engine ISUZU TROOPER 1995 Workshop Manual

6C-6 ENGINE FUEL
FUEL TANK
7
1 3
Removal steps
1.1nnerliner
2. Fuel filler hose and
breather hose
3. Under cover
4.
Fuel tank
wiring connector
5. Evapo fuel hose
6.
Fuel hose and fuel
return hose
7. Fuel tank
Installation steps
To
install, follow the
removal steps in the
reverse order.
Fig. 6C-6
B REMOVAL
Preparation:
• Disconnect battery ground cable.
•
Loosen fuel filler cap.
• Drain fuel.
Tighten drain plug to the specified torque
after draining fuel.
Torque
1. Inner liner
N·m (lb·ft) 20 (14)-M8
29 (22)-M14
• Remove
inner liner of wheel arch on rear
right side.
2.
Fuel filler hose and air breather hose
3.
Undercover
• Remove undercover fixing bolts on both
sides.
4. Fuel tank wiring connector
• Disconnect two connectors on front right
side of tank.
5. Evapo fuel hose
6. Fuel hose and fuel return hose
W NOTE:
• Cover fuel hose to prevent any dust entering
7. Fuel tank
• Remove fuel tank fixing bolts on both sides.
I!!] INSTALLATION
7.
6.
Fuel tank
• Place a flange on right side of tank on the
bracket.
• Install a flange on left side on the bracket
from the bottom, and tighten bolts to the
specified torque.
Fuel hose and fuel return hose
Torque N·m Ob·ft) 36 (27)
5. Evapo fuel hose
4. Fuel tank wiring connector
3. Undercover
2. Fuel filler hose and air breather hose
1. Inner liner
• Mount inner liner on the wheel arch.
• Fill the tank with fuel and tighten fuel filler
cap.
• Connect battery ground cable.

FUEL GAGE UNIT
1
ENGINE FUEL 6C - 7
Removal steps
1. Wiring connector
2. Fuel gauge unit
Installation steps
To
install, follow the
removal steps in the
reverse order.
Fig. 6C-7
E3REMOVAL ~F_U_E_L_F_IL_L_ER __ C_A_P ____________ ~
Preparation:
• Disconnect battery ground cable.
•
Loosen fuel filler cap.
• Drain fuel.
Tighten drain plug to the specified torque
after draining fuel.
Torque
1. Wiring connector
N-m (lb·ft) 20 (14)-M8
29 (22)-M14
• Disconnect wiring connector from the unit.
2. Fuel
gage unit
• Remove the fixing screws, then the fuel gage
unit.
w NOTE:
• After removing fuel gauge unit, cover fuel
tank to prevent any dust entering
B INSTALLATION
2. Fuel gage unit
1. Wiring connector
• Connect the wiring connector to the fuel
gage unit.
• Fill the tank with fuel and tighten fuel filler
cap.
• Connect battery ground cable.
Vacuum valve
Pressure valve
Fig. 6C-8
Fuel filler cap includes vacuum valve and pressure
valve.
In
case any high vacuum and any high pressure
happen in tank, each
valve works to adjust the
pressure to prevent the tank from being damaged.
(1!] INSPECTION
Check the seal ring in the filler cap for presence of
any abnormality and for seal condition.
Replace the filler cap, if abnormal.
\f CAUTION
Valves of fuel filler cap have characteristics.
As any defective valve, no valve or any wrong
characteristic valve will do a lot of harm to engine
condition, be sure to use the same fuel filler cap as
installed in this vehicle.

6C - 8 ENGINE FUEL
ACCELERATOR PEDAL CONTROL
ACCELERATOR PEDAL CONTROL CABLE
3
Accelerator pedal assembly Removal
steps
1. Adjusting nut 2. Cable clip
3. Accelerator Pedal (AP)
control cable
(Throttle valve side)
4. AP
control cable
(AP pedal side)
5.
Grommet
6. AP control cable
Installation steps
To install, follow the removal
steps in the reverse order.
Fig. 6C-9
EJ REMOVAL
1. Adjusting nut
• Loosen the adjust nut on the cable bracket
mounted on the common chamber.
2. Cable clip
3. Accelerator pedal (AP) control cable (on
throttle valve side)
4. AP control cable (on AP pedal side)
5. Grommet
6. AP control cable
(1!] INSPECTION
Check the following items, and replace the control
cable
if any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should be free of damage and
corrosion.
B INSTALLATION
6. AP control cable
5. Grommet
4. AP control cable (on AP side)
3. AP control cable (on throttle valve side)
2.
Cable clip
1. Adjusting nut
Adjustment of
AP control cable
1. Loosen the adjusting nut.
2. Lock the throttle valve to fully closed status, and
pull the outer cable. Then, adjust the nut B so that
the clearance between nut B and bracket is as
shown in Fig. 6C-10.
3. Push the nut B against the bracket and tighten nut
A to lock the cable.

