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1999-2001 Isuzu Npr / Npr Hd / Nqr W3500 W4500 W5500 Chassis Workshop Service Repair Manual – PDF DOWNLOAD
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Description
1999-2001 Isuzu Npr / Npr Hd / Nqr W3500 W4500 W5500 Chassis Workshop Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:1100
DOWNLOADABLE:YES
FILE TYPE:PDF
1999-2001 ISUZU NPR / NPR HD / NQR W3500 W4500 W5500 CHASSIS WORKSHOP SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1999-2001 Isuzu Npr / Npr Hd / Nqr W3500 W4500 W5500 Chassis Workshop Service Repair Manual
FOREWORD:
This service manual contains diagnosis, on-vehicle service, wiring diagrams, and component unit repair for Medium Duty Steel Cab Vehicles. Keep this manual in a handy place for ready reference. If properly used, it will enable the technician to serve the owners of these vehicles.
TABLE OF CONTENTS:
1999-2001 Isuzu Npr / Npr Hd / Nqr W3500 W4500 W5500 Chassis Workshop Service Repair Manual
INDEX.......................................................................................................................... 0 TOP............................................................................................................................ 1 Sec.0 GENERAL INFORMATION.................................................................................................. 8 GENERAL INFORMATION.................................................................................................... 8 MAINTENANCE AND LUBRICATION............................................................................................ 18 Sec.0A GENERAL INFORMATION................................................................................................. 8 HANDLING ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS................................................................. 9 MODEL DESIGNATION...................................................................................................... 9 VIN (VEHICLE IDENTIFICATION NUMBER) AND WEIGHT RATING PLATE............................................................ 9 GVWR (GROSS VEHICLE WEIGHT RATING)..................................................................................... 10 SERVICE PARTS IDENTIFICATION LABEL..................................................................................... 10 REGULAR PRODUCTION OPTIONS (RPO) CODE LIST............................................................................. 11 ENGINE SERIAL NUMBER................................................................................................... 12 GRAPHIC SYMBOLS........................................................................................................ 12 ACTION SYMBOLS......................................................................................................... 12 EMERGENCY STARTING A VEHICLE DUE TO A DISCHARGED BATTERY............................................................... 12 TOWING PROCEDURE....................................................................................................... 13 VEHICLE LIFTING POINTS................................................................................................. 14 ABBREVIATIONS CHARTS................................................................................................... 15 ESSENTIAL SERVICE TOOLS................................................................................................ 17 Sec.0B MAINTENANCE AND LUBRICATION......................................................................................... 18 LUBRICATION DETAIL INFORMATION......................................................................................... 18 ENGINE OIL AND VISCOSITY RECOMMENDATIONS........................................................................... 18 MAINTENANCE SCHEDULE................................................................................................... 20 EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE................................................................... 23 NORMAL VEHICLE USE................................................................................................. 23 OWNER SAFETY AND ROUTINE MAINTENANCE................................................................................... 26 NOISE EMISSION CONTROL................................................................................................. 27 NOISE CONTROL SYSTEM............................................................................................... 27 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED..................................................................... 27 RECOMMENDED FLUIDS AND LUBRICANTS...................................................................................... 28 LUBRICATION CHART...................................................................................................... 29 SPECIFICATIONS......................................................................................................... 30 CAPACITIES......................................................................................................... 30 MAINTENANCE ITEM................................................................................................... 30 FASTENER TORQUES................................................................................................... 30 Sec.1 HEATING AND AIR CONDITIONING......................................................................................... 32 HEATING AND VENTILATION................................................................................................ 32 AIR CONDITIONING....................................................................................................... 60 Sec.1A HEATING AND VENTILATION............................................................................................. 32 GENERAL DESCRIPTION.................................................................................................... 33 HEATER............................................................................................................. 33 CONTROL LEVER ASSEMBLY............................................................................................. 34 VENTILATION........................................................................................................ 34 AIR SELECT LEVER................................................................................................... 35 AIR SOURCE SELECT LEVER............................................................................................ 35 FAN SWITCH......................................................................................................... 35 TEMPERATURE CONTROL LEVER.......................................................................................... 35 CIRCUIT DIAGRAM........................................................................................................ 36 DIAGNOSIS.............................................................................................................. 37 HEATING CYCLE...................................................................................................... 37 FAN SWITCH......................................................................................................... 38 ELECTRICAL PARTS................................................................................................... 41 ON-VEHICLE SERVICE..................................................................................................... 42 HEATER UNIT / HEATER CORE.......................................................................................... 42 HEATER TEMPERATURE CONTROL LINK UNIT / AIR MIX DOOR................................................................ 44 HEATER MODE CONTROL LINK UNIT / MODE DOOR.......................................................................... 45 BLOWER ASSEMBLY.................................................................................................... 46 BLOWER LINK UNIT / MODE DOOR....................................................................................... 48 BLOWER MOTOR....................................................................................................... 49 VENTILATION GRILLE................................................................................................. 50 DEFROSTER NOZZLE / VENTILATION DUCT................................................................................ 51 CONTROL LEVER ASSEMBLY............................................................................................. 52 CONTROL PANEL ILLUMINATION BULB.................................................................................... 55 RESISTOR........................................................................................................... 56 HEATER, AIR CONDITIONING, CONDENSER FAN AND CERAMIC HEATER (M/T VEHICLE ONLY)...................................... 57 CERAMIC HEATER AND/OR FULL HOT SWITCH.............................................................................. 58 Sec.1B AIR CONDITIONING.................................................................................................... 60 DESCRIPTION............................................................................................................ 61 REFRIGERANT CYCLE.................................................................................................. 62 SYSTEM COMPONENTS AND LOCATION..................................................................................... 62 AIR CONDITIONING PARTS............................................................................................. 66 CIRCUIT DIAGRAM........................................................................................................ 67 CONNECTOR LIST..................................................................................................... 68 DIAGNOSIS.............................................................................................................. 70 AIR CONDITIONING CYCLE............................................................................................. 70 CHECKING REFRIGERANT SYSTEM WITH MANIFOLD GAGE..................................................................... 71 MAGNETIC CLUTCH.................................................................................................... 75 CERAMIC HEATER..................................................................................................... 77 CONDENSER FAN MOTOR................................................................................................ 78 ELECTRICAL PARTS................................................................................................... 79 ON-VEHICLE SERVICE..................................................................................................... 81 GENERAL REPAIR PROCEDURE........................................................................................... 81 COMPRESSOR......................................................................................................... 86 NEW COMPRESSOR INSTALLATION.................................................................................... 87 COMPRESSOR OVERHAUL............................................................................................ 88 COMPRESSOR OIL................................................................................................. 95 CONDENSER.......................................................................................................... 98 RECEIVER-DRIER..................................................................................................... 99 TRIPLE PRESSURE SWITCH............................................................................................. 100 EVAPORATOR ASSEMBLY................................................................................................ 101 EVAPORATOR CORE AND/OR EXPANSION VALVE............................................................................. 