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
### Anti-Roll Bar Replacement on Isuzu D-Max
#### Tools Needed
1. **Socket Set** (metric) - for various bolts
2. **Wrench Set** - for tightening and loosening bolts
3. **Torque Wrench** - to ensure proper torque settings
4. **Jack and Jack Stands** - to safely lift the vehicle
5. **Pry Bar** - for leverage if needed
6. **Hammer** - for tapping stubborn components
7. **Spray Lubricant** - to loosen rusted bolts
8. **Safety Gloves and Goggles** - for personal protection
#### Safety Precautions
1. **Work in a Well-Ventilated Area** - to avoid inhalation of fumes.
2. **Use Jack Stands** - never rely solely on a hydraulic jack for support.
3. **Wear Safety Gloves and Goggles** - to protect against sharp edges and debris.
4. **Disconnect Battery** - to prevent electrical issues if working near sensors.
#### Steps for Replacement
1. **Preparation**
- Park the D-Max on a level surface.
- Engage the parking brake and chock the rear wheels.
2. **Lifting the Vehicle**
- Use a jack to lift the front of the vehicle.
- Place jack stands under the vehicle for safety.
3. **Removing the Existing Anti-Roll Bar**
- Locate the anti-roll bar (sway bar) connected to the chassis and suspension links.
- Use spray lubricant on the bolts to ease removal.
- Remove the end links from the anti-roll bar using a socket and wrench. **Tip:** Hold the opposing side with a wrench to avoid spinning.
- Remove the mounting brackets from the chassis using the socket set.
- Carefully lower the anti-roll bar and remove it from the vehicle.
4. **Inspecting Components**
- Check the end links and bushings for wear. Replace if damaged.
- Common replacement parts include:
- New anti-roll bar
- New end links
- New bushings
5. **Installing the New Anti-Roll Bar**
- Position the new anti-roll bar in place.
- Install the mounting brackets back onto the chassis and tighten them loosely.
- Attach the end links to the anti-roll bar and the suspension components.
- Ensure that all components are aligned correctly.
6. **Tightening**
- Use a torque wrench to tighten the mounting bolts and end links to the manufacturer’s specifications (check service manual for specific torque values).
- Make sure there is no excessive play in the end links.
7. **Final Checks**
- Recheck all connections and ensure everything is secure.
- Lower the vehicle back to the ground.
- Reconnect the battery if it was disconnected.
8. **Test Drive**
- Take the vehicle for a short test drive to ensure proper installation.
- Listen for any unusual noises or handling issues.
#### Common Pitfalls to Avoid
- **Over-tightening bolts:** Can strip threads or damage components.
- **Not using jack stands:** Risk of injury if the vehicle falls.
- **Neglecting to replace worn components:** Old parts can cause issues even with a new anti-roll bar.
- **Forgetting to check torque specifications:** Can lead to performance issues or safety hazards.
By following these detailed steps, you can successfully replace the anti-roll bar on an Isuzu D-Max. Always refer to the vehicle’s service manual for specific details related to your model.
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To understand the process of testing and replacing the throttle position sensor (TPS) on an Isuzu D-Max, it's essential to grasp the theory behind the TPS and its role in the vehicle's engine management system.
### Theory Behind Throttle Position Sensor (TPS)
1. **Function of TPS**: The TPS is a potentiometer located on the throttle body that monitors the position of the throttle plate. It provides input to the Engine Control Unit (ECU) about how far the accelerator pedal is pressed, allowing the ECU to adjust fuel injection and ignition timing accordingly for optimal engine performance.
2. **Signal Output**: As the throttle plate opens or closes, the TPS varies its resistance, sending a corresponding voltage signal to the ECU. This signal typically ranges from 0.5V (closed throttle) to about 4.5V (fully open throttle). Any deviation from this expected range can indicate a fault.
3. **Symptoms of Fault**: A faulty TPS can cause a range of issues, including poor acceleration, stalling, rough idling, or a check engine light. This is because the ECU may receive incorrect data, leading to improper fuel-air mixture and ignition timing.
### Steps to Test and Replace the TPS
1. **Diagnostic Scanning**: Use an OBD-II scanner to check for any diagnostic trouble codes (DTCs) related to the TPS. Codes related to throttle position can give you a starting point to identify faults.
2. **Visual Inspection**: Check the wiring and connectors leading to the TPS for any signs of damage, corrosion, or loose connections. A bad connection can lead to incorrect voltage readings, mimicking a faulty sensor.
3. **Testing TPS Voltage**: Disconnect the TPS connector and use a multimeter to measure the voltage output while manually moving the throttle plate. You should see a smooth transition in voltage as the throttle position changes. Any erratic readings or flat spots indicate a faulty TPS.
