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Isuzu D-Max 2007-2012 Workshop Service Manual Repair

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๐Ÿท๏ธ Basic Information Identification Make: Isuzu Model: D-Max Generation: Second Generation (TF) Production Years Covered: 2007, 2008, 2009, 2010, 2011, 2012 Codes Platform Code: TF (Second Generation) ๐Ÿ‘‹ Introduction Market Position Segment: Mid-size Pickup Truck Target Audience: Professional technicians, DIY mechanics, Isuzu D-Max owners seeking in-depth repair and maintenance information. Competitive Analysis Competitors: Toyota Hilux, Mitsubishi Triton/ เชจเซเช‚ L200, Ford Ranger, Nissan Navara, Chevrolet Colorado (market dependent) Key Features Manual Features: Comprehensive coverage, detailed diagrams, step-by-step instructions, troubleshooting, electronic format for convenience. ๐Ÿ“‹ Manual Details Coverage Areas Regions Covered: Global (specifications may vary by market; manual intended for broad applicability) Page Count Estimated Page Count: Hundreds (as indicated by 'hundreds of pages') Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF ๐Ÿ“– Manual Coverage Systems Covered Powertrain: Engine (disassembly, assembly, diagnosis, overhaul), Fuel System, Cooling System, Lubrication System, Exhaust System Drivetrain: Transmission (manual and automatic), Clutch, Driveline, Axles, Differentials, Transfer Case (4WD models) Chassis: Suspension (front and rear), Steering System, Brakes (hydraulic, ABS, parking brake), Wheels and Tires Electrical: Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, Starter, Alternator, Battery, Wiring Diagrams Body And Frame: Body Panels, Doors, Hood, Tailgate, Interior Trim, Glass, Bumpers, Frame and Chassis Components Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement Diagnostics: Troubleshooting Guides, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs), Component Testing Repair: Step-by-step repair instructions for all major systems, component removal and installation, overhaul procedures Specifications: Torque Specifications, Clearances, Measurements, Fluid Capacities, Electrical Specifications Wiring: Detailed Wiring Diagrams for various circuits and systems Technical Depth Depth: Comprehensive coverage from basic maintenance to complex engine and transmission rebuilds, suitable for both DIY enthusiasts and professional technicians. ๐Ÿ“Š Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Zoom Capability: Yes (Zoom IN/OUT) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Versions of Windows & Mac โš™๏ธ Engine Specifications Primary Engine Engine Options: Multiple diesel and gasoline engines were available globally. Common diesel engines include the 4JA1-TC (2.5L), 4JH1-TC (3.0L), and potentially others like the 4JJ1-TC (3.0L). Gasoline options may include engines like the 4ZE1 (2.6L) or others depending on market. Performance Power Output Range: Varies significantly by engine. Diesel engines typically range from approximately 90 HP to 160 HP, with torque figures also varying considerably. Torque Output Range: Varies by engine. Diesel engines often produce between 200 Nm and 350 Nm or more. Fuel System Fuel Injection Diesel: Commonly utilizes direct injection with turbocharging and intercooling for most diesel variants. Fuel Injection Gasoline: Typically multi-point fuel injection (MPI) for gasoline variants. ๐Ÿ”ง Transmission Standard Transmission Type Standard: Manual Transmission (e.g., 5-speed or 6-speed depending on configuration) Optional Transmission Type Optional: Automatic Transmission (e.g., 4-speed or 5-speed depending on configuration) Features Drivetrain Options: Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) options available. ๐Ÿ“ Dimensions Exterior Body Styles: Single Cab, Extended Cab (Space Cab), Crew Cab Wheelbase Range: Approximately 3050 mm to 3380 mm, varying by cab configuration and model. Ground Clearance: Typically around 200-220 mm, providing off-road capability. Weights Curb Weight Range: Varies significantly by configuration, typically from 1700 kg to 2000 kg or more. Towing Capacity: Generally rated for towing up to 3000 kg (braked trailer), but check specific market regulations and vehicle specifications. ๐Ÿ›ก๏ธ Safety Features Ratings Crash Test Ratings: Ratings varied by region and specific testing body (e.g., ANCAP, Euro NCAP). Early models might have lower ratings compared to later generations. Active Features Active Safety: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA) were often optional or standard on higher trims. Passive Features Passive Safety: Front Airbags (driver and passenger), Seatbelt pretensioners, Side-impact door beams. ๐Ÿ’ก Technology Features Infotainment Infotainment Systems: Base models typically featured a simple AM/FM radio with CD player. Higher trims may have offered upgraded audio systems, optional CD changers, and in some markets, basic navigation or auxiliary inputs. Driver Assistance Driver Assistance Features: Limited compared to modern vehicles. Features like ABS were becoming more common. Parking sensors or rearview cameras were rare for this era. Connectivity Connectivity Options: Basic connectivity, often limited to auxiliary input jacks for audio devices. Bluetooth was not standard and rare for this model year range. ๐Ÿ”ง Maintenance Service Intervals Oil Change Interval: Typically every 5,000 km to 10,000 km (3,000 to 6,000 miles) or 6-12 months, depending on driving conditions and engine oil type. Consult the manual for specific recommendations. Air Filter Replacement: Recommended every 15,000 km to 30,000 km (9,000 to 18,000 miles), or more frequently in dusty environments. Fuel Filter Replacement Diesel: Crucial for diesel engines. Intervals typically range...
