2002 Isuzu NPR Repair Manual

GENERAL INFORMATION 0A-1

SECTION 0

GENERAL INFORMATION CONTENTS SUBJECT

PAGE

General Information ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................. ............................. ............................ ................ .. 0A Maintenance and Lubrication .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................. ............................ ............. 0B

SECTION 0A

GENERAL INFORMATION CONTENTS SUBJECT

PAGE

Handling Electrostatic Discharge (ESD) (ESD) Sensitive Parts ....................................... ..................................................... ............................ ....................... ......... 0A- 2 Model Reference ............ .......................... ............................ ............................ ............................. ............................. ............................ ............................ ............................ ............................ .................0A...0A- 2 VIN (Vehicle Identification Identification Number) Number) and Weight Rating Rating Plate................................ Plate.............................................. ............................ ....................... ......... 0A- 2 GVWR (Gross Vehicle Weight Rating) ............ ........................... ............................. ............................ ............................ ............................ ............................ ....................... ......... 0A- 3 Service Parts Identification Label ............ .......................... ............................ ............................ ............................. ............................. ............................ ............................ ................ .. 0A- 3 Regular Production Options Options (RPO) (RPO) Code List .............. ............................ ............................ ............................ ............................ ............................. ....................... ........ 0A- 4 Engine Serial Number .................. ................................ ............................ ............................ ............................ ............................. ............................. ............................ ............................ ................ .. 0A- 5 Graphic Symbols .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................. ............................. ........................... ............. 0A- 5 Action Symbols ............................ .......................................... ............................ ............................ ............................ ............................. ............................. ............................ ............................ ................ .. 0A- 5 Emergency Starting Starting a Vehicle Vehicle Due Due to a Discharged Discharged Battery ............ ........................... ............................. ............................ ............................ ................ .. 0A- 5 Towing Procedure ...................... .................................... ............................ ............................ ............................ ............................ ............................ ............................. ............................. .................. .... 0A- 6 Vehicle Lifting Points .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................. ............................. .................... ...... 0A- 7 Abbreviations Charts ................... ................................. ............................ ............................ ............................ ............................ ............................. ............................. ............................ ................ .. 0A- 8 Essential Service Tools ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................. ............................. .................. .... 0A-10

0A-2 GENERAL INFORMA INFORMATION TION HANDLING ELECTROSTA ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS When handling an electronic part that has an ESD sensitive sticker (figure 1), the service technician should follow these guidelines to reduce any possible electrostatic charge build-up on the service technician’s body and the electronic part in the dealership: 1. Do not open the package until until it is time to install the part. 2. Avoid touching the the electrical terminals terminals of the part. 3. Before removing the part part from its package, package, ground the package to a known good ground on the vehicle. 4. Always touch a known good ground ground before handling the part. This should be repeated while handling the part and more frequently after sliding across the seat, sitting down from a standing position or walking a distance.

Crew cab model

MODEL

NPR NQR

Figure 3. Model Reference (Crew Cab Model)

VIN (VEHICLE IDENTIFICATION NUMBER) AND WEIGHT RATING PLATE The VlN and Weight Rating Plate (figure 4) lists the manufacturer, gross vehicle weight for the vehicle, maximum front end weight at ground, maximum rear end weight at ground, and the VlN (vehicle identification number). This plate is attached to the inner face of the cab side panel on the driver side. The vehicle identification number is a legal identifier of your vehicle. It not only appears on the VlN plate, but also on the Vehicle Certificates of Title and Registration. The vehicle identification number specifically identifies a vehicle by code. Figure 5 displays the codes and descriptions for the model covered in this manual.

Figure 1. Electrostatic Discharge Symbol

MODEL REFERENCE The models covered in this manual are referred to as a NPR, NQR. Single cab model

MODEL

NPR NQR

Figure 2. Model Reference Reference (Sing (Single le Cab Model)

Figure 4. VIN Weight Rating Plate

0A-2 GENERAL INFORMA INFORMATION TION HANDLING ELECTROSTA ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS When handling an electronic part that has an ESD sensitive sticker (figure 1), the service technician should follow these guidelines to reduce any possible electrostatic charge build-up on the service technician’s body and the electronic part in the dealership: 1. Do not open the package until until it is time to install the part. 2. Avoid touching the the electrical terminals terminals of the part. 3. Before removing the part part from its package, package, ground the package to a known good ground on the vehicle. 4. Always touch a known good ground ground before handling the part. This should be repeated while handling the part and more frequently after sliding across the seat, sitting down from a standing position or walking a distance.

Crew cab model

MODEL

NPR NQR

Figure 3. Model Reference (Crew Cab Model)

VIN (VEHICLE IDENTIFICATION NUMBER) AND WEIGHT RATING PLATE The VlN and Weight Rating Plate (figure 4) lists the manufacturer, gross vehicle weight for the vehicle, maximum front end weight at ground, maximum rear end weight at ground, and the VlN (vehicle identification number). This plate is attached to the inner face of the cab side panel on the driver side. The vehicle identification number is a legal identifier of your vehicle. It not only appears on the VlN plate, but also on the Vehicle Certificates of Title and Registration. The vehicle identification number specifically identifies a vehicle by code. Figure 5 displays the codes and descriptions for the model covered in this manual.

Figure 1. Electrostatic Discharge Symbol

MODEL REFERENCE The models covered in this manual are referred to as a NPR, NQR. Single cab model

MODEL

NPR NQR

Figure 2. Model Reference Reference (Sing (Single le Cab Model)

Figure 4. VIN Weight Rating Plate

GENERAL INFORMATION 0A-3

Cab Type Code GVWR and Brake System Series Code

Identifiers

J

A

L

B

4

Model Year Code Engine Code

Chassis Type Code

B

1

Check Digit

4

*

Code Code Descri Descripti ption on J Japanese Built

Descri Des cripti ption on Chevrolet Incomplete GMC Incomplete Isuzu Incomplete

Code Code B C E

Descripti Descri ption on 10001 - 14000 lbs. 14001 - 16000 lbs. 16001 - 19500 lbs. Hydraulic Brake System

Y

7

Sequential Numbers

0

0

0

0

0

1

Code Code Plant Plant Locati Location on 7 Fujisawa Code Code X Y 1 2

Code Descri Code Descripti ption on A Isuzu Motors 8 Isuzu Motors Code Code B D L

Plant Code

Model Model Yea Yearr 1 999 2 000 20 01 20 02

Code Code Descri Descripti ption on 4 Isuzu 4HE1-TCS 5 Isuzu 4HE1-TCN Code Code Descri Descripti ption on 1 4×2 Code Descri Code Descripti ption on B Steel Tilt Cab 67.8 inch BBC* J Non Tilt Cab 109 inch BBC* *: Bumper to Back of Cab

Code Seri Code Series es 4 NPR/NPR HD 5 NQR

Figure 5. VIN Chart

GVWR (GROSS VEHICLE WEIGHT RATING) The GVWR is the weight of a vehicle plus the weight of a vehicle’s load. For the gross vehicle weight rating and the gross vehicle combined weight rating, refer to Model Explanation (figure 2). For the gross vehicle weight rating range refer to the VlN Chart (figure 5).

SERVICE PARTS IDENTIFICATION LABEL The “Service Parts Identification” label (figure 6) lists major components and their part numbers plus vehicle options and their codes. The information on the label was printed at the factory; therefore, therefore, it represents only the equipment on the vehicle when it was shipped from the factory. Always refer to this label when ordering replacement service parts. (Refer to the “NOTICE” on the label.) The service parts identification label is attached to the inner face of the cab side panel on the Passenger side.

Figure 6. Service Parts Identification Label

0A-4 GENERAL INFORMATION REGULAR PRODUCTION OPTIONS (RPO) CODE LIST The RPO list (figure 7) contains RPOs available on this model. Also, refer to the “Service Parts Identification” label (figure 6) for a list of the RPOs used on each specific vehicle.

Note;

F=Front R=Rear w/=With

OPTION CODE

OPTION DESCRIPTION

OPTION CODE

OPTION DESCRIPTION

100 153 729 730

INTERIOR-TRIM COLOR COMBI.(IN WHITE) INTERIOR-TRIM COLOR COMBI.(GRAY) BODY COLOR CODE-ARC WHITE (W301-P801) BODY COLOR CODE-ADRIATIC BLUE (B302-P801) BODY COLOR CODE-IN WHITE BODY COLOR CODE-HEILING MAYERS GREEN PAINT-TOUCH-UP, ONE COLOR WAX-PROTECTIVE UNDERBODY CANADIAN EQUIPMENT BUDGET PACKAGE OFFICE DEPOT PACKAGE FRIGID ZONE KIT DEALER INSTALLATION OPTION US TERRITORY GVWR CLASS-3 (10001-14000 LBS) GVWR CLASS-4 (14001-16000 LBS) GVWR CLASS-5 (16001-19500 LBS) VEHICLE CATEGORY-NQR FENDER COVER CAB-TILT, MANUAL MARK-VEHICLE NAME SEAT BELT EXTENSION SUNVISOR-CO-DRIVER SIDE HEATER & DEFROSTER AIR CONDITIONER-MANUAL CONTROL VENTILATOR-ROOF TRAILER PROVISIONS STABILIZER SHAFT-FRONT AXLE REAR-HEAVY DUTY AXLE REAR-HEAVY DUTY VAR.2 FINAL DRIVE GEAR RATIO-4.100 (41/10) FINAL DRIVE GEAR RATIO-4.556 (41/9) FINAL DRIVE GEAR RATIO-5.375 (43/8) FINAL DRIVE GEAR RATIO-5.857 (41/7) BRAKE SYSTEM-HYDRO BRAKE BOOSTER EXHAUST-BRAKE BRAKES-FT DISK, MULTIPLE PISTON BRAKE-WHEEL LOCK CONTROL, (L.S.P.V) ANTI LOCK BRAKE SYSTEM ENGINE-DIESEL 4CYL L 4.8L (4HE1) GOVERNOR-ENGINE, WITH HIGH ALTITUDE COMPENSATOR TURBO CHARGER AIR INTAKE SYSTEM; RR VERTICAL INTERCOOLER ENGINE POWER N-SPEC LONG LIFE COOLANT (50%) HEATER-OIL PAN HEATER-ENGINE BLOCK MANUAL TRANSMISSION-6 SPEED (MBP-6P)

RNJ RNL M11 V66 NL7 6HU N33

AUTOMATIC TRANSMISSION 4-SPEED (AISIN) MANUAL TRANSMISSION-5 SPEED (MXA-5C) SHIFT-FLOOR (REMOTE) POWER TAKE OFF-PROVISIONS FOR FUEL TANK-125L, 33GAL FUEL SEDIMENTER-WITH HEATER STEERING COLUMN-TILT TYPE (WITH TELESCOPIC) STEERING-POWER F/TIRE215/85R16-E, R/TIRE215/85R16-E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC, (BS BRAND, R187) F&R/TIRE 225/70R19.5 F&R/DISC 19.5X6.00-127, WHITE (FT HIGHWAY, RR MUD & SNOW) F&R/TIRE 225/70R19.5 F&R/DISC 19.5X6.00-127, WHITE (FT & RR HIGHWAY) F&R/TIRE 225/70R19.5 (FOR BUDGET) F&R/DISC 19.5X6.00-127, WHITE (FT & RR MUD & SNOW) F/TIRE 215/85R16-E, R/TIRE 215/85R16-E F&R/DISC 16X6K-128 w/DOT MARK WHITE DISC (ALL SEASON) F/TIRE 215/85R16-E, R/TIRE 215/85R16-E JU019 F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC F/TIRE 215/85R16-E, R/TIRE 215/85R16-E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC, FOR BUDGET F/TIRE 215/85R16-E, R/TIRE 215/85R16-E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC (ALL SEASON) F/TIRE 215/85R16-E, R/TIRE 215/85R16-E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC FOR BUDGET (ALL SEASON) F/TIRE 215/85R16-E, R/TIRE 215/85R16-E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC, (RR ALL SEASON) F/TIRE 215/85R16-E, R/TIRE 215/85R16-E F&R/DISC 16X6K-127 w/DOT MARK, WHITE US DISC (ALL SEASON, US GOODYEAR) SPARE TIRE & DISC WHEEL VAR.1 SPARE TIRE & DISC WHEEL-LESS CARRIER-SPARE WHEEL (TRUCK) LAMPS-FIVE, ROOF MARKER RADIO-AM/FM STEREO ETR 2-SPEAKERS AM/FM w/CASSETTE 2SP 31N-1 ANTENNA SPEAKER OPTION: 2-SPEAKER WIPER-WITH I NTERMITTENT

800 979 D94 VG1 RWC 6SH 7VH YL3 6JJ 6FM RQF RQG RQH 7NQ 6FZ RWZ EK7 6JS D20 C41 C60 C55 V92 F59 G73 6CP GT5 HC6 R40 R41 7QQ NF8 J52 6PH JE5 RLY EE2 K51 KJ3 6PL 7QV 8AA 6HT K05 RNC

N40 ASQ

AVE

AVU

AVZ

AZF

9YY

9YZ

9ZB

9ZC

9ZD

9ZV

R46 7NC P10 U01 6GZ 6VL U73 7FK C13

Figure 7. Regular Production Option List

GENERAL INFORMATION 0A-5 ENGINE SERIAL NUMBER

...Disassemble

The engine serial number is machined on the left side of the engine just above the oil pan.

...Assemble

GRAPHIC SYMBOLS Graphic symbols are used on some controls and displays on the vehicle (figure 8). Many of these symbols are used internationally.

...Clean ...Inspect ...Measure ...Adjust ...Tighten to specified torque ...Important

CLEARANCE LIGHTS

EMERGENCY STARTING A VEHICLE DUE TO DISCHARGED BATTERY

Figure 8. International Symbols

ACTION SYMBOLS In this manual, much of the general narrative has been replaced with step-by- step procedures and the addition of “Action Symbols.” To improve readability and to provide emphasis where necessary, the following symbols are used in the manual. ...Remove or Disconnect ...Install or Connect

If your vehicle will not start due to a discharged battery, it can often be started by using energy from another battery—a procedure called “jump starting.” This vehicle has a 12volt starting system and a negative ground electrical system. Be sure that the other vehicle also has a 12volt starting system, and that it is the negative (black “–”) terminal which is grounded (attached to the engine block, chassis or frame rail). Its owner’s manual may give you that information. DO NOT TRY TO JUMP START IF YOU ARE UNSURE OF THE OTHER VEHICLE’S VOLTAGE OR GROUND (OR IF THE OTHER VEHICLE’S VOLTAGE AND GROUND ARE DIFFERENT FROM YOUR VEHICLE). Some diesel engine vehicles have more than one battery because of higher torque required to start a diesel engine. This procedure can be used to start a single battery vehicle from any of the diesel vehicle’s batteries. However, it may not be possible to start a diesel engine from a single battery in another vehicle, at low temperatures. NOTICE: Never tow the vehicle to start, because the surge forward when the engine starts could cause a collision with the tow vehicle. Also, this vehicle has 12volt batteries. Be sure the vehicle or equipment used to jump start your engine is also a 12volt Use of any other system may damage the vehicle’s electrical components.

0A-6 GENERAL INFORMATION Jump Starting Instructions CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: • Always shield your eyes and avoid leaning over a battery whenever possible. • Do not expose a battery to open flames or sparks. • Be sure any batteries that have filler caps are properly filled with fluid. • Do not allow battery acid to contact eyes or skin. Flush any contacted area with water immediately and thoroughly, and get medical help. • Follow each step in the jump starting instructions. 1. Position the vehicle with the good (charged) battery so that the booster (jumper) cables will reach but never let the vehicles touch. Also, be sure the booster cables to be used do not have loose or missing insulation. 2. In both vehicles: • Turn off the engine control switch and all lights and accessories except the hazard flasher or any lights needed for the work area. • Apply the parking brake firmly, and shift the automatic transmission to Park or manual transmission to Neutral. 3. Make sure the cable clamps do not touch any other metal parts. Clamp one end of the first booster cable to the positive “+”terminal on one battery, and the other end to the positive terminal on the other battery. Never connect “+” to “–” (figure 9). 4. Clamp one end of the second cable to the negative “–” terminal of the good (charged) battery and the final connection (to any solid, stationary metallic object) on the engine at least 450 mm (18 in) from the discharged battery; or the frame rail, chassis or some other wellgrounded point, if the battery is mounted outside the engine compartment. Make sure the cables are not on or near pulleys, fans, or other parts that will move when the engine is started. 5. Start the engine of the vehicle with the good (charged) battery and run the engine at a moderate speed for several minutes. Then, start the engine of the vehicle that has the discharged battery. 6. Remove the jumper cables by reversing the above installation sequence exactly. While removing each clamp, take care that it does not touch any other metal while the other end remains attached.

Figure 9. Jump Starting Diagram

TOWING PROCEDURE Proper equipment must be used to prevent damage to vehicles during any towing. State (provincial in Canada) and local laws that apply to vehicles in tow must be followed. • Vehicles should not be towed at speeds in excess of 55 mph (90 km/h). • Connect to the main structural parts of the vehicle. • DO NOT attach to bumpers, tow hooks or brackets. • Use only equipment designed for this purpose. • Follow the instructions of the wrecker manufacturer. • A safety chain system must be used. • The procedures below must be followed when towing, to prevent possible damage.

Front End Towing (Front Wheels Off The Ground) Before Towing To prepare a disabled vehicle for front end towing with front wheels raised off the ground, the following steps are necessary: • Block the rear wheels of the disabled vehicle. Manual Transmission Models • Shift into neutral position. • If there is damage or suspected damage to the transmission, disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember. Automatic Transmission Models • Disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember. NOTICE: Never tow the vehicle with propeller

GENERAL INFORMATION 0A-7 shafts is connected, as this may cause damage to the automatic transmission. • Provide wood blocking to prevent towing chain and bar from contacting the bumper. • If there is damage or suspected damage to the rear axle, remove the axle shafts. Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects. After Towing • Block the rear wheels and install the axle and propeller shafts if removed. • Apply the parking brake before disconnecting from the towing vehicle. • Check and fill rear axle with oil if required.

Front End Towing (All Wheels On The Ground) Before Towing Your vehicle may be towed on all wheels provided the steering is operable. Remember that power steering and brakes will not power assist. There must be a tow bar installed between the towing vehicle and the disabled vehicle. To prepare a disabled vehicle for front end towing with all wheels on the ground, the following steps are necessary: • Block the rear wheels of the disabled vehicle. Manual Transmission Models • Shift into neutral position. • If there is damage or suspected damage to the transmission, disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember. Automatic Transmission Models • Disconnect the propeller shafts at the rear axle. Secure the propeller shafts to the frame or crossmember.

ahead position. Make certain that the front axle is not loaded above the front axle Gross Axle Weight Rating (GAWR) as indicated on the vehicle’s VIN and Weight Rating Plate.

Special Towing Instructions 1. All state and local laws regarding such items as warning signals, night illumination, speed, etc., must be followed. 2. Safety chains must be used. 3. No vehicle should ever be towed at over 55 mph (90 km/h). 4. Loose or protruding parts of damaged vehicles should be secured prior to moving. 5. A safety chain system completely independent of the primary lifting and towing attachment must be used. 6. Operators should not go under a vehicle that is being lifted by the towing equipment unless the vehicle is adequately supported by safety stands. 7. No towing operation that for any reason jeopardizes the safety of the wre cker operator or any bystanders or other motorists should be attempted.

VEHICLE LIFTING POINTS Figure 10 shows the jack stand placement points. CAUTION: To help avoid personal injury when a vehicle is on a jackstand, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off of the stand.

NOTICE: Never tow the vehicle with propeller shafts connected, as this may cause damage to the automatic transmission. • Provide wood blocking to prevent towing chain and bar from contacting the bumper. • If there is damage or suspected damage to the rear axle, remove the axle shafts. Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects.

= Indicates Area for Jackstand Placement, etc.

After Towing • Block the rear wheels and install the axle and propeller shafts if removed. • Apply the parking brake before disconnecting from the towing vehicle. • Check and fill rear axle with oil if required.

Rear End Towing When towing a vehicle with rear wheels raised, secure the steering wheel to maintain straight-

Figure 10. Vehicle Lifting Points

0A-8 GENERAL INFORMATION ABBREVIATIONS CHARTS For abbreviations of emission system, refer to the section 6E. LIST OF AUTOMOTIVE ABBRIVIATIONS WHICH MAY BE USED IN THIS MANUAL A – Ampere (s) ABS – Antilock Brake System AC – Alternating Current A/C – Air Conditioning ACCEL – Accelerator ACC – Accessary ACL – Air Cleaner Adj – Adjust A/F – Air Fuel Ratio AIR – Secondary Air Injection System Alt – Altitude AMP – Ampere (s) ANT – Antenna ASM – Assembly A/T – Automatic Transmission ATDC – After Top Dead Center ATF – Automatic Transmission Fluid Auth – Authority Auto – Automatic BARO – Barometric Pressure Bat – Battery B+ – Battery Positive Voltage Bbl – Barrel BHP – Brake Horsepower BPT – Back Pressure Transducer BTDC – Before Top Dead Center °C – Degrees Celsuis CAC – Charge Air Cooler Calif – California cc – Cubic Centimeter CID – Cubic Inch Deplacement CKP – Crankshaft Position CKT – Circuit CL – Closed Loop CLCC – Closed Loop Carburetor Control CMP – Camshaft Position CO – Carbon Monoxide Coax – Coaxial Conn – Connector Conv – Coverter Cu.In. – Cubic Inch CV – Constant Velocity DI – Distributor Ignition Diff – Differential Dist – Distributor DLC – Data Link Connector DOHC – Double (or Dual) Overhead Camshaft DRL – Daytime Running Light DTC – Diagnostic Trouble Code DTM – Diagnostic Test Mode DTT – Diagnostic Test Terminal

DVM – Digital Voltmeter (10 meg.) DVOM – Digital Volt Ohmmeter EBCM – Electronic Brake Control Module ECM – Engine Control Module ECT – Engine Coolant Temperature EEPROM – Electronically Erasable Programmable Read Only Memory EGR – Exhaust Gas Recirculation EI – Electronic Ignition ESD – Electrostatic Discharge ETR – Electronically Tuned Receiver EVAP – Evaporation Emission Exh – Exhaust °F – Degrees Fahrenheit Fed – Federal (All States Except Calif.) FF – Front Drive Front Engine FICD – Fast Idle Control Device FL – Fusible Link – Front Left FLW – Fusible Link Wire FP – Fuel Pump FR – Front Right FRT – Front ft – Foot FWD – Front Wheel Drive 4 × 4, 4WD – Four Wheel Drive 4 A/T – Four Speed Automatic Transmission Gal – Gallon (3.785 ) GEN – Generator GND – Ground Gov – Governor g – Gram Harn – Harness HBB – Hydraulic Brake Booster HC – Hydrocarbons HD – Heavy Duty Hg – Hydrargyrum (Mercury) HiAlt – High Altitude HO2S – Heated Oxygen Sensor HU – Hydraulic Unit HVAC – Heater-Vent-Air Conditioning IAC – Idle Air Control IAT – Intake Air Temperature IC – Integrated Circuit ID – Identification – Inside Diameter IGN – Ignition Int – Intake IP – Instrument Panel IPC – Instrument Panel Cluster ISC – Idle Speed Control

GENERAL INFORMATION 0A-9 J/B – Junction Block kg – Kilograms km – Kilometers km/h – Kilometer per Hour kPa – KiloPascals KS – Knock sensor kV – Kilovolts (Thousands of Volts) kW – Kilowatts L – Liter lb·ft – Foot Pounds lb·in – Inch Pounds LF – Left Front LH – Left Hand LR – Left Rear LS – Left Side LWB – Long Wheel Base L-4 – In-line Four Cylinder Engine MAF – Mass Air Flow MAN – Manual MAP – Manifold Absolute Pressure Max – Maximum MC – Mixture Control MFI – Multiport Fuel Injection MIL – Malfunction Indicator Lamp Min – Minimum mm – Millimeter MPG – Miles per Gallon MPH – Miles per Hour M/T – Manual Transmission/Transaxle MV – Millivolt NA – Natural Aspirated NC – Normally Closed N·m – Newton Meter NO – Normally Open NOx – Nitrogen, Oxides of OBD – On-Board Diagnostic OD – Outside Diameter O/D – Over Drive OHC – Overhead Camshaft OL – Open Loop O2 – Oxygen O2S – Oxygen Sensor PAIR – Pulsed Secondary Air Injection System P/B – Power Brakes PCM – Powertrain Control Module PCV – Positive Crankcase Ventilation PRESS – Pressure PROM – Programmable Read Only Memory PNP – Park/Neutral Position P/S – Power Steering PSI – Pounds per Square Inch PSP – Power Steering Pressure Pt. – Pint = 1/8 gallon 0.473125 Pri – Primary PWM – Pulse Width Modulate Qt – Quart = 1/4 gallon 0.94625

QWS – Quick Warming-up System REF – Reference RF – Right Front RFI – Radio Frequency Interference RH – Right Hand RL – Rear Left RPM – Revolutions per Minute RPS – Revolution per Second RPM Sensor – Engine Speed Sensor RPO – Regular Production Option RR – Right Rear RS – Right Side RTV – Room Temperature Vulcanizing RWAL – Rear Wheel Antilock Brake RWD – Rear Wheel Drive SAE – Society of Automotive Engineers Sec – Secondary SFI – Sequential Multiport Fuel Injection SI – System International SIR – Supplemental Inflatable Restraint System SOHC – Single Overhead Camshaft Sol – Solenoid SPEC – Specification Speedo – Speedometer SRS – Supplemental Restraint System ST – Start – Scan Tool Sw – Switch SWB – Short Wheel Base SYN – Synchronize Tach – Tachometer TB – Throttle Body TBI – Throttle Body Fuel Injection TCC – Torque Converter Clutch TCM – Transmission Control Module TDC – Top Dead Center Term – Terminal TEMP – Temperaure TP – Throttle Position TRANS – Transmission TURBO – Tubocharger TVRS – Television & Radio Suppression TVV – Thermal Vacuum Valve TWC – Three Way Catalytic Converter 3 A/T – Three Speed Automatic Transmission 2WD – Two Wheel Drive 4 × 2 – Two Wheel Drive U-joint – Universal Joint V – Volt (s) VAC – Vacuum VDC – Volts DC VIN – Vehicle Identification Number VRRRE – Vehicle Refrigerant Recovery and Recycling Equipment V-ref – ECM Reference Voltage VSS – Variable Swirl System

0A-10 GENERAL INFORMATION ABBREVIATIONS CHARTS (Continued) VSS – Vehicle Speed Sensor VSV – Vacuum Switching Valve V-6 – Six Cylinder “V” Engine W – Watt (s) w/ – With

ESSENTIAL SERVICE TOOLS Essential service tools that are shown in this service manual that have tool product numbers beginning with “J” are available for worldwide distribution from: Kent-Moore SPX Corporation 29784 Little Mack ROSEVILLE,MI 48066-2298 1-800-328-6657 Mon.-Fri. 8:00 p.m. EST Telex: 244040 KMTR UR FAX-313-578-7375

w/b – Wheel Base W/L – Warning Light w/o – Without WOT – Wide Open Throttle WSS – Wheel Speed Sensor

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Lubrication Detail Information ....................................................................................................................... 0B- 1 Engine Oil and Viscosity Recommendations............................................................................................ 0B- 1 Maintenance Schedule ................................................................................................................................... 0B- 3 Explanation of Complete Vehicle Maintenance Schedule ........................................................................... 0B- 6 Normal Vehicle Use ..................................................................................................................................... 0B- 6 Owner Safety and Routine Maintenance ...................................................................................................... 0B- 9 Noise Emission Control ................................................................................................................................. 0B-10 Noise Control System.................................................................................................................................. 0B-10 Tampering with Noise Control System Prohibited ................................................................................... 0B-10 Recommended Fluids and Lubricants ........................................................................................................... 0B-11 Lubrication Chart ............................................................................................................................................ 0B-12 Specifications .................................................................................................................................................. 0B-13 Capacities ..................................................................................................................................................... 0B-13 Mintenace Item ............................................................................................................................................. 0B-13 Fastener Torques......................................................................................................................................... 0B-13

LUBRICATION DETAIL INFORMATION ENGINE OIL AND VISCOSITY RECOMMENDATIONS The oil industry markets various types of engine oil under certain service designation and specification numbers. The selection of a reliable supplier and close attention to the oil and filter element change recommendations can provide satisfactory lubrication and longer life for the engine. Using the proper engine oil and following the recommended oil change intervals is your best assurance of continued reliability and performance from your vehicle’s engine. Engine oil containers are labeled with various APl(American Petroleum Institute) designations of

quality. Be sure the oil you use has the API designation “CD”, either alone or shown with other designations such as “SF/CD”. Oils which are not labeled “CD” should not be used. For example, do not use oils labeled only SA, SB, SC, SD, SE, CA, CB, CC, or oils with a combination of any of these letters—such as SE/CC, as this may cause engine damage. DO NOT USE SYNTHETIC OILS.