103 AIR CONDITIONER (A/C) SWITCH....................................................................................... 105 BLOWER FILTER...................................................................................................... 107 REFRIGERANT LINE................................................................................................... 108 SPECIFICATIONS......................................................................................................... 109 FASTENER TORQUES................................................................................................... 110 SPECIAL TOOLS.......................................................................................................... 110 Sec.2 FRAME AND CAB........................................................................................................ 112 FRAME AND BODY MOUNTS.................................................................................................. 112 CAB MAINTENANCE........................................................................................................ 128 SHEET METAL............................................................................................................ 140 Sec.2A FRAME AND BODY MOUNTS............................................................................................... 112 FRAME.................................................................................................................. 113 DESCRIPTION........................................................................................................ 113 DIAGNOSIS OF FRAME..................................................................................................... 114 ON-VEHICLE SERVICE..................................................................................................... 116 CHECKING FRAME ALIGNMENT........................................................................................... 116 STRAIGHTENING FRAMES............................................................................................... 117 REINFORCEMENTS..................................................................................................... 117 REPAIRING CRACKS................................................................................................... 120 WELDING............................................................................................................ 120 CROSSMEMBER REPLACEMENT............................................................................................ 121 BODY MOUNTS............................................................................................................ 121 DESCRIPTION........................................................................................................ 121 LONGITUDINAL SILL MOUNTING......................................................................................... 121 OTHER TYPES OF MOUNTINGS........................................................................................... 124 SPECIFICATIONS......................................................................................................... 124 WIDTHS BETWEEN THE WEB OF FRAME RAILS.............................................................................. 124 YIELD STRENGTH OF DIFFERENT METAL.................................................................................. 124 WELDING CHART...................................................................................................... 125 ELECTRODE CHART.................................................................................................... 125 PLUG WELD CHART.................................................................................................... 126 Sec.2B CAB MAINTENANCE..................................................................................................... 128 INTERIOR MAINTENANCE................................................................................................... 128 CARE AND CLEANING OF THE INTERIOR.................................................................................. 128 STEERING WHEEL REFINISHING......................................................................................... 129 WATER LEAKS........................................................................................................ 130 DUST LEAKS......................................................................................................... 131 EXTERIOR MAINTENANCE................................................................................................... 131 CAB REPAIRS........................................................................................................ 131 CAB ALIGNMENT AND STRAIGHTENING.................................................................................... 132 DINGING AND FINISHING.............................................................................................. 132 PAINTING SHEET METAL............................................................................................... 132 STATIONARY GLASS....................................................................................................... 133 OUTSIDE REAR VIEW MIRROR REPLACEMENT............................................................................... 133 WINDSHIELD GLASS REPLACEMENT....................................................................................... 133 REAR WINDOW REPLACEMENT............................................................................................ 137 GLASS POLISHING.................................................................................................... 138 MODEL AND SERIES DESIGNATION PLATE REPLACEMENT......................................................................... 139 Sec.2C SHEET METAL......................................................................................................... 140 INTRODUCTION........................................................................................................... 140 ON-VEHICLE SERVICE..................................................................................................... 140 GRILLE REPLACEMENT................................................................................................. 140 BUMPER AND BRACKETS REPLACEMENT.................................................................................... 140 BATTERY BOX REPLACEMENT............................................................................................ 141 SHEET METAL REPAIR................................................................................................. 142 Sec.3 STEERING, SUSPENSION, WHEELS AND TIRES............................................................................... 144 FRONT END ALIGNMENT.................................................................................................... 144 STEERING LINKAGE....................................................................................................... 152 POWER STEERING......................................................................................................... 160 STEERING COLUMN........................................................................................................ 186 FRONT AXLE AND SUSPENSION.............................................................................................. 192 REAR SUSPENSION........................................................................................................ 216 WHEELS AND TIRES....................................................................................................... 224 Sec.3A FRONT END ALIGNMENT................................................................................................. 144 DESCRIPTION............................................................................................................ 145 DEFINITION OF TERMS................................................................................................ 145 DIAGNOSIS.............................................................................................................. 146 ON-VEHICLE SERVICE..................................................................................................... 147 CHECKING AND CORRECTING TOE-IN..................................................................................... 147 CHECKING AND CORRECTING CAMBER..................................................................................... 147 CHECKING AND CORRECTING CASTER..................................................................................... 148 CHECKING AND CORRECTING KINGPIN INCLINATION........................................................................ 149 TURNING ANGLE MEASUREMENT AND ADJUSTMENT........................................................................... 149 SPECIFICATIONS......................................................................................................... 150 FRONT END ALIGNMENT SETTING........................................................................................ 150 Sec.3B1 STEERING LINKAGE................................................................................................... 152 DESCRIPTION............................................................................................................ 152 DIAGNOSIS OF STEERING LINKAGE.......................................................................................... 152 STEERING LINKAGE ON-VEHICLE SERVICE.................................................................................... 153 MAINTENANCE........................................................................................................ 153 PITMAN ARM REPLACEMENT............................................................................................. 153 DRAG LINK REPLACEMENT.............................................................................................. 154 TIE ROD REPLACEMENT................................................................................................ 155 STEERING ARM REPLACEMENT........................................................................................... 156 SPECIFICATIONS......................................................................................................... 158 FASTENER TORQUES................................................................................................... 158 SPECIAL TOOLS.......................................................................................................... 158 Sec.3B3 POWER STEERING..................................................................................................... 160 DESCRIPTION............................................................................................................ 160 DIAGNOSIS OF POWER STEERING SYSTEM..................................................................................... 161 POWER STEERING SYSTEM TEST......................................................................................... 165 POWER STEERING SYSTEM ON-VEHICLE SERVICE............................................................................... 166 MAINTENANCE........................................................................................................ 166 POWER STEERING FLUID AND FILTER SERVICE............................................................................ 166 STEERING GEAR REPLACEMENT.......................................................................................... 167 STEERING GEAR ADJUSTMENT........................................................................................... 168 HYDRAULIC PUMP REPLACEMENT......................................................................................... 168 TANDEM HYDRAULIC PUMP ASSEMBLY REPLACEMENT......................................................................... 169 BLEEDING THE HYDRAULIC SYSTEM...................................................................................... 