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Isuzu D-Max 2007-2012 Workshop Service Manual Repair
๐Ÿท๏ธ Basic Information
Identification
Make:
Isuzu
Model:
D-Max
Generation:
Second Generation (TF)
Production Years Covered:
2007, 2008, 2009, 2010, 2011, 2012
Codes
Platform Code:
TF (Second Generation)
๐Ÿ‘‹ Introduction
Market Position
Segment:
Mid-size Pickup Truck
Target Audience:
Professional technicians, DIY mechanics, Isuzu D-Max owners seeking in-depth repair and maintenance information.
Competitive Analysis
Competitors:
Toyota Hilux, Mitsubishi Triton/ เชจเซเช‚ L200, Ford Ranger, Nissan Navara, Chevrolet Colorado (market dependent)
Key Features
Manual Features:
Comprehensive coverage, detailed diagrams, step-by-step instructions, troubleshooting, electronic format for convenience.
๐Ÿ“‹ Manual Details
Coverage Areas
Regions Covered:
Global (specifications may vary by market; manual intended for broad applicability)
Page Count
Estimated Page Count:
Hundreds (as indicated by 'hundreds of pages')
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
๐Ÿ“– Manual Coverage
Systems Covered
Powertrain:
Engine (disassembly, assembly, diagnosis, overhaul), Fuel System, Cooling System, Lubrication System, Exhaust System
Drivetrain:
Transmission (manual and automatic), Clutch, Driveline, Axles, Differentials, Transfer Case (4WD models)
Chassis:
Suspension (front and rear), Steering System, Brakes (hydraulic, ABS, parking brake), Wheels and Tires
Electrical:
Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, Starter, Alternator, Battery, Wiring Diagrams
Body And Frame:
Body Panels, Doors, Hood, Tailgate, Interior Trim, Glass, Bumpers, Frame and Chassis Components
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs), Component Testing
Repair:
Step-by-step repair instructions for all major systems, component removal and installation, overhaul procedures
Specifications:
Torque Specifications, Clearances, Measurements, Fluid Capacities, Electrical Specifications
Wiring:
Detailed Wiring Diagrams for various circuits and systems
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complex engine and transmission rebuilds, suitable for both DIY enthusiasts and professional technicians.
๐Ÿ“Š Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Capability:
Yes (Zoom IN/OUT)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
Compatibility
Operating Systems:
All Versions of Windows & Mac
โš™๏ธ Engine Specifications
Primary Engine
Engine Options:
Multiple diesel and gasoline engines were available globally. Common diesel engines include the 4JA1-TC (2.5L), 4JH1-TC (3.0L), and potentially others like the 4JJ1-TC (3.0L). Gasoline options may include engines like the 4ZE1 (2.6L) or others depending on market.
Performance
Power Output Range:
Varies significantly by engine. Diesel engines typically range from approximately 90 HP to 160 HP, with torque figures also varying considerably.
Torque Output Range:
Varies by engine. Diesel engines often produce between 200 Nm and 350 Nm or more.
Fuel System
Fuel Injection Diesel:
Commonly utilizes direct injection with turbocharging and intercooling for most diesel variants.
Fuel Injection Gasoline:
Typically multi-point fuel injection (MPI) for gasoline variants.
