Isuzu D-Max (RT50/85) Pickup Repair Service Manual 2012 & UP

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Price: US$ 49.00

Complete service repair manual with Electrical Wiring Diagrams for 2nd Generation Isuzu D-Max (RT50/85) MY2012 to present, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Isuzu D-Max (RT50/85) MY2012 & UP (2011 production) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 4,332 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
BODY_CAB_ACCESSORIES........2
  4WD Switch Inspection........11
  4WD Switch Installation........12
  4WD Switch Removal........13
  Accessory Socket Installation........14
  Accessory Socket Removal........15
  Air Outlet Valve Installation........16
  Air Outlet Valve Removal........17
  Antenna Inspection........18
  Antenna Installation........19
  Antenna Removal........22
  Anti Theft Horn Installation........25
  Anti Theft Horn Removal........27
  Anti Theft Indicator Light Installation........29
  Anti Theft Indicator Light Removal........30
  Audio Control Steering Wheel Switch Inspection........31
  Audio Control Steering Wheel Switch Installation........32
  Audio Control Steering Wheel Switch Removal........34
  Audio and Navigation System Installation........37
  Audio and Navigation System Removal........40
  BCM Installation........43
  BCM Removal........45
  BCM Setting........47
  Backlight Glass Installation........49
  Backlight Glass Removal........53
  Backup Light Bulb Installation........55
  Backup Light Bulb Removal........57
  Body Mounting Installation........59
  Center In-Vehicle Antenna Installation........66
  Center In-Vehicle Antenna Removal........67
  Center Pillar Upper Trim Cover Installation........68
  Center Pillar Upper Trim Cover Removal........72
  Cigarette Lighter Installation........76
  Cigarette Lighter Removal........78
  Combination Switch Inspection........80
  Combination Switch Installation........82
  Combination Switch Removal........84
  Console Box Installation........87
  Console Box Removal........90
  Cruise Control Steering Wheel Switch Inspection........93
  Cruise Control Steering Wheel Switch Installation........94
  Cruise Control Steering Wheel Switch Removal........96
  DRM Installation........99
  DRM Removal........101
  Dome Light Bulb Installation........103
  Dome Light Bulb Removal........104
  Door Switch Inspection........105
  Door Switch Installation........106
  Door Switch Removal........107
  Driver Seat Disassembly........108
  Driver Seat Installation........113
  Driver Seat Reassembly........115
  Driver Seat Removal........120
  ESC OFF Switch Inspection........123
  ESC OFF Switch Installation........124
  ESC OFF Switch Removal........125
  Electronic Key Disassembly........126
  Electronic Key Reassembly........128
  Electronic Key Setting........129
  Engine Hood Control Cable Installation........130
  Engine Hood Control Cable Removal........132
  Engine Hood Installation........134
  Engine Hood Removal........137
  Engine Start_Stop Button Inspection........140
  Engine Start_Stop Button Installation........141
  Engine Start_Stop Button Removal........144
  External Buzzer Installation........147
  External Buzzer Removal........148
  Fog Light Bulb Installation........149
  Fog Light Bulb Removal........150
  Front Air Dam Installation........151
  Front Air Dam Removal........152
  Front Bumper Installation........153
  Front Bumper Removal........159
  Front Door Disassembly........165
  Front Door Installation........175
  Front Door Lock Inspection........180
  Front Door Lock Installation........189
  Front Door Lock Removal........193
  Front Door Power Window Switch Inspection........197
  Front Door Power Window Switch Installation........200
  Front Door Power Window Switch Removal........201
  Front Door Reassembly........202
  Front Door Removal........212
  Front Door Speaker Inspection........217
  Front Door Speaker Installation........218
  Front Door Speaker Removal........221
  Front Fender Panel Installation........225
  Front Fender Panel Removal........227
  Front Pillar Trim Cover Installation........229
  Front Pillar Trim Cover Removal........234
  Front Power Window Switch Inspection........239
  Front Power Window Switch Installation........240
  Front Power Window Switch Removal........244
  Front Turn Signal Light Bulb Installation........248
  Front Turn Signal Light Bulb Removal........249
  Front Windshield Glass Installation........250
  Front Windshield Glass Removal........258
  Fuel Filler Lid Cable Installation........264
  Fuel Filler Lid Cable Removal........269
  Glove Box Key Lock Installation........274
  Glove Box Key Lock Removal........275
  Halogen Headlight Bulb Installation........276
  Halogen Headlight Bulb Removal........278
  Hazard Warning Flasher Switch Inspection........280
  Hazard Warning Flasher Switch Installation........281
  Hazard Warning Flasher Switch Removal........283
  Head Lining (Crew Cab) Disassembly........285
  Head Lining (Crew Cab) Installation........286
  Head Lining (Crew Cab) Reassembly........295
  Head Lining (Crew Cab) Removal........296
  Head Lining (Extended Cab) Disassembly........305
  Head Lining (Extended Cab) Installation........306
  Head Lining (Extended Cab) Reassembly........314
  Head Lining (Extended Cab) Removal........315
  Head Lining (Regular Cab) Installation........323
  Head Lining (Regular Cab) Removal........331
  Headlight Inspection........340
  Headlight Installation........343
  Headlight Leveling Switch Inspection........345
  Headlight Leveling Switch Installation........346
  Headlight Leveling Switch Removal........349
  Headlight Removal........352
  Heated Seat Switch Inspection........354
  Heated Seat Switch Installation........355
  Heated Seat Switch Removal........356
  High Mounted Stoplight Bulb Installation........357
  High Mounted Stoplight Bulb Removal........358
  Hill Descent Control Switch Inspection........359
  Hill Descent Control Switch Installation........360
  Hill Descent Control Switch Removal........363
  Horn Inspection........366
  Horn Installation........367
  Horn Removal........369
  Horn Switch Inspection........371
