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2008-2011MY

WORKSHOP MANUAL

GENERAL INFORMATION

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
		1L	Power Take-Off (PTO)
2	SUSPENSION	2A1	Air Suspension Control System
		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
		3D	Transfer Case
4	BRAKES	4A2	Brake Control System (Air Over)
		4A3	Brake Control System (Full Air)
		4B2	Brake (Air Over)
		4B3	Brake (Full Air)
		4C	Anti-Lock Brake (ABS)
		4C1	Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
		4D	Parking Brake
		4E	Hill Start Aid (HSA)
		4F	Speed Retarder System
		4G	Trailer Brake
5	TRANSMISSION/TRANSAXLE	5A	Transmission Control System
		5B	Automatic Transmission
		5C	Manual Transmission
		5E	Clutch
		5G	Power Take-Off (PTO)
		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 AND FRAME ACCESSORIES	11A	Frame

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-15 General Precautions . . . . . . . . . . . . . . . . . . . . 0A-15 Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . 0A-17 Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . 0A-17 Caution for The Maintenance of Electrical Parts 0A-20 Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-20 Connector Handling Requirements . . . . . . . . . 0A-20 Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-23 Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-23 Regarding The Scan Tool. . . . . . . . . . . . . . . . . . 0A-25 Trouble Diagnosis Using The Scan Tool . . . . . 0A-25 Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-31 Recommended Liquid Gasket. . . . . . . . . . . . . 0A-31 Recommended Thread Locking Agent. . . . . . . . 0A-33 Recommended Thread Locking Agent . . . . . . 0A-33 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-34 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-34

Maintenance Schedule

(for Euro4 specification except Europe) . . . . . 0A-35 Maintenance Schedule

(for Euro2, Euro3 specification). . . . . . . . . . . . 0A-41 Maintenance Schedule (for Europe) . . . . . . . . 0A-45 Maintenance Schedule

(CNG engine for Australia) . . . . . . . . . . . . . . . 0A-50 Maintenance Schedule

(CNG engine for Thailand) . . . . . . . . . . . . . . . 0A-54 Transmission Oil — ZF6S1000/ZF9S1110 Type 0A-58 Transmission Oil — FS8209A/FSO5206B Type 0A-65 RS23/RS40 Type Axle . . . . . . . . . . . . . . . . . . 0A-67 RS25 Type Axle . . . . . . . . . . . . . . . . . . . . . . . 0A-68

Maintenance Schedule for Severe-condition . . . 0A-69 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-69 Maintenance Schedule for Severe-condition . 0A-69

Recommended Fluids, Lubricants and

Diesel Fuels (except Europe). . . . . . . . . . . . . . . 0A-73 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73 Diesel Engine Crankcase with DPD

(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73 Diesel Engine Crankcase without DPD. . . . . . 0A-74 CNG Engine Crankcase (for Australia) . . . . . . 0A-74 CNG Engine Crankcase (for Thailand) . . . . . . 0A-74 Manual Transmission (MZX/MZW/MLD

models), Transfer Case, Differential

(without LSD) and Oil Lubricated Hub

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-75

Manual Transmission (MZZ models). . . . . . . . 0A-75 Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-75 Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-75 Automatic Transmission, Power Steering . . . . 0A-76 Center Bearing, Clutch Shift Block,

Grease Lubricated Hub, Water Pump,

Propeller Shaft Sliding Yoke, Universal

Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-76 Multi-Purpose Grease Containing

Molybdenum . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-76 Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-76 Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-77 Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-77 Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-77 Diesel Fuel / Applicable Standard

(Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-78 Recommended Fluids, Lubricants and

Diesel Fuels (for Europe) . . . . . . . . . . . . . . . . . . 0A-79 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79 Diesel Engine Crankcase with DPD

(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79 Diesel Engine Crankcase without DPD. . . . . . 0A-79 Manual Transmission (MZX/MZW/MZZ/MLD

models), Differential (without LSD) and Oil Lubricated Hub Bearing . . . . . . . . . . . . . . . . . 0A-80

Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-80 Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-80 Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 0A-80 Center Bearing, Clutch Shift Block,

Grease Lubricated Hub, Water Pump,

Propeller Shaft Sliding Yoke, Universal

Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-81 Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-81 Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-81 Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-82 Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-82 Diesel Fuel / Applicable Standard

(Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-82 Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-83 Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . 0A-83 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 0A-84 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . 0A-84 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-97 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . 0A-97

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 shortcircuiting.

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.

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.

MFW70ASH000101

Engine number (4HK1 Engine)

The engine number is stamped on the right side of the cylinder body.

LNWB0ASH000101

Engine number (6HF1 Engine)

The engine number (1) is stamped on the right side of the cylinder body.

MFW90ASH000101

Engine number (6HK1 Engine)

The engine number is stamped on the right side of the cylinder body.

MFW80ASH000401

Service Parts ID Plate

The service parts ID plate is attached to the passenger side lower dashboard.

The service parts ID plate has the following information;

•Vehicle identification number (VIN)

•Wheelbase dimensions

•Paint information

•Production options or special equipment installed on the vehicle at the factory

0A-4 General Information

Refer to the service parts ID plate when ordering replacement parts.

MFU8Z0SH043301

Option Code List

	Option	Option Description
	Code


	AJ3	Driver side air bag

	AK3	Front seat belt & shoulder
	with retractor


	AK5	Driver and passenger side air bag

	AU4	Automatic door lock

	A31	Power window — front & rear door

	A32	Power window — front door

	A56	Driver seat — air suspension

	A83	Vinyl seat with reclining

	BDM	Power take off — transmission rear

	BFK	Transfer TF56

	BHW	Power take off — engine rear,
	electromagnetic clutch


	BJR	Brake adjuster — manual

	B02	South Africa equipment

	B03	Thailand equipment

	B04	Taiwan equipment

	B1S	Parking brake drum — 8.5 inch

	B1T	Parking brake drum — 10 inch

	B10	Malaysia equipment

	B12	Russia equipment

	B13	Australia equipment

	Option	Option Description
	Code


	B14	Hong Kong equipment

	B3A	Rear wheel parking brake — air
	control


	B30	Floor carpet — vinyl

	B84	Body side molding

	CB7	Colombia equipment

	CE4	Head lamp washer

	CGA	Morocco equipment

	CJ6	Country — Ireland

	CK1	Pakistan equipment

	CL1	Kenya equipment

	CT6	Country — Italy

	CU9	Country — United Kingdom

	CV4	Country — Israel

	CX6	Country — New Zealand

	C13	Wiper with intermittent

	C2C	Transmission oil cooler

	C2M	Propeller shaft — P60 type

	C3N	Final differential lock

	C3U	Air suspension — high control

	C4M	Air breather with flex hose

	C4Z	Propeller shaft — P46 type

	C41	Heater & defroster

	C5K	Hub lubrication — oil bath

	C5T	Propeller shaft — P90 type

	C60	Manual air conditioning

	C65	Manual air conditioning
	without heater core


	C68	Automatic air conditioning

	DH2	O/S rear view mirror — long arm

	DL8	O/S rear view mirror — remote control
	with heated


	DNB	O/S rear view mirror — pillar mounted

	D20	Assist side sun visor

	D31	Rear view mirror

	D37	Mirror — Outside rear view

	D6M	User — export government

	D8T	Iran equipment

	D94	Touch-up paint

General Information 0A-5

	Option	Option Description
	Code


	EAK	Disc wheel — 6 studs 19.5×6.75
	(136-12)


	EBB	Digital tachograph

	EBE	Front under run protector

	ECF	Speed limiter — 60km/h

	ECY	Speed limiter — 70km/h

	EDG	Header console — driver & assist

	EDH	Round curtain rail

	EDW	Speed limiter — 80km/h

	EDX	Speed limiter — 85km/h

	EFE	Regulation ECE R29

	EFK	Floor mat — vinyl mat Var.2

	E09	Europe equipment

	E11	Mexico equipment

	E13	New Zealand equipment

	E2N	Fuel pipe — steel

	E29	Auxiliary steps

	E40	Sleeper cab with mattress

	E46	Ecuador equipment

	FJC	Disc wheel — 10 studs 20×8.50V
	(138-13)


