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Isuzu NPR 2008, Owner'S Manual

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Isuzu NPR 2008 Owner'S Manual Download Page 156

5-47

Installation

1. Fix the headlight with bolts after positioning the guide pins on the

headlight and the holes of the cab panel.

2. Install the front corner panel clips and screw.
3. Install the front grille.

Clip

Connector

Cap

Headlight Bulb

Headlight bulb

1. Remove the rubber cover, press the right side of the clip for

fastening the bulb and displace upwards to remove the clip.

2. Pull out the bulb and replace it with a new one.

CAUTION:
• Do not touch the glass portion of the bulb with your fingers.
• When installing the cap, firmly push in the cap's inner and outer

circumference, installing securely so that there is no float
between the cap, and the headlight body and bulb. If the cap is
not correctly installed, water may infiltrate the headlight resulting
in a breakdown.

 55702_Sec05-2_'08  08.2.12 9:51 AM  Page 47

Summary of Contents for NPR 2008

Page 1: ...chniques 2 14 Steering Column Controls 2 16 Brake System 2 22 Instrument Panel and Controls 2 29 3 In Case of Emergency 3 1 Reporting Safety Defects 3 14 4 Appearance Care 4 1 5 Service and Maintenanc...

Page 2: ...oncern that has not been handled to your satisfaction follow the steps in the separate Warranty and Owner Assistance Information booklet We thank you for choosing an Isuzu product and want to assure y...

Page 3: ...XHAUST BRAKE WINDSHIELD WIPER WINDSHIELD WASHER BODY INTERIOR LIGHT SWITCH ILLUMINATION CONTROL IDLE SPEED CONTROL HAZARD WARNING FLASHER HIGH BEAM GLOW PLUG BATTERY CHARGING CONDITION FACE BI LEVEL F...

Page 4: ...N LIGHT CRUISE CONTROL RESUME ACCEL CRUISE CONTROL SET COAST HORN PARKING BRAKE INDICATOR BRAKE SYSTEM WARNING LIGHT DPF OVERDRIVE BRAKE LOW VACUUM ANTI LOCK BRAKE SYSTEM CHECK TRANS ENGINE SHUT DOWN...

Page 5: ...pension components for added durability may not increase any of the weight ratings shown on the Vehicle Identification Number VIN and Weight Rating Plate CAUTION The components of your truck are desig...

Page 6: ...ission frame springs brakes axles and tires Actual loads at the front and the rear axles can only be determined by weighing the vehicle This can be done at highway weigh stations or other such places...

Page 7: ...TION NUMBER VIN AND WEIGHT RATING PLATE Your VIN and Weight Rating Plate shows the GVWR Gross Vehicle Weight Rating and the front and rear GAWRs for your vehicle Gross Vehicle Weight GVW is the weight...

Page 8: ...0 7 MODEL REFERENCE The model covered in this manual is NPR Single cab model NPR MODEL 55702_Sec00_ 08 08 2 12 9 41 AM Page 7...

Page 9: ...Model Year Code Identifiers Cab Type Code 2008 Code Description JAL ISUZU Code Description 1 4 x 2 Code Plant Location 7 Fujisawa Code Description Cab Type W Code Series 4 NPR Code Description B 10001...

Page 10: ...cator light goes off then START The BRAKE system warning light should stay on when the parking brake is applied 2 Check all gauges including the fuel gauge and indicator lights 3 Adjust the seat 4 Be...

Page 11: ...eau of Motor Carrier Safety requirements See related topics under Maintenance Schedule in Section 5 especially if problems are found One key can operate all the locks on the vehicle Keep one of the tw...

Page 12: ...at the rear edge of the door s outer panel To open the door from outside the vehicle pull up on the handle INSIDE DOOR HANDLES An inside handle for opening each cab door is located in the recessed ar...

Page 13: ...y be locked from outside of the vehicle by inserting the key into the door lock and turning it counterclockwise for the driver s door and clockwise for the passenger s door Locking the driver s door w...

Page 14: ...o raise and lower the window POWER WINDOWS IF EQUIPPED POWER WINDOW SWITCH DRIVER S DOOR The power window switch on the driver s door can operate both driver s and passenger s power windows For driver...

Page 15: ...ontinues its downward motion until the switch is released or the window is fully opened Pull up on the switch to close the window The window continues its upward motion until the switch is released or...

Page 16: ...peration This helps you determine the location of objects seen in the mirror SUN VISORS The sun visors may be swung down to prevent glare from the front They may also be swung to the side CAUTION Do n...

Page 17: ...t adjustment and a seatback tilt adjustment The fore and aft adjustment lever is located in front of the seat at the base of the cushion Move the lever to the upside adjust the seat position and relea...

Page 18: ...UTION To reduce the risk of sliding under the lap belt during a collision an occupied reclining seat should not be reclined any more than needed for comfort The seatback and seat belts provide best re...

Page 19: ...release it by working the belt in and out until the belt rewinds far enough to unlock However if the belt remains jammed or other parts of the restraint system do not work properly have your dealer se...

