GENERAL INFORMATION 00-1

SECTION 00

GENERAL INFORMATION
INDEX

CONTENTS PAGE

General repair instructions 00— 1

How to use this manual 00— 2

Torque specifications 00— 5

Identification 00— 6

Lifting instructions 00— 7

Underbody measurements diagram 00— 9

Maintenance and lubrication 00 — 10

Recommended fluids and lubricants 00—23

Lock cylinder key and information 00 — 24
Servicing 00 — 25

Special tools 00 — 69

GENERAL REPAIR INSTRUCTIONS

1. If you are using a floor jack, always take the proper precautions to protect yourself from serious personal inj-
ury. Park the vehicle on level ground. Block either the front or rear wheels. Carefully set the jack in the proper
position against an axle or the frame.
Raise the vehicle and then support it with chassis stands. Then you can safely perform necessary service opera-
tions.

2. Before performing any service operation, always disconnect the battery ground cable. This protects other essen-
tial electrical cables from damage or burning due to accidental short circuiting.

3. Always cover the vehicle body, seats, and floor to protect against damage and dirt.

4. Brake fluid and anti-freeze solution must be handled with care. If these fluids are spilled on painted surfaces,
damage will result

5. Always use the proper tools for the job at hand. Where specified, use only an ISUZU SPECIAL TOOL.

6. Always use genuine ISUZU PARTS.

7. All used cotter pins, gaskets, O-rings, oil seals, locking washers, and self locking nuts removed during any service
operation should be replaced with new ones. Always discard the old ones. Do not reuse them.
0 0 - 2 GENERAL INFORMATION

8. Always keep disassembled parts neatly in groups.

Be sure to keep mounting nuts and bolts carefully separated. This is especially important as these nuts and bolts
vary in hardness and design depending upon their installation position.

9. Clean and inspect all parts before reassembly. Use compressed air to blow oil ports free of all obstructions.

10. Lubricate the rotating and sliding faces of all parts with oil or grease before installation.

1 1 . Where necessary, use a sealer on gaskets to prevent leakage.

1 2. Carefully observe all nut and bolt torque specifications.

1 3. After completing any service operation, make a final check to be sure that the service has been properly performed
and that all problems have been corrected.

HOW TO USE THIS MANUAL

1. Find the type of unit or equipment to be serviced by refering to the "Application chart" or "Identification of unit or
equipment" included in this section.

2. Find the applicable section by refering to the index.

3. This manual includes a "General information" section in which service data, maintenance items and specifications
with torques are included.

4. Each section includes Removal and Installation, Disassembly, Inspection and Repair, and Reassembly. When the
same service operation applies to more than one units, or equipment, a notice is inserted stating, "Refer to manual
for other units or equipment".
 GENERAL INFORMATION 0 0 - 3

5. Each service operation section begins with a disassembled view of the unit or equipment. This is useful for finding
components, service procedures, availability, and content of repair kits.
0 0 - 4 GENERAL INFORMATION

6. The section following the illustration(s) deals with important service steps marked with " 1 " .
This section also includes "notes", "use of special tools", and "service data".

7. In this manual, the following symbols are used to indicate the type of service operations to be performed.

.... Remove .... Adjustment

Install Clean

.... Disassemble .... Pay close attention — important

Reassemble .... Tighten to specified torque

.... Align the marks Use essential tool(s)

.... Correct direction .... Use available tool(s)

.... Inspect .... Lubricate with oil

.... Take measurement .... Lubricate with grease

8. The service standard is indicated in terms of "Standard" and "Limit".

The "Standard" means the assembly standard and standard range within which the parts are considered servicea-
ble.
"Limit" indicates the limit value (Correction or replacement is necessary when measurement is beyond this limit.)

9. In this manual, the components and parts are printed in singular form.
 GENERAL INFORMATION 0 0 - 5

TORQUE SPECIFICATIONS
STANDARD BOLTS
The torque values given in the following table should be applied when a particular torque is not specified.

kg-m (ft. lbs.)

Bolt identification

Bolt diameter x pitch

4T 7T 9T
(mm) (Low carbon steel) (High carbon steel) (Alloy steel)

M6 x 1.0 0.4 - 0.8 (3 - 6) 0.5 - 1.0 (4 - 7) —

M8 x 1.25 0.8 - 1.8 (6 - 13) 1.2 - 2.3 (9 - 17) 1.7 - 3.1 (12 - 22)
M10 x 1.25 2.1 - 3.5 (15 - 25) 2.8 - 4.7 (20 - 34) 3.8 - 6.4 (27 - 46)
*M10 x 1.5 2.0 - 3.4 (14 - 25) 2.8 - 4.6 (20 - 33) 3.7 - 6.1 (27 - 44)
M12 x 1.25 5.0 - 7.5 (36 - 54) 6.2 - 9.3 (45 - 67) 7.7 - 11.6 (56 - 84)
*M12 x 1.75 4.6 - 7.0 (33 - 51) 5.8 - 8.6 (42 - 62) 7.3 - 10.9 (53 - 79)
M14 x 1.5 7.8 - 11.7 (56 - 85) 9.5 - 14.2 (69 - 103) 11.6 - 17.4 (84 - 126)
*M14 x 2.0 7.3 - 10.9 (53 - 79) 9.0 - 13.4 (65 - 97) 10.9 - 16.3 (7 9 - 1 1 8 )
M16 x 1.5 10.6 - 16.0 (7 7 - 1 1 6 ) 13.8 - 20.8 (100 - 150) 16.3 - 24.5 (118 - 177)
*M16 x 2.0 10.2 - 15.2 (74 - 110) 13.2 - 19.8 (95 - 143) 15.6 - 23.4 ( 1 1 3 - 1 6 9 )
M18 x 1.5 15.4 - 23.0 ( 1 1 1 - 1 6 6 ) 19.9 - 29.9 (144 - 216) 23.4 - 35.2 (169 - 255)
M20 x 1.5 21.0 - 31.6 (152 - 229) 27.5 - 41.3 (199 - 299) 32.3 - 48.5 (234 - 351)
M22 x 1.5 25.6 - 42.2 (185 - 305) 37.0 - 55.5 (268 - 401) 43.3 - 64.9 (313 - 469)
M24 x 2.0 36.6 - 55.0 (265 - 398) 43.9 - 72.5 (318 - 524) 56.5 - 84.7 (409 - 613)

An asterisk * indicates that the bolts are used for female-threaded parts made of soft materials, such as casting.
0 0 - 6 GENERAL INFORMATION

IDENTIFICATION

VEHICLE IDENTIFICATION
The vehicle identification number is embossed on a plate
attached to the top left end of the instrument panel.
This number is visible and can be read through the windshield
glass.

ENGINE SERIAL NUMBER (gasoline)

The gasoline engine number is stamped on the right upper center
part of the cylinder body.

ENGINE SERIAL NUMBER (diesel)

The diesel engine serial number is stamped on the front part of
the cylinder body.

The paint color code identification plate is located in the engine

compartment.
 GENERAL INFORMATION 0 0 - 7

LIFTING INSTRUCTIONS

If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lift-
ing points (illustration). Raising the vehicle from any other point may result in serious damage.

JACK

Jacking points

Lower control arm

Rear axle
0 0 - 8 GENERAL INFORMATION

GARAGE JACK AND SAFETY

STANDS

Lifting points and supportable point-locations

1. Front axle center
2. Rear axle center
3. Side frame

Supportable points

SPARE TIRE

The spare wheel and tire is mounted on the left hand rear door.
 GENERAL INFORMATION 0 0 - 9

UNDER BODY MEASUREMENTS DIAGRAM

0 0 - 1 0 GENERAL INFORMATION

MAINTENANCE AND LUBRICATION

COMPLETE VEHICLE MAINTENANCE SCHEDULE

Gasoline engine

EVERY
No. ITEM MONTH 7.5 15 22.5 3 0 37.5 45 52.5
OR

1 CHECK FLUID/LUBRICANT LEVEL 12 x X X X X X X

2 CHANGE ENGINE OIL 12 X X X X X X X
3 REPLACE ENGINE OIL FILTER 12 X X X X
4 CHECK COOLING SYSTEM 12 X X X
5 CHANGE FRONT & REAR AXLE OIL — X X
6 CHANGE MANUAL/T.M. & TRANSFER OIL — X X
7 CHECK EXHAUST SYSTEM 12 X X X X X X X
8 CHECK FUEL LINE & FUEL TANK/CAP 12 X X X
9 CHECK DRIVE BELT 24 X
10 ADJUST ENGINE IDLE SPEED — X X X
11 REPLACE FUEL LINE FILTER — X
12 ADJUST VALVE CLEARANCE — X X X
13 REPLACE AIR CLEANER ELEMENT — X
14 CHECK CARBURETOR CHOKE 24 X
15 CHECK CARBURETOR CHOKE HOSE 24 (x)
16 CHECK DISTRIBUTOR ADVANCE MECHANISM 24 X
17 ADJUST IGNITION TIMING 24 X
18 CHECK THERMOSTATICALLY CONTROL AIR CLEANER 24 X
19 CHECK THERMOSTATICALLY CONTROL CLEANER HOSE 24
20 REPLACE SPARK PLUG — X
21 CHECK IGNITION COIL WIRES 24
22 CHECK AIR INJ. REACTOR SYS. HOSE & CONNECTIONS 24
23 CHECK EGR SYSTEM HOSE & CONNECTIONS 24
24 CLEAN PCV VALVE & HOSE 24
25 CHECK DISTRIBUTOR VACUUM ADVANCE HOSE 24
26 ROTATE TIRES — X X X X X X X
27 CHECK TIRES & WHEELS 12 X X X X X X X

28 CHANGE POWER STEERING FLUID — X

29 ADJUST STEERING GEAR PLAY 24 X
30 CHECK BRAKE LINES & HOSE 12 X X X X X X X

31 CHECK DRUM & DISC BRAKES 12 X X X

32 CHECK PARKING BRAKE 12 X X X

33 ADJUST BRAKE & CLUTCH PEDAL PLAY 12 X X X

34 REPACK FRONT & REAR WHEEL BEARINGS — X

35 LUBE ACCELERATOR LINKAGE 6 X X X X X X X

36 LUBE STEERING LINKAGE & SUSPENSION 6 X X X X X X X

37 LUBE BODY & CHASSIS 6 X X X X X X X

38 LUBE FRONT & REAR PROPELLER SHAFT 6 X X X X X X X

 GENERAL INFORMATION 0 0 - 1 1

(x 1 0 0 0 miles)

60 67.5 75 82.5 90 97.5 105 112.5 120 DESCRIPTION

X X X X X X X X X
X X X X X X X X X
X X X X
X X X X X
X X X
X X X
X X X X X X X X X
X X X X X
X X X
X X X X X
X X X EXCEPT CALIFORNIA
X X X X X
X X X
X X X
X (x) X (X) : CALL ONLY
X X X EXCEPT CALIFORNIA
X X X EXCEPT CALIFORNIA
X X X EXCEPT CALIFORNIA
X X EXCEPT CALIFORNIA
X X X

X X EXCEPT CALIFORNIA
X X EXCEPT CALIFORNIA
X X EXCEPT CALIFORNIA
X X EXCEPT CALIFORNIA
X X EXCEPT CALIFORNIA
X X X X X X X X X

X X X X X X X X X

X X X

X X X

X X X X X X X X X

X X X X X

X X X X X

X X X X X

X X X

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X
0 0 - 1 2 GENERAL INFORMATION

