2006-2010 Isuzu Commercial Truck Forward Tiltmaster NPR/NPR HD/NQR (W3500/W4500/W5500) Diesel Engines OEM Service & Repair Manual

ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER SERVICE MANUAL (2006) NPR/NPR-HD/NQR/NRR W3500/W4500/W5500/W5500HD (DIESEL ENGINE)

General Information 0A-1 GENERAL INFORMATION General Information TABLE OF CONTENTS Cautions and Notices . . . . . . . . . . . . . . . . . . . . . . 0A-2 Battery Disconnect Caution . . . . . . . . . . . . . . . . 0A-2 Fuel Tube Caution . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Road Test Caution . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Safety Glasses Caution . . . . . . . . . . . . . . . . . . . 0A-2 Vehicle Lifting Caution . . . . . . . . . . . . . . . . . . . . 0A-2 Belt Dressing Notice. . . . . . . . . . . . . . . . . . . . . . 0A-2 Fastener Notice . . . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Sealant Notice . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Handling Electrostatic Discharge (ESD) Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Model Reference . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 VIN (Vehicle Identification Number) and Weight Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-5 Vin Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-5 Regular Production Options (RPO) Code List . . 0A-6 Engine Serial Number . . . . . . . . . . . . . . . . . . . . 0A-7 Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 0A-8 Emergency Starting a Vehicle Due to Discharged Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-9 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . 0A-10 Vehicle Lifting Points . . . . . . . . . . . . . . . . . . . . 0A-11 Abbreviations Charts . . . . . . . . . . . . . . . . . . . . 0A-12 Essential Service Tools . . . . . . . . . . . . . . . . . . 0A-15

0A-2 General Information Cautions and Notices Battery Disconnect Caution Caution: Before servicing any electrical component, the ignition key must be in the 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. Fuel Tube Caution Caution: In order to reduce the risk of fire and personal injury observe the following items: • Replace all nylon fuel tubes 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 installing new fuel pipes. Damage to the nylon tubes 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 115°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.) 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 and vehicle damage. Safety Glasses Caution Caution: Wear safety glasses in order to avoid eye damage. SIR Caution Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: • Personal injury • Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: • Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. • If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in SIR. Vehicle Lifting Caution Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Belt Dressing Notice Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. 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 Injector Balance Test Notice Notice: Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding.

General Information 0A-3 Sealant Notice Notice: Do not allow the RTV sealant to enter any blind threaded hole. RTV sealant that is allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper fastener tightening can allow the components to loosen or separate leading to extensive engine damage.

0A-4 General Information General Information Handling Electrostatic Discharge (ESD) Sensitive Parts When handling an electronic part that has as ESD sensitive sticker, the service technician should follow these guidelines to reduce any possible electrostatic charge build-up on the service technician’s body and the electronic part in the dealership: 1. Do not open the package until it is time to install the part. 2. Avoid touching the electrical terminals of the part. 3. Before removing the part from its package, ground the package to a known good ground on the vehicle. 4. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across the seat, sitting down from a standing position or walking a distance. Model Reference The model covered in this manual are referred to as a NPR, NPR-HD, NQR, NRR. (W3500, W4500, W5500, W5500HD)

General Information 0A-5 VIN (Vehicle Identification Number) and Weight Rating Plate The VlN and Weight Rating Plate (1) lists the manufacturer, gross vehicle weight for the vehicle, maximum front end weight at ground, maximum rear end weight at ground, and the VlN (vehicle identification number). This plate is attached to the pillar above the shoulder belt hole on the driver’s side. The vehicle identification number is a legal identifier of your vehicle. It not only appears on the VlN plate, but also on the Vehicle Certificates of Title and Registration. The vehicle identification number specifically identifies a vehicle by code. Legend 1. VIN and Weight Rating Plate Vin Chart Position Definition Character Description 1–3 World Manufacturer Identifier Make Type JAL ISUZU Type: Incomplete Vehicle – Medium & Heavy Duty J8B CHEVROLET Type: Incomplete Vehicle – Medium & Heavy Duty J8D GMC TRUCK Type: Incomplete Vehicle – Medium & Heavy Duty 4 GVWR and Brake System B, C, E B: 10,001-14,000 lbs HYD Brake C: 14,001-16,000 lbs HYD Brake E: 16,001-19,500 lbs HYD Brake 5 Series Code 4, 5 4: W3500, W4500, NPR / NPR-HD 5: W5500, W5500HD, NQR / NRR 6 Cab Type Code B, J B: Steel Tilt Cab 67 inch Bumper to Back of Cab J: Non Tilt Cab 108 inch Bumper to Back of Cab 7 Chassis Type Code 1 4 × 2

