Isuzu Q Series Manual
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Isuzu Q Series Manual

Isuzu Q Series Manual

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We would like to take this opportunity to thank you for choosing an Isuzu product and assure you of our
continuing interest in your motoring pleasure and satisfaction.
This manual has been prepared to acquaint you with the operation and maintenance of your Isuzu vehicle, and
to provide important safety information. We urge you to read it carefully and follow the recommendations to help
assure the most enjoyable and trouble-free operation of your vehicle.
When it comes to service, remember that your Isuzu dealer knows your vehicle best and is interested in your
complete satisfaction.
This manual should be considered a permanent part of the vehicle, and must remain with the vehicle at time of
resale.
Cautionary statements
1. Statements concerning the possibility of personal injury are titled "WARNING" and appear within a
shaded block.
2. Statements concerning the possibility of mechanical damage to the vehicle are titled "CAUTION".
3. Other information which needs to be emphasized but which does not concern the possibility of
personal injury or mechanical damage is titled "NOTE".
4.
This symbol means "Do not", "Do not do this" or "Do not let this happen".
All information, illustrations and specifications contained in this manual are based on the latest product
information available at the time of publication. The right is reserved to make changes at any time
without notice.
Due to differences in vehicle specifications, the illustration used for description may not match your
vehicle.
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QKR-IE-1442̲4805234̲ALL.indb   i
FOREWORD
Isuzu Motors Limited
Tokyo, Japan
2017/09/27   13:34:35
2017/09/27   13:34:35

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  • Page 1 FOREWORD We would like to take this opportunity to thank you for choosing an Isuzu product and assure you of our continuing interest in your motoring pleasure and satisfaction. This manual has been prepared to acquaint you with the operation and maintenance of your Isuzu vehicle, and to provide important safety information.
  • Page 2 .......... 4JB1-TC engine model only..........4JH1-TC engine models only..........Turbo charged engine model only. All rights reserved. This material may not be reproduced or copied, in whole or in part, without permission in writing from Isuzu Motors Limited. QKR-IE-1442̲4805234̲ALL.indb   ii QKR-IE-1442̲4805234̲ALL.indb   ii 2017/09/27   13:34:36 2017/09/27   13:34:36...
  • Page 3 TABLE OF CONTENTS IMPORTANT INFORMATION CONTROLS AND INSTRUMENTS BEFORE DRIVING YOUR VEHICLE DRIVING SERVICE AND MAINTENANCE MAIN DATA AND SPECIFICATIONS QKR-IE-1442̲4805234̲ALL.indb   iii QKR-IE-1442̲4805234̲ALL.indb   iii 2017/09/27   13:34:36 2017/09/27   13:34:36...
  • Page 4 QKR-IE-1442̲4805234̲ALL.indb   iv QKR-IE-1442̲4805234̲ALL.indb   iv 2017/09/27   13:34:36 2017/09/27   13:34:36...

  • Page 5: Table Of Contents

    ........1–19 It is advisable to record the chassis and engine number as they are required when contacting your Isuzu dealer for repair The following information is important for services. proper care and economical operation of...

  • Page 6: Correct Cargo Loading

    IMPORTANT INFORMATION WARNING Overloading not only shortens the service life of your vehicle, but also creates serious potential safety hazards. The weight of the payload must be limited within the GVM rating and distributed over the front and rear axles so as not to exceed the axle capacities.
  • Page 7 IMPORTANT INFORMATION Never apply unnecessarily large force. When loading with a heavy cargo: Keep flammable materials away from the gap between the cab and the guard Fix the load securely using a load cover or In case of heavyweight cargo, use pads frame.
  • Page 8 NOTE When loading farming equipment, a device for securing the cargo bed is required. Use a car carrier or attach a rear support stand. If you have any questions, contact an Isuzu dealer. - 1–4 - QKR-IE-1442̲4805234̲ALL.indb   1‒4 QKR-IE-1442̲4805234̲ALL.indb   1‒4 2017/09/27   13:34:37 2017/09/27   13:34:37...
  • Page 9 IMPORTANT INFORMATION NO GOOD NO GOOD NO GOOD GOOD GOOD GOOD When using supports under a load, Place supports underneath when carrying Secure the load with a load cover and distribute them evenly. an extra-long item. Do not support it with rope to prevent it from falling.

  • Page 10: Operation Of New Vehicle

    IMPORTANT INFORMATION NO GOOD GOOD Avoid high loading. Without tachometer: OPERATION OF NEW VEHICLE Minimize the height to prevent the vehicle The shift speed label is attached to the The subsequent performance and the from rolling due to crosswind or when inside of the driver's door.

  • Page 11: Operation And Care Of Vehicle

    3. Always let the engine idle until it adjustments should be performed as becomes thoroughly warmed up. outlined in the "SERVICE AND MAINTENANCE" section. Your Isuzu dealer is trained to perform regular maintenance operation on your vehicle. WARNING When performing work on the electrical system, begin by turning the starter switch to the "LOCK"...

  • Page 12: Before Driving

    IMPORTANT INFORMATION WARNING (Continued) NOTE from the negative terminal on The specification of fuel varies battery. If the negative cable is depending on seasons and regions. disconnected within 1 minute, the Do not bring fuel containers, spray engine control module may cans, etc.
  • Page 13 IMPORTANT INFORMATION Do not keep the engine running Check around the rear of the vehicle Choose your footwear suitable for indoors before starting the engine driving WARNING WARNING CAUTION In a place with poor ventilation, Check for flammable materials Choose footwear that ensures proper carbon monoxide poisoning may around the rear of the vehicle operation of pedals when driving the...
  • Page 14 IMPORTANT INFORMATION Starting engine on the vehicle Grip • Getting in or out of the vehicle with oily or greasy hands or CAUTION shoes could cause you to slip. Always thoroughly clean grease • Before starting the engine on the etc.
  • Page 15 IMPORTANT INFORMATION Advice on seat adjustment a Adjust the seat so that you can move the steering wheel easily with your arms bent slightly. b Keep your shoulders on the seat-back. c You can depress each pedal fully. Precautions for wearing seat belts Why? A Be sure to wear the lap belt as low on Because it is dangerous in case that...

  • Page 16: When The Vehicle Runs

    IMPORTANT INFORMATION Pulling away in a manual transmission • If the starter switch is turned to the model "LOCK" position, the key may be LOCK removed. This locks the steering CAUTION wheel, therefore it is dangerous that you cannot turn the steering wheel. Pull away gently in first gear.
  • Page 17 Action to be taken when tires get flat Braking performance after passing nearest Isuzu dealer to have the or burst puddles and washing the vehicle engine, electric parts, transmission, Do not panic.
  • Page 18 IMPORTANT INFORMATION Proper shifting When going down a slope • When going down a slope, normally Downshifting has two main purposes. use the same gear that was used for • To provide the engine brake while going up that slope. However, drive the going down a steep or long slope.
  • Page 19 IMPORTANT INFORMATION NOTE Vapor lock Frequent use of the foot brake makes the brake system overheat, and the brake fluid boils due to this heat, then air bubbles form in the brake hose. In zone this case, the hydraulic pressure is not transmitted to the wheel cylinders though the brake is depressed because only air bubbles are...
  • Page 20 (if equipped) or engine brake or repaired at Isuzu dealer as soon as • When passing through an exit of may cause the vehicle to skid.) Drive possible.

  • Page 21: When Stopping / Parking The Vehicle

    IMPORTANT INFORMATION Run the engine whenever you move • Be careful that the engine may the vehicle overheat, or a fire may occur due to overheating of engine or CAUTION exhaust pipe if you unintentionally keep depressing Turning the steering wheel will be the accelerator pedal.
  • Page 22 IMPORTANT INFORMATION When leaving the vehicle Always apply the parking brake firmly, stop the engine, remove the key from the starter switch, and lock the doors to prevent theft or mischief. Do not leave any valuables on the place visible from outside of the vehicle.

