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1993-1996 Isuzu KB TF 140 Factory Workshop Manual

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🏷️ Basic Information Identification Make: Isuzu Model: KB TF 140 Model Variant: 140 Year Range Covered: 1993-1996 Codes Chassis Code: UG Series (likely) Engine Code Primary: G161 (most common 1.6L for this era KB) 👋 Introduction Market Position Vehicle Segment: Compact Pickup Truck Target Audience: Commercial use, light utility, entry-level personal transport. Competitive Analysis Key Competitors: Toyota Hilux/Pickup, Nissan D21/Hardbody, Mitsubishi L200/Triton, Mazda B-Series. Key Features Value Proposition: Durable, reliable, and cost-effective light commercial vehicle, often praised for its simplicity and workhorse capability. Manual Advantage: Provides factory-level accuracy and detail essential for maintaining and repairing these robust vehicles over their long service life. 📋 Manual Details Coverage Areas Primary Coverage: Full Factory Workshop Manual Secondary Coverage: Mechanical, Electrical, Body, Chassis Page Count Estimated Page Count: Likely 1000+ pages (typical for full factory workshop manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul procedures, fuel system, ignition system, cooling system, lubrication system, emissions control. Transmission: Manual transmission overhaul, clutch system, driveline components. Brakes: Front and rear brake system diagnosis, repair, hydraulic system, parking brake. Steering: Steering column, steering gear, power steering (if equipped). Suspension: Front and rear suspension components, shock absorbers, springs, alignment specifications. Wheels Tires: Tire specifications, wheel alignment, wheel bearing service. Frame Cab: Body construction, structural repair, cab components, doors, glass, interior trim. Heating Ac: HVAC system diagnosis, components, refrigerant service, repair procedures. Electrical: Wiring diagrams, charging system, starting system, lighting, instrumentation, fuses, relays, body electrical components. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacement, lubrication, inspections. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, common fault identification. Repair: Component removal, installation, adjustment, and overhaul for all covered systems. Diagnostics: Detailed diagnostic procedures for engine performance, electrical faults, and mechanical issues. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed torque specifications, clearances, and diagnostic parameters. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (assuming a well-OCR'd digital version) Printable: Yes Print Quality Quality: High (typical for factory manuals, with clear diagrams and text) Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder, SOHC (likely) Displacement: 1.6 Liters (1598cc) - common for the '140' designation Bore X Stroke: 83.0 mm x 73.7 mm (approximate for G161) Compression Ratio: Approx. 9.0:1 (typical for G161) Horsepower: Approx. 78-85 HP @ 5000-5200 RPM (typical for G161) Torque: Approx. 90-95 lb-ft @ 3000-3500 RPM (typical for G161) Performance Fuel Type: Unleaded Gasoline Fuel System Induction: Fuel Injection (MPI - Multi-Point Injection) likely standard for 1993 onwards Ignition System: Electronic Ignition (Distributorless or Distributor based) Engine Codes Engine Code Alternatives: May also cover other variants like G180 (1.8L) or the 4JB1 diesel depending on market, though '140' strongly suggests 1.6L G161. 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 4-Speed Automatic (less common on base models, but possible) Features Drivetrain: Rear-Wheel Drive (RWD) standard, 4-Wheel Drive (4WD) likely optional. Fluid Specifications Manual Transmission Fluid: API GL-4 SAE 75W-90 or 80W-90 (refer to manual for exact specification). Automatic Transmission Fluid: Dexron III (if automatic transmission equipped, refer to manual for exact specification). 📐 Dimensions Exterior Body Styles: Single Cab Pickup, Extended Cab Pickup (Space Cab), Chassis Cab. Wheelbase: Varies by configuration, typically around 2750mm (108.3 inches) for standard cab. Weights Curb Weight: Approx. 1100-1300 kg (2425-2866 lbs), varies by configuration. 🛡️ Safety Features Ratings Crash Test Data: Limited official crash test data available for this generation from major agencies like NHTSA/Euro NCAP. Typically basic safety features. Active Features Brakes: Front Disc / Rear Drum brakes standard. ABS not typically available on base models. Passive Features Airbags: Driver-side airbag not standard on all models, check specific vehicle configuration. Seatbelts: Lap and shoulder belts for front occupants. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player typically standard. Optional CD player may have been available on higher trims. Display: Analog gauges for speedometer, tachometer (optional), fuel level, coolant temperature, oil pressure. Basic warning lights. Driver Assistance Features: Minimal to none by modern standards. No electronic stability control, traction control, or advanced driver assistance systems. Connectivity Features: N/A (No factory Bluetooth, USB, or other modern connectivity options). 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 km (3,000-5,000 miles) or 6 months (refer to manual for precise interval based on driving conditions). Air Filter Replacement: Every 20,000-30,000 km (12,000-18,000 miles) or annually. Spark Plug Replacement: Every 40,000-60,000 km (25,000-37,000 miles). Fluid Specifications Engine Oil Type: API SG/SH or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specification and capacity). Coolant Type: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water (refer to manual for specific type and capacity). Brake Fluid Type: DOT 3 or...
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1993-1996 Isuzu KB TF 140 Factory Workshop Manual
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
KB TF 140
Model Variant:
140
Year Range Covered:
1993-1996
Codes
Chassis Code:
UG Series (likely)
Engine Code Primary:
G161 (most common 1.6L for this era KB)
👋 Introduction
Market Position
Vehicle Segment:
Compact Pickup Truck
Target Audience:
Commercial use, light utility, entry-level personal transport.
