Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1619

 

  Index      Ford     Isuzu D-Max / Isuzu Rodeo TFR/TFS series - service repair manual 1997-2003 year

 

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Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1619

 

 

MAINTENANCE AND LUBRICATION  0B-3

MAINTENANCE SCHEDULE (THIS SCHEDULE IS NOT APPLIED FOR EUROPE)

I : Inspect and correct or replace as necessary     A : Adjust
R : Replace or change     T : Tighten to specified torque    L : Lubricate

SERVICE INTERVAL:

×

1,000 km

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

(Use the odometer reading

×

1,000 miles

or months whichever comes first)

3

6

9

12

15

18

21

24

27

30

33

36

39

42

45

48

51

54

57

60

or months

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96 102 108 114 120

GASOLINE ENGINE

* Engine oil

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

* 

G4

 Engine oil filter

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

* 

G6

 Engine oil filter

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

-

Oil leakage and contamination

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

G4

 Timing belt

(Inspect every 70,000 km or 42,000 miles) & (Replace every 120,000 km or 75,000 miles)

G6

 Timing belt

(Replace every 165,000 km or 100,000 miles)

G4

 Engine/Accessory drive belt

-

-

-

-

-

-

-

-

-

I

-

-

-

-

-

-

-

-

-

I

G6

 Fan belt tension and damage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

G4

 Spark plugs (for leaded fuel use)

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

G4

 Spark plugs (for unleaded fuel use)

-

-

-

-

-

R

-

-

-

-

-

R

-

-

-

-

-

R

-

-

G6

 Spark plugs (for leaded fuel use)

-

-

-

-

-

R

-

-

-

-

-

R

-

-

-

-

-

R

-

-

G6

 Spark plugs (for unleaded fuel use)

(Replace every 165,000 km or 100,000 miles)

G4

 Spark plug wire

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

I

-

Exhaust system

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

G4

 Engine coolant concentration

-

I

-

I

-

I

-

I

-

R

-

I

-

I

-

I

-

I

-

R

G6

 Engine coolant concentration

-

-

-

-

-

-

-

-

-

R

-

-

-

-

-

-

-

-

-

R

Cooling system for water leakage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

All hoses and pipes in engine

compartment for clog damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

G4

 Fuel filter

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

-

-

-

R

G6

 Fuel filter

-

-

-

-

-

R

-

-

-

-

-

R

-

-

-

-

-

R

-

-

Fuel leakage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Fuel tank

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

*Air cleaner element

-

I

-

I

-

I

-

R

-

I

-

I

-

I

-

R

-

I

-

I

V

 Pre air cleaner

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Idling speed and acceleration

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

G6

 O

2

 senser (for leaded fuel use)

-

-

-

-

-

-

-

-

-

R

-

-

-

-

-

-

-

-

-

R

G6

 O

2

 senser (for unleaded fuel use)

(Replace every 150,000 km or 90,000 miles)

G6

 Valve clearance (98 model 

∼

)

(Check and adjust if necessary every 96,000 km or 60,000 miles)

DIESEL ENGINE

* Engine oil

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

* Engine oil filter

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

-

R

Oil leakage and contamination

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Idlig speed and acceleration

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Fan belt tension and damage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Exhaust system

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

All hoses and pipes in engine

compartment for clog or damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Valve clearance

A

-

-

A

-

-

-

A

-

-

-

A

-

-

-

A

-

-

-

A

* Air cleaner element

I

I

I

I

I

I

I

R

I

I

I

I

I

I

I

R

I

I

I

I

Fuel filter

-

-

R

-

-

R

-

-

R

-

-

R

-

-

R

-

-

R

-

-

Engine coolant concentration

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Cooling system for water leakage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

*Marks: Under severe driving conditions, additional maintenance is required.

Refer to "Maintenance schedule under severe driving conditions".

