Ford TRADER Page 886 Workshop Manual Download

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Summary of Contents for TRADER

Page 1: ...TRADER Workshop Manual ...

Page 2: ...ECTION OF THE VEHICLE GI 4 A WORD ABOUT SAFETY GI 5 PREPARATION OF TOOLS AND MEASURING EQUIPMENT GI 5 SPECIAL TOOLS GI 5 REMOVAL OF PARTS GI 5 DISASSEMBLY GI 5 REASSEMBLy GI 6 ADJUSTMENTS GI 7 RUBBER PARTS AND TUBING GI 7 JACK AND SAFETY STAND RIGID RACK POSiTIONS GI 8 TOWiNG GI 9 IDENTIFICATION NUMBER LOCATIONS GI 9 UNITS GI 10 ABBREViATIONS GI 10 CAUTION GI 11 ELECTRICAL TROUBLESHOOTING TOOLS GI...

Page 3: ...e jeopardized by the use of incorrect methods or tools POSSIBLE LOSS OF WARRANTY The manufacturer s warranty on Ford vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Ford Dealer WARNING ON LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils especially used oils Used oils contaminated during se...

Page 4: ...htening torques and symbols for oil grease and sealant are shown in the overview illustration 3 Pages related to service procedures are shown under the illustration Refer to this information when ser vicing the related part Example SHOWS EXPENDABLE PARTS SHOWS APPLICATION n 07 7 4 10 Sot 1IJ p 1 Ji SHOWS TIGHTENING TORQUE SPECIFICATION 2 POINT OF OIL _ J ETC L_ __ ________ dlSHOWS TIGHTENING TORQU...

Page 5: ...ed this is shown in the illustration NOTES CAUTIONS AND WARNINGS As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially c...

Page 6: ... sure that al necessary tools and measuring equipment are available before starting any work SPECIAL TOOLS Use special tools when they are required REMOVAL OF PARTS While correcting a problem try also to determine its cause Begin work only after first learning which parts and subassem blies must be removed and disassembled for replacement or repair DISASSEMBLY If the disassembly procedure is compl...

Page 7: ...carefully and thorotJghly cleaned in the appropriate method REASSEMBLY Standard values such as torques and certain adjustments must be strictly observed in the reassembly of all parts Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text If removed these parts should be replaced with new ones 1 Oil seals 2 Gaskets 3 a rings 4 Lock wash...

Page 8: ...AMENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and or testers when making adjustments 67UOGX 002 RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing 9MUGIX OOS GI 7 ...

Page 9: ...TIONS FRONT END Jack position At the center of the front axle REAR END Jack position At the center of differential GI 8 9TFGIX 2 9TGGIX 6 Safety stand positions On both sides of the front axle 9TGGIX Q03 Safety stand positions Spring clamps at both sides of the differential 9TGG1X 007 ...

Page 10: ... axle and steering system are not damaged the vehicle may be towed on all four wheels If they are damaged use a towing dolly Caution The gearshift lever must be set a NEUTRAL the en gine key in the ACC position and the parking brake released Remember that power brake assist will not be available when the engine is inoperative IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER YIN ENGINE...

Page 11: ... Accessories ASS Y Assembly ATDC After top dead center ATF Automatic transmission fluid BBDC Before bottom dead center BTDC Before top dead center CAB Cabin ECU Engine control unit ELR Emergency locking retractor EX Exhaust FIG Figure IGIIGN Ignition IN Intake INT Intermittent LH Left hand M Motor MAX Maximum MIN Minimum OFF Switch off OHV Overhead valve ON Switch on PCV Positive crankcase ventila...

Page 12: ...harnesses or electronic com ponents Voltmeter The DC voltmeter is used to measure of circuit voltage A volt meter with a range of 15V or more is used by connecting the positive probe red lead wire to the point where voltage is to be measured and the negative probe black lead wire to a body ground Diagnosis Connector Insert the probe into the service hole when connecting a jum per wire to the diagn...

Page 13: ...nectors Removal of connector Never pull on the wiring harness when disconnecting con nectors Connectors can be removed by pressing or pulling the lock le er as shown _ Locking of connector When locking connectors make sure to listen for a click that will indicate they are securely Iocked Inspection 1 When a tester is used to check for continuity or to measure voltage insert the tester probe from t...

Page 14: ...res to check that they are secured in the terminal Replacement of terminals Use the appropriate tools to remove the terminal as shown When installing the terminal be sure to insert it until it locks securely Female Insert a thin piece of metal from the terminal side of the con nector and then with the terminal locking tab pressed down pull the terminal out from the connector Male Same as the femal...

Page 15: ...e base color of the wire and the sec ond the color of the stripe CODE COLOR CODE COLOR B Black 0 Orange BR Brown P Pink G Green R Red GY Gray V Violet L Blue W White LB LiQht Blue Y Yellow LG Light Green INSTALLATION OF MOBILE TWO WAY RADIO SYSTEM If a mobile two way radio system is installed improperly or if a high powered type is used the control unit may be affected When the vehicle is to be eq...

Page 16: ...PRE DELIVERY INSPECTION AND SCHEDULED MAINTENANCE PRE DELIVERY INSPECTION TABLE A 2 SCHEDULED MAINTENANCE SERVICES A 3 9TGOAX 101 A I ...

Page 17: ... All lights including warning and indicator lights if equipped o Warning buzzers if equipped o Horn windshield wipers and washers if equipped o Radio and antenna if equipped o Cigarette lighter and clock if equipped o Tilt Steering if equipped o Heater defroster and air conditioner at various modes if equipped ADJUST antenna trimmer on radio Of equipped A 2 INTERIOR cont d CHECK the following item...

Page 18: ...stances only 2 If the vehicle is operated in very dusty or sandy areas clean or replace more often than at usual recom mended itervals 3 See page A 21 for detailed information Emission Control and Related Systems The ignition and fuel systems are vitally important to the proper operation of the emissions control and relat ed systems as well as for efficient engine operation It is strongly recommen...

Page 19: ...R I I Clutch fluid I I I R I I Brake and clutch pedals I I I I I I Drum brake I I I Power brake unit and hoses I I I Vacuum tank and hoses Diesel I I I I I I Parking brake I I I I I I Manual steering gear oil I I I Steering operation and gear housing I I I Power steering fluid and lines if equipped I I I I I I Manual transmission oil R I R I R I R Transmission linkage cables I I I Rear axle oil R ...

Page 20: ...usty or sandy areas clean or replace more often than at usual recom mended itervals 3 See page A 21 for detailed information Emission Control and Related Systems The ignition and fuel systems are vitally important to the proper operation of the emissions control and relat ed systems as well as for efficient engine operation It is strongly recommended hat all serving related to these systems be don...

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Page 22: ... clutch pedals I I I I I I I Drum brake I I I Power brake unit and hoses I I I Vacuum tank and hoses I I I I I I Parking brake I I I I I I I Manual steering gear oil I I I I Steering operation and gear housing I I I I I I I Power steering fluid and lines if equipped I I I I I I Manual transmission oil R I R I R I R Transmission linkage cables I I I I Rear axle oil R I R I R I R Propeller shaft L L...

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Page 24: ...spection of injection timing 9TFOAX 004 9TGOB2 457 9TGOB2 019 ADJUSTMENT OF ENGINE VALVE CLEARANCE 1 Remove the air intake pipe SL Turbo 2 Remove the seal cover SL TF and the cylinder head cover 3 Remove the cover from the clutch housing HA SL or from the end plate TF 4 Turn the crankshaft clockwise and set the No 1 cylinder to compression TOC 5 Measure the valve clearances as shown in the figure ...

Page 25: ... 0 3 4 N m 20 35 em kg 17 30 in Ib 9TGOB2 22 9TFOAX 06 A 8 12 Install the seat cover SL TF Tightening torque 2 9 4 9 N m 30 50 em kg 26 43 in Ib 13 Install the air intake pipe SL Turbo Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib TIGHTENING OF CYLINDER HEAD BOLTS Note SL TF The cylinder head bolts are pliant type bolt There fore retightening after installation is not necessary_ HA 1 Tight...

Page 26: ...e undercover for inspection of the PIS belt 2 Check the drive belts for wear cracks and fraying Replace if necessary 3 Verify that the drive belts are correctly mounted on the pulleys 4 Check the drive belt deflection by applying moderate pres sure 98 N 10 kg 221b midway between the pulleys as shown Adjust if necessary Deflection mm 0n New Used HA Alternator 9 0 10 0 0 35 0 39 10 0 11 0 0 39 0 43 ...

Page 27: ...flection at the midpoint of new belt specification 1 Alternator belt i HA SL TF 20A Loosen alternator bolts A and S and adjust the belt deflection Tightening torque A 19 25 N m 1 9 2 6 m kg 14 19 ft Ib B 37 52 N m 3 8 5 3 m kg 27 38 ft Ib ii TF 40A Loosen the locknut and adjust the belt deflection by turn ing the adjusting bolt Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib 2 PIS belt Loosen...

Page 28: ...L and F marks on the level gauge represents 2 0 liters 2 11 US qt 1 76 Imp qt 6 Refit the oil filler cap 7 Run the engine and check for leaks a Stop the engine and check the oil level Add oil if necessary 9TGOAX 017 0 10 20 30 40 50 20 40 60 80 100 120 30 40 2OW 2O 10W 30 OSUODX Q04 Anticipated ambient temperature range before succeeding oil change C oF REPLACEMENT OF OIL ALTER 1 Remove the oil fi...

Page 29: ...d the cap before removing it When removing the radiator cap loosen it slowly to the first stop until the pressure in the radiator is released and then remove it 9TFOAX 014 Coolant level Engine cola 1 Verify that the coolant level is near the coolant inlet port 2 Verify that the coolant level in the coolant reservoir is be tween the FULL and LOW marks Add coolant if necessary Coolant quality 1 Veri...

Page 30: ...5 1 078 05UOEX o10 REPLACEMENT OF ENGINE COOLANT Warning Never open the radiator cap while the engine is hot Wrap a thick cloth around the cap before loosen ing it Use caution when draining hot coolant Caution Do not use alcohol or methanol based coolant Use only soft demineralized water in the coolant mixture 1 Remove the radiator cap and loosen the drain plug 2 Drain the coolant into a suitable ...

Page 31: ...e new fuel filter 3 Install the new fuel filter and tighten it fully by hand 4 Additionally tighten the fuel filter with a fuel filter wrench 1 3 turns 5 Bleed air in the filter 6 Start the engine and check for fuel leakage INSPECTION OF AIR CLEANER ELEMENT Visually check that the element for excessive dirt damage or oil Clean or replace it if necessary Note When cleaning first blow dust from insi...

Page 32: ...the feeler of the measuring device is in contact with the plunger end at this time Note The SST specified by Diesel KikiCo Ltd is 157829 3520 4 Turn the flywheel to set the flywheel to approx 300 BTDC and find the position in which the needle of the dial gauge does not move when the flywheel is turned 5 When the dial gauge needle does not deflect set the nee dle to 0 on the scale 6 Turn the flywhe...

Page 33: ...Remove the service hole covers from the clutch housing and the timing gear case 2 Turn the flywheel in the direction of rotation until the indica tor pin is at 30 BTDC 3 Verify that the pointer of the timing gear case and the mark on the timer are aligned 4 If not as specified adjust the injection timing Adjustment 1 Remove the fuel stop cable from the cut lever 2 Remove the accelerator cable from...

Page 34: ...om the barrel Note If the delivery valve is lifted up without breaking it loose the barrel may also be lifted out of the pump If this happens the barrel may not reseal and may allow fuel into the engine and cause engine damage 8 Remove the delivery valve holding the flat washer with tweezers caution Do not pinch the sliding surface of the delivery valve 9 Reinstall the delivery valve holder 10 Tig...

Page 35: ...ps SL Non turbo 12 BTOC SL Turbo 13 BTOC TF 11 BTOC 14 If necessary adjust the injection timing by loosening the pump mounting bolts and rotating the pump outward or in ward as shown in the figure When advanced turn to right seen from front When retarded turn to left seen from front 15 Tighten the mounting nuts Tightening torque 34 39 N m 3 5 4 0 m kg 25 29 ft Ib 16 Mark the pump flange and pump b...

Page 36: ...ution The nozzle tester should be set up in a clean work place 9TGOAX 034 SHIM 9TGOF2 100 r 9TAOAX 029 Injection starting pressure 1 Connect the nozzle to a nozzle tester 2 Pump the nozzle tester handle and note the pressure when injection is started Injection starting pressure HA engine 13 244 13 734 kPa 135 140 kg cm2 1 920 1 991 psi SL engine New nozzle 17 168 kPa 175 kg cml 2 489 psi Used nozz...

Page 37: ... the nozzle tester in the non functioning condition quickly lower the handle lower the handle as quickly as possible so that a pulsating whistling sound can be heard Repeat this operation several times and check the atomizing condition 4 Make sure that the fuel is atomized uniformly and properly 5 Make sure that the injection angle and direction are normal 6 If the atomizing condition is incorrect...

Page 38: ...f the pedal pad to the dash panel is as specified Pedal height 226 231 mm 8 90 9 09 in Adjustment 1 Disconnect the stoplight switch connector 2 Loosen locknut and turn switch until it does not con tact the pedal 3 Loosen locknut and turn rod to adjust the height 4 Turn the stoplight switch until it contacts the pedal then turn an additional 1 2 turn Tighten locknut 5 Check the pedal play and stopH...

Page 39: ...lems Air in brake system Too much shoe clearance INSPECTION OF POWER BRAKE UNIT AND HOSES 1 Check the vacuum hoses connectors and check valve for cracks chafing deterioration etc 2 Check the power brake for proper operation To check de press the brake pedal several times to make sure the ped al travel does not change Then while depressing brake pedal start the engine At this time the pedal should ...

Page 40: ...on 1 Depress the clutch pedal by hand until resistance is felt Pedal free play 0 5 2 7mm 0 02 0 11 in Total pedal free play 5 0 11 0mm 0 20 0 43 in 2 If necessary adjust the pedal free play Adjustment 1 Loosen locknut C and turn push rod D until pedal free play is correct 2 Verify that the disengagement height from the upper sur face of the pedal to the floor panel is correct when the pedal is ful...

Page 41: ...gging INSPECTION OF MANUAL STEERING GEAR OIL LEVEL 1 Remove the filler plug 2 Insert a scale through the oil filler hole 3 Pull out the scale and measure the L dimension Add the specified gear oil if necessary Standard L dimension 10mm 0 39 in Specified gear oil API service GL 4 Viscosity SAE90 INSPECTION OF STEERING LINKAGE TIE ROD ENDS AND ARMS 1 Check the steering linkage for looseness and dama...

Page 42: ...from filler plug 3 Wipe clean and apply sealant to the plug threads before installing the plug Tightening torque 33 51 N m 3 4 5 2 m kg 25 38 ft lb Replacement 1 Remove the drain plug and drain the oil into a suitable con tainer 2 Wipe clean and apply sealant to the plug threads 3 Install the drain plug Tightening torque 33 51 N m 3 4 5 2 m kg 25 38 ft Ib 4 Add the specified oil from the filler pl...

Page 43: ...w washer and tighten the oil filler plug Tightening torque 39 54 N m 4 0 5 5 m kg 29 40 ft Ib Replacement 1 Remove the magnetic plug and drain the differential oil 2_ Clean the magnetic plug 3 Install a new washer and tighten the magnetic plug Tightening torque 39 54 N m 4 0 5 5 m kg 29 40 ft Ib 4 Remove the oil filler plug and fill the differential with the speci fied oil Specified oil Type Above...

Page 44: ...etween the bearings in the hub 3 Apply lithium grease NLGI No 2 to the oil seal lip use new oil seals LUBRICATION OF PROPELLER SHAFT JOINTS Lubricate each part with the specified grease through the nipples Nipples Grease NLGI No 2 Disulphide molybdenum grease INSPECTION OF WHEEL LUG NUT Check the tightening torque Tightening torque Single rear tire Item N m m kg ft Ib Front 167 215 Rear 17 22 123 ...

Page 45: ...PREPARATION B 56 PROCEDURE 8 56 D1SASSEMBLY B 58 PREPARATION 8 58 CYLINDER HEAD 8 60 CYLINDER BLOCK EXTERNAL PARTS I 8 65 CYLINDER BLOCK EXTERNAL PARTS II B 69 CYLINDER BLOCK INTERNAL PARTS 8 72 INSPECTION I REPAIR 8 76 CYLINDER HEAD B 76 VALVE MECHANiSM 8 76 ROCKER ARM ASSEMBLy 8 79 CYLINDER BLOCK 8 80 PISTON PISTON RING AND PISTON PIN 8 81 CONNECTING ROD 8 83 CRANKSHAFT 8 84 BEARING 8 85 CAMSHAF...

Page 46: ...0 0 35 0 39 10 0 11 0 0 39 0 43 COMPRESSION STANDARD PIS 9 0 11 0 0 35 0 43 12 0 13 0 0 47 0 51 INSPECTION PAGE B 8 ADJUSTMENT PAGE 8 9 1 Cylinder head gasket Replacement page B 21 2 Front oil seal Replacement page 8 28 3 Rear oil seal Replacement page B 31 B 2 2 943 kPa 30 0 kglcm2 427 psi 200 rpm INSPECTION PAGE 8 18 4 Engine 9TFOax 002 Removal page 8 33 Engine stand mounting page 8 56 Disassemb...

Page 47: ...1 Cylinder head gasket Replacement page B 21 2 Front oil seal Replacement page B 28 3 Rear oil seal Replacement page B 31 INTAKE MANIFOLD TIGHTENING TORQUE 16 24 N m 1 6 2 4 m kg 12 17 ft Ib COMPRESSION STANDARD NON TURBO 2 943 kPa 30 0 kglcm2 427 psi 300 rpm TURBO 2 551 kPa 26 0 kglcm 2 370 psi 320 rpm INSPECTION PAGE 8 18 9TFOBX 003 4 Engine Removal page B 33 Engine stand mounting page B 56 Disa...

Page 48: ...ront oil seal Replacement page B 28 3 Rear oil seal Replacement page 8 31 8 4 roM_ N EXHAUST MANIFOLD TIGHTENING TORQUE 44 48 N m 4 5 4 9 m kg 33 35 tt Ib INTAKE MANIFOLD TIGHTENING TORQUE 19 23 N m 1 9 2 3 m kg 14 17 tt Ib j STANDARD 2 943 kPa 30 0 kglcm2 427 psi 270 rpm INSPECTION PAGE 9TFOBX 004 4 Engine Removal page B 33 Engine stand mounting page 8 56 Disassembly page 8 58 Inspection Repair p...

Page 49: ...mm in EX 0 30 0 012 0 35 0 014 0 40 0_016 9TGOB2 QOS TROUBLESHOOTING GUIDE Problem Possible Cause Action Page Difficult starting Malfunction of engine related components Burned valve Replace B 76 Worn piston piston rings or cylinder Repair or replace 8 80 81 Failed cylinder head gasket Replace B 21 Malfunction of fuel system Refer to Section F Malfunction of electrical system Refer to Section G Po...

Page 50: ...rbon Malfunction of fuel system Refer to Section F Engine noise Crankshaft or bearing related parts Excessive main bearing oil clearance Repair or replace 8 92 Main bearing seized or heat damaged Replace B 85 Excessive crankshaft end play Repair or replace 8 94 Excessive connecting rod bearing oil clearance Repair or replace 8 95 Connecting rod bearing seized or heat damaged Replace 8 85 Piston re...

Page 51: ... or replace oil as necessary Note The distance between the Land F marks on the level gauge represents 2 0 liters 2 11 US qt 1 76 Imp qt ENGINE COOLANT Inspection Coolant level engine cold Warning Never remove the radiator cap while the engine is hot Wrap a thick cloth around the cap before removing it 1 Verify that the coolant level is near the coolant inlet port 2 Verify that the coolant level in...

Page 52: ... deflection by applying moderate pres sure 98 N 10 kg 221b midway between the pulleys as shown Adjust if necessary Deflection mm in New Used HA Alternator 9 0 10 0 0 35 0 39 10 0 11 0 0 39 0 43 PIS 9 0 11 0 0 35 0 43 12 0 13 0 0 47 0 51 SL Alternator 9 0 10 0 0 35 0 39 10 0 11 0 0 39 0 43 PIS 9 0 11 0 0 35 0 43 12 0 13 0 0 47 0 51 TF Alternator 10 0 11 0 0 39 0 43 11 0 12 0 0 43 0 47 5 Check the d...

Page 53: ...n the locknut and adjust the bett deflection by turn ing the adjusting bolt Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib 2 PIS belt Loosen PIS oil pump bolts A B and C and adjust the belt deflection Tightening torque A 37 52 N rn 3 8 5 3 m kg 27 38 ft Ib B 37 52 N m 3 8 5 3 m kg 27 38 ft Ib C 37 52 N m 3 8 5 3 m kg 27 38 ft lb VALVE CLEARANCE Inspection I Adjustment 1 Remove the air intake...

Page 54: ... mm in EX 0 30 0 012 0 35 0 014 OAO 0 016 adjust the valve clear 12 17 N m 120 170 em kg 104 148 in Ib 8 Turn the crankshaft clockwise one full turn and set the No 4 cylinder to compression TDe 9 Measure the remaining valve clearances as shown in the figure 10 Install the cover 11 Install the cylinder head cover Tightening torque 2 0 3 4 N m 20 35 em kg 17 30 in Ib 12 Install the seal cover SL TF ...

Page 55: ...tip of the feeler of the measuring device is in contact with the plunger end at this time Note The SST specified by Diesel Kiki Co Ltd is 157829 3520 5 Turn the flywheel and set to approx 300 BTDC 6 Find the position in which the needle of the dial gauge does not move when the flywheel is turned 7 When the dial gauge needle does not deflect set th e I ee die to 0 on the scale 8 Turn the flywheel u...

Page 56: ...stall the new head bolt and new gasket SL TF Engine Inspection Caution Direct injection type engine is sensitive to injection timing Incorrect timing will cause engine knocking or low power output Set the injection timing after installation of the in jection pump Note Usually it is enough to confirm that the external marks are aligned 1 Remove the blind covers from the clutch housing and the timin...

Page 57: ...ery valve body 7 Rock the delivery valve to break it loose from the barrel Note If the delivery valve is lifted up without breaking it loose the barrel may also be lifted out of the pump If this happens the barrel may not reseal and may allow fuel into the engine and cause engine damage 8 Remove the delivery valve holding the flat washer with tweezers caution Do not pinch the sliding surface of th...

Page 58: ... direction of rotation and verify that fuel flow stops as specified Fuel stops SL Non Turbo 120 BTOC SL Turbo 130 BTOC TF 11 0 BTOC 14 If necessary adjust the injection timing by loosening the pump mounting bolts and rotating the pump outward or in ward as shown in the figure When advanced tum to right seen from front When retarded turn to left seen from front 15 After adjustment tighten the mount...

Page 59: ...ming gear case 25 Bleed air from the system Refer to page B 16 26 Start the engine and check for fuel leaks IDLE SPEED Adjustment 1 Attach suitable reflector tape to the crankshaft pulley 2 Run the engine at idle to normal operating temperature 3 Turn OFF all electrical loads 4 Confirm the free play of the accelerator cable Free play 1 3mm 0 04 0 12 in 5 Aim the light of the photo tachometer onto ...

Page 60: ...NG HA Engine Warning Keep sparks cigarettes and open flames away from the fuel area 1 Remove the air bleeder plug 2 Pump the priming pump until clear no air bubbles fuel flows from the bleeder plug hole 3 Install the air bleeder plug 4 loosen the overflow pipe connector of the injection pump 5 Pump the priming pump until fuel flows from the pipe 6 Tighten the overflow pipe connector Tightening tor...

Page 61: ...ug 2 Pump the priming pump until no air is expelled 3 Tighten the air bleeder plug Tightening torque 5 9 8 8 N m 60 90 em kg 52 78 in Ib 4 Loosen the return pipe at the injection pump and pump the priming pump until no air is expelled 5 Tighten the bolt Tightening torque 12 15 N m 120 150 cm kg 104 130 in Ib 6 Push the priming pump down and tighten it 7 Loosen the injection pipes at the injection ...

Page 62: ... check the following 1 Compression 2 Fuel system Refer to Section F INSPECTION 1 Verify that the battery is fully charged Recharge it if necessary Refer to Section G 2 Warm up the engine to normal operating temperature 3 Turn the engine OFF 4 Remove all the fuel injection nozzles Refer to Section F 5 Connect a compression gauge with the SST to the No 1 cylinder injection nozzle hole 6 Prevent fuel...

Page 63: ... kg cm2 43 psi max 9TG082 059 9 If the compression in one or more cylinders is low pour a small amount of engine oil into the cylinder and recheck the compression 1 If the compression increases the piston piston rings or cylinder wall may be worn 2 If the compression stays low the valve may be stuck or seating improperly 3 If the compression in adjacent cylinders stays low the cylinder head gasket...

Page 64: ...h disc 8 20 E9D For installation of front oil seal For prevention of engine rotation For prevention of engine rotation For installation of rear oil seal For installation of clutCh disc 49 W011 102 Installer oil seal TF 498501 062 Collar HA 49 W011 103 Brake ring gear TF 49 G030 797 Handle TF For installation of front oil seal For prevention of engine rotation For prevention of engine rotation For ...

Page 65: ... the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal referring to Installation Note Steps After Installation 1 Fill the radiator with the specified amount and type of engine coolant Refer to Section E 2 Connect the negative battery cable 3 Check as follows 1 Engine oil and engine coolant leakage 2 Compression Refer to page 8 18 3 Drive belt deflection ...

Page 66: ...uel filter body 9 Fuel pipe 10 Intake manifold assembly 11 Cylinder head cover 8 22 ON VEHICLE MAINTENANCE 20 25 2 0 2 5 14 18 1 9 2 6 14 19 N m m kQ ft lb 9TFOBX 12 12 Cylinder head bolt Removal Note page B 23 Installation Note page 8 23 13 Rocker arm assembly 14 Push rod Installation Note page B 23 15 Cylinder head Disassembly page B 60 Inspection page B 76 Assembly page 8 113 16 Cylinder head g...

Page 67: ... of the push rods are properly set in to the tappets Cylinder head bolt Caution Verify that the rocker arms and push rods are properly engaged while tightening 1 Apply clean engine oil to the bolt threads and seat faces 2 Install the cylinder head bolts 3 Tighten the cylinder head bolts in two or three steps in the order shown in the figure Tightening torque 116 123 N m 11 8 12 5 m kg 85 90 ft Ib ...

Page 68: ... cover 6 Oil level gauge and guide pipe 7 Injection pipe and fuel hose 8 Fuel filter body 9 Upper radiator hose 10 Heater hose 11 Vacuum hose 12 Front exhaust pipe 8 24 N m m kg tt lb 9TFOBX 14 13 Turbocharger Turbo Service Section F 14 Cylinder head bolt Removal Note page B 25 Installation Note page B 25 15 Rocker arm assembly 16 Push rod Installation Note page B 25 17 Cylinder head Disassembly p...

Page 69: ...in 150 7 151 3mm 5 933 5 957 in Maximum 123 0mm 4 843 in 152 0mm 5 984 in Caution Verify that the rocker arms and push rods are properly engaged while tightening 2 Apply clean engine oil to the bolt threads and seat faces 3 Install the cylinder head bolts 4 Tighten the cylinder head bolts in two or three steps in the order shown in the figure Tightening torque 59 N m G O m kg 43 ft Ib 5 Make paint...

Page 70: ...diator hose 11 Heater hose 12 Front engine hanger 8 26 19 25 1 9 2 6 14 19 2 0 3 4 N m 20 35 em kg 17 30 in Ib O RING I 22 30 2 2 3 1 16 22 N m m kg ft lb 9TFOBX 16 13 Vacuum pipe 14 Cylinder head bolt Removal Note page 8 27 Installation Note page 8 27 15 Rocker arm assembly 16 Push rod Installation Note page 8 27 17 Cylinder head Disassembly page 8 60 Inspection page 8 76 Assembly page 8 113 18 C...

Page 71: ...0 2 130 8mm 5 126 5 150 in 158 2 158 8mm 6 228 6 252 in Maximum 131 5mm 5 177 in 159 5mm 6 280 in Caution Verify that the rocker arms and push rods are properly engaged while tightening 2 Apply clean engine oil to the bolt threads and seat faces 3 Install the cylinder head bolts 4 Tighten the cylinder head bolts in two or three steps in th order shown in the figure Tightening torque 54 Nm 5 5 m kg...

Page 72: ... 1 Disconnect the negative battery cable 2 Remove the undercover 3 Drain the engine coolant 4 Remove in the order shown in the figure referring to Removal Note 5 Install in the reverse order of removal referring to Installation Note 9TGOB2 083 Steps After Installation 1 Fill the radiator with the specified amount and type of engine coolant Refer to Section E 2 Install the undercover _ 3 Connect th...

Page 73: ...Removal Note HA page 8 30 Adjustment page 8 9 Installation Note page 8 30 4 Cooling fan 9TGOB2 086 Removal note Crankshaft pulley Caution Perform this operation with the aid of a helper 1 Remove the cover from the clutch housing HA SL or from the end plate TF 2 Set a suitable tool against the flywheel ring gear for preven tion of engine rotation 3 Remove the pulley bolt HA SL or nut TF 4 Remove th...

Page 74: ...n until it is 6 5mm 0 26 in inside the edge of the timing gear cover 3 Tap the oil seal in evenly with the SST HA TF or a suita ble pipe SL and a hammer Crankshatt pulley 1 Apply dean engine oil to the bolt threads and seat faces HA SL 2 Install the crankshaft pulley 3 Install the bolt or nut and washer Caution Perform this operation with the aid of a helper 4 Hold the flywheel and tighten the pul...

Page 75: ...tion Note Steps After Installation 1 Connect the negative battery cable 2 Start the engine and perform engine adjustments as necessary 1 Transmission RED HA 1n 196 18 0 20 0 130 145 SL TF 206 226 21 0 23 0 152 166 I REPLACE I 3 Flywheel B Nom m kg ft Ib 9TFOSX 020 Service Section J Removal Note page 8 32 2 Clutch cover clutch disc Installation Note page 8 32 Service Section H 4 Oil seal Installati...

Page 76: ...nd caution The oil seal must be tapped in until it is flush with the edge of the rear oil seal cap 3 Tap the oil seal in evenly with the SST TF or a suitable pipe HA SL and a hammer Flywheel 1 Apply clean engine oil to the bolt threads and seat faces 2 Set the flywheel onto the crankshaft and loosely install the bolts 3 Hold the flywheel with the SST 4 Tighten the bolts in two or three steps in th...

Page 77: ...ine assembly For removal of engine assembly 490259770B Wrench flare nut SLTurbo 490636000B Transmission lifter 11 i F 49 W017 303 Arm Part of 49 W017 3AO 1 D sconnect the negative battery cable 2 Remove the undercover 3 Drain the engine coolant 4 Remove in the order shown in the figure referring to Removal Note B For disconnection of clutch hose For removal of engine assembly For removal of engine...

Page 78: ... PIS oil pump 9 34 9TG062 102 REMOVAL 9TF08X 021 5 Tie rod Removal Note page 8 34 6 Accelerator cable Tie rod 1 Remove the cotter pin and loosen the nut 2 Separate the tie rod end from the knuckle with the SST 3 Remove the nut and tie rod Caution Do not reuse the cotter pin ...

Page 79: ...REMOVAL Step 2 1 Disconnect the harness connectors shown in the figure Step 3 1 Disconnect the hoses shown in the figure VACUUM HOSE VACUUM PUMP B 9TGOB2 098 9TG0B2 099 8 35 ...

Page 80: ...he hose with a rag because fuel will spray out when disconnecting Plug the disconnected hoses to avoid fuel leakage 1 Disconnect the fuel hoses 9TFOBX 022 5 Sub select cable Removal Note page 8 37 2 Exhaust shutter valve 6 Clutch release cylinder 3 Front exhaust pipe 4 Shift select cable 7 Speedometer cable 8 Propeller shaft Service Section L 8 36 ...

Page 81: ... note Parking brake cable 1 Remove stop ring A and pin B B 2 Remove the parking brake rear cable from the frame Step 5 9TFOBX Q23 1 Engine support bracket 2 Engine and transmission assembly Removal Note page 8 38 B 37 ...

Page 82: ...els and the ground is at least 1 m 3_3 ft 2 Tilt cabin Support the engine with a hoist Non tilt cabin Support the engine with the SST 3 Remove the control cable holder 4_ Remove the right engine mount 5 Remove the left engine mount 6 Support the engine and transmission assembly with the SST 7 Remove the transmission mount bracket 8 Remove the engine and transmission assembly ...

Page 83: ...REMOVAL Step 6 1 Disassemble in the order shown in the figure 1 Fuel hose 4 Transmission 2 Starter 5 Engine 3 Transmission mounting bolt I ct B 9TG0B2 109 8 39 ...

Page 84: ...ep 1 1 Air intake hose 2 Radiator cowling 3 Radiator hose 4 Drive belt 5 Cooling fan 8 40 REMOVAL CD 9TF08X 024 6 PIS oil pump Removal Note page 8 41 7 Accelerator cable 8 Fuel stop cable 9 Exhaust manifold insulator ...

Page 85: ... PIS oil pump Caution 00 not damage the hoses B 1 Remove the PIS oil pump with the hoses still connected 2 Position the pump away from the engine and affix it with wire 1 Disconnect the harness connectors shown in the figure 9TGOB2 111 8 41 ...

Page 86: ...X 78 8 42 REMOVAL HEATER HOSE Removal note Fuel hose Warning FUEL HOSE 9TGOB2 112 Keep sparks and open flame away from the fuel area Caution Cover the hose with a rag because fuel will spray out when disconnecting Plug the disconnected hoses to avoid fuel leakage 1 Disconnect the fuel hoses ...

Page 87: ...___ _ _ __ page 8 44 2 Exhaust shutler valve 3 Front exhaust pipe 4 T urbocharger Turbo Service Section F 5 Shift select cable 7 Clutch release cylinder Removal Note page 8 44 8 Speedometer cable 9 Tie rod Removal Note page 8 44 10 Propeller shaft Service _ Section L 6_ Sub select cable B 43 ...

Page 88: ...g brake rear cable from the frame Clutch release cylinder Non Turbo 1 Remove the clutch release cylinder Turbo 1 Disconnect the clutch hose with the SST Tie rod 1 Remove the cotter pin and loosen the nut 2 Separate the tie rod end from the knuckle with the SST 3 Remove the nut and tie rod Caution Do not reuse the cotter pin ...

Page 89: ...Removal Note page 8 45 9TGOB2 118 Removal note Engine support bracket 1 Raise the vehicle and support it on safety stands so that the distance between all wheels and the ground is at least 1 m 3 3 ft 2 Tilt cabin Support the engine with a hoist Non tilt cabin Support the engine with the SST 8 45 ...

Page 90: ...VAL 3 Remove the control cable holder 4 Remove the right engine mount 5 Remove the left engine mount 6 Support the engine and transmission assembly with the SST 7 Remove the transmission mount bracket 8 Remove the engine and transmission assembly ...

Page 91: ...REMOVAL B Step 6 1 Disassemble in the order shown in the figure 9TFOBX Q28 1 Fuel hose 2 Starter 4 Transmission 5 Engine 3 Transmission mounting bolt 8 47 ...

Page 92: ...X 29 Removal Note page 8 49 2 Radiator hose upper 8 Radiator hose lower 9 Alternator 3 Radiator cowling upper 4 Cooling fan 5 Drive belt 6 Water pump pulley 7 Radiator cowling lower Removal Note page 8 49 10 PIS oil pump Removal Note page 8 49 11 Accelerator cable 12 Fuel stop cable 13 Exhaust manifold insulator 8 48 ...

Page 93: ...sconnect the intake manifold elbow Alternator B 1 Disconnect the oil hose and vacuum hose shown in the figure 2 Remove the alternator strap 3 Remove the alternator PIS oil pump Caution Do not damage the hoses 1 Remove the PIS oil pump with the hoses still connected 2 Position the pump away from the engine and affix it with wire 8 49 ...

Page 94: ...B REMOVAL Step 2 1 Disconnect the harness conn ectors shown in the figure Step 3 1 Disconnect the hoses shown in the figure OIL HOSE VACUUM PUMP 8 50 J 9TG0B2 129 9TGOB2 130 ...

Page 95: ...fuel will spray out when disconnecting Plug the c iisconnected hoses to avoid fuel leakage 1 Disconnect the fuel hoses I GASKET REPLACE 6 Clutch release cylinder conER PIN REPLACE 9TFOBX 03O Removal Note page 8 52 7 Speedometer cable 2 Exhaust shutter valve 3 Front exhaust pipe 8 Tie rod Removal Note page 8 52 4 Shift select cable 9 Propeller shaft 5 Sub select cable Service Section L 8 51 ...

Page 96: ...emove stop ring A and pin B 2 Remove the parking brake rear cable from the frame Tie rod 1 Remove the cotter pin and loosen the nut 2 Separate the tie rod end from the knuckle with the SST 3 Remove the nut and tie rod Caution Do not reuse the cotter pin ...

Page 97: ...oval Note page 8 53 9TGOB2 135 Removal note Engine support bracket 1 Raise the vehicle and support it on safety stands so that the distance between all wheels and the ground is at least 1 m 3 3 ft 2 Tilt cabin Support the engine with a hoist Non tilt cabin Support the engine with the SST 8 53 ...

Page 98: ...139 REMOVAL 3 Remove the control cable holder 4 Remove the right engine mount 5 Remove the left engine mount 6 Support the engine and transmission assembly with the SST 7 Remove the transmission mount bracket 8 Remove the engine and transmission assembly ...

Page 99: ...REMOVAL B Step 6 1 Disassemble in the order shown in the figure 5 9TGOB2 140 1 Fuel hose 4 Transmission 2 Starter 5 Engine 3 Transmission mounting bolt 8 55 ...

Page 100: ...sembly of engine 490636007 Body 49 W06S 006 Attachment set SL TF 49 W06S 008 Collar B Part of 49 W065 006 PROCEDURE HA SL Engine j 8 S q 1 Remove the breather pipe SL For disassembly assembly of engine For disassembly assembly of engine For disassemblyl assembly of engine 9TGOB2 141 2 Remove the exhaust manifold and gasket 3 Remove the alternator and alternator bracket 4 Remove the right engine mo...

Page 101: ...B TF Engine 1 Remove the exhaust manifold and gasket 2 Disconnect the oil hose 3 Remove the right engine mount 4 Install the SST engine hanger to the holes shown in the figure 5 Mount the engine on the SST engine stand 8 57 ...

Page 102: ...uides installer valve guide HA For 49 V101 060A For removal of valve prevention of guides Brake ring gear engine rotation HA SL For 49 W065 062 For prevention of prevention of engine rotation Collar SL engine rotation For 490559210 For prevention of prevention of engine rotation Oil seal installer injection pump and centering gear rotation tool HA For 490223061 For prevention of removal of piston ...

Page 103: ...rs cylinder liner TF O 1 Code all identical parts such as pistons piston rings con necting rods and valve springs so that they can be reinstalled in the cylinder from which they were removed 2 Clean the parts with a steam cleaner Blow off any remaining water with compressed air Note During disassembly of any part or system be sure to study its order of assembly Also note any deformation wear or da...

Page 104: ...linder head bolt Disassembly Note page 8 61 13 Cylinder head Inspection page 8 76 14 Cylinder head gasket 15 Rocker arm assembly Inspection page 8 79 8 60 9TFOBX 032 16 Push rod 17 Valve cap 18 Valve keeper Disassembly Note page 8 61 19 Valve spring seat upper 20 Valve spring outer and inner Inspection page 8 79 21 Valve spring seat lower 22 Valve Inspection page 8 76 23 Valve seal Disassembly Not...

Page 105: ...inst the upper valve spring seat as shown in the figure 2 Remove the valve keepers Valve seal 1 Remove the valve seal with the SST Valve guide Caution If the valve guide is removed it must be replaced with a new one 1 Measure height A of each valve guide Height A 15 2 15 4mm 0 598 0 606 in 2 If height A is not wIThin specification replace the valve guide 3 Remove the valve guide from the side oppo...

Page 106: ...TGOB2 160 B 62 DISASSEMBLY Combustion chamber insert 1 Inspect the combustion chamber insert for damage and cracks 2 If necessary remove the insert with a suitable mandrel tap ping through the nozzle hole ...

Page 107: ...6 Injection nozzle and nozzle holder 7 Fuel filter body 18 Valve spring outer and inner Inspection page 8 79 8 Intake manifold assembly 19 Valve spring seat lower 9 Water outlet housing 20 Valve 10 Cylinder head bolt Inspection page 8 76 Disassembly Note page 8 64 11 Cylinder head 21 Valve seal Disassembly Note page 8 64 Inspection page 8 76 Inspect for wear or damage 12 Cylinder head gasket 13 Ro...

Page 108: ...the SST against the upper valve spring seat as shown in the figure 2 Remove the valve keepers Valve seal 1 Remove the valve seal with the SST Valve guide caution If the valve guide is removed it must be replaced with a new one 1 Measure height A of each valve guide Height A 14 2 14 4mm 0 559 0 567 in 2 If height A is not within specification replace the valve guide 3 Remove the valve guide from th...

Page 109: ...ote page 8 66 2 Clutch cover clutch disc Service Section H 3 Flywheel Disassembly Note page 8 66 Inspect for wear or damage 4 End plate 5 Left engine mount O RING REPLACE v 6 Water inlet pipe 7 Water pump 9TF09X 034 Service Section E 8 Rear oil seal cap 9 Rear oil seal 10 Oil filter 11 Oil cooler Service Section D 12 Oil pressure switch 8 65 ...

Page 110: ...U ley Ii r _ 2 Loo ywheel with th 111119 _1 iJ R 3 sen the p 11 e SST 0 Remove the IOu ey lock bolt _ Y ck bolt wash er and crankshaft pulley ____ _ ____ 1 Flywheel 1 Hold the flywh Loosen the fl eel with the SST Remove the twheel lock bolts ock bolts washers and fl ywheel 49 V101 060A 9TGOB2 170 8 66 ...

Page 111: ...Water pipe racket 3 Alternator b ulley page 8 68 4 Crankshaft p Note Disassembl lutch disc Section H Clutch cover 5 Service page 8 68 6 Flywheel bly Note Disassem r or damage Inspect for wea 7 PCV chamber 8 Oil pipe 9 Fuel pipe 10 Oil filter Od ount Left engine 8 67 11 ...

Page 112: ...embly Note Crankshaft pulley 1 Hold the flywheel with the SST 2 Loosen the pulley locknut 3 Remove the locknut washer and crankshaft pulley Flywheel 1 Hold the flywheel with the SST 2 Loosen the flywheel lock bolts 3 Remove the lock bolts washers and flywheel ...

Page 113: ...ction D 7 Timing gear cover 8 Front oil seal Disassembly Note page 8 70 9 Lock plate HA 10 Friction gear HA 9TF08X 36 11 Injection pump gear HA 12 Lock plate 13 Friction gear 14 Camshaft gear 15 Thrust plate 16 Idler gear 17 Idler gear spindle 18 Oil deflector 19 Friction gear spring 20 Friction gear 21 Crankshaft timing gear 22 Fuel injection pump Service Section F 23 Timing gear case 8 69 ...

Page 114: ... center bolt 9TFOBX 37 10 Timing gear cover 11 Friction gear spring Service Section D 12 Friction gear 3 Oil pressure switch 4 Seal plate 5 Stiffener 6 Oil pan Inspect for cracks deformation and damage 7 Oil strainer 8 Stiffening plate 9 Timing gear cover insulator 8 70 13 Idler gear 14 Idler gear spindle 15 Camshaft gear and friction gear Djsassembly Note page 8 71 16 Water pump 17 Timing gear ca...

Page 115: ...OISASSEMBLY B Disassembly Note Camshaft gear and friction gear 1 Hold the camshaft gear with the SST 2 Remove the camshaft gear lock bolt 3 Remove the friction gear 4 Remove the camshaft gear B 71 ...

Page 116: ...n clip 6 Piston pin Disassembly Note page 8 74 Inspection page 8 83 7 Piston Inspection page 8 81 8 Main bearing cap Disassembly Note page 8 75 8 72 9TFOBX 038 9 Crankshaft Disassembly Note page 8 75 Inspection page 8 84 10 Main bearing Inspection page 8 85 11 Thrust bearing 12 Camshaft thrust plate 13 Camshaft Inspection page 8 85 14 Tappet Inspection page 8 87 15 Cylinder liner Disassembly Note ...

Page 117: ...14 Camshaft thrust plate 5 Connecting rod bearing In pection page 8 85 15 Camshaft Inspection page 8 85 6 Piston ring 16 Tappet Disassembly Note page 8 74 Inspection page 8 87 Inspection page 8 82 7 Piston pin clip 17 Cylinder liner DiSassembly Note page 8 75 8 Piston pin Inspection page 8 80 Disassembly Note page 8 74 Inspection page 8 83 18 Oil jet Inspection page 8 87 9 Piston 19 Cylinder block...

Page 118: ... journals Caution Do not scratch the crankpin journal or the cylinder liner Protect the connecting rod bolts with rubber sleeves to prevent damage to the crankpin journal 3 Use the handle of a hammer to remove the piston and con necting rod assembly through the top of the cylinder block Piston ring Caution Do not apply excessive tension which may cause a ring to break 1 Remove the piston rings wit...

Page 119: ...aring cap bolts in two or three steps in the order shown in the figure 3 Remove the main bearing caps Crankshaft 1 Before removing the crankshaft measure the main bear ing oil clearances Refer to page B 92 Cylinder liner 1 Markthe cylinder liner and the cylinder block for proper reas sembly Note If necessary remove the cylinder liner with the SST 2 Remove the cylinder liner by hand 8 75 ...

Page 120: ...asure the cylinder head distortion in the six directions shown in the figure Distortion 0 10mm 0 004 in max 0 25mm 0 010 in max 3 If the cylinder head distortion exceeds specification replace the cylinder head 4 Measure the manifold contact surface distortion in the four directions shown in the figure Distortion 0 10mm 0 004 in max 5 If distortion exceeds specification replace the cylinder head VA...

