1994-2003 Isuzu NPR Series Trucks Service & Repair Manual

ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER SERVICE MANUAL (2006) NPR/NPR-HD/NQR/NRR W3500/W4500/W5500/W5500HD (DIESEL ENGINE)

General Information 0A-1 GENERAL INFORMATION General Information TABLE OF CONTENTS Cautions and Notices . . . . . . . . . . . . . . . . . . . . . . 0A-2 Battery Disconnect Caution . . . . . . . . . . . . . . . . 0A-2 Fuel Tube Caution . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Road Test Caution . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Safety Glasses Caution . . . . . . . . . . . . . . . . . . . 0A-2 Vehicle Lifting Caution . . . . . . . . . . . . . . . . . . . . 0A-2 Belt Dressing Notice. . . . . . . . . . . . . . . . . . . . . . 0A-2 Fastener Notice . . . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Sealant Notice . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Handling Electrostatic Discharge (ESD) Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Model Reference . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 VIN (Vehicle Identification Number) and Weight Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-5 Vin Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-5 Regular Production Options (RPO) Code List . . 0A-6 Engine Serial Number . . . . . . . . . . . . . . . . . . . . 0A-7 Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 0A-8 Emergency Starting a Vehicle Due to Discharged Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-9 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . 0A-10 Vehicle Lifting Points . . . . . . . . . . . . . . . . . . . . 0A-11 Abbreviations Charts . . . . . . . . . . . . . . . . . . . . 0A-12 Essential Service Tools . . . . . . . . . . . . . . . . . . 0A-15

0A-2 General Information Cautions and Notices Battery Disconnect Caution Caution: Before servicing any electrical component, the ignition key must be in the LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. Fuel Tube Caution Caution: In order to reduce the risk of fire and personal injury observe the following items: • Replace all nylon fuel tubes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes. • Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon tubes may result in a fuel leak. • Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. • Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Road Test Caution Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Safety Glasses Caution Caution: Wear safety glasses in order to avoid eye damage. SIR Caution Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: • Personal injury • Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: • Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. • If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. Vehicle Lifting Caution Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Belt Dressing Notice Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Fastener Notice Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Fuel Injector Balance Test Notice Notice: Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding.

General Information 0A-3 Sealant Notice Notice: Do not allow the RTV sealant to enter any blind threaded hole. RTV sealant that is allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper fastener tightening can allow the components to loosen or separate leading to extensive engine damage.

0A-4 General Information General Information Handling Electrostatic Discharge (ESD) Sensitive Parts When handling an electronic part that has as ESD sensitive sticker, 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. Model Reference The model covered in this manual are referred to as a NPR, NPR-HD, NQR, NRR. (W3500, W4500, W5500, W5500HD)

1994-2003 Isuzu NPR Series Trucks Service & Repair Manual

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