	F59	Front stabilizer

	GH3	Saudi Arabia equipment

	GL6	Rear shock absorber

	GN1	Rear stabilizer

	G86	Limited slip differential — no spin

	JAQ	Lighting system — Saudi Arabia

	JBF	Tire — KD special

	JBZ	Lighting system — Japanese standard

	JCA	Anti-noise equipment — ECE R51.02

	JDN	Compartment — I/P assist side with lid

	JDP	Compartment — I/P assist side without lid

	JE5	Anti-lock brake system

	J55	Brake system — heavy duty Var.1

	J91	Trailer brake control

	KC5	Receptacle — accessory

	KE1	Chile equipment

	KF0	Fuel filter — low quality

	KG2	Generator 24V60A

	Option	Option Description
	Code


	K30	Auto cruise

	K44	Generator 24V-90A

	K89	Generator 24V-50A

	M9A	Owners manual — Not required

	NCR	Memory system — Runnig condition

	NF7	Fuel tank 200L + 200L

	NJW	Ireland KD special

	NMJ	Speed limiter — 90km/h

	NMU	Speed limiter — 100km/h

	NNR	3 speaker system

	NT2	Emission system — Euro2

	NT3	Emission system — Euro3

	NT4	Emission system — Euro4

	N02	Fuel tank 100L — frame side mount

	N05	Fuel tank cap with key lock

	N19	Fuel tank — 140L frame side

	N20	Fuel tank 200L — frame side mount

	N79	Spare disc wheel

	PM1	Rear hook — double

	PP7	Pintle hook

	PR2	Driving position — wide leg space

	PS7	Air dryer

	PT1	Disc wheel — 8 studs 22.5×6.75
	(145-11)


	PT6	Thailand KD special

	P10	Spare tire carrier — frame rear mount

	P13	Spare tire carrier — frame side mount

	P38	Tire delete

	QM8	Disc wheel — 10 studs 22.5 x 8.25
	(165-13)


	Q47	Disc wheel — 8 studs 20×6.50T
	(145-10)


	Q87	Disc wheel — 10 studs 22.5×7.50
	(162-12)


	Q5T	Turbo — conventional

	Q50	Disc wheel — 8 studs 20×6.50T
	(152-11)


	Q54	Disc wheel — 8 studs 20×7.00T
	(162-12)


	Q58	Disc wheel — 10 studs 20×7.00T

0A-6 General Information

	Option	Option Description
	Code


	Q62	Disc wheel — 8 studs 20×7.50V
	(165-13)


	Q64	Disc wheel — 10 studs 20 x 7.50V

	Q87	Disc wheel — 10 studs 22.5×7.50
	(162-12)


	RC4	Dump control lever

	RC5	Tool box with key lock

	RE3	Spare tire fixing

	RE9	Clutch — 15 inch single plate
	strap drive


	RDV	4HK1-TCC engine

	RJS	4HK1-TCS engine

	RQZ	G.V.W. — 8.0-11.0 ton

	RRA	G.V.W. — 11.0-14.0 ton

	RR9	O/S rear view mirror — under

	RSA	Manual transmission — MZZ6W

	RSW	Manual transmission — MZX6P

	RSZ	Manual transmission — MZW6P

	RWE	Chevrolet brand

	R32	KD frame

	R46	Spare tire & disc wheel

	R9A	Service cab with electric

	R9B	Service cab without electric

	R9C	Deletion — service cab with electric

	R9D	Deletion — service cab without electric

	R9E	Service cab conversion with electric

	R9F	Deletion — service cab conversion
	without electric


	R9Z	Thailand localization spec.

	SAQ	Front suspension — multi leaf spring

	SAR	Front suspension — taper leaf spring

	SAS	Rear suspension — multi leaf spring

	SAU	Rear helper suspension — taper leaf
	spring


	SAY	Standard cab

	SAZ	Ventilator & defroster

	SBB	Disc wheel — 8 studs 20×6.00S
	(135-10)


	SBG	Disc wheel — 6 studs 17.5×6.00
	(135-9)

	Option	Option Description
	Code


	SDF	Room lamp with all door switch

	SDH	Fuel tank 400L

	SDK	Cab suspension — semi floating type

	SDP	Disc wheel — 8 studs 20×7.00T
	(152-12)


	SEG	Disc wheel — 8 studs 205×7.50V
	(130-13)


	SFC	Disc wheel — 6 studs 17.5×6.75
	(137-10)


	SFT	Electric outlet — one

	SGA	Front under spoiler delete

	SGX	Vietnam equipment

	SG4	Tire inflator device

	SG7	Disc wheel — 6 studs 16×6.00GS
	(135-9)


	SH5	Power take off — transmission side
	without lever


	SJA	Driver seat — Isringhausen

	SKU	Disc wheel — 8 studs 22.5×7.50
	(162-13)


	SKV	Disc wheel — 8 studs 22.5 x 8.25
	(165-13)


	SK4	Engine overrun buzzer

	SLB	Front bumper with headlamp

	SLC	Lighting system — ECE

	SLK	Anti-noise equipment — ECE

	SMS	Rear bumper — steel wide

	SP9	Assist seat without center seat

	SR6	Rearward double tire

	SV6	Power take off control

	SY8	Spare tire carrier — lifting type

	TAF	O/S rear view mirror — under & side
	under


	TAK	Anti-noise equipment — Var.2

	TAZ	Driver seat — rigid without arm rest

	TDU	Brake regulation — ADR

	TDV	Brake regulation — ECE

	TEC	Roof marker lamp

	TEE	Disc wheel — 8 studs 19.5×6.75
	(147-12)


	TFD	Cab all painting

General Information 0A-7

	Option	Option Description
	Code


	TFN	Driver’s seat belt with pre-tension
	reducer


	TGL	Anti corrosion package

	TM1	Battery — 80D26L

	TR6	Headlamp leveling system — manual

	TR7	Headlamp leveling system — automatic

	TT5	Halogen headlamp

	TT6	High intensity discharge headlamp

	T1A	Injection pump Q set — special
	+5%Q


	T62	Battery — dry

	T64	Battery delete

	T79	Rear fog lamp

	T87	Cornering lamp

	T96	Front fog lamp

	UC1	Speedometer — miles per hour (MPH)

	UC9	TachographKienzle

	UF3	Map lamp

	UG3	Engine oil temperature gauge

	UL5	Radio delete

	UT3	AM/FM radio with CD player

	U01	Roof marker — 5 lamps

	U18	Speedometer — kilometer

	U69	AM/FM radio

	U95	2 speaker system

	VG7	Front bumper reinforcement
	— heavy duty


	VP1	Front under spoiler

	VR7	Two eye rear hook

	VTK	Owners manual — Arabic language

	VTL	Owners manual — French language

	VTS	Owners manual — Spanish language

	VT7	Owners manual — English language

	VZA	VIN model year — 2010

	VZB	VIN model year — 2011

	V22	Radiator grille — chrome

	V4F	Chassis for fire car

	V76	Hook — tow

	WB7	Electrical horn

	Option	Option Description
	Code


	WC7	Tachograph — 140km/h

	WF6	Clutch — 14 inch single plate
	strap drive


	WG3	Brake system — heavy duty Var.2

	WH2	Spare tire — front tire

	WJ7	Cautions — Arabian

	WJ8	Cautions — French

	WL5	Inspection lamp

	WM3	Interior trim — full trimming

	WV2	Automatic cab tilt

	WX8	Shift control — assister

	W02	Highland zone package

	W1G	Final drive gear ratio — 6.143 (43/7)
	14.5 inch hypoid


	W1H	Final drive gear ratio — 5.571 (39/7)
	14.5 inch hypoid


	W1J	Final drive gear ratio — 6.500 (39/6)
	14.5 inch hypoid


	W1K	Final drive gear ratio — 6.833 (41/6)
	14.5 inch hypoid


	W1L	Final drive gear ratio — 6.500 (39/6)
	16.5 inch hypoid


	W1R	Final drive gear ratio — 6.143 (43/7)
	15.5 inch hypoid


	W1T	Final drive gear ratio — 6.500 (39/6)
	15.5 inch hypoid


	W1U	Final drive gear ratio — 4.875 (39/8)
	14.5 inch hypoid


	W12	Front locking hub — manual

	W14	Deluxe cab

	W16	Cab suspension — full floating

	W18	Transfer TF36

	W20	Disc wheel special painted (white)

