Isuzu Libro 1.pdf

CAUTION

In

_order

_to

_{reduce the}

_chance

_{of personal injury and/or}

_{property damage,}

_{carefully observe}

the

instructions

that

follow:

The service manuals

of Isuzu

Motors America

Inc. are 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. This could

also

damage the vehicle, or cause the vehicle to

operate

improperly.

Proper vehicle service and repair are important to the safety of

the

service technician and to

the

safe, reliable operation

of

all motor vehicles. If _you

_need

to

replace

a _{part, use the same}

part

number

or an

equivalent

part. Do not use a

_replacement

part of lesser quality.

The service

procedures we recommend and

describe

in this

service manual

are effective methods of

performing

service

and repair. Some of the

procedures

require

the

use of tools that are designed for specific purposes.

Accordingly,

any

person

who

intends to use a

_replacement

_part, a _service

_procedure,

_or a

tool that is _not

_recommended

_{by Isuzu, must first establish that}

_there

is _{no jeopardy to}

personal

safety or the

safe

operation of the vehicle.

This

manual contains various

CAUTIONS

and

NOTICES

that

you

must

observe

carefully in

order

to reduce the risk of

personal

injury during service or repair. Improper service or repair

may damage the

vehicle or render the vehicle unsafe.

These CAUTIONS

and NOTICES

are not

exhaustive. Isuzu can not possibly warn of all the potentially hazardous

consequences

of

your failure

to follow

these

instructions.

This manual

covers service

procedures

to vehicles

that are equipped

with a _Supplemental

Inflatable Restraint (SIR). Refer to the

CAUTIONS

in Cautions and Notices and In _Restraints. Refer to SIR

component

and wiring location

views

in

_Restraints

_{before performing} a

_service

on or around SIR

components

or

wiring.

Failure to follow

these CAUTIONS

could

cause

air bag deployment, personal injury, or

otherwise unneeded

SIR repairs.

In

_order

to help avoid accidental air bag deployment and

personal

injury,

whenever

you

service

a _{vehicle that requires repair of the SIR and}

_another

_{vehicle system, we recommend} that you first repair the SIR, then go on to the other

system.

New Style Service Manual

Structure

This

new

style service

manual

is

_{constructed with the following}

10 sections:

0.

General

Information

1.

Heating, Ventilation,

and

Air

Conditioning

(HVAC)

2. Steering

3.

Suspension

4.

Driveline

and

Axle

5. Brakes

6.

Engine

7. Transmission

8.

Body

and Accessories

9. Restraints

The

following

_table

gives

the

previous service

manual

sub-sections

with

the name

of

the

new

section

and sub-section.

Almost

all of

the

diagnosis

Truck Service

Manual Sub-Section to Section

and

Sub-Section Conversion

Table

Old

Sub-Section

OA OB OC 1A 1B 1D 2A 3A

3B,3B1A,

3B1B 3B3 3C 3D 3E 3F 4A 4B 4C 5 5A 5B 5C 5D 5E 5F 6, 6A 6B 6C 6D — 6F 6H 6J 7A

Old Sub-Section

General Information Maintenance and Lubrication Vibration Diagnosis

Heating and Ventilation Heating, Ventilation, and

Air Conditioning

A/C Compressors Frame and Bumpers Front Wheel Alignment Power Steering Gear and

Pump Steering Linkage Front Suspension Rear Suspension Tires and Wheels Steering Columns Propeller Shaft Rear Axle and Differential

Front Drive Axles and Differential Hydraulic Brakes

Master Cylinder Front Disc Brakes

Drum Brakes Hydraulic or Vacuum Booster Antilock Brakes Parking Brake Engine Mechanical Engine Cooling and

Radiator Engine Fuel Engine Electrical Driveability and Emissions

Exhaust System Vacuum Pump Turbocharger Automatic Transmission

New

Section

0 0 0 1 1 1 8 3 2 2 3 3 3 2 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 7

Section

Name

General Information General Information General Information HVAC HVAC HVAC

Body and Accessories Suspension Steering Steering Suspension Suspension Suspension Steering Driveline/Axle Driveline/Axle Driveline/Axle Brakes Brakes Brakes Brakes Brakes Brakes Brakes Engine Engine Engine Engine — — Engine Engine Transmission/Transaxle

Sub-Section Name

\

General

Information Maintenance and Lubrication Vibration Diagnosis Heating and Ventilation

(Non A/C) HVAC systems with Air

Conditioning HVAC systems with Air

Conditioning

Frame and Underbody, and Bumpers

Wheel Alignment Power Steering System

Steering Linkage Front Suspension Rear Suspension Tires and Wheels. Steering Wheel and

Column Propeller Shaft Rear Drive Axle Front Wheel Drive Shafts

and Front Drive Axle Hydraulic Brakes Hydraulic Brakes Disc Brakes Drum Brakes Hydraulic Brakes Antilock Brakes Parking Brake Engine Mechanical Engine Cooling Engine Controls Engine Electrical Engine Controls Exhaust System Vacuum Pump Turbocharger Automatic Transmission and Transmission/Transfer Case Unit _{Repair Manual}

