Diesel Engine, Truck, Heavy Equipment Service Manuals

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2006 Isuzu GM Commercial Truck 5.2L Diesel Service Manual

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Product Description

 High resolution, searchable, bookmarked, printable PDF  Instant download

Covers: 2006 Isuzu NPR, NPR-HD, NQR, NRR (GM / Chevrolet W3500, W4500, W5500, W5500HD) Medium-Duty Trucks

  • 5.2L diesel model only (4HK1-TC)

Pages: 2,149
Format
: PDF
Compatibility: Windows/Mac/Tablet

Topics in the 2006 Isuzu GM Commercial Truck 5.2L Diesel Service Manual (CTRL+F to search page):

General Information
Model Reference
VIN (Vehicle Identification Number) and Weight Rating Plate
Vin Chart
Regular Production Options (RPO) Code List
Engine Serial Number
Graphic Symbols
Emergency Starting a Vehicle Due to Discharged Battery
Towing Procedure
Vehicle Lifting Points
Abbreviations Charts
Essential Service Tools
0B Maintenance and Lubrication
Lubrication Detail Information
Engine Oil and Viscosity Recommendations
Maintenance Schedule
Explanation of Complete Vehicle Maintenance Schedule
Normal Vehicle Use
Owner Safety and Routine Maintenance
Noise Emission Control
Noise Control System
Tampering with Noise Control System Prohibited
Recommended Fluids and Lubricants
Lubrication Chart
Specifications
Metric and Fastener Information
Replacement Fasteners Description
Fastener Strength Identification Description
Prevailing Torque Fasteners Description
Recommendations for Reuse Description
Six-Lobed Socket Head Fasteners Description
Decimal and Metric Equivalents Description
Conversion Table Description
HVAC
1A Heating and Ventilation
Description and Operation
Heater System Description
Control Lever Assembly Description
Ventilation System Description
Air Select lever Description
Air Source Select Lever Description
Fan Switch Description
Temperature Control Lever Description
Schematic and Routing Diagrams
Fan Switch Schematic Diagrams
Connector List
Diagnostic Information and Procedures
No heating or Insufficient Heating
Control Knob Moves But Mode Door Does Not Operate
The Mode Door Cannot Be Set To The Mode Selected
Blower Motor Does Not Run
Blower Motor Does Not Run In Certain Position
Blower Motor Does Not Stop at OFF Position
Component Locator
Heater Unit and Heater Core
Repair Instructions
Heater Unit and Heater Core
Heater Temperature Control Link Unit and Air Mix Door
Heater Mode Control Link Unit and Mode Door
Blower Assembly
Blower Link Unit and Mode Door
Blower Motor
Ventilation Grille
Defroster Nozzle and Ventilation Duct
Control Lever Assembly
Control Panel Illumination Bulb
Resistor
Heater, Air Conditioning, Condenser Fan and Ceramic Heater (M/T Vechicle Only)
Ceramic Heater and/or Full Hot Switch
1B Air Conditioning
Description and Operation
Air Conditioning System Description
Refrigerant Cycle Description
System Components Description
Schematic and Routing Diagrams
Air Conditioning Switch Schematic
Connector List
Diagnostic Information and Procedures
Checking Refrigerant System With Manifold Gauge
No Cooling or Insufficient Cooling
Insufficient Velocity of Cooling Air
Discharge (High Gauge) Pressure Abnormally High
Discharge (High Gauge) Pressure Abnormally Low
Suction (Low Gauge) Pressure Abnormally High
Suction (Low Gauge) Pressure Abnormally Low
Suction (Low Gauge) And Discharge (High Gauge) Pressure Abnormally High
Suction (Low Gauge) And Discharge (High Gauge) Pressure Abnormally Low
Magnetic Clutch Dose Not Operate
Component Locator
Air Conditioning
Repair Instructions
Precautions for Replacement or Repair of Air Conditioning Parts
Repair of Refrigerant Leaks
Recovery, Recycling, Evacuation and Charging
Compressor Oil
Compressor
Condenser
Receiver-Drier
Pressure Switch
Evaporator Assembly
Evaporator Core, Expansion Valve and Thermostat
Air Conditioner (A/C) Switch
Blower Filter
Refrigerant Line
Specifications
Specifications
Fastener Torques
Special Tools
Special Tools
BODY, CAB, AND ACCESSORIES
2A Frame and Body Mounts
Description and Operation
Frame Description
Minimizing Frame Failures Description
Body Mounts Description
Longitudinal Sill Mounting
Other Types of Mountings Description
Diagnostic Information and Procedures
Sag
Buckle
Sidesway
Diamond
Twist
Improper Tracking
Cracks in the Web of the Rails
Repair Instructions
Checking Frame Alignment
Checking Alignment Without Gauges
Straightening Frames
Reinforcements
Repairing Cracks
Welding
Cross-member
