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. 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.
Isuzu Motors Limited
Tokyo, Japan

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 ABBREVIATIONS USED IN THIS MANUAL
V ................................................ Variation (optional on some
models).
OPT ................................................ Optional equipment.
RHD ................................................ Right-hand drive.
LHD ................................................ Left-hand drive.
4JB ................................................ 4JB1, 4JB1-TC engine
models only.
4JB1 ............................................. 4JB1 engine model only.
4JB1-TC .......................................... 4JB1-TC engine model only.
4JH ................................................ 4JH1-TC engine models
only.
TRB ................................................ 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.

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 TABLE OF CONTENTS

1. IMPORTANT INFORMATION
2. CONTROLS AND INSTRUMENTS
3. BEFORE DRIVING YOUR VEHICLE
4. DRIVING
5. SERVICE AND MAINTENANCE
6. MAIN DATA AND SPECIFICATIONS

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QKR-IE-1442_4805234_ALL.indb iv 2017/09/27 13:34:36
 IMPORTANT INFORMATION

IMPORTANT INFORMATION
• Location of chassis and
engine number ............................. 1–1
• Correct cargo loading .................. 1–2
• Operation of new vehicle ............. 1–6
• Operation and care of vehicle ..... 1–7
• Maintenance ................................. 1–7
• Before driving ............................... 1–8
• When the vehicle runs ............... 1–12
• When stopping / parking
the vehicle ................................... 1–17 LOCATION OF CHASSIS AND Engine number:
• To avoid damage to ENGINE NUMBER The engine number is stamped on the left
the vehicle ................................... 1–19 side of the cylinder body.
It is advisable to record the chassis and
engine number as they are required when
The following information is important for contacting your Isuzu dealer for repair
proper care and economical operation of services.
your Isuzu vehicle and should be
thoroughly understood before operating it Chassis number:
into service.
The chassis number is stamped on the
front right-hand side face of the chassis
side member.

- 1–1 -

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 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.

Vehicle identification plate: Wrong loading may cause unstable

CORRECT CARGO LOADING operation, overload on one of the
The vehicle identification plate is attached Overloading and uneven loading are very axles, and an excessive load on the
to the interior side of the cab side panel dangerous. Please use the correct loading wheel bolts. This is a major factor of
on the right side. based on the standard maximum load. the accident that a wheel comes off
Wrong loading may cause unstable due to wheel bolt breakage. Also,
operation, overload on one of the axles, the cargo bed and frame will be
and an excessive load on the wheel bolts. damaged.
This is a major factor of the accident that Refer to "MAIN DATA AND
a wheel comes off due to wheel bolt SPECIFICATIONS" for GVM and Axle
breakage. Also, the cargo bed and frame capacities.
will be damaged.

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 IMPORTANT INFORMATION

Never apply unnecessarily large force. When loading with a heavy cargo: Keep flammable materials away from
Fix the load securely using a load cover or In case of heavyweight cargo, use pads the gap between the cab and the guard
rope to prevent it from falling, but do not under the cargo to prevent it from moving frame.
apply unnecessarily large force as this and fix it firmly with wire rope, etc. Do not Make certain the load cover or rope ends
could break or otherwise damage the side fix cargo using excessive force. are tucked in tight and not hanging free in
drop, tail gate and guard frame, etc. the gap behind the cab, as the engine
heat may cause a fire while driving.

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 IMPORTANT INFORMATION
Loading methods
NO GOOD

GOOD

Loading farming equipment Do not leave a large space between

loads.
CAUTION Distribute the load evenly.

The frame may become deformed

when farming equipment is loaded
from the rear of the cargo bed. In
addition, the frame may become
deformed even when loading farming
equipment that has a weight under
the maximum loading capacity.

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.
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 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. Tuck the
the guard frame or the rear end of the fixing material with rubber bands or other
bed. appropriate material.

- 1–5 -

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 IMPORTANT INFORMATION

NO GOOD GOOD

Avoid high loading. OPERATION OF NEW VEHICLE Without tachometer:

Minimize the height to prevent the vehicle The shift speed label is attached to the
from rolling due to crosswind or when The subsequent performance and the
service life of your vehicle are under the inside of the driver's door.
turning. Shift each gear at 10 km/h (6 mph) lower
direct influence of the care and treatment
that your vehicle will receive during the than the recommended shift speed.
initial break-in period. It is therefore
always recommended that during the With tachometer:
initial 1,000 km (600 miles) break-in
period, the following few simple The shift speed label is not attached.
precautions are carefully observed. It is recommended that engine speed is
restricted to the following:
1. It is recommended that your speed 4JB1, 4JB1-TC : 2,800rpm
during initial 1,000 km (600 miles) be 4JH1-TC : 4,000rpm
confined to the following:

- 1–6 -

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 IMPORTANT INFORMATION

OPERATION AND CARE OF

VEHICLE
Every component and system of your
vehicle should be checked with the aid of
"CONTROLS AND INSTRUMENTS" and
"DRIVING" sections in this manual.

2. Avoid engine racing, abrupt starting MAINTENANCE

and needless hard stops by popping
the clutch. In order to maintain safe and dependable
vehicle operation, inspection and
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"
position, wait at least 1 minute, and
then disconnect the negative cable
WARNING (Continued)

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 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
engine control module may Do not bring fuel containers, spray
malfunction. cans, etc. into the vehicle

BEFORE DRIVING WARNING

Do you use the specified fuel? (low It is dangerous that a fire or MAP

sulfur diesel fuel only) explosion may occur when the

containers catch fire or get
damaged. Clear the driver’s footwell
CAUTION
Always use diesel fuel. WARNING
Use of low quality fuel may adversely It is dangerous that you cannot
affect to the engine parts, and cause operate the brake pedal when an
failure. object in the driver’s footwell moves
Use of other than specified fuel may behind the pedal. To ensure
adversely affect to the engine or operation of each pedal, place the
emission control system and cause floor mat properly.
failure. For models conforming to Euro
IV emission standards, be sure to use
low-sulfur diesel fuel (containing
sulfur of 50 ppm or lower) or extra-
low-sulfur diesel fuel (containing
sulfur of 10 ppm or lower).

- 1–8 -

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 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
occur. Starting or warming-up the before starting the engine. These vehicle. Use of footwear unsuitable for
engine should be performed in a materials may cause a fire. driving may cause an accident.
well-ventilated place. Especially, keep the vehicle more
than 30 cm (12 inch) away from any
wood. Otherwise, it is very
dangerous that this may cause
deformation, discoloration or a fire.

- 1–9 -

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 IMPORTANT INFORMATION

Grip • Getting in or out of the vehicle Starting engine on the vehicle

with oily or greasy hands or
shoes could cause you to slip. CAUTION
Always thoroughly clean grease • Before starting the engine on the
etc. from your hands and shoes vehicle, be seated in the driver’s
before getting in or out of the seat and make sure the parking
vehicle. brake is pulled securely. Also make
• Rain and snow can cause the sure the change lever is in "N"
Step step to become very slippery. position while depressing the clutch
Therefore, always remove snow pedal, and then start the engine.
and ice from your shoes and the • If you start the engine through the
step, and be careful not to slip window (not seated in the driver’s
Getting in and out of the vehicle
when getting in and out of the seat), it is dangerous that the
Carefully check that the area around the vehicle. vehicle may start to move when the
vehicle is safe, hold the grip, and place
• Exercise caution when opening change lever is in other than "N"
your foot on the step when getting in or
or closing doors, as strong winds position. Never do that.
out of the vehicle.
or steep slopes may cause doors
to open or close suddenly.
WARNING
• When getting in or out of the CAUTION
vehicle, make sure you use the
grip and step to always support Do not hold parts other than the grip
yourself from at least 3 points. when getting in or out of the vehicle.
It is very dangerous to stand on Doing so may cause damage to the
the tire or wheel when getting in vehicle or injuries to yourself or
or out of the vehicle. others.
Furthermore, do not try to jump in
or out of the vehicle, as doing so
could cause unexpected
accidents or injuries.
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 IMPORTANT INFORMATION

B Advice on seat adjustment

b a Adjust the seat so that you can move the steering wheel easily with your arms bent
slightly.
C
b Keep your shoulders on the seat-back.
a
c You can depress each pedal fully.
c

Precautions for wearing seat belts Why?

A
A Be sure to wear the lap belt as low on Because it is dangerous in case that
the hips as possible. each part of body may be pressured by
B Wear the shoulder belt so that it does the belt.
Adjusting the seat to your proper rest snugly across the shoulder, but
driving posture and wearing the seat does not contact the neck, chin or face.
belt are fundamental to safety drive C Make sure that the seat belt does not Because this will maximize its
have twist. effectiveness.
CAUTION
Before driving, be sure to adjust the
positions of the seats and mirrors, and
take a proper driving posture. Then
shake the seat lightly to make sure it is
securely fixed. Wear the seat belt
properly, not only drivers but also
passengers.

- 1–11 -

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 IMPORTANT INFORMATION

• If the starter switch is turned to the Pulling away in a manual transmission

LOCK "LOCK" position, the key may be model
removed. This locks the steering
wheel, therefore it is dangerous that CAUTION
you cannot turn the steering wheel.
Pull away gently in first gear. Pulling
away in a high gear, pulling away
rapidly or slipping the clutch for a long
time while pulling away would damage
the clutch.

WHEN THE VEHICLE RUNS

Do not turn off the engine while the
vehicle is running

CAUTION
• The engine may get damaged.
• The effectiveness of the brake will
worsen.
• Turning the steering wheel will be
heavy since the power steering
system is disabled.
• It is dangerous that each warning
light or indicator light does not
work.

- 1–12 -

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 IMPORTANT INFORMATION

CAUTION
When inevitably driving on flooded
road, it is advisable to run slowly at a
constant speed while confirming the
depth of water. Otherwise, water may
intrude in the engine cylinder and
cause damage on the engine (due to
water hammer phenomenon). It is also
advisable to slow down your vehicle
and drive with care. After driving on
flooded roads, it is recommended to
Action to be taken when tires get flat Braking performance after passing immediately take the vehicle to the
or burst puddles and washing the vehicle nearest Isuzu dealer to have the
Do not panic. Hold the steering wheel After passing or parking at puddles or engine, electric parts, transmission,
firmly and apply brake gradually (It is washing the vehicle, depress the brake differential, and clutch parts checked
dangerous to apply the brake suddenly. pedal lightly to check the braking for water intrusion. Also, have oil
This may cause loss of vehicle’s control.) performance. If the braking performance added or lubrication performed in
to slow down the vehicle. Park it in a safe weakens, dry the brake system by areas where necessary.
place, and replace the tire. depressing the brake pedal lightly several If water-ingress to the clutch bearing
times until the performance recovers, has occurred, or if such water-ingress
while driving the vehicle at the slow is suspected, replace the clutch
speed, paying attention to other vehicles release bearing.
ahead of and behind you.

- 1–13 -

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 IMPORTANT INFORMATION
Proper shifting When going down a slope
Downshifting has two main purposes. • When going down a slope, normally
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. vehicle at the appropriate speed so
• To improve quick response and fuel that the tachometer does not indicate
economy while going up a slope. the red zone to prevent the engine
from overrunning (exceeding the
Precautions for downshifting engine speed limit).
• Overrunning leads to damage to the
engine. Downshifting must be
performed within the appropriate
Park the vehicle in a safe place firstly if speed range of each gear.
the warning light comes on
• Even when the vehicle runs on other
Do not continue to drive disregarding the than a downhill slope, downshifting
lighting (blinking) of the warning light. Be must be performed within the
sure to take action for lighting or blinking appropriate speed range of each gear.
lights, referring to the instruction of how to
• On the new vehicle (less than about
see the meters, the warning lights, and
1000 km (600 miles) of mileage),
the indicator lights.
downshifting should be performed at
Refer to the "CONTROLS AND
around 10 km/h below the appropriate
INSTRUMENTS" section.
speed range.
When going up a slope
• Downshift early to avoid load on the
engine.

- 1–14 -

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 IMPORTANT INFORMATION

NOTE
Vapor lock
Frequent use of the foot brake makes
the brake system overheat, and the
Red brake fluid boils due to this heat, then
zone air bubbles form in the brake hose. In
this case, the hydraulic pressure is not
transmitted to the wheel cylinders
though the brake is depressed
because only air bubbles are
compressed, resulting in a sudden
Drive the vehicle at the appropriate speed When going down a long slope drop in the braking force.
so that the tachometer does not indicate • When going down a long slope, use Brake fade
the red zone. exhaust brake (if equipped) and engine Frequent use of the foot brake makes
brake at the same time. Depressing the the brake system overheat, and the
NOTE foot brake for a long time may lead to friction on the friction surface of brake
Engine brake is a braking force which brake fade or vapor lock, causing poor system reduces due to this heat,
is applied when the accelerator pedal brake force. resulting in a drop in the braking force.
is released while the vehicle is • Use of exhaust brake (if equipped) and
running. The lower gears apply the engine brake provided by the low gears
stronger engine brake force. are more effective than use of foot
brake because they reduce the load on
the foot brake and apply more braking
force. However, be careful not to
overrun the engine.

- 1–15 -

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 IMPORTANT INFORMATION
Driving on a wet or icy road surface Be careful with crosswinds When high impact on the underbody
such as due to rain, freeze and snow When crosswinds blow and the vehicle occurs
• Avoid sudden steering and sudden sways, hold the steering wheel firmly, and Immediately park the vehicle in a safe
braking, and slow down the vehicle by slow down to a moderate speed to get place so that it does not obstruct traffic,
using exhaust brake (if equipped) and the vehicle back to stable condition. Be and check for brake fluid, fuel leakage or
engine brake in combination. careful that strong crosswinds may blow damage to each part. If any damage or
(However, sudden use of exhaust in the following situations. fault is found, have your vehicle inspected
brake (if equipped) or engine brake • When passing through an exit of or repaired at Isuzu dealer as soon as
may cause the vehicle to skid.) Drive tunnel, bridge, embankment or possible.
moderately especially in areas where dugway.
puddles are likely to form, as
hydroplaning may occur. • When a large truck passes by your
vehicle.
• If you must drive through a water-
covered road, be sure to check the • When your vehicle passes by a large
depth and drive at a constant slow truck.
speed. Otherwise, water may get
inside the engine cylinder and the
engine may get damaged (water
hammer). Drive carefully at a moderate
speed.

NOTE
Hydroplaning
When a vehicle runs on a wet road at a
high speed, a film of water forms
between the tires and the road surface.
The tires will float on water and lose
their grips, resulting in loss of steering
and braking.
- 1–16 -

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 IMPORTANT INFORMATION

• Be careful that the engine may Run the engine whenever you move
overheat, or a fire may occur due the vehicle
to overheating of engine or
exhaust pipe if you CAUTION
unintentionally keep depressing Turning the steering wheel will be
the accelerator pedal. heavy since the power steering system
• Be careful that carbon monoxide is disabled when the engine is not
poisoning may occur depending running. The brake system is also
on circumstances such as a place disabled, resulting in poor braking
with poor ventilation if the force. Also, if you attempt to move the
exhaust gas gets inside the vehicle with the help of downhill slope,
vehicle. it may not move correctly, causing an
WHEN STOPPING / PARKING accident.
THE VEHICLE
When you take a nap in the vehicle

WARNING
• When you take a nap in the
vehicle, always turn the starter
switch to "LOCK" position to
turn off the engine. Otherwise, if
you unintentionally move the
change lever or depress the
accelerator pedal, the vehicle
may start moving, causing an
accident.

- 1–17 -

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 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.

CAUTION
Do not leave glasses or a lighter in the
vehicle. The lighter may explode, or the
Be careful with flammable materials Ensure braking on a slope plastic lens or flame of glasses may
deform or crack if they are left in the
When parking the vehicle on a slope,
vehicle.
CAUTION apply the parking brake firmly and make
sure the vehicle does not move, and put
• Make sure that there are no
wheel chocks for safety. Change the
flammable materials around the rear
directions of wheels by turning the
of vehicle and dried grass does not
steering wheel fully to the left or right so
wind around the exhaust pipe, and
that the vehicle stops at blocks (such as
then start the engine. Be careful that
curbs) when it goes down a slope in case
the hot exhaust pipe and hot
that the wheel chocks go off or the
exhaust gas may catch fire after
parking brake is released.
engine racing, or engine running at
high speed for long periods of time.
• Take extra care of the heat of
exhaust gas during idling.

- 1–18 -

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 IMPORTANT INFORMATION

TO AVOID DAMAGE TO THE Do not drive with your foot resting on Never keep the steering wheel turned
VEHICLE the clutch pedal fully for a long period
This causes a half-clutch condition
Do not mount any accessories on the
unintentionally. The half-clutch condition WARNING
windshield, windows, etc.
facilitates clutch disc wear resulting in
clutch slip. Do not keep the vehicle This causes the temperature of oil
WARNING stopped on an uphill slope using a half- in the power steering oil pump to
clutch, instead of brake. increase, resulting in poor
This may disturb safety driving. Also, lubrication. This leads damage to
a sucker of accessory may act as the oil tank or deterioration of the
lens, causing a fire. seal resulting in damage to the
power steering oil pump, power
steering unit and power steering
hose, etc. As a result, turning the
steering wheel may get heavy
suddenly or an accident such as a
fire may occur.

