Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1606

0A-2  GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS

1.Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.

2.Raise the vehicle with a jack set against the axle or the frame.

3.Support the vehicle on chassis stands.

4.Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.

5.Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to shortcircuiting.

6.Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.

7.The  use  of  the  proper  tool(s)  and  special  tool(s)  where  specified  is  essential  to  efficient,  reliable,  and  safe

service operations.

8.Always use genuine ISUZU replacement parts.

9.Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.

Normal function of these parts cannot be guaranteed if they are reused.

10.Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.

11.Keep the disassembled parts neatly in groups.

This will facilitate smooth and correct reassembly.

12.Keep fixing nuts and bolts separate.

Fixing nuts and bolts vary in hardness and design according to installation position.

13.Clean all parts before inspection or reassembly.

14.Clean  the  oil  ports  and  other  openings  with  compressed  air  to  make  certain  that  they  are  free  from  dirt  and

obstructions.

15.Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.

16.Use the recommended liquid gasket to prevent leakage.

17.Carefully observe all nut and bolt torque specifications.

18.When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be

sure  to  use  the  Vehicle  Refrigerant  Recovery  and  Recycling  Equipment  (VRRRE)  to  recover  and  recycle

Refrigerant-12, to promote the movement for the protection of the ozone layer covering the earth.

19.Check and recheck your work.  No service operation is complete until you have done this.

GENERAL INFORMATION  0A-3

NOTES ON THE FORMAT OF THIS MANUAL

1. Find the applicable Section by referring to the index at the front of the Workshop Manual binder.

2. The following technical service information is included in this Section:

• Identification
• Maintenance schedules
• Recommended Iubricants
• Recommended fuels
• Oil viscosity charts

3. Individual Sections of this Workshop Manual are divided into the following categories:

• Main data and specifications
• Torque specifications
• Recommended liquid gasket
• Loctite application procedure
• Servicing
• Removal and installation
• Disassembly
• Inspection and repair
• Ressembly
• Troubleshooting

4. Each "Major Components" page of this Workshop Manual has an exploded view of the applicable area.

A brief explanation of the notation used follows:

0A-4  GENERAL INFORMATION

5. Below is a sample of the Workshop Manual text following the " Major Components " page.

A brief explanation of the notation used follows:

6. The following symbols appear throughout the Workshop Manual.

They tell you at a glance the type of service operation to perform.

........Removal

........Adjustment

........Installation

........Cleaning

........Disassembly

........Important operation requiring extra care

........Reassembly

........Specified torque

........Alignment

........ISUZU special tool(s) required or recommended

........Directional indication

........Other special tool(s) required or recommended

........Inspection

........Lubrication (Oil)

........Measurement

........Lubrication (Grease)

........Torque Angle Method

........Liquid gasket application

GENERAL INFORMATION  0A-5

7. Measurement criteria are defined by the terms "standard" and "limit".

A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable.

"Limit" is an absolute value.

A measurement falling outside the "limit" indicates that the applicable part or parts must be repaired or replaced.

8. Components are parts are listed in the singular form throughout the Workshop Manual.

9. The following directional criteria are used throughout the Workshop Manual:

Front:

The cooling fan side of the engine.

Right:

The right-hand side of the engine viewed from the flywheel.

Left:

The left-hand side of the engine viewed from the flywheel.

Rear:

The flywheel side of the engine.

Cylinder numbers are counted from the front of the engine towards the rear.

The engine's rotation is clockwise viewed from the front of the engine.