1995 ISUZU TROOPER Workshop Manual

CRANKING SYSTEM 602 -7
STARTER DOES NOT STOP THOUGH STARTER
SWITCH IS RETURNED TO "ON"
DISCONNECT STARTER SWITCH WIRING CONNECTOR, AND CHECK STARTER SWITCH OPERATION.
KEY
BATTERY IGNITION BATTERY ACCESSORIES IGNITION STARTER
POSITION B1 IG1 B2 ACC IG2 ST
LOCK
OFF
ACC
--- -ON ----------START ----------
THERE MUST BE NO CONTINUITY EXCEPT ABOVE LINES
I
YES I I NO
I
MAGNETIC SWITCH CONTACTS I REPLACE STARTER SWITCH J ARE FUSED AND NOT MOVED, OR A RETURN SPRING IS BROKEN OR DETERIORATED
REPLACE
MAGNETIC SWITCH 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.
..

Removal steps
1. Nut
2.
Bolt 3. Magnetic switch
4. Dust cover
5. Torsion spring
6.
Screw 7. Through washer 8. Rear cover
9. Thrust washer
10. Brush holder
UNIT REPAIR
11. Brush
12. Yoke assembly 13. Armature
14. Center bracket
15. Dust cover
16.
Shift lever 17. Ball bearing
18. Bearing cover
19. Gear case
20. Internal gear
Fig. 602-4
13
CRANKING SYSTEM 602-9
21. Planet gear
22. E-ring
23. Pinion
24. Thrust washer
25. Center bracket
26. Pinion shaft
Installation steps
To install, follow the removal steps in the reverse order.

602-10 CRANKING SYSTEM
l•!•l DISASSEMBLY
1. Nut
• Loosen the nut on terminal "M" of magnetic
switch and disconnect the connector cable.
(Fig. 602-5)
Fig. 602-5
2. Bolt (2 pes)
3. Magnetic switch
4. Dust cover
5. Torsion spring
• Remove bolts, then the magnetic switch as­
sembly.
•
Remove torsion spring from magnetic switch
assembly. (Fig. 602-6)
Fig. 602-6
6. Screw (2 pes)
7. Through bolt (2 pes)
9. Thrust washer
• Remove screws and through bolts, then the
rear cover. (Fig. 602-7)
Brush holder assembly
Screw
Rear cover
Thrust washer
Fig. 602-7
10. Brush holder
11. Brush
• Raise a brush spring to detach brushes (4 pes)
from the commutator face and pull off the
brush holder. (Fig. 602-8)
Fig. 602-8
12. Yoke assembly
13. Armature
14. Center bracket (A)
• Pull off the yoke assembly, then remove arma­
ture,
washer and center bracket. (Fig. 602-9)
•

Center bracket (A)
Fig. 602-9
W 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.
15. Dust cover
16.
Shift lever
• Remove a dust cover and shift lever from the
gear case. (Fig. 602-10)
17. Ball bearing
18. Bearing cover
19. Gear case
Dust cover
/
~
Fig. 602-10
• Remove a ball bearing and bearing cover from
the gear case. (Fig. 602-11)
CRANKING SYSTEM 602 -11
Ball bearing
Bearing cover
Fig. 602-11
20.1nternal gear
21.
Planet gear (3)
• Remove internal gear and planet gear. (Fig.
602-12)
Internal gear
Fig. 602-12
22. E-ring
• Remove an E-ring from the pinion shaft using
a
flat-blade screwdriver. (Fig. 602-13)
E-ring
Fig. 602-13

602 -12 CRANKING SYSTEM
23. Pinion
Disassembling pinion
• Holding the pinion shaft, push pinion toward
the center bracket.
• Turn the pinion clockwise or counterclockwise
by one tooth of spline, then pull offthe pinion.
(Fig. 602-14)
To center bracket side
Pinion
Fig. 602-14
24. Thrust washer (2)
25. Center bracket
26. Pinion shaft (Fig. 602-15)
Center bracket ( P)
Fig. 602-16
~ 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. (Fig.
602-16)
mm(in)
Standard Limit
33(1.30) 32 (1.26)
•
Fig. 602-16
Check
for continuity between commutator and
segment.
Replace commutator if there is no con­
tinuity (i.e., disconnected). (Fig. 602-17)
Fig. 602-17
• Check for continuity between commutator and
shaft.
Also, check for continuity between commu­
tator and armature core,armature core and shaft.
Replace commutator if there is continuity (i.e.,
internally grounded). (Fig. 602-18)
Fig. 602-18
•