Manual PDF Isuzu MT&MV Series 2023 to 2025 Mechanical Repair Procedures HBHTML-WEN-2221

[Truck]

Download this document, you need 5600 Gallons

Isuzu MT&MV Series 2023 to 2025 Mechanical Repair Procedures HBHTML-WEN-2221
Size: 300.11 MB
Format: PDF
Language: English
Brand: Isuzu
Type of Machine: Bus
Type of Manual: Workshop Manual - Mechanical Repair Procedures
Model: Isuzu MT Series ; MV Series Bus Chassis
Date: 2023 to 2025
Engine: Isuzu 6HK1 Euro2 ; 6HK1 Euro3 ; 6HK1 Euro5 Engine
4th edition, General Export (Date: 2025/06/20)
Parts Number: HBHTML-WEN-2221
Number of Pages: 5025 Pages

Contents:
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​

Hazard warning flasher switch - inspection​

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​

Side turn signal light bulb - installation​

Side turn signal light bulb - removal​

Tail stoplight bulb - installation​

Tail stoplight bulb - removal​

9C. Electrical Control, Entertainment​

Cut switch interlocked with exhaust brake - inspection​

Horn - inspection​

Horn - installation​

Horn - removal​

Horn switch - inspection​

Horn switch - installation​

Horn switch - removal​

Ignition switch - inspection​

Ignition switch - installation​

Ignition switch - removal​

9E. Instrumentation, Driver Info​

Back buzzer - inspection​

Back buzzer - installation​

Back buzzer - removal​

Instrument panel cluster - diagnostics​

Instrument panel cluster - setting​

Speed sensor control unit - setting​

9Z. Body, Cab, Accessories Electrical Control​

Auto light control unit - setting​

Auto light sensor - inspection​

BCM - setting​

Brakes (Air over hydraulic)

4B. Brake System​

Air booster - disassembly​

Air booster - inspection​

Air booster - installation​

Air booster - reassembly​

Air booster - removal​

Air compressor (6HK1) - disassembly​

Air compressor (6HK1) - inspection​

Air compressor (6HK1) - installation​

Air compressor (6HK1) - reassembly​

Air compressor (6HK1) - removal​

Air dryer (with separate governor) - disassembly​

Air dryer (with separate governor) - inspection​

Air dryer (with separate governor) - installation​

Air dryer (with separate governor) - reassembly​

Air dryer (with separate governor) - removal​

Air governor - disassembly​

Air governor - inspection​

Air governor - installation​

Air governor - reassembly​

Air governor - removal​

Brake fluid - inspection​

Brake fluid - replacement​

Brake fluid tank - inspection​

Brake fluid tank - installation​

Brake fluid tank - 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​

Front drum brake - disassembly​

Front drum brake - inspection​

Front drum brake - installation​

Front drum brake - reassembly​

Front drum brake - removal​

Front wheel cylinder - disassembly​

Front wheel cylinder - inspection​

Front wheel cylinder - installation​

Front wheel cylinder - reassembly​

Front wheel cylinder - removal​

Low pressure switch - inspection​

Low pressure switch - installation​

Low pressure switch - removal​

Over stroke switch - inspection​

Over stroke switch - installation​

Over stroke switch - removal​

Rear drum brake - disassembly​

Rear drum brake - inspection​

Rear drum brake - installation​

Rear drum brake - reassembly​

Rear drum brake - removal​

Rear wheel cylinder - disassembly​

Rear wheel cylinder - inspection​

Rear wheel cylinder - installation​

Rear wheel cylinder - reassembly​

Rear wheel cylinder - 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​

Parking brake - inspection​

Parking brake - installation​

Parking brake - removal​

Parking brake lever - installation​

Parking brake lever - removal​

Parking brake switch - inspection​

Parking brake switch - installation​

Parking brake switch - 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 (6HK1) - inspection​

Exhaust brake valve (6HK1) - installation​

Exhaust brake valve (6HK1) - removal​

Brakes (Full air)

4B. Brake System​

Air compressor (6HK1 (Euro2 and Euro3 specification)) - disassembly​

Air compressor (6HK1 (Euro2 and Euro3 specification)) - inspection​

Air compressor (6HK1 (Euro2 and Euro3 specification)) - installation​

Air compressor (6HK1 (Euro2 and Euro3 specification)) - reassembly​

Air compressor (6HK1 (Euro2 and Euro3 specification)) - removal​

Air compressor (6HK1 (Euro5 specification)) - disassembly​

Air compressor (6HK1 (Euro5 specification)) - inspection​

Air compressor (6HK1 (Euro5 specification)) - installation​

Air compressor (6HK1 (Euro5 specification)) - reassembly​

Air compressor (6HK1 (Euro5 specification)) - removal​

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​

Air dryer (with separate governor) - disassembly​

Air dryer (with separate governor) - inspection​

Air dryer (with separate governor) - installation​

Air dryer (with separate governor) - reassembly​

Air dryer (with separate governor) - removal​

Air governor - disassembly​

Air governor - inspection​

Air governor - installation​

Air governor - reassembly​

Air 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) - 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 expander - disassembly​

