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Demo Manual

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ISUZU COMMERCIAL TRUCK

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FSR, FTR, FVR

Equipped with 6 HK1 engine

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SERVICE MANUAL (1998)

BOOK 1 OF 3

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CAUTION

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In order to reduce the chance of personal injury and/or property damage, carefully observe the instructions that follow:

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The service manuals of Isuzu Motors America Inc. are intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others. This could also damage the vehicle, or cause the vehicle to operate improperly.

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Proper vehicle service and repair are important to the safety of the service technician and to the safe, reliable operation of all motor vehicles. If you need to replace a part, use the same part number or an equivalent part. Do not use a replacement part of lesser quality.

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The service procedures we recommend and describe in this service manual are effective methods of performing service and repair. Some of the procedures require the use of tools that are designed for specific purposes.

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Accordingly, any person who intends to use a replacement part, a service procedure, or a tool that is not recommended by Isuzu, must first establish that there is no jeopardy to personal safety or the safe operation of the vehicle.

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This manual contains various CAUTIONS and NOTICES that you must observe carefully in order to reduce the risk of personal injury during service or repair. Improper service or repair may damage the vehicle or render the vehicle unsafe. These CAUTIONS and NOTICES are not exhaustive. Isuzu can not possibly warn of all the potentially hazardous consequences of your failure to follow these instructions.

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This manual covers service procedures to vehicles that are equipped with a Supplemental Inflatable Restraint (SIR). Refer to the CAUTIONS in Cautions and Notices and in Restraints. Refer to SIR component and wiring location views in Restraints before performing a service on or around SIR components or wiring. Failure to follow these CAUTIONS could cause air bag deployment, personal injury, or otherwise unneeded SIR repairs.

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In order to help avoid accidental air bag deployment and personal injury, whenever you service a vehicle that requires repair of the SIR and another vehicle system, we recommend that you first repair the SIR, then go on to the other system.

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New Style Service Manual Structure

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This new style service manual is constructed with the following 10 sections:

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0.General Information
1.Heating, Ventilation, and Air Conditioning (HVAC)
2.Steering
3.Suspension
4.Driveline and Axle
5.Brakes
6.Engine
7.Transmission
8.Body and Accessories
9.Restraints

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The following table gives the previous service manual sub-sections with the name of the new section and sub-section. Almost all of the diagnosis that was in section SA is now located in its applicable sub-section.

and Sub-Section Conversion Table

Old Sub-Section

Old Sub-Section

New Section

Section Name

Sub-Section Name

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OA

General Information

0

General Information

Gen ral Information

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OB

Maintenance and Lubrication

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0

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General Information

Mai enance and L brication

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Vibration Diagnosis

0

General Information

Vibration Diagnosis

1A

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Heating and Ventilation

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1

HVAC

Heating and Ventilation (Non NC)

1B

Heating, Ventilation, and Air Conditioning

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1

HVAC

HVAC systems with Air Conditioning

1D

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NC Compressors

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1

HVAC

HVAC systems with Air Conditioning

2A

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Frame and Bumpers

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8

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Body and Accessories

Frame and Underbody, and Bumpers

3A

Front Wheel Alignment

3

Suspension

Wheel Alignment

3B, 3B1A,

3B1B

Power Steering Gear and Pump

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2

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Steering

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Power Steering System

3B3

Steering Linkage

2

Steering

Steering Linkage

3C

Front Suspension

3

Suspension

Front Suspension

3D

Rear Suspension

3

Suspension

Rear Suspension

3E

Tires and Wheels

3

Suspension

Tires and Wheels

3F

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Steering Columns

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2

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Steering

Steering Wheel and Column

4A

Propeller Shaft

4

Driveline/Axle

Propeller Shaft

4B

Rear Axle and Differential

4

Driveline/Axle

Rear Drive Axle

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4C

Front Drive Axles and Differential

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4

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Driveline/Axle

Front Wheel Drive Shafts and Front Drive Axle

s

Hydraulic Brakes

s

Brakes

Hydraulic Brakes

SA

Master Cylinder

s

Brakes

Hydraulic Brakes

SB

Front Disc Brakes

s

Brakes

Disc Brakes

SC

Drum Brakes

s

Brakes

Drum Brakes

SD

Hydraulic or Vacuum Booster

s

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Brakes

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Hydraulic Brakes

SE

Antilock Brakes

s

Brakes

Antilock Brakes

SF

Parking Brake

s

Brakes

Parking Brake

6, 6A

Engine Mechanical

6

Engine

Engine Mechanical

6B

Engine Cooling and Radiator

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6

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Engine

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Engine Cooling

SC

Engine Fuel

6

Engine

Engine Controls

6D

Engine Electrical

6

Engine

Engine Electrical

Driveability and Emissions

6

Engine Controls

6F

Exhaust System

6

Exhaust System

6H

Vacuum Pump

6

Engine

Vacuum Pump

6J

Turbocharger

6

Engine

Turbocharger

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7A

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Automatic Transmission

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7

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Transmission/Transaxle

Automatic Transmission and Transmission/Transfer

Case Unit Repair Manual

and Sub-Section Conversion Table (cont’d)

Old Sub-Section

Old Sub-Section

New Section

Section Name

Sub-Section Name

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Manual Transmission

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7

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Transmission/fransaxle

Manual Transmission and Transmission/Transfer Case Unit Repair Manual

7C

Clutch

7

Transmission/fransaxle

Clutch

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7D

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Transfer Case

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4

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Driveline/Axle

Transfer Case and Transmission/Transfer Case Unit Repair Manual

88

Lighting Systems

8

Body and Accessories

Lighting Systems

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BC

Instrument Panel and Gages

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8

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Body and Accessories

Instrument Panel, Gages and Console

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SD

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Chassis Electrical

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8

Refer to the Index at the end of the manual

BE

Wipers and Washers

8

Body and Accessories

Wiper/Washer Systems

9A

Audio Systems

8

Body and Accessories

Entertainment

98

Cruise Control

8

Body and Accessories

Cruise Control

9E

Engine Coolant Heater

6

Engine

Engine Cooling

9F

Luggage Carrier

8

Body and Accessories

Roof

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9J

Supplemental Inflatable Restraint

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Restraints

Supplemental Inflatable Restraints

9K

Remote Keyless Entry

8

Body and Accessories

Keyless Entry

10A1

Doors

8

Body and Accessories

Doors

10A2

Seats

8

Body and Accessories

Seats

9

Restraints

Seat Belts

10A3

Stationary Windows

8

Body and Accessories

Stationary Glass

10A4

Interior Trim

8

Body and Accessories

Exterior/Interior Trim

10A5

Endgate

8

Body and Accessories

Body Rear End

108

Cab and Body Maintenance

Refer to the Index at the end of the manual

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1998 Medium Duty Truck

FSR,FTR,FVR

Service  Manual

Volume 1

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This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 1998 Isuzu Medium Duty Truck.

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The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better service the vehicle owners.

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When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication approval. Isuzu reserves the right to make changes at any time without notice.

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Published by

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ISUZU MOTORS AMERICA, INC.

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©1998 ISUZU MOTORS AMERICA, INC.

The information cutoff date is 12/1/97.

ALL RIGHTS RESERVED

LITHO IN U.S.A.

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No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of Isuzu Motors America, Inc. This applies to all text, illustrations, and tables.

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BLANK

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Table of Contents

Volume 1

Preface  1

Cautions and Notices  3

General Information  0-1

General Information  0-3

Maintenance and Lubrication  0-33

Vibration Diagnosis and Correction  0-51

HVAC  1-1

Heating and Ventilation (Non-A/C)  1-3

HVAC Systems with A/C Manual.  1-57

Body and Accessories  8-1

Lighting Systems  8-7

Wipers/Washer Systems  8-103

Entertainment  8-123

Wiring Systems  8-143

Instrument Panel, Gauges and Console  8-283

Horns  8-351

Exterior Trim  8-361

Waterleaks  8-363

Stationary Windows  8-365

Bumpers  8-373

Body Front End  8-377

Doors  8-399

Seats  8-431

Interior Trim  8-441

Plastic Panel Information and Repair  8-453

PainVCoatings  8-455

Frame and Underbody  8-463

Collision Repair  8-485

Restraints  9-1

Seat Belts  9-3

Volume2

Preface  1

Cautions and Notices  3

Steering  2-1

Power Steering System  2-3

Steering Linkage (Non-Rack & Pinion)  2-53

Steering Wheel and Column Tilt.  2-63

Suspension ……...........…………………………..3...1

Suspension General Diagnosis  3-3

Wheel Alignment.  3-17

Front Suspension  3-25

Rear Suspension  3-63

Tires and Wheels  3-87

Air Suspension  3-107

Driveline/Axle  4-1

Propeller Shaft  4-3

Rear Drive Axle  4-63

Rear Axle Controls  4-89

Brakes  5-7

Hydraulic Brakes  5-7

Disc Brakes  5-41

Park Brakes  5-89

Air Brakes  5-113

Air Drums  5-227

Air Compressor  5-287

Antilock Brake System  5-303

Air Antilock Brake System  5-399

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Volume3

Preface  1

Cautions and Notices  3

Engine  6-1

Engine Cooling  6-3

Engine Electrical  6-43

Engine Controls 7.8L.  6-111

Engine Exhaust.  6-137

Engine, On-vehicle Service  6A6

Engine Overhaul.  6A6B

Water Pump  661B

Fuel System  6C

Fuel Injection  6C2

Diesel Electrical  606

Emission and Electrical Diagnosis  6E

Turbocharger  6J

Transmissionrrransaxle………...………………..1...1.