MAINTENANCE AND LUBRICATION

COMPLETE VEHICLE MAINTENANCE SCHEDULE

Diesel turbocharged engine : except California

EVERY
No. ITEM MONTH 5.0 7.5 10 15 20 22.5 25 30
OR
1 CHECK FLUID/LUBRICANT LEVEL 12 X X X X
2 CHANGE ENGINE OIL & FILTER 12 x X X X X X
3 CHECK COOLING SYSTEM 12 X X
4 CHANGE FRONT & REAR AXLE OIL — X X
5 CHANGE MANUAL/T.M. & TRANSFER OIL — X X
6 DRAIN WATER : FUEL FILTER 12 X X X X
7 CHECK EXHAUST SYSTEM 12 X X X X
8 CHECK FUEL LINE & FUEL TANK/CAP 12 X X
9 CHECK DRIVE BELT 12 X X
10 ADJUST ENGINE IDLE SPEED — X X
11 REPLACE FUEL LINE FILTER — X
12 ADJUST VALVE CLEARANCE — X X
13 REPLACE AIR CLEANER ELEMENT — X
14 ROTATE TIRES — X X X X
15 CHECK TIRES & WHEELS 12 X X X X
16 CHANGE POWER STEERING FLUID — X
17 ADJUST STEERING GEAR PLAY 12 X
18 CHECK BRAKE LINES & HOSE 12 X X X X
19 CHECK DRUM & DISC BRAKES 12 X X
20 CHECK PARKING BRAKE 12 X X
21 ADJUST BRAKE & CLUTCH PEDAL PLAY 12 X X
22 REPACK FRONT & REAR WHEEL BEARINGS — X
23 LUBE ACCELERATOR LINKAGE 6 X X X X
24 LUBE STEERING LINKAGE & SUSPENSION 6 X X X X
25 LUBE BODY & CHASSIS 6 X X X X
26 LUBE FRONT & REAR PROPELLER SHAFT 6 X X X X
 GENERAL INFORMATION 0 0 - 1 3

(x 1000 miles)

35 37.5 40 45 50 52.5 55 60 65 67.5 70 75 80 82.5 85 90 95 97.5 100 105 110 112.5 115 I 20

X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X
X X X X X X
X X X
X X X
X X X X X X X X X X X X
X X X X X X X X X X X X
X X X X X X
X X X X X X
X X X
X X X
X X X X X X
X X X
X X X X X X X X X X X X
X X X X X X X X X X X X
X X X
X X X
X X X X X X X X X X X X
X X X X X X
X X X X X X
X X X X X X
X X X
X X X X X X X X X X X X
X X X X X X X X X X X X
X X X X X X X X X X X X
X X X X X X X X X X X X
0 0 - 1 4 GENERAL INFORMATION

EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE

The following is a brief description of each of the services listed in the preceding Complete Vehicle Maintenance
Schedule.

NORMAL VEHICLE USE

The owner's maintenance instructions in this Maintenance Schedule are based on the assumption that your car will be
used as designed:
• to carry passengers and cargo within the limitations specified on the tire placard located on the inside of the glove
compartment door;
to be driven on reasonable road surfaces within legal operating limits;
to be driven on a daily basis, as a general rule, for at least several miles/kilometres;
• to be driven on unleaded fuel
Unusual or severe operating conditions will require more frequent car maintenance, as specified in the following sections.

FLUID OR LUBRICANT LEVELS

Check level of fluid or lubricant in brake master cylinder, clutch master cylinder, power steering reservoir, rear
axle, engine and transmission.
Check fluid level of windshield washer reservoir and engine coolant.
CAUTION: To help avoid the danger of being burned, do not remove the radiator cap while the engine and
radiator are still hot.

ENGINE OIL AND FILTER RECOMMENDATIONS (GASOLINE ENGINE)

Engine oils are labeled on the containers with various API (American Petroleum Institute) designations of
quality. Use engine oils that are labeled SF, SE or SE/CC. Do not use oils labeled only SA, SB, SC, SD, CA,
CB, CC or CD; or oils with the combination label SE and CD (SE/CD). Higher quality oils labeled SF are
preferred and should be used when available.
The oil and filter change intervals for your engine are based on the use of SE-quality or SF-quality oils and high-
quality filters. Using oils other than SE-quality or SF-quality oils, or oil change intervals longer than recom-
mended, could reduce engine life and might affect your warranty.
Your engine was filled with a high-quality engine oil when it was built. You do not have to change this oil before
the suggested change period.
If your normal driving does not include one or more of the four "severe service" conditions listed below, change
the oil every 7,500 miles (1 2,000 kilometers) or 1 2 months, whichever comes first. Change the oil filter at the
first oil change, then every second oil change, if the change is based on mileage (7,500 miles or 12,000
kilometers). If the change is based on time (12 months), change the filter with every oil change.
Change the oil and oil filter every 3,750 miles (6,000 kilometers) or every 3 months if you often drive under one
or more of these "severe service" conditions:
• Driving in dusty areas
• Towing a trailer
• Frequent idling or idling for long periods
• Frequent short trips (4 miles [6 kilometers] or less) in cold or freezing weather, where the engine does not
thoroughly warm up.
Change the oil and oil filter as soon as possible after driving in a dust storm.
When installing the oil filter:
1. Apply engine oil to gasket.
2. Hand tighten until the gasket contacts the sealing face.
3. Using filter wrench, tighten filter 1 full turn.
4. Run the engine and check to see that no leakage is visible.
IMPORTANT: Improperly installed oil filters can result in engine damage.
 GENERAL INFORMATION 0 0 - 1 5

OIL VISCOSITY

Engine oil viscosity (thickness) has an effect on fuel economy. Lower viscosity engine oils can provide
increased fuel economy; however, higher temperature weather conditions require higher viscosity engine oils for
satisfactory lubrication.
To get the best fuel economy with your vehicle, you should use a fuel-saving engine oil of the proper
viscosity. These oils can be found in service stations and other retail stores. They are identified by words such
as: "Energy Saving,' "Conserves Gasoline," "Gas Saving," "Gasoline Saving," "Friction Reducing," "Improved
Gasoline Mileage" or "Fuel Saving."
The chart lists the engine oil viscosities recommended for the temperature range you expect before the next oil
change.

Using SAE 10W-40 oil, or any other viscosity other than those viscosities recommended may reduce
engine life and affect your warranty.

OIL LEVEL CHECK

It is the owner's responsibility to keep the engine oil at the proper level. Check the oil level at regular intervals
(such as every other fuel stop) and keep it above the "Add" line. Remember, your engine may use more oil
when it is new.
The best time to check the engine oil level is when the oil is warm, such as during a fuel stop. First, shut off the
engine and wait about 5 minutes for the oil to drain back to the oil pan, then, pull out the dipstick, wipe it clean,
and push it back down all the way. Now, pull out the dipstick and look at the oil level on the dipstick. The
dipstick has a marking which indicates the normal oil level. If the oil level is lower than the marked area, it indi-
cates the need for additional oil. Push the dipstick back down all the way after taking the reading.
If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain into the pan
fast enough to give a true oil level.

ENGINE OIL ADDITIVES

There are many extra engine oil additives (or helpers) for sale. Your engine does not need these extra additives
if you use SE-quality or SF-quality engine oil and change it as suggested. If you think your engine has an oil-
related problem, talk to your Isuzu Dealer.

AIR CLEANER ELEMENT

The operation of the vehicle in dusty areas will necessitate more frequent element replacement. See your Mainte-
nance Schedule List for change intervals. Your Isuzu Dealer can be of assistance in determining the proper rep-
lacement frequency for the conditions under which you operate your vehicle.

IMPORTANT: We strongly recommended that you use genuine Isuzu or EPA certified air cleaner elements as
replacements since they are of the viscous type and differ from the conventional dry type air
cleaners in construction and function.
Do not attempt to clean the element even if it is dirty, as the element is designed to provide normal filtering effi-
ciency during the replacement interval.
If the air cleaner is removed during repair or maintenance, be sure to reinstall it correctly. If the air cleaner is
incorrectly installed, a fire could result in the engine compartment (in case of a backfire or other engine malfunc-
tion.)
0 0 - 1 6 GENERAL INFORMATION

ENGINE OIL AND FILTER RECOMMENDATIONS (DIESEL ENGINE)

Choosing the Right Quality Oil

ENGINE OIL QUALITY(API)

RECOMMENDATIONS
SE/CD, SF/CD, CD PREFERRED
SE/CC, SF/CC ACCEPTABLE

Use ONLY engine oils labeled with API (American Petroleum Institute) designations of quality shown in
the above chart. Using any quality oils other than these recommended may reduce engine life and affect
your warranty.
The API designations are listed on the oil can, usually on the top or label. The API has several designations, such
as : SC, SD, SE, CB, CC. Several different designations may appear on the can.
IMPORTANT: Do not overfill the engine crankcase with engine oil. Overfilling may cause the engine to con-
tinue runing after the ignition key has been turned off. Contact your Isuzu Dealer if you
encounter a "run-on" condition.
The oil and filter change intervals for your engine are based on the use of recommended oils and high-quality
filters. Using oils other than those recommended oil or oil change intervals longer than recommended, could
reduce engine life and might affect your warranty.
Your engine was filled with a high-quality engine oil when it was built. You do not have to change this oil before
the suggested change period.
Change the oil and oil filter,every 2500 miles (4000 kilometers) or evry 3 months if you often drive under one or
more of these "Severe Service" conditions:
• Driving in dusty areas
• Towing a trailer
• Frequent idling or idling for long periods
• Frequent short trips (4 miles [6 kilometers] or less) in cold or freezing weather, where the engine does not
thoroughly warm up.
Change the oil and oil filter as soon as possible after driving in a dust storm.
When installing the oil filter:
1. Apply engine oil to the gasket.
2. Hand tighten until the gasket contacts the sealing face.
3. Using a filter wrench, tighten filter 1/2 turn.
4. Run the engine and check to see that no leakage is visible.
All specifications, time intervals and torque requirements pertain exclusively to Isuzu replacement
parts. Change the oil filter with every oil change.
IMPORTANT: Improperly installed oil filters can result in engine damage.

OIL VISCOSITY
 GENERAL INFORMATION 0 0 - 1 7

Engine oil viscosity (thickness) has an effect on fuel economy. Lower viscosity engine oils can provide better
fuel economy; however, higher temperature weather conditions require higher viscosity engine oils for satisfac-
tory lubrication.
Using SAE 10W-40 oil, or any other viscosity other than those viscosities recommended may reduce
engine life and affect your warranty.
The chart lists the engine oil viscosities that will provide the best balance of fuel economy, engine life, and oil
economy.

OIL LEVEL CHECK

The proper method of checking the oil level is given under the "Engine Oil and Filter Recommendations (Gasoline
Engine)" in this section.
ENGINE OIL ADDITIVES
Do not use any supplemental additives. Using oil additives may cause engine damage and could affect your
warranty. If you think your engine has an oil-related problem, see your Isuzu Dealer.

AIR CLEANER ELEMENT

The proper method of handling and maintaining the element is given under the "Engine Oil and Filter Recommen-
dations (Gasoline Engine)" in this section.

ENGINE COOLING SYSTEM

The coolant system is designed to maintain the engine at the proper operating temperatures. The cooling
system was filled at the factory with a quality coolant. The coolant system is designed to use coolant (a mixture
of water and ethylene glycol antifreeze) rather than plain water. The coolant solution should be used year-
round. It has many advantages, such as:
• provides freezing protection as low as -36°C (-33°F)
• protects against rust and corrosion in the cooling system
• maintains the proper engine temperature for efficient operation and emission control, and
• allows proper operation of the coolant temperature gauge.
See the Maintenance Schedule to find out when the coolant must be replaced.

Cooling system care

Check the coolant level at the interval shown in the Maintenance Schedule List unless there is evidence of leaking
or overheating. DO NOT REMOVE RADIATOR CAP WHEN SOLUTION IS HOT AND UNDER PRESSURE.
The coolant level should be between the maximum and the minimum level marks on the radiator reserve
tank. When replenishing the coolant, fill the coolant up to the maximum level mark of the radiator reserve tank.
Add a 50/50 mixture of good quality ethylene glycol antifreeze and water if coolant additions are necess-
ary. DO NOT OVERFILL. If frequent additions are needed, see your Isuzu Dealer for a cooling system check.
IMPORTANT: If the proper quality antifreeze is used, there is no need to add extra inhibitors or additives that
claim to improve the system. They may be harmful to the proper operation of the system.