Front expander - inspection​

Front expander - installation​

Front expander - reassembly​

Front expander - 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 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​

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​

Supplementary Information​

4E. Speed Retarder System​

Air cylinder - disassembly​

Air cylinder - inspection​

Air cylinder - installation​

Air cylinder - reassembly​

Air cylinder - removal​

Exhaust brake solenoid valve - inspection​

Exhaust brake solenoid valve - installation​

Exhaust brake solenoid valve - removal​

Exhaust brake valve (6HK1 (Euro2 and Euro3 specification)) - inspection​

Exhaust brake valve (6HK1 (Euro2 and Euro3 specification)) - installation​

Exhaust brake valve (6HK1 (Euro2 and Euro3 specification)) - removal​

Exhaust brake valve (6HK1 (Euro5 specification)) - inspection​

Exhaust brake valve (6HK1 (Euro5 specification)) - installation​

Exhaust brake valve (6HK1 (Euro5 specification)) - removal​

Retarder drum - inspection​

Retarder drum - installation​

Retarder drum - removal​

Retarder magnetic valve - inspection​

Retarder magnetic valve - installation​

Retarder magnetic valve - removal​

Stator - disassembly​

Stator - inspection​

Stator - installation​

Stator - reassembly​

Stator - removal​

Supplementary Information​

4Z. Brake Electrical Control​

ABS control unit - installation​

ABS control unit - removal​

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​

Driveline, Axle

3B. Differentials​

Differential oil - replacement​

Rear differential (single) (15.5H) - disassembly​

Rear differential (single) (15.5H) - inspection​

Rear differential (single) (15.5H) - installation​

Rear differential (single) (15.5H) - reassembly​

Rear differential (single) (15.5H) - removal​

Rear differential (single) (16.5H) - disassembly​

Rear differential (single) (16.5H) - inspection​

Rear differential (single) (16.5H) - installation​

Rear differential (single) (16.5H) - reassembly​

Rear differential (single) (16.5H) - removal​

Supplementary Information​

3C. Drive Shaft System​

Front axle (air over hydraulic brake) - disassembly​

Front axle (air over hydraulic brake) - inspection​

Front axle (air over hydraulic brake) - installation​

Front axle (air over hydraulic brake) - reassembly​

Front axle (air over hydraulic brake) - removal​

Front axle (full air brake) - disassembly​

Front axle (full air brake) - inspection​

Front axle (full air brake) - installation​

Front axle (full air brake) - reassembly​

Front axle (full air brake) - removal​

Front hub - inspection​

Front hub - installation​

Front hub - removal​

Knuckle (air over hydraulic brake) - disassembly​

Knuckle (air over hydraulic brake) - inspection​

Knuckle (air over hydraulic brake) - installation​

Knuckle (air over hydraulic brake) - reassembly​

Knuckle (air over hydraulic brake) - removal​

Knuckle (full air brake) - disassembly​

Knuckle (full air brake) - inspection​

Knuckle (full air brake) - installation​

Knuckle (full air brake) - reassembly​

Knuckle (full air brake) - removal​

Knuckle arm (air over hydraulic brake) - inspection​

Knuckle arm (air over hydraulic brake) - installation​

Knuckle arm (air over hydraulic brake) - removal​

Knuckle arm (full air brake) - inspection​

Knuckle arm (full air brake) - installation​

Knuckle arm (full air brake) - removal​

Propeller shaft - disassembly​

Propeller shaft - inspection​

Propeller shaft - installation​

Propeller shaft - reassembly​

Propeller shaft - removal​

Rear axle (air over hydraulic brake) - disassembly​

Rear axle (air over hydraulic brake) - inspection​

Rear axle (air over hydraulic brake) - installation​

Rear axle (air over hydraulic brake) - reassembly​

Rear axle (air over hydraulic brake) - removal​

Rear axle (full air brake) - disassembly​

Rear axle (full air brake) - inspection​

Rear axle (full air brake) - installation​

Rear axle (full air brake) - reassembly​

Rear axle (full air brake) - removal​

Rear axle shaft - inspection​

Rear axle shaft - installation​

Rear axle shaft - removal​

Rear hub - inspection​

Rear hub - installation​

Rear hub - removal​

Supplementary Information​

Tie rod - disassembly​

Tie rod - inspection​

Tie rod - installation​

Tie rod - reassembly​

Tie rod - removal​

Tie rod arm (air over hydraulic brake) - inspection​

Tie rod arm (air over hydraulic brake) - installation​

Tie rod arm (air over hydraulic brake) - removal​

Tie rod arm (full air brake) - inspection​

Tie rod arm (full air brake) - installation​

Tie rod arm (full air brake) - removal​

Wheel alignment check​

Engine (6HK1 (Euro2 and Euro3 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 - inspection​

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​

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​

Timing gear case - installation​

Timing gear case - removal​

