ISUZU KB TF 140 Workshop Repair Manual

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🏷️ Basic Information Identification Make: Isuzu Model: KB TF Engine Variant: 140 Codes Product Code: ISUZU_KB_TF_140_WSM 👋 Introduction Market Position Vehicle Segment: Light Commercial Vehicle / Utility Pick-up Truck Target...

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Description

🏷️ Basic Information

Identification

Make:

Isuzu

Model:

KB TF

Engine Variant:

Codes

Product Code:

ISUZU_KB_TF_140_WSM

👋 Introduction

Market Position

Vehicle Segment:

Light Commercial Vehicle / Utility Pick-up Truck

Target Audience:

Fleet operators, mechanics, automotive enthusiasts, DIY repairers seeking in-depth knowledge.

Competitive Analysis

Comparable Vehicles:

Toyota Hilux, Nissan Navara (D21), Mitsubishi Triton (L200), Ford Ranger (early generations), Mazda B-Series.

Key Features

Manual Advantage:

Provides the same level of detail and accuracy as official dealer workshop manuals, enabling professional-level servicing and repair.

Repair Confidence:

Empowers users to tackle complex repairs and maintenance tasks with confidence, reducing reliance on expensive dealership services.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Suspension:

Brakes:

Steering:

Electrical System:

Body And Chassis:

HVAC:

Diagnostics:

Troubleshooting:

Maintenance:

Repair Procedures:

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine overhaul, component replacement (pistons, rings, bearings, valves, camshaft, crankshaft), cylinder head repair, timing system (belt/chain), lubrication system.

Engine Fuel System:

Fuel injection system diagnosis and repair, fuel pump, injectors, fuel pressure regulator, fuel filter replacement.

Engine Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan operation and diagnosis.

Engine Ignition System:

Spark plugs, ignition coils, distributor (if applicable), wiring, ignition timing.

Transmission Manual:

Clutch system (hydraulics, disc, pressure plate), gearbox overhaul, component replacement, shift linkage adjustment.

Transmission Automatic:

(If applicable for the specific TF 140 variant, though typically manual) Fluid checks, filter replacement, torque converter diagnosis.

Drivetrain Rear Wheel Drive:

Propeller shaft, universal joints, differential (overhaul, fluid changes), rear axle components.

Suspension Front:

Independent front suspension components (wishbones, ball joints, shock absorbers, springs), alignment specifications.

Suspension Rear:

Leaf spring suspension (if applicable), shock absorbers, bushes, pivot points.

Brake System Front:

Disc brake components (calipers, pads, rotors), hydraulic lines, bleeding procedures.

Brake System Rear:

Drum brake components (shoes, drums, wheel cylinders), parking brake system.

Steering System:

Steering rack or box, tie rods, steering column, power steering system (if equipped), fluid specifications.

Electrical System Charging:

Alternator diagnosis and replacement, battery specifications and testing.

Electrical System Starting:

Starter motor diagnosis and replacement, starter solenoid.

Electrical System Lighting:

Headlights, taillights, interior lighting, bulb types and replacement.

Electrical System Wiring Diagrams:

Comprehensive wiring schematics for all major systems.

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, glass replacement, chassis components.

HVAC System:

Air conditioning system components, blower motor, heater core, refrigerant handling (general principles).

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant checks, brake fluid checks, power steering fluid checks.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common faults and drivability issues, fault code interpretation (if OBD I or II applicable).

Engine Repair:

Head gasket replacement, piston and connecting rod replacement, bearing replacement, timing belt/chain replacement, oil pump replacement, valve seal replacement.

Transmission Repair:

Clutch replacement, gearbox disassembly and reassembly, shifter linkage repair.

Brake System Repair:

Brake pad and shoe replacement, rotor and drum replacement, caliper and wheel cylinder repair/replacement, brake line repair/replacement, bleeding.

Suspension And Steering Repair:

Ball joint replacement, tie rod end replacement, shock absorber and strut replacement, spring replacement, power steering pump and rack replacement.

Electrical Component Replacement:

Alternator, starter motor, ignition coils, battery, fuses, relays, sensors.

Body And Trim Repair:

Door handle replacement, mirror replacement, interior panel removal, bumper repair/replacement.

