2005 Isuzu H-Series Service and Repair Manual

Isuzu's conventional-cab H-Series joined the US lineup for 2005, sharing the GM medium-duty conventional chassis built in Flint, Michigan. Three designations cover Class 6 to Class 8: HTR, HVR and HXR, with a 105-inch BBC regular cab or a 146-inch BBC crew cab and single or tandem axles. The only engine is the 7.8-liter 6HK1-TC inline-six turbodiesel, rated from 200 to 300 horsepower and paired with Allison automatic or Eaton manual transmissions. This service and repair manual gives 2005-specific procedures, specifications, torque values, wiring diagrams, diagnostics and maintenance schedules.

Engines covered

• 7.8L inline-six turbodiesel — SOHC, turbocharged, diesel

Body styles covered

• 2-door regular cab chassis
• 4-door crew cab chassis

Trims covered

• HTR
• HVR
• HXR

Known issues on the 2005 H-Series. One recall is on federal record: on trucks with the ZF model 8018 steering gear, the gear may have been produced incorrectly, giving a curb-strike feeling with a cracking or pinging sound when the wheel is turned, an off-center steering wheel and heavier steering effort. No owner complaints are logged for this year. The manual's steering gear procedures cover the inspection, adjustment and torque values involved.