charging ISUZU TROOPER 1995 User Guide

ENGINE DIAGNOSIS S-1
ENGINE
CONTENTS
Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section S
General
Engine Mechanical .................................................... Section SA
3.2L VS Engine ............................................................... Section SA1
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section S8
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SC
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SD
Driveability and Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SE2
Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SF
SECTION 6
ENGINE GENERAL INFORMATION
CONTENTS
Description of Engine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
DESCRIPTION OF ENGINE SECTION
SECTIONS-ENGINE GENERAL INFORMATION SECTION S8-ENGINE COOLING
General description
Engine cleanliness and care, and general information
on engine service are covered in this section.
Engine diagnosis
This section covers the components of the fuel,
ignition, and mechanical systems that could cause a
particular complaint, and then outlines repairs in a
logical sequence.
SECTION SA-ENGINE MECHANICAL
This section contains information on the mechanical
parts of the engine, such as cylinder block, cylinder
head, crankshaft, pistons, valve train, camshaft, and
engine
lubrication.
Overhaul
procedures, removal and replacement
procedures, and specifications are also covered.
Specific subsections are:
SA-GENERAL;
Disassembly and reassembly procedures,
inspection and repair procedures
off the vehicle.
6A 1-3.2L V6 ENGINE;
Removal
and replacement procedures on the
vehicle.
Engine cooling system components such as radiator,
engine
coolant pump, thermostat, and cooling fan, are
covered
in this section.
SECTION SC-ENGINE FUEL
This section contains information on all the parts of the
fuel system except the fuel injectors, or throttle body II
unit itself. Items covered are: fuel tank, fuel pump, fuel
filter,
and fuel lines. Specific sections are used for each
fuel system type:
Port
Injection fuel rail and injectors will be found in
Section
6E2.
SECTION SD-ENGINE ELECTRICAL
Items covered in this section are battery, generator,
starter, ignition
coil, spark plugs and wires.
Ignition system diagnosis will be found in Section 6E2
as a "C4" chart.
Specific sections are:
601 -Battery
602 - Cranking System
603 -Charging System
604 -Ignition System

ENGINE ELECTRICAL 601-1
SECTION 60
ENGINE ELECTRICAL
CONTENTS
Battery . . ..... . ...... . ... . .... . .... ..... .... . .... .. .... . .... . . ... . . . .... . . .. . . .... . ... . ... . .... . . .. ... . .... . . ... . ... . . .. . Section 601
Cranking System
........... ... . ... . .... . .... . . .... . .... .

. ... . . .... . .... . .... . . ... ...
.. .... . . ..... . .... . ......... ... Section 602
Charging System ..... .... . . .............. .... . .... . . .. .. . . ... . . ... . . ... . . ... . . ........ .... . . ..... .. .... . ... . .... . .. Section 603
Ignition System (V6 3.2L) .. .... ...... ...... .. .. .. .... ...... .... .. .... .... .... ...... ...... ...... .......... .... Section 6D4A
SECTION 601
BATTERY
CONTENTS
General Description ............................... 6D1-1
Diagnosis .............................................. 6D1-1
On-Vehicle Service ................................ 6D1-3
Battery Charging ................................ 6D1-3
Jump Starting .................................... 6D1-3
Removal and Installation of The Battery . . 6D1-4
Main Data and Specifications . . . . . . . . . . . . . . . . . . 6D1-4
GENERAL DESCRIPTION
There are six battery fluid caps at the top of the
battery. These are covered by a paper
label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes per­
mit the escape of small amounts of gas generated
by the battery.
This type
of battery has the following advantages
over
conventional batteries:
1. There is no need to add water during the entire
service
life of the battery.
2. The battery protects itself against overcharging.
The battery
will refuse to accept an excessive
charge. (A
conventional battery will accept an excessive
charge,
resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self­
discharge than a conventional type battery.
DIAGNOSIS
1. VISUAL INSPECTION
Inspect the battery for obvious physical damage,
such
as a cracked or broken case, which would per­
mit electrolyte loss.
Replace
the battery if obvious physical damage is
discovered during inspection.
Check
for any other physical damage and correct it
as necessary. If not, proceed to Step 2.
2. HYDROMETER CHECK
There is a built-in hydrometer (Charge test indica­
tor) at the top of the battery. It is designed to be
used during diagnostic procedures. Before
trying to read the hydrometer,
carefully
clean
the upper battery surface.
If your work area is poorly lit, additional light may
be necessary
to read the hydrometer (Fig. 6D1-1).
a. BLUE RING OR DOT VISIBLE -Go to Step
4.
b. BLUE RING OR DOT NOT VISIBLE -Go to
Step 3.

