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ISUZU Holden RODEO 2003 2008 Workshop Service Repair MANU

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Basic Information Identification Make: Isuzu / Holden Model: Rodeo Generation: Third Generation (RG) Model Years Covered: 2003-2008 Codes Chassis Code: RG Introduction Market Position Vehicle Type: Light Commercial Vehicle (LCV) / Ute / Pickup Truck Target Audience: DIY mechanics, independent workshops, fleet maintenance, and owners seeking to maintain and repair their Isuzu Holden Rodeo. Competitive Analysis Competitors: Ford Ranger, Mazda BT-50, Toyota Hilux, Mitsubishi Triton, Nissan Navara (during the 2003-2008 model years). Key Features Manual Value Proposition: Provides comprehensive, factory-level repair and maintenance information, crucial for accurate diagnosis and repair, saving significant costs compared to dealership servicing. Instant download offers immediate access. Vehicle Strengths: Known for its robust construction, off-road capability (especially 4x4 models), reliable diesel engines (4JA1/4JH1-TC), and versatility as both a workhorse and lifestyle vehicle. Manual Details Coverage Coverage Areas: General Information, Heating and Airconditioning, Frame and Cab, Steering, Suspension, Wheels and Tires, Axle, Brakes, Engine (4JA1, 4JH1-TC, 6VE1, C24SE, Petrol HFV6), Transmission (AW30-40LE, JR405E, MSG Models, MUA Models), Clutch, Transfer Case, Electrical (Body and Chassis), Accessories & Restraints, Cab, Security Page Count: N/A (Digital Download) Manual Type: Factory Workshop Service Repair Manual Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Delivery Method: Instant Download Manual Coverage Systems Covered Engine Systems: Comprehensive coverage for 4JA1 (2.5L Diesel), 4JH1-TC (3.0L Turbo Diesel), 6VE1 (3.5L V6 Petrol), C24SE (2.4L Petrol), and Petrol HFV6 (3.6L V6) engines including: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, emission control systems, engine diagnostics, and overhaul procedures. Drivetrain Systems: Detailed information for AW30-40LE (4-speed Automatic), JR405E (5-speed Automatic), MSG Models (Manual), and MUA Models (Manual) transmissions. Includes clutch system, transfer case operation and repair, drive shafts, axles, and differentials. Chassis Systems: In-depth coverage of steering system (power steering), suspension (front and rear), wheels, tires, brakes (hydraulic, ABS), and frame/chassis components. Electrical Systems: Extensive electrical schematics for body and chassis systems. Includes: lighting, instrumentation, power windows, door locks, wipers, horn, audio systems, air conditioning controls, security system, and accessory wiring. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad and rotor replacement, battery maintenance. Repair Procedures: Step-by-step instructions for engine overhaul, transmission repair, brake system repair, steering and suspension component replacement, electrical component diagnostics and repair, body panel repair, and HVAC system servicing. Troubleshooting Guides: Diagnostic procedures and fault finding for various systems, including engine performance issues, transmission shifting problems, electrical gremlins, brake system malfunctions, and HVAC issues. Often includes symptom-based troubleshooting charts. Technical Specifications: Torque specifications for fasteners, engine component clearances, fluid capacities and types, wiring diagrams, diagnostic trouble codes (DTCs) and their meanings, component testing procedures. Technical Depth Depth Of Coverage: Complete workshop level, covering everything from basic maintenance and fluid changes to complex engine and transmission rebuilds. Includes diagnostic procedures, component removal and installation, and troubleshooting. Manual Specifications File Details File Format: PDF Searchability: Likely searchable text within the PDF (depending on original scan quality) Printability: All pages are printable Software Requirements: Adobe PDF Reader, WinZip (for extraction if compressed) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Print Quality Print Quality: N/A (Digital Download, quality dependent on source scan) Engine Specifications Primary Engine Engine Codes Covered: 4JA1, 4JH1-TC, 6VE1, C24SE, Petrol HFV6 Performance 4Ja1 Specs: 2.5L (2499cc) SOHC Diesel; Approx. 