Isuzu Libro 1.pdf

8/21/2019 Isuzu Libro 1.pdf

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CAUTIONIn order to reduce the chance of personal injury and/or property damage, carefully observethe instructions that follow:The service manuals of Isuzu Motors America Inc. are intended for use by professional,qualified technicians. Attempting repairs or service without the appropriate training, tools,and equipment could cause injury to you or others. This could also damage the vehicle, orcause the vehicle to operate improperly.Proper vehicle service and repair are important to the safety of the service technician and tothe safe, reliable operation of all motor vehicles. If you need to replace a part, use the samepart number or an equivalent part. Do not use a replacement part of lesser quality.The service procedures we recommend and describe in this service manual are effectivemethods of performing service and repair. Some of the procedures require the use of toolsthat are designed for specific purposes.Accordingly, any person who intends to use a replacement part, a service procedure, or atool that is not recommended by Isuzu, must first establish that there is no jeopardy topersonal safety or the safe operation of the vehicle.This manual contains various CAUTIONS and NOTICES that you must observe carefully inorder to reduce the risk of personal injury during service or repair. Improper service orrepair may damage the vehicle or render the vehicle unsafe. These CAUTIONS and NOTICESare not exhaustive. Isuzu can not possibly warn of all the potentially hazardousconsequences of your failure to follow these instructions.This manual covers service procedures to vehicles that are equipped with a SupplementalInflatable Restraint (SIR). Refer to the CAUTIONS in Cautions and Notices and In Restraints.Refer to SIR component and wiring location views in Restraints before performing a serviceon or around SIR components or wiring. Failure to follow these CAUTIONS could cause airbag deployment, personal injury, or otherwise unneeded SIR repairs.In order to help avoid accidental air bag deployment and personal injury, whenever youservice a vehicle that requires repair of the SIR and another vehicle system, we recommendthat you first repair the SIR, then go on to the other system.


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New Style Service Manual StructureThis new style service manual is constructed with the following10 sections:

0. General Information1. Heating, Ventilation, and Air Conditioning (HVAC)2. Steering3. Suspension4. Driveline and Axle5. Brakes6. Engine7. Transmission8. Body and Accessories9. Restraints

The following table gives the previous service manual sub-sections withthe name of the new section and sub-section. Almost all of the diagnosisthat was in section 8A is now located in its applicable sub-section.


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Truck Service Manual Sub-Section to Sectionand Sub-Section Conversion TableOldSub-SectionOA

OBOC1A1B1D2A3A

3B,3B1A,3B1B3B33C3D3E3F4A4B4C5

5A5B5C5D5E5F

6, 6A6B6C6D

6F6H6J

7A

Old Sub-SectionGeneral Information

Maintenance andLubricationVibration Diagnosis

Heating and VentilationHeating, Ventilation, andAir Conditioning

A/C CompressorsFrame and Bumpers

Front Wheel AlignmentPower Steering Gear andPump

Steering LinkageFront SuspensionRear SuspensionTires and WheelsSteering Columns

Propeller ShaftRear Axle and Differential

Front Drive Axles andDifferentialHydraulic BrakesMaster Cylinder

Front Disc BrakesDrum Brakes

Hydraulic or VacuumBoosterAntilock BrakesParking Brake

Engine MechanicalEngine Cooling andRadiator

Engine FuelEngine Electrical

Driveability and EmissionsExhaust SystemVacuum PumpTurbocharger

Automatic Transmission

NewSection0

00

1

1

1

83

22333

244

45555

5556

6666666

7

Section NameGeneral InformationGeneral InformationGeneral Information

HVACHVACHVAC

Body and AccessoriesSuspension

SteeringSteering

SuspensionSuspensionSuspension

SteeringDriveline/AxleDriveline/AxleDriveline/Axle

BrakesBrakesBrakesBrakesBrakesBrakesBrakesEngineEngineEngineEngine

EngineEngine

Transmission/Transaxle

Sub-Section Name\General InformationMaintenance andLubrication

Vibration DiagnosisHeating and Ventilation(Non A/C)HVAC systems with AirConditioningHVAC systems with AirConditioning

Frame and Underbody, andBumpersWheel Alignment

Power Steering SystemSteering LinkageFront SuspensionRear SuspensionTires and Wheels.

Steering Wheel andColumnPropeller ShaftRear Drive Axle

Front Wheel Drive Shaftsand Front Drive AxleHydraulic BrakesHydraulic Brakes

Disc BrakesDrum Brakes

Hydraulic BrakesAntilock BrakesParking Brake

Engine MechanicalEngine CoolingEngine ControlsEngine ElectricalEngine ControlsExhaust SystemVacuum PumpTurbocharger

Automatic TransmissionandTransmission/TransferCase Unit Repair Manual


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Truck Service Manual Sub-Section to Sectionand Sub-Section Conversion Table (cont'd)OldSub-Section

7B7C

7D8B8C8D8E9A9B9E9F9J9K

10A110A210A310A410A510B

Old Sub-Section

Manual TransmissionClutch

Transfer CaseLighting Systems

Instrument Panel andGagesChassis Electrical

Wipers and WashersAudio SystemsCruise Control

Engine Coolant HeaterLuggage Carrier

Supplemental InflatableRestraintRemote Keyless Entry

DoorsSeats

Stationary WindowsInterior Trim

EndgateCab and BodyMaintenance

NewSection

77

48

8

888868

98889888

Section Name

Transmission/TransaxleTransmission/Transaxle

Driveline/AxleBody and AccessoriesBody and Accessories

Body and AccessoriesBody and AccessoriesBody and Accessories

EngineBody and Accessories

RestraintsBody and AccessoriesBody and AccessoriesBody and Accessories

RestraintsBody and AccessoriesBody and AccessoriesBody and Accessories

Sub-Section NameManual Transmission andTransmission/TransferCase Unit Repair Manual

ClutchTransfer Case andTransmission/TransferCase Unit Repair ManualLighting Systems

Instrument Panel, Gagesand ConsoleRefer to the Index at theend of the manualWiper/Washer Systems

EntertainmentCruise Control

Engine CoolingRoof

Supplemental InflatableRestraints

Keyless EntryDoorsSeats

Seat BeltsStationary Glass

Exterior/Interior TrimBody Rear EndRefer to the Index at theend of the manual


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1998 Medium Duty THickFSR, FTR, FVRService ManualVolume 1

This manual provides information on the diagnosis, the service procedures, the adjustments, and thespecifications for the 1998 Isuzu Medium Duty Truck.The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins betterservice the vehicle owners.When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product inplace of the recommended item. All information, illustrations and specifications in this manual are based on thelatest product information available at the time of publication approval. Isuzu reserves the right to make changesat any time without notice.

Published byISUZU MOTORS AMERICA, INC.

1998 ISUZU MOTORS AMERICA, INC.The information cutoff date is 12/1/97.

ALL RIGHTS RESERVEDLITHO IN U.S.A.

No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means(including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission ofIsuzu Motors America, Inc. This applies to all text, illustrations, and tables.


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Table of ContentsVolume 1

Preface........................................................................iCautions and Notices.................................................3General Information...........................................0-1General Information................................................0-3Maintenance and Lubrication................................0-33Vibration Diagnosis and Correction ......................0-51HVAC.........................................................................1-1Heating and Ventilation (Non-A/C)..........................1-3HVAC Systems with A/C - Manual........................1-57Body and Accessories......................................8-1Lighting Systems ....................................................8-7Wipers/Washer Systems.....................................8-103Entertainment.....................................................8-123Wiring Systems...................................................8-143Instrument Panel, Gauges and Console.............8-283

Horns..................................................................8-351Exterior Trim........................................................8-361Waterleaks..........................................................8-363Stationary Windows............................................8-365Bumpers..............................................................8-373Body Front End ...................................................8-377Doors..................................................................8-399Seats...................................................................8-431Interior Trim.........................................................8-441Plastic Panel Information and Repair.................8-453Paint/Coatings.....................................................8-455Frame and Underbody........................................8-463Collision Repair...................................................8-485

Restraints...............................................................9-1Seat Belts...............................................................9-3Volume 2

Preface...................................................Cautions and Notices............................Steering .................................................Power Steering System........................Steering Linkage (Non-Rack & Pinion).Steering Wheel and Column -Tilt.........

.......1

.......3...2-1...2-3.2-53.2-63

Suspension..............................Suspension General Diagnosis,Wheel Alignment........................Front Suspension.......................Rear Suspension.......................Tires and Wheels......................,Air Suspension...........................

Driveline/Axle...........................Propeller Shaft...........................Rear Drive Axle..........................Rear Axle Controls.....................Brakes.........................................Hydraulic Brakes........................Disc Brakes................................Park Brakes...............................Air Brakes ..................................Air Drums..................................,Air Compressor.........................Antilock Brake System ..............Air Antilock Brake System ........

Volume 3Preface................................................Cautions and Notices.........................Engine..................................................Engine Cooling..................................Engine Electrical................................Engine Controls - 7.8L.......................Engine Exhaust..................................Engine, On-vehicle Service ................Engine Overhaul.................................Water Pump.......................................Fuel System.......................................Fuel Injection......................................

Diesel Electrical..................................Emission and Electrical Diagnosis .....Turbocharger ......................................Transmission/Transaxle...............Manual Transmission - Medium Duty.Automatic Transmission - Allison.......Clutch.................................................Manual Transmission Overhaul..........

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Cautions and NoticesCautions and Notices..........................................3Definition of Caution, Notice, and Important......3ABS Handling Caution........................................3Battery Disconnect Caution......................Brake Dust Caution...................................Brake Fluid Caution ..................................Clutch Dust Caution ..................................Fuel and EVAP Pipe Caution...................Fuel Gauge Leak Caution ........................Fuel Pipe Fitting Caution..........................Fuel Storage Caution................................Gasoline/Gasoline Vapors Caution...........Moving Parts and Hot Surfaces Caution,

Road Test Caution ....................................

Safety Glasses and CompressedAir Caution.......................................Safety Goggles and Fuel Caution.......Vehicle Lifting Caution.........................Window Removal Caution ...................Work Stall Test Caution .......................Defective Scan Tool Notice.................Fastener Notice....................................Fuel Pressure Notice...........................Handling ESD Sensitive Parts Notice.Ignition OFF When DisconnectingBattery Notice..................................Nylon Fuel Lines Notice......................PCM and ESD Notice..........................Single Cylinder Flooding Notice..........