Cooling system service

The cooling system should be serviced at the intervals specified in the Maintenance Schedule List as follows:
1. Wash the radiator cap and filler neck with clean water. See Step 1 of the "Coolant Replacement" to
remove radiator cap.
2. Check the coolant level in the radiator and have it tested for freeze protection. Add ethylene glycol anti-
freeze, if needed, to maintain freeze protection at -36°C (-33°F).
3. Have the cooling system and radiator cap tested for a pressure capacity of 1 5 psi (103kPa). If a replace-
ment cap is needed, use a cap specified for your vehicle model.
4. Tighten all radiator and heater hose clamps and inspect all hoses. Replace the hoses if they are swollen,
"cracked," or otherwise worn.
IMPORTANT: Take care when tightening the hose clamps at the radiator. Overtightening could bend or col-
lapse the radiator fittings.
5. Clean the front of the radiator core and air conditioning condenser for the removal of dirt and other objects.
0 0 - 1 8 GENERAL INFORMATION

Coolant replacement
At the intervals specified in the Maintenance Schedule List, flush and refill the cooling system as follows:
1. Remove the radiator cap only when the engine is cool:
• Turn the cap slowly to the left until it reaches a "stop." (Do not press down while turning the cap.)
• Wait until any remaining pressure (indicated by a hissing sound) is relieved, then press down on the cap and
continue to turn it to the left.
CAUTION: To help avoid the danger of being burned, do not remove the radiator cap while the engine and
radiator are still hot. Scalding fluid and steam can be blown out under pressure if the cap is taken
off too soon.
2. When the cap is removed, run the engine until the upper radiator hose is hot (this shows that the thermostat
is open and the coolant is flowing through the system).
3. Stop the engine and open the radiator drain valve to drain the coolant. (Drainage may be speeded up by
removing the drain plugs in the engine block.)
4. Close the drain valve (install engine block drain plugs, if removed). Add water until the system is filled and
run the engine until the upper radiator hose is hot again.
5. Repeat steps three and four several times until the drained liquid is nearly colorless.
6. Drain the system and then close the radiator drain valve tightly. (Install engine block drain plugs, if
removed.)
7. Add enough water and ethylene glycol coolant to provide the required cooling, freezing, and corrosion pro-
tection. Use a solution that is at least 50 percent antifreeze, but no more than 60 percent antifreeze. Fill
the radiator and reserve tank to the proper level which is specified in the "Cooling System Care" in this sec-
tion.
8. Run the engine, with the radiator cap removed, until the upper radiator hose is hot.
9. With the engine idling, add coolant to the maximum level and install the radiator cap.

It is the owner's responsibility to:

Maintain the cooling system freeze protection at -36°C (-33°F) to ensure protection against corrosion and loss
of coolant from boiling. This should be done even if freezing temperatures are not expected.
Add ethylene glycol base antifreeze when antifreeze has to be added because of coolant loss or for more protec-
tion against freezing at temperatures lower than -36°C (-33°F).
Note: Do not use alcohol or methanol-base antifreeze, or plain water alone, in your vehicle at any time. They
will boil at a lower point than indicated by the temperature gauge and they do not provide proper protec-
tion against corrosion.

Thermostat
The engine coolant temperature is controlled by a thermostat. It stops coolant flow through the radiator until a
preset temperature is reached. This thermostat is installed in the engine coolant outlet on the engine
block. The same thermostat is used in both winter and summer.

FRONT AND REAR AXLE

See the Maintenance Schedule List to find out how often the lubricant should be change and level checked. Add
lubricant, if needed, by filling to the level of the filler plug hole. Use GL-5 gear lubricant of Viscosity as shown
be lows.

RECOMMENDED LUBRICANT

Viscosity Lubricant
Ambient Temperature
To Be Used
BELOW 10°C(50°F) SAE 80
-15°CTO30°C
SAE90
(0°T0 90°F)
ABOVE 10°C(50°F)
SAE140
CONSISTENTLY
 GENERAL INFORMATION 0 0 - 1 9

MANUAL TRANSMISSION & TRANSFER

Vehicles produced prior to August 31,1 985 were not equipped

with a transfer case filler plug. Oil is replenished through the oil
filler plug indicated by the arrow in the illustration.
CAUTION: Use only the filler plug shown in the illustration to
replenish the oil. Replenishing the oil from a
different location will result in an insufficient volume
of oil.

Vehicles produced prior to August 31,1 985 were not equipped

with a transfer case filler plug. Oil is replenished through the oil
filler plug indicated by the arrow in the illustration.
CAUTION: Use only the filler plug shown in the illustration to
replenish the oil. Replenishing the oil from a
different location will result in an insufficient volume
of oil.

See the Maintenance Schedule List to find out how often the lubricant level should be checked.

Add lubricant, if needed, to fill to the level of the filler plug hole. Use engine oil of the correct oil viscosity for
these temperatures as follows.

Viscosity Lubricant
Ambient Temperature
To Be Used
Areas where ambient
Temperatures of 32°C
SAE 40
(90°F) and higher
are regularly encounters
Other areas SAE5W-30SF

WATER DRAIN (DIESEL ENGINE)

Drain water from water separator attached to the fuel filter. See the Maintenance Schedule and water separator
instructions.

EXHAUST SYSTEM
Check the complete exhaust system and nearby body areas.
Look for damaged, missing, or mispositioned parts, open seams, holes, loose connections, or other deterioration
which could permit exhaust fumes to seep into the passenger compartment or cause a heat build up in floor
pan. Any necessary corrections should be made immediately. To help continue integrity, exhaust system
pipes and resonators rearward of the muffler must be replaced whenever a new muffler is installed.

FUEL LINES AND FUEL TANK/CAP

Inspect the fuel tank, cap and lines for damage which could cause leakage. Inspect fuel cap and gasket for cor-
rect sealing ability and indications of physical damage. Replace any damaged or malfunctioning parts.

DRIVE BELT
Check belts driving generator, power steering oil pump (if equipped) and air conditioning compressor (if equip-
ped) for cracks, fraying, wear and tension. Adjust or replace as necessary.
0 0 - 2 0 GENERAL INFORMATION

ENGINE IDLE SPEED

Adjustments must be made with test equipment known to be accurate. For engine idle speed adjustments,
follow the specifications shown on the label under the hood.

FUEL LINE FILTER

Replace filter at the interval in The Maintenance Schedule.

VALVE CLEARANCE
Incorrect valve clearance will result in increased engine noise and lower engine output thereby adversely affect-
ing engine performance. Retorque rocker shaft bracket nuts before checking and adjusting valve clearance.

AIR CLEANER ELEMENT

Replace the engine air cleaner element at the interval shown in the Maintenance Schedule. Operation of vehicle in
dusty areas will necessitate more frequent element replacement. Your dealer can be of assistance in determining
the proper replacement frequency for the conditions under which you operate your vehicle.
NOTE: Do not operate the engine without the air cleaner unless temporary removal is necessary during repair or
maintenance of the vehicle.

CARBURETOR CHOKE
Check choke valve operation. Any binding condition which may have developed due to petroleum gum forma-
tion on the choke shaft should be cleaned.

CARBURETOR CHOKE HOSE CHECK

Check choke hoses for proper connections, cracking, abrasion or deterioration to ensure proper operation of
choke mechanism and correct or replace as necessary.

DISTRIBUTOR ADVANCE MECHANISM, CAP AND ROTOR

Check and lubricate distributor advance mechanism, and carefully inspect and clean distributor cap and rotor.

IGNITION TIMING ADJUSTMENT

Check and adjust ignition timing.

THERMOSTATICALLY CONTROLLED AIR CLEANER (TCA)

Check valve and idle compensator for proper operation.

THERMOSTATICALLY CONTROLLED AIR CLEANER HOSE

Check The air cleaner hoses for loose connection and deterioration. Replace deteriorated hose.

SPARK PLUG
Replace plugs with type specified in this Manual.

IGNITION WIRES
Clean exterior of wires and remove any evidence of corrosion on terminals. Inspect spark plug and ignition coil
wires for evidence of checking, burning, or cracking of exterior insulation and tight fit at distributor cap, coil and
spark plugs. If corrosion cannot be removed, or other conditions above are noted, replace wire.

AIR INJECTION REACTOR SYSTEM HOSES AND CONNECTIONS

Check the system hoses and fittings for loose connections and deterioration. Deteriorated hoses must be rep-
laced.

EGR SYSTEM HOSES AND CONNECTIONS

Check the system hoses and fittings for loose connections and deterioration. Deteriorated hoses must be rep-
laced.
 GENERAL INFORMATION 0 0 - 2 1

PCV VALVE AND HOSES

Clean the PCV valve and hose with compressed air. Deteriorated hose must be replaced.

DISTRIBUTOR VACUUM ADVANCE HOSE

Check the distributor vacuum advancer hose for loose connection and deterioration. Replace deteriorated hose.

MASTER BRAKE CYLINDER

Check master cylinder fluid level in the reservoir at the interval shown in the Maintenance Schedule List. If the
fluid is low in the reservoir, it should be filled to the maximum level line with DOT-3 fluids.

CLUTCH
Check clutch for free play at pedal. Lubricate the clutch pedal bushing, clevis pin and clutch control cable ends at
the intervals shown in the Maintenance Schedule List with water resistant EP chassis lubricant. If a squeaking
noise arises from around the bushing, clevis pin or cable end at the clutch pedal arm when the clutch pedal is
depressed, lubricate with water resistant EP Chassis Grease.

WHEEL BEARINGS
Clean and repack the wheel bearings at the interval shown in the Maintenance Schedule. Due to the weight of
the tire and wheel assembly it is recommended that they be removed from the hub before lubricating the bear-
ings to prevent damage to the oil seal. Remove the wheel hub to lubricate the bearings.
IMPORTANT: "Long Fiber" type greases should not be used on roller bearing wheels or damage to the wheel
bearing can occur. Do not mix wheel bearing lubricants. Be sure to thoroughly clean bearings
and hubs of all oil lubricant before replacing.

SUSPENSION AND STEERING LINKAGE

Lubricate fittings at the interval shown in the Maintenance Schedule with water resistant EP Chassis Lubricant.
Also check rear suspension U-bolt for proper torque of 49-59 Nm (36 - 43 ft. lbs). Shackle bolt - 98Nm (72 ft.
lbs)
IMPORTANT: Ball joints should not be lubricated unless their temperature is -1 2°C (10°F), or higher. During
cold weather, they should be allowed to warm up as necessary before being lubricated or
damage to the ball joint could occur.

ACCELERATOR LINKAGE
Lubricate the accelerator pedal fulcrum pin through the hole in the bracket attached to the fire wall with engine oil
at the interval shown in the Maintenance Schedule.

DOORS AND ENGINE HOOD (INCLUDING TAILGATE)

Lubricate the latches and hinges according to the Maintenance Schedule List
1. Wipe off any accumulation of dirt or contamination on latch parts.
2. Apply multipurpose type grease NLGI No. 1 or 2.
3. Apply light engine oil to all pivot points in the release mechanism.
4. Lubricate the hinges with multipurpose type grease NLGI No. 1 or 2.
5. Check the hinge and latch mechanism to assure the assembly is working correctly.

AIR CONDITIONING
Periodically, have your Isuzu Dealer check your air conditioning system to be sure there has been no loss in cool-
ing output. See your Isuzu Dealer if you suspect that the system is not performing as it should.
0 0 - 2 2 GENERAL INFORMATION

BODY LUBRICATION
Normal use of a vehicle causes metal-to-metal movement at certain points in the cab or body. Noise, wear and
improper operation at these points will result when a protective film of lubricant is not provided.
For exposed surfaces, such as door checks, door lock bolts, lock striker plates, dovetail bumper wedges, etc.,
apply a thin film of light engine oil.
Where oil holes are provided in body parts a dripless oil can be safely used, but any lubricant should be used
sparingly. After application all excess lubricant should be carefully wiped off.
The seat adjusters and seat track should be lubricated with water resistant EP Chassis Lubricant.
There are other points on bodies which may occasionally require lubrication. Window regulators and controls
are confined in the space between the upholstery and the outside door panel. Easy access to the working parts
may be made by removing the trim. Door weatherstrips and rubber hood bumpers should be lightly coated with
a rubber lubricant

FRONT AND REAR PROPELLER SHAFT

Lubricate sliding yoke with EP Chassis Grease. Lubricate universal joints with grease containing M0S2 (disulfide
molybdenum type grease) at the interval shown in the Maintenance Schedule. Also check propeller shaft flange-to-pinion
bolts for proper torque of 30-34 Nm (22-25 ft. lbs.).
IMPORTANT: Most lubrication recommendations and procedures for four wheel drive-equipped vehicles are
the same for corresponding components of conventional drive vehicles.