6D1-2 ENGINE ELECTRICAL
Charge test indicator
Upper level
Lower level
OK Charging necessary
vv Blue Colorless
Fig. 6D1-1
3. FLUID LEVEL CHECK
The fluid level should be between the upper level
line
and lower level line on side of the battery (Fig.
6D1-1).
a. CORRECT FLUID LEVEL - Charge the bat­
tery.
b. BELOW LOWER LEVEL -Replace battery.
4. VOLTAGE CHECK
(1) Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE -Go to
Step 5.
b. VOLTAGE IS UNDER 12.4V -Go to proce­
dure
(2) below.
(2) Determine fast charge amperage from
specification. (See Main Data and Specifications
in this section).
Fast charge battery for
30 minutes at amperage
rate no higher than specified
value.
Take voltage and amperage readings after
charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE-Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE -Drop charging voltage
to 15V and charge for 10 -15 hours.
Then
go to Step 5.
c. VOLTAGE IS BETWEEN 12V AND 16V -
Continue charging at the same rate for
an
additional 3-1/2 hours. Then go to Step 5.
d. VOLTAGE IS BELOW 12V -Replace bat­
tery.
5. LOAD TEST
(1) Connect a voltmeter and a battery load tester
across the battery
terminals.
(2) Apply 300 ampere load for 15 seconds to
remove surface charge
from the battery.
Remove
load.
(3) Wait 15 seconds to let battery recover. Then
apply specified load from specifications (See
Main Data and Specifications in this section).
Read voltage after 15 seconds, then remove
load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN Fig. 6D1-2 -The bat­
tery is good and
should be returned to ser­
vice.
b. VOLTAGE IS LESS THAN MINIMUM LISTED
-Replace battery.
ESTIMATED MINIMUM TEMPERATURE OF oc VOLTAGE
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 -1 9.1
20 -7 8.9
10 -12 8.7
0 -18 8.5
The battery temperature must be estimated by feel and by the temperature the battery has been exposed to for
the preceding few hours.
Fig. 6D1-2
•