  • Page 23: To Avoid Damage To The Vehicle

    IMPORTANT INFORMATION Do not drive with your foot resting on Never keep the steering wheel turned TO AVOID DAMAGE TO THE the clutch pedal fully for a long period VEHICLE This causes a half-clutch condition Do not mount any accessories on the unintentionally.
  • Page 24 IMPORTANT INFORMATION Do not stand on the engine Engine compartment is the heart of the vehicle. Do not put your foot or stand on the engine. This may cause failure such as damage to the head cover or connectors. Keep engine oil clean The engine oil has the following important functions.
  • Page 25 CONTROLS AND INSTRUMENTS CONTROLS AND INSTRUMENTS • Meters and indicator lights ..2–3 • Steering column controls ..2–14 • Instrument cluster ...... 2–19 • Floor controls ......2–22 • Others .......... 2–24 1 Combination switch lever 2 Meter panel ventilators Front fog light switch 4 Meter and Indicator light panel 5 Steering wheel...
  • Page 26 CONTROLS AND INSTRUMENTS CONTROLS AND INSTRUMENTS Heater and defroster control panel 2 Hazard warning flasher switch 3 Meter panel ventilators 4 Windshield wiper and washer switch lever Exhaust brake switch lever 5 Horn button 6 Steering wheel 7 Meter and Indicator light panel Front fog light switch 9 Combination switch lever 10 Idling control knob...
  • Page 27 CONTROLS AND INSTRUMENTS METERS AND INDICATOR LIGHTS Meter panel 1 Speedometer 2 Odometer 3 Fuel gauge 4 Temperature gauge 5 Trip meter 6 Indicator lights and warning light panel 7 Engine tachometer 8 Digital clock 9 Push button - 2–3 - QKR-IE-1442̲4805234̲ALL.indb   2‒3 QKR-IE-1442̲4805234̲ALL.indb   2‒3 2017/09/27   13:34:38...
  • Page 28 CONTROLS AND INSTRUMENTS - 2–4 - QKR-IE-1442̲4805234̲ALL.indb   2‒4 QKR-IE-1442̲4805234̲ALL.indb   2‒4 2017/09/27   13:34:38 2017/09/27   13:34:38...
  • Page 29 CONTROLS AND INSTRUMENTS Indicator and warning lights ........ SVS (Service vehicle soon) indicator light ......Turn signal indicator light ........Seat belt warning light ........High beam indicator light (for GCC model) ........Rear fog indicator light ........Fuel indicator light ........
  • Page 30 CONTROLS AND INSTRUMENTS Odometer and trip meter Odometer and trip meter Push button Push button Speedometer Change indicator and push button Digital clock The speedometer indicates the vehicle Push the button for approximately one When the key switch is turned to the speed in kilometers per hour (km/h) or second or less, and the indication will be "ACC"...
  • Page 31 CONTROLS AND INSTRUMENTS zone zone Engine tachometer Temperature gauge The engine tachometer indicates the The temperature gauge shows the engine engine speed in rpm, the red zone coolant temperature when the starter represents over-running the engine. switch is turned "ON". The letters "C" and "H"...
  • Page 32 CONTROLS AND INSTRUMENTS Fuel gauge CAUTION The fuel gauge indicates the level of fuel • If the gauge needle is beyond the in the fuel tank. When the key is turned to red line, it indicates an engine the "LOCK" position: overheating condition.
  • Page 33 CONTROLS AND INSTRUMENTS Turn signal indicator lights High beam indicator light Rear fog indicator light When the turn signal switch or hazard The high beam indicator light comes on The rear fog indicator light comes on warning flasher switch is turned on, the when the head light high beams are in when the rear fog light is in use.
  • Page 34 CONTROLS AND INSTRUMENTS Fuel indicator light Exhaust brake indicator light Parking brake indicator and Brake fluid level indicator light The fuel indicator light comes on when When the exhaust brake switch is set to the fuel in the tank is lower than at the the "ON"...
  • Page 35 "ON" position and goes off when the engine is started. NOTE If the battery/generator indicator light comes on while driving, have the generator circuit checked at your nearest Isuzu dealer. - 2–11 - QKR-IE-1442̲4805234̲ALL.indb   2‒11 QKR-IE-1442̲4805234̲ALL.indb   2‒11 2017/09/27   13:34:40 2017/09/27   13:34:40...
  • Page 36 If the oil level is normal, have the lubricating system checked at your nearest Isuzu dealer. Do not run the engine if the light is continuously illuminated. Water separator indicator light...
  • Page 37 Even if the vehicle is driveable, and does not require towing, see your Isuzu dealer as soon as possible for service of the system. Continued driving without having the system serviced could cause damage to the emission control system.
  • Page 38 CONTROLS AND INSTRUMENTS WARNING Never turn the steering wheel while the vehicle is stationary and never keep the steering wheel turned fully for a long period. The temperature of oil in the power steering oil pump will rise abnormally high and cause the insufficient lubrication, damage to the hose or deterioration of the seal.
  • Page 39 CONTROLS AND INSTRUMENTS Adjustment procedure: 1. Release the steering column by rotating the lock lever to the upright position. 2. Sit upright in your seat and move the steering wheel up or down and the steering column back or forward as desired.
  • Page 40 CONTROLS AND INSTRUMENTS WARNING • If you need to turn off the engine with the vehicle in motion, turn the key only to "ACC". DO NOT turn the key to "LOCK". This will result in locking the steering wheel and loss of steering control.
  • Page 41 CONTROLS AND INSTRUMENTS Turn signal switch Dimmer switch Passing light switch Move the switch in the direction of the The head light beam is alternately The head light high beam comes on and turn being made so that the external turn switched from high to low or low to high goes off each time the switch is raised signal lights operate and the turn signal...
  • Page 42 CONTROLS AND INSTRUMENTS CAUTION Do not operate the wipers when the windshield is dry. It may scratch the windshield glass. Clear ice or packed snow from the wiper blades before using the wipers. If they are frozen to the windshield, carefully loosen or thaw them.
  • Page 43 CONTROLS AND INSTRUMENTS NOTE Type 1 • It is advisable to operate the exhaust brake when descending a slope or when stop-and-go driving is involved. Type 2 • When the warm-up system is "ON", the exhaust brake will not be released until the engine is Indicator light thoroughly warmed up, even if the...
  • Page 44 CONTROLS AND INSTRUMENTS Lock Unlock Central locking door Hazard warning flasher switch Idling control knob Locking or unlocking the driver's door When the switch is pushed, all the turn Turning the knob clockwise (in the with either the key or the lock button will signal lights are made to flash, regardless direction of the arrow) after cold starting also lock or unlock the remaining door.
  • Page 45 CONTROLS AND INSTRUMENTS WARNING The indicator light has no relationship to the efficiency of the parking brake. Always pull the parking brake lever as far up as possible when setting the parking brake. Release button Failure to fully set the parking brake could result in vehicle movement on an inclined surface.
  • Page 46 "ON" position. broken cigarette lighter, use an If a back-up warning buzzer is provided, WARNING Isuzu genuine part suitable for the the buzzer sounds when shifted to vehicle. Do not use other cigarette If the lighter does not spring back reverse.
  • Page 47 CONTROLS AND INSTRUMENTS Accelerator pedal Brake pedal Clutch pedal To avoid an unnecessary increase in fuel Avoid hard stops by depressing the foot The clutch pedal should be fully consumption, the accelerator pedal brake pedal smoothly. When descending depressed when disengaging. If this is should be operated smoothly and a slope, it is always advisable to use the not done, grating of the gears may result.
  • Page 48 CONTROLS AND INSTRUMENTS Sun visor Knob Hook Sun visor Dome light OTHERS Lower the sun visors when you are facing The dome light is operated at any key Glove box the sun. The sun visors can be moved to switch position. The glove compartment is provided on the the side by unhooking them at the ends.
  • Page 49 CONTROLS AND INSTRUMENTS NOTE To prevent the light from being left on and discharging the battery, be sure to completely close the doors. Door window Power window switch on the driver's door Turn the handle to raise or lower the door window.
  • Page 50 CONTROLS AND INSTRUMENTS WARNING • To ensure the safety of children and others make sure that all passengers have their hands, etc. inside the vehicle before closing the windows. • Remove the key when leaving the vehicle to avoid unintentional window operation by children.
  • Page 51 The washer tank should be filled only with tap water or Isuzu genuine washer WARNING solution. Engine coolant level check or replenishment should be made at...
  • Page 52 CONTROLS AND INSTRUMENTS CAUTION • Do not use radiator coolant in the windshield washer, as it could cause paint damage. • Clear ice or packed snow from the wiper blades before using the wipers. Brake and clutch fluid reservoir Power steering fluid tank The fluid reservoir is beside the meter The power steering fluid tank is located panel of the driver's side.
  • Page 53 If you need to replace the fuel filler emission control system and cause cap, use only a genuine Isuzu fuel failure. For models conforming to Euro filler cap. The use of an improper IV emission standards, be sure to use...