Page 20: ...2 To reduce the risk of sliding under the belt during a collision position the belt across your lap as low on your hips as possible and adjust it to a snug fit by pulling the shoulder portion upward t...

Page 21: ...e latch plate while the belt is retracting to keep it from hitting people or nearby objects To help prevent damage to the seat belt and interior trim before closing the door be sure the belt is fully...

Page 22: ...ractors anchorages and guide loops work properly look for loose parts or damage without disassembly that could keep the restraint system from doing its job Have a belt assembly replaced if the webbing...

Page 23: ...p Secure the child in the restraint in accordance with the child restraint manufacturer s instructions CAUTION Children small enough for child restraints as indicated on the label of such restraints i...

Page 24: ...clip is not used or installed properly the child restraint may move or tip over when your vehicle turns or stops abruptly Secure the child restraint with the lap belt portion of the seat belt in accor...

Page 25: ...n extender When you go in to order it take the heaviest coat you will wear so the extender will be long enough for you The extender will be just for you and just for the seat in your vehicle that you...

Page 26: ...the vehicle stop the engine to prevent burns Always use diesel fuel Use of low quality fuel may adversely affect the engine parts and cause failure Use of other than specified fuel may adversely affec...

Page 27: ...e exhaust brake valve is activated and deactivated This is not a failure A small amount of white smoke may be emitted from the exhaust pipe with Particulate Matter PM burned during DPF regeneration Th...

Page 28: ...periods of time Pay close attention to the heat of the exhaust gas during idling especially when using the PTO POWER TAKE OFF or afterburning on the vehicle equipped with the DPF CAUTION Always use di...

Page 29: ...nlet grille clear of snow leaves or other obstructions at all times Do not park with the engine running or idle this vehicle for more than 10 minutes with the ventilation system control switch in the...

Page 30: ...tarting a loaded vehicle and when climbing slopes to avoid lugging the engine Use the correct gear to maintain the desired road speed without lugging the engine Avoid racing the engine full throttle s...

Page 31: ...as printed no other fuel additive was recommended See your authorized dealer to find out if this has changed Take care not to run out of diesel fuel If you do run out of fuel you may need to bleed air...

Page 32: ...l fuel is sensitive to temperature All diesel fuel has a certain amount of paraffin components which are high in energy value and help improve fuel economy But when temperatures are below about 20 F 7...

Page 33: ...touch the fuel coming from the water separator drain valve and do not expose the fuel to open flames or sparks Be sure you do not overfill the drain pan Heat such as from the engine can cause the fue...

Page 34: ...ps that waste energy in the form of heat generated in braking Frequent short trips excessive idling and use of the air conditioner in cool weather when Vent would provide adequate comfort can all lead...

Page 35: ...eep pushing the key while turning from ACC to LOCK B ACC Accessory is in the first position clockwise Electrical accessories can be operated without the engine control circuit being energized C ON The...

Page 36: ...icient time to let the engine circulate lubricant oil before driving This usually requires 30 sec to 2 min depending on ambient conditions DO NOT RACE THE ENGINE TO SPEED WARM UP Turn the idle speed c...

Page 37: ...should be out when the parking brake is released and the engine is running If it stays on it could mean that the brake fluid level is low Check the brake fluid level indicator This condition must be...

Page 38: ...ng the vehicle parked on an incline block the wheels or turn the front wheel into the curb to prevent the vehicle from rolling KEY REMOVAL To remove the key turn the Engine Control Switch to the LOCK...

Page 39: ...in a garage the block and pan heaters should not be needed until the garage temperature drops below 10 F 23 C regardless of outside temperature The engine block and oil pan heaters are designed to war...

Page 40: ...vent theft of the vehicle its equipment and contents But these anti theft features depend upon you to work The time to be most on guard is when leaving the vehicle 1 Park in a lighted spot when you ca...

Page 41: ...at combustible materials could catch fire from the vehicle s hot exhaust system Carry a fire extinguisher with the vehicle at these times Avoid driving your vehicle through or over combustible materia...

Page 42: ...and it may pull to the right or left After checking to the rear for other vehicles apply the brakes lightly to check whether this has happened To dry them quickly Iightly apply the brakes At the same...

Page 43: ...engine electric parts transmission propeller shaft differential and transfer for water intrusion and apply grease and oil to each area Drive steering and braking traction is reduced when water snow i...

Page 44: ...speed under control and providing the grade conditions permit the transmission can be progressively down shifted using the exhaust brake in each gear Eventually the exhaust brake should slow the vehi...

Page 45: ...d to flash to tell you that the front and rear turn signal lights are working If the light stays on but does not flash check for a burned out turn signal bulb If the green light does not come on when...

Page 46: ...ghts are off pulling the switch up will momentarily turn on the high beams to signal your intention to pass RIGHT HAND CONTROL LEVER The right hand control lever controls the exhaust brake windshield...