76-80 kW (102-107 hp) @ 3800-4000 rpm; Approx. 175-185 Nm (129-136 lb-ft) @ 2000-2400 rpm 4Jh1-Tc Specs: 3.0L (2999cc) DOHC Turbo Diesel; Approx. 85-96 kW (114-129 hp) @ 3600-3800 rpm; Approx. 280-320 Nm (207-236 lb-ft) @ 1800-2000 rpm 6Ve1 Specs: 3.5L (3494cc) DOHC V6 Petrol; Approx. 145 kW (195 hp) @ 5200 rpm; Approx. 320 Nm (236 lb-ft) @ 3000 rpm C24Se Specs: 2.4L (2384cc) SOHC Petrol; Approx. 92 kW (123 hp) @ 5000 rpm; Approx. 190 Nm (140 lb-ft) @ 3000 rpm Petrol Hfv6 Specs: 3.6L (3564cc) DOHC V6 Petrol (LW7/LY7); Approx. 175-180 kW (235-241 hp) @ 5800-6000 rpm; Approx. 325-343 Nm (240-253 lb-ft) @ 3200-3600 rpm Fuel System Diesel Fuel System: Common Rail Direct Injection (CRDi) for 4JH1-TC; Indirect Injection for 4JA1. Petrol Fuel System: Multi-point Fuel Injection (MPI) for C24SE and 6VE1; Direct Injection (DI) or Port Injection (PI) for HFV6 depending on sub-model. Transmission Standard Transmission Standard Transmission Type: Varies by model and year. Common options include 5-speed Manual and 4-speed Automatic. Optional Transmission Optional Transmission Type: Available with 4-speed Automatic (AW30-40LE) or 5-speed Automatic (JR405E) on some models, and various Manual transmissions (MSG, MUA series). Features Transfer Case: Manual or automatic 4WD (Four-Wheel Drive) systems available on select models, controlled via a secondary gear lever or electronically. Dimensions Exterior Body Styles: Single Cab, Space Cab, Crew Cab Wheelbase Variants: Standard, Long Wheelbase (LWB) Weights Gross Vehicle Weight: Varies by configuration, typically ranging from 2500 kg to 3000 kg (approx....
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ISUZU Holden RODEO 2003 2008 Workshop Service Repair MANU
Basic Information
Identification
Make: Isuzu / Holden
Model: Rodeo
Generation: Third Generation (RG)
Model Years Covered: 2003-2008
Codes
Chassis Code: RG
Introduction
Market Position
Vehicle Type: Light Commercial Vehicle (LCV) / Ute / Pickup Truck
Target Audience: DIY mechanics, independent workshops, fleet maintenance, and owners seeking to maintain and repair their Isuzu Holden Rodeo.
Competitive Analysis
Competitors: Ford Ranger, Mazda BT-50, Toyota Hilux, Mitsubishi Triton, Nissan Navara (during the 2003-2008 model years).
Key Features
Manual Value Proposition: Provides comprehensive, factory-level repair and maintenance information, crucial for accurate diagnosis and repair, saving significant costs compared to dealership servicing. Instant download offers immediate access.
Vehicle Strengths: Known for its robust construction, off-road capability (especially 4x4 models), reliable diesel engines (4JA1/4JH1-TC), and versatility as both a workhorse and lifestyle vehicle.
Manual Details
Coverage
Coverage Areas: General Information, Heating and Airconditioning, Frame and Cab, Steering, Suspension, Wheels and Tires, Axle, Brakes, Engine (4JA1, 4JH1-TC, 6VE1, C24SE, Petrol HFV6), Transmission (AW30-40LE, JR405E, MSG Models, MUA Models), Clutch, Transfer Case, Electrical (Body and Chassis), Accessories & Restraints, Cab, Security
Page Count: N/A (Digital Download)
Manual Type: Factory Workshop Service Repair Manual
Language: English
Format
File Format: PDF
Compatibility: All Versions of Windows & Mac
Delivery Method: Instant Download
Manual Coverage
Systems Covered
Engine Systems: Comprehensive coverage for 4JA1 (2.5L Diesel), 4JH1-TC (3.0L Turbo Diesel), 6VE1 (3.5L V6 Petrol), C24SE (2.4L Petrol), and Petrol HFV6 (3.6L V6) engines including: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, emission control systems, engine diagnostics, and overhaul procedures.
