Download Isuzu D-Max TFS EV Series 2025 Mechanical Repair Procedure TFHTML-WEN-2541EV (English)

Master the maintenance and servicing of the Isuzu D-Max TFS EV Series 2025 with the official Mechanical Repair Procedure manual (TFHTML-WEN-2541EV). Designed for professional technicians and EV specialists, this comprehensive workshop guide offers step-by-step instructions for electric powertrain repairs, high-voltage component maintenance, chassis diagnostics, suspension setups, and mechanical overhauls. Ensure safety, precise alignment, and optimal performance for your electric pickup truck by accessing factory-standard repair protocols and specs detailed in manual TFHTML-WEN-2541EV.

MODEL COVERED :
Isuzu D-Max TFS EV Series Pickup

CONTENTS INCLUDED :
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

www.themanualsgroup.com