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​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - disassembly​

Water pump - inspection​

Water pump - installation​

Water pump - reassembly​

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 - inspection​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - inspection​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - 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 cooler - inspection​

EGR cooler - installation​

EGR cooler - removal​

EGR pipe - inspection​

EGR pipe - installation​

EGR pipe - removal​

EGR valve - inspection​

EGR valve - installation​

EGR valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator control link - installation​

Accelerator control link - removal​

Accelerator pedal - installation​

Accelerator pedal - removal​

Idle up sensor - installation​

Idle up sensor - removal​

Supplementary Information​

1J. Electrical​

Generator - disassembly​

Generator - inspection​

Generator - installation​

Generator - reassembly​

Generator - 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​

IAT sensor - inspection​

IAT sensor - installation​

IAT sensor - removal​

Supplementary Information​

Engine (6HK1 (Euro5 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 - inspection​

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​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet cover - installation​

Inlet cover - 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​

Timing gear case - installation​

Timing gear case - removal​

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​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - disassembly​

Water pump - inspection​

Water pump - installation​

Water pump - reassembly​

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 - inspection​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - inspection​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - 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 cooler (cylinder head side) - inspection​

EGR cooler (cylinder head side) - installation​

EGR cooler (cylinder head side) - removal​

EGR cooler (oil cooler side) - inspection​

EGR cooler (oil cooler side) - installation​

EGR cooler (oil cooler side) - removal​

EGR valve - inspection​

EGR valve - installation​

EGR valve - 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​

Generator - disassembly​

Generator - inspection​

Generator - installation​

Generator - reassembly​

Generator - 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​

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​

Suspension

2B. Front Suspension​

Leaf rigid suspension - disassembly​

Leaf rigid suspension - inspection​

Leaf rigid suspension - installation​

Leaf rigid suspension - reassembly​

Leaf rigid suspension - removal​

Supplementary Information​

2C. Rear Suspension​

Leaf rigid suspension - disassembly​

Leaf rigid suspension - inspection​

Leaf rigid suspension - installation​

Leaf rigid suspension - reassembly​

Leaf rigid suspension - removal​

Supplementary Information​

2D. Wheel, Tire System​

Disc wheel and tire - inspection​

Disc wheel and tire - installation​

Disc wheel and tire - removal​

Transmission, Transaxle (ESO11306A)

5C. Manual​

Counter shaft - disassembly​

Counter shaft - reassembly​

Gear control cable - installation​

Gear control cable - removal​

Input shaft - disassembly​

Input shaft - reassembly​

Lower quadrant box - disassembly​

Lower quadrant box - reassembly​

Main shaft - disassembly​

Main shaft - inspection​

Main shaft - reassembly​

Shift lever - disassembly​

Shift lever - inspection​

Shift lever - installation​

Shift lever - reassembly​

Shift lever - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

Transmission oil - inspection​

Transmission oil - replacement​

Upper quadrant box - disassembly​

Upper quadrant box - reassembly​

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 - installation​

Vehicle speed sensor - removal​

Transmission, Transaxle (MLD)

5C. Manual​

Backup light switch - inspection​

Backup light switch - installation​

Backup light switch - removal​

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​

Lower quadrant box - disassembly​

Lower quadrant box - inspection​

Lower quadrant box - reassembly​

Main shaft - disassembly​

Main shaft - inspection​

Main shaft - reassembly​

Neutral switch - inspection​

Neutral switch - installation​

Neutral switch - removal​

Power assist - disassembly​

Power assist - inspection​

Power assist - reassembly​

Rear oil seal - installation​

Rear oil seal - removal​

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​

Upper quadrant box - disassembly​

Upper quadrant box - inspection​

Upper quadrant box - reassembly​

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​

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​