	W3B	Final drive gear ratio — 5.571 (39/7)
	16.5 inch hypoid


	W3D	Final drive gear ratio — 4.875 (39/8)
	18.5 inch hypoid


	W3F	Final drive gear ratio — 6.167 (37/6)
	18.5 inch hypoid


	W3G	Final drive gear ratio — 6.667 (40/6)
	18.5 inch hypoid


	W3K	Final drive gear ratio — 5.571 (39/7)
	15.5 inch hypoid

0A-8 General Information

	Option	Option Description
	Code


	W3L	Final drive gear ratio — 6.143 (43/7)
	16.5 inch hypoid


	W3M	Final drive gear ratio — 5.125 (41/8)
	18.5 inch hypoid


	W3N	Final drive gear ratio — 4.556 (41/9)
	18.5 inch hypoid


	W3P	Final drive gear ratio — 5.125 (41/8)
	16.5 inch hypoid


	W3S	Final drive gear ratio — 5.857 (41/7)
	15.5 inch hypoid


	W3U	Final drive gear ratio — 7.167 (43/6)
	17.5 inch hypoid


	W3X	Final drive gear ratio — 6.429 (45/7)
	17.5 inch hypoid


	W3Y	Final drive gear ratio — 6.143 (43/7)
	17.5 inch hypoid


	W3Z	Final drive gear ratio — 5.571 (39/7)
	17.5 inch hypoid


	W4A	Final drive gear ratio — 5.125 (41/8)
	17.5 inch hypoid


	W4B	Final drive gear ratio — 4.875 (39/8)
	17.5 inch hypoid


	W4C	Final drive gear ratio — 4.556 (41/9)
	17.5 inch hypoid


	W4F	Final drive gear ratio — 5.125 (41/8)
	14.5 inch hypoid


	W4H	Final drive gear ratio — 5.125 (41/8)
	15.5 inch hypoid


	W4T	Final drive gear ratio — 4.333 (39/9)
	18.5 inch hypoid


	W4W	Final drive gear ratio — 6.833 (41/6)
	17.5 inch hypoid


	W4X	Final drive gear ratio — 4.333 (39/9)
	14.5 inch hypoid


	W5M	Final drive gear ratio — 4.100 (41/10)
	14.5 inch hypoid


	W5V	Final drive gear ratio — 6.833 (41/6)
	16.5 inch hypoid Rockwell


	W5Z	Final drive gear ratio — 4.89 (44/9)
	18.0 inch hypoid Rockwell


	W6A	Final drive gear ratio — 5.38 (43/8)
	18.0 inch hypoid Rockwell


	W6B	Final drive gear ratio — 5.63 (45/8)
	18.0 inch hypoid Rockwell


	W6C	Final drive gear ratio — 6.14 (43/7)
	18.0 inch hypoid Rockwell

	Option	Option Description
	Code


	W6M	Final drive gear ratio — 6.43 (45/7)
	18.0 inch hypoid Rockwell


	W6N	Final drive gear ratio — 6.83 (41/6)
	18.0 inch hypoid Rockwell


	W6R	Final drive gear ratio — 4.30 (43/10)
	18.0 inch hypoid Rockwell


	W6S	Final drive gear ratio — 6.14 (43/7)
	15.0 inch hypoid Rockwell


	W66	Disc wheel with step

	W71	Cab suspension — rigid type

	W8C	Final drive gear ratio — 4.56 (41/9)
	18.0 inch hypoid Rockwell


	W8D	Final drive gear ratio — 6.43 (45/7)
	15.0 inch hypoid Rockwell


	W8F	Final drive gear ratio — 4.555 (41/9)
	14.5 inch hypoid


	W8L	Final drive gear ratio — 6.83 (41/6)
	15.0 inch hypoid Rockwell


	X5J	Manual transmission — MLD6Q

	X7W	Manual transmission — MLD6S

	X9C	Transmission — manual

	X9D	Transmission — automatic

	YC4	Injection pump — high altitude
	compensator, aneroid type


	YK3	Rearward single tire

	YM9	Reversing warning buzzer

	YN1	Caution — Spanish

	YS1	O/S rear view mirror — flat type

	YT9	Pakistan KD special

	Y2C	Manual transmission — MLD6W

	Y21	Light duty package truck

	Y3A	Manual transmission
	— Fuller FS8209


	Y3B	Automatic transmission
	— Allison MD3560P


	Y4F	Automatic transmission
	— Allison LCT2000


	Y4G	Automatic transmission
	— Allison MD3060P


	Y4V	Manual transmission
	— Fuller FSO5206B


	Y48	Heavy duty package truck

	Y5D	Manual transmission — ZF 6S1000

General Information 0A-9

	Option	Option Description
	Code


	Y5E	Manual transmission — ZF 9S1110

	Z05	Brake system — air over hydraulic
	dual circuit


	Z06	Brake system — full air dual circuit

	Z1V	Equipment — additional key

	01D	KD package — South Africa

	01R	Tire — front & rear 8.25-20-14 lug

	02E	KD package — Taiwan

	05R	Tire — front & rear 8.25R20-14 rib

	09X	Tire — front 8.25-20-14 rib,
	rear 8.25-20-14 lug


	1D7	6HF1-TCN engine

	1D9	6HF1-TCC engine

	10T	Tire — front & rear 9.00-20-14 rib

	10X	Tire — front 9.00-20-14 rib,
	rear 9.00-20-14 lug


	11X	Tire — front 10.00-20-14 rib,
	rear 10.00-20-14 lug


	12X	Tire — front 10.00-20-16 rib,
	rear 10.00-20-16 lug


	15N	Tire — front & rear 9R22.5-14 rib

	155	Interior color — Charcoal gray

	2G0	Singapore equipment

	20D	Thailand KD deletion parts

	21R	Tire — front & rear 9.00-20-14 lug

	25R	Tire — front & rear 9.00R20-14 rib

	27X	Tire — front 11.00-20-16 rib,
	rear 11.00-20-16 lug


	30T	Tire — front & rear 10.00-20-14 rib

	34W	Wheel base 3,400mm

	35N	Tire — front & rear 10R22.5-14 rib

	36W	Wheel base 3,600mm

	37W	Wheel base 3,700mm

	38W	Wheel base 3,800mm

	39W	Wheel base 3,900mm

	40S	Tire — front & rear 8.25-16-14 rib

	40T	Tire — front & rear 10.00-20-16 rib

	40W	Wheel base 4,000mm

	41R	Tire — front & rear 10.00-20-14 lug

	41W	Wheel base 4,100mm

Option	Option Description
Code


42W	Wheel base 4,200mm

43P	Tire — front & rear 9R22.5-14

43W	Wheel base 4,300mm

45N	Tire — front & rear 11R22.5-14 rib

45P	Tire — front & rear 275/70R22.5

45R	Tire — front & rear 10.00R20-14 rib

46W	Wheel base 4,600mm

48W	Wheel base 4,800mm

49W	Wheel base 4,900mm

49P	Tire — front & rear 8.25R20-14
exp block


5D9	Tire — front & rear
295/80R22.5-152/148K rib/lug


5E0	Tire — front & rear
295/80R22.5-152/148J rib


5E1	Tire — front & rear 10R22.5-14

5G2	Tire — front 295/80R22.5,
rear 11R22.5-16


5H1	Tire — front 10.00-20-16 rib,
rear 10.00-20-16 lug


5J6	Tire — front 9.5R17.5 129/127L rib,
rear 9.5R17.5 129/127L traction


5J7	Tire — front & rear 11R22.5 148/145L
rib


5J8	Tire — front & rear 245/70R19.5 rib

5J9	Tire — front & rear 235/75R17.5 rib

5K0	Tire — front & rear 265/70R19.5 rib

5K4	Tire — front & rear 11R22.5 148/145K
rib/lug


5K5	Tire — front & rear 12R22.5 152/148K
rib/lug


5L1	Tire — front & rear 12.00R20-18

5L4	Tire — front & rear 275/70R22.5
148/145M rib


5L7	Tire — front & rear 9.00R-20-14
exp lug


5L8	Tire — front & rear 10.00R-20-16 lug

5N5	Tire — front & rear	265/70R19.5	140/
138M rib (BS brand)


5N6	Tire — front & rear	235/75R17.5	132/
130M rib (BS brand)


5P0	Tire — front & rear	235/75R17.5	132/
130M rib (BS brand)

0A-10 General Information

	Option	Option Description
	Code


	5P1	Tire — front 295/80R22.5,
	rear 11R22.5-16 (6×2, BS brand)


	5P2	Tire — front 295/80R22.5,
	rear 11R22.5-16 (BS brand)


	5P3	Tire — front & rear 10R22.5-14
	exp rib/lug (BS brand)


