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1999 RODEO
Isuzu 1999 RODEO Manuals
Manuals and User Guides for Isuzu 1999 RODEO. We have
2
Isuzu 1999 RODEO manuals available for free PDF download: Workshop Manual, General Description Manual
Isuzu 1999 RODEO Workshop Manual (2613 pages)
RODEO 1999
Brand:
Isuzu
| Category:
Automobile
| Size: 22.04 MB
Table of Contents
Table of Contents
2
General Repair Instruction
2
Illustration Arrows
3
Identification
4
Theft Prevention Standard
6
Anti Theft Stamping/Plate/Label
6
Lifting Instructions
11
Standard Bolts Torque Specifications
13
Abbreviations Charts
14
Service Parts Identification Plate
15
Maintenance and Lubrication
16
Maintenance Schedule List
20
Explanation of Complete Vehicle Maintenance Schedule
20
Recommended Fluids and Lubricants
23
Lubricant Viscosity Chart
24
Recommended Liquid Gasket
26
Recommended Thread Locking Agents
27
Maintenance Service Data
28
Service Precaution
30
Heating and Ventilation System
30
General Description
30
Control Lever Assembly
32
Wiring Diagram
34
Diagnosis
35
Individual Inspection
39
Heater Unit 1A-13
41
Heater Unit and Associated Parts
41
Removal
41
Removal
42
Heater Core and / or Mode Door
42
Disassembled View
42
Installation
42
Inspection
43
Installation
43
Heater Mode Control Link Unit 1A-16
44
Disassembled View
44
Removal
45
Installation
45
Heater Temperature Control Link Unit
45
Disassembled View
45
Removal
46
Installation
46
Blower Assembly 1A-18
46
Blower Assembly and Associated Parts
46
Removal
47
Installation
47
Blower Link Unit and / or Mode Door
47
Disassembled View
47
Removal
49
Installation
49
Blower Motor
49
Blower Motor and Associated Parts
49
Removal
50
Rear Heater Duct, Defroster Nozzle and Ventilation Duct 1A-22
50
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
50
Installation
51
Control Lever Assembly and / or Control Cable
51
Control Lever Assembly, Control Cable and Associated Parts
51
Removal
54
Installation
54
Control Panel Illumination Bulb
54
Evaporator Assembly
86
Evaporator Assembly and Associated Parts
86
Removal
86
Installation
87
Electronic Thermostat, Evaporator Core And/Or Expansion Valve
87
Disassembled View
87
Removal
88
Installation
88
Refrigerant Line
89
Refrigerant Line and Associated Parts
89
Removal
90
Installation
90
Main Data and Specifications
90
Compressor
93
Service Precaution
93
General Description
93
Diagnosis
94
Magnetic Clutch Assembly (DKV-14D Type) 1A-67
95
Parts Location View
95
Removal
95
Inspection and Repair
96
Installation
97
Compressor Oil
98
Oil Specification
98
Handling of Oil
98
Compressor Oil Check
98
Checking and Adjusting Oil Quantity for Used Compressor
98
Checking and Adjusting for Compressor Replacement
99
Contamination of Compressor Oil
99
Oil Return Operation
99
Replacement of Component Parts
99
Main Data and Specifications
100
Special Tools
102
CAUTION: Always Use the Correct Fastener in the Proper Location. When You Replace a Fastener, Use
104
ONLY the Exact Part Number for that Application
104
ISUZU will Call out those Fasteners that Require a
104
Replacement after Removal. ISUZU will also Call out
104
The Fasteners that Require Thread Lockers or Thread
104
Sealant. UNLESS OTHERWISE SPECIFIED, Do Not
104
Use Supplemental Coatings
104
Corrosion Inhibitors) on Threaded Fasteners or
104
Fastener Joint Interfaces. Generally, such Coatings
104
Adversely Affect the Fastener Torque and the Joint
104
General Description
110
Power Steering System Test
112
Maintenance
113
Fluid Level
113
Bleeding the Power Steering System
113
Bleeding Procedure
113
Flushing the Power Steering System
113
Steering Wheel Free Play Inspection
114
Front End Alignment Inspection and Adjustment
114
Main Data and Specifications
118
Special Tools
119
Power Steering Unit
120
Power Steering Unit and Associated Parts 2A-18 Removal
120
Installation (4 2 Model)
121
Installation (4 4 Model)
121
Power Steering Unit Disassembled View
122
Disassembly
122
Inspection and Repair
122
Reassembly
122
Main Data and Specifications
123
Special Tools
123
Power Steering Pump
124
Power Steering Pump and Associated Parts 2A-22 Removal
124
Installation
124
Power Steering Pump Disassembled View 2A-23 Disassembly
