Isuzu Q Series / QKR 2011–2013 Truck Workshop Manual Set (P/N LG4JB-WE-1111)

The system volumes work alongside the general maintenance information. Cross-references connect jobs such as cab removal with the relevant heater, fuel, brake, clutch, steering, and electrical procedures.

The heating volume covers heater and ventilation service, not refrigerant-system repair. The seat-belt volume contains belt and buckle procedures, not airbag diagnosis or repair.

Searchable PDFs and Wiring Detail

Text search and diagram labels: Each PDF has searchable text and embedded bookmarks. Small pin numbers and wire codes in the LHD and RHD circuit diagrams are readable when enlarged.

ZIP download containing 11 printable English PDFs totaling 1,332 pages. This total includes 44 cover, section-guide, and publication pages, 22 blank pages, and 18 memo pages.

Diesel Engine, Drivetrain, and Chassis Service

These selected content highlights show the repair and diagnostic coverage. Further topics include normal and severe-duty maintenance schedules and oil-viscosity charts.

• Engine repair: Step-by-step procedures cover compression testing, engine removal, cylinder-head work, timing gears, crankshaft inspection, piston service, and cylinder-block rebuilding.

• Fuel and cooling: Injection-nozzle disassembly and adjustment, injection-pump removal and timing, water-pump service, thermostat testing, radiator replacement, and drive-belt adjustment.

• Transmission and clutch: JC52 removal and unit repair, shaft and synchronizer work, control-cable adjustment, clutch hydraulic bleeding, master/slave cylinder overhaul, and PTO repair.

• Propeller shafts and axles: Long- and short-wheelbase shaft service, full-floating rear-axle repair, differential setup, front hub bearings, and knuckle/kingpin procedures.

• Brakes and steering: Drum-brake and hydraulic-cylinder repair, parking- and exhaust-brake service, steering-gear overhaul, pump pressure testing, alignment, and leaf-spring service.

• Cab and interior: Glass, doors, locks, regulators, seats, instrument panels, cab mounts, complete cab removal, panel sealing, and body sectional views.

• Electrical diagnosis: Separate LHD and RHD volumes provide circuit diagrams, connector configurations, parts locations, fuse/relay/diode maps, grounding points, and harness routing.

Suited to technicians and experienced owners with workshop-level repair knowledge and access to the specified pullers, gauges, presses, and lifting equipment.

Engine Rebuilding and Fuel-System Diagnosis

Cylinder-head procedures extend to valve guides, seals, and seat inserts. Internal engine repair covers the camshaft and tappets, rocker-arm assembly, oil pump, crankshaft bearings, pistons, connecting rods, and cylinder liners.

The engine-specific material also covers oil-cooler-equipped models, front and rear crankshaft seals, the flywheel and pilot bearing, and complete engine installation. The cylinder-block section specifies replacement of chrome-plated dry liners rather than reboring or honing.

Fuel-system coverage includes the filter and water separator, separate nozzle procedures for the two engine versions, and injection-volume and governor-performance diagrams. The 4JB1-TC nozzle section distinguishes first and second opening-pressure adjustments and explains their interaction.

Cooling procedures are supported by inspection specifications and leak checks. Engine electrical work covers the starter, alternator, battery, and QOS II preheating system; separate sections address EGR-equipped models, catalytic-converter configurations, and exhaust-brake applications.

Turbocharger scope: The 4JB1-TC material covers pressure and wastegate checks, shaft end play, and bearing clearance rather than internal turbocharger rebuilding. It warns that faulty servicing can damage pistons, valves, and cylinder liners.

Transmission and Axle Repair Depth

The JC52 unit-repair section breaks down the top-gear, main-shaft, and countershaft assemblies, with separate PTO replacement and internal repair procedures.

Rear-axle instructions distinguish single- and dual-rear-tire layouts and the 244 mm and 292 mm differentials. Pinion-depth measurement, bearing preload, backlash, and shim selection support differential setup after component replacement.

The transmission must not hang unsupported from the clutch during removal; the manual identifies clutch-assembly damage as the consequence.

Brake, Steering, and Cab Configurations

Brake procedures distinguish two-leading front drums and manual-adjuster rear drums, with hydraulic bleeding, pedal adjustment, the 178 mm parking brake, and exhaust-brake diagnosis.

Manual and power steering receive separate unit-repair instructions. Steering linkage and column replacement, pump bleeding, wheel alignment, leaf-spring replacement, and wheel balancing are also covered.

The cab procedures apply to Q Series bodies unless otherwise noted. Rear mounting instructions distinguish versions with and without rubber bushings. Heater work includes core replacement, blower-motor service, control-cable adjustment, and air-mix/mode-door procedures.

Electrical Fault Tracing and Workshop References

Named diagrams include Start and Charging, QOS II System, Exhaust Brake, Engine Stop, and the engine volume’s EGR System Wiring Diagram. Lighting, wiper/washer, horn, backup-warning, meter, heater, and fuel-heater sections combine circuit information with component locations and connector views.

The separate drive-position volumes let you follow the applicable harness routing and connector layout when tracing a fault.

Component-specific torque tables, lubricant requirements, electrical test data, and wear limits accompany the repair procedures. Listed tools include nozzle tester 5-8840-9016-0, static timing gauge adapter set 5-8840-2834-0, steering pressure gauge 5-8840-0162-0, and transmission anti-lash plate installer 5-8840-2044-0.

Engine rebuilding, turbocharger service, brake work, cab removal, and electrical testing require the specified support equipment, measuring tools, and safety procedures.

A Preview of Turbocharger and Transmission Inspection Limits

For the 4JB1-TC turbocharger, wheel-shaft end play is listed at 0.03–0.08 mm standard, with a 0.09 mm limit, measured under the specified alternating 11.8 N load.

The JC52 transmission inspection data lists main-shaft runout below 0.025 mm as standard and 0.1 mm as the service limit. These are inspection references for the respective assemblies.