	5P6	Tire — front & rear 225/70R19.5

	5P7	Tire — front & rear 8.25R16 128/126L
	exp rib/lug


	50W	Wheel base 5,000mm

	51R	Tire — front & rear 10.00-20-16 lug

	51W	Wheel base 5,100mm

	517	Body color — AL. gray

	53W	Wheel base 5,300mm

	538	Body color — Tool-IPEC yellow

	55N	Tire — front & rear 11R22.5-16 rib

	55P	Tire — front & rear 295/80R22.5
	152/148M rib


	55R	Tire — front & rear 10.00R20-16 rib

	55W	Wheel base 5,500mm

	58N	Tire — front & rear 11.00R20-16 rib

	58W	Wheel base 5,800mm

	59W	Wheel base 5,900mm

	6DY	Rear under run protector

	6EP	HSA system

	6HF	KD preparatory package

	6KK	Horn — heavy duty (dual)

	6ND	OK window

	6NF	Remote control door lock

	6PH	LSPV — Load sensing proportioning
	valve


	6SZ	Power take off — flywheel

	6UC	Fluorescent lamp

	6UH	O/S rear view mirror — assist side short
	stay


	6VE	O/S rear view mirror — door mount

	6WX	Floor mat — vinyl

	6XH	ASR system

	60W	Wheel base 6,000mm

	609	Body color — FT orange

	Option	Option Description
	Code


	61P	Tire — front & rear 225/90R17.5

	63E	KD package — Italy

	63W	Wheel base 6,300mm

	64E	KD package — Vietnam

	64N	Tire — front & rear 8.25R20-14 rib

	65W	Wheel base 6,500mm

	668	Body color — Purplish blue

	681	Body color — Geranium red

	695	Body color — Dark blue

	7BC	Assist seat with center seat

	7DM	Tuner band — Latin America

	7FL	Seat material — cloth

	7HZ	Rear bumper

	7KC	Immobilizer system

	7NY	Multi information display

	7SV	O/S rear view mirror — heated

	7TV	KD preparatory package

	70T	Tire — front & rear 11.00-20-14 rib

	71R	Tire — front & rear 11.00-20-14 lug

	71S	Tire — front & rear 7.50-20-12 lug

	71W	Wheel base 7,100mm

	729	Body color — Arc white

	736	Body color — Cardinal red

	78N	Tire — front & rear 8.25R16

	79R	Tire — front & rear 11.00R20-14

	8AA	Good quality ethylene glycol
	antifreeze 50%


	8AC	Good quality ethylene glycol
	antifreeze 30%


	8EJ	Battery — 65D23L

	8GF	Transmission with Smoother

	8GJ	Transmission without Smoother

	8JM	Diesel particulate diffuser

	8LF	Rear window glass

	8LX	Ash tray — assist side

	8MA	Battery 115E41L

	8MH	Fuel tank 370L

	8ML	O/S rear view mirror — middle arm

General Information 0A-11

	Option	Option Description
	Code


	8MV	O/S rear view mirror — extended long
	arm


	8NG	Decal — vehicle & pet name

	8NH	Decal — pet name

	8NV	Bio diesel fuel B10

	80L	6HK1-TCS engine

	80R	Tire — front & rear 11.00-20-16 rib

	800	Body color — In white

	807	Body color — Woodland green

	81L	6HK1-TCC engine

	81R	Tire — front & rear 11.00-20-16 lug

	81U	Tire — front & rear 8.25-16-14 lug

	812	Body color — Wheatland yellow

	82L	6HK1-TCN engine

	829	Body color — Sahara beige

	83N	Tire — front & rear 9.5R17.5

	84D	Colombia Var.2

	85N	Tire — front & rear 11R22.5-16

	85R	Tire — front & rear 11.00R20-16 rib

	85U	Tire — front & rear 8.25R16-14 rib

	87N	Tire — front & rear 10.00R20-14PR rib

	89N	Tire — front & rear 9.00R20-14PR rib

	89R	Tire — front & rear 11.00R20-16PR

	89T	Tire — front & rear 11.00R20-16

	890	Body color — Marine blue

	90S	Tire — front & rear 8.25-20-14 rib

	904	Body color — golden yellow

	91D	KD package — Philippine Var.2

	915	Body color — fire red

	92N	Tire — front & rear 8.25R16-14PR rib

	93N	Tire — front 12.00R20-18,
	rear 12.00R20-18 lug


	94K	Tire — front & rear 10.00R20-16

	94N	Tire — front & rear 12.00R20-16

	944	Body color — Highway orange

	95D	KD package — Ireland

	951	Body color — arc white

	97N	Tire — front 295/80R22.5,
	rear 11R22.5-16

	Option	Option Description
	Code


	982	Body color — Polar white

	989	Body color — Sunbelt green

	99D	KD package — United Kingdom

	99N	Tire — front & rear 11R22.5-16

	909	Body color — middle bronze green

	919	Body color — olive drab

	999	Body color — trans blue

Vehicle Identification Number (VIN)

The ID plate indicates the vehicle identification number (VIN).

This single number contains multiple pieces of information including the vehicle and engine model codes as shown below.

0A-12 General Information

Type 1

J A L F R R 3 4 L 8 7 0 0 0 0 0 1

1 2 3 4 5 6

MFW80ASF000201

Legend
1. World manufacturer identifier (WMI)
2.	Vehicle model code
3.	Engine code
4. Wheel base code
5.	Model year code
6.	Chassis number

1. World manufacturer identifier (WMI)		4. Wheel base code

	Code				Code

			ISUZU BRAND		H		3,201 — 3,500 mm
	JAL		Medium & Heavy Duty			(126.02 — 137.80 in)

			Incomplete Vehicle
				J		3,501 — 3,800 mm

2. Vehicle model code				(137.83 — 149.61 in)


		K		3,801 — 4,100 mm

	Code					(149.65 — 161.42 in)


	FRR		4×2 Truck FRR model
			L		4,101 — 4,400 mm
						(161.46 — 173.23 in)
	FSR		4×2 Truck FSR model


							4,401 — 4,700 mm
	FTR		4×2 Truck FTR model		M
				(173.27 — 185.04 in)

	FVR		4×2 Truck FVR model

			N		4,701 — 5,000 mm

	FVZ		6×4 Truck FVZ model
				(185.08 — 196.85 in)


	FVM		6×2 Truck FVM model
			P		5,001 — 5,300 mm
						(196.89 — 208.66 in)
	GVR		4×2 Tractor GVR model


							5,301 — 5,600 mm
	FSS		4×4 Truck FSS model		7
				(208.70 — 220.47 in)

	FTS		4×4 Truck FTS model

			R		5,601 — 5,900 mm


						(220.51 — 232.28 in)
3. Engine code

		S		5,901 — 6,200 mm

	Code
					(232.32 — 244.09 in)

	34		6HK1 Engine
			T		6,201 — 6,500 mm

	86		6HF1 Engine			(244.13 — 255.91 in)



	90		4HK1 Engine

General Information 0A-13

			5. Model year code
Code

U	6,501 — 6,800 mm		Code

(255.94 — 267.72 in)
	8		2008MY


	6,801 — 7,100 mm
V		9		2009MY
(267.76 — 279.53 in)
		A		2010MY

W	7,101 — 7,400 mm

	B		2011MY
(279.57 — 291.34 in)


Type 2

J A L		H		5		K		1		6			8	7	7 0 0 0 0 1

1	2		3		4		5		6	7	8	9	10

MFW80ASF000301

Legend		6.	Engine code
1.	World manufacturer identifier (WMI)
2.	Gross vehicle weight (GVW) and brake system	7.	Check digit
3.	Series code		8.	Model year code
4.	Line/Cab type code		9.	Plant code
5.	Chassis code		10.	Production sequential number

1. World manufacturer identifier (WMI)		3. Series code

	Code					Code

			ISUZU BRAND			5		FRR
	JAL		Medium & Heavy Duty
				6		FSR
			Incomplete Vehicle

						7		FTR, FTS, FVR
2. Gross vehicle weight (GVW) and brake system

	4. Line/Cab type code

	Code

						Code
	H		8,846 — 10,659 kg

		(19,501 — 23,500 lb)					Tilt cab,

						K		BBC = 1,726 mm (67.95 in),
			10,660 — 11,793 kg
	K						Narrow Cab
		(23,501 — 26,000 lb)

								Tilt cab,
			11,794 — 14969 kg
	M				M		BBC = 2,066 mm (81.34 in),
		(26,001 — 33,000 lb)
							Narrow Cab

			14,970 — 18,370 kg
	P						Tilt cab,
		(33,001 — 40,500 lb)
					S		BBC = 2,066 mm (81.34 in),

								Wide Cab

0A-14 General Information

5. Chassis code

Code

1	4×2, 2 Axles, 1 driving

2	4×4, 2 Axles, 1 driving

4	6×4, 3 Axles, 2 driving

6. Engine code

Code

3	6HK1-TC

6	4HK1-TC

Type 3

8. Model year code

Code

8		2008MY

9		2009MY

A		2010MY

B		2011MY

9. Plant code

3 M G F R R 9 0 A M 6 5 4 3 2 1

MFWB0ASF000101

Legend
1.	World manufacturer identifier (WMI)	4.	Model year code
2.	General attributes	5.	Plant code
3.	Check digit	6.	Production sequential number

1. World manufacturer identifier (WMI)	4. Model year code

Code

ISUZU BRAND

3MG Medium & Heavy Duty

Incomplete Vehicle

2. General attributes		5. Plant code

			Code
Code

			M	Mexico (IMEX)
FRR90	FRR90


FTR34	FTR34

FVR34	FVR34

General Information 0A-15

General Precaution

General Precautions

MFW70AMF000201

Legend

1. Clean and safe costume 3. Support by stand after jack up 2. Installation of Chock blocks

Work preparations

•Prepare the tools, instruments, and special tools in advance.