AUTOMATIC LOCKING HUB

Clean and lubricate the free wheeling hubs at the same time the front wheel bearings are serviced as outlined in
the Maintenance Schedule. Use wheel bearing lubricant.
 GENERAL INFORMATION 0 0 - 2 3

RECOMMENDED FLUIDS & LUBRICANTS

USAGE FLUID/LUBRICANT

Engine SE or SF Engine oil (See oil chart in MAINTENANCE

AND LUBRICATION of this section for proper
viscosity.)
Transmission Engine oil (See oil chart in MAINTENANCE AND
LUBRICATION of this section for proper viscosity.)
Differential GL-5 gear lubricant (See oil chart in MAINTENANCE
AND LUBRICATION of this section for proper
viscosity.)
Power steering DEXRON Automatic transmission fluid
Brake system and master cylinder DOT-3 hydraulic brake fluid.
Clutch system Engine oil.
a. Pivot points Chassis grease.
b. Clutch fork joint
Hood latch assembly Engine oil.
a. Pivots and spring anchor Chassis grease.
b. Release pawl
Hood and door hinges Engine oil.
Chassis lubrication Chassis grease.
Parking brake cables Chassis grease.
Front wheel bearings Wheel bearing grease.
Front propeller shaft
a. Sliding yoke Chassis grease
b. Universal joint M0S2 contained grease or Multipurpose type grease NLGI No.2
Rear propeller shaft
a. Universal joint MoS2 contained grease or Multipurpose type grease NLGI No.2
Body door hinge pins and linkage, fuel Engine oil.
door hinge, rear compartment lid
hinges, heater water valve.
Windshield washer solvent Washer fluid.
Engine coolant Mixture of water and a high quality
Ethylene Glycol base type antifreeze.
0 0 - 2 4 GENERAL INFORMATION

LOCK CYLINDER KEY AND INFORMATION

Ignition and door locks on the KB82 are operated with the same key.
The key code number is stamped on the attached key ring and also on the ignition lock cylinder housing. The code num-
ber will be somewhere between C6001 and C7042.
The door lock cylinders are not marked with the key number.
When a lock cylinder is replaced, a new coded key will be provided.
There are one thousand key combinations between the code identification numbers C6001 and C7042.
Each key has four bitting depths. These bitting depths are identical on each side of the key, permitting insertion of the
key in either direction.
The lock cylinder tumbler bits are preset at the factory and can not be reset in the field.
All vehicles come with two keys, the second one to be used as a spare.
In the event both keys are lost, a new set of lock cylinders and keys may be required.
It the key number is known, replacement keys can be made.
 GENERAL INFORMATION 0 0 - 2 5

SERVICING
GASOLINE ENGINE

COOLING SYSTEM

The cooling water level should be between the maximum and the
minimum level marks on the radiator reserve tank.

The radiator cap is designed to hold 1.05 kg/cm2 (15 psi) of

pressure in the cooling system. The cap may be checked using
a radiator cap tester. Replacement of the cap is necessary
should it fail to hold pressure during the test procedure.
kg/cm2(psi)
Pressure valve Negative pressure valve

0.9 - 1.2 (13 - 17) 0.04 - 0.05 (0.6 - 0.7)

Install the radiator filler cap tester on the radiator and check the
cooling system for leakage by applying test pressure.
Test pressure should not exceed the specified pressure.
kg/cm2(psi)
Testing pressure 2 (28)

Flush the cooling system any time the fluid is replaced.

Be sure to remove all contaminants.

An adequate amount of anti-freeze should be added to the cool-

ing system depending on the lowest temperature anticipated.
Total cooling system capacity is 6.0 liters. (1.585 gal.s)
0 0 - 2 6 GENERAL INFORMATION

FAN BELT

Adjustment
Adjust the belt tension by moving the generator pulley and the
fan pulleys (A, B).
Specified belt deflection

Fan belt mm(in.) 10 (0.4)

AIR CLEANER

Visual check
Servicing is unnecessary until replacement interval is reached.

The air cleaner element should be replaced at specified intervals

or more often when the element is subjected to dusty or severe
driving conditions. The element should be replaced immediate-
ly if it is damaged or fouled.

ENGINE OIL

Check the oil level in the engine oil pan with the oil dipstick, and
replenish as necessary.
Liters (US quart)
with filter 4.2 (1.11)
Oil capacity
without filter 3.8 (1.00)

Check the engine oil for contamination. If engine oil has

deteriorated through contact with or gasoline, establish cause
and perform the necessary service.
The replace the engine oil at specified intervals.

OIL FILTER (CARTRIDGE)

Removal steps
1. Drain the engine oil by removing the drain plug on the oil pan.
 GENERAL INFORMATION 0 0 - 2 7

2. Remove the oil filter using a filter wrench.

Filter wrench : J-2270

Installation steps
1. Apply engine oil to the circumference of the oil filter O-ring.
2. Turn in oil filter element until the O-ring is seated against the
filter body. Further turn in the filter 1 turn using a filter
wrench.

The filter wrench should be fitted against the portion near the
bottom of the filter.

Torque mm(in.) 0.5 (36.17)

Remove the oil filter cap and pour in engine oil.

Start the engine and check for oil leakage from around the seal-
ing face.

CARBURETOR

Check carburetor float level

The fuel level is normal if it is within the marks on the window
glass of the float chamber when the engine is stationary. If the
fuel level is outside the lines, make the necessary adjustment by
bending the float seat. The needle valve should have an effec-
tive stroke of about 1.5 mm (0.059 in.)
To check the stroke, hold the carburetor with the bottom side up
and fully raise the float. The needle valve stroke is normal when
a clearance of 1.5 mm (0.059 in.) is provided between the valve
stem (resting on bottom position) and the float seat. When
necessary, the needle valve stroke can be adjusted by bending
the float stopper.

NOTICE: Be careful not to bend the needle valve rod when

installing the float and baffle plate.
0 0 - 2 8 GENERAL INFORMATION

FUEL FILTER

Check the fuel filter connections for leakage and the fuel hoses
for cracks and fatigue, and replace if necessary.

DISTRIBUTOR

1. Distributor cap
Remove the distributor cap and check the following points.
Replace the parts as necessary.
1) Check center electrode (1) and side electrode (2) for cor-
rosion and burning.
2) Check rotor (3) for wear and burning.
3) Check the center carbon for wear and cracks.

2. Inspection of ignition unit

Disconnect the high-tension cable between the ignition coil
and the distributor at the distributor and hold the end of
cable about 6 mm away from the ground.
Engage the starter and check to see if a spark jumps across
the gap.
If there is no spark, check the following points: (If no trouble
is found through the checks, the distributor is at fault and
should be replaced.)
1 Check to see if the ignition coil is energized when the
key switch is ON.
2 Make a continuity test on the ignition coil.

IGNITION COIL

Ignition coil resistance

1. Disconnect the wiring and the ignition coil and high tension
cable at the connector.
2. Set a circuit tester to x1 H range and x1 K ( l f and measure
the resistance.
At 20°C Standard
Primary coil resistance ( C — E ) (ft) 1.130 - 1.529

Secondary coil resistance (C — D ) (Kft) 10.20 - 13.80

Insulation resistance ( C — Body ) (M ft) More than 10
 GENERAL INFORMATION 0 0 - 2 9

HIGH-TENSION CABLE

Check the high tension cables for broken insulation and the
terminals for corrosion or damage, and replace with new
ones if necessary.
Measure the resistance in the cables, and replace the cables
with new ones if the measurements deviate from the
specified value.

Resistance (Kft/m) 9.6 - 22.6

Coil to disributor (KH) 3.3 - 7.0

2. Replace the terminals if they fit loosely.

Note: The cables contain a synthetic conductor and
should not be stretched hard or kinked sharply.
Sticking a needle or pointed end of a probe into the
cable in the course of timing check will cause an
increase in the resistance at that point, causing
burning of the cable.

SPARK PLUG

1. Check the condition of the electrodes and insulators for

cracks and replace if faulty.
2. Check the electrodes for wear and replace if necessary.
3. Make a spark test using a spark tester and replace all parts
found to be defective.
4. Check the gasket for damage and replace if necessary.

5. Check the insulation resistance using an ohm-

meter. Replace the part if found to be defective.

6. Adjustment of the spark gap

mm(in.)
Spark gap 1 . 0 - 1 . 1 (0.039 - 0.043)

If fouling of the spark plugs is excessive, check the fuel and the
electrical systems for possible causes of trouble. If the fuel and
the electrical systems are normal, install spark plugs of a higher
heat range. If burning of the insulators and electrodes is con-
siderable, install spark plugs of a lower heat range.
0 0 - 3 0 GENERAL INFORMATION

FUEL TANK

Check the fuel tank for deformation, rusting, or fuel leakage and
correct or replace as necessary. To check for leakage, proceed
as follows:
Submerge the fuel tank in water with all the openings plug-
ged. Apply compressed air 0.1 kg/cm2 (1.4 psi) into the tank
from the evaporator pipe and lock for air bubbles.

NOTICE: A cracked or leaking tank should be replaced, not

welded.

FUEL PUMP

Inspection
1. Check the entire portion of fuel pump for cracking or
damage and replace the entire fuel pump assembly with a
new one if any abnormal condition is present.
2. Check the fuel pump gasket for deterioration in material or
cracking and replace with a new one if it is found to be leak-
ing.

CYLINDER HEAD BOLT

Apply engine oil to the threaded sections of the head bolts and
temporarily tighten them in the order indicated in the figure,
followed by tightening with predetermined torque.

kg-m(ft.lbs.)
First step 8.0 (57.8)
Torque
Final step 9.0 - 11.0 (65.1 - 79.5)
 GENERAL INFORMATION 0 0 - 3 1

VALVE CLEARANCE

Check the rocker arm bracket bolts for looseness and retighten
as necessary before adjusting the valve clearances.

Torque kg-m(ft.lbs.) 1.95 - 2.45 (14.1 - 17.8)

Turn the crankshaft one full turn in the normal direction and align
the notched line in the crankshaft pulley with the " 0 " mark on
the timing gear case cover, so that piston in either the No. 1 or
No. 4 cylinder is brought to top dead center on the compression
stroke.

Measurement should be taken at the clearance between the

rocker arm and the valve stem.
Turn the crankshaft one full turn and adjust the clearance of the
remaining valves.
mm(in.)
Cold 0.15 (0.006)
Intake valves
Hot 0.25 (0.010)

Cold 0.25 (0.010)

Exhaust valves
Hot 0.30 (0.012)
0 0 - 3 2 GENERAL INFORMATION

COMPRESSION TEST

Preparation
1. Set the engine tachometer after warming up the engine
thoroughly.
2. Stop the engine. Disconnect the fuel hose between the
pressure regulator and the fuel distributor pipe to reduce the
fuel pressure. Remove the main relay connector.
3. Remove all spark plugs.
4. Engage the starter and check that the cranking speed is
approximately 300 rpm.
* Replace the battery if the cranking speed does not reach
300 rpm.

Measurement
1. With the throttle valve opened fully, keep the starter
engaged until the compression gauge needle reaches the
maximum level and then take the reading of the gauge.
2. Repeat the test on each cylinder.

kg/cm2 (psi)
Standard value Limit
Compression pressure
Higher than
(At cranking speed of 8.4 (119.5)
12.0 (170.6)
approximately 300 rpm)

Variance in compression
0.6 (8.53)
pressure in cylinders

If the compression pressures obtained were lower than the

limit engine overhaul is necessary.
 GENERAL INFORMATION 0 0 - 3 3

IGNITION TIMING
Preparation
1. After the engine has thoroughly warmed up, check that the
idling speed is correct.
2. Set the engine tachometer and timing light.
3. Shut off the air conditioning system.

Adjustment
1. Loosen the nut (A) holding the distributor and start the
engine.

