Isuzu FSR - User Manual

To Next Page

Main Page

Cautions and Notices14
Table of Contents18
General Information18
How to Use21
Transmission Identification25
Rear Axle Identification26
Metric Fasteners35
Maintenance and Lubrication50
Specifications50
Approximate Fluid50
Fluid and Lubricant Recommendations51
Maintenance Schedule60
General Information65
Inspections and Other Services67
Vibration Diagnosis and Correction69
Diagnostic Information and Procedures69
Systematic Approach69
Vibration Diagnosis69
Classifying the Vibration Test73
Tire and Wheel Vibration76
Tire and Wheel Runout Measurement76
Driveline Vibration Analysis with80
Engine Related Vibration84
Repair Instructions88
General Service Precautions88
Balancing Tires and Wheels88
Wheel Weight Usage92
Correcting Non-Uniform Tires92
Correcting Driveline Vibration93
RWD and 4WD93
Description and Operation111
General Description111
Special Tools and Equipment122
Heating and Ventilation (Non-A/C126
Specifications126
Fastener Tightening Specifications126
Schematic and Routing Diagrams126
Heater Blower Controls Schematic126
Heater Blower Controls Schematics127
HVAC Mode128
Component Locator129
Heater Blower129
Heater Blower Controls Component129
Heater Blower Controls129
HVAC System132
End Views135
Diagnostic Information and Procedures137
Blower Motor Inoperative at137
Blower Motor Inoperative at Medium Speed138
Blower Motor Inoperative at Low Speed Only140
Heating Insufficient140
Poor Ventilation141
Heat Excessive141
Repair Instructions142
Control Assembly Replacement142
Blower Switch143
Blower Motor Resistor Replacement144
Air Distributor Duct Replacement (Lower)150
Air Distributor Duct150
Air Inlet Actuator151
Temperature Actuator Replacement156
Mode Actuator Replacement160
Heater Pipes164
Heater Pipes Replacement (Outlet)166
Heater Core Replacement (Right)168
Heater Core Replacement (Left)170
Heater System175
Air Distribution System176
HVAC Systems with A/C Manual180
Specifications180
Fastener Tightening Specifications180
Compressor Specifications180
Refrigerant Oil Distribution Specifications181
Schematic and Routing Diagrams181
HVAC Schematic References181
HVAC Schematic181
Icons181
HVAC Blower Control Schematics182
Component Locator188
HVAC Components188
HVAC Component Views188
HVAC Connector End188
Diagnostic Information and Procedures201
Functional Check201
HVAC Blower Controls System Check201
HVAC Compressor Clutch Does Not Engage202
HVAC Compressor Clutch Does Not Disengage205
Blower Motor Inoperative at any206
Blower Motor Low Speed Inoperative206
Blower Motor Medium Speed Inoperative207
Blower Motor Low and Medium Speeds Inoperative208
Blower Motor High Speed Inoperative208
Condenser Fan Inoperative209
Condenser Fan on at All Times210
System Performance Chart211
Refrigerant System Checks212
Leak Testing213
Heat Excessive216
Cooling Insufficient216
Air Delivery217
Repair Instructions217
Odor Correction217
Refrigerant Recovery218
Compressor Replacement219
Compressor Sealing Washers Replacement222
0-Ring Replacement224
Clutch Assembly225
Compressor Magnetic Clutch (Disassembly)228
Compressor Magnetic Clutch228
Compressor Magnetic Clutch (A/C Compressor Seal)228
Compressor Overhaul231
Compressor Hose Assembly Replacement231
Evaporator Hose Assembly Replacement234
Receiver Dehydrator and Evaporator Hose Assembly238
Receiver Dehydrator Replacement240
Thermal Expansion Valve Replacement242
A/C Temperature Sensor Replacement245
Condenser Fan Replacement247
Condenser Replacement247
Blower Motor and Fan Replacement254
HVAC Module Assembly Replacement257
Evaporator Core Replacement258
Heater Core Replacement (Right)262
Heater Core Replacement262
Heater Pipes Replacement266
