Give your content the digital home it deserves. Get it to any device in seconds. Isuzu npr service manual Publish for free today. Other Manuals 2 Pages. Isuzu - Impulse - Wiring Diagram - - Isuzu - N Series - Owners Manual - - 2. Isuzu I 2wd Workshop Manual L Repair Guide Pages. Other Manuals 28 Pages. Isuzu - i - Wiring Diagram - - Other Manuals 97 Pages.
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Brochure 2 Pages. Isuzu - Axiom - Workshop Manual - - Brochure 32 Pages. Isuzu - i - Workshop Manual - - Also check the steering wheel for play and looseness in mount by moving it back and forth and sideways.
While driving check for hardsteering, shimmy and tendency of steering to pull to one side. Adjust 1. Align the front wheels properly in the straight ahead position. Loosen the lock nut on the adjusting screw of the steering unit. Turn the adjust screw clockwise to decrease free play or counter- clockwise to increase. After check of specified free play, tighten the lock nut to specified torque.
Rear Axle See Service Manual Propeller Shaft Hydraulic Brakes See Service Manual Parking Brakes See Service Manual Description See Service Manual Inspection and Repair See Service Manual System Inspection See Service Manual Bleeding Brakes See Service Manual Master Cylinder Adjust the specified rear axle weight by loading the rear body as according to the chart values by model description. Rear Axle Weight kg lb 2, 2, 1, 1, 3, 3, 2, 2, 3, 2, 2, 2, Connect a miniature lamp 1 and a battery 2 as shown below between the valve bracket 3 and linkage 4.
This is done to locate the point where the piston in the valve assembly comes in contact with the linkage. Loosen the nut 6 and raise the valve assembly 7 all the way.
Then lower the valve assembly gradualily and tighten the nut 6 lamp 1 turns on. If the miniature lamp 1 goes out as the nut 6 is tightened, lower the valve assembly 7 slightly with the nut loosened, then retighten the nut 6. Figure 5. Load-Sensing Proportioning Valve Adjustment-1 4. Depress the linkage 4 near the valve assembly slightly downward with finger test pressure Lamp goes out : OK Adjustment is completed. Lamp remains on : NG Repeat adjustment operation outlined under paragraph 3.
Excessive force is exerted on linkage by piston 8 within the valve assembly. Miniature Lamp Wiring Note: As the linkage is coated with insulation material, turn the clip 5 with 2 or 3 turns to break insulation. Adjust the rear axle weight as specified under the paragraph 1.
Install the pressure gauge on the bleeder screws on the front and rear brakes. Depress the brake pedal and obtain the pressure gauge reading. Figure 6. Load-Sensing Proportioning Valve Adjustment-2 Note: Adjustment can also be made by means of nuts 9 and 10 on shackle at rear axle case side.
However, shackle nut is not normally used for adjustment as it is for making fine adjustment. The brake pedal should be depressed gradually until specified pressure is reached without pumping or adjusting foot pressure. General Description See Service Manual Booster Assembly See Service Manual System Outline See Service Manual Notes See Service Manual Guard Replacement Remove the cover 1 and cap 2 figure1.
Remove the filter 3. Clean the filter 3 in clean solvent. Then blow the filter dry with compressed air. Raise the vehicle until the tires are off the floor. Support the frame with stands. Disconnect the reservoir hose 5 single cab, 6 crew cab at the reservoir. Drain the fluid reservoir 4. Connect the reservoir hose. Install the filter 3. Fill and bleed the hydraulic system. Refer to page 5A of the Service Manual. Install the cap 2 and cover 1. Manifolds, Turbocharger and Components. Charge air pipe connection hose.
Injection pipes. Bolts and nuts for fixing intake manifold. Intake manifold with gasket. EGR case. Connecting hoses clamps. Connecting hoses. Bracket bolts and washers and charge air pipe from turbocharger to charge air cooler. Connecting hose. Bracket accelerator cable. Bracket engine stop cable and vacuum hose. Engine harness connector. Charge air pipe from charge air cooler to intake manifold. Install or Connect Figure 9 1. Charge air pipe from charge air cooler. Charge air pipe from turbocharger to charge air cooler and bracket bolts.
Injection nozzle cover. Vacuum hose from intake manifold. Vacuum hoses EGR valve and throttle valve. EGR pipe. EGR case with liquide gasket. Vacuum hose to intake manifold from injection pump. Turbocharger air inlet pipe figure Heat shield 22 bolt figure 9.
Water feed figure 12 and drain lines. Oil feed line figure Oil drain line figure Exhaust pipe to exhaust adapter Nuts. Exhaust adapter 16 to exhaust manifold bolts 17 figures 9 and Turbocharger to exhaust manifold nuts 18 figures Turbocharger 19 figure 9. Exhaust adapter 16 figures 9 and Figure 11a. Radial Clearance Measurement Oil Supply Line. Air Inlet Pipe. Figure If any of the above conditions exist, the turbocharger must be replaced or repaired by an authorized repair facility.
