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WORKSHOP MANUAL

US VERSION

RIGHT HAND MODEL

EXP UBS

PubNo. RV99_02-01.E

WORKSHOP MANUAL

1998/1999

UBS

2000

UBS

2002

UBS

PAGE NEXT

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS

0A General Information

0B Maintenance and Lubrication

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00 SERVICE INFORMATION

1A HEATING AND VENTILATION

1B AIR CONDITIONING

1D COMPRESSOR OVERHAUL

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2A FRONT END ALIGNMENT

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3C FRONT SUSPENSION

3D REAR SUSPENSION; COIL SPRING

3E WHEELS AND TIRES

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4A1 DIFFERENTIAL (FRONT)

4A2A DIFFERENTIAL (Rear 220mm)

4A2B DIFFERENTIAL (REAR 244mm)

4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)

4B2 DRIVELINE CONTROL SYSTEM (TOD)

4C DRIVE SHAFT SYSTEM

4D1 TRANSFER CASE (STANDARD TYPE)

4D2 TRANSFER CASE (TOD)

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5A BRAKE CONTROL SYSTEM

5B ANTI-LOCK BRAKE SYSTEM

5C POWER ASSISTED BRAKE SYSTEM

5D PARKING BRAKES

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6VD1 / 6VE1


6A ENGINE MECHANICAL

6B ENGINE COOLING

6C ENGINE FUEL

6D1 ENGINE ELECTRICAL

6D2 IGNITION SYSTEM

6D3 STARTING AND CHARGING SYSTEM

6E ENGINE DRIVEABILITY AND EMISSIONS

6F ENGINE EXHAUST

6G ENGINE LUBRICATION

6H ENGINE SPEED CONTROL SYSTEM

6J INDUCTION

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4JG2

4JX1




6A2 4JG2-NA / 4JG2-TURBO ENGINE

6B ENGINE COOLING

6C FUEL SYSTEM

6D ENGINE ELECTRICAL

6E -

6F EXHAUST

6G -



6B ENGINE COOLING

6C ENGINE FUEL

6D ENGINE ELECTRICAL

6E ENGINE DRIVEABILITY AND EMISSIONS

6F ENGINE EXHAUST

6G ENGINE LUBRICATION

6H ENGINE SPEED CONTROL

6J INDUCTION

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7A AUTOMATIC TRANSMISSION (4L30-E)

7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)

7B MANUAL TRANSMISSION (AR-5)

7B MANUAL TRANSMISSION (MUA)

7C CLUTCH

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8A LIGHTING SYSTEM

8B WIPER / WASHER SYSTEM

8C ENTERTAINMENT

8D WIRING SYSTEM

8E METER AND GAUGE

8F BODY STRUCTURE

8G SEATS

8H SECURITY AND LOCKS

8I SUN ROOF/CONVERTIBLE TOP

8J EXTERIOR / INTERIOR TRIM

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9A SEAT BELT SYSTEM

9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

9J1 RESTRAINT CONTROL SYSTEM

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10A CRUISE CONTROL SYSTEM

GENERAL INFORMATION 0A–1

SECTION 0A

GENERAL INFORMATION

CONTENTS

PAGE

General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 2

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 3

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 6

Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 8

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–10

Recommended Liquid Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–11

Recommended Thread Locking Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–11

Abbreviations Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–12

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTALRESTRAINT SYSTEM (SRS). REFER TO THE SRSCOMPONENT AND WIRING LOCATION VIEW INORDER TO DETERMINE WHETHER YOU AREPERFORMING SERVICE ON OR NEAR THE SRSCOMPONENTS OR THE SRS WIRING. WHEN YOUARE PERFORMING SERVICE ON OR NEAR THESRS COMPONENTS OR THE SRS WIRING, REFERTO THE SRS SERVICE INFORMATION. FAILURETO FOLLOW WARNINGS COULD RESULT INPOSSIBLE AIR BAG DEPLOYMENT, PERSONALINJURY, OR OTHERWISE UNNEEDED SRSSYSTEM REPAIRS.