Manual Transmission – Medium Duty  7-3

Automatic Transmission Allison  7-15

Clutch  7-43

Manual Transmission Overhaul.  7-49

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1998 MD•ISUZU

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Cautions and Notices

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Cautions and Notices  3

Definition of Caution, Notice, and lmportant.  3

ABS Handling Caution  3

Battery Disconnect Caution  3

Brake Dust Caution  3

Brake Fluid Caution  4

Clutch Dust Caution  4

Fuel and EVAP Pipe Caution  4

Fuel Gauge Leak Caution  4

Fuel Pipe Fitting Caution  4

Fuel Storage Caution  4

Gasoline/Gasoline Vapors Caution  4

Moving Parts and Hot Surfaces Caution  4

Road Test Caution  4

Safety Glasses and Compressed

Air Caution  4

Safety Goggles and Fuel Caution  4

Vehicle Lifting Caution  4

Window Removal Caution  4

Work Stall Test Caution  5

Defective Scan Tool Notice  5

Fastener Notice  5

Fuel Pressure Notice  5

Handling ESD Sensitive Parts Notice  5

Ignition OFF When Disconnecting

Battery Notice  5

Nylon Fuel Lines Notice  5

PCM and ESD Notice  5

Single Cylinder Flooding Notice  5

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1998 MD-Isuzu

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1998 MD-Isuzu

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Preface  Cautions and Notices 3

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Cautions and Notices

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Definition of Caution, Notice, and Important

The diagnosis and repair procedures in the Isuzu Service Manual contain both general and specific Cautions, Notices, and lmportants. Isuzu is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner. Cautions, Notices, and lmportants are elements designed to prevent these hazards, however, not all hazards can be foreseen.

This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring:

Serious bodily injury to the technician
Damage to the vehicle
Unnecessary vehicle repairs
Unnecessary component replacement
Improper repair or replacement of vehicle components. Any caution or notice that appears in general information is referenced from the individual service categories.

CAUTION Defined

When encountering a CAUTION, you will be asked to take a necessary action or not to take a prohibited action. If a CAUTION is not heeded, the following consequences may occur:

Serious bodily injury to the technician
Serious bodily injury to other technicians in the workplace area
Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired

NOTICE Defined

Notices call special attention to a necessary action or to a prohibited action. If a NOTICE is not heeded, the following consequences may occur:

Damage to the vehicle
Unnecessary vehicle repairs
Unnecessary component replacement
Improper operation or performance of the system or component under repair
Damage to any systems or components which are dependent upon the proper operation of the system or component under repair
Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair
Damage to fasteners, basic tools, or special tools
The leakage of coolant, lubricant, or other vital fluids

1998 MD-Isuzu

IMPORTANT Defined

IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure.

IMPORTANT statements are designed to do the following:

Clarify a procedure
Present additional information for accomplishing a procedure
Give insight into the reason or reasons for performing a procedure in the manner recommended
Present information that will help to accomplish a procedure in a more effective manner
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease

ABS Handling Caution

Caution: Certain components In the Antilock Brake System (ABS) are not intended to be serviced individually. Attempting to remove or disconnect certain system components may result in personal injury and/or improper system operation. Only those component with approved removal and installation procedures should

be serviced.

Battery Disconnect Caution

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Brake Dust Caution

Caution: Avoid taking the following actions when you service wheel brake parts:

Do not grind brake linings.
Do not sand brake linings.
Do not clean wheel brake parts with a dry brush or with compressed air.

Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment Is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.

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4 – Cautions and Notices  Preface

Brake Fluid Caution

Caution: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions:

Eye contact-rinse eyes thoroughly with water.
Skin contact-wash skin with soap and water.

Clutch Dust Caution

Caution: When servicing clutch parts, do not create dust by grinding or sanding the clutch disc or by cleaning parts with a dry brush or with compressed air. A water-dampened

cloth-NOT SOAKED-should be used. The clutch disc contains asbestos fibers which can become airborne If dust is created during servicing.

Breathing dust containing asbestos fibers may cause serious bodily harm.

Fuel and EVAP Pipe Caution

Caution: In order to Reduce the Risk of Fire and Personal Injury observe the following Items:

Replace all nylon fuel pipes that are nicked, scratched or damaged during Installation, Do Not attempt to repair the sections of the nylon fuel pipes
Do Not hammer directly on the fuel harness body clips when insta/1/ng new fuel pipes. Damage to the nylon pipes may result In a fuel leak.
Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 11s·c (239″F) for more than one hour, or more than 90″C (194°F) for any extended period.
Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located In the female connector will swell and may prevent proper reconnection if not lubricated.)

Fuel Gauge Leak Caution

Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel In an approved container when the connection of the fuel pressure gauge is complete.

Fuel Pipe Fitting Caution

Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings In order to reduce the risk of fire and personal injury.

This w/11 ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

Fuel Storage Caution

Caution: Do not drain the fuel into an open container. Never store the fuel In an open container due to the possibility of a fire or an explosion.

Gasoline/Gasoline Vapors Caution

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur If an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class BJ fire extinguisher nearby.

Moving Parts and Hot Surfaces Caution

Caution: While working around a running engine, avoid contact with moving parts and hot surfaces to prevent possible bodily injury.

Road Test Caution

Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could Jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal Injury.

Safety Glasses and Compressed Air Caution

Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

Safety Goggles and Fuel Caution

Caution: Always wear safety goggles when working with fuel In order to protect the eyes from fuel splash.

Vehicle Lifting Caution

Caution: To help avoid personal Injury, when a vehicle Is on a hoist, provide additional support for the vehicle at the opposite end from which you are removing components. The additional support will reduce the possibility of the vehicle falling off the hoist. When you are removing major components· from the vehicle while the vehicle Is on a hoist, chain the vehicle frame to the hoist pads at the same end from which you are removing the major components to prevent tip-off. If you fall to follow these precautionary measures, vehicle damage, serious personal Injury, or death may result.

Window Removal Caution

Caution: When working with any type of glass, use approved safety glasses and gloves to reduce the chance of personal injury.

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1998 MD-Isuzu

Work Stall Test Caution

Caution: One or more of the following guidelines may apply when performing specific required tests in the work stall:

When a test requires spinning the drive wheels with the vehicle jacked up, adhere to the following precautions:
Do not exceed 56 km/h (35 mph} when spinning one drive wheel with the other drive wheel stopped. This limit is necessary because the speedometer indicates only one-half the actual vehicle speed under these conditions. Personal injury may result from excessive wheel spinning.

If all of the drive wheels are spinning at the same speed, do not exceed 112 km/h (70 mph}. Personal injury may result from excessive wheel spinning.

All persons should stay clear of the rotating components and the balance weight areas in order to avoid possible personal injury.
When running an engine in the repair stall for an extended period of time, use care not to overheat the engine and the transmission.
When a test requires jacking up the vehicle and running with the wheels and brake rotors removed, adhere to the following precautions:
Do not apply the brake with the brake rotors removed.
Do not place the transmission in PARK

with the drive wheels still spinning.

Turn Off the ignition in order to stop the powertrain components from spinning.

Defective Scan Tool Notice

Notice: Do not use a scan tool that displays faulty data. Report the scan tool problem to the manufacturer. Use of a faulty scan tool can result in misdiagnosis and unnecessary parts replacement.

Fastener Notice

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Fuel Pressure Notice

Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel pressure regulator or the fuel pressure gauge may result.

1998 MD-Isuzu

Handling ESD Sensitive Parts Notice

Notice: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled with the ESD symbol. Handle all electrical components carefully. Use the following precautions in order to avoid ESD damage:

Touch a metal ground point in order to remove your body’s static charge before servicing any

electronic component; especially after sliding across the vehicle seat.

Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage.

Do not allow tools to contact exposed terminals when servicing connectors.

Do not remove components from their protective packaging until required to do so.

Avoid the following actions unless required by the diagnostic procedure:

Jumpering or grounding of the components or connectors.

Connecting test equipment probes to components or connectors. Connect the ground lead first when using test probes.

Ground the protective packaging of any component before opening. Do not rest solid-state components on metal workbenches, or on top of TVs, radios, or other electrical devices.

Ignition OFF When Disconnecting Battery Notice

Notice: Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.

