ISUZU Giga Service Manual

2008-2011MY

WORKSHOP MANUAL

GENERAL INFORMATION

This Workshop Manual deals only with the screen toned section(s) in the table below.

	Section		Sub Section
0	GENERAL INFORMATION	0A	General Information
1	ENGINE	1A	Engine Control System
		1B	Engine Mechanical
		1C	Engine Cooling
		1D	Engine Fuel
		1E	Engine Electrical
		1F	Emission Control
		1G	Engine Exhaust
		1H	Engine Lubrication
		1I	Engine Speed Control System
		1J	Induction
		1K	Pre-Heating System
		1L	Power Take-Off (PTO)
2	SUSPENSION	2A1	Air Suspension Control System
		2B	Front Suspension
		2C	Rear Suspension
		2D	Wheel and Tire System
3	DRIVELINE/AXLE	3A1	Front Differential
		3A2	Rear Differential
		3C1	Propeller Shaft
		3C2	Front Axle
		3C3	Rear Axle
		3D	Transfer Case
4	BRAKES	4A2	Brake Control System (Air Over)
		4A3	Brake Control System (Full Air)
		4B2	Brake (Air Over)
		4B3	Brake (Full Air)
		4C	Anti-Lock Brake (ABS)
		4C1	Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
		4D	Parking Brake
		4E	Hill Start Aid (HSA)
		4F	Speed Retarder System
		4G	Trailer Brake
5	TRANSMISSION/TRANSAXLE	5A	Transmission Control System
		5B	Automatic Transmission
		5C	Manual Transmission
		5E	Clutch
		5G	Power Take-Off (PTO)
		5G1	Side Power Take-Off
6	STEERING	6B	Power Steering
7	HVAC	7A	Heating and Ventilation
		7B	Manual Air Conditioning
		7C	Automatic Air Conditioning
8	RESTRAINTS	8A	Seat Belt
		8B	Supplemental Restraint System (SRS)
		8C	SRS Control System
9	BODY, CAB AND ACCESSORIES	9A	Lighting System
		9B	Wiper/Washer System
		9C	Entertainment
		9D	Wiring System
		9E	Instrumentation/Driver Info.
		9F	Body Structure
		9G	Cab
		9H	Seats
		9I	Security and Lock
		9K	Exterior/Interior Trim
		9L	Cab Mounting
10	CONTROL SYSTEMS	10B	Vehicle Control
11	FRAME AND FRAME ACCESSORIES	11A	Frame

General Information 0A-1

GENERAL INFORMATION

General Information

TABLE OF CONTENTS

General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 General Repair Instructions . . . . . . . . . . . . . . . 0A-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3

Chassis Number/Engine Number Stamping

Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Option Code List . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Vehicle Identification Number (VIN) . . . . . . . . 0A-11 General Precaution . . . . . . . . . . . . . . . . . . . . . . 0A-15 General Precautions . . . . . . . . . . . . . . . . . . . . 0A-15 Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . 0A-17 Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . 0A-17 Caution for The Maintenance of Electrical Parts 0A-20 Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-20 Connector Handling Requirements . . . . . . . . . 0A-20 Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-23 Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-23 Regarding The Scan Tool. . . . . . . . . . . . . . . . . . 0A-25 Trouble Diagnosis Using The Scan Tool . . . . . 0A-25 Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-31 Recommended Liquid Gasket. . . . . . . . . . . . . 0A-31 Recommended Thread Locking Agent. . . . . . . . 0A-33 Recommended Thread Locking Agent . . . . . . 0A-33 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-34 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-34

Maintenance Schedule

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

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

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

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

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

Recommended Fluids, Lubricants and

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

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

models), Transfer Case, Differential

(without LSD) and Oil Lubricated Hub

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

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

Grease Lubricated Hub, Water Pump,

Propeller Shaft Sliding Yoke, Universal

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

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

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

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

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

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

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

Grease Lubricated Hub, Water Pump,

Propeller Shaft Sliding Yoke, Universal

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

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

0A-2 General Information

General Information

General Repair Instructions

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

2.Use covers on the vehicle body, seats, and floor to prevent damage and/or contaminations.

3.Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to shortcircuiting.

4.Raise the vehicle with a jack set against the axle or the frame.

5.Support the vehicle on chassis stands.

6.Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.

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

8.Always use genuine ISUZU replacement parts.

9.Discard used cotter pins, gasket, O-rings, oil seals, lock washers, and self-locking nuts at disassembly. Normal function of these parts cannot be guaranteed if they are reused.

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

11.Keep fixing nuts and bolts separate.

Fixing nuts and bolts vary in hardness and design according to installation positions.

12.Clean all parts before inspection or reassembly.

13.Clean the oil ports and other openings with compressed air to make certain that they are free of dirt and obstructions.

14.Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.

15.Use the recommended liquid gasket to prevent leakage.

16.Be sure to tighten nuts and bolts to the specified torque, using a properly maintained torque wrench.