- 1–19 -

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 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.
• Prevents wear of the engine parts.
• Cools down the engine parts.
• Cleans the engine parts.
• Keeps the combustion chamber airtight
and prevents rust. Change the engine
oil, etc. periodically.
Refer to "SERVICE AND
MAINTENANCE" and "MAIN DATA AND
SPECIFICATIONS".

- 1–20 -

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 CONTROLS AND INSTRUMENTS

CONTROLS AND
INSTRUMENTS LHD
• 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
3 OPT Front fog light switch
4 Meter and Indicator light panel
5 Steering wheel
6 Horn button
7 Windshield wiper and washer switch
lever
OPT Exhaust brake switch lever
8 Hazard warning flasher switch 18 OPT Steering adjusting lock lever
9 OPT Heater and defroster control (Vertical, back and forth)
panel 19 Idling control knob
10 Ash tray
11 Transmission gearshift lever
12 Cigarette lighter
13 Parking brake lever
14 Accelerator pedal
15 Brake pedal
16 Starter switch
17 Clutch pedal
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 CONTROLS AND INSTRUMENTS

CONTROLS AND
INSTRUMENTS RHD

1 OPT Heater and defroster control

panel
2 Hazard warning flasher switch
3 Meter panel ventilators
4 Windshield wiper and washer switch
lever
OPT Exhaust brake switch lever
5 Horn button
6 Steering wheel
7 Meter and Indicator light panel
8 OPT Front fog light switch
9 Combination switch lever
10 Idling control knob
11 Accelerator pedal 18 Transmission gearshift lever
12 Starter switch 19 Ash tray
13 Brake pedal
14 OPT Steering adjusting lock lever
(Vertical, back and forth)
15 Clutch pedal
16 Parking brake lever
17 Cigarette lighter
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 CONTROLS AND INSTRUMENTS

METERS AND INDICATOR LIGHTS

V
Meter panel
V

1 Speedometer V
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

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 CONTROLS AND INSTRUMENTS

V
11 22 55 33 66

9
9 44 77
V 1
1 22 55 33 66

9
9 44 77

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 CONTROLS AND INSTRUMENTS
Indicator and warning lights
................................ V SVS (Service vehicle soon)
............................. Turn signal indicator light indicator light

..................................... High beam indicator light .................................... V Seat belt warning light
(for GCC model)
..................................... V Rear fog indicator light

..................................... Fuel indicator light

..................................... Battery/Generator indicator light

..................................... Parking brake indicator

and brake fluid level
indicator light

..................................... Glow plug indicator light

..................................... Oil pressure indicator light

..................................... OPT Exhaust brake indicator light

..................................... V Water separator indicator light

................................... 4JH Check engine indicator light

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 CONTROLS AND INSTRUMENTS

V V V
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" or "ON" position, the time will
miles per hour (mph). changed in order of odometer, trip meter appear digitally on the clock face.
Odometer and trip meter A, trip meter B, and odometer. Continue To set the time, operate the knob for the
to push the knob for approximately one following functions:
The odometer and the trip meter indicate second or more when the meter (trip A, To set hours:
kilometers (or miles). trip B) is indicated, and the indication will Depress and turn the knob counter-
The odometer indicates total running return to 0 (zero). clockwise to advance the hour.
mileage, and the trip meter is used when
you want to know point-to-point distance To set minutes:
and running mileage reached in a certain Depress and turn the knob clockwise to
period of time. Further, the trip meter can advance the minutes. The hour
indicate two kinds of point-to-point indication will remain unchanged when
distance. the minute changes from "59" to "00".
To reset minutes:
Pull the knob out to reset the minutes
to "00".

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 CONTROLS AND INSTRUMENTS

V V V

Red Red
zone zone

Engine tachometer V 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" on the dial represent "cold" and "hot".
NOTE
The calibration and the red zone of
tachometer are various depending on
the models fitted.

CAUTION
Never operate the vehicle with the
tachometer needle in the red zone.
Continued operation with the
tachometer needle in the red zone can
lead to serious engine damage.

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 CONTROLS AND INSTRUMENTS

V V V

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. the needle does not return to the E
Stop the vehicle safely and follow (empty) mark but remains at the
the instructions given under the appropriate fuel level.
heading "Engine overheating" in The letters "F" and "E" represent "Full"
"DRIVING" section of this manual. and "Empty" respectively.
• Continued operation of an
overheated engine can result in NOTE
serious engine damage.
Make a habit of refueling early and take
care not to run short of fuel.

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 CONTROLS AND INSTRUMENTS

Turn signal indicator lights High beam indicator light Rear fog indicator light V

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.
turn signal indicator light flashes to use.
indicate the operation of the external turn
signals or hazard warning flasher.

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 CONTROLS AND INSTRUMENTS

Fuel indicator light Exhaust brake indicator light OPT Parking brake indicator and
The fuel indicator light comes on when When the exhaust brake switch is set to Brake fluid level indicator light
the fuel in the tank is lower than at the the "ON" position, the indicator light The parking brake indicator light comes
specified level. (7 to 10 liters, 1.5 to 2.2 comes on. on when the parking brake lever is pulled
gal (UK)). with the starter switch "ON".
Fill up the tank as soon as possible. The NOTE The brake fluid level indicator light comes
indicator light comes on when the starter on when the brake fluid in the reservoir is
When traveling over an uneven road
switch is turned to "ON" position and after lower than the specified level.
surface, the exhaust brake may be
starting the engine, it goes off normally. The indicator light comes on when the
disengaged for short intervals even if
starter switch is turned to the "ON"
the brake pedal is not depressed.
NOTE position and after starting the engine, it
goes off normally.
Driving on a road with many sharp
curves may cause the fuel indicator
light to blink intermittently. This is
normal and should be ignored.

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 CONTROLS AND INSTRUMENTS

WARNING
If the light comes on while driving,
stop the vehicle immediately and
check the level of the brake fluid in
the reservoir.
If the level is too low and braking
force is lost, have the vehicle towed
in for repairs.

Battery/Generator indicator light Oil pressure indicator light

The battery/generator indicator light The oil pressure indicator light warns
comes on when the starter switch is about "Low oil pressure", and "Low oil
turned to the "ON" position and goes off level" by the oil level switch.
when the engine is started and the The oil pressure indicator light comes on
generator circuit is brought into normal when the starter switch is turned to the
function. "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.

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 CONTROLS AND INSTRUMENTS

CAUTION
If the oil pressure indicator light comes
on while driving, it indicates that the
oil pressure is dangerously low. Stop
the engine immediately and check the
level of the oil in the engine crankcase.
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 V Glow plug indicator light
The indicator light comes on when the The glow plug indicator light comes on
water level in the water separator on the when the starter switch is turned to the
fuel line is beyond the specified level. "ON" position and goes off when the glow
plug is sufficiently heated.
NOTE
If the indicator light comes on while
driving, stop the vehicle and drain the
water immediately. Refer to the
"DRIVING" section.

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 CONTROLS AND INSTRUMENTS

4JH
CAUTION
If the light comes on either
intermittently or continuously while
driving, service is required.
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
Check engine indicator light 4JH the emission control system. It SVS (Service Vehicle Soon) indicator
could also affect fuel economy and light V
The "CHECK ENGINE" light on the driveability.
instrument panel is designed to indicate The SVS indicator light will come on
the need for system service. It will come when the starter switch is in the "ON"
on when the starter switch is in the "ON" position and the engine is not started, to
position, but before the engine started, let you know the bulb is working.
to let you know the bulb is working. (The The indicator light will go off after the
light will stay on a short time after the engine starts.
engine starts.) Have the system repaired If the indicator light comes on during
if the "CHECK ENGINE" light does not operation, immediately contact your
come on when the starter switch is in the Isuzu dealer for inspection.
"ON" position, but before the engine is
started.

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 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. This may lead to the damage to
Seat belt warning light V STEERING COLUMN the power steering oil pump and
(for GCC model) power steering unit etc. and as a
CONTROLS result, the steering wheel operation
The seat belt warning light comes on may get heavy suddenly.
Steering wheel and horn button
when the driver does not fasten the seat
belt with the starter switch "ON". The horn button on the steering wheel
operates the horn.
NOTE
This warning light goes off when the
driver fastens the seat belt.

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 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.
Lock lever Lock
3. At the desired position, lock the
column rotating the lock lever down.

Fully adjustable steering wheel OPT Starter switch

The steering wheel is adjustable in a back The starter switch has four positions as
and forth direction and a vertical direction. shown in the figure.
Adjust the steering wheel position along
"LOCK": Normal parking position. Locks
with the driver seat for maximum comfort.
the steering and prevents normal
use of the steering wheel.
CAUTION The key can be removed only
Fully tighten the lock lever after when the starter switch is in this
making adjustments. Always make an position.
adjustment with the vehicle stationary
and NEVER attempt to adjust while
driving.

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 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.
• Turning the engine off with the
vehicle in motion is dangerous,
as braking efficiency will be
reduced. Combination switch lever Light control switch
The combination switch lever consists of The control switch operates in three steps
"ACC": You can use some electrical the light control switch, turn signal switch, to operate the following lights:
accessories when the engine dimmer switch and passing light switch. 1st step: Clearance lights, tail lights,
is not running. On the LHD model, this switch lever is on license plate lights and
"ON": The "ON" position is for pre- the left side of the steering column. instrument cluster lights.
heating and normal running. 2nd step: Head lights in addition to the
"START": Turning the key to this above lights.
position will start the engine. 3rd step: Rear fog light in addition to
The key returns to the "ON" the above lights.
position when released.

CAUTION
Do not keep the starter engaged for
more than 10 seconds.

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 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 each time the switch is raised. The high and released with the light switch in either
indicator light on the instrument panel beam indicator on the instrument panel "OFF" or the first stop position. To give a
flashes. The switch returns automatically lights up when the head lights are on high signal of overtaking, operate the lever
to the neutral position when steering beam. repeatedly so that the head lights flash in
wheel is returned to a straight-ahead the daytime and at night the high and low
position. beams come on alternately.

Cornering light V

When the head lights and a turn signal

light are both turned on, the cornering
light will automatically come on.

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 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.

Windshield wiper switch lever Windshield washer switch lever

The windshield wiper switch has 3 (or 4) Push and hold the center switch button
positions to control the windshield so that the washing solution is squirted to
wipers. the windshield.
Off OPT Intermittent On the LHD model this switch is on the
Low speed High speed right side of the steering column.

WARNING
In cold weather, warm the
windshield with the defrosters
before using the washer. This will
help prevent icing which may block
the driver's vision.

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 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
transmission gearshift lever is in the
neutral position.
Exhaust brake switch OPT
• If a buzzer is actuated while the INSTRUMENT CLUSTER
Pull the exhaust brake switch upward to exhaust brake is engaged, Front fog light switch OPT
engage the exhaust brake and the immediately stop the vehicle in a
indicator light on the instrument panel will safe place and call for inspection. When fog or heavy mist reduce your
light up. forward vision, push this switch to turn the
The exhaust brake will disengage when fog lights on.
the acceleration or clutch pedal is The fog lights will operate only when the
depressed or the transmission gearshift head lights low beams are in use. The
lever is shifted into neutral, but the indicator light in this switch will turn on
indicator light will remain on until it is when the front fog lights are operated.
switched off on the column. To turn off the switch press it again.

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 CONTROLS AND INSTRUMENTS

Lock

Unlock

Hazard warning flasher switch Idling control knob Central locking door V

When the switch is pushed, all the turn Turning the knob clockwise (in the Locking or unlocking the driver's door
signal lights are made to flash, regardless direction of the arrow) after cold starting with either the key or the lock button will
of the turn signal position. of the engine will increase idling speed also lock or unlock the remaining door.
To turn off the switch press it again. thereby facilitating smooth engine idling. Locking or unlocking the passenger door
Always drive with the knob returned to the with the key will also lock or unlock the
home position. other doors.
CAUTION Locking or unlocking the passenger door
• Use the warning flasher to warn WARNING with the lock button will not lock or
other drivers that your vehicle is a unlock the remaining doors.
traffic hazard, day or night. Do not use the idle control while
the vehicle is in motion. This
• Avoid stopping on a roadway if at all WARNING
could reduce your ability to stop in
possible.
an emergency, resulting in Before driving, make sure that the
personal injury and/or property doors are closed and locked,
damage. especially when young children are
in the vehicle.

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 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
Release button the parking brake.
Failure to fully set the parking brake
could result in vehicle movement
on an inclined surface.
Parking brake lever Ash tray
When parking the vehicle, fully apply the To use, pull the tray out. To clean, pull
parking brake lever without pressing the the tray out further while pushing down on
release button. The parking brake the ash dump plate.
warning light in the instrument panel will
come on when the lever is pulled up. WARNING
To release the parking brake, pull upward
slightly. Then depress the release button • After using the ash tray, push it
and push down all the way. back in completely. If not, the
To help remind you, the brake system flame of a cigarette may cause
indicator light is designed to come on other cigarette butts to burn,
if the parking brake control is not fully resulting in a fire.
released when the key is on. • Never throw lit cigarette butts out
the window. They not only litter
the road and around but also can
cause a roadside fire.

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 CONTROLS AND INSTRUMENTS

CAUTION
• Avoid holding the lighter in by hand
while it is heating, as damage to the
heating element may result.
• To substitute the cigarette lighter
socket for an accessory power
outlet, consult the nearest Isuzu
Dealer.
• If the cigarette lighter socket
was used as an accessory power
outlet by necessity, the inside of
Cigarette lighter socket may be deformed. When FLOOR CONTROLS
the cigarette lighter is used with
To operate the lighter with the key switch the deformed inside, it may cause Transmission gearshift lever
in the "ACC" or "ON" position, push the failures such as that the red-hot
light in all the way and then release it. When shifting the transmission, depress
cigarette lighter pops out or it does the clutch pedal completely. The
The lighter will spring back to its normal not come out as it is pressed in.
position within about 15 seconds after gearshift pattern is shown on the lever
• To use it once again as the cigarette knob. The back-up lights operate when
being pushed in and when it is ready for lighter changing from the accessory
use. Pull the lighter out and use it. shifted into reverse with the key switch in
power outlet, or to replace the the "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. V
lighters.
after 18 seconds, it is faulty and
must be pulled out in its normal • When cleaning the cigarette lighter,
do not use too much force. It may NOTE
position by hand.
cause a deformation. Allow the vehicle to stop completely
• Remove ashes and dirt inside the before shifting into reverse.
cigarette lighter socket and on the
heater portion of cigarette lighter.
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 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.
reasonably. foot brake in combination with the engine
braking effect. NOTE
Do not allow your foot to rest on the
NOTE pedal when not using the clutch.
If the engine stops while the vehicle is
running, the brake booster is not
effective and braking efficiency is
reduced. Vehicle stopping is still
possible by depressing the brake
pedal strongly.

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 CONTROLS AND INSTRUMENTS

Knob Sun visor

Hook

OTHERS Sun visor Dome light

Glove box Lower the sun visors when you are facing The dome light is operated at any key
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.
passenger side end of the instrument "OFF" position:
For passenger seat side the hook is on
panel. The light remains off.
the opposite side. OPT
To open the glove compartment, pull the "DOOR" position:
compartment lid out while pulling the knob The dome light turns on when the
outward. driver side door is opened.
"ON" position:
WARNING The light turns on regardless of the
Avoid driving with the glove box lid door position.
open. In the event of a sudden stop
or an accident, it could cause
injuries.

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 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

Turn the handle to raise or lower the door door V
window. When the starter switch is in the "ON"
position, you can open and close the
window on all doors by operating the
power window switches on the driver's
door side.
Lightly press the switch end, and the
window will continue to open until the
switch is released. Press the switch end
hard, and the window will open
automatically to a full open position even
if the switch is released. To stop the
window on its way, pull the switch end
lightly.
Lightly pull the switch end, and the
window will continue to close until the
switch is released.
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 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.

Power window switch on the Power window lock V

passenger door V When the power window lock switch is in
When the starter switch is in the "ON" the "ON" position, you cannot open or
position, you can open and close the close by means of the power window
window by operating the power window switch on the driver’s door or passenger
switch on the passenger door. door. Press the lock switch once again
Press the switch end, and the window will and the power window will be unlocked.
continue to open until the switch is
released.
Pull the switch end, and the window will
continue to close until the switch is
released.

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 CONTROLS AND INSTRUMENTS

4JB1 4JH
4JB1-TC

MAX

MIN

Radiator reserve tank Windshield washer tank

The radiator reserve tank is located on The windshield washer tank is located
the left side of the engine compartment or under passenger side of the instrument
on the behind the cab. panel.
The washer tank should be filled only with
WARNING tap water or Isuzu genuine washer
solution.
Engine coolant level check or
replenishment should be made at
the reserve tank and the radiator
WARNING
cap should not be removed unless In cold weather, warm the
necessary. Refer to the section of windshield with the defrosters
"SERVICE AND MAINTENANCE" for before using the washer.
more details. This will help prevent icing which
may block the driver’s vision.

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 CONTROLS AND INSTRUMENTS

4JB
CAUTION
• Do not use radiator coolant in the
windshield washer, as it could cause
paint damage.
MAX
• Clear ice or packed snow from the
wiper blades before using the MIN
wipers. MAX
ADD

Brake and clutch fluid reservoir Power steering fluid tank V

The fluid reservoir is beside the meter The power steering fluid tank is located
panel of the driver's side. on the right side of the engine
compartment 4JB or on the right side
behind the cab 4JH . It has a removable
plastic shield cover.

