1997-2002 Isuzu F Series (FSR / FTR / FVR) Service & Repair Manual

CAUTION In order to reduce the chance of personal injury and/or property damage, carefully observe the instructions that follow: The service manuals of Isuzu Motors America Inc. are intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others. This could also damage the vehicle, or cause the vehicle to operate improperly. Proper vehicle service and repair are important to the safety of the service technician and to the safe, reliable operation of all motor vehicles. If you need to replace a part, use the same part number or an equivalent part. Do not use a replacement part of lesser quality. The service procedures we recommend and describe in this service manual are effective methods of performing service and repair. Some of the procedures require the use of tools that are designed for specific purposes. Accordingly, any person who intends to use a replacement part, a service procedure, or a tool that is not recommended by Isuzu, must first establish that there is no jeopardy to personal safety or the safe operation of the vehicle. This manual contains various CAUTIONS and NOTICES that you must observe carefully in order to reduce the risk of personal injury during service or repair. Improper service or repair may damage the vehicle or render the vehicle unsafe. These CAUTIONS and NOTICES are not exhaustive. Isuzu can not possibly warn of all the potentially hazardous consequences of your failure to follow these instructions. This manual covers service procedures to vehicles that are equipped with a Supplemental Inflatable Restraint (SIR). Refer to the CAUTIONS in Cautions and Notices and in Restraints. Refer to SIR component and wiring location views in Restraints before performing a service on or around SIR components or wiring. Failure to follow these CAUTIONS could cause air bag deployment, personal injury, or otherwise unneeded SIR repairs. In order to help avoid accidental air bag deployment and personal injury, whenever you service a vehicle that requires repair of the SIR and another vehicle system, we recommend that you first repair the SIR, then go on to the other system.

New Style Service Manual Structure This new style service manual is constructed with the following 10 sections: 0. General Information 1. Heating, Ventilation, and Air Conditioning (HVAC) 2. Steering 3. Suspension 4. Driveline and Axle 5. Brakes 6. Engine 7. Transmission 8. Body and Accessories 9. Restraints The following table gives the previous service manual sub-sections with the name of the new section and sub-section. Almost all of the diagnosis that was in section 8A is now located in its applicable sub-section.

Truck Service Manual Sub-Section to Section and Sub-Section Conversion Table Old Sub-Section OA OB OC 1A 1B 1D 2A 3A 3B,3B1A, 3B1B 3B3 3C 3D 3E 3F 4A 4B 4C 5 5A 5B 5C 5D 5E 5F 6, 6A 6B 6C 6D — 6F 6H 6J 7A Old Sub-Section General Information Maintenance and Lubrication Vibration Diagnosis Heating and Ventilation Heating, Ventilation, and Air Conditioning A/C Compressors Frame and Bumpers Front Wheel Alignment Power Steering Gear and Pump Steering Linkage Front Suspension Rear Suspension Tires and Wheels Steering Columns Propeller Shaft Rear Axle and Differential Front Drive Axles and Differential Hydraulic Brakes Master Cylinder Front Disc Brakes Drum Brakes Hydraulic or Vacuum Booster Antilock Brakes Parking Brake Engine Mechanical Engine Cooling and Radiator Engine Fuel Engine Electrical Driveability and Emissions Exhaust System Vacuum Pump Turbocharger Automatic Transmission New Section 0 0 0 1 1 1 8 3 2 2 3 3 3 2 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 7 Section Name General Information General Information General Information HVAC HVAC HVAC Body and Accessories Suspension Steering Steering Suspension Suspension Suspension Steering Driveline/Axle Driveline/Axle Driveline/Axle Brakes Brakes Brakes Brakes Brakes Brakes Brakes Engine Engine Engine Engine — — Engine Engine Transmission/Transaxle Sub-Section Name General Information Maintenance and Lubrication Vibration Diagnosis Heating and Ventilation (Non A/C) HVAC systems with Air Conditioning HVAC systems with Air Conditioning Frame and Underbody, and Bumpers Wheel Alignment Power Steering System Steenng Linkage Front Suspension Rear Suspension Tires and Wheels Steering Wheel and Column Propeller Shaft Rear Drive Axle Front Wheel Drive Shafts and Front Drive Axle Hydraulic Brakes Hydraulic Brakes Disc Brakes Drum Brakes Hydraulic Brakes Antilock Brakes Parking Brake Engine Mechanical Engine Cooling Engine Controls Engine Electrical Engine Controls Exhaust System Vacuum Pump Turbocharger Automatic Transmission and Transmission/Transfer Case Unit Repair Manual

