Isuzu D-Max 2012 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

### Gearbox Torque Converter Clutch Repair on an Isuzu D-Max

#### **Theory Behind the Repair**

The torque converter clutch (TCC) is an important component in automatic transmissions, including the Isuzu D-Max. Its primary function is to lock the torque converter when the vehicle reaches a certain speed, allowing direct drive from the engine to the transmission. This improves fuel efficiency and reduces engine load.

**Why Repair is Needed:**
1. **Slipping:** If the TCC fails to engage, it can lead to slipping, causing increased fuel consumption and engine strain.
2. **Overheating:** A malfunctioning TCC can cause overheating, damaging the transmission.
3. **Shuddering:** A failing TCC may cause the vehicle to shudder or vibrate during acceleration.

#### **How the System Works**

- **Torque Converter:** The torque converter uses fluid to transmit power from the engine to the transmission. It consists of three main components: the impeller, turbine, and stator.
- **TCC Activation:** When engaged, the TCC locks the impeller and turbine, creating a direct connection and eliminating slip.
- **Control Module:** The vehicle’s computer monitors various parameters (speed, throttle position) to determine when to engage the TCC.

#### **Components Involved**

1. **Torque Converter:** Contains the TCC within it.
2. **TCC Solenoid:** Controls the fluid flow to engage or disengage the TCC.
3. **Transmission Fluid:** Essential for hydraulic pressure and cooling.
4. **Control Module:** Electronic control that manages TCC operation.
5. **Seals and Gaskets:** Prevent fluid leaks.
6. **Pan and Filter:** Collect debris and ensure clean fluid circulation.

### **Tools Required**

- Socket set
- Wrench set
- Torque wrench
- Screwdrivers
- Transmission jack
- Fluid catch pan
- Replacement TCC solenoid (if needed)
- Transmission fluid
- Gasket maker or replacement gasket
- Safety gloves and goggles

### **Step-by-Step Repair Procedure**

1. **Preparation:**
- Park the vehicle on a level surface and engage the parking brake.
- Disconnect the battery to prevent any electrical shorts.

2. **Drain Transmission Fluid:**
- Locate the transmission pan and place a fluid catch pan beneath it.
- Remove the pan bolts and carefully drop the pan to drain the fluid.

3. **Remove Transmission Pan:**
- Clean the pan and inspect the filter. Replace if necessary.
- Remove any old gaskets or sealant from the mating surfaces.

4. **Access the Torque Converter:**
- Depending on the model, you may need to remove the transmission from the vehicle. Use a transmission jack to support it.
- Disconnect any electrical connectors and transmission lines.

5. **Remove the Torque Converter:**
- Unbolt the torque converter from the flywheel.
- Carefully pull the torque converter away from the transmission.

6. **Inspect the Torque Converter:**
- Check for damage, wear, or debris in the converter. If damaged, replace it.

7. **Replace the TCC Solenoid:**
- Locate the TCC solenoid within the transmission assembly.
- Disconnect electrical connectors and remove the solenoid.
- Install the new solenoid, ensuring it is seated properly.

8. **Reassemble:**
- Reinstall the torque converter, making sure it is properly aligned and secured.
- Reattach the transmission, ensuring all bolts are tightened to specifications.
- Reinstall the transmission pan with a new gasket or sealant.

9. **Refill Transmission Fluid:**
- Use a funnel to add new transmission fluid through the dipstick tube. Consult the owner’s manual for the correct type and amount.
- Start the engine and let it idle, checking for leaks.

10. **Test Drive:**
- Take the vehicle for a test drive to ensure the TCC engages smoothly and there are no leaks or abnormal sounds.

### **Common Issues to Watch For**

- **Fluid Leaks:** After reassembly, check for leaks around the pan, solenoid, and torque converter.
- **Check Engine Light:** If the TCC fails to engage or disengage properly, it may trigger a warning light.
- **Shuddering:** If the vehicle shudders during acceleration, the TCC may still be malfunctioning.

### **Conclusion**

Repairing the torque converter clutch in an Isuzu D-Max involves a detailed understanding of the components and their functions. Proper diagnosis and attention to detail during the repair process will ensure the vehicle operates efficiently and effectively. Always consult the vehicle’s service manual for specific torque specifications and procedures.
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- **Safety Gear**
- **Gloves**: Protects hands from sharp edges and hot components.
- **Safety Glasses**: Shields eyes from debris and fluids.

- **Basic Tools Needed**
- **Socket Set**: A set of sockets to fit various bolts and nuts. Typically, you'll need 10mm, 12mm, and 14mm sockets for Isuzu D-Max.
- **How to Use**: Select the correct size socket, attach it to a ratchet handle, and turn counterclockwise to loosen bolts.
- **Ratchet Wrench**: Used with the socket set to tighten or loosen bolts.
- **How to Use**: Attach the socket; pull the handle to turn the socket; reverse direction to loosen.
- **Pliers**: Useful for gripping and pulling hoses or small components.
- **How to Use**: Open the jaws, place them around the object, and squeeze to grip.
- **Screwdriver Set**: A flathead and Phillips screwdriver can be necessary for removing panels and securing screws.
- **How to Use**: Match the head of the screwdriver to the screw type; turn counterclockwise to remove screws.
- **Hose Clamp Pliers**: Specialized pliers to remove and install hose clamps on the heater hoses.
- **How to Use**: Squeeze the handles to compress the clamp and slide it off the hose.
- **Coolant Catch Pan**: To collect any coolant that spills during the process.
- **How to Use**: Position it under the area where coolant will drain.

- **Additional Tools (if required)**
- **Torque Wrench**: Ensures that bolts are tightened to the manufacturer’s specifications when reassembling.
- **How to Use**: Set the desired torque value, attach the socket, and turn until you hear a click indicating the set torque is reached.

