Manual PDF Isuzu LR Series 2019 Mechanical Repair Procedures MBHTML-WEN-1991

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Isuzu LR Series 2019 Mechanical Repair Procedures MBHTML-WEN-1991
Size: 303.60 MB
Format: PDF
Language: English
Brand: Isuzu
Type of Machine: Bus Chassis
Type of Manual: Workshop Manual - Mechanical Repair Procedures
Model: Isuzu LR Series Bus Chassis
Date: 2019
Engine: Isuzu 4HK1 Euro4 ; 4HK1 Euro6 Engine
Hong Kong, Singapore and Vietnam only (Date: 2020/10/09)
Parts Number: MBHTML-WEN-1991
Number of Pages: 4726 Pages

Contents:
1.1. Engine (4HK1 (Euro4 specification))

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - disassembly​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - reassembly​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet cover - installation​

Inlet cover - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Rocker arm shaft - disassembly​

Rocker arm shaft - inspection​

Rocker arm shaft - installation​

Rocker arm shaft - reassembly​

Rocker arm shaft - removal​

Supplementary Information​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

FRP regulator - installation​

FRP regulator - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Injector - installation​

Injector - removal​

Pre-fuel filter - installation​

Pre-fuel filter - removal​

Pre-fuel filter element - inspection​

Pre-fuel filter element - installation​

Pre-fuel filter element - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Engine coolant level switch - inspection​

Engine coolant level switch - installation​

Engine coolant level switch - removal​

Fan drive belt - inspection​

Fan drive belt - installation​

Fan drive belt - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - disassembly​

Oil cooler - installation​

Oil cooler - reassembly​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure sensor - installation​

Oil pressure sensor - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - inspection​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - removal​

Oil separator - installation​

Oil separator - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR - inspection​

EGR - installation​

EGR - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator control link - installation​

Accelerator control link - removal​

Accelerator pedal - installation​

Accelerator pedal - removal​

Idle up sensor - inspection​

Idle up sensor - installation​

Idle up sensor - removal​

Supplementary Information​

1J. Electrical​

Cooler generator - installation​

Cooler generator - removal​

Generator - disassembly​

Generator - inspection​

Generator - installation​

Generator - reassembly​

Generator - removal​

Generator drive belt - inspection​

Generator drive belt - installation​

Generator drive belt - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Barometric pressure sensor - inspection​

Barometric pressure sensor - installation​

Barometric pressure sensor - removal​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - installation​

ECM - removal​

ECM - setting​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

Fuel temperature sensor - inspection​

Fuel temperature sensor - installation​

Fuel temperature sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

Supplementary Information​

VGS control unit - installation​

VGS control unit - removal​

1.2. Engine (4HK1 (Euro6 specification))

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - disassembly​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - reassembly​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet cover - installation​

Inlet cover - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Rocker arm shaft - disassembly​

Rocker arm shaft - inspection​

Rocker arm shaft - installation​

Rocker arm shaft - reassembly​

Rocker arm shaft - removal​

Supplementary Information​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

FRP regulator - installation​

FRP regulator - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Injector - installation​

Injector - removal​

Pre-fuel filter - installation​

Pre-fuel filter - removal​

Pre-fuel filter element - inspection​

Pre-fuel filter element - installation​

Pre-fuel filter element - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Engine coolant level switch - inspection​

Engine coolant level switch - installation​

Engine coolant level switch - removal​

Fan drive belt - inspection​

Fan drive belt - installation​

Fan drive belt - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - disassembly​

Oil cooler - installation​

Oil cooler - reassembly​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure sensor - installation​

Oil pressure sensor - removal​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - inspection​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - removal​

Oil separator - installation​

Oil separator - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

DPD - disassembly​

DPD - inspection​

DPD - installation​

DPD - reassembly​

DPD - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Exhaust throttle solenoid valve - inspection​

