Isuzu KB TF 140 1996 Digital Factory Repair Manual

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🏷️ Basic Information Identification Make: Isuzu Model: KB TF 140 Year: 1996 Chassis Code: TF Series Body Style: Light Commercial Vehicle (LCV) / Pickup Truck Generation Generation Identifier: Second Generation TF Series (Facelifted) Codes Engine Code Common Petrol: C22NE (2.2L) Engine Code Common Diesel: 4JA1 (2.5L Diesel) 👋 Introduction Market Position Vehicle Segment: Compact to mid-size pickup truck, popular for utility, work, and light-duty off-roading Target Audience: DIY mechanics, fleet owners, professional workshops, enthusiasts Competitive Analysis Key Competitors 1996: Toyota Hilux/Tacoma, Nissan D21/Frontier, Mitsubishi Triton/L200, Ford Ranger, Chevrolet S-10/Blazer Key Features Manual Advantage 1: Dealer-level information ensures accuracy and completeness Manual Advantage 2: Step-by-step diagrams facilitate understanding of complex procedures Manual Advantage 3: Covers both petrol and diesel engine variants, offering broad applicability Manual Advantage 4: Essential for maintaining vehicle reliability and longevity Manual Advantage 5: Facilitates accurate diagnosis and repair, saving time and money 📋 Manual Details Coverage Areas Manual Type: Factory Repair/Service Manual Language: English Format: Digital (PDF) Page Count: Estimated 1000+ pages (typical for comprehensive factory manuals) Compatibility: Windows, macOS Software Requirements: Adobe Acrobat Reader, WinZip or equivalent decompression utility Searchability: Likely searchable text within PDF format Zoom Functionality: Yes 📖 Manual Coverage Systems Covered Engine Petrol Systems: Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, engine management (ECU) Engine Diesel Systems: Engine mechanical, lubrication, cooling, fuel injection, glow plug system, emissions control Transmission Systems: Manual transmission (MT), Automatic transmission (AT) if applicable, clutch system, drive shafts, differentials Chassis And Suspension: Frame, suspension components (front and rear), steering system, wheel alignment Brake Systems: Front and rear brakes (drum/disc configuration depending on model), hydraulic system, parking brake Electrical Systems: Battery, starting system, charging system, lighting (headlights, taillights, interior), instrumentation, wiring diagrams, fuses, relays, power distribution Body And Interior: Body panels, doors, windows, locks, interior trim, seats, HVAC system (Heating, Ventilation, and Air Conditioning), bumpers Accessories: Ancillary systems, potentially including optional accessories if specified in the factory documentation Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt tensioning, lubrication points Troubleshooting Procedures: Diagnostic charts, symptom-based troubleshooting guides, common fault identification Repair Procedures: Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly Overhaul Procedures: Engine rebuild, transmission overhaul, differential overhaul Electrical Diagnostics: Wiring diagram interpretation, component testing, fault tracing in electrical circuits HVAC Service: Refrigerant system service, component replacement (compressor, condenser, evaporator), blower motor service Bodywork Repair: Panel replacement, rust repair, glass replacement, bumper repair/replacement Technical Depth Depth Level: Comprehensive Factory Workshop Level Detail Level: Detailed step-by-step instructions with accompanying diagrams and illustrations Torque Specifications: Included for all critical fasteners Fluid Capacities: Included for all service fluids (engine oil, coolant, transmission fluid, brake fluid, etc.) Diagnostic Information: Specific diagnostic procedures, fault codes (if applicable via OBD-I or similar), and troubleshooting trees Electrical Diagrams: Complete vehicle wiring schematics Illustrations And Diagrams: Step-by-step diagrams for most procedures 📊 Manual Specifications File Format Digital Format: PDF Print Quality Digital Quality: High resolution, suitable for screen viewing and printing Binding Type Binding Type: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) File Size Estimated File Size: Likely several hundred MB due to diagrams and comprehensive nature ⚙️ Engine Specifications Primary Engine Petrol Engine Type Petrol: Inline 4-Cylinder, DOHC (Double Overhead Camshaft) Displacement Petrol: 2.2 Liters (2198 cc) Engine Code Petrol: C22NE Bore X Stroke Petrol: 89.0 mm x 87.0 mm (approximate) Compression Ratio Petrol: 9.2:1 (approximate) Horsepower Petrol: Approx. 120-125 PS (90-93 kW) at ~5000 RPM Torque Petrol: Approx. 180-185 Nm (133-136 lb-ft) at ~3000-3500 RPM Fuel System Petrol: Multi-point Fuel Injection (MPI) Ignition System Petrol: Electronic Ignition (Distributorless or Distributor-based) Primary Engine Diesel Engine Type Diesel: Inline 4-Cylinder, SOHC (Single Overhead Camshaft), Naturally Aspirated or Turbocharged (depending on specific variant) Displacement Diesel: 2.5 Liters (2499 cc) Engine Code Diesel: 4JA1 (Naturally Aspirated) / 4JA1-T (Turbocharged) Horsepower Diesel: Naturally Aspirated: Approx. 75-80 PS (55-59 kW); Turbocharged: Approx. 90-100 PS (66-74 kW) Torque Diesel: Naturally Aspirated: Approx. 140-150 Nm; Turbocharged: Approx. 180-200 Nm Fuel System Diesel: Indirect Injection (IDI) with Rotary Injection Pump Cooling System: Pressurized liquid cooling system with fan Lubrication System: Forced lubrication via oil pump and filter 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (MT) Optional Transmission Type Optional: 4-speed Automatic Transmission (AT) (less common than MT) Features Drive Layout: Rear-Wheel Drive (RWD) or Four-Wheel Drive (4WD) variants available Clutch Type: Dry single plate clutch (for MT) Transfer Case 4Wd: Part-time 4WD system with manual or automatic free-wheeling hubs (depending on specification) 📐 Dimensions Exterior Wheelbase: Approximately 2,755 mm to 3,025 mm (depending on cab configuration - Single Cab, Extended Cab) Overall Length: Varies by cab and bed configuration, e.g., Single Cab Long Bed ~4,800 mm Overall Width: Approximately 1,690 mm Overall Height: Approximately 1,650 mm (unladen, varies by suspension) Weights Curb Weight: Approx. 1,300 kg -...

