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ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER – Service Manual – PDF DOWNLOAD
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ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER – Service Manual
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Description
ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER – Service Manual
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LANGUAGE:ENGLISH
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ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE ENGINE )- ISUZU TRUCK FORWARD TILTMASTER – SERVICE MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER – Service 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.
- This service manual is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your vehicle that may cause it not to operate properly.
- These vehicles contain parts dimensioned in the metric system as well as in the customary system. Some fasteners are metric and are very close in dimension to familiar customary fasteners in the inch system. It is important to note that, during any vehicle maintenance procedures, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their strength.
- Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings.) Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury.
- Therefore, fasteners removed from the vehicle should be saved for re-use in the same location whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. For information and assistance, see your Authorized dealer.
TABLE OF CONTENTS:
ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER – Service Manual
1996/1997 SERVICE MANUAL NPR/W4 V8 GASOLINE ENGINE MODELS................................... 4 FOREWORD.................................................................................... 2 CAUTION................................................................................. 2 CAUTION..................................................................................... 3 SECTION 0 GENERAL INFORMATION............................................................... 8 GENERAL INFORMATION..................................................................... 8 Maintenance adn Lubrication............................................................. 18 SECTION 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 SECTION OB MAINTENANCE AND LUBRICATION...................................................... 18 Lubrication Detail Information ......................................................... 18 Engine Oil and Viscosity Recommendations............................................ 18 Maintenance Schedule ................................................................... 21 Explanation of Complete Vehicle Maintenance Schedule.................................... 24 Normal Vehicle Use ................................................................ 24 Owner Safety and Routine Maintenance ................................................... 27 Noise Emission Control ................................................................. 28 Noise Control System................................................................ 28 Tampering with Noise Control System Prohibited ..................................... 28 Recommended Fluids and Lubricants ...................................................... 29 Specifications.......................................................................... 31 Maintenance Item.................................................................... 31 SECTION 1 HEATING AND AIR CONDITIONING...................................................... 32 Heating and Ventilation................................................................. 32 Air Conditioning........................................................................ 58 SECTION 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 SECTION 1B AIR CONDITIONING................................................................. 58 Description............................................................................. 59 Refrigerant Cycle .................................................................. 60 System Components and Location ..................................................... 60 Air Conditioning Parts ............................................................. 64 Circuit Diagram ........................................................................ 65 Connector list...................................................................... 0 Diagnosis............................................................................... 0 Air Conditioning Cycle ............................................................. 0 Checking Refrigerant System with Manifold Gage ..................................... 0 Magnetic Clutch..................................................................... 0 Electrical parts ................................................................... 0 On-Vehicle Service...................................................................... 0 General Repair Procedure ........................................................... 0 Compressor.......................................................................... 82 New Compressor Installation ................................................... 83 Compressor Overhaul ............................................................ 84 Compressor Oil.................................................................. 91 Condenser........................................................................... 94 Receiver/Drier .................................................................... 95 Pressure Switch .................................................................... 96 Evaporator Assembly ............................................................... 97 Evaporator Core and/or Expansion Valve ............................................. 99 Air Conditioner (A/C) Switch .......................................................101 Blower Filter.......................................................................103 Refrigerant Line....................................................................104 Specifications..........................................................................105 Fastener Torques....................................................................106 Special Tools...........................................................................106 SECTION 2 FRAME AND CAB.....................................................................108 Frame and Body Mounts...................................................................108 Cab Maintenance.........................................................................124 Sheet Metal.............................................................................136 SECTION 2A FRAME AND BODY MOUNTS............................................................108 Frame...................................................................................108 Description.........................................................................108 Diagnosis of Frame ....................................................................110 On-Vehicle Service......................................................................112 Checking Frame Alignment ...........................................................112 Straightening Frames ..............................................................113 Reinforcements......................................................................113 Repairing Cracks....................................................................116 Welding.............................................................................116 Crossmember Replacement.............................................................117 Body Mounts ...........................................................................117 Description.........................................................................117 Longitudinal Sill Mounting ........................................................117 Other Types of Mountings............................................................120 Specifications..........................................................................120 Widths Between the Web of Frame Rails .............................................120 Yield Strength of Different Metal .................................................120 Welding Chart.......................................................................121 Electrode Chart ...................................................................121 Plug Weld Chart ...................................................................122 SECTION 2B CAB MAINTENANCE..................................................................124 Interior Maintenance....................................................................124 Care and Cleaning of the Interior...................................................124 Steering Wheel Refinishing ........................................................125 Water Leaks.........................................................................126 Dust Leaks..........................................................................127 Exterior Maintenance ..................................................................127 Cab Repairs .......................................................................127 Cab Alignment and Straightening ...................................................128 Dinging and Finishing ..............................................................128 Painting Sheet Metal ..............................................................128 Paint Code Numbers ................................................................128 