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Preface Cautions and Notices - 3Cautions and NoticesDefinition of Caution, Notice,and ImportantThe diagnosis and repair procedures in the IsuzuService Manual contain both general and specificCautions, Notices, and Importants. Isuzu is dedicatedto the presentation of service information that helpsthe technician to diagnose and repair the systemsnecessary for the proper operation of the vehicle,however, certain procedures may present a hazardto the technician if they are not followed in therecommended manner. Cautions, Notices, andImportants are elements designed to prevent thesehazards, however, not all hazards can be foreseen.This information is placed at strategic locations withinthe service manual. This information is designed toprevent the following from occurring:

Serious bodily injury to the technician Damage to the vehicle Unnecessary vehicle repairs Unnecessary component replacement Improper repair or replacement of vehicle

components. Any caution or notice that appearsin general information is referenced from theindividual service categories.CAUTION DefinedWhen encountering a CAUTION, you will be askedto take a necessary action or not to take aprohibited action. If a CAUTION is not heeded, thefollowing consequences may occur:

Serious bodily injury to the technician Serious bodily injury to other technicians in theworkplace area Serious bodily injury to the driver and/orpassenger(s) of the vehicle, if the vehicle has

been improperly repairedNOTICE DefinedNotices call special attention to a necessary actionor to a prohibited action. If a NOTICE is not heeded,the following consequences may occur:

Damage to the vehicle Unnecessary vehicle repairs Unnecessary component replacement Improper operation or performance of the

system or component under repair. Damage to any systems or components whichare dependent upon the proper operation of the

system or component under repair Improper operation or performance of anysystems or components which are dependent

upon the proper operation or performance ofthe system or component under repair Damage to fasteners, basic tools, orspecial tools The leakage of coolant, lubricant, or other

vital fluids1998 - MD-lsuzu

IMPORTANT DefinedIMPORTANT statements emphasize a necessarycharacteristic of a diagnostic or repair procedure.IMPORTANT statements are designed to dothe following: Clarify a procedure Present additional information for accomplishing

a procedure Give insight into the reason or reasons forperforming a procedure in the mannerrecommended. Present information that will help to accomplish

a procedure in a more effective manner Present information that gives the technicianthe benefit of past experience in accomplishing

a procedure with greater ease

ABS Handling CautionCaution: Certain components In the AntilockBrake System (ABS) are not intended to beserviced individually. Attempting to remove ordisconnect certain system components mayresult in personal Injury and/or Improper systemoperation. Only those component with approvedremoval and Installation procedures shouldbe serviced.Battery Disconnect CautionCaution: Before servicing any electricalcomponent, the ignition key must be in the OFFor LOCK position and all electrical loads must beOFF, unless instructed otherwise in theseprocedures. If a tool or equipment could easilycome in contact with a live exposed electricalterminal, also disconnect the negative batterycable. Failure to follow these precautions maycause personal injury and/or damage to thevehicle or its components.Brake Dust CautionCaution: Avoid taking the following actions whenyou service wheel brake parts:

Do not grind brake linings. Do not sand brake linings. Do not clean wheel brake parts with a drybrush or with compressed air.

Some models or aftermarket brake parts maycontain asbestos fibers which can becomeairborne In dust. Breathing dust with asbestosfibers may cause serious bodily harm. Use awater-dampened cloth in order to remove anydust on brake parts. Equipment is availablecommercially in order to perform this washingfunction. These wet methods prevent fibers frombecoming airborne.


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4 - Cautions and Notices PrefaceBrake Fluid CautionCaution: Brake fluid may be irritating to theskin or eyes. In case of contact, take thefollowing actions:

Eye contactrinse eyes thoroughlywith water. Skin contactwash skin with soap

and water.Clutch Dust CautionCaution: When servicing clutch parts, do notcreate dust by grinding or sanding the clutchdisc or by cleaning parts with a dry brush orwith compressed air. A water-dampenedclothNOT SOAKEDshould be used. The clutchdisc contains asbestos fibers which can becomeairborne If dust Is created during servicing.Breathing dust containing asbestos fibers maycause serious bodily harm.Fuel and EVAP Pipe CautionCaution: In order to Reduce the Risk of Fire andPersonal Injury observe the following Items:

Replace all nylon fuel pipes that are nicked,scratched or damaged during Installation, DoNot attempt to repair the sections of thenylon fuel pipes Do Not hammer directly on the fuel harnessbody clips when installing new fuel pipes.Damage to the nylon pipes may result In afuel leak. Always cover nylon vapor pipes with a wettowel before using a torch near them. Also,

never expose the vehicle to temperatureshigher than 115C (239F) for more than onehour, or more than 90C (194F) for anyextended period. Apply a few drops of clean engine oil to themale pipe ends before connecting fuel pipefittings. This will ensure proper reconnectlonand prevent a possible fuel leak. (Duringnormal operation, the 0-rings located In thefemale connector will swell and may preventproper reconnectlon if not lubricated.)

Fuel Gauge Leak CautionCaution: Wrap a shop towel around the fuelpressure connection in order to reduce the risk offire and personal Injury. The towel will absorb anyfuel leakage that occurs during the connection ofthe fuel pressure gauge. Place the towel In anapproved container when the connection of thefuel pressure gauge is complete.Fuel Pipe Fitting CautionCaution: Always apply a few drops of cleanengine oil to the male pipe ends beforeconnecting fuel pipe fittings In order to reducethe risk of fire and personal Injury.This will ensure proper reconnectlon and preventa possible fuel leak.

During normal operation, the 0-rings located inthe female connector will swell and may preventproper reconnectlon if not lubricated.Fuel Storage CautionCaution: Do not drain the fuel into an opencontainer. Never store the fuel In an opencontainer due to the possibility of a fire oran explosion.Gasoline/Gasoline Vapors CautionCaution: Gasoline or gasoline vapors are highlyflammable. A fire could occur if an ignitionsource is present. Never drain or store gasolineor diesel fuel In an open container, due to thepossibility of fire or explosion. Have a drychemical (Class B) fire extinguisher nearby.Moving Parts and Hot Surfaces CautionCaution: While working around a running engine,avoid contact with moving parts and hot surfacesto prevent possible bodily injury.Road Test CautionCaution: Road test a vehicle under safeconditions and while obeying all traffic laws. Donot attempt any maneuvers that could jeopardizevehicle control. Failure to adhere to theseprecautions could lead to serious personal Injury.Safety Glasses and CompressedAir CautionCaution: Wear safety glasses when usingcompressed air in order to prevent eye Injury.Safety Goggles and Fuel CautionCaution: Always wear safety goggles whenworking with fuel In order to protect the eyesfrom fuel splash.Vehicle Lifting CautionCaution: To help avoid personal Injury, when avehicle Is on a hoist, provide additional supportfor the vehicle at the opposite end from whichyou are removing components. The additionalsupport will reduce the possibility of the vehiclefalling off the hoist. When you are removingmajor components from the vehicle while thevehicle Is on a hoist, chain the vehicle frame tothe hoist pads at the same end from which youare removing the major components to preventtip-off. If you fail to follow these precautionarymeasures, vehicle damage, serious personalInjury, or death may result.Window Removal CautionCaution: When working with any type of glass,use approved safety glasses and gloves toreduce the chance of personal injury.

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Preface Cautions and Notices - 5Work Stall Test CautionCaution: One or more of the following guidelinesmay apply when performing specific requiredtests in the work stall:

When a test requires spinning the drivewheels with the vehicle jacked up, adhere tothe following precautions:- Do not exceed 56 km/h (35 mph) whenspinning one drive wheel with the otherdrive wheel stopped. This limit is necessarybecause the speedometer indicates onlyone-half the actual vehicle speed underthese conditions. Personal injury may resultfrom excessive wheel spinning.- If all of the drive wheels are spinning atthe same speed, do not exceed 112 km/h(70 mph). Personal injury may result fromexcessive wheel spinning.- All persons should stay clear of therotating components and the balanceweight areas in order to avoid possible

personal Injury.- When running an engine in the repair stallfor an extended period of time, use carenot to overheat the engine and thetransmission.

When a test requires jacking up the vehicleand running with the wheels and brakerotors removed, adhere to the followingprecautions:- Do not apply the brake with the brakerotors removed.- Do not place the transmission in PARKwith the drive wheels still spinning.- Turn Off the Ignition in order to stop thepowertrain components from spinning.

Defective Scan Tool NoticeNotice: Do not use a scan tool that displays faultydata. Report the scan tool problem to themanufacturer. Use of a faulty scan tool can result inmisdiagnosis and unnecessary parts replacement.Fastener NoticeNotice: Use the correct fastener in the correctlocation. Replacement fasteners must be the correctpart number for that application. Fasteners requiringreplacement or fasteners requiring the use of threadlocking compound or sealant are identified in theservice procedure. Do not use paints, lubricants, orcorrosion inhibitors on fasteners or fastener jointsurfaces unless specified. These coatings affectfastener torque and joint clamping force and maydamage the fastener. Use the correct tighteningsequence and specifications when installing fastenersin order to avoid damage to parts and systems.Fuel Pressure NoticeNotice: Do not allow the fuel pressure to exceed thespecified value because damage to the fuel pressureregulator or the fuel pressure gauge may result.1998 - MD-lsuzu

Handling ESD Sensitive Parts NoticeNotice: Electrostatic discharge (ESD) can damagemany solid-state electrical components. ESDsusceptible components may or may not be labeledwith the ESD symbol. Handle all electricalcomponents carefully. Use the following precautionsin order to avoid ESD damage:Touch a metal ground point in order to removeyour body's static charge before servicing anyelectronic component; especially after sliding acrossthe vehicle seat.Do not touch exposed terminals. Terminals mayconnect to circuits susceptible the ESD damage.Do not allow tools to contact exposed terminalswhen servicing connectors.Do not remove components from their protectivepackaging until required to do so.Avoid the following actions unless required by thediagnostic procedure:Jumpering or grounding of the componentsor connectors.Connecting test equipment probes to components orconnectors. Connect the ground lead first whenusing test probes.Ground the protective packaging of any componentbefore opening. Do not rest solid-state componentson metal workbenches, or on top of TVs, radios, orother electrical devices.Ignition OFF When DisconnectingBattery NoticeNotice: Always turn the ignition OFF whenconnecting or disconnecting battery cables, batterychargers, or jumper cables. Failing to do so maydamage the Powertrain Control Module (PCM) orother electronic components.Nylon Fuel Lines NoticeNotice: Do not attempt to straighten the kinked nylonfuel lines. Replace any kinked nylon fuel feed or returnpipes in order to prevent damage to the vehicle.PCM and ESD NoticeNotice: Do not touch the connector pins or solderedcomponents on the circuit board in order to preventpossible electrostatic discharge (ESD) damage tothe PCM.Single Cylinder Flooding NoticeNotice: In order to prevent flooding of a singlecylinder and possible engine damage, relieve thefuel pressure before performing the fuel injectorcoil test procedure.