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Sku: 358541

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Labels: 1996 Cars Isuzu KB TF 140 TF Truck

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Description

🏷️ Basic Information

Identification

Make:

Isuzu

Model:

KB TF 140

Year:

Chassis Code:

TF Series

Body Style:

Light Commercial Vehicle (LCV) / Pickup Truck

Generation

Generation Identifier:

Second Generation TF Series (Facelifted)

Codes

Engine Code Common Petrol:

C22NE (2.2L)

Engine Code Common Diesel:

4JA1 (2.5L Diesel)

👋 Introduction

Market Position

Vehicle Segment:

Compact to mid-size pickup truck, popular for utility, work, and light-duty off-roading

Target Audience:

DIY mechanics, fleet owners, professional workshops, enthusiasts

Competitive Analysis

Key Competitors 1996:

Toyota Hilux/Tacoma, Nissan D21/Frontier, Mitsubishi Triton/L200, Ford Ranger, Chevrolet S-10/Blazer

Key Features

Manual Advantage 1:

Dealer-level information ensures accuracy and completeness

Manual Advantage 2:

Step-by-step diagrams facilitate understanding of complex procedures

Manual Advantage 3:

Covers both petrol and diesel engine variants, offering broad applicability

Manual Advantage 4:

Essential for maintaining vehicle reliability and longevity

Manual Advantage 5:

Facilitates accurate diagnosis and repair, saving time and money

📋 Manual Details

Coverage Areas

Manual Type:

Factory Repair/Service Manual

Language:

English

Format:

Digital (PDF)

Page Count:

Estimated 1000+ pages (typical for comprehensive factory manuals)

Compatibility:

Windows, macOS

Software Requirements:

Adobe Acrobat Reader, WinZip or equivalent decompression utility

Searchability:

Likely searchable text within PDF format

Zoom Functionality:

📖 Manual Coverage

Systems Covered

Engine Petrol Systems:

Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, engine management (ECU)

Engine Diesel Systems:

Engine mechanical, lubrication, cooling, fuel injection, glow plug system, emissions control

Transmission Systems:

Manual transmission (MT), Automatic transmission (AT) if applicable, clutch system, drive shafts, differentials

Chassis And Suspension:

Frame, suspension components (front and rear), steering system, wheel alignment

Brake Systems:

Front and rear brakes (drum/disc configuration depending on model), hydraulic system, parking brake

