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Isuzu N Series 2008, Owner'S Manual

The Isuzu N Series 2008 Owner's Manual is available for free download on manualshive.com. This comprehensive manual provides detailed instructions on how to operate and maintain your Isuzu N Series truck. Get your hands on this essential manual today to ensure smooth operations of your vehicle.

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7-59

SERVICE AND MAINTENANCE

CHASSIS-RELATED SERVICE AND 

MAINTENANCE

●

 Brakes

7-60

●

 Parking Brake

7-70

●

 Brake Hoses and Pipes

7-72

●

 Disc Brakes 

V

7-73

●

 Drum Brakes 

V

7-75

●

 Wheels and Tyres

7-77

●

 Tyre Rotation

7-86

●

 Changing Tyres

7-88

●

 Spare Tyre 

V

7-98

● 

Clutch 

M/T

7-100

● 

Transmission Oil

7-105

●

 AMT Clutch Oil 

SA

7-109

● 

Rear Axle Differential Gear Oil

7-112

● 

Front Axle Differential Gear Oil 

V

7-114

● 

Transfer Gear Case Oil 

V

7-117

● 

Power Steering Fluid

7-120

● 

Hub Bearing Grease

7-123

●

 Greasing Chassis Components

7-124

2008N_sec07-2_print2.indd   59

3/09/2008   5:53:04 PM

Summary of Contents for N Series 2008

Page 1: ...y and properly filled out and signed by your Selling Dealer Owner s Name Business Name Address City Town State Postcode Business Phone Private Phone Mobile Email Registration Number Isuzu Truck Model...

Page 2: ...2008N_sec00_print2 indd 2 3 09 2008 4 21 51 PM...

Page 3: ...to follow these instructions identified by this symbol could result in a fire inside your vehicle in addition to death or serious injury to you and or other people CAUTION Failure to follow these ins...

Page 4: ...ibution ELR Emergency Locking Retractor FMVSS Federal Motor Vehicle Safety Standards GVM Gross Vehicle Mass HBB Hydraulic Brake Booster HSA Hill Start Aid JASO Japanese Automobile Standards Organizati...

Page 5: ...FIND A SPECIFIC TOPIC HOW TO USE THIS MANUAL 0 2 HOW TO FIND A SPECIFIC TOPIC 0 3 CHAPTER DESCRIPTION 0 5 PICTORIAL INDEX 0 6 WARNING INDICATOR LIGHT INDEX 0 13 WARNING CAUTION LABELS 0 18 2008N_sec00...

Page 6: ...rette butt could set fire to other cigarette butts resulting in a fire Do not allow the ashtray to become overly full of cigarette butts Also do not put flammable material in the ashtray Ashtray V Ref...

Page 7: ...age describing it by using the pictorial indexes Use device names as keys Pages 10 1 to 10 4 INDEX If you know the name of the switch or other device for which you need information locate the page des...

Page 8: ...0 4 2008N_sec00_print2 indd 4 3 09 2008 4 21 57 PM...

Page 9: ...ols and instruments describes special equipment such as the AMT and HSA COMFORT AND CONVENIENCE 5 Contains information on the audio system air conditioning system and other comfort and convenience fea...

Page 10: ...switch 4 69 Windshield washer and wiper switch 4 71 No Equipment Page 7 Combination light control switch 4 64 8 V Ashtray 5 23 9 V Idling control knob 4 62 10 Cigarette lighter 5 22 11 Relay box 8 40...

Page 11: ...or lights 4 8 4 15 2 V Front fog light switch 4 67 3 SA AMT adjustment switch 4 93 4 SA AMT emergency switch 4 95 No Equipment Page 5 Horn button 4 73 V Driver s SRS airbag 4 143 6 DPD switch 4 154 7...

Page 12: ...5 V Small article storage pocket 5 25 No Equipment Page 6 Exhaust brake switch 4 69 Windshield washer and wiper switch 4 71 7 Combination light control switch 4 64 8 V Idling control knob 4 62 9 Ciga...

Page 13: ...tor lights 4 8 4 15 8 V Front fog light switch 4 67 9 V Headlight leveling switch 4 66 10 Horn button 4 73 V Driver s SRS airbag 4 143 No Equipment Page 11 V Remote control mirror switch 4 73 12 V HSA...

Page 14: ...cator lights 4 8 4 15 8 V Front fog light switch 4 67 9 V PTO lever 4 128 10 V Headlight leveling switch 4 66 11 Horn button 4 73 V Driver s SRS airbag 4 143 No Equipment Page 12 V Remote control mirr...

Page 15: ...Centre console box 5 26 10 Parking brake lever 4 77 11 Gear shift lever 4 78 12 Fully adjustable steering 3 21 No Equipment Page 1 V Coat hook 5 29 2 Seat Belt 3 23 3 Dome light 5 20 4 V Overhead tra...

Page 16: ...80 6 Headlight 8 24 7 V Front fog light 8 24 No Equipment Page 1 Outside rearview mirrors 3 22 2 Turn signal light 8 24 3 Clearance light 8 24 4 V Cornering light 8 24 Exterior NLR NNR NPR NQR NPS Mo...

Page 17: ...r failure Red 4 57 CAN system error Red 4 57 Over speed Red 4 38 Abnormal voltage Red 4 22 Multi Information Display MID V WARNING LIGHTS INDICATOR LIGHTS Message Display indication Color Page Automat...

Page 18: ...e oil level check Amber 4 41 Air cleaner check Amber 4 41 Engine oil and filter Green 4 40 Transmission oil Green 4 45 AMT clutch oil Green 4 46 Fuel filter Green 4 47 Power steering fluid Green 4 48...

Page 19: ...mmer Green 4 25 WARNING LIGHTS Instrument Panel Name Symbol Color Page Check engine warning light Amber 4 42 Engine oil pressure warning light Red 4 38 Engine overheat warning light Red 4 39 V ABS war...

Page 20: ...Green 4 54 V Cruise control set indicator light Green 4 54 High beam indicator light Blue 4 51 V ASR indicator light Green amber 4 53 INDICATOR LIGHTS Name Symbol Color Page Water separator fuel filte...

Page 21: ...filled out and signed by your Selling Dealer Owner s Name Business Name Address City Town State Postcode Business Phone Private Phone Mobile Email Registration Number Isuzu Truck Model Vehicle Indenti...

Page 22: ...Dealer for a replacement Some examples of warning caution labels are indicated on the following pages but there are many others not shown Also the contents of these labels may vary from model to mode...

Page 23: ...driver s SRS airbag passenger s SRS airbag 4 Passenger s SRS airbag model with passenger s SRS airbag 5 Brake fluid 6 4WD 2WD selection 4WD model 7 Free wheel hub 4WD model 8 Front propeller shaft lu...

Page 24: ...ter fuel tank only Warning Caution Labels Engine Compartment No Description 1 Engine oil level check 4JJ1 engine 2 Fuel Filter Element 4JJ1 engine 3 Engine oil 4JJ1 engine 4 Radiator cap 5 Engine cool...

Page 25: ...1 VEHICLE INFORMATION Chassis Number 1 2 Vehicle Identification Number 1 3 Engine Number 1 5 Change of Ownership or Address 1 6 2008N_sec01_print2 indd 1 3 09 2008 4 28 11 PM...

Page 26: ...cle They are also necessary when your vehicle undergoes official inspections Provide your Isuzu Dealer with these numbers when you are having the vehicle repaired or are ordering replacement parts The...

Page 27: ...rer Identifier WMI 2 Vehicle model code NLR 4 2 truck NLR model NNR 4 2 truck NNR model NPR 4 2 truck NPR model N1R 4 2 truck NQRmodel NPS 4 4 truck NPS model 3 Engine code 75 4HK1 Engine 85 4JJ1 Engi...

Page 28: ...There are more option codes than those indicated above Depending on the market an option code may not be shown For detailed specifications of your vehicle please ask your Isuzu Dealer Option Codes En...

Page 29: ...Number The engine number is stamped on the left side rear part of the engine block The engine number is stamped on the right side front part of the engine block 4JJ1 engine 4HK1 engine 2008N_sec01_pri...

Page 30: ...nty in order that you can be contacted if the need arises NOTICE OF NAME ADDRESS OWNERSHIP CHANGE Owner s Name Business Name Address City Town State Postcode Business Phone Private Phone Mobile Email...

Page 31: ...venting Breakdowns 2 56 When to Visit Your Isuzu Dealer 2 58 Diesel Particulate Defuser DPD 2 60 Model with Speed Limit Device V 2 63 Seat Belt with Pretensioner and SRS Airbag System V 2 64 Vehicle D...

Page 32: ...ubject to the exclusions below this warranty covers the correction during the warranty period of any vehicle defect in materials or workmanship and advised to an Isuzu dealer or IAL authorised service...

Page 33: ...harge is payable IAL reserves the right to refuse any claim under this Warranty on the grounds if it reasonably believes that a warranty exclusion applies or the vehicle was used in an application tha...

Page 34: ...proved by IAL or conforming to IAL s specifications Cosmetic or surface corrosion resulting from scratches stone chips etc Any work carried out on the vehicle by someone other than an authorised Isuzu...

Page 35: ...or IAL authorised service dealer Parts and Accessories not conforming to IAL specification Any parts or accessories not approved by IAL or not conforming to IAL specifications and all costs in connec...

Page 36: ...icle warranty is required to enable the vehicle to be operated safely and it is not practical for you to go to an Isuzu dealer the service but only to the extent that it is necessary to enable the veh...

Page 37: ...ioning refrigerant after 5 000 km Any necessary adjustments to drive belts transmissions clutch park brake etc Wheel balancing after 5 000 km Wheel alignment front rear De dusting or de glazing of bra...

Page 38: ...any purpose of any IAL product or in connection with the supply of any IAL product which is at variance with any written statement assertion or undertaking on any of these subjects given or made by I...

Page 39: ...ends on certain variables type and method of operation or application and the schedule of maintenance For example if a vehicle is repeatedly overloaded driven at excessive speed or improperly shifted...

Page 40: ...hrough your Isuzu Dealer please contact us on the Isuzu Customer Care toll free line 1800 035 640 To assist us in helping you please provide the following details when calling Your name and address Co...

Page 41: ...tration This free service is extended to you whether you are a private truck purchaser a fleet taxi truck or rental company or a Commonwealth State or Local Government customer Isuzu Assist is deliver...

Page 42: ...ll be provided Flat Battery An Isuzu Assist service provider will attempt a battery boost to start your truck If the original battery is found to be faulty and is still inside the term of the battery...

Page 43: ...e driver s expense to the same destination as the towed truck 3 Alternatively the Driver may elect to have the truck towed to an alternate destination However the driver must agree to accept any addit...

Page 44: ...ng recovery vehicle Bogged Trucks If your truck becomes bogged on a road which is considered to be legally trafficable to normal two wheel drive vehicles and where no special equipment is required Isu...

Page 45: ...le under the circumstances Damage during Service If you believe your truck has been damaged by a service person providing roadside assistance you should contact Isuzu Assist on 1800 947 898 The truck...

Page 46: ...abnormality the previous time the vehicle was driven have the vehicle repaired by the nearest Isuzu Dealer before it is driven again 1 Checking components that showed abnormalities during the previou...

Page 47: ...rn and turn signal lights 4 73 4 65 Fuel level 4 13 Operation of door locks 3 4 4 Checks performed during a walk around the vehicle Check item Reference page Illumination flashing or for stained or da...

Page 48: ...gine and the diesel particulate defuser DPD the exhaust emission cleaning system possibly leading to breakdown of the engine related systems If an incorrect fuel should accidentally be added drain all...

Page 49: ...rawn is dangerous because the auto stop mechanism may not work resulting in an overflow of fuel All parts of the refueling procedure from opening the fuel tank filler cap to completing the refueling a...

Page 50: ...e cargo unstable It can also cause an overload condition confined to a small area resulting in damage to the cargo bed and frame Overloading places undue strain on vehicle parts It can shorten the veh...

Page 51: ...ot allow long cargo to protrude beyond the rear edge of the cargo bed Rather use supports to raise it at an angle Avoid supporting it using just the front guard frame and the rear edge of the cargo be...

Page 52: ...uring it too tightly can damage the cargo bed s gates and front guard frame Economical Driving LNU720SH005201 Driving too fast driving so slowly that the engine knocks driving with the exhaust brake s...

Page 53: ...angles where they are easy to see When you load or unload cargo at the roadside select a place where stopping and parking are allowed and other drivers and passersby will not be inconvenienced Do Not...

Page 54: ...peration it is also essential to lay floor mats properly Incorrectly installed floor mats would hinder free movement of the pedals Do not use the dashboard pocket or the top of the dashboard as a plac...

Page 55: ...u to easily turn the steering wheel with your elbows slightly bent b Position the seatback so it is always touching your shoulders c Make sure you can adequately press each pedal Seat belt fastening c...

Page 56: ...You can adjust the position of the steering wheel in the up down and fore aft directions After making an adjustment make sure the steering wheel and lock lever are securely locked WARNING When you ha...

Page 57: ...l should get advice from a physician beforehand An expectant mother should use a three point seat belt An expectant mother should position the lap belt snugly as low as possible on the hips not across...

Page 58: ...the impact on the child seat during deployment of the passenger airbag could inflict life threatening injuries on the child NOTE The appropriate type of baby seat child seat or junior seat and the pro...

Page 59: ...oors Refer to page 3 7 Power Windows V Refer to page 3 10 An Adult must Open Close and Lock the Door for a Child WARNING To protect the child from the danger of getting his her hands and head trapped...

Page 60: ...orly ventilated It is particularly dangerous to run the engine in a garage or other indoor place that could easily fill with exhaust gases because you could suffer carbon monoxide poisoning Inspect th...

Page 61: ...firmly and make sure the gearshift indicator is showing N before starting the engine Be sure to sit in the driver s seat to start the engine If you are not sitting in the driver s seat if for example...

Page 62: ...emely hot while the engine is idling Before warming up the engine make sure there is no flammable material for example dry grass waste paper oil or old tyres near the exhaust pipe ADVICE Before using...

Page 63: ...Garage Parking Brake Warning Light Refer to page 4 51 Parking Brake Lever Refer to page 4 77 Do not Forget to Release the Parking Brake ADVICE Pulling away with the parking brake still applied can dam...