Measure Play in axial clearance. Moving the rotor in the axial clearance, measure the play by a dial gage. Service limit is 0. If excessive, replace the turbocharger. Measure Play in radial clearance.
Moving the rotor in the radial clearance, measure the play by a dial gage. Do not use the pointed one. Figure 11b. Figure 11c. Measurement Oil leakage check 1. Remove the charge air pipe connecting hose to the compressor side of the turbocharger. Clean the area around the compressor wheel. Remove the blow-by hose. Start the engine and let idle. Rev the engine and hold at wide open throttle WOT for five seconds, then release and let idle for five seconds.
Repeat this cycle for a total of five times, then let the engine idle steady for five minutes. Shut off the engine. Check the compressor area for an oil leakage. If mist or spray is present, however, this is normal and is NOT indicative of a turbocharger problem. If the turbocharger is suspect any problem, refer to the turbocharger replacement procedures in this section. Exhaust Adapter Exhaust Adapter Bolts Turbocharger to Manifold Nuts Figure Exhaust adapter 16 to turbocharger New gasket 20 and turbocharger 19 to exhaust manifold 21 figure 9.
Exhaust adapter 16 to exhaust manifold 21 figure New gasket and exhaust pipe to exhaust adapter 16 figure 9. Turbocharger oil drain line figure Turbocharger 19 refer to the turbocharger replacement in this section. Exhaust manifold Bolts 23 , nuts 23a and washers.
Exhaust manifold Gaskets Inspect Figure 9. Water supply and drain lines figure Heat shield 22 to exhaust adapter 16 figure 9. Charge air pipe connecting hoses and clamps to turbocharger 19 figure 9. Air inlet pipe to turbocharger 19 figure Gaskets 24 as shown in figures 9. Washers nuts 23a and bolts 23 as shown in figure 9.
Exhaust Manifold Bolt Torquing Sequence 4. Heat shield Bolt 33 , nut 34 and oil cap 35 figure Cylinder head cover Gasket Install or Connect Figure 17 1. Cylinder head cover 36 to cylinder head. Glow 2. Glow 3. Glow 4. Glow plug connector Glow plug connector nuts. Glow plug wire Glow Plug Glow Plug Connector Glow Plug Wire Glow Plug Connector nots Figure Glow Plug Replacement.
Drain engine coolant at lower rear of radiator trough drain valve. Radiator upper hose at thermostat housing. Water pump bypass hose at thermostat housing. Heater hose return. Turbocharger refer to the turbocharger replacement. Front exhaust pipe from exhaust manifold.
Fuel pipes, gaskets from the fuel filter and fuel filter. Injector leak off pipe and gasket. Fan guide bracket. Engine harness connectors. Glow plug harness connector 58 Figure Charge air hose and pipe from the intake manifold. Cylinder cover refer to the cylinder head cover replacement.
Rocker arm and shaft assembly refer to the valve train component replacement. Camshaft assembly. Cylinder head bolts Figure Cylinder head assembly. Cylinder head gasket. Cylinder Head Bolt Loosening Sequence. Injectors and gasket 2. Glow plugs 3. Exhaust manifold and gasket. Fuel filter bracket. Engine hanger 9. Water outlet pipe from front of cylinder head.
Valve caps from top of valve stem. Use J to remove the valve spring and relation parts. Split colors. Upper spring seat. Valve springs. Valve stem seal. Lower spring seal. If the valves are to be reinstalled, mark their installation position each valve with the cylinder number from which it was removed.
Sealing cap for idle gear C. Bolt with thrust washer. Idle gear C with shaft. Inspect — Cylinder head for cracks, damaged threaded parts, etc. Measure Figures 27 and — Cylinder head gasket surface for warpage. Use a straightedge and feeler gage as shown in figure Check in six different directions, as shown.
If the cylinder head is warped more than 0. Cylinder head cannot be machined. J Figure Do not use a wire wheel.
Checking Cylinder Head Distortion — Valve installed depth figure Production depth is 0. If more than 2. Measuring Valve Installed Depth — Valve stem diameter, as shown in figure Check in three places, as shown.
Valve Valve Guide A. Dial Indicator Figure Measuring Valve Stem Diameter — Valve guide 77 inside diameter, using an inside micrometer. Clean thoroughly the top faces of the piston head and the cylinder body. Use the dial gauge to measure the piston head projection.
Take measurements at two location for each cylinder. The measurement points of the piston head and the reference point of the cylinder body are shown in the illustration.
Find the maximum value Tmax of the average of each cylinder. Based on the Tmax obtained, select a gasket of the appropriate grade. Tmax 0. Figure 42b. Measurement Points 3. For each cylinder, calculate the average value T of the piston projection. Head Gasket Marking. Cylinder head bolts. Make punch mark on the bolt heads, as shown.
Then, make a second punch mark on the cylinder head, 30—60 degrees clockwise from the first mark, as shown. Then, tighten all head bolts 30—60 degrees, using the tightening sequence shown in figure Reference Punch Mark on Bolt B. Camshaft assembly refer to the camshaft replacement.
