1998 ISUZU TROOPER Remove engine

6C – 20 ENGINE FUEL
FUEL TANK
REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 N·m (2.0 kg·m/14 lb ft)
4. Remove fuel filler hose and let air pull off hose.
5. Remove breather hose.
6. Remove fuel feed hose and fuel return hose.
7. Disconnect harness connector from fuel gauge unit.
8. Remove under cover.
9. Remove fuel tank assembly.
INSTALLATION
1. Fuel tank assembly.
1) Place a flange on right side of tank on the
bracket.
2) Install a flange to left side of the bracket from the
bottom, and tighten bolts to the specified torque.
Torque : 36 N·m (3.7 kg·m/26.8 lb ft)
2. Install fuel hose and fuel return hose.
3. Install the breather hose.
4. Reconnect harness connector to fuel gauge unit.
5. Install under cover.
6. Install fuel filler hose and let air pull off hose.
7. Fill fuel tank with fuel and tighten filler cap.
8. Reconnect battery ground cable.
1
2
4
8
678 Europe, Nicaragua, Argentina, Philippin
6
5
3
Legend
(1) Fuel Tank Assembly
(2) Gauge Unit
(3) Bolt(4) Under Cover
(5) Bolt
(6) Fuel Filler Hose
(7) Fuel Filler Cap
(8) Breather Hose
140R200032

ENGINE FUEL 6C – 21
FUEL GAUGE UNIT
1
2
3
140R200033
REMOVAL
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 N·m (2.0 kg·m/14 lb ft)
4. Disconnect harness connector from fuel gauge unit.
5. Fuel Gauge Unit
1) Remove the fixing screws, then the fuel gauge
unit.
INSTALLATION
1. Fuel Gauge Unit
2. Connect the harness connector to the fuel gage
unit.
3. Fill the tank with fuel and tighten fuel filler cap.
4. Connect battery ground cable.
FUEL FILLER CAP
The fuel filler cap contains a vacuum valve. If a
negative pressure develops in the fuel tank, the
external valve of the fuel filler cap opens to allow the
fresh air to flow into the fuel tank through the vacuum
valve.
INSPECTION
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.Legend
(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring Legend
(1) Fuel Tank Assembly
(2) Fuel Gauge Unit
(3) Drain Plug
1
3
2
060R200247

6D – 2 ENGINE ELECTRICAL
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 battery.
5. LOAD TEST (Step 5)
(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 FOLLOWING TABLE –
The battery is good and should be returned to
service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.
ESTIMATED
TEMPERATUREMINIMUM
°F °CVOLTAGE
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.

ENGINE ELECTRICAL 6D – 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
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system 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 starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
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
transmission 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 positive
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 A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: 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
accessories 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.

6D – 6 ENGINE ELECTRICAL
RELATION BETWEEN STARTER SWITCH AND STARTER
M
Key
PositionB1 B2 ACCIG1 IG2 ST
LOCKKey
Removed
Inserted OFF
ACC
ON
START
BSBattery
+-
2
17
3
4
5
6
Legend
(1) Starter Switch
(2) To Generator
(3) To QOS4 Control(4) Starter Relay
(5) Immobilizer Relay (for Europe)
(6) Magnetic Switch
(7) Battery
065R200029

ENGINE ELECTRICAL 6D – 7
ON-VEHICLE SERVICE
STARTER
REMOVAL
1 Battery ground cable
2 Remove the slave cylinder and bind with wire it to
the frame.
3 Disconnect the connector from terminals “B” and
“S”.
4. Remove mounting bolts
5. Remove starter assembly
INSTALLATION
1. Install starter assembly, tighten the fixing bolt and
nut to the specified torque.
Torque: 94 N·m (9.6 kg·m/69 lb ft)
2. Reconnect the starter terminals.
CAUTION: When installing the starter motor wiring,
do not allow the S-circuit wiring to obstruct the B-
circuit terminal.
Install the wiring exactly as shown on the attached
illustration.
If S-circuit wiring obstructs the B-circuit terminal,
harness cover breakage and short circuiting may
occur.2-1. Install the wire harness from the battery to the
terminal “B” with tightening torque 8.6 N·m
(0.88 kg·m/6.4 lb·ft).
2-2. Cover the terminal “B” together with wire
harness.
2-3. Connect the wire harness from starter relay to
the terminal “S”.
3. Install the clutch slave cylinder, tighten the fixing
bolt and nut to the specified torque.
Torque: 78 N·m (8.0 kg·m/58 lb·ft)
1
32
4
Legend
(1) Clutch Slave Cylinder
(2) Magnetic Switch(3) Bolt
(4) Starter Assembly
065RW00003
Do not recommend
wiring route.
Recommend wiring route
from S terminal.From
battery
From
starter relay Terminal B
Terminal MTerminal SIn this area,
Scratch to break the wire
cover and make shortage.
065RW00002

ENGINE ELECTRICAL 6D – 9
DISASSEMBLY
1. Terminal Nut
1) Loosen the nut on terminal “M” of magnetic
switch and disconnect the connector cable.
2. Bolt (2 pcs)
3. Magnetic Switch Assembly
4. Torsion Spring
1) Remove torsion spring from magnetic switch
assembly.
5. Plunger
6. Shim
7. Magnetic Switch
8. Through Bolt
9. Rear Cover
1) Remove the through bolts, then remove the rear
cover.10. Motor Assembly
11. Brush Holder
1) Raise a brush spring to detach the negative side
of the brushes (2 pcs) from the commutator face
and remove the positive side of brushes (2 pcs)
from the positive side of brushes (2 pcs) from
the brush holder.
12. Armature
13. Yoke Assembly
14. Bearing Retainer
15. Pinion Assembly
16. Bearing Holder
17. Bearing
18. Pinion Stopper Clip
1) Remove the stopper clip using a screw driver of
equivalent size.
19. Pinion Stopper
20. Return Spring
21. Pinion Shaft
22. Clutch
23. Dust Cover
24. Shift Lever
25. Gear Case
065RW044
065RW043
065RW042

6D – 18 ENGINE ELECTRICAL
DISASSEMBLY
1. Remove the through bolt.
Insert the tip of a pry bar into the gaps between the
front cover and the stator core.
Pry apart and separate the front cover, rotor, the
rear cover and stator.
NOTE: Take care not to scratch or otherwise damage
the stator coil with pry bar.
2. Clamp the rotor in a vise and then remove the nut
and pulley.
3. Remove the rotor assembly from front cover.4. Remove screws with bearing retainer from front
cover and remove bearing.
5. Remove the mounting nuts holding the “B”
terminal, the diode, and the brush holder.
6. Separate the rear cover from the stator.
F06RT021
F06RT022
F06RT023
F06RT024