Isuzu 2008 N Series Workshop Manual
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Isuzu 2008 N Series Workshop Manual

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WORKSHOP MANUAL

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Summary of Contents for Isuzu 2008 N Series

  • Page 1 WORKSHOP MANUAL GENERAL INFORMATION...
  • Page 2 This Workshop Manual deals only with the screen toned section(s) in the table below. Section Sub Section GENERAL INFORMATION General Information ENGINE Engine Control System Engine Mechanical Engine Cooling Engine Fuel Engine Electrical Emission Control Engine Exhaust Engine Lubrication Engine Speed Control System Induction Pre-Heating System SUSPENSION...
  • Page 4 General Information 0A-1 GENERAL INFORMATION General Information TABLE OF CONTENTS General Information ..... . . 0A-2 General Repair Instructions ....0A-2 Identification .
  • Page 5 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.
  • Page 6 General Information 0A-3 Identification Chassis Number/Engine Number Stamping Engine number (4HK1 Engine) Position The engine number is stamped on the right side of the cylinder body. Chassis number It is stamped on the front right-hand side face of the chassis side member. LNW70ASH001901 Legend 1.
  • Page 7 0A-4 General Information Engine number (4HG1 Engine) • Three-digit option codes which means production options or special equipment installed on the The engine number is stamped on the right side front of vehicle at the factory the cylinder body. Refer to the vehicle identification plate when ordering replacement parts.
  • Page 8 General Information 0A-5 Option Option Option Description Option Description Code Code Tire - front & rear 195/75R16C Tire - front & rear 215/75R17.5 Disc wheel - 16x5.5J-116.5 Disc wheel - 17.5x6.00-127 silver (front & rear - highway, MICHELIN) Tire - front & rear 195/75R16C Disc wheel - 16x5.5J-116.5 white Tire - front &...
  • Page 9 Assist grip Tire - front & rear 7.00R-15-10 Disc wheel - 15x5.50F-25-170 Front bumper - gray Tire - front & rear 7R-16-10 Tail gate decal - ISUZU Disc wheel - 5.5F-16-25 Europe equipment Tire - front & rear 7.50R-16-10 Mexico equipment Disc wheel - 16x6.00GS-127...
  • Page 10 General Information 0A-7 Option Option Option Description Option Description Code Code Fuel filter - low quality G.V.W. 6.5-7.0 ton Generator 24V60A G.V.W. 7.0-7.5 ton Glow system - fast G.V.W. 7.5-8.0 ton Air cleaner - heavy duty G.V.W. 8.0-8.5 ton 4JJ1-TCS engine O/S rear view mirror - under Owner’s manual - not required Manual transmission - MZZ6U...
  • Page 11 0A-8 General Information Option Option Option Description Option Description Code Code Final drive gear ratio - 5.375 (43/8) Battery delete Final drive gear ratio - 5.857 (41/7) Rear fog lamp Final drive gear ratio - 6.142 (43/7) Cornering lamp Manual transmission - MSB5S Front fog lamp Spare tire &...
  • Page 12 General Information 0A-9 Option Option Option Description Option Description Code Code KD package - Myanmar Body color - Pl white Tire - front & rear 7R-16-10 Body color - Toll-IPEC yellow Disc wheel - 16x5.5F-115 Body color - RAL4010 tele-magenta KD package - Iran Var.2 Tire - front &...
  • Page 13 O/S rear view mirror - middle arm KD preparatory package Decal - vehicle name / pet name Front seat - long size Decal - pet name Isuzu brand Fuel sedimenter - heated high capa city Anti-erosion spec. KD package - Colombia Generator 24V80A KD package - Venezuela Var.5...
  • Page 14 General Information 0A-11 Option Option Option Description Option Description Code Code Body color - Woodland green Body color - Arc white Body color - Wheatland yellow Tire - front & rear 7-16-12 Disc wheel - 16x5.5F-115 Body color - Sahara beige KD package - Colombia Var.6 KD package - Colombia Var.3 Tire - front &...
  • Page 15 0A-12 General Information 1. World manufacturer identifier (WMI) Code Code 4HV1 Engine ISUZU BRAND 4JJ1 Engine Light Duty Complete Vehicle 4. Wheel base code Code 2. Vehicle model code 2,451 - 2,600 mm Code (96.50 - 102.36 in) 4x2 Truck NHR model...
