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Isuzu D-MAX 2011 Service Repair Manual
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Basic Information Identification Make: Isuzu Model: D-MAX Year: 2011 Codes Platform Code: RT50 / RT85 (Second Generation) Introduction Market Position Segment: Mid-size Pickup Truck Target Audience: Commercial users, fleet operators,...
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| Basic Information | |
| Identification | |
| Make: | Isuzu |
| Model: | D-MAX |
| Year: | 2011 |
| Codes | |
| Platform Code: | RT50 / RT85 (Second Generation) |
| Introduction | |
| Market Position | |
| Segment: | Mid-size Pickup Truck |
| Target Audience: | Commercial users, fleet operators, off-road enthusiasts, and general consumers seeking a durable and capable utility vehicle. |
| Competitive Analysis | |
| Key Competitors: | Toyota Hilux, Ford Ranger, Mitsubishi Triton, Nissan Navara. |
| Key Features | |
| Vehicle Focus: | Ruggedness, reliability, towing capacity, off-road capability, and practicality. |
| Manual Details | |
| Coverage Areas | |
| Market Regions: | Global (specific regional variations may exist, but the core information is comprehensive) |
| Page Count | |
| Approximate Pages: | 1500+ |
| Manual Type | |
| Type: | Factory Authorized Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital (PDF) |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system, intake and exhaust systems. |
| Engine Electrical: | Ignition system, starting system, charging system, emission control systems, engine control unit (ECU) diagnostics and wiring diagrams. |
| Transmission Manual: | Manual transmission (MUA) disassembly, assembly, overhaul, clutch system, and driveline components. |
| Transmission Automatic: | Automatic transmission (MYY) disassembly, assembly, overhaul, hydraulic control systems, torque converter, and transmission control unit (TCU). |
| Drivetrain: | Front axle, rear axle, differential, driveshafts, propeller shafts, CV joints, and transfer case (if applicable). |
| Suspension Steering: | Front suspension (independent double wishbone), rear suspension (leaf springs), shock absorbers, springs, steering gear, power steering system. |
| Brakes: | Front disc brakes, rear drum brakes (or disc depending on configuration), hydraulic system, ABS (Anti-lock Braking System) diagnostics, parking brake. |
| Electrical Chassis: | Lighting system, horn, wipers, washers, power windows, central locking, instrument cluster, body control module (BCM). |
| Body Exterior: | Body panel removal and installation, doors, hood, tailgate, bumpers, glass replacement, chassis and frame construction. |
| Body Interior: | Dashboard removal, seats, trim panels, HVAC system (heating, ventilation, and air conditioning), interior lighting. |
| Diagnostics Troubleshooting: | On-board diagnostics (OBD-II) procedures, fault codes (DTCs), diagnostic flowcharts, symptom-based troubleshooting. |
| Procedures Included | |
| Scheduled Maintenance: | Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, tire rotation, brake inspections. |
| Repair Overhaul: | Complete engine rebuilds, transmission repairs, suspension component replacement, brake caliper servicing, starter motor and alternator replacement. |
| Troubleshooting Guides: | Detailed diagnostic procedures for common and uncommon faults, circuit diagrams for electrical issues. |
| Component Testing: | Procedures for testing sensors, actuators, fuel injectors, ignition coils, batteries, and other electrical components. |
| Specifications Data: | Torque specifications for all fasteners, clearances, fluid capacities, electrical system voltages, resistance values. |
| Technical Depth | |
| Depth: | Comprehensive from basic maintenance to full vehicle repair and diagnostics. |
| Diagnostic Capability: | Includes advanced diagnostic procedures and troubleshooting trees for complex electronic systems. |
| Rebuild Procedures: | Detailed step-by-step instructions for rebuilding major components like engines and transmissions. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Searchable: | Yes, text-searchable for quick information retrieval. |
| Print Quality | |
| Printability: | High-resolution, suitable for printing individual sections or the entire manual. |
| Binding Type | |
| Binding: | N/A (Digital Format) |
| Paper Type | |
| Paper: | N/A (Digital Format) |
| Engine Specifications | |
| Primary Engine | |
| Engine Code Gasoline: | 4J12 (2.4L MIVEC DOHC) |
| Engine Code Diesel: | 4JJ1 (3.0L DOHC Common Rail Turbo Diesel) |
| Performance | |
| Horsepower 4Jj1: | 134 hp @ 3,600 rpm (approximate, varies by market tune) |
| Torque 4Jj1: | 294 Nm (217 lb-ft) @ 1,600-2,800 rpm (approximate, varies by market tune) |
| Horsepower 4J12: | 140 hp @ 5,750 rpm (approximate) |
| Torque 4J12: | 220 Nm (162 lb-ft) @ 4,000 rpm (approximate) |
| Fuel System | |