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 CONTROLS AND INSTRUMENTS

4JH Since fueling with the engine

running may cause a fire, be sure to
stop the engine before fueling.
Keep fire away when fueling. A fire
may occur due to fuel catching fire.
Be sure to wipe off the fuel that is
spilled at fueling.
Make sure that the fuel cap is tightly
closed after fueling.

Fuel tank filler cap NOTE

The fuel tank filler cap is provided on the Always use diesel fuel.
fuel tank. To open, turn the cap Use of low quality fuel may adversely
counterclockwise. affect to the engine parts, and cause
failure.
WARNING Use of other than specified fuel may
If you need to replace the fuel filler adversely affect to the engine or
cap, use only a genuine Isuzu fuel emission control system and cause
filler cap. The use of an improper failure. For models conforming to Euro
fuel filler cap could cause fuel IV emission standards, be sure to use
spillage in the event of an accident. low-sulfur diesel fuel (containing
The use of an improper fuel filler sulfur of 50 ppm or lower) or extra-
cap could also affect the fuel low-sulfur diesel fuel (containing
system and the emission control sulfur of 10 ppm or lower).
system. If other than specified diesel fuel is
used, the vehicle may not conform to
specifications.

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Fuel tank filler cap with key OPT Spare wheel hanger To raise, turn the handle clockwise until it
Open the filler lid and unlock and lock with The spare wheel is secured to either the stops. Give an additional tug on the
the key. Turn the filler cap rear of the frame or the left side of the handle to securely hold the spare wheel in
counterclockwise to remove it. frame with a chain. To lower the spare position of stowage.
wheel, insert the handle into the hole in
NOTE the rear of the vehicle to engage the catch WARNING
and turn the handle counterclockwise. Turn the handle clockwise to raise
Do not use any additive fuel or water
treatment. the spare wheel, give a final turn by
hand (with a force of 20 to 50 kg (44
to 110 lbs)) and make sure the
spare wheel is securely fixed in
position.
Be sure the spare tire assembly is
properly secured to prevent it from
becoming a hazard in the event of a
sudden stop or an accident.

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 CONTROLS AND INSTRUMENTS

Engine inspection cover Engine inspection sub cover

To gain access to the engine, release the (Non tilt cab)
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.
adjustment.

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 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 N
the engine cooling fan when the
5 speed
engine is running.

1. Preparation for cab tilting. 2. Squeeze the lock lever, and pull the
cab tilt out and up.
WARNING
• Park the vehicle on level ground
and check that there is sufficient
space in front of the cab and
above the cab.
• Set the parking brake firmly.
• Put the gearshift lever in the
neutral position.
• Keep the interior of the cab free
from items that are liable to fall.
• Close the doors completely.

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 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. Lower
raising of the cab. the cab by holding the assist handle.

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 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 Opening and closing rear gate: gates:
that the cab is locked with the main 1. Release the rear gate locks.
hook and tilting lever securely. Turn the left and right levers up 180°,
release the locks and open the gate. To 2. Release the vertical lock by sliding the
close, shut the gate then lower the lever lock lever to the left and lower the
to secure the gate. lever.

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 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 V Rear fog light
secured by the gate hold at this time. Turn signal lights Back up lights
To open the gate, pull it with some Clearance lights / Cornering lights Reflectors
force. OPT Fog lights Tail and stop lights
To close the gate, lock the front of the Turn signal lights
gate securely with the hook lever,
push in the vertical lock of the rear
gate and lock the gate with the lever.

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Heater-defroster OPT 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
FACE (Air to your face) flow rate).
BI-LEVEL (Air to your face and foot)
FOOT (Air to your foot)
FOOT/DEF. (Air to your foot and
windshield)
DEF. (Air to windshield)

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 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. source select lever as shown in the
outside air and the circulation. figure, and slide the fan blower switch
Air circulated in the vehicle. on.
Outside air brought into the vehicle.

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 CONTROLS AND INSTRUMENTS

Heating: Power ventilator (on models with and Antenna

Set the temperature lever as shown in without heater): 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. When you want to warm up position except "OFF". when the radio is to be used.
quickly, set the air source select lever Set the air source lever as shown in Retract the antenna before entering an
as shown in the figure and slide the fan this figure. area with restricted headroom.
blower switch to the "4" position. Fresh air will then be drawn in from
outside the vehicle.
NOTE
Windshield is often misted up when
the air source select lever is set as
shown. To demist, slide the lever to
the far right.

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 CONTROLS AND INSTRUMENTS

Cup holder OPT

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. If
there is a spill, wipe it up immediately
with a dry cloth.

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 - NOTE -

- 2–40 -

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 BEFORE DRIVING YOUR VEHICLE

BEFORE DRIVING YOUR

VEHICLE
• Operation of controls ................... 3–1
• Driver's check list
(Regular inspection) .................. 3–10

Proper care and driving is important not

only in extended service life of your
vehicle, but also in improved fuel and oil
economy. Drive carefully and
defensively.
OPERATION OF CONTROLS
Key
This key is used for the starter switch and
the door lock. The code number of each
key is stamped on it.
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.

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 BEFORE DRIVING YOUR VEHICLE

Lock Unlock

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.
Doors can be locked by inserting the key lock lever on the door inside to the "lock"
in the door key hole and turning it. position and closing the door with the
outside handle pulled outward.

NOTE
Avoid leaving the key inside.

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 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.
Door lock (Inside) Locking the doors will also Driver's seat
discourage intruders while the
The doors can be locked by pressing the vehicle is temporarily stopped. The driver's seat may be adjusted forward
door lock lever after closing the door. or backward by pulling up the lever at the
• When leaving the vehicle front of the seat and then using your body
unattended, shut off the engine to move the seat to the desired position.
and lock all doors. Let go of the lever at the desired position.

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 BEFORE DRIVING YOUR VEHICLE

WARNING • Try to move the seat without

unlatching it after making
• Use caution when adjusting the adjustments to check that it is
seat, as failure to do so could completely locked. A loosely
cause injury. locked seat may move
• Never allow children to adjust unexpectedly and your position
their seats themselves; an adult might then become unstable; this
should adjust the seat for could lead to an accident. Take
occupants who are children. the vehicle to your Isuzu Dealer
• Adjust the seat only before you for service if you find that your
start driving. Adjusting the seat seat adjusters do not latch. In
while the vehicle is in motion addition, the seat belt will not
Front seatbacks can be tilted backward if operate properly if the seatback
must be avoided not only
so desired, using the lever on the door is not completely locked.
because the unlocked seat will
side of each front seat. Raise the lever
move back and forth unstably, • Driving with the seat excessively
and the front seatback will tilt forward.
preventing you from taking the reclined could be very dangerous
Raise the lever and adjust the seatback to
correct position, but might also in the event of a collision or
the desired position. Keep seat belt and
cause you to lose control of the sudden stop. Raise the seatback,
latch clear of the seat when you tilt the
vehicle, possibly resulting in an and apply the seat belt correctly
folding seats forward or backward. This
accident. while sitting straight in the seat.
helps to prevent damage to the seat belt
system. • Do not place a cushion or similar
object between your back and
the seatback. Doing so not only
affects the stability of your
driving position but also prevents
the seat belt from working
effectively in the event of a
collision.
WARNING (Continued)
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 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. Be
careful that your hand or foot
does not become trapped in the
seat or rails when adjusting the Seat belt (2-points) 3. Position the lap belt across the lap as
seat. low on the hips as possible. Then,
1. Sit up straight and well back in the
• When adjusting the seat, be seat. adjust to a snug fit by holding the free
careful that the seat does not hit end of the strap and pulling it through
2. Take hold of the latch plate at an the latch plate until the lap belt is
passengers or objects. Doing so
angle to the strap and slide it toward snug across the lap. This reduces
could cause injury to passengers,
the front of the vehicle. the risk of sliding under the belt
or damage objects.
Then pull it slowly across your lap and during an accident.
• Make sure not to hit passengers push the latch plate into the buckle
or luggage when adjusting your until it clicks.
seat.

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 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.

4. To unfasten the belt, push in the

button on the buckle. WARNING
• A snug fit with the lap belt
positioned low on the hips is
necessary to lessen the chance
of injury and/or a degree of injury
in an accident. This spreads the
force of the lap belt over the hip
bone instead of across the
abdomen.
• Never use the same seat belt for
more than one person at a time.
A seat belt worn by more than
one person will not provide
adequate protection in the event
of a collision.

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 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
1. Adjust the seat as needed and sit well belt during a collision, position the belt on the buckle. The belt should
back and straight up. Grasp the latch across your lap as low on your hips as retract when the buckle is unlatched
plate and: possible and adjust it to a snug fit by but hold the latch plate as it does so,
pulling the "shoulder" portion upward to keep it from hitting people or
• Pull the belt as far as it will reach through the latch plate. nearby objects. To help prevent
across your lap. damage to the safety belt and interior
The lap-shoulder belt is designed to
• Hold the latch plate at an angle to lock during a sudden stop or impact. trim, before closing the door be sure
the strap and slide it further (toward At other times it should move freely. the belt is fully retracted and the latch
the front of the vehicle). plate is out of the way.
• Then pull it slowly across your lap CAUTION
and push it into the buckle until it
clicks. If the retractor locks before To help reduce the risk of personal
the latch plate reaches the buckle, injury in an accident, if a shoulder belt
let the belt retract slightly, then is on or very close to a child's face or
withdraw it more slowly than neck, move the child toward the center,
before. away from the shoulder belt.

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 BEFORE DRIVING YOUR VEHICLE
Seat belt inspection and care: General notice
CAUTION
• Periodically inspect belts, buckles, In the interest of safety, seat belts should
latch plates, retractors and anchors It is important that you understand be checked regularly. Your dealer will
for damage that could lessen the how to correctly wear a seat belt. You inspect and check the belts for you as
effectiveness of the restraint system. should also ensure that all occupants part of the normal guardian maintenance
wear a properly adjusted seat belt service.
• Keep sharp edges and damaging
whenever the vehicle is moving. Never attempt to modify or change the
objects away from belts.
seat belt away from the original
• Replace belts if cut, weakened, specification as this will affect the
frayed or subjected to collision loads. operation of the belts and reduce their
• Check that anchor mounting bolts are effectiveness, in preventing injury in an
tight to the floor. accident.
• Have questionable parts replaced.
• Keep seat belts clean and dry.
• Clean only with mild soap solution
and lukewarm water.
• Do not bleach or dye belts since this
may weaken belts.
• Care should be taken to avoid
contamination of the strap with
polishes, oils and chemicals, and
particularly battery electrolyte.
• No modifications or additions should
be made by the user that will affect its
function.

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 BEFORE DRIVING YOUR VEHICLE

Mirrors Outside rearview mirrors

Inside rearview mirror Adjust the outside rearview mirrors so you
To adjust, push the mirror right or left, and up can see not only each side of the road
or down. behind you but also each side of your
vehicle. This helps you determine your
relation to the objects behind.

WARNING
Do not adjust the exterior mirrors
while the vehicle is moving.

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 BEFORE DRIVING YOUR VEHICLE

Underview mirror OPT DRIVER'S CHECK LIST Exterior

Adjust the underview mirror so you can (REGULAR INSPECTION) 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
dependable vehicle operation.
has lost its pressure. Therefore, use a
(Refer to the "MAINTENANCE GUIDE"
tire gauge to check the tire pressure.
for proper check-up procedures.)

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 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.
3. Visually check the following items.
• Check for faults, such as missing
wheel nut, broken wheel bolt, etc.
• Check the wheel bolt area for trace
of rust fluid.
• Check if the protrusions of the
wheel bolts from the wheel nuts are
uniform.

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 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.

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 BEFORE DRIVING YOUR VEHICLE

Within cab 2. Check parking brake lever travel. 3. Check operation of horns, windshield
1. Check for steering wheel excess play wipers and turn signals.
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.

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 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.

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 BEFORE DRIVING YOUR VEHICLE

MAX
ADD

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.

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 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.

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 BEFORE DRIVING YOUR VEHICLE

4JB1 4JH To open the radiator cap or

4JB1-TC reserve tank cap, put a piece of
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,
MAX
immediately vomit it and seek
MIN prompt medical attention.
• If the engine coolant gets in your
eyes, rinse it off immediately with
3. Check the engine coolant level and a large amount of water for 15
the radiator cap for looseness. WARNING minutes or longer. Also, if still
abnormality such as irritation is
• When the engine coolant is
felt, seek medical attention.
heated to a high temperature, be
sure not to remove the radiator • If the engine coolant gets on your
cap or reserve tank cap. If skin, rinse it off using a soap
removing unnecessarily, steam with a large amount of water.
spouts and may cause a burn. Also, if abnormality is seen, seek
The reserve tank or engine medical attention.
coolant temperature inside of the WARNING (Continued)
reserve tank is also very hot, so
its boiling water may cause a
burn. Be sure to perform
checking, adding or changing
when engine coolant temperature
is low.

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 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. Take care not to splash
it.
• For storage, close the cap
securely and keep it in a place
inaccessible to children.
Refer to the "MAINTENANCE After starting engine 2. Check the brake pedal free play and
GUIDE" for proper check-up 1. With the engine running, check function.
procedure. that the generator indicator light, oil
pressure indicator light and check
engine indicator light 4JH go off and
remain off.

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 BEFORE DRIVING YOUR VEHICLE

3. Check for any abnormal engine noise

or color of exhaust gases.

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 - NOTE -

- 3–20 -

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 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
• Parking .......................................... 4–6 5 speed
• Driving precautions ..................... 4–7
• Driving for economy ...................4–11
PREPARATION FOR STARTING 2. Place the transmission gearshift lever
• Operation and care in winter ..... 4–13 in the neutral position.
ENGINE
• Driving on ice or snow ............... 4–14
1. Apply the parking brake.
• In case of emergency................. 4–16

Proper care and operation will not only

extend the service life of your vehicle but
also improve oil and fuel economy.

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 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.

STARTING ENGINE 2. Warm weather or hot engine:

1. When the starter switch is turned to Turn the key switch to the "START"
the "ON" position, the glow plug position (do not step on the
indicator light comes on and it goes accelerator pedal). Release the key
off after about 0.5 seconds when the switch as soon as the engine starts.
engine is warm. Cold weather:
When the engine is cold, the indicator When the glow plug indicator light
light goes off after about 4.0 seconds goes off, depress the clutch and
for 4JB1 engine model or after about accelerator pedals to floor and hold.
1.0 to 7.0 seconds for 4JH1 engine Turn the key switch to the "START"
model. position. Release the key switch,
clutch pedal and accelerator pedal as
soon as the engine starts.

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 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.

3. Turn the idling control knob as needed STOPPING ENGINE

to achieve a smooth idle.
1. Turn the starter switch to the "ACC" or
"LOCK" position.
CAUTION
Do not leave the vehicle at this time. NOTE
If the engine gives a sign of overheating,
4. When the engine is thoroughly do not stop it immediately. Keep it
warmed up, turn the idling control running at a fast idle for a while.
knob to the home position.

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 DRIVING

BEFORE DRIVING OFF 2. Adjust the seat position. 3. Adjust the inside and outside mirrors.
1. Lock all doors.

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 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.

4. Fasten the seat belt. OPERATING PRECAUTIONS

FOR TURBOCHARGED ENGINE
TRB

Engine starting in general

The turbocharged engine should be
started in a way which ensures the
bearings supporting the rotating parts of
the turbocharger are sufficiently
lubricated.
Do not race a cold engine.

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 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
3. Turn the key to the "LOCK" position. period. The temperature of oil in
PARKING the power steering oil pump will
4. Remove the key.
Find a level area where parking is 5. Close all windows and lock all doors. rise abnormally high and cause
permitted, and park the vehicle not to 6. Check to make certain the lights are the insufficient lubrication,
obstruct traffic. turned off. damage to the hose or
Avoid parking the vehicle on a hill. Park it 7. Use wheel stoppers when leaving the deterioration of the seal. This
on a level surface as much as possible. vehicle unattended on a gradient. may lead to the damage to the
power steering oil pump and
When leaving your vehicle unattended: CAUTION power steering unit etc. and as a
1. Apply the parking brake firmly, and result, the steering wheel
make sure the vehicle does not move. • Avoid parking the loaded vehicle for operation may get heavy
2. When parking a vehicle on an upward a long period of time. suddenly.
slope, place the shift lever in the "1st" • Wipe off dirt on each lamp lens or WARNING (Continued)
position. reflector thoroughly in order to be
When parking a vehicle on a seen clearly that the vehicle is
downward slope, place the shift lever parked.
in the "Reverse" position.

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 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. They could touch the hot
exhaust system and ignite.
• Do not leave your vehicle DRIVING PRECAUTIONS 2. If an abnormal noise or smell
unattended with the engine becomes noticeable while driving,
1. Avoid over-running the engine. When stop the engine and check to locate
running. If the engine should
descending a slope pay close the cause of the trouble.
overheat, you would not be there
attention to prevent engine over-
to react to the temperature
running. Particularly when
warning light or gauge. This
downshifting as the engine may over-
could result in costly damage to
run. Over-running the engine is
your vehicle and its contents.
running it faster than its maximum
allowed revolutions (rpm/s).

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 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.
of the trouble.

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 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. before the engine begins to lug. of the engine.
Use the exhaust brake (if equipped)
when descending a slope or when it
is raining.

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 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
into the air duct causing serious reduction in brake force. efficiency is reduced. It is very
engine damage. After driving across dangerous to turn the switch to the
water, check the gear oil in the rear "LOCK" position while driving because
axle and transmission case for the the steering will be locked.
presence of water.
If any water is present, drain and refill
it with the specified gear oil.