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Section 0General Information

General Information..........................................o-3Conversion - English/Metric.............................0-3Equivalents - Decimal and Metric ...................0-3Paper Version of the Service Manual -How to Use..................................................0-4Arrows and Symbols........................................0-5Special Tools Ordering Information .................0-5Vehicle Identification.........................................0-5VIN Derivative...................................................0-6Label - Vehicle Certification.............................0-7Engine Identification.........................................0-8Transmission Identification ...............................0-8Rear Axle Identification....................................0-9Label - Service Parts ID................................0-11RPO Code List...............................................0-11Labels - How to Obtain Replacement...........0-17Fasteners (Prevailing Torque Fasteners)......0-17Fasteners (Strength Identification).................0-19Fasteners (Metric Fasteners).........................0-20Thread Inserts................................................0-20Torque Wrenches ...........................................0-21Abbreviations and Their Meanings................0-23Key and Lock Cylinder Coding......................0-26Lifting and Jacking the Vehicle......................0-26Cab Tilting......................................................0-27Towing a Disabled Vehicle.............................0-30Strategy Based Diagnosis..............................0-32Maintenance and Lubrication......................o-33

Specifications....................................................0-33Approximate Fluid Capacities........................0-33Fluid and Lubricant Recommendations......... 0-34Maintenance Items .........................................0-34

Maintenance ......................................................0-35Maintenance Schedule...................................0-35Maintenance Schedule - Short Trip/City.......0-43Maintenance Schedule -Long Trip/Highway .....................................0-43Owner Checks and Services (General)........0-43Owner Checks and Services (Single Axle)...0-46Explanation of Scheduled Services...............0-47Inspections and Other Services ....................0-50Vibration Diagnosis and Correction.........0-51

Specifications....................................................0-51Specifications..................................................0-51Diagnostic Information and Procedures .......0-52Systematic Approach .....................................0-52Vibration Diagnosis ........................................0-52Road Test.......................................................0-52Classifying the Vibration ................................0-56Tire and Wheel Vibration...............................0-59Tire and Wheel Runout Measurement..........0-59Driveline Vibration Analysis with EVA...........0-63Engine Related Vibration...............................0-67Repair Instructions...........................................0-71General Service Precautions.........................0-71Correcting Tire and Wheel Vibration.............0-71Balancing Tires and Wheels..........................0-71Wheel Weight Usage.....................................0-75Correcting Non-Uniform Tires........................0-75Correcting Driveline Vibration -RWD and 4WD..........................................0-76Description and Operation..............................0-94General Description........................................0-94Special Tools and Equipment. .0-105

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0-2 Table of Contents General Information

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General Information General Information 0-3General Information

Conversion - English/Metric (cont'd)In order to convert English units to metric units,multiply the English units by the conversion factorshown in the conversion table.In order to convert metric units to English units,divide the metric units by the conversion factorshown in the conversion table.

Conversion - English/MetricEnglish

LENGTHinft

ydmi

AREAsq insq ft

sq ydVOLUME

cu in

qtgal

cu ydMASS

Ib

ton

kgozIb

ACCELERATIONft/s2in/s2

TORQUEIb inIbft

POWERhp

Multiply/Divide by

25.40.30480.91441.609

645.26.45

0,09290.8361

16,387.016.3970.01640.94643.78540.7646

0.4536907.180.907

FORCE9.807

0.27804.448

0.30480.0254

0.112981.3558

0.746

Metric

mmm

km

sq mmsq cmsq m

cu mmcu cm

L

cu m

kgtonne (t)

newtons (N)

m/s2

N.m

kW

EnglishPRESSURE (STRESS)

inches of Mercuryinches of H20

Ib/sq inLIGHT

Foot CandleVELOCITY

mphTEMPERATURE

FC

FUEL PERFORMANCEmpg

Multiply/Divide by

3.3770.24916.895

10.764

1.6093

5/9(-F-32)9/5('C+32)

2.3527

Metric

RPakPa

lm/m2

km/h

CF

L/km

Refer to the following table for equivalent offractions to decimals in English (inches), tometric (millimeters).

Equivalents Decimal and MetricFraction (in)

1/641/323/641/165/643/327/641/8

9/645/3211/643/1613/647/3215/64

1/417/649/3219/645/16

21/64

Decimal (in)0.0156250.03125

0.0468750.0625

0.0781250.09375

0.1093750.125

0.1406250.15625

0.1718750.1875

0.2031250.21875

0.2343750.25

0.2656250,28125

0.2968750.3125

0.328125

Metric (mm)0.396880.793751.190621.5875

1.984372.381252.77812

3.1753.571873.968754.365624.7625

5.159375.556255.95312

6.356.746877.143757.540627.9375

8.33437

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0-4 General Information General InformationEquivalents - Decimal and Metric (cont'd)Fraction (in)

11/3223/64

3/825/6413/3227/647/16

29/6415/3231/64

1/233/6417/3235/649/16

37/6419/3239/64

5/841/6421/3243/6411/1645/6423/3247/64

3/449/6425/3251/6413/1653/6427/3255/64

7/857/6429/3259/6415/1661/6431/3263/64

1

Decimal (in)0.34375

0.3593750.375

0.3906250.406250.421875

0.43750.4531250.46875

0.4843750.5

0.5156250.53125

0.5468750.5625

0.5781250.59375

0.6093750.625

0.6406250.65625

0.6718750.6875

0.7031250.71875

0.7343750.75

0.7656250.78125

0.7968750.8125

0.8281250.84375

0.8593750.8750.890625

0.906250.921875

0.93750.9531250.96875

0.9843751.0

Metric (mm)8.731259.12812

9.5259.9218710.3187510.7156211.1125

11.5093711.9062512.30312

12.713.0968713.4937513.8906214.2875

14.6843715.0812515.47812

15.87516.2718716.6687517.0656217.4625

17.8593718.2562518.65312

19.0519.4468719.8437520.2406220.6375

21.0343721.4312521.82812

22,22522.6218723.0187523.4156223.8125

24.2093724.6062525.00312

25.4

Paper Version of the Service Manual -How to UseConstructionThis service manual is constructed with the following10 major sections:

Major SectionNumber

012345678910

Major Section NameGeneral Information

Heating, Ventilation, andAir Conditioning (HVAC)Steering

SuspensionDriveline/Axle

BrakesEngine

Transmission/TransaxleChassis/Body Electrical

AccessoriesBody

Information FlowEach major section will be structured as follows:

1. A single table of contents for the entire majorsection; including all contents of thesubsections within the major section.

2. SubsectionsThe service information located within eachsubsection will be ordered as follows:1. Specifications2. Diagnosis3. Repair procedures4. General description and system operation5. Special tools

Improvements MadeThis service manual provides many more illustrationsthan in earlier manuals. Illustrations serve as theprimary source for repair procedures. Theseillustrations will be supplemented with textdescriptions. In the previous service manuals, textwas the primary source of information for repairprocedures and illustrations provided support.Repair procedures, illustrations, and the descriptivetext have been arranged so that they will correspondwith the way you work. This manual providesdisassembled views, wherever possible, so that it willbe easy to look up parts, names, and order ofassembly. The text descriptions have been rewritteninto simple, complete sentences.

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General Information General Information 0-5Arrows and Symbols

^^^^^^^4

5^

\.> \^, 1211>- ^196216

Legend(1) Front of Vehicle(2) View Detail(3) Ambient Air Mixed With Another Gas, CanIndicate Temperature Change(4) Motion or Direction(5) View Angle(6) Dimension (1:2)(7) Ambient/Clean Air Flow, Cool Air Flow(8) Lubrication PointOil or Fluid*(9) Task Related

(10) Sectioning (1:3)(11) Gas Other Than Ambient Air, Hot Air Flow(12) Lubrication PointGrease or Jelly*

Special Tools Ordering InformationSpecial ToolsThe special service tools shown in this servicemanual have tool product numbers beginning withJ or BT. Special tools are distributed worldwide byKent-Moore:Kent-MooreSPX Corporation29784 Little MackRoseville, Ml 48066-22981-800-328-6657Mon.-Fri. 8:00 a.m. to 7:00 p.m. ESTTelex: 244040 KMTR URFax: 1-800-578-7375Purchase scan tools and accessories fromKent-Moore at the address above.Vehicle Identification

The Isuzu Commercial Truck is available in theabove body style.205884

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0-6 General Information General InformationVIN DerivativeThe Vehicle Identification Number (VIN) is the legalidentifier of the vehicle. The VIN contains thefollowing information:

The manufacturer The model The chassis type The engine type The Gross Vehicle Weight (GVW) range The model year The plant code The sequential number

205886The VIN plate is attached to the driver's dooropening.

Vehicle Identification Number (VIN) SystemPosition

123

4

5

678

DefinitionCountry of Origin

ManufacturerModel

GVWR/Brake System

SeriesCab Type

Chassis TypeEngine Type

Character4GTABCDEFGHJKLMNPRSTVW67C12

DescriptionUnited StatesIsuzuIsuzu Incomplete Vehicle9001-10000 Hydraulic10001-14000 Hydraulic14001-16000 Hydraulic14001-16000 Air16001-19500 Hydraulic16001-19500 Air19501-23500 Hydraulic19501-23500 Air23501-26000 Hydraulic23501-26000 Air26001-33000 Hydraulic26001-33000 Air33001-40500 Hydraulic33001-40500 Air40501-48500 Hydraulic40501-48500 Air48501-58000 Air58001-69500 Air69501-over Air60007000Medium Tilt, Steel, 226 cm (89") BBC4 x 2, 2 Axles, 1 DrivingIsuzu 6 Cylinder Turbo Diesel (7.8L)

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General Information General Information 0-7Vehicle Identification Number (VIN) System (cont'd)

Position9

1011

12-17

DefinitionCheck DigitModel Year

Plant LocationPlant Sequence Number

Character1

J

Description

1998Janesville6-Digit Sequential Numbers

Label - Vehicle CertificationComplete Vehicle Certification Label

QVW RATINQ INFORMATIONOWR-LB/KQ QAWR FBT OAWR INT QAWB RB

TIRE SIZE PSI/KPA (COLD)

ASSEMBLED IN JANESVILLE Wl^ SEE OWNER'S MANUAL FOR ADDITIONAL INFORMATION II L^

The Gross Vehicle Weight (GVW) is the weight ofthe stock vehicle and all the options added to thevehicle after leaving the factory. The GVW includes,but not limted to, the weight of the following items:

The body Winches Booms The driver All occupants The load that the vehicle is carrying

Ensure that the Gross Vehicle Weight (GVW) doesnot exceed the Gross Vehicle Weight Rating(GVWR). Ensure that the front and the rear GrossAxle Weights (GAW) do not exceed the front and therear Gross Axle Weight Rating (GAWR).

