ISUZU RODEO KB TF 140 1990-2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Isuzu Model: Rodeo KB TF 140 Product Type: Service Repair Manual 👋 Introduction Market Position Segment: Compact/Mid-size Pickup Truck / SUV (depending on specific configuration) Competitive Analysis Competitors Era: Ford Ranger, Toyota Hilux/Tacoma, Nissan Hardbody/Frontier, Mitsubishi Triton/L200, Mazda B-Series Key Features Utility: Durable construction, off-road capability (especially 4x4 variants), reliable powertrains, practical utility for work and recreation Value Proposition Manual Value: Essential for owners and independent mechanics to maintain and repair vehicles cost-effectively, prolonging vehicle life and ensuring optimal performance. 📋 Manual Details Coverage Areas Years Covered: 1990-2004 Page Count Estimated Pages: High (typically 1000+ pages for comprehensive manuals of this era) Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission control systems Drivetrain: Clutch, transmission (manual & automatic), transfer case, driveshafts, axles, differentials, wheel bearings Chassis: Suspension systems (front & rear), steering system, brake system (front & rear), anti-lock braking system (ABS) if applicable Electrical: Battery, charging system, starting system, lighting system, instrumentation, gauges, wipers, horn, power windows, power locks, audio system, ECU/ECM diagnostics and wiring diagrams Body And Frame: Body construction, interior trim, exterior trim, doors, windows, glass, bumpers, chassis frame and repair Climate Control: Heater core, A/C system (if equipped), blower motor, control panels, refrigerant system diagnostics. Procedures Included Maintenance: Routine maintenance procedures, fluid changes, filter replacements, lubrication, belt and hose inspection/replacement Repair: Component removal and installation, system diagnostics, troubleshooting, adjustments, and complete rebuild procedures Troubleshooting: Diagnostic charts, symptom-based troubleshooting, fault code identification and resolution Specifications And Tolerances: Torque specifications, clearances, wear limits, electrical resistance values, pressure readings Body Repair: Panel replacement, door alignment, glass installation, bumper repair/replacement, rust repair techniques. Technical Depth Depth: Comprehensive, covering all aspects from basic adjustments to complex engine and transmission overhauls Diagnostic Tools: Covers use of basic hand tools, specialized tools (e.g., for fuel injection systems, suspension), and OBD-I/OBD-II (if applicable for later models) diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text content for easy navigation Print Quality: Printable at home or professional print shop Accessibility: Instant download for immediate use Binding Type Binding: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Codes Common: C223, 4JA1, 4JB1, C240 (Diesel), G200, C22NE, C24NE (Petrol - availability may vary by market) Engine Variants Engine Displacements Common: 2.0L (2000cc), 2.2L (2180cc, 2200cc), 2.4L (2300cc, 2400cc) Performance Horsepower Range: Typically 70-100 HP for diesel, 90-120 HP for petrol (specific output varies by engine and tuning) Torque Range: Strong low-end torque, especially in diesel variants, crucial for towing and off-road. Fuel System Diesel Injection: Indirect Injection (IDI) or Direct Injection (DI) with mechanical or electronic fuel pumps Petrol Injection: Carbureted or Multi-point Fuel Injection (MPI) Cooling System Cooling Type: Liquid-cooled, pressurized system Lubrication System Oil Type Common: API CD/CE/CF for diesel, API SF/SG for petrol. Viscosity typically 10W-30 or 15W-40. 🔧 Transmission Standard Manual Transmission: Commonly available 4-speed or 5-speed manual transmissions Optional Automatic Transmission: Optional 3-speed or 4-speed automatic transmissions available on select models/trims Transfer Case 4Wd Transfer Case: Part-time 4WD system with manual or automatic locking hubs, and a 2-speed transfer case for low-range gearing on off-road variants. Fluid Specifications Manual Gearbox Oil: API GL-4 or GL-5, SAE 75W-90 or 80W-90 (check specific manual for exact specification) Automatic Transmission Fluid: Dexron II or Dexron III compatible ATF (check specific manual for exact specification) 📐 Dimensions Exterior Body Styles: Single Cab, Extra/Space Cab, Double Cab pickup trucks; Short Wheelbase (SWB) and Long Wheelbase (LWB) chassis for utility vehicles. Wheelbase Common: Approx. 2650mm (SWB), 3050mm (LWB) - specific to cab configuration and chassis Weights Curb Weight Range: 1300 kg - 1800 kg (depending on configuration, engine, and drivetrain) Towing Capacity: Varies significantly, typically 1000-2000 kg, check local regulations and specific model rating. 🛡️ Safety Features Ratings Crash Test Data: Limited official global crash test data available for this specific era and model, focus on structural integrity and basic safety features. Active Features Braking System: Front disc brakes, rear drum brakes. ABS was optional on higher trims or later models. Passive Features Seatbelts: Standard lap and shoulder belts for front occupants, lap belts for rear occupants. Airbags: Driver-side airbag became available on some later models, but not standard across all trims/years. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, cassette player, optional CD player on later or higher-spec models. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature, not standard across the range. Connectivity Connectivity Features: Very limited by modern standards, primarily focused on basic vehicle functions. No integrated Bluetooth or USB ports typically. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000 km - 7,500 km...
