🏷️ Basic Information

Make:

Isuzu

Model:

KB TF 140

Model Designation:

KB TF

Model Code:

TF Series

Generation Name:

Second Generation (TF)

Chassis Code:

TF

👋 Introduction

Vehicle Segment:

Compact Pickup Truck

Market Role:

Known for durability, reliability, and versatility, the Isuzu KB TF 140 was a popular choice for both work and personal use, particularly in markets valuing ruggedness.

Competitors:

Toyota Hilux, Nissan D21/D22 (Hardbody/Frontier), Mazda B-Series, Mitsubishi Triton/L200.

Durability:

Renowned for its robust construction and ability to withstand demanding conditions.

Simplicity:

Generally featured straightforward mechanicals, making it easier to maintain and repair compared to more complex vehicles of its era.

📋 Manual Details

Applicable Years:

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

Page Count:

5600

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF

File Format Details:

Digital Download (PDF)

Print Quality:

Printable

Binding Type:

N/A (Digital)

Paper Type:

N/A (Digital)

📖 Manual Coverage

Engine Systems:

Engine mechanical, cooling system, lubrication system, fuel system (including injection/carburetion), ignition system, exhaust system, emissions control.

Drivetrain Systems:

Clutch, manual transmission, automatic transmission (if applicable), transfer case (if applicable), driveshafts, axles, differentials.

Chassis Systems:

Suspension (front and rear), steering system, braking system (including ABS if equipped).

Electrical Systems:

Battery, charging system, starting system, lighting system, instrumentation, wiring diagrams, fuses, relays, control modules.

Body And Frame:

Body construction, exterior panels, interior trim, doors, windows, locks, seats, climate control, body hardware.

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication, tune-ups.

Repair Procedures:

Removal, disassembly, inspection, repair, assembly, and installation of all major vehicle components and systems.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical troubleshooting charts.

Adjustment Procedures:

Detailed instructions for adjustments to engine, transmission, brakes, suspension, and electrical systems.

Technical Depth:

Comprehensive, step-by-step instructions with detailed explanations, pictorial diagrams, exploded views, and photos covering basic maintenance to complete overhauls.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair operations.

Specifications:

Detailed specifications including torque values, wear limits, clearances, fluid capacities, and electrical data.

Safety Precautions:

Inclusion of special notes, important points, precautions, DANGER, CAUTION, and NOTE remarks for safe operation and to prevent damage.

⚙️ Engine Specifications

Engine Type:

Inline 4-Cylinder Gasoline and Diesel (Specific engines vary by market and year)

Displacement:

Commonly 2.3L (4ZD1) and 2.6L (4ZE1) Gasoline; Diesel variants often included 2.2L (4JA1) and 2.5L (4JA1-T/TC) Turbo Diesel.

Horsepower Range:

Gasoline engines typically produced between 90-120 HP; Turbo Diesel variants offered around 70-90 HP.

Torque Range:

Torque figures varied significantly by engine, but diesel variants generally offered higher low-end torque suitable for hauling.

Fuel Delivery:

Carburetor (early gasoline models), Electronic Fuel Injection (EFI) for later gasoline models, Direct Injection for naturally aspirated diesels, Indirect Injection for turbo diesel variants.

Fuel Type:

Unleaded Gasoline, Diesel Fuel

Ignition System:

Distributor-based ignition with electronic control for EFI models.

🔧 Transmission

Transmission Type Standard:

5-Speed Manual Transmission

Transmission Type Optional:

4-Speed Automatic Transmission (Availability varied by market and model year)

Drivetrain Options:

Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD) configurations were commonly available.

📐 Dimensions

Body Styles:

Single Cab, Extended Cab

Bed Lengths:

Short bed, Long bed (typical configurations, specific dimensions vary)

Curb Weight:

Varies significantly by configuration, but typically ranged from approximately 1300-1700 kg (2866-3748 lbs).

Payload Capacity:

Generally rated for payloads between 500-1000 kg (1100-2200 lbs).

🛡️ Safety Features

Safety Ratings:

N/A (Crash testing standards and reporting varied significantly by region and era; specific official ratings for this model are not readily available).

Active Safety:

Front disc brakes, rear drum brakes. Some later models or higher trims may have featured ABS (Anti-lock Braking System) depending on the market.

Passive Safety:

Three-point seat belts, reinforced cabin structure. Airbags were not standard across all models and years.

💡 Technology Features

Infotainment System:

Basic analog radio and cassette player were standard. Optional CD players or more advanced audio systems were available on higher trims or as dealer upgrades.

Driver Assistance:

Limited by modern standards. Features like ABS were optional. No advanced electronic driver aids like stability control or adaptive cruise control.

Connectivity:

No integrated Bluetooth or smartphone connectivity. Auxiliary input for audio devices might be present on some later models.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 km (3,000-5,000 miles) or 6 months, depending on driving conditions and oil type used. Refer to manual for exact specifications.

Coolant Change Interval:

Recommended every 2-3 years or 40,000-60,000 km (25,000-37,000 miles).

Transmission Fluid Change:

Manual: Inspect periodically, change as needed or based on mileage (e.g., 50,000-80,000 km / 30,000-50,000 miles). Automatic: Typically every 50,000-100,000 km (30,000-60,000 miles).

Engine Oil Type:

API SG or higher classification, SAE 10W-30 or 10W-40 recommended for most gasoline engines. Diesel engines may require specific diesel engine oils (e.g., API CF or CD). Consult manual for exact viscosity and API service category.

Coolant Type:

Ethylene glycol-based antifreeze (e.g., silicate-free or low-silicate type) mixed with distilled water at a 50/50 ratio.

Transmission Fluid Manual:

API GL-4 or GL-5 rated gear oil, typically SAE 75W-90 or 80W-90.

Transmission Fluid Automatic:

Dexron II or equivalent automatic transmission fluid (ATF).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Common Wear Items:

Suspension components (ball joints, tie rod ends), clutch wear, exhaust system corrosion, minor oil leaks from engine seals, radiator aging.

Engine Specific:

Overheating due to radiator or cooling fan issues, timing belt wear (on applicable engines), injector pump issues on some diesel models.

Electrical Quirks:

Flickering dashboard lights or instrument cluster issues, aging wiring harnesses, starter motor solenoid wear.

Oil Filter Example:

Example: Bosch 3300, Wix 51515 (Part numbers vary by engine and manufacturer; specific OEM numbers would be in the manual's parts section).

Air Filter Example:

Example: Mann-Filter C22004, Fram CA5512.

📚 Vehicle History

Brand Heritage:

Isuzu has a long history in commercial vehicles and trucks, with the KB nameplate representing their light commercial vehicle offerings for decades.

Generation Transition:

The TF generation (1991-2002) succeeded the older KB series and was globally marketed under various names including Chevrolet LUV, Rodeo, and Isuzu D-Max in later iterations or different regions.

Production Period:

1991-2002 (specific to the TF generation covered by this manual).

Manufacturing Locations:

Primarily manufactured in Japan, with assembly plants in other countries depending on the target market.

🏆 Awards & Recognition

Industry Recognition:

While specific awards for the Isuzu KB TF 140 are not widely documented, it consistently received recognition in various markets for its value, reliability, and workhorse capabilities within the light commercial vehicle segment.

Reliability Perception:

Generally considered a reliable vehicle, especially those with well-maintained diesel engines, praised for its longevity and straightforward engineering.

Manufacturing Standards:

Manufactured to Isuzu's internal quality and production standards, adhering to Japanese domestic market (JDM) and international automotive regulations of the era.