Manual PDF Isuzu D-Max TFS EV Series 2025 Mechanical Repair Procedures TFHTML-WEN-2541EV

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Isuzu D-Max TFS EV Series 2025 Mechanical Repair Procedures TFHTML-WEN-2541EV
Size: 236.89 MB
Format: PDF
Language: English
Brand: Isuzu
Type of Machine: Automotive-Pickup
Type of Manual: Workshop Manual - Mechanical Repair Procedures
Model: Isuzu D-Max TFS EV Series Pickup
Date: 2025
Engine: EV Engine
2nd edition, Europe, Israel, and Turkey only (Date: 2025/08/01)
Parts Number: TFHTML-WEN-2541EV
Number of Pages: 3112 Pages

Contents:
Body, Cab, Accessories

9A. Lighting Systems​

Backup light bulb - installation​

Backup light bulb - removal​

Combination switch - inspection​

Combination switch - installation​

Combination switch - removal​

Dome light bulb - installation​

Dome light bulb - removal​

Door switch - inspection​

Door switch - installation​

Door switch - removal​

Fog light - installation​

Fog light - removal​

Front turn signal light bulb - installation​

Front turn signal light bulb - removal​

Hazard warning flasher switch - inspection​

Hazard warning flasher switch - installation​

Hazard warning flasher switch - removal​

Headlight - inspection​

Headlight - installation​

Headlight - removal​

Headlight leveling switch - inspection​

Headlight leveling switch - installation​

Headlight leveling switch - removal​

High mounted stoplight - installation​

High mounted stoplight - removal​

License plate light bulb - installation​

License plate light bulb - removal​

Map light bulb - installation​

Map light bulb - removal​

Rear combination light - installation​

Rear combination light - removal​

Rear fog light bulb - installation​

Rear fog light bulb - removal​

Rear turn signal light bulb - installation​

Rear turn signal light bulb - removal​

Side turn signal light (door mirror integrated type) - installation​

Side turn signal light (door mirror integrated type) - removal​

9B. Wiper, Washer Systems​

Supplementary Information​

Washer motor - inspection​

Washer motor - installation​

Washer motor - removal​

Washer nozzle - installation​

Washer nozzle - removal​

Washer tank - installation​

Washer tank - removal​

Wiper arm - installation​

Wiper arm - removal​

Wiper blade rubber - installation​

Wiper blade rubber - removal​

Wiper linkage - installation​

Wiper linkage - removal​

Wiper motor - inspection​

Wiper motor - installation​

Wiper motor - removal​

9C. Electrical Control, Entertainment​

Accessory socket - installation​

Accessory socket - removal​

Antenna - installation​

Antenna - removal​

Audio and navigation system - installation​

Audio and navigation system - removal​

Audio and navigation system - setting​

Audio control steering wheel switch - inspection​

Audio control steering wheel switch - installation​

Audio control steering wheel switch - removal​

Cruise control steering wheel switch - inspection​

Cruise control steering wheel switch - installation​

Cruise control steering wheel switch - removal​

ECO switch - inspection​

ECO switch - installation​

ECO switch - removal​

ESC OFF switch - inspection​

ESC OFF switch - installation​

ESC OFF switch - removal​

EV system start_stop button - inspection​

EV system start_stop button - installation​

EV system start_stop button - removal​

Front door speaker - inspection​

Front door speaker - installation​

Front door speaker - removal​

Front seat USB port - installation​

Front seat USB port - removal​

Heated seat switch - inspection​

Heated seat switch - installation​

Heated seat switch - removal​

Hill descent control switch - inspection​

Hill descent control switch - installation​

Hill descent control switch - removal​

Horn - inspection​

Horn - installation​

Horn - removal​

Horn switch - inspection​

Horn switch - installation​

Horn switch - removal​

Illumination control switch - installation​

Illumination control switch - removal​

Parking aid system OFF switch - inspection​

Parking aid system OFF switch - installation​

Parking aid system OFF switch - removal​

Passenger airbag cut off switch - inspection​

Passenger airbag cut off switch - installation​

Passenger airbag cut off switch - removal​

Rear door speaker - inspection​

