1998 ISUZU TROOPER clutch

AIR CONDITIONING 1BÐ75
FULL AUTO display
INTAKE indication
(LED)
(switching between
fresh and interior air)
MODE indication
(LED) (Blow port)
AC display (LED)
FAN indication (LED)
FAN KNOB
AUTO SET
REC FRESH SWITCH
TEMP LEVER
(temperature control)
MODE SWITCH
(blow port selection)
AC SWITCH
IN CAR SENSOR
AMBIENT SENSOR
SUN SENSOR
DUCT SENSOR
MIX ACTUATOR
POTENTIOMETER
MODE ACTUATOR
POTENTIOMETER
AIR MIX DOOR
MODE DOOR
INTAKE ACTUATOR
RECINTAKE DOOR
FAN MOTORPOWER
TRANSISTOR
AUTOMATIC HEATER/AIR CONDITIONER CONTROL UNIT (with the built-in micro-computer)
MAX HI RELAY
PRESSURE
SWITCHAIR CONDITIONER
THERMO RELAY
COMPRESSOR
SWITCH MAGNET
CLUTCH
PCM
PRESSURE
SWITCHAIR CONDITIONER
THERMO RELAYMAGNET
CLUTCH
(4JX1engine)
MIX FRESH
FULL AUTOMATIC AIR CONDITIONER BLOCK DIAGRAM
F01RY00009

1BÐ118 AIR CONDITIONING
Inspection of the Magnet Clutch System
6VE1 Engine
I-32
C-1C-3I-33
E-3E-19
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9 10111213141516
1
112
123
134
145
156
167
178
189
1910
20
B-19C-25
A 2
B-361
H-14
C-19
25A
BLOWER
MOTOR
C-20
10A
A/C FL-1
80A
MAIN
Heater
Relay
1B-3610
H-13
0.3
B 0.85
W/G0.85
W/R
3.0
W
3.0
L/R
0.5
BR
1.25
B
B-19
BODY-LH3
B-36
4B-36
BATT.(+)
Blower
MotorIntake
Actuator STARTER
RELAY(1)
0.5
LG 0.5
BR0.5
BR
0.5
G/W
0.5
P/G0.5
P/G0.5
G/O
0.5
G/O
PCM
(C3-E15)
31 13
COMP-F/B 70.5
BR
0.5
BR/Y 0.3
G/B0.5
G/B0.5
BR/Y 0.5
BR
Triple
Pressure
Switch
0.5
BR
A
A/C
Thermo Relay
Auto A/C Control Unit
3X-5
16
H-1617H-16
14
I-3218I-33
1X-5
13H-24
12
H-41
2 1
C-25
C-25
4X-5X-5 2
X-57
H-16
A/C
Compressor
Relay
Magnetic
clutch
1X-7
3X-74X-72
X-7
PCM
(C-1-B14)
E-39
1
H-67
H-41
5
H-41
Engine
Coolant
Temperature
Sensor
ENGINE COOLANT
TEMPERATURE GAUGE
0.5
Y/B
0.5
Y/B
0.5
Y/B
E-1911
1
H-61
H-24
I-334
B-36X-5X-7
H-14
1
2
1
2
H-16
H-24
H-13
H-6H-41
12
3412111
362
51
4 123
45 610987654321
22212019181514131211171612345111213141567891018192021221617
6H-41
4321
8765
12 11 10 9
16 15 14 13123 4
567 8
9101112
13 14 15 16
17 18 16 15 1478 6 5
12 13 11 10 94 132
5 6 7 8
15 16 17 18 142 3 41
10 11 12 13 9A1 A2 A3 A4 A5 A6 A7 A8 A9A10 A11 A12 A13 A14 A15 A16B1 B2 B3 B4 B5 B6 B7 B8 B9B10 B11 B12 B13 B14 B15 B16E1 E2 E3 E4 E5 E6 E7 E8 E9E10 E11 E12 E13 E14 E15 E16F1 F2 F3 F4 F5 F6 F7 F8 F9F10 F11 F12 F13 F14 F15 F16
D08RY00182