CAUTION: Always use the correct fastener in theproper location. When you replace a fastener, useONLY the exact part number for that application.ISUZU will call out those fasteners that require areplacement after removal. ISUZU will also call outthe fasteners that require thread lockers or threadsealant. UNLESS OTHERWISE SPECIFIED, do notuse supplemental coatings (Paints, greases, orother corrosion inhibitors) on threaded fastenersor fasteners joint interfaces. Generally, suchcoatings adversely affect the fastener torque andthe joint clamping force, and may damage thefastener. When you install fasteners, use thecorrect tightening sequence and specification.Following these instructions can help you avoiddamage to parts and systems.

GENERAL REPAIR INSTRUCTIONS

1. Park the vehicle on level ground and chock thefront or rear wheels before lifting the vehicle.

2. Use covers on the vehicle body, seats, andfloor to prevent damage and/orcontaminations.

3. Disconnect the grounding cable from thebattery before performing service operations.This will prevent cable damage or burning dueto shortcircuiting.

4. Raise the vehicle with a jack set against therecommended lifting points (see “Liftinginstructions” in this section).

5. Support the vehicle on chassis stands.6. Handle brake fluid and antifreeze solution with

great care.Spilling these liquids on painted surfaces willdamage the paint.

7. The use of the proper tool(s) and special tool(s)where specified is essential to efficient,reliable, and safe service operations.

8. Always use genuine ISUZU replacement parts.9. Discard used cotter pins, gasket, plastic clips,

O-rings, oil seals, lock washers, and self-locking nuts at disassembly.Normal function of these parts cannot beguaranteed if they are reused.

10. Keep the disassembled parts neatly in groups.This will facilitate smooth and correctreassembly.

11. Keep fixing nuts and bolts separate.Fixing nuts and bolts vary in hardness anddesign according to installation positions.

12. Clean all parts before inspection orreassembly.

13. Clean the oil ports and other openings withcompressed air to make certain that they arefree of dirt and obstructions.

14. Lubricate the rotating and sliding faces of allmoving parts with oil or grease beforeinstallation.

15. Use the recommended liquid gasket to preventleakage.

16. Carefully observe all nut and bolt torquespecifications.

17. When service operation is completed, make afinal check to be sure service has been doneproperly and problem has been corrected.

18. When removing or replacing parts that requirerefrigerant to be discharged from the airconditioning system, be sure to use thefollowing tools to recover and recycle theRefrigerant-134a (R-134a).For 134a:

Use the R-134a Refrigerant Recovery/Recovery/Recycling/Recharging/System (ACR4) or itsequivalent to prevent the discharge ofrefrigerant into the air.

0A–2 GENERAL INFORMATION


HOW TO USE THIS MANUAL

1. Find the applicable section by referring to thetable of contents on the introduction page ofeach manual.

2. In “Service Information”, an opening section ofeach manual, the troubleshooting, maintenanceservicing, service data and/or information onspecial tools required for the service operationsdescribed in the next subsequent sections arearranged and compiled so concisely that youcan see at a first glance.

3. Each section except the Service Informationsection is basically arranged in the followingorder of headings:General descriptionOn-vehicle serviceUnit repair

4. The service operations are in two groups: one isthe “On-vehicle service” where operations canbe directly performed on the vehicle, and theother is the “Unit repair” where the operationsare done on the work bench after removing theunit from the vehicle.

5. Each service operation section begins with adisassembled view of unit or equipment, whichis useful to find relative components, serviceprocedure, availability and contents of repairkits, etc.

The number represents sequence ofremoval or disassembly

Removal of unnumbered the parts(excluding bolts, nuts, washers,gaskets, cotter pins, etc.) isunnecessary unless replacement isneeded.Where parts replacement requiresspecific information, instructions aregiven in “Inspection and Repair”.

This frame is to be removed as alarge disassembly with all the partsassembled in the frame. Each one ofthe parts in the frame is removed asa small disassembly.

Parts to be removed or installed as aunit.

★ Parts contained in repair kit.

★ Indicates repair kit availability.

When the installation (reassembly)procedure is the reverse order of theremoval (disassembly) procedure,the sequence of service operationand the parts names will be omitted.

Name of parts listed in sequence ofservice operation.

For illustrations where there are few items tobe performed:

The sequence of removal(disassembly) and the parts nameswill be given.