Page 121: ...e outer diameter of the valve stem from the in ner diameter of the corresponding valve guide to calculate the valve stem to guide clearance Clearance mm in Standard Maximum HA IN 0 038 0 078 0 0015 0 0031 EX 0 058 0 098 0 0023 0 0039 0 127 0 0050 SL IN 0 038 0 068 0 0015 0 0027 TF EX 0 058 0 088 0 0023 0 0035 7 If the clearance exceeds specification replace the valve and or valve guide Valve Seat ...

Page 122: ... L mm in IN EX HA 48 05 1 892 48 05 1 892 SL 48 05 1 892 47 95 1 888 TF 48 40 1 906 48 40 1 906 1 If dimension L is as below no correction needed IN EX HA 48 05 48 55 1 892 1 911 48 05 48 55 1 892 1 911 SL 48 05 48 55 1 892 1 911 47 95 48 45 1 888 1 907 TF 48 40 48 90 1 906 1 925 48 40 48 90 1 906 1 925 9TG0B2 199 2 If dimension L is as below adjust with washer on spring seat area of cylinder head...

Page 123: ... 2 343 58 5 2 303 EX Inner 51 4 2 024 50 4 1 984 Outer 59 5 2 343 58 5 2 303 Out of square mm in max Outer Inner HA IN 1 37 0 0539 1 25 0 0492 EX 1 37 0 0539 1 25 0 0492 SL Non IN 1 85 0 0728 1 63 0 0642 Turbo EX 1 85 0 0728 1 63 0 0642 SL IN 1 85 0 0728 1 63 0 0642 Turbo EX 1 96 0 0772 1 72 0 0677 TF IN 2 07 0 0815 1 79 0 0705 EX 2 07 0 0815 1 79 0 0705 ROCKER ARM ASSEMBLY 1 Check for wear or dam...

Page 124: ...er block in the six directions shown in the figure Distortion 0 10mm 0 004 in max 0 25mm 0 010 in max 3 If the distortion exceeds specification replace the cylinder block 4 Measure each cylinder liner bore in X and Y directions at three levels upper middle and lower as shown Cylinder liner bore diameter mm in Mark Bore diameter HA 98 500 98 526 3 8779 3 8790 SL A 103 500 103 513 4 0748 4 0753 B 10...

Page 125: ...place it with one with the same mark A or B and verify that it agrees with the mark on the cylinder block 8 If the difference between measurements of the cylinder lin er exceeds the maximum taper replace the cylinder liner Taper 0 03mm 0 0012 in max 9 If the difference between measurements X and Y of the cyl inder liner exceeds the maximumout of round replace the cylinder liner Out of round O 03mm...

Page 126: ...he piston diameter from the cylinder liner inner diameter to calculate the piston to cylinder liner clearance Clearance mm in HA 0 032 0 083 0 0013 0 0033 SL 0 050 0 076 0 0020 0 0030 TF 0 058 0 084 0 0023 0 0033 5 If the clearance exceeds specification replace the piston and or the cylinder liner 9TGOB2 216 Piston and Piston Rings 1 Measure the piston ring to ring land clearance around the entire...

Page 127: ...each piston pin bore diameter in X and Y direc tions at four points Diameter mm in HA 29 996 30 008 1 1809 1 1814 SL 33 996 34 008 1 3384 1 3389 TF 34 996 35 008 1 3778 1 3783 2 Measure each piston pin diameter in X and Y directions at four points Diameter mm in HA 29 994 30 000 1 1809 1 1811 SL 33 993 34 000 1 3383 1 3386 TF 34 993 35 000 1 3777 1 3780 3 Calculate the piston pin to piston clearan...

Page 128: ...x 100 3 94 CRANKSHAFT 1 Check the journals and pins for damage scoring and oil hole clogging 2 Set the crankshaft on V blocks 3 Measure the crankshaft runout at the center journal Replace the crankshaft if necessary Runout 0 05mm 0 0020 in max 4 Measure each journal diameter in X and Y directions at two points Main journal diameter mm in HA SL 75 805 75 825 2 9844 2 9852 TF I No 1 2 4 5 78 980 79 ...

Page 129: ... 3 0892 0 762 0 0300 No 1 2 4 5 78 218 78 238 3 0794 3 0802 undersize NO 3 78 192 78 212 3 0784 3 0792 9TG0B2 230 Crankpin journal diameter undersize mm in Bearing size Journal diameter 0 254 0 0100 60 858 60 871 2 3960 2 3965 undersize HA 0 508 0 0200 60 604 60 617 2 3860 2 3865 SL undersize 0 762 0 0300 60 350 60 363 2 3760 2 3765 undersize 0 254 0 0100 63 733 63 746 2 5092 2 5097 undersize TF 0...

Page 130: ... 2 2898 2 2909 No 3 57 910 57 940 2 2799 2 2811 No 4 57 660 57 690 2 2701 2 2713 6 Measure the camshaft bore diameters in X and Y directions shown Diameter mm in No 1 52 000 52 030 2 0472 2 0484 HA No 2 51 750 51 780 2 0374 2 0386 SL NO 3 51 500 51 530 2 0276 2 0287 No 4 51 250 51 280 2 0177 2 0189 No 1 58 500 58 530 2 3031 2 3043 TF No 2 58 250 58 280 2 2933 2 2945 No 3 58 000 58 030 2 2835 2 284...

Page 131: ...nce Standard 0 055 0 101 mm 0 0022 0 0040 in Maximum 0 1Smm 0 006 in 5 If the clearance exceeds the maximum replace the tappet and or cylinder block OIL JET 1 Push the check ball and verify that it moves smoothly 2 Blow through the oil jet and veri fy that air flows IDLER GEAR 1 Measure the idler gear inner diameter Diameter 44 009 44 034mm 1 7326 1 7336 in 2 Measure the idler gear spindle outer d...

Page 132: ...tion of rear oil seal Extractor HA For 49 S120 710 installation of front oil seal Holder coupling frange TF For 49 V101 060A installation of front oil seal Brake ring gear HA SL For 49 W06S 062 prevention of engine rotation Collar SL For 49 SE01 310 prevention of engine rotation Centering tool clutch disc For 49 L012 001 installation of valve guides and Installer valve seals Part of 49 L012 OAO E ...

Page 133: ... Spacer valve seals Part of Part of 49 L012 OAO 49 L012 OAO 490636100A For 490107222A For JL installation of installation of Arm valve spring valves Pivot valves lifter 9TG082 241 1_ Clean all parts before reinstallation 2 Apply new engine oil to all sliding and rotating parts 3_ Replace bearings if they are peeling burned or otherwise damaged 4 Tighten ali bolts and nuts to the specified torques ...

Page 134: ...AL PARTS HA SL Engine Torque Specifications 11 HA 16 24 1 6 2 4 12 17 SL 19 25 1 9 2 6 14 19 12 18 Nom ASSEMBLY 120 180 em kg 104 156 in lb B 90 HA 108 115 11 0 11 7 8D 85 Sl 98 105 10 0 10 7 72 77 Nom m Icg ft lb 9TGOB2 243 ...

Page 135: ...AL NEW i 88 9 0 65 ii LOOSEN THE NUTS iii 34 3 5 25 900 12 18 N m 120 180 crn kg 104 156 in Ib Oil Jet 1 Install the oil jets t 1f 0 tP I i 118 12 0 87 ii LOOSEN THE BOLT iii 44 J4 5 33 900 N m m kg ft Ib 9TGOB2 244 Tightening torque Ib 12 18 N m 120 180 em kg 104 156 m 8 91 ...

Page 136: ...Ib SL TF 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Crankshaft 1 Before installing the crankshaft inspect the main bearing oil clearances as follows 1 Remove all foreign material and oil from the journals and bearings Caution Install the no grooved main bearing in the No 3 cen ter main bearing cap Install the thrust bearings with the oil groove fac ing the crankshaft 2 Install the upper main bearings and ...

Page 137: ...mQn Standard Maximum HA SL 0 058 0 092 0 0023 0 0036 0 12 0 005 TF I No 1 2 4 5 0 058 0 092 0 0023 0 0036 0 12 0 005 I No 3 0 084 0 118 0 0033 0 0046 0 15 0 006 2 Apply a liberal amount of clean engine oil to the main bear ings thrust bearings and main journals 3 Install the crankshaft and the main bearing caps accord ing to the cap number and I mark 4 Tighten the main bearing cap bolts in two or ...

Page 138: ...ecting rod bolts with rubber sleeves to prevent damage to the crankpin journal 1 Install one piston pin clip into the clip groove in the piston 2 Assemble the piston and the connecting rod so that the pis ton combustion chamber cutout and the connecting rod mark are faces at the same side 3 Heat the piston to 50 60 C 122 140 F 4 Apply clean engine oil to the piston pin 5 Install the piston pin fro...

Page 139: ...k the piston rings for correct end gap alignment 16 Insert each piston assembly into the cylinder block with the marks Y or Z facing the front of the engine Use a piston ring compressor commercially available 17 Remove the rubber sleeves from the connecting rod bolts 18 Measure the connecting rod bearing oil clearance Caution Align the marks on the cap and the connecting rod when insta1l1ng the co...

Page 140: ...0 074 0 0015 0 0029 TF 0 040 0 076 0 0016 0 0030 Maximum 0 10mm 0 004 in 19 Apply a liberal amount of clean engine oil to the connect ing rod bearings and crankpin journals 20 Install the connecting rod bearings and caps with the marks aligned and tighten the nuts in two or three steps Tightening torque HA SL 80 88 N m 8 2 9 0 m kg 59 65 ft Ib TF 88 N m 9 0 m kg 65 ft Ib 21 TF Engine i Loosen the ...

Page 141: ... Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 2 Apply a small amount of clean engine oil to the lip of the new oil seal 3 Install the oil seal with the SST and a hammer CYLINDER BLOCK EXTERNAL PARTS n HA SL Engine Torque Specifications 19 25 1 9 2 6 14 19 HA ENGINE 19 25 1 9 2 6 14 19 N m m I g ft Ib 9TGOB2 271 8 97 ...

Page 142: ... Crankshaft Timing Gear 1 Align the Woodruff key and install the crankshaft gear 2 Install the friction gear friction gear spring and oil deflector Idler Gear 1 Install the idler gear spindle 2 Align the marks and install the idler gear and thrust plate Tightening torque HA 23 31 N m 2 3 3 2 m kg 17 23 ft Ib SL 19 25 N m 1 9 2 6 m kg 14 19 ft Ib camshaft Gear and Injection Pump Gear 1 Align the ma...

Page 143: ...tion The oil seal must be pressed in until it is 6 5mm 0 26 in inside the edge of the timing gear cover 4 Press the oil seal in evenly with the SST HA or a suitable pipe SL and a hammer Oil Pump 1 Apply clean engine oil to the oil pump driven gear 2 Install the oil pump Tightening torque 37 53 N m 3 8 5 4 m kg 27 39 ft IP Oil Strainer and Oil Pipe 1 Install the oil strainer and a new gasket Tighte...

Page 144: ...applied 1 Apply silicone sealant as shown to the shaded areas of a new oil pan gasket front and rear 2 Install the gaskets onto the cylinder block 3 Apply silicone sealant to the shaded areas of the cylinder block 4 Install the oil pan upper block and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Oil Pan 1 Install the oil pan and a new gasket 2 Install the stiffener Tightening ...

Page 145: ... 9 2 6 14 19 9TGOB2 287 7 8 11 N m 80 110 em kg 69 95 in Ib 19 25 1 9 2 6 14 19 12 18 NofTI 120 180 em kg 104 156 in Ib GASKET NEW 19 25 1 9 2 6 14 19 tkn m Icg tt lb 9TGOB2 286 Oil Pump 1 Apply engine oil to the rotor then install the oil pump and a new gasket Tightening torque 19 25 N rn 1 9 2 6 m kg 14 19 ft Ib 8 101 ...

Page 146: ...ooler and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Timing Gear case 1 Install the timing gear case Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 2 Apply silicone sealant as shown to the shaded areas of the timing gear case and the cylinder block Water Pump 1 Install the water pump and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib ...

Page 147: ... block oil hole 3 Install the idler gear as shown in the figure 4 Install the friction plate and washer to the cam gear and affix them with the SST 5 Install and tighten the lock bolt Tightening torque 63 93 N m 6 4 9 5 m kg 46 69 ft Ib 6 Install the idler gear and thrust plate Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 8 103 ...

Page 148: ...njection pump Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Timing Gear Cover 1 Install tDe timing gear cover and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Stiffening Plate 1 Install the stiffening plate Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Oil Strainer 1 Install the oil strainer and a new gasket Tightening torque 7 8 11 Nom 80 110 em kg 69 95 in Ib ...

Page 149: ...Install new O rings on the bolts 2 Install a new gasket 3 Install the oil pan 4 Install the stiffener and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 5 Install the seal plate Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib B 8 105 ...

Page 150: ... 19 25 1 9 2 6 14 19 22 f NEW 16 23 1 6 2 3 12 17 22 30 HA ENGINE HA 32 47 3 3 4 8 24 35 SL 37 52 3 8 5 3 27 38 19 25 1 9 2 6 14 19 Oil Pressure Switch 1 Install the pressure switch Tightening torque HA 177 196 18 0 20 0 1300 145 SL 206 226 21 0 23 0 152 166 1 9 2 6 14 19 Nom m kg ft Ib 9TGOB2 307 r 12 18 N m 120 180 cm kg 104 156 in Ib 9TGOB2 308 B 106 ...

Page 151: ...cap and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 2 Apply a small amount of clean engine oil to the lip of the new oil seal 3 Push the oil seal slightly in by hand Caution The oil seal must be pressed in until it is flush with the edge of th rear oil seal cap 4 Press the oil seal in evenly with a suitable pipe and a hammer Water Pump 1 Install the water pump and a new gaske...

Page 152: ...d loosely install the bolts 3 Hold the flywheel with the SST 4 Tighten the bolts in two or three steps in the order shown in the figure Tightening torque HA 177 196 N m 18 0 20 0 m kg 130 145 ft Ib SL 206 226 N m 21 0 23 0 m kg 152 166 ft Ib Clutch Disc and Clutch Cover 1 Install the clutch disc and the clutch cover using the SST Refer to Section H Tightening torque 18 26 N m 1 8 2 7 m kg 13 20 ft...

Page 153: ...EW 206 226 21 0 23 0 152 166 19 25 1 9 26 14 19 _ 1 o 100 130t m 1 W v 87 113 in lb II CD __________21 9 2 1 9 1 r 100 130 cm kg 87 113 in lb En glne Mount 1 Install the left engine mount 19 25 1 9 2 6 14 19 Tightening torque 31 46 N m 3 2 47 mk g 23 34 ft Ib 9TGOB2 320 8 109 ...

Page 154: ...ning torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Injection Pump Oil Pipe 1 Install the injection pump oil pipe Tightening torque 9 8 13 N m 100 130 em kg 87 113 in Ib 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Fuel Pipe 1 Install the fuel pipe Tightening torque 9 8 13 N m 100 130 em kg 87 113 in Ib PCV Chamber 1 Install the PCV chamber Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib ...

Page 155: ...two orthree steps in the order shown in the figure Tightening torque 206 226 N m 21 0 23 0 m kg 152 166 ft Ib Clutch Disc and Clutch Cover 1 Install the clutch disc and the clutch cover with the SST Refer to Section H Tightening torque 18 26 N m 1 8 2 7 m kg 13 20 ft Ib Crankshaft Pulley 1 Install the crankshaft pulley 2 Hold the flywheel with the SST 3 Install the washer and locknut Tightening to...

Page 156: ...new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Alternator Bracket 1 Install the alternator bracket Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib Vacuum Pipe 1 Install the vacuum pipe Tightening torque 9 8 13 N m 100 130 em kg 7 113 in Ib 8 112 ...

Page 157: ...H Specifications Torque 2 9 m 30 50 C e 19 25 1 9 2 6 4 4 6 4 N m 56 in lb m 26 43 in Ib 1 6 2 4 12 17 HA 16 24 14 19 25 1 9 2 6 SL 19 51 27 37 37 50 3 8 5 14 18 20 25 2 0 2 5 34 40 46 54 4 7 5 19 25 1 9 2 6 14 19 7 8 11 N m 8 69 95 in Ib 0 110 cm kg B ...

Page 158: ...er with a punch Valve Guide 1 Assemble the SST so that depth L is as specified Depth L 15 2 1S 4mm 0 598 0 606 in 2 Tighten the locknut 3 Tap the valve guide in from the side opposite the combus tion chamber until the SST contacts the cylinder head 4 Verify that the valve guide height is within specification Height 15 2 15 4mm 0 598 0 606 in 5 If not within specification repeat Steps 1 4 Valve Sea...

Page 159: ...pring with the SST 5 Install the valve keepers 6 Remove the SST 7 Tap the end of the valve stem lightly two or three times with a plastic hammer to verify that the keepers are all fully seated 8 Install the valve caps Cylinder Head Gasket 1 Remove all foreign material from the deck of the cylinder block 2 Place the new cylinder head gasket in position Cylinder Head 1 Install the cylinder head asse...

Page 160: ...52 0mm 5 984 in Ca tion Verify that the rocker arms and push rods are oR erly engaged while tightening 8 Apply clean engine oil to the bolt threads and seat faces 9 Install the cylinder head bolts 10 Tighten the bolts in two or1hree steps in the order shown in the figure Tightening torque HA 116 123 N m 11 8 12 5 85 90 ft Ib SL 59 N m 6 0 m kg 43 ft Ib 11 SL Engine 1 Make paint marks on the bolt h...

Page 161: ...14 19 ft Ib Intake Manifold Assembly 1 Install the intake manifold assembly and a new gasket Tightening torque HA 16 24 N rn 1 6 2 4 m kg 12 17 ft Ib SL 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Engine Hanger 1 Install the front right engine hanger Tightening torque 37 52 N rn 3 8 5 3 m kg 27 38 ft Ib 2 Install the front left engine hanger Tightening torque 64 89 N rn 6 5 9 1 m kg 47 6 Jl lb __ Oil Level...

Page 162: ...ghtening torque 46 54 N m 4 7 5 5 m kg 34 40 ft Ib Injection Pipe 1 Install the injection pipe Tightening torque 20 25 N m 2 0 2 5 m kg 14 18 ft Ib 2_ Install the injection pipe clip Tightening torque 4 4 6 4 N m 45 65 em kg 39 56 iMb Injection Pump Oil Pipe SL 1 Install the injection pump oil pipe_ Tightening torque 24 35 N m 2 4 3 6 m kg 17 26 ft Ib I B 9 8 13 N m 100 130 em kg 87 113 i n Ib c 1...

Page 163: ...LY 4 5 6 5 N m 46 66 em kg 40 57 in Ib J ct cV a i I i a i 22 30 2 2 3 1 16 22 Valve Guide B 20 25 2 0 2 5 14 18 N m m kg ft Ib 9TGOB2 36C 1 Assemble the SST so that depth L is as specified Depth L 14 2 14 4mm 0 559 0 567 in 2 Tighten the locknut 8 11 ...

Page 164: ...559 0 567 in 5 If not within specification repeat Steps 1 4 Valve Seal 1 Assemble the SST so that depth L is as specified Depth L 15 5 15 9mm 0 610 0 626 in 2 Slide the valve seal onto the valve guide 3 Set the SST against the valve seal Caution Do not use a hammer 4 Press the valve seal on until the SST contacts the cylinder head Valve Valve Spring and Valve Spring Seat 1 Install the lower spring...

Page 165: ... position Cylinder Head 1 Install the cylinder head assembly 2 Apply clean engine oil to the push rod 3 Install the push rods Caution Verify that the ends of the push rods are properly set in to the tappets 4 Apply clean engine oil to the rocker arms and shaft 5 Assemble the rocker arms springs and shaft 6 Install the rocker arm and shaft assembly onto the cylinder head 7 Measure the length of the...

Page 166: ...ightening torque 54 N m 5 5 m kg 40 ft Ib 11 Make paint marks on the bolt heads as shown in the figure 12 With the paint marks as a reference point tighten the cylin der head bolts another 90 15 in the tightening order 13 Tighten the bolts once again 90 150 in the tightening order 14 Adjust the valve clearance Refer to page 8 9 Water Outlet Housing 1 Install the water outlet housing Tightening tor...

Page 167: ...ening torque 46 54 N m 4 7 5 5 m kg 34 40 ft Ib Injection Pipe 1 Install the injection pipe Tightening torque 25 29 N m 2 5 3 0 m kg 18 22 ft Ib 2 Install the injection pipe clip Tightening torque 4 4 6 4 N m 45 65 em kg 39 56 in Ib 8 Oil Level Gauge and Guide Pipe 1 Apply clean engine oil to a new a ring and install the oil level gauge guide pipe Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft ...

Page 168: ...B ASSEMBLY Seal Cover 1 Install the seal cover Tightening torque 2 0 3 4 N m 20 35 em kg 17 30 in Ib 2 Install the filler cap 8 124 ...

Page 169: ...ket Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib 3 Install the alternator Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 37 52 N m 3 8 5 3 m kg 27 38 ft Ib 4 Install the right engine mount Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft Ib 5 Install the exhaust manifold and a new gasket Tightening torque HA 26 32 Nom 2 7 3 3 m kg 20 24 ft Ib SL 23 26 N m 2 3 2 7 m kg 17 20 ft Ib 6 ...

Page 170: ...B ENGINE STAND DISMOUNTING 2 Connect the oil hose 3 Install the exhaust manifold and a new gasket Tightening torque 44 48 N m 4 5 4 9 m kg 33 35 ft Ib 9TG0B2 390 8 126 ...

Page 171: ...bly For installation of engine assembly For installation of engine assembly 490636000B Transmission lifter Gti x mp 49 W017 303 Arm Part of 49 W017 3AO 490259770B Wrench flare nut SLTurbo 1 Tighten all bolts and nuts to the specified torques B For installation of engine assembly For Installation of engine assembly For connection of clutch hose 9TGOB2 391 9TGOB2 392 6 127 ...

Page 172: ...B HA Engine Step 1 1 Assemble the engine and transmission Torque Specifications b b 8 128 INSTALLATION a 89 117 9 1 11 9 66 86 b 37 52 3 8 5 3 27 38 64 89 6 5 9 1 47 66 N m m kg ft lb 9TGOB2 393 ...

Page 173: ... engine into the engine compartment 3 Mount the engine bracket to the vehicle Tightening torque 55 80 N m 5 6 8 2 m kg 41 59 ft Ib 4 Lower the engine and align the engine mount rubber with the engine bracket 5 Install the engine mount nuts and loosely tighten them 6 Install and tighten the transmission mount bracket Tightening torque 55 80 N m 5 6 8 2 m l g 41 59 ft Ib 31 46 N m 3 2 4 7 m kg 23 34...

Page 174: ...LATION 98 118 10 0 12 0 72 87 13 18 1 3 1 8 9 4 13 Propeller shaft I N m m Icg ft lb 9TGOB2 397 1 Install the propeller shaft Refer to Section L Speedometer cable 1 Install the speedometer cable Clutch release cylinder 1 Install the clutch release cylinder Tightening torque 19 25 N 1 9 2 6 m kg 14 19 ft Ib ...

Page 175: ...e front exhaust pipe Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft lb Pipe 22 30 N m 2 2 3 1 m kg 16 22 ft lb Bracket Exhaust shutter valve 1 Instali the exhaust shutter valve Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib Parking brake cable 1 Mount the parking brake rear cable to the vehicle frame Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft Ib 2 Connect the front and rear cable w...

Page 176: ...ion on hoses and squeeze the clamps lightly with large pliers to ensure a good fit 1 Connect the hoses shown in the figure COOLANT RESERVOIR HOSE FUEL HOSE RADIATOR HOSE UPPER HEATER HOSE 9TGOB2 404 Step 5 1 Connect the harness connectors shown in the figure 8 132 9TGOB2 405 ...

Page 177: ...n touches the cowling adjust the radiator cowling mounting position Torque Specifications 7 8 11 N m 80 110 em kg 69 95 in Ib 98 118 10 0 12 0 72 87 J 37 52 3 8 5 3 27 38 37 52 3 8 5 3 27 38 Nom m Icg ft lb 9TG0B2 406 Accelerator cable 1 Install the accelerator cable 2 Adjust the cable deflection by turning the adjusting nut Deflection 1 3mm 0 04 0 12 in 9TGOB2 407 8 133 ...

Page 178: ...g torque 98 118 N m 10 0 12 0 m kg 72 87 ft Ib PIS oil pump 1 Install the PIS oil pump and loosely tighten the mounting bolts Drive belt 1 Install the drive belts Cooling fan 1 Install the cooling fan Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Radiator cowling upper 1 Install the upper radiator cowling Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib 9TGOB2 410 ...

Page 179: ...SL Engine Step 1 1 Assemble the engine and transmission Torque Specifications INSTALLATION a 89 117 9 1 11 9 66 86 b 37 52 3 8 5 3 27 38 B 64 89 6 5 9 1 47 66 t n m kg ft lb 9TFOBX 049 8 135 ...

Page 180: ...he SST 2 Lift the engine into the engine compartment 3 Mount the engine bracket to the vehicle Tightening torque 55 80 N m 5 6 8 2 m kg 41 59 ft Ib 4 Lower the engine and align the engine mount rubber with the engine bracket 5 Install the engine mount nuts and loosely tighten them 6 Install and tighten the transmission mount bracket Tightening torque 55 80 N m 5 6 8 2 m kg 41 59 ft Ib 31 46 Nom 3 ...

Page 181: ...9 2 6 14 19 COTTER PIN NEW C F 98 118 10 0 12 0 72 87 Nom m kg ft lb 9TFOBX 051 Propeller shaft 1 Install the propeller shaft Refer to Section L Tie rod 1 Apply grease to the ball jOint of the tie rod end 2 Install the tie rod to the knuckle 3 Install the nut and a new cotter pin Tightening torque 98 118 N m 10 0 12 0 m kg 72 87 ft Ib Speedometer cable 1 Install the speedometer cable 8 137 ...

Page 182: ... the shift select cable Turbocharger Turbo 1 Install the turbocharger Refer to Section F Front exhaust pipe 1 Install the front exhaust pipe Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft lb Pipe 22 30 N m 2 2 3 1 m kg 16 22 ft lb Bracket Exhaust shutter valve 1 Install the exhaust shutter valve Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib Parking brake cable 1 Mount the parking brake r...

Page 183: ...Step 5 VACUUM HOSE INTAKE SHUTIER VALVE INSTALLATION 1 Connect the harness connectors shown in the figure I FUEL HOSE B 9TGOB2 423 9TGOB2 424 8 139 ...

Page 184: ...ith large pliers to ensure a good fit After radiator cowling installation rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling If the fan touches the cowling adjust the radiator cowling mounting position Torque Specifications 19 25 1 9 2 6 14 19 N m m k9 ft lb 8 140 9TGOB2 425 ...

Page 185: ...sely tighten the mounting bolts Drive belt 1 Install the drive belts Cooling fan 1 Install the cooling fan Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Radiator hose 1 Connect the upper and lower radiator hoses Radiator cowling 1 Install the radiator cowling Exhaust manifold insulator 1 Install the exhaust manifold insulator Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib Air intake ...

Page 186: ...B INSTALLATION TF Engine Step 1 1 Assemble the engine and transmission Torque Specifications 64 89 6 5 9 1 47 66 8 142 b b a 89 117 9 1 11 9 66 86 b 37 S2 3 8 5 3 27 38 i Nom m kg ft Ib 9TGOB2 431 ...

Page 187: ...the SST 2 lift the engine into the engine compartment 3 Mount the engine bracket to the vehicle Tightening torque 55 80 Nom 5 6 8 2 m kg 41 59 ft Ib 4 Lower the engine and align the engine mount rubber with the engine bracket 5 Install the engine mount nuts and loosely tighten them 6 Install and tighten the transmission mount bracket Tightening torque 55 80 N m 5 6 8 2 m kg 41 59 ft Ib 31 46 N m 3...

Page 188: ... PIN NEW 37 3 8 6 4 27 46 N m rn kg ft lb 9TGOB2 435 Propeller shaft 1 Install the propeller shaft Refer to Section L Tie rod 1 Apply grease to the ball joint of the tie rod end 2 Install the tie rod to the knuckle 3 Install the nut and a new cotter pin Tightening torque 98 118 Nrn 10 0 12 0 m kg 72 87 ft Ib Speedometer cable 1 Install the speedometer cable ...

Page 189: ...t exhaust pipe 1 Install the front exhaust pipe Tightening torque 37 63 N m 3 8 6 4 m kg 27 46 ft Ib 2 Install the bracket to the transmission Tightening torque 1 8 25 N rn 1 8 2 5 m kg 13 18 ft Ib Exhaust shutter valve 1 Install the exhaust shutter valve Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft Ib Parking brake cable 1 Mount the parking brake rear cable to the vehicle frame Tightening to...

Page 190: ...Step 4 1 Connect the hoses shown in the figure COOLANT RESERVOIR HOSE VACUUM HOSE INTAKE SHUTTER VALVE OIL HOSE VACU PUMP I Step 5 1 Connect the harness connectors shown in the figure 8 146 i I 9TGOB2 442 V 9TG0B2 443 ...

Page 191: ...an blade does not touch the radiator cowling If the fan touches the cowling adjust the radiator cowling mounting position Torque Specifications 19 25 1 19 25 1 9 2 6 14 19 r I I40A 19 25 1 9 2 6 14 19 I I I 37 52 3 8 5 3 27 38 L __________________ 19 25 1 9 2 6 14 19 14 19 19 25 1 9 2 6 14 19 N m m kg ft lb 9TGOB2 445 Exhaust manifold insulator 1 Install the exhaust manifold insulator Tightening t...

Page 192: ...p and new O ring Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Alternator 1 Install the alternator strap Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 2 Install the alternator Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 37 52 N m 3 8 5 3 m kg 27 38 ft Ib Radiator hose lower 1 Connect the lower radiator hose Radiator cowling lower 1 Install the lower radiator cowling Tighteni...

Page 193: ...all the upper radiator cowling Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib Radiator hose upper 1 Connect the upper radiator hose Air hose intake manifold elbow 1 Install the intake manifold elbow and air heater and a new gasket 2 Install the vacuum pipe Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib 19 25 Nom 1 9 2 6 m kg 14 19 ft Ib 3 Connect the vacuum hose 8 149 ...

Page 194: ...he specified amount and type of transmission oil Refer to Section J 5 Adjust the drive belt deflection Refer to page 8 9 6 Bleed the air from the fuel system Refer to page B 16 7 Bleed the air from the clutch system Refer to Section H 8 Connect the negative battery cable 9 Start the engine and check the following 1 Engine oil transmission oil and engine coolant leakage 2 Injection timing idle spee...

Page 195: ...RESSURE 0 6 PREPARATION 0 6 INSPECTION 0 6 ENGINE OIL 0 7 INSPECTION 0 7 REPLACEMENT 0 7 OIL FILTER 0 8 REPLACEMENT 0 8 OIL BYPASS FILTER 0 8 REPLACEMENT 0 8 OIL COOLER 0 9 REMOVAL JINSTALLATION 0 9 OIL PAN 0 11 REMOVAL I INSTALLATION 0 11 OIL PUMP 0 14 REMOVAL I INSTALLATION 0 14 DISASSEMBLY I INSPECTION I ASSEMBLY 0 17 9TFODX 001 D ...

Page 196: ...ngine oil Inspection page 0 7 Replacement page 0 7 3 Oil filter Replacement page D 8 4 Oil bypass filter Replacement page 0 8 Removal Installation page 0 9 6 Oil pan Removal Installation page 0 11 7 Oil pump Removal Installation page 0 14 Disassembly Inspection I Assembly page 0 17 0 2 ...

Page 197: ...filter Replacement page D 8 4 Oil bypass filter Replacement page D 8 ENGINE OIL SPECIFICATION API SERVICE CC D TOTAL CAPACITY 8 8 liters 9 3 US qt 7 7 Imp qt 9TFOOX 003 5 Oil cooler Removal Installation page 0 9 6 Oil pan Removal Installation page 0 11 7 Oil pump Removal Installation page 0 14 Disassembly Inspection f Assembly page 0 17 D 3 ...

Page 198: ...4 Oil bypass filter Replacement page D 8 D 4 OIL JET SERVICE SECTIONB 5 II ENGINE OIL SPECIFICATION API SERVICE CC TOTAL CAPACITY 9 3 liters 9 8 US qt 8 2 Imp qt 9TFODX 4 5 Oil cooler Removal Installation page 0 9 6 Oil pan Removal Installation page 0 11 7 Oil pump Removal Installation page 0 14 Disassembly I Inspection I Assembly page 0 17 ...

Page 199: ...0 53 Engine oil API service CC 9TGOD2 005 TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Engine hard starting Improper viscosity engine oil Replace D 7 Insufficient engine oil Add oil D 7 Excessive oil Oil working up or down Refer to Section B consumption Oil leakage Repair Oil pressure low Insufficient oil Add oil 0 7 Oil leakage Repair Worn and or damaged oil pump gear Replace 0 17 Wor...

Page 200: ... into the oil pressure switch installation hole 3 Warm up the engine to normal operating temperature 4 Run the engine at 3 600 rpm and note the gauge reading Oil pressure 373 kPa 3 8 kg cm2 54 psi min 5 If the pressure is not as specified check for the cause and repair Refer to Troubleshooting Guide 6 Remove the SST and install the oil pressure switch SL ENGINE 9TG002 OO7 D 6 ...

Page 201: ... careful when draining the oil is hot 1 Warm up the engine to normal operating temperature and stop it 2 Remove the oil filler cap and the oil pan drain plug 3 Drain the oil into a suitable container 4 Install a new gasket and the drain plug Tightening torque 29 41 N m 3 0 4 2 m kg 22 30 ft Ib 5 Refill the engine with the specified type and amount of en gine oil Oil pan capacity HA SL 6 5 liters 6...

Page 202: ...ter wrench 6 Start the engine and c heck for leaks 7 Check the oil level and add oil if necessary Oil filter capacity 1 0 liter 1 06 US qt 0 88 Imp qt OIL BYPASS FILTER REPLACEMENT 1 Remove the oil bypass filter with a suitable wrench 2 Use a clean rag to wipe off the mounting surface on the engine 3 Apply a small amount of clean engine oil to the rubber seal of the new filter 4 Install the oil by...

Page 203: ... check for leaks 5 Check the engine oil and engine coolant levels HA SL Engine w J f ff REPLACE 16 24 1 6 2 4 12 17 15 25 1 2 5 11 18 20 29 2 O 14 22 9 8 13 gTFODX 007 37 S2 3 8 27 38 19 25 1 9 2 6 14 19 V iit REPLACE 20 29 2 0 14 22 7 8 11 80 110 em kg 69 95 in lb 9 8 13 Nom 100 130 cm kg 87 113 in Ib 100 130 cm kg _ __ 87 113 in Ib r 19 25 11 9 2 6 14 19 Nom m kg ft lb 9TFODX OO8 1 Oil pipe Oil ...

Page 204: ...Engine CD 19 25 1 9 2 6 14 19 REPLACE 19 25 1 9 2 6 14 19 REPLACE Nom m kg ft lb 9TGOD2 17 1 Intake manifold and fuel injection pump Service Section F3 2 Oil pipe 3 O ring 4 Oil cooler cover 5 Oil cooler 6 O ring 0 10 ...

Page 205: ...ge 0 7 2 Connect the negative battery cable 3 Start the engine and check for leaks 4 Check the oil level and add oil if necessary HA SL Engine REPLACE 7 _ I 1 Stiffener 2 Rubber gasket 3 Oil pan Inspect for cracks deformation and damage 4 Rubber gasket 5 Oil level gauge and pipe 9TFODX OO s RING II 19 25 1 9 2 6 14 19 HA 16 23 1 6 2 3 12 17 Sl 19 25 1 9 2 6 14 19 6 Oil pan upper block 9TFODX o10 I...

Page 206: ...ithin 30 minutes after the sealant is applied to the oil pan rear gasket 1 Apply silicone sealant to the shaded areas of the new oil pan rear gasket 2 Install the oil pan rear gasket to the oil pan upper block Oil pan upper block 1 Apply silicone sealant to the shaded areas of the cylinder block 2 Install the oil pan upper block and new gaskets Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib ...

Page 207: ...rmation and damage N m m kg ft Ib 9TFODX 011 5 Rubber gasket 6 O ring Installation Note page 0 13 9iGOD2 024 Installation Note Oil pan Caution The oil pan must be secured within 30 minutes after the sealant is applied to the cylinder block_ 1 Apply silicone sealant to the shaded areas of the cylinder block 2 Install the oil pan and a new gasket Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib ...

Page 208: ...battery cable 2 Drain the engine oil 3 Remove in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal referring to Installation Note Steps After Installation 1 Fill with the specified amount and type of engine oil Refer to page 0 7 2 Connect the negative battery cable 3 Start the engine and check for leaks 4 Check the oil level and add oil if necessary ...

Page 209: ... Drive belt Adjustment Section B 3 Crankshaft pulley Removal Note page 0 16 Installation Note page 0 16 N m m kg ft 9TFODX 014 4 Oil pipe Fuel injection pump 5 PIS oil pump 6 Timing gear cover 7 Idler gear 8 Oil pump Disassembly I Inspection I Assembly page D 17 0 15 ...

Page 210: ...ar to prevent the engine from rotating 3 Loosen the pulley locknut 4 Remove the crankshaft pulley Installation Note Crankshaft pulley 1 Install the crankshaft pulley 2 Install the locknut and washer Caution This operation must be performed by two people 3 Prevent the engine from rotating and tighten the locknut Tightening torque 383 432 N m 39 0 44 0 m kg 282 318 ft Ib 4 Install the blind cover to...

Page 211: ... 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Assemble in the reverse order of disassembly referring to Assembly Note HA SL ENGINE 25 33 2 5 3 4 18 25 N m m kg ft lb TF ENGINE 9TGOD2 032 1 Relief valve HA SL 2 Pump cover HA SL Inspect for wear or damage 3 Pump body D 17 ...

Page 212: ...he rotor and the edge of the pump body Clearance Standard 0 04 0 09mm 0 0016 0 0035 in Maximum 0 15mm 0 0059 in 3 If the clearance exceeds the maximum replace the oil pump assembly Operation Check HA SL 1 Install the relief valve to the pump body 2 Install the oil strainer to the pump body 3 Submerge the oil strainer in engine oil as shown in the figure 4 Rotate the oil pump driven gear counterclo...

Page 213: ... ENGINE COOLANT E 6 PREPARATION E 6 INSPECTION E 6 REPLACEMENT E 7 RADIATOR CAP E 8 PREPARATION E 8 INSPECTION E 8 RADIATOR E 9 REMOVAL f INSTALLATION E 9 THERMOSTAT E 10 REMOVAL I INSPECTION I INSTALLATION E 10 WATER PUMP E 11 REMOVAL I INSTALLATION E 11 COOLING FAN E 12 INSPECTION E 12 REMOVAL I INSTALLATION E 12 9TFOEX 001 ...

Page 214: ...ngine coolant Inspection page E 6 Replacement page E 7 2 Radiator cap Inspection page E 8 3 Radiator Removal Installation page E 9 4 Thermostat Removal Inspection Installation page E 10 5 Water pump Removal Installation page E 11 6 Cooling fan Inspection page E 12 Removal Installation page E 12 E 2 ...

Page 215: ... coolant Inspection page E 6 Replacement page E 7 2 Radiator cap Inspection page E 8 3 Radiator Removal Installation page E 9 4 Thermostat Removal Inspection 9TFOEX OO3 Installation page E 10 5 Water pump Removal Installation page E 11 6 Cooling fan Inspection page E 12 Removal Installation page E 12 E 3 ...

Page 216: ...cap Inspection page E 8 3 Radiator Removal Installation page E 9 E 4 CDENGINE COOLANT 13 5 liters 14 3 US qt 11 9 Imp qt 4 Thermostat Removal Inspection 9TFOEX Q04 Installation page E 10 5 Water pump Removal Installation page E 11 6 Cooling fan Inspection page E 12 Removal Installation page E 12 ...

Page 217: ... Cooling fan Non Turbo Blade Outer diameter mm in 410 16 1 410 16 1 420 16 5 Turbo 420 16 5 9TFOEX S TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Overheating Coolant level insufficient Add coolant E 7 Coolant leakage Repair Radiator fins clogged Clean E 9 Radiator cap malfunction Replace E 8 Cooling fan malfunction Replace E 12 Thermostat malfunction Replace E 10 Water passage clogged ...

Page 218: ...r is released and then remove it 9TG0E2 OO7 Coolant Level Engine Cold 1 Verify that the coolant evel is near the coolant inlet port 2 Verify that the coolant level in the coolant reservoir is be tween the FULL and LOW marks Add coolant if necessary Coolant Quality 1 Verify that there is no buildup of rust or scale around the radiator cap or coolant inlet port 2 Verify that coolant is free of oil R...

Page 219: ...54 Above 26 C 15 F 55 45 I 1 066 Above 40 C 40 F 45 55 i 1 078 OSUOEX Ol0 REPLACEMENT Warning Never open the radiator cap while the engine is hot Wrap a thick cloth around the cap before loosen ing it Use caution when draining hot coolant Caution Do not use alcohol or methanol based coolant Use only soft demineralized water in the coolant mixture 1 Remove the radiator cap and loosen the drain plug...

Page 220: ...ue from be tween the radiator cap valve and the valve seat 2 Attach the radiator cap to a radiator cap tester commer cially available with the SST Appl pressure gradually to 74 103 kPa 0 75 1 05 kg em 11 15 psi 3 Wait about 10 sec Verify that the pressure has not decreased Negative Pressure Valve 1 Pull the negative pressure valve to open it Verify that it closes completely when released 2 Check f...

Page 221: ...e 2 Drain the engine coolant 3 Remove the undercover 4 Remove in the order shown in the figure 5 Install in the reverse order of removal Steps After Installation 1 Install the undercover 2 Fill the radiator with the specified amount and type of engine coolant Refer to page E 7 3 Connect the negative battery cable 4 Start the engine and check for leaks CD TURBO CHECK THE RADIATOR FOR FOLLOWING CRAC...

Page 222: ... 7 2 Connect the negative battery cable 3 Start the engine and check for leaks 7 8 11 N m SO 110 em kg 69 95 in Ib SEAL PRINT SIDE FACING THE CYLINDER HEAD REPLACE 1 Thermostat cover 2 Gasket E 10 9TGOE2 016 9TFOEX 009 3 Thermostat Inspection page E 10 INSPECTION 1 Visually check that the thermostat valve is airtight 2 Place the thermostat and a thermometer in water 3 Heat the water and check the ...

Page 223: ...t the negative battery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure 4 Install in the reverse order of removal Steps After Installation 1 Fill the radiator with the specified amount and type of engine coolant Refer to page E 7 2 Connect the negative battery cable 3 Start the engine and check for leaks 19 25 1 9 2 6 14 19 CD 9TFOEX o10 1 Radiator cowling 4 Water pump pu...

Page 224: ...ve if necessary After radiator cowling installation rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling If the fan touches the cowling adjust the radiator cowling mounting position 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal Steps After Installation 1 Connect the negative ba...

Page 225: ...9 INTAKE AIR SySTEM Ft 11 COMPONENTS F1 11 FUEL SYSTEM F1 13 PREPARATION F1 13 FUEL TANK F1 13 INJECTION PUMP F1 14 SEDIMENTOR F1 16 SEDIMENTOR SENSOR DETECTOR F1 16 FUEL FILTER F1 17 INJECTION NOZZLE F1 19 tl CCELERATOR PEDAL ACCELERATOR CABLE F1 22 FUEL CUT CONTROL SYSTEM F1 23 SYSTEM OPERATION F1 23 FUEL CUT SOLENOID VALVE F1 23 IDLE SPEED CONTROL SYSTEM F1 24 STRUCTURAL ViEW F1 24 IDLING KNOB ...

Page 226: ...DEVICES 1 Fresh air duct Removal Inspection I Installation page F1 11 2 Air cleaner Removal Inspection Installation page F1 11 Inspection of element F1 2 3 Intake manifold Removal Inspection 9TGOF1 2 Installation page F1 11 ...

Page 227: ...F1 EXHAUST DEVICES 9TGOFHl03 1 Exhaust manifold Removal Inspection 3 Silencer Removal Inspection Installation page F1 26 Installation page F1 26 2 Exhaust pipe Removal Inspection Installation page F1 26 F1 3 ...

Page 228: ...1 3 Sedimentor Installation page F1 21 Draining water page F1 16 6 Accelerator pedal Accelerator cable Inspection page F1 16 Inspection Adjustment page F1 22 4 Fuel filter Removal Installation page F1 22 Air bleeding page F1 17 7 Idling knob Idling cable Inspection page F1 17 Inspection I Adjustment page F1 24 Replacement page F1 18 Removal Installation page F1 25 8 Fuel cut solenoid valve Inspect...

Page 229: ...OUTLINE SYSTEM DIAGRAM W J t o l JW W J lO L CI I 0 l 0 l a z W E a 0 J W l U ti OUTLINE l 0 a c J CI W a u W J N N 0 Z Z 0 1 W a W z t W J a 0 F1 9TGOF1 5 F1 5 ...

Page 230: ... PLUG lRl IB YiB11 ffi 5 It ilJI _ LR IF __ IX DlI ENG 15A I 1 IK3IlI B IFI W B lliRI If Ern METEA 15A D V IFI WATER THEIM SWITCH J 8 05 IB V IRI B 06 FUEL CUT SOLENOID VALVE 0 04 GLOW PLUG A IBIRIw sl 0 0 5 WATEA Tt RMO SWITCH 10 6 FUEL CUT SOLENOID I VALVE A IB VIEI 10 AIEI e NOTE NOT USED IE D Z C c C i n o c I C z m ...

Page 231: ...e Fuel injection pipe Cracks Replace Leaking from jOint Repair Improper idle speed adjustment Adjust Engine knocking Faulty injection timing Adjust Low quality fuel Replace Faulty injection nozzle opening pressure Adjust Seized needle valve of injection nozzle Replace Fuel dripping from injection nozzle Replace High fuel consumption Fuel injection pump Faulty full load adjust screw Adjust Faulty i...

Page 232: ...le the engine is hot Wrap a thick cloth around the cap while carefully removing it Verify that the coolant level is near the radiator inlet port and that the level in the reservoir is between the FULL and LOW marks Add coolant as necessary Battery 1 Check for corrosion on the terminals and for loose cable connections 2 Check the electrolyte level If the level is too low add distilled water to the ...