125
Inspection and Repair
126
Reassembly
126
Main Data and Specifications
128
Transfer Gear Assembly
129
Transfer Gear Assembly and Associated Parts
129
Removal
129
Inspection and Repair
129
Installation
129
Supplemental Restraint System Steering Wheel & Column
130
Service Precaution
130
SRS Connectors
130
Inflator Module
132
Inflator Module and Associated Parts
132
Removal
132
Inspection and Repair
133
Installation
133
Steering Wheel
134
Steering Wheel and Associated Parts
134
Removal
134
Installation
136
Combination Switch
137
Removal
137
Installation
139
Lock Cylinder
141
Lock Cylinder and Associated Parts
141
Removal
141
Installation
143
System Inspection
144
Steering Column
145
Steering Column and Associated Parts
145
Removal
145
Insepction
148
Installation
149
System Inspection
150
Supplemental Restraint System Steering Wheel & Column and Associated Parts
151
Main Data and Specifications
151
Special Tools
151
Front Suspension
153
Removal
156
Installation
156
Stabilizer Bar 3C-6
157
Stabilizer Bar and Associated Parts 3C-6
157
Removal
157
Installation
157
Torsion Bar
158
Torsion Bar and Associated Parts
158
Removal
158
Inspection and Repair
159
Installation
159
Knuckle
161
Knuckle and Associated Parts
161
Removal
161
Inspection and Repair
162
Installation
162
Front Suspension
162
Upper Control Arm
164
Upper Control Arm and Associated Parts
164
Removal
164
Inspection and Repair
165
Installation
165
Lower Control Arm
167
Lower Control Arm and Associated Parts
167
Removal
167
Inspection and Repair
168
Installation
169
Upper Ball Joint
170
Upper Ball Joint and Associated Parts
170
Removal
170
Inspection and Repair
171
Installation
171
Lower Ball Joint
172
Lower Ball Joint and Associated Parts
172
Removal
172
Inspection and Repair
173
Installation
173
Main Data and Specifications
174
Special Tools
175
CAUTION: Always Use the Correct Fastener in the Proper Location. When You Replace a Fastener, Use
176
ONLY the Exact Part Number for that Application
176
ISUZU will Call out those Fasteners that Require a
176
Replacement after Removal. ISUZU will also Call out
176
The Fasteners that Require Thread Lockers or Thread
176
Sealant. UNLESS OTHERWISE SPECIFIED, Do Not
176
Use Supplemental Coatings
176
Corrosion Inhibitors) on Threaded Fasteners or
176
Fastener Joint Interfaces. Generally, such Coatings
176
Adversely Affect the Fastener Torque and the Joint
176
Coil Spring
180
Coil Spring and Associated Parts
180
Removal
180
Inspection and Repair
181
Installation
181
Shock Absorber
182
Shock Absorber and Associated Parts
182
Removal
182
Inspection and Repair
182
Installation
182
Trailing Link
183
Trailing Link and Associated Parts
183
Removal
183
Inspection and Repair
183
Installation
184
Upper Link
185
Upper Link and Associated Parts
185
Removal
185
Inspection and Repair
185
Installation
186
Lateral Rod
187
Lateral Rod and Associated Parts
187
Removal
187
Inspection and Repair
187
Installation
188
Stabilizer Bar
189
Stabilizer Bar and Associated Parts
189
Removal
189
Inspection and Repair
189
Installation
190
Main Data and Specifications
191
Special Tools
193
Wheel and Tire System
194
Tire Replacement
205
Differential (Front)
209
Front Drive Axle
209
Pinion Shaft Oil Seal
210
Pinion Shaft Oil Seal and Associated Parts 4A1-3
210
Removal
210
Inspection and Repair
211
Installation
211
Front Drive Axle Assembly
212
Front Drive Axle Assembly and Associated Parts
212
Removal
213
Differential (Front)
214
Installation
214
Differential Assembly
215
Disassembled View
215
Differential Cage Assembly 4A1-19
226
Disassembled View
226
Disassembly
226
Inspection and Repair
227
Reassembly
227
Main Data and Specifications
229
Special Tools
232
General Description
235
Diagnosis
236
Axle Housing
238
Axle Housing and Associated Parts
238
Removal
238
Installation
240
Axle Shaft, Oil Seal and Bearing
240
Axle Shaft and Associated Parts
240
Removal
241
Inspection
241
Installation
241
Pinion Oil Seal
243
Pinion Oil Seal and Associated Parts
243
Removal
243
Inspection and Repair
244
Installation
244
Differential Assembly
246
Disassembled View
246
Inspecting the Axle before Disassembly
247
Disassembly
247
Inspection and Repair