17.When service operation is completed, male a final check to be sure service has been done properly and problem has been corrected.

18.When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be sure to use the ACR4 or equivalent to recover and recycle Refrigerant - 134a (HFC-134a), to promote the movement for the protection of the ozone layer covering the earth.

19.To assure safety, always slowly release air pressure from the air tanks before disconnecting pipes, hoses or other parts from any unit under pressure.

20.Prior to start the welding work, the following operations are required:

•Disconnect all connectors of electronic control unit.

•Disconnect battery ground terminal.

•Welding machine ground cable must be connected near the welding point.

•Turn off the all switches.

General Information 0A-3

Identification

Chassis Number/Engine Number Stamping Position

Chassis number

It is stamped on the front right-hand side face of the chassis side member.

MFW70ASH000101

Engine number (4HK1 Engine)

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

LNWB0ASH000101

Engine number (6HF1 Engine)

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

1

MFW90ASH000101

Engine number (6HK1 Engine)

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

MFW80ASH000401

Service Parts ID Plate

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

The service parts ID plate has the following information;

•Vehicle identification number (VIN)

•Wheelbase dimensions

•Paint information

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

0A-4 General Information

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

MFU8Z0SH043301

Option Code List

	Option	Option Description
	Code
	AJ3	Driver side air bag
	AK3	Front seat belt & shoulder
		with retractor
	AK5	Driver and passenger side air bag
	AU4	Automatic door lock
	A31	Power window - front & rear door
	A32	Power window - front door
	A56	Driver seat - air suspension
	A83	Vinyl seat with reclining
	BDM	Power take off - transmission rear
	BFK	Transfer TF56
	BHW	Power take off - engine rear,
		electromagnetic clutch
	BJR	Brake adjuster - manual
	B02	South Africa equipment
	B03	Thailand equipment
	B04	Taiwan equipment
	B1S	Parking brake drum - 8.5 inch
	B1T	Parking brake drum - 10 inch
	B10	Malaysia equipment
	B12	Russia equipment
	B13	Australia equipment

	Option	Option Description
	Code
	B14	Hong Kong equipment
	B3A	Rear wheel parking brake - air
		control
	B30	Floor carpet - vinyl
	B84	Body side molding
	CB7	Colombia equipment
	CE4	Head lamp washer
	CGA	Morocco equipment
	CJ6	Country - Ireland
	CK1	Pakistan equipment
	CL1	Kenya equipment
	CT6	Country - Italy
	CU9	Country - United Kingdom
	CV4	Country - Israel
	CX6	Country - New Zealand
	C13	Wiper with intermittent
	C2C	Transmission oil cooler
	C2M	Propeller shaft - P60 type
	C3N	Final differential lock
	C3U	Air suspension - high control
	C4M	Air breather with flex hose
	C4Z	Propeller shaft - P46 type
	C41	Heater & defroster
	C5K	Hub lubrication - oil bath
	C5T	Propeller shaft - P90 type
	C60	Manual air conditioning
	C65	Manual air conditioning
		without heater core
	C68	Automatic air conditioning
	DH2	O/S rear view mirror - long arm
	DL8	O/S rear view mirror - remote control
		with heated
	DNB	O/S rear view mirror - pillar mounted
	D20	Assist side sun visor
	D31	Rear view mirror
	D37	Mirror - Outside rear view
	D6M	User - export government
	D8T	Iran equipment
	D94	Touch-up paint

General Information 0A-5

	Option	Option Description
	Code
	EAK	Disc wheel - 6 studs 19.5x6.75
		(136-12)
	EBB	Digital tachograph
	EBE	Front under run protector
	ECF	Speed limiter - 60km/h
	ECY	Speed limiter - 70km/h
	EDG	Header console - driver & assist
	EDH	Round curtain rail
	EDW	Speed limiter - 80km/h
	EDX	Speed limiter - 85km/h
	EFE	Regulation ECE R29
	EFK	Floor mat - vinyl mat Var.2
	E09	Europe equipment
	E11	Mexico equipment
	E13	New Zealand equipment
	E2N	Fuel pipe - steel
	E29	Auxiliary steps
	E40	Sleeper cab with mattress
	E46	Ecuador equipment
	FJC	Disc wheel - 10 studs 20x8.50V
		(138-13)
	F59	Front stabilizer
	GH3	Saudi Arabia equipment
	GL6	Rear shock absorber
	GN1	Rear stabilizer
	G86	Limited slip differential - no spin
	JAQ	Lighting system - Saudi Arabia
	JBF	Tire - KD special
	JBZ	Lighting system - Japanese standard
	JCA	Anti-noise equipment - ECE R51.02
	JDN	Compartment - I/P assist side with lid
	JDP	Compartment - I/P assist side without lid
	JE5	Anti-lock brake system
	J55	Brake system - heavy duty Var.1
	J91	Trailer brake control
	KC5	Receptacle - accessory
	KE1	Chile equipment
	KF0	Fuel filter - low quality
	KG2	Generator 24V60A