Page 64: ...oad Driving downhill In principle you should use the same gear s that you used to drive up the hill Drive at a speed that does not cause the engine to overrun exceed its r min limit and the tachometer...

Page 65: ...ing the engine while driving would be extremely dangerous because the power steering would stop working making the steering wheel extremely hard to turn Stopping the engine while driving would be extr...

Page 66: ...riving The lower the gear the stronger the engine brake What is the exhaust brake The exhaust brake is a system that closes the exhaust pipe and uses the force of the exhaust emissions to enhance the...

Page 67: ...What is hydroplaning If a vehicle is driven at high speed on a road that is covered with water a layer of water can form between the tyres and road surface causing the tyres to lose their grip and sl...

Page 68: ...and gently press the brake pedal several times until the brakes dry out and start working normally Before parking the vehicle in winter press the brake pedal several times in the same way to get rid o...

Page 69: ...ing overtaken by a large truck or bus overtaking a large truck or bus Dealing with a Blowout or Flat Tyre while Driving ADVICE If a blowout or flat tyre occurs while you are driving calmly grip the st...

Page 70: ...oken promptly have the vehicle inspected and repaired by the nearest Isuzu Dealer How to Read the Instruments Instrument Layout Refer to page 4 8 Warning and Indicator Lights Layout Refer to page 4 15...

Page 71: ...and apply the parking brake Immediately after engine startup while the air conditioner is running and during diesel particulate defuser DPD regeneration the engine speed rises making creep stronger th...

Page 72: ...dal check the pedal positions and practice putting your foot on the desired pedal To ensure reliable brake application be sure to use your right foot to press the brake pedal Pulling Away WARNING When...

Page 73: ...o look rearward so pedal operation becomes difficult Firmly press the brake pedal while twisting your body Also get in the habit of immediately returning the gearshift lever to the N position after re...

Page 74: ...se it could cause the vehicle to slip making the steering wheel useless Winter Tyres Refer to page 6 20 Using Tyre Chains Refer to page 6 22 LNU720SH002401 Four Wheel Drive 4WD Model V Driving on Snow...

Page 75: ...aler perform water ingress checks and where necessary greasing on the engine electrical components transmission propeller shaft differential and transfer case Driving through Water Drive type 2WD 4WD...

Page 76: ...ropriately depending on driving conditions Transfer Gear Control Switch V Gear Switching Method Use the transfer gear control switch to switch the gear from 2H 4H to 4L and vice versa Be sure to stop...

Page 77: ...light lenses and reflectors to ensure that the vehicle can be seen from other vehicles Parking Brake Lever Refer to page4 77 Parking Safely on a Slope LNU720SH002901 CAUTION Avoid parking your vehicle...

Page 78: ...n Otherwise any unintended contact with the gearshift lever or accelerator pedal while you are asleep could cause the vehicle to move resulting in an accident If you leave the engine running and unint...

Page 79: ...ser DPD may automatically start regeneration when the vehicle is stopped and parked with the engine running To prevent a fire make sure there is no flammable material near the muffler DPD and exhaust...

Page 80: ...e is not running the power steering system does not work so the steering wheel is hard to turn Also the brake booster does not work so there is little braking ability If you coast down a slope without...

Page 81: ...Has Been Parked WARNING When leaving the vehicle be sure to apply the parking brake stop the engine and lock the doors Do not leave valuables where they can be seen from outside the vehicle If you ar...

Page 82: ...safe to back up get out of the vehicle and check behind it LNU720SH004001 Reversing Pulling Away after a Temporary Stop CAUTION Make it a habit to look around and confirm that it is safe to pull away...

Page 83: ...particulate defuser DPD silencer and exhaust pipe are extremely hot Be careful not to inadvertently touch them when working near them for example tilting the cab or operating an attachment Otherwise...

Page 84: ...ident by acting as lenses Do not Use a Mobile Telephone while Driving CAUTION Drivers should never use mobile telephones or car phones in any mode other than Hands Free while driving Doing so is dange...

Page 85: ...t position Do not forget to first apply the parking brake and place chocks around the wheels When a rear wheel is jacked up the parking brake has no effect Failing to first put chocks in the correct p...

Page 86: ...isengage without you realizing it causing the clutch plates to wear and the clutch to slip Also do not slip the clutch as a way to hold the vehicle in position instead of using the brakes on for examp...

Page 87: ...poor lubrication oil tank damage and seal deterioration leading to power steering oil pump damage power steering unit damage and power steering hose damage As a result the steering wheel could become...

Page 88: ...ke pedal resistance and fire could unexpectedly result in an accident When to Visit Your Isuzu Dealer Do not Modify the Vehicle CAUTION Attaching parts that are not suitable for the vehicle s performa...

Page 89: ...hat are not the specified size Doing so would impede safe vehicle operation Electric Welding ADVICE Careless electric welding of vehicle parts can cause welding current to flow back through the vehicl...

Page 90: ...hanging the alignment length or diameter of the exhaust pipe would adversely affect the exhaust system s exhaust emission reduction function If any modification is necessary to install a component to...

Page 91: ...not indicate a fault Do not perform manual regeneration in any poorly ventilated indoor place When a new vehicle has been driven a certain distance it can emit white smoke during DPD regeneration The...

Page 92: ...ction Reference page White exhaust smoke Engine not sufficiently warming up Allow the engine to warm up 4 63 Too much engine oil Correct the oil level 7 24 Engine control system faulty Fuel system fau...

Page 93: ...is possible for the vehicle to exceed the set speed on downhill slopes If the tyre size is changed the speed limit device may not work normally Have adjustments made by your Isuzu Dealer NOTE The spe...

Page 94: ...passenger can suffer burns and other serious injuries on the arms and face No person riding in the vehicle should hold any object on his her lap or otherwise place any object between him herself and...

Page 95: ...er to the steering wheel pad would be dangerous because it could result in defective operation and cause the sticker to be propelled toward you in the event of airbag deployment Also do not affix any...

Page 96: ...adversely affected such that they fail to operate Any repair or replacement in the vicinity of the steering wheel instrument panel centre console clutch pedal or brake pedal Repair replacement or dis...

Page 97: ...has legal force EDR Records In the event that the vehicle suffers an impact or comes close to suffering an impact the EDR records the following data whether or not the driver s seat belt is fastened d...

Page 98: ...2 68 IMPORTANT INFORMATION 2008N_sec02_print2 indd 68 15 09 2008 10 37 02 AM...

Page 99: ...nsponder Chip V 3 3 Keyless Entry System V 3 4 Opening and Closing Doors 3 7 Power Windows V 3 11 Fuel Tank Filler Cap 3 13 Tool Box V 3 16 Seats 3 17 Fully Adjustable Steering 3 21 Mirrors 3 22 Seat...

Page 100: ...to the nearest Isuzu Dealer The Isuzu Dealer will be able to duplicate your key If you resell the vehicle be sure to hand over the plate with key code to the new owner together with the vehicle Both...

Page 101: ...e START position to start the engine There is a facility nearby that is emitting strong radio waves A metallic object is touching or covering the handle of the key Another vehicle s transponder key is...

Page 102: ...d or longer The vehicle s keyless entry system causes the right and left turn signal lights to simultaneously flash once upon receiving the signals from the remote control unit If the dome light is on...

Page 103: ...ng the unit from working If this happens wait for a while The system will then work normally If the keyless entry system fails to operate normally lock and unlock the doors using the key and have the...

Page 104: ...e battery holder with the mark side facing up and place the holder in position in the cover Replacing the Battery in the Remote Control Unit ADVICE When closing the cover check that there is no dust h...

Page 105: ...light or near a fire or other sources of heat Be sure to install the battery with the side up and the side down Incorrect installation will result in leakage of chemicals from inside the battery or ot...

Page 106: ...ore closing the door be sure to check that you have the key with you Locking and Unlocking the Door from Outside Using the Key Turn the key toward the front of the vehicle to lock the door and turn it...

Page 107: ...k all doors simultaneously Power Door Lock Central Door Lock V Locking the Door from Outside Push the door lock button forward and then close the door the door will be locked Locking and Unlocking the...

Page 108: ...ch lightly To Close the Driver s Window Lightly raising the driver side window switch will cause the driver s window to move up until the switch is released To Open the Passenger s Window The passenge...

Page 109: ...on Passenger s Door and Rear Doors CAUTION Be sure to warn passengers especially in the case of a child not to let any part of the body become trapped or caught in a moving window NOTE When the rear p...

Page 110: ...h the rear power window lock switch only the driver s window and front passenger s window will be openable To cancel the rear power window lock push the switch again CAUTION Use the rear power window...

Page 111: ...fuel or its mixture with a diesel fuel will badly affect the fuel filter and result in lubrication problems in fuel lubricated components of the injectors In addition this practice can also impair the...

Page 112: ...ank filler cap 2 Slowly turn the cap counterclockwise to open it 3 Refuel the tank 4 Align the grooves on the cap and tank and turn the cap clockwise to close it 5 Check that the cap is tightly closed...

Page 113: ...ank filler cap onto the fuel tank 6 Turn the key to the CLOSE position to lock the fuel tank filler cap 7 Pull the key out then make sure the fuel tank filler cap is securely closed WARNING If the fue...

Page 114: ...V The tool box is located on the vehicle s outer chassis either in the middle or near the rear CAUTION Securely close the tool box so the lid does not come open while the vehicle is moving 2008N_sec0...

Page 115: ...voided not only because the unlocked seat will move back and forth unstably preventing you from taking the correct position but might also cause you to lose control of the vehicle possibly resulting i...

Page 116: ...o check that it is fully locked Driver s Seat Reclining Adjustment To recline the seatback raise the seatback tilt lever and gently lean back to the desired position To move the seatback forward lean...

Page 117: ...revent the driver from operating the pedals Suspension Adjustment V Before sitting on the seat use the knob to adjust the suspension to suit your weight Turn the knob clockwise to move the pointer dow...

Page 118: ...oard tools CAUTION Do not drive with the seat cushion removed The seat would not be stable which could lead to an accident Tools Refer to Page 7 7 NOTE The rear seat headrests are not adjustable Do no...

Page 119: ...Firmly lock the steering wheel at the selected position by moving the lock lever to the lock position Fully Adjustable Steering WARNING After adjusting the steering wheel try moving it up and down to...

Page 120: ...ehicle is stationary not while the vehicle is in motion After properly adjusting your seat for the correct driving position adjust the mirrors indicated below so that they provide adequate views for c...

Page 121: ...e on a narrow road moving the vehicle into a garage or driving near pedestrians Do not drive with the mirrors folded The protection provided by seat belts might be significantly reduced if they are no...

Page 122: ...in the event of a collision or sudden stop Instead use an appropriate child restraint system available on the market For further details please contact your Isuzu Dealer Use a child restraint system...

Page 123: ...ocks and restrains the occupant during forward force caused by the occupant s body following a strong shock Adjust the driver s shoulder belt for proper position by means of the shoulder anchor To Fas...

Page 124: ...could damage a nearby window or interior trim unless the latch plate is properly held Hold the latch plate to ensure that the belt is taken up slowly Before closing the door check that the retracted s...

Page 125: ...limiter allows the seat belt to extend while maintaining the load working on the belt at a constant level This helps alleviate the shock applied on the occupant s chest Seat Belt with Pretensioner an...

Page 126: ...t right angles with the belt makes this easier 3 After checking that there are no twists in the belt insert the latch plate into the buckle until it clicks 4 Position the seat belt across the lap as l...

Page 127: ...t it cannot be connected with any of the window side seat belts three point seat belts with ELR In addition both the latch plate and buckle of the centre seat belt are identified by CENTER marks to pr...

Page 128: ...3 30 DOORS WINDOWS AND SEATS 2008N_sec03_print2 indd 30 3 09 2008 4 35 57 PM...

Page 129: ...4 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE 4 3 INSTRUMENTS WARNING LIGHTS AND INDICATOR LIGHTS 4 7 SWITCHES 4 59 DRIVING CONTROLS 4 75 2008N_sec04 1_print2 indd 1 3 09 2008 5 27 55 PM...

Page 130: ...2008N_sec04 1_print2 indd 2 3 09 2008 5 27 57 PM...

Page 131: ...4 3 CONTROLS AND INSTRUMENTS STARTING AND STOPPING THE ENGINE Starting the Engine 4 4 Stopping the Engine 4 6 2008N_sec04 1_print2 indd 3 3 09 2008 5 27 57 PM...

Page 132: ...sition If your vehicle is equipped with a AMT system firmly engage the parking brake when you sit in the driver s seat check that the gearshift lever is in the N position and the shift indicator shows...

Page 133: ...n the N position and firmly press the brake pedal 2 When the starter switch is turned to the ON position the glow plug indicator light comes on and it goes out in about 0 5 seconds when the engine is...

Page 134: ...arshift lever is in the N position and the shift indicator shows N a AMT equipped model To prevent the battery from going dead turn the starter switch to the ACC or LOCK position after stopping the en...

Page 135: ...yout 4 8 Speedometer 4 9 Analog Tachograph V 4 11 Tachometer 4 11 Engine Coolant Temperature Gauge 4 12 Fuel Gauge 4 13 Hour Meter V 4 14 Warning and Indicator Lights Layout 4 15 Multi Information Dis...

Page 136: ...i Information Display MID 4 17 3 Speedometer 4 9 4 Fuel gauge 4 13 No Name Reference page 5 SA Shift indicator 4 79 6 Engine coolant temperature gauge 4 12 7 V Analog Tachograph 4 11 How to Read the I...

Page 137: ...layed Trip Meter Use the trip meter to learn the distance between the specific points or the distance traveled during a specific period of time In the case of a speedometer graduated in kilometers the...

Page 138: ...each time you turn the starter switch to the ON position To do this turn the starter switch to the LOCK or ACC position while the odometer is being displayed and then with the select reset knob press...

Page 139: ...dangerous engine speeds beyond permissible levels Do not drive your vehicle with the needle of the tachometer in the red zone Tachometer ADVICE Exercise extreme caution when shifting down on a steep d...

