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Holden Rodeo KB TF 140 1990-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Holden Model: Rodeo Chassis Code: KB TF Generation Designation: Second Generation (TF) Variant: 140 Codes Production Years: 1990-2004 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size Pickup Truck Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance. Competitive Analysis Key Competitors Era: Toyota Hilux, Nissan Navara (D22), Mitsubishi Triton (MK). Key Features Manual Benefit: Enables comprehensive vehicle maintenance and repair, reducing reliance on expensive dealership services. Manual Value Proposition: Cost-effective solution for maintaining vehicle reliability and longevity. 📋 Manual Details Coverage Areas Manual Scope: Complete Factory Service and Repair Page Count Estimated Page Count: Varies by specific engine/drivetrain configuration, but comprehensive. Manual Type Manual Category: Workshop Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control. Drivetrain Systems: Manual transmission, automatic transmission, clutch, driveshafts, differentials. Chassis Systems: Suspension (front and rear), steering, braking system, wheels and tires. Electrical Systems: Battery, charging system, starting system, lighting, instruments, wiring diagrams, body electrical, engine control module (ECM). Body And Interior: Body panels, doors, glass, seats, trim, heating and air conditioning (HVAC). Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication. Repair Procedures: Component removal and installation, rebuilding procedures for major assemblies. Troubleshooting: Diagnostic procedures for engine, transmission, electrical, and chassis issues. Diagnostic Information: Diagnostic trouble codes (DTCs) and their interpretation, diagnostic flowcharts. Technical Specifications: Torque values, clearances, specifications for all adjustable components. Technical Depth Diagnostic Capability: Advanced diagnostics and troubleshooting for experienced mechanics and DIY enthusiasts. Rebuild Depth: Comprehensive rebuild instructions for engines, transmissions, and other major components. Diagram Quality: High-quality diagrams, exploded views, and illustrations for clarity. 📊 Manual Specifications File Format PDF Quality: High-resolution, clear text and images. Print Quality Printability: Printable without restriction. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Format: PDF ⚙️ Engine Specifications Primary Engine Engine Family: Isuzu G161Z/G200Z/4ZD1 (petrol), Isuzu C223/4JA1 (diesel) Engine Configuration: Inline 4-cylinder Engine Displacement Petrol Common: 1.6L, 2.0L, 2.3L (4ZD1) Engine Displacement Diesel Common: 2.2L (C223), 2.5L (4JA1) Performance Typical Horsepower Range: 60-95 kW (Varies by engine and tuning) Typical Torque Range: 110-180 Nm (Varies by engine and tuning) Fuel System Fuel Delivery Petrol: Carbureted (early models), Electronic Fuel Injection (EFI) (later models) Fuel Delivery Diesel: Indirect injection (IDI) with mechanical injection pump 🔧 Transmission Standard Standard Transmission Type: 5-speed manual Optional Optional Transmission Type: 4-speed automatic (on select models/engines) Features Drivetrain Options: Rear-wheel drive (RWD), Four-wheel drive (4WD) 📐 Dimensions Exterior Body Styles: Single Cab, Space Cab, Dual Cab Wheelbase Range: Approximately 2755 mm - 3295 mm (Varies by cab style and chassis) Weights Gross Vehicle Weight Rating Gvwr: Typically around 2000-2500 kg (Varies by configuration) 🛡️ Safety Features Ratings Australian Ancap Rating: Not applicable for this era of vehicle according to modern standards. Active Features Braking System: Front disc brakes, rear drum brakes. Passive Features Airbags: Driver airbag became standard on later models; passenger airbag rarely fitted. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player was common, some later models offered CD players. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on later models. Connectivity Connectivity Features: None in the modern sense; analog systems. 🔧 Maintenance Service Intervals Oil Change Interval Petrol: Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions. Oil Change Interval Diesel: Typically every 5,000-7,500 km or 6 months. Timing Belt Replacement: Not applicable for most engines as they utilize timing chains. Fluid Specifications Engine Oil Specification Petrol: API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific engine). Engine Oil Specification Diesel: API CF or higher, SAE 15W-40 (refer to manual for specific engine). Coolant Specification: Ethylene glycol-based, phosphate-free (e.g., Holden Genuine Coolant or equivalent). Transmission Fluid Manual: GL-4 Gear Oil, SAE 75W-90 or 80W-90. Transmission Fluid Automatic: Dexron II or Dexron III ATF (Automatic Transmission Fluid). Brake Fluid Specification: DOT 3 or DOT 4. Known Issues Common Engine Wear: Oil leaks from rocker cover gaskets and rear main seals, piston ring wear leading to oil consumption in high-mileage engines. Common Suspension Issues: Worn ball joints, tie rod ends, and bushings due to typical use. Common Electrical Issues: Corroded electrical connectors, failing alternator or starter motor, intermittent dashboard warning lights. Common Transmission Issues: Wear in manual gearbox synchros, potential leaks from transmission seals. 📚 Vehicle History Brand Heritage Manufacturer Origin: Holden (Australia) utilized rebadged Isuzu platforms. Model Evolution Platform Sharing: Based on the second generation Isuzu TF platform. Production Assembly Location: Thailand (primarily for Isuzu), assembled and sold by Holden in Australia. 🏆 Awards & Recognition Recognitions Pickup Of The Year Awards: The Holden Rodeo consistently performed well in Australian automotive publications for its durability and utility.