291017Incomplete Vehicle Certification Label

6VWR-IB/KQ QAWR FRT QAWB INT OAWH RR

TIRE SIZE

205890

291007The Vehicle Certification Label indicates the followingratings for the vehicle:

. The Gross Vehicle Weight Rating (GVWR) The front and rear Gross Axle WeightRating (GAWR) The payload rating

The payload rating shown on the label is themaximum allowable cargo load (including the weightof the driver and all occupants) that the vehicle maycarry based on the stock equipment. The payloadrating lowers if any accessories or other equipmentare added to the vehicle after the final date ofmanufacture. Determine the weight of any addedaccessories and deduct the amount from thepayload rating.The vehicle may also have a Gross CombinationWeight Rating (GCWR). The GCWR is the totalweight of the loaded tow vehicle (includingpassengers) and a loaded trailer.

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0-8 General Information General InformationEnsure that the tires on the vehicle are the propersize and at the proper inflation pressure for the loadthat the vehicle is carrying. The vehicle certificationlabel shows the stock tire size and recommendedinflation pressures.Engine IdentificationDiesel EngineThe engine serial number is located on the frontright side comer of the engine block.Transmission IdentificationIsuzu

Allison

208521The Allison transmission identification plate islocated on the rear left side of the housing, justabove the oil pan.

208509The Isuzu transmission identification plate is locatedon the left upper side of the housing.

Eaton Fuller _TransmissionsF^RT-'^ "^

200589

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General Information General Information 0-9Rear Axle Identification

Eaton Rear Axle ID

200579Legend(1) Axle Specification Number

(2) Casting Number(3) Rough Number

(4) Capacity(5) Housing Subassembly Number (IncludingTubes)

All axle housings have identification tags oridentification information stamped on the side of thedifferential carrier.Differential CarrierThe carrier tag may contain the following information:

The axle model The ratio The carrier assembly number The carrier serial number The date of assembly

Use all the information on the carrier tag in order toidentify the axle assembly.

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0-10 General Information General InformationEaton Differential Carrier ID

200584Legend(1) Side View

(2) Top ViewDana/Spicer Rear Axle Differential Carrier ID

200587

Axle HousingDana/Spicer Rear Axle ID

Legend(1)(2)(3)(4)(5)

200582Dana Part NumberCustomer Part Number (Optional)Julian Date CodeLine Set Number (Optional)Last Six Digits of Vehicle Serial Number(Optional)

Legend(1) Dana Part Number(2) Customer Part Number (Optional)(3) Model(4) Julian Date Code(5) Line Set Number (Optional)(6) Last Six Digits of Vehicle Serial Number(Optional)

The housing tag is the same type of tag used forthe Differential Carrier.1998 - MD-lsuzu


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General Information General Information 0-11Label - Service Parts ID RPO Code List

205849The Service Parts Identification Label is on thepassenger's side sun visor.

mnn h u.t.A.SERVICE PARTS IDENTIFICATION

WIGDI iHpasia i.|.N. v.hlcl. KHnUlteolta Niinr

HOTT: Th opHonot )ufpmnl lttd blow hu bn IrrloaKlan thh hiel*. lor prflfMxnIMcaMon 1 fploeflnrnt parti b w pMlfy th oppflcabi* opKon numbw.OP-ID,*

IMPORTANT ".i.ii..i.b...,.p.,m...,,,.ci .

aescmpnoN OPTION ocscmpTtOf*

200611Always refer to the Service Parts Identification Labelwhen ordering parts. The label lists the followingitems:

The Vehicle Identification Number (VIN) The wheelbase The paint information All production options All factory-installed special equipment

RPOASA

AV8

BAGBPUBPVBPWBUBBUCCKDCV3C60DFO

DNN

DTEEG5EH8EK8EM2EQ8ERAERBERCERDEREESSEV9EXPEY1

FDO

FD5FF1

DescriptionSeat: Front Bucket, Driver High Back,Self Contained Air SuspensionSeat: Center Front Bucket, Auxiliary,Folding

Parts Package ExportFirst Position Prop Hanger, NON-BOC,Height AFirst Position Prop Hanger, NON-BOC,Height BFirst Position Prop Hanger, NON-BOC,Height CFirst Position Prop Hanger, NON-BOC,Height DFirst Position Prop Hanger, NON-BOC,Height EVehicle Completely Knocked DownCountry MexicoHVAC System Air Conditioner, FrontManual ControlsMirror: Outside, LH and RH,17.8 cm x 40.6 cm (7 in x 16 in), SSTMirror: Outside, Dual Velvac Heated,15.2 cm x 40.6 cm (6 in x 16 in),Stainless SteelMirror: Auxiliary Outside 20 cm (8 in)Spot, Dual Retrac, SST401 cm (158 in) Wheelbase432 cm (170 in) Wheelbase478 cm (188 in) Wheelbase508 cm (200 in) Wheelbase592 cm (233 in) WheelbaseSecond Position Prop Hanger, Height ASecond Position Prop Hanger, Height BSecond Position Prop Hanger, Height CSecond Position Prop Hanger, Height DSecond Position Prop Hanger, Height E630 cm (248 in) WheelbaseSuspension: Attach BoltedExport I.E.S.Yoke: Propeller Shaft, Driveline, DanaFrame: Rail, Full Depth,612 cm x 15 cm (241 in x 6 in),22 680 kg (50,000 Ib)Frame: Rail, Full Depth,622 cm x 20 cm (245 in x 8 in),36 288 kg (80,000 Ib)Hub: Front, Oil Filled

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0-12 General Information General InformationRPO Code List (cont'd) RPO Code List (cont'd)

RPOFK9FL1FL2FL3FMO

FM4FPLFQTFS7F03

F08F12F14F15F26F59

GGO

GG7GNOGN1GN2GN8GPGGPO

GP1GQBGQCGQDGQEGQFGQO

DescriptionSuspension: Front, Multileaf, 4 090 kg(9,017 Ib)Axle: Front, 3 674 kg (8,100 Ib)Axle: Front, 4 990 kg (11,000 Ib)Axle: Front, 6 623 kg (14,600 Ib)Suspension: Front, Multileaf, 6 610 kg(14,600 Ib)Suspension: Front, Multileaf, 6 350 kg(14,000 Ib)554 cm (218 in) Wheelbase356 cm (140 in) WheelbaseAxle: Front, 5 443 kg (12,000 Ib) HDFrame: Rail, Full Depth,232 cm x 25 cm (249 in x 10 in),49,896kg (110,000 Ib)Reinforcement: Frame, Outside,Inverted L Type, 36,288 kg (80,000 Ib)Suspension: Front, Tapered Leaf,3 175 kg (7,000 Ib)Suspension: Front, Tapered Leaf,3674kg (8,100 Ib)Suspension: Front, Tapered Leaf,4 082 kg (9,000 Ib)Suspension: Front, Tapered Leaf,5 443 kg (12,000 Ib)Stabilizer Shaft: FrontSuspension: Rear, Multileaf, 6 804 kg(15,000 Ib)Suspension: Rear, Tapered Leaf7 666 kg (16,900 Ib)Suspension: Rear, Tapered Leaf,8 620 kg (19,000 Ib)Stabilizer Shaft: RR (Dup with F61)Suspension: Rear, Multileaf, 8 620 kg(19,000 Ib)Suspension: Rear, Multileaf, 9 525 kg(21,000lb)Vehicle: Low Profile PackageSuspension: Rear, Tapered Leaf,10 430 kg (23,000 Ib)Suspension: Rear, Multileaf, 10 660 kg(23,500 Ib)Third Position Prop Hanger, Height AThird Position Prop Hanger, Height BThird Position Prop Hanger, Height CThird Position Prop Hanger, Height DThird Position Prop Hanger, Height ESuspension: Rear, Tapered Leaf,8 600 kg (15,000 Ib)

RPOGR9GZIGZTG40G60G68G86G98HNAHPGHPHHPKHPMHPPHPQHPZ

HWYHZTHZWH08

H10H11

H15H20JE3JE4JE5

JPV

DescriptionSuspension: Rear, Tapered Leaf,9 525 kg (21,000 Ib)GVW Rating: 11 771 kg (25,950 Ib)Provisions for Taperleaf/Multileaf RearSpringsSuspension: Rear Air, 8 618 kg(19,000 Ib)Spring: Rear, AuxiliaryShock Absorbers: Rear, Heavy DutyAxle: Limited SlipSeal: Rear Axle Oil, StemcoAxle: Rear, Eaton 23105S, SingleSpeed, 10 433 kg (23,000 Ib)Axle: Rear, Eaton 22060S, SingleSpeed, 9 979 kg (22,000 Ib)Axle: Rear, Eaton 22060T, TwoSpeed, 9 979 kg (22,000 Ib)Axle: Rear, Eaton 19060S, SingleSpeed, 8618kg (19,000 Ib)Axle: Rear, Eaton 19060T, TwoSpeed, 8618kg (19,000 Ib)Axle: Rear, Eaton 21060S, SingleSpeed, 9526kg (21,000lb)Axle: Rear, Eaton 23080S, TwoSpeed, 10 433 kg (23,000 Ib)Control: Rear Axle Shift, Two Speed,ElectricAxle: Rear, Eaton 19050S, SingleSpeed, 7666kg (16,900 Ib)Axle: Rear, Eaton 19050T, TwoSpeed, 8097kg (17,850 Ib)Axle: Rear, Eaton 19050S, SingleSpeed, 8097kg (17,850 Ib)Axle: Rear, Dana S150-S, SingleSpeed, 6 804 kg (15,000 Ib)Axle: Rear, Eaton 15040S, SingleSpeed, 6 804 kg (15,000 Ib)Axle: Rear, Eaton 19050S, SingleSpeed, 8618kg (19,000 Ib)Axle: Rear, Eaton 21060T, TwoSpeed, 9526kg (21,000lb)Axle: Rear, Eaton 23080T, TwoSpeed, 10 433 kg (23,000 Ib)Brake: HydraulicBrake: AirBraking System, Power, Antilock, Frontand WheelBrake Rating: Rear, Air Carlisle,NAB9ML, Non-Abestos Lining, 14cm(5.5 in) Slack, 42 cm x 178 cm (16.5 inx 7 in) Fab Shoe, 16 Hole Mounting

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General Information General Information 0-13RPO Code List (cont'd) RPO Code List (cont'd)