4. **Replacement**: If the TPS is confirmed faulty, replace it by removing the screws or bolts securing it to the throttle body. Install the new sensor, ensuring it is properly aligned and secured.
5. **Recalibration**: Some vehicles may require a recalibration of the TPS after replacement, which can involve resetting the ECU or performing a specific relearn procedure.
6. **Final Testing**: After installation, reconnect the battery (if disconnected) and clear any stored DTCs. Take the vehicle for a test drive to ensure the engine responds properly to throttle inputs and there are no warning lights.
### How the Repair Fixes the Fault
By replacing a faulty TPS, you restore accurate communication between the throttle position and the ECU. This ensures that the ECU can make informed decisions regarding fuel delivery and ignition timing, leading to improved engine performance, better fuel economy, and a smoother driving experience. Essentially, the repair fixes the fault by eliminating the source of incorrect voltage signals that disrupt normal engine operation.
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### Rocker Arms in an Isuzu D-Max
**What Are Rocker Arms?**
Rocker arms are part of the engine's valvetrain. Their main job is to transfer motion from the camshaft to the engine's valves, opening and closing them to allow air and fuel in and exhaust out. Think of rocker arms like a set of seesaws: when one side goes up, the other side goes down.
### Components of the Rocker Arm System
1. **Rocker Arm**: A lever that pivots on a shaft. It pushes down on the valve stem to open the valve.
2. **Camshaft**: A shaft with lobes (protrusions) that rotate. As it turns, the lobes push against the rocker arms to open the valves at the right time.
3. **Push Rod**: In overhead valve engines, these rods connect the camshaft to the rocker arms. They transfer the motion from the cam to the rocker arm.
4. **Valve Spring**: A spring that holds the valve closed when it’s not being pushed by the rocker arm. It ensures the valve closes tightly to prevent leaks.
5. **Valve**: Opens and closes to regulate the intake of air and fuel and the expulsion of exhaust gases.
6. **Rocker Arm Shaft**: A shaft that holds the rocker arms in place. It allows them to pivot.
### Theory Behind Repair
Rocker arms can wear out or become damaged due to the constant motion and pressure they endure. This wear can lead to:
- **Valve Misalignment**: If a rocker arm is damaged, it may not push the valve down correctly, leading to poor engine performance.
- **Increased Engine Noise**: Worn rocker arms may create excessive clearance, causing a ticking noise.
- **Engine Damage**: If a rocker arm fails completely, it could lead to catastrophic engine failure, where valves may remain open or closed when they shouldn’t.
### How the System Works
1. **Camshaft Rotation**: As the engine runs, the camshaft rotates.
2. **Lobe Movement**: The lobes on the camshaft push the push rods up.
3. **Rocker Arm Action**: The push rods push the rocker arms, which pivot on their shafts.
4. **Valve Operation**: The downward motion of the rocker arms pushes the valves open against the tension of the valve springs.
5. **Sealing**: When the cam lobe passes and the rocker arm returns, the valve spring closes the valve tightly.
### What Can Go Wrong
1. **Wear and Tear**: Over time, rocker arms can wear out, leading to improper valve operation.
2. **Lack of Lubrication**: Insufficient oil can cause increased friction and wear on the rocker arms.
3. **Improper Adjustment**: If the rocker arms are not adjusted correctly, it can lead to engine noise and performance issues.
4. **Accidental Damage**: If a component of the valvetrain breaks, it can damage the rocker arm.
### Repair Steps
1. **Gather Tools**: You’ll need a socket set, torque wrench, screwdrivers, and possibly a replacement rocker arm set.
2. **Disconnect Battery**: Always disconnect the battery to avoid electrical issues while working.
3. **Remove Engine Cover**: If present, take off the engine cover to access the rocker arms.
4. **Remove Rocker Arm Assembly**: Unbolt the rocker arm assembly from the cylinder head. Keep track of hardware.
5. **Inspect Components**: Check for wear on the rocker arms, push rods, and valve springs. Look for any cracks or excessive play.
6. **Replace Worn Parts**: If any components are worn or damaged, replace them with new parts. Make sure to lubricate them before installation.
7. **Reinstall Assembly**: Bolt the rocker arm assembly back onto the cylinder head. Follow the manufacturer’s torque specifications.
8. **Reattach Engine Cover**: Once everything is back in place, reattach the engine cover.
9. **Reconnect Battery**: Finally, reconnect the battery and start the engine to ensure everything is functioning properly.
### Conclusion
Understanding your rocker arms and their function is crucial for maintaining engine performance. Regular checks and timely repairs can prevent bigger issues down the line. Think of it as maintaining a well-oiled machine: A small part can have a significant impact on the overall functionality of the engine.
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