Specifications
Widths Between The Web of Frame Rails
Yield Strength of Different Metal
Welding Chart
Electrode Chart
Plug Weld Chart
2B Cab Maintenance
Description and Operation
Interior Maintenance Description
Care and Cleaning of The Interior
Steering Wheel Refinishing
Water Leaks
Dust Leaks
Exterior Maintenance Description
Exterior Maintenance Description
Cab Repairs
Cab Alignment and Straightening
Dinging and Finishing
Painting Sheet Metal
Repair Instructions
Outside Rear View Mirror
Windshield Glass
Rear Window Replacement
Glass Polishing
Model and Series Designation Plate Replacement
2C Sheet Metal
Description and Operation
Sheet Metal Description
Repair Instructions
Grille Replacement
Bumper and Bumper Reinforce Replacement
Battery Box Replacement
Sheet Metal Repair
STEERING
3A Front End Alignment
Description and Operation
Steering, Suspension, Wheels and Tires Description
Front End Alignment Chart Description
Diagnosis Information and Procedures
Noisy Front End
Wheel Bounce
Excessive Tire Wear
On-Vehicle Service
On-Vehicle Service
Checking and Correcting Toe-ln
Checking and Correcting Camber
Checking and Correcting Caster
Checking and correcting Kingpin Inclination
Turning Angle Measurement and Adjustment
Specifications
Front End Alignment Settings
3B1 Steering Linkage
Description and Operation
Steering Linkage Description
Diagnostic Information and Procedures
Diagnosis of Steering Linkage
Repair Instructions
Pitman Arm
Drag Link
Tie Rod
Left Steering Arm
Specifications
Fastener Torques
Special Tools
Special Tools
3B3 Power Steering
Description and Operation
Power Steering Description
Maintenance Description
Fluid Level Adjustment Description
Steering Wheel Free Play Description
Steering Gear Adjustment Description
Bleeding the Hydraulic System Description
Hydraulic System Flushing Description
Power Steering System Test Description
Power Steering Gear Unit Repair Description
Tandem Hydraulic Pump Description
Diagnosis Information and Procedures
Objectionable “Hiss”
Rattle or Chuckle Noise in Steering Gear
Groan Noise in Steering Pump
Rattle or Knock Noise in Steering Pump
Rattle Noise in Steering Pump
Swish Noise in Steering Pump
Whine Noise in Steering Pump
Growl Noise in Steering Pump
Growl Noise in Steering Pump (Particularly Noticeable at Standstill Parking)
Excessive Play or Looseness in Steering System (Steering Wanders)
Vibration and Shimmy
Hard Steering Excessive Effort Required at Steering Wheel
Pump Inoperative, Poor, or no Assist (Hard Steering)
Momentary Increase in Effort when Turning Wheel Fast to Right or Left
Steering Wheel Surges or Jerks when Turning with Engine Running Especially During Parking
Steering Pulls to Left or Right
Poor Return of Steering Wheel
Snapping or Chucking in Steering Column or Wheel
Excessive Road Shock
Repair Instructions
Power Steering Oil Pump
Tandem Hydraulic pump
Steering Gear
Power Steering Pump
Tandem Hydraulic Pump Assembly Replacement (Hydraulic Booster Brake Model)
Power Steering Gear Unit
Specifications
Steering Gear Specifications
Fastener Torques
Special Tools
Special Tools
3B4 Steering Column
Description and Operation
Steering Column Description
Diagnosis of Steering Column
Diagnosis of Steering Column
Repair Instructions
Steering Wheel
Steering Column
Steering Shaft
Specifications
Fastener Torques
Special Tools
Special Tools
3C Front Axle and Suspension
Description and Operation
Front Axle and Suspension Description
Front Hubs and Bearings Description
Diagnostic Information and Procedures
Hard Steering, Excessive Effort Required at Steering Wheel
Steering Pulls to Left or Right
Poor Return-ability
Snapping or Chucking in Steering Column or Wheel
Spring Noise
Spring Sag or Bottom
Spring Breakage
Excessive Road Shock
Excessive Play or Looseness in Steering Wheel (Steering Wanders)
Vibration and Shimmy
Tapered Roller Bearing Diagnosis
Shock Absorber Diagnosis
Repair Instructions
Front Axle
Steering Knuckle and Bearing
Front Spring
Shock Absorber
Shackle
Front Hubs and Discs
Specifications
Front Axle
Fastener Torques
Special Tools
Special Tools
3D Rear Suspension
Description and Operation
Rear Suspension Description
Spring Maintenance
Diagnosis Information and Procedures
Spring Noise
Spring Sag or Bottom
Spring Breakage
Repair Instructions
Spring
Spring Leaf
Spring Eye Bushing
Shock Absorber
Specifications
Fastener Torques
3E Wheels and Tires
Description and Operation
Wheels and Rims Description
Tires and Tubes Description
