Isuzu Workshop Manual (EN)

GENERAL INFORMATION

This Workshop Manual deals only with the screen toned section(s) in the table below.

Section Sub Section 0 GENERAL INFORMATION 0A General Information 1 ENGINE 1A Engine Control System 1B Engine Mechanical 1C Engine Cooling 1D Engine Fuel 1E Engine Electrical 1F Emission Control 1G Engine Exhaust 1H Engine Lubrication 1I Engine Speed Control System 1J Induction 1K Pre-Heating System 1L Power Take-Off (PTO) 2 SUSPENSION 2A1 Air Suspension Control System 2B Front Suspension 2C Rear Suspension 2D Wheel and Tire System 3 DRIVELINE/AXLE 3A1 Front Differential 3A2 Rear Differential 3C1 Propeller Shaft 3C2 Front Axle 3C3 Rear Axle 3D Transfer Case 4 BRAKES 4A2 Brake Control System (Air Over) 4A3 Brake Control System (Full Air) 4B2 Brake (Air Over) 4B3 Brake (Full Air) 4C Anti-Lock Brake (ABS) 4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR) 4D Parking Brake 4E Hill Start Aid (HSA) 4F Speed Retarder System 4G Trailer Brake 5 TRANSMISSION/TRANSAXLE 5A Transmission Control System 5B Automatic Transmission 5C Manual Transmission 5E Clutch 5G Power Take-Off (PTO) 5G1 Side Power Take-Off 6 STEERING 6B Power Steering 7 HVAC 7A Heating and Ventilation 7B Manual Air Conditioning 7C Automatic Air Conditioning 8 RESTRAINTS 8A Seat Belt 8B Supplemental Restraint System (SRS) 8C SRS Control System 9 BODY, CAB AND ACCESSORIES 9A Lighting System 9B Wiper/Washer System 9C Entertainment 9D Wiring System 9E Instrumentation/Driver Info.

9F Body Structure 9G Cab 9H Seats 9I Security and Lock 9K Exterior/Interior Trim 9L Cab Mounting 10 CONTROL SYSTEMS 10B Vehicle Control 11 FRAME AND FRAME ACCESSORIES 11A Frame

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General Information

General Information 0A-1 GENERAL INFORMATION General Information TABLE OF CONTENTS General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 General Repair Instructions . . . . . . . . . . . . . . . 0A-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Chassis Number/Engine Number Stamping Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Option Code List . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Vehicle Identification Number (VIN) . . . . . . . . 0A-11 General Precaution . . . . . . . . . . . . . . . . . . . . . . 0A-15 General Precautions . . . . . . . . . . . . . . . . . . . . 0A-15 Lifting Instruction . . . .

. . . . . . . . . . . . . . . . . . . . 0A-17 Lifting Instruction. . . . . . . . . . . . . . . . . . . . . . . 0A-17 Caution for The Maintenance of Electrical Parts 0A-20 Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-20 Connector Handling Requirements . . . . . . . . . 0A-20 Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-23 Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-23 Regarding The Scan Tool. . . . . . . . . . . . . . . . . . 0A-25 Trouble Diagnosis Using The Scan Tool . . . . . 0A-25 Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-31 Recommended Liquid Gasket. . . . . . . . . . . . . 0A-31 Recommended Thread Locking Agent. .

. . . . . . 0A-33 Recommended Thread Locking Agent . . . . . . 0A-33 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-34 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-34 Maintenance Schedule (for Euro4 specification except Europe) . . . . . 0A-35 Maintenance Schedule (for Euro2, Euro3 specification). . . . . . . . . . . . 0A-41 Maintenance Schedule (for Europe) . . . . . . . . 0A-45 Maintenance Schedule (CNG engine for Australia) . . . . . . . . . . . . . . . 0A-50 Maintenance Schedule (CNG engine for Thailand) . . . . . . . . . . . . . . .

0A-54 Transmission Oil - ZF6S1000/ZF9S1110 Type 0A-58 Transmission Oil - FS8209A/FSO5206B Type 0A-65 RS23/RS40 Type Axle . . . . . . . . . . . . . . . . . . 0A-67 RS25 Type Axle . . . . . . . . . . . . . . . . . . . . . . . 0A-68 Maintenance Schedule for Severe-condition . . . 0A-69 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-69 Maintenance Schedule for Severe-condition . 0A-69 Recommended Fluids, Lubricants and Diesel Fuels (except Europe). . . . . . . . . . . . . . . 0A-73 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73 Diesel Engine Crankcase with DPD (Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . .

