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Type :
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ENGINE STARTER
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Specification :
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5.5KW 24V
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Number of feet :
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11T
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Brand :
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NUOJIN
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Number :
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1811004250
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Quality :
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NEW
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Delivery time :
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30DAYS
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1811004250 M009T62372 M9T62371 M9T61871 STR71303 6UZ1
Necessary tools: Socket wrench (including 10mm, 12mm, 14mm, 17mm specifications), torque wrench, Phillips/flathead screwdriver, extension bar, universal joint, crowbar (for auxiliary positioning), electrician's pliers, multimeter (for circuit testing).
Auxiliary materials: New starter assembly, original factory matching bolts (8.8 grade or higher high-strength bolts), lock washers (spring washers/flat washers), high-temperature resistant grease (lithium-based grease), medium-strength threadlocker (e.g., Loctite 243), rags, cleaning agent (for removing oil stains).
Disconnect the negative terminal of the vehicle battery (to avoid short-circuit and burnout of the circuit), confirm that the engine is cold, the parking brake is locked, and the gear is in neutral.
Clean the starter installation area to remove oil stains, dust and rust, check the appearance of the flywheel ring gear (no broken teeth or excessive wear), replace the flywheel ring gear first if there are abnormalities.
Align the new starter assembly with the mounting holes of the engine flywheel housing, manually screw in 2-3 mounting bolts (do not tighten), adjust the starter angle to ensure a reasonable meshing gap between the drive gear and the flywheel ring gear (gap standard: 2-4mm, which can be fine-tuned by prying the starter).
Use a torque wrench to tighten the mounting bolts in a diagonal sequence, with the torque value strictly following the original factory standard (usually 35-45N·m, subject to the Isuzu engine manual), apply threadlocker to the bolts and install lock washers to prevent loosening due to vibration.
Power cable connection: Connect the positive battery power cable (thick cable) to the main terminal (marked "B+" or "30") of the starter solenoid, tighten the nut (torque 12-15N·m), ensure the terminal is free of oxidation and looseness, and apply conductive paste to enhance conductivity if necessary.
Control wire connection: Connect the signal wire (thin wire) controlled by the ignition switch to the auxiliary terminal (marked "SW" or "50") of the starter solenoid, tighten the fixing nut (torque 8-10N·m), arrange and fix the wire harness (avoid interference with high-temperature and moving parts of the engine).
Ground wire check: Confirm that the starter housing is in good contact with the engine block, polish the contact surface if there is rust to ensure reliable grounding (24V systems have high requirements for grounding; poor grounding will cause weak starter operation or failure to work).
After connecting the negative battery terminal, gently press the ignition switch (without starting the engine), observe whether the starter drive gear pops out smoothly and meshes with the flywheel ring gear without jamming or abnormal noise; if meshing abnormalities occur, re-adjust the starter installation position or check the flywheel ring gear status.
Engine start test: The starter should run smoothly during normal start-up without idling or gear hitting noise, and the drive gear should retract quickly after start-up.
Strictly verify the compatibility between the starter model and the engine model (e.g., 4HK1, 6HK1, 6UZ1, etc.), confirm that the power (5.5KW), voltage (24V), mounting hole dimensions and the number of drive gear teeth are consistent with the original factory specifications to avoid installation failure or meshing faults caused by incorrect installation.
Compare the solenoid switch position, drive gear extension length and one-way clutch specifications of the new and old starters; if it is an improved accessory, confirm its compatibility with the flywheel ring gear (some batches of accessories have minor design adjustments).
Check the flywheel ring gear: Visually inspect the tooth surface of the ring gear for wear, chipped teeth or rust; turn the engine by hand to confirm that the ring gear is not loose. If the wear depth of the meshing surface of the ring gear is >1.5mm or there are broken teeth, replace the ring gear first, otherwise it will cause starter gear hitting or poor meshing.
Clean the mounting surface: Thoroughly remove oil stains, rust and sealant residues from the mounting surface of the engine flywheel housing and the flange surface of the starter to ensure tight fit (oil stains will cause bolt loosening, and rust will affect the grounding effect).
