Isuzu 2008 N Series Instruction manual

WORKSHOP MANUAL
GENERAL INFORMATION
No.LGGEN-WE-0871
mechanikar

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
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General Information 0A-1
GENERAL INFORMATION
General Information
TABLE OF CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
General Repair Instructions . . . . . . . . . . . . . . . 0A-2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3
Chassis Number/Engine Number Stamping
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3
Option Code List . . . . . . . . . . . . . . . . . . . . . . . . 0A-4
Vehicle Identification Number (VIN) . . . . . . . . 0A-11
General Precaution . . . . . . . . . . . . . . . . . . . . . . 0A-14
General Precautions . . . . . . . . . . . . . . . . . . . . 0A-14
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . 0A-16
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . 0A-16
Caution for The Maintenance of Electrical Parts 0A-18
Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-18
Connector Handling Requirements . . . . . . . . . 0A-18
Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-21
Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-21
Regarding the Scan Tool . . . . . . . . . . . . . . . . . . 0A-23
Trouble Diagnosis Using the Scan Tool . . . . . 0A-23
Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-29
Recommended Liquid Gasket. . . . . . . . . . . . . 0A-29
Recommended Thread Locking Agent. . . . . . . . 0A-31
Recommended Thread Locking Agent . . . . . . 0A-31
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-32
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-32
Maintenance Schedule . . . . . . . . . . . . . . . . . . 0A-33
Maintenance Schedule for Severe-condition . . . 0A-46
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-46
Maintenance Schedule for Severe-condition . 0A-46
Recommended Fluids, Lubricants and
Diesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-49
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-49
Diesel Engine Crankcase with DPD
(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-49
Diesel Engine Crankcase without DPD. . . . . . 0A-50
CNG Engine Crankcase (For Thailand) . . . . . 0A-50
CNG Engine Crankcase (For Australia) . . . . . 0A-50
Manual Transmission, Transfer Case . . . . . . . 0A-51
Clutch Oil (Smoother) . . . . . . . . . . . . . . . . . . . 0A-51
Differential (without LSD) . . . . . . . . . . . . . . . . 0A-51
Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-52
Power Steering, Hydro Brake Booster . . . . . . 0A-52
Center Bearing, Kingpins . . . . . . . . . . . . . . . . 0A-52
Propeller Shaft Sliding Yoke, Universal Joint . 0A-53
Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-53
Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-54
Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-54
Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-55
Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . 0A-55
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 0A-57
Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . 0A-57
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0A-2 General Information
General Information
General Repair Instructions
1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle.
2. Use covers on the vehicle body, seats, and floor to
prevent damage and/or contaminations.
3. Disconnect the grounding cable from the battery
before performing service operations.
This will prevent cable damage or burning due to
short-circuit.
4. Raise the vehicle with a jack set against the axle or
the frame.
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.
7. The use of the proper tool(s) and special tool(s)
where specified is efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, O-rings, oil seals,
lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design
according to installation positions.
12. Clean all parts before inspection or reassembly.
13. Clean the oil ports and other openings with
compressed air to make certain that they are free
of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before installation.
15. Use the recommended liquid gasket to prevent
leakage.
16. Be sure to tighten nuts and bolts to the specified
torque, using a properly maintained torque wrench.
17. When service operation is completed, male a final
check to be sure service has been done properly
and problem has been corrected.
18. When removing or replacing parts that require
refrigerant to the discharged from the Air
conditioning system, be sure to use the ACR4 or
equivalent to recover and recycle Refrigerant -
134a (HFC-134a), to promote the movement for
the protection of the ozone layer covering the
earth.
19. To assure safety, always slowly release air
pressure from the air tanks before disconnecting
pipes, hoses or other parts from any unit under
pressure.
20. Prior to start the welding work, the following
operations are required:
• Disconnect all connectors of electronic control
unit.
• Disconnect battery ground terminal.
• Welding machine ground cable must be
connected near the welding point.
• Turn off the all switches.
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General Information 0A-3
Identification
Chassis Number/Engine Number Stamping
Position
Chassis number
It is stamped on the front right-hand side face of the
chassis side member.