Nylon Fuel Lines Notice

Notice: Do not attempt to straighten the kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

PCM and ESD Notice

Notice: Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM.

Single Cylinder Flooding Notice

Notice: In order to prevent flooding of a single cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure.

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1998 MD-Isuzu

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General Information  Table of Contents  0-1

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Section O

General Information

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General Information  0-3

Conversion – English/Metric  0-3

Equivalents – Decimal and Metric  0-3

Paper Version of the Service Manual –

How to Use  0-4

Arrows and Symbols  0-5

Special Tools Ordering Information  0-5

Vehicle ldentification  0-5

VIN Derivative  0-6

Label – Vehicle Certification  0-7

Engine Identification  0-8

Transmission Identification  0-8

Rear Axle Identification  0-9

Label – Service Parts ID  0-11

RPO Code List  0-11

Labels – How to Obtain Replacement.  0-17

Fasteners (Prevailing Torque Fasteners)  0-17

Fasteners (Strength Identification)  0-19

Fasteners (Metric Fasteners)  0-20

Thread Inserts  0-20

Torque Wrenches  0-21

Abbreviations and Their Meanings  0-23

Key and Lock Cylinder Coding  0-26

Lifting and Jacking the Vehicle  0-26

Cab Tilting  0-27

Towing a Disabled Vehicle  0-30

Strategy Based Diagnosis  0-32

Maintenance and Lubrication  0-33

Specifications  0-33

Approximate Fluid Capacities  0-33

Fluid and Lubricant Recommendations  0-34

Maintenance Items  0-34

Maintenance  0-35

Maintenance Schedule  0-35

Maintenance Schedule – Short Trip/City  0-43

Maintenance Schedule –

Long Trip/Highway  0-43

Owner Checks and Services (General)  0-43

Owner Checks and Services (Single Axle)  0-46

Explanation of Scheduled Services  0-47

Inspections and Other Services  0-50

Vibration Diagnosis and Correction  0-51

Specifications  0-51

Specifications  0-51

Diagnostic Information and Procedures  0-52

Systematic Approach  0-52

Vibration Diagnosis  0-52

Road Test  0-52

Classifying the Vibration  0-56

Tire and Wheel Vibration …….;  0-59

Tire and Wheel Runout Measurement  0-59

Driveline Vibration Analysis with EVA  0-63

Engine Related Vibration  0-67

Repair Instructions  0-71

General Service Precautions  0-71

Correcting Tire and Wheel Vibration  0-71

Balancing Tires and Wheels  0-71

Wheel Weight Usage  0-75

Correcting Non-Uniform Tires  0-75

Correcting Driveline Vibration –

RWD and 4WD  0-76

Description and Operation  0-94

General Description  0-94

Special Tools and Equipment.  0-105

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1998 MD-Isuzu

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0-2  Table of Contents  General Information

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BLANK

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1998 MD-Isuzu

General Information

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In order to convert English units to metric units, multiply the English units by the conversion factor shown in the conversion table.

In order to convert metric units to English units, divide the metric units by the conversion factor shown in the conversion table.

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Conversion English/Metric

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English

Multiply/

Divide by

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Metric

LENGTH

in

25.4

mm

ft

0.3048

.

m

yd

0.9144

mi

1.609

km

AREA

.

sq in

645.2

sq mm

6.45

sq cm

sq ft

0.0929

.

sq m

sq yd

0.8361

VOLUME

.

cu in

16,387.0

cu mm

16.397

cu cm

0.0164

.

L

qt

0.9464

gal

3.7854

cu yd

0.7646

cum

MASS

lb

0.4536

.

kg

.

ton

907.18

0.907

tonne (t)

FORCE

kg

9.807

.

newtons (N)

oz

0.2780

lb

4.448

ACCELERATION

fVs2

0.3048

m/s2

in/s 2

0.0254

TORQUE

lb in

0.11298

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N.m

lb ft

1.3558

POWER

hp

0.746

kW

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1998 MD-Isuzu

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Conversion English/Metric (cont’d)

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English

Multiply/

Divide by

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Metric

PRESSURE (STRESS)

inches of Mercury

3.377

kPa

inches of H2O

0.2491

.

kPa

lb/sq in

6.895

LIGHT

Foot Candle

10.764

2

lm/m

VELOCITY

mph

1.6093

km/h

TEMPERATURE

‘F

5/9( • F-32)

·c

·c

9/5(‘C+32)

‘F

FUEL PERFORMANCE

mpg

2.3527

Ukm

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Refer to the following table for equivalent of fractions to decimals in English (inches), to metric (millimeters).

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Equivalents Decimal and Metric

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Fraction (in)

Decimal (in)

Metric (mm)

1/64

0.015625

0.39688

1/32

0.03125

0.79375

3/64

0.046875

1.19062

1/16

0.0625

1.5875

5/64

0.078125

1.98437

3/32

0.09375

2.38125

7/64

0.109375

2.77812

1/8

0.125

3.175

9/64

0.140625

3.57187

5/32

0.15625

3.96875

11/64

0.171875

4.36562

3/16

0.1875

4.7625

13/64

0.203125

5.15937

7/32

0.21875

5.55625

15/64

0.234375

5.95312

1/4

0.25

6.35

17/64

0.265625

6.74687

9/32

0.28125

7.14375

19/64

0.296875

7.54062

5/16

0.3125

7.9375

21/64

0.328125

8.33437

Equivalents Decimal and Metric (cont’d)

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Fraction (in)

Decimal (in)

Metric (mm)

11/32

0.34375

8.73125

23/64

0.359375

9.12812

3/8

0.375

9.525

25/64

0.390625

9.92187

13/32

0.40625

10.31875

27/64

0.421875

10.71562

7/16

0.4375

11.1125

29/64

0.453125

11.50937

15/32

0.46875

11.90625

31/64

0.484375

12.30312

1/2

0.5

12.7

33/64

0.515625

13.09687

17/32

0.53125

13.49375

35/64

0.546875

13.89062

9/16

0.5625

14.2875

37/64

0.578125

14.68437

19/32

0.59375

15.08125

39/64

0.609375

15.47812

5/8

0.625

15.875

41/64

0.640625

16.27187

21/32

0.65625

16.66875

43/64

0.671875

17.06562

11/16

0.6875

17.4625

45/64

0.703125

17.85937

23/32

0.71875

18.25625

47/64

0.734375

18.65312

3/4

0.75

19.05

49/64

0.765625

19.44687

25/32

0.78125

19.84375

51/64

0.796875

20.24062

13/16

0.8125

20.6375

53/64

0.828125

21.03437

27/32

0.84375

21.43125

55/64

0.859375

21.82812

7/8

0.875

22.225

57/64

0.890625

22.62187

29/32

0.90625

23.01875

59/64

0.921875

23.41562

15/16

0.9375

23.8125

61/64

0.953125

24.20937

31/32

0.96875

24.60625

63/64

0.984375

25.00312

1

1.0

25.4

Paper Version of the Service Manual

How to Use

Construction

This service manual is constructed with the following 1O major sections:

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Major Section Number

.

Major Section Name

0

General Information

1

Heating, Ventilation, and Air Conditioning (HVAC)

2

Steering

3

Suspension

4

Driveline/Axle

5

Brakes

6

Engine

7

Transmission/Transaxle

8

Chassis/Body Electrical

9

Accessories

10

Body

.

Information Flow

Each major section will be structured as follows:

1.A single table of contents for the entire major section; including all contents of the subsections within the major section.
2.Subsections

The service information located within each subsection will be ordered as follows:

1.Specifications
2.Diagnosis
3.Repair procedures
4.General description and system operation
5.Special tools

Improvements Made

This service manual provides many more illustrations than in earlier manuals. Illustrations serve as the primary source for repair procedures. These illustrations will be supplemented with text descriptions. In the previous service manuals, text was the primary source of information for repair procedures and illustrations provided support.

Repair procedures, illustrations, and the descriptive text have been arranged so that they will correspond with the way you work. This manual provides disassembled views, wherever possible, so that it will be easy to look up parts, names, and order of assembly. The text descriptions have been rewritten into simple, complete sentences.

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1998 MD-Isuzu

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Arrows and Symbols

9

4

12

8

\6

11r+

7

10

\_

6

5

h

4

;.o \

Cl

IP

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Legend

(1)Front of Vehicle
(2)View Detail

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196216

Special Tools Ordering Information

Special Tools

The special service tools shown in this service manual have tool product numbers beginning with J or BT. Special tools are distributed worldwide by Kent-Moore:

Kent-Moore

SPX Corporation 29784 Little Mack

Roseville, Ml 48066-2298

1-800-328-6657

Mon.-Fri. 8:00 a.m. to 7:00 p.m. EST Telex: 244040 KMTR UR

Fax: 1-800-578-7375

Purchase scan tools and accessories from Kent-Moore at the address above.