Diesel Engine Oil Viscosities Viscosity numbers make up a classification of lubricants in terms of fluidity or viscosity, but with no reference to any other characteristics or properties.

0B-2 MAINTENANCE AND LUBRICATION

DO NOT USE SYNTHETIC OILS Figure 1. Oil Viscosity Chart Where cold weather starting is a problem,oil and coolant system heaters,as well as proper fuel selection, will be helpful. However, if these are not available, lighter viscosity oils may be used only to facilitate starting. Do not use starting aids in the air intake system. Such “aids” can cause immediate engine damage. The engine oil viscosity specification depends on the temperature of the engine oil at the time of starting the engine. Viscosity recommendations for various starting temperatures are shown in the “Viscosity Chart”. When choosing an oil, consider the range of temperature your vehicle will operate in before the next oil change. Then, select the recommended oil viscosity from the chart (figure 1).

Diesel Break-In Oils And Additives The use of proprietary blends of supplementary additives or concentrates such as engine oil supplements, break-in oils, tune-up compounds, friction reducing compounds, etc., is not recommended in lubricating oils of the diesel engine in these vehicles.

Change Intervals The oil and oil filter change intervals for the engine are based on the use of CD-quality oil and high quality filters. Using oil other than CDquality, or not changing the oil and filter often enough could reduce engine life. Damage to engines due to improper maintenance or use of incorrect oil quality and/or viscosity is not covered by the warranty.


MAINTENANCE SCHEDULE s s l e a l i ) r t v s r M s r e i r e r t e v f t e n o e h s I c e s m e h i o m c h l i t i o v n w k c r o ( e M S

s e i r e S W / R Q N , R P N R O F E L U D E H C S E C N A N E T N I A M

s h t n o m 2 1 y r e v e r o

*

166 400

104,000

I

I A I

I R

156 000

97,500

I

R

145 600

91,000

I

R

135 200

84,500

I

R

124 800

78,000

I

R

114 400

71,500

I

R

104 000

65,000

I

R

93 600

58,500

I

R

83 200

52,000

I

72 800

45,500

I

R

62 400

39,000

I

R

52 000

32,500

I

R

41 600

26,000

I

R

31 200

19,500

I

R

20 800

13,000

I

R

10 400

6,500

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8

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MAINTENANCE SCHEDULE (CONT.) s h t n o m 2 1 y r e v e r o

s s l e ) t a i l v r s r M s r e i r e e f t r t v e n I o e h s c e s m e h o i m c t l h i i o v w k c r n ( o e S M

) . T N O C ( s e i r e S W / R Q N , R P N R O F E L U D E H C S E C N A N E T N I A M



I R I

166 400

104,000

156 000

97,500

I

I

145 600

91,000

I

I

135 200

84,500

I

I

124 800

78,000

I R I

114 400

71,500

I

I

104 000

65,000

I

I

93 600

58,500

I

I

83 200

52,000

I R I

72 800

45,500

I

I

62 400

39,000

I

I

52 000

32,500

I

I

41 600

26,000

I R I

31 200

19,500

I

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20 800

13,000

I

I

10 400

6,500

I

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m e t s y S t s u a h x E

m e t s y S e n i L l e u F

I



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I

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I

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MAINTENANCE SCHEDULE (CONT.) s h t n o m 4 2 y r e v e r o

s s l e a l i ) r t v s r M s r e i r e r t e v f t e n o e h s I c e s m e h i o m c h l i t i o v n w k c r o ( e S M

) . T N O C ( s e i r e S W / R Q N , R P N R O F E L U D E H C S E C N A N E T N I A M



R R

166 400

104,000

156 000

97,500

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145 600

91,000

I

135 200

84,500

I

124 800

78,000

114 400

71,500

I

104 000

65,000

I R

93 600

58,500

I

83 200

52,000

72 800

45,500

I

62 400

39,000

I

52 000

32,500

I R

41 600

26,000

31 200

19,500

I

20 800

13,000

I

10 400

6,500

I


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EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE The following is a brief explanation of the service listed in the preceding Complete Vehicle Maintenance Schedule.

NORMAL VEHICLE USE The vehicle maintenance instructions in the Maintenance Schedule are based on the assumption that the vehicle will be used as designed: • to carry passengers and cargo within the limitations specified on the tire placard. • to be driven on reasonable road surfaces within legal operating limits. • to be driven on a daily basis, as a general rule,

for at least several miles/kilometers. • to be driven on proper fuel (See Owner’s Manual; Diesel Fuel Requirement.). Unusual operating conditions will require more frequent vehicle maintenance, as specified in the following section. 1. ENGINE NOISE—These components have an effect on the control of noise emissions. 2. IDLE SPEED — Check and adjust the engine idle speed on the first 6,500 miles (10,400 km) and every 52,000 miles (83,200 km). Adjustments must be made with test equipment known to be accurate.

Engine (Every 6,500 miles or 10,400 km)

Inspection sound absorption materials for tears, broken out sections or attachment. Repair or replace as necessary.

Cooling system (Every 13,000 miles or 20,800 km)

Inspection fan, shroud and radiator for attachment, tears or cleanliness. Repair or replace as necessary.

Air intake system (Every 26,000 miles or 41,600 km)

Inspect all ducts, hoses and intake silencers for leaks or chafing.Repair or replace as necessary.

Exhaust system (Every 6,500 miles or 10,400 km)

Inspect silencer, pipes, gaskets, clamps and mounting for exhaust gas leaks or Iooseness. Repair or replace as necessary.

Cab (Every 6,500 miles or 10,400 km)

Inspect sound absorption materials for tears, broken out sections or attachment. Repair or replace as necessary.

3. VALVE LASH — Incorrect valve clearance will result in increased engine noise and lower engine output, thereby adversely affecting engine performance. Retorque rocker shaft bracket nuts before checking and adjusting valve clearance. Check and adjust valve clearance at every 52,000 miles (83,200 km). 4. INJECTION TIMING — Incorrect injection timing could result in increased exhaust emission or smoke emission, or lower engine output. Check and adjust injection timing every 52,000 miles (83,200 km). 5. INJECTOR — Check spray condition at every 52,000 miles (83,200 km). 6. ENGINE OIL AND OIL FILTER — Change at interval noted below depending upon driving conditions. • NORMAL SERVICE — Change every 6,500 miles (10,400 km) or 12 months whichever

occurs first. • SEVERE SERVICE — Change every 3,600 miles (5,760 km) or 3 months if the vehicle is often driven under one or more of these conditions (a) driving in dusty areas, (b) frequent idling or idling for long periods, (c) driving four miles (6 km) or less in freezing weather, or other short trips in cold weather, where engine dose not thoroughly warm up. Change oil and filter soon after driving in a dust storm. 7. FUEL FILTER (SINGLE CAB MODEL) — Replace filter at every 13,000 miles (20,800 km) or 12 months whichever occurs first, or more frequently if clogged. Drain water from the water separator every 6,500 miles (10,400 km). 8. FUEL FILTER / WATER SEPARATOR (CREW CAB MODEL) — Replace main filter near the engine at every 13,000 miles (20,800 km) or 12 months whichever occurs first, or more

MAINTENANCE AND LUBRICATION 0B-7 frequently if clogged. Replace filter beneath rear left seat at every 12,000 miles (19,000 km) or 12 months whichever occurs first, or more frequently if clogged. Drain water from the water separator as same frequency as filter under rear left seat. 9. AIR CLEANER FILTER — Replace the engine air cleaner filter under normal operations every 26,000 miles (41,600 km). Operation of vehicle in dusty areas will necessitate more frequent filter replacement. 10. AIR INTAKE SYSTEM — Check if air cleaner hoses and ducts are connected and correctly installed every 26,000 miles (41,600 km). 11. DRIVE BELT — Check belt driving the fan, generator at every 52,000 miles (83,200 km). Look for cracks, fraying, wear, and proper tension. Replace at every 104,000 miles (166,400 km). 12. ENGINE BOLT TORQUE — Loosened bolts result in lower engine output. Check and adjust manifold mounting, and injection nozzle to correct torque every 52,000 miles (83,200 km). Specified tightening torque INTAKE/EXHAUST, MANIFOLDS 18/34 N·m (13/25 lb·ft) INJECTOR 19 N·m (14 lb·ft) 13. ROTATE TIRES — To equalize wear, rotate tires and adjust tire pressures at every 6,500 miles (10,400 km).

Figure 2. Rotate Tires

14. ENGINE COOLING SYSTEM — At 12 months or 6,500 miles (10,400 km) intervals, rinse radiator cap and filler neck with clean water, pressure test system and radiator cap for proper pressure holding capacity, tighten hose clamps and inspect condition of all cooling and heater hoses. Replace hoses if cracked, swollen or otherwise deteriorated. Also each 12 months or 6,500 miles (10,400 km), clean exterior of radiator core and if necessary, drain, flush and refill the engine cooling system with a new engine coolant solution as described in the Owner’s Manual. 15. ENGINE COOLING — Every 24 months or 26,000 miles (41,600 km), drain the engine coolant by opening the drain cock at the bottom of the radiator core, flush and refill the engine cooling system with a new engine coolant solution. 16. EXHAUST SYSTEM — Check the complete exhaust system at every 6,500 miles (10,400 km). Check body areas near the exhaust system. Look for broken, damaged, missing, or out-of position parts. Also inspect for open seams, holes, loose connections, or other conditions which could cause heat build-up in the floor pan, which could let exhaust fumes seep into the passenger compartment. Dust or water in the cabin may indicate a leak in the area. Needed repairs should be made at once. 17. FUEL LINE SYSTEM — Inspect the fuel tank, cap and lines for damage at every 13,000 miles (20,800 km). Inspect fuel cap for correct sealing ability and indications of physical damage. Replace any damaged or malfunctioning parts. 18. BRAKE LINING AND PAD FOR WEAR — Check drum brake lining and disc brake pad for wear or cracks at every 6,500 miles (10,400 km). Check brakes (including parking brake) more often if conditions and habits result in frequent braking. Front disc brake have built-in wear indicators which are designed to make a high pitched squeal or cricket-like warning sound when the brake pads are worn to the point where new pads are needed. When the vehicle is in motion, the sound may be constant or it may come and go. Pressing the brake pedal firmly may cause the sound to stop. Have the brake linings or the brake pads replaced, if these conditions exist. Failure to do so can result in expensive damage to the brake system or a serious accident. 19. BRAKE DRUM AND ROTOR FOR WEAR AND DAMAGE — Check brake drums (rear and parking) and rotor (front) for wear or damage at

0B-8 MAINTENANCE AND LUBRICATION every 26,000 mile (41,600 km) or 12 months whichever occurs first. 20. BRAKE FLUID — Check the brake fluid level in the brake fluid reservoir every 6,500 miles (10,400 km). 21. HYDRAULIC BRAKE BOOSTER FLUID — Replace power steering fluid every 24 months or 32,500 miles (52,000 km), whichever occurs first. 22. BRAKE LINE, LSV AND HOSES — Check lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. every 26,000 miles (41,600 km). Any questionable parts should be replaced or repaired at once. When rubbing or wear is noted on lines or hoses, the cause must be corrected at once. 23. CLUTCH PEDAL CONTROL — Check lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. at every 13,000 miles (20,800 km). Any questionable parts should be replaced or repaired. 24. MANUAL TRANSMISSION OIL — Replace lubricant at every 19,500 miles (31,200 km). Check lubricant level at every 6,500 miles (10,400 km), and add lubricant to level of filler hole if necessary. 25. AUTOMATIC TRANSMISSION FLUID (ATF) — Check the ATF at each engine oil change and replace fluid every 26,000 miles (41,600 km). To check the fluid level, first set the parking brake, then start the engine in “P” position. With the regular brakes applied, move the selector through all the gear position, ending with “P”. You must check the ATF level with the engine running at slow idle and the truck must be on a level surface. NOTICE: If you have driven for a prolonged period of time or in city traffic in hot weather, wait until the fluid cools down (Approx. 30 minutes) before checking ATF level. Remove the dipstick located at the left rear side of the engine (Single cab model). Remove the dipstick located beneath the panel for the inspection (Crew cab model). Carefully touch the wet end of the dipstick to find out if the ATF is cool, warm or hot. Wipe it clean and push it back in until the cap seats. Pull out the dipstick and read the ATF level.

Figure 3(a). Dipstick of the ATF Level (Crew Cab Model)

Figure 3(b). ATF Level Check • If it felt cool, about room temperature, the level should be in the “C” range. • If it felt warm, about normal operating temperature of 158° to 176° F(70° to 80°C), the level should be in the “H” range. 26. AUTOMATIC TRANSMISSION FLUID FILTER — Replace filter at every 26,000miles (41,600Km) 27. DIFFERENTIAL GEAR OIL — Replace lubricant at every 26,000 miles (41,600 km). Check lubricant level at every 6,500 miles (10,400 km) or every 12 months, and add lubricant to within 0 to 10 mm (0 to 0.4 in) of bottom edge of the filler hole if necessary.


Figure 4. Differential Gear Oil Level 28. POWER STEERING FLUID — Replace power steering fluid every 24 months or 32,500 miles (52,000 km), whichever occurs first. 29. STEERING GEAR BOX TORQUE — Retighten the fixing bolts of the steering gear box to the specified torque at every 26,000 miles (41,600 km). Specified tightening torque STEERING GEAR BOX 102 N·m (75 lb·ft) 30. PROPELLER SHAFT FLANGE TORQUE — Check the fixing bolts of propeller shaft flange for looseness or damage at first 6,500 miles (10,400 km). Retighten the fixing bolts to the specified torque at every 13,000 miles (20,800 km). Specified tightening torque PROPELLER SHAFT FLANGE 102 N·m (75 lb·ft)

31. LEAF SPRING U-BOLT TORQUE — Tighten the U-Bolt nuts to the specified torque at 650 miles (1,050 km), 6,500 miles (10,400 km) and thereafter each 13,000 miles (20,800 km). Specified tightening torque LEAF SPRING U-BOLT Front 127 N·m (94 lb·ft) Rear 177 N·m (130 lb·ft) 32. WHEEL NUT TORQUE — Check tire for excessive or abnormal wear, or damage. Also check tire inflation pressures and adjust. Be sure wheels are not bent or cracked and that wheel nuts have been tightened to the specified torque at 650 miles (1,050 km) and then every 6,500 mile (10,400 km). Refer to Section 3 for the specified torque. Specified tightening torque Front and Rear wheel 440 N·m (325 lb·ft) 33. KING PIN — Lubricate the grease fitting on the king pins at 12 months or 6,500 miles (10,400 km) whichever occurs first. 34. PROPELLER SHAFT — Lubricate the grease fitting on each universal joint and spline coupling at 12 months or 13,000 miles (20,800 km) whichever occurs first. 35. WHEEL BEARING GREASE — Clean and repack front wheel bearings at every brake relining or 32,500 miles (52,000 km) whichever comes first. 36. REAR SPRING PINS — Lubricate the grease fitting on the rear spring pins every 6,500 miles (10,400 km).

OWNER SAFETY AND ROUTINE MAINTENANCE Listed below are vehicle checks which should be made periodically by either the owner or a qualified technician to ensure proper performance and safety of the vehicle. For your safety and that of others, any of the safety-related components that may have been damaged in an accident should be checked and necessary repairs performed before operating the vehicle. At the minimum, these routine checks should be made every 6 months or 6,000 miles (10,000 km), whichever comes first. Whenever repairs are necessary, have them completed before operating the vehicle. A PARKING BRAKE — Park on a fairly steep hill and hold the vehicle with the parking brake only. This checks holding ability.

Before checking item (B), be sure to have enough room around the vehicle. Then firmly apply both the parking brake and the regular brake. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition/engine control switch at once. Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage. B STARTER SAFETY SWITCH (AUTOMATIC TRANSMISSION) — Check by trying to start the engine in each gear. The starter should crank only with selector in position “P” or “N.” C TRANSMISSION SHIFT INDICATOR (AUTOMATIC TRANSMISSION) — Check that the indicator points to the gear chosen. D STEERING — Be alert for any changes in

0B-10 MAINTENANCE AND LUBRICATION steering action. An inspection or service is needed when the steering wheel is harder to turn or has too much free play, or when there are strange sounds when turning or parking. E WHEEL ALIGNMENT, BALANCE, AND TIRES — Check tires for abnormal wear or damage. Also, check for damaged wheels. A pull to the right or left on a straight and level road may show the need for a wheel alignment. A vibration of the steering wheel or seat at normal highway speeds may mean a wheel balancing is needed. Check tire pressure when the tires are “cold”, at least monthly, and whenever the vehicle is serviced. (Include the spare, if equipped.) Inspect the tire for any cuts or punctures if frequent tire inflation is needed. F BRAKES — Be alert for the low vacuum warning light or for the tone alarm, or changes in braking action, such as repeated pulling to one side, unusual sounds when braking or increased brake pedal travel. Check regularly that the brake fluid reservoir is properly filled and check for fluid leaks. Any of these conditions could indicate the need for brake system inspection and/or service. G EXHAUST SYSTEM — Be alert for any changes in the sound of the exhaust system or exhaust oder. These are signs the system may be leaking. Have it checked and/or repaired at once. H WINDSHIELD WIPERS AND WASHERS — Check operation and condition of the wiper blades. Check the flow and aim of the washer spray. I DEFROSTER — Turn the control lever to “Defrost” and the fan lever to “4”. Then check the airflow from the ducts at the inside base of the windshield. The engine must be running at this time. J REARVIEW MIRRORS AND SUN VISORS — Check that friction joints hold mirrors and sun visors in place. K HORN — Sound the horn periodically to be sure it works. L LAP-SHOULDER BELTS — Check seat belt system (including webbing, buckles, latch plates, and anchors) for proper operation, and

for damage. M SEAT ADJUSTERS — When adjusting a manual seat, be sure seat adjusters latch by pushing the seat forward and backward. Do not attempt to adjust the seat when the vehicle is in motion. N LAMPS — Check panel lighting, warning lamps, indicator lamps, and interior lamps. On the outside, check: license plate lamps, side marker lamps, reflectors on outside mirrors, headlamps, parking lamps, identification and clearance lamps, taillights, brake lamps, turn signals, backup lamps, and hazard warning flashers. Have headlamp aim checked at once if beams seem improperly aimed. O GLASS, MIRRORS, LIGHTS AND/OR REFLECTORS CONDITION — Look for broken, scratched, dirty or damaged glass, mirrors, lamps or reflectors that could reduce the view or visibility, or cause injury. Replace, clean or repair promptly. P DOOR LATCHES — Check that doors close, latch, and lock tightly. Check for broken, damaged or missing parts that might prevent tight latching. Q TILT CAB — Be sure the tilt lever is raised and the lock pin is inserted in the lever bracket. R FLUID LEAKS — Check for fuel, water, oil, or other fluid leaks by looking at the surface beneath the vehicle after it has been parked for a while. If you notice diesel fumes or fluid at any time, have the cause found and corrected at once. S SPARE AND JACK — Check that spare tire assembly and jack equipment (if equipped) are securely stowed at all times. T UNDERBODY — Corrosive materials used for ice removal, snow removal, and dust control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can occur on underbody parts such as fuel lines, frame, floor pan, and exhaust system. At least every spring, flush these materials from the underbody with plain water. Thoroughly clean the underbody where mud and debris can accumulate. Sediment packed in closed areas of the frame should be loosened before being flushed.

NOISE EMISSION CONTROL NOISE CONTROL SYSTEM The following information relates to compliance with Federal noise emission standards for vehicles with a Gross Vehicle Weight Rating (GVWR) of more than 10,000 lb (4,536 kg). The Maintenance Schedule provides information on maintaining the

noise control system to minimize wear of the noise emission control system during the life of the vehicle. The noise control system warranty is given in the vehicle Warranty Folder. These standards apply only to vehicles sold in the United States.

MAINTENANCE AND LUBRICATION 0B-11 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement of any device or element of design incorporated in any new vehicle for the purpose of noise control, prior to its sale or delivery to the ultimate purchaser or while it is in use. 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are acts listed below. Insulation • Removal of noise shields or underhood insulation.

Engine • Removal of engine speed governor, if so equipped,or rendering inoperative so as to allow engine speed to exceed manufacturer specifications. Fan and Drive • Removal of fan clutch, if so equipped, or rendering clutch inoperative. • Removal of fan shroud, if so equipped. Air Intake • Removal of air cleaner silencer. • Reversing air cleaner cover. Exhaust • Removal of muffler and/or resonator. • Removal of exhaust pipes and exhaust pipe clamps.

RECOMMENDED FLUIDS AND LUBRICANTS USAGE

FLUIDS/LUBRICANTS

Engine Oil

SG/CE, SF/CD, SE/CD, CD Engine Oil

Manual Transmission Oil

SAE 5W-30 SF below 32 °C (90 °F) or SAE 40 engine oil above 32 °C (90 °F) ATF Dexron ® - III

Automatic Transmission Fluid Power Steering Fluid Hydro Boost Brake Fluid Rear Axle

Multi-purpose gear oil SAE90 GL-5

Chassis Lubricant

Multi-purpose grease with high temperature, good quality, lithium soap, extreme pressure grease

Battery Terminals

Petroleum Jelly

Clutch and Brake Fluid

Brake fluid DOT 3 or equivalent

Cab-Door Hinges and Latches Lubricant

A semi-fluid grease having extreme pressure properties and containing zinc oxide (Lubricant or equivalent)

Engine Coolant

Mixture of water and high quality ethylene glycol base type antifreeze conforming to GM Spec. 6038-M or equivalent.

Windshield Washer Solvent

Washer Solvent

Propeller Shaft, Universal Joints and Sliding Sleeve Lubricant

NLGI #1 or #2 multi -purpose type grease

Propeller Shaft Center Bearing, Wheel Hub Bearing Lubricant

NLGI #2 or #3


LUBRICATION CHART

GREASE POINTS

REMARKS

2. King Pins 3. Propeller Shaft Universal Joints, Sliding Sleeve and Center Bearing 4. Rear Spring Pins

— 4 fittings — 5 fittings

GREASE POINTS CHART

Figure 5. Grease Points Chart

— 2 fittings


SPECIFICATIONS CAPACITIES Engine Crankcase This capacity is for a normal refill and it is an approximate amount. Keep the level as close as possible to the full mark without overfilling. Do not operate with the level below the low mark. 4HE1-TC......................................................................................................................................13 (3.4 gal) This figure includes the full-flow oil filter, which should be changed at each oil change.

Engine Cooling System Capacity.......................................................................................................................................14 (3.7 gal) Thermosta t ....................................................... .............................. .............................. 82, 85 °C (180, 185 °F) Radiator Pressure Cap .............................. ........................................................... ..............103 kPa (15.46 psi)

Fuel Tank The fuel tank capacity is stated on a metal plate attached to the fuel tank body. Only fill the tank to 95 percent of its capacity. This will allow for fuel expansion.

Transmission Manual Transmission Oil...............................................................................................NPR; 3.2 ( 6.8 pints) NQR; 5.3 (11.2 pints) Automatic Transmission Fluid...............................................................................................13.5 (28.5 pints)

Rear Axle Capacity.................................................................................................................................9.7

(20.5 pints)

MAINTENANCE ITEM Air Cleaner (DONALDSON EGB10-8107) Filter ............ISUZU Part No. 8-94430-250-0 GM Part No. 94430250 Engine Oil Filter Cartridge ............................................ISUZU Part No. 8-97148-270-0 GM Part No. 97148270 Fuel Filter Cartridge ......................................ISUZU Part No. 1-13240-074-1 or -079-1 GM Part No. 94414796

FASTENER TORQUES Intake Manifold Nut and Bolts ............................................................................................ 18 N ·m Exhaust Manifold Nut and Bolts ......................................................................................... 34 N ·m Injector .......................................................................................1st 10 N ·m (7 ft·lbs), 2nd 19 N·m Steering Gear Box Fixing Nuts and Bolts ...........................................................................102 N ·m Propell er Shaft Flange Nuts ...............................................................................................102 N ·m Leaf Spring U-Bolt Nuts ............................................................................................Front 127 N ·m Rear 177 N·m Wheel Nuts ........................................................................................................................440 N ·m

( 13 ( 25 ( 14 ( 75 ( 75 ( 94 (130 (325

ft·lbs) ft·lbs) ft·lbs) ft·lbs) ft·lbs) ft·lbs) ft·lbs) ft·lbs)

0B-14 MAINTENANCE AND LUBRICATION MEMO .................................................................................................................................................................................................................................................................................................................

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HEATING AND VENTILATION 1A-1

SECTION 1

HEATING AND AIR CONDITIONING CONTENTS SUBJECT

PAGE

Heating and Ventilation ..........................................................................................See 1999-2001 Service Manual Air Conditioning......................................................................................................See 1999-2001 Service Manual

1A-2 HEATING AND VENTILATION MEMO .................................................................................................................................................................................................................................................................................................................

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FRAME AND BODY MOUNTS 2A-1

SECTION 2

FRAME AND CAB CONTENTS SUBJECT

PAGE

Frame and Body Mounts ..................................................................................... See 1999-2001 Service Manual Cab Maintenance ................................................................................................... See 1999-2001 Service Manual Sheet Metal ............................................................................................................. See 1999-2001 Service Manual

2A-2 FRAME AND BODY MOUNTS MEMO .................................................................................................................................................................................................................................................................................................................

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FRONT END ALIGNMENT 3A-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES CONTENTS SUBJECT

PAGE

Front End Alignment.............................................................................................. See 1999-2001 Service Manual Steering Linkage .................................................................................................... See 1999-2001 Service Manual Power Steering .................................................................................................................................................... 3B3 Steering Column..................................................................................................... See 1999-2001 Service Manual Front Axle and Suspension ................................................................................... See 1999-2001 Service Manual Rear Suspension .................................................................................................... See 1999-2001 Service Manual Wheels and Tires.................................................................................................... See 1999-2001 Service Manual

POWER STEERING 3B3-1

SECTION 3B3

POWER STEERING NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Description ............................................................................................................. See 1999-2001 Service Manual Diagnosis of Power Steering System .................................................................. See 1999-2001 Service Manual Power Steering System Test............................................................................. See 1999-2001 Service Manual Power Steering System On-Vehicle Service ....................................................... See 1999-2001 Service Manual Maintenance ....................................................................................................... See 1999-2001 Service Manual Power Steering Fluid and Filter Service .......................................................... See 1999-2001 Service Manual Steering Wheel Free Play ............................................................................................................................ 3B3-2 Steering Gear Replacement .............................................................................. See 1999-2001 Service Manual Steering Gear Adjustment ................................................................................ See 1999-2001 Service Manual Hydraulic Pump Replacement ......................................................................... See 1999-2001 Service Manual Tandem Hydraulic Pump Assembly Replacement ......................................... See 1999-2001 Service Manual Bleeding the Hydraulic System ........................................................................ See 1999-2001 Service Manual Hydraulic System Flushing............................................................................... See 1999-2001 Service Manual Power Steering Gear Unit Repair ......................................................................... See 1999-2001 Service Manual Removal of Major Sub-assemblies From Power Steering Gear Unit ............ See 1999-2001 Service Manual Cleaning, Inspection and Repair ...................................................................... See 1999-2001 Service Manual Assembling Major Sub-assemblies into Power Steering Gear Unit.............. See 1999-2001 Service Manual Hydraulic Pump Unit Repair ................................................................................. See 1999-2001 Service Manual Tandem Hydraulic Pump Unit Repair................................................................... See 1999-2001 Service Manual Specifications......................................................................................................... See 1999-2001 Service Manual Fastener Torques .............................................................................................. See 1999-2001 Service Manual Special Tools.......................................................................................................... See 1999-2001 Service Manual

DESCRIPTION Vehicles covered by this manual are equipped with power steering as standard equipment. An integral steering gear is used. In an integral steering gear, the power cylinder and control valve are integrated into the steering gear. No separate power cylinder is necessary.