0B-4  MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE

I : Inspect and correct or replace as necessary     A : Adjust
R : Replace or change     T : Tighten to specified torque    L : Lubricate

SERVICE INTERVAL:

×

1,000 km

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

(Use the odometer reading

×

1,000 miles

or months whichever comes first)

3

6

9

12

15

18

21

24

27

30

33

36

39

42

45

48

51

54

57

60

or months

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96 102 108 114 120

CLUTCH

Clutch fluid

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Clutch pedal travel and play

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

TRANSMISSION OR TRANSMISSION

WITH TRANSFER CASE

* Manual transmission with transfer case

oil

-

R

-

I

-

-

-

R

-

-

-

I

-

-

-

R

-

-

-

I

Oil leakage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Gear control mechanisum for looseness

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

* 

AT

 Automatic transmission fluid

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

* 

AT

 Transfer case oil

-

R

-

I

-

-

-

R

-

-

-

I

-

-

-

R

-

-

-

I

PROPELLER SHAFT

Loose connections

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

* Universal joints and splines for wear

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Universal joints and sliding sleeve

-

L

-

L

-

L

-

L

-

L

-

L

-

L

-

L

-

L

-

L

FRONT AND REAR AXLE

* Differential gear oil (Front and rear)

-

R

-

I

-

-

-

R

-

-

-

I

-

-

-

R

-

-

-

I

Oil leakage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Shift on the fly system

Gear oil

I

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Front axle shaft rubber boot for damage

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Axle case for distortion or damage

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Axle shafts for distortion or damage

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

STEERING

Steering gear oil

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Power steering fluid

I

I

I

I

I

I

R

I

I

I

I

I

I

R

I

I

I

I

I

I

Oil leakage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

* Steering system for looseness or

damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Power steering hose

-

I

-

I

-

I

-

I

-

I

-

I

-

R

-

I

-

I

-

I

Steering wheel play

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Steering function

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Right and left turning radius

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Wheel alignment

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Joint ball for oil leakage or damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Joint ball rubber boot for damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

*Marks: Under severe driving conditions, additional maintenance is required.

Refer to "Maintenance schedule under severe driving conditions".

MAINTENANCE AND LUBRICATION  0B-5

MAINTENANCE SCHEDULE

I : Inspect and correct or replace as necessary     A : Adjust
R : Replace or change     T : Tighten to specified torque    L : Lubricate

SERVICE INTERVAL:

×

1,000 km

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

(Use the odometer reading

×

1,000 miles

or months whichever comes first)

3

6

9

12

15

18

21

24

27

30

33

36

39

42

45

48

51

54

57

60

or months

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96 102 108 114 120

SERVICE BRAKES

Brake fluid

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Brake system for fluid leakage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Brake function

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

* Front Disc brake pads and discs wear

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

* Rear brake linig and drum wear

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Brake pedal travel and play

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Pips and hoses for loose connections or

damage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

PARKING BRAKE

Parking brake function

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Parking brake level travel

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Cables for looseness or damage and

guide for damage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Ratchet for wear or damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

SUSPENSION

Leaf springs for damage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Mount for looseness or damage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Shock absorbers for oil leakage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Shock absorbers mount for looseness

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Rubber bushes of suspension wear or

damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Spring action for loss of balance due to

weakening

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

-

-

-

I

Joint ball rubber boot for damage

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

WHEELS'

Wheel nuts

T

T

-

T

-

T

-

T

-

T

-

T

-

T

-

T

-

T

-

T

Wheel disc for damage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Hub bearing grease

-

-

-

-

-

R

-

-

-

-

-

R

-

-

-

-

-

R

-

-

Front and rear hub bearings for

looseness

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Tire pressure and damage

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Tire rotation

(Rotate as required)

OTHERS

Bolts and nuts on chassis and body

I

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

-

I

Lube front free-wheeling hubs

-

-

-

-

-

L

-

-

-

-

-

L

-

-

-

-

-

L

-

-

*Marks: Under severe driving conditions, additional maintenance is required.

Refer to "Maintenance schedule under severe driving conditions".

0B-6  MAINTENANCE AND LUBRICATION

SEVERE CONDITIONS MAINTENANCE SCHEDULE

Severe driving conditions

A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on

salted roads

G4

: HEC Engine Series L4 Gasoline engine

G6

: 6V Series V6 Gasoline engine

D

 

DT

: 4J Series L4 Diesel engine, with Turbocharger

MT

: Manual transmission

AT

: Automatic transmission

Condition

A

B

C

D

A+D

Engine oil

G

: Change every 5,000km (3,000

miles) or 3 month

D

 

DT

: Change every 2,500km (1,500

miles)

●

●

Engine oil filter

G4

: Replace every 5,000km (3,000

miles) or 3 month

G6

: Replace every 10,000km (6,000

miles)

D

 

 

 

 

 

 

 

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