Vehicle Identification

(1)Ambient Air Mixed With Another Gas, Can Indicate Temperature Change
(2)Motion or Direction
(3)View Angle
(4)Dimension (1:2)
(5)Ambient/Clean Air Flow, Cool Air Flow
(6)Lubrication Point-Oil or Fluid*
(7)Task Related
(8)Sectioning (1:3)
(9)Gas Other Than Ambient Air, Hot Air Flow
(10)Lubrication Point-Grease or Jelly*

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The Isuzu Commercial Truck is available in the above body style.

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205884

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1998 MD-Isuzu

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VIN Derivative

The Vehicle Identification Number (VIN) is the legal identifier of the vehicle. The VIN contains the following information:

The manufacturer
The model
The chassis type
The engine type
The Gross Vehicle Weight (GVW) range
The model year
The plant code
The sequential number

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205886

The VIN plate is attached to the driver’s door opening.

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Vehicle Identification Number (VIN) System

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Position

Definition

Character

Description

1

Country of Origin

4

United States

2

Manufacturer

G

Isuzu

3

Model

T

Isuzu Incomplete Vehicle

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GVWR/Brake System

A

9001-10000 Hydraulic

B

10001-14000 Hydraulic

C

14001-16000 Hydraulic

D

14001-16000 Air

E

16001-19500 Hydraulic

F

16001-19500 Air

G

19501-23500 Hydraulic

H

19501-23500 Air

J

23501-26000 Hydraulic

K

23501-26000 Air

L

26001-33000 Hydraulic

M

26001-33000 Air

N

33001–40500 Hydraulic

p

33001–40500 Air

R

40501–48500 Hydraulic

s

40501–48500 Air

T

48501-58000 Air

V

58001-69500 Air

w

69501-over Air

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5

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Series

6

6000

7

7000

6

Cab Type

C

Medium Tilt, Steel, 226 cm (89″) BBC

7

Chassis Type

1

4 x 2, 2 Axles, 1 Driving

8

Engine Type

2

Isuzu 6 Cylinder Turbo Diesel (7.8L)

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1998 MD-Isuzu

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Vehicle Identification Number (VIN) System (cont’d)

Position

Definition

Character

Description

9

Check Digit

1

10

Model Year

1998

11

Plant Location

J

Janesville

12-17

Plant Sequence Number

6-Digit Sequential Numbers

Label Vehicle Certification

Complete Vehicle Certification Label

The Gross Vehicle Weight (GVW) is the weight of the stock vehicle and all the options added to the vehicle after leaving the factory. The GVW includes, but not limted to, the weight of the following items:

The body

;lll M;;;;;;;;;;;;;;;;;i PSI/KPA (COLO)

:r -A-8-SE….,MBLED IN J’-AN-ES-VI-LL-E-‘WI ,..  _, c:::J

SEE OWNER’S  MANUAL FOR  ADDITIONAL INFOIIMATION c:::J

c=::::::J

GWI IIATING INFOIIMATIOH

G\IWA- LB/KG  GAWII FAT  GAWR INT  GAWII 1111

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TIRE SIZE

Winches
Booms
The driver
All occupants
The load that the vehicle is carrying

Ensure that the Gross Vehicle Weight (GVW) does not exceed the Gross Vehicle Weight Rating (GVWR). Ensure that the front and the rear Gross Axle Weights (GAW) do not exceed the front and the rear Gross Axle Weight Rating (GAWR).

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Incomplete Vehicle Certification Label

291017

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The payload rating shown on the label is the

r

‘-

I  

    G\,WII -Ulll((l  GAWR FRT  

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  7  c::::::::J

GAWR INT  BAWR FIR

7

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I

I

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  TIIIE SIZE

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     IIIM    P8111<PA (COLO)

FRT   

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    C=::J

RR  

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    c:::::::::J CJ

  I  

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CJ 1

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205890

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291007

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The Vehicle Certification Label indicates the following ratings for the vehicle:

The Gross Vehicle Weight Rating (GVWR)
The front and rear Gross Axle Weight Rating (GAWR)
The payload rating

maximum allowable cargo load (including the weight of the driver and all occupants) that the vehicle may carry based on the stock equipment. The payload rating lowers if any accessories or other equipment are added to the vehicle after the final date of manufacture. Determine the weight of any added accessories and deduct the amount from the payload rating.

The vehicle may also have a Gross Combination Weight Rating (GCWR). The GCWR is the total weight of the loaded tow vehicle (including passengers) and a loaded trailer.

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1998 MD-Isuzu

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0-8  General Information  General Information

Ensure that the tires on the vehicle are the proper size and at the proper inflation pressure for the load that the vehicle is carrying. The vehicle certification label shows the stock tire size and recommended inflation pressures.

Engine Identification

Diesel Engine

The engine serial number is located on the front right side corner of the engine block.

Transmission Identification

Isuzu

Allison

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The Allison® transmission identification plate is located on the rear left side of the housing, just above the oil pan.

ISUZU

TY  E

s,noo

QEARS

fllOO,No.

Ml.lllQ

111/ZU MOTOll8 Llllll1E>

TOKYO, JAPAN

208521

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208509

The Isuzu transmission identification plate is located on the left upper side of the housing.

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F

200589

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1998 MD-Isuzu

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General Information  General Information  0-9

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Rear Axle Identification

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PT NO

HSG MODEL

HSG CAP  LHS

SERIAL NO

[email protected] Rear Axle ID

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.

=::::.-‘\S28321A

/r

1″ =

a.

SA101974

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5  4

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Legend

{1) Axle Specification Number

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(4)Capacity

200579

(2)Casting Number
(3)Rough Number

All axle housings have identification tags or identification information stamped on the side of the differential carrier.

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Differential Carrier

The carrier tag may contain the following information:

The axle model
The ratio
The carrier assembly number
The carrier serial number
The date of assembly

Use all the information on the carrier tag in order to identify the axle assembly.

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1998 MD-Isuzu

(4)Housing Subassembly Number {Including Tubes)

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%1-10General Information  General Information

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Eaton® Differential Carrier ID

SPEC.

HEAD

SERIAL NO.

IIT:lllt

H:r,n1

4.11

CUST. PART NO.

Legend

(1)Side View
(2)Top View

Dana/Spicer® Rear Axle Differential Carrier ID

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Axle Housing

Dana/Spicer® Rear Axle ID

1

2

_-)  ‘:/,.,..J,—3

il I  lllr:0

SIil!  l!I

\

llll42_j

,..,.L

4

6

\

5

200584

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Legend

(1)Dana® Part Number
(2)Customer Part Number (Optional)
(3)Julian Date Code
(4)Line Set Number (Optional)

200587

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Legend

(1)Dana® Part Number
(2)Customer Part Number (Optional)
(3)Model

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200582

(5) Last Six Digits of Vehicle Serial Number (Optional)

(4)Julian Date Code
(5)Line Set Number (Optional)
(6)Last Six Digits of Vehicle Serial Number (Optional)

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The housing tag is the same type of tag used for the Differential Carrier.

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1998 MD-Isuzu

.

Label Service Parts ID  RPO Code List

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ffi\

0

205849

The Service Parts Identification Label is on the passenger’s side sun visor.

I

·

Att•in lttll llbtl II lllllffltll•”llltCOt::I

IMPORTANT

OCSCltlPTK>tt

09:. 0N

0£SCIIUP’JIGN

O ON

ldulNkollon ol reploctm.”t po,b b• aw• •• •peel th• opplcobi. opKon numb••

NO’ff’: The optlonot eqwlpm•nl atat.d below hoa H•n ln•loUlldan thll ••hlcle, lor proper

  BERVICE PARTS IOENTFICATION

V.U 1  I

I/,1.N. Vthfelt lcftnttf!Calfon Numbfr

1’11111>• bl II.I.A.

RPO

Description

ASA

Seat: Front Bucket, Driver High Back, Self Contained Air Suspension

.

AV8

Seat: Center Front Bucket, Auxiliary, Folding

BAG

Parts Package Export

BPU

First Position Prop Hanger, NON-BOC, Height A

BPV

First Position Prop Hanger, NON-BOC, Height B

BPW

First Position Prop Hanger, NON-BOC, Height C

BUB

First Position Prop Hanger, NON-BOC, Height D

BUC

First Position Prop Hanger, NON-BOC, Height E

CKD

Vehicle Completely Knocked Down

CV3

Country Mexico

C60

HVAC System Air Conditioner, Front Manual Controls

DFO

Mirror: Outside, LH and RH,

17.8 cm x 40.6 cm (7 in x 16 in), SST

.

