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
### Tensioner Pulley Replacement on Isuzu D-Max
#### Tools Needed
1. **Socket Set** (including 10mm, 12mm, and 14mm sockets)
2. **Ratchet Wrench**
3. **Torque Wrench**
4. **Pry Bar** (if necessary)
5. **Belt Removal Tool** (optional, for easier belt removal)
6. **Replacement Tensioner Pulley** (if needed)
7. **Safety Gloves**
8. **Safety Goggles**
9. **Mechanic's Creeper** (optional, for comfort)
#### Safety Precautions
1. **Disconnect Battery**: Always disconnect the negative terminal of the battery to prevent electrical shorts or accidental starts.
2. **Work in a Well-Ventilated Area**: Ensure good airflow to avoid inhaling any fumes.
3. **Wear Safety Gear**: Gloves and goggles protect against sharp edges and debris.
4. **Use Jack Stands**: If you need to lift the vehicle, use jack stands to secure it safely.
#### Steps to Replace the Tensioner Pulley
1. **Preparation**:
- Park the vehicle on a level surface and engage the parking brake.
2. **Access the Engine Compartment**:
- Open the hood and locate the serpentine belt and tensioner pulley.
3. **Remove Serpentine Belt**:
- Use a belt removal tool or a ratchet with the appropriate socket to relieve tension on the tensioner. Rotate the tensioner pulley counterclockwise to release the belt.
- Carefully slide the serpentine belt off the tensioner pulley and note the belt routing for reinstallation.
4. **Remove the Tensioner Pulley**:
- Inspect the tensioner assembly. Locate the bolts securing the tensioner pulley. These are typically 10mm or 12mm.
- Use the ratchet and appropriate socket to remove the bolts. Keep these bolts as you will reuse them.
5. **Take Out the Tensioner Pulley**:
- Gently pull the tensioner pulley off the tensioner assembly. If it’s stuck, use a pry bar gently to ease it off.
6. **Install New Tensioner Pulley**:
- Compare the old pulley with the new one to ensure they are identical.
- Align the new tensioner pulley on the tensioner assembly and press it into place.
7. **Reattach Bolts**:
- Reinstall the bolts you previously removed and tighten them to the manufacturer's specifications using a torque wrench.
8. **Reinstall the Serpentine Belt**:
- Refer to the belt routing diagram (usually found on a sticker in the engine bay).
- Use the ratchet to rotate the tensioner again and slide the belt back onto the tensioner pulley.
9. **Check Tension**:
- Ensure the belt is seated properly on all pulleys and that the tensioner is functioning correctly.
10. **Reconnect Battery**:
- Reconnect the negative terminal of the battery.
11. **Start Engine**:
- Start the engine and observe the tensioner pulley and belt for any unusual noises or misalignment.
#### Common Pitfalls to Avoid
- **Incorrect Belt Routing**: Always double-check the routing of the serpentine belt before starting the engine.
- **Over-tightening Bolts**: Ensure you adhere to the specified torque settings to avoid damaging the tensioner or the engine.
- **Neglecting Inspection**: Inspect other components such as idler pulleys and the serpentine belt for wear and replace if necessary.
### Replacement Parts
- Always use OEM or high-quality aftermarket tensioner pulleys to ensure proper function and longevity. If the serpentine belt shows signs of wear, it may be prudent to replace it simultaneously.
Following these steps carefully will help ensure a successful tensioner pulley replacement on your Isuzu D-Max.
rteeqp73
### Overview of Ball Joint Replacement
**What is a Ball Joint?**
A ball joint is a crucial component of your vehicle's suspension system. It connects the control arm to the wheel hub and allows for smooth movement of the suspension as well as steering. Think of it like a ball-and-socket joint in your body (like your shoulder), allowing for a wide range of motion while supporting weight.
### Why Ball Joint Replacement is Needed
**Why Repair?**
Ball joints can wear out over time due to constant stress, dirt, and lack of lubrication. When they wear, they can cause:
- **Poor Handling:** The vehicle may feel loose or unstable.
- **Uneven Tire Wear:** This can lead to premature tire replacement.
- **Noise:** You may hear clunking or popping noises from the front end of the vehicle.