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 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,
turning over the moment it crosses the 1. Needless high-speed driving and slow
avoid driving the vehicle backward as driving in a high gear will result in
slope. Drive carefully selecting the much as possible. Drive it forward
road surfaces so that the tires on the excessive fuel consumption.
slowly on the down slope.
higher side of the slope may not run
on any convex part of the slope • Compared with forward movement,
surface. the braking distance of backward
movement is longer, and the steering
response of that is worse.
• If you must drive the vehicle
backward, drive it very carefully and
gradually by moving and stopping
repeatedly in order to stop it any time.
• A slip due to the road conditions (rain,
snow, sand, gravel, etc.) causes
longer braking distance.

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 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. range.

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 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.
Replace damaged rubber hoses as the
engine coolant becomes liable to leak
even past minor cracks when the engine
coolant solution is used.
Refer to "Preparing engine coolant".
Refer to "RECOMMENDED FLUIDS,
LUBRICANTS AND DIESEL FUELS".
Refer to "MAINTENANCE SCHEDULE"
for service interval.

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 DRIVING

Capacity (%)
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.
with a viscosity suited to ambient specific gravity of the electrolyte lowers
temperature. with the rate of discharge. Therefore,
batteries should be protected against
WARNING
freezing. Immediately after the engine has
stopped running, the exhaust pipe
and the muffler are hot, so be
careful not to touch these parts.

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 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.

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 DRIVING

IN CASE OF EMERGENCY Engine overheating

Stowage of jack and tools If engine power drops and the needle on
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. After use, be safety zone and enters the "H" zone, the
sure to put them back where they were so engine is overheating. Take the following
that they do not rattle during driving. corrective actions immediately.
1. Operate the hazard warning flasher
and pull the vehicle immediately over
to a safe place that does not impede
traffic (shoulder, verge) and park it.
2. Lower the temperature of the engine
for a while with the engine idling.

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 DRIVING

CAUTION • When removing the radiator cap • Coolant is flammable, and

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. little by little. sources. Coolant also could
• Coolant is toxic and must not be ignite if it comes in contact with
3. When the needle of the engine a hot surface, such as the
coolant temperature gauge returns ingested. If the coolant is
mistakenly ingested, immediately exhaust manifold. Exercise
to the middle of the safety zone, stop caution to prevent this from
the engine. vomit it and seek prompt medical
attention. happening.

WARNING • If the coolant gets in your eyes,

• Even when the engine has been rinse it off immediately with a
stopped, the engine coolant in large amount of water for 15
the radiator remains under minutes or longer. Also, if still
pressure. Immediately removing abnormality such as irritation is
the radiator cap could cause felt, seek medical attention.
steam or hot water to blow out, • If the coolant gets on your skin,
and you could be scalded as a rinse it off using a soap with a
result. The engine coolant in the large amount of water. Also, if
reserve tank may also be hot. abnormality is seen, seek medical
Immediately removing the cap attention.
could cause hot water to blow
• For storage, close the cap
out, and possibly scald you.
securely and keep it in a place
• Check, replenish or change the inaccessible to children.
engine coolant only after the
engine has sufficiently cooled
down.

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 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. Check the engine coolant level in • When tap water only has been used
the reserve tank and radiator after for engine coolant in an emergency,
the engine has sufficiently cooled. If adjust the engine coolant
the level is insufficient, add engine concentration as soon as possible.
coolant. Refer to "Preparing engine
coolant". Also, check to see if the fan
belt is loose or has been damaged. Emergency stop
Refer to "Fan belt".
1. If you must stop your vehicle on the
5. Inspect to see if there is any dirt, road for some reason, pull your
etc. attached to the front surface of vehicle over to the left (right) side of
the radiator and intercooler. Also, the road as far as possible and try not
inspect to see if there is anything to park on the driving lane.
blocking the core. If there is anything
attached, clean and remove it. Refer
to "Cleaning the radiator core and
intercooler core".

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 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
2. Make certain to apply the parking Emergency starting burns, or damaged electric
brake and turn on hazard warning components.
lights, day or night. WARNING
Never tow the vehicle to start it
because the surge forward when
the engine starts could cause a
collision with the tow vehicle.

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 DRIVING

12V vehicle with 1 battery installed 12V vehicle with 2 batteries installed
Vehicle with Disabled vehicle Vehicle with Disabled vehicle
booster batteries booster batteries
Negative side jumper cable 4 Use the vehicle
4 Use the vehicle frame as the ground
2 frame as the ground
MAX
3
Negative side
LOW jumper cable
2
1
3 1
Positive side jumper cable Positive side jumper cable

Connecting procedures: 3. Remove the battery cover and 6. If the engine in the disabled vehicle
The engine can be started with another connect the jumper cables in the starts, remove the jumper cables in
vehicle battery using jumper cables: numbered sequence in the drawing. the reverse sequence as they were
(The following drawing is an example connected.
1. Check the battery electrolyte level in of a connection between vehicles
the disabled vehicle. installed with the same type of CAUTION
2. Use a vehicle which has a battery of battery.)
the same voltage (12 V). Never connect the cable between the
4. After connecting the cables, start the
positive and negative terminals.
engine of the vehicle with the booster
battery. Do not remove the battery cables from
the terminals while the engine is
5. Slightly rev up the engine of the
running. It may result in troubles in
vehicle with the booster battery and
the electrical system.
start the engine of the disabled
vehicle.

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 DRIVING

5 speed
Hook

Towing 2. If the transmission is found to be out 3. If the vehicle is towing or being

Your vehicle should be towed by an Isuzu of order, disconnect the propeller shaft towed, firmly attach a rope to the
dealership or professional towing service at the rear axle flange and fasten the front or rear towing hook on the same
to prevent damage. Proper equipment end to the chassis frame. side.
must be used and local laws which apply 4. During towing, carefully watch the
to vehicles in tow must be followed. WARNING stop lights of the towing vehicle
1. If the transmission is in normal Always put wheel chocks when in order to prevent the rope from
working condition, shift into a neutral disconnecting the propeller shaft. becoming slack. Ensure that there
position. is no strong shock or lateral force
If you fail to do so, the vehicle may applied to the vehicle.
start moving and it can lead to a
serious accident.

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 DRIVING

CAUTION
Usable
range of 15° Then, fit the towing rope (safety chains
towing 15° or cables) between the hooks
rope equipped on the tow truck and the
disabled vehicle.
Usable Drive at the speed of 40 km/h (25 mph)
range of 15° or less and up to a distance less than
towing 15° 80 km (50 miles).
Hook rope

WARNING • When coming to channels or

muddy areas, unload the vehicle.
• Do not tow a vehicle at an angle Do not use the towing hook to
of greater than 15°. This could tow, but tow with a rope attached
exert too much stress on the to the axle.
vehicle and damage it.
• Attach a rope to the towing hook
only. Attaching a rope to other
part of the vehicle could damage
it.
• The towing hook is for use to tow
a vehicle with about the same
weight as the towing vehicle on
good roads.

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 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. same time the glow plug indicator
(1) Operate hand pump until it light goes off.
becomes hard to push (about 15 If the engine does not start, repeat the
pushes). steps (4), (5), (6) and (7).
(2) Wait for 1 min. (8) Immediately after rev-up, put your
(3) Operate hand pump until it hand off key and your foot off
becomes hard to push (about 10 accelerator pedal.
pushes). (9) Allow the engine to idle for 5 min.
Bleeding of the fuel system (4) Wait for 1 min.
If the fuel tank has gone empty, there is a (5) Operate hand pump until it
chance that air has been allowed into the becomes hard to push (about 5
fuel system. With air in the fuel system, pushes).
smooth flow of fuel into the engine is
interrupted. To prevent this, bleeding of (6) When the key switch is turned to
the fuel system should be performed. "ON" position, the glow plug
indicator light comes on and goes
off after about 4.0 to 7.0 seconds
CAUTION (with cold engine). Please notice
BLEEDING OF FUEL SYSTEM the glow plug indicator light does
not turn on when the engine
If the fuel tank has been emptied, the
already warm (engine coolant
chance is that air might have been
temperature above 25 °C (77°F)).
allowed into the fuel system.

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 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.

4. After starting the engine, remain in

4JB 4JH idle for 1 minute. If the engine stalls
when in idle, perform step 3 and then
1. Operate the priming pump on the 1. Confirm that sufficient fuel is held in start the engine again.
water separator to bleed the fuel the fuel tank.
system air into the injection pump. 5. Fully depress the accelerator pedal to
2. Operate the priming pump until it increase the engine speed. When the
2. When you have finished the bleeding, becomes hard to push.
start the engine with the starter switch. engine speed reaches its maximum,
3. If the engine does not start within ten 3. Turn the starter switch to "START" immediately release the accelerator
seconds, repeat the bleeding position to start the engine. pedal and return to idle. Repeat this
operation. operation three times.

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 DRIVING

4JB 4JB 4JH

Draining of the water separator 3. Loosen the drain plug by turning it

counterclockwise and push the CAUTION
If the fuel filter warning light lights up,
drain the water accumulated in the fuel priming pump down about ten times If the water separator requires frequent
filter. until the water is drained. draining, have the fuel tank drained at
If use is continued with the warning light 4. After draining, securely tighten the your nearest Isuzu dealer.
on, there is danger of damage to the fuel drain plug by turning it clockwise and
injection system. To protect the engine push the priming pump up and down
when replacing elements, be sure to use several times.
a pure filter. 5. After starting the engine, check to see
1. Find a safe place to park the vehicle. that there are no fuel leaks from the
2. Open the engine inspection cover and drain plug. Also check that the water
place a container (approximately 0.2 separator indicator has turned off.
liters capacity) beneath the drain plug
on the separator.

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 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 jacking equipment. 5. Slightly loosen but do not remove the
tire wheel nuts.
• Do not start or run the engine
If you feel something is wrong while while the vehicle is on the jack.
driving the vehicle, safely stop the vehicle NOTE
• Make sure the jack is positioned
immediately and check the tires. The wheel nuts on the right side
on a level and soiled surface.
When you cannot find a safe location wheels have right-hand threads and
nearby, slow down to a safe speed to Preparations: the wheel nuts on the left side wheels
drive the vehicle. have left-hand threads.
Driving the vehicle with a flat tire puts an 1. Park on a level surface and set the
excessive load on the wheel bolts. This is parking brake firmly.
a major factor of the accident that a wheel 2. Set the transmission gearshift lever in
comes off due to wheel bolt breakage. "REVERSE".
3. Activate the hazard warning.
4. Block the wheel diagonally opposite
the jacking position.

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 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
Never position the jack at points other pipe or the muffler either
than those specified. immediately after driving the
vehicle because these parts will be
Front wheel: hot.
Leaf spring suspension models
Place the jack under the leaf spring.

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 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. shown in the figure.
under the jack.
Insert the jack bar as shown in the figure
• The wood board must be thick and and move it up and down.
hard with a width larger than that of
the jack base.

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 DRIVING

5-studs
4. When installing the wheel, clean
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. to the threaded
portion of the wheel bolts and
wheel nuts, and the seating surface
of the wheel nut.
Wheel replacement 3. With the wheel wrench, tighten the 5. Tighten the wheel nuts in a
1. Jack up the vehicle so the tire just wheel nuts in sequence as shown in diagonal order in two or three
clears the surface, remove the wheel the figure. The wheel nuts can be steps.
nuts and wheel, then install the spare securely tightened at the specified
torque as listed on the chart. 6. Using a torque wrench, tighten the
wheel. wheel nuts to the specified torque.
2. Install the wheel nuts with the cone 7. If an impact wrench is used, pay
shaped end toward the wheel, then CAUTION
attention to the tightening period,
semi-tighten each nut with the wheel 1. When the wheel is removed, check compressed air pressure, etc. to
wrench. the wheel bolts, wheel nuts, wheel avoid over-tightening. Also, check
The wheel nut must be seated on the disc, etc. for damage. with a torque wrench after
hub. tightening.
2. If the wheel bolt must be replaced
Lower the vehicle by turning the
due to breakage of it, replace all the 8. After driving the vehicle for a
bleeder screw counterclockwise to the
wheel bolts of the wheel. certain distance (50 to 100 km (30
ground.
3. If aluminum wheels are replaced to 60 miles)), retighten the wheel
with steel wheels, or vice versa, nuts to the specified torque.
replace also the wheel bolts and
wheel nuts with purpose-built ones.
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 DRIVING

6-studs

Front Wheel Nut Torque N•m (kgf•m/lbf•ft)

Single tire rear wheel
170 (17/123)
model
Dual tire rear wheel
500 (50/362)
model

Rear Wheel Nut Torque N•m (kgf•m/lbf•ft)

Single tire rear wheel
170 (17/123)
model
Dual tire rear wheel
500 (50/362)
model

- 4–30 -

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 SERVICE AND MAINTENANCE

SERVICE AND MAINTENANCE SCHEDULE Maintenance operations

MAINTENANCE To ensure driving safety and maximum I : Inspect then clean, repair or replace
operating economy, periodic inspection as necessary
• Maintenance schedule ................. 5–1
and maintenance should be performed at A: Adjust
• Maintenance guide ....................... 5–7 your Isuzu dealer according to the R: Replace
• Periodic maintenance ................ 5–19 maintenance schedule. T: Tighten to specified torque
• Lubrication.................................. 5–58 For service operations which call for L: Lubricate
disassembly or specialized instruments,
• Recommended fluids, lubricants
and diesel fuels .......................... 5–60 contact your Isuzu dealer. When performing checks on the
• Lubrication chart ........................ 5–64 following items, regular inspection
items should also be checked.
• Lubrication guide ....................... 5–65
*Marks: Under severe driving
• Correct cargo loading ................ 5–69
conditions, more frequent
maintenance is required. Refer
In order to maintain safety and operating to "Maintenance schedule
economy, it is suggested that periodic under severe driving
inspection and maintenance should be conditions".
performed regularly according to the
recommendations outlined in this section.

- 5–1 -

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 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 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Use odometer

reading or months,
whichever occurs
x 100 mile 6 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450 480 510 540 570 600 first

4JB *Engine oil - R R R R R R R R R R R R R R R R R R R R or every 3 months

4JH *Engine oil - - R - R - R - R - R - R - R - R - R - R or every 6 months
*Engine oil filter - - R - R - R - R - R - R - R - R - R - R or every 6 months
Fuel filter - - - - R - - - R - - - R - - - R - - - R or every 12 months
*Air cleaner element - - I - I - I - R - I - I - I - R - I - I or every 24 months
Idling speed and acceleration - - - - I - - - I - - - I - - - I - - - I or every 12 months
Valve clearances - - - - - - - - A - - - - - - - A - - - - or every 12 months
Fuel tank cap & fuel pipes for loose
- - - - - - - - I - - - - - - - I - - - I or every 24 months
connections or damage
4JB Drive belt tension and damage I - I - I - I - I - I - I - I - I - I - I or every 6 months
4JH Drive belt tension and damage 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), - - - - I - - - I - - - I - - - I - - - I or every 12 months
silencer, and their mountings
4JH Exhaust pressure pipe Every 12 months: I
Cooling system - - - - I - - - I - - - I - - - I - - - I or every 24 months
Damage to air intake ducts and hoses - - - - - - I - - - - - I - - - - - I - - or every 12 months
Engine operation condition - - I - I - I - I - I - I - I - I - I - I or every 6 months
Clutch fluid - - I - I - I - R - I - I - I - R - I - I or every 24 months
Clutch pedal travel and free play - I I I I I I I I I I I I I I I I I I I I or every 3 months
- 5–2 -

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 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 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Use odometer

reading or months,
whichever occurs
x 100 mile 6 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450 480 510 540 570 600 first

*Manual transmission oil - - - I - - I - - R - - I - - I - - R - - or every 24 months

Gear control mechanism for
- - - - - - - - I - - - - - - - I - - - - or every 24 months
looseness
Gear control cable - - - - A - - - A - - - A - - - A - - - A or every 12 months
*Propeller shaft universal joints and
- - - L - - - - - L - - - - - L - - - - - or every 12 months
sliding sleeve
Propeller shaft loose connections - - - I - - I - - I - - I - - I - - I - - or every 6 months
Propeller shaft splines for excessive
- - - - - - - - I - - - - - - - I - - - - or every 24 months
wear
Propeller shaft bearings and related
- - - - - - - - I - - - - - - - I - - - - or every 24 months
parts for looseness
Propeller shaft center bearing - - - - L - - - L - - - L - - - L - - - L or every 12 months
*Differential gear oil - - - I - - I - - I/R - - I - - I - - I/R - - or every 24 months
*King pin - - L - L - L - L - L - L - L - L - L - L or every 6 months
*Tie rod end - - L - L - L - L - L - L - L - L - L - L or every 6 months
Manual steering gear oil - - - - - - I - - - - - I - - - - - I - - or every 18 months
OPT Power steering system oil leakage - - I - I - I - I - I - I - I - I - I - I or every 6 months
OPT Power steering fluid - - - - - - - - R - - - - - - - R - - - - or every 24 months
* OPT Power steering system for
- - I - I - I - I - I - I - I - I - I - I or every 6 months
looseness or damage

- 5–3 -

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 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 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Use odometer

reading or months,
whichever occurs
x 100 mile 6 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450 480 510 540 570 600 first