  • Page 54 CONTROLS AND INSTRUMENTS Fuel tank filler cap with key Spare wheel hanger To raise, turn the handle clockwise until it stops. Give an additional tug on the Open the filler lid and unlock and lock with The spare wheel is secured to either the handle to securely hold the spare wheel in the key.
  • Page 55 CONTROLS AND INSTRUMENTS Engine inspection cover Engine inspection sub cover (Non tilt cab) To gain access to the engine, release the catch hooks and raise the entire seat To gain more access to the engine cushion. The cover can be held up by a compartment, raise the driver's seat strap, permitting engine inspection and cushion and remove the sub cover.
  • Page 56 CONTROLS AND INSTRUMENTS Tilt cab When inspecting or servicing the engine, the cab can be tilted to gain access to the engine compartment. WARNING To prevent personal injury, keep hands, tools and clothing clear of the engine cooling fan when the 5 speed engine is running.
  • Page 57 CONTROLS AND INSTRUMENTS 3. Pull the safety lever while holding 4. Raise the cab to the stop position and 5. To lower the cab, unlock the cab stay the assist handle to prevent abrupt check that the cab stay is locked. by pulling the stay rearward.
  • Page 58 CONTROLS AND INSTRUMENTS 6. To lock the cab, push the cab tilt lever Rear body Opening and closing left and right side downward firmly, then visually check gates: Opening and closing rear gate: that the cab is locked with the main 1.
  • Page 59 CONTROLS AND INSTRUMENTS 6 5 4 3 2 1 3. Release the front hook by raising the External lights Rear side: hook lever at the front of the gate. Front side: License plate light 4. The front of the gate is temporarily Head lights Rear fog light secured by the gate hold at this time.
  • Page 60 CONTROLS AND INSTRUMENTS Heater-defroster Air outlet select lever: Temperature lever: The air flows out from the outlets shown The select lever is used to control the The temperature lever is for temperature in the figure. mode of operation. control (through controlling of the hot air flow rate).
  • Page 61 CONTROLS AND INSTRUMENTS Air source select lever: Fan blower switch: Windshield demisting: The air source select lever controls the The fan blower switch controls the volume Set the air outlet select lever and air setting of the air intake between the of air delivery in four steps.
  • Page 62 CONTROLS AND INSTRUMENTS Heating: Power ventilator (on models with and Antenna without heater): Set the temperature lever as shown in Pull out the antenna to gain sensitivity. the figure and slide the fan blower switch The fan blower switch can be in any The antenna should be fully extended on.
  • Page 63 CONTROLS AND INSTRUMENTS Cup holder In the center of the dash, there is a cup holder in which two beverage cups or cans etc. can be placed. CAUTION Do not place a cup that is too full in the cup holder. Spillages could cause damage to the electrical circuits.
  • Page 64 - NOTE - - 2–40 - QKR-IE-1442̲4805234̲ALL.indb   2‒40 QKR-IE-1442̲4805234̲ALL.indb   2‒40 2017/09/27   13:34:44 2017/09/27   13:34:44...
  • Page 65 Record the key number and keep it in a safe place such as your wallet, NOT IN THE VEHICLE. NOTE In the event that the original keys are lost, duplicates can be made by your Isuzu dealer using the key code information. - 3–1 - QKR-IE-1442̲4805234̲ALL.indb   3‒1 QKR-IE-1442̲4805234̲ALL.indb   3‒1 2017/09/27   13:34:44...
  • Page 66 BEFORE DRIVING YOUR VEHICLE Unlock Lock Outside door handle Door lock (Outside) Inside door handle The doors can be opened by pulling the The doors can be locked from outside The doors can be opened by pulling the outside door handle. without using the key by setting the door inside door handle.
  • Page 67 BEFORE DRIVING YOUR VEHICLE WARNING • When driving keep doors locked. Locked doors will provide maximum protection for both passenger and driver. When seat belts (if so equipped) are properly used and all the doors are locked, it is highly improbable that anyone would be thrown from the vehicle in the event of an accident.
  • Page 68 Take occupants who are children. the vehicle to your Isuzu Dealer for service if you find that your • Adjust the seat only before you seat adjusters do not latch. In start driving.
  • Page 69 BEFORE DRIVING YOUR VEHICLE WARNING (Continued) • Do not place any objects under the seat. If there are any objects under the seat, the seat could be locked in an improper position. • Before making adjustments, check that the seat rails are free of anything that could obstruct the locking of the seat.
  • Page 70 BEFORE DRIVING YOUR VEHICLE • Never wear twisted seat belts. • Be very careful not to damage seat belts or seat belt buckles by pinching them in the seat or the door. • Too much slack could increase the amount of injury because the belt would not be able to properly restrain you in an accident.
  • Page 71 BEFORE DRIVING YOUR VEHICLE Latch plate Slide button Buckle Keep as low on hips as possible Seat belt (3-points) 2. To reduce the risk of sliding under the 3. To unfasten the belt, push the button belt during a collision, position the belt on the buckle.
  • Page 72 BEFORE DRIVING YOUR VEHICLE Seat belt inspection and care : General notice CAUTION • Periodically inspect belts, buckles, In the interest of safety, seat belts should It is important that you understand latch plates, retractors and anchors be checked regularly. Your dealer will how to correctly wear a seat belt.
  • Page 73 BEFORE DRIVING YOUR VEHICLE Mirrors Outside rearview mirrors Inside rearview mirror Adjust the outside rearview mirrors so you can see not only each side of the road To adjust, push the mirror right or left, and up behind you but also each side of your or down.
  • Page 74 BEFORE DRIVING YOUR VEHICLE Underview mirror Exterior DRIVER'S CHECK LIST (REGULAR INSPECTION) Adjust the underview mirror so you can 1. Check the tire inflation pressure just see the front end of your vehicle. securely. Especially on vehicles with The following checks should be double tire, it is hard to find out by performed to maintain safe and visual check even if one of the tires...
  • Page 75 BEFORE DRIVING YOUR VEHICLE WARNING If any fault such as breakage is found in the check, do not drive the vehicle. Perform the proper maintenance immediately. 2. Using an inspection hammer etc., 4. Check chassis springs for damage. check the wheel bolt for breakage, wheel nut for looseness, etc.
  • Page 76 BEFORE DRIVING YOUR VEHICLE 5. Check operation of lights. 6. Check level of electrolyte in each cell 7. Check for any oil, water, fuel and of the battery. brake fluid leakage. - 3–12 - QKR-IE-1442̲4805234̲ALL.indb   3‒12 QKR-IE-1442̲4805234̲ALL.indb   3‒12 2017/09/27   13:34:46 2017/09/27   13:34:46...
  • Page 77 BEFORE DRIVING YOUR VEHICLE Within cab 2. Check parking brake lever travel. 3. Check operation of horns, windshield wipers and turn signals. 1. Check for steering wheel excess play and looseness in its mounting. If the vehicle is equipped with a power steering unit, the wheel free play should be checked with the engine running.
  • Page 78 BEFORE DRIVING YOUR VEHICLE 4. Check operation of instruments and 5. Check the fuel gauge for the level of 6. Check the angle of rearview mirrors. indicator lights. the fuel in the tank against fuel gauge. - 3–14 - QKR-IE-1442̲4805234̲ALL.indb   3‒14 QKR-IE-1442̲4805234̲ALL.indb   3‒14 2017/09/27   13:34:46 2017/09/27   13:34:46...
  • Page 79 BEFORE DRIVING YOUR VEHICLE 7. Check the level of clutch and brake 8. Check the level of the windshield 9. Check the operation of the door fluid in the reservoir. washer solution in the washer tank. locking mechanism. - 3–15 - QKR-IE-1442̲4805234̲ALL.indb   3‒15 QKR-IE-1442̲4805234̲ALL.indb   3‒15 2017/09/27   13:34:47...
  • Page 80 BEFORE DRIVING YOUR VEHICLE 10. Check the clutch pedal play and Within engine compartment 2. Check the fan belt tension. function. 1. Check the engine oil level. - 3–16 - QKR-IE-1442̲4805234̲ALL.indb   3‒16 QKR-IE-1442̲4805234̲ALL.indb   3‒16 2017/09/27   13:34:47 2017/09/27   13:34:47...
  • Page 81 BEFORE DRIVING YOUR VEHICLE To open the radiator cap or 4JB1 reserve tank cap, put a piece of 4JB1-TC thick cloth on the cap and loosen the cap slowly. • Engine coolant is toxic and must not be ingested. If the engine coolant is mistakenly ingested, immediately vomit it and seek prompt medical attention.
  • Page 82 BEFORE DRIVING YOUR VEHICLE WARNING (Continued) • Keep fire away from the engine coolant since it is easy to catch fire. Also it may catch fire if it is splashed on some parts that are in high temperature such as a manifold.
  • Page 83 BEFORE DRIVING YOUR VEHICLE 3. Check for any abnormal engine noise or color of exhaust gases. - 3–19 - QKR-IE-1442̲4805234̲ALL.indb   3‒19 QKR-IE-1442̲4805234̲ALL.indb   3‒19 2017/09/27   13:34:47 2017/09/27   13:34:47...
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  • Page 85 DRIVING DRIVING • Preparation for starting engine ... 4–1 • Starting engine ......4–2 • Stopping engine ......4–3 • Before driving off ......4–4 • Operating precautions for turbocharged engine....4–5 5 speed • Parking .......... 4–6 • Driving precautions ..... 4–7 •...