Page 47: ...g the winter to allow for expansion if the temperature should fall low enough to freeze the solution NOTICE Do not use radiator antifreeze in the windshield washer it could cause paint damage and clou...

Page 48: ...ill help control your speed Do not hold the brake pedal down too long or too often while going downhill This could cause the brakes to get hot and not work as well As a result the truck will not slow...

Page 49: ...steering control which may result in personal injury or death POWER STEERING If the power assist steering system goes out because the engine has stopped or the assist system has malfunctioned the veh...

Page 50: ...eration have brake system checked immediately Do not pump the brake pedal as this will only deplete the vacuum reserve Always turn off the manual engine idle control knob to the full counterclockwise...

Page 51: ...from that of conventional diesel vehicles With long continuous idling the exhaust brake may be activated to prevent white smoke after a certain period of time VACUUM POWER ASSISTED BRAKES If the engi...

Page 52: ...ed when the engine control switch is on Never drive the vehicle with the parking brake set as this will cause excessive wear reduce parking brake effectiveness and increase fuel consumption If you not...

Page 53: ...or SELECTING GEARS Push the button located on the end of the selector when engaging the R and P positions and when shifting from 2 to 1 as indicated by the arrow The selector can be shifted freely int...

Page 54: ...hich the engine can be started NEVER MOVE THE SELECTOR TO THE P POSITION WHEN THE TRUCK IS IN MOTION R REVERSE Bring the truck to a complete stop before moving the selector to the R position N NEUTRAL...

Page 55: ...ing DRIVING TIPS Before descending a long steep grade reduce speed and turn off the overdrive switch This is the safe way to control your truck s speed Avoid continuous or frequent use of the wheel br...

Page 56: ...ry road a winding road or a long downhill slope you will want to take advantage of the engine s braking power Push the overdrive switch to the OFF position at this time NOTICE Continued Operating the...

Page 57: ...on the instrument panel By activating certain controls and switches an indicator will light to confirm the selection and operation of equipment or system However a warning light should automatically t...

Page 58: ...ngine Malfunction Indicator Light 6 Oil Level Indicator Light 7 Engine Oil Pressure Warning Light 8 Glow Plug Indicator Light 9 Service Vehicle Soon SVS Light 10 Parking Brake Indicator Light Brake Sy...

Page 59: ...line In addition after topping up close the cap securely See the Maintenance Schedule in Section 5 for other brake checks If the Anti lock brake system malfunctions the ABS malfunction warning light...

Page 60: ...ean that there is something wrong with part of the brake system What to do 1 Check to see that the parking brake has been released If it has been 2 Turn on the exhaust brake to help slow the vehicle 3...

Page 61: ...ning Light The warning light comes on and the alarm buzzer rings when the engine coolant temperature gauge goes into the red zone indicating overheat BRAKE CAUTION If this light comes on and stays on...

Page 62: ...evel Indicator Light can indicate if the engine oil level is OK or low With the engine control switch in the OFF position push the OIL CHECK switch on the left hand side of the instrument panel The re...

Page 63: ...eakage of fluid from the transmission breather hose The indicator light should turn on when the engine control switch is turned to the ON position but should go out after a few seconds If this light c...

Page 64: ...er Red If the indicator light comes on amber or red you must regenerate the DPF If the indicator changes from amber to red the DPF requires immediate regeneration If the DPF is not regenerated the che...

Page 65: ...p of the wheels during braking by automatically changing the brake pressure This occurs only during braking which would have caused one or more wheels to lock NOTICE If the light comes on during vehic...

Page 66: ...xplanation of Electronic Braking force Distribution EBD The ABS has an EBD function The EBD uses the ABS system and is a function that prevents early stage rear wheel lock up by adequately controlling...

Page 67: ...control several aspects of the vehicle s performance Your vehicle uses onboard vehicle computers to monitor emission control components to optimize fuel economy and if so equipped to provide anti lock...

Page 68: ...f you have an automatic transmission and you apply your brakes the cruise control will shut off CAUTION Cruise control can be dangerous where you can t drive safely at a steady speed Do not use cruise...

Page 69: ...the switch or apply the brake So unless you want to go faster do not hold the switch at the RES position INCREASING SPEED WHILE USING CRUISE CONTROL There are two ways to go to a higher speed Use the...

Page 70: ...ke or shift to a lower gear to keep your speed down Of course applying the brake takes you out of cruise control Many drivers find this to be too much trouble and do not use cruise control on steep hi...

Page 71: ...t of the steering column mounted on a panel in the instrument panel Engine RPM can be increased by turning the idle speed control knob clockwise To return the engine to its normal idle speed turn the...

Page 72: ...the outside rearview mirror s face to defog With the engine control switch in the ON position press the outside rearview mirror heater switch to operate and the operation indicating light will turn to...

Page 73: ...stopped and on sloping ground As a result the red Engine Oil Pressure Warning Light may light up When checking the oil level press the Oil check switch on level ground while the engine is cool MILES...

