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Isuzu Vehicross Service Repair Workshop Manual 1999-2001

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🏷️ Basic Information Identification Make: Isuzu Model: VehiCROSS Years Covered: 1999-2001 Codes Platform Code: KG (based on Isuzu Trooper platform) 👋 Introduction Market Position Segment: Compact SUV with a unique,...
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Type: Car
Vendor:
Sku: 585132
Isuzu Vehicross Service Repair Workshop Manual 1999-2001
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
VehiCROSS
Years Covered:
1999-2001
Codes
Platform Code:
KG (based on Isuzu Trooper platform)
👋 Introduction
Market Position
Segment:
Compact SUV with a unique, stylized design and off-road capabilities.
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Subaru Forester, Nissan Xterra (though VehiCROSS positioned as more niche/stylized).
Key Features
Design:
Distinctive, aggressive, futuristic styling with asymmetric body panels, prominent fender flares, and a unique rear end.
Drivetrain:
Advanced Torque-On-Demand (TOD) 4WD system for on-the-fly engagement and optimized traction.
Interior:
Sporty, driver-focused cockpit with supportive seats and unique interior design elements.
📋 Manual Details
Coverage Areas
Main Coverage:
Mechanical systems, electrical systems, body, chassis, and specifications for 1999-2001 Isuzu VehiCROSS models.
Page Count
Estimated Pages:
Approximately 1000-1500 pages (typical for a comprehensive factory service manual).
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
3.5L V6 (6VD1) - Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting, charging.
Transmission:
4-speed Automatic (RM4) - Operation, diagnosis, overhaul, torque converter, transmission control system.
Drivetrain:
Torque-On-Demand (TOD) 4WD System - Operation, diagnosis, front axle, rear axle, propeller shafts, differentials.
Suspension:
Front Independent Suspension (Double Wishbone), Rear Solid Axle - Springs, shock absorbers, control arms, steering knuckles, wheel bearings.
Brakes:
Front ventilated discs, Rear discs - Hydraulic system, ABS (Anti-lock Braking System), parking brake.
Steering:
Power-assisted rack and pinion - Steering gear, steering column, power steering pump and lines.
Body:
Exterior body panels, interior trim, doors, glass, roof panel (optional sunroof), bumpers, sealing.
Electrical:
Battery, charging system, starting system, lighting, instruments, HVAC controls, power accessories, wiring diagrams, fuse/relay locations.
Climate Control:
Air conditioning system, heater, ventilation, HVAC unit, controls, refrigerant.
Procedures Included
Maintenance:
Routine inspections, oil changes, filter replacements, fluid checks and changes, belt and hose inspections.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II), specific system testing.
Repair:
Component removal and installation, engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical system repair.
Special Tools:
Identification and usage of Isuzu-specific service tools.
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
📊 Manual Specifications
File Format
Quality:
High-resolution scans, often searchable PDF for easy navigation.
Print Quality
Scalability:
Printable pages, allowing for hard copy use in a workshop environment.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6VD1
Configuration:
3.5L (3498 cc) SOHC V6
Bore X Stroke:
93.4 mm x 84.5 mm
Compression Ratio:
9.1:1
Performance
Horsepower:
205 hp @ 5400 rpm (approx.)
Torque:
235 lb-ft @ 3200 rpm (approx.)
Fuel System
Injection:
Electronic Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Regular (87 Octane recommended)
Engine Management
ECM Type:
Isuzu Electronic Control Module (ECM)
🔧 Transmission
Standard
Type:
4-speed Automatic Transmission (RM4)
Optional
Type:
N/A (Only Automatic was offered in most markets for this model year range)
Features
Drivetrain Control:
Torque-On-Demand (TOD) 4WD System, electronically controlled.
Fluid Type:
Dexron III (or equivalent)
📐 Dimensions
Exterior
Length:
167.5 inches (4255 mm)
Width:
71.5 inches (1816 mm)
Height:
65.2 inches (1656 mm)
Wheelbase:
104.7 inches (2659 mm)
Ground Clearance:
8.0 inches (203 mm) (approx.)
Weights
Curb Weight:
3,900 - 4,050 lbs (1769 - 1837 kg) (approx.)
Cargo
Cargo Volume Behind Rear Seat:
20.7 cu ft (586 L) (approx.)
Cargo Volume With Rear Seat Folded:
56.4 cu ft (1597 L) (approx.)
Wheels Tires
Wheel Size:
16-inch alloy
Tire Size:
P245/70R16
Bolt Pattern:
6 x 139.7 mm (6 x 5.5 inches)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars (1999 model year data)
NHTSA Frontal Impact Passenger:
4 Stars (1999 model year data)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Part of the TOD 4WD system, offering enhanced traction.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seats.
Frame Construction:
Body-on-frame construction for durability and off-road resilience.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player, optional premium sound system.
Navigation:
N/A (No factory navigation offered for these model years).
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Auxiliary Input:
N/A (No factory auxiliary input for audio).
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 miles or 6 months, whichever comes first (refer to manual for specific conditions).
Air Filter Replacement:
Every 30,000 miles or 24 months.
Spark Plug Replacement:
Every 60,000 miles (for platinum tipped plugs).
Transmission Fluid Change:
Every 60,000 miles or 48 months (under normal driving conditions).
Fluid Specifications
Engine Oil:
API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature).
Engine Coolant:
Isuzu Long Life Coolant (Blue) or equivalent phosphate-free OAT coolant, mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine:
Occasional issues with intake manifold gaskets, valve stem seals (oil consumption), and timing chain guides on higher mileage examples.
Transmission:
Potential for torque converter shudder or solenoid issues if fluid is not maintained.
Body:
Rust issues can occur on the frame and underbody, especially in areas with road salt. Trim pieces may degrade over time.
Electrical:
Relay failures, window regulator issues, and alternator problems can be reported.
📚 Vehicle History
Brand Heritage
Manufacturer:
Isuzu Motors Ltd., a Japanese automotive manufacturer known for its trucks and SUVs.
Model Evolution
Origins:
The VehiCROSS was conceived as a concept vehicle and introduced as a production model, aiming to be a stylish and capable compact SUV.
Uniqueness:
Its radical design set it apart from its contemporaries and is a key part of its collector appeal.
Production
Production Years:
1997 (Japan) / 1999-2001 (North America)
Assembly Location:
Japan
🏆 Awards & Recognition
Recognitions
Design Awards:
Praised for its distinctive and bold design, though it didn't win specific major automotive design awards widely publicized.
Ratings
Reliability:
Generally considered average to good for its era, with specific models and maintenance history playing a significant role.
Certifications
Emissions Compliance:
Meets EPA emissions standards for the respective model years.
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