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ISUZU
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Giga
Service Manual
114 pgs6.23 Mb51
Table of contents
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ISUZU Giga Service Manual

2008-2011MY
WORKSHOP MANUAL
GENERAL INFORMATION
General Information 0A-1

GENERAL INFORMATION

General Information
TABLE OF CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
General Repair Instructions . . . . . . . . . . . . . . . 0A-2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3
Chassis Number/Engine Number Stamping
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3
Option Code List . . . . . . . . . . . . . . . . . . . . . . . . 0A-4
Vehicle Identification Number (VIN) . . . . . . . . 0A-11
General Precaution . . . . . . . . . . . . . . . . . . . . . . 0A-15
General Precautions . . . . . . . . . . . . . . . . . . . . 0A-15
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . 0A-17
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . 0A-17
Caution for The Maintenance of Electrical Parts 0A-20
Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-20
Connector Handling Requirements . . . . . . . . . 0A-20
Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-23
Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-23
Regarding The Scan Tool. . . . . . . . . . . . . . . . . . 0A-25
Trouble Diagnosis Using The Scan Tool . . . . . 0A-25
Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-31
Recommended Liquid Gasket. . . . . . . . . . . . . 0A-31
Recommended Thread Locking Agent. . . . . . . . 0A-33
Recommended Thread Locking Agent . . . . . . 0A-33
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-34
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-34
Maintenance Schedule
(for Euro4 specification except Europe) . . . . . 0A-35
Maintenance Schedule
(for Euro2, Euro3 specification). . . . . . . . . . . . 0A-41
Maintenance Schedule (for Europe) . . . . . . . . 0A-45
Maintenance Schedule
(CNG engine for Australia) . . . . . . . . . . . . . . . 0A-50
Maintenance Schedule
(CNG engine for Thailand) . . . . . . . . . . . . . . . 0A-54
Transmission Oil - ZF6S1000/ZF9S1110 Type 0A-58 Transmission Oil - FS8209A/FSO5206B Type 0A-65
RS23/RS40 Type Axle . . . . . . . . . . . . . . . . . . 0A-67
RS25 Type Axle . . . . . . . . . . . . . . . . . . . . . . . 0A-68
Maintenance Schedule for Severe-condition . . . 0A-69
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-69
Maintenance Schedule for Severe-condition . 0A-69
Recommended Fluids, Lubricants and
Diesel Fuels (except Europe). . . . . . . . . . . . . . . 0A-73
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73
Diesel Engine Crankcase with DPD
(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-73
Diesel Engine Crankcase without DPD. . . . . . 0A-74
CNG Engine Crankcase (for Australia) . . . . . . 0A-74
CNG Engine Crankcase (for Thailand) . . . . . . 0A-74
Manual Transmission (MZX/MZW/MLD models), Transfer Case, Differential
(without LSD) and Oil Lubricated Hub
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-75
Manual Transmission (MZZ models). . . . . . . . 0A-75
Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-75
Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-75
Automatic Transmission, Power Steering . . . . 0A-76
Center Bearing, Clutch Shift Block, Grease Lubricated Hub, Water Pump,
Propeller Shaft Sliding Yoke, Universal
Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-76
Multi-Purpose Grease Containing
Molybdenum . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-76
Engine Cooling System . . . . . . . . . . . . . . . . . . 0A-76
Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-77
Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-77
Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-77
Diesel Fuel / Applicable Standard
(Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-78
Recommended Fluids, Lubricants and
Diesel Fuels (for Europe) . . . . . . . . . . . . . . . . . . 0A-79
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79
Diesel Engine Crankcase with DPD
(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-79
Diesel Engine Crankcase without DPD. . . . . . 0A-79
Manual Transmission (MZX/MZW/MZZ/MLD
models), Differential (without LSD) and Oil
Lubricated Hub Bearing . . . . . . . . . . . . . . . . . 0A-80
Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-80
Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-80
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 0A-80
Center Bearing, Clutch Shift Block,
Grease Lubricated Hub, Water Pump,
Propeller Shaft Sliding Yoke, Universal
Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-81
Engine Cooling System . . . . . . . . . . . . . . . . . . 0A-81
Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-81
Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-82
Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-82
Diesel Fuel / Applicable Standard
(Sulfur content below 50 ppm) . . . . . . . . . . . . 0A-82
Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-83
Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . 0A-83
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 0A-84
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-84
Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-97
Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . 0A-97
0A-2 General Information

General Information

General Repair Instructions

1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Use covers on the vehicle body, seats, and floor to prevent damage and/or contaminations.
3. Disconnect the grounding cable from the battery before performing service operations. This will prevent cable damage or burning due to shortcircuiting.
4. Raise the vehicle with a jack set against the axle or the frame.
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with great care. Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is efficient, reliable, and safe service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, O-rings, oil seals, lock washers, and self-locking nuts at disassembly. Normal function of these parts cannot be guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups. This will facilitate smooth and correct reassembly.
11. Keep fixing nuts and bolts separate. Fixing nuts and bolts vary in hardness and design according to installation positions.
12. Clean all parts before inspection or reassembly.
13. Clean the oil ports and other openings with compressed air to make certain that they are free of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
15. Use the recommended liquid gasket to prevent leakage.
16. Be sure to tighten nuts and bolts to the specified torque, using a properly maintained torque wrench.
17. When service operation is completed, male a final check to be sure service has been done properly and problem has been corrected.
18. When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be sure to use the ACR4 or equivalent to recover and recycle Refrigerant ­134a (HFC-134a), to promote the movement for the protection of the ozone layer covering the earth.
19. To assure safety, always slowly release air pressure from the air tanks before disconnecting pipes, hoses or other parts from any unit under pressure.
20. Prior to start the welding work, the following operations are required:
• Disconnect all connectors of electronic control unit.
• Disconnect battery ground terminal.
• Welding machine ground cable must be connected near the welding point.
• Turn off the all switches.

