Isuzu D-Max 2007 factory workshop and repair manual download pdf

The Isuzu D-Max is a pickup truck built by automaker Isuzu since 2002. It shares the exact same system with some General Motors (GM) mid-size trucks in the United States as the Chevrolet Colorado, GMC Canyon and Isuzu i-Series. The Chevrolet Colorado name is additionally used to a rebadged variation of the D-Max in the Middle East and Thailand, although not identical to the American version. The original D-Max is sold alongside the Chevrolet Colorado in the Thai market in which they are both built. In Australasia between 2003 and 2008, the D-Max was marketed as the Holden Rodeo, but has since been relaunched as the Holden Colorado. The Isuzu D-Max itself was additionally introduced in Australia during 2008, selling alongside the Holden offering. in the United Kingdom, the D-Max is offered there as the Isuzu Rodeo.

Julie Beamer, director of GM Chile announced on March 5, 2008 to their workers of the only remaining automobile factory in Chile would close on July 31. To that day, the only product currently on production on that factory was the Chevrolet D-Max. The information came little after Hugo reduced the import quota for cars in Venezuela, the main export market of Chilean-made Chevrolet D-Max, but GM Chile said on its official statement that the reason behind the end of manufacturing in Arica were the lack of favourable conditions for vehicle production in Chile, and the stiff competition from many other carmakers and countries on Chile's car market.

The Thai-market Colorado is smaller than the North United states model of the exact same name and almost unrelated. In belated January 2006, Chevrolet introduced a G-80 differential lock system as elective for most Colorado trim levels. This feature is not available on the D-Max. The Thai-market Colorado received a minor redesign in late 2007.

Late first quarter of 2008, Chevrolet additionally introduced Colorado 4x2 2.5 with diesel dual fuel system via CNG tank. Switchable between diesel (65) and compressed natural gas (35) as the separated aspect (65:35); moreover additionally can use diesel purely as well. Biodiesel B5 is also acceptable. Location of tank is on the bed behind cab. Available for 2 cabstyles.

In March 2011, Chevrolet revealed the prototype version of all-new Colorado at Bangkok Motor Show, not related anymore to D-Max, shown as Extended cab with rear access system, and some of high-tech stuff, In June 2011, Chevrolet revealed crew cab in adventure concept at Buenos Aires, Argentina (this car also shown at Frankfurt Auto Show on September, 2011), and in July 2011, a Holden version of crew-cab version concept car got its premier at Australian International Motor Show, but the interior of this vehicle looked like manufacturing models any more than 2 concepts before.

In September 9, 2011, General Motors (Thailand) are opening the diesel engine manufacture plant, to make the "Duramax" engine, as the VM Motori rebadge engine (same as old 2-liter diesel Captiva) with 2.5 or 2.8-liter, manual and 2WD, automatic or 4WD. New 2012 Isuzu D-MAX Pickup Truck is actually the Chevy Colorado's Asian Twin.

Isuzu has long abandoned the U.S. Passenger and truck marketplace but it continues to have strong ties with General Motors, which was once its primary stockholder. In 2011, the Japanese automaker revealed its all-new D-MAX pickup truck, which was designed in cooperation with GM and is a sibling model to the 2012 Chevrolet Colorado. Albeit on separate occasions, both pickup truck models were presented in Thailand. On the outside, the new 2012 D-MAX qualities different front and back end styling treatments as well as bespoke trim parts, while inside, the changes over the Colorado are limited to the color options and the instrument panel. The body-on-frame Isuzu D-MAX launches in Thailand with three turbodiesel engines, including a pair of 2.5-liter units producing 115HP and 136HP, and a larger 3.0-liter powerplant with 177-horses.

Isuzu D-Max 2007-2012 Factory Service Workshop Manual

### Spark Plug Replacement on Isuzu D-Max

#### Tools Needed:
1. **Socket Wrench Set** (including 10mm and 14mm sockets)
2. **Spark Plug Socket** (usually 5/8" or 16mm)
3. **Torque Wrench**
4. **Extension Bar** (if needed)
5. **Gap Tool** (for checking spark plug gap)
6. **Anti-Seize Compound** (optional)
7. **Dielectric Grease** (optional)
8. **Ratcheting Wrench** (for tight spaces)
9. **Vacuum or Compressed Air** (for cleaning)
10. **Safety Goggles**
11. **Gloves**

#### Safety Precautions:
- Ensure the engine is cool before starting.
- Disconnect the negative battery terminal to prevent electrical shorts.
- Wear safety goggles to protect your eyes from debris.
- Use gloves to protect your hands from dirt and engine oil.

#### Step-by-Step Instructions:

1. **Preparation:**
- Park the vehicle on a level surface and turn off the ignition.
- Open the hood and locate the spark plugs, which are typically found on the engine cylinder head.