  Horn Switch Installation........372
  Horn Switch Removal........373
  ICU Installation........376
  ICU Removal........378
  ICU Setting........381
  Ignition Switch Inspection........387
  Ignition Switch Installation........388
  Ignition Switch Removal........389
  Illumination Control Switch Installation........390
  Illumination Control Switch Removal........393
  Instrument Panel Cluster Diagnostics........396
  Instrument Panel Cluster Installation........400
  Instrument Panel Cluster Removal........402
  Instrument Panel Cluster Setting........405
  Instrument Panel Installation........410
  Instrument Panel Removal........429
  Key Reminder Switch Inspection........450
  Key Reminder Switch Installation........451
  Key Reminder Switch Removal........452
  Keyless Entry Receiver Installation........453
  Keyless Entry Receiver Removal........456
  License Plate Light Bulb Installation........459
  License Plate Light Bulb Removal........461
  Outside Rearview Mirror Installation........463
  Outside Rearview Mirror Removal........466
  Passenger Seat Disassembly........470
  Passenger Seat Installation........473
  Passenger Seat Reassembly........474
  Passenger Seat Removal........477
  Passive Entry and Start System Control Unit Installation........479
  Passive Entry and Start System Control Unit Removal........481
  Passive Entry and Start System Control Unit Setting........483
  Passive Entry and Start System Receiver Installation........492
  Passive Entry and Start System Receiver Removal........497
  Radiator Grille Installation........502
  Radiator Grille Removal........504
  Rear Body Installation........506
  Rear Body Removal........511
  Rear Door Disassembly........515
  Rear Door Installation........523
  Rear Door Lock Inspection........528
  Rear Door Lock Installation........534
  Rear Door Lock Removal........537
  Rear Door Power Window Switch Inspection........540
  Rear Door Power Window Switch Installation........541
  Rear Door Power Window Switch Removal........542
  Rear Door Reassembly........543
  Rear Door Removal........551
  Rear Door Speaker Inspection........556
  Rear Door Speaker Installation........557
  Rear Door Speaker Removal........560
  Rear End Trim Cover Installation........563
  Rear End Trim Cover Removal........567
  Rear Fog Light Bulb Installation........571
  Rear Fog Light Bulb Removal........573
  Rear In-Vehicle Antenna Installation........575
  Rear In-Vehicle Antenna Removal........580
  Rear Mudguard Installation........586
  Rear Mudguard Removal........588
  Rear Pillar Trim Cover (Crew Cab) Installation........590
  Rear Pillar Trim Cover (Crew Cab) Removal........595
  Rear Pillar Trim Cover (Extended Cab) Installation........600
  Rear Pillar Trim Cover (Extended Cab) Removal........604
  Rear Pillar Trim Cover (Regular Cab) Installation........607
  Rear Pillar Trim Cover (Regular Cab) Removal........612
  Rear Seat Disassembly........617
  Rear Seat Installation........619
  Rear Seat Reassembly........624
  Rear Seat Removal........626
  Rear Step Bumper Disassembly........631
  Rear Step Bumper Installation........634
  Rear Step Bumper Reassembly........636
  Rear Step Bumper Removal........639
  Rear Turn Signal Light Bulb Installation........641
  Rear Turn Signal Light Bulb Removal........643
  Rearview Camera Installation........645
  Rearview Camera Removal........647
  Reinforcement Installation........649
  Reinforcement Removal........652
  Remote Control Mirror Switch Inspection........655
  Remote Control Mirror Switch Installation........656
  Remote Control Mirror Switch Removal........659
  Remote Controller Key Disassembly........662
  Remote Controller Key Reassembly........664
  Remote Controller Key Setting........665
  Roof Speaker Inspection........668
  Roof Speaker Installation........669
  Roof Speaker Removal........670
  Side Access Panel Disassembly........671
  Side Access Panel Installation........678
  Side Access Panel Reassembly........683
  Side Access Panel Removal........690
  Side Step Installation........695
  Side Step Removal........697
  Side Turn Signal Light (Door Mirror Integrated Type) Installation........699
  Side Turn Signal Light (Door Mirror Integrated Type) Removal........701
  Side Turn Signal Light Bulb Installation........703
  Side Turn Signal Light Bulb Removal........704
  Steering Lock Installation........705
  Steering Lock Removal........710
  Steering Lock Setting........716
  Supplementary Information (Cab Structure)........717
  Supplementary Information (Glass)........718
  Supplementary Information (Hood_Fenders_Door)........720
  Supplementary Information (Seat)........734
  Supplementary Information (Subframes)........737
  Supplementary Information (Trim)........743
  Supplementary Information (Wiper Washer)........750
  Tail Gate Installation........752
  Tail Gate Removal........757
  Tail Stoplight Bulb Installation........760
  Tail Stoplight Bulb Removal........762
  Tweeter Installation........764
  Tweeter Removal........765
  USB Charge Port Installation........766
  USB Charge Port Removal........770
  USB_HDMI Port Installation........773
  USB_HDMI Port Removal........775
  Underguard Installation........777
  Underguard Removal........780
  Washer Motor Inspection........782
  Washer Motor Installation........783
  Washer Motor Removal........786
  Washer Nozzle Installation........789
  Washer Nozzle Removal........792
  Wiper Arm Installation........795
  Wiper Arm Removal........796
  Wiper Blade Rubber Installation........797
  Wiper Blade Rubber Removal........798
  Wiper Linkage Installation........799
  Wiper Linkage Removal........803
  Wiper Motor Inspection........807
  Wiper Motor Installation........808
  Wiper Motor Removal........810
BRAKES........812
  ABS Supplementary Information........814
  Brake Booster Inspection........816
  Brake Booster Installation........817
  Brake Booster Removal........828
  Brake Electrical Control Supplementary Information........830
  Brake Fluid Inspection........834
  Brake Fluid Replacement........835
  Brake Master Cylinder Disassembly........841
  Brake Master Cylinder Inspection........843
  Brake Master Cylinder Installation........844
