ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER - Service / Repair / Workshop Manual * BEST *

FOREWORD This service manual contains diagnosis, on-vehicle service, wiring diagrams, and component unit repair for Medium Duty Steel Cab Vehicles. Keep this manual in a handy place for ready reference. If properly used, it will enable the technician to serve the owners of these vehicles. CAUTION: This service manual is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your vehicle that may cause it not to operate properly. These vehicles contain parts dimensioned in the metric system as well as in the customary system. Some fasteners are metric and are very close in dimension to familiar customary fasteners in the inch system. It is important to note that, during any vehicle maintenance procedures, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings.) Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury. Therefore, fasteners removed from the vehicle should be saved for re-use in the same location whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. For information and assistance, see your Authorized dealer.

CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part. Do not use a replacement part of lesser quality. The service procedures recommended and described in this service manual are effective methods of performing service and repair. Some of these procedures require the use of tools specially designed for the purpose. Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part, service procedure or tool selected. It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these 'Cautions' and 'Notices' are not exhaustive, because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions.

1996/1997 SERVICE MANUAL NPR/W4 V8 GASOLINE ENGINE MODELS Any reference to brand names in this manual is intended merely as an example of types of lubricants, tools, materials, etc., recommended for use. In all cases, an equivalent may be used. All information, illustrations, and specifications contained in this manual are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice. PUBLICATION NO. NPG96-WSM-C01 Isuzu Motors Limited ©1996 Isuzu Motors Limited Printed in U.S.A. August 1996 No part of this publication may be reproduced, stored in any retrieval system, or transmitted, in any from or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Isuzu Motors Limited. This includes all text, illustrations, tables, and charts.

TABLE OF CONTENTS he table of contents on this page indicates the sections covered in this manual. At the beginning of each ividual section is a table of contents which gives the page number on which each major subject begins. SECTION 0 1 2 3 4 5 6 7A 8 9 10 SUBJECT GENERAL INFORMATION HEATING AND AIR CONDITIONING FRAME AND CAB STEERING SUSPENSION, WHEELS AND TIRES REAR AXLE AND PROPELLER SHAFT BRAKES ENGINE AUTOMATIC TRANSMISSION CAB AND CHASSIS ELECTRICAL METRIC AND FASTENER INFORMATION STEEL TILT CAB CONTENTS OA GENERAL OB MAINTENANCE AND INFORMATION LUBRICATION 1A HEATING AND 1B AIR CONDITIONING VENTILATION 2A FRAME AND BODY 2C SHEET METAL MOUNTS 2B CAB MAINTENANCE 3A FRONT END ALIGNMENT 3C FRONT AXLE AND 3B1 STEERING LINKAGE SUSPENSION 3B3 POWER STEERING 3D REAR SUSPENSION 3B4 STEERING COLUMN 3E WHEELS AND TIRES 4A1 REAR AXLE 4B PROPELLER SHAFT 5A HYDRAULIC BRAKES 5A2 HYDRAULIC FOUNDATION 5A1 HYDRAULIC BRAKE BRAKES BOOSTER SYSTEM 5C PARKING BRAKE 6A GENERAL ENGINE MECHANICAL 6D1 BATTERY 6A5 V8 ENGINE 6D2 CRANKING SYSTEM 6B1 COOLING SYSTEM 6D3 CHARGING SYSTEM 6B2 RADIATOR 6D4 IGNITION SYSTEM 6B3 FAN 6E1 DRIVEABILITY AND 6D ENGINE ELECTRICAL EMISSIONS 6F EXHAUST SYSTEM 7A2A AUTOMATIC TRANSMISSION 7A2C AUTOMATIC TRANSMISSION DIAGNOSIS ON-VEHICLE SERVICE 7A2B AUTOMATIC TRANSMISSION 7A2D AUTOMATIC TRANSMISSION DIAGNOSTIC TROUBLE CODES UNIT REPAIR 8 CAB AND CHASSIS ELECTRICAL 9 METRIC AND FASTENER INFORMATION 10D STEEL TILT CAB

NPR/W4 V8 GASOLINE ENGINE MODEL DATA Truck Model NPR/W4 Engine Standard V8 GASOLINE ENGINE Clutch Front Axle Standard Reverse Elliott, 1-Beam Rear Axle Standard Single Speed Banjo, Full Floating Transmission Standard AUTOMATIC TRANSMISSION