Identification

General Information 0A-3

Chassis Number/Engine Number Stamping Position

Chassis number
It is stamped on the front right-hand side face of the chassis side member.
MFW70ASH000101
Engine number (4HK1 Engine)
The engine number is stamped on the right side of the cylinder body.
Engine number (6HF1 Engine)
The engine number (1) is stamped on the right side of the cylinder body.
1
MFW90ASH000101
Engine number (6HK1 Engine)
The engine number is stamped on the right side of the cylinder body.
LNWB0ASH000101
MFW80ASH000401
Service Parts ID Plate
The service parts ID plate is attached to the passenger side lower dashboard. The service parts ID plate has the following information;
• Vehicle identification number (VIN)
• Wheelbase dimensions
• Paint information
• Production options or special equipment installed on the vehicle at the factory
0A-4 General Information
Refer to the service parts ID plate when ordering replacement parts.
MFU8Z0SH043301

Option Code List

Option
Code
B14 Hong Kong equipment
B3A
B30 Floor carpet - vinyl
B84 Body side molding
CB7 Colombia equipment
CE4 Head lamp washer
CGA Morocco equipment
CJ6 Country - Ireland
CK1 Pakistan equipment
CL1 Kenya equipment
CT6 Country - Italy
CU9 Country - United Kingdom
CV4 Country - Israel
CX6 Country - New Zealand
Rear wheel parking brake - air control
Option Description
Option
Code
AJ3 Driver side air bag
AK3
AK5 Driver and passenger side air bag
AU4 Automatic door lock
A31 Power window - front & rear door
A32 Power window - front door
A56 Driver seat - air suspension
A83 Vinyl seat with reclining
BDM Power take off - transmission rear
BFK Transfer TF56
BHW
BJR Brake adjuster - manual
B02 South Africa equipment
Front seat belt & shoulder with retractor
Power take off - engine rear, electromagnetic clutch
Option Description
C13 Wiper with intermittent
C2C Transmission oil cooler
C2M Propeller shaft - P60 type
C3N Final differential lock
C3U Air suspension - high control
C4M Air breather with flex hose
C4Z Propeller shaft - P46 type
C41 Heater & defroster
C5K Hub lubrication - oil bath
C5T Propeller shaft - P90 type
C60 Manual air conditioning
C65
C68 Automatic air conditioning
DH2 O/S rear view mirror - long arm
DL8
Manual air conditioning without heater core
O/S rear view mirror - remote control with heated
B03 Thailand equipment
B04 Taiwan equipment
B1S Parking brake drum - 8.5 inch
B1T Parking brake drum - 10 inch
B10 Malaysia equipment
B12 Russia equipment
B13 Australia equipment
DNB O/S rear view mirror - pillar mounted
D20 Assist side sun visor
D31 Rear view mirror
D37 Mirror - Outside rear view
D6M User - export government
D8T Iran equipment
D94 Touch-up paint
General Information 0A-5
Option
Code
EAK
EBB Digital tachograph
EBE Front under run protector
ECF Speed limiter - 60km/h
ECY Speed limiter - 70km/h
EDG Header console - driver & assist
EDH Round curtain rail
EDW Speed limiter - 80km/h
EDX Speed limiter - 85km/h
EFE Regulation ECE R29
EFK Floor mat - vinyl mat Var.2
E09 Europe equipment
E11 Mexico equipment
E13 New Zealand equipment
E2N Fuel pipe - steel
E29 Auxiliary steps
E40 Sleeper cab with mattress
E46 Ecuador equipment
FJC
F59 Front stabilizer
GH3 Saudi Arabia equipment
GL6 Rear shock absorber
GN1 Rear stabilizer
G86 Limited slip differential - no spin
JAQ Lighting system - Saudi Arabia
JBF Tire - KD special
JBZ Lighting system - Japanese standard
JCA Anti-noise equipment - ECE R51.02
Disc wheel - 6 studs 19.5x6.75 (136-12)
Disc wheel - 10 studs 20x8.50V (138-13)
Option Description
Option
Code
K30 Auto cruise
K44 Generator 24V-90A
K89 Generator 24V-50A
M9A Owners manual - Not required
NCR Memory system - Runnig condition
NF7 Fuel tank 200L + 200L
NJW Ireland KD special
NMJ Speed limiter - 90km/h
NMU Speed limiter - 100km/h
NNR 3 speaker system
NT2 Emission system - Euro2
NT3 Emission system - Euro3
NT4 Emission system - Euro4
N02 Fuel tank 100L - frame side mount
N05 Fuel tank cap with key lock
N19 Fuel tank - 140L frame side
N20 Fuel tank 200L - frame side mount
N79 Spare disc wheel
PM1 Rear hook - double
PP7 Pintle hook
PR2 Driving position - wide leg space
PS7 Air dryer
PT1
PT6 Thailand KD special
P10 Spare tire carrier - frame rear mount
P13 Spare tire carrier - frame side mount
P38 Tire delete
QM8
Disc wheel - 8 studs 22.5x6.75 (145-11)
Disc wheel - 10 studs 22.5 x 8.25 (165-13)
Option Description
JDN Compartment - I/P assist side with lid
