Isuzu D-Max 2010 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

### Intake Gasket Replacement on Isuzu D-Max

#### Overview
The intake gasket is a seal located between the intake manifold and the engine block (or cylinder head). Its primary purpose is to ensure a proper seal that prevents air and fuel mixture from leaking out. A faulty gasket can lead to performance issues, increased fuel consumption, or engine damage.

### Why This Repair is Needed
The intake manifold draws air into the engine for combustion. The intake gasket ensures that this air enters the engine without any leaks. If the gasket fails, it can cause:

- **Air Leaks**: Unmetered air enters the engine, leading to a lean fuel mix, causing poor engine performance and increased emissions.
- **Coolant Leaks**: If the engine has a coolant passage, a failed gasket can allow coolant to leak into the intake, leading to overheating and potential engine damage.
- **Oil Leaks**: Oil can also leak, leading to contamination and performance issues.

### Components Involved
1. **Intake Gasket**: The main seal that sits between the intake manifold and the engine.
2. **Intake Manifold**: The component that distributes the air-fuel mixture to the engine cylinders.
3. **Bolts**: Used to secure the intake manifold to the engine.
4. **Throttle Body**: Controls the amount of air entering the engine.
5. **Vacuum Lines**: Small hoses that connect to the intake for various sensors and components.

### Tools Required
- Socket set
- Torque wrench
- Gasket scraper
- Clean rags
- Engine degreaser
- New intake gasket

### Step-by-Step Procedure

1. **Preparation**
- **Disconnect Battery**: Safety first—disconnect the negative terminal to prevent electrical shorts.
- **Remove Engine Cover** (if applicable): Some models have a cover that needs to be removed first.

2. **Remove the Intake Manifold**
- **Label and Disconnect Components**: Take note of where each vacuum line, throttle body, and sensor connects. Use tape or tags if necessary.
- **Unbolt the Intake Manifold**: Use a socket wrench to remove the bolts securing the manifold. Keep them organized.
- **Carefully Lift the Manifold**: Gently pull the manifold away from the engine block, being cautious about any attached components.

3. **Remove Old Gasket**
- **Inspect the Old Gasket**: Look for cracks, tears, or signs of wear.
- **Clean the Surfaces**: Use a gasket scraper to remove any remnants of the old gasket from both the engine block and the intake manifold. Ensure the surface is clean and smooth.

4. **Install New Gasket**
- **Position the New Gasket**: Align the new gasket perfectly with the openings on the engine block.
- **Check Alignment**: Make sure all ports (air, coolant, etc.) are aligned properly.

5. **Reattach the Intake Manifold**
- **Place the Manifold Back**: Carefully lower the manifold onto the new gasket.
- **Bolt it Down**: Hand-tighten the bolts first, then use a torque wrench to tighten them to the manufacturer’s specified torque settings (found in the service manual). Generally, it's done in a criss-cross pattern to ensure even pressure.

6. **Reconnect Components**
- **Reattach Throttle Body and Vacuum Lines**: Ensure all connections are secure.
- **Reconnect Battery**: Reattach the negative terminal.

7. **Test the Repair**
- **Start the Engine**: Check for odd noises or leaks.
- **Monitor Performance**: Ensure the engine runs smoothly without stalling or misfires.

### Common Issues
- **Improper Torque**: If bolts are not torqued correctly, it can lead to leaks.
- **Contaminated Surfaces**: Any debris left on the surfaces can prevent a proper seal.
- **Incorrect Gasket**: Ensure the new gasket matches the specifications for your vehicle.

### Final Thoughts
Replacing the intake gasket is a crucial task for maintaining engine performance. Think of the intake manifold as a pipe that carries air and fuel to your engine. If there's a hole in that pipe (a leaky gasket), it can disrupt the flow, causing your engine to run poorly. By ensuring a good seal with a new gasket, you help your engine perform efficiently and reliably.
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### Tools Required

- **Socket Set**
- **Description**: A set of various-sized sockets and a ratchet handle.
- **Use**: To remove bolts and nuts securing the shock mount to the vehicle.
- **Extra Tip**: Make sure to have a metric socket set, as most fasteners on Isuzu vehicles are metric.

- **Wrench Set**
- **Description**: A set of open-end and box-end wrenches.
- **Use**: Helpful if there are tight spaces where a socket cannot fit.
- **Extra Tip**: Use the proper size to avoid stripping the bolts.

- **Pry Bar**
- **Description**: A long, sturdy metal tool used for leverage.
- **Use**: To help remove stubborn components or to create space when necessary.
- **Extra Tip**: Use it gently to avoid damaging surrounding parts.

- **Torque Wrench**
- **Description**: A tool to ensure bolts are tightened to specific torque settings.
- **Use**: To properly tighten shock mount bolts according to manufacturer specifications.
- **Extra Tip**: This prevents over-tightening, which can damage parts.