RPOJPZJOBJQFJQMJQPJQQJQRJRA

JRDJRF

JRL

JRN

JTJ

JTKJTTJUEJUZJVA

JVQ

JWB

JWF

JXDJXG

DescriptionValve: Air Suspension, Air ReleaseUniversal Joint: Main, 1480/148NSeriesAdjuster: Rear Slack, Automatic,RockwellUniversal Joint: Main, 1710/17N SeriesUniversal Joint: Main, 1550/155NSeriesUniversal Joint: Main, 1710/17N Series,HD TubeUniversal Joint: Main,1610/161 N SeriesUniversal Joint: Inter Axle,1610/161 N SeriesBrake Rating: Front, Air Carlisle, E145ANon-Abestos Lining, 14 cm (5.5 in)Slack, 4 or 8 Hole MountingShield: Rear Brakes, DustBrake Rating: Rear, Air Carlisle, E145ANon-Abestos Lining, 14 cm (5.5 in)Slack, 42 cm 18 cm (16.5 in x 7 in) FabShoe, 10 Hole MountingBrake Rating: Rear, Air Carlisle, E145ANon-Abestos Lining, 15 cm (6 in) Slack,42 cm x 18 cm (16.5 in x 7 in) FabShoe, 9 Hole MountingBrake Adjuster, RR Slack, EatonAutomaticBrake Adjuster, Front Slack, EatonAutomaticAir Dryer B/W Model, AD9 Heated,Brake Air TankBrake Adjuster: Front Slack, RockwellAutomaticEquipment RR Brake Chamber Brand,MGM E-SeriesProvisions Antilock Brake DeleteBrake Rating: Front, Air Carlisle, E145ANon-Abestos Lining, 14 cm (5.5 in)Slack, 42 cm x 13 cm (16.5 in x 5 in)Fab Brake Shoe, 8 Hole MountingBrake Rating: Rear, Air Carlisle, E145ANon-Abestos Lining, 14 cm (5.5 in)Slack, 42 cm x 18 cm (16.5 in x 7 in)Fab Brake Shoe, 16 Hole MountingBrake Rating: Rear, Air Carlisle, E145ANon-Abestos Lining, 15 cm (6 in) Slack,42 cm x 18 cm (16.5 in x 7 in) FabShoe, 16 Hole MountingUniversal Joint: Main, 1750/176NSeries, HD TubeValve: Air Brake Moisture Ejector, B/WDV2, Heated, Front

RPOJYVJZCJZDJZEJZFJZGJ71J78J91KG8KRWKVBKYCK40K60LG4LQBLQCMF1

MPUMRKMWEMWFMWMMWWMWX

M54NB5NLO

NL5NXNNXYPNB

DescriptionBrake Provisions: Full TrailerChamber: Front Brake, Type 16Chamber: Front Brake, Type 20Chamber: Front Brake, Type 24Chamber: Rear Brake, Type 30Chamber: Rear Brake, Type 24Parking Brake: Power OperatedValve: Moisture Ejector Air BrakeBrake Provisions: TrailerGenerator: 130 AMPHose: Radiator, SiliconeHose: Water, Silicone, Except RadiatorAir Compressor: Zexel, 185L/MN, WaterCooledEngine Brake: ExhaustGenerator: 100 AMPEngine: Diesel, 6 Cylinder, 7.8L, TurboEngine: Diesel, 6 Cylinder, 7.8L,149 kW (200 Gross hr), 2400 RPMEngine: Diesel, 6 Cylinder, 7.8L,172 kW (230 Gross tip), 2400 RPMTransmission: Allison AT545,AutomaticTransmission Manual 5-speed FullerFS5005AClutch: 350 mm, (13.8 in) Single Plate,Push Type, Dana-SpicerPilot Shaft: Automatic Transmission,No SplinePilot Shaft: Automatic ElectricTransmission, No SplineClutch Spicer 14-1 Cerametallix, PullType, Greasable BearingPilot Shaft: Transmission, 44.45 mm(1.75 in) SplinePilot Shaft: Transmission, 38.1 mm(1.5 in) SplineTransmission: Manual, 6 Speed,ISUZU, 136 mm (5.35 in), 6.72 1st,Over DriveExhaust System: SingleFuel Tank: 189L, (50 gal), LH,Rectagular, SteelFuel Tank: 189L, (50 gal), Dual,Rectangular, SteelFuel: 57L (15 gal) AdditionalSteering: Power, ZFWheel: Polished Aluminum,Both Sides, Rear

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RPOPNLPNQPNRPNSPNUPNXPNYPQRPQS

PQU

PQV

PQYPQZPRSPTAPVG

PVHP2CP53P54QE5QH3

QH4

Q82Q83RNE

RNFRPMRPQ

DescriptionSecondary Color: Exterior, PenskeAngle: Rear Axle Pinion, Nominal 3"Angle: Rear Axle Pinion, Nominal 4'Angle: Rear Axle Pinion, Nominal 5"Primary Color: Interior, PenskeAngle: Rear Axle Pinion, Nominal 6"Angle: Rear Axle Pinion, Nominal 7'Wheel: Front Generic, 8 Hole, 275 mm(10.8 in), BC, FNWheel: Rear Generic, 8 Hole Disc,275mm (10.8 in), BC, FNWheel: Front, Generic Steel, 10 Hole,285.75 mm (11.25 in), BC, DiscPiloted, DiscWheel: Rear, Generic Steel, 10 Hole,285.75 mm (11.25 in), BC, DiscPiloted, DiscWheel: Front, Generic Steel, 10 Hole,287.75 mm (11.25 in), BC, PilotedWheel: Rear, Generic Steel, 10 Hole,287.75 mm (11.25 in), BC, PilotedIdentification Pro-SpecProvisions Low Profile Front TiresWheel: Front, Generic 8 Hole, 275 mm(10.8 in), BCWheel: Rear, Generic 8 Hole, 275 mm(10.8 in), BCPricing Wheels, Class ATire Tread, Spare Tread and Brand,Front MatchTire Tread, Spare Tread and Brand,Rear MatchOdometer Rear Axle HubWheel: Front, 22.5 x 7.50, 10 Hole,287.75 mm (11.25 in) BC, FN, HubPilotedWheel: Rear, 22.5 x 7.50, 10 Hole,287.75 mm (11.25 in) BC, FN, HubPilotedWheel: Front, 19.5 x 6.0, 8 Hole,275mm (10.8 in), BC, FNWheel: Rear, 19.5x6.0, 8 Hole,275mm (10.8 in), BC, FNWheel: Front, 22.5 x 8.25, 10 Hole,285.75 mm (11.25 in), BC, Piloted HubWheel: Rear, 22.5x8.25, 10 Hole,285.75 mm (11.25 in), BC, Piloted HubWheel: Front, 19.5x6.75, 8 Hole,275 mm (10.8 in), BC, FN, Piloted HubWheel: Front, 22.5 x 8.25, 10 Hole,285.75 mm (11.25 in), BC, Piloted Hub

RPORPR

RPWRQ2R3BR3CR3MR3NR4AR4HR4LR4NR4RR4TR6BR6GR6PR9USGBSMASMBSMCSMDSNFSNRS3BS3CS3DS3ES3FS3HS3JS3KS3LS3MS3NS4AS4C

DescriptionWheel: Rear, 22.5x8.25, 10 Hole,285.75 mm (11.25 in), BC, Piloted HubWheel: Rear, 19.5 x 6.75, 8 Hole,275 mm (10.8 in), BC, FN, Piloted HubVehicle Application: Truck ServiceFront Tire: Extra Strength HighwayTreadFront Tire: Premium Highway TreadFront Tire: All Season TreadFront Tire: Premium Highway ImprovedSteering Control TreadFront Tire Brand: GoodyearFront Tire Brand: GeneralFront Tire Brand: MichelinFront Tire Brand: BridgestoneFront Tire Brand: Select, Brand PlantFront Tire Brand: YokohamaControl Sales Item No. 02Control Sales Item No. 07Control Sales Item No. 15Control Sales Item No. 95Form Advanced Broadcast DocumentSpacer Pack: Right Spring CabLeveling, +10 mm (+.374 in)Spacer Pack: Right Spring CabLeveling, +0 mm (+0 in)Spacer Pack: Right Spring CabLeveling, -10 mm (-.374 in)Spacer Pack: Right Spring CabLeveling, -20 mm (-.787 in)Wheel: Front, SpareWheel: Rear, SpareTire Tread: Rear, Extra StrengthHighwayTire Tread: Rear, Premium HighwayTire Tread: Rear, Highway PremiumTire Tread: Rear, On/Off Road HighwayTire Tread: Rear, Off Road RollingTire Tread: Rear, HighwayTire Tread: Rear, Highway TractionTire Tread: Rear, On/Off Road RibTire Tread: Rear, Off Road TractionTire Tread: Rear, All SeasonTires: Tread, Rear, Premium Highway,Improved Steering ControlRear Tire Brand: GoodyearRear Tire Brand: Dunlop

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General Information General Information 0-15RPO Code List (cont'd) RPO Code List (cont'd)

RPOS4HS4LS4NS4RS4TTMOTNLTNNTRFTRGTRHTRRTRZT62UEAUETUM6UM7UZFU08U86VCOVC5VC6VH4VPGVPHVWNVXTV01V48V76V78V98

WDBXQTXRLXRN

DescriptionRear Tire Brand: GeneralRear Tire Brand: MichelinRear Tire Brand: BridgestoneRear Tire: Select, Brand PlantRear Tire Brand: YokohamaBattery: 900 CCA, DualBattery: Twin, 12V (1110)Battery: Twin, Deico 1150, 12VTires: Front, Radial IdentifierTire Selection, Customer BrandTire Selection, Customer BrandTires: Rear, Radial IdentifierEquipment Air Shift TransmissionLighting: Daytime RunningTaillamp DeleteIndicator, Electronic Transmission,Oil LevelRadio: AM/FM Stereo, Seek & Scan,Auto Reverse Cassette, Clock, ETRRadio: AM/FM Stereo, Seek & Scan,Clock, ETRAlarm B/U Electrical, 97 DeciblesHorn: Dual ElectricWiring Harness: Full Trailer, 7-WireVehicle Label, Noise ControlInformationLabel, Shipping, Except US, or JapanLabel, Shipping, Hawaii, US Territories,and Puerto RicoMud FlapsCable: Trailer Jumper Cable, 7-Wire,12-foot, Synflex CoiledVehicle Preparation Overseas DeliveryHook: Tow, Rear, Bolt OnVehicle IncompleteRadiator: Heavy DutyCoolant: Maximum Protection EngineHook: TowVehicle Statement: DeleteVehicle Statement: DeleteControl Engineering EditTire: Front, 8.00R19.5/E, 10PR,BL TL RadialTire: Front, 235/80R22.5/G, 14PR,BL TL RadialTire: Front, 295/75R22.5/G, 14PR,BL TL Radial