The symbol mark attached to the titleindicates the action to be taken in theoperations of each title.Example for this case;1st step – Reassemble pinion shaft

The numbers given to the installation(assembly) procedure are the sameas those given in the removal(disassembly) procedure in theillustration. Therefore, start with thelarger number during reassembly.

The titles of operations done in theillustration are given in bold letters.They are described in the order ofthe procedure of the operations.

Special tools are identified with toolname and/or tool number.The drawing illustrates how the toolis used.

Service data and specifications arelisted in table.

Important note.

The action symbol indicates the stepof service to be followed.Refer to the following paragraph forthe meaning of each symbol.

information such as the notes in each operation,and places where special tools are to be usedand their usage, and the specified service data.


6. After the illustration, the details of eachoperation are shown in the order the operationsare carried out in the illustration. Refer to theexplanations when checking important


7. In this manual, the following action symbolsare used to indicate the type of serviceoperations to be performed.

. . . Remove or disconnect . . . Adjust

. . . Install or connect . . . Clean

. . . Disassemble . . . Pay close attention - Important

. . . Reassemble . . . Tighten to specified torque

. . . Align the marks . . . Use special tool(s)

. . . Correct direction . . . Lubricate with oil

. . . Inspect . . . Lubricate with grease

. . . Take measurement . . . Use liquid gasket

8. The service standard is indicated in terms of“Standard” and “Limit”.The “Standard” means the assembly standardand standard range within which the parts are

considered serviceable.“Limit” indicates the limit value (Correction orreplacement is necessary when measurementis beyond this limit.)

VEHICLE IDENTIFICATION NUMBER (VIN)

This is the legal identification of the vehicle.It appears on the manufacturer’s Plate attached to the leftof the engine compartment front end. VIN number is alsostamped on the rear right side of the frame.

VIN

VIN

ISUZU MOTORS LTD.

JAC UBS 26 G Y 7 200001

Sequential Number

Plant Code

Model Year (Y: 2000)

Wheel Base (D: Short, G: Long)

Engine Type (26: 6VE1, 73: 4JX1)

Vehicle Model

World Manufacturer Identifier

ENGINE SERIAL NUMBER

The engine serial number is stamped on the left rear lowerarea of the cylinder block above the starter.

4JX1

6VE1


IDENTIFICATION

905RW014

905RW016


TRANSMISSION SERIAL NUMBER

Manual: Stamped on the left side of the transmissionintermediate plate.

Automatic: Stamped on the identification plate, located onthe left side of the transmission above themode switch.

96

0000 000

018

PART No.

SERIAL No.SAL

HYDRAMATICSTRASBOURGMADE IN FRANCE

G 20

272

FP

SERVICE PARTS IDENTIFICATION PLATE

The Vehicle Information Plate (Service Parts ID plate) isprovided on all vehicle models.It is located on the center dash wall inside the enginecompartment. The plate lists the VIN (Vehicle IdentificationNumber), paint information and all production options andspecial equipment on the vehicle when it was shippedfrom the factory.

Service parts ID plateISUZU MOTORS LT D. JAPAN

V.I.N.M.D.ENGINEGRADE

TRANS.TIRE

BODY TYPEB. COLOR/TRIM

OPTION

905RW015

905RW018

905RW007


LIFTING INSTRUCTIONS

CAUTION:• If a lifting device other than the original jack

is used, it is most important that the device

be applied only to the correct lifting points.

Raising the vehicle from any other point

may result in serious damage.

• When jacking or lifting a vehicle at the

frame side rail or other prescribed lift

points, be certain that lift pads do not

contact the catalytic converter, brake

pipes or cables, or fuel lines. Such contact

may result in damage or unsatisfactory

vehicle performance.

LIFTING POINTS AND SUPPORTABLE POINT LOCATIONS

Long wheel Base Model

Short Wheel Base Model

Lifting point

Supportable point


LIFTING POINT; FRONT

When using floor jack, lift on the center of the skid plate.

SUPPORTABLE POINT; FRONT

Position the chassis stands at the bottom of the framesidemember, backward of front wheel.

LIFTING POINT; REAR

Position the floor jack at the center of the rear axle casewhen lifting the vehicle.

SUPPORTABLE POINT; REAR

Position the chassis stands at the bottom of the framesidemember, just behind of the trailing link bracket.

