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Isuzu D-Max 2007 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Isuzu Model: D-Max Year: 2007 Codes Chassis Codes: TF (South Africa), Rodeo (some markets) Engine Codes: 4JA1, 4JB1, 4JG2 (diesel variants likely, specific to 2007 models not explicitly stated but common in generation) 👋 Introduction Market Position Market Segment: Mid-size pickup truck, known for its durability, utility, and off-road capability, particularly in commercial and adventurous use cases. Competitive Analysis Competitors 2007: Toyota Hilux/Tacoma, Ford Ranger, Mitsubishi Triton/L200, Nissan Navara/Frontier. Key Features Key Selling Points: Robust ladder-frame chassis, reliable diesel engines (common in many markets), practical utility, strong towing and payload capacity, proven off-road performance. 📋 Manual Details Coverage Areas Manual Coverage Overview: Comprehensive repair and service for the 2007 Isuzu D-Max. Page Count Estimated Page Count: Varies significantly based on specific engine and body style. Expect 1500-2500+ pages for a complete factory manual. Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (likely PDF, as per common sales practices for service manuals) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection (diesel common rail and mechanical), cooling system, lubrication system, ignition system (petrol variants), exhaust system, emissions control. Drivetrain Systems: Manual and automatic transmissions, transfer case, driveshafts, differentials, axles, propeller shafts, CV joints. Chassis And Suspension: Front and rear suspension (leaf springs, torsion bars typical), steering system, braking system (front disc, rear drum common), wheels and tires. Electrical Systems: Battery, charging system, starting system, lighting system, instrument cluster, body control modules, engine control unit (ECU), wiring diagrams, fuses and relays. Body And Interior: Body panels, doors, glass, interior trim, seats, HVAC system, exterior trim, bumpers, tailgate/rear gate. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid level checks and top-offs, brake pad replacement, tire rotation, belt inspection and replacement, spark plug replacement (petrol). Repair Procedures: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper repair, steering rack replacement, electrical component diagnosis and replacement, body panel repair and replacement. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation, wiring diagram analysis, pressure testing, electrical testing. Installation Procedures: Component installation and removal, accessory installation, diagnostic tool connection and usage. Technical Depth Technical Depth: Comprehensive, covering everything from basic maintenance to complex engine and transmission overhauls. Includes detailed torque specifications, clearances, diagnostic procedures, and wiring diagrams. 📊 Manual Specifications File Format Digital File Format: PDF (Portable Document Format), optimized for searchability and readability. Print Quality Print Quality Suitability: High resolution for clear diagrams, schematics, and text. Suitable for printing specific sections or the entire manual. Binding Type Suggested Binding For Print: Coil-binding or three-ring binder recommended for ease of use and lay-flat functionality in a workshop environment. Paper Type Recommended Paper For Print: Durable, high-quality paper (e.g., 24-32 lb bond) to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Common Engine Options: 4JA1-T (2.5L Turbo Diesel I4), 4JB1-T (2.8L Turbo Diesel I4), 4JG2 (3.1L Diesel I4). Petrol options existed but diesel was more prevalent and central to D-Max identity. Performance Typical Horsepower Range: 80-120 HP (diesel variants), depending on specific engine and turbocharging. Typical Torque Range: 170-250 Nm (diesel variants), prioritizing low-end torque for hauling and towing. Fuel System Fuel Injection System: Typically indirect injection (IDI) for older 4JA1/4JB1 variants, and high-pressure common rail diesel injection (HPCRDI) for later models or specific markets. Manual details will cover specific system. 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission. Optional Optional Transmission: 4-speed automatic transmission (less common in base configurations but available). Features Drivetrain Configurations: Rear-wheel drive (RWD) and selectable four-wheel drive (4WD) with high-low range transfer case. 📐 Dimensions Exterior Typical Wheelbase: Approx. 3050 mm (120.1 inches) for standard cab models, longer for crew cab variants. Typical Length: Approx. 4700-5000 mm (185-197 inches) depending on cab style and bed length. Typical Width: Approx. 1700-1800 mm (67-71 inches). Typical Height: Approx. 1650-1750 mm (65-69 inches). Cargo Typical Payload Capacity: Up to 1000 kg (2200 lbs) or more, depending on configuration and market regulations. Weights Typical Curb Weight: Approx. 1700-2000 kg (3750-4400 lbs). 🛡️ Safety Features Ratings Common Safety Features Availability: Varies by market and trim. ABS and airbags were becoming more common but not always standard on base models in 2007. Active Features Active Safety Systems: Anti-lock Braking System (ABS) often optional or standard on higher trims, Electronic Brake-force Distribution (EBD). Passive Features Passive Safety Systems: Driver and front passenger airbags (standard on many models), three-point seat belts, reinforced cabin structure. 💡 Technology Features Infotainment Infotainment System Type: Basic. Typically a factory-installed AM/FM radio with CD player, and potentially an auxiliary input. Speaker count varies by trim. Driver Assistance Driver Assistance Features: Minimal. Focus on core vehicle operation rather than advanced driver aids. Cruise control may be available on higher trims. Connectivity Connectivity Options: Limited. Often featured basic audio connectivity. Bluetooth or USB ports were not common for this model year...