2. While aligning the notched line on the crankshaft pulley with

the timing light adjust the ignition timing by turning the dis-
tributor clockwise or counter-clockwise as required.
3. Check that the ignition timing is within the specified range.

6/800 (Federal)
Specified value (BTDC°/rpm)
6/900 (California)

4. After adjustment tighten nut (A) holding the distributor.

0 0 - 3 4 GENERAL INFORMATION

IDLE ADJUSTMENT
1. Set the parking brake and block the drive wheels.
2. Place the transmission in neutral.
3. The following conditions are essential for idle speed adjust-
ment:
The engine should be running at a normal temperature.
The choke should be open.
The air conditioning system should be off.
The air cleaner should be installed on the engine.
The distributor line, the canister plug line, and the EGR
vacuum line should all be disconnected and plugged.
The idle compensator vacuum line should be closed. This
can be done by bending the attached rubber hose.
4. Adjust throttle adjust screw to 900 ± 5 0 rpm (California) or
8 0 0 ± 5 0 rpm (Federal).
5. Additional procedures if the vehicle has an conditioner.

• Turn A.C. to Max. Cold and High blower.

• Open the throttle to approx. 1 /3 and allow the throttle to

close. (This allows the speed up solenoid to reach full
travel.)

• Adjust the speed up controller adjusting screw to set idle

at 9 0 0 ± 5 0 rpm.

IDLE MIXTURE ADJUSTMENT

Federal
1. Set the parking brake and block the drive wheels.
2. Place the transmission in neutral.

3. Remove the carburetor assembly.

4. Drill a hole in seal plug and remove plug with proper tool.
After drilling, be sure to remove shavings with compressed
air.

5. Re-install the carburetor assembly.

6. Make idle speed adjustment with engine at normal operating
temperature, choke open, air conditioner off if installed, and
distributor vacuum line, canister purge line and EGR vacuum
line disconnected and plugged, and idle compensator
vacuum line closed by bending rubber hose.
7. Turn the idle mixture adjust screw all the way in and then
back out 3 turns.
 GENERAL INFORMATION 0 0 - 3 5

8. Adjust the throttle adjust screw to 800 rpm.

9. Adjust the setting of the idle mixture adjust screw to achieve
the maximum speed.
10. Reset throttle adjust screw to 850 rpm.
11. Turn idle mixture adjust screw clockwise (lean) until the
engine speed is down to 800 ± 5 0 rpm.
12. Reset idle mixture adjust screw 1/4 turn counterclockwise
(rich) from item position.
13. Reset throttle adjust screw to 800 rpm.
14. Replace the idle mixture screw plug.

• Additional procedures if the vehicle has an air-conditioner

are listed under "IDLE ADJUSTMENT".

California
1. Follow the steps 1 to 5 under "IDLE MIXTURE ADJUST-
MENT" (Federal model).
2. The following conditions are essential for idle speed adjust-
ment:
The engine should be running at a normal temperature.
The choke should be open.
The air conditioning system should be off.
The air cleaner should be installed on the engine.
The distributor line, the canister plug line, and the EGR
vacuum line should all be disconnected and plugged.
The idle compensator vacuum line should be closed. This
can be done by bending the attached rubber hose.
3. Turn the idle mixture adjust screw all the way in and back
out 1-1/2 turns.
4. Adjust the throttle adjust screw to 900 ± 5 0 rpm.
5. After confirming dwell or duty to vary, adjust setting of idle
mixture adjustment screw to obtain an average dwell or duty
as specified.

Dwell meter
Duty meter
(4-cyl. scale)

Average 36° 40%

The dwell or duty reading specified is the average of the

most constant vibration.
6. Reset throttle adjust screw to 900 ± 5 0 rpm.
7. Replace the idle mixture screw plug.
0 0 - 3 6 GENERAL INFORMATION

DIESEL ENGINE (C223T)

COOLING SYSTEM

Coolant level should be in between the maximum and the

minimum level marks on the radiator reserve tank.

The radiator filler cap is designed to maintain the pressure of

coolant in the system at 1.05 kg/cm 2 (15 psi). The filler cap
may be checked using a radiator cap tester. Replacement of
cap is necessary should it fail to hold pressure during test pro-
cedure.
kg/cm2(psi)
Pressure valve Negative pressure valve

0.9 - 1.2 0.04 -- 0.05

(13 - 17) (0.6 -- 0.7)

Install radiator filler cap tester on the radiator and check the cool-
ing system for leakage by applying testing pressure.
Testing pressure should not exceed the specified pressure.
kg/cnrr(psi)
Testing pressure 2(28)

The cooling system should be flushed if coolant becomes con-

taminated or at time of replacement. Clean water should be
used to flush system until all contaminants are removed.

An adequate amount of anti-freeze should be added to the cool-

ing system according to lowest temperature antici-
pated. Cooling system must be drained and flushed every 1 2
months or 1 5,000 miles; refill with new coolant solution. Total
cooling system capacity is 10.6 liters (2.80 gal.) including heater.
 GENERAL INFORMATION 0 0 - 3 7

FAN CLUTCH WITH COOLING FAN

Visually inspect for damage, leak (silicone grease) or other

abnormal conditions.

V-BELT

Check belts for fraying and damage and replace as necessary.

Adjustment
The tension of the fan belt can be adjusted by pivoting the
generator.

Adjustment (If so equipped)

To adjust compressor drive belts:
1. Move idler as necessary.
2. On models with power-steering, move the oil pump as
necessary.

To adjust tension of the power-steering drive belts, move the oil

pump.
On models with air conditioner and power-steering, both of the
belts should be replaced at the same time when belt replacement
becomes necessary.
0 0 - 3 8 GENERAL INFORMATION

TURBOCHARGER

1. Disconnect boost hose at injection pump side.

2. Install boost pressure gauge.
3. Take measurement with specified engine speed.

Boost pressure 280 mmHg or more/4,000 rpm

Check boost hoses for loose connection or leakage.

Check turbocharger mounting for leakage or looseness connec-

tions.

Check oil line for leakage restriction or damage.

 GENERAL INFORMATION 0 0 - 3 9

SERVICE NETWORK (AiResearch)

For inquiries relating to turbochargers, please contact Isuzu distributor or Garrett AiResearch turbocharger ser-
vice network established throughout the below.

UNITED STATES

ALABAMA Alabama Diesel Co. H. G. Makelim Co.

3328 Sixth Avenue So. 219 Shaw Road
Birmingham, Alabama 35222 P. O. Box 2827
TELEPHONE: (205) 324-4406 So. San Francisco, California
94083-2827
TELEPHONE: (415) 873-1310
Alabama Diesel Co.
3341 Old Selma Road H. G. Makelim Co.
Montgomery, Alabama 36108 2504 Ventura
TELEPHONE: (205) 262-6624 Fresno, California 93721
TELEPHONE: (209) 485-3000
Gerhardt's Inc. TurboMaster, Inc.
819 Central Avenue 14908 Gwen Chris Court
Jefferson, Lousiana 70121 Paramount, California 90723
TELEPHONE: (504) 733-2500 TELEPHONE: (213) 634-4202

ALASKA Hatch and Kirk COLORADO Central Motive Power Inc.

5111 Leary Avenue N.W. 6301 No. Broadway
Seattle, Washington 98107 Denver, Colorado 80217
TELEPHONE: (206) 783-2766 TELEPHONE: (303) 428-3611
CONNECTICUT
ARIZONA Turbo and Electric Sales and
C. A. Krohne & Sons Inc.
Service
500 West Columbus Avenue
2408 Grand Avenue
Springfield, Massachusetts 01105
Phoenix, Arizona 85009
TELEPHONE: (602) 253-6817 TELEPHONE: (413) 781-5824
DELAWARE Virginia Diesel Service
ARKANSAS J & H Turbo Service Inc. 1120 Bruce Street
1313 No. Hills Boulevard Richmond, Virginia 23224
Little Rock, Arkansas 72114 TELEPHONE: (804) 232-8988
TELEPHONE: (501) 758-1304
FLORIDA Diesel Air Systems, Inc.
CALIFORNIA Coast Fuel Injection Inc. 4710 Edison Avenue
1590 Industrial Avenue Jacksonville, Florida 32205
San Jose, California 95112 TELEPHONE: (904) 387-4112
TELEPHONE: (408) 287-7600
Interstate Dieselect Inc.
Coast Fuel Injection Inc. 4220 No. Orange Blossom Trail
88 Chamberlain Street Orlando, Florida 32804
Salinas, California 93901 TELEPHONE: (305) 293-7971
TELEPHONE: (408) 758-9459
GEORGIA Diesel Injection and Electric Co.
Diamond Diesel Service, Inc.
4767 Clark Howell Highway
2550 East 12th Street
College Park, Georgia 30349
Oakland, California 94601
TELEPHONE: (404) 768-8745
TELEPHONE: (415) 532-8500
HAWAII TurboMaster, Inc.
Diamond Diesel Service, Inc.
14908 Gwen Chris Court
2572 Industrial Boulevard
Paramount, California 90723
Sacramento, California 95691
TELEPHONE: (213) 634-4202
TELEPHONE: (916) 371-5223
0 0 - 4 0 GENERAL INFORMATION

UNITED S T A T E S (continued)

IDAHO Advanced Diesel and Supply LOUISIANA Gerhardt's Inc.

2929 E. Sprague 819 Central Avenue
Spokane, Washington 99202 Jefferson, Louisiana 70121
TELEPHONE: (509) 535-0336 TELEPHONE: (504) 733-2500
Fuel Injection Service Co. J & H Turbo Service, Inc.
1666 Commerce Avenue Highway 82 East
Boise, Idaho 83705 P. O. Box 5278
TELEPHONE: (208) 336-8460 Greenville, Mississippi 38701
TELEPHONE: (601) 378-8711
ILLINOIS All Brake and Drive Unit Service,
Inc.
5551 West Ogden Avenue MAINE C. A. Krohne & Sons Inc.
Cicero, Illinois 60650 500 W. Columbus Avenue
TELEPHONE: (312) 235-4567 Springfield, Massachusetts 01105
TELEPHONE: (413) 781-5824
Area Diesel Service Inc.
North on University
Carlinville, Illinois 62626 MARYLAND Virginia Diesel Service
TELEPHONE: (217) 854-2641 1120 Bruce Street
Richmond, Virginia 23224
Industrial Fuel Injection and TELEPHONE: (804) 232-8988
Diesel Service
1660 So. Eastwood Drive
Woodstock, Illinois 60098 MASSACHUSETTS
TELEPHONE: (815) 338-6705 C. A. Krohne & Sons Inc.
500 W. Columbus Avenue
National Auto Supply Co. Springfield, Massachusetts 01105
1100 Martin Luther King Drive TELEPHONE: (413) 781-5824
East St. Louis, Illinois 62201
TELEPHONE: (618) 271-1285 MICHIGAN Diesel Injection Service, Inc.
430 - 54th St. S.W.
INDIANA Turbo and Diesel Injection Co. Grand Rapids, Michigan 49508
450 W. Troy Avenue TELEPHONE: (616) 531-1030
Indianapolis, Indiana 46225
TELEPHONE: (317) 738-5451 Fuel Systems, Inc.
12730 Robin Lane
IOWA Area Diesel Service, Inc. Brookfield, Wisconsin 53005
1909 N.E. 58th Street TELEPHONE: (414) 781-4353
Des Moines, Iowa 50313
TELEPHONE: (515) 265-6303 Michigan Turbo, Inc.
1501 Rensen Ave.
KANSAS Sam Brown Company Lansing, Michigan 48910
275 Southwest Boulevard TELEPHONE: (517) 394-4746
Kansas City, Kansas 66103
TELEPHONE: (913) 831-9770 Stateline Diesel Service
25162 U.S. 12 East
Kansas Turbo and Diesel Inc. Edwardsburg, Ml 4&112
5043 Merriam Drive TELEPHONE: (616) 663-8571
Shawnee Mission, Kansas 66203
MINNESOTA Diesel Components Inc.
TELEPHONE: (913) 432-2202
12050 Riverwood Circle
Thompson Diesel Inc. Bumsville, Minnesota 55337
3220 So. Hoover Road TELEPHONE: (612) 890-2885
Wichita, Kansas 67215
Diesel Service Company
TELEPHONE: (316) 942-7462
1253 Eagan Industrial Road
St. Paul, Minnesota 55121
KENTUCKY Diesel Injection Service Inc. TELEPHONE: (612) 454-5530
4710 Allmond Avenue
MISSISSIPPI J & H Turbo Service Inc.
P.O. Box 14502
2626 So. Gallatin
Louisville, Kentucky 40214
Jackson, Mississippi 39204
TELEPHONE: (502) 361-1181
TELEPHONE: (601) 353-1030
 GENERAL INFORMATION 00-41