A vane-type hydraulic pump with remote reservoir is used. The hydraulic pump is gear driven. The power steering fluid reservoir is equipped with a screen and fluid filter to help keep the system fluid clean.

3B3-2 POWER STEERING STEERING WHEEL FREE PLAY Preparation • Remove the Front grille. Refer to page 2C-1 of the 1999-2001 Service Manual. • Remove the Headlight assembly and related parts. Refer to page 8-72 of the 1999-2001 Service Manual. Inspect 1. Check the amount of the steering wheel play by turning the wheel in both directions until the tires begin to move with the front wheels properly in the straight ahead position. NOTE: If the vehicle is equipped with a power steering unit, the wheel free play should be checked with the engine running. Steering wheel free play 10-50mm (0.4-2.0 in) 2. Also check the steering wheel for play and looseness in mount by moving it back and forth and sideways. While driving check for hardsteering, shimmy and tendency of steering to pull to one side. Adjust 1. Align the front wheels properly in the straight ahead position. 2. Loosen the lock nut on the adjusting screw of the steering unit. 3. Turn the adjust screw clockwise to decrease free play or counterclockwise to increase. 4. After check of specified free play, tighten the lock nut to specified torque. Tighten • Lock nut to 69N.m (51 Ib ft).

440L200001

3A-2 FRONT END ALIGNMENT MEMO ...........................................................................................................................................................................................................................................................................................................

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REAR AXLE 4A1-1

SECTION 4

REAR AXLE AND PROPELLER SHAFT CONTENTS SUBJECT

PAGE

Rear Axle ............................................................................................................... See 1999-2001 Service Manual Propeller Shaft ...................................................................................................... See 1999-2001 Service Manual

4A1-2 REAR AXLE MEMO .................................................................................................................................................................................................................................................................................................................

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HYDRAULIC BRAKES 5A-1

SECTION 5

BRAKES CONTENTS SUBJECT

PAGE

Hydraulic Brakes ..................................................................................................................................................5A Vacuum Booster Brake System .............................................................................See 1999-2001 Service Manual Hydraulic Booster Brake System ........................................................................................................................5A2 Hydraulic Foundation Brakes.................................................................................See 1999-2001 Service Manual Anti-lock Brake System (ABS)................................................................................See 1999-2001 Service Manual Parking Brakes.........................................................................................................See 1999-2001 Service Manual

SECTION 5A

HYDRAULIC BRAKES NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Introduction .............................................................................................................See 1999-2001 Service Manual Description ..........................................................................................................See 1999-2001 Service Manual Hydraulic Brake Fluid .........................................................................................See 1999-2001 Service Manual Brake System Diagnosis ........................................................................................See 1999-2001 Service Manual Road Testing Brakes ..........................................................................................See 1999-2001 Service Manual Brake System Diagnosis Chart..........................................................................See 1999-2001 Service Manual Brake Lining Diagnosis Chart............................................................................See 1999-2001 Service Manual Brake Drum Diagnosis Chart ............................................................................See 1999-2001 Service Manual Front Disc Brake Diagnosis Chart.....................................................................See 1999-2001 Service Manual Inspection and Repair ...........................................................................................See 1999-2001 Service Manual System Inspection ..............................................................................................See 1999-2001 Service Manual Contamination of Brake System........................................................................See 1999-2001 Service Manual Flushing Brake System ......................................................................................See 1999-2001 Service Manual Bleeding Brakes..................................................................................................See 1999-2001 Service Manual Load-Sensing Proportioning Valve (LSPV) Adjustment ...........................................................................5A- 2 Brake Lines..........................................................................................................See 1999-2001 Service Manual Brake Fluid Reservoir ........................................................................................See 1999-2001 Service Manual Load-Sensing Proportioning Valve (LSPV) .....................................................See 1999-2001 Service Manual Master Cylinder ...................................................................................................See 1999-2001 Service Manual Brake Pressure Metering Valve .........................................................................See 1999-2001 Service Manual Specifications..........................................................................................................See 1999-2001 Service Manual Fastener Torques ...............................................................................................See 1999-2001 Service Manual Special Tools...........................................................................................................See 1999-2001 Service Manual

5A-2 HYDRAULIC BRAKES LOAD-SENSING PROPORTIONING VALVE (LSPV) ADJUSTMENT This adjustment should be performed with the battery voltage applied to the valve. 1. Adjust the specified rear axle weight by loading the rear body as according to the chart values by model description. Model

GVWR (Ibs)

NPR

12,000

NPR

14,500

NQR

17,950

Wheel Base(in) 109 132.5 150 176 109 132.5 150 176 109 132.5 150 176

Rear Axle Weight kg(lb) 1200(2,650) 1000(2,210) 900(1,990) 900(1,990) 1500(3,310) 1400(3,090) 1300(2,870) 1300(2,870) 1400(3,090) 1300(2,870) 1150(2,540) 1150(2,540)

2. Connect a miniature lamp (1) and a battery (2) as shown below between the valve bracket (3) and linkage (4). This is done to locate the point where the piston in the valve assembly comes in contact with the linkage.

3. Loosen the nut (6) and raise the valve assembly (7) all the way. Then lower the valve assembly gradualily and tighten the nut (6) lamp (1) turns on. If the miniature lamp (1) goes out as the nut (6) is tightened, lower the valve assembly (7) slightly with the nut loosened, then retighten the nut (6).

Figure 5. Load-Sensing Proportioning Valve Adjustment-1 4. Depress the linkage (4) near the valve assembly slightly downward with finger (test pressure :4.97.8N (1.1-1.7lb)) and check to see if the miniature lamp (1) goes out. Lamp goes out : OK Adjustment is completed. Lamp remains on : NG Repeat adjustment operation outlined under paragraph 3. Excessive force is exerted on linkage by piston (8) within the valve assembly.

Figure 4. Miniature Lamp Wiring Note: As the linkage is coated with insulation material, turn the clip (5) with 2 or 3 turns to break insulation.

HYDRAULIC BRAKES 5A-3 5. Inspection of brake fluid pressure (Reference value) 1) 2) 3)

Adjust the rear axle weight as specified under the paragraph 1. Install the pressure gauge on the bleeder screws on the front and rear brakes. Depress the brake pedal and obtain the pressure gauge reading. The brake fluid pressure is normal if the pressure of fluid within the rear wheel cylinders is within the range of 5,030±590kPa (729±97psi) when pressure of fluid within the front wheel cylinders reaches 7,850kPa (1,138psi). Important

Figure 6. Load-Sensing Proportioning Valve Adjustment-2 Note: Adjustment can also be made by means of nuts (9) and (10) on shackle at rear axle case side. However, shackle nut is not normally used for adjustment as it is for making fine adjustment.

Figure 6-1. Load-Sensing Proportioning Valve Adjustment-3

The brake pedal should be depressed gradually until specified pressure is reached without pumping or adjusting foot pressure.

HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-1

SECTION 5A2

HYDRAULIC BOOSTER BRAKE SYSTEM NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

General Description................................................................................................See 1999-2001 Service Manual Booster Assembly ..............................................................................................See 1999-2001 Service Manual Fluid and Fluid Handling ....................................................................................See 1999-2001 Service Manual Flushing The Hydraulic Booster System..........................................................See 1999-2001 Service Manual System Outline....................................................................................................See 1999-2001 Service Manual Hydraulic Booster Troubleshooting......................................................................See 1999-2001 Service Manual Notes ....................................................................................................................See 1999-2001 Service Manual Supply Parts Replacement.................................................................................See 1999-2001 Service Manual On-Vehicle Service .................................................................................................See 1999-2001 Service Manual Accumulator and O-Ring Replacement ............................................................See 1999-2001 Service Manual Hydraulic Booster Replacement........................................................................See 1999-2001 Service Manual Clevis and Lock Nut Replacement ....................................................................See 1999-2001 Service Manual Guard Replacement ............................................................................................See 1999-2001 Service Manual Brake Pedal Replacement ..................................................................................See 1999-2001 Service Manual Brake Pedal Adjustment.....................................................................................See 1999-2001 Service Manual Hydraulic Booster Brake Fluid and Filter ...................................................................................................5A2-1 Specifications..........................................................................................................See 1999-2001 Service Manual Fastener Torques................................................................................................See 1999-2001 Service Manual

5A2-2 HYDRAULIC BOOSTER BRAKE SYSTEM

2 3

4 1

7 5

9

6 8

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cover Cap Filter Fluid Reservoir Hose (Single Cab) Hose (Crew Cab) Tubing (Hydraulic Pump ⇔ Brake Booster Hose (Reservoir ⇔ Brake Booster) Hydraulic Pump 331L200001

Figure 1. Hydraulic Booster Brake Fluid Reservoir

HYDRAULIC BOOSTER BRAKE FLUID AND FILTER 1. Remove the cover (1) and cap (2) (figure1). 2. Remove the filter (3). 3. Clean the filter (3) in clean solvent. Then blow the filter dry with compressed air. 4. Raise the vehicle until the tires are off the floor. Support the frame with stands.

5. Disconnect the reservoir hose (5) single cab, (6) crew cab at the reservoir. Drain the fluid reservoir (4).

HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-3 6. Connect the reservoir hose. DO NOT START ENGINE 7. Install the filter (3).

8. Fill and bleed the hydraulic system. Refer to page 5A2-7 of the 1999-2001 Service Manual. 9. Install the cap (2) and cover (1).

ENGINE 6A-1

SECTION 6

ENGINE CONTENTS SUBJECT

PAGE

Engine ....................................................................................................................................................................6A Isuzu Engine..........................................................................................................................................................6A6 Cooling System.....................................................................................................................................................6B1 Radiator .................................................................................................................................................................6B2 Fan ........................................................................................................................................................................6B3 Fuel System...........................................................................................................................................................6C1 Fuel Injection System...........................................................................................................................................6C3 Engine Electrical...............................................................................................SEE 1999-2001 SERVICE MANUAL Emission and Electrical Diagnosis .................................................................SEE 1999-2001 SERVICE MANUAL Exhaust..............................................................................................................SEE 1999-2001 SERVICE MANUAL

SECTION 6A

ENGINE NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Engine Replacement.........................................................................................................................................6A- 2 Engine Mountings ............................................................................................SEE 1999-2001 SERVICE MANUAL Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL Maintenance .................................................................................................SEE 1999-2001 SERVICE MANUAL Front Engine Mount Replacement..............................................................SEE 1999-2001 SERVICE MANUAL Rear Engine Mount Replacement ..............................................................SEE 1999-2001 SERVICE MANUAL Exhaust Brake System ....................................................................................SEE 1999-2001 SERVICE MANUAL Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL Operation ......................................................................................................SEE 1999-2001 SERVICE MANUAL Diagnosis of Exhaust Brake ...........................................................................SEE 1999-2001 SERVICE MANUAL Exhaust Brake On-Vehicle Service ................................................................SEE 1999-2001 SERVICE MANUAL Component Locations .................................................................................SEE 1999-2001 SERVICE MANUAL Magnetic Valve Replacement......................................................................SEE 1999-2001 SERVICE MANUAL Vacuum Chamber Replacement .................................................................SEE 1999-2001 SERVICE MANUAL Exhaust Brake Valve Replacement ...........................................................SEE 1999-2001 SERVICE MANUAL

6A-2 ENGINE Throttle Position Sensor Replacement ......................................................SEE 1999-2001 SERVICE MANUAL Clutch Switch Replacement........................................................................SEE 1999-2001 SERVICE MANUAL Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL Fastener Torques.........................................................................................SEE 1999-2001 SERVICE MANUAL

ENGINE REPLACEMENT 6. Air intake pipe (6) from the turbocharger and the air cleaner (figure 3).

Remove or Disconnect (Figures 1-12) 1. Battery negative cable (1) at the battery (figure 1). Main feed wire (5) at the starter solenoid (figure 2).

6

2 6. Air Intake Pipe 1

For 12 Volt

1. Battery Negative Cable 2. Battery Positive Cable

Figure 3. Air Intake Pipe to Turbocharger Attachment 7. Air intake pipe (9) with connecting hoses (10), (11) from the turbocharger (8) and the charge air cooler (12) (figure 4).

Figure 1. Battery Cable Identification

8

10 5 4 4. Solenoid Wire 5. Main Feed Wire Figure 2. Wiring at Starter 2. Cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). 3. Rear floor engine cover and rear engine cover assembly. 4. Drain the coolant from the drain cock at the bottom rear of the radiator. 5. Engine oil from the oil pan plug.

8. 9. 10. 11. 12.

9 Turbocharger Air Inlet Pipe Connecting Hose Connecting Hose Charge Air Cooler

11

12

Figure 4. Air Inlet Pipe Attachment Important • Tape the inlet opening of the turbocharger to prevent entry of foreign material.

ENGINE 6A-3 8. Air intake pipe (13) with connecting hoses (14) from the intake manifold and the charge air cooler (12) (figure 5).

14 13. Air Inlet Pipe 14. Connecting Hose

13

14

Figure 5. Intake Manifold Pipe Attachment 9. Radiator upper hose and lower hose. 10. Heater hoses. 11. Vacuum hoses (16) at the vacuum pump (15). 12. Loosen the generator adjusting bolts (17) (figure 6).

13. Generator electrical wire harness (19) (figure 7).

18. Generator 19. Generator Electrical Wire Figure 7. Wiring and Generator 14. Driver belts for air conditioning condenser, generator, and water pump. 15. Air conditioning condenser (20). Do not disconnect the hoses from the condenser (figure 8). 16. Air conditioning condenser bracket.

20

15. Vacuum Pump 16. Vacuum Hose 17. Generator Adjusting Bracket Figure 6. Vacuum Hose Attachment at Vacuum Pump

20. A/C Compressor Figure 8. Air Conditioner (A/C) Compressor Removed 17. Fan and fan clutch from the fan clutch plate. Refer to FAN (SEC. 6B3). 18. Fuel filter and fuel filter bracket from cylinder head. Refer to FUEL INJECTION SYSTEM (SEC. 6C3).

6A-4 ENGINE 19. Accelerator cable and engine stop cable. Refer to FUEL SYSTEM (SEC. 6C1). 20. Accelerator cable bracket. 21. Power steering pipe bracket and turbocharger oil feed pipe bracket from the flywheel housing. 22. Power steering pump. Do not disconnect the hoses from the power steering pump. Refer to POWER STEERING (SEC. 3B3). 23. Power steering pump bracket. 24. EGR pipe from EGR valve and exhaust manifold. 25. Turbocharger water return pipe and feed pipe. 26. Turbocharger oil return pipe and feed pipe. 27. Exhaust brake unit assembly (22) (figure 9). 28. Front exhaust pipe (23) (figure 9).

20

22

23

20. Vacuum Chamber 22. Exhaust Brake Unit Assembly 23. Front Exhaust Pipe Figure 9. Exhaust Brake

29. Exhaust manifold with turbocharger. 30. Fuel lines at the frame near the injection pump. Refer to FUEL SYSTEM (SEC. 6C1). 31. Fuel shutoff cable at the injection pump and at the support bracket. Refer to FUEL SYSTEM (SEC. 6C3). 32. Starter motor harness from the starter motor. 33. Starter motor. 34. Propeller shaft. Refer to MANUAL TRANSMISSION (SEC. 7B). 35. Transmission shift cable and parking brake from transmission. Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 36. Speedometer cable from transmission. 37. Automatic transmission (A/T) oil cooler from transmission (A/T only). Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 38. ATF level guide tube. 39. Electrical wiring harness with bracket and connector. 40. Set jack beneath the engine and transmission. Secure the engine and transmission to the jack with wire. 41. Turn the steering wheel fully to one side. This moves the tie rod forward to provide additional working space. 42. Transmission bracket (33) from cross member (figure 12). 43. Engine mount insulator (24) bolts from engine mounting cross member (figure 11). 44. Engine mounting cross member from Chassis frame. 45. Use the jack to lower the engine / transmission assembly.

ENGINE 6A-5

24. Engine Mount Insulator 26. Engine Mount Bracket Figure 11. Front Engine Mount

28. Crossmember 29. Engine Mount Insulators 30. Side Supports 31. Upper Mount Assembly 32. Transmission Cover 33. Bracket Figure 12. Transmission Mount

6A-6 ENGINE Install or Connect (Figures 1-12) NOTICE: See “NOTICE” on page 6A-1 of this section for steps 7, 8, 9 and 10. 1. Turn the steering wheel fully to on side. This moves the tie rod forward to provide additional working space. 2. Position the engine / transmission assembly underneath the vehicle with the jack. Use the jack to raise the engi ne / transmis sion asse mbly in to the installed position. 3. Engine mounting cross member to Chassis•frame. 4. Engine mount insulator (24) to engine mounting cross member (figure 11). Tighten • The engine mount insulator bolts to 75 N·m (55 lb·ft). 5. Transmission bracket (33) to cross member (figure 12). Tighten • The bracket to cross member nuts to 69 N·m (51 lb·ft). 6. Electrical wiring harness with bracket and connector. 7. ATF level guide tube. 8. Automatic transmission (A/T) oil cooler to transmission. Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 9. Propeller shaft. Refer to MANUAL TRANSMISSION (SEC. 7B). 10. Speedometer cable to transmission. 11. Transmission shift cable and parking brake to transmission. Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 12. Propeller shaft. Refer to MANUAL TRANSMISSION (SEC. 7B). 13. Starter motor 14. Starter motor harness to the starter motor. 15. Fuel lines at the frame near the injection pump. Refer to FUEL SYSTEM (SEC. 6C1). 16. Exhaust manifold with turbocharger. Tighten • The exhaust manifold with turbocharger. To cylinder head to 34 N·m (25 lb·ft). 17. Front exhaust pipe (23) (figure 9). 18. Exhaust brake unit assembly (22) (figure 9). Refer to EXHAUST (SEC. 6F). 19. Turbocharger oil return pipe and feed pipe.

20. Turbocharger water return pipe and feed pipe. 21. EGR pipe to EGR valve and exhaust manifold. 22. Power steering pump bracket. 23. Power steering pump. Refer to POWER STEERING (SEC. 3B3). 24. Power steering pipe bracket and turbocharger oil feed pipe bracket to the flywheel housing. 25. Accelerator cable bracket. 26. Accelerator cable and engine stop cable. Refer to FUEL SYSTEM (SEC. 6C1). 27. Fuel filter and fuel filter bracket to cylinder head. 28. Fan and fan clutch to the fan clutch plate. Refer to FAN (SEC. 6B3). 29. Air conditioning condenser bracket. 30. Air conditioning condenser (20) (figure 8). 31. Air conditioning condenser, generator, and water pump belts. 32. Generator adjusting (17) (figure 6). 33. Generator electrical wiring harness (19) (figure 7). 34. Vacuum hoses (16) at the vacuum pump (15) (figure 6). 35. Heater hoses. 36. Radiator upper hose and lower hose. 37. Air intake pipe (13) with connecting hoses (14) to the intake manifold and the charge air cooler (figure 5). 38. Air intake pipe (9) with connecting hoses (10), (11) to the charge air cooler (12) and the turbocharger (8) (figure 4). 39. Air intake pipe (6) to the turbocharger and the air cleaner (figure 3). 40. Be sure the oil pan plug is tight. Install 13 liters (3 gal) of engine oil. Refer to MAINTENANCE AND LUBRICATION (SEC. 0B). 41. Close the radiator drain cock. Fill the coolant as described in COOLING SYSTEM (SEC. 6B1). 42. Rear floor engine cover and rear engine cover assembly. 43. Cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). 44. Check the automatic transmission fluid level and replenish as necessary (automatic transmission only). Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 45. Connect the main feed wire (5) at the starter, and the battery negative (1) cable at the battery (figures 1 and 2).

ISUZU ENGINE 6A6-1

SECTION 6A6

ISUZU ENGINE NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

General Information.........................................................................................SEE 1999-2001 SERVICE MANUAL Statement on cleanliness and care ............................................................SEE 1999-2001 SERVICE MANUAL Description .......................................................................................................SEE 1999-2001 SERVICE MANUAL Lubrication system ......................................................................................SEE 1999-2001 SERVICE MANUAL Diagnosis of Isuzu diesel engine ...................................................................SEE 1999-2001 SERVICE MANUAL Engine will not turn over .............................................................................SEE 1999-2001 SERVICE MANUAL Engine turns over slowly but does not start .............................................SEE 1999-2001 SERVICE MANUAL Engine cranks normally but does not start ...............................................SEE 1999-2001 SERVICE MANUAL Engine cranks normally but is difficult to start.........................................SEE 1999-2001 SERVICE MANUAL Inconsistent idle speed (Engine “Lopes”).................................................SEE 1999-2001 SERVICE MANUAL Engine misses at idle ..................................................................................SEE 1999-2001 SERVICE MANUAL Engine misses at high speeds....................................................................SEE 1999-2001 SERVICE MANUAL Engine misses at all speeds .......................................................................SEE 1999-2001 SERVICE MANUAL Engine misses on one cylinder ..................................................................SEE 1999-2001 SERVICE MANUAL Lack of power or performance ...................................................................SEE 1999-2001 SERVICE MANUAL Excessive exhaust smoke...........................................................................SEE 1999-2001 SERVICE MANUAL Engine fails to reach operating temperature.............................................SEE 1999-2001 SERVICE MANUAL Engine overheats .........................................................................................SEE 1999-2001 SERVICE MANUAL Low oil pressure ..........................................................................................SEE 1999-2001 SERVICE MANUAL High oil pressure..........................................................................................SEE 1999-2001 SERVICE MANUAL Burned, sticking or broken valves .............................................................SEE 1999-2001 SERVICE MANUAL Excessive fuel consumption.......................................................................SEE 1999-2001 SERVICE MANUAL Excessive oil consumption.........................................................................SEE 1999-2001 SERVICE MANUAL Engine noises...............................................................................................SEE 1999-2001 SERVICE MANUAL Compression check.....................................................................................SEE 1999-2001 SERVICE MANUAL Maintenance .....................................................................................................SEE 1999-2001 SERVICE MANUAL Valve adjustment .........................................................................................SEE 1999-2001 SERVICE MANUAL Turbocharger maintenance.........................................................................SEE 1999-2001 SERVICE MANUAL Changing the engine oil and oil filter.........................................................SEE 1999-2001 SERVICE MANUAL Isuzu Engine On-Vehicle Service ...................................................................SEE 1999-2001 SERVICE MANUAL Statement on cleanliness and care ............................................................SEE 1999-2001 SERVICE MANUAL Air intake manifold and exhaust manifold with turbocharger .................................................................6A6- 3 Charge air pipe replacement.......................................................................................................................6A6- 4 Intake manifold replacement ......................................................................................................................6A6- 4 Turbocharger replacement .........................................................................................................................6A6- 4 Exhaust manifold replacement...................................................................................................................6A6- 7 Cylinder head cover replacement ..............................................................................................................6A6- 8 Valve stem seal and components replacement ........................................SEE 1999-2001 SERVICE MANUAL

6A6-2 ISUZU ENGINE Valve train component replacement ..........................................................SEE 1999-2001 SERVICE MANUAL Glow plug replacement ...............................................................................................................................6A6- 8 Cylinder head replacement .........................................................................................................................6A6- 9 Valve seat grinding ......................................................................................SEE 1999-2001 SERVICE MANUAL Valve grinding ..............................................................................................SEE 1999-2001 SERVICE MANUAL Valve guide replacement.............................................................................SEE 1999-2001 SERVICE MANUAL Valve seat replacement ...............................................................................SEE 1999-2001 SERVICE MANUAL Valve lapping ...............................................................................................SEE 1999-2001 SERVICE MANUAL Cylinder head gasket selection ..................................................................SEE 1999-2001 SERVICE MANUAL Piston and connecting rod replacement ..................................................................................................6A6-15 Piston and liner grade selection................................................................................................................6A6-20 Cylinder liner replacement..........................................................................SEE 1999-2001 SERVICE MANUAL Cylinder liner grade selection.....................................................................SEE 1999-2001 SERVICE MANUAL Piston pin bushing replacement ................................................................SEE 1999-2001 SERVICE MANUAL Vibration damper replacement ..................................................................................................................6A6-23 Oil pump replacement .................................................................................SEE 1999-2001 SERVICE MANUAL Bypass valve ................................................................................................SEE 1999-2001 SERVICE MANUAL Timing gear replacement ...........................................................................................................................6A6-24 Camshaft replacement ...............................................................................................................................6A6-30 Flywheel replacement..................................................................................SEE 1999-2001 SERVICE MANUAL Flywheel housing replacement..................................................................................................................6A6-34 Crankshaft front oil seal replacement.......................................................................................................6A6-37 Crankshaft rear oil seal replacement .........................................................SEE 1999-2001 SERVICE MANUAL Power steering pump replacement ............................................................SEE 1999-2001 SERVICE MANUAL Oil pan replacement.....................................................................................SEE 1999-2001 SERVICE MANUAL Crankshaft and main bearing replacement ...............................................SEE 1999-2001 SERVICE MANUAL Crankshaft gear replacement .....................................................................SEE 1999-2001 SERVICE MANUAL Oil jet replacement.......................................................................................SEE 1999-2001 SERVICE MANUAL Oil cooler replacement ...............................................................................................................................6A6-40 Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL Engine main specifications.........................................................................SEE 1999-2001 SERVICE MANUAL Fastener torques..........................................................................................SEE 1999-2001 SERVICE MANUAL Engine mechanical data ..............................................................................SEE 1999-2001 SERVICE MANUAL Special tools.....................................................................................................SEE 1999-2001 SERVICE MANUAL

ISUZU ENGINE 6A6-3 AIR INTAKE MANIFOLD AND EXHAUST MINFOLD WITH TURBOCHARGER

11. 11a. 12. 13. 14. 15. 16. 19. 20. 21. 22. 23. 23a. 24. 25.

Intake Manifold EGR case Nut Bolt Gasket Nut Exhaust Adapter Turbocharger Gasket Exhaust Manifold Heat shield Bolt Nut Gasket Cylinder Head Figure 9. Manifolds, Turbocharger and Components

6A6-4 CHARGE AIR PIPE REPLACEMENT Refer to “Statement on Cleanliness and Care” previously in this section.

5. Charge air pipe connection hose. 6. Injection pipes. 7. Bolts and nuts for fixing intake manifold. 8. Intake manifold with gasket. 9. EGR case.

Remove or Disconnect (Figure 9) Install or Connect (Figure 9) • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Connecting hoses clamps. 2. Connecting hoses. 3. Bracket bolts and washers and charge air pipe from turbocharger to charge air cooler. 4. Clamps. 5. Connecting hose. 6. Bracket accelerator cable. 7. Bracket engine stop cable and vacuum hose. 8. Engine harness connector. 9. Charge air pipe from charge air cooler to intake manifold. Inspect • Hoses for deterioration, or damage. • Charge air pipes for damage. Install or Connect (Figure 9) 1. Charge air pipe from charge air cooler. 2. Engine harness connector. 3. Bracket engine stop cable and vacuum hose. 4. Bracket accelerator cable. 5. Connecting hose. 6. Clamps. 7. Charge air pipe from turbocharger to charge air cooler and bracket bolts. 8. Connecting hoses. 9. Clamps. • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E).

INTAKE MANIFOLD REPLACEMENT Remove or Disconnect • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Injection nozzle cover. 2. Vacuum hose from intake manifold. 3. Vacuum hoses EGR valve and throttle valve. 4. EGR pipe.