	Option	Option Description
	Code
	K30	Auto cruise
	K44	Generator 24V-90A
	K89	Generator 24V-50A
	M9A	Owners manual - Not required
	NCR	Memory system - Runnig condition
	NF7	Fuel tank 200L + 200L
	NJW	Ireland KD special
	NMJ	Speed limiter - 90km/h
	NMU	Speed limiter - 100km/h
	NNR	3 speaker system
	NT2	Emission system - Euro2
	NT3	Emission system - Euro3
	NT4	Emission system - Euro4
	N02	Fuel tank 100L - frame side mount
	N05	Fuel tank cap with key lock
	N19	Fuel tank - 140L frame side
	N20	Fuel tank 200L - frame side mount
	N79	Spare disc wheel
	PM1	Rear hook - double
	PP7	Pintle hook
	PR2	Driving position - wide leg space
	PS7	Air dryer
	PT1	Disc wheel - 8 studs 22.5x6.75
		(145-11)
	PT6	Thailand KD special
	P10	Spare tire carrier - frame rear mount
	P13	Spare tire carrier - frame side mount
	P38	Tire delete
	QM8	Disc wheel - 10 studs 22.5 x 8.25
		(165-13)
	Q47	Disc wheel - 8 studs 20x6.50T
		(145-10)
	Q87	Disc wheel - 10 studs 22.5x7.50
		(162-12)
	Q5T	Turbo - conventional
	Q50	Disc wheel - 8 studs 20x6.50T
		(152-11)
	Q54	Disc wheel - 8 studs 20x7.00T
		(162-12)
	Q58	Disc wheel - 10 studs 20x7.00T

0A-6 General Information

	Option	Option Description
	Code
	Q62	Disc wheel - 8 studs 20x7.50V
		(165-13)
	Q64	Disc wheel - 10 studs 20 x 7.50V
	Q87	Disc wheel - 10 studs 22.5x7.50
		(162-12)
	RC4	Dump control lever
	RC5	Tool box with key lock
	RE3	Spare tire fixing
	RE9	Clutch - 15 inch single plate
		strap drive
	RDV	4HK1-TCC engine
	RJS	4HK1-TCS engine
	RQZ	G.V.W. - 8.0-11.0 ton
	RRA	G.V.W. - 11.0-14.0 ton
	RR9	O/S rear view mirror - under
	RSA	Manual transmission - MZZ6W
	RSW	Manual transmission - MZX6P
	RSZ	Manual transmission - MZW6P
	RWE	Chevrolet brand
	R32	KD frame
	R46	Spare tire & disc wheel
	R9A	Service cab with electric
	R9B	Service cab without electric
	R9C	Deletion - service cab with electric
	R9D	Deletion - service cab without electric
	R9E	Service cab conversion with electric
	R9F	Deletion - service cab conversion
		without electric
	R9Z	Thailand localization spec.
	SAQ	Front suspension - multi leaf spring
	SAR	Front suspension - taper leaf spring
	SAS	Rear suspension - multi leaf spring
	SAU	Rear helper suspension - taper leaf
		spring
	SAY	Standard cab
	SAZ	Ventilator & defroster
	SBB	Disc wheel - 8 studs 20x6.00S
		(135-10)
	SBG	Disc wheel - 6 studs 17.5x6.00
		(135-9)

	Option	Option Description
	Code
	SDF	Room lamp with all door switch
	SDH	Fuel tank 400L
	SDK	Cab suspension - semi floating type
	SDP	Disc wheel - 8 studs 20x7.00T
		(152-12)
	SEG	Disc wheel - 8 studs 205x7.50V
		(130-13)
	SFC	Disc wheel - 6 studs 17.5x6.75
		(137-10)
	SFT	Electric outlet - one
	SGA	Front under spoiler delete
	SGX	Vietnam equipment
	SG4	Tire inflator device
	SG7	Disc wheel - 6 studs 16x6.00GS
		(135-9)
	SH5	Power take off - transmission side
		without lever
	SJA	Driver seat - Isringhausen
	SKU	Disc wheel - 8 studs 22.5x7.50
		(162-13)
	SKV	Disc wheel - 8 studs 22.5 x 8.25
		(165-13)
	SK4	Engine overrun buzzer
	SLB	Front bumper with headlamp
	SLC	Lighting system - ECE
	SLK	Anti-noise equipment - ECE
	SMS	Rear bumper - steel wide
	SP9	Assist seat without center seat
	SR6	Rearward double tire
	SV6	Power take off control
	SY8	Spare tire carrier - lifting type
	TAF	O/S rear view mirror - under & side
		under
	TAK	Anti-noise equipment - Var.2
	TAZ	Driver seat - rigid without arm rest
	TDU	Brake regulation - ADR
	TDV	Brake regulation - ECE
	TEC	Roof marker lamp
	TEE	Disc wheel - 8 studs 19.5x6.75
		(147-12)
	TFD	Cab all painting