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Isuzu D-Max 2007 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
D-Max
Year:
2007
Codes
Chassis Codes:
TF (South Africa), Rodeo (some markets)
Engine Codes:
4JA1, 4JB1, 4JG2 (diesel variants likely, specific to 2007 models not explicitly stated but common in generation)
👋 Introduction
Market Position
Market Segment:
Mid-size pickup truck, known for its durability, utility, and off-road capability, particularly in commercial and adventurous use cases.
Competitive Analysis
Competitors 2007:
Toyota Hilux/Tacoma, Ford Ranger, Mitsubishi Triton/L200, Nissan Navara/Frontier.
Key Features
Key Selling Points:
Robust ladder-frame chassis, reliable diesel engines (common in many markets), practical utility, strong towing and payload capacity, proven off-road performance.
📋 Manual Details
Coverage Areas
Manual Coverage Overview:
Comprehensive repair and service for the 2007 Isuzu D-Max.
Page Count
Estimated Page Count:
Varies significantly based on specific engine and body style. Expect 1500-2500+ pages for a complete factory manual.
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, as per common sales practices for service manuals)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection (diesel common rail and mechanical), cooling system, lubrication system, ignition system (petrol variants), exhaust system, emissions control.
Drivetrain Systems:
Manual and automatic transmissions, transfer case, driveshafts, differentials, axles, propeller shafts, CV joints.
Chassis And Suspension:
Front and rear suspension (leaf springs, torsion bars typical), steering system, braking system (front disc, rear drum common), wheels and tires.
Electrical Systems:
Battery, charging system, starting system, lighting system, instrument cluster, body control modules, engine control unit (ECU), wiring diagrams, fuses and relays.
Body And Interior:
Body panels, doors, glass, interior trim, seats, HVAC system, exterior trim, bumpers, tailgate/rear gate.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid level checks and top-offs, brake pad replacement, tire rotation, belt inspection and replacement, spark plug replacement (petrol).
Repair Procedures:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper repair, steering rack replacement, electrical component diagnosis and replacement, body panel repair and replacement.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation, wiring diagram analysis, pressure testing, electrical testing.
Installation Procedures:
Component installation and removal, accessory installation, diagnostic tool connection and usage.
Technical Depth
Technical Depth:
Comprehensive, covering everything from basic maintenance to complex engine and transmission overhauls. Includes detailed torque specifications, clearances, diagnostic procedures, and wiring diagrams.
📊 Manual Specifications
File Format
Digital File Format:
PDF (Portable Document Format), optimized for searchability and readability.
Print Quality
Print Quality Suitability:
High resolution for clear diagrams, schematics, and text. Suitable for printing specific sections or the entire manual.
Binding Type
Suggested Binding For Print:
Coil-binding or three-ring binder recommended for ease of use and lay-flat functionality in a workshop environment.
Paper Type
Recommended Paper For Print:
Durable, high-quality paper (e.g., 24-32 lb bond) to withstand workshop conditions.
