Manuel d'entretien Isuzu N Série (FR)

INDEX GENERAL INFORMATION GENERAL INFORMATION ......................................................................................................................... 3 General Repair Instructions .................................................................................................................... 3 General Repair Instructions ............................................................................................................... 3 Identification............................................................................................................................................ 4 Chassis Number:

............................................................................................................................... 4 Engine Number:................................................................................................................................. 4 Vehicle Identification Plate................................................................................................................. 4 Lifting Instruction.....................................................................................................................................

5 Lifting Instruction................................................................................................................................ 5 Garage Jack and Safety Stand.......................................................................................................... 5 Torque Specifications ............................................................................................................................. 8 Standard Bolts ...................................................................................................................................

8 Recommended Liquid Gasket................................................................................................................. 9 Recommended Liquid Gasket............................................................................................................ 9 Application Procedure...................................................................................................................... 10 Recommended Thread Locking Agent ................................................................................................. 11 MAINTENANCE AND LUBRICATION .......................................................................................................

12 Maintenance Schedule ......................................................................................................................... 12 Recommended Fluids, Lubricants and Diesel Fuels............................................................................. 22 Recommended Fluids, Lubricants and Diesel Fuels........................................................................ 22 Oil Viscosity Chart................................................................................................................................. 25 Engine Oil ........................................................................................................................................

25 Manual Transmission and Transfer Case Oil (Engine Oil)............................................................... 26 Front Axle and Rear Axle Oil ........................................................................................................... 27 Lubrication Chart................................................................................................................................... 28 NPR75 And NQR75 Models ............................................................................................................ 28 NKR77 And NPR77 (Front Rigid Suspension) Models....................................................................

29 NKR77 (Front Independent Suspension) Model.............................................................................. 30 BRAKES SERVICE INFORMATION ......................................................................................................................... 37 Troubleshooting .................................................................................................................................... 37 Brake System...................................................................................................................................

37 Hydraulic Booster............................................................................................................................. 42 Brake Lining..................................................................................................................................... 45 Brake Drum...................................................................................................................................... 46 Exhaust Brake..................................................................................................................................

46 Parking Brakes................................................................................................................................. 47 Main Data and Specifications ............................................................................................................... 48 Service Standard .................................................................................................................................. 73 Servicing ...............................................................................................................................................

74 Service Brakes................................................................................................................................. 74 Parking Brake .................................................................................................................................. 80 Fixing Torque........................................................................................................................................ 82 Special Tools ........................................................................................................................................

92 Hydraulic Brakes.............................................................................................................................. 92 Anti-lock Brake System (ABS) ......................................................................................................... 92 Parking Brakes................................................................................................................................. 92 HYDRAULIC BRAKES...............................................................................................................................

94 General Description .............................................................................................................................. 94 Hydraulic Brake System................................................................................................................... 94 Hydraulic Booster Brake System ..................................................................................................... 95 Front Drum Brake ............................................................................................................................

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Front Disc Brake ............................................................................................................................ 108 Load Sensing Proportioning Valve (LSPV).................................................................................... 109 Deceleration Sensing Proportioning Valve (DSPV) ....................................................................... 109 On-vehicle Service.............................................................................................................................. 110 Front Disc Brake Assembly............................................................................................................

110 Front Disc Brake Pad..................................................................................................................... 116 Front Drum Brake Assembly (Two Leading and Dual Two Leading)............................................. 122 Rear Drum Brake Assembly (Except Drum Inside Diameter 370 Mm).......................................... 130 Rear Drum Brake Assembly (Drum Inside Diameter 370 Mm)...................................................... 138 Brake Pedal and Control................................................................................................................

142 Hydraulic Booster And Brake Pedal Assembly.............................................................................. 149 Hydraulic Booster........................................................................................................................... 152 Accumulator and O-ring Replacement........................................................................................... 154 Clevis and Lock Nut Replacement................................................................................................. 155 Guard Replacement.......................................................................................................................

156 Load Sensing Proportioning Valve................................................................................................. 157 Deceleration Sensing Proportioning Valve .................................................................................... 161 Unit Repair.......................................................................................................................................... 163 Wheel Cylinder Assembly (Without Auto-adjuster)........................................................................ 163 Wheel Cylinder Assembly (With Auto-adjuster).............................................................................

166 Master Cylinder Assembly (NHR).................................................................................................. 180 Master Cylinder Assembly (NKR / NPR / NQR / NPS) .................................................................. 183 ANTI-LOCK BRAKE SYSTEM (ABS) ...................................................................................................... 187 General Description ............................................................................................................................ 187 Service Precaution.........................................................................................................................

187 General Description ....................................................................................................................... 187 System Components...................................................................................................................... 188 Electronic Hydraulic Control Unit (EHCU)...................................................................................... 188 Hydraulic Unit (HU)........................................................................................................................

188 ABS Warning Light......................................................................................................................... 188 Wheel Speed Sensor..................................................................................................................... 188 Normal and Anti-lock Braking ........................................................................................................ 188 Brake Pedal Travel ........................................................................................................................