Rear door speaker - installation​

Rear door speaker - removal​

Rear seat USB charge port - installation​

Rear seat USB charge port - removal​

Regenerative brake level switch - inspection​

Regenerative brake level switch - installation​

Regenerative brake level switch - removal​

Roof speaker - inspection​

Roof speaker - installation​

Roof speaker - removal​

Rough terrain mode switch - inspection​

Rough terrain mode switch - installation​

Rough terrain mode switch - removal​

SOS button - inspection​

SOS button - installation​

SOS button - removal​

TPMS load selector switch - inspection​

TPMS load selector switch - installation​

TPMS load selector switch - removal​

Tweeter - installation​

Tweeter - removal​

Vehicle approaching speaker - inspection​

Vehicle approaching speaker - installation​

Vehicle approaching speaker - removal​

9E. Instrumentation, Driver Info​

Antenna - installation​

Antenna - removal​

Forward collision warning light - installation​

Forward collision warning light - removal​

Instrument panel cluster - diagnostics​

Instrument panel cluster - installation​

Instrument panel cluster - removal​

Instrument panel cluster - setting​

Passenger airbag indicator - installation​

Passenger airbag indicator - removal​

Radar sensor - installation​

Radar sensor - removal​

Radar sensor - setting​

Rearview camera - installation​

Rearview camera - removal​

Sonar sensor - installation​

Sonar sensor - removal​

Speaker microphone - installation​

Speaker microphone - removal​

Stereo camera - cleaning​

Stereo camera - installation​

Stereo camera - removal​

Stereo camera - setting​

Stereo camera - writing​

9G. Hood, Fenders, Doors​

Front door - disassembly​

Front door - installation​

Front door - reassembly​

Front door - removal​

Front fender panel - installation​

Front fender panel - removal​

Hood - installation​

Hood - removal​

Hood control cable - installation​

Hood control cable - removal​

Hood lock - installation​

Hood lock - removal​

Rear door - disassembly​

Rear door - installation​

Rear door - reassembly​

Rear door - removal​

Rear mudguard - installation​

Rear mudguard - removal​

Side access panel - disassembly​

Side access panel - installation​

Side access panel - reassembly​

Side access panel - removal​

Supplementary Information​

Underguard - installation​

Underguard - removal​

9H. Cab Structure​

Air outlet valve - installation​

Air outlet valve - removal​

Back panel seal - installation​

Back panel seal - removal​

Front bumper - disassembly​

Front bumper - installation​

Front bumper - reassembly​

Front bumper - removal​

Radiator grille - installation​

Radiator grille - removal​

Rear step bumper - disassembly​

Rear step bumper - installation​

Rear step bumper - reassembly​

Rear step bumper - removal​

Rear underrun protector - installation​

Rear underrun protector - removal​

Roof rail - installation​

Roof rail - removal​

Side step - installation​

Side step - removal​

Supplementary Information​

9I. Seats​

Driver seat - disassembly​

Driver seat - installation​

Driver seat - reassembly​

Driver seat - removal​

Passenger seat - disassembly​

Passenger seat - installation​

Passenger seat - reassembly​

Passenger seat - removal​

Rear seat - disassembly​

Rear seat - installation​

Rear seat - reassembly​

Rear seat - removal​

Supplementary Information​

9J. Security and Locks​

Anti theft horn - installation​

Anti theft horn - removal​

Center in-vehicle antenna - installation​

Center in-vehicle antenna - removal​

Charging port lid cable - installation​

Charging port lid cable - removal​

Electronic key - disassembly​

Electronic key - reassembly​

Electronic key - setting​

External buzzer - installation​

External buzzer - removal​

Front door lock - inspection​

Front door lock - installation​

Front door lock - removal​

Key cylinder (door) - installation​

Key cylinder (door) - removal​

Key cylinder (tailgate) - installation​

Key cylinder (tailgate) - removal​

Rear door lock - inspection​

Rear door lock - installation​

Rear door lock - removal​

Steering lock - installation​

Steering lock - removal​

Steering lock - setting​

9L. Exterior, Interior Trim​

