radiator cap ISUZU TROOPER 1998 Service Repair Manual

AIR CONDITIONING 1B Ð 5
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.
The specified amount of the DKV-14D, DKS-15CH
and HD6 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.
The magnetic clutch connector is a waterproof type.
MAGNETIC CLUTCH
The compressor is driven by the drive belt from the
crank pulley of the engine. If the compressor is
activated each time the engine is started, this
causes too much load to the engine. The magnetic
clutch transmits the power from the engine to the
compressor and activates it when the air
conditioning is ÒONÓ. Also, it cuts off the power
from the engine to the compressor when the air
conditioning is ÒOFFÓ. (Magnetic clutch repair
procedure can be found in Section 1D.)
CONDENSER
The condenser assembly in front of the radiator,
which carry the refrigerant and cooling fins to
provide rapid transfer of heat.
Also, it functions to cool and liquefy the high-
pressure and high-temperature vapor sent from the
compressor by the radiator fan or outside air.
A condenser may malfunction in two ways: it may
leak, or it may be restricted. A condenser restriction
will result in excessive compressor discharge
pressure. If a partial restriction is present, the
refrigerant expands after passing through the
restriction.
Thus, ice or frost may from immediately after the
restriction. If air flow through the condenser or
radiator is blocked, high discharge pressures will
result. During normal condenser operation, the
refrigerant outlet line will be slightly cooler than the
inlet line.
The vehicle is equipped with the condenser of the
parallel flow type condenser. A larger thermal
transmission area on the inner surface of the tube
allows the radiant heat to increase and the
ventilation resistance to decrease.
The refrigerant line connection has a bolt at the
block joint, for easy servicing.
RECEIVER/DRIER
The receiver/drier performs four functions;
·As the quantity of refrigerant circulated varies
depending on the refrigeration cycle conditions,
sufficient refrigerant is stored for the refrigera-
tion cycle to operate smoothly in accordance
with fluctuations in the quantity circulated.
·The liquefied refrigerant from the condenser is
mixed with refrigerant gas containing air
bubbles. If refrigerant containing air bubbles is
sent to the expansion valve, the cooling
capacity will decrease considerably. Therefore,
the liquid and air bubbles are separated and
only the liquid is sent to the expansion valve.
·The receiver/drier utilizes a filter and dryer to
remove the dirt and water mixed in the cycling
refrigerant.
·The sight glass, installed atop the receiver/
drier, show the state of the refrigerant.
A receiver/drier may fail due to a restriction inside
the body of the unit. A restriction at the inlet to the
receiver/drier will cause high pressures.
Outlet restrictions will be indicated by low pressure
and little or no cooling. An excessively cold
receiver/ drier outlet may indicate a restriction.
The receiver/drier of this vehicle is made of
aluminum with a smaller tank. It has 300 cc
(8.5 Imp fl oz) refrigerant capacity.
The refrigerant line connection has a bolt at the
block joint, for easy servicing.
DKV-14D TYPE
DKS-15CH TYPE
HD6 TYPE
Magnetic clutch
CompressorSuction side
Discharge side
Compressor Magnetic clutch
852RW031 871RY00012
871RY00011

1B Ð 26 AIR CONDITIONING
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
·Refer to Refrigerant Recovery in this section.
3. Disconnect magnetic clutch harness connector.
4. Remove radiator fan shroud.
5. Remove radiator fan.
·When the fan is removed, be sure to tighten
the fan fixing nuts temporarily to their original
positions.
6. Remove serpentine belt.
·Move serpentine belt tensioner to loose side
using wrench, then remove serpentine belt.
Legend
(1) Tensioner
(2) Idle Pulley
(3) Cooling Fan Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
7. Disconnect refrigerant line connector.
·When removing the line connector, the
connecting part should immediately be
plugged or capped to prevent foreign matter
from being mixed into the line.
8. Remove compressor.
Installation
1. Install compressor.
·Tighten the compressor fixing bolts to the
specified torque.
Compressor Fixing Torque Nám (kgám / lbáft)
19 (1.9 / 14)
2. Connect refrigerant line connector.
·Tighten the refrigerant line connector fixing
bolts to the specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
15 (1.5 / 11)
·O-rings cannot be reused. Always replace with
new ones.
·Be sure to apply new compressor oil to the O-
rings when connecting refrigerant lines.
3. Install serpentine belt.
·Move serpentine belt tensioner to loose side
using wrench, then install serpentine belt to
normal position.
4. Install radiator fan.
5. Install radiator fan shroud.
6. Connect magnetic clutch harness connector.
3
4
2
7 86 1
5
850RX003