0A-73 Diesel Engine Crankcase without DPD. . . . . . 0A-74 CNG Engine Crankcase (for Australia) . . . . . . 0A-74 CNG Engine Crankcase (for Thailand) . . . . . . 0A-74 Manual Transmission (MZX/MZW/MLD models), Transfer Case, Differential (without LSD) and Oil Lubricated Hub Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-75 Manual Transmission (MZZ models). . . . . . . . 0A-75 Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-75 Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-75 Automatic Transmission, Power Steering . . . .

0A-76 Center Bearing, Clutch Shift Block, Grease Lubricated Hub, Water Pump, Propeller Shaft Sliding Yoke, Universal Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-76 Multi-Purpose Grease Containing Molybdenum . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-76 Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-76 Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-77 Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-77 Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-77 Diesel Fuel / Applicable Standard (Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-78 Recommended Fluids, Lubricants and Diesel Fuels (for Europe) . . . . . . . . . . . .

. . . . . . 0A-79 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79 Diesel Engine Crankcase with DPD (Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79 Diesel Engine Crankcase without DPD. . . . . . 0A-79 Manual Transmission (MZX/MZW/MZZ/MLD models), Differential (without LSD) and Oil Lubricated Hub Bearing . . . . . . . . . . . . . . . . . 0A-80 Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-80 Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-80 Power Steering . . . . . . . . . . . . . . . . . . . . . . . .

0A-80 Center Bearing, Clutch Shift Block, Grease Lubricated Hub, Water Pump, Propeller Shaft Sliding Yoke, Universal Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-81 Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-81 Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-81 Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-82 Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-82 Diesel Fuel / Applicable Standard (Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-82 Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-83 Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . 0A-83 Lubrication Chart . . . . . . . . . . . . .

. . . . . . . . . . . 0A-84 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . 0A-84 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-97 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . 0A-97

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General Repair Instructions

0A-2 General Information General Information General Repair Instructions 1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle. 2. Use covers on the vehicle body, seats, and floor to prevent damage and/or contaminations. 3. Disconnect the grounding cable from the battery before performing service operations. This will prevent cable damage or burning due to shortcircuiting. 4. Raise the vehicle with a jack set against the axle or the frame. 5. Support the vehicle on chassis stands. 6. Handle brake fluid and antifreeze solution with great care. Spilling these liquids on painted surfaces will damage the paint. 7.

The use of the proper tool(s) and special tool(s) where specified is efficient, reliable, and safe service operations. 8. Always use genuine ISUZU replacement parts. 9. Discard used cotter pins, gasket, O-rings, oil seals, lock washers, and self-locking nuts at disassembly. Normal function of these parts cannot be guaranteed if they are reused. 10. Keep the disassembled parts neatly in groups. This will facilitate smooth and correct reassembly. 11. Keep fixing nuts and bolts separate. Fixing nuts and bolts vary in hardness and design according to installation positions. 12. Clean all parts before inspection or reassembly. 13.

Clean the oil ports and other openings with compressed air to make certain that they are free of dirt and obstructions. 14. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation. 15. Use the recommended liquid gasket to prevent leakage. 16. Be sure to tighten nuts and bolts to the specified torque, using a properly maintained torque wrench. 17. When service operation is completed, male a final check to be sure service has been done properly and problem has been corrected. 18.

When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be sure to use the ACR4 or equivalent to recover and recycle Refrigerant - 134a (HFC-134a), to promote the movement for the protection of the ozone layer covering the earth. 19. To assure safety, always slowly release air pressure from the air tanks before disconnecting pipes, hoses or other parts from any unit under pressure. 20. Prior to start the welding work, the following operations are required: Disconnect all connectors of electronic control unit. Disconnect battery ground terminal. Welding machine ground cable must be connected near the welding point.

Turn off the all switches.

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Chassis Number/Engine Number Stamping Position

General Information 0A-3 Identification Chassis Number/Engine Number Stamping Position Engine number (6HF1 Engine) The engine number (1) is stamped on the right side of the cylinder body. Chassis number It is stamped on the front right-hand side face of the chassis side member. 1 MFW90ASH000101 Engine number (6HK1 Engine) MFW70ASH000101 The engine number is stamped on the right side of the cylinder body. Engine number (4HK1 Engine) The engine number is stamped on the right side of the cylinder body. MFW80ASH000401 Service Parts ID Plate LNWB0ASH000101 The service parts ID plate is attached to the passenger side lower dashboard.

The service parts ID plate has the following information; Vehicle identification number (VIN) Wheelbase dimensions Paint information Production options or special equipment installed on the vehicle at the factory

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