1. EGR case with liquide gasket. 2. Intake manifold with gasket. Tighten • Nuts (12) and bolt, a little at a time, to 19 N·m (14 lb·ft). 3. Injection pipes. Tighten • Fuel injector line nuts to 29 N·m (22 lb·ft). 4. Charge air pipe connection hose. 5. Vacuum hoses EGR valve and throttle valve. 6. Vacuum hose to intake manifold from injection pump. 7. Injection nozzle cover. • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E).

TURBOCHARGER REPLACEMENT Refer to “Statement on Cleanliness and Care” previously in this section. Remove or Disconnect (Figures 9, 11, 12 and 13) • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Turbocharger air inlet pipe (310) (figure 11). 2. Connecting hose. 3. Heat shield (22) bolt (figure 9). 4. Water feed (300) (figure 12) and drain lines. 5. Oil feed line (280) (figure 11). 6. Oil drain line (290) (figure 12). 7. Exhaust pipe to exhaust adapter Nuts. 8. Exhaust adapter (16) to exhaust manifold bolts (17) (figures 9 and 13). 9. Turbocharger to exhaust manifold nuts (18) (figures 13). 10. Turbocharger (19) (figure 9). 11. Exhaust adapter (16) (figures 9 and 13).

6A6-5

280

19

310

Figure 11a. Radial Clearance Measurement 19. Turbocharger. 280. Oil Supply Line. 310. Air Inlet Pipe. Figure 11. Turbocharger Oil Feed Line Attachment Inspect (Figure 9) — Turbocharger (19) housing for cracks or damage. — Gasket surfaces for damage. — Seals and gaskets for damage. — Turbine and compressor blades for damage or carbon deposit. — Air and exhaust exit openings for oil or wetness. — For grinding or roughness when spinning turbine and compressor wheels by hand. — For evidence of turbine or compressor blades contacting the shroud or housing. If any of the above conditions exist, the turbocharger must be replaced or repaired by an authorized repair facility.

Measure Play in axial clearance. Moving the rotor in the axial clearance, measure the play by a dial gage. • Measure the play at several points while letting the rotor revolve. • Attach the turbocharger and dial gage firmly. Service limit is 0.090 mm (0.0035 in). If excessive, replace the turbocharger.

Measure Play in radial clearance. Moving the rotor in the radial clearance, measure the play by a dial gage. • Measure the play at several points while letting the rotor revolve. • Use only the flat dial gage attachment. Do not use the pointed one. • Attach the turbocharger and dial gage firmly. Service limit is 0.140 mm (0.0055 in). If excessive, replace the turbocharger.

Figure 11b. Axial Clearance Measurement Operation of waist gate • Disconnect hose ➁ from waist gate acutuator  , and install pressure gauge ➂ as shown in the figure. • With the engine stopped, operate the pressure gauge pump to apply pressure to the waist gate for check the waist gate function.

6A6-6 280

19 300

290

Figure 11c. Measurement Oil leakage check 1. Remove the charge air pipe connecting hose to the compressor side of the turbocharger. 2. Clean the area around the compressor wheel. 3. Remove the blow-by hose. 4. Start the engine and let idle. Rev the engine and hold at wide open throttle (WOT) for five seconds, then release and let idle for five seconds. Repeat this cycle for a total of five times, then let the engine idle steady for five minutes. 5. Shut off the engine. 6. Check the compressor area for an oil leakage.

19. 280. 290. 300.

Turbocharger. Oil Supply Line. Oil Drain Line. Water Feed Line.

Figure 12. Turbocharger Oil Lines Attachment

Important • A leaking of oil indicates a possible defective turbocharger. If mist or spray is present, however, this is normal and is NOT indicative of a turbocharger problem. 7. If the turbocharger is suspect any problem, refer to the turbocharger replacement procedures in this section.

16. Exhaust Adapter 17. Exhaust Adapter Bolts 18. Turbocharger to Manifold Nuts Figure 13. Turbocharger Mounting Attachment Install or Connect (Figures 9, 11, 12 and 13) 1. Exhaust adapter (16) to turbocharger (19). 2. New gasket (20) and turbocharger (19) to exhaust manifold (21) (figure 9). Tighten • Nuts (18) to 25 N·m (18 lb·ft) (figure 13). 3. Exhaust adapter (16) to exhaust manifold (21) (figure 13).

6A6-7 Tighten • Bolts (17) to 25 N·m (18 lb·ft). 4. New gasket and exhaust pipe to exhaust adapter (16) (figure 9). Tighten

EXHAUST MANIFOLD REPLACEMENT Remove or Disconnect (Figure 9) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly.

• Nuts (15) to 37 N·m (27 lb·ft). 5. Turbocharger oil drain line (290) (figure 12). Tighten • Bolts to 9 N·m (6 lb·ft) turbocharger side. • Bolts to 22 N·m (15 lb·ft) cyl. block side. 6. Turbocharger oil supply line (280) to turbocharger (19) (figure 12).

1. Turbocharger (19) refer to the turbocharger replacement in this section. 2. Exhaust manifold Bolts (23), nuts (23a) and washers. 3. Exhaust manifold (21). 4. Gaskets (24). Inspect (Figure 9) • Exhaust manifold (21) and cylinder head (25) for cracks or damage to gasket surfaces.

Tighten • Fitting (280) to 27 N·m (20 lb·in). 7. Water supply and drain lines (300) (figure 12). Tighten • Fitting (300) to 41 N·m (30 lb·ft). 8. Heat shield (22) to exhaust adapter (16) (figure 9). 9. Charge air pipe connecting hoses and clamps to turbocharger (19) (figure 9). 10. Air inlet pipe (310) to turbocharger (19) (figure 11).

Install or Connect (Figures 9, 16) 1. Gaskets (24) as shown in figures 9. 2. Exhaust manifold (21). 3. Washers nuts (23a) and bolts (23) as shown in figure 9. Tighten • Nuts and bolts, a little at a time, in the sequence shown in figure 16, to 34 N·m (25 lb·ft).

• Remove the rear floor engine cover and rear engine cover assembly. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E).

Figure 16. Exhaust Manifold Bolt Torquing Sequence 4. Turbocharger (19) refer to the turbocharger replacement in this section. 5. Heat shield (22). • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

6A6-8 CYLINDER HEAD COVER REPLACEMENT

Cylinder Head Cover Nut and Bolt Torque: 18 N·m (13 lb·ft)

Remove or Disconnect (Figures 17) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Injection nozzle cover. 2. Bolt (33), nut (34) and oil cap (35) (figure 17). 3. Cylinder head cover (36). 4. Gasket (37).

Figure 104. Cylinder Head cover 3. Injection nozzle cover. 33. Bolt 34. Nut 35. Oil Cap 36. Cylinder Head Cover 37. Gasket Figure 17. Cylinder Head Cover Assembly Clean (Figure 17) • All sludge and dirt from cylinder head cover (36). • The gasket (37). Inspect (Figure 17) • Cylinder head cover (36) for damage. Install or Connect (Figure 17) 1. Gasket (37). 2. Cylinder head cover (36) to cylinder head. Tighten • Tighten the cylinder head cover nuts and bolts to the specified torque in the numerical order shown in the illustration.

• Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

GLOW PLUG REPLACEMENT Remove or Disconnect (Figure 25) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Glow 2. Glow 3. Glow 4. Glow

plug wire (58). plug connector nuts (59). plug connector (57). plug (56). Use a deep socket.

6A6-9 CYLINDER HEAD REPLACEMENT

Install or Connect (Figure 25)

Refer to “Statement on Cleanliness and Care” in this section.

1. Glow plug (56). Tighten

Tools Required: J-43287 Valve Spring Compressor J-43283 Valve Guide Remove and Installer J-43284 Valve Stem Seal Installer

• Glow plug (56) to 23 N·m (17 lb·ft). 2. Glow plug connector (57). 3. Glow plug connector nuts.(59)

Remove or Disconnect (Figures 27 and 28) Tighten

• Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly.

• Glow plug connector nuts(59) to 1.2 N·m (0.88 lb·ft). 4. Glow plug wire (58). • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable. 59

58

56 57 56. Glow Plug 57. Glow Plug Connector 58. Glow Plug Wire 59. Glow Plug Connector nots Figure 25. Glow Plug Replacement

1. Drain engine coolant at lower rear of radiator trough drain valve. Refer to RADIATOR (SEC. 6B2). 2. Radiator upper hose at thermostat housing. Refer to RADIATOR (SEC. 6B2). 3. Water pump bypass hose at thermostat housing. 4. Heater hose return. 5. Injection nozzle cover. 6. Turbocharger refer to the turbocharger replacement. 7. Front exhaust pipe from exhaust manifold. 8. Injection pipes. Important * Plug the delivery valve holder ports and injector holder ports with caps to prevent entry of the foreign material. 9. Fuel pipes, gaskets from the fuel filter and fuel filter. 10. Injector leak off pipe and gasket. 11. Fan guide bracket. 12. Engine harness connectors. 13. Glow plug harness connector(58) (Figure 25). 14. A/C compressor and bracket. 15. EGR pipe.

6A6-10

69 70 71 72 75 74

69. 70. 71. 72. 73. 74. 75.

73

Valve cap Split collar Spring upper seat Valve spring Intake and exhaust valve Valve stem Seal Spring lower seat

Figure 27. Cylinder Head and Components

16. Charge air hose and pipe from the intake manifold. 17. Cylinder cover refer to the cylinder head cover replacement. 18. Rocker arm and shaft assembly refer to the valve train component replacement. 19. Camshaft assembly. 20. Cylinder head bolts (Figure 28). * Loosen the cylinder head bolts in numerical order a little at a time. 21. Cylinder head assembly. 22. Cylinder head gasket. Figure 28. Cylinder Head Bolt Loosening Sequence

6A6-11 Disassemble (Figure 9, 27, 29) 1. Injectors and gasket 2. Glow plugs 3. Exhaust manifold and gasket. 4. Intake manifold with gasket. 5. EGR case. 6. Fuel filter bracket. 7. C/box bracket. 8. Engine hanger 9. Water outlet pipe from front of cylinder head. 10. Thermostats. 11. Valve caps from top of valve stem. 12. Use J-43287 to remove the valve spring and relation parts. 13. Split colors. 14. Upper spring seat. 15. Valve springs. 16. Valve stem seal. 17. Lower spring seal. 18. Valves. If the valves are to be reinstalled, mark their installation position each valve with the cylinder number from which it was removed. 19. Sealing cap for idle gear C. 20. Bolt with thrust washer. 21. Idle gear C with shaft.

Inspect — Cylinder head for cracks, damaged threaded parts, etc. — Cylinder head gasket surface for damage. — Valves for warping, pitting, etc. Measure (Figures 27 and 30-37) — Cylinder head gasket surface for warpage. Use a straightedge and feeler gage as shown in figure 30. Check in six different directions, as shown. If the cylinder head is warped more than 0.05 mm (0.0020 in), it must be replaced. Cylinder head cannot be machined.

352

352. J-43287 Figure 29. Compressing Valve Spring Inspection and repair Clean — All carbon from valve ports. — Valve guide bore of dirt and carbon. — Valve stems and heads. Do not use a wire wheel. — All traces of old gaskets from cylinder head and block.

14. A. B. C.

Cylinder Head Straight Edge Feeler Gage Check in Six Directions

Figure 30. Checking Cylinder Head Distortion — Valve installed depth (figure 31). Production depth is 0.70–1.20 mm (0.027–0.046 in). If more than 2.5 mm (0.100 in), replace the valve (73) or valve seat (76) as required.

6A6-12

14. 73. 76. A.

Cylinder Head Valve Valve Seat Valve Installed Depth

Figure 31. Measuring Valve Installed Depth — Valve stem diameter, as shown in figure 32. Check in three places, as shown. Check against “Specifications” at the end of this section.

73. Valve 77. Valve Guide A. Dial Indicator Figure 33. Measuring Valve Stem to Guide Clearance — Valve springs for length and straightness. Check against “Specifications” at the end of this section. • Check length with vernier calipers (figure 34). • Check amount of inclination from vertical with a square on a surface plate, as sown in figure 35.

Figure 32. Measuring Valve Stem Diameter — Valve guide (77) inside diameter, using an inside micrometer. Check against “Specifications” at the end of this section. — Valve guide to valve stem clearance (figure 33). • Locate a dial indicator as shown. • Hold the valve on its seat. • Move the valve stem from side to side to obtain the clearance reading. Check against “Specifications” at the end of this section.

Figure 34. Measuring Valve Spring Length

6A6-13 Cylinder head gasket grade selection procedure 1. Clean thoroughly the top faces of the piston head and the cylinder body. 2. Use the dial gauge to measure the piston head projection. Take measurements at two location for each cylinder. The measurement points of the piston head and the reference point of the cylinder body are shown in the illustration.

4. Find the maximum value (Tmax) of the average of each cylinder. (piston projection) 5. Based on the Tmax obtained, select a gasket of the appropriate grade. Cylinder Head Gasket Selection Gasket Grade A B C

mm (in)

Tmax

Gasket Thickness

0.479 - 0.559

1.70

(0.0189 - 0.0220)

(0.0669)

0.559 - 0.629

1.75

(0.0220 - 0.0248)

(0.0689)

0.629 - 0.709

1.80

(0.0248 - 0.0280)

(0.0708)

Figure 42a. Measurement of Piston projection Measurement points :

Points G1 and G2 of the piston head

Reference point :

Point R on the top face of the cylinder body

Install or Connect (Figures 27 and 43-45)

Point R

5 0

°

Point G2

Figure 42c. Location of Cylinder Head Gasket Grade

0 7

1. Cylinder head gasket. • Install the cylinder head gasket with its “PART NUMBER” mark facing up and toward the left of the engine.

2 0 °

Ø

1 0 0

Point G1

Figure 42b. Measurement Points 3. For each cylinder, calculate the average value (T) of the piston projection. Figure 43. Head Gasket Marking

6A6-14 2. Cylinder head assembly. 3. Cylinder head bolts. • Apply grease containing molybdenum disulfide to all head bolts. Tighten (Figures 44 and 45) • Cylinder head bolts in three stages, as outlined below. (For sequence number 1-18) • Stage 1: Tighten all head bolts to 98 N•m (72 lb•ft) using the tightening sequence shown figure 44. • Stage 2: Tighten all head bolts to 147 N•m (108 lb•ft) using the tightening sequence shown figure 44. • Stage 3: Refer to figure 45. Make punch mark on the bolt heads, as shown. Then, make a second punch mark on the cylinder head, 30–60 degrees clockwise from the first mark, as shown. Then, tighten all head bolts 30–60 degrees, using the tightening sequence shown in figure 44. • The sequence number 19 and 20 are tightened to 38 N•m (28 lb•ft).

Figure 44. Head Bolt Tightening Sequence

A. Reference Punch Mark on Bolt B. Reference Punch Mark on Cylinder Head Figure 45. Anglar Tightening Method for Cylinder Head Bolts 4. Camshaft assembly refer to the camshaft replacement. 5. Rocker arm and shaft assembly refer to the valve train component. 6. Adjust for valve clearance. Refer to the maintenance: valve adjustment. 7. Cylinder head cover refer to the cylinder head cover replacement. 8. Charge air hose and pipe to the intake manifold. 9. EGR pipe. 10. A/C compressor and bracket. 11. Glow plug connector refer to the glow plug replacement. 12. Engine harness connectors. 13. Fan guide bracket. 14. Injector leak off pipe and gasket. 15. Fuel pipes, gaskets to the fuel filter and fuel filter. 16. Injector pipes. 17. Front exhaust pipe to exhaust manifold. 18. Turbocharger refer to the turbocharger replacement. 19. Injection nozzle cover. 20. Heater hose return. 21. Water pump bypass hose. 22. Radiator upper hose. Refer to RADIATOR (SEC. 6B2). 23. Engine coolant. • Fill the radiator with the proper quantity and grade of engine coolant. • Install the rear floor engine cover and rear engine cover. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

6A6-15 PISTON AND CONNECTING ROD REPLACEMENT Refer to “ Statement on Cleanliness and Care” Care ” previously mentioned in this section. Remove or Disconnect (Figures 46 and 47) • Engine refer to the engine replacement (SEC. 6A). 1. Cylinder head assembly assembly refer to to the cylinder head replacement. 2. Oil level gauge tube tube with dip stick. stick. 3. Oil pan pan.. 4. Oil straine strainer. r. 5. Oil jets jets 6. Connecting cap bolts (83). 7. Connecting rod cap (82) with with bearing (87). 8. Piston (80) with connecting connecting rod (81). If the piston is to be reused, mark the cylinder number on it so it can be returned to the proper cylinder as assembly. Be sure to keep the connecting rod cap (82), connecting rod (81) and connecting rod bearing inserts (86 and 87) together as a matched set. Numbers are stamped on the connecting rod and cap to help keep the parts together (figure 47).

Disassemble (Figures 46, 48 and 59) 1. Rings (75, 76, 77 and 78), using using a ring expander (figure 48). 2. Snap rings rings (79). (79). 3. Piston Piston pin (84). (84). Clean (Figure 46) — Piston (80) and rings (75, 76, 77 and 78) in solvent. Do not use wire brush the piston. — Liner (89) bore with a solvent soaked cloth (figure 59). — Piston (80) ring grooves.

6A6-16 75. Compression Compression 1st Ring Ring 76. Compression Compression 2nd Ring Ring 77. Compression Compression 3rd Ring Ring 78. Oil Control Control Ring Ring 79. Snap Ring Ring 80. 80. Pisto Piston n 81. Connecting Connecting Rod 82. Connecting Connecting Rod Rod Cap Cap 83. 83. Bolt Bolt 84. Piston Piston Pin 86. Upper Connectin Connecting g Rod Bearing Bearing 87. Lower Connectin Connecting g Rod Bearing Bearing 88. Connecting Connecting Rod Bearing Bearing Set

75

76

77

78

79

84

80

79

81

86

82

88 87 83

Figure 46. Piston, Connecting Rod and Components Inspect (Figure 46) — Piston (80) for cracks and scoring. — Liner (89) for scratches, cracks and scoring (figure 59). — Connecting rod (81) and connecting rod cap (82) for cracks, damage etc. — Connecting rod bearing (86 and 87) for scoring. — Connecting rod bearing (86 and 87) tension (figure 53). Moderate finger pressure should be needed to push the bearing inserts into place. If the inserts fit loosely, they should be replaced. — Connecting rod journal on the crankshaft for scoring or other damage.

81. Connec Connectin ting g Rod 82. Connec Connectin ting g Rod Cap A. Connecting Connecting Rod Markings Markings (“2” Means #2 Rod) Figure 47. Connecting Rod Markings

6A6-17

75 77

76 A. Pist Piston on Ring ing 80. 80. Pisto Piston n

78

80

Figure 49. Measuring Measuring Piston Piston Ring Ring to Groove Clearance

75. Compression Compression 1st Ring Ring 76. Compression Compression 2nd Ring Ring 77. Compression Compression 3rd Ring Ring 78. Oil Contro Controll Ring 80. Pisto Piston n Figure 48. Removing or Installing Installing Piston Rings Rings Measure Piston Ring to Piston Ring Groove Clearance (Figure 49) • The clearance should be as specified in “Specifications” Specifications” at the end of this section. A. Pist Piston on Ring ing Piston Ring End Gap (Figure 50) • The gap should be as specified in “specifications” specifications” at the end of this section.

Figure 50. Measuring Piston Ring Ring End Gap

Piston Pin Hole Inside Diameter (Figure 51) • The hole should measure 40.004– 40.004 –40.012 (1.5749– (1.5749–1.5752 in). Piston Pin Diameter (Figure 52) • Measure in three places as shown. The production diameter is 39.995– 39.995 –40.000 mm (1.5746– (1.5746–1.5748 in).

Figure 51. Measuring Piston Pin Pin Hole Diameter Diameter

6A6-18 Piston Pin to Piston Pin Hole Clearance (Figures 51 and 52) • Subtract the piston pin diameter from the piston pin hole diameter to obtain the clearance.The proper clearance is 0.004–0.017 mm (0.00016–0.00067 in). Connecting Rod Small End Bushing Inside Diameter (Figure 54) • The correct diameter is 40.012–40.022 mm (1.5752–1.5756 in). Piston Pin to Connecting Small End Bushing Clearance • Subtract the piston pin diameter from bushing inside diameter to obtain the clearance.The standard clearance is 0.012–0.027 mm (0.0005–0.0011 in).The service limit is 0.05 mm (0.002 in).

Figure 54. Measuring Piston Pin Bushing Inside Diameter Crankpin Diameter (Figure 55) • Measure in two places and in the horizontal and vertical, as shown. The crankpin should measure 72.920–72.922mm (2.7979–2.7980 in). Important • If the crankshaft is worn, it should be replaced. It cannot be reground. Undersize bearings are not available. This is becaus of the special “tufftriding” hardening process that has been applied to it.

84. Piston Pin Figure 52. Measuring Piston Pin Diameter

Crankpin to Connecting Rod Bearing Clearance (Figure 46) Method 1 of measuring procedure. • Apply molybdenum disulfide grease to the threads of the bolts (83). • Install the connecting rod cap (82), connecting rod bearing insert (86 and 87) and bolts (83). Tighten • Bolts (83) to 1st stage 39 N·m (29 lb·ft), 2nd stage 60 degrees and 3rd stage 30 degrees.

Figure 53. Checking Connecting Rod Bearing Tension

• Measure the connecting rod bearing (88) inside diameter, using an inside micrometer (figure 56). • Subtract the crankpin diameter from the connecting rod bearing inside diameter to obtain the clearance. The production clearance is 0.036 – 0.077 mm (0.0014 –0.0030 in).The service limit is 0.10 mm (0.004 in). • Remove the bolts (83). • Remove the connecting rod cap (82) and bearings (86 and 87).

6A6-19 2. A piece of plastigage the length of the bearing (parallel to the crankshaft) on the journal (figure 68). Do not turn the crankshaft with the gaging plastic installed.

Figure 55. Measuring the Crankpin

A. Place Gaging Plastic Parallel to Crankshaft Figure 68. Placing the Gaging Plastic on the Crankpin

Figure 56. Measuring the Connecting Rod Bearing Inside Diameter Method 2 of measuring procedure (Figures 46 and 68~70) The simplest, most accurate way to measure connecting rod bearing clearance is with the use of plastigage. This wax-like material compresses evenly between the bearing and journal surfaces without damaging them. Proceed as follows. Clean • All oil from the crankpin and the bearing inserts (86 and 87). 1. Install the connecting rod (81) with the upper bearing insert (86) to the crankpin. Important • If a bearing is being fitted to an out-of-round crankpin, be sure to fit to the maximum diameter of the crankpin. If the bearing is fitted to the minimum diameter and the crankpin is excessively out-of-round, interference between the bearing and the crankpin will result in rapid bearing failure.

3. Install the connecting rod cap (82) with the lower bearing insert (87). Be sure the numbers on the connecting rod (81) and connecting rod cap align. • Apply molybdenum disulfide grease to the threads of the bolts (83). 4. Install the Bolts (83). Tighten • Bolts (83) to 1st stage 39 N·m (29 lb·ft), 2nd stage 60 degrees and 3rd stage 30 degrees. 5. Remove the bolts (83). 6. Remove the connecting rod cap (82). • The gaging plastic will be found sticking either to the crankpin or lower bearing insert (87). Do not remove it at this time.

6A6-20

Figure 57. Liner and Piston Grade Marking A. Measure Widest Point of Gaging Plastic With Graduated Scale Figure 69. Measuring the Gaging Plastic • Gaging plastic at its widest point, using the scale at the gaging plastic envelope (figure 69). • If the clearance exceeds specifications, select a new, correct size connecting rod bearing and remeasure the clearance. Connecting Rod Bearing Selection Table

Method 1 The cylinder block deck has been marked during production to indicate both the correct liner and piston sizes. The liner grade (i.e. 1, 2, 3) is indicated in permanent ink (figure 57) . The piston grade is indicated (i.e. A, B, C, D) by a metal stamping. This information is for reference to select the piston service grades. In the case of a questionable liner marking use the next method for correct liner selection.

Conbination of Bearing Grades Connecting rod Grade A B

Bearing Grade Green Yellow

Connecting Rod Grade A B

Oil Clearance mm(in) 0.036–0.077 (0.0014–0.0030) 0.036–0.077 (0.0014–0.0030) Measurement mm(in) 77.985–77.992 (3.0703-3.0705) 77.993–78.000 (3.0706-3.0709)

• Do not attempt to use shims or file the bearing to obtain the needed clearance. • If clearance cannot be brought to within specifications, replace the crankshaft. The crankshaft cannot be reground. Undersize bearings are not available. • Remove the gaging plastic. Piston and Liner Grade Selection The cylinder inner diameter grade and the piston service grade are supplied two grades. The service grade AX for the production grade A and B, and the service grade CX for the production grade C and D. There are two methods by whitch liners can be selected.

Figure 58. Measuring the Cylinder Bore Method 2 In order to select the correct liner for each cylinder bore, six measurements must be taken(figure 58). These measurements are then averaged as follows: Diameter Average =

1+2+3+4+5+6 6

6A6-21 Cylinder Liner and Piston Service Grade Production grade

Cylinder liner innner diameter mm (in)

Service grade

Piston outer diameter mm (in)

Liner to piston clearance mm (in)

A and B

110.066 – 110.075 (4.3333 – 4.3337)

AX

109.944 – 109.959 (4.3285 – 4.3291)

0.107 – 0.131 (0.0042 – 0.0052)

C and D

110.076 – 110.085 (4.3337 – 4.3340)

CX

109.960 – 109.975 (4.3291 – 4.3297)

0.101 – 0.125 (0.0040 – 0.0049)

Assemble and Install or Connect (Figures 46, 48, 49, and 64-70) • Heat the piston (80) in an oven, if necessary, to ease insertion of the piston pin (84). 1. Piston (80) to the connecting rod (81). Align the piston and connecting rod as shown in figure 64. • Lubricate the piston pin (84) with engine oil. 2. Piston pin (84). 3. Snap rings (79). Rotate the snap rings in their grooves to be sure they are fully seated.

4. Oil control ring expander to the piston (80). 5. Oil control ring (78). Use a ring installing tool (figure 48). 6. Compression 3rd ring (77). Use a ring installing tool. 7. Compression 2nd ring (76). Use a ring installing tool. 8. Compression 1st ring (75). Use a ring installing tool. The marked 1st ring has 1N, 2nd and 3rd rings have N) face of the ring must face up (figure 65). • Locate the ring end gaps as shown in figure 66. Marked Side Up 75 76 77 78

75. 76. 77. 78. A. B. 80. 81. 82.

“Front” Mark Emboss dots Piston Connecting Rod Connecting Rod Cap

Figure 64. Aligning the Piston and Connecting Rod

Compression 1st Ring Compression 2nd Ring Compression 3rd Ring Oil Control Ring Figure 65. Installing the Piston Rings

6A6-22 75

76 78 FRONT MARK

77 B

75. 76. 77. 78. A. B.

B

A

Compression 1st Ring Compression 2nd Ring Compression 3rd Ring Oil Control Ring Oil Ring Expander 45 degrees

Figure 66. Piston Ring End Gap Locations 9. Upper connecting rod bearing insert (86) to the connecting rod (81) (Figure 46). 10. Lower connecting rod bearing insert (87) to the connecting rod cap (82). 11. Piston (80) and connecting rod (81) assembly to the proper liner. • Lubricate the piston (80) and connecting rod bearing with engine oil. • Without disturbing the ring end gap locations, install the piston ring compressor tool over the piston. • Push the piston into place (figure 67). Make the “front” marks face the front of the engine, as shown.

