ISUZU Holden RODEO 2003-2008 Service Repair Manual
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🏷️ Basic Information Identification Make: Isuzu Model: Holden Rodeo Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008 Codes Platform Code: GM U-body (TF series) 👋 Introduction Market Position Segment: Compact to mid-size pickup truck, often used for commercial and recreational purposes. Competitive Analysis Competitors: Ford Ranger, Toyota Hilux, Mitsubishi Triton, Nissan Navara (in relevant markets). Key Features Manual Usability: Step-by-step illustrated repair procedures, easy to navigate, no installation required. Owner Benefit: Empowers owners to perform maintenance and repairs, saving on labor costs and increasing vehicle longevity. 📋 Manual Details Coverage Areas Primary Regions Covered: Global (specific focus implied by Holden branding for Australasia) Page Count Estimated Page Count: Extensive (specific number not provided, but described as comprehensive) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, fuel system, cooling system, ignition system, lubrication system, emissions control, engine management (ECU). Drivetrain Systems: Clutch, gearbox (manual and automatic), propeller shafts, rear axle, front axle (if applicable to 4WD variants). Suspension Steering Brakes: Front and rear suspension components, steering system (rack and pinion, power steering), brake system (discs, drums, ABS, hydraulic lines). Body Chassis: Bodywork, chassis frame, interior trim, exterior panels, glass, seals. Electrical Electronic: Complete electrical system, wiring diagrams, lighting, starting and charging system, dashboard instruments, HVAC controls, infotainment wiring. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, belt inspections and replacements, spark plug replacement, brake pad/shoe replacement. Repair Procedures: Engine component replacement (e.g., cylinder head, pistons), transmission overhaul, brake caliper/master cylinder replacement, suspension component repair (e.g., ball joints, shock absorbers), steering rack repair, electrical component diagnosis and replacement. Troubleshooting: Diagnostic procedures for common faults, fault code interpretation (if applicable), symptom-based troubleshooting guides. Technical Depth Depth: Dealer-level instructional guides, covering basic repairs to advanced diagnostics and overhauls. 📊 Manual Specifications File Format Compatibility: Compatible with all Windows Operating Systems, smartphones, and tablets that can open PDF files. Print Quality Printability: Individual pages or entire sections can be printed. Binding Type Binding: Digital (PDF, not a physical book) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Options 2003 2008: Commonly included: 2.4L 4-cylinder (petrol), 3.0L V6 (petrol), 2.8L 4-cylinder (diesel - often Isuzu's 4JB1-T or similar). Performance Hp Range Typical: Approximately 110-150 hp for 4-cylinders, 160-200 hp for V6 variants. Torque Range Typical: Varies significantly by engine; diesel engines typically offer higher torque for towing and hauling. Fuel System Fuel Delivery: Multi-point fuel injection (MPI) for petrol engines, direct injection for diesel engines. Maintenance Timing Belt Chain: Likely timing belt for petrol engines, timing chain for some diesel variants (refer to manual for specific engine). 🔧 Transmission Standard Gearbox Options: Typically 5-speed manual transmission as standard. Optional Automatic Transmission Option: Optional automatic transmission (e.g., 4-speed or 5-speed depending on engine/variant). Features Drivetrain Options: Rear-wheel drive (RWD) and selectable 4-wheel drive (4WD) configurations. 📐 Dimensions Exterior Body Styles: Single Cab, Space Cab (Extra Cab), Dual Cab. Wheelbase Variations: Multiple wheelbase options depending on cab configuration and bed length. Weights Gross Vehicle Weight Rating Gvwr: Varies by configuration, typically in the range of 2500-3000+ kg. Towing Capacity: Significant, often rated for 2500-3500 kg braked towing capacity, depending on engine and configuration. 🛡️ Safety Features Ratings Ancap Rating Typical: Varies by year and specific testing; early models may have lower ratings compared to later generations. Active Features ABS: Anti-lock Braking System (ABS) available on higher trims or as an option. Traction Control: Traction control systems might be available on specific models. Passive Features Airbags: Driver and passenger front airbags standard on most models within this range. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player or cassette player depending on trim and year. Speaker configuration varies by cab type. Driver Assistance Cruise Control: Cruise control available on higher trim levels, particularly for V6 models. Connectivity Aux Input: Auxiliary audio input jack may be present on later models or as an aftermarket addition. 🔧 Maintenance Service Intervals Oil Change Interval Typical: Generally 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used. Timing Belt Replacement Interval: For models with timing belts, typically 80,000-100,000 km or 5-7 years. Crucial to verify with the manual. Fluid Specifications Engine Oil Spec: Varies by engine type (petrol/diesel) and climate. Common specs include API SG/SH/SJ or higher for petrol, CD/CE/CF for older diesels. Viscosity grades like 10W-30, 10W-40, 15W-40 are common. Manual will specify exact type and capacity. Transmission Fluid Spec Manual: API GL-4 or GL-5 gear oil, with specific viscosity (e.g., 75W-90, 80W-90). Transmission Fluid Spec Automatic: Dexron-III or equivalent for older automatic transmissions. Specific type and capacity must be confirmed in the manual. Coolant Spec: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Specific color or type...