Technical Depth

Depth:

Comprehensive (from basic maintenance to full component overhaul and diagnostics)

Diagnostic Tools:

Includes guidance on using common diagnostic tools and interpreting results (may vary depending on vehicle's diagnostic capabilities).

Specifications And Tolerances:

Detailed torque specifications, clearances, fluid capacities, and wear limits for all major components.

Diagrams And Illustrations:

Step-by-step procedures accompanied by detailed diagrams and exploded views for clear understanding.

📊 Manual Specifications

File Format

Format:

Searchable Text:

Yes (typically)

Printable:

Print Quality

Quality:

High resolution, suitable for professional use and clear reproduction of diagrams.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Typical:

C190, C223 (Common for this era, specific to '140' variant needs confirmation, but likely a 1.9L or 2.2L diesel or petrol).

Engine Type:

Inline 4-cylinder (likely Diesel, but could be Petrol depending on market/year for '140' designation).

Displacement Estimated:

1.9L to 2.2L (1900cc - 2200cc)

Performance

Horsepower Range Estimated:

60 - 80 HP (typical for engines of this displacement in this period).

Torque Range Estimated:

130 - 170 Nm (typical for engines of this displacement in this period).

Fuel System

Fuel Delivery:

Indirect injection (diesel) or Carburetor/MPI (petrol) depending on exact variant.

Fuel Type:

Diesel or Petrol (specific to '140' model variant).

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

4-speed Automatic Transmission (less common, may be market-dependent)

Features

Drivetrain:

Rear-Wheel Drive (RWD) or Selectable Four-Wheel Drive (4WD).

📐 Dimensions

Exterior

Body Styles:

Single Cab, Extended Cab (Space Cab), Double Cab.

Wheelbase Typical:

2755 mm - 3250 mm (varies by cab and bed configuration).

Weights

Curb Weight Estimated:

1200 - 1600 kg (depending on configuration).

Gross Vehicle Weight Rating Estimated:

2000 - 2500 kg.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Likely not independently tested to modern standards during its production era).

Active Features

Active Safety Features:

Basic braking system (ABS typically not standard on early models).

Passive Features

Passive Safety Features:

Seat belts, reinforced chassis structure.

💡 Technology Features

Infotainment

Infotainment Features:

Basic AM/FM radio, cassette player or CD player (depending on year/trim).

Driver Assistance

Driver Assistance Features:

Very limited, primarily focused on mechanical reliability. No advanced electronic driver aids.

Connectivity

Connectivity Options:

None (No Bluetooth, USB, or smartphone integration).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically 5,000 km to 10,000 km or 6 months, depending on oil type and driving conditions.

Air Filter Replacement:

10,000 km - 20,000 km or annually.

Fuel Filter Replacement:

20,000 km - 40,000 km (especially critical for diesel models).

Timing Belt Replacement:

If applicable, typically 80,000 km - 100,000 km (critical maintenance item).

Fluid Specifications

Engine Oil Viscosity:

API SG or higher, SAE 10W-30 or 10W-40 (check specific engine requirements).

Coolant Type:

Ethylene Glycol based antifreeze/coolant (e.g., G11 equivalent).

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Manual:

GL-4 or GL-5 SAE 75W-90 or 80W-90 gear oil.

Differential Fluid Type:

API GL-5 SAE 80W-90 or 85W-140.

Known Issues

Common Wear Items:

Clutch wear, suspension bushings, exhaust system corrosion, starter motor, alternator, rust on body panels and chassis.

Diesel Engine Specifics:

Glow plug issues, injection pump wear, turbocharger (if fitted) maintenance.

📚 Vehicle History

Brand Heritage

Brand Focus:

Isuzu has a long-standing reputation for robust and reliable commercial vehicles and engines.

Model Evolution

Generation:

This refers to the Isuzu Faster/Pick-Up platform (TF generation), which ran from the mid-1980s to the early 2000s.

Production

Production Years Estimated:

1988 - 2002 (for the TF generation).

🏆 Awards & Recognition

Recognitions

Reputation:

The Isuzu KB/TF series is widely recognized for its durability, ruggedness, and suitability for demanding work environments. Often lauded as a 'workhorse'.