๐Ÿ”ง Transmission
Standard
Transmission Type Standard:
Manual Transmission (e.g., 5-speed or 6-speed depending on configuration)
Optional
Transmission Type Optional:
Automatic Transmission (e.g., 4-speed or 5-speed depending on configuration)
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) options available.
๐Ÿ“ Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Space Cab), Crew Cab
Wheelbase Range:
Approximately 3050 mm to 3380 mm, varying by cab configuration and model.
Ground Clearance:
Typically around 200-220 mm, providing off-road capability.
Weights
Curb Weight Range:
Varies significantly by configuration, typically from 1700 kg to 2000 kg or more.
Towing Capacity:
Generally rated for towing up to 3000 kg (braked trailer), but check specific market regulations and vehicle specifications.
๐Ÿ›ก๏ธ Safety Features
Ratings
Crash Test Ratings:
Ratings varied by region and specific testing body (e.g., ANCAP, Euro NCAP). Early models might have lower ratings compared to later generations.
Active Features
Active Safety:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA) were often optional or standard on higher trims.
Passive Features
Passive Safety:
Front Airbags (driver and passenger), Seatbelt pretensioners, Side-impact door beams.
๐Ÿ’ก Technology Features
Infotainment
Infotainment Systems:
Base models typically featured a simple AM/FM radio with CD player. Higher trims may have offered upgraded audio systems, optional CD changers, and in some markets, basic navigation or auxiliary inputs.
Driver Assistance
Driver Assistance Features:
Limited compared to modern vehicles. Features like ABS were becoming more common. Parking sensors or rearview cameras were rare for this era.
Connectivity
Connectivity Options:
Basic connectivity, often limited to auxiliary input jacks for audio devices. Bluetooth was not standard and rare for this model year range.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km to 10,000 km (3,000 to 6,000 miles) or 6-12 months, depending on driving conditions and engine oil type. Consult the manual for specific recommendations.
Air Filter Replacement:
Recommended every 15,000 km to 30,000 km (9,000 to 18,000 miles), or more frequently in dusty environments.
Fuel Filter Replacement Diesel:
Crucial for diesel engines. Intervals typically range from 20,000 km to 40,000 km (12,000 to 24,000 miles). Water in fuel separation is also a key maintenance item.
Fluid Specifications
Engine Oil Type:
Depends on engine and climate. Commonly API CI-4 or CH-4 rated diesel engine oils (e.g., 15W-40 or 10W-30), and API SG/SH or higher for gasoline engines. Always check the manual or oil cap for exact specifications.
Coolant Type:
Typically a silicate-free, long-life ethylene glycol-based coolant. Refer to manual for specific color and mixture ratio (e.g., 50/50 with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.
Transmission Fluid Automatic:
Specific ATF (Automatic Transmission Fluid) as specified by Isuzu. Often Dexron III or equivalent.
Known Issues
Common Wear Items:
Clutch wear (especially in manual transmissions under heavy use), brake pad and rotor wear, suspension bushings and ball joints.
Diesel Engine Specific:
Potential for injector issues or turbocharger problems if maintenance is neglected. Fuel system maintenance is critical for longevity.
Electrical Gremlins:
As with many vehicles of this age, intermittent electrical issues can arise, often related to connectors or grounds. Wiring diagrams in the manual are essential for diagnosis.
๐Ÿ“š Vehicle History
Brand Heritage
Isuzu Truck Legacy:
Isuzu has a long and storied history in the production of commercial vehicles and reliable diesel engines, a heritage that extends to its pickup trucks.
Model Evolution
Dmax Second Gen:
The second generation (TF) D-Max, introduced around 2002 globally and updated through 2012, represented a significant evolution from its predecessor, offering improved styling, comfort, and powertrain options. This 2007-2012 period covers a mid-cycle refresh and continued production of this robust platform.
Production
Manufacturing Locations:
Produced in various Isuzu and partner facilities worldwide, including Thailand, which is a major global production hub for the D-Max.
๐Ÿ† Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2007-2012 model may not be as widely publicized as newer models, the D-Max consistently received positive recognition in various markets for its durability, reliability, and value for money, especially within the light commercial vehicle segment.
Ratings
Reliability Reputation:
Generally considered a reliable and robust vehicle, particularly praised for its Isuzu diesel engines and sturdy chassis, making it a popular choice for work and off-road use.
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