UNITED S T A T E S (continued)

J & H Turbo Service Inc. NEW MEXICO Central Motive Power Inc.
P. O. Box 5278 3740 Princeton Drive, N.E.
Greenville, Mississippi 38701 Albuquerque, New Mexico 87107
TELEPHONE: (601) 378-8711 TELEPHONE: (505) 884-2525
NEW YORK D & D Rebuilding Services
MISSOURI Area Diesel Service, Inc. 618 18th Avenue
North on University New Brighton, Pennsylvania 15066
Carlinville, Illinois 62606 TELEPHONE: (412) 846-1290
TELEPHONE: (217) 854-2641
LaBan Equipment Corporation
Sam Brown Company 627 W. Merrick Road
275 Southwest Boulevard Valley Stream, New York 11580
Kansas City, Kansas 66103 TELEPHONE: (516) 561-2203
TELEPHONE: (913) 831-9770
Kansas Turbo and Diesel Inc. NORTH Diesel Sales and Service Co.
5043 Merriam Drive CAROLINA 928 Main Street
Shawnee Mission, Kansas 66203 Nashville, Tennessee 37206
TELEPHONE: (913) 432-2202 TELEPHONE: (615) 227-2242
National Auto Supply TurboAir, Inc.
1100 Martin Luther King Drive 1920J Starita
East St. Louis, Illinois 62201 Charlotte, North Carolina 28206
TELEPHONE: (618) 271-1285 TELEPHONE: (704) 597-0022

MONTANA Advanced Diesel and Supply The Turbo Center

2929 E. Sprague 6881 Bulldog Drive
Spokane, Washington 99202 Charleston, South Carolina 29405
TELEPHONE: (509) 535-0336 TELEPHONE: (803) 797-7321

Crown Parts Virginia Diesel Service

1733 Highway 87 East 1666 Commerce Avenue
Billings, Montana 59101 Richmond, Virginia 23224
TELEPHONE: (406) 252-6682 TELEPHONE: (804) 232-8988

NEBRASKA Central Motive Power Inc. NORTH Diesel Components Inc.

6301 No. Broadway DAKOTA 12050 Riverwood Circle
Denver, Colorado 80217 Bumsville, Minnesota 55337
TELEPHONE: (303) 428-3611 TELEPHONE: (612) 890-2885
Diesel Service Company
NEVADA Sierra Diesel Injection 1253 Eagan Industrial Road
2525 Mill Street St. Paul, Minnesota 55121
Reno, Nevada 85902 TELEPHONE: (612) 454-5530
TELEPHONE: (702) 329-4232
TurboMaster Inc. OHIO Columbus Diesel Supply Co. Inc.
14908 Gwen Chris Court 1575 Integrity Drive East
Paramount, California 90723 Columbus, Ohio 43209
TELEPHONE: (213) 634-4202 TELEPHONE: (614) 445-8391

NEW C. A. Krohne & Sons, Inc. Diesel Injection Service

3032 Reading Road
HAMPSHIRE 500 W. Columbus Avenue
Cincinnati, Ohio 45206
Springfield, Massachusetts 01105
TELEPHONE: (413) 781-5824 TELEPHONE: (513) 281-5315

NEW JERSEY Fuel Injection Sales and Service OKLAHOMA Diesel Injection Service of Texas
Inc. 4816 E. 22nd
Rt. 8, Box 137 Amarillo, Texas 79102
Allentown, Pennsylvania 18104 TELEPHONE: (806) 634-0331
TELEPHONE: (215) 395-3718
Thompson Diesel Inc.
Laban Equipment 5700 S.W. Fifth Street
41 Lincoln Avenue P. O. Box 82068
Orange, New Jersey 07050 Oklahoma City, Oklahoma 73148
TELEPHONE: (201) 677-9800 TELEPHONE: (405) 943-8536
0 0 - 4 2 GENERAL INFORMATION

UNITED STATES (continued)

Thompson Diesel Inc. Diesel Sales and Service Co.

10738B E. 55th Place 2236 McCalla Avenue
Tulsa, Oklahoma 74145 Knoxville, Tennessee 37915
TELEPHONE: (918) 663-7666 TELEPHONE: (615) 546-7751
Turbo Specialists, Inc. J & H Turbo Service Inc.
8500 W. Reno 2821 Winchester
Oklahoma City, Oklahoma 73127 Memphis, Tennessee 38118
TELEPHONE: (405) 495-4002 TELEPHONE: (901) 794-8833
TEXAS Central Motive Power, Inc.
OREGON Western Turbo and Fuel Injection 3740 Princeton Drive, N.E.
Inc. Albuquerque, New Mexico 87103
2630 No. Columbia Boulevard TELEPHONE: (901) 794-8833
Portland, Oregon 97217
TELEPHONE: (503) 285-7781 Diesel Injection Service of Texas
Inc.
2850 Stevens Road
PENNYSYLVANIA Odessa, Texas 79762
D & D Rebuilding Services TELEPHONE: (915) 367-8638
618 18th Avenue
New Brighton, Pennsylvania 15066 Diesel Injection Service of Texas
TELEPHONE: (412) 846-1290 Inc.
1001 Slaton Highway
Fuel Injection Sales and Service Lubbock, Texas 79408
Inc. TELEPHONE: (806) 745-4122
Rt. 8, Box 137
Allentown, Pennsylvania 18104 Diesel Injection Service of Texas
TELEPHONE: (215) 395-3718 Inc.
3508 Doug Drive
Dallas, Texas 75247
RHODE C. A. Krohne & Sons Inc. TELEPHONE: (214) 634-0331
ISLAND 500 West Columbus Avenue
Springfield, Massachusetts 01105 Diesel Injection Service of Texas
TELEPHONE: (413) 781-5724 Inc.
4816 E. 22nd
SOUTH The Turbo Center Amarillo, Texas 79102
CAROLINA 6881 Bulldog Drive TELEPHONE: (806) 374-3754
Charleston, South Carolina 29405
TELEPHONE: (803) 797-7321 Doug's Fuel Injection Service
and Sales, Inc.
Route One, Box 541-Z
SOUTH Diesel Components, Inc. Weslaco, Texas 78596
DAKOTA 12050 Riverwood Circle TELEPHONE: (512) 968-5506
Bumsville, Minnesota 55337
TELEPHONE: (612) 890-2885 Gerhardt's Inc.
5601 Braxton Drive
Diesel Service Company Houston, Texas 77036
1253 Eagan Industrial Road TELEPHONE: (713) 789-8860
St. Paul, Minnesota 55121
TELEPHONE: (612) 454-5530 M & D Distributors
1002 Paulsun Drive
TENNESSEE Diesel Sales and Service Co. San Antonio, Texas 78219
P. O. Box 60393 TELEPHONE: (512) 225-7616
Nashville, Tennessee 37206 Magneto & Diesel Injector
TELEPHONE: (615) 227-2242 Service Inc.
Diesel Sales and Service Co. 6931 Navigation Boulevard
103 Jubilee Drive Houston, Texas 77011
Chattanooga, Tennessee 37421 TELEPHONE: (713) 928-5686
TELEPHONE: (615) 894-4050 Turbo Specialists of Texas, Inc.
Diesel Sales and Service Co. 3420 Irving Boulevard,
419 W. Main Street Dallas, Texas 75247
Johnson City, Tennessee 37601 TELEPHONE: (214) 688-0805
TELEPHONE: (615) 928-1661
 GENERAL INFORMATION 00-43

UNITED S T A T E S (continued) CANADA

UTAH Fuel Injection Service Co.
1197 South 300 West ALBERTA G.C.L. Diesel Injection Service
Salt Lake City, Utah 84101 Ltd.
TELEPHONE: (801) 487-0881 15614- 112 Avenue
VERMONT C. A. Krohne & Sons Inc. Edmonton, Alberta
500 W. Columbus Avenue T5M 2W1
Springfield, Massachusetts 01105 TELEPHONE: (403) 453-6786
TELEPHONE: (413) 781-5824 Hutton's Limited
VIRGINIA Diesel Sales and Service 2530 21st Street, N.E.
928 Main Street Calgary, Alberta
Nashville, Tennessee 37206 T2E 7L3
TELEPHONE: (615) 227-2242 TELEPHONE: (403) 230-4261
Virginia Diesel Service United Diesel
1120 Bruce Street 4210 Calgary Trail
Richmond, Virginia 23224 Edmonton, Alberta
TELEPHONE: (804) 232-8988 T6H 4S4
TELEPHONE: (403) 434-8517
WASHINGTON United Diesel Injection
Advanced Diesel and Supply 11123 97th Avenue
2929 E. Sprague Grand Prairie, Alberta
Spokane, Washington 99202 T8V 3J6
TELEPHONE: (509) 535-0336 TELEPHONE: (403) 532-5587
Hatch and Kirk Union Tractor Ltd.
5111 Leary Avenue N.W. 926 46th Avenue S.E.
Seattle, Washington 98107 Calgary, Alberta
TELEPHONE: (206) 783-2766 T2G 2A6
TELEPHONE: (403) 243-3211
WEST D&D Rebuilding Services
VIRGINIA 618 18th Avenue Union Tractor Ltd.
New Brighton, West Virginia 15066 255 McDonald Crescent
TELEPHONE: (412) 856-1290 Ft. McMurray, Alberta
T9H 2A6
Virginia Diesel Service TELEPHONE: (403) 743-1459
1120 Bruce Street
Richmond, Virginia 23224 Union Tractor Ltd.
TELEPHONE: (804) 232-8988 Box 320
Grimshaw, Alberta
WISCONSIN Fuel Systems Inc. TOH 1WO
12730 Robin Lane TELEPHONE: (403) 332-4661
Brookfield, Wisconsin 53005
TELEPHONE: (414) 781-4353 Union Tractor Ltd.
A125 Scott Street
WYOMING Central Motive Power Inc. Hinton, Alberta
6301 No. Broadway TOE 1C0
Denver, Colorado 80217 TELEPHONE: (403) 865-3554
TELEPHONE: (303) 428-3611
Union Tractor Ltd.
Crown Parts 4766 62nd Street
1733 Highway 87 East Red Deer, Alberta
Billings, Montana 59101 T4N 2R5
TELEPHONE: (406) 252-6682 TELEPHONE: (403) 347-1157
Fuel Injection Service Co.
1197 South 300 West BRITISH Dynamic Engineering Inc.
Salt Lake City, Utah 84101 COLUMBIA 1270 Frances Street
TELEPHONE: (801) 487-0881 Vancouver, British Columbia
V6A 1Z5
TELEPHONE: (604) 253-4427
0 0 - 4 4 GENERAL INFORMATION

CANADA (continued)