189 Acronyms and Abbreviations ......................................................................................................... 189 General Diagnosis .............................................................................................................................. 190 General Information ....................................................................................................................... 190 ABS Service Precautions............................................................................................................... 190 Computer System Service Precautions .........................................................................................

190 General Service Precautions ......................................................................................................... 190 Note On Intermittents..................................................................................................................... 190 Test Driving ABS Complaint Vehicles............................................................................................ 190 “ABS” Warning Light ...................................................................................................................... 191 Normal Operation...........................................................................................................................

191 Basic Diagnostic Flow Chart.......................................................................................................... 191 Basic Inspection Procedure ........................................................................................................... 192 Tech 2 Scan Tool........................................................................................................................... 193 Tech 2 Features.............................................................................................................................

194 Getting Started............................................................................................................................... 194 Operating Procedure (For Example).............................................................................................. 195 DTC Modes.................................................................................................................................... 196 DTC Information Mode...................................................................................................................

196 Plotting Snapshot Graph................................................................................................................ 197 Plotting Graph Flow Chart (Plotting Graph After Obtaining Vehicle Information) .......................... 198 Flow Chart for Snapshot Replay (Plotting Graph) ......................................................................... 199 Tech 2 Data Display....................................................................................................................... 200 Special Function ............................................................................................................................

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Symptom Diagnosis ............................................................................................................................ 218 Symptom Diagnosis....................................................................................................................... 218 Chart A-1 ABS Works Frequently But Vehicle Does not Decelerate ............................................. 218 Chart TA-1 ABS Works Frequently But Vehicle Does not Decelerate (Use Tech 2) ..................... 219 Chart A-2 Uneven Braking Occurs While ABS Works ...................................................................

219 Chart TA-2 Uneven Braking Occurs While ABS Works (Use Tech 2) ........................................... 220 Chart A-3, TA-3 The Wheels Are Locked ...................................................................................... 220 Chart A-4, TA-4 Braking Sound (From Hydraulic Unit) Is Heard While Not Braking...................... 221 Diagnostic Trouble Codes................................................................................................................... 222 Diagnostic Trouble Codes..............................................................................................................

222 Diagnosis By “ABS” Warning Light Illumination Pattern ..................................................................... 223 Diagnosis By “ABS” Warning Light Illumination Pattern ................................................................ 223 Diagnostic Trouble Codes (DTCs)................................................................................................. 224 Chart B-1-1 With The Key In The ON Position (Before Starting The Engine) Warning Light (W/l) Is not Activated..............................................................................................

227 Chart 1 (DTC13/C0213) Vehicle Type Error ................................................................................. 228 Chart 2 (DTC14/C0214) EHCU Abnormality ................................................................................. 228 Chart 3 (DTC15/C0215) EHCU Voltage Out of Range ................................................................. 229 Chart 4 (DTC25/C0225) Exhaust Brake Cut Circuit Abnormality................................................... 230 Chart 5 (DTC33/C0233) Motor Drive Circuit Abnormality..............................................................

230 Chart 6 (DTC 34/C0234) Abnormal Motor Rotation....................................................................... 230 Chart 7 (DTC41/C0241) Solenoid Valve Power Supply Abnormality............................................. 231 Chart 8 (DTC 43, 45/C0243, C0245) Solenoid Valve Circuit Abnormality..................................... 231 Chart 9 (DTC51/C0251) FL Speed Sensor Circuit Abnormality..................................................... 231 Chart 10 (DTC52/C0252) FR Speed Sensor Circuit Abnormality.................................................. 231 Chart 11 (DTC53/C0253) RL Speed Sensor Circuit Abnormality ..................................................

232 Chart 12 (DTC54/C0254) RR Speed Sensor Circuit Abnormality.................................................. 233 Chart 13 (DTC61/C0261) Abnormal FL Speed Sensor Signal ...................................................... 234 Chart 14 (DTC62/C0262) Abnormal FR Speed Sensor Signal...................................................... 235 Chart 15 (DTC63/C0263) Abnormal RL Speed Sensor Signal...................................................... 237 Chart 16 (DTC64/C0264) Abnormal RR Speed Sensor Signal .....................................................

238 Unit Inspection Procedure................................................................................................................... 240 Unit Inspection Procedure.............................................................................................................. 240 Chart C-1-1 FL Speed Sensor Output Inspection Procedure ........................................................ 240 Chart C-1-2 FR Speed Sensor Output Inspection Procedure........................................................ 241 Chart C-1-3 RL Speed Sensor Output Inspection Procedure........................................................

241 Chart C-1-4 RR Speed Sensor Output Inspection Procedure ....................................................... 243 Chart TC-1 Sensor Output Inspection Procedure (Use Tech 2) .................................................... 244 On-vehicle Service.............................................................................................................................. 245 Electronic Hydraulic Control Unit (EHCU)...................................................................................... 245 Front Speed Sensor.......................................................................................................................

248 Front Speed Sensor Rotor............................................................................................................. 249 Rear Speed Sensor ....................................................................................................................... 251 Rear Speed Sensor Rotor.............................................................................................................. 253 PARKING BRAKES .................................................................................................................................