Page 233: ...Confirm the free play of the accelerator cable Free play 1 0 3 0mm 0 039 0 118 in 4 Aim the light of the photo tachometer onto the reflecting tape to measure the engine speed Idle speed 600 650 rpm 5 If not as specified loosen the locknut of the idle adjusting bolt and turn the bolt to adjust the idle 6 Tighten the locknut Tightening torque 5 9 8 8 N m 0 6 0 9 rn kg 4 3 7 2 ft Ib Injection Timing ...

Page 234: ... the normal direction until 30 BTDC is indicated The injection timing is normal when the dial gauge needle is advanced 1 00mm 0 039 in ahead of the value set in Step 5 Static injection Cam lift 1 00mm 0 0394 in 7 Ifthe change is not as specified adjust the injection timing Adjusting Injection Pump 1 If the injection timing is faulty turn the injection pump to a position in which the dial gauge nee...

Page 235: ...0 2 2 3 1 16 22 y22 30 2 2 3 1 16 22 7 8 11 N m 37 52 S0 11 0 em kg 3 8 5 3 27 38 69 95 in Ib 7 S 11N m 80 110 em kg 69 95 in Ib _ ____2 5 3 4 N m 25 35 em kg 20 25 2 0 2 5 14 18 Nom 80 110 em kg 89 95 in Ib 22 30 in Ib F1 Nom m k g ft lb 1 Fresh air duct Check for contamination cracks and other damage Installation Note page F1 12 2 Air cleaner Inspection of element page F1 9 9TGOF1 023 3 Intake m...

Page 236: ...SYSTEM 9TGOF1 025 Installation Note Fresh air duct Install in the order shown in the figure Intake manifold 1 Use a new gasket 2 Tighten in the order shown in the figure Tightening torque 22 31 N m 2 2 3 1 m kg 15 22 ft Ib ...

Page 237: ...l parts and repair or replace as necessary 3 Install in the reverse order of removal Warning Keep sparks cigarettes and open flames away from the fuel tank Note Drain the fuel before removing the fuel tank 4 1 Connector 2 Fuel hose 3 Evaporative hose Be sure the air flows through the hose each side Nom m kg loIb 9TGOF1 027 4 Fuel tank strap 5 Fuel tank Check for contamination cracks and other dama...

Page 238: ...mp 1 Remove the negative battery cable 2 Remove in the order shown in the figure referring to Removal Note 3 Install in the reverse order of removal referring to Installation Note 4 Adjust the injection timing Refer to page F1 9 5 Bleed air from the fuel system Refer to page F1 17 2 2 3 1 1s 22 Nom m kg tt 9TGOF1 28 1 Fan and upper cooling fan shroud 6 Pump cover 2 Air hose 7 Locknut 3 Injection p...

Page 239: ...e a mirror to see key 2 Attach the SST Use the side marked M 3 Turn the SST bolt to push the pump free of the drive gear Caution Do not drop the key into the gear case Installation Note Before installing the key into the driveshaft of the injection pump lightly tab the key groove of the shaft with a hammer to assure that the key is tightly held in the key groove F1 15 ...

Page 240: ...les fuel is expelled from the air bleeder plug Tighten the bleeder plug Inspection 1 Visually check the sedimentor for damage and fuel leak age Repair or replace if necessary 2 Check the position of the float ring If the ring is near the float level line drain the water SEDIMENTOR SENSOR DETECTOR 1nspection 1 Remove the sedimentor sensor from sedimentor 2 Check continuity of the detector Float Con...

Page 241: ...engine and run it at idle until it runs smoothly Stop the engine 8 Loosen the aU flare nuts of the injection pipes of injection nozzle side 9 Confirm fuel injection from the injection pipes while cranking 10 Tighten the nuts Tightening torque 20 25 N m 2 0 2 5 m kg 14 18 ft Ib Inspection of priming pump Warning Keep sparks cigarettes and open flames away from the fuel filter 1 Remove the air bleed...

Page 242: ... Run the engine and verify that there are no fuel leaks 37 52 3 8 5 3 27 38 CD N m m g ft Jb 9TGOFH 42 1 Filter element 2 Fuel filter body Removal Note page F1 18 Installation Note page F1 18 Removal Note 1 Remove the filter element with an oil filter wrench 9TGOF1 43 9TGOF1 44 F1 18 Installation Note 1 Apply fuel to the O ring 2 Install the filter element and tighten by hand then tighten with an ...

Page 243: ... hands or any other part of the body to come into the direct path of the spray when using the nozzle tester because the spray has enough force to break the skin and possi bly cause blood poisoning Caution The nozzle tester should be set up in a clean work place 9TGOF1 046 Injection starting pressure 1 Connect the nozzle to a nozzle tester 2 Pump the nozzle tester handle and note the pressure when ...

Page 244: ...assemble clean and recheck the nozzle or replace it Atomizing condition 1 Connect the nozzle on the nozzle tester 2 Air bleed by operating the nozzle tester handle several times 3 Keeping the pressure gauge of the nozzle tester in the non functioning condition quickly lower the handle lower the handle as quickly as possible so that a pulsating whistling sound can be heard Repeat this operation sev...

Page 245: ...ody Verify that the needle valve drops into the body under its own weight when released Assembly 1 Assemble in the reverse order of disassembly Tightening torque 78 98 N m 8 0 10 0 m kg 58 72 ft Ib 2 Retest the nozzle after assembly Installation Caution Do not reuse the copper washers Tighten the nozzle into the cylinder head to the specified torque 1 Install in the reverse order of removal Tighte...

Page 246: ... Inspection I Adjustment 1 Verify that the control lever of injection pump is in the fuUy open position when the accelerator pedal is fully depressed 2 Loosen nut A and adjust the stop bolt if necessary Tightening torque 6 9 9 8 N m 0 7 1 0 m kg 5 1 7 2 ft Ib 3 Check the free play of the accelerator cable Free play 1 0 3 0mm 0 039 0 12 in 4 Adjust nuts B if necessary Tightening torque 9 8 15 N m 1...

Page 247: ...clicks when the en gine switch is turned ON and OFF 2 If it does not disconnect the fuel cut solenoid valve and check the voltage to the valve Engine switch Voltage ON 12V OFF OV 3 If as specified replace the fuel cut solenoid valve Replacement 1 Disconnect the fuel cut solenoid valve connector 2 Remove the fuel cut solenoid valve from the injection pump 3 Install in the reverse order of removal T...

Page 248: ...age F1 25 IDLING KNOB IDUNG CABLE 1 Verify that the control lever of the injection pump is at idle position when the idling knob is not turned 2 Verify that the idle speed increases when the knob is turned clockwise 3 Check the free play of the cable when the idling knob is not turned Free play 0 5mm 0 0 2 in 4 If not as specified loosen the locknuts and adjust the free play Tightening torque 11 1...

Page 249: ...IDLE SPEED CONTROL SYSTEM F1 Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 9TGOF1 66 1 Idling knob 2 Idling cable F1 25 ...

Page 250: ... the reverse order of removal 26 32 2 7 3 3 211 24 1 Exhaust manifold insulator 2 Exhaust manifold Check for contamination cracks and other damage 3 Front pipe assembly Check for contamination cracks and other damage 4 Middle pipe assembly F1 26 Check for contamination cracks and other damage 37 52 3 8 5 3 27 38 Nom m kg ft Ib 9TGOF1 67 5 Main silencer Check for contamination cracks and other dama...

Page 251: ... 12 EXHAUST HEATING CONTROL ENGINE TUNE UP F2 13 UNIT F2 48 BASIC INSPECTION F2 13 EXHAUST BRAKE UNIT ADJUSTMENT F2 14 POWER CHAMBER F2 49 INTAKE AIR SySTEM F2 18 MAGNETIC VALVE COMPONENTS F2 18 FOR EXHAUST SHUTTER VALVE F2 50 TURBOCHARGER F2 21 INTAKE SHUTTER VALVE F2 51 PREPARATION F2 21 INTAKE SHUTTER VALVE TURBOCHARGER F2 21 ACTUATOR F2 51 INTERCOOLER F2 27 SOLENOID VALVE FUEL SYSTEM F2 29 FOR...

Page 252: ...ne 1 Fresh air duct Removal Inspection Instaliation page F2 18 2 Air cleaner Inspection page F2 13 F2 2 9TGOF2 002 3 Intake shutter valve Removal Installation page F2 18 Inspection page F2 49 4 Intake manifold Installation Note page F2 20 ...

Page 253: ...e F2 18 Replacement page F2 27 2 Air cleaner 5 Intake shutler valve Removal Inspection Installation page F2 18 Removal Installation page F2 22 Inspection page F2 51 Inspection page F2 13 6 Intake manifold 3 Turbocharger RemovaL page F2 22 Removal Inspection Installation page F2 22 Inspection page F2 23 Installation page F2 23 F2 3 ...

Page 254: ...page F2 36 5 Injection nozzle RemovaL page F2 37 Inspection page F2 37 Disassembly page F2 38 Cleaning page F2 39 Assembly page F2 39 Installation page F2 39 F2 4 9TGOF2 Q4 6 Accelerator pedal Accelerator cable Inspection Adjustment page F2 40 Removal Installation page F2 40 7 Fuel stop cable Inspection Adjustment page F2 41 Removal Installation page F2 42 8 Idling knob Idling cable Inspection Adj...

Page 255: ...gnetic valve Exhaust shutter valve 8 Clutch switch RemovaL page F2 50 Inspection page F2 54 Inspection page F2 50 Replacement page F2 54 Installation page F2 50 9 Neutral switch 4 Actuator Intake shutter valve Inspection page F2 54 Inspection page F2 51 Replacement page F2 55 Replacement page F2 51 10 Exhaust brake switch 5 Solenoid valve Intake shutter valve Inspection page F2 S5 Inspection page ...

Page 256: ...F2 EXHAUST DEVICES 1_Main silencer 2_ Exhaust pipe 3_ Exhaust manifold F2 6 iI INDEX tj 4_ Exhaust brake unit 5_ Tail pipe 9TGOF2 006 ...

Page 257: ...OUTLINE F2 MEMO F2 7 ...

Page 258: ...EUTRAL SWITCH INTAKE SHUTTER VALVE SOLENOID VALVE EXHAUST SHUTTER VALVE I EXHAUST r 1I SHUTTER VALVE EXHAUST BRAKE UNIT SOLENOID VALVE INTAKE SHUTTER VALVE AIR CLEANER I C C r mC 1 1 cam 5 s DO lJ s gLI____ ____________________________________________________________________________________________ o c C z m n N o c I C z m ...

Page 259: ...LVE 11 EXHAUST EXHAUST BRAKE UNIT SHUTTER VALVE 1II0f EXHAUST HEATING SWITCH ACCELERATOR 7 oCf SWITCH TO SOLENOID VALVES CLUTCH SWITCH NEUTRAL SWITCH INTAKE AND EXHAUST SHUTTER VALVES I N l____________________________________ __________________________________________________________________ I r c u g m m S o c I z m N ...

Page 260: ...i 8 01 AIR HEATER CONTROL LtlIT F 0 o2 AIR fiEATEA RELAY A O B 03 WATER THERMO SENSOR 10 04 AIR HEATER A R 114 9 SOLENOIO VALVE EXHAUST HEATING VSTEM R olBIRI 8 10 EXHAUST BRAKE SWITcH B 11 F ffi A o2STARTlNG MOTOR lsi FUSIBLE LINK A B FUSIBLE LIIf 5 Osq 0j9 J cr o o EXHAUST HEATING SHITCH l 0 Y BR 0 05 ACcELERATOR SWITCH 10 06 MAGNETICVA1 VE IA3 IF rMl 8 0 12 CLUTCII SWITCH IF IIG RII fL wl A 03 ...

Page 261: ...VACUUM HOSE ROUTING DIAGRAM OUTLINE I Z I W II m I I X W C W I C F2 9TGOF2 011 F2 11 ...

Page 262: ...ocking Incorrect injection timing Adjust Incorrect injection starting pressure Adjust Malfunction of injection nozzle Clean or adjust Low quality of fuel Drain and replace Excessive exhaust Incorrect injection timing Adjust smoke Water in injection pump fuel filter or sedimentor Drain Incorrect injection starting pressure Adjust Clogged air cleaner Clean or replace Malfunction of delivery valve Cl...

Page 263: ...nt level is near the radiator inlet port and that the level in the reservoir is between the FULL and LOW marks Add coolant as necessary Battery 1 Check for corrosion on the terminals and for loose cable connections 2 Check the electrolyte level If the level is low add distilled water to the UPPER LEV EL mark 3 Check the specific gravity with a hydrometer If the speCif ic gravity reading is 1 23 or...

Page 264: ...0 rpm SL 660 710 rpm SL Turbocharged Engine 5 If not as specified loosen the locknut of the idle adjusting bolt and turn the bolt to adjust the idle 6 Tighten the locknut Tightening torque 9 8 14 N m 100 140 em kg 87 121 in Ib Injection Timing Inspection Note Usually it is enough to confirm that the external marks are aligned Caution Direct injection engines are sensitive to injection timing Incor...

Page 265: ... 3 Remove the bracket 4 Loosen injection pipes No 2 4 at the pump 5 Remove No 1 injection pipe and the delivery valve holder 6 Remove the delivery valve spring seat and spring Caution Do not remove the delivery valve body 7 Rock the delivery valve to break it loose from the barrel Note If the delivery valve is lifted up without breaking it loose the barrel may also be lifted out of the pump If thi...

Page 266: ... holder 10 Tighten No 1 injection pipe so that it points away from the pump 11 Turn the flywheel in the direction of rotation and set it at 20 BTDC 12 Place a container under No 1 injector pipe and verify that fuel is expelled when pumping the primer pump 13 While pumping the priming pump turn the flywheel in the normal direction of rotation and verify that fuel flow stops as specified Fuel stops ...

Page 267: ...mp body for future reference 17 Install the delivery valve spring and spring seat 18 Tighten the delivery valve holder Tightening torque 39 44 N m 4 0 4 5 m kg 29 33 ft Ib 19 Install No 1 injection pipe 20 Tighten injection pipes No 2 4 21 Install the bracket 22 Install the accelerator cable to the control lever 23 Install the fuel stop cable to the cut lever 24 Install the service hole covers ont...

Page 268: ...nstall in the reverse order of removal referring to Installation Note SL Engine 9TGOF2 038 1 Fresh air duct 3 Intake shutter valve Check for contamination cracks and other Inspection page F2 49 damage page F2 18 4 Intake manifold Installation Note page F2 20 Check for contamination cracks and other 2 Air cleaner damage page F2 18 Inspection page F2 13 Installation Note page F2 20 F2 18 ...

Page 269: ...ntake shutter valve Check for contamination cracks and other Inspection page F2 S1 damage page F2 19 Installation Note page F2 20 2 Air cleaner 4 Intake manifold Check for contamination cracks and other damage page F2 19 Inspection page F2 13 Installation Note page F2 20 F2 19 ...

Page 270: ... 9TGOF2 040 9TGOF2 Q41 Installation note Fresh air duct Install in the order shown in the figure Intake manifold 1 Use a new gasket 2 Tighten in the order shown in the figure Tightening torque 22 31 N m 2 2 3 1 m kg 15 22 ft Ib ...

Page 271: ...wheel 1 Allow the engine to cool 2 Remove the air hose 3 Verify that the rotor assembly turns Smoothly 4 If there is excessive load or noise replace the turbocharger Oil passage 1 Allow the engine to cool 2 Remove the oil return pipe 3 Verify that carbonized oil has not blocked the oil passage of the turbocharger or the oil return pipe 4 If the oil passage is clogged replace the turbocharger and r...

Page 272: ...ure 37 52 3 8 5 3 27 38 1 Air intake hose 2 Change rod bracket 3 Joint rubber 4 Heat insulator 5 Oil pipe 6 Water pipe 7 Insulator 8 Front pipe F2 22 9 Turbo bracket spring 10 Oil hose 11 Joint hose 12 Water hose 13 Stud bolt 14 Exhaust manifold 15 Turbocharger 16 Oil pipe N m m kg ft lb 9TGOF2 47 ...

Page 273: ...tion After removing the turbocharger check the oil feed pipe and oil return pipe for clogging Replace if necessary Installation 1 Pour in 25 cc of oil through the oil inlet of the turbocharger 2 Install the exhaust manifold using a new gasket and nuts Note Install the gasket with the folded side facing the cyl inder head Tightening torque 22 6 26 5 N m 2 3 2 7 m kg 17 19 ft Ib 3 Install the turboc...

Page 274: ...g 13 19 ft Ib 6 Tightening the turbocharger mounting bolts Tightening torque 37 3 62 8 N m 3 8 6 4 m kg 28 46 ft Ib 7 Install the front exhaust pipe using a new gasket and nuts Note Install the gasket with the folded side facing the tur bocharger Tightening torque 37 3 62 8 N m 3 8 6 4 m kg 28 46 ft Ib 8 Connect the oil hose 9 Connect the water hose ...

Page 275: ... a new washer Tightening torque 15 7 23 5 N m 1 6 2 4 m kg 12 17 ft Ib 9TGOF2 S9 I 12 Install the water pipe and a new washer Tightening torque 15 7 23 5 N m 1 6 2 4 m kg 12 17 ft Ib 13 Install the exhaust manifold heat insulator Tightening torque 7 8 10 8 N m 0 8 1 1 m kg 5 8 8 0 ft Ib 14 Install the turbocharger heat insulator Tightening torque 7 8 10 8 N m 0 8 1 1 m kg 5 8 8 0 ft Ib F2 25 ...

Page 276: ...hange rod and select rod 18 Fill the radiator and subtank with coolant 19 Fill the engine with the specified amount and type of en gine oil Refer to Section 02 After Installation 1 Start the engine and let it idle 2 Check for engine oil and coolant leakage Caution Let the engine idle for a few minutes to lubricate the turbocharger ...

Page 277: ...er shown in the figure 2 Install in the reverse order of removal 1 Air intake pipe 2 Joint rubber Outlet side 3 Under cover 7 11Ntn 8D 110 c aHrg 5 8 8 0 in Ib 4 Air intake pipe 5 Joint rubber Inlet side 6 Intercooler Intercooler stay F2 Nom m kg ft Ib 9TGOF2 067 F2 27 ...

Page 278: ...RBOCHARGER Inspection and Repair 1 Inspect the intercooler for cracks restriction or damage 9TGOF2 068 2 Repair bent fins with a screwdriver Caution Be careful not to break the fins when repairing them F2 28 ...

Page 279: ...rder of removal Warning Keep sparks cigarettes and open flames away from the fuel tank Note Drain the fuel before removing the fuel tank 25 29 2 5 3 0 18 22 1 Connector 2 Fuel hose 12 17 6 Nom 120 180 cm kg 104 173 in Ib 4 Fuel tank strap 5 Fuel tank F2 Nom m kg ft Ib 9TGOF2 70 3 Evaporative hose Verify air flows in both directions Check for contamination corrosion and other damage F2 29 ...

Page 280: ...I j II 9TGOF2 071 Caution Before remove injection pump perform the fol lowing 1 Remove the negative battery cable 2 Remove the cover from the flywheel and turn the flywheel until No 1 cylinder is at to 30 BTDC 3 Remove the cover from the gear case and confirm that the mark on the timer and the pointer are aligned Note If they are not agreed No 4 cylinder is at 300 BTDC 4 Remove in the order shown ...

Page 281: ...e shutter valve Air heater 3 Fuel stop cable Accelerator cable 4 Fuel hose Fuel pipe FUEL SYSTEM 5 Harness 6 Oil pipe 7 Bracket 8 Bolts F2 I 22 30 I 2 2 3 1 16 22 Nom rn k9 ft Ib 9TGOF2 074 Removal Note page F2 32 9 Fuel injection pump F2 31 ...

Page 282: ...er bolt 2 Remove the timer and gear assembly from the pump 3 Remove the woodruff key from the pump shaft 4 Remove the flange plate 5 Affix the pump in a vise and install the flange plate 6 Align the marks on the pump and flange plate and tighten the mounting nuts Tightening torque 34 39 N m 3 5 4 0 m kg 25 29 ft Ib 7 Install the woodruff key and install the timer and gear as sembly onto the pump s...

Page 283: ...g the injection pump verify that No 1 cylin der is at 30 BTDC 2 Align the notches of the flange plate and the injection pump gear 3 Install the injection pump 4 Verify that the mark on the timer and the tab of the timing gear case are aligned Accelerator cable fuel stop cable 1 After installing the accelerator cable adjust the free play of the cable Refer to page F2 40 2 After installing the fuel ...

Page 284: ...ar no air bubbles fuel is expelled from the air bleeder plug Tighten the bleeder pfug Inspection 1 Visually check the sedimentor for damage and fuel leak age Repair or replace it if necessary 2 Check the position of the float ring If the ring is near the float level line drain the water SEDIMENTOR SENSOR DETECTOR Inspection 1 Remove the sedimentor sensor from the sedimentor 2 Check continuity of t...

Page 285: ... 5 9 8 8 N m 60 90 em kg 52 78 in Ib 4 Loosen the return pipe at the injection pump and PUml the priming pump until no air is expelled 5 Tighten the bolt Tightening torque 12 15 N m 120 150 em kg 104 130 in Ib 6 Push the priming pump down and tighten it 7 Loosen the injection pipes at the injection nozzles 8 Crank the engine and verify that fuel is expelled from eacr injection pipe 9 Tighten the i...

Page 286: ...es away from the fuel filter 1 Remove the filter with a filter wrench 2 Apply fuel to the a ring 3 Install the filter and tighten by hand then tighten with filter wrench an additional 1 3 turn 4 Bleed air from the filter Refer to page F2 35 5 Start the engine and verify that there is no fuel leakage around the filter ...

Page 287: ...y other part of the body to come into the direct path of the fuel spray when using the nozzle tester because the spray has enough force to break the skin and possibly cause blood poisoning Caution The nozzle tester should be set up in a clean work place 9TGOF2 99 9TGOF2 098 Injection starting pressure 1 Connect the nozzle to a nozzle tester 2 Pump the nozzle tester handle and note the pressure whe...

Page 288: ...zle on the nozzle tester 2 Air bleed by operating the nozzle tester handle several times 3 Keeping the pressure gauge of the nozzle tester in the non functioning condition quickly lower the handle lower the handle as quickly as possible so that a pulsating whistling sound can be hard Repeat this operation several times and check the atomizing condition 4 Make sure that the fuel is atomized uniform...

Page 289: ...thirds of the way into the body Verify that the needle valve drops into the body under it s own weight when released Assembly 1 Assemble in the reverse order of disassembly Tightening torque 29 39 N m 3 0 4 0 m kg 22 29 ft Ib 2 Retest the nozzle after assemble Refer to page F2 37 Installation Caution Use new gaskets and O rings 1 Install in the reverse order of removal Tightening torque Retainer b...

Page 290: ...ightening torque 6 9 9 8 N m 70 100 em kg 61 87 in Ib 3 Check the free play of the accelerator cable Free play 1 0 3 0mm 0 039 0 12 in 4 Adjust nuts B if necessary Tightening torque 9 8 15 N m 100 150 em kg 87 130 in Ib 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 1 Accelerator cable 2 Accelerator pedal F2 40 3 2 5 5 0 Mm 25 50 c m kg 6 9 9 8 Nom 70 100 cm kg...

Page 291: ...ondition of tensed po sition of the fuel stop cable Free play 0 2mm 0 0 078 in 5 Verify that the engine stops when turn the engine switch OFF 6 If not as specified adjust the cable as follows Adjustment 1 Turn the engine switch OFF 2 Loosen nut and remove the fuel stop cable from the bracket 3 Pull the fuel stop cable and verify that the fuel stop lever is at the fuel stop position 4 Adjust nut CD...

Page 292: ...TEM Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 3 Adjust the free play of the fuel stop cable 9TGOF2 115 1 Steering column cover 2 Locknuts 3 Fuel stop cable 1 2 42 ...

Page 293: ...LE Adjustment 1 Verify that the control lever of the injection pump is at the idle position when the idling knob is not turned 2 Verify that the idle speed increases when the knob is turned clockwise 3 Check the free play of the cable when the idling knob is not turned Free play 0 5mm 0 0 2 in 4 If not specified loosen the locknuts and adjust the free play Tightening torque 9 8 15 N m 100 150 em k...

Page 294: ...PEED CONTROL SYSTEM Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 9 8 15 N m 100 150 c m kg 87 130 in Ib 9TGOF2 119 1 Idling knob 2 Idling cable F2 44 ...

Page 295: ...8 15 20 t 1 Exhaust manifold insulator SL engine only SL turbocharged engine refer to page F2 22 2 Exhaust manifold SL engine only Check for contamination cracks and other damage SL turbocharged engine refer to page F2 22 3 Front pipe assembly SL engine only Check for contamination cracks and other damage SL turbocharged engine refer to page F2 22 tMn nHcg ft lb 9TGOF2 12C 4 Main silencer Check fo...

Page 296: ...F2 EXHAUST CONTROLLED HEATING SYSTEM EXHAUST CONTROLLED HEATING SYSTEM STRUCTURAL VIEW 9TGOF2 121 ...

Page 297: ...aL page F2 S0 Inspection page F2 SL Inspection page F2 S0 Replacement page F2 SL Installation page F2 S0 10 Neutral switch 4 Intake shutter valve actuator Inspection page F2 SL Inspection page F2 S1 Replacement page F2 Se Replacement page F2 S1 11 Vacuum switch pay load above 3 St only S Solenoid valve for intake shutter valve Inspection Section 1 Inspection page F2 S2 12 Exhaust brake switch 6 Ca...

Page 298: ...pedal Approx OV Clutch switch released Refer to page F2 54 Accelerator or clutch pedal Approx OV Accelerator switch depressed Refer to page F2 53 Wire harness Neutral Approx 12V Neutral switch In gear Approx OV Refer to page F2 54 Wire harness Exhaust brake switch OFF Approx 12V Exhaust brake switch Exhaust brake switch ON Approx OV Refer to page F2 55 Wire harness Constant Approx 12V Exhaust brak...

Page 299: ...st brake unit 2 Remove the exhaust brake unit assembly Note It is difficult to remove the exhaust brake unit when the exhaust shutter valve is open Connect a vacu um pump to hold the valve closed to remove it Inspection 1 Remove the exhaust brake unit assembly 2 Remove the service hole cover 3 Connect a vacuum pump and check the following Starts closing 100 mmHg 3 9 inHg Fully closed 350 mmHg 13 8...

Page 300: ...UTTER VALVE Removal 1 Remove the vacuum hose from the magnetic valve 2 Disconnect the connector from the magnetic valve 3 Remove the magnetic valve Inspection 1 Verify air flow through the valve A B Flow A C No flow B C No flow 2 Connect 12V to the valve and verify air flow A B No flow A C Flow B C No flow Installation Note After installing the magnetic valve the vacuum warning buzzer may ring unt...

Page 301: ... rod of the actuator moves smoothly when moved by hand 3 Start the engine and run it at idle 4 Verify that there is vacuum at the vacuum hose If not check the intake shutter valve solenoid valve Refer to page F2 52 5 Install the vacuum hose and verify that the actuator rod is pulled Replacement Note After installing the actuator the vacuum warning buzzer may ring until vacuum is built up 1 Disconn...

Page 302: ... the valve A B No flow A C No flow B C Flow 3 Connect 12V to the valve and verify air flow A B Flow A C No flow B C No flow CANCEL RELAY Removal Remove as shown in the figure Inspection 1 Disconnect the cancel relay 2 Check for continuity between terminals A and Dof the relay 3 Connect 12V between terminals Band C and verify that there is no continuity between terminals A and D 4 If not as specifi...

Page 303: ...ween A and B and B and C connect the negative tester lead to ter minal B Installation Install in the reverse order of removal ACCELERATOR SWITCH Inspection 1 Run the engine until it is at normal operating temperature 2 Stop the engine and affix reflecting tape to the crankshaft pulley 3 Start the engine 4 Disconnect the accelerator switch connector S Connect a photo tach0meter 6 Verify that there ...

Page 304: ... the locknut CLUTCH SWITCH Inspection 1 Disconnect the clutch switch connector 2 Check continuity of the switch Clutch pedal Continuity Depressed No Released Yes Replacement 1 Disconnect the clutch switch connector 2 Loosen the locknut and remove the clutch switch 3 Install the new clutch switch 4 Adjust the switch as shown in Inspection above 5 Tighten the locknut Tightening torque 14 18 N m 1 4 ...

Page 305: ... switch 3 Install in the reverse order of removal Tightening torque 14 18 N m 1 4 1 8 m kg 10 13 ft Ib EXHAUST BRAKE SWITCH Inspection 1 Remove the steering column cover 2 Disconnect the exhaust brake switch connector 3 Check continuity of the switch Exhaust brake switch Continuity OFF No ON Yes 4 If not as specified replace the switch Refer to Section T F2 55 ...

Page 306: ...ZLE F3 25 ACCELERATOR PEDAL ACCELERATOR CABLE F3 28 FUEL CUT CONTROL SYSTEM F3 29 SYSTEM OPERATION F3 29 FUEL STOP CABLE F3 29 IDLE SPEED CONTROL SYSTEM F3 31 I STRUCTURAL ViEW F3 31 IDLING KNOB IDLING CABLE F3 31 EXHAUST SYSTEM F3 33 COMPONENTS F3 33 EXHAUST CONTROLLED HEATING SYSTEM F3 35 STRUCTURAL ViEW F3 35 EXHAUST HEATING CONTROL UNIT F3 37 EXHAUST BRAKE UNIT POWER CHAMBER F3 38 MAGNETIC VAL...

Page 307: ...F3 INDEX INDEX INTAKE AND FUEL DEVICES 9TGOF3 002 F3 2 ...

Page 308: ...pe Removal page F3 19 Installation page F3 22 7 Injection nozzle Removal Inspection page F3 25 Disassembly page F3 26 Installation page F3 27 8 Injection pump RemovaL page F3 18 Installation page F3 21 9 Fuel filter Air bleeding page F3 23 Replacement page F3 24 10 Accelerator pedal Accelerator cable Inspection Adjustment page F3 28 Removal Installation page F3 28 11 Fuel stop cable Inspection Adj...

Page 309: ...F3 INDEX EXHAUST AND EXHAUST CONTROLLED HEATING DEVICES F3 4 I ...

Page 310: ...Inspection I Replacement page F3 40 6 Solenoid valve Intake shutter valve Inspection page F3 41 Cancel relay Removal Inspection Installation page F3 41 8 Exhaust heating switch Removal Inspection I 9TGO Installation page F3 42 9 Accelerator switch Inspection page F3 42 Replacement page F3 43 10 Clutch switch Inspection Replacemen page F3 43 11 Neutral switch Inspection page F3 43 Replacement page ...

Page 311: ...KE UNIT INJECTION PUMP h ACCELERATOR SWITCH I EXHAUST HEATING SWITCH I EXHAUST BRAKE SWITCH TO SOLENOID EXHAUST VALVES HEATING t r l l EXHAUST AND Z TROL INTAKE SHUTTER VALVES NEUTRAL SWITCH INTAKE SHUTTER VALVE FRESH AlIl DUCT VALVE INTAKE SHUTTER VALVE I W Alrl CLEANEIl g U U t m c Ci D 01 W C Z m o c t r Z m ...

Page 312: ...r I EXHAUST SOLENOID VALVE EXHAUST SHUTIER UNIT CHECK VALVE VACUUM PUMP ACTUATOR INTAKE SHUTIER VALVE VACUUM TANK G l Tl WCr I g c o o m c Z c o c Z m W ...

Page 313: ... BRAKE SNITCH o F 8 F C I I I I f l ILlY lFI IX3QI NEUTRAL SWITCH 8 F LIN A B Ol AlA HEATEA CONTROL lJ IJT F 8 02 AlA HEATER AEL IRJ T O 11 1 3 WATEA THERMO SENSOR AI 8 05 ACCELERATOR SWITCH 18 06 MAGNETIC VAlVE A3 Ff S j 5a Et ID VAlYE EXHAUST HEATING YSTEM IAI I J 18IRI o 8 10 EXHAUST IlRAkE S1I11 j IHIE j HAUST HEA WCH I ffi N 8 8 ti 6 V BR A 02 StARTlNG MOTOR IBI FUSl8LE LfliK1RI BI fUSIBLE LI...

Page 314: ...ine knocking Incorrect injection timing Adjust Incorrect injection starting pressure Adjust Malfunction of injection nozzle Clean or adjust Low quality of fuel Drain and replace Excessive exhaust Incorrect injection timing Adjust smoke Water in injection pump fuel filter or sedimentor Drain Incorrect injection starting pressure Adjust Clogged air cleaner Clean or replace Malfunction of delivery va...

Page 315: ...level is near the radiator inlet port and that the level in the reservoir is between the FULL and LOW marks Add coolant as necessary Battery 1 Check for corrosion on the terminals and for loose cable connections 2 Check the electrolyte level If the level is low add distilled water to the UPPER LEV EL mark 3 Check the specific gravity with a hydrometer If the specif ic gravity reading is 1_23 or le...

Page 316: ...70 0 rpm 5 If not as specified loosen the locknut of idle adjust bolt and then adjust turning the bolt 6 Tighten the locknut Tighting torque 9 8 14 N m 100 140 em kg 87 121 in Ib Injection Timing Inspection Note Usually it is enough to confirm that the external marks are aligned Caution Direct injection engine is sensitive to injection tim ing Incorrect timing will cause engine knocking or low pow...

Page 317: ...ontrol lever 3 Remove the bracket 4 Loosen injection pipes No 2 4 at the pump 5 Remove NO 1 injection pipe and the delivery valve holder 6 Remove the delivery value spring seat and spring Caution Do not remove the delivery valve body 7 Rock the delivery valve to break it loose from the barrel Note If the delivery valve is lifted up without breaking it loose the barrel may also be lifted out of the...

Page 318: ...r 10 Tighten No 1 injection pipe so that it points away from the pump 11 Turn the flywheel in the direction of rotation and set it at 200 BTDC 12 Place a container under No 1 injection pipe and verify that fuel is expelled when pumping the primer pump 13 While pumping the priming pump turn the flywheel in the normal direction of rotation and verify that fuel flow stops as specified Fuel stops 12 B...

Page 319: ...ange and pump body for future reference 17 Install the delivery valve spring and spring seat 18 Tighten the delivery valve holder Tighten torque 39 44 N m 4 0 4 5 m kg 29 33 ft Ib 19 Install No 1 injection pipe 20 Tighten injection pipes No 2 4 21 Install the bracket 22 Install the accelerator cable to the control lever 23 Install the fuel stop cable to the cut lever 24 Install the service hole co...

Page 320: ...Ib 22 30 2 2 3 1 16 22 19 25 1 9 2 6 14 19 1 Fresh air duct Check for contamination cracks and other damage Installation Note page F3 16 2 Air cleaner Inspection page F3 10 3 Intake shutter valve Inspection page F3 40 4 Air heater Inspection Section G S Seal cover Visually check the seal cover for contamina tion cracks or other damage N m m kg ft lb 9TGOF3 034 6 Injection pipe Check for contaminat...

Page 321: ... CD 9TGOF3 035 9TGOF3 036 Installation note Fresh air duct Install in the order shown in the figure Intake manifold 1 Use a new gasket 2 Tighten in the order shown in the figure Tightening torque 22 31 N m 2 2 3 1 m kg 15 22 ft Ib ...

Page 322: ...der of removal Warning Keep sparks cigarettes and open flames away from the fuel tank Note Drain the fuel before removing the fuel tank 25 29 2 5 3 0 18 21 0 0 5 u 020 _ 14 17 1 4 1 7 10 12 25 29 2 5 3 0 18 21 9TGOF3 037 1 Connector 4 Fuel tank strap 2 Fuel hose 5 Fuel tank 3 Evaporative hose Be sure the air flows through the hose each side Check for contamination corrosion and other damage F3 17 ...

Page 323: ...OF3 OQl Caution Before removing the injection pump perform the following procedure 1 Remove the negative battery cable 2 Remove the cover from the flywheel and turn the flywheel until No 1 cylinder is at 300 8TDC 3 Remove the cover from the gear case and verify that the mark on the timer and the pointer are aligned Note If they are not aligned No 4 cylinder is at 30 BTDC 4 Remove in the order show...

Page 324: ...5 4 N m 35 55 cm kg 30 48 in lb Nom m kg ft lb 1 Air hose 2 Seal cover 3 Injection pipe 4 Intake manifold air heater intake shutter valve 5 harness 9TGOF3 Q4 6 Fuel stop cable accelerator cable 7 Fuel hose pipe 8 Oil pipe 9 Bracket 10 Bolt and nut for installation pump 11 Injection pump assembly F3 19 ...

Page 325: ...aft 4 Remove the flange plate 5 Affix the pump in a vise and install the flange plate 6 Align the marks on the pump and flange p te and tighten the mounting nuts Tightening torque 34 39 N m 3 5 4 0 m kg 25 29 ft Ib 7 Install the woodruff key and install the timer and gear as sembly onto the pump shaft 8 Affix the timer in a vise and tighten the nut Tightening torque 59 69 N m 6 0 7 0 m kg 43 51 ft...

Page 326: ... the injection pump verify that No 1 cylin der is at 30 BTDC 2 Align the notches of the flange plate and the injection pump gear 3 Install the injection pump 4 Verify that the mark on the timer and the tab of the timing gear case are aligned Accelerator cable fuel stop cable 1 After installing the accelerator cable adjust the free play of the cable Refer to page F3 28 2 After installing the fuel s...

Page 327: ...el filter 4 Loosen the bleeder screw of fuel filter and bleed the air Inspection 1 Visually check the sedimentor for damage and fuel leak age Repair or replace if necessary 2 Check the position of the float ring and if the ring is near the float level line drain the water SEDIMENTOR SENSOR DETECTOR Inspection 1 Remove the sedimentor sensor from the sedimentor 2 Verify that there is continuity with...

Page 328: ...N m 60 90 em kg 52 78 in Ib 4 Loosen the return pipe at the injection pump and pump the priming pump until no air is expelled 5 Tighten bolt Tightening torque 12 15 N m 120 150 em kg 104 130 in Ib 6 Push the priming pump down and tighten it 7 Loosen the injection pipes at the injection nozzles 8 Crank the engines and verify that fuel is expelled from each injection pipe 9 Tighten the injection pip...

Page 329: ...en flames away 1 Rei nove the filter with a filter wrench 2 Apply to the O ring 3 Install the filter and tighten by hand Then tighten with filter wrench an additional 1 3 turn 4 Bleed air from the filter Refer to page F3 23 5 Start the engine and verify that there is no fuel leakage around the filter ...

Page 330: ...tion pipe holder 3 Injection pipe Inspection 4 Holder bracket S Injection nozzle F3 N m rn kg ft lb 9TG0F3 063 Warning Do not allow your hands or any other part of the body to come into the direct path of the spray when using the nozzle tester because the spray has enough force to break the skin and possi bly cause blood poisoning Caution The nozzle tester should be set up in a clean work place F3...

Page 331: ...han the specified injection pressure and see if the fuel leaks from the nozzle injection hole If the fuel leaks it is necessary to disassemble wash and recheck the nozzle or replace it Atomizing condition 1 Connect the nozzle on the nozzle tester 2 Bleed the air by operating the nozzle tester handle several times 3 Keeping the pressure gauge of the nozzle tester in the non functioning condition qu...

Page 332: ...nozzle body upright and insert the needle valve approximately two thirds of the way into the body Verify that the needle valve drops into the body under it s own weight when released Assembly 1 Assemble in the reverse order of disassembly Tightening torque 29 39 N m 3 0 4 0 m kg 22 29 It Ib 2 Retest the nozzle after assemble Refer to page F3 26 Installation caution Use new gaskets and O rings 1 In...

Page 333: ...the stop bolt if necessary Tightening torque 6 9 9 8 N m 70 100 m kg 61 87 in Ib 3 Check the free play of the accelerator cable Free play 1 0 3 0mm 0 039 0 12 in 4 Adjust the nuts if necessary Tightening torque 9 8 15 N m 100 150 em kg 87 130 in Ib 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 1 Accelerator cable 2 Accelerator pedal F3 28 2 5 5 0 N m 25 50 cm ...

Page 334: ...dition of tensed po sition of the fuel stop cable Free play 0 2mm 0 0 078 in 5 Verify that the engine stops when turn the engine switch OFF 6 If not as specified adjust the cable as follows Adjustment 1 Turn the engine switch OFF 2 Loosen nut and remove the fuel stop cable from the bracket 3 Pull the fuel stop cable and verify that the fuel stop lever is at the fuel stop position 4 Adjust nut G so...

Page 335: ...EM Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 3 Adjust the free play of the fuel stop cable 9TGOF3 080 1 Steering column cover 3 Fuel stop cable 2 Locknuts F3 30 ...

Page 336: ...KNOB IDLING CABLE Adjustment 1 Verify that the control lever of the injection pump is at the idle position when the idling knob is not turned 2 Verify that the idle speed increases when the knob is turned clockwise 3 Check the free play of the cable when the idling knob is not turned Free play 0 5mm 0 0 2 in 4 If not as specified loosen the locknuts and adjust the free play Tightening torque 9 8 1...

Page 337: ...IDLE SPEED CONTROL SYSTEM Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 100 150 cm kg 87 130 in Ib 9TGOF3 084 1 Idling knob 2 Idling cable F3 32 ...

Page 338: ...order of removal 37 52 3 8 5 3 27 38 19 o e 19 25 1 9 2 6 14 19 1 Exhaust manifold insulator 2 Exhaust manifold Check for contamination cracks and other damage 3 Front pipe assembly Check for contamination cracks and other damage 4 Exhaust brake unit Inspection page F3 38 REPLACE GASKET 37 63 3 8 6 4 27 6 N m m kg ft lb 9TG0F3 oas 5 Main silencer assembly Check for contamination cracks and other c...

Page 339: ...F3 EXHAUST SYSTEM MEMO F3 34 ...

Page 340: ...EXHAUST CONTROLLED HEATING SYSTEM EXHAUST CONTROLLED HEATING SYSTEM STRUCTURAL VIEW F3 9TGOF3 086 F3 35 ...

Page 341: ...e F3 39 Replacement page F3 43 Installation page F3 39 11 Neutral switch 4 Intake shutter valve Inspection page F3 43 Inspection page F3 40 Replacement page F3 44 Removal I Installation page F3 15 12 Vacuum switch pay load above 3 5t only 5 Intake shutter valve actuator Inspection Section T Inspection page F3 40 13 Exhaust brake switch Replacement page F3 40 Inspection page F3 44 6 Solenoid valve ...

Page 342: ...sed Refer to page F3 43 Accelerator or clutch pedal Approx OV Accelerator switch depressed Refer to page F3 42 Wire harness Neutral Approx 12V Neutral switch In gear Approx OV Refer to page F3 43 Wire harness Exhaust brake switch OFF Approx 12V Exhaust brake switch Exhaust brake switch ON Approx OV Refer to page F3 44 Wire harness Constant Approx 12V Exhaust brake switch Refer to page F3 44 Exhaus...

Page 343: ...ust brake unit 2 Remove the exhaust brake unit assembly Note It is difficult to remove the exhaust brake unit when the exhaust shutter valve is open Connect a vacu um pump to hold the valve closed to remove it Inspection 1 Remove the exhaust brake unit assembly 2 Remove the service hole cover 3 Connect a vacuum pump and check the following Starts closing 100mmHg 3 9 inHg Fully closing 350mmHg 13 8...

Page 344: ...emoval 1 Remove the vacuum hose from the magnetic valve 2 Disconnect the connector from the magnetic valve 3 Remove the magnetic valve Inspection 1 Verify air flow through the valve A B Flow A C No flow B C No flow 2 Connect 12V to the valve and verify air flow A B No flow A C Flow B C No flow Installation Note After installing the magnetic valve the vacuum warning buzzer may ring until vacuum is ...

Page 345: ...ify that the rod of the actuator smoothly when moved by hand 3 Start the engine and run it at idle 4 Verify that there is vacuum at the vacuum hose If not check the intake shutter solenoid valve Refer to page F3 41 5 Install the vacuum hose and verify that the actuator rod is pulled Replacement Note After installing the actuator the vacuum warning buzzer may ring until vacuum is built up 1 Disconn...

Page 346: ...bleeding B C Bleeding 3 Check the bleeding condition of each pipe by breathing when there is battery voltage between terminals of the sole noid valve It is normal if it is the same as following A B Bleeding A C No bleeding B C No bleeding CANCEL RELAY Removal Remove as shown in the figure Inspection 1 Disconnect the cancel relay 2 Check for continuity between terminals A and D of the relay 3 Conne...

Page 347: ...king continuity between A and B Band C connect the negative tester load to terminal B Installation Install in the reverse order of removal ACCELERATOR SWITCH Inspection 1 Run the engine to normal operating temperature 2 Stop the engine and affix reflecting tape to the crankshaft pulley 3 Start the engine 4 Disconnect the accelerator switch connector 5 Connect a photo tachometer 6 Verify that there...

Page 348: ... Inspection 1 Disconnect the clutch switch connector 2 Check continuity of the switch Clutch pedal Continuity Depressed No Released Yes Replacement 1 Disconnect the clutch switch connector 2 Loosen the locknut and remove the clutch switch 3 Install the new clutch switch 4 Adjust the switch as shown in Inspection above 5 Tighten the locknut Tightening torque 14 18 N m 1 4 1 8 m kg 10 13 ft Ib NEUTR...

Page 349: ...eutral switch 3 Install in the reverse order of removal Tightening torque 14 18 N m 1 4 1 8 m kg 10 13 ft Ib EXHAUST BRAKE SWITCH Inspection 1 Remove the steering column cover 2 Disconnect the exhaust brake switch connector 3 Check continuity of the switch Exhaust brake switch Continuity OFF No ON Yes 4 If not as specified replace the switch Refer to Section T ...

Page 350: ... 11 SUB STARTER SYSTEM G 16 AIR HEATER SySTEM G 18 STRUCTURAL ViEW G 17 CIRCUIT DIAGRAM G 18 AIR HEATER CONTROL UNIT G 19 AIR HEATER G 20 AIR HEATER RELAy G 20 WATER THERMOSENSOR G 21 GLOW INDICATOR LAMP G 21 aUICK START SYSTEM aSS G 22 STRUCTURAL ViEW G 22 CIRCUIT DIAGRAM G 23 ass CONTROL UNIT G 23 GLOW PLUG G 24 GLOW PLUG RELAy G 25 WATER THERMOSENSOR G 25 9TFOGX QOl G ...