AIR CONDITIONING 1BÐ119
Chart A: Magnet Clutch Does Not work
NOThe harness is disconnected.
NOReplace the failed relay.
NOFailure on the power supply system.
NO
NO
NOReplace the fuse.
YESFailure on the magnet clutch.
NOReplace the electronic thermostat.
YES
YES YES
YES
YESNO
YES
The harness is disconnected.
Failure on the pressure switch or
refrigerant is insufficient.
Turn the A/C (air conditioner) switch on.
Are the pressure switch side connector
terminals No.1 and No.2
conducted?C-25C-25
Are relays normal?
Is fuse (C-20) 10A normal?
Is the electronic thermostat normal?
Is the battery voltage present between
the chassis harness side connector
terminal No.1 and the ground?
E-3
Is the battery voltage present between
the chassis harness side connector
terminal No.1 and the ground.
C-25
Is the battery voltage present between
the chassis side relay terminal No.3
and the ground, and No.1
and the ground?
X-7X-5
YES
Turn the ignition switch off.
Is conduction provided between the
following chassis harness side connecter
terminals?
No.2 and No.2 .
No.4 and No.1 .
E-3X-7
X-7X-5
Turn the ignition switch on (the engine is
started).
Magnet clutch does not work
Chart A
Type of trouble

AIR CONDITIONING 1BÐ121
4JX1 Engine
Magnet clutch does not work.
Chart A
Type of trouble
C-25
0.5 BR
C-25
X-5X-5
X-5X-5
2 1
4 3
0.5 P/G FL-1 MAIN
80A
C-20
10A A/C
0.5 G/W 0.5 G/O
C-25E-27H-16
Pressure
switch
Relay:
Air conditioning
thermostat
Automatic heater/air conditioner
control unitRelay:
Air conditioning
0.5 BR
1
2
I-3214
Fan “ON”
12
I-32X-5
12
34
E-271
Magnet
clutch
B-36
B-36
H-1616
1117 18 16 15 1478 6 5
12 13 11 10 94 132
5 6 7 8
15 16 17 18 142 3 41
10 11 12 13 9
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D08RY00183

1BÐ122 AIR CONDITIONING
Chart A: Magnet Clutch Does Not Work
NOReplace the fuse.
NOReplace the failed relay.
NOReplace the electronic thermostat.
YESFailure on the magnet clutch.
NOThe harness is disconnected.
NOFailure on the power supply system.
YES
Is fuse C-20 (10A) normal?
Are relays normal?
YES
YES
Is the electronic thermostat normal?
YES
Turn the A/C (air conditioner) switch on.
Is the battery voltage present between the
chassis harness side connector terminal
No.1 and the ground?
E-27
NO
Is the battery voltage present between the
chassis harness side connector terminal
No.1 and the ground.
C-25
YES
NOFailure on the pressure switch or refrigerant is
insufficient.
NOThe harness is disconnected.Is the battery voltage present between the
chassis side relay terminal No.1
and the ground?X-5
Are the pressure switch side connector
terminals No.1 and No.2
conducted?C-25C-25
YES
YES
Failure on the automatic heater/air
conditioner control unit.
NOThe harness is disconnected.
Is conduction provided between the
chassis harness side connecter terminals
No.1 and No.4 ?
X-5E-27
YES
Are the chassis harness connector
terminals No.14 and No.3 ?X-5I-32

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.

COMPRESSOR OVERHAUL 1D Ð 9
7. Install drive plate bolt by using drive plate holder
J-7624 (1) to prevent the drive plate from rotating.
·Tighten the drive plate bolt to the specified torque.
Torque: 13 Nám (113 lb in)
·After tightening the drive plate bolt, check to be
sure the pulley rotates smoothly.
·Check to be sure that the clutch clearance is
between 0.3-0.6 mm (0.01-0.02 in.)
·If necessary, install adjusting shim(s).
·Adjusting shims are available in the following
thickness.
Thickness
·0.1 mm (0.0039 in.)
·0.3 mm (0.0118 in.)
·0.5 mm (0.0197 in.)
1
901RX055
871RX014

COMPRESSOR OVERHAUL 1D Ð 17
19. Install shim(s).
20. Install drive plate.
·Install the drive plate to the compressor drive
shaft together with the original shim(s)(1) press
the drive plate by hand.
21. Install drive plate bolt by using drive plate holder
J-7624 (1) to prevent the drive plate from rotating.
·Tighten the bolt to the specified torque.
Torque: 15Nám (11 lbáin)
NOTE
After tightening the bolt, check to be sure the
pulley rotates smoothly.·Check to be sure that the clutch clearance is
between 0.3Ð0.6 mm (0.01Ð0.02 in.)
·If necessary, install adjusting shim(s).
·Adjusting shims are available in the following
thickness.
Thickness
·0.1 mm (0.0039 in.)
·0.3 mm (0.0118 in.)
·0.5 mm (0.0197 in.)
1
871RY00009
871RY00007
1
901RY00010