Truck

Service Manual Sub-Section to

Section

and Sub-Section

Conversion

Table

(cont'd)

Old

Sub-Section

7B 7C 7D 8B 8C 8D 8E 9A 9B 9E 9F 9J 9K 10A1 10A2 10A3 10A4 10A5 10B

Old

Sub-Section

Manual Transmission Clutch Transfer Case Lighting Systems Instrument Panel and

Gages Chassis Electrical Wipers and Washers

Audio Systems Cruise Control Engine Coolant Heater

Luggage Carrier Supplemental Inflatable

Restraint Remote Keyless Entry

Doors Seats Stationary Windows

Interior Trim Endgate Cab and Body

Maintenance

New

Section

7 7 4 8 8 8 8 8 8 6 8 9 8 8 8 9 8 8 8 —

Section Name

Transmission/Transaxle Transmission/Transaxle Driveline/Axle Body and Accessories

Body and Accessories

Body and Accessories Body and Accessories Body and Accessories

Engine

Body and Accessories

Restraints Body and Accessories Body and Accessories Body and Accessories

Restraints Body and Accessories Body and Accessories Body and Accessories

—

Sub-Section

Name

Manual Transmission and Transmission/Transfer Case Unit Repair Manual

Clutch Transfer Case and Transmission/Transfer Case Unit Repair Manual

Lighting Systems Instrument Panel, Gages

and Console Refer to the Index at the

end of the manual Wiper/Washer Systems Entertainment Cruise Control Engine Cooling Roof Supplemental Inflatable Restraints Keyless Entry Doors Seats Seat Belts Stationary Glass Exterior/Interior Trim

Body _Rear End Refer to the Index at the

1998

_{Medium Duty THick}

FSR,

FTR, FVR

Service Manual

Volume

1

This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 1998 Isuzu Medium Duty Truck.

The technicians who understand the material in this _{manual and} in the appropriate Dealer Service Bulletins better service the vehicle owners.

When this _{manual refers} to a _{brand name,} a _{part number, or} a specific _tool, you may use an equivalent product in

place of the recommended item. All information, illustrations and specifications in this _{manual are based on} the latest product information available at the time of publication approval. Isuzu reserves the right to make changes

at any time without notice.

Published by

ISUZU MOTORS AMERICA, INC.

©1998

ISUZU

MOTORS

AMERICA, INC. The information cutoff date is _12/1/97.

ALL RIGHTS RESERVED LITHO IN _U.S.A.

No part of this _{manual may} be reproduced, stored in _{any retrieval system, or transmitted} in _{any form or by any means}

(including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of

Table

of Contents

Volume

1

Preface...i Cautions and _Notices...3

General

_{Information...0-1} General Information...0-3 Maintenance _{and Lubrication...0-33} Vibration Diagnosis and Correction _...0-51 HVAC...1-1 Heating and Ventilation _{(Non-A/C)...1-3} HVAC Systems with A/C -

Manual...1-57

Body and

_{Accessories...8-1}

Lighting Systems ...8-7 Wipers/Washer Systems...8-103 Entertainment...8-123 Wiring Systems...8-143 Instrument Panel, Gauges and Console...8-283 Horns...8-351 Exterior _Trim...8-361 Waterleaks...8-363 Stationary _{Windows...8-365} Bumpers...8-373 Body Front End

...8-377 Doors...8-399 Seats...8-431 Interior

Trim...8-441 Plastic Panel Information and _{Repair...8-453} Paint/Coatings...8-455 Frame and _{Underbody...8-463} Collision Repair...8-485 Restraints...9-1 Seat Belts...9-3

Volume

2 Preface... Cautions and Notices...

Steering

_... Power Steering _System... Steering Linkage (Non-Rack & _Pinion).

Steering Wheel and Column _-Tilt...

...1 ...3 ...2-1 ...2-3 .2-53 .2-63

Suspension...

Suspension General Diagnosis, Wheel _Alignment... Front Suspension... Rear _{Suspension...} Tires and Wheels..., Air Suspension...

Driveline/Axle...

Propeller Shaft... Rear Drive Axle... Rear Axle _Controls... Brakes... Hydraulic Brakes... Disc Brakes... Park Brakes... Air Brakes _... Air Drums..., Air _{Compressor...} Antilock Brake System _... Air Antilock Brake System

...

Volume

3 Preface...

Cautions and Notices... Engine... Engine Cooling... Engine Electrical... Engine Controls - 7.8L... Engine Exhaust... Engine, On-vehicle Service _... Engine _Overhaul... Water Pump... Fuel System... Fuel Injection... Diesel Electrical... Emission and Electrical Diagnosis

...

Turbocharger _...

Transmission/Transaxle...

Manual Transmission - Medium Duty.

Automatic Transmission -

Allison... Clutch... Manual Transmission _Overhaul...