Heater Pipes Replacement (Outlet)267
Passenger Compartment Air Replacement268
Passenger Compartment Air Filter268
Control Assembly Replacement269
Blower Switch Replacement270
Replacement272
Replacement275
Air Distributor Duct Replacement (Lower)285
Air Distributor Duct Replacement285
Description and Operation287
System Description288
Refrigeration System Description288
Speed290
Refrigeration System Description290
Maintaining Chemical Stability293
Evaporator Description293
Condenser Description294
Accumulator Description294
Compressor Description294
Ventilation Description295
Relays and Sensors Description295
HVAC Compressor Controls Circuit Description297
Equipment299
And Recharging300
Body and Accessories302
Lighting Systems308
Specifications308
Schematic and Routing Diagrams308
Systems320
Component Locator320
Lighting Systems Components320
Lighting Systems Component Views320
Left Rear View324
Visual Identification344
Lighting Systems Connector End Views344
Cigar Lighter345
Diagnostic Information and Procedures351
DRL System351
Exterior Lights System351
Backup Lights System Check351
Interior Lights System Check351
Interior Lights Dimming System Check351
Backup Lamps Inoperative352
Clearance Lamps Inoperative353
Courtesy or Dome Lamps Inoperative354
DRL Headlamps Always on354
DRL Indicator Inoperative354
Open355
Hazard Lamps Inoperative356
Headlamps Inoperative357
Headlamps Inoperative358
(DRL Off)360
Headlamps Inoperative360
Headlamp Switch off361
Low Beams361
Headlamps Inoperative Right High Beam (Headlamp)363
Headlamps Inoperative Flash363
High Beams363
(Right)364
Headlamps, DRL on with Engine Not Running365
Instrument Panel Lamps Inoperative366
(Dimming Lamps Inoperative)367
Instrument Panel Lamps Inoperative367
License and Tail Lamps Inoperative368
Park Lamps Inoperative369
Park Lamp Inoperative LF370
Park Lamp Inoperative RF370
Park, Side, and Front Marker Lamps Inoperative371
Park, Side Marker, and Clearance Lamps Always on371
Park, Side Marker, and Clearance Lamps Inoperative372
Rearview Mirror Lamps Inoperative373
Outside (both Mirrors)373
Rearview Mirror Lamps Inoperative374
Outside (Left Mirror)374
Side Marker Lamp Inoperative374
One Lamp (Left)374
Side Marker Lamp Inoperative375
One Lamp (Right)375
Side Marker Lamps Inoperative376
Headlamp Aiming394
Park/Turn Signal Lamp Replacemen (Housing)395
Clearance Lamp Replacement (Lamp Housing)395
Clearance Lamp Replacement Outside Mirror (Housing)400
Description and Operation401
DRL Circuit Description401
Backup Lights Circuit Description402
Special Tools and Equipment403
Wipers/Washer Systems404
Schematic and Routing Diagrams404
Wiper/Washer System Schematic References404
Wiper/Washer System (Pulse)406
Component Locator406
Wiper/Washer System Components406
Wiper/Washer System Component Views407
Visual Identification409
Wiper/Washer System Connector End Views409
Diagnostic Information and Procedures410
Wiper/Washer Diagnostic System Check410
Wipers All Modes and Washer Inoperative410
Wipers All Modes Inoperative411
Wipers High Mode Inoperative, Low Mode Operates412
Wipers Low Mode Inoperative, High Mode Operates412
Wipers Always on413
Washers Inoperative414
Washers Always on414
Wiper Arm Tip Pressure Check, Blade Element Check415
Repair Instructions415
Washer Pump/Reservoir Replacement415
Arm Replacement415
Wiper/Washer System415
Body and Accessories432
Speaker Noise432
Antenna Diagnostic Check434
(Left Front Speaker)435
Speakers Inoperative One436
Repair Instructions438
Radio Replacement438
Cassette Cleaning439
Speaker Replacement441
Description and Operation442
Radio/Audio System Description442
Radio/Audio System Operation442
Circuit Description443
Wiring Systems444