Page 74: ...ch PTO Main Switch CAUTION If you activate the PTO on the vehicle with PTO for a long time make sure that the DPF indicator light does not come on CAUTION In PTO mode Cruise Set Resume Switch can be u...

Page 75: ...pe mixes air with the exhaust gas to lower its temperature before it leaves the exhaust pipe Do not alter or block the airflow from the exhaust pipe The DPF will regenerate self clean itself as part o...

Page 76: ...neration may not complete in some cases of operating and driving patterns and conditions In the event of this the DPF indicator amber or red will come on Depending on the driving conditions Automatic...

Page 77: ...DPF performs regeneration automatically when a certain quantity of PM accumulates in the filter Depending upon running conditions however the regeneration may sometimes not be completed In this case...

Page 78: ...gine speed 4 In the case of a vehicle fitted with a PTO POWER TAKE OFF unit stop operation of the PTO Return the PTO switch and the external acceleration control to their initial positions Emergency r...

Page 79: ...ion white smoke may be emitted Do not perform the regeneration in a poorly ventilated room CAUTION When you wish to operate the PTO on a vehicle fitted with a PTO unit for a long period confirm that t...

Page 80: ...ed more quickly after the vehicle has just stopped driving compared to when the engine is cold During manual regeneration the coolant temperature may sometimes rise When the DPF indicator light red is...

Page 81: ...ire ensure that there is no combustible material near the DPF exhaust pipe or muffler Be careful not to burn yourself on the hot exhaust gas CAUTION Perform selectable regeneration without interruptio...

Page 82: ...case promptly stop the vehicle press the DPF switch again and wait until the completion of selectable regeneration Do not continue to drive the vehicle while the indicator lights amber green remain on...

Page 83: ...a certain period of time Furthermore the trip meter can indicate two different point to point distances Change indicator and reset knob Push the odometer and the trip meter knob for approximately 0 8...

Page 84: ...witch If equipped 12 Cruise Control Main Switch 13 Hazard Lights Warning Flasher Switch 14 Heater and Defroster Control Panel 15 Card Holder 16 Beverage Holder 17 Door Lock Switch If equipped 18 Miles...

Page 85: ...condition exists as indicated by the pointer moving beyond the white color line immediate action by the driver is required If an overheat condition is shown refer to Engine Cooling System Overheating...

Page 86: ...e is reached ACCESSORY POWER OUTLET Accessory power outlets are located beside the cigarette lighter in the instrument panel You can plug in auxiliary electrical equipment Just flip the outlet cover o...

Page 87: ...upward and warm air downward 1 Air Conditioning Switch 2 Fan Control Knob 3 Temperature Control Knob 4 Air source Selector Lever 5 Air Selector Knob CAUTION See Engine Exhaust Gas Caution Carbon Monox...

Page 88: ...e floor outlets The air from the floor outlets is warmer than the air from the upper outlets in this position However when the temperature control lever is moved to either the full HOT or the full COL...

Page 89: ...eas of the windshield under most inclement weather conditions The windshield should be scraped clear if coated with ice or snow When the DEFROST mode is selected and the fan control knob is in other p...

Page 90: ...witch again EMERGENCY STARTING YOUR VEHICLE DUE TO A DISCHARGED BATTERY If your vehicle will not start due to discharged batteries it can often be started by using energy from another battery a proced...

Page 91: ...battery acid to contact eyes or skin Flush any contacted area with water immediately and thoroughly and get medical help Follow each step in the jump starting instructions JUMP STARTING INSTRUCTIONS...

Page 92: ...Coolant Temperature Gauge shows an overheat condition or you have other reasons to suspect the engine may be overheating continued operation of the engine other than as described here even for a shor...

Page 93: ...t remove the radiator cap while the engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if either cap is taken off too soon If no steam or engine coolant can be...

Page 94: ...ndition If no cause for the overheat condition was found see a qualified service technician DAMAGED TIRES CAUTION To help avoid being burned do not spill antifreeze or engine coolant on the exhaust sy...

Page 95: ...r is seriously low on air without first having the tire taken off the wheel and the tire checked for damage 4 Note that taking off and mounting tires on truck wheels requires proper tools safety equip...

Page 96: ...used on the wheels must seat before the fastener will hold a uniform clamp load and remain fully tightened Also have a technician tighten wheel stud nuts and rim clamp nuts with a torque wrench after...

Page 97: ...DO NOT attach to bumpers tow hooks or brackets Use only equipment designed for this purpose Follow the instructions of the wrecker manufacturer A safety chain system must be used The procedures below...

Page 98: ...wing vehicle FRONT END TOWING ALL WHEELS ON THE GROUND Your vehicle may be towed on all wheels provided the steering is operable Remember that power steering and brakes will not have power assist Ther...

Page 99: ...t towing chains and bar from coming into contact with the bumper If there is damage or suspected damage to the rear axle remove the axle shafts Cover the hub openings to prevent the loss of lubricant...