Diagnostic Information and Procedure
Wheel Hop (Vehicle Vibration and Rough Steering)
Wobble (Vehicle Vibrations and Rough Steering)
Cracked or Broken Wheel Discs (Cracks Develop in the Wheel Disc from Handhole to
Handhole, from H…
Tire Slippage on Rim
Tire Mounting Difficulties
Tires Show Excessive Wear on Edges of Tread
Tires Show Excessive Wear in Center of Tread
Excessive Tire Wear
Dual Tires Rubbing
Tire Wear
Damaged Stud Holes (stud Holes Become Worn, Elongated or Deformed, Metal Builds up
Around Stud Ho…
Damaged Stud Threads
Loose Drum
Loose Inner Wheel
Broken Wheel Studs
Stripped Threads
Rust Streaks from Stud Holes Correction
Lateral or Radial Run-out Description
Wheel Studs and Nuts Description
Repair Instructions
Wheel
On-Vehicle Service: Tires and Tubes
How To Match Tires on the Rear Axle
Tire Rotation
Wheel and Tire Balancing
What Happens When Tires Get Hot
Inflation of Tires
Valve Core and Cap
Spare Tire
Specifications
Specifications
DRIVELINE/AXLE
4A1 Rear Axle
Description and Operation
Rear Axle Description
Diagnosis of the Rear Axle
Diagnosis of the Rear Axle
Bent Housing Check
On-Vehicle Service
Axle Shaft Replacement
Hub and Drum Assembly
Rear Axle Assembly Replacement
Differential Carrier
Unit Repair of 292mm/320mm Differential Carrier Assembly
Unit Repair of Differential Carrier Assembly
Specifications
Specifications
Fastener Torques
Specifications
Fastener Torques
Special Tools
Special Tools
4B Propeller Shaft
General Description
General Description
Propeller Shaft
Center Bearing
Universal Joint
Diagnosis of the Propeller Shaft and Universal Joint
Diagnosis of the Propeller Shaft and Universal Joint
On-Vehicle Service
Propeller Shaft Balance Check
Propeller Shaft Run-out Check
Propeller Shaft Replacement
Universal Joint Replacement
Splined Yoke Replacement
Center Bearing Replacement
Lubrication
Specifications
Specifications
Fastener Torques
BRAKES
5A Hydraulic Brakes
Description and Operation
Description and Operation
Hydraulic Brakes System Description
Hydraulic Brake Fluid Description
Diagnostic Information and Procedure
Road-Testing Brakes
External Conditions That Affect Brake Performance
No Brakes
Insufficient Brakes
Slow Brake Application
Uneven Braking (Front or Rear Brakes not Working)
Wet Weather: Brakes Grab or won’t Hold
Brakes Squeak
Brakes Chatter
Shoe Click
Noise and Chatter Squealing, Clicking, or Scraping Sound Upon Brake Application
Pulls to One Side
One Wheel Locks
Light Pedal Pressure-Brakes too Severe (Grabby Brakes)
Low Pedal or Pedal Goes to Floor
Slow Brake Release
Poor Assist or Loss of Assist
Brake Fade
All Brakes Drag when Adjustment is Known to be Correct
One Wheel Drags
Dragging Brakes
Poor Contact at the Center of Shoe
Unequal Wear on the Shoes in the Same Brake
Material at the Center of the Shoe Excessively Thin
Lining Tapered across the Width
Lining Worn at One End
Linings Glazed
Rivets Tear Loose
Unequal Wear Opposite Brakes, Same Axle
Linings at Scored
Cracks at Bolt Holes or Rivet Holes
Elongation of the Bolt Holes or Rivet Holes
Wear on the Edge of the Lining
Groove on the Edge of the Lining
Brake Drum Heat Checked in Spots
Drum Uniformly Heat Checked
Excessive Scoring of the Drum
Excessive Drum Cracks
Brake Pull
Brake Roughness-or Chatter (Pulsates)
Excessive Pedal Effort
Brake Drag
Grabbing or Uneven Braking Action (All conditions listed under “Pull”)
Brake Noisy
Poor Brake Action
Inspection and Repair Instructions
System Inspection
Contamination of Brake System
Flushing Brake System
Bleeding Brakes
Load-Sensing Proportioning Valve (LSPV) Adjustment
Load-Sensing Proportioning Valve (LSPV) Inspection
Brake Lines
Flexible Hose
Vacuum Pump (for GVWR 14,500 lb Model)
Brake Line Supporting Components
Brake Fluid Reservoir
Load-sensing Proportioning Valve (LSPV)
Master Cylinder
Brake Pressure Metering Valve (GVWR 12,000 lb or 14,500 lb Models)
Specifications
Fastener Torques
Special Tools
Special Tools
5A1 Vacuum Booster Brake System
Description and Operation
Vacuum Booster Brake System
Repair Instructions
Vacuum Booster (SERVO) Replacement
Brake Pedal
Brake Pedal Adjustment
Specifications
Specifications
Fastener Torques
5A2 Hydraulic Booster Brake System
Description and Operation
Description
Booster Assembly Description
Fluid and Fluid Handling Description
Flushing The Hydraulic Booster System
System Outline
Hydraulic Booster Troubleshooting
Large force pressing on the brake pedal (boosting insufficient)
Brake dragging
Oil leakage