JDP Compartment - I/P assist side without lid
JE5 Anti-lock brake system
J55 Brake system - heavy duty Var.1
J91 Trailer brake control
KC5 Receptacle - accessory
KE1 Chile equipment
KF0 Fuel filter - low quality
KG2 Generator 24V60A
Q47
Q87
Q5T Turbo - conventional
Q50
Q54
Q58 Disc wheel - 10 studs 20x7.00T
Disc wheel - 8 studs 20x6.50T (145-10)
Disc wheel - 10 studs 22.5x7.50 (162-12)
Disc wheel - 8 studs 20x6.50T (152-11)
Disc wheel - 8 studs 20x7.00T (162-12)
0A-6 General Information
Option
Code
Q62
Q64 Disc wheel - 10 studs 20 x 7.50V
Q87
RC4 Dump control lever
RC5 Tool box with key lock
RE3 Spare tire fixing
RE9
RDV 4HK1-TCC engine
RJS 4HK1-TCS engine
RQZ G.V.W. - 8.0-11.0 ton
RRA G.V.W. - 11.0-14.0 ton
RR9 O/S rear view mirror - under
RSA Manual transmission - MZZ6W
RSW Manual transmission - MZX6P
RSZ Manual transmission - MZW6P
RWE Chevrolet brand
Disc wheel - 8 studs 20x7.50V (165-13)
Disc wheel - 10 studs 22.5x7.50 (162-12)
Clutch - 15 inch single plate strap drive
Option Description
Option
Code
SDF Room lamp with all door switch
SDH Fuel tank 400L
SDK Cab suspension - semi floating type
SDP
SEG
SFC
SFT Electric outlet - one
SGA Front under spoiler delete
SGX Vietnam equipment
SG4 Tire inflator device
SG7
SH5
SJA Driver seat - Isringhausen
SKU
Disc wheel - 8 studs 20x7.00T (152-12)
Disc wheel - 8 studs 205x7.50V (130-13)
Disc wheel - 6 studs 17.5x6.75 (137-10)
Disc wheel - 6 studs 16x6.00GS (135-9)
Power take off - transmission side without lever
Disc wheel - 8 studs 22.5x7.50 (162-13)
Option Description
R32 KD frame
R46 Spare tire & disc wheel
R9A Service cab with electric
R9B Service cab without electric
R9C Deletion - service cab with electric
R9D Deletion - service cab without electric
R9E Service cab conversion with electric
R9F
R9Z Thailand localization spec.
SAQ Front suspension - multi leaf spring
SAR Front suspension - taper leaf spring
SAS Rear suspension - multi leaf spring
SAU
SAY Standard cab
SAZ Ventilator & defroster
Deletion - service cab conversion without electric
Rear helper suspension - taper leaf spring
SKV
SK4 Engine overrun buzzer
SLB Front bumper with headlamp
SLC Lighting system - ECE
SLK Anti-noise equipment - ECE
SMS Rear bumper - steel wide
SP9 Assist seat without center seat
SR6 Rearward double tire
SV6 Power take off control
SY8 Spare tire carrier - lifting type
TAF
TAK Anti-noise equipment - Var.2
TAZ Driver seat - rigid without arm rest
TDU Brake regulation - ADR
TDV Brake regulation - ECE
Disc wheel - 8 studs 22.5 x 8.25 (165-13)
O/S rear view mirror - under & side under
SBB
SBG
Disc wheel - 8 studs 20x6.00S (135-10)
Disc wheel - 6 studs 17.5x6.00 (135-9)
TEC Roof marker lamp
TEE
TFD Cab all painting
Disc wheel - 8 studs 19.5x6.75 (147-12)
General Information 0A-7
Option
Code
TFN
TGL Anti corrosion package
TM1 Battery - 80D26L
TR6 Headlamp leveling system - manual
TR7 Headlamp leveling system - automatic
TT5 Halogen headlamp
TT6 High intensity discharge headlamp
T1A
T62 Battery - dry
T64 Battery delete
T79 Rear fog lamp
T87 Cornering lamp
T96 Front fog lamp
UC1 Speedometer - miles per hour (MPH)
UC9 Tachograph- Kienzle
UF3 Map lamp
UG3 Engine oil temperature gauge
Driver’s seat belt with pre-tension reducer
Injection pump Q set - special +5%Q
Option Description
Option
Code
WC7 Tachograph - 140km/h
WF6
WG3 Brake system - heavy duty Var.2
WH2 Spare tire - front tire
WJ7 Cautions - Arabian
WJ8 Cautions - French
WL5 Inspection lamp
WM3 Interior trim - full trimming
WV2 Automatic cab tilt
WX8 Shift control - assister
W02 Highland zone package
W1G
W1H
W1J
W1K
Clutch - 14 inch single plate strap drive
Final drive gear ratio - 6.143 (43/7)
14.5 inch hypoid
Final drive gear ratio - 5.571 (39/7)
14.5 inch hypoid
Final drive gear ratio - 6.500 (39/6)
14.5 inch hypoid
Final drive gear ratio - 6.833 (41/6)
14.5 inch hypoid
Option Description
UL5 Radio delete
UT3 AM/FM radio with CD player
U01 Roof marker - 5 lamps
U18 Speedometer - kilometer
U69 AM/FM radio
U95 2 speaker system
VG7
VP1 Front under spoiler
VR7 Two eye rear hook
VTK Owners manual - Arabic language
VTL Owners manual - French language
VTS Owners manual - Spanish language
VT7 Owners manual - English language
VZA VIN model year - 2010
VZB VIN model year - 2011
V22 Radiator grille - chrome
Front bumper reinforcement
- heavy duty
W1L
W1R
W1T
W1U
W12 Front locking hub - manual
W14 Deluxe cab
W16 Cab suspension - full floating
W18 Transfer TF36