Page 140: ...above the upper limit of the safety zone and enters the H zone while you are driving the engine is likely to overheat Immediately pull safely off the road out of the way of any traffic and take the ne...

Page 141: ...fter the starter switch is turned to the ON position If the fuel tank is filled while the engine is off but the starter switch is in the ON position the fuel gauge needle takes a while to show the cor...

Page 142: ...the left side of the decimal point indicate hours while the figure on the right side indicates 1 10 of an hour This is displayed on the MID Use the MID select knob to select the hour meter Multi Info...

Page 143: ...4 15 CONTROLS AND INSTRUMENTS Warning and Indicator Lights Layout Model without multi information display MID Model with MID 2008N_sec04 1_print2 indd 15 3 09 2008 5 28 08 PM...

Page 144: ...ght 4 51 15 Brake booster warning light 4 36 No Name Reference page 16 V MID 4 17 17 Generator warning light 4 42 18 V PTO indicator light 4 55 19 High beam indicator light 4 51 20 V ABS warning light...

Page 145: ...ing or indicator lights indicated on the MID can be temporarily cleared for 60 seconds by pressing the MID select knob once However if the warning light you have cleared is an engine overheat warning...

Page 146: ...in Routine This page shows you the basic screens of the MID and what operations are necessary to access these screens Use the MID select knob to select the desired screen or function 2008N_sec04 1_pri...

Page 147: ...4 19 CONTROLS AND INSTRUMENTS 2008N_sec04 1_print2 indd 19 3 09 2008 5 28 11 PM...

Page 148: ...d 4 158 Amber System is checking if selectable regeneration of DPD is possible 4 159 Amber DPD is being manually regenerated 4 156 Amber Manual regeneration of DPD is needed 4 155 Amber Fuel level is...

Page 149: ...s function displays vehicle operation related information on such items as fuel economy battery voltage calendar and clock which is useful for efficient management of your vehicle operation Operation...

Page 150: ...immediately after the engine is started an abnormal L voltage red letters on a black background may be indicated on the MID If the warning disappears after the engine has started there is no problem...

Page 151: ...ockwise to decrease the year If you hold the switch after turning it clockwise or counterclockwise the year continues to increase or decrease until the switch is released 4 Set the month While in the...

Page 152: ...reen The minute segment starts flashing 6 Turn the MID select knob clockwise to increase the minutes and counterclockwise to decrease the minutes If you hold the switch after turning it clockwise or c...

Page 153: ...er is set to ON MID is dimmed while the headlights are on Use the MID select knob to select the night time dimmer If the MID is too dark when driving with the headlights on during daytime set the nigh...

Page 154: ...ed Diesel Particulate Defuser DPD State When ERROR is Displayed Refer to page 4 33 Message Display indication Color Display condition DPD PM accumulation level Green The current level of PM accumulati...

Page 155: ...progressed to 4th step Regeneration progressed to 2nd step Regeneration progressed to 5th step Regeneration progressed to 3rd step Regeneration complete Status Display Status Display PM level 0 PM lev...

Page 156: ...ible Maintenance Data ADVICE The displayed distance represents the interval for each maintenance item before or after the expiration of the scheduled maintenance When the next scheduled maintenance is...

Page 157: ...next AMT clutch oil change is displayed 4 46 Amber This is displayed when the next change of AMT clutch oil is near or has already been reached Fuel filter Green Distance remaining until the next fuel...

Page 158: ...ance item for which you want to adjust 2 Enter the setting change screen by pressing and holding the MID select knob 3 Pressing and holding the MID select knob sets the new change time distance NOTE I...

Page 159: ...nce Turn counterclockwise Decrease distance The distance increases or decreases by 5 000 km increments 4 Complete the setting by pressing and holding the MID select knob NOTE Your vehicle has been shi...

Page 160: ...t knob NOTE Your vehicle has been shipped from the factory with no warning speed set Therefore the initial indication on the SPEED WARNING screen is OFF Over Speed 1 On the multi information display M...

Page 161: ...r maintenance indication have your vehicle inspected serviced at the nearest Isuzu Dealer When ERROR is Displayed Per trip fuel economy Instantaneous fuel economy Total fuel economy State of progress...

Page 162: ...on when the driver is not wearing the seat belt while the starter switch is in the ON position SRS Airbag Warning Light V The SRS airbag warning light should flash seven times when the starter switch...

Page 163: ...en should go out after the engine is started The brake system warning light comes on while the engine is running after startup in the following situations Drop in the level of brake fluid due to brake...

Page 164: ...models When the hydraulic brake booster pressure is low and or the hydraulic brake booster fluid DEXRON III level is low the light and warning buzzer alarm should come on Do not use brake fluid in the...

Page 165: ...ons With the engine still running turn off the exhaust brake switch A problem in the exhaust brake system will be confirmed if the warning light goes out in several seconds If the warning light does n...

Page 166: ...Display MID The display will show this warning light when the vehicle speed approaches the speed that was set on the SPEED WARNING screen of the MID CAUTION If this warning light comes on while drivi...

Page 167: ...cle and take necessary actions WARNING When the coolant is still hot do not remove the radiator cap Hot vapor will come out and you may be scalded Add coolant only when the coolant temperature has dro...

Page 168: ...ght amber has come on have the vehicle inspected serviced at your Isuzu Dealer Multi Information Display MID V Refer to page 4 17 When ERROR is Displayed Refer to page 4 33 Engine Oil Refer to page 7...

Page 169: ...l Filter Refer to page 7 28 Model with Multi Information Display MID This warning light appears on the display when the engine oil level is too low Air Cleaner Indicator Light V Model with MID This in...

Page 170: ...light comes on while the engine is running immediately pull off to a safe place well clear of traffic and promptly contact the nearest Isuzu Dealer for inspection Check Engine Warning Light This warni...

Page 171: ...he display a model with MID when water in the water separator fuel filter needs draining Drain water following the instructions in the Draining Water from the Fuel Filter and make sure the warning lig...

Page 172: ...inspected as soon as possible at the nearest Isuzu Dealer If this warning light flashes while driving the AMT oil is abnormally hot Pull off to a safe place well clear of traffic as soon as possible D...

Page 173: ...ssing the maintenance interval When the maintenance is near or has already been reached this message appears after the starter switch is turned to the ON position The message remains on the display un...

Page 174: ...ce interval When the maintenance interval is near or has already been reached this message appears after the starter switch is turned to the ON position The message remains on the display until the MI...

Page 175: ...tenance interval When the maintenance interval is near or has already been reached this message appears after the starter switch is turned to the ON position The message remains on the display until t...

Page 176: ...aintenance interval When the maintenance interval is near or has already been reached this message appears after the starter switch is turned to the ON position The message remains on the display unti...

Page 177: ...e maintenance interval When the maintenance interval is near or has already been reached this message appears after the starter switch is turned to the ON position The message remains on the display u...

Page 178: ...ly if bulbs of incorrect wattage are used Low Fuel Warning Light This warning light comes on a model without multi information display MID or the message appears on the display a model with MID when t...

Page 179: ...een high and low beams passing signal Light Control Switch Refer to page 4 64 Parking Brake Warning Light This warning light comes on when the parking brake lever is pulled up CAUTION The illumination...

Page 180: ...icator Light V This indicator light comes on when the hill start aid HSA system is in operation The indicator light flashes and a buzzer sounds if you leave your seat while the HSA is in operation the...

Page 181: ...ndicator light should come on and change color from amber to green before it goes out 2 seconds later This indicator light stays on green while the anti slip regulator ASR is in operation This indicat...

Page 182: ...e Refer to page 4 88 This indicator light comes on when the cruise control main switch is placed in the ON position This indicator light comes on when the starter switch is turned to the ON position a...

Page 183: ...tor Light V DPD Indicator Light Model without Multi Information Display MID The DPD automatic regeneration indicator light green comes on while the DPD is being automatically regenerated This indicato...

Page 184: ...with MID When the AUTO REGEN green message appears on the display the DPD is under automatic regeneration When the PUSH DPD SWITCH amber message is flashing the DPD needs to be manually regenerated Wh...

Page 185: ...d Meter Failure V Model with MID This message appears on the display when there is a problem with the instrument panel While the message is displayed the instrument panel does not function properly Pu...

Page 186: ...Model without MID Hill start aid HSA V Refer to page 4 106 Refer to page 4 106 AMT SA Refer to page 4 91 Refer to page 4 91 Long lasting alarm No alarm Refer to Condition column Warning Buzzer A warni...

Page 187: ...4 64 Headlight Leveling Switch V 4 66 Front Fog Light Switch V 4 67 Rear Fog Light Switch V 4 68 Hazard Warning Flasher Switch 4 68 Exhaust Brake Switch 4 69 Windshield Wiper and Windshield Washer Sw...

Page 188: ...locks the steering wheel This is extremely dangerous ADVICE After starting the engine do not turn the starter switch to the START position Otherwise the starter motor may be damaged Using electrical d...

Page 189: ...s position the audio and other accessories can be used with the engine stopped ON The key stays in this position while the engine is running This position is also used for preheating before starting t...

Page 190: ...to move suddenly during standing start or it will consume more fuel during subsequent driving or have a shortened clutch life Never forget to fully turn the idling control knob back to the lowest spe...

Page 191: ...ndicator light on the instrument panel comes on and the engine warms up faster After the engine has warmed up press the switch again to turn the warm up system to the OFF position The indicator light...

Page 192: ...y go dead making it impossible to restart the engine Name Position Headlight OFF OFF ON ON Clearance light ON Taillight License plate light Illumination light control Rear fog light V OFF OFF Switchin...

Page 193: ...the high beam indicator light on the instrument panel comes on and off Use this function as a signal for flash to pass a vehicle or other purposes When turning left or right move the lever up or down...

Page 194: ...d that you may be involved in an accident Cornering Light V During nighttime the cornering light illuminates the area to which the vehicle is turning With the headlights on the clearance lights come o...

Page 195: ...on To turn off the lights press the switch again The front fog lights are useful when forward visibility is poor such as in fog WARNING When replacing a front fog light bulb do not use one of a large...

Page 196: ...VICE Do not leave the hazard warning flasher operating for an extended time period with the engine stopped Otherwise the battery may go dead making it impossible to restart the engine LNU740SH002501 R...

Page 197: ...a stop The exhaust brake reengages when gear shifting is completed or when the engine speed increases sufficiently ADVICE If a warning buzzer sounds when the exhaust brake is in operation promptly pul...

Page 198: ...not depressed When you pull the exhaust brake switch toward you while driving the exhaust brake indicator light on the instrument panel comes on and strong engine brake is applied Under the following...

Page 199: ...when excessive load is applied on the motor In this case turn the switch to the OFF position and a few minutes later check to see if the wiper is back to normal operation If the wiper frequently stops...

Page 200: ...ed for more than 30 seconds Otherwise the washer pump may sustain damage If windshield washer fluid does not come out release the windshield washer switch immediately Otherwise the motor may seize up...

Page 201: ...tor switch on the L or R side to move the mirror to the desired direction 2 Press the angle adjustment switch to adjust the mirror angle ADVICE Do not try to forcefully move the mirror surface by hand...

Page 202: ...irror heater The mirror heater indicator light amber comes on Press the switch again to turn it to OFF The mirror heater indicator light goes out ADVICE Do not use the mirror heater while the engine i...

Page 203: ...V 4 108 Hydraulic Brake Booster HBB V 4 113 Anti lock Brake System ABS V 4 115 Electronic Braking force Distribution EBD V 4 119 Anti Slip Regulator ASR V 4 120 Four Wheel Drive 4WD Model V 4 124 Pow...

Page 204: ...omponents as well as fuel economy may be badly affected If your vehicle has a manual transmission do not drive with your foot resting on the clutch pedal Doing so may damage the clutch Pedals WARNING...

Page 205: ...arked facing up a hill place the gearshift lever in the 1 1st gear and if parked facing down a hill place the lever in the R reverse gear In addition chocks must always be applied in either of these s...

Page 206: ...nto R Reverse the back up lights come on and in a model with back up warning a buzzer will also sound ADVICE Make a shift into the reverse gear from a forward gear or into a forward gear from the reve...

Page 207: ...ressing the push button Push button Reverse Model with AMT SA Move the gearshift lever to make it shift into each gear WARNING When operating the gearshift lever while the vehicle is stationary fully...

Page 208: ...ange the gear When the vehicle is stationary with the engine running the shift lock function works for safety You cannot move the gearshift lever from N into D or R without depressing the brake pedal...

Page 209: ...the air conditioning is in operation or the diesel particulate defuser DPD is being regenerated This makes the transmission produce a stronger creeping force than usual You need to firmly depress the...

Page 210: ...utomatic gearshift 3 Make sure that the shift indicator indicates D or R at the left upper portion release the parking brake release the brake pedal and then slowly press the accelerator pedal The veh...

Page 211: ...to start the vehicle change to 1st start mode 3 Make sure that the shift indicator indicates D or R at its left upper portion check the surrounding area to make sure it is safe to move the vehicle ea...

Page 212: ...d by depressing the brake pedal placing the gearshift lever into M and moving the lever towards downshift When stopping the vehicle to wait for a traffic light it is recommended that you place the gea...

Page 213: ...er into the D position Make sure that D is displayed on the upper left of the shift indicator ADVICE Shift into the gear appropriate for the vehicle speed If an inappropriate gear shift position is se...

Page 214: ...vehicle must be stationary for several minutes set the parking brake CAUTION When leaving the driver s seat be sure to place the gearshift lever into the N position make sure that the shift indicator...

Page 215: ...position Make sure the shift indicator displays 1 or R 2 Stop the engine and slowly ease your right foot off the brake pedal 3 Make sure the vehicle does not move Be sure to block the wheels with choc...

Page 216: ...the normal start mode 2nd start mode by pressing the 1st start switch again 1st Start Mode CAUTION The transmission shifts when you press the 1st start switch while the vehicle is stationary Fully de...

Page 217: ...manual mode is still retained To enable automatic gear shifting to take place drive the vehicle and then stop it or press the 1st start switch again to re select the 1st start mode or return the tran...

Page 218: ...ctive the ECONO mode indicator light will go out When the transmission is changed from manual mode back to auto mode the gearshift lever is moved from M to D the ECONO mode resumes and the ECONO mode...

