ISUZU TROOPER 1998 Service Repair Manual

6D2±6
IGNITION SYSTEM
Main Data and Specifications
General Specifications
Ignition System
Ignition FormElectronic Ignition System (El system) with Crankshaft angle Sensor
Spark Plug
TypeK16PR±P11
RC10PYP4
PK16PR11
Plug gap1.0 mm (0.04 in) ± 1.1 mm (0.043 in)
Torque18 N´m (1.8 Kg´m/13 lb ft)
Torque Specifications
N´m (Kg´m/lb ft)

E06RW038

6D3±1 STARTING AND CHARGING SYSTEM
ENGINE
STARTING AND CHARGING SYSTEM
CONTENTS
Service Precaution 6D3±1. . . . . . . . . . . . . . . . . . . . . .
Starting System 6D3±2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D3±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D3±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±6. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±7. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±9. . . . . . . . . . . . . . . . . .
Reassembly 6D3±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±15. . . . . . . . . . .
Charging System 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . General Description 6D3±18. . . . . . . . . . . . . . . . . . . . .
General On±Vehicle Inspection 6D3±18. . . . . . . . . . .
Generator 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±20. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±23. . . . . . . . . . . . . . . . . .
Reassembly 6D3±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test 6D3±25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±26. . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6D3±2STARTING AND CHARGING SYSTEM
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
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 armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the 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 the 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.

6D3±3 STARTING AND CHARGING SYSTEM
C06RW005

6D3±4STARTING AND CHARGING SYSTEM
Diagnosis
ConditionPossible causeCorrection
Starter does not runCharging failureRepair charging system
Battery FailureReplace Battery
Terminal connection failureRepair or replace terminal connector
and/or wiring harness
Starter switch failureRepair or replace starter switch
Starter failureRepair or replace starter

6D3±5 STARTING AND CHARGING SYSTEM
Starter
Removal
1. Battery ground cable.
2. Remove exhaust front left pipe(1).
150RW062
3. Remove heat protector(3).
4. Disconnect starter wiring connector from terminals
ªBº and ªSº(4).
5. Remove starter assembly mounting bolts on inside
and outside(5).
6. Remove starter assembly toward the bottom of
engine(6).
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Installation
1. Install starter assembly(6).2. Install mounting bolts and tighten bolts to specified
torque(5).
Torque: 40 N´m (4.1 Kg´m/30 lb ft)
3. Reconnect the connectors to terminals ªBº and ªSº
and tighten Terminals ªBº to specified torque.
Torque: 9 N´m (0.9 Kg´m/80 lb in)
4. Install heat protector(3).
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5. Install exhaust front left pipe and tighten bolts and
nuts to specified torque(2).
Stud Nuts
Torque: 67 N´m (6.8 Kg´m/49 lb ft)
Nuts
Torque: 43 N´m (4.4 Kg´m/32 lb ft)
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6. Reconnect the battery ground cable.

6D3±6STARTING AND CHARGING SYSTEM
Disassembled View
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Legend
(1) Bolt (2 pcs)
(2) Ball Bearing
(3) Pinion
(4) Shift Lever
(5) Dust Cover
(6) Torsion Spring
(7) Dust Cover
(8) Magnetic Switch
(9) Nut
(10) Gear Case
(11) Bearing Cover
(12) E±Ring
(13) Thrust Washer (2)(14) Center Bracket
(15) Pinion Shaft
(16) Planet Gear (3)
(17) Internal Gear
(18) Center Bracket (A)
(19) Yoke Assembly
(20) Armature
(21) Brush
(22) Brush Holder
(23) Thrust Washer
(24) Rear Cover
(25) Screw (2 pcs)
(26) Through Bolt (2 pcs)

6D3±7 STARTING AND CHARGING SYSTEM
Disassembly
1. Loosen the nut(1) on terminal ªMº of magnetic switch
and disconnect the connector cable.
2. Remove bolt (2 pcs) (2).
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3. Remove magnetic switch(5).
4. Remove dust cover(4).
5. Remove torsion spring bolts, then the magnetic
switch assembly.
6. Remove torsion spring(3) from magnetic switch
assembly(5).
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7. Remove screw (2 pcs) (8).
8. Remove through bolt (2 pcs) (7).9. Remove screws and through bolts, then the rear
cover(9) then remove thrust washer(10).
10. Remove brush holder(6).
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11. Raise a brush spring to detach brushes (4 pcs) from
the commutator face and pull off the brush holder(12)
and brush(11).
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12. Remove yoke assembly(14).
13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,
washer and center bracket.(A) (13).

6D3±8STARTING AND CHARGING SYSTEM
NOTE: In disassembling the yoke assembly, hold the
armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.
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15. Remove dust cover(17).
16. Remove a dust cover and shift lever(16) from the gear
case.
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17. Remove ball bearing(19).
18. Remove bearing cover(20).
19. Remove a ball bearing and bearing cover from the
gear case(18).
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20. Internal gear(21).
21. Remove internal gear and planet gear(3) (22).
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6D3±9 STARTING AND CHARGING SYSTEM
22. Remove an E±ring(23) from the pinion shaft using a
flat blade screwdriver.
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23. Holding the pinion shaft, push pinion toward the
center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.
24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft.
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Inspection and Repair
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Standard: 33.0 mm (1.30 in)
Limit: 32.0 mm (1.26 in)
065RS014Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).
065RS015