DNN

Mirror: Outside, Dual Velvac Heated,

15.2 cm x 40.6 cm (6 in x 16 in), Stainless Steel

DTE

Mirror: Auxiliary Outside 20 cm (8 in) Spot, Dual Retrac, SST

EG5

401 cm (158 in) Wheelbase

EH8

432 cm (170 in) Wheelbase

EK8

478 cm (188 in) Wheelbase

EM2

508 cm (200 in) Wheelbase

EQ8

592 cm (233 in) Wheelbase

ERA

Second Position Prop Hanger, Height A

ERB

Second Position Prop Hanger, Height B

ERC

Second Position Prop Hanger, Height C

ERO

Second Position Prop Hanger, Height D

ERE

Second Position Prop Hanger, Height E

ES5

630 cm (248 in) Wheelbase

EV9

Suspension: Attach Bolted

EXP

Export I.E.S.

EY1

Yoke: Propeller Shaft, Driveline, Dana®

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FOO

Frame: Rail, Full Depth,

612 cm x 15 cm (241 in x 6 in),

22 680 kg (50,000 lb)

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FD5

Frame: Rail, Full Depth,

622 cm x 20 cm (245 in x 8 in),

36 288 kg (80,000 lb)

FF1

Hub: Front, Oil Filled

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200611

Always refer to the Service Parts Identification Label when ordering parts. The label lists the following items:

The Vehicle Identification Number (VIN)
The wheelbase
The paint information
All production options
All factory-installed special equipment

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1998 MD-Isuzu

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  .

RPO

Description

FK9

Suspension: Front, Multileaf, 4 090 kg

(9,017 lb)

FL1

Axle: Front, 3 674 kg (8,100 lb)

FL2

Axle: Front, 4 990 kg (11,000 lb)

FL3

Axle: Front, 6 623 kg (14,600 lb)

FM0

Suspension: Front, Multileaf, 6 610 kg

(14,600 lb)

FM4

Suspension: Front, Multileaf, 6 350 kg

(14,000 lb)

FPL

554 cm (218 in) Wheelbase

FQT

356 cm (140 in) Wheelbase

FS7

Axle: Front, 5 443 kg (12,000 lb) HD

.

F03

Frame: Rail, Full Depth,

232 cm x 25 cm (249 in x 10 in),

49,896 kg (110,000 lb)

FOB

Reinforcement: Frame, Outside, Inverted L Type, 36,288 kg (80,000 lb)

F12

Suspension: Front, Tapered Leaf, 3 175 kg (7,000 lb)

F14

Suspension: Front, Tapered Leaf, 3 674 kg (8,100 lb)

F15

Suspension: Front, Tapered Leaf, 4 082 kg (9,000 lb)

F26

Suspension: Front, Tapered Leaf, 5 443 kg (12,000 lb)

F59

Stabilizer Shaft: Front

GG0

Suspension: Rear, Multileaf, 6 804 kg

(15,000 lb)

GG7

Suspension: Rear, Tapered Leaf 7 666 kg (16,900 lb)

GN0

Suspension: Rear, Tapered Leaf, 8 620 kg (19,000 lb)

GN1

Stabilizer Shaft: RR (Dup with F61)

GN2

Suspension: Rear, Multileaf, 8 620 kg

(19,000 lb)

GN8

Suspension: Rear, Multileaf, 9 525 kg

(21,000 lb)

GPG

Vehicle: Low Profile Package

GPO

Suspension: Rear, Tapered Leaf, 10 430 kg (23,000 lb)

GP1

Suspension: Rear, Multileaf, 10 660 kg

(23,500 lb)

GQB

Third Position Prop Hanger, Height A

GQC

Third Position Prop Hanger, Height B

GQD

Third Position Prop Hanger, Height C

GQE

Third Position Prop Hanger, Height D

GQF

Third Position Prop Hanger, Height E

GOO

Suspension: Rear, Tapered Leaf, 8 600 kg (15,000 lb)

.

RPO

Description

GR9

Suspension: Rear, Tapered Leaf, 9 525 kg (21,000 lb)

GZI

GVW Rating: 11 771 kg (25,950 lb)

GZT

Provisions for Taperleaf/Multileaf Rear Springs

G40

Suspension: Rear Air, 8 618 kg

(19,000 lb)

G60

Spring: Rear, Auxiliary

G68

Shock Absorbers: Rear, Heavy Duty

G86

Axle: Limited Slip

G98

Seal: Rear Axle Oil, Stemco

HNA

Axle: Rear, Eaton® 23105S, Single Speed, 10 433 kg (23,000 lb)

HPG

Axle: Rear, Eaton® 22060S, Single Speed, 9 979 kg (22,000 lb)

HPH

Axle: Rear, Eaton® 22060T, Two Speed, 9 979 kg (22,000 lb)

HPK

Axle: Rear, Eaton® 19060S, Single Speed, 8 618 kg (19,000 lb)

HPM

Axle: Rear, Eaton® 19060T, Two Speed, 8 618 kg (19,000 lb)

HPP

Axle: Rear, Eaton® 21060S, Single Speed, 9 526 kg (21,000 lb)

HPQ

Axle: Rear, Eaton® 23080S, Two Speed, 10 433 kg (23,000 lb)

HPZ

Control: Rear Axle Shift, Two Speed, Electric

HWY

Axle: Rear, Eaton® 19050S, Single Speed, 7 666 kg (16,900 lb)

HZT

Axle: Rear, Eaton® 19050T, Two Speed, 8 097 kg (17,850 lb)

HZW

Axle: Rear, Eaton® 19050S, Single Speed, 8 097 kg (17,850 lb)

HOB

Axle: Rear, Dana® S150-S, Single Speed, 6 804 kg (15,000 lb)

H10

Axle: Rear, Eaton® 15040S, Single Speed, 6 804 kg (15,000 lb)

H11

Axle: Rear, Eaton® 19050S, Single Speed, 8 618 kg (19,000 lb)

H15

Axle: Rear, Eaton® 21060T, Two Speed, 9 526 kg (21,000 lb)

H20

Axle: Rear, Eaton® 23080T, Two Speed, 10 433 kg (23,000 lb)

JE3

Brake: Hydraulic

JE4

Brake: Air

JE5

Braking System, Power, Antilock, Front and Wheel

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JPV

Brake Rating: Rear, Air Carlisle, NAB9ML, Non-Abestos Lining, 14 cm (5.5 in) Slack, 42 cm x 178 cm (16.5 in x 7 in) Fab Shoe, 16 Hole Mounting

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1998 MD-Isuzu

  .

RPO

Description

JPZ

Valve: Air Suspension, Air Release

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JOB

Universal Joint: Main, 1480/148N Series

.

JOF

Adjuster: Rear Slack, Automatic, Rockwell

JOM

Universal Joint: Main, 1710/17N Series

.

JOP

Universal Joint: Main, 1550/155N Series

.

JOO

Universal Joint: Main, 1710/17N Series, HD Tube

JOR

Universal Joint: Main, 1610/161N Series

.

JRA

Universal Joint: Inter Axle, 1610/161N Series

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JRD

Brake Rating: Front, Air Carlisle, E145A Non-Abestos Lining, 14 cm (5.5 in)

Slack, 4 or 8 Hole Mounting

JRF

Shield: Rear Brakes, Dust

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JRL

Brake Rating: Rear, Air Carlisle, E145A Non-Abestos Lining, 14 cm (5.5 in)

Slack, 42 cm 18 cm (16.5 in x 7 in) Fab

Shoe, 10 Hole Mounting

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JRN

Brake Rating: Rear, Air Carlisle, E145A Non-Abestos Lining, 15 cm (6 in) Slack, 42 cm x 18 cm (16.5 in x 7 in) Fab

Shoe, 9 Hole Mounting

.

JTJ

Brake Adjuster, RR Slack, Eaton® Automatic

JTK

Brake Adjuster, Front Slack, Eaton® Automatic

JTT

Air Dryer B/W Model, AD9 Heated, Brake Air Tank

JUE

Brake Adjuster: Front Slack, Rockwell® Automatic

JUZ

Equipment RR Brake Chamber Brand, MGM E-Series

JVA

Provisions Antilock Brake Delete

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JVO

Brake Rating: Front, Air Carlisle, E145A Non-Abestos Lining, 14 cm (5.5 in)

Slack, 42 cm x 13 cm (16.5 in x 5 in) Fab Brake Shoe, 8 Hole Mounting

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JWB

Brake Rating: Rear, Air Carlisle, E145A

Non-Abestos Lining, 14 cm (5.5 in)

Slack, 42 cm x 18 cm (16.5 in x 7 in) Fab Brake Shoe, 16 Hole Mounting

.

JWF

Brake Rating: Rear, Air Carlisle, E145A

Non-Abestos Lining, 15 cm (6 in) Slack, 42 cm x 18 cm (16.5 in x 7 in) Fab Shoe, 16 Hole Mounting

JXD

Universal Joint: Main, 1750/176N Series, HD Tube

JXG

Valve: Air Brake Moisture Ejector, B/W

DV2, Heated, Front

.

