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Isuzu Pick-ups 1981-1993 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Isuzu Model: Pick-up Generation Model Generations Covered: Second Generation (KB/TF series) Codes Chassis Codes Covered: KB26, KB27, KB28 👋 Introduction Market Position Market Segment: Compact Pickup Truck (Light Commercial Vehicle) Competitive Analysis Key Competitors: Toyota Hilux, Nissan Datsun Truck, Mazda B-Series, Mitsubishi Mighty Max/L200 Key Features Vehicle Strengths: Reliability, durability, value for money, capable off-road performance (especially 4WD models), relatively simple mechanicals 📋 Manual Details Coverage Areas Geographic Coverage: Global (specific to models sold between 1981-1993) Page Count Estimated Page Count: 1500+ Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital (likely PDF, based on typical sales) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, cooling system, lubrication system, fuel injection/carburetion, ignition system, emissions control Transmission: Manual and Automatic transmission overhaul, clutch system, driveline, transfer case (4WD models) Brakes: Hydraulic system, disc and drum brake service, parking brake, ABS (if applicable to later models) Steering: Power steering system, manual steering rack/box, suspension components Electrical: Complete wiring diagrams, starter, alternator, battery system, lighting, instrumentation, accessories, fuse/relay identification Body And Chassis: Body panel repair, interior trim removal, chassis lubrication, frame straightening (basic) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, belt adjustments, spark plug replacement Repair: Component disassembly, reassembly, replacement, and adjustment for all covered systems Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (if applicable) Technical Specifications: Torque specifications, clearances, fluid capacities, pressure readings, electrical specifications Technical Depth Depth: Comprehensive workshop-level repair and overhaul procedures suitable for professional technicians and advanced DIY mechanics 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Resolution: High-resolution (typically 300 dpi for clarity of diagrams and text) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Codes And Types: G161Z (1.6L I4 Carbureted), C190 (1.9L I4 Carbureted), 4ZD1 (2.3L I4 Carbureted/EFI), 4ZE1 (2.6L I4 Carbureted/EFI) Performance Horsepower Range: 68 hp (G161Z) to 110 hp (4ZE1 EFI) Torque Range: 80 lb-ft (G161Z) to 150 lb-ft (4ZE1) Fuel System Fuel Delivery Methods: Carbureted (various models), Electronic Fuel Injection (EFI) on later/higher trims Engine Management Ignition System: Distributor-based ignition, electronic ignition on later models 🔧 Transmission Standard Manual Transmission: 4-speed and 5-speed manual transmissions Optional Automatic Transmission: 3-speed and 4-speed automatic transmissions available on select models Features Drivetrain Options: Rear-Wheel Drive (RWD) and Selectable 4-Wheel Drive (4WD) 📐 Dimensions Exterior Wheelbase Options: Short bed (approx. 102.4 in), Long bed (approx. 118.1 in) Body Styles: Standard Cab, Extended Cab (Space Cab) Weights Curb Weight Range: 2500 lbs - 3500 lbs (approx., depending on configuration) Towing Capacity: Varies by model and engine, typically 2000-4000 lbs 🛡️ Safety Features Ratings Crash Test Data: Limited official NHTSA/IIHS data for this era, general construction focused on basic structural integrity Active Features Braking System: Front disc brakes, rear drum brakes. Optional front ventilated discs on some higher trims. Passive Features Restraint Systems: Seat belts (lap and shoulder belts in front) 💡 Technology Features Infotainment Audio System: Factory AM/FM radio, optional cassette player. Basic analog controls. Driver Assistance Cruise Control: Optional on some higher trim levels Connectivity Auxiliary Inputs: N/A (Pre-modern connectivity era) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 miles or 6 months, depending on driving conditions Timing Belt Replacement: Refer to manual, typically 60,000-90,000 miles for interference engines (check specific engine code) Fluid Specifications Engine Oil Type: API SF or SG service category, SAE 10W-30 or 10W-40 (consult manual for specific viscosity based on temperature) Coolant Type: Ethylene glycol-based coolant (conventional green type), 50/50 mix with distilled water Transmission Fluid Manual: API GL-4 gear oil, SAE 75W-90 or 80W-90 Transmission Fluid Automatic: Dexron II or Dexron III ATF Brake Fluid Type: DOT 3 or DOT 4 brake fluid Known Issues Common Wear Items: Suspension bushings, ball joints, clutch wear, carburetor issues (older models), exhaust system rust, alternator and starter motor reliability Engine Specific Concerns: Head gasket leaks on some 4ZD1/4ZE1 engines under high mileage; carburetors require periodic tuning Rust Prone Areas: Wheel arches, rocker panels, cab corners, frame rails (especially in rust-belt regions) 📚 Vehicle History Brand Heritage Isuzu Truck History: Isuzu has a long history of producing robust commercial and light-duty trucks globally, known for their diesel engine expertise. Model Evolution Kb Series Development: The KB series represented Isuzu's entry into the compact pickup market, evolving from earlier models with improved styling and features. Production Manufacturing Locations: Primary production in Japan; also produced or assembled in various international markets under Isuzu or rebadged as other marques (e.g., Chevrolet LUV in some early years). Production Span: 1981-1993 for this specific generation 🏆 Awards & Recognition Recognitions Industry Awards: While specific awards for these models are scarce, Isuzu trucks of this era were widely recognized for their durability and value in the commercial and utility segments....