•Prepare the parts that require replacement and parts that cannot be re-used in advance.

Clothing

•The service technician must wear a clean service technician uniform, hat, and safety footwear.

Protect the vehicle.

•Make sure to use a seat cover, etc.

•Disconnect the terminal of the battery (–) in advance.

Always focus on safety

•Make sure to use chock block when the vehicle is jacked up.

•After jacking up, make sure to support the specified position using a stand.

•When lifting up the vehicle using a lift, make sure to set the safety device.

•When performing a procedure with two or more people, make sure to ensure each other’s safety before performing an action.

•Do not leave the engine running for an extended period of time or perform painting in a poorly ventilated working environment.

•Make sure to use only the special tools if the procedure requires them for the work. Performing the procedure using other tools may cause damage to parts or personal injury.

•Do not use tools such as a wrench that has lost its edges, a hammer with frayed edges, or a chipped chisel.

•When performing work using a device such as a grinder, crane, or welder, make sure that a qualified technician performs the procedure while paying sufficient attention to the handling precautions.

0A-16 General Information

•When performing maintenance on fuel systems, make sure that there is no fuel leakage. (may possibly catch fire)

•When handling volatile materials, take care that they do not catch fire.

Also make sure to wipe away any oil that sticks to rubber parts, as it can cause deterioration.

Work Precaution

•Arrange removed parts in the correct order and ensure they do not get mixed up with parts that cannot be re-used.

•Perform sufficient cleaning and washing when performing assembly / installation.

Also perform sufficient grease removal for areas to apply liquid gasket, etc.

After-procedure check

•After completing the procedure, perform a final check to confirm that the problem has been solved.

•Check that there is no fuel, oil, or coolant leakage.

General Information 0A-17

Lifting Instruction

If it necessary to use a lifting device other than the original equipment jack, see illustration for acceptable lifting points.

Lifting should only be done at the positions indicated to prevent possible damage to the vehicle.

CAUTION:

Failure to observe the acceptable lift points may result in unsatisfactory vehicle performance or a durability failure which may result in loss of control of the vehicle.

Garage Jack and Safety Stand

Lifting Point and Supportable Point Location

MFW70ASH000201

Legend

1.Front axle

2.Rear axle center

3.Side member front side

4.Side member rear side

Lifting Point Positions — Front side

CAUTION:

Do not lift or support on engine oil pan.

F*R/FVM/FVZ/GVR models

MFW80ASH000101

FSS model

MFU770SH015801

0A-18 General Information

FTS model

MFU8Z0SH025501

Lifting Point Positions — Rear side

CAUTION:

Do not lift or support on rear axle tube.

FRR/FSR models (with air suspension)

MFU770SH002801

FRR/FSR/FTR/FVR/GVR models (with leaf spring suspension), FSS/FTS models (except rear singletire model)

MFW80ASH000201

FSS/FTS models (rear single-tire model)

MFU9Z0SH015301

General Information 0A-19

NOTE:

Let the tire run over a piece of block, etc., and apply the jack.

FTS model(rear single-tire model)

MFU9Z0SH015401

FVR/FVM/FVZ/GVR models (with air suspension, except Europe)

MFU8Z0SH037501

FVR model (with air suspension, for Europe)

MFU8Z0SH077401

FVM/FVZ models (with leaf spring suspension)

MFW80ASH000301

0A-20 General Information

Caution for The Maintenance of Electrical Parts

Battery Cable

Disconnecting the battery cables

1.Turn all the switches «OFF».

2.Disconnect the battery ground cable (1).

3.Disconnect the battery plus cable (3).

4.Disconnect the battery cable (2).

CAUTION:

Make sure to disconnect the battery ground cable first. Disconnecting the plus cable first may cause a short circuit.

MFW70ASH000401

Connecting the battery cables

Connect the battery cables in the reverse order of the disconnection procedure.

CAUTION:

Clean the area surrounding the battery terminal, and apply a thin layer of grease to the terminal to prevent corrosion.

Connector Handling Requirements

Visual inspection

With the male and female connectors connected

•Gently pull the connector and check whether the connector becomes disconnected or partially disconnected, and that the lock is properly set.

If a problem is found, reconnect the connectors.

•Check that there is no damage to the connector

housing.

If a problem is found, perform replacement. With the male and female connectors disconnected

•Check that no foreign material or water has entered the inside of the connectors.

Remove any foreign material or water that has entered the connector using an air brush, etc. If the material cannot be removed, replace them.

•Check that no foreign material is stuck to the terminals, and there is no corrosion or deformation.

Remove any foreign material by cleaning with an air brush, or clean rag, etc. If the material cannot be removed by cleaning, or there is corrosion or deformation, replace them.

•Gently pull the wires to check that no terminals are missing from the connector and there is no breakage in the terminal area.

If a terminal is missing, reinsert it until it locks into place. If you find a disconnection, replace them.

•Insert the male connector into the same female connector, and check that there is no abnormality in the terminal contact pressure.

If you find an abnormality, replace them.

•For waterproof connectors, check that there is no damage or foreign material stuck to the seal parts (wire seal of wiring, O-ring or waterproofing seal of connector, etc.) or seal area of the connector housing.

Remove any foreign material by cleaning with an air brush, or clean rag, etc. If the material cannot be removed by cleaning, or there is damage, replace them.

CAUTION:

•Do not perform polishing that would remove the plating of the terminals, nor wash the inside of the connector. If there is dirt that requires washing, replace them.

•Be careful when attaching the seal areas of waterproof connectors, as some have specific positions and directions they must be attached. Also do not attach them in a twisted state.

Regarding vehicle washing

Even for electric parts that are installed outside the cab and are waterproofed, try to avoid exposing them directly to high pressure water when washing the vehicle (cover them with plastic sheets, etc.) as much as possible.

General Information 0A-21

Disconnecting the connector

Many connectors have a lock to ensure secure connections.

The two types of locks generally used are those that open by lifting the release area of the lock (1), and those that open by pressing the release area (2). Before disconnecting the connector, determine in advance which type of lock the connector is using.

LNW20ASH001201

When disconnecting the connector, first securely grasp the male side and female side of the connector. Release the lock, and carefully disconnect the connector.

Do not pull the harness when disconnecting the connector, as this may cause wires to come out or break.

LNW20ASH001301

Connecting the connector

Securely grasp the female side and male side of the connector, and align them correctly.

Firmly push them together until both sides click into place.

LNW20ASH001401

Connector circuit inspection requirements

Check the continuity of the connector using a circuit tester. Insert the probes (1) of the tester from the harness side of the connector, as indicated in the diagram.

LNW20ASH001501

0A-22 General Information

Never insert the probes (1) from the connection closure area of the connector, as this will cause the connector terminals to break.

LNW20ASH001601

Inspection requirements for waterproof connector circuit

For waterproof connectors, the probes of the tester cannot be inserted from the wiring side, due to the structure of the connectors.

Therefore, perform the continuity inspection as indicated in the diagram, by connecting a testing connector (1) prepared in advance to the connector (2) to test, and connect the probes (3) of the tester to the harness of the testing connector.

LNW20ASH001701

Disconnecting connector terminals —Built-in lock type

1.As indicated in the diagram, insert a thin screwdriver-shaped metal rod (1) from the connector closure area (5).

2.Push the lock (2) up in the direction of the arrow using the metal rod to release the lock. In that state, pull out the harness (3) together with the terminal (4).

