Installation
To install, follow the removal step in the reverse
order.
Automatic Heater/Air Conditioner Control
Unit
Legend
(1) Connector
(2) Automatic Heater / Air Conditioner Control
Unit
(3) Instrument Panel Cluster
(4) Set Screw
Removal
1. Disconnect the battery ground cable.
2. Remove instrument panel cluster.
·Refer to Instrument Panel Assembly in Body
Structure section.
3. Disconnect the automatic heater / air conditioner
control unit connector.
4. Remove automatic heater/ air conditioner
control unit.
Installation
To install, follow the removal step in the reverse
order.
7
6
5
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AIR CONDITIONING 1BÐ127
In Car Sensor
Legend
(1) In Car Sensor
(2) Automatic Heater / Air Conditioner Control
Unit
Removal
1. Disconnect the battery ground cable.
2. Remove the automatic heater / air conditioner
control unit.
·Refer to the automatic heater / air conditioner
control unit section.
3. Remove in car sensor.
Installation
To install, follow the removal step in the reverse
order.
Ambient Sensor
Legend
(1) Ambient Sensor
(2) Sensor Connector
(3) Radiator Grill
Removal
1. Disconnect the battery ground cable.
2. Remove radiator grille.
·Refer to Radiator Grille in Body Structure
section.
3. Disconnect the ambient sensor connector.
4. Remove the ambient sensor.
Installation
To install, follow the removal step in the reverse
order.


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1BÐ128 AIR CONDITIONING
Sun Sensor
Legend
(1) Sun Sensor
Removal
1. Disconnect the battery ground cable.
2. Remove the sun sensor.
3. Disconnect the sun sensor connector.
Installation
To install, follow the removal step in the reverse
order.
Electronic Thermostat
Legend
(1) Duct Sensor
(2) Thermostat Assembly
(3) Evaporator Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove evaporator assembly.
·Refer to Evaporator Assembly section.
3. Remove electronic thermostat.
Installation
To install, follow the removal step in the reverse
order.
1
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1
3
2
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AIR CONDITIONING 1BÐ129
Mode Actuator
Legend
(1) A/T Control Unit
(2) Mode Actuator
(3) Actuator Rod
Removal
1. Disconnect the battery ground cable.
2. Remove the A/T control unit.
·The connector shall remain connected.
3. Remove the actuator rod.
4. Remove the mode actuator.
Installation
To install, follow the removal step in the reverse
order.
MIX Actuator
Legend
(1) Instrument Panel Assembly
(2) Instrument Panel Center Bracket
(3) Actuator Rod
(4) Mix Actuator
Removal
1. Disconnect the battery ground cable.
2. Remove the instrument panel assembly.
·Refer to the Instrument Panel Assembly in
Body Structure section.
3. Remove the instrument panel center bracket.
4. Remove the actuator rod.
5. Remove the mix actuator.
Installation
To install, follow the removal step in the reverse
order.
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1BÐ130 AIR CONDITIONING
Intake Actuator
Legend
(1) Evaporator Assembly
(2) Intake Actuator
(3) Intake Actuator Connector
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
·Refer to Refrigerant Recovery in this section.
3. Remove the evaporator assembly.
·Refer to Eevaporator Assembly section.
4. Disconnect the intake actuator connector.
5. Remove the intake actuator.
Installation
To install, follow the removal step in the reverse
order.
1
2
3
860RX018
This illustration is based on RHD

COMPRESSOR OVERHAUL 1D 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 1D
COMPRESSOR OVERHAUL
CONTENTS
PAGE
General Description.....................................................1DÐ 2
General Information.....................................................1DÐ 4
Compressor Oil.......................................................1DÐ 4
Service Procedures......................................................1DÐ 6
DKV-14D Type Compressor.............................................1DÐ 6
DKS-15CH Type Compressor............................................1DÐ10
HD6 Type Compressor.................................................1DÐ18

1D Ð 2 COMPRESSOR OVERHAUL
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 compressorshould be cleaned before any ÒOn-VehicleÓ 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
Trichloroethane, naphtha, kerosene, or equivalent
DKS-15CH TYPE DKV-14D TYPE
871RY00014

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.

1D Ð 4 COMPRESSOR OVERHAUL
COMPRESSOR OIL
OIL SPECIFICATION
·The HFC-134a system requires a synthetic
(PAG) compressor oil.
·Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified
for the model of compressor.
DKV-14D : ZXL-200PG
(ISUZU PART NO.
8-97101-336-0)
DKS-15CH : ZXL-100PG
(ISUZU PART NO.
8-97101-338-0)
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.
·The compressor oil must be stored in steel
containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is
circulating 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 (4.2 Imp fl oz)
Compressor (Service
150cc (4.2 Imp fl oz)
parts) charging amount
Checking and Adjusting for Used Compressor
1) Perform Oil return operation.
(Refer to ÒOil Return OperationÓ in this section.)
2) Discharge refrigerant and remove the
compressor.
3) Drain the compressor oil and measure the
extracted oil with a measuring cylinder.
4) If the amount of oil drained is much less than
90cc (2.5 Imp 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 ÒContamination of Compressor OilÓ in
this section.)
6) Adjust oil level following the procedure below.
Collected Amount Charging Amount
same as collected
more than 90cc (2.5 Imp fl oz)
amount
less than 90cc (2.5 Imp fl oz) 90cc (2.5 Imp 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
operation, the compressor oil should be checked in
the following order:
1) Discharge 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 (2.5 Imp 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
(2.5 Imp fl oz), recheck the compressor oil in the
following order:
5) Supply 90cc (2.5 Imp fl oz) of oil to the
compressor and install it onto the vehicle.
6) Perform oil return operation.
7) Remove the compressor and recheck the
amount of oil.
8) Adjust the compressor oil, if necessary.
Collected Amount Charging Amount
same as collected
more than 90cc (2.5 Imp fl oz)
amount
less than 90cc (2.5 Imp fl oz) 90cc (2.5 Imp fl oz)
GENERAL INFORMATION
871RX020