Content

General information

• General repair instructions
• Notes on the format of this manual
• Identification
• Lifting instructions

Maintenance and lubrication

• Maintenance schedule (for general export)
• Maintenance schedule (for Europe)
• Severe conditions maintenance schedule (for general export)
• Severe conditions maintenance schedule (for Europe)
• Recommended fluids and lubricants (for general export)
• Recommended fluids and lubricants (for Europe)
• Oil viscosity chart

Heater and air conditioning

• General description
• Main data and specifications
• Special parts fixing nuts and bolts
• On-vehicle service.
• Precautions for replacement or repair of air conditioning parts
• Condenser
• Condenser fan motor
• Receiver / drier
• Compressor
• Heater unit
• Vent unit (without heater)
• Evaporator (with A/C)
• Duct (without A/C)
• Blower unit assembly
• Defroster nozzle and vent duct
• Rear heater duct
• Control lever assembly
• Control panel illumination bulb
• Troubleshooting
• Special service tool

Frame and bumper

• Front bumper
• Rear step bumper
• Rear bumper and rear guard
• Front air dam
• Frame dimensions

Sheet metal

• Engine hood assembly
• Engine hood lock
• Front fender panel
• Radiator grille
• Rear body
• Body mounting
• Body dimensions

Front alignment

• Front end alignment inspection and adjustment
• Alignment for 4x2 (except high ride suspension)
• Alignment for 4x2 (high ride suspension) and 4x4

Power-assisted steering system

• General description
• Power steering system test
• Maintenance
• Fluid level
• Bleeding the power steering system
• Bleeding procedure
• Flushing the power steering system
• Steering wheel free play inspection
• Front end alignment inspection and adjustment
• Power steering unit
• Power steering pump
• Power steering pump and associated parts (4JH1-TC, 4JA1-T)
• Power steering pump (4JJ1-TC, 4JK1-TC)
• Supplemental restraint system steering wheel and column
• SRS connectors
• Inflator module
• Steering wheel
• Combination switch
• Lock cylinder
• Steering column
• Supplemental restraint system steering wheel and column and associated parts

Front suspension

• Main data and specifications
• Torque specififcations
• Front suspension

Rear suspension

• Main data and specifications
• Rear suspension
• Leaf spring and shock absorber
• Leaf spring assembly
• Rear stabilizer bar
• Troubleshooting

Wheels and tires

• Main data and specifications
• Torque specifications
• Wheels and tires
• Troubleshooting

Propeller shaft

• Service precautions
• Main data and specifications
• Rear propeller shaft
• Front propeller shaft

Rear axle

• Main data and specifications
• Recommended liquid gasket
• Recommended thread locking agents
• Rear axle assembly
• Servicing
• Rear axle
• Differential assembly
• Differential cage assembly
• Limited slip differential

Front wheel drive

• Main data and specifications
• Special parts fixing nuts and bolts
• Recommended liquid gasket
• Recommended thread locking agents
• Front drive axle assembly
• Front axle drive shaft
• Differential
• Front hub and disc (4?2 except high ride suspension model)
• Front hub and disc (4?4, 4?2 high ride suspension, 4?4 rigid hub, 4?4 shift on the fly model)
• Front hub and disc (4?4 manual locking hub model)
• Troubleshooting
• Special service tool

Shift on the fly system

• Service precaution
• Shift on the fly system
• Shift on the fly electrical equipment
• Shift on the fly system and association parts

Brake control system

• Service precaution
• General description
• General diagnosis
• Diagnostic trouble codes
• Diagnosis by "ABS" warning lamp illumination pattern
• Basic diagnostic flow chart
• Basic inspection procedure
• Wheel speed sensor inspection procedure
• Symptom diagnosis

Anti-lock brake system

• Service precaution
• Torque specifications
• Electronic hydraulic control unit
• Front wheel speed sensor
• Rear wheel speed sensor
• Front sensor rotor
• Rear sensor rotor
• G-sensor
• Special tools

Brakes

• General description
• Main data and specifications
• Torque specifications
• Servicing
• Front disc brake assembly
• Rear drum brake assembly
• Brake control
• Master cylinder
• Vacuum booster
• Special tools