Fraser Valley Turbochargers Garrett Manufacturing Limited *

#105-18935 96th Avenue, R.R. #4 (A Subsidiary of The Garrett Corp.)
Surrey, British Columbia (Master Distributor — Eastern)
V3T 4W2 255 Attwell Drive
TELEPHONE: (604) 888-3726 Rexdale, Ontario M9W 5B8
TELEPHONE: (416)675-1411
Union Tractor Ltd. TELEX: 06-989142
9359 Milwaukee Way 'Authorized Aircraft Products Distributor
V2L 4V6
TELEPHONE: (604) 562-3191 QUEBEC United Auto Parts
Heavy Duty Division
2105 Haig Avenue
MANITOBA Western Turbo and Fuel Injection Montreal, Quebec H1N 3E2
Ltd. TELEPHONE: (514) 254-4501
2040 Logan Avenue
Winnipeg, Manitoba SASKATCHEWAN
R2R OH9 Diesel Injection Service Regina
TELEPHONE: (204) 632-1366 (1976) Ltd.
2139 Eighth Avenue
Regina, Saskatchewan S4R 1G1
NEW Stairs Diesel Supply Ltd. TELEPHONE: (306) 527-4159
BRUNSWICK Post Office Box 335
Lower St. Mary's
Fredericton, New Brunswick
E3B 4X9
TELEPHONE: (506) 472-7851
Stairs Diesel Supply Ltd.
P. O. Box 203 PUERTO RICO
R.R. #6
Salisbury, New Brunswick
EOA 3EO
TELEPHONE: (506) 372-5007 Motors & Parts Distributors Inc.
652 Ponce de Leon Avenue
NEWFOUNDLAND Hato Rey 00918
Diesel Injection Sales and TELEPHONE: (809) 765-8600
Service TELEX: 325 2686 MOPADI PT
122 George Street
St. Johns, Newfoundland
A1C5M3
TELEPHONE: (709) 726-6774
NOVA SCOTIA Stairs Diesel Supply Ltd.
12 Waddell Avenue
Dartmouth, Nova Scotia
B3B 1K3
TELEPHONE: (902) 469-0098
ONTARIO R. Brammall Sales Limited
307 Lesmill Road
Don Mills, Ontario M3B 2V1
TELEPHONE: (416) 449-5671
Cadel Specialized Products
A Division of UAP
240A Bridgeland Avenue
Toronto, Ontario M6A 1Z4
TELEPHONE: (416) 781-9351
 GENERAL INFORMATION 0 0 - 4 5

ENGINE OIL AND FILTER

Check oil level in engine oil pan with oil dipstick, replenish as
necessary. Oil level should be maintained at a level not less
than one quart below full.
Oil capacity is approx. 6 liters (1,59 gal.) with oil filter.
Check engine oil for contamination.
If engine oil has deteriorated because of contact with water or
diesel fuel check to determine the cause and perform service
necessary.

Oil filter replacement

Removal steps
1. Drain engine oil by removing the drain plug on the oil pan.
2. Place a suitable size tray under the oil filter to receive oil
flowing out from the filter.
3. Remove the oil filter cartridge using filter wrench.
Filter wrench : J-29772

Installation steps
1. Apply a thin coat of engine oil to the O-ring for new filter
cartridge.
2. Turn in filter cartridge until O-ring becomes seated on the
seal, and further turn filter cartridge 1/2 turns using filter
wrench.
Filter wrench: J-29772.
3. Install the drain plug.
4. Remove the oil filler cap and pour in engine oil.
Oil level should never go more than one quart below full.
5. Start the engine and check for oil leakage from around the
sealing face.

FUEL FILTER

Fuel filter (cartridge) replacement

Removal steps
1. Disconnect water separator sensor wiring at the connector.
2. Remove the filter cartridge using filter wrench.
Filter wrench: J-29772
When removing filter cartridge use care so as not to spill fuel
within the cartridge.
3. Drain cartridge using a suitable tray to catch fuel, then
remove the sensor from the filter cartridge.
0 0 - 4 6 GENERAL INFORMATION

Installation steps
1. Apply diesel fuel to the new sensor O-ring and install the
sensor on a new filter cartridge.
2. Apply diesel fuel to cartridge O-ring. Install and turn in filter
until sealing face is brought into contact with the 0-
ring. Further tighten 2/3 of a turn using filter wrench.

3. Connect the connector to the sensor.

4. Fill the filter cartridge with fuel by operating the priming
pump handle 30 to 40 times.
The force needed to operate the priming pump increases as
the filter becomes filled.
5. Start the engine and check for diesel fuel leakage from
around the sealing portions.

Water draining procedure from the water separater

Steps
1. Place a container (approx. 0.2 liters or 0.05 gal capacity) at
the end of the vinyl hose beneath the drain plug of the
separator.
2. Loosen the drain plug (approx. five turns)
3. Move the priming pump up and down about ten times until
the water is drained (approximately 0.2 US pints, 0.1 metric
liters).
4. Tighten the drain plug
5. Move the priming pump up and down several times.
6. After starting the engine, check to see that there are no fuel
leaks from the drain plug.
7. Also check to see that the "FILTER" indicator light remains
out.
 GENERAL INFORMATION 0 0 - 4 7

AIR CLEANER

Check air cleaner element for distortion and damage; check air
cleaner body for cracks, distortion or improper sealing. Correct
or replace as necessary.
Air cleaner element should be replaced at specified intervals and
more often when element is subject to dusty or severe condi-
tions.
The element should be replaced immediately if found to be
damaged or fouled.

CYLINDER HEAD

Tighten the cylinder head bolts in the sequence shown in the

figure.
Torque :
kg-m(ft lbs.)
(T) 1 st step (snug torque) 4.5 - 5.5 (33 - 40)

Tighten the cylinder head bolts to the specified angle in

sequence above.
Angle :
degree
(2) 2nd step 120-150

Apply bisulfide molybdenum grease to thread and contact sur-

face when reusing bolt. (See the illustration).
0 0 - 4 8 GENERAL INFORMATION

VELVE CLEARANCE ADJUSTMENT

Check the rocker arm shaft bracket bolts for looseness and
retighten as necessary before adjusting the valve clearances.
Rocker arm bracket bolt

Torque kg-m(ft lbs) 1.3 - 2.3 ( 9 - 1 7 )

Bring either the No. 1 or No. 4 piston to top dead center on com-
pression stroke by turning the crankshaft until timing mark on
crankshaft pulley aligns with pointer.

Adjust the valve clearances in the following manner using a

feeler gauge.
mm(in.)
Cold 0.40 (0.016)
Intake and exhaust
Hot 0.40 (0.016)

Adjust the clearances of the valves marked with " O " in step 1
(piston in No. 1 cylinder is at top dead center on compression
stroke). Turn the crankshaft one full turn to bring piston in No.
4 cylinder to top dead center on compression stroke (step 2) and
adjust the clearances of the valves marked with " © " .
 GENERAL INFORMATION 0 0 - 4 9

COMPRESSION TEST

1. Start and warm up the engine.

Engine coolant temperature; above 80°C (176°F)
2. Remove the following parts;
• Sensing resistor
• Glow plug connector
• Fuel cut solenoid connector
• Fusible link wire of Q.O.S (Quick on system) at the con-
nector
3. Install adaptor and compression gauge.
4. Take measurement by engaging starter motor.
kg/cm2(psi) at 200rpm
Standard Limit
31.0 (441) 28.0 (398)

If compression pressure is lower than the Limit a cylinder

leakage test should be performed to determine the cause.
Compression gauge with adaptor : J-29762

INJECTION PUMP (Fuel cutout solenoid)

Inspection
Check pipes and joints for fuel leakage.
When it becomes necessary to check fuel cutout solenoid valve,
proceed as follows.
Remove the fuel cutout solenoid valve from the pump and check
valve action, replace the valve if found to be defective.

FUEL TANK

Inspection
Check the fuel tank for abnormalities, rusting or fuel leakage and
correct or replace as necessary.
Water draining procedure from the fuel tank.
Proceed as follows if the fuel filter indicator light on the instru-
ment panel turns on.
Steps
1. Position an adequate tray under the drain plug on the fuel
tank.
2. Remove the drain plug and continue to drain until water is
removed.
3. Install the drain plug.
0 0 - 5 0 GENERAL INFORMATION

INJECTION TIMING

Inspection
Check that the notched line on the injection pump flange is in
alignment with the notched line on the injection pump front
bracket.

Bring the piston in No. 1 cylinder to top dead center on compres-

sion stroke by turning the crankshaft as necessary.

With the timing pulley housing cover removed, check that timing
belt is properly tensioned and that timing marks are aligned.

Disconnect the injection pipe from the injection pump and

remove the distributor head screw, then install static timing
gauge.
Set the lift approximately 1 mm (0.04 in.) from the plunger.
Static timing gauge: J-29763 or J-28827
Use a wrench to hold the delivery holder when loosening the
sleeve nuts on the injection pump side.
 GENERAL INFORMATION 0 0 - 5 1

Bring the piston in No. 1 cylinder to a point 45 — 60 degrees

before top dead center by turning the crankshaft then calibrate
the dial indicator to zero.
Turn the crankshaft pulley slightly in both directions and check
that gauge indication is stable.

Turn the crankshaft in normal direction of rotation , and take the

reading of the dial indicator when the timing mark (10 degrees)
on the crankshaft pulley is in alignment with the pointer.
mm(in.)
Standard reading 0.5 (0.020)

Adjustment

If the reading of the dial indicator deviates from the specified

range, hold crankshaft in position 10 degrees before top dead
center and loosen the two nuts on the injection pump flange.
Move the injection pump to a point where the dial indicator gives
a reading of 0.5 mm (0.020 in.), then tighten pump flange nuts.
0 0 - 5 2 GENERAL INFORMATION

INJECTION NOZZLE

Inspection
Check the spray condition and injection starting pressure.
kg/cm2(psi)(Bar)
Injection pressure: 1 3 0 - 1 4 0 (1849-1991)(128-138)

Injection nozzle should be cleaned or replaced if the spray pat-

tern is incorrect.
Refer to "Fuel System" in Section 02A for the nozzle cleaning.

Adjustment
Adjust the injection starting pressure with the adjusting screw
using a nozzle tester.
Nozzle tester : J-28829

IDLE SPEED

Inspection
Check the idle speed at specified intervals and adjust it if
necessary.

Adjustment
Steps
1. Set parking brake and block drive wheels.
2. Place transmission in neutral.
3. Start and warm up the engine.
Engine coolant temperature: above 80°C (1 76°F)
4. Set air conditioner off and air cleaner installed.
5. Set the engine tachometer.

Engine tachometer : J-28885

(rpm)
Idle speed 700 - 800

If the idle speed deviates from the specified range, loosen the
idle speed adjusting screw lock nut.
Turn the adjusting screw in or out until the idle speed is in the
correct range. After tightening the lock nut lock it in place.
 GENERAL INFORMATION 0 0 - 5 3

FAST IDLE ADJUSTMENT

Adjustment
Steps
1. Start and normalize the engine.
Engine coolant temperature : above 80°C
2. Set the engine tachometer.
Engine tachometer : J-28885

3. Disconnect the hoses ® and ® from the vacuum switch

valve, then connect a pipe (4 mm dia.) in position between
the hoses 0 and @.

4. Loosen lock nut ® and adjust engine idle speed by moving

the adjusting screw ®.
(rpm.)
Fast idle 900 - 950

5. Tighten the nut @.

6. Remove engine tachometer.
0 0 - 5 4 GENERAL INFORMATION

QUICK ON SYSTEM

If it is necessary to check Q.O.S. proceed as follows;

Inspection
1. Disconnect thermo switch connector on the thermostat out-
let line.

2. If the glow plug relay " 1 " makes a clicking noise within 5 to
9 seconds after the starter switch is turned on, it indicates
normal operation of the quick on system.
3. With the starter switch on, measure the glow plug terminal
voltage using a circuit tester.
5.0 — 9.0 Sec. (V)
Standard 8 - 9

BATTERY

Recharging
Because redundant an explosive gas mixture forms in each cell
during charging, the area should be well ventilated and the
following precautions observed:
1. Do not smoke or break a live circuit near the top of the bat-
tery as sparks could cause an explosion.
NOTICE: It is recommended that the battery ground cable from
battery charger be attached to a ground point other
than the negative pole of the battery. Also the nega-
tive cable should be disconnected before attaching or
removing the positive cable.
2. Exercise care when attaching charger positive lead to battery
to avoid contact with vehicle metal components which
would result in damage to the battery.
There are two separate methods of recharging batteries
which differ basically in the rate of charge.
 GENERAL INFORMATION 0 0 - 5 5

Slow charging method

Slow charging is the best and only method of completely
recharging a battery. This method, when properly applied, may
be used safely under all possible conditions of the battery, pro-
viding the battery electrolyte is at proper level and the battery is
capable of being fully charged. The normal charging rate is 5
amperes.
A fully charged battery is indicated when all cell specific gravities
do not increase when checked at three one hour intervals and all
cells are tutting freely.
Charge periods of 24 hours or more may be required because of
the low charging rate.
Quick charging method
In order to get an owner back on the road in the least amount of
time, it is sometimes necessary to quick charge his battery.
It can be substantially recharged or boosted but, in order to bring
it to a fully charged condition, the charging cycle must be
finished by charging at a low or normal rate. Some quick
chargers have a provision for finishing the charging cycle at a
low rate to bring the battery up to a fully charged condition.
NOTICE: Too high a current during quick charging will damage
battery plates.
To quick charge a battery, charge at 50 amperes for 20 minutes
(50 x 20 = 1,000 ampere minutes). If charger will not give this
rate, charge for an equal number of ampere minutes at the best
available rate.
Used with care and employing all safeguards provided by the
manufacturer, a quick charger will not damage a battery which is
in good condition.
0 0 - 5 6 GENERAL INFORMATION

ELECTRICAL

Electrical circuit

Voltage (Volt) 12

Ground Negative

Removal of the harness couplers

The connector plugs should always be disconnected using both
hands. Pulling the connector apart with one hand may cause
separation of the terminal from the wire.