| Fuel Type Diesel: | Diesel |
| Fuel Type Gasoline: | Gasoline |
| Injection System Diesel: | Common Rail Direct Injection (CRDI) |
| Turbocharger Diesel: | Yes, Variable Geometry Turbocharger (VGT) |
| Transmission | |
| Standard | |
| Transmission Type Standard: | 5-speed Manual Transmission (MUA) |
| Optional | |
| Transmission Type Optional: | 4-speed Automatic Transmission (MYY) |
| Features | |
| Drivetrain Options: | Rear-Wheel Drive (RWD) and Selectable 4-Wheel Drive (4WD). |
| Transfer Case: | 2-speed transfer case with neutral and low-range gearing (on 4WD models). |
| Dimensions | |
| Exterior | |
| Wheelbase: | 3095 mm (121.9 inches) (Double Cab) |
| Overall Length: | 5025 mm (197.8 inches) (Double Cab) |
| Overall Width: | 1800 mm (70.9 inches) |
| Overall Height: | 1740 mm (68.5 inches) (approximate, varies by trim) |
| Cargo | |
| Bed Length: | 1550 mm (61.0 inches) (Double Cab) |
| Bed Width: | 1530 mm (60.2 inches) |
| Weights | |
| Curb Weight: | 1800-2000 kg (approximate, varies by configuration) |
| Gross Vehicle Weight Rating: | 2700-3000 kg (approximate) |
| Safety Features | |
| Ratings | |
| Ancap Rating: | 4-star (for some configurations, Euro NCAP testing varied by market and year) |
| Active Features | |
| ABS: | Standard on most models |
| Ebs: | Electronic Brake-force Distribution (EBD) (standard) |
| Bas: | Brake Assist System (BAS) (available on some models) |
| Passive Features | |
| Airbags: | Driver and front passenger airbags standard; side and curtain airbags available on higher trims. |
| Seatbelts: | 3-point seatbelts with pretensioners and load limiters. |
| Child Anchors: | ISOFIX child seat anchors. |
| Technology Features | |
| Infotainment | |
| Audio System: | Base models feature AM/FM radio with CD player and auxiliary input; higher trims offer MP3 compatibility, USB ports, and Bluetooth connectivity. |
| Navigation: | Optional GPS navigation system available on higher trim levels. |
| Driver Assistance | |
| Parking Sensors: | Available on select higher-trim models. |
| Cruise Control: | Available on higher-trim models. |
| Connectivity | |
| Bluetooth: | Available for hands-free calling and audio streaming on equipped models. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval Diesel: | Every 10,000 km or 6 months, whichever comes first (or per owner's manual recommendation). |
| Air Filter Replacement: | Every 20,000 km or 12 months, or more frequently in dusty conditions. |
| Fuel Filter Replacement Diesel: | Every 40,000 km or 24 months. |
| Fluid Specifications | |
| Engine Oil Diesel: | API CI-4 or CJ-4, SAE 5W-30 or 10W-30 synthetic diesel engine oil. Capacity: 6.5 Liters (approx). |
| Engine Oil Gasoline: | API SN/SP, SAE 0W-20 or 5W-30 synthetic gasoline engine oil. Capacity: 5.1 Liters (approx). |
| Transmission Fluid Manual: | GL-4 rated gear oil, SAE 75W-90. Capacity: 2.2 Liters (approx). |
| Transmission Fluid Automatic: | Dexron III or equivalent ATF. Capacity: 8.0 Liters (approx, for complete fill). |
| Coolant: | Ethylene glycol based, long-life coolant (e.g., OAT), pre-mixed 50/50. Capacity: 7.0 Liters (approx). |
| Brake Fluid: | DOT 3 or DOT 4 brake fluid. |
| Known Issues | |
| Common Complaints Diesel: | DPF (Diesel Particulate Filter) regeneration issues if not driven regularly at highway speeds, potential turbocharger wear over high mileage, injector issues with poor fuel quality. |
| Common Complaints Gasoline: | Less common issues reported, potential for spark plug fouling and minor electrical faults on older units. |
| Common Repairs | |
| Suspension Wear: | Leaf springs in the rear can sag under heavy loads over time; front ball joints and bushings may require replacement due to typical usage. |
| Brake Wear: | Front brake pads and rotors are consumable items, requiring regular replacement depending on driving conditions. |
| Vehicle History | |
| Brand Heritage | |
| Brand Focus: | Isuzu has a long history of producing robust diesel engines and commercial vehicles, including trucks and SUVs. |
| Model Evolution | |
| Second Generation: | The 2011 D-MAX represents the second generation (RG series) of the Isuzu D-MAX globally, building on the legacy of the previous model. |
| Production | |
| Manufacturing Locations: | Primarily manufactured in Thailand, with assembly plants in various other countries for specific markets. |
| Awards & Recognition | |
| Recognitions | |
| Segment Awards: | The D-MAX consistently receives accolades in its segment for durability, value for money, and off-road capability from various automotive publications and consumer surveys worldwide. |
| Ratings | |
| Australian Ute Of The Year: | Has been a strong contender and winner of various 'Ute of the Year' awards in Australia and other major markets. |
| Certifications | |
| Emissions Standards: | Meets various regional emissions standards (e.g., Euro 4/5) depending on the market of sale. |