Page 219: ...Release the accelerator pedal and apply the brakes The vehicle continues to be driven in an inappropriate gear Short repeated beeps Release the accelerator pedal or shift down to an appropriate gear...

Page 220: ...at low speed in a higher gear Short repeated beeps Choose a suitable gear when driving in manual mode AMT emergency switch is in the ON position Flashes Turn the AMT emergency switch OFF The AMT adju...

Page 221: ...ng brake lever and place the gearshift lever into the N position 2 Press the FAST side or SLOW side of the AMT adjustment switch If you feel the clutch slip press the FAST side If you feel the clutch...

Page 222: ...o 3 times When you feel the clutch engage abruptly 2 to 3 times CAUTION If it is not possible to make a full adjustment within the adjustable range 4 stages have the default setting checked at the nea...

Page 223: ...ys N Then push the vehicle to move it to a safe place If the shift indicator displays any position other than N press the AMT emergency switch to the ON position and place the gearshift lever into the...

Page 224: ...the AMT warning light flashes 4 Start the engine while fully depressing the brake pedal Release the parking brake and then place the gearshift lever into D or M for a forward movement or into R for a...

Page 225: ...n be sure to keep the brake pedal depressed When the emergency switch is in the ON position the engine can be started even with the gearshift lever in a position other than N When the engine is starte...

Page 226: ...e until the HSA is deactivated The HSA works only while the engine is in operation Hill Start Aid HSA V LNU740SH003801 Press this switch when deactivating the HSA The HSA stops working Pressing the sw...

Page 227: ...akes seem to be dragging 2 to 3 times Vehicle tends to move down on a slope 2 to 3 times Brakes are dragging 3 to 5 times Vehicle moves down on a slope 3 to 5 times HSA Adjustment Switch CAUTION If th...

Page 228: ...e HSA indicator light in the meter panel comes on When the HSA OFF switch remains ON the HSA indicator light does not come on HSA OFF Switch Refer to page 4 98 3 Pull the parking brake Confirm deactiv...

Page 229: ...vated a buzzer sounds to alert you If the brake pedal is not pressed down sufficiently when on a steep downslope the vehicle may move In such a case depress the brake pedal down further The HSA is act...

Page 230: ...of HSA Refer to page 4 102 When the parking brake lever is pulled up When the HSA OFF switch is pressed into the ON position When the starter switch is placed into the ACC or LOCK position Adjustment...

Page 231: ...t comes on and then depress the clutch pedal and place the gearshift lever into a position other than N 3 If the HSA releases the brakes too slowly and the brakes drag when starting the vehicle press...

Page 232: ...vehicle is started The control unit of the HSA is replaced Adjustment 1 Pull the parking brake lever make sure the gearshift lever is placed in the N position and then start the engine 2 Depress the c...

Page 233: ...the HSA adjustment switch so that the brakes are released at the appropriate time ADVICE Perform the series of operations while the parking brake is firmly set After placing the gearshift lever into t...

Page 234: ...tor light and buzzer are activated Flashes Short repeated beeps Stop the vehicle safely and deactivate the HSA using the HSA OFF switch Flashes On Beep continuous Starter switch LOCK or ACC warning Th...

Page 235: ...a gradient of 10 or higher if the vehicle is loaded up to the rating limit When stopping the vehicle for a long time set the parking brake rather than relying on the HSA If you suspect a problem with...

Page 236: ...e Control V WARNING Do not use the cruise control function on the following roads where using it could be dangerous A road with a heavy traffic such as an urban road A road that includes sharp curves...

Page 237: ...erate the switch is set in the system enabling you to drive with the set speed automatically maintained without using the accelerator pedal At the same time the cruise control set indicator light come...

Page 238: ...temporarily to pass another vehicle while driving using the cruise control depress the accelerator pedal When you release the accelerator pedal the speed returns to the original set vehicle speed Cha...

Page 239: ...lowing cases When the brake pedal is depressed When depressing the clutch pedal manual transmission model When applying the exhaust brake When the vehicle speed decreases to approx 40 km h 25 MPH or l...

Page 240: ...Driving Auxiliary Brake Function Automatic activation of the auxiliary brake exhaust brake during cruise control driving suppresses an increase in the speed on a downhill slope decreasing the need for...

Page 241: ...ON If the brake booster warning light comes on or a warning buzzer continues to sound there may be a problem with the HBB If this warning light comes on while driving immediately pull off to a safe pl...

Page 242: ...pending on temperature changes in the accumulator During auto charge a hissing and clicking sound can be heard This is not a malfunction With the engine running a booming sound can be heard during har...

Page 243: ...ng a proper distance between vehicles ABS does not prevent accidents if you do not drive safely Drive the vehicle at a safe speed Install tyres of the specified size same brand and same tread design i...

Page 244: ...he brake is applied during cornering or driving over a bump This is because inside wheels or wheels that have gone over a bump tend to lock ABS is not activated immediately after starting the vehicle...

Page 245: ...ulty Please contact the nearest Isuzu Dealer If the ABS warning light comes on during driving The light does not come on when the starter switch is placed into the ON position Even if a problem has oc...

Page 246: ...ing a standing start acceleration and cornering which do not involve braking On a very slippery icy road tyres may lose grip and steering wheel operation may not be able to control the vehicle s direc...

Page 247: ...EBD V CAUTION If a problem should occur with the EBD function the ABS warning light and the brake warning light will come on simultaneously The rear wheels will lock more easily if there is a problem...

Page 248: ...th the ASR equipped model when driving on a snowy or icy road carefully drive the vehicle installing tyre chains or winter tyres ASR is not a device to drastically improve the vehicle starting perform...

Page 249: ...When the switch is pressed again the ASR function turns back on ASR OFF Switch ADVICE When you turn off ASR it will not be available to assist you in slippery driving conditions Always use caution wh...

Page 250: ...ht amber comes on NOTE If the ASR indicator light does any of the following ASR may be faulty Please contact the nearest Isuzu Dealer When the ASR indicator light green remains on while driving on a f...

Page 251: ...e behavior Always drive the vehicle observing a safe speed well matched to the road surface and tyre conditions and also avoid speeding Even if ASR is equipped avoid sudden operation of the accelerato...

Page 252: ...ed and disconnected Freewheel Hub CAUTION Whenever driving in 4WD mode confirm that the knobs on the freewheel hubs are set to the LOCK position Do not press the 4WD switch when driving with the knobs...

Page 253: ...eels are disconnected from the drive shaft during driving in 2WD mode rotation of the front wheels will not be transferred to the front drive system As a result noise and friction levels can be reduce...

Page 254: ...ow covered icy steep or other roads that cannot easily be negotiated with 2WD CAUTION Driving in 4WD mode on dry well paved roads can accelerate wearing of the front tyres and reduce fuel efficiency A...

Page 255: ...ad or highway LOW Press this side for driving on a snowy road icy road steep slope or rough terrain ADVICE Do not operate the transfer gear control switch while driving Be sure to bring the vehicle to...

Page 256: ...DPD regeneration or upon startup of a cold engine when the quick warm system is activated The PTO cannot be engaged during fast idle control immediately after cold engine startup or when the engine s...

Page 257: ...rking brake lever and with the vehicle at a complete stop set the gearshift lever in the N position Then start the engine 2 Press the PTO switch and while the buzzer is making short repeated beeps low...

Page 258: ...witch and then operate the PTO lever within approximately 10 seconds If it is not possible to operate the PTO lever within approximately 10 seconds press the PTO switch once again and then operate the...

Page 259: ...ng the lock button in order to engage the PTO 3 Slowly remove your foot from the clutch pedal To Disengage the PTO 1 While depressing the clutch pedal press the lock button on the PTO lever and move t...

Page 260: ...e to short slow beeps and the clutch will automatically engage 4 Operate the special equipment s control switch Switch type PTO SA To Disengage the PTO Press the PTO switch The warning buzzer will beg...

Page 261: ...time the PTO indicator light in the instrument panel will come on ADVICE If the PTO switch is set to the ON position immediately after pressing down the clutch pedal a gear grinding noise may occur or...

Page 262: ...sure that the PTO indicator light in the instrument panel goes out and PTO drive is stopped 2 Slowly remove your foot from the clutch pedal CAUTION Before starting the vehicle you should confirm the f...

Page 263: ...on Be sure to press and hold the lock button when operating the dump control lever To Lower the Dump Body Shown with a thick line in the drawing at left is the lever position to lower the dump body No...

Page 264: ...e dump control lever cannot be secured in this position using the lock button CAUTION The dump control lever cannot be secured in the Temporary Stop position This position must be used only to stop ra...

Page 265: ...cold engine when the quick warm system is activated The PTO cannot be engaged during fast idle control immediately after cold engine startup or when the engine speed is increased with the idling contr...

Page 266: ...e dump body will rise Once the dump body has reached the highest possible position it will stop automatically ADVICE Simply operating the dump control lever alone will not cause the dump body to rise...

Page 267: ...rshift lever in N Then start the engine 2 Depress the clutch pedal fully and after waiting for a short time move the dump control lever to the UP position 3 Slowly remove your foot from the clutch ped...

Page 268: ...posts to prevent the dump body from falling CAUTION When the dump body is to be left in the raised position for cleaning inspection or the like always position the vehicle on a level surface fully eng...

Page 269: ...as been moved to the DOWN position This does not indicate any abnormal condition The gear grinding noise can be avoided however by returning the lever to the DOWN position pressing the PTO switch to s...

Page 270: ...the cargo bed These operations should be performed only when the dump body has been fully lowered Avoid raising the dump body when a bottom hinged gate is open If this precaution is not observed the g...

Page 271: ...njury due to impacts resulting from the seat belt with pretensioner and airbag operation Operation Check MFU8Z0SH026801 Airbag assembly for driver seat The SRS airbag warning light should flash seven...

Page 272: ...off in the event of system activation Attaching stickers or placing such things as accessories or air fresheners on the top surface of the instrument panel is also dangerous They may prevent normal o...

Page 273: ...receives an impact exceeding a certain level during a frontal collision the pretensioner causes the seat belt to be retracted instantly and removes the slack in the seat belt to securely restrain the...

Page 274: ...a slight bruise or burn due to heat generated by rubbing When the vehicle receives an impact exceeding a certain level resulting in airbag deployment deformation of the vehicle may cause the windshie...

Page 275: ...deformation of and damage to the vehicle do not necessarily coincide with the activation of the airbag When and How the Seat Belt with Pretensioner and SRS Airbag System Operates When are the Seat Be...

Page 276: ...ioner and SRS airbag system are less likely to be activated even if they are working properly When the vehicle gets under an obstacle or vehicle When the vehicle collides against a utility pole or sta...

Page 277: ...speed When the vehicle becomes airborne and hits the ground receiving a strong impact on the bottom of the vehicle When are the Seat Belt with Pretensioner and SRS Airbag System Activated Other than...

Page 278: ...es the seat belt with pretensioner and airbag system are not activated even if they are working properly When the vehicle is hit from the side When the vehicle is hit from the rear LNU740SH005501 LNU7...

Page 279: ...vehicle equipped with an airbag system consult your Isuzu Dealer CAUTION Have your vehicle inspected at the nearest Isuzu dealer at once in the following cases When the SRS airbag warning light does...

Page 280: ...bag do not allow the passenger to put his her hands or feet on the instrument panel and to sit with his her face or chest close to it When the airbags are activated you or the passenger may suffer a b...

Page 281: ...n and hit your face Doing so also hinders normal activation of the airbag which is dangerous Do not wet the airbag sensor with water or subject it to an impact The system may malfunction this is very...

Page 282: ...when the PUSH DPD SWITCH message amber flashes if your vehicle is equipped with MID the flashing occurs at about one second intervals and is accompanied by short repeated beeps of a warning buzzer Pe...

Page 283: ...l flash if your vehicle is equipped with MID Promptly take the manual regeneration steps according to the instructions described later The manual regeneration is necessary to recover the DPD function...

Page 284: ...into the N position and firmly engage the parking brake In a AMT model place the gearshift lever into the N position confirm the N indication and securely pull the parking brake 3 Run the engine at i...

Page 285: ...rily produced from the exhaust pipe This results from combustion of PM it does not indicate a failure Manual regeneration will complete earlier immediately after driving than when the engine is cold T...

Page 286: ...tomatic Regeneration of DPD NOTE The engine speed may increase and the exhaust brake may activate while the vehicle is stopped with the engine idling When this occurs the DPD is automatically regenera...

Page 287: ...ure and exhaust pipe are still warm such as when the day s operation is finished Procedure for Selectable Regeneration of DPD CAUTION Perform the selectable regeneration until it is completed without...

Page 288: ...ssage amber does not change to a flashing PUSH DPD SWITCH message amber if your vehicle is equipped with MID In either case the DPD does not require regeneration so it ignores the DPD switch operation...

Page 289: ...ing to operate or being disengaged will produce a sound but this does not indicate a failure During regeneration white smoke may be temporarily produced from the exhaust pipe This results from combust...

Page 290: ...4 162 CONTROLS AND INSTRUMENTS 2008N_sec04 2_print2 indd 162 3 09 2008 5 32 21 PM...

Page 291: ...21 Cigarette Lighter 5 22 Ashtray V 5 23 Small Article Storage Pocket V 5 25 Card Holder 5 25 Glove Compartment V 5 26 Centre Console Box V 5 26 Overhead Tray V 5 27 Cup Holder V 5 27 Back Panel Tray...

Page 292: ...Air flow direction adjustment tab No Outlet Features 1 Driver side outlet Air flow direction is adjustable with the tab 2 Passenger side outlet Air flow direction is adjustable with the tab 3 Door wi...

Page 293: ...tlets 5 Feet door windows and windshield Air flows through outlets 5 and some through outlets 3 and 4 Feet door windows and windshield Air flows through outlets 5 and air of a greater volume than in p...

Page 294: ...to any of the 4 speeds available Lever position Purpose Outside air ventilation Use this position to ventilate the cab s interior This position should be normally selected Inside air recirculation Us...

Page 295: ...Knob position Air delivery Outlet Face Air flows through outlets 1 and 2 Bi level Air flows through outlets 1 2 and 5 Feet Air flows through outlets 5 Feet and defroster 1 Air flows through outlets 5...

