Isuzu FSR FTR FVR 1997 to 2002 - Service Manual - Repair Manual

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ISUZU FSR, FTR, FVR (1997-2002) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual for vehicles Isuzu FSR FTR FVR 1997 to 2002.
 

CONTENTS:

1998 FSR FTR FVR with 6 HK1 Engine Book 1 of 3

Cautions and Notices
- Definition of Caution, Notice, and Important
- ABS Handling Caution
- Battery Disconnect Caution
- Brake Dust Caution
- Brake Fluid Caution
- Clutch Dust Caution
- Fuel and EVAP Pipe Caution
- Fuel Gauge Leak Caution
- Fuel Pipe Fitting Caution
- Fuel Storage Caution
- Gasoline/Gasoline Vapors Caution
- Moving Parts and Hot Surfaces Caution
- Road Test Caution
- Safety Glasses and Compressed Air Caution
- Safety Goggles and Fuel Caution
- Vehicle Lifting Caution
- Window Removal Caution
- Work Stall Test Caution
- Defective Scan Tool Notice
- Fastener Notice
- Fuel Pressure Notice
- Handling ESD Sensitive Parts Notice
- Ignition OFF When Disconnecting Battery Notice
- Nylon Fuel Lines Notice
- PCM and ESD Notice
- Single Cylinder Flooding Notice

Section 0 General Information
- General Information
- Conversion - English/Metric
- Equivalents- Decimal and Metric
- Paper Version of the Service Manual- How to Use
- Arrows and Symbols
- Special Tools Ordering Information
- Vehicle Identification
- VIN Derivative
- Label- Vehicle Certification
- Engine Identification
- Transmission Identification
- Rear Axle Identification
- Label - Service Parts ID
- RPO Code List
- Labels - How to Obtain Replacement
- Fasteners (Prevailing Torque Fasteners)
- Fasteners (Strength Identification)
- Fasteners (Metric Fasteners)
- Thread Inserts
- Torque Wrenches
- Abbreviations and Their Meanings
- Key and Lock Cylinder Coding
- Lifting and Jacking the Vehicle
- Cab Tilting
- Towing a Disabled Vehicle
- Strategy Based Diagnosis
- Maintenance and Lubrication
- Specifications
- Maintenance
- Vibration Diagnosis and Correction
- Specifications
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation

Section 1 HVAC
- Heating and Ventilation (Non-A/C)
- Specifications
- Schematic and Routing Diagrams
- Component Locator
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- HVAC Systems with A/C – Manual
- Specifications
- Schematic and Routing Diagrams
- Component Locator
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Special Tools and Equipment

Section 8 Body and Accessories
- Lighting Systems
- Specifications
- Schematic and Routing Diagrams
- Component Locator
- Visual Identification
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Special Tools and Equipment
- Wipers/Washer Systems
- Schematic and Routing Diagrams
- Component Locator
- Visual Identification
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Entertainment
- Schematic and Routing Diagrams
- Component Locator
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Wiring Systems
- Specifications
- Diagnostic Information and Procedures
- Schematic and Routing Diagrams
- Component Locator
- Diagnostic Information and Procedures
- Schematic and Routing Diagrams
- Component Locator
- Visual Identification
- Diagnostic Information and Procedures
- Description and Operation
- Instrument Panel, Gauges and Console
- Specifications
- Schematic and Routing Diagrams
- Component Locator
- Visual Identification
- Diagnostic Information and Procedures
- Schematic and Routing Diagrams
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Horns
- Specifications
- Schematic and Routing Diagrams
- Component Locator
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Exterior Trim
- Repair Instructions
- Waterleaks
- Diagnostic Information and Procedures
- Repair Instructions
- Diagnostic Information and Procedures
- Stationary Windows
- Repair Instructions
- Special Tools and Equipment
- Bumpers
- Specifications
- Repair Instructions
- Body Front End
- Specifications
- Repair Instructions
- Doors
- Specifications
- Schematic and Routing Diagrams
- Component Locator
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Special Tools and Equipment
- Seats
- Specifications
- Diagnostic Information and Procedures
- Repair Instructions
- Interior Trim
- Repair Instructions
- Plastic Panel Information and Repair
- Repair Instructions
- Paint/Coatings
- Specifications
- Repair Instructions
- Frame and Underbody
- Specifications
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation
- Collision Repair
- Repair Instructions