Center pillar upper trim cover - installation​

Center pillar upper trim cover - removal​

Console box - installation​

Console box - removal​

Front pillar trim cover - installation​

Front pillar trim cover - removal​

Head lining (crew cab) - disassembly​

Head lining (crew cab) - installation​

Head lining (crew cab) - reassembly​

Head lining (crew cab) - removal​

Head lining (extended cab) - disassembly​

Head lining (extended cab) - installation​

Head lining (extended cab) - reassembly​

Head lining (extended cab) - removal​

Instrument panel - installation​

Instrument panel - removal​

Rear end trim cover - installation​

Rear end trim cover - removal​

Rear pillar trim cover (crew cab) - installation​

Rear pillar trim cover (crew cab) - removal​

Rear pillar trim cover (extended cab) - installation​

Rear pillar trim cover (extended cab) - removal​

Reinforcement - installation​

Reinforcement - removal​

Supplementary Information​

9P. Unibody Sub-frames​

Body mounting - installation​

Body mounting - removal​

Rear body - installation​

Rear body - removal​

Supplementary Information​

Tail gate - installation​

Tail gate - removal​

9T. Glass, Windows, Mirrors​

Backlight glass - installation​

Backlight glass - removal​

Front door power window switch - inspection​

Front door power window switch - installation​

Front door power window switch - removal​

Front door power window switch - setting​

Front windshield glass - installation​

Front windshield glass - removal​

Outside rearview mirror - disassembly​

Outside rearview mirror - installation​

Outside rearview mirror - reassembly​

Outside rearview mirror - removal​

Rear door power window switch - inspection​

Rear door power window switch - installation​

Rear door power window switch - removal​

Remote control mirror switch - inspection​

Remote control mirror switch - installation​

Remote control mirror switch - removal​

Supplementary Information​

9Z. Body, Cab, Accessories Electrical Control​

BCM - installation​

BCM - removal​

BCM - setting​

Central gateway control unit - installation​

Central gateway control unit - removal​

Central gateway control unit - setting​

ECall unit - installation​

ECall unit - removal​

ECall unit - setting​

ECall unit backup battery - installation​

ECall unit backup battery - removal​

Headlight auto leveling control unit - installation​

Headlight auto leveling control unit - removal​

Headlight auto leveling control unit - setting​

Heated seat control unit - installation​

Heated seat control unit - removal​

Information module - installation​

Information module - removal​

Information module - setting​

MAP unit - installation​

MAP unit - removal​

MAP unit - setting​

Parking aid system control unit - installation​

Parking aid system control unit - removal​

Parking aid system control unit - setting​

Rain and light sensor - installation​

Rain and light sensor - removal​

Vehicle approaching speaker control unit - installation​

Vehicle approaching speaker control unit - removal​

Wireless access module - installation​

Wireless access module - removal​

Wireless access module - setting​

Brakes

4B. Brake System​

Brake booster - inspection​

Brake booster - installation​

Brake booster - removal​

Brake fluid - inspection​

Brake fluid - replacement​

Brake master cylinder - disassembly​

Brake master cylinder - inspection​

Brake master cylinder - installation​

Brake master cylinder - reassembly​

Brake master cylinder - removal​

Brake pedal - inspection​

Brake pedal - installation​

Brake pedal - removal​

Disc brake pad - inspection​

Disc brake pad - installation​

Disc brake pad - removal​

Electric vacuum pump - inspection​

Electric vacuum pump - installation​

Electric vacuum pump - removal​

Front disc brake - disassembly​

Front disc brake - inspection​

Front disc brake - installation​

Front disc brake - reassembly​

Front disc brake - removal​

Rear drum brake - inspection​

Rear drum brake - installation​

Rear drum brake - removal​

Rear wheel cylinder - disassembly​

Rear wheel cylinder - inspection​

Rear wheel cylinder - installation​

Rear wheel cylinder - reassembly​

Rear wheel cylinder - removal​

Silencer - inspection​

Silencer - installation​

