GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 1999 🢒 Isuzu MD Steel Tilt (F Model) 🢒 General Information 🢒 Maintenance and Lubrication 🢒 Explanation of Scheduled Services
  1. (1) Replace the automatic transmission fluid and the filter at 10 400 km (6,500 mi), 41 600 km (26,000 mi) and then every 41 600 km (26,000 mi) thereafter.

    2. Inspect the automatic transmission fluid level at each 10 400 km (6,500 mi) interval that does not call for a fluid change (or every month, whichever occurs first).

  2. (2) Replace the manual transmission fluid every 62 400 km (39,000 mi).

    3. Inspect the manual transmission fluid level at each 10 400 km (6,500 mi) interval that does not call for a fluid change (or every 3 months, whichever occurs first).

  3. (3) This is an emission control service.
  4. (4) This is a noise emission control device.
  5. (5) This service applies only to vehicles sold in the United States.
  6. (6) Inspect the fluid level in the following components:
    7. • The brake master cylinder. A low fluid level in the brake master cylinder may indicate worn brake linings and should be inspected.
    • The clutch master cylinder (if equipped)
    • The power steering pump
    • The axle
    • The transmission
    • The hydraulic spring parking brake pump (if equipped)
  7. (7) Inspect the following brake components:
    8. • The brake lines and the hoses. Inspect the lines and the hoses for the following conditions:
       - Proper hookup
       - Binding
       - Leaks
       - Cracks
       - Chafing
    • The disc brake pads for wear
    • The rotors for surface condition
    • The drum brake linings for wear or cracks
    • The drums
    • The wheel cylinders
    • The piston heat shields and the boots
    • Other brake parts
    • The brake pedal for excessive free play or travel (or every 6 months, whichever occurs first). Perform the service, if necessary.
    • Inspect the brakes more often if driving habits and conditions result in frequent braking.

    Important: The spring brake section of the actuator is NOT serviceable.

  8. (8) Inspect the hydraulic parking brake drum and the linings for wear or cracks. Inspect the linkage and the adjustment. Inspect the spring brake actuator and the pump for leaks.
  9. (9) Change the main oil filter and the partial oil filter element.
  10. (10) Inspect the clutch pedal for free travel. Use the following procedure:
    11.  - Press the pedal using your hand until resistance is felt.
     - Maintain free travel at 38-51 mm (1.5-2.0 in) measured at the clutch pedal pad.
     - Inspect the clutch pedal for free travel at 5 200 km (3,250 mi) and 10 400 km (6,500 mi) and then every 10 400 km (6,500 mi) thereafter.
  11. (11) Inspect the rear axle air shift motor for fluid leaks. Use the following procedure:
    12. • Remove the plug in order to inspect the fluid level.
    • Inspect the air lines and the hoses for the following conditions:
       - Proper hookup
       - Binding
       - Leaks
    • Inspect the rear axle air shift motor at 5 200 km (3,250 mi) and 14 00 km (24,000 mi) and then every 16 000 km (26,000 mi) thereafter.
  12. (12) Lubricate all the grease fittings in the front suspension, the front axle, and the steering linkage.

    13. Lubricate the suspension, the axle and the steering linkage more often when operating under dusty or muddy conditions and in excessive off-road use.

    DO NOT lubricate the kingpin bushings with air pressure equipment. Use a hand-held grease gun in order to ensure complete purge and eliminate sealer cap distortion.

    Lubricate the following components:

    • The transmission and the shift linkage
    • The hood latches and the hinges
    • The parking brake lever pivot
    • The clevis pins and the linkage
    • The disc brake caliper rails
    • The clutch linkage and the release bearing (if equipped)
    • The propeller shaft slip joint
    • The universal joint
    • The brake camshaft bracket
    • The slack adjusters
    • The pedal shaft
    • The clutch cross shaft
    • The clutch pedal springs
  13. (13) Inspect the steering the system for damaged, loose or missing parts. Inspect for parts showing signs of wear or lack of lubrication. Replace the parts as needed.

    14. Inspect the following components:

    • The steering gear mounting bolts. Tighten if necessary.
    • The pitman arm nut. Tighten if necessary.
    • The gear housing upper cover and the side cover attaching bolts. Tighten if necessary.
    • The steering column mounting bolts. Tighten if necessary.
    • The cardan joint clamp bolts. Tighten if necessary.
    • The power steering hoses, the tubes and the fittings for leaks. Ensure that the hoses and the lines are not twisted, kinked, or tightly bent.
    • The clips, the clamps, the supporting tubes, and the hoses for proper location and secureness.
    • The steering gear for leakage around the pitman shaft and the housing. If leakage is evident (lubrication oozing out, not just an oily film), repair the leak immediately.
  14. (14) Inspect the front and rear suspension for damaged, loose or missing parts, or parts showing signs of wear or lack of lubrication. Replace the parts as needed.
  15. (15) Adjust the tire pressure as indicated in the Isuzu Owner's Manual for optimum tire life.

    16. Inspect the tires for excessive or abnormal wear or damage. Inspect the wheels for damage. Replace the wheels and/or tires as needed.

  16. (16) Inspect the spring-to-axle U-bolts and the shackle bolts for the proper torque.

    17. When the vehicle is new or when you have replaced the parts, inspect and adjust the torque more often during the first 10 000 km (6,000 mi). Inspect the torque at 800 km (500 mi) and 3 000 km (2,000 mi) after the parts are first used.

  17. (17) In order to maintain the exhaust system integrity, replace the exhaust pipes whenever a new muffler is installed.