Bad brake operation (lack of smoothness in operation)
Abnormal brake noise (when pressing the pedal)
No pedal boosting effect immediately after turning the engine off
Warning buzzer continuously sounds
Charge operation remains in effect
Notes
Supply Parts Replacement
Repair Instructions
Accumulator and O-ring Replacement
Hydraulic Booster Replacement
Clevis and Lock Nut Replacement
Guard Replacement
Brake Pedal Replacement
Brake Pedal Adjustment
Hydraulic Booster Brake Fluid and Filter Replacement
Specifications
Specifications
Fastener Torques
5A3 Hydraulic Foundation Brakes
Description and Operation
Hydraulic Foundation Brakes Description
Repair Instructions
Brake Shoe and Lining (Except GVWR 19,500 lb Model)
Brake Assembly Replacement (Except GVWR 19,500 lb Model)
Brake Shoe and Lining (GVWR 19,500 lb Model)
Brake Assembly Replacement (GVWR 19,500 lb Model)
Caliper and Support
Front Disk Brake Pad
Wheel Cylinder
Auto-Adjuster (Except GVWR 19,500 lb Model)
Auto-Adjuster (GVWR 19,500 lb Model)
Brake Drum Removal and Installation (Except GVWR 19500 lb)
Brake Drum Removal and Installation (GVWR 19500 lb)
Brake Linings
Brake Drums
Specifications
Foundation Brake specifications
Fastener Torques
Special Tools
Special Tools
5A4 Anti-Lock Brake System (ABS)
Schematic and Routing Diagrams
ABS Controls Schematics
Component Locator
Anti-Lock Brake (ABS) Controls Component Views
Electronic Hydraulic Control Unit (EHCU) Connector End View
Anti-Lock Brake System (ABS) Controls Connector End Views
Harness Connector, Joint and Ground Locations
Diagnostic Information and Procedures
General Information
ABS Warning Light
Computer System Service Precautions
General Service Precautions
Note on Intermittents
Test Driving ABS Complaint Vehicles
Reading Flash Diagnostic Trouble Code (DTC)
Clearing Diagnostic Trouble Code (DTC) without Scan Tool
Diagnostic System Check – Anti-lock Brake system (ABS) Controls
Scan Tool Data List
Scan Tool Data Definitions
Scan Tool Output Controls
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with Class 2 Device
Lost Communications with the Electronic Hydraulic Control Unit (EHCU)
Diagnostic Trouble Code (DTC) List
C0221 (Flash Code 52)
C0222 (Flash Code 62)
C0225 (Flash Code 51)
C0226 (Flash Code 61)
C0231 (Flash Code 54)
C0232 (Flash Code 64)
C0235 (Flash Code 53)
C0236 (Flash Code 63)
C0241 (Flash Code 43)
C0242 (Flash Code 45)
C0265 (Flash Code 41)
C0267 (Flash Code 33)
C0268 (Flash Code 34)
C0271 (Flash Code 14)
C0277 (Flash Code 15)
C0299 (Flash Code 25)
ABS Warning Light Always On
ABS Warning Light Inoperative
Symptom Diagnosis
Repair Instructions
Electronic Hydraulic Control Unit (EHCU) Replacement
Front Speed Sensor Replacement
Front Speed Sensor Rotor Replacement
Rear Speed Sensor Replacement
Rear Speed Sensor Rotor Replacement
Description and Operation
Anti-lock Brake System (ABS) General Information
System Components
Electronic Hydraulic Control Unit (EHCU)
ABS Warning Light
Wheel Speed Sensor (WSS)
Normal and Anti•lock Braking
Brake Pedal Travel
Acronyms and Abbreviations
Special Tool and Equipment
Special Tools
5C Parking Brake
Description and Operation
Parking Brake Description
Repair Instructions
Parking Brake Assembly
Preparation
Brake shoe Adjustment
Shoe Replacement
Drum Replacement
Cover Replacement
Lever Adjustment
Brake Lever Replacement
Specifications
Parking Brake Specifications
ENGINE
6A ENGINE MECHANICAL (4HK1-TC)
ISUZU DIESEL ENGINE (4HK1-TC)
Service Precautions
Trouble Shooting
Main Data and specifications
Engine Assembly
Removal
Installation
Engine Mount
Component
Removal
Installation
Torque Specifications
Cylinder Head Cover
Component
Removal
Installation
Torque Specifications
Inlet Cover
Component
Removal
Installation
Torque Specifications
Turbocharger and Exhaust Manifold
Component
Removal
Inspection
Installation
Torque Specifications
Timing Gear Train
Component
Removal
Inspection
Installation
Torque Specifications
Special tool
Rocker Arm Shaft Assembly
Component
Removal
Dismount
Reassembly
Installation
Torque Specifications
Camshaft Assembly
Component
Removal
Disassembly
Reassembly
Installation
Torque Specifications
Valve Stem Seal and Valve Spring
Component
Removal
Inspection
Installation
Special tool
Cylinder Head
Component
Removal
Disassembly
Inspection
Reassembly
Installation
Torque Specifications
Special tool
Piston and Connecting Rod
Component
Removal
Disassembly
Reassembly
Installation
Torque Specifications
Special tool
Flywheel
Component