Page 351: ...ol unit Removal Installation page G 7 Inspection page G 22 Disassembly I Assembly page G 7 8 Glow plug Inspection page G 8 Inspection page G 24 3 Drive belt 9 Glow plug relay Inspection Adjustment page G 10 Inspection page G 26 4 Starter 10 Water thermosensor Inspection On vehicle page G 11 Inspection page G 26 Removal Installation page G 11 11 Glow indicator lamp Disassembly Assembly page G 12 In...

Page 352: ...rol unit Removal Installation page G 7 Inspection page G 19 Disassembly Assembly page G 7 8 Air heater Inspection page G 8 Inspection page G 20 3 Drive belt 9 Air heater relay Inspection Adjustment page G 10 Inspection page G 20 4 Starter 10 Water thermosensor Inspection On vehicle page G 11 Inspection page G 21 Removal Installation page G 11 11 Glow indicator lamp Disassembly Assembly page G 12 I...

Page 353: ...ter control unit Replace Faulty air heater relay Replace Faulty air heater Replace Faulty water thermosensor Replace Broken or grounded of harness in air heater system Repair or replace and related parts Quick start system and related parts Faulty QSS control unit Replace Faulty glow plug relay Replace Faulty glow plug Replace Faulty water thermosensor Replace Broken or grounded of harness in ass ...

Page 354: ...Do not overfill Specific Gravity 1 Measure the specific gravity by using a hydrometer 2 If the specific gravity reading is less than standard recharge the battery Standard specific gravity 1 27 1 29 20 C 68 F Charging 1 Remove the battery cover and battery from the vehicle 2 Remove all the vent caps 3 Perform a charge Standard Current Battery Charging Electric Rapid Charging Electric Current A Cur...

Page 355: ...ficantly lower than the battery voltage 0 5 4V If the voltmeter reading is the same as the battery voltage there may be a malfunction in the al ternator 4 Short circuit the terminals of the ammeter and then start the engine After starting discontinue the short circuiting Caution Be careful when starting the motor that the cur rent of the starter doesn t flow to the ammeter 5 Under no load conditio...

Page 356: ...er to page G 10 10 Tighten the bolt and bolt Tightening torque Bolt 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Bolt 37 52 Nom 3 8 5 3 m kg 27 38 ft Ib 1 Disassemble in the numbered order shown in the figure Refer to disassemble Note 2 Assemble in the reverse order of disassemble Refer to assemble Note 1 Stator 2 9 6 4 30 65 26 56 Inspection page G 8 2 Nut set 3 Pulley 4 Front bracket 5 Rotor Inspection pa...

Page 357: ...gulator Assembly 1 Use a soldering iron to disconnect the brush holder and IC regulator assembly from the rectifier Inspection Inspect the following parts and repair or replace if a problem is found Stator 1 Use a circuit tester to check for continuity between the core and each lead wire No continuity is the normal condition 2 Use a circuit tester to check for continuity between lead wires Continu...

Page 358: ... If the brushes are worn almost to or beyond the limit re place them Minimum Smm 0 31 in 2 When install new brush pull lead wire to put brush into ap prox 5mm 0 2 in holder and install with soldering iron Caution Replace both brushes in the same time Rectifier 1 Check for continuity of the diodes by using an ohmmeter Negative terminal Positive terminal Continuity E Yes B Pl P2 Ps No L No E No Pl P...

Page 359: ...HA SL SL 4WD TF Used one 245 294 343 392 373 471 383 520 25 30 55 66 35 40 n 88 38 48 83 106 39 53 86 117 New one 294 392 392 491 471 569 451 520 30 40 66 88 40 50 88 110 48 58 110 128 46 53 101 117 3 Check the drive belt deflection by applying moderate pres sure 10 kg load midway between the pulleys Deflection Used one 10 11mm 0 39 0 43 in 14 16mm 0 55 0 63 in SL 4WO 11 12mm 0 43 0 49 in TFengine...

Page 360: ...een S terminal and ground by using a voltmeter 5 If the voltage is 8V or more the starter is malfunctioning 6 If less than 8V the wiring harness is malfunctioning Removal I Installation 1 Disconnect the negative battery cable 2 Disconnect the wiring from the starter 3 Remove the starter bolts 4 Draw out the starter from lower side of the vehicle 5 Install in the reverse order of removal Tightening...

Page 361: ...er 9 Armature 3 Pinion gear Inspection page G 13 4 Front bracket 10 Yoke field coil 5 Overrunning clutch Inspection page G 16 6 Driving gear Replacing brush page G 17 Magnetic Switch 9TFOGX QOS 11 Brushes and brush holder Inspection page G 16 Replacing brush page G 17 12 Rear bracket 1 Verify that there is continuity between and terminal by using a circuit tester Replace if necessary 9TGOG1 035 G ...

Page 362: ...re with a circuit tesrer Replace the armature if there is con tinuity 2 Insulation of armature coil Check for continuity between the commutator and the shaft with a circuit tester Replace the armature if there is con tinuity 3 Vibration of the commutator 1 Place the armature on V blocks and measure the vibra tion by using a dial gauge 2 If the vibration is at limit or more repair with a lathe so t...

Page 363: ... assembly if there is no continuity 2 Ground of the field coil 1 Check for continuity between the connector and yoke by using a circuit tester 2 Repair or replace the yoke assembly if there is continuity 3 Installation of the field coil Replace the yoke assembly if the field coil is loose Brushes and Brush Holder 1 Check for continuity between the insulated brush and the plate with a circuit teste...

Page 364: ...brush wire on yoke 2 Solder a new brush around the cut part of the wire No load Test 1 Connect the starter and the battery as shown in the figure 2 If the conditions below are met when the starter is operat ed the starter is functioning properly Output kW 2 7 Terminal voltage M 11 Electric current A Less than 120 Rotating speed rpm More than 4 000 G 15 ...

Page 365: ...e engine does not start check the neutral switch sub starter switch and wire harness Inspection Neutral switch 1 Disconnect the neutral switch connector 2 Check continuity between terminals A and B Transmission Continuity Neutral Yes In gear No Sub starter switch 1 Disconnect the sub starter switch connector 2 Check continuity between terminals of the switch Sub starter switch Continuity ON Yes OF...

Page 366: ...e Install in the order shown in the figure referring to Installation Note 9TFOGX 6 1 Air heater control unit Inspection page G 21 3 Air heater relay Inspection page G 22 2 Air heater 4 Water thermosensor Inspection page G 22 Inspection page G 23 Installation Note page G 20 5 Glow indicator Inspection page G 23 G 17 1 ...

Page 367: ...in the figure CIRCUIT DIAGRAM G 18 AI l HEATER CONTROL UNIT 8 01 i MAIN 60A COMBINATION METER 4 ENGINE 15A GIY B Y B W FI F F w B BIR F F ALTERNATOR B R R B F WATEA THERMO SENSOR B F 8 F BAITERY STARTER 8 01 Y F 8R R ENGINE SWITCH B 01 AIR HEATER CONTROL UNIT F G Y B W B R Y B SlY W B B 02 AIR HEATER RELAY R A O B 03 WATEA THERMO SENSOR RI 8 R B 04 AIR HEATER R IW BIO 9TGOGH 53 ...

Page 368: ...olant temperature approx 80 C 17S F 2 3 Engine switch ON 0 Engine running Approx 12 Engine switch ON or ST Approx 12 Engine switch ACC or OFF 0 Engine switch ST Approx 12 Engine switch ON ACC or OFF 0 Always 0 Coolant temperature less than 20 C 68 F 1 Engine SW ON for 0 approx 2 seconds 2 Engine SW ON after approx 2 secondso2 Approx 12 Coolant temperature less than 20 C 68 F 2 Engine SW ON for app...

Page 369: ...e wiring harness 3 Check the voltage of the relay B terminal with circuit tester Standard voltage Approx 12V 4 Be sure the voltage of the relay A terminal is appox 12V for 7 seconds after engine switch is ON 5 If not as specified be sure the voltage of the relay C termi nal is appox 12V for 7 seconds after engine switch is ON 6 If as specified perform the resistance inspection as follows If not as...

Page 370: ...r with a thermometer and heat the water gradually 3 Measure the resistance as shown Standard resistance Water temperature Oe oF 0 32 40 104 80 176 100 212 GLOW INDICATOR LAMP Inspection Resistance n 1 860 207 255 46 8 55 2 25 2 30 8 1 Turn the engine switch ON and verify that the GLOW indi cator flashes for a few seconds G 21 ...

Page 371: ...oval I Installation 1 ass control unit 5 9 8 8 N m 60 90 em kg 52 78 in Jb Inspection page G 25 2 Glow plug Inspection page G 26 3 Glow plug relay Inspection page G 27 G 22 9TFOOX Q07 4 Water thermosensor Inspection page G 27 5 Glow indicator lamp Inspection page G 27 ...

Page 372: ...IT LESS THAN 30 C 86 F ON 1SA METER WATER THERMO SWITCH 8 05 SIR G R SATTERY W R STARTER S F SlY SIR B WIB 1 R R R R 1 GLOW PLUG I ass CONTROL UNIT Inspection 1 Remove the ass control unit X 04 9TGOG1 065 2 Measure the voltage at each terminal of the control unit 9TGOG1 066 G 23 ...

Page 373: ... 0 After cranking for approx 15 sec coolant temperature is less Approx 12 0 than 30 C 86 F Engine switch ON or ST Approx 12 Engine switch ACC or OFF 0 Engine Switch 5T Approx 12 Engine switch ON ACC or OFF 0 Constant 0 After Engine switch ON for approx 3 sec 0 Engine switch ON after approx 3 sec Approx 12 After engine switch ON for approx 6 sec Approx 12 The engine switch ON after approx 6 sec 0 C...

Page 374: ...erature is less than 30 C 86 F 12 0 E Always 0 Note 12 0V dndicates voltage fluctuates between 12V and OV Operation 1 Disconnect the negative battery terminal 2 Remove the glow plug relay 3 Measure resistance between terminals D and E Resistance Approx 130 4 Apply 12V bet yeen terminals 0 and E and verify that there are continuity beween terminals A and 8 and A and C WATER THERMOSENSOR Inspection ...

Page 375: ...N H 8 AIR BLEEDING H 10 OVERHAUL H 11 VACUUM POWER ASSIST H 13 INSPECTION H 13 REMOVAL INSPECTION INSTALLATION H 14 CLUTCH RELEASE CYLINDER H 15 PREPARATION H 15 REMOVAL INSTALLATION H 15 AIR BLEEDING REFER TO PAGE H 10 OVERHAUL H 16 CLUTCH UNIT H 17 PREPARATION H 17 REMOVAL INSTALLATION H 18 RELEASE BEARING H 21 INSPECTION H 21 CLUTCH COVER H 21 INSPECTION H 21 CLUTCH DISC H 21 INSPECTION H 21 PI...

Page 376: ...nstallation page H 8 Removal Installation page H 18 Air bleeding page H 10 OverhauL page H 11 Inspection page H 21 8 Clutch disc 3 Vacuum power assist Removal Installation page H 18 Inspection page H 13 Inspection page H 21 Removal Inspection 9 Pilot bearing Installation page H 14 Inspection page H 18 4 Clutch release cylinder Removal Installation page H 22 Removal Installation page H 15 10 Flywhe...

Page 377: ... play Adjust H 5 Clutch pedal sticking Repair or replace H 6 Flywheel damaged Repair or replace H 18 22 Faulty Excessive runout or damaged clutch disc Replace H 18 21 disengagement Clutch disc splines rusted or worn Remove rust or replace H 18 Oil on facing Repair or replace H 18 Diaphragm spring weakened Replace H 18 Excessive clutch pedal play Adjust H 5 Insufficient clutch fluid Add fluid H 3 L...

Page 378: ... the master cylinder through a wheel cylinder 2 Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug 3 Place the other end of the vinyl hose in a clear container 4 Slowly pump the clutch pedal several times 5 With the clutch pedal depressed loosen the bleeder screw with the SST to let the fluid escape Close the bleeder screw with the SST 6 Repeat Step...

Page 379: ... m 100 140 cm kg 87 122 in Ib 4 After adjustment measure the pedal free play Clutch Pedal Free Play Inspection 1 Depress the clutch pedal by hand until resistance is felt Pedal free play 0 5 2 7mm 0 02 0 11 in Total pedal free play 5 0 11 0mm 0 20 0 43 in 2 If necessary adjust the pedal free play Adjustment 1 Loosen locknut C and turn push rod 0 until pedal free play is correct 2 Verify that the d...

Page 380: ...l referring to Installation Note EXCEPT VACUUM POWER ASSIST REPLACE WITH VACUUM POWER ASSIST N m m kg ft Ib 9TFOHX Q04 1 Cover 9 Bolt 2 Column cover 10 Spring With vacuum power assist 3 Meter cover 11 Assist spring Except vacuum power assist 4 Instrument cluster Installation Note page H 7 5 Retaining ring 12 Clutch pedal 6 Pin Adjustment page H 5 7 Push rod 13 Spacer Except vacuum power assist 8 N...

Page 381: ...LUTCH PEDAL H Installation Note Assist Spring Except vacuum power assist 1 Adjust the length of the assist spring by turning the adjust ing nut after installing the clutch pedal Standard 35 8 36 8mm 1 41 1 45 in H 7 ...

Page 382: ...s get on a painted surface wipe it off immediately with a rag 1 Remove in the order shown in the figure referring to Removal Note 2 Inspect all parts and repair or replace as necessary 3 Install in the reverse order of removal referring to Installation Note 2 19 25 1 9 2 6 14 19 D N m m kg ft lb 9TFDHX OO5 1 Cover 5 Bolt 2 Clutch pipe 6 Nut Removal Note page H 9 7 Clutch master cylinder Installati...

Page 383: ...ssist 1 Set the SST on the clutch master cylinder 2 Turn the adjusting bolt until the end of the bolt contacts the piston 3 Apply a vacuum of 500 mmHg 19 7 inHg to the vacuum power assist using a vacuum pump 4 Turn over the SST and set it on the vacuum power assist 5 Verify that the clearance between the SST and the push rod is 0 1 0 3mm 0 004 0 012 in Adjust the push rod if necessary Clutch pipe ...

Page 384: ... fluid does get on a painted surface wipe it off im mediately Do not mix different brands of clutch fluid Do not reuse the clutch fluid that was drained 1 Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug 2 Insert the other end of the vinyl hose in a clear container 3 Slowly pump the clutch pedal several times 4 While depressing the pedal loosen th...

Page 385: ...I 6 REPLACE 58 N m m kg ft lb 9TFOHX OO7 1 Joint 5 Spacer 2 Bushing 6 Primary cup 3 Snap ring Inspect for wear and cracks Disassembly Note page H 11 7 Return spring Assembly Note page H 12 8 One way check valve 4 Piston and secondary cup assembly 9 Master cylinder body Disassembly Note page H 12 Inspect cylinder bore for scoring and corrosion Assembly Note page H 12 Inspect for wear scoring and cr...

Page 386: ...llation hole Assembly Note Caution Before assembly make sure all parts are completely clean Do not mix different brands of clutch fluid Do not reuse the clutch fluid that was drained Apply the specified clutch fluid to the piston and secondary cup assembly spacer primary cup and cylinder bore before assembly Replace parts with new ones whenever specified to do so 03UOHX 01g Snap ring Caution Do no...

Page 387: ...d depress the pedal a few times and confirm that the pedal height does not change 2 Start the engine and confirm that the pedal depression force is reduced Vacuum Loss Check 1 Start the engine 2 Stop the engine after 1 or 2 minutes and depress the pedal several times 3 Verify that the pedal depression force becomes higher Vacuum Loss Check Loaded Condition 1 Start the engine and depress the pedal ...

Page 388: ...e reverse order of removal referring to Installation Note 1 Cover 2 Column coyer 3 Meter cover 4 Instrument cluster 5 Duct 6 Sub select cable H 14 7 Vacuum pipe 8 Bolt 9 Bolt Nut 10 Bolt 11 Nut 12 Vacuum power assist clutch pedal assembly Nom m kg ft lb 9TFOHX Q09 13 Retaining ring 14 Pin 15 Nut 16 Vacuum power assist Installation note page H 9 17 Clutch pedal assembly ...

Page 389: ...ove in the order shown in the figure referring to Removal Note 2 Install in the reverse order of removal referring to Installation Note 1i 22 26 W 2 2_2 7 16 PACKING REPLA Nom m kg ft lb 9TFOHX Ol0 1 Flexible hose 3 Clutch release cylinder Removal Note page H 15 Remove boot and check for fluid leakage Installation Note page H 16 OverhauL page H 16 2 Bolt Nut 9TGOHX 025 Removal Note Flexible hose C...

Page 390: ...parts are completely clean Apply the specified clutch fluid to the piston and cup assembly and cylinder bore before as sembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Installation Note 1 Boot band 2 Boot 3 Push rod 4 Piston and cup assembly Inspect ...

Page 391: ...t of 491285071 CLUTCH UNIT For prevention of engine rotation For prevention of engine rotation For alignment of clutch disc For removal of pilot bearing 49 W011 103 Brake ring gear TF engine 49 W065 062 Collar SL engine 49 1285071 Puller bearing For prevention of engine rotation For prevention of engine rotation For H removal of pilot bearing 9TFOHX 011 H 17 ...

Page 392: ... 166 SL TURBO ENGINE EXCEPT TF ENGINE TF ENGINE 1 9 2 6 14 19 N m m kg ft Ib 9TFOHX 012 1 Clutch release cylinder 7 Clutch disc 2 Transmission and transfer case Removal Note page H 19 Service Section J1 J2 Inspection page H 21 3 Boot Installation Note page H 20 4 Clutch release bearing 8 Pilot bearing Inspection page H 21 Inspection page H 19 5 Clutch release fork Removal Note page H 22 6 Clutch c...

Page 393: ...rn at a time in a crisscross pattern until spring tension is released Then remove the clutch cov er and disc Pilot bearing 1 Remove the pilot bearing with the SST Flywheel Note After removing the flywheel inspect for oil leakage past the crankshaft rear oil seal If necessary replace the oil seal Refer to Section B 1 Hold the flywheel with the SST 2 Remove the bolts and remove the flywheel H 19 ...

Page 394: ...0 N m 15 5 16 3 m kg 112 118 ft Ib HA engine 177 196 N m 18 0 20 0 m kg 130 145 ft Ib SL engine 206 226 N m 21 0 23 0 m kg 152 166 ft Ib SL Turbo TF engine Pilot bearing Note Install the pilot bearing flush with the flywheel 1 Install the new bearing with the suitable pipe Clutch disc 1 Clean the clutch disc splines and main drive gear splines then apply organic molybdenum grease 2 Hold the clutch...

Page 395: ...rce in the axial direction If the bearing sticks or has excessive resistance replace it CLUTCH COVER INSPECTION Note Minor scoring or burning should be removed with emery paper 1 Inspect the contact surface of the clutch disc for scoring cracks and burning Repair or replace as necessary 2 Inspect the contact surface of the clutch release bearing fqr wear and cracks If there is wear or cracks repla...

Page 396: ...um runout 0 7mm 0 027 in PILOT BEARING INSPECTION 1 Turn the bearing while applying force in the axial direction If the bearing sticks or has excessive resistance replace it FLYWHEEL INSPECTION Note Minor scoring or burning should be removed with emery paper 1 Inspect the contact surface of the clutch disc for scoring cracks and burning Repair or replace as necessary 2 Inspect the ring gear teeth ...

Page 397: ...OTING GUiDE J1 12 TRANSMISSION OIL J1 13 INSPECTION J1 13 REPLACl MENT J1 13 TRANSMiSSiON J1 14 PREPARATION J1 14 REMOVAL INSTALLATION J1 14 DiSASSEMBLy J1 17 INSPECTION J1 28 ASSEMBLY J1 31 SHIFT MECHANISM TRANSMISSION J1 47 REMOVAL INSTALLATION J1 47 SHIFT MECHANISM SUB TRANSMiSSiON J1 49 REMOVAL INSTALLATION J1 49 9TFOJ1 OO1 J1 ...

Page 398: ...ansmission Removal Installation page J1 14 Disassembly page J1 17 Inspection page J1 28 Assembly page J1 31 J1 2 9TFOJ1 02 2 Shift mechanism Transmission Removal Installation page J1 47 3 Transmission oil Inspection page J1 13 Replacement page J1 13 ...

Page 399: ... J1 28 Assembly page J1 31 2 Shift mechanism Transmission Removal Installation page J1 47 GRADE API SERVICE GL OR GL S SAE 7SW 90 CAPACITY 3 3 liters 3 5 US qt 2 9 Imp qt 9TFOJ1 003 3 Shift mechanism Sub transmission Removal Installation page J1 29 4 Transmission oil Inspection page J1 13 Replacement page J 1 13 J1 3 ...

Page 400: ...nt mesh Sub transmission mesh system Synchromesh m mp Shift pattern 2 4 R EcoLmy 2 4 R 1st 5 833 5 478 2nd 2 855 3 075 3rd 1 651 1 637 Transmission 4th 1 000 1 000 Gear ratio 5th 0 800 0 794 Reverse 5 372 5 197 Sub Economy 0 804 transmission Power 1 000 Type API Service GL 4 or GL 5 SAE 75W 90 Oil Capacity liters US qt Imp qt 3 5 3 7 3 1 3 3 3 5 2 9 9TFOJ1 P04 J1 4 ...

Page 401: ...WITHOUT SUB TRANSMISSION 1 1st gear 2 2nd gear 3 3rd gear 4 Main drive gear 4th gear 5 Reverse gear OUTLINE J1 9TFOJ1 005 6 5th gear 7 Counter 5th gear 8 Reverse idler gear 9 Countershaft gear 10 Speedometer drive gear J1 5 ...

Page 402: ...gear 2 2nd gear 3 3rd gear 4 Main drive gear 4th gear 5 Reverse gear 6 5th gear 7 Counter 5th gear J1 6 OUTLINE 8 Reverse idler gear 9 Countershaft gear 10 High gear 11 Output shaft 12 Counter high gear 13 Speedometer drive gear 9TGOJ1 007 ...

Page 403: ... cover 3 Center brake drum 4 Rear housing 5 Counter high gear 6 Output shaft 7 High gear OUTLINE 8 Case adapter 9 Main shaft assembly 10 Countershaft gear 11 Counter 5th gear 12 Reverse idler gear 13 Transmission case J1 9TGOJ 09 J1 7 ...

Page 404: ...J1 OUTLINE POWERFLOW Without Sub transmission 1ST 2ND 3RD 9TGOJ1 0l0 J1 8 ...

Page 405: ...OUTLINE J1 4TH 5TH REVERSE J1 9 ...

Page 406: ...J1 POWERFLOW With Sub transmission 1ST 2ND 3RD J1 10 OUTLINE Power Economy 9TGOJ1 l11 ...

Page 407: ...OUTLINE 4TH 5TH REVERSE r J1 Power Economy c J1 11 ...

Page 408: ...rk and shift rod Replace Worn synchronizer ring Replace J1 30 Worn synchronizer cone of gear Replace J1 30 Poor contact of synchronizer ring and gear cone Replace J1 S0 Excessive longitudinal play of gears Replace Worn bearing Replace J1 31 Fatigued synchronizer key spring Replace Jumps out of gear Weak detent ball spring Replace Worn shift fork Replace J1 30 Worn clutch hub sleeve Replace J1 29 E...

Page 409: ...Ib REPLACEMENT 1 Remove the drain plug and drain the oil into a suitable con tainer 2 Wipe clean and apply sealant to the plug threads 3 Install the drain plug Tightening torque 33 S1 N m 3 4 S 2 m kg 2S 38 ft Ib 4 Add the specified oil from the filler plug hole until the level reaches the bottom of the hole Specified oil Type API Service GL 4 or GL S SAE 7SW 90 Capacity W lthout sub transmission ...

Page 410: ...ng For installation of bearing For installation of bearing 1 Disconnect the negative battery cable 498501 631A ttachment rear axle shaft puller e T 490500330 Installer I transmission bearing 490839425C O 0 c _ a Puller set bearing 490862350 Guide shift fork assembly 49 F401 331 Body Part of 49 F401 3308 490600 330 CIS Installer rI transmission bearing 49 F015 002 Installer water seal 2 Raise the v...

Page 411: ... 4 1 Clutch release cylinder Removal Note page J1 16 2 Ground wire Installation Note page J1 16 3 Starter 4 Fuel pipe clip bolt 5 Exhaust pipe and power chamber 6 Sub selector cable 7 Shift selector cable 8 Parking brake cable 9 Ground wire Installation Note page J1 16 10 Speedometer cable 11 Backup lamp switch con nector 12 Neutral switch connector 13 Sub transmission switch con nector Nom m kg t...

Page 412: ...il pan 2 Support the transmission with a transmission jack 3 Remove the transmission mount bolts 4 Remove the transmission from under the vehicle Installation Note Transmission 1 Install the transmission with the transmission jack 2 Tighten the transmission mount bolts Tightening torque a 89 117 Nom 9 1 11 9 m kg 66 86 ft Ib b 37 52 N m 3 8 5 3 m kg 27 38 ft lb Ground wire 1 Install the ground wir...

Page 413: ...eferring to Disassembly Note 6 1 Center brake drum Disassembly Note 14 page J1 18 2 Center brake assembly 3 Transmission mount 4 Oil seal Inspect for damage Replace if necessary On vehicle replacement page J1 18 5 Top cover Disassembly page J1 27 Assembly page J1 33 6 Front cover 7 Clutch housing 8 Adjustment shim 9 Gasket 10 Oil seal Inspect for damage Replace if necessary 11 Sub transmission swi...

Page 414: ...SST Rear housing 1 Remove the rear housing If necessary tap the housing with a plastic hammer Ball bearing Caution Do not damage the oil seal 1 Remove the ball bearing with a brass bar and a hammer On vehicle replacement Oil seal rear 1 Remove the propeller shaft Refer to Section L 2 Remove the center brake drum Refer to page J1 18 3 Remove the center brake assembly and suspend it with a rope ...

Page 415: ...e oil seal 5 Apply transmission oil to outer periphery and lip of the new oil seal 6 Install the new oil seal with the SST 7 Install the center brake assembly 8 Apply sealant to center brake drum splines and install it 9 Install the propeller shaft Refer to Section L J1 19 ...

Page 416: ... Output shaft Inspection page J 1 28 J1 20 9 Bearing Disassembly Note page J1 21 Inspection page J1 31 10 Cap plug 11 Steel ball and spring 12 Shift rod 13 Shift fork 14 Locknut Disassembly Note page J1 21 15 Clutch hub assembly 16 Double cone assembly Inspection page J1 30 9TFOJ1 011 17 Inner cone hub 18 Clutch hub sleeve 19 Synchronizer key 20 Synchror 1izer key spring 21 High gear Inspection pa...

Page 417: ...J1 1 Remove the bearing from the output shaft with the SST Bearing 1 Remove the bearing with the SST Locknut 1 Uncrimp the tab of the locknut 2 Shift the clutch hub sleeves to 1st gear and reverse gear to put the gears in a double engaged condition 3 Remove the locknut J1 21 ...

Page 418: ...J1 i haft TRANSMISSION __s_s_emble in th e order shown In the fig ure referring to 0 sassembly Note 9TGOJ1 037 J1 22 ...

Page 419: ...e J1 28 24 Synchronizer ring 3rd 48 Thrust washer Inspection page J1 30 49 Needle bearing 25 3rd gear Inspection page J1 31 Inspection page J1 28 50 Countershaft assembly 26 Needle bearing Disassembly Note Inspection page J1 31 page J1 25 27 Clutch hub sleeve 51 Countershaft front bearing 28 Synchronizer key Disassembly Note 29 Synchronizer key spring page J1 25 30 Clutch hub Inspection page J1 31...

Page 420: ...ng snap ring so that the ends are 90 to the case grooves 2 Remove the mainshaft bearing with the SST Mainshaft assembly 1 Remove the mainshaft assembly from the transmisSion case Main drive gear 1 Remove the main drive gear from the transmission case Clutch hub assembly 3rd 4th 1 Remove the clutch hub assembly with the SST ...

Page 421: ...ission Caution Do not tap the bearing inner race 2 Gently strike the front of the countershaft with a brass ham mer and remove the bearing outer race from the rear 3 Remove the countershaft assembly from the transmission case Countershaft front bearing 1 Move the bearing away from the spacer with a chisel and a hammer 2 Remove the bearing with the SST J1 25 ...

Page 422: ...e the spacer away from the diaphragm spring with a chisel and a hammer Note j I Do not reuse the diaphragm spring 2 Remove the spacer diaphragm spring and friction gear with the SST Countershaft rear bearing 1 Remove the bearing and thrust washer wijh the SST f ...

Page 423: ...k pin Disassembly Note page J1 28 ill 9 Shift rod 10 Shift fork 3rd 4th 11 Shift rod end 12 Interlock pin Disassembly Note page J1 28 13 Shift rod 14 Shift rod end 15 Shift fork 5th reverse 16 Steel ball and spring 17 Spring seat and spring 18 Selector lever 19 Snap ring 20 Selector arm 21 Cap plug ball and spring 22 Roll pin Disassembly Note 7 page J1 28 23 Shift lever 24 Change lever 25 Reverse ...

Page 424: ... pin punch INSPECTION Inspect all parts and repair or replace as necessary Each gear and main drive gear 1 Inspect synchronizer cones for wear 2 Inspect individual gear teeth for damage wear and cracks 3 Inspect synchronizer ring matching teeth for damage and wear 4 Inspect main drive gear splines for damage and wear Mainshaft 1 Measure the mainshaft runout Runout 0 035mm 0 0014 in max 2 Inspect s...

Page 425: ...1 in max Selector lever and change lever 1 Measure the clearance between the selector lever and change lever Clearance 0 8mm 0 031 in max Inner shift lever and shift fork 1 Measure the clearance between the inner shift lever and shift fork Clearance 0 8mm 0 031 in max Clutch hub assembly 1 Inspect for clutch hub sleeve and hub operation 2 Inspect individual gear teeth for damage wear and cracks 3 ...

Page 426: ... synchronizer ring squarely in the gear then measure around the circumference 3 Measure the clearance between the synchronizer ring and flank surface of gear Clearance 1 0mm 0 039 in min Double cone Note If a problem exists replace the assembly 1 Inspect individual teeth for damage wear and cracks 2 Inspect taper surface for wear and cracks Note Measure around the circumference 3 Measure the heigh...

Page 427: ...lling the transmission with transmission oil rhiYIR f lSI kSPWWI FRONT i 9MUOJX 067 9TGOJ1 072 DOUBLE CONE CLUTCH HUB DOUBLE CONE ASSEMBLY ASSEMBLY 9TGOJ1 073 9TGOJ1 71 Clutch hub caution Align the synchronizer ring grooves with the clutch hub keys during installation Note The synchronizer rings have the same basic shape carefully note these distinguishing features a 3rd 4th and 5th synchronizer r...

Page 428: ...as follows mm in CD 1st and 2nd 18 0 709 5 45 0 215 6 0 236 3rd 4th 5th 17 0 669 4 25 0 67 5 0 197 and Rev Sub 22 0 866 7 77 0 306 6 0 236 Transmission Install the clutch hubs as shown in the figure Shift fork shift rod and shift rod end Note Install the shift forks shift rods and shift rod ends as shown in the figure ...

Page 429: ... 5 3 5 18 25 10 Selector lever 11 Roll pin selector lever Assembly Note page J1 34 12 Spring seat and spring 13 Steel ball and spring 14 Shift fork 5th reverse 15 Shift rod end 16 Shift rod Assembly Note page J1 34 17 Interlock pin Assembly Note page J1 34 18 Shift rod end 19 Shift fork 3rd 4th N tn m kg ft lb 9TFOJ1 o14 20 Shift rod Assembly Note page J1 34 21 Interlock pin Assembly Note page J1 ...

Page 430: ...stopper and springs in the proper direction Roll pin change lever 1 Install the roll pins as shown in the figure Roll pin Selector lever 1 Install the roll pins as shown in the figure Shift rod 1 Slide the shift rod into the top cover while pushing the ball downward as shown in the figure Interlock pin 1 Slide the SST into the top cover to guide the interlock pin and insert the pin ...

Page 431: ...TRANSMISSION J1 Note The interlock pins must be installed as shown 9TGOJ1 083 Roll pin 1 Install the roll pin as shown in the figure J1 35 ...

Page 432: ...J1 TRANSMISSION Mainshaft 1 Assemble in the order shown in the figure referring to Assembly Note J1 36 I N m m kg ft lb 9TGOJ1 085 ...

Page 433: ... 2nd gear pageJ1 38 35 Needle bearing 11 Needle bearing 36 Gear sleeve 12 Thrust washer 37 Snap ring 13 Reverse idler gear 38 Clutch hub 14 Reverse idler gear shaft 39 Synchronizer key spring 15 Mounting bolt 40 Synchronizer key Assembly Note page J1 39 Assembly Note Snap ring 41 Clutch hub sleeve 42 Needle bearing 43 3rd gear 44 Synchronizer ring 3rd 45 Clutch hub assembly 3rd 4th Assembly Note J...

Page 434: ...ase 2 Set the counter 5th gear to its normal position and fit the snap ring Adjustment shim 1 Install the clutch housing Tightening torque 120 155 N m 12 2 15 8 m kg 88 114 ft Ib 2 Drive in the rear bearing outer race with a punch or similar tool 3 Measurethe depth ofthe rear bearing outer race in the trans mission case Select a shim s plus to adjust the clearance between the outer race and the ca...

Page 435: ...lt hole 2 Apply sealant to the mounting bolt then install the bolt Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Clutch hub assembly 3rd 4th 1 Set the mainshaft with a press 2 Install the clutch hub assembly with the SST Thrust lock washer 1 Push the C washers toward 5th gear and measure the clear ance between the C washers and the thrust lock washer If the clearance is not as specified sel...

Page 436: ...1 9TGOJ1 100 J1 40 TRANSMISSION Main drive gear bearing 1 Install the SST between the 4th synchronizer ring and syn chromesh gear on the main drive gear 2 Install the main drive gear bearing with the SST ...

Page 437: ...leeve 7 Needle bearing 8 High gear 9 Synchronizer key spring 10 Synchronizer key 11 Clutch hub sleeve 12 Inner cone hub 13 Double cone assembly Assembly Note page J1 42 17 Shift rod Assembly Note page J1 42 18 Steel ball and spring 19 Cap plug 20 Bearing Assembly Note page J1 42 N m m kg ft lb 21 Output shaft 22 Output shaft bearing Assembly Note 9TFOJ O S page J1 42 23 Spacer 24 Needle bearing 25...

Page 438: ...will be within specifi cation Bearing end play 0 0 1 mm 0 0 004 in Adjustment shim thickness 0 8 0 031 0 9 0 035 1 0 0 039 1 1 0 043 1 2 0 047 Locknut 1 Slide the clutch hub sleeves onto 1st and reverse gears to lock the mainshaft 2 Tighten the new locknut Tightening torque 157 235 N m 16 24 m kg 116 174 ft Ib 3 Use a chisel to stake the locknut Shift fork and shift rod 1 Install the shift fork an...

Page 439: ...SION J1 Mounting bolt 1 Align the counter gear shaft with the mounting bolt hole 2 Apply sealant to the mounting bolt then install the bolt Tightening torque 36 54 N rn 3 7 5 5 m kg 27 40 ft Ib 9TGOJ1 107 J1 43 ...

Page 440: ...45 8 Inner shift lever J1 44 Assembly Note page J1 45 9 Roll pin Assembly Note page J1 45 10 Gasket 11 Rear housing Assembly Note page J1 45 12 Lock bolt Assembly Note page J1 45 13 Speedometer driven gear 14 Sub transmission switch 15 Oil seal 16 Adjustment shim Assembly Note page J1 46 4 N m m kg ft lb 9TFOJ1 017 17 Gasket 18 Clutch housing 19 Front cover 20 Gasket 21 Top cover 22 Oil seal Assem...

Page 441: ...04 in Adjustment shim thickness 0 8 0 031 0 9 0 035 1 0 0 039 1 1 0 043 1 2 0 047 Outer and inner shift lever 1 Install the shift lever as shown in the figure Roll pin 1 Install the roll pin as shown in the figure Rear housing 1 Align the thrust washer silent of the counter gear and the rear housing groove 2 Align the inner shift lever and shift fo k groove and install the rear housing Lock bolt 1...

Page 442: ... plus gasket thickness 0 3mm 0 012 in minus B so that bearing end play will be within specifi cation Bearing end play 0 0 1mm 0 0 004 in Adjustment shim thickness 0 8 0 031 0 9 0 035 1 0 0 039 1 1 0 043 1 2 0 047 Oil seal Caution Do not damage the mainshaft spline 1 Install the oil seal with the SST Center brake drum 1 Install the center brake drum 2 Hold the drum with the SST and tighten the lock...

Page 443: ...o Installation Note A 1 i P 16 26 1 6 2 6 12 19 1 Shift knob Installation Note page J1 48 2 Console 3 Shift cable ball jOint Installation Note page J1 48 4 Selector cable ball joint Installation Note page J1 48 5 Bolt Nom m kg ft lb 9TFOJH 18 6 Clip Installation Note page J1 48 7 Selector cable Inspect boots for damage Inspect cable for damage and function 8 Shift cable Inspect boots for damage In...

Page 444: ... of the shift lever 4 Tighten the locknut Tightening torque 10 15 N m 1 0 1 5 m kg 7 11 ft Ib Shift cable ball joint 1 Measure A and 8 shown in the figure 2 Caluculate the neutral position of the shift lever as follows Neutral position C B A 2B 3 Hold the shift lever in neutral position 4 Loosen the shift cable locknut 5 Turn the ball jOint so that the shift cable aligns with the in stallation hol...

Page 445: ...9 2 6 14 19 1 Steering column cover 6 Clip J1 Nom m kg ft lb 9TFOJ1 19 2 Nut Installation Note page J1 48 Installation Note page J1 49 3 Selector lever 7 Sub selector cable 4 Bolt 5 Spring pin and pin INSTRUMENT PANEL 1 97 in POWER ECONOMY 9TGOJ1 121 Inspect boot for damage Inspect cable for damage and function Installation Note Nut 1 Shift the selector lever to POWER position 2 Adjust the positio...

Page 446: ...OOTING GUiDE J2 12 TRANSMISSION OIL J2 13 INSPECTION J2 13 REPLACEMENT J2 13 TRANSMiSSiON J2 14 PREPARATION J2 14 REMOVAL INSTALLATION J2 14 DISASSEMBLY J2 18 INSPECTION J2 30 ASSEMBLy J2 33 SHIFT MECHANISM TRANSMISSION J2 47 REMOVAL INSTALLATION J2 47 SHIFT MECHANISM SUB TRANSMISSION J2 49 REMOVAL INSTALLATION J2 49 9TGOJ2 Q01 J2 ...

Page 447: ...isassembly page J2 18 Inspection page J2 30 Assembly page J2 33 J2 2 GRADE API SERVICE GL 4 OR GL 5 SAE 75W 90 CAPACITY 4 5 liters 4 8 US qt 4 0 Imp qt 9TGOJ2 OO2 2 Shift mechanism Transmission Removal Installation page J2 47 3 Transmission oil Inspection page J2 13 Replacement page J2 13 ...

Page 448: ...ge J2 30 Assembly page J2 33 2 Shift mechanism Transmission Removal Installation page J2 47 GRADE API SERVICE GL 4 OR GL 5 SAE 75W 90 CAPACITY 4 2 liters 4 4 US qt 3 7 Imp qt 9TGOJ2 003 3 Shift mechanism Sub transmission Removal Installation page J2 49 4 Transmission oil Inspection page J2 13 Replacement page J2 13 J2 3 ...

Page 449: ...h Rev Economy Sub transmission Power Oil Type Capacity liters US qt Imp qt J2 4 OUTLINE ZSM R Without Sub Transmission With Sub Transmission SL Turbo Forward Synchromesh Reverse Constant mesh Synchromesh I m CD POWER m I 2 4 ECONOMY 5 862 2 954 1 661 1 000 0 783 5 318 0 812 1 000 API Service GL 4 or GL 5 SAE 75W 90 4 5 4 8 4 0 4 2 4 4 3 7 9TGOJ2 004 ...

Page 450: ...T SUB TRANSMISSION 1 1st gear 2 2nd gear 3 3rd gear 4 Main drive gear 4th gear OUTLINE 5 Reverse gear 6 5th gear 7 Counter 5th gear J2 CD I I 9TGOJ2 005 8 Reverse idler gear 9 Countershaft gear 10 Speedometer drive gear J2 5 ...

Page 451: ...B TRANSMISSION 9TGOJ2 006 1 1st gear 2 2nd gear 3 3rd gear 4 Main drive gear 4th gear 5 Reverse gear 6 5th gear 7 Counter 5th gear 8 Reverse idler gear 9 Countershaft gear 10 High gear 11 Counter high gear 12 Speedometer drive gear J2 6 ...

Page 452: ...OUTLINE J2 COMPONENTS 9TGOJ2 Q07 1 Clutch housing 2 Mainshaft assembly 5 Transmission case 6 Top cover assembly 3 High gear 4 Countershaft assembly 7 Front cover 8 Rear cover J2 7 ...

Page 453: ...J2 OUTLINE POWERFLOW Without Sub Transmission 1ST 2ND 3RD 9TGOJ2 008 J2 8 ...

Page 454: ...OUTLINE J2 4TH 5TH REVERSE J2 9 ...

Page 455: ...J2 With Sub Transmission 1ST 2ND 3RD J2 10 OUTLINE Power Economy c 9TGOJ2 009 ...

Page 456: ...OUTLINE 4TH 5TH REVERSE J2 Power Economy J2 11 ...

Page 457: ...fork and shift rod Replace Worn synchronizer ring Replace J2 31 Worn synchronizer cone of gear Replace J2 31 Poor contact of synchronizer ring and gear cone Replace J2 31 Excessive longitudinal play of gears Replace Worn bearing Replace J2 32 Fatigued synchronizer key spring Replace Jumps out of gear Weak detent ball spring Replace Worn Shift fork Replace J2 31 Worn clutch hub sleeve Replace J2 31...

Page 458: ...1 Nm 3 4 5 2 m kg 25 38 ft Ib REPLACEMENT 1 Remove the drain plug and drain the oil into a sUITable con tainer 2 Wipe clean and apply sealant to the plug threads 3 Install the drain plug Tightening torque 33 51 N m 3 4 5 2 m kg 25 38 ft Ib 4 Add the specif ed oil from the filler plug hole until the level reaches the oottom of the hole Specified oil Type API Service GL 4 or GL 5 SAE 75W 90 capacity...

Page 459: ...20620 For 490600330 For installation of installation of Installer rear bearing Installer bearing shaft bearing transmission bearing 49 W501 445 For 49 F401 330B eQ For installation of installation of Holder bearing Installer set clutch hub synchronizer ring bearing 9TGOJ2 014 REMOVAL I INSTALLATION 1 Disconnect the negative battery cable 2 Raise the vehicle and support it with safety stands 3 Drai...

Page 460: ...ake cable 9 Ground wire Installation Note page J2 17 10 Speedometer cable 98 1 117 7 10 12 72 3 86 8 Nom m kg It lb 9TGOJ2 016 11 Back up light switch connector 12 Neutral switch connector 13 Sub transmission switch connector 14 Propeller shaft Service Section L 15 Transmission mount bracket 16 Transmission Removal Note page J2 16 Disassembly page J2 18 Inspection page J2 30 Assembly page J2 33 In...

Page 461: ...er the oil pan 2 Support the transmission with a transmission jack 3 Remove the transmission mounting bolts 4 Remove the transmission from under the vehicle 9TGOJ2 018 4 Remove the transmission from under the vehicle Installation Note Transmission 1 Install the transmission with the transmission jack 2 Tighten the transmission mounting bolts Tightening torque a 89 117 NfIl 9 1 11 9 rn kg 66 86 ft ...

Page 462: ...TRANSMISSION J2 Ground wire 1 Install the ground wires Tightening torque 16 23 N m 1 6 2 3 m kg 12 17ft lb 9TGOJ2 022 J2 17 ...

Page 463: ... bearings and all sealing surfaces with cleaning solvent and dry with compressed air Clean out all holes and passages with a compressed air and check that there are no obstructions 3 Wear eye protection when using compressed air to clean components Housing Components 1 Disassemble in the order shown in the figure referring to Disassembly Note J2 18 WITHOUT SUB TRANSMISSION 9TGOJ2 23 ...

Page 464: ...r 21 Locknut Front Disassembly Note page J2 19 Inspect for damage 22 Dust boot On vehicle replacement page J2 20 23 Clutch housing assembly Disassembly page J2 22 10 Rear cover 11 Gasket 12 Adjustment shim 13 Speedometer drive gear 9TGOJ2 025 49 8501 631A 490223630A 9TGOJ2 Q26 24 Transmission case assembly Disassembly page J2 26 25 Gasket Disassembly Note Center brake drum 9TGOJ2 24 1 Hold the cen...

Page 465: ...center brake drum Refer to page J2 19 3 Remove the center brake assembly and suspend it with a rope 9TGOJ2 029 caution Do not damage the mainshaft splines 4 Remove the oil seal 5 Apply transmission oil to outer edge and lip surface of the new oil seal 6 Install the new oil seal with the SST 7 Install the center brake assembly 8 Apply sealant to the center brake drum splines arid install the drum 9...

Page 466: ...e REPLACE 9TGOJ2 033 1 Back up light switch 2 Neutral switch 3 Select lever 4 Snap ring 5 Selection arm Inspection page J2 31 6 O ring 7 Spring and steel ball 8 Control lever 9 Dust boot 10 Change lever Inspection page J2 30 11 Reverse lock stopper 12 Spring 13 Washer 14 Oil seal 15 Guide plate 16 Top cover J2 21 ...

Page 467: ...TRANSMISSION ______ J 2L__ toDisassembly Note _ Components the figure refernng Sub transmlsslo he order shown In I li 1 Disassemble In 4 2 6 J2 22 9TGOJ2 034 ...

Page 468: ...bly Note page J2 24 Inspection page J2 31 23 Diaphragm spring 10 Shift fork rod 24 Friction gear 11 Steel ball and spring 25 Input shaft 12 Hub sleeve Disassembly Note page J2 24 13 Synchronizer key 26 Snap ring 14 Synchronizer key spring 27 Ball bearing 15 Clutch hub Inspection page J2 32 16 Synchronizer ring High gear 28 Guide cover Inspection page J2 31 29 Oil seal 9TGOJ2 o35 Disassembly Note I...