170 HYDRAULIC SYSTEM FLUSHING.......................................................................................... 170 POWER STEERING GEAR UNIT REPAIR........................................................................................ 171 REMOVAL OF MAJOR SUB-ASSEMBLIES FROM POWER STEERING GEAR UNIT...................................................... 172 CLEANING, INSPECTION AND REPAIR.................................................................................... 174 ASSEMBLING MAJOR SUB-ASSEMBLIES INTO POWER STEERING GEAR UNIT...................................................... 176 HYDRAULIC PUMP UNIT REPAIR............................................................................................. 177 TANDEM HYDRAULIC PUMP UNIT REPAIR...................................................................................... 180 SPECIFICATIONS......................................................................................................... 184 FASTENER TORQUES................................................................................................... 184 SPECIAL TOOLS.......................................................................................................... 184 Sec.3B4 STEERING COLUMN.................................................................................................... 186 DESCRIPTION............................................................................................................ 186 DIAGNOSIS OF STEERING COLUMN........................................................................................... 186 STEERING COLUMN ON-VEHICLE SERVICE..................................................................................... 187 STEERING WHEEL REPLACEMENT......................................................................................... 187 STEERING COLUMN REPLACEMENT........................................................................................ 188 STEERING COLUMN UNIT REPAIR............................................................................................ 190 STEERING SHAFT REPLACEMENT......................................................................................... 190 SPECIFICATIONS......................................................................................................... 191 FASTENER TORQUES................................................................................................... 191 SPECIAL TOOLS...................................................................................................... 191 Sec.3C FRONT AXLE AND SUSPENSION........................................................................................... 192 DESCRIPTION............................................................................................................ 192 FRONT AXLE......................................................................................................... 192 FRONT SUSPENSION................................................................................................... 192 FRONT HUBS AND BEARINGS............................................................................................ 192 DIAGNOSIS OF FRONT AXLE AND SUSPENSION................................................................................. 193 DIAGNOSIS OF FRONT-WHEEL BEARINGS...................................................................................... 195 TAPERED ROLLER BEARING DIAGNOSIS................................................................................... 195 DIAGNOSIS OF SHOCK ABSORBER........................................................................................ 198 FRONT AXLE ON-VEHICLE SERVICE.......................................................................................... 198 INTRODUCTION....................................................................................................... 198 FRONT AXLE REPLACEMENT............................................................................................. 198 STEERING KNUCKLE AND BEARING REPLACEMENT........................................................................... 201 FRONT SUSPENSION ON-VEHICLE SERVICE.................................................................................... 207 FRONT SPRING REPLACEMENT........................................................................................... 207 SHOCK ABSORBER REPLACEMENT......................................................................................... 208 SHACKLE REPLACEMENT................................................................................................ 209 FRONT HUBS AND DISCS ON-VEHICLE SERVICE................................................................................ 209 SPECIFICATIONS......................................................................................................... 214 FRONT AXLE......................................................................................................... 214 SUSPENSION......................................................................................................... 214 FASTENER TORQUES................................................................................................... 214 SPECIAL TOOLS.......................................................................................................... 215 Sec.3D REAR SUSPENSION..................................................................................................... 216 DESCRIPTION............................................................................................................ 216 SPRING MAINTENANCE................................................................................................. 216 DIAGNOSIS OF SPRINGS................................................................................................... 217 ON-VEHICLE SERVICE..................................................................................................... 217 SPRING REPLACEMENT................................................................................................. 217 SPRING LEAF REPLACEMENT............................................................................................ 222 SPRING EYE BUSHING REPLACEMENT..................................................................................... 222 SHOCK ABSORBER REPLACEMENT......................................................................................... 223 SPECIFICATIONS......................................................................................................... 223 FASTENER TORQUES................................................................................................... 223 Sec.3E WHEELS AND TIRES.................................................................................................... 224 WHEELS AND RIMS........................................................................................................ 225 DESCRIPTION........................................................................................................ 225 DIAGNOSIS OF WHEELS.................................................................................................... 225 ON-VEHICLE SERVICE: WHEELS............................................................................................. 227 LATERAL OR RADIAL RUNOUT........................................................................................... 227 WHEEL STUDS AND NUTS............................................................................................... 227 WHEEL REPLACEMENT.................................................................................................. 228 TIRES AND TUBES........................................................................................................ 229 DESCRIPTION........................................................................................................ 229 DIAGNOSIS OF TIRES..................................................................................................... 231 TIRE WEAR.......................................................................................................... 232 ON-VEHICLE SERVICE: TIRES AND TUBES.................................................................................... 234 HOW TO MATCH TIRES ON THE REAR AXLE................................................................................ 234 TIRE ROTATION...................................................................................................... 234 WHEEL AND TIRE BALANCING........................................................................................... 235 WHAT HAPPENS WHEN TIRES GET HOT.................................................................................... 236 INFLATION OF TIRES................................................................................................. 236 VALVE CORE AND CAP................................................................................................. 237 TUBES AND FLAPS.................................................................................................... 237 SPARE TIRE......................................................................................................... 240 SPECIFICATIONS......................................................................................................... 240 Sec.4 REAR AXLE AND PROPELLER SHAFT........................................................................................ 242 REAR AXLE.............................................................................................................. 242 PROPELLER SHAFT........................................................................................................ 264 Sec.4A1 REAR AXLE.......................................................................................................... 242 GENERAL DESCRIPTION.................................................................................................... 242 DIAGNOSIS OF THE REAR AXLE............................................................................................. 243 BENT HOUSING CHECK................................................................................................. 243 ON-VEHICLE SERVICE..................................................................................................... 244 AXLE SHAFT REPLACEMENT............................................................................................. 244 HUB AND DRUM ASSEMBLY.............................................................................................. 245 REAR AXLE ASSEMBLY REPLACEMENT..................................................................................... 248 DIFFERENTIAL CARRIER............................................................................................... 249 UNIT REPAIR OF 292MM/320MM DIFFERENTIAL CARRIER ASSEMBLY............................................................... 250 SPECIFICATIONS......................................................................................................... 261 FASTENER TORQUES................................................................................................... 261 SPECIAL TOOLS.......................................................................................................... 263 Sec.4B PROPELLER SHAFT..................................................................................................... 264 DESCRIPTION............................................................................................................ 264 PROPELLER SHAFT.................................................................................................... 264 CENTER BEARING..................................................................................................... 266 UNIVERSAL JOINTS................................................................................................... 266 DRIVELINE VIBRATION DIAGNOSIS (ROAD TEST).............................................................................. 266 DIAGNOSIS OF THE PROPELLER SHAFT....................................................................................... 