1998 ISUZU TROOPER Service Repair Manual

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Page 257 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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
numbe

Page 258 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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

Page 259 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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,

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.

Page 260 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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 us

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

Page 261 of 3573

ISUZU TROOPER 1998 Service Repair Manual COMPRESSOR OVERHAUL 1D Ð 5
Checking and Adjusting for Compressor
Replacement
150cc (4.2 Imp fl oz) of oil is charged in compressor
(service parts). So it is necessary to drain the proper
amount of o

COMPRESSOR OVERHAUL 1D Ð 5
Checking and Adjusting for Compressor
Replacement
150cc (4.2 Imp fl oz) of oil is charged in compressor
(service parts). So it is necessary to drain the proper
amount of oil from the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the
compressor.
3) Drain the compressor oil and measure the
extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.
Amount of oil drained Draining amount of oil
from used compressor from new compressor
less than Same as drained
90cc (2.5 Imp fl oz) amount
more than
90cc (2.5 Imp fl oz)
90cc (2.5 Imp fl oz)
6) Evacuate, charge and perform oil return
operation.
7) Check system operation.
CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a
long period of time (approximately 1 season), the
oil never becomes contaminated as long as there is
nothing wrong with the compressor or its method
of use.
Inspect the extracted oil for any of the following
conditions:
·The capacity of the oil has increased.
·The oil has changed color to red.
·Foreign substances, metal powder, etc., are
present in the oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier
must be replaced.
OIL RETURN OPERATION
There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system.
When checking the amount of oil in the system, or
replacing any component of the system, the
compressor must be run in advance for oil return
operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is ÒONÓ and
Set the fan control knob at its highest position.
3) Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate
the system.
4) Stop the engine.
REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply
the following amount of oil to the component parts
to be installed.
Component parts to be installed Amount of oil
Evaporator 50cc (1.4 Imp fl oz)
Condenser 30cc (0.8 Imp fl oz)
Receiver/drier 30cc (0.8 Imp fl oz)
871RX013

Page 262 of 3573

ISUZU TROOPER 1998 Service Repair Manual 1D Ð 6 COMPRESSOR OVERHAUL
Legend
(1) Drive Plate Bolt
(2) Drive Plate
(3) Snap Ring(4) Pulley Assembly
(5) Field Coil
(6) Shim(s)
(7) Lead Wire
Removal
1. Remove drive plate bolt by using drive plat

Page 263 of 3573

ISUZU TROOPER 1998 Service Repair Manual COMPRESSOR OVERHAUL 1D Ð 7
3. Remove shim(s).
4. Remove snap ring (1) by using snap ring pliers.
5. Remove pulley assembly by using pulley puller pilot
J-38424 (2), pulley puller J-8433 (1) and pull

Page 264 of 3573

ISUZU TROOPER 1998 Service Repair Manual 1D Ð 8 COMPRESSOR OVERHAUL
Inspection and Repair
Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
Chec

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