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Isuzu 2008 N Series, Workshop Manual

The Isuzu 2008 N Series Workshop Manual is a comprehensive guide for maintaining and repairing your vehicle. Download this manual for free at manualshive.com to access detailed instructions and diagrams for easy troubleshooting. Keep your Isuzu N Series running smoothly with this essential resource at your fingertips.

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 General Information    0A-39

NPR75, NPS75, NQR75 models (1/3)

LNW90AXF000701

I:

Inspect,

clean,

or

repair

or

replace

as

required

A

:Adjust

R

:Replace

T

:Tighten

to

the

specified

torque

L

:Lubricate

Service

Interval

x1,000

km

1

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

105

x1,000

miles

0.6

*

-

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

or

every

12

months

*

-

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

or

every

12

months

-

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

or

every

12

months

*

-

-

I

-

I

-

I

-

R

-

I

-

I

-

I

-

R

-

I

-

I

-

or

every

24

months

-

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

or

every

12

months

--------

A

-------

A

-----

or

every

24

months

--------

I

-------

I

-----

or

every

24

months

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

or

every

6

months

--------

R

-------

R

-----

or

every

24

months

*

-

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

or

every

12

months

-

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

or

every

12

months

-

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

or

every

6

months

-

-

I

-

I

-

I

-

R

-

I

-

I

-

I

-

R

-

I

-

I

-

or

every

24

months

-

IIIIIIIIIIIIIIIIIIIII

or

every

3

months

*

-

-

-

I

-

-

I

-

-

R

-

-

I

-

-

I

-

-

R

-

-

I

or

every

24

months

*

-

-

I

-

I

-

I

-

R

-

I

-

I

-

I

-

R

-

I

-

I

-

or

every

24

months

--------

I

-------

I

-----

or

every

24

months

-

-

-

-

A

-

-

-

A

-

-

-

A

-

-

-

A

-

-

-

A

-

or

every

12

months

*

-

-

-

I

-

-

I

-

-

R

-

-

I

-

-

I

-

-

R

-

-

I

or

every

24

months

--------

I

-------

I

-----

or

every

24

months

-

-

-

-

A

-

-

-

A

-

-

-

A

-

-

-

A

-

-

-

A

-

or

every

12

months

*

-

-

-

-

L

-

-

-

L

-

-

-

L

-

-

-

L

-

-

-

L

-

or

every

12

months

-

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

or

every

6

months

*

:The

vehicle

needs

to

be

maintained

more

often

if

it

is

driven

in

severe

condition.

Refer

to

"Maintenance

Schedule

for

Severe-condition"

in

this

secti

on.

Gear

control

mechanism

looseness

Gear

control

cable

Loose

propeller

shaft

joints

Transmission

and

transfer

case

oil

(4WD

model)

Looseness

in

transmission

and

transfer

case

gear

control

mechanism

(4WD

model)

Transmission

and

transfer

case

gear

control

cables

(4WD

model)

Propeller

shaft,

universal

joints

and

sliding

sleeves

Smoother

clutch

oil

(Vehicle

equipped

with

the

Smoother

system)

Engine

operating

conditions

Clutch

fluid

(Manual

transmission

model)

Clutch

pedal

stroke

and

free

play

(Manual

transmission

model)

Transmission

oil

(2WD

model)

Drive

belt

tension

and

damage

Engine

coolant

Damage

to

or

looseness

in

exhaust

pipe,

exhaust

brake,

exhaust

throttle,

and

their

mounting

Cooling

system

-

-

-

-

-

-

I

-

-

-

-

-

I

-

-

-

-

-

I

-

-

-

or

every

12

months

Intake

system

Air

cleaner

element

Idle

speed

and

acceleration

Valve

clearance

Looseness

in

or

damage

to

fuel

tank

cap

and

fuel

line

Odometer

reading

or

months,

whichever

comes

first

Engine

oil

Engine

oil

filter

Fuel

filter

3

6

9

121

51

82

12

42

73

13

43

74

04

34

64

95

25

55

9

626

5

or

every

24

months

------

-

-I

---

-

---I

-

-

---

Looseness

in

propeller

shaft

bearings

and

related

components

or

every

24

months

------

-

-I

---

-

---I

-

-

---

Propeller

shaft

spline

wear

--------

R

---

----

R

-----

or

every

12

months

Pre-fuel

filter

(if

so

equipped)

LGGEN-WE-0871_7th.book  39 

ページ

  

２００９年１０月１日　木曜日　午後３時２６分

mechanikar

Summary of Contents for 2008 N Series

Page 1: ...WORKSHOP MANUAL GENERAL INFORMATION No LGGEN WE 0871 m e c h a n i k a r...