Exhaust throttle solenoid valve - installation​

Exhaust throttle solenoid valve - removal​

Exhaust throttle valve - inspection​

Exhaust throttle valve - installation​

Exhaust throttle valve - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

Dosing module - disassembly​

Dosing module - installation​

Dosing module - reassembly​

Dosing module - removal​

EGR - inspection​

EGR - installation​

EGR - removal​

Supplementary Information​

Urea fluid - inspection​

Urea fluid supply module - disassembly​

Urea fluid supply module - inspection​

Urea fluid supply module - installation​

Urea fluid supply module - reassembly​

Urea fluid supply module - removal​

Urea fluid supply module filter - installation​

Urea fluid supply module filter - removal​

Urea fluid tank - installation​

Urea fluid tank - removal​

Urea fluid tank heater coolant control valve - installation​

Urea fluid tank heater coolant control valve - removal​

Urea fluid tank level gauge - installation​

Urea fluid tank level gauge - removal​

Urea SCR - disassembly​

Urea SCR - inspection​

Urea SCR - installation​

Urea SCR - reassembly​

Urea SCR - removal​

1I. Speed Control Systems​

Accelerator control link - installation​

Accelerator control link - removal​

Accelerator pedal - installation​

Accelerator pedal - removal​

Idle up sensor - inspection​

Idle up sensor - installation​

Idle up sensor - removal​

Supplementary Information​

1J. Electrical​

Cooler generator - installation​

Cooler generator - removal​

Generator - disassembly​

Generator - inspection​

Generator - installation​

Generator - reassembly​

Generator - removal​

Generator drive belt - inspection​

Generator drive belt - installation​

Generator drive belt - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

Charge air cooler temperature sensor 1 - inspection​

Charge air cooler temperature sensor 1 - installation​

Charge air cooler temperature sensor 1 - removal​

Charge air cooler temperature sensor - inspection​

Charge air cooler temperature sensor - installation​

Charge air cooler temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

DCU - installation​

DCU - removal​

DCU - setting​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

EGR gas temperature sensor 1 - inspection​

EGR gas temperature sensor 1 - installation​

EGR gas temperature sensor 1 - removal​

EGR gas temperature sensor 2 - inspection​

EGR gas temperature sensor 2 - installation​

EGR gas temperature sensor 2 - removal​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Exhaust differential pressure sensor - inspection​

Exhaust differential pressure sensor - installation​

Exhaust differential pressure sensor - removal​

Exhaust gas temperature sensor 3 - installation​

Exhaust gas temperature sensor 3 - removal​

Exhaust gas temperature sensor - inspection​

Exhaust gas temperature sensor - installation​

Exhaust gas temperature sensor - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