Truck Service Manual Sub-Section to Section and Sub-Section Conversion Table (cont'd) Old Sub-Section 7B 7C 7D 8B 8C 8D 8E 9A 9B 9E 9F 9J 9K 10A1 10A2 10A3 10A4 10A5 10B Old Sub-Section Manual Transmission Clutch Transfer Case Lighting Systems Instrument Panel and Gages Chassis Electrical Wipers and Washers Audio Systems Cruise Control Engine Coolant Heater Luggage Carrier Supplemental Inflatable Restraint Remote Keyless Entry Doors Seats Stationary Windows Interior Trim Endgate Cab and Body Maintenance New Section 7 7 4 8 8 8 8 8 8 6 8 9 8 8 8 9 8 8 8 — Section Name Transmission/Transaxle Transmission/Transaxle Driveline/Axle Body and Accessories Body and Accessories Body and Accessories Body and Accessories Body and Accessories Engine Body and Accessories Restraints Body and Accessories Body and Accessories Body and Accessories Restraints Body and Accessories Body and Accessories Body and Accessories — Sub-Section Name Manual Transmission and Transmission/Transfer Case Unit Repair Manual Clutch Transfer Case and Transmission/Transfer Case Unit Repair Manual Lighting Systems Instrument Panel, Gages and Console Refer to the Index at the end of the manual Wiper/Washer Systems Entertainment Cruise Control Engine Cooling Roof Supplemental Inflatable Restraints Keyless Entry Doors Seats Seat Belts Stationary Glass Exterior/Interior Trim Body Rear End Refer to the Index at the end of the manual

1998 Medium Duty THick FSR, FTR, FVR Service Manual Volume 2 This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 1998 Isuzu Medium Duty Truck. The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better service the vehicle owners. When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication approval. Isuzu reserves the right to make changes at any time without notice. Published by ISUZU MOTORS AMERICA, INC. ©1998 ISUZU MOTORS AMERICA, INC. The information cutoff date is 12/1/97. ALL RIGHTS RESERVED LITHO IN U.S.A. No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of Isuzu Motors America, Inc. This applies to all text, illustrations, and tables.

Table of Contents Volume 1 Preface........................................................................ i Cautions and Notices................................................. 3 General Information........................................... 0-1 General Information................................................ 0-3 Maintenance and Lubrication................................ 0-33 Vibration Diagnosis and Correction...................... 0-51 HVAC......................................................................... 1-1 Heating and Ventilation (Non-A/C) .......................... 1-3 HVAC Systems with A/C - Manual ........................ 1-57 Body and Accessories...................................... 8-i Lighting Systems.................................................... 8-7 Wipers/Washer Systems..................................... 8-103 Entertainment ..................................................... 8-123 Wiring Systems................................................... 8-143 Instrument Panel, Gauges and Console............. 8-283 Horns.................................................................. 8-351 Exterior Trim........................................................ 8-361 Waterleaks.......................................................... 8-363 Stationary Windows............................................ 8-365 Bumpers.............................................................. 8-373 Body Front End ................................................... 8-377 Doors.................................................................. 8-399 Seats................................................................... 8-431 Interior Trim......................................................... 8-441 Plastic Panel Information and Repair ................. 8-453 Paint/Coatings..................................................... 8-455 Frame and Underbody........................................ 8-463 Collision Repair ................................................... 8-485 Restraints............................................................... 9-1 Seat Belts............................................................... 9-3 Volume 2 Preface................................................... Cautions and Notices............................ Steering ................................................. Power Steering System ........................ Steering Linkage (Non-Rack & Pinion). Steering Wheel and Column - Tilt ......... ....... 1 ....... 3 ...2-1 ...2-3 .2-53 .2-63 Suspension.............................. Suspension General Diagnosis Wheel Alignment ....................... Front Suspension....................... Rear Suspension ....................... Tires and Wheels....................... Air Suspension........................... Driveline/Axle........................... Propeller Shaft........................... Rear Drive Axle.......................... Rear Axle Controls..................... Brakes......................................... Hydraulic Brakes........................ Disc Brakes................................ Park Brakes ............................... Air Brakes .................................. Air Drums................................... Air Compressor.......................... Antilock Brake System............... Air Antilock Brake System ......... Volume 3 Preface................................................ Cautions and Notices......................... Engine................................................. Engine Cooling .................................. Engine Electrical ................................ Engine Controls - 7.8L....................... Engine Exhaust .................................. Engine, On-vehicle Service ............... Engine Overhaul ................................. Water Pump....................................... Fuel System ....................................... Fuel Injection ...................................... Diesel Electrical ............................ —.. Emission and Electrical Diagnosis .... Turbocharger...................................... Transmission/Transaxle............... Manual Transmission - Medium Duty. Automatic Transmission - Allison....... Clutch................................................. Manual Transmission Overhaul .......... 1998 - MD-lsuzu

1997-2002 Isuzu F Series (FSR / FTR / FVR) Service & Repair Manual

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