Diagnostic procedures for common faults, fault code interpretation (if applicable), symptom-based troubleshooting guides.
Technical Depth
Depth:
Dealer-level instructional guides, covering basic repairs to advanced diagnostics and overhauls.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all Windows Operating Systems, smartphones, and tablets that can open PDF files.
Print Quality
Printability:
Individual pages or entire sections can be printed.
Binding Type
Binding:
Digital (PDF, not a physical book)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Options 2003 2008:
Commonly included: 2.4L 4-cylinder (petrol), 3.0L V6 (petrol), 2.8L 4-cylinder (diesel - often Isuzu's 4JB1-T or similar).
Performance
Hp Range Typical:
Approximately 110-150 hp for 4-cylinders, 160-200 hp for V6 variants.
Torque Range Typical:
Varies significantly by engine; diesel engines typically offer higher torque for towing and hauling.
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) for petrol engines, direct injection for diesel engines.
Maintenance
Timing Belt Chain:
Likely timing belt for petrol engines, timing chain for some diesel variants (refer to manual for specific engine).
🔧 Transmission
Standard
Gearbox Options:
Typically 5-speed manual transmission as standard.
Optional
Automatic Transmission Option:
Optional automatic transmission (e.g., 4-speed or 5-speed depending on engine/variant).
Features
Drivetrain Options:
Rear-wheel drive (RWD) and selectable 4-wheel drive (4WD) configurations.
📐 Dimensions
Exterior
Body Styles:
Single Cab, Space Cab (Extra Cab), Dual Cab.
Wheelbase Variations:
Multiple wheelbase options depending on cab configuration and bed length.
Weights
Gross Vehicle Weight Rating Gvwr:
Varies by configuration, typically in the range of 2500-3000+ kg.
Towing Capacity:
Significant, often rated for 2500-3500 kg braked towing capacity, depending on engine and configuration.
🛡️ Safety Features
Ratings
Ancap Rating Typical:
Varies by year and specific testing; early models may have lower ratings compared to later generations.
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims or as an option.
Traction Control:
Traction control systems might be available on specific models.
Passive Features
Airbags:
Driver and passenger front airbags standard on most models within this range.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player depending on trim and year. Speaker configuration varies by cab type.
Driver Assistance
Cruise Control:
Cruise control available on higher trim levels, particularly for V6 models.
Connectivity
Aux Input:
Auxiliary audio input jack may be present on later models or as an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval Typical:
Generally 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used.
Timing Belt Replacement Interval:
For models with timing belts, typically 80,000-100,000 km or 5-7 years. Crucial to verify with the manual.
Fluid Specifications
Engine Oil Spec:
Varies by engine type (petrol/diesel) and climate. Common specs include API SG/SH/SJ or higher for petrol, CD/CE/CF for older diesels. Viscosity grades like 10W-30, 10W-40, 15W-40 are common. Manual will specify exact type and capacity.
Transmission Fluid Spec Manual:
API GL-4 or GL-5 gear oil, with specific viscosity (e.g., 75W-90, 80W-90).
Transmission Fluid Spec Automatic:
Dexron-III or equivalent for older automatic transmissions. Specific type and capacity must be confirmed in the manual.
Coolant Spec:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Specific color or type (e.g., OAT, HOAT) may apply. Capacity around 7-9 liters.
Known Issues
Common Wear Items:
Clutch wear (manual transmission), front suspension components (ball joints, tie rod ends) due to load, exhaust system corrosion, diesel engine injector pump seals (on older diesel models).
Diesel Engine Considerations:
Some older Isuzu diesel engines may be susceptible to head gasket issues if overheated, or injector pump leaks.
📚 Vehicle History
Brand Heritage
Isuzu Truck Heritage:
Isuzu has a long-standing reputation for producing robust and reliable commercial vehicles and diesel engines.
Model Evolution
Tf Series Significance:
The TF series Rodeo (also sold as Isuzu D-Max in some markets) was a highly popular utility vehicle known for its durability and workhorse capabilities.
Production
Manufacturing Locations:
Primarily manufactured in Thailand and Japan, with assembly in other countries including Australia for the Holden branded version.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2003-2008 Holden Rodeo are not prominently listed, the model consistently received praise for its ruggedness and value for money in its segment, often topping sales charts in certain markets.