Page 100: ...tanders or other motorists should be attempted FREEING THE VEHICLE FROM SAND MUD SNOW AND ICE CAUTION Do not spin wheels faster than 20 MPH 32 km h Personal injury or death and damage may result from...

Page 101: ...while coasting Refer to Exhaust Brake System in Section 2 for operating instructions STOPPING THE VEHICLE IN THE EVENT OF SERVICE BRAKE MALFUNCTION The exhaust brake should be turned on as soon as a s...

Page 102: ...e dealership please contact Isuzu Commercial Truck of America Customer Relations Department 46401 Commerce Center Drive Plymouth MI 48170 in writing or call 1 866 441 9638 Our representatives will rev...

Page 103: ...ds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Isuzu Commercial...

Page 104: ...a health problem that is more likely to occur in small unventilated spaces NOTICE To avoid possible permanent discoloration of light colored seats DO NOT Iet materials with non fast colors come into...

Page 105: ...sheen or luster For suede raise nap with dry scrub brush and vacuum to remove any final traces of residue Spot Cleaning Fabric Type Trim With Solvent Type Cleaner Before trying to remove a spot or st...

Page 106: ...yonnaise chili sauce and unknown stains Carefully scrape off excess stain then clean with cool water and allow to dry If stain remains clean it with Fabric Cleaner Solvent type Cleaning Vinyl Trim Ord...

Page 107: ...cle in lukewarm or cold water Do not use hot water or wash your vehicle in the direct rays of the sun Do not use strong soap or chemical detergents All cleaning agents should be flushed promptly from...

Page 108: ...requires sheet metal repair or replacement make sure the body repair shop applies anti corrosion material to the parts repaired or replaced so that corrosion protection is restored Also see Finish Dam...

Page 109: ...s frames floor pan and exhaust system even though they have been provided with corrosion protection At least every spring flush these materials from the underbody with plain water Take care to clean w...

Page 110: ...n good condition see your authorized dealer the place many Isuzu truck owners choose to have their maintenance work done Your authorized dealer can be relied upon to use proper parts and practices Som...

Page 111: ...e repeated after the initial 110 000 miles 176 000 kilometers at the same intervals PREVENTIVE MAINTENANCE As any mechanical device operates a certain amount of wear occurs The amount of wear depends...

Page 112: ...lometers 1 When recommended oil is used it conforms to this maintenance schedule Recommended oil CJ 4 API DESIGNATIONS with viscosity W40 Use of oils other than CJ 4 may require shorter maintenance in...

Page 113: ...Damage I I I I I I or every 12 months 19 Brake Fluid I I R I I R I I R I I or every 12 months 5 4 I Inspect replace or adjust if necessary A Adjust R Replace T Tighten to specified torque L Lubricate...

Page 114: ...R R or every 24 months 25 Power Steering Oil Hose R R or every 24 months 26 Steering Gear Box Torque T T T T T or every 12 months 27 Driveshaft Flange Torque T T T T T T T T T T T or every 12 months...

Page 115: ...rque Every 6 500 miles 10 400 km 31 King Pin L L L L L L L L L L L or every 12 months 32 Wheel Bearing Grease R R R or every 12 months 33 Air Conditioner Blower Filter Cleaned once a month No Item Int...

Page 116: ...icle s diesel engine see CHOOSING OIL VISCOSITY on page 5 22 Genuine ISUZU SCS Transmission Fluid Do not use DEXRON III ATF DEXRON III Multi purpose gear oil SAE90 GL 5 Multi purpose gear oil SAE90 GL...

Page 117: ...ce Retorque rocker shaft bracket nuts before checking and adjusting valve clearance Check and adjust valve clearance every 50 000 miles 80 000 km 3 ENGINE OIL AND OIL FILTER Change at interval noted b...

Page 118: ...indicator When the air filter is checked up it cleans When 6 times it cleans you exchange with new ones Your dealer or service facility can be of assistance in determining the proper replacement freq...

Page 119: ...0 hours whichever occurs first 14 DPF Pressure Difference Sensor 0 Point Adjustment Adjust the sensor every 100 000 miles 160 000 km or 3 000 hours whichever occurs first 15 DPF Pressure Difference Se...

Page 120: ...INE AND HOSES Check lines and hoses for proper hook up binding leaks cracks chafing etc every 20 000 miles 32 000 km Any questionable parts should be replaced or repaired at once When rubbing or wear...

Page 121: ...24 POWER STEERING FLUID Replace power steering fluid every 24 months or 30 000 miles 48 000 km whichever occurs first 25 POWER STEERING OIL HOSE Replace power steering oil hose every 24 months or 50 0...

Page 122: ...miles 1 040 km and then every 6 500 miles 10 400 km Note that there are left and right hand threads Specified tightening torque 490 N m 362 ft Ibs 31 KING PIN Lubricate the grease fitting on the king...

Page 123: ...tarts be ready to turn off the ignition engine control switch at once Take these precautions because the vehicle could move without warning and possibly cause injury or property damage B STARTER SAFET...

