Isuzu N Series Elf Workshop Manual Section 0 General Information LGGEN WE 9991 PDF
Isuzu N Series Elf Workshop Manual Section 0 General Information LGGEN WE 9991 PDF
Isuzu N Series Elf Workshop Manual Section 0 General Information LGGEN WE 9991 PDF
GENERAL INFORMATION
SECTION 0
Applicable Model
N-Series
0A General Information
SECTION 0A
GENERAL INFORMATION
CONTENTS
PAGE
General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 2
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 6
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 7
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 9
Recommended Liquid Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–10
Recommended Thread Locking Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–12
0A–2 GENERAL INFORMATION
6. Handle brake fluid and antifreeze solution 16. Be sure to tighten bolts and nuts to the
with great care. specified torque, using a properly maintained
Spilling these liquids on painted surfaces will torque wrench.
damage the paint.
17. When service operation is completed, make a
7. The use of the proper tool(s) and special final check to be sure service has been done
tool(s) where specified is essential to efficient, properly and problem has been corrected.
reliable, and safe service operations.
18. When1removing1or1replacing1parts1that
8. Always use genuine ISUZU replacement1 require refrigerant to the discharged from the
parts. Air conditioning system, be sure to use the
ACR4 or equivalent to recover and recycle
9. Discard used cotter pins, gasket, O-rings, oil Refrigerant-134a, to promote the movement
seals, lock washers, and self-locking nuts at for the protection of the ozone layer covering
disassembly. the earth.
Normal function of these parts cannot be
guaranteed if they are reused. 19. To1assure1safety, always1slowly1release1air
pressure1from1the1air1tanks1before
10. Keep the disassembled parts neatly in groups. disconnecting1pipes,1hoses1or1other1parts
This1will1facilitate1smooth1and1correct from1any1unit1under1pressure.
reassembly.
GENERAL INFORMATION 0A–3
2. The “SERVICE INFORMATION” at the describes the following information and data
beginning of each service operation section, 1 to 6 necessary for the service operation.
1 Troubleshooting 4 Servicing
2 Main Data and Specifications 5 Fixing Torque
3 Service Standard 6 Special Tools
4. Each service operation section begins with a This illustration is useful for finding components,
disassembly view of the unit of equipment service procedure, etc.
(with exception of Inspection and Repair).
The1number1represents1the
service1operation1sequence.
... Align the marks ... Use special tool(s) (parts manufacturer’s tool(s))
... Adjustment
7. The service standard is indicated in terms of considered serviceable. “Limit” indicates the
“Standard” and “Limit”. limit1value1(Correction1or1replacement1is
The “Standard” means the assembly standard necessary when measurement is beyond this
and standard range within which the parts are limit).
0A–6 GENERAL INFORMATION
IDENTIFICATION
Chassis Number:
It is stamped on the front right-hand side face of the
chassis side member.
1: NHR and NKR models with independent front
suspension.
2: NPR, NQR and NPS models with rigid axle front
suspension.
Engine Number:
4J Series Engine
It is stamped on the left side rear of the cylinder body.
4H Series Engine
The engine number is stamped on the right side of
the cylinder body.
LIFTING INSTRUCTION
If it is necessary to use a lifting device other than Lifting should only be done at the positions
the original equipment jack, see illustration for indicated to prevent possible damage to the
acceptable lifting points. vehicle.
CAUTION:
Failure to observe the acceptable lift points may result in
unsatisfactory vehicle performance or a durability failure
which may result in loss of control of the vehicle.
1 3 1 Front axle
2 Side frame front side
3 Rear axle center
4 Side frame rear side
5 Suspension cross member
4
6 Jack up bracket
2
NPS
NPS
1 3
4
2
NHR,NKR
NHR,NKR
(Front
(Front independent
independent suspention)
suspention)
5 3
6
4
NHR,NKR
(Front independent suspention)
NHR,NKR
(Front independent suspention)
TORQUE SPECIFICATIONS
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials
such as casting, etc.
FLARE NUTS
N·m (kg·m / lb·ft)
Pipe diameter mm (in) Torque Pipe diameter mm (in) Torque
NOTE:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.001 in). Poor adhesion will result.
3. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.
GENERAL INFORMATION 0A–11
Application Procedure
mm (in.)
SCREW JUDGE-
DEPRESSION
HOLE MENT
1~3
(0.04~0.12)
OK
OK
Apply liquid gasket to
Depression the bolt hole interior
Specified
bead width
NG
Example
Anaerobic Type : 2-3mm (0.08-0.12 inch)
Others : 2-6mm (0.08-0.24 inch)
NOTE:
When the application procedures are specified in this Workshop manual, follow them.
0A–12 GENERAL INFORMATION
NOTE:
When the application procedures are specified in this Workshop manual, follow them.