General Information 0A-7

	Option	Option Description
	Code
	TFN	Driver’s seat belt with pre-tension
		reducer
	TGL	Anti corrosion package
	TM1	Battery - 80D26L
	TR6	Headlamp leveling system - manual
	TR7	Headlamp leveling system - automatic
	TT5	Halogen headlamp
	TT6	High intensity discharge headlamp
	T1A	Injection pump Q set - special
		+5%Q
	T62	Battery - dry
	T64	Battery delete
	T79	Rear fog lamp
	T87	Cornering lamp
	T96	Front fog lamp
	UC1	Speedometer - miles per hour (MPH)
	UC9	TachographKienzle
	UF3	Map lamp
	UG3	Engine oil temperature gauge
	UL5	Radio delete
	UT3	AM/FM radio with CD player
	U01	Roof marker - 5 lamps
	U18	Speedometer - kilometer
	U69	AM/FM radio
	U95	2 speaker system
	VG7	Front bumper reinforcement
		- heavy duty
	VP1	Front under spoiler
	VR7	Two eye rear hook
	VTK	Owners manual - Arabic language
	VTL	Owners manual - French language
	VTS	Owners manual - Spanish language
	VT7	Owners manual - English language
	VZA	VIN model year - 2010
	VZB	VIN model year - 2011
	V22	Radiator grille - chrome
	V4F	Chassis for fire car
	V76	Hook - tow
	WB7	Electrical horn

	Option	Option Description
	Code
	WC7	Tachograph - 140km/h
	WF6	Clutch - 14 inch single plate
		strap drive
	WG3	Brake system - heavy duty Var.2
	WH2	Spare tire - front tire
	WJ7	Cautions - Arabian
	WJ8	Cautions - French
	WL5	Inspection lamp
	WM3	Interior trim - full trimming
	WV2	Automatic cab tilt
	WX8	Shift control - assister
	W02	Highland zone package
	W1G	Final drive gear ratio - 6.143 (43/7)
		14.5 inch hypoid
	W1H	Final drive gear ratio - 5.571 (39/7)
		14.5 inch hypoid
	W1J	Final drive gear ratio - 6.500 (39/6)
		14.5 inch hypoid
	W1K	Final drive gear ratio - 6.833 (41/6)
		14.5 inch hypoid
	W1L	Final drive gear ratio - 6.500 (39/6)
		16.5 inch hypoid
	W1R	Final drive gear ratio - 6.143 (43/7)
		15.5 inch hypoid
	W1T	Final drive gear ratio - 6.500 (39/6)
		15.5 inch hypoid
	W1U	Final drive gear ratio - 4.875 (39/8)
		14.5 inch hypoid
	W12	Front locking hub - manual
	W14	Deluxe cab
	W16	Cab suspension - full floating
	W18	Transfer TF36
	W20	Disc wheel special painted (white)
	W3B	Final drive gear ratio - 5.571 (39/7)
		16.5 inch hypoid
	W3D	Final drive gear ratio - 4.875 (39/8)
		18.5 inch hypoid
	W3F	Final drive gear ratio - 6.167 (37/6)
		18.5 inch hypoid
	W3G	Final drive gear ratio - 6.667 (40/6)
		18.5 inch hypoid
	W3K	Final drive gear ratio - 5.571 (39/7)
		15.5 inch hypoid

0A-8 General Information

	Option	Option Description
	Code
	W3L	Final drive gear ratio - 6.143 (43/7)
		16.5 inch hypoid
	W3M	Final drive gear ratio - 5.125 (41/8)
		18.5 inch hypoid
	W3N	Final drive gear ratio - 4.556 (41/9)
		18.5 inch hypoid
	W3P	Final drive gear ratio - 5.125 (41/8)
		16.5 inch hypoid
	W3S	Final drive gear ratio - 5.857 (41/7)
		15.5 inch hypoid
	W3U	Final drive gear ratio - 7.167 (43/6)
		17.5 inch hypoid
	W3X	Final drive gear ratio - 6.429 (45/7)
		17.5 inch hypoid
	W3Y	Final drive gear ratio - 6.143 (43/7)
		17.5 inch hypoid
	W3Z	Final drive gear ratio - 5.571 (39/7)
		17.5 inch hypoid
	W4A	Final drive gear ratio - 5.125 (41/8)
		17.5 inch hypoid
	W4B	Final drive gear ratio - 4.875 (39/8)
		17.5 inch hypoid
	W4C	Final drive gear ratio - 4.556 (41/9)
		17.5 inch hypoid
	W4F	Final drive gear ratio - 5.125 (41/8)
		14.5 inch hypoid
	W4H	Final drive gear ratio - 5.125 (41/8)
		15.5 inch hypoid
	W4T	Final drive gear ratio - 4.333 (39/9)
		18.5 inch hypoid
	W4W	Final drive gear ratio - 6.833 (41/6)
		17.5 inch hypoid
	W4X	Final drive gear ratio - 4.333 (39/9)
		14.5 inch hypoid
	W5M	Final drive gear ratio - 4.100 (41/10)
		14.5 inch hypoid
	W5V	Final drive gear ratio - 6.833 (41/6)
		16.5 inch hypoid Rockwell
	W5Z	Final drive gear ratio - 4.89 (44/9)
		18.0 inch hypoid Rockwell
	W6A	Final drive gear ratio - 5.38 (43/8)
		18.0 inch hypoid Rockwell
	W6B	Final drive gear ratio - 5.63 (45/8)
		18.0 inch hypoid Rockwell
	W6C	Final drive gear ratio - 6.14 (43/7)
		18.0 inch hypoid Rockwell