  • Page 86: Starting Engine

    DRIVING CAUTION Do not step on the accelerator pedal before starting. When the accelerator pedal is depressed before the starter switch is turned on, the "START FUEL ENRICH SYSTEM" may not function correctly. Accordingly, starting becomes substantially more difficult. 2. Warm weather or hot engine: STARTING ENGINE Turn the key switch to the "START"...

  • Page 87: Stopping Engine

    DRIVING CAUTION Do not activate the starter motor continuously for more than 10 seconds, or the starter motor and the battery will be adversely affected. Fire may occur due to overheating. Repeat step 1 and 2 above after one minute break if the engine does not start.

  • Page 88: Before Driving Off

    DRIVING 2. Adjust the seat position. 3. Adjust the inside and outside mirrors. BEFORE DRIVING OFF 1. Lock all doors. - 4–4 - QKR-IE-1442̲4805234̲ALL.indb   4‒4 QKR-IE-1442̲4805234̲ALL.indb   4‒4 2017/09/27   13:34:48 2017/09/27   13:34:48...

  • Page 89: Operating Precautions For Turbocharged Engine

    DRIVING Engine shut-off in general CAUTION After highway driving, at least 3 minutes of operation should be at idle until it cools down. Engine oil pressure is available for lubrication at this time and will prolong the life of the turbocharger bearings.

  • Page 90: Parking

    DRIVING • To be much safer, turn the steering wheel in the direction to the obstacles in order to have the least effect in case that the vehicle moves and crashes. WARNING • Never turn the steering wheel while the vehicle is stationary and never keep the steering wheel turned fully for a long period.

  • Page 91: Driving Precautions

    DRIVING WARNING (Continued) • Never leave a child alone and unattended inside the vehicle. The child could activate the vehicle controls, resulting in an accident. • Do not drive through, idle or park your vehicle over combustible materials, such as grass or leaves.
  • Page 92 DRIVING 3. If the indicator lights or instruments 4. Avoid needless hard acceleration and 5. Do not drive with your foot resting on give an indication of an abnormal hard stops. the clutch pedal as it produces a partly condition while driving, stop the disengaged condition, causing engine and check to locate the cause premature wear of the clutch facing.
  • Page 93 DRIVING 6. Allow vehicle to stop completely 7. When climbing a slope, shift to a lower 8. When descending a slope, shift into a before shifting to reverse or shifting gear to relieve the engine of overload lower gear to gain a retardation effect from reverse to any forwarding gear.
  • Page 94 DRIVING 9. When driving across a shallow river 10. Drive carefully after running in heavy 11. Never turn off the starter switch while or a deep puddle, extreme care must rain or driving across a shallow river driving the vehicle. The brake booster be exercised or water may be drawn as wet brakes cause temporary does not operate, and the brake...

  • Page 95: Driving For Economy

    DRIVING 12. When making a U-turn on a sharp 13. Going down on a steep slope DRIVING FOR ECONOMY slope, the vehicle is in danger of • When going down on a steep slope, 1. Needless high-speed driving and slow turning over the moment it crosses the avoid driving the vehicle backward as driving in a high gear will result in...
  • Page 96 DRIVING 2. After acceleration, shift to a higher 3. It is strongly advisable to keep your 4. Always make sure the engine coolant gear and engage the clutch smoothly. speed as constant as possible after temperature is kept within the normal shifting into top gear.

  • Page 97: Operation And Care In Winter

    DRIVING OPERATION AND CARE IN WINTER Use of specified coolant 5. Under-inflated tires cause To prevent the engine damage due to deterioration in fuel economy. freezing of the engine coolant, mix the coolant and water (distilled water or deionized water) to be an appropriate concentration.

  • Page 98: Driving On Ice Or Snow

    DRIVING Temperature of electrolyte (°C) Engine oil Batteries DRIVING ON ICE OR SNOW The engine oil tends to harden with The capacity of the battery tends to 1. Use of tire chains or snow tires is lowering temperatures. Use engine oil decline with lowering temperatures and recommended.
  • Page 99 DRIVING 2. Avoid high speed, hard acceleration, 3. Use lower gears to overcome the 4. Drive with a sufficient distance hard stops and sharp steering. retardation effect of the engine. Apply between you and the vehicle ahead. the foot brakes lightly. - 4–15 - QKR-IE-1442̲4805234̲ALL.indb   4‒15 QKR-IE-1442̲4805234̲ALL.indb   4‒15...

