Isuzu Trooper (1998-2002 year). Manual - part 581

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/27 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

6

7

8

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

MEMO

ENGINE ELECTRICAL 6D – 1

ENGINE ELECTRICAL

CONTENTS 

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6D–1

General Description . . . . . . . . . . . . . . . . 

6D–1

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 

6D–1

On Vehicle Service . . . . . . . . . . . . . . . . . 

6D–3

Main Data and Specification . . . . . . . . . . 

6D–4

Starting System . . . . . . . . . . . . . . . . . . . . . 

6D–5

General Description . . . . . . . . . . . . . . . . 

6D–5

On Vehicle Service . . . . . . . . . . . . . . . . . 

6D–7

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 

6D–7

Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 

6D–8

Charging System . . . . . . . . . . . . . . . . . . . . 

6D–15

General Description . . . . . . . . . . . . . . . . 

6D–15

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 

6D–16

Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 

6D–17

Main Data and Specification . . . . . . . . . . 

6D–22

QOS4 Preheating System . . . . . . . . . . . . . . 

6D–23

General Description . . . . . . . . . . . . . . . . 

6D–23

System Diagram . . . . . . . . . . . . . . . . . . . 

6D–23

Inspection of QOS4 System Operation . . 

6D–24

BATTERY

GENERAL DESCRIPTION

DIAGNOSIS

There are six battery fluid caps at the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes permit
the escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages over
conventional batteries:

1. There is no need to add water during the entire

service life of the battery.

2. The battery protects itself against overcharging.

The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)

3. The battery is much less vulnerable to self-

discharge than a conventional type battery.

1. VISUAL INSPECTION (Step 1)

Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary. If not, proceed to Step 2.

2. HYDROMETER CHECK (Step 2)

There is a built-in hydrometer (Charge test indicator) at
the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.

a. BLUE RING OR DOT VISIBLE – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE – Go to

Step 3.

3. FLUID LEVEL CHECK (Step 3)

The fluid level should be between the upper level line
and lower level line on side of the battery.

a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.

4. VOLTAGE CHECK (Step 4)

(1) Put voltmeter test leads to battery terminals.

a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure

(2) below.

(2) Determine fast charge amperage from

specification. (See Main Data and Specifications in
this section.)
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF

AMPERAGE RATE – Replace battery.

SECTION