Cautions and

Notices

Cautions

and

_Notices...3

Definition of _{Caution, Notice, and Important...3} ABS Handling

Caution...3 Battery Disconnect Caution...

Brake Dust Caution... Brake Fluid Caution

... Clutch Dust Caution

... Fuel and EVAP Pipe _Caution... Fuel _Gauge Leak Caution

... Fuel Pipe Fitting Caution... Fuel Storage _Caution... Gasoline/Gasoline _{Vapors Caution...} Moving Parts and Hot Surfaces Caution, Road Test Caution

...

Safety Glasses and Compressed Air

Caution... Safety Goggles _{and Fuel Caution...} Vehicle Lifting

Caution... Window Removal Caution

... Work Stall Test Caution

... Defective Scan Tool _Notice... Fastener _Notice... Fuel Pressure Notice... Handling ESD Sensitive Parts Notice. Ignition

OFF

When Disconnecting

Battery

Notice... Nylon Fuel Lines _Notice... PCM and ESD

Notice... Single Cylinder Flooding _Notice...

Preface

Cautions

and Notices

- 3

Cautions and

Notices

Definition of Caution, Notice,

and

Important

The diagnosis and repair procedures in _{the Isuzu}

Service Manual contain both general and specific Cautions, Notices, and Importants. Isuzu is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of _{the vehicle,}

however, certain procedures may present a _hazard

to the technician if _{they are not} followed in the recommended manner. Cautions, Notices, and Importants _{are elements designed to prevent} these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is _designed to

prevent the following from occurring:

• Serious bodily injury to the technician • Damage to the vehicle

• Unnecessary vehicle repairs

• Unnecessary component replacement • Improper repair or replacement of vehicle

components. Any caution or notice that appears

in _{general information} is _{referenced from the}

individual service categories.

CAUTION

Defined

When encountering a CAUTION, you will be asked

to take a _{necessary action or not to take} a

prohibited action. If a

CAUTION

is not heeded, the following _{consequences may occur:}

• Serious bodily injury to the technician

• Serious bodily injury to other technicians in the

workplace area

• Serious bodily injury to the driver and/or

passenger(s) of the vehicle, if _{the vehicle has}

been improperly repaired

NOTICE

Defined

Notices call special attention to a _{necessary action}

or to a prohibited action. If a

NOTICE

is _{not heeded,}

the following consequences may occur:

• Damage to the vehicle • Unnecessary vehicle repairs

• Unnecessary component replacement • Improper operation or performance of the

system or component under repair

. Damage to any systems or components which

are dependent upon the proper operation of the system or component under repair

• Improper operation or performance of any

systems or components which are dependent upon the proper operation or performance of

the system or component under repair

• Damage to fasteners, basic tools, or

special tools

• The leakage of coolant, lubricant, or other

vital fluids

1998 - MD-lsuzu

IMPORTANT Defined

IMPORTANT statements emphasize a _necessary characteristic of a _{diagnostic or repair procedure.} IMPORTANT _{statements are} designed to do the following:

• Clarify a procedure

• Present additional information for accomplishing

a procedure

• Give insight into the reason or reasons for

performing a _procedure in the manner recommended

. Present information that will help to accomplish

a _procedure in a more effective manner

• Present information that gives the technician

the benefit of past experience in accomplishing a _{procedure with greater ease}

ABS

Handling Caution

Caution: Certain components In

the Antilock

Brake

System

(ABS) are not intended to be

serviced individually. Attempting to remove or disconnect certain

system components may

result in _{personal Injury and/or Improper}

_system

operation. Only those component with approved removal and Installation

procedures should

be serviced.

Battery

Disconnect

Caution

Caution: Before servicing any electrical

component, the ignition key must be in the

OFF

or LOCK position

and

all electrical loads must be OFF, unless instructed

otherwise

in

these

procedures. If a _{tool or}

_equipment

_could

_easily

come in _{contact with} a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow

these precautions

may

cause

personal injury

and/or

damage to

the

vehicle

or

its _components.

Brake Dust Caution

Caution:

Avoid

taking

the

following actions

when

you

service wheel brake parts:

• Do not grind brake _linings. • Do not

sand

brake linings.

• Do not clean wheel brake parts with a _dry

brush

or

with compressed air.

Some

models or aftermarket brake

parts may

contain

asbestos

fibers

which

can become airborne In _{dust. Breathing dust with asbestos} fibers may cause serious bodily harm. Use a

water-dampened cloth in

_order

to

remove

any dust on brake parts.

Equipment

is available

commercially

in

order

to

perform

this

washing

function. These

wet

methods

prevent

fibers from becoming airborne.

4 -

Cautions

and Notices

Preface

Brake

Fluid Caution

Caution: Brake fluid may be irritating to

the

skin

or

eyes. In

case

of contact, take the following actions:

• Eye

contact—rinse

eyes thoroughly

with

water.

• Skin

contact—wash

skin with soap

and

water.

Clutch Dust Caution

Caution:

When servicing

clutch parts, do

not

create

dust

by grinding

or

sanding

the

clutch disc or by cleaning parts with a _{dry brush}

_or

with compressed air. A

water-dampened

cloth—NOT

SOAKED—should be

_used.