Page 469: ...ANSMISSION Spacer 1 Remove the spacer from the counter high gear with the chis el and the SST Input shaft 1 Remove the input shaft assembly with a press 2 Remove the snap ring 3 Remove the input shaft with a press ...

Page 470: ...9TGOJ2 42 6 Adjustment shim 7 Shift rod Disassembly Note page J2 25 Inspection page J2 31 8 Shift fork 3 Input clutch 4 Magnet 5 Bearing cover Inspection page J2 31 9 Steel ball and spring Disassembly Note Shift rod Note The steel detent balls will come out Be careful not to lose them 1 Remove the shift rod with the suitable bar and a plastic hammer J2 2S ...

Page 471: ...J2 TRANSMISSION Mainshaft Components 1 Disassemble in the order shown in the figure referring to Disassembly Note 9TGOJ20044 J2 26 ...

Page 472: ...ear Inspection page J2 30 26 Needle bearing Inspection page J2 32 27 Mainshaft Inspection page J2 30 28 Synchronizer ring 4th Inspection page J2 31 29 Needle bearing Inspection page J2 32 30 Main drive gear Inspection page J2 30 31 Hub sleeve Disassembly Note J2 32 Synchronizer key 33 Synchronizer key spring 34 Clutch hub 35 Bolt 36 Reverse idler gear shaft 37 Thrust washer 38 Needle bearing Inspe...

Page 473: ... not fall 2 Press the mainshaft out of the clutch hub assembly 5th re verse and reverse gear Clutch hub assembly 3rd 4th 1 Position the SST between 2nd and 3rd gears Caution Hold the mainshaft with one hand so that it does not faU 2 Press the mainshaft out of the clutch hub assembly 3rd 4th and 3rd gear Countershaft assembly 1 Remove the snap ring from the counter 5th gear and move the gear toward...

Page 474: ...aring inner race with the SST_ 2 Move the front bearing away from the spacer with a chisel 3 Remove the front bearing with the SST Spacer 1 Move the spacer away from the diaphragm spring with a chisel Note Do not reuse the diaphragm spring 2_ Remove the spacer with the SST_ J2 29 ...

Page 475: ...3 Inspect the synchronizer ring matching or wear 4 Inspect the main drive gear splines for t Mainshaft 1 Measure the mainshaft runout Runout 0 035mm 0 0014 in max 2 Inspect the splines for damage and wear Counte 1 Inspect gear th for damage wear and crac 2 Inspect the splines for damage and wear Shift fork and change lever 1 Measure the clearance between the shift fork and the change lever Clearan...

Page 476: ...nspect the synchronizer keys for damage wear and cracks 4 Measure the clearance between the hub sleeve and the re lease fork Clearance 0 8mm 0 031 max Synchronizer ring 1 Inspect individual synchronizer ring teeth for damage wear and cracks 2 Inspect the taper surface for wear and cracks Note Set the synchronizer ring squarely in the gear then measure around the circumference 3 Measure the clearan...

Page 477: ...ecified replace the assembly 1 Inspect the teeth for damage wear and cracks 2 Inspect the taper surface for wear and cracks Note Measure around the circumference 3 Measure the height between the inner cone and the outer cone as shown in the figure Height 2 8mm 0 110 in min Bearing 1 Inspect for damage or rough rotation ...

Page 478: ...2 069 9MUOJX 066 Clutch hub Caution Align the synchronizer ring grooves with the clutch hub keys during installation Note The synchronizer rings have the same basic shape Carefully note these distinguishing features a Sub transmission synchronizer rings are the smallest b 5th synchronizer ring is next larger c 3rd and 4th are the biggest and are exactly the same There are two types of synchronizer...

Page 479: ... 4 Washer 5 Spring 6 Reverse lock stopper 7 Change lever 8 Dust boot J2 34 25 34 2 5 3 5 18 25 J 7 9 Control lever 10 Roll pin Change lever Assembly Note page J2 35 11 Steel ball and spring 12 O ring 13 Selection arm 14 Snap ring 9TGOJ2 70 15 Select lever 16 Roll pin Select lever Assembly Note page J2 35 17 Neutral switch 18 Backup light switch ...

Page 480: ...TRANSMISSION J2 Assembly Note Roll pin Change lever 1 Install the roll pins as shown in the figure Roll pin Select lever 1 Install the roll pins as shown in the figure 9TGOJ2 072 J2 35 ...

Page 481: ...J2 TRANSMISSION Mainshaft Components 1 Assemble in the order shown in the figure referring to Assembly Note N m m Icg ft lb J2 36 9TGOJ2 Q73 ...

Page 482: ...2nd gear Assembly Note page J2 37 31 Needle bearing 32 Gear sleeve 33 Snap ring Assembly note 34 3rd gear 35 Needle bearing 36 Synchronizer ring 3rd 37 Clutch hub assembly 3rd 4th Assembly Note J2 page J2 37 38 Snap ring 39 Needle bearing 40 Reverse gear 41 Retaining ring 42 Clutch hub assembly 43 Synchronizer ring 5th 44 Snap ring 45 5th gear 46 Mainshaft bearing Assembly Note page J2 38 47 Main ...

Page 483: ...with the SST Countershaft bearing Rear 1 Install the new snap ring and counter 5th gear 2_ Set the countershaft gear in the transmission case 3_ Set the counter 5th gear into position and fit the snap ring 3_ Install the countershaft bearing with the SST Mainshaft bearing 1_lnstall the mainshaft bearing with the SST 9TGOJ2 082 J2 38 ...

Page 484: ...TGOJ2 Q84 TRANSMISSION J2 Main drive gear bearing 1 Set the SST between the 4th synchronizer ring and the syn chromesh gear on the main drive gear 2 Install the main drive gear bearing with the SST J2 39 ...

Page 485: ...J2 TRANSMISSION Sub Transmission Components 1 Assemble in the order shown in the figure referring to Assembly Note J2 40 WITHOUT SUB TRANSMISSION Nom m kg ft lb 9TGOJ2 OSS ...

Page 486: ...Counter high gear 24 Snap ring Assembly Note page J2 42 25 Counter lever set bolt 9 Needle bearing 26 Shift rod set bolt 10 High bear 27 Sleeve joint 11 Counter lever 28 Guide cover 12 Outer shift lever 29 Oil seal 13 Inner shift lever 9TGOJ2 oa7 14 Roll pin Assembly Note page J2 42 9TGOJ2 089 Assembly Note Input shaft bearing 1 Press the ball bearing onto the input shaft with a press 2 Install th...

Page 487: ...into position from the I 9TGOJ2 Q90 9TGOJ2 Q92 rear side of the clutch housing 2 Press the bearing onto the counter high gear with the SST and a press Clutch hub assembly 1 With the shift fork on the hub sleeve install it to the high gear Roll pin 1 Install the roll pin as shown in the figure ...

Page 488: ...rk rod Assembly Note page J2 44 4 Adjustment shim Assembly Note page J2 44 5 Bearing cover 6 Magnet 7 Input clutch 8 Synchronizer ring Input clutch 9 Snap ring Assembly Note Spring Note J2 N4n m kg ft lb 9TGOJ2 93 There are two types of springs be sure to install them correctly Wire dia Shift fork p1 4mm 0 055 in 3RD 4TH and 5TH Rev p1 8mm 0 070 in 1ST 2ND 9TGOJ2 094 J2 43 ...

Page 489: ... the clearance between the bearing outer race and the transmission case If not within specification adjust the clearance by installing the proper adjustment shim s Standard clearance O OOSmm O OSSmm 0 0002 in 0 002 in Adjusting shim thickness mm in 0 1 0 004 0 15 0 006 0 3 0 012 1 0 0 039 Adjustment shim Mainshaft 1 After measuring dimensions A and i3 shown in the figure use an adjustment shim s a...

Page 490: ...ssembly Note page J2 46 6 Gasket 7 Front cover 8 Dust boot 9 Release fork 15 20 108 145 10 Release bearing 11 Oil guide 12 Steel ball 13 Speedometer drive gear 14 Oil seal Assembly Note page J2 46 15 Adjustment shim Rear Assembly Note page J2 46 16 Gasket tkn m kg ft lb 9TGOJ2 Q99 17 Rear cover 18 Transmission mount 19 Center brake assembly 20 Center brake drum Assembly Note page J2 46 21 Locknut ...

Page 491: ...shim thickness 0 1 0 004 0 3 0 012 0 6 0 024 0 7 0 028 0 8 0 031 0 9 0 035 1 0 0 039 Adjustment shim Rear mm in 1 After measuring dimensions A and B shown in the figure use an adjustment shim s as specified below of the thick ness corresponding to the value of A plus gasket thickness O 3mm 0 012 in minus 8 so that bearing end play will be within specification Bearing end play 0 0 1mm 0 0 004 in Ad...

Page 492: ... Installation Note 1 Shift knob Installation Note page J2 48 2 Console 3 Shift cable ball joint Installation Note page J2 48 4 Selector cable ball joint Installation Note page J2 48 5 Bolt NmJm Icg ft Ib 9TGOJ2 104 6 Clip Installation Note page J2 48 7 Selector cable Inspect boots for damage Inspect cable for damage and function 8 Shift cable Inspect boots for damage Inspect cable for damage and f...

Page 493: ...locknut Tightening torque 10 15 N m 1 0 1 5 m kg 7 11 ft Ib Shift cable ball joint 1 Measure A and B shown in the figure 2 Caluculate the neutral position of the shift lever as follows Neutral position C B A 2B 3 Hold the shift lever in neutral position 4 Loosen the shift cable locknut 5 Turn the ball joint so that the shift cable aligns with the in stallation hole of the shift lever 6 Tighten the...

Page 494: ... 9 2 6 14 19 1 Steering column cover 5 Spring pin and pin 2 Nut 6 Nut Installation Note page J2 49 7 Sub selector cable 3 Selector lever Inspect boot for damage J2 Mtn m kg ft lb 9TGOJ2 107 4 901t Inspect cable for damage and function ECONOMY 9TGOJ2 1OS Installation Note Nut Selector lever side 1 With the selector lever at power position turn the nuts to adjust the position of the lever shown in t...

Page 495: ...PROPELLER SHAFT OUTLINE L 2 SPECIFICATIONS L 2 TROUBLESHOOTING GUIDE L 3 PROPELLER SHAFT L 3 PREPARATION L 3 REMOVAL INSPECTION INSTALLATION L 4 OVERHAUL L 5 LUBRICATION L 11 9TFOl X 001 L ...

Page 496: ...diameter mm in D D1 L 2 OUTLINE L L 9TGOLX 2 HA SL SL Turbo TF 10 14 14 17 14 17 883 892 735 28 94 754 29 68 999 39 33 713 28 07 958 37 72 34 76 35 12 968 983 914 928 1 279 1 289 921 928 1 281 1 288 38 11 38 70 35 98 36 54 50 35 50 75 36 26 36 54 50 43 50 71 82 6 3 25 90 0 3 54 82 6 3 25 90 0 3 54 9TFOLX 2 ...

Page 497: ... bearing yoke Abnormal noise Worn or damaged bearing cup Improperly installed universal joint snap ring Worn or damaged center bearing Loose yoke mounting bolts Worn or damaged sliding joint splines Insufficient grease PROPELLER SHAFT PREPARATION SST 490839425C Puller set bearing For removal of center companion flange and center bearing 9TGOLX 005 Action Repair Replace Repair Replace Tighten Tight...

Page 498: ...place as necessary 3 Install in the reverse order of removal referring to Installation Note THREE JOINT TYPE 6 HA SL MODEL 62 69 6 3 7 0 4 51 TWO JOINT TYPE N m m kg tt lb 9TFOlX 4 1 Bolt 8 Nut 2 Safety loop 3 Bolt 4 Washer 5 Center bearing bracket 6 Nut 9 Propeller shaft Removal Note page L 5 Overhaul page L 5 Installation Note page L 5 10 Plate 7 Bolt L 4 ...

Page 499: ... and install the propeller shaft Use pads in the vise to prevent damaging the part Do not remove the oil seal if not necessary 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note 4 Lubricate the propeller shaft after assembling referring to page ...

Page 500: ... 13 Washer Disassembly Note page L 7 14 Center companion flange Assembly Note page L 9 Disassembly Note page L 7 4 Bearing cup Assembly Note page L 9 Disassembly Note page L 7 15 Center bearing Inspect for wear damage and rotation Disassembly Note page L 8 Assembly Note page L 9 Inspect for damage and rough rotation 5 Spider Assembly Note page L 8 Inspect for wear and damage 16 Center bearing rubb...

Page 501: ...p the propeller shaft in a vise 3 Remove the snap ring Bearing cup 1 Push one bearing cup out of the propeller shaft by tapping the propeller shaft yoke 2 Remove the opposite bearing cup in the same manner 3 Separate the propeller shaft and yoke 4 Clamp the yoke in a vise 5 Remove the bearing cups and the spider from the yoke as in Steps 1 and 2 Center companion flange 1 Mark the flange and shaft ...

Page 502: ...er shaft Caution Measure the runout of No 1 and No 2 propeller shafts Replace the propeller shaft as an assembly if runout is excessive 1 Measure the propeller shaft runout with a dial indicator Runout O Smm 0 02 in max Assembly Note Center bearing caution Face the oil seal breather rearward 1 Install the center bearing onto the propeller shaft with a suita ble pipe and a hammer Pipe diameter 45mm...

Page 503: ...he snap ring bearing cup or spider 1 Apply lithium based grease to the bearing rollers inside the bearing cups 2 Clamp the yoke in a vise Note Install the spider with the grease nipple toward the propeller shaft 3 Set the new spider into the yoke and tap in a bearing cup using the spider to hold the rollers 4 Slide the yoke to the opposite side and install the other bear ing cup Snap ring Caution ...

Page 504: ...4 Ib 0 49 1 37 Nm 8 14 22 86 N HA SL Center yoke 5 14 em kg 0 83 2 33 kg 4 34 12 15 in Ib 1 83 5 13Ib 8 14 22 86 N Rear yoke 0 83 2 33 kg 1 83 5 13 Ib 0 78 1 76 Nm 11 28 25 41 N SL Turbo TF 8 18 em kg 1 15 2 59 kg 6 94 15 62 in Ib 2 53 5 70 Ib 5 Install different snap rings to adjust the starting torque if necessary Snap ring thickness mm in HA SL 1 45 0 057 1 48 0 058 I 1 50 0 059 1 54 0 061 1 57...

Page 505: ...ossible regular lubrication The type of grease used for the universal joints and slip yoke is different Lubricant For fitting Lithium based grease For fitting Disulphide molybdenum grease THREE JOINT TYPE PROPELLER SHAFT NO 1 PROPELLER SHAFT NO 2 TWO JOINT TYPE 9TGOLX Q27 L 11 ...

Page 506: ...FiCATIONS M 3 TROUBLESHOOTING GUiDE M 4 FRONT AXLE M 4 PREPARATION M 4 WHEEL HUB STEERING KNUCKLE M 5 REAR AXLE M 15 PREPARATION M 15 REAR AXLE M 15 DIFFERENTIAL M 20 PREPARATION M 20 DIFFERENTIAL OIL M 23 OIL SEAL M 24 DIFFERENTIAL M 26 9TFOMX 001 M ...

Page 507: ...M 2 OIL SPECIFICATION ABOVE 18 C O F GL 5 SAE 90 BELOW 18 C Q0F GL 5 SAE SOW CAPACITY W TYPE 2 6 liters 2 7 US qt 2 3 Imp qt Y TYPE 3 6 liters 3 8 US qt 3 2 Imp qt PROPELLER SHAFT SERVICE REFER TO SECTION L 2 Rear axle 9TFOMX 2 Preinspection page M 15 Preload adjustment page M 15 Removal Inspection Installation page M 16 Disassembly I Inspection Assembly page M 18 3 Differential Differential oil p...

Page 508: ... ratio 5 857 6 142 6 571 6 571 Grade API GL 5 Oil Viscosity Above 18 C O F SAE 90 Below 18 C O F SAE SOW Amount liters US qt Imp qt 2 6 2 7 2 3 3 6 3 B 3 2 I Engine type SL Turbo T TF Cargo box length ft 17 14 17 Cabin style Wide cabin Body style Truck Crew cabin I Truck Item Pay load t 4 3 5 I 4 Front axle Bearing preload Pull scale reading N kg Ib 10 8 29 4 1 1 3 0 2 4 6 6 Rear axle Bearing prel...

Page 509: ... drain plug Binding kingpin Insufficient kingpin oil Steering unit related problem Improperly adjusted front wheel bearing preload Steering unit related problem Worn or improperly adjusted front wheel bearing Worn kingpin Steering unit related problem Improperly adjusted front wheel bearing preload Worn kingpin Steering unit related problem For 491316600 removal and tiA installation of Guide kingp...

Page 510: ...ry Preload Adjustment 1 Remove the wheel and tire 2 Remove the hub cap Note Do not remove the screw mounted type brake drum Verify that the brake shoes do not drag If there is drag adjust the shoe clearance 3 Remove the brake drum Refer to page M 6 4 Remove the stop retainer 5 Loosen the hub nut until it can be turned by hand 6 Attach a pull scale to a wheel lug bolt and measure the frictional for...

Page 511: ...ary 3 Install in the reverse order of removal referring to Installation Note 9TFOMX 7 1 Brake drum 4 Wheel hub Removal Note page M 6 Service Section P Removal Note page M 7 2 Stop retainer 3 Hub nut Disassembly Inspection Assembly page M 7 Installation Note page M 7 Removal Note Brake drum 1 Support the brake drum with a jack and remove it Caution Do not damage the oil seal M 6 ...

Page 512: ...the specified torque Tightening torque 29 39 N m 3 4 m kg 22 29 ft Ib 2 Turn the wheel hub several times to seat the bearings fully 3 Loosen the hub nut until it can be turned by hand 4 Attach a pull scale to a wheel hub bolt and measure the frictional force while turning Tighten the locknut until the preload is as specified Preload Frictional force plus 11 30 N 1 1 3 0 kg 2 4 6 6Ib M 7 ...

Page 513: ...mbly Note page M 9 Assembly Note page M 9 6 Wheel hub 3 Bearing inner race Inner Inspect for damage and rotation 4 Bearing outer race Inner 7 Hub bolt Disassembly Note page M 9 Assembly Note page M 9 Disassembly Note page M 8 M 8 Assembly Note page M 9 Disassembly Note Bearing outer race Caution Replace the inner and outer race as a set Do not reuse the removed oil seal Note When removing the bear...

Page 514: ... with a brass hammer Assembly Note Hub bolt 1 Install the hub bolts with a brass hammer Bearing outer race M 1 Install the bearing outer race wtth a brass bar and a hammer Oil seal 1 Apply grease around the new oil seal lip 2 Drive the oil seal into the wheel hub with a suitable plate and a hammer 3 Pack grease into the shaded areas shown in the figure M 9 ...

Page 515: ...1IlD 98 118 10 12 72 87 9 REPLACE 1 Brake backing plate Removal Note page M 11 Service Section P 2 Tie rod ball joint Service Section N 3 Drag link ball joint Service Section N 4 Kingpin oil level gauge Installation Note page M 13 5 Kingpin cap Removal Note page M 11 M 10 Nom m kg ft 9TFOMX 009 5 Lock pin Removal Note page M 11 7 Kingpin Removal Note page M 11 Inspection page M 11 Installation Not...

Page 516: ... pan 1 Remove the upper and lower kingpin caps Lock pin Caution Do not reuse the removed lock pin 1 Remove the lock pin with a hammer Kingpin 1 Remove the kingpin with a brass bar and a hammer Inspection Kingpin bushing and kingpin clearance 1 Measure the kingpin bushing inner diameter and kingpin outer diameter with a micrometer then figure out the clear ance between them Clearance 0 01 o 04mm 0 ...

Page 517: ...between the front axle and the knuckle with a feeler gauge 4 Adjust the clearance to the specification by selecting the proper adjustment shim s Clearance 0 20 0 35mm 0 008 0 014 in caution Use a maximum of three shims Adjustment shim thickness mm in 0 35 0 014 0 5 0 020 0 6 0 024 0 7 0 028 Kingpin 1 Align the front axle and the knuckle with a SST 2 Index the kingpin lock groove to the hole in the...

Page 518: ...to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note mil PLACE B VREPLACE 1 Knuckle arm Inspect for damage and cracking 2 O ring 9TGOMX 039 REPLACE Nom m kg ft Ib 9TFOMX Ol0 3 Kingpin bushing Disassembly Note page M 13 Assembly Note page M 14 4 Steering knuckle Inspect for damage and cracking Disassembl...

Page 519: ...ONT AXLE Assembly Note Kingpin bushing Caution Install the kingpin bushing with the oil groove to ward the front axle 1 Install the kingpin bushing with the SST and a press 2 When installing allow 4 S S 0mm 0 18 0 20 in clear ance between the end of the bushing and the matching sur face of the knuckle ...

Page 520: ...t there is no abnormal noise and that the tire ro tates smoothly when rotated by hand 3 Adjust the wheel bearing preload as necessary Preload Adjustment 1 Remove the wheel and tire assembly 2 Remove the brake drum 3 Remove the axle shaft 4 Remove the set plate 5 Loosen the hub nut until it can be turned by hand 6 Tighten the locknut with the SST until the preload is as specified Preload Frictional...

Page 521: ... or replace as necessary 3 Install in the reverse order of removal referring to Installation Note 1 Brake drum Removal Note page M 17 2 Axle shaft Removal Note page M 17 3 Oil seal Installation Note page M 18 4 Set plate M 16 N m m kg ft lb 9TFOMX 11 5 Locknut 6 Wheel hub Removal Note page M 17 Inspect for damage and cracks Disassembly I Inspection I Assembly page M 18 Installation Note page M 17 ...

Page 522: ...t drop the bearing inner race 1 Remove the wheel hub from the axle housing Installation Note Wheel hub 1 Tighten the locknut with the SST 2 Turn the wheel hub several times to seat the bearings 3 Loosen the locknut until it can be turned by hand 4 Attach a pull scale to a wheel hub bolt and measure the frictional force while turning Tighten the bearing locknut with the SST until the preload is as ...

Page 523: ...arts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note 1 Bearing inner race Outer Inspect for damage and rotation 2 Oil seal Assembly Note page M 19 3 Bearing inner race Inner Inspect for damage and rotation 4 Bearing outer race Inner Disassembly Note page M 19 Assembly Note page M 19 M 18 5 Bearing outer race Outer Inspect for damage or w...

Page 524: ...Tap the bearing outer race at the notches in the wheel hub shown by arrows with a brass bar and a hammer Hub bolt 1 Remove the hub bolts with a brass hammer Assembly Note Bearing outer race 1 Apply grease to the new bearing outer race 2 Install the outer race with a brass bar and a hammer Oil seal 1 Apply grease to the lip of the new oil seal 2 Drive the oil seal into the wheel hub with a suitable...

Page 525: ...stment of drive pinion and ring gear backlash For 49 F401 330B installation of side bearing Installer set inner race bearing For 49 F401 336B installation of rear bearing Attachment B inner race Part of 49 F401 33OB For 49 F027 007 installation of front bearing Attachment for outer race bearing 4 72 Part of 49 F027 OA1 For 49 W033 101 installation of rear bearing Body outer race Part of 49 W033 1A...

Page 526: ...easurement of Pinion model pinion height Gauge body pinion height 0 pinion height 49 F027 OAO For 490305555 0 For measurement of measurement of Gauge set pinion height Gauge block pinion height pinion height 6jgO Part of adjusting 49 F027 OAO 49 W027 004 g For 490710520 Ii For measurement of removal of Gauge block pinion height Puller pilot bearing bearing inner race 9TGOMX 113 For Y type 495231 6...

Page 527: ... of installation of Attachment C pilot bearing Installer oil seal Part of outer race dust cover 49 F401 330B 49 G030 795 For 49 G030 797 For installation of installation of Installer rear bearing Handle rear bearing oil seal outer race Part of outer race 49 G030 795 491363565 For 490727570 For measurement of measurement of Pinion model pinion height Gauge body pinion height pinion height O 0 _ 49 ...

Page 528: ...ment 1 Remove the magnetic plug and drain the differential oil 2 Clean the magnetic plug 3 Install a new washer and tighten the magnetic plug Tightening torque 39 S4 N m 4 0 5 S m kg 29 40 ft Ib 4 Remove the oil filler plug and fill the differential with the speci fied oil Specified oil Type Above 18 C O F GL S SAE 90 Below 18 C O F GL S SAE 80W Capacity W type 2 6 liters 2 7 US qt 2 3 Imp qt Y ty...

Page 529: ... drive pinion to ring gear backlash Note Make a notation of this torque for proper reas sembly 3 Hold the companion flange with the SST and remove the locknut Note Mark the companion flange and the drive pinion for proper reassembly 4 Remove the companion flange with the SST 5 Pry out the oil seal Note Apply a thin coat of differential oil to the lip of the oil seal 6 Install the new oil seal with...

Page 530: ...Ib 203 289 ft Ib Drive pinion 0 8 1 6 Nm 2 6 3 4 N m preload 8 16 em kg 27 35 em kg 7 14 in Ib 23 30 in Ib Caution If the specified preload cannot be obtained remove the differential and replace the distance piece or ad just the shim thickness and check it again 9_ Hold the companion flange with the SST and tighten lock nut and new washer until the specified drive pinion preload is obtained 10_ In...

Page 531: ... the gear oil 2 Remove in the order shown in the figure referring to Removal Note 3 Install in the reverse order of removal referring to Installation Note 4 Add gear oil and check the level Refer to page M 23 W TYPE 49 54 5 0 5 5 36 40 _ r r Y TYPE 69 93 7 0 9 5 51 69 88 108 9 11 6s eG AM HA SL MODEL 62 69 6 3 7 0 46 51 SL TURBO TF MODEL 98 118 100 12 72 7 98 118 10 12 72 87 N m m kg It 9TFOMX o14...

Page 532: ...port the differential assembly with a jack during removal Installation Note Differential assembly 1 Apply gasket to the differential housing mounting surfaces and mounting bolts 2 Support the differential assembly with a jack during instal lation Tightening torque W type 49 54 N m 5 0 5 5 m kg 36 40 ft Ib Y type 69 93 N m 7 0 9 5 m kg 51 69 ft Ib M 27 ...

Page 533: ... 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note M 28 W TYPE 2D 29 2 11 3 0 14 22 Y TYPE 43 61 4 4 6 2 32 45 N m m kg fl lb 9TGOMX 131 ...

Page 534: ...inner race Inspect for damage and rotation 16 Front bearing outer race Disassembly Note page M 31 Assembly Note page M 32 17 Rear bearing outer race Disassembly Note page M 31 Assembly Note page M 32 18 Rear bearing inner race Disassembly Note page M 31 Assembly Note page M 36 19 Snap ring W type no stopper 20 Pilot bearing inner race W type no stopper Disassembly Note page M 31 Assembly Note page...

Page 535: ...ing screw and the carrier for proper reas sembly Side bearing outer race Note Identify the left and right side bearing outer races for proper reassembly 1 Remove the side bearing outer races Locknut 1 Hold the companion flange with the SST and remove the locknut Companion flange 1 Pull the companion flange off with the SST Bearing housing 1 Drive the bearing housing from the carrier by tapping the...

Page 536: ...ion Do not damage the drive pinion gear with the chisel 2 Make approx 10mm 0 39 in of clearance between the drive pinion gear and the bearing inner race with a chisel 0N type 3 Remove the bearing inner race with a brass bar and a hammer Pilot bearing inner race II type no stopper 1 Protect the drive pinion with a rag and place it in a vise Caution Do not damage the drive pinion gear with the chise...

Page 537: ...earing inner races for proper reassembly 1 Remove the side bearing inner race from the gear case with the SST Ring gear 1 Mark the ring gear and the gear case for proper reassembly Gear case 1 Mark the gear case for proper reassembly Assembly Note Front bearing outer race 1 Press the front bearing outer race into the bearing housing with the SST and a press Rear bearing outer race 1 Press the new ...

Page 538: ... inner race onto the SST then install them into the carrier 2 Install the front bearing inner race companion flange and washer onto the SST and tighten the nut so that the SST can still be turned by hand caution Do not install the adjustment shim 3 Install the bearing housing assembly into the carrier Tightening torque 20 29 N m 2 0 3 0 m kg 15 22 ft Ib 4 Place the SST on the surface plate and set...

Page 539: ...e pinion height adjustment value Drive pinion end mark 2 0 02mm O OOOS in 1 O 01mm 0 0004 in Example The two values obtained in Step 6 are 0 1Smm 0 007 in and 0 26mm 0 010 in and the drive pin ion end mark is 2 0 1S 0 26 _ 0 20 2 100 0 007 0 010 _ O OOOS 0 008 The drive pinion adjustment value is 0 20mm O ooa in Select the proper adjustment shims and install them between the bearing housing and th...

Page 540: ...SST 49 1363565 Tighten the nut so that the SST 49 1363565 can still be turned by hand Caution Do not install the adjustment shim 3 Install the bearing housing assembly into the carrier Tightening torque 43 61 N m 4 4 6 2 m kg 32 45 ft Ib 4 Place the SST on the surface plate and set the dial indi cator to zero 5 Set the SST as shown in the figure 6 Place the feeler of the dial indicator so that it ...

Page 541: ... 007 in and 0 26mm 0 010 in and the drive pin ion end mark is 2 0 18 0 26 _ 0 20 2 100 0 007 0 010 _ O OOOS O OOS The drive pinion adjustment value is 0 20mm O ooS in Select the proper adjustment shims and install them between the bearing housing and the carrier Refer to page M 38 Note Select adjustment shims within 0 I 0 03mm 0 I 0 001 in of the specified thickness Use a maximum of five shims Adj...

Page 542: ...ied preload cannot be obtained reas semble and check it again 4 Hold the flange with the SST and tighten the locknut to the lowest value of the specified torque to obtain the specified preload Wtype Y type 235 392 N m 275 392 N m Tightening torque 24 40 m kg 28 40 m kg 174 289 ft Ib 203 289 ft Ib 0 8 1 6 N m 2 6 3 4 N m Preload 8 16 em kg 27 35 em kg 7 14 in Ib 23 30 in Ib 5 Remove the locknut was...

Page 543: ...aring outer race into the carrier with the SST 2 Install the stopper plate into the carrier 0N type with stopper Tightening torque 19 26 N m 1 95 2 60 m kg 14 19 ft Ib Bearing housing 1 Install the adjustment shim s selected in pinion height ad justment and the bearing housing to the carrier Tightening torque W type 20 29 Nm 2 0 3 0 rn kg 14 22 ft Ib Y type 43 61 Nom 4 4 6 2 m kg 32 45 ft Ib Gear ...

Page 544: ...justing screws to the differential carrier Bearing cap Note Align the bearing cap and the adjusting screw threads 1 Install the bearing cap and apply a small amount of thread locking compound 0N type then temporarily tighten the bolts Adjustment of backlash 1 While turning the ring gear tighten the left and right adjust ing screws alternately with the SST to reduce the backlash 2 Mark the ring gea...

Page 545: ...ly when the dis tance between the pilot sections on the bearing caps is low and loosen when the distance is high 6 Measure the distance between the pilot sections on the bear ing caps L with a micrometer Distance l W type 279 5 8 08 mm 11 00 8 003 in Y type 289 5 g mm 11 40 g in 7 After adjustment of distance L recheck that the backlash is as specified Inspection and adjustment of teeth contact 1 ...

Page 546: ... face contact Replace the adjustment shim with a thicker one to bring the drive pinion in Lock plate 1 Tighten the bearing cap bolts to the specified torque Tightening torque W type 79 98 Nom 8 10 m kg 58 72 ft Ib V type 128 147 N m 13 15 m kg 94 108 ft lb 2 Install the lock plates on the bearing caps Tightening torque 18 25 N m 1 8 2 6 m kg 13 19 ft Ib M 41 ...

Page 547: ... BOOT N 8 STEERING WHEEL AND COLUMN N 11 STEERING GEAR AND LINKAGE N 15 ENGINE SPEED SENSING POWER STEERING N 21 PREPARATION N 21 TROUBLESHOOTING GUIDE N 22 AIR BLEEDING N 23 POWER STEERING FLUiD N 24 STEERING WHEEL AND COLUMN N 27 STEERING GEAR AND LINKAGE N 28 POWER STEERING OIL PUMP N 37 DRIVE BELT N 46 9TFONX 001 N ...

Page 548: ...8 2 Steering wheel and column On vehicle inspection page N 11 Removal I Installation page N 12 Disassembly I Inspection Assembly page N 13 N 2 3 Steering gear and linkage Removal Inspection I 9TFONX 2 Installation page N 15 Disassembly f Inspection I Assembly page N 16 ...

Page 549: ...y page N 29 3 Power steering oil pump Removal Installation page N 37 Disassembly I Inspection Assembly page N 39 N 9TFONX 003 4 Drive belt Inspection page N 46 Adjustment page N 46 Replacement page N 47 5 Power steering fluid Inspection page N 24 6 Steering wheel and column On vehicle inspection page N 27 Removal Installation page N 12 Disassembly I Inspection Assembly page N 13 N 3 ...

Page 550: ...e N 28 Disassembly Inspection Assembly page N 29 3 Power steering oil pump Removal Installation page N 43 Disassembly Inspection Assembly page N 44 N 4 9TFONX Q04 4 Power steering fluid Inspection page N 24 5 Steering wheel and column On vehicle inspection page N 27 Removal Installation page N 12 Disassembly I Inspection I Assembly page N 13 ...

Page 551: ...emoval of ball joint For removal and installation of adjusting plug For removal of outer race For installation of outer race For installation of inner race and oil seal MANUAL POWER STEERING STEERING 430 16 93 3 9 4 2 3 9 4 2 Collapsible 1 cross joint standard 2 cross joint tilt 30 1 18 50 1 97 Ball nut 28 33 22 6 API service GL 4 SAE90 ATF M2C33F or DEXRON I 0 94 0 99 0 83 2 0 2 11 1 76 490208701...

Page 552: ...y wheel alignment toe in Incorrect tire pressure Deformed or unbalanced wheels Steering wheel effort Malfunctioning steering gear uneven Malfunctioning joints of steering system Steering linkage does not operate smoothly Excessive steering Improper adjustment of gear box backlash wheel play Worn steering gear Worn or damaged joints of steering system Loose steering gear mounting bolts Worn kingpin...

Page 553: ... Incorrect tire pressure Adjust Section Q Irregular tire wear Replace Section Q Depth of tire tread is different between left and right Replace Section Q tires Deformed or unbalanced wheels Repair or replace Section Q Malfunctioning or loose shock absorbers Replace or tighten Section R Loose U bolts Tighten Section R Faulty wheel alignment toe in Adjust Section R Abnormal noise from Loose or worn ...

Page 554: ...ion Note 1 Cotter pin nut 2 Tie rod end Removal note page N 9 3 Locknut Removal note page N 9 4 Tie rod end boot Removal note page N 9 Installation note page N 10 5 Cotter pin nut N 8 4 REPLACEEiI Nfn m kg ft Jb 9TfONX 7 6 Drag link Removal note page N 9 7 Plug 8 End plug Installation note page N 10 9 Spring ball seat 10 Dust seal Removal note page N 9 11 Ball stud 12 Ball seat ...

Page 555: ...eference during installa tion before loosening Tie rod end boot 1 Secure the tie rod end in a vise Place a chisel against the boot and hold it at the angle shown Remove the boot Caution Do not scar the part where the boot attaches to the tie rod end 1 r IIT 7 Drag link 1 Separate the drag link with the SST iiI iii4i t Dust seal 1 Remove the dust seal with the SST N 9 ...

Page 556: ...ighten the end plug fully and then loosen it before the adjustment 2 Adjust the starting torque of the ball stud by turning the end plug Starting torque 5 15 kg 11 33 Ib Tie rod end boot 1 Put a small amount of grease lithium base NLGI No 2 into the new boot and set it onto the tie rod end Install the boot to the tie rod end with the SST and a press ...

Page 557: ...1 Move the steering wheel in directions 1 2 and 3 to check for column bearing wear steering shaft joint play steering wheel looseness and column looseness Steering wheel effort 1 With the vehicle on a hard level surface move the steering wheel to put the wheels in the straight ahead position Note Measure after turning the steering wheel to the left and right 5 times or more 2 Measure the steering ...

Page 558: ...Note CD d 39 49 4 0 5 0 29 36 TILT CABIN NON TILTITELESCOPIC 19 25 1 9 2 6 14 19 0 O NON TILT CABIN NON TlLTITELESCOPIC 11 39 49 4 0 5 0 29 36 N tn m kg ft lb 9TFONX oos 1 Horn cover 2 Locknut 7 Fuel stop cable 4 0 L 3 5 L Turbo engine 8 Joint cover 3 Steering wheel Removal note page N 13 4 Column cover 5 Combination switch 6 Sub transmission selection cable 9 Fixing bolt 10 Steering shaft Install...

Page 559: ...ghten the bolts in the order shown in the figure 9TGONX 23 Disassembly Inspection Assembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note REPLACE 9TFONX 009 1 Steering lock assembly Disassembly note page N 14 2 Steering shaft Inspection page...

Page 560: ...ve the steering lock assembly Inspection Steering shaft 1 Column bearing damage 2 Operation and damage of steering shaft and joint Steering lock assembly 3 5 L TURBO and 4 0 L Engine type 1 Verify that the cable connector moves only as shown in the figure when the key is in the LOCK and ACC position Assembly note Steering lock assembly 1 Install the steering lock assembly on the jacket Install new...

Page 561: ...as necessary 6 Install in the reverse order of removal REPLACE 1 Fixing bolt 2 Cotter pin nut 3 TIe rod end Removal note page N 9 Inspect for damage Inspect operation of ball joint 4 Locknut Removal note page N 9 5 TIe rod Inspect for bending 6 Cotter pin nut 7 Drag link 298 118 1o 1 72 17 l 88 118 9 12 65 87 N m m kg ft lb 9TFONX 010 Removal note page N 9 Inspect for bending Inspect operation of ...

Page 562: ... page N 30 Assembly note page N 36 4 Side cover Disassembly note page N 30 Inspect bushing for damage and corrosion Assembly note page N 34 5 Sector shaft Disassembly note page N 30 Inspection page N 18 Assembly note page N 34 N 16 ADJUSTING SHIM 29 39 3 CI 4 0 22 29 _ l 44 S4 4 5 5 5 33 40 ADJUSTING SCREW Nom m kg ft lb 9TGONX Q31 6 Adjusting plug Disassembly note page N 17 Assembly note page N 1...

Page 563: ...ve the locknut with the SST 2 Remove the adjusting plug with the SST 3 Press the oil seal out with a 23mm 15 16 in socket from the front side as shown 4 Press the outer race out with a socket and the SST as shown Worm ball nut assembly 1 Remove the two inner races with the SST N 17 ...

Page 564: ...learance with a feeler gauge in the axial direction 3 If the clearance exceeds speCification adjust it with the ad justment shims supplied in the adjustment shim kit Clearance in axial direction 0 0 1 mm 0 0 004 in Available adjustment shims 1 9Smm o on in 2 00mm 0 079 in 2 0Smm O 081 in 4 Measure the outer diameter Limit 3S 94mm 1 41 in 5 Check for damage and wear of the teeth Worm ball nut assem...

Page 565: ...ing plug 1 Press the oil seal in with a 23mm 15 16 in socket as shown 2 Press the outer race on with the SST as shown 3 Insert the worm ball nut assembly into the gear housing 4 Verify that the worm ball nut assembly turns smoothly 5 Turn the adjusting plug with the SST 6 Measure the worm shaft preload with the SST and a pull scale A I 7 Turn the adjusting plug to obtain the specified preload Worm...

Page 566: ...sector shaft end and the axis of the worm shaft cross are at a right angle 4 Turn the adjusting bolt 5 Measure the worm shaft preload in the straight ahead po sition with the SST and a pull scale 6 Turn the adjusting bolt to obtain the specified preload Worm shaft preload after sector shaft installed Pull scale reading 6 9 1 1 N 0 7 1 1 kg 1 5 2 4 Ib 7 Loosen the adjusting bolt one full turn and t...

Page 567: ... 327 4901805108 removal of Installer bearing bearing and oil Attachment and oil seal seal preload measuring 49 F401 331 For 490727415 installation of Body oil seal Installer bearing 49 G032 317 For 49 G032 316 hermetic Hose inspection Adapter Part of 49 G032 3A1 49 F015 002 iii For 49 F017 1AO Q installation of Installer water oil seal Universal wrench seal For inspection of fluid pressure For rem...

Page 568: ...ment Adjust Section R Steering effort not Loose oil pump drive belt Adjust or replace N 46 uniform Malfunctioning steering gear Replace N 28 Malfunctioning steering joint Replace N 8 Malfunctioning steering linkage Replace N 28 Excessive steering Worn steering gear Replace N 28 wheel play Worn or damaged steering joint Replace N 8 Loose steering gear mounting bolts Tighten N 28 Improperly adjusted...

Page 569: ... system Bleed air N 23 Malfunctioning oil pump Replace N 37 Obstruction near steering column or pressure hose Adjust or replace 9TFONX 012 AIR BLEEDING Caution While air bleeding add fluid to ensure the proper fluid level thus preventing air from getting into fluid 9TFONX 013 9TGONX 055 9TGONX 53 1 Jack up the front of the vehicle and support it with safety stands 2 Check the fluid level Refer to ...

Page 570: ... steering fluid Fluid specification ATF M2C33F or DEXRON ll 1 Start the engine Turn the steering wheel fully to the left and right to apply fluid pressure Check for fluid leakage Caution To prevent damage to the steering system do not keep the steering wheel in the fully turned position for more than 15 seconds Note The points where fluid leakage may occur are indicated by arrows in the figure 3 5...

Page 571: ...ENGINE SPEED SENSING POWER STEERING N 4 0 L ENGINE MODEL 9TFONX 15 N 25 ...

Page 572: ...e engine speed to 1 000 1 500 rpm and measure the fluid pres sure generated by the oil pump If the pressure is below specification replace the oil pump assembly Oil pump fluid pressure 10 301 kPa 105 kg cm2 1 493 psi Caution If the valve is left closed for more than 15 seconds the fluid temperature will increase excessively and adversely affect the oil pump 6 Open the gauge valve fully again and i...

Page 573: ...the engine and warm the power steering fluid to 50 60 C 122 140 F Note To raise the fluid temperature tum the steering wheel fully left and right several times 9TFONX Q18 9TGONX Q66 3 With the engine running at idle speed attach a pull scale to the outermost point of the steering wheel spoke Then starting with the wheels in the straight ahead position check the steering effort required to turn the...

Page 574: ...r replace as necessary 6 Install in the reverse order of removal WOODRUF KEY REPLACE 1 Fixing bolt 7 Drag link m kg ft lb 9TFONX 019 2 Cotter pin nut 3 Tie rod end Removal note page N 9 Removal note page N 9 Inspect for damage Inspect operation of ball joint 4 Locknut Removal note page N 9 5 Tie rod Inspect for bending 6 Cotter pin nut N 28 Inspect for bending Inspect operation of ball stud 8 Pres...

Page 575: ... 22 29 INNER RACE Q RING REPLACE _ I 3 BEARING 71 j OUTER RACE e 1 ADJUSTING SHIM EDI ADJUSTING SCREW LOCKNUT 177 225 18 23 131 166 Nom m kg It lb 1 Locknut 6 Valve housing 2 Pitman arm Disassembly note page N 31 Disassembly note page N 30 Inspect for damage Assembly note page N 36 3 Side cover Assembly note page N 33 7 Worm ball nut assembly Disassembly note page N 30 Disassembly note page N 31 I...

Page 576: ...3 This position sets the steering gear in the straight ahead po sition Note At this pOSition the slit of the sector shaft end and the axis of the worm shaft cross at a right angle 4 Remove the side cover and the sector shaft together by strik ing the sector shaft end with a plastic hammer Caution Before removing remove all dirt and oil from the serrations of the sector shaft 5 Remove the side cove...

Page 577: ... assembly 1 Remove the valve housing and the worm ball nut assem bly together by hitting the worm shaft end with a plastic hammer 2 Press the ball bearing and the oil seal out with the a socket 3 Remove the outer race with a screwdriver Gear housing 1 Remove the oil seal the U packing and the O ring with a screwdriver Caution Do not remove the needle bearing Do not damage the inside of the gear ho...

Page 578: ...earance in axial direction 0 0 1 mm 0 0 004 in Available adjustment shims 1 9Smm 0 077 in 2 00mm 0 079 in 2 0Smm 0 081 in 4 Measure the outer diameter Limit Models Side cover side Pitman arm side General RHO 34 95mm 34 95mm 10 ft 2 000 kg 1 38 in 1 38 in Others 39 94mm 44 39mm 1 57 in 1 75 in 5 Check for damage and wear of the teeth and the shaft Worm ball nut assembly 1 Measure the play in the ve...

Page 579: ...acking as shown to install It Smooth it into place by hand after installation Install the U packing into position with a hammer handle caution Do not damage the inside of the gear housing or the needle bearing Valve housing 1 Press the oil seal and the ball bearing in with the SST and apply ATF to the oil seal 2 Press the outer race in with a flat plate Worm ball nut assembly Caution Do not damage...

Page 580: ...9 5 9 N 0 4 0 6 kg 0 9 1 3 Ib 8 Tighten the locknut with the SST Tightening torque When using the SST 167 196 N m 17 20 m kg 123 144 ft Ib 9 Verify the worm shaft preload Sector shaft side cover 1 Insert the sector shaft into the side cover 2 Turn the adjusting bolt counterclockwise with a screwdriver until it no longer turns Return one turn 3 Temporarily tighten the locknut Caution Not to damage ...

Page 581: ...worm shaft preload in the straight ahead po sition with the SST and a pull scale 6 Turn the adjusting bolt to obtain the specified preload o Worm shaft preload after sector shaft installed Pull scale reading 5 9 7 8 N 0 6 0 8 kg 1 3 1 8 Ib 7 Loosen the adjusting bolt one full turn and then tighten it a half turn 8 Tighten the locknut 9 Verify the worm shaft preload Gear housing 1 Tap the oil seal ...

Page 582: ...of the sector shaft end and the punch mark as shown and install the pitman arm Measurement of the backlash 1 Set the steering gear in the straight ahead position 2 Pull the pitman arm with the specified force 3 Measure the backlash Specified force 20 N 2 0 kg 4 4 Ib Backlash O 2Smm 0 010 in max ...