267 ON-VEHICLE SERVICE..................................................................................................... 268 DRIVELINE ANGLE ADJUSTMENT......................................................................................... 268 PROPELLER SHAFT BALANCING.......................................................................................... 269 PROPELLER SHAFT REPLACEMENT........................................................................................ 270 UNIVERSAL JOINT REPLACEMENT........................................................................................ 270 CENTER BEARING REPLACEMENT......................................................................................... 272 LUBRICATION........................................................................................................ 273 SPECIFICATIONS......................................................................................................... 274 FASTENER TORQUES................................................................................................... 274 Sec.5 BRAKES............................................................................................................... 276 HYDRAULIC BRAKES....................................................................................................... 276 VACUUM BOOSTER BRAKE SYSTEM............................................................................................ 296 HYDRAULIC BOOSTER BRAKE SYSTEM......................................................................................... 302 HYDRAULIC FOUNDATION BRAKES............................................................................................ 318 ANTI - LOCK BRAKE SYSTEM (ABS)......................................................................................... 340 PARKING BRAKES......................................................................................................... 430 Sec.5A HYDRAULIC BRAKES.................................................................................................... 276 INTRODUCTION........................................................................................................... 277 DESCRIPTION........................................................................................................ 277 HYDRAULIC BRAKE FLUID.............................................................................................. 277 BRAKE SYSTEM DIAGNOSIS................................................................................................. 277 ROAD TESTING BRAKES................................................................................................ 277 BRAKE SYSTEM DIAGNOSIS CHART....................................................................................... 278 BRAKE LINING DIAGNOSIS CHART....................................................................................... 282 BRAKE DRUM DIAGNOSIS CHART......................................................................................... 283 FRONT DISC BRAKE DIAGNOSIS CHART................................................................................... 284 INSPECTION AND REPAIR.................................................................................................. 285 SYSTEM INSPECTION.................................................................................................. 285 CONTAMINATION OF BRAKE SYSTEM...................................................................................... 285 FLUSHING BRAKE SYSTEM.............................................................................................. 285 BLEEDING BRAKES.................................................................................................... 285 LOAD-SENSING PROPORTIONING VALVE (LSPV) ADJUSTMENT................................................................. 287 BRAKE LINES........................................................................................................ 289 BRAKE FLUID RESERVOIR.............................................................................................. 290 LOAD-SENSING PROPORTIONING VALVE (LSPV)............................................................................ 291 MASTER CYLINDER.................................................................................................... 292 BRAKE PRESSURE METERING VALVE...................................................................................... 294 SPECIFICATIONS......................................................................................................... 295 FASTENER TORQUES................................................................................................... 295 SPECIAL TOOLS.......................................................................................................... 295 Sec.5A1 VACUUM BOOSTER BRAKE SYSTEM........................................................................................ 296 ON-VEHICLE SERVICE..................................................................................................... 296 VACUUM BOOSTER (SERVO) REPLACEMENT................................................................................. 296 BRAKE PEDAL REPLACEMENT............................................................................................ 299 BRAKE PEDAL ADJUSTMENT............................................................................................. 299 SPECIFICATIONS......................................................................................................... 301 FASTENER TORQUES................................................................................................... 301 Sec.5A2 HYDRAULIC BOOSTER BRAKE SYSTEM..................................................................................... 302 GENERAL DESCRIPTION.................................................................................................... 302 BOOSTER ASSEMBLY................................................................................................... 302 FLUID AND FLUID HANDLING........................................................................................... 302 FLUSHING THE HYDRAULIC BOOSTER SYSTEM.............................................................................. 303 SYSTEM OUTLINE..................................................................................................... 304 HYDRAULIC BOOSTER TROUBLESHOOTING...................................................................................... 305 NOTES.............................................................................................................. 307 SUPPLY PARTS REPLACEMENT........................................................................................... 307 ON-VEHICLE SERVICE..................................................................................................... 309 ACCUMULATOR AND O-RING REPLACEMENT................................................................................. 309 HYDRAULIC BOOSTER REPLACEMENT...................................................................................... 309 CLEVIS AND LOCK NUT REPLACEMENT.................................................................................... 314 GUARD REPLACEMENT.................................................................................................. 314 BRAKE PEDAL REPLACEMENT............................................................................................ 315 BRAKE PEDAL ADJUSTMENT............................................................................................. 315 SPECIFICATIONS......................................................................................................... 317 FASTENER TORQUES................................................................................................... 317 Sec.5A3 HYDRAULIC FOUNDATION BRAKES........................................................................................ 318 INTRODUCTION........................................................................................................... 319 DESCRIPTION........................................................................................................ 319 ON-VEHICLE SERVICE OF BRAKE ASSEMBLY................................................................................... 320 BRAKE SHOE AND LINING REPLACEMENT.................................................................................. 320 BRAKE ASSEMBLY REPLACEMENT......................................................................................... 321 CALIPER AND SUPPORT REPLACEMENT.................................................................................... 323 FRONT DISK BRAKE PAD REPLACEMENT................................................................................... 328 WHEEL CYLINDER..................................................................................................... 330 AUTO-ADJUSTER...................................................................................................... 332 BRAKE DRUM REMOVAL AND INSTALLATION (WITH AUTO-ADJUSTER)........................................................... 334 BRAKE LININGS...................................................................................................... 334 BRAKE DRUMS........................................................................................................ 335 SPECIFICATIONS......................................................................................................... 337 FOUNDATION BRAKES.................................................................................................. 337 FASTENER TORQUES................................................................................................... 338 SPECIAL TOOLS.......................................................................................................... 338 Sec.5A4 ANTI-LOCK BRAKE SYSTEM (ABS)....................................................................................... 340 SERVICE PRECAUTION..................................................................................................... 341 GENERAL DESCRIPTION................................................................................................ 342 SYSTEM COMPONENTS.................................................................................................. 342 ELECTRONIC BRAKE CONTROL MODULE (EBCM)............................................................................. 342 HYDRAULIC UNIT (HU)................................................................................................ 342 ABS WARNING LIGHT.................................................................................................. 343 WHEEL SPEED SENSOR................................................................................................. 343 NORMAL AND ANTI-LOCK BRAKING....................................................................................... 343 BRAKE PEDAL TRAVEL................................................................................................. 343 ACRONYMS AND ABBREVIATIONS......................................................................................... 343 GENERAL DIAGNOSIS...................................................................................................... 344 GENERAL INFORMATION................................................................................................ 344 ABS SERVICE PRECAUTIONS............................................................................................ 344 COMPUTER SYSTEM SERVICE PRECAUTIONS................................................................................ 344 GENERAL SERVICE PRECAUTIONS........................................................................................ 344 NOTE ON INTERMITTENTS.............................................................................................. 344 TEST DRIVING ABS COMPLAINT VEHICLES................................................................................ 