Page 2: ...4 BRAKES 4B Brake 4C1 Anti Lock Brake ABS Anti Slip Regulator ASR 4D Parking Brake 4E Hill Start Aid HSA 5 TRANSMISSION TRANSAXLE 5A Transmission Control System 5B Automatic Transmission 5C Manual Tr...

Page 3: ...LGGEN WE 0871 Maegaki 08 7 3 3 38 PM 2 m e c h a n i k a r...

Page 4: ...g Agent 0A 31 Maintenance Schedule 0A 32 Introduction 0A 32 Maintenance Schedule 0A 33 Maintenance Schedule for Severe condition 0A 46 Introduction 0A 46 Maintenance Schedule for Severe condition 0A 4...

Page 5: ...ss 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...

Page 6: ...ped on the left side rear of the cylinder body Legend 1 Engine model 2 Engine number Engine number 4HK1 Engine The engine number is stamped on the right side of the cylinder body Legend 1 Engine model...

Page 7: ...the vehicle at the factory Refer to the vehicle identification plate when ordering replacement parts Option Code List LNW90ASH000101 LNW90ASH000901 1 2 Option Code Option Description AJ3 Driver side a...

Page 8: ...75R17 5 Disc wheel 17 5x6 00 127 silver front rear highway MICHELIN CRW Tire front rear 215 75R17 5 Disc wheel 17 5x6 00 127 white front rear highway MICHELIN CSA Tire front rear 195 85R16 Disc wheel...

Page 9: ...75R16 Disc wheel 16x5 5J 85 CVH Tire front rear 7 50R 16 12 Disc wheel 16x6 00GS 127 5 wheel nuts CV4 Country Israel CX1 Country Argentina CX6 Country New Zealand C13 Wiper with intermittent Option C...

Page 10: ...6 0 ton RPV G V W 6 0 6 5 ton Option Code Option Description RPW G V W 6 5 7 0 ton RPX G V W 7 0 7 5 ton RPY G V W 7 5 8 0 ton RPZ G V W 8 0 8 5 ton RR9 O S rear view mirror under RSF Manual transmiss...

Page 11: ...y 95D31L TRQ Voltage spec 12V TR6 Headlamp leveling system manual TT5 Halogen head lamp T62 Dry battery Option Code Option Description T64 Battery delete T79 Rear fog lamp T87 Cornering lamp T96 Front...

Page 12: ...olor Ebony black 2 517 Body color Al gray Option Code Option Description 534 Body color Pl white 538 Body color Toll IPEC yellow 539 Body color RAL4010 tele magenta 57H Tire front rear 7R 15 18 Disc w...

Page 13: ...n Code Option Description 736 Body color Cardinal red 73E KD package Vietnam Bus 74E KD package Guatemala Bus 75D KD package Iran 76E KD package Ukraine Bus Var 2 77E KD package Turkey Var 3 78E KD pa...

Page 14: ...ckage Uzbekistan Bus 83D KD package Venezuela 83E KD package Russia 83V Tire front rear 7 50R 16 10 Disc wheel 16x6 00GS 127 84D KD package Colombia Var 2 890 Body color Marine blue 904 Body color Gol...

Page 15: ...NHR model NLR 4x2 Truck NLR model NMR 4x2 Truck NMR model NNR 4x2 Truck NNR model NPR 4x2 Truck NPR model N1R 4x2 Truck NQR model NLS 4x4 Truck NLS model NPS 4x4 Truck NPS model Code 55 4JB1 Engine 7...

Page 16: ...001 8 000 lb Hydraulic brake system G 3 630 4 082 kg 8 001 9 000 lb Hydraulic brake system H 4 083 4 536 kg 9 001 10 000 lb Hydraulic brake system J 4 537 6 350 kg 10 001 14 000 lb Hydraulic brake sys...

