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.
This service manual is a scanned PDF file that includes 514+590 pages, which are printable and readable. We recommend to use Adobe PDF Reader, to be sure all images / graphics will display correctly.
CONTENTS:
- SECTION 0 - GENERAL INFORMATION
- General Information
- Maintenance and Lubrication
- SECTION OA - GENERAL INFORMATION
- Handling Electrostatic Discharge (ESD) Sensitive Parts
- Model Designation
- VIN (Vehicle Identification Number) and Weight Rating Plate
- GVWR (Gross Vehicle Weight Rating)
- Service Parts Identification Label
- Regular Production Options (RPO) Code List
- Engine Serial Number
- Graphic Symbols
- Action Symbols
- Emergency Starting a Vehicle Due to a Discharged Battery
- Towing Procedure
- Vehicle Lifting Points
- Common Automotive Abbreviations
- Essential Service Tools
- SECTION OB - MAINTENANCE AND LUBRICATION
- Lubrication Detail Information
- Maintenance Schedule
- Explanation of Complete Vehicle Maintenance Schedule
- Owner Safety and Routine Maintenance
- Noise Emission Control
- Rcommended Fluids and Lubricants
- Lubrication Chart
- Specifications
- SECTION 1 - HEATING AND AIR CONDITIONING
- Heating and Ventilation
- Air Conditioning
- SECTION 1A - HEATING AND VENTILATION
- General Description
- Circuit Diagram
- Diagnosis
- On-Vehicle Service
- SECTION 1B - AIR CONDITIONING
- Description
- Circuit Diagram
- Diagnosis
- On-Vehicle Service
- Specifications
- Special Tools
- SECTION 2 - FRAME AND CAB
- Frame and Body Mounts
- Cab Maintenance
- Sheet Metal
- SECTION 2A - FRAME AND BODY MOUNTS
- Frame
- Diagnosis of Frame
- On-Vehicle Service
- Body Mounts
- Specifications
- SECTION 2B - CAB MAINTENANCE
- Interior Maintenance
- Exterior Maintenance
- Stationary Glass
- Model and Series Designation Plate Replacement
- SECTION 2C - SHEET METAL
- Introduction
- On-Vehicle Service
- SECTION 3 - STEERING, SUSPENSION, WHEELS AND TIRES
- Front End Alignment
- Steering Linkage
- Power Steering
- Steering Column
- Front Axle and Suspension
- Rear Suspension
- Wheels and Tires
- SECTION 3A - FRONT END ALIGNMENT
- Description
- Diagnosis
- On-Vehicle Service
- Specifications
- SECTION 3B1 - STEERING LINKAGE
- Description
- Diagnosis of Steering Linkage
- Steering Linkage On-Vehicle Service
- Specifications
- Special Tools
- SECTION 3B3 - POWER STEERING
- Description
- Diagnosis of Power Steering System
- Power Steering System On-Vehicle Service
- Power Steering Gear Unit Repair
- Hydraulic Pump Unit Repair
- Specifications
- Special Tools
- SECTION 3B4 - STEERING COLUMN
- Description
- Diagnosis of Steering Column
- Steering Column On-Vehicle Service
- Steering Column Unit Repair
- Specifications
- SECTION 3C - FRONT AXLE AND SUSPENSION
- Description
- Diagnosis of Front Axle and Suspension
- Diagnosis of Front-Wheel Bearings
- Front Axle On-Vehicle Service
- Front Suspension On-Vehicle Service
- Front Hubs and Discs On-Vehicle Service
- Specifications
- Special Tools
- SECTION 3D - REAR SUSPENSION
- Description
- Diagnosis of Springs
- On-Vehicle Service
- Specifications
- SECTION 3E - WHEELS AND TIRES
- Wheels and Rims
- Diagnosis of Wheels
- On-Vehicle Service: Wheels
- Tires and Tubes
- Diagnosis of Tires
- On-Vehicle Service: Tires and Tubes
- Specifications
- SECTION 4 - REAR AXLE AND PROPELLER SHAFT
- Rear Axle
- Propeller Shaft
- SECTION 4A1 - REAR AXLE
- General Description
- Diagnosis of the Rear Axle
- On-Vehicle Service
- Unit Repair of Differential Carrier Assembly
- Specifications
- Special Tools
- SECTION 4B - PROPELLER SHAFT
- Description
- Driveline Vibration Diagnosis (Road Test)
- Diagnosis of the Propeller Shaft
- On-Vehicle Service
- Specifications
- SECTION 5 - BRAKES
- Hydraulic Brake
- Hydraulic Brake Booster System
- Hydraulic Foundation Brakes
- Parking Brakes
- SECTION 5A - HYDRAULIC BRAKES
- Introduction
- Brake System Diagnosis
- Inspection and Repair
- Specifications
- SECTION 5A1 - HYDRAULIC BRAKE BOOSTER SYSTEM
- On-Vehicle Service
- Brake Pedal Replacement
- Brake Pedal Adjustment
- Specifications
- SECTION 5A2 - HYDRAULIC FOUNDATION BRAKES
- Introduction
- On-Vehicle Service of Brake Assembly
- Specifications
- Special Tools
- SECTION 5C - PARKING BRAKE
- Description