	Option	Option Description
	Code
	W6M	Final drive gear ratio - 6.43 (45/7)
		18.0 inch hypoid Rockwell
	W6N	Final drive gear ratio - 6.83 (41/6)
		18.0 inch hypoid Rockwell
	W6R	Final drive gear ratio - 4.30 (43/10)
		18.0 inch hypoid Rockwell
	W6S	Final drive gear ratio - 6.14 (43/7)
		15.0 inch hypoid Rockwell
	W66	Disc wheel with step
	W71	Cab suspension - rigid type
	W8C	Final drive gear ratio - 4.56 (41/9)
		18.0 inch hypoid Rockwell
	W8D	Final drive gear ratio - 6.43 (45/7)
		15.0 inch hypoid Rockwell
	W8F	Final drive gear ratio - 4.555 (41/9)
		14.5 inch hypoid
	W8L	Final drive gear ratio - 6.83 (41/6)
		15.0 inch hypoid Rockwell
	X5J	Manual transmission - MLD6Q
	X7W	Manual transmission - MLD6S
	X9C	Transmission - manual
	X9D	Transmission - automatic
	YC4	Injection pump - high altitude
		compensator, aneroid type
	YK3	Rearward single tire
	YM9	Reversing warning buzzer
	YN1	Caution - Spanish
	YS1	O/S rear view mirror - flat type
	YT9	Pakistan KD special
	Y2C	Manual transmission - MLD6W
	Y21	Light duty package truck
	Y3A	Manual transmission
		- Fuller FS8209
	Y3B	Automatic transmission
		- Allison MD3560P
	Y4F	Automatic transmission
		- Allison LCT2000
	Y4G	Automatic transmission
		- Allison MD3060P
	Y4V	Manual transmission
		- Fuller FSO5206B
	Y48	Heavy duty package truck
	Y5D	Manual transmission - ZF 6S1000

General Information 0A-9

	Option	Option Description
	Code
	Y5E	Manual transmission - ZF 9S1110
	Z05	Brake system - air over hydraulic
		dual circuit
	Z06	Brake system - full air dual circuit
	Z1V	Equipment - additional key
	01D	KD package - South Africa
	01R	Tire - front & rear 8.25-20-14 lug
	02E	KD package - Taiwan
	05R	Tire - front & rear 8.25R20-14 rib
	09X	Tire - front 8.25-20-14 rib,
		rear 8.25-20-14 lug
	1D7	6HF1-TCN engine
	1D9	6HF1-TCC engine
	10T	Tire - front & rear 9.00-20-14 rib
	10X	Tire - front 9.00-20-14 rib,
		rear 9.00-20-14 lug
	11X	Tire - front 10.00-20-14 rib,
		rear 10.00-20-14 lug
	12X	Tire - front 10.00-20-16 rib,
		rear 10.00-20-16 lug
	15N	Tire - front & rear 9R22.5-14 rib
	155	Interior color - Charcoal gray
	2G0	Singapore equipment
	20D	Thailand KD deletion parts
	21R	Tire - front & rear 9.00-20-14 lug
	25R	Tire - front & rear 9.00R20-14 rib
	27X	Tire - front 11.00-20-16 rib,
		rear 11.00-20-16 lug
	30T	Tire - front & rear 10.00-20-14 rib
	34W	Wheel base 3,400mm
	35N	Tire - front & rear 10R22.5-14 rib
	36W	Wheel base 3,600mm
	37W	Wheel base 3,700mm
	38W	Wheel base 3,800mm
	39W	Wheel base 3,900mm
	40S	Tire - front & rear 8.25-16-14 rib
	40T	Tire - front & rear 10.00-20-16 rib
	40W	Wheel base 4,000mm
	41R	Tire - front & rear 10.00-20-14 lug
	41W	Wheel base 4,100mm