Page 17: ...using a stand When lifting up the vehicle using a lift make sure to set the safety device When performing a procedure with two or more people make sure to ensure each other s safety before performing...

Page 18: ...k precaution Arrange removed parts in the correct order and ensure they do not get mixed up with parts that cannot be re used Perform sufficient cleaning and washing when performing assembly installat...

Page 19: ...may result in loss of control of the vehicle Garage jack and safety stand Lifting point and supportable point location front rigid suspension model Legend 1 Front axle 2 Rear axle center 3 Side membe...

Page 20: ...support on rear axle tube Over slung leaf spring suspension model Under slung leaf spring suspension model LNW80ASH000701 Jacking point Front of vehicle LNU8Z0SH016801 Front of vehicle Axle LNW80ASH00...

Page 21: ...foreign material by cleaning with an air brush or clean rag etc If the material cannot be removed by cleaning or there is corrosion or deformation replace them Gently pull the wires to check that no t...

Page 22: ...Release the lock and carefully disconnect the connector Do not pull the harness when disconnecting the connector as this may cause wires to come out or break Connecting the connector Securely grasp th...

Page 23: ...As indicated in the diagram insert a thin screwdriver shaped metal rod 1 from the connector closure area 5 2 Push the lock 2 up in the direction of the arrow using the metal rod to release the lock In...

Page 24: ...unction when excess current flows This may cause parts or wires etc to burn and can result in a vehicle fire Handling Electronic Parts Handle electronic parts with sufficient care and do not damage th...

Page 25: ...iverting it around other parts give the harness a sufficient amount of free length and use a protective tube 2 and clip 1 to ensure it does not contact surrounding parts 5 For wiring between the engin...

Page 26: ...e for diagnosing electrical failures in electronic control units and performing system checks If you connect the Tech2 to the DLC installed in the vehicle it performs communication with the control un...

Page 27: ...e PCMCIA card after turning the power off The Tech2 has the capacity for two snapshots As the PCMCIA card is sensitive to magnetism and static electricity take care when handling it The Tech2 is able...

Page 28: ...DLC cable connection connector 12 AC adaptor connector 13 PCMCIA card insertion opening with cover 14 PCMCIA card release removal button 15 Connector for external communication RS 485 port 16 Connect...

Page 29: ...ion connector Connector for using connecting the Tech2 with the vehicle Connect the DLC cable 12 AC adaptor connector Connector for connecting the included AC adaptor Enables the Tech2 to be used away...

Page 30: ...e ignition is turned OFF 6 Connect the Tech2 24 V adaptor 2 to the vehicle side DLC connector pole 16 blue RHD model LHD model NOTE The CNG engine becomes sensitive to fluctuation of the power voltage...

Page 31: ...put check the 3 A fuse 7 Turn the ignition ON and press the PWR key of the Tech2 8 Confirm the display of the Tech2 CAUTION Remove install the PCMCIA card after confirming that power is not being supp...

Page 32: ...bead width to one side of the contact surface Make sure there are no cuts in the beads Type Product name Manufacturer name Area used reference Silicon type Room temperature vulcanization process Thre...

Page 33: ...2 1 3 0 04 0 12 More than 2 0 08 Depression Apply liquid gasket to the bolt hole interior Specified bead width Anaerobic Type 2 3 mm 0 08 0 12 in 1 Completely remove lubricant and moisture from the co...

Page 34: ...e and the threaded portion of nut Make sure the contact surface is dry 2 Apply LOCTITE to the end 1 3 of the screw 3 Tighten the bolt at the specified torque CAUTION After tightening do not apply exce...

Page 35: ...the checks on the following items regular inspection items should also be checked Abbreviations used in this manual I Inspect clean or repair or replace as required A Adjust R Replace T Tighten to the...

Page 36: ...or every 9 months I I R I I R I or every 27 months I I I I I I I I I I I I I I I I I I I I I or every 3 months I I R I I R I or every 24 months I I R I I I or every 24 months I or every 36 months A A...

Page 37: ...for Severe condition in this section Inspection of lights horn windshield wiper and washer Inspection of nuts and bolts on chassis and body Disc wheel damage Wheel hub bearing grease Tire air pressure...