The clutch

disc

contains

asbestos fibers which

can

become

airborne If dust Is _{created during}

_servicing.

Breathing dust containing

asbestos

fibers

may

cause serious bodily

harm.

Fuel

and

EVAP Pipe Caution

Caution: In

_order

to

Reduce

the Risk of Fire

and

Personal Injury

observe the

following Items:

• Replace all nylon fuel pipes that

are

nicked,

scratched

or

damaged

during Installation, Do Not attempt to repair

the sections of the

nylon fuel

pipes

• Do

Not

hammer directly on the fuel harness

body clips

when

installing

new

fuel pipes.

Damage

to the nylon pipes

may

result In a

fuel leak.

•

Always cover

nylon vapor

pipes with

a

wet

towel before using a _{torch near them. Also,}

never expose

the vehicle to temperatures higher than 115°C (239°F) for

more than one

hour, or

more

than 90°C (194°F)

for

any

extended

period.

•

Apply

_a few

drops of

clean engine oil

to the

male

pipe

ends before connecting fuel

pipe

fittings. This will

ensure

proper

reconnectlon

and prevent

a

_possible

_{fuel leak. (During}

normal operation, the

0-rings

located In

the

female connector

will swell

and may prevent

proper reconnectlon

if not lubricated.)

Fuel

Gauge

Leak

Caution

Caution: Wrap a _{shop towel around the fuel}

pressure connection in order to reduce the risk of fire _{and personal} Injury. The towel will

absorb

any fuel leakage that occurs during _{the connection}

of

the fuel _{pressure gauge. Place the} towel In an approved container when the connection

of

the fuel pressure

gauge

is complete.

Fuel

Pipe

Fitting

_Caution

Caution:

Always apply

a

_few

_{drops of clean}

engine oil to the male

pipe

ends before

connecting fuel

pipe

fittings In

order to reduce

the

risk of fire

and

personal Injury.

This will

_ensure

_{proper reconnectlon}

and

prevent a _{possible fuel leak.}

During

normal

operation, the

0-rings

located in the

female connector

will swell and

may prevent

proper

reconnectlon if _{not lubricated.}

Fuel

Storage

Caution

Caution: Do not drain the fuel into an open container. Never

store

the fuel In an open

container

due to the possibility

of

a _fire

_or

an explosion.

Gasoline/Gasoline Vapors Caution

Caution: Gasoline

or

gasoline vapors

are

highly

flammable. A _{fire could}

_occur

if _{an ignition}

source

is _present.

Never

drain or

store

gasoline

or

diesel fuel In

_an

_{open container, due to the} possibility of fire

or

explosion. Have a dry

chemical

(Class B) fire extinguisher nearby.

Moving

Parts

and

Hot

Surfaces Caution

Caution:

While working

around a _{running engine,}

avoid contact with moving parts

and

hot surfaces to

prevent possible

bodily injury.

Road

Test

Caution

Caution:

Road test

a _vehicle

_under

_safe

conditions

and while obeying

all traffic laws. Do not attempt any

maneuvers that

could

jeopardize

vehicle control.

Failure

to

adhere

to

these

precautions

could lead to

serious

personal Injury.

Safety Glasses and Compressed

Air Caution

Caution:

Wear safety

glasses

when

using

compressed

air in

order

to

_{prevent eye}

Injury.

Safety Goggles

and

Fuel Caution

Caution:

Always wear safety goggles

when

working

with fuel In order to

protect

the

_eyes

from

fuel splash.

Vehicle Lifting Caution

Caution: To help avoid

personal

Injury, when a

vehicle Is on a _hoist,

_{provide additional support}

for

the

vehicle

at

the opposite

end

from which

you are

removing components. The additional support will

reduce the

possibility

of

the

vehicle

falling off the hoist.

When

you are removing major

components

from the vehicle

while

the vehicle Is on a _{hoist, chain the}

_vehicle

_{frame to}

the

hoist pads

at the same

end

from which you

are

removing

the major components

to

prevent

tip-off. If

you

fail to

follow

these

precautionary

measures,

vehicle

damage,

serious personal

Injury,

_{or death may}

result.

Window Removal Caution

Caution:

When

working

with any

type

of

glass, use

approved safety

glasses and

gloves to

reduce

the

chance

of

personal

injury.

Preface

Cautions and Notices

- 5

Work

Stall

Test Caution

Caution: One or more

of

the following guidelines

may

apply

when

performing specific required tests in the

work

stall:

•

When

a _{test requires spinning}

_the

_drive

wheels

with the vehicle

jacked

up,

adhere

to the following precautions:

- Do not exceed 56 km/h (35 mph) when

spinning one drive wheel with the other drive wheel stopped. This limit is _necessary because the speedometer indicates only one-half the actual vehicle

speed

under these conditions. Personal injury may result from excessive wheel spinning.