W20 Disc wheel special painted (white)
W3B
W3D
W3F
Final drive gear ratio - 6.500 (39/6)
16.5 inch hypoid
Final drive gear ratio - 6.143 (43/7)
15.5 inch hypoid
Final drive gear ratio - 6.500 (39/6)
15.5 inch hypoid
Final drive gear ratio - 4.875 (39/8)
14.5 inch hypoid
Final drive gear ratio - 5.571 (39/7)
16.5 inch hypoid
Final drive gear ratio - 4.875 (39/8)
18.5 inch hypoid
Final drive gear ratio - 6.167 (37/6)
18.5 inch hypoid
V4F Chassis for fire car
V76 Hook - tow
WB7 Electrical horn
W3G
W3K
Final drive gear ratio - 6.667 (40/6)
18.5 inch hypoid
Final drive gear ratio - 5.571 (39/7)
15.5 inch hypoid
0A-8 General Information
Option
Code
W3L
W3M
W3N
W3P
W3S
W3U
W3X
W3Y
W3Z
W4A
W4B
Option Description
Final drive gear ratio - 6.143 (43/7)
16.5 inch hypoid
Final drive gear ratio - 5.125 (41/8)
18.5 inch hypoid
Final drive gear ratio - 4.556 (41/9)
18.5 inch hypoid
Final drive gear ratio - 5.125 (41/8)
16.5 inch hypoid
Final drive gear ratio - 5.857 (41/7)
15.5 inch hypoid
Final drive gear ratio - 7.167 (43/6)
17.5 inch hypoid
Final drive gear ratio - 6.429 (45/7)
17.5 inch hypoid
Final drive gear ratio - 6.143 (43/7)
17.5 inch hypoid
Final drive gear ratio - 5.571 (39/7)
17.5 inch hypoid
Final drive gear ratio - 5.125 (41/8)
17.5 inch hypoid
Final drive gear ratio - 4.875 (39/8)
17.5 inch hypoid
Option
Code
W6M
W6N
W6R
W6S
W66 Disc wheel with step
W71 Cab suspension - rigid type
W8C
W8D
W8F
W8L
X5J Manual transmission - MLD6Q
X7W Manual transmission - MLD6S
X9C Transmission - manual
Final drive gear ratio - 6.43 (45/7)
18.0 inch hypoid Rockwell
Final drive gear ratio - 6.83 (41/6)
18.0 inch hypoid Rockwell
Final drive gear ratio - 4.30 (43/10)
18.0 inch hypoid Rockwell
Final drive gear ratio - 6.14 (43/7)
15.0 inch hypoid Rockwell
Final drive gear ratio - 4.56 (41/9)
18.0 inch hypoid Rockwell
Final drive gear ratio - 6.43 (45/7)
15.0 inch hypoid Rockwell
Final drive gear ratio - 4.555 (41/9)
14.5 inch hypoid
Final drive gear ratio - 6.83 (41/6)
15.0 inch hypoid Rockwell
Option Description
W4C
W4F
W4H
W4T
W4W
W4X
W5M
W5V
W5Z
W6A
W6B
W6C
Final drive gear ratio - 4.556 (41/9)
17.5 inch hypoid
Final drive gear ratio - 5.125 (41/8)
14.5 inch hypoid
Final drive gear ratio - 5.125 (41/8)
15.5 inch hypoid
Final drive gear ratio - 4.333 (39/9)
18.5 inch hypoid
Final drive gear ratio - 6.833 (41/6)
17.5 inch hypoid
Final drive gear ratio - 4.333 (39/9)
14.5 inch hypoid
Final drive gear ratio - 4.100 (41/10)
14.5 inch hypoid
Final drive gear ratio - 6.833 (41/6)
16.5 inch hypoid Rockwell
Final drive gear ratio - 4.89 (44/9)
18.0 inch hypoid Rockwell
Final drive gear ratio - 5.38 (43/8)
18.0 inch hypoid Rockwell
Final drive gear ratio - 5.63 (45/8)
18.0 inch hypoid Rockwell
Final drive gear ratio - 6.14 (43/7)
18.0 inch hypoid Rockwell
X9D Transmission - automatic
YC4
YK3 Rearward single tire
YM9 Reversing warning buzzer
YN1 Caution - Spanish
YS1 O/S rear view mirror - flat type
YT9 Pakistan KD special
Y2C Manual transmission - MLD6W
Y21 Light duty package truck
Y3A
Y3B
Y4F
Y4G
Y4V
Y48 Heavy duty package truck
Y5D Manual transmission - ZF 6S1000
Injection pump - high altitude compensator, aneroid type
Manual transmission
- Fuller FS8209
Automatic transmission
- Allison MD3560P
Automatic transmission
- Allison LCT2000
Automatic transmission
- Allison MD3060P
Manual transmission
- Fuller FSO5206B
General Information 0A-9
Option
Code
Y5E Manual transmission - ZF 9S1110
Z05
Z06 Brake system - full air dual circuit
Z1V Equipment - additional key
01D KD package - South Africa
01R Tire - front & rear 8.25-20-14 lug
02E KD package - Taiwan
05R Tire - front & rear 8.25R20-14 rib
09X
1D7 6HF1-TCN engine
1D9 6HF1-TCC engine
10T Tire - front & rear 9.00-20-14 rib
10X
Brake system - air over hydraulic dual circuit
Tire - front 8.25-20-14 rib, rear 8.25-20-14 lug
Tire - front 9.00-20-14 rib, rear 9.00-20-14 lug
Option Description
Option
Code
42W Wheel base 4,200mm
43P Tire - front & rear 9R22.5-14
43W Wheel base 4,300mm
45N Tire - front & rear 11R22.5-14 rib
45P Tire - front & rear 275/70R22.5
45R Tire - front & rear 10.00R20-14 rib
46W Wheel base 4,600mm
48W Wheel base 4,800mm
49W Wheel base 4,900mm
49P
5D9
5E0
5E1 Tire - front & rear 10R22.5-14
Tire - front & rear 8.25R20-14 exp block
Tire - front & rear 295/80R22.5-152/148K rib/lug
Tire - front & rear 295/80R22.5-152/148J rib
Option Description
11X
12X
15N Tire - front & rear 9R22.5-14 rib
155 Interior color - Charcoal gray