0A-6 General Information GVWR (Gross Vehicle Weight Rating) The GVWR is the weight of a vehicle plus the weight of a vehicle’s load. For the gross vehicle weight rating and the gross vehicle combined weight rating, refer to Model Explanation. For the gross vehicle weight rating range refer to the VlN Chart. Service Parts Identification Label The "Service Parts Identification" label lists major components and their part numbers plus vehicle options and their codes. The information on the label was printed at the factory; therefore, it represents only the equipment on the vehicle when it was shipped from the factory. Always refer to this label when ordering replacement service parts. (Refer to the "NOTICE" on the label.) The service parts identification label is located on the right-hand step support panel. Regular Production Options (RPO) Code List The RPO list contains RPOs available on this model. Also, refer to the Service Parts Identification label for a list of the RPOs used on each specific vehicle. 8 Engine Code 6 Isuzu 4HK1-TC 9 Check Digit * Check Digit 10 Model Year Code 6 6: 2006 11 Plant Code 7 7: Fujisawa 12 Sequential Numbers 0 Sequential Numbers 13 0 14 0 15 0 16 0 17 1 Position Definition Character Description OPTION CODE OPTION DESCRIPTION 100 INTERIOR-TRIM COLOR COMBI. (IN WHITE) 153 INTERIOR-TRIM COLOR COMBI. (GRAY) 729 BODY COLOR CODE-ARC WHITE (W301-P801) 890 BODY COLOR CODE-MARINE BLUE (4040-P2) 800 BODY COLOR CODE-IN WHITE D94 PAINT-TOUCH-UP, ONE COLOR VG1 WAX-PROTECTIVE UNDERBODY RWC CANADIAN EQUIPMENT YL3 FRIGID ZONE KIT 6JJ DEALER INSTALLATION OPTION 6FM US TERRITORY RQF GVWR CLASS-3 (10001-14000 LBS) RQG GVWR CLASS-4 (14001-16000 LBS) RQH GVWR CLASS-5 (16001-19500 LBS) RQQ GVWR CLASS-5 (18001-19500 LBS) 7NQ VEHICLE CATEGORY-NQR 6FZ FENDER COVER RWZ CAB-TILT, MANUAL EK7 MARK-VEHICLE NAME