RPO

Description

JYV

Brake Provisions: Full Trailer

JZC

Chamber: Front Brake, Type 16

JZD

Chamber: Front Brake, Type 20

JZE

Chamber: Front Brake, Type 24

JZF

Chamber: Rear Brake, Type 30

JZG

Chamber: Rear Brake, Type 24

J71

Parking Brake: Power Operated

J78

Valve: Moisture Ejector Air Brake

J91

Brake Provisions: Trailer

KGB

Generator: 130 AMP

KRW

Hose: Radiator, Silicone

KVB

Hose: Water, Silicone, Except Radiator

KYC

Air Compressor: Zexel, 185UMN, Water Cooled

K40

Engine Brake: Exhaust

K60

Generator: 100 AMP

LG4

Engine: Diesel, 6 Cylinder, 7.8L, Turbo

.

LOB

Engine: Diesel, 6 Cylinder, 7.8L, 149 kW (200 Gross hr), 2400 RPM

.

LOC

Engine: Diesel, 6 Cylinder, 7.8L, 172 kW (230 Gross hp), 2400 RPM

MF1

Transmission: Allison® AT545, Automatic

MPU

Transmission Manual 5-speed Fuller FS5005A

MRK

Clutch: 350 mm, (13.8 in) Single Plate, Push Type, Dana-Spicer®

MWE

Pilot Shaft: Automatic Transmission, No Spline

MWF

Pilot Shaft: Automatic Electric Transmission, No Spline

MWM

Clutch Spicer 14-1 Cerametallix, Pull Type, Greasable Bearing

MWW

Pilot Shaft: Transmission, 44.45 mm (1.75 in) Spline

MWX

Pilot Shaft: Transmission, 38.1 mm (1.5 in) Spline

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M54

Transmission: Manual, 6 Speed, ISUZU, 136 mm (5.35 in), 6.72 1st,

Over Drive

NBS

Exhaust System: Single

NL0

Fuel Tank: 189L, (50 gal), LH, Rectagular, Steel

NL5

Fuel Tank: 189L, (50 gal), Dual, Rectangular, Steel

NXN

Fuel: 57L (15 gal) Additional

NXY

Steering: Power, ZF

PNB

Wheel: Polished Aluminum, Both Sides, Rear

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1998 MD-Isuzu

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RPO

Description

PNL

Secondary Color: Exterior, Penske

PNO

Angle: Rear Axle Pinion, Nominal 3 ·

PNR

Angle: Rear Axle Pinion, Nominal 4•

PNS

Angle: Rear Axle Pinion, Nominal 5•

PNU

Primary Color: Interior, Penske

PNX

Angle: Rear Axle Pinion, Nominal 6 •

PNY

Angle: Rear Axle Pinion, Nominal 7 •

POR

Wheel: Front Generic, 8 Hole, 275 mm (10.8 in), BC, FN

POS

Wheel: Rear Generic, 8 Hole Disc, 275 mm (10.8 in), BC, FN

.

POU

Wheel: Front, Generic Steel, 10 Hole,

285.75 mm (11.25 in), BC, Disc Piloted, Disc

.

POV

Wheel: Rear, Generic Steel, 10 Hole,

285.75 mm (11.25 in), BC, Disc Piloted, Disc

POY

Wheel: Front, Generic Steel, 10 Hole,

287.75 mm (11.25 in), BC, Piloted

POZ

Wheel: Rear, Generic Steel, 10 Hole,

287.75 mm (11.25 in), BC, Piloted

PRS

Identification Pro-Spec

PTA

Provisions Low Profile Front Tires

PVG

Wheel: Front, Generic 8 Hole, 275 mm (10.8 in), BC

PVH

Wheel: Rear, Generic 8 Hole, 275 mm (10.8 in), BC

P2C

Pricing Wheels, Class A

P53

Tire Tread, Spare Tread and Brand, Front Match

P54

Tire Tread, Spare Tread and Brand, Rear Match

OE5

Odometer Rear Axle Hub

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OH3

Wheel: Front, 22.5 x 7.50, 10 Hole,

287.75 mm (11.25 in) BC, FN, Hub Piloted

.

OH4

Wheel: Rear, 22.5 x 7.50, 10 Hole,

287.75 mm (11.25 in) BC, FN, Hub Piloted

082

Wheel: Front, 19.5 x 6.0, 8 Hole,

275 mm (10.8 in), BC, FN

083

Wheel: Rear, 19.5 x 6.0, 8 Hole,

275 mm (10.8 in), BC, FN

RNE

Wheel: Front, 22.5 x 8.25, 10 Hole,

285.75 mm (11.25 in), BC, Piloted Hub

RNF

Wheel: Rear, 22.5 x 8.25, 10 Hole,

285.75 mm (11.25 in), BC, Piloted Hub

RPM

Wheel: Front, 19.5 x 6.75, 8 Hole,

275 mm (10.8 in), BC, FN, Piloted Hub

RPO

Wheel: Front, 22.5 x 8.25, 10 Hole,

285.75 mm (11.25 in), BC, Piloted Hub

.

RPO

Description

RPR

Wheel: Rear, 22.5 x 8.25, 10 Hole,

285.75 mm (11.25 in), BC, Piloted Hub

RPW

Wheel: Rear, 19.5 x 6.75, 8 Hole,

275 mm (10.8 in), BC, FN, Piloted Hub

RO2

Vehicle Application: Truck Service

R3B

Front Tire: Extra Strength Highway Tread

R3C

Front Tire: Premium Highway Tread

R3M

Front Tire: All Season Tread

R3N

Front Tire: Premium Highway Improved Steering Control Tread

R4A

Front Tire Brand: Goodyear

R4H

Front Tire Brand: General

R4L

Front Tire Brand: Michelin

R4N

Front Tire Brand: Bridgestone

R4R

Front Tire Brand: Select, Brand Plant

R4T

Front Tire Brand: Yokohama

R6B

Control Sales Item No. 02

R6G

Control Sales Item No. 07

R6P

Control Sales Item No. 15

R9U

Control Sales Item No. 95

SGB

Form Advanced Broadcast Document

SMA

Spacer Pack: Right Spring Cab Leveling, +10 mm (+.374 in)

SMB

Spacer Pack: Right Spring Cab Leveling, +0 mm (+0 in)

SMC

Spacer Pack: Right Spring Cab Leveling, -10 mm (-.374 in)

SMD

Spacer Pack: Right Spring Cab Leveling, -20 mm (-.787 in)

SNF

Wheel: Front, Spare

SNR

Wheel: Rear, Spare

S3B

Tire Tread: Rear, Extra Strength Highway

S3C

Tire Tread: Rear, Premium Highway

S3D

Tire Tread: Rear, Highway Premium

S3E

Tire Tread: Rear, On/Off Road Highway

S3F

Tire Tread: Rear, Off Road Rolling

S3H

Tire Tread: Rear, Highway

S3J

Tire Tread: Rear, Highway Traction

S3K

Tire Tread: Rear, On/Off Road Rib

S3L

Tire Tread: Rear, Off Road Traction

S3M

Tire Tread: Rear, All Season

S3N

Tires: Tread, Rear, Premium Highway, Improved Steering Control

S4A

Rear Tire Brand: Goodyear

S4C

Rear Tire Brand: Dunlop

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1998 MD-Isuzu

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  .

RPO

Description

S4H

Rear Tire Brand: General

S4L

Rear Tire Brand: Michelin

S4N

Rear Tire Brand: Bridgestone

S4R

Rear Tire: Select, Brand Plant

S4T

Rear Tire Brand: Yokohama

TM0

Battery: 900 CCA, Dual

TNL

Battery: Twin, 12V (1110)

TNN

Battery: Twin, Delco® 1150, 12V

TRF

Tires: Front, Radial Identifier

TAG

Tire Selection, Customer Brand

TRH

Tire Selection, Customer Brand

TAR

Tires: Rear, Radial Identifier

TRZ

Equipment Air Shift Transmission

T62

Lighting: Daytime Running

UEA

Taillamp Delete

UET

Indicator, Electronic Transmission, Oil Level

UM6

Radio: AM/FM Stereo, Seek & Scan, Auto Reverse Cassette, Clock, ETA

UM?

Radio: AM/FM Stereo, Seek & Scan, Clock, ETA

UZF

Alarm B/U Electrical, 97 Decibles

uoa

Hom: Dual Electric

U86

Wiring Harness: Full Trailer, 7-Wire

vco

Vehicle Label, Noise Control Information

VC5

Label, Shipping, Except US, or Japan

VC6

Label, Shipping, Hawaii, US Territories, and Puerto Rico

VH4

Mud Flaps

VPG

Cable: Trailer Jumper Cable, ?-Wire, 12-foot, Synflex Coiled

VPH

Vehicle Preparation Overseas Delivery

VWN

Hook: Tow, Rear, Bolt On

VXT

Vehicle Incomplete

V01

Radiator: Heavy Duty

V48

Coolant: Maximum Protection Engine

V76

Hook: Tow

V78

Vehicle Statement: Delete

V98

Vehicle Statement: Delete

WDB

Control Engineering Edit

XQT

Tire: Front, 8.00R19.5/E, 10PR,

BL TL Radial

XRL

Tire: Front, 235/80R22.5/G, 14PR, BL TL Radial

XRN

Tire: Front, 295/75R22.5/G, 14PR, BL TL Radial

.