  • Page 100: In Case Of Emergency

    DRIVING Engine overheating IN CASE OF EMERGENCY If engine power drops and the needle on Stowage of jack and tools the engine coolant temperature gauge The tools and jack are stowed away goes up above the upper limit of the behind the driver's seat.
  • Page 101 DRIVING • When removing the radiator cap • Coolant is flammable, and CAUTION and reserve tank cap, use a thick therefore, it must be kept away Do not stop the engine immediately. cloth to cover the cap and turn it from flames and other heat Otherwise, the engine may seize.
  • Page 102 DRIVING CAUTION CAUTION When the cooling fan for the radiator • Adding engine coolant suddenly to is not turning, turn off the engine the overheated engine may cause a immediately. breakdown of the engine. Add the engine coolant slowly little by little. 4.
  • Page 103 DRIVING To start the vehicle when the battery is discharged, use an auxiliary battery of the same nominal voltage i.e. 12 volts, as the discharged battery. WARNING Exercise extreme care when handling the battery to avoid serious personal injury and damage to your vehicle which might result from a battery explosion, acid burns, electrical...
  • Page 104 DRIVING 12V vehicle with 2 batteries installed 12V vehicle with 1 battery installed Vehicle with Disabled vehicle Vehicle with Disabled vehicle booster batteries booster batteries Use the vehicle Negative side jumper cable Use the vehicle frame as the ground frame as the ground Negative side jumper cable Positive side jumper cable...
  • Page 105 3. If the vehicle is towing or being of order, disconnect the propeller shaft towed, firmly attach a rope to the Your vehicle should be towed by an Isuzu at the rear axle flange and fasten the front or rear towing hook on the same dealership or professional towing service end to the chassis frame.
  • Page 106 DRIVING CAUTION Usable Then, fit the towing rope (safety chains 15° range of or cables) between the hooks towing 15° rope equipped on the tow truck and the disabled vehicle. Drive at the speed of 40 km/h (25 mph) Usable 15°...
  • Page 107 DRIVING With air in fuel system, smooth flow of (7) Depress the clutch pedal fully and fuel into the engine is interrupted and turn the key switch to "START" to prevent this bleeding of the fuel position to start the engine at the system should be performed.
  • Page 108 DRIVING CAUTION Do not keep the starter switch in the "START" position for more than about 10 seconds. If the engine does not start, wait more than about 30 seconds, then try starting the engine again. If you try three times and the engine does not start, perform step 2, then try starting the engine again.
  • Page 109 Isuzu dealer. If use is continued with the warning light 4. After draining, securely tighten the on, there is danger of damage to the fuel drain plug by turning it clockwise and injection system.
  • Page 110 DRIVING WARNING To help avoid personal injury: • Follow all lifting and stowage instructions. • Use the jack only for lifting this vehicle during a wheel change. • Never get beneath the vehicle when using the jack. • Always securely stow again the spare tire (or a flat tire), and all Jacking instruction and changing a flat 5.
  • Page 111 DRIVING Jack up point FRONT Front 6. Place the jack at the recommended Independent suspension model Rear wheel: jacking point. WARNING CAUTION Take care not to touch the exhaust pipe or the muffler either Never position the jack at points other immediately after driving the than those specified.
  • Page 112 DRIVING Usage of the jack To lower: NOTE To jack up: Slowly turn the bleeder screw • If the jack stroke is insufficient, If the jack up point is high, extend the jack counterclockwise with the jack bar as place a wood board or equivalent head by turning it counterclockwise.
  • Page 113 DRIVING 4. When installing the wheel, clean 5-studs the flat surface on the wheel, the area on the hub that contacts the wheel, the threaded portion of the wheel bolt, the spherical surface on the wheel nut, etc. to remove rust, dust, additional paint and foreign objects, and then apply a thin coat of the ATF etc.
  • Page 114 DRIVING 6-studs Front Wheel Nut Torque m (kgf m/lbf • • • Single tire rear wheel 170 (17/123) model Dual tire rear wheel 500 (50/362) model Rear Wheel Nut Torque m (kgf m/lbf • • • Single tire rear wheel 170 (17/123) model Dual tire rear wheel...
  • Page 115 • Maintenance schedule ....5–1 A: Adjust and maintenance should be performed at • Maintenance guide ....... 5–7 your Isuzu dealer according to the R: Replace • Periodic maintenance ....5–19 maintenance schedule. T: Tighten to specified torque For service operations which call for •...

  • Page 116: Service And Maintenance

    Every 7,500 km (4,500 miles): I or every 4.5 months Every 12 months: I Engine coolant Every 24 months: R (when Isuzu recommended coolant is used) *Damage to or looseness of the exhaust pipe, exhaust brake (if equipped), or every 12 months...
  • Page 117 SERVICE AND MAINTENANCE Maintenance schedule: 4JB1, 4JB1-TC, 4JH1-TC engine Model specification (I): Inspect then clean, repair or replace as necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate SERVICE INTERVAL x 1000 km 95 100 Use odometer reading or months, whichever occurs first...
  • Page 118 SERVICE AND MAINTENANCE Maintenance schedule: 4JB1, 4JB1-TC, 4JH1-TC engine Model specification (I): Inspect then clean, repair or replace as necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate SERVICE INTERVAL x 1000 km 95 100 Use odometer reading or months, whichever occurs first...
  • Page 119 SERVICE AND MAINTENANCE Maintenance schedule: 4JB1, 4JB1-TC, 4JH1-TC engine Model specification (I): Inspect then clean, repair or replace as necessary (A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate SERVICE INTERVAL x 1000 km 95 100 Use odometer reading or months, whichever occurs first...
  • Page 120 SERVICE AND MAINTENANCE Maintenance schedule under severe driving conditions Severe driving conditions A: Repeated short trips B: Driving on rough roads C: Driving on dusty roads D: Driving in extremely cold weather and/or on salted roads Condition Item Interval Engine oil Change every 2,500 km (1,500 miles) •...

  • Page 121: Maintenance Guide

    SERVICE AND MAINTENANCE MAINTENANCE GUIDE NOTE REGULAR INSPECTION If the engine in running, stop the engine and allow 5 minutes for the oil Engine oil level to settle down before checking the oil Pull out the oil level gauge rod (oil level.
  • Page 122 Also check the belt for cracks or other damage. If there are cracks or damage or if the inspected value is not within the standard value range, replace the belt. Have adjustment and replacement of the fan belt performed at an Isuzu Dealer. CAUTION...
  • Page 123 SERVICE AND MAINTENANCE Engine cooling system • Do not loosen or remove the cap • If the engine coolant gets on your The engine cooling system is designed to of the radiator or reserve tank skin, rinse it off using a soap with maintain the engine at the proper cap when the engine coolant is a large amount of water.
  • Page 124 CAUTION CAUTION To prevent the engine damage due to Replace the engine coolant • Isuzu does not guarantee the use of freezing of the engine coolant and to periodically. the engine or vehicle at the outside protect the cooling system from corrosion, temperature of -30°C (-22°F) or...
  • Page 125 CAUTION below for your use as a guideline when changing the engine coolant. After • Coolant is toxic and must not be • Use only an Isuzu recommended ingested. If the coolant is changing the engine coolant, check that coolant.
  • Page 126 SERVICE AND MAINTENANCE CAUTION (Continued) • If the engine coolant decreases 4JB1-TC rapidly, go immediately to the nearest Isuzu dealer for a check or repair. Engine coolant level Tighten the cap securely after filling. Also check the radiator cap part, radiator or...
  • Page 127 Also, if still cooling capability that have not been result. The engine coolant in the abnormality such as irritation is specifically approved by Isuzu are reserve tank may also be hot. felt, seek medical attention. not recommended in the cooling Immediately removing the cap system.
  • Page 128 SERVICE AND MAINTENANCE Operation and care in winter Protection of engine against over- cooling Over-cooling of the engine not only accelerates wear of the vital engine parts but also deteriorates fuel economy. Radiator Intercooler Use of specified coolant Cleaning the radiator core and intercooler core To prevent the engine damage due to freezing of the engine coolant, mix the...
  • Page 129 It is dangerous. Do not spill it serviced at your Isuzu dealer. on your skin or clothing. Be especially careful not to get it in your eyes. If battery acid should get...
  • Page 130 16 notches, the braking is at the periphery of the steering wheel condition is noted, have the steering insufficient and brake adjustment when checked with the front wheels system checked at your Isuzu dealer should be performed. properly in the straight-ahead position. immediately. NOTE...
  • Page 131 • Inspect and change brake (clutch) your vehicle inspected by the For hydraulic brake models, clutch fluid is fluid according to the Maintenance nearest Isuzu Dealer immediately. also used as brake fluid and is contained Schedule. in the same tank.
  • Page 132 SERVICE AND MAINTENANCE Free play Windshield washer solution level Clutch pedal free play WARNING Check that the washer tank is filled Free play: The brake indicator light does not sufficiently with solution. Also check the 15 to 25 mm (0.59 to 0.98 in) indicate the parking brake function operating condition of the windshield or non-function.