General Information 0A-7 Note; F=Front, R=Rear, w/=With Engine Serial Number The engine serial number is located on a boss on the left, rear of the engine block above the oil filter. 6JS SEAT BELT EXTENSION D20 SUNVISOR-CO-DRIVER SIDE C41 HEATER & DEFROSTER C60 AIR CONDITIONER-MANUAL CONTROL C55 VENTILATOR-ROOF F59 STABILIZER SHAFT-FRONT G73 AXLE REAR-HEAVY DUTY 6CP AXLE REAR-HEAVY DUTY VAR.2 GV1 FINAL DRIVE GEAR RATIO-5.571 (39/7) HC6 FINAL DRIVE GEAR RATIO-4.556 (41/9) RU1 FINAL DRIVE GEAR RATIO-5.125 (41/8) R41 FINAL DRIVE GEAR RATIO-5.857 (41/7) S7C FINAL DRIVE GEAR RATIO-4.300 7QQ BRAKE SYSTEM-HYDRO BRAKE BOOSTER NF8 EXHAUST-BRAKE J52 BRAKES-FT DISK, MULTIPLE PISTON 6PH BRAKE-WHEEL LOCK CONTROL, (L.S.P.V) JE5 ANTI LOCK BRAKE SYSTEM RJS ENGINE-DIESEL 4CYL L 5.2L 4-VLV (4HK1) K30 CRUISE CONTROL-AUTOMATIC K51 TURBO CHARGER KJ3 AIR INTAKE SYSTEM; RR VERTICAL 6PL INTERCOOLER 8AA LONG LIFE COOLANT (50%) 6HT HEATER-OIL PAN K05 HEATER-ENGINE BLOCK RNJ AUTOMATIC TRANSMISSION 4-SPEED (AISIN) RSF MANUAL TRANSMISSION 6-SPEED (MZZ6U) M11 SHIFT-FLOOR (REMOTE) V66 POWER TAKE OFF-PROVISIONS FOR NL7 FUEL TANK-125L, 33GAL 6HU FUEL SEDIMENTER-WITH HEATER N33 STEERING COLUMN-TILT TYPE (WITH TELESCOPIC) OPTION CODE OPTION DESCRIPTION N40 STEERING-POWER ASQ F/TIRE215/85R16-E, R/TIRE215/85R16- E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC, (BS BRAND, R187) AZF F/TIRE 215/85R16-E, R/TIRE 215/ 85R16-E F&R/DISC 16X6K-128 w/DOT MARK WHITE DISC (ALL SEASON) BYS F/TIRE 215/85R16-E, R/TIRE 215/ 85R16-E F&R/DISC 16X6K-127 w/DOT MARK WHITE DISC (MICHELIN BRAND, XPS) CQR F&R/TIRE 225/70R19.5, F&R/DISC 19.5X6.00-127 WHITE R46 SPARE TIRE & DISC WHEEL VAR.1 7NC SPARE TIRE & DISC WHEEL-LESS P10 CARRIER-SPARE WHEEL (TRUCK) U01 LAMPS-FIVE, ROOF MARKER 6GZ RADIO-AM/FM STEREO ETR 2- SPEAKERS 6VL AM/FM w/CASSETTE 2SP 31N-1 U73 ANTENNA 7FK SPEAKER OPTION: 2-SPEAKER C13 WIPER-WITH INTERMITTENT NB6 EMISSION SYSTEM-CALIFORNIA OPTION CODE OPTION DESCRIPTION

0A-8 General Information Graphic Symbols Graphic symbols are used on some controls and displays on the vehicle. Many of these symbols are used internationally.

General Information 0A-9 Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Legend 1. Front of Vehicle 2. Up Side 3. Task Related 4. View Detail 5. View Angle 6. Dimension 7. Sectioning 8. Ambient/Clean Air Flow or Cool Air 9. Gas other than Ambient Air or Hot Air Flow 10. Ambient Air Mixed with Another Gas 11. View Angle 12. Lubrication Point Oil or Fluid 13. Lubrication Point Grease 14. Lubrication Point Liquid Gasket Emergency Starting a Vehicle Due to Discharged Battery If your vehicle will not start due to a discharged battery, it can often be started by using energy from another battery–a procedure called "jump starting." This vehicle has a 12volt starting system and a negative ground electrical system. Be sure that the other vehicle also has a 12volt starting system, and that it is the negative (black "–") terminal which is grounded (attached to the engine block, chassis or frame rail). Its owner's manual may give you that information. DO NOT TRY TO JUMP START IF YOU ARE UNSURE OF THE OTHER VEHICLE’S VOLTAGE OR GROUND (OR IF THE OTHER VEHICLE’S VOLTAGE AND GROUND ARE DIFFERENT FROM YOUR VEHICLE).

2006-2010 Isuzu Commercial Truck Forward Tiltmaster NPR/NPR HD/NQR (W3500/W4500/W5500) Diesel Engines OEM Service & Repair Manual

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