Section 9 Restraints
- Seat Belts
- Specifications
- Diagnostic Information and Procedures
- Repair Instructions
- Description and Operation


1998 Medium Duty Truck FSR, FTR, FVR Service Manual Book 2 of 3

- Cautions and Notices
- Definition of Caution, Notice, and Important
- ABS Handling Caution
- Battery Disconnect Caution
- Brake Dust Caution
- Brake Fluid Caution
- Clutch Dust Caution
- Fuel and EVAP Pipe Caution
- Fuel Gauge Leak Caution
- Fuel Pipe Fitting Caution
- Fuel Storage Caution
- Gasoline/Gasoline Vapors Caution
- Moving Parts and Hot Surfaces Caution
- Road Test Caution
- Safety Glasses and Compressed Air Caution
- Safety Goggles and Fuel Caution
- Vehicle Lifting Caution
- Window Removal Caution
- Work Stall Test Caution
- Defective Scan Tool Notice
- Fastener Notice
- Fuel Pressure Notice
- Handling ESD Sensitive Parts Notice
- Ignition OFF When Disconnecting Battery Notice
- Nylon Fuel Lines Notice
- PCM and ESD Notice
- Single Cylinder Flooding Notice
- Section 2 Steering
- Power Steering System
- Steering Linkage (Non-Rack & Pinion)
- Steering Wheel and Column - Tilt
- Section 3 Suspension
- Suspension General Diagnosis
- Wheel Alignment
- Front Suspension
- Rear Suspension
- Tires and Wheels
- Section 4 Driveline/Axle
- Propeller Shaft
- Rear Drive Axle
- Rear Axle Controls
- Section 5 Brakes
- Hydraulic Brakes
- Disc Brakes
- Park Brake
- Air Brakes
- Air Drums
- Air Compressor
- Antilock Brake System
- Air Antilock Brake System