  • Page 133: Periodic Maintenance

    Free play Allowance engine running. NOTE It is strongly advisable to use Isuzu Brake pedal free play and allowance genuine air cleaner elements for replacement. Free play: 4 to 7 mm (0.16 to 0.28 in)
  • Page 134 SERVICE AND MAINTENANCE CAUTION Handle the element carefully so as not to damage it. Element removal (Type 1) Element removal (Type 2) 1. Loosen the wing nut and remove the 1. Unhook the three hooks and remove outside cover. the cover. 2.
  • Page 135 SERVICE AND MAINTENANCE Element removal (Type 3) 2. Remove the wing nut retaining the Cleaning of air cleaner body and cover element and take out the element. 1. Loosen the hooks and remove the 1. Wipe the inside of the air cleaner dust-pan.
  • Page 136 SERVICE AND MAINTENANCE Drain valve CAUTION Do not apply compressed air to the outer face of the element as it causes the dust to lodge in the inner face. 2. Clean the drain valve on the bottom of Cleaning the air cleaner element the air cleaner body.
  • Page 137 SERVICE AND MAINTENANCE When the air cleaner element is 2. Submerge the element in the cleaning 3. Take out the element and rinse it well clogged with carbon and oil: solution for approximately 30 minutes. with running water. Occasionally shake the element inside The pressure of water should not 1.
  • Page 138 SERVICE AND MAINTENANCE Drain plug 4. Allow the element to dry in a well Main oil filter (on models with partial- Oil filter ventilated place. To dry the element flow oil filters) 1. Loosen the oil filter by turning it quickly, use an electric fan.
  • Page 139 Start the engine and of the oil filter, so that the new oil filter It is strongly advisable to use an Isuzu check for leaks at the oil filter. It is can be seated properly.
  • Page 140 SERVICE AND MAINTENANCE Fuel filter 3. Lightly oil the O-ring. Reinstall and 4. Push the priming pump on the water turn the filter assembly clockwise separator several times to bleed fuel carefully to prevent the fuel from system of air. 1.
  • Page 141 SERVICE AND MAINTENANCE Drain plug Fuel hose Bolt Clip Pre-fuel filter Main fuel filter Main fuel filter 3. Pinch the clip of the fuel hose connected to the filter body and This type is equipped with 2 filters, 1. Connect one end of a plastic hose remove the fuel hose.
  • Page 142 SERVICE AND MAINTENANCE 6. Further loosen the half loosened Flat-head Filter body union and remove the element case. screwdriver Then remove the element. 7. Remove the O-ring from the element case. 8. Use a clean cloth to wipe off any foreign matter that has accumulated Inner gasket on the inside surface of the filter...
  • Page 143 Mark Check that there is no breakage of the fuel hose such as cracking. Have your vehicle inspected at the nearest Isuzu dealer as soon as Element case possible if there is any fuel hose Outer gasket breakage such as cracking.
  • Page 144 SERVICE AND MAINTENANCE Flat-head Filter body Wire screwdriver Inner gasket Outer gasket Drain plug Union Element Pre-fuel filter 2. Turn the union by hand and pull out O-ring the filter body. 1. Insert a flat-head screwdriver into the At this time, check the alignment groove on the filter body and turn the Element case position of the filter body and element...
  • Page 145 SERVICE AND MAINTENANCE 5. Loosen the drain plug to drain fuel. Connection After draining, tighten the drain plug. point 6. Remove the O-ring from the element case. 7. Use a clean cloth to wipe off any foreign matter that has accumulated on the inside surface of the filter body.
  • Page 146 1/3 to 2/3 of a fuel filter can be seated properly. turn with the filter wrench. CAUTION It is strongly advisable to use an Isuzu genuine fuel filter assembly for replacement. - 5–32 - QKR-IE-1442̲4805234̲ALL.indb   5‒32 QKR-IE-1442̲4805234̲ALL.indb   5‒32...
  • Page 147 SERVICE AND MAINTENANCE FRONT FRONT Drain plug Radiator 4. Push the priming pump on the water Engine coolant The reserve tank or engine separator to bleed the fuel system. coolant temperature inside of the Draining the cooling system reserve tank is also very hot, so For proper instructions of the cooling its boiling water may cause a system and the coolant, refer to "Engine...
  • Page 148 SERVICE AND MAINTENANCE WARNING (Continued) CAUTION • If the engine coolant gets in your • The radiator cap is a double-action eyes, rinse it off immediately with type that must be opened and closed a large amount of water for 15 in two turning motions.
  • Page 149 SERVICE AND MAINTENANCE 2. Check and clean the radiator cap. Replace the cap if there is anything abnormal with it. 3. Securely fasten the radiator cap. 4. Engine coolant may leak from even minor cracks. Replace damaged rubber hoses. 5. Refill the reserve tank with tap water to the "MAX"...
  • Page 150 SERVICE AND MAINTENANCE 1. Confirm that the engine has fully cooled down before starting work. 2. Tighten the drain plugs on the radiator and the engine. Apply sealant (LOCTITE ® 262 or equivalent) to the screw threads of the engine drain plug before installing it. Engine drain plug tightening torque: 21.6 N m (2.2 kgf...
  • Page 151 SERVICE AND MAINTENANCE warm-up switch, maintain the engine 4JB1 speed approximately 2,000 r/min to 4JB1-TC warm up the engine. After the needle of the coolant temperature gauge reaches the center, increase the engine speed to approximately 2,000 r/min, and maintain this speed for 5 minutes.
  • Page 152 SERVICE AND MAINTENANCE engine coolant leaks. 12. Repeat steps 9 through 11 until the engine coolant level in the radiator filler opening stops declining. 13. Firmly close the radiator cap. 14. Replenish the engine coolant in the reserve tank up to the "MAX" line, and then close the reserve tank cap.
  • Page 153 SERVICE AND MAINTENANCE REPEATEDLY HOLD 2. Check the level of the clutch fluid in 3. Remove the rubber cap from the 5. Hold it to depress. the reservoir and replenish it if bleeder screw and wipe clean the 6. Loosen the bleeder screw on the necessary.
  • Page 154 SERVICE AND MAINTENANCE Service brake adjustment To adjust front and rear brakes, 7. Repeat the above adjustment proceed as follows: procedures for adjusting the brakes The use of a brake system with excessive on the remaining wheels. brake lining clearances is unsafe as the brake performance deteriorates with an 1.
  • Page 155 SERVICE AND MAINTENANCE Bleeding of the brake hydraulic circuit To bleed, proceed as follows: CAUTION If air enters the brake lines, it will cause 1. Set the parking brake firmly. Brake booster (master-vac) will be poor braking. Therefore, the bleeding 2.
  • Page 156 SERVICE AND MAINTENANCE 4. Bleeding of the brake hydraulic circuit should be performed in the following sequence: Right-hand rear wheel –> Right-hand front wheel –> Left-hand front wheel. Right-hand rear wheel –> Left-hand front wheel –> Right-hand front wheel. 5. Remove the rubber cap from the 6.
  • Page 157 SERVICE AND MAINTENANCE 7. Release the brake pedal carefully. 8. When the bleeding operation is Parking brake adjustment Repeat the above operation until air completed on each wheel, check the The parking brake lever stroke is normal bubbles disappear from the brake fluid level of brake fluid in the reservoir and when the lever comes within 6 to 8 being pumped out into the container.
  • Page 158 SERVICE AND MAINTENANCE Adjuster screw notches and clearance Notches Clearance mm (in) 0.78 (0.03) 5. Jack up the rear wheels clear of the 6. Fit a screwdriver into the adjust hole ground. Set a supporter for safety, in the brake drum and turn the move the gearshift lever into the adjuster upward all the way until it neutral position and bring the adjuster...
  • Page 159 SERVICE AND MAINTENANCE Tire rotation To allow the tires to wear evenly and to prolong their life, exchange the front and rear tire locations as shown in the figure. To set the parking lever stroke to the Tire inflation pressure normal range, adjust the setting of the Check the tire inflation pressure securely.
  • Page 160 SERVICE AND MAINTENANCE WARNING (Continued) • Over-inflation or under-inflation can affect vehicle handling and result in loss of control as well as excessive tire wear and tire damage. • Especially, the tire pneumatic Tire air pressure plate pressure lowered thus may cause (The Position of a LHD the tire to wear out earlier or vehicle is opposite)
  • Page 161 SERVICE AND MAINTENANCE Cleaning of battery Head lights Replacing light bulbs If the external part of the battery is dirty, Proper aiming of the head lights is most The illustration shows how to gain access clean with tepid water. Apply a thin coat important to ensure sufficient illumination to the bulbs.
  • Page 162 SERVICE AND MAINTENANCE Wattage Location 12 volt No. of system bulbs Halogen head lights 60W/55W Turn signal Front combination lights Cornering/ 21W/5W Clearance Stop/Tail 21W/5W Rear combination lights Turn signal Back up License plate light Dome light Fog lights Rear fog light - 5–48 - QKR-IE-1442̲4805234̲ALL.indb   5‒48 QKR-IE-1442̲4805234̲ALL.indb   5‒48...
  • Page 163 SERVICE AND MAINTENANCE 3. Fit the iron pin in the upper side portion by aligning it with the center of corresponding grommet. NOTE Push it in securely until a click is heard. 4. Pull the front combination light assembly lightly toward the front of vehicle to make sure that the pin and grommet are fitted securely.
  • Page 164 SERVICE AND MAINTENANCE Rear combination lights Rear fog light License plate light Remove the screws retaining the lens and Remove the screws retaining the lens and The lens can be pulled out easily with remove the lens. remove the lens. screwdriver.
  • Page 165 SERVICE AND MAINTENANCE Dome light Fuse junction block When replacing a fuse, turn the starter switch to the "LOCK" position and The cover of the light can be removed The fuse box is located in the glove box. only use fuses of the same amperage. very easily with a screwdriver.
  • Page 166 OK, check the fusible link. If a fusible link is burnt out, it must be replaced with one of the same amperage. WARNING Always use Isuzu genuine fusible links for replacement. Never install a wire, even if it is temporary. It may cause extensive damage and possibly a fire.
  • Page 167 SERVICE AND MAINTENANCE Fuse and fusible link location The numbers (1 to 28) in the illustration indicate the fuse numbers, and circled Relay box (installed on the left side rear of the cab) numbers (1 to 23) indicate the relay numbers.
  • Page 168 SERVICE AND MAINTENANCE Coin Relay box (located in the dashboard) - 5–54 - QKR-IE-1442̲4805234̲ALL.indb   5‒54 QKR-IE-1442̲4805234̲ALL.indb   5‒54 2017/09/27   13:34:58 2017/09/27   13:34:58...
  • Page 169 SERVICE AND MAINTENANCE Fuse Relay 4JB1 MODEL ENGINE 4JB1 MODEL ENGINE AIR CON TAIL EXH. BRAKE, FUEL HEATER HEAD LAMP REAR HEATER HORN AUDIO (B), DOOR LOCK WIP KEY ON STOP LIGHT FRT FOG LIGHT, CORNERING LAMP TAIL LIGHT GLOW MARKER LAMP FUEL CUT RR FOG...
  • Page 170 SERVICE AND MAINTENANCE Fuse Relay 4JH1 MODEL ENGINE 4JH1 MODEL ENGINE HEATER TAIL AIR CON HEAD LAMP HORN AUDIO (B), DOOR LOCK WIP KEY ON P/WINDOW STOP LAMP TAIL LAMPS GLOW FOG LAMP ECU (BATT) HORN, HAZARD Relay STARTER CUT WIPER TURN LAMPS ECM MAIN...
  • Page 171 SERVICE AND MAINTENANCE Cleaning inside cab CAUTION Do not wash by sousing water directly inside the cab. It causes a malfunction of electronic control devices installed on the back side of the glove box or rust on the floor. - 5–57 - QKR-IE-1442̲4805234̲ALL.indb   5‒57 QKR-IE-1442̲4805234̲ALL.indb   5‒57 2017/09/27   13:34:58...