Engine number (4JJ1 Engine)
The engine number is stamped on the left side rear of
the cylinder body.
Legend
1. Engine model
2. Engine number
Engine number (4HK1 Engine)
The engine number is stamped on the right side of the
cylinder body.
Legend
1. Engine model
2. Engine number
Engine number (4JB1 Engine)
The engine number is stamped on the left side rear of
the cylinder body.
LNW70ASH000201
LNW70ASH001801
2
1
LNW70ASH001901
21
RTW36ASH000401
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0A-4 General Information
Engine number (4HG1 Engine)
The engine number is stamped on the right side front of
the cylinder body.
Engine number(4HV1 Engine)
The engine number is stamped on the right side of the
cylinder body.
Legend
1. Engine model
2. Engine number
Vehicle identification plate
The vehicle identification plate is attached to the interior
side of the cab side panel on the right side.
The vehicle identification plate has the following
information;
• Vehicle identification number (VIN)
• Paint information
• Three-digit option codes which means production
options or special equipment installed on the
vehicle at the factory
Refer to the vehicle identification plate when ordering
replacement parts.
Option Code List
LNW90ASH000101
LNW90ASH000901
1
2
Option
Code Option Description
AJ3 Driver side air bag
AK5 Driver and passenger side air bag
APL Passenger seat delete
AQE Tire - front & rear 7-16-14
Disc wheel - 16x5.5F-115
AUJ
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127
(front - highway, rear - mud & snow,
MICHELIN)
AU4 Automatic door lock
AYS Tire - front & rear 215/75R16C
Disc wheel - 16x5.5J-127
AYX Tire - front & rear 205/75R16C
Disc wheel - 16x5.5J-85 white
A31 Power window - front & rear door
A32 Power window - front door
A83 Vinyl seat
BQN Tire - front & rear 7R-16-10
Disc wheel - 5.5F-16-115
BQQ Tire - front & rear 7.5R-16-10
Disc wheel - 6.00GSx16-127
LNW80ASH000401
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General Information 0A-5
BQU Tire - front & rear 195/75R16C
Disc wheel - 16x5.5J-116.5
BQV Tire - front & rear 195/75R16C
Disc wheel - 16x5.5J-116.5 white
BUM Tire - front & rear 7.5R-16-12
Disc wheel - 16x6.00GS-127
B00 Indonesia equipment
B02 South Africa equipment
B03 Thailand equipment
B04 Taiwan equipment
B07 India equipment
B09 Egypt equipment
B10 Malaysia equipment
B11 Turkey equipment
B12 Russia equipment
B13 Australia equipment
B14 Hong Kong equipment
B15 Philippine equipment
B84 Body side molding
CB7 Colombia equipment
CJ6 Country - Ireland
CQB
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127
(front - highway, rear - mud & snow,
DUNLOP)
CQC
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127
(front & rear - highway, DUNLOP)
CQS Tire - front & rear 205/75R16C
Disc wheel - 16x5.5J-85 silver
CQT
Tire - front & rear 215/75R16C
Disc wheel - 16x5.5J-127
(low noise tire)
CQU
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127 silver
(front & rear - highway)
CRC Tire - front & rear 7.5R-16-10
Disc wheel - 16x6.00GS-127
CRR Tire - front & rear 225/70R19.5
Disc wheel - 19.5x6.00-127 white
CRU
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127
(front & rear - highway, MICHELIN)
Option