1	2
5	4	3

		LNW20ASH001801

—Terminal lock type

1.Insert a metal rod (1) from the connector closure area (5).

2.As indicated in the diagram, release the terminal lock (2) by pushing it to the harness side, pull out the harness (3) together with the terminal (4).

LNW20ASH001901

Connecting connector terminals

1.Check that the terminal lock (1) area is raised fully and can be locked.

2.Insert the terminal (3) from the harness (2) side of the connector, and push it in until the lock area clicks.

General Information 0A-23

3.Gently pull the harness and check whether the terminal is completely locked inside the connector.

Replacing the fuse

WARNING:

If a fuse melts down, make sure to replace it with a nondefective fuse of the same capacity, after identifying the cause of the melt down.

If you use a fuse with high capacity, the fuse will not perform its function when excess current flows. This may cause parts or wires, etc. to burn, and can result in a vehicle fire.

LNW20ASH002101

Handling Electronic Parts

Handle electronic parts with sufficient care, and do not damage the parts by dropping or throwing them.

LNW20ASH002201

Cable Harness

1.When installing electronic parts, take care to ensure the harness does not get stuck and do not forcibly push the harness in.

LNW20ASH002301

2.Make sure that all connections are clean and secure.

0A-24 General Information

3.When the harness will be contacting sharp edges or surfaces of other parts, protect the harness using a grommet or tube to prevent damage due to the contact.

LNW20ASH002401

4.When wiring the harness by diverting it around other parts, give the harness a sufficient amount of free length, and use a protective tube (2) and clip

(1) to ensure it does not contact surrounding parts.

5.For wiring between the engine and chassis, give the wiring sufficient free length to prevent wear and damage caused by vibrations.

LNW20ASH002601

General Information 0A-25

Regarding The Scan Tool

Trouble Diagnosis Using The Scan Tool

Regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 /CAN-di module

This tool is effective for diagnosing electrical failures in electronic control units and performing system checks. If you connect the Tech2 to the DLC installed in the vehicle, it performs communication with the control units of the vehicle, and enables various diagnoses and tests to be performed.

Legend

1. PCMCIA card (dedicated) 3. DLC cable

2. Tech2 (body)

0A-26 General Information

LNW7Z0SF000101

Legend
1.	Tech2 24V adaptor 2 (body)	3.	Tech2 connecting cable
2.	Signal change switch	4.	DLC connecting cable

[Euro4 specification]

LNW7Z0SF000401

Legend

1. CAN-di module (body) 3. DLC connecting cable 2. Tech2 connecting cable

Features and cautions regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 / CAN-di module [Euro4 specification]

•The Tech2 has a 12 V power system. Do not directly use 24 V power. Do not directly supply power from the cigar lighter.

•Remove/install the PCMCIA card after turning the power off.

•The Tech2 has the capacity for two snapshots.

•As the PCMCIA card is sensitive to magnetism and static electricity, take care when handling it.

•The Tech2 is able to draw graphs of snapshots.

•To select a menu, press the selection key or choose a menu with a function key and press the ENTER key.

•You can return to the main menu at any time by pressing the EXIT key.

•To clear the diagnostic trouble codes (DTC), open the application menu and select «Clear DTC Information».

•The Tech2 adaptor 2 has a built-in DC to DC converter (that converts 24 V to 12 V).

General Information 0A-27

•The Tech2 adaptor 2 has a selector for switching signals (the signals for each electronic control unit (ECU)).

•The CAN-di module has a built-in signal converter (that converts CAN serial data to keyword serial data)

Parts of the Tech2

		1
	2
		3
13
	4
	8
14
		3
	5	6
15
16
7	12
	11
	9
	10
		HCW35ALF001401

Legend	10.	VCI module fastening bar
1.	Soft key
2.	Selection key (arrow key)	11.	DLC cable connecting connector
3.	Action keys (YES, NO, ENTER, EXIT)	12.	AC adaptor connector
4.	Function key (F0 – F9)	13.	PCMCIA card insertion opening (with cover)
5.	Help key (?)	14.	PCMCIA card release (removal) button
6.	Control key (PWR or SHIFT)	15.	Connector for external communication (RS-485
7.	Wide stand		port)
8.	Display (liquid crystal display)	16.	Connector for external communication (RS-232
9.	Vehicle communication interface (VCI) Module		port)

1. Soft keys	displayed on the screen.
When operating the Tech2, the selection box is	2. Selection key (arrow key)
displayed on the top of the screen. The soft keys	Selects menu items on the Tech2 screen, and
correspond to that selection box. The soft keys	switches the display. The highlighted area of the
cannot be used unless the selection box is	screen display indicates what is being selected.

0A-28 General Information

3.Action keys (YES, NO, ENTER, EXIT)

Confirm Tech2 operations, respond to screen instructions/questions, switch/move to the various menu screens.

4.Function keys (F0 — F9)

Confirm menu functions displayed on the screen. Also when «F0» etc., is displayed on the menus on the screen, the keys correspond to that display.

5.Help key (?)

Displays a screen explaining the Tech2 function being used.

6.Control key (PWR or SHIFT)

The PWR key turns the power of the Tech2 ON/ OFF. The SHIFT key is used when adjusting the screen contrast. The LED (orange) lights up when the SHIFT key is available. At this time, the key and functions other than the selection key are locked. The LED (green) lights up when the power is turned ON.

7.Wide stand

Used as a stand. The operating angle of the stand is 0 to 180°.

8.Display (liquid crystal display)

The liquid crystal display has a contrast adjustment function. Displays the ECM information and the various instruction screens.

9.Vehicle communication interface (VCI) module The module that enables communication between the vehicle and Tech2.

Parts of the Tech2 24 V adaptor 2

10.VCI module fastening bar

Operate the bar to attach/fix, or remove the VCI.

11.DLC cable connecting connector

Connector for using (connecting) the Tech2 with the vehicle. Connect the DLC cable.

12.AC adaptor connector

Connector for connecting the included AC adaptor. Enables the Tech2 to be used away from the vehicle.

13.PCMCIA card insertion opening (with cover) Open the cover to insert a PCMCIA card into the Tech2. Insert the PCMCIA card with the cover opened. Never insert/remove the PCMCIA card with the Tech2 turned ON.

14.PCMCIA card release (removal) button

Used when removing the PCMCIA card from the Tech2. The PCMCIA card can be removed when the button is pressed. Never remove the PCMCIA card with the Tech2 turned ON.

15.Connector for external communication (RS-485 port)

This port is for connecting to a telephone line, but is currently not used for the Tech2. Do not connect a telephone line, etc., to this port.

16.Connector for external communication (RS-232 port)

This port is for connecting the Tech2 to another computer.

1.Signal change switch

The Tech2 adaptor 2 has a selector for switching signals (the signals for each electronic control unit (ECU)).

(The position of the switch is free for other than the following device)

•“1” : —

•“2” : HSA

•“3” : —

2.DLC connecting cable

Connects the Tech2 adaptor 2 to the vehicle DLC (pole 16, blue).

3.Tech2 connecting cable

Connects the Tech2 adaptor 2 to the Tech2.

General Information 0A-29

Parts of the CAN-di module [Euro4 specification]

LNW7Z0SF000501

1.Tech2 connecting cable

Connects the CAN-di module to the Tech2.

2.DLC connecting cable

Connects the CAN-di module to the Tech2 adaptor 2.

Connection method

1.Insert the ISUZU system PCMCIA card into the Tech2 unit.

2.Connect the DLC cable to the Tech2 unit.

3.Connect the CAN-di module to the DLC cable. [Euro4 specification]

4.Connect the Tech2 24 V adaptor 2 to the CAN-di module. [Euro4 specification]

Connect the Tech2 24 V adaptor 2 to the DLC cable. [Except Euro4 specification]

5.Confirm that the ignition is turned «OFF».

6.Connect the Tech2 24 V adaptor 2 to the vehicle side DLC connector (pole 16, blue).

RHD model

9		1

10		2

11		3

12		4
13		5

14		6

15		7

16		8

LHD model

9		1

10		2

11		3

12		4

13		5

14		6

15		7

16		8

MFW82ASH000401

NOTE:

The CNG engine becomes sensitive to fluctuation of the power voltage when the temperature of ECM unit is high while or after driving, and communication failures may occur.

To avoid this situation, input 12 V power supply from a 12 V battery using a battery power cable, separately from the power for the Tech2 24 V adaptor 2.