  Brake Master Cylinder Reassembly........851
  Brake Master Cylinder Removal........853
  Brake Pedal Inspection........855
  Brake Pedal Installation........856
  Brake Pedal Removal........861
  Brake Supplementary Information........863
  Disc Brake Pad Inspection........869
  Disc Brake Pad Installation........872
  Disc Brake Pad Removal........879
  EHCU Installation........883
  EHCU Removal........890
  EHCU Setting........893
  Front Disc Brake Disassembly........895
  Front Disc Brake Inspection........899
  Front Disc Brake Installation........904
  Front Disc Brake Reassembly........921
  Front Disc Brake Removal........932
  Front Exciter Ring Inspection........939
  Front Exciter Ring Installation........940
  Front Exciter Ring Removal........964
  Front Wheel Speed Sensor Inspection........974
  Front Wheel Speed Sensor Installation........976
  Front Wheel Speed Sensor Removal........981
  Parking Brake Inspection........986
  Parking Brake Installation........987
  Parking Brake Lever Installation........994
  Parking Brake Lever Removal........999
  Parking Brake Removal........1005
  Parking Brake Supplementary Information........1012
  Parking Brake Switch Inspection........1017
  Parking Brake Switch Installation........1019
  Parking Brake Switch Removal........1021
  Rear Drum Brake Inspection........1023
  Rear Drum Brake Installation........1026
  Rear Drum Brake Removal........1033
  Rear Exciter Ring Inspection........1037
  Rear Exciter Ring Installation........1038
  Rear Exciter Ring Removal........1056
  Rear Wheel Cylinder Disassembly........1062
  Rear Wheel Cylinder Inspection........1064
  Rear Wheel Cylinder Installation........1066
  Rear Wheel Cylinder Reassembly........1078
  Rear Wheel Cylinder Removal........1081
  Rear Wheel Speed Sensor Inspection........1085
  Rear Wheel Speed Sensor Installation........1087
  Rear Wheel Speed Sensor Removal........1091
  Stoplight Switch Inspection........1094
  Stoplight Switch Installation........1096
  Stoplight Switch Removal........1101
DESCRIPTION........1103
  BODY_CAB_ACCESSORIES........1104
    Both of the Rear Windows Do Not Operate........1106
    Brake System Warning Light Does Not Light up Even When the Brake Fluid in the Tank Decreases........1107
    Brake System Warning Light Lights Even When Brake Fluid is Filled to Specified Level........1108
    Driving Information is Not Displayed........1109
    Engine Oil Pressure Warning Light Does Not Turn off Even When the Engine is Running........1110
    Function, Structure, Operation of Body, Cab, Accessories........1111
    Indicated Error of the Speedometer is Significantly Large........1135
    Indicated Error of the Tachometer is Significantly Large........1136
    Introduction to the Trouble Diagnosis of Body, Cab, Accessories........1137
    Low Fuel Warning Light Does Not Light Even When the Fuel Tank is Empty........1138
    Low Fuel Warning Light Lights Even When the Fuel Tank is Full........1139
    Maintenance Precautions of Body, Cab, Accessories........1140
    None of the Windows Operate........1141
    Odometer Does Not Count up (Speedometer is Normal)........1142
    Operation Abnormality of the Backup Light Function........1143
    Operation Abnormality of the Clearance Light Function........1144
    Operation Abnormality of the Dome Light Function........1145
    Operation Abnormality of the Headlight Function........1147
    Operation Abnormality of the Instrument Panel Cluster Illumination Function........1149
    Operation Abnormality of the License Plate Light Function........1155
    Operation Abnormality of the Taillight_Stoplight Function........1156
    Operation Abnormality of the Turn Signal Light Function........1157
    Parking Brake Warning Light Does Not Light up Even When the Parking Brake Lever is Engaged........1159
    Parking Brake Warning Light Does Not Turn off Even When the Parking Brake Lever is Fully Released........1160
    Primary Specifications of Body, Cab, Accessories........1161
    Reading of the Engine Coolant Temperature Gauge is Lower (Higher) than Reality........1181
    Rear Left Side Window Does Not Operate........1182
    Right Rear Window Does Not Operate........1183
    Segment Display of the Fuel Gauge ( Goes up to f) Even When the Fuel Tank is Not Full........1184
    Segment Display of the Fuel Gauge Does Not Indicate f Even When the Fuel Tank is Full........1185
    Speedometer Accuracy Check Inspection........1186
    Speedometer Does Not Operate (Odometer is Normal)........1187
    Speedometer and Odometer Do Not Operate........1188
    Tachometer Accuracy Check Inspection........1189
    Washer Motor Does Not Operate........1190
    Water Separator Warning Light Does Not Light Even When Water Exceeds Water Separator Drain Line........1191
    Water Separator Warning Light Lights Even When Water Level is Low in Water Separator........1192
    Window at the Driver Side Does Not Operate........1193
    Window at the Passenger Side Does Not Operate........1194
    Wiper Does Not Operate Regardless of the Switch Position........1195
    Wiper Does Not Operate at the HI Position........1196
    Wiper Does Not Operate at the INT Position........1197
    Wiper Does Not Operate at the LO Position........1198
    Wiper Motor Does Not Stop........1199
  BODY_CONTROL_BCM........1200
    Function, Structure, Operation of Body Control........1201
    Introduction to the Trouble Diagnosis of Body Control........1211
    Maintenance Precautions of Body Control........1214
  BRAKES........1216
    ABS Works Frequently but the Brake is Not Effective or TCS Operates Frequently........1217
    Function, Structure, Operation of Brake........1220
    Intermittent Conditions of Brake........1245
    Introduction to the Trouble Diagnosis of Brake........1247
    Maintenance Precautions of Brake........1255
    Primary Specifications of Brake........1257
  DRIVELINE_AXLE........1258
    Abnormal Noise and Vibration from Front Axle........1259
    Abnormal Noise and Vibration from Propeller Shaft........1260
    Abnormal Noise and Vibration from Rear Axle........1261
    Abnormal Sound or Noise from the Transfer........1263
    Brake Abnormal Noise........1264
