Segment:
Compact Pickup Truck / Light Commercial Vehicle
Target Audience:
Individuals and businesses requiring a robust, reliable, and relatively simple workhorse vehicle.
Competitors:
Mitsubishi L200/Triton, Toyota Hilux, Nissan D22/Frontier, Ford Ranger (global variants).
Durability:
Known for robust construction and powertrain, suitable for demanding work.
Simplicity:
Relatively straightforward mechanical systems, making it easier to maintain and repair compared to more modern vehicles.
Diesel Engine:
The 2.6L 4ZE1 diesel offers good torque and fuel efficiency for its class.
Utility:
Practical for hauling, towing, and off-road use (depending on configuration).
Engine Mechanical:
Complete engine overhaul, disassembly, assembly, diagnosis, and repair of all internal and external engine components.
Fuel System:
Diesel fuel injection system, pump, injectors, lines, filters, and related diagnostics.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, and cooling system diagnostics.
Lubrication System:
Oil pump, oil filter, oil pan, lubrication passages, and oil pressure testing.
Exhaust System:
Exhaust manifold, pipes, muffler, catalytic converter (if applicable), and mounting hardware.
Ignition System:
Glow plug system diagnosis and replacement.
Transmission:
Manual and Automatic transmission service, repair, clutch, gear ratios, fluid specifications, and troubleshooting.
Drivetrain:
Driveshafts, differentials, axles, U-joints, and 4WD system components.
Suspension:
Front and rear suspension components, springs, shocks, control arms, bushings, and alignment specifications.
Steering:
Steering gear, linkage, power steering pump, hoses, and steering wheel assembly.
Brakes:
Front and rear brake systems (disc/drum), master cylinder, brake lines, calipers, wheel cylinders, ABS (if equipped), and brake fluid specifications.
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting, and diagnostic procedures.
HVAC System:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant, diagnosis, and repair.
Body And Frame:
Body panel removal/installation, chassis components, doors, windows, mirrors, interior trim, and corrosion protection.
Paint And Trim:
Color codes, trim identification, and basic bodywork repair guidance.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups, and lubrication.
Troubleshooting:
Diagnostic flowcharts and procedures for identifying and resolving common and complex issues across all systems.
Repair:
Step-by-step instructions for component removal, repair, reassembly, and installation.
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical systems, including testing parameters and specifications.
Specifications:
Torque specifications, clearances, tolerances, and electrical resistance/voltage values.
Depth:
Factory-level diagnostic and repair procedures, suitable for professional technicians and advanced DIY mechanics.
Engine Type:
Inline 4-Cylinder, Naturally Aspirated Diesel
Displacement:
2.6 Liters (2598 cc)
Bore X Stroke:
94.0 mm x 93.4 mm (approximate)
Compression Ratio:
21.0:1 (typical for this engine)
Valvetrain:
SOHC (Single Overhead Camshaft), 8 Valves
Horsepower Net Hp:
Approximately 85-95 PS (63-70 kW) at ~3,700 rpm (specifications vary by market and exact configuration)
Torque Net Lb-Ft:
Approximately 130-145 lb-ft (176-197 Nm) at ~2,000-2,500 rpm (specifications vary by market and exact configuration)
Injection Type:
Indirect Injection (IDI) with Bosch VE rotary injection pump.
Glow Plug System:
Equipped with a pre-heating system for cold starts.
Wheelbase:
Varies by configuration (e.g., short, standard, long bed versions exist). Common ranges from approx. 2,755 mm to 3,330 mm.
Overall Length:
Varies by configuration (e.g., Single Cab, Double Cab, Bed Length). Typically ranges from approx. 4,400 mm to 5,300 mm.
Overall Width:
Approx. 1,690 mm - 1,790 mm (depending on market and body style).
Overall Height:
Approx. 1,600 mm - 1,800 mm (depending on body style and suspension).
Curb Weight:
Approximately 1,500 kg - 1,800 kg (varies significantly with configuration, drivetrain, and body type).
Gross Vehicle Weight Rating Gvw:
Typically in the 2,500 kg - 3,000 kg range.
Towing Capacity:
Up to approx. 1,500 kg - 2,000 kg depending on configuration and market regulations.
Bed Length:
Varies, common lengths include approx. 1800 mm (short bed) and 2100 mm (long bed).
Oil Change Interval:
Typically every 5,000 km or 3 months for diesel engines (refer to manual for exact specification).
Air Filter Replacement:
Every 20,000 km or as needed based on operating conditions.
Fuel Filter Replacement:
Every 20,000 - 40,000 km or as recommended.
Timing Belt Or Chain:
4ZE1 uses a timing chain, which generally requires no periodic replacement but should be inspected for wear/noise.
Engine Oil Type:
API CF or CD grade diesel engine oil, SAE 15W-40 or 10W-30 depending on climate. (Verify with manual)
Engine Oil Capacity:
Approx. 6.5 - 7.0 Liters (including filter). (Verify with manual)
Coolant Type:
Ethylene glycol-based antifreeze (blue or green). 50/50 mix with distilled water. (Verify with manual)
Transmission Oil Type Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil. (Verify with manual)
Transmission Oil Type Automatic:
Dexron III ATF or equivalent. (Verify with manual)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. (Verify with manual)
Differential Fluid Type:
API GL-5 SAE 80W-90 gear oil. (Verify with manual)
Engine Wear:
High mileage engines may experience wear in piston rings, cylinder liners, and valve guides, leading to oil consumption or blow-by.
Glow Plugs:
Glow plugs can become fouled or fail, leading to hard starting in cold weather.
Turbocharger Failure:
If equipped with a turbocharger (less common on base 4ZE1), oil starvation or overheating can lead to failure. Regular oil changes are critical.
Rust And Corrosion:
Like many vehicles of this era, susceptible to rust, especially in areas with harsh winters or coastal environments. Chassis and body panels require regular inspection.
Suspension Bushings:
Rubber suspension bushings can degrade over time, leading to knocking noises and poor handling.
Brake System:
Seized brake calipers or wheel cylinders can occur due to lack of use or corrosion. Regular brake fluid flushes are recommended.
Manufacturer:
Isuzu Motors Ltd., a Japanese manufacturer with a long history in commercial vehicles and diesel engines.
Predecessors:
Direct successor to earlier Isuzu Faster/Pickups.
Generation:
This TF generation (often referred to as the Isuzu Faster/Pick-Up/Rodeo Pick-up globally, and D-Max in later iterations) was a significant model in Isuzu's pickup truck lineup.
Successors:
Evolved into the Isuzu D-Max platform in many markets.
Production Years:
Circa 1997-2003 (for this specific manual's coverage, actual production may extend slightly earlier/later depending on market).
Manufacturing Locations:
Primarily Japan, with assembly also conducted in various international locations through joint ventures or knock-down kits.
