Isuzu Trooper (2000 year). Manual - part 25

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–69

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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

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.

1A–70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Metric Thread Size Information

Compressor to mounting bracket bolts (Front)

M10 

×

 1.5 – 6H

Compressor to mounting bracket bolts (Rear)

M8 

×

 1.25 – 6H

Suction-discharge port screw

M10 

×

 1.5 – 6H

Compressor shaft

M9 

×

 1.25 – 6H

Internal hub-clutch drive assembly

M22 

×

 1.5 – 6H

Compressor Clutch Plate and Hub Assembly

Removal

1. Clamp the holding fixture J-33026 in a vise and attach

compressor to holding fixture with thumb screws
J-33026-1.

2. With center screw forcing tip in place to thrust against

the end of the shaft, thread the Clutch Plate and Hub
Assembly Installer-Remover J-33013-B into the hub.
Hold the body of the remover with a wrench and turn
the center screw into the remover body to remove the
clutch plate and hub assembly (1).

CAUTION: Do not drive or pound on the clutch hub
or shaft.  Internal damage to compressor may result.
The forcing tip on J-33013-B remover-installer center
screw must be flat or the end of the shaft/axial plate
assembly will be damaged.

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3. Remove the shaft key and retain for reassembly.

Installation

1. Install the shaft key into the hub key groove.  Allow the

key to project approximately 3.2 mm (1/8 in) out of
the keyway. The shaft key is curved slightly to provide
an interference fit in the hub key groove.

2. Be sure the frictional surface of the clutch plate and

the clutch rotor (2) are clean before installing the
clutch plate and hub assembly (1).

3. Align the shaft key (4) with the shaft keyway (3) and

place the clutch plate and the hub assembly onto the
compressor shaft.

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4. Remove the forcing tip on J-33013-B clutch plate and

hub assembly installer-remover center screw and
reverse the body direction on the center screw, as
shown in Figure.

5. Install the clutch plate and hub installer-remover

J-33013-B with bearing as shown in Figure.
The body of the J-33013-B installer-remover should
be backed off sufficiently to allow the center screw to
be threaded onto the end of the compressor shaft.

6. Hold the center screw with a wrench.  Tighten the hex

portion of the installer-remover J-33013-B body to
press the hub onto the shaft.  Tighten the body
several turns, remove the installer and check to see
that the shaft key is still in place in the keyway
before installing the clutch plate and hub
assembly to its finial position.  The air gap (2)
between frictional surfaces of the clutch plate and
clutch rotor should be 0.50–0.76 mm (.020–.030 in).

CAUTION: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of the

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–71

installer is held and the center screw is rotated, the
key will wedge and will break the clutch hub.

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7. Remove installer J-33013-B, check for proper

positioning of the shaft key (even or slightly above the
clutch hub).

8. Spin the pulley rotor by hand to see that the rotor is not

rubbing the clutch drive plate.

Compressor Clutch Rotor and/or Bearing

Removal

1. Remove the clutch plate and hub assembly as

described previously.

2. Remove rotor (1) and bearing assembly retaining ring

(2), using snap ring pliers.

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3. Install pulley rotor and bearing puller guide J-33023-A

to the front head and install J-41552 pulley rotor and
bearing puller down into the inner circle of slots (1) in
the rotor. Turn the J-41552 puller clockwise in the
slots in the rotor.

4. Hold the J-41552 puller in place and tighten the puller

screw against the puller guide to remove the pulley
rotor and bearing assembly.

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Installation

1. With the compressor mounted to the J-34992 holding

fixture, position the rotor and bearing assembly on the
front head.

2. Position the J-33017 pulley, rotor and bearing installer

and J-33023-A puller pilot directly over the inner race
of the bearing.

1A–72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

3. Position puller crossbar J-8433-1 on the puller pilot

J-33023-A and assemble the two J-33026 through
bolts and washers through the puller bar slots and
thread them into the J-33026 holding fixture. The
thread of the through bolts should engage the full
thickness of the holding fixture.

4. Tighten the center screw in the J-8433-1 puller

crossbar to force the pulley rotor (1) and bearing
assembly onto the compressor front head.  Should
the J-33017 pulley rotor and bearing installer slip off
direct in-line contact with the inner race of the bearing,
loosen the J- 8433-1 center forcing screw and realign
the installer and pilot so that the J-33017 installer will
properly clear the front head.

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5. Install rotor and bearing assembly retainer ring, using

snap ring pliers .

6. Reinstall clutch plate and hub assembly as described

previously.

Compressor Clutch Coil

Removal

1. Perform Steps 1 through 4 of “Clutch Rotor and/or

Bearings” removal procedure.  Mark clutch coil
terminal location (1) on compressor front head.

2. Install J-33023-A puller pilot on front head of

compressor. Also install J-8433-1 puller crossbar with
J-33025 puller legs as shown in figure.

3. Tighten J-8433-3 forcing screw against the puller pilot

to remove the clutch coil (2).

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