ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Compressor

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Removing the air conditioning compressor-1991 Trooper



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Fig. Fig. 2: Air conditioning compressor-2.3L and 2.6L engines



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Fig. Fig. 3: Air conditioning compressor-2.8L and 3.1L engines



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Fig. Fig. 4: Air conditioning compressor sealing rings must be in place-2.2L gasoline engine



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Fig. Fig. 5: Air conditioning compressor-3.2L engine

1.8L and 2.0L Gasoline Engines; 2.2L Diesel Engine

The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the undercover, if so equipped.
  4.  
  5. If necessary for clearance, matchmark the distributor rotor and housing position, then remove the distributor assembly.
  6.  
  7. Disconnect and plug the high and low pressure fittings from the compressor.
  8.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Loosen the belt tension center bolt and adjusting bolt. Remove the belt.
  2.  
  3. Disconnect the clutch electrical wire.
  4.  
  5. Remove the retaining bolts and compressor.
  6.  

To install:
  1. Install the compressor and retaining bolts.
  2.  
  3. Connect the clutch electrical wire.
  4.  
  5. Install the belt, adjust belt tension and tighten center bolt.
  6.  
  7. Connect the high and low pressure fittings to the compressor.
  8.  
  9. Install the distributor.
  10.  
  11. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance .
  12.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

2.2L Gasoline Engine

The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the accessory drive belt.
  4.  
  5. Disengage the compressor clutch connector.
  6.  
  7. Disconnect the compressor condenser hose assembly.
  8.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Remove the compressor brace.
  2.  
  3. Remove the compressor.
  4.  

To install:
  1. Install the compressor and retaining bolts. Tighten to 37 ft. lbs. (50 Nm).
  2.  
  3. Install the compressor brace and retaining bolts. Tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. Connect the clutch electrical wire.
  6.  
  7. Install the accessory drive belt.
  8.  
  9. Connect the compressor and condenser hose assembly. Use new seals. Tighten to bolt to 25 ft. lbs. (33 Nm).
  10.  
  11. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance .
  12.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

2.3L and 2.6L Engines

The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the accessory drive belt.
  4.  
  5. Remove the power steering pump and bracket, if equipped.
  6.  
  7. Disconnect the compressor clutch connector.
  8.  
  9. Disconnect the compressor refrigerant line.
  10.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Remove the compressor.
  2.  

To install:
  1. Install the compressor and retaining bolts. Tighten to 29 ft. lbs. (40 Nm).
  2.  
  3. Connect the clutch electrical wire.
  4.  
  5. Install the accessory drive belt.
  6.  
  7. Connect the high and low pressure fittings to the compressor. Tighten to 20 ft. lbs. (28 Nm).
  8.  
  9. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance .
  10.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

2.8L and 3.1L Engines

The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove drive belt.
  4.  
  5. Disconnect the compressor clutch connector.
  6.  
  7. Disconnect the compressor refrigerant line.
  8.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Remove the compressor brace.
  2.  
  3. Remove the dynamic damper, if equipped.
  4.  
  5. Remove the compressor.
  6.  

To install:
  1. Install the compressor and brace retaining bolts. Tighten to 35 ft. lbs. (47 Nm).
  2.  
  3. Install the dynamic damper. Tighten to 58 ft. lbs. (78 Nm).
  4.  
  5. Connect the clutch electrical wire.
  6.  
  7. Install the belt, adjust belt tension and tighten center bolt.
  8.  
  9. Connect the high and low pressure fittings to the compressor. Tighten to 20 ft. lbs. (27 Nm).
  10.  
  11. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance .
  12.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

3.2L Engine

The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Disconnect the compressor clutch connector.
  4.  
  5. Disconnect the compressor refrigerant line.
  6.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Remove the compressor.
  2.  

To install:
  1. Install the compressor and retaining bolts. Tighten to 14 ft. lbs. (19 Nm).
  2.  
  3. Connect the clutch electrical wire.
  4.  
  5. Install the belt, adjust belt tension and tighten center bolt.
  6.  
  7. Connect the high and low pressure fittings to the compressor. Tighten to 11 ft. lbs. (15 Nm).
  8.  
  9. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance .
  10.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

 
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