249
Reassembly
249
Side Bearing Preload Adjustment
253
Pinion Installation
254
Determination of Backlash & Preload Shims 4A2-22
255
Backlash Adjustment
256
Gear Tooth Pattern Check
256
Adjustments Affecting Tooth Contact
257
Differential Case Assembly
258
Disassembled View
258
Disassembly
259
Inspection and Repair
259
Reassembly
259
Limited Slip Differential Assembly
260
Disassembled View
260
Disassembly
260
Inspection and Repair
262
Reassembly
262
Main Data and Specifications
264
Special Tools
266
Driveline Control System
268
General Description
291
Diagnosis
291
Front Hub and Disc (2WD Model)
292
Disassembled View
292
Disassembly
292
Inspection and Repair
293
Reassembly
294
Front Hub and Disc (4WD Model)
297
Disassembled View
297
Disassembly
297
Inspection and Repair
298
Reassembly
299
Front Drive Shaft Joint
302
Front Drive Shaft Joints Replacement
302
Front Axle Drive Shaft
303
Front Axle Drive Shaft and Associated Parts
303
Disassembly
304
Inspection and Repair
305
Bushing Replacement
305
Reassembly
305
Shift on the Fly System
308
Shift on the Fly System and Associated Parts
308
Disassembly
308
Inspection and Repair
310
Reassembly
313
Drive Shaft System
314
Main Data and Specifications
315
Special Tools
317
Propeller Shaft
318
General Description
318
Universal Joint
319
Diagnosis of Propeller Shaft and Universal Joint
320
Front Propeller Shaft
321
Front Propeller Shaft and Associated Parts 4C-32
321
Removal
321
Installation
321
Disassembly
322
Universal Joint Disassembly
323
Inspection and Repair
324
Universal Joint Reassembly
325
Reassembly
326
Main Data and Specifications
327
Rear Propeller Shaft
328
Rear Propeller Shaft and Associated Parts 4C-39
328
Removal
328
Installation
328
Slip Joint Disassembly
329
Universal Joint Disassembly
330
Inspection
332
Universal Joint Reassembly
333
Slip Joint Reassembly
334
Main Data and Specifications
335
CAUTION: Always Use the Correct Fastener in the Proper Location. When You Replace a Fastener, Use
336
ONLY the Exact Part Number for that Application
336
ISUZU will Call out those Fasteners that Require a
336
Replacement after Removal. ISUZU will also Call out
336
The Fasteners that Require Thread Lockers or Thread
336
Transfer Case
336
General Description
337
Transfer Rear Oil Seal
339
Transfer Rear Oil Seal and Associated Parts
339
Removal
339
Installation
339
Transfer Case Assembly (a
341
Transfer Case Assembly (A/T) and Associated Parts
341
Removal
342
Installation
343
Transfer Rear Case Assembly (A/T)
346
Transfer Rear Case Assembly (A/T) and Associated Parts
346
Removal
346
Installation
348
Transfer Rear Cover Assembly
351
Disassembly
351
Inspection and Repair
352
Reassembly
352
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)
354
Disassembled View
354
Disassembly
355
Inspection and Repair
356
Reassembly
356
Transfer Case Assembly
358
Disassembled View
358
Disassembly
359
Inspection and Repair
362
Reassembly
365
Main Data and Specifications
372
Special Tools
375
CAUTION: Always Use the Correct Fastener in the Proper Location. When You Replace a Fastener, Use
377
ONLY the Exact Part Number for that Application
377
ISUZU will Call out those Fasteners that Require a
377
Replacement after Removal. ISUZU will also Call out
377
The Fasteners that Require Thread Lockers or Thread
377
Sealant. UNLESS OTHERWISE SPECIFIED, Do Not
377
Brake Control System
377
Anti-Lock Brake System
385
System Components
385
Electronic Hydraulic Control Unit (EHCU) . 5A-10
385
ABS Warning Light
385
Wheel Speed Sensor
385
G-Sensor
385
Normal and Anti-Lock Braking
385
Brake Pedal Travel
385
Acronyms and Abbreviations
385
General Diagnosis
386
General Information
386
ABS Service Precautions
386
Computer System Service Precautions
386
General Service Precautions
386
Note on Intermittents
386
Test Driving ABS Complaint Vehicles
387
ABS" Warning Light
387
Normal Operation
387
Tech 2 Scan Tool
388
Data List
391
Actuator Test
392
Tech 2 Service Bleed
396
Basic Diagnostic Flow Chart
397
Basic Inspection Procedure
398
EHCU Connector Pin-Out Checks
399
Circuit Diagram
400
Connector List
403
Part Location
404
Symptom Diagnosis
405
Chart A-1 ABS Works Frequently but Vehicle Does Not Decelerate
