🏷️ Basic Information

Make:

Isuzu

Model:

D-Max

Generation:

Second Generation (RG)

Production Years Covered:

2007, 2008, 2009, 2010, 2011, 2012

Platform Code:

RG (Global D-Max platform, shared with Chevrolet Colorado and other GM/Isuzu ventures)

👋 Introduction

Vehicle Segment:

Mid-size Pickup Truck (Ute in some markets)

Key Competitors:

Toyota Hilux, Mitsubishi Triton/L200, Ford Ranger, Nissan Navara/Frontier, Holden Colorado (GM shared platform)

Vehicle Strengths:

Rugged construction, strong diesel engines, reliable powertrain, capable off-road (especially 4WD models), versatile cargo bed

Target Audience:

Professional technicians, DIY mechanics, automotive repair shops, fleet maintenance departments.

📋 Manual Details

Primary Regions Of Operation:

Global (specific to markets where the D-Max was sold during these years, including Asia, Australia, Europe, and South America)

Estimated Page Count:

Likely 2000+ pages (typical for comprehensive full service repair manuals covering multiple years and engine options)

Manual Classification:

Full Service and Repair Manual

Language Of Documentation:

English

Digital Format:

PDF

📖 Manual Coverage

Powertrain Components:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control system (ECU/ECM), turbocharger system

Drivetrain Components:

Transmission (manual & automatic), clutch, driveshafts, differentials (rear axle, potentially front axle for 4WD variants), transfer case (for 4WD)

Chassis Components:

Suspension (front & rear), steering system, braking system (front & rear), wheels and tires

Electrical And Electronics:

Complete wiring diagrams, lighting systems, starting system, charging system, instruments and gauges, body electricals (power windows, locks, mirrors, HVAC), diagnostic connectors (OBD-II)

Body And Frame:

Body panels, doors, windows, interior trim, chassis frame, bumpers, tailgate/rear door

Maintenance Tasks:

Scheduled maintenance (oil changes, filter replacements, fluid checks), inspection procedures, lubrication, belt replacement, spark plug replacement

Repair Tasks:

Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, steering rack repair, starter/alternator replacement

Diagnostics And Troubleshooting:

Step-by-step diagnostic flowcharts for common issues, symptom-based troubleshooting, fault code interpretation (where applicable)

Electrical Diagnostics:

Wiring diagram analysis, component testing, circuit tracing, troubleshooting of electrical faults

Timing Belt Or Chain:

Details on inspection, tensioner adjustment, and replacement if applicable (most common diesel engines in this era use timing chains, which are generally maintenance-free but require inspection for wear).

Turbocharger System Repair:

Includes diagnosis of boost leaks, turbocharger removal and installation, and related component checks (actuators, intercooler).

Brake System Overhaul:

Detailed steps for brake pad replacement, rotor machining or replacement, caliper overhaul, brake line inspection and replacement, and bleeding procedures.

Suspension And Steering Geometry:

Information on wheel alignment specifications, component replacement (ball joints, tie rod ends, control arms), and troubleshooting steering play or noise.

Body And Trim Removal:

Instructions for disassembling interior and exterior trim panels for access to components or for repair/replacement.

Diagnostics Engine Performance:

Procedures for testing fuel pressure, checking for vacuum leaks, performing compression tests, and analyzing engine sensor data.

Diagnostics Electrical Systems:

Guidance on using multimeters, oscilloscopes, and scan tools for diagnosing electrical faults, including testing sensors, actuators, and control modules.

Depth Of Information:

Comprehensive (covers from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics)

Torque Specifications:

Extensive torque specifications for all critical fasteners throughout the vehicle, essential for proper assembly and preventing damage.

Illustrations And Diagrams:

Highly detailed diagrams, exploded views, and step-by-step illustrations for mechanical procedures and electrical wiring.

Special Tools Requirements:

Lists and descriptions of specialized tools needed for specific repair or diagnostic procedures.