Fuel temperature sensor - inspection​

Fuel temperature sensor - installation​

Fuel temperature sensor - removal​

IMT sensor - inspection​

IMT sensor - installation​

IMT sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

NOx sensor 1 - inspection​

NOx sensor 1 - installation​

NOx sensor 1 - removal​

NOx sensor 2 - inspection​

NOx sensor 2 - installation​

NOx sensor 2 - removal​

PM sensor - installation​

PM sensor - removal​

Supplementary Information​

Turbocharger outlet temperature sensor - inspection​

Turbocharger outlet temperature sensor - installation​

Turbocharger outlet temperature sensor - removal​

Urea fluid sensor - inspection​

Urea fluid sensor - installation​

Urea fluid sensor - removal​

VGS control unit - installation​

VGS control unit - removal​

2. Suspension

2B. Front Suspension​

Leaf rigid suspension - disassembly​

Leaf rigid suspension - inspection​

Leaf rigid suspension - installation​

Leaf rigid suspension - reassembly​

Leaf rigid suspension - removal​

Leveling valve - disassembly​

Leveling valve - inspection​

Leveling valve - installation​

Leveling valve - reassembly​

Leveling valve - removal​

Supplementary Information​

2C. Rear Suspension​

Air suspension - disassembly​

Air suspension - inspection​

Air suspension - installation​

Air suspension - reassembly​

Air suspension - removal​

Leveling valve - disassembly​

Leveling valve - inspection​

Leveling valve - installation​

Leveling valve - reassembly​

Leveling valve - removal​

Supplementary Information​

2D. Wheel, Tire System​

Disc wheel and tire - inspection​

Disc wheel and tire - installation​

Disc wheel and tire - removal​

3. Driveline, Axle

3B. Differentials​

Differential oil - replacement​

Rear differential (single) (14.5H) - disassembly​

Rear differential (single) (14.5H) - inspection​

Rear differential (single) (14.5H) - installation​

Rear differential (single) (14.5H) - reassembly​

Rear differential (single) (14.5H) - removal​

Supplementary Information​

3C. Drive Shaft System​

Front axle - disassembly​

Front axle - inspection​

Front axle - installation​

Front axle - reassembly​

Front axle - removal​

Front hub - inspection​

Front hub - installation​

Front hub - removal​

Knuckle - disassembly​

Knuckle - inspection​

Knuckle - installation​

Knuckle - reassembly​

Knuckle - removal​

Knuckle arm - inspection​

Knuckle arm - installation​

Knuckle arm - removal​

Rear axle - disassembly​

Rear axle - inspection​

Rear axle - installation​

Rear axle - reassembly​

Rear axle - removal​

Rear axle shaft - inspection​

Rear axle shaft - installation​

Rear axle shaft - removal​

Rear hub - inspection​

Rear hub - installation​

Rear hub - removal​

Rear propeller shaft - disassembly​

Rear propeller shaft - inspection​

Rear propeller shaft - installation​

Rear propeller shaft - reassembly​

Rear propeller shaft - removal​

Supplementary Information​

Tie rod - disassembly​

Tie rod - inspection​

Tie rod - installation​

Tie rod - reassembly​

Tie rod - removal​

Tie rod arm - inspection​

Tie rod arm - installation​

Tie rod arm - removal​

Wheel alignment check​

4. Brakes

4B. Brake System​

Air dryer (with integrated governor) - disassembly​

Air dryer (with integrated governor) - inspection​

Air dryer (with integrated governor) - installation​

Air dryer (with integrated governor) - reassembly​

Air dryer (with integrated governor) - removal​

Brake pedal - inspection​

Brake pedal - installation​

Brake pedal - removal​

Brake valve - disassembly​

Brake valve - inspection​

Brake valve - installation​

Brake valve - reassembly​

Brake valve - removal​

Check valve - inspection​

Check valve - installation​

Check valve - removal​

Dual relay valve - disassembly​

Dual relay valve - inspection​

Dual relay valve - installation​

Dual relay valve - reassembly​

Dual relay valve - removal​

Front brake chamber (power) - disassembly​

Front brake chamber (power) - inspection​

Front brake chamber (power) - installation​

Front brake chamber (power) - reassembly​

Front brake chamber (power) - removal​

Front drum brake - disassembly​

Front drum brake - inspection​

Front drum brake - installation​

Front drum brake - reassembly​

Front drum brake - removal​

Front expander - disassembly​