SUPPORTABLE POINT; REAR

Position the chassis stands at the bottom of the rear axlecase.

TORQUE SPECIFICATIONS

STANDARD BOLTS

The torque values given in the following table should be applied where a particular torque is not specified.


N·m (kg·m / lb·ft)N·m kg·cm / lb·in

Strength

Class4.8 8.8 9.8

Refined Non-RefinedBolt

Identifi-

cation

Bolt

Diameter x

Pitch (mm)

M 6x1.0 6 (60 / 52 7 (75 / 65 –

M 8x1.25 13 (130 / 113 17 (175 / 152 24 (240 / 208

M10x1.25 27 (2.8 / 20) 37 (3.8 / 27) 50 (5.1 / 37)

M12x1.25 61 (6.3 / 45) 76 (7.8 / 56) 95 (9.7 / 70)

M14x1.5 96 (9.8 / 71) 116 (11.9 / 86) 142 (14.5 / 105)

M16x1.5 130 (13.3 / 96) 170 (17.3 / 125) 200 (20.4 / 148)

M18x1.5 188 (19.2 / 139) 244 (24.9 / 180) 287 (29.3 / 212)

M20x1.5 258 (26.3 / 190) 337 (34.4 / 249) 396 (40.4 / 292)

M22x1.5 332 (33.9 / 245) 453 (46.3 / 335) 530 (54.1 / 391)

M24x2.0 449 (45.8 / 331) 570 (58.2 / 421) 692 (70.6 / 511)

*M10x1.5 26 (2.7 / 20) 36 (3.7 / 27) 48 (4.9 / 35)

*M12x1.5 57 (5.8 / 42) 71 (7.2 / 52) 89 (9.1 / 66)

*M14x2.0 89 (9.1 / 66) 110 (11.2 / 81) 133 (13.6 / 98)

*M16x2.0 124 (12.7 / 92) 162 (16.5 / 119) 191 (19.5 / 141)

The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materialssuch as casting, etc.

FLARE NUTS

N·m (kg·m / lb·ft)

Pipe diameter mm (in) Torque Pipe diameter mm (in) Torque

4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)

6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)

8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)

4

No mark

8 8 9


RECOMMENDED LIQUID GASKET

* RTV: Room Temperature Vulcanizer

NOTE:1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.2. Be careful to use the specified amount of liquid gasket.

Follow the manufacturer’s instructions at all times.3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying

the liquid gasket.The connecting surfaces must be perfectly dry.

4. Do not apply LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greaterthan 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

NOTE: When the application procedures are specified in this manual, follow them.

Type Brand Name Manufacturer Remarks

RTV* Three Bond 1207B Three Bond For Engine RepairsSilicon Base Three Bond 1207C Three Bond

Three Bond 1215 Three Bond For Axle CaseThree Bond 1280 Three Bond Repairs. T/M

Water Base Three Bond 1141E Three Bond For Engine Repairs

Three Bond 1104 Three BondBelco Bond 4 Isuzu

SolventBelco Bond 401 Isuzu

For Engine Repairs

Belco Bond 402 Isuzu

LOCTITE 515 LoctiteAnaerobic

LOCTITE 518 Loctite All

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242 Blue

LOCTITE 262 Red

LOCTITE 270 Green

LOCTITE 271 Red

1. Completely remove all lubricant and moisture from the boltsand the female threaded surfaces of the parts to be joined.The surfaces must be perfectly dry.

2. Apply LOCTITE to the bolts.

Apply LOCTITE to at least 1/3 of thebolt’s threaded area

3. Tighten the bolts to the specified torque.After tightening, be sure to keep the bolts free from vibrationand torque for at least an hour until LOCTITE hardens.