1B Ð 34 AIR CONDITIONING
REMOVAL
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
·Refer to Refrigerant Recovery in this section.
3. Remove radiator grille.
4. Remove front bumper assembly.
·Refer to Bumpers in Body and Accessories section.
5. Remove engine hood front end stay.
6. Disconnect pressure switch connector.
7. Disconnect refrigerant line.
·When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line.
8. Remove condenser assembly.
·Handle with care to prevent damaging the
condenser or radiator fin.
·Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
INSTALLATION
1. Install condenser assembly.
·If installing a new condenser, be sure to add 30cc
(1.0 fl. oz.) of new compressor oil to a new one.
·Tighten the condenser fixing bolts to the specified
torque.
Condenser Fixing Torque Nám (kgám / lbáin)
6 (0.6 / 52)
2. Connect refrigerant line.
·Tighten the inlet line connector fixing bolt to the
specified torque.
Inlet Line Torque Nám (kgám / lbáft)
15 (1.5 / 11)
·Tighten the outlet line connector fixing bolt to the
specified torque.
Outlet Line Torque Nám (kgám / lbáin)
6 (0.6 / 52)
·O-rings cannot be reused. Always replace with new
ones.
·Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line..
3. Connect pressure switch connector.
4. Install engine hood front end stay.
5. Install front bumper assembly.
6. Install radiator grille.

AIR CONDITIONING 1B Ð 37
Removal Steps
1. Radiator grille
2. Pressure switch connector
3. Refrigerant line
4. Bracket bolt
5. Receiver/drier
Installation Steps
To install, follow the removal steps in the
reverse order.
RECEIVER/DRIER
3
35 2
4
1
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section.)
1. Radiator Grille
2. Pressure Switch Connector
3. Refrigerant Line
When removing the line connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter from being mixed
into the line.
4. Bracket Bolt
5. Receiver/Drier
Loosen the bolt, then, using care not to touch or bend
the refrigerant line, carefully pull out the receiver/
drier.

AIR CONDITIONING 1B Ð 39
Removal Steps
1. Radiator grille
2. Pressure switch connector
3. Pressure switch
Installation Steps
To install, follow the removal steps in the
reverse order.
PRESSURE SWITCH
2
3
1
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section.)
1. Radiator Grille
2. Pressure Switch Connector
3. Pressure Switch
When removing the switch connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter from being mixed
into the line.
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
Pressure Switch Torque Nám (kgám / lbáin)
13 (1.3 / 113)

1B Ð 40 AIR CONDITIONING
Legend
1. Pressure Switch Connector
2. Refrigerant Line
3. Receiver / Drier
4. Radiator Grille
5. Bracket Bolt
Receiver/Drier and Associated Parts (LHD V6 without Condenser Fan)
4
2
32 51
REMOVAL
1. Disconnect the battery ground cable
2. Discharge and recover refrigerant
·Refer to ÒREFRIGERANT RECOVERYÓ in this
section.
3. Remove radiator grille.
4. Disconnect pressure switch connector.
5. Disconnect refrigerant line.
·When removing the line connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter form being mixed
in to line.
6. Remove bracket bolt.
7. Remove receiver/drier.
·Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. If installing a new receiver/drier, be sure to add
30cc(1.0 fl. oz.) of new compressor oil to a new one.
2. Put the receiver/drier in the bracket and connect with
the refrigerant line. Check that no excessive force is
imposed on the line. Fasten the bracket bolt to the
receiver/drier.
3. Tighten the refrigerant line to the specified torque.
Refrigerant Line Blot Torque Nám (kgám / lbáin)
6 (0.6 / 52)
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
875RW002