2. **Remove Engine Cover (if applicable):**
- Use a socket wrench to remove any bolts securing the engine cover. Set the cover aside.

3. **Disconnect Ignition Wires:**
- Carefully pull off the ignition coil or spark plug wires. Use dielectric grease to help prevent future sticking if necessary.
- Note the order of the wires for reinstallation.

4. **Clean Area Around Spark Plugs:**
- Use a vacuum or compressed air to remove any debris around the spark plugs. This prevents dirt from entering the combustion chamber.

5. **Remove Old Spark Plugs:**
- Use the spark plug socket attached to a ratcheting wrench or lever to loosen the spark plug. Turn counter-clockwise.
- Carefully pull out the spark plug once it's loose. Inspect for any signs of damage or wear.

6. **Check Spark Plug Gap:**
- Use the gap tool to check the gap on the new spark plug against manufacturer specifications (usually found in the owner’s manual).

7. **Install New Spark Plugs:**
- Apply a small amount of anti-seize compound to the threads of the new spark plug (optional).
- Insert the new spark plug into the socket and hand-tighten it into the cylinder head.
- Use a torque wrench to tighten to the manufacturer’s specifications (usually around 15-20 lb-ft).

8. **Reconnect Ignition Wires:**
- Reattach the ignition coil or spark plug wires in the correct order, ensuring they snap into place securely.

9. **Reinstall Engine Cover (if removed):**
- Place the engine cover back and secure it with bolts.

10. **Reconnect Battery:**
- Reconnect the negative battery terminal.

11. **Test the Engine:**
- Start the engine and listen for smooth operation. Check for any warning lights on the dashboard.

#### Common Pitfalls to Avoid:
- **Over-tightening the Spark Plugs:** This can strip the threads in the cylinder head.
- **Incorrect Gap Size:** Always verify the gap; an incorrect size can lead to misfires or poor performance.
- **Forgetting to Reconnect Wires:** Double-check that all ignition wires are reconnected properly.
- **Neglecting to Clean the Area:** Failing to clean around the spark plugs can lead to debris entering the combustion chamber.

By following these steps carefully, you will successfully replace the spark plugs on an Isuzu D-Max.
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### Tools Required for Flywheel Resurfacing

- **Torque Wrench**:
- **Description**: A precision tool used to apply a specific torque to fasteners.
- **Use**: Essential for tightening flywheel bolts to manufacturer specifications to prevent damage.

- **Impact Wrench**:
- **Description**: A power tool that delivers high torque output with minimal effort.
- **Use**: Useful for removing stubborn bolts quickly and efficiently.

- **Flywheel Resurfacing Machine**:
- **Description**: A specialized machine designed to grind the flywheel surface to achieve a flat, smooth finish.
- **Use**: Ensures that the flywheel has a perfect mating surface for the clutch, preventing slippage and improving performance.

- **Dial Indicator**:
- **Description**: A precision measuring tool that helps check for runout (warping) on the flywheel.
- **Use**: Ensures the flywheel is within acceptable tolerances before resurfacing.

- **Safety Gear**:
- **Description**: Includes safety glasses, gloves, and ear protection.
- **Use**: Protects against debris, noise, and potential injuries during the resurfacing process.

### Steps for Flywheel Resurfacing

- **Preparation**:
- Remove the flywheel from the Isuzu D-Max by disconnecting the transmission. Use the impact wrench to remove bolts.
- **Replacement Consideration**: If the flywheel is excessively worn, cracked, or has deep grooves, replacement may be necessary. Look for signs of damage.

- **Check for Runout**:
- Attach the dial indicator to the flywheel surface and rotate it.
- Measure the runout; if it exceeds manufacturer specifications, replacement is advised.

- **Resurfacing Process**:
- Mount the flywheel on the resurfacing machine securely.
- Adjust the machine settings according to the manufacturer's guidelines.
- Slowly grind the surface until it is flat and smooth. Regularly check the surface for evenness.

- **Cleaning**:
- After resurfacing, clean the flywheel with a suitable solvent to remove any debris or particles.

- **Reinstallation**:
- Place the resurfaced flywheel back onto the engine. Use the torque wrench to tighten the bolts to the specified torque setting.
- Reinstall the transmission and other components.

### Additional Considerations

- **Replacement Parts**:
- If the flywheel is beyond repair or if the clutch shows signs of wear, consider replacing both the clutch and flywheel.
- Common replacement parts include a new clutch disc, pressure plate, and possibly the flywheel itself if it is damaged.

- **Why Replacement is Necessary**:
- A damaged or uneven flywheel can lead to clutch slippage, poor engagement, and vibrations, ultimately affecting vehicle performance and safety.