Competitive Analysis
Key Competitors:
Toyota Hilux/Pickup, Nissan D21/Hardbody, Mitsubishi L200/Triton, Mazda B-Series.
Key Features
Value Proposition:
Durable, reliable, and cost-effective light commercial vehicle, often praised for its simplicity and workhorse capability.
Manual Advantage:
Provides factory-level accuracy and detail essential for maintaining and repairing these robust vehicles over their long service life.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Factory Workshop Manual
Secondary Coverage:
Mechanical, Electrical, Body, Chassis
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for full factory workshop manuals)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, overhaul procedures, fuel system, ignition system, cooling system, lubrication system, emissions control.
Transmission:
Manual transmission overhaul, clutch system, driveline components.
Brakes:
Front and rear brake system diagnosis, repair, hydraulic system, parking brake.
Steering:
Steering column, steering gear, power steering (if equipped).
Suspension:
Front and rear suspension components, shock absorbers, springs, alignment specifications.
Wheels Tires:
Tire specifications, wheel alignment, wheel bearing service.
Frame Cab:
Body construction, structural repair, cab components, doors, glass, interior trim.
Heating Ac:
HVAC system diagnosis, components, refrigerant service, repair procedures.
Electrical:
Wiring diagrams, charging system, starting system, lighting, instrumentation, fuses, relays, body electrical components.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacement, lubrication, inspections.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common fault identification.
Repair:
Component removal, installation, adjustment, and overhaul for all covered systems.
Diagnostics:
Detailed diagnostic procedures for engine performance, electrical faults, and mechanical issues.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed torque specifications, clearances, and diagnostic parameters.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (assuming a well-OCR'd digital version)
Printable:
Yes
Print Quality
Quality:
High (typical for factory manuals, with clear diagrams and text)
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-Cylinder, SOHC (likely)
Displacement:
1.6 Liters (1598cc) - common for the '140' designation
Bore X Stroke:
83.0 mm x 73.7 mm (approximate for G161)
Compression Ratio:
Approx. 9.0:1 (typical for G161)
Horsepower:
Approx. 78-85 HP @ 5000-5200 RPM (typical for G161)
Torque:
Approx. 90-95 lb-ft @ 3000-3500 RPM (typical for G161)
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Induction:
Fuel Injection (MPI - Multi-Point Injection) likely standard for 1993 onwards
Ignition System:
Electronic Ignition (Distributorless or Distributor based)
Engine Codes
Engine Code Alternatives:
May also cover other variants like G180 (1.8L) or the 4JB1 diesel depending on market, though '140' strongly suggests 1.6L G161.
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic (less common on base models, but possible)
Features
Drivetrain:
Rear-Wheel Drive (RWD) standard, 4-Wheel Drive (4WD) likely optional.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or 80W-90 (refer to manual for exact specification).
Automatic Transmission Fluid:
Dexron III (if automatic transmission equipped, refer to manual for exact specification).
📐 Dimensions
Exterior
Body Styles:
Single Cab Pickup, Extended Cab Pickup (Space Cab), Chassis Cab.
Wheelbase:
Varies by configuration, typically around 2750mm (108.3 inches) for standard cab.
Weights
Curb Weight:
Approx. 1100-1300 kg (2425-2866 lbs), varies by configuration.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official crash test data available for this generation from major agencies like NHTSA/Euro NCAP. Typically basic safety features.
Active Features
Brakes:
Front Disc / Rear Drum brakes standard. ABS not typically available on base models.
Passive Features
Airbags:
Driver-side airbag not standard on all models, check specific vehicle configuration.
Seatbelts:
Lap and shoulder belts for front occupants.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player typically standard. Optional CD player may have been available on higher trims.
Display:
Analog gauges for speedometer, tachometer (optional), fuel level, coolant temperature, oil pressure. Basic warning lights.
Driver Assistance
Features:
Minimal to none by modern standards. No electronic stability control, traction control, or advanced driver assistance systems.
Connectivity
Features:
N/A (No factory Bluetooth, USB, or other modern connectivity options).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months (refer to manual for precise interval based on driving conditions).
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles) or annually.
Spark Plug Replacement:
Every 40,000-60,000 km (25,000-37,000 miles).
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specification and capacity).
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water (refer to manual for specific type and capacity).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification).
Known Issues
Engine Reliability:
Generally robust, but can experience head gasket leaks, oil leaks from seals, and carburetor (if equipped) or injector issues.
Chassis Durability:
Rust can be a significant issue, especially in body panels, frame rails, and suspension components in corrosive environments.
Electrical Quirks:
Age-related electrical issues such as faulty grounds, corroded connectors, and failing switches are common.
Maintenance Cost Index
Index:
Moderate. Parts are generally available, and the simplicity of the design contributes to reasonable labor costs.
📚 Vehicle History
Brand Heritage
Company Focus:
Isuzu has a long history of producing robust commercial vehicles, trucks, and SUVs, known for durability.
Model Evolution
Predecessor:
Isuzu Faster / Rodeo (preceding generations of the KB/TF lineage).
Successor:
Isuzu D-Max (later generations would adopt this global nameplate).
Production
Manufacturing Locations:
Primarily Japan and various global assembly plants (e.g., Thailand, South Africa).
Production Period:
The Isuzu KB/TF platform had a long production run, with this generation spanning from the early 1980s through the mid-1990s with facelifts.
🏆 Awards & Recognition
Recognitions
Awards:
No widely publicized awards for this specific model generation, but the Isuzu KB/TF line was consistently recognized in many markets for its workhorse capabilities and affordability.
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