ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service Manual
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ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service Manual
FOREWORD :
This service supplemental manual contains diagnosis, on-vehicle service, wiring diagrams, and component unit repair for Medium Duty Steel Tilt Cab Vehicles FRR/WS. When used with the Isuzu Commercial Truck Service Manual (Pub. No. FRR97-WSM-C0’I), complete service coverage is provided. Keep this manual in a handy place for ready reference. If properly used, it will enable the technician to serve the owners of these vehicles.
- This service manual is intended for use by professional, qualified technicians. 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 invehicle damage or malfunction, or possibly personal injury.
- Therefore, fasteners removed from the vehicle should be saved for reuse 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.
TABLE OF CONTENTS:
ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service Manual
INDEX................................................................................. 0 TOP................................................................................... 1 Sec.0 GENERAL INFORMATION......................................................... 7 Sec.0A GENERAL INFORMATION........................................................ 7 HANDLING ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS........................ 7 SERVICE PATRS IDENTIFICATION LABEL............................................ 8 RPO (REGULAR PRODUCTION OPTIONS) LIST......................................... 8 VEHICLE IDENTIFICATION NUMBER (VIN)........................................... 9 CERTIFICATION LABEL........................................................... 9 MODEL REFERENCE............................................................... 9 ENGINE IDENTIFICATION NUMBER.................................................. 9 EMERGENCY STARTING YOUR VEHICLE DUE TO A DISCHARGED BATTERY................... 9 TOWING PROCEDURE.............................................................. 11 GRAPHIC SYMBOLS............................................................... 13 ACTION SYMBOLS................................................................ 13 COMMON AUOMOTIVE ABBREVIATIONS................................................ 15 Sec.0B MAINTENANCE AND LUBRICATION................................................ 18 ENGINE OIL AND VISCOSITY RECOMMENDATIONS...................................... 18 MAAINTENANCE SCHEDULE......................................................... 19 SPECIFICATIONS................................................................ 31 ESSENTIAL SERVICE TOOLS....................................................... 32 Sec.1 HEATING AND AIR CONDITIONING................................................ 33 Sec.2 FRAME....................................................................... 34 Sec.3 STEERING, SUSPENSION, WHEELS AND TIRES...................................... 35 Sec.3B3 POWER STEERING............................................................ 36 POWER STEERING SYSTEM ON-VEHICLE SERVICE...................................... 39 HYDRAULIC PUMP UNIT REPAIR.................................................... 40 SPECIAL TOOLS................................................................. 43 Sec.3B4 STEERING COLUMN........................................................... 44 STEERING COLUMN ON-VEHICLE SERVICE............................................ 45 STEERING COLUMN UNIT REPAIR................................................... 48 SPECIFICATIONS................................................................ 49 Sec.3C FRONT AXLE AND SUSPENSION.................................................. 50 FRONT HUBS AND BEARINGS ON-VEHICLE SERVICE.................................... 51 Sec.3E WHEELS AND TIRES........................................................... 52 SPECIFICATIONS................................................................ 53 Sec.4 REAR AXLE AND PROPELLER SHAFT............................................... 54 Sec.4B1A REAR AXLE................................................................ 55 ON-VEHICLE SERVICE............................................................ 56 Sec.5 BRAKES (AIR OVER HYDRAULIC BRAKES).......................................... 57 Sec.5A AIR OVER HYDRAULIC BRAKES.................................................. 57 INTRODUCTION.................................................................. 58 DIAGNOSIS OF THE BRAKE SYSTEM................................................. 59 DIAGNOSIS OF BRAKE SYSTEM..................................................... 60 DIAGNOSIS OF BRAKE LINING..................................................... 66 DIAGNOSIS OF BRAKE DRUM....................................................... 67 PLUMBING SCHEMATIC............................................................ 68 ON-VEHICLE SERVICE............................................................ 69 Sec.5A1 HYDRAULIC BRAKE BOOSTER SYSTEM............................................ 78 INTRODUCTION.................................................................. 