Page 124: ...and the fan lever to the fully clockwise position Then check the airflow from the ducts at the inside base of the windshield J REARVIEW MIRRORS AND SUN VISORS Check that friction joints hold mirrors a...

Page 125: ...at any time have the cause found and corrected at once S UNDERBODY Corrosive materials used for ice removal snow removal and dust control can collect on the underbody If these materials are not remove...

Page 126: ...r or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or...

Page 127: ...If you need to replace the fuel filler cap use only a genuine Isuzu fuel filler cap The use of an improper fuel filler cap could cause fuel spillage in the event of an accident The use of an improper...

Page 128: ...engine Be sure to reinstall the dipstick CHECK ENGINE OIL LEVEL The DPF performs regeneration automatically when a certain quantity of PM accumulates within the filter To perform regeneration post inj...

Page 129: ...n fast enough to give an accurate reading NOTICE Be sure to add enough oil to put the level somewhere between the MIN and FULL range Never add oil above the FULL mark 2 Pull out the dipstick wipe the...

Page 130: ...an the Position A level on the oil level gauge there is a possibility engine damage may occur If the oil level exceeds the Position A level the engine oil must be drained and refilled with oil of the...

Page 131: ...r conditions require higher viscosity engine oils for satisfactory lubrication When choosing an oil consider the range of temperature your vehicle will be operated in before the next oil change Then s...

Page 132: ...ine oil filters Using oil other than recommended or oil and filter change intervals longer than recommended could reduce engine life Damage to engines due to improper maintenance or use of incorrect o...

Page 133: ...ne when it is warm or hot or when it is running can cause serious damage to the engine and its components particularly the fuel supply pump Discard used engine oil and other oils properly EXTERNAL DIE...

Page 134: ...o the side never above or opposite the filler opening 3 Check that the fuel cap is tight and see to it that engine oil engine coolant in the reservoir and washer fluid etc are at proper levels Then do...

Page 135: ...AUTION The diesel engine in models covered by this manual will operate on any fuel which enters the cylinders whether it be from the fuel injectors or the air inlet system If any of the solvent which...

Page 136: ...m of the fuel filter NOTICE To help avoid engine damage When the water separator indicator light comes on loosen the drain plug under the fuel filter and move the priming pump up and down by hand from...

Page 137: ...l enter the fuel system and cause starting trouble Before Starting The Engine 1 Sufficiently loosen the air bleeding plug on the side of the fuel filter Attach a vinyl hose etc to the plug in order to...

Page 138: ...d period If by mistake gasoline is poured into the diesel fuel tank and the engine is operated for a short period of time the entire system must be drained otherwise damage to the fuel injector fuel s...

Page 139: ...windshield washer solvents Hard water contaminants may plug orifices in the washer system and reduce performance Do not use radiator antifreeze in the windshield washer it could cause cab paint damag...

Page 140: ...ture for efficient operation and emission control Proper operation of the engine coolant temperature gauge See the Maintenance Schedule in Section 5 to find out when the engine coolant must be replace...

Page 141: ...ator Overtightening could bend or collapse the radiator fittings ENGINE COOLING SYSTEM SERVICE The engine cooling system should be serviced at the intervals specified in the Maintenance Schedule as fo...

Page 142: ...k Fill the engine coolant reserve tank to the MAX mark 5 Install the radiator cap and the reserve tank cap Engine Coolant Replacement and Cleaning Draining NOTICE Dispose of and handle the waste engin...

Page 143: ...corrosion protection Install the radiator cap and reserve tank cap 5 Press the radiator upper hose 2 or 3 times If due to the hose being pressed air is released from inside the hose and the water lev...

Page 144: ...ype must be installed tightly otherwise engine coolant may be lost and damage to the engine may result from overheating Radiator pressure cap should be checked periodically for proper operation If a r...

Page 145: ...act your dealer for information CAUTION Winter fronts or grille covers are not to be used Radiator shutters may cause the engine s radiator cooling fan to fatigue from the alternate unloading and load...

Page 146: ...reservoir regularly DOT 3 brake fluid or equivalent When topping off take care not to allow dirt or water to enter the tank as this may cause the brakes to malfunction As the brake fluid needs to be r...

Page 147: ...ear of the cab 2 Read the label on the rear of the cab 3 Unlock the cab tilt lever 2 while pulling the lock lever 1 4 Hold the assist handle 3 and pull the safety lever 4 5 Raise the cab fully and be...

Page 148: ...5 39 Always be sure the safety lock pin is installed when the cab is tilted 2 1 1 Lock Lever 2 Tilt Lever 4 3 3 Assist Handle 4 Safety Lever 55702_Sec05 2_ 08 08 2 12 9 51 AM Page 39...

Page 149: ...essing the support lock lever 7 5 Lower the cab and push the tilt lever 2 down firmly to lock CAUTION To help avoid personal injury or death be sure the tilt cab is securely locked in the lowered posi...

