Isuzu Trooper (1998-2002 year). Manual — part 583
6D – 6 ENGINE ELECTRICAL
RELATION BETWEEN STARTER SWITCH AND STARTER
M
Key
Position
B1
B2
ACC
IG1
IG2
ST
LOCK
Key
Removed
Inserted
OFF
ACC
ON
START
B
S
Battery
+
-
2
1
7
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: 85 N·m (8.7 kg·m/63 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
3
2
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 M
Terminal S
In this area,
Scratch to break the wire
cover and make shortage.
065RW00002
6D – 8 ENGINE ELECTRICAL
UNIT REPAIR
8
24
1
3
23
25
2
14
15
21
22
20
19
18
17
16
10
9
11
13
12
7
6
5
4
Legend
(1)
Terminal
(2)
Bolt
(3)
Magnetic Switch
(4)
Torsion Spring
(5)
Plunger
(6)
Shim
(7)
Magnetic Switch
(8)
Through Bolt
(9)
Rear Cover
(10)
Motor Assembly
(11)
Brush Holder
(12)
Armature
(13)
Yoke Assembly
(14)
Bearing Retainer
(15)
Pinion Assembly
(16)
Bearing Holder
(17)
Bearing
(18)
Clip
(19)
Stopper
(20)
Spring
(21)
Pinion Shaft
(22)
Clutch
(23)
Dust Cover
(24)
Shift Lever
(25)
Gear Case
065RW040
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
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