344 "ABS" WARNING LIGHT................................................................................................ 345 NORMAL OPERATION................................................................................................... 345 BASIC DIAGNOSIS FLOW CHART......................................................................................... 346 BASIC INSPECTION PROCEDURE......................................................................................... 346 TECH 2 SCAN TOOL................................................................................................... 347 TECH 2 FEATURES.................................................................................................... 348 GETTING STARTED.................................................................................................... 348 OPERATING PROCEDURE (FOR EXAMPLE).................................................................................. 349 DTC MODES.......................................................................................................... 350 DTC INFORMATION MODE............................................................................................... 350 PLOTTING SNAPSHOT GRAPH............................................................................................ 351 PLOTTING GRAPH FLOW CHART (POTTING GRAPH AFTER OBTAINING VEHICLE INFORMATION)...................................... 352 FLOW CHART FOR SNAPSHOT REPLAY (PLOTTING GRAPH).................................................................... 353 TECH 2 DATA DISPLAY................................................................................................ 354 SPECIAL FUNCTION................................................................................................... 354 EBCM CONNECTOR PIN-OUT CHECKS...................................................................................... 361 CIRCUIT DIAGRAM.................................................................................................... 363 CONNECTOR LIST..................................................................................................... 365 PART LOCATION...................................................................................................... 366 SYMPTOM DIAGNOSIS...................................................................................................... 367 CHART A-1 ABS WORKS FREQUENTLY BUT VEHICLE DOES NOT DECELERATE..................................................... 367 CHART TA-1 ABS WORKS FREQUENTLY BUT VEHICLE DOES NOT DECELERATE (USE TECH 2)....................................... 367 CHART A-2 UNEVEN BRAKING OCCURS WHILE ABS WORKS.................................................................... 368 CHART A-3, TA-3 THE WHEELS ARE LOCKED.............................................................................. 368 CHART A-4 BRAKE PEDAL FEED IS ABNORMAL............................................................................. 369 CHART A-5, TA-5 BRAKING SOUND (FROM HYDRAULIC UNIT) IS HEARD WHILE NOT BRAKING..................................... 370 DIAGNOSTIC TROUBLE CODES............................................................................................... 371 DIAGNOSIS BY "ABS" WARNING LIGHT ILLUMINATION PATTERN.................................................................. 373 DIAGNOSTIC TROUBLE CODES (DTCS).................................................................................... 373 CHART B-1-1 WITH THE KEY IN THE ON POSITION (BEFORE STARTING THE ENGINE). WARNING LIGHT (W/L) IS NOT ACTIVATED..... 376 CHART B-1-2 (DTC 20) REFERENCE VOLTAGE HIGH........................................................................ 377 CHART B-2 (DTC 14 / C0271) EBCM ABNORMALITY........................................................................ 379 CHART B-3 (DTC 15 / C0277) LOW POWER VOLTAGE....................................................................... 379 CHART B-4 (DTC 25 / C0299) EXHAUST BRAKE CUT RELAY ABNORMALITY..................................................... 380 CHART B-5 (DTC 33 / C0267) MOTOR RELAY ABNORMALITY................................................................. 381 CHART B-6 (DTC 34 / C0268) ABNORMAL MOTOR ROTATION................................................................. 382 CHART B-7 (DTC 41 / C0265) SOLENOID VALVE RELAY ABNORMALITY........................................................ 383 CHART B-8 (DTC 42 / C0241) ABNORMAL SOLENOID VALVE POWER LINE...................................................... 385 CHART B-9-1 (DTC 43 / C0241) OPEN OR SHORTED SOLENOID VALVE (FL VALVE)............................................. 387 CHART B-9-2 (DTC 43 / C0241) OPEN OR SHORTED SOLENOID VALVE (FR VALVE)............................................. 388 CHART B-9-3 (DTC 43 / C0241) OPEN OR SHORTED SOLENOID VALVE (RL VALVE)............................................. 389 CHART B-9-4 (DTC 43 / C0241) OPEN OR SHORTED SOLENOID VALVE (RR VALVE)............................................. 390 CHART B-10-1 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (FL HOLDING VALVE).................................... 391 CHART B-10-2 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (FR HOLDING VALVE).................................... 392 CHART B-10-3 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (RL HOLDING VALVE).................................... 393 CHART B-10-4 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (RR HOLDING VALVE).................................... 394 CHART B-10-5 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (FL DECOMPRESSION VALVE).............................. 395 CHART B-10-6 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (FR DECOMPRESSION VALVE).............................. 396 CHART B-10-7 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (RL DECOMPRESSION VALVE).............................. 397 CHART B-10-8 (DTC 45 / C0242) SHORTED SOLENOID VALVE CIRCUIT (RR DECOMPRESSION VALVE).............................. 398 CHART B-11 (DTC 51 / C0225) OPEN OR SHORTED FL SPEED SENSOR CIRCUIT................................................ 399 CHART B-12 (DTC 52 / C0221) OPEN OR SHORTED FR SPEED SENSOR CIRCUIT................................................ 400 CHART B-13 (DTC 53 / C0235) OPEN OR SHORTED RL SPEED SENSOR CIRCUIT................................................ 401 CHART B-14 (DTC 54 / C0231) OPEN OR SHORTED RR SPEED SENSOR CIRCUIT................................................ 402 CHART B-15 (DTC 61 / C0226) ABNORMAL FL SPEED SENSOR SIGNAL........................................................ 403 CHART B-16 (DTC 62 / C0222) ABNORMAL FR SPEED SENSOR SIGNAL........................................................ 405 CHART B-17 (DTC 63 / C0236) ABNORMAL RL SPEED SENSOR SIGNAL........................................................ 406 CHART B-18 (DTC 64 / C0232) ABNORMAL RR SPEED SENSOR SIGNAL........................................................ 407 UNIT INSPECTION PROCEDURE.............................................................................................. 408 CHART C-1-1 FL SPEED SENSOR OUTPUT INSPECTION PROCEDURE............................................................ 408 CHART C-1-2 FR SPEED SENSOR OUTPUT INSPECTION PROCEDURE............................................................ 409 CHART C-1-3 RL SPEED SENSOR OUTPUT INSPECTION PROCEDURE............................................................ 410 CHART C-1-4 RR SPEED SENSOR OUTPUT INSPECTION PROCEDURE............................................................ 412 CHART TC-1 SENSOR OUTPUT INSPECTION PROCEDURE (USE TECH 2)......................................................... 413 CHART C-2 HU RELAY BOX INSPECTION PROCEDURE........................................................................ 414 HYDRAULIC UNIT......................................................................................................... 416 HYDRAULIC UNIT AND ASSOCIATED PARTS................................................................................ 416 REMOVAL............................................................................................................ 416 INSTALLATION....................................................................................................... 417 HU RELAY BOX........................................................................................................... 418 REMOVAL............................................................................................................ 418 INSPECTION AND REPAIR.............................................................................................. 419 INSTALLATION....................................................................................................... 419 ELECTRONIC BRAKE CONTROL MODULE (EBCM)................................................................................. 420 REMOVAL............................................................................................................ 420 INSTALLATION....................................................................................................... 420 FRONT SPEED SENSOR..................................................................................................... 421 FRONT SPEED SENSOR AND ASSOCIATED PARTS............................................................................ 421 REMOVAL............................................................................................................ 421 INSPECTION AND REPAIR.............................................................................................. 421 INSTALLATION....................................................................................................... 422 FRONT SPEED SENSOR ROTOR............................................................................................... 423 FRONT SPEED SENSOR ROTOR AND ASSOCIATED PARTS...................................................................... 423 REMOVAL............................................................................................................ 423 INSPECTION AND REPAIR.............................................................................................. 424 INSTALLATION....................................................................................................... 424 REAR SPEED SENSOR...................................................................................................... 425 REAR SPEED SENSOR AND ASSOCIATED PARTS............................................................................. 425 REMOVAL............................................................................................................ 426 INSPECTION AND REPAIR.............................................................................................. 426 INSTALLATION....................................................................................................... 426 REAR SPEED SENSOR ROTOR................................................................................................ 427 REAR SPEED SENSOR ROTOR AND ASSOCIATED PARTS....................................................................... 427 REMOVAL............................................................................................................ 427 INSPECTION AND REPAIR.............................................................................................. 427 INSTALLATION....................................................................................................... 427 SPECIAL TOOLS.......................................................................................................... 429 Sec.5C PARKING BRAKE....................................................................................................... 430 DESCRIPTION............................................................................................................ 430 ON-VEHICLE SERVICE..................................................................................................... 