- On-Vehicle Service
- Specifications
- SECTION 6 - ENGINE
- Engine
- Isuzu Engine
- Cooling System
- Radiator
- Fan
- Fuel System
- Diesel Fuel Injection
- Engine Electrical
- Exhaust
- SECTION 6A - ENGINE
- Engine Replacement
- Engine Mountings
- Exhaust Brake System
- Diagnosis of Exhaust Brake
- Exhaust Brake On-Vehicle Service
- Specifications
- SECTION 6A6 - ISUZU ENGINE
- General Information
- Description
- Diagnosis of Isuzu Diesel Engine
- Maintenance
- Isuzu Engine On-Vehicle Service
- Specifications
- Special Tools
- SECTION 6B1 - COOLING SYSTEM
- Cooling System
- Diagnosis of Cooling System
- Operations and Maintenance
- On-Vehicle Service: Cooling System Components
- Water Pump Unit Repair
- Engine Warming-Up System
- Specifications
- Special Tools
- SECTION 6B2 - RADIATOR
- On-Vehicle Service
- Specifications
- SECTION 6B3 - FAN
- Description
- Diagnosis of Automatic Fan Clutch
- On-Vehicle Service: Cooling Components
- On-Vehicle Service: Drive Belts
- Specifications
- Special Tools
- SECTION 6C1 - FUEL SYSTEM
- Air Cleaner
- Fuel Filters
- Accelerator Linkage and Hand Throttle
- Engine Stop Linkage
- Fuel Tank
- Specifications
- SECTION 6C3 - FUEL INJECTION SYSTEM
- Fuel Injection System
- Diagnosis of Fuel Injection System
- On-Vehicle Service
- Specifications
- Special Tools
- SECTION 6D - ENGINE ELECTRICAL
- General Description
- Battery
- Charging System
- Starting System
- Generator Unit Repair
- Starter Motor Unit Repair
- Engine Heaters
- Specifications
- SECTION 6F - EXHAUST
- Description
- Diagnosis of Exhaust System
- On-Vehicle Service
- Exhaust System Replacement
- Specifications
- SECTION 7 - TRANSMISSION
- Automatic Transmission
- Manual Transmission
- Clutch
- SECTION 7A - AUTOMATIC TRANSMISSION
- Construction and Function
- Diagnosis
- On-Vehicle Service
- Overhaul
- SECTION 7A1 - CONSTRUCTION AND FUNCTION
- Description
- Transmission Serial Number
- Component Location
- Structure and Function of Component
- Control Mechanism
- SECTION 7A2 - DIAGNOSIS
- Description
- Self Diagnosis
- Diagnosis by Using Scan Tool
- Identification of Transmission Control Module (TCM)
- Diagnosis Based on Diagnostic Trouble Code (DTC)
- Diagnosis Based on Vehicle Condition
- Inspection Based on Fauty Simptom
- Wiring Diagram
- Control Signal Inspection
- Line Pressure Test
- Stall Test
- Road Test
- SECTION 7A3 - ON-VEHICLE SERVICE
- Description
- Automatic Transmission Fluid (ATF)
- ATF Level
- ATF Change
- Transmission Control Module (TCM)
- Idle Switch
- Throttle Position Sensor and Kick Down Switch
- Inhibitor Switch
- VehicleSpeedSensor-1
- Vehicle Speed Sensor-2
- EngineSpeedSensor
- Overdrive OFF Switch
- Dropping Register
- Oil Pan
- Valve Body Assembly
- Solenoids and ATF Thermosensor
- Band Servo Assembly
- Rear Cover Oil Seal
- Power Take Off (PTO) Cover
- Vehicle Speed (Speedometer) Sensor Driven Gear
- Control Lever Assembly
- Control Cable
- Flushing the Transmission Fluid Cooler and Line
- Transmission Assembly
- Torque Converter
- Front Oil Seal
- SECTION 7A4 - AUTOMATIC TRANSMISSION OVERHAUL
- Cautions Regarding Disassembly and Reassembly
- Non-Reusable Part List
- Disassembly and Inspection of Major Component
- Disassembly, Reassembly and Inspection of Minor Component
- Reassembly and Adjustment of Major Component
- Specification
- Special Tool
- SECTION 7B - MANUAL TRANSMISSION
- Description
- Diagnosis of Manual Transmission
- On-Vehicle Service
- Unit Repair
- Specifications
- Special Tools
- SECTION 7C - CLUTCH
- Description
- Diagnosis of Clutch
- On-Vehicle Service
- Component Parts Replacement
- Unit Repair
- Specifrications
- Special Tools
- SECTION 8 - CAB AND CHASSIS ELECTRICAL
- General Information
- Main Data and Specifications
- System Repair
- Meter and Wasning / Indicator Light
- Heater, Air Conditioning and Condensor Fan
- Service Terminal
- SECTION 9 - METRIC AND FASTENER INFORMATION
- Metric Fasteners
- Fastener Strehgth Identification
- Prevalling Torque Fasteners
- Six-Lobed Socket Head Fasteners
- Decimal and Metric Equivalents
- Conversion Table
- SECTION 10 - STEEL TILT CAB
- Cab Description
- Diagnosis of Steel Tilt Cab
- On-Vehicle Service
- Specifications
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