ENGINE ELECTRICAL 601-3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the
fluid level is below the lower level line on the
side
of the battery. In this case, the battery
must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging
should be discontinued or the
rate
of charge reduced if the battery feels hot
to the touch.
Battery charging
should be discontinued or the
rate
of charge reduced if the battery begins to
gas or spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer
blue dot or ring, it may be necessary to jiggle
or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the
same manner
as other batteries.
Whichever method you decide
to use, be sure
that you
completely charge the battery. Never
partially charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER)
BATTERY
W CAUTION:
Never push or tow the vehicle in an attempt to
start it.
Serious damage to the emission sys­
tem as
well as other vehicle parts will result.
Treat both the discharged battery and the
booster battery
with great care when using
jumper cables. Carefully follow the jump start­
ing procedure, being
careful at all times to
avoid sparking.
wwARNING:
Failure to carefully follow the jump starting
procedure
could result in the following:
1. Serious personal injury, particulaly to your
eyes.
2. Property damage from a battery explo­
sion, battery acid, or an electrical fire.
3. Damage to the electronic components of
one or both vehicles particularly.
Never expose the battery to an open flame or elec­
trical
spark. Gas generated by the battery may catch
fire
or explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect
your eyes by
wearing
an approved set of goggles.
Never allow battery fluid to come in contact with
your eyes or skin.
Never
allow battery fluid to come in contact with
fabrics or painted surfaces.
Battery
fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface,
immediately and
thoroughly rinse the affected area with clean tap
water. Never
allow metal tools or jumper cables to come
in contact with the positive battery
terminal, or any
other
metal surface of the vehicle. This will protect
against a short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission,
place the selector lever in the
"PARK" position.
If the vehicle is equipped with a manual trans­
mission
place the shift lever in the "NEUTRAL"
position.
Turn
"OFF" the ignition.
Turn
"OFF" all lights and any other accessory
requiring
electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer
is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the posi­
tive
terminal of the booster battery.
Attach the other end
of the same cable to the
positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This
will cause a ground connection, effectively
neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt
rating.
4. Attach one end of the remaining cable to the
negative
terminal of the booster battery.
Attach the other end
of the same cable to a
solid engine ground (such as the air condition­
ing compressor bracket or the generator
mounting bracket)
of the vehicle with the dis­
charged battery.
This ground connection must be at
least 450
mm (18 in) from the battery of the vehicle
whose battery is being charged.

CRANKING SYSTEM 602 -3
DIAGNOSIS
Check if the battery is normal, then perform the following diagnosis.
I STARTER DOES NOT RUN I
I CHECK BATTERY I
I
CHARGING FAILURE BATTERY FAILURE I I BATTERY IS NORMAL I
I REPLACE BATTERY OR REPAIR CHARGING SYSTEM I
I
CHECK TERMINAL CONNECTION
I CONNECTION FAILURE I I TERMINAL CONNECTION IS NORMAL J
I CLEAN BATTERY TERMINALS, AND RECONNECT I
I CHECK STARTER OR STARTER SWITCH I
I FAILURE I
I REPAIR OR REPLACE I
TURN ON HEAD LAMPS AND STARTER SWITCH I
I
HEAD LAMPS DO NOT COME ON HEAD LAMP ILLUMINATES I OR THEY ARE EXTREMELY DARK
I
a) DISCONNECTED STARTER CIRCUIT
a) LACK OF BATTERY CHARGING b) DISCONNECTED STARTER COIL
b) SHORT-CIRCUIT IN STARTER COIL c) FAULTY STARTER SWITCH
c) FAULTY STARTER PARTS

CHARGING SYSTEM 6D3-1
SECTION 603
CHARGING SYSTEM
CONTENTS
General Description ....................... .
Diagnosis
.................................... .
On-Vehicle Service ........................ . 6D3-1
6D3-3
6D3-4 Unit
Repair . . .. .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 6D3-6
Inspection and Repair . . . . . . . . . . . . . . . . . . 6D3-8
Main Data and Specifications............ 6D3-12
GENERAL DESCRIPTION
The charging system is the IC integral regulator charg­
ing system and its main components are connected as
shown in Fig. 6D3-1.
The regulator is a solid state
type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover. The
generator does not require particular mainte­
nance such
as voltage adjustment. The rectifier con­
nected
to the stator coil has eight diodes to transform
A.C. voltage into D.C. voltage. This D.C. voltage is
connected
to the output terminal of generator. (Fig.
6D3-1)