- If all of the drive wheels are

spinning

at

the same speed, do not

exceed

112 km/h (70 mph). Personal injury

may

result

from

excessive

wheel spinning.

- All persons should stay

clear

of the

rotating

components and the

balance weight

areas

in _{order to}

avoid possible

personal Injury.

- When running an engine in the repair stall

for an extended

period

of time,

use care

not to

overheat

the engine

and

the transmission.

• When a _{test requires jacking up}

_the

_vehicle

and

running with the wheels

and

brake rotors removed, adhere to the following precautions:

- Do not

apply the brake

with

the

brake

rotors removed.

- Do not

place

the transmission in

PARK

with the drive

wheels

still _spinning.

- Turn Off

the

Ignition in

order

to stop

the

powertrain components

from

spinning.

Defective

Scan

Tool

Notice

Notice: Do not use a _{scan tool that displays faulty} data. Report the scan tool problem to the

manufacturer. Use of a faulty scan tool can result in misdiagnosis and unnecessary parts replacement.

Fastener

Notice

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners

in _order to avoid damage to parts and systems.

Fuel

Pressure

Notice

Notice: Do not allow the fuel pressure to exceed the specified _{value because damage} to the fuel pressure regulator or the fuel pressure gauge may result.

1998 - MD-lsuzu

Handling

ESD

Sensitive Parts Notice

Notice: Electrostatic discharge (ESD) _{can damage} many solid-state electrical components. ESD

susceptible components may or may not be labeled

with the ESD _symbol. Handle all _electrical

components carefully. Use the following precautions

in order to avoid ESD _damage:

Touch a _{metal ground point} in _{order to remove}

your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat.

Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage. Do not allow tools to contact exposed terminals when servicing connectors.

Do not remove components from their protective packaging until required to do so.

Avoid the following actions unless required by the diagnostic procedure:

Jumpering or grounding of the components or connectors.

Connecting test equipment probes to components or connectors. Connect the ground lead first _when

using test probes.

Ground the protective packaging of any component before opening. Do not rest solid-state components

on metal workbenches, or on top of _TVs, radios, or other electrical devices.

Ignition

OFF When Disconnecting

Battery Notice

Notice: Always turn the ignition OFF _when

connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.

Nylon Fuel Lines Notice

Notice: Do not attempt to straighten the kinked nylon

fuel lines. Replace any kinked nylon fuel _{feed or} return

pipes in _order to _{prevent damage} to the vehicle.

PCM

_{and ESD}

_Notice

Notice: Do not touch the connector pins or soldered components on the circuit board in _order to prevent possible electrostatic discharge (ESD) damage to

the PCM.

Single

Cylinder

Flooding

Notice

Notice: In _order to prevent flooding of a single cylinder and possible engine damage, relieve the

fuel pressure before performing the fuel injector

Section

0

General

Information

General

_{Information...o-3}

Conversion -

English/Metric...0-3 Equivalents - Decimal and Metric

...0-3 Paper Version of the Service Manual -

How to

Use...0-4 Arrows and _{Symbols...0-5} Special Tools Ordering Information

...0-5 Vehicle Identification...0-5 VIN

Derivative...0-6 Label - Vehicle Certification...0-7

Engine Identification...0-8 Transmission Identification

...0-8 Rear Axle _{Identification...0-9} Label - Service Parts

ID...0-11 RPO Code

List...0-11 Labels - How to Obtain

Replacement...0-17 Fasteners (Prevailing Torque _{Fasteners)...0-17} Fasteners (Strength Identification)...0-19 Fasteners (Metric

Fasteners)...0-20 Thread _{Inserts...0-20} Torque Wrenches

...0-21 Abbreviations and Their _{Meanings...0-23} Key and Lock Cylinder _{Coding...0-26} Lifting and Jacking the _{Vehicle...0-26} Cab

Tilting...0-27 Towing a Disabled _{Vehicle...0-30} Strategy Based Diagnosis...0-32

Maintenance and

_{Lubrication...o-33}

Specifications...0-33 Approximate Fluid _{Capacities...0-33} Fluid and Lubricant Recommendations... 0-34 Maintenance Items

...0-34

Maintenance _...0-35 Maintenance Schedule...0-35 Maintenance Schedule - Short

Trip/City...0-43 Maintenance Schedule -

Long Trip/Highway

...0-43 Owner Checks and Services _{(General)...0-43} Owner Checks and Services (Single Axle)...0-46 Explanation of _{Scheduled Services...0-47}

Inspections and Other Services _...0-50

Vibration

Diagnosis

and

_{Correction...0-51}

Specifications...0-51 Specifications...0-51 Diagnostic Information

and Procedures

_...0-52

Systematic Approach

...0-52 Vibration Diagnosis _...0-52 Road

Test...0-52 Classifying the Vibration

...0-56 Tire and Wheel _{Vibration...0-59} Tire and Wheel Runout _{Measurement...0-59} Driveline Vibration Analysis with _EVA...0-63 Engine Related Vibration...0-67 Repair Instructions...0-71 General Service _{Precautions...0-71} Correcting Tire and Wheel Vibration...0-71 Balancing Tires and _{Wheels...0-71} Wheel Weight