Washing and Waxing ................................................................128 Stationary Glass ......................................................................129 Outside Rear View Mirror Replacement ..............................................129 Mirror Glass Replacement ...........................................................129 Windshield Glass Replacement ......................................................129 Rear Window Replacement ...........................................................132 Glass Polishing ...................................................................134 Model and Series Designation Plate Replacement ........................................135 SECTION 2C SHEET METAL......................................................................136 Introduction............................................................................136 On-Vehicle Service......................................................................136 Grille Replacement..................................................................136 Bumper and Brackets Replacement ....................................................136 Battery Box Replacement.............................................................137 Sheet Metal Repair..................................................................138 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES............................................140 Front End Alignment.....................................................................140 Steering Linkage........................................................................148 Power Steering..........................................................................156 Steering Column.........................................................................174 Front Axle and Suspension...............................................................180 Rear Suspension.........................................................................204 Wheels and Tires........................................................................212 SECTION 3A FRONT END ALIGNMENT..............................................................140 Description.............................................................................141 Definition of Terms ...............................................................141 Diagnosis...............................................................................142 On-Vehicle Service ....................................................................143 Checking and Correcting Toe-in ....................................................143 Checking and Correcting Camber......................................................143 Checking and Correcting Caster......................................................144 Checking and Correcting Kingpin Inclination.........................................145 Turning Angle Measurement and Adjustment ...........................................145 Specifications..........................................................................146 Front End Alignment Settings ......................................................146 SECTION 3B1 STEERING LINKAGE................................................................148 Description.............................................................................148 Diagnosis of Steering Linkage...........................................................148 Steering Linkage On-Vehicle Service ...................................................149 Maintenance.........................................................................149 Pitman Arm Replacement .............................................................149 Drag Link Replacement .............................................................150 Tie Rod Replacement ...............................................................151 Steering Arm Replacement ..........................................................152 Specifications..........................................................................154 Fastener Torques ..................................................................154 Special Tools .........................................................................154 SECTION 3B3 POWER STEERING..................................................................156 Description.............................................................................156 Diagnosis of Power Steering System ....................................................157 Power Steering System Test ........................................................161 Power Steering System On-Vehicle Service ..............................................162 Maintenance.........................................................................162 Fluid Level Adjustment ............................................................162 Steering Gear Replacement .........................................................163 Steering Gear Adjustment ...........................................................164 Power Steering Pump Replacement ....................................................164 Bleeding the Hydraulic System .....................................................165 Hydraulic System Flushing .........................................................165 Power Steering Gear Unit Repair.........................................................166 Removal of Major Sub-assemblies From Power Steering Gear Unit.......................166 Cleaning, Inspection and Repair.....................................................169 Assembling Major Sub-assemblies into Power Steering Gear Unit.......................171 Specifications .........................................................................172 Steering Gear Specifications .......................................................172 Fastener Torques ...................................................................172 Special Tools .........................................................................173 SECTION 3B4 STEERING COLUMN.................................................................174 Description.............................................................................174 Diagnosis of Steering Column ...........................................................174 Steering Column On-Vehicle Service......................................................175 Steering Wheel Replacement..........................................................175 Steering Column Replacement.........................................................176 Steering Column Unit Repair.............................................................178 Steering Shaft Replacement..........................................................178 Specifications..........................................................................179 Fastener Torques....................................................................179 Special Tools...........................................................................179 SECTION 3C FRONT AXLE AND SUSPENSION........................................................180 Description.............................................................................180 Front Axle..........................................................................180 Front Suspension....................................................................180 Front Hubs and Bearings.............................................................180 Diagnosis of Front Axle and Suspension..................................................181 Diagnosis of Front-Wheel Bearings.......................................................183 Tapered Roller Bearing Diagnosis....................................................183 Diagnosis of Shock Absorber.........................................................186 Front Axle On-Vehicle Service...........................................................186 Introduction........................................................................186 Front Axle Replacement..............................................................186 Steering Knuckle and Bearing Replacement ...........................................189 Front Suspension On-Vehicle Service.....................................................195 Front Spring Replacement............................................................195 Shock Absorber Replacement..........................................................196 Shackle Replacement.................................................................197 Front Hubs and Discs On-Vehicle Service ................................................197 Specifications..........................................................................202 Front Axle..........................................................................202 Suspension..........................................................................202 Fastener Torques....................................................................202 Special Tools...........................................................................203 SECTION 3D REAR SUSPENSION..................................................................204 Description ...........................................................................204 Spring Maintenance..................................................................204 Diagnosis of Springs....................................................................205 On-Vehicle Service .....................................................................205 Spring Replacement..................................................................205 Spring Leaf Replacement.............................................................210 