Page 38: ...onths I I I I I I I I I I I I I I I I I I I I I I I I I I I I or every 6 months R R I I I I I I I I R R or every 24 months I I I I I I I I I I I I I I I I I I I I I or every 3 months I I R I I R I or...

Page 39: ...n of nuts and bolts on chassis and body Disc wheel damage Wheel hub bearing grease Tire air pressure and damage Specific gravity of battery fluid Looseness in or damage to suspension mounting Shock ab...

Page 40: ...ry 6 months The vehicle needs to be maintained more often if it is driven in severe condition Refer to Maintenance Schedule for Severe condition in this section Engine oil When using ISUZU genuine Eng...

Page 41: ...and body Disc wheel damage Wheel hub bearing grease Tire air pressure and damage Specific gravity of battery fluid Looseness or damage to suspension mounting Shock absorber oil leaks Shock absorber m...

Page 42: ...condition Refer to Maintenance Schedule for Severe condition in this section Gear control mechanism looseness Gear control cable Loose propeller shaft joints Transmission and transfer case oil 4WD mod...

Page 43: ...ion Propeller shaft center bearing Front propeller shaft double cardan joints and sliding sleeves 4WD model Looseness in front propeller shaft joints 4WD model HBB fluid Vehicle equipped with HBB Stee...

Page 44: ...r every 24 months The vehicle needs to be maintained more often if it is driven in severe condition Refer to Maintenance Schedule for Severe condition in this section Looseness in or damage to suspens...

Page 45: ...odel Gear control mechanism looseness Gear control cable Looseness in or damage to fuel tank cap and fuel line Drive belt tension and damage Engine coolant Damage to or looseness in exhaust pipe exhau...

Page 46: ...ydraulic brake booster HBB fluid Vehicle equipped with the HBB or every 6 months or every 24 months or every 6 months or every 6 months or every 24 months or every 3 months or every 3 months or every...

Page 47: ...r every 3 months Transmission oil I I R I I R I or every 24 months Gear control mechanism looseness I I or every 24 months Gear control cable A A A A A or every 12 months Propeller shaft universal joi...

Page 48: ...n of nuts and bolts on chassis and body 1 0 6 5 3 10 6 15 9 20 12 25 15 30 18 35 21 40 24 45 27 50 31 55 34 60 37 65 40 70 43 75 46 80 49 85 52 90 55 95 59 100 62 105 65 or every 24 months I I I R I I...

Page 49: ...nce covered Condition A B C D A D Engine Oil NHR85 NLR85 NMR85 NNR85 NPR85 models Replace every 7 500 km 4 500 miles NMR82 NPR82 models For Thailand Replace every 5 000 km 3 000 miles NLR82 NPR82 mode...

Page 50: ...y 20 000 km 12 000 miles Damage to or Looseness in Exhaust Pipe Exhaust Brake Exhaust Throttle exc 4HV1 engine and Their Mounting Inspect every 10 000 km 6 000 miles Transmission Oil 2WD model Replace...

Page 51: ...tem Mounting Inspect every 5 000 km 3 000 miles Brake Shoe Lining and Drum Wear Inspect every 10 000 km 6 000 miles Disc Brake Pad and Disc Wear Inspect every 5 000 km 3 000 miles Item Distance covere...

Page 52: ...U genuine lubricants or recommended lubricants as given in the chart which will serve as a guide for selecting lubricants of proper brand name Diesel Engine Crankcase with DPD Low Ash Oil NOTE For the...

Page 53: ...de 15W 40 CE CF CI 4 E3 E5 DH 1 Shell Rimula X 15W 40 CH 4 E5 DH 1 Shell Rimula D 15W 40 30 40 CF Castrol RX Super Plus 15W 40 CH 4 E3 DH 1 Castrol Tection J Plus 15W 40 CH 4 E3 B3 DH 1 BP BP Vanellus...

Page 54: ...D CE CF BP BP Vanellus C6 15W 40 CD CE CF ExxonMobil Exxon Essolube XD 3 15W 40 CI 4 ExxonMobil Mobil Delvac MX 15W 40 CI 4 MAKE BRAND GRADE API ACEA JASO ISUZU GENUINE BESCO ATF III MAKE BRAND GRADE...