Page 296: ...show that the air conditioning system is in operation The air conditioning system can also be used for dehumidifying while the heater is being used NOTE Even if the A C switch is turned on the air con...

Page 297: ...or position Use the position for warming your feet while defogging the windshield Set the air selector lever 2 to the position Adjust the temperature control knob 3 and the fan speed control knob 4 to...

Page 298: ...osition Turn on the warm up switch if equipped Warm Up Switch V Refer to page 4 63 NOTE Extended use of the inside air recirculation position causes the windshield and windows to fog up easily making...

Page 299: ...Set the fan speed control knob 4 to any speed position not the OFF position If your vehicle is equipped with an air conditioning system using the dehumidifying effect of the system is very effective f...

Page 300: ...te cooling Adjust the temperature control knob 3 to the desired position Adjust the fan speed control knob 4 as desired Cooling NOTE When using the air conditioning system with the engine idling in ex...

Page 301: ...ght open the windows or doors to ventilate the cab s interior and release the heat before turning the air conditioning system on Prolonged use of the air conditioning system in the maximum cooling set...

Page 302: ...Air selector switch 7 Defroster switch 8 Air conditioning switch A C 9 Outlet selector switch MODE switch 1 Automatic air conditioning switch AUTO switch Press this switch to use the air conditioning...

Page 303: ...outside temperature on the display However a temperature higher than the actual outside air temperature may be displayed under the following conditions The traffic is congested or the vehicle is stat...

Page 304: ...ch Use this switch to turn the air conditioning on or off If the A C switch is pressed during fully automatic mode operation the AUTO and A C indications will disappear from the display Pressing it ag...

Page 305: ...rature at 18 C 64 F the system invariably sets the control for maximum cooling if you set it at 32 C 90 F the system sets the control for maximum heating When you press the OUTSIDE switch OUTSIDE will...

Page 306: ...automatic air conditioning mode press the AUTO switch 1 Outside Air Ventilation Press the A C switch 8 to turn off the air conditioning system The A C indication on the display will go out Select the...

Page 307: ...ulation than when it is showing the sign outside air ventilation Press the MODE switch to select the desired air outlets If you press the switch so that the or sign appears on the display you can defo...

Page 308: ...on to turn the air conditioning system on CAUTION After defrosting make sure to press the air selector switch so that the sign outside air introduction will be shown on the display Failure to do so wi...

Page 309: ...ws or doors to ventilate the cab s interior and release the heat before turning the air conditioning system on Prolonged use of the air conditioning system in the maximum cooling setting will make the...

Page 310: ...emoved from the starter switch OFF The light stays off regardless of the doors being open or closed Rear Light Crew Cab Model The dome light operates regardless of the starter switch position To make...

Page 311: ...sunlight is too bright To reduce side glare unhook the sun visor and swing it around to the side Sun Visor CAUTION For safety make sure to fold up the sun visor after use Driver s side Passenger s sid...

Page 312: ...orce It may become bent Keep the cigarette lighter socket and the heater free of ash and dirt WARNING As the lighter s tip can become extremely hot take due precautions against burns Do not leave your...

Page 313: ...ette butt has not been extinguished completely other butts in the ashtray may catch fire Do not leave the ashtray full of cigarette butts Put matches and cigarette butts in the ashtray only after they...

Page 314: ...out tab Rear Ashtray Crew Cab Model Pull the ashtray towards you to use it Pull out lit cigarettes on the crush out tab The ashtray cannot be removed To empty the ashtray turn it down while pushing th...

Page 315: ...Storage Pocket V Use this to hold your cards Card Holder CAUTION Do not leave eyeglasses or lighters inside the cab Lighters may explode and plastic lenses or frames may deform or crack if the interio...

Page 316: ...e Lighters may explode and plastic lenses or frames may deform or crack if the interior temperature becomes very hot Pull up the lid to open the centre console Centre Console Box V CAUTION Do not leav...

Page 317: ...sses or a lighter in the vehicle If the cab became hot a lighter left there could explode and plastic eyeglass lenses or frames could deform or crack Pull towards you to open Cup Holder V CAUTION Do n...

Page 318: ...fter installing the back panel tray turn the knob to the LOCK position CAUTION Do not use the back panel tray to hold any object weighing more than 2 kg 71 oz or an object that may fly or fall out dur...

Page 319: ...clothing Coat Hook V This can be used to hold plastic shopping bags Hook CAUTION Do not hang anything weighing over 3 kg 106 oz or that may fall off the hook while driving Doing so may be dangerous 20...

Page 320: ...n be used ADVICE On cold or rainy days condensation may form in the CD player preventing normal operation If this occurs eject the CD and use the air conditioning system to dehumidify or ventilate the...

Page 321: ...oving vehicle may not be sustainable The directness of FM signal transmission As FM signals are more strongly directional than AM signals they are blocked easily by large objects such as mountains and...

Page 322: ...5 32 COMFORT AND CONVENIENCE 2008N_sec05_print2 indd 32 3 09 2008 5 37 36 PM...

Page 323: ...Driving Safely and with Confidence 6 2 On the Road 6 3 Cautions for Parking 6 15 Cautions for Driving in Hot Regions 6 16 Cautions for Driving in Cold Regions 6 17 Using Tyre Chains 6 22 2008N_sec06_...

Page 324: ...tired you will get sleepy and lose concentration Please get plenty of rest before you drive Driving Safely and with Confidence Take Breaks during Long Journeys Driving long distances is tiring Please...

Page 325: ...or a buzzer sounds while you are driving immediately stop the vehicle in a safe place and perform checks Do not put your foot on the clutch pedal except when using the gearshift lever Doing so would c...

Page 326: ...mountain road or on a narrow or congested urban road pay careful attention to obstacles on either side and to the condition of the shoulder of the road When Turning the Rear Wheels will Follow Tighte...

Page 327: ...ast on a downhill road Use the same gear s that you used to drive up the hill Also use the exhaust brake in order to avoid going too fast Do not let the engine overrun NOTE Overrunning An engine overr...

Page 328: ...point where the driver senses danger and presses the pedal to the point where the brakes start to work and a braking distance from the point where the brakes start to work to the point where the vehi...

Page 329: ...side air position Also use commercially available antifog spray Nighttime Visibility If there is an oil film on the windshield the lights of oncoming traffic will be reflected in many directions makin...

Page 330: ...dangerous only to follow the lights of the preceding vehicle because they can cause optical illusions Drive with caution Driving at Night Nighttime driving is more dangerous than daytime driving becau...

Page 331: ...eaking from the radiator and other parts of the cooling system Check that the coolant level is high enough Check that the fan belt is properly tensioned and free of damage Check that the engine oil le...

Page 332: ...e and the exhaust brake when you wish to decelerate NOTE Brake fade Frequent use of the brakes can cause the brakes to overheat so that the frictional force of the brake linings decreases and the brak...

Page 333: ...rp turns of the steering wheel There is a risk of reduced grip between the tyres and road surface and of increased braking distances The danger of icy road surfaces is particularly great on bridges in...

Page 334: ...pedal works smoothly Check the Fuel Level Fuel consumption becomes higher when tyre chains are used Check how much fuel you need to reach your destination and top up the tank in advance Fuel Refer to...

Page 335: ...he brakes do not work well drive slowly and gently press the brake pedal several times until the brakes dry out and start working normally Removing Snow from the Glass and Underbody To maintain an ade...

Page 336: ...ADVICE When driving in sand or mud avoid hard braking sudden acceleration and sharp turns of the steering wheel Such actions could get the vehicle stuck and make it impossible to extricate After drivi...

Page 337: ...parts from freezing up and to help make the engine easy to start Parking in Gear Refer to page 4 87 Cautions for Parking NOTE When parking outdoors take steps to prevent the engine from getting unnec...

Page 338: ...r passages the cooling system s performance will deteriorate Check the air passages for clogging and remove any foreign matter using water under low pressure CAUTION Do not put well water river water...

Page 339: ...o page 7 138 Engine Oil Refer to page 7 22 Using Tyre Chains Refer to page 6 22 Winter Tyres Refer to page 6 20 CAUTION Do not cover the front of the radiator with newspapers cardboard or any other fl...

Page 340: ...west temperature that your vehicle is expected to operate in Changing the Engine Coolant Refer to page 7 37 Preparing Coolant Refer to page 7 43 Replacing the Engine Oil In all seasons use Isuzu genui...

Page 341: ...e fuel filter and result in lubrication problems in fuel lubricated components of the injectors In addition this practice can also impair the operation of the engine and the diesel particulate defuser...

Page 342: ...tyre has reached its wear limit when the tread grooves have worn to half of the depth of the new tyre At this time platforms indicating that the tyre can no longer give adequate performance on snow b...

Page 343: ...the components Do not use a sharp implement to remove snow Sharp edges could damage rubber parts CAUTION Remove snow that has stuck to the inside of the fenders and to the brake hoses Otherwise it may...

Page 344: ...esel particulate defuser DPD regeneration is under way because the exhaust temperature then is very high Be careful not to hurt yourself on the edges of the vehicle while working with the tyre chains...

Page 345: ...oser to you the outer tyre Then unfold the top half of the tyre chain and lay it on the inner tyre 2 Pull both ends of the tyre chain as far as possible Couple the inner hooks first and then couple th...

Page 346: ...do the inner hooks 2 Move the vehicle and remove the chain ADVICE If a tyre chain breaks or comes partially unfastened while the vehicle is moving it will harm the vehicle body Take corrective action...

Page 347: ...3 DAILY CHECKS 7 15 ENGINE RELATED SERVICE AND MAINTENANCE 7 19 CHASSIS RELATED SERVICE AND MAINTENANCE 7 59 OTHER SERVICE AND MAINTENANCE 7 127 INTERIOR AND EXTERIOR MAINTENANCE 7 147 MAINTENANCE DA...

Page 348: ...2008N_sec07 1_print2 indd 2 3 09 2008 5 47 12 PM...

Page 349: ...Checking and Adjustments 7 4 Discarded Parts Oils and Other Liquids 7 6 Isuzu Genuine Oils and Grease 7 6 Tools 7 7 Inspection Hatches V 7 10 Tilting the Cab V 7 12 BEFORE SERVICE AND MAINTENANCE 2008...

Page 350: ...to perform work make sure the vehicle is supported with jack stands When performing work on the electrical system be sure to remove the cable from the negative terminal on the battery The engine exha...

Page 351: ...he Maintenance Schedule when either the specified driving distance or period of time whichever comes first has expired Confirm that all systems and components are normal after performing the work Do n...

Page 352: ...suzu Genuine Oils and Grease Periodically replenishing and changing the oil and grease is extremely important for maintaining your vehicle s performance and preventing malfunctions Isuzu Motors guaran...

Page 353: ...t Refer to page 3 18 Passenger Seat Centre Seat V Refer to page 3 19 ADVICE If your vehicle has a back panel tray the back panel tray must be removed before you can take out or store the tools ADVICE...

Page 354: ...our Vehicle Model with dual tyres NLR NNR NPR NQR NPS models No Tool name 1 Jack bar Spare tyre removal bar 2 Wheel nut wrench handle 3 Wheel nut wrench 4 Screwdriver with switchable Phillips and flat...

Page 355: ...t of the passenger s seat cushion to release the lock 2 Lift up the seat cushion and attach the belt extending from behind the seatback to the left catch lever to hold the cushion in the raised positi...

Page 356: ...while pulling toward you Then remove the cushion 2 Lift up the mat and then remove the engine maintenance sub lid by pulling the handle Closing 1 Reinstall the engine maintenance sub lid and place th...

Page 357: ...ity of the rear seat To open an inspection hatch lift the floor mat first and then grip the handle on the hatch to raise the hatch Power Steering Fluid Refer to page 7 120 AMT Clutch Oil SA Refer to p...

Page 358: ...hing these when doing a cab tilt operation Do not tilt the cab when objects are placed on or in the instrument panel seats cup holders or floor surface Tilt the cab only with the engine turned off Mak...

Page 359: ...u have raised the cab support the cab with the grip D using your left hand and confirm that the tilt support s lock E has been securely engaged WARNING If the lock E has not been fully engaged there i...

Page 360: ...the grip D drop the cab with enough force to ensure that the lever B engages and then confirm that this lever has engaged securely 4 Lower the handle C until the lever A is fully locked NOTE Confirm...

Page 361: ...SERVICE AND MAINTENANCE Daily Checks Preoperational Checks 7 16 Checking Components that Showed Abnormalities during Previous Operation 7 18 DAILY CHECKS 2008N_sec07 1_print2 indd 15 3 09 2008 5 47 2...

Page 362: ...page Checking components that showed abnormalities during the previous operation 7 17 2 Checks performed with the engine inspection hatch opened or cab tilted Check item Reference page Fan belt loose...

Page 363: ...eakage of oil coolant fuel brake fluid power steering fluid and HBB oil Water collecting in the fuel filter bottom 7 53 5 Checking wheels and tyres Check item Reference page Air pressure 7 81 Cracks a...

Page 364: ...7 18 SERVICE AND MAINTENANCE 2008N_sec07 1_print2 indd 18 3 09 2008 5 47 26 PM...

Page 365: ...ngine Conditions 7 20 Engine Oil 7 22 Engine Coolant 7 34 Fan Belt 7 44 Air Cleaner 7 49 Fuel Filter 7 53 Diesel Particulate Defuser DPD 7 60 ENGINE RELATED SERVICE AND MAINTENANCE 2008N_sec07 1_print...

Page 366: ...CAUTION If your vehicle is equipped with the AMT system the engine will not start unless the transmission is actually in neutral For safety firmly press the brake pedal before starting the engine 3 T...

Page 367: ...page 4 4 3 Check that the engine is running at a speed within the standard idle speed range Idling Control Knob V Refer to page 4 62 NOTE During regeneration of the diesel particulate defuser DPD the...

Page 368: ...ing engine performance and longevity Be sure to use only the specified oil and oil filters The engine oil level must be checked and the oil should be changed regularly according to the Maintenance Sch...

Page 369: ...the Inspection MAX mark on the oil dipstick may cause engine malfunctions Change the oil whenever its level exceeds the Inspection MAX mark Fuel will gradually become mixed with the engine oil thinni...

