🏷️ Basic Information

Make:

Isuzu

Model:

D-MAX

Model Generation:

Second Generation

Model Years Covered:

2004, 2005, 2006, 2007

👋 Introduction

Vehicle Segment:

Compact Pickup Truck / Light Commercial Vehicle

Target Audience:

Owners, mechanics, parts suppliers, enthusiasts requiring detailed part information for maintenance and repair.

Competitors Era:

Toyota Hilux, Mitsubishi Triton (L200), Ford Ranger, Nissan Navara, Chevrolet Colorado (global variants).

Utility Focus:

Known for its robustness, durability, and workhorse capabilities, particularly in its diesel variants.

Parts Catalog Utility:

Essential for sourcing correct replacement parts, crucial for maintaining the longevity and functionality of the D-MAX.

📋 Manual Details

Manual Type:

Parts Manual / Parts Catalog

Language:

English

Format:

Illustrated / Exploded Views

📖 Manual Coverage

Engine Components:

Engine block, cylinder head, pistons, crankshaft, camshafts, valves, intake manifold, exhaust manifold, cooling system, lubrication system, fuel injection system, ignition system, emission control systems.

Transmission Drivetrain:

Manual transmission, automatic transmission (if applicable), transfer case, driveshafts, differentials, axles, CV joints.

Suspension Steering:

Front suspension (e.g., double wishbone, coil springs), rear suspension (e.g., leaf springs), shock absorbers, springs, control arms, ball joints, steering gearbox, tie rods, steering column.

Braking System:

Front brakes (e.g., disc), rear brakes (e.g., drum or disc), brake calipers, brake pads, brake rotors, master cylinder, brake lines, parking brake system.

Electrical System:

Battery, alternator, starter motor, lighting system (headlights, taillights, interior), wiring harnesses, fuses, relays, sensors, ECUs, instrument cluster, wipers, horn.

Body Exterior:

Chassis components, frame, body panels (hood, fenders, doors, tailgate), bumpers, grille, mirrors, windows, seals, chassis hardware.

Body Interior:

Dashboard, seats, seat belts, interior trim panels, steering wheel, shift levers, pedals, HVAC system components (vents, controls), audio system components.

Cooling System:

Radiator, radiator fan, water pump, thermostat, coolant hoses, coolant reservoir.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors/carburetor (depending on engine). (For diesel: Glow plugs, injection pump.)

Disassembly Assembly Aid:

Provides exploded views and part identification, aiding in the systematic disassembly and reassembly of components.

Parts Identification:

Comprehensive identification of all individual parts and sub-assemblies with associated part numbers.

Depth:

Detailed breakdown of all factory-specified parts, facilitating accurate ordering and replacement. Does not include repair procedures or diagnostic information.

📊 Manual Specifications

Format Type:

Digital (likely PDF, though not explicitly stated, common for parts manuals)

Searchability:

Likely searchable if PDF, allowing quick access to part numbers and descriptions.

Printability:

Printable for on-site reference.

Illustration Quality:

Fully illustrated with high-quality exploded views.

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code Common:

4JA1-T (2.5L Diesel Turbocharged), 4JH1-T (3.0L Diesel Turbocharged), 4ZD1 (2.6L Petrol - less common in many markets for this generation).

Displacement 2 5L:

2499 cc

Horsepower 2 5L Diesel:

Approx. 75-90 HP (varies by specific tune and market)

Torque 2 5L Diesel:

Approx. 170-200 Nm (varies by specific tune and market)

Displacement 3 0L:

2999 cc

Horsepower 3 0L Diesel:

Approx. 110-130 HP (varies by specific tune and market)

Torque 3 0L Diesel:

Approx. 240-280 Nm (varies by specific tune and market)

Injection Type Diesel:

Direct Injection, Rotary or Inline Injection Pump (Bosch/Denso/Zexel), Common Rail (later variants of this gen might start featuring it).

Fuel Type:

Diesel (primarily), Gasoline (for 2.6L variants)

Emission Control Diesel:

Euro 2/3 standards, EGR (Exhaust Gas Recirculation) likely standard.