Replacement of fuse
It is important to use a fuse of the specified amperage.
The use of fuses higher than the specified amperage can cause
burning of the wiring harnesses.

Inspection of the fusible link

The fusible link is inserted between the starter motor B terminal
and the starter switch B terminal.
It melts when excess current flows through the circuit to protect
the main power circuit against overloading. Test the circuit by
checking the continuity across the terminals using a circuit
tester.
 GENERAL INFORMATION 0 0 - 5 7

Aiming of headlights
1. A headlight should be aimed properly after removal or rep-
lacement of the sealed beam.
2. A headlight tester or aiming is necessary.

Rear wiper
Washer tank

TRANSMISSION

Vehicles produced prior to August 31,1 985 were not equipped

with a transfer case filler plug. Oil is replenished through the oil
filler plug indicated by the arrow in the illustration.
CAUTION: Use only the filler plug shown in the illustration to
replenish the oil. Replenishing the oil from a
different location will result in an insufficient volume
of oil.

Vehicles produced from September 1, 1 985 are equipped with a

transfer case filler plug. Use this filler plug (indicated by the
arrow in the illustration) to replenish the oil.
CAUTION: Use only the filler plug shown in the illustration to
replenish the oil. Replenishing the oil from a
different location will result in an insufficient volume
of oil.
0 0 - 5 8 GENERAL INFORMATION

CLUTCH

Pedal free play and height

mm(in.)
Pedal free
Type Height (H2)
play (H1)

Mechanical 20 (0.79) 231 - 2 4 1 (9.1 - 9 . 5 )

Pedal height adjustment

Adjust pedal height with pedal stopper bolt (California) or the
clutch switch (Federal).

FRONT SUSPENSION

Adjustment of front wheel alignment

1. Caster

Caster angle 30'

The caster angle can be adjusted with the caster shims installed
in position between the chassis frame and the fulcrum pins.
 GENERAL INFORMATION 0 0 - 5 9

Position of shims Caster angle

Front side Rear side
When added When removed Decreases
When removed When added Increases

2. Camber

Camber angle 35'

The camber angle can be adjusted with the camber shims

installed in position between the chassis frame and the fulcrum
pins.

Position of shims Camber angle

When added Decreases

When removed Increases

3. Toe-in

Limit mm(in.) 0 ± 2(0.08)

0 0 - 6 0 GENERAL INFORMATION

To adjust the toe-in angle, loosen the lock nut on the outer track
rod and turn the outer track rod.

Adjustment of vehicle height

Adjust the height of the vehicle by means of the adjusting bolt on
the height control arms.
1. Check and adjust the tire inflation pressures.
Front wheels: (when not loaded) - 1.8 kg/cm2
Rear Wheels: (when not loaded) - 2.6 kg/cm2
2. Park the vehicle on level ground and move the front of the
vehicle up and down several times to settle the suspension.
3. Loosen the nuts on the front end of the strut bar.
4. Make necessary adjustments with the adjusting bolts on the
height control arms.
Trim height

Z mm(in.) 131 (5.16)

5. Securely tighten the strut bar nuts

A mm(in.) 36 - 38 (1.42 - 1.50)

Hub bearing preload at the wheel pin

Preload kg (lbs.) 1.5 (3.31)

 GENERAL INFORMATION 0 0 - 6 1

Amount of hub grease required (reference)

g(oz)
Inner bearings 8 (0.28)
Outer bearings 4 (0.14)
Hubs 60 (2.12)

FRONT AXLE

Drive axle oil replacement

Oil capacity liter(us gal.) 1.0(0.26)

REAR AXLE

Rear axle oil replacement

Oil capacity literslus gal.) 1.5 (0.80)

Repacking of bearing grease

Required (reference)

Bearing holder g(oz) 80 (2.8)

0 0 - 6 2 GENERAL INFORMATION

TIRE & WHEELS

Tire inflation pressure

Tire size Inflation pressure

P225/75R-15kg/cmMpsi) 1.8(26)

Tire tread wear

Limit (A) mm(in.) 1.6 (0.06)

Measurement of wheel lateral run-out

Jack up the wheels clear of the ground and check for lateral run-
out. Check the wheel nuts for looseness and hub bearings for
play before checking the wheel run-out.

Limit mm(in.) 3.0 (0.12)

Tire rotation
Tire position on the vehicle determines the way in which the tire
tread wears. Rear tires tend to wear gradually and in an even
fashion as they are alternately subject to both traction and brak-
ing force. Tires on the front of the vehicle, on the other hand,
are subject to braking and turning forces and tend to wear more
rapidly and erratically.
Rotating your tires evens out tire wear and prolongs tire life. It
should be done periodically in the manner shown in the figure.
 GENERAL INFORMATION 0 0 - 6 3

Tighten wheel nuts in numerical order.

kgm(ft.lbs.)
Steel wheel 8-12(58 -87)

Almi wheel 11 - 1 3 (80 - 94)

BRAKE

Brake pedal adjustment

The push-rod serves as the brake pedal stopper when the pedal
is fully released. Brake pedal height adjustment should be per-
formed as follows.

1. Brake pedal — Height

Measure the brake pedal height after making sure the pedal has
been fully returned by the pedal return spring.

mm(in)
Pedal height (H) 198 - 208 (7.8 - 8.2)
Free play (H1) 6 -8(0.24-0.31)

If the measured value deviates from the above range, adjust the
brake pedal as follows.

a) Disconnect the stop lamp switch.

b) Loosen the lock nut on the push rod.
c) Adjust the brake pedal to the specified height rotating the
push rod in the appropriate direction.

Nut torque kg-m(ft.lbs.) 1.8 - 2.2 ( 1 3 - 1 6 )

d) Install the stop lamp switch.

Clearance
mm(in.)
Between the switch 0.5 - 1.0
housing and brake pedal (A) (0.02 - 0.04)
0 0 - 6 4 GENERAL INFORMATION

ADJUSTMENT PROCEDURE OF SERVICE BRAKE

All brakes are self-adjusting. The front brakes self-adjust when the vehicle is moved slowly back and forth while apply-
ing the service brakes. The rear brakes self-adjust when the parking brake is set and released.

Take the following steps after overhauling the rear brake assem-
bly.
1. Move the parking brake handle to its fully released position.

2. Firmly grasp the second relay lever rod. Rotate the adjust-
ing nut until all slack disappears from the cable. Set the
adjusting nut.

3. Applying about thirty kilograms of force, pull the parking

brake handle to its fully set position three or four times.
4. If the parking brake is properly adjusted, the traveling range
between the fully disengaged position and the fully engaged
position will be between twelve and fourteen notches.
If the traveling range is not within these limits, again reset
the adjusting nut
 GENERAL INFORMATION 0 0 - 6 5

Bleeding
• Perform bleeding operation with ENGINE RUNNING, to pre-
vent damage to push rod seal. Make sure exhaust is suitab-
ly ventilated.
• Bleed the hydraulic system with the fluid reservoir filled to
the specified level.
• Bleed the system starting with the left hand (right hand) side
rear wheel cylinder farthest to the master cylinder.

1. Fill the brake fluid reservoir with brake fluid.

Handle the brake fluid with reasonable care to avoid spillage
as it is damaging to paint
NOTE: Take care to prevent foreign matter from entry, when
replenishing or replacing brake fluid.

2. Connect a vinyl pipe to the bleeder screw on the wheel

cylinder and the other end of the pipe in a transparent con-
tainer.
3. Pump the brake pedal several times and hold it
depressed. Loosen the bleeder screw to release brake fluid
together with air bubbles. Tighten the bleeder screw
before pressure is released completely.
4. Repeat the step in paragraph 3 above until the air bubbles
disappear completely. Securely tighten the bleeder screw
when the air bubbles disappear completely.
5. Repeat the step in paragraph 4 above on the remaining
wheel cylinders. Bleed the system starting with rear side
farthest from the brake fluid reservoir.
6. Fill the brake fluid reservoir to the specified level.
Pour brake fluid carefully so as not to produce air bubbles.
7. If the cap diaphragm is stretched, attach a reserver after
tightening the cap.

Proportioning & bypass valve

The proportioning and bypass valve is not repairable and must be
replaced as a complete assembly.
0 0 - 6 6 GENERAL INFORMATION

Parking brake adjustment

1. Fully release the parking brake lever.
2. Make an adjustment with the nuts (C) and (D) connecting
equalizer of rear cable (A) with the front cable (B) to remove
play in parking brake cable.

3. After adjustment operation, check that lever travel is within

1 1 — 1 2 notches when tested by pulling the parking brake
lever with a force of approximately 30 kg, then caulk the nut.

Stroke (notches) 12 - 14

Note: Avoid pulling the parking brake lever while making an

adjustment.
Be sure to re-install the drums in their original positions.

STEERING

Power steering oil level

Maximum steering angle adjustment

The maximum steering angle of the front wheels can be adjusted
with the stopper bolts under the frame side members.
1. Position each front wheel on the turning radius gauge in a
straight-ahead position.
2. Set the parking brake firmly.
 GENERAL INFORMATION 0 0 - 6 7

3. Adjust the inside wheel angle of each side with the stopper
bolts.

Outside wheel 33°

Inside wheel 35°

Note: Maximum steering angles should be set after adjusting

front wheel alignment.

AIR CONDITIONER
(IF SO EQUIPPED)

Air-purging
Use a vacuum pump to remove air, moisture, and other foreign
matter from the system.
1 Compressor
2 Receiver unit
3 High pressure gauge
4 Low pressure gauge
5 Vacuum pump
Gauge adapter : J-25499
Gauge adapter : J-9459

1. Operate the vacuum pump.

2. Using the gauge manifold valves, continue to operate the
vacuum pump until the gauge on the low pressure side
reaches 740 mm Hg. Then continue pumping for 5 more
minutes.
3. Close the gauge manifold valves.
4. Stop the vacuum pump.

Gas charging
Charge the system with refrigerant after air-purging and inspec-
tion for leaks.
1 Compressor
2 Receiver unit
3 High pressure gauge
4 Low pressure gauge
5 Charge valve
6 Gas container
Gauge adapter : J-25499
Gauge adapter : J-9459
0 0 - 6 8 GENERAL INFORMATION

1. Load refrigerant gas into the system by opening the low

pressure side valve on the gauge manifold.
2. When charging is finished, start and let the engine run at
approximately 1000 rpm.
3. Close the low pressure side valve on the gauge manifold
when the low pressure side gauge reaches nearly zero and
the gas container is emptied.

4. When the sight glass on the receiver unit becomes clear, the
system is fully charged.
5. Disconnect the charge hose from the service valves.
ESSENTIAL
OR ILLUSTRATION PARTS NO. PARTS NAME
AVAILABLE

Oil filter wrench (101 mm-diesel)

J-29772
for extra-large C223 oil filter

Compression gauge
J-22888 (J-26999-20 adapter included)
J-26999-20 Glow plug port adapter
(also available separately)

Static timing gauge

J-28827
same as J-29763

J-28829 Injection nozzle tester (diesel Kiki)

J-28885 Tachometer (Ono Sokki)

J-25499 Gauge adapter

J-9459 Gauge adapter

J-35691 Boost gauge

MEMO