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Isuzu Pick-ups 1981-1993 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
Pick-up
Generation
Model Generations Covered:
Second Generation (KB/TF series)
Codes
Chassis Codes Covered:
KB26, KB27, KB28
👋 Introduction
Market Position
Market Segment:
Compact Pickup Truck (Light Commercial Vehicle)
Competitive Analysis
Key Competitors:
Toyota Hilux, Nissan Datsun Truck, Mazda B-Series, Mitsubishi Mighty Max/L200
Key Features
Vehicle Strengths:
Reliability, durability, value for money, capable off-road performance (especially 4WD models), relatively simple mechanicals
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (specific to models sold between 1981-1993)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, based on typical sales)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, cooling system, lubrication system, fuel injection/carburetion, ignition system, emissions control
Transmission:
Manual and Automatic transmission overhaul, clutch system, driveline, transfer case (4WD models)
Brakes:
Hydraulic system, disc and drum brake service, parking brake, ABS (if applicable to later models)
Steering:
Power steering system, manual steering rack/box, suspension components
Electrical:
Complete wiring diagrams, starter, alternator, battery system, lighting, instrumentation, accessories, fuse/relay identification
Body And Chassis:
Body panel repair, interior trim removal, chassis lubrication, frame straightening (basic)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, belt adjustments, spark plug replacement
Repair:
Component disassembly, reassembly, replacement, and adjustment for all covered systems
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (if applicable)
Technical Specifications:
Torque specifications, clearances, fluid capacities, pressure readings, electrical specifications
Technical Depth
Depth:
Comprehensive workshop-level repair and overhaul procedures suitable for professional technicians and advanced DIY mechanics
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Image Resolution:
High-resolution (typically 300 dpi for clarity of diagrams and text)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Codes And Types:
G161Z (1.6L I4 Carbureted), C190 (1.9L I4 Carbureted), 4ZD1 (2.3L I4 Carbureted/EFI), 4ZE1 (2.6L I4 Carbureted/EFI)
Performance
Horsepower Range:
68 hp (G161Z) to 110 hp (4ZE1 EFI)
Torque Range:
80 lb-ft (G161Z) to 150 lb-ft (4ZE1)
Fuel System
Fuel Delivery Methods:
Carbureted (various models), Electronic Fuel Injection (EFI) on later/higher trims
Engine Management
Ignition System:
Distributor-based ignition, electronic ignition on later models
🔧 Transmission
Standard
Manual Transmission:
4-speed and 5-speed manual transmissions
Optional
Automatic Transmission:
3-speed and 4-speed automatic transmissions available on select models
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Selectable 4-Wheel Drive (4WD)
📐 Dimensions
Exterior
Wheelbase Options:
Short bed (approx. 102.4 in), Long bed (approx. 118.1 in)
Body Styles:
Standard Cab, Extended Cab (Space Cab)
Weights
Curb Weight Range:
2500 lbs - 3500 lbs (approx., depending on configuration)
Towing Capacity:
Varies by model and engine, typically 2000-4000 lbs
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official NHTSA/IIHS data for this era, general construction focused on basic structural integrity
Active Features
Braking System:
Front disc brakes, rear drum brakes. Optional front ventilated discs on some higher trims.
Passive Features
Restraint Systems:
Seat belts (lap and shoulder belts in front)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio, optional cassette player. Basic analog controls.
Driver Assistance
Cruise Control:
Optional on some higher trim levels
Connectivity
Auxiliary Inputs:
N/A (Pre-modern connectivity era)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months, depending on driving conditions
Timing Belt Replacement:
Refer to manual, typically 60,000-90,000 miles for interference engines (check specific engine code)
Fluid Specifications
Engine Oil Type:
API SF or SG service category, SAE 10W-30 or 10W-40 (consult manual for specific viscosity based on temperature)
Coolant Type:
Ethylene glycol-based coolant (conventional green type), 50/50 mix with distilled water
Transmission Fluid Manual:
API GL-4 gear oil, SAE 75W-90 or 80W-90
Transmission Fluid Automatic:
Dexron II or Dexron III ATF
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Common Wear Items:
Suspension bushings, ball joints, clutch wear, carburetor issues (older models), exhaust system rust, alternator and starter motor reliability
Engine Specific Concerns:
Head gasket leaks on some 4ZD1/4ZE1 engines under high mileage; carburetors require periodic tuning
Rust Prone Areas:
Wheel arches, rocker panels, cab corners, frame rails (especially in rust-belt regions)
📚 Vehicle History
Brand Heritage
Isuzu Truck History:
Isuzu has a long history of producing robust commercial and light-duty trucks globally, known for their diesel engine expertise.
Model Evolution
Kb Series Development:
The KB series represented Isuzu's entry into the compact pickup market, evolving from earlier models with improved styling and features.
Production
Manufacturing Locations:
Primary production in Japan; also produced or assembled in various international markets under Isuzu or rebadged as other marques (e.g., Chevrolet LUV in some early years).
Production Span:
1981-1993 for this specific generation
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for these models are scarce, Isuzu trucks of this era were widely recognized for their durability and value in the commercial and utility segments.
Ratings
Reliability Perception:
Generally considered reliable and long-lasting with proper maintenance, especially the naturally aspirated diesel variants (though less common in US market for this specific generation of pick-up).
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