Spring Eye Bushing Replacement......................................................210 Shock Absorber Replacement..........................................................210 Specifications..........................................................................211 Fastener Torques....................................................................211 SECTION 3E WHEELS AND TIRES.................................................................212 Wheels and Rims.........................................................................213 Description.........................................................................213 Diagnosis of Wheels.....................................................................213 On-Vehicle Service: Wheels..............................................................215 Lateral or Radial Runout ...........................................................215 Wheel Studs and Nuts................................................................215 Wheel Replacement...................................................................216 Tires and Tubes.........................................................................217 Description.........................................................................217 Diagnosis of Tires .....................................................................219 Tire Wear...........................................................................220 On-Vehicle Service: Tires and Tubes.....................................................222 How To Match Tires on the Rear Axle.................................................222 Tire Rotation.......................................................................222 Wheel and Tire Balancing ...........................................................223 What Happens When Tires Get Hot.....................................................223 Inflation of Tires..................................................................224 Valve Core and Cap..................................................................225 Tubes and Flaps.....................................................................225 Spare Tire..........................................................................228 Specifications..........................................................................228 SECTION 4 REAR AXLE AND PROPELLER SHAFT.....................................................230 Rear Axle ..............................................................................230 Propeller Shaft.........................................................................250 SECTION 4A1 REAR AXLE.......................................................................230 General Description ....................................................................230 Diagnosis of the Rear Axle .............................................................231 Bent Housing Check .................................................................231 On-Vehicle Service .....................................................................232 Axle Shaft Replacement .............................................................232 Hub and Drum Assembly ..............................................................233 Rear Axle Assembly Replacement......................................................235 Differential Carrier ...............................................................236 Unit Repair of Differential Carrier Assembly ...........................................237 Specifications..........................................................................247 Fastener Torques....................................................................247 Special Tools ..........................................................................248 SECTION 4B PROPELLER SHAFT..................................................................250 General Description ....................................................................250 Propeller Shaft ....................................................................250 Center Bearing .....................................................................250 Universal Joint ....................................................................252 Diagnosis of the Propeller Shaft and Universal Joint ...................................252 On-Vehicle Service......................................................................254 Propeller Shaft Balance Check.......................................................254 Propeller Shaft Runout Check........................................................254 Propeller Shaft Replacement.........................................................255 Universal Joint Replacement.........................................................257 Splined Yoke Replacement............................................................258 Center Bearing Replacement..........................................................258 Lubrication.........................................................................259 Specifications..........................................................................260 SECTION 5 BRAKES............................................................................262 Hydraulic Brakes........................................................................262 Hydraulic Brake Booster System .........................................................284 Hydraulic Foundation Brakes ............................................................290 Parking Brakes..........................................................................312 SECTION 5A HYDRAULIC BRAKES.................................................................262 Introduction............................................................................263 Description.........................................................................263 Hydraulic Brake Fluid .............................................................263 Brake System Diagnosis..................................................................263 Road-Testing Brakes.................................................................263 Brake System Diagnosis Chart ......................................................264 Brake Lining Diagnosis Chart ......................................................268 Brake Drum Diagnosis Chart ........................................................269 Front Disc Brake Diagnosis Chart ...................................................270 Inspection and Repair ..................................................................271 System Inspection...................................................................271 Contamination of Brake System.......................................................271 Flushing Brake System...............................................................271 Bleeding Brakes.....................................................................271 Load-Sensing Proportioning Valve (LSPV) Adjustment .................................273 Brake Lines.........................................................................275 Brake Fluid Reservoir...............................................................276 Load-Sensing Proportioning Valve (LSPV).............................................277 Master Cylinder.....................................................................278 Specifications..........................................................................282 Fastener Torques ...................................................................282 Special Tool............................................................................282 SECTION 5A1 HYDRAULIC BRAKE BOOSTER SYSTEM..................................................284 On-Vehicle Service .....................................................................284 Hydraulic Booster (Servo) Replacement...............................................284 Brake Pedal Replacement.................................................................286 Brake Pedal Adjustment..................................................................286 Specifications..........................................................................288 Fastener Torques....................................................................288 SECTION 5A2 HYDRAULIC FOUNDATION BRAKES.....................................................290 Introduction............................................................................291 Description.........................................................................291 On-Vehicle Service of Brake Assembly ...................................................292 Brake Shoe and Lining Replacement ..................................................292 Brake Assembly Replacement ........................................................293 Caliper and Support Replacement ....................................................294 Front Disc Brake Pad Replacement ...................................................299 Wheel Cylinder .....................................................................301 Auto Adjuster .....................................................................303 Brake Drum Removal and Installation (with Auto Adjuster) ..........................305 Brake Linings .....................................................................305 Brake Drums .......................................................................306 Specifications..........................................................................309 Foundation Brakes .................................................................309 Fastener Torques ..................................................................310 Special Tools .........................................................................310 SECTION 5C PARKING BRAKE....................................................................312 Description.............................................................................312 On-Vehicle Service......................................................................312 Brake Shoe Adjustment .............................................................312 Lever Adjustment ...................................................................313 Lining Replacement .................................................................313 Support Plate Replacement .........................................................314 Parking Brake Lever Replacement ...................................................314 Parking Brake Cable Replacement ...................................................315 Specifications..........................................................................316 Fastener Torques ...................................................................316 SECTION 6 ENGINE............................................................................318 General Engine Mechanical ..............................................................318 V8 Engine 5.7L (350 CID) RPO L31 VIN R ................................................336 Cooling System .........................................................................386 Radiator............................................................................402 Fan ................................................................................410 Fuel System ............................................................................422 Model 220 TBI Unit .................................................................318 Engine Electrical ......................................................................430 Battery ............................................................................430 Cranking System ...................................................................438 Charging System ...................................................................456 Ignition System ...................................................................466 Driveability and Emissions ............................................................480 Exhaust System ........................................................................482 SECTION 6A GENERAL ENGINE MECHANICAL........................................................318 General Information.....................................................................319 Statement on Cleanliness and Care...................................................319 Use of RTV Sealer and Anaerobic Gasket Eliminator .................................319 Use RTV Sealer..................................................................319 Using Anaerobic Gasket Eliminator .............................................320 Replacing Engine Gaskets............................................................320 Cylinder Bores, Pistons, Rings, and Connecting Rods ....................................320 Measuring Cylinder Bore Taper and Out-of-Round .....................................320 Cylinder Bore Reconditioning .......................................................321 Boring..........................................................................321 Honing..........................................................................322 Piston and Connecting Rod Assemblies ...............................................322 Disassembly.....................................................................322 Cleaning and Inspection ........................................................323 Measuring Piston Pin to Piston Clearance .......................................323 Piston Selection ...................................................................324 Assembly........................................................................324 Camshaft Bearings ..................................................................326 Camshaft Bearing Replacement ..................................................326 Hydraulic Lifters ......................................................................328 Valve lifter Leak-Down Rate Test ..................................................328 Cylinder Head ..........................................................................328 Disassembly.........................................................................328 Cleaning and Inspection ............................................................328 Repair..............................................................................330 Valve Grinding .................................................................330 Valve Seat Grinding ............................................................330 Reaming Valve Guides............................................................331 Assembly............................................................................331 Measuring Main Bearing Clearance........................................................331 Measuring Connecting Rod Bearing Clearance..............................................332 Thread Repair...........................................................................334 Special Tools...........................................................................335 SECTION 6A5 V8 ENGINE 5.7L (350 CID) RPO L31, VIN R.........................................336 General Description ...................................................................337 Engine Identification...............................................................337 Engine Lubrication .................................................................341 On-Vehicle Service......................................................................343 Tools and Shop Equipment ..........................................................343 Accessory Removal...................................................................343 Cleaning............................................................................344 Draining The Engine.................................................................344 Exhaust Manifold Replacement ......................................................344 Coolant Pump Replacement ..........................................................346 Intake Manifold Replacement .......................................................346 Rocker Arm Cover Replacement ......................................................351 Rocker Arm and Pushrod Replacement ................................................352 Valve Adjustment ..................................................................352 Valve Stem Seal and Valve Spring Replacement ......................................353 Hydraulic Lifter Replacement .......................................................354 Rocker Arm Stud Replacement .......................................................355 Cylinder Head Replacement .........................................................356 Torsional Damper and Crankshaft Front Seal Replacement ............................358 Front Cover Replacement ...........................................................359 Oil Pan Replacement ...............................................................360 Oil Pump Replacement ..............................................................361 Crankshaft Rear Oil Seal Replacement ..............................................363 Crankshaft Rear Oil Seal Retainer Replacement .....................................364 Measuring Camshaft Lobe Lift ......................................................365 Camshaft Replacement ..............................................................365 Crankshaft Position Sensor Reluctor Ring Replacement ..............................368 Connecting Rod and Piston Replacement ..............................................368 Oil Filter Bypass Valve ............................................................371 Main Bearing Replacement ..........................................................372 Crankshaft Replacement ............................................................373 Crankshaft and Bearings ............................................................373 Flywheel Replacement (Automatic and Manual Transmission) ..........................375 Engine Mountings....................................................................376 Front Mounting Replacement ........................................................376 Rear Mounting Replacement ..........................................................377 Engine Replacement ................................................................378 Block...............................................................................378 Main Bearing Cap Replacement ......................................................379 Cylinder Bores......................................................................380 Specifications..........................................................................381 Special Tools...........................................................................385 SECTION 6B1 COOLING SYSTEM..................................................................386 General Description.....................................................................386 Cooling System......................................................................386 Coolant Recovery Tank...............................................................387 Coolant Pump........................................................................387 Thermostat..........................................................................387 Diagnosis of Engine