Compact/Mid-size Pickup Truck / SUV (depending on specific configuration)
Competitive Analysis
Competitors Era:
Ford Ranger, Toyota Hilux/Tacoma, Nissan Hardbody/Frontier, Mitsubishi Triton/L200, Mazda B-Series
Key Features
Utility:
Durable construction, off-road capability (especially 4x4 variants), reliable powertrains, practical utility for work and recreation
Value Proposition
Manual Value:
Essential for owners and independent mechanics to maintain and repair vehicles cost-effectively, prolonging vehicle life and ensuring optimal performance.
📋 Manual Details
Coverage Areas
Years Covered:
1990-2004
Page Count
Estimated Pages:
High (typically 1000+ pages for comprehensive manuals of this era)
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission control systems
Comprehensive, covering all aspects from basic adjustments to complex engine and transmission overhauls
Diagnostic Tools:
Covers use of basic hand tools, specialized tools (e.g., for fuel injection systems, suspension), and OBD-I/OBD-II (if applicable for later models) diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text content for easy navigation
Print Quality:
Printable at home or professional print shop
Accessibility:
Instant download for immediate use
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Codes Common:
C223, 4JA1, 4JB1, C240 (Diesel), G200, C22NE, C24NE (Petrol - availability may vary by market)
Typically 70-100 HP for diesel, 90-120 HP for petrol (specific output varies by engine and tuning)
Torque Range:
Strong low-end torque, especially in diesel variants, crucial for towing and off-road.
Fuel System
Diesel Injection:
Indirect Injection (IDI) or Direct Injection (DI) with mechanical or electronic fuel pumps
Petrol Injection:
Carbureted or Multi-point Fuel Injection (MPI)
Cooling System
Cooling Type:
Liquid-cooled, pressurized system
Lubrication System
Oil Type Common:
API CD/CE/CF for diesel, API SF/SG for petrol. Viscosity typically 10W-30 or 15W-40.
🔧 Transmission
Standard
Manual Transmission:
Commonly available 4-speed or 5-speed manual transmissions
Optional
Automatic Transmission:
Optional 3-speed or 4-speed automatic transmissions available on select models/trims
Transfer Case
4Wd Transfer Case:
Part-time 4WD system with manual or automatic locking hubs, and a 2-speed transfer case for low-range gearing on off-road variants.
Fluid Specifications
Manual Gearbox Oil:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 (check specific manual for exact specification)
Automatic Transmission Fluid:
Dexron II or Dexron III compatible ATF (check specific manual for exact specification)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extra/Space Cab, Double Cab pickup trucks; Short Wheelbase (SWB) and Long Wheelbase (LWB) chassis for utility vehicles.
Wheelbase Common:
Approx. 2650mm (SWB), 3050mm (LWB) - specific to cab configuration and chassis
Weights
Curb Weight Range:
1300 kg - 1800 kg (depending on configuration, engine, and drivetrain)
Towing Capacity:
Varies significantly, typically 1000-2000 kg, check local regulations and specific model rating.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official global crash test data available for this specific era and model, focus on structural integrity and basic safety features.
Active Features
Braking System:
Front disc brakes, rear drum brakes. ABS was optional on higher trims or later models.
Passive Features
Seatbelts:
Standard lap and shoulder belts for front occupants, lap belts for rear occupants.
Airbags:
Driver-side airbag became available on some later models, but not standard across all trims/years.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, cassette player, optional CD player on later or higher-spec models.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature, not standard across the range.
Connectivity
Connectivity Features:
Very limited by modern standards, primarily focused on basic vehicle functions. No integrated Bluetooth or USB ports typically.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 km - 7,500 km (3,000-5,000 miles) for petrol, 7,500 km - 10,000 km (5,000-6,000 miles) for diesel, depending on operating conditions.
Air Filter Replacement:
Every 15,000 km - 25,000 km (9,000-15,000 miles) or as needed based on environment.
Fuel Filter Replacement:
Every 20,000 km - 30,000 km (12,000-18,000 miles), especially critical for diesel engines.
Timing Belt Replacement:
If equipped with a timing belt (some petrol engines), typically every 80,000 km - 100,000 km (50,000-60,000 miles). Many diesel variants use timing chains.
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, typically a green or orange type (check manual for specific OAT/HOAT requirements if applicable).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation).
Power Steering Fluid:
Dexron II or III compatible ATF or specific power steering fluid (check manual).
Known Issues
Diesel Engines:
Glow plug reliability, injection pump seals, exhaust manifold cracks, head gasket failures (especially with overheating), turbocharger issues on turbocharged variants.
Rust on chassis and bodywork, U-joint wear, differential noise, front end suspension component wear (ball joints, tie rods), clutch wear, transmission synchro wear.
Electrical:
Wiring harness degradation, alternator and starter motor failures, gauge cluster issues.
📚 Vehicle History
Brand Heritage
Isuzu Legacy:
Isuzu has a long history in commercial vehicles, trucks, and SUVs, known for robust diesel engines and durability.
Model Evolution
Rodeokb Tf Generations:
The KB/TF platform represents a significant lineage of Isuzu pickups and SUVs, evolving from earlier models like the Faster/KB.
Production
Manufacturing Locations:
Primarily Japan, with significant production and assembly in various international markets through joint ventures or licensing (e.g., Thailand, South Africa, Australia).
🏆 Awards & Recognition
Recognitions
Reputation:
Known for durability and off-road prowess in many markets, particularly with diesel engines. Often lauded as a workhorse vehicle.