    Brake Does Not Work Efficiently........1265
    Brake Operation Sounds Are Heard from the Hydraulic Unit Even Though the Brake is Not Applied........1266
    Brake Pedal Feeling is Abnormal........1268
    Brake Pedal Pulsates........1270
    Defective Straight Driving........1271
    Dragging Brakes........1272
    ESC Does Not Work Efficiently........1273
    Function, Structure, Operation of Driveline, Axle........1274
    Gear Does Not Engage When Switching from HIGH to LOW........1294
    Gear Does Not Engage When Switching to Front Drive........1295
    Intermittent Conditions of Transfer Case Control System........1296
    Introduction to the Trouble Diagnosis of Driveline, Axle........1299
    Maintenance Precautions of Driveline, Axle........1300
    Oil Leakage from Front Drive Axle........1303
    Oil Leakage from Rear Axle........1304
    Oil Leakage from Transfer........1305
    One Wheel Locks........1306
    Power Not Being Transmitted to the Wheels........1307
    Primary Specifications of Driveline, Axle........1308
    Stepping Power of the Brake Pedal is Large........1310
    Stroke of the Brake Pedal is Abnormal........1311
    Wheel Alignment Check........1312
    Wheels Lock When Braking........1323
  ENGINE (RZ4E-TC)........1325
    Abnormal Combustion Noise........1327
    Abnormal Sound in Generator........1328
    Black Smoke........1329
    Charging System Check........1331
    Cuts Out........1332
    DPD System Regeneration Long Time........1334
    Defect of Charging System........1336
    Defect of Turbocharger........1338
    Engine Compression Pressure Inspection........1340
    Engine Does Not Stop........1342
    Engine Does Not Turn Over........1343
    Engine Has Overcooled........1345
    Engine Has Overheated........1346
    Engine Slow to Warm Up........1347
    Exhaust Gas Leak, Noise........1348
    Fuel Supply Pump Functional Inspection........1349
    Function, Structure, Operation of Engine........1353
    Function, Structure, Operation of IBS........1403
    Hard Start........1408
    Hesitation, Sag or Stumble........1410
    High Idle Speed........1412
    Intermittent Conditions of Engine........1413
    Intermittent Conditions of IBS........1417
    Introduction to the Trouble Diagnosis of Engine........1420
    Introduction to the Trouble Diagnosis of IBS........1423
    Lack of Power, Sluggishness or Sponginess........1424
    Lubricating System Inspection........1426
    Maintenance Precautions of Engine........1427
    Maintenance Precautions of IBS........1431
    Poor Fuel Economy........1433
    Preheating Does Not Operate........1435
    Preheating Time is Too Long........1436
    Preheating Time is Too Short........1437
    Primary Specifications of Engine........1438
    Rough, Unstable........1441
    Starter Overrun........1443
    Surges........1444
    Vibrations and Rattling Sounds from the Exhaust System........1446
    White Smoke........1447
  FRAME........1449
    Primary Specifications of Frame, Frame Accessories........1450
  GENERAL_INFORMATION........1457
    Abbreviations........1458
    Contents Included in Service Information........1468
    Handling Electronic Parts........1471
    PLASTIGAUGE........1476
    Preliminary and Post Procedures........1478
    Recommended Liquid Gasket........1479
    Recommended Thread Locking Agent........1481
    Standard Bolts........1482
    Term........1488
    Using the ETM........1489
    Wiring Repair........1507
  HVAC........1521
    Air Conditioning System Check........1522
    Automatic Air Conditioning Control Unit Power Circuit Inspection........1524
    Blower Motor Does Not Function at the HI Position........1525
    Blower Motor Does Not Function at the LOW Position........1526
    Blower Motor Does Not Function at the MEDIUM HI Position........1527
    Blower Motor Does Not Function at the MEDIUM LOW Position........1528
    Blower Motor Does Not Operate Regardless of the Switch Position........1529
    Blower Motor Does Not Stop Operating........1531
    Checking the Air Conditioning System Using the Manifold Gauge........1532
    Code 22 Shows on the Control Panel Display........1535
    Code 24 Shows on the Control Panel Display........1536
    Code 25 Shows on the Control Panel Display........1537
    Code 31 Shows on the Control Panel Display........1538
    Code 32 Shows on the Control Panel Display........1540
    Code 33 Shows on the Control Panel Display........1542
    Code 34 Shows on the Control Panel Display........1544
    Code 35 Shows on the Control Panel Display........1546
    Code 37 Shows on the Control Panel Display........1548
    Code 38 Shows on the Control Panel Display........1550
    Code 39 Shows on the Control Panel Display........1552
    Cooling System is Not Functioning or is Weak........1554
    Function, Structure, Operation of Heating, Ventilation Air Conditioning........1555
    Insufficient Air Flow from the Cooling System........1581
    Intake Actuator Does Not Work........1582
    Introduction to the Trouble Diagnosis of Heating, Ventilation Air Conditioning........1583
    Magnetic Clutch is Not Functioning........1589
    Maintenance Precautions of Heating, Ventilation Air Conditioning........1591
    Mode Door Cannot Be Set to a Specified Mode........1595
    Primary Specifications of Heating, Ventilation Air Conditioning........1596
  RESTRAINTS........1598
    Function, Structure, Operation of Restraint........1599
    Intermittent Conditions of SRS Control........1619
    Introduction to the Trouble Diagnosis of Restraint........1620
    Maintenance Precautions of Restraint........1626
  SECURITY_&_LOCK_CONTROL........1637
    Answer Back Buzzer (External Buzzer) Does Not Work........1638
    Doors Do Not Lock Even When Operating the Door Lock Button on the Driver Side........1639
    Doors Do Not Lock or Unlock with Electronic Key Button Operation........1641
    Doors Do Not Unlock Even When Gripping the Driver Side Door Handle........1642
    Function, Structure, Operation of Security and Locks Control........1644
    Intermittent Conditions of Passive Entry and Start System........1653
    Introduction to the Trouble Diagnosis of Security and Locks Control........1656