Electrical Systems:

Battery, starting system, charging system, lighting (headlights, taillights, interior), instrumentation, wiring diagrams, fuses, relays, power distribution

Body And Interior:

Body panels, doors, windows, locks, interior trim, seats, HVAC system (Heating, Ventilation, and Air Conditioning), bumpers

Accessories:

Ancillary systems, potentially including optional accessories if specified in the factory documentation

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt tensioning, lubrication points

Troubleshooting Procedures:

Diagnostic charts, symptom-based troubleshooting guides, common fault identification

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly

Overhaul Procedures:

Engine rebuild, transmission overhaul, differential overhaul

Electrical Diagnostics:

Wiring diagram interpretation, component testing, fault tracing in electrical circuits

HVAC Service:

Refrigerant system service, component replacement (compressor, condenser, evaporator), blower motor service

Bodywork Repair:

Panel replacement, rust repair, glass replacement, bumper repair/replacement

Technical Depth

Depth Level:

Comprehensive Factory Workshop Level

Detail Level:

Detailed step-by-step instructions with accompanying diagrams and illustrations

Torque Specifications:

Included for all critical fasteners

Fluid Capacities:

Included for all service fluids (engine oil, coolant, transmission fluid, brake fluid, etc.)

Diagnostic Information:

Specific diagnostic procedures, fault codes (if applicable via OBD-I or similar), and troubleshooting trees

Electrical Diagrams:

Complete vehicle wiring schematics

Illustrations And Diagrams:

Step-by-step diagrams for most procedures

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Digital Quality:

High resolution, suitable for screen viewing and printing

Binding Type

Binding Type:

Not Applicable (Digital Format)

Paper Type

Paper Type:

Not Applicable (Digital Format)

File Size

Estimated File Size:

Likely several hundred MB due to diagrams and comprehensive nature

⚙️ Engine Specifications

Primary Engine Petrol

Engine Type Petrol:

Inline 4-Cylinder, DOHC (Double Overhead Camshaft)

Displacement Petrol:

2.2 Liters (2198 cc)

Engine Code Petrol:

C22NE

Bore X Stroke Petrol:

89.0 mm x 87.0 mm (approximate)

Compression Ratio Petrol:

9.2:1 (approximate)

Horsepower Petrol:

Approx. 120-125 PS (90-93 kW) at ~5000 RPM

Torque Petrol:

Approx. 180-185 Nm (133-136 lb-ft) at ~3000-3500 RPM

Fuel System Petrol:

Multi-point Fuel Injection (MPI)

Ignition System Petrol:

Electronic Ignition (Distributorless or Distributor-based)

Primary Engine Diesel

Engine Type Diesel:

Inline 4-Cylinder, SOHC (Single Overhead Camshaft), Naturally Aspirated or Turbocharged (depending on specific variant)

Displacement Diesel:

2.5 Liters (2499 cc)

Engine Code Diesel:

4JA1 (Naturally Aspirated) / 4JA1-T (Turbocharged)

Horsepower Diesel:

Naturally Aspirated: Approx. 75-80 PS (55-59 kW); Turbocharged: Approx. 90-100 PS (66-74 kW)

Torque Diesel:

Naturally Aspirated: Approx. 140-150 Nm; Turbocharged: Approx. 180-200 Nm

Fuel System Diesel:

Indirect Injection (IDI) with Rotary Injection Pump

Cooling System:

Pressurized liquid cooling system with fan

Lubrication System:

Forced lubrication via oil pump and filter

🔧 Transmission

Standard Transmission

Type Standard:

5-speed Manual Transmission (MT)

Optional Transmission

Type Optional:

4-speed Automatic Transmission (AT) (less common than MT)

Features

Drive Layout:

Rear-Wheel Drive (RWD) or Four-Wheel Drive (4WD) variants available

Clutch Type:

Dry single plate clutch (for MT)

Transfer Case 4Wd:

Part-time 4WD system with manual or automatic free-wheeling hubs (depending on specification)

📐 Dimensions

Exterior

Wheelbase:

Approximately 2,755 mm to 3,025 mm (depending on cab configuration - Single Cab, Extended Cab)

Overall Length:

Varies by cab and bed configuration, e.g., Single Cab Long Bed ~4,800 mm

Overall Width:

Approximately 1,690 mm

Overall Height:

Approximately 1,650 mm (unladen, varies by suspension)

Weights

Curb Weight:

Approx. 1,300 kg - 1,600 kg (depending on configuration and engine)

Gross Vehicle Weight Rating Gvw:

Typically around 2,000 kg to 2,500 kg

Payload Capacity:

Approx. 500 kg to 1,000 kg

🛡️ Safety Features

Ratings

Crash Test Ratings Era:

Safety standards and ratings for this era were less standardized globally. Specific official ratings for NHTSA or Euro NCAP for the 1996 model may not be readily available or comparable to modern standards.