80. A. B. C.

Piston “Front” Mark Front of Engine Piston Ring Compressor Figure 67. Installing the Piston

12. Connecting rod cap (82) with the lower bearing insert to the connecting rod (81). The numbers on the connecting rod and connecting rod cap must align (figure 47). • Apply molybdenum disulfide grease to the threads of the connecting rod cap bolts (83). 13. Bolts (83). Tighten • Bolts (83) in three stages, as follows: • Stage 1: Tighten both bolts to 39 N·m (29 lb·ft). • Stage 2: Refer to figure 70. Make a punch mark on the bolt heads, as shown. Then make a second punch mark on the connecting rod cap, 60 degrees clockwise from the first mark. Tighten both bolts 60 degrees (until the punch marks align). • Stage 3: Make a punch mark on the bolt heads, as shown. Then make a second punch mark on the connecting rod cap 30 ° degrees clockwise from the first mark. Tighten both bolts 30 degrees.

6A6-23

93

91

90

90. Vibration Damper 91. Pulley 93. Bolt Figure 71. Crankshaft Damper and Pulley Install or Connect (Figure 71)

A. Reference Punch Mark on Bolt B. Reference Punch Mark on Connecting Rod Cap Figure 70. Anglar tightening Method for Connecting Rod Bolts

14. Oil jet to 21 N·m (15 lb·ft). 15. Oil strainer with o-ring to 31 N·m (23 lb·ft). 16. Oil level gauge tube with dip stick 17. Cylinder head assembly refer to the cylinder head replacement. • Engine refer to the engine replacement (SEC. 6A).

VIBRATION DAMPER REPLACEMENT Remove or Disconnect (Figure 71) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Three stay for fan shroud. 2. Cooling fan (2) (figure 4, SEC. 6B3). 3. Loosen the generator adjusting plate bolt and remove the drive belts. 4. Loosen the A/C compressor drive belt tensioner and remove the drive belt. Refer to AIR CONDITIONING (SEC. 1B). 5. Damper bolts (93). 6. Vibration damper (90).

1. Vibration damper (90). 2. Lubricate the bolt (93) threads with engine oil. 3. Bolts (93). Tighten • Bolts (93) to 200 N·m (147 lb·ft). 4. Routine the drive belts. 5. Adjust the generator drive belts to push the belt 8 - 12 mm (0.3150 - 0.4724in) with 98 N·m (22 lb·ft). 6. Adjust the A/C compressor drive belt tensioner to push the belt 16 - 20 mm (0.6300 - 0.7874 in) with 98 N·m (22 lb·ft). 7. Cooling fan (2) (figure 4, SEC. 6B3). 8. Stay for fan shroud (figure 1, SEC. 6B2). • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

6A6-24 ISUZU ENGINE TIMING GEAR REPLACEMENT

161. 162. 160. 163. 63. 174. 159.

Camshaft bearing cap Camshaft bearing upper Camshaft assembly Camshaft bearing lower Cylinder head gasket Camshaft Oil pipe

171. Clutch pressure plate assembly 172. Driven plate 164. Injection pump assembly 173. Flywheel 134. Oil pan

Figure 79. Timing Gear Replacement

167. Power steering pump idle gear cover 166. Power steering pump idle gear 165. Flywheel housing 168. Idle gear A 169. Idle gear B 170. Idle gear B shaft

ISUZU ENGINE 6A6-25 Befor removal the timing gears, measure the following items 1. Idle gear backlash measurement. Measure (Figure 86a) 1-1. Set a dial indicator to the timing gear to be measured. Hold both the gear to be checked and the adjoining gear stationary. 1-2. Move the gear to be checked right and left as far as possible. Take the dial indicator reading. Timing Gear Backlash Gear to Gear: Standard: 0.10—0.17 mm (0.0039—0.0067 in) Limit: 0.30 mm (0.012 in)

Figure 86b. Idler Gear End Play Remove or Disconnect Preparation • Engine refer to the engine replacement (SEC. 6A). 1. Injection nozzle cover. 2. Front exhaust pipe. 3. Cylinder head cover refer tot the cylinder head cover replacement. 4. Rocker arm shaft assembly refer to the valve train and component replacement. 5. Camshaft assembly(174) refer to the camshaft replacement.

Figure 86a. Timing Gear Backlash Measurement 2. Idler Gear End Play Measure (Figure 86b) Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end play. If the measured value exceeds the specified limit, the thrust collar must be replaced. Idler Gear End Play: Standard: 0.058—0.115 mm (0.002—0.005 in) Limit: 0.2 mm (0.008 in)

Figure 80. Camshaft 6. Clutch assembly for M/T(170, 171) refer to the Section 7C. 7. Flywheel for M/T(169) or Flywheel and flexible plate(172) for A/T.

6A6-26 ISUZU ENGINE 13. Power steering idle gear bolt with thrust collar. 14. Power steering pump idle gear.

Figure 84a. Flywheel (M/T) & (A/T) 8. Oil pipe (159). 9. Engine control wires.

Figure 85. Power Steering Pump Gear 15. Oil pan (134) refer to the oil pan replacement. 16. RH and LH stiffeners. 17. Rubber spacer. 18. Flywheel housing (165) refer to the flywheel housing replacement. 19. Rear oil seal slinger. 20. Oil seal refer to the rear oil seal replacement. 21. Idle gear A fixing bolt with thrust collar. 22. Idle gear A. 23. Idle gear B fixing bolt with thrust collar. 24. Idle gear B. 25. Idle gear B shaft fixing three bolts with idle gear B shaft.

Figure 83. Engine Control Wires 10. Injection pump assembly(164).

Figure 86. Idle Gear Inspection and Repair 1. Idler Gear Shart Outside Diameter Measure (Figure 87) Figure 83a. Injection Pump Assembly 11. Power steering pump from front side of flywheel housing. 12. Power steering pump idle gear cover from flywheel housing.

Use a micrometer to measure the idler gear shaft outside diameter. If the measured value is less than the specified limit, the idler gear must be replaced.

ISUZU ENGINE 6A6-27 Idler Gear Shaft (A, B) Outside Diameter: Standard: 29.959—29.980 mm (1.1795—1.1803 in) Limit: 29.80 mm (1.1732 in)

Install or Connect 1. Idle gear B shaft with bolts to cylinder block. Tighten bolts to 31 N·m (23 Ib·ft). Apply the engine oil to the idle gear shaft after installation.

Figure 87. Idler Gear Shaft Outside Diameter Idler Gear (A, B) Inside Diameter Measure (Figure 87a) Use an inside dial indicator or an inside micrometer to measure the idler gear inside diameter.

Figure 88. Idler Gear B Sahft 2. Idle gear B. 3. Idle gear B fixing bolt with thrust collar. Tighten bolt to 110 N·m (81 lb·ft)

Idler Gear Inside Diameter: Standard: 30.000—30.021 mm (1.1811—1.1819 in) Limit: 30.100 mm (1.1850 in) If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the limit, the idler gear must be replaced. Idler Gear Shaft and Idler Gear Clearance: Standard: 0.020—0.062 mm(0.0008—0.0024 in) Limit: 0.200 mm (0.0079 in) Figure 88a. Idle Gear B 4. Turn crankshaft to align No1 piston at TDC. 5. Idle gear A shaft to cylinder block. 6. Idle gear A. Align the crankshaft gear with the engagement mark of the idle gear and install the idle gear A. (Figure 88b) 7. Idle gear A fixing bolt with thrust collar. Tighten bolt 133 N·m (98 lb·ft).

Figure 87a. Idler Gear Inside Diameter

6A6-28 ISUZU ENGINE

Figure 88b. Timing Gear Alignment 8. Flywheel housing refer to the flywheel housing replacement. 9. Crankshaft rear oil seal refer to the crankshaft rear oil seal replacement. 10. RH and LH stiffeners refer to the flywheel housing replacement. 12. Oil pan refer to the oil pan replacement. 13. Power steering idle gear with collar and bolt. Tighten bolt to 133 N·m (98 lb·ft).

Figure 89d. Power Steering Pump Idle Gear and Shaft

14. Power steering idle gear cover to flywheel housing. Tighten bolt to 19 N·m (14 l b·ft)

Figure 89c. Power Steering Pump Idle Gear

Figure 89e. Power Steering Pump Cover

ISUZU ENGINE 6A6-29 15. Injection pump assembly refer to the injection pump replacement.

Figure 83a. Injection Pump Assembly 16. Engine control wire. 17. Oil pipe. 18. Flywheel for M/T or flywheel and flexible plate for A/T refer to the flywheel replacement.

Figure 84a. Flywheel (M/T) & (A/T) 19. Clutch assembly for M/T refer to the Section 7C. 20. Camshaft assembly(174) refer to the camshaft replacement. 21. Rocker arm shaft assembly refer to the valve train and component replacement. 22. Cylinder head cover refer tot the cylinder head cover replacement. 23. Front exhaust pipe. 24. Injection nozzle pipe cover. 25. Charged air pipe and hose to turbocharger. 26. Charged air pipe and hose to intake manifold. 27. Fill coolant and engine oil. • Engine refer to the engine replacement (SEC. 6A).

6A6-30 ISUZU ENGINE CAMSHAFT REPLACEMENT

174. 175. 176. 177. 179.

Camshaft Washer Camshaft Gear Bolt Key

Remove or Disconnect • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Injection nozzle cover. 2. EGR pipe between exhaust manifold and EGR valve. 3. cylinder head cover refer to the cylinder head cover replacement. 4. Before remove the rocker shaft assembly and camshaft assembly measure the camshaft end play. Use a thickness gauge to measure the end play between the camshaft gear and the camshaft bracket. If the measured value exceeds the service limit, the camshaft gear or camshaft must be replaced. The production end play is 0.085 - 0.205 mm (0.0033 - 0.0081 in), the service limit is 0.25 mm (0.0098 in)

6A17-1.tif

5. Rocker arm shaft assembly refer to the valve train and component replacement. 6. Camshaft bracket bolt and bracket. 7. Camshaft with camshaft gear. 8. Camshaft fixing bolt. 9. Separate the camshaft and camshaft gear. 10. Sealing cap. 11. Idle gear C fixing bolt with thrust collar. 12. Idle gear C shaft. 13. Idle gear C. Inspection and Repair Inspect — Camshaft (174) lobes and bearing journals for pitting, galling, or scratches. — Camshaft gear (176) for chipped or broken teeth.

ISUZU ENGINE 6A6-31 Measure 1. Camshaft (174) runout (Figure 87f). Replace the camshaft if the runout is more than 0.05 mm (0.002 in). 2. Camshaft (174) journal diameter using a micrometer (Figure 87c). Measure in two places, as shown. The production diameter is 39.950—39.975 mm (1.5728—1.5738 in). The service limit is 39.850 mm (1.569 in).

Figure 87f. Measuring Camshaft Runout

174. Camshaft A. Camshaft Journal B. Camshaft Lobe Figure 87c. Measuring the Camshaft Journal 3. Camshaft bearing inside diameter (Figure 87e). The correct measurement is 40.000—40.037 mm (1.5748—1.5763 in). 4. Camshaft (174) journal to camshaft bearing clearance. • Subtract the camshaft journal diameter from the camshaft bearing inside diameter to obtain the clearance. • The production clearance is 0.025—0.087 mm (0.0010—0.0034 in). The service limit is 0.15 mm (0.006 in).

Figure 87e. Measuring the Camshaft Bearing Inside Diameter

6A6-32 ISUZU ENGINE 5. Cam height. Measure the cam height “A” with a micrometer. If the measured value is less than 53.6 mm (2.110) in), the camshaft must be replaced.

174. Camshaft Figure 87d. Measuring Camshaft Lobe Lift Install or Connect 1. Idle gear C with oil groove face to cylinder head.

2. Apply engine oil to idle gear C shaft and install to cylinder head. 3. Idle gear C fixing bolt with thrust collar. Tighten bolt to 95 N·m (70 lb·ft). 4. Apply loctite to sealing cap and install to cylinder head as shown in the illustration.

5. Install the camshaft gear with align the key groove of the camshaft gear to the camshaft dowel pin on the camshaft. 6. Camshaft gear fixing bolt with washer to 142 N.m (105 lb·ft). 7. Camshaft bearing lower to the cylinder head. 8. Camshaft assembly. 8-1. Turn the crankshaft in the direction of normal rotation until the timing mark on the crankshaft damper pulley is aligned with the TDC notched line. 8-2. Apply engine oil to the camshaft journal and the camshaft bearing surfaces before installation. 8-3. Carefully align the camshaft gear "I" mark and the cylinder head upper face shown in the illustration.

ISUZU ENGINE 6A6-33 10. Rocker arm shaft assembly refer to the valve train and component replacement. Caution: Take sufficient care not to let valve caps fall into the gear.

Figure 98. Camshaft Gear Alignment Mark 9. Camshaft bracket with upper bearing. Install • Install the bracket with the bracket head mark (arrow) facing forward. • Apply a coat of engine oil to the bracket bolt and stud threads.

Figure 100. Valve Cap 11. Adjust the valve clearance refer to the valve adjustment in maintenance. Valve Clearance: At cold: 0.4 mm (0.016 in)

Figure 98a. Camshaft Bearing Upper Tighten • Tighten the bracket bolts to the specified torque. (Figure 99) Tighten bracket bolt to 27 N·m (20 lb·ft).

Figure 103. Valve Clearance 12. Cylinder head cover refer to the cylinder head cover replacement. 13. EGR pipe. 14. Injection nozzle cover. • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

Figure 99. Camshaft Bracket Bolts

6A6-34 ISUZU ENGINE FLYWHEEL HOUSING REPLACEMENT Tool required J-43285 Slinger puller Remove or Disconnect

Install or Connect 1. Apply the recommended liquid gasket (Three Bond 1141E) or its equivalent to the shaded areas shown in the illustration.

• Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Transmission (M/T or A/M). 2. EGR pipe. 3. Power steering pump. 4. Oil pipe with oil pipe clamps. 5. Breather hose from C/box with clamp. 6. RH and LH stiffeners. 7. Insulater from lower portion of the flywheel housing. 8. Oil pan refer to the oil pan replacement. 9. Flywheel refer to the flywheel replacement. 10. Power steering pump idle gear cover. 11. Power steering pump idle gear. 12. Set J-43285 Slinger puller to remove the crankshaft rear oil seal.

Figure 89. Smearing Area for Liquid Gasket 2. Align the cylinder body knock pins with the flywheel housing knock pin holes. Tighten Tighten the flywheel housing bolts to the specified torque shown in the illustration. Flywheel Housing Bolt Torque (Figure 89a) : : : : :

96 48 48 48 38

N·m N·m N·m N·m N·m

(71 (35 (35 (35 (28

Ib·ft) Ib·ft) Ib·ft) Ib·ft) Ib·ft)

• Tighten the bolts marked with “ ” or “ ” from the injection pump side, and those with “ ” from the cylinder body side. 13. Flywheel housing fixing bolts. 14. Flywheel housing. Inspection and Repa ir 1. Visual check for damage on the flywheel housing. 2. Replace the flywheel housing, if find any damage. Clean 1. Carefully wipe any foreign material from the cylinder body rear face. 2. Liquid gasket from flywheel housing. Figure 89a. Flywheel Housing Bolts

ISUZU ENGINE 6A6-35 4. Power Steering Pump Idle Gear (Figure 89c, 89d) 1) Apply the engine oil to the idle gear shaft. 2) Install the idle gear shaft 1 with the idle gear 2 to the cylinder body A portion as shown in the illustration.

Figure 89e. Power Steering Pump Cover 6. Oil Pan. 1) Apply a 3 mm (0.1 inch) bead of recommended liquid gasket (Three Bond 1207C) or its equivalent to the shaded areas shown in the illustration. Figure 89d. Power Steering Pump Idle Gear and Shaft

Figure 89c. Power Steering Pump Idle Gear Tighten Idle Gear Shaft Bolt Torque: 133 N·m (98 lb·ft) 5. Power steering Pump Idle Gear Cover (167) (Figure 89e) Install the gear cover with the O-ring. Tighten Gear Cover Bolt Torque: 19 N·m (14 lb·ft) Tighten oil pan bolts and nuts to the specified torque in the numerical order. “ ” marks are located on nut positions. Oil pan bolts and nuts torque. 24 N·m (17 lb·ft) for numerical order 1 - 22 and numerical order 24 - 26. 18 N·m (13 lb·ft) for numerical order 23.

6A6-36 ISUZU ENGINE

020LY00001

7. Insulator Use stiffener bolt to tighten together with the stiffener.

020LY00007

8. Stiffener LH. Tighten stiffener fixing bolts to 128 N.m (93 lb·ft) for star mark and 76 N·m (56 lb·ft) for circle mark.

020LY00002

9. Stiffener RH. Tighten stiffener fixing bolts to 48 N·m (35 lb·ft) for black triangle mark and 76 N·m (56 lb·ft) for square mark.

10. Crankshaft rear oil seal refer to the crankshaft rear oil seal replacement. 11. Flywheel refer to the flywheel replacement. 12. Breather hose with clamp to flywheel housing. 13. Oil pipe with pipe clamps. 14. Power steering pump refer to the power steering pump replacement. 15. EGR pipe with gaskets. Tighten three bolts and two nuts. 24 N·m (17 lb·ft) for bolt and 28 N·m (21 lb·ft) for nut. EGR pipe clamp bolt to 24 N·m (17 lb·ft). 16. Transmission. • Install the rear floor engine cover and rear engine cover assembly. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

ISUZU ENGINE 6A6-37 CRANKSHAFT FRONT OIL SEAL REPLACEMENT Tool required J-43285 Slinger puller J-43282 Oil seal setting tool kit Oil Seal Setting Tool Kit Applicable Part Name

Stamp

Slinger

Oil Seal

?

?

Front-use adapter

FT

Rear-use adapter

RR

Front-use slinger sleeve

FT

Rear-use slinger sleeve

RR

Front-use oil seal sleeve

FT

Rear-use oil seal sleeve

RR

?

Center bolt

—

?

?

Adapter bolt

—

Collar

RR

? ?

? ?

?

6A3-87-3.tif

13. Crankshaft front oil seal. Caution: Be careful not to damage the crankshaft front oil seal contact surface during the removal procedure.

Preparation • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. • Drain the coolant. • Drain the engine oil. Remove or Disconnect 1. Under cover (M/T model) 2. Starter 3. Radiator upper hose 4. Coolant reserve tank hose or bypass hose. 5. Radiator lower hose 6. Charge air hose at charger air cooler both from turbocharger and intake manifold. 7. Fan guide bracket at top of engine front and lower of engine front. 8. Radiator (with fan guide) 9. Loosen generator adjust plate bolt and A/C compressor belt tensioner. 10. Fan belts. 11. Fan assembly. 12. Damper pulley. 12-1. Use suitable crankshaft stopper to prevent turning the crankshaft 12-2. Remove the damper pulley bolts.

6A3-87-4.tif

14. Slinger. Use J-43285 slinger puller to pull out slinger.

6A3-88-1.tif

6A6-38 ISUZU ENGINE Install or Connect Note: Be sure to replace the slinger and oil seal as a set. 1. Slinger Press in the slinger using oil seal setting tool kit 1-1. Insert the slinger 1 onto the end of adapter 2 and install the adapter on the crankshaft front.

6A3-89-1.tif

6A3-88-2.tif

1-2. Cover the sleeve 3 and tighten the bolt until the sleeve comes to contact the adapter stopper.

6A3-88-3.tif

2. Crankshaft front oil seal Press in the oil seal using the front oil seal setting tool kit. 2-1. Apply engine oil to the lip of the oil seal. 2-2. Remove the slinger sleeve and insert the oil seal 5 onto the adapter 2. 2-3. Install the oil seal sleeve 6 and tighten the center bolt until the sleeve comes to contact the adapter stopper 7. 2-4. Remove the oil seal setting tool. 2-5. Make sure of the measurements specified value in the illustration. Specified value from front end of crankshaft. C = 31 ±0.3 mm (1.2205 ±0.0118 in)

6A3-89-3.tif

1-3. Make sure of measurements specified value as well as of slinger deflection. Specified value from front end of crankshaft. A = 40.5 ±0.3 mm (1.5945 ±0.0118 in) B = 34 ±0.1 mm (1.3386 ±0.0039 in)

6A3-89-2.tif

ISUZU ENGINE 6A6-39 3. Damper pulley Apply engine oil to thread and seat of damper pulley bolt. Tighten damper pulley bolt to 100 N.m (148 lb·ft) Remove the crankshaft stopper.

• Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

OIL COOLER REPLACEMENT Remove or Disconnect • Engine refer to the engine replacement (SEC. 6A). 1. Vacuum Hose 2. Oil Level Guide Tube Remove the guide tube fixing bolt and pull out the guide tube. 3. Intake Air Duct 4. Engine Stop Cable Loosen the locking nut at the bracket and disconnect engine stop cable from injection pump stop lever.

6A3-89-4.tif

4. Fan assembly. Tighten fan assembly fixing bolts to 24 N.m (17 lb·ft). 5. Routing the fan belts 6. Adjust the belt tension to 8 - 12 mm (0.3150 0.4724 in) for new belt and 10 - 14 mm (0.3937 - 0.5512 in) for reuses belt when apply 98 N (22 lb).

6A3-62-1.tif

5. Accelerator Control Cable Loosen the locking nut at the bracket and disconnect accelerator control cable from injection pump control lever.

6A3-89-5.tif

7. Radiator (with fan guide). Tighten radiator mounting bolt to 76 N.m (56 lb·ft). 8. Fan guide bracket at top of engine front and lower of engine front. 9. Charge air hose at charger air cooler both to turbocharger and intake manifold. 10. Radiator lower hose 11. Coolant reserve tank hose or bypass hose. 12. Radiator upper hose 13. Starter 14. Under cover (M/T model) • Install the rear floor engine cover and rear engine cover assembly.

6A3-62-3.tif

6. Engine Control Cable 7. Engine Control Lever

6A6-40 ISUZU ENGINE

6A3-63-1.tif

8. Oil Pipe 9. Fuel Return Hose 10. Fuel Feed Hose Disconnect fuel hose from injection pump side and take care not to spill and enter dust. 11. Nozzle Cover 12. Leak Off Pipe 13. Fuel Pipe 14. Positive Crankcase Ventilation (PCV) Hose 15. Water Bypass Hose 16. Injection Pipe 17. Injection pump Assembly Above works refer to “Section 6C Fuel System” in this manual. 18. Injection Pump Rubber Spacer 19. Air Conditioning (A/C) Drive Belt (If equipped with A/C) 20. Idle Pulley Bracket (If equipped with A/C) After removal of the A/C drive belt, remove the three bracket fixing bolts. Then, remove the bracket with the tensioner and the idler attached.

6A3-65-1.tif

25. Oil Cooler Assembly 1) Remove the oil cooler bolts. 2) Install a oil cooler fixing bolt to the oil cooler replace hole as shown in the illustration, and tighten the bolt alternately a little at a time. 26. O-Ring

4HE1-TC

050LY00003

Disassemble 1. Element fixing bolts 2. Element 3. O-Ring

6A3-63-2.tif

21. Heater Hose 22. Radiator Lower Hose 23. Heater Pipe 24. Water Suction Pipe

6A3-64-1.tif

ISUZU ENGINE 6A6-41 Reassemble 1. O-Ring Apply a coat of engine oil to the O-rings and install to the oil cooler. 2. Element 3. Element fixing bolts to 20 N·m (14 lb·ft).

3. Water Suction Pipe 3-1. Apply 2mm-3mm bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the groove of the water suction pipe fitting surface.

Install or Connect 1. O-Ring 2. Oil Cooler Assembly 2-1. Apply 2mm-3mm (0.08-0.1 in) bead of the recommended liquid gasket (Three Bond 1207C) or its equivalent on the oil cooler fitting surface. 2-2. Apply a coat of engine oil to the O-rings (2 pieces) and install the O-rings to the oil cooler. NOTE: Take care that the O-ring is not smeared with liquid gasket. • Install the oil cooler within 7 minutes after application of liquid gasket.

6A3-64-5.tif

3-2. Install the water suction pipe to the oil cooler. Tighten fixing bolts to 24 N·m (17 lb·ft). NOTE: Install the water suction pipe immediately after the installation of the oil cooler for prevent into foreign material.

6A3-64-3.tif

2-3. Tighten the oil cooler bolts and nut to the specified torque a little at a time in the sequence shown in the illustration. Tighten the oil cooler bolts and nut to 24 N·m (17 lb·ft).

13

9

4

1

5

10

6A3-65-1.tif

4. Heater Pipe 4-1. Install the O-ring to the heater pipe. 4-2. Install the heater pipe to the oil cooler.

14

12

15 16 8 7

3

2

6

11

17

050LY00002

6A6-65-2.tif

6A6-42 ISUZU ENGINE 5. Radiator Lower Hose 6. Heater Hose 7. Idle Pulley Bracket (If equipped with A/C) Tighten bracket bolt to 48 N·m (35 lb·ft).

23. Accelerator Control Cable 23-1. Check to see if the idling control knob is turned to the utmost limit to the left. 23-2. Install the end tip of the cable to the engine control lever. 23-3. With the outer cable pulled toward the front of the vehicle, provide the engine control wire and the inner cable with the appropriate play. Then, fasten the clamp with a nut. 23-4. Check to see if the control lever of the injection pump is set at the idling positio (with the lever attached to the stopper bolt). NOTE: Refer TPS re-learning procedure on page 6C3–17. 6A3-65-4.tif

8. Adjust the drive belt tension to 8-12 mm (0.3150-0.4724 in) for new belt and 10-14 mm (0.3937-0.5512 in) for reuses belt when apply 98N (22 lb). For A/C compressor drive belt to 16-20 mm (0.6300-0.7874 in) for new belt and 18-22 mm (0.7087-0.8661 in) for reuses belt when apply 98 N (22 lb). Tighten Locking nut to 27 N·m (20 lb·ft). 9. Injection Pump Rubber Spacer 10. Injection Pump Assembly 11. Injection Pipe 12. Water Bypass Hose 13. Positive Crankcase Ventilation (PCV) Hose 14. Fuel Pipe 15. Leak Off Pipe 16. Nozzle Cover 17. Fuel Feed Hose 18. Fuel Return Hose 19. Air Bleeding Above works refer to “Section 6C Fuel System” in this manual. 20. Oil Pipe 21. Engine Control Lever Assembly 22. Engine Control Cable

6A3-67-2.tif

24. Engine Stop Cable 24-1. Install the end tip of the cable to the engine stop lever. 24-2. Pull the cable toward the rear of the vehicle, and fasten the clamp with a nut at the position where the lever stops.

6A3-67-4.tif

25. Intake Air Duct 26. Oil Lever Gauge Guide Tube 26-1. Install the O-rings to the guide tube lower portion and insert the guide tube completely to the cylinder body.

ISUZU ENGINE 6A6-43 26-2. Tighten the guide tube bolt to 13 N·m (9.4 lb·ft). 27. Vacuum Hose • Pour coolant into radiator. • Connect battery ground cable. • Check engine oil level. • Start engine and check for oil and water leakage carefully. • Engine refer to the engine replacement (SEC. 6A).

COOLING SYSTEM 6B1-1

SECTION 6B1

COOLING SYSTEM NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Cooling System................................................................................................SEE 1999-2001 SERVICE MANUAL Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL Engine Coolant Recommendations ...........................................................SEE 1999-2001 SERVICE MANUAL Corrosion Prevention ..................................................................................SEE 1999-2001 SERVICE MANUAL Diagnosis of Cooling System .........................................................................SEE 1999-2001 SERVICE MANUAL Operations and Maintenance..........................................................................SEE 1999-2001 SERVICE MANUAL Cooling System Checks ..............................................................................SEE 1999-2001 SERVICE MANUAL Cooling System Pressure Check................................................................SEE 1999-2001 SERVICE MANUAL Radiator Maintenance..................................................................................SEE 1999-2001 SERVICE MANUAL Draining and Filling the Cooling System ...................................................SEE 1999-2001 SERVICE MANUAL Cleaning the Cooling System .....................................................................SEE 1999-2001 SERVICE MANUAL Flushing the Cooling System .....................................................................SEE 1999-2001 SERVICE MANUAL Cold-Weather Operation..............................................................................SEE 1999-2001 SERVICE MANUAL On-Vehicle Service: Cooling System Components .......................................................................................6B1-2 Engine Thermostat ......................................................................................................................................6B1-2 Engine Oil Cooler..........................................................................................................................................6B1-3 Water Pump Replacement............................................................................................................................6B1-5 Water Pump Unit Repair ..............................................................................SEE 1999-2001 SERVICE MANUAL Engine Warming-up System ...........................................................................SEE 1999-2001 SERVICE MANUAL Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL Thermostat ...................................................................................................SEE 1999-2001 SERVICE MANUAL Fastener Torques.........................................................................................SEE 1999-2001 SERVICE MANUAL Special Tools....................................................................................................SEE 1999-2001 SERVICE MANUAL

6B1-2 COOLING SYSTEM

ON-VEHICLE SERVICE: COOLING SYSTEM COMPONENTS ENGINE THERMOSTAT 1

The thermostat consists of a restriction valve controlled by a thermostatic element. The restriction valve starts to open at a predetermined temperature and continues to open as the engine coolant temperature increases. To assure proper cooling and engine warm up, it is important that the correct thermostat be used.