### Conclusion
- Ensure you have all tools ready, follow safety precautions, and carefully assess the flywheel's condition before deciding on resurfacing or replacement. Always refer to the Isuzu D-Max service manual for specific torque specifications and procedures.
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### Wheel Bearing Replacement on an Isuzu D-Max

#### **Theory Behind Wheel Bearings**

**Function**:
Wheel bearings allow the wheels to rotate smoothly with minimal friction. They support the weight of the vehicle and facilitate the rotation of the wheel hub.

**Structure**:
A wheel bearing consists of an inner and outer race, rolling elements (usually ball bearings or tapered rollers), and a cage that keeps the rolling elements spaced evenly.

**Why Replacement is Needed**:
- **Wear and Tear**: Bearings can wear out from constant use, leading to increased friction, noise, and heat.
- **Contamination**: Dirt and moisture can enter the bearing, causing corrosion and failure.
- **Overloading**: Carrying heavy loads can exceed the bearing's capacity, leading to premature wear.

**Symptoms of Failure**:
- Grinding or whining noises while driving
- Vibration in the steering wheel
- Uneven tire wear

### **Components Needed for the Repair**

1. **New Wheel Bearings** (inner and outer)
2. **Bearing Grease** (high-temperature wheel bearing grease)
3. **Tools**:
- Jack and jack stands
- Lug wrench
- Socket set
- Torque wrench
- Hammer
- Bearing puller or slide hammer
- Screwdrivers (flat and Phillips)
- Pliers
- Cleaning cloths
- Safety glasses and gloves

### **Step-by-Step Replacement Process**

#### **1. Prepare the Vehicle**

- **Safety First**: Ensure the vehicle is on a level surface. Engage the parking brake.
- **Loosen Lug Nuts**: Using a lug wrench, slightly loosen the lug nuts on the wheel where you will be replacing the bearing. Do not remove them yet.

#### **2. Lift the Vehicle**

- **Jack Up the Vehicle**: Use a jack to lift the front or rear of the vehicle (depending on which bearing is being replaced).
- **Secure with Jack Stands**: Place jack stands under the vehicle for safety.

#### **3. Remove the Wheel**

- **Take Off the Wheel**: Fully remove the loosened lug nuts and take off the wheel. Set it aside.

#### **4. Access the Wheel Hub Assembly**

- **Remove Brake Caliper**: Unbolt the brake caliper from its mount. Support it using a bungee cord or rope (do not let it hang by the brake line).
- **Remove Brake Rotor**: If applicable, remove the brake rotor by pulling it off the hub assembly.

#### **5. Remove the Wheel Bearing**

- **Remove the Hub Assembly**:
- If your D-Max has a hub nut, use a socket to remove it.
- If applicable, remove any retaining clips or washers.
- Use a bearing puller or slide hammer to extract the hub assembly if needed.

- **Remove the Old Bearing**:
- Use a hammer and punch to knock out the old bearing from the hub. Be careful not to damage the hub itself.

#### **6. Install the New Wheel Bearing**

- **Clean the Hub Area**: Wipe the inside of the hub with a clean cloth to remove any debris or old grease.
- **Grease the New Bearing**: Apply a generous amount of high-temperature grease to the new bearing.
- **Insert the New Bearing**: Tap the new bearing into the hub carefully using a hammer and a block of wood to avoid damage.

#### **7. Reassemble the Hub Assembly**

- **Reattach the Hub**: If you removed it, place the hub back onto the spindle.
- **Install the Hub Nut**: Tighten it to the manufacturer’s specifications using a torque wrench.
- **Reattach the Brake Rotor and Caliper**: Put the brake rotor back in place and reattach the brake caliper.

#### **8. Reinstall the Wheel**

- **Put the Wheel Back On**: Align the wheel with the hub and hand-tighten the lug nuts.
- **Lower the Vehicle**: Carefully remove the jack stands and lower the vehicle back to the ground.

#### **9. Tighten Lug Nuts**

- **Torque Lug Nuts**: Use a torque wrench to tighten the lug nuts to the specified torque. Start with one nut and work in a crisscross pattern to ensure even tightening.

#### **10. Test Drive**

- **Check for Noise**: Drive the vehicle a short distance to check for any unusual noises or vibrations.

### **What Can Go Wrong?**

- **Incorrect Installation**: Misalignment can cause premature bearing failure.
- **Not Using the Right Tools**: Using improper tools can lead to damage.
- **Neglecting Maintenance**: Failing to regularly check and maintain bearings can cause severe wear and potential wheel failure.

### Conclusion

Replacing wheel bearings is a crucial maintenance task that ensures the safe and smooth operation of your Isuzu D-Max. By following these steps carefully, you can successfully replace the wheel bearings and prolong the life of your vehicle. Always prioritize safety and consult your vehicle’s manual for specific torque specifications and procedures.
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