HOME
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PAGE
Maintenance Schedule (for Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–12
Maintenance Schedule (Except Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–18
Recommended Fluids, Lubricants and Diesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–14
Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–16
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–18
0B–2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
(For Europe only)
When performing the checks on the following items,
regular inspection items should also be checked.
Maintenance schedule
Use odometer reading or months whichever comes first
4J ENGINE
*Engine oil – R – R – R – R – R – R – R – R – R – R
*Oil filter – R – R – R – R – R – R – R – R – R – R
Fuel filter – – – R – – – R – – – R – – – R – – – R
*Air cleaner element – I – I – I – I – I – I – I – I – I – I
Idling speed and acceleration – – – I – – – I – – – I – – – I – – – I
Valve clearances – – – – – – – A – – – – – – – A – – – –
Fuel tank cap & fuel pipes for loose
connections or damage – – – – – – – I – – – – – – – I – – – –
Drive belt tension and damage – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – R – – – – – – – R – – – –
*Exhaust pipes and mounting
damage or looseness – – – I – – – I – – – I – – – I – – – I
Cooling system – – – I – – – I – – – I – – – I – – – I
Engine operation condition – I – I – I – I – I – I – I – I – I – I
4H ENGINE
*Engine oil – – R – – R – – R – – R – – R – – R – –
*Oil filter – – R – – R – – R – – R – – R – – R – –
Fuel filter: Main Fuel filter – – – R – – – R – – – R – – – R – – – R
OPT Main Fuel filter and Sub Fuel
filter: With Sub fuel filter – – – – – – – R – – – – – – – R – – – –
*Air cleaner element – I – I – I – R – I – I – I – R – I – I
Idling speed and acceleration – – – I – – – I – – – I – – – I – – – I
Valve clearances – – – – – – – A – – – – – – – A – – – –
Feed pump strainer – – – I – – – I – – – I – – – I – – – I
Fuel tank cap & fuel pipes for loose
connections or damage – – – – – – – I – – – – – – – I – – – –
Drive belt tension and damage – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – R – – – – – – – R – – – –
*Exhaust pipes and mounting
damage or looseness – – – I – – – I – – – I – – – I – – – I
Cooling system – – – I – – – I – – – I – – – I – – – I
Engine operation condition – I – I – I – I – I – I – I – I – I – I
CLUTCH
Clutch fluid – – I – – I – – R – – I – – R – – I – –
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
0B–4 MAINTENANCE AND LUBRICATION
Maintenance schedule
Use odometer reading or months whichever comes first
TRANSMISSION
PROPELLER SHAFT
REAR AXLE
FRONT AXLE
*Kingpin – L – L – L – L – L – L – L – L – L – L
STEERING
Maintenance schedule
Use odometer reading or months whichever comes first
SERVICE BRAKES
Brake fluid – – I – – I – – R – – I – – I – – R – –
V Hydro booster fluid (ATF) – – I – – I – – R – – I – – I – – R – –
Brake system for fluid leakage – – I – – I – – I – – I – – I – – I – –
*Brake lining and drum for wear – – I – – I – – I – – I – – I – – I – –
*Disc brake pads and discs for wear – – I – – I – – I – – I – – I – – I – –
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
Pipes and hoses for loose
connections or damage – I – I – I – I – I – I – I – I – I – I
PARKING BRAKE
SUSPENSION
WHEELS
Maintenance schedule
Use odometer reading or months whichever comes first
ELECTRICAL EQUIPMENT
OTHERS
Condition
Item Interval
A B C D A+D
4J Engine oil and oil filter Change every 5,000 km (3,000 miles) ● ●
4H Engine oil and oil filter Change every 7,500 km (4,500 miles) ● ●
MAINTENANCE SCHEDULE
(EXCEPT EUROPE)
When performing the checks on the following items,
regular inspection items should also be checked.