Page 370: ...e engine oil level is near the MIN mark on the oil dipstick remove the oil filler cap and add the oil Remove the oil dipstick at this time Use only the specified engine oil 4JJ1 engine model 4HK1 engi...

Page 371: ...ng the engine s operation Continually using the same oil without checking the level or without replenishing and changing it could cause seizure or damage to the engine Add or change the oil when the q...

Page 372: ...evel Failure to use DPD compatible oil could result in engine or DPD breakdown or to poor fuel efficiency Be sure to use DPD compatible engine oil Quantity of engine oil to be changed Maintenance Sche...

Page 373: ...remove the filter case Next remove the filter element 4 To ensure that the new oil filter makes good contact wipe the filter mounting surface clean using a workshop rag 5 Replace the three O rings an...

Page 374: ...any oil leaks around the oil filter or drain plug ADVICE Avoid revving up the engine as it could damage the engine 9 Shut off the engine Then after waiting at least 30 minutes check the oil level usi...

Page 375: ...he oil filter 5 Lightly coat the gasket of the new oil filter with clean engine oil 6 Install the new oil filter After the filter gasket comes in contact with the surface to which it will be attached...

Page 376: ...e oil filler 9 Install the oil dipstick and the oil filler cap Start the engine 5 minutes after refilling it with the new oil and let it idle While the engine is idling check to see if any oil leaks a...

Page 377: ...fire Make sure to wipe it all up Do not leave flammable items such as rags or gloves in the engine compartment beneath the cab They could cause a fire Also do not forget your tools ADVICE Avoid revvi...

Page 378: ...lowly Engine coolant is toxic and must not be ingested If coolant gets in your eyes rinse them immediately Engine coolant is flammable and therefore it must be kept away from flames and other heat sou...

Page 379: ...e no leaks from the radiator or radiator hose Check for fluid or stains on the ground showing leaks where the vehicle is parked Contact your Isuzu Dealer when you discover leaks Checking the Engine Co...

Page 380: ...ngine has sufficiently cooled down ADVICE Check the surge tank to determine engine coolant level In situations however where the level in the surge tank rises or falls suddenly open the radiator cap a...

Page 381: ...gal 2 20 Imp gal 4HK1 18 0 litres 4 76 US gal 3 96 Imp gal Draining the Cooling System When changing the engine coolant also clean the radiator cap radiator and coolant passages 1 Confirm that the en...

Page 382: ...rrosion of the radiator core Periodically wash the radiator core with water Engine drain plug tightening torque 21 6 N m 2 2 kgf m 16 lb ft 5 For the 4JJ1 engine apply sealant LOCTITE 262 or equivalen...

Page 383: ...lling the coolant After filling with water firmly tighten the air bleed plug 4HK1 engine model 2 Check and clean the radiator cap Replace the cap if it is damaged 3 Install and securely fasten the rad...

Page 384: ...5 Close the cap of the surge tank 6 Start the engine and let it idle for 20 minutes Stop the engine wait until it cools down and then drain out the water Draining the Cooling System Refer to page 7 37...

Page 385: ...ew one After filling with coolant firmly tighten the air bleed plug 3 Squeeze the radiator upper hose two or three times If this action results in air being discharged from the hose and the level of e...

Page 386: ...2 000 r min to warm it up 10 When the needle of the engine coolant temperature gauge reaches the centre let the engine idle at normal idle speed for 5 minutes and then stop the engine 11 After making...

Page 387: ...s 4 76 US gal 3 96 Imp gal When using Isuzu genuine engine coolant the percentage of engine coolant in the coolant should be 50 If it is more than 60 overheating is likely to occur while if it is less...

Page 388: ...s required with the conventional V belt Inappropriate tension could cause the belt to make noise or break When the fan belt is damaged electricity is not properly generated or becomes a cause of engin...

Page 389: ...range indicated below Otherwise adjust the tension or replace the belt Also check the fan belt for cracks or other damage If there are cracks or damage replace the belt 4JJ1 engine model Engine with...

Page 390: ...t the tension or replace the belt Also check the fan belt for cracks or other damage If there are cracks or damage replace the belt Engine with 50A alternator Engine with 80A alternator Alternator Sta...

Page 391: ...lower nuts and bolts 1 2 and then detach the belt from the pulleys 3 Take out the belt through the opening in the fan 4 Insert the new belt through the opening in the fan and install the belt while a...

Page 392: ...ng bolt and remove the belt from the pulleys 3 Take out the belt through the opening in the fan 4 Insert the new belt through the opening in the fan and install the belt while aligning its grooves wit...

Page 393: ...ulti information display MID check the air cleaner element regardless of whether or not it is due for inspection Air Cleaner Indicator Light V Refer to page 4 41 Maintenance Schedule Refer to page 7 1...

Page 394: ...e air cleaner cover 2 Remove the air cleaner element by pulling it out toward you 3 Remove the dirt that has accumulated on the air cleaner cover and the air cleaner body 4 Clean the drain valve at th...

Page 395: ...ck into position in the air cleaner body 6 Install the air cleaner cover Line up the notch on the left side of the body with the claw on the cover Secure the cover in position by fastening the 3 clips...

Page 396: ...ged or become thin in places 2 When the element has become blackened by oily smoke or soot a Soak the element in a mixture of water and neutral detergent for about 30 minutes b Remove the element from...

Page 397: ...has gone out Draining Water from the Fuel Filter Refer to page 7 55 CAUTION Water remaining that is not discharged from the water separator could freeze and damage the vehicle If the warning light com...

Page 398: ...ol like a 29 mm 1 14 in socket wrench to turn the hexagonal part at the bottom of the element case counterclockwise and remove the element case ADVICE Check the float at the bottom of the interior of...

Page 399: ...king sure that it is not damaged by the screw threads 6 After lightly coating the inner and outer gaskets of the new filter element with diesel fuel insert the element until it touches the filter body...

Page 400: ...rt a fire ADVICE Be sure to use an Isuzu genuine fuel filter element Replace the gaskets when replacing the filter element Dispose of the replaced filter element in a method conforming to the regulato...

Page 401: ...check that there are no fuel leaks from the drain plugs of the chassis side fuel filter and engine side fuel filter Also check that the water separator fuel filter warning light stays off CAUTION Cle...

Page 402: ...ulti information display MID or the MANUAL REGEN message and the AUTO REGEN message appear alternately model with MID 3 Make sure that the DPD automatic regeneration indicator light and the DPD manual...

Page 403: ...7 57 SERVICE AND MAINTENANCE Notes 2008N_sec07 1_print2 indd 57 3 09 2008 5 47 49 PM...

Page 404: ...7 58 SERVICE AND MAINTENANCE Notes 2008N_sec07 1_print2 indd 58 3 09 2008 5 47 49 PM...

Page 405: ...yres 7 77 Tyre Rotation 7 86 Changing Tyres 7 88 Spare Tyre V 7 98 Clutch M T 7 100 Transmission Oil 7 105 AMT Clutch Oil SA 7 109 Rear Axle Differential Gear Oil 7 112 Front Axle Differential Gear Oi...

Page 406: ...n the system could cause the vehicle to lose braking functions Inspect and change brake fluid according to the Maintenance Schedule Use non petroleum base brake fluid when adding brake fluid Be carefu...

Page 407: ...the fluid the boiling point of the fluid decreases and this causes vapor lock a highly dangerous problem that affects brakes functionality Do not allow engine oil gear oil and any other oils to mix wi...

Page 408: ...with an anti lock brake system ABS remove the ABS fuse 10A from the fuse box before starting an air bleeding operation Failure to observe this precaution will result in incomplete bleeding of air and...

Page 409: ...quence Right hand drive Left rear wheel Right rear wheel LSPV model with LSPV only Left front wheel Right front wheel Left hand drive Right rear wheel Left rear wheel LSPV model with LSPV only Right f...

Page 410: ...s not below the ADD line If the engine is not running during air bleeding the brake booster may be adversely affected 9 After you finish the bleeding for each wheel press the brake pedal to check that...

Page 411: ...ithin the hydro booster can rise above 100 C 212 F For this reason special care will be required when working with hydro booster components If the hydro booster is to be removed from the vehicle shut...

Page 412: ...r approximately 5 seconds 3 Stop the engine and check the fluid level in the tank 4 If the fluid level in the hydro booster fluid tank is below the MIN mark add fluid until it rises to between the MIN...

Page 413: ...brake pedal approximately 30 times at intervals of between 1 and 3 seconds until the booster reaches the full load range Once the full load condition has been reached do not keep the pedal pressed fo...

Page 414: ...Model without HBB 4 7 mm 0 16 0 28 in Model with HBB 24 29 mm 0 95 1 14 in MFU770SH002301 Free play Model without HBB Clearance between the brake pedal and the brake pedal bracket with a pressure of 4...

Page 415: ...ing the pedal two or more times in succession Before checking the free play of the brake pedal stop the engine and press the pedal 4 or 5 times in succession ADVICE If after continued pressing of the...

Page 416: ...leased position with pull force of about 147 N 15 kgf 33 lb Inspection Adjustments 1 Park the vehicle on a level and flat ground surface prevent the vehicle from moving by applying chocks to the front...

Page 417: ...stroke is adjusted to a number of notches within the standard value range below After the adjustment securely tighten the lock nut Vehicle model Number of teeth by which the adjuster wheel should be...

Page 418: ...are free of scratches cracks and bulging Also make sure that the hose and pipe do not interfere with any chassis part or wheel and that their joints are not leaking and free of any type of damage Che...

Page 419: ...and chock the wheels Parking Brake Lever Refer to page 4 77 2 Raise the vehicle until the wheel is completely clear of the ground 3 Support the raised vehicle with jack stands 4 Remove the wheel Remo...

Page 420: ...8 in 35 0 mm 1 378 in 33 0 mm 1 299 in 14 0 mm 0 551 in 1 0 mm 0 04 in 285 x 35 mm 11 22 x 1 38 in 35 0 mm 1 378 in 33 0 mm 1 299 in 14 0 mm 0 551 in 1 0 mm 0 04 in 293 x 40 mm 11 54 x 1 57 in 40 0 mm...

Page 421: ...check the side surfaces of the lining for cracks flaking or other damage 3 The wear limit for bonded brake shoe linings is when the thickness is reduced to 1 mm 0 04 in and the wear limit for riveted...

Page 422: ...hicle with jack stands 4 Remove the rubber plug from the adjustment hole in the backing plate 5 Insert a screwdriver into the adjustment hole and turn in the direction indicated by the arrow on the ba...

Page 423: ...lso check the air pressure of the spare tyre using a tyre air pressure gauge at the intervals specified by the Maintenance Schedule The wheels have a major influence upon the safety and comfort of dri...

Page 424: ...NNR85F 195 75R16C 195 75R16C 475 4 75 69 475 4 75 69 195 85R16 195 85R16 600 6 00 87 600 6 00 87 215 75R17 5 215 75R17 5 600 6 00 87 600 6 00 87 NNR85H 195 85R16 185 80R15 600 6 00 87 450 4 50 64 195...

Page 425: ...10PR 575 5 75 83 575 5 75 83 7 50 16 12PR 7 50 16 12PR 600 6 00 87 600 6 00 87 7 50R16 12PR 7 50R16 12PR 650 6 50 94 650 6 50 94 7 50 16 14PR 7 50 16 14PR 650 6 50 94 650 6 50 94 7 50R16 14PR 7 50R16...

Page 426: ...12PR 600 6 00 87 600 6 00 87 7 50R16 12PR 7 50R16 12PR 650 6 50 94 650 6 50 94 195 75R16C 195 75R16C 475 4 75 69 475 4 75 69 195 85R16 195 85R16 600 6 00 87 600 6 00 87 205 85R16 205 85R16 600 6 00 87...

Page 427: ...5 00 73 8 25 16 14PR 8 25 16 14PR 575 5 75 83 575 5 75 83 215 75R17 5 215 75R17 5 600 6 00 87 600 6 00 87 NQR75L 7 50 16 10PR 7 50 16 10PR 525 5 25 76 525 5 25 76 7 50R16 10PR 7 50R16 10PR 575 5 75 83...

Page 428: ...ressure of any tyre If your vehicle is equipped with aluminum wheels use an extension attached to the inner tyre valve together with a standard tyre air pressure gauge or use a special air pressure ga...

Page 429: ...might have an increased chance of getting punctured or bursting while driving Check all tyres to see if tread wear indicators appear on their treads and also check their entyre tread for its depth wi...

Page 430: ...CAUTION Any abnormality in wheel installation is likely to lead to loose or missing wheel nuts and or broken wheel studs Checking Wheel Installation Condition with an Inspection Hammer Place your fing...

Page 431: ...Low Aspect Ratio Tyres Low aspect ratio tyres for truck applications aspect ratio at 70 or 75 have an air volume 20 to 30 smaller than that of standard tyres When air begins to leak therefore low asp...

Page 432: ...here the load is smaller If there is a difference in diameter between the inner and outer tyres of a dual tyre wheel install the smaller diameter tyre inside The difference in diameter of the tyres fo...

Page 433: ...under an excessive load ADVICE The tightening torque of the wheel nuts may decrease after a tyre change due to their initial settlement Upon driving 50 to 100 km 31 to 62 miles after a tyre change re...

Page 434: ...rface after checking safety in the surrounding area Handling the Jack Refer to page 7 128 Every stud or nut for right hand wheels is marked R or and each stud or nut for left hand wheels is marked L o...

Page 435: ...ic to the presence of your vehicle Fully pull the parking brake lever Chock both the front and back sides of the wheel diagonally opposite to the one to be changed with chocks or stones wood blocks et...

Page 436: ...event the vehicle from moving When a rear wheel is jacked up the vehicle blocked only by the parking brake would move creating a very dangerous situation Never open doors or start the engine while jac...

Page 437: ...ge such as cracks the hub for excessive wear of the disc wheel fitting surface and the wheel studs and nuts for damage to the threads If anything abnormal is found in the above parts check other parts...

Page 438: ...holes and decorative holes Cracks or other damage or deformation on the wheel nut seating surfaces tapered surfaces Cracks or other damage on welds Wear or other damage on the hub fitting surface or...