  • Page 16 General Information 0A-13 11. Production sequential number 1. World manufacturer identifier (WMI) 6. Engine code Code Code ISUZU BRAND 4HG1 engine Light Duty 4JJ1 engine Complete Vehicle 4HK1 engine ISUZU BRAND Light Duty 8. Model year code Incomplete Vehicle Code 2.
  • Page 17 0A-14 General Information General Precaution General Precautions LNW70AMF000101 Legend 1. Clean and safe costume 3. Support by stand after jack up 2. Installation of Chock blocks Work preparations • When lifting up the vehicle using a lift, make sure to set the safety device. •...
  • Page 18 General Information 0A-15 • 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.
  • Page 19 0A-16 General Information Lifting Instruction Lifting Instruction Lifting point and supportable point location - front wishbone suspension model 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.
  • Page 20 General Information 0A-17 Wishbone suspension model Lifting point positions - rear side CAUTION: Do not lift or support on rear axle tube. Over-slung leaf spring suspension model Jacking point Front of vehicle Leaf spring Front of vehicle LNW80ASH000701 Rigid suspension model (4WD) LNW80ASH000801 Under-slung leaf spring suspension model Leaf spring...
  • Page 21 0A-18 General Information Caution for The Maintenance of Electrical Parts Battery Cable With the male and female connectors disconnected • Check that no foreign material or water has Disconnecting the battery cables entered the inside of the connectors. 1. Turn all the switches "OFF". Remove any foreign material or water that has 2.
  • Page 22 General Information 0A-19 Disconnecting the connector Connecting the connector Many connectors have a lock to ensure secure Securely grasp the female side and male side of the connections. connector, and align them correctly. The two types of locks generally used are those that Firmly push them together until both sides click into open by lifting the release area of the lock (1), and place.
  • Page 23 0A-20 General Information Never insert the probes (1) from the connection closure 2. Push the lock (2) up in the direction of the arrow area of the connector, as this will cause the connector using the metal rod to release the lock. In that terminals to break.
  • Page 24 General Information 0A-21 3. Gently pull the harness and check whether the Handling Electronic Parts terminal is completely locked inside the connector. Handle electronic parts with sufficient care, and do not damage the parts by dropping or throwing them. LNW20ASH002001 LNW20ASH002201 Replacing the fuse WARNING:...
  • Page 25 0A-22 General Information 3. When the harness will be contacting sharp edges 5. For wiring between the engine and chassis, give or surfaces of other parts, protect the harness the wiring sufficient free length to prevent wear and using a grommet or tube to prevent damage due to damage caused by vibrations.
  • Page 26 General Information 0A-23 Regarding the Scan Tool Trouble Diagnosis Using the Scan Tool Regarding the scan tool (Tech2) / Tech2 24 volt adaptor 2 /CAN-di module [Euro4 specification] 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...
  • Page 27 0A-24 General Information LNW7Z0SF000101 Legend 1. Tech2 24V adaptor 2 (body) 3. Tech2 connection cable 2. Signal change switch 4. DLC connection cable [Euro4 specification] LNW7Z0SF000401 Legend 1. CAN-di module (body) 3. DLC connection cable 2. Tech2 connection cable Features and cautions regarding the scan tool •...
  • Page 28 General Information 0A-25 • The Tech2 adaptor 2 has a selector for switching • The CAN-di module has a built-in signal converter signals (the signals for each electronic control unit (that converts CAN serial data to keyword serial (ECU)). data) [Euro4 specification] Parts of the Tech2 HCW35ALF001401 Legend...
  • Page 29 0A-26 General Information 3. Action key (YES, NO, ENTER, EXIT) 10. VCI module fastening bar Confirm Tech2 operations, respond to screen Operate the bar to attach/fix, or remove the VCI. instructions/questions, switch/move to the various 11. DLC cable connection connector menu screens.
  • Page 30 2. DLC connection cable Connects the CAN-di module to the Tech2 adaptor Connection method 1. Insert the ISUZU system PCMCIA card into the Tech2 unit. 2. Connect the DLC cable to the Tech2 unit. 3. Connect the CAN-di module to the DLC cable.
  • Page 31 0A-28 General Information MFW90ASH000401 Legend 1. Tech2 2. Battery power cable 3. 3 A fuse 4. Clip (black) 5. Clip (red) • If the power supply is not input, check the 3 A fuse. 7. Turn the ignition "ON", and press the "PWR" key of the Tech2.