Front expander - inspection​

Front expander - installation​

Front expander - reassembly​

Front expander - removal​

HSA valve - disassembly​

HSA valve - inspection​

HSA valve - installation​

HSA valve - reassembly​

HSA valve - removal​

Low pressure switch - inspection​

Low pressure switch - installation​

Low pressure switch - removal​

Multi-protection valve - disassembly​

Multi-protection valve - inspection​

Multi-protection valve - installation​

Multi-protection valve - reassembly​

Multi-protection valve - removal​

Rear brake chamber (spring) - disassembly​

Rear brake chamber (spring) - inspection​

Rear brake chamber (spring) - installation​

Rear brake chamber (spring) - reassembly​

Rear brake chamber (spring) - removal​

Rear drum brake - disassembly​

Rear drum brake - inspection​

Rear drum brake - installation​

Rear drum brake - reassembly​

Rear drum brake - removal​

Rear expander - disassembly​

Rear expander - inspection​

Rear expander - installation​

Rear expander - reassembly​

Rear expander - removal​

Relay valve - disassembly​

Relay valve - inspection​

Relay valve - installation​

Relay valve - reassembly​

Relay valve - removal​

Safety valve - inspection​

Safety valve - installation​

Safety valve - removal​

Stoplight switch - inspection​

Stoplight switch - installation​

Stoplight switch - removal​

Supplementary Information​

4C. Parking Brake System​

Hand control brake valve - disassembly​

Hand control brake valve - inspection​

Hand control brake valve - installation​

Hand control brake valve - reassembly​

Hand control brake valve - removal​

Parking brake switch - inspection​

Parking brake switch - installation​

Parking brake switch - removal​

Supplementary Information​

4D. ABS​

Front ABS modulator - disassembly​

Front ABS modulator - inspection​

Front ABS modulator - installation​

Front ABS modulator - reassembly​

Front ABS modulator - removal​

Front exciter ring - inspection​

Front exciter ring - installation​

Front exciter ring - removal​

Front relay valve - disassembly​

Front relay valve - inspection​

Front relay valve - installation​

Front relay valve - reassembly​

Front relay valve - removal​

Rear ABS modulator - disassembly​

Rear ABS modulator - inspection​

Rear ABS modulator - installation​

Rear ABS modulator - reassembly​

Rear ABS modulator - removal​

Rear exciter ring - inspection​

Rear exciter ring - installation​

Rear exciter ring - removal​

Rear relay valve - disassembly​

Rear relay valve - inspection​

Rear relay valve - installation​

Rear relay valve - reassembly​

Rear relay valve - removal​

Supplementary Information​

4E. Speed Retarder System​

Exhaust brake solenoid valve - inspection​

Exhaust brake solenoid valve - installation​

Exhaust brake solenoid valve - removal​

Exhaust brake valve (4HK1 (Euro4 specification)) - inspection​

Exhaust brake valve (4HK1 (Euro4 specification)) - installation​

Exhaust brake valve (4HK1 (Euro4 specification)) - removal​

Exhaust brake valve (4HK1 (Euro6 specification)) - inspection​

Exhaust brake valve (4HK1 (Euro6 specification)) - installation​

Exhaust brake valve (4HK1 (Euro6 specification)) - removal​

4Z. Brake Electrical Control​

ABS control unit - installation​

ABS control unit - removal​

EBS control unit - installation​

EBS control unit - removal​

EBS control unit - setting​

Front wheel speed sensor - inspection​

Front wheel speed sensor - installation​

Front wheel speed sensor - removal​

Rear wheel speed sensor - inspection​

Rear wheel speed sensor - installation​

Rear wheel speed sensor - removal​

Supplementary Information​

Yaw rate sensor - installation​

Yaw rate sensor - removal​

Yaw rate sensor - setting​

5.1. Transmission, Transaxle (MZW)

5C. Manual​

Backup light switch - inspection​

Backup light switch - installation​

Backup light switch - removal​

Control box - disassembly​

Control box - inspection​

Control box - reassembly​

Counter shaft - disassembly​

Counter shaft - inspection​

Counter shaft - reassembly​

Gear control - disassembly​

Gear control - inspection​

Gear control - reassembly​

Gear control cable - installation​

Gear control cable - removal​

Input shaft - disassembly​

Input shaft - inspection​

Input shaft - reassembly​