Specifications444
Fastener Tightening Specifications444
Diagnostic Information and Procedures444
How to Use Connector End450
How to Use Diagnostic450
Electrical Symbols452
Strategy Based Diagnostic Flow461
High Beams462
Symptom Diagnostic Example462
Troubleshooting with463
Test Light463
Troubleshooting with464
Digital Multimeter464
Using Connector Test Adapters464
Testing for Continuity465
Splicing Inline Harness473
Connector Repairs474
Connector Position475
Terminal Position Assurance Locks475
Schematic and Routing Diagrams476
Power and Grounding Schematic References476
Lamp486
Fuse Block Details Schematics486
Ground Distribution Schematics492
Component Locator505
Power and Grounding Components505
Power and Grounding Component Views519
Diagnostic Information and Procedures528
Data Link Connector End Views528
Data Link Connector528
Components (EBCM (Hydraulic))528
Description and Operation530
Data Link Connector Description530
Data Link Connector Operation530
Data Link Connector Circuit530
Inline Harness Connector End Views531
Harness Routing559
Icons584
Instrument Panel, Gauges and Console584
Specifications584
Fastener Tightening Specifications584
Schematic and Routing Diagrams584
Instrument Cluster Schematic References584
Instrument Cluster Schematic Icons584
Component Locator592
Instrument Panel592
Instrument Cluster Components592
Instrument Cluster Component Views593
Visual Identification604
Instrument Cluster Connector End Views604
Fuel Transfer Pump605
Diagnostic Information and Procedures610
Gauge Engine Coolant Temp Always Cold610
Gauge Eng Coolant Temp Inaccurate or Inoperative612
Gauge Engine Oil Pressure Always High613
Gauge Engine Oil Pressure613
Gauge614
Always Indicates Empty615
Tanks)615
Gauges Inoperative622
All622
Gauge Voltmeter Inaccurate or Inoperative623
Indicator Check Gauge Always on (Cell 41)624
Indicator Check Gauge Inoperative624
Indicator Fasten Safety Belt Always on625
Indicator Fasten Safety Belt625
Inoperative625
Indicator Low Engine Coolant Always on626
Inoperative (Cell 41)626
Indicator Low Engine Coolant Inoperative (Cell 81)627
Speedometer Inaccurate (J 38522 Unavailable)628
Speedometer And/Or Odometer Inoperative628
Tachometer Inoperative629
Schematic and Routing Diagrams629
Audible Warnings Schematic References629
Diagnostic Information and Procedures631
Audible Warnings Components631
Audible Warnings Component Views631
Audible Warnings Connector End Views634
Audible Warnings Diagnostic System Check635
Chime Always635
Chime Inoperative636
Repair Instructions638
IP Cluster Replacement (Instrument Cluster)638
IP Cluster Replacement (Speedometer)639
Cigar Lighter Replacement640
Engine Oil Pressure Switch Replacement640
IP Carrier Replacement641
Multifunction Alarm Module Replacement646
Description and Operation647
Instrument Cluster Circuit Description647
Audible Warnings Operation648
Audible Warnings Circuit Description651
Horns652
Specifications652
Fastener Tightening Specifications652
Schematic and Routing Diagrams652
Horns Schematic References652
Horns Schematics653
Component Locator654
Horns Components654
Horns Component Views654
Horns Connector End Views658
Diagnostic Information and Procedures658
Horns Inoperative (One Does Not Sound)659
Horns Always on659
Repair Instructions660
Horn Replacement (Single)660
Horn Replacement (Dual)661
Description and Operation661
Horns Circuit Description661
Exterior Trim662
Repair Instructions662
Emblem/Nameplate662
Washing and Foreign Material Deposit Removal663
Washing and Waxing663
Cleaning Bright Metal663
Waterleak Test664
Repair Instructions664
Generalized Testing664
Diagnostic Information and Procedures664
Water Hose Test665
Air Hose Test665