1998 Isuzu Commercial Truck FSR, FTR, FVR Equipped with 6 HK1 Engine Service Manual Book 3 of 3

- Truck Service Manual Sub-Section to Section and Sub-Section Conversion Table
- 1998 Medium Duty THick FSR,FTR, FVR Service Manual Volume 3
- Table of Contents
- Cautions and Notices
- Definition of Caution, Notice, and Important
- ABS Handling Caution
- Battery Disconnect Caution
- Brake Dust Caution
- Brake Fluid Caution
- Clutch Dust Caution
- Fuel and EVAP Pipe Caution
- Fuel Gauge Leak Caution
- Fuel Pipe Fitting Caution
- Fuel Storage Caution
- Gasoline/Gasoline Vapors Caution
- Moving Parts and Hot Surfaces Caution, Road Test Caution
- Road Test Caution
- Safety Glasses and Compressed Air Caution
- Safety Goggles and Fuel Caution
- Vehicle Lifting Caution
- Window Removal Caution
- Work Stall Test Caution
- Defective Scan Tool Notice
- Fastener Notice
- Fuel Pressure Notice
- Handling ESD Sensitive Parts Notice
- Ignition OFF When Disconnecting Battery Notice
- Nylon Fuel Lines Notice
- PCM and ESD Notice
- Single Cylinder Flooding Notice
- Section 6 Engine
- Engine Cooling
- Engine Electrical
- Engine Controls - 7.8L
- Engine Exhaust
- SECTION 6A6 DIESEL ENGINE ON-VEHICLE SERVICE
- General Description
- On-Vehicle Service
- Specifications
- Special Tools
- SECTION 6A6B DIESEL ENGINE OVERHAUL
- Diesel Engine Overhaul.
- General Description
- Disassembly of the Engine
- Cleaning, Inspection, and Repair
- Assembly of the Engine
- Thread Repair
- Specifications.
- Special Tools
- SECTION 6B1 B WATER PUMP OVERHAUL
- Disassembly
- Specifications
- Special Tools
- SECTION 6C FUEL SYSTEM
- SECTION 6C2 DIESEL FUEL INJECTION
- General Description
- Fuel Injection System
- On Vehicle Service
- Specifications
- SECTION 6D6 DIESEL ELECTRICAL
- General Description
- Glow Plugs
- Diagnosis
- On-Vehicle Service
- Specifications
- Special Tools
- SECTION 6E ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
- General Description
- Diagnosis
- System Parts Description
- ECM System Wiring Diagram
- Location Of Sensor And Switch
- Engine Control Module(ECM
- Chart Of ECM Input/Output
- Connector Pin Assignation
- Troubleshooting
- Diagnostic Indication
- Typical Scan Data Values
- ECM Diagnosis Trouble Codes
- DTC P15 Crank Position Sensor Error (NE Sensor)
- DTC P14 Pump Position Sensor Error (G Sensor
- DTC P245 Abnormal Common Rail Pressure (PC Sensor System
- DTC P115 Common Rail Pressure Sensor Output Fixed
- DTC P151 Common Rail Pressure Abnormal (Pump Over Pressure Supply)
- DTC P118 Common Rail Pressure Abnormal (Control System) 1st And 2nd Stage
- DTC P34 Q-Adjusted Data Error (No History Recorded
- DTC P23 Water Temperature Sensor Error
- DTC P211 Fuel Temperature Sensor Error
- DTC P22 Atmospheric Temperature Sensor Error
- DTC P24 Accelerator Sensor Error 1 And 2
- DTC P711 Atmospheric Pressure Sensor Error
- DTC P417 Starter Switch Abnormal
- DTC P261 to P266 (Cylinder No. 1 To No. 6) Flow Damper Activated
- DTC P271 to P276 (Cylinder Nol 1 To No. 6) TWV Side Disconnected
- DTC P158, P159 TWV Driving System Error (+B Short Circuited Or Ground Line Disconnected)
- DTC P158, P159 TWV Driving System Error (+B Short Circuited Or Ground Line Disconnected)
- DTC P226 Injection Pump Non Pressure Supply Or Pressure Limiter Activation
- DTC P227 Injection Pump Non Pressure Supply
- DTC P217, P218 PCV 1, 2 (Coil Or Harness) +B Shortage
- DTC P247, P248 PCV 1, 2 (Coil Or Hanress) Disconnect Or GND Shorted
- DTC P35 Analog Digital Conversion Error, CPU Monitoring 1C Error And Charging Circuit Error
- DTC P421 PCV Relay (R/L) System Error
- DTC P416 Main Relay System Error (No History Records)
- DTC P32 Boost Pressure Sensor Error
- DTC P42, P32 High Boost Pressure Abnormal
- DTC P65 Low Boost Pressure Abnormal
- DTC P543 Overrun Judgment
- A/T Relay Output Error (Not Available DTC
- Exhaust Brake Relay Error (Not Available DTC
- MFAM Signal Error (Option Equipment) ( Not Available DTC)
- Power Supply System Inspection (Not Available DTC
- Tachometer Output Error (Not Available DTC
- PCV Relay Error (Not Available DTC)
- Engine Hunting
- Startup Failure Do Not Come Initial Combustion
- White Smoke (Excessive) Or Blue Smoke
- Black Smoke(Excessive
- Lack Of Power
- Surging, Hesitation
- Engine Stall
- Engine Does Not Stop
- Idle Control Error
- High Idle Engine Speed
- SECTION 6J TURBOCHARGER
- General Description
- On Vehicle Service
- Specifications
- Special Tools
- Section 7 Transmission/Transaxle
- Manual Transmission - Medium Duty
- Automatic Transmission - Allison
- Clutch