Cooling.............................................................387 System Checks.......................................................................387 Fan Clutch Diagnosis................................................................388 Thermostat Diagnosis................................................................389 Coolant Diagnosis...................................................................389 Cooling System Diagnosis............................................................390 Uncommon Cooling System Problems....................................................392 Diagnosis of Drive Belt System .........................................................393 On-Vehicle Service: Cooling System Components ..........................................395 Engine Thermostat .................................................................395 Water Pump Replacement ............................................................396 Belt Tensioner Inspection .........................................................397 Belt Tensioner Replacement ........................................................397 Drive Belt Replacement ............................................................397 Engine Oil Cooler Line Replacement ................................................398 Specifications..........................................................................401 Special Tools...........................................................................401 SECTION 6B2 RADIATOR........................................................................402 General Description.....................................................................402 Radiator............................................................................402 Radiator Cap ......................................................................402 Diagnosis of Radiator .................................................................404 Maintenance Recommendations ...........................................................404 On-Vehicle Service ....................................................................405 Radiator Replacement ..............................................................405 Drain Cock ........................................................................406 Specifications..........................................................................408 Cooling System Capacity ...........................................................408 Pressure Cap........................................................................408 Special Tools...........................................................................408 SECTION 6B3 FAN.............................................................................410 Description.............................................................................410 Fan.................................................................................410 Automatic Fan Clutch................................................................411 Diagnosis of Automatic Fan Clutch ......................................................412 On-Vehicle Service: Cooling Components ................................................413 Fan and Fan Clutch Replacement ....................................................413 Fan Pulley Replacement ............................................................413 Fan Adjustment .....................................................................414 Drive Belts.............................................................................415 Diagnosis of Belts..................................................................415 Inspection and Replacement .........................................................417 Belt Tension Adjustment.............................................................418 Cleaning and Storage................................................................419 Specifications..........................................................................420 Fastener Torques ...................................................................420 Special Tools...........................................................................420 SECTION 6C FUEL SYSTEM......................................................................422 General Description.....................................................................422 On-Vehicle Service......................................................................424 Air Cleaner Element Replacement ....................................................424 Fuel System Pressure Relief ........................................................424 Fuel Filter Replacement ............................................................424 Fuel Pump Test .....................................................................424 Fuel Pump Relay ....................................................................425 Fuel Tank...............................................................................425 Description.........................................................................425 Fuel Tank Replacement .............................................................425 Fuel Lines..........................................................................426 Accelerator Linkage.....................................................................428 Description.........................................................................428 Accelerator Linkage Adjustment ....................................................428 Specifications..........................................................................429 Fastener Torques ...................................................................429 SECTION 6D ENGINE ELECTRICAL................................................................430 Battery ................................................................................430 Cracking System.........................................................................438 Charging System ........................................................................456 Ignition System ......................................................................466 Engine Wiring ........................................................................430 SECTION 6D1 BATTERY.........................................................................430 Battery.................................................................................430 Description.........................................................................430 Diagnosis of Battery ...............................................................432 On-Vehicle Service: Battery .......................................................433 Specifications..........................................................................436 SECTION 6D2 CRANKING SYSTEM.................................................................438 General Description ....................................................................438 Cranking Circuit ..................................................................438 Starter Motor.......................................................................438 Diagnosis of Cranking System ...........................................................440 Cranking Circuit ..................................................................440 Starter Motor Noise ...............................................................440 Diagnosis of Starter Motor Noise ......................................................444 Cranking System On-Vehicle Service .....................................................444 Maintenance.........................................................................444 Starter Motor .....................................................................445 Starter Motor Replacement .........................................................445 Unit Repair ...........................................................................446 Diagnosis of the Starter Motor .....................................................446 Disassembly of the SD-300 Starter Motor.............................................447 Inspection and Repair...............................................................450 Assembly of the SD-300 Starter Motors ..............................................453 Drive End Housing and Field Frame...................................................453 Pinion Clearance Check..............................................................454 Specifications..........................................................................455 Starter.............................................................................455 Solenoid Switches...................................................................455 SECTION 6D3 CHARGING SYSTEM.................................................................456 General Description.....................................................................456 Diagnosis of the Charging System........................................................456 Undercharged Battery................................................................457 Overcharge (or Overvoltage) Condition ..............................................457 Noisy Generator.....................................................................457 Electrical Tests....................................................................457 On-Vehicle Service......................................................................457 Generator Replacement .............................................................457 Generator Unit Repair .................................................................460 Description of Generator ..........................................................460 