405
Chart A-2 Uneven Braking Occurs While ABS Works
406
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)
406
Chart A-3, TA-3 the Wheels Are Locked
407
Chart A-5, TA-5 Braking Sound
409
Diagnostic Trouble Codes
410
Diagnosis by "ABS" Warning Light Illumination Pattern
412
Diagnostic Trouble Codes (Dtcs)
413
Chart B-1 with the Key in the on Position (before Starting the Engine). Warning Light (W/L) Is Not Activated
415
Chart B-2 CPU Error (DTC 14 (Flash Out) / C0271, C0272, C0273, C0284 (Serial Communications))
416
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash Out) / C0277, 0278 (Serial Communications))
416
Chart B-4 Excessive Dump Time (DTC 17 (Flash Out) / C0269 (Serial Communications))
416
Chart B-5 Excessive Isolation Time (DTC 18 (Flash Out) / C0274 (Serial Communications))
417
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash Out) / C0276 (Serial Communications))
417
Chart B-7 Brake Switch Failure (DTC 22 (Flash Out) / C0281 (Serial Communications))
417
Chart B-8 2WD Controller in 4WD Vehicle
418
Chart B-9 Pump Motor Failure (DTC 32 (Flash Out) / C0267, C0268 (Serial Communications))
418
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash Out) / C0265, C0266 (Serial Communications))
419
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash Out) / C0245, C0247 (Serial Communications))
419
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash Out) / C0246, C0248 (Serial Communications))
419
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash Out) / C0241, C0243 (Serial Communications))
420
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash Out) / C0242, C0244 (Serial Communications))
420
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash Out) / C0251, C0253 (Serial Communications))
420
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash Out) / C0252, C0254 (Serial Communications))
421
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash Out) / C0225 (Serial Communications))
421
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash Out) / C0221 (Serial Communications))
422
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash Out) / C0235 (Serial Communications))
423
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash Out) / C0226, C0227 (Serial Communications))
424
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash Out) / C0222, C0223 (Serial Communications))
425
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash Out) / C0236, C0237 (Serial Communications))
426
Chart B-23 Simultaneous Drop-Out of Front Speed Sensor Signal (DTC 64 (Flash Out) / C0229 (Serial Communications))
427
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash Out) / C0238 (Serial Communications))
428
Unit Inspection Procedure
429
Chart C-1-1 FL Sensor Output Inspection Procedure
429
Chart C-1-2 FR Sensor Output Inspection Procedure
430
Chart C-1-3 Rear Sensor Output Inspection Procedure
430
Chart TC-1 Sensor Output Inspection Procedure
431
Special Tools
432
Anti-Lock Brake System
433
Removal
434
Installation
435
Reassembly
435
Installation
436
Front Wheel Speed Sensor
436
Front Wheel Speed Sensor and Associated Parts
436
Removal
436
Inspection and Repair
436
Installation
437
Service Precaution
439
General Description
439
Diagnosis
443
General Diagnosis
444
Hydraulic Brakes
447
Filling Master Cylinder Reservoir
447
Deterioration of Brake Fluid
447
Leakage of Brake Fluid
447
Bleeding Brake Hydraulic System
447
Flushing Brake Hydraulic System
448
Brake Pipes and Hoses
448
Brake Hose Inspection
448
Front Caliper Brake Hose
449
Front Caliper Brake Hose and Associated Parts
449
Removal
449
Installation
449
Rear Axle Brake Hose
450
Rear Axle Brake Hose and Associated Parts
450
Removal
450
Installation
450
Brake Pipe
451
Removal
451
Installation
451
P & B (Proportioning and Bypass) Valve
452
Removal
452
Installation
452
Main Data and Specifications
453
Brake Pedal
454
Checking Pedal Height
454
Checking Pedal Travel
454
Brake Pedal and Associated Parts
455
Removal
455
Installation
455
Stoplight Switch
456
Parts Location
456
Removal
456
Installation
456
Main Data and Specifications
457
Fluid Reservoir Tank
458
Fluid Reservoir Tank and Associated Parts 5C-21