Rocker arm and shaft assembly refer to the valve train component. Adjust for valve clearance. Refer to the maintenance: valve adjustment. Cylinder head cover refer to the cylinder head cover replacement. Charge air hose and pipe to the intake manifold. Glow plug connector refer to the glow plug replacement. Fuel pipes, gaskets to the fuel filter and fuel filter. Injector pipes. Front exhaust pipe to exhaust manifold. Water pump bypass hose. Radiator upper hose. Engine coolant.
Cylinder head assembly refer to the cylinder head replacement. Oil level gauge tube with dip stick. Oil pan. Oil strainer. Oil jets 6. Connecting cap bolts Connecting rod cap 82 with bearing Piston 80 with connecting rod If the piston is to be reused, mark the cylinder number on it so it can be returned to the proper cylinder as assembly. Be sure to keep the connecting rod cap 82 , connecting rod 81 and connecting rod bearing inserts 86 and 87 together as a matched set.
Numbers are stamped on the connecting rod and cap to help keep the parts together figure Disassemble Figures 46, 48 and 59 1. Rings 75, 76, 77 and 78 , using a ring expander figure Snap rings Piston pin Clean Figure 46 — Piston 80 and rings 75, 76, 77 and 78 in solvent. Do not use wire brush the piston. Moderate finger pressure should be needed to push the bearing inserts into place. If the inserts fit loosely, they should be replaced. Connecting Rod Connecting Rod Cap A.
Connecting Rod Markings. The production diameter is The proper clearance is 0. The standard clearance is 0. The service limit is 0. The crankpin should measure It cannot be reground. Undersize bearings are not available. The production clearance is 0. A piece of plastigage the length of the bearing parallel to the crankshaft on the journal figure Do not turn the crankshaft with the gaging plastic installed.
Placing the Gaging Plastic on the Crankpin. This wax-like material compresses evenly between the bearing and journal surfaces without damaging them.
Proceed as follows. Install the connecting rod 81 with the upper bearing insert 86 to the crankpin. If the bearing is fitted to the minimum diameter and the crankpin is excessively out-of-round, interference between the bearing and the crankpin will result in rapid bearing failure.
Install the connecting rod cap 82 with the lower bearing insert Be sure the numbers on the connecting rod 81 and connecting rod cap align. Install the Bolts Remove the bolts Remove the connecting rod cap Do not remove it at this time.
Liner and Piston Grade Marking A. Connecting Rod Bearing Selection Table. Method 1 The cylinder block deck has been marked during production to indicate both the correct liner and piston sizes. The liner grade i. The piston grade is indicated i. A, B, C, D by a metal stamping. This information is for reference to select the piston service grades.
In the case of a questionable liner marking use the next method for correct liner selection. Oil Clearance mm in 0. The crankshaft cannot be reground. Piston and Liner Grade Selection The cylinder inner diameter grade and the piston service grade are supplied two grades.
There are two methods by whitch liners can be selected. Measuring the Cylinder Bore Method 2 In order to select the correct liner for each cylinder bore, six measurements must be taken figure Piston 80 to the connecting rod Align the piston and connecting rod as shown in figure Rotate the snap rings in their grooves to be sure they are fully seated. Oil control ring expander to the piston Oil control ring Use a ring installing tool figure Compression 3rd ring Use a ring installing tool.
Compression 2nd ring Compression 1st ring The marked 1st ring has 1N, 2nd and 3rd rings have N face of the ring must face up figure Marked Side Up 75 76 77 Installing the Piston Rings. Piston Ring End Gap Locations 9. Upper connecting rod bearing insert 86 to the connecting rod 81 Figure Lower connecting rod bearing insert 87 to the connecting rod cap Piston 80 and connecting rod 81 assembly to the proper liner.
Connecting rod cap 82 with the lower bearing insert to the connecting rod The numbers on the connecting rod and connecting rod cap must align figure Bolts Make a punch mark on the bolt heads, as shown. Then make a second punch mark on the connecting rod cap, 60 degrees clockwise from the first mark. Tighten both bolts 60 degrees until the punch marks align. Tighten both bolts 30 degrees.
Vibration Damper Pulley Bolt Figure Anglar tightening Method for Connecting Rod Bolts Oil level gauge tube with dip stick Three stay for fan shroud. Cooling fan 2 figure 4, SEC. Loosen the generator adjusting plate bolt and remove the drive belts. Damper bolts Vibration damper Lubricate the bolt 93 threads with engine oil. Routine the drive belts. Adjust the generator drive belts to push the belt 8 - 12 mm 0. Stay for fan shroud figure 1, SEC. Camshaft bearing cap Camshaft bearing upper Camshaft assembly Camshaft bearing lower Cylinder head gasket Camshaft Oil pipe.
Clutch pressure plate assembly Driven plate Injection pump assembly Flywheel Oil pan Figure
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