clutch ISUZU TROOPER 1998 Service Owner's Manual

SERVICE INFORMATION 00 Ð 35
MAGNETIC CLUTCH DOES NOT RUN
·TURN THE STARTER SWITCH ON AND START THE
ENGINE.
·TURN THE FAN SWITCH ON.
·DOES THE BLOWER MOTOR RUN?
YESNO
REFER TO THE DIAGNOSIS PROCEDURE FOR
ÒBLOWER MOTOR DOES NOT RUNÓ.·IS THE FUSE C-20 (10A) NORMAL?
YESNO
REPLACE THE FUSE.·DISCONNECT THE A/C SWITCH CONNECTOR AND
REMOVE THE A/C SWITCH.
·IS THE A/C SWITCH NORMAL?
YESNO
YESNO
REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND I23-2.·REINSTALL THE A/C SWITCH AND DISCONNECT THE DUAL
PRESSURE SWITCH (OR TRIPLE PRESSURE SWITCH) CON-
NECTOR C25.
·TURN THE A/C SWITCH ON.
·IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE
CONNECTOR C25-1?
YESNO
REPLACE THE SWITCH.·RECONNECT THE CONNECTOR C25 AND DISCONNECT THE
A/C THERMO RELAY CONNECTOR X5.
·IS THERE CONTINUITY BETWEEN HARNESS SIDE CONNEC-
TOR C25-2 AND X5-1?
YESNO
REPAIR AN OPEN CIRCUIT BETWEEN I23-6
AND C25-1.·IS THE DUAL PRESSURE SWITCH (OR TRIPLE PRESSURE
SWITCH) NORMAL?
YESNO
REPAIR OR REPLACE THE SWITCH.·IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE
CONNECTOR I23-2?

00 Ð 36 SERVICE INFORMATION
·IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE
CONNECTOR X5-2?REPAIR AN OPEN CIRCUIT.
YESNO
·IS THE A/C THERMO RELAY NORMAL?REPAIR AN OPEN CIRCUIT BETWEEN THE
FUSE C-20 AND X5-2.
YESNO
·DISCONNECT THE ELECTRONIC THERMOSTAT CONNEC-
TOR I42.
·IS THE BATTERY VOLTAGE APPLIED AT HARNESS SIDE
CONNECTOR I42-3?
YESNO
·IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-
NECTOR X5-3 AND I42-1?REPAIR AN OPEN CIRCUIT BETWEEN I23-6
AND I42-3.
YESNO
REPAIR AN OPEN CIRCUIT.
YESNO
·IS THERE CONTINUITY BETWEEN HARNESS SIDE CON-
NECTOR I42-2 AND THE GROUND?REPAIR AN OPEN CIRCUIT.
REPLACE THE RELAY.
·DIS CONNECT THE MAGNETIC CLUTCH CONNECTOR E27.
·CONNECT THE BATTERY WITH MAGNETIC CLUTCH SIDE
CONNECTOR E27-1.
·DOES THE MAGNETIC CLUTCH.
YESNO
REPAIR OR REPLACE THE MAGNETIC CLUTCH.·REPAIR AN OPEN CIRCUIT BETWEEN X5-4 AND E27-1.

00 Ð 40 SERVICE INFORMATION
1. Defective rotor/piston
2. Defective bearing (DKS-15CH)
3. Defective shaft
1. Defective bearing
2. Defective clutch
3. Clearance between drive plate
and pulley not standard
1. Defective gasket
2. Defective rotor/reed valve
3. Defective trigger valve/suction
valve
1. Defective rotor/piston
2. Defective shaft
3. Rotating parts seized due to
insufficient oil
1. Defective seal
2. Defective O-ringReplace compressor/cylinder and
shaft assembly
Replace cylinder and shaft assembly
Replace compressor/cylinder and
shaft assembly
Replace magnetic clutch
Replace magnetic clutch
Adjust the clearance or replace
magnetic clutch
Replace compressor/gasket
Replace compressor/valve plate
Replace compressor/suction valve
Replace compressor/cylinder and
shaft assembly
Replace compressor/cylinder and
shaft assembly
Replace compressor
Replace compressor/shaft seal
Replace Noise from compressor
Noise from magnetic
clutch face
Insufficient cooling
Not rotating
Oil and/or gas leakage 1
2
3
4
5
ITEM PROBLEM POSSIBLE CAUSES CORRECTION
COMPRESSOR TROUBLESHOOTING