### Symptoms of a Worn Ball Joint
- Excessive play or movement in the wheel.
- Clunking noises when going over bumps.
- Uneven tire wear.
- Steering issues, such as pulling to one side.
### Tools and Components Required
**Tools:**
1. Jack and jack stands
2. Lug wrench
3. Socket set (including deep sockets)
4. Wrench set
5. Ball joint separator (pickle fork)
6. Hammer
7. Torque wrench
8. Grease gun (if the new joint is greaseable)
9. Safety goggles and gloves
**Components:**
1. New ball joint (make sure it's the correct part for your model)
2. Cotter pin (if applicable)
3. New nuts and bolts (if necessary)
### Step-by-Step Ball Joint Replacement
#### 1. Preparation
- **Safety First:** Wear gloves and safety goggles. Ensure you have a clean workspace.
- **Gather Tools and Parts:** Make sure you have all required tools and the new ball joint ready.
#### 2. Lift the Vehicle
- **Loosen Lug Nuts:** Before lifting, slightly loosen the lug nuts on the wheel where you're replacing the ball joint.
- **Jack Up the Vehicle:** Use a jack to lift the vehicle and secure it with jack stands.
- **Remove the Wheel:** Completely remove the loosened lug nuts and take off the wheel.
#### 3. Access the Ball Joint
- **Locate the Ball Joint:** It's usually at the bottom of the steering knuckle.
- **Remove the Cotter Pin:** If there’s a cotter pin securing the ball joint nut, use pliers to remove it.
#### 4. Remove the Ball Joint Nut
- **Use the Socket/Wrench:** Remove the nut holding the ball joint to the steering knuckle. Keep this nut for reinstallation unless it's damaged.
#### 5. Separate the Ball Joint
- **Use Ball Joint Separator:** Position the separator between the steering knuckle and the ball joint.
- **Apply Force:** Tap the separator with a hammer if necessary to break the joint free. Be careful to avoid damaging surrounding components.
#### 6. Remove the Old Ball Joint
- **Unbolt the Joint:** If the ball joint is pressed into the control arm, you may need to unbolt it. Otherwise, simply pull it out from the steering knuckle.
#### 7. Install the New Ball Joint
- **Insert the New Joint:** Position the new ball joint into the control arm or steering knuckle.
- **Bolt it Down:** If it requires bolting, use new bolts for a secure fit.
#### 8. Reattach the Steering Knuckle
- **Reinsert the Ball Joint:** Place the ball joint back into the steering knuckle.
- **Secure with Nut:** Tighten the nut securely and insert a new cotter pin if applicable.
#### 9. Reassemble Everything
- **Reattach the Wheel:** Place the wheel back on and hand-tighten the lug nuts.
- **Lower the Vehicle:** Carefully remove the jack stands and lower the vehicle back to the ground.
- **Torque the Lug Nuts:** Use a torque wrench to tighten the lug nuts to the manufacturer’s specifications.
#### 10. Test Drive
- **Check for Issues:** After replacing the ball joint, take the vehicle for a short test drive. Listen for unusual noises and check for proper handling.
### Recap of the Theory Behind the Repair
Ball joints allow for articulation in the suspension while supporting the vehicle's weight. Over time, they can wear out, leading to handling issues, noise, and uneven tire wear. Replacing them restores proper function and safety.
### Conclusion
Replacing a ball joint may seem daunting, but by following these steps and understanding the function and importance of the component, you can successfully perform the repair. Always ensure safety and adhere to manufacturer specifications throughout the process.
rteeqp73
### Clutch Release Bearing Replacement on Isuzu D-Max
#### Theory Behind the Repair
**What is the Clutch Release Bearing?**
The clutch release bearing, also known as the throw-out bearing, is a crucial component in the clutch assembly of your Isuzu D-Max. It allows the clutch to disengage when you press the clutch pedal, enabling smooth gear changes.
**How the System Works:**
- **Clutch Components:** The clutch system consists of the clutch pedal, clutch master cylinder, slave cylinder, clutch disc, pressure plate, and the release bearing.