  • Page 32 Water pump Water Base ThreeBond 1141E ThreeBond Rear axle ThreeBond 1102 ThreeBond Etc. ThreeBond 1104 ThreeBond Solvent BelcoBond 4 Isuzu BelcoBond 401 Isuzu BelcoBond 402 Isuzu LOCTITE 515 LOCTITE Engine oil seal retainer LOCTITE 518 LOCTITE Water pump Anaerobic LOCTITE 17430...
  • Page 33 0A-30 General Information 1. Completely remove lubricant and moisture from the connecting surfaces. The surfaces must be perfectly dry. 2. Apply specified bead width of liquid gasket to one of the connecting surfaces. There must be no gaps in the bead. mm (in) SCREW JUDGE...
  • Page 34 General Information 0A-31 Recommended Thread Locking Agent Recommended Thread Locking Agent Type Color LOCTITE 242 Blue LOCTITE 262 LOCTITE 271 Work procedure 1. Completely wipe off any water or oil from the contact surface of the bolt and bolt hole, and the threaded portion of nut.
  • Page 35 0A-32 General Information Maintenance Schedule Introduction When performing the checks on the following items, regular inspection items should also be checked. Abbreviations used in this manual Inspect, clean, or repair or replace as required A : Adjust R : Replace Tighten to the specified torque Lubricate...
  • Page 36 General Information 0A-33 Maintenance Schedule NHR85, NLR85, NMR85, NNR85, NPR85 models (1/2) LNW90AXF002701...
  • Page 37 0A-34 General Information NHR85, NLR85, NMR85, NNR85, NPR85 models (2/2) LNW90AXF002801...
  • Page 38 General Information 0A-35 NMR82, NPR82 models (For Thailand) (1/2) LNW90AXF005101...
  • Page 39 0A-36 General Information NMR82, NPR82 models (For Thailand) (2/2) LNW90AXF005201...
  • Page 40 General Information 0A-37 NLR82, NPR82 models (For Australia) (1/2) LNW90AXF006601...
  • Page 41 0A-38 General Information NLR82, NPR82 models (For Australia) (2/2) LNW90AXF005501...
  • Page 42 General Information 0A-39 NPR75, NPS75, NQR75 models (1/3) LNW90AXF000701...
  • Page 43 0A-40 General Information NPR75, NPS75, NQR75 models (2/3) LNW90AXF002401...
  • Page 44 General Information 0A-41 NPR75, NPS75, NQR75 models (3/3) LNW90AXF005801...
  • Page 45 0A-42 General Information NMR71, NPR71, NPS71, NQR71 models (1/2) LNW90AXF001201...
  • Page 46 General Information 0A-43 NMR71, NPR71, NPS71, NQR71 models (2/2) LNW90AXF001301...
  • Page 47 0A-44 General Information NLR55, NMR55 models (1/2) LNW90AXF000801...
  • Page 48 General Information 0A-45 NLR55, NMR55 models (2/2) LNW90AXF001901...
  • Page 49 (4,500 miles) Replace NMR82, NPR82 models every 5,000 km (For Thailand) (3,000 miles) NLR82, NPR82 models Replace (When using ISUZU genuine for every 10,000 km Australia) (6,000 miles) NLR82, NPR82 models Replace Engine Oil (When using FUCHS for every 5,000 km...
  • Page 50 (4,500 miles) Replace NMR82, NPR82 models every 5,000 km (For Thailand) (3,000 miles) NLR82, NPR82 models Replace (When using ISUZU genuine every 10,000 km engine oil for Australia) (6,000 miles) NLR82, NPR82 models Replace Engine Oil (When using FUCHS engine oil...
  • Page 51 0A-48 General Information Condition Item Distance covered Inspect Looseness in or Damage to every 5,000 km Power Steering System Mounting (3,000 miles) Inspect Brake Shoe Lining and Drum Wear every 10,000 km (6,000 miles) Inspect Disc Brake Pad and Disc Wear every 5,000 km (3,000 miles)
  • Page 52 Recommended Fluids, Lubricants and Diesel Fuels Introduction In order to obtain the maximum performance and the longest service life from your ISUZU vehicles, it is very important to select and use correctly best lubricant and diesel fuels. When lubricating, be sure to use ISUZU genuine...