2G0 Singapore equipment
20D Thailand KD deletion parts
21R Tire - front & rear 9.00-20-14 lug
25R Tire - front & rear 9.00R20-14 rib
27X
30T Tire - front & rear 10.00-20-14 rib
34W Wheel base 3,400mm
35N Tire - front & rear 10R22.5-14 rib
36W Wheel base 3,600mm
37W Wheel base 3,700mm
38W Wheel base 3,800mm
39W Wheel base 3,900mm
40S Tire - front & rear 8.25-16-14 rib
40T Tire - front & rear 10.00-20-16 rib
Tire - front 10.00-20-14 rib, rear 10.00-20-14 lug
Tire - front 10.00-20-16 rib, rear 10.00-20-16 lug
Tire - front 11.00-20-16 rib, rear 11.00-20-16 lug
5G2
5H1
5J6
5J7
5J8 Tire - front & rear 245/70R19.5 rib
5J9 Tire - front & rear 235/75R17.5 rib
5K0 Tire - front & rear 265/70R19.5 rib
5K4
5K5
5L1 Tire - front & rear 12.00R20-18
5L4
5L7
5L8 Tire - front & rear 10.00R-20-16 lug
5N5
Tire - front 295/80R22.5, rear 11R22.5-16
Tire - front 10.00-20-16 rib, rear 10.00-20-16 lug
Tire - front 9.5R17.5 129/127L rib, rear 9.5R17.5 129/127L traction
Tire - front & rear 11R22.5 148/145L rib
Tire - front & rear 11R22.5 148/145K rib/lug
Tire - front & rear 12R22.5 152/148K rib/lug
Tire - front & rear 275/70R22.5 148/145M rib
Tire - front & rear 9.00R-20-14 exp lug
Tire - front & rear 265/70R19.5 140/ 138M rib (BS brand)
40W Wheel base 4,000mm
41R Tire - front & rear 10.00-20-14 lug
41W Wheel base 4,100mm
5N6
5P0
Tire - front & rear 235/75R17.5 132/ 130M rib (BS brand)
Tire - front & rear 235/75R17.5 132/ 130M rib (BS brand)
0A-10 General Information
Option
Code
5P1
5P2
5P3
5P6 Tire - front & rear 225/70R19.5
5P7
50W Wheel base 5,000mm
51R Tire - front & rear 10.00-20-16 lug
51W Wheel base 5,100mm
517 Body color - AL. gray
53W Wheel base 5,300mm
538 Body color - Tool-IPEC yellow
55N Tire - front & rear 11R22.5-16 rib
55P
55R Tire - front & rear 10.00R20-16 rib
55W Wheel base 5,500mm
58N Tire - front & rear 11.00R20-16 rib
58W Wheel base 5,800mm
59W Wheel base 5,900mm
6DY Rear under run protector
6EP HSA system
6HF KD preparatory package
6KK Horn - heavy duty (dual)
6ND OK window
6NF Remote control door lock
6PH
6SZ Power take off - flywheel
6UC Fluorescent lamp
6UH
6VE O/S rear view mirror - door mount
6WX Floor mat - vinyl
6XH ASR system
60W Wheel base 6,000mm
609 Body color - FT orange
Tire - front 295/80R22.5, rear 11R22.5-16 (6x2, BS brand)
Tire - front 295/80R22.5, rear 11R22.5-16 (BS brand)
Tire - front & rear 10R22.5-14 exp rib/lug (BS brand)
Tire - front & rear 8.25R16 128/126L exp rib/lug
Tire - front & rear 295/80R22.5 152/148M rib
LSPV - Load sensing proportioning valve
O/S rear view mirror - assist side short stay
Option Description
Option
Code
61P Tire - front & rear 225/90R17.5
63E KD package - Italy
63W Wheel base 6,300mm
64E KD package - Vietnam
64N Tire - front & rear 8.25R20-14 rib
65W Wheel base 6,500mm
668 Body color - Purplish blue
681 Body color - Geranium red
695 Body color - Dark blue
7BC Assist seat with center seat
7DM Tuner band - Latin America
7FL Seat material - cloth
7HZ Rear bumper
7KC Immobilizer system
7NY Multi information display
7SV O/S rear view mirror - heated
7TV KD preparatory package
70T Tire - front & rear 11.00-20-14 rib
71R Tire - front & rear 11.00-20-14 lug
71S Tire - front & rear 7.50-20-12 lug
71W Wheel base 7,100mm
729 Body color - Arc white
736 Body color - Cardinal red
78N Tire - front & rear 8.25R16
79R Tire - front & rear 11.00R20-14
8AA
8AC
8EJ Battery - 65D23L
8GF Transmission with Smoother
8GJ Transmission without Smoother
8JM Diesel particulate diffuser
8LF Rear window glass
8LX Ash tray - assist side
8MA Battery 115E41L
8MH Fuel tank 370L
8ML O/S rear view mirror - middle arm
Good quality ethylene glycol antifreeze 50%
Good quality ethylene glycol antifreeze 30%
Option Description
General Information 0A-11
Option
Code
8MV
8NG Decal - vehicle & pet name
8NH Decal - pet name
8NV Bio diesel fuel B10
80L 6HK1-TCS engine
80R Tire - front & rear 11.00-20-16 rib
800 Body color - In white
807 Body color - Woodland green
81L 6HK1-TCC engine
81R Tire - front & rear 11.00-20-16 lug
81U Tire - front & rear 8.25-16-14 lug
812 Body color - Wheatland yellow
82L 6HK1-TCN engine
829 Body color - Sahara beige
O/S rear view mirror - extended long arm
Option Description
Option
Code
982 Body color - Polar white
989 Body color - Sunbelt green
99D KD package - United Kingdom
99N Tire - front & rear 11R22.5-16
909 Body color - middle bronze green
919 Body color - olive drab
999 Body color - trans blue
Option Description

