Isuzu Trooper (2000 year). Service manual — part 27
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–77
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Charging amount of oil
to new compressor)
more than 90 cc (3.0
fl.oz)
same as drained amount
less than 90 cc (3.0 fl.oz)
90 cc (3.0 fl.oz)
6. Evacuate, charge and perform the oil return
operation.
7. Check the 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 one 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:
D
The capacity of the oil has increased.
D
The oil has changed to red.
D
Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the 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 all the doors and the engine hood.
2. Start the engine and air conditioning switch to “ON”
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 the 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
50 cc (1.7 fl. oz.)
Condenser
30 cc (1.0 fl. oz.)
Receiver/dryer
30 cc (1.0 fl. oz.)
Refrigerant line (one
piece)
10 cc (0.3 fl. oz.)
Compressor Leak Testing (External
and Internal)
Bench-Check Procedure
1. Install test plate J-39893 on rear head of compressor.
2. Using Refrigerant Recovery System, attach center
hose of manifold gage set on charging station to a
refrigerant drum standing in an upright drum.
3. Connect charging station high and low pressure lines
to corresponding fittings on test plate J-39893.
Suction port (low-side) of compressor has large
internal opening. Discharge port (high-side) has
smaller internal opening into compressor and deeper
recess.
4. Open low pressure control, high pressure control and
refrigerant control on charging station to allow
refrigerant vapor to flow into compressor.
5. Using a leak detector, check for leaks at pressure
relief valve, rear head switch location, compressor
front and rear head seals, center cylinder seal,
through bolt head gaskets and compressor shaft
seal. After checking, shut off low pressure control and
high-pressure control on charging station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
certain the leak has been connected.
7. Recover the refrigerant.
8. Disconnect both hoses from the test plate J-39893.
9. Add 90 ml (3 oz.) new PAG lubricant to the
compressor assembly. Rotate the complete
compressor assembly (not the crankshaft or drive
plate hub) slowly several turns to distribute oil to all
cylinder and piston areas.
10. Install a M9
×
1.25 threaded nut on the compressor
crankshaft if the drive plate and clutch assembly are
not installed.
11. Using a box-end wrench or socket and handle, rotate
the compressor crankshaft or clutch drive plate on the
crankshaft several turns to insure piston assembly to
cylinder wall lubrication.
12. Using Refrigerant Recovery System, connect the
charging station high-pressure line to the test plate
J-39893 high-side connector.
13. Using Refrigerant Recovery System, connect the
charging station low-pressure line to the low pressure
port of the test plate J-39893. Oil will drain out of the
compressor suction port if the compressor is
positioned with the suction port downward.
1A–78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
14. Attach the compressor to the J-34992 holding fixture
and mount the compressor in a vise so that the
compressor will be in a horizontal position and the
shaft can be turned with a wrench.
15. Using a wrench, rotate the compressor crankshaft or
drive plate hub ten complete revolutions at a speed of
approximately one-revolution per second turning the
compressor at less than one-revolution per second
can result in a lower pump-up pressure and disqualify
a good pumping compressor.
16. Observe the reading on high-pressure gauge at the
completion of the tenth revolution of the compressor.
The pressure reading for a good pumping
compressor should be 690 kPa (100 psi) or above. A
pressure reading of less than 620 kPa (90 psi) would
indicate one or more suction and/or discharge valves
leaking an internal leak, or an inoperative valve, and
the refrigerant must be recovered and the
compressor disassembled and checked for cause of
leak. Repair as needed, reassemble and repeat the
pump-up test. Externally leak test.
17. When the pressure pump-up test is completed,
recover the refrigerant from the high-side and remove
the test plate J-39893.
18. Tilt the compressor so that the compressor suction
and discharge ports are down. Drain the PAG
lubricant from the compressor.
19. Allow the compressor to drain for 10 minutes, then
refill with the proper amount of PAG lubricant, per oil
balance procedure described previously. The PAG
lubricant may be poured into the suction port. If
further assembly or processing is required, a shipping
plate or test plate J-39893 should be installed to keep
out air, dirt and moisture until the compressor is
installed.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–79
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J-33013-B
Hub and Clutch Drive
Plate Asm. remover
J-33026
Compressor Holding
Fixture
J-33023-A
Puller Pilot
J-41552
Pulley Puller
J-33017
Pulley and Bearing
Assembly Installer
J-8433-1
Puller Bar
ILLUSTRATION
TOOL NO.
TOOL NAME
J-8433-3
Forcing Screw
J-33025
Clutch Coil Installer
Adapter
J-33024
Clutch Coil Installer
Adapter
J-23128-A
Seal Seat Remover and
Installer
J-9553-01
O-Ring Remover
J-33011
O-Ring Installer
1A–80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
ILLUSTRATION
TOOL NO.
TOOL NAME
J-34614
Shaft Seal Protector
J-39893
Pressure Testing
Connector
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