Page 439: ...he vehicle while driving This could be very dangerous 4 Install the wheel while aligning the stud holes in the disc wheel with the wheel studs When installing the rear wheel place the outer wheel so t...

Page 440: ...eel nut tightening sequence Wheel with 5 nuts Wheel with 6 nuts LNU770SH016301 3 1 6 4 2 5 Right side tire Left side tire LNU770SH012401 3 1 4 2 5 Right side tire Left side tire 5 Screw in each wheel...

Page 441: ...instructions in the Retightening Wheel Nuts section in this chapter Retightening Wheel Nuts Refer to page 7 96 Model or Specification Front wheel nuts Rear wheel nuts Tightening torque Quantity Tighte...

Page 442: ...to retighten the wheel nuts to the specified torque Single Tyre Turn the wheel nuts in the tightening direction to the specified torque Dual Tyre 1 Of the nuts on the wheel studs loosen the outer whe...

Page 443: ...ls and could lead to wheel detachment Adhere to the specified tightening torques When replacing a tyre with a new one use only a tyre of the same type and size as the replaced tyre otherwise driving s...

Page 444: ...k handle counterclockwise to remove the spare tyre Spare tyre stored at rear of frame Spare tyre stored at side of frame LNU770SH013001 Spare tire removing crank handle Spare tire removing bar To rais...

Page 445: ...wise to fully wind up the chain apply at least 196 N 20 kgf 44 lb of force to the crank handle by hand and make sure that the spare tyre is firmly secured in place After storing the spare tyre check t...

Page 446: ...ith your skin Should the fluid be spilled on a painted surface or come in contact with your skin wash away the fluid with water and immediately wipe the area clean Use only the specified clutch fluid...

Page 447: ...h system failure Clutch fluid melts paintwork and vehicle component materials such as plastic vinyl and rubber It is also highly corrosive on metals If it is spilled immediately wipe the area clean or...

Page 448: ...bleeding by yourself it should be done with the help of another person 1 Chock the wheels and firmly apply the parking brake 2 Check the level of the clutch fluid in the clutch fluid tank and add flui...

Page 449: ...he container and then tighten the bleeder screw immediately 7 Release the clutch pedal slowly Repeat Steps 5 and 6 until the fluid from the tube no longer contains air bubbles After bleeding install t...

Page 450: ...15 25 mm 0 59 0 98 in MFU770SH014901 Free play MFU770SH015001 Position of fully pressed pedal Pedal position just before clutch engagement ADVICE Release the clutch pedal carefully to prevent the veh...

Page 451: ...the transmission oil After changing the oil make sure the oil is at the required level Drained oil must be disposed of in a method conforming to the regulatory requirements in your country Quantity of...

Page 452: ...ug hole If the oil level is too low add oil through the oil level plug hole 3 Fasten the oil level plug to the specified torque Also check to see if there are any transmission oil leaks ADVICE Any dir...

Page 453: ...refill the transmission with new oil through the oil level plug hole up to the lower edge of the hole ADVICE The dirt on the plug should be wiped off before installing it Drain plug tightening torque...

Page 454: ...alling it ADVICE Because the cases of the MYY and MZZ transmissions are made of aluminum be extremely careful not to tighten the oil level plug and drain plug to an excessively large torque when insta...

Page 455: ...will cause oil leaks Too little oil will cause malfunction of the system Before checking the AMT clutch oil level thoroughly clean the dipstick and the area around it to prevent dust or other foreign...

Page 456: ...e dipstick when the oil temperature is low or within the H marked range when the oil temperature is high 5 If the oil level is too low add oil as necessary 6 After checking insert the dipstick fully i...

Page 457: ...w oil through the dipstick guide tube 7 Check the oil level according to the Checking the Oil Level section Checking the Oil Level Refer to page 7 110 5 Install the drain plug by tightening it to the...

Page 458: ...a method conforming to the regulatory requirements in your country 1 Remove the oil level plug Checking the Oil Level HCU7C0SH005201 Oil level lower edge of level check plug hole Level check plug hol...

Page 459: ...is up to the lower edge of the oil level plug hole 5 Install the oil level plug by tightening it to the specified torque HCU7C0SH005201 Oil level lower edge of level check plug hole Level check plug...

Page 460: ...intenance Schedule Refer to page 7 159 2 Check that the oil level is up to the lower edge of the oil level plug hole If the oil level is too low add oil through the oil level plug hole 3 Fasten the oi...

Page 461: ...ter installing the drain plug by tightening it to the specified torque refill the front axle differential with new oil through the oil level plug hole up to the lower edge of the hole ADVICE Any dirt...

Page 462: ...y of front axle differential gear oil to be changed Oil quantity Reference value 2 7 litres 0 71 US gal 0 59 Imp gal ADVICE Any dirt on the plug should be wiped off before installing it 2008N_sec07 2_...

Page 463: ...LNU770SH015101 Oil level lower edge of oil level plug hole Oil level plug hole Oil surface 2 Check that the oil level is up to the lower edge of the oil level plug hole If the oil level is too low add...

Page 464: ...stalling the drain plug by tightening it to the specified torque refill the transfer gear case with new oil through the oil level plug hole and up to the lower edge of the hole ADVICE Any dirt on the...

Page 465: ...antity of transfer gear case oil to be changed Oil quantity Reference value 1 8 litres 0 48 US gal 0 40 Imp gal ADVICE Any dirt on the plug should be wiped off before installing it 2008N_sec07 2_print...

Page 466: ...efer to page 7 11 CAUTION Before adding fluid clean the area around the cap and pour fluid from a clean jug or filler Foreign matter getting in the tank will cause power steering system failure Do not...

Page 467: ...ly clear of the ground 4 Disconnect the oil pipe between the steering unit and reserve tank as well as the oil hose between the oil pump and reserve tank and discharge the power steering fluid 5 When...

Page 468: ...wheel in both directions a few times If you do not hear any abnormal sounds the system has been properly bled CAUTION While refilling the system keep the reserve tank full of the fluid by making addit...

Page 469: ...ew times to increase the fluid temperature When the fluid temperature has risen to between 60 to 80 C 140 to 176 F stop the engine and wait for about 5 minutes allowing air to be collected from high t...

Page 470: ...reasing according to the Maintenance Schedule King pins left and right Front propeller shaft Double cardan joint 2 points each Rigid axle suspension 3 points 4WD model Propeller shaft centre bearing P...

Page 471: ...NCE ADVICE Each of propeller shaft universal joint must be greased heavily until grease oozes at the 4 needle bearing oil seal locations After greasing wipe off excess grease 2008N_sec07 2_print2 indd...

Page 472: ...7 126 SERVICE AND MAINTENANCE 2008N_sec07 2_print2 indd 126 3 09 2008 5 54 00 PM...

Page 473: ...CE Handling the Jack 7 128 Windshield Washer Fluid 7 133 Windshield Wiper Blades 7 134 Headlights and Turn Signal Lights 7 137 Handling the Battery 7 138 Air Conditioning Filters V 7 144 Refrigerant V...

Page 474: ...cified point In order to provide extra safety should the jack slip once a spare tyre has been removed it should be placed under the vehicle near the jack Before starting a jacking operation ensure tha...

Page 475: ...lat Refer to page 7 132 2 Turn the head of the jack to extend it to the height of the jacking point Turn it counterclockwise to extend 3 Insert the jack handle into the socket Before jacking up use th...

Page 476: ...ng point behind the lower link Four Wheel Drive 4WD Model Apply the jack to the bottom of the axle LNU8Z0SH016801 Front of vehicle Axle Lowering the Vehicle 1 Line up the jack handle end notch with th...

Page 477: ...the leaf spring or axle case LNU770SH013901 Front of vehicle Leaf spring LNU770SH014001 Front of vehicle Leaf spring Band section Under slung Leaf Spring Suspension Model some dual tyre models standar...

Page 478: ...r to improve stability As the bottom of the leaf spring is curved special care must be taken during the jacking operation Slipping of the jack can lead to extremely dangerous situations such as entrap...

Page 479: ...nd fill the tank with windshield washer fluid to the opening ADVICE Upon factory shipment new vehicles contain only tap water in the washer fluid tank Adjust the concentration of the fluid to suit you...

Page 480: ...per blade hook towards the arm slide the blade downwards towards the base of the arm 3 With the blade and arm almost perpendicular remove the blade from the arm Daily Checks Spray windshield washer fl...

Page 481: ...sh up the blade until it locks into place on the arm ADVICE Do not lower the wiper arm with its blade removed the windshield glass may be scratched Whenever a wiper blade has been attached ensure that...

Page 482: ...Pull Installation 1 Insert a new wiper rubber insert into the wiper blade 2 Continue pushing in the wiper rubber insert until the wiper blade s hook engages with the hole in it and then confirm that...

Page 483: ...on depress the brake pedal to confirm whether the stop lights come on and shift the transmission to R position to confirm whether the back up lights come on Also examine the lights for discoloration d...

Page 484: ...unusually fast rate have an inspection carried out immediately by the nearest Isuzu Dealer DANGER Usage or charging of the battery when the battery fluid is below the LOWER LEVEL line can accelerate d...

Page 485: ...to the LOCK position turn all other switches OFF and disconnect the battery s negative cables from the terminals There is a danger that electrical components could be damaged if inspection or mainten...

Page 486: ...please consult with your Isuzu Dealer Installing the Battery 1 When installing the battery in your vehicle ensure that it is oriented correctly and securely fastened without any looseness If the batt...

Page 487: ...R LEVEL mark or in a range between 10 and 15 mm 0 39 to 0 59 inches from the top of the battery plates When you have finished adding the distilled water securely install the cap and battery cover Chec...

Page 488: ...ase if you fail to recharge the battery If the battery fluid level continues to drop at an unusually fast rate have an inspection carried out immediately by the nearest Isuzu Dealer Crew Cab Model Ope...

Page 489: ...with warm water and then wipe fully dry Excessively corroded terminals should be polished using a wire brush or sandpaper 3 When you have finished cleaning the terminals apply a thin layer of grease a...

Page 490: ...ll out the clips 2 Remove the cover by pushing it upwards 3 Remove the filter Use a vacuum cleaner or the like to clean dust and dirt from its surface LNU770SH015401 Filter inside air ADVICE Avoid int...

Page 491: ...nel on the passenger side While pressing in the filter lock on both sides pull out the filter 2 Use a vacuum cleaner or the like to clean dust and dirt from its surface ADVICE In order to avoid filter...

Page 492: ...rant level is too low leads not only to poor cooling performance but also to air conditioning system damage This vehicle uses the new refrigerant HFC134a R134a in the air conditioning system No other...

Page 493: ...7 147 SERVICE AND MAINTENANCE INTERIOR AND EXTERIOR MAINTENANCE Exterior Maintenance 7 148 Interior Maintenance 7 151 2008N_sec07 2_print2 indd 147 3 09 2008 5 54 13 PM...

Page 494: ...have been applied When a large amount of mud or dirt has adhered to the exterior 1 Fully turn on the tap and wash out the undercarriage and suspension 2 Close all openings and wash the cab and cargo...

Page 495: ...plastic components or to water leaks into the cab When using an automatic car or truck wash ensure that a distance of at least 0 4 m 15 75 inches is maintained between the nozzle and the vehicle and w...

Page 496: ...dshield A layer of wax can impair your view in rainy weather and can also lead to rough movements of the windshield wiper If engine oil or grease comes into contact with the windshield staining or dis...

Page 497: ...n the case of a collision therefore the belts could be insufficiently effective and serious life threatening injuries could result When cleaning use warm water in which a small amount of neutral deter...

Page 498: ...bsorbent gauze or the like of approximately 50 mm 2 in in width into a rectangle 2 Mix one part neutral detergent into approximately twenty parts warm water 3 Wet the cloth in the detergent mixture pa...

Page 499: ...e seat belt through the retractor there is a possibility that the belt is making contact with the door pillar trim In this case arrange for inspection and maintenance to be carried out by your Isuzu D...

Page 500: ...7 154 SERVICE AND MAINTENANCE Notes 2008N_sec07 2_print2 indd 154 3 09 2008 5 54 15 PM...

Page 501: ...7 155 SERVICE AND MAINTENANCE Notes 2008N_sec07 2_print2 indd 155 3 09 2008 5 54 15 PM...

Page 502: ...7 156 SERVICE AND MAINTENANCE Notes 2008N_sec07 2_print2 indd 156 3 09 2008 5 54 15 PM...

Page 503: ...ERVICE AND MAINTENANCE MAINTENANCE DATA Inspection and Maintenance 7 159 Maintenance Schedule Validation 7 164 Recommended Lubricants and Diesel Fuels 7 172 2008N_sec07 3_print2 indd 157 4 09 2008 8 1...

Page 504: ...2008N_sec07 3_print2 indd 158 4 09 2008 8 16 30 AM...

Page 505: ...ified maintenance schedule Contact your Isuzu Dealer for inspection that requires disassembly and or special equipment Letters Used to Indicate Maintenance Service Types I Inspect clean or repair or r...

Page 506: ...n R Engine drive belts I I Valve clearances A A Power steering fluid I I R Exhaust pipes mounting exhaust brake operation T I I Perform manual regeneration check exhaust pressure and clean DPD filter...

Page 507: ...uid leaks and operation I I Inspect coil springs and ball joints independent suspension models only I I Front rear wheel bearing grease R Wheel nuts for tension T T Tyre wear pressures rotation I I Ba...

Page 508: ...s D Driving in extremely cold and or hot weather Less than 0 Deg C or greater than 40 Deg C Condition Item Interval A B C D Engine oil Change every 10 000 km 200hrs Engine oil filters Replace every 10...

Page 509: ...ension for wear and damage Inspect every 5 000 km 100hrs General Inspection Fuel brake cooling oil air exhaust systems for leaks All fluid levels Inspect every 5 000 km 100hrs LUBRICANTS Recommended D...

Page 510: ...ealer 30 000 kilometres or 1 year Service carried out at kilometres on date Servicing Dealer 45 000 kilometres or 1 5 years Service carried out at kilometres on date Servicing Dealer 60 000 kilometres...