Removal
Inspection
Installation
Torque Specifications
Special tool
Front Cover
Component
Removal
Installation
Torque Specifications
Crankshaft Front Oil Seal
Component
Removal
Installation
Torque Specifications
Special tool
Crankshaft Rear Oil Seal
Component
Removal
Installation
Special tool
Crankshaft
Component
Removal
Disassembly
Reassembly
Inspection
Installation
Torque Specifications
Special tool
Cylinder Block
Component
Removal
Inspection
Installation
Lubrication System
Service Precautions
Functional check
Special tool
Oil Filter Assembly
Components
Removal
Installation
Oil Filter Cartridge
Components
Removal
Installation
Special tool
Oil Cooler
Components
Removal
Disassembly
Reassembly
Installation
Oil Pan
Components
Removal
Installation
Oil Pump
Components
Removal
Disassembly
Reassembly
Inspection
Installation
Oil Pressure Switch
Inspection
Air Cleaner Element
Removal
Inspection
Installation
Cleaning
6B Cooling System
Cooling System
Service Precautions
Functional check
A list of defective phenomena
Main Data and Specifications
Water Pump
Components
Removal
Inspection
Installation
Torque Specifications
Thermostat
Components
Removal
Inspection
Installation
Radiator and Intercooler
Components
Removal
Inspection
Installation
Drive Belt
Components
Inspection
Torque Specifications
6C Fuel System
Fuel System
Service Precautions
A list of defective phenomena
Special tool
Trouble Shooting
Fuel System Check
Special tool
Fuel Filter Assembly
Components
Removal
Installation
Fuel Filter Cartridge
Removal
Installation
Special tool
Fuel Injector
Components
Removal
Installation
Torque Specifications
Special Tool
Fuel Supply Pump
Components
Removal
Installation
Torque Specifications
Fuel Rail
Components
Removal
Disassembly
Reassembly
Installation
Torque Specifications
Fuel Sedimenter Switch
Inspection
Fuel Tank
Service Precautions
Fuel Tank Unit
Torque Specifications
6D Engine Electrical
Service Precautions
General Procedure
Battery
Description
Diagnosis of Battery
On-vehicle Service: Battery
Charging System
General Description
Generator
Component
Repair Instruction
Inspection
Removal
Inspection
Disassembly
Inspection
Reassembly
Installation
Main Data and Specifications
Starting System
General Description
On-vehicle Service: Starter System
Starter
Components
Repair Instruction
Removal
Disassembly
Inspection
Reassembly
Installation
Main Data and Specifications
Preheating System
Glow Plug Replacement
Service Precautions
A list of defective phenomena
Main Data and Specifications
Glow Plug Controller (12,000 lbs GVW)
6E Engine Control System – 5.2L
Specifications
Temperature vs Resistance
Altitude vs Barometric Pressure
Diagnostic Trouble Code (DTC) Type Definitions
Schematic and Routing Diagrams
Engine Controls Schematics
Component Locator
Engine Controls Component Views
Engine Control Module (ECM) Connector End Views
Engine Controls Connector End Views
Diagnostic Information and Procedures
Diagnostic Starting Point – Engine Controls
Diagnostic System Check – Engine Controls
Scan Tool Data List
Scan Tool Data Definitions
Scan Tool Output Controls
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with Class 2 Device
Lost Communications With The Engine Control Module (ECM)
Engine Cranks but Does Not Run
Engine Starts and Stalls
DTC P0016
DTC P0087
DTC P0088
DTC P0089
DTC P0091
DTC P0092
DTC P0093
DTC P0101
DTC P0102
DTC P0103
DTC P0112
DTC P0113
DTC P0116
DTC P0117
DTC P0118
DTC P0126
DTC P0128
DTC P0181
DTC P0182
DTC P0183
DTC P0192
DTC P0193
DTC P0201 – P0204
DTC P0219
DTC P0234
DTC P0237
DTC P0238
DTC P0261, P0264, P0267 & P0270
DTC P0299
DTC P0300
DTC P0301 – P0304
DTC P0335
DTC P0336
DTC P0340
DTC P0341
DTC P0381
DTC P0382
DTC P0401
DTC P0403
DTC P0404
DTC P0405
DTC P0406
DTC P0477
DTC P0478
DTC P0500
DTC P0506
DTC P0507
DTC P0512
DTC P0562
DTC P0563
DTC P0567
DTC P0568
DTC P0571
DTC P0602
DTC P0606
DTC P0642
DTC P0643
DTC P0650
DTC P0652
DTC P0653
DTC P0670
DTC P0671 – P0674
DTC P0687
DTC P0698
DTC P0699
DTC P0700
DTC P0802
DTC P1093
DTC P1125
DTC P1293
DTC P1404
DTC P1593
DTC P1594
DTC P1597
DTC P1621
DTC P2122
DTC P2123
DTC P2127
DTC P2128
DTC P2132
DTC P2133
DTC P2138
DTC P2139
DTC P2140
DTC P2146
DTC P2147
DTC P2148
DTC P2149
DTC P2150
DTC P2151
DTC P2227
DTC P2228
DTC P2229
DTC P2293
DTC U0073, U0101 & U0106
Malfunction Indicator Lamp (MIL) Inoperative
Malfunction Indicator Lamp (MIL) Always On
Service Vehicle Soon (SVS) Lamp Inoperative [12,000 lbs GVW] Service Vehicle Soon (SVS) Lamp Always On [12,000 lbs GVW] EGR Control System Check