603-2 CHARGING SYSTEM
Battery
+ -...--o ?
,.h,
a: a:l co BOA MAIN . .-. -,., ~
3: co
50 A KEYSW
Key
Position
LOCK
OFF
ACC
ON
START Key
Removed
Inserted
3WB
TO IG COIL
Battery Ignition Battery Accessories Ignition Starter 81 IG1 82 ACC IG2 ST
0 -o
,.... ,....
,.... ,... ,.... ...., ...., ...., ...., ....,
0 ,.... ,.... ,.... 0 ....,
...., ....,
I J
3BY ~ ,.,.
15A 15 A IGCOIL ENGINE
V
"B" termin_a_I _____ _,"IG" terminal
Generator assembly
s_:a_t_er_co __ i_l __ ~~~.-.-~ - Connector
/...-"""\. 0.85BY
B IG
I ~ I ~ A~
-~ ..->--~~ 0.85 WG 0.85 WR To ch arge
' _-: .~:f--<·1'
.~ ~ ~~~~ T ~-r-~ L
. L_ __j
• 1 .... ~ ~ E IC Regulator
L_ Rotor coil ----9---------------'
"L" terminal
warni ng light
0.85WR To ch arge
signal
0.85
WG To Relay, restart
Fig. 603-1
•

CHARGING SYSTEM 603 -3
DIAGNOSIS
GENERAL ON-VEHICLE INSPECTION
The operating condition of charging system is indi­
cated
by the charge warning lamp. The warning lamp
comes on when the starter switch is turned to "ON"
position. The charging system operates normally if
the lamp goes off when the engine starts. If the
Battery
+
warning lamp shows abnormality or if undercharged
or overcharged battery condition is suspected, per­
form diagnosis by checking the charging system as
follows:
Resistor
Ignition switch
"B" terminal
Fig. 603-2
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the starter switch to
"ON" position and observe the warning lamp.
• If lamp does not come on:
Disconnect
wiring connector from generator,
and
ground the terminal "L" on connector
side.
• If lamp comes on:
Repair
or replace the generator.
Connector
"L" terminal
l

603 - 4 CHARGING SYSTEM
ON-VEHICLE SERVICE
GENERATOR (fig. 603-3}
"B" terminal
Pullry
Fig. 603-3
~ INSPECTION
Wiring connector
I C regulator
assembly
Brush spring
ifier
Rear cover
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to
"ON" and connect a voltmeter between connector
terminal Land ground or between terminaiiG and
ground. (Fig. 603-4)
"IG" terminal
Fig. 603-4
If voltage is not present, the line between battery
and
connector is disconnected and so requires
repair.
3. Reconnect the wiring connector to the generator,
run the
engine at middle speed, and turn off all
electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair
or replace the generator.
5. Connect an ammeter to outputterminal of genera­
tor, and measure output current under load by
turning on the other electrical devices (eg., head­
lights). At this time, the voltage must not be less
than 13V.
Generator rating
Ammeter reading
12V-60A 20A
12V -75A 25A
Fig. 603-5
•

2,5 3
6 4
CHARGING SYSTEM 603 - 5
Removal steps
1. Front under cover
2. Loosen generator fixing bolt
3. Fan belt
4. Adjuster
5. Remove generator fixing bolt
in step 2. 6. Wiring connector
7. AC generator assembly
Installation steps To install, follow the removal
steps in
the reverse order.
Fig. 603-6
E] REMOVAL
Preparation
• Battery ground cable
1. Front under cover
2. Generator fixing bolt
• Loosen fixing bolt.
3. Fan Belt
• Loosen lock bolt.
•
Loosen adjust bolt.
4. Adjuster
5. Generator fixing bolt
• Remove the fixing bolt.
6. Wiring connector
• Disconect terminal "B" and connector.
• From generator, supporting generator assem­
bly by hand.
7. Generator assembly
• Take out generator below.
EJ INSTALLATION
7. Generator assembly
• Direct terminal "B" to below side and bring
generator assembly to the position to be in­
stalled.
6. Wiring connector
• Connect harness connector and direct termi­
nal "B" to above side.
5. Generator fixing bolt
• Temporarily secure with bolts.
4. Adjuster
3. Fan Belt
• Refer to item "Drive belt adjustment" in the 10
page of section 6B-1 0.
2. Fan belt
1. Front under cover
• Battery ground cable