Page 583: ...al referring to Installation Note 3 5 L TURBO Engine type 1 Pump protector 2 Locknut Do not remove if not necessary Removal note page N 38 6 Pressure pipe 7 Return hose 8 Oil pump assembly Disassembly I Inspection I N N m m kg ft lb 9TFONX Q21 Installation note page N 38 3 Strap bolt Assembly page N 39 4 Bolt 5 Drive belt Inspection page N 46 Adjustment page N 46 Replacement page N 47 N 37 ...

Page 584: ...NX 099 9TGONX 100 Removal note Locknut 1 Push the drive belt as shown and loosen the locknut Installation note Locknut 1 Push the drive belt as shown and tighten the locknut to the specified torque Tightening torque 49 59 N m 5 0 6 0 m kg 36 43 ft Ib ...

Page 585: ...l valve assembly Inspect for damage and wear 11 Spring Inspect for damage 12 Rear body Inspect for damage and wear 13 O ring 14 Pressure plate Inspect for damage and wear Assembly note page N 42 15 Cam ring Inspect for damage and wear Assembly note page N 42 16 Vane Inspect for wear Assembly note page N 42 Nom m kg ft Ib 9TFONX 022 17 Rotor Inspect for damage and wear Assembly note page N 42 18 Pi...

Page 586: ...gure Snap ring 1 Remove the snap ring with snap ring pliers Driveshaft 1 Press the driveshaft and bearing out as shown 2 Remove the snap ring 3 Press the bearing out as shown Woodruff key If necessary 1 Secure the driveshaft in a vise with rag as shown Caution Do not damage the shaft Do not remove the woodruff key if it is not defective 2 Remove the Woodruff key with a chisel and a hammer ...

Page 587: ...amage the front body and the needle bearing Assembly note Woodruff key 1 Tap the Woodruff key into the shaft Caution Not to damage the shaft use a rag under the shaft for protection Driveshaft 1 Press the bearing on as shown 2 Install the snap ring Front body 1 Press the oil seal in as shown 2 Press the driveshaft and the bearing in as shown 3 Install the snap ring N 41 ...

Page 588: ...ntification mark facing the front body as shown Cam ring 1 Install the pin 2 Apply ATF to the cam ring and install it with the identifica tion mark facing the front body as shown Vane 1 Apply ATF to the vanes and place them in the rotor with the rounded edges against the cam ring Pressure plate 1 Apply ATF to the pressure plate and install it ...

Page 589: ...ator cowling upper and lower and the cooling fan Refer to Section E 2 Remove in the order shown 3 Install in the reverse order of removal 4 0 L Engine type 1 Pressure pipe 2 Return hose N m m kg ftolb 9TFONX 23 3 Oil pump assembly Disassembly I Inspection Assembly page N 44 N 43 ...

Page 590: ...Control valve assembly Inspect for damage and wear 11 Spring Inspect for damage 12 Rear body Inspect for damage 13 O ring 14 Cam ring Inspect for damage and wear Assembly note page N 46 15 Vane Inspect for wear Assembly note page N 42 16 Rotor Inspect for damage and wear Assembly note page N 45 N 44 N m 60 100 cm kg 52 87 in Ib N m In kg ft Ib 9TFONX 024 17 Pressure plate nspect for damage and wea...

Page 591: ...aution Do not damage the driveshaft or the drive gear 3 Remove the locknut Oil seal 1 Remove the oil seal with a screwdriver as shown Caution Do not damage he front body or the bushing Assembly note Front body 1 Press the oil seal in with the SST 2 Press the driveshaft and the bearing in together as shown 3 Install the snap ring Rotor 1 Apply ATF to the rotor and install it with the beveled side f...

Page 592: ...aying Replace if necessary 2 Check the drive belt deflection by applying moderate pres sure 98 N 10 kg 221b midway between the pulleys Ad just if necessary Deflection Depressed at 98 N 10 kg 22 Ib New 9 11mm 0 35 0 43 in Used 12 13mm 0 47 0 51 in Adjustment 3 5 L Turbo Engine type 1 Loosen bolts A and B and strap bolt C 2 Move the oil pump until the correct deflection is obtained and tighten strap...

Page 593: ...ID P 8 VACUUM LINE P 9 BRAKE PEDAL P 10 MASTER CYLINDER P 12 POWER BRAKE UNIT P 15 VACUUM PUMP P 22 LOAD SENSING G VALVE LSGV P 25 FRONT BRAKE DRUM P 27 WHEEL CyLINDER P 31 REAR BRAKE DRUM P 32 WHEEL CyLINDER P 36 PARKING BRAKE SYSTEM P 37 TROUBLESHOOTING GUIDE P 37 PARKING BRAKE LEVER P 37 PARKING BRAKE CABLE P 39 CENTER BRAKE P 40 EXHAUST BRAKE SYSTEM Refer to Section F2 and F3 9TFOPX 001 p ...

Page 594: ... On vehicle inspection page P 15 On vehicle inspection page P 37 Removal JInstallation page P 18 Adjustment page P 37 Disassembly Inspection Removal Inspection Assembly page P 18 Installation page P 38 6 Vacuum pump 13 Parking brake cable On vehicle inspection page P 22 Removal Inspection I Removal JInstallation page P 23 Installation page P 39 Inspection page P 23 14 Center brake Disassembly I As...

Page 595: ...to next page Shoe clearaf lce adju lmer lt Manual adjustment Type Dual 2 leading Rear brake Wheel cylinder inner diameter mm in 25 4 1 00 Drum lining dimensions Refer to next page Drum inner diameter Refer tp next page Shoe clearance adjustment Manual adjustment Power brake Type Tandem diaphragm unit Diameter mm in a 188 215 7 4 S 5 b 213 240 S 4 9 4 Type Center brake Operating type Stick type Par...

Page 596: ...95xO 24 307 0x75 0x8 0 304 0x75 0x8 0 12 09x2 95xO 31 12 09x2 95xO 31 307 0x90 0x8 0 307 0x90 0x8 0 12 09x3 54xO 31 12 09x3 54xO 31 Dual 320 12 60 320 12 60 334 9x110 0x10 5 334 9x11 0 Ox1 0 5 13 18x4 33xO 41 13 18x4 33x0 41 9TFOP X 4 For 49 W033 106 For removal and removal and installation of Wrench locknut installation of hub brake pipe locknut For 49 G030 797 For adjustment of disassembly and c...

Page 597: ...lace or adjust Section M preload Brakes do not No brake pedal play Adjust P 10 release Improperly adjusted push rod clearance Adjust P 12 Clogged master cylinder return port Clean Weak shoe return spring Replace P 28 33 Wheel cylinder not returning properly Clean or replace P 28 33 Improperly adjusted pedal height Adjust P 10 Improperly adjusted wheel bearing preload Adjust Section M Pedal goes to...

Page 598: ... brake fluid onto other parts 2 After removing the bleeder cap connect one end of a trans parent vinyl tube to the bleeder screw and place the other end in a receptacle 3 One person should depress the brake pedal a few times and then hold it in the depressed position 4 A second person should loosen the bleeder screw drain out the fluid and retighten the screw Tightening torque 5 9 8 8 N m 0 6 0 9 ...

Page 599: ... 2 Damage of brake pipe threads 3 Scars cracks or swelling of flexible hose 4 All lines for fluid leakage 5 Looseness or damage of pipe and hose connection Removal I Installation Removal I Installation note 1 Remove or install the brake pipe with the SST 2 Tighten the flare nut to the specified torque Flare nut tightening torque 13 22 N m 1 3 2 2 m kg 9 4 16 ft Ib P 7 ...

Page 600: ...oes not con tact other parts when the vehicle bounces or when the steer ing wheel is turned fully right or left 7 Bleed the air from the brake system when the pipe or hose is removed BRAKE FLUID On vehicle Inspection 1 Check that the fluid level in the reserve tank is between Max and Min If necessary add brake fluid up to the specified level Replacement 1 Operate the same procedure as air bleeding...

Page 601: ... or swelling of vacuum hose 3 Looseness of pipe and hose connection 4 All lines for vacuum leakage 5 Cracking or damage of vacuum tank Note Australia payload 3 500 kg and 4 000 kg A vacuum switch is equipped in the vacuum tank When the vacuum amount in the tank becomes less than the specification the switch activates the brake vacuum warning buzzer to notify a driver it 9TGOPX 19 P 9 ...

Page 602: ...he pedal again by hand and check the free play until the valve plunger contacts the stopper plate until the power piston begins to move Pedal play 9 11mm 0 35 0 43 in Caution Australia payload 3 500 kg and 4 000 kg Do not inspect the pedal play with the ignition switch ON The brake vacuum warning buzzer will operate when the ignition switch is ON Adjustment 1 Loosen locknut of push rod then turn t...

Page 603: ...if necessary Refer to page P 10 1 Coupler Stoplight switch 2 Vacuum hose 3 Brake pipe and hose 4 Master cylinder Removal Installation page P 12 5 Nut 6 Bolt 7 Power brake unit and pedal assembly 8 Snap pin 9 Clevis pin 10 Nut and washer 11 Bolt Nm m kg ft lb 12 Return spring Inspect for weakness or damage 13 Spacer 14 Bushing Inspect for weakness or damage 15 Brake pedal Inspect for bending or dam...

Page 604: ... 1 Brake pipe Removal note below 5 Master cylinder Installation note below 2 Brake hose 3 Bolt 4 Nut ADJUSTMENT BOLT I 9TGOPX 28 P 12 Disassembly Inspection I Removal note Brake pipe Assembly page P 14 1 Disconnect the brake pipe from the master cylinder with the SST Caution Brake fluid will damage painted surfaces If it does get on a painted surface wipe it off im mediately Installation note Mast...

Page 605: ...osen the push rod locknut and turn the push rod to make the adjustment Adjustment 1 Loosen the push rod locknut 2 Turn the tip of the push rod and adjust the push rod clearance 3 Recheck the clearance Note By making the above adjustment the clearance be tween the push rod and piston after installation of the master cylinder and the power brake unit will be as shown in the table below Push rod to p...

Page 606: ... of the cylinder or piston cups 1 Hose connector 2 Bushing Inspect for wear or damage 3 Stopper screw and a ring Disassembly note below Assembly note page P 15 4 Snap ring 7 Joint bolt 8 O ring 9 Oil seal 10 Spring Inspect for wear 11 Bleeder cap and screw 12 Cylinder body REPLACE 5 Primary piston assembly Inspect piston cups for damage 6 Secondary piston assembly Inspect for crack or damage Inspe...

Page 607: ...the unit is defective repair or replace the power brake unit THIRD FIRST SECOND 9TGOPX D38 Power brake unit function check Method without tester Step 1 9TGOPX 036 1 With the engine stopped depress the pedal a few times 2 With the pedal depressed start the engine 3 If immediately after the engine starts the pedal moves down slightly the unit is operating Step 2 1 Start the engine 2 Stop the engine ...

Page 608: ...art the engine 2 Stop the engine when the vacuum gauge reading reaches 500 mmHg 19 7 inHg 3 Observe the vacuum gauge for 15 seconds If the gauge shows 475 500 mmHg 18 7 19 7 inHg the unit is operating Loaded condition 1 Start the engine 2 Depress the brake pedal with a force of 196 N 20 kg 44 Ib 3 With the brake pedal depressed stop the engine when the vacuum gauge reading reaches 500 mmHg 19 7 in...

Page 609: ... of unit 196 N 20 kg 44 Ib 6 180 kPa 188 215mm 63 0 kg cm2 896 psi 7 4 8 5 in 196 N 20 kg 44 Ib 6 278 kPa 213 240mm 64 0 kg cm2 910 psi 8 4 9 4 in Inspection of check valve 1 Disconnect the vacuum hose from the power brake unit 2 Apply suction and pressure to the hose from the power brake unit side Check that air flows only toward the vacuum pump Note If the air passes in both directions or not at...

Page 610: ...to page P 10 5 Check function of the power break unit Refer to page P 15 1 Snap pin 2 Clevis pin 3 Nut 4 Power break unit Disassembly I Inspection I Assembly page P 19 Disassembly Inspection I Assembly 5 Nut 6 Operating lever 1 Disassemble in the order shown in the figure referring to Disassembly Note caution Nom m Jcg ft tb 9TGOPX 47 Remove all the retainers with a screwdriver When removing them ...

Page 611: ...Silencer 16 Retainer rear diaphragm Assembly Note page P 21 17 Rear diaphragm Inspect for cuts and other damage 18 Rear diaphragm plate Disassembly Note page P 20 Assembly Note page P 21 19 Center plate Assembly Note page P 21 20 Retainer center plate Assembly Note page P 20 p 1 9TGOPX 49 21 Seal 22 Bearing 23 Valve body Disassembly Note page P 20 Inspect for cracks and other damage 24 O ring 25 R...

Page 612: ...two suitable nuts Caution The rear shell is spring loaded loosen it carefully 4 Rotate the rear shell counterclockwise to unlock Rear diaphragm plate Remove the diaphragm plate while holding it at an angle Valve body 1 Pry up the diaphragm plate 2 Remove the valve body Assembly note Retainer center plate 1 Fit the seal to the bearing 2 Apply grease to the inner surface of the center plate 3 Instal...

Page 613: ...rotect the seal from damage 3 Install the center plate Rear diaphragm plate Install the diaphragm plate while holding it at an angle Retainer rear diaphram Press in the retainer with the SST Stop key Install the stop key while pushing the valve rod Rear shell assembly and center plate Align the notches of the rear shell and the center plate P 21 ...

Page 614: ...ks are aligned VACUUM PUMP On vehicle Inspection Function check 1 Warm up the engine 2 Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in the figure then check the vacuum Vacuum specification In 20 seconds 1 500 rpm 440 mmHg 17 3 inHg 3 000 rpm 580 mmHg 22 8 inHg Maximum vacuum 700 mmHg 27 6 inHg or more 3 If the pressure is less than specified check for the fol...

Page 615: ...p assembly Inspection below Disassembly I Assembly page P 24 3 Oil hose 9TGOPX 54 Inspection page P 24 Inspection Vacuum hose Function check 1 Disconnect the vacuum hose 2 Apply suction and pressure to the hose from the vacuum tank side Check that air flows only toward the vacuum pump Note If the air passes in both directions or not at all re place the check valve along with the hose P 23 ...

Page 616: ... and washer 6 Set bolt 2 Bracket 7 Washer 3 Rotor 8 Connector 4 Vane 9 Joint Inspection below 10 O ring 5 O ring 9TGOPX 056 P 24 11 Pump housing Inspection Check the following and replace if necessary 1 Worn or damaged rotor 2 Worn or damaged vane Umit Vane height 7 6mm 0 299 in Vane width 4 9mm 0 193 in 3 Worn or damaged housing 9TGOPX 055 ...

Page 617: ...itional pressure until the master cylinder pressure becomes 13 734 kPa 140 kg cm2 1 991 psi and then measure output fluid pressure P2 8 After the measurement release the input side fluid pressure 9 Change P1 to P3 and follow step 4 to 8 10 If the measured value is within the standard fluid pressure shown in the table below the LSGV is good If the value is out of standard replace the LSGV assembly ...

Page 618: ...moval Note 2 Install in the reverse order of removal 3 Bleed the air after installation Refer to page P 6 ___ l J 1 Brake pipe 2 Bolt Removal note below 3 Load sensing G valve LSGV kH tfi i J i 9TGOPX 06S P 26 Removal note Brake pipe 1 Remove the break pipe with the SST tkn m kg ft ll 9TGOPX 064 ...

Page 619: ...sure the drum inner diameter If the diameter exceeds the limit replace the drum Diameter limit Refer to Section TO Adjustment Adjustment of brake shoes 1 Remove the rubber plug from the backing plate 2 Place a screwdriver against the adjuster through hole and turn the adjuster in the direction of the arrow until the drum is locked 3 Turn the adjuster in the reverse direction from the locked positi...

Page 620: ...lly designed vacuum cleaner or equivalent to clean the brake assembly When removing the drum support it with a jack nMcg ft lb 9TFOPX 10 1 Set screw 12 Brake shoe 2 Brake drum Removal note page P 29 Inspection page P 29 3 Hub cap 4 Stop retainer 5 Locknut Installation note page P 29 Inspection page P 30 13 Brake pipe Removal note page P 29 14 Bolt pipe clip 15 Wheel cylinder Installation note page...

Page 621: ...he projections of the backing plate 2 Install the brake shoe Locknut 1 Loosely tighten the locknut to the hub spindle 2 Rotate the front hub 2 3 times to settle the bearing 3 Measure the bearing preload If necessary tighten or loos en the locknut Bearing preload Scale reading 11 29 N 1 1 3 0 kg 2 4 8 8 Ib 4 Install the stop retainer Inspection Brake drum 1 Measure the drum inner diameter Diameter ...

Page 622: ...contact caution If there are extremely uneven wear grind within the limit or replace the drum After the check wipe off the chalk Brake shoe 1 Inspect for peeling cracks or abnormal wear of the lining If necessary replace the brake shoe 2 Measure thickness of the lining If thickness is less than specified replace the brake shoe Lining thickness 1 0mm 0 04 in min ...

Page 623: ...ly 3 Inspect all parts and repair or replace as necessary Caution Do not let foreign material enter the cylinder 9TGOPX 84 1 Spring Inspect for deformation or weakness 2 Adjusting screw 3 Pistons 6 Feeling block 7 Spring Inspect for deformation or weakness 8 Bleeder cap Inspect for damage 4 Dust boots 9 Bleeder screw 10 Steel ball 5 Piston rubber cups P 31 ...

Page 624: ...ameter If the diameter exceeds the limit replace the drum Diameter limit Refer to Section TO Adjustment Adjustment of brake shoes 1 Remove the rubber plug from the backing plate 2 Place a screwdriver against the adjuster through hole and turn the adjuster in the direction of the arrow until the drum is locked 3 Turn the adjuster in the reverse direction from the locked position 5 notches 4 Inspect...

Page 625: ...valent to clean the brake assembly When removing the drum support it with a jack 7 11 14 0 11 1 4 5 11 10 5 88 108 9 11 65 80 3 1 Set screw 2 Brake drum Removal note page P 34 Inspection page P 35 3 Bolt 4 Rear axle shaft 5 Bolt 6 Set plate 7 Locknut Removal note page P 34 Installation note page P 34 8 Rear hub 9 Hold pin 10 Set spring Inspect for deformation or weakness 11 Return spring Inspect f...

Page 626: ... if the drum is hard to remove Locknut 1 Remove the locknut with the SST Brake pipe 1 Remove the brake pipe with the SST Installation note Brake shoe 1 Before installation apply grease to the wheel cylinder and anchor sliding parts the projections of the backing plate Locknut 1 Tighten the locknut with the SST ...

Page 627: ...f there are extremely uneven wear grind within the limit or replace the drum 2 Check the contact of drum and lining Apply chalk to the inside of the drum and rub the shoe against the drum Note Check for extremely bad contact Caution If there are extremely uneven wear grind within the limit or replace the drum After the check wipe off the chalk Brake shoe 1 Inspect for peeling cracks or abnormal we...

Page 628: ...rts and repair or replace as necessary Caution Do not let foreign material enter the cylinder 1 Spring REPLACE REPLACE REPLACE REPLACE 6 11 Inspect for deformation or weakness 6 Feeling block 7 Spring 9TGOPX 101 2 Adjusting screw 3 Pistons Inspect for deformation or weakness Inspect for damage 8 Bleeder cap 9 Bleeder screw 4 Dust boots 10 Steel ball 5 Piston rubber cups P 3S ...

Page 629: ...ter brake shoe Clean or replace P 40 Worn center brake drum 7 13 NOTCHES Grind or replace PARKING BRAKE LEVER On vehicle Inspection Lever stroke P 41 9TFOPX 015 1 Check that the stroke is within specification when the park ing brake lever is pulled with aforce of 294 N 30 kg 66Ib Stroke 7 13 notches Adjustment 1 Loosen locknut and turn the adjusting bolt so that the stroke is within the above rang...

Page 630: ...plit pin 2 Clevis pin 3 Return spring Inspect for deformation or weakness 4 Split pin 5 Clevis pin 6 Parking brake rod InspeCt for wear or damage of ratchet pawl 7 Spring Inspect for deformation or weakness 8 Front cable Removal Inspection r I i A 10 Clevis pin 11 Nut 12 Adjusting bolt 13 Joint 14 Tension rod Inspect for damage or deformation 15 Split pin 16 Clevis pin 17 Parking brake lever Inspe...

Page 631: ... Inspect all parts and repair or replace as necessary 4 After installation adjust the parking brake lever stroke Refer to page P 37 Caution When installing the parking cable do not twist it N m m kg ft Ib 9TFOPX o17 1 Front cable end 7 Rear cable end 2 Nuts 8 Nuts 3 Stop ring 9 Rear cable 4 Clevis pin Inspect for damage 5 Bolt 6 Front cable Inspect for damage P 39 ...

Page 632: ...r 190mm 7 48 in Limit 191mm 7 52 in 4 Visual inspect the lining thickness Thickness 3 6mm 0 14 in Limit 1 0mm 0 04 in Adjustment Center brake shoe clearance 1 Remove the plug 2 Place a screwdriver against the adiuster through hole and turn the adjuster in the direction of the arrow until the drum is locked 3 Turn the adjuster in the reverse direction from the locked position 6 7 notches Replacemen...

Page 633: ... 37 3 Inspection for function and 9rag of parking brake r ott s p 275 324 28 33 203 239 N m m IIg It 1 Nut 2 Propellershaft 3 Locknut Removal note page P 42 4 Washer 5 Oil seal 6 Center brake drum Inspection page P 43 7 Hold pin 8 Stop plate 9 Spring Inspect for weakness or deformation 10 Sleeve 11 Adjusting nut 12 Adjusting screw 13 Stop retainer 9TFOPX 2 14 Parking cable 15 Return spring Inspect...

Page 634: ...n Caution If there are extremely uneven wear grind within the limit or replace the drum 2 Check the contact of drum and lining Apply chalk to the inside of the drum and rub the shoe against the drum Note Check for extremely bad contact Caution Hthere are extremely uneven wear grind within the limit or replace the drum After the check wipe off the chalk Brake shoe 1 Inspect for peeling cracks or ab...

Page 635: ...UTLINE Q 2 SPECIFICATION Q 2 TROUBLESHOOTING GUiDE Q 3 WHEELS AND TIRES Q 4 SPECIAL NOTES ABOUT WHEELS AND TIRES Q 4 NOTES REGARDING TIRE REPLACEMENT Q 4 INSPECTION I ADJUSTMENT Q 4 REMOVAL I INSTALLATION Q 7 9TFoaX 1 Q ...

Page 636: ...psi 184 15 7 25 7 00 15 10 392 4 00 55 417 4 25 60 9TFOQX 02 Tire Diameter of Tire pressure pitch circle Size kPa kglcm2 psij mm in 6 50 16 10 491 5 00 71 6 50R16 10 540 5 50 78 203 2 8 6 50 16 8 417 4 25 60 6 50 16 10 441 4 50 64 6 50R16 10 491 5 00 71 7 00 16 10 466 4 75 68 7 00 16 12 466 4 7S 68 7 00R16 10 441 4 S0 64 203 2 8 7 00 16 10 491 5 00 71 7 00 16 12 515 5 25 75 7 00R16 10 540 5 50 78 ...

Page 637: ...t Stuck or damaged steering ball joint Replace Section N Excessive tire and wheel runout Replace Loose lug nuts Tighten 0 5 Unbalanced wheel Adjust or replace Q 8 Incorrect tire pressure Adjust 0 2 unevenly wom tires Replace Malfunction of shock absorber Replace Section R Loose shock absorber mounting bolts Tighten Section R Struck or damaged lower arm ball joint Replace Section R Cracked or worn ...

Page 638: ...rrectly 6 After mounting a tire onto a wheel inflate it to a little higher pressure than specified level Verify that the bead is seated correctly onto the rim and that there are no air leaks Then reduce the pressure to the specified level 1 1 I I VI i 4 V 1 J 9TFOOX OOS 9TGOOX OO7 WEAR INDICATOR WEAR INDICATOR 9TGOOX ooa Q 4 INSPECTION I ADJUSTMENT Air pressure 9TGOax oos 1 Check the air pressure ...

Page 639: ...essary Wheel runout 1 Set the probe of a dial indicator against the wheel and turn the wheel one full revolution Wheel runout Horizontal 3 0mm 0 120 in max Vertical 2 Smm 0 098 In max Wheel lug nut 1 Check the tightening torque Tightening torque Single rear tire Dual rear tires Item Nom m ic g ft Ib N m m kg ft Ib Front 491 735 50 75 362 542 167 215 Inside 540 784 17 22 123 159 55 80 398 578 Rear ...

Page 640: ...f rotation Overinflation Lack of rotation Incorrect toe in Incorrect camber or caster Malfunctioning suspension Unbalanced wheel Out of round brake drum or disc Lack of rotation Other mechanical conditions Action Adjust tire pressure Repair or replace axle and suspension parts Reduce speed Rotate tires Adjsut tire pressure Rotate tires Adjust tOe in Repair or replace axle and suspension parts Repa...

Page 641: ... and outer tire are not be in the same position Dual tires 3 Tighten the lug nuts in two or three times steps in a criss cross fashion Tighten to the specified torque Tightening torque Refer to page Q S caution Tighten the lug nuts to the specified torque again when the vehicle has run about 1 000 km 600 miles Never apply oil to the nuts bolts or wheels doing so might cause looseness or seizure of...

Page 642: ...en the front wheels are different from rear wheels in size When the front and rear wheels are the same in size and num ber of plies When the front tires are different from rear tires in number of plies Wheel Balance Adjustment 1 If a wheel becomes unbalanced or if a tire is replaced or repaired the wheel must be rebalanced to within specifi cation Maximum unbalance at rim edge 30 g 1 06 oz Balance...

Page 643: ...G GUIDE R 7 WHEEL ALIGNMENT R 8 PREPARATION R 8 PREINSPECTION R 8 FRONT WHEEL ALIGNMENT R 9 FRONT SUSPENSION LEAF SPRING R 12 PREPARATION R 12 FRONT SHOCK ABSORBER R 13 FRONT LEAF SPRING R 14 REAR SUSPENSION LEAF SPRING R 17 PREPARATION R 17 REAR SHOCK ABSORBER R 18 REAR LEAF SPRING R 19 9TFORX 1 ...

Page 644: ...R INDEX INDEX FRONT SUSPENSION 1 Front shock absorber Removal Inspection Installation page R 13 Inspection page R 13 R 2 2 Front leaf spring Removal Inspection 9TFORX 102 Installation page R 14 ...

Page 645: ...SION SINGLE LEAF SPRING DOUBLE LEAF SPRING 1 Rear shock absorber Removal Inspection I INDEX Installation page R 18 Inspection page R 18 2 Rear leaf spring Removal Inspection R 9TFORX 003 Installation page R 19 R 3 ...

Page 646: ... See next page Shock absorber type Cylindrical double acting 9TFORX 004 Wheel Alignment C lUnladen condition BOdy Truck Truck and Crew cab Cargo deck 10 feet 14 17 feet Cabin type Standrd cabin Wide cabin Front wheel alignment mm in 0 3 0 0 12 Total toe in degree 0 0 3 Camber 0 40 30 Caster 2 30 20 King pin angle 7 00 Inner 380 20 42 2 Maximum steering angle Outer 290 2 31 2 Rear wheel alignment m...

Page 647: ...x 70 x 9 49 1 x 2 8 x 0 35 970 x 70 x 9 38 2 x 2 8 x 0 35 E 830 x 70 x 10 32 7 x 2 8 x 0 39 700 x 70 x 10 27 6 x 2 8 x 0 39 570 x 70 x 11 22 4 x 2 8 x 0 43 410 x 70 x 11 16 1 x 2 8 x 0 43 260 x 70 x 11 10 2 x 2 8 x 0 43 1 506 x 70 x 10 59 3 x 2 8 x 0 39 950 x 70 x 12 37 4 x 2 8 x 0 47 1 248 x 70 x 10 49 1 x 2 8 x 0 39 900 x 70 x 12 35 4 x 2 8 x 0 47 F 880 x 70 x 10 34 6 x 2 8 x 0 39 900 x 70 x 12 ...

Page 648: ...go deck Cargo deck height1 Payload Front Rear length feet Rear tire ton HA Std High Single 1 5 A E Truck 10 2 0 B G SL Crew cab 2 75 B H 14 3 0 C F 0 I Truck SL TURBO Wide High Double 4 0 0 I 17 0 I Crew cab 3 5 0 I 14 TF 0 I Truck 4 0 17 0 I 9TFORX 008 R 6 ...

Page 649: ...el heavy Improperly adjusted wheel alignment Adjust R 8 Steering system related problem Section N Wheel and tire related problem Section Q Steering wheel pulls Weak leaf spring Replace R 14 19 to one side Improperly adjusted wheel alignment Adjust R 8 Steering system related problem Section N Brake system related problem Section P Wheel and tire related problem Section Q Shimmy occurs Malfunction ...

Page 650: ...d condi tion and set the wheels straight ahead 2 Check the tire inflation and bring to recommended pressure 3 Inspect the front wheel bearing play and correct it ff necessary 4 Inspect the wheel and tire runout 5 Shake the vehicle and check the operation of the shock at sorber 6 Verify that the difference between the left and right sides of the vehicle from the fender brim tothe center ofthe wheel...

Page 651: ...he vehicle level 3 Check the steering angle Standard steering angle 10 feet cargo deck 14 and 17 feet cargo deck Standard cabin Wide cabin I Inner 380 2 420 2 I Outer 290 20 31 2 Adjustment 1 Loosen the steering stop bolt locknut 2 Turn the stop bolt and adjust the steering angle 3 Tighten the stop bolt locknut to the specified torque Tightening torque 59 88 N m 6 9 m kg 43 65 ft Ib camber caster ...

Page 652: ...p the front axle and support the front frame with safety stands Warning Support the front axle with the jack 2 Remove the leaf spring U bolts 9TFORX 014 3 Lower the front axle and replace the caster wedge Caster wedge Part No_ Change of Angle W02334142A 0 20 W02334 143A 0 50 W02334 144A 1 20 W02334145A 1 50 W02334 146A 2 20 W02334 147A 2 50 Caution When installing the caster wedge face the thicker...

Page 653: ...ard to turn the front wheels 1800 6 Measure the distance between the marks now toward the front of the vehicle A 7 If the difference between 8 and A is not as specified ad just the toe in Total toe in 3 3mm 0 12 0 12 in Adjustment 1 Loosen the tie rod locknuts Note The right tie rod locknut is left hand threaded 2 Turn the left and right tie rods equally to adjust the toe in Note To increase the t...

Page 654: ...rt of shackle pin 49 W038 OAO bushing 49 W038 004 For removal and Attachment installation of Part of shackle pin 49 W038 OAO bushing R 12 49 W038 001 Shaft Part of 49 W038 OAO 49 W038 003 c o Support block Part of 49 W038 OAO 49W0380Q5 Bearing r q Part of 49 W038 OAO For removal and installation of shackle pin bushing For removal and installation of shackle pin bushing For removal and installation...

Page 655: ... 34 _ _ 1 Nut 2 Retainer 3 Bushing Inspect for damage and deterioration 4 Nut and washer 9TGORX 28 Nom m kg ft lb 9TGORX Q27 5 Retainer 6 Bushing Inspect for damage and deterioration 7 Shock absorber Inspection below Inspection Shock absorber Check for the following and replace as necessary 1 Oil leakage from shock absorbers 2 Poor operation of shock absorbers D Depress the shock absorbers several...

Page 656: ...orque with the vehicle lowered and in an unladen condition 1 Nut 2 Washer 3 Retainer 4 Bushing Inspect for damage and deterioration 5 Shock absorber 6 Nut 7 U bolt Removal note page R 15 8 Bound stop Inspect for damage and deterioration 9 Nut and washer 10 Spring pin Removal note page R 15 11 Nut and washer 12 Shackle plate R 14 Nom m kg ft JII1 9TFORX 18 13 Shackle pin Removal note page R 15 14 T...

Page 657: ...d stop 4 Lower the front axle Spring pin and shackle pin 1 Remove the spring pin and shackle pin with a brass bar Shackle pin bushing 1 Remove the shackle pin bushing from the frame with the SST Spring bushings Front side 1 Remove one side of the bushing with a chisel 2 Remove the remaining bushing with a suitable pipe Spri g bushing Rear side 1 Remove the bushing with the SST and a press R 15 ...

Page 658: ...ion note Sring bushing Rear side 1 Install the bushing with the SST and a press Spring bushings Front side 1 Install the bushings with a vise Shackle pin bushing 1 Install the new bushing into the frame with the SST caster wedge 1 Install the caster wedge with the thicker side facing toward rear ...

Page 659: ...hackle pin 49 W038 OAO bushing 49 W038 004 For removal and Attachment installation Of Part of shackle pin 49 WOOS OAO bushing 49 W038 001 Shaft Part of 49 W038 DAD 49 W038 003 Qj Support block Part of 49 W038 OAO 49 WOOS 005 r Il Part of iii 49 W03S OAO R For removal and installation of shackle pin bushing For removal and installation of shackle pin bushing For removal and installation of shackle ...

Page 660: ... 2 Retainer 3 Bushing Inspect for damage and deterioration 4 Nut and washer 9TGORX Q58 R 18 N m 1IIokg ft lb 9TGORX 057 5 Retainer 6 Bushing Inspect for damage and deterioration 7 Shock absorber Inspection below Inspection Shock absorber Check for the following and replace parts as necessary 1 Oil leakage from shock absorbers 2 Poor operation of the absorbers G Depress the shock absorbers several ...

Page 661: ...5 8 2 47 59 64 80 6 5 8 2 47 59 1iCI 118 147 12 15 REPLACE 1 Nut and washer 2 Retainer 3 Bushing Inspect for damage and deterioration 4 Shock absorber 5 Nut 6 Spring clamp 7 U bolt Removal note page R 20 a Bound stop Inspect for damage and deterioration 9 Nut ana washer 10 Bolt and washer 11 Spring pin Removal note page R 20 18 22 130 159 N m nHg ft Ib 9TF0AX 020 12 Nut and washer 13 Shackle pin R...

Page 662: ... axle Spring pin and shackle pin 1 Remove the spring pin and shackle pin with a brass bar Shackle pin bushing 1 Remove the shackle pin bushing from the frame with the SST Spring bushings Front side 1 Remove one side of the bushing with a chisel 2 Remove the remaining bushing with a suitable pipe Spring bushing Rear side 1 Remove the bushing with the SST and a press ...

Page 663: ... Spring bushing Rear side 1 Install the new bushing with the SST and a press 12 iCl I I 9TGORX 065 Spring bushing Front side 1 Install the new rubber bushing with a vise Shackle pin bushing 1 Install the new bushing into the frame with the SST R 21 ...

Page 664: ...DSHIELD WIPER AND WASHER S 23 STRUCTURAL VIEW S 23 TROUBLESHOOTING GUIDE S 24 COMPONENTS S 29 WIPER MOTOR 8 33 WASHER MOTOR 8 34 INTERMITTENT WIPER RELAy 8 34 WIPER AND WASHER SWITCH 8 34 ROOF VENTILATOR S 35 WINDSHIELD S 36 BACK WiNDOW S 38 TILT LOCK SYSTEM 0 S 40 CABIN MOUNT S 42 DAMPER 8 42 CABIN MOUNT 8 42 FRONT CABIN DAMPER 8 42 REAR CABIN MOUNT S 44 CONSOLE 8 49 INSTRUMENT PANEL S 50 SEAT S ...

Page 665: ...s INDEX INDEX BODY 9TGOSX 002 S 2 ...

Page 666: ...ont door lock and opener Removal page S 43 Removal Installation page S 12 Installation page S 43 4 Rear door 9 Rear cabin mount with damper Removal Installation page S 13 Inspection On vehicle page S 42 Adjustment page S 14 Removal page S 44 5 Rear door lock and opener Installation page S 46 Removal Installation page S 17 10 Rear cabin mount without damper 6 Roof ventilator Removal Installation pa...

Page 667: ...s INDEX EXTERIOR S 4 9TGOSX 004 ...

Page 668: ...nk 5 Front bumper Removal Installation page 8 30 Removal Installation page 8 18 14 Washer nozzle 6 Rear bumper Removal Installation page 8 31 Removal Installation page 8 19 Adjustment page 8 32 7 Radiator grille Front grille 15 Intermittent wiper relay Removal Installation page 8 20 Inspection page 8 34 8 8tep 16 Wiper and washer switch Removal Installation page 8 21 Inspection page 8 34 9 Mirror ...

Page 669: ... Removal Installation page S 59 Inspection page S 60 7 Floormat 3 Clock Removal Installation page 8 61 4 Front seat Removal Installation page S 53 Disassembly Assembly page S 55 5 Rear seat Removal Installation page S 54 Removal Installation page 8 62 8 Headliner Removal page S 63 Installation page S 65 9 Trim Removal Installation page S 68 8 6 ...

Page 670: ...ONT FENDER PANEL COMPONENTS Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removaL 1 Radiator grille 2 Front combination light 3 Mirror 4 Front fender panel s 9TGOSX 007 S 7 ...

Page 671: ...ferring to Installation Note caution Remove the door screen carefully so that it may be reused Nom rn kg ft lb 9TGOSX ooa 1 Trim with door speaker model 6 Front door 2 Door screen with door speaker model 3 Connector door speaker 4 Front fender panel Installation Note page 5 9 Adjustment page 5 9 7 Door lock striker 5 Bolt Adjustment page S 9 S 8 ...

Page 672: ...em loosen the striker mounting screws and adjust by moving the striker down or laterally 2 Check the rear offset of the door to the body or rear door crew cabin If there is a problem adjust by moving the door lock striker laterally Tightening torque 18 26 N rn 1 8 2 7 m kg 13 20 ft Ib 1 Loosen the hinge bolts and adjust as shown in the figure Tightening torque 18 29 N m 1 8 3 0 m kg 13 22 ft Ib 8 ...

Page 673: ...in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal Caution Remove the door screen carefully so that it may be reused 6 9 9 8 NofTI 70 100 cm kg 61 87 in Ib 1 Regulator handle Removal Note page S 11 6 Outer weatherstrip 7 Cover 2 Armrest 3 Door trim 8 Door screen 9 Front door glass 9TGOSX 12 4 Inner handle 5 Inner weatherstrip Removal Note page S 11...

Page 674: ...LATOR AND GLASS s 9TGQSX 014 Removal note Regulator handle 1 Remove the regulator handle with a rag as shown in the figure Front door glass 1 Remove the door glass from the door while lifting the rear of the glass 5 11 ...

Page 675: ... 4 Install in the reverse order of removal Caution Remove the door screen carefully so that it may be reused 4 2 6 1 N m 43 63 em kg 38 54 in lb 6 9 S 8 N m 70 100 em kg 61 87 in Ib 1 Regulator handle 7 Opener link Removal Note page S 11 8 Outer door handle 2 Armrest 9 Door lock link 3 Door trim 10 Bracket 4 Inner handle 11 Lock cylinder retainer 5 Cover 12 Lock cylinder 6 Door screen 13 Door lock...

Page 676: ...Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal I 1 Bolt 2 Rear door REAR DOOR s N m m kg ft lb 9TGOSX 016 3 Door lock striker Adjustment page 8 14 Adjustment page 8 14 8 13 ...

Page 677: ...the striker down or laterally 2 Check the rear offset of the door to the body or front door crew cabin If there is a problem adjust by moving the door lock striker laterally Tightening torque 18 26 N m 1 8 2 7 m kg 13 20 ft Ib 1 Loosen the hinge bolts and adjust as shown in the figure Tightening torque 16 23 N m 1 6 2 3 m kg 12 17 ft Ib 7 1 7mm 0 28 0 07 in 7 1 7mm 0 28 0 07 in 7 1 7mm 0 28 0 07 i...

Page 678: ... to Removal Note 4 Install in the reverse order of removal Caution Remove the door screen carefully so that it may be reused 1 Regulator handle Removal Note page 5 16 2 Armrest 3 Door trim 8 Run channel 9 Glass guide 10 Rear door lock assembly 11 Rear window regulator s 9TGOSX 019 4 Inner handle Removal Note page 5 16 5 Door screen 12 Rear window glass 6 Inner weatherstrip Removal Note page 5 16 7...

Page 679: ... 9TGOSX 021 9TGOSX 022 Removal note Regulator handle 1 Remove the regulator handle with a rag as shown in the figure Rear window regulator 1 Remove the regulator as shown in the figure Rear window glass 1 Remove the glass from the door by moving it in the order shown in the figure ...

Page 680: ...he figure referring to Removal Note 4 Install in the reverse order of removal Caution Remove the door screen carefully so that it may be reused 6 9 9 8 N m 70 100 c m kg 61 87 in lb 1 Regulator handle Removal Note page S 16 2 Armrest 3 Door trim 4 Inner handle 5 Door screen 5 6 Opener link 7 Door lock link 1 8 Outer door handle 9 Door lock link 2 10 Door lock assembly s 9TGOSX 023 S 17 ...

Page 681: ...allation 1 Disconnect the negative battery cable FRONT BUMPER 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 16 23 1 6 2 3 12 17 1 Undercover 2 Fog light 3 Front bumper assembly S 18 m kg tt Jb 9TGOSX 24 ...

Page 682: ...EAR BUMPER COMPONENTS Removal 1 Disco nstallation 2 R nnect the n emove in egatlve batte 3 Install in th the order shown ry cable __ e re ve9rrse ord In the figure er of removal 1 Bolt 2 Rear bumper s 9TGOSX 25 5 19 ...

Page 683: ...RADIATOR GRILLE FRONT GRILLE COMPONENTS Removal Installation 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 1 Radiator grille 8 20 2 Front grille 9TGOSX Q26 ...

Page 684: ...tion of step 1 Torx wrench specification STEP Removal Installation 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 1 Torx screw 2 Step s Torx wrench A T30 5 5mm 0 2 in 2 9TGOSX Q27 S 21 ...

Page 685: ...connect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal RIGHT 1 11 13 N m 110 130 cm kg 95 112 in Ib 1 Bolt S 22 MIRROR LEFT 1 11 13 N m 110 130 cm kg 95 112 in Ib 9TGOSX 28 2 Mirror ...

Page 686: ...9 Disassembly Assembly page 8 33 Inspection page S 33 3 Wiper link assembly Removal Installation page 8 30 4 Wiper and washer switch Inspection page 8 34 9TGOS 29 5 Intermittent wiper relay Inspection page S 34 6 Washer tank assembly Removal Installation page S 29 7 Washer motor Removal Installation page S 29 Inspection page S 34 8 Washer nozzle Removal Installation page S 31 Adjustment page S 32 ...

Page 687: ... L F 0 WIPER 15A WIPER WASHER 0 01 SWITCH 0 01 B F r ____ G F ____ 0 01 LIB L 1 F F 0 04 t d INTERMITTENT B F WIPER RELAY 1r_ 1r_ 0 01 WIPER WASHER 0 02 WASHER MOTOR F 0 03 WIPER MOTOR F 0 04 INTERMITTENT RHO SWITCH F WIPER RELAY F L G L R LIB S 24 G R L W L W L R L L Y 9TGOSX 03O ...

Page 688: ...ction e Check for continuity between B NO wire of intermittent wiper relay con 9 Poor ground Repair ground circuit I nector and ground Continuity YES Turn engine switch ON Wiper switch inspection 1 Set wiper switch to INT position Wiper switch malfunction Inspect wiper switch I 2 Check G wire voltage at wiper Refer to page S 34 switch connector Battery voltage t YES Harness inspection Check G wire...

Page 689: ...rn engine switch ON t Wiper switch inspection 1 Set wiper switch to Lo position 2 Check UW wire voltage at wip Wiper switch malfunction er switch connector Battery voltage YES Harness inspection 1 Set wiper switch to Lo pOSition H Open circuit in wiring harneSs 2 Check UW wire voltage at wip Wiper motor wiper switch er motor connector Battery voltage l YES Wiper motor malfunction 5 26 Inspect wipe...

Page 690: ...ntermittent wiper function check wiper motor opera with intermittent function tion and wiring harness Fu Wiper motor only Turn engine switch ON t Harness inspection IN lOpen circuit in wiring harness Check L wire voltage at wiper me Repair wiring harness J tor connector Fuse wiper motor Battery voltage tYES Operate wiper motor and turn en gine switch OFF to stop wipers at other than park position ...

Page 691: ...n washer switch ON 2 Check G R wire voltage at washer motor connector Battery voltage I Washer continues to operate when switch OFF S 28 Wiper switch malfunction Wiper switch malfunction NO j Poor ground A Washer switch malfunction Open circuit in wiring harness Washer switch washer motor YES J Washer motor malfunction Washer switch malfunction Inspect wiper switch Refer to page S 34 Inspect wiper...

Page 692: ...g the wiper arm and blade only_ CD J 6 9 9 8 N m 70 100 em kg 61 87 in Ib 9 _ _ NUT A Wiper arm and blade 9 Duct A 1 Wiper arm cover 10 Blower unit 2 Nuts 11 Wiper motor and bracket s 9TGOSX 040 3 Wiper arm and blade Installation Note page 5 31 Adjustment page 8 32 Wiper motor Disassembly I Assembly page 5 33 Inspection page 5 33 4 Glove box Washer motor 5 Lower panel 12 Washer tank assembly 6 Was...

Page 693: ...100 em kg 61 87 in Ib 3 9TGOSX 41 1 Wiper arm and blade 4 Wiper motor and bracket Adjustment page 8 32 2 Nut 3 Instrument panel Removal Installation page 8 50 Installation Note page 8 31 Disassembly I Assembly page 8 33 Inspection page 8 33 5 Windshield wiper link assembly 5 30 ...

Page 694: ...R s Washer nozzle 9TGOSX 1 Instrument panel 3 Washer nozzle Removal Installation page 8 50 Adjustment page S 32 2 Clip Installation note Wiper motor and bracket 1 Align the wiper motor arm as shown in the figure 9TGOSX 043 5 31 ...

Page 695: ...14 37 grN 9TGOSX 045 Adjustment Wiper arm height 1 Turn the wiper switch from ON to OFF to set the wiper arm park position 2 Adjust the arm height as shown in the figure Height 40 5mm 1 57 0 2 in Tightening torque 9 8 14 N m 100 140 em kg 87 121 in Ib Washer spray 1 Insert a needle or similar object into the nozzle hole and move the nozzle to change the direction of spray ...

