engine ISUZU TROOPER 1995 Workshop Manual

CRANKING SYSTEM 6D2 - 1
SECTION 602
CRANKING SYSTEM
CONTENTS
General Description ....................... .
Diagnosis
.................................... .
On-Vehicle Service ........................ . 6D2-1
6D2-3
6D2-8 Unit
Repair.................................... 6D2-9
Main Data and Specifications
............ 6D2-17
Torque Specifications
...................... 6D2-18
GENERAL DESCRIPTION
CRANKING CIRCUIT
The cranking system consists of a battery, starter,
starter switch, starter relay, etc. and these main com-
Pull in coil
Hold
in coil
Plunger
Shift lever
Pinion clutch
Internal
gear
Planetary gear
ponents are connected as shown in Fig. 602-1. For
details of the cranking circuit, see Fig. 602-2.
Anti theft controller or mode switch
Battery
(AfT} '-------------. ' '
To Generator "B" terminal
Fig. 602-1
STARTER
The cranking system employs a magnetic type reduc­
tion starter in which the motor shaft is also used as a
pinion shaft. When the starter switch is turned on, the
contacts of magnetic switch are closed, and the arma­
ture rotates. At the same time, the plunger is attracted,
and the pinion is pushed forward by the shift lever to
mesh with ring gear. Then, the ring gear runs to start
the engine. When the engine starts and the starter
switch is turned off, the plunger returns, the pinion is
disengaged from ring gear, and the armature stops
rotation. When the engine speed is higher than the
pinion, the pinion idles, so that the armature is not
driven.

602 - 2 CRANKING SYSTEM
CRANKING CIRCUIT
STARTING SYSTEM
a: co 00
/ +
Battery
50 A
Kew
Position
LOCK
OFF
Key
Removed
ACC Inserted
ON
START Battery
Ignition Battery
Accessories Ignition Starter B1 IG1 B2 ACC IG2 ST
o----o
o----o
oc l---+----+--<0---o
BOA MAIN KEYSW 3WB I I ~~ ...;~-4:) -
IG COIL --------1~-:r uJ----a~ (+) 15A 15A IG COIL ENGINE
GENERATOR IG co :5: ('f)
RELAY; STARTER
3BW r---~
._,()-.L___j -v CLUTCH START SWITCH(M/T)
0.5
BW-I '~ I -0.5 BW ~-+-4~--~~~------~ T I ~ I T : ___________________ ~
.. (NT)
TO AIR CONDITIONING RELAY
Mode SW (NT)
PULLIN
B C\~L _S -/OLD I~ COl~
fl-~ooe--------O<>Ol -----MAGNETIC SWITCH
~-T ------+-----~.
I M
L _______ _
STARTER
Fig. 602-2
•

602-6 CRANKING SYSTEM
PINION MESHES WITH RING GEAR BUT ENGINE DOES NOT CRANK
CHECK
GROUND CABLE I
I
YES I NO I
I
REPAIR OR REPLACE I GROUND CABLE
I I I I
FAULTY CONNECTION BURNED-OUT DISCONNECTION DISCONNECTION SLIP OF OF BRUSH AND MAGNETIC OR DAMAGE OF OR DAMAGE OF PINION COMMUTATOR STARTER
SWITCH FIELD COIL ARMATURE COIL CLUTCH
I I I J
REPAIR OR REPLACE STARTER I
•