78 ON-VEHICLE SERVICE............................................................ 79 UNIT REPAIR................................................................... 81 Sec.5A2 HYDRAULIC FOUNDATION BRAKES............................................... 89 INTRODUCTION.................................................................. 90 ON-VEHICLE SERVICE OF BRAKE ASSEMBLY.......................................... 92 LININGS AND DRUMS............................................................. 98 SPECIFICATIONS................................................................100 SPECIAL TOOL..................................................................100 Sec.5A4 ANTILOCK BRAKE SYSTEM.....................................................101 SERVICE PRECEAUTION...........................................................103 GENERAL DESCRIPTION...........................................................104 GENERAL DIAGNOSIS.............................................................106 EBCM CONNECTOR PIN-OUT CHECKS.................................................109 SYMPTOM DIAGNOSIS.............................................................115 DIAGNOSTIC TROUBLE CODES......................................................118 DIAGNOSIS BY "ABS" WARNING LIGHT ILLUMINATION PATTERN.........................121 UNIT INSPECTION PROCEDURE.....................................................151 WHEEL SPEED SENSOR............................................................156 MODULATOR.....................................................................158 SPECIAL TOOLS.................................................................159 Sec.5B1 AIR BRAKE VALVES..........................................................160 INTRODUCTION..................................................................161 ON-VEHICLE SERVICE OF BRAKE VALVES............................................161 UNIT REPAIR...................................................................164 Sec.5D AIR COMPRESSOR AND GOVERNOR................................................168 DESCRIPTION...................................................................168 DIAGNOSIS OF THE AIR COMPRESSOR AND GOVERNOR..................................169 ON-VEHICLE SERVICE............................................................170 AIR COMPRESSOR UNIT REPAIR....................................................172 SPECIFICATIONS................................................................176 Sec.5E EXHAUST BRAKE..............................................................177 DESCRIPTION...................................................................178 DIAGNOSIS OF EXHAUST BRAKE....................................................179 EXHAUST BRAKE ON-VEHICLE SERVICE..............................................180 SPECIFICATIONS................................................................185 Sec.6 ENGINE......................................................................186 Sec.6A6B DIESEL ENGINE OVERHAUL...................................................205 DIESEL ENGINE OVERHAUL........................................................205 GENERAL DESCRIPTION...........................................................206 DISASSEMBLY OF THE ENGINE.....................................................208 CLEANING, INSPECTION, AND REPAIR..............................................212 ASSEMBLY OF THE ENGINE........................................................231 SPECIFICATIONS................................................................244 SPECIAL TOOLS.................................................................248 Sec.6B1B WATER PUMP OVERHAUL......................................................249 DISASSEMBLY...................................................................249 SPECIFICATIONS................................................................253 SPECIAL TOOLS.................................................................253 Sec.6A6 DIESEL ENGINE ON-VEHICLE SERVICE..........................................254 GENERAL DESCRIPTION...........................................................254 ON-VEHICLE SERVICE............................................................187 SPECIFICATIONS................................................................203 SPECIAL TOOLS.................................................................204 Sec.6C FUEL SYSTEM................................................................255 Sec.6C2 DIESEL FUEL INJECTION.....................................................256 GENERAL DESCRIPTION...........................................................257 FUEL INJECTION SYSTEM.........................................................263 ON VEHICLE SERVICE............................................................264 SPECIFICATIONS................................................................270 Sec.6E ENGINE EMISSION AND ELECTRICAL DIAGNOSIS...................................271 GENERAL DESCRIPTION...........................................................273 DIAGNOSIS.....................................................................282 SYSTEM PARTS DESCRIPTION......................................................301 ECM SYSTEM