Option	Option Description
Code
42W	Wheel base 4,200mm
43P	Tire - front & rear 9R22.5-14
43W	Wheel base 4,300mm
45N	Tire - front & rear 11R22.5-14 rib
45P	Tire - front & rear 275/70R22.5
45R	Tire - front & rear 10.00R20-14 rib
46W	Wheel base 4,600mm
48W	Wheel base 4,800mm
49W	Wheel base 4,900mm
49P	Tire - front & rear 8.25R20-14
	exp block
5D9	Tire - front & rear
	295/80R22.5-152/148K rib/lug
5E0	Tire - front & rear
	295/80R22.5-152/148J rib
5E1	Tire - front & rear 10R22.5-14
5G2	Tire - front 295/80R22.5,
	rear 11R22.5-16
5H1	Tire - front 10.00-20-16 rib,
	rear 10.00-20-16 lug
5J6	Tire - front 9.5R17.5 129/127L rib,
	rear 9.5R17.5 129/127L traction
5J7	Tire - front & rear 11R22.5 148/145L
	rib
5J8	Tire - front & rear 245/70R19.5 rib
5J9	Tire - front & rear 235/75R17.5 rib
5K0	Tire - front & rear 265/70R19.5 rib
5K4	Tire - front & rear 11R22.5 148/145K
	rib/lug
5K5	Tire - front & rear 12R22.5 152/148K
	rib/lug
5L1	Tire - front & rear 12.00R20-18
5L4	Tire - front & rear 275/70R22.5
	148/145M rib
5L7	Tire - front & rear 9.00R-20-14
	exp lug
5L8	Tire - front & rear 10.00R-20-16 lug
5N5	Tire - front & rear	265/70R19.5	140/
	138M rib (BS brand)
5N6	Tire - front & rear	235/75R17.5	132/
	130M rib (BS brand)
5P0	Tire - front & rear	235/75R17.5	132/
	130M rib (BS brand)

0A-10 General Information

	Option	Option Description
	Code
	5P1	Tire - front 295/80R22.5,
		rear 11R22.5-16 (6x2, BS brand)
	5P2	Tire - front 295/80R22.5,
		rear 11R22.5-16 (BS brand)
	5P3	Tire - front & rear 10R22.5-14
		exp rib/lug (BS brand)
	5P6	Tire - front & rear 225/70R19.5
	5P7	Tire - front & rear 8.25R16 128/126L
		exp rib/lug
	50W	Wheel base 5,000mm
	51R	Tire - front & rear 10.00-20-16 lug
	51W	Wheel base 5,100mm
	517	Body color - AL. gray
	53W	Wheel base 5,300mm
	538	Body color - Tool-IPEC yellow
	55N	Tire - front & rear 11R22.5-16 rib
	55P	Tire - front & rear 295/80R22.5
		152/148M rib
	55R	Tire - front & rear 10.00R20-16 rib
	55W	Wheel base 5,500mm
	58N	Tire - front & rear 11.00R20-16 rib
	58W	Wheel base 5,800mm
	59W	Wheel base 5,900mm
	6DY	Rear under run protector
	6EP	HSA system
	6HF	KD preparatory package
	6KK	Horn - heavy duty (dual)
	6ND	OK window
	6NF	Remote control door lock
	6PH	LSPV - Load sensing proportioning
		valve
	6SZ	Power take off - flywheel
	6UC	Fluorescent lamp
	6UH	O/S rear view mirror - assist side short
		stay
	6VE	O/S rear view mirror - door mount
	6WX	Floor mat - vinyl
	6XH	ASR system
	60W	Wheel base 6,000mm
	609	Body color - FT orange

	Option	Option Description
	Code
	61P	Tire - front & rear 225/90R17.5
	63E	KD package - Italy
	63W	Wheel base 6,300mm
	64E	KD package - Vietnam
	64N	Tire - front & rear 8.25R20-14 rib
	65W	Wheel base 6,500mm
	668	Body color - Purplish blue
	681	Body color - Geranium red
	695	Body color - Dark blue
	7BC	Assist seat with center seat
	7DM	Tuner band - Latin America
	7FL	Seat material - cloth
	7HZ	Rear bumper
	7KC	Immobilizer system
	7NY	Multi information display
	7SV	O/S rear view mirror - heated
	7TV	KD preparatory package
	70T	Tire - front & rear 11.00-20-14 rib
	71R	Tire - front & rear 11.00-20-14 lug
	71S	Tire - front & rear 7.50-20-12 lug
	71W	Wheel base 7,100mm
	729	Body color - Arc white
	736	Body color - Cardinal red
	78N	Tire - front & rear 8.25R16
	79R	Tire - front & rear 11.00R20-14
	8AA	Good quality ethylene glycol
		antifreeze 50%
	8AC	Good quality ethylene glycol
		antifreeze 30%
	8EJ	Battery - 65D23L
	8GF	Transmission with Smoother
	8GJ	Transmission without Smoother
	8JM	Diesel particulate diffuser
	8LF	Rear window glass
	8LX	Ash tray - assist side
	8MA	Battery 115E41L
	8MH	Fuel tank 370L
	8ML	O/S rear view mirror - middle arm

