Vehicle Segment:
Mid-size pickup truck
Target Audience:
Commercial users, fleet owners, off-road enthusiasts, and individuals requiring a robust and versatile utility vehicle.
Key Competitors:
Toyota Hilux, Ford Ranger, Mitsubishi Triton/Pajero Sport, Nissan Navara, Chevrolet Colorado (in relevant markets).
Vehicle Strengths:
Renowned for durability, reliability, strong diesel engine performance, off-road capability, and payload capacity.
Usability:
Digital format allows for easy navigation, keyword searching, and magnification of diagrams for clear visualization of repair procedures.
Market Coverage:
Global (markets where D-MAX and Colorado were sold)
Regional Focus:
Primarily Asia-Pacific and other international markets, with 'Colorado' designation used in specific regions like South America and North America (often rebranded or shared platform with Chevrolet Colorado).
Estimated Page Count:
Likely several thousand pages (typical for comprehensive factory service manuals)
Type:
Factory Service and Repair Manual
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine management, cooling system, lubrication system, turbocharging.
Drivetrain:
Manual transmission, automatic transmission, transfer case, drive shafts, differentials (front, rear), axles.
Chassis And Suspension:
Frame construction, front suspension (independent or solid axle depending on variant), rear suspension (leaf spring, coil spring), steering system, wheel alignment.
Brakes:
Front disc brakes, rear drum or disc brakes, ABS (Anti-lock Braking System), brake system hydraulics, parking brake.
Electrical System:
12V electrical system, battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), instrumentation, fuses, relays, wiring diagrams.
Body And Interior:
Body panels, doors, windows, locks, interior trim, seating, climate control system (HVAC), safety restraints (airbags, seatbelts).
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), lubrication points, tire rotation, brake inspections.
Diagnostics And Troubleshooting:
Diagnostic procedures for all major systems, symptom-based troubleshooting guides, fault code identification and resolution.
Repair And Overhaul:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly of engine, transmission, suspension, brakes, and electrical components.
Specifications And Data:
Torque specifications for fasteners, fluid capacities, clearances, diagnostic values, component dimensions.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and bodywork repairs.
Engine Code Examples:
4JJ1-TC (3.0L Turbo Diesel), 4JK1-TC (2.5L Turbo Diesel), possibly gasoline variants depending on region.
Displacement Examples:
2.5 Liters, 3.0 Liters
Engine Type:
Inline 4-cylinder, turbocharged, common rail diesel (primary).
Horsepower Range:
Approximately 100-180 hp (depending on engine and tuning).
Torque Range:
Approximately 250-400 Nm (depending on engine and tuning).
Fuel Delivery:
Common Rail Direct Injection (CRDI)
Coolant Type:
Ethylene Glycol based coolant (specific specifications detailed in manual, e.g., Dex-Cool compatible or equivalent).
Engine Oil Specification:
API CI-4 or ACEA E7 (for diesel engines), viscosity grades like 15W-40 or 5W-30 depending on climate and specific engine. Manual will specify exact grades and capacities.
Type:
5-speed or 6-speed Manual Transmission (MT)
Type:
4-speed or 5-speed Automatic Transmission (AT) (availability varies by market and engine).
Transfer Case:
Part-time 4WD system with electronic or manual engagement, and low-range gearing.
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90 (specifics in manual).
Automatic Transmission Fluid:
Dexron III or Dexron VI equivalent (specifics in manual).
Body Styles:
Single Cab, Extended Cab (Space Cab), Double Cab.
Wheelbase Variants:
Multiple wheelbase options available depending on cab configuration and specific market model.
Gross Vehicle Weight Rating Gvwr:
Varies by configuration and market, typically around 2,500 - 3,000 kg.
Curb Weight:
Varies significantly by configuration (cab type, 2WD/4WD, engine), typically starting around 1,700 kg.
Crash Test Results:
Ratings vary by region and testing body (e.g., ANCAP, Euro NCAP). Some models may have achieved 3-5 stars depending on safety equipment fitted. Detailed results typically not included in service manuals but are publicly available.
Braking Systems:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD).
Restraint Systems:
Driver and front passenger airbags, potentially side airbags and curtain airbags on higher trims. Three-point seatbelts with pretensioners.
Engine Oil And Filter:
Typically every 5,000 - 10,000 km or 6 months, whichever comes first (depending on operating conditions and oil type used). Manual will provide precise recommendations.
Air Filter:
Inspect every 20,000 km, replace as needed or every 40,000 - 60,000 km.
Fuel Filter:
Replace every 30,000 - 40,000 km for diesel models, or as specified. Critical for common rail systems.
Timing Belt Or Chain:
Most diesel engines of this era use timing chains, which are generally designed to last the life of the engine. If a belt is present on gasoline variants, refer to manual for replacement intervals (typically 80,000 - 100,000 km).
Coolant Capacity:
Approximately 7-9 liters (varies by engine and radiator size). Manual will specify exact capacity and coolant type.
Brake Fluid Type:
DOT 3 or DOT 4 (specifics in manual).
Diesel Engines:
Potential for injector issues, turbocharger wear, and EGR valve clogging in high-mileage or poorly maintained vehicles. Glow plug failure is also possible.
Suspension And Drivetrain:
Wear on ball joints, tie rod ends, and bushings due to heavy-duty use or off-road driving. Universal joint wear on driveshafts. Differential seals may leak.
Electrical:
Corrosion on electrical connectors in humid environments, alternator or battery issues.