  • Page 172: Lubrication

    SERVICE AND MAINTENANCE LUBRICATION Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table. Oil viscosity chart for diesel engines Oil viscosity chart for transmission cases - 5–58 - QKR-IE-1442̲4805234̲ALL.indb   5‒58...
  • Page 173 SERVICE AND MAINTENANCE Oil viscosity chart for rear axle - 5–59 - QKR-IE-1442̲4805234̲ALL.indb   5‒59 QKR-IE-1442̲4805234̲ALL.indb   5‒59 2017/09/27   13:34:58 2017/09/27   13:34:58...

  • Page 174: Recommended Fluids, Lubricants And Diesel Fuels

    SERVICE AND MAINTENANCE RECOMMENDED FLUIDS, LUBRICANTS AND DIESEL FUELS In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to select and use correctly best lubricants and diesel fuels. When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to the maintenance schedule for each vehicle model.
  • Page 175 SERVICE AND MAINTENANCE GRADE LUBRICATION MAKER BRAND/TYPE ACEA JASO ISUZU BESCO DURAMAX (10W-30) CH-4 — DH-1 ISUZU BESCO MULTI Z CH-4 (10W-30) CH-4 — DH-1 ISUZU BESCO MULTI Z CH-4 (10W-40)* CH-4 — — Castrol Tection J-Max (15W-40) CH-4 DH-1...
  • Page 176 SERVICE AND MAINTENANCE GRADE LUBRICATION MAKER BRAND/TYPE ACEA JASO ISUZU BESCO TRANSAXLE (5W-30) — — — Chevron/Texaco/Caltex Delo 400 Multigrade (15W-40) CI-4 DH-1 Manual Performance Victory (15W-40) CI-4 — transmission ExxonMobil Delvac MX (15W-40) CI-4 — Shell Rimula R4X (15W-40)
  • Page 177 Engine cooling system BASF Glysantin G34 Total Glacelf Auto Supra Total Coolelf Auto Supra 37 *: Use Isuzu recommended coolant, or GENERAL MOTORS ENGINEERING STANDARDS GM6277M (Ethylene glycol based non- silicate and non-borate coolant) or equivalent. FLUID MAKER BRAND GRADE* ISUZU...

  • Page 178: Lubrication Chart

    SERVICE AND MAINTENANCE LUBRICATION CHART: QKR55 AND QKR77 : Gear oil : MoS contained type grease : Change W : Wheel bearing grease : Brake fluid : Check and Replenish or Lubricate : Multipurpose type grease : Automatic transmission fluid : Engine oil Kingpin Power steering fluid...

