Vehicle Class:
Compact pickup truck / Ute.
Target Audience:
Commercial users, fleet operators, individuals seeking a rugged and versatile utility vehicle for work or recreation.
Key Competitors 2004-2007:
Toyota Hilux, Ford Ranger, Mitsubishi Triton (L200), Nissan Navara (Frontier), Mazda BT-50, Chevrolet Colorado.
Vehicle Strengths:
Durability, reliability, off-road capability (especially 4x4 variants), strong towing and payload capacity, utilitarian design.
Manual Utility:
Essential reference for parts identification and owner operation, crucial for maintenance, repair, and parts ordering.
Manual Set Description:
Includes both a comprehensive Parts Manual and an Owner's Manual for the Isuzu D-MAX 2004-2007 models.
Parts Manual Estimated Pages:
Estimated 800-1200 pages (typical for comprehensive parts catalogs).
Owner Manual Estimated Pages:
Estimated 200-350 pages (typical for owner's manuals).
Parts Manual Type:
Illustrated Parts Catalog / Parts Manual
Owner Manual Type:
Owner's Manual / User Manual
Format:
Digital (likely PDF), searchable and printable.
Parts Manual Systems:
Engine (mechanical, cooling, lubrication, fuel), Transmission (manual & automatic), Drivetrain (transfer case, differentials, axles, driveshafts), Suspension (front & rear), Steering, Brakes (front discs, rear drums/discs), Electrical System (wiring harnesses, starting, charging, ignition, lighting, instrumentation), Body & Chassis (frame, body panels, doors, glass, interior trim, seats, bumpers), HVAC (heating, ventilation, air conditioning), Fuel Tank & Lines, Exhaust System, Wheels & Tires, Accessories.
Owner Manual Systems:
Vehicle operation, controls, dashboard indicators, seating adjustments, safety features, basic maintenance procedures, fluid checks, tire pressure, intended use, troubleshooting for common warning lights, care and cleaning, warranty information.
Parts Manual Procedures:
Identification of all original equipment manufacturer (OEM) parts, part numbers, exploded views of component assemblies, cross-referencing of interchangeable parts, basic component identification for repair planning.
Owner Manual Procedures:
Starting and driving the vehicle, operating climate control, audio system, trip computer, parking procedures, emergency procedures, checking and topping up essential fluids (oil, coolant, brake fluid, washer fluid), changing a flat tire, jump-starting the battery.
Parts Manual Depth:
Detailed OEM part identification and sourcing. Primarily focused on part numbers and assembly diagrams, not step-by-step repair instructions.
Owner Manual Depth:
Consumer-level information for safe and efficient operation and basic self-maintenance. Does not cover diagnostic procedures or detailed repair steps.
File Searchability:
Text-searchable for quick part number or component lookup.
Print Quality Recommendation:
High-resolution for clear display of diagrams and text, suitable for printing.
Binding Type For Printed:
N/A (digital format), but typically would be coil-bound or perfect-bound for workshop use.
Paper Type For Printed:
N/A (digital format), but typically printed on durable, high-gloss paper for diagrams.
Engine Code Common:
4JA1-T (2.5L Turbo Diesel), 4JJ1-TC (3.0L Common Rail Turbo Diesel), 4KH1-TC (2.5L Turbo Diesel), possibly 4ZD1 (2.6L Petrol) in some markets.
Displacement Common Diesel:
2.5 Liters (2499 cc) / 3.0 Liters (2999 cc)
Horsepower 2.5L Turbo Diesel:
Approx. 80-95 hp @ 3800-4000 rpm
Torque 2.5L Turbo Diesel:
Approx. 170-190 Nm @ 1800-2500 rpm
Horsepower 3.0L Common Rail Diesel:
Approx. 100-130 hp @ 3400-3700 rpm
Torque 3.0L Common Rail Diesel:
Approx. 240-280 Nm @ 1800-2400 rpm
Fuel System Type:
Direct Injection (DI) with Turbocharger (for diesel engines), Common Rail Direct Injection (CRDI) for later 3.0L variants.
Fuel Type:
Diesel / Unleaded Gasoline (for petrol variants).
Standard Transmission Type:
5-speed Manual Transmission.
Optional Transmission Type:
4-speed Automatic Transmission (typically on higher trims or specific engine variants).
Drivetrain Options:
Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) with manual or automatic front hub engagement.
Body Styles:
Single Cab, Extended/Space Cab, Double Cab.
Bed Lengths:
Varies by cab configuration and market (e.g., approximately 1.8m for Single Cab, shorter for extended/double cabs).
Gross Vehicle Weight Rating Gvw:
Typically around 2,500 kg to 3,000 kg depending on configuration.
Curb Weight:
Varies significantly by configuration, generally 1,700 kg to 2,100 kg.
Crash Test Ratings Era:
Varies by market; many markets did not have standardized robust crash testing for light commercial vehicles during this period. Refer to specific regional test results (e.g., ANCAP for Australia).
Active Safety Features:
ABS (Anti-lock Braking System) - often standard or optional depending on trim and market, EBD (Electronic Brakeforce Distribution).
Passive Safety Features:
Seat belts (pre-tensioners on some models), driver and passenger airbags (often standard on higher trims or later models).
Audio System:
Base models often feature a basic AM/FM radio with CD player. Higher trims may offer improved sound systems and auxiliary inputs.
Driver Assistance Features:
Limited by modern standards. Primarily focused on mechanical systems and basic safety features like ABS.
Connectivity Options:
Typically basic, with some models offering Bluetooth (often aftermarket additions) or basic phone integration on higher trims.
Oil Change Interval:
Typically every 5,000 - 10,000 km or 6 months, depending on driving conditions and oil type used. Refer to Owner's Manual for exact specification.
Fuel Filter Replacement:
Recommended every 20,000 - 40,000 km for diesel engines, critical for longevity.
Timing Belt Chain:
Diesel engines often use timing chains which are designed to last the life of the engine. Some petrol variants or specific engine codes might use belts, requiring replacement around 80,000-100,000 km. This manual will clarify.
Engine Oil Viscosity Diesel:
Typically 15W-40 or 10W-40 API CD/CF/CF-4/CG-4 or higher specification. Modern synthetic oils meeting API CJ-4 or CK-4 are also suitable if specified.
Coolant Type:
Ethylene glycol-based coolant, typically green or orange, meeting JIS K 2234 standards or equivalent. Check for silicate-free or low silicate formulations.
Transmission Fluid Manual:
API GL-4 gear oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron III or equivalent ATF (Automatic Transmission Fluid). Capacity around 6-8 liters.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch wear (manual), shock absorbers, bushings, exhaust components, turbocharger seals (especially on high-mileage units), glow plugs (diesel).
Diesel Specific Concerns:
Injectors and fuel pumps can be sensitive to fuel quality. Turbocharger reliability depends heavily on maintenance and avoiding prolonged hard acceleration from cold.
Electrical Gremlins:
While generally robust, aging wiring harnesses or corroded grounds can lead to intermittent issues with lights or sensors.
Isuzu Truck Legacy:
Isuzu has a long history in commercial vehicles and robust diesel engine technology, dating back to the early 20th century.
D Max Lineage:
The D-MAX replaced the Isuzu TF series pickup (also known as Rodeo, Bighorn, etc. in various markets) and shares its platform with vehicles from GM's global truck division.
Production Era:
First generation D-MAX production began in 2002, with this 2004-2007 period representing early models of this generation.
Manufacturing Locations:
Primarily manufactured in Thailand, with assembly in other countries depending on regional markets (e.g., Australia, South Africa, Vietnam, Malaysia).