Fitting of knuckles and front axle for

- - I - I - I - I - I - I - I - I - I - I or every 6 months
looseness
Steering mechanism for looseness or
- - - - - - - - I - - - - - - - I - - - - or every 24 months
damage
Steering wheel play - I I I I I I I I I I I I I I I I I I I I or every 3 months
Steering function - I I I I I I I I I I I I I I I I I I I I or every 3 months
Wheel alignment - - - - - - - - I - - - - - - - I - - - - or every 24 months
OPT Power steering hose - - - - - - - - - - - - - - - - R - - - - or every 48 months
Brake fluid - - I - I - I - R - I - I - I - R - I - I or every 24 months
Brake system for fluid leakage - - I - I - I - I - I - I - I - I - I - I or every 6 months
*Brake lining and drum for wear - - - - I - - - I - - - I - - - I - - - I or every 12 months
Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I I or every 3 months
Pipes and hoses for loose
- - I - I - I - I - I - I - I - I - I - I or every 6 months
connections or damage
Parking brake cables - - I - I - I - I - I - I - I - I - I - I or every 6 months
Parking brake function - - I - I - I - I - I - I - I - I - I - I or every 6 months
Parking brake lever travel - - I - I - I - I - I - I - I - I - I - I or every 6 months
Lining for wear - - - - - - - - I - - - - - - - I - - - - or every 24 months
Drum for wear or damage - - - - - - - - I - - - - - - - I - - - - or every 24 months
Ratchet for wear or damage - - - - - - - - I - - - - - - - I - - - - or every 24 months
Spring leaves for damage - - I - I - I - I - I - I - I - I - I - I or every 6 months

- 5–4 -

QKR-IE-1442_4805234_ALL.indb 5‒4 2017/09/27 13:34:51

 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 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Use odometer

reading or months,
whichever occurs
x 100 mile 6 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450 480 510 540 570 600 first

Suspension mount for looseness or

- - I - I - I - I - I - I - I - I - I - I or every 6 months
damage
Shock absorbers for oil leakage - - I - I - I - I - I - I - I - I - I - I or every 6 months
Shock absorbers mount for looseness - - I - I - I - I - I - I - I - I - I - I or every 6 months
Wheel pins and nuts T - - - T - - - T - - - T - - - T - - - T or every 12 months
Wheel disc for damage - - - - I - - - I - - - I - - - I - - - I or every 12 months
Hub bearing grease - - - - - - - - R - - - - - - - R - - - - or every 24 months
Tire pressure and damage - - I - I - I - I - I - I - I - I - I - I or every 6 months
Specific gravity of battery electrolyte - - I - I - I - I - I - I - I - I - I - I or every 6 months
Lights, horn, windshield, wiper and
- - I - I - I - I - I - I - I - I - I - I or every 6 months
washer
Bolts and nuts on chassis and body I - - - - - - - I - - - - - - - I - - - - or every 24 months

- 5–5 -

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 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
A B C D A+D
4JB Engine oil Change every 2,500 km (1,500 miles) • •
4JH Engine oil Change every 5,000 km (3,000 miles) • •
Engine oil filter Replace every 5,000 km (3,000 miles) • •
Damage to or looseness of the exhaust pipe, exhaust
Inspect every 10,000 km (6,000 miles) • • •
brake (if equipped), silencer, and their mountings
Inspect every 5,000 km (3,000 miles)
Air cleaner element •
Replace every 20,000 km (12,000 miles)
Power steering system for looseness or damage Inspect every 5,000 km (3,000 miles) •
Propeller shaft universal joints and sliding sleeve grease Lubricate every 10,000 km (6,000 miles) •
Manual transmission and differential gear oil Change every 20,000 km (12,000 miles) • •
Brake lining and drum for wear Inspect every 10,000 km (6,000 miles) • • •
Kingpins Lubricate every 5,000 km (3,000 miles) • •
Tie rod end Lubricate every 5,000 km (3,000 miles) • •

- 5–6 -

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 SERVICE AND MAINTENANCE

4JH

4JB

MAINTENANCE GUIDE NOTE

REGULAR INSPECTION If the engine in running, stop the
Engine oil level engine and allow 5 minutes for the oil
to settle down before checking the oil
Pull out the oil level gauge rod (oil level.
dipstick), wipe clean it and reinsert. Again
pull it out and check that oil level is within
MAX and MIN level marks. Also check
the oil on the gauge rod for
contamination.

NOTE
Engine oil level should be checked
with the vehicle parked on level
ground (before the operation of
engine).

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 SERVICE AND MAINTENANCE
Fan belt
Press the center of the span between pulleys (see the figure) of the belt with a force of
10.0 kgf (22 lb/98 N) and check the amount of deflection. The amount of deflection must Amount
of
fall within the standard value range indicated below. Otherwise, adjust the tension. Amount deflection
When inspecting by vibration frequency, place and hold the sensor mike surface parallel of
deflection
to the belt 10 mm (0.39 in) from the center of the span between pulleys (indicated by the
arrow) and tap the belt with a handle of screwdriver etc. to make the belt vibrated and
measure the value. Measure the value 2 or 3 times and calculate the average value. Generator drive
belt Power steering
The average value must be within the standard value range indicated below. Otherwise,
pump drive belt
adjust the tension.
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
Amount of deflection Vibration frequency
Belt types Insufficient tension will result
mm (in) Hz
in battery discharge or engine
Power steering New belt 8.0 - 12.0 (0.31 - 0.47) 135 - 165 overheating, whereas excessive
pump drive belt When reused 11.0 - 13.0 (0.43 - 0.51) 117 - 135 tension could cause damage to the
New belt 7.0 - 9.0 (0.28 - 0.35) 133 - 157 generator or V belt.
Generator drive belt
When reused 9.0 - 11.0 (0.35 - 0.43) 112 - 126 Check the fan belt without fail. If the
fan belt breaks, the brake booster will
not operate.

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 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. Also, if
operating temperature. The cooling still hot. Hot vapor or boiling abnormality is seen, seek medical
system was filled at the factory with a water may burst out and cause a attention.
quality engine coolant. The engine cooling burn. Cover the cap with a cloth, • Engine coolant is flammable, and
system is designed to use engine coolant etc. and remove it gradually after therefore, it must be kept away
rather than water (distilled water or the engine is fully cooled down from flames and other heat
deionized water) . The engine coolant and the temperature of the sources. Engine coolant also
solution should be used year round. It has engine coolant becomes low. could ignite if it comes in contact
many advantages such as: • When removing the radiator cap, with a hot surface, such as the
• Protecting against rust and corrosion in use a thick cloth to cover the cap exhaust manifold. Exercise
the cooling system and turn it slowly. caution to prevent this from
• Maintaining the proper engine • Engine coolant is toxic and must happening.
temperature for efficient operation and not be ingested. If the engine • For storage, close the cap
emission control. coolant is mistakenly ingested, securely and keep it in a place
• Allowing proper operation of the engine immediately vomit it and seek inaccessible to children.
coolant temperature gauge. prompt medical attention.
See the "MAINTENANCE SCHEDULE" in • If the engine coolant gets in your
this section to find out when the engine eyes, rinse it off immediately with
coolant must be replaced. a large amount of water for 15
minutes or longer. Also, if still
abnormality such as irritation is
WARNING
felt, seek medical attention.
• Check, replenish or change the
engine coolant only after the
engine has sufficiently cooled
down.

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 SERVICE AND MAINTENANCE
Preparing engine coolant
CAUTION CAUTION
To prevent the engine damage due to
Replace the engine coolant freezing of the engine coolant and to • Isuzu does not guarantee the use of
periodically. protect the cooling system from corrosion, the engine or vehicle at the outside
If the engine coolant is not replaced mix the Isuzu recommended coolant and temperature of -30°C (-22°F) or
periodically, rust is generated due to water (distilled water or deionized water) below.
degradation of the engine coolant, to be at 50% concentration. • However, if the engine or vehicle is
which may cause a failure such as For other than Isuzu genuine coolant used at the outside temperature of
water leakage or clogging of the (Arteco/BASF/Total, etc.), it is -30°C (-22°F) or below, the coolant
radiator or heater core. recommended to use directly "50/50 Pre- concentration of 55% is
diluted" product which is already diluted recommended.
NOTE to 50% concentration.
Refer to "RECOMMENDED FLUIDS,
Engine coolant is fluid which is made LUBRICANTS AND DIESEL FUELS" in
by mixing coolant and water (distilled this section for Isuzu recommended
water or deionized water) at an coolant.
appropriate concentration.

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 SERVICE AND MAINTENANCE
The quantity of engine coolant is indicated
below for your use as a guideline when
WARNING CAUTION
changing the engine coolant. After • Coolant is toxic and must not be • Use only an Isuzu recommended
changing the engine coolant, check that ingested. If the coolant is coolant.
the engine coolant is up to the specified mistakenly ingested, immediately
vomit it and seek prompt medical • Using any coolant other than that
level.
attention. Isuzu recommended could cause
damage to the engine, radiator or
Engine coolant quantity • If the coolant gets in your eyes, heater core. In particular, use of
Engine model [Reference value]: rinse it off immediately with a
coolants containing borate salts or
liters (US/Imp gal.) large amount of water for 15
silicates may result in engine or
4JB1, 4JB1-TC 10.1 (2.67/2.22) minutes or longer. Also, if still
radiator corrosion, causing engine
4JH1-TC 11.3 (2.99/2.49) abnormality such as irritation is
coolant leaks and other problems.
felt, seek medical attention.
• If the coolant gets on your skin, • To dilute the coolant, use distilled
rinse it off using a soap with a water or deionized water.
large amount of water. Also, if • Do not use the coolant at any
abnormality is seen, seek medical coolant concentration other than
attention. that specified. If the coolant
• Coolant is flammable, and concentration is 60% or higher,
therefore, it must be kept away overheating is likely to occur, while
from flames and other heat if it is 30% or lower, anti-corrosion
sources. Coolant also could function is not provided sufficiently.
ignite if it comes in contact with • Using coolant at any coolant
a hot surface, such as the concentration other than that
exhaust manifold. Exercise specified may reduce anti-freezing
caution to prevent this from performance, and engine coolant
happening. may freeze.
• For storage, close the cap
CAUTION (Continued)
securely and keep it in a place
inaccessible to children.

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 SERVICE AND MAINTENANCE

CAUTION (Continued) 4JB 4JH

• If the engine coolant decreases 4JB1-TC

rapidly, go immediately to the
nearest Isuzu dealer for a check or
repair.

MAX

MIN

Engine coolant level Tighten the cap securely after filling. Also
Overheating may result in engine damage check the radiator cap part, radiator or
or breakdown. To avoid this, be sure to hose for engine coolant leakage, and
check the amount of engine coolant confirm that no stain due to engine
periodically. coolant leakage remains in the ground
Check the level of engine coolant when where the vehicle is parked. Contact
the engine is cold and replenish as Isuzu dealer in case leakage is found.
necessary at the radiator reserve tank.

Checking and adding

The engine coolant level inside the
reserve tank should be between the
"MIN" and "MAX" level line. If the level is
low, open the reserve tank cap and fill to
"MAX" level line with the engine coolant.

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 SERVICE AND MAINTENANCE

WARNING • Engine coolant is toxic and must CAUTION

not be ingested. If the engine
• Even when the engine has been coolant is mistakenly ingested, • Do not overfill the reserve tank.
stopped, the engine coolant in immediately vomit it and seek • The radiator cap must not be
the radiator remains under prompt medical attention. removed unless absolutely
pressure. Immediately removing
• If the engine coolant gets in your necessary.
the radiator cap could cause
steam or hot water to blow out, eyes, rinse it off immediately with • Supplement inhibitors or additives
and you could be scalded as a a large amount of water for 15 claiming to provide increases in
result. The engine coolant in the minutes or longer. Also, if still cooling capability that have not been
reserve tank may also be hot. abnormality such as irritation is specifically approved by Isuzu are
Immediately removing the cap felt, seek medical attention. not recommended in the cooling
could cause hot water to blow • If the engine coolant gets on your system.
out, and possibly scald you. skin, rinse it off using a soap with
• Check, replenish or change the a large amount of water. Also, if
engine coolant only after the abnormality is seen, seek medical
engine has sufficiently cooled attention.
down. • For storage, close the cap
• When removing the radiator cap securely and keep it in a place
and reserve tank cap, use a thick inaccessible to children.
cloth to cover the cap and turn it
little by little.
• 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. Take care not to splash
it.

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 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

To prevent the engine damage due to intercooler core
freezing of the engine coolant, mix the Cooling efficiency is compromised when
coolant and water (distilled water or there is dirt or dust plugging air passages
deionized water) to be an appropriate in the radiator core and intercooler core.
concentration. This can also cause corrosion of these
Replace damaged rubber hoses as the cores. Wash the radiator core with tap
engine coolant becomes liable to leak water every 2 years.
even past minor cracks when the engine
coolant solution is used.
Refer to "Preparing engine coolant".
Refer to "RECOMMENDED FLUIDS,
LUBRICANTS AND DIESEL FUELS".
Refer to "MAINTENANCE SCHEDULE"
for service interval.

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 SERVICE AND MAINTENANCE

Radiator core CAUTION

Intercooler core
• Do not clean the radiator,
intercooler and their surrounding
areas using water that is supplied MAX
under high pressure. Doing so may
cause damage. LOW

Fin • When cleaning the radiator core and

intercooler core, do not crush or
damage the fins.
• The fins are very fragile so be
careful not to bend them out of Level of battery electrolyte
WARNING shape. If they become deformed,
their cooling efficiency will be The Ievels of battery electrolyte are
• Make sure to turn the engine off normal if they are flush with the ellipse
and remove the key from the impaired.
hole in the filler port. If the level is too
starter switch before cleaning • Before cleaning, take steps to low, replenish with distilled water. The
cores. ensure that no water will splash battery is located in the battery
• The engine, exhaust pipe and onto the surrounding electrical compartment in the center portion of the
radiator will be hot immediately components and wires. left side of the chassis frame.
after the vehicle is driven. Be • If stubborn dirt still remains even
careful around these parts to after the radiator core and WARNING
prevent burns. Clean the engine intercooler core have been cleaned, The fluid in the battery is sulfuric
when it is cold. have the vehicle inspected and acid. 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
into your eyes, flush them with
clean fresh water and immediately
seek proper medical treatment.
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 SERVICE AND MAINTENANCE

Steering wheel Also check the steering wheel for play Parking brake lever travel
Check the amount of the steering wheel and looseness in its mount by moving it
play by turning the wheel in both directions back and forth and sideways.
Normal parking brake travels: 6 to 8
until the tires begin to move. The standard While driving check for hard steering, notches
free play is within the range of steering shimmy and a tendency of the
manual steering: 10 to 30 mm (0.39 to steering to pull to one side.
1.18 in) When pulled with a force of 15 kg
power steering: 10 to 50 mm (0.39 to CAUTION (33 lbs, 147 N).
1.97 in)
If the steering parts have excess play
OPT V When parking brake lever travel is in
or looseness or if any abnormal
at the periphery of the steering wheel excess of 16 notches, the braking is
condition is noted, have the steering
when checked with the front wheels insufficient and brake adjustment
system checked at your Isuzu dealer
properly in the straight-ahead position. should be performed.
immediately.
NOTE
If the vehicle is equipped with a power
steering unit, the wheel free play should
be checked with the engine running.
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 SERVICE AND MAINTENANCE

• Brake (clutch) fluid readily absorbs

CAUTION
moisture. Therefore, it is necessary
• Before refilling the tank, clean the to close the container tightly for
area around the cap and fill clutch storage.
fluid from a clean container. Foreign • Never mix the specified brake
objects getting in the tank will lead (clutch) fluid with fluids of any other
to a clutch system failure. brand.
MAX • When adding fluid to the tank, take
ADD • If the brake (clutch) fluid level
care to prevent dirt and water from decreases rapidly, there may be a
entering it. Any dirt or water in the problem in the brake system or
system could cause the vehicle to clutch system, or brake pads or shoe
lose brake and clutch functions. linings may have worn out. Have
Brake and clutch fluid level
• 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.
Check that the brake and clutch fluid level • Use non-petroleum base brake
is between the "MAX" and "ADD" mark on (clutch) fluid when adding brake
the reservoir. (clutch) fluid.
The level should be between the MAX • Be careful not to spill brake (clutch)
and ADD level line. If the level is lower fluid onto painted surfaces or to let
than the ADD level line, fill the MAX level it come in contact with skin. If fluid
line with the recommended hydraulic is spilled onto a painted surface or
brake fluid. come in contact with skin, wash
If the brake fluid reservoir is equipped away the fluid with water and
with a level indicator, periodic fluid level immediately wipe the area clean.
checking is not necessary.

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 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
indicate the parking brake function 15 to 25 mm (0.59 to 0.98 in)
operating condition of the windshield
or non-function. When applying the washer.
parking brake, pull the parking
brake lever as far up as possible.
Do not continue to operate the
vehicle when the brake indicator
light is on. There may be serious
trouble in the brake system. Vehicle
operation under this condition is
extremely dangerous and can lead
to an accident.

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 SERVICE AND MAINTENANCE

Allowance: 60 mm (2.36 in) PERIODIC MAINTENANCE

Note: Air cleaner
When depressed with force of 50 kg
Use of clogged air cleaner element not
(110 lbs).
only causes a deterioration in the engine
output but also increased fuel
NOTE consumption and dark exhaust smoke.
Let the engine run for at least 1 minute The air cleaner element should be
Free play before taking measurement with the serviced in the following manner.
Allowance engine running.
NOTE
It is strongly advisable to use Isuzu
Brake pedal free play and allowance genuine air cleaner elements for
Free play: 4 to 7 mm (0.16 to 0.28 in) replacement.