    18. Inspect the complete exhaust system for the following conditions. Perform any needed repairs immediately.

    • Broken parts
    • Damaged parts
    • Missing parts
    • Out of position parts
    • Open seams
    • Holes
    • Loose connections
    • Other conditions which may permit exhaust fumes to seep into the driver compartment.
  18. (18) Inspect all of the engine drive belts for cracks, fraying, wear, and proper tension. Adjust or replace the belts as needed. Replace the belts at 83 200 km (52,000 mi) and every 83 200 km (52,000 mi) thereafter.
  19. (19) Do not lubricate the accelerator and cruise control cables.

    20. Inspect the throttle linkage for the following conditions. Perform any needed repairs immediately.

    • Damaged parts (including throttle return springs)
    • Missing parts (including throttle return springs)
    • Interference
    • Binding
  20. (20) With the engine OFF and below normal operating temperature, verify that the thermostatically controlled engine cooling fan may be rotated by hand on viscous-operated drives. Replace the components as needed.
  21. (21) Inspect the shields and the underhood insulation for damage or looseness. Adjust or replace the components as needed.
  22. (22) Lubricate the following components:
    23. • The brake caliper V-ways
    • The brake caliper retainer
    • The brake caliper retainer spring
  23. (23) Perform the following wheel bearing service:
    24. • Grease type: Clean, inspect and lubricate using the proper wheel bearing grease at designated intervals or whenever the hubs are removed. Refer to Fluid and Lubricant Recommendations .
    • Oil-filled type: Some wheel bearings require a rear axle lubricant. If you have the oil-filled hubs, use a lubricant identical to that used in the rear axle. Lubricant change intervals are the same for both the front and the rear axles. Maintain the oil level at the OIL LEVEL mark between the change intervals. Refer to Fluid and Lubricant Recommendations .
  24. (24) Inspect the air intake system installation in order to ensure that the gaskets are seated properly and all of the hose connections, fasteners, and other components are tight.

    25. For gasoline engines, ensure that the air cleaner housing is properly seated, that the cover fits tightly and that the wing nut is tight.

    Tighten the connections and the fasteners or replace the parts as needed.

  25. (25) Incorrect injection timing may result in increased exhaust emission or reduced engine output. Inspect the tip of the injector needle valve and the injector orifices for accumulation of carbon.

    26. Remove any contamination with an injector cleaning tool by thoroughly cleaning the inside and outside of the injector end.

  26. (26) Inspect all of the fuel lines connections on the fuel injection pump and the injector.
  27. (27) Replace the air cleaner filter (or every 24 months, whichever occurs first). Replace the filter more often when driving in dusty conditions. Ask your dealer for the proper replacement intervals for your driving conditions.
  28. (28) Adjust the valve lash. Incorrect valve clearance will result in increased engine noise and reduced engine output. Retorque the rocker shaft bracket nuts before inspecting and adjusting the valve clearance. The intake and exhaust valve clearance is 0.4 mm (0.016 in) for cold adjustment.
  29. (29) Verify curb idle speed at 10 400 km (6,500 mi), 83 200 km (52,000 mi) and then every 83 200 km (52,000 mi) thereafter. If necessary, perform the adjustment by turning the injection pump governor low idle adjusting screw.
  30. (30) Perform the following inspections, replacing the parts as needed:
    31. • Inspect the following components for damage which may cause leakage:
       - The fuel tank
       - The fuel cap
       - The fuel lines
    • Inspect the fuel cap for proper sealing ability and damage.
    • Inspect the fuel cap gasket for an even filter neck imprint.
  31. Not applicable
  32. Not applicable
  33. Not applicable
  34. Not applicable
  35. (35) Drain, flush, and refill the cooling system. Refer to Fluid and Lubricant Recommendations .

    36. Inspect the hoses. Clean the radiator, the condenser, the pressure cap, and the neck. Perform the cooling system pressure test and the pressure cap test.

  36. (37) Change the lubricant. Refer to Fluid and Lubricant Recommendations .
  37. (38) Repack the upper kingpin roller bearing.

    38. Notice: The spring brake section of the rear brake diaphragms are non-serviceable.

  38. (39) Perform the following air brake service:
    39. • Test the air lines for leaks.
    • Tighten the air line connections as necessary.
    • Replace the compressor filter.
    • Inspect the air parking brake chamber for leaks and damage.
    • Inspect the lines and the hoses for leaks, cracks, chafing, etc.
    • Inspect all attachments for tightness, wear, or damage.
  39. (40) Clean and lubricate the air brake automatic slack adjuster. Inspect the pushrod travel and the auto adjustment operation. Perform the air brake automatic slack adjuster service, if necessary.
  40. (41) Inspect the operation of the air brake chamber and the following components. Inspect for leaks.
    41.  - The mounting
     - The clamps
     - The air lines
  41. (42) Inspect the operation of the trailer brake hand control valve. Lubricate the cam and the follower.
  42. (44) Remove, disassemble, clean, and inspect the following air brake components. Replace any parts showing wear. Replace any rubber parts:
    43. • The safety valve
    • The standard brake chamber
    • The quick release valve
    • The quick release/double check valve combination
    • The parking brake control valve
    • The double check valve
    • The spring brake control valve
  43. Not applicable
  44. (45) For Stud Wheels Only: Tighten the wheel stud nuts to the specified torque values at 100 miles (160 km), 500 miles (800 km) and 1,000 miles (1,600 km) and thereafter.
  45. (46) For Hub Piloted Wheels Only: Tighten the wheel stud nuts to the specified torque values at 1,000 miles (1,600 km). Thereafter, tighten them 1,000 miles (1,600 km) after each time the wheel is removed.