Glow Control System Check [Except 12,000 lbs GVW] Cruise Control System Check
Symptoms – Engine Controls
Symptoms – Engine Controls
Intermittent Conditions
Hard Start
Rough, Unstable, or Incorrect Idle and Stalling
High Idle
Cuts Out, Misses
Surges/Chuggles
Lack of Power, Sluggishness, or Sponginess
Hesitation, Sag, Stumble
Fuel Knock/Combustion Noise
Poor Fuel Economy
Excessive Smoke (Black Smoke)
Excessive Smoke (Blue or Gray Smoke)
Excessive Smoke (White Smoke)
Repair Instructions
Engine Control Module (ECM) Replacement/Fuel Injector Flow Rate Programming & Option
Programming
Accelerator Pedal Position (APP) Sensor Replacement
Boost Pressure Sensor Replacement
Brake Switch Replacement
Camshaft Position (CMP) Sensor Replacement
Crankshaft Position (CKP) Sensor Replacement
EGR Valve Replacement
Engine Coolant Temperature (ECT) Sensor Replacement
Fuel Injector Replacement/ Fuel Injector Flow Rate Programming
Fuel Rail Replacement
Fuel Supply Pump Replacement / Fuel Supply Pump Relearn Procedure
Glow Plug Controller Replacement
Fuel System Air Bleeding
Idle Up Sensor Replacement
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Replacement
Vehicle Speed Sensor (VSS) 2 Replacement
Power Take Off (PTO) System
PTO Control System Description
Stationary Preset PTO Mode
Stationary Variable PTO Mode
Mobile Variable PTO Mode
PTO Option Programming
Description and Operation
Engine Control Module (ECM) Description
Engine Control Component Description
Fuel System Description
Fuel System Component Description
Fuel Injection Quantity Control Description
Fuel Injection Timing Control Description
Exhaust Gas Recirculation (EGR) System Description
Glow Plug Controller Description (12,000lbs GVW)
Turbocharger Description
Special Tools and Equipment
Special Tools and Equipment
6F Exhaust System
EGR System
Service Precautions
Explanations on functions and operation
EGR Valve and EGR Cooler
Components
Removal
Inspection
Installation
Torque Specifications
Exhaust System
Service Precautions
Explanations on functions and operation
Functional check
List of abnormal phenomena
Trouble Shooting
Exhaust System Check
Exhaust Pipe
Removal
Inspection
Installation
Torque Specifications
Exhaust Brake System
Service Precautions
Explanations on functions and operation
Functional check
Exhaust Brake
Components
Removal
Disassembly
Reassembly
Inspection
Installation
Torque Specifications
TRANSMISSION/TRANSAXLE
7A Automatic Transmission 450-43LE
Specifications
Component Item Diameter, Clearance, Thickness and Piston Stroke
Automatic Transmission Fluid (ATF) Temperature Sensor Specifications
Bearings and Races Diameter
Pistons and Springs Specifications
Fastener Torques
Schematic and Routing Diagrams
Transmission Controls Schematics
Component Locator
Component Location
Automatic Transmission Mechanical Component
Overdrive Direct Clutch
Front Clutch
Rear Clutch
Overdrive (OD) Brake
2nd Brake
1st and Reverse Brake
Overdrive (OD) One-way Clutch
One-way Clutch No.2
Valve Body
Disassemble Views
Oil Pump Assembly
Overdrive (OD) Planetary Gear and Direct Clutch
Overdrive (OD) Brake
Front Clutch
Rear Clutch
Second Brake
Planetary Gears, One-way Clutch and Output Shaft
First and Reverse Brake
Valve Body
Extension Housing
Transmission Control Module (TCM) Connector End Views
Transmission Controls Connector End Views
Diagnostic Information and Procedures
Diagnosis Procedure
Self Diagnosis Information
Diagnostic System Check – Transmission Controls
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with Class 2 Device
Lost Communications With The Transmission Control Module (TCM)
Scan Tool Data Display
Scan Tool Output Controls
Diagnostic Trouble Code (DTC) Type Definitions [12,000 lbs GVW] DTC P0475 (Flash Code 37)
DTC P0500 (Flash Code 24)
DTC P0503 (Flash Code 24)
DTC P0560 (Flash Code 25)
DTC P0602 (Flash Code 63)
DTC P0705 (Flash Code 17)
DTC P0710 (Flash Code 15)
DTC P0711 (Flash Code 18)
DTC P0712 (Flash Code 15)
DTC P0713 (Flash Code 16)
DTC P0717 (Flash Code 14)
DTC P0722 (Flash Code 11) [12,000 lbs GVW] DTC P0722 (Flash Code 11) [Except 12,000 lbs GVW] DTC P0723 (Flash Code 11)
DTC P0727 (Flash Code 13)
DTC P0741 (Flash Code 15)
DTC P0742 (Flash Code 74)
DTC P0743 (Flash Code 34)
DTC P0748 (Flash Code 35)
DTC P0751 (Flash Code 51)
DTC P0752 (Flash Code 71)
DTC P0753 (Flash Code 31)
DTC P0756 (Flash Code 52)
DTC P0757 (Flash Code 72)
DTC P0758 (Flash Code 32)