Vehicle Identification Number (VIN)

The ID plate indicates the vehicle identification number (VIN). This single number contains multiple pieces of information including the vehicle and engine model codes as shown below.
83N Tire - front & rear 9.5R17.5
84D Colombia Var.2
85N Tire - front & rear 11R22.5-16
85R Tire - front & rear 11.00R20-16 rib
85U Tire - front & rear 8.25R16-14 rib
87N Tire - front & rear 10.00R20-14PR rib
89N Tire - front & rear 9.00R20-14PR rib
89R Tire - front & rear 11.00R20-16PR
89T Tire - front & rear 11.00R20-16
890 Body color - Marine blue
90S Tire - front & rear 8.25-20-14 rib
904 Body color - golden yellow
91D KD package - Philippine Var.2
915 Body color - fire red
92N Tire - front & rear 8.25R16-14PR rib
93N
Tire - front 12.00R20-18, rear 12.00R20-18 lug
94K Tire - front & rear 10.00R20-16
94N Tire - front & rear 12.00R20-16
944 Body color - Highway orange
95D KD package - Ireland
951 Body color - arc white
97N
Tire - front 295/80R22.5, rear 11R22.5-16
0A-12 General Information
Typ e 1
JALFRR34L87000001
Legend
1. World manufacturer identifier (WMI)
2. Vehicle model code
3. Engine code
4. Wheel base code
5. Model year code
6. Chassis number
1. World manufacturer identifier (WMI)
654321
MFW80ASF000201
4. Wheel base code
Code
JAL
2. Vehicle model code
Code
FRR 4x2 Truck FRR model
FSR 4x2 Truck FSR model
FTR 4x2 Truck FTR model
FVR 4x2 Truck FVR model
FVZ 6x4 Truck FVZ model
FVM 6x2 Truck FVM model
GVR 4x2 Tractor GVR model
FSS 4x4 Truck FSS model
FTS 4x4 Truck FTS model
3. Engine code
Code
34 6HK1 Engine
86 6HF1 Engine
ISUZU BRAND
Medium & Heavy Duty
Incomplete Vehicle
Code
H
J
K
L
M
N
P
7
R
S
T
3,201 - 3,500 mm
(126.02 - 137.80 in)
3,501 - 3,800 mm
(137.83 - 149.61 in)
3,801 - 4,100 mm
(149.65 - 161.42 in)
4,101 - 4,400 mm
(161.46 - 173.23 in)
4,401 - 4,700 mm
(173.27 - 185.04 in)
4,701 - 5,000 mm
(185.08 - 196.85 in)
5,001 - 5,300 mm
(196.89 - 208.66 in)
5,301 - 5,600 mm
(208.70 - 220.47 in)
5,601 - 5,900 mm
(220.51 - 232.28 in)
5,901 - 6,200 mm
(232.32 - 244.09 in)
6,201 - 6,500 mm
(244.13 - 255.91 in)
90 4HK1 Engine
General Information 0A-13
Typ e 2
Code
U
V
W
5. Model year code
6,501 - 6,800 mm
Code
(255.94 - 267.72 in)
6,801 - 7,100 mm
(267.76 - 279.53 in)
7,101 - 7,400 mm
(279.57 - 291.34 in)
JAL 5K16 87
H
2 431
8 9765
8 2008MY
9 2009MY
A 2010MY
B 2011MY
700001
10
Legend
1. World manufacturer identifier (WMI)
2. Gross vehicle weight (GVW) and brake system
3. Series code
4. Line/Cab type code
5. Chassis code
1. World manufacturer identifier (WMI)
Code
ISUZU BRAND
JAL
Medium & Heavy Duty
Incomplete Vehicle
2. Gross vehicle weight (GVW) and brake system
Code
H
K
M
P
8,846 - 10,659 kg
(19,501 - 23,500 lb)
10,660 - 11,793 kg
(23,501 - 26,000 lb)
11,794 - 14969 kg
(26,001 - 33,000 lb)
14,970 - 18,370 kg
(33,001 - 40,500 lb)
6. Engine code
7. Check digit
8. Model year code
9. Plant code
10. Production sequential number
3. Series code
Code
5FRR
6FSR
7 FTR, FTS, FVR
4. Line/Cab type code
Code
K
M
S
BBC = 1,726 mm (67.95 in),
BBC = 2,066 mm (81.34 in),
BBC = 2,066 mm (81.34 in),
MFW80ASF000301
Tilt cab,
Narrow Cab
Tilt cab,
Narrow Cab
Tilt cab,
Wide Cab
0A-14 General Information
5. Chassis code
Code
1 4x2, 2 Axles, 1 driving
2 4x4, 2 Axles, 1 driving
4 6x4, 3 Axles, 2 driving
6. Engine code
Code
36HK1-TC
64HK1-TC
Typ e 3
8. Model year code
Code
8 2008MY
9 2009MY
A 2010MY
B 2011MY
9. Plant code
Code
7 Fujisawa
3MG FRR 9 0 AM654321
Legend
1. World manufacturer identifier (WMI)
2. General attributes
3. Check digit
1. World manufacturer identifier (WMI)
Code
ISUZU BRAND
3MG
2. General attributes
Code
FRR90 FRR90
Medium & Heavy Duty
Incomplete Vehicle
643 521
MFWB0ASF000101
4. Model year code
5. Plant code
6. Production sequential number
4. Model year code
Code
A 2010MY
B 2011MY
5. Plant code
Code
MMexico (IMEX)
FTR34 FTR34
FVR34 FVR34