NOTE
Stop the engine and depress the brake
pedal strongly about 10 times to set
the vacuum to 0 before measuring.

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 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. Remove the wing nut retaining the 2. Pull out the element.
element and take out the element.
CAUTION
Handle the element carefully so as not
to damage it.

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 SERVICE AND MAINTENANCE

Element removal (Type 3) 2. Remove the wing nut retaining the Cleaning of air cleaner body and cover
1. Loosen the hooks and remove the element and take out the element. 1. Wipe the inside of the air cleaner
dust-pan. body, outside cover and the gasket
CAUTION fitting surface to free it from dust.
Handle the element carefully so as not
to damage it.

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 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. To clean the element, apply one of the
following methods according to the
condition of the element.

When the air cleaner element is

clogged with dust but dry:
Apply compressed air to the element from
inside while turning the element by hand.
The pressure of compressed air should
not exceed 686 kPa (7 kgf/cm2, 99.5 psi).

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 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.
1. Prepare a cleaning solution (laundry Occasionally shake the element inside The pressure of water should not
detergent dissolved in warm water). the solution. exceed 274 kPa (2.8 kgf/cm2, 39.8
psi).

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 SERVICE AND MAINTENANCE

4JB

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. 1. Drain the engine oil by loosening the counterclockwise with a filter wrench.
Avoid use of compressed air or open drain plug on the filter cover. 4JB 2. With a rag wipe clean the fitting face
flames for quick drying. It is 2. Loosen the oil filter by turning it of the oil filter so that the new oil filter
recommended that a spare element counterclockwise with a filter wrench. can be seated properly.
be used as it normally takes 2 to 3 3. With a rag wipe clean the fitting face
days for natural element drying. of the oil filter so that the new oil filter
can be seated properly.

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 SERVICE AND MAINTENANCE

4JB

Drain plug

3. Lightly oil the O-ring and screw in the Partial-flow oil filter OPT 4. Lightly oil the O-ring and screw in the
oil filter until the sealing face is fitted The oil filter body should also be drained oil filter until the sealing face is fitted
against the O-ring. Using the filter when changing engine oil. Discard the against the O-ring. Turn 1 1/4 turns
wrench, tighten the filter: filter element and install a new one further with a filter wrench.
1 1/8 turns regularly.
1. Drain engine oil by loosening the drain CAUTION
CAUTION plug on the filter cover. 4JB Check the level of the oil in the engine
2. Loosen the oil filter by turning at and replenish it to the specified level
Check the level of the oil in the engine
counterclockwise with a filter wrench. as necessary. Start the engine and
and replenish it to the specified level
3. With a rag wipe clean the fitting face check for leaks at the oil filter.
as necessary. 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. genuine oil filter assembly for
strongly advisable to use an Isuzu
genuine oil filter assembly for replacement.
replacement.

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 SERVICE AND MAINTENANCE

Fuel filter 3. Lightly oil the O-ring. Reinstall and 4. Push the priming pump on the water
4JB turn the filter assembly clockwise separator several times to bleed fuel
carefully to prevent the fuel from system of air.
1. Loosen the fuel filter by turning it spilling. Turn it until the O-ring is fitted 5. Start the engine with the starter
counterclockwise with a filter wrench. against the sealing face of the filter switch, when the bleeding has been
2. With a rag wipe clean the fitting face cover. finished.
on the upper cover, so that the new 6. If the engine does not start within ten
fuel filter can be seated properly. Further turn the filter assembly 1/3 to
2/3 of a turn with a filter wrench. seconds, repeat the bleeding
operation.

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 SERVICE AND MAINTENANCE

Drain plug Fuel hose

Bolt

Clip
Pre-fuel filter
Main fuel filter

4JH Main fuel filter 3. Pinch the clip of the fuel hose
This type is equipped with 2 filters, 1. Connect one end of a plastic hose connected to the filter body and
a main fuel filter and a pre-fuel filter. to the drain plug at the bottom of the remove the fuel hose.
Replace both filters at the same time. element case and place the other
Depending on the model, the positions end of the hose inside a container to CAUTION
and directions of the fuel filters are receive the drained fuel.
Prevent foreign matter from getting
different. 2. Loosen the drain plug to drain fuel. into the fuel hose. The engine may be
After draining, tighten the drain plug. damaged if foreign matter intrudes.

4. Loosen the installation bolt and

remove the main fuel filter assembly.

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 SERVICE AND MAINTENANCE
6. Further loosen the half loosened
Flat-head Filter body
screwdriver
union and remove the element case.
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
Union Outer gasket body. In addition, clean any foreign
matter or dirt inside the element
Element case.
5. Insert a flat-head screwdriver into
the groove on the filter body and turn O-ring CAUTION
the union to lightly loosen. After that, Do not use compressed air to remove
turn the union by hand and loosen Element case foreign matter. Using compressed air
halfway. could cause an intrusion of foreign
matter into the fuel passage. (The
engine may be damaged if foreign
matter intrudes.) Use a clean cloth to
remove any dirts.

9. Install a new O-ring to the element

case and lightly coat the O-ring with
diesel fuel.

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 SERVICE AND MAINTENANCE
14. Connect the fuel hose to the filter
Filter body Mark body.

WARNING
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
Outer gasket possible if there is any fuel hose
Alignment position breakage such as cracking.

10. Lightly coat the inner gasket and 11. Install the element case to the filter
outer gasket of the new element with body while holding the element with
diesel fuel. your hand.
Insert the element into the filter body. After aligning the filter body and
element case to the alignment
CAUTION position shown in the illustration,
align the claws on the filter body with
After inserting the element into the the element case notches and tighten
filter body, check that the outer gasket the union halfway, while holding the
is securely engaged in the element filter body and element case.
groove. Incomplete installation may
12. Tighten the union until the mark on
cause an intrusion of foreign matter
the union comes to the right of the
into the fuel passage resulting in
mark on the filter body.
engine damage.
13. Install the main fuel filter assembly
with a bolt and nut.
Tightening torque: 18.6 ± 4.9 N•m
(1.9 ± 0.5 kgf•m / 13.7 ± 3.6 lbf•ft)

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 SERVICE AND MAINTENANCE

Flat-head Filter body

Wire
screwdriver

Inner gasket
Drain plug Outer gasket
Union

Element

Pre-fuel filter 2. Turn the union by hand and pull out

the filter body. O-ring
1. Insert a flat-head screwdriver into the
groove on the filter body and turn the At this time, check the alignment
position of the filter body and element Element case
union to lightly loosen.
case.

NOTE
When pulling out the filter body, fuel
will flow out of the filter body. Using a
wire, etc., fasten at a high position so
that fuel does not flow out. 3. Remove the element from the filter
body.
4. Connect one end of a plastic hose
to the drain plug at the bottom of the
element case and place the other
end of the hose inside a container to
receive the drained fuel.

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 SERVICE AND MAINTENANCE
5. Loosen the drain plug to drain fuel.
After draining, tighten the drain plug. Connection
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. In addition, clean any foreign Mark
matter or dirt inside the element Outer gasket
case. At this time, check that the float
at the bottom of the element case
interior moves freely and smoothly.
9. Lightly coat the inner gasket and 10. While supporting the element
outer gasket of the new element with inserted into the filter body with
CAUTION diesel fuel. your hand, install the filter body to
Do not use compressed air to remove Insert the element into the filter body. the element case. After aligning the
foreign matter. Using compressed air alignment positions of the filter body
could cause an intrusion of foreign CAUTION and element case, align the claws
matter into the fuel passage. (The on the filter body with the element
engine may be damaged if foreign After inserting the element into the case notches and tighten the union
matter intrudes.) Use a clean cloth to filter body, check that the outer gasket until the mark on the union comes
remove any dirts. is securely engaged in the element to the right of the connection point
groove. Incomplete installation may of the hose, while holding the filter
8. Install a new O-ring to the element cause an intrusion of foreign matter body.
case and lightly coat the O-ring with into the fuel passage resulting in
11. Bleed air from the fuel system.
diesel fuel. engine damage.
12. Start the engine and check that there
is no fuel leakage from the fuel filter.

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 SERVICE AND MAINTENANCE

WARNING
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
possible if there is any fuel hose
breakage such as cracking.

Dual type fuel filter OPT 4JB 3. Lightly oil the O-ring. Install and turn
1. Loosen each fuel filter by turning them in the filter assembly clockwise
counterclockwise with a filter wrench. carefully to prevent fuel spillage. Turn
2. With a rag wipe clean the fitting face it until the O-ring is fitted against the
on the upper cover, so that the new sealing face of the filter cover. Further
fuel filter can be seated properly. turn the filter assembly 1/3 to 2/3 of a
turn with the filter wrench.

CAUTION
It is strongly advisable to use an Isuzu
genuine fuel filter assembly for
replacement.

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 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
burn. Be sure to perform
cooling system" and "Preparing engine
checking, adding or changing
coolant".
when engine coolant temperature
1. Confirm that the engine has fully
is low. To open the radiator cap or
cooled down before starting work.
reserve tank cap, put a piece of
2. Remove the radiator cap.
thick cloth on the cap and loosen
WARNING the cap slowly.
• Engine coolant is toxic and must
• When the engine coolant is
heated to a high temperature, be not be ingested. If the engine
sure not to remove the radiator coolant is mistakenly ingested,
cap or reserve tank cap. If immediately vomit it and seek
removing unnecessarily, steam prompt medical attention.
spouts and may cause a burn. WARNING (Continued)

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 SERVICE AND MAINTENANCE

WARNING (Continued) CAUTION 4JB

• 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. When
minutes or longer. Also, if still
removing the cap, take care not to
abnormality such as irritation is
damage the cap or filler.
felt, seek medical attention.
• Tighten the radiator drain plug by Drain plug
• If the engine coolant gets on your
hand. Tightening with pliers or some
skin, rinse it off using a soap with
other tool could damage it.
a large amount of water. Also, if
abnormality is seen, seek medical
attention. NOTE
3. Open the drain plugs on the radiator
Discard the drained engine coolant in and the engine to let the engine
• Keep fire away from the engine
the specified way. coolant run out. Drain the engine
coolant since it is easy to catch
fire. Also it may catch fire if it is coolant from the reserve tank as well.
splashed on some parts that are 4. Tighten the drain plugs on the radiator
in high temperature such as a and the engine. Apply sealant
manifold. Take care not to splash (LOCTITE® 262 or equivalent) to the
it. screw threads of the engine drain plug
• For storage, close the cap before installing it.
securely and keep it in a place Engine drain plug tightening torque:
inaccessible to children. 21.6 N•m (2.2 kgf•m / 16 lb•ft)

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 SERVICE AND MAINTENANCE

4JH 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" line.
6. Close the cap of the reserve tank.
Drain plug
7. Start the engine and let it idle for 20
minutes. Stop the engine, wait until it
Cleaning the engine coolant passages cools down, and then drain out the
WARNING water.
1. Remove the air bleed plug from the (Refer to "Draining the cooling
Do not start the engine when engine water outlet (if equipped). Refill the
coolant has been drained from the system".)
radiator with tap water up to the top of
radiator. This could cause the the opening. After refilling, tighten the
engine to seize up. air bleed plug.
Water outlet air bleed plug tightening
NOTE torque: 23.5 N•m (2.4 kgf•m / 17 lbf•ft)
For best results it is suggested that the
engine cooling system should be CAUTION
flushed when the engine coolant is
replaced. It is advisable to flush the The radiator cap is a double-action
interior of the cooling system type that must be opened and closed
including the radiator before using the in two turning motions. When
engine coolant solution. removing the cap, take care not to
damage the cap or filler.

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 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•m / 16 lb•ft)
Air bleed
Air bleeding bolt
plug
3. Remove the air bleed plug from the
water outlet (if equipped) and pour
engine coolant in the specified
Filling the cooling system concentration. After filling with engine 4. Squeeze the radiator upper hose two
coolant, replace the gasket of air or three times. If this action results in
CAUTION bleed plug with a new one and tighten air being discharged from the hose
the air bleed plug. and the level of engine coolant goes
• A failure to correctly fill the engine down, add engine coolant up to the
cooling system in changing or Water outlet air bleed plug tightening
torque: 23.5 N•m (2.4 kgf•m / 17 lbf•ft) top of the radiator filler opening from
topping up engine coolant may the radiator cap section. Repeat until
sometimes cause the engine coolant the level of the engine coolant no
to overflow from the filler neck even CAUTION longer decreases.
before the engine and radiator are • The radiator cap is a double-action
completely full. type that must be opened and closed
• If the engine runs under this in two turning motions. When
condition, the shortage of engine removing the cap, take care not to
coolant may possibly result in damage the cap or filler.
engine overheating. To avoid such • Refill with engine coolant slowly to
trouble, the following precautions avoid air being mixed in.
should be taken when refilling with
the engine coolant.
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 SERVICE AND MAINTENANCE

4JB1 4JH warm-up switch, maintain the engine

4JB1-TC
speed approximately 2,000 r/min to
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
MAX minutes. If the vehicle is equipped
with an air conditioner, turn the A/C
MIN
switch off to facilitate warming. If the
vehicle is equipped with a heater, turn
off the fan to facilitate warming. Check
5. Close the radiator cap. 8. After checking that the engine has if the thermostat is open or not by
sufficiently cooled down, remove the checking whether the upper hose and
6. Fill the reserve tank with engine lower hose are hot. If the vehicle is
coolant to the "MAX" line. Close the radiator cap. If the engine coolant
level has decreased, replenish with equipped with a heater, turn the
cap of the reserve tank. temperature control to the maximum
engine coolant up to the radiator filler
7. Start the engine, let it idle for 5 opening. If the engine coolant level setting and make sure that hot air
minutes or more and then stop the has abnormally decreased, check for comes out.
engine. leaks from the radiator, the engine 10. Let the engine idle for 5 minutes and
coolant passages, or the reserve tank then stop the engine.
hose. 11. After checking that the engine has
9. After firmly closing the radiator cap, sufficiently cooled down, remove the
idle the engine until the needle of the radiator cap and check the engine
coolant temperature gauge reaches coolant level. If the engine coolant
the center and the thermostat opens. level has decreased, replenish with
In order to save time, if the vehicle is engine coolant up to the radiator filler
equipped with a warm-up switch, turn opening from the radiator cap
the switch on to warm up the engine. section. If the engine coolant level
If the vehicle is not equipped with a has abnormally decreased, check for
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 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.
15. Check the engine coolant level of the
reserve tank the next morning. If the
engine coolant level has decreased,
refill with engine coolant to the "MAX" Bleeding of clutch hydraulic circuits To bleed, proceed as follows:
line. If air enters the clutch circuit, it will cause 1. Set the parking brake.
clutch dragging. Therefore, bleeding
operation should be performed if the
clutch fluid reservoir has been emptied
due to failure or if the hydraulic circuit has
been disassembled. Bleeding operation
calls for the cooperative action of the two
men.

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 SERVICE AND MAINTENANCE

REPEATEDLY HOLD

MAX
ADD

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. bleeder screw. Connect a vinyl tube clutch slave cylinder to release clutch
to the bleeder screw and insert the fluid with air bubbles into the container
other end of the vinyl tube into a and tighten the bleeder screw
transparent container. immediately.
4. Depress the clutch pedal repeatedly 7. Release the clutch pedal carefully.
and hold it depressed. Repeat the above operation until air
bubbles disappear from the clutch fluid
being pumped out into the container.
During the bleeding operation, keep
the clutch fluid reservoir filled to the
specified level.
Reinstall the rubber cap.

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 SERVICE AND MAINTENANCE

Service brake adjustment To adjust front and rear brakes, 7. Repeat the above adjustment
The use of a brake system with excessive proceed as follows: procedures for adjusting the brakes
brake lining clearances is unsafe as the on the remaining wheels.
brake performance deteriorates with an 1. Jack up a wheel clear of the ground.
increase in lining clearance. The brake 2. Then set a supporter for safety.
lining clearance should be checked and 3. Remove the rubber plugs from the
adjusted at specified intervals. brake adjuster holes in the front and
rear faces of the brake back plate.
4. Insert a screwdriver into adjuster hole
and turn the adjuster in the direction of
the arrow until the wheel can not turn.
5. Back off the adjusters 5 to 6 notches.
6. Replace the rubber plugs in position.

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 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.
poor braking. Therefore, the bleeding 2. Start and keep the engine running Brake booster (master-vac) will be
operation should be performed if the until the vacuum accumulates adversely affected if the bleeding
brakes have been used with an excessive sufficiently. operation is performed without
level of brake fluid in the reservoir or if the running the engine.
brake pipes have been disconnected in
3. Check the level of brake fluid in the
the course of brake servicing. Bleeding
reservoir and replenish it as
operation calls for the cooperative action
necessary.
of two men.

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 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.
LHD
Right-hand rear wheel –> Left-hand
front wheel –> Right-hand front wheel.
RHD

5. Remove the rubber cap from the 6. Pump the brake pedal slowly 3 times
bleeder screw and wipe and clean the and hold it depressed.
bleeder screw. Connect a vinyl tube Loosen the bleeder screw to release
to the bleeder screw and insert the brake fluid with air bubbles into the
other end of the vinyl tube into a container and tighten the bleeder
transparent container. screw immediately.