ABBREVIATIONS CHARTS

LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUAL

A – Ampere(s)ABS – Antilock Brake SystemA/C – Air ConditioningACCEL – AcceleratorACC – AccessaryAdj – AdjustA/F – Air Fuel RatioAIR – Air Injection Reaction SystemALDL – Assembly Line Diagnostic LinkAlt – AltitudeAMP – Ampere(s)ANT – AntennaAPS – Absolute Pressure SensorASM – AssemblyA/T – Automatic Transmission/TransaxleATDC – After Top Dead CenterAuth – AuthorityAuto – AutomaticBARO – BarometicBat – BatteryBat+ – Battery Positive TerminalBbl – BarrelBCM – Body Control ModuleBHP – Brake HorsepowerBP – Back PressureBTDC – Before Top Dead Center°C –Degrees CelsiusCat. Conv. – Catalytic Convertercc – Cubic CentimeterCCC – Computer Command ControlCCOT – Cycling Clutch Orifice TubeCCP – Controlled Canister PurgeCID – Cubic Inch DisplacementCL – Closed LoopCLCC – Closed Loop Carburetor ControlCO – Carbon MonoxideCoax – CoaxialConn – ConnectorConv – ConverterCP – Canister PurgeCPS – Central Power SupplyCrank – CrankshaftCTS – Coolant Temperature SensorCu.In. – Cubic InchCV – Constant VelocityCyl – Cylinder(s)C3I – Computer Controlled Coil IgnitionDBM – Dual Bed MonolithDiff – DifferentialDIS – Direct Ignition SystemDist –DistributorDOHC – Double Overhead CamshaftDVM – Digital Voltmeter (10 meg.)DVOM – Digital Volt OhmmeterDVDV – Differential Vacuum Delay Valve

EAC –Electric Air ControlEAS – Electric Air SwitchingEBCM – Electronic Brake Control ModuleECC – Electronic Climate ControlECM – Electronic Control ModuleECU – Electronic Control Unit

– Engine Calibration Unit (PROM)EECS – Evaporative Emission Control SystemEFE – Early Fuel EvaporationEFI – Electronic Fuel InjectionEGR – Exhaust Gas RecirculationEGR/TVS – Exhaust Gas Recirculation/Thermostatic

Vacuum SwitchELC – Electronic Level ControlESC – Electronic Spark ControlEST – Electronic Spark ControlETR – Electronically Tuned ReceiverEVRV – Electronic Vacuum Regulator Valve (EGR)Exh – Exhaust°F – Degrees FahrenheitFF – Front Drive Front EngineFL – Fusible LinkFLW – Fusible Link WireFRT –FrontFWD – Front Wheel Drive4WD – Four Wheel Drive4x4 – Four Wheel Drive4 A/T – Four Speed Automatic Transmission/TransaxleGal – GallonGen – GeneratorGov – Governorg – GramHarn – HarnessHC – HydrocarbonsHD –Heavy DutyHEI – High Energy IgnitionHg – MercuryHiAlt – High AltitudeHVAC – Heater-Vent-Air ConditioningIAC – Idle Air ControlIC – Integrated CircuitID – Identification

– Inside DiameterIDI – Integrated Direct IgnitionIGN – IgnitionILC – Idle Load CompensatorINJ –InjectionIP – Instrument PanelIPC – Instrument Panel ClusterINT – IntakeJ/B – Junction Blockkm – Kilometerskm/h – Kilometer per HourkPa – KiloPascalsKV – Kilovolts (thousands of volts)KW – Kilowatts


SAE – Society of Automotive EngineersSec – SecondarySFI – Sequential-port Fuel InjectionSI – System InternationalSIR – Supplemental Inflatable Restraint SystemSOHC – Single Overhead CamshaftSol – SolenoidSPEC – SpecificationSpeedo – SpeedometerSRS – Supplemental Restraint SystemST – StartSw – SwitchSWB – Short Wheel BaseSYN – SynchronizeTAC – Thermostatic Air CleanerTach – TachometerTBI – Throttle Body InjectionTCC – Transmission/Transaxle Converter ClutchTCM – Transmission/Transaxle Control ModuleTDC – Top Dead CenterTerm – TerminalTEMP – TemperatureTPS – Throttle Position SensorTRANS – Transmission/TransaxleTURBO – TurbochargerTV – Throttle ValveTVRS – Television & Radio SuppressionTVS – Thermal Vacuum Switch3 A/T – Three Speed Automatic Transmission/

Transaxle2WD – Two Wheel Drive4x2 – Two wheel DriveU-joint – Universal JointV – Volt(s)VAC – VacuumVIN – Vehicle Identification NumberVRRRE – Vehicle Refrigerant Recovery and Recycling