Parking brake system

• Service precaution
• Parking brake lever
• Front parking brake cable
• Parking brake lever
• Parking brake rear cable
• Main data and specifications

Engine 4JA1 / 4JH1 models

• Troubleshooting
• Engine mechanical
• Engine cooling
• Fuel system
• Engine electrical
• Engine control system (4JH1)
• Exhaust system
• Accelerator control

Engine 4JK1/4JJ1 models

• Engine mechanical
• Engine cooling
• Fuel system
• Engine electrical
• Engine control system
• Exhaust system
• Engine speed control system

Engine C24SE models

• Engine diagnosis
• Engine mechanical
• Engine cooling
• Fuel system
• Engine electrical
• Engine driveability and emissions
• Exhaust system
• Engine lubrication
• Engine speed control system
• Induction

Engine HFV6 models

• Engine mechanical
• Engine mechanical update
• Engine management general information
• Engine management diagnostics
• Engine management service operations
• Charging system V6
• Battery V6
• Powertrain interface module V6
• Engine cooling
• Fuel system V6
• Starting system V6
• Exhaust system V6

Automatic transmission

• General Information
• On vehicle servicing
• Electrical diagnosis

Transmission

• Transmission control system
• On vehicle service
• Unit repair

Manual transmission

• Manual transmission MSG
• Manual transmission MUA
• Manual transmission MUX

Clutch

• Main data and specifications
• General description
• Torque specification
• Servicing
• Clutch
• Clutch control
• Master cylinder
• Slave cylinder
• Hydraulic damper cylinder
• Troubleshooting
• Special service tool

Transfer case

• Transfer house
• Transfer control system

Electrical-body and chassis

• General information
• Notes for working on electrical items
• Symbols and abbreviations
• Parts for electrical circuit
• Wiring
• Fuse
• Fusible Link
• Relay
• Diode
• Connector
• Battery
• Reading the circuit diagram
• Parts location
• Circuit diagram
• Connector list
• Main data and specifications
• Bulb specifications
• Relay and fuse
• Grounding point
• Cable harness routing
• Connector list

Cruise control system

• General description
• Brake switch
• Clutch switch
• Starter switch
• Cruise control main switch
• Cruise control switch (combination switch)

Cruise control – HFV6

• General information
• Warnings, cautions and notes
• System components
• System operation
• Diagnostics
• Diagnostic general information
• Diagnostic systems check
• Wiring diagrams
• Cruise control inoperative / malfunctioning
• Service operations
• Cruise control main switch
• Cruise control switch assembly
• Stop lamp switch assembly
• Clutch pedal switch (manual only)
• Special tools

Accessories

• Parts location
• Circuit diagram
• Connector list
• Audio
• Front speaker
• Tweeter
• Rear speaker (extend cab)
• Rear speaker (crew cab)
• Clock
• Antenna

Supplemental restraint system (SRS)

• Service precaution
• General description
• Circuit diagram
• SRS component and wiring location view
• Component description
• Definitions
• Diagnosis
• SRS connector body face views
• Repairs and inspections required after an accident
• On-vehicle service
• Air bag assembly shipping procedure for live (undeployed) air bag
• Service precautions for SRS component service
• SRS connectors
• SRS control unit
• Driver air bag assembly
• Steering wheel
• SRS coil assembly
• Steering column
• Passenger air bag assembly
• Pretensioner seat belt (if so equipped)
• Main data and specifications
• Special tools

Restraint control system

CAB

• Windshield
• Rear window assembly
• Front door assembly
• Rear door assembly (crew Cab)
• Instrument panel
• Floor console
• Console box (without floor console)
• Headlining
• Interior trim panels
• Fuel filler lid opener lever / cable
• Quarter glass (extend Cab)
• Font seat
• Rear seat (crew Cab)
• Jump seat (extend Cab)
• Front seat belt
• Rear seat belt (crew Cab)
• Rear seat belt (extend Cab)
• Front wheel extension
• Tail gate assembly

Immobilizer control system

Antitheft system