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Isuzu TF Series 2003 2004 2005 2006 2007 2008 Service Repair Manual

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🏷️ Basic Information Identification Make: Isuzu Model: TF Series Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008 Codes Chassis Code: KB 👋 Introduction Market Position Segment: Compact pickup truck...
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Isuzu TF Series 2003 2004 2005 2006 2007 2008 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
TF Series
Model Years Covered:
2003, 2004, 2005, 2006, 2007, 2008
Codes
Chassis Code:
KB
👋 Introduction
Market Position
Segment:
Compact pickup truck
Target Audience:
DIY mechanics, professional repair shops, fleet managers
Competitive Analysis
Key Competitors:
Toyota Hilux, Ford Ranger, Mitsubishi Triton (L200), Nissan D22 Navara
Key Features
Vehicle Strengths:
Robust chassis, reliable engines, practical utility, good off-road capability (especially 4WD models)
Manual Value:
Comprehensive coverage for a critical maintenance and repair period of the TF Series, enabling extended vehicle lifespan and cost-effective ownership.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Page Count
Total Pages:
4264
Manual Type
Type:
Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine mechanicals, diagnostics, overhaul, specific engine variants
Fuel System:
Fuel injection, fuel pump, injectors, fuel pressure diagnostics
Emission Control:
Catalytic converter, EGR system, evaporative emissions control
Cooling System:
Radiator, water pump, thermostat, cooling fan operation
Lubrication System:
Oil pump, oil pressure, oil filter replacement, oil capacity
Ignition System:
Spark plugs, ignition coils, ignition timing, troubleshooting
Transmission Manual:
Clutch operation, gearbox overhaul, gear ratios, maintenance
Transmission Automatic:
Automatic transmission operation, fluid changes, troubleshooting, overhaul (if applicable)
Drivetrain:
Driveshafts, CV joints, differential, 4WD system operation (if applicable)
Suspension:
Front and rear suspension components, alignment specifications, shock absorbers, springs
Steering:
Power steering system, steering rack, tie rods, steering column
Brakes:
Disc brakes, drum brakes, brake fluid specifications, ABS system diagnostics (if equipped)
Electrical System:
Battery, alternator, starter motor, fuses, relays, wiring diagrams
Lighting:
Headlights, taillights, interior lighting, bulb replacement
Instrumentation:
Dashboard indicators, gauges, warning lights
HVAC:
Heating, Ventilation, and Air Conditioning system operation, components, and servicing
Body And Frame:
Body panels, doors, glass, interior trim, chassis repair
Restraints:
Seat belts, airbag system diagnostics (if equipped)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks
Troubleshooting:
Diagnostic procedures for common faults, symptom-based troubleshooting guides
Repair:
Step-by-step repair procedures for all major components and systems
Overhaul:
Complete engine, transmission, and differential overhaul procedures
Diagnostics:
On-board diagnostics (OBD) procedures, scan tool usage, specific diagnostic tests
Specifications:
Torque specifications, clearances, measurements for all components
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems
Technical Depth
Depth:
Full workshop level: from basic maintenance to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear text and images
Print Quality
Printability:
Printable pages for easy on-site reference
Binding Type
Binding:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
4JA1, 4JB1, C223, 4ZE1 (Note: Specific engine availability may vary by market and trim)
Performance
Displacement Range:
2.2L - 2.8L Diesel; 2.6L Petrol
Horsepower Range:
Approx. 70-100 HP (Diesel), 115-125 HP (Petrol)
Torque Range:
Approx. 140-200 Nm (Diesel), 190-210 Nm (Petrol)
Fuel System
Fuel Type:
Diesel (Common Rail Injection or Indirect Injection), Unleaded Petrol
Injection System:
Bosch VE, Denso, or similar for Diesel; MPI for Petrol
Other
Engine Layout:
Inline-4 Cylinder
Aspiration:
Naturally Aspirated or Turbocharged (Diesel variants)
🔧 Transmission
Standard
Type Standard:
5-Speed Manual Transmission
Optional
Type Optional:
4-Speed Automatic Transmission (market dependent)
Features
Drivetrain Options:
2WD (RWD), 4WD (4x4)
Transfer Case:
Part-time 4WD with low-range gearing (on 4WD models)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Space Cab, Crew Cab
Bed Lengths:
Short Bed, Long Bed (market dependent)
Weights
Curb Weight Range:
Approx. 1400 kg - 1800 kg
Payload Capacity:
Approx. 500 kg - 1000 kg
Towing Capacity:
Up to 2000 kg (braked, market dependent)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Variable, dependent on market and specific equipment (generally considered basic for its era)
Active Features
ABS:
Optional on some models/trims
Traction Control:
Rarely equipped
Passive Features
Airbags:
Driver airbag standard on most models, passenger airbag optional/market dependent
Seatbelts:
3-point front seatbelts, 2-point rear (often)
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player. Aftermarket upgrades common.
Driver Assistance
ABS Availability:
Optional on select trims and model years.
Connectivity
Bluetooth:
Not factory equipped.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km or 6-12 months (whichever comes first), dependent on oil type and usage.
Air Filter Replacement:
Every 20,000-40,000 km or annually.
Fuel Filter Replacement Diesel:
Every 20,000-40,000 km for diesel engines.
Timing Belt Replacement Petrol:
If equipped with a timing belt, typically every 80,000-100,000 km. Many Isuzu diesels use timing chains.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher. Viscosity: 5W-30, 10W-30, 10W-40, 15W-40 (Diesel) depending on climate. Check manual for specific diesel recommendations (e.g., CI-4).
Engine Oil Capacity:
Approx. 5.5 - 7.0 Liters (Varies by engine and oil filter)
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90
Transmission Fluid Automatic:
Dexron III or equivalent
Coolant:
Ethylene Glycol based, green or gold, long-life coolant (50/50 mix with distilled water).
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, ball joints, exhaust components, glow plugs (diesel).
Diesel Engine Specifics:
Potential for injector pump issues on older indirect injection models, glow plug failure, turbocharger wear (if equipped).
Electrical Quirks:
Occasional issues with wiring harnesses, grounds, or alternator/starter reliability over time.
📚 Vehicle History
Brand Heritage
Isuzu Truck Legacy:
Isuzu has a long-standing reputation for robust and reliable commercial vehicles and pickup trucks globally.
Model Evolution
Tf Series Lineage:
The TF Series is part of Isuzu's global pickup truck lineage, succeeding earlier models and evolving into the D-Max.
Production
Manufacturing Locations:
Globally produced, with significant manufacturing in Japan, Thailand, and other locations under license or joint ventures.
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