General Precautions

General Information 0A-15

General Precaution

Legend
1. Clean and safe costume
2. Installation of Chock blocks
1
2
3
MFW70AMF000201
3. Support by stand after jack up
Work preparations
• Prepare the tools, instruments, and special tools in advance.
• Prepare the parts that require replacement and parts that cannot be re-used in advance.
Clothing
• The service technician must wear a clean service technician uniform, hat, and safety footwear.
Protect the vehicle.
• Make sure to use a seat cover, etc.
• Disconnect the terminal of the battery (–) in advance.
Always focus on safety
• Make sure to use chock block when the vehicle is jacked up.
• After jacking up, make sure to support the specified position using a stand.
• When lifting up the vehicle using a lift, make sure to set the safety device.
• When performing a procedure with two or more people, make sure to ensure each other's safety before performing an action.
• Do not leave the engine running for an extended period of time or perform painting in a poorly ventilated working environment.
• Make sure to use only the special tools if the procedure requires them for the work. Performing the procedure using other tools may cause damage to parts or personal injury.
• Do not use tools such as a wrench that has lost its edges, a hammer with frayed edges, or a chipped chisel.
• When performing work using a device such as a grinder, crane, or welder, make sure that a qualified technician performs the procedure while paying sufficient attention to the handling precautions.
0A-16 General Information
• When performing maintenance on fuel systems, make sure that there is no fuel leakage. (may possibly catch fire)
• When handling volatile materials, take care that they do not catch fire. Also make sure to wipe away any oil that sticks to rubber parts, as it can cause deterioration.
Work Precaution
• Arrange removed parts in the correct order and ensure they do not get mixed up with parts that cannot be re-used.
• Perform sufficient cleaning and washing when performing assembly / installation. Also perform sufficient grease removal for areas to apply liquid gasket, etc.
After-procedure check
• After completing the procedure, perform a final check to confirm that the problem has been solved.
• Check that there is no fuel, oil, or coolant leakage.

Lifting Instruction

General Information 0A-17

Lifting Instruction

If it necessary to use a lifting device other than the original equipment jack, see illustration for acceptable lifting points. Lifting should only be done at the positions indicated to prevent possible damage to the vehicle.
CAUTION:
Failure to observe the acceptable lift points may result in unsatisfactory vehicle performance or a durability failure which may result in loss of control of the vehicle.
Garage Jack and Safety Stand
Lifting Point and Supportable Point Location
31 24
Lifting Point Positions - Front side
CAUTION:
Do not lift or support on engine oil pan.
F*R/FVM/FVZ/GVR models
MFW80ASH000101
FSS model
Legend
1. Front axle
2. Rear axle center
3. Side member front side
4. Side member rear side
MFW70ASH000201
MFU770SH015801
0A-18 General Information
FTS model
Lifting Point Positions - Rear side
CAUTION:
Do not lift or support on rear axle tube.
FRR/FSR/FTR/FVR/GVR models (with leaf spring suspension), FSS/FTS models (except rear single­tire model)
MFU8Z0SH025501
MFW80ASH000201
FSS/FTS models (rear single-tire model)
FRR/FSR models (with air suspension)
MFU9Z0SH015301
MFU770SH002801
General Information 0A-19
NOTE:
Let the tire run over a piece of block, etc., and apply the jack.
FTS model(rear single-tire model)
MFU9Z0SH015401
FVR/FVM/FVZ/GVR models (with air suspension, except Europe)
FVR model (with air suspension, for Europe)
MFU8Z0SH077401
FVM/FVZ models (with leaf spring suspension)
MFU8Z0SH037501
MFW80ASH000301
0A-20 General Information

Caution for The Maintenance of Electrical Parts

Battery Cable

Disconnecting the battery cables
1. Turn all the switches "OFF".
2. Disconnect the battery ground cable (1).
3. Disconnect the battery plus cable (3).
4. Disconnect the battery cable (2).
CAUTION:
Make sure to disconnect the battery ground cable first. Disconnecting the plus cable first may cause a short circuit.
3
1
2
MFW70ASH000401
Connecting the battery cables
Connect the battery cables in the reverse order of the disconnection procedure.
CAUTION:
Clean the area surrounding the battery terminal, and apply a thin layer of grease to the terminal to prevent corrosion.
• Check that no foreign material or water has entered the inside of the connectors. Remove any foreign material or water that has entered the connector using an air brush, etc. If the material cannot be removed, replace them.
• Check that no foreign material is stuck to the terminals, and there is no corrosion or deformation. Remove any foreign material by cleaning with an air brush, or clean rag, etc. If the material cannot be removed by cleaning, or there is corrosion or deformation, replace them.
• Gently pull the wires to check that no terminals are missing from the connector and there is no breakage in the terminal area. If a terminal is missing, reinsert it until it locks into place. If you find a disconnection, replace them.
• Insert the male connector into the same female connector, and check that there is no abnormality in the terminal contact pressure. If you find an abnormality, replace them.
• For waterproof connectors, check that there is no damage or foreign material stuck to the seal parts (wire seal of wiring, O-ring or waterproofing seal of connector, etc.) or seal area of the connector housing. Remove any foreign material by cleaning with an air brush, or clean rag, etc. If the material cannot be removed by cleaning, or there is damage, replace them.
CAUTION:
• Do not perform polishing that would remove the plating of the terminals, nor wash the inside of the connector. If there is dirt that requires washing, replace them.
• Be careful when attaching the seal areas of waterproof connectors, as some have specific positions and directions they must be attached. Also do not attach them in a twisted state.

