Contents

General

• Vehicle model coding system
• Equipment type codes list
• Power train table
• How to read this manual
• Chassis number, vehicle identification number, engine number and name plate
• Precautions for maintenance operation
• General precautions
• Handling of battery
• Handling of sensors, relays and electronic control units
• Handling precautions for electric circuits
• Service precautions for alternators
• Intermittent faults
• Precautions for ARC welding
• Precautions when repainting
• Jacking up the vehicle
• Diagnosis codes
• Diagnosis codes
• Reading and erasing the diagnosis code
• Table of standard tightening torques
• Tightening torques
• Table of standard tightening torque

Engine

• Specifications
• Structure and operation
• Exploded view
• Valve mechanism
• Cylinder head gasket
• Water director
• Connecting rod
• Piston
• Timing gears
• Troubleshooting
• On-vehicle inspection and adjustment
• Measuring compression pressure
• Inspection and adjustment of valve clearances
• Engine removal and installation
• Cylinder head
• Piston and connecting rod, cylinder sleeve
• Flywheel
• Timing gears
• Camshaft
• Crankshaft and crankcase
• Camshaft bushings

Lubrication

• Specifications
• Structure and operation
• Lubrication system
• Oil pump
• Oil cooler and oil filter
• Lubrication of engine components
• Troubleshooting
• On-vehicle inspection and adjustment
• Oil filter replacement
• Engine oil replacement
• Oil pressure measurement
• Oil pan and oil jets
• Oil pump
• Oil cooler and oil filter

Fuel and engine control

• Specifications
• Structure and operation
• Fuel system (flow of fuel)
• Engine control
• Fuel filter
• Water separator
• Injection pump body
• Governor
• Feed pump
• Automatic timer
• Injection nozzle
• Troubleshooting
• On-vehicle inspection and adjustment
• Inspection and adjustment of fuel injection timing
• Inspecting and adjusting no-load minimum and maximum speeds
• Air-bleeding of fuel system
• Cleaning gauze filter
• Fuel filter replacement
• Fuel tank
• Spare fuel tank
• Fuel filter
• Water separator
• Engine control
• Injection pump
• Injection nozzle

Cooling

• Specifications
• Structure and operation
• Cooling system (flow of coolant)
• Thermostat
• Water pump
• Troubleshooting
• On-vehicle inspection and adjustment
• Coolant replacement and cleaning of cooling system
• Air bleeding of cooling system
• Air/gas leakage test
• Inspection of belts
• Disconnection and connection of hoses and pipes
• Radiator
• Cooling fan, belt and water pump
• Thermostat and pressure cap

Intake and exhaust

• Specifications
• Structure and operation
• Air cleaner
• Turbocharger assembly
• Exhaust brake system
• Troubleshooting
• On-vehicle inspection and adjustment
• Measurement of turbo boost pressure
• Inspection and adjustment of exhaust brake system
• Air duct and air cleaner
• Turbocharger
• Intercooler
• Intake manifold
• Exhaust manifold
• Exhaust pipe and muffler