458
Removal
458
Installation
458
Master Cylinder Assembly
459
Master Cylinder Assembly and Associated Parts
459
Removal
459
Inspection and Repair
459
Installation
460
Main Data and Specifications
461
Special Tools
461
Vacuum Booster Assembly
462
Vacuum Booster Assembly and Associated Parts
462
Removal
462
Inspection and Repair
462
Installation
463
Exterior Components
465
Exterior Components and Associated Parts 5C-28
465
Removal
465
Inspection and Repair
466
Installation
466
Vacuum Booster Overhaul
466
Vacuum Booster
466
Main Data and Specifications
467
Special Tools
468
Front Disc Brake Pads
469
Front Disc Brake Pads Inspection
469
Front Disc Brake Pads and Associated Parts
469
Removal
470
Installation
470
Front Disc Brake Rotor
472
Inspection
472
Replacing Brake Rotors
472
Refinishing Brake Rotors
472
Front Disc Brake Caliper Assembly
473
Front Disc Brake Caliper Assembly and Associated Parts
473
Removal
474
Installation
474
Front Disc Brake Caliper
476
Front Disc Brake Caliper Disassembled View
476
Disassembly
476
Inspection and Repair
477
Reassembly
477
Main Data and Specifications
479
Rear Disc Brake Pads (4 4 Model)
480
Brake Pads Inspection
480
Brake Pads and Associated Parts
480
Removal
481
Installation
481
Rear Disc Brake Rotor (4 4 Model)
483
Inspection
483
Replacing Brake Rotors
483
Refinishing Brake Rotors
483
Rear Drum (in Disc) Inside Diameter Check 5C-47
484
Rear Disc Brake Caliper Assembly (4 4 Model)
485
Rear Disc Brake Caliper Assembly and Associated Parts
485
Removal
485
Installation
486
Rear Disc Brake Caliper (4 4 Model)
487
Rear Disc Brake Caliper Disassembled View
487
Disassembly
488
Inspection and Repair
488
Reassembly
488
Brake Lining
491
Brake Lining and Associated Parts
491
Removal
491
Brake Lining Inspection
492
Installation
492
Drum Brake Adjustment (4 2 Model)
493
Servicing the Brake Drum
493
Wheel Cylinder Assembly (4 2 Model)
494
Wheel Cylinder Assembly and Associated Parts
494
Removal
494
Installation
494
Disassembled View
495
Disassembly
495
Inspection and Repair
495
Reassembly
495
Main Data and Specifications
497
Removal
500
Installation
500
Parking Brake Rear Cable
501
Parking Brake Rear Cable and Associated Parts
501
Removal
502
Installation
502
Inspection and Repair
503
Parking Brake Adjustment
503
Main Data and Specifications
504
Removal
506
Installation
506
Parking Brake Lever
506
Parking Brake Rear Cable and Associated Parts
507
Removal
508
Installation
508
Main Data and Specifications
509
Engine Mechanical
511
Service Precaution
511
General Description 6A-2
511
Engine Diagnosis
512
Cylinder Head Cover
525
Removal
525
Installation
526
Exhaust Manifold
527
Removal
527
Installation
527
Crankshaft Pulley
528
Removal
528
Installation
528
Intake Manifold
529
Removal
529
Installation
530
Cylinder Head Assembly
531
Removal
531
Installation
533
Timing Belt
537
Removal
537
Installation
538
Camshaft
541
Removal
541
Installation
542
Engine Assembly
544
Removal
545
Installation
546
Cylinder Head
548
Cylinder Head and Associated Parts
548
Disassembly
548
Inspection and Repair
549
Reassembly
550
Valve Spring, Valve, Valve Guide
551
Valve Spring, Valve, Valve Guide and Associated Parts
551
Disassembly
551
Reassembly
553
Camshaft
554
Camshaft and Associated Parts
554
Disassembly
554
Reassembly
555
Crankshaft
556
Crankshaft and Associated Parts
556
Disassembly
556
Inspection and Repair
557
Inspection and Repair
558
Reassembly
559
Piston and Connecting Rod
562
Disassembly
562
Inspection and Repair 6A-54
563
Reassembly
565
Cylinder Block
566
Cylinder Block and Associated Parts
566
Disassembly
567
Inspection and Repair
567
Reassembly
568
Cylinder Head Cover
569
Cylinder Head Cover and Associated Parts 6A-60
569
Removal
570
Installation
570
Balance Unit Assembly
572
Balance Unit Assembly Associated Parts
572
Disassembly
573
Adjustment
573
Reassembly
575
Main Data and Specifications
577
Special Tools
582
Special Tool
591
Fuel Metering
594
Fuel Filter
595
Fuel Pump
597
Cautions During Work
598
Assembling Advice
600
Fuel Pump Relay
601
Fuel Tank
601
Fuel Gage Unit
602
Fuel Filler Cap
603
Battery Installation
608
Specifications
633
Tightening Specifications
633
Diagrams and Schematics