Code Option Description
CRV
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127 silver
(front & rear - highway, MICHELIN)
CRW
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127 white
(front & rear - highway, MICHELIN)
CSA Tire - front & rear 195/85R16
Disc wheel - 16x5.5J-116.5 silver
CSB Tire - front & rear 205/85R16
Disc wheel - 16x5.5J-116.5 silver
CSC Tire - front & rear 215/85R16
Disc wheel - 16x6K-128 silver
CSK
Tire - front & rear 195/85R16
Disc wheel - 16x5.5J-116.5 silver
(MICHELIN)
CSM
Tire - front & rear 205/75R17.5
Disc wheel - 17.5x6.00-127 silver
(MICHELIN)
CSZ Tire - front & rear 185/85R16
Disc wheel - 16x5.5J-116.5 silver
CTE
Tire - front 205/70R16 rear 175R14-8
Disc wheel - front 16x5.5J-116.5
rear 14-4.0J-100 silver
CTF Tire - front & rear 7.5R-16-14
Disc wheel - 16x6.00GS-127
CTP Tire - front & rear 6.5R-15-10
Disc wheel - 5.5F-25-170
CTQ Tire - front 7R-15-8 rear 7.5R-15-10
Disc wheel - 5.5F-15-25
CTV
Tire - front & rear 215/75R17.5
Disc wheel - 17.5x6.00-127 silver
(front - highway, rear - mud & snow,
MICHELIN)
CTX
Tire - front & rear 8.50R17.5
Disc wheel - 17.5x6.00-127 silver
(MICHELIN)
CTZ Tire - front & rear 225/85R16
Disc wheel 16x6K-128 silver
CT6 Country - Italy
CUA Tire - front & rear 205/85R16
Disc wheel - 16x5.5J-116.5 silver
CUB Tire - front & rear 215/85R16
Disc wheel - 16x6K-128 silver
CUC Tire - front & rear 195/85R16
Disc wheel - 16x5.5J-116.5 silver
CUD Tire - front & rear 205/75R16C
Disc wheel - 16x5.5J-116.5 silver
Option
Code Option Description
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0A-6 General Information
CUE
Tire - front 195/85R16 rear 185/80R15
Disc wheel - front 16x5.5J-116.5
rear 15x5J-116.5 silver
CUG Tire - front & rear 205/75R16C-8
Disc wheel - 16x5.5J-116.5 silver
CUH Tire - front & rear 195/75R16C,
Disc wheel - 16x5.5J-116.5 white
CUL
Tire - front 6.5R-15-10 rear 155R-13-8
Disc wheel - front 15x5.5F-25
rear 13x4J-98
CUN Tire - front & rear 205/75R16C
Disc wheel - 16x5.5J-116.5 silver
CUP Tire - front 6.5R-15-10 rear 7R-15-10
Disc wheel - 5.5F-25-170
CUQ Tire - front 7R-15-8 rear 7.5R-15-12
Disc wheel - 5.5F-15-25
CUR Tire - front & rear 205/75R16C-8
Disc wheel - 16x5.5J-116.5 white
CUS Tire - front & rear 195/75R16C
Disc wheel - 16x5.5J-116.5 silver
CUT Tire - front & rear 7.00R-15-10
Disc wheel - 15x5.50F-25-170
CUU Tire - front & rear 7R-16-10
Disc wheel - 5.5F-16-25
CUV Tire - front & rear 7.50R-16-10
Disc wheel - 16x6.00GS-127
CUW Tire - front & rear 7.00R-16-10
Disc wheel - 16x5.50F-115
CUX
Tire - front & rear 7.50R-16-12
Disc wheel - 16x6.00GS-127
(6 wheel nuts)
CUZ Tire - front & rear 8.25R-16-14
Disc wheel - 16x6.00GS-135
CU9 Country - United Kingdom
CVG Tire - front & rear 205/85R16
Disc wheel - 16x5.5J-116.5
CVK Tire - front & rear 205/75R16
Disc wheel - 16x5.5J-85
CVH
Tire - front & rear 7.50R-16-12
Disc wheel - 16x6.00GS-127
(5 wheel nuts)
CV4 Country - Israel
CX1 Country - Argentina
CX6 Country - New Zealand
C13 Wiper with intermittent
Option
Code Option Description
C35 Rear heater
C39 Forged air ventilation
C41 Heater & defroster
C60 Manual air conditioning
C65 Manual air conditioning
without heater
C68 Automatic air conditioning
DH2 O/S rear view mirror - long arm