Generator Output Tests ............................................................460 Disassembly of Generator............................................................461 Inspection and Repair...............................................................461 Electrical Bench Tests (Generator) ................................................463 Assembly of Generator...............................................................464 Specifications..........................................................................465 SECTION 6D4 IGNITION SYSTEM.................................................................466 General Description.....................................................................467 Distributor Ignition (DI) System ...................................................467 Unit Repair lnformation .......................................................467 Ignition Base Timing ..............................................................467 Spark Plugs.........................................................................467 Spark Plug Wires....................................................................468 Diagnosis...............................................................................468 Distributor Ignition (DI) System ...................................................468 Distributor Inspection..............................................................468 Ignition Coil Test .................................................................468 Visual Inspection of Spark Plug Wires and Boots.....................................469 Spark Plug Wire Resistance Test ...............................................469 Diagnosis of Spark Plugs ...............................................................470 On-Vehicle Service .....................................................................471 Service Precautions ...............................................................471 Distributor Replacement ............................................................471 Ignition Coil Replacement ..........................................................473 Spark Plug Replacement ............................................................473 Service Precautions ...........................................................473 Spark Plug Wiring and Boots ........................................................474 Service Precautions.............................................................474 Spark Plug Wire Replacement .......................................................474 Distributor Unit Repair ................................................................476 Specifications..........................................................................478 Spark Plugs ........................................................................478 Fastener Tightening Specifications..................................................478 Special Tools...........................................................................478 SECTION 6E DRIVEABILITY AND EMISSION........................................................480 SECTION 6F EXHAUST SYSTEM...................................................................482 General Description.....................................................................482 Diagnosis of Exhaust System.............................................................483 On-Vehicle Service......................................................................484 Inspection..........................................................................484 Removing Exhaust Parts..............................................................484 Installing Exhaust Parts............................................................484 Catalytic Converter Replacement.....................................................484 Specifications..........................................................................489 Fastener Tightening Specifications..................................................489 SECTION 7A AUTOMATIC TRANSMISSION...........................................................490 Automatic Transmission Diagnosis .......................................................490 Automatic Transmission Diagnostic Trouble Codes ........................................550 Automatic Transmission On-Vehicle Service...............................................618 Automatic Transmission Unit Repair .....................................................646 SECTION 7A2A AUTOMATIC TRANSMISSION DIAGNOSIS...............................................490 General Information.....................................................................492 How to Use This Section ............................................................492 Basic Knowledge Required............................................................492 Special Tools...................................................................492 Transmission Fluid Checking Procedure ..........................................492 Transmission Fluid Level Information............................................492 Transmission Definitions and Abbreviations..........................................492 Throttle Positions..............................................................492 Shift Conditions ...............................................................493 Noise Conditions................................................................493 Abbreviations...................................................................493 Vehicle Control Module (VCM) ...................................................493 Data Link Connector (DLC) ......................................................494 Input Information...............................................................494 Wiring Harness and Connectors ..................................................494 Transmission Scan Tool Data Definitions ........................................494 Transmission General Description........................................................499 Transmission Components and System Descriptions.....................................500 Transmission Adapt Function ........................................................500 Transmission Identification Information 4L80-E......................................500 Component Locations ................................................................501 Electronic Component Location Views.................................................502 Electronic Component Descriptions...................................................503 Transmission Electrical Connector...................................................506 Range Reference Chart ..............................................................507 Diagnosis...............................................................................508 Functional Test Procedure...........................................................508 Line Pressure Check Procedure.......................................................508 Electrical/Garage Shift Test........................................................508 Road Test Procedure.................................................................508 Upshifts and Torque Converter Clutch (TCC) Apply ...............................509 Part Throttle Detent Downshift .................................................509 Full Throttle Detent Downshift ................................................509 Manual Downshifts ..............................................................509 Coasting Downshifts ............................................................509 Manual Gear Range Selection.....................................................510 Torque Converter Clutch (TCC) Diagnosis.............................................510 Torque Converter Evaluation ....................................................510 Torque Coverter Clutch (TCC) Shudder Diagnosis .................................511 Flexplate/Torque Converter Vibration Test Procedure ...........................512 4L80-E Transmisssion Fluid Checking Procedure ......................................515 Hydra-Matic 4L80-E Line Pressure Check Procedure....................................516 Shift Speed Chart...................................................................517 4L80-E Transmission Internal Wiring Harness Check...................................518 Wiring Diagram..................................................................519 4L80-E Component Resistance Chart ..............................................520 4L80-E Transmission Pressure Switch Assembly Resistance Check...................521 Clutch Plate Diagnosis..............................................................522 Engine Coolant In Transmission .....................................................522 Cooler Flushing and Flow Test.......................................................522 Fluid Leak Diagnosis and Repair.....................................................523 Methods for Locating Leaks .....................................................523 General Method..............................................................523 Powder Method .............................................................523 Dye and Black Light Method .................................................523 Repairing the Leak .............................................................523 Gaskets.....................................................................523 Seals.......................................................................523 Possible Points of Oil Leaks ...................................................524 Case Porosity Repair............................................................524 Leak Inspection