⚙️ Engine Specifications
Primary Engine
Common Engine Options:
4JA1-T (2.5L Turbo Diesel I4), 4JB1-T (2.8L Turbo Diesel I4), 4JG2 (3.1L Diesel I4). Petrol options existed but diesel was more prevalent and central to D-Max identity.
Performance
Typical Horsepower Range:
80-120 HP (diesel variants), depending on specific engine and turbocharging.
Typical Torque Range:
170-250 Nm (diesel variants), prioritizing low-end torque for hauling and towing.
Fuel System
Fuel Injection System:
Typically indirect injection (IDI) for older 4JA1/4JB1 variants, and high-pressure common rail diesel injection (HPCRDI) for later models or specific markets. Manual details will cover specific system.
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission.
Optional
Optional Transmission:
4-speed automatic transmission (less common in base configurations but available).
Features
Drivetrain Configurations:
Rear-wheel drive (RWD) and selectable four-wheel drive (4WD) with high-low range transfer case.
📐 Dimensions
Exterior
Typical Wheelbase:
Approx. 3050 mm (120.1 inches) for standard cab models, longer for crew cab variants.
Typical Length:
Approx. 4700-5000 mm (185-197 inches) depending on cab style and bed length.
Typical Width:
Approx. 1700-1800 mm (67-71 inches).
Typical Height:
Approx. 1650-1750 mm (65-69 inches).
Cargo
Typical Payload Capacity:
Up to 1000 kg (2200 lbs) or more, depending on configuration and market regulations.
Weights
Typical Curb Weight:
Approx. 1700-2000 kg (3750-4400 lbs).
🛡️ Safety Features
Ratings
Common Safety Features Availability:
Varies by market and trim. ABS and airbags were becoming more common but not always standard on base models in 2007.
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS) often optional or standard on higher trims, Electronic Brake-force Distribution (EBD).
Passive Features
Passive Safety Systems:
Driver and front passenger airbags (standard on many models), three-point seat belts, reinforced cabin structure.
💡 Technology Features
Infotainment
Infotainment System Type:
Basic. Typically a factory-installed AM/FM radio with CD player, and potentially an auxiliary input. Speaker count varies by trim.
Driver Assistance
Driver Assistance Features:
Minimal. Focus on core vehicle operation rather than advanced driver aids. Cruise control may be available on higher trims.
Connectivity
Connectivity Options:
Limited. Often featured basic audio connectivity. Bluetooth or USB ports were not common for this model year unless added aftermarket.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically 5,000-10,000 km (3,000-6,000 miles) or 6 months, whichever comes first, depending on driving conditions and oil type.
Transmission Fluid Change Interval:
Manual: Approx. 40,000-80,000 km (25,000-50,000 miles). Automatic: Approx. 40,000-60,000 km (25,000-37,000 miles).
Fluid Specifications
Engine Oil Specification:
API CG-4 or CH-4 for diesel engines (check manual for specific viscosity, e.g., 15W-40 or 10W-30).
Coolant Specification:
Ethylene glycol-based coolant, typically a 50/50 mix with deionized water. Check for specific Isuzu or DEX-COOL compatibility.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Clutch wear (manual transmission), suspension bushings and ball joints, exhaust system components (corrosion), turbocharger wear (on turbo diesel models).
Diesel Engine Specifics:
Glow plug reliability, injector wear (especially with poor fuel quality), potential for turbocharger issues if not maintained.
📚 Vehicle History
Brand Heritage
Isuzu Truck Legacy:
Isuzu has a long-standing reputation for building robust and reliable commercial vehicles, including trucks and SUVs, dating back decades.
Model Evolution
D Max Generation:
The 2007 D-Max belongs to the first generation (often referred to as the TF series, though Isuzu's nomenclature varied by region), which debuted in 2002. It was a significant global model for Isuzu.
Production
Production Locations:
Globally produced by Isuzu and its manufacturing partners, including Thailand, South Africa, and other assembly plants.
🏆 Awards & Recognition
Recognitions
Market Reputation:
The D-Max is widely recognized for its ruggedness, reliability, and value, particularly in international markets and for commercial use. It often garners praise for its workhorse capabilities.
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