00 Ð 42 SERVICE INFORMATION
TRIPLE PRESSURE SWITCH (W/CONDENSER FAN)
43
12
1) Disconnect the connector and check for continuity
between pressure switch side connector terminal.
2) Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connectors and the fan operates.
[A/C OFF]
[A/C ON]
Terminal No. Control Continuity
1- 2Magnetic Clutch Continuity
3- 4Condenser Fan No Continuity
Terminal
Refrigerant Pressure Continuity Fan
No.
1079±98 kPa No
OFF
(11.0±1.0 kgácm
2/ 156±14 psi) Continuity
3- 4
1471±98 kPa
Continuity ON
(15.0±1.0 kgácm
2/ 213±14 psi)
BLOWER MOTOR
1
2
1) Disconnect the blower motor (B-5) connector from
the blower motor.
2) Connect the battery positive terminal to the No. 1
(NO.2; RHD) terminal of the blower motor and
negative to the No. 2 (NO. 1; RHD).
3) Be sure to check to see if the blower motor operates
correctly.
Terminal Normal
SW. No.12346Operating
position Resistance
2.4W
0.90W
0.28W
Ð 1
2
3
4
RESISTOR
14263
2
Motor3641
432
(SW.position) (Connector
terminal)
1
1) Disconnect resistor (I-41) connector.
2) Check for continuity and resistance between the
terminals of the resistor.

00 Ð 46 SERVICE INFORMATION
COMPRESSOR
Model DKV-14D
Type Vane rotary (Invariable)
Number of vanes 5
Rotor diameter mm (in.) 64 (2.52)
Stroke mm (in.) 8.75 (0.34)
Displacement cc (Imp fl oz) 140 (3.9)
Maximum speed (rpm) 7,000 (up to 8,400)
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (Imp fl oz) ZXL-200PG, 150 (4.2)
ISUZU PART NO.
8-97101-336-0
Refrigerant g (lbs.) HFC-134a, 750 (1.65)
Shaft seal Lip type
Weight kg (lbs.) 3.6 (7.94)
MAGNETIC CLUTCH
Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption (A) 3.7
Starting torque Nám 39 (4.0 / 30)
(kgám / lbáft)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs.) 2.2 (4.9)
6VD1/6VE1 (RHD) & 6VD1 (LHD) (SAUDI/PHILIPPINE)
6VD1/6VE1 (LHD) Except SAUDI/PHILIPPINE
COMPRESSOR
Model HD6
Type Vane rotary (Invariable)
Number of vanes 6
Rotor diameter mm (in.) 64 (2.52)
Stroke mm (in.) 24 (0.94)
Displacement cc (Imp fl oz) 164 (4.59)
Maximum speed (rpm) 9,000
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (Imp fl oz) SD2-231, 150 (4.2)
Refrigerant g (lbs.) R-134a, 750 (1.65)
Shaft seal Lip type
Weight kg (lbs.) 6.8 (14.99)
MAGNETIC CLUTCH
Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption (A) 3.7
Starting torque Nám 39 (4.0 / 30)
(kgám / lbáft)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs.) 2.2 (4.9)

SERVICE INFORMATION 00 Ð 47
4JG2/4JX1
COMPRESSOR
Model DKS-15CH
Type Swash plate type
Number of cylinder 6
Bore mm (in.) 36 (1.4)
Stroke mm (in.) 24 (0.94)
Displacement cc (Imp fl oz) 147 (4.1)
Maximum speed (rpm) 7,000 (up to 8,400)
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant cc (Imp fl oz) ZXL-100PG, 150 (4.2)
ISUZU PART NO.
8-97101-338-0
Refrigerant g (lbs.) HFC-134a, 750 (1.65)
Shaft seal Lip type
Weight kg (lbs.) 4.1 (9.0)
MAGNETIC CLUTCH
Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption (A) 3.7
Starting torque Nám 49 (5.0 / 36)
(kgám / lbáft)
Direction of rotation Clockwise (Front-side view)
Weight kg (lbs.) 2.3 (5.1)

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

SERVICE INFORMATION 00 Ð 51
Metric Thread Size Information
Compressor to mounting bracket bolts(Front)
M10´1.5 Ð 6H
Compressor to mounting bracket bolts(Rear)
M8´1.25 Ð 6H
Suction-discharge port screw
M10´1.5 Ð 6H
Compressor shaft
M9´1.25 Ð 6H
Internal hub-clutch drive assembly
M22´1.5 Ð 6H

SERVICE INFORMATION 00 Ð 55
ILLUSTRATION TOOL NO. TOOL NAME
5-8840-2610-0
Hub and Clutch Drive Plate Asm. remover
(J-33013-B)
5-8840-2615-0
Compressor Holding Fixture
(J-33026)
5-8840-2612-0
Puller Pilot
(J-33023-A)
5-8840-2617-0
Pulley Puller
(J-41552)
5-8840-2611-0
Pulley and Bearing Assembly Installer
(J-33017)
5-8840-0111-0
Puller Bar
(J-8433-1)
5-8840-0111-0
Forcing Screw
(J-8433-3)
5-8840-2614-0
Clutch Coil Installer Adapter
(J-33025)
5-8840-2613-0
Clutch Coil Installer Adapter
(J-33024)
5-8840-2629-0
Seal Seat Remover and Installer
(J-23128-A)
5-8840-2630-0
O-Ring Remover
(J-9553-01)
DELPHI Harrison HD6/HDT6 Special Tools
901RW012
901RW013
901RW015
901RW016
901RW017
901RW018
901RW019
901RW020
901RW021
901RW024
901RW025

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