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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

Содержание NPR 2008

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

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