  • Page 53 0A-50 General Information Diesel Engine Crankcase without DPD GRADE MAKE BRAND ACEA JASO ISUZU GENUINE BESCO MULTI-Z TYPE CF-4 (10W-30) CF-4 ISUZU GENUINE BESCO CLEAN SUPER (10W-40) DH-2 ISUZU GENUINE BESCO CLEAN (10W-30, 40) DH-2 Caltex/Chevron Delo CXJ (15W-40), (20W-50), (40)
  • Page 54 General Information 0A-51 Manual Transmission, Transfer Case GRADE MAKE BRAND ACEA JASO ISUZU GENUINE BESCO GEAR OIL TRANSAXLE (5W-30) CD/CE/CF/ Caltex/Chevron Delo 400 Multigrade (15W-40) E3/E5 DH-1 CI-4 Shell Rimula X (15W-40) CH-4 DH-1 Castrol RX Super Plus (15W-40) CD/CE/CF...
  • Page 55 0A-52 General Information Differential (with LSD) GRADE MAKE BRAND ACEA JASO ISUZU GENUINE BESCO GEAR OIL LSD (140) *GL-5 Caltex Gear Oil LSD (90) GL-5 Shell Spirax A LS 90 (90) GL-5 Castrol Hypoy LSX (90) GL-5 Energear LS-M (90)
  • Page 56 30%, the coolant’s anti corrosion performance will be inadequate. When using an anti-freeze solution other than the Isuzu Use a 30% LLC and 60% water mixture for moderate genuine LLC (Isuzu specified product), use the outside temperatures.
  • Page 57 0A-54 General Information Clutch and Brake Fluid Reservoir MAKE BRAND GRADE* ISUZU GENUINE BESCO brake fluid super DOT 3 AC Delco Delco supreme 11 DOT 3 *:This material meets GENERAL MOTORS ENGINEERING STANDARDS GM4653M, FMVSS 116 or SAE J1703 reguirements.
  • Page 58 General Information 0A-55 Oil Viscosity Chart Oil Viscosity Chart ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE SAE 40, 50 [Single grade] SAE 30 SAE 20, 20W SAE 10W -30 C -25 C -15 C 15 C 25 C 30 C -22 F...
  • Page 59 0A-56 General Information GEAR OIL(front and rear axle/transfer case) VISCOSITY CHART GEAR OIL(front and rear axle/transfer case) VISCOSITY GRADE - AMBIENT TEMPERATURE [Single grade] SAE 140 SAE 90 SAE 80W SAE 75W -25 C -10 C 15 C 30 C 35 C -13 F 14 F...
  • Page 60 General Information 0A-57 Lubrication Chart Lubrication Chart : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Brake and clutch fluid Kingpin...
  • Page 61 0A-58 General Information : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Brake and clutch fluid Front hub bearing Front hub bearing...
  • Page 62 General Information 0A-59 : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Brake and clutch fluid Kingpin Front hub bearing Kingpin...
  • Page 63 : Automatic transmission fluid : Multipurpose type grease Brake fluid Front hub bearing Front hub bearing Power steering fluid Engine (When using Smoother clutch ISUZU genuine) fluid SA Engine (When using Transmission FUCHS) Prop.shaft universal joint Prop.shaft Prop.shaft universal joint center bearing Prop.shaft...
  • Page 64 Hydraulic assist brake (HAB) fluid reservoir Brake fluid Kingpin Front hub bearing Kingpin Front hub bearing Power steering fluid Engine (When using Smoother clutch ISUZU genuine) fluid SA Engine (When using Transmission FUCHS) Prop.shaft universal joint Prop.shaft Prop.shaft universal joint center bearing Prop.shaft...
  • Page 65 0A-62 General Information : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Kingpin Brake and clutch fluid Front hub bearing Kingpin...
  • Page 66 General Information 0A-63 : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Differential gear Brake and clutch fluid Kingpin Kingpin Front hub bearing...
  • Page 67 0A-64 General Information : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Brake and clutch fluid Kingpin Front hub bearing Kingpin...
  • Page 68 General Information 0A-65 : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Differential gear Brake and clutch fluid Kingpin Kingpin Front hub bearing...
  • Page 69 0A-66 General Information : Change : Check and Replenish or Lubricate : Engine oil : MoS contained type grease : Gear oil : Brake fluid : Wheel bearing grease : Automatic transmission fluid : Multipurpose type grease Brake and clutch fluid Kingpin Kingpin Front hub bearing...
  • Page 70 Published: Sep., 2009 All rights reserved. Seventh Edition WORKSHOP MANUAL GENERAL INFORMATION Issued by ISUZU MOTORS LIMITED E-Solutions & Service Marketing Dept. Shinagawa-ku, Tokyo, 140-8722 Japan 0-XXXKI...
  • Page 72 No.LGGEN-WE-0871...

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2009 my n series

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