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Holden Rodeo KB TF 140 1990-2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Holden
Model:
Rodeo
Chassis Code:
KB TF
Generation Designation:
Second Generation (TF)
Variant:
140
Codes
Production Years:
1990-2004
👋 Introduction
Market Position
Vehicle Segment:
Compact/Mid-size Pickup Truck
Target Audience:
DIY enthusiasts, independent repair shops, fleet maintenance.
Competitive Analysis
Key Competitors Era:
Toyota Hilux, Nissan Navara (D22), Mitsubishi Triton (MK).
Key Features
Manual Benefit:
Enables comprehensive vehicle maintenance and repair, reducing reliance on expensive dealership services.
Manual Value Proposition:
Cost-effective solution for maintaining vehicle reliability and longevity.
📋 Manual Details
Coverage Areas
Manual Scope:
Complete Factory Service and Repair
Page Count
Estimated Page Count:
Varies by specific engine/drivetrain configuration, but comprehensive.
Manual Type
Manual Category:
Workshop Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control.
Drivetrain Systems:
Manual transmission, automatic transmission, clutch, driveshafts, differentials.
Chassis Systems:
Suspension (front and rear), steering, braking system, wheels and tires.
Electrical Systems:
Battery, charging system, starting system, lighting, instruments, wiring diagrams, body electrical, engine control module (ECM).
Body And Interior:
Body panels, doors, glass, seats, trim, heating and air conditioning (HVAC).
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, lubrication.
Repair Procedures:
Component removal and installation, rebuilding procedures for major assemblies.
Troubleshooting:
Diagnostic procedures for engine, transmission, electrical, and chassis issues.
Diagnostic Information:
Diagnostic trouble codes (DTCs) and their interpretation, diagnostic flowcharts.
Technical Specifications:
Torque values, clearances, specifications for all adjustable components.
Technical Depth
Diagnostic Capability:
Advanced diagnostics and troubleshooting for experienced mechanics and DIY enthusiasts.
Rebuild Depth:
Comprehensive rebuild instructions for engines, transmissions, and other major components.
Diagram Quality:
High-quality diagrams, exploded views, and illustrations for clarity.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, clear text and images.
Print Quality
Printability:
Printable without restriction.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Format:
PDF
⚙️ Engine Specifications
Primary Engine
Engine Family:
Isuzu G161Z/G200Z/4ZD1 (petrol), Isuzu C223/4JA1 (diesel)
Engine Configuration:
Inline 4-cylinder
Engine Displacement Petrol Common:
1.6L, 2.0L, 2.3L (4ZD1)
Engine Displacement Diesel Common:
2.2L (C223), 2.5L (4JA1)
Performance
Typical Horsepower Range:
60-95 kW (Varies by engine and tuning)
Typical Torque Range:
110-180 Nm (Varies by engine and tuning)
Fuel System
Fuel Delivery Petrol:
Carbureted (early models), Electronic Fuel Injection (EFI) (later models)
Fuel Delivery Diesel:
Indirect injection (IDI) with mechanical injection pump
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual
Optional
Optional Transmission Type:
4-speed automatic (on select models/engines)
Features
Drivetrain Options:
Rear-wheel drive (RWD), Four-wheel drive (4WD)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Space Cab, Dual Cab
Wheelbase Range:
Approximately 2755 mm - 3295 mm (Varies by cab style and chassis)
Weights
Gross Vehicle Weight Rating Gvwr:
Typically around 2000-2500 kg (Varies by configuration)
🛡️ Safety Features
Ratings
Australian Ancap Rating:
Not applicable for this era of vehicle according to modern standards.
Active Features
Braking System:
Front disc brakes, rear drum brakes.
Passive Features
Airbags:
Driver airbag became standard on later models; passenger airbag rarely fitted.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player was common, some later models offered CD players.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on later models.
Connectivity
Connectivity Features:
None in the modern sense; analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions.
Oil Change Interval Diesel:
Typically every 5,000-7,500 km or 6 months.
Timing Belt Replacement:
Not applicable for most engines as they utilize timing chains.
Fluid Specifications
Engine Oil Specification Petrol:
API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific engine).
Engine Oil Specification Diesel:
API CF or higher, SAE 15W-40 (refer to manual for specific engine).
Coolant Specification:
Ethylene glycol-based, phosphate-free (e.g., Holden Genuine Coolant or equivalent).
Transmission Fluid Manual:
GL-4 Gear Oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron II or Dexron III ATF (Automatic Transmission Fluid).
Brake Fluid Specification:
DOT 3 or DOT 4.
Known Issues
Common Engine Wear:
Oil leaks from rocker cover gaskets and rear main seals, piston ring wear leading to oil consumption in high-mileage engines.
Common Suspension Issues:
Worn ball joints, tie rod ends, and bushings due to typical use.
Common Electrical Issues:
Corroded electrical connectors, failing alternator or starter motor, intermittent dashboard warning lights.
Common Transmission Issues:
Wear in manual gearbox synchros, potential leaks from transmission seals.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Holden (Australia) utilized rebadged Isuzu platforms.
Model Evolution
Platform Sharing:
Based on the second generation Isuzu TF platform.
Production
Assembly Location:
Thailand (primarily for Isuzu), assembled and sold by Holden in Australia.
🏆 Awards & Recognition
Recognitions
Pickup Of The Year Awards:
The Holden Rodeo consistently performed well in Australian automotive publications for its durability and utility.
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