634
PCM WIRING DIAGRAM (1 of 10)
634
PCM WIRING DIAGRAM (2 of 10)
635
PCM WIRING DIAGRAM (3 of 10)
636
PCM WIRING DIAGRAM (4 of 10)
637
PCM WIRING DIAGRAM (5 of 10)
638
PCM WIRING DIAGRAM (6 of 10)
639
PCM WIRING DIAGRAM (7 of 10)
640
PCM WIRING DIAGRAM (8 of 10)
641
PCM WIRING DIAGRAM (9 of 10)
642
PCM WIRING DIAGRAM (10 of 10)
643
Pcm Pinouts
644
PCM Pinout Table, 32-Pin Red Connector - Row "A
644
PCM Pinout Table, 32-Pin Red Connector - Row "B
645
PCM Pinout Table, 32-Pin White Connector - Row "D
647
PCM Pinout Table, 32-Pin White Connector - Row "E
648
PCM Pinout Table, 32-Pin White Connector - Row "F
649
Component Locator
650
Undercarriage Component Locator Table . 6E1-25
652
Fuse and Relay Panel (Underhood Electrical Center)
652
DIAGNOSIS Strategy-Based Diagnostics
654
Strategy-Based Diagnostics
654
DTC Stored
654
No DTC
654
No Matching Symptom
654
Intermittents
654
No Trouble Found
654
Verifying Vehicle Repair
654
General Service Information
655
OBD II Serviceability Issues
655
Emissions Control Information Label
655
Maintenance Schedule
656
Visual/Physical Engine Compartment Inspection
656
Basic Knowledge of Tools Required
656
Serial Data Communications
656
Class II Serial Data Communications
656
On-Board Diagnostic (Obd II)
656
On-Board Diagnostic Tests
656
Comprehensive Component Monitor Diagnostic Operation
656
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations
657
Common OBD II Terms
657
The Diagnostic Executive
658
DTC Types
659
Decimal/Binary/Hexadecimal Conversions 6E1-33
660
Verifying Vehicle Repair
660
Reading Diagnostic Trouble Codes Using a Tech 2 Scan Tool
660
Tech 2 Features
662
Getting Started
662
Operating Procedure (Example)
663
DTC Modes
664
DTC Information Mode
664
Miscellaneous Test
665
Lamps Test
665
Relays Test
666
EVAP Test
668
Idle Air Control System Test
669
Fuel System Test
671
EGR Control Test
672
Injector Balance Test
673
Plotting Snapshot Graph
674
Plotting Graph Flow Chart (Plotting Graph after Obtaining Vehicle Information)
675
Flow Chart for Snapshot Replay (Plotting Graph)
676
Primary System-Based Diagnostics
677
Fuel Control Heated Oxygen Sensors
677
HO2S Heater
677
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation
677
Misfire Monitor Diagnostic Operation
678
Misfire Monitor Diagnostic Operation 6E1-51
678
Misfire Counters
678
Fuel Trim System Monitor Diagnostic Operation
679
Fuel Trim System Monitor Diagnostic Operation 6E1-52
679
Fuel Trim Cell Diagnostic Weights
679
On-Board Diagnostic (Obd II) System Check
680
A/C Clutch Control Circuit Diagnosis
683
Electronic Ignition System Diagnosis
686
Evap Canister Purge Solenoid
686
Visual Check of the Evaporative Emission Canister
686
Idle Air Control (Iac) Valve
686
Fuel System Pressure Test
686
Fuel Metering System Check
686
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure
687
Test Description
687
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
688
Powertrain Control Module (Pcm) Diagnosis
692
Multiple Pcm Information Sensor
692
Exhaust Gas Recirculation (Egr) Diagnosis
696
Typical Scan Data Values
699
No Malfunction Indicator Lamp (Mil)
703
Malfunction Indicator Lamp (Mil) on Steady
706
Engine Cranks but will Not Run
708
Fuel System Electrical Test
714
Fuel System Diagnosis
717
Idle Air Control (Iac) System Check 6E1-95
722
Exhaust Gas Recirculation (Egr) System Check
725
Manifold Absolute Pressure (Map) Output Check
727
Evaporative (Evap) Emissions Canister Purge Valve Solenoid Check
729
Upshift Lamp System Check (Manual Transmission Only)
732
Pcm Diagnostic Trouble Codes
735
Diagnostic Trouble Code (Dtc) P0106 Manifold Absolute Pressure (Map) Circuit/Range Performance Problem
738
Diagnostic Trouble Code (Dtc) P0107 Manifold Absolute Pressure (Map) Sensor Circuit Low Input
741
Diagnostic Trouble Code (Dtc) P0108 Manifold Absolute Pressure (Map) Circuit High Input
744
Diagnostic Trouble Code (Dtc) P0112 Intake Air Temperature (Iat) Sensor Circuit Low Input
747
Diagnostic Trouble Code (Dtc) P0113 Intake Air Temperature (Iat) Sensor Circuit High Input
750
Diagnostic Trouble Code (Dtc) P0117 Engine Coolant Temperature (Ect) Sensor Circuit Low Input
753