Must use original factory specification high-strength mounting bolts of grade 8.8 or above, matched with lock washers (combination of spring washers and flat washers); apply medium-strength threadlocker (e.g., Loctite 243) to the bolt threads. Do not use ordinary bolts or omit lock parts.
Tighten the bolts step by step in a diagonal sequence: First manually pre-tighten all bolts, then use a torque wrench to tighten them to the original factory standard torque (35-45N·m) in 2-3 times to avoid deformation of the mounting surface or bolt breakage due to uneven force caused by one-time tightening (the flywheel housing is made of aluminum alloy, which is prone to cracking when over-tightened).
Power cable (thick cable) connection: The tightening torque of the nut on the main terminal (B+/30) is 12-15N·m; clean the oxide layer at the terminal, and apply conductive paste to enhance conductivity if necessary. The wire harness must be fixed with clips, kept away from high-temperature components such as exhaust pipes and turbochargers (distance ≥50mm), and install heat insulation sleeves if necessary.
Control wire (thin wire) connection: The torque of the nut on the auxiliary terminal (SW/50) is 8-10N·m; confirm that the control wire is matched with the ignition switch and relay (24V system needs corresponding voltage-resistant specifications) to avoid excessive voltage drop caused by too thin wire diameter.
Grounding reliability: The contact surface between the starter housing and the engine block must be polished to remove rust to ensure the grounding resistance <0.1Ω; poor grounding of the housing will cause weak starter operation or incomplete suction of the solenoid switch.
After installation, manually pry the starter to fine-tune its position to ensure the meshing gap between the drive gear and the flywheel ring gear is 2-4mm (measurable with a feeler gauge); too small a gap will easily cause gear jamming, and too large a gap will cause impact and abnormal noise during meshing.
Test by gently pressing the ignition switch (without starting the engine): Observe whether the drive gear pops out smoothly, meshes without jamming, and retracts without sticking; if meshing abnormalities occur, re-adjust the starter installation position or check the status of the one-way clutch.
Apply a small amount of high-temperature resistant lithium-based grease to the tooth surface of the drive gear and the bearing raceway (the dosage is based on covering the contact surface, about 0.5g per part); do not apply excessive grease (to avoid being thrown into the engine combustion chamber or clutch plate).
No additional lubrication is required for the inside of the solenoid switch and the sliding part of the shift fork (the original factory has pre-applied long-acting lubricant; additional lubrication is easy to absorb dust and cause jamming).
The wiring terminals must be covered with insulating sleeves to prevent short circuit with metal components; wrap the wire harness joints with waterproof tape to avoid water ingress and oxidation during wading.
The ventilation holes on the starter housing must be kept unobstructed to prevent internal moisture condensation or oil contamination (blockage of ventilation holes will accelerate brush wear).
References：
The "Precautions for Installation of Isuzu 5.5KW 24V Starter" you received earlier does not come from a single official public document, but is a structured integration based on Isuzu's original factory maintenance data and industry general specifications. The following is an explanation of its core information sources and basis:
The Engine Maintenance Manual for corresponding Isuzu engines (e.g., 4HK1, 6HK1, etc.), which includes core parameters such as starter mounting hole positions, bolt torque (35-45N·m), and circuit wiring specifications.
Isuzu after-sales service technical materials (e.g., TSM series maintenance manuals), covering detailed standards such as the meshing gap between the starter and flywheel ring gear (2-4mm) and the wiring definitions of the solenoid switch (B+, SW, etc.).
General operating guidelines for automobile starter installation, such as diagonal bolt tightening, torque requirements for circuit connections (12-15N·m for main terminals, 8-10N·m for control terminals), and starting intervals (single start ≤5 seconds, interval ≥15 seconds), which are commonly found in automobile maintenance industry manuals and component installation guides.
Fastener usage specifications, such as the selection of 8.8-grade high-strength bolts and medium-strength threadlocker (Loctite 243), comply with general anti-loosening and fastening requirements for automotive mechanical installation.
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