    Maintenance Precautions of Security and Locks Control........1657
    No Electronic Key Warning Buzzer (External Buzzer) Does Not Work........1659
    The Power Mode Does Not Change........1660
  STEERING........1661
    Abnormal Kickback of the Steering Wheel........1662
    Abnormal Noises of Power Steering........1663
    Excessive Play of the Steering........1664
    Function, Structure, Operation of Steering........1665
    Improper Return of the Steering Wheel to the Center Position........1668
    Inspection of Steering Free Play........1669
    Key Cannot Be Pull out at the........1670
    Large Force Required to Operate the Steering........1671
    Lock Does Not Lock........1672
    Lock Does Not Unlock........1673
    Measurement of the Power Steering Operating Pressure........1674
    Primary Specifications of Steering........1677
    Rattling of the Steering Wheel........1678
    Steering Malfunction When the Brake is Applied........1679
    Steering Operation is Heavy, or Power Assist Does Not Work........1680
    Steering Wheel is Difficult to Control........1681
    Surging of Power Steering........1682
    Unstable Steering........1683
    Vibration of the Steering Wheel........1684
  SUSPENSION........1685
    Abnormal Noises from Suspension........1686
    Abnormal Wear of the Tire........1687
    Function, Structure, Operation of Suspension........1688
    Primary Specifications of Suspension........1695
    Spring Breakage........1697
    Suspension Hits the Bottom........1698
    Tilting of the Body........1699
    Trim Height is Uneven........1700
    Uncomfortable Ride........1701
    Unevenness During Wheel Rotation........1702
  TRANSMISSION_TRANSAXLE........1703
    ATF Leakage........1704
    Abnormal Noise or Vibration of the Vehicle with Automatic Transmission........1706
    Acceleration Failure of the Vehicle with Automatic Transmission........1708
    Automatic Transmission Cannot Shift........1709
    Automatic Transmission Slips........1711
    Engine Cannot Be Started When Shifted to N or P........1712
    Engine of the Vehicle with Automatic Transmission Stalls........1713
    Erratic Shifting of the Automatic Transmission........1714
    Function, Structure, Operation of Transmission, Transaxle........1715
    Harsh Shocks During Automatic Transmission Shifting........1751
    Intermittent Conditions of Automatic Transmission........1759
    Introduction to the Trouble Diagnosis of Transmission, Transaxle........1762
    Kickdown Does Not Occur........1766
    Maintenance Precautions of Transmission, Transaxle........1767
    Measurement of the Automatic Transmission Operating Pressure........1768
    Mode Select Does Not Work........1770
    Primary Specifications of Transmission, Transaxle........1771
    Selector Lever Movement is Stiff or Loose........1772
    Shift Time Lag of Automatic Transmission........1773
    Time Lag Test........1774
    Vehicle with Automatic Transmission Does Not Move........1775
DRIVELINE_AXLE........1776
  Differentials........1777
    Differential Oil Inspection........1778
    Differential Oil Replacement........1780
    Front Final Drive (F194 Mm { 7.64 in }) Disassembly........1783
    Front Final Drive (F194 Mm { 7.64 in }) Inspection........1793
    Front Final Drive (F194 Mm { 7.64 in }) Installation........1798
    Front Final Drive (F194 Mm { 7.64 in }) Reassembly........1824
    Front Final Drive (F194 Mm { 7.64 in }) Removal........1846
    Rear Final Drive (F220 Mm { 8.66 in }) Disassembly........1861
    Rear Final Drive (F220 Mm { 8.66 in }) Inspection........1869
    Rear Final Drive (F220 Mm { 8.66 in }) Installation........1874
    Rear Final Drive (F220 Mm { 8.66 in }) Reassembly........1891
    Rear Final Drive (F220 Mm { 8.66 in }) Removal........1913
    Supplementary Information........1918
  Drive Shaft System........1922
    Front Axle Shaft Disassembly........1924
    Front Axle Shaft Inspection........1928
    Front Axle Shaft Installation........1929
    Front Axle Shaft Reassembly........1951
    Front Axle Shaft Removal........1957
    Front Drive Axle Disassembly........1970
    Front Drive Axle Inspection........1975
    Front Drive Axle Installation........1976
    Front Drive Axle Reassembly........1996
    Front Drive Axle Removal........2002
    Front Hub Disassembly........2014
    Front Hub Inspection........2019
    Front Hub Installation........2027
    Front Hub Reassembly........2037
    Front Hub Removal........2047
    Front Propeller Shaft Disassembly........2054
    Front Propeller Shaft Inspection........2058
    Front Propeller Shaft Installation........2061
    Front Propeller Shaft Reassembly........2063
    Front Propeller Shaft Removal........2068
    Knuckle Inspection........2070
    Knuckle Installation........2072
    Knuckle Removal........2092
    Oil Catcher Tank Inspection........2106
    Oil Catcher Tank Installation........2107
    Oil Catcher Tank Removal........2110
    Rear Axle Disassembly........2112
    Rear Axle Inspection........2114
    Rear Axle Installation........2115
    Rear Axle Reassembly........2133
    Rear Axle Removal........2138
    Rear Axle Shaft Disassembly........2146
    Rear Axle Shaft Inspection........2151
    Rear Axle Shaft Installation........2153
    Rear Axle Shaft Reassembly........2169
    Rear Axle Shaft Removal........2175
    Rear Propeller Shaft Disassembly........2181
    Rear Propeller Shaft Inspection........2184
    Rear Propeller Shaft Installation........2187
    Rear Propeller Shaft Reassembly........2190
    Rear Propeller Shaft Removal........2195
    Shift on the Fly System Disassembly........2197
    Shift on the Fly System Inspection........2199
    Shift on the Fly System Installation........2205
    Shift on the Fly System Oil Inspection........2227
    Shift on the Fly System Oil Replacement........2228
    Shift on the Fly System Reassembly........2231
    Shift on the Fly System Removal........2235
    Supplementary Information........2249
    Wheel Alignment Check........2264
  Electrical Control........2273
    TCCM Installation........2274
    TCCM Removal........2278
  Transfer Case........2282