Page 511: ...Servicing Dealer 150 000 kilometres or 5 years Service carried out at kilometres on date Servicing Dealer 165 000 kilometres or 5 5 years Service carried out at kilometres on date Servicing Dealer 180...

Page 512: ...rvicing Dealer 270 000 kilometres or 9 years Service carried out at kilometres on date Servicing Dealer 285 000 kilometres or 9 5 years Service carried out at kilometres on date Servicing Dealer 300 0...

Page 513: ...ervicing Dealer 390 000 kilometres or 13 years Service carried out at kilometres on date Servicing Dealer 405 000 kilometres or 13 5 years Service carried out at kilometres on date Servicing Dealer 42...

Page 514: ...ing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Servicing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Serv...

Page 515: ...ing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Servicing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Serv...

Page 516: ...ing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Servicing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Serv...

Page 517: ...ing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Servicing Dealer Intermediate Severe Engine Hours Service carried out at kilometres or hours on date Serv...

Page 518: ...ash SAE 10W40 15W40 Manual Transmission and Transfer Case Same as engine oil Clutch Automated Manual Transmission AMT Isuzu AMT FLUID or equivalent Differential API GL5 SAE 85W140 plus Isuzu additive...

Page 519: ...el Deutsche Industrie Normen DIN Based on EN590 2004 American Society for Testing and Materials ASTM Based on D975 04c NO 1 D S15 or NO 2 D S15 below 15 ppm British Standards BS Based on EN590 2004 AD...

Page 520: ...7 174 SERVICE AND MAINTENANCE Notes 2008N_sec07 3_print2 indd 174 4 09 2008 8 16 33 AM...

Page 521: ...the Brakes Do not Work 8 11 When the Battery Goes Flat 8 12 When the Fuel Runs Out 8 14 When the Warning Light Comes On 8 16 When the Engine Overheats 8 22 When the Meter Shows an Abnormality 8 23 Wh...

Page 522: ...own in the following table occurs perform inspections and take corrective action in accordance with the table If you are unable to perform a repair the corrective action shown in the table does not el...

Page 523: ...N position AMT vehicles 4 82 Haven t depressed brake pedal or apply parking brake AMT vehicles Depress brake pedal or apply parking brake 4 82 Starter turns over No fuel Make sure there are no fuel l...

Page 524: ...clogged with dirt Clean with a soft bristle brush Radiator cap not sufficiently tightened Make sure it is firmly tightened Fan belt loose Adjust the tension or replace the belt 7 45 Coolant dirty Cle...

Page 525: ...rail system faulty Engine faulty DPD clogged Brakes not effective Drum to lining gap too large Air in brake fluid Brake system failure Uneven braking Unbalanced air pressure in tyres Adjust to proper...

Page 526: ...sufficient clutch fluid Add fluid 7 101 Excessive clutch pedal free play Adjust to proper level 7 104 Loud or abnormal noises From the transmis sion Insufficient transmission oil Add oil 7 107 Transmi...

Page 527: ...o the presence of your vehicle 2 Have the other passengers get out and wait in a safe place 3 Walk to a safe place and take appropriate measures by using the closest telephone etc When the Vehicle Bre...

Page 528: ...o prevent obstructing other vehicles or pedestrians When the Tyre Goes Flat WARNING If you continue to drive on a flat tyre undue force will be applied to the wheel studs possibly causing the studs to...

Page 529: ...ke effectiveness will be greatly reduced Be sure to apply more pressure than usual to the brake pedal As the brake booster will no longer operate brake effectiveness will be reduced If the engine cann...

Page 530: ...ion Then make sure that the shift indicator displays N and push the vehicle to a safe place When the Engine Stalls and Cannot be Restarted If the AMT System Fails Refer to page 4 95 CAUTION In case of...

Page 531: ...the vehicle on the side of the road CAUTION It is very dangerous to suddenly pull the parking brake lever all the way while moving at high speed Reduce speed first by shifting down and then gradually...

Page 532: ...ach other Ask the nearest Isuzu Dealer to recharge the battery Do not disconnect a battery terminal with the engine running It could cause a breakdown in the electrical system 1 Check the battery flui...

Page 533: ...connect one end of the jumper cable shown in Step 4 in the drawing directly to the battery s negative terminal Connect the jumper cable to a metal part of the engine that is away from the battery Do n...

Page 534: ...the driver s seat and make sure that the gearshift lever is placed in the N position Alternatively in the case of the AMT vehicle make sure that the shift indicator displays N Do not start the engine...

Page 535: ...wn about 10 times to feed air in the fuel system to the fuel supply pump 5 Turn the starter switch to start the engine After starting the engine 1 Without depressing the accelerator pedal turn the sta...

Page 536: ...also come on CAUTION If the warning buzzer should sound during usage of the exhaust brake immediately park the vehicle in a safe place and take the following action With the engine still running turn...

Page 537: ...light comes on while the engine is running after startup in the following situations Drop in the level of brake fluid due to brake lining wear or fluid leakage etc Abnormality in the charging system s...

Page 538: ...if the fan belt is broken or loose 2 If the fan belt is loose adjust the tension 3 If there is no abnormality in the fan belt contact the nearest Isuzu Dealer Fan Belt Refer to page 7 45 CAUTION Do n...

Page 539: ...d there are no oil leaks the oil filter may be clogged Replace the oil filter 4 When the oil level is normal and the oil filter is not clogged but there are oil leaks contact the nearest Isuzu Dealer...

Page 540: ...abnormality in seat belts with a pretensioner and the SRS airbag system they may not work normally Have the system checked by the nearest Isuzu Dealer NOTE It is normal for the warning light to come...

Page 541: ...repairing the control system is required immediately contact the nearest Isuzu Dealer HSA Indicator Light V HSA Indicator Light V Refer to page 4 52 ASR Indicator Light V ASR Indicator Light V Refer...

Page 542: ...E Do not stop the engine immediately Otherwise the engine may seize 3 When the needle of the engine coolant temperature gauge returns to the middle of the safety zone stop the engine WARNING Even when...

Page 543: ...ot sufficiently cool could cause a breakdown in the engine or damage it When tap water only has been used for coolant in an emergency adjust the coolant concentration as soon as possible Engine Coolan...

Page 544: ...te light 10W 1 light type 5W 2 light type Rear fog light V 21W Interior Dome light V 10W Rear dome light V 10W Roof Roof mounted clearance light V 5W 1 Check each bulb for blowout 2 If a bulb has blow...

Page 545: ...This will cause abnormal flashing particularly for turn signal lights When replacing headlight bulbs have the headlight aim adjusted at your Isuzu Dealer Bulb Wattage Refer to page 8 24 ADVICE When o...

Page 546: ...rd the front of the vehicle and remove it Halogen Headlight NLR NNR NPR NQR NPS Models 1 Remove the screw from the centre of the grille Push up on the tabs of the five clips on the upper side of the g...

Page 547: ...ect the headlight leveling connector Then remove the headlight assembly ADVICE When removing the headlight connector pull out the connector while holding the centre portion of the rubber boot If the h...

Page 548: ...Do not touch the glass of the bulb with your hand Soiling the glass will cause the bulb to blow out When attaching the rubber boot press in both the outside and inside circumference of it Make sure t...

Page 549: ...rely water could get inside the light and lead to a breakdown Replacing a Clearance Light NLR NNR NPR NQR NPS Models 1 Refer to Replacing the Headlights and remove the headlight assembly Replacing the...

Page 550: ...If the socket is not locked securely water could get inside the light and lead to a breakdown 2 Disconnect the connector for the turn signal light and then remove the socket Replacing a Turn Signal L...

Page 551: ...on the side of the rear of the light from the door panel MFU780SH001201 Clips 3 When the clip has been removed pull the light out while sliding it out toward the rear of the vehicle Replacing a Corner...

Page 552: ...e to lock securely ADVICE If the socket is not locked securely water could get inside the light and lead to a breakdown b Insert the clip on the back of the rear part of the light into the door panel...

Page 553: ...support is securely engaged after the cab is tilted Do not tilt the cab when objects are placed on or in the instrument panel seats cup holders or floor surface Remove any ice or snow accumulating on...

Page 554: ...ng points Since there are different notches on the bulb on top and bottom rounded or square pay attention to the direction of insertion when installing The round notch should face up on both the left...

Page 555: ...move the lens 3 Loosen the bulb by turning it counterclockwise while pressing on it 4 To install the lights follow the removal procedure in reverse Replacing the Rear Fog Light 1 Loosen the screws and...

Page 556: ...hts follow the removal procedure in reverse Replacing the Dome Light Replacing the Roof Mounted Clearance Light V 1 Loosen the screws and remove the lens 2 Remove the bulb and replace it with a new on...

Page 557: ...cover of the relay box at the rear of the cab must also be opened at this time When the lights won t come on or flash or the equipment in the electrical system does not operate check to see if a fuse...

Page 558: ...NING Use fuses of the same rating for replacement Do not use any other fuses than those designated Using fuses other than those specified could result in fire or damage to the equipment If the new fus...

Page 559: ...but there is no problem with the fuses check the slow blow fuse Replace the slow blow fuse when it blows Please contact the nearest Isuzu Dealer Slow blow fuses protect the electrical circuits and the...

Page 560: ...10A 11 H LAMP LO RH 10A 12 STOP LAMP 10A 13 IGNITION2 15A 14 H LAMP HI LH 10A 15 H LAMP HI RH 10A 16 ELEC PTO KEY ST 10A 17 STARTER 10A No Description Rating 18 IGNITION1 15A 19 SRS 10A 20 ECM 10A 21...

Page 561: ...5 REAR FOG LAMP 6 WIPER MAIN 7 HORN 8 WIPER HIGH LOW 9 FOG LAMP 10 PTO MAIN 11 DOOR LOCK UNLOCK No Description 12 POWER WINDOW 13 HEAD LAMP LOW 14 4WD 15 HEAD LAMP HIGH 16 TAIL LAMP 17 PTO SOLENOID M...

Page 562: ...STARTER 2 ECM 3 GLOW PLUG 4 A C COMPRESSOR 5 CONDENSER FAN 6 STARTER CUTOFF 7 MARKER LAMP 8 GEARSHIFTER 9 4WD 4HK1 ENGINE MODEL 10 TRANSFER GEAR CONTROL No Fuse name Rating 1 MARKER LAMP 10A 2 ECM MA...

Page 563: ...receive instructions 4 Confirm information from other parties name address and telephone number and the conditions of the accident 5 If necessary contact the insurance company or the dealer you purch...

Page 564: ...place the gearshift lever in the N position and make sure the shift indicator displays N Tow for a maximum distance of 10 km 6 2 miles at speeds less than 40 km h 25 MPH When the shift indicator does...

Page 565: ...he engine cannot be started If the transmission is damaged disconnect the propeller shaft at the rear axle flange and secure it to the frame If the rear axle fails or rear axle failure is suspected re...

Page 566: ...and damage it Attach a rope to the towing hook only Attaching a rope to other part of the vehicle could damage it Make sure there are no people near the towing rope and hook before towing a vehicle I...

Page 567: ...uld cause the brakes to activate during towing Contact a tow truck at these times When the vehicle will descend long hills The brakes could overheat and become ineffective When the transmission or dif...

Page 568: ...8 48 IN CASE OF EMERGENCY 2008N_sec08_print2 indd 48 4 09 2008 8 14 37 AM...

Page 569: ...MAIN DATA Main Data and Specifications 9 2 9 2008N_sec09_print2 indd 1 4 09 2008 8 19 25 AM...

Page 570: ...Valve clearance mm in Both intake and exhaust valves 0 15 0 006 in cold engine Idling speed r min 575 625 Fan belt tension mm in Hz New belt 4 6 0 16 0 24 212 236 Used belt 6 8 0 24 0 31 181 195 Oil f...

Page 571: ...tres US gal lmp gal 2WD model 13 0 3 43 2 86 including capacity of 3 0 0 79 0 66 in filter 4WD model 12 5 3 30 2 75 including capacity of 3 0 0 79 0 66 in filter Coolant capacity Reference value litre...

Page 572: ...ratio to 1 1st 6 369 2nd 3 767 3rd 1 966 4th 1 355 5th 1 000 6th 0 782 Reverse 6 369 Transmission oil capacity Reference value litres US gal lmp gal Model without PTO 4 4 1 16 0 97 Model with PTO 5 3...

Page 573: ...MAIN DATA Main Data and Specifications 9 2 9 2008N_sec09_print2 indd 1 4 09 2008 8 19 25 AM...

Page 574: ...Valve clearance mm in Both intake and exhaust valves 0 15 0 006 in cold engine Idling speed r min 575 625 Fan belt tension mm in Hz New belt 4 6 0 16 0 24 212 236 Used belt 6 8 0 24 0 31 181 195 Oil f...

Page 575: ...tres US gal lmp gal 2WD model 13 0 3 43 2 86 including capacity of 3 0 0 79 0 66 in filter 4WD model 12 5 3 30 2 75 including capacity of 3 0 0 79 0 66 in filter Coolant capacity Reference value litre...

Page 576: ...ratio to 1 1st 6 369 2nd 3 767 3rd 1 966 4th 1 355 5th 1 000 6th 0 782 Reverse 6 369 Transmission oil capacity Reference value litres US gal lmp gal Model without PTO 4 4 1 16 0 97 Model with PTO 5 3...

Page 577: ...ook V 5 29 Combination Light Control Switch 4 64 Cruise Control V 4 108 Cup Holder V 5 27 D Daily Checks Preoperational Checks 7 16 Diesel Particulate Defuser DPD 2 60 4 154 7 58 Disc Brakes V 7 73 Di...

Page 578: ...enuine Oils and Grease 7 6 K Key 3 2 Key with Immobilizer Transponder Chip V 3 3 Keyless Entry System V 3 4 M Main Data and Specifications 9 2 Mirror Heater Switch V 4 74 Mirrors 3 22 Model with AMT S...

Page 579: ...4 15 Warning Buzzer 4 58 Warning Caution Labels in Your Vehicle 0 21 Warning Indicator Light Index 0 16 Wheels and Tyres 7 77 When Driving on Bad Roads 8 42 When the Battery Goes Flat 8 12 When the B...

Page 580: ...MEMO 2008N_sec10_print2 indd 4 4 09 2008 8 20 28 AM...

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