DL8 O/S rear view mirror - remote control
with heated
D20 Assist side sun visor
D37 O/S rear view mirror - short stay
D8T Iran equipment
D94 Touch-up paint
EBB Digital tachograph
EE2 Governor with high altitude
compensator
EG5 Assist grip
EQ9 Front bumper - gray
EX9 Tail gate decal - ISUZU
E09 Europe equipment
E11 Mexico equipment
E14 Venezuela equipment
E4K KD breakdown - Venezuela
E7N Idle stop system
FE1 Soft ride suspension system
FF0 Front suspension - Wishbone
F59 Front stabilizer
GH3 Saudi Arabia equipment
GNA Final drive gear ratio - 3.909 (43/11)
GN1 Rear stabilizer
GT5 Final drive gear ratio - 4.100 (41/10)
GV1 Final drive gear ratio - 5.571 (39/7)
G73 Rear axle - heavy duty
HC6 Final drive gear ratio - 4.556 (41/9)
JE5 Anti-lock brake system
JF9 Front & rear disc brake
J52 Front disc brake
KE1 Chile equipment
Option
Code Option Description
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General Information 0A-7
KF0 Fuel filter - low quality
KG2 Generator 24V60A
KM6 Glow system - fast
K46 Air cleaner - heavy duty
LFB 4JJ1-TCS engine
M9A Owner’s manual - not required
NA8 Emission system - Mexico domestic
NF8 Exhaust brake
NMJ Speed limiter - 90km/h
NMT High idle switch - engine speed control
NT1 Emission system - Euro1
NT2 Emission system - Euro2
NT3 Emission system - Euro3
NT4 Emission system - Euro4
NT5 Emission system - Euro5
N02 Fuel tank - 100L frame side
N05 Fuel tank cap with key lock
N19 Fuel tank - 140L frame side
N2D Owner’s manual - Chinese language
N33 Tilt steering with telescopic
P10 Spare tire carrier - frame rear mount
P15 Spare tire carrier - inside mount
P38 Tire delete
RC4 Dump control lever
RDN 4HV1 CNG engine
RDQ 4HK1-TCN engine
RDT 4JB1-TC engine
RDU 4JJ1-TCC engine
RJH 4HG1 engine
RJS 4HK1-TCS engine
RM5 Manual transmission - MSB5M
RPP G.V.W. 3.0-3.5 ton
RPQ G.V.W. 3.5-4.0 ton
RPR G.V.W. 4.0-4.5 ton
RPS G.V.W. 4.5-5.0 ton
RPT G.V.W. 5.0-5.5 ton
RPU G.V.W. 5.5-6.0 ton
RPV G.V.W. 6.0-6.5 ton
Option
Code Option Description
RPW G.V.W. 6.5-7.0 ton
RPX G.V.W. 7.0-7.5 ton
RPY G.V.W. 7.5-8.0 ton
RPZ G.V.W. 8.0-8.5 ton
RR9 O/S rear view mirror - under
RSF Manual transmission - MZZ6U
RSM Manual transmission - MYY5T
RSR Manual transmission - MZZ6F
RSS Manual transmission - MYY5S
RST Manual transmission - MYY6S
RSL Manual transmission - MYY5A
RS6 Rear body - flat bed
RS7 Rear body - dump 2.8m (Shinmeiwa)
RS9 Rear body - dump long (Shinmeiwa)
RU1 Final drive gear ratio - 5.125 (41/8)
RV9 Final drive gear ratio - 4.875 (39/8)
RWA KD package - STD breakdown
RWE Chevrolet brand
RWK KD breakdown - Kenya
RWZ Manual tilt cab
RW1 KD breakdown - South Africa
RW5 KD breakdown - Thailand Var.1
RW7 KD breakdown - Philippine
RW8 KD breakdown - Indonesia
RXA KD breakdown - Egypt Var.2
RXB KD breakdown - Morocco
RXC KD breakdown - West Malaysia
RZT KD breakdown - cab floor
RZU KD breakdown - bus
RZV KD breakdown - cab
RZX Engine breakdown
R32 KD breakdown - frame
R39 Rear axle - standard
R4H KD breakdown - Colombia
R4L KD breakdown - Venezuela
R4M KD breakdown - Taiwan
R4R KD breakdown - Taiwan Var.2
R4S KD breakdown - Colombia Var.2
Option
Code Option Description
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