    Front Output Shaft Oil Seal Installation........2283
    Front Output Shaft Oil Seal Removal........2288
    Rear Output Shaft Oil Seal Installation........2290
    Rear Output Shaft Oil Seal Removal........2292
    Supplementary Information........2293
    Transfer Disassembly........2303
    Transfer Inspection........2321
    Transfer Installation........2328
    Transfer Oil Inspection........2335
    Transfer Oil Replacement........2336
    Transfer Reassembly........2338
    Transfer Removal........2366
ENGINE (RZ4E-TC)........2371
  Aux. Emission Control Devices........2372
    EGR Cooler Bypass Control Solenoid Valve Installation........2373
    EGR Cooler Bypass Control Solenoid Valve Removal........2378
    EGR Inspection........2383
    EGR Installation........2384
    EGR Removal........2398
    Supplementary Information........2409
  Cooling........2410
    Auto Tensioner Installation........2411
    Auto Tensioner Removal........2412
    Coolant Inspection........2413
    Coolant Replacement........2418
    Cooling Fan Belt Inspection........2424
    Cooling Fan Belt Installation........2425
    Cooling Fan Belt Removal........2427
    Cooling Fan Clutch Inspection........2429
    Cooling Fan Clutch Installation........2431
    Cooling Fan Clutch Removal........2437
    Radiator Inspection........2441
    Radiator Installation........2443
    Radiator Removal........2451
    Supplementary Information........2458
    Thermostat Inspection........2461
    Thermostat Installation........2462
    Thermostat Removal........2466
    Water Pump Inspection........2469
    Water Pump Installation........2470
    Water Pump Removal........2472
  Electrical........2474
    Battery Sensor Installation........2475
    Battery Sensor Removal........2476
    Generator Inspection........2477
    Generator Installation........2478
    Generator Removal........2480
    Glow Control Unit Installation........2482
    Glow Control Unit Removal........2483
    Glow Plug Inspection........2484
    Glow Plug Installation........2485
    Glow Plug Removal........2490
    Starter Motor Disassembly........2495
    Starter Motor Inspection........2499
    Starter Motor Installation........2505
    Starter Motor Reassembly........2508
    Starter Motor Removal........2517
    Supplementary Information........2519
  Engine Electrical Control........2522
    Boost Pressure Sensor Inspection........2524
    Boost Pressure Sensor Installation........2525
    Boost Pressure Sensor Removal........2526
    CKP Sensor Inspection........2527
    CKP Sensor Installation........2528
    CKP Sensor Removal........2529
    CMP Sensor Inspection........2530
    CMP Sensor Installation........2531
    CMP Sensor Removal........2534
    Charge Air Cooler Temperature Sensor 1 Inspection........2537
    Charge Air Cooler Temperature Sensor 1 Installation........2538
    Charge Air Cooler Temperature Sensor 1 Removal........2539
    Charge Air Cooler Temperature Sensor 2 Inspection........2540
    Charge Air Cooler Temperature Sensor 2 Installation........2541
    Charge Air Cooler Temperature Sensor 2 Removal........2542
    ECM Inspection........2543
    ECM Installation........2544
    ECM Removal........2546
    ECM Setting........2551
    EGR Gas Temperature Sensor Inspection........2557
    EGR Gas Temperature Sensor Installation........2558
    EGR Gas Temperature Sensor Removal........2559
    Engine Coolant Temperature Sensor Inspection........2560
    Engine Coolant Temperature Sensor Installation........2562
    Engine Coolant Temperature Sensor Removal........2565
    Exhaust Differential Pressure Sensor Inspection........2567
    Exhaust Differential Pressure Sensor Installation........2569
    Exhaust Differential Pressure Sensor Removal........2572
    Exhaust Gas Temperature Sensor 1 Inspection........2574
    Exhaust Gas Temperature Sensor 1 Installation........2575
    Exhaust Gas Temperature Sensor 1 Removal........2576
    Exhaust Gas Temperature Sensor 2 Inspection........2577
    Exhaust Gas Temperature Sensor 2 Installation........2578
    Exhaust Gas Temperature Sensor 2 Removal........2579
    Heated Oxygen Sensor 1 Installation........2580
    Heated Oxygen Sensor 1 Removal........2584
    Heated Oxygen Sensor 2 Installation........2586
    Heated Oxygen Sensor 2 Removal........2589
    MAF and IAT Sensor Inspection........2590
    MAF and IAT Sensor Installation........2591
    MAF and IAT Sensor Removal........2592
    PM Sensor Installation........2593
    PM Sensor Removal........2595
  Exhaust........2596
    DPD Inspection........2597
    DPD Installation........2598
    DPD Removal........2606
    Exhaust Pipe Inspection........2610
    Exhaust Pipe Installation........2611
    Exhaust Pipe Removal........2613
    Supplementary Information........2615
  Fuel System........2616
    Common Rail (Fuel Rail) Installation........2618
    Common Rail (Fuel Rail) Removal........2623
    Filler Neck Installation........2628
    Filler Neck Removal........2630
    Fuel Air Bleed........2631
    Fuel Drain Water........2632
    Fuel Filler Cap Inspection........2633
    Fuel Filler Cap Installation........2634
    Fuel Filler Cap Removal........2635
    Fuel Filter Element Installation........2636
    Fuel Filter Element Removal........2638
    Fuel Filter Inspection........2639
    Fuel Filter Installation........2640
    Fuel Filter Removal........2643
    Fuel Inspection........2645
    Fuel Supply Pump Installation........2646
    Fuel Supply Pump Removal........2653
    Fuel Tank Installation........2659
    Fuel Tank Removal........2664
    Fuel Tank Unit Inspection........2668
    Fuel Tank Unit Installation........2671
    Fuel Tank Unit Removal........2674
    Fuel Tube Inspection........2676
    Fuel Tube Installation........2677
    Fuel Tube Removal........2678
    Injector Installation........2680
    Injector Removal........2689
    Supplementary Information........2695
    Water Sedimenter Switch Inspection........2702
    Water Sedimenter Switch Installation........2703
    Water Sedimenter Switch Removal........2704
  Inuduction........2705
    Air Cleaner Element Inspection........2706
    Air Cleaner Element Installation........2707