- **Replacement Parts**
- **Heater Core**: If the heater core is leaking or clogged, it needs replacement.
- **Why**: A faulty heater core can lead to overheating, coolant leaks, or poor heating in the cabin.
- **Replacement Part**: Purchase a new heater core specific to the Isuzu D-Max model year.
- **Hoses and Clamps**: Inspect hoses for cracks or leaks; replace if damaged.
- **Why**: Old or damaged hoses can fail under pressure and lead to further leaks or overheating.

- **Procedure Overview**
- **Drain Coolant**: Use the coolant catch pan to catch coolant from the radiator.
- **How**: Open the radiator drain valve or remove the lower hose.
- **Remove Dashboard Components**: Detach any necessary panels and the glove box to access the heater core.
- **How**: Use screwdrivers and pliers as needed.
- **Disconnect Heater Hoses**: Use hose clamp pliers to slide clamps off the hoses and pull the hoses off the heater core.
- **Remove Heater Core**: Unbolt the heater core from its housing and carefully pull it out.
- **Install New Heater Core**: Insert the new core into the housing and secure it with bolts.
- **Reattach Hoses**: Slide hoses back on the heater core and secure clamps.
- **Reassemble Dashboard Components**: Replace any panels or parts removed, ensuring everything is secured.
- **Refill Coolant**: Fill the radiator with new coolant and run the engine to check for leaks.

- **Final Checks**
- **Test the Heater**: Turn on the vehicle and the heater to ensure proper function.
- **Check for Leaks**: Monitor the area around the heater core for any signs of coolant leakage after installation.
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### Brake Rotor Replacement on Isuzu D-Max

#### Tools Needed:
1. **Jack and Jack Stands** - To lift and secure the vehicle.
2. **Lug Wrench** - For wheel nut removal.
3. **Socket Set** - Typically 12mm and 14mm for caliper bolts.
4. **Torque Wrench** - For properly torquing bolts.
5. **Brake Caliper Tool** - For compressing the caliper piston.
6. **Brake Cleaner** - To clean the rotors.
7. **Shop Towels/Rags** - For cleaning and wiping surfaces.
8. **C-clamp or Piston Tool** - To compress caliper piston.
9. **Anti-Seize Compound** (optional) - For rotor installation.

#### Safety Precautions:
1. **Wear Safety Glasses and Gloves** - To protect your eyes and hands.
2. **Ensure Vehicle is on a Flat Surface** - To prevent rolling.
3. **Use Proper Jack Stands** - Never work under a vehicle supported only by a jack.
4. **Ensure Parking Brake is Engaged** - To prevent the vehicle from moving.

#### Steps for Brake Rotor Replacement:

1. **Preparation**
- Park the vehicle on a flat surface, engage the parking brake, and place wheel chocks behind the rear wheels.

2. **Loosen Lug Nuts**
- Using a lug wrench, slightly loosen the lug nuts of the wheel where the rotor will be replaced, but do not remove them completely.

3. **Lift Vehicle**
- Jack the vehicle up and secure it with jack stands. Ensure it is stable before proceeding.

4. **Remove Wheel**
- Fully remove the loosened lug nuts and take off the wheel to expose the brake components.

5. **Remove Caliper**
- Locate the caliper mounting bolts (usually 12mm or 14mm). Use a socket to remove these bolts.
- Carefully slide the caliper off the rotor. Do not disconnect the brake line; instead, support the caliper using a bungee cord or similar to prevent strain on the hose.

6. **Remove Old Rotor**
- If the rotor is held in place by retaining screws, remove these using the appropriate screwdriver or socket.
- Slide the rotor off the hub. If it’s stuck, gently tap it with a rubber mallet to free it.

7. **Prepare New Rotor**
- Clean the new rotor with brake cleaner to remove any protective oils. Allow it to dry.

8. **Install New Rotor**
- Slide the new rotor onto the hub. If applicable, replace any retaining screws.

9. **Compress Caliper Piston**
- Use a C-clamp or brake caliper tool to compress the caliper piston back into the caliper housing. This is necessary to accommodate the new, thicker rotor.

10. **Reinstall Caliper**
- Place the caliper back over the new rotor and align it with the mounting bracket. Replace and tighten the caliper bolts to the manufacturer’s torque specifications.

11. **Reinstall Wheel**
- Place the wheel back on the hub and hand-tighten the lug nuts.

12. **Lower Vehicle**
- Carefully lower the vehicle back to the ground.

13. **Tighten Lug Nuts**
- Using the torque wrench, tighten the lug nuts to the manufacturer’s specifications in a criss-cross pattern to ensure even tension.

14. **Test Brake Functionality**
- Pump the brake pedal a few times to ensure the caliper piston is properly seated against the new rotor.

15. **Check for Leaks**
- Inspect the brake lines for any signs of leakage around the caliper.

#### Common Pitfalls to Avoid:
- **Not Compressing the Caliper Piston**: Failing to compress the piston can prevent the caliper from fitting over the new rotor.
- **Over-Torquing Caliper Bolts**: This can strip the threads or damage the caliper.
- **Ignoring Brake Pad Condition**: Always check brake pads; if they are worn, replace them at the same time.
- **Leaving Residue on New Rotors**: Ensure all oil or grease is cleaned off before installation.

#### Replacement Parts:
- New brake rotors (ensure they match the D-Max specifications).
- New brake pads (recommended if worn).
- New caliper hardware or retaining clips (if necessary).

By following these steps carefully, you can successfully replace the brake rotors on an Isuzu D-Max. Always refer to the vehicle’s service manual for specific details and torque specifications.
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