Maintenance schedule
Use odometer reading or months whichever comes first
4J ENGINE
*Engine oil – R R R R R R R R R R R R R R R R R R R R
*Oil filter – – R – R – R – R – R – R – R – R – R – R
Fuel filter – – – – R – – – R – – – R – – – R – – – R
*Air cleaner element – – I – I – I – I – I – I – I – I – I – I
Idling speed and acceleration – – – – I – – – I – – – I – – – I – – – I
Valve clearances I – – – – – – – A – – – – – – – A – – – –
Fuel tank cap & fuel pipes for loose
connections or damage – – – – – – – – I – – – – – – – I – – – –
OPT 4JG Timing belt – – – – – – – – – – – – – – – – – – – – R
Drive belt tension and damage I – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – – R – – – – – – – R – – – –
*Exhaust pipes and mounting
damage or looseness – – – – I – – – I – – – I – – – I – – – I
Cooling system – – – – I – – – I – – – I – – – I – – – I
Engine operation condition – – I – I – I – I – I – I – I – I – I – I
4H ENGINE
*Engine oil – – R – R – R – R – R – R – R – R – R – R
*Oil filter – – R – R – R – R – R – R – R – R – R – R
Fuel filter: Main Fuel filter – – – – R – – – R – – – R – – – R – – – R
OPT Main Fuel filter and Sub Fuel
filter: With Sub fuel filter – – – – – – – – R – – – – – – – R – – – –
*Air cleaner element – – I – I – I – R – I – I – I – R – I – I
Idling speed and acceleration – – – – I – – – I – – – I – – – I – – – I
Valve clearances I – – – – – – – A – – – – – – – A – – – –
Feed pump strainer (Except 4HF1-2 ) – – – – I – – – I – – – I – – – I – – – I
Fuel tank cap & fuel pipes for loose
connections or damage – – – – – – – – I – – – – – – – I – – – –
Drive belt tension and damage I – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – – R – – – – – – – R – – – –
*Exhaust pipes and mounting
damage or looseness – – – – I – – – I – – – I – – – I – – – I
Cooling system – – – – I – – – I – – – I – – – I – – – I
Engine operation condition – – I – I – I – I – I – I – I – I – I – I
MT CLUTCH
Clutch fluid – – I – I – I – R – I – I – I – R – I – I
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
0B–10 MAINTENANCE AND LUBRICATION
Maintenance schedule
Use odometer reading or months whichever comes first
TRANSMISSION
PROPELLER SHAFT
REAR AXLE
FRONT AXLE
*Kingpin – – L – L – L – L – L – L – L – L – L – L
Differential gear oil
(NPS model only) – – I – I – I – R – I – I – I – R – I – I
MAINTENANCE AND LUBRICATION 0B–11
Maintenance schedule
Use odometer reading or months whichever comes first
STEERING
SERVICE BRAKES
Brake fluid – – I – I – I – R – I – I – I – R – I – I
V Hydro booster fluid (ATF) – – I – I – I – R – I – I – I – R – I – I
Brake system for fluid leakage – – I – I – I – I – I – I – I – I – I – I
*Brake lining and drum for wear – – – – I – – – I – – – I – – – I – – – I
*Disc brake pads and discs for wear – – I – I – I – I – I – I – I – I – I – I
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
Pipes and hoses for loose
connections or damage – – I – I – I – I – I – I – I – I – I – I
PARKING BRAKE
Maintenance schedule
Use odometer reading or months whichever comes first
SUSPENSION
WHEELS
ELECTRICAL EQUIPMENT
OTHERS
Condition
Item Interval
A B C D A+D
4J Engine oil:
Change every 2,500 km (1,500 miles) ● ●
with Partial-flow oil filter
4H Engine oil:
Change every 5,000 km (3,000 miles) ● ●
with Partial-flow oil filter
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SAE 20, 20W
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SAE 10W
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SAE 10W–30
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SAE 15W–40, 20W–40, 20W–50
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DO NOT USE SYNTHETIC OILS.
* At ambient temperatures below –25°C (–13°F), starting aids (oil pan
heater, block heater, etc.) are recommended to prevent hard starting
[Multi grade] and other engine problems.
[Single grade]
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SAE 40, 50
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SAE 30
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SAE 75W
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LUBRICATION CHART
NHR, NKR (Front Independent Suspension) models
◎ Change W : Wheel bearing grease
○ Check and Replenish or Lubricate C : Multipurpose type grease
E : Engine oil M : MoS2 contained type grease
G : Gear Oil B : Brake fluid
A : Automatic transmission fluid
Steering
gear box
G
Brake and
clutch fluid B C Upper link
Front hub
bearing W W Front hub bearing
Prop. shaft
M sliding sleeve
Prop.shaft
center bearing M
Steering
gear box G
Brake and
clutch fluid
B C King pin
Front hub
bearing
W
Prop. shaft
M universal joint
Prop. shaft
Prop. shaft
M universal joint
center bearing M
Prop. shaft
M sliding sleeve
Brake and
clutch fluid B C King pin
Front hub
bearing
W
Power steering
A fluid
Automatic
A transmission
E Transmission
Prop. shaft
V Hydro booster
M universal joint
A
fluid
Prop. shaft
M sliding sleeve
Prop. shaft
center bearing M
Brake and
B clutch fluid
Differential
gear G
C King pin
Front hub
W W Front hub bearing
bearing
King pin
A Power steering
C
Prop. shaft
M universal joint
Prop. shaft
M sliding sleeve
Prop. shaft
M universal joint
Prop. shaft
center bearing M
Prop. shaft
M sliding sleeve
Rear spring
spring pin
C
Rear spring
C spring pin
Rear hub
Differential
G W bearing
gear
Issued by
Tokyo, Japan