- **Jack and Jack Stands**
- **Description**: A hydraulic jack to lift the vehicle, and jack stands to support it.
- **Use**: To safely elevate the car, allowing access to the shock mounts.
- **Extra Tip**: Never work under a vehicle supported only by a jack.

- **Replacement Shock Mounts**
- **Description**: The rubber or metal components that connect the shock absorber to the vehicle frame.
- **Use**: If existing mounts are worn, cracked, or damaged, they need replacement for proper functionality.

### Steps for Shock Mount Repair

- **Preparation**
- Secure the car on a flat surface.
- Use the jack to lift the vehicle and place jack stands under the chassis for safety.

- **Remove the Wheel**
- Use a lug wrench to remove the wheel where the shock mount is located. This provides better access.

- **Locate the Shock Mount**
- Identify the shock absorber and locate the upper and lower shock mounts.

- **Remove the Shock Absorber**
- Use the socket set to remove bolts securing the shock absorber to the mounts.
- If the bolts are stuck, apply penetrating oil and wait a few minutes.

- **Check the Shock Mounts**
- Inspect the rubber grommets or bushings on the shock mounts.
- If they are cracked or worn, they need to be replaced.

- **Install New Shock Mounts**
- Position the new mounts in place.
- Align them and insert bolts, tightening them by hand first.

- **Torque the Bolts**
- Use the torque wrench to tighten bolts to manufacturer specifications.
- This ensures the shock mount is securely fastened without being over-tightened.

- **Reinstall the Shock Absorber**
- Position the shock absorber back into place, securing it with bolts.

- **Reattach the Wheel**
- Place the wheel back on and tighten the lug nuts.

- **Lower the Vehicle**
- Carefully remove the jack stands and lower the vehicle using the jack.

### Additional Notes

- **Replacement Parts**: Always replace worn or damaged shock mounts to ensure the suspension system functions correctly.
- **Safety**: Wear safety glasses and gloves during the repair to protect yourself from debris and sharp objects.
- **Consult Manual**: If in doubt, refer to the Isuzu D-Max service manual for specific torque settings and part numbers.
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A transmission fluid flush on an Isuzu D-Max (or any vehicle) is performed to maintain the health of the transmission system. Here's the theory behind it and how the process works to fix potential issues:

### Theory Behind Transmission Fluid Flush

1. **Purpose of Transmission Fluid**:
- Transmission fluid lubricates the moving parts within the transmission, cools the system, and provides hydraulic pressure for gear shifting. Over time, the fluid can become contaminated with debris, metal shavings, and degraded additives.

2. **Symptoms of Contaminated Fluid**:
- Contaminated fluid can lead to poor shifting performance, overheating, slippage, and potential transmission failure. Flushing the fluid helps restore optimal function and prolongs the lifespan of the transmission.

3. **Flushing vs. Draining**:
- A flush involves circulating a cleaning solution through the transmission to remove old fluid and contaminants, while a drain and fill only removes a portion of the fluid. A flush aims for a more thorough cleaning.

### Steps of the Flush Process

1. **Preparation**:
- Ensure the vehicle is on a level surface, and gather necessary tools and materials (flush machine, new fluid, etc.).

2. **Connect Flush Machine**:
- Attach the flush machine to the transmission cooler lines. This machine will push the cleaning solution through the transmission and remove old fluid.

3. **Circulate Cleaning Solution**:
- Start the machine, which pumps the cleaning fluid into the transmission. This fluid dislodges contaminants and old fluid, effectively cleaning the internal components.

4. **Fluid Replacement**:
- As the old fluid is expelled, new transmission fluid is introduced. This process often involves a continuous cycle where old fluid is removed, and new fluid is added until the fluid coming out is clean.

5. **Inspect and Replace Filter**:
- While performing a flush, it’s advisable to check and replace the transmission filter if applicable. A clogged filter can restrict fluid flow and cause issues regardless of fluid cleanliness.

6. **Final Checks**:
- Once the flush is complete, reconnect any removed components, check fluid levels, and run the engine to circulate the new fluid. Check for leaks and ensure proper operation.

### How the Repair Fixes the Fault

- **Restores Fluid Quality**: The flush replaces degraded fluid with fresh fluid that has the correct viscosity and additive package, ensuring effective lubrication and cooling.
- **Removes Contaminants**: The cleaning solution eliminates sludge and metal particles that could hinder performance, thus restoring optimal hydraulic function.
- **Improves Shifting Performance**: Fresh fluid provides better hydraulic pressure for smoother gear shifts, reducing slippage and enhancing responsiveness.
- **Prevents Overheating**: Clean fluid helps maintain better thermal management, preventing overheating and reducing the risk of transmission failure.

By performing a transmission fluid flush, you effectively address the degradation of fluid quality and contaminants, leading to improved transmission performance and longevity.
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