Silencer - removal​

Stoplight switch - inspection​

Stoplight switch - installation​

Stoplight switch - removal​

Supplementary Information​

Vacuum tank - inspection​

Vacuum tank - installation​

Vacuum tank - removal​

4C. Parking Brake System​

Parking brake - inspection​

Parking brake - installation​

Parking brake - removal​

Parking brake lever - installation​

Parking brake lever - removal​

Parking brake switch - inspection​

Parking brake switch - installation​

Parking brake switch - removal​

Supplementary Information​

4D. ABS​

Front exciter ring - installation​

Front exciter ring - removal​

Supplementary Information​

4Z. Brake Electrical Control​

EHCU - installation​

EHCU - removal​

EHCU - setting​

Front wheel speed sensor - inspection​

Front wheel speed sensor - installation​

Front wheel speed sensor - removal​

Rear wheel speed sensor - inspection​

Rear wheel speed sensor - installation​

Rear wheel speed sensor - removal​

Supplementary Information​

Driveline, Axle

3C. Drive Shaft System​

Front drive shaft - disassembly​

Front drive shaft - inspection​

Front drive shaft - installation​

Front drive shaft - reassembly​

Front drive shaft - removal​

Front hub - disassembly​

Front hub - inspection​

Front hub - installation​

Front hub - reassembly​

Front hub - removal​

Knuckle - inspection​

Knuckle - installation​

Knuckle - removal​

Rear axle - inspection​

Rear axle - installation​

Rear axle - removal​

Rear drive shaft - disassembly​

Rear drive shaft - inspection​

Rear drive shaft - installation​

Rear drive shaft - reassembly​

Rear drive shaft - removal​

Rear hub - inspection​

Rear hub - installation​

Rear hub - removal​

Supplementary Information​

Wheel alignment check​

EV Control

51B. Mechanical​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

Breather - installation​

Breather - removal​

eAxle (front) - inspection​

eAxle (front) - installation​

eAxle (front) - removal​

eAxle (front) - setting​

eAxle (front) oil cooler - installation​

eAxle (front) oil cooler - removal​

eAxle (front) oil seal - installation​

eAxle (front) oil seal - removal​

eAxle (rear) - inspection​

eAxle (rear) - installation​

eAxle (rear) - removal​

eAxle (rear) - setting​

eAxle (rear) oil cooler - installation​

eAxle (rear) oil cooler - removal​

eAxle (rear) oil seal - installation​

eAxle (rear) oil seal - removal​

eAxle gear oil - replacement​

PBW - installation​

PBW - removal​

PBW - setting​

Selector lever - disassembly​

Selector lever - installation​

Selector lever - reassembly​

Selector lever - removal​

Supplementary Information​

51D. Cooling Warm up System​

Chiller - installation​

Chiller - removal​

Coolant for EV system - inspection​

Coolant for EV system - replacement​

Coolant for high voltage battery pack - inspection​

Coolant for high voltage battery pack - replacement​

High voltage heater (high voltage battery pack) - inspection​

High voltage heater (high voltage battery pack) - installation​

High voltage heater (high voltage battery pack) - removal​

Radiator (EV system) - inspection​

Radiator (EV system) - installation​

Radiator (EV system) - removal​

Radiator (high voltage battery pack) - inspection​

Radiator (high voltage battery pack) - installation​

Radiator (high voltage battery pack) - removal​

Reserve tank (EV system) - installation​

Reserve tank (EV system) - removal​

Sub-tank (high voltage battery pack) - installation​

Sub-tank (high voltage battery pack) - removal​

Supplementary Information​

Water control valve - inspection​

Water control valve - installation​

Water control valve - removal​

Water pump1 (for EV system) - installation​

Water pump1 (for EV system) - removal​

Water pump2 (for EV system) - installation​

Water pump2 (for EV system) - removal​

Water pump (high voltage battery pack) - installation​

Water pump (high voltage battery pack) - removal​

51J. Electrical System​

Charge indicator light (green) and charging error light (red) and charging cancel switch - inspection​

Charge indicator light (green) and charging error light (red) and charging cancel switch - installation​

Charge indicator light (green) and charging error light (red) and charging cancel switch - removal​