RPOXSBXSH

XTBXTI

XTNXTQXTUXTX

XTYXWJXWKXWLXWMX80YA6YESYF5YF6YQTYRLYRNYSBYSHYTBYTIYTNYTQ

DescriptionTire: Front, 255/80R22.5/G, 14PR, BLTL RadialTire: Front, 275/80R24.5/G, 14PR, BLTL RadialTire: Front 255/70R22.5/H, 16PR, BLTL RadialTire: Front, 245/70R19.5/F, 12PR, BLTL RadialTire: Front, 225/70R19.5/F, BW, R/STTLHWYTire: Front, 245/75R22.5/G, BL TLRadialTire: Front, 265/75R22.5/G, BL TLRadialTire: Front, 8.00R19.5/F, 12 PR, BLTLRadialTire: Front, 245/70R19.5/G, 14PR, BLTL RadialTire: Front, 10.00R22.5/F, 12PR, BLTLRadialTire: Front, 10.00R22.5/G, 14PR, BLTLRadialTire: Front, 11 .OOR22.5/G, 14PR, BLTLRadialTire: Front, 11.00R22.5/H, 16PR, BLTLRadialPlate GVW RatingSales Package Body Override,CaliforniaVehicle Test, EngineeringCertification Emission, CaliforniaSales Processing Option GeographicControl, CaliforniaTire: Rear, 8.00R19.5/E, 10PR, BLTLRadialTire: Rear, 235/80R22.5/G, 14PR, BLTL RadialTire: Rear, 295/75R22.5/G, 14PR, BLTL RadialTire: Rear, 255/80R22.5/G, 14PR, BLTL RadialTire: Rear, 275/80R24.5/G, 14PR, BLTL RadialTire: Rear, 255/70R22.5/H, 16PR, BLTL RadialTire: Rear, 245/70R19.5/F, 12PR, BLTLRadialTire: Rear, 225/70R19.5/F, BW, R/STST TL HWYTire: Rear, 245/75R22.5/G, BL TLRadial

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RPOYTU

YTX

YTYYU8YWJYWKYWLYWM

YX6YX7YX8YX9YY7YY9ZQTZRLZRNZSBZSHZTBZTI

ZTNZTQZTUZTXZTYZV1

DescriptionTire: Rear, 265/75R22.5/G, BL TLRadialTire: Rear, 8.00R19.5/F, 12PR, BL TLRadialTire: Rear, 245/70R19.5/G, 14PR, BLTL RadialWheel: Single, Polished Aluminum, OneSide, FrontTire: Rear, 10.00R22.5/F, 12PR, BL TLRadialTire: Rear, 10.00R22.5/G, 14PR, BL TLRadialTire: Rear, 11.00R22.5/G, 14PR, BL TLRadialTire: Rear, 11.00R22.5/H, 16PR, BL TLRadialAttachment Main Driveline One-ShaftSystemAttachment Main Driveline Two-ShaftSystemAttachment Main Driveline Three-ShaftSystemAttachment Main Driveline Four-ShaftSystemPaint Process ChassisPaint Process WheelTire: Spare, 8.00R19.5/E, 10 PR, BLTL RadialTire: Spare, 235/80R22.5/G, 14PR, BLTL RadialTire: Spare, 295/75R22.5/G, 14PR, BLTL RadialTire: Spare, 255/80R22.5/G, 14PR, BLTL RadialTire: Spare 275/80R22.5/G, 14PR, BLTL RadialTire: Spare, 255/70R22.5/H, 16PR BLTL RadialTire: Spare, 245/70R19.5/F, 12PR BLTL RadialTire: Spare, 225/70R19.5/F, BW, R/STST TL HWYTire: Spare, 245/75R22.5/F, BL TLRadialTire: Spare, 265/75R22.5/G, BL TLRadialTire: Spare, 8.00/19.5/F, 12PR, BL TLRadialTire: Spare, 245/70R19.5/G, 14PR BLTL RadialStatement of Origin Manufacture

RPOZWJ

ZWK

ZWLZWMZY1ZY2Z49Z8900100200300500600800901 L01U01001101201401501601701801902002203203803905706606907009216L16U23L23U

DescriptionTire: Spare, 10.00R22.5/F, 12PR, BLTT RadialTire: Spare, 10.00R22.5/G, 14PR, BLTT RadialTire: Spare, 11.00R22.5/G, 14PR, BLTT RadialTire: Spare, 11.00R22.5/H, 16PR, BLTL RadialColor Combination: SolidColor Combination: Two-ToneExport Canadian Modified MandatoryBase EquipmentConversion Name Plate ISUZU3.70 Ratio Code4.11 Ratio Code4.33 Ratio Code4.56 Ratio Code4.63 Ratio Code4.88 Ratio Code5.29 Ratio CodeSecondary Color: Exterior, SpecialPrimary Color: Exterior, Special5.43 Ratio Code5.57 Ratio Code5.83 Ratio Code6.14 Ratio Code6.17 Ratio Code5.25 Ratio Code6.50 Ratio Code6.65 Ratio Code6.67 Ratio Code5.63 Ratio Code7.17 Ratio Code6.29 Ratio Code6.57 Ratio Code3.55 Ratio Code3.36 Ratio Code4.10 Ratio Code3.90 Ratio Code5.38 Ratio Code4.30 Ratio CodePrimary Color: Exterior, White Kodiak,FrostColor: Primary Exterior, White Kodiak,FrostSecondary Color: Exterior, Ocean BluePrimary Color: Exterior, Ocean Blue

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General Information General Information 0-17RPO Code List (cont'd) Fasteners (Prevailing Torque Fasteners)

RPO24L40P41 P46L46U5DO61L61 U70L71 L71 U72U86L86U88L88U

DescriptionSecondary Color: Exterior, MediumBlue MetallicWheel Color: WhiteWheel Color: BlackSecondary Color: Exterior, Dark GreenPrimary Color: Exterior, Dark GreenPaint Process Bumper, Light GraySecondary Color: Exterior, TanPrimary Color: Exterior, TanSecondary Color: Exterior, Dark MapleSecondary Color: Exterior, Red OrangePrimary Color: Exterior, Red OrangePrimary Color Exterior, Standard RedSecondary Color: Exterior, WheatlandYellowPrimary Color: Exterior, WheatlandYellowSecondary Color: Exterior, TangierOrangePrimary Color: Exterior, Tangier Orange

Labels - How to Obtain ReplacementOrder the following replacement labels through IsuzuService Parts:

The Vehicle Emission Control Information(Exhaust Emission Tune-Up) The Spare Wheel Caution The Jacking The Spare Tire Storage The Belt Routing The Engine Fan Caution

The Standard Parts Catalog lists the above labelsand other labels. The Vehicle Certification Label, theTire Pressure Placard, and the Service PartsIdentification Label are NOT available asservice parts.

la}2 5

9

171892Engineers design prevailing torque nuts in order todevelop an interference between the nut and boltthreads. Usually the interference is caused bydistorting the top of a metal nut (1,2) or by a nylonpatch on the threads in the middle of the hex flat (3).A nylon insert between the nut and bolt threads alsomay cause the interference (4,5).Engineers design prevailing torque bolts in order todevelop an interference between the bolt and nutthreads, or the threads of a tapped hole. Theinterference is caused by distorting some of thethreads using one of the following methods:

A nylon patch (8) Adhesive (6) A deformed thread profile (7) An out of round thread area (9)

Recommendations for ReusePerform the following steps in order to reuse clean,non-rusted, prevailing torque nuts:

1. Clean dirt and other foreign material off of thenuts and bolts.2. Inspect the nuts or bolts for the followingconditions. If any of the following conditions

exist, use a new prevailing torque fastener: Cracks. Rust Damage Elongation Signs of abuse Signs of overtightening

3. Assemble the parts.4. Hand start the nuts or bolts.5. Ensure that the fastener develops proper torquebefore the fastener seats. Refer to the TorqueTable. If the proper torque does not develop,use a new prevailing torque fastener.6. Tighten the fastener to the torque specified in

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0-18 General Information General InformationMetric Fasteners (Prevailing Torque)

Fastener TypeNuts/Metal Bolts

66.3810121416

Adhesive or Nylon Coated Bolts66.3810121416

SpecificationMetric

0.4 N.m0.4 N.m0.8 N.m1.4 N.m2.2 N.m3.0 N.m4.2 N.m

0.4 N.m0.4 N.m0.6 N.m1.2 N.m1.6 N.m2.4 N.m3.4 N.m

English

4lbin4lbin7 Ib in12 Ibin19 Ib in27 Ib in37 Ib in

4lbin4lbin5 Ibin11 Ibin14 Ibin21 Ib in30 Ib in

English Fasteners (Prevailing Torque)Fastener Type/Torque Units

Nuts/Metal Bolts0.2500.3120.3750.4370.5000.5620.625

Adhesive or Nylon Coated Bolts0.2500.3120.3750.4370.5000.5620.625

SpecificationMetric

0.4 N.m0.6 N.m1.4 N.m1.8 N.m2.4 N.m3.2 N.m4.2 N.m

0.4 N.m0.6 N.m1.0 N.m1.4 N.m1.8 N.m2.6 N.m3.4 N.m

English

4lbin5 Ibin12 Ib in16 Ib in21 Ib in28 Ib in37 Ib in

4lbin5 Ibin9 Ibin12 Ib in16 Ib in23 Ib in30 Ib in

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General Information General Information 0-19Fasteners (Strength Identification)

6

171891Legend(1) English Bolt, Grade 2 (Strength Class)

(2) English Bolt, Grade 5 (Strength Class)(3) English Bolt, Grade 7 (Strength Class)(4) English Bolt, Grade 8 (Strength Class)(5) Metric Nut, Strength Class 9(6) Metric Bolts, Strength Class Increases asNumbers Increase

Notice: The designation of the standard fastenersused on this vehicle are of coarse screw thread upto M8 and fine screw thread beyond M10. Thedesignation to pitch relations are somewhat differentbetween coarse screw thread and fine screw thread.Therefore, when replacing fasteners, the pitch shouldbe confirmed carefully even if the replacementfastener is the same metric fastener.The most common metric fastener strength propertyclasses are 9.8 and 10.9. The class identificationnumber is embossed on the head of each bolt (6).Some metric nuts are marked with single digitstrength identification numbers on the nut face.English strength classes range from 2 (low strength)to 8 (high strength). A grade-2 bolt has no linesembossed on the bolt head (1). One radial line is

embossed on the bolt head for each strength gradeabove 2. That is, a bolt with one embossed lineindicates grade-3. Two embossed lines indicategrade-4. Six embossed lines signify grade-8, thehighest-grade bolt (4).Correct replacement bolts and nuts are availablethrough American Isuzu Parts Distributor Network(AIPDN). Many metric fasteners available in theafter-market parts channels are designed to foreignmetric standards, and may have a different threadpitch. Isuzu products use metric fasteners designedto new, international standards. Some non-domesticbolt and nut suppliers may not yet use theinternational standards.