Page 696: ... between terminals Terminal UR UY Auto stop position Other position 0 UW 4 If not as specified replace the wiper motor Operation Note 9TGOSX 049 L Connect the negative battery terminal to the motor ground wire if checking out of the vehicle 1 Disconnect the wiper motor connector 2 Verify motor operation when appling 12V to the terminals of the motor connector 12V applied to Motor operation UW wire...

Page 697: ... for continuity between terminals of washer motor con nector 3 If not as specified replace the washer motor Operation 1 Disconnect the washer motor connector 2 Connect 12V to B terminal and ground A terminal Verify motor operation erminal Connection Motor operation A Ground 8 12V Operates 3 If not as specified replace the washer motor INTERMITTENT WIPER RELAY Inspection 9TGOSX 047 1 Connect a jump...

Page 698: ...PONENTS Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 1 Lever 2 Ventilator grille 3 Retaining ring 4 Shaft 5 Lever assembly 6 Roof lid assembly 7 Seal rubber s 9TGOSX 053 s 35 ...

Page 699: ...indshield 9TGOSX 054 1 Disconnect the negative battery cable 2 Remove the rearview mirror wiper arm and blade 3 Remove in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal referring to Installation Note 1 Windshield and weatherstrip Removal Note page 5 37 Installation Note page 5 37 8 36 9TGOSX 055 ...

Page 700: ...allation between the weatherstrip and the body 5 Locate the glass and weatherstrip squarely in the windshield frame Note The following operation must be done with a partner 6 Tap lightly on the outside of the windshield while pulling the string to install the weatherstrip around the entire circum ference 7 Move the glass by hands on the inside and outside of the glass if it is not properly seated ...

Page 701: ...l and installation of windshield 9TGOSX OS1 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure referring to Removal Note 3 Install in the reverse order of removal referring to Installation Note 1 Back window and weatherstrip Removal Note page 8 39 Installation Note page 8 39 S 38 9TGOSX Q62 ...

Page 702: ...ensure smooth installation between the weatherstrip and the body 5 Locate the glass and weatherstrip squarely in the window frame Note The following operation must be done by the partner 6 Tap lightly on the outside of the back window while pulling the string to install the weatherstrip around the entire cir cumference 7 Move the glass by hands on the inside and the outside of the glass if it is n...

Page 703: ...gative battery cable 2 Tilt the cabin and verify that it is securely locked in position 3 Remove in the order shown in the figure 4 Install in the reverse order of removal STANDARD CABIN 1 Rod 2 Hook assembly S 40 19 25 1 9 2 6 14 19 cq E 2 3 Lock lever assembly Nom nHtg ft lb 9TFOSX 001 ...

Page 704: ...nce between the main hook and eye bolt Clearance Smm 0 2 in min 2 Verify that when the main hook is completely locked the clearance between safety hook and striker is as specified Clearance Wide cabin approx 27 0mm 1 06 in Standard cabin approx 22 0mm 0 87 in 3 If clearance is not within specification check for a worn main hook or worn eye bolt and check the lock installation S 41 ...

Page 705: ...eaking CABIN MOUNT With rear cabin damper Inspection On vehicle 1 Check for heights A as shown in the figure Height Wide cabin 43 0 1 0mm 1 69 0 04 in Standard cabin 26 4 1 0mm 1 04 0 04 in Caution Loosen the damper mounting bolts when adjusting 2 Adjust the height by moving the set plate if not as specified N rn m kg ft lb 9TGOSX 073 3 Nut lock washer washer 4 Front cabin damper Inspection On veh...

Page 706: ...3 Remove the nuts and front cabin damper 9TGOSX 076 Installation 1 Install the damper between the frame and cabin 2 Install nuts and tighten to the specified torque Tightening torque 64 83 N m 6 5 8 5 m kg 47 61 ft Ib 9TGosx on 3 Install the undercover and radiator grille 9TGOSX 78 S 43 ...

Page 707: ... 8 2 41 59 iii N m m kg f1 1b 9TGOSX 79 Inspection On vehicle page S 42 5 Stopper rubber 6 Front flap bracket 3 Wedge 7 Cabin mount bracket Removal Caution Securely lock the cabin when raised Disconnect the negative battery cable_ 1 Remove the mud guard flap 9TGOSX 8 2 Remove the damper mounting bolts and damper 9TGOSX oa1 ...

Page 708: ...CABIN MOUNT s 3 Remove the wedge 4 Remove the arm mounting bolts and arm 5 Remove the nuts and stopper rubber 6 Remove the front flap bracket 9TGOSX oas 7 Remove the cabin mount bracket 9TGOSX Q86 5 45 ...

Page 709: ...HT 9TGOSX 091 CABIN MOUNT Installation 1 Install the cabin mount bracket Tightening torque 37 52 Nrn 3 8 5 3 m kg 27 38 ft Ib 2 Install the front flap bracket 3 Install the stopper rubber 4 Install the arm and bolt Tightening torque 116 156 N m 11 8 16 0 m kg 85 115 ft Ib 5 Install the wedge as shown in the figure ...

Page 710: ...he bolts 7 Check for heights A as shown in the figure Refer to page 8 42 s 8 Adjust the height by moving the set plate if not as specified 9 Tighten the bolt with specified torque Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft Ib 10 Install the mud guard flap S 47 ...

Page 711: ...e cabin while raised 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 1 Mud guard and flap 2 Wedge 3 Bushing S 48 2 INSTALL WEDGE IN PROPERLAY POSITION 4 Front flap bracket 5 Rear cabin bracket N m m Icg ft lb 9TGOSX 9S ...

Page 712: ...CONSOLE COMPONENTS Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal Console 1 Screws 2 Console CONSOLE s 9TFOSX 003 8 49 ...

Page 713: ...INSTRUMENT PANEL 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure referring to Removal Note 3 Install in the reverse order of removal referring to Installation Note MODE WIRE s so 39 49 4 5 29 36 N m m Icg ft Ib 9TGOSX 97 ...

Page 714: ...ket mounting bolt 9 Connector audio antenna feeder 23 Bracket 10 Audio 24 Instrument panel mounting bolt 11 Heater control wire Installation Note page S 51 Removal Note page S 51 25 Brake reserve tank bracket Installation Note page S 52 26 Brake reserve tank 12 Connector heater control unit 9TGOSX 099 MODE WIRE MIXWIRE 9TGOSX l00 9TG OSX l0l 27 Instrument panel Removal note Steering wheel 9TGOSX 0...

Page 715: ...lever to verify that it moves the full stroke from DEF to VENT MIX wire Adjustment 1 Set the MIX lever to maximum hot position 2 Set the MIX door link to maximum hot position as shown in the figure and connect the wire 3 Clamp the wire Caution After installation move the MIX lever to verify that it moves the full stroke from HOT to COLD REC FRESH wire Adjustment 1 Set the REG FRESH lever to REC po...

Page 716: ...al referring to Installation Note Front seat Driver seat 1 Seat mounting bolt 2 Driver seat Installation Note page S 54 Disassembly I Assembly page 8 55 Passenger seat 3 Shutter lever 4 Mounting bolt 5 Passenger seat Installation Note page 8 54 Di ssembly IAssembly page 8 56 57 s 38 51 3 9 5 2 28 38 N m m kg ft lb STFOSX OO4 Seatback tray 6 Seatback tray 5 53 ...

Page 717: ...SX OOS 9TGOSX ll0 5 S4 SEAT 2 Rear seat Installation note Passenger seat CD 9TGOSX l08 1 Verify that the seatback lock is securely locked after instal lation 2 Adjust the seatback striker if necessary Driver seat 1 Verify that the seat slides smoothly ...

Page 718: ...ring to Disassembly Note 2 Assemble in the reverse order of disassembly Driver seat 16 27 1 6 2 8 12 20 Nom m kg ft lb 9TGOSX 1 Knuckle knob 6 Seatback trim 2 Knuckle cover 7 Seatback cushion 3 Reclining knuckle 4 Adjuster 8 Seat cushion trim 9 Seat cushion 5 Lumbar support dial S 55 ...

Page 719: ...TFOSX 6 1 Seatback tray 8 Plate 2 Front seatback trim 9 Front seat trim 3 Front seatback cushion 4 Rubber 10 Front seat cushion 11 Insulator 5 Lock pin 6 Bushing Disassembly Note page S 58 12 Rubber seal 7 Spring Disassembly Note page 5 58 8 56 ...

Page 720: ...SMl07 1 Front seatback trim 8 Front seat trim 2 Front seatback cushion 9 Front seat cushion 3 Rubber 10 Insulator 4 Lock pi n Disassembly Note page 5 58 5 Bushing 6 Spring 11 Rubber seal Disassembly Note page 5 58 7 Plate 5 57 ...

Page 721: ... hog rings from the seatback and seat cushion 2 Remove the seat cushion cover 3 Remove the fasteners and insulator Rubber seal 1 Remove the hog rings from the seatback and seat cushion 2 Remove the seat cushion cover 3 Remove the rubber seal fasteners as shown in the figure ...

Page 722: ... order of removal Caution SEAT BELT s Do not disassemble the buckle and retractor assembly Front seat belt EXCEPT CREW CABIN CD 38 78 3 9 8 0 28 58 tr CD38 78 3 9 8 0 28 58 CREW CABIN CD38 78 3 9 8 0 28 58 CD38 78 3 9 8 0 28 58 Nom m kg ft lb 9TGOSX 118 Front seat belt Buckle 1 Bolt 4 Bolt 2 Screw 5 BuckJe 3 Front seat belt Inspection page 8 60 5 59 ...

Page 723: ...y locking retractor ELR 1 Verify that the belt can be pulled out smoothly and that it moves smoothly when worn 2 Verify that the retractor locks when quickly pulling the belt 3 Remove the retractor 4 Hold the retractor as it is installed 5 Slowly incline the retractor while pulling out the belt 6 Verify that the retractor locks at Approx 30 degrees incli nation ...

Page 724: ...reverse order of removal referring to Installation Note 1 Steering column 3 Instrument cluster panel 2 Steering wheel 4 Clock Removal Note page 8 61 Installation Note page 8 61 Removal note Steering wheel s 9TGOSX 122 1 Remove the steering wheel with a steering wheel puller 9TGOSX 124 Installation note Steering wheel 1 Set the cancel cam as shown in the figure s 61 ...

Page 725: ...of removal FRONT FLOORMAT Front floormat 1 Front seat REAR FLOORMAT Removal IInstallation page 5 53 2 Console Removal I Installation page S 49 3 Scuff plate 4 Front floormat 5 62 _ _ 38 51 3 9 5 2 28 38 Rear floormat 5 Rear seat 38 51 3 9 5 2 28 38 Nom m kg ft lb 9TFOSX 0Q8 Removal Installation page 5 54 6 Brim plate 7 Back plate mat 8 Mat side plate 9 Rear floorrnat ...

Page 726: ...ADLINER Removal 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure Except crew cabin 1 Roof ventilator grille 2 Fastener HEADLINER s 9TGOSX 126 3 Headliner Installation page S SS S 63 ...

Page 727: ... 9TGOSX 127 1 Rear interior lamp Rear headliner Service Section T 6 Rear headliner 2 Roof reinforcement Front headliner Installation pageS 66 3 Roof ventilator grille 4 Fastener 5 Front headliner Installation page S 66 8 64 ...

Page 728: ...s Installation 1 Install in the reverse order of removal referring to Installation Note Except crew cabin MATCHING MARKS 9TGOSX 128 1 Headliner 2 Fastener Installation Note page S 67 3 Roof ventilator grille 8 65 ...

Page 729: ...s HEADLINER Crew cabin 9TGOSX 129 1 Headliner 3 Roof reinforcement Installation Note page S 67 2 Fastener 4 Rear interior lamp 5 Roof ventilator grille 5 66 ...

Page 730: ...OSX 130 WIDE CABIN CREW CABIN STANDARD CREW CABIN WIDE 9TGOSX 131 HEADLINER Installation note Headliner s 1 Remove the protective sheet shaded area from the headliner 2 Push the headliner into place with a flat too 5 67 ...

Page 731: ...er shown in the figure referring to Removal Note 3 Install in the reverse order of removal Door trim 1 Regulator handle Removal Note page S 11 2 Armrest 3 Door trim Scuff plate 4 Screw 5 Scuff plate 8 68 Brimplate crew cabin 6 Screw 7 Brimplate Mat side plate crew cabin 8 Screw 9 Mat side plate 9TGOSX 132 ...

Page 732: ...5 492 240 9 45 n 0 123 4 84 242 9 53 I 1 0 CO ui F D t it1 l It 230 9 06 135 5 31 60 2 36 0 305 12 01 k I t 228 137 5 39 8 98 i 1 10 500 19 69 CD S r 1 c i I S 1 j p d 55 2 17 10 1 1 V 100 3 94 90 3 54 j v 0 It I f cO N ci CD It 0 N I f 10 ci N CD e CD s E E 9TGOSX 133 5 69 ...

Page 733: ... 167 6 57 198 7 8 f I 49 r316 12 44 1 93 en cO Id 117 bl 248 9 76 4 61 183 7 2 y 182 7 17 l 83 3 27 3 282 11 10 C 0 60 2 36 305 12 0 k 239 126 4 96 9 41 1 I 500 19 69 N co o crf _49 1 93 be I 1 100 3 94 90 3 54 e tC C J C J C l Ii CX tC 0 0 0 0 N It a C j i It W 0 It c i It C i IX 0 It co cD C J 0 E E ...

Page 734: ...9 I 55 tl 310 12 2 2 17 IIf r Q A cD 65 IT 300 11 ts1 2 56 CD 129 236 9 29 5 08 I 201 7 91 It 164 6 46 0 365 14 37 A C bJ T 0 239 9 41 126 4 96 l L 500 19 69 1 l CD O o loIS pc PCI 49 1 93 100 3 94 90 3 54 900 35 s cg 0 N r eD It r It r C a 0 til li N CIi 2 N CD oq CD CD 0 r r N 5 71 ...

Page 735: ... oo _9 8 7_ 8 I I r C 0 49 316 12 44 1 93 1170 248 9 76 4 61 183 7 2 16 l182 7 17 83 3 27 1 282 11 10 i1b 60 2 36 1 t r 305 12 0 L 126 4 96 239 9 41 y 1 L 500 __H l i W J 19 69 CD IIiiI ooi o D C to C N N 0 L r 1r OC _ eel 001 49 1 93 i I NN 1 11 00 LI J _ _I _ _ 100 3_ 94 90 3_ 54 E E ...

Page 736: ...09 55 W Ie 2 17 1 _3_1_0 _12_ 2 _ o t 65 i 2 56 r 300 11 81 1 29 ___ 5 08 1 236 9 29 Ic ro 201 7 91 1 _ 1 164 6 46 65 2 56 1 300 11 81 83 3 27 r 282 11 1 P 60 2 36 1 l 305 12 0 126 4 96 239 9 41 JI I I 500 19 69 o It g J r_ _r r pc cgC J o 4 9 1 9 3 l g H VI C I C Io l __ _ r 100 3 94 90 3 54 s E E 5 73 ...

Page 737: ...40 5 5 1 4oIIt 22 5 8 8 6 j 185 7 28 180 7 09 F 67 2 64 Ic t 298 11 73 IC 65 2 56 k 300 11 81 I o 135 5 31 e 230 9 06 1 Ie 6 201 7 91 14 1 6 4 6 4 6 t 60 2 36 f i 30 5 12 0 1 t 239 9 41 126 4 96 r rr l n 500 19 69 1A PC 49 1 93 p 100 3 94 I I90 3_ 54 j j E E ...

Page 738: ...ERIOR LIGHTING SYSTEM T 20 PREPARATION T 63 STRUCTURAL ViEW T 20 STRUCTURAL ViEW T 63 SPECIFICATIONS T 21 TROUBLESHOOTING T 64 AIMING T 22 INSTRUMENT CLUSTER METER T 68 TROUBLESHOOTING T 23 WATER THERMOSENSOR T 71 HEADLIGHT T 36 FUEL GAUGE SENDER UNIT T 71 FRONT COMBINATION LIGHT T 37 PICKUP SENSOR T 72 FOG LIGHT T 38 HORN T 73 REAR COMBINATION LIGHT T 39 HORN T 73 BACK UP LIGHT T 40 HORN RELAy T ...

Page 739: ...T INDEX RELAY FUSE SWITCH INTERMITTENT WIPER RELAY SERVICE SECTION S CANCEL RELAY SERVICE SECTION G T 2 INDEX GLOW PLUG RELAY SERVICE SECTION G 9TGOTX 2 ...

Page 740: ... T 13 Inspection page T 19 3 Stoplight checker relay 8 Stoplight switch Inspection page T 15 60 Inspection page T 41 4 Flasher unit 9 Back up light switch Inspection page T 15 Inspection page T 41 5 Horn relay 10 Fog light switch Inspection page T 73 Inspection page T 42 6 Engine switch 11 Door switch Inspection page T 17 Inspection page T 46 Removal Installation page T 17 9TFOTX 2 T 3 ...

Page 741: ...T INDEX EXTERIOR LIGHT INTERIOR LAMP 9TGOTX Xl4 T 4 ...

Page 742: ...unit Removal Inspection Inspection page T 15 Installation page T 37 8 Stoplight switch 3 Rear combination light Inspection page T 41 Removal Inspection 9 Sack up light switch Installation page T 39 Inspection page T 41 1 Turn and hazard warning light 10 Fog light switch Troubleshooting page T 25 Inspection page T 42 Removal Inspection 11 Sack up light Instaliation page T 39 Troubleshooting page T ...

Page 743: ...58 3 Warning buzzer 12 Water thermosensor Troubleshooting page T 57 Removal Installation page T 71 Removal Installation page T 69 Inspection page T 71 Inspection page T 61 13 Fuel gauge sender unit 4 Brake fluid level sensor Removal Installation page T 71 Inspection page T 60 Inspection page T 71 Removal I Installation page T 60 14 Pickup sensor 5 Vacuum switch Inspection page T 72 Troubleshooting...

Page 744: ...stallation page T 74 4 Speaker Troubleshooting page T 78 Removal Installation page T 89 Inspection page T 90 Inspection page T 74 3 Audio unit Troubleshooting page T 78 Removal Installation page T 88 5 Antenna feeder Troubleshooting page T 78 Removal Installation page T 91 Inspection page T 91 T 7 ...

Page 745: ... T 44 Interior tamp stays ON Switch Door position T 44 Warning system Brake warning tamp comes ON after engine started T 49 Brake warning tamp does not operate parking brake set T 49 Brake warning lamp does not operate when brake fluid level below MIN T 50 Alternator warning lamp comes ON after engine started T 5O Alternator warning lamp does not operate when engine switch ON T 50 Oil pressure war...

Page 746: ... temperature gauge does not operate T 66 Fuel gauge does not operate T 67 Audio system AM RADIO No sound T 79 Bad sound quality T 79 Noise T 80 No disptay of frequency Preset memory canceled T 81 AM FM RADIO No sound T 82 Bad sound quality T 83 Noise T 84 Tuning does not stop Auto memory does not operate T 84 No display of frequency Preset memory canceled T 85 9TFOTX OOS T 9 ...

Page 747: ...for verifying the condition of ground connections caution Do not connect the jumper wire between a power source line and body ground because this may cause burning or other damage to harnesses or electronic components Voltmeter The DC voltmeter is used for measuring circuit voltage A volt meterwith a range of 15V or more is used by connecting the positive probe red lead to the point where voltage ...

Page 748: ...tch NO type relay NC type relay NO switch NC switch t La 0 Not in operation No power supply c tX c OX c STOP FLOW STOP FLOW 8 I In operation Power supply c c 4x CfX FLOW STOP FLOW STOP Other Electrical Symbols L HOLDER BOX BATTERY BODY GROUND FUSE FUSIBLE LINK l MOTOR COIL SOLENOID RESISTOR VARIABLE RESISTOR t 1 T THERMISTER DIODE CONDENSER LIGHT 1 TRANSISTOR SPEAKER CIGARETTE LIGHTER HEATER 69G1S...

Page 749: ...ing FUSES Specifications Main fuse block Fuse MAIN 100A MAIN 60A HEAD 30A WORKING LAMP 30A T 12 Housing color Blue Yellow Pink Pink 9TGOTX OO9 Protected circuit Glow plug Engine switch Alternator Circuits protected in fuse box Engine switch Alternator Air heater Circuits protected in fuse box Alternator Headlight Working lamp MAIN FUSE 9TFOTX 6 ...

Page 750: ... Hazard lights Radio Cigar lighter T l5A lOA fulii CIGAR OPT W1 i l _ Fusible link Circuit protected ass or air heater system 9TGOTX O Removal I Installation Main fuse 1 Disconnect the negative battery cable 2 Remove the main fuse box attaching nuts 3 Remove the bolts and wiring harness from the main fuse box 4 Pull out the MAIN 100A or MAIN 60A fuse from the main fuse box 5 Install the reverse or...

Page 751: ...ion page T 15 60 5 Air heater relay Service Section G 2 Flasher unit Inspection page T 15 6 Assist relay Service Section G 3 Horn relay Inspection page T 73 4 Cancel relay Service Section G 7 Glow plug relay Service Section G 8 Intermittent wiper relay Service Section S T 14 ...

Page 752: ...0 8 A C X C A 0 0 0 B C X C B 0 0 0 C 0 0 0 2 Replace the relay if not as specified FLASHER UNIT Inspection A A A 8 B c Continuity 0 0 0 0 0 X 1 Connect 12V to terminal b and ground terminal e 2 Connect the test lamp between terminal I and a ground and verify that the test lamp glows Caution Apply the battery voltage to terminals properly 3 Replace the flasher unit if not as specified T 15 ...

Page 753: ...on page T 17 Removal Installation page T 17 2 Combination switch Including hazard warning switch 3 Fog light switch Inspection page T 42 4 Exhaust heating switch Service Section F2 F3 Removal Installation page T 18 Disassembly Assembly page T 18 Inspection page T 19 T 16 ...

Page 754: ... switch 81 B2 ACC IG1 1G2 ST OFF ACe 0 0 ON 0 STA 0 2 Replace the engine switch if not as specified Removal I Installation 1 Disconnect the negative battery cable 2 Remove the steering column cover 3 Disconnect the engine switch connector 4 Remove the engine switch 5 Install in the reverse order of removal T 17 ...

Page 755: ...erse order of removal 1 Horn cap 2 Steering 3 Steering column cover 4 Connector Combination switch Disassembly Assembly 1 Remove the light switch unit 2 Assemble in the reverse order of disassembly T 18 39 49 4 0 5 0 29 36 0 CB J l 4 7 vII 2 rI N m rn kg tt Jb 9TGOTX Q21 5 Combination switch Disassembly Assembly page T 18 Inspection page T 19 9TGOTX 022 ...

Page 756: ...warning switch Light switch BTN TNS SA HL HU Hazard Turn FU TL TR TIG HSA FB OFF Right 0 Passing r OFF Neutral Small light r Left 0 ro Passing r ON f 0 ro ON Low High Passing 0 ro u Wiper and washer switch Exhaust brake switch Wiper AS SWL SWH WIG INT SW Exhaust brake switch EX1 EX2 OFF 0 f O OFF lonetouch r ON ON i2 u INT 0 0 ro Low 0 0 High 0 Washer ON 0 0 0 Indicates continuity T 19 ...

Page 757: ...T EXTERIOR LIGHTING SYSTEM EXTERIOR LIGHTING SYSTEM STRUCTURAL VIEW T 20 SINGAPORE ...

Page 758: ... 39 1 Turn and hazard warning light Inspection page T 41 9 Back up light switch Inspection page T 41 10 Fog light switch Troubleshooting page T 25 Inspection page T 42 Removal Inspection 11 Back up light Instaliation page T 39 Troubleshooting page T 30 2 Small light control system Removal Inspection I Troubleshooting page T 28 Installation page T 40 Removal Inspection 9TGOlX Q25 Installation page ...

Page 759: ...GHT SIDE I AIMING 1 Adjust the tire air pressures to specification 2 Position the unloaded vehicle on a flat level surface 3 Adjust the headlights to meet local vehicle regulations To adjust turn the adjusting screws OTGOiX 027 T 22 ...

Page 760: ... j FOG LIGHT LH B IF r 2 E 04 HEAOCIGHT LH IN Iw1l 1 E II LICENSE UGHT I J H 0 IwPl 1 E 12 tEATEA CONTROL ILLUMI III K ofRAOIO ILLUMI III n r IA B III IA B III C OI _ fl 8 RADIO r ILLUMI FOG 3 Hx2 LIGHT I Hxl fH H O TACHO 1 4Hx2 8 W TACHO 4 1K E F B IF E 06 HEADLIGHT RH OUT E 07 POSITION IGHTTCHI F B G E 13 FOG LIGHT SWITCHU IE 14 FOG LIGHT LH F fR Bl E 0ID c 10ID R II l I lie ___II c I I I e t t ...

Page 761: ...ht R Light switch malfunction Replace light switch J switch connector 4 pin connector Battery voltage YES Headlight inspection 1 Disconnect headlight connector MOpen circuit in wire harness 2 Check RIL wire High RIW wire Light switch Headlight Repair wire harness J voltage at headlight connector Battery voltage tYES Headlight inspection Check continuity between B wire NO J R Poor ground Repair gro...

Page 762: ...ONDENSER F d ifi 11 l Tlr II I I 8 G 8 I G JiIOT li NOT U9EO B IFI l uf HORN HORN HORN LH Rl SWITCH B IF 1 2 F 04 HORNli l QJ F l1 BACk up LIGHT IFOR SINGAPORE IlIJl 05 STOP LIGHT SIiItCH IF rsiWl l J E 02 HORN SWlfCH Fl fA tIL G BA W RIG IR2 FOR SING APOAE E 09 Fe OR NGAPORE F l1 lfIV lfIV F l1 23t1 21M liN 23M F l1 __ It__ __ It __ F l1 o If E 09 BACK UP ll rT rf2 IlEDZI B R F 06 STOP LIGHT CI C...

Page 763: ... switch Flasher unit Battery voltage I YES Flasher unit inspection 1 Connect jumper wire between NO Repair ground J ground and B wire at flasher R Poor ground unit connector 2 Check flasher unit operation Does not operate 1 YES Turn switch inspection Open circuit in wire harness I IN H Repair wire harness Check G R wire voltage at turn Flasher unit Turn switch Check flasher unit switch connector 8...

Page 764: ...air ground I I Bulb malfunction Replace bulb 9TGOTX 034 Hazard warning function does not operate Tum function normal Fuse inspection Check HAZARD 15A fuse in fuse NO Replace fuse after repairing I R Short circuit in wire harness box harness Normal YES 1 Turn hazard warning switch ON t Hazard warning switch inspection Check B l wire voltage at turn H Open circuit in wire harness Repair wire harness...

Page 765: ...09 10 lRH E II LIGHT E 14 B FOG R2 LIGHT 6 I IIF IF H 0 112 E II B R LICENSE lIGHT Ihl1I ffi E 05 t AOLIGHT IRliIN F I IQ J I E 12 t ATER CONTROL ILLUMI tIl IlfJl K o fRlOIO ILLUMI II I flJ C OI E 12 METER HEATE Ol C OI E 12 ILLUMI ILLUMI E 15 FOG 3 411 2 LIGHT I 411 1 RH 11 0 TACHOI 1 4W 2 4 4 II TACHO 0 W B F E 06 HEADLIGHT RH DUT F IE 07 POSH ION LIGHT LHI F B G jP E 13 FOG fGHT SIIITCHmlE 14 F...

Page 766: ...MOpen circuit in wire harness Repair wire harness I switch connector 2 pin connector Fuse Light switch Battery voltage YES Light switch inspection Check RIB wire voltage at light Light switch malfunction Replace light switch I switch connector 4 pin connector Battery voltage 1 YES Light inspection 1 Disconnect light connector H Bulb malfunction Replace bulb I 2 Check RIB voltage at light con Poor ...

Page 767: ...OfNSER F Jed 1 11 E 09 REAR ClIIeINATlON E IO REAR ClIIeItiATlON _ GHT ILH R2 SiGHT iii R2 M I N a G a G NOTE NOT USED a F IEUII STOP ffiA I r 0 10 _ a II IF BIY IF G II F G wIIG y HORN F 05 WIG F 9 N Tt rAY F 06 I _ r 8 F IO F 09 Im T 1 ER rr G A IF G A IF lG B F l lir HORN HORN HORN a IF LH AH SWITCH F vv G IF I 1 IK3m G IR2 I 2 a IA IEOZJ AIG R2 RIG F_o IR BACK HORN FOR SINGAPORE FOR SINGAPOAE ...

Page 768: ...ion Check RIG wire voltage at light Back up light switch malfunction switch connector 2 pin connector Battery voltage YES Back up light inspection 1 Disconnect light connector H Bulb malfunction 2 Check R Y voltage at light con Poor ground nector Battery voltage I NO rOpen circuit in wire harness I Sack up light Back up light switch One back up light does not operate I Bulb malfunction Poor ground...

Page 769: ...ONOENSER F fGiwl EJ 8 IF GIW F STOP 15A l Jl1El I I r t f 18 _ IlEll1I METER 15A COMIIINAnON SWITCH SECTION CI 9 HORN F O 5 IV B Y FI F IO F oltS_ RELAY F CONDENSER _ _ F 06 F IO _ rt t F 09 STOP k TeIY RI 1 r G R FI G R IFI LIGHT CHECKER RELAY l G B IFI tULJmll r G IF RIG HI F OB fnBACK VJHORN ar HORN HORN HORN B F ILH RH SWITCH 1 2 B RI RIG R21 FOR SINGAPORE FOR SINGAPORE B IF I i E 09 F Iel lff...

Page 770: ...isconnect stoplight connector 2 Check G voltage at stoplight connector Battery voltage l One stoplight does not operate Bulb malfunction Poor ground Replace bulb Repair ground EXTERIOR LIGHTING SYSTEM T INq lS h Replace fuse after repairing 1 hort clrCUIt In wire arness harness Open circuit in wire harness Fuse Stoplight switch Repair wire harness J NO Replace switch J j Stoplight switch malfuncti...

Page 771: ...LIGHT ILHI 0 8 IF II B F B F E 02 COMBINAtION SIiITCH F C OI METER Il iliii iff 2 E 03 t AtlLIGHT LH DUTn IE 04 HEADLIGHT LH IN F 1 05 HEADLIGHT AH IN Ff H 0 R2 E II IncPl 1 LICENSE LIGHT ILH R2 ffi IncPl 1 E 12 tEATER CONTROL ILLUMI I Iffil K ol RAoro ILiUM If I riB IRIB I C OI METER E 12 ILLUMI E 12 C OI E 15 3 411x2 I 411xl Iroo IWID TACHD 4 4 1lERI LIGHT I 411x2 RHI W TACHOI Ic 0 I F 06 HEAOi ...

Page 772: ...ght connector Battery voltage tYES Fog light inspection 1 Disconnect fog light connector B wire 2 Check continuity between B wire and ground Continuity I One fog light does not operate Bulb malfunction Poor ground Replace bulb Repair gro nd EXTERIOR LIGHTING SYSTEM T NO Replace bulb I MOpen circuit in wire harness Fog light switch Combination switch Repair wire harness I IN I Fog light switch malf...

Page 773: ... shown in the figure referring to Removal Note 3 Install in the reverse order of removal 1 Radiator grille RIGHT SIDE 9TGOiX 049 T 36 9TGOTX 48 2 Headlight Removal Note page T 36 Removal note Headlight 1 To remove push the headlight and slide it to right or left Right headlight Slide to left Left headlight Slide to right ...

Page 774: ...ion 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Inspect all parts and repair or replace as necessary 4 Install in the reverse order of removal 1 Screws 2 Lens 3 Bulb Inspect for failure and poor contact 4 Housing 5 Socket T 9TGOTX 050 T 37 ...

Page 775: ...ve battery cable 2 Remove in the order shown in the figure 3 Inspect all parts and repair or replace as necessary 4 Install in the reverse order of removal 1 Radiator grille 2 Connector 3 Fog light assembly 4 Lens T 38 5 Bulb Inspect for failure and poor contact 6 Fog light body assembly 9TGOTX S1 ...

Page 776: ...nnect the negative battery cable 2 Remove in the order shown in the figure 3 Inspect all parts and repair or replace as necessary 4 Install in the reverse order of removal SINGAPORE 1 Bolts 2 Screws 3 Lens 4 Bulb Inspect for failure and poor contact 5 Gasket 6 Housing 7 Cover T 9TFOTX 10 T 39 ...

Page 777: ...tallation 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Inspect all parts and repair or replace as necessary 4 Install in the reverse order of removal SINGAPORE CD 9TGOTX 053 1 Lens 2 Bulb Inspect for failure and poor contact T 40 ...

Page 778: ...ect for failure and poor contact 7 Socket STOPLIGHT SWITCH Inspection 1 Disconnect the stoplight switch connector 2 Check continuity of the stoplight switch Brake pedal Continuity Depressed Yes Released No 3 Replace the stoplight switch if not as spcified BACK UP LIGHT SWITCH Inspection 1 Disconnect the backup light switch connector 2 Check continuity of the back up li ght switch Transmission Cont...

Page 779: ...t switch 2 Disconnect the fog light switch connector 3 Check continuity of the fog light switch Switch Continuity ON Yes OFF No 4 Replace the fog light switch if not as specified 2 Door switch 9TGOTX Qsa Troubleshooting page T 43 Inspection page T 46 Removal Inspection I Installation page T 46 SPECIFICATIONS Lamp Bulb W Remark lnterior lamp 10 Front interior lamp 10 Rear interior lamp Crew cab 9TG...

Page 780: ...O 1 I YB H 06J H QS LlO III ES t _ u CD 0 J co O C _ m _rr R 3mm iii z M v III 3 8 r I n _ z __ to IB Y IL O F IF BIY IFI H OB t i l r I r RAOIO IGIR I H OB H 09 SEAT BELT TIMER IGIR F GIR H tO BUCKLE SWITCH H IO IBR B F Z m D o D r is z G en Ui I Ii B F H 0711 L l SPEAKER H 09 i T H 7 SPEARElml rGiRJ NOTE Ii NoT USED 1 1 08 AT BELT TIMER F H 03ROOM LAMP REAR AMI H 04 CIGARETTE LIGHTER o rVwl If 0...

Page 781: ...ssembly malfunction lamp connector 2 Check that lamp comes ON Comes ON YES Remove door switch Door switch inspection Check door switch continuity Door switch Continuity NO H Door switch malfunction Switch depressed No Switch repleased Yes Poor ground Repair ground Replace lamp assembly Replace lamp assembly Replace door switch YES Open circuit in wire harness H Repair ground Door switch Interior l...

Page 782: ... door switch continuity NO Door switch Continuity rl Door switch malfunction Replace door switch I Switch depressed No Sw ch released Yes Poor ground YES Open circuit in wire harness H Repair ground I Door switch Interior lamp Repair harness assembly 9TGOTX 063 T 45 ...

Page 783: ...lace as necessary 4 Install in the reverse order of removal fl CD 1 Lens 2 Bulb VERIFY FOR DIRECTION 3 Interior lamp assembly Inspect for failure and poor contact I I Ijll 9TGOTX 065 DOOR SWITCH Inspection 1 Remove the door switch 2 Check continuity of the door switch Switch Switch depressed Switch released Continuity No Yes 3 Replace the door switch if not as specified 9TGOTX 66 T 46 9TGOTX 064 ...

Page 784: ...lation page T 69 Inspection pa Qe T 60 Inspection page T 61 10 Coolant level sensor 3 Brake fluid level sensor Inspection page T 62 Inspection page T 60 Removal Installation page T 60 11 Indicator lamp Inspection page T 58 4 Vacuum switch Inspection page T 62 Troubleshooting page T 56 5 Parking brake switch 12 Oil bypass alarm switch Inspection page T 59 Inspection page T 60 13 Coolant warning uni...

Page 785: ...ATION SWITCH 1N 1 AUSTRALIA i m lJ 3 1C cD m 21 2J 2K 2H 2A 2F 2C 10 TERMINAL CONNECTION TO 2A VACUUM SWITCH 2B 2C COOLANT WARNING UNIT 20 GROUND 2E 2F ALTERNATOR 2G ALTERNATOR 2H STOPLIGHT CHECKER RELAY 21 OIL LEVEL SENSOR OIL BYPASS ALARM SWITCH 2J OIL PRESSURE SWITCH 2K BRAKE FLUID LEVEL SENSOR PARKING BRAKE SWITCH 2L FUSE 2M COMBINATION SWITCH 2N COMBINATION SWITCH Ci 1F 1A I 8 z o LI_________...

Page 786: ...ng brake switch Brake lever Continuity Parking brake switch mal Pulled Yes function Released No YES Check brake fluid level sensor Refer to page T 60 Brake warning lamp does not operate parking brake set 1 Disconnect parking brake switch connector 2 Connect a jumper wire be Open circuit in wire harness tween ground and switch connector Switch Lamp 3 Check that lamp comes ON Comes ON YES Check cont...

Page 787: ...of brake flu id level sensor Brake fluid level sensor Brake fluid Continuity Below MIN Yes malfunction Above MIN No YESJ LPoor ground Alternator warning lamp Alternator warning lamp comes ON after engine started Check alternator output volt age Refer to Section G Normal I I Alternator malfunction l _____Y_E_S Short circuit in wire harness l Alternator Lamp Alternator warning lamp does not operate ...

Page 788: ...sor Lamp OFF Goes OFF C1 YES OIL LEVEL SENSOR Connect oil bypass alarm switch connector Check engine oil level Add engine oil Between L F YES Check continuity of oil level sensor Oil level Continuity Oil level sensor malfunction Below L Yes Above L No caution Check oil level sensor con YES tinuity after warm up the engine 9TGOTX 074 Check oil pressure NO Check oil pump Refer to Section D Refer to ...

Page 789: ...nd Sensor Lamp 3 Check that lamp comes ON Comes ON YES Check continuity of oil level sensor Oil level Continuity Oil level sensor malfunction Below L Yes Above L No YES I 1 Poor ground Stoplight warning lamp Stoplight warning lamp comes ON after engine started 1 Disconnect stoplight checker relay connector 2 Check that lamp goes OFF Goes OFF YES Check if stoplight burned Normal Short circuit in wi...

Page 790: ... Bulb burned Comes ON YES 9TGOTX 077 Disconnect stoplight checker relay connector and ground Y wire at relay connector 1 Start engine 2 Check that lamp comes Open circuit in wire harness ON Relay Lamp Comes ON YES 1 Connect a jumper wire be tween Y wire and B wire H at relay connector 2 Check that lamp comes Poor ground ON Comes ON YES Check stoplight checker relay Refer to page T 60 T 53 ...

Page 791: ...Check sedimentor water level NO Drain water Water level high Refer to Section F1 F2 F3 YES 1 Disconnect sedimentor sensor connector I RIY wire Short circuit in wire harness 2 Check that lamp goes RIY wire Instrument cluster OFF and buzzer stops Lamp goes OFF and buzzer stops YES Check sedimentor sensor l Refer to page T 62 ...

Page 792: ... sounds Lamp comes ON and buzzer sounds YES Check cintinuity between B Wire at sensor connector and I ground Poor ground Continuity I YES ICheck sedimentor sensor 1 I Refer to page T 62 Sedimentor warning lamp comes ON without buzzer after en gine started Check continuity between 2F terminal at instrument cluster Instrument cluster malfunction I and buzzer A terminal as shown in the figure Continu...

Page 793: ... 700 mmHg 27 56 inHg or more YES 1 Disconnect vacuum switch connector 2 Check that lamp goes OFF and buzzer stops Vacuum switch malfunction Goes OFF and buzzer stops NO Short circuit in wire harness Vacuum switch Instrument cluster Vacuum warning lamp comes ON without buzzer after engine started Check continuity between 2A terminal at instrument cluster H and buzzer A terminal as Instrument cluste...

Page 794: ... to page T 54 for troubleshooting 9TGOTX 085 H Check engine coolant level Between Land F Add coolant YES 1 Disconnect coolant level sensor connector Y 1 Coolant level sensor 2 Check that buzzer stops malfunction Stops NO 1 Disconnect coolant warn ing unit connector IYE Coolant warning unit 2 Check that buzzer stops malfunction Stops NO Short circuit in wire harness sensor Unit Short circuit in ins...

Page 795: ...ure Pressure Oil level warning Bypass alarm Alternator warning CHARGE Brake warning Vacuum warning T 58 probe probe probe probe 2F 2H 2J 21 2G 2K 2A h 0 9TGOTX 088 2L 1G ECONO indicator High beam indicator BEAM Glow indicator Air heater indicator GLOW Exhaust brake indicator Turn I Left indicator I Right OIL PRESSURE SWITCH Inspection 1A 1L 1F 1F 1D 2N 2M 1 Disconnect the oil pressure switch conne...

Page 796: ...r B Engine switch Engine switch ON C Coolant level Cooling system in D sensor normal Others E F Ground Constant OIL BYPASS ALARM SWITCH Inspection Specification Battery voltage Battery Voltage 00 00 00 1 Disconnect the oil bypass alarm switch connector 2 Check continuity between the switch and ground Continuity No continuity 3 If there is continuity check lubrication system for clogged 4 Replace t...

Page 797: ...of the brake fluid sensor Brake fluid level Continuity Below MIN Yes Above MIN No 2 Replace brake fluid sensor if not as specified Removal Installation 0 0 0 0 0 X 1 Remove the instrument panel Refer to Section S 2 Remove the brake reserve tank 3 Remove the brake fluid level sensor 4 Install in the reverse order of removal PARKING BRAKE SWITCH Inspection 1 Disconnect the parking brake switch conne...

Page 798: ...e it and apply 12V to the buzzer Verify that the buzzer sounds 3 If the buzzer does not sound replace it 4 If the buzzer sounds replace the meter printed OIL LEVEL SENSOR Removal I Installation 1 Drain the engine oil 2 Remove the bolts 3 Remove the oil level sensor 4 Install in the reverse order of removal Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib Inspection 1 Place the oil level senso...

Page 799: ... when the float is up 4 Replace the sedimentor sensor if not as specified COOLANT LEVEL SENSOR Inspection 1 Remove the level sensor and reconnect the connector 2 With the sensor not grounded to the body start the engine 3 After checking that the warning lamp illuminates ground the threaded part of the sensor 4 If the warning lamp remains illuminated the sensor is normal If it does not the sensor i...

Page 800: ...T 70 2 Tachometer Troubleshooting page T 65 Inspection page T 70 3 Water temperature gauge Troubleshooting page T 66 Inspection page T 70 4 Fuel gauge Troubleshooting page T 67 Inspection page T 70 5 Warning and indicator lamp Troubleshooting page T 48 Inspection page T 58 6 Odometer 7 Trip meter 2 Water thermosensor Removal Installation page T 71 Inspection page T 71 3 Fuel gauge sender unit Remo...

Page 801: ...L ______ J 1C I m m 21 2J 2K 2H 2A 2F 2C 10 TERMINAL CONNECTION TO 2A VACUUM SWITCH 2B 2C COOLANT WARNING UNIT 20 GROUND 2E 2F ALTERNATOR 2H STOPLIGHT CHECKER RELAY 21 OIL LEVEL SENSOR OIL BYPASS ALARM SWITCH 2J OIL PRESSURE SWITCH 2K BRAKE FLUID LEVEL SENSOR PARKING BRAKE SWITCH 2L FUSE 2M COMBINATION SWITCH 2N COMBINATION SWITCH G IF lA 8 z o L ___________________________________________________...

Page 802: ...urned by hand 3 If the cable or gear is stiff replace the speedometer cable or gear 4 If the speedometer cable and gear are OK replace the speedometer Tachometer does not operate 9TGOTX 110 9TGOT 109 1 Remove the instrument cluster 2 Connect a test tachometer between terminals 1G and 1J of the harness side connector 3 Start the engine 4 Check that the test tachometer indicates engine speed Indicat...

Page 803: ...ace water thermosensor No Go to Step 2 caution Continue the above checks for at the least two minutes each to correctly judge the condition The allowable indication error is twice the width of the needle Step 2 1 Remove the instrument cluster 2 Apply 12V to terminal 1G and ground terminal 1H 3 Connect the red lead of the SST to terminal 1K and the black lead to a negative battery terminal 4 Set th...

Page 804: ...Action Yes Replace fuel gauge sender unit in fuel tank No Go to Step 2 Caution Continue the above checks for at least two minutes each to correctly judge the condition The allowable indication error is twice the width of the needle Step 2 1 Remove the instrument cluster 2 Apply 12V to terminal 1G and ground terminal1H 3 Connect the red lead of the SSTto terminal 1E and the black lead to a negative...

Page 805: ...on Note 1 Steering column 5 Connector 2 Steering wheel 6 Instrument cluster meter Nom m kg tt lb 9TGOTX 121 Removal Note page T 68 Troubleshooting page T 64 Installation Note page T 68 Disassembly I Assembly page T 69 3 Meter panel 4 Speedometer cable 9TGOTX l22 T 68 Inspection page T 70 Removal note Steering wheel 1 Remove the steering wheel with a steering wheel puller Installation note Steering...

Page 806: ...6 Bulbs 2 Cover 7 Meter printed circuit 3 Meter hood 8 Indicator lamp assembly Speedometer Inspection page T 58 4 Screws 9 Screws 5 Speedometer 10 Tachometer gauge assembly Inspection page T 70 Inspection page T 70 WITH TACHOMETER WITHOUT TACHOMETER 9TGOTX 124 11 Screws 12 Fuel gauge Inspection page T 70 13 Water temperature gauge Inspection page T 70 Warning buzzer 14 Warning buzzer Inspection pa...

Page 807: ... the odometer Replace if necessary 2 Check the speedometer for fluctuation and or abnormal noise Caution If significant fluctuation occurs or the speedome ter does not move at all remove the speedometer cable If it is normal replace the speedometer as sembly Tire wear and improper inflation will increase speedometer error Fuel gauge 1 Remove the instrument cluster 2 Apply 12V to terminal 1G and gr...

Page 808: ...he water thermosensor 2 Remove the sensor 3 Install in the reverse order of removal Inspection 1 Place the water thermosensor and a thermometer in wa ter and gradually heat the water 2 Measure the resistance of the sensor with an ohmmeter Resistance 190 2600 at 50 C 122 F 3 Replace the water thermosensor if not as specified FUEL GAUGE SENDER UNIT Removal I Installation 1 Disconnect the connector f...