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 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. replenish it as necessary. notches when pulled with a force of 15 kg
During the bleeding operation, keep (33 lbs, 147N). The parking brake can be
the brake fluid reservoir filled to the adjusted in the following manner:
specified level. Install the rubber cap. 1. Chock the front wheels.
2. Release the parking brake.
3. Loosen the lock nut.
4. Turn the adjust nut to loosen the
cable completely.

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 SERVICE AND MAINTENANCE
Adjuster screw notches and clearance
Notches Clearance mm (in)
30 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 stops.
hole in the brake drum into alignment 7. Back off the adjuster 30 notches and
with the adjuster by turning the check the stroke of the brake lever.
propeller shaft. The adjuster is
positioned below the center line of the
propeller shaft.

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 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.
parking brake cable with the adjust nut as Especially on vehicles with double tire, it
follows: is hard to find out by visual check even if
(1) Loosen the lock nut. one of the tires has lost its pressure.
(2) Adjust the length of the cable with the Therefore, use a tire gauge to check the
adjust nut. tire pressure.
(3) Tighten and lock the adjust nut with Be sure to check the spare tires, too.
the lock nut. For standard inflation pressures, refer to
"MAIN DATA AND SPECIFICATIONS".

WARNING
• Never drive the vehicle unless the
tires are properly inflated and in
safe condition.
WARNING (Continued)

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 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)
overheat, causing burst. If the tire
bursts, it may burn. In the worst
case, fire will take place in the Tire air pressure plate Specific gravity of battery electrolyte
vehicle.
The recommended tire pressure is listed Check the specific gravity of the battery
on each tire air pressure plate, pasted on electrolyte using a hydrometer. If the
NOTE the inner position of the driver’s side door. specific gravity is too low, the battery
Check or maintain tire pressure when (Partial Vehicle) should be charged.
the tires are cold. (After the vehicle has Specific gravity at an electrolyte
been inoperative for more than 3 hours temperature of 20°C (68°F): 1.27 to 1.29
or driven less than 1.6 km (1 mile)).
Inner and outer ones of double tires
must be the same tire pressure.

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 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.
of vaseline or grease to the battery of the highway without blinding other When replacing a bulb, make sure the
terminals to prevent corrosion. motorists. When light aiming is necessary light switch is "OFF". Use only bulbs with
it is advisable to contact an authorized the same wattage rating. The standard
dealer who has special equipment for this bulb wattage ratings are shown on the
purpose. chart.

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 SERVICE AND MAINTENANCE

Wattage
Location 12 volt No. of
system bulbs
Halogen head lights - 60W/55W 2
Turn signal 21W 2
Front combination lights Cornering/
21W/5W 2
Clearance
Stop/Tail 21W/5W 2
Rear combination lights Turn signal 21W 2
Back up 21W 2
V 10W 1
License plate light -
V 5W 2
Dome light - 10W 1
V Fog lights - 55W 2
V Rear fog light - 21W 1

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 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.
Front combination lights 5. Tighten the lower side screw of front Fog lights V

[Removal procedure] combination light assembly. Then, Remove the screws retaining the lens
1. Remove the seal rubber under the hook the seal rubber on two and remove the lamp unit.
head light and loosen the side screw projections under the head light.
of front combination light assembly.
2. Pull out the front combination light
assembly. At this time, open the front
door and push the stud pin head by
inserting a cross slot screwdriver
through the clearance between the
door and cab.
[Installation procedure]
1. Connect the connector of front
combination light assembly.
2. Position it by aligning two pawls with
the groove of head light.

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 SERVICE AND MAINTENANCE

Rear combination lights Rear fog light V 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.

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 SERVICE AND MAINTENANCE

Dome light Fuse junction block When replacing a fuse, turn the starter
The cover of the light can be removed The fuse box is located in the glove box. switch to the "LOCK" position and
very easily with a screwdriver. Open the glove box cover to check and only use fuses of the same amperage.
replace fuses. Use specified fuses only. Unspecified
The cover can be easily pulled out fuses can cause fire and malfunction
manually. of equipment.
To replace a fuse, use the provided fuse
puller.

NOTE
If a fuse has been burnt out, check to
locate the cause of the trouble and
give necessary service attention before
replacing the fuse.

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 SERVICE AND MAINTENANCE
If there is an overload in the circuits from
the battery, the fusible links are designed
to burn out before the entire wiring
harness is damaged.

WARNING
The cause of electrical overload
should always be determined before
Normal Burnt out replacing a fusible link.

Fusible link
If the head lights or other electrical
components do not work and the fuses
are 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.

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 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. 25 26
5 6 7
Refer to the table on the following page for 27 28

the specified amperages and names of 8

9 10 11 12 13 14
15
each fuse, as well as names of each relay.

Fuse box (located in the glove box)

PULLER
22 19 16 13 10 7 4 1

FUSE
4 3 2 1 23 20 17 14 11 8 5 2
24 21 18 15 12 9 6 3

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 SERVICE AND MAINTENANCE

Coin Lid

23 22 21 20 19 18 17 16

Relay box (located in the dashboard)

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 SERVICE AND MAINTENANCE
Fuse Relay
12V 12V
No. 4JB1 MODEL ENGINE No. 4JB1 MODEL ENGINE
1 10A AIR CON 1 TAIL
2 15A EXH. BRAKE, FUEL HEATER 2 HEAD LAMP
3 15A REAR HEATER 3 HORN
4 15A AUDIO (B), DOOR LOCK 4 WIP KEY ON
5 10A STOP LIGHT 5 -
6 10A FRT FOG LIGHT, CORNERING LAMP 6 -
7 10A TAIL LIGHT 7 GLOW
8 10A EGR 8 MARKER LAMP
9 10A FUEL CUT 9 RR FOG
10 15A FRONT WIPER & WASHER 10 -
11 10A TURN LIGHT 11 EXH BRAKE CUT
12 10A H/LAMP LEVEL Relay 12 CSD
13 - - 13 -
14 - - 14 -
Fuse
15 15A AUDIO (IG), CIGAR LIGHTER 15 STARTER
16 10A METER 16 BLOWER
17 - - 17 CHARGE WARNING
18 - - 18 -
19 15A HORN, HAZARD 19 CORNER LAMP
20 10A ABS (IG) 20 EXH BRAKE
21 15A GENERATOR 21 P/WINDOW
22 10A STARTER 22 DIMMER
23 10A HEAD LIGHT RH 23 -
24 10A HEAD LIGHT LH
25 15A MARKER LAMP
26 - -
27 10A RR FOG
28 - -

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 SERVICE AND MAINTENANCE
Fuse Relay
12V 12V
No. 4JH1 MODEL ENGINE No. 4JH1 MODEL ENGINE
1 25A HEATER 1 TAIL
2 10A AIR CON 2 HEAD LAMP
3 - - 3 HORN
4 15A AUDIO (B), DOOR LOCK 4 WIP KEY ON
5 25A P/WINDOW 5 -
6 10A STOP LAMP 6 -
7 15A TAIL LAMPS 7 GLOW
8 10A FOG LAMP 8 -
9 - - 9 -
10 10A ECU (BATT) 10 -
11 15A HORN, HAZARD 11 -
12 - - Relay 12 STARTER CUT
13 15A WIPER 13 -
14 10A TURN LAMPS 14 ECM MAIN
Fuse
15 15A ACC, CIGAR LIGHTER 15 STARTER
16 10A METER 16 HEATER AC
17 10A ECM 17 CHARGE (ENG RUN)
18 - - 18 THERMO
19 - - 19 ECU IGN
20 10A ABS 20 CORNERING LAMP
21 15A GENERATOR 21 POWER WINDOW (model with power window)
22 10A STARTER 22 DIMMER
23 10A HEAD LAMP RH 23 -
24 10A HEAD LAMP LH
25 - -
26 10A ECM2
27 - -
28 20A ECM

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 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.

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 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

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 SERVICE AND MAINTENANCE
Oil viscosity chart for rear axle

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 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.
The lubrication intervals in the maintenance schedule and the coverage and period of new vehicle warranty are based on the use of
ISUZU genuine lubricants or recommended lubricants as given in the chart which will serve as a guide for selecting lubricants of proper
brand name.

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 SERVICE AND MAINTENANCE

GRADE
LUBRICATION MAKER BRAND/TYPE
API 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)*1 CH-4 — —
Castrol Tection J-Max (15W-40) CH-4 E3 DH-1
Chevron/Texaco/Caltex Delo 400 Multigrade (15W-40) CI-4 E7 DH-1
Diesel engine Chevron/Texaco/Caltex Delo Gold Multigrade (15W-40) CH-4 E3 —
crankcase Elf Performance Victory (15W-40) CI-4 E7 —
ExxonMobil Delvac MX (15W-40) CI-4 E7 —
ExxonMobil Delvac 1 (5W-40) CI-4 E7 DH-1
Shell Rimula R4X (15W-40) CI-4 E7 DH-1
Total Rubia Works 1000 (15W-40) CI-4 E7 DH-1
Total Rubia TIR 7400 (15W-40) CI-4 E7 —
ISUZU BESCO GEAR SH (80W-90), (90), (140) GL-5 — —
Castrol Syntrax Universal (80W-90) GL-5/MT-1 — —
Chevron/Texaco/Caltex Delo Gear EP-5 (80W-90), (85W-140) GL-5/MT-1 — —
Elf Tranself Type B (80W-90), (85W-140) GL-5 — —
ExxonMobil Mobil Delvac 1 Gear Oil (75W-90) GL-5/MT-1 — —
Differential
ExxonMobil Mobilube S (80W-90) GL-5/MT-1 — —
Shell Spirax S2 A IZ (80W-90) GL-5 — —
Shell Spirax S3 AX (80W-90) GL-5 — —
Total Transmission Gear 9 (80W-90) GL-5/MT-1 — —
Total Transmission Axle 7 (80W-90), (85W-140) GL-5 — —
NOTE:
*1: Models for Russian market

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 SERVICE AND MAINTENANCE

GRADE
LUBRICATION MAKER BRAND/TYPE
API ACEA JASO
ISUZU BESCO TRANSAXLE (5W-30) — — —
Chevron/Texaco/Caltex Delo 400 Multigrade (15W-40) CI-4 E7 DH-1
Manual Elf Performance Victory (15W-40) CI-4 E7 —
transmission ExxonMobil Delvac MX (15W-40) CI-4 E7 —
Shell Rimula R4X (15W-40) CI-4 E7 DH-1
Total Rubia TIR 7400 (15W-40) CI-4 E7 —
ISUZU BESCO ATF III (Dexron® III) — — —
BP Autran DXIII (Dexron® III) — — —
Castrol ATF Heavy Duty (Dexron® III) — — —
Chevron/Texaco/Caltex Havoline ATF-J (Dexron® III) — — —
Power steering
ExxonMobil Mobil Multipurpose ATF (Dexron® III) — — —
Shell Spirax S3 ATF MD3 (Dexron® III) — — —
Total Fluidmatic IIIG (Dexron® III) — — —
Total Fluide G3 (Dexron® III) — — —
ISUZU BESCO L2 GREASE (No.2), L3 GREASE — — —
Tie rod end
(No.3)
Center bearing
Chevron/Texaco/Caltex Delo Starplex EP (No.2) — — —
Kingpins
ExxonMobil Mobilgrease XHP 222 (No.2), 223 (No.3) — — —
(Multi purpose
Shell Gadus S3 V220C 2 (No.2) — — —
grease)
Total Multis Complex EP2 (No.2), EP3 (No.3) — — —
Propeller shaft
sliding yoke
ISUZU BESCO ONE LUBER Mo GREASE (No.2) — — —
Universal joint
Chevron/Texaco/Caltex Multifak Moly EP (No.2) — — —
(Multi purpose
Shell Gadus S2 V220AD 2 (No.2) — — —
grease containing
Total Multis Complex HV2 Moly (No.2) — — —
molybdenum
disulfide)

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 SERVICE AND MAINTENANCE

COOLANT MAKE BRAND*

ISUZU BESCO LLC SUPER TYPE E, AS
Arteco Havoline XLC
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 BESCO BRAKE FLUID SUPER DOT 3
Clutch and brake fluid reservoir
AC Delco Supreme 11 DOT 3
*: This material meets GENERAL MOTORS ENGINEERING STANDARDS GM4653M, FMVSS 116 or SAE J1703 requirements.

DIESEL FUEL/APPLICABLE STANDARD

JIS (JAPANESE INDUSTRIAL STANDARDS) Based on K2204: 1997 Diesel Fuel
DIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590: 1997
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS) Based on D975-04c No.1-D S500 or No.2-D S500 (below 500
ppm)
BS (BRITISH STANDARDS) Based on BS EN590: 1997

DIESEL FUEL/APPLICABLE STANDARD (Sulfur content below 50ppm)

JIS (JAPANESE INDUSTRIAL STANDARDS) Based on K2204: 2007 Diesel Fuel
DIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590: 2004
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS) Based on D975-04c NO.1-D S15 or NO.2-D S15 (below 15 ppm)
BS (BRITISH STANDARDS) Based on EN590: 2004
NOTE:
Do not use fuels other than those listed above. Doing so may adversely affect the engine.
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 SERVICE AND MAINTENANCE

LUBRICATION CHART: QKR55 AND QKR77

: Change G : Gear oil M : MoS2 contained type grease
: Check and Replenish or Lubricate W : Wheel bearing grease B : Brake fluid
E : Engine oil C : Multipurpose type grease A : Automatic transmission fluid

Kingpin Power steering fluid OPT Prop. shaft universal joint Rear hub bearing
Front hub bearing Transmission Prop. shaft universal joint Prop. shaft universal joint
Tie rod end Prop. shaft sliding sleeve
E
W A W

M M M M
C C

Every 12 months or 20,000km (12,000 miles)

Every 24 months or 40,000km (24,000 miles)

Every 24 months or 45,000km (27,000 miles)

Every 18 months or 30,000km (18,000 miles)
Every 12 months or 15,000km (9,000 miles)
Every 6 months or 10,000km (6,000 miles)
Every 3 months or 5,000km (3,000 miles)
E
C C E

M
G
B W W
G
Kingpin Tie rod end Engine 4JB Prop. shaft center bearing
Brake and clutch fluid Engine 4JH Differential gear

Steering gear box Front hub bearing Rear hub bearing

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 SERVICE AND MAINTENANCE

Drain plug

LUBRICATION GUIDE When the engine crankcase and oil filter Then fill the engine crankcase from the
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-
flow oil filter.

WARNING
A hot engine oil can cause severe
skin burns. Allow the engine to cool
before draining the engine oil.

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 SERVICE AND MAINTENANCE

NOTE
Use the recommended engine oil.
(Refer to "RECOMMENDED FLUIDS, (F)
LUBRICANTS AND DIESEL FUELS".)

When the engine crankcase is filled to the

high level mark on the oil dipstick, start
(D)
and let the engine idle for a few minutes.
Stop the engine and recheck the oil level
and replenish, if necessary.

Changing transmission oil Changing differential oil

Drain the transmission case by removing Drain the rear axle case by removing the
the drain plug (D) on the lower face of the drain plug (D) on the lower part of the rear
transmission case. Fill the transmission axle case. Fill the rear axle case to the
case to the filler plug (F) with the specified level plug (L) with specified gear oil
engine oil through the filler plug hole. through the level plug hole.

WARNING Use GL-5 Gear Lubricant of the correct

viscosity for the existing ambient
Right after driving, the oil may be temperatures.
hot, so be careful.

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 SERVICE AND MAINTENANCE

4JB

(A)

To fluid reservoir

(B)

Changing power steering fluid Refilling: 3. Lower the front wheels to the ground.
Draining: 1. Install the fluid pipe and hose securely Start the engine and let it idle for a few
and fill the fluid reservoir with the minutes.
1. Jack up the front wheels until they are Recheck the fluid level and replenish if
clear of the ground. specified automatic transmission fluid.
2. When the fluid reservoir is filled to the necessary.
2. Remove the fluid pipe (A) between the
steering unit and the fluid reservoir, specified level, allow 2 or 3 minutes.
and the fluid hose (B) between the
pump and the fluid reservoir.
NOTE
3. When draining is completed, remove After refilling regularly check and keep
the remaining fluid within the hydraulic fluid reservoir replenished as
system by turning the steering wheel necessary to prevent air from entering
until it stops in both directions several the hydraulic system.
times.

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 SERVICE AND MAINTENANCE

4JH

Repacking the front and rear hub Greasing points

bearing with grease 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.

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 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. Also, the cargo bed and frame
will be damaged.
Lubricate the following points with MoS2 Lubricate the following points with wheel
type grease. bearing grease.
Universal joints and sliding sleeve. Center bearing.

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 SERVICE AND MAINTENANCE

Never apply unnecessarily large force. When loading with a heavy cargo: Keep flammable materials away from
Fix the load securely using a load cover In case of heavyweight cargo, use pads the gap between the cab and the guard
or rope to prevent it from falling, but do under the cargo to prevent it from moving frame.
not apply unnecessarily large force as this and fix it firmly with wire rope, etc. Do not Make certain the load cover or rope ends
could break or otherwise damage the side fix cargo using excessive force. are tucked in tight and not hanging free in
drop, tail gate and guard frame, etc. the gap behind the cab, as the engine
heat may cause a fire while driving.

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 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.

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 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 from rolling due to crosswind or when
bed. appropriate material. turning.