GENERAL INFORMATION OA-1 SECTION 0 GENERAL INFORMATION CONTENTS SUBJECT General Information ................ Maintenance and Lubrication, OA .OB SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Handling Electrostatic Discharge (ESD) Sensitive Parts ............................................................................ OA- 2 Model Designation ........................................................................................................................................... OA- 2 VIN (Vehicle Identification Number) and Weight Rating Plate..................................................................... OA- 2 GVWR (Gross Vehicle Weight Rating) .......................................................................................................... OA- 3 Service Parts Identification Label ................................................................................................................. OA- 3 Regular Production Options (RPO) Code List ............................................................................................. OA- 4 Engine Serial Number ..................................................................................................................................... OA- 5 Graphic Symbols ........................................................................................................................................... OA- 5 Action Symbols ............................................................................................................................................... OA- 5 Emergency Starting a Vehicle Due to a Discharged Battery....................................................................... OA- 5 Towing Procedure ........................................................................................................................................... OA- 6 Vehicle Lifting Points ..................................................................................................................................... OA- 7 Abbreviations Charts....................................................................................................................................... OA- 8 Essential Service Tools .................................................................................................................................. OA-10

OA-2 GENERAL INFORMATION HANDLING ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS When handling an electronic part that has as 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 it is time to install the part. 2. Avoid touching the electrical terminals of the part. 3. Before removing the part from its package, ground the package to a known good ground on the vehicle. 4. Always touch a known good 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. NOTICE ^A CONTENTS SENSITIVE TO STATIC ELECTRICITY Model NPR/W4 4x2 Figure 3. Model Identification VIN (VEHICLE IDENTIFICATION NUMBER) AND WEIGHT RATING PLATE The VIN 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 VIN (vehicle identification number). This plate is located on the driver's door in the lower right hand corner. The vehicle identification number is a legal identifier of your vehicle. It not only appears on the VIN plate, but also on the Vehicle Certificates of Title and Registration. The vehicle identification number specifically identifies a vehicle by code. Figure 5 displays plays the codes and descriptions for the model covered in this manual. Figure 1. Electrostatic Discharge Symbol MODEL DESIGNATION The model designation for this vehicle is NPR/W4S042. Refer to figure 2 for the model explanation and figure 3 for the model identification. CODE W 4 S 0 42 DESCRIPTION Steel Tilt Cab GVW Range - 10,001-16,000 Ib Cab Style-68.0 in BBC Steel Cab Constant - For Future Expansion Chassis Type-4 x 2 Figure 4. VIN Weight Rating Plate Figure 2. Model Explanation

GENERAL INFORMATION OA-3 Ident | 4 | Code Description 4KL Isuzu Incomplete Janesville Assembly Plant 4KD GMC Incomplete Janesville Assembly Plant 4KB Chevrolet Incomplete Janesville Assembly Plant Code Description B 10001 - 14000 Ib C 14001-16000 Ib Hydraulic Brake System GVWf Brake S ifiers t- <] L] [B] 4 B [1 | Code Series 4 NPR/W4 Cab Type Code Model Year Code 1 and system Series Code ~T Cha Type Engine Code ssis Code H Check Digit ^ . T J 0 Q [o] JT| [0} fT Plant Code L -LTJ, 1 1 1 1 Sequential Numbers 1 Code Plant Location J Janesville Code Model Year T 1996 V 1997 Code Description R V8 Gasoline Englne(L31) Code Description 1 4x2 Code Description B Steel Tilt Cab 68.0 in BBC' * -- Bumper to Back of Cab 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 3). For the gross vehicle weight rating range refer to the VIN 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, 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 located on the right-hand step support panel. ^ V. VIN M.D ENG TRA TIR Y SUZU MC INE NS E B. COL< IIL i—r n ii )TORS LTD. JAPAN 4KLB4B1A7SJ000001 | OR/ < ^ | RR AXLE ) FINAL u TRIM 3PT10N a a —r~i~~ i ii ~ZJZZ ~]LZ. CD LZ] y Figure 6. Service Parts Identification Label

You're Reading a Preview

ISUZU NPR / W4 / 4000 ( V8 EFI GASOLINE Engine )- ISUZU Truck FORWARD TILTMASTER - Service / Repair / Workshop Manual * BEST *

Description

Reviews

Q&A

Recently Viewed