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