Drivetrain Systems: Detailed information for AW30-40LE (4-speed Automatic), JR405E (5-speed Automatic), MSG Models (Manual), and MUA Models (Manual) transmissions. Includes clutch system, transfer case operation and repair, drive shafts, axles, and differentials.
Chassis Systems: In-depth coverage of steering system (power steering), suspension (front and rear), wheels, tires, brakes (hydraulic, ABS), and frame/chassis components.
Electrical Systems: Extensive electrical schematics for body and chassis systems. Includes: lighting, instrumentation, power windows, door locks, wipers, horn, audio systems, air conditioning controls, security system, and accessory wiring.
Procedures Included
Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad and rotor replacement, battery maintenance.
Repair Procedures: Step-by-step instructions for engine overhaul, transmission repair, brake system repair, steering and suspension component replacement, electrical component diagnostics and repair, body panel repair, and HVAC system servicing.
Troubleshooting Guides: Diagnostic procedures and fault finding for various systems, including engine performance issues, transmission shifting problems, electrical gremlins, brake system malfunctions, and HVAC issues. Often includes symptom-based troubleshooting charts.
Technical Specifications: Torque specifications for fasteners, engine component clearances, fluid capacities and types, wiring diagrams, diagnostic trouble codes (DTCs) and their meanings, component testing procedures.
Technical Depth
Depth Of Coverage: Complete workshop level, covering everything from basic maintenance and fluid changes to complex engine and transmission rebuilds. Includes diagnostic procedures, component removal and installation, and troubleshooting.
Manual Specifications
File Details
File Format: PDF
Searchability: Likely searchable text within the PDF (depending on original scan quality)
Printability: All pages are printable
Software Requirements: Adobe PDF Reader, WinZip (for extraction if compressed)
Binding Type
Binding Type: N/A (Digital Download)
Paper Type
Paper Type: N/A (Digital Download)
Print Quality
Print Quality: N/A (Digital Download, quality dependent on source scan)
Engine Specifications
Primary Engine
Engine Codes Covered: 4JA1, 4JH1-TC, 6VE1, C24SE, Petrol HFV6
Performance
4Ja1 Specs: 2.5L (2499cc) SOHC Diesel; Approx. 76-80 kW (102-107 hp) @ 3800-4000 rpm; Approx. 175-185 Nm (129-136 lb-ft) @ 2000-2400 rpm
4Jh1-Tc Specs: 3.0L (2999cc) DOHC Turbo Diesel; Approx. 85-96 kW (114-129 hp) @ 3600-3800 rpm; Approx. 280-320 Nm (207-236 lb-ft) @ 1800-2000 rpm
6Ve1 Specs: 3.5L (3494cc) DOHC V6 Petrol; Approx. 145 kW (195 hp) @ 5200 rpm; Approx. 320 Nm (236 lb-ft) @ 3000 rpm
C24Se Specs: 2.4L (2384cc) SOHC Petrol; Approx. 92 kW (123 hp) @ 5000 rpm; Approx. 190 Nm (140 lb-ft) @ 3000 rpm
Petrol Hfv6 Specs: 3.6L (3564cc) DOHC V6 Petrol (LW7/LY7); Approx. 175-180 kW (235-241 hp) @ 5800-6000 rpm; Approx. 325-343 Nm (240-253 lb-ft) @ 3200-3600 rpm
Fuel System
Diesel Fuel System: Common Rail Direct Injection (CRDi) for 4JH1-TC; Indirect Injection for 4JA1.
Petrol Fuel System: Multi-point Fuel Injection (MPI) for C24SE and 6VE1; Direct Injection (DI) or Port Injection (PI) for HFV6 depending on sub-model.