    Air Cleaner Element Removal........2708
    Intercooler Inspection........2709
    Intercooler Installation........2711
    Intercooler Removal........2713
    Supplementary Information........2716
    Turbocharger Control Solenoid Valve Inspection........2718
    Turbocharger Control Solenoid Valve Installation........2719
    Turbocharger Control Solenoid Valve Removal........2721
    Turbocharger Inspection........2723
    Turbocharger Installation........2725
    Turbocharger Removal........2736
  Lubrication........2744
    Engine Oil Inspection........2745
    Engine Oil Replacement........2747
    Oil Cooler Installation........2749
    Oil Cooler Removal........2751
    Oil Filter Element Installation........2753
    Oil Filter Element Removal........2756
    Oil Filter Installation........2759
    Oil Filter Removal........2766
    Oil Pan Installation........2772
    Oil Pan Removal........2775
    Oil Pressure Switch Inspection........2777
    Oil Pressure Switch Installation........2779
    Oil Pressure Switch Removal........2781
    Oil Pump Disassembly........2783
    Oil Pump Installation........2784
    Oil Pump Reassembly........2786
    Oil Pump Removal........2787
    Supplementary Information........2789
  Mechanical........2795
    Camshaft Disassembly........2798
    Camshaft Inspection........2799
    Camshaft Installation........2802
    Camshaft Reassembly........2810
    Camshaft Removal........2812
    Crankcase Inspection........2820
    Crankcase Installation........2821
    Crankcase Removal........2825
    Crankshaft Disassembly........2828
    Crankshaft Front Oil Seal Installation........2829
    Crankshaft Front Oil Seal Removal........2831
    Crankshaft Inspection........2833
    Crankshaft Installation........2839
    Crankshaft Pulley Installation........2846
    Crankshaft Pulley Removal........2854
    Crankshaft Rear Oil Seal Installation........2860
    Crankshaft Rear Oil Seal Removal........2863
    Crankshaft Reassembly........2865
    Crankshaft Removal........2866
    Cylinder Block Inspection........2869
    Cylinder Block Installation........2872
    Cylinder Block Removal........2888
    Cylinder Head Cover Installation........2898
    Cylinder Head Cover Removal........2902
    Cylinder Head Disassembly........2904
    Cylinder Head Inspection........2910
    Cylinder Head Installation........2921
    Cylinder Head Reassembly........2941
    Cylinder Head Removal........2951
    Engine Installation........2962
    Engine Mounting Installation........2981
    Engine Mounting Removal........2985
    Engine Removal........2990
    Exhaust Manifold Inspection........3004
    Exhaust Manifold Installation........3005
    Exhaust Manifold Removal........3009
    Flywheel Disassembly........3011
    Flywheel Housing Installation........3012
    Flywheel Housing Removal........3056
    Flywheel Inspection........3082
    Flywheel Installation........3083
    Flywheel Reassembly........3089
    Flywheel Removal........3090
    Front Cover Installation........3095
    Front Cover Removal........3101
    Idle Gear Inspection........3105
    Idle Gear Installation........3107
    Idle Gear Removal........3113
    Inlet Manifold Installation........3117
    Inlet Manifold Removal........3131
    Intake Throttle Valve Installation........3142
    Intake Throttle Valve Removal........3145
    Piston Disassembly........3147
    Piston Inspection........3149
    Piston Installation........3157
    Piston Reassembly........3160
    Piston Removal........3163
    Supplementary Information........3164
    Swirl Control Solenoid Valve Installation........3182
    Swirl Control Solenoid Valve Removal........3187
    Timing Chain Installation........3192
    Timing Chain Removal........3237
  Speed Control Systems........3264
    Accelerator Pedal Inspection........3265
    Accelerator Pedal Installation........3266
    Accelerator Pedal Removal........3267
HVAC........3268
  A_C Compressor (RZ4E) Installation........3270
  A_C Compressor (RZ4E) Removal........3273
  A_C Compressor Magnet Clutch Inspection........3276
  A_C Compressor Magnet Clutch Installation........3277
  A_C Compressor Magnet Clutch Removal........3279
  Blower Installation........3281
  Blower Module Inspection........3283
  Blower Module Installation........3284
  Blower Module Removal........3286
  Blower Motor Inspection........3288
  Blower Motor Installation........3290
  Blower Motor Removal........3292
  Blower Removal........3294
  Blower Resistor Inspection........3296
  Blower Resistor Installation........3297
  Blower Resistor Removal........3298
  Center Ventilation Grille Installation........3299
  Center Ventilation Grille Removal........3304
  Condenser Installation........3308
  Condenser Removal........3310
  Control Panel and Control Lever Inspection........3312
  Control Panel and Control Lever Installation........3313
  Control Panel and Control Lever Removal........3318
  Evaporator Core Installation........3323
  Evaporator Core Removal........3325
  Heater Core Installation........3327
  Heater Core Removal........3329
  Heater Evaporator Unit Installation........3331
  Heater Evaporator Unit Removal........3333
  Inside Air Temperature Sensor Inspection........3335
  Inside Air Temperature Sensor Installation........3337
  Inside Air Temperature Sensor Removal........3340
  Intake Actuator Installation........3344
  Intake Actuator Removal........3347
  Intake Door Installation........3350
  Intake Door Removal........3353
  Mix Actuator Installation........3356
  Mix Actuator Removal........3357
  Mode Actuator Installation........3358
  Mode Actuator Removal........3359
  Outside Air Temperature Sensor Inspection........3360
  Outside Air Temperature Sensor Installation........3361
  Outside Air Temperature Sensor Removal........3363
  Pressure Switch Inspection........3365
  Pressure Switch Installation........3367
  Pressure Switch Removal........3368
  Rear Heater Duct Installation........3369
  Rear Heater Duct Removal........3372
  Sun Sensor Inspection........3375
  Sun Sensor Installation........3376
  Sun Sensor Removal........3377
  Supplementary Information........3378
  Vent Grille Installation........3391