430 BRAKE SHOE ADJUSTMENT.............................................................................................. 430 LEVER ADJUSTMENT................................................................................................... 431 PARKING BRAKE DISASSEMBLY (NPR MANUAL TRANSMISSION MODEL).......................................................... 432 SPECIFICATIONS (NPR MANUAL TRANSMISSION MODEL)......................................................................... 433 Sec.7 TRANSMISSION......................................................................................................... 440 AUTOMATIC TRANSMISSION................................................................................................. 440 MANUAL TRANSMISSION (MXA).............................................................................................. 696 MANUAL TRANSMISSION (MBP).............................................................................................. 744 CLUTCH (FOR MXA TRANSMISSION).......................................................................................... 796 CLUTCH (FOR MBP TRANSMISSION).......................................................................................... 812 Sec.7A AUTOMATIC TRANSMISSION.............................................................................................. 440 CONSTRUCTION AND FUNCTION.............................................................................................. 441 DIAGNOSIS.............................................................................................................. 484 ON-VEHICLE SERVICE..................................................................................................... 560 AUTOMATIC TRANSMISSION OVERHAUL........................................................................................ 584 7A1 CONSTRUCTION AND FUNCTION.............................................................................................. 441 DESCRIPTION............................................................................................................ 442 CONSTRUCTION....................................................................................................... 442 TRANSMISSION SERIAL NUMBER............................................................................................. 443 NUMBER PLATE LOCATION.............................................................................................. 443 COMPONENT LOCATION..................................................................................................... 444 STRUCTURE AND FUNCTION OF COMPONENT.................................................................................... 445 TORQUE CONVERTER................................................................................................... 445 OIL PUMP........................................................................................................... 445 SHAFT.............................................................................................................. 446 GEAR SHIFTING MECHANISM............................................................................................ 447 ACCUMULATOR........................................................................................................ 455 SOLENOID........................................................................................................... 456 AUTOMATIC TRANSMISSION FLUID (ATF) THERMOSENSOR.................................................................... 457 AUTOMATIC TRANSMISSION FLUID (ATF) TEMPERATURE SWITCH.............................................................. 457 INHIBITOR SWITCH (NEUTRAL/START SWITCH)............................................................................ 457 KICK-DOWN SWITCH................................................................................................... 458 THROTTLE POSITION SENSOR........................................................................................... 458 VEHICLE SPEED SENSOR 2............................................................................................. 459 VEHICLE SPEED SENSOR 1............................................................................................. 459 ENGINE SPEED SENSOR................................................................................................ 460 TRANSMISSION CONTROL MODULE (TCM).................................................................................. 460 CONTROL MECHANISM...................................................................................................... 461 CONTENT OF FUNCTION AND CONTROL.................................................................................... 461 CONTROL ITEM, INPUT AND OUTPUT..................................................................................... 462 MAJOR INPUT/OUTPUT COMPONENT FUNCTION.............................................................................. 463 CONTROL CIRCUIT BLOCK DIAGRAM...................................................................................... 464 CIRCUIT DIAGRAM.................................................................................................... 465 VALVE OPERATION.................................................................................................... 466 VALVE FUNCTION................................................................................................. 466 VALVE BODY CONSTRUCTION........................................................................................ 468 GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION.......................................................................... 469 CONSTRUCTION AND OPERATION......................................................................................... 469 COMPONENT NAME AND FUNCTION........................................................................................ 470 COMPONENT AND THEIR OPERATING CONDITION............................................................................ 470 N AND P RANGES..................................................................................................... 471 FIRST GEAR IN D OR 2 RANGE......................................................................................... 472 SECOND GEAR IN D RANGE............................................................................................. 473 THIRD GEAR IN D, 2, L RANGE........................................................................................ 475 OVERDRIVE GEAR IN D RANGE.......................................................................................... 477 SECOND GEAR IN 2 RANGE............................................................................................. 478 FIRST GEAR IN L RANGE.............................................................................................. 480 R RANGE............................................................................................................ 481 7A2 DIAGNOSIS.............................................................................................................. 484 DESCRIPTION............................................................................................................ 485 DIAGNOSIS PROCEDURE................................................................................................ 485 SELF DIAGNOSIS......................................................................................................... 486 SELF DIAGNOSIS INFORMATION......................................................................................... 486 CLEARING MEMORY OF THE DIAGNOSTIC TROUBLE CODE (DTC)............................................................... 489 IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM).................................................................... 490 DIAGNOSIS BASED ON DIAGNOSTIC TROUBLE CODE (DTC)....................................................................... 491 DTC 11 VEHICLE SPEED SENSOR 1...................................................................................... 492 DTC 13 ENGINE SPEED SENSOR......................................................................................... 494 DTC 15 AUTOMATIC TRANSMISSION FLUID (ATF) THERMOSENSOR............................................................. 496 DTC 17 INHIBITOR SWITCH............................................................................................ 498 DTC 19 ABS OPERATION SIGNAL........................................................................................ 500 DTC 21 THROTTLE POSITION SENSOR.................................................................................... 502 DTC 24 VEHICLE SPEED SENSOR 2...................................................................................... 505 DTC 31 NO. 1 SHIFT SOLENOID........................................................................................ 507 DTC 32 NO. 2 SHIFT SOLENOID........................................................................................ 509 DTC 33 TIMING SOLENOID............................................................................................. 511 DTC 34 LOCK-UP SOLENOID............................................................................................ 513 DTC 35 LINE PRESSURE SOLENOID...................................................................................... 515 DTC 37 EXHAUST BRAKE CUT SYSTEM.................................................................................... 517 DTC 38 ENGINE WARMING UP CUT SYSTEM................................................................................ 519 DIAGNOSIS BASED ON VEHICLE CONDITION................................................................................... 521 INSPECTION BASED ON FAULTY SYMPTOM..................................................................................... 523 WIRING DIAGRAM......................................................................................................... 539 PARTS LOCATION..................................................................................................... 540 CONNECTOR CONFIGURATIONS........................................................................................... 541 CONTROL SIGNAL INSPECTION.............................................................................................. 543 LINE PRESSURE TEST..................................................................................................... 548 STALL TEST............................................................................................................. 550 ROAD TEST.............................................................................................................. 551 SHIFT POINT DIAGRAM AND LOCK-UP POINT DIAGRAM...................................................................... 551 DIAGNOSIS BY USING SCAN TOOL........................................................................................... 555 SPECIAL TOOLS.......................................................................................................... 559 7A3 ON-VEHICLE SERVICE..................................................................................................... 560 DESCRIPTION............................................................................................................ 561 AUTOMATIC TRANSMISSION FLUID (ATF)..................................................................................... 561 ATF LEVEL.............................................................................................................. 561 ATF CHANGE............................................................................................................. 562 TRANSMISSION CONTROL MODULE (TCM)...................................................................................... 562 THROTTLE POSITION SENSOR AND KICK-DOWN SWITCH.......................................................................... 563 INHIBITOR SWITCH....................................................................................................... 