- **Functionality:** When you press the clutch pedal, hydraulic fluid is sent from the master cylinder to the slave cylinder, which pushes the release bearing against the pressure plate. This action disengages the clutch, allowing you to change gears.
**Why Replacement is Needed:**
Over time, the release bearing can wear out due to:
- **Friction:** Continuous engagement and disengagement create wear.
- **Heat:** Excessive heat from the clutch can cause the bearing to fail.
- **Contamination:** Dust and dirt can enter the bearing, causing it to grind and wear prematurely.
**Symptoms of Failure:**
- Grinding or squeaking noises when the clutch is engaged.
- Difficulty in engaging or disengaging gears.
- Vibration in the clutch pedal.
### Tools and Components Required
#### Tools:
1. **Socket Set:** Metric sockets (10mm to 19mm).
2. **Torque Wrench:** To ensure proper tightening of bolts.
3. **Pliers:** For removing clips and hoses.
4. **Screwdrivers:** Flathead and Phillips.
5. **Jack and Jack Stands:** For lifting the vehicle safely.
6. **Clutch Alignment Tool:** Ensures the clutch disc is centered when reassembling.
7. **Brake Cleaner:** For cleaning components.
#### Components:
1. **Clutch Release Bearing:** New bearing to replace the old one.
2. **Clutch Kit (optional):** Includes clutch disc and pressure plate if worn.
3. **Pilot Bearing:** Sometimes replaced simultaneously.
4. **Transmission Fluid:** For refilling after reassembly.
### Step-by-Step Replacement Process
#### Preparation:
1. **Safety First:** Park the vehicle on a flat surface, engage the parking brake, and disconnect the battery.
2. **Lift the Vehicle:** Use a jack to raise the front of the vehicle and secure it with jack stands.
#### Disassembly:
1. **Remove the Transmission:**
- **Disconnect Components:** Remove the driveshaft, starter motor, and any electrical connectors attached to the transmission.
- **Unbolt the Transmission:** Remove the bolts securing the transmission to the engine. Support the transmission with a jack and carefully slide it away from the engine.
2. **Remove the Clutch Assembly:**
- **Unbolt the Pressure Plate:** Remove the bolts securing the pressure plate to the flywheel. Note the order of removal.
- **Take Out the Clutch Disc:** Once the pressure plate is off, slide the clutch disc out.
3. **Access the Release Bearing:**
- **Remove the Release Bearing:** The release bearing may be attached to the fork or the transmission casing. If it’s on the fork, pull it off gently. If it’s pressed into a housing, you may need to use a puller.
#### Installation:
4. **Install the New Release Bearing:**
- **Position the New Bearing:** If it sits on a fork, slide it onto the fork. If it fits into a housing, ensure it's seated correctly.
5. **Reinstall the Clutch Assembly:**
- **Place the Clutch Disc:** Position the new or existing clutch disc onto the flywheel.
- **Align with the Tool:** Use the clutch alignment tool to ensure proper alignment.
- **Attach Pressure Plate:** Bolt the pressure plate back onto the flywheel, tightening in a crisscross pattern for even pressure.
6. **Reattach the Transmission:**
- **Guide the Transmission:** Carefully align it with the engine and slide it back into place. Ensure the input shaft fits into the clutch disc.
- **Bolt the Transmission Back On:** Reinstall the bolts, securing it to the engine.
#### Final Steps:
7. **Reconnect Components:** Reattach the driveshaft, starter motor, and any electrical connectors.
8. **Refill Transmission Fluid:** Check the level and add fluid if necessary.
9. **Lower the Vehicle:** Remove jack stands and lower the vehicle to the ground.
10. **Reconnect the Battery:** Reconnect the negative terminal.
#### Testing:
1. **Start the Vehicle:** Turn on the engine and press the clutch pedal, checking for smooth engagement and disengagement.
2. **Test Drive:** Take the vehicle for a test drive, ensuring that you can shift gears without issues.
### Conclusion
Replacing the clutch release bearing is a manageable task with the right tools and knowledge. Regular maintenance can prevent premature wear, ensuring your Isuzu D-Max operates smoothly. Always refer to your vehicle's service manual for specific torque specifications and procedures.
rteeqp73
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