Usage...0-75 Correcting Non-Uniform Tires...0-75 Correcting Driveline Vibration -

RWD and _4WD...0-76 Description and Operation...0-94 General Description...0-94 Special Tools and Equipment. .0-105

0-2 Table of

Contents

General Information

BLANK

General Information

General

Information

0-3

General Information

Conversion

-

English/Metric

(cont'd)

In _order to convert English units to metric units,

multiply the English units by the conversion factor shown in _{the conversion table.}

In _order to convert metric units to English units,

divide the metric units by the conversion factor shown in _{the conversion table.}

Conversion

-

English/Metric

English LENGTH in ft yd mi AREA sq in sq ft sq yd VOLUME cu in qt gal cu yd MASS Ib ton kg oz Ib ACCELERATION ft/s2 in/s2 TORQUE Ib in Ibft POWER hp Multiply/ Divide by 25.4 0.3048 0.9144 1.609 645.2 6.45 0,0929 0.8361 16,387.0 16.397 0.0164 0.9464 3.7854 0.7646 0.4536 907.18 0.907 FORCE 9.807 0.2780 4.448 0.3048 0.0254 0.11298 1.3558 0.746 Metric mm m km sq mm sq cm sq m cu mm cu cm L cu m kg tonne (t) newtons (N) m/s2 N.m kW English PRESSURE (STRESS) inches of Mercury inches of H20 Ib/sq in LIGHT Foot Candle VELOCITY mph TEMPERATURE •F •C FUEL PERFORMANCE mpg Multiply/ Divide by 3.377 0.2491 6.895 10.764 1.6093 5/9(-F-32) 9/5('C+32) 2.3527 Metric RPa kPa lm/m2 km/h •C •F L/km

Refer to the following table for equivalent of fractions to decimals in English (inches), to metric (millimeters).

Equivalents

•

Decimal

and

Metric

Fraction (in) 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 Decimal (in) 0.015625 0.03125 0.046875 0.0625 0.078125 0.09375 0.109375 0.125 0.140625 0.15625 0.171875 0.1875 0.203125 0.21875 0.234375 0.25 0.265625 0,28125 0.296875 0.3125 0.328125 Metric (mm) 0.39688 0.79375 1.19062 1.5875 1.98437 2.38125 2.77812 3.175 3.57187 3.96875 4.36562 4.7625 5.15937 5.55625 5.95312 6.35 6.74687 7.14375 7.54062 7.9375 8.33437 1998 - MD-ISUZU

0-4

General Information

General

Information

Equivalents

-

Decimal and Metric (cont'd)

Fraction (in) 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 Decimal (in) 0.34375 0.359375 0.375 0.390625 0.40625 0.421875 0.4375 0.453125 0.46875 0.484375 0.5 0.515625 0.53125 0.546875 0.5625 0.578125 0.59375 0.609375 0.625 0.640625 0.65625 0.671875 0.6875 0.703125 0.71875 0.734375 0.75 0.765625 0.78125 0.796875 0.8125 0.828125 0.84375 0.859375 0.875 0.890625 0.90625 0.921875 0.9375 0.953125 0.96875 0.984375 1.0 Metric (mm) 8.73125 9.12812 9.525 9.92187 10.31875 10.71562 11.1125 11.50937 11.90625 12.30312 12.7 13.09687 13.49375 13.89062 14.2875 14.68437 15.08125 15.47812 15.875 16.27187 16.66875 17.06562 17.4625 17.85937 18.25625 18.65312 19.05 19.44687 19.84375 20.24062 20.6375 21.03437 21.43125 21.82812 22,225 22.62187 23.01875 23.41562 23.8125 24.20937 24.60625 25.00312 25.4

Paper Version of

the

Service

Manual

-

How

to Use

Construction

This service manual is constructed with the following 10 major sections: Major Section Number 0 1 2 3 4 5 6 7 8 9 10

Major Section Name

General Information Heating, Ventilation, and Air Conditioning (HVAC)

Steering Suspension Driveline/Axle Brakes Engine Transmission/Transaxle Chassis/Body Electrical Accessories Body

Information

Flow

Each major section will _{be structured as follows:} 1. A single table of contents for the entire major

section; including all _contents of the subsections within the major section. 2. Subsections

The service information located within each subsection will _{be ordered as} follows:

1. Specifications

2. Diagnosis

3. Repair procedures

4. General description and system operation 5. Special tools

Improvements

Made

This service manual provides many more illustrations than in _{earlier manuals. Illustrations serve as the}

primary source for repair procedures. These illustrations will _{be supplemented} with text

descriptions. In _{the previous service manuals, text}

was the primary source of information for repair procedures and illustrations provided support. Repair procedures, illustrations, and the descriptive text have been arranged so that they will _correspond with _{the way you work. This} manual provides

disassembled views, wherever possible, so that it will

be easy to look up parts, names, and order of

assembly. The text descriptions have been rewritten into simple, complete sentences.