565 VEHICLE SPEED SENSOR-2................................................................................................. 567 VEHICLE SPEED SENSOR-1................................................................................................. 568 AUTOMATIC TRANSMISSION FLUID (ATF) TEMPERATURE SWITCH.................................................................. 569 ENGINE SPEED SENSOR.................................................................................................... 570 OVERDRIVE OFF SWITCH................................................................................................... 570 OIL PAN................................................................................................................ 571 OIL FILLER TUBE........................................................................................................ 572 OIL STRAINER........................................................................................................... 573 SOLENOIDS.............................................................................................................. 573 REAR COVER OIL SEAL.................................................................................................... 574 VEHICLE SPEED (SPEEDOMETER) SENSOR DRIVEN GEAR......................................................................... 575 CONTROL LEVER ASSEMBLY................................................................................................. 576 CONTROL CABLE.......................................................................................................... 577 TRANSMISSION ASSEMBLY.................................................................................................. 579 TORQUE CONVERTER....................................................................................................... 581 SPECIFICATIONS......................................................................................................... 582 SPECIAL TOOLS.......................................................................................................... 582 Sec.7A4 AUTOMATIC TRANSMISSION OVERHAUL.................................................................................... 584 GENERAL REPAIR INSTRUCTION............................................................................................. 585 COMPONENT PARTS REMOVAL................................................................................................ 586 OIL PUMP............................................................................................................... 601 OVERDRIVE PLANETARY GEAR AND DIRECT CLUTCH............................................................................. 605 OVERDRIVE BRAKE........................................................................................................ 615 FRONT CLUTCH........................................................................................................... 621 REAR CLUTCH............................................................................................................ 628 SECOND BRAKE........................................................................................................... 634 PLANETARY GEARS, ONE-WAY CLUTCH AND OUTPUT SHAFT....................................................................... 641 FIRST AND REVERSE BRAKE................................................................................................ 650 VALVE BODY............................................................................................................. 656 EXTENSION HOUSING...................................................................................................... 664 COMPONENT PARTS INSTALLATION........................................................................................... 668 SPECIFICATIONS......................................................................................................... 690 SPECIAL TOOLS.......................................................................................................... 694 Sec.7B1 MANUAL TRANSMISSION (MXA).......................................................................................... 696 DESCRIPTION............................................................................................................ 697 DIAGNOSIS OF MANUAL TRANSMISSION....................................................................................... 697 ON-VEHICLE SERVICE..................................................................................................... 701 TRANSMISSION OIL LEVEL CHECK....................................................................................... 701 CHANGING TRANSMISSION OIL.......................................................................................... 701 GEARSHIFT LEVER REPLACEMENT........................................................................................ 701 GEARSHIFT CABLE ADJUSTMENT......................................................................................... 702 GEARSHIFT CABLE REPLACEMENT........................................................................................ 703 VEHICLE SPEED SENSOR DRIVEN GEAR REPLACEMENT....................................................................... 705 REAR COVER GASKET REPLACEMENT...................................................................................... 705 VEHICLE SPEED SENSOR DRIVE GEAR REPLACEMENT........................................................................ 708 REAR OIL SEAL REPLACEMENT.......................................................................................... 709 TRANSMISSION ASSEMBLY REPLACEMENT.................................................................................. 711 FRONT OIL SEAL REPLACEMENT......................................................................................... 714 CONTROL BOX GASKET REPLACEMENT..................................................................................... 715 UNIT REPAIR............................................................................................................ 717 MAJOR PARTS ASSEMBLIES............................................................................................. 717 INPUT GEAR SHAFT, MAINSHAFT AND COUNTERSHAFT ASSEMBLIES............................................................ 725 CONTROL BOX ASSEMBLY............................................................................................... 735 SPECIFICATIONS......................................................................................................... 741 FASTENER TORQUES................................................................................................... 741 SPECIAL TOOLS.......................................................................................................... 742 Sec.7B2 MANUAL TRANSMISSION (MBP).......................................................................................... 744 DESCRIPTION............................................................................................................ 745 DIAGNOSIS OF MANUAL TRANSMISSION....................................................................................... 745 ON-VEHICLE SERVICE..................................................................................................... 749 TRANSMISSION OIL LEVEL CHECK....................................................................................... 749 CHANGING TRANSMISSION OIL.......................................................................................... 749 GEARSHIFT LEVER REPLACEMENT........................................................................................ 749 GEARSHIFT CABLE ADJUSTMENT......................................................................................... 750 GEARSHIFT CABLE REPLACEMENT........................................................................................ 751 REAR COVER GASKET AND OIL SEAL REPLACEMENT......................................................................... 753 TRANSMISSION ASSEMBLY REPLACEMENT.................................................................................. 755 FRONT OIL SEAL REPLACEMENT......................................................................................... 758 QUADRANT BOX GASKET REPLACEMENT.................................................................................... 760 UNIT REPAIR............................................................................................................ 763 MAJOR PARTS ASSEMBLY............................................................................................... 763 TOP GEAR SHAFT ASSEMBLY................................................................................................ 774 MAIN SHAFT ASSEMBLY.................................................................................................... 776 COUNTER SHAFT ASSEMBLY................................................................................................. 782 UPPER QUADRANT BOX..................................................................................................... 784 LOWER QUADRANT BOX..................................................................................................... 787 SPECIFICATIONS......................................................................................................... 793 FASTENER TORQUES................................................................................................... 793 SPECIAL TOOLS.......................................................................................................... 794 Sec.7C1 CLUTCH (FOR MXA TRANSMISSION)...................................................................................... 796 DESCRIPTION............................................................................................................ 796 CLUTCH SYSTEM...................................................................................................... 796 DIAGNOSIS OF CLUTCH.................................................................................................... 797 ON-VEHICLE SERVICE..................................................................................................... 800 CLUTCH SYSTEM INSPECTION........................................................................................... 800 CLUTCH PEDAL FREE PLAY, HEIGHT AND TRAVEL ADJUSTMENT............................................................... 800 BLEEDING THE CLUTCH HYDRAULIC CIRCUITS............................................................................. 802 COMPONENT PARTS REPLACEMENT............................................................................................ 803 CLUTCH DISC AND PRESSURE PLATE..................................................................................... 803 CLUTCH HOUSING..................................................................................................... 805 CLUTCH CONTROLS.................................................................................................... 806 UNIT REPAIR............................................................................................................ 808 MASTER CYLINDER.................................................................................................... 808 SLAVE CYLINDER..................................................................................................... 809 SPECIFICATIONS......................................................................................................... 811 FASTENER TORQUES................................................................................................... 811 SPECIAL TOOLS.......................................................................................................... 811 Sec.7C2 CLUTCH (FOR MBP TRANSMISSION)...................................................................................... 812 DESCRIPTION............................................................................................................ 