General Information 0A-11

	Option	Option Description
	Code
	8MV	O/S rear view mirror - extended long
		arm
	8NG	Decal - vehicle & pet name
	8NH	Decal - pet name
	8NV	Bio diesel fuel B10
	80L	6HK1-TCS engine
	80R	Tire - front & rear 11.00-20-16 rib
	800	Body color - In white
	807	Body color - Woodland green
	81L	6HK1-TCC engine
	81R	Tire - front & rear 11.00-20-16 lug
	81U	Tire - front & rear 8.25-16-14 lug
	812	Body color - Wheatland yellow
	82L	6HK1-TCN engine
	829	Body color - Sahara beige
	83N	Tire - front & rear 9.5R17.5
	84D	Colombia Var.2
	85N	Tire - front & rear 11R22.5-16
	85R	Tire - front & rear 11.00R20-16 rib
	85U	Tire - front & rear 8.25R16-14 rib
	87N	Tire - front & rear 10.00R20-14PR rib
	89N	Tire - front & rear 9.00R20-14PR rib
	89R	Tire - front & rear 11.00R20-16PR
	89T	Tire - front & rear 11.00R20-16
	890	Body color - Marine blue
	90S	Tire - front & rear 8.25-20-14 rib
	904	Body color - golden yellow
	91D	KD package - Philippine Var.2
	915	Body color - fire red
	92N	Tire - front & rear 8.25R16-14PR rib
	93N	Tire - front 12.00R20-18,
		rear 12.00R20-18 lug
	94K	Tire - front & rear 10.00R20-16
	94N	Tire - front & rear 12.00R20-16
	944	Body color - Highway orange
	95D	KD package - Ireland
	951	Body color - arc white
	97N	Tire - front 295/80R22.5,
		rear 11R22.5-16

	Option	Option Description
	Code
	982	Body color - Polar white
	989	Body color - Sunbelt green
	99D	KD package - United Kingdom
	99N	Tire - front & rear 11R22.5-16
	909	Body color - middle bronze green
	919	Body color - olive drab
	999	Body color - trans blue

Vehicle Identification Number (VIN)

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

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

0A-12 General Information

Type 1

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

1 2 3 4 5 6

MFW80ASF000201

Legend
1. World manufacturer identifier (WMI)
2.	Vehicle model code
3.	Engine code
4. Wheel base code
5.	Model year code
6.	Chassis number
1. World manufacturer identifier (WMI)					4. Wheel base code
	Code				Code
			ISUZU BRAND		H		3,201 - 3,500 mm
	JAL		Medium & Heavy Duty				(126.02 - 137.80 in)
			Incomplete Vehicle
					J		3,501 - 3,800 mm
2. Vehicle model code							(137.83 - 149.61 in)
					K		3,801 - 4,100 mm
	Code						(149.65 - 161.42 in)
	FRR		4x2 Truck FRR model
					L		4,101 - 4,400 mm
							(161.46 - 173.23 in)
	FSR		4x2 Truck FSR model
							4,401 - 4,700 mm
	FTR		4x2 Truck FTR model		M
							(173.27 - 185.04 in)
	FVR		4x2 Truck FVR model
					N		4,701 - 5,000 mm
	FVZ		6x4 Truck FVZ model
							(185.08 - 196.85 in)
	FVM		6x2 Truck FVM model
					P		5,001 - 5,300 mm
							(196.89 - 208.66 in)
	GVR		4x2 Tractor GVR model
							5,301 - 5,600 mm
	FSS		4x4 Truck FSS model		7
							(208.70 - 220.47 in)
	FTS		4x4 Truck FTS model
					R		5,601 - 5,900 mm
							(220.51 - 232.28 in)
3. Engine code
					S		5,901 - 6,200 mm
	Code
							(232.32 - 244.09 in)
	34		6HK1 Engine
					T		6,201 - 6,500 mm
	86		6HF1 Engine				(244.13 - 255.91 in)
	90		4HK1 Engine

General Information 0A-13

				5. Model year code
	Code
	U	6,501 - 6,800 mm		Code
		(255.94 - 267.72 in)
				8		2008MY
		6,801 - 7,100 mm
	V			9		2009MY
		(267.76 - 279.53 in)
				A		2010MY
	W	7,101 - 7,400 mm
				B		2011MY
		(279.57 - 291.34 in)
	Type 2