WIRING DIAGRAM (1OF4)..............................................306 LOCATION OF SENSOR AND SWITCH.................................................310 ENGINE CONTROL MODULE (ECM)...................................................312 CHART OF ECM INPUT/OUTPUT.....................................................313 CONNECTOR PIN ASSIGNMENT......................................................313 TROUBLESHOOTING...............................................................317 TYPICAL SCAN DATA VALUES......................................................322 SYMPTOM DIAGNOSIS.............................................................323 THCHOMETER OUTPUT ERRIR (NO AVAILABLE DTC)....................................324 ENGINE HUNTING................................................................326 ENGINE CRANKS BUT DOES NOT RUN................................................327 ENGINE STARTS AND STALLS......................................................330 ENGINE STARTS BUT WILL NOT ACCELERATE.........................................331 EXCESSIVE WHITE OR BLUE SMOKE.................................................332 EXCESSIVE BLACK SMOKE.........................................................333 LACK OF POWER.................................................................334 SURGING, HESITATION...........................................................336 ENGINE STALL..................................................................338 ENGINE DOES NOT STOP..........................................................339 IDLE CONTROL ERROR............................................................340 HIGH IDLE ENGINE SPEED........................................................341 EXHAUST BRAKE ERROR (NO DTC SET)..............................................342 Sec.6J TURBOCHARGER...............................................................471 GENERAL DESCRIPTION...........................................................471 ON-VEHICLE SERVICE............................................................472 SPECIFICATIONS................................................................475 SPECIAL TOOLS.................................................................475 Sec.7 TRANSMISSION AND CLUTCH.....................................................476 Sec.8 CAB AND CHASSIS ELECTRICAL..................................................477 GENERAL DESCRIPTION...........................................................478 MAIN DATA AND SPECIFICATIONS..................................................491 SYSTEM REPAIR.................................................................500 Sec.10 CAB........................................................................574 1. DISMOUNTING OF CAB.........................................................576 2. MOUNTING OF CAB............................................................578 3. DISASSEMBLING OF FRONT PART................................................581 4. ASSEMBLING OF FRONT PART...................................................582 5. DISASSEMBLING OF FENDER AND ITS ASSOCIATED PARTS...........................583 6. ASSEMBLING OF FENDER AND ITS ASSOCIATED PARTS..............................584 7. DISASSEMBLING OF FRONT DOOR (LEFT-HAND SIDE)...............................585 8. ASSEMBLING OF FRONT DOOR (LEFT-HAND SIDE)..................................587 9. DISASSEMBLING OF FRONT DOOR (RIGHT-HAND SIDE)..............................589 10. ASSEMBLING OF FRONT DOOR (RIGHT-HAND SIDE)................................591 11. DISASSEMBLING OF FRONT WINDSHIELD GLASS...................................594 12. ASSEMBLING OF FRONT WINDSHIELD GLASS......................................596 13. DISASSEMBLING OF QUARTER WINDOW GLASS.....................................598 14. ASSEMBLING OF QUARTER WINDOW GLASS........................................600 15. DISASSEMBLING OF BACKLIGHT GLASS..........................................602 16. ASSEMBLING OF BACKLIGHT GLASS.............................................604 17. DISASSEMBLING OF OUTSIDE MIRROR...........................................606 18. ASSEMBLING OF OUTSIDE MIRROR..............................................607 19. DISASSEMBLING OF INSTRUMENT PANEL AND ITS ASSOCIATED PARTS................608 20. ASSEMBLING OF INSTRUMENT PANEL AND ITS ASSOCIATED PARTS...................610 21. DISASSEMBLING OF FRONT SEATS AND THEIR ASSOCIATED FLOOR PARTS.............612 22. ASSEMBLING OF FRONT SEATS AND THEIR ASSOCIATED FLOOR PARTS................614 23. DISASSEMBLING OF HEAD LINING AND ITS ASSOCIATED PARTS.....................616 24. ASSEMBLING OF HEAD LINING AND ITS ASSOCIATED PARTS........................618 25. DISASSEMBLING OF INTERIOR TRIMS...........................................620 26. ASSEMBLING OF INTERIOR TRIMS..............................................622 27. DISASSEMBLING AND INSPECTION OF CAB TILTING MECHANISM (STANDARD MODEL)....623 28. ASSEMBLING OF CAB TILTING MECHANISM (STANDARD MODEL)......................626 29. DISASSEMBLING AND INSPECTION OF CAB LOCK..................................629 30. ASSEMBLING OF CAB LOCK....................................................631
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