602-8 CRANKING SYSTEM
ON-VEHICLE SERVICE
STARTER
3
3
6
Removal steps
1. Heated
Oxygen Sensor connector (A/T)
2. Exhaust pipe, front left 3. Heat protector
4.
Starter wiring connector 5. Mounting bolts 6. Starter assembly
Installation
steps
To install, follow the removal steps in the reverse order.
Fig. 602-3
EJ REMOVAL
Preparation
• Battery ground cable
1. Heated Oxygen Sensor connector (A/T)
2. Exhaust pipe, front left
3. Heat protector
4. Starter wiring connector
• Disconnect the connector from terminals "B"
and "S".
B INSTALLATION
6. Starter assembly
5. Mounting bolts
~~~ Torque N·m (lb·ft) I
4. Starter wiring connector
40 (30)
• Reconnect the connectors to terminals "B"
and "S".
• Terminals "B"
5. Mounting bolts
• Remove mounting bolts on inside and out-~~~ Torque N·m (lb·in) I side. __ _;_ ______ -J.... ______ _ 8.5 (73)
6. Starter assembly
• Remove starter assembly toward the bottom
of engine.
3. Heat protector
2. Exhaust pipe, front left
• Nuts
~~~ Torque N·m (lb.ft)
• Bolts
and Nuts
~~~ Torque N·m (lb·ft) I
67 (49)
27
(20)
1. Heated Oxygen Sensor connector (A/T)
• Reconnect the battery ground cable.
..

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
•

IGNITION SYSTEM 6D4 - 1
SECTION 604
IGNITION SYSTEM
CONTENTS
General Description ...................... .
Diagnosis
................................... .
On-Vehicle Service ....................... .
Spark Plug Wire ....................... .
Spark Plug .............................. . 6D4-1
6D4-2 6D4-3
6D4-3
6D4-3
Electronic Ignition (EI) Assembly ...
Crankshaft Position Sensor
(CKP sensor) ........................ .
Torque Specifications
................ .
Main Data and Specifications
......... . 6D4-5
6D4-5
6D4-6
6D4-7
GENERAL DESCRIPTION
Ignition is done by the Electronic Ignition (EI) that
fires directly the ignition plugs from ignition coils
through spark plug wires without using a distributor.
A pair of ignition coils for the cylinders having differ­
ent phases by 360° (No.1 and No.4, No.2 and No.5,
No.3 and No.6) are
fired simultaneously.
Since the cylinder on exhaust stoke requires less
energy to fire its ignition plug, energy from the
ignition coils can be utilized to fire the mating cylin­
der on compression stroke. After additional 360°
rotation, respective cylinder stokes are reversed.
TheEl consists of three ignition coils, ignition control
module, crank angle sensor, Engine Control Module
(ECM) and other components.
Module is provided under the ignition coil, connected
with ECM by means of 6-pin connector. The
ignition control module turns on/off the primary
circuit of ignition coils, and also it controls the igni­
tion timing at the engine
speed below 538 rpm.
A notch in
the timing disc on the crankshaft activates
the crank angle sensor which then sends information
such as firing order and starting timing of each
ignition coil to the ECM.
Further, the El employs Ignition Control (I C) to control
similar to a distributor system.
By receiving
signals such as crank position, engine
speed, water temperature and Manifold Absolute
Pressure (MAP), the ECM controls the ignition timing.

604-2 IGNITION SYSTEM
IGNITION SWITCH
Key
Key Battery
Ignition Battery Acc111ories Ignition
Starter Position 81 IG1 82 ACC IG2 ST
LOCK Removed
BATTERY OFF
/'1 ~ o-
~ Inserted ...... {) ACC ..., -
ON ...... ..... ...... ...... ...... ~ -.....
a: ...... -lXI START Q II) '-' '-' ...., ,_,
BOA 50 A
I 1 MAIN K~YSW 3WB
FL-1 FL-2 3BY -15A 15A IG.COIL ENGINE
ACG (IG)
ELECTRONIC
IGNITION ECM (CONNECTOR) > 1.25 r--""
~~ ~~ BO o""' I
~
1.25 B rrvl -~~ ' f"--~ CONNECTOR C-1
_l_ .... __ .J ~~ c1 mp Shr (E-18)
(C-1) B8 0.85 VB ,, ... , ~~ R!'i YR I I Cl.lo
I !ita lui (C-1) 89 I 0 0.5 BR d 0: IBIBIIIINIBI111Io
(C-2) 05 0.85Y "'I I I > ---(C-2) 011 I
I
)+ 0.85 '-'I a:
~~ ,_, <( TACHO YG (E-21)
~
;;!] METER ,:. .... , a: ~~ 0.5WR q 0! 0... ~~
0.5W I ~$ ... _, ~0 c ( (E-22)
(E-27) CONNECTOR C-2
CRANKSHAFT POSITION .::::> rL
r;::::l enD. .-SENSOR I~ ~~
~ ~ ~~ rt~·· IC4 IT>TiiTiil
f §~
~g l CIJ 0::
·~'l
IGNITION IGNITION CONTROL
COIL MODULE tii1it SPARK PLU Fig. 604-1
DIAGNOSIS
Refer to Section 6E for the diagnosis to the Electronic
ignition system (EI system).
•

604-4 IGNITION SYSTEM
Fig. 604A-5
~ INSPECTION AND REPAIR
The spark plug affects entire engine performance and
therefore its inspection is very important.
• Check electrode and insulator for presence of
crack, and replace if any.
• Check electrode for wear, and replace if neces­
sary.
• Check gasket for damage, and replace if neces­
sary.
• Measure insulation resistance with an ohmmeter,
and replace if faulty.
• Adjust spark plug gap to 1.0(0.04) -1.1 (0.043)
mm(in).
• Check fuel and electrical systems if spark plug is
extremely dirty.
• Use spark plugs having low heat value (hot type
plug) if fuel and electrical systems are normal.
• Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely
burned.
Sooty spark plugs
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine perfor­
mance.
Possible causes:
• Too rich mixture
• Retarded ignition timing
• Presence of oil in combustion chamber
• Incorrectly adjusted spark plug gap
Burning electrodes
This fault is characterized by scorched or heavily
oxidized electrode or blistered insulator nose.
Possible causes:
• Too lean mixture
• Advanced ignition timing
• Improper heat value
Measuring Insulation Resistance
• Measure insulation resistance using a 500 volt
megaohm meter. (Fig. 604-6)
Fig.
604-6
• Replace spark plugs if measured value is out of
standard.
I @!.j Insulation resistance MQ 50 or more
Cleaning Spark Plugs
• Clean spark plugs with a spark plug cleaner.
• Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.
• After spark plug is thoroughly cleaned, check
insulator for presence of crack.
• Clean threads and metal body with a wire brush.
• File the electrode tip if electrode is extremely
worn.
• Bend the ground electrode to adjust the spark
plug gap. (Fig. 604-7)
Fig. 604-7
•