Clearance 2 -3.5
Fig. 6C-10
ACCELERATOR PEDAL
E) REMOVAL
1. Automatic cruise control cable
2. Accelerator Pedal control cable
3. Accelerator Pedal assembly
Fig. 6C-11
B INSTALLATION
ENGINE FUEL 6C - 9
Removal steps
1.
Auto cruise control cable
2. Accelerator Pedal
control cable
3. Accelerator Pedal
assembly
Installation
steps To install, follow the removal steps in the reverse order.
3. Accelerator pedal assembly
2. Accelerator Pedal control cable
1. Automatic cruise control cable

6C -10 ENGINE FUEL
Adjustment of pedal stroke
Manual Transmission:
• Rotate counterclockwise to loosen the stopper
bolt sufficiently.
• Fully depress the pedal and hold it there hand.
Next, rotate the stopper bolt until it hits the
stopper of pedal bracket. Then, lock the stopper
bolt there.
Automatic Transmission:
• Rotate counterclockwise to loosen the kickdown
switch sufficiently.
• Fully depress the pedal and hold it there hand.
Rotate
the switch clockwise and then rotate
further by 1/2 turn from the position where the
switch clicks. Lock the switch there.
• Step on the accelerator pedal and make sure that
you can hear clicking sound at the full stroke
position.
AIR CLEANER FILTER
EJ REMOVAL
1. Air hose
2. Air cleaner cover
3. Air Cleaner Filter
(Fig.6C-12), (Fig.6C-13)
2. Air cleaner cover
3. Air Cleaner filter
(DOHC)
Fig. 6C-12
2. Air clearner cover
3.
Air Cleaner filter
(SOHC)
Fig. 6C-13
~ INSPECTION
Check the Air Cleaner filter for damage or dust clog­
ging. Replace if it is damaged, or clean if it is clogged.
Cleaning method
Hit the Air Cleaner filter gently with care not to dam­
age the paper filter, or clean the element by blowing
with compressed air of about 49kPa (71 psi) from the
clean side if it is extremely dirty.
Fig. 6C-14
8 INSTALLATION
3. Air Cleaner filter
2. Air cleaner cover
• Meet the cover to the body completely, then
clamp it with the clip.
1. Air cleaner hose
•

ENGINE FUEL 6C -11
MAIN DATA AND SPECIFICATIONS
TORQUE SPECIFICATIONS
Fig. 6C-15
20 (14)-M8
29
(22)-M14
N·m (lb·ft)

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.

601-4 ENGINE ELECTRICAL
'IT7 WARNING:
'if Never attach the end of the jumper cable
directly
to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good
battery.
Make sure that
all unnecessary electrical acces­
sories have been turned
"OFF".
6. Start the engine of the vehicle with the dead
battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable
from the vehicle with the discharged battery.
REMOVAL AND INSTALLATION OF THE
BATTERY
5
Fig. 601-3
1+•1 REMOVAL
1. Negative cable
2. Positive cable
3. Retainer screw and rods
4. Retainer
5. Battery
I••IINSTALLATION
To install the battery, follow the removal procedure
in the reverse order, noting the
following points:
1. Make sure that the rod is hooked on the body
side.
MAIN DATA AND SPECIFICATIONS
Model
(JIS) 95D31R-MF 80D26R-MF 75D26R-MF
Voltage (V) 12 12 12
Cold-Cranking Performance (Amp)
622 582 490
Reserve Capacity
(Min.)
159 133
123
Load Test
(Amp)
310 290 245
Fast Charge
Maximum Amperage
(Amp) 20 20 20
BCI Group No. 27 24 24
..