🔧 Transmission

Transmission Type Common:

5-speed Manual Transmission (e.g., Isuzu MYY, MUA)

Transmission Type Optional:

4-speed Automatic Transmission (e.g., Isuzu Supermatic)

Drivetrain Options:

RWD (Rear-Wheel Drive), 4WD (Four-Wheel Drive) with part-time transfer case.

📐 Dimensions

Body Styles Available:

Single Cab, Extended/Space Cab, Double Cab.

Wheelbase Range:

Approx. 3000 mm - 3380 mm (depending on cab and chassis configuration).

Bed Length Range:

Approx. 1800 mm - 2250 mm (depending on configuration).

Gross Vehicle Weight Rating Gvwr:

Typically in the range of 2,500 kg to 3,000 kg (GVWR).

🛡️ Safety Features

Crash Test Availability:

Limited public availability of formal crash test ratings for this specific generation in all markets. Typically built to meet local regulatory standards.

ABS Availability:

ABS (Anti-lock Braking System) available on higher trim levels or as an option, not standard across all variants.

Airbags:

Driver airbag standard on many models; passenger airbag optional or absent on base trims. Side airbags were rare for this generation.

Seatbelts:

3-point seatbelts for front occupants, 2-point or 3-point for rear depending on cab configuration.

💡 Technology Features

Audio System Base:

Basic AM/FM radio with CD player or cassette player. Often aftermarket head units are installed by owners.

Speaker Configuration:

Typically 2 or 4 speakers.

Cruise Control:

Optional on higher trim levels or specific engine variants, not standard.

Bluetooth:

Rarely factory-equipped on this generation. Most connectivity would be via aftermarket additions.

🔧 Maintenance

Oil Change Interval Diesel:

Typically every 5,000 - 10,000 km or 6 months (whichever comes first), depending on operating conditions and oil specification. Consult manual for specifics.

Air Filter Replacement:

Recommended every 20,000 - 40,000 km, or more frequently in dusty conditions.

Fuel Filter Replacement Diesel:

Recommended every 20,000 - 40,000 km, critical for diesel engine longevity.

Engine Oil Type Diesel:

API CF-4 or CH-4, SAE 15W-40 or 10W-30 (check manual for specific viscosity and API rating based on climate and engine variant).

Engine Oil Capacity 2 5L Diesel:

Approx. 6.5 - 7.0 Liters (including filter).

Engine Oil Capacity 3 0L Diesel:

Approx. 7.0 - 7.5 Liters (including filter).

Coolant Type:

Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Check for silicate-free or OAT formulations suitable for Isuzu.

Transmission Fluid Manual:

GL-4 Gear Oil, SAE 75W-90 or 80W-90.

Transmission Fluid Automatic:

Dexron III (or equivalent specification for Isuzu automatic transmissions).

Brake Fluid Type:

DOT 3 or DOT 4.

Diesel Engine Durability:

Generally robust, but early direct injection systems can be sensitive to fuel quality. Turbocharger maintenance is important.

Suspension Wear:

Leaf springs can sag under heavy loads over time. Ball joints and tie rod ends are wear items subject to road conditions.

Rust Corrosion:

Common in certain climates, particularly on chassis components, wheel arches, and underbody.

Electrical Connectors:

Corrosion or looseness in electrical connectors can lead to intermittent faults, especially in humid or coastal environments.

📚 Vehicle History

Isuzu Truck Legacy:

Isuzu has a long-standing reputation for producing durable and reliable trucks and commercial vehicles.

First Generation Impact:

The D-MAX replaced the popular Isuzu Rodeo/TF model globally. This second generation built upon the success and reputation for ruggedness.

Manufacturing Locations:

Primarily manufactured in Thailand, with assembly plants in various other countries (e.g., Japan, Philippines, Indonesia, Vietnam, South Africa).

🏆 Awards & Recognition

Segment Performance:

Consistently recognized in its segment for reliability, durability, and value for money by automotive publications and consumer surveys in its target markets.

Diesel Engine Reputation:

Isuzu's diesel engines are highly regarded for their longevity and low-cost operation.