Page 55: ...ar Oil LSD 90 GL 5 Shell Spirax A LS 90 90 GL 5 Castrol Hypoy LSX 90 GL 5 BP Energear LS M 90 GL 5 ExxonMobil Mobilube LS 85W 90 GL 5 MAKE BRAND GRADE API ACEA JASO ISUZU GENUINE BESCO ATF III Caltex...

Page 56: ...than the expected outside temperature When using an anti freeze solution other than the Isuzu genuine LLC Isuzu specified product use the following mixture ratios When the outside temperature is abov...

Page 57: ...fuels as they may adversely affect the engine MAKE BRAND GRADE ISUZU GENUINE BESCO brake fluid super DOT 3 AC DelcoTM Delco supreme 11 DOT 3 Japanese Industrial Standards JIS Based on K2204 Diesel Fue...

Page 58: ...ne problems ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE ENGINE OIL VISCOSITY CHART Single grade Multi grade SAE 10W 30 SAE 10W 40 SAE 5W 40 SAE 30 SAE 20 20W SAE 40 50 SAE 10W SAE 15W 40 20W 40 20W...

Page 59: ...30 C 13 F 14 F 32 F 59 F 86 F 35 C 95 F GEAR OIL front and rear axle transfer case VISCOSITY GRADE AMBIENT TEMPERATURE GEAR OIL front and rear axle transfer case VISCOSITY CHART Single grade Multi gra...

Page 60: ...uid SA B W W G W W A A E E C C M M M M M Front hub bearing Kingpin Kingpin Power steering fluid Transmission Prop shaft universal joint Prop shaft center bearing Prop shaft universal joint Prop shaft...

Page 61: ...M M M M Front hub bearing Power steering fluid Transmission Prop shaft universal joint Prop shaft center bearing Prop shaft universal joint Prop shaft universal joint Prop shaft sliding sleeve Rear h...

Page 62: ...or 40 000 km 24 000 miles Every 6 months or 10 000 km 6 000 miles Every 12 months or 20 000 km 12 000 miles Brake and clutch fluid W W G W W A E E C C M M M M M Front hub bearing Kingpin Kingpin Power...

Page 63: ...km 6 000miles Every12monthsor20 000km 12 000miles Brake fluid W W G W W A E M M M M M Front hub bearing Power steering fluid A Smoother clutch fluid SA Transmission Prop shaft universal joint Prop sha...

Page 64: ...ths or 20 000 km 12 000 miles Brake fluid W W G W W A E E C C M M M M M Front hub bearing Kingpin Kingpin Power steering fluid A Smoother clutch fluid SA Transmission Prop shaft universal joint Prop s...

Page 65: ...ering fluid Transmission Prop shaft universal joint Prop shaft center bearing Prop shaft universal joint Prop shaft universal joint Prop shaft sliding sleeve Rear hub bearing Front hub bearing Hydro b...

Page 66: ...oint Prop shaft double cardan joint Prop shaft universal joint Prop shaft sliding sleeve Prop shaft sliding sleeve Rear hub bearing Front hub bearing Engine Rear hub bearing Differential gear Change C...

Page 67: ...or 40 000 km 24 000 miles Every 6 months or 10 000 km 6 000 miles Every 12 months or 20 000 km 12 000 miles Brake and clutch fluid B W W G W W A E E C C M M M M M Front hub bearing Kingpin Kingpin Pow...

Page 68: ...oint Prop shaft double cardan joint Prop shaft universal joint Prop shaft sliding sleeve Prop shaft sliding sleeve Rear hub bearing Front hub bearing Engine Rear hub bearing Differential gear Change C...

Page 69: ...hub bearing Kingpin Kingpin Power steering fluid Transmission Prop shaft universal joint Prop shaft center bearing Prop shaft universal joint Prop shaft universal joint Prop shaft sliding sleeve Rear...

Page 70: ...dition Issued by ISUZU MOTORS LIMITED E Solutions Service Marketing Dept Shinagawa ku Tokyo 140 8722 Japan All rights reserved 0 XXXKI WORKSHOP MANUAL GENERAL INFORMATION 62013 LGGEN WE 0871 09 9 10 1...

Page 71: ...62013 LGGEN WE 0871 09 9 10 1 12 PM 2 m e c h a n i k a r...

Page 72: ...WORKSHOP MANUAL GENERAL INFORMATION No LGGEN WE 0871 m e c h a n i k a r...

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