2

Thermostat Replacement Remove or Disconnect (Figure 3) • Disconnect the battery negative cable.

4

1. Partially drain the radiator. 2. Hose at thermostal cover to turbocharger. 3. Thermo sensor connecter. 4. Thermostat bolts (1) from the thermostat cover (2). 5. Thermostats (3). Inspect The thermostat to be sure it’s in good condition. The following test should be done: Suspend the thermostat (3) and thermometer (6) in water with the thermometer located close to the thermostat. Be sure the thermostat is placed on the wood piece (8) inside the flask. Agitate the water with a small rod. Apply heat (7) to the water and record both the temperature at which the thermostat begins to open and the temperature at which the thermostat is fully opened (figure 4). Compare temperature readings taken in the test. The valve opening temperature should be about 82~85°C (180~185°F). The full open temperature should be about 95~100°C (203~212°F). For details, refer to ‘‘Specifications’’ at the end of this section.

3

3b 3a

1. Bolt 2. Thermostat Cover 3a. Thermostat with dual valves 3b. Thermostat with single valve 4. O-Ring Figure 3. Thermostat Components

COOLING SYSTEM 6B1-3 ENGINE OIL COOLER Oil is circulated through the radiator oil cooler, through the oil filter, and into the engine main oil passage. If engine difficulties are encountered, or the engine has stopped, foreign material may have entered the oil cooler. The oil cooler, connecting lines, and filter adapter assembly must be flushed before the engine is put back into operation. The oil cooler should be flushed in the following manner. 1. Remove oil cooler from the engine as outline in “Oil Cooler Replacement” later in this section. 2. Back-flush oil cooler and lines using clean solvent and compressed air. Important • Do not exceed 690 kPa (100 psi) air pressure. 3. 6. 7. 8. 9.

Thermostat Thermometer Heat Wood Piece Rod Figure 4. Testing the Thermostat Important

• Do not attempt to repair the thermostat. If the thermostat does not function properly, replace with a new unit which has been checked as described previously. Install or Connect (Figure 3) 1. Thermostats (3). 2. Thermostat cover (2). NOTICE: See “NOTICE” on page 6B1-1 of this section. 3. Bolts (1). Tighten • Bolts to 24 N·m (17 lb·ft). 4. Thermo sensor connecter. 5. Hose at thermostat cover to turbocharger. 6. Upper radiator hose. 7. Fill the cooling system and run the engine. Check for engine coolant leaks at thermostat housing and at cover gasket. • Connect the battery negative cable.

3. Remove all remaining cleaning solvent from the system with compressed air. 4. Flush the system again, this time with engine oil. 5. Remove the filter adapter from the engine and clean the adapter in solvent. Dry with compressed air and flush thoroughly with engine oil. 6. Remove the gasket from the engine block and inspect the seal (0-ring) on the adapter for damage or distortion. Install a new gasket in the engine block cavity and a new seal on the adapter if needed. 7. Install adapter screws and a new oil filter. 8. Test the flow of oil through the cooler before connecting the oil lines. If the flow is not restricted, connect the oil lines to the adapter. If the flow is restricted, replace the radiator. 9. Start the engine and check for leaks.

Oil Cooler Replacement (Figures 5 and 6) • Engine refer to the engine replacement (Section 6A). 1. Intake air duct (310) (figure 11, SEC. 6A6). 2. Accelerator cable injection pump side. 3. Remove the injection pump assembly. Refer to DIESEL FUEL INJECTION (SEC. 6C3) in this manual. 4. Oil cooler oil pipe. 5. Remove the oil cooler mounting bolts (14). 6. Remove the oil cooler element (10) and oil cooler housing (15).

6B1-4 COOLING SYSTEM

10. Element 14. Oil Cooler Mounting Bolts 15. Oil Cooler Housing Figure 5. Oil Cooler Assembly 7. Clean the all parts. NOTICE: For steps 2, see “NOTICE” on page 6B1-1 of this section. 8. Install the oil cooler element (10) to oil cooler housing (15) using new gaskets. 9. Install the oil cooler mounting bolts (14). Tighten in numerical sequence as shown in figure 6. Tighten • Oil cooler mounting bolts to 24 N·m (17 lb·ft). 10. Install the injection pump assembly. Refer to DIESEL FUEL INJECTION (SEC. 6C3) in this manual. • Engine refer to engine replacement (Section 6A) • Time the engine as described in DIESEL FUEL INJECTION (SEC. 6C3) of this manual.

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9

4

1

5

10

14

12

15 16 8 7

3

2

6

11

17

050LY00002

Figure 6. Oil Cooler Mounting Bolts Tightening Sequence

COOLING SYSTEM 6B1-5 WATER PUMP REPLACEMENT

Tighten

Remove or Disconnect (Figure 7)

• Water pump bolts to 24 N·m (17 lb·ft).

• Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). 1. Drain engine coolant. 2. Stay bell-mouth upper. 3. Cooling fan (17) and fan clutch (16). 4. Generator adjusting bolt. 5. Fan drive belt (21). 6. Water pump pully. 7. Radiator lower hose (2). 8. Hose water pump to cylinder head. 9. Water pump fixing bolts. 10. Water pump.

3. Hose water pump to cylinder head. 4. Radiator lower hose (2). 5. Water pump pully. Tighten • Bolts (20) to 24 N·m (17 lb·ft). 6. Fan drive belt (21). 7. Generator adjusting bolt. • Refer to “Drive Belts” in FAN (SEC. 6B3) in this manual for adjustment procedure. 8. Fan clutch (16) and cooling fan (17).


Tighten

NOTICE: For steps 2, 4 and 6 see “NOTICE” on page 6B1-1 of this section.

• Nuts (23) to 24 N·m (17 lb·ft). 9. Stay bell-mouth upper. 10. Pour engine coolant. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

1. Water pump. 2. Pump bolts.

17

16

20

22

23

21

16. Cooling Fan Clutch 17. Cooling Fan 18. Nut 20. Bolt 21. Fan Belt 22. Spacer 23. Nut

18

Figure 7. Cooling System Components

RADIATOR 6B2-1

SECTION 6B2

RADIATOR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

On-Vehicle Service .........................................................................................SEE 1999-2001 SERVICE MANUAL Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL Radiator Maintenance..................................................................................SEE 1999-2001 SERVICE MANUAL Radiator Replacement ..................................................................................................................................6B2-1 Eingine Coolant Recovery System..............................................................................................................6B2-2 Radiator Mountings .....................................................................................SEE 1999-2001 SERVICE MANUAL Stabilizer Rods .............................................................................................SEE 1999-2001 SERVICE MANUAL Shroud Replacement ....................................................................................................................................6B2-2 Pressure Cap................................................................................................SEE 1999-2001 SERVICE MANUAL Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL

RADIATOR REPLACEMENT When oil cooler lines are removed, use an approved container to catch the oil from the cooler and lines. DO NOT reuse this oil. Refill any drained reservoirs to a recommended level with clean, new fluid after radiator installation. After the radiator has been removed from the vehicle, be sure to check the mounting supports, retainers, and brackets. If any of these components are deteriorated or worn, replace them immediately. Remove or Disconnect (Figure 1) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Drain the engine coolant. 1. Lower and upper radiator hoses (1 and 2), clips or brackets attached to the radiator. 2. Heater hose bracket (3). 3. Rubber Ring (4), bell-mouth to shroud. 4. Fan shroud assembly (5). 5. Flexible hose (6, 7), inter cooler LH & RH.

6. Stay radiator support (8). 7. Inter cooler assembly (9). 8. Reserve tank hose (10). 9. Air duct panel (11). 10. Guide panel (12). 11. Mount nut and cushion rubber (13). 12. Radiator assembly (14). Install or Connect (Figure 1) 1. Radiator assembly (14). 2. Mount nut and cushion rubber (13). 3. Guide panel (12). 4. Air duct panel (11). 5. Reserve tank hose (10). 6. Inter cooler assembly (9). 7. Stay radiator support (8). 8. Flexible hose (6, 7). 9. Fan shroud assembly (5). 10. Rubber ring (4). 11. Heater hose bracket (3). 12. Lower and upper radiator hoses (1 and 2), clips or brackets that were removed. • Fill the system with new engine coolant as

6B2-2 RADIATOR described in COOLING SYSTEM (SEC. 6B1) of this manual. Then check the system for leaks. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

ENGINE COOLANT RECOVERY SYSTEM

SHROUD REPLACEMENT A radiator shroud is attached to the rear of the radiator and is designed to assist the fan in directing airflow, through the radiator core. The shroud also serves as a fan guard. Inspect

The engine coolant recovery system consists of a reserve tank, cap, brackets, and hose. The engine coolant level must be maintained between the MAX and MIN markings on the tank.

The shroud for damage or deterioration. Check for missing and loose fasteners. Replace the shroud if it is damaged. Remove or Disconnect (Figure 1) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Disconnect battery ground cables. • Partially drain the radiator. 1. Upper radiator hose (2). 2. Stay bell-mouth (figure 1). 3. Bell-mouth (figure 1). 4. Shroud fixing bolts. 5. Shroud assembly (5).

Forward

MAX

MIN Coolant Reserve Tank


901L200003

Figure 2. Reserve Tank Remove or Disconnect (Figure 2) 1. Battery ground cables. Important • Drain the reserve tank. 2. Hose and clip. 3. Reserve tank. Install or Connect (Figure 2) 1. Reserve tank. 2. Hose and clip. 3. Battery cables. Important • Fill the reserve tank with new engine coolant. Start the engine and check for leaks.

1. Shroud assembly (5). 2. Shroud fixing bolts. 3. Bell-mouth (figure 1). 4. Stay bell-mouth (figure 1). 5. Upper radiator hose (2). • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable. Important Fill the radiator with new engine coolant. Connect the battery cables. Start the engine and check for leaks.

FAN 6B3-1

SECTION 6B3

FAN NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Description .......................................................................................................SEE 1999-2001 SERVICE MANUAL Fan.................................................................................................................SEE 1999-2001 SERVICE MANUAL Automatic Fan Clutch..................................................................................SEE 1999-2001 SERVICE MANUAL Diagnosis of Automatic Fan Clutch ...............................................................SEE 1999-2001 SERVICE MANUAL On-Vehicle Service: Cooling Components .....................................................................................................6B3-2 Fan Replacement .........................................................................................................................................6B3-2 Fan Clutch Replacement .............................................................................................................................6B3-3 Fan Pulley Replacement...............................................................................................................................6B3-3 Fan Adjustment............................................................................................SEE 1999-2001 SERVICE MANUAL On-Vehicle Service: Drive Belts .....................................................................SEE 1999-2001 SERVICE MANUAL Diagnosis of Belts........................................................................................SEE 1999-2001 SERVICE MANUAL Inspection and Replacement .....................................................................SEE 1999-2001 SERVICE MANUAL Belt Tension Adjustment ............................................................................SEE 1999-2001 SERVICE MANUAL Cleaning and Storage ..................................................................................SEE 1999-2001 SERVICE MANUAL Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL Fastener Torques ......................................................................................6SEE 1999-2001 SERVICE MANUAL Special Tools....................................................................................................SEE 1999-2001 SERVICE MANUAL

6B3-2 FAN

ON-VEHICLE SERVICE: COOLING COMPONENTS FAN REPLACEMENT


CAUTION: Keep hands and clothing clear of moving fan blades. (Fan may run when the engine is off.) Blades are exposed and can cause personal injury.

2

• Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). 1. Stay bell mouth upper. 2. Nuts (5). 3. Cooling fan (2).

1

6

4

5

7

1. Cooling Fan Clutch 2. Cooling Fan 3. Bolt; Fan to Clutch 4. Fan Clutch Plate 5. Nut; Plate to Clutch 6. Bolt; Plate to Water Pump 7. Fan Belt

3

Figure 4. Cooling System Components

FAN 6B3-3 Install or Connect (Figure 4) 1. Cooling Cooling fan (2). (2). NOTICE: See “NOTICE” NOTICE” on page 6B3-1 of this section. 2. Nuts (5). Tighten • Nuts (5) to 24 N ·m (17 lb· lb · ft). 3. Stay bell mouth mouth upper. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

FAN PULLEY REPLACEMENT Remove or Disconnect (Figures 4 and 5) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). 1. Generator adjusting bolt. 2. Fan belt belt (7). (7). 3. Stay bell mouth mouth upper. upper. 4. Plate to clutch clutch nuts (5). 5. Fan and clutch clutch assembly. assembly. 6. Plate to water water pump bolts (6). (6). 7. Plate (4) and fan fan pulley (8) (figure (figure 5).

FAN CLUTCH REPLACEMENT Remove or Disconnect (Figure 4) • Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). 1. Stay bell mouth mouth upper. upper. 2. Plate to clutch clutch nuts (5). (5). 3. Fan (2) and clutch (1) assembly. 4. Fan to clutch clutch nuts (3). 5. Fan (2) from the fan clutch clutch (1).

8. Fan Pulle Pulley y 9. Wa Wate terr Pump Pump

Install or Connect (Figure 4) NOTICE: See “NOTICE” NOTICE” on page 6B3-1 of this section for steps 2 and 3. 1. Fan (2) to the fan clutch (1). 2. Fan to clutch clutch nuts (3). Tighten • Nuts (3) to 9 N· N ·m (78 lb· lb ·in). 3. Fan (2) and fan fan clutch (1) assembly. 4. Plate to clutch clutch nuts (5). (5). Tighten • Nuts (5) to 24 N ·m (17 lb· lb · ft). 5. Stay bell mouth mouth upper. upper. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

Figure 5. Fan Pulley Replacement Install or Connect (Figures 4 and 5) NOTICE: For steps 2 and 4 see “NOTICE” NOTICE” on page 6B3-1 of this section. 1. Fan pulley (8) and fan clutch plate plate (4). 2. Plate to water water pump bolts (6). (6). Tighten • Bolts (6) to 24 N· N ·m (17 lb· lb ·ft). 3. Fan and clutch clutch assembly. assembly. 4. Plate to clutch clutch nuts (5). Tighten • Nuts (5) to 24 N· N ·m (17 lb· lb ·ft).

6B3-4 6B3-4 FAN 5. Stay bell bell mouth upper. 6. Drive Drive belts (7). (7). 7. Generator adjusting bolt. • Refer to “ Belt Tension Adjustment” Adjustment” later in this section. • Install the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Connect the battery negative cable.

FUEL SYSTEM 6C1-1

SECTION 6C1

FUEL SYSTEM NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Air Cleaner Cleaner.............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................. ............................. .........................6C1...........6C1- 2 Description .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................. ............................. ....................6C1......6C1- 2 Air Filter Replacement........................ Replacement...................................... ............................ ............................ ............................ ............................ ............................. ............................. ....................6C1......6C1- 3 Air Filter Cleaning ............ .......................... ............................ ............................ ............................ ............................ ....................SEE ......SEE 1999-2001 SERVICE MANUAL Fuel Filters.......................... Filters........................................ ............................ ............................ ............................ ............................ ............................ ............................. ............................. ...........................6C .............6C11- 4 Description .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................. ............................. ....................6C1......6C1- 4 Draining the Pre-Fuel Filter....................... Filter..................................... ............................ ............................ ............................ ............................ ............................. ............................6C .............6C11- 4 Fuel Filter Replacement .............. ............................ ............................ ............................ ............................ ......................SEE ........SEE 1999-2001 SERVICE MANUAL Accelerator Linkage and Hand Throttle Throttle............... ............................. ............................ ............................S ..............SEE EE 1999-2001 SERVICE MANUAL Description .............. ............................ ............................ ............................ ............................ ............................ ............................ ...............SEE .SEE 1999-2001 SERVICE MANUAL Accelerator Linkage Linkag e Adjustment ............. ............................ ............................. ............................ .....................SEE .......SEE 1999-2001 SERVICE MANUAL Hand Throttle Adjustment ............ .......................... ............................ ............................ ............................ ....................SEE ......SEE 1999-2001 SERVICE MANUAL Adjustment of Accelerator Pedal Stopper Bolt...................................... Bolt........................................SEE ..SEE 1999-2001 SERVICE MANUAL MANUAL Engine Stop Linkage ............. ............................ ............................. ............................ ............................ ............................ .................SEE ...SEE 1999-2001 SERVICE MANUAL Description .............. ............................ ............................ ............................ ............................ ............................ ............................ ...............SEE .SEE 1999-2001 SERVICE MANUAL Engine Stop Linkage Adjustment.............. Adjustment............................ ............................ ............................ .....................SEE .......SEE 1999-2001 SERVICE MANUAL Fuel Tank .............. ............................ ............................ ............................ ............................ ............................ ............................ ......................SEE ........SEE 1999-2001 1999-200 1 SERVICE MANUAL Description .............. ............................ ............................ ............................ ............................ ............................ ............................ ...............SEE .SEE 1999-2001 SERVICE MANUAL Fuel Tank Replacement........................ Replacement...................................... ............................ ............................ ...........................S .............SEE EE 1999-2001 SERVICE MANUAL Fuell tank Fue tan k Unit Replacement .............. ............................ ............................ ............................ ............................ ...............SEE .SEE 1999-2001 SERVICE SERVICE MANUAL MANUAL Specifications.............................. Specifications................ ............................ ............................ ............................ ............................ ...........................S .............SEE EE 1999-2001 SERVICE MANUAL Fastener Torques Torques............. ........................... ............................ ............................ ............................ ............................ ....................SEE ......SEE 1999-2001 SERVICE MANUAL

6C1-2 FUEL SYSTEM

AIR CLEANER DESCRIPTION The function of the air cleaner assembly is to prevent dirt and water from entering the engine. Air enters the air cleaner assembly and hits a helical ramp that is around the air filter. This causes the air to spin. Centrifugal force separates the dirt and water from the intake air. A rubber ejector valve is placed in the bottom of the assembly to eject dirt and water from the air cleaner assembly. Air cleaners should be inspected and serviced at intervals listed in the Maintenance Schedule, or more often under severe dust conditions. Under adverse conditions or long periods of time

1. 2. 3. 4.

on dusty or sandy roads, the unit should be cleaned every day. Air cleaners on vehicles operating in dust storm areas should be cleaned immediately after such storms occur. NOTICE: In addition to its function of filtering air drawn into the engine, the air cleaner also acts as a flame arrester in the event the engine backfires. Because backfiring may cause fire in the engine compartment, the air cleaner should be installed at all times unless temporary removal is necessary during repair or maintenance of the vehicle.

Cover Wing Nut End Cover Air Filter Air Cleaner Body 130LX00001

Figure 1. Air Cleaner Assembly

FUEL SYSTEM 6C1-3

8

4

6

4. Air Cleaner Body 6. Air Intake 8. Engine Intake Hose 130L200001

Figure 2. Air Cleaner Assembly

AIR FILTER REPLACEMENT Remove or Disconnect (Figure 1) 1. Cover wing nut (1). 2. End cover (2). 3. Air Filter (3). Clean (Figure 3) • Wipe out the inside of the air cleaner assembly. • Wipe off the cover.

130LX00002

Figure 3. Cleaning the Air Cleaner Assembly Inspect • The air filter with a light for tears or holes (figure 4). • Ejector valve.

6C1-4 FUEL SYSTEM Install or Connect (Figures 1 and 2) 1. Air filter (3). 2. End cover (2). 3. Cover wing nut (1).

FUEL FILTERS DESCRIPTION The purpose of the fuel filters is to clean the fuel of any dirt particles that can cause wear on the fuel injector's sliding surface; and to separate any water from the fuel, which is ever-present from the condensation in the fuel tank. The pre-fuel filter (water separator) is located between the fuel tank and the injection pump (figure 6). The secondary fuel filter is located between the fuel pump and the injection pump (figure 7).

1

3. Fuel Lines 4. Fuel Filter 041LX00002

Figure 7. Fuel Filter

Pre-Fuel Filter When the condensed water in the pre-fuel filter (water separator) comes to the warning level indicated on its plastic body, drain the fluid immediately from the drain plug located bottom of water separator.

2

1. Vent Plug 2. Drain Plug 901L200006

Figure 6. Pre-Fuel Filter

Fuel Filter The fuel filter is spin-on cartridge-type. The filter should be replaced. Never try to clean it. For the replacement interval refer to MAINTENANCE AND LUBRICATION (SEC. 0B).

DRAINING THE PRE-FUEL FILTER 1. Loosen the vent plug (12) and drain plug (2) by turning them counterclockwise (figures 6 and 8). 2. Drain approximately 0.1 liters (3.4 oz) of water. 3. Securely tighten the drain plug and air intake plug. 4. Operate the primer pump on the fuel pump to bleed the fuel system. Refer to FUEL INJECTION SYSTEM (SEC. 6C3). 5. Start the engine and check to be sure no fuel is leaking from the drain plug.

FUEL INJECTION SYSTEM 6C3-1

SECTION 6C3

FUEL INJECTION SYSTEM NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Fuel Injection System ......................................................................................SEE 1999-2001 SERVICE MANUAL Description ...................................................................................................SEE 1999-2001 SERVICE MANUAL System Operation ........................................................................................SEE 1999-2001 SERVICE MANUAL Boost Compensator Function ....................................................................SEE 1999-2001 SERVICE MANUAL Fuel Low Cut Function ................................................................................SEE 1999-2001 SERVICE MANUAL Diagnosis of Fuel Injection System ...............................................................SEE 1999-2001 SERVICE MANUAL Fuel Injector Test .........................................................................................SEE 1999-2001 SERVICE MANUAL On-Vehicle Service .........................................................................................................................................6C3- 2 Fuel Pump....................................................................................................................................................6C3- 2 Fuel Pump Replacement ............................................................................................................................6C3- 2 Fuel Injector.................................................................................................................................................6C3- 2 Fuel Injection Pump Replacement ............................................................................................................6C3- 6 Bleeding the Fuel System ..........................................................................................................................6C3-10 Re-learning of the Throttle Position Sensor Voltage Procedure .............SEE 1999-2001 SERVICE MANUAL Specifications...................................................................................................SEE 1999-2001 SERVICE MANUAL Fastener Torques ........................................................................................SEE 1999-2001 SERVICE MANUAL Emission Specifications..............................................................................SEE 1999-2001 SERVICE MANUAL

6C3-2 FUEL INJECTION SYSTEM

ON-VEHICLE SERVICE FUEL PUMP FUEL INJECTOR The fuel pump is mounted on the side of the fuel injection pump. A primer pump for fuel system bleeding is also located on top of the pump (figure 6).

CAUTION: Do not bend injection lines in any shape or form to ease injector replacement. Remove or Disconnect (figure 7)

FUEL PUMP REPLACEMENT Remove or Disconnect (Figure 6) • Engine refer to the engine replacement (Section 6A). 1. Fuel line from the fuel pump. 2. Mounting stud nuts. 3. Fuel pump and gasket. Install or Connect (Figure 6) 1. New gasket to the fuel pump. 2. Fuel pump to the side of injection pump. 3. Fuel line. 4. Bleed the fuel system. • Engine refer to the engine replacement (Section 6A).

• Disconnect the battery negative cable. • Remove the cab floor cover. Refer to STEEL CREW CAB (SEC. 10E). • Remove the rear floor engine cover and rear engine cover assembly. 1. Nozzle cover. 2. Fuel line fitting at the injector assembly (1). 3. Fuel return line bolt (16), gasket (15) and fitting. 4. Flange (14). 5. Injector assembly (1) from the cylinder head. • Cap the fuel lines. • Plug the hole in the cylinder head with a clean shop rag. 6. Injector gasket (13). 7. Check injector opening pressure, spray pattern, chatter and oil leakage. Refer to FUEL INJECTOR TEST in this service manual.

10 16

11

15

4 15

14

1

12

4. Fuel pump 10. Primer Pump 11. Fuel Bolt and Gaskets (Outlet) 12. Fuel Bolt and Gaskets (Inlet) 042LX00002

Figure 6. Fuel Pump

1. Injection Assembly 13. Injector Gasket 14. Flange 15. Fuel Return Line Gasket 16. Fuel Return Line Bolt

13

040LX00026

Figure 7. Injector Assembly

FUEL INJECTION SYSTEM 6C3-3 Disassemble (Figure 8) 1. Clamp the injector holder assembly into a vise. 2. Injector retaining nut (43). 3. Injector (45). 4. Spacer (46). 5. Spring seat (47). 6. Injector spring (48). 7. Shim (49). 8. Injector holder (44).

CAUTION: Clean the injector holder mating surface and both sides of the spacer with a hardwood piese or a soft cloth. Do not use a metal brush since scars on these surfaces cause oil leakage. Carefully remove carbon residues sticking to inside of the retaining nut with the appropriate scraper. Remove carbon residues and dirt on the seat surface, inside surface of the body sliding section, sac cone and spray hole inside of the injector body using the cleaning tools (figures 9 and 10).

44

49 48

B. Scraper (J-39533)

47

040LX00019

46

Figure 9. Cleaning of Injector Sac Cone

45

43

43. Injector Retaining Nut 44. Injector Holder 45. Injector 46. Spacer 47. Spring Seat 48. Injector Spring 49. Shim

C. Scraper (J-39532) 040LX00020

Figure 10. Cleaning of Seat Section

040LX00027

Figure 8. Injector Assembly Clean (Figures 9, 10, 11 and 12) Tool Required: J-39531 Injector Cleaning Kit J-39532 Scraper J-39533 Scraper 1. Soak all parts other than the injector in a cleaning oil and wipe off all excess residue with a soft cloth or the like. Use the wire brush to clean excessively dirty parts.

2. Pull out the needle valve from the injector body and clean both of them to clean the injector. First, Holding the needle by the stem only clean the shaft section and seat surface of the needle valve using a hardwood dipped in oil or a clean soft cloth (figure 11). Clean the spray holes of the hole type injector with the special cleaning needle contained in the cleaning kit (figure 12). If a large amount of carbon residue remains and the injector cannot be cleaned well enough, dip the injector in carbon cleaner, and repeat the cleaning process. CAUTION: Never use sand paper, metal scraper, or other abrasive materials to clean the injector body and needle valve.

6C3-4 FUEL INJECTION INJECTION SYSTEM

040LX00021

Figure 11. Needle Seat Cleaning with a Wooden Piece

040LX00022

Figure 12. Spray Holes Holes Cleaning 3. Wash all parts in a clean oil and place them on a clean work table. For best results compressed air should be applied to them after the oil cleaning. CAUTION: After cleaning, all parts must be coated with a light oil to prevent rust.

040LX00023

Figure 13. Injector Slide Slide test Assemble (Figure 8) CAUTION: New injector must be cleaned in a solvent to remove protective coating. The injector body and needle must always be replaced as an assembly.

Inspect (Figures 8 and 13) • The followin following g items should should be checked checked on all all parts (figure 8): Abrasion, corrosion, impact marks, scars, breaks, cracks, cavitation erosion, damages caused by foreign material in the fuel, or excessive. Replace any worn, corroded or damaged parts. Injector slide test (Figure 13) Dip the injector and needle in light oil and assemble. Insert the needle all the way into the body. Raise the needle 1/3 (one-third) of the way out and release. The needle must slide all the way back into the body by its own weight. If the needle sticks, reclean and repeat the slide test. Any injector that fails must be replaced.