812 CLUTCH SYSTEM...................................................................................................... 812 DIAGNOSIS OF CLUTCH.................................................................................................... 813 ON-VEHICLE SERVICE..................................................................................................... 816 CLUTCH SYSTEM INSPECTION........................................................................................... 816 CLUTCH PEDAL FREE PLAY, HEIGHT AND TRAVEL ADJUSTMENT............................................................... 816 BLEEDING THE CLUTCH HYDRAULIC CIRCUITS............................................................................. 818 COMPONENT PARTS REPLACEMENT............................................................................................ 819 CLUTCH ASSEMBLY.................................................................................................... 819 CLUTCH CONTROLS.................................................................................................... 822 UNIT REPAIR............................................................................................................ 824 MASTER CYLINDER.................................................................................................... 824 SLAVE CYLINDER..................................................................................................... 825 SPECIFICATIONS......................................................................................................... 827 FASTENER TORQUES................................................................................................... 827 SPECIAL TOOLS.......................................................................................................... 827 Sec.8 CAB AND CHASSIS ELECTRICAL........................................................................................... 828 GENERAL INFORMATION.................................................................................................... 829 NOTES FOR WORKING ON ELECTRICAL ITEMS.............................................................................. 829 SYMBOLS AND ABBREVIATIONS.......................................................................................... 835 SYMBOLS........................................................................................................ 835 ABBREVIATIONS.................................................................................................. 836 PARTS FOR ELECTRICAL CIRCUIT....................................................................................... 837 WIRING......................................................................................................... 837 FUSE, FUSIBLE LINK AND CIRCUIT BREAKER......................................................................... 838 RELAY.......................................................................................................... 840 DIODE.......................................................................................................... 841 CONNECTOR...................................................................................................... 842 READING THE CIRCUIT DIAGRAM........................................................................................ 843 CONNECTOR SYMBOL................................................................................................... 845 JOINT CONNECTOR.................................................................................................... 845 MAIN DATA AND SPECIFICATIONS........................................................................................... 846 BULB SPECIFICATIONS................................................................................................ 846 FUSE AND FUSIBLE LINK LOCATION..................................................................................... 848 FUSE BLOCK CIRCUIT................................................................................................. 850 REFERENCE TABLE OF FUSE............................................................................................ 851 RELAY LOCATION..................................................................................................... 853 RELAY LIST......................................................................................................... 854 DIODE LOCATION..................................................................................................... 855 REFERENCE TABLE OF GROUNDING POINT................................................................................. 856 GROUNDING POINT LOCATION........................................................................................... 857 CABLE HARNESS ROUTING.............................................................................................. 858 SYSTEM REPAIR.......................................................................................................... 861 START AND CHARGING................................................................................................. 861 ENGINE CONTROL MODULE.............................................................................................. 867 ENGINE STOP SYSTEM................................................................................................. 880 HEADLIGHT, D.R.L AND CORNERING LIGHT............................................................................... 885 CLEARANCE LIGHT, TAILLIGHT, LICENSE PLATE LIGHT, ID LIGHT AND ILLUMINATION LIGHT................................... 904 TURN SIGNAL LIGHT, HAZARD WARNING LIGHT AND STOPLIGHT.............................................................. 917 HORN AND BACKUP LIGHT.............................................................................................. 930 DOME LIGHT AND CAB INTERIOR LIGHT.................................................................................. 942 TRANSMISSION CONTROL MODULE (TCM).................................................................................. 949 WINDSHIELD WIPER AND WASHER........................................................................................ 954 AUDIO AND CIGARETTE LIGHTER........................................................................................ 972 METER AND WARNING/INCICATOR LIGHT.................................................................................. 980 HEATER, AIR CONDITIONING, CONDENSOR FAN AND CERAMIC HEATER.........................................................1017 SERVICE TERMINAL...................................................................................................1022 ABS (ANTI-LOCK BRAKE SYSTEM).......................................................................................1026 POWER WINDOW.......................................................................................................1032 POWER DOOR LOCK....................................................................................................1046 WIRING DIAGRAM.....................................................................................................1058 Sec.9 METRIC AND FASTENER INFORMATION......................................................................................1060 METRIC FASTENERS.......................................................................................................1060 REPLACEMENT FASTENERS..............................................................................................1060 FASTENER STRENGTH IDENTIFICATION.......................................................................................1061 PREVAILING TORQUE FASTENERS............................................................................................1061 SIX-LOBED SOCKET HEAD FASTENERS........................................................................................1062 DECIMAL AND METRIC EQUIVALENTS.........................................................................................1063 CONVERSION TABLE.......................................................................................................1064 Sec.10D STEEL TILT CAB.....................................................................................................1066 CAB DESCRIPTION........................................................................................................1067 DESIGN AND CONSTRUCTION............................................................................................1067 WINDOWS............................................................................................................1067 DIAGNOSIS OF STEEL TILT CAB............................................................................................1067 ON-VEHICLE SERVICE.....................................................................................................1070 CAB INTERIOR.......................................................................................................1070 DRIVER'S SEAT..................................................................................................1070 PASSENGER SEAT.................................................................................................1071 SEAT BELTS:SIDE SEAT BELT TONGUE...............................................................................1072 FRONT CENTER AND DRIVER SIDE SEAT BELT BUCKLE..................................................................1073 FRONT CENTER SEAT BELT TONGUE AND PASSENGER SIDE SEAT BELT BUCKLE..............................................1074 INSTRUMENT PANEL...............................................................................................1075 INSTRUMENT PANEL REINFORCEMENT.................................................................................1078 HEADLINING.....................................................................................................1080 DOORS..............................................................................................................1081 DESCRIPTION....................................................................................................1081 DOOR...........................................................................................................1081 LOCK MECHANISM.................................................................................................1083 LOCK CYLINDER AND OUTSIDE DOOR RELEASE HANDLE..................................................................1084 TRIM PANEL.....................................................................................................1085 WINDOW AND WINDOW REGULATOR ASSEMBLY...........................................................................1087 CAB MOUNTS.........................................................................................................1090 REAR MOUNT BRACKETS AND CUSHIONS...............................................................................1090 CAB MOUNTING LEVER.............................................................................................1091 HOLD-DOWN MECHANISM................................................................................................1092 LOCK ASSEMBLY..................................................................................................1092 CAB REPLACEMENT....................................................................................................1094 SPECIFICATIONS.........................................................................................................1096 FASTENER TORQUES...................................................................................................1096
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
2 reviews for 1999-2001 Isuzu Npr / Npr Hd / Nqr W3500 W4500 W5500 Chassis Workshop Service Repair Manual – PDF DOWNLOAD
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Kareem Franco –
I ordered a dirt bike repair manual and the purchase went perfect.
Zain Clay –
Quick and easy to download. Good manual with everything I need.