Connector Handling Requirements

Visual inspection
With the male and female connectors connected
• Gently pull the connector and check whether the connector becomes disconnected or partially disconnected, and that the lock is properly set. If a problem is found, reconnect the connectors.
• Check that there is no damage to the connector housing. If a problem is found, perform replacement.
With the male and female connectors disconnected
Regarding vehicle washing
Even for electric parts that are installed outside the cab and are waterproofed, try to avoid exposing them directly to high pressure water when washing the vehicle (cover them with plastic sheets, etc.) as much as possible.
General Information 0A-21
Disconnecting the connector
Many connectors have a lock to ensure secure connections. The two types of locks generally used are those that open by lifting the release area of the lock (1), and those that open by pressing the release area (2). Before disconnecting the connector, determine in advance which type of lock the connector is using.
1
2
Connecting the connector
Securely grasp the female side and male side of the connector, and align them correctly. Firmly push them together until both sides click into place.
OK
NO
LNW20ASH001401
LNW20ASH001201
When disconnecting the connector, first securely grasp the male side and female side of the connector. Release the lock, and carefully disconnect the connector. Do not pull the harness when disconnecting the connector, as this may cause wires to come out or break.
OK
NO
Connector circuit inspection requirements
Check the continuity of the connector using a circuit tester. Insert the probes (1) of the tester from the harness side of the connector, as indicated in the diagram.
OK
1
LNW20ASH001501
LNW20ASH001301
0A-22 General Information
Never insert the probes (1) from the connection closure area of the connector, as this will cause the connector terminals to break.
NO
1
LNW20ASH001601
Inspection requirements for waterproof connector circuit
For waterproof connectors, the probes of the tester cannot be inserted from the wiring side, due to the structure of the connectors. Therefore, perform the continuity inspection as indicated in the diagram, by connecting a testing connector (1) prepared in advance to the connector (2) to test, and connect the probes (3) of the tester to the harness of the testing connector.
2. Push the lock (2) up in the direction of the arrow using the metal rod to release the lock. In that state, pull out the harness (3) together with the terminal (4).
1
5
2
4
LNW20ASH001801
3
—Terminal lock type
1. Insert a metal rod (1) from the connector closure area (5).
2. As indicated in the diagram, release the terminal lock (2) by pushing it to the harness side, pull out the harness (3) together with the terminal (4).
1
2
3
LNW20ASH001701
Disconnecting connector terminals
—Built-in lock type
1. As indicated in the diagram, insert a thin screwdriver-shaped metal rod (1) from the connector closure area (5).
1
2
3
45
LNW20ASH001901
Connecting connector terminals
1. Check that the terminal lock (1) area is raised fully and can be locked.
2. Insert the terminal (3) from the harness (2) side of the connector, and push it in until the lock area clicks.
General Information 0A-23
3. Gently pull the harness and check whether the terminal is completely locked inside the connector.
1
2
3
LNW20ASH002001
Replacing the fuse
WARNING:
If a fuse melts down, make sure to replace it with a non­defective fuse of the same capacity, after identifying the cause of the melt down. If you use a fuse with high capacity, the fuse will not perform its function when excess current flows. This may cause parts or wires, etc. to burn, and can result in a vehicle fire.

Handling Electronic Parts

Handle electronic parts with sufficient care, and do not damage the parts by dropping or throwing them.
LNW20ASH002201

Cable Harness

1. When installing electronic parts, take care to ensure the harness does not get stuck and do not forcibly push the harness in.
30A 60A
10
15
LNW20ASH002101
LNW20ASH002301
2. Make sure that all connections are clean and secure.
0A-24 General Information
3. When the harness will be contacting sharp edges or surfaces of other parts, protect the harness using a grommet or tube to prevent damage due to the contact.
NO
OK
LNW20ASH002401
4. When wiring the harness by diverting it around other parts, give the harness a sufficient amount of free length, and use a protective tube (2) and clip (1) to ensure it does not contact surrounding parts.
5. For wiring between the engine and chassis, give the wiring sufficient free length to prevent wear and damage caused by vibrations.
NO
OK
LNW20ASH002601
OK
NO
1
2
LNW20ASH002501

Regarding The Scan Tool

Trouble Diagnosis Using The Scan Tool

Regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 /CAN-di module
This tool is effective for diagnosing electrical failures in electronic control units and performing system checks. If you connect the Tech2 to the DLC installed in the vehicle, it performs communication with the control units of the vehicle, and enables various diagnoses and tests to be performed.
1
General Information 0A-25
2
Legend
1. PCMCIA card (dedicated)
2. Tech2 (body)
3
HCW35ALF001301
3. DLC cable
0A-26 General Information
Legend
1. Tech2 24V adaptor 2 (body)
2. Signal change switch
[Euro4 specification]
1 2
4
3
LNW7Z0SF000101
3. Tech2 connecting cable
4. DLC connecting cable
3
Legend
1. CAN-di module (body)
2. Tech2 connecting cable
Features and cautions regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 / CAN-di module [Euro4 specification]
• The Tech2 has a 12 V power system. Do not directly use 24 V power. Do not directly supply power from the cigar lighter.
• Remove/install the PCMCIA card after turning the power off.
• The Tech2 has the capacity for two snapshots.
• As the PCMCIA card is sensitive to magnetism and static electricity, take care when handling it.
1
2
LNW7Z0SF000401
3. DLC connecting cable
• The Tech2 is able to draw graphs of snapshots.
• To select a menu, press the selection key or choose a menu with a function key and press the ENTER key.
• You can return to the main menu at any time by pressing the EXIT key.
• To clear the diagnostic trouble codes (DTC), open the application menu and select "Clear DTC Information".
• The Tech2 adaptor 2 has a built-in DC to DC converter (that converts 24 V to 12 V).
General Information 0A-27
• The Tech2 adaptor 2 has a selector for switching signals (the signals for each electronic control unit (ECU)).
Parts of the Tech2
13
14
• The CAN-di module has a built-in signal converter (that converts CAN serial data to keyword serial data)
1
2
4
8
3
3
15
16
7
Legend
1. Soft key
2. Selection key (arrow key)
3. Action keys (YES, NO, ENTER, EXIT)
4. Function key (F0 – F9)
5. Help key (?)
6. Control key (PWR or SHIFT)
7. Wide stand
8. Display (liquid crystal display)
9. Vehicle communication interface (VCI) Module
1. Soft keys When operating the Tech2, the selection box is displayed on the top of the screen. The soft keys correspond to that selection box. The soft keys cannot be used unless the selection box is
56
12
11
9
10
HCW35ALF001401
10. VCI module fastening bar
11. DLC cable connecting connector
12. AC adaptor connector
13. PCMCIA card insertion opening (with cover)
14. PCMCIA card release (removal) button
15. Connector for external communication (RS-485 port)
16. Connector for external communication (RS-232 port)
displayed on the screen.
2. Selection key (arrow key) Selects menu items on the Tech2 screen, and switches the display. The highlighted area of the screen display indicates what is being selected.
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