1. Clamp the injector injector holder to a vise. 2. Shim Shim (49). (49). 3. Injector Injector spring (48). (48). 4. Spring Spring seat (47). (47). 5. Spacer Spacer (46). (46). 6. Injector Injector (45). (45). 7. Injector retaining nut nut (43). Tighten • Retaining Retaining nut nut to 34 N·m N·m (25 (25 lb·ft lb·ft). ). 8. Check injector opening pressure, pressure, spray pattern, pattern, chatter and oil leakage. Refer to FUEL INJECTION TEST in this service manual.

FUEL INJECTION SYSTEM 6C3-5 Injector Opening Pressure Adjustment 1. Check injector injector opening pressure. • The gage gage should should read 21600 21600 kPa (3130 (3130 psi). psi). 2. If the injector opening pressure pressure does not meet specification, disassemble the injector and holder assembly and replace the shim with a new one. • Use a thicker thicker shim, shim, if the pressur pressure e is lower than the specification. • Use a thinner thinner shim, shim, if the pressu pressure re is higher higher than the specification. The shim is available in the following thickness. 1. 0.1 mm (0.0 (0.0039 0394 4 in) in) 2. 0.2 mm (0.0 (0.0078 0787 7 in) in) 3. 0.3 mm (0.0 (0.0118 1181 1 in) in) 4. 0.4 mm (0.0 (0.0157 1575 5 in) in) 5. 0.5 mm (0.0 (0.0196 1969 9 in) in) 6. 0.5 0.52 2 mm (0.0 (0.0204 2047 7 in) 7. 0.5 0.54 4 mm (0.0 (0.0212 2126 6 in) 8. 0.5 0.56 6 mm (0.0 (0.0220 2205 5 in) 9. 0.5 0.58 8 mm (0.0 (0.0228 2283 3 in)

Install or Connect (Figure 7) 1. New injector injector gasket (13). 2. Injector Injector assembly assembly (1). 3. Flange (14). (14). Tighten • Nuts to 19 N·m (14 lb·ft lb·ft). ). 4. Gasket (15), fuel fuel return line and bolt (16). (16). Tighten • Fuel return return line bolt bolt to 13 N·m (113 (113 lb·in). lb·in). 5. Fuel Fuel line. line. Tighten • Fuel line line sleeve sleeve nut to 29 29 N·m (22 (22 lb·ft). lb·ft). • Install Install the rear rear floor engine engine cover cover and engine engine cover assembly. • Install Install the cab floor floor cover. cover. Refer to STEEL STEEL CREW CAB (SEC. 10E). • Connect Connect the batter battery y negative negative cable. cable.

6C3-6 FUEL INJECTION INJECTION SYSTEM FUEL INJECTION PUMP REPLACEMENT Remove or Disconnect (Figures 14–16) Preparation • Engine Engine refer to the engine engine replacemen replacementt (Section (Section 6A). 1. Inta Intake ke Air Duct Duct 2. Vacuum Vacuum Hose Hose 3. Oil Level Level Guide Tube Tube • Remove Remove the guide guide tube fixing fixing bolt bolt and pull out the guide tube. 4. Engine Stop Calbe (Figure (Figure 14) • Loosen Loosen locking nut nut at bracket bracket and disconnect disconnect.. • Engine Engine stop cable cable from injecti injection on pump stop stop lever.

6. Engine Engine Control Control Wire 7. Engine Engine Control Control Lever 8. Oil Pipe Pipe 9. Fuel Return Return Hose Hose 10. Fuel Feed Feed Hose Hose • Disconnec Disconnectt fuel hose from from injection injection pump side and take care not to spill and enter dust. 11. Nozzle Nozzle Cover Cover 12. Leak-Off Leak-Off Pipe Pipe 13. Fuel Fuel Pipe 14. Fuel Filter Filter Assembly Assembly 15. PCV Hose Hose 16. Injection Pipe (Figure (Figure 16) • Loosen Loosen the injecti injection on pipe sleeve sleeve nuts nuts 1. Do not apply excessive force to the i njection pipes 5. • Loose Loosen n the inject injection ion pipes pipes clips clips 3. • Remo Remove ve the inject injection ion pipe assem assembly. bly. Plug the delivery valve holder 2 ports and nozzle holder 4 ports with caps to prevent the entry of foreign material.

060LX00036

Figure 14. Engine Stop Cable 5. Accelerator Control Control Cable (Figure (Figure 15) • Loosen Loosen locking locking nut (6) (6) at bracket bracket and and disconnect accelerator control cable (3) from injection pump control lever.

040LX00024

Figure 16. Injection Pipe 17. Injection Pump Assembly 1. Remo Remove ve the the inject injection ion pump brac bracket ket bolts and the injection pump rear bracket bolts. 2. Then remov remove e the the inject injection ion pump asse assembly. mbly.

101LX00004

Figure 15. Accelerator Control Control Cable

FUEL INJECTION SYSTEM 6C3-7 Install or Connect (Figures 17–26) 1. Injection Pump Assembly 1) Turn the crankshaft until the timing mark on the crankshaft damper pulley is aligned with “13°” line. Inspect 2) Check the No.1 cylinder intake and exhaust valve rocker arms for any play. If the No.1 cylinder intake and exhaust valve rocker arms are depressed the No.4 piston is at on the compression stroke. Rotate the crankshaft one full turn (360 degrees) and realign the crankshaft damper pulley timing mark with the “13°” line. (Figure 17)

085LX00001

Figure 18. Bracket Slit and Timer Slit 4) Install the injection pump assembly to the cylinder body. NOTICE: When the injection pump has a poor gear engagement while installing the assembly to the cylinder body, insert a screwdriver into the slit on the time peripheral with the pump bracket slit used as a guide, and move it up and down to get it into forcibly. 5) After mounting make sure the 13° mark is in position through the check hole. (Figure 19)

020LX00009

Figure 17. TDC Mark and Crank Pulley Mark NOTICE: BTDC 13° to be aligned with here is an angle at which the injection pump is installed, and has nothing to do with the injection timing. • Remove the inspection hole plug from the cylinder body. • Install the O-ring to the injection pump bracket. 3) Align the injection pump bracket slit with the timer slit. (Figure 18) 080LX00004

Figure 19. Timing Check Hole (13°) 6) Lightly tighten nuts and bolts. NOTICE: Check to see no play between cylinder Body and injection pump. 7) Monut injection pump blacket and retighten only the cylinder side of bolts.

6C3-8 FUEL INJECTION SYSTEM 8) Turn the crankshaft until the timing mark on the crankshaft damper pulley is aligned with “8°” position. NOTICE: Position in its normal rotating direction.

080LX00006

Figure 22. Timing Adjust Tighten

020LX00008

Figure 20. TDC Mark and Crank Pulley Mark 9) Adjust injection pump downward so that the “8°” comes to position in the timing check hole, (Figure 21 and Figure 22)

10) Tighten bolts and nuts to the specified torque. Injection Pump Bracket Bolt and Nut to 48 N·m (35 Ib·ft). 11) Tighten the inspection hole plug to 95 N·m (75 Ib·ft). NOTICE: Be careful not to loosen the stud nuts to excess. Too much loosening may make a clearance between cylinder Body and injection pump, which could put timing out of order after retightening. 2. Fuel Injection Pipe 1) Install the injection pipe assembly and temporarily tighten the injection pipe sleeve nuts. 2) Set the clips in the prescribed position shown in the illustration (Figure 23).

080LX00005

CAUTION: Make absolutely sure that the clip is correctly positioned. An improperly positioned clip will result in injection pipe breakage and fuel pulsing noise.

Figure 21. Timing Check Hole (8°) Tighten Clip Screw to 3 N·m (26 Ib·in) Tighten 3) Tighten the injection pipe sleeve nuts to the specified torque. Injection Pipe Sleeve Nut to 29 N·m (22 Ib·ft)

FUEL INJECTION SYSTEM 6C3-9 3. PCV Hose 4. Fuel Filter Tighten Fuel Filter Bracket Bolt to 34 N·m (25 Ib·ft) 5. Fuel Pipe (Figure 23) Do not apply excessive force to the fuel pipe. Tighten Fuel Pipe Joint Bolt 1 to 41 N·m (30 Ib·ft) Fuel Pipe Joint Bolt 2 to 22 N·m (16 Ib·ft) Clip Screw to 4 N·m (35 Ib·in) Fuel Pipe Bracket Bolt to 18 N·m (13 Ib·ft) 040LX00025

Figure 24. Leak Off Pipe 7. Nozzle Cover 8. Fuel Feed Hose 9. Fuel Return Hose 10. Oil Pipe Tighten Oil Pipe Joint Bolt to 17 N·m (12 Ib·ft) 11. Engine Control Lever Assembly Tighten Engine Control Lever Bolt to 24 N·m (17 Ib·ft)

042LX00001

Figure 23. Fuel Pipe Joint Bolt 6. Leak Off Pipe (Figure 24) Tighten Leak-Off Pipe Joint Bolt to 13 N ·m (113 Ib·in)

12. Engine Control Wire 13. Accelerator Control Cable (Figure 25) • Check to see if the idling control knob is turned to the extreme left. • Attach the tip end of the cable to the engine control lever. • Pull the outer cable toward the front side of the vehicle, and provide the engine control wire and the inner cable with an appropriate play before fastening the clamp with a nut. • Check to see if the injection pump control lever is at the idling position (with the lever in touch with the stopper bolt). 14. Engine Stop Cable (Figure 26) • Attach the end tip of the cable to the engine stop lever. • Pull the cable toward the rear side of the vehicle, and fasten the clamp with a nut at the position where the lever stops.

6C3-10 FUEL INJECTION SYSTEM BLEEDING THE FUEL SYSTEM Anytime the fuel system is opened to the atmosphere, outside air can enter. Air bubbles, trapped in the fuel system, will cause the engine to run poorly. After any service that requires opening the fuel system has been performed, all trapped air must be removed by bleeding the system (figure 27,28). 1. Loosen the vent plug. 2. Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. 3. Tighten the vent plug. 19 18 101LX00004

Figure 25. Accelerator Control Cable 15. Oil Level Gauge Guide Tube 1) Install the o-rings to the guide tube lower portion and insert the guide tube completely to the cylinder body. 2) Tighten the guide tube bolt to the specified torque. Tighten 18. Vent Plug 19. Priming Pump

Guide Tube Bolt to 13 N·m (113 Ib·in)

901L200005

16. Vacuum Hose 17. Intake Air Duct • Pour coolant into radiator. • Connect battery ground cable. • Start engine and check for oil and fuel leakage carefully.

Figure 27. Bleeding Fuel System 4. After peeling the mat on the floor of the rear cabin and removing the bolts of the panel for inspection, open the rear floor engine coner. Then, loosen the bleed bolt on the injection pump. 5. Operate the priming pump. Pump the primer pump until fuel flow is free of air bubbles. 6. Tighten the bleed bolt on the injection pump. 7. If the vehicle does not start, repeat the procedure.

1/2 inch(13mm) Ring wrench (Boxhead wrench) 060LX00036

Caution plate

Figure 26. Engine Stop Cable

Bleed bolt

• Engine refer to the engine replacement (Section 6A). Figure 28. Bleed bolt

AUTOMATIC TRANSMISSION 7A1-1

SECTION 7

TRANSMISSION CONTENTS SUBJECT

PAGE

Automatic Transmission........................................................................................See 1999-2001 Service Manual Manual Transmission (MXA)..................................................................................See 1999-2001 Service Manual Manual Transmission (MBP)..................................................................................See 1999-2001 Service Manual Clutch (For MXA Transmission) ............................................................................See 1999-2001 Service Manual Clutch (For MBP Transmission) ............................................................................See 1999-2001 Service Manual

7A1-2 CONSTRUCTION AND FUNCTION MEMO .................................................................................................................................................................................................................................................................................................................

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CAB AND CHASSIS ELECTRICAL 8-1

SECTION 8

CAB AND CHASSIS ELECTRICAL NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound, will be called out. The correct torque values must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

General Information.........................................................................................SEE 1999-2001 SERVICE MANUAL Notes for Working on Electrical Items .......................................................SEE 1999-2001 SERVICE MANUAL Symbols and Abbreviations........................................................................SEE 1999-2001 SERVICE MANUAL Symbols ....................................................................................................SEE 1999-2001 SERVICE MANUAL Abbreviations ...........................................................................................SEE 1999-2001 SERVICE MANUAL Parts for Electrical Circuit ...........................................................................SEE 1999-2001 SERVICE MANUAL Wiring........................................................................................................SEE 1999-2001 SERVICE MANUAL Fuse and Fusible Link .............................................................................SEE 1999-2001 SERVICE MANUAL Relay .........................................................................................................SEE 1999-2001 SERVICE MANUAL Diode.........................................................................................................SEE 1999-2001 SERVICE MANUAL Connector .................................................................................................SEE 1999-2001 SERVICE MANUAL Reading the Circuit Diagram......................................................................SEE 1999-2001 SERVICE MANUAL Connector Symbol .......................................................................................SEE 1999-2001 SERVICE MANUAL Joint Connector ...........................................................................................SEE 1999-2001 SERVICE MANUAL Main Data and Specifications .........................................................................SEE 1999-2001 SERVICE MANUAL Bulb Specifications .....................................................................................SEE 1999-2001 SERVICE MANUAL Fuse and Fusible Link Location .................................................................SEE 1999-2001 SERVICE MANUAL Fuse Block Circuit .......................................................................................SEE 1999-2001 SERVICE MANUAL Reference Table of Fuse ............................................................................SEE 1999-2001 SERVICE MANUAL Relay Location .............................................................................................SEE 1999-2001 SERVICE MANUAL Relay List ......................................................................................................SEE 1999-2001 SERVICE MANUAL Diode Location .............................................................................................SEE 1999-2001 SERVICE MANUAL Reference Table of Grounding Point .........................................................SEE 1999-2001 SERVICE MANUAL Grounding Point Location...........................................................................SEE 1999-2001 SERVICE MANUAL Cable Harness Routing ..............................................................................SEE 1999-2001 SERVICE MANUAL System Repair ..................................................................................................SEE 1999-2001 SERVICE MANUAL Start and Charging.......................................................................................SEE 1999-2001 SERVICE MANUAL Engine Control Module................................................................................SEE 1999-2001 SERVICE MANUAL Engine Stop System ....................................................................................SEE 1999-2001 SERVICE MANUAL Headlight, D.R.L and Cornering Light ........................................................SEE 1999-2001 SERVICE MANUAL Clearance Light, Taillight, License Plate Light, ID Light and Illumination Light....... SEE 1999-2001 SERVICE MANUAL Turn Signal Light, Hazard Warning Light and Stoplight ..........................SEE 1999-2001 SERVICE MANUAL Horn and Backup Light ...............................................................................SEE 1999-2001 SERVICE MANUAL Dome Light and Body Interior Light ...............................................................................................................8- 4 Transmission Control Module (TCM) .........................................................SEE 1999-2001 SERVICE MANUAL Windshield Wiper and Washer ...................................................................SEE 1999-2001 SERVICE MANUAL Audio and Cigarette Lighter........................................................................SEE 1999-2001 SERVICE MANUAL

8-2 CAB AND CHASSIS ELECTRICAL Meter and Warning/Indicator Light.............................................................SEE 1999-2001 SERVICE MANUAL Heater, Air Conditioning, Condensor Fan and Ceramic Heater ..............SEE 1999-2001 SERVICE MANUAL Service Terminal ..........................................................................................SEE 1999-2001 SERVICE MANUAL ABS (Anti-lock Brake System)....................................................................SEE 1999-2001 SERVICE MANUAL Power Window .............................................................................................SEE 1999-2001 SERVICE MANUAL Power Door Lock .............................................................................................................................................8-12 Wiring Diagram ............................................................................................SEE 1999-2001 SERVICE MANUAL

CAB AND CHASSIS ELECTRICAL 8-3 MEMO

8-4 CAB AND CHASSIS ELECTRICAL

DOME LIGHT AND BODY INTERIOR LIGHT GENERAL DESCRIPTION The circuit consists of the dome light, dome li ght switch, door switch and body interior switch. The dome light lights up when the left side door is opened with the switch set at the door mode. It can be lit by operating ON or OFF of the dome light switch.

The dome light can be lit using the switch mounted on the instrument panel regardless of the position of the ignition switch.

LIGHTING CIRCUIT

BATTERY (+)

OFF

DOOR BODY INTERIOR LIGHT ON

B O D Y I N T E R I O R S W

DOOR DOME LIGHT OFF

ON

TO BODY INTERIOR LIGHT DOME LIGHT SW :Lighting circuit by door SW :Lighting circuit by dome light SW :Lighting circuit by body interior SW

NOTE:Arrow marks "

" indicate the direction of current

Figure 1. Lighting Circuit

DOOR SW (DRIVER SIDE)

CAB AND CHASSIS ELECTRICAL 8-5 PARTS LOCATION

D08L200005

Figure 2. Parts Location

8-6 CAB AND CHASSIS ELECTRICAL CIRCUIT DIAGRAM

FL-1 80A 2L

MAIN

5 W 0.85R

C

2 H-6

0.85R P-1 P-2

0.85R

0.5R

D

P-3

F-6 10A

P-4

DOME LIGHT

6 H-10

0 . 5 R

P-5

FRAME

1 2

L-2

H-20

OFF

DOOR ON

L-2

L-2

3

2

0 . 5 Y

D I O D E

1

0 . 5 R

L-4

OFF

DOOR ON

0 . 5 G R / B

1

D O M E L I G H T

0.5GR/B

B

L-4

L-4

3

2

0 . 5 Y

L-1 4

1

H-10

L-3

L-1 2

B O D Y I N T E R I O R L I G H T

0 . 5 G R / B 0.5GR/B

L-3 2

0.5GR

A

H-20

0 . 5 G R

1

0 . 5 G R

5

0 . 5 G R / B

H-10

0 . 5 G R

0.85LG/R

RELAY; TAIL(5)

0.5LG/B

ILLUMINATION CONTROLLER(3)

1

4

B-86

B-86

B-86

B-86

3

2

0 . 5 B

HEADLIGHT BRACKET (LH)

B-7

FRAME-LH (CENTER)

J-9

3B

2

D O M E L I G H T S W I T C H

0 . 5 G R / B

3

4

H-3

H-12

0 . 5 G R / B 1

D O O N-7 R S W I T C H ( R H )

A

1 .2 5 G R / R

0 . 5 G R / B

0 . 5 G R / B

R E A R 1 D O L-31 O R S W I T C H ( R H )

R E A R 1 D O L-32 O R S W I T C H ( L H )

0 . 5 G R / B 3 H-20

B

D O R S W I T C H ( L H )

1 O

N-2

7

B-272 JOINT CONNECTOR

3B

3B

E

F

D08L200003

Figure 3(a). Circuit Diagram

CAB AND CHASSIS ELECTRICAL 8-7 CIRCUIT DIAGRAM

0.85LG/R

RELAY, TAIL(5)

3 H-70

0.85R

C

0 . 8 5 L G / R

0.5R

D

2 H-70

1 B-158

B-158 3

B-158 2

B O D Y I N T E R I O R L I G H T S W I T C H

0 . 8 5 R

0 . 5 L G / R

0.85R 1 J-20

2 J-20

I D R E L L I A G H Y T : J-20

J-20 5

0 . 5 R / Y

4

0 . 8 5 R / G

5 H-69

0 . 8 5 R / Y

0 . 8 5 R

11 H-69

0 . 8 5 R / G

0 . 8 5 R / G

0 . 5 B

0 . 8 5 R / Y

1

L C I A G H B T

0 . 8 5 R

2

S P O O U W R E C R E

0 . 8 5 R / G

3 B

3

4

M A R K E R

E A R T H

0 . 8 5 R / Y

3 B

1

2

L C I A G H B T

S P O O U W R E C R E

3

4

M A R K E R

E A R T H

J-143

J-144

MANUFACTURER'S CONNECTION(FRT)

MANUFACTURER'S CONNECTION(RR)

2 H-10

0 . 5 B

0 . 5 R / G

I D L I G H T

E

F

3B

D08L200004

Figure 3(b). Circuit Diagram

8-8 CAB AND CHASSIS ELECTRICAL CONNECTOR LIST

1

2

1

2

3

4

4

3

2

1

5

6

7

8

8

7

6

5

9 10 11 12

1 2

3

4

4 5

1

2

3

4

Figure 4. Connector List

3

2

1

12 11 10 9

CAB AND CHASSIS ELECTRICAL 8-9 DOME LIGHT BULB BODY INTERIOR LIGHT BULB Remove or Disconnect (Figure 5) Preparation:Disconnect the battery ground cable. 1. Lens Hold the lens and pull it downward. 2. Bulb

Terminal SW No. position

2

4

1

3

ON OFF

Figure 6. Dome Light Switch Connector

Remove or Disconnect (Figure 7) Preparation: Disconnect the battery ground cable.

Screw Lenz

Figure 5. Dome Light Bulb

805L100001

Install or Connect To install, follow the removal steps in the reverse order.

1. Meter cluster Refer to the “METER AND WARNING/INDICATOR LIGHT” in this section. 2. Dome light switch Release the lock pushing the switch from the back side of the meter cluster. 1. Meter Cluster 2. Dome Light Switch

DOME LIGHT SWITCH Inspect (Figure 6) Check the continuity between the dome light switch connector terminals. Repair or replace the switch when the result of inspection is found abnormal.

Figure 7. Dome Light Switch Removal

8-10 CAB AND CHASSIS ELECTRICAL Install or Connect


To install, follow the removal steps in the reverse order noting the following point. • Push the switch with your fingers until it l ocks securely.

DOOR SWITCH REAR DOOR SWITCH

Preparation:Disconnect the battery ground cable. 1. Door switch • Remove the screw. • Disconnect the connector of the switch.

Inspect (Figure 8) Check to see if there is any continuity between the terminals and the body while operating the door switch. Repair or replace the switch, when the result of inspection is found abnormal.

Figure 9. Door Switch Removal Install or Connect To install, follow the removal steps in the reverse order. Connector No.

SW operation

T e r m i n a l N o .

N-2

N-7

L-31

L-32

1

Push Release

Figure 8. Door Switch

Body


BODY INTERIOR LIGHT SWITCH Inspect (Figure 10) Check the continuity when the switch is in "ON" position.

Terminal SW No. position

1

2

3

OFF ON

Figure 10. Body Interior Light Switch Check Remove or Disconnect (Figure 11) Preparation: Disconnect the battery ground cable. 1. Body interior light switch • To release the lock, push the switch from back side of switch panel. • Disconnect the connector.

1. Body Interior Light Switch Figure 11. Body Interior Light Switch Removal Install or Connect To install, follow the removal steps in the reverse order.


POWER DOOR LOCK GENERAL DESCRIPTION The circuit consists of the door lock switch, actuator for the front passenger door, rear doors and the door lock controller. The door lock controller is always provided with battery voltage. The key or the inside lock knob on the driver’s door can activate the lock mechanism

of all the doors. When the driver’s door lock switch is turned on, current flows for about one second to the door lock actuator of each door connected in parallel with the controller to activates the actuator to lock and unlock the doors.

OPERATION OF DOOR LOCK CONTROLLER When locking the door.

When locking the door.

Battery(+)

Battery(+)

Relay;Door lock

Relay;Door lock

To actuator (Actuator operates to unlock position)

To actuator (Actuator operate to lock side)

Door lock sw. (Lock position)

Door lock sw. (Unlock position)

NOTE: Arrow marks “

” indicate the direction of current 825LX003

Figure 12. Operation of Door Lock Controller


PARTS LOCATION ) H L ( R O T A U T C A K C O L R O O D R A E R 9 D

) B A C W E R C ( 8 1 H > ) H L ( ) B A C W E R R C ( R O O D R A E R <

2 P 4 P

) B A C W E R C ( 8 1 H > ) H R ( ) B A C W E R C ( R O O D R A E R <

3 P

Y 1 - R P E T T A B M S A X O B Y A L E R

6 2 0 1 3 - B B ) B A C W E R C ( 9 1 H

) H R ( R O T A U T C A K C O L R O O D R A E R 0 1 D

) H L ( H C T I W S K C O L R O O D T N O R F 4 D

1 1 H

K N I L E L B I S U F 1 L F

1 6 H

7 B

2 1 H

1 B

6 H

M S A X O B E S 7 U F F

2 H

R R O O O T D A T U N T C O A R K F ) C 8 - O H D L R (

3 H

7 2 F

R O T C E N N O C T N I O J 2 7 2 B

D08L200006

Figure 13. Parts Location


CIRCUIT DIAGRAM FL-1 80A MAIN

2

8W

5W

F-27 15A POWER DOOR LOCK H-6

5W

3W

L 2

P-1

P-3

P-2

P-4

R 5 8 . 0

6

RELAY: DOOR LOCK

B-12

P-5

FRAME B-12

B-12

B-12

B-12

7

0.85BR/R

A

2

0.85BR/Y

B

3

B-12

5

1

B / G 3 . 0

R / R B 5 8 . 0

Y / R B 5 8 . 0

R / R B 5 8 . 0

Y / R B 5 8 . 0

0.3G/B

G / R 3 . 0 B / G 3 . 0

K 5 C B-306 O L N U

6 B-306

B 5 K 8 . C 0 O L

DOOR LOCK SW B-306

4 H-11

3 H-61

1 H-61

B / G 3 . 0

R / R B 5 8 . 0

Y / R B 5 8 . 0

6 D-4

K C O L N U

K C O L

2 D-4

K C O L

3

D-4 4

B 5 . 0

4 H-2

R / R B 5 8 . 0

1 D-4

2 D-8

L K C O L N U

DOOR LOCK SWITCH & ACTUATOR-LH

3 H-2

Y / R B 5 8 . 0 1 D-8

K C O L N U

K C O L

DOOR LOCK ACTUATOR-RH

B 3 . 0

B 2 3 H-11

B 2 HEADLIGHT BRACKET (LH)

B-7

3B

3B

2

1 B-272 JOINT CONNECTOR D08L200001

Figure 14(a). Circuit Diagram


CIRCUIT DIAGRAM

A

B

R / R B 5 . 0

6 H-12

14 H-12

R / R B 5 . 0

Y / R B 5 . 0

2 H-18

1 H-18

R / R B 5 8 . 0

Y / R B 5 8 . 0

K C O L

R / R B 5 . 0

Y / R B 5 . 0

Y / R B 5 . 0

1

4

H-3

H-3

R / R B 5 . 0 2 H-19

R / R B 5 8 . 0

Y / R B 5 . 0 1 H-19

Y / R B 5 8 . 0

1

2

1

2

D-9

D-9

D-10

D-10

K C O L N U

REAR DOOR LOCK ACTUATOR-LH (CREW CAB)

K C O L N U

K C O L

REAR DOOR LOCK ACTUATOR-RH (CREW CAB)

D08L200002

Figure 14(b). Circuit Diagram


CONNECTOR LIST B-12

1 2

B-272

3

D-4

1 2 3

4 5

6

9 10

7 8

1

4 5 6 7 8

4

H-2

2

H-18

3

5

6

H-11

3

2

1

6

5

4

H-19

1

D-10

2

H-3

1

H-6

2 1

1

2

3

3

2

1

8 7 6 5 4

4

5

6

6

5

4

3

3

4 5 6 7 8

D-9

2

1

1 2

D-8

2

1

2

H-6

H-7

2

1

2

1

1 2 3 4

4 3 2 1

5 6 7 8

8 7 6 5

9 10111213

13121110 9 H-8

1415161718

1817161514

H-12

1 2

3

7 8 9 10

P-4

P-3

6 5 4

4 5 6 11 12 13 14

14131211

3 2 1 10 9 8 7

P-5

P-1

B-306

1

H-61

2

3 4 5 6

1 2 3 4

Figure 15. Connector List

4

3

2

1

P-2


DIAGNOSIS QUICK CHART FOR CHECK POINT Check point Trouble mode 1.

2.

3. 4.

5. 6.