Page 809: ... CLUSTER METER _ _ t T 30 281 5 11 08 r 32 50 123 1100 9TGOTX 135 PICKUp SENSOR Inspection 1 Disconnect the pickup sensor connector 2 Check for continuity with an ohmmeter 3 Replace the pickup sensor if ther is no continuity ...

Page 810: ...removal 1 Radiator grille HORN T Nom m kg ft lb 9TGOTX 136 3 Front bumper 4 Horn 2 Fog light Removal Inspection Installation _ page T 38 9TGOTX 137 HORN RELAY Inspection 1 Apply 12V to 0 terminal and ground B terminal and check continuity between A and C terminals 2 Replace horn relay if not as specified T 73 ...

Page 811: ...in the reverse order of removal 1 Connector 9TGOTX 139 T 74 9TGOTX 138 2 Backing warning horn Inspection page T 74 Inspection 1 Disconnect the connector from the backing warning horn 2 Connect the battery to the backing warning horn as shown in the figure 3 Verify that the horn operates 4 Replace the backing warning horn if not as specified ...

Page 812: ...leshooting page T 78 Removal Installation page T 88 2 Speaker Troubleshooting page T 78 Removal Installation page T 89 Inspection page T 90 9TFQT o1S 3 Antenna feeder Troubleshooting page T 78 Removal Installation page T 91 Inspection page T 91 T 75 ...

Page 813: ... Auto memory Dark current DESCRIPTIONS AM Radio c CI c M J L CHef TUNE m k e c a nljhfdb T 76 8 AUDIO AM radio 531 1 602 9 5W x 1 o up and down o up only mA M 3 CD I JI 11 J AM FM radio Remark 531 1 602 87 9 107 9 9 100 25W x 2 o up and down 0 Max 3 9TFOTX 017 TONE SW VOl 0 a 13 2V ACC b c d e f h j k SPEAKER I SPEAKER m SPEAKER n SPEAKER 9TGOTX 142 ...

Page 814: ...1 OUTPUT 1 OUTPUT b 2 INPUT 2 13 2V CONTROL POWER c BACK UP 3 OUTPUT 3 OUTPUT d 4 INPUT 4 OUTPUTH e ILLUMINATION 5 SIGNAL GROUND 5 OUTPUTH f 6 ILLUMINATION 6 GROUND h 7 13 2V ACC E SHIELD GROUND j 8 BATTERY k SPEAKER 9 SYSTEM ON I SPEAKERH 10 SYSTEM OFF DECK m SPEAKER 11 SYSTEM OFF AUX n SPEAKERH 12 13 SYSTEM MUTE E GROUND 9TGOTX 143 T 77 ...

Page 815: ...lR LIB IR LIB JJ IJ JJ IJ RIB RIB IJ I SEAT BELT TIMER RADIO B AUTO H 05 G R IJ CLOCK F B _______________ IJ LID GIR JJ IJ OR H 09 8 IF 4 H 02 DOOR SNITCH IF H 06 RADIO lIJ I I 1iJwl ItIT jI LIII L R H 07 SPEAKER J H OB SEAT BELT TIMER F H 09 BUCKLE SWITCH CORO IF H IO BUCKLE SWITCH Il il ttl II II l jI _ ti NIlE iI NoT USED E t _ xl o Ie cam or m men ca x iii 0 30 z C I c c o ...

Page 816: ...adio connector NO Open circuit in wire harness Fuse Radio 12 pin connector Repair harness Battery voltage YES 1 Connect a jumper wire between radio unit and ground YES Poor ground 2 Check that radio operates I Repair ground Operate NO Check speaker operation Refer to page T 90 YES Radio malfunction Operation normal Replace radio NO Speaker malfunction Replace speaker 9TFOTX 01a Bad sound quality I...

Page 817: ...tight Tight YES Check if noise still there when antenna disconnected Noise Check wire harness Normal YES YES Check ground condition of unit Normal AUDIO Speaker malfunction Replace speaker Antenna or feeder malfunction Replace antenna or feeder NO YES Radio malfunction Replace radio Poor connection Connect tightly I _ Poor installation Tighten screws Antenna malfunction Check antenna Refer to page...

Page 818: ...ir all memory is cancelled The stations must be preset again 1 Turn engine switch OFF 2 Check back up terminal voltage NO JOpen circuit in wire harness Higher than approx 8V 1 Repair back up circuit YES Check that connectors are tight MPoor connection Tight Connect tightly YES J Radio malfunction I Replace radio 9TGOTX 149 T 81 ...

Page 819: ...n wire harness I Normal Replace fuse after repairing harness YES Check ROOM 10A fuse in fuse box NO Short circuit in wire harness Normal Replace fuse after repairing harness YES 1_ Turn engine switch to ACe position 2_ Check UB wire voltage at radio connector Open circuit in wire harness Fuse Radio 12 pin connector Repair harness Battery voltage YES Check UR wire voltage at radio connector Open ci...

Page 820: ...installation Loose speaker Tight Tighten speaker mounting YES Check speaker operation Refer to page T 90 NO Speaker malfunction I Operation normal Replace speaker YES Check antenna installation NO Poor connection Installation correct r Install antenna properly YES 1 Remove antenna feeder from radio 2 Check that there is no continu lty between plug termi Antenna or feeder malfunction nals Refer to ...

Page 821: ...tion Normal Repair wIre harness YES Check ground condition of unit NO Poor ground Normal Repair ground YES Refer to Causes of Noise page T 86 9TFOTX 023 Tuning does not stopf Auto memory does not operate Check antenna installation NO J Poor connection Installation correct 1 Install antenna properly YES 1 Remove antenna feeder from radio 2 Check that there is no continuity between plug termi MAnten...

Page 822: ...pair all memory is cancelled The stations must be preset again 1 Turn engine switch OFF 2 Check back up terminal voltage Open circuit in wire harness Higher than approx ev Repair back up circuit YES Check that connectors are tight NO Poor connection Tight Connect tightly YES I Radio malfunction l Replace radio 9TGOTX 154 T 85 ...

Page 823: ...of the noise must be determined through troubleshooting guide Once it has been determined refer to the suppression chart to find the proper procedure for eliminating the noise FM STATION 93U1SX 071 Troubleshooting There is still noise Defective audio system T 86 9TGOTX 162 FM multipath FM waves can cause a problem called multipath receiving This happens when the radio picks up a direct wave and re...

Page 824: ...tor noise Remedy 1 Check grounding 2 Install condensers to motor circuit ACC L A t WIPER MOTOR HI LO l I Connect condenser to power line of flasher unit I n ER I Note IT CONDENSER Condenser should be placed near flasher unit Connect condenser near altemator nf f TO RADIO CONDENSER T 9TGOTX 164 T 87 ...

Page 825: ...in the order shown In the figure 2 Install in the reverse order of removal 1 Steering column cover 2 Meter panel 3 Screws 4 Connectors T 88 AUDIO 9TFOTX o25 5 Antenna feeder e T 91 Removal Installation pag T 91 Inspection page 6 Audio unitlRadio ...

Page 826: ...reverse order of removal Instrument panel speaker 1 Glove box 2 Connectors 3 Duct Door speaker CAUTION AUDIO T 9TFOTX o26 4 Speaker Inspection page T 90 REMOVE DOOR SCREEN CAREFULLY so THAT IT MAY BE REUSED 9TFOTX o27 1 Door trim 4 Speaker 2 Door screen Inspection page T 90 3 Connectors T 89 ...

Page 827: ...spection Caution Use an ohmmeter at x10 range 1 Check for resistance of the speaker Resistance 40 2 Verify that the speaker clicks when the ohmmeter is con nected to the speaker terminal 3 Replace the speaker if not as specified ...

Page 828: ...er of removal 1 Screws 2 Antenna 3 Screws ANTENNA FEEDER fJ PLUG o OHMMETER 9TGOTX 170 AUDIO T 9TFOTX 028 4 Instrument panel Service Section S 5 Antenna feeder Inspection page T 91 Inspection 1 Check that there is no continuity between the plug terminals 2 Replace the antenna feeder if not as specified T 91 ...

Page 829: ...AIR CONDITIONER SYSTEM INDEX U 2 TROUBLESHOOTING U 3 TROUBLESHOOTING GUIDE U 3 WIRING DIAGRAM U 3 FRONT HEATER U 7 STRUCTURAL VIEW U 7 FRONT HEATER UNIT U 8 FRONT BLOWER UNIT U 10 HEATER CONTROL UNIT U 13 9TGOUx Ol ...

Page 830: ...val I Installation page U 8 Disassembly Assembly page U 9 Inspection page U 9 Removal Installation page U 13 Disassembly Assembly page U 16 4 Fan switch 2 Front blower unit Removal Installation page U 10 Disassembly Assembly page U 12 Inspection page U 16 Inspection page U 12 U 2 ...

Page 831: ...e if fan switch is 2 position Blower motor does not operate if fan switch is 3 position Blower motor does not operate if fan switch is 4 position Blower motor does not operate Mode control does not operate Air temperature does not change WIRING DIAGRAM R Y IF e IF r 1 BLOWER MOTOR IF l jl NOTE NOT usee 6 02 RESISTOR G 03 FA SWITCH I weLYIFl u Reference page U 4 U 4 U 4 U 5 U 5 U 5 U 6 U 6 9TFOUX 1...

Page 832: ...h ON OK J 2 Set fan switch 1 position I Resister assembly malfunction 3 Check that there is OV at G W wire Check resister assembly Refer to page U 12 voltage of resister assembly connector NG 1 Check that there is OV at G W wire voltage of fan OK Open circuit in wiring harness switch connector I Resister assembly fan switch G W wire NG Fan switch malfunction Check fan switch Refer to page U 16 9TG...

Page 833: ...blower motor Refer to page U 12 motor connector NG 1 Check that there is OV at L wire voltage of fan switch OK Open circuit in wiring harness connector Resister assembly fan switch L wire NG Fan switch malfunction Check fan switch Refer to page U 1S 9TGOUX 0Q9 ISymptom IBlower motor does not operate NG 1 Check that heater fuse is normal Short circuit in wiring harness OK Check wiring harness 1 Tur...

Page 834: ...Blower motor fan switch L wire Repair wiring harness OK Fan switch malfunction I Check fan switch Refer to page U 16 9TGOUX 010 ISymptom IMode control does not operate l1 Check that mode wire is installed on correct poSition I NG I Incorrect adjustment of mode wire _________ _________ JI I Adjust mode wire Refer to page U 14 OK OK Mode door malfunction I2 Check that mode door operates smoothly Che...

Page 835: ... control unit Removal Installation page U 8 Removal Installation page U 13 Disassembly Assembly page U 9 Disassembly Assembly page U 16 Inspection page U 9 Inspection page U 16 2 Front blower unit Removal Installation page U 10 Disassembly Assembly page U 12 Inspection page U 12 U 7 ...

Page 836: ...er shown in the figure 4 Install in the reverse order of removal Caution Carefully remove the heater unit to prevent spilling engine coolant from the heater core 9TGOUX 14 1 Radiator grille 5 Nuts 2 Front grille 6 Bolts 3 Water hose 7 Front heater unit 4 Instrument panel Service Section S Disassembly Assembly page U 9 Inspection page U 9 U 8 ...

Page 837: ... disassembly ltJ 1 Heater core 3 MODE door assembly Inspection page U 9 4 Heater unit case 2 MIX door assembly Inspection Heater core 1 Check the heater core fins for blockage 2 If the fins are clogged clean them 3 Check the fittings for cracks or damage 4 Replace the heater core if necessary 9TGOUX 016 9TGOUX 015 U 9 ...

Page 838: ...Removal Note 3 Install in the reverse order of removal referring to Installation Note 9TGOUX l17 1 Lower panel 7 REC FRESH wire 2 Fuse box 3 Bracket 4 Washer motor connector Removal Note page U 11 Installation Note page U 11 8 Bolts 5 Washer tank 9 Connector 6 Natural duct 10 Front blower unit Disassembly Assembly page U 12 Inspection page U 12 U 1O ...

Page 839: ...C FRESH wire 1 Set the REC FRESH lever to REC position u 2 Set the REC FRESH door link to REC position as shown in the figure and connect the wire 3 Clamp the wire Caution After installation move the REC FRESH lever to be sure the wire is securely attached and that it moves the full stroke from REC to FRESH U 11 ...

Page 840: ...age U 12 Inspection Blower motor 1 Remove the grove box 2 Disconnect the blower motor connector 3 Apply 12V to A terminal and ground B terminal Check that the motor operates Terminal Apply voltage Motor condition A 12V Operate B Ground Resister assembly 1 Remove the grove box 2 Disconnect the resister assembly connector 3 Check for continuity between terminals i I g I I D o 0 0 Indicates continuit...

Page 841: ...emoval referring to Installation Note 1 Steering column 2 Steering wheel Removal Note page U 14 Installation Note page U 15 3 Connector 4 Meter panel 5 Heater control wire Removal Note page U 14 Installation Note page U 14 39 2 49 4 0 5 0 28 9 36 1 N m m kg ft lb 9TGOUX 023 6 Grove box 7 Connector for heater control unit 8 Heater control unit Disassembly I Assembly page U 16 Inspection page U 16 U...

Page 842: ... Installation note Heater control wire Caution Connect the heater control wires to the correct po sition Do not bend and twist the wires when installing After installation move the lever to be sure that the wire is securely attached MODE wire Adjustment 1 Set the MODE lever to DEF position 9TGOUX 026 2 Set the MODE door link to DEF position as shown in the figure and connect the wire 3 Clamp the w...

Page 843: ...e the MIX lever to be sure that it moves the full stroke from HOT to COLD REC FRESH wire Adjustment 1 Set the REC FRESH lever to REC position 2 Set the REC FRESH door link to REC position as shown in the figure and connect the wire 3 Clamp the wire Caution After installation move the REC FRESH lever to be sure that it moves the full stroke from REC to FRESH Steering wheel 1 Set the cansel cam as s...

Page 844: ...er of disassembly 1 Knob 2 Switch body 3 REC FRESH wire 4 MODE wire 5 MIX wire 6 REC FRESH lever 7 MODE lever Inspection Fan switch 9TGOUX 31 8 MIX lever 9 Fan switch Inspection page U 16 1 Check for continuity between the terminals Switch pos 1ion A 8 C 0 E OFF 1 2 0 n 3 r J 4 Indicates continUity 9TGOUX Q32 U 16 ...

Page 845: ...A SL SL TURBOCHARGED TF ENGINES TD 10 G ENGINE ELECTRICAL SYSTEM HA SL SL TURBOCHARGED TF ENGINES TD 1 0 H CLUTCH T0 11 J TRANSMISSION T0 12 L PROPELLER SHAFT T0 13 M FRONT AND REAR AXLES T0 13 N STEERING T0 14 P BRAKING SYSTEM T0 15 Q WHEELS AND TIRES T0 16 R SUSPENSION T0 17 S BODy TD 19 T BODY ELECTRICAL SySTEM TD 19 9TFTOX OOl TO ...

Page 846: ... 180 85 82 2 195 86 42 2 155 84 84 2 505 98 62 2 510 98 81 3 335 131 30 3 940 155 12 3 335 131 30 1 410 55 51 1 650 64 96 1 650 64 96 1 655 65 35 1 650 64 96 1 405 55 31 1 470 57 87 1 470 57 87 1 495 48 86 1 495 58 86 Specifications SL TF SL TURBO TF Truck Crew cab Truck Crew cab Wide 10 14 17 14 17 14 High Double 2 0 3 0 2 75 4 0 3 5 4 660 5 890 5 890 5 890 6 790 5 890 6 790 5 890 183 46 231 e9 2...

Page 847: ... max Longitudinal direction 0 25 0 010 max Manifold contact surface 0 10 0 004 max Valve and valve guide IN 44 9 45 1 45 4 45 6 1 787 1 795 46 9 47 1 1 768 1 776 1 846 1 854 Valve head diameter mm In 37 4 37 6 40 9 41 1 EX 1 472 1 480 38 2 38 4 1 504 1 512 1 610 1 618 Valve head margin thickness mm In IN 1 0 0 039 min EX O 0 039 min 1 2 0 047 min 1 5 0 059 min Valve face angle IN 450 EX 300 IN Sta...

Page 848: ... 58 7 40 3 1 59 68 0 76 8 IN 40 3 1 59 41 9 1 65 119 130 191 216 Inner 12 1 13 3 149 165 15 2 16 8 19 5 22 0 26 6 29 3 33 4 37 0 37 8 1 49 42 9 48 4 Setting load height 37 8 1 49 39 4 1 55 N kg lb mm On 318 336 236 262 228 251 303 342 Outer 32 4 34 2 24 1 26 7 23 2 25 6 30 9 34 9 71 3 75 2 53 0 58 7 51 0 56 3 68 0 76 8 EX 40 3 1 59 40 3 1 59 40 3 1 59 41 9 1 65 119 130 149 165 159 175 191 216 Inne...

Page 849: ... 3 8790 103 513 103 525 109 D13 109 026 B 4 0753 4 0758 4 2918 4 2924 A 103 474 103 487 108 974 108 987 98 530 98 580 4 0738 4 0743 4 2903 4 2908 Cylinder liner outer diameter mm in 3 8791 3 8811 103 487 103 500 108 987 109 000 B 4 0743 4 0748 4 2908 4 2913 Cylinder block to cylinder liner clearance mm in 0 004 0 080 0 Q13 0 039 0 0005 0 0015 0 0002 0 0031 Liner protrusion above cylinder block mm ...

Page 850: ...0 0 0005 0 0016 0 0005 0 0015 Piston to piston pin clearance mm in 0 004 0 014 0 004 0 015 0 0002 0 0006 0 0002 0 0006 Connecting rod Length Center to center mm in 178 000 178 050 7 0079 7 0098 183 500 183 550 7 2244 7 2264 Bending mm in 0 05 0 0020 0 10 0 0039 max l1oo 3 94 max 100 3 94 Small end bore Bush inner diameter mm in 30 012 30 033 34 012 34 033 P 3391 1 3399 35 012 35 033 1 1816 1 1824 ...

Page 851: ...0 0036 0 0023 0 0036 NO 3 Main journal bearing oil clearance 0 084 0 118 mm in 0 0033 0 0046 No 1 2 4 5 Maximum 0 12 0 005 0 12 0 005 NO 3 0 15 0 006 Available undersize bearing mm in 0 254 0 0100 0 508 0 0200 0 762 0 0300 Crankpin bearing Standard 0 038 0 074 0 0015 0 0029 0 040 0 076 Crankpin bearing oil clearance mm in 0 0016 0 0030 Maximum 0 10 0 004 Available undersize bearing mm 0n 0 254 0 0...

Page 852: ... paper element Relief pressure differential kPa kg cm2 psi 78 118 0 8 1 2 11 17 Regulating pressure kPa kg cm2 psi I 608 667 6 2 6 8 88 97 Oil bypass filter Type Paper element Oil cooler Type Water cooled Oil pressure switch Activation pressure kPa kg cm psi 20 39 0 2 0 4 2 8 5 7 Engine oil Total dry engine 8 8 9 3 7 7 I 9 3 9 8 8 2 Capacity liters US qt Imp qt Oil pan 6 5 6 9 5 7 I 7 0 7 4 6 2 Oi...

Page 853: ...orrugated fin Cap valve opening pressure kPa kg cm psi 74 103 0 75 1 05 11 15 Cooling system checking pressure kPa kg cm2 psi 88 0 9 13 COOling fan Type Thermo modulated Number of blades 4x2 8 4x4 10 Outer diameter mm in 4x2 410 16 1 4x4 390 15 4 I 420 16 5 Coolant Capacity liters US t 1m t I lth heater core 13 5 14 3 11 9 q P q I Without heater core 12 5 13 2 11 0 Mixture percentage volume Specif...

Page 854: ... Injection pressure 13 2 13 7 135 16 7 17 2 170 175 2 42 2 49 19 6 20 1 200 kPa kg cm2 psi 140 1 92 1 99 205 2 92 2 99 Fuel tank capacity 100 26 4 22 0 100 70 26 4 18 5 22 0 15 4 liters US gal Imp gal Fuel filter type Paper elelne t Air cleaner type Paper element G ENGINE ELECTRICAL SYSTEM HA SL SL TURBOCHARGED TF ENGINES Engine HA SL J TF Item Non Turbo 1 Turbo I Voltage 12V negative ground Batte...

Page 855: ...phragm spring Clutch cover Set load N kg Ib 5 248 I 6 229 I 7 652 I 6 377 535 1 177 635 1 397 780 1 716 650 1 430 Type Single dry plate Diameter I Outer mm in 260 10 24 I 275 10 83 Clutch disc I Inner mm in 170 6 69 I 180 7 09 Runout mm On 1 0 0 04 Wear limit mm On 0 3 0 01 Master cylinder Inner diameter mm On 15 87 0 62 Release cylinder Inner diameter mm in 22 22 0 87 Flywheel Rul lout mm in 0 2 ...

Page 856: ... sub transmission with sub transmission Mainshaft Runout limit mm in 0 035 0 0014 Synchronizer ring Clearance between ring and flank Standard 1 5 0 059 surface of gear mm n Limit 1 0 0 039 Shift fork Clearance between fork and sleeve Standard 0 380 0 528 0 0150 0 0208 mm in Limit 0 8 0 0315 Clearance between fork and Standard 0 2 0 4 0 0079 0 0157 change lever mm in Limit 0 8 0 0315 Bearing end pl...

Page 857: ...axle Wheel bearing preload N m cm kg in lb 0 11 0 29 1 1 3 0 0 95 2 60 Clearance between king pin and bush mm in 0 01 0 04 0 0004 0 0016 Clearance between front axle and steering knuckle mm in 0 20 0 35 0 008 0 014 Kingpin bearing preload N kg Ib Adjustment shim mm in 0 35 0 014 0 5 0 020 0 6 0 024 0 7 0 028 Rear axle Wheel bearing preload Nm cm kg in Ib 0 11 0 29 1 1 3 0 0 95 2 60 Driving and Dif...

Page 858: ...Hem Gear type Manual Power Shaft type Regular type Shaft joint type I Non tilt steering 1 joint I Tilt steering 2 joints Wheel diameter mm in 430 16 9 Lock to lock turns 3 9 or 4 2 3 9 4 2 or 4 5 Range of up down movement Telescopic steering 30 1 18 mm in At steering wheel center position Amount of tilt mm in 50 1 97 At steering wheel center position Free play of steering wheel mm in 0 40 0 1 57 S...

Page 859: ...inner diameter Standard Refer to next page Limit Refer to next page Shoe clearance adjustment Turn the adjuster in the reverse direction from locked position 5 notches Type Tandem diaphragm Diameter mm n a 188 215 7 4 S 5 b 213 240 S 4 9 4 Power brake Fluid pressure per Vacuum a 687 7 0 100 196 20 44 unit OmmHg b 589 6 0 85 196 20 44 treading force Vacuum a 6 180 63 896 196 20 44 kPa kg cm2 psi N ...

Page 860: ... 4 528 6 00GSx16 127 5 6 00GSx16 127 5 6 00GSx16 127 5 300 301 229 3x75 0x6 0 228 6 229 6 11 81 11 85 9 02x2 95xO 24 9 00 9 04 304 0x75 0x8 0 12 09x2 95xO 31 307 0x90 0x8 0 320 321 12 09x3 54xO 31 320 321 12 60 12 64 12 60 12 64 334 9x11 0 Ox1 0 5 13 18x4 33x0 41 Tire Diameter of Tire pressure pitch circle Size kPa kg em2 psi mm in 184 15 7 25 7 00 15 10 392 4 00 55 417 4 25 60 Tire Diameter of Ti...

Page 861: ...Suspension type Leaf spring Spring LType Semielliptic leaf spring I Dimension See next page Shock absorber type Cylindrical double acting Wheel Alignment lUnladen condition It Body Truck Truck and Crew cab Cargo deck 10 feet 14 17 feet Cabin type Standard cabin Wide cabin Front wheel alignment Total toe in I mm in 0 3 0 0 12 I degree 0 0 3 Camber 0 40 I 30 Caster 2 30 I 20 King pin angle 7 00 Maxi...

Page 862: ... 2 8 x 0 35 1 246 x 70 x 9 49 1 x 2 8 x 0 35 970 x 70 x 9 38 2 x 2 8 x 0 35 E 830 x 70 x 10 32 7 x 2 8 x 0 39 700 x 70 x 10 27 6 x 2 8 x 0 39 570 x 70 x 11 22 4 x 2 8 x 0 43 410 x 70 x 11 16 1 x 2 8 x 0 43 260x70x11 10 2 x 2 8 x 0 43 1 506 x 70 x 10 59 3 x 2 8 x 0 39 950 x 70 x 12 37 4 x 2 8 x 0 47 1 248 x 70 x 10 49 1 x 2 8 x 0 39 900 x 70 x 12 35 4 x 2 8 x 0 47 F 880 x 70 x 10 34 6 x 2 8 x 0 39 ...

Page 863: ...0 1 69 0 04 bracket T BODY ELECTRICAL SYSTEM Specification W Item RHO AUSTRALIA SINGAPORE 12V 12V 12V Headlights Outside 40 60 45 60 40 60 Inside 50 45 50 Turn signal lights Front 21 Rear 21 21 27 Taillights 5 5 8 Ucense plate lights 7 5 Stoplights 21 I 21 27 Back up lights 21 21 23 Interior lights 10 Fog lights If equipped 35 Indicator and warning lights Hazard 1 4 x 2 Turn signals 1 4 x 2 High b...

Page 864: ...OOLS GENERAL INFORMATION ST 2 ENGINE ST 3 CLUTCH AND TRANSMISSION ST 5 DIFFERENTIAL ST 6 FRONT AND REAR AXLES ST 8 BRAKING SYSTEM ST 8 STEERING AND SUSPENSiON ST 8 CHECKER AND OTHER EQUiPMENT ST 10 9TFSTX OOl ST ...

Page 865: ... that all ser ce shops have these tools B Selective The tools in this list are not as necessary as tools ranked A but all service shops should have these tools to perform repairs more easily and more efficientiy Note When ordering tool sets that consist of several tools check the List in the Parts Catalogue to make sure that some tools are not duplicated in other sets you may already have If they ...

Page 866: ...r A installer valve guide HA 490107680A Engine stand A J 490107451A Remover A I I J iIf installer valve guide SL TF 490636007 80dy A 490223061 Remover 8 installer piston pin HA 49 V101 009 80lt A HA 498043 002 Installer bearing 8 SL 49 W065 006 490636040 Attachment set A 8 SL TF 1J qJ Piston pin 8 a j1 installer TF 490636100A 491363 015 Arm valve spring A lifter aJ m Replacer A cylinder liner HA 4...

Page 867: ... seal installer and centering tool HA ST 4 SPECIAL TOOLS PRIORITY ILLUSTRATION A A A A A A A TOOL NUMBER DESCRIPTION 49 W011 102 Installer oil seal TF 491456010 Adapter set compression gauge HA 49 W065 010 Adapter compression gauge 8L TF 499140074 Cam lift measuring device HA 499200145 Radiator cap tester adapter set 490727575 Puller socket joint 498120170 Remover valve seal 49 W017 3AO Supporter ...

Page 868: ... TOOL NUMBER PRIORITY DESCRIPTION 490600330 I Installer A 49 W017 101 Remover A bearing clutch hub 490727415 490839425C Installer main A fII 0 shaft front Puller set A bearing rear bearing 4902236308 49 W501 445 Puller hear 8 Holder 8 axle shaft synchronizer ring 490862350 Guide shift A fork assy 4906006208 Puller main A drive shaft bearing 49 F026 103 Puller wheel hub A 490500330 Installer transm...

Page 869: ... type 495231 626 Suppoet block C f type ST 6 PRIORITY A A PRIORITY A B A A A SPECIAL TOOLS ILLUSTRATION ILLUSTRAnON S TOOL NUMBER DESCRIPTION 49 1285071 Puller bearing 498501 631A Attachment rear shaft puller TOOL NUMBER DESCRIPTION 49 W033 1AO Installer set bearing 49 W027 003 Installer bearing C f type 49 G033 107 Installer dust cover 49 F027 007 Attachment p72 CN type 49 F401 3308 Installer set...

Page 870: ... ryv type 490552087 Installer camshaft A 0 bush ryv type 491363565 Pinion model A O O 49 G030 795 Installer oil seal A c JII ID 490305555 0 Gauge block A eN type 490710520 a Puller bearing A 49 W027 004 Cd Gauge block A eN type 49 W003 105 8 Installer oil seal A Y type 49 1316555 Gauge block A Y type 490727570 Gauge body A pinion height adjust 49 YOO1 555 Gauge block A Y type 5T 7 ...

Page 871: ... DESCRIPTION TOOL NUMBER DESCRIPTION 49 F043 001 Adjust gauge A 49 0259 7708 Wrench flare nut STEERING AND SUSPENSION TOOL NUMBER PRIORITY DESCRIPTION 4901805108 Attachment B preload measuring 491232670A Gauge set A power steering 49 HOO2671 Adapter A ST 8 ILLUSTRATION c9 TOOL NUMBER DESCRIPTION 49 W032 302 Adapter 49 W032 2A0 Remover set bearing 49 F017 1AO Universal wrench PRIORITY ILLUSTRATION ...

Page 872: ...auge 49 H032 327 Installer bearing and oil seal 49 F401 331 Body PRIORITY A A B A A A SPECIAL TOOLS ST illUSTRATION TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49 W023 585A Adjust wrench A e g1 C C CD 49 FT01 361 Remover bearing A 49 H025 003 Bearing installer A 49 G032 3A1 Joint hose A 49 G032 316 Adapter A 49 F027 005 Attachment for A bearing c 62 ST 9 ...

Page 873: ...nserting tool window glass 490839285 Checker fuel and thermometor 499200020 PRIORITY B A Tension gauge B V ribbed belt ST 10 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION 49 H080 740 Pressure tester 490187280 Gauge oil pressure PRIORITY ILLUSTRATION A B ...

Page 874: ...MBINATION SWiTCH T 18 CONSOLE 8 49 COOLANT LEVEL SENSOR T 62 COOLANT WARNING UNIT T 59 COOLING FAN E 12 CYLINDER HEAD GASKET 8 21 D DIFFERENTIAL M 20 DIFFERENTIAL OIL M 23 DOOR SWiTCH T 46 DRIVE BELT ALTERNATOR B 6 9 DRIVE BELT COOLING FAN B 9 DRIVE BELT POWER STEERING N 46 DRIVE BELT PIS B 9 E ENGINE B 33 CAMSHAFT B 85 CONNECTING ROD B 83 CRANKSHAFT B 84 CYLINDER BLOCK B 80 CYLINDER HEAD B 76 IDL...

Page 875: ...SL SL TURBO ENGINE F2 51 FRONT SHOCK ABSORBER R 13 INTAKE SHUTTER VALVE ACTUATOR FRONT WINDOW REGULATOR 8 10 TF ENGINE F3 40 FUEL CUT SOLENOID VALVE INTAKE SHUTTER VALVE HA ENGINE F1 23 SL SL TURBO ENGINE _ F2 18 51 FUEL FILTER HA ENGINE F1 17 INTAKE SHUTTER VALVE TF ENGINE F3 15 40 FUEL FILTER SL SL TURBO ENGINE F2 35 INTERCOOLER F2 27 FUEL FILTER TF ENGINE F3 23 INTERIOR LAMP _ T 46 FUEL GAUGE S...

Page 876: ...T 15 60 STOPLIGHT SWiTCH T 41 R T RADIATOR E 9 RADIATOR CAP E 8 THERMOSTAT E 10 RADIATOR GRILLE 8 20 TILT LOCK 8 40 REAR AXLE M 15 TRANSMISSION OIL W5M R J1 13 AXLE SHAFT M 16 TRANSMISSION OIL ZSM R J2 13 WHEEL HUB M 16 TRANSMISSION WSM R J1 14 REAR BRAKE DRUM P 32 TRANSMISSION ZSM R J2 14 BRAKE DRUM P 33 TRIM 8 68 BRAKE SHOE P 33 TURBOCHARGER F2 21 WHEEL CYLINDER P 33 REAR BUMPER 8 19 REAR CABIN ...

Page 877: ...PARTS INDEX WINDSHIELD WIPER LINK S 30 WIPER AND WASHER SWITCH S 34 WIPER ARM AND BLADE S 29 32 WIPER MOTOR S 29 33 PI 4 ...

Page 878: ... B 1 For SL SL Turbo TF AIR HEATER CONTROL SYSTEM Z 14 B 2 EXHAUST CONTROLLED HEATING SYSTEM Z 14 B 2 METERS WARNING LAMPS Z 16 C WIPER WASHER 2 18 0 HEADUGHTS Z 20 E TAIL UGHTS Z 20 E POSITION UGHTS Z 20 E UCENSE UGHTS Z 20 E FOG UGHTS Z 20 E ILLUMINATION LAMPS Z 20 E TURN HAZARD FLASHER UGHTS Z 22 F BACK UP UGHTS Z 22 F STOP UGHTS Z 22 F HORN Z 22 F BACK HORN Z 22 F HEATER Z 24 G ROOM LAMPS Z 26...

Page 879: ...on Symbol System name CHARGING SYSTEM System circuit diagram oo c3l C SeE C 00 J oo 1 ICOMMON CONNECTOR lISTEi 0 0 ill J IiillJ i trI 1 ct J ItltD a lC C OJ 0 C D e I I I Connector diagram identifies the exclusive applicable connectors iaI the circuit l r CONNECTOR m LttP c J CJ Female Male Z 2 Right page illustrates the actual location of each connector and the routing diagram of the harness View...

Page 880: ...gnition W Watt ACe Accessory R Resistance AS Auto stop Tr Transistor INT Interminent M Motor Lo 10 1 SW Mi Middle Sq Hi High RH Right hand lH left hand FR Front fIght FL Front left MT transaxle RR Rear right NO Normal opened RL Rear left NC Normal cOl sed Volt AlC Air Conditioner PIS Power Steerin AT Automatic Transaxle 1 J Gl 0 tnJ NO type y Ne tYPe reIey The relays and switches are identified as...

Page 881: ...M X 4 B FJ j B E It is seen from the above that the male side black line of the X 4 shows the engine harness and the female side black line shows the front harness It is seen from the above that the X 04 connector is a connector connecting the engine and the front harness DESCRIPTION OF HARNESS NO 3 Rear Harness NO 3 Rear Harness R2J Rear Harness RJ EXAMPLE OF CONNECTOR COO Fuel Tank Unit R tiilH ...

Page 882: ...t on the right INV Inverter In case of input to A B is grounded ower A o B Wl en A is OFF OV B is ON 12V A J_ ij B When A is ON 12V B is OFF OV This is shown in the relay circuit on the right 7 5 v PROCESS makes a simplified representation of complicated functions of the circuit r I Signal converter I r Functions mainly used I 1 I I 1 Detection of signals 1 Coil signal I I 10 I converted to I I 2 ...

Page 883: ...uel Tank Gauge Unit C Fusible Link 11 Glow Plug Relay 8 2 Glow Plug 8 2 o Headlight E Horn Relay F Horn SWitch F Horn F Illumination Lamps E Heater Control IlIum Meter Illumi Radio Illumi Intermittent Wiper Relay O License Light E Magnetic Valve B 2 Main Fuse A H PARTS NAME SECTION Neutral Switch II B 2 i Oi1 Bypass SwitCh C 011 Leve1 Sensor C Oil Pressure SWitch C e PIE Select SwitCh C PTa Switch...

Page 884: ...Z WIRING DIAGRAM JC GROUND CIRCUIT 0 0 Connector FJ R 1 2 J z a o 0 0 FRONT o REAR ...

Page 885: ...I I I I I I R I IIOIlN LAMPS I I ENGINE I I H I SWITCH I I I L R I I I_J__ oo ___Laq AUTO CLOCK H St I I II C I I I III 15A CIGER I I I I L r I L R I I I J I ____ RADIO H I t 1 I I I I ___o tl TE I I I 1 0 H I I I I I I I I I I I I I I I I I I iSA WIPER I _____1 __1 WIPER WASHER I I D I I I 1SA NETER ____ea_l_ NATlOfI I I c iSA TURN ___ __ I I I I I I 30A HEATER I R Y ________ HEATER I G I I i I I...

Page 886: ...B W F B W Rl L R R I AO 30A COMBINATION METER SECTION C 3 AIR t ATER CCJIITROL R UNIT A SECTICJII B 2 2 W B W B F F W B 01 STARTING KlTOR ALTERNATOR WITH REGULATOR A oS A 01 STARTIfIG MOTOR R A 04 SUB STARTING SWITCH R A 02 STARTING MOTOR B FUSIBLE LItf A FISTBI E LINK 1 25sQ FOR HA R B 00 L10 FUSIBLE INK 05a SL SL 1 JRBO TF A 05 ALTERNATOR WITH A oS ALTERNATOR WITH REGULATOR Rl REGlLATOR R o NOTE...

Page 887: ...Z A HARNESS SYMBOlS F a nIlUl R rmnD Fm Connector FHRJ For HAl Engine Switch BLACK Alternator With Regulater A 05 Atternator With Regulator A 05 Starting Motor A 02 Z A Neutral Switch Main Fuse A 03 Z l1 ...

Page 888: ...41 1 1 8 R BII eGINE 15A 8 F W B lHA 8 Y F IX3 II METEA 15A B Y F f A 8 1 A ENGINE SWITCH B 06 FLEL CUT SOLENOID VALVE 8 1 ____________________ O W P L __________ 8 01 QSS CONTROL UNIT F IB 02 GLOW PLUG RELAY A IB YiB11 ffi 8 153 GLOW PL R 1 8 1ILl NOTE NOT USED 8 04 GLOW PL R 8 R1w S 8 05 WATER THERMO SWITCH 18 06 FLEL CUT SOLENOID A VALVE A 18IVIEI 18 AIEI e ...

Page 889: ...1 HARNESS SYMBOLS F a ITIJ III IR Il IIIIl Am BLACK Fuel Cut water Thermo Switch 8 05 Connecto lfl RJ L _ 1 8 04 Glow Plug Relay Glow Plug BLACK Main Fuse 8 01 QSSControl Unit Engine Switch BLACK Z B 1 Z 13 ...

Page 890: ... F 1 lr 1 B 01 AlA HEATER CONTROL UNIT F B 08 CANCEL AELAY F B 02 AlA HEATER AELAY A JO B 03 WATEA THERMO SENSa IB 04 AlA HEATEA A CSIB AI o B 10 EXHAUST BRAKE 5WITCHB 11 EXHAUST HEATING L W F I IIIII NEUTAAL SWITCH IlBI B F L W A B 05 ACCELEAATOR SWITCH le 06 MAGNETIC VALVE A3 F 8 B 12 CLUTCH SWITCH F rL7Wl E B 09 SOLENOIO VALVE EXHAUST HEATING YSTEM A Io l B F SWITCH I ill LlWBR IIG AII A 02 STA...

Page 891: ...8 06 Air Heater Relay BlACK Solenoid Valve Eld1ausI Heating System Cancel Relay 8 08 Fuse Box Connector 9 IR COnnector IFl R Main Fuse Clutch Switch 8 12 Control Unit Exhaust Brake Switch B 1O Z B 2 8 11 BLACK Accelerator Switch 8 05 Exhaust Heating Switch Z 15 ...

Page 892: ...EL TANK GAUGE UNITIC 06 OIL LEVEL SENSOR R R3 I liV BI C 12 SEOIMENTOR LEVEL SENSOR R3 IR VIQ 0Q NOTE NOT USED Z 16 ffi C 13 PTa SWITCH CORD F lJ IRlLIQ C 07 SUB MISSION SWITCH R IR G R GI C 14 PTa SWITCH Q 2H 2G 2F 2E l8 C OB PIE SELECT SWITCH R IC 09 OIL PRESSURE SWITCH IC 10 PARKING BRAKE SWITCHlc 11 R F IJG I IV GIQ 0Q Q BRAKE FLUID LEVEL ffiIDOOO C 15 VACUUM SWITCH F FOR AUSTRALIA C 16 COOLAN...

Page 893: ...CK C l1 Blake Fluid Level Sensor C 14 PTO Switch BLACK Walet Thermo Sensor C 04 For HA C 03 Pick Up Sensor BLACK C 18 Oil Bypass Switch C 06 Oil Level Sensor CoeIant Level Seosor C 17 Oil Bypass C 06 Switch 011 Level Sensor BLACK Water Thermo Sensor C 04 Coolant Level Sensor C 17 BLACK Oil pressure Switch C 9 PIE Select Switch C 8 Main Fuse PIE Select Switch C 8 8 Main Fuse z c 8 Z 17 ...

Page 894: ...D O 9 OFF Hb OFF L F LO oINT LOO INT 0 01 0 01 _ __ oc c LCFI t L B G G R L R L W L L F F F F F F F 0 02 0 03 I 0 04 WASHER b MOTOR C0 a M LlY Fl 1 0 0 03 O O f 0 01 WIPER WASHER SWITCH F L G G R L R L B L W NOTE NOT USED Z i8 D 02 WIPER 0 04 MOTOR B B F F l 0 02 WASHER MOTOR F 0 03 WIPER MOTOR F 11 11 L W L R L L Y d INTERMITTENT WIPER RELAY 0 04 INTERMITTENT WIPER RELAY F G A ml L Y G L B H F 0 ...

Page 895: ... z o HARNESS SYMBOLS FJ a rr Il1i1 Rl rmIlIllRmJ BLACK Wiper Motor D 03 D 02 Washer Motor Connector IFJ IRJ 0 01 Wiper Washer Switch Main Fuse z o o Z 19 ...

Page 896: ...IRIB R2 E 09 BL l RIB R2 E 11 RIB R2 POSITION 5W TAIL f LICENSE LIGHT w LIGHT RH E 11 rGrr RH E B I E 03 HEAlLIGHT LH am Ff lQ I IE 10 TAIL LIGHT iii R2 I J H 6 E OS I E 04 HEADLIGHT LH ni F al E 11 LICENSE LIGHT LH R2 I ffi B R2 E 14 FOG LIGHT LH B F E 5 HEADLIGHT RH IN F I I I I E 12 HEATER CONTROL ILLUMI I IIR BII K Ol RADIO ILLUMI CIl FOG LIGHT SWITCH E 15 FOG LIGHT RH B F IR B F FOR AUSTR IA ...

Page 897: ...dlight RHIN E 15 Fog Ugh RH BLACK E 14 Fog Light LH BLACK E 4 Headlight LH IN E 3 Headlight LH OUT Tail Light RH E 1O Connector IRJ IR2 Tail Light LH E 09 Fuse Box Radio IIlumi 8 Main Fuse Meter IIlumi C l Combination Switch Z E E l Combination Switch Z 21 ...

Page 898: ...IF F IF 8 Y F HORN F 05 l F 10 F OSlU RELAY CtN ENSER _ _ F oS X3g f F 10 F oS STOP i LIGHT CHECKER 1 G A F GIR F RELAY l G 8 F crr HORN HORN HORN 8 F LH RH SWITCH F 06 G F 11 g 1BZl G 82 E OS ci 21M LH E 09 ICi F 07 _ lTI BACK UP LIGHT 9 SWITCH F 07 IBZf A G A A G R2 F oa A G A 01 FOA SINGAPORE FOR SINGAPORE A G 82 E lIl STOP 21M LIGHT iii E 10 B F E o S F 11 lfN lf Y F l1 Q 21 1 21M Q F l _Jt__ ...

Page 899: ...r Combination Light RH E 10 For Singapore Back up Light F 11 Rear Combination Light LH E 09 Back Horn F 03 Condenser Flasher Unit 0 Stop Light F 02 Che ker Relay I F 06 Horn Relay F 09 Connector FJ R Combination E 02 Switch Horn Switch Back up Light Switch Main Fuse Z F Condenser F 10 F 05 Stop Light Switch Z 23 ...

Page 900: ...Z WIRING DIAGRAM G HEATER HEATER 30A R Y L F F FAN SWITCH HI G 03 G W F G W I OFF G 01 BLOWER MOTOR F G 02 RESISTOR G 03 FAN SWITCH I IIR YII NOTE NOT USED Z 24 ASSEMBLY F fR1G7wl R G W B L Y L if ...

Page 901: ...Z G HARNESS SYMBOLS FI a rr D III AI rImlY l Ami o Fuse 80 Fan Switch G Ol Blower Motor Engine Switch BLACK Main Fuse Z G 7 ...

Page 902: ... IX3llI LIR ROOM i0A F IX3l2I COMBINATION SWITCH SECTION E L R IL B IQ I H 04 I IR B REAR Y f II L W AM B 1 I IlB2I B F IX3llI CIGAR 15A 1 ILlR1IL B F IF RADIO L OI IG R II I H 4 4 H 01 ROOM LAMP FEONTf RM IH 02 DOOR SWITCH Fl rL7Rl G H 07 SPEAKER I O NOT USED IZIIL W I H 03 ROOM LAMP REAR I IMn H 04 CIGARETTEL GHTER l wl H 06 RADIO I ...

Page 903: ...B R WiG Y GIB I I BIL Y Rlf AND X 07 R VIV Bll N B I R IG Y R3 WIRING DIAGRAM BR L W B LIB R R R2 r2 5 L Y R GIR G Y G W L B L L o B Y G W S Y G RIB L W G Y R Y G BIR L V RIG GIB Y WIG R IY R B l BR RIGI BIG IS N It IRIBISIBI W B Y L BR VIB L z B W Y R W B l R B RIB f I I 1 Y R B H W B 0 If I I 11 F AM Z 27 ...

Page 904: ...ESS SYMBOLS ___ F I A t1tlUtJ Rm BLACK Connector IFJ Rm Room Lamp Front H 01 Room Lamp Rear YROOmLamp v H 01 BLACK Connector F Rm Speaker H 07 BLACK Cigarette Lighter H 04 H 05 Auto Clock Z H BLACK Door Switch ...

Page 905: ...h Clutch Switch stop Light Checker Relay Cancel Relay Horn Relay haust ConIroIlbt L exhaust Heating Switch For HA J Glow Plug Relay Pick Up Sensor soo Starter Switch PARTS LOCATION Z PA Water Thermo Switch NUnIf Swit II Back up light Switch Wator Thermo Sensor NeUIJaI Switch Back Light Switch ...

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Summary of Contents for TRADER

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Ford TRADER, Workshop Manual

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Summary of Contents for TRADER

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