•Do not input 24 V battery power supply to the Tech2 unit. Do not use the cigar lighter power supply on the vehicle side, which is also 24 V.

MFA7Z0SH000201

0A-30	General Information
	1
	2
	3
	4
	5
	MFW90ASH000401
Legend

1.Tech2

2.Battery power cable

3.3 A fuse

4.Clip (black)

5.Clip (red)

•If the power supply is not input, check the 3 A fuse.

7.Turn the ignition «ON», and press the «PWR» key of the Tech2.

8.Confirm the display of the Tech2.

Press (ENTER) To Continue

HCW46ESH001901

CAUTION:

Remove/install the PCMCIA card after confirming that power is not being supplied to the Tech2.

General Information 0A-31

Recommended Liquid Gasket

Type	Product name	Manufacturer name	Area used (reference)

	ThreeBond 1207B	ThreeBond	Engine oil seal retainer
Silicon type	ThreeBond 1207C	ThreeBond	Engine oil pan
(Room temperature	ThreeBond 1215	ThreeBond	Timing gear case
vulcanization process)	ThreeBond 1216	ThreeBond	Cylinder head cover
	ThreeBond 1281	ThreeBond	Fuel pump
			Water pump
Water Base	ThreeBond 1141E	ThreeBond
Rear axle

	ThreeBond 1102	ThreeBond	Etc.
Solvent	ThreeBond 1104	ThreeBond
	ThreeBond 1194	ThreeBond

	LOCTITE 515	LOCTITE	Engine oil seal retainer
Anaerobic	LOCTITE 518	LOCTITE	Water pump
LOCTITE 17430	LOCTITE	Transaxle

	FMD127	LOCTITE	Etc.

•Make sure to use a liquid gasket with the above product name or equivalent.

•Do not use LOCTITE 515, 518 or FMD 127, as they are anaerobic, and do not provide sufficient effect when there is a gap larger than 0.25 mm (0.010 in) between the contact surfaces of metals.

•Use an appropriate amount of liquid gasket. Follow the handling precautions for the product.

Application method

1.Wipe any water or oil from the contact surface. Make sure the contact surface is dry.

2.Apply liquid gasket of the specified bead width to one side of the contact surface. Make sure there are no cuts in the beads.

1. Completely remove lubricant and moisture from the connecting surfaces.The surfaces must be perfectly dry.

2. Apply specified bead width of liquid gasket to one of the connecting surfaces.There must be no gaps in the bead.

		mm (in)
SCREW	DEPRESSION	JUDGE
HOLE	MENT

1˜3
(0.04˜0.12)
		OK
1˜3	More than
(0.04˜0.12)	2 (0.08)
		OK
		Depression	Apply liquid gasket to
			the bolt hole interior
			Specified
			bead width
		NG
		Example
		Anaerobic Type :2-3 mm (0.08-0.12 in)
		Others	:2-6 mm (0.08-0.24 in)

MFW70AMF000101

0A-32 General Information

NOTE:

If the repair manual specifies an application method, follow that method.

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Руководство по эксплуатации Исузу Гига / Макс / Ц / Е-серии

Руководство по эксплуатации Исузу Гига / Макс / Ц / Е-серии

Серия: Восток
Формат: A5
Кол-во стр.: 238
Автор: Коллектив авторов
Тип двигателя: 6WF1-TC / 6WG1-TC / 8TD1 / 8PE1 / 10PE1
Мощность: 285/325/360/370/410/450/480 л.с.

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Книга: ISUZU TROOPER бензин с 1999 г.в., ремонт, техническое обслуживание
Практическое руководство по автомобилям Isuzu Trooper c 1999 года выпуска, с бензиновыми двигателями рабочим объемом 3,2, 3,5 л.

Книга: ISUZU GIGA 1996-2003 г.в., дизель эксплуатация, техническое обслуживание
Руководство по эксплуатации грузовых автомобилей Isuzu Giga / Giga Max / Isuzu C/E 1996-2003 годы выпуска, оборудованных дизельными двигателями 6WF1-TC, 6WF1-TC, 6WG1-TC, 8TD1, 8PE1, 10PE1.

Книга: ISUZU FORWARD дизель 1985-2000 г.в., ремонт, эксплуатация, техническое обслуживание
Данная книга содержит подробные сведения об устройстве, эксплуатации, техобслуживанию и ремонту грузовых автомобилей Isuzu Forward, которые выпускались с 1985 по 2000 год, оснащались дизельными двигателями 6HH1 (объем 8,2 л) и 6BG1 (объем 6,5 л), 6HE1 (объем 7,1 л) и 6SA1 (объем 8,4 л) и оборудовались автоматической коробкой передач либо коробкой отбора мощности.

Книга: OPEL MONTEREY / ISUZU TROOPER BIGHORN AMIGO (MU) бензин c 1981 — 1992 / с 1988 — 1997 г.в., ремонт, экс
Руководство по ремонту автомобилей Opel Monterey/Isuzu Trooper, Bighorn, Amigo(MU) c 1981 по 1992 и с 1988 по 1997 годы выпуска для моделей с бензиновыми двигателями объемом 1,8; 2,0; 2,3; 2,6; 2,8; 3,1 л.

Книга: Двигатели ISUZU (4HF1 / 4HG1 / 4BB1 / 6BB1 / 4BD1 / 4BD1-T / 6BD1 / 6BD1-T / 4BG1 / 4BG1-T / 6BG1 / 6BG1-T) дизель ремонт, эксплуатация, техническое обслуживание
Подробное руководство по ремонту и техобслуживанию двигателей ISUZU (4HF1 / 4HG1 / 4BB1 / 6BB1 / 4BD1 / 4BD1-T / 6BD1 / 6BD1-T / 4BG1 / 4BG1-T / 6BG1 / 6BG1-T).

Книга: Двигатели ISUZU (6HK1-TC / 6HL1 / 6HH1 / 4HK1-T / 4HK1-TC / 4HL1 / 4HL1-TC) дизель ремонт, эксплуатация, техническое обслуживание
Подробное руководство по ремонту и техобслуживанию двигателей ISUZU (6HK1-TC / 6HL1 / 6HH1 / 4HK1-T / 4HK1-TC / 4HL1 / 4HL1-TC).

Книга: ISUZU ELF дизель до 1993 г.в., ремонт, эксплуатация, техническое обслуживание
Руководство по ремонту, эксплуатации и техническому обслуживанию, устройство автомобилей Isuzu Elf до 1993 года выпуска, с дизельными двигателями 4JA1 (2,5 л), 4JB1 (2,8 л), 4JB1-T (2,8 л, Turbo), 4BC2 (3,3 л), 4BE1 / 4BE2 (3,6 л), 4BD1 (3,9 л), 4BD1-T (3,9 л, Turbo).

Книга: CHEVROLET S-10 /BLAZER GMC SONOMA OLDSMOBILE BRAVADA ISUZU HOMBRE бензин с 1994 г.в., ремонт, эксплуатация,
Руководство по ремонту и техническому обслуживанию автомобилей Chevrolet S-10 / Blazer, GMC Sonoma, Oldsmobile Bravada, Isuzu Hombre 1994-2001 гг. выпуска, с бензиновыми двигателями рабочим объемом 2,2, 4,3 л.

Источник

Руководство по ремонту ISUZU GIGA ⇐ Giga (C/E-Series)

Модератор: RANGER

Автор темы

Войтенко Александр: Новичок; Всего сообщений: 6; Зарегистрирован: 09.09.2013; Откуда: Россия, Красноярск; Возраст: 42

Руководство по ремонту ISUZU GIGA

У кого есть — поделитесь пожалуйста, уж больно редкий вид.
Если есть каталожные номера — пожалуйста тоже.

Автор темы

Войтенко Александр: Новичок; Всего сообщений: 6; Зарегистрирован: 09.09.2013; Откуда: Россия, Красноярск; Возраст: 42

Re: Руководство по ремонту ISUZU GIGA

Сообщение

Войтенко Александр » 24 сен 2013, 01:21

Он японец, у него в сртс указан № шасси: CXG50X3000040,
а в кабине указан VIN: CXG50X3000040

А VIN везде требуется 17 знаков а у меня 13.
И кстати, поиском естественно пользовался. Пересмотрены все ссылки до 10 — 15 страниц по разным поисковым запросам.