  • Page 179: Lubrication Guide

    SERVICE AND MAINTENANCE Drain plug When the engine crankcase and oil filter Then fill the engine crankcase from the LUBRICATION GUIDE are completely drained, reassemble the filler port with new engine oil of the Changing engine oil drain plug. specified grade. Drain the engine crankcase completely by removing the drain plug on the lower part of the oil pan, main oil filter and partial-...
  • Page 180 SERVICE AND MAINTENANCE NOTE Use the recommended engine oil. (Refer to "RECOMMENDED FLUIDS, LUBRICANTS AND DIESEL FUELS".) When the engine crankcase is filled to the high level mark on the oil dipstick, start and let the engine idle for a few minutes. Stop the engine and recheck the oil level and replenish, if necessary.
  • Page 181 SERVICE AND MAINTENANCE To fluid reservoir Changing power steering fluid Refilling: 3. Lower the front wheels to the ground. Start the engine and let it idle for a few Draining: 1. Install the fluid pipe and hose securely minutes. and fill the fluid reservoir with the 1.
  • Page 182 Lubricate the following points with It is suggested that the vehicle be brought multipurpose type grease. into an Isuzu dealer when the above Kingpins (4 points). operation becomes necessary as the operation calls for disassembly and reassembly operations.

  • Page 183: Correct Cargo Loading

    SERVICE AND MAINTENANCE CORRECT CARGO LOADING Overloading and uneven loading are very dangerous. Please use the correct loading based on the standard maximum load. Wrong loading may cause unstable operation, overload on one of the axles, and an excessive load on the wheel bolts. This is a major factor of the accident that a wheel comes off due to wheel bolt breakage.
  • Page 184 SERVICE AND MAINTENANCE Never apply unnecessarily large force. When loading with a heavy cargo: Keep flammable materials away from the gap between the cab and the guard Fix the load securely using a load cover In case of heavyweight cargo, use pads frame.
  • Page 185 SERVICE AND MAINTENANCE Loading methods NO GOOD NO GOOD GOOD GOOD Do not leave a large space between When using supports under a load, loads. distribute them evenly. Distribute the load evenly. - 5–71 - QKR-IE-1442̲4805234̲ALL.indb   5‒71 QKR-IE-1442̲4805234̲ALL.indb   5‒71 2017/09/27   13:34:59 2017/09/27   13:34:59...
  • Page 186 SERVICE AND MAINTENANCE NO GOOD NO GOOD NO GOOD GOOD GOOD GOOD Place supports underneath when carrying Secure the load with a load cover and Avoid high loading. an extra-long item. Do not support it with rope to prevent it from falling. Tuck the Minimize the height to prevent the vehicle the guard frame or the rear end of the fixing material with rubber bands or other...
  • Page 187 MAIN DATA AND SPECIFICATIONS MAIN DATA AND SPECIFICATIONS OF ENGINE Engine model 4JB1 MODEL ENGINE 4JB1-TC MODEL ENGINE 4JH1-TC MODEL ENGINE Model and type 4JB1-TC diesel engine, 4JH1-TC diesel engine, 4JB1 diesel engine, four cycle, four cylinder, four cycle, four cylinder, four cycle, four cylinder, overhead valve, overhead valve,...
  • Page 188 MAIN DATA AND SPECIFICATIONS MAIN DATA AND SPECIFICATIONS OF TRANSMISSION Transmission type JC520T9D JC521T5H MSB5S TRANSMISSION Model and type 5-speed overdrive, 5-speed overdrive, 5-speed overdrive, synchromesh on all forward gear synchromesh on all forward gear synchromesh on all forward gear (with MT) (with MT) (with MT)
  • Page 189 MAIN DATA AND SPECIFICATIONS MAIN DATA AND SPECIFICATIONS ; QKR Vehicle model QKR55E QKR55F QKR55H DIMENSIONS Wheelbase mm (in) 2,490 (98.0) 2,765 (108.9) 3,360 (132.3) Tread: Front mm (in) 1,385 (54.5) 1,385 (54.5) 1,385 (54.5) Rear mm (in) 1,395 (54.9) 1,425 (56.1) 1,425 (56.1) Minimum ground clearance...
  • Page 190 MAIN DATA AND SPECIFICATIONS Vehicle model QKR55E QKR55F QKR55H STEERING Type Recirculating ball Recirculating ball Recirculating ball Recirculating ball with power assisted Recirculating ball with power assisted Recirculating ball with power assisted Steering wheel free play 10 to 30 (0.39 to 1.18) 10 to 30 (0.39 to 1.18) 10 to 30 (0.39 to 1.18) mm (in)
  • Page 191 MAIN DATA AND SPECIFICATIONS Vehicle model QKR77E QKR77F QKR77H DIMENSIONS Wheelbase mm (in) 2,490 (98.0) 2,765 (108.9) 3,360 (132.3) Tread: Front mm (in) 1,400 (55.1) 1,400 (55.1) 1,400 (55.1) Rear mm (in) 1,395 (54.9) 1,425 (56.1) 1,425 (56.1) Minimum ground clearance mm (in) 190 (7.5) 190 (7.5)
  • Page 192 MAIN DATA AND SPECIFICATIONS Vehicle model QKR77E QKR77F QKR77H SERVICE BRAKE Type Hydraulic dual circuit with vacuum booster Hydraulic dual circuit with vacuum booster Hydraulic dual circuit with vacuum booster Pedal free play mm (in) 4 to 7 (0.16 to 0.28) 4 to 7 (0.16 to 0.28) 4 to 7 (0.16 to 0.28) PARKING BRAKE...
  • Page 193 MAIN DATA AND SPECIFICATIONS TIRE SIZE AND TIRE INFLATION PRESSURE Tire inflation pressure Tire size kPa (kgf/cm , psi) Front Rear Front Rear Vehicle model 7.00R15-8PR 7.50R15-10PR 350 (3.50/50) 575 (5.75/85) QKR55 7.00R15-8PR 7.50R15-12PR 350 (3.50/50) 650 (6.50/94) (Single tire rear wheel model) 7.00R16-10PR 7.00R16-10PR 525 (5.25/75)
  • Page 194 - NOTE - - 6–8 - QKR-IE-1442̲4805234̲ALL.indb   6‒8 QKR-IE-1442̲4805234̲ALL.indb   6‒8 2017/09/27   13:35:00 2017/09/27   13:35:00...
  • Page 195 INDEX Changing transmission oil ....5–66 Dual type fuel filter ......5–32 Chassis number ......... 1–1 Check engine indicator light..... 2–13 Accelerator pedal ......2–23 Checking and adding ....... 5–12 Air cleaner ........5–19 Cigarette lighter ........ 2–22 Antenna ........... 2–38 Emergency starting ......
  • Page 196 INDEX Fuel tank filler cap with key ....2–30 MAIN DATA AND SPECIFICATIONS Fully adjustable steering wheel ..2–15 OF TRANSMISSION ...... 6–2 Fuse and fusible link location ... 5–53 Main fuel filter ........5–27 Jacking instruction and changing a flat Fuse junction block ......
  • Page 197 INDEX OPERATING PRECAUTIONS FOR Pre-fuel filter ........5–30 Specific gravity of battery electrolyte TURBOCHARGED ENGINE ..4–5 PREPARATION FOR STARTING ............. 5–46 OPERATION AND CARE IN WINTER ENGINE ......... 4–1 Speedometer ........2–6 ..........4–13, 5–14 Preparing engine coolant ....5–10 Starter switch ........
  • Page 198 INDEX Underview mirror ......3–10 Usage of the jack ......4–28 Vehicle identification plate ....1–2 Water separator indicator light ..2–12 Wheel replacement ......4–29 WHEN STOPPING / PARKING THE VEHICLE ........1–17 WHEN THE VEHICLE RUNS ..1–12 Windshield washer solution level ..
  • Page 199 This manual is applicable for vehicles in all countries except USA and Canada. All rights reserved. This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by ISUZU MOTORS LIMITED Service Technical &...
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