Charging inlet - inspection​

Charging inlet - installation​

Charging inlet - removal​

DC-DC converter (12V) - installation​

DC-DC converter (12V) - removal​

High voltage battery pack - inspection​

High voltage battery pack - installation​

High voltage battery pack - removal​

High voltage battery pack - setting​

High voltage motor cable - installation​

High voltage motor cable - removal​

Junction box - installation​

Junction box - removal​

Junction box cover - installation​

Junction box cover - removal​

Junction box fuse - installation​

Junction box fuse - removal​

OBC - installation​

OBC - removal​

OBC - setting​

Service plug - installation​

Service plug - removal​

Supplementary Information​

51Z. EV Control Electrical Control​

Coolant level sensor (high voltage battery pack) - inspection​

Coolant level sensor (high voltage battery pack) - installation​

Coolant level sensor (high voltage battery pack) - removal​

Coolant temperature sensor (Front of high voltage battery pack) - inspection​

Coolant temperature sensor (Front of high voltage battery pack) - installation​

Coolant temperature sensor (Front of high voltage battery pack) - removal​

Coolant temperature sensor (Front of radiator for EV system) - inspection​

Coolant temperature sensor (Front of radiator for EV system) - installation​

Coolant temperature sensor (Front of radiator for EV system) - removal​

Coolant temperature sensor (Rear of high voltage battery pack) - inspection​

Coolant temperature sensor (Rear of high voltage battery pack) - installation​

Coolant temperature sensor (Rear of high voltage battery pack) - removal​

Coolant temperature sensor (Rear of radiator for EV system) - inspection​

Coolant temperature sensor (Rear of radiator for EV system) - installation​

Coolant temperature sensor (Rear of radiator for EV system) - removal​

Coolant temperature sensor (Rear of Radiator for high voltage battery pack) - inspection​

Coolant temperature sensor (Rear of Radiator for high voltage battery pack) - installation​

Coolant temperature sensor (Rear of Radiator for high voltage battery pack) - removal​