Stationary Window Waterleak Repair665
Stationary Windows666
Repair Instructions666
Windshield Upper Reveal666
Replacement666
Windshield Replacement667
Quarter Window Replacement669
Rear Window Replacement670
Window Polishing672
Special Tools and Equipment673
Bumpers674
Specifications674
Fastener Tightening674
Repair Instructions674
Bumper Replacement674
Body Front End678
Specifications678
Fastener Tightening Specifications678
Repair Instructions679
Hood Replacement679
Hood Latch679
Fender Replacement682
Battery Box684
Component Box Replacement685
Cab Replacement686
Cab Lock Replacement689
Cab Tilt Support Replacement692
Step and Support Replacement693
Fender Extension Bracket695
Air Scoop Replacement696
Panel Replacement Front697
Splash Shield Replacement697
Wheelhouse Panel Replacement699
Wheelhouse Panel Replacement (Upper)699
Specifications700
Component Locator703
Power Door Systems Components703
Power Door Systems Component Views703
Mirror)705
Power Door Systems Connector707
Power Window Switch707
Power Windows System Check708
Heated Mirror System Check708
Power Window Inoperative RF709
Power Windows Inoperative from LF Switch710
Heated Mirrors Inoperative (Switch Indicator)712
Heated Mirrors Inoperative712
Heated Mirrors Inoperative713
Heated Mirrors Always on713
Repair Instructions714
Trim Panel Replacement714
Door Replacement715
Door Handle Replacement716
Lock Replacement719
(Right Side)719
Striker Replacement721
Window Regulator Replacement (Left Side)723
Window Handle Replacement723
Window Replacement724
Window Run Channel725
Window Replacement Inner726
Window Replacement Outer727
Mirror Replacement728
Description and Operation730
Heated Mirror Circuit Description730
Special Tools and Equipment731
Specifications732
Fastener Tightening Specifications732
Diagnostic Information and Procedures732
Seat Manual Adjuster Does732
Lock732
Repair Instructions733
Seat Replacement733
Seat Replacement734
Seat Riser Replacement (Passenger)735
Seat Riser Replacement (Driver)739
Repair Instructions742
Mat/Carpet Replacement742
Trim Panel Replacement743
Area Rear743
Door Sill Plate Replacement743
Headliner Replacement744
Upper744
Console Replacement745
Center746
Side Door748
Cleaning Glass Surfaces752
Trim752
Seat Belt Care753
Paint/Coatings756
Specifications756
Clearcoat Repair Specifications756
3M Products756
Clearcoat Repair Specifications757
Meguiar Products757
Anti-Corrosion Treatment and Repair758
Paint Identification760
Repair Instructions761
Clearcoat Repair W/O Repainting761
Corrosion Repair762
Environmental Fallout (Acid Rain)762
Paint Gauges763
Clearcoat Thickness763
Damage Repair763
Specifications764
Fastener Tightening Specifications764
Electrode764
Plug Weld Chart765
Diagnostic Information and Procedures765
Checking Frame Alignment765
Frame766
Frame Conditions767
Repair Instructions768
Straightening Description768
Frame Repair769
Crossmember Replacement774
Installation Procedure774
Body Mount Replacement (Cab Mounts)774
Body Mount Replacement (Cab Mount)778
Body Mount Replacement (Bracket)780
Tow Hook Replacement781
Assist Step and Support Replacement Lower782
Description and Operation784
Frame and Underbody Description784
Minimizing Frame Service Description785
Metals786
Repair Instructions786
Seat Belts790
Specifications790
Diagnostic Information and Procedures790
Operational and Functional Checks790
Repair Instructions790
Seat Belt Service Precautions790
Driver or Passenger Seat Belt Replacement791
Center Seat Belt Fleplacement798
Description and Operation799
Seat Belt System Operation799

Brand	Isuzu
Model	FSR
Category	Trucks
Language	English

Isuzu FSR - User Manual

Table of Contents

Isuzu FSR Specifications

Related product manuals