DTC P0785 (Flash Code 33)
DTC P1382 (Flash Code 19)
DTC P1790 (Flash Code 61)
DTC P1791 (Flash Code 62)
DTC P1813 (Flash Code 42)
DTC P1839 (Flash Code 45)
DTC U2100 (Flash Code 41)
DTC U2104 (Flash Code 41)
DTC U2105 (Flash Code 41)
Check Trans Lamp Inoperative
Check Trans Lamp Always On
Diagnosis based on vehicle condition
Control Signal Inspection
Line Pressure Test
Stall Test
Road Test
Shift Point Chart
Lock-Up Point Chart
Repair Instructions (On-Vehicle)
Automatic Transmission Fluid (ATF)
Automatic Transmission Fluid (ATF) Level
Automatic Transmission Fluid (ATF) Change
Transmission Control Module (TCM)
Inhibitor Switch
Vehicle Speed Sensor 2 (SP1)
Vehicle Speed Sensor 1 (SP2)
Input Shaft Speed Sensor (C0) [12,000 lbs GVW] Automatic Transmission Fluid (ATF) Temperature Switch
Crank Position (CKP) Sensor
Overdrive Off Switch
Oil Pan
Oil Filler Tube
Oil Strainer
Solenoids
Rear Cover Oil Seal
Vehicle Speed (Speedometer) Sensor Driven Gear
Control Lever Assembly
Control Cable
Transmission Assembly
Torque Converter
Repair Instructions (Overhaul)
General Description
Transmission Wiring
Breather Plug and Hose
Control Shaft Lever
Inhibitor Switch
Automatic Transmission Fluid (ATF) Temperature Switch
Oil Cooler Unions
Torque Converter Housing
Vehicle Speed Sensor SP2
Speedometer Driven Gear Assembly
Input Shaft Speed Sensor (C0) [12,000 lbs GVW] Extension Housing
Speedometer Drive Gear and Spacer
Parking Lock Gear
Oil Pan
Oil Strainer
Solenoid Valve Connectors
Valve Body
Center Support Apply Gaskets
Solenoid Valve Wiring
C1 Accumulator Piston and Spring
C2 B0 B1 Accumulator Pistons And Springs
Manual Valve Lever, Shaft and Oil Seals
Thrust Clearance of Overdrive (OD) Input Shaft (Overdrive Planetary Gear)
Oil Pump
Overdrive (OD) Planetary Gear, Overdrive Direct Clutch and One-Way Clutch Assembly
Overdrive (OD) Planetary Ring Gear Assembly
Thrust Clearance of Input Shaft (Front Clutch Drum)
Overdrive (OD) Case Assembly
Front Clutch Assembly
Rear Clutch Assembly
Center Support Assembly
Planetary Gears, One-Way Clutch and Output Shaft Assembly
General Notes
Oil Pump Assembly
Oil Pump Body
Overdrive (OD) Planetary Gear and Direct Clutch
Overdrive (OD) Brake
Front Clutch
Rear Clutch
Second Brake
Planetary Gears, One-Way Clutch and Output Shaft
First and Reverse Brake
Valve Body
Extension Housing
Component Parts Installation
General Installation Description
Manual Valve Lever, Shaft and Oil Seals
Planetary Gears, One-Way Clutch and Output Shaft Assembly
Temporarily Install Center Support Assembly
Parking Lock Gear
Output Shaft Spacer and Speedometer Drive Gear
Extension Housing
Thrust Clearance of Center Support
Center Support Assembly
Rear Clutch Assembly
Front Clutch Assembly
Temporarily Install Overdrive (OD) Case Assembly
Thrust Clearance of Input Shaft (Front Clutch Drum)
Overdrive (OD) Case Assembly
Overdrive (OD) Ring Gear Assembly
Overdrive Planetary Gear, Overdrive (OD) Direct Clutch and One-Way Clutch Assembly
Temporarily Install Oil Pump
Thrust Clearance of Overdrive (OD) Input Shaft (Overdrive Planetary Gear)
Oil Pump
Accumulator Springs and Pistons
Center Support Apply Gasket
Solenoid Valve Wiring
Valve Body
Solenoid Valve and Automatic Transmission Fluid (ATF) Temperature Sensor Connectors
Oil Strainer
Magnet in Pan
Oil Pan
Torque Converter Housing
Transmission PTO Cover
Vehicle Speed Sensor SP2
Transmission Oil Cooler Unions
Automatic Transmission Fluid (ATF) Temperature Switch
Inhibitor Switch
Breather Plug and Hose
Speedometer Driven Gear Assembly
Input Shaft Speed Sensor (C0) [12,000 lbs GVW] Description and Operation
Transmission Identification Information
Torque Converter
Oil Pump
Shaft
Gear Shifting Mechanism
Overdrive (OD) Direct Clutch
Front Clutch
Rear Clutch
Overdrive (OD) Brake
2nd Brake
1st and Reverse Brake
Planetary Gear
Overdrive (OD) One-way clutch
One-way Clutch No.2
Accumulator
Solenoid Valve
Automatic Transmission Fluid (ATF) Temperature Sensor
Automatic Transmission Fluid (ATF) Temperature Switch
Inhibitor Switch (Neutral/Start Switch)
Accelerator Pedal Position Sensor
Vehicle Speed Sensor 2 (SP1)
Vehicle Speed Sensor 1 (SP2)
Crank Position (CKP) Sensor
Input shaft speed sensor (C0) [12,000 lbs GVW] Transmission Control Module (TCM)
Identification Of Transmission Control Module (TCM)
Automatic Transmission
Control Mechanism
Valve Operation
Gear Train (Transmission Mechanism) Operation
N and P ranges
First Gear in D or 2 Range
Second Gear in D Range
Third Gear in D, 2, L Range