Page 150: ...er normal engine operations the engine oil level may increase above the FULL mark as a result of DPF regeneration A small increase in the oil level between the oil change interval is normal When check...

Page 151: ...IESEL PARTICULATE FILTER DPF DPF inspection and cleaning Clean the DPF at every 100 000 miles 160 000 km or every 3 000 hours at your Isuzu dealer Refer to Maintenance Schedule in this section 1 Turn...

Page 152: ...T TENSION ADJUSTMENT CAUTION The air conditioning drive belt if equipped must be adjusted after fan belt adjustment If the required procedure is not followed the A C belt may experience excessive tens...

Page 153: ...the two screws indicated by arrows in the diagram 1 Remove the rubber beneath the headlight 2 Two screws should be turned in the same direction at the same time to adjust aiming 3 When the Headlight...

Page 154: ...lip Clip NOTICE When replacing a bulb make sure the light switch is OFF Use only bulbs with the same wattage rating 2 Remove the turn signal light Remove the nut from the frontside turn signal light O...

Page 155: ...turn signal light followed by removing the turn signal light 3 Remove the headlight Remove the seal rubber from the two protruding parts below the headlight Unfasten the four bolts Remove the headlig...

Page 156: ...the clip for fastening the bulb and displace upwards to remove the clip 2 Pull out the bulb and replace it with a new one CAUTION Do not touch the glass portion of the bulb with your fingers When ins...

Page 157: ...one 3 When installing proceed in the reverse order while paying attention to the following points Turn the connector to the right and lock securely NOTICE If the locking procedure is inadequate water...

Page 158: ...ion to the following Turn the socket to the right to lock it firmly FRONT TURN SIGNAL LIGHTS 1 Remove the bulb from the socket and replace it with a new one NOTICE If the socket is not locked firmly w...

Page 159: ...bottom of the door followed by unfastening the nut 2 Displace the cornering light and side indicator towards the front of the vehicle to pull out the rear of the light followed by removing the tabs on...

Page 160: ...ling it out Clip Cornering light bulb Side turn signal light bulb Side marker light bulb 1 Remove the bulb socket by turning counterclockwise 2 Remove the bulb from the socket and replace it with a ne...

Page 161: ...om the inner side followed by mounting the rubber cap NOTICE If the socket is not locked firmly water may infiltrate the light and cause malfunctioning 3 Pay attention to the following when mounting T...

Page 162: ...or property damage may result from battery explosion battery fluid or electrical short circuit burns Screw Bulb Socket Lens ROOF MARKER LIGHT IDENTIFICATION LIGHT CLEARANCE LIGHT 1 Unfasten the screw...

Page 163: ...cable from the negative terminal of the batteries to prevent discharge For full power needs at replacement time a DELKOR battery with the same catalog number as shown on the original DELKOR battery s...

Page 164: ...al amperage rating The amperage rating of each fuse is molded in its head Fuses are installed in the fuse panel and behind the glove box ELECTRICAL CIRCUIT PROTECTION Your vehicle is equipped with fus...

Page 165: ...ed stamped with maximum load and maximum cold inflation rating For rims and wheels not so identified or for service conditions exceeding the rate capacities consult the rim and wheel manufacturer to d...

Page 166: ...ause air leakage An underinflated tire in a dual wheel assembly is harder to notice than one in a single wheel assembly The properly inflated dual tire carries its own load plus that of the underinfla...

Page 167: ...ehicle speed should be adjusted to the road conditions When driving on wet or slushy roads it is possible for a wedge of water to build up between the tire and road surface This is known as hydroplani...

Page 168: ...designed for tubeless tires Such wheels may have structural damage and could fail without warning When replacing wheels for any reason the new wheels should be equal in load capacity diameter width o...

Page 169: ...the lubricant level should be checked and what type of lubricant should be used VEHICLE STORAGE If the vehicle is to be placed in storage for a prolonged period of time certain precautions must be ta...

Page 170: ...5 61 LUBRICATION POINTS GREASE POINTS 1 King Pins 4 fittings 2 Driveshaft Universal Joints Sliding Sleeve and Center Bearing 5 fittings 1 1 2 55702_Sec05 2_ 08 08 2 12 9 51 AM Page 61...

Page 171: ...ATION NUMBER AND WEIGHT RATING PLATE The VIN and Weight Rating plate lists the manufacturer s gross vehicle weight for the vehicle maximum front end weight at the ground maximum rear end weight at the...

Page 172: ...essories especially designed for you and your new truck They can install all of the Safety Accessories you will need to comply with local state and D O T regulations and advise you how to comply with...

Page 173: ...XPLANATION OF COMPLETE TRUCK MAINTENANCE SCHEDULE for correct fluid level checking procedure Transmission fluid 14 0L 29 6 pints REAR AXLE Gear Oil 10 0L 21 1 pints Lubricant to within 0 to 10 mm 0 to...