Diagnostic Trouble Code (Dtc) P0118 Engine Coolant Temperature (Ect) Sensor Circuit High Input
756
Diagnostic Trouble Code (Dtc) P0121 Throttle Position (Tp) Sensor Circuit Range/Performance Problem
759
Diagnostic Trouble Code (Dtc) P0122 Throttle Position (Tp) Sensor Circuitlow Input
762
Diagnostic Trouble Code (Dtc) P0123 Throttle Position (Tp) Sensor Circuit High Input
765
Diagnostic Trouble Code (Dtc) P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control
768
Diagnostic Trouble Code (Dtc) P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
771
Diagnostic Trouble Code (Dtc) P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
774
Diagnostic Trouble Code (Dtc) P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)
777
Diagnostic Trouble Code (Dtc) P0134 O2 Sensor Circuit no Activity Detected (Bank 1 Sensor 1)
780
Diagnostic Trouble Code (Dtc) P0135 O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)
783
Diagnostic Trouble Code (Dtc) P0137 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)
786
Diagnostic Trouble Code (Dtc) P0138 O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)
789
Diagnostic Trouble Code (Dtc) P0140 O2 Sensor Circuit no Activity Detected (Bank 1 Sensor 2)
792
(Bank 1 Sensor 2)
792
Diagnostic Trouble Code (Dtc) P0171 System too Lean (Bank 1)
798
Diagnostic Trouble Code (Dtc) P0172 System too Rich (Bank 1)
802
Diagnostic Trouble Code (Dtc) P0201 Injector Circuit Malfunction - Cylinder
806
Cylinder 2
807
Diagnostic Trouble Code (Dtc) P0203 Injector Circuit Malfunction - Cylinder
809
Cylinder 3
810
Cylinder 4
813
Diagnostic Trouble Code (Dtc) P0300 Random/Multiple Cylinder Misfire Detected
818
Diagnostic Trouble Code (Dtc) P0301 Random/Multiple Cylinder Misfire Detected
822
Diagnostic Trouble Code (Dtc) P0302 Random/Multiple Cylinder Misfire Detected
826
Diagnostic Trouble Code (Dtc) P0303 Random/Multiple Cylinder Misfire Detected
830
Diagnostic Trouble Code (Dtc) P0304 Random/Multiple Cylinder Misfire Detected
834
Diagnostic Trouble Code (Dtc) P0325 Knock Sensor (Ks) Circuit Malfunction
838
Diagnostic Trouble Code (Dtc) P0327 Knock Sensor (Ks) Circuit Low Input
841
Diagnostic Trouble Code (Dtc) P0336 Crankshaft Position (Ckp) Sensor Circuit Range/Performance
844
Diagnostic Trouble Code (Dtc) P0337 Crankshaft Position (Ckp) Sensor Circuit Low Input
846
Diagnostic Trouble Code (Dtc) P0341 Camshaft Position (Cmp) Sensor Circuit Range/Performance
849
Diagnostic Trouble Code (Dtc) P0342 Camshaft Position (Cmp) Sensor Circuit Low Input
852
Diagnostic Trouble Code (Dtc) P0351 Ignition Coil "A" Primary/Secondary Circuit Malfunction
855
Diagnostic Trouble Code (Dtc) P0352 Ignition Coil "B" Primary/Secondary Circuit Malfunction
857
Diagnostic Trouble Code (Dtc) P0401 Exhaust Gas Recirculation (Egr) Flow Insufficient Detected
859
Diagnostic Trouble Code (Dtc) P0402 Exhaust Gas Recirculation (Egr) Excessive Flow Detected
862
Diagnostic Trouble Code (Dtc) P0404 Exhaust Gas Recirculation (Egr) Circuit Range/Performance
864
Diagnostic Trouble Code (Dtc) P0405 Exhaust Gas Recirculation (Egr) Sensor Circuit Low
868
Diagnostic Trouble Code (Dtc) P0406 Exhaust Gas Recirculation (Egr) Sensor Circuit High
871
Diagnostic Trouble Code (Dtc) P0420 Catalyst System Efficiency below Threshold
875
Diagnostic Trouble Code (Dtc) P0440 Evaporative Emission (Evap) Control System Malfunction
878
Diagnostic Trouble Code (Dtc) P0442 Evaporative Emission (Evap) Control System Small Leak Detected
883
Diagnostic Trouble Code (Dtc) P0443 Evaporative Emission (Evap) Control System Purge Control Valve Circuit Malfunction
887
Diagnostic Trouble Code (Dtc) P0446 Evaporative Emission (Evap) Control System Vent Control Circuit Malfunction
890
Diagnostic Trouble Code (Dtc) P0449 Evaporative Emission (Evap) Control System Vent Valve/Solenoid Circuit Malfunction
894
Diagnostic Trouble Code (Dtc) P0461 Fuel Level Sensor Circuit Range/Performance
897
Diagnostic Trouble Code (Dtc) P0462 Fuel Level Sensor Circuit Low Input
899
Diagnostic Trouble Code (Dtc) P0463 Fuel Level Sensor Circuit High Input
901
Diagnostic Trouble Code (Dtc) P0480 Cooling Fan 1 Control Circuit Malfunction
903
Diagnostic Trouble Code (Dtc) P0481 Cooling Fan 2 Control Circuit Malfunction
