2007-2012 Isuzu D-max holden Colorado Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Isuzu / Holden Model: D-Max / Colorado Model Years Covered: 2007, 2008, 2009, 2010, 2011, 2012 Codes Chassis Code: RG Series (Isuzu D-Max) / RC Series (Holden Colorado) 👋 Introduction Market Position Vehicle Segment: Mid-size pickup truck / light commercial vehicle. Competitive Analysis Key Competitors: Toyota Hilux, Mitsubishi Triton, Nissan Navara, Ford Ranger, Mazda BT-50. Key Features Robust Construction: Known for its durable chassis and body-on-frame construction, suitable for heavy-duty work and off-road use. Powertrain Options: Primarily diesel engines, offering good torque and fuel efficiency, with various transmission and drivetrain configurations. Versatility: Available in various body styles (single cab, extra cab, double cab) and configurations, catering to work, leisure, and family needs. 📋 Manual Details Coverage Areas Regions Covered: Global (specific variants may apply to certain regions, particularly Australia for Holden Colorado) Page Count Estimated Page Count: Over 2000 (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Manual (Workshop Manual) Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, piston, connecting rods, crankshaft, camshaft, timing, lubrication system, cooling system Engine Management: Fuel injection system (common rail diesel), ignition system (if applicable to petrol variants), emissions control, ECU (Engine Control Unit) diagnostics, sensors, actuators Transmission Manual: Manual transmission assembly, disassembly, clutch, gearbox operation, service procedures Transmission Automatic: Automatic transmission assembly, disassembly, torque converter, hydraulic control, service procedures, diagnostics Drivetrain: Transfer case, drive shafts, differentials (front, rear), axles, hubs, wheel bearings Suspension: Front suspension (e.g., double wishbone, torsion bar), rear suspension (e.g., leaf springs, multi-link), shock absorbers, springs, bushings, alignment specifications Steering: Power steering system, steering rack, steering column, tie rods, alignment Brakes: Front brakes (disc), rear brakes (disc or drum depending on variant), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake fluid specifications, bleeding procedures Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM) HVAC: Heating, Ventilation, and Air Conditioning system components, diagnosis, refrigerant, service Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, trim, paint codes Body Interior: Dashboard, seats, upholstery, interior trim, airbags, restraint systems Chassis Frame: Frame inspection, straightening, repair procedures Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common fault codes Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, tire rotation, spark plug replacement (if applicable) Major Repairs: Engine rebuilds, transmission overhauls, differential service, suspension component replacement Diagnostic Procedures: Fault code retrieval and interpretation, sensor testing, electrical circuit testing Specification Data: Torque specifications for fasteners, clearances, fluid capacities, electrical resistance values Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Depth Of Coverage: Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Searchable Text: Yes (typical for high-quality PDF manuals) Print Quality Printability: All pages are printable Binding Type Binding Type: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Code Examples: 4JJ1-TC (3.0L Diesel), 4JK1-TC (2.5L Diesel), 4G94 (2.4L Petrol - less common in this era for D-Max/Colorado) Performance Displacement Common: 2.5 Liters, 3.0 Liters Power Output Range: Approx. 100 kW to 130 kW (85-175 hp) depending on engine and tune. Torque Output Range: Approx. 320 Nm to 400 Nm depending on engine and tune. Fuel System Fuel Type: Diesel (primarily common rail direct injection), Petrol (less common in later models/specific markets) Turbocharger: Typically turbocharged and intercooled for diesel variants. 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: 4-speed or 5-speed Automatic Transmission (depending on year and variant) Features Drivetrain Options: Rear-Wheel Drive (RWD), Part-Time Four-Wheel Drive (4WD) 📐 Dimensions Exterior Body Styles: Single Cab, Space Cab (Extra Cab), Crew Cab (Double Cab) Weights Gross Vehicle Weight Rating Gvw: Varies significantly by configuration (e.g., 2800 kg to 3000 kg+) Towing Capacity: Typically up to 3000 kg (braked trailer), check specific vehicle VIN and local regulations. 🛡️ Safety Features Ratings Ancap Rating: Varies by year and specific model. Early models may have lower ratings, later models improved. Refer to ANCAP reports for specific year/model. Active Features ABS: Anti-lock Braking System (standard on most variants). Ebd: Electronic Brake-force Distribution (often paired with ABS). Passive Features Airbags: Driver and passenger airbags standard on most models. Side and curtain airbags available on higher trims or later models. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, CD player, optional MP3 compatibility and auxiliary input. Higher trims may offer improved sound systems. Driver Assistance Cruise Control: Available on higher trim levels. Parking Sensors: Optional on some models. Connectivity Bluetooth: Optional on some higher trim levels or aftermarket. 🔧 Maintenance Service Intervals Engine Oil Change Interval: Typically every 10,000 km or 6 months, whichever comes first (refer to manual for...