RPO

Description

XSB

Tire: Front, 255/80R22.5/G, 14PR, BL

TL Radial

XSH

Tire: Front, 275/80R24.5/G, 14PR, BL

TL Radial

XTB

Tire: Front 255/70R22.5/H, 16PR, BL

TL Radial

XTI

Tire: Front, 245/70R19.5/F, 12PR, BL

TL Radial

XTN

Tire: Front, 225/70R19.5/F, BW, A/ST TL HWY

XTO

Tire: Front, 245/75R22.5/G, BL TL Radial

XTU

Tire: Front, 265/75R22.5/G, BL TL Radial

XTX

Tire: Front, 8.00R19.5/F, 12 PR, BL TL

Radial

XTY

Tire: Front, 245/70R19.5/G, 14PR, BL

TL Radial

XWJ

Tire: Front, 10.00R22.5/F, 12PR, BL TL

Radial

XWK

Tire: Front, 10.00R22.5/G, 14PR, BL TL

Radial

XWL

Tire: Front, 11.00R22.5/G, 14PR, BL TL

Radial

XWM

Tire: Front, 11.00R22.5/H, 16PR, BL TL

Radial

xao

Plate GVW Rating

YA6

Sales Package Body Override, California

YES

Vehicle Test, Engineering

YF5

Certification Emission, California

YF6

Sales Processing Option Geographic Control, California

YQT

Tire: Rear, 8.00R19.5/E, 10PR, BL TL

Radial

YRL

Tire: Rear, 235/80R22.5/G, 14PR, BL

TL Radial

YAN

Tire: Rear, 295/75R22.5/G, 14PR, BL

TL Radial

YSB

Tire: Rear, 255/80R22.5/G, 14PR, BL

TL Radial

YSH

Tire: Rear, 275/80R24.5/G, 14PR, BL

TL Radial

YTB

Tire: Rear, 255/70R22.5/H, 16PR, BL

TL Radial

YTI

Tire: Rear, 245/70R19.5/F, 12PR, BL TL

Radial

YTN

Tire: Rear, 225/70R19.5/F, BW, A/ST ST TL HWY

YTQ

Tire: Rear, 245/75R22.5/G, BL TL

Radial

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1998 MD-Isuzu

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  .

RPO

Description

YTU

Tire: Rear, 265/75R22.5/G, BL TL

Radial

YTX

Tire: Rear, 8.00R19.5/F, 12PR, BL TL

Radial

YTY

Tire: Rear, 245/70R19.5/G, 14PR, BL

TL Radial

YU8

Wheel: Single, Polished Aluminum, One Side, Front

YWJ

Tire: Rear, 10.00R22.5/F, 12PR, BL TL

Radial

YWK

Tire: Rear, 10.00R22.5/G, 14PR, BL TL

Radial

YWL

Tire: Rear, 11.00R22.5/G, 14PR, BL TL

Radial

YWM

Tire: Rear, 11.00R22.5/H, 16PR, BL TL

Radial

YX6

Attachment Main Driveline One-Shaft System

YX7

Attachment Main Driveline Two-Shaft System

YX8

Attachment Main Driveline Three-Shaft System

YX9

Attachment Main Driveline Four-Shaft System

YY7

Paint Process Chassis

YY9

Paint Process Wheel

ZQT

Tire: Spare, 8.00R19.5/E, 10 PR, BL

TL Radial

ZRL

Tire: Spare, 235/80R22.5/G, 14PR, BL

TL Radial

ZAN

Tire: Spare, 295/75R22.5/G, 14PR, BL

TL Radial

ZSB

Tire: Spare, 255/80R22.5/G, 14PR, BL

TL Radial

ZSH

Tire: Spare 275/80R22.5/G, 14PR, BL

TL Radial

ZTB

Tire: Spare, 255/70R22.5/H, 16PR BL

TL Radial

ZTI

Tire: Spare, 245/70R19.5/F, 12PR BL

TL Radial

ZTN

Tire: Spare, 225/70R19.5/F, BW, A/ST ST TL HWY

ZTQ

Tire: Spare, 245/75R22.5/F, BL TL Radial

ZTU

Tire: Spare, 265/75R22.5/G, BL TL Radial

ZTX

Tire: Spare, 8.00/19.5/F, 12PR, BL TL

Radial

ZTY

Tire: Spare, 245/70R19.5/G, 14PR BL

TL Radial

ZV1

Statement of Origin Manufacture

.

RPO

Description

ZWJ

Tire: Spare, 10.00R22.5/F, 12PR, BL

TT Radial

ZWK

Tire: Spare, 10.00R22.5/G, 14PR, BL

TT Radial

ZWL

Tire: Spare, 11.00R22.5/G, 14PR, BL

TT Radial

ZWM

Tire: Spare, 11.00R22.5/H, 16PR, BL

TL Radial

ZY1

Color Combination: Solid

ZY2

Color Combination: Two-Tone

249

Export Canadian Modified Mandatory Base Equipment

Z89

Conversion Name Plate ISUZU

001

3.70 Ratio Code

002

4.11 Ratio Code

003

4.33 Ratio Code

005

4.56 Ratio Code

006

4.63 Ratio Code

008

4.88 Ratio Code

009

5.29 Ratio Code

01L

Secondary Color: Exterior, Special

01U

Primary Color: Exterior, Special

010

5.43 Ratio Code

011

5.57 Ratio Code

012

5.83 Ratio Code

014

6.14 Ratio Code

015

6.17 Ratio Code

016

5.25 Ratio Code

017

6.50 Ratio Code

018

6.65 Ratio Code

019

6.67 Ratio Code

020

5.63 Ratio Code

022

7.17 Ratio Code

032

6.29 Ratio Code

038

6.57 Ratio Code

039

3.55 Ratio Code

057

3.36 Ratio Code

066

4.10 Ratio Code

069

3.90 Ratio Code

070

5.38 Ratio Code

092

4.30 Ratio Code

16L

Primary Color: Exterior, White Kodiak, Frost

16U

Color: Primary Exterior, White Kodiak, Frost

23L

Secondary Color: Exterior, Ocean Blue

23U

Primary Color: Exterior, Ocean Blue

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1998 MD-Isuzu

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9

8

7

6

5

4

3

2

1

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Labels – How to Obtain Replacement

Order the following replacement labels through Isuzu Service Parts:

The Vehicle Emission Control Information (Exhaust Emission Tune-Up)
The Spare Wheel Caution
The Jacking
The Spare Tire Storage
The Belt Routing
The Engine Fan Caution

The Standard Parts Catalog lists the above labels and other labels. The Vehicle Certification Label, the Tire Pressure Placard, and the Service Parts Identification Label are NOT available as

service parts.

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1998 MD-Isuzu

171892

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Engineers design prevailing torque nuts in order to develop an interference between the nut and bolt threads. Usually the interference is caused by distorting the top of a metal nut (1,2) or by a nylon patch on the threads in the middle of the hex flat (3). A nylon insert between the nut and bolt threads also may cause the interference (4,5).

RPO

Description

24L

Secondary Color: Exterior, Medium Blue Metallic

40P

Wheel Color: White

41P

Wheel Color: Black

46L

Secondary Color: Exterior, Dark Green

46U

Primary Color: Exterior, Dark Green

5DO

Paint Process Bumper, Light Gray

61L

Secondary Color: Exterior, Tan

61U

Primary Color: Exterior, Tan

70L

Secondary Color: Exterior, Dark Maple

71L

Secondary Color: Exterior, Red Orange

71U

Primary Color: Exterior, Red Orange

72U

Primary Color: Exterior, Standard Red

86L

Secondary Color: Exterior, Wheatland Yellow

86U

Primary Color: Exterior, Wheatland Yellow

88L

Secondary Color: Exterior, Tangier Orange

88U

Primary Color: Exterior, Tangier Orange

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Engineers design prevailing torque bolts in order to develop an interference between the bolt and nut threads, or the threads of a tapped hole. The interference is caused by distorting some of the threads using one of the following methods:

A nylon patch (8)
Adhesive (6)
A deformed thread profile (7)
An out of round thread area (9)

Recommendations for Reuse

Perform the following steps in order to reuse clean, non-rusted, prevailing torque nuts:

1.Clean dirt and other foreign material off of the nuts and bolts.
2.Inspect the nuts or bolts for the following conditions. If any of the following conditions exist, use a new prevailing torque fastener:
Cracks
Rust
Damage
Elongation
Signs of abuse
Signs of overtightening
3.Assemble the parts.
4.Hand start the nuts or bolts.
5.Ensure that the fastener develops proper torque before the fastener seats. Refer to the Torque Table. If the proper torque does not develop, use a new prevailing torque fastener.
6.Tighten the fastener to the torque specified in the appropriate fastener tightening specification.

