Target Audience:
Technicians, Mechanics, DIY Enthusiasts
Value Proposition:
Low Price, Great Quality, Instant Access
Comprehensive Coverage:
The manual provides unparalleled detail across all major vehicle systems, making it an indispensable resource for any repair or maintenance task.
Advantage:
Provides official factory information for efficient and accurate repairs, eliminating the need to search multiple sources or physical bookstores.
Powertrain:
Engine Service/Repair, Fuel Injection, Fuel System, Emission System, Engine Control System, Transmission Service/Repair, Differential/Drive Axle
Chassis:
Brake System, Suspension, Steering, Chassis/Body
Electrical And HVAC:
Electrical System, Wiring Diagram, Heater/Air Conditioner
Interior And Safety:
Restraint System, Interior
Exhaust System:
Information on exhaust manifold, catalytic converter, mufflers, and pipework, including inspection and replacement.
Fuel System Diesel:
Detailed coverage of the diesel fuel system, including the fuel tank, fuel lines, fuel filter, high-pressure fuel pump, and common rail injectors.
Diagnostics And Troubleshooting:
Troubleshooting, Circuit Diagrams, Datasheet Information
Maintenance:
General Maintenance, Periodic Lubrication, Maintenance Check List, Maintenance Chart, Service Instruction
Repair And Overhaul:
Complete engine rebuild, transmission overhauls, brake system repairs, suspension component replacement, electrical component diagnosis and repair, HVAC system servicing
Wheel Alignment:
Specifications for wheel alignment angles (camber, caster, toe) and procedures for adjustment.
Tire Rotation And Balancing:
Recommendations for tire rotation patterns and procedures for wheel balancing.
HVAC System Servicing:
Procedures for refrigerant handling, component replacement (compressor, condenser, evaporator), and leak testing of the air conditioning system.
Depth:
Comprehensive Factory-Level Detail
Diagnostics:
Includes procedures for diagnosing engine fault codes (OBD-II), transmission issues, brake system malfunctions, and electrical system faults.
Rebuilding Procedures:
Provides step-by-step instructions for the complete disassembly, inspection, repair, and reassembly of major mechanical components like the engine and transmission.
Torque Specifications:
Crucial torque values for all critical fasteners across various systems (engine, chassis, suspension, brakes) are provided for accurate assembly.
Clearances And Tolerances:
Specific engine bearing clearances, piston ring gaps, and other critical tolerances for engine rebuilding will be detailed.
Special Tools:
Identification of any specific tools or equipment required for particular diagnostic or repair procedures may be included.
Primary Engine Families:
The manual likely covers common diesel engines fitted to the D-Max/Colorado of this era, such as the Isuzu 4JJ1-TC (3.0L) and potentially others depending on regional specifications. Specific engine codes would be detailed within the manual.
Horsepower Torque:
Detailed specifications for each engine variant, including horsepower, torque figures, and power curves, will be present in the manual.
Injection Type:
Common Rail Direct Injection (CRDI) is highly probable for diesel variants of this period. Specific injection pressures and component details will be covered.
Diesel Engines:
Likely includes the 4JH1-TC (3.0L Turbo Diesel) and potentially other variants of the Isuzu 4J engine series. Specific injector types, turbocharger models, and intercooler systems will be detailed.
Cooling System:
Comprehensive coverage of the cooling system, including radiator, thermostat, water pump, fan clutch, coolant flow diagrams, and capacity.
Emission Control:
Details on the exhaust gas recirculation (EGR) system, diesel particulate filter (DPF) if applicable to specific models/markets, and catalytic converters, along with diagnostic procedures.
Types:
The manual should cover both manual and automatic transmission options. Likely manual transmissions include 5-speed and 6-speed units, and automatic transmissions may include 4-speed or 5-speed units.
Transmission Fluid:
Specific API/GL ratings and OEM-approved fluid part numbers for both manual and automatic transmissions will be provided.
Drive Modes:
Information on 2WD and 4WD (4x4) drivetrain operation, including transfer case engagement and operation, will be included.
Gear Ratios:
Specific gear ratios for all forward gears and reverse for applicable manual transmissions will be listed.
Shift Points:
Information on automatic transmission shift logic, solenoids, and control modules, including diagnostic procedures for shift quality issues.
Propeller Shaft And Cv Joints:
Maintenance and repair procedures for propeller shafts, universal joints, and Constant Velocity (CV) joints on drive axles.