Page 174: ...ERMOSTAT Starts to Open 82 85 C 180 185 F RADIATOR PRESSURE 108 kPa 16 psi WHEEL WHEEL STUD NUT TORQUE Front and Rear 490 N m 362 ft Ibs Refer to Sections 3 and 5 for complete wheel changing and tire...

Page 175: ...W 2 Side Turn Signal Light 5W 2 Side Marker Light 5W 2 Stoplight Taillight 27 8W 2 Backup Light 27W 2 Rear Turn Signal Light 27W 2 License Plate Light 7 5W 1 Identification Light Clearance Light 5W 5...

Page 176: ...KUP LIGHT 10A 8 WIPER 25A 9 HEADLIGHT LOW LH 10A 10 LIGHTS BATT 10A 11 HEADLIGHT LOW RH 10A 12 BRAKE LIGHTS 10A 13 STARTER 10A 14 HEADLIGHT HI LH 10A FUSE BLOCK CAB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 177: ...A 22 ECU BATT 10A 23 MIRROR 10A 24 AUDIO ACCESSORIES 15A 25 HORN 15A 26 TURN HAZARD 15A 27 TAILLIGHTS 10A 28 ILLUMINATIONS 10A 29 CORNERING LIGHT 10A 30 AIR CONDITIONER 10A 31 CIGAR 20A 32 ACCESSORIES...

Page 178: ...Isuzu No 8 97148 270 1 Fuel Isuzu No 8 98037 011 0 FUSE BLOCK FRAME No Circuit Fuse 1 MARKER LIGHT 20A 2 TAIL MAIN 20A 3 ECM MAIN 10A 4 5 6 RR DOME LIGHT 15A 7 CONDENSER FAN 20A 8 AIR CONDITIONER 10A...

Page 179: ...2 3 5 Brake Alarm System 2 36 Brake Low Vacuum Warning Light 2 32 Brake Maintenance 5 37 Brake System 2 22 5 36 Brake Pedal 2 22 Parking Brake 2 24 Vacuum Power Brakes 2 23 Brake System Warning Light...

Page 180: ...Use of the Exhaust Brake 2 15 Wet Brakes 2 14 Driving Tips 2 27 DRL 2 35 Dual Tire Operation 5 57 E Effect on Warranty 0 5 Electrical Data 6 5 Exterior Lights 6 5 Fuse Block 6 6 Interior Lights 6 5 El...

Page 181: ...5 55 G Gasoline 2 5 4 1 GAWR 0 4 Glass Surfaces 4 3 Glow Plug Indicator Light 2 31 Graphic Symbols 0 2 Guard Against Theft 2 12 GVWR 0 4 H Hazard Warning Flasher 2 21 3 1 Headlight Dimmer Switch 2 18...

Page 182: ...Lever 2 17 Cornering Lights 2 17 Headlight Dimmer Switch 2 18 Headlights 2 17 Passing Light Switch 2 18 Turn Signal 2 17 Light Control Switch 2 43 Lock Button 1 5 Locking Clip Full Size 1 16 Low Coola...

Page 183: ...r 2 18 Adjustable Steering Column 2 20 Engine Control Switch 2 21 Exhaust Brake 2 19 Hazard Warning Flasher 2 21 Horn 2 21 Steering Column Adjustment 2 20 Windshield Washer 2 19 Windshield Wipers 2 18...

Page 184: ...2 29 U Underbody Maintenance 4 6 Use of the Exhaust Brake on slippery surfaces 2 15 Used Oil Disposal 5 24 Using the Engine as a Brake 3 11 Stopping the Vehicle in the Event of Service Brake Malfunct...

Page 185: ...DATE MILEAGE FUEL OIL REPAIRS DATE MILEAGE FUEL OIL REPAIRS OPERATING RECORD 55702_Sec07_ 08 08 2 12 9 57 AM Page 1...

Page 186: ...DATE MILEAGE FUEL OIL REPAIRS DATE MILEAGE FUEL OIL REPAIRS OPERATING RECORD 55702_Sec07_ 08 08 2 12 9 57 AM Page 2...

Page 187: ...om them directly In the event that you are unable to contact your local dealer use the below website As a do it yourselfer you ll be glad to know that these Service Manuals are the same manuals utiliz...

Page 188: ...is 100 00 and is subject to credit Approval For purchases outside of the U S A and for publications prior to the year s shown contact Helm Incorporated at P O Box 07280 Detroit Michigan 48207 or call...

Page 189: ...TAL MATERIAL MICH PURCHASERS ADD 6 SALES TAX HANDLING CHARGE 6 95 GRAND TOTAL VEHICLE MODEL QTY PRICE EACH TOTAL PRICE NAME YEAR NOTE Dealers and Companies please provide dealer or company name and al...

Page 190: ...55702_Sec07_ 08 08 2 12 9 57 AM Page 6...

Page 191: ...55702_Sec07_ 08 08 2 12 9 57 AM Page 7...

Page 192: ...55702_Sec07_ 08 08 2 12 9 57 AM Page 8...

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