  Vent Grille Removal........3392
  Ventilation Duct Installation........3393
  Ventilation Duct Removal........3396
INTRODUCTION........3399
  Safety Information........3400
RESTRAINTS........3408
  Buckle Side Driver Seat Belt Installation........3410
  Buckle Side Driver Seat Belt Removal........3411
  Buckle Side Passenger Seat Belt Installation........3412
  Buckle Side Passenger Seat Belt Removal........3414
  Curtain Airbag Installation........3416
  Curtain Airbag Removal........3418
  Curtain Airbag Scrapping........3421
  Door Side Airbag Sensor Installation........3434
  Door Side Airbag Sensor Removal........3437
  Driver Airbag Installation........3441
  Driver Airbag Removal........3443
  Driver Airbag Scrapping........3447
  Front Airbag Sensor Installation........3461
  Front Airbag Sensor Removal........3463
  Passenger Airbag Installation........3465
  Passenger Airbag Removal........3469
  Passenger Airbag Scrapping........3474
  Rear Buckle Side Seat Belt Installation........3494
  Rear Buckle Side Seat Belt Removal........3498
  Rear Tongue Side Center Seat Belt Installation........3502
  Rear Tongue Side Center Seat Belt Removal........3505
  Rear Tongue Side Seat Belt Installation........3507
  Rear Tongue Side Seat Belt Removal........3512
  SRS Coil Installation........3517
  SRS Coil Removal........3520
  SRS Control Unit Installation........3525
  SRS Control Unit Removal........3526
  Seat Belt with Pretensioner (Crew Cab) Installation........3527
  Seat Belt with Pretensioner (Crew Cab) Removal........3532
  Seat Belt with Pretensioner (Crew Cab) Scrapping........3537
  Seat Belt with Pretensioner (Extend Cab) Installation........3549
  Seat Belt with Pretensioner (Extend Cab) Removal........3553
  Seat Belt with Pretensioner (Extend Cab) Scrapping........3557
  Seat Belt with Pretensioner (Regular Cab) Installation........3569
  Seat Belt with Pretensioner (Regular Cab) Removal........3574
  Seat Belt with Pretensioner (Regular Cab) Scrapping........3579
  Side Airbag Installation........3591
  Side Airbag Removal........3594
  Side Airbag Scrapping........3597
  Side Airbag Sensor (Crew Cab) Installation........3610
  Side Airbag Sensor (Crew Cab) Removal........3613
  Side Airbag Sensor (Extend Cab) Installation........3617
  Side Airbag Sensor (Extend Cab) Removal........3620
  Supplementary Information (AirBag)........3623
  Supplementary Information (Seat Belt)........3625
STEERING........3632
  Power Steering Fluid Replacement........3633
  Power Steering Oil Pump (RZ4E) Installation........3636
  Power Steering Oil Pump (RZ4E) Removal........3641
  Power Steering Unit Disassembly........3642
  Power Steering Unit Inspection........3645
  Power Steering Unit Installation........3646
  Power Steering Unit Reassembly........3653
  Power Steering Unit Removal........3658
  Steering Angle Sensor Installation........3664
  Steering Angle Sensor Removal........3670
  Steering Angle Sensor Setting........3678
  Steering Column Inspection........3679
  Steering Column Installation........3680
  Steering Column Removal........3689
  Supplementary Information (Power Assisted System)........3701
  Supplementary Information (Steering Electrical Control)........3706
SUSPENSION........3707
  Front Suspension........3708
    Independent Suspension Disassembly........3709
    Independent Suspension Inspection........3711
    Independent Suspension Installation........3713
    Independent Suspension Reassembly........3742
    Independent Suspension Removal........3745
    Supplementary Information........3769
  Rear Suspension........3780
    Leaf Rigid Suspension Disassembly........3781
    Leaf Rigid Suspension Inspection........3785
    Leaf Rigid Suspension Installation........3786
    Leaf Rigid Suspension Reassembly........3795
    Leaf Rigid Suspension Removal........3796
    Supplementary Information........3803
  Wheel and Tire........3807
    Disc Wheel and Tire Inspection........3808
    Disc Wheel and Tire Installation........3816
    Disc Wheel and Tire Removal........3818
    Supplementary Information........3820
TRANSMISSION_TRANSAXLE (AWR6B45)........3821
  ATF Cooler Pipe Inspection........3823
  ATF Cooler Pipe Installation........3824
  ATF Cooler Pipe Removal........3833
  ATF Inspection........3835
  ATF Replacement........3836
  Automatic Transmission Control Cable Installation........3852
  Automatic Transmission Control Cable Removal........3856
  Brake Piston No.1 Disassembly........3859
  Brake Piston No.1 Reassembly........3861
  Brake Piston No.2 Disassembly........3863
  Brake Piston No.2 Reassembly........3865
  Forward Clutch Assembly Disassembly........3867
  Forward Clutch Assembly Inspection........3876
  Forward Clutch Assembly Reassembly........3880
  Front Planetary Ring Gear Disassembly........3894
  Front Planetary Ring Gear Inspection........3896
  Front Planetary Ring Gear Reassembly........3897
  Inhibitor Switch Inspection........3899
  Inhibitor Switch Installation........3901
  Inhibitor Switch Removal........3903
  Middle Planetary Ring Gear Disassembly........3905
  Middle Planetary Ring Gear Reassembly........3908
  Oil Pump Disassembly........3911
  Oil Pump Inspection........3913
  Oil Pump Reassembly........3915
  Output Speed Sensor Installation........3918
  Output Speed Sensor Removal........3919
  Rear Planetary Ring Gear Disassembly........3922
  Rear Planetary Ring Gear Inspection........3925
  Rear Planetary Ring Gear Reassembly........3927
  Selector Lever Disassembly........3930
  Selector Lever Installation........3932
  Selector Lever Reassembly........3937
  Selector Lever Removal........3940
  Supplementary Information........3944
  TCM Installation........3963
  TCM Removal........3965
  TCM Setting........3967
  Transmission Disassembly........3968
  Transmission Inspection........4014
  Transmission Installation........4035
  Transmission Reassembly........4057
  Transmission Removal........4122
  Turbine Speed Sensor Inspection........4134
  Turbine Speed Sensor Installation........4137
  Turbine Speed Sensor Removal........4138

Isuzu D-Max (RT50/85) Pickup Repair Service Manual 2012 & UP

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