EquipmentV-ref – ECM Reference VoltageVRV – Vacuum Reducer ValveVSS – Vehicle Speed SensorVSV – Vacuum Switching ValveV-6 – Six Cylinder “V” EngineV-8 – Eight Cylinder “V” EngineW – Watt(s)w/ – Withw/b – Wheel Basew/o – WithoutWOT – Wide Open Throttle

L – Literlb·ft – Foot Poundslb·in – Inch PoundsLF – Left FrontLH – Left Hand LR – Left RearLS – Left SideLWB – Long Wheel BaseL-4 – In-line Four Cylinder EngineMAF – Mass Air FlowMAN – ManualMAP – Manifold Absolute PressureMAT – Manifold Air TemperatureMEM-CAL – Memory and Calibration UnitMax – Maximum M/C – Mixture ControlMin – Minimummm – MillimeterMPFI – Multi-Port Fuel InjectionMPG – Miles per GallonMPH – Miles per HourM/T – Manual Transmission/TransaxleMV – MillivoltNA – Natural AspiratedNC – Normally ClosedN·m – Newton MetersNO – Normally OpenNOx – Nitrogen, Oxides ofOD – Outside DiameterO/D – Over DriveOHC – Overhead CamshaftOL – Open LoopO2 – OxygenPAIR – Pulse Air Injection Reactor SystemP/B – Power BrakesPCV – Positive Crankcase VentilationPFI – Port Fuel InjectionPRESS – PressurePROM – Programmable Read Only MemoryP/N – Park/NeutralP/S – Power SteeringPSI – Pounds per Square InchPt. – PintPri – PrimaryPWM – Pulse Width ModulatedQt – QuartREF – ReferenceRF – Right FrontRFI – Radio Frequency InterferenceRH – Right HandRPM – Revolutions per MinuteRPO – Regular Production OptionRR – Right RearRS – Right SideRTV – Room Temperature VulcanizingRVB – Rear Vacuum BrakeRVR – Response Vacuum Reducer RWAL – Rear Wheel Antilock Brake RWD - Rear Wheel Drive


MAINTENANCE AND LUBRICATION 0B–1

SECTION 0B

MAINTENANCE AND LUBRICATION

CONTENTS

PAGE

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B– 2

Recommended Fluids, Lubricants and Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B– 7

Oil Viscosity Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–10

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTALRESTRAINT SYSTEM (SRS). REFER TO THE SRSCOMPONENT AND WIRING LOCATION VIEW INORDER TO DETERMINE WHETHER YOU AREPERFORMING SERVICE ON OR NEAR THE SRSCOMPONENTS OR THE SRS WIRING. WHEN YOUARE PERFORMING SERVICE ON OR NEAR THESRS COMPONENTS OR THE SRS WIRING, REFERTO THE SRS SERVICE INFORMATION. FAILURETO FOLLOW WARNINGS COULD RESULT INPOSSIBLE AIR BAG DEPLOYMENT, PERSONALINJURY, OR OTHERWISE UNNEEDED SRSSYSTEM REPAIRS.

CAUTION: Always use the correct fastener in theproper location. When you replace a fastener, useONLY the exact part number for that application.ISUZU will call out those fasteners that require areplacement after removal. ISUZU will also call outthe fasteners that require thread lockers or threadsealant. UNLESS OTHERWISE SPECIFIED, do notuse supplemental coatings (Paints, greases, orother corrosion inhibitors) on threaded fastenersor fasteners joint interfaces. Generally, suchcoatings adversely affect the fastener torque andthe joint clamping force, and may damage thefastener. When you install fasteners, use thecorrect tightening sequence and specification.Following these instructions can help you avoiddamage to parts and systems.