Neutral switch - inspection​

Neutral switch - installation​

Neutral switch - removal​

Rear oil seal - installation​

Rear oil seal - removal​

Relay lever - disassembly​

Relay lever - reassembly​

Shift lever - disassembly​

Shift lever - inspection​

Shift lever - installation​

Shift lever - reassembly​

Shift lever - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

Transmission oil - inspection​

Transmission oil - replacement​

5E. Clutch System​

Clutch - disassembly​

Clutch - inspection​

Clutch - installation​

Clutch - reassembly​

Clutch - removal​

Clutch booster - disassembly​

Clutch booster - inspection​

Clutch booster - installation​

Clutch booster - reassembly​

Clutch booster - removal​

Clutch master cylinder - disassembly​

Clutch master cylinder - inspection​

Clutch master cylinder - installation​

Clutch master cylinder - reassembly​

Clutch master cylinder - removal​

Clutch switch - installation​

Clutch switch - removal​

Shift fork - inspection​

Shift fork - installation​

Shift fork - removal​

Supplementary Information​

5Z. Transmission Electrical Control​

Vehicle speed sensor - inspection​

Vehicle speed sensor - installation​

Vehicle speed sensor - removal​

5.2. Transmission, Transaxle (MZZ)

5C. Manual​

Backup light switch - inspection​

Backup light switch - installation​

Backup light switch - removal​

Control box - disassembly​

Control box - reassembly​

Counter shaft - disassembly​

Counter shaft - inspection​

Counter shaft - reassembly​

Gear control cable - installation​

Gear control cable - removal​

Input shaft - disassembly​

Input shaft - inspection​

Input shaft - reassembly​

Main shaft - disassembly​

Main shaft - inspection​

Main shaft - reassembly​

Neutral switch - inspection​

Neutral switch - installation​

Neutral switch - removal​

Rear oil seal - installation​

Rear oil seal - removal​

Shift lever - disassembly​

Shift lever - inspection​

Shift lever - installation​

Shift lever - reassembly​

Shift lever - removal​

Speedometer driven gear - installation​

Speedometer driven gear - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

Transmission oil - inspection​

Transmission oil - replacement​

5E. Clutch System​

Clutch (13 inch) - inspection​

Clutch (13 inch) - installation​

Clutch (13 inch) - removal​

Clutch (14 inch) - disassembly​

Clutch (14 inch) - inspection​

Clutch (14 inch) - installation​

Clutch (14 inch) - reassembly​

Clutch (14 inch) - removal​

Clutch booster (14 inch clutch) - disassembly​

Clutch booster (14 inch clutch) - inspection​

Clutch booster (14 inch clutch) - installation​

Clutch booster (14 inch clutch) - reassembly​

Clutch booster (14 inch clutch) - removal​

Clutch control (13 inch clutch) - inspection​

Clutch control (13 inch clutch) - installation​

Clutch control (13 inch clutch) - removal​

Clutch master cylinder - disassembly​

Clutch master cylinder - inspection​

Clutch master cylinder - installation​

Clutch master cylinder - reassembly​

Clutch master cylinder - removal​

Clutch switch - installation​

Clutch switch - removal​

Shift fork (13 inch clutch) - inspection​

Shift fork (13 inch clutch) - installation​

Shift fork (13 inch clutch) - removal​

Shift fork (14 inch clutch) - inspection​

Shift fork (14 inch clutch) - installation​

Shift fork (14 inch clutch) - removal​

Slave cylinder (13 inch clutch) - disassembly​

Slave cylinder (13 inch clutch) - inspection​

Slave cylinder (13 inch clutch) - reassembly​

Supplementary Information​

5Z. Transmission Electrical Control​

Vehicle speed sensor - inspection​

Vehicle speed sensor - installation​

Vehicle speed sensor - removal​

5.3. Transmission, Transaxle (Smoother (MZW))

5C. Manual​

ATF - inspection​

ATF - replacement​

ATF cooler pipe - inspection​

ATF cooler pipe - installation​

ATF cooler pipe - removal​

Backup light switch - inspection​

Backup light switch - installation​

Backup light switch - removal​

Counter shaft - disassembly​

Counter shaft - inspection​

Counter shaft - reassembly​

Gear control - disassembly​

Gear control - inspection​

Gear control - reassembly​

Gear shift unit - disassembly​

Gear shift unit - inspection​

Gear shift unit - reassembly​

Input shaft - disassembly​

Input shaft - inspection​