906
Diagnostic Trouble Code (Dtc) P0502 Vehicle Speed Sensor (Vss) Circuit Low Input
909
Diagnostic Trouble Code (Dtc) P0506 Idle Control System Rpm Lower than Expected
911
Diagnostic Trouble Code (Dtc) P0507 Idle Control System Rpm Higher than Expected
914
Diagnostic Trouble Code (Dtc) P0532 A/C Refrigerant Pressure Sensor Circuit Low Input
917
Diagnostic Trouble Code (Dtc) P0533 A/C Refrigerant Pressure Sensor Circuit High Input
920
Diagnostic Trouble Code (Dtc) P0562 System Voltage Low
923
Diagnostic Trouble Code (Dtc) P0563 System Voltage High
925
Diagnostic Trouble Code (Dtc) P0601 Internal Control Module Memory Check Sum Error
927
Diagnostic Trouble Code (Dtc) P1106 Manifold Absolute Pressure (Map) Sensor Circuit Intermittent High Voltage
929
Diagnostic Trouble Code (Dtc) P1107 Manifold Absolute Pressure (Map) Sensor Circuit Intermittent Low Voltage
931
Diagnostic Trouble Code (Dtc) P1111
933
Intake Air Temperature (Iat) Sensor
934
Diagnostic Trouble Code (Dtc) P1112
936
Circuit Intermittent Low Voltage
936
Diagnostic Trouble Code (Dtc) P1114 Engine Coolant Temperature (Ect) Sensor Circuit Intermittent Low Voltage
938
Diagnostic Trouble Code (Dtc) P1115 Engine Coolant Temperature (Ect) Sensor Circuit Intermittent High Voltage
940
Diagnostic Trouble Code (Dtc) P1121 Throttle Position (Tp) Sensor Circuit Intermittent High Voltage
943
Diagnostic Trouble Code (Dtc) P1122 Throttle Position (Tp) Sensor Circuit Intermittent Low Voltage
945
Diagnostic Trouble Code (Dtc) P1133
947
Diagnostic Trouble Code (Dtc) P1134
950
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Isuzu 1999 RODEO General Description Manual (57 pages)
BRAKE CONTROL SYSTEM
Brand:
Isuzu
| Category:
Automobile Parts
| Size: 0.42 MB
Table of Contents
Table of Contents
1
Service Precaution
2
General Description
3
Functional Description
4
System Components
10
Electronic Hydraulic Control Unit (EHCU) . 5A-10
10
ABS Warning Light
10
Wheel Speed Sensor
10
G-Sensor
10
Normal and Anti-Lock Braking
10
Brake Pedal Travel
10
Acronyms and Abbreviations
10
General Diagnosis
11
General Information
11
ABS Service Precautions
11
Computer System Service Precautions
11
General Service Precautions
11
Note on Intermittents
11
Test Driving ABS Complaint Vehicles
12
ABS" Warning Light
12
Normal Operation
12
Tech 2 Scan Tool
13
Data List
16
Actuator Test
17
Tech 2 Service Bleed
21
Basic Diagnostic Flow Chart
22
Basic Inspection Procedure
23
EHCU Connector Pin-Out Checks
24
Circuit Diagram
25
Connector List
28
Part Location
29
Symptom Diagnosis
30
Chart A-1 ABS Works Frequently but Vehicle Does Not Decelerate
30
Chart TA-1 ABS Works Frequently but Vehicle Does Not Decelerate (Use TECH 2)
31
Chart A-2 Uneven Braking Occurs While ABS Works
31
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)
31
Chart A-3, TA-3 the Wheels Are Locked
32
Chart A-5, TA-5 Braking Sound
34
Diagnostic Trouble Codes
35
Diagnosis by "ABS" Warning Light Illumination Pattern
37
Diagnostic Trouble Codes (Dtcs)
38
Chart B-1 with the Key in the on Position (before Starting the Engine). Warning Light (W/L) Is Not Activated
40
Chart B-2 CPU Error (DTC 14 (Flash Out) / C0271, C0272, C0273, C0284 (Serial Communications))
41
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash Out) / C0277, 0278 (Serial Communications))
41
Chart B-4 Excessive Dump Time (DTC 17 (Flash Out) / C0269 (Serial Communications))
41
Chart B-5 Excessive Isolation Time (DTC 18 (Flash Out) / C0274 (Serial Communications))
42
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash Out) / C0276 (Serial Communications))
42
Chart B-7 Brake Switch Failure (DTC 22 (Flash Out) / C0281 (Serial Communications))
42
Chart B-8 2WD Controller in 4WD Vehicle
43
Chart B-9 Pump Motor Failure (DTC 32 (Flash Out) / C0267, C0268 (Serial Communications))
43
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash Out) / C0265, C0266 (Serial Communications))
44
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash Out) / C0245, C0247 (Serial Communications))
44
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash Out) / C0246, C0248 (Serial Communications))
44
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