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0-20 General Information General InformationFasteners (Strength Identification)

Metric Coarse Screw ThreadsThread

M39M36M33M30M27M24M22M20M18M16M14M12M10

Pitch44

3.53.5

33

2.52.52.522

1.751.5

ThreadM8M7M6

M5x0.8M4x0.7M4x0.7

M3.5M3x0.5

M2.5M2.2M2

M1.6

Pitch1.25

11

0.80.750.70.60.5

0.450.450.4

0.35

Metric Fine Screw ThreadsThreadM39x3M36x3M33x2M30x2M27x2M24x2

M22x1.5

Pitch332222

1.5

~

ThreadM20x1.5M18.1.5M16x1.5M14x1.5

M12x1.25M 10x1.25

M8x1

Pitch1.51.51.51.5

1.251.25

1

Fasteners (Metric Fasteners)Current model Isuzu vehicles are dimensionedprimarily in the metric system. Many fasteners aremetric and are very close in dimension to fastenersin the inch system. Replace the fasteners using thefollowing identical specifications:

The nominal diameter The thread pitch The strength

Most stock metric fasteners have numbers indicatingthe strength of the material in the fastener. "Beauty"bolts, such as exposed bumper bolts have nostrength indicator. Identify metric cross-recess screwsby a Posidriv or Type 1A marking. Use a Type 1Across-recess screwdriver in order to fasten orunfasten metric cross-recess screws. If a Type 1Across-recess screwdriver is not available, use aPhillips head screwdriver.Isuzu Engineering Standards and other NorthAmerican industries use a portion of the standardmetric fastener sizes defined by the InternationalStandards Organization (ISO). Now the total numberof fastener sizes in use is lower, and the overallstrength quality of each thread size is higher.For example, the metric M6.0 x 1 screw replaces theEnglish V4-20 and "1/4-28 screws, which have nearlythe same diameter. The thread pitch, 25.4 threadsper inch, is between coarse and fine thread pitchesin English. Metric and English thread notations differslightly. The thread major diameter of a 1/4-20 bolt is1/4-inch, and the bolt has 20 threads per inch. Thethread major diameter of a 6.0 x 1 bolt is 6.0 mm,and the distance between threads is 1 mm.

Thread InsertsRepair ProcedureTools RequiredGeneral purpose thread repair kits. These kits areavailable commercially.Caution: Wear safety glasses in order to avoideye damage.

4962Important: Refer to the thread repair kitmanufacturer's instructions regarding the size of thedrill and tap to use.Avoid any buildup of chips. Back out the tap everyfew turns and remove the chips.

1. Determine the size, the pitch, and the depth ofthe damaged thread. If necessary, adjust thestop collars on the cutting tool and tap to therequired depth.

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General Information General Information 0-212. Drill out the damaged threads. Clean outany chips.3. Lubricate the tap with light engine oil. Tap thehole. Clean the threads.

49634. Thread the thread insert onto the mandrel ofthe installer. Engage the tang of the insert ontothe end of the mandrel.

Important: The insert should be flush to oneturn below the surface.5. Lubricate the insert with light engine oil(except when installing in aluminum) andinstall the insert.6. If the tang of the insert does not break offwhen backing out the installer, break the tangoff with a drift.

Torque WrenchesTorque DefinedTorque is defined as the measurement of resistanceto turning or rotating. Torque, often called torsional ortwisting movement, tends to twist a body about anaxis of rotation. A typical application is the tighteningof a screw.Torque applied in tightening a common bolt, nut, orscrew is expended in three areas:

The head Bearing surface Clamp load

Clamp LoadAbout 50 percent of applied torque is used inovercoming bearing friction. This is the frictionbetween the bearing surface of the bolt head, screwhead or nut face, and the base material or washer(the surface the fastener is rotating on).Approximately 40 percent of the applied torque isused in overcoming thread friction. This leaves onlyabout 10 percent of the applied torque to developuseful clamp load. Clamp load is the force that holdsa joint together. Friction can account for as much as90 percent of the applied torque on a fastener.1998 - MD-lsuzu

Torque TechniquesThe frictional characteristics of each fastener orthreaded hole can vary under a variety ofcircumstances. For example, consider a joint that has10 bolts. If all 10 fasteners were torqued to 20 N.mand the clamp load is measured, all 10 bolts wouldmost likely have different clamp load readings. Eventhough all 10 bolts are torqued at 20 N.m, it is notguaranteed that they have all reached the same clampload. A rule of thumb is that the clamp load can vary 25 percent using torque control for joint assemblyAt times, critical applications such as cylinder headbolts require very tight tolerances for clamp loaddistribution. If torque is not considered to beaccurate enough for these critical joints, analternative method of tightening called TORQUEANGLE may be used.Torque Angle Method

65532Torque angle is required for critical joints because itcan help eliminate frictional variations in the joint.The following are the general steps used for thetorque angle method:

1. Tighten to a predetermined seating torque toremove any compliance out of the joint.2. Turn the fastener to a specified angle ofrotation. Use the Torque Angle Meter J 36660.

This is the only acceptable general method formeasuring this angle of rotation. Follow the specificprocedure where it is provided.Torque Wrenches and TechniquesThe term TORQUE WRENCH is commonly used todescribe a type of measuring tool. The tool is set orcalibrated in such a way as to make possible themeasurements of the resistance to turning (torque).The torque wrench measures this resistance toturning and, therefore, is the method used to obtainobjective tightening data used in the assembly offasteners. A torque wrench is a gage tool that canbe compared with micrometers, dial indicators,vernier calipers, levels, and other measuring devices.


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0-22 General Information General InformationTapered Beam Model Torque Wrench Pivoted Handle Torque Wrench

65520Of the many different types of torque wrenchesavailable, the most popular in the service field is thetapered beam model. This model uses a pointerattached to the head that runs the length of theflexible beam (shaft) to a scale located near thehandle. As the wrench is pulled, the beam bendsand the pointer indicates the torque on the scale.Click-type Torque Wrench

289952Some types of torque wrenches are equipped with apivoted handle. If used properly, this handle permitsthe accurate and correct use of the torque wrench.In order to hold a pivoted type handle, it should befloated on the pivot point. This concentrates yourpulling force. If the pivoting handle comes in contactwith the yoke extension during the process of pulling,there is a very good chance the torque readings willbe inaccurate because this could alter the wrenchloading point. The design of the handle, however,makes it inconvenient to deliberately use the floatingprinciple improperly.Direct Reading Torque Wrench

6484Another type of torque wrench is the CLICK typewhich is adjusted to a predetermined torque. Oncethe designated torque has been reached, the wrenchhas a reflex signalling feature that causes amomentary breakaway of the body of the torquewrench. This feature has the effect of sending astrong impulse to the technician's hand. Althoughonce quite popular, these wrenches are not thepreferred method for torque applications.

6486Some of the newer model wrenches, such as theSnap-on Direct Reading Torqometer wrench (ModelTES or equivalent) can be held at any position onthe wrench without affecting accuracy. Thesewrenches are preferred over the flexible beam typesbecause of their greater degree of accuracy,compact design, and scales that are easily readable.1998 - MD-lsuzu


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General Information General Information 0-23Torque Wrench AccuracySelecting the proper size and range of a torquewrench is important in obtaining accurate results.The best quality torque wrenches (the Snap-onDirect Reading Torqometer models or equivalent) areaccurate within 2 percent of the indicated readingfrom 20 percent of full scale to full scale. Forexample, a 200 N.m (148 Ib ft) full scale torquewrench is guaranteed to be accurate from 40 N.m to200 N.m (30-148 Ib ft) (20-100 percent of full scale).Using this wrench below 40 N.m (30 Ib ft) (itsguaranteed operating range) could result ininaccurate torque readings and possible joint failuredue to either an overtorque or undertorque condition.Torque Wrench SelectionSince it is not possible to purchase one wrench to fitthe widest range of torque specifications in theservice environment, the following guidelines shouldbe used for torque wrench selection:

0-20 N.m Full Scale (177 Ib in). Accurate from4-20 N.m (35-177 Ib in). 0-75 N.m Full Scale (55 Ib ft). Accurate from15-75 N.m (11-55lbft).. 0-250 N.m Full Scale (185 Ib ft). Accurate from50-250 N.m (37-185 Ib ft).

Torque Wrench CalibrationThis is a general guideline and is published tofacilitate the selection of a range or torque wrenchesthat would cover most applications and would remainin the guaranteed accuracy ranges of the wrenches.Once a wrench is put into service, nothingguarantees that the wrench will remain calibratedwithin its accuracy range. It is recommended,therefore, that torque wrenches be calibrated aminimum of twice annually. Once again, the torquewrench is a precision measuring device. The torquewrench is exposed to rugged working conditions.Precautions must be taken in order to protect againstinaccurate measurements.Continuous Pull MethodOnce a torque wrench is selected, use a techniquecalled the CONTINUOUS PULL METHOD in order toincrease accuracy during torquing. Pull the torquewrench in one continuous, smooth action until thespecified torque is reached. There is no jerking orratcheting during this final tightening effort. Thecontinuous pull method is an excellent way todevelop consistency.Abbreviations and Their MeaningsThe following abbreviations may appear inthis manual.

Abbreviations TableAbbreviation

AA/CAC

ACLADJA/FAIRAlt

AMPAM/FM

AntAP

ASMAT

ATDCAuthAuto

BB+

BAROBatBP

BTDCC

CCACCalif

CCOTCDCFI

CFMCIDCKPCLcmCMPCO

CoaxConnConvCPPCPS

CrankCTPCV

Meaning

Air ConditioningAlternating CurrentAir CleanerAdjustAir/Fuel (Ratio)Secondary Air InjectionAltitudeAmpere(s)AM/FM StereoAntennaAccelerator PedalAssemblyAutomatic TransmissionAfter Top Dead CenterAuthorityAutomatic

Battery Positive VoltageBarometric (pressure)BatteryBack PressureBefore Top Dead Center

Degrees CelsiusCharge Air CoolerCaliforniaCycling Clutch Orifice TubeCompact DiscContinuous Fuel InjectionCubic Feet Per MinuteCubic Inch DisplacementCrankshaft PositionClosed LoopCentimetersCamshaft PositionCarbon MonoxideCoaxialConnectorConverterClutch Pedal PositionCentral Power SupplyCrankshaftClosed Throttle PositionConstant Velocity

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0-24 General Information General InformationAbbreviations Table (cont'd)

AbbreviationCyl

DDCDFIDiffDl

DistDLCDTCDTMDVM

EEACEASECLECMEOTECU

EEPROMEFEEGR

EGRTVVEl

EMEPROM

ESCESDETR

EVAPExh

FFC

FED

galGAW

GAWRGCWR

GenGov

g

MeaningCylinder(s)

Direct CurrentDirect Fuel InjectionDifferentialDistributor IgnitionDistributorData Link ConnectorDiagnostic Trouble CodeDiagnostic Test ModeDigital Voltmeter

Electric Air ControlElectric Air SwitchingEngine Coolant LevelEngine Control ModuleEngine Coolant TemperatureEngine Calibration Unit (PROM)Electronically Erasable ProgrammableRead Only MemoryEarly Fuel EvaporationExhaust Gas RecirculationExhaust Gas Recirculation ThermalVacuum ValveElectronic IgnitionEngine ModificationErasable Programmable Read OnlyMemoryElectronic Spark ControlElectrostatic DischargeElectronically Tuned ReceiverEvaporative EmissionExhaust