Length Width Height:
The manual will contain exact exterior dimensions for various body styles (single cab, space cab, crew cab) and configurations.
Curb Gross Weight:
Gross Vehicle Weight Rating (GVWR), Curb Weight, Payload Capacity, and Towing Capacities for different configurations will be detailed.
Wheel Bolt Pattern:
Standard wheel sizes, tire sizes, and bolt patterns (e.g., 6x139.7mm) will be specified.
Cabin Space:
While not typically in service manuals, interior ergonomics and component locations are covered, aiding in accessibility for repair.
Bed Dimensions:
Specifications for various bed lengths and widths for single cab, extended cab, and crew cab configurations.
Restraint System:
Details on airbags (driver, passenger, side), seatbelts (pretensioners, load limiters), and other passive safety systems.
Braking System:
Information on ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), and potentially brake assist will be covered.
Crash Test Results:
While the manual itself doesn't contain crash test results, it details the systems that contribute to safety performance, which are evaluated in crash tests.
Disc Rotor Specifications:
Minimum and maximum rotor thickness, runout specifications, and pad material types will be provided.
Hydraulic System:
Details on brake fluid types, master cylinder specifications, and brake line routing.
Shock ABSorber Specifications:
Information on shock absorber types, mounting, and potential replacement procedures.
Audio System:
The manual may contain basic information on the factory radio and speaker systems, including wiring for upgrades or repairs.
Electronic Stability Control:
Details on the operation and troubleshooting of any electronic stability control (ESC) systems, if equipped on specific trims.
Wiring Diagrams:
Extensive wiring diagrams are a key feature, covering all electrical components, allowing for diagnosis and repair of lights, sensors, control modules, and accessories.
Battery Specifications:
Recommended battery type, capacity (CCA), and terminal configurations will be detailed.
Lighting Systems:
Details on headlamp bulb types, taillight assemblies, and interior lighting, including replacement procedures and wiring.
Oil Change Intervals:
The manual will provide recommended intervals for engine oil and filter changes, typically based on mileage or time (e.g., 10,000 km or 6 months).
Transmission Fluid Change:
Recommended intervals for transmission fluid and filter changes for both automatic and manual transmissions will be specified, often based on severe usage conditions.
Differential And Transfer Case Oil:
Recommended intervals and fluid types for front and rear differentials, and transfer cases (for 4WD models).
Engine Oil:
Specific viscosity grades (e.g., 5W-30, 10W-40) and API/ACEA specifications for diesel engine oils will be detailed.
Coolant:
Recommended coolant type (e.g., OAT, HOAT) and mixture ratio (e.g., 50/50 with distilled water) will be specified. Likely a long-life coolant.
Brake Fluid:
Standard DOT 3 or DOT 4 brake fluid specification will be provided.
Common Problems And Fixes:
The manual's troubleshooting section is invaluable for addressing common issues such as turbocharger problems, injector issues (especially in diesel variants), EGR system faults, and suspension wear. Specific diagnostic procedures will be outlined.
Suspension Wear Points:
Guidance on common wear items in the suspension and steering system, such as ball joints, tie rod ends, and bushings, and their inspection procedures.
Brake Component Wear:
Information on wear limits for brake pads and rotors, and procedures for brake caliper servicing.
Grease Points:
Details on chassis lubrication points, including universal joints, ball joints, and tie rod ends, along with recommended grease types (e.g., lithium-based grease).
Part Numbers:
Specific part numbers for oil filters, fuel filters, air filters, and cabin filters for various configurations will be listed.
Isuzu Truck Legacy:
Isuzu has a long and respected history in commercial vehicles and trucks, with the D-Max being a successor to previous robust utility vehicles.
Kb Generation:
The KB generation represents the second iteration of the Isuzu D-Max, which globally served as the basis for various models, including the Holden Colorado in certain markets. This generation saw significant updates in styling, comfort, and powertrain compared to its predecessor.
Holden Colorado Rebadging:
The Holden Colorado was a rebadged version of the Isuzu D-Max, reflecting a long-standing partnership and platform sharing between Isuzu and General Motors (Holden).
Manufacturing Locations:
Isuzu D-Max vehicles of this era were primarily manufactured in Thailand by Isuzu Motors Thailand, with Holden variants also being produced or assembled in various locations depending on the target market.