Points..........................................................525 Electronic Component Malfunctions...................................................526 Diagnosis Charts....................................................................527 Electrical Diagnosis Tools..............................................................547 SECTION 7A2B AUTOMATIC TRANSMISSION DIAGNOSTIC TROUBLE CODES................................550 Diagnostic Trouble Code Diagnosis .....................................................551 Transmission Scan Tool Data (VCM) .....................................................553 Diagnostic Trouble Code (DTC) Identification Diagnostic Types (VCM).....................555 Full Mechanization (1 of 2).............................................................557 Full Mechanization (2 of 2).............................................................558 DTC P0502 Output Speed Sensor (OSS) -Low lnput ....................................559 DTC P0560 System Voltage Malfunction................................................562 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit-Low Input ............565 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit-High Input ...........568 DTC P0716 Input Speed Sensor Circuit-Range/Performance .............................571 DTC P0717 Input Speed Sensor Circuit-No Signal......................................574 DTC P0719 Brake Switch Circuit-Low Input (stuck "On") ..............................577 DTC P0724 Brake Switch Circuit-High Input (stuck "Off").............................580 DTC P0741 Torque Converter Clutch (TCC) System Stuck "Off" .........................582 DTC P0742 Torque Converter Clutch (TCC) System Stuck "On" ..........................584 DTC P0748 Pressure Control Solenoid (PCS) Circuit-Electrical ......................586 DTC P0751 Shift Solenoid A Performance .............................................589 DTC P0753 Shift Solenoid A Electrical .............................................592 DTC P0756 Shift Solenoid B Performance ............................................596 DTC P0758 Shift Solenoid B Electrical ..............................................599 DTC P1810 Pressure Switch Assembly (PSA) Circuit Malfunction .......................603 DTC P1812 Transmission Fluid Overtemperature ......................................607 DTC P1860 Torque Converter Clutch (TCC) Solenoid Electrical ........................609 DTC P1870 Transmission Component Slipping ..........................................612 DTC P1871 Undefined Gear Ratio......................................................614 SECTION 7A2C AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE......................................618 Parts Cleaning, Inspection, and Replacement ...........................................619 Flywheel and Torque Converter Vibration Test ..........................................619 Fluid Leak Diagnosis and Repair.........................................................619 Torque Converter Clutch (TCC) Electrical Controls ....................................620 TCC Diagnosis...........................................................................621 Shift Cable Replacement ...............................................................621 Shift Cable Adjustment ................................................................622 Park/Neutral Position Switch Replacement/Adjustment ...................................623 Park Lock Pawl and Actuator Assembly ..................................................624 Changing the Fluid and Filter .........................................................626 Pressure Regulator Replacement ........................................................627 Torque Converter Clutch (TCC) Valve and Spring Replacement ............................627 Control Valve Body Removal and Disassembly..............................................627 Accumulator Housing Assembly Removal ...................................................631 Accumulator Housing Assembly............................................................631 Control Valve Body Assembly ............................................................632 Installing Control Valve Assembly and Accumulator Housing...............................632 Front Servo Replacement ...............................................................633 Rear Servo Replacement ................................................................634 Rear Servo Assembly Band Apply Pin Check ..........................................634 Rear Servo Accumulator..............................................................635 Oil Level Indicator Tube Replacement ..................................................637 Speed Sensor Replacement ..............................................................638 Transmission Heat Shield Replacement ...................................................638 Transmission Replacement ..............................................................639 Transmission Cooler Flushing ..........................................................641 Manifold Absolute Pressure (MAP) Sensor Replacement ...................................643 Throttle Position (TP) Sensor Replacement .............................................643 Specifications..........................................................................644 Fastener Torques ..................................................................644 Lubrication.........................................................................644 Special Tool ..........................................................................645 SECTION 7A2D AUTOMATIC TRANSMISSION UNIT REPAIR.............................................646 Transmission Disassembly ..............................................................648 Converter Assembly ................................................................648 Holding Fixture ...................................................................648 Speed Sensors.......................................................................648 Pan and Filter Assembly ...........................................................649 Wire Harness Assembly...............................................................649 Control Valve Assembly ............................................................650 Manual 2-1 and Low & Reverse Servo ................................................651 Low & Reverse Band Servo Pin Check ................................................652 Case Extension Assembly ...........................................................653 Parking Lock Pawl and Actuator Assembly ............................................653 Front End Play Check ...............................................................655 Rear Unit End Play Check ...........................................................655 Pump Assembly.......................................................................656 Overdrive Unit and Fourth Clutch Assembly .........................................657 Forward Clutch Assembly ...........................................................658 Direct Clutch Assembly ............................................................658 Intermediate Clutch Assembly ......................................................658 Center Support and Gear Unit Assembly and Low & Reverse Band .......................659 Component Repair and Transmission Reassembly ...........................................661 Transmission Case .................................................................661 Parking Lock Pawl and Actuator Assembly ............................................662 Low & Reverse Band and Selective Thrust Washer .....................................663 Center Support and Gear Unit Assembly .............................................664 Reaction Drum and Carrier Assembly .............................................666 Center Support Assembly.........................................................667 Gear Unit Assembly..............................................................668 Rear Unit End Play Check............................................................672 Center Support Bolt ...........................................................672 Direct Clutch Assembly ............................................................673 Intermediate Clutch Assembly and Manual 2-1 Band....................................676 Forward Clutch Assembly ...........................................................678 Fourth Clutch Assembly..............................................................681 Overrun Clutch Assembly ............................................................683 Overdrive Carrier Assembly......................................................685 Turbine Shaft and Overdrive Carrier Assembly .......................................687 Fourth Clutch Plates................................................................688 Oil Pump ...........................................................................689 Pump Body.......................................................................689 Pump Cover .....................................................................691 Pump Assembly .................................................................691 Front Unit End Play Check .........................................................694 Manual 2-1 Servo Assembly .........................................................694 Low & Reverse Band Servo Pin Check ................................................695 Low & Reverse Band Servo/1-2 Accumulator ...........................................696 Control Valve Assembly/Accumulator Housing ........................................697 