FDegrees FahrenheitFan ControlFederal (all the United States exceptCalifornia)

GGallonGross Axle WeightGross Axle Weight RatingGross Combination Weight RatingGeneratorGovernorgram

Abbreviations Table (cont'd)Abbreviation

gndGVW

GVWRH

HamHCHDHg

Hi AltH02S

hp

IACIAT1C

ICMIDIFIignILCINJINT1/PIPCISC Kkgkm

km/hkPaKSkV

IbIbftIb in

LLFLHLRLS

MMAFManMAP

MeaningGroundGross Vehicle WeightGross Vehicle Weight Rating

HarnessHydrocarbonsHeavy DutyMercuryHigh AltitudeHeated Oxygen SensorHorse Power

1Idle Air ControlIntake Air TemperatureIgnition ControlIgnition Control ModuleIdentification or Inside DiameterIndirect Fuel InjectionIgnitionIdle Load CompensatorInjectionIntakeInstrument PanelInstrument Panel ClusterIdle Speed ControlKilogramKilometerKilometers per hourKilopascalsKnock SensorKilovolts

LPound(s)Pound feet (torque)Pound inch (torque)Liter (engine displacement)Left FrontLeft HandLeft RearLeft Side

Mass Air FlowManualManifold Absolute Pressure

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General Information General Information 0-25Abbreviations Table (cont'd)

AbbreviationMATMaxMC

MDPMFImi

MILMinml

mmmpgmphMSTmV

NNCN.mNO

NOxNVRAM

0OBDOCODOL02

02Soz

PAIRP/B

PCMPCVPNP

PRESSPROM

PSpsiPt

PTOPWM

Qqt

MeaningManifold Air TemperatureMaximumMixture ControlManifold Differential PressureMulti-Port Fuel InjectionMile(s)Malfunction Indicator LampMinimumMilliliterMillimeterMiles per GallonMiles per HourManifold Surface TemperatureMillivolt

Normally ClosedNewton-meter (torque)Normally OpenOxides of NitrogenNon-Volatile Random Access Memory

On-Board DiagnosticsOxidation Converter (Catalytic)Outside DiameterOpen LoopOxygenOxygen SensorOunce(s)

PPulsed Secondary Air InjectionPower BrakesPowertrain Control ModulePositive Crankcase VentilationPark/Neutral PositionPressureProgrammable Read Only MemoryPower SteeringPounds per Square InchPintPower Take OffPulse Width Modulated

Quart(s)

Abbreviations Table (cont'd)Abbreviation

RRAMRefRFRFIRH

ROMRPMRPORRRS

RTVRVBRVR

SSAESecSlsol

SPECSpeedo

SPLSRISRTSTsyn

TTAGTachTCCTCM

TEMPTDCTerm

ThemnoTP

TRANSTV

TVRSTVVTWC

TWC+OC

Meaning

Random Access MemoryReferenceRight FrontRadio Frequency InterferenceRight HandRead Only MemoryEngine Speed (Revolutions Per Minute)Regular Production OptionRight RearRight SideRoom Temperature Vulcanizing (sealer)Rear Vacuum BrakeResponse Vacuum Reducer

Society of Automotive EngineersSecondarySystem InternationalSolenoidSpecificationSpeedometerSmoke Puff LimiterService Reminder IndicatorService Readiness TestScan ToolSynchronize

Throttle Actuator ControlTachometerTorque Converter ClutchTransmission Control ModuleTemperatureTop Dead CenterTerminalThermostatic Air CleanerThrottle PositionTransmissionThrottle ValveTelevision and Radio SuppressionThermal Vacuum ValveThree Way Converter (Catalytic)Three Way + Oxidation Converter(Catalytic)

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0-26 General Information General InformationAbbreviations Table (cont'd)

AbbreviationU

U-BoltU-Joint

VV6V8V

V-refVacVAF

VDOTVINVR

VRVVSS WW/

W/BW/0WOT

WU-OCWU-TWC

Meaning

Universal BoltUniversal Joint

Six Cylinder Engine, V-TypeEight Cylinder Engine, V-TypeVolt(s)ECM Reference GroupVacuumVolume Air FlowVariable Displacement Orifice TubeVehicle Identification NumberVacuum RegulatorVacuum Reducer ValveVehicle Speed SensorWithWheel BaseWithoutWide Open ThrottleWarm Up Oxidation Converter(Catalytic)Warm Up Three Way Converter(Catalytic)

Identify keys by the five-character key code stampedonto the key. Use the code numbers and a code listin order to determine the lock combination of thevehicle. The owners of key cutting equipment receivethe code list from equipment suppliers. If the codenumber is not available from records or from thefive-character key code number, a key code numberlabel is on the inside of the bottom glass on thepassenger's side door.Key Code Diagram

^

12345678 1234

205851Legend

(1) Position(2) Level

Key and Lock Cylinder CodingMedium Duty Trucks use a one-key locking system.A single, two-sided key operates the ignition andboth doors. The key is reversible, and inserts witheither side facing up.

^

205853

Cutting Keys1. Determine the code from the code list or thekey code diagram.2. Cut a blank key to the proper level for each ofthe eight tumbler positions.3. Ensure that the key locks and unlocks the lockcylinder.

Replacement Lock CylindersThe service parts warehouses offer lock cylinders asa complete assembly, including the key. Do notservice or code the lock cylinders. If a lock cylinderis faulty, replace the cylinder. Order lock cylindersfrom the service parts warehouses.Lifting and Jacking the VehicleCaution: To help avoid a personal injury when avehicle is on a hoist, provide additional supportfor the vehicle at the opposite end from whichcomponents are being removed. This will reducethe possibility of the vehicle falling off the hoist.Notice: When jacking or lifting a vehicle atprescribed lift points, be certain that lift pads do notcontact the exhaust system, brake pipes, cables, fuellines or under body. Such contact may result indamage or unsatisfactory vehicle performance.1998 - MD-lsuzu


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General Information General Information 0-27Any time you lift a vehicle on one end, chock thewheels at the opposite end. Use jack stands in orderto provide support. When supporting the vehicleusing jack stands, place the jack stands under theside rails or the axle.Park the vehicle on a clean, hard, level surfacebefore lifting the vehicle. Ensure that the liftingequipment meets weight requirements. Ensure thatthe lifting equipment is in good working order. Beforelifting the vehicle, ensure that the vehicle loads aresecure and equally distributed. In some cases onlythe frame side rails are able to support the vehicle.Do not put excessive stress on the frame side rails.You may lift and support the front of the vehicle atthe front axle near the wheel assemblies.In order to remove the front axle, support the vehiclenear the rear front spring support brackets usingsuitable jack stands and/or other lifting equipment.The lifting points for the front frame are just behindthe rear front spring support brackets.You may lift and support the rear of the vehicle atthe rear axle near the wheel assemblies. Do notsupport the vehicle at the differential assembly.In order to remove the rear axle, support the vehicleat the frame side rails and the rear crossmember,just in front of the rear spring brackets.When you are removing the vehicle's majorcomponents while the vehicle is on a hoist, chain thevehicle frame to the hoist pads nearest thecomponent to be removed. Chaining the vehicle tothe hoist pads will prevent tip-off.Cab TiltingIn order to gain access to the components under thecab, complete the following procedure:Before Tilting the Cab

1. Park the vehicle in a level place.2. Secure all loose articles in the cab.3. Close the cab doors.4. Inspect the area for sufficient clearance in frontof and above the cab.5. In order to prevent the vehicle from moving,take the following steps:

Apply the parking brake. Place an automatic transmission inPARK (P). Place a manual transmission inNEUTRAL (N). Turn the engine OFF. Block both the front and the rear wheels.

Tilting the Cab

205878Caution: A tilt cab not properly locked in thetilted position could fall, causing serious injury.To insure that the cab Is securely locked Inposition and won't move, the safety lockpin mustalways be inserted into the cab support when thecab is in the tilted position.Caution: Things that burn can get on hot engineparts and start a fire. These include liquids likegasoline or diesel fuel, oil, brake fluid, windshieldwasher and other fluids and plastic or rubber. Becareful not to drop or spill things that will burnonto a hot engine.

1. Remove the leverpin. Turn the pin in order toalign the tab with the slot.

2058792. Move the primary tilt lever all the waydownward.

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0-28 General Information General Information

205872 2058713. Pull the secondary latch lever in order to

release the hook from the catch at the back ofthe cab. Now the cab is able to tilt.5. Tilt the cab all the way forward until the cab

support(3) under the cab is fully locked.

2058774. Use the handle located at the bottom of thecab at the back in order to rotate the cab

forward. Torsion bars located under the cabassist the tilting.

2058766. Remove the lockpin(2) from the retainer(4) onthe cab support(3).7. Insert the lockpin(2) into the hole in thecab support.

Caution: A tilt cab not properly locked in thetilted position could fall, causing serious Injury.To insure that the cab Is securely locked inposition and won't move, the safety lockpin mustalways be inserted into the cab support when thecab is in the tilted position.Caution: Things that bum can get on hot engineparts and start a fire. These include liquids likegasoline or diesel fuel, oil, brake fluid, windshieldwasher and other fluids and plastic or rubber. Becareful not to drop or spill things that will burnonto a hot engine.

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General Information General Information 0-29When you are ready to lower the cab, complete thefollowing procedure:Lowering the Cab

2058694. Use the handle located at the bottom of the

cab toward the back in order to lower the cabuntil the hook catches and holds the cab down.205858

1. Rotate and pull on the lockpin(2) in order toremove the lockpin(2) from the cab support(3).2. Insert the lockpin(2) into the retainer(4) on thecab support(3).

2058615. Push the primary tilt lever upward fully in orderto lock the cab to the chassis.

2058593. Squeeze the lock lever(1) on the cab support inorder to release the detent.

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0-30 General Information General Information

2058556. Replace the lever pin. Insert and turn the pin in

order to align the tab with the slot.Towing a Disabled VehicleWhen towing a Medium Duty Truck, take thefollowing precautions in order to prevent damage tothe vehicle:

. Use an Isuzu dealer or a professionaltowing service in order to tow a disabledCommercial Truck.

Use proper equipment. Turn on the hazard warning flashers (if they are

not damaged).. Connect the towing components to the mainstructural parts of the vehicle. Do not attach towing components to thefollowing parts:

- Bumpers- Tow hooks- Brackets

. Only use equipment designed for towing. Follow the instructions given by the tow truck

manufacturer.. Use a safety chain system.

Front End Towing (Front Wheels offthe Ground)Before TowingBlock the rear wheels of the disabled vehicle. Onvehicles with air brakes, release the parking brakesystem by compressing the brake chamber springs.Refer to Air Brakes. Releasing the parking brakesystem prevents the parking brake from engagingwhile the vehicle is in tow.On vehicles with hydraulic brakes, release theparking brake fully by moving the lever handle to thefully releas

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