Fuel injection system (common rail diesel), ignition system (if applicable to petrol variants), emissions control, ECU (Engine Control Unit) diagnostics, sensors, actuators
Transmission Manual:
Manual transmission assembly, disassembly, clutch, gearbox operation, service procedures
Front suspension (e.g., double wishbone, torsion bar), rear suspension (e.g., leaf springs, multi-link), shock absorbers, springs, bushings, alignment specifications
Steering:
Power steering system, steering rack, steering column, tie rods, alignment
Brakes:
Front brakes (disc), rear brakes (disc or drum depending on variant), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake fluid specifications, bleeding procedures
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM)
HVAC:
Heating, Ventilation, and Air Conditioning system components, diagnosis, refrigerant, service
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass, trim, paint codes
Body Interior:
Dashboard, seats, upholstery, interior trim, airbags, restraint systems
Single Cab, Space Cab (Extra Cab), Crew Cab (Double Cab)
Weights
Gross Vehicle Weight Rating Gvw:
Varies significantly by configuration (e.g., 2800 kg to 3000 kg+)
Towing Capacity:
Typically up to 3000 kg (braked trailer), check specific vehicle VIN and local regulations.
🛡️ Safety Features
Ratings
Ancap Rating:
Varies by year and specific model. Early models may have lower ratings, later models improved. Refer to ANCAP reports for specific year/model.
Active Features
ABS:
Anti-lock Braking System (standard on most variants).
Ebd:
Electronic Brake-force Distribution (often paired with ABS).
Passive Features
Airbags:
Driver and passenger airbags standard on most models. Side and curtain airbags available on higher trims or later models.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, CD player, optional MP3 compatibility and auxiliary input. Higher trims may offer improved sound systems.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Optional on some models.
Connectivity
Bluetooth:
Optional on some higher trim levels or aftermarket.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically every 10,000 km or 6 months, whichever comes first (refer to manual for exact specification based on operating conditions).
Air Filter Replacement Interval:
Inspect every 20,000 km, replace as needed (or every 40,000 km).
Fuel Filter Replacement Interval:
Diesel: Inspect/replace every 40,000 km or as recommended.
Fluid Specifications
Engine Oil Specification:
API CI-4 or ACEA E7/E5 (for Diesel engines), SAE 5W-30 or 10W-30 (check manual for exact viscosity).
Transmission Fluid Manual:
GL-4 SAE 75W-90 or 80W-90 (check manual for specific type).
Transmission Fluid Automatic:
Dexron III or equivalent (check manual for specific type, e.g., Dexron VI for later models).
Brake Fluid:
DOT 3 or DOT 4 (check manual).
Coolant:
Ethylene glycol-based, phosphate-free coolant (e.g., OAT) or IAT coolant depending on original fill (check manual). Typically a 50/50 mix with distilled water.
Some models may have DPF systems that require specific maintenance or regeneration cycles, which can be covered in the manual.
📚 Vehicle History
Brand Heritage
Isuzu Heritage:
Isuzu has a long-standing reputation for producing durable diesel engines and commercial vehicles.
Model Evolution
Isuzu D Max Generation:
This era (2007-2012) represents the second generation (TF chassis) of the Isuzu D-Max, which was also rebadged and sold as the Holden Colorado in many markets.
Holden Colorado Development:
The Holden Colorado in this period was a badge-engineered version of the Isuzu D-Max, developed through the Isuzu-General Motors (GM) alliance.
Production
Manufacturing Locations:
Primarily Thailand, also other GM plants globally depending on market.
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