Accumulator Housing Assembly ......................................................697 Control Valve Assembly ............................................................699 Control Valve Assembly and Accumulator Housing ................................699 Case Extension Assembly.............................................................704 Pan and Filter Assembly.............................................................704 Speed Sensor Assemblies ............................................................705 Torque Converter Assembly...........................................................706 Holding Fixture.....................................................................706 Case and Associated Parts ..........................................................707 Bushing and Bearing Locations ......................................................716 Seal Locations......................................................................717 Fastener Tightening Specifications......................................................718 Basic Specifications ...................................................................719 Wiring Diagram ........................................................................720 Component Resistance Chart ............................................................721 Fluid Flow and Circuit Descriptions.....................................................722 Park or Neutral (Engine Running) ..................................................724 Overdrive Range First Gear..........................................................726 Overdrive Range Second Gear.........................................................728 Overdrive Range Third Gear (Torque Converter Clutch Applied) .......................730 Overdrive Range Fouth Gear (Torque Converter Clutch Applied) .......................732 4-3 Downshift (Valve in Third Gear Position) .......................................734 3-2 Downshift (Valve in Second Gear Position) ......................................736 Manual Third........................................................................738 Manual Second.......................................................................740 Manual First........................................................................742 Reverse.............................................................................744 Fluid Passages..........................................................................745 Special Tools...........................................................................752 SECTION 8 CAB AND CHASSIS ELECTRICAL........................................................760 General Information ....................................................................761 Notes for Working on Electrical Items...............................................761 Symbols and Abbreviations...........................................................767 Symbols.........................................................................767 Abbreviations...................................................................768 Parts for Electrical Circuit........................................................769 Wiring..........................................................................769 Fuse, Fusible Link and Circuit Breaker..........................................770 Relay...........................................................................772 Diode...........................................................................773 Connector ......................................................................774 Reading the Circuit Diagram ........................................................775 Connector Symbol....................................................................777 Joint Connector.....................................................................777 Main Data and Specifications............................................................778 Bulb Specifications ................................................................778 Fuse and Fusible Link Location......................................................780 Fuse Block Circuit..................................................................783 Reference Table of Fuse ............................................................785 Relay Location......................................................................787 Relay List..........................................................................788 Diode Location......................................................................789 Reference Table of Grounding Point..................................................790 Grounding Point Location............................................................791 Cable Harness Routing ..............................................................792 System Repair...........................................................................795 Start and Charging..................................................................795 Vehicle Control Module (VCM)........................................................801 Headlight and Cornering Light.......................................................809 Clearance Light, Taillight, License Plate Light, ID Light and Illumination Light....825 Turn Signal Light, Hazard Warning Light and Stoplight...............................839 Horn and Backup Light...............................................................854 Dome Light and Cab Interior Light ..................................................867 Windshield Wiper and Washer.........................................................874 Audio and Cigarette Lighter.........................................................892 Meter and Warning/Indicator Light...................................................900 A/T Shift Indicator.................................................................933 Heater and Air Conditioning.........................................................938 Service Terminal ...................................................................942 Wiring Diagram..........................................................................944 SECTION 9 METRIC AND FASTENER INFORMATION...................................................946 Metric Fasteners .......................................................................946 Replacement Fasteners ..............................................................946 Fastener Strength Identification........................................................947 Prevailing Torque Fasteners ............................................................947 Recommendations for Reuse...........................................................947 Six-Lobed Socket Head Fasteners.........................................................948 Decimal and Metric Equivalents..........................................................949 Conversion Table .......................................................................950 SECTION 10D STEEL TILT CAB..................................................................956 Cab Description.........................................................................957 Design and Construction.............................................................957 Windows.............................................................................957 Diagnosis of Steel Tilt Cab.............................................................957 On-Vehicle Service......................................................................960 Cab lnterior .......................................................................960 Driver's Seat ..................................................................960 Passenger Seat .................................................................961 Safety Belts: Side Seat Belt Tongue.............................................962 Front Center and Driver Side Seat Belt Buckle...................................963 Front Center Seat Belt Tongue and Passenger Side Seat Belt Buckle...............964 Instrument Panel................................................................965 Instrument Panel Reinforcement..................................................968 Headlining......................................................................970 Doors...............................................................................971 Description ....................................................................971 Door ...........................................................................971 Lock Mechanism..................................................................973 Lock Cylinder and Outside Door Release Handle ..................................974 Trim Panel .....................................................................975 Window and Window Regulator Assembly ...........................................977 Cab Mounts..........................................................................980 Rear Mount Brackets and Cushions ...............................................980 Cab Mounting Lever .............................................................981 Hold-Down Mechanism.................................................................982 Lock Assembly...................................................................982 Cab Replacement.....................................................................984 Specifications .........................................................................986 Fastener Torques....................................................................986 Back Cover..................................................................................994
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