Сам грузовик вот такой:

Гость

Re: Руководство по ремонту ISUZU GIGA

Сообщение

Гость » 25 ноя 2015, 06:16

момент затяжки ДВС-10РЕ1

Гость

Re: Руководство по ремонту ISUZU GIGA

Сообщение

Гость » 11 дек 2015, 18:04

Гость: момент затяжки ДВС-10РЕ1[/q

Гость: момент затяжки ДВС-10РЕ1

привет
нашел что нибудь по Исузу своему, у меня двигатель 12PD1, вообще по нему ничего найти не могу

Для отправки ответа, комментария или отзыва вам необходимо авторизоваться

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Источник

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It is not for nothing that the founder of the automobile company Isuzu named the leadership of one of the most powerful industrial enterprises of Japan in the early 20th century
— Tokyo Ishikawajima Shipbuilding and Engineering. It was under the auspices of this organization that a company was established whose specialization was the production of heavy automotive
equipment using mainly diesel engines, the history of which by that time was only a few dozen years old.

Isuzu FRR 33L F-Series Truck

The debut step made by representatives of the company, which in the future became known as Isuzu, was the signing in 1918 of an agreement with the British company Wolseley Motors on the assembly
of trucks by the Japanese under license from the British. Already four years later, in 1922, a truck of the A-9 model was presented. And the first own development, made at the Ishikawajima
Automotive Works corporation, representatives of the future Isuzu was demonstrated in 1928. In 1933 Ishikawajima Automotive Works merged with another successful automotive company from Japan —
Dot Automobile Manufacturing.

As a result of the transformation, the organization was named Automobile Industries. The following year became even more important for the formation of future success. Having received an order
from the Ministry of Trade and Industry, the company within its framework produced and produced the Isuzu model, named after one of the Japanese rivers. In the same year, the young corporation
created a unit, which was to deal with research in the field of diesel engines. Three years later, after another restructuring, a new name for the firm was announced — Tokyo Automobile
Industries. And in 1938, the first two trucks of the TX40 model came off the production line in Kawasaki.

ISUZU NPR 275 Medium Truck

40th years of the twentieth century became no less successful than the previous decade. Already in 1941, Tokyo Automobile Industries received permission from the Japanese government to
manufacture cars equipped with diesel power units, becoming the only such company throughout the country. In 1945, the postwar production of the TX40 truck was resumed, and the active sales of
the TU60 also began. And in 1949 the company was renamed to Isuzu Motors Limited. The only negative factor was the separation of Hino Works, one of the parts of the corporation,
and the subsequent establishment of an independent company Hino Heavy Industries in 1942.

The beginning of the next decade was marked by the successful development of the diesel V-shaped 8-cylinder engine with water cooling, which received the index DA80. In early 1953, Isuzu
Corporation presented the first ever company, made in cooperation with the British firm Rootes, a Hillman car, which became a copy of the British car of the same name. By October of the same
year, Hillman entered the conveyor production. And in October 1959 was marked by the beginning of the conveyor assembly of the truck Elf LT, equipped with an extremely economical diesel engine
DA640.

In the early 60’s, a real production boom occurred, as a result of which representatives of the Isuzu company were presented to the public by a diesel engine for a DL201 car, the volume of which
was 2 liters. Approximately at the same time, a new plant was opened in the city of Fujisawa, and new models of cars, the WASP truck and the Bellel and Bellet cars, were also on sale. In the
second half of the decade, the new products were a large truck TM, as well as passenger cars 117 Coupe and Florian.

Isuzu Giga

The next decade also began with major presentations: in 1970, the Isuzu Forward cargo models were presented, as well as the Isuzu Elf 350 (KS). One of the most important events
in the history of Isuzu was the signing of an agreement on cooperation with the American automobile magnate General Motors, which in 1971 became the owner of 35% of the shares of the Japanese
company. The results of joint labor did not take long. Already in 1974, the assembly line for a Gemini passenger car developed within the framework of cooperation between Isuzu and General Motors
began. Over the next few years, the company’s lineup was also updated.

So in 1977, the production of Isuzu Florian started with a diesel engine, and in 1979 debuted the diesel version of Gemini. A few years earlier, in 1975, the Isuzu North American division, Isuzu
Motors America, was opened, whose prospects, in view of cooperation with General Motors, looked extremely serious. And in the very end of the 70s, the construction of a testing range for the
Japanese automaker in Hokkaido was completed. Later, in May 1984, in the same Hokkaido, a new plant was opened. The beginning of the 80s of the 20th century foreshadowed new successes. The main
confirmation of this is the rapid upgrade of the lineup.

First, in 1980, a series of commercial Fargo minibuses entered the conveyor assembly, which were almost immediately widely used in Japan. Almost immediately, in the first half of 1981, the
passenger car Piazza and SUV Rodeo Bighorn debuted, in 1983 Florian Aska model was put on the conveyor, after half a year celebrating the victory in the British RAC rally. And already in 1985
they introduced the FF Gemini car. In the same year 1985, the first representative office of Isuzu in China was opened, which was originally considered as the most important market.

Isuzu ELF Truck

1987 was a landmark in the history of the company in connection with the founding of the joint venture Isuzu Motors and General Motors, which was named IBC Vehicles. Two years later, the fruit of
common labor was presented — the debut SUV MU (Amigo), which launched a new class of «heavy passenger cars». At the same time, a joint venture with Subaru was founded. In the same year 1989,
Isuzu became the world leader in the production of medium and heavy trucks. After the successful development in 1990 of the world’s first electromagnetic brake in cooperation with Sumitomo Metal
Industries, a joint venture with Subaru launched a new model of the Rodeo SUV, which in early 1991 was already in the US.

A very important role in the history of development of Isuzu was played by the Charter of Environmental Protection, which was adopted in mid-1992, and according to which the company carried out
its further activities. All decade passed under the sign of new developments and improvements. In 1991, debuted an updated SUV Trooper. In 1993, the first representative of the Isuzu N series of
commercial vehicles came off the assembly line. Next year, a series of commercial cars F, C and E were presented. In 1997, Isuzu showed the public another novelty developed specifically for
off-road — VehiCross, and in 1998 it was marked The release of a truck Elf CNG, working on gas.

At the same time, the 90s were remembered by the fans of Isuzu’s developments and major successes at various competitions. So in 1994, the car Trooper won in two races Paris-Dakar rally, and two
years later, the first place in the Australian safari took the model Holden Jackaroo. In addition, the organization received many awards for its innovative developments. And in 1999, the fate
again brought Isuzu Motors with the company Hino, as a result of which was established joint production of buses. The beginning
of the XXI century marked the receipt by the company representatives of new awards for successful development.

Isuzu C-Series

In particular, 2001 was marked by the presentation of the diesel engine Duramax 6600, which was called one of the best powertrains in the history of the automotive industry. At the same time, the
Japanese actively worked in foreign markets. At the same time, not only the USA and Asian countries, such as Indonesia, Thailand or Japan, received dividends from this work. The company Isuzu
Motors gradually entered the European market. In 2002, a 3-year business plan of the Japanese automaker was adopted, which was supposed to minimize costs and make the company’s revenue more
solid. According to this plan, by January 2003 the share of ownership of Isuzu shares by the automobile giant General Motors had decreased to 12%.

At the same time, these companies continued active cooperation. It should be noted the establishment of another joint venture, whose goal was the development of transmissions. According to the
new business plan of the company, calculated from April 2005 to March 2008, Isuzu was to become the world leader in the production of diesel engines, as well as commercial vehicles and buses. It
should be noted that the company did it. An important role in the development of Isuzu Motors as a world giant was played by the company’s unique developments. In particular, debuted in mid-2005
truck Elf Hybrid with a mixed engine.

After the introduction of new environmental standards in Japan in the same year of 2005, the very important step was the development of the Isuzu Giga truck, which became the first Japanese car
in its class to meet these standards. After the dissolution of the alliance between Isuzu Motors and General Motors in 2006, these companies have set up a joint venture, which is already
preparing for the presentation its new products, which, according to the plan, will pleasantly surprise the whole world.

Источник

GENERAL INFORMATION

General Information

General Repair Instructions

Identification

Chassis Number/Engine Number Stamping Position

Option Code List

Vehicle Identification Number (VIN)

General Precaution

General Precautions

Lifting Instruction

Lifting Instruction

Caution for The Maintenance of Electrical Parts

Battery Cable

Connector Handling Requirements

Handling Electronic Parts

Cable Harness

Regarding The Scan Tool

Trouble Diagnosis Using The Scan Tool

Recommended Liquid Gasket

Recommended Liquid Gasket

Руководство по эксплуатации Исузу Гига / Макс / Ц / Е-серии

Руководство по ремонту ISUZU GIGA ⇐ Giga (C/E-Series)

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