Input shaft - reassembly​

Neutral switch - inspection​

Neutral switch - installation​

Neutral switch - removal​

Oil filter - installation​

Oil filter - removal​

Rear oil seal - installation​

Rear oil seal - removal​

Relay lever - disassembly​

Relay lever - reassembly​

Shift lever - installation​

Shift lever - removal​

Smoother parts - inspection​

Smoother parts - installation​

Smoother parts - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

Transmission oil - inspection​

Transmission oil - replacement​

5Z. Transmission Electrical Control​

Input speed sensor - inspection​

Input speed sensor - installation​

Input speed sensor - removal​

Select stroke sensor - inspection​

Select stroke sensor - installation​

Select stroke sensor - removal​

Shift stroke sensor - inspection​

Shift stroke sensor - installation​

Shift stroke sensor - removal​

TCM - installation​

TCM - removal​

TCM - setting​

Transmission oil temperature sensor - inspection​

Transmission oil temperature sensor - installation​

Transmission oil temperature sensor - removal​

Turbine speed sensor - inspection​

Turbine speed sensor - installation​

Turbine speed sensor - removal​

Vehicle speed sensor - inspection​

Vehicle speed sensor - installation​

Vehicle speed sensor - removal​

6. Steering

6B. Power Assisted System​

Drag link - disassembly​

Drag link - inspection​

Drag link - installation​

Drag link - reassembly​

Drag link - removal​

Power steering fluid - replacement​

Power steering oil pump - disassembly​

Power steering oil pump - inspection​

Power steering oil pump - installation​

Power steering oil pump - reassembly​

Power steering oil pump - removal​

Power steering unit - disassembly​

Power steering unit - inspection​

Power steering unit - installation​

Power steering unit - reassembly​

Power steering unit - removal​

Steering shaft - inspection​

Steering shaft - installation​

Steering shaft - removal​

Supplementary Information​

6Z. Steering Electrical Control​

Steering angle sensor - installation​

Steering angle sensor - removal​

Steering angle sensor - setting​

Supplementary Information​

7. Body, Cab, Accessories

9A. Lighting Systems​

Backup light bulb - installation​

Backup light bulb - removal​

Combination switch - inspection​

Combination switch - installation​

Combination switch - removal​

Fog light bulb - installation​

Fog light bulb - removal​

Fog light switch - inspection​

Front clearance light bulb - installation​

Front clearance light bulb - removal​

Front turn signal light bulb - installation​

Front turn signal light bulb - removal​

Headlight bulb - installation​

Headlight bulb - removal​

License plate light bulb - installation​

License plate light bulb - removal​

Rear fog light bulb - installation​

Rear fog light bulb - removal​

Rear fog light switch - inspection​

Rear turn signal light bulb - installation​

Rear turn signal light bulb - removal​

Tail stoplight bulb - installation​

Tail stoplight bulb - removal​

9C. Electrical Control, Entertainment​

Air horn - inspection​

Air horn - installation​

Air horn - removal​

Battery relay switch - inspection​

Cut switch interlocked with exhaust brake - inspection​

DPD switch - inspection​

DPD switch and HSA OFF switch - inspection​

Emergency stop switch - inspection​

Engine stop switch - inspection​

ESC OFF switch - inspection​

Horn - inspection​

Horn - installation​

Horn - removal​

Horn switch - inspection​

Horn switch - installation​

Horn switch - removal​

HSA adjustment switch - inspection​

Ignition switch - inspection​

Ignition switch - installation​

Ignition switch - removal​

Oil pressure gauge switch - inspection​

Smoother emergency switch - inspection​

Starter safety switch - inspection​

Sub-starter switch - inspection​

Warm up switch - inspection​

9E. Instrumentation, Driver Info​

Back buzzer - inspection​

Back buzzer - installation​

Back buzzer - removal​

Instrument panel cluster - diagnostics​

Oil pressure gauge - inspection​

Speed sensor control unit - setting​

9Z. Body, Cab, Accessories Electrical Control​

Auto light control unit - setting​

Auto light sensor - inspection​

CAN converter control unit (FCG) - setting​

Information module - setting​

VCM - setting​