255 General Description ............................................................................................................................ 255 Parking Brake Assembly, Parking Brake Lever .................................................................................. 256 Unit Repair [178 mm, 190 mm TYPE]................................................................................................. 261 Unit Repair [203 mm TYPE]................................................................................................................

264 EXHAUST BRAKE................................................................................................................................... 267 General Description ............................................................................................................................ 267 On-vehicle Service.............................................................................................................................. 268 Unit Repair..........................................................................................................................................

270 ABS/ASR ABS/ASR.................................................................................................................................................. 279 ABS/ASR System ............................................................................................................................... 279 Description of Function and Operation .......................................................................................... 279 Parts Location................................................................................................................................

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Procedure of Trouble Diagnosis .................................................................................................... 292 Function Check.............................................................................................................................. 297 Trouble Diagnosis with Scan Tool ................................................................................................. 301 List of Diagnostic Trouble Code..................................................................................................... 308 ABS Warning Lamp does not Come on with the Starter Switch ON..............................................

312 ABS Warning Lamp Repeats Blinking After Turning the Starter Switch to ON.............................. 313 ABS Warning Lamp Repeats Blinking After Turning the Starter Switch to ON............................. 314 DTC:C0213 (Flash Code 13) Model Type Identification Fault Due to Wrong Assembly of Control Unit................................................................................................................................... 315 DTC:C0214 (Flash Code 14) EHCU Fault5A4-40 ......................................................................... 317 DTC:C0215 (Flash Code 15) ECU Power Supply Fault ................................................................

318 DTC:C0216 (Flash Code 16) CAN Communication Fault.............................................................. 319 DTC:C0226 (Flash Code 26) ECM Communication Fault ............................................................ 321 DTC:C0233 (Flash Code 33) Motor Drive Circuit Fault ................................................................. 322 DTC:C0234 (Flash Code 34) Motor Rotation Fault........................................................................ 323 DTC:C0235 (Flash Code 35) ASR Communication Line Fault/ASR Continuous Operation.......... 324 DTC:C0241 (Flash Code 41) Fail-Safe Relay Fault.......................................................................

325 DTC:C0243 (Flash Code 43) Solenoid Drive Circuit Fault............................................................. 326 DTC:C0245 (Flash Code 45) Solenoid Monitor Circuit Fault......................................................... 327 DTC:C0251 (Flash Code 51) Speed Sensor Open/ Short Circuit; FL............................................ 328 DTC:C0252 (Flash Code 52) Speed Sensor Open/ Short Circuit; FR........................................... 329 DTC:C0253 (Flash Code 53) Speed Sensor Open/ Short Circuit; RL ........................................... 330 DTC:C0254 (Flash Code 54) Speed Sensor Open/ Short Circuit; RR...........................................

331 DTC:C0261 (Flash Code 61) Speed Sensor Signal Fault/Wrong Tire Size; FL ........................... 332 DTC:C0262 (Flash Code 62) Speed Sensor Signal Fault/Wrong Tire Size; FR........................... 334 DTC:C0263 (Flash Code 63) Speed Sensor Signal Fault/Wrong Tire Size; RL............................ 336 DTC:C0264 (Flash Code 64) Speed Sensor Signal Fault/Wrong Tire Size; RR ........................... 338 List of Trouble Symptom................................................................................................................ 339 Symptom:

[The ABS Operates Frequently but Brake Force is Insufficient, or the ASR Operates Frequently] (Check Flow A-1).................................................................... 340 Symptom: [The ABS Operates Frequently but Brake Force is Insufficient, or the ASR Operates Frequently] (Check Flow TA-1).................................................................. 341 Symptom: [The ABS Operates but Pulling to One Side] (Check Flow A-2) .................................. 342 Symptom: [The ABS Operates but Pulling to One Side] (Check Flow TA-2) ................................ 343 Symptom: [Wheels are Locked During Brake Operation] (Check Flow A-3, TA-3) ..................... 344 Symptom:

[Feeling of Brake Pedal is Faulty] (Check Flow A-4) .................................................... 345 Symptom: [Brake Operating Noise Comes from the Hydraulic Unit Though the Brake Pedal is not Depressed] (Check Flow A-5, TA-5) .......................................................................... 346 Electronic Hydraulic Control Unit (EHCU) .......................................................................................... 347 Components ................................................................................................................................

347 Removal......................................................................................................................................... 347 Installation...................................................................................................................................... 349 Speed Sensor (Front) ........................................................................................................................ 351 Components .................................................................................................................................

351 Removal ........................................................................................................................................ 351 Installation...................................................................................................................................... 351 Inspection ...................................................................................................................................... 352 Sensor Rotor (Front Wheel) ...............................................................................................................

355 Components ................................................................................................................................. 355 Removal ........................................................................................................................................ 355 Installation ..................................................................................................................................... 356 Sensor Harness (Rear Axle) ..............................................................................................................

359 Components ................................................................................................................................. 359 Removal......................................................................................................................................... 359 Installation ..................................................................................................................................... 359 Rear Speed Sensor ...........................................................................................................................

361 Components ................................................................................................................................. 361 Removal ........................................................................................................................................ 361 Installation...................................................................................................................................... 363 Inspection ...................................................................................................................................... 365

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