Content

General information

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

Maintenance and lubrication

• Maintenance schedule
• Severe conditions maintenance schedule
• Recommended lubricants and diesel fuels
• Oil viscosity char

Heating and air conditioning

• General information
• Main data and specifications
• Special parts fixing nuts and bolts
• Servicing
• Condencer
• Receiver dehydrator
• Compressor
• Heater unit, blower unit and evaporator assembly
• Control lever assembly
• Troubleshooting

Frame and bumper

• Front bumper
• Rear step bumper
• Rear body
• Frame dimensions

Sheet metal

• Engine hood assembly
• Removal and installation
• Cab protector
• Exterior rope hook
• Interior rope hook

Steering

• Main data and specifications
• Torque specifications
• Servicing
• Steering mechanism
• Power steering oil pump
• Troubleshooting

Front suspension

• Main data and specifications
• Torque specifications
• Front suspension
• Troubleshooting

Rear suspension

• Main data and specifications
• Torque specifications
• Rear suspension
• Troubleshooting

Wheels and tyres

• Tyre pressure data
• Torque specification
• Wheels and tyres
• Troubleshooting

Propeller shaft

• Main data and specifications
• Special parts fixing nut and bolt
• Propeller shaft assem bly
• Centre bearing (4ZE1, 4JB1T, 4ZC1, 4JA1 engine)

Rear axle

• Model variations and pinion assemblies
• Main data and specifications
• Special tools
• Identification, description and operation
• Diagnosis and testing
• Bearing noise
• In-car adjustment and repairs
• Rear wheel oil seal replacement
• Drive pinion oil seal
• Drive pinion seal replacement
• Off-car repairs
• Gear tooth contact patterns
• Differential case and drive pinion removal
• Inspection after removal and disassembly
• Gears
• Bearing cups
• Cone and roller assemblies
• Drive pinion flange
• Carrier casting
• Differential case
• Dismantling
• Reassemble
• Diff bearing pre-load torque setting
• Rear pinion shim selection
• Gauging of the carrier
• Gauging the rear pinion bearing
• Drive pinion assembly and installation
• Pinion bearing pre-load torque specification
• Collapsible pinion pre-load spacer
• Setting pinion bearing pre-load with collapsible spacer
• Summary of rebuild operation

Front wheel drive

• Main data and specifications
• Special parts fixing nut and bolt
• Recommended liquid gasket
• Recommended thread locking agnents
• Servicing
• General description
• Front drive axle assembly
• Differentia
• Front hub and disc ( 4 x 2 model)
• Front hub and disc ( 4 x 4 model)
• Front hub and disc (automatic locking hub)
• Front hub and disc (manual locking hub)
• Front propeller shaft
• Troubleshooting

Differential locking device

• Description and operating principle
• Servicing

Brakes

• General description
• Main data and specifications
• Special parts fixing nut and bolt
• Servicing
• Front brake assembly
• Rear drum brake assembly
• Brake control
• Master cylinder
• Vacuum servo
• Parking brake (stem type)
• Parking brake (floor mount type)
• Troubleshooting

Troubleshootin

• Hard starting
• Unstable idling
• Insufficient power
• Excessive fuel consumption
• Excessive oil consumption
• Overheating
• W hite exhaust smoke
• Dark exhaust smoke
• Oil pressure does not rise
• Abnormal engine noise
• Turbocharger

Engine mechanical

• Main data and specifications
• Torque specifications
• Recommended liquid gasket
• Loctite application procedure
• Servicing
• General description
• Removal and installation
• Engine repair kit
• Engine overhaul
• Lubricating system

Engine cooling

• Main data and specifications
• General description
• Water pump
• Thermostat
• Fan clutch with cooling fan

Fuel system

• Main data and specifications
• General description
• Injection pump
• Solenoid valve type cold start device (C.S.D.)
• Inspection and repair
• Injection pump calibration data
• Injection nozzle

Engine electrical

• Main data and specifications
• General description
• Wire coding
• Symbols and abbreviations
• Torque specifications
• Alternator
• Starter motor
• Pre-heating system
• Troubleshooting
• Qosii preheating system
• Qosii system troubleshooting

Exhaust system

• Main data and specifications
• General description
• Removal and installation
• Inspection and repair
• Turbocharger
• General description
• Inspection and repair
• Ihi service network

Manual transmission

Clutch

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

Electrical-body and chassi

• General information
• Symbols and abbreviations
• Parts for electrical circuit
• Reading the circuit diagram
• Main data and specifications
• Main cable harness routing
• System repair
• Connector list

Cab

• Servicing
• Windshield and back light glasses
• Sliding rear window assembly
• Interior mirror
• Doors
• Instrument panel
• Driver’s footrest
• Console box
• Headlining
• Front seat
• Front and rear seat belts
• Vehicle security system
• Rear seat back rest
• Body side mouldings
• Mud flaps
• Roll bar
• Grille guard
• Wheel arch mouldings
• Stone guard