Overdrive (OD) Gear in D Range
Second Gear in 2 Range
First Gear in L Range
R Range
Special Tools and Equipment
7B3 Manual Transmission (MZZ)
Description and Operation
Function and operation explanation
Function check
Repair Instructions
Gearshift Lever
Gearshift Cable
Vehicle Speed Sensor
Reverse, Neutral, And Selector Switches
Rear Oil Seal
Transmission
Top Gear Shaft
Main Shaft
Counter Shaft
Control Box
Specifications
Specifications
Fastener Torques
Special Tools
Special Tools
7C3 CLUTCH
Description and Operation
Clutch System
Diagnostic Information and Procedures
Diagnosis of Clutch
On-Vehicle Service
Clutch System Inspection
Clutch Pedal Free Play, Height and Travel Adjustment
Bleeding the Clutch Hydraulic Circuits
Repair Instructions
Clutch Assembly
Clutch Controls
Master Cylinder
Slave Cylinder
Specifications
Specifications
Fastener Torques
Special Tools
Special Tools
BODY, CAB, AND ACCESSORIES
8 Cab and Chassis Electrical
General Information
General Information
Notes for Working on Electrical Items
Symbols and Abbreviations
Parts for Electrical Circuit
Fuse, Fusible Link And Circuit Breaker
Relay
Diode
Connector
Reading the Circuit Diagram
Main Data and Specifications
Bulb Specifications (Under Creation)
Fuse, Fusible Link and Slow Blow Fuse Location
Power Distribution
Fuse and Relay Box Details
Reference Table of Fuse
Relay Location
Relay List
Diode Location
Diode List
Joint Connection and Weld Splice Location
Joint Connection Circuit
Reference Table of Weld Splice
Ground Point Location
Grounding Point Circuit
Cable Harness Routing
System Repair
Start and Charging
Engine Control Module (ECM)
Exhaust Brake
Headlight and Cornering Light
Identification Light, Illumination Light and Horn
Front Combination Light, Rear Combination Light and License Plate Light
Dome Light and Rear Dome Light
Windshield Wiper and Washer
Audio and Cigarette Lighter
Instrument Panel Cluster (IPC) and Warning / Indicator Light
Transmission Control Module (TCM)
Heater and Air Conditioning
Service Terminal
Anti-lock Brake System (ABS)
Power Window
Power Door Lock
In-Line Harness Connector End of Views
Connector Test Adapter List
Connector Test Adapter List
8F Steel Tilt Cab
Description and Operation
Cab Description
Diagnostic Information and Procedures
Cab Tilts with Difficulty.
Cab will not Tilt.
Cab does not Stay Firmly in the Driving Position; It Jiggles Up and down
Seat will not move
Seat moves only on One Side
Seat is Hard to Move
Seat will not Stay in Desired Position
Door will not Latch or Latches with Difficulty
Door will not Lock
Door will not Open but It is Unlocked (Door Handles do not Work Freely)
Door will not Open, It is Unlocked, but Release Handle/Lever Works Freely
Door is Hard to Open
Door Window is Difficult to Move
Door Window will not Close Nor will Regulator Handle Work
Door Window will not Move but Regulator Handle Moves Freely
Repair Instructions
Cab Interior
Driver’s Seat
Passenger Seat
Seat Belts: Side Seat Belt Tongue
Front Center and Driver Side Seat Belt Buckle
Front Center Seat Belt Tongue and Passenger Side Seat Belt Buckle
Instrument Panel
Instrument Panel Reinforcement
Headlining
Door
Door Lock Mechanism
Door Lock Cylinder and Outside Door Release Handle
Trim Panel
Window and Window Regulator Assembly
Cab Mounts
Rear Mount Brackets and Cushions
Cab Mounting Lever
Lock Assembly
Front Step Assembly
Cab Replacement
Specifications
Fastener Torques
8G Crew Cab
Description and Operation
Cab Description
Diagnostic Information and Procedures
Seat will not move
Seat moves only on One Side
Seat is Hard to Move
Seat will not Stay in Desired Position
Door will not Latch or Latches with Difficulty
Door will not Lock
Door will not Open but It is Unlocked (Door Handles do not Work Freely)
Door will not Open, It is Unlocked, but Release Handle/Lever Works Freely
Door is Hard to Open
Door Window is Difficult to Move
Door Window will not Close or Regulator Handle will not Work
Door Window will not Move but Regulator Handle Moves Freely
Repair Instructions
Rear Seat
Front Seat Belts:Side Seat Belt Tongue
Rear Seat Belts: Side Seat Belt Tongue
Rear Door-Side Seat Belt Buckle And Rear Center Seat Belt/Buckle
Headlining
Cab Floor Cover
Rear Door
Rear Door Lock Mechanism
Rear Door Outside Door Release Handle
Rear Door Trim Panel
Rear Window and Window Regulator Assembly
Rear Step Assembly
Cab Mounting Lever
Specifications
Fastener Torques

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