1998 -

General

Information

General

Information

0-5

Arrows

and

Symbols

^^^

^^^^

4 5

^

0

\.

y>

_\^,

12 11

>-

^

196216 Legend

(1)

Front of Vehicle (2) View Detail

(3) Ambient Air Mixed With Another Gas, Can Indicate Temperature Change

(4)

Motion or Direction

(5)

View Angle

(6)

Dimension (1:2)

(7) Ambient/Clean Air Flow, Cool Air Flow

(8)

Lubrication Point—Oil or Fluid*

(9) Task Related (10) Sectioning (1:3)

(11) Gas Other Than Ambient Air, Hot Air Flow (12) Lubrication Point—Grease or Jelly*

Special

Tools

Ordering Information

Special Tools

The special service tools shown in _{this service}

manual have tool product numbers beginning with J or BT. Special tools are distributed worldwide by Kent-Moore: Kent-Moore

SPX

Corporation

29784

Little Mack Roseville, Ml 48066-2298 1-800-328-6657

Mon.-Fri. 8:00 a.m. to 7:00 p.m. EST Telex: 244040 KMTR UR

Fax:

1-800-578-7375

Purchase scan tools and accessories from Kent-Moore at the address _above.

Vehicle

Identification

The Isuzu Commercial Truck is available in the above body style.

205884

0-6 General Information

General

Information

VIN Derivative

The Vehicle Identification Number (VIN) is the legal

identifier of the vehicle. The VIN contains the following information:

• The manufacturer • The model • The chassis type • The engine type

• The Gross Vehicle Weight (GVW) range • The model year

• The plant code

• The sequential number

205886

The

VIN plate is attached to the driver's door

opening.

Vehicle Identification

Number

(VIN) System

Position 1 2 3 4 5 6 7 8 Definition Country of Origin Manufacturer Model GVWR/Brake System Series Cab Type Chassis Type Engine Type Character 4 G T A B C D E F G H J K L M N P R S T V W 6 7 C 1 2 Description United States Isuzu

Isuzu Incomplete Vehicle 9001-10000 Hydraulic 10001-14000 Hydraulic 14001-16000 Hydraulic 14001-16000 Air 16001-19500 Hydraulic 16001-19500 Air 19501-23500 Hydraulic 19501-23500 Air 23501-26000 Hydraulic 23501-26000 Air 26001-33000 Hydraulic 26001-33000 Air 33001-40500 Hydraulic 33001-40500 Air 40501-48500 Hydraulic 40501-48500 Air 48501-58000 Air 58001-69500 Air 69501-over Air 6000 7000

Medium Tilt, Steel, 226 cm (89") BBC

4 x _{2, 2 Axles,} 1 Driving

Isuzu 6 _{Cylinder Turbo Diesel (7.8L)}

General

Information

General

Information 0-7

Vehicle Identification

Number (VIN) System

(cont'd)

Position 9 10 11 12-17 Definition Check Digit Model Year Plant Location

Plant Sequence Number

Character 1 — J — Description — 1998 Janesville

6-Digit Sequential Numbers

Label

-

Vehicle Certification

Complete Vehicle Certification Label

QVW RATINQ INFORMATION

OWR-LB/KQ QAWR FBT OAWR INT QAWB RB TIRE SIZE PSI/KPA (COLD)

ASSEMBLED IN JANESVILLE Wl

^ SEE OWNER'S MANUAL FOR ADDITIONAL INFORMATION I————I L^

The Gross Vehicle Weight (GVW) is the weight of

the stock vehicle and all _{the options added to} the vehicle after leaving the factory. The GVW includes, but not limted to, the weight of the following items:

• The body • Winches • Booms • The driver • All occupants

•

The

load that the vehicle is carrying

Ensure that the Gross Vehicle Weight (GVW) _does not exceed the Gross Vehicle Weight Rating (GVWR). Ensure that the front and the rear Gross Axle Weights (GAW) do not exceed the front and the rear Gross Axle Weight Rating (GAWR).

291017

Incomplete Vehicle Certification Label

6VWR-IB/KQ QAWR FRT QAWB INT OAWH RR

TIRE SIZE

205890

291007

The Vehicle Certification Label indicates the following ratings for the vehicle:

. The Gross Vehicle Weight Rating (GVWR) • The front and rear Gross Axle Weight

Rating (GAWR)

• The payload rating

The payload rating shown on the label is the maximum allowable cargo load (including the weight

of the driver and all _{occupants) that the vehicle may}

carry based on the stock equipment. The payload rating lowers if _{any accessories or other equipment}

are added to the vehicle after the final date of

manufacture. Determine the weight of any added accessories and deduct the amount from the payload rating.

The vehicle may also have a _{Gross Combination} Weight Rating _(GCWR).

_The

GCWR is _{the total}

weight of the loaded tow vehicle (including passengers) and a loaded trailer.

0-8

General

Information

General Information

Ensure that the tires on the vehicle are the proper

size and at the proper inflation pressure for the load that the vehicle is _carrying. The vehicle certification

label shows the stock tire _size and recommended

inflation _pressures.