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%1-18General Information  General Information

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Metric Fasteners (Prevailing Torque)

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Fastener Type

Specification

Metric

English

Nuts/Metal Bolts

6

0.4 N.m

4Ib in

6.3

0.4 N.m

4 lbin

8

0.8 N-m

7Ibin

10

1.4 N-m

12 lbin

12

2.2 N.m

19 lb in

14

3.0 N-m

27 lb in

16

4.2 N.m

37 lbin

Adhesive or Nylon Coated Bolts

6

0.4 N.m

4Ibin

6.3

0.4 N-m

4Ibin

8

0.6 N.m

Sib in

10

1.2 N.m

11 lb in

12

1.6 N.m

14 lbin

14

2.4 N.m

21 lb in

16

3.4 N-m

30 lb in

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English Fasteners (Prevailing Torque)

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Fastener Typefrorque Units

Specification

Metric

English

Nuts/Metal Bolts

0.250

0.4 N.m

4Ib in

0.312

0.6 N-m

Sib in

0.375

1.4 N-m

12 lbin

0.437

1.8 N.m

16 lb in

0.500

2.4 N-m

21 lb in

0.562

3.2 N-m

28 lb in

0.625

4.2 N.m

37 lbin

Adhesive or Nylon Coated Bolts

0.250

0.4 N-m

4Ib in

0.312

0.6 N.m

Sib in

0.375

1.0 N.m

9 lb in

0.437

1.4 N.m

12 lb in

0.500

1.8 N.m

16 lb in

0.562

2.6 N.m

23 lbin

0.625

3.4 N.m

30 lb in

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1998 MO-Isuzu

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General Information  General Information  0-19

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Fasteners (Strength Identification)

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6

5

4

3

2

1

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Legend

(1)English Bolt, Grade 2 (Strength Class)
(2)English Bolt, Grade 5 (Strength Class)

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(4)English Bolt, Grade 8 (Strength Class)
(5)Metric Nut, Strength Class 9

171891

(3) English Bolt, Grade 7 (Strength Class)

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Notice: The designation of the standard fasteners used on this vehicle are of coarse screw thread up to MB and fine screw thread beyond M10. The designation to pitch relations are somewhat different between coarse screw thread and fine screw thread. Therefore, when replacing fasteners, the pitch should be confirmed carefully even if the replacement fastener is the same metric fastener.

The most common metric fastener strength property classes are 9.8 and 10.9. The class identification number is embossed on the head of each bolt (6). Some metric nuts are marked with single digit strength identification numbers on the nut face.

English strength classes range from 2 (low strength) to 8 (high strength). A grade-2 bolt has no lines embossed on the bolt head (1). One radial line is

(4)Metric Bolts, Strength Class Increases as Numbers Increase

embossed on the bolt head for each strength grade above 2. That is, a bolt with one embossed line indicates grade-3. Two embossed lines indicate grade-4. Six embossed lines signify grade-a, the highest-grade bolt (4).

Correct replacement bolts and nuts are available through American Isuzu Parts Distributor Network (AIPDN). Many metric fasteners available in the after-market parts channels are designed to foreign metric standards, and may have a different thread pitch. Isuzu products use metric fasteners designed to new, international standards. Some non-domestic bolt and nut suppliers may not yet use the international standards.

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1998 MD-Isuzu

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%1-20General Information  General Information

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Fasteners (Strength Identification)

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Metric Coarse Screw Threads

Metric Fine Screw Threads

Thread

Pitch

Thread

Pitch

Thread

Pitch

Thread

Pitch

M39

4

MB

1.25

M39x3

3

M20x1.5

1.5

M36

4

M7

1

M36x3

3

M18.1.5

1.5

M33

3.5

M6

1

M33x2

2

M16x1.5

1.5

M30

3.5

M5x0.8

0.8

M30x2

2

M14x1.5

1.5

M27

3

M4x0.7

0.75

M27x2

2

M12x1.25

1.25

M24

3

M4x0.7

0.7

M24x2

2

M10x1.25

1.25

M22

2.5

M3.5

0.6

M22x1.5

1.5

M8x1

1

M20

2.5

M3x0.5

0.5

M18

2.5

M2.5

0.45

M16

2

M2.2

0.45

M14

2

M2

0.4

M12

1.75

M1.6

0.35

M10

1.5

Fasteners (Metric Fasteners)

Current model Isuzu vehicles are dimensioned primarily in the metric system. Many fasteners are metric and are very close in dimension to fasteners in the inch system. Replace the fasteners using the following identical specifications:

The nominal diameter
The thread pitch
The strength

Most stock metric fasteners have numbers indicating the strength of the material in the fastener. “Beauty” bolts, such as exposed bumper bolts have no strength indicator. Identify metric cross-recess screws by a Posidriv® or Type 1A marking. Use a Type 1A cross-recess screwdriver in order to fasten or unfasten metric cross-recess screws. If a Type 1A cross-recess screwdriver is not available, use a Phillips head screwdriver.

Isuzu Engineering Standards and other North American industries use a portion of the standard metric fastener sizes defined by the International Standards Organization (ISO). Now the total number of fastener sizes in use is lower, and the overall strength quality of each thread size is higher.

For example, the metric M6.0 x 1 screw replaces the English 1/4-20 and 1/4-28 screws, which have nearly the same diameter. The thread pitch, 25.4 threads per inch, is between coarse and fine thread pitches

Thread Inserts

Repair Procedure

Tools Required

General purpose thread repair kits. These kits are available commercially.

Caution: Wear safety glasses in order to avoid eye damage.

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Important: Refer to the thread repair kit

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4962

in English. Metric and English thread notations differ slightly. The thread major diameter of a 1/4-20 bolt is 1/4-inch, and the bolt has 20 threads per inch. The thread major diameter of a 6.0 x 1 bolt is 6.0 mm, and the distance between threads is 1 mm.

manufacturer’s instructions regarding the size of the drill and tap to use.

Avoid any buildup of chips. Back out the tap every few turns and remove the chips.

1.Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.

1998 MD-Isuzu

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General Information  General Information  0-21

1.Drill out the damaged threads. Clean out any chips.
2.Lubricate the tap with light engine oil. Tap the hole. Clean the threads.

Torque Techniques

The frictional characteristics of each fastener or threaded hole can vary under a variety of circumstances. For example, consider a joint that has 1O bolts. If all 1O fasteners were torqued to 20 N.m and the clamp load is measured, all 1O bolts would most likely have different clamp load readings. Even though all 1O bolts are torqued at 20 N-m, it is not guaranteed that they have all reached the same clamp load. A rule of thumb is that the clamp load can vary

± 25 percent using torque control for joint assembly.

At times, critical applications such as cylinder head bolts require very tight tolerances for clamp load distribution. If torque is not considered to be accurate enough for these critical joints, an alternative method of tightening called TORQUE ANGLE may be used.

Torque Angle Method

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1.Thread the thread insert onto the mandrel of

4963

the installer. Engage the tang of the insert onto the end of the mandrel.

Important: The insert should be flush to one turn below the surface.

1.Lubricate the insert with light engine oil (except when installing in aluminum) and install the insert.
2.If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Torque Wrenches

Torque Defined

Torque is defined as the measurement of resistance to turning or rotating. Torque, often called torsional or twisting movement, tends to twist a body about an axis of rotation. A typical application is the tightening of a screw.

Torque applied in tightening a common bolt, nut, or screw is expended in three areas:

The head
Bearing surface
Clamp load

Clamp Load

About 50 percent of applied torque is used in overcoming bearing friction. This is the friction between the bearing surface of the bolt head, screw head or nut face, and the base material or washer (the surface the fastener is rotating on).

Approximately 40 percent of the applied torque is used in overcoming thread friction. This leaves only about 1O percent of the applied torque to develop useful clamp load. Clamp load is the force that holds a joint together. Friction can account for as much as 90 percent of the applied torque on a fastener.

1998 MD-Isuzu

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65532

Torque angle is required for critical joints because it can help eliminate frictional variations in the joint.

The following are the general steps used for the torque angle method:

1.Tighten to a predetermined seating torque to remove any compliance out of the joint.
2.Turn the fastener to a specified angle of rotation. Use the Torque Angle Meter J 36660.

This is the only acceptable general method for measuring this angle of rotation. Follow the specific procedure where it is provided.

Torque Wrenches and Techniques

The term TORQUE WRENCH is commonly used to describe a type of measuring tool. The tool is set or calibrated in such a way as to rryake possible the measurements of the resistance to turning (torque). The torque wrench measures this resistance to turning and, therefore, is the method used to obtain objective tightening data used in the assembly of fasteners. A torque wrench is a gage tool that can be compared with micrometers, dial indicators, vernier calipers, levels, and other measuring devices.

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