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 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,
overhead valve,
water cooled, direct injection, water cooled, direct injection,
water cooled, direct injection
turbocharger with intercooler turbocharger with intercooler
Compression ratio (to 1) 18.2 V 18.1 18.2 15.9
Piston displacement cc (cu.in.) 2,771 (169.1) 2,771 (169.1) 2,999 (183.0)
Firing order 1-3-4-2 1–3–4–2 1-3-4-2
Fan belt tension mm (in) Refer to page 5-8 Refer to page 5-8 Refer to page 5-8
Idling speed r.p.m 775-825 V 725-775 775-825 675-725
Engine oil quantity [reference value] When changing oil only: When changing oil only: When changing oil only:
liters (US/Imp gal.) 6.4 (1.69/1.41) 6.4 (1.69/1.41) 6.0 (1.59/1.32)
When changing oil and filter: When changing oil and filter: When changing oil and filter:
7.0 (1.85/1.54) 7.0 (1.85/1.54) 6.6 (1.74/1.45)
Engine coolant quantity [reference
value] 10.1 (2.67/2.22) 10.1 (2.67/2.22) 11.3 (2.99/2.49)
liters (US/Imp gal.)
Oil pan drain plug tightening torque
83 (8.5, 61) 83 (8.5, 61) 83 (8.5, 61)
N•m (kgf•m, lbf•ft)

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 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)

Oil capacity
2.7 (0.71/0.59) 2.7 (0.71/0.59) 2.7 (0.71/0.59)
liters (US/Imp gal.)

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 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 mm (in) 190 (7.5) 190 (7.5) 190 (7.5)
WEIGHTS
Gross vehicle mass kg (lb) 4,100 (9,041) 5,200 (11,466) 5,200 (11,466)
RHD 2,500 (5,513) RHD 2,500 (5,513)
Axle capacity: Front kg (lb) LHD 2,400 (5,292)
LHD 2,400 (5,292) LHD 2,400 (5,292)
Rear kg (lb) 2,500 (5,513) 3,500 (7,718) 3,500 (7,718)
ENGINE
Model 4JB1 4JB1
TRB 4JB1-TC
TRB 4JB1-TC TRB 4JB1-TC
Fuel tank capacity
75 (19.8/16.5) 100 (26.4/22.0) 100 (26.4/22.0)
liters (US/Imp gal.)
CLUTCH
Type Hydraulic control, diaphragm spring, Hydraulic control, diaphragm spring, Hydraulic control, diaphragm spring,
dry single plate dry single plate dry single plate
Pedal free play mm (in) 15 to 25 (0.59 to 0.98) 15 to 25 (0.59 to 0.98) 15 to 25 (0.59 to 0.98)
TRANSMISSION
Manual transmission JC520T9D JC521T5H JC521T5H
REAR AXLE
Type Spiral bevel pinion and hypoid gear Spiral bevel pinion and hypoid gear Spiral bevel pinion and hypoid gear
Oil capacity
Ø244 2.7 (0.71/0.59) Ø292 3.0 (0.79/0.66) Ø292 3.0 (0.79/0.66)
liters (US/Imp gal.)

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 MAIN DATA AND SPECIFICATIONS

Vehicle model QKR55E QKR55F QKR55H

STEERING
Type Recirculating ball Recirculating ball Recirculating ball
OPT Recirculating ball with power assisted OPT Recirculating ball with power assisted OPT 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) OPT 10 to 50 (0.39 to 1.97) OPT 10 to 50 (0.39 to 1.97) OPT 10 to 50 (0.39 to 1.97)

Oil capacity 0.55 (0.15/0.12) 0.55 (0.15/0.12) 0.55 (0.15/0.12)

liters (US/Imp gal.) OPT 1.6 (0.42/0.35) OPT 1.6 (0.42/0.35) OPT 1.6 (0.42/0.35)

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
Type Mechanical internal expanding Mechanical internal expanding Mechanical internal expanding
at rear of transmission at rear of transmission at rear of transmission
Brake lever travel (when pulled with
6 to 8 6 to 8 6 to 8
a 15 kgf (33 lbf, 147 N)) notches
SUSPENSION
Type: Front Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring
with hydraulic double acting telescopic with hydraulic double acting telescopic with hydraulic double acting telescopic
shock absorbers shock absorbers shock absorbers
Rear Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring
with hydraulic double acting telescopic with hydraulic double acting telescopic with hydraulic double acting telescopic
shock absorbers shock absorbers shock absorbers
ELECTRICAL
Type 12 volt system with negative polarity ground 12 volt system with negative polarity ground 12 volt system with negative polarity ground
Battery 95D31R (12/80) 95D31R (12/80) 95D31R (12/80)
volt/amp. hr. OPT 130E41R (12/115) OPT 130E41R (12/115) OPT 130E41R (12/115)

Starter V 12/2.0 V 12/2.0 V 12/2.0

volt/kw V 12/2.2 V 12/2.2 V 12/2.2
AC generator volt/amp. hr. 12/50 12/50 12/50

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 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) 190 (7.5)
WEIGHTS
Gross vehicle mass kg (lb) 4,100 (9,041) / 4,550 (10,033) 3,500 (7,718) / 5,200 (11,466) 5,200 (11,466)
Axle capacity: Front kg (lb) 2,500 (5,513) 2,400 (5,292) 2,400 (5,292)
Rear kg (lb) 3,600 (7,938) 3,500 (7,718) 3,500 (7,718)
ENGINE
Model TRB 4JH1-TC TRB 4JH1-TC TRB 4JH1-TC
Fuel tank capacity
75 (19.8/16.5) 100 (26.4/22.0) 100 (26.4/22.0)
liters (US/Imp gal.)
CLUTCH
Type Hydraulic control, diaphragm spring, Hydraulic control, diaphragm spring, Hydraulic control, diaphragm spring,
dry single plate dry single plate dry single plate
Pedal free play mm (in) 15 to 25 (0.59 to 0.98) 15 to 25 (0.59 to 0.98) 15 to 25 (0.59 to 0.98)
TRANSMISSION
Manual transmission MSB5S MSB5S MSB5S
REAR AXLE
Type Spiral bevel pinion and hypoid gear Spiral bevel pinion and hypoid gear Spiral bevel pinion and hypoid gear
Oil capacity
Ø244 2.7 (0.71/0.59) Ø292 3.0 (0.79/0.66) Ø292 3.0 (0.79/0.66)
liters (US/Imp gal.)
STEERING
Type Recirculating ball Recirculating ball Recirculating ball
OPT Recirculating ball with power assisted OPT Recirculating ball with power assisted OPT 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) OPT 10 to 50 (0.39 to 1.97) OPT 10 to 50 (0.39 to 1.97) OPT 10 to 50 (0.39 to 1.97)

Oil capacity 0.54 (0.14/0.12) 0.54 (0.14/0.12) 0.54 (0.14/0.12)

liters (US/Imp gal.) OPT 1.6 (0.42/0.35) OPT 1.6 (0.42/0.35) OPT 1.6 (0.42/0.35)

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 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
Type Mechanical internal expanding Mechanical internal expanding Mechanical internal expanding
at rear of transmission at rear of transmission at rear of transmission
Brake lever travel (when pulled with
6 to 8 6 to 8 6 to 8
a 15 kgf (33 lbf, 147 N)) notches
SUSPENSION
Type: Front Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring
with hydraulic double acting telescopic with hydraulic double acting telescopic with hydraulic double acting telescopic
shock absorbers shock absorbers shock absorbers
Rear Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring Semi-elliptical, alloy steel leaf spring
with hydraulic double acting telescopic with hydraulic double acting telescopic with hydraulic double acting telescopic
shock absorbers shock absorbers shock absorbers
ELECTRICAL
Type 12 volt system with negative polarity ground 12 volt system with negative polarity ground 12 volt system with negative polarity ground
Battery volt/amp. hr. 80D26L 80D26L 80D26L
Starter volt/kw 12/2.0 12/2.0 12/2.0
AC generator volt/amp. hr. 12/60 12/60 12/60

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 MAIN DATA AND SPECIFICATIONS

TIRE SIZE AND TIRE INFLATION PRESSURE

Tire inflation pressure
Tire size
kPa (kgf/cm2, psi)
Vehicle model Front Rear Front Rear
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) 525 (5.25/75)
7.00R15-8PR 7.00R15-8PR 450 (4.50/64) 450 (4.50/64)
QKR55 7.00R16-10PR 7.00R16-10PR
525 (5.25/75) 525 (5.25/75)
113/111M 113/111M
7.00R15-8PR 7.50R15-10PR 350 (3.50/50) 575 (5.75/85)
7.00R15-8PR 7.50R15-12PR 350 (3.50/50) 650 (6.50/94)
QKR77
7.00R16-10PR 7.00R16-10PR 525 (5.25/75) 525 (5.25/75)
(Single tire rear wheel model)
7.00R16-10PR 7.50R16-12PR 525 (5.25/75) 650 (6.50/94)
7.00R16-12PR 7.00R16-12PR 600 (6.00/87) 600 (6.00/87)
7.00R15-8PR 7.00R15-8PR 450 (4.50/64) 450 (4.50/64)
QKR77
7.00R16-10PR 7.00R16-10PR 525 (5.25/75) 525 (5.25/75)

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 - NOTE -

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 INDEX
Changing transmission oil ............... 5–66 Dual type fuel filter ........................... 5–32
A Chassis number................................. 1–1
Accelerator pedal ............................. 2–23 Check engine indicator light............. 2–13
Air cleaner ....................................... 5–19 Checking and adding ....................... 5–12 E
Antenna ........................................... 2–38 Cigarette lighter................................ 2–22 Emergency starting.......................... 4–19
Ash tray ........................................... 2–21 Cleaning inside cab ......................... 5–57 Emergency stop ............................... 4–18
Cleaning of battery .......................... 5–47 Engine coolant ................................. 5–33
Clutch pedal..................................... 2–23 Engine coolant level......................... 5–12
B Clutch pedal free play ...................... 5–18 Engine cooling system ....................... 5–9
Combination switch lever ................. 2–16 Engine inspection cover .................. 2–31
Battery/Generator indicator light .......2–11 Cornering light ................................. 2–17
BEFORE DRIVING ............................ 1–8 Engine inspection sub cover ............ 2–31
CORRECT CARGO LOADING Engine number .................................. 1–1
BEFORE DRIVING OFF.................... 4–4 ............................................. 1–2, 5–69
Bleeding of clutch hydraulic circuits .. 5–38 Engine oil level................................... 5–7
Cup holder ....................................... 2–39 Engine overheating .......................... 4–16
Bleeding of the brake hydraulic
circuit ............................................ 5–41 Engine tachometer ............................ 2–7
Bleeding of the fuel system.............. 4–23 Exhaust brake indicator light............ 2–10
D Exhaust brake switch ....................... 2–19
Brake and clutch fluid level .............. 5–17
Brake and clutch fluid reservoir ....... 2–28 Digital clock ....................................... 2–6 External lights .................................. 2–35
Brake pedal ..................................... 2–23 Dimmer switch ................................. 2–17
Brake pedal free play and allowance Dome light ............................. 2–24, 5–51
..................................................... 5–19 Door lock (Inside) .............................. 3–3 F
Door lock (Outside)............................ 3–2 Fan belt .............................................. 5–8
Door window .................................... 2–25 FLOOR CONTROLS ....................... 2–22
C Draining of the water separator ....... 4–25 Fog lights ......................................... 5–49
DRIVER’S CHECK LIST (REGULAR Front combination lights................... 5–49
Central locking door ......................... 2–20 INSPECTION) .............................. 3–10
Change indicator and push button ..... 2–6 Front fog light switch ........................ 2–19
Driver’s seat ....................................... 3–3 Fuel filter .......................................... 5–26
Changing differential oil ................... 5–66 DRIVING FOR ECONOMY ..............4–11
Changing engine oil ......................... 5–65 Fuel gauge ......................................... 2–8
DRIVING ON ICE OR SNOW .......... 4–14 Fuel indicator light............................ 2–10
Changing power steering fluid ......... 5–67 DRIVING PRECAUTIONS ................. 4–7 Fuel tank filler cap............................ 2–29

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 INDEX
Fuel tank filler cap with key .............. 2–30 MAIN DATA AND SPECIFICATIONS
Fully adjustable steering wheel ........ 2–15 J OF TRANSMISSION ...................... 6–2
Fuse and fusible link location........... 5–53 Jacking instruction and changing a flat Main fuel filter .................................. 5–27
Fuse junction block .......................... 5–51 tire ................................................ 4–26 Main oil filter .................................... 5–24
Fusible link ....................................... 5–52 MAINTENANCE ................................ 1–7
MAINTENANCE GUIDE .................... 5–7
K Maintenance operations .................... 5–1
G MAINTENANCE SCHEDULE ............ 5–1
Key..................................................... 3–1 Maintenance schedule under severe
Glove box......................................... 2–24
Glow plug indicator light .................. 2–12 driving conditions ........................... 5–6
Greasing points ............................... 5–68 Meter panel........................................ 2–3
L METERS AND INDICATOR LIGHTS
Level of battery electrolyte ............... 5–15 ....................................................... 2–3
H License plate light ............................ 5–50 Mirrors ............................................... 3–9
Light control switch .......................... 2–16
Hazard warning flasher switch ......... 2–20 Loading farming equipment ............... 1–4
Head lights....................................... 5–47 Loading methods ..................... 1–4, 5–71 O
Heater-defroster ............................... 2–36 LOCATION OF CHASSIS AND ENGINE
High beam indicator light ................... 2–9 Odometer and trip meter ................... 2–6
NUMBER........................................ 1–1 Oil filter ............................................ 5–24
LUBRICATION ................................. 5–58 Oil pressure indicator light ................2–11
LUBRICATION CHART .................... 5–64 Oil viscosity chart for diesel engines
I LUBRICATION GUIDE..................... 5–65 ..................................................... 5–58
Idling control knob ........................... 2–20 Oil viscosity chart for rear axle ........ 5–59
IN CASE OF EMERGENCY ............ 4–16 Oil viscosity chart for transmission cases
Indicator and warning lights ............... 2–5 M ..................................................... 5–58
Inside door handle ............................. 3–2 MAIN DATA AND Opening and closing left and right side
Inside rearview mirror ........................ 3–9 SPECIFICATIONS .......................... 6–3 gates ............................................ 2–34
INSTRUMENT CLUSTER ............... 2–19 MAIN DATA AND SPECIFICATIONS OF Opening and closing rear gate......... 2–34
ENGINE ......................................... 6–1

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 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 ................................... 2–15
OPERATION AND CARE OF VEHICLE STARTING ENGINE .......................... 4–2
....................................................... 1–7 STEERING COLUMN
OPERATION OF CONTROLS ........... 3–1 R CONTROLS ................................. 2–14
OPERATION OF NEW VEHICLE ...... 1–6 Radiator reserve tank ...................... 2–27 Steering wheel ................................. 5–16
OTHERS .......................................... 2–24 Rear body ........................................ 2–34 Steering wheel and horn button ....... 2–14
Outside door handle .......................... 3–2 Rear combination lights ................... 5–50 STOPPING ENGINE ......................... 4–3
Outside rearview mirrors.................... 3–9 Rear fog indicator light ....................... 2–9 Stowage of jack and tools ................ 4–16
Rear fog light ................................... 5–50 Sun visor.......................................... 2–24
RECOMMENDED FLUIDS, SVS (Service Vehicle Soon) indicator
P LUBRICANTS AND DIESEL FUELS light............................................... 2–13
PARKING ........................................... 4–6 ..................................................... 5–60
Parking brake adjustment ................ 5–43 REGULAR INSPECTION .................. 5–7
Parking brake indicator and Brake fluid Repacking the front and rear hub bearing
T
level indicator light ........................ 2–10 with grease ................................... 5–68 Temperature gauge............................ 2–7
Parking brake lever .......................... 2–21 Replacing light bulbs ....................... 5–47 Tilt cab ............................................. 2–32
Parking brake lever travel ................ 5–16 Tire air pressure plate ...................... 5–46
Partial-flow oil filter........................... 5–25 Tire inflation pressure ...................... 5–45
Passing light switch ......................... 2–17 S Tire rotation...................................... 5–45
PERIODIC MAINTENANCE ............ 5–19 Seat belt (2-points) ............................ 3–5 TIRE SIZE AND TIRE INFLATION
Power steering fluid tank.................. 2–28 Seat belt (3-points) ............................ 3–7 PRESSURE ................................... 6–7
Power window lock .......................... 2–26 Seat belt inspection and care ............ 3–8 TO AVOID DAMAGE TO THE VEHICLE
Power window switch on the driver’s Seat belt warning light ..................... 2–14 ..................................................... 1–19
door .............................................. 2–25 Service brake adjustment ................ 5–40 Towing ............................................. 4–21
Power window switch on the passenger Spare wheel hanger ........................ 2–30 Transmission gearshift lever ............ 2–22
door .............................................. 2–26 Turn signal indicator lights ................. 2–9
Turn signal switch ............................ 2–17

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 INDEX

U
Underview mirror ............................. 3–10
Usage of the jack ............................. 4–28

V
Vehicle identification plate ................. 1–2

W
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 ..... 5–18
Windshield washer switch lever ....... 2–18
Windshield washer tank ................... 2–27
Windshield wiper switch lever .......... 2–18

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 QKR-IE-1442

You are requested to order this manual using the manual number
that is shown above.

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 & Training Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan

First edition August, 2015 181710-811K-x

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