Engine Identification

Diesel Engine

The engine serial number is _{located on the front}

right side _comer of the engine block.

Transmission Identification

Isuzu

Allison

208521 The Allison® transmission identification plate is

located on the rear left side of the housing, just above the oil _pan.

208509

The Isuzu transmission identification plate is _located

on the left _{upper side of the housing.}

Eaton

Fuller

_{_}

Transmissions

F^RT-—'^

"^

200589 1998 - MD-lsuzu

General Information

General

Information

0-9

Rear Axle

Identification

Eaton® Rear

Axle

ID

200579

Legend

(1) Axle Specification Number (2) Casting Number

(3)

Rough Number

(4) Capacity

(5) Housing Subassembly Number (Including Tubes)

All _{axle housings have identification tags or}

identification information stamped on the side of the differential carrier.

Differential Carrier

The carrier tag may contain the following information:

• The axle model • The ratio

• The carrier assembly number • The carrier serial number • The date of assembly

Use all the information on the carrier tag in _{order to}

identify the axle assembly.

0-10

General

Information

General

Information

Eaton®

Differential Carrier ID

200584

Legend

(1)

Side View (2) Top View

Dana/Spicer®

Rear Axle Differential Carrier ID

200587

Axle

Housing

Dana/Spicer® Rear

Axle ID

Legend

(1)

(2)

(3)

(4)

(5) 200582 Dana® Part Number

Customer Part Number (Optional) Julian Date Code

Line Set Number (Optional)

Last Six Digits of Vehicle Serial Number (Optional)

Legend

(1) Dana® Part Number

(2)

Customer Part Number (Optional)

(3)

Model

(4)

Julian Date Code

(5)

Line Set Number (Optional)

(6)

Last Six Digits of Vehicle Serial Number (Optional)

The housing tag is the _{same type} of _{tag used} for

the Differential Carrier.

General Information

General

Information

0-11

Label

-

Service Parts ID

RPO

Code

List

205849

The Service Parts Identification Label is _on the passenger's side sun visor.

mnn h _u.t.A.

SERVICE PARTS IDENTIFICATION

WIGDI iHpasia i

».|.N. v.hlcl. KHnUlteolta Niin««r

HOTT: Th« opHonot •«)ufpm»nl lt«t«d b«low hu b««n IrrloaKlan thh ••hiel*. lor _prflf MxnIMcaMon »1 _{fploeflnrnt parti} b« w !• •pMlfy th« oppflcabi* opKon _numbw.

OP-ID,*

IMPORTANT _{".i.«ii..i.b...,.p.,m...,,,.c«i} .

aescmpnoN OPTION ocscmpTtOf*

200611 Always refer to the Service Parts Identification Label when ordering parts. The label lists the following items:

• The Vehicle Identification Number (VIN) • The wheelbase

• The paint information • All production options

• All factory-installed special equipment

RPO ASA AV8 BAG BPU BPV BPW BUB BUC CKD CV3 C60 DFO DNN DTE EG5 EH8 EK8 EM2 EQ8 ERA ERB ERC ERD ERE ESS EV9 EXP EY1 FDO FD5 FF1 Description

Seat: Front Bucket, Driver High Back, Self Contained Air Suspension Seat: Center Front Bucket, Auxiliary,

Folding

Parts Package Export

First Position Prop Hanger, NON-BOC,

Height A

First Position Prop Hanger, NON-BOC,

Height B

First Position Prop Hanger, NON-BOC,

Height C

First Position Prop Hanger, NON-BOC,

Height D

First Position Prop Hanger, NON-BOC,

Height E

Vehicle Completely Knocked Down Country Mexico

HVAC System Air Conditioner, Front

Manual Controls

Mirror: Outside, LH _{and RH,}

17.8 cm x _{40.6 cm} (7 in x 16 in), SST

Mirror: Outside, Dual Velvac Heated,

15.2 cm x _{40.6 cm} (6 in x 16 in),

Stainless Steel

Mirror: Auxiliary Outside 20 cm (8 in) Spot, Dual Retrac, SST

401 _cm (158 in) Wheelbase 432 _cm (170 in) Wheelbase

478 cm (188 in) Wheelbase

508 cm (200 in) Wheelbase 592 _cm (233 _{in) Wheelbase}

Second Position Prop Hanger, Height A

Second Position _{Prop Hanger, Height} B

Second Position Prop Hanger, Height C

Second Position Prop Hanger, Height D

Second Position Prop Hanger, Height E

630 cm (248 in) Wheelbase

Suspension: Attach Bolted

Export I.E.S.

Yoke: Propeller Shaft, Driveline, Dana®

Frame: Rail, Full Depth,

612 cm x 15 cm (241 in x 6 in),

22 680 kg (50,000 Ib)

Frame: Rail, Full Depth,

622 _cm x 20 _{cm (245} in x 8 in),

36 288 kg (80,000 Ib)

Hub: Front, Oil Filled