J A L		H		5		K		1		6				8		7			7 0 0 0 0 1
1	2			3		4		5		6	7		8			9	10

MFW80ASF000301

Legend				6.		Engine code
1.	World manufacturer identifier (WMI)
2.	Gross vehicle weight (GVW) and brake system			7.		Check digit
3.	Series code			8.		Model year code
4.	Line/Cab type code			9.		Plant code
5.	Chassis code			10.		Production sequential number
1. World manufacturer identifier (WMI)					3. Series code
	Code					Code
			ISUZU BRAND			5		FRR
	JAL		Medium & Heavy Duty
						6		FSR
			Incomplete Vehicle
						7		FTR, FTS, FVR
2. Gross vehicle weight (GVW) and brake system
					4. Line/Cab type code
	Code
						Code
	H		8,846 - 10,659 kg
			(19,501 - 23,500 lb)					Tilt cab,
						K		BBC = 1,726 mm (67.95 in),
			10,660 - 11,793 kg
	K							Narrow Cab
			(23,501 - 26,000 lb)
								Tilt cab,
			11,794 - 14969 kg
	M					M		BBC = 2,066 mm (81.34 in),
			(26,001 - 33,000 lb)
								Narrow Cab
			14,970 - 18,370 kg
	P							Tilt cab,
			(33,001 - 40,500 lb)
						S		BBC = 2,066 mm (81.34 in),
								Wide Cab

0A-14 General Information

5. Chassis code

Code
1	4x2, 2 Axles, 1 driving
2	4x4, 2 Axles, 1 driving
4	6x4, 3 Axles, 2 driving
6. Engine code
Code
3	6HK1-TC
6	4HK1-TC

Type 3

8. Model year code
Code
8		2008MY
9		2009MY
A		2010MY
B		2011MY

9. Plant code

Code
7	Fujisawa

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

1

2

3

4

5

6

MFWB0ASF000101

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

Code

ISUZU BRAND

3MG Medium & Heavy Duty

Incomplete Vehicle

Code
A	2010MY
B	2011MY

2. General attributes				5. Plant code
				Code
Code
				M	Mexico (IMEX)
FRR90		FRR90
FTR34		FTR34
FVR34		FVR34

General Information 0A-15

General Precaution

General Precautions

2

1

3

MFW70AMF000201

Legend

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

Work preparations

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

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

Clothing

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

Protect the vehicle.

•Make sure to use a seat cover, etc.

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

Always focus on safety

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

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

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

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

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

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

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

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

0A-16 General Information

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

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

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

Work Precaution

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

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

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

After-procedure check

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

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

General Information 0A-17

Lifting Instruction

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

3

1

2

4

MFW70ASH000201

Legend

1.Front axle

2.Rear axle center

3.Side member front side

4.Side member rear side

Lifting Point Positions - Front side

CAUTION:

Do not lift or support on engine oil pan.

F*R/FVM/FVZ/GVR models

MFW80ASH000101

FSS model

MFU770SH015801

0A-18 General Information

FTS model

MFU8Z0SH025501

Lifting Point Positions - Rear side

CAUTION:

Do not lift or support on rear axle tube.

FRR/FSR models (with air suspension)

MFU770SH002801

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

MFW80ASH000201

FSS/FTS models (rear single-tire model)

MFU9Z0SH015301

General Information 0A-19

NOTE:

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

FTS model(rear single-tire model)

MFU9Z0SH015401

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

MFU8Z0SH037501

FVR model (with air suspension, for Europe)

MFU8Z0SH077401

FVM/FVZ models (with leaf spring suspension)

MFW80ASH000301

0A-20 General Information

Caution for The Maintenance of Electrical Parts

Battery Cable

Disconnecting the battery cables

1.Turn all the switches "OFF".

2.Disconnect the battery ground cable (1).

3.Disconnect the battery plus cable (3).

4.Disconnect the battery cable (2).

CAUTION:

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

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.

Connector Handling Requirements

Visual inspection

With the male and female connectors connected

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

If a problem is found, reconnect the connectors.

•Check that there is no damage to the connector

housing.

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

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

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

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

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

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

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

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

If you find an abnormality, replace them.

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

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

CAUTION:

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

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

Regarding vehicle washing

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

General Information 0A-21

Disconnecting the connector

Many connectors have a lock to ensure secure connections.

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

12

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

LNW20ASH001301

Connecting the connector

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

Firmly push them together until both sides click into place.

OK

NO

LNW20ASH001401

Connector circuit inspection requirements

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

OK

1

LNW20ASH001501

0A-22 General Information

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

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.

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).

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

1	2
5	4	3
		LNW20ASH001801

—Terminal lock type

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

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

1

2

3

54

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.

30A

60A

10

15

LNW20ASH002101

Handling Electronic Parts

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

LNW20ASH002201

Cable Harness

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

LNW20ASH002301

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

0A-24 General Information

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

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.

	NO
1	2
OK
	LNW20ASH002501

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

General Information 0A-25

Regarding The Scan Tool

Trouble Diagnosis Using The Scan Tool

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

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

1

2

3

HCW35ALF001301

Legend

1. PCMCIA card (dedicated) 3. DLC cable

2. Tech2 (body)

0A-26 General Information

12

4

3

LNW7Z0SF000101

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

[Euro4 specification]

1

2

3

LNW7Z0SF000401

Legend

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

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

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

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

•The Tech2 has the capacity for two snapshots.

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

•The Tech2 is able to draw graphs of snapshots.

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

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

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

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

General Information 0A-27

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

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

Parts of the Tech2

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

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

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