Transmission
Standard Transmission
Standard Transmission Type: Varies by model and year. Common options include 5-speed Manual and 4-speed Automatic.
Optional Transmission
Optional Transmission Type: Available with 4-speed Automatic (AW30-40LE) or 5-speed Automatic (JR405E) on some models, and various Manual transmissions (MSG, MUA series).
Features
Transfer Case: Manual or automatic 4WD (Four-Wheel Drive) systems available on select models, controlled via a secondary gear lever or electronically.
Dimensions
Exterior
Body Styles: Single Cab, Space Cab, Crew Cab
Wheelbase Variants: Standard, Long Wheelbase (LWB)
Weights
Gross Vehicle Weight: Varies by configuration, typically ranging from 2500 kg to 3000 kg (approx. 5500 lbs to 6600 lbs).
Safety Features
Ratings
Ancap Rating: Varies by specific model year and safety equipment fitted. Early models may have lower ratings, later models with optional airbags generally improve.
Active Features
Active Safety Features: Anti-lock Braking System (ABS) - standard on higher trims and later models, optional on others. Limited-slip differential (LSD) available on some performance or 4WD variants.
Passive Features
Passive Safety Features: Dual front airbags (optional on early models, standard on later models), seatbelt pre-tensioners, reinforced cabin structure.
Technology Features
Infotainment
Infotainment Systems: Basic infotainment systems typical for the era, including AM/FM radio, CD player, and optional auxiliary input. Speaker configurations varied by trim level.
Driver Assistance
Driver Assistance Features: Limited by era. ABS was the primary driver assistance system. No electronic stability control (ESC) or advanced driver-assistance systems (ADAS) were typically offered.
Connectivity
Connectivity Options: Basic connectivity, often through 12V power outlets for charging devices. Some later models might have had Bluetooth hands-free kits as an aftermarket or dealer option.
Maintenance
Service Intervals
Oil Change Interval: Typically 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, depending on engine type (petrol/diesel), driving conditions, and oil used. Refer to manual for specific recommendations.
Transmission Fluid Change: Automatic: 40,000 - 80,000 km (25,000 - 50,000 miles). Manual: Check for leakage, typically serviced if issues arise. Refer to manual for specific fluid type and interval.
Fluid Specifications
Engine Oil Specification: API CD/CE or SF/SG for older diesel engines; API SG/SH or higher for petrol engines. Viscosity grades like 15W-40, 10W-30 or 5W-30 depending on engine and climate. Refer to manual for precise specifications and capacities (e.g., 4JH1-TC typically requires 7.5L).
Coolant Specification: Ethylene glycol-based, anti-freeze/anti-corrosion coolant. Capacity varies by engine, typically 8-10L. Use a 50/50 mix with distilled water.
Brake Fluid Specification: DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items: Clutch wear, brake components (pads, rotors), suspension bushings and ball joints, exhaust system corrosion, radiator hoses, glow plugs (diesel), EGR valve (diesel).
Diesel Specific Issues: Potential for turbocharger issues on 4JH1-TC if maintenance is neglected, injector problems, DPF (Diesel Particulate Filter) issues on later emissions models (though less common on this generation).
Vehicle History
Brand Heritage
Isuzu Heritage: Isuzu has a long history as a manufacturer of commercial vehicles, trucks, and diesel engines, known for durability and reliability.
Model Evolution
Rodeo Lineage: The Isuzu Rodeo (TF series) was first introduced in the late 1980s. This manual covers the third generation (RG), which was a rebadged Isuzu D-Max sold under the Holden brand in various markets, particularly Australia and New Zealand.
Production
Manufacturing Locations: Primarily manufactured in Thailand (as Isuzu D-Max) and assembled/marketed by Holden in Australia. Some models were sourced from Japan.
Awards & Recognition
Recognitions
Model Awards: The Rodeo, particularly in Australia as a Holden, was a very popular vehicle and frequently ranked highly in sales charts for light commercial vehicles. Specific awards are less documented than for passenger cars, but its market success speaks to its reputation.
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