Active Features

Brakes:

Front disc brakes, Rear drum brakes. Some higher trims may have rear discs. ABS was an option on some later models or specific markets, less common on the 1996 base models.

Steering:

Power steering typically standard on higher trims or optional.

Passive Features

Seatbelts:

Front seat belts, likely with pre-tensioners on some variants. Rear seat belts for passenger variants.

Airbags:

Driver's airbag was an option on some models, not standard on all.

Body Construction:

Body-on-frame construction, designed for durability and load-carrying capacity.

💡 Technology Features

Infotainment

Audio System 1996:

Basic AM/FM radio with cassette player, optional CD player on higher trims

Speakers:

Typically 2 or 4 speakers

Driver Assistance

Optional on some models/markets, not standard

Traction Control:

Rarely available on this model year

Connectivity

Connectivity Features:

No advanced connectivity features (e.g., Bluetooth, USB) as expected for the era.

Other Features

HVAC:

Manual air conditioning and heating controls

Power Windows:

Optional on some models, typically manual windows on base trims

Central Locking:

Optional on some models

🔧 Maintenance

Service Intervals

Engine Oil Change Petrol:

Every 5,000 - 7,500 km or 6 months, whichever comes first (depending on driving conditions)

Engine Oil Change Diesel:

Every 5,000 km or 6 months (diesel engines generally require more frequent changes)

Air Filter Replacement:

Every 15,000 - 20,000 km or annually

Fuel Filter Replacement Diesel:

Every 10,000 - 15,000 km

Coolant Flush:

Every 2-3 years or 40,000-60,000 km

Transmission Fluid Change Atf:

Every 30,000 - 40,000 km (AT), Every 50,000 - 60,000 km (MT)

Spark Plugs Petrol:

Every 30,000 - 40,000 km (standard plugs), longer for platinum/iridium

Fluid Specifications

Engine Oil Petrol Viscosity:

API SG or higher, SAE 10W-30 or 5W-30 recommended (check manual for specifics)

Engine Oil Diesel Viscosity:

API CF or CD, SAE 15W-40 recommended (check manual for specifics)

Coolant Type:

Ethylene glycol-based coolant, typically green (Isuzu specified or equivalent)

Transmission Fluid Mt:

API GL-4 Gear Oil, SAE 75W-90 or 80W-90

Transmission Fluid At:

Dexron II or III ATF (Automatic Transmission Fluid)

Brake Fluid:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Issues Diesel:

Glow plug failure, injector pump issues, exhaust manifold cracking (turbo models), starter motor wear

Common Issues Petrol:

Oil leaks from valve cover gasket or oil pan, timing belt wear (if applicable to specific engine variant), ignition coil issues

Common Issues Suspension:

Ball joint wear, leaf spring fatigue, shock absorber degradation

Common Issues Electrical:

Corrosion in connectors, alternator or starter motor failure, window regulator issues

Common Issues Body:

Rust formation, especially in wheel wells and chassis rails; door lock actuator failure

📚 Vehicle History

Brand Heritage

Isuzu Lcab History:

Isuzu has a long history in producing robust and reliable commercial vehicles and pickup trucks, often known for their diesel engine technology.

Model Evolution

Kb Series Development:

The KB series evolved significantly over generations, with the TF representing a major update and modernization of the pickup truck platform.

Tf Series Introduction:

The TF series (also known as Rodeo in some markets) was introduced in the early 1990s and saw a facelift around 1995-1996, bringing updated styling and potentially new features.

Production

Global Markets:

Isuzu KB/TF was sold globally under various names, including Chevrolet Rodeo, Isuzu Faster, and others, depending on the region and OEM agreements.

Manufacturing Locations:

Primarily manufactured in Japan and Thailand, with assembly in other international locations.