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