AIR CONDITIONING 1B Ð 41
Pressure Switch and Associated Parts
2
3 1
Legend
1. Pressure switch connector
2. Pressure switch
3. Radiator Grille
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section.)
1. Radiator Grille
2. Pressure Switch Connector
3. Pressure Switch
When removing the switch connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter from being mixed
into the line.
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
Pressure Switch Torque Nám (kgám / lbáin)
13 (1.3 / 113)
875RW005

1B Ð 50 AIR CONDITIONING
Removal Steps
1. Radiator grille
2. Air cleaner
2a. Dust
2b. Battery and reserver tank
2c. Air cleaner cover
3. Clip and clamp
4. Liquid line (High-pressure pipe)
5. Suction line (Low-pressure pipe)
6. Suction line (Low-pressure hose)
7. Discharge line (High-pressure hose)
Installation Steps
To install, follow the removal steps in the
reverse order.
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section.)
1. Radiator Grille
2. Air Cleaner
2a. Duct
2b. Battery and Reserver Tank
2c. Air Cleaner Cover
3. Clip and Clamp
4. Liquid Line (High-pressure pipe)
5. Suction Line (Low-pressure pipe)
6. Suction Line (Low-pressure hose)
7. Discharge Line (High-pressure hose)
·Use a back-up wrench when disconnecting and
reconnecting the refrigerant lines.
·When removing the refrigerant line connecting
part, the connecting part should immediately be
plugged or capped to prevent foreign matter from
being mixed into the line.
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. O-rings cannot be reused. Always replace new ones.
2. Be sure to apply compressor oil to the O-rings when
connecting refrigerant lines.
3. Tighten the refrigerant line to the specified torque.
(Refer to ÒSERVICE INFORMATIONÓ for FIXING
TORQUE in section 00.)

POWER ASSISTED BRAKE SYSTEM 5C – 21
SPECIAL TOOLS
ILLUSTRATION PART NO. PARTNAME
Primary piston holder
5-8840-2306-0
(including master cylinder attach-
(J-39242)
ment and master cylinder plug)
5-8840-0277-0
Radiator cap tester
(J-24460-01)
5-8840-2300-0
Push rod gauge
(J-39216)
5-8840-0279-0
Vacuum pump
(J-23738-A)
5-8840-2305-0
Push rod support
(J-39241)

5C – 66 POWER ASSISTED BRAKE SYSTEM
Radiator cap tester: 5-8840-0277-0 (J-24460-01)
•Connect master cylinder attachment with the end
of radiator cap tester, and apply air pressure with
the cap tester. Make sure there is no rise in
pressure and that with the adjusting bolt further
screwed in 5 mm (align the adjusting bolt to the
“5” line). There should be a pressure increase of
49 kpa (0.5 kg/cm
2/7.1 psi) or more.
NOTE:
When checking the front (or primary) side, be sure to
mount master cylinder plug in the rear (or secondary)
port.
NOTE:
1) Do not use an air compressor, as the air from
compressor is mixed with compressor oil.
2) When installing the master cylinder onto the
vacuum booster, always adjust vacuum booster
push rod. (Refer to Vacuum Booster Assembly in
this section.)
3) After the master cylinder is installed onto the
vehicle, check for leakage, pedal travel and pedal
free play.
Master cylinder
plug
Master cylinder attachment
5-8840-0277-0
Radiator cap tester
5-8840-2306-0
“0” line“5” line
Apply air No pressure Pressure
pressure to rise. increase of
the front and
49 kpa (0.5 kg/cm2/
rear ports 7.1 psi) more
Remarks Check port into Checks air
the atmospheric tightness of the
pressure pressure
chamber chamber