VCU - installation​

VCU - removal​

VCU - setting​

HVAC

7B. Heater Ventilator Airconditioner​

Accumulator - installation​

Accumulator - removal​

Actuator - installation​

Actuator - removal​

Blower - installation​

Blower - removal​

Blower module - inspection​

Blower module - installation​

Blower module - removal​

Blower motor - inspection​

Blower motor - installation​

Blower motor - removal​

Compressor oil - replacement​

Condenser - installation​

Condenser - removal​

Control panel - inspection​

Control panel - installation​

Control panel - removal​

Control panel - setting​

Coolant for cabin heater - inspection​

Coolant for cabin heater - replacement​

Coolant level sensor (for air conditioning) - inspection​

Coolant level sensor (for air conditioning) - installation​

Coolant level sensor (for air conditioning) - removal​

Electric compressor - installation​

Electric compressor - removal​

Evaporator core - installation​

Evaporator core - removal​

Heater core - installation​

Heater core - removal​

Heater evaporator unit - installation​

Heater evaporator unit - removal​

High voltage heater (for air conditioning) - inspection​

High voltage heater (for air conditioning) - installation​

High voltage heater (for air conditioning) - removal​

Intake door - installation​

Intake door - removal​

Rear ventilation duct - installation​

Rear ventilation duct - removal​

Sub tank (for air conditioning) - installation​

Sub tank (for air conditioning) - removal​

Supplementary Information​

Vent grille - installation​

Vent grille - removal​

Ventilation duct - installation​

Ventilation duct - removal​

Water pump (for air conditioning) - installation​

Water pump (for air conditioning) - removal​

Water-cooled condenser - installation​

Water-cooled condenser - removal​

7Z. HVAC Control​

A_C control unit - installation​

A_C control unit - removal​

A_C control unit - setting​

Battery expansion valve - inspection​

Battery expansion valve - installation​

Battery expansion valve - removal​

Cooling expansion valve - inspection​

Cooling expansion valve - installation​

Cooling expansion valve - removal​

Evaporator temperature sensor - inspection​

Evaporator temperature sensor - installation​

Evaporator temperature sensor - removal​

Heating expansion valve - inspection​

Heating expansion valve - installation​

Heating expansion valve - removal​

Inside air temperature sensor - inspection​

Inside air temperature sensor - installation​

Inside air temperature sensor - removal​

Low pressure solenoid valve - inspection​

Low pressure solenoid valve - installation​

Low pressure solenoid valve - removal​

Outside air temperature sensor - inspection​

Outside air temperature sensor - installation​

Outside air temperature sensor - removal​

Pressure sensor - inspection​

Pressure sensor - installation​

Pressure sensor - removal​

Refrigerant temperature sensor (outside cab) - inspection​

Refrigerant temperature sensor (outside cab) - installation​

Refrigerant temperature sensor (outside cab) - removal​

Sun sensor - inspection​

Sun sensor - installation​

Sun sensor - removal​

Supplementary Information​

Thermal management control unit - installation​

Thermal management control unit - removal​

Restraints

8B. Airbag Systems​

Curtain airbag - installation​

Curtain airbag - removal​

Curtain airbag - scrapping​

Driver airbag - installation​

Driver airbag - removal​

Driver airbag - scrapping​

Far side air bag - installation​

Far side air bag - removal​

Far side air bag - scrapping​

Knee air bag - installation​

Knee air bag - removal​

Knee air bag - scrapping​

Passenger airbag - installation​

Passenger airbag - removal​

Passenger airbag - scrapping​

Side airbag - installation​

Side airbag - removal​

Side airbag - scrapping​

SRS coil - installation​

SRS coil - removal​

8C. Seat Belt Systems​

Front buckle side seat belt - installation​

Front buckle side seat belt - removal​

Front tongue side seat belt (with pretensioner) (crew cab) - installation​

Front tongue side seat belt (with pretensioner) (crew cab) - removal​

Front tongue side seat belt (with pretensioner) (crew cab) - scrapping​

Front tongue side seat belt (with pretensioner) (extend cab) - installation​

Front tongue side seat belt (with pretensioner) (extend cab) - removal​

Front tongue side seat belt (with pretensioner) (extend cab) - scrapping​

Front tongue side seat belt (without pretensioner) (crew cab) - installation​

Front tongue side seat belt (without pretensioner) (crew cab) - removal​

Front tongue side seat belt (without pretensioner) (extend cab) - installation​

Front tongue side seat belt (without pretensioner) (extend cab) - removal​

Rear buckle side seat belt - installation​

Rear buckle side seat belt - removal​

Rear tongue side seat belt (with pretensioner) - installation​

Rear tongue side seat belt (with pretensioner) - removal​

Rear tongue side seat belt (with pretensioner) - scrapping​

Rear tongue side seat belt (without pretensioner) - installation​

Rear tongue side seat belt (without pretensioner) - removal​

Supplementary Information​

8Z. Seat Belt and SRS Airbag Electrical Control​

Door side airbag sensor - installation​

Door side airbag sensor - removal​

Floor side airbag sensor - installation​

Floor side airbag sensor - removal​

Front airbag sensor - installation​

Front airbag sensor - removal​

Rear side airbag sensor (crew cab) - installation​

Rear side airbag sensor (crew cab) - removal​

Rear side airbag sensor (extend cab) - installation​

Rear side airbag sensor (extend cab) - removal​

SRS control unit - installation​

SRS control unit - removal​

SRS control unit - setting​

Supplementary Information​

Steering

6B. Power Assisted System​

Power steering unit - disassembly​

Power steering unit - inspection​

Power steering unit - installation​

Power steering unit - reassembly​

Power steering unit - removal​

Power steering unit - setting​

Steering column - inspection​

Steering column - installation​

Steering column - removal​

Supplementary Information​

6Z. Steering Electrical Control​

Steering angle sensor - installation​

Steering angle sensor - removal​

Steering angle sensor - setting​

Suspension

2B. Front Suspension​

Independent suspension - disassembly​

Independent suspension - inspection​

Independent suspension - installation​

Independent suspension - reassembly​

Independent suspension - removal​

Supplementary Information​

2C. Rear Suspension​

Leaf rigid suspension - disassembly​

Leaf rigid suspension - inspection​

Leaf rigid suspension - installation​

Leaf rigid suspension - reassembly​

Leaf rigid suspension - removal​

Supplementary Information​

2D. Wheel, Tire System​

Barometric pressure sensor - inspection​

Barometric pressure sensor - installation​

Barometric pressure sensor - removal​

Disc wheel and tire - inspection​

Disc wheel and tire - installation​

Disc wheel and tire - removal​

Supplementary Information​

Tire air pressure sensor - installation​

Tire air pressure sensor - removal​

Tire air pressure sensor - setting​