0B–2 MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE

GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: AdjustR: Replace or change T: Tighten to specified torque L: Lubricate

SERVICE INTERVAL: x 1,000 km(Use odometer reading x 1,000 milesor months whichever comes first) or months

536

10612

15918

201224

251530

301836

352142

402448

452754

503060

553366

603672

653978

704284

754590

804896

8551102

9054108

9557114

10060120

GASOLINE ENGINE* Engine oil* Engine oil filter

Oil leakage and contamination* Timing belt

Spark plugs (For leaded fuel use)Spark plugs (For unleaded fuel use)Exhaust systemRadiator coolant concentrationCooling system for water leakageAll hoses and pipes in engine compartment

for clog or damageFuel filterFuel leakageFuel tank

* Air cleaner elementPre air cleanerEngine drive beltValve clearanceO2 Sensor (For leaded fuel use)O2 Sensor (For unleaded fuel use)

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RRR

-

III

I-IIII-

-

---

-

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-

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-

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-

RRI

-

III

IRIIIII

-

---

-

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-

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R

---

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-

RRI

-

III

I-IIRI-

-

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R

---

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-

RRI

-

III

IRIIIII

-

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RRI

-

III

I-IIII-

-

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R

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RRI

-

III

IRIIRII

-

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R

(Replace every 165,000 km or 100,000 miles)

(Replace every 165,000 km or 100,000 miles)

(Check and adjust if necessary every 100,000 km or 60,000 miles)

(Replace every 150,000 km or 90,000 miles)CLUTCH

Clutch fluidClutch pedal travel and free play

TRANSMISSION OR TRANSMISSION WITHTRANSFER CASE* Manual transmission with transfer case oil* Automatic transmission fluid leakage*(1) Automatic transmission fluid* Transfer case oilPROPELLER SHAFT

Loose connections* Universal joints and splines for wear

Universal joints and sliding sleeve (front and rear)FRONT AND REAR AXLE* Differential gear oil (Front and rear)

Shift on the fly system gear oilFront axle shaft rubber boot for damageAxle case for distortion or damageAxle shafts for distortion or damage

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II

RI-R

IIL

RIIII

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II

II-I

IIL

IIIII

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II

RI-R

IIL

RIIII

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II

II-I

IIL

IIIII

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II

RI-R

IIL

RIIII

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II

II-I

IIL

IIIII

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I-II

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ATATAT

STEERING* Power steering fluid

Oil leakage* Steering system for looseness or damage

Power steering hoseSteering wheel playSteering functionRight and left turning radiusWheel alignmentJoint ball for oil leakage or damageJoint ball rubber boot for damage

SERVICE BRAKESBrake fluidBrake system for fluid leakageBrake function

* Disc brake pads and discs wearBrake pedal travel and free playPipes and hoses for loose connections or damage

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IIIIII--II

IIIIII

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IIIIIIIIII

IIIIII

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RIIIII--II

RIIIII

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IIIIIIIIII

IIIIII

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IIIRII--II

IIIIII

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RIIIIIIIII

RIIIII

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(1): Adjust or change automatic transmission fluid.*Marks:Under severe driving conditions, additional maintenance is required.

Refer to “Maintenance schedule under severe driving conditions”.

MAINTENANCE AND LUBRICATION 0B–3

GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: AdjustR: Replace or change T: Tighten to specified torque L: Lubricate

SERVICE INTERVAL: x 1,000 km(Use odometer reading x 1,000 milesor months whichever comes first) or months

536

10612

15918

201224

251530

301836

352142

402448

452754

503060

553366

603672

653978

704284

754590

804896

8551102

9054108

9557114

10060120

PARKING BRAKEParking brake functionParking brake lever travelCables for looseness or damage and guide for

damageRatchet for wear or damage

SUSPENSIONSpring leaves for damageMount for looseness or damageShock absorbers for oil leakageShock absorbers mount for loosenessRubber bushes of suspension wear or damageSpring action for loss of balance due to weakeningJoint ball rubber boot for damage

WHEELSWheel pinsWheel disc for damageHub bearing greaseFront and rear hub bearings for loosenessTire pressure and damageTire rotation

OTHERSBolts and nuts on chassis and bodyLube front free-wheeling hubs

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III

I

IIIIIII

TI-II

I-

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III

I

IIIIIII

TIRII

IL

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III

I

IIIIIII

TI-II

I-

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-

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III

I

IIIIIII

TIRII

IL

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III

I

IIIIIII

TI-II

I-

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III

I

IIIIIII

TIRII

IL

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(Rotate as required)

*Marks:Under severe driving conditions, additional maintenance is required.Refer to “Maintenance schedule under severe driving conditions”.

workshop manual us version right hand · pdf fileworkshop manual us version right hand model...

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