📊 Manual Specifications

Digital File Type:

PDF

Printability:

Fully printable, allowing for creation of physical copies for workshop use

Binding For Physical Copy:

N/A (Digital Download - user can bind if printed)

Paper Type For Physical Copy:

N/A (Digital Download - user can choose paper type if printed)

Required Software:

Adobe PDF Reader, WinRAR (for extracting archived files if applicable)

Operating System Compatibility:

All versions of Windows and Mac OS

⚙️ Engine Specifications

Common Engine Options:

4JJ1-TC (3.0L Turbo Diesel), RZ4E-TC (1.9L Turbo Diesel - less common in early models of this generation, more prevalent in later ones or specific markets), various gasoline engines depending on market (less common for D-Max)

Horsepower Range:

Approximately 130-177 HP (for 3.0L diesel, varies by tune and market)

Torque Range:

Approximately 294-380 Nm (for 3.0L diesel, varies by tune and market)

Injection Type:

Common Rail Direct Injection (CRDi)

Emission Control:

Euro III, Euro IV (depending on market and year), potential for DPF (Diesel Particulate Filter) on later models or specific configurations

Common Engine Code Diesel:

4JH1-TC (3.0L Turbo Diesel)

🔧 Transmission

Manual Transmission:

5-speed or 6-speed manual transmission (e.g., MUA-5, MUX-6)

Automatic Transmission:

4-speed or 5-speed automatic transmission (e.g., RC4L02A, RC42LS)

Drivetrain Options:

Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) with manual or electronic engagement

📐 Dimensions

Body Styles:

Single Cab, Extended/Space Cab, Double Cab

Chassis Type:

Body-on-frame construction

Gross Vehicle Weight Rating Gvw:

Varies by configuration, typically around 2,800 - 3,200 kg

Curb Weight:

Varies significantly by configuration (cab style, drivetrain, options), typically ranging from 1,700 kg to 2,000 kg.

🛡️ Safety Features

Crash Test Performances:

Variable by region and testing body. Later models and specific markets may have achieved ANCAP 4 or 5 stars. Early models might have lower ratings.

Braking Systems:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA) available on some trims/markets

Restraint Systems:

Front airbags (driver and passenger), seatbelt pretensioners. Side airbags and curtain airbags available on higher trims/later models.

💡 Technology Features

Audio System Features:

Base models often feature AM/FM radio with CD player and basic speaker system. Higher trims may include MP3 playback, USB/AUX input, and potentially Bluetooth connectivity.

Advanced Features:

Limited for this era. ABS is common. Traction control (TCS) and Electronic Stability Control (ESC) were introduced on higher trims or later in the production run for certain markets.

Telematics Or Navigation:

Generally not standard. Navigation systems or advanced connectivity features were typically aftermarket or optional on top-tier models in specific markets.

🔧 Maintenance

Engine Oil And Filter Change:

Typically every 5,000-10,000 km or 6 months, whichever comes first. Consult manual for specific engine and oil type.

Fuel Filter Replacement:

Every 20,000-40,000 km, depending on fuel quality and operating conditions. Crucial for diesel longevity.

Air Filter Replacement:

Every 20,000-40,000 km or as needed based on driving environment (dusty conditions require more frequent checks/replacement).

Engine Oil Type:

API CI-4 or higher for diesel engines, SAE 5W-30 or 10W-30 viscosity grade (check manual for precise specifications and DPF compatibility if applicable).

Transmission Fluid Manual:

GL-4 or GL-5 gear oil (specific viscosity and API rating as per manual, e.g., 75W-90 or 80W-90)

Transmission Fluid Automatic:

Dexron III or Dexron VI compatible fluid (check manual for exact specification and capacity).

Coolant Type:

Isuzu Long Life Coolant (or equivalent ethylene glycol-based coolant with silicate inhibitors), typically pink or red color.

Common Diesel Engine Concerns:

Injector issues (especially with poor fuel quality), turbocharger wear, EGR valve clogging, glow plug failure, potential for clutch wear in heavy-duty use.

Common Chassis Concerns:

Brake pad and rotor wear, suspension component wear (bushings, ball joints, shock absorbers) particularly with heavy loads or off-road use, potential for exhaust system rust.

📚 Vehicle History

Isuzu Legacy:

Isuzu has a long history in commercial vehicles and diesel engine technology, dating back to the early 20th century. The D-Max lineage builds on their expertise in durable trucks.

Second Generation Context:

The second generation D-Max (RG) represented a significant evolution from the previous model, with updated styling, chassis improvements, and more refined diesel engines. It was a key product in Isuzu's global strategy, often shared or developed in conjunction with General Motors.

Manufacturing Locations:

Primary manufacturing plant was in Thailand (for most global markets). Other assembly plants existed in various countries.

🏆 Awards & Recognition

Industry Accolades:

The D-Max range has consistently received praise in automotive reviews for its robustness, towing capacity, and value for money, often winning specific categories in ute/pickup truck awards in Australia and other key markets.