All the doors do not lock and unlock All the doors do not get locked (or unlocked) Driver side door does not get locked (or unlocked)

Door Door Fuse lock sw lock F-27 (15A) (Driver controller side) (1)

Door lock actuator Front (Passenger side)

Cable harness

(3)

(1)

(2)

(1)

(2)

(1)

Rear door-RH side does not get locked (or unlocked)

(2)

(1)

Rear door-LH side does not get locked (or unlocked) Figure in parenthesis “(

Rear (LH)

(2)

Front passenger side door does not get locked (or unlocked)

NOTE:

Rear (RH)

(2)

(1) )” indicates the order of inspection.

(2)

8-18 CAB AND CHASSIS ELECTRICAL 1. ALL THE DOORS DO NOT LOCK AND UNLOCK •

IS FUSE F-27 (15A) NORMAL?

YES

•

IS THE DOOR LOCK SWITCH NORMAL?

YES

•

IS B-7 GROUNDED SECURELY?

YES

• •

DISCONNECT THE CONTROLLER CONNECTOR IS THE BATTERY VOLTAGE APPLIED AT THE 6 B-12 AND GROUND?

YES

•

IS THE DOOR LOCK CONTROLLER NORMAL?

YES

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 D-4 AND B-7

NO REPLACE THE FUSE

NO REPLACE THE DOOR LOCK SWITCH

NO GROUND IT SECURELY

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-27 (15A) AND 6 B-12

NO REPLACE THE DOOR LOCK CONTROLLER

CAB AND CHASSIS ELECTRICAL 8-19 2. ALL THE DOORS DO NOT GET LOCKED (OR UNLOCKED) •

IS DOOR LOCK SWITCH NORMAL?

YES

•

•

NO

DISCONNECT THE DOOR LOCK CONTROLLER CONNECTOR IS THERE CONTINUITY BETWEEN 5 B-12 AND 4 B-12 OF HARNESS SIDE CONNECTORS

REPAIR OR REPLACE THE DOOR LOCK SWITCH

YES

NO

REPLACE THE DOOR LOCK CONTROLLER

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT

3. DRIVER SIDE DOOR DOES NOT GET LOCKED (OR UNLOCKED) REPLACE THE DOOR LOCK SWITCH

4. FRT PASSENGER SIDE DOOR DOES NOT GET LOCKED (OR UNLOCKED) 5. RR DOOR-RH SIDE DOES NOT GET LOCKED (OR UNLOCKED) 6. RR DOOR-LH SIDE DOES NOT GET LOCKED (OR UNLOCKED) REPLACE THE DOOR LOCK ACTUATOR


DOOR LOCK RELAY The door lock controller sends out to each door lock actuator the lock/unlock signals received from door lock switch from the driver seat side.

DOOR

LOCK

8-9725 0192-0 051 500-3680

12V

DENSO

MADE IN JAPAN

Figure 16. Door Lock Relay

Circuit Inspection (Figure 17) Check the voltage and the continuity between the controller harness side connector terminals.

B-12

1 2

3

4 5 6 7 8

Harness side

Terminal No.

Wire color

7

R/G

Door lock SW (Unlock)

7-Ground

Driver seat side door

Unlock

Continuity

Lock

No continuity

5

G/B

Door lock SW (Lock)

5-Ground

Driver seat side door

Unlock

No continuity

Lock

Continuity

1-Ground

–

3-2

–

2-3

–

6-Ground

–

Connected to

1

B

Ground

3

BR/Y

Actuator (Unlock)

2

BR/R

Actuator (Lock)

6

R

Fuse F-27 (15A)

Item to be checked

Continuity (Resistance)

Voltage

Connecting terminal

Checking conditions

Figure 17. Door Lock Relay Circuit Check

Standard

Continuity Continuity (There is some resistance) Continuity (There is some resistance) Battery voltage

CAB AND CHASSIS ELECTRICAL 8-21 Inspect (Figure 18) Remove the connector of the door lock controller, and check the continuity and the voltage between the controller side connector terminals. (Connect the + terminal of the battery to 6 B-12 and the – terminal to 1 B-12 )

DOOR LOCK SWITCH (DRIVER SEAT SIDE) The door lock switch on the driver’s door is connected with the door lock cylinder and the inside lock knob with a rod. The switch sends lock/unlock signals to the door lock controller.

1 B-12 – 2 B-12 .........Continu ity 1 B-12 – 3 B-12 .........Continu ity

Door lock ASM

(Then, ground 5 B-12 ) 2 B-12 .........Voltage for approx. 1 second

Door lock SW

(Disconnect the ground of 5 B-12 , and ground 7 B-12 .) 3 B-12 .........Voltage for approx. 1 second Replace the controller if the result of the inspection is found abnormal. Figure 20. Door Lock Switch B-12

Inspection (Figure 21) 3 8

7

6

2

1

5

4

Check to see if there is any continuity between the connector terminals of the door lock switch. Replace the switch if the result of the inspection is found abnormal.

Controller side

Figure 18. Door Lock Relay Check D-4

Inspect (Figure 19) After confirming that there is continuity between the harness side connector terminals 3 B-12 and 2 B-12 of the door lock controller, apply battery voltage to each of the terminals to conduct the operation test. If the door lock will not operate, check the door lock actuator for functionality.

1

2

3

4

5

6

Switch side

Terminal No. Operation

1

2

Lock

–

+

Unlock

+

–

Figure 21. Circuit Check B-12

1 2

3

4 5 6 7 8

Connecting terminal 3 (BR/Y) 2 (BR/R) + – + –

Harness side

Operation Unlock Lock

Figure 19. Circuit Check

Remove or Disconnect Refer to Section 10 “CAB” for “DOOR LOCK ASSEMBLY (front and rear)”. Install or Connect Refer to Section 10 “CAB” for “DOOR LOCK ASSEMBLY (front and rear)”.


DOOR LOCK ACTUATOR

Inspection (Figure 23)

Receiving forward or reverse current from the door lock controller, the door lock actuator locks or unlocks the door with the rod connected to the door lock mechanism.

Door lock ASM

Apply the battery voltage to the connector terminals of the door lock actuator to check the operation. When the door lock actuator is checked on the vehicle and there is no continuity, and when the door lock actuator itself is checked and no trouble is found, check the circuit between the door lock actuator and the door lock controller for any failure.

Actuator

Figure 22. Door Lock Actuator

D-8

D-9

D-10

Door lock ASM 2

Actuator side

Door Actuator

1

2

Refer to Section 10 “CAB” for “DOOR LOCK ASSEMBLY (Front and rear)”. Install or Connect Refer to Section 10 “CAB” for “DOOR LOCK ASSEMBLY (Front and rear)”.

Actuator side

FRT Passenger

RR-LH

RR-RH

D-8

D-9

D-10

Connector No. Terminal No. Operation

1

2

1

2

1

2

Lock

–

+

+

–

+

–

Unlock

+

–

–

+

–

+

Figure 23. Door Lock Actuator Check

Remove or Disconnect

1

METRIC AND FASTENER INFORMATION 9-1

SECTION 9

METRIC AND FASTENER INFORMATION NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Metric Fasteners .................................................................................................... See 1999-2001 Service Manual Replacement Fasteners..................................................................................... See 1999-2001 Service Manual Fastener Strength Identification ........................................................................... See 1999-2001 Service Manual Prevailing Torque Fasteners................................................................................. See 1999-2001 Service Manual Recommendations for Reuse ........................................................................... See 1999-2001 Service Manual Six-Lobed Socket Head Fasteners ....................................................................... See 1999-2001 Service Manual Decimal and Metric Equivalents ........................................................................... See 1999-2001 Service Manual Conversion Table ................................................................................................... See 1999-2001 Service Manual

9-2 METRIC AND FASTENER INFORMATION MEMO .................................................................................................................................................................................................................................................................................................................

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STEEL CAB 10-1

SECTION 10

STEEL CAB CONTENTS SUBJECT

PAGE

Steel Tilt Cab ......................................................................................................... See 1999-2001 Service Manual Steel Crew Cab ................................................................................................................................................... 10E

10-2 STEEL CAB MEMO .................................................................................................................................................................................................................................................................................................................

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STEEL CREW CAB 10E-1

SECTION 10E

STEEL CREW CAB NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS SUBJECT

PAGE

Cab Description.............................................................................................................................................. 10E- 2 Design and Construction ...................................................................................................................... 10E- 2 Windows ................................................................................................................................................. 10E- 2 Diagnosis of Steel Crew Cab ........................................................................................................................ 10E- 3 On-Vehicle Service ..........................................................................................SEE 1999-2001 SERVICE MANUAL Cab Interior...................................................................................................SEE 1999-2001 SERVICE MANUAL Driver’s Seat ............................................................................................SEE 1999-2001 SERVICE MANUAL Passenger Seat .......................................................................................SEE 1999-2001 SERVICE MANUAL Rear Seat .................................................................................................................................................10E- 5 Front Seat Belts:Side Seat Belt Tongue .............................................................................................. 10E- 6 Front Center and Driver Side Seat Belt Buckle.....................................SEE 1999-2001 SERVICE MANUAL Front Center Seat Belt Tongue and Passenger Side Seat Belt Buckle....SEE 1999-2001 SERVICE MANUAL Rear Seat Belt: Side Seat Belt Tongue .................................................................................................10E- 8 Rear Door-side Seat Belt Buckle and Rear Center Seat Belt/Buckle .................................................10E- 9 Instrument Panel .....................................................................................SEE 1999-2001 SERVICE MANUAL Instrument Panel Reinforcement ...........................................................SEE 1999-2001 SERVICE MANUAL Headlining ...............................................................................................................................................10D-11 Cab Floor Cover ......................................................................................................................................10E-13 Doors.............................................................................................................SEE 1999-2001 SERVICE MANUAL Description ..............................................................................................SEE 1999-2001 SERVICE MANUAL Front Door ...............................................................................................SEE 1999-2001 SERVICE MANUAL Front Lock Mechanism............................................................................SEE 1999-2001 SERVICE MANUAL Front Lock Cylinder and Outside Door Release Handle .....................SEE 1999-2001 SERVICE MANUAL Front Trim Panel .....................................................................................SEE 1999-2001 SERVICE MANUAL Front Window and Window Regulator Assembly ................................SEE 1999-2001 SERVICE MANUAL Rear Door.................................................................................................................................................10E-14 Rear Door Lock Mechanism...................................................................................................................10E-15 Rear Door Outside Door Release Handle .............................................................................................10E-16 Rear Door Trim Panel .............................................................................................................................10E-17 Rear Window and Window Regulator Assembly .................................................................................10E-19 Rear Step Assembly ...................................................................................................................................10E-21 Cab Replacement.........................................................................................SEE 1999-2001 SERVICE MANUAL Specifications..................................................................................................................................................10D-22 Fastener Torques....................................................................................................................................10D-22

10E-2 STEEL CREW CAB

CAB DESCRIPTION DESIGN AND CONSTRUCTION

WINDOWS

The Steel Crew Cab Model (figure 1)is all steel welded construction. The cab fully surrounds the engine. The cab rests on three mount brackets which are bolted to the frame rail on both sides of the truck. The combination brake fluid/clutch fluid reservoir is located inside the cab, on the left side of the dash.

Door windows are covered in this section under "Doors". All other windows are covered in CAB MAINTENANCE (SEC.2B) under "Stationary Glass".

604L200001

Figure 1 Steel Crew Cab

STEEL CREW CAB 10E-3

DIAGNOSIS OF STEEL CREW CAB TROUBLE

POSSIBLE CAUSE

CORRECTION

1. Obstructed adjustment mechanism. 2. Frozen or obstructed guide rails.

3. Broken adjustment lever.

1. Remove the obstruction. 2. Replace obstruction and/or remove the seat and the adjustment mechanism . Clean the guide rails and lubricate. 3. Replace the adjustment machanism.

Seat moves only on One Side

1. Obstructed guide rail. 2. Obstructed adjustment mechanism.

1. Remove the obstruction. 2. Remove the obstruction.

Seat is Hard to Move

1. Tension spring is broken or disconnected. 2. Rusty or obstructed guide rails.

1. Remove or connect the spring.

1. Missing or disconnected adjustment springs. 2. Broken adjustment lever.

1. Remove or connect the spring(s).

1. Door is out of alignment. 2. Striker is out of alignment. 3. Cam of the locking mechanism is in the closed position.

1. Align the door. 2. Align the striker. 3. Unlock the door, pull the outside handle, and manually rotate the cam. 4. Tighten the attaching screws of the locking mechanism. 5. Straighten the cam or replace the locking mechanism.

Seat will not move

Seat will not Stay in Desired Position

Door will not Latch or Latches with Difficulty

4. Locking mechanism is not attached securely to the door. 5. Cam of the locking mechanism is bent or broken. Door will not Lock

Door will not Open but It is Unlocked (Door Handles do not Work Freely)

2. Remove the obstruction and/or lubricate.

2. Replace the adjustment machanism.

1. Disconnected lock rod between the outside handle and locking mechanism. 2. Arm of the lock cylinder has not properly engaged the lug of the locking mechanism. 3. Lug of the locking mechanism is broken. 4. Frozen lock cylinder.

1. Connect rod. Use a new clip.

1. Door out of alignment. 2. Striker bolt out of alignment. 3. Frozen locking mechanism.

1. Align the door. 2. Adjust the striker bolt. 3. Remove the locking mechanism and lubricate or replace it.

2. Remove the lock cylinder and install as directed later in this section. 3. Replace the locking mechanism. 4. Lubricate the lock cylinder or replace.


DIAGNOSIS OF STEEL CREW CAB (CONT.) TROUBLE

POSSIBLE CAUSE

Door will not Open, It is Unlocked, but Release Handle/Lever Works Freely

Disconnected rod from the door release mechanism to the locking mechanism.

If disconnected from the release mechanism, remove the mechanism and connect the rod to it. If disconnected from the locking mechanism, connect the rod.

Door is Hard to Open

1. Frozen hinge-dirty or incorrect lubricant. 2. Door is out of alignment.

1. Clean the hinge and lubricate.

1. Rusty or dirty regulator.

1. Remove the regulator, clean and lubricate. 2. Remove obstruction.

Door Window is Difficult to Move

2. Obstructed run channel. Door Window will not Close or Regulator Handle will not Work

1. Obstructed or frozen regulator.

Door Window will not Move but Regulator Handle Moves Freely

1. Stripped window regulator handle. 2. Stripped window regulator shaft. 3. Regulator roller is not in the guide channel. 4. The teeth of the regulator gear are broken.

2. Obstructed regulator guide channel. 3. Obstructed run channel. 4. Misaligned run channel.

CORRECTION

2. Align the door.

1. Remove the regulator, clean and lubricate. 2. Remove obstruction. 3. Remove obstruction. 4. Reposition run channel bracket and/or division channel. 1. Replace handle. 2. Replace regulator. 3. Remove regulator and install as outlined in this section. 4. Replace regulator.

STEEL CREW CAB 10E-5 REAR SEAT

1

Clip

1. Rear seat cushion 2. Rear seat frame 2

Figure 2. Rear Seat Removal or Installation

Remove or Disconnect (Figure 2) 1. Rear seat cushion (1) • Pull the seat cushion at the three clip positions from the seat frame. 2. Rear seat frame (2) • Remove the 6 bolts. Install or Connect (Figure 2) To install, follow removal steps in the reverse order, noting the following point. 1. Tighten the rear seat frame mounting bolts to the specified torque. Tighten • Rear seat frame bolts to 13 N•m (9 lb•ft).

755L200001

10E-6 STEEL CREW CAB FRONT SEAT BELTS:SIDE SEAT BELT TONGUE

2

Bracket Seat belt tongue side assembly

1. Seat belt lower ancher bolt 2. Retractor cover 3. Through bolt anchor cover 4. Seat belt upper anchor bolt 5. Retractor mounting bolt Seat belt lower anchor bolt mounting hole

Figure 3. Side Seat Belt Removal or Installation

760L200001

STEEL CREW CAB 10E-7 Remove or Disconnect (Figure 3) 1. Seat belt lower ancher bolt (1) 2. Retractor cover (2) • Remove the 2 mounting screws. 3. Through bolt anchor cover (3) 4. Seat belt upper anchor bolt (4) 5. Retractor mounting bolt (5) • Remove the bolt and pull out the upper bracket of the retractor from the panel. Install or Connect (Figure 3) To install, follow the removal steps in the reverse order, noting the following points: 1. Apply the sealant around the seat belt lower anchor bolt mounting hole.(Figure.4)

Figure 4. Sealant Application 2. Install the lower anchor in the specified direction and tighten it to the specified torque.(Figure 5) Tighten • Anchor bolt to 45 N·m (33 lb·ft) NOTICE: Install the seat belt lower anchor so that it may not run on the anchor detent bead

Figure 5. Anchor Direction

10E-8 STEEL CREW CAB REAR SEAT BELTS: SIDE SEAT BELT TONGUE

3

2 Clip 4

Bracket

Seat belt tongue side assembly

1 5

1. Seat belt lower ancher bolt 2. Rear piller lower trim cover 3. Through bolt anchor cover 4. Seat belt upper anchor bolt 5. Retractor mounting bolt

Seat belt lower anchor bolt mounting hole

Figure 6. Side Seat Belt Removal or Installation

Remove or Disconnect (Figure 6) 1. Seat belt lower ancher bolt (1) 2. Rear piller lower trim cover (2) • Remove the two clips and pull the cover upwards. 3. Through bolt anchor cover (3) 4. Seat belt upper anchor bolt (4) 5. Retractor mounting bolt (5) • Remove the bolt and pull out the upper bracket of the retractor from the panel.

760L200008

Install or Connect (Figure 6) To install, follow the removal steps in the reverse order, noting the following points: 1. Apply the sealant around the seat belt lower anchor bolt mounting hole.(Figure.7)

STEEL CREW CAB 10E-9 Tighten • Anchor bolt to 45 N·m (33 lb·ft) NOTICE: Install the seat belt lower anchor so that it may not run on the anchor detent bead

Figure 7. Sealant Application 2. Install the lower anchor in the specified direction and tighten it to the specified torque.(Figure 8) Figure 8. Anchor Direction

REAR DOOR-side SEAT BELT BUCKLE AND REAR CENTER SEAT BELT/BUCKLE

3

Rear seat belt reinforcement 1

4

Rear floor panel

3

5

2

1. Rear seat cushion 2. Lower anchor bolt 3. Door-side seat belt buckle 4. Center seat belt tongue 5. Center seat belt buckle

760L200009

Figure 9. Rear Door-side Seat Belt Buckle and Rear Center Seat Belt/Buckle Removal and Installation Remove or Disconnect (Figure 9) 1. Rear seat cushion (1) • Refer to “Rear seat” in this section. 2. Lower anchor bolt (2)

3. Door-side seat belt buckle (3) 4. Center seat belt tongue (4) 5. Center seat belt buckle (5)

10E-10 STEEL CREW CAB Install or Connect (Figure 9) To install, follow the removal steps in the reverse order, noting the following points: 1. Apply the sealant around the door-side seat belt buckle lower anchor bolt mounting hole.(Figure 10)

Figure 10. Sealant Application 2. Install the anchor in the specified direction and tighten it to the specified torque.(Figure 11) Tighten • Anchor bolt to 45 N·m (33 lb·ft) 3 Install the anchor bracket to match the detent bead. (Figure 11)

760L200003

Figure 11. Anchor Bracket Installation

STEEL CREW CAB 10E-11 HEADLINING Dome light

Adhesive tape

Roof ventilator

6

5

5

2

1. 2. 3. 4. 5. 6.

4

1

3

Roof ventilator grille Front retainer Interior light Roof reinforcement Headlining Insulator 666L200001

Figure 12. Headlining Removal or Installation. Remove or Disconnect (Figure 12) Front side

Preparati on:Disconnect the battery ground cable. 1. Roof ventilator grille (1) (Figure 13) • Remove one mounting screw and pull the four mounting clips.

Roof panel

1

Roof ventilator grille Clip 668L100001

Figure 13. Roof Ventilator Grille Removal

10E-12 STEEL CREW CAB 2. Front retainer (2) • Remove the 5 clips. 3. Interior light (3) (Figure 14) • After removing the lens, remove the 2 screws. • Disconnect the connector.

Connector

Screw Lens

805L200002

Figure 14. Interior Light 4. Roof reinforcement (4) • Remove the 4 screws. 5. Headlining (5) 6. Insulator (6)

Install or Connect (Figure 12) To install, follow the removal steps in the reverse order.

STEEL CREW CAB 10E-13 CAB FLOOR COVER

2 4

5

1

7

3

8

6

1. Driver’s seat 2. Passenger seat with engine cover 3. Automatic transmission (A/T) control lever cover 4. Center console 5. Parking brake lever with cable 6. Automatic transmission (A/T) with shift cable 7. Driver and center seat belt buckle 8. Cab floor cover

Figure 15. Cab Floor Cover Removal and Installation. Remove or Disconnect (Figure 15) 1. Driver’s seat (1) • Refer to “Driver’s seat” in this section. 2. Passenger seat with engine cover (2) 3. Automatic transmission (A/T) control lever cover (3) • Refer to AUTOMATIC TRANSMISSION (SEC. 7A3). 4. Center console (4) 5. Parking brake lever with cable (5) 6. Automatic transmission (A/T) with shift cable. (6) • Refer to AUTOMATIC TRANSMISSION (SEC. 7A3). 7. Driver and center seat belt buckle (7) 8. Cab floor cover (8)

676L200001

Install or Connect (Figure 15) To Install, follow the removal steps in the reverse order, noting the following point: 1. Before installing the cab floor cover, apply the sealant to the contact surface of the cab floor cover.

10E-14 STEEL CREW CAB REAR DOOR

1

Hinge

2

1. Mounting bolt 2. Rear door assembly

Figure 16. Rear Door Assembly Removal or Installation Remove or Disconnect (Figure 16) 1. Mounting bolt (1) • Remove the 3 mounting bolts for each hinge. 2. Rear door assembly (2) Install or Connect (Figure 16) To Install, follow the removal steps in the reverse order, noting the following point: 1. Tighten the mounting bolt to the specified torque. Tighten • Mounting bolts to 25 N·m (18 lb·ft).

650L200001

STEEL CREW CAB 10E-15 REAR DOOR LOCK MECHANISM 1. 2. 3. 4.

Rear door trim panel Water-proof sheat Glass run rear channel Lock mechanism

3

2 1

4

Figure 17. Lock mechanism Remove or Disconnect (Figure 17) 1. Rear door trim panel (1) • Refer to “Rear door trim panel” in this section. 2. Water-proof sheet (2) (Figure 18) • Peel off the water-proof sheet carefully with a cutter or knife. Take care not to damage it when peeling it off.

651L200001

3. Glass run rear channel (3) • Remove the 2 mounting screws and pull the rear channel out. 4. Lock mechanism (4) • Remove the 3 mounting screws and disconnect the locking links. Install or Connect (Figure 17) To Install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the mounting screw to the specified torque. Tighten • Mounting screws to 6 N·m (52 lb·in) 2. After installation, check the operation.

635LX005

Figure 18. Water-proof Sheet Removal

10E-16 STEEL CREW CAB REAR DOOR OUTSIDE DOOR RELEASE HANDLE 1. Rear door trim panel 2. Water-proof sheat 3. Outside door release handle 3

2 1

A

Figure 19. Outside Door Release Handle Removal or Installation Remove or Disconnect (Figure 19)

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1. Rear door trim panel (1) • Refer to “Rear door trim panel” in this section. 2. Water-proof sheet (2) (Figure 18) • Refer to “Rear door lock mechanism” in this section. 3. Outside door release handle (3) (Figure 20) • Disconnect the link and remove the 2 mounting bolts.

View A

Outside door release handle

652L200002

Figure 20. Outside Door Release Handle Removal

To Install, follow the removal steps in the reverse order, noting the following point: 1. Tighten the mounting bolt to the specified torque. Tighten • Mounting bolts to 13 N·m (113 lb·in) ~18 N·m (13 lb ft)

STEEL CREW CAB 10E-17 REAR DOOR TRIM PANEL 1. 2. 3. 4.

Inside lever garnish Regulator handle Arm rest Rear door trim panel

1

2

4 3

Figure 21. Trim Panel Removal or Installation

655L100001

Remove or Disconnect (Figure 21) 1. Inside lever garnish (1) • Remove the mounting screw and pull the bezel out toward you while pulling and holding the inside lever. 2. Regulator handle (2) • Remove the clip on the rear side of the regulator handle using a wire. 3. Arm rest (3) 4. Rear door trim panel (4) (Figure 22) • Remove the clip at 11 positions.

Clip position 655L200001

Figure 22. Trim Panel Clip Position

10E-18 STEEL CREW CAB Install or Connect (Figure 21) To Install, follow the removal steps in the reverse order, noting the following points: 1. Adjust the trim panel clip to the mounting hole on the door panel side and install the trim pad. (Figure 23)

Clip mounting hole 655L200002

Figure 23. Rear Door Panel Clip Position 2. Carefully install the arm rest and tighten the mounting screws. (Figure 24)

Rear door trim panel Arm rest

655L200003

Figure 24. Arm Rest Installation

STEEL CREW CAB 10E-19 REAR WINDOW AND WINDOW REGULATOR ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8.

Rear Rear d door oor trim trim panel panel Wate Wa terr-pr proo ooff sheet sheet Door Door bott bottom om bracke brackett Rear Rear door door glas glass s plug plug Rear Rear wind window ow glas glass s Wind Window ow reg regula ulato torr Glass lass run run Glass Glass run rear rear chann channel el

Figure 25. Rear Window and Window Regulator Removal or Installation

651L200002

Remove or Disconnect (Figure 25) 1. Rear door door trim trim panel (1) • Refer to to “Rear door door trim trim panel” in in this section. section. 2. Water-proof Water-proof sheet (2) • Refer to to “Rear door door lock mechanis mechanism” m” in this section. 3. Door bottom bottom bracket bracket (3) • Remove the 4 mount mounting ing screws. screws. 4. Rear door door glass glass plug (4) 5. Rear window window glass (5) (5) • Operate Operate the requlator requlator to to adjust the the glass height height and expose the access hole. Remove the 2 bolts mounting the bottom channel and the requlator. Remove the glass from the bottom access hole. 6. Window requlator requlator (6) • Remove the 5 mounting mounting screws, screws, and remove itit through the access hole. (Figure 26)

Window regulator mounting screws 651L200003

Figure 26. Window Screw Position

10E-20 10E-20 STEEL STEEL CREW CAB CAB 7. Glass Glass run run (7) • Pull the the glass run run out from from the the channel. channel. 8. Glass run run rear channel channel (8) (8) • Remove Remove th the e 2 mounting mounting screw screws. s. Install or Connect (Figure 25) To Install, follow the removal steps in the reverse order, noting the following points:

1. Align the notch a of the glass run lip with the door outer waist line A . Align the glass run slit b with the door B and fit fit the the glass run between A and B . Next, align the notch c of the glass run lip with the door outer waist line C and fit the glass run between B and C . Fit the glass run in the channel within the door. (Figure 27) • Fit the glass glass run with with the lip lip toward toward the outside outside of the vehicle. NOTICE: When reusing the glass run, apply the sealant to the range shown in the figure. (Figure 27)

Figure 27. Glass Run Installation 2. Tighten Tighten the mounting screw screw to the specified specified torque.

Tighten • Moun Mounting ting bolts bolts to 7 N·m N·m (61 (61 lb·in) lb·in)

3. Check the water-proo water-prooff sheet for breakage. breakage.

655L200004

STEEL CREW CAB 10E-21 REAR STEP STE P ASSEMBLY

1

1. Rear Rear step step stay stay 2. Rear Rear step step assem assembly bly

2

Figure 28. Rear Step ASM Removal or Installation Remove or Disconnect (Figure 28) 1. Rear step stay stay (1) (1) • Remove the 2 bolts from each side. side. 2. Rear step step assembly assembly (2) (2) • Remove Remove the 4 bolts bolts..

Install or Connect (Figure 28) To Install, follow the removal steps in the reverse order.

620L200001


FASTENER TORQUES

SPECIFICATIONS N•m (lb•ft)

Figure 29. Fastener Torques

2002 Isuzu NPR Repair Manual

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